Scenario ..!!

Coal Feeder A and K coal flow capacity is 150 T/H each. Both feeders feed coal in furnace via conveyer.
So, if when coal flow increased in these feeders it takes time to enter into the furnace, because belt
speed(frequency) increased but at conveyer coal amount is same as previous flow demand and it take
few minutes to fill all conveyer according to new coal flow demand. So, for a while actual coal entering
furnace will not increase and coal demand is decreased at other feeders that are on auto, to adjust the
total coal flow demand. All feeders at front of furnace are directly connected to furnace so when front
side feeders lower their flow the coal entering in the furnace is decreased at the same time (while feeder
A & K coal do not follow this phenomenon due to conveyer).

Scenario..!!

Feeder A and K are lengthy and weight cells are installed near the inlet.

If coal feeder A or K coal flow reduced due to feeder inlet choking, feeder speed increased to maintain
coal flow. Due to increasing speed (Frequency) coal feeding to conveyer and then furnace is increased
(because coal flow is reduced only at weight cell and before cell to inlet of feeder, while after weight cell
to conveyer inlet, coal pile on belt is normal and belt is also lengthy having enough amount of coal). Due
to reduction in coal flow at DCS (because Feeder A or K which ever is chocked showing less coal flow due
to chocking) others coal feeder increases coal flow accordingly to maintain total coal flow demand.

Now coal entering furnace increased significantly because of increased speed of feeder A/K and also
from feeders that are auto selected. In the consequences main steam temperature and pressure will
increase. Even coal demand and coal flow are same (because rear coal conveyer is filled with coal and
feeding coal to furnace and this amount of coal is not calculated in to total coal flow, because feeder
weight cell is near inlet of feeder, and there is less or no coal on weight cell).

Scenario ..!!

Coal feeder A and K coal capacity is greater than other feeders, so little variation in feeder speed
(frequency) significantly increase/decrease coal flow.

If Coal Feeder A or K are in service and remain blocked for a few minutes, the feeder speed will be high
(to maintain feeder coal flow) and the feeder belt will probably empty. In this case if feeder unblock
suddenly or a lump carry forward on the belt the weight cell will read and multiply with feeder
frequency (that is already high to maintain coal flow demand), due to high frequency feeder flow will
suddenly be increased to excessive value, and then this flow will add in total coal flow, that will also
show increased value of total coal flow. The feeders that are on auto in this situation will decrease their
flow to maintain coal flow demand. Keep in mind that coal flow shown at the feeder A/K is not fed into
furnace yet due to lengthy belts and conveyer. So actual coal entering in the furnace will significantly be
reduced (almost equal to coal flow read by feeder A/K). in the consequences furnace temperature, main
steam temperature, reheat steam temperature and main steam flow will be reduced (depending on the
coal flow amount reduction due to feeder A/K)
Feeder A&K operation first time:

If feeder A/K is put in operation when there is no coal on feeder belt and conveyer, care must be taken
that coal flow must be minimum (2 ~ 3 T/H) for extended time that all feeder belt filled with coal and
coal is visible from sight glass of conveyer. After that coal flow can be increased accordingly.

Coal feeder A/K operation when blockage and coal flow decreased:

If coal flow decreases or low coal signal appeared at feeder A/K feeder must be tripped automatically if
“IN” interlock is selected from DCS. If feeder is not trip in this scenario (coal flow is low) and feeder
frequency is increasing, immediately trip the feeder and conveyer, because coal is still present on feeder
and conveyer (low coal flow is due to there is no coal on weight cell, but rest of the belt and conveyer is
still filled with coal). In this case if feeder frequency increased, this remaining coal on the feeder belt and
conveyer will be fed to furnace rapidly due to increasing frequency of belt because of deviation in coal
flow and setpoint, auto selected feeder will also increase their coal flow to maintain total coal flow.

Coal Feeder A/K starting after tripping of conveyer on low coal flow:

If the feeder trips on low coal flow or due to conveyer fault (if conveyer trips it trip feeder immediately),
care must be taken before feeder put into operation, because conveyer is filled with coal according to
previous coal flow setpoint of feeder. Remember feeder belt is lengthy and if weight cell measures no
coal flow, coal is still existed on belt and conveyer.

After startup of feeder if coal flow establishes on DCS and observed from the sight glass near inlet of
feeder increase coal flow of feeder before tripping setpoint, because maximum feeder belt and conveyer
is filled with coal according to the previous coal flow value.

Coal Feeder A/K Operation when feeder has blockage:

Feeder A/K operation must be avoided when feeder has blockage and coal flow is zero. During blockage
feeder frequency increases due to deviation in setpoint and actual coal flow, if feeder auto trip “IN”
button is selected at “CUT”. Now if feeder blockage clear during this situation when feeder frequency is
high, the coal flow suddenly increases to excessive value on this feeder and total coal flow as well. Coal
flow on others feeder will decrease to adjust the total coal flow, while coal flow showing on the blocked
feeder will also nor fed to furnace because most of the feeder belt and conveyer is empty due to
blockage. So, actual feeding into furnace is significantly reduced and in the consequences furnace
temperature and main steam pressure will reduce accordingly. During blockage if feeder frequency is
more then 35 Hz, and somehow blockage clear and coal flow established, the situation could be verse
because feeder A/K design flow is 150 T/H each, so coal flow at high frequency will be abruptly excessive
and verse consequences like ‘boiler master on manual due to deviation in actual and demand coal flow,
could be happen.

To avoid this situation feeder must be trip when coal flow is very low and feeder frequency is increasing
continuously