Steam Generation Plant

7/25/2019 Steam Generation Plant

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OPERATING MANNUAL

FOR

STEAM GENERATION PLANT

NATIONAL FERTILIZERS LIMITED

PANIPAT

1


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INDEX

ITEM

Page

1. Introduction 1

2. Brief of description of the process 1

3. Equipment specification and design operating datas 7VU!" Boi#er

Pac$age Boi#ers

!. Unit operating procedure 3"

%orma# &tart up 'Boi#er co#d( 3"

Preparation 3"

)i##ing of Boi#er *ith *ater 32

+ighting off. 32

%orma# operationUnit #oad charges 3,

%orma# shutdo*n to hot stand - 3/

0ot restart 3

Emergenc Procedure. !2

%orma# &hutdo*n to co#d

. +iquidation of tpica# emergenc in Boi#er !,

&ign and causes of emergenc ction.

,. 4perating Procedure of !

Mi##s !

&oot B#o*er 7I5 6 )5 fans

ir Preheater ,1

sh hand#ing sstem ,

7. Inter#oc$s 72

/. &pecification !

oa# !

)ue# 4i# !

Po#ish 8ater !

)eed 8ater

&team

. 5iagram

2


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STEAM GENERATION PLANT

1.1 INTRODUCTION

The &team 9eneration P#ant comprises of three identica# pu#:eri;ed coa# fired -oi#ers*ith oi# support< ha:ing a ma=imum continuous rating 'M>( of 1" T?0r steam at a

pressure of @gs?cm2g and !". The norma# rate of steam generation '%>( is

/!T?0r. The -oi#ers are tangentia## fired< -a#anced draught< %atura# circu#ationegenerati:e tpe of irheater

:iii( &team?air preheater

i=( Economiser

=( E#ectrostatic Precipitation for f# ash

=i( 8ater drum< steam drum and -oi#er< tu-es

=ii( &team desuperheater and superheater

common chimne is pro:ided for fina# disposa# of f#ue gases for a## thethree -oi#ers.

5E&>IPTI4% 4) T0E P>4E&&

1.3 )EE5 8TE>

Boi#er feed *ater at a temperature of 131 " and a pressure of 1!1@g?cm2g is

pumped from the 5eaerator - -oi#er feed *ater pumps 97"1B. This feed *ater

passes through a snthesis economi;er and goes to -oi#er house at a temp of 2"" ". It

-oi#er house it is distri-uted to each -oi#er through an / indi:idua# feed *ater #ine.

1.! )UE+ %5 &0A

oa# is pu#:eri;ed in the -o*# mi## and used as feed for the -oi#ers under norma#

operation. sh *hich is formed as a resu#t of -urning of coa# is co##ected in the -ottom

ash hopper?f# ash hoppers is disposed off through the ash disposa# sstem. )#ue gases

are discharged out through the chimnes.

1. I.5. )% 6 ).5. )%A

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Motor dri:en )5 fan I5 fan pro:ide a draft for the furnance

)5 fan supp#ies the com-ustion air to the furnance after heating the air in tee

regenerati:e tpe air preheater. The f#ue gases are fina## disposed off - the I5 fan to

the atmosphere :ia chimne.

1., &TEM &UPP+C %5 5I&T>IBUTI4%A

&uper heated steam at 1" @g?cm2g and !" is produced in -oi#er. part of this

steam is #et do*n to a pressure of 3 @gs?cm2g in a desuperheater for use in fue# oi#

un#oading sstem.

>est of high pressure steam is carried to mmonia P#ant *here steam from mmonia

P#ant steam superheaters B7"1 at 1"3@g?cm2and !" is a#so mi=ed *ith it and

the entire superheater steam is distri-uted as underA

1. &nth compressor tur-ine 17.4 T

2. %2ompressor tur-ine /".4 T

3. 42ompressor tur-ine 2.4 T

!. ir ompressor tur-ine /.4 T

E=haust steam from ir ompressor< 4=gen compressor tur-ines and condensing

tur-ines of snthesis is compressor is condensed in respecti:e surface condensers and

the condensate< thus o-tained is sent to the 5M?P#ant for treatment for reuse as -oi#er

feed *ater.

The e=traction steam from -ac$ pressure tur-ines of snthesis compressor and % 2compressor meets the entire demand for the process p#ants< uti#ities and off site area at

:arious pressure #e:e#s of ,

2. Urea !" @g?cm2?37"

o

/"." &n. ompressor

3. %03ompressor !" @g?cm2 7"." &n. ompressor

!. mmonia @g?cm2?23"o 1." %03ompressor

. 5eaerator 3@g?cm2?1/7o 2"." mmonia

,. )4 &torage Tan$ 3@g?cm2?1/7o /." %03P#ant

7.

Boi#er )4 da

Tan$

3@g?cm2?1/7o ".1 do

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/. +P9 Vapori;er 3 @g?cm2?1/7o ".1 mmonia

. austic &oda do ".2 do1". austic soda

Un#oading

do ".7 do

11. Misce##aneous do 3." do

1.7 &TEM )4> )U>%E 4I+ U%+45I%9

part from the steam required for :arious p#ants< steam at a pressure of 3 @g?cm 2g is

a#so required for fue# oi# un#oading faci#ities. The requirement ma f#uctuate from 4

T?hr to 21.7T?hr depending on the am-ient conditions< quantit and qua#it of oi# -eing

un#oaded.

1./ &T>T UP )I+ITIE&A

i( 5uring start up< the -oi#ers use 0&54 upto 1" of the norma# #oad< then fue# oi#

upto 3" and coa# a-o:e 3" of the norma# #oad suita-#e. )iring faci#ities are

pro:ided for each -oi#er.

ii( 4ne e#ectric motor dri:en feed *ater pump is pro:ided in mmonia P#ant to

pump -oi#er feed *ater to the -oi#er unti# enough steam is generated and thetur-o feed pump is put into operation.

B.). 8TE> %5 &TEM I>UIT

)eed *ater coming from %03P#ant after dosing required amount of hdra;ine

'%20!( and ammonium hdro=ide '%0!40( enters the economi;er in#et heater :ia feed *ater

common heads and feed #ine contro# :a#:e.

The economi;er is #ocated in the second pass of the -oi#er a-o:e the air heater.

Each section is composed of a num-er of para##e# tu-e circuits arranged in hori;onta# ro*s.

## tu-e circuits originate from in#et heads and discharge into on#et header. The feed *ater

f#o* is up*ard through the economiser that is in counter f#o* to the hot f#ue gases. Most

efficient heat transfer is there- accomp#ished. n chance of steam generation *ith in the

economi;er is e#iminated - the up*ater f#o*.


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steam at !o G o and 1" @g?cm2is supp#ied to %03P#ant through &H common header

for further use.

)UE+& 4MBU&TI4% A

Each -oi#er is designed for steaming *ith t*o mi##s supported *ith )4 guns.

Pu#:eri;ed coo# is supp#ied to the furnance at the four corners of the -oi#er in three e#e:ations

.B and . Each mi## supp#iers P) coa# in a## the four corners of one e#e:ation on#. There

are t*o tpes of )4 guns in -et*een e#e:ation B and B in a## the four corners of the

-oi#ers. s such< there are 12 %os. of pu#:eri;ed coo# -urners and / %os of )4 guns. There

is pro:ision to -urn 0&5 in #o*er tre )4 guns as and *hen required.

The coa# from un#oading -a comes to the ra* coa# -un$ers passing through crusher

houses con:eed - a sstem of con:eer -e#ts. oa# coming from ra* coa# -un$ers comes

to ra* co#a feeder and then supp#ied to the mi## Duantit of coa# supp#ied to the mi## is

contro##ed - changing the speed of ra* coa# feeder. This coa# is crushed in -et*een -o*#

and -u## ring segments of mi##. 0ot air is introduced to mi##< *hich is coming from >0& and

+0& *ind -o=es of the -oi#er. There is pro:ision to supp# co#d air to maintain the

temperature of coa# dust and air mi=ture from 7"o to "o. This coa# dust and air mi=ture is

passing :ia c#assifier :anes and e=hauster of the mi##s< supp#ied to a## the four corners of the-oi#er furnance through distri-utor. &i;e of the coa# dust is 2"" m of 7" passing >egu#ating

of the fireness of grinding is done - changing the ang#e of the :anes of c#assifier of the mi##.

In order to ensure safet against e=p#osion ha;ards are pro:ided peepho#es in furnace

and e=p#osion diaphragms in f#ue gas path at different p#aced on f#ue gas ducts after ir Pre

heater.

This co#a dust and air mi=ture -urns in the furnace *ith the support of fue# oi#. dequate

quantit of secondar air supp#ied to the furnace to -oost up ignitions - -oth side *ind

-o=es< regu#ated - au=.air dampers in each corner. 0eat #i-erated due to com-ustion of fue#

in furnace is a-sor-ed - *ater *a##s for steaming inside tu-e *ater and remaining heat goes

*ith f#ue gas for further use. This f#ue gas heat is used in superheaters to superheat steam

temperature in -an$ tu-es and economi;er for further heating up *ater temperature in air pre

heatet to raise the temperature of air coming from )5 fans.

7" to /" of the ash partic#es are dri:en out *ith f#ue gas and remaining are co##ected

in -ottom ash hoppers. More than of ash partic#es are #i-erated in e#ectrostatic

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precipitators from f#ue gas. This f#ue gas< temp< a-out 1!"o goes to chimne through 2 %os.

of I5 fans< and then to atmosphere. The ashes of -ottom ash hoppers and e#ectrostatic

precipitators hoppers transferred to the ash ponds< out side of factor - ashing sstem

equipment.

B&I 4MBU&TI4% >ETI4%&

ar-on< 0drogen and &u#phur in the fue#< om-ine *ith o=gen in the air to form

42< 024 :apours and &42and re#easing heat as fo##o*sA

G42 42G/"1! @.ca#s?@g of ar-on

2G42 24G2!3" @ ca#s?@g of ar-on

202G42 2024G2/22@ ca#s?@g of 0drogen

&G42 &42G222! @.ca#s?$g of &u#phur

If e=cess air is used for com-ustion< &u#phur trio=ide'&42( ma a#so -e formed

as com-ustion product.

TU>% 548% >TI4A

The re#ationship -et*een the ma=imum and minimum fue# input *ithout heating

e=cess air #e:e# is ca##ed Turn do*n >ation )or e=amp#e a -urner *hose ma=imum input is

2"


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EDUIPME%T &PEI)ITI4% %5 5E&I9% 4PE>TI%9 5TE

5TE &0EET

Boi#ers TpeA Tangentia## )ired< Ba#anced 5rought< %atura# ircu#ation< >adiant

dr Bottom *ith 5irect fired Pu#:erised coa# *ith Bo*# Mi##s.

Boi#er 5esignationA TT 1?2"Vu!" !?2< !?2"< 2"?,7

)urnaceA 7,,mm *ith 5epth ,"7"mm Vo#ume // m3 Tpe

)usion *e#ded >adiant dr -ottom

&uperheaterA P#aten 0eating surface 37/ m3 &paced )ina# do ,3m3

EconomiserA Tpe Tota# heating %o. of stages

ontinuous &urface in m2 4ne

)inned 1!2

ir 0eaterA Tpe 0 & in m2 %o. of B#oc$

>egenerati:e 2"VI>,2 !/2 4ne

Burning E#ement BurnersTi#ting Taugentia# -urnersA

apacit %o. of?Boi#er +ocation

oa# Burners 2.2 Te?0r 12 orners of

)ue# oi# Burner 3.2 Te?0r. !/ furnace

Mi##s

Tpe &stem apacit Motor

H>&

,"3

&uction

Tpe

1! Te?0r 2/" @8 for oa# 1 grinda-i#it 7

through a 2"" mesh


10/99

E=hauster

Tpe &peed 5ri:e

27! V2 " >.P.M 5ri:en -Motor

>adia# Padd#e tpe e=hauster to suit themi##

)ans

)an Tpe %o.

9f?B#r

5E&I9% 4%5ITI4% Motor

@8 >PM

ontro#

).5. %5)

1/,

2 2 3

m3?&ec

3/3

@g?m2!"o 13 1! In#et Vane

I.5 %5E

2!,

2 !1

m3?&ec

2"

@g?m213o 1! 7!" In#et Vane

&oot B#o*er

Tpe Dt?B#r Medium

)urnace 8a## B#o*ers

>* &E

2! &0 &team

P#atens

on:ection Jone

+ong >etracta-#e

Mode# T3" Ma$e IE

, &0 &team

&afet Va#:es

+ocation Ma$e

6Tpe

%o. off

Per B#r

>e#ie:ing

apacit

&i;e &et Pressure

5rum 5resser

173/8

1 11/./

Te?0r.

2 12" ! @g?cm2

5resser

173/8

1 2 123 @g?cm2

&uper

heater

5resser

172/85

1 2 7

Te?0r

2 1" 2 @g?cm2

1"


11/99

Pipe +ine

Main &team )eed 8ater

&i;e 273H32 21H2"

%o. off?Boi#er 4ne 4ne

11


12/99

P>E5ITE5 PE>)4>M%E

E:aporation Te?0r 1"" M>

Te?0r 1"

)eed 8ater temperature o 2""

)eed 8ater Temperature o

+eaning Economiser o 2!

&TEM TEMPE>TU>E

5rum o 32"

&uper 0eater out#et o !

&TEM P>E&&U>E

5rum design atg 121."

4perating atg 113.!

&uper heater out#et atg 1"."

P>E&&U>E 5>4P

Economiser atg ".

)ina# super heater atg /.!

)+UE 9& TEMPE>TU>E

+ea:ing furnace o 1"2

Entering super heater o 1"2

Entering Economiser o !7

Entering air heater o 327+eaning air heater corrected o 1!2

P>E&&U>E 5>4P )+UE 9&

)urnace mm*c !

&uper heater 6 -oi#er mm*c 21

Economiser mm*c 2"

5uets< -ends< dengers etc. mm*c 2"

ir 0eater mm*c 1"

&tatic head mm*c 2"

E#ectrostatic precipitator mm*= 2"

Tota# mm*c 21"

P>E&&U>E 5>4P I> &I5E

8ind -o= mm*c 11"

ir heater air side mm*c /2

ir ducts mm*c 3"

&team coi# 6 :enturi mm*c 1

12


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Tota# mm*c

0ET +4&&

5r gas !.!

024 in air 6 02in fue# .2ar-on 2.""

>adiation ".32

Unaccounted 6 manufacturing

Margin "."

Tota# 13.,

Efficienc /,.!!

E=cess air #ea:ing

Economi;er 2

oa# Bituminous

oa#

)i=ed car-on 3"."

Vo#ati#e matter 2!.

Moisture ,.

sh 3."

0drogen 3."

9rinda-i#it 0ardgroore "

0igh heating :a#:e @ca#?@g !271

+o*er heating :a#:e @ca#?@g !1""

&i;e of mi## mm 2"

PE>)4>M%E

Tota# coa# fired Te?0r 2!.3/

%um-er of mi##s operating T*o

oa#? mi## Te?0r 12.1

Ma=imum mi## capacit Te?0r 1!."

ir f#o* through mi## @g?hr per mi## 2/

Temp of air?fue# mi=ture after

c#assifier

" 77

Temp. of air at in#et to mi## " 1!

Temp. of tempering air " !"

0ot air temp. a:ai#a-#e " 2//

Tota# tempering air to mi##s @g?hr 273!

Tota# hot air to mi##s @g?hr 2!3,

13


14/99

.

%.

5escription Duantit

?Per B#r

Duantit

per

ProFect

apacit )u## #oad

current?:o#tage

>PM

1. 0.T.Motors

Mi## Motors

3 2/" @8 3.3. @V "

1. +.T. Motors

).5.)an Motor

2 , 1" @8 !1V?2/ "

2. I.5. )an motor 2 , 1," @8 !1V?27 "

3. +ight oi# pump motor 2 . @8 !1V11" 1!,"

!. )ue# 4i# pump Motor 2 1 @8 !1V?27 1!,"

. Igniter fan motor 1 3 2.2@8 !1V?!., 2/"

,. &canner fan Motor 1 3 2.2@8 !1V?apping mechanism

for discharge

, 1/ ".2@8 !1V 13"

11 0P dosing pump

motor

, 2 1.@8 !1V?3.2 2""

12 Mi=ing tan$ motor 2 ".7@8 !1V 1!!"13 +ong retracta-#e soot

-#o*er tra:erse

, 1/ ".37@8 !1V?1.3, 1""

>otar , 1/ ".!@8 !1V?".!! 1""

1! 8a## -#o*er

Trans:erse

2! 72 ".,@8 !1V?"./ 1""

>otar 2! 72 "."@8 !1V?1.2, 1""

1

.

ir heater -#o*er 1 3 ".1/@8 !1V

1,

.

sh

*ater pump

3 3 2"@8 33""V?." 1!//

Va#:e 5ri:ers

1!


15/99

&.%o. 5escription Duantit?per

B#r

Duantit

per

proFect

apacit )u## #oad

current?Vo#tage

>PM

1. Main &team

stop V?V2"?2"?"

1 3 2.2 @8 !1V 1!3"

2. &tart up

:a#:e

,?2"?"

1 3 ".@8 !1V 1!3"

3. &oot -#o*er

drain :a#:e

1 3 ".12@8 !1V 1!3"

!. &oot -#o*er

main :a#:e

!"?2"?

1 3 ".1/@8 !1V 1!3"

. )eed stop

:a#:e

1 3 2.2 @8 !1V 1!""

,. ir heater

soot -#o*er

stop :a#:e

1 3 ".7@8 !1V 1!""

7. B pass

:a#:e for

main

steam stop

:a#:e

1 3 ".12@8 !1V 1!""

1


16/99

Economiser

continuous

finned

steam#ess

)ina# &uperheater

'Pendant

on:ecti:e(

P#aten

superheater

'Pane# tpe(

Pendant

>adiant2 33 1/ %o. of superheater assem-#

1, ,, ! %o. of coi#s'tu-es(?-#r

! %o. of #oops

ounter Para##e# Para##e# )#o* tpe

&taggered In#ine In#ine rrangement

!!.H!. !!. !!. Tu-e si;e out side dia in mm

&21"9r

1

&213T11&213T22

&

2"T1B&3"

P2&2,2" &

213T22

Materia# of construction

'!.(

'('!!.H!.,(

'!!.H!.(

'!!H(

Materia# thic$ness'mm(

12! , , +ongitudina# mm&pacing

7/ #ternati:e#

13.7H1,.1

3"!./ Trans:erse mm

1 %o. off In#etheader

21.1 H

2/

323.G32 21.1H2/ &i;e mm

&1",9r

B

& 33 P12 &1",9r B Materia#

1 1 12 %o. offKKK4ut#et

header

21.1 H 2/ 323.H3, 32.H32 &i;e mm

&1",9r

B

& 33 P12 & 33" P12 Materia#

1 'each( 1Main

12 %o. off Transfer

tu-es212.1H2" 273H32 1"/H1" &i;e mm

&1",

9rB

&33 P12 &1", 9r2B &1", 92B

1,


17/99

METALURGY COMPONENT

Meta#

9rade

ar-on

&i#iea

&i

Mang

anese

Mn

Phos

phoru

s P

&u#phu

r &

hro

mium

r

Mo#i-d

enum

M4

1 & 2" TI Min ".1" ".1" ".3" ".!!

Ma

=

".1 "." "./" "."! "."! ".,

2 &213 TII Min "." ".3" 1."" ".!!

Ma=

".12 1."" ".," "."3 "."3 1." ".,

3 &213T22 Min ".3" "."3" 1." "./7

Ma

=

".12 "." ".," "."3" "."3 2.," 1.13

! &33 P12 ".13 ".32 ".!7 "."1 "."22 "., ".!

&1",

92B

".2" ".2, ".7" "."13 "."1! %itro

gen

".""/

7

opp

eru

%ic

$e+

%#

, B& 3"

P2&2 ,2"

".1"

To

".1

".1"

To

".3

".!"

To

".7"

"."!" "."!" ".7"

To

1.1"

".!

To

".,

".2 ".3

7 9rinding

>o##

3." 2." ".7 !."

to

."

/ Bu##ring

segmentPPE>& )4> 4++ETI4% E+ET>45E&

i( %o. ond tpe of rapper 4ne drop of hammer per ro* of

co##ecting e#ectrodes ro*ing a

co##ecting surface of !3.2m2

ii( 8eight of hammer ! @g.

iii( )requenc of rap Varing from , rpm?hr at the in#et

fie#d to 1 rap?hr at the e=it fie#d. The

frequenc of rapping at intermediate

fie#d can -e adFusted -et*een , and

ELECTRASTATIC PRECIPITATOR

1 5E&I9% 4%5ITI4% A

i( 9as f#o* rate ,/ M3?&ec.

ii( Temp. of f#ue gas at the in#et of precipitation 1"o.

iii( 5ust concentration 3.,1 gm?sec.

i:( Pressure at the in#et of precipitator 1," mm 8.:( Tpe of precipitator 2 )3=3,,,"2.

:i( %o. of precipitator 1.

:ii( %o of para##e# gas pans per -ott#e 2.

:iii

(

%o. of fie#ds in series in each gas pan 3.

i=( 9uaranteed co##ection efficienc for design

condition

/. .

=( Pressure drop across the precipitator for design

condition

1 mm*c.

=i( Ve#ocit of gas at e#ectrode ;one on tota# area "./7m?sec.

=ii( Treatment time 12.!1 sec.

2 4++ETI4% E+ET>45E&

I( %o. of ro*s of co##ecting e#ectrodes per fie#d 27.

ii( %o. of co##ecting e#ectrodes per fie#d ' %ine

p#ates are arranged in each ro*(

2!3 '=27(.

iii( Tota# no. of co##ecting p#ates per -oi#er 1!/ ',=2!3(.i:( %omina# height of co##ecting p#ates , Mtrs

:( %omina# #ength of co##ecting p#ates !"" mm.

:i( &pecific co##ecting area .1" m/?!?sec.

3 EMITTI%9 E+ET>45E&

I( Tpe &pira# *ith hoo$ tpe

endsii( &i;e 5ia. 2.mm.

iii( %o. of e#ectrodes in the frame forming one ro* 3,.

i:( %o. of e#ectrode in each fie#d 3,.

1/


19/99

1?hr according to requirement during

commissioning.

i:( 5ri:e 9eared e#ectric motor contro##ed -

snchronous programmer.

:( +ocation 4n the side of the casing.

. >PPE>& )4> EMITTI%9 E+ET>45E&

i( %o. and tpe of rappers ppro=imate# one drop hammer for

t*o ro*s of e#ectrodes.

ii( >apper si;e 3." @gs.

iii( )requenc of rap 1" raps?hr.

i:( 5ri:e 9eared motor contro##ed -

snchronous programmer.

:( +ocation 4n the side pane# of conn.

,. 0PPE>&

i( Tpe B ramididica#.

ii( %o. of happers , 'one per fie#d(.

iii( apacit / hr storage.

i:( 0eating E#ectrica# heating pro:ided for the

-ottom of happers

:( Baff#ing arrangement 2 sets of def#ector p#ates for each

happer underneath the co##ecting

p#ates to pre:ent gas #ea$age.

7. 9& 5I&T>IBUTI4% &C&TEM

i( Tpe and qua#it Perforated p#ate 2 sets

ii( +ocation In#et of precipitator.

/ >ETI)IE>

i( >ating ," @V< ,"" V.

ii( %um-er 3 ' one for t*o fie#d (.

iii( Tpe &i#icon diode< fu## *a:e -ridgeconnection.

i:( +ocation Mounted on top of precipitator.

>ETI)IE> 4%T>4+ P%E+

i( Tpe of contro# Transducer

ii( %um-er 3.

iii( +ocation E P contro# room.

1" UHI+IE>C 4%T>4+ P%E+

i( %um-er 2 'one per pass(.

ii( Equipment contro# 9eared motor of rapping mechanism

heating e#ements< insu#ation houring

and shaft insu#ator.

iii( +ocation E P contro# room.

11 M4T4>

i( >apping of e#ectrode ,G,.

ii( >ating 9ear motor 33@8?1.1 >pm at 3 ph tota#.

:i( Turndo*n 3A1.:ii( 4i# firing rate 2/" @g?cm2g.

:iii( 4i# pressure at gun 3.@g?cm2g.

I=( tomi;ing air quantit &er:ice air *ater free.

=( tomi;ing air consumption ," %m2?hr?gun on norma# sca:enging

operation.

1""%m3?hr?gun on gun sca:enging.

21


22/99

=i( tomising air pressure at the gun !."$g?cm2g

=ii( 5ifferentia# pressure -et*een oi# 6 air 1."" $g?cm2 air pressure to -e

more than oi# pressure.

=iii( tomising no;;#e assem-# designation Mi=ing p#aton !1 spra p#ate

,"%!1

0EVC )UE+ 4I+ 9U%&

pp#ication &ta-i#i;ing coa# f#ame #o* #oad

carring hot startup

Tpe Ti#ting tangentia# steam atomi;ed

interna# mi=

%o. off / '! per e#e:ation(

+ocated at E#e:ations B and B at the corner

*ind -o=ed

apacit 1 of -oi#er M> per e#e:ation

ma=m 3" of -oi#er M> tota# in

t*o e#e:ationTurn do*n !A1

4i# firing rate !3 @g?hr?gun

4i# Pressure at the gun 7.7 $g?cm2g

4i# #eiseasit at the gun 1, to 2/ centisto$e

&team consumption 7" $g?hr?gun during norma#

operation 11 $g?hr?gun during gun

sca:aning

&team pressure at the gun /.7 $g?cm2?g

5efferia# pressure -etnoi# 6 steam 1."" $g?cm2?g steampressure to -e

more than oi# pressure

tomi;er no;;#e assem-# designation Mi=ing p#ate %!! &0 spra p#ate

," %!!

-o:e said figures and designa :a#ue corresponding to norma# operating conditions

22


23/99

0EVC 4I+ 0ETE>&

1. Tpe UTu-e< hair pin tpe< oi# on the

she## side< condensing tpe

2. %o. off 2 'Inc#uding one stand-(

3. 0eater area each 2" m2

!. 4i# f#o* rate "" $g?he '." MT?hr(

. 4i# temperature range !"o to 11o

,. &team pressure 1"." $g?cm2

7. 5esign pressure 2!." $g?cm2g oi# side )4>

0EVC 4I+

PUMP

2 @ir#os$ar 0ori;onta# foot in

mounted squirre#

cage f#ame proof

motor @8 < rpm

3"""< :o#ts!1

2!


25/99

MI++&

1( Tpe of Pu#:erisation Bo*# mi## *ith c#assifier 6 e=hauster

2( &i;e ,"3 H >& suction tpe

3( %o. of Mi##s 3 %os.? Boi#er !( apacit 1/ T?0r. hardgro:e inde=< 7"

Thro 2"" mesh 2"mm ra* each si;e

( Motor 2/" @8 com-ined mi## and e=hauster

,( oup#ing 9ear tpe coup#ing -oth sides of

mi##'Motormi## 6 mi##e=hauster(

7( oo#ing &stem 4i# -oth in main mi## dri:e gear housing

for #u-rication *orm geer and -earing

oi# is coo#ed - circu#ating *ater inside

the tu-e -und#es immersed in oi# -ath !

to !.cm2?hr coo#ing *ater required per

mi## at 3,o

/( 8ear &urfaces 9rinding ro##< -u## ring segments and

#iner are made of high qua#it %1 hard

costing

( )eeders >otar feeders< Independent feeders

1"( apacit to 3" t?hours

11( &peed 2.,7 to 1,."" rpm

12( 5ri:e Positi:e# infinite# :aria-#e speed unit*ith f#ange mounted motor

V>IT4> 4) >8 4+ )EE5E>

V&peed :ariation contro#

1( V 3.7 @8

2( Variation ratio ,A1

3( &peed change operation +o*er contro#

!( 5ri:e motor 3.7 @8


26/99

( %omina# reduction rates

of signa# gear on motorside

1A2

,( %omina# reduction ration

of sing#e gear on output

side

1A3"

7( Techno9enerator Inc#uding techo motor direc# mounted

on the V -od

/( &afet coup#ing onnected to V output shaft and

designed to s#ip if e=cess torque is

forced on the outpu shaft

( &pecia# air -reather Pro:ided on the V

2,


27/99

TCPE VU B4I+E>&

5T 4) I5 6 )5 )%&

&.%o. Particu#ars )5 )an I5 )an

1. Tpe %5)C 1/, %5)C 2!,

2. )an 4rientation &t#e "1 #eft

-ottom o to

:ertica# :ie*

from dri:e end

&t#e "1 #eft up

*ards :ie* from

dri:e end

3 Medium hand#ed tmosphere air )#anges

!. %on of fans?-ir 2 2.

i(

)an designating

2.3 !1apacit M3?&ec.

ii( Tota# head de:e#oped

mm*c

3/3 2"

iii( Temperature of medica

o

!"

i:( &p. 8t of medium 1.12/ ".//2

:( &peed rpm " 7!"

7 5ri:e coup#ing Pin tpe Pin tpe

/. 5ri:e motor supp#ier &iemens

i( )rame si;e !"" M !"" M

ii( >ating @8 1" 1,"

iii( Vo#tage @V !1 !1

i:( )requenc cps " "

:( Phase 3 3

. )an *eight in $g ,/// ,,

1". Tpe of fan regu#ation In#et guide :ane In#et guide :ane

11. Bearing %U3323 %U3323

12. Thrust -earing 723! BV 723! BV13. oup#ing side %23!3 %23!3

27


28/99

ALARM AND TRIP SETTINGS. No. Tag No. Serv!e Se""#g

1 P&27.! Mi## differ press. high 27" mm 89

2 P&27. Mi## differ press. #o* 3 mm 89

3 P&27., Mi## differ press. 0igh inter#oc$ 2/" mm 89

! P&!.! Mi## temp. high ""

TI/.2 Mi## oi# -ath temp. high /""

, T&,,.! Mi## motor 859 temp.high

'8inding(

7,"

7 T>2.2 Mi## -earing temp.high /!"

/ P&!. ir f#o* #o* 2. M3 ? &ec

P&!., ir f#o* V #o* "." M3 ? &ec

1" P&!./ ir f#o* norma# inter#oc$ 1"." M3 ? &ec

11 P&13.! )urnace P> V 0I90 inter M)> Trip G!"." mm 89

12 P&13. )urnace P> high G1 mm 024

13 P&13., )urnace P> #o* 2 mm 024

1! P&13./ )urnace P> norma# inter#oc$ mm 024

1 T>,3.3 Meta# Temp. high 7""

1, P&7.! )eed *ater P> #o* 1"/ $g?cm2

17 P&!1.! Main in#et steam temp.high ""1/ P&.! 5rum #e:e# high G1"" mm 024

1 P&. 5rum #e:e# #o* 1"" mm 024

2" +&1".1 5rum #e:e# V #o* T>IP 2"" mm 024

21 P&1".! &hoot -#o*er steam P> #o* / $$?m2

22 P&".! u= &team P> #o* / $g?m2

23 P&!. oo#ing *ater P> #o* 2." $g?m2

2! P&.! ).4. Pump disch P> #o* / $g?m2

2 TI3.1 ).4. heating Unit temp. high 12""

S. No. Tag No. Serv!e Se""#g

2, P&1.3 Inset air P> #o* 1." $g?m2

27 P&2.3 ompressed air P> #o* . $g?m2

2/ P&B01"2 B)P 5ischarge P> high 1! $g?m2

2 P&B+1"2 B)P 5ischarge P> #o* 12" $g?m2

2/


29/99

3" T&7".2 ir heater -earing high

""

31 T&7".2 B ir heater -earing high ,""

LU$RICATION CHART

&.%o. +u-rication hart Tpe of +u-e 4i# Duantit in +iters

1 Mi## gear -o= 27?!" ""2 Mi## e=h. Bearing 33 2

3 Mi## >o##er 33 1112

! I5 )an 317 1

)5 )an 317 1

, sh *ater pump -earing housing

'-oth sides(

317 2

7 ir heater gear -o= 33 3"

/ #in$er grinder gear -o= 33 1

#in$er grinder f#uid coup#ing 31! !

1" &oot -#o*er gear -o= 317 1

11 Phosphate dosing pump 3 2"2

12 ir heater -earing 'top?-ottom( c1"" 1"1

13 >apping motors 3 7

1! M&&V 'MV( 317 7

1 M&&V - pass 'MV( 317 2!

1, &tart up :ent 'M4V( 317 !,

17 >) 9E> B4H 33 12"

1/ +r &oot -#o*ers 317 2

1 +54 un#oading pump 317 1

P@9E B4I+E>

5ETI+E5 &PEI)ITI4% &0EET

1 &he## 5iameter 'I5( 3/"" mm p#ain 1"1" mm

2 om-ustion Tu-e 5ia p#ain?corrugated orrugated 1"""?11"" mm

2 %os.

3 5istance o:er Tu-e P#ates 73"! mm

! %o. of p#ain Tu-es ',3. mm 45( ! %o. of &ta Tu-es ',3. mm 45( 3

, Thic$ness of P#ain Tu-es 8.9

7 0earing surface '8ater &ide( ,,3 M2

/ Thic$ness of &ta Tu-e . mm

8ater &torage 'apacit( 'up to storage

#e:e#(

!"


30/99

11. P48E> >EDUI>E5 E0

)eed Pumps 2 %os.

apacit 33.32 M3 +tsMotor 0P?@* "?37

0ead 1/.2 $g?cm2

>.P.M. 3"""

4i# Pump 2 %os.

apacit 3"""

0ead 3" $g?cm2

>.P.M. 1""

)5 )an 2 %os.

apacit 12""" %M3?0rs

Pressure 1 MM?*g

Motor 0P?$* "?37

>.P.M. 1""

%ESTER %OR& HORIZENTAL SMO&E TU$E

PAC&AGED $OILER

MAJOR SPECIFICATIONS

1. Boi#er %o.8!/2< ear of Ma$e1/" O A1

7. E#ectric Po*er >equirement :o#tage O !1 cc#es"??3 P0

! *ire sstem 1," @8

/. )eed *ater #ine from #eft *ater ser:ice tan$ to pump ! %B 5ia

3"


31/99

. Main steam stop V?V 7

'B#o* do*n V?V 21?2 5ia(

1". 5rain #ine 8+ drain 1 5ia

'9 9#ass drain 3?/ B&P

11. &afet V?V drain Q B&P

'&afet V?V EH ,%B(12. Boi#er f#ue gas opening 132" mm

13. >ecommended :est chimne O dia 1!2"

UNIT OPERATING PROCEDURE

%4>M+ &T>TUP 'Boi#er o#d(

To ensure a ma=imum safet during co#d startup< it is recommended that a high air

f#o* of at #east 3" M> -e used in order to produce an airrich furnace atmosphere. This

prec#udes the possi-i#it of accumu#ations of e=p#osi:es mi=tures in the e:ents of poor or

de#aed ignition after fie#d in introduced to the furnace. It is recommended that this high air

f#o* -e maintained during the #ighting off and *ard up period unti# the -oi#er is on the #ine

and reaches a #oad *here additiona# air is required to maintain the design operating e=cess air.

5uring startups< #ighting off is done *ith igniters and *armup oi# guns *ith #ight oi# firing.

It is recommended that during startsups initia# firing -e done - means of oi# guns in the

#o*er -urner. 8hen -urning the unit up to pressure and temperature< saturated steam

temperature rises< shou#d -e #imited to o per hour.

5uring a## startups the firing rate must -e contro##ed to $eep the ma=imum

temperature of gases #ea:ing the furnace -e#o* !7o. )#ue gas temperature pro-es shou#d

-e used near the #o*er -ends of first gas touched superheater e#ements so that the furnace

out#et gas temperature can -e measured frequent# or recorded continuous#.

31


32/99

The fo##o*ing steps out#ine the procedure for -ringing co#d -oi#er up to *or$ing

pressure 6 temperature. It is assumed that -oi#er has -een -oi#ed out and prepared for

operation. The -oi#er shou#d -e fi##ed up *ith treated feed *ater. The *ater #e:e# in steam

drum shou#d -e at norma# operating #e:e#.

PREPARATIONS

1. I%&PET T0E B4I+E> P>I4> T4 &T>TI%9 0E@A

## foreign materia#s has -een remo:ed from pressure part.

## personne# c#ear.

## access door c#osed.

&tarting equipment and inter#oc$ c#eared.

>etracta-#e soot -#o*er e#ements remo:ed from gas side.

Indi:idua# fue# :a#:es at -urner c#osed.

## -oi#er fitting 6 :a#:es in proper order.

2. &EE T0T )4++48I%9 V+VE& >E +4&E5.

)eed *ater regu#ating :a#:es 'c#osed and on manua# contro#(

## -#o* do*n 6 drain :a#:es on -oi#er and *ater *a##s.

Boi#er and super heater on fi##ing :a#:es.

&oot -#o*er master steam supp# :a#:es.

Main steam #ine stop :a#:es.

5esuperheater contro# :a#:es 6 - pass #ine :a#:es.

3. 4PE% T0E

5rum :ents

8ater gauge g#ass :a#:es '+oc$ed open(

&uperheater header drains and :ents and main steam #ine drain

## instrument and contro# connections to the -oi#er

Inc#uding :a#:es on -oth side of desuperheater contro# :a#:es.

32


33/99

%4TEA #ose a## superheater drains *hen headers are free of *ater e=cept the

superheater out#et header drain *hich remains open.

!. 0E@A

)o##o*ing equipments for adequate #u-rication< coo#ing *ater f#o* and read

for ser:ice.

ir heater and dri:e 'if rotar air heater is pro:ide(

)ans and dri:e

Boi#er feed pump and dri:e

ag remo:ing sstems

## ser:o?Pneumatic dri:e for :a#:e and dampers.

. >E0E@ ITEM& &U0 &

4i# guns proper# inserted and coup#ed.

## oi# guns and igniter piping read for ser:ice

## manua# :a#:es open. ## contro# :a#:es c#osed.

,. It is presumed that pu#:eri;ed equipment has -een chec$ed for proper functioning

and read for ser:ice rechec$.

1( E=hausters discharge :a#:e open.

2( 0ot air g#ass c#oses< 0ot air dampers c#osed.

3( >a* coa# gate is open and coa# is a:ai#a-#e to feeders.

!( ## c#assifiers :ane setting identica#

7. It is presumed that a## the soot -#o*ing equipment has -een chec$ed for proper

operation and sstem is in the startup condition.

/. It is presumed that *ind -o=es ha:e -een chec$ed for proper damper positioning9E%C P>4E5U>E&A Emergenc shut do*n procedure due to

1. Master fue# trip.

2. +o* 8ater #e:e#

3. 0igh *ater #e:e#S

1. M&TE> )UE+ T>IPA

Under conditions requiring a master fue# trip through norma# inter#oc$s or operators

action'manua# trip(< a## fue# shou#d -e tripped instantaneous#. If coa# *as -eing

fired the pu#:erisers shou#d -e tripped immediate#. Tripping the pu#:erisers *i##

automatica## trip the feeders and c#ose the hit air shut off gates.

If oi# *as -eing fired< the oi# and ignitor trip :a#:es and indi:idua# no;;#e shut off

shou#d -e c#osed immediate#.

)o##o*ing steps to -e ta$en immediate#A

a( Maintain the unit airf#o* at pretrip :a#ue for at #east minutes to purge the sstem. If

a hot restart is anticipated the airf#o* ma -e gradua## reduced to #ightoff air f#o*

'3" of fu## #oad air f#o*( during the purge period.

-( If oi# guns *ere in ser:ice *hen the fue# trip occurred< chec$ to ensure that a##

indi:idua# no;;#es shut off :a#:es are c#osed. 4i# guns shou#d -e retracted< remo:ed +EVE+&A

If the *ater #e:e# fa##s out of sight in *ater gauge< due to fai#ure of feed *ater

supp# or neg#ect of operator< e=cept in the case of momentar f#uctuations that night

occur *ith e=traordinar changes in #oad< appropriate action shou#d -e ta$en at once totrip the fue#. n decision to continue to operate< e:en if on# for a short time at a

reduced rating *ou#d ha:e to -e made - someone in authorit *ho is thorough#

fami#iar *ith the circumstances that #ead to emergenc and positi:e# certain that the

*ater #e:e# can -e restored immediate# *ithout damaging the -oi#er.

In a-sence of such a decisionA

a( Trip a## fue# immediate#+A

5uring the fai#ure of direct *ater gauge< the -oi#er can -e #eft in operation on#

*hen the remote *ater gauges is in perfect condition. >epair of the direct *ater gauges must

-e carried out as quic$# as possi-#e i.e. *ithin 2! 0rs. The remote *ater gauge must -e

o-ser:ed *ith greater attention pro#onged operation *ith one disconnected *ater gauge is not

permissi-#e.

In the case the safet :a#:es -#o* up -ecause of e=ceeding the ma=imum of

design pressure< it is necessar to -ring do*n the pressure - reducing the firing

increasing the feeding and steam e=traction and -#o*ing do*n the -oi#er.

In case of ma=imum temperature of out#et superheated steam is e=ceeded e:en

under fu## inFection of desuperheater or if ma=imum permissi-#e temperature

!3


44/99

after the indi:idua# superheater is e=ceeding it is necessar to #imit the firing and

to chec$ up the feed *ater temperature.

In case the qua#it of feed *ater of -oi#er *ater gets *orse *hich might cause

dangerous po##ution or damage to the tu-e *a##s it is necessar to reduce the

-oi#er output or to shut do*n the same if the condition does not impro:e.

In case of unusua# phenomenon the cases of *hich cant -e in:estigated 6

remo:ed during -oi#er operation the -oi#er must -e shut do*n.

The -oi#er must -e shut do*n immediate# in casesA

a( 8ater #e:e# in indicator continuous# drops e:en after -#o*ing 6 c#osure of

steam supp#.

-( )ai#ure of -oth *ater gauges

c( )ai#ure of feed pumps.

d( 5efect in feed piping.

e( 4ccurrence of crac$ing of #ea$age to such e=tent that it is not possi-#e to

maintain the minimum #e:e# in the -oi#er e:en at increased feeding or that

might induce e=p#osion or endanger the personne#.

f( E=p#osion furnace *hich had damaged the -ric$*or$ or pressure parts.

g( )ue# -urning on the heat reco:er areas accompanied - a-norma# rise of

temperature of #ea:ing there gases.

h( 5eformation of pressure parts *hich might cause e=p#osion and endanger the

personne#.

i( In a## cases *here there is danger of accident or occurrence of defect at #ong

time operation< e.g. at impermissi-#e rise of superheated steam temperature.

F( >e#ia-#e operation of -oi#er cannot -e ensured -ecause of conditions #i$e -ad

:isi-i#it fire and danger of e=p#osion.

!!


45/99

&hutting do*n of -oi#er and reduction of its output in most of fai#ures is

secured - automatic inter#oc$ing of the -oi#er.

NORMAL SHUTDO%N TO COLD

The fo##o*ing procedure for norma# shutdo*n are -ased on the assumption that theunit is operating at fu## #oad on automatic contro# and that if is the intention to reduce the

pressure to ;ero 6 coo# the -oi#er comp#ete#.

i( 9radua## reduce the #oad on the unit< reduce the firing rate in #ine *ith the

decreasing steam f#o*. ##o* the pressure to drop *ith the reduction in #oad to

acce#erate coo#ing. >educe the steam temperature at the rate prescri-ed.

!


46/99

&team temperature contro# ma -e #eft on automatic unti# the point is reached

*here -etter contro# can -e o-tained on manua#.

ii( 8hen the feeder rating on pu#:erisers is reduced to -e#o*" put the fue# oi#

gun in ser:ice. P#ace the pu#:eriser supp#ing the upper coa# e#e:ation on manua# contro#

9radua## reduce the feeder rating. 8hen minimum rating is reached c#ose the hot air shutoff gate. &top the feeder *hen the coa# air temperature has dropped to ! o. It is ad:isa-#e

to c#ose the coa# shut off gates a-o:e the feeder and run the spouts and feeders empt -efore

stopping the feeder. @eep the pu#:eriser running for a-out 2 minutes or unti# it is comp#ete#

empt. Then stop the pu#:eriser.

iii( s pu#:eriser are ta$en out of ser:ice< the secondar air damper contro# sstem

shou#d c#ose the associated *ind -o= dampers and thrott#e other dampers as required to

compensate for the reduction in firing rate.

i:( Ta$e the second pu#:eriser out of ser:ice *hen the feeder rating on this

pu#:eriser reaches !"

:( 4perate a## soot -#o*ers.

:i( >educe the airf#o* in #ine *ith fue# reduction unti# 3" of ma=imum air

f#o* is reached. 5o not reduce the air f#o* -e#o* this rating unti# a## fires are

out and the unit is off the #ine. To a:oid firing insta-i#it during this period of

high re#ati:e air f#o*< the au=i#iar air dampers at a## e#e:ations shou#d open and

reduce the *ind -o= to furnace differentia# pressure to its #o*er setting.

:ii( hec$ the e=pansion equipment of the unit as #oad is -eing reduced.

:iii( fter the #ast pu#:eriser has -een shut do*n< remo:e the fue# oi# guns and the

ignitors from the ser:ice shut off coo#ing *ater to pu#:erisers. ## fires shou#d -e

remo:ed *hen the unit is off the #ine.

i=( Immediate# after the -oi#er is off the #ine< open *ide the superheater out#et

:ents and drains. 4pen other drains in the superheater sstem as required for

further pressure reduction.

=( #ose desuperheateriso#ating :a#:es.

=i( If during the shut do*n period< it

*i## not -e necessar to enter the unit< a s#o* rate of pressure and temperature

deca ma -e desira-#e. This can -e esta-#ished as fo##o*sA

!,


47/99

a( Purge the unit - running the induced draft and forced draft fans for at #east fi:e

minutes '3" air f#o*( after the fires are e=tinguished.

-( >educe the airf#o* through the unit to a minimum @eep the fans in ser:ice unti#

the unit has coo#ed to the desired temperature.

c( @eep the *ater #e:e# near norma# in the gauge g#ass and ma$e up as required.

d( 4pen the drum :ents *hen the unit pressure has decaed to 2 @g?cm2?gauge.

=ii( It is desira-#e to acce#erate the coo#ing process in order to permit entr into the

unit for maintenance proceed as fo##o*sA

a( Purge the unit - running the induced draft and forced draft fans for at #east fi:e

minutes 'at a minimum of 3" air f#o* after the fires are e=tinguished.

-( ontinue running the fans to coo# the unit at the desired rate.

c( Maintain the *ater #e:e# near norma# in the gauge g#ass.

d( 4pen the drum :ents *hen unit pressure has -een reduced to 2@g?cm2g.

=iii( If the -oi#er is to -e emptied< the -oi#er *ater temperature shou#d -e reduced at

#east o -efore draining.

LIQUIDATION OF TYPICAL EMERGENCY

Boi#er must -e immediate# &hut5o*n

1. 8hen the *ater #e:e# in the drum fa##s do*n -e#o* 1" to 2""mm and #e:e# cannot -e

seen in gauge g#ass *hi#e c#osing the steam VIV of 9.I.9

2. 8hen *ater #e:e# rises -eond :isi-#e #e:e# in the gauge g#ass.

!7


48/99

3. 8hen there is a -rea$ in the heating surfaces and impossi-#e to maintain proper *ater

#e:e#.

!. 8hen a## gauge g#asses fai#s.

. 8hen drum pressure rises -eond 12! atm 'If safet :a#:es had not opened and pressure

cou#d not -e reduced(,. 8hen -oi#er frame -eams gets red hot and there is danger that #i:ings *i## fa##.

7. 8hen soot and fue# partic#es start to -urn in the -oi#er gas f#ues.

/. 8hen there are crac$s< -rea$ in pipes #ea$s in *e#ding Foints ri:eted Foints in main

e#ements of the -oi#er 'drum< header and piping( main steam pipe#ine.The -oi#er must -e

shut do*n in a## emergenc cases that required shutting do*n -oi#er.

5I>ETI4% %5 +IDUI5TI4% 4) TCPI+ EME>9E%C I% B4I+E>

1. )u## of partia# #oadoff on compressors

'B %03P#ant(

( &ign of #oad off on -oi#ers

I( &harp increase of steam pressure in -oi#er drum and steam pipe #ine '>ight to

tripping of safet :a#:es(

II( dditiona# rise of steam temp.

III( )a##s in steam consumption

IV( >apid rise in *ater #e:e# in -oi#er drum

B( TI4% 4) B4I+E> 04U&E PE>&4%%E+

I( >educe fue# supp# to the -oi#er furnace to maintain -oi#er furnace and

readFusted adequate furnace droughts.

II( ontro# -oi#er feed *ater to maintain norma# #e:e#S

III( #ose?adFust?inFection to desuperheater

2. E+ET>I+ &UPP+C T4 B4I+E> UHI+I>C +4&T

( I( ## the e#ectrica# motors of au=i#iaries equipments *i## stop e=cept those of

5. supp# equipments' 5.. supp# equipments can -e operate(

!/


49/99

II( )#ame in furnace dies

III( Boi#er steam pressure drops.

IV( &team consumption drops

V( )eed *ater pressure dropped for short term :o#tage dip< persona# shou#d not

interfere in their performance on dis continuation of au=i#iar supp# then

action to -e ta$en 'If inter#oc$ fai#s(B( TI4%A

I( E#ectrica# motors are s*itched off and shut the dampers of )5 fans< hot air

#ine to mi##< and partia## I5 fans< so as not to o:er #oad during further

starting up.

II( #ose inFection to desuperheater.

III( 5ri:e manua## P0 motor.

IV( Ta$e out partia## scanner guns of a## the corners.

V( #ose manua## main steam #ine :a#:es to chec$ further reduction of steam

or. 4f B?r.

VI( To fo##o* -oi#er -o=up operations.

( 5M9E I% 0ETI%9 &U>)E TUBE I% B4I+E>

i( &harp noise of steam Fet in furnace can heard.

ii( 5ifference in reading of steam and *ater f#o*< meters '&harp increase of

feed *ater consumption(

iii( >apped drop in *ater #e:e# to drum and steam pressure in -oi#er.

i:( Positi:e pressure in the furnace.

:( &team and gaseous coming out of feed ho#es and crac$s in -oi#er #inings

etc.

B( TI4% 80E% 8TE> 8++ PIPE 5M9E 'B>4@E%(

i( harge o:er the head to on other -oi#ers.

ii( &hut do*n the furnace stop >)s< mir#s< fue# oi# to furnace. )5 fans and

#ea:e I5 fans in ser:ice unti# the main mass of steam and f#o*s of furnace

remo:ed.

iii( &top feeding the -oi#er *ith *ater.

!. &I9% 4) B>E@ I% 8TE> 8++ 4> &UPE> 0ETE> PIPEA

i( &ound of issuing sstem in the are of the furnace or &0.

!


50/99

ii( Unstead com-ustion in furnance

iii( 5ifference in readings of steam f#o* meters and *ater f#o* metes.

The *ater issuing out of the *ater *a## and steam from super heater tu-es can

damage the neigh-oring tu-es in short time. 0ence damage and increasing time

e#iminated - immediate shutdo*n.

. ( &I9% 4) 5M9E I% E4%4MI&E> TUBE&

i( 5ifference in readings of steam f#o* meters and *ater f#o* meters.

ii( %oise in the area of economi;er.

iii( 5rop in f#ue gas temp. out#et to economi;er and air pre heater'P0(

i:( Positi:e pressure in the furnace'furnace dropt distur-ance(

:i( 8ater #ea$age from economi;er P0 ash hopper to -e *ater chec$.

8ater issuing out of damage part in short time can damage neigh-oring pipesincreasing the si;e of damage and time required its e#imination.

B( TI4% 4) B4I+E> 04U&E PE>&4%%E+

Immediate information shou#d reach to chief of shift of -oi#er house and get the

instruction from him. In case< it is necessar to continue running the -oi#er< on#

permissi-#e in sma## #ea$ages.

i( arefu## *atch the *ater #e:e# in -oi#er and feed #iner pressure. If

feed #ine pressure dropping and #arge difference in f#o* of *ater meter and steam f#o*

meter< then demand to start stand - feed pump.

ii( If *ater #e:e# is dropping e:en intersit the feeding and gets #o*er the mar$ and

signa# a *ater escaped from the drum. If protection fai#s< shut do*n the -oi#er and stop

feeding. I.5 fan is #eft in ser:ice ti## steam and gas f#ues are remo:ed.

iii( 4pen super heat -#o* do*n and after 12" minutes< c#ose the superheater -#o*

do*n.

,. E&PEME%T 4) 8TE> I% T0EB4I+E>A

( >E&4%&

i( +o*ered #e:e# gauge g#asses are out of order.

ii( 8ater #e:e# instrument supp# fai#s or defecti:e instrument< impu#se #ine

condensate escapement pro-#ems etc.

iii( Pressure in feed #ine gets #o*.

"


51/99

i:( >egu#ating :a#:es in feed #ien are out of order

:( 5raining :a#:es are #ea$ing or passing hea:i#.

:i( 8ater *a## piping or economi;er pipings are damaged.

:ii( Uncarefu# contro# from the side of operation.

B( &I9% 4) 8TE> E&PME%TIf *ater #e:e# gets do*n the #imit #e:e# then 'a( *ater #e:e# #o* '-( *ater #e:e# :er

#o* '-oi#er trip( 'c( *ater #e:e# dangerous# #o* indications *i## appear. Boi#er *i## trip

in inter#oc$ if it is in ser:ice.

( TI4% 4) T0E PE>&4%%E+

i( Ma$e sure that *ater escapement too$ p#ace< compare the *ater #e:e#

instruments reading at contro# room instruments and #e:e# gauge g#asses.

ii( ompare the readings of steam and *ater f#o* meters.

iii( Duic$# chec$ the -oi#er drum gauge g#asses.

i:( If there is no #e:e# in gauge g#ass.

a( -#o* do*n the drains of 9?9. '-( The c#ose :a#:e can $ept open *ater :a#:e&E I% P>E&&U>E T &UPE> 0ETE> 4UT+ET

>E&4%A Increase in super heater steam pressure

I( Partia# #oading of compressors

II( )a## steam #oads off from mmonia P#ant

III( 8rong performance of fue# regu#ation to -oi#er furnace

IV( Uncontro##a-#e of coa# f#o* from >e$ and coa# dust from mi## to furnace

TI4%A

1. )ind out the reason for increase of pressure of steams and act according#.

2. ut out ra* coa# feeders and remaining a#so if necessar.

3. Vent steam thro 71" :a#:e to contro# pressure -ut practice to :enting of steam

shou#d -e a:oided so for as possi-#e< due to reason of sa:ing of ra* materia#s and

cost.

!. To chec$ the coa# dust sstem and cut it out if necessar.

. hec$ the fue# oi# regu#ation sstem

,. If *e are una-#e to contro# increasing of pressure and safet de:ices 'drums 6 &0

safet VIV3 6 :enting sstem of &0 &team( fai#s to operate to contro# pre. Then

emergent# shut do*n -oi#er.


56/99

4PE>TI4% 4) MI++&

P>I%IP+E&

The coa#enters to the center of the re:o#:ing -o* entrifuga# force causes the materia#

to tra:e# to*ard the outer perimeter of the -o*# *here it comes -et*een the grinding ring inthe re:o#:ing -o* and the mi##s. The mi##s< *hich are spring #oaded< impart the pressure

necessar for grinding. The partia## pu#:erised materia# continuous up o:er the edge of the

-o*#.

ir enters the mi## housing -e#o* the -o*#< in directed up*ard part the -o*# passes

through the c#assifier :anes at the top of the iner cone. The air pic$s up P.). and hea:ier

partic#es stri$ing against the def#ectors return the -o*# and get crushed. +ighter partic#es

through c#assifier :anes is suc$ed - e=hauster fan and goes to -urner through distri-utor

pipes.

n tramps iron or difficu#t to grind foreign materia# in the feed is carried o:er the top

of the -o*# *here it drops out through the air stream to the #o*er part of the mi## housing.

Pi:oted scrapers attached to the -o*# hu- s*eep the tramp iron into reFecting sport.

Mi## tpe,"3 H>&Hapacit 2,./ T 'Moro( 33@V Motor @8 amps )ineness 7"

through 2"" mesh screen.

MI++ 4PE>TI4%

0E@I%9&A

1. 9et sure that the maintenance *or$ on mi##e=hauster oa# feeder or an of its motors

are not going on and *or$ permits if an has -een surrendered - the respecti:e department

:i; B?M< P?M 6 I?M.

2. Ma$e sure that po*er is a:ai#a-#e in mi## motor and coa# feeder motor.

3. Ma$e sure that inter#oc$ sstem of hot air gate mi## feeder is 4.@.

!. Ma$e sure that feeder contro#0ot air contro# 6 e=hauster contro# dri:es are 4.@.

. Ma$e sure a-out #u-rication in mi## gear housing and >o##er Fourna#s housing PIV

gear housing and e=hauster -earing etc.

,. Ma$e sure a-out coo#ing *ater f#o* through mi## gear housing oi# coo#er.

7. Ma$e sure that adequate supporting f#ame is there in the furnace.

,


57/99

&T>TI%9A

Ma$e sure that inset air supp# is assured.

1. &tart the mi##< starting amps< and time. %o #oad amps.2. hec$ for an unusua# -eha:iors if Vi;.< unusua# :i-ration sound of an -earing parts

or an -i## -od.

3. Ta$e care a-out furnace draft5r. #e:e# etc.

!. 4pen e=hauster gate< :ent *i## c#ose.

. 4pen hot air gate

,. +et mi## temp. to go at a-out ,o.

7. Esta-#ish adequate air f#o* through mi## to #ift the co#a in the furnace.

/. &tart the coa# feeder.

. Mi## #oading to -e increased gradua## - $eeping *atch on furnace draft&T.

pressure and steam temperature mi## temperature< mi## amps. etc.

1". %orma#ise the mi## #oading - $eeping *atch on the mi## motor amps.

11. @eep a continuous *atch on mi##ing equipments to run it smooth#.

&hut do*n 'a( Esta-#ish oi# support in the mi## 9roup to -e cut out.

-( 9radua## reduce mi## amps< feeder amps< mi## temperature &t. pressure< steam

temperature< furnace draft etc.

. t no #oad stop coa# feeder.

5. t no #oad of mi## shut hot air gate and e=hauster iso#ation gate.

!. @eep *atch on mi## temperature to -e -e#o* ,"o< stop mi##.Emergenc shut do*n. If fire is #ost or for an other $anor tour-#es mi## can -e tripped

on fu## #oad. utomatica## hot air gate and feeder motor *i## -e tripped. Ta$e care

-efore the mi## started again to a:oid an o:er #oading.

MI++ T>4UB+E&A

1. Mi## temperature highA Increase temperature air and decrease hot air. #so increase

coa# feeding *atch on mi## amps.

2. Mi## fireA )eed coa# to the ma=imum e=tent possi-#e - $eeping *atch on mi## amps.

4pen coa# air damper no* and reduce hot air. The fire shou#d decrease or #ost

other*ise shut do*n the mi## and iso#ate the mechanica##. harge foam e=tinguishers

through manho#e inside. +et the mi## get coo#ed gradua##.

3. 0igh motor ampsA >educe coa# #oading. 4-ser:e for an unusua# sound< :i-ration

for an foreign materia# and chec$ reFection gate to -e c#ear.

7


58/99

!. Mi## puffingA 5ue to #o* air f#o* maintain minimum air f#o* to get required coa#

air :e#ocit.

. Poor grinda-i#itA 5ue to *arm out ro##er parts in -u## ring< ring housing. >educing

mi## #oading.,. E=cess reFectionA 5ue to minimum air through the mi## deracted capacit of the mi##.

MI++ I%TE>+4@&A

1. There is an inter#oc$ sstem for protection of the mi## groups and associated -oi#er.

a( If )5 fan gets tripped the mi## group trips.

-( If mi## trips then coa# feeder trips.

c( If hot air gate gets c#osed then coa# feeder trips.

e( Either e=hauster iso#ating gate or e=hauster :ent :a#:e *i## open or c#ose

a#ternati:e.

0E@I%9 5U>I%9 4PE>TI4%A

1. hec$ the -earing temperature and :i-ration.

2. hec$ the recircu#ation oi# f#o*.

3. hec$ the *ater f#o* and temperature.

!. hec$?operate the reFection gate and remo:e the reFection time to time.

. onstant *ater on norma# sound< :i-ration of the running mi##.

,. hec$ the ro##er oi# #e:e#.

7. 8atch on c#assifier temperature.

/


59/99

SOOT $LO%ER AND SOOT $LO%ING SYSTEM

&team at pressure of 113 @g?cm2 'g( is tapped from P#aten &uper heater out#et header'&002( for the purpose of &oot B#o*ing. The Pressure is reduced to 3" @g?cm2 'g( -

means of pressure reducing :a#:es. The set pressure for safet :?: is 3, @g?cm2'g(. It is

capa-#e of discharging the fu## capacit of the soot -#o*ing steam. The pressure after

reduction :a#:e is further reduced to operating pressure of indi:idua# B#o*er - adFusting at

the &oot B#o*ers :a#:e head.

5uring starting of soot -#o*ing cc#e< drain :a#:es are to -e opened *ide# and main

in#et :a#:es are to -e gradua## opened. ## the condensate are to -e comp#ete# drained 6

*armed. The drain :a#:es are to -e c#osed and the soot -#o*ing operation is to -e started.

4n# one -#o*er operates at a time. The sequence of operating of -#o*er *hich is

predetermined is contro##ed - the soot -#o*er contro# pane#. fter the soot -#o*ing cc#e is

comp#eted the main in#et :a#:es are to -e c#eaned and drain :a#:es are to -e $ept open.

Medium of f#o* &uperheater steam

Before reduction 11, @g?m2'g( at !!"o

fter reduction !" @g?cm2'g( at 3/"o

%o. of #ong >etracta-#e ,

&oot -#o*ers

%o. of *a## -#o*ers 2!

%o. of air heat -#o*er 1

+4%9 &44T B+48E> IMP4>T%E I%&T>UTI4%& )4> 4PE>TI4%&

1. 5o not operate *ith *et steam2. 54 not operate the same -#o*er in quic$ &uccession Minimum one hour period.

3. Ta$e care to a:oid e=tending the #ance in to the -oi#er *ithout -#oning medium.

&u-Fecting the #ance to temperature in e=cess of "o

!. 5o not operate the soot -#o*er *ithout -#o*ing medium during -oi#er operation.

. 54 not put the -#o*er in to manua# operation *hen the steam #ine in 4%

,. hec$ #u-ricating oi# #e:e# frequent#.

7. 5o not attempt maintenance *or$ *hen po*er and?or -#o*ing medium are 4%

/. 4-ser:e a## safet practice in use.


60/99

. 5o not operate the soot -#o*er *ith e=cessi:e steam #ea$age through pec$ing.

1". The hand cran$s pro:ided for emergenc operation shou#d -e remo:ed after their use

on the -#o*er.

B#o*er %o. Tpe >ecommended set Pressure @g?cm2'g(

2.2, T3"M@IE 11

27 to 3" T3" %@IE

1 to 2! >8&E 1".

8++ B+48E>

I%&T>UTI4%&A

1. 5o not operate the *a## des#agger *ith *et steam.

2. 5onot operate the -#o*ers adFacent to -urner at #oads #ess than ," M>.

3. hec$ no;;#e position an a#ignment *ith respect to *ater *a## after each shutdo*n of

the -oi#er.

!. 8hen adFusting #imit s*itches< s*itch off the po*er to the unit to a:oid an inFuries.

. Before operating the -#o*er made sure the drain ho#es in the motor frames point

do*n*ards and are open.

,. hec$ #u-ricating oi# #e:e# frequent#.

,"


61/99

I.5 6 ).5. )%&

0E@ +I&T )4> 54&

1. hec$ for #u-ricant in -earing housing.

2. hec$ tightness of foundation -o#ts and other -ot fi=ing impe##er< -earing and

motor.

3. hec$ for operation of in#et guide :ane unit. ## the -#ades shou#d -e in correct

position.

!. hec$ for cored -earing c#earance'Tu-e done - mechanica# engg. deptt. in case

an *or$ in done on -earing.

. Ensure correct a#ignment of coup#ing

,. Ensure no foreign matter #eft inside the fan casing.'In case Fo- *as attended inside

the casing(

7. hec$ impe##er c#earances 'To -e done - mechanica# engg. deptt.(

/. hec$ for correct direction of rotation of the fan< chec$ the emergenc off s*itch

for correct functioning.

II( &T>T UP %5 %4M>+ >U%%I%9

1. #ose the in#et guide :anes of fan.

2. #ose dampers at suction and de#i:er.

3. hec$ up for starting current and norma# running current of motor :i;a:i; the

manufacturing specification.

!. hec$ for :i-ration and temperature of -earing.

. hec$ for the #u-rication of -earing housing and in#et guide :anes etc.

,. hec$ for the a-norma# noise in the fan if an.

7. hec$ up the *ire mesh pro:ided for*ards the suction side of )5 fan and arrange

for the c#eaning of the same periodica##.

/. In case an a-norma#it in -earing temperature?motor temperature is noticed record

it proper# and inform the shift in charge.

. In case an #ea$ages are noticed from oi# sea#s or #e:e# indicator< inform the shift in

charge to get the same attended.

,1


62/99

1". Before starting of the fan ma$e sure that the man ho#es of the fan< drain co:er arec#osed. %o *ater traces shou#d -e there in the )5 fan duct.

11. In case of I5 fan an erosion notice in the in#et duct or caring shou#d -e proper#

recorded and informed to the concerned super:isor for necessar action


63/99

Vi-ration amp#itude at the -earing in micron 'm(

I> P>E0ETE>

The regenerati:e tpe of air heater a-sor-s *aste heat from f#are gas< then transfers to

incoming co#d air - means of continuous# rotating heat transfer e#ements of specia##

formed meta# p#ates. Thousands of these high efficienc e#ements are speed and comp#ete#

arranged *ith t*e#:e sector shaped compartment of gradua## di:ided c#indrica# she## ca##ed

the rotor. The housing surrounding the motor is pro:ided *ith duct connections at -oth ends

and is adequate# sea#ed - radia# and circumferentia# sea#ing mem-ersforming an air

passage through one ha#f of the preheater and a gas passage through the other.

s the motor s#o*# re:o#:es the mass of e#ements a#ternati:e# through the gas and air

passage< heat is a-sor-ed - the e#ement surfaces raising through the hot gas stream< then as

these same surfaces are carried through the air stream< then re#ease the stored up

heat.thus great# increasing the temperature of the incoming com-ustion process air.

The comp#ete rotor is supported - a thrust -earing'spherica# rotor -earing. To guide

the upper end of the rotor< a guide tornion is -o#ted to the face of the rotor post. The position

of this trunnion is maintained - a radia# guide -earing assem-#. The -earing is *ater

coo#ed.

The oi# #e:e# of the support -earing is to -e maintained such that the ro##ing e#ements of

the -earing are su-merged in the oi#.

n au=i#iar dri:e through an oi# tur-ine is pro:ided to $eep the air heater running in

case of fai#ure of motor. The air passes through so#enoid operated :a#:e.

The air heater is pro:ided *ith soot -#o*ing arrangement at the -ottom part of the

rotor to*ards the f#ue path.

8ater *ashing arrangement through no;;#e is pro:ided for c#eaning during shut do*n.

,3


64/99

84>@I%9 P>I%IP+E 4) % E+ET>4&TTI P>EIPITT4>

The precipitator essentia## consists of t*o sets of e#ectrodes :i; co##ecting e#ectrodes

and emitting'discharge( e#ectrodes. The co##ecting e#ectrode is made up of stea# sheetsEM4TE M%U+ 4PE>TI4%A

)or remote manua# operation of hoppers< first the utoNogManua# &e#ector

&*itch is set at Manua# position.

73


74/99

%o* the -ranch se#ection sha## -e done - 0eader &e#ector &*itch and indi:idua#

hopper c#eaning sha## -e carried out - setting 0opper &e#ector &*itch to

se#ected positions.

Vacuum s*itches V&2 63 sha## -e inter#oc$ed *ith manua# c#earing in the same

manner as descri-ed a-o:e for automatic sequentia# operation< and :acuum s*itchV&1 gi:es the empt hopper indication #ighting an m-er +amp 0opper &e#ector

&*itch is to -e to the ne=t se#ected position there- c#osing the ear# operating

:a#:e and opening the se#ected hopper :a#:e.

It sha## -e possi-#e to carr cut this operation for a## the f# ash hoppers at random.

The f#uidi;ing -#o*er and the so#enoids in the f#uidi;ing air pipe #ine sha## -e

inter#oc$ed *ith the f# ash sstem operation as descri-ed in automatic operation.

5. &C&TEM I%TE>+4@&A

1. I%TE>+4@& BET8EE% B4TT4M &0 &C&TEM %5 )+C &0 &C&TEM

%5 BET8EE% B4TT4M &0 &C&TEM& 4) 5I))E>E%T B4I+E> U%IT&.

i( n inter#oc$s sha## -e pro:ided -et*een Bottom ash s#urr #ine iso#ating :a#:e and

f# ash s#urr #ine :a#:e so that one :a#:e cannot -e opened ti## ht other :a#:e is c#osed.

ii( 8hi#e c#eaning -ottom ash sstem of an of the -oi#er units depending on the

position of the Bottom sh Unit and )# sh &e#ector &*itch< it is ensured that

c#eaning of other B Units and f# ash sstem cannot -e carried out simu#taneous#.

2. B4TT4M &0 &C&TEM I%TE>+4@&

i( The *ater #ine motor operated :a#:e -efore Fet pump cannot -e opened un#ess the

respecti:e s#urr #ine -utterf# :a#:e is $ept open.

ii( The motor operated :a#:e *i## c#ose immediate# *hene:er the -utterf# :a#:e in

s#urr #ine c#oses.

iii( The s#urr #ine -utterf# :a#:e can -e c#osed on# if the respecti:e *ater#ine motor

operated :a#:e is $ept c#osed.

i:( #in$er grinder motor cannot -e started un#ess the fo##o*ing requirements are

metA

7!


75/99

a( >equired *ater pressure a:ai#a-#e at the Fet pump in#et< sensed :ia a pressure

s*itch P&83.

-( >equired *ater pressure a:ai#a-#e at the c#in$er grinder g#and sea# sensed :ia

a per pressure s*itch P&8!.

In the e:ent of *ater pressure at the Fet pump in#et and the c#in$er grinderg#and sea# fa## -e#o* preset :a#:es the running grinder motor sha## trip.

3. )+C &0 &C&TEM I%TE>+4@&

i( )our '!( %os pressure s*itches sha## -e pro:ided in *ater #ine -et*een

0drau#ic e=hauster and the motor operated *ater #ine :a#:e.

a( 4ut of these four< t*o '2( pressure s*itches 'P&81( sha## -e inter#oc$ed *ith

the :acuum -rea$er such that if adequate *ater pressure is not there the :acuum

-rea$er cannot -e c#osed to start f# ash c#eaning. If the *ater pressure fa##s during

operation< the :acuum -rea$er *i## there- stopping the f# ash c#eaning operation.

-( 4ther pressure s*itches 'P&82( sha## -e inter #oc$ed *ith the f# ash sstem

such that if adequate *ater press is not there f# ash c#eaning cannot -e started and

con:erse# the sstem stops automatica## *hen pressure drops -e#o* the preset :a#:e.

ii( T*o '2( %os. air pressure s*itches P& 'one for each stream of f# ash(

connected to the compressed air #ine sha## -e so inter#oc$ed *ith the f# ash

sstem that the f# ash sstem cannot -e started un#ess there is sufficient airpressure. The f# ash c#earing sha## stop *hen the air pressure fai#s -e#o* set

pressure.

iii( sh e=traction :a#:e sha## open in sequence such that the ash hopper :a#:e

nearest to the air inta$e :a#:e sha##?open first for each -ranch.

i:( sh c#earing *i## start from the economi;er 0opper -ranch and end in E.P.

0opper -reach for stream for stream B< the ash c#earing *i## start from the ir

0eater 0opper -ranch and end in E.P. 0opper -ranch.

:( s the e=traction :a#:e of each of the hopper ha:ing f#uidi;ing pads opens< its

respecti:e f#uidi;er air :a#:e sha## a#so open to inFect f#uidi;er air to the pads.

:i( The *ater #ine motor operated :a#:e -efore e=hauster cannot -e opened un#ess

the f# ash s#urr #ine -utterf# :a#:e is $ept open.

:ii( The motor operated :a#:e *i## c#ose immediate# *hene:er the s#urr #ine

-utterf# :a#:e c#oses.

:iii( The s#urr #ine -utterf# :a#:e can -e c#osed on# if the motor operated :a#:e is

$ept c#ose.

E. %%U%ITI4% &C&TEM

7


76/99

a( B4TT4M &0 &C&TEM

nnunciation *i## -e pro:ided on the B . +oca# ontro# Pane# for tripping of

c#in$er grinder motor.

There *i## -e an ccept push -ottom in the +oca# ontro# Pane#.

c( )+C &0 &C&TEM

1. This sstem sha## ha:e audio:isua# a#arming arrangement - means of

f#ashing of #amps a#ong *ith sounding of a -ooter. There sha## -e accept%E> 4%T>4+ &C&TEM

1. 9E%E>+

This -oi#er is pro:ided *ith / %os. of oi# -urners< ! %os. of oi# guns to fire #ight orhea: oi# in E+ RB and ! %os. of oi# guns to fire hea: oi# in E+B. The #ight oi# is used

for co#d startup and hea: oi# for f#ame sta-i#i;ation and #oad carring upto 3" of the

-oi#er M>. The #ight oi#?-urners can -e put into operation after starting the corresponding

ignitors and pro:ing ignitor f#ame.

2. BU>%E> 4%T>4+A

4i# -urner sstem consists of the fo##o*ing fie#d equipment. These are contro##ed from

the -urner contro# pane# #ocated in the unit contro# room. The equipment send necessar feed

-ac$ and f#ame present signa#s to the contro# pane#.

1. Ignitor oi# trip :a#:e 1 %o.

2. +ight oi# trip :a#:e 1 %o.

3. 0ea: oi# trip :a#:e 1 %o.

!. Ignitor trip :a#:es / %os.

. Burner trip :a#:es / %os.

,. Burner atomi;ing :a#:es / %os.

7,


77/99

7. Burner sca:enge :a#:es / %os.

/. Ignitor contro# -o=es / %os.

. )#ame scan head assem-#ies / %os.

Ignitor oi#< #ight oi# and hea: oi# trip :a#:es can -e indi:idua## operated from the

contro# pane#. Ignitor trip :a#:es?Burner trip :a#:es and Burner sca:enge :a#:e can -eoperated in pairs from the contro# pane#.

0ea: oi# manua# :a#:e< #ight oi# manua# :a#:e< atomi;ing steam manua# :a#:e and atomi;ing

air manua# :a#:e -efore eadh -urner in E+B ha:e to -e operated manua## as per fue#

se#ected in the contro# pane#.

Burner contro# pane# consists of 3 sectionsA one for common equipment. and 5 supp#

changeo:er sstem and annunciation sstemA second for contro# of indi:idua# -urner

equipment in E+B and annunciation sstem third for contro# of indi:idua# -urner

equipment in E+B and annunciation sstem.

II( BU>%E> 4%T>4+ P%E+ 4%&I&T& 4) T0E )4++48I%9 4MM%5I%9

EDUIPME%TA

&8IT0E& 6 PU&0 BUTT4%&

1. &upp# 4%4)) s*itch '&1(

2. 5 &upp# 4%4)) s*itch '&2(

3. &upp# se#ector s*itch '&3(

!. Burners emergenc trip push -utton 'PB1"< PB 11(

. I4TV c#ose #uminous push -utton 'PB1(

,. I4TV c#ose #uminous push -utton 'PB2(

7. I4TV c#ose #uminous push -utton 'PB3(

/. +4TV c#ose #uminous push -utton 'PB!(

. 04TV c#ose #uminous push -utton 'PB(

1". 04TV c#ose #uminous push -utton 'PB,(

11. #arm accept #uminous push -utton 'PB7(

12. #arm test #uminous push -utton 'PB/(

13. )au#t reset #uminous push -utton 'PB(

1!. Ignitor 1 6 3 pair stop push -utton '13PB1(

1. Ignitor 2 6 ! pair stop push -utton '2!PB1(

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78/99

1,.Ignitor 6 7 pair stop push -utton

'7PB1(

17. Ignitor , 6 / pair stop push -utton ',/PB1(

1/. Ignitor 1 6 3 pair start push -utton '13PB2(

1. Ignitor 2 6 ! pair start push -utton '2!PB2(

2". Ignitor 6 7 pair start push -utton '7PB2(

21. Ignitor , 6 / pair start push -utton ',/PB2(22. Burner 1 6 3 pair stop #uminous push

-utton

'13PB3(

23. Burner 2 6 ! pair stop #uminous push

-utton

'2!PB3(

2!. Burner 6 7 pair stop #uminous push

-utton

'7PB3(

2. Burner , 6 / pair stop #uminous push

-utton

',/PB3(

2,. Burner 1 6 3 pair start #uminous push

-utton

'13PB!(

27. Burner 2 6 ! pair start #uminous push

-utton

'2!PB!(

2/. Burner 6 7 pair start #uminous push

-utton

'7PB!(

2. Burner , 6 / pair start #uminous push

-utton

',/PB!(

3". Burner 1 6 3 sca:enge 4% push -utton '13PB(

31. Burner 2 6 ! sca:enge 4% push -utton '2!PB(

32. Burner 6 7 sca:enge 4% push -utton '7PB(33. Burner 1 6 3 sca:enge 4% push -utton ',/PB(

3!. Burner 1 6 3 +.4. firing se#ection

#uminous push -utton

'13PB,(

3. Burner 2 6 ! +.4. firing se#ection


'2!PB,(

3,. Burner 1 6 3 +.4. firing se#ection


'13PB7(

37. Burner 1 6 3 +.4. firing se#ection


'2!PB7(

B. I%5ITI%9 +MP&A

1. >E5 +MP& T4 I%5ITEA

a. 1 supp# R4% indication '1+(

-. 2 supp# R4% indication '2+(

7/


79/99

c.1 supp# R4% indication

'15+(

d. 1 supp# R4% indication '25+(

e. Pane#1 heater R4% indication '0+(

f. Pane#2 heater R4% indication '0+2(

g. Pane#3 heater R4% indication '0+3(

h. Master fue# re#a R4% indication '+2(i. Ignitor fan R4% indication '+3(

F. &canner fan R4% indication '+!(

$. 9un1 in firing position indication '1+1(

#. 9un2 in firing position indication '2+1(

m. 9un3 in firing position indication '3+1(

n. 9un! in firing position indication '!+1(

o. 9un in firing position indication '+1(

p. 9un, in firing position indication ',+1(

q. 9un7 in firing position indication '7+1(

r. 9un/ in firing position indication '/+1(

7


80/99

2. 9>EE% +MP& T4 I%5ITE A

a. ## ITVs c#osed indication '+1(-. ompressed air pressure R4@ indication '+(

c. +.4.pressure R4@ indication '+,(

d. 0.4.pressure R4@ indication '+7(

e. E#e:ation #oad more than 3" M> indication '+/(

f. 0.4. temperature R4@ indication '+(

3. 80ITE +MP& T4 I%5ITE

a. Burner pair 163 sca:enge comp#ete indication '13 +1(

-. Burner pair 26! sca:enge comp#ete indication '2!+1(

c. Burner pair 67sca:enge comp#ete indication '7+1(

d. Burner pair ,6/ sca:enge comp#ete indication ',/+1(

!. %%U%ITI4% 8I%548% T4 I%5ITE

1 E#e:ation RB f#ame fai#ure '1)+(

2 E#e:ation RB f#ame fai#ure '2)+(3 0ea: 4i# Pressure #o* '3)+(

! +ight 4i# Pressure #o* '!)+(

. 0ea: oi# temperature #o* ')+(

, +.4.?ir differentia# pressure #o* ',)+(

7 0.4.?&team differentia# pressure #o* '7)+(

/. ompressed air pressure #o* '/)+(

Ignitor oi# pressure #o* ')+(

1". Ignitor 1?3 fai#ed '13)+(

11 Ignitor 2?! fai#ed '2!)+"

12 Ignitor ?7 fai#ed '7)+(

13 Ignitor ,?/ fai#ed ',/)+(

1! &canner 2 fai#ed '1)+1(

1 &canner O2 fai#ed '2)+1(

1, &canner O3 fai#ed '2)+1(

17 &canner O! fai#ed '2)+1(

1/ &canner O fai#ed '2)+1(

1 &canner O, fai#ed '2)+1(

/"


81/99

2"&canner O7fai#ed

'2)+1(

21 &canner O/ fai#ed '2)+1(

22 Burner1 auto trip '1)+1(

23 Burner2 auto trip '2)+1(

2! Burner3 auto trip '3)+1(

2 Burner! auto trip '!)+1(2, Burner auto trip ')+1(

27 Burner, auto trip ',)+1(

2/ Burner7 auto trip '7)+1(

2 Burner/ auto trip '/)+1(

III TE&TI%9 T0E I%ITI+ 4%5ITI4%A

1( &e#ect I supp# - supp# se#ection s*itch '&3(< &*itch R4% 6 5

supp# sstem s*itches '&1unning condition of ignitor fan is indicated - the -urning of red #amp '+3(

!( >unning condition of scanner fan is indicated - the -urning of red #amp '+!(

( 0ea: oi# '0.4.( temperature 4@ is indicated - the -urning of green #amp '+7(

,( #osed condition of a## ignitor trip :a#:es is indicated - the -urning of green

#amp '+I(

7( ompressed air pressure R4@ is indicated - the -urning of green #amp +.

/( +ight oi# pressure R4@ is indicated - the -urning of green #amp +,.

( 0.4. Pressure R4@ is indicated - the -urning of green #amp +7.

1"( hec$up *hether the annunciation sstem and other operation indicating #amps

are functioning a#right - pressing the sstem test push -utton PB/.

IV &T>TI%9 6 T>IPPI%9 4%5ITI4%& )4> ++ T0E T>IP V+VE&.

/1


82/99

. I9%IT4> 4I+ T>IP V+VEA

1. The fo##o*ing conditions shou#d -e satisfied to open the ignitor oi# trip :a#:e I4TV.

a( Boi#er master fue# re#au energi;ed 'M)>(-( ompressed air pressure R4@ 'set at !. $g?cm2(

c( +ight oi# pressure R4@ '&et at 12. $g?cm2(

d( ## ignitor trip :a#:e c#osed.

e( Ignitor fan running

f( I4>V open push -utton in pressed position.

2. n one of the fo##o*ing condition shou#d -e present to trip?c#ose I4TV.

a( Emergenc trip push -utton in pressed position.

-( Boi#er M)> is deenergised

c( Ignitor oi# pressure #o* for more than 2 secs and an ITV open '&et at .1 $g?cm2

d( ompressed air pressed R#o* '&et at ! @g?cm2(

e( Ignitor fan tripped

f( I4TV c#ose push -utton is pressed position.

B. +I90T 4I+ T>IP V+VE.

3. The fo##o*ing conditions shou#d -e satisfied to open +4TV

a( Boi#er M)> energi;ed.

-( +ight oi# pressure R4@ '&et 12.$g?cm2(

c( ## -urner trip :a#:es in e#e:ation RB in c#osed position or a## -urner +.4.

manua# :a#:es c#osed.

d( +4TV open push -utton in pressed position.

!. n one of the fo##o*ing conditions in pressed positionA

a( Emergenc trip push -utton in pressed position

-( Boi#er M)> deenergised.

c( 5P of f#ight oi# and atomi;ing air #o* for more than 2 secs. and en an

e#e:ation RB -urner trip :a#:e not c#osed an an #ight oi# manua# :a#:e not

c#osed.

d( +4TV c#osed push -utton in pressed position.

/2


83/99

. 0EVC 4I+ T>IP V+VEA

The fo##o*ing conditions shou#d satisfied to open 04TV.

a( Boi#er M)> energi;ed or hea: oi# manua# recircu#atrion

:a#:e in '04>MV( open position.

-( 0ea: oi# pressure 4@ 'set at $g?cm2(

c( 0ea: oi# temperature R4@ '&et at o(

d( ## -urner trip :a#:es in e#e:ation RB c#osed?a## 0.4. manua# :a#:es in E+ RB

c#osed and a## -urner trip :a#:es in E+ RBc#osed.

e( 04TV open push -utton in pressed position.

n one of the fo##o*ing condition shou#d -e present to trip?c#ose 04TV.

a( Boi#er M)> is deenergised 04>MV is in c#osed position.

-( Emergenc trip push -utton in pressed position and 04>MV

c( 04?&team 5P R#o* or 04 pressure #o* for more than 2 secs. and an -urner

trip :a#:e not c#osed in E+ RB an -urner trip :a#:e in E+ RB not c#osed and

an -urner 0.4. manua# :a#:e in E+ RB not c#osed.

d( 0ea: oi# temperature #o* an -urner trip :a#:e not c#osed in E+ RB an

-urner trip :a#:e in E+ RB not c#osed and an -urner 0.4. manua# :a#:e in E+

RB not c#osed.

f( 04TV c#ose push -utton is pressed position.

B. I9%IT4> PI>A

7. Ignitors at four corners of an e#e:ation B?B start in pair'i.e. 1 6 3?2 6 !? 6 7?, 6

if the fo##o*ing conditions are satisfied.

a( Ignitor oi# trip :a#:e is in open position.

-( Ignitor f#ame not pro:ed.

c( ITV in c#osed position.

d( Ignitor pair start push -utton in pressed position.

/. n one of the fo##o*ing conditions shou#d -e in present positionA

a( M)> deenergised

-( Emergenc trip push -utton in pressed position

c( Ignition time e#apsed and f#ame not pro:ed.

/3


84/99

d( +4TV c#osed .

e( Ignitor pair stop push -utton in pressed position and e#e:ation #oad greater than

3" and -oth -urner pair se#ected on 04 and a## four BTVs of the e#e:ation open.

f( Ignitor pair stop push -utton in pressed position and corresponding sca:enge trip

:a#:es open and sca:enge time e#apsed or corresponding sca:enge trip :a#:es c#osed.

%4TEA

1.( Ignitors shou#d not -e stopped *hi#e firing +.4. in E+ RB or 04

in E+ RB?B *hen the e#e:ation #oad is #ess than 3"

2.( )or stopping ignitors under the a-o:e conditions< the corresponding -urners sha## -e

stopped for norma# shut do*n.

3.( 8hen ignitor start command is initiated< corresponding ITVs open and simu#taneous#

corresponding timer and ignition transformer are energi;ed. Timer and ignition

transformer deenergise once the f#ame is pro:ed *ithin the preset time. If f#ame is not

pro:ed *ithin preset time< ignition transformer *i## deenergise and ITV *i## a#so

c#ose.

!.( 5iagona## opposite corner ignitor form a pair.

E. BU>%E> PI> &T>T A. The fo##o*ing conditions shou#d -e satisfied to start the -urners in pair A


-( +.4.firing se#ected in E+ RB and +4 manua# :a#:e and atomi;ing air manua#

:a#:e of the pair se#ected for + 4 firing open and 0 4 manua# :a#:e steam

atomi;ing manua# :a#:e of the pair se#ected for +.4 firing c#osed.

4>

0.4.firing se#ected in E+ RB and 04 manua# :a#:e and atomi;ing steam

manua# :a#:e of the pair se#ected for 0 4 firing open and + 4 manua# :a#:e and

air atomi;ing manua# :a#:e of the pair se#ected for 0.4 firing c#osed.

%4TEA

/!


85/99

)or E+B corresponding pair of 04 manua# :a#:e an atomi;ing steam manua#

:a#:es are to -e ensured open manua## since on# 04 firing

Is en:isaged in E+B.

c( +4TV?04TV open *hen +4 or 04 se#ected ')or E+ RB on# O )or E+RB 04TV open(.

d( ssociated ignitor in ser:ice.

e( Burner sca:enge :a#:e c#osed.

f( Burner gun in firing position.

g( Burner atomi;ing :a#:e open.

h( Burner ti#t hori;onta# or an > feeder on.

i( 04>MV c#osed *hen 04 se#ected.

F( Burner pair start push -utton in pressed position.

1". n of the fo##o*ing conditions shou#d -e present to trip the -urner pairA


-( Emergenc trip push -utton in pressed position.

c( +4TV?04TV c#osed *hen +4?04 is fired ')or E+ RB on# O )or E+

RB 04TV c#osed(.

d( ssociate ignitors not in ser:ice and #ess than 2 out of ! scanner sho*

f#ame.

e( ssociate ignitor not in ser:ice and E+ #oad #ess than 3" and adFacent

#ess E+ feeders not in ser:ice.

f( Burner sca:enge :a#:e not c#osed.

g( Burner atomi;ing :a#:e c#osed.

h( Burner gun not in firing position.

i( orresponding +4?04 manua# :a#:e c#osed or 04?+4 manua# :a#:e not

c#osed *hen +4?04 firing se#ected ' for E+B on#(

F( orresponding atomi;ing air?steam manua# :a#:e c#osed or steam?air

manua# :a#:e not c#osed *hen +4?04 firing se#ected 'for E+ RB on#(.

$( 04?+4 se#ected *hen firing +4?04 ' for E+ RB on#(

#( 04 recircu#ation manua# :a#:e opened *hen firing 04 in an -urners.

m( Burner pair stop push -utton in pressed position.

%4TEA

/


86/99

1( 8hen -urner pair start push -utton is pressed< one of the t*o -urners *i## start

and the second -urner *i## start after a time de#a of 1 secs.

2( Burner pair start push -utton is common for t*o -urner trip :a#:es and -urner

atomi;ing :a#:es. 8hen the push -utton is depressed< first the -urner atomi;ing:a#:e *i## open and then the -urner trip :a#:e.

3( Burners in opposite corners from a pair.

!( If one of the ignitor fai#s< on# the corresponding -urner stopped.

). &VE%9EA

11. The fo##o*ing conditions shou#d -e satisfied to open -urner sca:enge :a#:es in

pairA

a( Boi#er M)> energised

-( Ignitor fan running.

c( Burner trip :a#:es c#osed.

d( Burner trip :a#:es c#osed.

e( ssociate manua# :a#:es in atomosing air or steam #ine to -urners open.

f( ssociate -urner atomi;ing :a#:es c#osed.

g( ssociate -urner sca:enge :a#:es c#osed.

h( ssociate -urner guns in firing position.

V. 4PETI4% P>4E5U>EA

. &UPP+C 0%9E4VE> &C&TEMA

utomatic supp# changeo:er sstem is pro:ided in the contro# pane# for -oth 6

5 supp#ies. %ecessar inter#oc$ing sstems and indicating #amps for this sstem are

incorporated in this pane#.

B. &EDUE%E 4) 4PE>TI4%A

1( &e#ect position R4% in the 6 5 supp# s*itches &1 6 &2 and se#ect

position 1 in s*itch &3. The supp# a:ai#a-i#it is indicated - the -urning

of the red #amps.

2( hec$ up *hether a## initia# conditions are 4@ as under section III.

/,


87/99

3( hec$up *hether a## initia# conditions required to open ignitor oi# trip

:a#:e 'I4TV( are satisfied Press the +4TV open push -utton PB2 I4TV

so#enoid energises through contacts of >2 'M)> energi;ed(< >3

'Ignitor fan R4%( > ' compressed air pressure 4@(< PB1 'I4TV c#ose

PB(< PB2 'I4TV open

>, '+.4 pressure 4@( and >1 '## ITVs c#osed( and ho#es on through contacts

of >2< >3< >< PB1< >!(< >!4 'I4TV open( and >/ 'I4 pressure 4@( or

>1. The open condition of the :a#:es is indicated - the g#o*ing of the red

#amp +.

( fter opening I4TV< chec$ up *here a## initia# conditions required for starting

the ignitors are satisfied. Press ignitor pair 1 6 3 start push -utton 13 PB11 and 13T1 energise. Through contacts of

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Steam Generation Plant