Met GENERAL DESCRIPTION OF STEAM GENERATING PLANT The steam generating plant is designed to supply 71.2 TPH ( MCR) , dry and saturated steam at pressure 10 kg/om2 (g) ( outlet of MSSV) . The plant consists of a site assembled FM boiler. The FM boiler is bottom supported, bi-drum, water tube, natural circulation type, furnace oil fired, designed for forced draft operation. The boiler is designed to conform to the Indian Boiler Regulations (IBR). The steam generating plant is a combination of different systems as follows 1. Water and steam systems. 2. Air & flue gas systems. 3. Fuel firing system. 4. Boiler blow down & boiler water & steam quality control system 5. Soot blowing system. 6. Sampling system. 7. Piping system 8. Instrumentation and control systems. PAGE NO. A-1/1* Tubes: The boiler is of water cooled wall type construction. The furnace side, roof, bottom, rear boiler side wall, tubes are of membrane wall. Baffle wall ( studded type ) separates the convection zone from the furnace. Boiler convection bank is formed by an array of tubes. Tubes connecting steam and water drums enter radially into the drums and are expanded in the drums. The boiler block is provided with inner and outer casing for making it pressure tight and suitable for forced draft operation. The inner casing is of carbon steel and covered by mineral wool insulation for personal protection. The insulation is further covered by aluminium cladding & carbon steel sheets. * Refractory Castable refractory is applied in the gap between studded tubes and casing. The floor tubes are covered with refractory bricks to maintain circulation of fluid inside the tubes. The front wall which houses burner is entirely covered with refractory bricks. * Boiler base frame The base frame supports all the pressure parts, casing and refractory . The baseframe anchors the bottom side of water drum on front side so that during operation the boiler is allowed to expand vertically up and on rear side. * Access doors & peep holes A bolted access door in the boiler front wall is provided for access to the boiler furnace. Peep holes mounted in boiler side wall and burner front plates are provided for viewing the flame pattern. The peep holes are pressurised and cooled by using service air. Water from feed water control stations enters the steam drum. The water gets Circulated naturally through both the drums and tubes and in turn pick sup heat from the flue gases. The water gets converted into steam due to heat, passes out through main steam nozzle on the steam drum. Main steam piping carries a stop valve called main steam stop valves ( MSSV), a non return valves and its supplied steams for the process, PAGE NO. A-1/32. AIR & FLUE GAS SYSTEMS : The air & flue gas system covers supply of combustion air to the boiler and forcing of the flue gases through the boiler upto the stack. The components coming under this system are i Forced draft (FD ) fan. Windbox & furnace of boiler. iii, Ducting Scanner cooling, sealing & scavenging air system i Forced draft ( FD) fan Combustion air required for burning of fuel is supplied by one no. motor driven fan. FD Fan is of centrifugal type with backward curved blades. FD fan sucks air from its environments through the silencer and the inlet damper. The silencer minimises the noise level of the fan. The percentage opening of the inlet damper regulates the capacity of the fan to meet the varying combustion air requirements of the boiler for more details refer FD fan manual ji, Wind box & furnace of boiler ‘The windbox is mounted on the boiler front wall. It has opening for burner front plates and for connecting combustion air duct i.e, FD fan - wind box duct. The fumace is pressurised water cooled type. Combustion of fuel takes place in the furnace with the help of burner. The flue gases formed out of combustion Pass on towards boiler rear side and then leave furnace to convection bank zone. il, Ducting FD fan suction duct supplies air to FD Fan. The combustion air flow is measured by an aerofoil which is part of the suction duct. FO Fan - wind box duct conveys air from FD fan outlet to windbox. A fabric €xPansion joint in the duct isolates FD fan vibrations from being transmitted to the duct & further. Boiler to stack duct carries flue gases from boiler bank exit to stack inlet, 'solation dampers and expansion joints are provided in the ducting, PAGE NO. A-1/4iv. Scanner cooling, sealing & scavenging air system. The scanners used in the bumers are exposed to flame radiation in the furnace and require to be maintained below 70 deg.c . to obtain optimum performance. For this air tapping is taken from FD Fan wind box duct and air is supplied to the scanners. In a forced draft boiler, flue gas is above atmospheric pressure at all sections of the system. The peep holes require to be cooled and sealed with a stream of air to make comfortable observations of the furnace through the peep holes. The flue gas because of its pressure may escape through the shaft openings in the soot blower boxes, mounted on boiler walls. These shaft openings are to be sealed by a steam of air at a higher pressure than the flue gas pressure. PAGE NO. A-1/53. FUEL FIRING SYSTEM Fuel firing system consists of the following components i Fuel oil tank. ii ~ Oil pumping & heating unit Fuel oil train. Burner v. Burner management system, i Fuel oil tank Fuel oil tank_of 4.5 m3 capacity stores fuel oil in it. It has got steam heating Provision to maintain temperature of oil level switch - high & low are mounted on the tank to maintain oil level within a particular range. It supplies oil to oi pumping and heating unit through piping. ii, Oil pumping and heating ( OPH) unit As its name indicates the function of OPH unit is to pump and heat oil to feed it to »_ gn the bumer. itis a skid mounted unit with 100 % capacity steam heater and25 % otc Capacity electric heatel? Two oil pumps ( 1 working & 1 stand by ) of screw type (are mounted init. iii. Fue! oil train The fuel oil train is mounted very close to the bumer and it is at the tail end of the fuel oil & atomising steam piping. It connects OPH unit with the burner. Fuel oi {rain carries piping of fuel oil , atomising steam, atomising air and pilot gas, The train consists of piping with isolation vaives, fuel flow meter , fuel flow control station, strainers, non retum valves, gauges & switches & quick shut off valves. The fuel oil train covers all the necessary equipments & instruments required for controlling the firing, of fuel in burner. PAGE NO. 4-1/61. WATER AND STEAM SYSTEMS The water & steam systems comprise of the components which convert feed water into steam. The components in the serial order in the flow path are a) Feed water control station. ——— ot exi&t rim prensaing sal) —? “ot <7 c) Boiler @) Feed water control station The feedwater from feed pump outlet passes through the feed water control station before it enters the drum. It consists of a feed regulating control valve & a bypass arrangement. The control valve is @ pneumatically operated, globe type of vale & used during boiler start up & part load operation, ») (Crum preheating Sad) —> Nox exis The preheating coil is housed inside water drum and serves to further heat the feedwater admitted to economiser utilising the heat picked up by the drum water During low loads, the flue gas temperature at boiler exit is low & may fall below sulphur dew point temperature while passing through the economiser. So as to avoid this feed water temperature is raised by passing it through preheating coil and hence lowering heat pick up in economiser. The preheating coil is having bypass arrangement & can be bypassed under full load conditions & when flue gas exit temperature is above sulphur dew point ©) Boiler The boiler is site assembled, FM type ( Model FM 120/97) of boiler designed as per Babcock & Wilcox design. The major components of boiler block are © Steam drum & water drum Upper drum is called steam drum and lower drum is called water drum. The Grums are manufactured in accordance with IBR, Both the drums are having manholes, various nozzles and internals. Nozzles for main steam atomising steam, safety vales, water level gauges. Pressure gauges , pressure & level transmitter, level switch, blow down and vent are provided on steam drum. Water drum is provided with intermittent blow down connection. For removing moisture from steam, steam drum is equipped with internals such as baffles & scrubbers. PAGE NO. A-1/2iv. Burner 2 nos, each 100 % capacity burner are mounted on the windbox. The burner is air/ steam atomised oil burner complete with air register. 2 x 100 % main gun. 2 x 100% auxilliary gun and electric / gas ignitor. The bumer is air atomised during start up and steam atomised during normal operation. Burner is the most critical part of the boiler and is designed to maintain a well - shaped fiame, light orange in colour, stable without sparks or smoke surrounding the flame v) Burner management system Burner management system consists of burner safeguard / interlock, being executed through a progammable logic control ( PLC). 4. BOILER BLOW DOWN & BOILER WATER & STEAM QUALITY CONTROL SYSTEM i Boiler blow down system It is designed for safe draining of high pressure and temperature, steam & water from boiler to the drain pit Blow down is the stream of water which is bled from the boiler to control the concentration of total dissolved solids (TDS) in the boiler water. Continuous blowdown - CBD ( from steam drum) & intermittent blow down - IBD ( from water drum ) are collected in drain header which is connected to blow down tank through piping. The drain water is safely drained from blow down tank to the drain pit. ii, Boiler - water & steam quality control system This system is designed to maintain the steam quality. It ensures corrosion & scale free operation of boiler & purity of steam, Two controls ate exercised on boiler water to avoid corrosion of boiler tubes & the drum water washed surfaces. ‘The controls are a) CBD to restrict the contaminants to prescribed levels 5) High pressure ( HP) - trisodium phosphate dosing to convert the hardness producing insoluble calcium, magnesium salts to soluble sodium salts which can be drained by CBD & to maintain the alkalinity levels of boiler water. Detail description of HP dosing system is covered under HP dosing system manual, ( pH dosing in feed water line which is to maintain pH level is covered under pH dosing system) PAGE NO. A-1/75. | SOOT BLOWING SYSTEM : Soot blowing system is provided to keep thi soot blowing is done with the help of steam, main steam piping. There are 2 nos. manual operated fixed position blowers ( 2 nos. for boiler - one on front and one on rear side ). The steam is supplied to the soot blowers through a globe valve on common line and isolation valves on individual supply line, Soot blowers direct the steam through nozzles against the soot or ash accumulated on the heat transfer surfaces of boiler & economiser, to remove the deposits & maintain the heat transfer efficiency. For more details refer to the soot blower manual Se TR Cone S/eooler Shean in €FD, ee eee ee Sampling system is provided to check samples of main steam & CBD. Tappings are taken from main steam and CBD piping and led to individual sample coolers The sample coolers are of shell and tube type construction side and cooling water on shell side. 6. | SAMPLING SYSTEM 7. PIPING SYSTEM Piping system connects individual equipments in the plant & carries fluids from one equipment to another. Piping system covers the piping, fittings, valves & instruments. The flow paths of various piping system are as follows. i. Water system Feedwater o/s- boiler-boiler -CBD, IBD-Drain header- Blowdown tank Cooling water - sample cooler ji, Steam system : Boiler -Main steam battery limit Main steam line - soot blowers, Boiler - OPH unit & oil train for atomising, PAGE NO. A-1/8Fuel oil system Fuel oil tank - OPH - Oil train - Burner. Instrument air / service air system : Instrument air at battery limit - consuming points. Atomising/ain’at battery limit - oil train for atomising v. HP dosing system : HP dosing system - Boiler PH dosing Drum Coil Heater The purpose of the heating element is to keep the boiler hot during periods when. the boiler is idle for various reasons such as reduce start up time, prevent freezing , low temperature, corrosion protection, ete. The boiler pressure that can be expected to be maintained with a given supply steam pressure to the heating element is the pressure equivalent to a saturation temperature 40 deg.c. below the saturation temperature of the supply steam with saturated water discharging from the heating element and a tight fitting stack damper in the closed position. Controls for the heating element are to be supplied by the purchaser. The degree of contro! will depend on what the purchaser expects to accomplish with the steam conditions available a minimum of control however will be a steam trap at the heating element discharge PAGE NO. A-1/9 TIMMTSUNGENDES.00CPRESSURE PART DETAILS For more details please refer pressure part drawing in © & M Manual Vol-2 nee DESIGN DATA MAIN PARAMETERS UNIT VALVE Design & construction code BR | = Maximum allowable working | Kgf/em*(g)| 13.00 pressure = Design pressure | | Saal Hydraulic test pressure Kgt/cm*(g) | 19.5 q Steam pressure at outlet of main 0 steam stop valve & at outlet of pressure reducing valve. 6.70 = ‘Steam saturation temperature Cc { 194) 6 Feed water inlet temperature Cera (care OSeaae) 7. Design metal temperature Go| 22 8 Feed water temperature at inlet of Cc | 60(Miny boiler on F.O. firing | 9. Evaporation capacity (AtMCR) Kg/Hr 71200 (AtNCR) Kg/Hr 70000 Total heating surface of boiler M800 Water holding capaci T | 3.6 12. SAFETY VALVE SET PRESSURE S.N. | SAFETY VALVE | TAG | LOCATION | QTY.| SETPR. MAKE NO. | Kg/em’ (g) A FMCSANMAR | SV1 | Steamdrum ) 1 12 Spring loaded full lift | B FMCSANMAR | SV2 | Steam dram) 1 13 Spring loaded fi | PAGE NO. A - 2/113. Quantity of chemicals required for Alkali boil out (Quantity indicates for 1 boil out) CHEMICALS QUANTITY | | InKg. ‘A Hydrous Trisodium phosphate 1 155 | (Na; PO, 12 HO) | (B) Anhygrous disodium phosphte 34 | | (Naz HPO, ) | ‘© _| Wetting agent 9 | | Detergent / Surfactant | PAGE NO. A - 2/2MATERIAL DATA LS.N. DESCRIPTION | SIZE MATERIAL fot Steam Drum | ID 1375 x 20 THK SA 515Grad 70 | | SA 515 Grad 70. | 2 Water Drum | 1D 750 x 16 THK SA 515 Grade 70 | | SA 516 Grade 70 3. | Convection bank tubes | OD 50.8 x 3.66 TH B.S. 3059, Part = 1 I ERW 320 | 4 Baffle wall tubes | OD 50.8x3.66TH | B.S. 3059, Part— | | ERW 320 & Furnace side wall | OD 70x 4.06 TH B.S. 3059, Part - 1 panels & tubes | ERW 320 6. i | OD 50.8 x 4.06 TH B.S. 3059, Part- 1 L panels & tubes ERW 320 ri ler rear wall tubes | OD 50.8 x 3.66 TH B.S. 3059, Part - 1 | ERW 320 PAGE NO. ATERMINAL POINTS The various utilities are supplied to/from each boiler at the following battery limit. Outlet of Pressure reducing station / Main steam stop valve Outlet of drum safety valves at a safe elevation Outlet of air vent at a safe elevation Outlet of all other vents/connections at a safe elevation WATER: Boiler feed water Pressurised drains/blowdown Non pressurised drains Cooling water FUEL: Furnace oil LPG AIR: Instrument air/service air FLUE GAS: CHEMICALS & WATER Inlet of feed water control station At outlet of blowdown tank upto nearest drain trench At nearest open trench At one point in the boiler area Inlet of service oil tank of 4.5 M eapacity ‘At inlet of pilot gas tain at cylinder (Pressure terre eee At one point near boiler Suction of FD Fan At one point near boiler Outlet of stack Inlet of HP chemical dosing tank PAGE NO. A -POWER: For Electricals For Instruments Earthing At inlet of Motors At inlet of local junction boxes / control panel At individual equipment pigtails INSTRUMENT SIGNALS / CABLING From field instruments to control panel. Inlet/Outlet of BMS cum control panel. PAGE NO.A - 4/2RAW WATER Supply Pressure Kg/em’g Supply Temperature °C Quality Duty Approximate continuous requirement per Boiler at MCR m‘/hr FEED WATER Hardness ppm Silica as SiOz ppm Oil & organic matter mg/kg Oxygen ppm Cu ppm Fe ppm pH value Total dissolved solids ppm Conductivitymicro siemens/em Water temperature at battery limit *e Water pressure at battery limit Kg/em’g Approximate continuous requirement at MCR TPH BOILER DRUM WATER TDs ppm pH value Silica SiO, ppm Sodium phosphate as PO, ppm Alkalinity as CaCO; ppm Oil & organic ppm Sodium sulphite as SO; ppm 3 35 Raw Blowdown cooling a5 Nil 0.02 Nil sat 0.05 [max] 0.1 [max] GD 250 [max] NIL 390 38 PAGE NO. A- 5/14, COOLING WATER Supply Pressure Kg/em’g Return Pressure Ke/em’g SupplyTemperature °c Return Temperature oC. Quality Duty Approximate continuous requirement per Boiler at MCR TPH ELECTRICAL POWER For motors upto 110 KW Voltage v Frequency Hz Type Approximate continuous requirement at MCR KW v Frequency Hz Type Approximate continuous requirement KVA per Boiler at MCR BLOWDOWN Design % Operating % 3.1 2.4 35 4, Soft | Sample coolers 3.5 415 + 10% 50+ 3% Ac. 3 phase, 4 wire 290 110+ 10% 50+ 3% AC Single phase. Through UPS 5 PAGE NO.A-5/2INSTRUMENT AIR Pressure Temperature Dew point at 7 Kg/em’g pressure "C Quality Duty INERT GAS (NITROGEN) Pressure Kg/em’g: Temperature 9G Duty Approximate requirement foreach = Nm; prolonged shutdown LA ATOMISING/AIR’ Pressure Kg/em’g: Temperature TCH Quality Duty Approximate requirement in each Startup Kg/hr : 65 Ambient 0 il & Moisture free Instruments, scanner cooling + control valves + actuators 6.0 40 Boiler preservation 50 65 Ambient Oil & Moisture free Atomising for startup on FO 300 PAGE NO.A- 5/310 12 SERVICE(AIR 7 Pressure Kg/em?g: Temperature ‘c Quality Duty Approximate requirement at MCR Normal for continuous operation Nmy/hr : Peak including intermittent operation Nm/hr: DRY BULB TEMPERATURE (at site location) Max. rc Min °e Design [B c Design [Electricals] "e RELATIVE HUMIDITY (at site location) Max. % Min % Boiler performance % Design % 6.5 Ambient Moisture Free For removed soot blowers & burner gun + Peep hole sealing 91 176 38.0 7.0 30 40 100 30 60 100 PAGE NO A- 5/4FUEL SPECIFICATION Main fuels Ignition fuel FURNACE OIL Carbon Yow Hydrogen owt : Sulphur wt : Moisture ‘wt : Nitrogen wt : Ash wt: Sediment [max] Ywt Vanadium [max] ppm Sodium & Potassium [max] ppm Nitrogen (FBN) GcVv Keal/k; NCV Keal/kg: Kinematic viscosity at 100°C [max] cst Flash point [min] %G Pour point [1nax] °c Pressure at battery limit Keem’g: Temperature at battery limit " Approximate continuous requirement at MCR with blow down Kg/Hr: Furnace Oil /LPG 83.38 11.30 4.00 1.00 0.22 0.10 0.00 150.00 35.00 0.00 10110 9500 50.0 66.00 20.00 25 suitable for free flowing aa 5647 with feed water at) i 0c PAGE NO.A- 6/1EQUIPMENT Industrial centrifugal fan (FD fan) Make --—- THERMAX Quantity Fan Model - BCA, CL - II, SZ - 156, ARR - 1, SWSI Motor - 335 HP / 4 Pole 26.45 AS22075, TECHNICAL DATA S.N. | DESCRIPTION UNIT VALUE A ‘Air quantity AM’ Sec B Static pressure @ 20°C MMWG 779 [¢c Static pressure @ MMWG 692 Operating temp. [Dd Operating temperature c 38 |"E_| Gas density @ operating temp. | Kg /AM® 1.066 F Damper torque KGM Force KGS G Fan RPM H GD* value KGM* I Dust loading MG/ AM” J G.A. drawing No. 70405 833 21 - ~ (REV 3) K Lubrication = Grease | Servogem - 2 or LITHON - 2 or Bharat multi purposepH Dosing System No. of system Read. - 1 No.. Dosing System Data SNOT DESCRIPTION VALUE7 | | | OTHER DETAILS | fa ‘Application Feed water line 2 Chemicals to be dosed MorpholineS—|+y Tes 3 Temp. of water (used for dissolving | 30°C chemicals) a Tank | A) Min, live storage capacity 300 Ltrs. | 3 Agitator Reqd. (Manual) 6 Level gauge ( INo.) Tubular with guard rods 7 Pumps (variable stroke with pulsation) Plunger | per system 1 x 100% | C) Flow ( Litre / hour ) Oto 10 | D) Discharge pressure 19Kg/em%(g) PAGE NO. A - 7/2BOILER START UP AND SHUT DOWN (FM BOILER) 1. AIM This chapter describes the boiler start up and shutdown procedures as applicable for the following boiler condition, © Start up of a cold boiler. * Boiler shut down * Start up of warm boiler ‘© Start up of hot boiler. Note: a) The procedure explained here applies for start up of a boiler already commissioned. Commissioning a new boiler call for several additional requirements described in Section. B. b) Itis assumed that operators are fully familiar with the design and construction feature described in the earlier chapters. ¢) Itis assumed that operators are trained in operation of similar oil fired boilers and have been licensed to operate boilers by the State Boiler Inspectorate. 2. OPERATION PROCEDURES : (Please see the P & | Diagram of steam and water system, air & flue gas system, fuel oil system for the valve references described in this section.) 2.1 START UP OF ACOLD BOILER: A boiler start up can be termed as cold start up when any of the following condition is met. He -#/ The boiler has been idle for more than 3 days. *~ There is no pressure in the steam drum and its metal temperature is less than 70°C. In a cold start up, possibilities of some inspection or maintenance works having been done is presumed. A walkdown check is required and the boiler and its auxiliaries are to be prepared meticulously for a start up. Before a walkdown check ensure that all works permits have been returned, tags removed and maintenance permission for boiler start up is available. PAGE NO. C-1/1WALKDOWN CHECKS. Using powerful torches or low voltage inspection lamps inspect the furnace boiler bank, flue gas ducting, and FD fan to windbox ducting and ensure that: * Fumace, boiler bank, fiue gas ducting, FD Fan to windbox ducting are clear, maintenance personnel have been removed. * Fumace floor, furnace panel is clean without evidence of any water drips, slug or ash deposit. * Verify that all soot blowers in convection bank are in position. * Verify that all access doors, inspection doors are tightly closed. + Verify that all peep holes, have been tightly closed and sealing air connections have been made, and the seal air valves are open * Verify that the flue gas duct from boiler outlet to stack is clear without soot accumulation and that all maintenance personnel have been withdrawn. * Verify that flue gas HZSC damper is open. i dripping and there is no ‘STEAM DRUM: * Check that safety valve PSVS010A & PSV5010B are not gagged * Verify that the illumination of local level gauges (2 nos.) is on. Inlet valves from steam and waterside is open and drain valves are closed F.D. FAN: * Verify that bearing is properly greased. * Verify that suction damper of the fan is closed. * Verify that stop push buttons of fan in MCC is released if the fan was last stopped from MCC. * Verify that fan start push button is either on local or remote mode. © Verify that fan casing is clear of foreign materials & fan manhole is closed. HP DOSING SYSTEM: * Check that the HP dosing tank is having at least 30 % tank level. Prepare a full tank level of phosphate solution. Check that pump inlet valves are open PAGE NO. C-1/2DAY OIL TANK: + Verify that sufficient quantity of oil is available in the tank and verify that oi tank low level alarm is reset * Verify that heating steam at pressure of 3.0 kg/cm2 (g) is available. For this valve,MV01 on external supply line to be opened and valve PRV5011 to be adjusted to reduce external steam supply pressure to 3.0 kg/cm2(g). + Verify the oil temp. in the tank through-TC-503 if temp. is less that 45 to 50 °C then start steam heating of oil in the tank by opening steam temp. control valve TV-503. For this inlet valve (038-102) of control valve shall be open. Automatic temp. control valve will close automatically once temp is reached around 45 to 50°C. BURNER (A&B): * Verify that the main oil gun has been manually cleaned and inserted in the ignition position. * Verify that the au ignition position. * Verify that both the oil guns connected through flexible hoses to steam and oi lines. * Verify that the igniter has been inserted in the burner housing and connected to pilot gas line through flexible hose. * Verify that HT cable is connected to the igniter and H.T. transformer power supply is available. + Verify that the UV scanner has been inserted and cooling air hose connected. iary oil gun has been manually cleaned and taken out from VALVES LINE UPS: As the boiler is to be operated mainly from the control room (except for some venting / draining during filling / charging etc. which are done locally), the valve lit up has to be prepared accordingly. Note: Root valves of all instruments (pressure gauges, pressure transmitter, flow transmitter, DP transmitter etc.) must be kept open and their drain if any are to be kept closed. They are not separately listed. Remaining valve positions shall be as indicated in given chart. PAGE NO. C-1/3VALVE POSITIONS CHART (BEFORE LIGHT UP ) Valve | Tag no. | ‘Service Remarks BOILER FW LINE TO DRUM Bw02 transmitter FOTSO1 -{@2NOS) i BW-03 let valve of drum level “Y@NOS) BW-04 | Bypass valve of drum level To be opened once drum level control valve control valve is taken out of service Drain valve before level control valve Level control vaive ut into” service during and steady load is Flow transmitter FITS010 isolation To be opened when heater is 10 be taken into services. Inlet valve of drum coil heater is to be kept opened only en drum coil heater is to be taken in service. ‘STEAM DRUM Level gauge isolation valve on steam and water connection Level gauge isolation valve on steam and water connection, Level transmitter (LCT-501) isolation Valve on steam and water connection Drain valves of water column of level gauges Vent valves of water column of LCT-501 AND LAT-501 isolation valve of _level transmitter very low LAT-501 on steam = and water eonnection Phosphate dosing isolation valve. To be opened just before starting dosing into drum PAGE NO. C-1/4‘Service Remarks Pressure transmitter PAT-502 isolation valve ‘Drum air vent isolation valve | 7 [This valve to be dosed once boiler is connected to load, Tsolation_valves_of pressure | 7 gauges PG5010 8 &C isolation valve of etomising 7 steam connection from drum Z MAIN STEAMLINE 501 | Main steam stop valve 502 Bypass valve of main Steam) | stop valve, JB Main steam pr Transmitter [7 DRAIN VALVE AND DRAIN HEADER WWW "Mud drum drain isolation valve Z ~ANWOS Mud drum drain 18D valve. ~ ‘Common isolation valve _of v | A | eco. Inlet and outlet header drain DNVOT— Drain header drain isolation 7 | valve to trench. AIR SYSTEM (FD FAN SUCTION TO WINDBOX ) AGS- “Isolation valve of FCT-503 7 ‘oor FOVS03 | FD. Tan suction damper | Damper to be opened after start r of fan based on combustion air requirement ‘ACS Isolalion valves of FD. Fan| 7 101 & | discharge draft gauges (PG- ‘YAGS- " 5010W). Discharge pressure 102 __ transmitter (PAT-303) [PADT Isolation valve of windbox araft | 7 gauge FURNACE & FLUE GAS LPATH [FEO Fumace drat gauge PG-| 7 | 5010Y isolation valves. [FE-01 | Fumaco craft transmitter PAT | 7 501 isolation valve [EG-O1 | Flue gas draft gauge PGSOTOZ | isolation valve PAGE NO. C-1/5Valve | Service Open Close Remarks Tag no. | [SAMPLE COOLER, Www02 | Boller water sample cooler 7 TThese valve should be opened V2 NOS.) | isolation vaive at inlet and | just before sample collection | outlet i BLOW DOWN TANK WW07 | Blow down tank drain isolation | To be kept opened when tank vaive needs to be drained. S25 Blow down tank level gauge | ~ @ NOS) | (1.65011) isolation vaive. RW-01 | Cooling water isolation vaive | To be opened before charging 10 8.0. Tank the B.D. Tank OIL FIRING SYSTEM FUEL OIL TANK 035-102 | Inlet isolation valve of temp. v [To be opened just before {42 NOS) | control valve (TV 503) putting temp. control valve into a service. [3V-503_| Fuel oll temp. control valve 7 |To be closed while temp. control is put on. auto mode based on oil temp. in the oil tank. 035-103 | Steam trap bypass valve ol | To be closed when steam trap is put into service. 135-104 Y [To be opened just before putting steam trap into service. FO-146_| inlet outlet vaive of fuel oil tank | 7 ‘0-147 _| level control valve | LGV-502 | Fuel oil tank level control valve | 7 To be dosed when oil in the tank is high. ‘OPH ASSEMBLY _Fo1 ¥ | To be opened after informing control room operator |Fo-702 7 This vaive can be kept opened | | closed based on working/ standby pump respectivel FO-105 7 | This valve can be kept opened closed based on working/ standby pump respectively FO-130 7 FO-131 FO-104 To be dosed once pump is stand by. | [FO-107 7 | To be opened wien pump is to | pump 85501. be put into operation. FO-108 from pump outlet to | ion valve. FO-108 Z PAGE NO. C-1/6| Valve Se ‘Open | Close Remarks tag no. | FO-111 | Steam heater oil inlet isolation v To be opened before putting valve heater into service. ‘Steam heater vent valve ¥ | To be opened for venting air while putting heater into service. ‘Steam heater drain valve v Heating steam to steam neater v [To be opened when steam isolation vaive heater to be charged ‘Bypass valve of steam heater 7 [To be opened when steam oil temp. control valve heater to be charged. Inlet / outlet valve of steam 7 [To be opened just before heater temp. control valve Putting temp. control valve into service, ‘Steam heater oil temp. control To opened’ closed based on valve lower / higher oil temp. than rated 120° C Bypass valve of steam heater 7 | To be opened before charging steam trap steam into steam heater. ‘Steam trap isolation valve of 7 [To be opened before putting steam heater steam trap into service. Oil outlet valve of steam ¥ | To be opened before putting heater steam heater into service. Isolation valve of PGSO118 & |v A Bypass valve of flow) ~ To be closed once flow meter is transmitter FOT-504 Put into service. Inlet valve of FOT-504 7 [To be opened just before putting flow meter into service. Outlet valve of FCT-504 7 | To be opened just before | putting flow meter into service. Bypass vaive of oll flow conirol v vaive inlet vaive of olf flow conirol ¥ [To be opened just before valve FCV-504 putting control valve into service. FO-117 | Outlet vaive of oil low control ¥ [To be opened just before . valve FCV-504 putting control valve into service. FCV- | Oilflow control valve v To be opened initially to re- 504 circulate the oil and have heating of oll, This valve opened’ Close based on ‘combustion control demand. FO-143 | inlet valve of PCV 5074 7 To be closed after PCV 5014 taken out of service, FO-144 | Outlet valve of POV-S014 v To be closed after PCV 5014 / taken out of services PCV- | Oilpressure control valve 7 | To be used during initial start 5014 up. [ro-135 | Pressure gauge PG 5010) 7 isolation vaive I RV-502_ | Retum oil shut off valve v Closed when bumer is on, based on BMS command. PAGE NO. C-1/7Valve | Service [ ome | CPR Remarks | Pressure transmitter isolation | 7 PAT 504 vaive _YEO-Ti9_| Retum oil isolation valve ZI /RV-501_| Main fuel trip valve (MFT) Y | Opened based on BMS command. /FO-121 | Main Oil isolation vane after| 7 MET vaive (Bumer A) FO-123 | Main gun isolation valve | _~ ‘To be closed once auxiliary gun | (Bumer A) is taken into service. FO-124 | Auxiliary gun isolation valve ¥ [To be opened just before (Gumer A) auxiliary gun is taken into service. ./FO-137_| Main gun oil pressure gauge | 7 | at bummer inlet isolation valve, | (Bumer A) [FO-138 [Auxiliary ol gun pressure | 7 Y gauge at bumer inlet isolation | valve.(Burner A) ‘ATOMISING STEAM SYSTEM | 135-703 | Bypass vaive of steam tap) 7 To be closed once stream trap A@NOS) | 135-102 is put into service and condenses disappears from steam. 735-101 _| Steam trap isolation Vv [To be opened just before (NOs) putting steam trap into service. isolation valve of atomizing | 7 [To be opened just before light ‘steam at battery limit up. , [Isolation valves of PG-5010, | 7 PG-5010J & PAT 505, | Inlet isolation valve of PDV-| 7 To be closed when PDV-5013 5013 is under maintenance or bypassed. 135-177 | Outlet isolation valve of PDV- | 7 To be closed when PDV-5013 is 5 | 5013 under maintenance or bypassed _ BEATE Bypass valve of PDV-50TS ¥ | To be opened when PDV-5013 tL | is under maintenance. RZS | Bumer gun clearing valve. | 7 | Opened based on the common (805 A) from BMS. PAGE NO. C-1/8Service ‘Open Close | Remarks Bypass vaive of steam strap | after PDV-5013 7 To be Kept opened for sometime after changing of steam then closed immediately. Siy [Bypass valve of SB. sieam trap (514) To be opened for sometime for charging the soot blower line. Isolation valve of steam trap | | To be opened while steam trap after PDV-5013 is charged Cleating steam isolation valve | 7) To be opened just before fight | up. ‘Atomising steam shut off valve 7 | Open based on the demand of BMS Manual isolation vaNe of 7 | To be opened just before light atomising steam near guns up. PILOT GAS, Isolation valve of pilot gas at| 7 ery limit / near cylinder Pilot gas pr. Control valve v Can be adjusted to have 08 kg/om2(g) pr. At PG 420 Pliot gas shut off valve | Open based on BMS command | Manual regulating valve after | 7 [To be opened just before light | POV. | up. Manual isolation valve near) 7 bumer | BURNER, | Cooling airisolaion vave | 7 INSTRUMENT AIR instrument air isolation valve |v at battery limit Isolation valve of instrument |v air pr. transmitter PAT 507 ATOMISING, TRACING & | “| | HEATING ‘STEAM FROM | | ‘STEAM DRUM [S19 [isolation valve of atomising v | Tobe opened just before steam | steam tapping at drum charging to atomising line. ‘Sat valve of atomising | 7 To be closed after atomising steam is taken from drum, S20 v [To be opened when soot blowing is to be started. [sai idual isolation valves of Y | To be opened when soot 2 Nos) | soot blowers blowing is to be started. 2 | Isolation vaive of soot blower | 7 steam trap (514) | 7 PAGE NO. C-1/9CHARGING UP OF FUEL OIL UPTO BURNER (It is assumed that line up of the valve in oil system has been done as given in valve position chart prior to charging up of the fuel oil) Open isolation valve (FO-101) just before course duplex filter (B5501-N1) + Line up one element of duplex filter by opening two way valve as required, * Open air vent valve of duplex filter and close immediately once oil gushes out. + Now oil is available upto the oil pump B-5501-G1A + Then start the pump as per instruction given in manual. Pump must be vented out prior to start if pump maintenance was done during shut down period. ‘+ Adjust return oil control valve (PCV-5012) to have oil pressure of about 5 to 8 kg/cm2 (g) at pump discharge and above same just before the fine duplex filter (BS501-N2) + Line up one element of duplex filter (B5501-N2) by opening two way valve as required. Now oil is available upto MFT valve (RV-501) * Adjust oil flow control valve manually to have oil pressure of above 2 to 3 kg before MFT valve. Return oil flow to tank will get established after flow control valve and return l shut off valve is open. * Meanwhile charge steam tracing and steam heater and observe that oil temp. rises gradually and alarm TAL-502 is reset. For this open bypass valve ( 06S-103) of steam trap of heater. Steam trap inlet isolation valve (068-104) and inlet and outiet valve of heater steam temp. control valve ( TCV-S01) Now gradually open isolation valves at battery limit ( 06S-101) . Adjust TCV- 501 manually to obtain F.O. temp. at burner about 120 deg.c. valve TCV-501 can be put on. Auto control once oil temp. is stabilised CHARGING UP OF ATOMISING STEAM UPTO BURNER A It is assumed that line up of the valve in steam atomising system is done as given in valve position chart ) * Open atomising steam isolation valve at battery limit. * Adjust valve PDV 5013 in such a way to have 1.5 to 2.0 kg/em2(g) higher atomising steam pressure than oil pressure near burner. * Verify that atomising steam pressure low alarm is reset. Now steam is available upto atomising steam shut off valve(RV-504A) PAGE NO. C-1/10CHARGING UP OF LPG GAS UPTO BURNER A It is assumed that line up of the valve in LPG system is done as given in valve position chart) © Open vaive on the LPG cylinder. © Adjust pressure control valve PCV-5011 to have at PG-5010K. + Verify that LPG pressure low alarm is reset. Now LPG is available upto LPG shut off valve. cgicm2(g) LPG pressure FILLING WATER IN BOILER (itis assumed that the line up of valves in boiler system has been done as given in vaive position chart) QD at battery limit pressure gauge PG501i Open level control vaive FCV-501 manually from the control room Now water will start flowing to the drum. Water rises to the steam drum, mud drum and furnace panels It may take about 30 minutes to fill water to the required level in the steam drum, + As level of water reaches - 150 mm on direct water level gauges (confirmation by attendant) then close level control valve ( FCV-501) PLACE FD FAN INTO SERVICE Check prior to start: * Verify bearings are properly greased * Check that the fan is free to rotate. (verify by manual rotation of coupling) * Check control air supply to /P controller FIC-503 and position of power cylinder FCV-501 * Check that fan suction damper is in fully closed position and limit switch of closed position is energised. ‘* Depress the start push button of fan from the local panel Observe that the fan runs up to speed and comes into service. Observe that there are no excessive vibrations (by feel) and there is no abnormal noise from the fan. Observe the bearing temperature is okay. Observe the motor current is normal at no load. From the DCS then load the fan to 20 % suction damper opening. Observe that motor current is normal Observe combustion air pressure on PG-5010W and PG-5010X (windbox pressure) PAGE NO. C-1/14BOILER LIGHT UP Before boiler light up the following valve positions are ensured: + Open steam drum air vent (BW-15) * Open ail, atomising steam, pilot gas manual isolating valves of burner- A (FO-123, 136-127, PG-105) BOILER PRE INTERLOCK 1. Verify that the boiler pre interlock requirements are met. The conditions are : a) Boiler steam drum water level is within permissible levels ( about -150 mm for cold light up ) b) F.D. Fan running ¢) Instrument air pressure not low (Alarm PAL-507 is reset) d) Combustion air pressure not low (Alarm PAL-503 is reset) e) Boiler emergency push button is not activated (Absence of alarm) f) Drum pressure not high 9) Boiler outlet damper not close. When the above conditions are met the operator can set the "Boiler Pre-interiock satisfied flag”. Boiler ready for start indication appears. After depressing the boiler start push button the "Furnace purge ready " lamp glows if following conditions are satisfied. a) Pre- interlock is satisfied b) Oil shut off valve is closed (RZSC-502 energised) ©) F.D. Fan damper open to 50 % (FZSC-503 energised) d) All air registers are full open (RZSO energised) Once the "Furnace purge ready “ lamps light up, then purge start is initiated by operator action. Purge running lamps light up. On expiry of the present three- minute purge period, purge complete lamp light's up and purge-running lamp extinguishes. Once the boiler is purged then it has to be started within 15 minutes (max. firing trial time). Failure to start within 15 minutes will require repeat purge. Indication lamps on panel show the status of purge sequence. Purge required indication would also come if firing trial fails. Once the purging is finished F.D. Fan damper and oil flow c.v. are required to be taken to start position. PAGE NO. C-1/12Before starting of the burner, the following needs to be satisfied in addition to pre-interiocks to get oil firing main interlock okay and burner ready for start: a) Drum level not very low (LALL 501 reset) b) Oil temp. not low. (TAL 502 reset) c) Atomising media pressure not low (PAL- 505 reset) d) Furnace pressure not high (off delay timer - 4 sec.) (PAH-501 reset) e) Combustion air pressure not low (PAL- 503 reset) f) Drum steam pressure not high. (PAH-502reset) g) Pilot gas pressure not low ( PAT -506 reset) h) Oil flow control valve is in start position (FZS-504 energised) i) F.D. Fan damper start position (FZS - 503 energised) i) Burner stop PBS is not operated. If the above conditions are satisfied, fuel oil permissive is available to BMS for ighting up a burner. With fuel oil permissive "Burner ready " signal is on the operator initiates burner (A) start command. The following sequences take place by BMS command. a) Atomising steam shut off valve (RV-504A) opens and if it proved by its limit switch then only oil firing start i.e. oil shut off valve (RV-503A) opens. For fuel cil shut off valve to open following condition needs to be satisfied. © Main interlock is satisfied * Atomising steam shut off valve is open. * Clearing shut off valve is closed. b) H.T. Transformer of igniter is energised for 5 seconds for sparks. c) Pilot gas shut off valve opens (RSV-508A) d) Pilot gas is ignited by the spark and the scanner senses pilot flame. e) On sensing pilot flame BMS verified that FD Fan suction damper is 20 % open and atomising steam shut off is open. f) Opens fuel oil shut off valve (RV-503A) and return (RV-502) 9) Oil atomises sprays into the furnace and gets ignited by pilot flame. h) Flame on signal from UV scanner (XA 501A) shut off valve closes Note: If there is no pilot flame subsequent action do not take place. If main flame is not established within 10 seconds of opening of fuel oil shut valve then atomising steam shut off valve closes. In such cases boiler goes for repeat purge. PAGE NO. C-1/13AFTER ESTABLISHING FLAME IN BURNER, THE OPERATOR TAKES CARE OF FOLLOWING: Deputes the local operator to inspect the flame in the furnace through peepholes. Proper flame is important. Flame is not proper then minor adjustment such as axial position of the gun, fuel oil pressure by flow control valve and air flow by F.D. Fan suction damper can be adjusted. In case the flame is still poor, the operator trips the burner, carries out steam cleaning and restarts the burner. © Monitor and control the steam drum water level between prescribed limit by running feed pump and positioning level control valve as required. ‘* Monitor parameter, which can cause boiler trip. (Atomising steam pressure, mini fuel oil pressure, instrument air pressure, combustion air pressure low, furnace pressure high, and drum water level very low.) * Place in service one phosphate dosing pump on minimum stroke / speed. « Regulate the firing rate to have pressure rise as per the start up curve enclosed. * By gradually throttling the drum air vent valve (BW/15) and adjusting firing rate to 25 % drum pressure is raised. © Once drum pressure is at about 8.0 kg/em2 (g) boiler water sample cooler can be put in service. * Once drum pressure is at about 10 kg/om2 (g) boiler is now ready for connecting to load. BOILER CONNECTING TO LOAD * Please check up physically open position of valve PCV-502 on M.S. line. © Open M.S. line drain Valves ( $13,826,S12) © Open air vent valves on M.S. line (S04) * Open bypass valve (S02) of main steam stop valve gradually. Thus main steam line is heated. Put steam traps on M.S. Line into operation. * When clear steam comes out from drain then drain valves are closed and main steam stop valve is open (S01). After opening M.S. stop valve (S01) close its bypass valve (S02), © By this time drum air vent valve are fully closed & air vent valve on M.S line (S04) are kept open until such time when battery limits stop valves of M.S. Line (S05) is open then b connected to load. PAGE NO. C-1/14Based on the steam demand firing rate is gradually increased by adjusting flow control valve and F.D. Fan suction damper. At load above 35 % and when steady steam flow is obtained then following auto controls are put into auto mode. © Drum level control * Combustion control © CBD control. At load above 35 % convection bank superheater also to taken into service. At load above 50 % burner B can be taken into operating. For this burner B valve shall be lined up as given in valves position chart for burner A. * Now boiler can be gradually loaded to 100 % as per process requirement. PAGE NO. C-1/15* Atnormal continuous rating i.e. at 70 Uhr compare the fol with the predicted values : Boiler drum pressure. M.S. pressure F.W. Temperature before feed control station. ‘Combustion air flow kg/hr. Fuel oil flow kg/hr Feed water flow kg/hr. Steam flow kg/hr. Fuel oil pressure at burner inlet. Fuel oil temperature at burner inlet. Atomising steam pressure at burner inlet Burner windbox pressure mmwe. Furnace pressure mmwe. Flue gas temperature at boiler outlet. % 02 at boiler outlet, wing parameters A comparison of the actual values with the predicted values gives an assurance that the boiler performance is normal and also highlighted areas where attention is required * AtNCR request the local operator to make walkdown check of the boiler, fuel oil, water, gas lines to note any leakage’s or abnormalities. * When the boiler is in service, the operator is alert to the alarms appearing on DCS. When an alarm registers, the local operator is deputed to check locally the cause for the alarm. Corrective steps are taken where necessary by switching the affected controller to manual mode to restore normal values. Quick action by the operator prevents further deterioration of values to the boiler trip level. * When the boiler is in service the operator verifies the laboratory reports of boiler water, boiler feed-water & M.S. sample at four-hour intervals and ensures that the boiler water quality is as per norms. + When the boiler is in service, the operator ensures that the data acquisition system prints out boiler log sheets at hourly basis, or log sheet are manually. PAGE NO. C-1/16BOILER SHUT DOWN (FM BOILER ) Aboiler shut down can be of two types : A. Planned shutdown where the operator gets advance notice and adequate time to shut down boiler in an orderly manner for inspection, maintenance or cold reserve. B. Boiler trip on protection or an emergency shut down by the operator. A n to be taken by the operator for each type of shut is described below. A. PLANNED SHUT DOWN: A planned shut down has to be co-ordinated with other working departments based on the steam demand of the plant + Reduce the load of the boiler from 100 % MCR to 25 % MCR (preferably in steps of 5 % MCR every five minutes ) by the combustion controller. * At25 % MCR take following controls on manual model. = Drum level control * Carry out a cycle of soot blowing. + If steam demand is not there, then boiler may be tripped manually by activating burner tip push button in BMS, «Immediately close the main steam stop valve (S-01) and open drum air vent valve (BW/15) to crack open. * Gradually reduce the drum pressure if boiler is to be taken for maintenance / inspection. Or else keep the boiler in hot condition by closing drum air vent valve. Once the boiler pressure falls below 3.0 kg/cm2 then steam coil heater in the water drum can be charged with steam from external supply. For this first open bypass valve of steam coil heater steam trap (S18) and steam trap let isolation valve (S17). Then gradually open steam coil heater inlet ‘lation valve (S15) when condensed steam starts oozing out from bypass line then close the bypass valve (S16). © If sufficient time is available then allow the boiler to cool naturally. * Close battery limit isolation valve on fuel oil LPG line. Day oil tank inlet to OPH assembly ( when boiler is to be kept out of service for prolonged period) * Continue to feedwater to the boiler to maintain water level upto +100 mm until boiler is hot. ‘* Stop phosphate dosing pump. PAGE NO. C-1/17Stop F.D. fan after the furnace purge. Close CBD isolating valve (WW01) Verify the drain valve (WW04) are closed. Boiler has to be preserved as per preservation procedure if shutdown is more than 72 hours ( See preservation procedure enclosed in the manual) B. BOILER EMERGENCY TRIP : ‘Sometime a boiler trips either by a protection or due to a power failure or by an emergency trip command by the operator causing the MFT valve to close and the firing is abruptly stopped. In emergency trip the operator action is: * For protecting the boiler + For investigating the cause of trip and if possible to eliminate the cause. © Ifthe cause is el © If the cause cannot be immediately eliminated to continue the shutdown ti is done BOILER TRIP DUE TO INSTRUMENT AIR FAILURE : When the boiler trips due to instrument air that fail safe valves do not endanger the boiler. lure exercise extra caution to see For e.g. : If feed water control valve remains open, then isolating valve before or after the control valve to be closed BOILER PROTECTION AFTER A TRIP : Close main steam stop valve immediately (S-01) Continue to feed the water if level requires to be maintained. Check that MFT valve (RV-501) is closed. Check that there is no flame in the furnace. Carry out post trip purge of the furnace ( 50 % air flow for 2 minutes and 20 % air flow for 5 minutes ) PAGE NO. C-1/18HOT RESTART / WARM START: Restarting the boiler immediately after a trip out when the boiler is still hot with steam pressure is more that 5 kg/cm2 (a) is termed as hot restart / warm start. © Charge fuel oil, atomising air, steam-tracing line, and LPG gas as explained earlier by opening respective isolating valve at battery limit. © Check that oil temperature of about 120 ° C is available at the burner. * Check that feed water is available at battery limit. © Start F.D. Fan while inlet damper is closed, * Follow furnace purge sequence by satisfied pre-interlock / main inter locks as explained above. © Start the bumer, and see that flame is established. Gradually adjust the flame by adjusting FD Fan damper and oil flow control valve. + Crack open the drum air vent valve. * Gradually raise the drum pressure to operating pressure. In hot start drum pressure can be raised fast at the rate of 200 ° C /hr. ‘* Once operating pressure is about 10 kg/om2 (g) then connect the boiler to load as explained earlier. Now drum air vent can be closed. * Atload above 25 % and when steady steam flow is obtained then auto control loops can be put into service such as = Drum level control ~ Combustion control = Closing of Eco. Bypass. * Gradually raise the load on the boiler as per the plant steam demand to 100%. Soot blowing and phosphate dosing to be restored as and when required. PAGE NO. C-1/19