POINTS OF DISCUSSION

SUB CRITICAL & SUPER CRITICAL BOILER

SIPAT BOILER DESIGN

BOILER DESIGN PARAMETERS

CHEMICAL TREATMENT SYSTEM

OPERATION

FEED WATER SYSTEM

BOILER CONTROL

BOILER LIGHT UP

START UP CURVES

WHY SUPER CRITICAL TECHNOLOGY

To Reduce emission for each Kwh of electricity generated : Superior Environmental

1% rise in efficiency reduce the CO2 emission by 2-3%

The Most Economical way to enhance efficiency

To Achieve Fuel cost saving : Economical

Operating Flexibility

Reduces the Boiler size / MW

To Reduce Start-Up Time

UNDERSTANDING SUB CRITICAL TECHNOLOGY

Water when heated to sub critical pressure, Temperature increases until it

starts boiling

This temperature remain constant till all the water converted to steam

When all liquid converted to steam than again temperature starts rising.

Sub critical boiler typically have a mean ( Boiler Drum) to separate Steam And
Water

The mass of this boiler drum, which limits the rate at which the sub critical
boiler responds to the load changes

Too great a firing rate will result in high thermal stresses in the boiler drum

Role of SG in Rankine Cycle

Perform Using Natural resources of energy .

UNDERSTANDING SUPER CRITICAL TECHNOLOGY

When Water is heated at constant pressure above the critical pressure, its
temperature will never be constant

No distinction between the Liquid and Gas, the mass density of the two
phases remain same

No Stage where the water exist as two phases and require separation : No
Drum

The actual location of the transition from liquid to steam in a once through
super critical boiler is free to move with different condition : Sliding Pressure
Operation

For changing boiler loads and pressure, the process is able to optimize the
amount of liquid and gas regions for effective heat transfer.

Circulation Vs Once Through

No Religious Attitude

540C, 255 Ksc

568C, 47
Ksc

492C, 260 Ksc

457C, 49 Ksc

FUR ROOF
I/L HDR

ECO HGR O/L

HDR

HRH LINE
MS LINE
411C,
277Ksc

411C,
275 Ksc

SEPARATOR

T
A
N
K

G
LPT
C
O
N
D
E
N
S
E
R

LPT

IPT

FINAL SH
FINAL
RH
DIV PANELS SH

LTRH

PLATEN
SH

VERTICAL WW
ECO
JUNCTION
HDR

305C, 49 Ksc

S
T
O
R
A
G
E

HPT

Sp

ate
lw
a
ir

all
rw

ECONOMISER

ECO I/L

FEED WATER

BWRP

290C, 302 KSC

FUR LOWER HDR

FRS

Steam

Partial Steam Generation

Steam

Complete or Once-through
Generation

Water

Heat Input

Heat Input

Water
Water

Boiling process in Tubular Geometries

SEPARATOR TANK

PENTHOUSE

Eco. O/L hdr (E7)

LTRH O/L hdr (R8)
2nd pass top hdrs (S11)

Back pass Roof o/l hdr (S5)

SH final I/L hdr (S34)

SH final O/L hdr (S36)

F19

1 pass top hdrs

st

RH O/L hdr (R12)

RH I/L hdr (R10)

Platen I/L hdr (S28)

Platen O/L hdr (S30)

F28
F28

Div. Pan. O/L hdrs (S24)

Div. Pan. I/L hdrs

(S20)
Back pass Roof i/l hdr
Separator (F31)

F8
S2

1st pass top hdrs

Storage Tank (F33)

SIPAT SUPER CRITICAL BOILER

BOILER DESIGN PARAMETER

DRUM LESS BOILER : START-UP SYSTEM

TYPE OF TUBE
Vertical
Spiral

SPIRAL WATER WALL TUBING

Advantage
Disadvantage over Vertical water wall

Vertical Tube Furnace

To provide sufficient flow per tube, constant pressure

furnaces employ vertically oriented tubes.

Tubes are appropriately sized and arranged in multiple

passes in the lower furnace where the burners are located
and the heat input is high.

By passing the flow twice through the lower furnace

periphery (two passes), the mass flow per tube can be
kept high enough to ensure sufficient cooling.

In addition, the fluid is mixed between passes to reduce

the upset fluid temperature.

Spiral Tube Furnace

The spiral design, on the other hand, utilizes fewer

tubes to obtain the desired flow per tube by wrapping
them around the furnace to create the enclosure.

This also has the benefit of passing all tubes through

all heat zones to maintain a nearly even fluid
temperature at the outlet of the lower portion of the
furnace.

Because the tubes are wrapped around the furnace

to form the enclosure, fabrication and erection are
considerably more complicated and costly.

SPIRAL WATER WALL

ADVANTAGE

Benefits from averaging of heat absorption variation : Less tube leakages

Simplified inlet header arrangement

Use of smooth bore tubing

No individual tube orifice

Reduced Number of evaporator wall tubes & Ensures minimum water flow

Minimizes Peak Tube Metal Temperature

Minimizes Tube to Tube Metal Temperature difference

DISADVANTAGE

Complex wind-box opening

Complex water wall support system

tube leakage identification : a tough task

More the water wall pressure drop : increases Boiler Feed Pump Power

Adherence of Ash on the shelf of tube fin

BOILER OPERATING PARAMETER

FD FAN

2 NoS ( AXIAL )

11 kv / 1950 KW

228 mmwc
1732 T / Hr

PA FAN

2 Nos ( AXIAL)

11 KV / 3920 KW

884 mmwc
947 T / Hr

ID FAN

2 Nos ( AXIAL)

11 KV / 5820 KW

TOTAL AIR

2535 T / Hr

SH OUT LET PRESSURE / TEMPERATURE /

FLOW

256 Ksc / 540 C

2225 T / Hr

RH OUTLET PRESSURE/ TEMPERATURE /

FLOW

46 Ksc / 568 C
1742 T / Hr

SEPARATOR OUT LET PRESSURE/

TEMPERATURE

277 Ksc / 412 C

ECONOMISER INLET

304 Ksc / 270 C

MILL OPERATION

7 / 10

COAL REQUIREMENT

471 T / Hr

SH / RH SPRAY

89 / 0.0 T / Hr

BOILER EFFICIENCY

87 %

3020 T / Hr

Coal Analysis
1.

High erosion
potential for
pulverizer and
backpass tube is
expected due to
high ash content.

2. Combustibility
Index is relatively
low but
combustion
characteristic is
good owing to
high volatile
content.

Ash Analysis

1.

Lower
slagging
potential is
expected due
to low ash
fusion temp.
and low
basic / acid
ratio.

2. Lower fouling
potential is
expected due
to low Na2O
and CaO
content.

AIR AND FLUE GAS SYSTEM

AIR PATH

: Similar as 500 MW Unit

FLUE GAS PATH:

No Of ESP Passes

6 Pass

No Of Fields / Pass

18

1-7 fields 70 KV.

8&9 field 90 KV

No Of Hopper / Pass

36

Flue Gas Flow / Pass

1058 T/ Hr

HOT PRIMARY AIR DUCT

PAPH # A

TO PULVERISER SYSTEM

AIR MOTOR

AIR MOTOR

PA FAN # A

FD FAN # A

SAPH # A

M
M

AIR MOTOR

AIR MOTOR

M
M

FD FAN # B

SAPH # B

PA FAN # B

PAPH # B

HOT PRIMARY AIR DUCT

M

TO PULVERISER SYSTEM

LHS WIND BOX

RHS WIND BOX

ECONOMISER

BACK PASS
LTRH

FINAL SUPERHEATER

FINAL REHEATER

PLATEN COILS

DIVISIONAL PANEL

FURNACE

AIR PATH

FUEL OIL SYSTEM

Type Of Oil

LDO / HFO

Boiler Load Attainable With All Oil Burner In Service

30 %

Oil Consumption / Burner

2123 Kg / Hr

Capacity Of HFO / Coal

42.1 %

Capacity Of LDO / Coal

52.5 %

HFO Temperature

192 C

All Data Are At 30 % BMCR

DESIGN BASIS FOR SAFETY VALVES :

1.Minimum Discharge Capacities.
Safety valves on Separator and SH

Combined capacity 105%BMCR

(excluding power operated impulse safety valve)

Safety valves on RH system

Combined capacity 105% of Reheat

flow at BMCR

(excluding power operated impulse safety valve)

Power operated impulse safety valve

40%BMCR at super-heater outlet

60% of Reheat flow at BMCR at RH

outlet
2. Blow down

4% (max.)b

BOILER FILL WATER REQUIREMENT

Main Feed Water Pipe ( FW Shut Off Valve to ECO I/L HDR)

28.8 m3

Economizer

253.2 m3

Furnace ( Eco Check Valve to Separator Link)

41.5 m3

Separators & Link

13.8 m3

OXYGENATED TREATMENT OF FEED WATER

WATER CHEMISTRY CONTROL MAINTAINS PLANT HEALTH.

Dosing

of oxygen(O2) or Hydrogen peroxide

(H2O2) in to feed water system.

Concentration

in the range of 50 to 300

g/L.
Formation

oxide

of a thin, tightly adherent ferric

(FeOOH) hydrate layer.

This

layer is much more dense and tight

than
that of Magnetite layer.
39

All Volatile
Treatment

Oxygenated
Water
Treatment

40

DOSING POINTS

41

AVT Dosing Auto Control

42

OWT Dosing Auto Control

43

U#1

FUR ROOF I/L HDR

VENT HDR

VENT HDR

WATER LINE

N2 FILL LINE

N2 FILL LINE

N2 FILLING LINE
VENT LINE

SAMPLE COOLER

SAMPLE COOLER

SEPRATOR #1

DRAIN LINE
SAMPLE COOLER LINE

SEPRATOR #2

2
VENT HDR

VENT HDR

FUR WW HDR

FUR INTERMITTENT HDR

STORAGE TANK
DRAIN HDR

FUR BOTTOM RING HDR

FLASH TANK

DRAIN HDR

MIXING PIECE
WR

VENT HDR

ZR

BACK PASS ECO O/L HDR

N2 FILL LINE

ECO JUNCTION HDR

BRP

ECO MIXING LINK

BACK PASS ECO I/L HDR

BLR FILL PUMP
FROM FEED WATER

TO DRAIN HDR

WATER CIRCULATION SYSTEM

FEED WATER SYSTEM

MODES OF OPERATION
1.

BOILER FILLING

2.

CLEAN UP CYCLE

3.

WET MODE OPERATION (LOAD < 30 % )

4.

DRY MODE OPERATION (LOAD > 30 %)

5.

DRY TO WET MODE OPERATION ( WHEN START UP SYSTEM NOT AVAILABLE)

BOILER FILLING LOGIC

If the water system of the boiler is empty (economizer, furnace walls, separators),
then the system is filled with approximately 10% TMCR ( 223 T/Hr) feed water flow.

When the level in the separator reaches set-point, the WR valve will begin to open.

When the WR valve reaches >30% open for approximately one minute, then
increase feed water flow set-point to 30% TMCR ( approx 660 T/Hr).

As the flow increases, WR valve will reach full open and ZR valve will begin to
open.

The water system is considered full when:

The separator water level remains stable for two(2) minutes

and
The WR valve is fully opened and ZR valve is >15% open for two(2)
minutes

After completion of Filling, the feed water flow is again adjusted to 10 % TMCR for
Clean up cycle operation

BOILER INITIAL WATER LEVEL CONTROL (UG VALVE)

The boiler circulating pump is started following the start of a feed water
pump and the final clean-up cycle.

This pump circulates feed water from the evaporator outlet back to the
economizer inlet.

Located at the outlet of this pump is the UG valve which controls

economizer inlet flow during the start-up phase of operation.

Demand for this recirculation, control valve is established based on

measured economizer inlet flow compared to a minimum boiler flow set
point.

Boiler Clean-up
When

the feedwater quality at the outlet of deaerator and separator is not

within the specified limits, a feedwater clean-up recirculation via the boiler is
necessary.
During

this time, constant feedwater flow of 10% TMCR ( 223 T/Hr) or more
is maintained.
Water

flows through the economizer and evaporator, and discharges the

boiler through the WR valve to the flash tank and via connecting pipe to the
condenser.
From

the condenser, the water flows through the condensate polishing

plant, which is in service to remove impurities ( Like Iron & its Oxide, Silica,
Sodium and its salts ), then returns to the feed water tank.
The

recirculation is continued until the water quality is within the specified

limits.

FEED WATER QUALITY PARAMETER FOR START UP

MODE OF OPERATION
WET MODE :

Initial Operation Of Boiler Light Up. When Economizer Flow is maintained by

BCP.

Boiler Will Operate till 30 % TMCR on Wet Mode.

DRY MODE :

At 30 % TMCR Separator water level will become disappear and Boiler

Operation mode will change to Dry

BCP Will shut at this load

Warm Up system for Boiler Start Up System will get armed

Boiler will turn to once through Boiler

ECO Water flow will be controlled by Feed Water Pump in service

SYSTEM DESCRIPTION ( WET MODE OPERATION)

1.

2.

Flow Control Valve ( 30 % Control Valve )

Ensures minimum pressure fluctuation in Feed Water Header

It measures Flow at BFP Booster Pump Discharge and compare it with a calculated flow
from its downstream pressure via a function and maintains the difference 0

100 % Flow Valve To Boiler

3.

Remains Closed

BFP Recirculation Valve

It Measures Flow at BFP Booster Pump Discharge

Ensures minimum Flow through BFP Booster Pump

4.

Closes when Flow through BFP Booster Pump discharge > 2.1 Cum
Open When Flow through BFP Booster Pump Discharge < 1.05 Cum
( Minimum Flow will be determined by BFP Speed via BFP Set limitation Curve)

BFP Scoop

It measures value from Storage tank level Transmitter

Maintain Separator Storage Tank Level

5.

6.

7.

UG Valve

Maintain Minimum Economizer Inlet Flow ( 30 % TMCR = Approx 660 T/Hr)

Maintain DP across the BRP ( Approx 4.0 Ksc)

It Measures Flow Value from Economizer Inlet Flow Transmitter

WR / ZR Valve

Maintains Separator Storage Tank Level

It Measures value from the Storage tank Level

Storage Tank Level

3 Nos Level Transmitter has been provided for Storage tank level measurement

1 No HH Level Transmitter has been provided

At 17.9 Mtr level it will trip all FW Pumps also MFT will act

1 No LL Level Transmitter has been provided

At 1.1 Mtr level MFT will Act

SYSTEM DESCRIPTION ( DRY MODE OPERATION)

1.

Following System will be isolated during Dry Mode Operation

FCV ( 30 % )

Start Up System Of Boiler

2.

WR / ZR Valve
Storage Tank
BRP
BRP Recirculation System

BFP Recirculation Valve

Following System will be in service

UG Valve ( Full Open)

100 % FW Valve ( Full Open)

Platen / Final Super-heater spray control

Start Up System Warming Lines

Separator Storage Tank Wet Leg Level Control

SYSTEM OPERATION ( DRY MODE OPERATION)

1.

2.

3.

START UP SYSTEM

In Dry Mode Start Up System Of Boiler will become isolated

Warming System for Boiler Start Up system will be charged

Separator Storage Tank level will be monitored by Separator storage tank wet leg level
control valve ( 3 Mtr)

TRANSITION PHASE :- Changeover of FW Control valve (30 % to 100 % Control )

100 % FW Flow valve will wide open

During the transition phase system pressure fluctuates

The system pressure fluctuation will be controlled by 30 % FW Valve. After stabilization of

system 30 % CV Will become Full Close

FEED WATER CONTROL

It will be controlled in three steps

Feed Water demand to maintain Unit Load

Maintain Separator O/L Temperature
Maintain acceptable Platen Spray Control Range

FEED WATER DEMAND ( DRY MODE OPERATION)

1.

FINAL SUPER HEATER SPRAY CONTROL

2.

Maintain the Final Steam Outlet Temperature ( 540 C)

PLATEN SUPER HEATER SPRAY CONTROL

Primary purpose is to keep the final super heaer spray control valve in the desired
operating range

3.

Measures the final spray control station differential temperature

It Compares this difference with Load dependent differential temperature setpoint
Output of this is the required temperature entering the Platen Super Heater Section
(Approx 450 C)

FEED WATER DEMAND

1.

FEED FORWARD DEMAND

It is established by Boiler Master Demand.

This Demand goes through Boiler Transfer Function where it is matched with the actual
Evaporator Heat Transfer to minimize the temperature fluctuations

2.

FEED BACK DEMAND

Work With two controller in cascade mode

FEED WATER DEMAND ( DRY MODE OPERATION)

2.

FEED BACK DEMAND

Work With two controller in cascade mode

FIRST CONTROLLER

One Controller acts on Load dependent average platen spray differential

temperature

Its Output represents the desired heat transfer / steam generation to maintain
the desired steam parameters and Flue gas parameters entering the Platen
section

SECOND CONTROLLER

Second Controller acts on the load dependent Separator Outlet Temperature

adjusted by Platen spray differential temperature

This controller adjust the feed water in response to firing disturbances to

achieve the separator O/L Temperature

THE RESULTING DEMAND FROM THE COMBINED FEEDFORWARD AND FEEDBACK

DEMANDSIGNAL DETERMINED THE SETPOINT TO THE FEED WATER MASTER CONTROL
SETPOINT

DRY TO WET MODE OPERATION ( START UP SYSTEM NOT AVAILABLE)

1.

The combined Feed Forward and Feed back demand ( as calculated in dry mode operation)
will be compared with minimum Economizer Flow
This ensures the minimum flow through Economizer during the period when start up system
is unavailable

2.

Output of the first controller is subjected to the second controller which monitors the
Separator Storage tank level ( Since the system is in Wet Mode now)

3.

The output of the second controller is the set point of Feed water master controller.

4.

The Feed back to this controller is the minimum value measured before the start up system
and Economizer inlet.

WATER & STEAM PATH

BLR PATH ( WHEN WET MODE)

Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH - HP By-pass
- Cold R/H Line - Primary R/H (Lower Temp R/H) - Final R/H - LP By-pass - Condenser
BLR Path (When Dry Mode)

Primary Eco - Secondary Eco - Ring HDR - Spiral W/W - W/W Intermediate HDR - Vertical
W/W - Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH - HP
TBN - Cold R/H Line - Primary R/H (Lower Temp R/H)- Final R/H - IP and LP TBN - Condenser

Wet Mode and Dry Mode of Operation

DIV SH

406

451

PLATEN SH

440

FINAL SH

480

486

DSH1
15%

DSH2
3%

540

BOILER LOAD CONDITION

Constant Pressure Control

Above 90% TMCR The MS Pressure remains constant at rated pressure

The Load is controlled by throttling the steam flow

Below 30% TMCR the MS Pressure remains constant at minimum

Pressure

Sliding Pressure Control

Boiler Operate at Sliding pressure between 30% and 90% TMCR

The Steam Pressure And Flow rate is controlled by the load directly

CONSTANT PRESSURE VS SLIDING PRESSURE

Valve throttling losses occur because the boiler operates at constant pressure while the
turbine doesn't.

The most obvious way to avoid throttling losses therefore is to stop operating the boiler
at constant pressure!

Instead, try to match the stop valve pressure to that existing inside the turbine at any
given load.

Since the turbine internal pressure varies linearly with load, this means that the boiler
pressure must vary with load similarly.

This is called .sliding pressure operation..

If the boiler pressure is matched to the pressure inside the turbine, then there are no
valve throttling losses to worry about!

While sliding pressure is beneficial for the turbine, it can cause difficulties for the boiler.

ADVERSE AFFECT

As the pressure falls, the boiling temperature (boiling point) changes. The boiler is
divided into zones in which the fluid is expected to be entirely water, mixed steam /
water or dry steam. A change in the boiling point can change the conditions in each
zone.

The heat transfer coefficient in each zone depends upon the pressure. As the pressure
falls, the heat transfer coefficient reduces. This means that the steam may not reach
the correct temperature. Also, if heat is not carried away by the steam, the boiler tubes
will run hotter and may suffer damage.

CHALLANGES

The heat transfer coefficient also depends upon the velocity of the steam in the boiler tubes.

Any change in pressure causes a change in steam density and so alters the steam velocities and
heat transfer rate in each zone.

Pressure and temperature cause the boiler tubes to expand. If conditions change, the tubes will
move. The tube supports must be capable of accommodating this movement.

The expansion movements must not lead to adverse stresses.

The ability to use sliding pressure operation is determined by the boiler

Boilers can be designed to accommodate sliding pressure.

When it is used, coal fired boilers in the 500 to 1000 MW class normally restrict
sliding pressure to a limited load range, typically 70% to 100% load, to minimize
the design challenge. Below this range, the boiler is operated at a fixed pressure.

This achieves an acceptable result because large units are normally operated at
high load for economic reasons.

In contrast, when sliding pressure is used in combined cycle plant, the steam
pressure is varied over a wider load range, typically 50% to 100% load or more

As stated, in coal-fired plant, sliding pressure is normally restricted to a limited

load range to reduce design difficulties.

In this range, the boiler pressure is held at a value 5% to 10% above the turbine
internal pressure. Consequently, the governor valves throttle slightly.

The offset is provided so that the unit can respond quickly to a sudden increase in
load demand simply by pulling the valves wide open.

This produces a faster load response than raising the boiler firing rate alone.The
step in load which can be achieved equals the specified margin ie 5% to 10%.

The throttling margin is agreed during the tendering phase and then fixed.

A margin of 5% to 10% is usually satisfactory because most customers rely upon

gas turbines, hydroelectric or pumped storage units to meet large peak loads.

The throttling margin means that the full potential gain of sliding pressure is not
achieved.

Nevertheless, most of the throttling losses which would otherwise occur are
recovered.

ADVANTAGES

Temperature changes occur in the boiler and in the turbine during

load changes. These can cause thermal stresses in thick walled
components.

These are especially high in the turbine during constant-pressure

operation. They therefore limit the maximum load transient for the
unit.

By contrast, in sliding pressure operation, the temperature changes

are in the evaporator section. However, the resulting thermal
stresses are not limiting in the Once through boiler due to its
thermo elastic design.

In fixed pressure operation , temperature change in the turbine when load

changes, while in sliding-pressure operation ,they change in the boiler

The enthalpy increase in the boiler for preheating, evaporation and

pressure.

superheating changes with

However, pressure is proportional to output in sliding pressure operation

In a uniformly heated tube, the transitions from preheat to evaporation and from evaporation to
superheat shift automatically with load such that the main steam temperature always remains
constant.

Sliding Pressure

At loads over 25% of rated load, the water fed by a feed-water pump
flows through the high pressure feed-water heater, economizer
,furnace water wall, steam-water separator, rear-wall tubes at the
ceiling, and super heaters, The super heaters steam produced is
supplied to the turbine.

At rated and relatively high loads the boiler is operated as a purely

once through type. At partial loads, however, the boiler is operated by
sliding the pressure as a function of load.

24.1 Mpa

9.0 Mpa

CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC

Boiler Load %
20

60

40

80

Efficiency Change %

+1
0
-1
-2
-3
-4

Variable Pressure

re
P
nt
a
st
n
Co

re
u
ss

100

Benefits Of Sliding Pressure Operation ( S.P.O)

Able to maintain constant first stage turbine temperature

Reducing the thermal stresses on the component : Low Maintenance & Higher
Availability

No additional pressure loss between boiler and turbine.

low Boiler Pr. at low loads.

WHY NOT S.P.O. IN NATURAL/CONTROL CIRCULATION BOILERS

Circulation Problem : instabilities in circulation system due to steam formation in

down comers.

Drum Level Control : water surface in drum disturbed.

Drum : (most critical thick walled component) under highest thermal stresses

The Basis of Boiler Start-up Mode

Mode Basis

Restart

Hot

Warm

Cold

Stopped time

2Hr Within

6~12Hr

56Hr Within

96Hr Above

SH Outlet Temp

465 above

300 above

100 above

100 below

Separator Tank pr

120 200 /

30 120 /

30 / below

0/

Starting Time

STARTING TIME

Startup Mode

Light off TBN

Rolling(minutes)

Light off
Full Load(minutes)

Cold

120

420

Except Rotor and Chest Warming Time

Warm

90

180

"

Hot

Restart

30

90

PURGE CONDITIONS

No Boiler Trip Condition Exists

All System Power Supply Available

Unit Air Flow > 30 % BMCR

Nozzle Tilt Horizontal and Air Flow < 40 %

Both PA Fans Off

The Following Condition Exist At Oil Firing System

The HOTV / LOTV Should Be Closed
All Oil Nozzle Valve Closed

The Following Condition Exists at Coal Firing System

All Pulverisers are Off
All Feeders are Off
All Hot Air Gates Of Pulverisers are closed

All Flame Scanner on all elevation shows no Flame

Aux Air Damper At All Elevation should be modulating

After Purging Boiler Light Up activites are same as in 500 MW plant

MFT CONDITIONS

Both ID Fans Off

Both FD Fans Off

Unit Air Flow < 30 % TMCR

All Feed Water Pumps Are Off For More Than 40 Sec

2 / 3 Pressure Transmitter indicate the furnace pressure High / Low for more than 8 sec ( 150
mmwc / -180 mmwc))

2 / 3 Pressure Transmitter indicate the furnace pressure High High / Low - Low ( 250 mmwc
/ - 250 mmwc)

Loss Of Re-heater Protection

EPB Pressed

All SAPH Off

Economizer Inlet Flow Low For More Than 10 Sec (223 T/Hr)

Furnace Vertical Wall Temperature High For more than 3 Sec (479 C)

SH Pressure High On Both Side (314 KSc)

SH Temperature High For More Than 20 Sec ( 590 C)

RH O/L Temperature High For More Than 20 Sec ( 590 C)

Separator Level Low-Low During Wet Mode ( 1.1 M)

Separator Level High-High During Wet Mode ( 17.7 M)

MFT Relay Tripped

Loss Of Fuel Trip : It Arms when any oil burner proven.

it occurs when all of the following satisfied

All Feeders Are Off

HOTV Not Open or all HONV Closed

LOTV Not Open or all LONV Closed

Unit Flame Failure Trip : It Arms when any Feeder Proves

it occurs when all 11 scanner elevation indicates flame failure as listed below ( Example is
for only elevation A)

Feeder A & Feeder B is Off with in 2 Sec Time Delay

following condition satisfied

Any oil valve not closed on AB Elevation

3 /4 valves not proven on AB Elevation

Less Than 2 / 4 Scanner Shows Flame

Both Of The Following Condition Satisfied

Less Than 2 / 4 Scanner Flame Shows Flame

2 / 4 Oil Valves not open at AB Elevation

Boiler Light Up Steps

Start the Secondary Air Preheater

Start one ID fan, then the corresponding FD fan and adjust air flow to a min. of
30% TMCR

Start the scanner air fan.

Adjust fan and SADC to permit a purge air flow of atleast 30% of TMCR and
furnace draft of approx. -12.7 mmWC.

When fans are started, SADC should modulate the aux. air dampers to maintain
WB to furnace DP at 102 mmWC(g).

Check that all other purge permissives are satisfied.

Place FTPs in service.

Check The MFT Conditions

For First Time Boiler Light Up do the Oil Leak Test

Initiate a furnace purge.

SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP

FURNACE READINESS
PRESSURE
SCANNER
BOTTOM
FUEL

PARTS

AIR FAN

ASH HOPPER READINESS

FIRING SYSTEM

START

UP SYSTEM

SEC AIR PATH READINESS

FD

FAN

SAPH
WIND

BOX / SADC

FLUE GAS SYSTEM

ESP
ID

PASS A , B

FAN

SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP

CONDENSATE SYSTEM
CONDENSER
CEP
CPU

FEED WATER SYSTEM

D/A
MDBFP

VACCUME SYSTEM
SEAL STEAM SYSTEM
TURBINE ON BARRING

#A

Evaporator heat absorption

Reduced number of evaporator wall tubes.

Ensures minimum water wall flow.

PIRAL WALL ARRAMGEMENT AT BURNER BLOCK AREA

SPIRAL

Support System for Evaporator Wall

Spiral wall

Horizontal and vertical buck stay with tension strip

Vertical wall Horizontal buck stay

Key source

NTPC SIPAT

DOSSAN BOILER

BGR ENERGY

THANK
YOU