BTPP - CFBC BOILERS - LDO FIRING SYSTEM

1.0 LDO (LIGHT DIESEL OIL ) System in General:

a) There are 2X100 M3 LDO tanks of 5 Meter height. The LDO tank-2 drain is
connected to HFO tank -2 drain (500 M3 - 8 Meter height) so that LDO can be
stored in HFO (Heavy Fuel Oil) tank-2 also. The maximum possible height of
storage is 4.7M as the overflow is tapped from that elevation.
The LDO from one tank may be transferred to the other tank by using LDO
unloading pump, to improve the level. The LDO tanks have electrical heaters
(4 Nos./Tank),to heat the LDO in case of requirement. These heaters have to
be manually switched “ON” from FOPH control panel and it will be switched
off at 25O C to 30OC automatically. The LDO tanks can also be kept in
parallel, in case of requirements, by opening the interconnection valves.

b) There are 3X100 M3 LDO screw pumps in FOPH (Fuel Oil Pump House). One
pump/Unit is required for start up and the third pump is common reserve for
both the Units. However, any pump to any Boiler is possible by opening the
pump discharge header appropriate interconnection valves.
c) 2X200% suction filters are provided at the LDO screw pump suction. One
filter has to be kept in closed condition, when the LDO screw pump/ pumps
are in service.
d) Each LDO pump supply oil to the Boiler, to cater the need of 2 start up
burners (2X3.25 = 6.50 T/Hr) located in combustor front/ rear wall. In case
of non requirement of LDO in Boiler, the LDO will go back to the tank,
through the LDO PCV. The LDO pump capacity is 150 LPM each and discharge
pressure is 28 ksc.
e) Service air at a pressure of about 7 KSc is tapped from Service air
compressor, is used for atomizing the LDO, for the proper combustion.
f) LPG is used for the ignition of LDO.

Page 1 of 21
 g) The total oil required for the cold start is about 60KL.The dead stock of the 3
tanks (HFO +LDO) is about 135 KL for 1metre height. In case of HFO system
problem, prolonged operation with LDO has to be considered. Hence the LDO
minimum stock needed is about 235 KL before a Light up (100 KL for light up
till stabilization –provisional value).
h) Confirm that No LC is pending for starting of the LDO system for boiler light
up.

Note :

1. For all the pneumatic drive valves and dampers, the local instrument air valve
near the drive has to be kept open to facilitate the operation from DCS.
2. The Spiess Valves (6 Valves) view port cooling air valves has to be opened.
3. The Spiess Valves (7 Valves) sealing air valves has to be opened.

LIGHT DIESEL OIL (LDO) ANALYSIS AS PER IS 1460, 1995

Sl.No: Description Unit Value/Range

1 Viscosity at 40 oC Cst 2.5 to 15.7

Density at 15oC Kg/m3 850-870

2
(Approximate)
o
3 Flash Point, Min C 66

o
Pour Point, Max C 12 for Winter
4
21 for Summer

5 Water Content, Max % vol 0.25

6 Sediment, Max % wt 0.10

7 Sulphur, Max % wt 1.8

8 Ash Content, Max % wt 0.02

Gross Calorific Value Kcal/Kg 10,000

9
(Approximate)

Page 2 of 21
2.0 System preparatory works @ LDO tank area:

2.1 The following valves have to be kept in closed condition.

a) LDO tank inter connection valves, 3 Nos.( to unloading system )

b) The reserve LDO tank outlet valve to pump, if parallel operation is not
required.
c) The recirculation valve of the reserve tank.
d) Ensure both tank drains are in closed condition.
2.2 The following valves have to be kept in Open condition.

a) Service tank outlet valve.

b) The recirculation valve at tank inlet in service tank.

2.3 Note that the Tank levels in Local indicator and inform to control room.

2.4 Check and confirm that the Fire fighting system is available in

FOPH area.

3.0 System preparatory works in FOPH:

3.1 The following LDO system valves have to be kept in closed condition.

a) Reserve filter Inlet and Outlet valves

b) The individual Boiler main line isolation valve located before the PCV

inlet isolation valve .

3.2 The following LDO system valves have to be kept in opened condition.

a) The suction filter Inlet and Outlet.

b) The above suction filter air vent valves.

c) The PCV bypass valve. (About 50%)

Page 3 of 21
 d) The PCV (from the Control room) full open.

e) The PCV Inlet and Outlet valves.

f) The Inlet and Outlet valves of the pump to be started.

g) The Inlet and Outlet valves of the reserve pump.

h) The pump discharge header, interconnection valves as per

Boiler 1/2 requirement.

i) The main isolation valve common to both suction filters Inlet.

j) The filter air vents valve has to be closed, once the free flow of oil

is observed.

3.3 Starting of LDO Screw pump.

a) Local latch has to be released for the pump to be started & the Reserve
pump.

b) Motor & pump area is free from abnormalities.

c) Start the LDO screw pump from DCS with reserve pump selection.

d) Slowly adjust the LDO pressure by closing the LDO PCV bypass Valve
and adjusting the PCV.

e) Now the LDO screw pump is in service, with 100%

recirculation to the tank.

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3.4 LDO to Boiler Front.:

a. Open the isolation valve before MTV valve in boiler front left corner.
b. Slowly Open the Boiler line valve located before the PCV inlet valve at
FOPH (Ref 3.1b), in co -ordination with the control room. Ensure that the
LDO header pressure is not dropping fast.
c. Adjust the LDO pressure at the Boiler front local (12 to 14 KSc) by using
LDO PCV from DCS.
d. Now the LDO is connected to Boiler front (Up to MTV) and also to the LDO
tank.
e. Put LDO PCV on auto mode at 12-14 ksc.

4.0 LDO System preparatory works at Boiler front:

4.1 The following LDO valves have to be kept in closed condition.

a) Flow meter bypass valve.

b) LDO FCV bypass line valve.

c) LDO line drains.

d) Ensure Burner Trip valve 1 &2 are in closed condition.

4.2 The following LDO valves has to be kept in Open condition.

a) Flow meter Inlet and Outlet valves.

b) LDO FCV Inlet and Outlet Valves.

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5.0 Atomizing air system preparatory works:

a) Ensure one Service air compressor is in service at about 7.0 ksc.

b) The main isolation valve at 6.5 ML, Boiler left side has

to be opened.

c) The PCV inlet and outlet valves have to be opened.

d) The isolation valve before PCV inlet isolation valve has to be opened.

e) The PCV bypass valve has to be in closed condition.

f) Observe atomizing air pressure at about 7 KSc in PCV inlet.

g) Open atomizing PCV and check for 7 ksc at outlet also in DCS.

6.0 LPG System Preparatory works:

a) Ensure 2/3 cylinders with sufficient gas are connected to the LPG bus.
b) LPG MTV Inlet and Outlet valves are open.
c) Adjust the LPG Pressure to 3- 4 KSc in inlet header.

7.0 Pre Conditions For SUB Cut In:

7.1 The following BP-1 TRIP CONDITIONS should not exist (Observe in
DCS):
a) Boiler Emergency Trip from OWS or CD or UCP
b) ID-Fan 1&2 Speed < 150 rpm
c) Both ID Fan Off
d) MS Pressure before Stop Valve > 20 Ksc and Boiler Stop Valve Not Open

Page 6 of 21
e) Turbine Trip & (HP BP 1&2) < Min (Position < 2 %) & MS Pressure before HP
BP > 40 Ksc & Combustion Lower temperature > 450 oC with a delay of 4
seconds.
f) Inlet Convective Pass pressure > 30 mbar
g) Compensated drum level < – 225mm Or Deaerator Level < 800 mm
h) Compensated Drum Level > +250 mm
i) MS temperature at SH outlet > 560 oC
j) HRH temperature at RH outlet > 560 oC
k) Instrument Air Pressure < 4.5 Ksc
l) Both DMCW BPs Off (5 sec delay)
m) Combustor temperature Lower > 950 oC
n) Combustor temperature Middle > 950 oC
o) Cyclone 1 Outlet temperature > 950 oC
p) Cyclone 2 Outlet temperature > 950 oC
7.2 The following NO MFT CONDITIONS should exist
(Observe in DCS):

a) Pilot MTV Closed

b) LDO MTV Closed
c) HFO MTV Closed
d) All Burners Scavenging valves Closed
e) All Scanner Show No Flame
f) All LDO BTV Closed
g) All HFO Burner BTV Closed
h) SUB-1 HORV Closed
i) SUB-2 HORV Closed
j) All HFO atomizing valves closed
k) Instrument air pressure OK
l) Purge Complete (< 30 min.)
Or Any Oil Burner in service
Or Combustor Middle Temperature > 600 oC
m) 110 V A.C. Supply available
n) SUB-1/2: Trip Not Acted

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 o) Any LDO Burner Selection & LDO pressure OK
(Or) Any HFO Burner Selection & HFO pressure OK & HFO temp OK
p) No Flame Failure Trip
q) No loss of Fuel Trip
r) Any ID Fan in Service
s) Boiler Protection –I Not Acted

7.3 PURGE PERMISSIVES (Observe in DCS)

a) Combustor Middle Temperature < 600oC
b) Purge permit 1
c) ESP 1&2 Off
d) Any ID Fan in service
e) Any P&S Blower in Service
f) Any One SA Fan in Service
g) Any One PA Fan in Service
h) Any Two SP Blowers in Service
i) Any One EC Blower in Service
j) BP-1 Not Acted

7.4 PURGE SEQUENCE:

a) Purge Ready
b) Purge in Progress (00-seconds) – Confirm purge on
c) Purge Failed
d) Purge Complete

8.0 START UP BURNER(SUB) OPERATION (From DCS):

Ensure that SCRALF of both Transport Feeders are in Reverse Rotation

A.Permissives:

1. Purging Completed
2. No MFT.
3. LDO Manual Feed valve Open.
4. LDO selected.

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 5. LDO Pressure OK (12 KSc)
6. Atomizing Air Pressure OK. ( 5 KSc)
7. Keep the SUB air flow around 10 to 12 T/Hr.

B Start up Sequence

Ensure LDO start permit is available in DCS.

1. SUB Start Command.

2. Gun advance & Control Auto (Oil FCV & Air flow in Auto).If
not, keep LDO FCV to about 25 -30%.
3. Pilot Vent Valve Close & pilot MTV Open.
4. Pilot BTV Open.
5. Pilot ON & pilot Flame OK.
6. Atomizing Air & LDO MTV Open (Atomizing Air PCV Control Auto).
7. LDO BTV Open.
8. Burner Flame ON.
9. Pilot MTV & pilot BTV Close ( Pilot OFF )
10. Pilot Vent valve Open.
C. SUB PROTECTIONS:

a. BP-1 Acted
b. Combustion air flow is less than minimum. (<2.7 Kg/sec)(9.7 T/hr)
c. PA Air Flow < 15 Kg/sec (54 Tons/Hr)
d. NO MFT CONDITION acted.
e. SUB Emergency Push Button Pressed (OWS Or UCP)
f. No. of failed ignitions > 4.
g. LDO manual valve not opened
h. LDO ATM. Trip valve not opened.
i. Scavenging valve not closed.
D. MTV CLOSE:
a. LDO pressure low.
b. LDO pressure high.
c. Any LDO deselected.
d. ∆P low.

Page 9 of 21
NOTE:

a. While cutting in the Burner, a person shall be available in Local with walkie
talkie for monitoring the sequence and safety purpose.
b. During the cold start of Boiler, the initial LDO oil pressure in DCS shall be about
3 to 4ksc so that the LDO flow will be about 1.0 T/Hr. The LDO PCV opening will
be about 30% for this pressure.
c. In case of oil leak in Burner, Control room has to be informed to stop the
burner immediately. Also the Hand operated Valve (HOV) in the Burner station
shall be closed.
d. In case of oil leak observed between LDO MTV and the Burner HOV,
immediately inform control room to close the MTV and to stop the LDO
pressurizing pump.
e. After the Burner is cut in, check the smoke at chimney for proper combustion
indication (i.e. No black colour in the smoke). In case of black colour, adjust the
air flow / atomizing air Pressure.
f. After the Burner is cut in Check for LDO oil Pressure and Atomizing air pressure
at Burner station and inform the Control room for comparison and healthiness of
Burner. When the Burner pressure is more (nearer to the pump pressure)
means the Oil gun is choked. The same has to be cleaned.
g. After the Burner is cut in, the suction filter ∆p and LDO tank level has to be
closely monitored on hourly basis, to avoid pump Trip on suction Pressure Very
Low.
h. During oil firing, frequent local checks have to be carried out in burner area to
watch out for any oil leak /fire and earlier detection.
i. If burner ∆p (Atomizing air pressure – LDO oil pressure) is not in auto, adjust
the ∆p to be about 0.5 to 1.0 KSc, for better combustion.
j. If the Burner flame is not established within 30 minutes after the purge
completion or after 4 unsuccessful attempts, re purging has to be carried out.
k. The rate of rise of combustor middle temperature (reference temperature)
permissible is 50-70°c for smooth heating up of the refractory. The firing has to
be adjusted to match the above rate. The oil flow details are furnished below.

Page 10 of 21
II. LDO OIL FLOW VS PRESSURE DETAILS (APPROX) :

Sl LDO LDO Atomizing Air Remarks

No flow pressure
Pressure flow
ksc *
t/hr ksc * t/hr

1 0.8 1.5 2.0 9 * The LDO oil pressure

and atomizing air /steam
(min) (min) pressure values are at
burner station. Hence
2 1.0 1.9 2.4 11 about 1.5 ksc (∆p across
valves ) shall be
3 1.5 2.9 3.3 17 subtracted from the DCS
values, to know the value
4 2.0 4.0 4.3 22 at burner station.

5 2.5 5.0 5.2 28 Example :

LDO oil pressure in DCS

6 3.0 6.0 6.1 33
= 8.0 ksc.

7 3.25 6.5 6.5 35 LDO oil pressure at burner

= 8 - 1.5 = 6.5 Ksc. This
(max) (max) may be compared with
burner pressure.

III Shut down of the START UP BURNER ( SUB ) :

1. Inform the UCR/Shift in charge before stopping the burner and obtain the
concurrence.
2. Before cutting out the SUB, please ensure that the Lignite Flow Low
annunciation vanishes which ensure stability of Boiler firing. (About 37 T /Hr )
3. Initiate stop command from DCS and ensure the following sequence.
a. BTV Close.
b. Atomizing Valve remains Open

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 c. Scavenging Valve Open & Pilot ON – 60 Seconds.
d. Scavenging Valve Close.
e. Atomizing Valve Close.
4. Keep SUB air flow in line with MCR load, based on revised SUB secondary air flow
curve.

TROUBLE SHOOTING FOR START UP BURNERS

Sl.No TROUBLE CAUSE REMEDY

1 No ignition spark a) Carbon deposits on Clean the electrode tip

electrodes with emery paper

b) Defective ignition Replace

transformer

c) Broken ignition cable

Replace
d) Ignition gas fixing
not proper
Correct or replace

2 Flame – improper Scanner shadowed by Adjust air fuel ratio

black smoke

3 There is spark and a) Check gas pressure is

no pilot flame available to the pilot at
the required pressure.(3
Ksc at LPG Station)

b) Check the operation of

the gas solenoid valve,
which should be energized
at the same time as pilot
electrode.(solenoid action
may be felt by wrapping
the hand around the
solenoid cover at the time
the valve is energized.

c) Check the P&S air flow

valve open position (2-3
turns)

Page 12 of 21
4 Pilot flame - a) Flame scanner not
established but picking up pilot re-sight
scanner not sensing scanner.
flame. b) Flame relay wiring not
proper-check and rewire.
c) Excessive combustion
air through register is
causing the pilot to burn
in the hood. Reduce air
flow.
d) Faulty flame scanner
lens. Remove and wash
with soap & water and
remove any foreign
material in the sight tube.
5 Main flame not - a) Check condition of
established atomizing /main fuel train
valves, manual cocks etc.

b) Check main fuel

pressure. If it is high
reduce to 3-4 Ksc.

c) Check for faulty or

sluggishly operating main
fuel shut off valve.

d) Adjust the air flow to

minimum permissive
value.

6 Main Flame No Feed Dust accumulation in a) Clean the dust

Back view path / C & I b) Healthiness of C&I
Circuit to be checked

Page 13 of 21
 Oil-Water
FOPH LAYOUT
Separator Pumps

HFO / LDO
Decanting Point
LDO LDO
1 2

HFO
2
HFO Tanks

HFO
1

Unit-2
F
HFO Filters
W S W S W S

LDO Pumps LDO HFO F

Heater-2
Heater-3

Heater-1
Unloading Unloading
For Lime Unit-1
Pumps Pumps
Plant

F F
To Sump Pump

C B A C B A
Staircase

Oil-Water LDO HFO

Sump Pumps Pumps Pumps
Unloading Pressurizing
Sump Pump Sump Pump

Entrance To FOPH
Page 14 of 21
 LDO TANKS AND CONNECTIONS

Hi_LS 0 Hi_LS 0

1 1
LDO LDO
Tank-I 2 Tank-II 2
Manhole Manhole
100 m3 100 m3 3
3
Elect. Heaters
4 LT 4 Nos Each 4
Lo_LS Lo_LS LT

VLo_LS 5 VLo_LS 5

LDO From Decanting Area

LDO To Lime Handling Sys

LDO To Pump Suction

LDO To DOT

Tanks Interconnection

LDO Return to Tank

LDO Discharge From Unloading Pump

NOTE:
1. LDO Tank -2 ( Lignite Handling System Side)
2. LDO Tank -2 Drain is connected to HFO Tank -2 for more LDO storage purpose

LDO to P/H Unit

LDO Discharge

LDO Suction
LDO to Lime Handling Sys
LDO to DOT

LDO Return to Tank

Page 15 of 21
 LDO To Lime Handling Plant Pumps
LDO LDO
LDO Discharge To Tank Tank-I Tank-II
100 M3 100 M3
LDO Suction From
Filter Decanting Area

W S ∆P Filter ∆P
LDO To P/H Unit

LDO Pumps For

Lime Plant
PG PG LDO Return
W S PG
PG PG
To Tank
PS LDO Unloading Pumps AV
Filter HFO
PUMPING
∆P ∆P
UNIT
To Lime Handling Plant
Drain
LDO PCV-Unit#2
LDO PCV-Unit#1

PS PS
PS PS PS
TE TE PT PT
TE
PG PG PG PG
LDO To Unit #1

PG PG
LDO Pump-C
LDO To Unit #2

PG
PG LDO Pump-B

Page 16 of 21
LDO Pump-A
 HFO SUB-2 Station (10.5 ML)
From Z Bed Lance Station (6.5 ML)
PG PG
Scavenging
valve
FM SUB-2 BTV BTV
From PT PG Impulse Lines
HFO Long
Return BTV BTV
Y Return from
(Steam) SUB-2 T

FCV
PCV
PG Impulse Lines PT X

HFO
LDO

Steam to Bed Lances LDO/HFO to SUB-2

Atomizing
Air
Atomizing
Steam

HFO to Bed Lances Air/Steam to SUB-2

Scavenging
BTV PG BTV BL-4 BL-5 BL-6
Drain
SUB-1 Station PG
SUB-2
(10.5 ML)

BTV BTV LDO/HFO To SUB-1 COMBUSTOR

OIL FIRING
Steam Steam/Air To SUB-1 SUB-1 SYSTEM
Air
SUB-1 BL-1 BL-2 BL-3
A
Return
To DOT
valve Impulse Lines
To DOT PG
PT Impulse Lines
Impulse Lines
To SUB-2

To SUB-1

X
Impulse Lines PG
LDO
To SUB-2

To SUB-1

LDO From PG PT PG
MTV
LDO Station (10.5 ML)
FOPH FM
FM
To DOT FCV PCV
TE PG PS PT TG PG PG PG
TE TG
MTV PT
Vent

FM
FM HFO From
Atomizing
Air

FCV Short PCV

Z HFO Station (10.5 ML)
To Bed Lances TE R/C Line FOPH for To Bed Lances
HFO Return From Unit-2
Drain

Y
Atomizing
Steam
Atm.
Drain

From DOT
FM HFO Return Line (10.5 ML)
Return
HFO Return Atomizing Steam & Air Station (10.5 ML)
Valve From X Page 17 of 21
From A (Long Return) From Unit-1
From SUB 1&2 To FO Tank at FOPH
NLC - BTPP -2 X125 MW - UNIT START UP SEQUENCE - BRIEF WRITE UP

No Activity /operation
1 The following equipments /systems are in service.(Prior to Boiler Light up)

(Note: As the unit is under shut down, the power supply is from grid.)

Fire Hydrant system.

Circulating water pump

Auxiliary cooling water pump

DMCW pump

Instrument air compressor

Service air compressor.

DMCW booster pump.

ESP hopper heaters switched on.ESP field in OFF condition.

Turbine on barring gear.( Main oil pump and Lifting oil pump are in service )

Fire Hydrant Booster system available.

LPG system available with minimum pressure of about 3.0 ksc

Emergency Boiler Feed Pump availability ensured

Bed Material System is available with sufficient quantity in the Bunkers

2 LDO in circulation.

3 Auxiliary steam not available

4 Water side drains in closed condition after filling up to normal working level in Drum.

5 Drum air vent in open condition.

6 All Super heaters drain open and diverted to IBD.

7 All Super heater air vents in open condition

Page 18 of 21
No Activity /operation
8 Both Super heater Start up vents in open condition

9 All Re heater drains open and diverted to IBD.

10 Re heater Start up vent in open condition

11 Boiler stop valve and bypass valve in closed condition.

12 The drain before Boiler stop valve in open condition to IBD tank.

13 Boiler expansion readings are noted for cold condition.

14 Steam soot blower line main isolation valve in closed condition.

15 Ensure power supply for all fans, blowers and local checking for start up.

16 The following equipments are in service( Boiler Light up requiremnts)

ID fan ( Preferably both ID fans )- Ensure air conditioning in ESP Control Room

Purge and seal air blower with sand filter blower

Both Seal pot blowers.

Empty chamber blower.

Secondary air fan with sand filter blower

Primary air fan with sand filter blower

Ash cooler blower./Blowers

Bundle chamber blowers (Four nos ).

17 Boiler purging-Ensure Lignite Rotary Air Lock Feeder is on reverse mode

Boiler light up with Startup burner-2(SUB-2) . SUB-1 as per requirement. The firing
18 rate shall be about 60 -80 deg C /hour to rise in middle bed temperature.

19 Phosphate dosing pump start.

20 Ensure the following system vents /drains in open condition.

Main steam PRDS station.

Page 19 of 21
No Activity /operation
HT AST header.

LT AST header.

Atomizing steam.

Fuel oil heating steam line to FOPH .(secondary heater included )-Only if HFO is to be
taken

Floor coil heating steam.

Suction coil heating steam.

Tracing steam lines in pipe rack.

21 Electrical heat tracing system in Boiler house is switched ON.

22 Boiler Feed pump start with Ammonia and Hydrazine dosing system inclusion..

23 HP bypass oil supply unit ON.

24 CEP start. Ensure CEP Pit is empty

Drum pressure -2 Ksc

25 Drum and super heater air vent - close.

Super heater start up vents - close.

Drum pressure -5 Ksc

26 Boiler stop valve by pass valve open.MST line charging.

Super heater drains - close.

Drain before Boiler stop valve close.

Drum pressure – 7 to 8 Ksc

27 Boiler stop valve open.

PRDS charging. AST pressure 10KSC.and AST temperature .200 deg C.

Heavy Fuel oil tank heating.HFO pump start with short circulation when tank
temperature is about 50 deg C.

Page 20 of 21
No Activity /operation
28 Gland steam charging.

29 Vacuum pulling.

30 Drum pressure -17 Ksc.

31 HP by pass open. Control oil pump start.

Hot Re heater pressure 2KSC.

32 Re heater air vents and drains close.

LP bypass open in parallel with Re heater start up vents close .

33 Re heater start up vent close.

HFO system in LONG circulation at 125 -130 deg C.

34 Switch over one LDO SUB to HFO.( If necessary both SUB on HFO )

35 Bed lances cut in.

36 Adjust HP -LP bypass as per firing / permissible gradient.

37 Reaching lignite firing condition.

38 Ensure availability of Diesel Generator Set.

39 Reaching rolling parameters.

40 Rolling.

41 Synchronizing.

42 Load raising as per the requirement.

Page 21 of 21