1.

Process
familiarization of
MES boiler after
revamp
2.Types of mills and
operation of bowl
mills

Process familiarization of MES

boiler after revamp
The support fuel changeover from oil to
Natural Gas in CPP boiler is being executed
by M/s Thermax India. The total cost of the
project is Rs.6.49 crore.

Objective of support fuel change over:

The objective of conversion of oil firing to

gas firing is to replace the existing oil
firing system to Natural gas firing system.
Natural gas will be used for boiler start up and
as support fuel for flame stability at various
loads including MCR with pulverized coal as
main fuel.
Natural gas will be used as main fuel with
capability to raise the load up to as near as
possible to the 100% of MCR

SALIENT FEATURES OF REVAMP

The upgrade for fuel change over project of CPP boiler broadly
comprises of following sub systems:
New Pulverized coal cum NG fired Burners equipped with gas
ignitors and new flame scanner.
Burner Register dampers (Manual operated) / Auto Operated
Secondary air dampers along with actuators.
Modification of Wind box to install the new burners along with
insulation and cladding.
Burners throat refractory modification.
NG Piping from pressure reducing station to CPP Boiler.
NG control station and field instruments for monitoring and safety
shutdown.
NG train to burners with safety shut off valves.
NG piping for igniters / support firing.
Natural gas detectors.
New DCS system for BMS and Boiler operation and control.
Cabling from field instruments of NG system to the new DCS panels.

BURNERS
The burners are of Babcock & Wilcox (USA) design, with Central NG
Gun Gas Spud, total 6 Nos. burners installed on the boiler, mounted in
the existing windbox which is mounted on the boiler front wall, the
burners are dual fuel fired capable of firing Pulverized Coal and Natural
Gas up to 100% MCR Steam generation. The individual burners are
designed to operate only as follows:
a) Individual burners on Solo Pulverised Coal or Natural Gas firing.
b)Burners can be fired in combination firing mode with Natural Gas
and Pulverised Coal together. Individual burners on Variable Pulverised
Coal firing and Variable Natural Gas Firing (During Pulverised Coal
firing the burners shall start in a pair only of the designated elevation
selected by the operator).
The burners have the capability to fire Pulverized coal equivalent to
100% steam generation by operating any 4 numbers (any two levels)
with 25% NG support firing through the main NG burners i.e. Minimum
6.25% each burner capacity.
Each burner is equipped to fire Natural Gas in solo mode up to
maximum rated burner input of 40.0 M. kcal/hr. The burners have the
capability to fire Natural Gas equivalent to 100% steam generation by
operating all 6 burners. At part load operation lesser number of
burners can be operated.

New Pulverized coal cum NG fired Burner

Each natural gas gun is equipped with one no. Super spud. It is a
fixed spud. Each super spud consists of 17 holes (16 peripheral
and 1 at centre). The orientation of gas gun alongwith the gas
spud shall be CW (Clockwise) for a CCW (Counter Clockwise
Burner) and CCW (Counterclockwise) for a CW Clockwise burner.
Care to be taken to install the correct orientation gun as described
and mentioned above in the correct burner.
The sliding air dampers are used to control air flow and balance
air distribution among burners. The SA is freely admitted to the
burner wind box and available to all burners in that wind box. SA
flow to each burner is regulated by an automated pneumatic
actuator device which controls the burner adjustable sliding air
damper at the entrance to the air sleeve. SA enters the burner
past the sliding air damper, continues through the adjustable spin
vanes located in the air sleeve and exits through the burner throat
into the furnace. To provide proper mixing of the fuel and air, swirl
is imparted by means of adjustable spin wanes located in the air
sleeve.

Secondary air sliding damper.

The adjustable spin vanes in the air zones should not

require periodic adjustment except with some major
fuel changes.
When a burner is out of service, the sliding air
damper is set by the automated linear actuator to
provide sufficient cooling air to prevent burner
component overheating. Overheating is most likely to
occur on out-of-service burners on the upper burner
levels, due to higher furnace temperatures. To help
prevent overheating, mechanical stops are also
installed (if required) on the burner to prevent
complete closure of the sliding air damper, assuring
some cooling air at all the times.

New Burner front view inside the furnace

Adjustable spin vanes in the air

zones

Control system of spin vanes

Coal Nozzle
and 38 PC SDETAILS OF18THE
NEW
Type
BURNER

e & Type of Burner

of Burners per boiler

pacity of each Burner (%MCR)

Six (4 Operating + 2 Standby)

25%

ner Throat Dia, inch

Lead lag arrangement, FD fan in

vanes
38

e & No. of Gas spuds

One No. Super Spud (Main Spud

e of air control & accessories

nstruction of Spuds

rler / Impeller Information

ner turndown (Coal)

Fix Spud
Impeller(swirl motion for
homogeneous mixture/combustio
1: 2.25

IGNITERS
Burners are equipped with FPS class 1, Gas
(NG) fired ignitor to ignite the main gas flame
and to support Pulverized coal flame. Each
igniter is Non retractable and equipped with a
high energy spark rod. The igniter flame is
detected by ionization principle.Heat release
rate of 4 Nos. ignitor would be 10% MCR
equivalent of steam generation. It also helps in
adhering to cold start up curve. During Coal
Firing, maximum 10% BMCR NG support will be
given by 4 Nos. Gas fired igniters. At that time
Gas Fired Igniters will be kept in continuous
operation

Igniter transformer for each burner is supplied in a

Flame proof enclosure. Ignition logic shall be
incorporated as part of BMS logic in the new DCS.
Ignition Fuel: Natural Gas.
Battery Limit Fuel Pressure: 5 kg/cm2
Battery Limit Fuel Temperature: 30 degC
Igniter Quantity: 6 Nos (Each Burner having one
igniter)
The ignitor requires clean combustion/cooling air to the
(2.5 FNPT) External Combustion air inlet of 140 SCF/M
@ 50-100 mm water column above furnace pressure
(3.96 m3/min @ 5-10 mBar). This air is required
continuously while the boiler is in operation and will keep
the igniter tip clean from coal dust and prevent choking.

Igniter Data
Type & Make of the Igniter

4 Stationary FPS Gas Fired

Igniter

Fuel

NG

Guide Tube Diameter

Maximum Heat Release

20 Million Btu / hr (5MKCal/hr)

Minimum Heat Release

5 Million Btu / hr 1.25(MKCal/hr)

Turndown

4:1

No of Igniter for each Burner

One

Continuous Cooling /
Combustion Air Requirement

140 scfm @ 50-100 mm wc

above furnace pressure

Gas pressure at Igniter Inlet

0.28 to 1.76 kg/cm2

FLAME SCANNERS
Each burner is equipped with One (1)
Flame scanner of UV + IR type to
sense Coal flame as well as the NG
flame. New flame scanner will be
mounted on the burner front plate of
New PC S Type Burner. Ensure that
always the flame scanners are
kept in service and never
bypassed.

BURNER THROAT &WIND BOX

Burner throat size selected would be more

or less of existing burners throat size.
Existing Burner throat refractory
reconstructed according to the new burner
profile.
Existing common wind box will be retained
and no modification is required for new
burners installation.
Insulation and aluminium / GI cladding shall
be applied afresh on wind box.

NG GAS PIPING FROM BATTERY LIMIT

TO BOILER NG FLOW CONTROL STATION

8 Natural gas line (Approx. length

200M) laid from NG Pressure
Reducing Station tapping in SGP
ground floor to boiler NG control
station in CPP

NATURAL GAS TRAIN TO BOILER

New natural gas train with control, monitoring
and safety shutdown equipments / Instruments
has been provided as shown in the P&I diagram.
The required gas pressure reduction will be
through pressure control valves to facilitate NG
burner start up. For NG flow control, a Flow
control valve with pneumatic actuator and E/P
converter are provided to meet the load
requirements.
For measurement of natural gas to the boiler,
one Mass flow meter is provided for in common
NG line to the boiler

Gas station for each burner with complete necessary

trips and isolating valves located at three elevations for
all six burners. The isolation of each gas burner is
through block and bleed Quick shut off valves of
leakage class VI with pneumatic actuators and position
feedback switches has been provided for each burner
fuel gas trip.
The bleed gas vent is located at 36M elevation of the
boiler for safe venting.
Pressure transmitters are proposed for process
parameters tripping signals such as fuel gas pressure
very low & very high interlocks for fuel cut off / safety
shutdown. These trips have been realized through 2oo3
logic with independent process tapings.

Igniter / Support gas supply train:

New igniter gas train with control &

monitoring and safety shutdown equipments
has been provided as shown in the P&I
diagram.
Block & Bleed Quick shut off valves have been
provided for each burner ignite gas trip.
For controlling the gas pressure to the igniters
a pressure control valve with pneumatic
actuator and E/P converter is provided.
Detectors for flammable gas are to be
installed near the NG flow control station and
at burner levels.

DISTRIBUTED CONTROL
SYSTEM (DCS)

Existing DCS for boiler operation & control and

the PLC based BMS / FSSS (Furnace safety
supervisory system) system shall be replaced
with a new DCS system (Emerson make).
Boiler operation and control schematics
implemented in the new DCS system. Apart
from the NG system, existing inputs & outputs
of coal (including coal feed & coal mill, etc.),
Boiler accessories (which are incorporated in
the existing DCS) and boiler control &
monitoring instruments shall be reconfigured
in the new DCS.

CONTROLLING FACTORS DURING START-UP (EXISTING SYSTEM TO BE

FOLLOWED)

Rate of Temperature and Pressure Rise

Drum shell Temperature Differentials
Combustion Gas Temperature
Steam Temperatures

Following Existing water conditioning

during Boiler Start-up will be
followed.
Dissolved Oxygen
Silica Purging

BOILER COLD START UP

(EXISTING PROCEDURE TO BE
FOLLOWED)

Preparation Works.
Drafting System Function.
Secondary Air Slide Damper Function.
Furnace Purge Function.
MFT Function (Pilot Gas Piping)
Pilot Gas NG Burner Light up.
MFT Function (Main Gas Piping)
Main NG Burner light up.
Pressure Raising Function.
Boiler Loading Function.
Fuel Change Function from Natural Gas to Pulverised
Coal.

PREPARATION FOR BOILER START - UP (EXISTING PROCEDURE)

Confirmation of Utilities to be Available.

Confirmation of Feed Water System to be ready.
Confirmation of Ash Handling Equipment to be
Running.
Confirmation of Fuel Supply Equipment to be
Required Ready.
Confirmation of Boiler Trim Valve to be Required
Position.
Confirmation of ESP Start-up.
Confirmation of Start-up of Chemical Dosing
Pump.

DRAFTING SYSTEM FUNCTION

(EXISTING PROCEDURE)

Rotary Air Heater Start as per existing

procedure.
ID FAN Start as per existing procedure.
FD Fan Start as per existing procedure.
Maintain furnace draft to -5.0mmwc
with furnace draft control
loop in Auto mode of operation.
Scanner cooling air Fan Start as per
existing procedure.

DRAFTING SYSTEM START

Air Heater (AH) start
Following is Startup Permissive:
Cooling water flow for AH bearings is not
low
Following Condition is used for Tripping:
MCC (Main control centre) Trip
Air Heater can be started or stopped
Manually from BCP (Backup Control
Panel) as well as from DCS/ Sequential

ID Fan 1 Start
Followings are Startup Permissive:
AH Running.
ID Fan 1 Inlet Isolation damper close.
ID Fan 1 Outlet Isolation damper close.
ID Fan 1 Inlet vane Close.
ID Fan 1 motor bearing (CP Coupling Side) Cooling water flow not
low.
ID Fan 1 motor bearing (ACP Anti Coupling Side) Cooling water flow
not low.
Following Conditions are used for Tripping:
ID Fan 1 motor bearing (CP Coupling Side) temperature high.
ID Fan 1 motor bearing (ACP Anti Coupling Side) temperature high.
MCC Trip.
ID Fan 1 can be started or stopped Manually from BCP (Backup
Control Panel) as well as from DCS/ Sequential.
Start ID fan-1
Open ID Fan 1 Inlet Isolating damper (FGDM 004A).
Open ID Fan 1 Outlet Isolating damper (FGDM 006A).

FD Fan 1 Start

Followings are Startup Permissive:

ID Fan 1 Running
FD Fan 1 Outlet Cross over damper (CADM 002A) Close.
SAH 1 Outlet damper (CADM 003A) Close.
FD Fan 1 Inlet vane (CADM 001A) Close.
FD Fan motor bearing (CP Coupling Side) Cooling
water flow not low.
FD Fan motor bearing (ACP Anti Coupling Side)
Cooling water flow not low.
Followings are used for Tripping:
FD Fan motor bearing (CP Coupling Side) temperature
high.
FD Fan motor bearing (ACP Anti Coupling Side)
temperature high.
MCC Trip.
IDF 1 Trip.

FD Fan 1 can be started or stopped Manually from BCP

(Backup Control Panel) as well as from DCS/ Sequential.
Start FD Fan-1
Open FD Fan 1 Outlet Cross over damper (CADM 002A).
Open SAH 1 Outlet damper (CADM 003A).
Control Station of ID Fan 1 Inlet vane (FGDM 005A) to be
changed to Auto Mode.
Master Station of ID Fan to be changed to Auto Mode.
Control Station of FD Fan 1 Inlet vane (CADM 001A) to be
changed to Auto Mode.
Master Station of FD Fan to be changed to Auto Mode.

Start Scanner Cooling Air Fan (SCF1) Motor

Following is Startup Permissive:

Furnace Pressure is not low not high.
Following Condition is used for Tripping:
MCC Trip.
SCF 1 can be started or stopped from DCS/
Sequential.
SCF 2 is kept in Auto Mode then SCF 2 will Start
Automatically if
SCF 1 Trip.
DP in between Scanner Discharge Pressure (PX 2011)
and Wind box Pressure (PX 2004) is below 450 mmwc
Same logic prevails for SCF 1 when SCF2 is running
and SCF1 is in Auto Mode

SECONDARY AIR SLIDE DAMPER FUNCTION

Air slide damper controls the air flow as per the requirement
during furnace purge, cooling of burner, ignition/pilot cycle,
and burner ON condition.
When all fuel valves are closed, all the burner air slide
dampers shall be in 100 % OPEN position.
During furnace purging all the burner air slide dampers shall
be in 100.00% OPEN position.
After furnace purge finished and FD air flow at boiler start up
position (@30.0% MCR Air flow); all the burner air slide
dampers shall be in cooling / Light up position.
During burner start-up, particular air slide damper shall
advance and taken to full open position after 3.0 seconds
delay of close feedback of block valves not available.
Air slide damper of the particular burner regains cooling /
Light up position after burner stop command is given.

Burner Air Slide Damper Logic

Burner Air Slide Damper will move to Light-up/cooling position if
any of the following condition prevails
Purge finished.
Appertaining NG burner trip AND appertaining coal feeder not in service.
Appertaining NG burner stop command given AND appertaining coal
feeder not in service.
Appertaining coal feeder trips AND appertaining main NG burner not in
service.
Appertaining coal feeder burner stop command given AND appertaining
main NG burner not in service.
Appertaining Burner Air Slide Damper will move to full open
position if any one of the signal is present
After 3.0 seconds delay of closed feedback of the appertaining NG main
block valve not available.
After 5.0 minutes of appertaining coal feeder speed reaching above 10%
AND Appertaining Main NG burners are NOT ON
Boiler Trip OR MFT Condition Prevails.

FURNACE PURGE

Boiler purge is a process of flowing air through the ducts,

furnace, and all gas passages of the boiler, flues, and stack to
remove any gaseous or accumulated combustibles. Boiler
purge shall be completed before the MFT system can be reset.
Prior to boiler start and burner light up (start-up), the air and
gas passages of the boiler as well as the ESP, RGAH etc. will
be purged of any combustibles that may have accumulated.
An open flow path through the boiler from the inlet of the FD
Fan(s) to the stack must be ensured. The purging will be
accomplished by maintaining a constant air flow.
Purging cycle will start automatically when the purge
permissive is established and an air flow of > 50.0% (130.0
TPH) of MCR air Flow must be maintained flowing through the
entire flue gas path for at least five minutes continuously in
order to achieve five volume changes before a furnace purge
is considered complete allowing the operator to manually rest
the Master Fuel Trip.

The operator is permitted to give a command to the MFT reset

button after boiler purge is complete. The MFT relays are
reset by giving command to reset button sequentially resetting
the BMS logic and all BMS MFT relays while the button is
depressed.
Once the purge is complete, a continuous purge at the purge
rate must be maintained. Failure to do so will inhibit the
starting of additional fuel equipment until the continuous purge
rate is re-established for five minutes.
Two attempts for Pilot Igniter light available. After two
unsuccessful light up attempts the unit shall go for purge.
The Master Fuel Trip relay system will de-energize to directly
stop all fuel input to the furnace. No interposing logic, relays or
other devices will be permitted between the Master Fuel Trip
Relay(s) and the equipment to be shutdown.
Unit shall go to re purge if burner start command is not
issued for more then 20 minutes.

The following permissives must be met before purge cycle can take place.
Furnace purge Not Completed
FD Fan Running (At Least One)
ID Fan Running (At Least One)
AH Running
Air Flow > 50% MCR
All burners Secondary Air slide damper advanced to 100.0% Open position.
Furnace Pressure not low low and not high high
All gas Igniter group Double Block valves are closed & Bleed valves are opened.
Igniter gas header MFT Valve is closed
All Main Gas burner Double Block valves are closed & Bleed valves are opened.
Main Gas header MFT Valve is closed
All Coal Plug Valves Closed.
All PA Fan Stopped.
All Mill & Coal Feeder Stopped.
All Mill Isolation Dampers Closed.
Drum level not low low and not high high.
Instrument air pressure not low low.
Scanner cooling air pressure not low low.
No flame detected.
MFT trip button not pressed from DCS and from Auxiliary control console.
No loss of critical power
Unit shall go to re purge if burner start command is not issued for more then
20 minutes.

MFT FUNCTION (PILOT GAS PIPING)

PILOT NG-MFT (XV-109) can be opened from DCS by

giving command for MFT OPEN.
Following conditions must be satisfied:
After Purge Complete within 20 minutes otherwise re
purge is required.
Main interlocks satisfied.
Pilot gas piping MFT close button not operated from
DCS AND No Pilot MFT close command given from
sequence logic.
Pilot Burner Fault not Present.
Pilot Header Vent Valve (XV-110)
Pilot NG header vent valve (XV-110) shall close when
all the following conditions are satisfied:
Pilot MFT open command given

PILOT GAS BURNER LIGHT UP

All trip valves are Fail-safe close except Gas vent valves,
which are fail Open type. Bleed valve of the Block &
Bleed valves are fail Open types.
The following permissive must be met before pilot gas
igniter burner can be taken in service. These include but
are not limited to:
Purge Complete OR Any Main NG Burner ON OR Any Mill
ON OR Any Pilot Burner ON.
Pilot MFT Valve open command given AND Pilot MFT
Open feedback
Pilot gas pressure not low-low. (0.10 Kg/cm2g) OR any
one pilot burner NOT ON.
Pilot gas pressure not High High (1.76 Kg/cm2g) or any
one pilot burner NOT ON.
Main interlocks satisfied.

Ensure that the valve line-up of the pilot gas train is completed and the fuel gas is
charged up to the pilot gas piping MFT. Ensure that the 2.5 butterfly valve for pilot gas
augmenting / combustion air is always open
To open the Pilot fuel gas MFT, the fuel MFT permissive has to be satisfied.
After satisfying the permissive.
Open the pilot gas PCV - 103 in manual mode to maintain a minimum Natural
Gas pressure of 0.28 to 1.0 Kg/cm2 at the burner header.
The airflow has to be maintained at 30% of the full load flow and logics made
ready for burner start.
Pilot gas pressure not low-low (0.10 K/cm2g) This condition is bypassed for
the 1st ignitor.
Select any one burner for light up. Give start command from DCS for NG
firing. Once the start command is given to the appertaining burner for start
up, the following sequence of events takes place. Simultaneously the natural
gas double block valve opens and Bleed valve closes.
Ignition transformer energises and High Energy Spark of 1000.0 Volts DC is
created for 7.0 seconds. After 7.0 seconds the spark shall stop.
Pilot gas flame establishes and is detected by the sun spot flame detector
working on ionisation principle. The flame must establish and get detected by
the sun spot flame detector within 10.0 seconds from the start command in
order to keep the pilot gas burner in continuous operation, otherwise if flame
not established or detected then double block valve shall close and bleed
valve shall open.
The above procedure is common for start up of all the six pilot burners.

Ignition Transformer ON Condition

Pilot Burner Start command given
AND
Pilot Burner stop command not given AND Appertaining Pilot NG
Block Valves Closed.

MFT FUNCTION (MAIN GAS PIPING)

Main NG-MFT (XV-101) can be opened from DCS

by giving command for MFT OPEN.
Following conditions should be satisfied:
Main interlocks satisfied.
NG-MFT (XV-101) shall get close after 20 minutes
if any one Main NG burner is not ON.
Main NG MFT close button not operated from
DCS AND No Main NG MFT close command given
from sequence logic.
Main NG Header Vent Valve (XV-102)
Main NG header vent valve (XV-102) shall close
when all the following conditions are satisfied:
Main NG MFT open command given

MAIN NG BURNER LIGHTUP

All trip valves are Fail-safe close except Gas vent valves, which are
fail Open type. Bleed valve of the Block & Bleed valves are fail
Open types.
The following permissive must be met before main burner light up
on Natural Gas firing can be taken in service. These include but
are not limited to:
Purge Complete OR Main NG burner ON or Any PA Fan ON OR any Mill
ON, OR any Pilot burner ON.
Main interlocks satisfied.
Select any burner for light up.
Pilot burner flame ON for appertaining main burner.
Natural Gas pressure not low-low. (0.01 Kg/cm2) This condition is
bypassed for the 1st burner.
Appertaining PA Fan to that group not ON.
Main NG MFT open command given AND Main NG MFT Open feedback
Natural gas pressure not very high (1.5 Kg/cm2g) or Any One NG Burner
(NOT ON).
FCV - 101 in closed position OR any Main NG Burner ON

Following is the sequence of operation of the Main burner light up on

Natural Gas firing (the procedure may be slightly changed after
commissioning to suit site conditions)
Ensure that the valve line-up of the main Natural Gas train and the Main
NG Burner is completed and the fuel gas is charged up to the main gas
piping MFT.
The secondary air slide damper operated by power cylinder for all the
burners are kept in cooling / light up position during main burner light up on
Natural Gas.
The pilot burner is in service of the appertaining burner to be started.
To open the main burner fuel gas MFT, the fuel MFT permissive has to be
satisfied. After satisfying the permissive.
MFT of Natural Gas piping for Main burner is open and simultaneously the
command for header vent valve initiates to close the vent valve.
Open the main Natural gas PCV - 102 in manual mode to maintain a
minimum Natural Gas pressure of 0.045 to 0.10 Kg/cm2 at the burner
header. The NG pressure can be adjusted and set point freeze suitable to
site conditions during commissioning.
Start up Control Valve (PCV-102) can be in Manual or Auto mode from the
beginning with the desired set point of 0.045 kg/cm2 or 30% NG Flow of
burner.

Burner block valves open command shall be given on proving that the
header gas pressure is normal. Natural gas pressure not high
high (1.5 Kg/cm2g) or not low low (0.01 Kg/cm2g) .
FCV shall be fully closed till the first burner is ON (shall be released after
30 seconds timer for stabilization).
The airflow has to be maintained at 30% of the full load flow and logics
made ready for burner start.
For main gas firing, the Main gas burner start command is given from DCS
for NG firing. Select any one burner for light up. Once the start command is
given to that appertaining burner for start up, the following sequence of
events takes place.
The natural gas double block valve opens and Bleed valve closes. Main
Natural Gas Burner ON indication shall appear when Flame scanner ON
feedback received and close feedback of block valve not available. Air slide
damper shall OPEN after 5 sec of close feedback of Appertaining Main
Natural Gas Burner block valve not available. Burner shall remain ON till all
conditions mentioned above are satisfied and burner stop is not operated.

Main gas flame establishes and is detected by the Flame scanner for main
flame detection working on UV flame detection principle. The flame must
establish and get detected by the flame scanner within 15.0 seconds from
the start command in order to keep the main gas burner in continuous
operation, otherwise if the flame does not get established or detected then
double block valve shall close and bleed valve shall open.
Post proving of main burner flame by the flame scanner on natural gas
firing the secondary air sliding damper advances to 100.0% open position.
NG main burner shall trip in the event if the air slide damper 100.0% opens
position signal is not achieved and feedback not received.
Proving of main flame takes 15 seconds from the start command given for
main burner start up on Natural Gas firing. On achieving 15 seconds the
command for igniter pilot gas burner stop shall be issued, hence the igniter
shall get removed from service with manual intervention of the operator
(Operator to switch off the pilot Gas Burner) and the main burner shall be
sustaining and firing Natural Gas on its own without support from Pilot Gas
burner / Flame.
The above procedure is common for start up of all the six main Natural Gas
burners.

PRESSURE RAISING BY NATURAL GAS FIRED IGNITERS / MAIN

BURNERS.

Start the Igniter of Burner No. 1 (Bottom Elevation).

Start the Igniter of Burner No. 2 (Bottom Elevation).
Start the Igniter of Burner No. 3 (Middle Elevation).
Start the Igniter of Burner No. 4 (Middle Elevation).
Start the Igniter of Burner No. 5 (Highest Elevation).
Start the Igniter of Burner No. 6 (Highest Elevation
The boiler load can be achieved till 15.0% MCR value in
MANUAL MODE with the above 6 Nos of Igniters / pilot burners
in service or it can be achieved by firing individual main
burners. In order to raise the boiler load further in MANUAL
MODE up to 30.0% MCR, please follow the above Main NG
burner light up procedure as stated above, lighting up main
NG fired burners one by one through the pilot igniters meeting
the below boiler existing cold start up procedure as explained.

BOILER TRIM VALVE OPEN/CLOSE (EXISTING PROCEDURE)

Drum vent valve to be closed at 2.0 (two) kg/cmg,

b) Start-up vent valve to be opened.
c) S/H vent to be closed at 5.0(five) kg/cmg.
d) S/H outlet drain valve to be closed at 7.0(seven)
kg/cmg.
e) Single Element drum level control loop to be
taken in Auto mode after achieving drum pressure
10.0kg/cm2g..
f) The rate of boiler water temperature rising to be
changed to 55.0C/HR at 30.0 kg/cmg.
At reaching 100.0 kg/cm2 g at S/H outlet, Pressure
rising finished.

BOILER LOADING FUNCTION (EXISTING PROCEDURE TO BE

FOLLOWED)

The boiler load can be increased and achieved to BMCR with 6

Nos. of Burners in operation.
Boiler load to be increased till 30% BMCR in Manual mode.
Start-up vent valve opening to be regulated by which S/H
outlet temperature is maintained above 450C.
Bypass valve MSMV - 012 to Main steam stop valve is to be
taken service for warming up the main steam piping.
Main Steam Stop valve MSMV 011 to be taken in service
once its bypass valve is fully opened and in service.
Maintain CPP Boiler Master control in Manual Mode only".
CPP Boiler load to be increased until the S/H outlet temp. reach
495C (470C at turbine generator inlet) along with ramp rate
of 3% load increase per minute.
After finishing temperature rising, start-up vent valve to be
closed gradually.
Three element drum level control loop to be taken in AUTO
Mode.

FUEL CHANGE OVER FUNCTION FROM

NATURAL GAS TO PULVERISED COAL
On each elevation of boiler there are two Main load carrying burners
installed in the boiler front abreast to each other. There are three elevations
namely Bottom elevation, Middle and Top. Two Number burners are installed
in one elevation, hence total 6.0 Number Main Load Carrying Burners are
installed at the above three elevations which is able to fire in solo mode
firing Natural Gas or Pulverised Coal any one fuel at one time / instance in
one elevation or in combination mode Natural Gas and Pulverised Coal
together in same burner and at same elevation. Two burners on each
elevation create one group, hence for three elevations, there shall be three
groups. Group 1 consist of Burner No. 1 and 2 at Bottom Elevation, Group
2 Consists of Burner No. 3 and 4 at Middle Elevation, and Group 3
consists of Burner No. 5 and 6 on the highest elevation.
Each Main Burner is provided and installed with a Single igniter pilot gas
burner having a full load capacity of 10.0% of the Main burner capacity,
firing Natural Gas as a fuel delivering a continuous support flame while the
Main burner is firing Pulverised Coal till the PC firing stabilises, once the PC
firing stabilises the pilot gas burner to be removed by manual intervention
of the Operator. Each burner is provided and installed with a Single Main NG
burner having a full load capacity, firing Natural Gas as a fuel delivering a
continuous support flame while the Main burner is firing Pulverised Coal.

The igniter pilot Natural Gas fired burners of the

appertaining elevations may be taken in service prior to
giving command to start the main burners on pulverised
coal.
Select any one elevation (Two Main Burners) where
Pulverized coal is to be introduced / fired, ensuring either the
main burners are in operation with Natural Gas and / OR
pilot natural gas burners are also taken in service manually.
Since the four Main NG burners are in operation, prior to
starting the Primary Air fan and opening the primary air fan
dampers which is supplying the air to the burners, Increase
the flow of Secondary Combustion Air from the FD Fans,.
This is to assure that adequate combustion air is available to
all the operating burners.

Now prepare the boiler for Pulverised coal firing/introduction. Coal firing can
be commenced when boiler generates approximately 25% to 30% BMCR
load also.
Each Pulveriser Group Consists of the BTM pulveriser, associated primary air
system, two (2) nos. motor operated gravimetric coal feeders, BTM outlet directly goes
two (2) nos. Classifiers. Outlet of each classifier is directly connected to each main PC
Fired burner. Ensure that continuous seal air is provided and in continuous service to
all the burners for cooling from both the cooling ports.
Open coal plug gates.
Start Existing appertaining seal air fan and ensure that the seal air is available to
pulveriser yoke sealing and coal feeders.
Start Existing appertaining primary air fan to supply primary air to BTM pulveriser.
Start Appertaining lube oil system for the Appertaining Ball tube Mill.

Start appertaining pulveriser Ball Tube Mill meant to supply PC coal for the
appertaining elevation burners. Ball tube Mill warming up begins with hot Primary
Air. The PA suction temperature of 70 Deg C is maintained by mixing tempering air
at ambient temperature directly from FD discharge and hot air from Air Heater outlet
which is at 180.0 Deg C. The PA air from outlet of PA fan is delivered to the Ball tube
Mill @70.0 Deg C and then the Primary Air flows to the classifier and finally to the
burners. The PA air flows till the burner inlet is maintained at 70.0 Deg C hence
warming up of the BTM and the coal path is completed.
Start appertaining coal feeders for appertaining elevation burners and gradually
increase firing through the feeders after main flame stabilisation on pulverised coal.
The coal enters the BTM through the two coal feeders joins the hot Primary air @
70 Deg C flowing through the BTM, further the coal is pulverised by the balls to a
fine powder (99.0% passing through 50 Mesh and 75% passing through 200 Mesh).
Pulverised coal flows to the PC burners and comes in contact with the Natural
Gas in both the burners.
Second Pulveriser group can be started at approximately 40% to 50% Boiler MCR
load by following the above procedure.
Continue coal firing at Bottom & Middle elevation for Boiler loading up to 100%
BMCR or Continue coal firing at any two nos of elevations available for firing
pulverised coal. The boiler can generate 100.00% BMCR with only 4.0 Nos burners
and two elevations in service.