61120-0011-2 REV.0 Description

Guodian Taizhou Power Plant / Boiler 　　　　　　　　　　　　07457/07458 61120-0011-2 Rev.
Contents
5 Coal burner control

5.1 Coal burner ignition and shutdown procedures
5.2 Coal mill, Coal burner and Coal feeder start permit
5.3 Coal burner start-up
5.4 Ignition energy adequate condition
5.5 Coal mill warming
5.6 Initial coal feed operation
5.7 Coal burner shutdown
5.8 Coal mill purge
5.9 Monitoring concept of coal mill and coal feeder
5.10 Coal mill trip condition
5.11 Coal feeder trip condition
5.12 Supplemental description
5.13 Runback operation
BASIC PLAN FOR MBC (COAL) Mitsubishi Heavy Industries, LTD. Page 1 of 19
Guodian Taizhou Power Plant / Boiler 　　　　　　　　　　　　07457/07458 61120-0011-2 Rev. 0
5 Coal Burner Control

5.1 Coal burner ignition and shutdown procedures
The coal burner ignition and shutdown is based on Band operation.
MWD receives restriction by the number of operating Coal burner as following table.
For example, in case 3 coal burners operation, MWD upper limit is 50%B-MCR.
MW(%B-MCR) Number of Coal mill

25% - 30％* 2
30% - 50%* 3
50% - 75%* 4
75% - 100%* 5
*) Final confirmation will be carried out at commissioning stage.
In normal load operation, coal burner ignition and shutdown command on elevation is given
by manual operation on OPS.
In APS start-up and shutdown, automatic command of ignition and shutdown is given from
APS to MBC, if it is applicable.
As shown in Fig. 5-1-1 "Coal burner ignition and shutdown procedures", the ignition and
shutdown of the coal burners are performed by start-up and shutdown the coal mill, coal
feeder and its related dampers, and auxiliary equipment sequentially. The time chart for it is
as shown in Fig. 5-1-2 “Coal burner ignition and shut-down timing chart”.
Also, the related analog controls of coal amount, primary air flow, temperature, and wind
box dampers are performed by CCS, coal mill auxiliary control and burner control will be
performed by MBC.
The mill burner controller can automatically ignite and shutdown the coal burners without
requiring an operator by performing the start-up and stop of the equipment and the interface
of the equipment with the related controllers (control mode switching command)
sequentially.
Fig.5-1-1 to be attached on this page
Fig.5-1-2 to be attached on this page
5.2 Coal mill, Coal burner and Coal Feeder start permit
(1) Coal mill start permit
When the following conditions are satisfied, coal mill can be started.
a) Primary air pressure normal
b) Any PAF is running.
c) Coal mill seal air valve open
d) Coal mill seal air differential pressure not low
e) Spillage hopper level not high, if it is applicable.
f) Spillage hopper inlet gate and damper open, if it is applicable
g) No coal mill trip command existed.
h) Coal mill outlet temperature not high
i) Cold air gate open
(2) Coal burner start permit

In the ignition of the coal burners, when the following conditions are satisfied, the coal mill
becomes usable and the coal burners become ignitable.
a) Coal mill start permit established
b) Coal gate open
c) Generator synchronaized
d) Boiler load > X%*
e) Coal mill purge completed
* To be decided at commissioning stage.
(3) Coal feeder start permit

When the following conditions are satisfied, coal feeder can be started.
a) Coal mill start permit is established.
b) Rotary coal chute started
c) Rotary separator started
d) Coal mill warming completed
e) Not any coal feeder start in progress
f) Coal mill purge completed
5.3 Coal burner start-up

As similar as light oil burner, it is recommended to start the all auxiliary equipment related to
coal burner in accordance with orderly operating sequence by one kick operation from the
OPS.
5.4 Ignition energy adequate condition
In order to ignite the coal burners, either of the following two conditions must be satisfied.
a) Adjacent oil burner is in service.
b) Coal flow of adjacent coal burner is greater than 50%.
5.5 Coal mill warming

Before the coal feeder is started and fuel coal is actually charged, the "Coal mill warming" is
required.
In the coal mill warming, to ensure the starting of coal pulverization and drying, the coal mill
is getting warmed by primary air obtained by mixing primary hot air with primary cold air. By
modulating the coal mill inlet primary hot air damper (HAD) and the coal mill inlet primary
cold air damper (CAD), the coal mill outlet temperature is adjusted to 70 to 80℃ with a
primary air flow.
Coal mill warming time required depends on the initial temperature of the coal mill,
generally 10 – 15 min.
Note; Temperature and timer setting must be decided during commissioning stage.
5.6 Initial coal feed operation

When the Coal mill is started and warmed up, the coal feeder can be started. The purpose
of “initial coal feed operation” is to establish the starting of pulverization, shorten the coal
mill startup time and stabilize the coal mill system, so that the coal burners can easily
stabilize the flame at the beginning of the ignition. A series of steps taken for this purpose is
called the “initial coal feed operation”.
The parameters for initial coal feed operation are finally adjusted during the commissioning
stage, and its outline is as shown below.
Detection of starting pulverization
Coal master demand
Initial coal feed operation
Shaded area indicates
Y t/h estimated actual pulverized
coal supplied to furnace.
Coal flow
Z t/h
The state of the starting pulverization is monitored by the logic as shown in Fig. 5-3. When
the coal feeder fails to perform the starting pulverization, an alarm is issued and, at the
same time, the operation mode is switched from “automatic” to "manual", and the coal flow
is restricted to the minimum.
(This function is performed by CCS.)
Coal feeder stop
Coal mill start Coal mill. Initial

1.5S S coal feed
Coal mill. ΔH/L detection
R
current
Coal mill.
current at coal
feeder start
120S
Coal mill. Initial
coal feed
120S 3.0S error
Note) Timer setting values must be finalized at commissioning stage.
Fig. 5-6-1 Coal mill initial coal feed detection
5.7 Coal burner shutdown

To shutdown the Coal mill, the following sequence are performed:
a) Coal flow decrease command is given from MBC to CCS to decrease a coal feed
demand to minimum.
b) Close the hot air gate after fully closing the hot air damper
c) Coal feeder is stopped at the coal mill outlet temperature of 65℃ or below
d) Purge the residual coal and cooling by cold air.
The shutdown time until coal feeder stop depends upon a time in which the coal mill outlet
temperature lowers to 65℃. Normally the time varies according to the initial coal flow at the
start of shutdown and the water content of the coal. It is 3 to 4min according to MHI’s
experience.
As an initial set value, a purge time from the coal feeder OFF to coal mill OFF is set to 5
minutes based on the experience of the other plants.
5.8 Coal mill purge

When the coal burner is tripped containing coal, in order to protect accumulation of volatile gas
in coal mill and to cool down the residual coal, HAD and HAG are closed and CAD is kept on
the minimum position. If it is possible to re-ignite the coal burner immediately, re-start the coal
mill, and purge shall be carried out with only cold primary air as coal mill cleaning. If it is not
possible, the residual coal shall be removed from manhole of coal mill by using vacuum system
or man power at local after confirmation of the coal mill cooling down. During cooling down
operator shall pay full attention to the indication of coal mill fire such as the coal mill outlet
temperature. In such case, it is recommended to sprinkle water on the residual coal from the
water nozzle installed on the coal feeder as a preventive measure for coal mill fire. The detailed
operation philosophy or procedure for this item including inert system will be recommended and
finalized by coal mill supplier.
5.9 Monitoring concept of coal mill and coal feeder

Monitoring system concept for coal mill and coal feeder is shown on Fig. 5.9.3.
a) Coal monitor on the coal chute

Coal is always filled in the coal feeding pipe (chute) ranging from the coal bunker to the coal
feeder to prevent back flow of hot air into the bunker. The coal monitor is installed at the
lower part of the coal bunker and also at the coal chute section (the detector is installed at
two positions for each coal feeder to detect whether the coal layer seal is present or not).
When the upper and lower monitors detect any abnormality after the coal feeder is started,
an alarm indicating that the coal flow of the coal feeder is abnormal is initiated.
(The coal monitor, which detects the flow of coal, adopts the logic shown below so that an
ANN is not initiated during the initial starting of the coal feeder.)
Fig. 5-9-1 Monitoring logic diagram of coal flow on coal chute
3S Alarm
Coal monitor abnormal (chute section) Coal monitor abnormal
(chute section)
3S Alarm
Coal monitor abnormal (bunker section) Coal monitor abnormal
(bunker section)
Coal gate open
5S
Coal mill & Coal feeder under operation Coal flow monitor
abnormal
* To next page
b) Coal flow monitor on the Coal feeder

The coal feeder must always be monitored during the operation to check that coal layer is
on the conveyor belt. When no coal on the belt is detected by the coal monitor (that is no
coal be fed to the coal mill), alarm logic is shown as per below, the coal feeder trips due to
loss of coal on the coal feeder (NOT COAL ON BELT) or the clogging of the coal feeding
pipe (pressure difference between coal feeder and coal mill is high, with coal mill current <
Min).
Fig. 5-9-2 Monitoring logic diagram of coal flow on Coal feeder
Coal mill & coal feeder

under operation 180 sec.
7 sec.
Coal feeder-to – Coal mill.
Difference pressure HIHI
180 sec.
Coal mill & coal feeder

shut-down in progress
3 sec.
Coal mill current < Min
5 sec.
COAL ON BELT
Coal feeder trip

(to Fig.5-11-1)
Coal feeder & Coal mill
Shutdown in progress
Coal flow monitor abnormal
From previous page *.

(ANN)
Coal feeding pipe
clogged
(ANN)
Loss of coal on
coal feeder
Note) Timer setting values are finalized at commissioning stage.
c) Monitoring of temperature in coal mill

The coal mill outlet temperature is measured by a thermocouple and is set normally to 70 to
80℃.
d) Monitoring of Coal mill overload

Overloading of the Coal mill is detected by using a Coal mill current and a pressure
difference of the grinding table (Table DP). When the coal mill is overloaded, the quantity of
re-circulating coal in the coal mill is increasing excessively. It is detected by “Table DP” and
“Motor Current”.
Under such overload condition, abnormal vibration is tended to occur. To detect such
abnormal vibration, a vibration monitor is installed.
e) Detection of starting of pulverizing action

A coal mill motor current is used to detect that the state of starting pulverization, when the
initial coal feeding is performed by starting the coal feeder when coal is surely caught
between the rollers and the table liners, the pulverization of coal is started and the motor
current is increased.
f) Monitoring of state of coal stored in bunker

To assure the stable supply of coal to the Coal mill, it is necessary to properly maintain a
bunker level. If the bunker level lowers to a specified value or below, “coal flow abnormal”
will occur and an operation trouble may be happened. To prevent this problem, the bunker
level must be monitored on DCS.
g) Monitoring of state of combustion (flame detector and their interlock)

Since the flame detector plays an important role in ensuring the safety of combustion in the
furnace, based on the concept of monitoring of fire vortex type boilers, the monitoring logic
uses a fire monitoring logic formed of low load area (at start of boiler) individual monitoring
and high load area fire vortex monitoring combined with each other.
The major interlock items (Table 5-10-1, 5-11-1) and the interlock logic diagram (Fig. 5-10-1,
5-11-1) of the coal mill system are given on the subsequent pages.
Fig.5.9.3 to be attached on this page
5.10 Coal mill trip condition
Table 5-10-1 Interlock of Coal mill and Coal feeder

Signal Name Application Reason Remark
Coal mill outlet dampers To cut out supply of coal into

closed furnace.
Ignition energy lost Coal mill & coal Continuous combustion is not
feeder trip allowed.
Coal mill outlet-furnace To prevent fine coal from being

pressure difference LOW accumulated in pulverized coal pipe
LOW and primary air flow due to insufficient air flow.
LOW LOW
Run back trip command To reduce the quantity of coal mill to To be checked
gain a target load after run back necessity.
occurs.
MFT
Electrical Failure To protect motor of coal mill.
Coal mill lubricating oil Bearing protection To be checked

temperature HIGH HIGH necessity.
Coal mill lubricating oil Bearing protection

pressure LOW LOW
Seal air differential To protect bearings and prevent

pressure LOW LOW leakage of hot air and fine coal from
to the outside of coal mill.
Coal mill outlet temp. Coal mill fire protection To be checked

HIGH HIGH by coal mill
manufacturer.
Coal mill-Furnace Coal mill fire protection To be checked

differential pressure HIGH necessity.
HIGH and primary air flow
LOW LOW
Coal mill bearing Bearing protection To be checked

temperature HIGH HIGH by coal mill
manufacturer.
Fig. 5-10-1 Interlock logic diagram of Coal mill

H/W
Electrical failure
MFT
3S
Coal mill start
Coal mill lubricating oil 3S

pressure LOW LOW
Coal mill
Trip
Coal mill lubricating oil

temperature HIGH HIGH
60 sec.
Coal mill seal air
differential pressure LOW
LOW
Coal mill outlet damper

open
(not under clearing)
160S
Coal mill & feeder start TD/WO
Coal flow decrease

command in progress
20S
Coal burner ignition Ignition energy lost
command in progress (to coal feeder interlock)
Coal mill under cleaning
Ignition energy lost
Coal mill-furnace
differential pressure LOW
LOW 5 sec.
Coal mill & feeder under

operation
90 sec.
Primary air flow LOW
LOW
Coal mill trip command from Run back operation
MFT
～　Next Page
Pulv. start
～　Previous Page
Coal mill bearing temperature HIGH HIGH
Coal mill outlet temperature HIGH HIGH
Coal mill-furnace differential pressure HIGH

HIGH and primary air flow LOW LOW
Note) Timer setting values are finalized at commissioning stage.
Pulv. start
5.11 Coal feeder trip condition
Table 5-11-1 Interlock of Coal feeder

Signal Name Application Reason Remark
Coal mill motor stop Pulverization of coal is not allowed.
Coal gate closed
Coal feeding pipe Coal feeder trip Coal is not allowed to be charged
clogged into coal mill.
Coal feeder-Coal mill

pressure difference
HIGH HIGH and coal
mill current < MIN
Loss of coal on coal

feeder
Coal mill current < Min

and NOT COAL ON
BELT
Coal feeding pipe

clogged
Coal monitor abnormal

and coal feeder-Coal
mill differential pressure
HIGH HIGH
Loss of coal on coal

feeder
NOT COAL ON BELT

and coal monitor
abnormal
MFT
Fig. 5-11-1 Interlock logic diagram of Coal feeder

H/W
MFT
Coal feeder
trip
(to coal feeder control panel)

(from coal mill interlock)
MFT
2S
Coal mill & feeder under
operation
Coal mill start
Coal gate open
5S
Coal mill & feeder shut- Note) Timer setting values are
down in progress
finalized at commissioning stage.
Coal feeder trip

Fig. 5-9-2
5.12 Supplemental description
MHI’s standard Coal mill operation after MFT is explained below.
Basic concept on Coal mill purge after MFT (summary)

1. If MFT occurs, to stop admission of unburned fuel into the furnace, trip the coal mill
immediately, and also stop admission of the hot primary air into the coal mill.
2. Perform furnace purge to prevent the accumulation of gas. Then the volatile gas in coal mill
is exhaust to furnace by cold primary air..
3. Remove the residual coal as soon as possible to prevent the spontaneous ignition.
Operation of Coal mill system after MFT

1. If MFT occurs, operate the Coal mill system in accordance with step 1 of the basic concept
as follows:
(1) Stop the coal feeder.
(2) Stop the Coal mill motor.
(3) Fully close the Coal mill hot air gate (HAG).
(4) Fully close the Coal mill inlet primary hot air control damper (HAD).
(5) Decrease the Coal mill inlet primary cold air control damper (CAD) to minimum position.
(6) Trip the primary air fan (PAF) (IDF/FDF is kept under continuous operation).
2. In accordance with step 2 of the basic concept above,

(1) Immediately after MFT, purge the furnace at the air flow of 30% MCR or higher.
(2) Do not perform boiler hot banking with the residual coal remaining in the Coal mill.
3. In accordance with step 3 of the basic concept above,

(1) The residual coal shall be removed from manhole of coal mill by using vacuum system
or man power at local after confirmation of the coal mill cooling down. During cooling
down operator shall pay full attention to the indication of coal mill fire such as the coal
mill outlet temperature. In such case, it is recommended to sprinkle water on the residual
coal from the water nozzle installed on the coal feeder as a preventive measures for coal
mill fire.
5.13 Run back operation (To be checked necessity)

If the major equipment trips or a trouble related to the unit occurs during normal operation,
a boiler input demand (BID) is reduced rapidly to a load equivalent to the residual auxiliary
equipment capacity, or to the allowable load for the unit. This run back operation is
performed to continue the operation without tripping the unit.
If a run back occurs, the coal burner are tripped sequentially so that the number of the
operating coal mills matches an output load excluding the coal mill run back.
In case any coal mill or coal feeder trips, BID is automatically decreased corresponding to
the number of operating coal burner.

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Guodian Taizhou Power Plant / Boiler 07457/07458 61120-0011-2 Rev.

5 Coal burner control

5 Coal Burner Control

MW(%B-MCR) Number of Coal mill

Fig.5-1-1 to be attached on this page

Fig.5-1-2 to be attached on this page

(2) Coal burner start permit

(3) Coal feeder start permit

5.3 Coal burner start-up

5.4 Ignition energy adequate condition

5.5 Coal mill warming

5.6 Initial coal feed operation

Coal feeder stop

Coal mill start Coal mill. Initial

Note) Timer setting values must be finalized at commissioning stage.

Fig. 5-6-1 Coal mill initial coal feed detection

5.7 Coal burner shutdown

5.8 Coal mill purge

5.9 Monitoring concept of coal mill and coal feeder

a) Coal monitor on the coal chute

Fig. 5-9-1 Monitoring logic diagram of coal flow on coal chute

Coal gate open

b) Coal flow monitor on the Coal feeder

Coal mill & coal feeder

Coal mill & coal feeder

Coal feeder trip

Coal flow monitor abnormal

From previous page *.

c) Monitoring of temperature in coal mill

d) Monitoring of Coal mill overload

e) Detection of starting of pulverizing action

f) Monitoring of state of coal stored in bunker

g) Monitoring of state of combustion (flame detector and their interlock)

Fig.5.9.3 to be attached on this page

5.10 Coal mill trip condition

Table 5-10-1 Interlock of Coal mill and Coal feeder

Coal mill outlet dampers To cut out supply of coal into

Coal mill outlet-furnace To prevent fine coal from being

Electrical Failure To protect motor of coal mill.

Coal mill lubricating oil Bearing protection To be checked

Coal mill lubricating oil Bearing protection

Seal air differential To protect bearings and prevent

Coal mill outlet temp. Coal mill fire protection To be checked

Coal mill-Furnace Coal mill fire protection To be checked

Coal mill bearing Bearing protection To be checked

Fig. 5-10-1 Interlock logic diagram of Coal mill

Coal mill lubricating oil 3S

Coal mill lubricating oil

Coal mill outlet damper

Coal flow decrease

Coal mill under cleaning

Ignition energy lost

Coal mill & feeder under

Coal mill trip command from Run back operation

Guodian Taizhou Power Plant / Boiler 07457/07458 61120-0011-2 Rev. 0

Coal mill outlet temperature HIGH HIGH

Coal mill-furnace differential pressure HIGH

Guodian Taizhou Power Plant / Boiler 07457/07458 61120-0011-2 Rev. 0

5.11 Coal feeder trip condition

Table 5-11-1 Interlock of Coal feeder

Coal mill motor stop Pulverization of coal is not allowed.

Coal gate closed

Guodian Taizhou Power Plant / Boiler 　　　　　　　　　　　　07457/07458 61120-0011-2 Rev.

Guodian Taizhou Power Plant / Boiler 　　　　　　　　　　　　07457/07458 61120-0011-2 Rev. 0

Guodian Taizhou Power Plant / Boiler 　　　　　　　　　　　　07457/07458 61120-0011-2 Rev. 0