Beruflich Dokumente
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KORBA SIMULATOR 2
KORBA SIMULATOR 3
CONTENTS
3. BOILER SYSTEM
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GENERATOR SYNCHRONISATION 125-128
12. APPENDIX
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CHARGING OF ELECTRICAL SYSTEM
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CHARGING OF ELECTRICAL SYSTEM
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- Tie Xmers 1 & 2 are - Switchyard operation.
CHARGED from 400 Not simulated.
KV and 33 KV sides.
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supply fault" and
"UATs cooler/ OLTC
trouble and "415 V
boiler/turbine MCC
fault" annunciations
reset.
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CONDENSATE
AND
FEED WATER SYSTEM
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CEP OPERATION
PRE-START CHECKS OF CEP
CONDENSATE SYSTEM
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- CEP discharge valves - UCB operation.
are CLOSED (MC-5/ Interlock, before
MC-6). starting the first CEP.
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- Deaerator inlet valve - Local check Not
(MC-75) is OPEN. simulated.
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STARTING PROCEDURE OF CEP
1. CHECK before starting - All pre-start checks are - Local /UCB checks &
any condensate pump. OVER. operation
3. CLOSE the air vents on - The air vents are - Local operation Not
condensate lines. locally closed. simulated
Alarm Trip
Bearing Temperature 75 oC 90 oC
Vibration 40 microns 75 microns
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6. CHECK that the - Breaker control switch - UCB control switch on
second condensate is on 'Normal After 'off' position
pump is ready for Stop' position.
starting and is
available on STANDBY.
Alarm Trip
Bearing Temperature 75 oC 90 oC
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CEP SHUTDOWN PROCEDURE
- Discharge header
pressure goes up
slightly.
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BFP OPERATION
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2. CHECK that before - BFP lub oil, working oil - Local operations.
BFP is locally and seal water coolers are Not simulated.
LINED UP starting. in CHARGED position. All
manual valves for cooling
water to bearings are
OPEN.
3. CHECK that feed - All air vents on suction - Local check. Not
water system is and discharge lines of BFP simulated.
lined-up (Required and feed regulating station
only for the first are OPEN.
BFP to be started).
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FEED WATER SYSTEM
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101/FW102/FW-103) start
opening.
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- Re-circulation valve control
transfers to auto.
Alarm Trip
Brg. temp. 95 oC 105 oC
Working oil outlet temp 95 oC 130 oC DAS/Local indication.
Vibration 9 mm/sec. 12 mm/sec. DAS/local point.
Motor wdg temp. 110 oC 135 oC
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automatically as the main
oil pump takes over.
- Re-circulation valve
modulates to maintain set
re-circulation flow.
5. ADJUST BFP bias - BFP biasing set has been - M/A release must be
to 50% and provided above BFP scoop pressed for
ADJUST BFP control. auto/manual
master controller transfers
equal to BFPs scoop
tube position.
- Controller error on the
scoop controls of the
running BFPs becomes
zero.
7. Adjust FRS DP, set - Controller error on BFP - UCB M/A release
to 60% -80% and master Controller becomes push button is to be
TRANSFER BFP zero, when actual& set pressed for auto/
master control to values of DP are matching manual changeovers.
auto.
- BFP master trips to
manual if any of the
running BFPs trips or
individual BFP
control is changed to
manual mode.
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BFP SHUTDOWN PROCEDURE
NOTE:- Before closing the suction valve, please ensure that discharge valve is
closed & there is no passing in the discharge valve and NRV. Otherwise,
due to back pressurising booster pump glands may fail, leading to leakages
etc. Watch for any increase in suction pressure when closing suction valve.
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SINGLE ELEMENT FEEDWATER CONTROL
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BOILER SYSTEM
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AUXILIARY PRDS CHARGING
ACTION OBSERVATION REMARKS
4. ENSURE all the - Oil tank level is - Local check only. Not
conditions are satisfied ADEQUATE & oil pump simulated.
before charging the unit is RUNNING and its
PRDS system. pressure is ADEQUATE.
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- All hydraulic valves' - Local
controls are on operation/check. Not
REMOTE. simulated.
- Isolating valve AS-6 and - Local operation. Not
AS-9 are OPEN 100% simulated.
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HEAVY FUEL OIL SYSTEM
In coal fired Thermal Power Plants, the Fuel Oil plays a vital role in initial firing of the
Boilers and running it up to 25-30% of its capacity. The fuel oil is also used as a
stabilising fuel in the coal fired boilers till the coal flame stabilises in the furnace and
for proper coal burning while the load is reduced in the boiler for a shut down.
All the main storage tanks are generally interconnected to the suction side of
unloading pumps so that oil from one tank can be transferred to another for the
purpose of any maintenance work. The storage tanks are equipped with Magnetic type
float switches and Mechanical type float level Indicators to measure the quantity of oil
stored.
In order to keep the viscosity of oil in storage tank low, it is essential to keep the oil
warm between 50 0C to 70 0C so that the oil from main tanks can be transferred to
service tanks for normal / daily utilisation of fuel oil for the firing. For this purpose a
steam floor-heating coil has been laid at the bottom of the tank. Thermostatic
temperature controller installed at the inlet of steam heating coil, controls the
temperature of oil tank at the desired point selected between 500C to 700C.
The HFO passes through the oil strainer on the suction side of the high-pressure
screw pump. Heavy oil pumping unit consists of oil suction strainers and screw
pumps each coupled through flexible coupling and mounted on a common frame.
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The screw pump, when connected to an induction motor with constant speed, is a
constant quantity pump and valves in the delivery line control the delivery pressure.
When only a small quantity of oil is fired, the excess oil from the pump discharge
should be bypassed. This is done automatically by electrically operated, pressure
maintaining valve bypassing the excess quantity through the return oil line to storage
tank and the delivery pressure of oil is maintained constant at the pump outlet,
whatever be the quantity of fuel oil.
HFO from the delivery side of the HFO pumping unit enters the HFO pre-heater where
it is heated from pumping temperature to a temperature corresponding to an
atomising viscosity. The outlet temperature of HFO from the heat exchanger is
automatically maintained at a constant value by the automatic temperature-
regulating valve, mounted on the steam supply line to heaters. The temperature-
regulating valve controls the quantity of steam to the heater according to the outlet
temperature of the oil from the heater.
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FURNACE SAFEGUARD AND SUPERVISORY SYSTEM
FSSS facilitates remote manual/automatic control of fuel firing equipments through
mechanised system with suitable interlocks and logics. It is designed to ensure the
execution of a safe, orderly operating sequence in start up and shutdown of fuel
firing equipments, and thereby to prevent errors or omissions in following such
procedure.
The system provides protection against malfunction of fuel firing equipments and
associated air system. The safety feature of system is designed for protection in most
common emergency situations. FSSS comprises of control circuits, various logics and
indicators to carry out the following:
This consists of all switches for initiating controls and also indications of status of
all fuel firing equipment & their auxiliaries.
The cabinets consist of relays, timers, programmers, circuit breakers for AC and
DC control supplies flame scanner unit, number of coal flow units etc. They
control the process logic.
3. Field Equipment:
Field equipments are those which help in actual remote operation of fuel firing
equipments and those, which provide the status to the operating, console and
relay logic cabinet.
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Field Equipment Includes:
Ignitor/HFO Trip Valves, HFO atomising steam, Scavenging steam/ Nozzle valves
(Hydra motor type), gun advance/retract mechanisms, oil gun assembly, ignitors
and its cabinets, flame scanner and ignitor air fans, pressure switches,
temperature switches, flow switches and limit switches, Mill Discharge valves, hot
air gates, seal air valves, cold air, tramp iron gate etc.
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220 V AC SUPPLY SYSTEM
1. ANALOGUE CONTROL SYSTEM (ACS) : (H&B)
2. ANNUNCIATION
3. AUX. PRDS :(SULZER)
4. AUX. RELAY PANEL
5. DATA ACQUISITION SYSTEM (DAS)
6. FEEDER CABINET
7. FSSS AC SUPPLY
8. HP BYPASS CABINET: (SULZER)
9. HYDRASTEP
10. SECONDARY AIR DAMPER CONTROL (SADC)
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FSSS LOGICS AND INTERLOCKS
FURNACE PURGE
Furnace purge is required after every boiler trip-out and before light up to expel all
unburnt fuel particles, gases, vapour etc. from the boiler, so that possibilities of
explosion are eliminated, when ignition energy is made available.
Boiler purging cycle is of 5 minutes duartion. 'PURGE READY' appears only when all
the purge permissives are satisfied. Pressing ‘PURGE START’ push button will start
purging. When purge cycle is completed, 'PURGE COMPLETE' signal will come. This
is an indication that boiler MFR is reset and now boiler can be lighted up. If any time
during purging, any of the Purge Permissive conditions are violated, 'PURGE READY'
signal will disappear, and purging cycle is to be started once again after establishing
'PURGE READY' conditions. Once purging is completed, boiler will trip if any of the
'Boiler Trip' conditions occur.
1. No Boiler Trip
2. Warm-up valves closed
3. All auxiliary air dampers modulating and wind-box to furnace DP O.K.
4. All feeders off.
5. All elevation flame scanners show 'no flame'.
6. Both PA fans off.
7. All ignitors and Warm-up Trip valves closed.
8. Hot Air Gate closed.
9. Ignitor Valves closed.
10. All pulverisers off.
11. Nozzle Tilt Horizontal AND Airflow less than 40%.
A) Ignitor trip valves will open when trip valve 'open' Push Button is pressed
provided all the following conditions are fulfilled:
2
a. Ignitor oil supply pressure is adequate, more than 13 Kg/cm
b. All ignitor valves are closed
c. No boiler trip command is persisting.
d. Scanner air to wind box differential pressure more than 125 mm WCL.
When ignitor trip valve is fully open, 'Open' signal comes on FSSS console.
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B) Ignitor trip valve will close under following conditions:
When ignitor trip valve is closed, the valve ''closed'' green lamp comes on.
Ignitor Starting
There is no separate ignitor start switch provided for any of the elevation AB, CD
or EF Ignitors. Pressing any one pair of oil gun ' START' or STOP' push button
gives a starting impulse to all four ignitors of that elevations. The spark is applied
for 10 seconds only for every pressing of ignitor start push button.
Ignitor Stopping
All four ignitors of each elevation are provided with one 'STOP' push button for
taking out ignitors from service. Also ignitor gets stop command, at the end of stop
time trial of HFO oil elevation. When individual ignitors get stop command its
motorised oil/air valve closes thus taking out ignitors from service.
Heavy oil can be fired at AB, CD and EF elevation. Heavy oil gun have been
programmed to light up on pair basis, diametrically opposite corners (1,3 and 2,4)
form the pairs. Each pair is provided with start/stop push button.
HFO guns are self-sustaining only when elevation firing rate is at 30%, hence,
ignitors corresponding to HFO guns in service must only be removed when HFO
burner header pressure is above 3 Kg/cm2 (g) and at least 3 HFO guns at the
elevation are in service and corresponding flame scanners are sensing flame.
Flame scanners monitor heavy oil guns flame only when the following conditions
are fulfilled.
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HFO TRIP VALVE INTERLOCK
A. HFO Trip Valve (HOTV) can be opened by pressing 'OPEN' push button,
provided the following conditions are fulfilled.
Opening: HFO re-circulation valve can be opened following a boiler trip and before
starting furnace purge cycle by pressing valve 'open' push button. Valve opens
provided:
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HFO Corner Start Permissive
a. The main oil guns are inserted in guide pipe and coupled.
b. The local maintenance control switch is placed in REMOTE.
c. HFO manual isolation valve is open.
d. Atomising steam manual isolation valve is open.
e. Scavenging steam valve is closed.
f. 'Elevation Start' Permissive available
When HFO Pair start push button is pressed a pair of HFO guns is placed in
service in following sequence (provided HFO elevation start premissives are
satisfied).
• Within first 10 seconds of pair start trial time associated elevation ignitors are
started. When ignitors are proven, Ignitor 'ON' signal comes on. If the flame is
not proven, sparkwill cease and Jamesbury Valve is closed after 10 seconds.
• When minimum 3 out of 4 ignitors at the associated elevation are proven ‘ON’ at
the end of 10 seconds, a start command is given to heavy oil gun no. 1 (if pair 1
- 3 is selected) or to heavy oil gun no. 2 (if pair 2 - 4 is selected), if corner-
scavenging valve is closed.
• Twenty five seconds later a start command is sent to corner no 3 (in case of 1 -
3 pair) or corner no. 4 (in case of 2 - 4 pair)
When an individual heavy oil corner receives a 'start' command and its associated
ignitor is proven 'ON' it is placed in service in following sequence.
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- Minimum 3 out of 4 flame scanners sensing flame at that
elevation.
Unsuccessful Corner Start:
At the end of 90 seconds of pair start trial time a heavy oil corner trip is
initiated for any corner when -
Heavy oil elevation is removed from service on a pair basis. Depressing the
associated elevation pair stop P.B. will initiate a 375 sec. time trial to
shutdown and scavenge the associated pair of heavy oil guns as follows:
When an individual heavy oil gun that is in service, receives a stop command:
Six minutes after, remaining pair of HFO guns stop is initiated, a back-up trip
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signal is established which will remove the associated elevation of ignitors
from service and initiate a close signal to all HFO nozzle valves, all of the
scavenge valves at the elevation to ensure they are closed. Fifteen seconds
later an 'Unsuccessful Elevation Shut-down' alarm comes if –
PULVERISER INTERLOCKS
1. Start Permit.
2. Pulveriser discharge valve open.
3. Seal air O.K.
4. Cold air gate open.
When all the above conditions are satisfied for the respective Pulveriser, its
associated 'Pulveriser Ready' light appears.
Pulveriser-A
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Pulveriser-B
OR
Pulveriser - C
Pulveriser - D
Pulveriser - E
Pulveriser - F
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ii. Boiler loading is greater than 30 % and feeder-E is in service and
greater than 50 % loading.
Pulveriser Start
When both ''Ignition Permit'' and 'Pulveriser Ready' are established for the respective
Pulveriser, the Pulveriser may be placed in service as follows:
Coal flow must be proven either by the coal flow detector or satisfactory Pulveriser
amps within five seconds after the feeder is started. Fifteen seconds after the feeder
is started, the feeder output is released to automatic control, and the fuel air damper
is opened to modulate as a function of feeder speed.
When a minimum of two feeders are established at greater than 50% load the
associated elevation of oil guns may be shutdown provided the feeder has been on for
a minimum of three minutes.
Either of the following conditions will force the feeder speed to manual and
minimum until the initiating condition is corrected.
Loss of coal flow and low Pulveriser power as confirmed by Pulveriser amps will trip
the feeder. Any Pulveriser trip shall trip the associated feeder instantly.
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Hot/Cold Air Dampers and Hot Air Gate Interlocks
All cold air dampers (CADs) will close to less than 5% open when the START
command is given to any PA Fan if no PA fan is running.
All CADs shall open 100% if boiler trips.
When the start command is given to any Pulveriser, the associated cold air
damper is open 100%.
When any Pulveriser outlet temperature is more than 95oC the CAD is open
100% and HAD is closed 100%.
Operation release for the CAD is obtained when the associated HAG (hot air gate)
is opened 100%.
The HAG can be opened manually when the associated Pulveriser is 'ON'. or it
can be opened automatically when Pulveriser on command is given on 'AUTO'.
HAG of any Pulveriser will close if the temperature at outlet of Pulveriser is more
than 95oC or the associated feeder trips with a time delay of 40 sec.
The HAG will close instantaneously if the associated Pulveriser trips from
service.
1. When both PA fans are tripped or hot PA pr. falls below the low set point of
585 mm wcl all pulverisers in service receive a trip command with a time delay
of 5 seconds. When hot primary air duct pressure falls below very low set
point of 525 mm WCL, all pulverisers in service are tripped instantaneously.
2. When only one PA fan trips or stopped and four or more pulverisers are in
service, a trip command will be initiated to trip the running Pulveriser from
the top until the number of pulverisers running is reduced to three.
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BOILER TRIP CONDITIONS (200MW)
FSSS protects the boiler by trippingout all fuel inputs, under the
following conditions
1. Simulate Trip.
2. Loss of 220V DC to FSSS.
3. Elevation Power Failure.
4. Flame failure.
5. Loss of all fuel.
6. Airflow falls below 30% (MCR).
7. Furnace pressure high (+ 200 mm WCL).
8. Furnace pressure low (- 200 mm WCL).
9. Drum level high (+ 225 mm).
10. Drum level low (-225 mm).
11. Re-heater protection trip.
12. Turbine Trip with boiler load more than HP/LP Bypass capacity (60%).
13. Loss of all Boiler Feed Pumps.
14. Both Emergency Push Buttons pressed.
15. Loss of ACS Power.
16. Loss of Unit Critical Power.
17. Both FD Fans OFF.
18. Both ID Fans OFF.
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STEPWISE OPERATION LOGICS OF F.S.S.S. (200 MW)
1. PURGE PERMISSIVE & PURGE COMPLETE
2. IGNITOR WARM-UP & RE-CIRCULATION FUEL TRIP VALE
3. IGNITOR FAN AND OUTLET DAMPER CONTROL
4. SCANNER AIR FAN CONTROL
5. WARM-UP ELEVATION START PERMIT
6. PAIR 1-3 AND 2-4 WARM-UP ELEVATION CONTROL
7. SELECTION OF OPERATION MODE
8. OPERATION IN ELEVATION MODE
9. WARM-UP ELEVATION IGNITOR CONTROL
10. WARM-UP ELEVATION CORNER NOZZLE CONTROL
11. PULVERISER READY
12. PULVERISER TRIP
13. COAL ELEVATION PULVERISER CONTROL
14. PULVERISER SEAL AIR VALVE & DISCHARGE VALVE CONTROL
15. FEEDER CONTROL
16. AUTO CLOSE COMMAND FOR HOT AIR GATE
17. HOT AIR GATE CONTROL
18. COLD AIR DAMPER CONTROL
19. MILL FEEDER SPEED DEMAND TO MINIMUM
20. MILL FEEDER PROVEN SIGNAL
21. RELEASE FOR AIR AND TEMP. CONTROL TO AUTO
22. PULVERISER IGNITION PERMIT A & F
23. PULVERISER IGNITION PERMIT B & E
24. PULVERISER IGNITION PERMIT C & D
25. CONTROL OF SEAL AIR FAN
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OPERATION PROCEDURE
AIR PRE-HEATER OPERATION
PRE-START CHECKS
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- Starting current shoots up - UCB indication.
and comes down to
normal load current.
Note: Air pre-heaters air motors can be started manually provided electrical motors
are off, isolating valves of air motor solenoid are open and service air pressure
is normal. The air motors come into service on auto interlock, when
corresponding electrical motors trip-out on any protection.
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- Electrical supply is - Refer to the respective
AVAILABLE modules.
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3 STOP the - Fan breaker goes open. - Maintain desired oxygen
associated FD percentage.
fan.
5 STOP air heater - Air heater electrical motor - Breaker off green lamp
electrical motor. goes off. comes on
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ID FAN OPERATION
PRE-START CHECKS
1 CHECK all the - Fan lub oil pressure is - If not, ask the local
start permissive ADEQUATE (1.2 Kg/cm2). operator to start the lub
are satisfied oil pump and check the
before starting pressure.
the ID Fan.
- Fan inlet/outlet dampers - The dampers start
(GD 17/18, GD 21/22 is closing after the first fan
CLOSED. start command is given.
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3 CHECK if flue - ID fans' suction/ - Local check.
gas path is discharge dampers are
LINED-UP for ID OPEN 100% and
Fan operation. operational.
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STARTING PROCEDURE
1 Check before starting - All pre-start checks are - ''Inlet guide vanes
ID Fan. OVER. min.'' & Inlet/outlet
dampers closed''
permissive become
available after the fan
start command is
given.
- Local operator is
informed before the fan
is started.
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vanes to maintain vane position increasing
furnace draught (Controller output
between - 5 mm. to - increasing).
10 mm.
- Furnace airflow
indication increases
slightly.
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2 START fan motor - Fan motor current - Breaker closed
settles down at 45A. indication comes on.
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SHUT DOWN PROCEDURE
3 STOP the ID fan. - The flue gas after EP - Associated red lamps
interconnecting dampers come on.
open on interlock.
- Maintain desired
amount of oxygen
percentage.
Normal 100 0C
Trip 130 0C
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FD FAN OPERATION
PRE START CHECKS
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- FD fan discharge - UCB checks.
dampers are
OPERATIONAL and
electrical supplies are
AVAILABLE.
STARTING PROCEDURE
1 CHECK before - All pre-start checks are OVER. - "Blade pitch minimum"
starting FD Fan. and "Discharge damper
closed" permissive are
available after the fan
start command is given
- Control/lub oil pressure: OK
- Bearing temp is NOT HIGH.
- Blade pitch is MINIMUM.
- Discharge damper is CLOSED.
- Control oil temp is NORMAL.
- Local operator is INFORMED.
2 START the FD - Discharge dampers start closing - UCB indication.
fan motor.
- Blade pitch comes to minimum. - Controller output 0%.
- As soon as discharge damper - Associated saffron lamp
closes, "Blade pitch minimum" on.
permissive comes on.
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3 Instruct local - Bearing temperature and - UCB OMNIGUARD
operator to vibration limits are: indicators must be
check bearing regularly checked for
vibration and bearing temperatures.
temperature.
Alarm Trip
Fan 90 oC 105 oC UCB indication
Motor 80 oC 95 oC UCB indication
Vibration. 2 mm/sec 2.5 mm/sec. UCB indication
Motor wdg temp. 120 oC 135 oC DAS indication
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- Control oil temperature is - Local check.
NORMAL
2 START the FD fan - The fan breaker gets closed. - Red lamp ON.
4 CHECK vibration - The limiting values of vibration - UCB vibration & bearing
and bearing & bearing temperatures are: temperature indicators
temperatures in must be monitored
the UCB. regularly.
Alarm Trip
Vibration. 2mm/ sec.pk 3mm/ sec.pk - Check locally also.
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FURNACE PURGE PROCEDURE
ACTION OBSERVATION REMARKS
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- Oil elevation dampers also - Refer to the
modulate with aux. air secondary air damper
dampers when no oil gun control logics
is in service
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WIND BOX CORNER NOZZLE ASSEMBLY
As soon as "NO BOILER TRIP" permissive becomes available, a "post trip damper
reset programme" is initiated. A separate timer starts and after a time delay of 5
minutes, coal air dampers are closed in a phased sequence, from the top. Elevation,
F, E and D closes first; then with a time delay of 5-second, elevation C, B and A
close. After all the coal air dampers are closed, 10 sec later, all auxiliary air and oil
air dampers are released for modulation. If the air damper controllers are in manual,
auxiliary dampers and oil dampers together follow auxiliary air damper controller
output. If the controllers are in auto, they will modulate together to maintain set
wind box to furnace DP. When oil is introduced, oil air dampers modulate as a
function of oil header pressure. After feeders are started, corresponding coal air
dampers modulate as a function of feeder speed, if put on auto.
Wind box to furnace DP must be maintained 40 mm wcl, when boiler loading is less
than 30% MCR. Above 30% loading wind box to furnace DP must be constantly
ramped up to the maximum of 100 to 120 mm wcl, at full load.
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BOILER LIGHT-UP
PREPARATION FOR BOILER LIGHT-UP
4 INSTRUCT local
operator to
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BOILER LIGHT-UP PROCEDURE
2. Open heavy fuel oil re- - HFO re-circulation valve - UCB indication
circulation valve opens up. Interlock before
opening HFO
trip valve.
3. OPEN heavy fuel oil - HFO trip valve opens up. - UCB indication
trip valve on FSSS
console.
- Short re-circulation valve - Interlock. UCB
closes. indication.
4. OPEN heavy fuel oil - HFO header pressure rises up - UCB indication.
control valve. 2
to 10 Kg/cm (approx.)
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automatically. trip valve logics.
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8. CLOSE heavy fuel oil - HFO re-circulation flow valve - UCB indication.
re-circulation valve. closes.
- HFO re-circulation flow comes - UCB check
to minimum position only.
9. PUSH " Pair 1-3 or 2-4 - In the first 10 secs of the pair - Associated
Start" push button. start trial time; ignitors 1-3 ignitors “ON”
and 2-4 are proven, in the indications
associated oil elevation. come on.
- Gun. "Advance",
lamps come on
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- HFO control valve modulates - Maximum HFO
to maintain set HFO header header pressure
pressure must not be
more than 13
Kg/cm2 (alarm)
10. ADJUST heavy oil - HFO header pressure changes - HFO trip valve
pressure controller to accordingly trips at the
desired firing header pressure
of 3.5 Kg/cm2
11. PUSH second pair - HFO guns advance and - Refer to the
"Start"(Pair 1-3/2-4) corresponding nozzle valves FSSS oil gun
push button. open up. logics.
12. PUSH "Ignitor Stop" - All the elevation ignitors go - UCB indication.
push button to remove off.
ignitors if the oil flame
is stable in every corner
in the elevation
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PA FAN OPERATION
PRE-START CHECKS
2 CHECK that PA fan is - PA fan lub oil coolers are - Local operation. Not
locally line up for CHARGED from aterside. simulated.
starting.
- PA Fan LOP : ON and - Local operation and
other pump is on AUTO check.
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- Seal air fans are LINED- - Local operation. Not
UP and their suction simulated.
dampers AD-31/32/33
are OPEN.
STARTING PROCEDURE
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- All mills cold air dampers - Saffron lamp
go to less than 5% open (permissive) glow on.
and "FSSS start command"
permissive comes on.
KORBA SIMULATOR 98
WHEN ONE FAN IS RUNNING
KORBA SIMULATOR 99
4 ADJUST the fan guide - Fan discharge - Maintain PA Header
vanes to get desired PA pressure read approx. pressure
header pressure and 800 mm wcl. 760 mm wcl
equalise fan loadings. constantly
- PA header pressure
rises to 760 mm wcl.
ADJUST the fan - Header pressure and - Biasing set point can
biasing and header biasing set points be altered suitably to
pre. set point to 50% & have been provided change the fan
80% respectively and over the IGV loadings.
transfer vane controllers of PA fan
controllers to auto. A&B respectively.
4 STOP the fan motor. - The fan breaker opens - UCB indication.
- Discharge damper - Associated green lamps
(AD-15/AD-16), starts come on.
closing.
1 SHUTDOWN all - Boiler total fuel flow - Adequate oil elevation must
running pulverisers starts decreasing. be cut-in before stopping
one by one. pulverisers.
- ID fan vanes
modulate (on auto),
to maintain set
furnace draught.
- Discharge dampers
of both PA fans go to
100% open.
- Pulveriser starting
current settles down at 12
amps.
6 RAISE mill feeder - Mill differential pressure - Watch the flame quality
speed gradually. goes up to 180 mm wcl. at improving in coal flame
34 T/Hr. coal firing, scanners. If flame is not
depending upon coal good, instruct the local
quality & mill condition.). operator to check the
furnace flame and oil
flame. If the need be
increased the HFO
pressure by adjusting
HFO control valve (to
2
approx. 12 Kg/cm .) to
improve flame quality.
- Mill current goes up to 30
-32 amp. At maximum
loading of 34 T/Hr.
depending upon the coal
grindability (Hargrove
index).
7 ADJUST flow & - Flow & temp Control set - Refer to ACS drawings
temp control set points are provided over for details of flow and
points to 70% and CAD & HAD respectively. temperature controllers
50% respectively of the pulveriser.
and RELEASE mill
air control to auto.
NOTE:
- Operator must monitor continuously the mill temperature and bowl DP,
which should not exceed 95 oC and 200 mm wcl respectively.
- Before starting mill, operator must make sure water supply for oil bath
coolers.
2 START AOP and - "Control oil pressure low" and - UCB indication &
one JOP. "Lub. Oil pressure low" alarms check only.
get cleared off.
- M S pressure 12 Kg/cm .
2 - UCB check.
NOTE: -
1. MS pressure set point must not fall too much below the actual MS pressure;
otherwise due to pressure interlock (error deviation + 10), a fast opening
command is given to HP bypass control valves.
2. At 380 O C, HP bypass valves receive a closing command and their control trips
to manual. The temperature set point must be suitably altered to maintain the
desired HRH temperature.
3. For details on ACI (Automatic Control Interface) device, please refer to the text
on HP/LP bypass system (Volume-1)
1 CHECK that all the - All UCB indicators and - If required, contact
turbo-Supervisory recorders are functional the related C&I
instrumentations are and healthy. engineer for
functional. maintenance.
- Electro-hydraulic - Indication on
controller's output is zero. governor console.
All differential
expansions of the
turbine are NORMAL
and within the alarms
values
Alarm Trip
HPT +4.5mm +5.5mm
-2.5mm -3.5mm
IPT +5.0mm +6.0mm
-2.0mm -3.0mm
LPT +25 mm +30 mm
- 5 mm - 7mm
- Condenser vacuum is - "Condenser vacuum
NORMAL. 0.92 Kg/cm
2 low" (150 mmHg) &
approx. "Turbine electric
protection for low
vacuum" (225 mm
Hg) are not ON.
1 CHECK turbine start- - Main steam, at the turbine - Applicable during all
up criteria as inlet should have minimum turbine start-ups.
determined from the of 50 oC superheat.
X-curves.
- M.S. pressure is 30 KSC - For cold start-up
approx. & temp. 280oC only.
2 CHECK before closing - Turbine RPM is more than - UCB & switchyard
the field breaker 2980 rpm. Generator operator's
before isolators are closed from responsibility/ UCB
synchronisation switchyard. indication
Alarm Trip
Cold gas temp. (HI) 47oC -
NOTE: For changing-over the supply from UATs to station or station to UATS use
appropriate synchroscope switches. OLTC operation of station transformer
is not simulated. In the reference plant the same is operated from CSSAEP
panel located in UCB-1.
NOTE :
Isolating valve of Group Bypass charging line (pressurising line) locally has
to be opened. This only causes group bypass to operate after some time.
''HPHs bypass'' indication is from the group bypass valve limit switch, not
from the solenoids.
5 ADJUST S/H outlet - S/H temperature set points - M/A release must be
temp set points to are provided over respective pressed for manual
90% each. (540oC). controllers. to auto transfers.
- ADJUST hot reheat - Hot reheat temperature set - Auto controller for
temp set point to 90% point is provided over SH/HR temp trips to
and biasing set point burner tilt controller. manual if BFP DP
to 50%. across FRS is >
20KSC
NOTE :
2. Blowing time for LRSBs is approx. 8 min. and blowing operation for LRSB
continues right from the moment it leaves its home position unlike wall
blowers in which case, blowing starts after the blower reaches blowing
position.
1. CHECK all pre-start - All work permits on main - Refer to the PTW
conditions are boiler, all electrical panels, record book and
satisfied before all aux. Systems are unit controller's
starting the unit CANCELLED logbook.
from cold.
- All man/materials are - Local checks.
REMOVED from equipments
and site.
- Lube oil levels in bearing - Local Checks. Not
and MOT/oil tanks are simulated.
ADEQUATE.
- Clarified/Raw water pumps - Local checks/
are ON and water systems operation.
are LINED-UP. Not simulated.
- Ash hopper sealing/ flushing - HP/LP water pump
water Supplies are are ON Not
AVAILABLE. simulated.
- Service/Instrument Air Pr. - Local operation.
ADEQUATE (7-8 kg/cm ).
2 UCB indications.
2 OPEN all drains/ - Valves AS-5, AS-6 AS-8, AS- - Local operation.
vents on aux. steam 9, AS-10 are OPEN. Not simulated.
header & line-up unit
aux. steam hdr for
charging.
- All aux. steam (unit) supply - Local operation.
valves AS-11/ 12/ 13/ 14/
16/17/18 19/32 are OPEN.
3 OPEN AS-31, the - Unit aux. steam pressure - UCB indication.
interconnection starts rising to 13 kg/cm
2
4 CLOSE all associated - All aux. steam hdr drains & - Local operation.
drains and vents on vents are closed after the Not simulated.
the aux. steam aux. steam header reaches
header to 2-3 kg/cm
2
8 CHARGE D/A feed D/A feed storage tank water DAS indication.
storage tank heating temp starts rising.
by opening AS-78
slightly and transfer
D/A pr controller to
auto control after DA
pressure is 1.5
kg/cm2.
D/A pressure starts building AS-78 not
up to 1.5 kg/cm2, gradually. simulated. Local
operation.
13 START furnace MRF (A&B) are reset after "MFR TRIP” alarm
purging. five minutes. goes off.
OR
20 CLOSE all drum SH SH-RH and drum air vents Local operation
and RH air vents after closed. Not simulated.
the drum pr. comes
2
to 2-3 Kg/cm and
throttle start-up
vents.
S-28, S-23, R-15 and R-20 UCB operation.
are throttled.
- Steam temperatures
must be maintained
at minimum values
as indicated to
minimise soaking
times.
37 TRANSFER all ID, FD, - ID fan vanes transfer to auto - UCB operation.
PA fans controls and & maintain set furnace Furnace draft of -5
BFP scoop controller vacuum. to –10 mm wcl is to
to auto. be maintained
38 ENSURE the mill PA - Auto lamp of both the - Both the controller
flow and temp control controller is ON. must be in auto
on auto. mode before feeders
are put in auto.
39 ADJUST raw coal - The feeder speed controller's - UCB check only.
feeders' biasing to error deviation comes to 0%
50% and the Fuel (biasing may be adjusted to
Master Controller’s get dev. 0% for a given fuel
output, as per master output).
requirement.
42 ADJUST Unit Master - Boiler Master controls the - Refer to the CMC
output equal to the boiler firing rate, depending logics.
T/ G load and set on the unit load demand and
max/min. load limits throttle pressure set point.
and load rate on CMC
console. RELEASE
Boiler master
controller to auto and
unit control to CMC.
4 ENSURE all purge - Boiler MFR (A&B) gets reset - UCB operation.
permissive are after a time delay of 5
available and do minutes.
furnace purging for
5 minutes.
BASIC CONCEPT
• Group controls
• Sub group controls
• Sub loop controls
The Group Controls contain the logic for controlling the subordinated subgroup
controls. They utilise gating logic.
The function of the Group control is to decide when, how many and which of the
subordinated group controls should start or shutdown and realise the fault
changeover in case of several subgroups
Sub Group Controls contain the sequence logics for switching units ON and OFF,
and all the associated auxiliary equipments. Normally, step techniques are preferred
for the design of subgroup controls.
Sub Loop Controls comprise only a part of the automated operation of a functional
group or unit. They are always of logic gating design. They may (as in the case of
subordinated sub loop controls) form part of a functional group control and be
switched ON or OFF by it.
Sub Loop controls (with the exception of unit changeover controls) differ from sub-
group control in that although they can be switched ON and OFF manually they can
only receive direction-dependent commands (control elements HIGHER/LOWER,
Motor ON/OFF) through criteria (e.g. automatic controls for auxiliary oil pumps,
pressure or level switches).
Sub Loop Controls include the unit changeover controls. These come into action
when changeover operations are required for units of the same type during fault
conditions. In general, changeover controls cannot be switched off directly from their
own desk tile. If the design concept calls for a changeover control that can be
switched off, a manual-automatic module shall be provided.
Command
Protective logic consists in logic gating between ON or OFF commands with criteria,
which serve, to the plant (e.g. boiler interlocking) or the unit (e.g. unit interlocking).
Protective logic cannot be switched off.
Sequential Control
Each functional group is divided into logical steps arranged in a proper sequence.
Prior to the commencement of any step, it is necessary that certain conditions
regarding status of plant get fulfilled and the relevant Parameters acquire the desired
value. All these pre-conditions are meticulously planned for each step and demanded
from the system as 'Enabling Criteria' for next step.
According to the pre-determined sequence, SGC & SLC ensure various requirements
of control oil, lube oil, oil for hydraulic turning etc. under run-up, shutdown and trip
conditions.
The sub-loop controllers get switched on and off according to the pre-defined
sequence logic built in the SGC. However, the actual execution of command of a SLC
takes place only if the enabling criteria for the fulfilment of a particular command are
completely satisfied. It is possible to intervene manually at any level namely interface
sub-loop control or sub-group control.
The enabling criteria at the various level of hierarchy are of different nature. For
instance, the enabling criteria at the ‘Interface Level’ envisaged are based on the
equipment protection point of view rather than the process consideration.
It is also possible to manually start the plant up to any level/status then ask the
sub-group control to perform the remaining functions. To facilitate such modes of
operations, the sequential logic has been development in such a manner the sub-
group control shall quickly skip to the proceeding step done manually and
accomplish the steps automatically in the desired logical manner. The SGC Turbine
logics for (ATRS) incorporating various steps and criteria required to execute each
steps are in the following sections.
1. When SLC emergency oil pump is ON AND if lube oil pressure < 1.1
2
Kg/cm command is given to switch on EOP.
1. When SLC JOP - 1 is ON AND if turbine speed < 510 RPM, command is
given to switch on JOP -1,
2. If turbine speed > 540 RPM, command is given to switch off JOP - 1
1. With SLC turning gear is ON AND if turbine speed < 200 RPM, command is
given to open the gate valve gearing.
2. If turbine speed is greater than 240 RPM, Command is given to close gate
valve gearing
STEP - 3
1. SWITCH ON SLC OIL TEMPERATURE CONTROLLER
2. MONITORING TIME 20 SEC
STEP-5
1. SLC AOP-1: ON
2. SLC AOP-2: ON
3. SLC EOP: ON
4. SLC JOP-1: ON
5. SLC JOP-2: ON
6. MONITORING TIME 200 SEC
STEP - 9
1. SWITCH AUXILIARY OIL PUMP (1) OFF
2. SWITCH AUXILIARY OIL PUMP (2) OFF
3. MONITORING TIME 0.5 SEC
STEP - 10
1. NO COMMAND ISSUED
2. MONITORING TIME 10 SEC
STEP - 11
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED
STEP: 51
1. SLC TURNING GEAR: OFF
2. GATE VLV GEARING: CLOSE
3. MONITORING TIME 60 SEC
STEP: 52
1. NO COMMAND ISSUED
2. MONITORING TIME: 100 SEC
STEP: 53
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED
STEP: 54
1. SLC JOP 1 OFF
2. SLC JOP 2 OFF
3. SLC OIL TEMP CONTROL OFF
4. JOP 1 OFF
5. MONITORING 4 SEC
STEP: 2
1. NO COMMAND ISSUED
2. MONITORING TIME: 500 SEC
STEP-2 COMPLETED AND IF TURBINE SPEED < 900 RPM AND
SPEEDER GEAR < 100%, COMMAND IS ISSUED TO RAISE SPEEDER GEAR.
STEP: 6
1. NO COMMAND ISSUED
2. MONITORING TIME 60 SEC
CRITERIA FOR STEP: 7
1. HP ESV1 OPEN
2. HP ESV2 OPEN
STEP-7
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED
STEP: 9
1. STARTING DEVICE RAISE
2. MON TIME 20 SEC
STEP: 13
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED
STEP: 14
1. TSE TEST PROGRAMME BLOCK
2. WAIT TIME 180 SEC
STEP: 16
1. TURB SPEED SET POINT: RAISE
2. DRN BEF HP CONTROLL VLV-1: CLOSE
3. DRN BEF HP CONTROLL VLV-2: CLOSE
4. MON TIME 200 SEC
STEP: 17
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED
STEP: 20
1. GEN FIELD BREAKER ON
2. WAIT TIME 15 SEC
STEP: 22
1. STARTING DEVICE RAISE
2. MONITORING TIME 100 SEC
STEP: 23
1. NO COMMAND ISSUED
2. WAIT & MONITORING TIME 2 SEC
STEP: 25
1. NO COMMAND ISSUED
2. MONITORING TIME BLOCKED
STEP: 51
1. SLC DRAINS ON
2. MONITORING TIME 2 SEC
STEP: 52
1. POWER SET POINT LOWER
2. MONITORING TIME BLOCK
120 MW
9. CLOSE ES-7. Ensure AS-64 opens up at CRH
2
pressure less than 9 Kg/cm .
10. STOP one P.A. Fan.
11. REDUCE load to 80 MW.
12. STOP one set of ID/FD Fan.
CHECK APH tripping interlock.
13. CHECK APH gates isloated from
gas/air side.
80 MW
14. CHECK changeover dampers
before ID Fan have opened.
15. STOP one B.F.P
16. REDUCE firing of the remaining Boiler airflow may be reduced to
two mills.
maintain only the required amount
TURBINE STOPPED
19. PURGE boiler for 5-minutes Any of the boiler protections can
keeping all auxiliary /
be tested after the turbine is
secondary / fuel dampers open.
tripped.
20. STOP remaining ID/FDFans,
ignitor fans.
210 MW
2. ENSURE HP/LP bypass Keep the HP/LP Bypass control on
operation. AUTO.
160 MW
4. ENSURE AS-62 is open.
(CRH steam to Deaerator)
120 MW
80 MW
50 MW
30 MW
Turbine Trip
510 RPM
210 RPM
HP casing drain.
Drain after CRH NRV's
Drain before/after IV's. NRV's.
Drain before extraction NRV's
Seal steam header drain.
Drain before ESV's.
22. STOP turbine barring. Barring can be stopped after
casing/shaft temp. have reduced
below 150oC
23. SHUTDOWN all condensate
pumps.
''Hotwell level low'' Loss of NPSH for the pump. Open Hotwell make-up
alarm comes on at 400 valves MC-49/48.
mm wcl of
Hot well level.
CEP will trip at 250 mm wcl Ensure cycle makeup
of hot well level. from surge tank MC-54
is open.
MC-27 may be closed. Deaerator level will start Close cycle make-up if
(No flow to Deaerator coming down, if the flow it is open.
or surge tank). from Hotwell has been
stopped.
Too much DM make-up Running BFPs can trip on CHECK & ADJUST set
to Hotwell. ''D/A level very low''. point less than 600
mm wcl.
Cond. surge tank level Turbine control valves open Take additional air
may be very low. more to meet load demand ejectors in service.
and boiler firing increases
on CMC.
Cond. pump may have Low vacuum causes the Ensure CW header pr.
tripped or MC-27/28 is cycle efficiency to decrease. and condenser
closed & MC-33/34 is circulating water flows
not open. are normal.
Condenser CW flow Unit may trip on low Cut-in one more main
decreases and its condenser vacuum and ejector and starting
differential temp cause low plant load ejector, if required.
increases. (DAS factors/availability
indication).
BFP bearing
temperature may
increase due to
cavitations or
churning.
Lub oil pressure low Any feed pump; trip ping Ensure immediately
alarm comes. out of service may cause that standby BFP is
serious drum level available.
disturbances.
Lub oil pres sure Lo-Lo Boiler may trip on drum Maintain level
alarm comes level protection. otherwise, unit may
trip on 'Low' drum level
protection.
Filters may be chocked Drum level will drop Unit may run back on
up momentarily and Deaerator CMC mode. Avoid any
may increase slightly possible failure by
cutting in oil elevation
("lub. oil pr. adequate" The standby BFP gets an If the standby BFP has
lamp remains on). auto start command & not started, then start
comes into service after 5 it manually.
sec. time delay
Instruct local operator
to change over the oil
filters (duplex).
Lub oil quality bad. BFP may trip at high (7 Unit runs back on
mm/sec.) vibration level. CMC if any BFP trips
and the standby pump
do not come into
operation within 10 sec
Damaged bearing. Boiler may trip if no other
Mechanical problems BFP is in operation
in pump
Cavitation due to Boiler may also trip on Avoid any possible
air/vapour ingress into drum level fluctuations flame failure due to
BFP. (V.HI / V.LO). unloading of the mills
on CMC runback, Cut-
in oil elevation.
BFP working oil cooler Unit may run-back on CMC Ensure ARCW pump
may be fouled up. to lower load limit. pr. is adequate.
BFP cooling water pr. Unit may trip due to loss of Increase BFP scoop
(ARCW) may be low. all BFPs. tube position.
''BFP suction pressure BFP may cavitate and seize Shut-down the BFP
low'' and ''BFP suction ultimately. for strainer cleaning
strainer clogged'' and maintenance.
alarms start flashing.
BFP speed controllers Drum level will start Transfer the BFP
go to maximum. increasing. master controller to
manual mode.
F.W. control valve The high range feed control Reduce the individual
differential pres- sure valve will start closing in speed controller’s
indicator goes to zero. response of high feed water output to bring down
flow and drum. the Water flow, if
needed.
Feed water flow BFP may trip on account of If BFP flow is more
increases. high feed flow. than 430 T/hr. for
more than a minute,
BFP will trip
immediately reduce the
scoop controllers
Possible Causes: Extraction line drain valve If level does not come
on turbine panel opens down, try to bypass the
when NRV is less heater.
HPH-6 level high and Drum pressure will increase Tilt the burner tilts to
hi-hi alarm comes in due to closure of extraction negative side to
DAS. valve. prevent the shooting
up of R/H
temperature.
HPH-6 & HPH-5 heater Flue gas temperature Watch the drum level.
extraction drain valves leaving furnace will Take it on manual if
ES-6 and ES-5 set increase. necessary
closed.
Extraction steam line Drum level drops due to Check the heater level
drains DW-75 and DW- shrinkage. from the local.
74 open.
Spurious control When all the condensate has Restore instrument air
signal. got drained out of the FW pressure if possible.
heater, steam will start
blowing directly through the
heater and into the
condenser.
Instrument air Reset and put on
failure. Remote, if needed; the
pneumatic control valves,
after air supply is
restored.
AIR PRE-HEATER
Motor/breaker protection Fuel rich mixtures may Ensure sevice air pr.
may have acted. cause boiler explosion is adequate and air
and result in damages motor isolating valves
to boiler supports. are open.
Electrical supply may have Unit runs back on If air motor is not
failed. CMC mode due to available, cut in oil
ID/FD fans tripping. elev. & reduce boiler
firing to approx (50%)
and transfer load of
the corresponding
ID/FD Fans on the
other pair completely.
2.B. APH ELECTRIC DRIVE TRIPPED AND AIR MOTOR FAILS TO START.
Air motor may not be With a time delay of 30 Ensure service air pr.
lined up. secs. tripped APH's is adequate and the
isolating dampers are isolating valves of the
closed and corresponding air motor are open.
ID/FD fans also trip-out.
Service air pressure Unit runs back on CMC. If air motor is not
< 5 Kg/cm .
2 available,
immediately transfer
load of ID/FD fans to
the other pair or start
afresh the 2nd pair of
ID/FD FANS &
maintain draft &
airflow in boiler.
High flue gas Loss of generation due to Stop air heater and
temperature unavailability of one set of ensure isolation
APH/ID/ FD Fans. dampers are closed.
''APH fire detection Lower cycle efficiency due Wait until all
temperature trouble'' to part load operation. temperatures become
alarm comes in the normal. Then start
UCB. air heater electrical
motor again
Note : Any APH may be allowed to run on air motor (or air motor bypass mode)
provided the gas inlet temperature of the APH is maintained within 370oC
(max.)
Lub. oil filters may be Unit runs back on CMC Top-up oil level in the
choked. to low load limit. (Approx. lub. oil tank. Clean the
50%). filters.
If unavoidable,
shutdown the ID Fan.
The other fan set must
be running before
shutting down any ID
Fan.
2. ID FAN TRIP.
Lub. Oil pressure The other ID/FD Fan pair Immediately cut in
problem. becomes over-loaded if on suitable oil elevations.
auto.
Bearing temperature May lead to partial flame Reduce boiler firing from
problem. failure due to fuel rich the upper elevations to
mixtures in the furnace make it compatible with
and cause a lot of furnace available airflow; to avoid
disturbance. fuel rich furnace.
1. FD FAN TRIPPED.
''FD Fan trip'' Flame fluctuations. may If boiler has tripped then
alarm and white take place. make preparation for
trip lamp comes light-up again.
on.
Boiler may trip on ''all FD
fans tripped''.
Bearing temperature Unit may trip on '' All If the other fan set is
increases. Alarm FDs tripped''. not running and
comes in at 95oC. available for operation,
put them in to avoid a
unit trip.
1. PA FAN TRIPPED
If possible, RESTART
and load the PA Fan
Quality of lub oil may Machine down time If required (on account
have deteriorated. increases the maintenance of high vibration) stop
overhead. the fan immediately.
(Follow shutdown
procedures).
Lub. oil pressure may Fan trips if lub. oil CHECK if the other
be lower than 1.6 pressure Lo-Lo alarm pump comes on
Kg/cm2. comes on at 1.2 Kg/cm2. interlock, at 1.6
kg/cm2. if pressure
keeps falling.
No coal flow to the Mill current goes no load Check the healthiness of
pulveriser for amps Boiler/ unit load feeder's electrical supply.
more than 10 also comes down. Change
secs. fuse if needed.
3. PULVERISER TRIPPED
Ensure continuous
coal supply for the
mill.
Feeder coal flow HAD & HAG close at 95 Take associated oil
transmitter may be 0C. as mill outlet temp guns in service to
faulty. goes up with loss of coal to stabilise furnace
mill. draught.
NOTE: All pneumatically operated dampers must be reset and put on remote
operation, only after ensuring E/P converter and the actual damper position
are matching.
9. PULVERISER AIRFLOW FEED BACK OFF SET 25% HIGH AIRFLOW READING)
UCB instrument for Mill DP increase as the Take mill air control on
airflow indicator coal retention in the mill manual and adjust the
may be faulty. goes up due to airflow to the required 60
decreased airflow; hence T/Hr.
mill DP goes up along
with pulveriser current.
Broken pieces from the blade may - Prepare for shutting down the boiler
damage the condenser tubes, by cutting out the coal firing.
resulting in condenser tube leakage.
HP control valves go
100% open and the
boiler firing goes up
on boiler follow mode.
"Thrust bearing metal Unit may trip on high Immediately de- crease
temp high'' alarm may thrust pad wear load on M/C and watch
come in UCB. protection (0.6 mm). if axial shift improves.
Otherwise, unit trips
on thrust pad wear
protection. (Boiler may
trip on R/H protection)
Lub. Oil coolers may be Oil viscosity comes Take in service the
fouled-up. ''Lub oil down with increasing standby lub oil cooler
temperature after temperature of lub oil. if available.
coolers high'' alarm at That may lead to
47 0C. (UCB boundary lubrication
and metal-to-metal
annunciation).
contact. It may cause
extensive damages to
T/G bearing and high
brg. Vibrations.
If high vibrations are
observed, trip the
turbine immediately.
''Turbine stress
Cubicle fault' and
'Turbine stress effect
off annunciations come
on.
''Generator cooling /seal oil Seal oil DP goes low. Instruct local
working filters clogged'' alarm (Alarm at 0.9 operator to charge
may come on. Kg/cm )
2 more hydrogen
cylinders.
Seal babbit liners may be H2 may leak out of Maintain Gen. load
damaged. So due to the system. as per generator
increased clearances more capability curves;
seal oil may drain. with falling H2 Pr.
Rotor temperature
goes up.
''Seal oil pressure low'' alarm Hot gas temperature Ensure rotor and
comes at 3.6 Kg/cm2 and high alarm comes at gen. winding temp
reserve seal oil pump comes 75 0 C. are within limits.
on interlock.
Under extreme If DPR is found to
conditions generator be malfunctioning
may have to be get it bypassed,
tripped, manually. locally.
MISCELLANEOUS SYSTEMS
Compressor tripping.
Pressure indication in This may lead to oil valves Attend to the fault
UCB starts to drop. tripping if corresponding & get the leakages,
oil flame scanners are if any, rectified.
flickering and possibility
to boiler tripping on 'Loss
of all fuel' or 'Flame
Failure'.
Low service air OPEN Instrument&
pressure alarm comes service air inter-
2
at 6 Kg/cm . connection valve.
Compressor tripping. 2
At 5 Kg/cm instrument Decrease load gradually
air pressure the to keep drum level in
following valves will control and also the
OPEN rate of vacuum drop.
Over heating of tubes. Feed water flow goes Reduce firing to keep steam
up, to maintain temperature under control.
drum level.
Indications will be Make-up Eventually unit has to be
consumption shut down. So make
increases. preparation for a planned
shut- down.
NOTE:
A decrease in boiler Boiler metal temp go
water pH is the up as firing
primary indication of increases to
any water wall tube maintain throttle
leakage. pressure which goes
down due to leakage
Furnace draught
starts hunting.
It is of paramount importance that power plant engineers get aware of causes of poor
efficiency and adopt methods to control and keep check on process parameters those
will be affecting the power plant efficiency.
In this chapter, an attempt has been made to educate engineers so as to find the
means and ways in solving numerous problems concerning efficiency losses in power
station operation.
The curve represents the total heat, useful heat & the rejected heat as well. An ideal
Rankine Cycle incorporating reheat and regenerative feed water heating can be
represented by the curve.
In the ideal cycle the steam expands in the turbine and the expansion is assumed to
be frictionless and adiabatic. The expansion of steam continues until some reduced
pressure. Condensation at a constant temperature takes place until all latent heat
had removed (rectangle covered under X line as rejected Heat). The formulae that
follow can be referred for calculating the thermal efficiency. There are two ways to
improve the basic Rankine efficiency. Those are: Reduce the rejected heat
component and then increase the useful heat component.
The Carnot efficiency is obtained for any substance working between the limits of
temperatures and the Carnot efficiency is given by (T1-T2)/T1 in which T1 is the
upper absolute and T2 is the lower absolute temperature and the heat addition &
heat rejection are isothermal process and that the expansion and compression of the
working substance is isentropic. Of course no such substance as portrayed in the
Carnot cycle exists. However the Equivalent Carnot cycle is one, which is equivalent
of a given Rankine cycle. The temperature is assumed to be constant at the average
temperature at which heat is received in Rankine cycle; they give the same results.
Let us take a case of a unit having different figures.
Selected parameters and its complete T-S Diagram (Ideal Steam Cycle)
Carnot Efficiency Basic: 52.1%(with dry/sat steam between 347oC & 24oC)
64.8%(Between 570oC and 24oC)
(with SH, RH &Regenerative feed heating): 53.2%(with feed Water temp = 180oC)
55.8% (with Feed water Temp. 250oC)
Useful heat
Thermal efficiency =
Total heat
Condensate temperature:24(297.1)0C/K
Entropy of final feed: 2.9763 KJ/kgK
Total heat at TSV: 3469.9 -do-
Entropy at TSV: 6.3539 -do-K
Total heat at R/H inlet: 3013.0 -do-
Total heat at IP inlet: 3595.1 -do-
Entropy at IP inlet: 7.1769 -do-K
Heat in final feed water: 1185.2 -do-
Heat added in Boiler (H1-hf):2284.7-do-
Heat added in R/H(H1-H2): 582.1-do-
Total Heat added: (1) 2866.1 -do-
Entropy change(S2-S1):(2) 4.2006 -do-K
Heat rejected T.(S2-S1):(3) 1248.0 -do-
Work done :(1)-(3): (4) 1618.8 -do-
Ideal cycle frequency:(5) (4)100/(1):56.5%
Alternatively
Average temp. (1)/(2): 682.5 K (6)
Equivalent Carnot efficiency: (7) 56.5 %
= { (6) –T } 100/(6)
Overall efficiency: 46.9%
In general, entire cycle efficiency of a power station depends upon the efficiency of its
components i.e. boiler, turbine, generator, pumps etc., efficiency of which in turn
depends on many other factors as discussed here.
BOILER EFFICIENCY
There are two ways of determining the boiler efficiency: i) Direct & ii) Loss method.
Direct method was standard for long time, but is little used nowadays. It is
basically the straight forward of measuring the heat supplied in a given time
and heat added to the steam in the boiler. By this method the efficiency of a
non-reheat boiler is:
Losses Method: The efficiency of a modern boiler is dependent basically upon the
efficiency of combustion and the heat transfer within the boiler.
The efficiency of the Boiler is therefore 100% -losses. Thus, if the losses are known,
the efficiency can be derived easily.
This loss is due to residual thermal energy contained in the dry flue gas when its
temperature is too low for further useful work. At this point it is exhausted to
atmosphere. This loss constitutes the largest portion of boiler losses and is
dependent upon-
a. Quantity of dry combustion gases.
b. Temperature rise between FD Fan inlet and gas exit temperature.
c. Mean specific heat of the flue gases (Constant pressure).
The amount of excess air supplied over and above the theoretical air, has the greatest
bearing upon this loss as this causes both quantity and temperature of the flue to
deviate. A change in excess air quantity by 5% effects + 1.0% in dry flue gas loss.
Dry flue gas loss ={100/12*(CO2+CO) + C/100+(S/267)-C ash}*30.6 (T-t) K J/Kg. (In
fuel)
Alternatively
Dry flue gas loss % = K x (T-t) (on GCVv basis)
This loss is the thermal energy in water vapour entrapped in flue gases leaving boiler.
The water is in the form of superheat steam if exit gas temperature is above the dew
point at the stack. The total moisture loss is due to water derived from three sources:
-
Wet flue gas loss =(M + 9H)/100 [1.88 (T-25) + 2442 + 4.2(25-t)] KJ/Kg. of fuel.
Sensible heat in water vapour. = Wet flue Gas Loss - (GCV - NCV)
Moisture in combustion air loss = Ma*h*1.88(T-t) KJ/Kg.fuel
For solid liquid fuels Ma =3.034 N2/ (CO2 + CO ){C/100 + S/267 -C in ash}
The main source of this loss is due to the carbon contained in bottom ash or
entrained in fly-ash leaving boiler furnace.
Radiation and Ash Hopper Losses: For modern boilers, these losses can be as small
as 0.25%. Additionally some unaccountable losses may occur due to additional heat
loss at hoppers and sensible heat in ash.
This loss may be kept very small if the milling plant is designed, operated and
maintained correctly. It can be calculated by sample of reject for calorific value and
weight of rejects.
Note: Efficiency calculations done on the basis of NCVp yield higher values than
GCVv. Hence, calorific values must be specified clearly.
Most of these boiler losses can be kept under acceptable limits by ensuring complete
combustion at minimum excess air. Control of combustion process requires
regulation and distribution of fuel & air to and within the furnace using:
b. The need to avoid deposition of burnt coal onto wall tubes. This can
induce corrosion of tubes, ultimately involving a loss of plant availability.
c. The need to avoid acid corrosion of lower temperature flue gases. (The
excess air quantity and flame temperature can influence Dew point
temperature).
TURBINE EFFICIENCY
Internal Losses
Nozzle Friction: The effect of nozzle friction is to reduce the effective heat drop of
steam as it passes over the nozzle. The velocity of steam is reduced as it
subsequently strikes the moving blades. Because of reduction of velocity there will be
some shock as steam strikes the blades because blade profile is designed so that
steam glides over it (for a particular steam velocity).
Blade Friction: Its effect is same as of nozzle friction. Without friction the outlet
relative velocity of steam would be same as inlet but because friction cannot be
avoided, velocities are reduced to 90%. As friction increases, steam expansion tends
to be more ''irreversible''.
Disc Friction: The discs on impulse turbine shafts rotate in an atmosphere of steam.
The disc surface friction causes some drag and produces eddies of steam causing
loss of power. This effect is more pronounced where the steam is densest.
The basic construction and assembly of partial arc and full arc i.e. nozzle governed
and throttle governed turbines, are a lot similar with only real difference being the
absence of the control stage in full arc admission turbine. This arrangement
dispenses with excessive stresses in the HP turbine blades and enhances the
reliability of full arc admission turbines and improves their efficiency.
Upon comparing the thermal performance curves of the two types of turbines it can
be noted that the throttle governed, full-arc-admission turbine has better efficiency.
Although as compared to the throttle governed, the nozzle controlled partial arc
admission turbine does show a lower net heat rate in the lower load range; when
operated in constant pressure mode, the full arc admission turbines can also exhibit
a better performance in the upper load range with only periodic load drops; by way of
both, better heat rate and energy consumption. Various degrees of hybrid operation
(combination of both, constant pressure and variable pressure mode) of both types
further improve the thermal performance of each at partial loads also.
The variable pressure mode of operation is best suited for full arc admission
turbines, whereas the partial arc admission turbine operates over the entire load
range with some what a lower heat rate level. For constant pressure operation, the
load changing characteristics of both types of turbines indicate a better ability of full
arc admission turbines to deal with severe load transient conditions, because they
exhibit smaller changes in temperatures for a given load change.
On the other hand if control valves are left fully open and boiler pressure is reduced
for maintaining full steam temperature, the turbine expansion line becomes CD
resulting in increased available heat drop and reduced wetness after LPT exhaust, as
a bonus. Sliding pressure control is very common at part load.
In nozzle governed machines when operating at part load the control valves are wide
open. Hence with increase of pressure the available energy increases and efficiency
improves. Consequently sliding pressure control is not applicable to this type of
machine.
Exhaust Losses: The kinetic energy of steam leaves the last LP stage cannot be
gainfully employed to do any useful work and hence it is a loss.
The loss varies with (velocity) 2 and velocity varies with backpressure change.
External Losses: Shaft gland leakage.; Journal and thrust bearing; Governor and oil
pump.
By accurately measuring the temperature and pressure of steam before and after HP
and LP cylinder, it is quite easy to determine the respective cylinder efficiency. The
LP cylinder efficiency can't be ascertained as the steam is wet there and exact 'state
point' can't be located.The cylinder efficiencies do not change appreciably with load,
as ratio of blade to steam speed (u/V) remains constant with load. However, due to
deteriorating cylinder efficiencies, change in turbine heat rate can be computed with
the following formulae:
HP Cylinder
∆(HR) = {{0.43 (H-h) ∆ (n)%}1/ Kwa} *2.36 Qr/ HRa _ 2.158 Qh/3600}
Where,
∆(HR) = % change in heat rate value.
H = Enthalpy at TSV, KJ/Kg. (ref. data)
h = Enthaply at HPT exhaust, KJ/Kg. (ref. data)
∆n % = % change of efficiency from designed value.
KWa = Ref. alternator output, KW
Qr = Reheater steam flow (present) Kg/hr.
HRa = Reference test heat rate, KJ,/KWH
Qh = Present steam flow to HP cylinder, Kg/hr.
The surface roughness affects the HP cylinder maximum, then IP cylinder and then
comes LP cylinder. Larger machines are affected to a lesser extent as compared to
smaller machines.
This is a very useful tool indicating the internal condition of turbine. Following steps
are followed for preparing the pressure survey diagram
i) Choose a pressure scale on Y-axis from zero to any pressure above ESV pressure,
say, at rated load.
ii) From acceptance test results or design reference, mark off various pressures at
various points of tapping as shown below.
iii) Join all points with a straight line.
If at some later date, the pressures are noted at each point while the load is the same
as plotted, as before, the points will lie on the same line if the cylinder condition has
not deteriorated. But, if the load is lower and the condition of machine is same the
points will plot on a line lower than the previous. When plotted pressure points are
on the optimum pressure line for a particulars load it is indicative of general wear of
Silica can enter the system through reheater leaks during shutdown because of
vacuum built up in the steam space as steam condenses. This can happen especially
when vents are not opened prior to pressure decay. Also BFP and feed heaters when
they are opened for maintenance, silica can enter the system.
The complexity of a power station unit offers scope for many parameters to have
deviation from optimum. Fortunately technical expertise and know-how gathered
over the years facilitate ascertaining the causes of efficiency loss due to deviation
from optimum, by monitoring just a few terminal conditions. They are
a. Turbine backpressure.
b. ESV steam pressure.
c. ESV/RH steam temperature.
d. Amount of attemperation spray.
e. Final feed water temperature.
f. Boiler excess air.
This is the most important parameter that severely affects efficiency of a power plant
cycle. It is dependent upon
2. CW inlet temperatures.
5. CW flows in condenser.
Generally speaking, improving the backpressure improves the amount of work done
by steam, but up to a limit. Because, with increase in certain losses also increases.
1. CW pumping power.
2. Leaving/exhaust loss.
Loss due to high CW inlet temperature may be due to inefficient cooling tower
operation; can be compensated by increasing flow of CW. But the gain in efficiency
must be weighted against loss due to increased CW pumping power.
Loss due to incorrect CW flow can be eliminated. If the temperature rise across the
condenser is less, that means more than optimum CW flow. It can be reduced.
Excessive CW flow can cause under cooling of the condensate, ultimately lowering
the final condensate temperature.
Loss due to air ingress is entirely preventable and steps must be taken to ascertain
air tightness and points of leakages, if any. Remember, 1 mm. thick air sheet has the
same resistance as 17 mm. copper slab.
a. The total heat drop to vary, higher pressure causes increased heat drops
(at the same inlet temperature conditions).
c. Increased turbine output for a given control valve opening such that 10%
increase of pressure will produce 10% extra output.
For more common reheat type machine, variation of ACV (after control/throttle valve)
pressures are proportionally dependent on load conditions, such that 50% reduction
of load will reduce ATV pressure by 50% as shown in the figure. Ignoring pressure
drops in reheat lines at 100% expansion lines in HP and IP/LP turbine is AB and CD
respectively as shown in the figure. At. 50% output turbine expansion is EF and GH
as shown.
a. Boiler pressure is reduced hence cycle efficiency is very much lower than
optimum at full load conditions.
b. At very low pressure, at higher loads steam volume is more, which tends to
envelop water in the boiler tubes, leading to film boiling and subsequently
overheating of tubes.
Any deviation in turbine inlet pressure can change the steam flow through turbine,
because of which stage pressure and extraction pressure will change, changing feed
water temperature. The volumetric flow to condenser also changes accordingly.
Hence, ramifications of a small pressure change can be seen through out the cycle.
CE make Korba Boiler is not designed for Sliding Press. Operation.
Also reheat pressures along with HPT exhaust pressure at various load must be
recorded for a healthy machine so that the same can be used for comparisons at a
future date.
Throttle governing
In modern, large machines the economic rating coincides with the maximum rating.
The steam flow is controlled by the degree of opening of the throttle valves, which are
located in the HP cylinder steam chest. Obviously the up-stream steam pressure at
the throttle valves will be constant, irrespective of the turbine load, but the pressure
after the throttle valves will reduce as the valve opening reduces. This will cause the
available energy per kilogram of steam due to expansion to be reduced, as well as the
mass flow of steam. This is illustrated for a non-reheat turbine the in fig.
Nozzle Governing
Here the first-stage nozzles are divided into a number of groups, sometime more than
ten. The steam admitted to each a valve controls group, and each valve is opened in
turn as loading is increased as shown in the fig. Consider a four-valve arrangement
where the first valve only is in service from no-load to quarter-load, and at quarter
load it is fully open. This is followed by the second half-load, and then valves three to
three-quarter load. Finally, the last permits maximum loading when fully open. The
only valve operating in the throttling mode is the last one to be brought into service,
all the previous ones being wide open, so the losses due to throttling are not so great
as with the previous type, so operation is more efficient.
*The internal efficiency of throttle and nozzle governed machines can be the same
(Represented by slope of the expansion lines on H-S diagram) after the wheel case.
Other effects for reduced steam temperature for a non-reheat set are:
For reheat machines as shown in the figure reduction of main steam temperature
causes available energy of steam to be reduced causing reduction in efficiency. Also,
extra heat is required in reheater to have the same hot reheat temperature.
Expansion in IP/LP turbine remains unchanged as long as HRH temperature is
constant:
High temperature yield high heat drops but cause significant reduction in operation
life of high temperature components.
Note that the effect of reducing the ATV temperature to 560OC is significant with
reference to total heat drop even though it only affects the HP cylinder heat drop and
does not affect the wetness.
Steam Attemperation
Attemperation of steam invariably causes loss of power output and increase in heat
rates. But is not entirely avoidable in modern high capacity boilers.
The feed water temperature at boiler inlet is another main important factor
determining cycle efficiency. It is mainly dependent on
a. Heater performance.
a. Feed flow through heaters.
c. Terminal Temperature difference (outlet feed water temperature steam
saturation temperature at the extraction pressure).
d. Bled steam pipe pressure drop.
e. Steam temperature at heater inlet.
One degree centigrade rise in TTD (Terminal Temperature Difference) leads to 0.027%
drop in efficiency. A bad heater performance can be attributed to the following:
- Air blanketing
- Waterside contamination.
- Steam side contamination.
- Drainage defects.
In order to avoid this factor, the boiler must be operated at constant pressure, so
that feed flow remains optimum. Proper and frequent air venting of heaters,
prevention of oxygen ingress and thus exfoliation i.e. flaking of tubes causing
subsequent choking and TTD increase; and maintaining of proper pH value in
Condenser should be practiced.
These leakages put extra burden on ID Fans and limitations on unit loading. The
leakages after air pre-heaters do not affect the efficiency significantly.
Low air pre-heater gas outlet temperature may be due to the following:
Soot blowing
Soot blowing must be done selectively and only when required. Frequency of soot
blowing is also dependent upon coal quality and furnace temperature and firing
configuration.
Machine Loading
As the unit load is decreased, percentage aux. power rises as shown in the fig. In
common practice, operator must have three mills running at full load rather than
four mills running at part capacity. CW pump flow must be controlled in accordance
with optimum backpressure requirements so that benefits from running equipments
should be more than the cost of running them.
Mill outlet temperatures must be maintained at the rated value. Low temperature
puts a limitation on loading of the mill. High mill reject operation puts extra burden
on PA Fans and also it is a loss in terms of loss of some pulverized coal from the mill.
The efficiency of a unit improves as the loading improves. So, all out attempts must
be made to ensure, there is no part loading or outages to maintain a high load factor,
and shortfalls should be kept to minimum. Because fixed heat has to be sustained at
all loads. It is important to generate every possible megawatt while on high load. One
important way of preventing short-falls, is to ensure that boiler firing must be
controlled to control boiler pressure not, by varying load on T/G.
CONDENSER PERFORMANCE
Determination of deviation
The manufacturer supplies various performance curves for the condensing plant,
which should be verified by test as soon as possible. Two important relationship
must be established - load vs. CW temperature rise and load vs. terminal
temperature difference.
To make heat flow from condensing steam to cooling water requires some
temperature gradient, steam temperature being higher than that of cooling water.
Excellent heat transfer requires small gradient whereas bad heat conduction requires
a large gradient. Hence TTD is a measure of effectiveness of heat transfer.
To determine the contribution of each of the main factor to the total deviation in
backpressure from optimum we can use condenser condition graph.
Plot a line vertically from actual CW inlet temperature point up to the optimum CW
rise line and then horizontally to the optimum TTD. From this point drop a vertical
line to intercept the saturation temperature line at 34OC with corresponding
backpressure of 53.2 mbar. So the backpressure deviation due to CW inlet
temperature alone is (53.2 - 43.7) = 9.5 mbar.
In the list it can be seen that actual rise is less, hence the CW flow must be more
than optimum. To determine its component affecting backpressure, plot a line from
actual CW inlet to actual CW rise, then to optimum TTD line, finally downward to cut
saturated steam temperature line at 31.5OC. Equivalent backpressure is 46.2 mbar.
Therefore, the pressure deviation due to high flow is 46.2 - 53.2 = 7 mbar. High CW
flow improves the backpressure by 7 mbar.
Deduct from actual backpressure of 59.4 the backpressure of 46.2 (= 13.2 mbar).
This is the deviation caused by high TTD.
Shift Monitoring
For this purpose, the required curves are CW temperature rise v/s. load, optimum
TTD v/s. load (both have been illustrated earlier) and target back pressure for
various CW inlet temperature v/s, load.
The effect of internal tube deposits and the effect of air blanketing on outside of
tubes are indistinguishable in their effect on TTD. Hence, when the air ingress is
ascertained and rectified, then any deviation in back pressure ascribed in air/dirty
tubes will be due only to the dirty tubes and hence a decision can be taken to clean
dirty tubes.
In modern power stations direct and indirect feed water heaters are invariably in use
to enhance the unit performance. Usually the number of feed water heaters provided
on a power plant depends on the trade off between the full costs saved by a
particular no of heaters balanced against the annual fixed charge on heater
investment for minimum generating cost. Economically justifiable maximum number
of heaters on a plant is ten. It is common to find 6-7 feed water heaters on power
generating units in our country.
Heat transfer to feed water in non-contact type heater is achieved by the surrender of
latent heat of steam primarily because heat recovery by de-superheating and drain
cooling is about 6%-8% of the total latent heat recovered by feed water.
The two important parameters used in assessing heater performance are TTD
(Terminal Temperature Difference) and Drain Approach. TTD is defined as the
difference between saturation temperature of extraction steam and feed water
temperature after the heater. Where as drain TTD or drain approach is defined as
difference between feed water temperature at inlet to heater and drain outlet
temperature after the heater.
It is not sufficient to just measure final feed water temperature to determine if the
heaters are operating efficiently, because trouble at one heater can be compensated
for by other heaters doing more work. This causes bled steam flow to heaters, to alter
and thus affect the work done. So cycle efficiency is altered. Therefore, it is
necessary to check individual heaters from time to time, checking particularly the
TTD and drain approach as a general rule, preferably twice in a year, heaters
(individually) investigation must be carried out.
• Air accumulation
• Steam side fouling
• Water side fouling
• Drainage defects.
Air is a superb thermal insulator, hence, highly undesirable. Proper vents are
generally provided on heaters (to condenser) body to prevent accumulation of air. Air
can get into heaters when extraction pressure in them is reduced below atmosphere
i.e. wherever the machine load is reduced or machine is off-loaded.
Hence, the vents of sub-atmospheric heaters must be permanently open while those
on the rest should be open long enough to vent them thoroughly while machine
comes on load and periodically thereafter. It needs to be emphasised that steam
(generally 0.5%) passing through the vents is a loss to the system.
Cupro-nickel (70/30) alloys was generally used in the past. However, it was found
that this material exfoliates (i.e. it flakes off like a dead skin). Due to this the space
between the tubes in the cluster becomes blocked with debris and heat transfer is
progressively reduced. It has been practically established in one case that TTD rose
from 4 OC to 14 OC continuously over a period of 7 years.
Alternatively now 90/10 cupro-nickel, Monel metal, mild steel etc. are used as tube
material to reduce problems of exfoliation.
Most common cause of waterside fouling is oil. Oil can get into the system from
leaking bearings and important gland seals of LP turbine. Deposition of them occurs
in HP heaters affecting them all but being worst at the highest-pressure heater.
Thermal manifestations of troubles are similar to those for exfoliation except that the
Slightly fouled tubes can be chemically cleaned. In the worst cases high pressure
water jetting may be required.
Drainage Defects
Apart from obvious problems such as passing valves etc. the usual troubles are due
to
A typical flash box has an orifice followed by a diffuser, which diverts the flashing
drain downward on to water reservoir. If the diffuser disintegrates, its pieces can
create obstruction in pipes and cause flooding. Further flashing steam/water may
cause erosion of flash box internals.
Reduction due to fouling, of the orifices is very common. It results in drain blocking
up to previous flash box resulting in flooding and some water droplets are carried
into flash steam to the bled steam pipe. Heat is taken up by the water and steam to
heater temperature drops.
Conversely, orifice size can increase due to erosion and can reduce differential
pressure from inlet to outlet. The orifice plate does not alter the bled steam pressure
at upstream and downstream heater so the reduced differentials achieved by
lowering the water level in upstream heater. Sometimes high-pressure heater drain
cascade to a drain pump which pump it to deaerator. At deaerator pressure the
O
saturation temperature is of the order of 160 C approx. and if the pump suction
head is not sufficient then water can flash in the pump itself interfering with the
pumping. This causes heater level to rise; consequently drain to condenser opens up
and results in lowering heater efficiency.
Fouled heater gives increased TTD, as is already evident i.e. lower feed water out
temperature. This relatively cold water goes to the next heater, which has to work
harder to maintain its TTD and draws more steam in the process. This steam is not
available for doing work hence cycle efficiency is lost. Increased steam flow also
causes mechanical damage to the nearing tube bundles because of increased velocity
and mass flow.
Anyone heater being out of service considerably affects the cycle efficiency. Feed
water outlet is lowered and the next heater has to do extra work as is explained
earlier. If the final (highest pressure) heater is taken out the feed water to boiler is at
lower temperature and has to have extra heat given to it in the boiler. Further bled
As a general guide to the effect of having a heater out of service, the following
efficiency reductions may be used.
Feed heater surveys can be conducted every six months to detect any early
deterioration of heater performance. Operations staff must keep a routine check of
the performance on a shift-to shift basis noting down final FW temperature, heater
TTD and steam-to heater temperature.
Magnetic layer, against corrosion by feed water, protects low alloy/mild steel tubes.
O O
At temperature between 140 C and 200 C magnetic layer is more porous than it
would be if it is formed under higher temperature. Since it has slight solubility it can
be removed by turbulent/ past feed flows in heaters. A fresh layer is formed and
eroded and go on causing metal loss at bends and bifurcations.
To deal with these problems, 20-150 micro gm. per litre of oxygen is injected into
feed water before heater drain. This oxygen causes iron oxide to be deposited as
hematite. To save this layer of hematite feed water should have low anion content
(low chlorides, sulphate), or i.e. should have low after cation conductivity, usually
below 20 micro siemens /m. This can be achieved by good condensate polishing.
TITLE Page No
NOTE:
Aux steam is available from external source The Deaerator drawl from CRH is expected to cut in
after synchronisation and at least 20% loading is done.
Steam temperature downstream of HP Bypass HP Heaters from CRH may cut in afterwards at 30%
need not be regulated by spray until the MS Temp is load.
above 300OC. Then HP BP downstream temp may
be regulated to 230OC. SH Spray need not be used for controlling SH outlet
temp until the boiler flow is at least 160 T/H. SH & RH
temp may be regulated and allowed to raise along
the suggested curve at higher loads.
NOTE:
The metal temp anticipated: HP Casing: 140OC The Deaerator drawl from CRH is expected to cut in
ST Valve: 50OC after synchronisation and at least 20% loading is
Boiler : Ambient. done. HP Heaters from CRH may cut in afterwards at
30% load.
Aux steam is available from external source.
SH Spray need not be used until the boiler flow is at
Steam temperature downstream of HP Bypass least 160 T/H. SH & RH temp may be regulated and
need not be regulated until MS temp is above 300 allowed to raise along the suggested curve at higher
OC. Then this may be regulated to 230 OC. loads.
NOTE:
The metal temp anticipated: HP Casing: 350OC SH Spray need not be used until the boiler flow is
ST Valve: 210 OC. at least 120 T/H.
Steam temperature downstream of HP Bypass need Aux steam is available from external source.
not be regulated until 90 T/H bypass flow is established.
Afterwards this may be regulated to 260 OC. Deaerator is to be kept pegged at 140 OC
minimum before firing the unit.
Only Deaerator steam is extracted from CRH. HP
Heaters are anticipated to be put into service only Reheater temp control by spray may be adopted
after synchronisation. if required, after HP bypass closes.
NOTE:
The metal temp anticipated: HP Casing: 465OC Full vacuum should be available before firing.
ST Valve: 410OC.
SH Spray need not be used for controlling SH
Aux steam is available from external source. outlet temp until the boiler flow is at least 160 T/H. SH
& RH temp may be regulated and allowed to raise
Deaerator is to be kept pegged at 140 OC along the suggested curve at higher loads.
minimum before firing the unit.
Turbine can be loaded along the dotted line i.e.
Steam temperature downstream of HP Bypass 21 MW/Minute. For this, the boiler should be at rated
need not be regulated until 50 T/H bypass flow is parameters before rolling using HP and LP bypass.
established.