GENERAL ASPECT OF BOILER

General Description

The steam generator is of radiant, reheat, natural circulation single drum, dry bottom and semi-outdoor type unit, designed for firing coal as the principal fuel and the HFO oil firing capacity is equivalent to 22.5% boiler MCR. 4 LDO burners are capable for 7.5% boiler MCR heat input. As per layout arrangement the mills are located between Boiler and ESPs. The complete furnace section is of fusion welded wall type, arranged as a gas and pressure tight envelope. The extended side wall section ( where re-heaters are located) is covered with water cooled fin welded walls. The superheater steam system has mainly three sections. The LTSH (arranged in the back pass of the Unit ), the radiant platen superheater ( arranged at the outlet section of the furnace) and the final superheater ( arranged after the reheater). Two number superheater desuperheaters are provided in between the LTSH section and the platen superheater ( in the connecting links ) for controlling superheated steam temperature over wide load range. The complete back pass of the boiler (up to the

economizer) has been covered with steam cooled superheater wall panels. The complete reheater has been arranged as one section and located in the horizontal pass of the boiler in between the radiant platen superheater and final superheater. Two number reheater desuperheaters are provided in the cold reheat steam piping at the inlet of the reheater for emergency control of the final reheat steam temperature. The maximum flue gas velocity in the pressure part system is limited to 10-12 m/sec. At 100% boiler MCR load. All the headers in the pressure part system are provided with necessary hand holes and hand hole plates arrangement. All headers are located outside the gas path, except for the economizer inlet and intermediate headers which are located in the low gas temperature section in 2nd pass. The complete pressure parts are suspended from the boiler structural

steel roof sections and arranged for free expansion downward.

Low Temperature Superheater The LTSH section is of the continuous loops, plain tubular, drainable, horizontal, in line spaced type, with steam flow upwards and gas flow downwards arrangement and located above the Economiser section, in the back section, in the back pass of the Boiler. This

convective spaced heating surface has 120 assemblies, 4 elements per assembly. The outlet section of LTSH alone is arranged vertically.

Radiant Platen Superheater The radiant platen superheater section is of the continuous loop, plain, tubular, nondrainable, vertical in line tangent tube type, arranged for parallel flow. The platen

superheater section assemblies are widely spaced, and located in the radiant zone at the furnace outlet section. The radian platen heating surface has 29 assemblies 7 elements per assembly.

Final ( Finish Pendant )- Superheater (FSH) Finish pendant superheater ( FSH ) section, is of spaced type continuous loop, plaint tubular, non-drainable, vertical in line spaced type, arranged for parallel flow. This FSH is located in the horizontal pass, after the reheater section. The convective final superheater has 119 assemblies 2 elements per assembly.

Reheater System The reheater section is a single stage, spaced type, continuous loop, plain tubular, non-drainable, and vertical in line spaced type, arranged for parallel flow. The reheater-Front pendant and Rear pendant section is located in the horizontal pass, in between the Radiant Platen superheater and final superheater section. This convective reheater section has 59

assemblies 6 elements per assembly. The approx. total convective heating surface is 2910 msq. The entire reheater section is suspended from the roof structural steel sections.

Super Heater De Super Heater For controlling the final superheat steam temperature at the rated value, two numbers of spray type de-super heaters are located in the steam connecting links between the LTSH outlet header and platen SH inlet header. This inter stage de-super heaters are of welded type. Spray tubes and liners are provided. For emergency control of the re-heater outlet temperature two numbers spray type desuper-heaters are provided. These are located in the cold reheat piping and used during any

abnormal emergency conditions for the steam temperature control. The de-super-heaters are of welded type, spray nozzles and liners are provided.

Economiser System The economizer, in two banks, is of the continuous loop plain tubular, drainable, horizontal, in line arrangement with water flow upwards and gas flow downwards. The economizer tubes are suspended from economizer intermediate headers, using ladder type supports. The heating surface is 5450 msq. An economizer re-circulation system is

provided, connecting the down comer ( near water wall lower ring header ) and economizer inlet pipe to ensure required flow through economizer tubes during starting conditions of the Boiler.

Steam Drum The steam drum is of the fusion welded construction, fabricated from carbon steel plates. At each end of the drum, a man hole of 406 mm dia is provided, arranged to open inwards. The drum is located on the upper front of the unit. The drum is equipped with

primary turbo separators, secondary corrugated scrubbers and screen dryers, to limit the solids carry over in the steam leaving the drum. All drum internals are of carbon steel construction. The turbo separators (along with the scrubbers ) and the screen driers are of

the removable type. The drum is suspended from boiler roof structures.

Down Comer Pipes Six (6) Nos. Down Comers are provided, connecting the lowest part of drum and water wall lower ring header.

Water Wall System

Furnace Width Furnace Depth Furnace Volume (Approx.) Furnace area effective projected

13,868 mm 10,592 mm 5200m3 2100m2

RISER PIPES:

From the upper outlet headers of the water wall system, the steam water mixture are taken to the steam drum through 118 numbers pipes called up risers.

WATER WALL/ FURNACE DESIGN PRESSURE The complete furnace walls, and the other steam cooled walls ( in second pass ), are strengthened by providing buck stays and tie bars system, to withstand furnace pressure/forces and avoid buckling.

SUPPORTS/SUSPENSION: The complete circulation system is suspended from boiler roof structures and is arranged for free expansion downwards.

FURNACE HOPPER: The furnace hopper outlet section is provided with an opening of approx. 1100mm depth, for the full width of the furnace. On each side wall, in the furnace hopper area, one water cooled access door ( oval in shape of size 406 x 457 mm ) is provided. These openings are provided for taking maintenance cradle parts/ scaffolding sections etc. inside the furnace during maintenance of the furnace.

SPECIAL FITTINGS & VALVES: Access doors, Feed Water valves, gauge glasses and safety valves etc. are included under this headings. The access doors are installed at:

FIRST PASS i) Right & left side ( one each ) at 8.5 mtr. one each on front & rear for access to s- enclosures . ii) Pent House : Right & left ( 5 Nos. each ) front side ( 2 Nos.)

SECOND PASS i) ii) iii) 27.6 Mtrs. 35.2 Mtrs. Right & left ( one each ) below Eco. -dobetween Eco upper / lower bank.

38.450 Mtrs. Right & left side ( one each)

iv)

43.400 Mtrs. Right & left ( one each )

Special type of feed water regulating valves and gate valves are installed to withstand the high pressure. There is provision of gauge glasses for Boiler Drum level indications.

SAFETY VALVES: i) Drum: Right side 1 no. spring loaded Left side 2 nos. spring loaded ii) iii) iv) v) Superheater: Super heater: Reheater inlet: Reheater outlet Right side 1 No. spring loaded Left side 1 no. Electromatic Right side 1 no. spring loaded Right side 2 nos. spring lead. Left side 1 no. spring loaded

MAJOR AUXILLIARIES

Following are the major auxiliaries of Boilers at GHTP:-

i. ii. iii.-

ID Fans FD Fans PA Fans

3 nos. including one standby 2 Nos. 2 Nos.

GENERAL ASPECT OF BOILER

iv.v.vi.-

Milling circuits Rotary Air heaters Electrostatic Precipitators

6 Nos. 2 Nos.

2 Nos.

vii.viii.-

Ash Handling Plant Fuel oil system etc.

BOILER PARAMETERS Sr. No. 1.SUPERHEATER OUTLET STEAM FLOW 690 T/Hr (MCR)

2.3.4.5.-

STEAM PRESSURE AT SH. OUTLET STEAM TEMPERATURE AT SH. OUTLET REHEATER OUTLET STEAM FLOW STEAM PRESSURE AT RH. INLET 6.STEAM PRESSURE AT RH. OUTLET

155 Kg/Cm(G) 540 C 597.5 T/Hr. 37.6 Kg/ Cm(G) 36.1 Kg/ Cm(G) 342 C 540 C 243 C

7.8.9.-

STEAM TEMPERATURE AT RH. INTLET STEAM TEMPERATURE AT RH. OUTLET FEED WATER TEMPERATURE ENTERING ECONOMISER

10.-

AMBIENT AIR TEMPERATURE

40 C

FILLING OF BOILER

The following portion of the Boiler has to be filled with water before the furnace is lighted-up:i.ii.iii.Water Wall portion of Boiler. Economiser. Boiler Drum up to ( 60 mm) level.

The initial filling of the Boiler is done by Boiler Fill Pump. Normal, filling is done from Boiler Feed Pump. The procedure for filling is shown in Figure No.8: Step by step operation for filling the Boiler system is as follows:i.ii.iii.iv.Clear Boiler for operation. Commission Drum gauge glass. Open all air vents of Boiler system. Line-up Boiler fill Pump and initial filling line. Also crack open the recirculation valve. v.vi.a. b. vii) Close valves on S.H. filling side and Deaerator Filling side. Close Drain valves of Boiler Blow Down Header: Economiser drain valve. Valves on drain line of water walls. Start Boiler fill pump and now initial filling is in progress. Close filling valves of water walls when water appears in Drum. Further, filling be done

through Economiser filling until the level reaches ( 60 mm). Then stop filling. Feed Regulating Station The location of this station is at firing floor and feed water supply to the Boiler is regulated through this station. During initial period of starting the unit, feed is regulated through 30% line because the requirement of water is small during this period. Later on during normal operation, either of the 100% line on left or right is charged. Other is standby. All the valves (isolating & regulating) are opera table from UCB. Before taking the above

lines into service the whole piping has to be thoroughly vented to avoid possibility of air lock in the boiler system. .

SOOT BLOWERS: Soot blowers have been provided for cleaning & soot blowing the water walls, superheater & Reheater tubes for efficient heat transfer in both radiation & convection zones. Details of different type of soot blowers is as follows:-

Sr.No.

Description WB

Type of soot blowers IE LRD IE LRD IE

1.2.3.4.-

Blower Number Travel Nozzle size in MM Steam consumption per pressure in Kg/cm

1 to56 305 26

65R&66L 7200 25

67 R to 82 L 7200 25

11

10

v.- Platen Superheater & Final Superheater

Chrome Molly, austenitic stainless steel ( T-22 and T-91 )

Filling Capacity Boiler Drum Economiser Water wall Super heaters Reheater Water required for normal light up For Hydrostatic test - 35 Ton - 25 Ton - 130 Ton - 95 Ton - 50 Ton - 190 Ton - 335 Ton

BOILER AIR AND GAS SCHEME

Air is required in Boiler mainly for the following purposes at GHTP unit:-

1. -

For combustion of fuel in the furnace, called Secondary Air.

2. -

For drying and transportation of pulverised coal to the furnace from the mill, called Primary Air.

COMBUSTION SECONDARY AIR

The secondary air is supplied by two forced Draft Fans. The rating of FD fans is given below:Suppliers Data Forced Draft Fan Continuous Two per Boiler Atmospheric Air Horizontal delivery and vertical suction.

Sr.No. 1.2.3.4.5.-

Particulars Equipment Type of operation No. of fans Medium handled Fan Orientation

6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22.23.-

Location Type of FAN Capacity Total head developed Temp. of medium Fan Speed Motor Rating Motor Type Fan Bearings lubrication Motor bearing Lub. Fan Regulation Fan Weight Sp. Wt. Medium Fan Desgn. NLC Amp SC % FLC For Reserve Flow% Pr.%

Ground Floor Axial type 110.0 m/sec. 520 mmwc 50C 1480 RPM 750 KW 6.6 KV, 1480 RPM,80AMP SQ, CAGE Induction Forced oil Lub. Grease. Variable pitch fan 8570 Kg. 1.044 Kg/ m AP-1 18/22

22.6 Amp 550 Amps 43 49

The secondary air for combustion is preheated up to 329C by means of regenerative air-heaters ( Rotary Air Heaters). The FD 0/L Duct & air heater air out ducts are

interconnected to provide a balanced air flow to the furnace and to make it possible to operate the unit at reduced load if one fan is out of service. Distribution of secondary air to the Wind Box compartments is controlled by the secondary air dampers. The steam coil air preheaters (SCAPH), one each at the outlet of F.D. Fans & before RAH have been provided to avoid the corrosion of RAH by increasing the temperature of secondary air entering the RAH when the Boiler is initially lighted-up. The secondary air path is shown in Fig. No.-12.

CONVEYING AND DRYING OF PULVERISED COAL

The air used to dry and transport the pulverized coal is referred to as primary air. Two primary air fans suck air from atmosphere & supply the same to the pulverizers. The specifications of PA fans are given below:-

Sr.No.

Particulars

Suppliers Data

1.2.3.4.5.6.-

Equipment Type of operation No. of fans Medium handled Location Orientation

PA Fan Continuous Two per Boiler Atmospheric Air Ground Floor Vertical suction Bottom horizontal delivery

7.8.9.10.11.-

Fan Capacity Total head developed Fan speed Temp. of medium Motor rating

70 m/sec. 1220 mmwc 1480 RPM 50C 1250 KW 6.6 KV 1480 RPM

12.13.14.15.16.17.18.19.-

Fan bearing lub. Motor bearing lub. Type of fan regulation Fan wt. NLC FLC SC% Perm. Temp Rise above amp. Temp. of

Forced oil lub. Grease Inlet Damper control 18.9 T 43 Amps 131.1 Amps. 600 70C 50C 84.7% 51.5%

20.-

Fan Reserve Flow Pressure

21.

Brg. Vib. Velocity

Alarm .Trip

6.3 mm/sec 12.6 mm/sec

To ensure proper drying in the pulverizers, both hot and cold air must be available. Therefore, a portion of the air from the primary air fns passes through the air pre-heater. The

primary air fan inlet vanes modulate to maintain a predetermined pressure in the hot air duct, cold air duct and hot air duct for both the fans are inter connected for balanced air flow.

The air flow and mill outlet temp. can be controlled by simultaneous operation of hot and cold air dampers.

If a primary air fan is not available for service, it must be isolated from the system by closing its control and outlet shut-off, gates. The Primary Air Path has been shown in Fig. No.-13.

AIR FLOW DISTRIBUTION

The function of the wind box compartment dampers is to proportion the amount of secondary air admitted to an elevation of fuel compartments in relation to that admitted to adjacent elevation of auxiliary air compartments.

Windbox compartment damper positioning affects the air distribution as follows:-

Opening-up the fuel air dampers or closing down the auxiliary air dampers increases the air flow around the fuel nozzle. Closing down the fuel air dampers and opening the auxiliary air dampers decreases the air flow directly around the fuel stream.

Proper distribution of secondary air is important for:-

i.-

Furnace stability when lighting up individual fuel nozzles.

ii.-

When firing at low rates.

iii.-

For achieving optimum combustion conditions in the furnace at all loads.

The correct proportioning between fuel compartments and aux. air compartments depends primarily on the burning characteristics of the fuel. It influences the degree of mixing, the rapidity of combustion and the flame pattern within the furnace.

The wind box compartment dampers are operated by the secondary air damper control system in conjunction with the furnace safeguard supervisory system. When on Automatic control the system provides modulation of the auxiliary air dampers as required to maintain a pre-set wind box to furnace differential pressure. The fuel air dampers are closed prior to and during light-up. When the fuel elevation is proven in service the associated fuel air dampers are opened and positioned in proportion to the elevation firing rate/ mill loading.

COMBUSTION AIR DISTRIBUTION

Of the total combustion air, a portion is supplied by primary air fans that goes to coal mill for drying and pulverizing the coal and carrying it to the coal nozzles. This primary air quantity is decided by the coal mill load and the number of coal mills in service. The primary air flow rate is controlled at the air inlet to the individual mills by dampers.

The balance of the combustion air referred to as secondary air is provided by FD fans. A portion of secondary air (normally 30% to 40% ) called Fuel Air is admitted immediately around the coal fuel nozzles (annular space around the casting insert) into the furnace. The rest of the secondary air called Auxiliary Air is

admitted through the auxiliary air nozzles and end air nozzles.

The quantity of secondary air (Fuel air + auxiliary air) is dictated by boiler load controlled by FD fan vane regulation.

and

The proportioning of air flow between the various coal fuel nozzle and auxiliary air nozzles is done based on boiler load, individual burner load, and the coal, oil burners in service by a series of air dampers. Each of the coal fuel nozzles, auxiliary air nozzles and end air nozzles is provided with a louver type regulating dampers at the air entry to individual nozzle or compartment. At GHTP units with 6 mills there are 6 fuel air dampers, 5 auxiliary air dampers and 2 end air dampers per corner.

Each damper is driven by an air cylinder positioner set, which receives signal from secondary air control system (SADC). The dampers regulate on elevation basis in unison, at all corners.

GAS FLOW

Flue gases travel upward in the furnace and downward through the rear gas pass to the economizer and air heaters. In the economizer, the some heat of flue gases is utilized to heat the feed water before it goes to drum. Further in the air heaters, the residual heat of the flue gases is utilized to pre-heat the secondary and primary air. From the air heaters, the gases pass through the electrostatic precipitators and induced draft fans to the stack. Interconnections of the gas ducts at inlet and outlet of electrostatic precipitators are provided.

CHAPTER 6

ROTARY AIR PRE-HEATER SYSTEM

INTRODUCTION:The air preheater used here is of Ljungstrom regenerative type. It absorbs waste heat from flue gas and transfers this heat to incoming cold air by means of continuously rotating heat transfer elements of specially formed metal sheets. The air heater is an essential boiler auxiliary because hot air is necessary for rapid and efficient combustion (secondary air) in the furnace and for drying coal (primary air) in the milling plant. It helps to recover waste heat from the flue gas to increase boiler efficiency.

Thousands of specially formed metal sheet elements are spaced and compactly arranged within 12 sector shaped compartments of a radially divided cylindrical shell called the Rotor.

DIAPHRAGM Brg

SHELL

SECTOR

ROTOR TOP/BOTTOM VIEW

The housing surrounding the rotor is provided with duct connections at both the ends, and is adequately sealed by radial, axial and bypass sealing members forming an air passage (primary and secondary air) through one half of the preheaters and a gas passage (flue gas) through the other.

As the rotor slowly rotates the mass of the elements alternately through the air and gas passages, heat is absorbed by the heating element surfaces passing through the hot gas stream; then, as the same surfaces are carried through the air stream (secondary and primary air), they release the stored up heat energy thus increasing the temperature of the incoming combustion and primary air.

The heating element is a compact arrangement of formed metal sheets contained in the rotor in three layers (Hot end, Hot intermediate and cold end). The sheets are of double undulated type designed to give the maximum turbulence and heat transfer as well as giving the individual plate a self spacing characteristic.

These elements are compactly packed in the form of baskets and arranged as below: in each if the 12 sectors:

COLD END

GENERAL SPECIFICATIONS:

Heater size/type : 27VIMT 1850 (2000) Heating elements height

Hot End Hot Intermediate Cold End

: : :

500mm 1050mm 300mm

ROTOR BEARINGS:

The complete rotor is supported by a thrust bearing (support bearing). The load is transmitted to the thrust bearing by a trunnion bolted to the lower end of the rotor post or by an extension to the rotor post. To guide the upper end of the rotor, a guide trunnion is bolted to the face of the rotor post. The position of this trunnion is maintained by a radial guide bearing assembly. Both the support and guide bearings are lubricated with an oil bath.

OIL CIRCULATION SYSTEM:

The Oil circulation system is designed to supply the bearing with a bath of continuously cleaned oil at proper viscosity. To accomplish this, the bearing oil is circulated by means of a ROTARY AIR PRE-HEATER SYSTEM

motor driven pump through an external filtering system. The system (one main and one standby) components are a pump, motor, relief v/v, thermometer, pressure gauge, cooler, filter and flow meter(common). A thermostat is used to limit the operation of the system to temperature which will not overload the pump or motor as a result of high oil viscosities. The thermostat is set to start the lub oil pump at 35C for support bearings and 40C for guide bearing. Similarly the pump should stop when temperature drops to 30C for support bearing and 35C for guide bearing. The alarm set points for RTDs of both support and guide bearingsis 70C. Operating temperatures exceeding 80C are not recommended. The fouling of the filter progresses thereby requiring cleaning or replacement of filter cartridge.

ROTOR DRIVE UNIT:

The driving force for turning the rotor is applied at its periphery. A pin rack mounted on the rotor shell is engaged by a pinion attached

to the low speed shaft of a power driven (AC motor) speed reduce. The motor and speed reducer are coupled together through a high speed fluid coupling. The speed reducer is also provided with an auxiliary drive which ensures the continued operation of the preheater even if power to the electric motor is interrupted. Air motor is used for the auxiliary drive. Oil level in the speed reducer and the air line lubricator of air motor is to be checked at every shift along with guide/support bearing housing oil levels. Run air motor for two minutes daily to keep it fit for operation.

ROTOR SEALS:

Seals are provided at both ends of the APH to minimize leakage between the air side and the gas side. The hot end and cold end radial seals are attached to each diaphragm (sector dividing plate) of the rotor and are set at a specified clearance from the sector plates which separate the gas and air steams. Similarly axial seals are attached to each diaphragm extension of the rotor in the axial plane and are set at a specified clearance from the axial seal plates separating the gas and air streams. The circumferential /bypass seals provide sealing between the periphery of the rotor and the connecting plate/housing.

TWIN NOZZLE CLEANING DEVICE (SOOT BLOWER):

Cleaning device is provided at the cold end and hot end on gas side to remove soot deposits on the heating elements. The hot end elements generally remain clean due to erosive action of the fly ash and do not need cleaning during coal firing. However, the same is required to be operated during oil firing at least once in 4 hours. The cold end soot blower is operated at least once daily or more, if need arises, depending on DP across APH. The cleaning device consists of an electric motor coupled to a gear driven crank mechanism which oscillates the swivel header carrying the nozzle pipe. medium (steam from SB header or PRDS) is conveyed through the swivel header and respective nozzle pipe to the nozzle at the end. A rotary joint in the supply line permits free motion of the swivel header while connected to the source of steam supply. The arc traversed by the nozzle and the rotation of the rotor subjects the entire area of the rotor to the action of the cleaning jet. Special care should be taken to see that the heating elements remain free from deposit build up, particularly during start up periods. During operation of heaters, the condition of The cleaning

coal end heating elements can be observed through a glass faced observation post provided in secondary air duct below APH. A vapour proof light to illuminate the inside of duct is also mounted near the port. The recommended steam pressure is 14 Kg/cm2 at 150C super heat (>+250C) but never above 17 kg/cm2. Before admitting steam to the cleaning device nozzle, drain the supply lines thoroughly to assure complete removal of wet steam and condensate from lines ahead of the cleaning device. ROTARY AIR PRE-HEATER SYSTEM

WATER WASHING OF AIR HEATER:

Most deposit accumulations forming on the air preheater heat transfer surface are highly soluble in water and therefore are easily removed by washing provided a sufficient quantity of water is used. Washing devices are located at both the hot end cold ends of the air preheaters and they should be operated simultaneously to provide effective removal of the deposit.

Frequency of washing is an unpredictable factor, depending upon such variables as the quality of the fuel burnt, nature and amount of deposit, boiler operating conditions, dryness of soot blowing medium, etc. If a regular soot blowing schedule using a dry cleaning medium is followed, it is ordinarily not necessary to wash the air preheater except during regular outages.Two no wash pumps are installed out of which one remain standby, for water washing for both units.

AIR PREHEATER FIRES:

A fire may occur during cold start up on oil or start-up following hot stand-by because of poor combustion of the fuel oil. The improper Combustion results in unburnt or partially burnt oil condensing and depositing on the air preheater element surface. As the temperature entering the APH increases, this deposit is baked to a hard varnish-like material which can ignite as temperature increases to 315-370C range. The ignition usually starts in a small area and most of the heat generated is absorbed by the metal heat transfer element nearby due to which the actual temperature build up during this period is relatively slow. If detected at this stage, it can be easily controlled. If this deposit remains undetected it will continue to

generate heat until the metal heat transfer element reaches 730 to 765C, at which point, metal may ignite with temperature reaching 1650C and higher in a matter of minutes. Metal fires are self-sustaining and would require more water than is normally available to drop the temperature to a reasonable level.

PROTECTIONS / INTER LOCKS:

Before taking RAPHs in service the following protections should be checked and cleared: 1) 2) 3) 4) 5) Auto starting of air motor on tripping of AC motor. Auto stopping of air motor on starting of AC motor. Appearance of rotor stoppage alarm. Auto opening/closing of dampers of APH. Lube oil pump start/stop or Guide Bearing (40C/35C) and support bearing (35C/30C).

COAL PULVERISING SYSTEM

At GHTP, Bowl Mills have been installed for pulverizing the raw coal. Coal of maximum size of 25mm is received in Raw Coal Bunkers from Coal Handling Plant. From the Bunker, this coal is fed into the mill through Raw Coal Feeder. The feed to the coal mill can be controlled by regulating the speed of the Feeder.

Type of Pulvriser:

BOWL MILL XRP-803, coal pulverizing capacity 36.9 T/HR Motor340 KW 6.6KV

Broadly the Bowl Mill can be divided into four parts:-

1.

Mill Base:

This is the lowest position of the mill and it contains mill drive system i.e. worm shaft, worm gear, vertical shaft, oil cooler as main parts. The gear Housing is always filled with lubrication oil before the pulverizer is put into operation. Level of the oil can be checked from the oil level gauge provided on the mill base. Correct level is indicated only while the mill is idle. For cooling the oil while mill is in operation, Tube type water coolers have been installed in the Gear Housing.

1.

Mill Side

This portion is just above the mill base and it contains mill side liners, Scrapper assembly and Tramp iron spout discharge arrangement & vane wheel assembly. Heated primary air enters the mill side housing below the Bowl. Any tramp iron, stone etc. drop in this portion and are scrapped to the Tramp iron discharge spout for emptying in the Mill Reject Belt.

2.

Separator Body Assembly

This portion is just above the mill side housing and this is the portion where coal is pulverized. Main parts of this assembly are Bowl, Journal assembly, Grinding Roll Assembly, Bull ring segments, liners, Inner cone, classifier assembly, Separator body liner assembly and center feed pipe. The Grinding Rolls do not rotate if the mill is empty. When the raw coal from center feed pipe comes in between the Grinding Rolls and revolving bowl, it causes the rolls to turn and thus, the coal gets pulverized.

The roller journals are lubricated by means of a self contained circulating system. Seal air is supplied to roller journal shaft to prevent coal dust from entering the roller journal bearings.

3.

Mill Outlet Assembly

This portion contains classifier venturi and deflector regulator. Mill discharge valve assembly is connected at the top of this portion from where the pulverized coal is sent to each of four coal nozzles at one elevation. Raw coal feeder

Transport coal from RC Bunker to coal mill by belt conveyor having drive motor connected with dynadrive to control the coal feed. RC Bunker- 6 nos. one for each RC feeder, fabricated from sheet metal having capacity of 650 Tones approx have been provided.

Operation The coal is fed through center feed pipe into the revolving Bowl where it travels towards outer perimeter of Bowl due to centrifugal force. Thus, the coal comes below the roller

and gets pulverized. Hot air entering the mill side housing below the bowl passes upward around the Bowl. It picks up the pulverized coal and passes through deflector openings at the top of inner cone and goes out through the venturi to mill outlet part assembly. The deflector blades impart a spinning action to coal air mixture and thus, any oversize coal is sent back to the Bowl through the inner cone for additional grinding.

Any tramp iron or other foreign material which is difficult to grind drops out through the air stream to the lower part of the mill side housing where it is swept to the tramp iron spout by the two scrappers attached to the bowl mill skirt.

Operating Parameters:

i)

Air flow and Mill outlet Temperature Hot air is supplied to the mill by primary air fan which is heated in the Air

preheaters. The temperature of the air entering the mills can be controlled by mixing cold air from cold primary air duct. a. b. c. The designed air flow per mill is 53.89 tons/hr. Recommended mill outlet temperature is 85C Lower air flow and mill outlet temperature below 60C to 80C may not dry the coal sufficiently and may cause choking. d. Outlet temperature must not exceed 95C in any case as the high temperature may lead to mill fires. The air flow and mill outlet temperature can be controlled by simultaneous operation of hot and cold air dampers. PA flow (T/hr) to individual mill is kept at 9-10 more than mill current in amps. to achieve best results.

Pulverized Fuel Fineness:

Fineness of coal is measured as the percentage of the coal that will pass through a test sieve, if 70% of coal passes through 200 mesh sieve then it has the desired fineness. The fineness can be controlled by operating the classifier vanes. It must be remembered that operating the mills at higher fineness increases the wear rate and reduces the capacity of the mill. PA flow to mill is also a key factor for controlling fineness. Higher flow tends to pick up large particles and there by reduce fineness

Mill Capacity Designed mill capacity is 36.9 tone /hr. But it depends on the hard groove grindability index, the moisture content of coal and fineness requirement of pulverized coal.

Normal start-up ( No coal in Mill ) Start Permissive At the respective pulverizer, following conditions are to be satisfied. Each condition is indicated by white light on FSSS console. a.b.c.d.e.f.g.h.i.Pulverizer discharge valve open Pulverizer discharge temperature less than 95C Cold air valve open Seal air valve opens after mill starts. Seal air to Bowl D.P.O.K. Tramp iron hopper valve open. Feeder inlet gate open No primary air trip Pulverizer Feeder start permit.

When all the above- conditions are satisfied for the respective pulverizer, its associated (white) PULVERIZER READY light comes ON.

Pulverizer Start

By establishing ignition energy available, seal air header to pulverizer bowl differential pressure OK and pulverizer ready conditions for the respective pulverizer, it may be placed in service as follows:i.ii.Start pulverizer by depressing its associated ON push button. When the pulverizer is proven on as indicated by the red pulverizer ON light coming on, open the hot air gate by depressing its OPEN push button and allow the pulverizer to come-up to the temp by opening hot air damper iii.If the volatile contents are below 30% in the coal, the mill outlet temperature is to be controlled at 75 to 80C. It the coal volatile material is higher, then the temperature should be kept at 65 to 75C. If the sulphur contents are high, the temperature should be kept at 65C. After observing this feeder ON-pushbutton should be depressed. Coal flow must be proven either by the coal flow detector or satisfactory pulverizer current within 5 secs. after the feeder is started. When a minimum of two feeders are established at greater than 50% loading, the associated elevation of oil guns may be shut-down provided the feeder has been on for a minimum of 3 minutes.

Pulverizer in Service

The following conditions will initiate a pulverizer trip command. a) b) c) Pulverizer discharge valve not open. Loss of unit DC power for more than 2 secs. Pulverizer ignition permit is not satisfied, i.e. support ignition is required and less than 3 of the 4 associated oil guns in service or loss of elevation AC power ( for more than 2 secs.). d) e) f) Boiler trip Primary air trip Seal air header to pulverizer differential pressure low <125 mmwc for more than 2 secs.

When the hot primary header pressure falls below the low set point 600mmwcl (for more than 10 seconds) upper tier mills E&F receive stop command.

When both PA fans stop or the hot primary header pressure goes very low, all the pulverizers are tripped simultaneously.

When both PA fans or one FD fan trips and four or more pulverizers are in service, trip command will be given starting from the pulverizer service top most coal elevation until the number of pulverizers remaining in service is reduced to three.

Pulverizer shut-down

Shut-down of a pulverizer is accomplished as follows:i. ii. iii. Start the associated oil elevation if it is not in service. Reduce the feeder speed to minimum Close the hot air gate by depressing its CLOSE push button.

iv.

When the pulverizer outlet temperature is reduced to approximately 50C shutdown the feeder by depressing its OFF push button.

v.

Allow the pulverizer to run for about 2 minutes to ensure that it is completely empty of coal, then shut-down the pulverizer by depressing its OFF push button.

FUEL OIL FIRING SYSTEM

INTRODUCTION

A coal-fired unit incorporates oil burners to a firing capacity of 22% of boiler load for the following reasons: a) To provide necessary ignition energy to light off coal burner.

b) c)

To stabilize the coal flame at low boiler/burner loads. As a safe start-up fuel and for controlled heat input during light-off.

Two types of fuel oils are used, LFO and HFO. Normally LFO is used for firing at AB elevation only (4 Nos. oil guns) in a cold furnace. However, HFO is also recommended as a start-up fuel in a cold boiler if steam is available for following services: a) b) c) For atomizing the HFO at the oil gun. For tank heating, main heating (oil pre-heater) and heat tracing of HFO lines. To preheat the combustion air at the steam coil air preheater (SCAPH) and to warm up the main air heater (this reduces sulpher oxide condensation in cold end). With the above provisions and with proper oil, steam and combustion air parameters at the burner, HFO can also be safely fired in a cold furnace. HFO firing can be done at all the three elevations i.e. AB, CD & EF (12 Nos. oil guns).

FUEL OIL STORAGE:

The fuel oil is stored in cylindrical tanks having the following capacities:

OIL STORAGE TANK CAPACITIES:

Sr.No. Description 1. 2. 3. KL/M 4. 5. Capacity (Approx.) Height of suction pipe from bottom of tank(Centre of suction pipe. 6. Dead Stock (Approx.) Height Internal Diameter Multiplying factor

HFO Tank # I 17.5 M 22.0 M 380.1 KL/M

HFO Tank # II 17.5 M .22.0 M 380.1 KL/M

LDO Tank 17.5 M 12.5 M 122.8

6000 KL 0.35 M

6000 KL 0.35 M

2000 KL 0.45 M

2566 KL (0.7 M)

266 KL (0.7 M)

86 KL (0.7 M)

OIL SPECIFICATIONS HFO/HPS: 1. Density : 880-960 Kg/m3 at 15C

2.

Kimatic viscosity

: 50 Cst Max. at 100C 500 Cst Max. at 50C : 72C Max. : 93C Min. : 4.50% max. by mass : 9500 K Cal/Kg. : 1.00% Max. by volume

3. 4. 5. 6. 7.

Pour point Flash point Sulphur content Gross calorific value Water

Both the HFO tanks are provided with steam coils for oil heating.

BOILER FRONT ARRANGEMENT/EQUIPMENT:

The main trip valves (HOTV/LOTV/HORTV), flow /pressure control valves (LOFCV, HOFCV&ASPRV), HFO discharge strainers, flow meters and required instruments are arranged at the main operating floor. The burner trip valve stations (comprising HONV, LONV etc.) are located nearer to individual burners at respective floors.

After the operating floor fittings the piping of each fluid medium (LFO, HFO, Atomizing steam and atomizing air) goes below the main operating floor, branches into two legs and forms a "U" shape distribution header to reach all the four corners of the furnace. At each corner, riser pipes are branched off, from where tappings for each oil burner are taken at different levels.

For HFO alone, the corner risers take a "U" turn above the topmost burner level and come down (called "down-pipes") to form the HFO return header below the operating floor. The HFO down pipes at each corner run close to the individual burner fittings of different elevations and burner tappings are taken from these down pipes.

The burner fittings are arranged close to the respective burners. The piping between the oil gun and the burner trip valves and the piping between the burner valves and the corner down pipes are limited to the barest minimum considering the following:-

a) b) c) d) e)

Minimum cold oil legs. Minimum header pressure dips while cutting in oil burner. Oil reaching the gun in the shortest time. Minimum condensate legs.

The oil lines are provided with vent valves at the top of corner riser for air removal during initial charging. The oil header layout is such that all pipings slope downs towards a common point where drain valves are provided. In the steam lines, steam traps are provided to remove condensate to have dry steam for atomization.

Atomization steam lines are lagged with HFO lines for tracing purposes, from the point where the HFO line from heater set enters the operating floor of boiler including all the lines in between like U-header, discharge strainers, riser pipes, down pipes, HFO line instrument tappings and burner fittings upto the point where the return line leaves the operating floor for the storage tanks. The portion of HFO supply line between HFO heater set and operating floor, and the HFO return line between the operating floor and the storage tanks is electrically heat traced.

The simplex basket type steam jacketed discharge strainers are at the heater outlet located on operating floor provided with fine mesh of 250 microns filtration. The fine filtering prevents choking of lines, valves and burner atomizers and reduces the burner tip wearing rate. When the pressure drop across the strainer exceeds about 0.5 Kg/cm2

(corresponding to 50%-clogged status), the standby strainer is put into service and it is taken for cleaning.

LOTV (Light Oil Trip Valve) and HOTV (Heavy Oil Trip Valve) can be opened after furnace purge and with adequate pump discharge header pressure which in case of HOTV is 10 Kg./cm2 and for LOTV 8 Kg./cm2. HOTV will close at header pressure < 3.5 Kg./cm2 and LOTV at 2.1 Kg./cm2.

The oil burner loading can be varied by varying the oil pressure cum flow control valves LOFCV as LO23 (for LFO) and HOFCV as HO33 (for HFO) opening remote manually. This maintains a constant down stream pressure irrespective of the number of oil burners in service. The pressure controller is available on CRT with a set point variator. When additional oil burners are introduced or a few burners removed from service, this pressure set point need not be disturbed and the pressure control loop adjusts the flow control valve opening suitably.

To control the atomizing medium (air or steam) and fuel (LFO or HFO) flow to the oil guns, electro-pneumatically actuated valves called nozzles valves (LONV, HONV, etc.) are used. Valve closing is instantaneous whereas the opening is slow. This assures instantaneous closing of fuel to the burners on tripping and flow opening will assure a reduced pressure dip of fuel oil and atomizing medium during opening.

HEA ((High Energy Aux.) Igniters which can directly ignite either LFO or HFO with the help of disuate sparks providing a large burst of ignition energy. These are of retractable type but still use service air connections for cooling the igniter tips. The retract mechanism is electro-pneumatically operated.