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PROJECT : PROBLEM :

JSL DUBRI

UNIT-1

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 or load reduction, one at a time. After pitch positions have improved and air flow auto. Presently both fans are running at 30% without stopping the unit rectification, the blade control could be put on 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 each with blade pitch power cylinder. was adjusted to 26 seconds

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 considered. Leakage air in this problem, anti stall ring installation can be

air heaters Vs PA header pressure curve by operating point of

BHEL/Ranipet will help in identifying clearly the 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 was completed. and 72 hours of trial operation