PROJECT : JSL DUBRI UNIT-1

PROBLEM : UNIT-1 STABLE OPERATION COULD NOT BE

ACHIEVED DUE TO DIFFICULTIES FACED IN
THE FOLLOWING AREAS.


- AIR FLOW CONTROL COULD NOT BE PUT ON AUTO - WIND BOX
TO FURNACE DP WAS LOW
- DIFFICULTY IN PARALLELING OF PA FANS
- DEAERATOR LEVEL CONTROL COULD NOT BE PUT ON AUTO
- MILL OUTLET TEMPERATURE AND FLOW CONTROL
- SUPERHEATER AND REHEATER TEMPERATURE CONTROL

AIR FLOW CONTROL
MILL AIR FLOWS:
It was observed that the unit was running at 115 MW with 5%
oxygen level instead of 3.5 %. Total secondary air flow
maintained was much less. Due to low secondary air flow, the
wind box DP maintained was also lower. Also the O2 calibration
was to be done with standard gas.
Mill air flows were suspected to be high, as the hot air
dampers were almost in full open condition. Hence all the mill
air flows were to be checked for correctness of measurement.




Recalibration of air flow transmitters of all Mills :
While recalibration of flow transmitters, it was observed that the
mill air flows were far exceeding the transmitter range. It was
verified with actual manometer measurement, which indicated 100
mm WCL against the range of 80 mmWCL. All the
transmitters were recalibrated to 100 mmWCL and the
corresponding corrections were incorporated in MAX control. The
air flow curve was also extrapolated to a range of 0 to 100 mm WCL.
After completing this exercise, the mill air flows maintained
were observed to be far in excess and was at 70 TPH. Any reduction
in mill air flow was also drastically reducing mill outlet temperature.
Higher fuel flow in feeders suspected, which are to be attended by
site one by one.

SECONDARY AIRFLOWS :
Due to higher flow of primary air going through the mills,
the secondary air flow requirement was lower. In addition, it was
observed that the blade pitch positions indicated at control room
for both FD FANS were around 5-10 % only. On physical inspection, it
was observed that the blade pitch positions had slipped from original
setting.

Both FD FANs blade pitches were attended without stopping the unit
or load reduction, one at a time. After rectification, the blade
pitch positions have improved and air flow control could be put on
auto. Presently both fans are running at 30% blade pitch on auto.


02 analyzer was calibrated with standard oxygen cylinder and air
flow control was put on auto.

WIND BOX TO FURNACE DP LOW
The lower wind box DP was due to the less flow of secondary
air because of more primary air flow through mills. Also discrepancies
were observed in the physical position of SADC dampers. The
same were corrected and recalibrated. After recalibration of mill air
flow, oxygen analyser and correction of SADC dampers, wind
box to furnace differential pressure was put on auto and it was
maintaining at 100 mmWCL.
PARALLEL OPERATION OF PA FANS : Step 1 :
PA fans were taken out of service, one at a time and blade pitch &
control slide travel were checked by adjusting the stoppers.

Step 2 :

Stroking time of servomotor of blade pitch was checked for each
fan and was found to be equal ( 17 seconds each).

Step 3 :

The stroking time of both the fans was adjusted to 26 seconds
each with blade pitch power cylinder.








Step 4 :

The approximate paralleling point identified from fan curve was at 30
% of blade opening ( around 200 Tons of PA flow ) for the running
flow conditions and system resistance. The second fan was started
and the load on first fan was reduced to maintain PA header pressure
less than the trough point on the curve (fan curve). The second fan
blade pitch was increased to 30 %.

As the running fan blade pitch position was slightly decreased, both
the PA fans got paralleled. This operation was taken up with two
mills in service and third mill on no load, to maintain total primary
air flow of 200 TPH. After paralleling, PA header pressure was put
on auto and tuned to the requirement. While tuning, the speed of
response of blade pitch matters and shall be equal. This was taken
care by steps 1 & 2. Once paralleled, the operating point was
taken further to the right on the curve by increasing the air flow
for the same header pressure.

During the first paralleling operation, as the blade pitch
paralleling point and responses need to be studied, it was done
manually and then put on auto operation. It was paralleled at 585-610
mmWCL of hot air header pressure.

After paralleling, it is imperative that the operating point shall
be taken further right on the curve to avoid de - paralleling and
before putting PA header pressure on auto operation






Points to be noted:

In the initial trial, there can be a reduction in mill air flows
followed by increase after paralleling, which may create fluctuations
in furnace draft. Hence auto loops such as furnace draft, mill
air flow and temperature controls shall be commissioned to make
paralleling of PA FANS much simpler.

Suggestions :

To eliminate this problem, anti stall ring installation can be
considered.

Leakage air in air heaters Vs PA header pressure curve by
BHEL/Ranipet will help in identifying clearly the operating point of
both PA fans.

DEAERATOR LEVEL CONTROL:

In the indirect method, the controller sees and assigns higher order
of priority to hot well level. Whenever the deaerator level falls, the
hot well make up will be increased and as the level builds up more in
hot well, more flow will be allowed to Feed Storage Tank ( FST )
of deaerator. Since the capacity of FST is large in relation to hot
well, this will reduce the emergencies and result in a stable
control. Deaerator level control was put on auto and tuned.









SUPER HEATER AND REHEATER TEMPERATURE CONTROL

The logic blocks built in super heater and reheater level controls had
certain deficiencies. For example, the DESH outlet temperature
set point (variable) as decided by the output of the PID of
final temperature controller was not functional because of missing
links between the feed forward blocks provided from fuel control,
steam flow control, drum pressure. A similar problem was also
noticed in reheater temperature controls.
The above problems were resolved by suitably inserting the missing
links of the logic blocks and temperature controls put on auto and
tuned.


After the above correction and changes, the boiler follow up mode was
tuned and put on auto for a short duration.

The machine was taken to rated load and 72 hours of trial operation
was completed.