14 1.2 1.3 BIO-GAS FIRING SYSTEM GENERAL The operating instructions contain only the principal instructions required for attending the equipment delivered and they cannot comprise all the details of operation. The absence of a detailed instruction cannot therefore be the basis of a claim that the supplier can be held responsible for damage which could have been prevented by including the said instruction in the operating instructions. The operating instructions can be supplemented or corrected in the course of the trial and guarantee periods. When operating the equipment, the attendent must also respect the relevant instruction authorities and all safety regulations. Further it is necessary to adhere to the operating instructions for the equipment delivered by our sub-contractors ‘Some conditions of equipment operation a) Before starting operation, a valid diagram, layout, and operating instructions of all the equipment must be available. b)_ The operating personnel should be acquainted in detail with the equipment as well as with the layout of the different parts of the equipment before operation is started. ©) Every time operation is to be started, the shift foreman must inspect all the equipment. d) During operation, the personnel is responsible for due attendance to and control of the equipment, particularly for checking the overflows from the safety valves and drain valves. e) All the valves and control elements must be opened and closed slowly without any excessive force. f) The environment of the equipment must be kept clean. 9) Small defects ascertained during operation must be removed in as short a time as possible. h) During the guarantee period, it is necessary to operate the equipment strictly in adherence to the instructions of the suppliers, General Operating Instructions For reliable operation of the equipment, it is necessary that the fuel stipulated in the contract should be available. It is necessary that the equipment should be operated according to these instructions and the instructions of the sub-contractor. The equipment must be duly attended to and it shall not be over loaded. The user will take no action except for service operations without a written approval of the supplier. In the course of trial operation, the user will record the measurements and observations, made during operation. It is necessary to observe all the safety regulation and keep the premises clean, removing all defects they may occur without delay. 0488, 0457 1 Bharat Heavy Elects-ais LimitedHi BIO-GAS FIRING SYSTEM 1.4 Checking, Cleaning and Repairs of the equipment The equipment of the fuel gas system must be inspected and cleaned regularly. The test results must be kept on record in writing and defects discovered must be removed immediately. The checking, cleaning and repairs of the equipment may be carried out only by experienced, reliable persons physically fit and well acquainted with the danger which inflammable matter may engender. While working they must be under the supervisor of a well experienced worker with a special technical and security training. Before inspection, cleaning or repairing, the equipment must be emptied and the residue of fuel and inflammable gases must be suitably removed The equipment undergoing repair must be suitably separated from the rest of the equipment containing fuel or fumes. 1.8 Prohibition for Safety ‘i a) Prohibition of smoking In all spaces where on inflammable liquid/gases to be stored, pumped and used as well as in their immediate vicinity, it is forbidden to smoke and handle fire, open light or heated objects. Itis further not allowed to bring matches, lighters and other easily inflammable materials into these spaces b) Prohibition of entrance of unauthorised persons Only operating, service and inspection personnel are admitted into the store rooms and operator premises of the fuel gas system. Unauthroised persons have no admittance into these spaces ¢) Display of Prohibitions All prohibitions and notices must be in suitable places (usually near or directly on the respective parts of equipment) in the form of well visible and legible inscriptions. 2 BOILER FRONT 2.4 Introduction The boiler is provided in the 2 numbers of R-type front wall fired burners. The construction details of the burners are explained under seperate section on R-burners. The burners are located in one tire. The burners can fire Bio-gas to 20,000 Nm*/day. 2.2 Fuel Gas System Fuel Gas System is designed for input of 20,000 Nm*/day on Bio-gas. The system is provided in the safety trip valves like fuel gas main trip valve and burner gas trip valves. The gas burner trip valve is of block and bleed construction of Ball type to ensure bubble tight leakage service. The burner trip valve is also provided with a 0458, 0487 2 Bharat Heavy Electricals LimitedBIO-GAS FIRING SYSTEM 34 vent connection between the seats of the valve. If a leakage occurs in the first set of seats, the leakage gas will not pass into the furnace and it is only vented. ‘The gas trip valve must be tested periodically for its seat leakage. The fuel gas main trip valve leakage can be detected by closing this main trip valve and burner gas trip valve for half-an-hour and observing the pressure in the jine downstream of the trip valve of the line is pressurised then the seals must be replaced promptly. The burner gas trip valve can also be tested in a similar manner. The vent port must be assembled with a suitable pressure gauge. The upstream of the valve must be pressurised and the leakage can be tested by isolating the gas line down stream of the valve by a blank flange at the burner and observing for a pressure build up. It is advisable to change the complete set of seats when one seat of the valve is in leakage, Drains are provided in the fuel gas line to remove any condensate formed in the header. The condensates should be removed periodically and the drain valves should be, ensured closed while the boiler is in operation. TECHNICAL DATA Specification for fuel gas (Bio-gas) i. Analysis by volume by % age a) Methane (CH,) 57.5 b) Carbon-di-oxide (CO,) a5 ) HS . 1.0 li, Properties a) Calorific Value 4444 Keals/kg b) Density at 15°C 1.178 (Air = 1) c) Gas Pressure at the terminal point (Boiler operating floor) 1000 mm WC d) Temperature 30 to 40°C 3.2 Burners (on Gas Firing) i Type ii, No. of Burners iil, Size 0486 0457 Front wail fired R-Burner 2 at ‘ Bharat Heavy Electricals LimitedBIO-GAS FIRING SYSTEM vi vii vil Air flow burner Air temperature Predicted pressure drop across the burner Excess air Burner assembly drawing No 3.3. Gas Guns vi. Type No. off per boiler Capacity Firing rate Gas pressure at the burner Minimum gas pressure for tip 13835 kg/hr 206°C 75 mm WC at full vane open position 15% 0-41-100-00124 Single annular speed 2 415 Nme/he 445 Nm*yhe 800 mm WC 800 mm WC. 4A 0486, 0487 4 R-BURNER WITH OIL AND GAS GUN Introduction The general construction of the type "R" or Horizontal Burner is as shown in drg. No. 0-41-100-00124. Essentially the burner consists of an air register, oil and gas gun assembly, HEA Ignitor assembly and burner throat. The air register, through which air from the windbox enters the burner, is composed of a ring damper, a series of pivoted secondary air vanes, a primary air sleeve and pivoted primary air Vanes. The ring damper is operated from the burner front by means of three operating mechanisms. By turning the damper handles the dampers can be moved backward or forward, thereby changing the total amount of air admitted to the burner. By cocking the damper itis possible to equalise the air distribution around one individual burner, ‘The purpose of the ring dampers is to equalise the air distribution between the burners and around the periphery of each individual burner. They should not be used to regulate the air flow. During initial firing the ring dampers should be set to obtain equal static pressure in all burner registers, with equal vane positions. Fittings are provided at three points near each ring damper operating mechanism for pressure measurement, Once proper setting of the ring dampers is established, it should not be further adjusted. Bharat Heavy Electricals Limited| fii fat | BIO-GAS FIRING SYSTEM The burner vanes, which are arranged concentrically around the burmer, are operated as a group by means of a vane ring and operating mechanism. The vanes import a rotary motion to the secondary air entering the burner proper at the same time affect the velocity of the air entering the burner throat and mixing with the fuel The swirl intensity and the air velocity depend not only on the vane opening but also on the windbox pressure in turn is affected by the vane position of the individual burners. Therefore, when changing vane setting on one burner, the vane settings on other burners in service should be changed equally before observing the fires, in order to get a true picture of the result of the change. ‘A portion of the air entering the register is admitted as “primary air’ to the primary air sleeve. The purpose of the primary air is two fold : (1) To introduce air at the oil and gas gun tip for initial combustion. (2) To fill the vortex created by combustion in the secondary air zone, thus preventing the fire from drawing back into the burner nozzles, with resulting overheating and fouling, There is a adjustable vane assembly on the primary air side. During commissioning the vanes are adjusted for better flame stability at all the loads and the adjusting handle locked in that position. The ignitor is located within the primary air sleeve by the side of the oil gun. For details refer to the ignitor instructions. The burner throat consists of refractory material around the furnace wall tubes, which are bent to form the burner opening. This arrangement permits tangent tube construction through the entire furnace wall and minimizes the amount of exposed refractory surface 4.2. Oil burning equipment Oil burning equipment selected for this particular unit is described in detail in other sections of this manual. The fuel burning equipment consists of ignitors, oil and gas guns. Ignitor serves for ignition of the adjacent oil guns. Guns are provided for lighting off, warming up and for load carrying service Generally it car be stated that the selection of fuel burning equipment for each installation is governed by many factors, such as required heat input, characteristics and availability of fuels, available fuel pressure, physical arrangement of the unit, etc. The equipment for this particular unit has been designed to serve specific ‘purpose. It should be operated within the design ranges and in accordance with the recommended procedures. 4.3. Ring damper and vane operation The ring dampers should be opened wide on all burners prior to initia firing. They should be further adjusted after air burners are in operation (See point 4.1). During start-ups, with a cold furnace, ignitors, should be lighted with a minimum windbox pressure and burner vanes closed. 0456, 0457 5 Bharat Heavy Electricals LimitedBIO-GAS FIRING SYSTEM 44 Just prior to lighting off a oil gun, crack open the burner vanes. After the burner is lit, the vanes should be opened gradually and adjusted, if necessary to obtain a satisfactory flame During normal operation, after the ring dampers have been adjusted to equalize air distribution, consideration should be given to the correct setting of the vanes. Correct vane setting depends on local conditions and cannot be predicted for each individual installation. Itcan only be established by experience, through observation of the fires during various load conditions. The general appearance of the fire and ignition stability are important factors in determining the most favorable flame shape. Figure 2A and 28 illustrate two extreme : Figure 2B shows a satisfactory flame. Generally, closing down the burner vanes will cause the fire to fan out and approach the front wall (See Figure 2A). A long flame, impingement on the rear wall (Figure 2C) can generally be corrected by closing down the burner vanes. In short, the necessary quantity of air per minute to burn a given amount of gas or oil can be introduced by using either a low windbox pressure with large vane openings or a jh windbox pressure with small vane openings. Once the most favourable vane setting has been determined for normal load conditions, it should not be changed. Air flow requirements are observed by the fan damper controls. During very high or peak loads additional vane adjustment may be necessary. If with an arrangement of several burners in one windbox, it is necessary to operate with one or more burners out, the vanes on the idle burners should be closed. This will check the entrance of large amounts of excess air but will permit sufficient leakage to prevent damaging the burner structure. Air Regulation In order to assure safe lighting off conditions, a high air flow (see note 1) should be maintained after the pre-operational purge during the entire warm up period, until the boiler is on the line and the boiler load has reached the point where the air flow must be increased to accommodate further load increase. The burner register secondary vanes should be open during the purge period and during the lighting off and the warm-up period to permit the required oil flow, When the unit is on the fine and carrying load, the total required amount of air (total air flow) is a function of the boiler load, other words, the air flow “follows” the steam flow, proper air flow to certain loads depends on the characteristics of the fuel fired and the amount of excess air. This can best be determined from flue gas analysis through Orsat Measurements. Refer to Flue Gas Analysis Chart. Note: 1. The term “high air flow" should be interpreted as the maximum permissible air flow (up to 30% of full load air flow) consistent with controlling steam temperatures within design limitations, Note : 2. Pinching down on the burner vanes, when placing an individual burner in service, may require proportionate opening of burner vanes on idle burners, in order to maintain the “high air flow" without changing the 0456, 0487 6 Bharat Heavy Electricals LimitedBIO-GAS FIRING SYSTEM 45 46 47 48 burner windbox pressure at the burners in service. When opening up the vanes of the burners in service, the vane opening at the other burners should be adjusted accordingly. Burner light off and operation For the purging operation all the primary air drum and the secondary air vanes of all the burners must be ensured open. The purging is carried out with 30% air flow. After purging is over, the secondary vanes of two burners which are open, close the valves of the burner which is going to be started immediately. Now the command of cutting in the burner, lights up the ignitor and subsequently. The flame is sensed by the scanner provided in the burner panel and burner continues in operation if the flame is proven. If the flame is not present the burner is automatically tripped. While operating the boiler at more than 30% MCR load, the secondary vanes of the non-operating burners should be closed for correct air distribution. Gas Guns Each burner is provided with one gas gun. The gas gun tip is made of stainless steel casting to withstand high temperature. The gas gun is welded to the burner mounting panel assembly The gas gun is located centrally in a refractory throat casting. The position of the gas gun tip in the burner is very important for a trouble free and reliable operations This position must be checked during the erections. During commissioning of the boiler, this position can be slightly adjusted, if required, to obtain the best flame conditions. This position must be recorded in the O & M Manual for future reference Ignitors The ignitors are located just above gas guns. The position of the ignitor with respect to the gas gun should be correctly maintained for reliable ignition. The ignitor construction is explained under seperate heading elsewhere Burner Maintenance Little maintenance is generally required for type-R Burners. The following points wise will serve as guidelines for routine maintenance of the Burners. i. Inspect periodically the throat of the burner atleast once in a shift for any unburnt deposits ii. Inspect periodically to the flame leading to tube failures. iii Keep the burner area clean from’any dripping and sludge. Do not allow the vane drive and handles to be operated with loose keys. Replace the key promptly, 0456, 0457 7 Bharat Heavy Electricals LimitedBIO-GAS FIRING SYSTEM v. Lubricate the threaded portion during annual overhaul by high temperature molybdenum disulphide grease. vi, Checkup the position and conditions of the vanes, primary air drum from furnace side during shutdown. Vii, When the gas gun is not operated blow through the gas nozzle by compressed air periodically to avoid blocking of gas gun holes by possible deposits. The Period should be worked out depending on the requirement. 4.9 Check list for burners To be filled up by the commissioning engineer after final burner adjustment BURNER POSITION “tet Right i, Vane angle after final adjustment ii. Gas gun position with respect to the throat in mm lil. Ignitor position with respect to the throat in mm iv Direction of primary air vanes Clockwise | Anticlockwise v. Direction of secondary air vanes Clockwise | Anticlockwise 0456, 0457 8 Bharat Heavy Electricals Limited