Starting, Operating and Emergency Procedures for Supercritical Boilers

Presentation on
Supercritical Boiler Start

up, Operation & Shutdown
including Emergency
operation
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L&T-MHPS BOILERS
Index
 Basics of Supercritical Plant
 Special Feature for Supercritical Plant
 Boiler Performance Parameter
 Coal & ASH Characteristic
 Start-up Curve
 Boiler Startup checks
 Boiler Startup Sequence
 Boiler Light Up to Full Load up
 Oil Burner Startup Sequence
 Mill Startup Sequence
 Operational Controls
 Boiler Shutdown Sequence
 Oil Burner Shutdown Sequence
 Mill Shutdown Sequence
 Boiler Forced Cooling Method
 Boiler Trip Conditions
 Special Operating Condition
a. FCB
b. Runback
c. Forced Cooling
 Emergency Operating Condition
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Basics of Supercritical Plant
(1) Why the Supercritical plant is selected?
User Needs
To economize and save running cost

For Environmental Protection
Rise the Efficiency
Select the Elevated steam conditions
Supercritical pressure boiler

3 / 212
L&T-MHPS BOILERS
(1) Comparison with conventional drum type boiler
Initial cost : Higher

Construction Period : Longer
Operation : More difficult
Main Advantage
Plant Efficiency : Higher
- Reduction of Operation cost (i.e. fuel cost)
- Less CO2 discharge
4 / 212
L&T-MHPS BOILERS
(2) What is supercritical pressure ?
1000
900
800
Sat
ura
700 ted
W at er
Line
Bulk Density [kg/m3]
600
779.3 kg/m3
500
400 No fixed
steam and
300 waterline
24.8 kg/m3
200 Quick
Steam
100 Line Generation
ed Steam
Saturat
0
0 4.9 9.8 14.7 19.6 24.5 29.4
Pressure [MPa] Critical Pressure:

22.12MPa
5 / 212
L&T-MHPS BOILERS
(3) What is supercritical temperature ?
1000
600℃
800
500℃
Enthalpy (kcal/kg)
600
→Supercritical
Steam/Water
400℃
400 (Saturated) Critical Temperature:
　 374.15℃
300℃
200 200℃
Water
0
0 10 20 30 40
Pressure (MPa)
Pressure vs. Enthalpy Chart for Sliding Pressure Boiler 6 / 212
L&T-MHPS BOILERS
(4) Compared conceptual diagram
between Drum and Once-through type
Drum Boiler The drum stably storage

the large capacity water,
Heat storage and evaporation point is
capacity is large. Boiler
fixed.
Large Capacity
Water Strong against
disturbance
Evaporation Simple controllability
point is fixed. Conversely, heat storage
capacity is large.
Load following capability
is slower than the once-
Burner through type.
7 / 212
L&T-MHPS BOILERS
Once-through Boiler at sub-critical
Once-through Section
Water Saturation Steam
Burner
8 / 212
L&T-MHPS BOILERS

Once-through Boiler at sub-critical
Burner
9 / 212
L&T-MHPS BOILERS
Once-through Boiler at sub-critical Evaporation point is moved. It

is affected by fuel input and
feed water flow.
Disturbance-proof is
inferior to the drum type
Complicated controllability
Heat storage capacity is

Evaporation smaller than the drum type.
Burner point is moved.
Load following capability is
faster than the drum type.
10 / 212
L&T-MHPS BOILERS

Once-through Boiler at supercritical
Once-through Section Evaporation point is obscure.

However, steam is quickly
Water Saturation Steam generated by means of only
compressed water feeding.
Load following capability is
fastest among the all.
Burner
Evaporation point
is obscure
11 / 212
L&T-MHPS BOILERS
(5) What is the type of Once-through boiler?
The general feature of the once-through boiler is as
follows.
to • The boiler itself has no circulation system such
SH Steam Turbine as drum type boiler. It is better suited for high
pressure boiler.
Water • Water passes through water wall tube and
Separator becomes steam absorbing the heat from fire.
Furnace For this purpose, continuous feeding of the
water is necessary while firing.
• Holding water quantity is less than the drum
type so that the required steam quantity can be
BFP
generated in a short period of time.
Eco
• Balance control between feed water flow and
fuel flow is more difficult than drum type
because the pressure fluctuation is easy to
occur due to load fluctuation.
• High water purity is required due to no blow
down line and higher heat load.
12 / 212
L&T-MHPS BOILERS
follows.
to • The boiler itself has no circulation system
SH Steam Turbine such as drum type boiler. It is better suited
for high pressure boiler.
BFP
Eco
13 / 212
L&T-MHPS BOILERS
The general feature of the once-through boiler is
as follows.
Separator becomes steam absorbing the heat from
Furnace fire. For this purpose, continuous feeding of
the water is necessary while firing.
type so that the required steam quantity can
BFP
be generated in a short period of time.
Eco
• Balance control between feed water flow
and fuel flow is more difficult than drum
type because the pressure fluctuation is
easy to occur due to load fluctuation.
14 / 212
L&T-MHPS BOILERS
follows.
pressure boiler.
BFP
Eco
15 / 212
L&T-MHPS BOILERS
The general feature of the once-through boiler is
as follows.
Separator becomes steam absorbing the heat from
Furnace fire. For this purpose, continuous feeding of
the water is necessary while firing.
BFP
Eco
• Balance control between feed water flow
and fuel flow is more difficult than drum
type because the pressure fluctuation is
easy to occur due to load fluctuation.
16 / 212
L&T-MHPS BOILERS
follows.
pressure boiler.
BFP
Eco
17 / 212
L&T-MHPS BOILERS
(6) Basic philosophy of the controllability of the Once-through type
(a) Steam temperature control
Once-through Boiler Feed water flow is kept at constant.
Once-through Section If fuel input is increased
Water Saturation Steam Saturation region is moved to left side and

superheat region is relatively long, and then
main steam temperature is elevated.
Burner Steam temperature is controlled by

water fuel ratio
(= ratio between fuel and water).
18 / 212
L&T-MHPS BOILERS
(b) Steam pressure control
A certain level of degree of superheat

Once-through Boiler
in steam is kept.
Degree of superheat
If increase the compressed water
feeding
Steam generation is quick increased

without stagnation.
Burner
Steam generation (pressure/load) is
controlled by feed water flow.
19 / 212
L&T-MHPS BOILERS
(c) Steam temperature control by enthalpy
1000
SH Outlet
800 600℃
Superheater
W.W Outlet
500℃
Enthalpy (kcal/kg)
600
Saturation Water Wall
400 (Water/Steam) 400℃
W.W Inlet Economizer
300℃
Eco. Inlet
200 200℃
35% 50% 75% 100% BMCR
Water
0
0 10 20 30 40
Pressure (MPa) 20 / 212
L&T-MHPS BOILERS
(c) Steam temperature control by enthalpy
1000
SH Outlet
800 600℃
Superheater
W.W Outlet
500℃
Enthalpy (kcal/kg)
600
300℃
Eco. Inlet
200 200℃
35% 50% 75% 100% BMCR
Water
0
0 10 20 30 40
L&T-MHPS BOILERS
(d) Tentative steam temperature is controlled by spray water
SH
W
S
Furnace
ECO
(A) No Spray 22 / 212
L&T-MHPS BOILERS
Temp is decreased by spray water
temporarily
SH SH
W W
S S
Furnace Furnace
ECO ECO Spray water : From ECO outlet
(A) No Spray (B) Spray Injection 23 / 212
L&T-MHPS BOILERS
Finally, SH outlet temp. become
same as no spray condition
SH SH WS outlet steam temperature is
increased.
W W
S S Heat Input : Constant
Furnace Furnace
ECO ECO Spray water : From ECO outlet
Feed water flow : Constant

(A) No Spray (B) Spray Injection 24 / 212
L&T-MHPS BOILERS
No spray condition
Steam Temp. (deg C)
WW out 1SH 1ry DeSH 2SH 2ry DeSH 3SH
25 / 212
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Spray injection
Steam temperature
decreasing tentatively.
Steam Temp. (deg C)

Spray Spray
26 / 212
L&T-MHPS BOILERS
WS outlet
temperature Steam temperature
recovery. recovery.
Steam Temp. (deg C)

Spray Spray
27 / 212
L&T-MHPS BOILERS
(e) Pressure control under superheated condition at WW outlet
1000
SH Outlet
800 600℃
Superheater
W.W Outlet
500℃
Enthalpy (kcal/kg)
600
300℃
Eco. Inlet
200 200℃
35% 50% 75% 100% BMCR
Water
0
0 10 20 30 40
L&T-MHPS BOILERS
(6) Basic philosophy of the controllability of the once-through type
(f) Summary of comparison for main process control

between supercritical type and drum type
Main parameters for main steam pressure / temperature control
Supercritical
Drum
Once-through
Main steam Wet SH Spray

MS Temp
temperature
SH Spray
Dry Water Fuel Ratio
Main
Main steam
steam Wet Fuel Flow
pressure Fuel Flow
pressure Dry Feed Water Flow
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(7) Characteristics of sliding pressure operation
Main steam pressure setting (MPa)
Turbine governor opening (%)

25.12
100
8.43
Sliding pressure range
35% 100%
For Reference Generator load
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L&T-MHPS BOILERS
(7) Characteristics of sliding pressure operation
Merit of the sliding pressure operation

Thermal efficiency of the plant is elevated for the
following reasons.
1) Throttle pressure loss of the steam turbine
governor can be reduced. Accordingly, internal
efficiency of the turbine is elevated.
2) 　 Shaft power of the boiler feed water pump can
be reduced.
3) 　 Steam temperature is easy to rise by means of
reducing pressure. (Specific heat of the steam
is reduced in the vicinity of the low pressure
range.)
31 / 212
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(8) Strict control of water quality
All feed water evaporates in the Boiler
and conveyed to the Turbine
SH Contaminants in feed water cannot be
Water blown out
Separator
The heat load at water wall is higher
WSDT than the drum one.
Contaminants in feed water is easier to
Furnace adhere to water wall as scale.
BCP
BFP
Eco High water purity required !
 Condensate polisher system
 Clean-up operation during start-up
32 / 212
L&T-MHPS BOILERS
Pre-Boiler Clean-up Operation Completion Criteria

Required Water Quality
Once-through
Item
AVT
pH (25°C) - 9.3 – 9.6

Conductivity μS/cm 5-11 (8)
CC μS/cm ≤ 0.5
Hydrazine Ppb > 200
Deaerator outlet
DO ppb ≤ 10
Iron ppb ≤ 50
Copper ppb ≤ 20
Silica ppb ≤ 30 33 / 212
L&T-MHPS BOILERS
Boiler Clean-up Operation Completion Criteria
Required Water Quality
Once-through
Item
AVT
Combined HP heater WSDT ≤X

& Boiler Cold Clean outlet Iron ppb (X depends on inlet
up blow burden capacity)
Combined HP heater WSDT
& Boiler Cold Clean Iron ppb ≤ 200
up recirculation outlet
WSDT Iron ppb ≤ 100

Hot Clean up
outlet Silica ppb ≤ 30
34 / 212
L&T-MHPS BOILERS
Required Water Quality from Pressurisation to Synchronization
Once-through
Item
AVT
Deaerator outlet DO Ppb ≤ 10

pH (25°C) 9.3-9.6 (9.45)
CC μS/cm ≤ 0.5
Boiler Economizer Hydrazine ppb ≥ 200
Inlet DO ppb ≤ 10
Iron ppb ≤ 50 (30)
Copper ppb ≤ 20
Silica ppb ≤ 30 35 / 212
L&T-MHPS BOILERS
Required Water Quality from Synchronization to Full Load
Once-through
Item
AVT
Deaerator outlet DO Ppb ≤7

pH (25°C) 9.3-9.6 (9.45)
CC μS/cm ≤ 0.5
Boiler Economizer Hydrazine ppb ≥ 10
Inlet DO ppb ≤7
Iron ppb ≤ 50 (20)
Copper ppb ≤ 20
Silica ppb ≤ 30 36 / 212
L&T-MHPS BOILERS
Required Water Quality from COD onwards
Once-through
Item
AVT CWT
Deaerator outlet DO Ppb ≤7

pH (25°C) 9.3-9.6 (9.45) 8.5-9.3
Conductivity μS/cm 5-11 (8) -
CC μS/cm ≤ 0.5 (0.25) ≤ 0.2 (0.1)
Boiler Hydrazine ppb ≥ 10 -
Economizer
Inlet DO ppb ≤7 20-200 (SP-50)
Iron ppb ≤ 20 (10) ≤2
Copper ppb ≤ 20 ≤2
Silica ppb ≤ 30 ≤ 20 37 / 212
L&T-MHPS BOILERS
Dosing Points for AVT & CWT Mode of Operation
Once-through
Item
AVT CWT
Ammonia (NH3) CPP O/L CPP O/L

Chemical Hydrazine (N2H4) CPP O/L
injection Point CPP O/L &
Oxygen (O2) -
Deaerator O/L
38 / 212
L&T-MHPS BOILERS
Special System for Supercritical Plant
(1) Special Feature for once-through boiler
Once-through boiler has start-up system
including BCP.
SH
Water To maintain minimum flow and to equalize
Separator flow to many parallel tubes, it is always
necessary to feed water to the boiler at
WSDT
rate of 25% load while firing.
Furnace
Eco However, the steam generation is in low

BFP conditions which is less than the rate of
25% load, the heat loss is very high
accordingly.
39 / 212
L&T-MHPS BOILERS
including BCP.
SH
Water However, the steam generation is low
Separator conditions which is less than at rate of
25% load, the heat loss is very high
WSDT
accordingly.
Furnace
BCP
To recover the possible heat loss, hot

Eco
water of approx.20% load is returned to
BFP
Economizer inlet to accumulate the heat in
the boiler water using BCP.
40 / 212
L&T-MHPS BOILERS
including BCP.
SH
Water During start-up of the boiler, approx. 5%
Separator load flow is fed to the boiler continuously
by BFP and balance approx. 20% required
WSDT
to maintain 25% load flow through
economizer and furnace water wall tubes
Furnace
is supplied by the BCP.
BCP 20% load flow
Eco
BFP
5% load flow
25% load flow
41 / 212
L&T-MHPS BOILERS
including BCP.
SH
Water The steam water mixture flows to water
Separator separator (WS), where it is separated to
steam and water. The separated steam
WSDT
flows to the superheater and water flows
to water separator drain tank (WSDT).
Furnace
BCP
Eco
BFP
42 / 212
L&T-MHPS BOILERS
including BCP.
SH
Water The BCP takes the suction from
Separator
WSDT and re-circulates approx.
20% load flow.
WSDT
The recirculation flow joins the
approx. 5% BFP flow and
Furnace
approx. 25% is fed to the boiler.
BCP
The excess 5% load flow is
BFP
discharged to condenser from
Eco WSDT as per the water level in
WS.
Indicated system is called
CONDENSER “Start-up system”.
43 / 212
L&T-MHPS BOILERS
Boiler Performance Parameters
Sr. No Parameters UOM BMCR TMCR
1 MS Flow Ton /Hr 2120 1918.6
2 RH Flow Ton / Hr 1680.1 1612.6
SH Out
3 Kg/cm2 (a) 256 254.4
Press
HPT-IN
Kg/cm2 (a) 247 247
Press
4
HPT-IN
◦C 565 565
Temp
HPT-Out
Kg/cm2 (a) 58.61 56
Press
5
HPT-Out
◦C 340.4 336.7
Temp
44 / 212
L&T-MHPS BOILERS
Boiler Performance Parameters
Sr. No Parameters UOM BMCR TMCR

6 RH-IN Press Kg/cm2 56.11 53.62
7 RH-Out Press Kg/cm2 54.11 51.78
8
IPT-IN Temp ◦C 593 593
9 ECO Temp ◦C 292.73 290
Press drop through

5.86 for BMCR condition and
RH incl cold & RH Kg/cm2
10 correspondingly lower for other
Piping
condition.
D W B D W B
11 Total Coal Flow tph
468 558 377 431 507 343
45 / 212
L&T-MHPS BOILERS
Coal Characteristics
Sr. No Characteristics Design Worst Best
1 Total Moisture (%) 15 17 12
2 Ash (%) 40 44 34
3
Volatile Matter (%) 19 18 22
4 Fixed Carbon (%) 26 21 32
HGI
5 55 50 60
6 GCV (Kcal /Kg) 3300 2800 4000
7 YGP (mg/Kg) 75 80 70
46 / 212
L&T-MHPS BOILERS
Ash Characteristics
Sr. No Characteristics Design Worst Best
1 Silica (%) 59.79 61.3 56.7
2 Aluminum (%) 25.36 28 23.5

3
Iron Oxide (%) 7.2 6 10
4 ASH FUSION TEMP (UNDER REDUCING ATMOSPHERE)
4a IDT (◦C) 1100 1100 1100
Hemispherical Temp
4b 1300 1250 1350
(◦C)
4c Flow Temp (◦C) 1400 1400 1400
47 / 212
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LMB Unit Startup Sequence
48 / 212
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49 / 212
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50 / 212
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51 / 212
L&T-MHPS BOILERS
Start-up Condition
Boiler Startup Condition
Sr. No Operation Mode WS Inlet Fluid Temp (◦C)
1 Cold Start ≤ 120 ◦ C
2 Warm Start > 120 & ≤ 260 ◦ C
3 Hot Start > 260 ◦ C
Unit Startup Condition

Turbine Condition Boiler Condition Unit Start up Mode
Cold Cold Cold
Cold Warm Cold
Cold Hot Cold
Warm Cold Cold
Hot Warm Warm
Hot Hot Hot
Note: Turbine startup Mode is judged based on Average Rotor temperature 52 / 212
L&T-MHPS BOILERS
Startup Condition
• Boiler Start-up mode is selected when MFT resets (5 Sec Pulse)
• Turbine Startup mode is selected when either MFT resets or Turbine

trip resets
• Unit Startup mode resets when any of the following conditions are
satisfied:
1. MWD > 50 % TMCR

2. Turbine Trip
3. FCB Operate
53 / 212
L&T-MHPS BOILERS
Steam admission Criteria for Unit Startup
Sr. No Start-up MS Press MS Temp HRH temp
Mode
1 Cold 80 KSC G 380°C ~ 390°C 380°C ~ 390°C
2 Warm 80 KSC G 400°C ~ 430°C 400°C ~ 430°C
3 Hot 112 KSC G Minimum 490°C Minimum 484°C
54 / 212
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Start- Up Curves
55 / 212
L&T-MHPS BOILERS
Start- Up Curves
56 / 212
L&T-MHPS BOILERS
Start- Up Curves
57 / 212
L&T-MHPS BOILERS
Preparation of Boiler Start-up
 Before Boiler start-up, Operator shall confirm the following conditions:
 Instrument & Service Headers Pressure > 6 KSC
 EDG System
 Electrical Distribution System is in service
 Water Treatment system is in service
 Waste Water treatment is in service
 Service water system is in service.
 Cooling water system is in service.
 ACW Header Charged
 Fire Protection System charged for Boiler area
 Pre-boiler cleanup completed with required criteria
 DM Water Stock availability in DMST & CST
 Boiler Auxiliaries Power ON
 ESP System
 Chimney
 Ash Handling System (Bottom Ash, Eco Hoppers, AH Hoppers, ESP Hoppers)
 Coal Handling System including Coal Stock
 Aux Steam Header charged. Aux Steam Pressure > 15 KSC & Temp > 250° C
 Coal Mill reject handling System is available
 LDO tank Level is normal
 DC Scanner Air fan is available
 Ensure all interlocks are in place and none of them have been bypassed. 58 / 212
L&T-MHPS BOILERS
Boiler Startup Sequence
59 / 212
L&T-MHPS BOILERS
60 / 212
L&T-MHPS BOILERS
61 / 212
L&T-MHPS BOILERS
Air and Flue Gas System Start-up
There are three (3) kinds of start up operational modes, namely cold start up, warm
start up and hot start up.
In all cases the draft system is started up before the boiler firing. The draft system
operation is balanced draft.
RAPH-A RAPH-B IDF-A FDF-A
AC Scanner 15% Air Flow

FDF-B IDF-B Established
Air Fan
31 % Air Flow Furnace LDO Leak MFT

Established Purge Test Reset
Sequence of start of Air & Flue gas system

62 / 212
L&T-MHPS BOILERS
Boiler Startup- Furnace Purge
Furnace Purge Condition
1.All System Power including flame detector is available and normal.
2.Any Air & Flue gas line in service (A or B side AH & FDF are in service)
3.Any Induced draft (I.D) fan in service.
4.More than 31% of combustion air flow (764.5 tph) is established.
5.Windbox damper controller on Auto Mode (Damper not close).
6.All Ignitor sparks rods are retracted.
7.All Oil Burner valves are closed.
8.LDO Shutoff valve is closed.
9.LDO Leak check valve is closed.
10.“NO FLAME” is detected on all Flame detectors
11.All Coal Feeders are off
12.Both PAF are off.
13.No MFT Condition is existed
14.MFT
15.LDO leak test not abnormal
16.LDO supply pressure is normal. 63 / 212
L&T-MHPS BOILERS
Boiler Startup- Furnace Purge
Sequence flow diagram
for furnace purge :
64 / 212
L&T-MHPS BOILERS
Boiler Startup- LDO Leak Test
Sequence flow diagram
for LDO Leak test :
65 / 212
L&T-MHPS BOILERS
Leak Test is performed to check leakage upto burner valves for each fuel
piping before burning fuel.
Permissive:
1. LDO supply pressure > 17.2 KSC
2. Flow control valve in leak test position
3. LDO shutoff valve in closed condition
4. Leak check valve in closed condition
5. All LDO burner valve are closed
6. No MFT condition is existed
7. More than 31% air flow is established
8. Furnace Purge Completed

66 / 212
L&T-MHPS BOILERS
LEAK TEST
PT
FT
BURNER
VALVE
SHUT OFF
VALVE Leak
Charging
Test
CHARGE
VALVE
 Charging Time (Leak Check Valve Open Time) :
60 sec or until LDO supply header pressure (PT: HHF30CP104) reaches 12.77 KSC
 Leak Test Time:
3 minutes
 Successful Completion Criteria:
LDO header pressure is kept within the specified value (Maximum allowable pressure
drop is 1.5 KSC ) for preset period of 3 minutes
 LDO Shutoff Valve Open Command:
After MFT reset.
68 / 212
L&T-MHPS BOILERS
Boiler Startup
Arrangement of Burner Elevation (Shows only one corner)
69 / 212
L&T-MHPS BOILERS
Boiler Startup
Arrangement of Burner
Wind box Assembly (Shows only
one corner)
70 / 212
L&T-MHPS BOILERS
Boiler Startup- Pre checks Before Light up
1. Pre-checks for Boiler light up (for Hot Clean up)
 SADC Damper Opening confirmation at Local

 Burner tilt to Zero Position
 Confirmation of SH/ RH Gas Distribution damper opening: 80 % / 20 %
 WB to Furnace dP control loop in Auto
 ERV ready (Power & Control Supply healthy, Instrument air available, ERV
local control panel in healthy condition)
 Confirm ERV Isolation valve in Open Condition
 Confirm line up of Atomizing Air & LDO line for all elevation
71 / 212
L&T-MHPS BOILERS
Boiler Light Up Preparation
2. Preparation
i. Main / Reheat Steam drain & vent group preparation

Step-1: Put all Steam side drain and vent valves in auto from individual drive loop
plate.
Step-2: Start the group by Pressing “ ON “ PB from SG-DCS HMI
i. SH & RH Spray Water group Preparation

Step-1: Put all SH & RH Spray valves in auto from individual drive loop plate.
Step-2: Start the group by Pressing “ ON “ PB from BOP- DCS HMI
72 / 212
L&T-MHPS BOILERS
Boiler Light Up
3. Light up
 Light up Sequence is as follows:-
UNIT START UP
Elevation Elevation Sequence Elevation Sequence

during Oil Burner On during oil Burner Off
Elevation GH 3 2
Elevation EF 2 3
Elevation CD 1 4
Elevation AB 4 1
73 / 212
L&T-MHPS BOILERS
START-UP OF OIL
BURNER
IGNITOR
PI
BURNER VALVE
PI BURNER GUN
ATOMIZING MEDIUM VALVE FLAME ON ■ 　 15SEC
74 / 212
L&T-MHPS BOILERS
START-UP OF OIL
BURNER
Corner- 8 Corner- 7 Corner- 6 Corner- 5
Corner- 1 Corner- 2 Corner- 3 Corner- 4
75 / 212
L&T-MHPS BOILERS
START-UP OF OIL
BURNER
In-service condition
Atomize
valve
Air
Steam To Burner
Purge
valve
Burner
valve
Oil To Burner
Purge Out of service condition
Atomize
valve
Steam To Burner Air
Air Air
Purge
valve
Burner
valve
Oil To Burner
76 / 212
L&T-MHPS BOILERS
Boiler Light Up- Post Checks
 Post light up checks are as follows:-
 Oil Pressure / Flow to be controlled based on Number of guns in service

 Atomizing air pressure to be maintained around 5 KSC
 Oil dampers shall be modulated based on LDO Header pressure
 Water wall metal temperature to be monitored (deviation in water wall right to
left should be less than 150 deg C- Preferably less than 75 deg c)
 Boiler expansion to be check
 Local walkthrough to be done for any abnormality checks
 Sudden increase of fuel to be prohibited to avoid WSDT Swelling
 Boiler expansion to be check during first light up
77 / 212
L&T-MHPS BOILERS
SCAPH CHARGING
4. SCAPH Charging
Purpose:
 During start-up and low loads it is not possible to heat the combustion air to
required temperatures by air preheater.
 During low load operation it is necessary to maintain minimum temperature

at the cold end of the air preheater to avoid acid corrosion.
 Steam coil air preheater is used to heat combustion air during low load boiler
operation and to maintain minimum cold end temperature.
 It is located down stream of the forced draft fan.
78 / 212
L&T-MHPS BOILERS
SCAPH CHARGING
Permissive:
•Boiler MFT Reset
•Any Fuel Oil Burner in service
•Aux Steam Header Pressure > 15 KSC
•SCAPH-A & B inlet & outlet Secondary Air ON-OFF MOD open with bypass MOD
closed.
Temperature Control Valve Operation Control:

It will control the “Average Cold End temperature for AH based on Combustion ratio”.
AVG Cold End Temp of AH = Avg Temp of AH inlet Sec Air Temp + Avg Temp of AH Outlet Flue Gas
Temp
Mix Comb Ratio Avg Cold
2 End Temp of AH
0 100
0.25 100
0.5 100
0.75 76
1 76 79 / 212
L&T-MHPS BOILERS
SCAPH CHARGING
Steam Cut-Off (if any of below condition occur):
•SCAPH Inlet ON-OFF MOD Closed
•SCAPH Outlet ON-OFF MOD Closed
•FDF Stopped
Above condition is to protect the tube from over heating in absence of Cooling
Media.
During SCAPH in Operation, Boiler Flash tank & DRT level to be monitored and
controlled.
80 / 212
L&T-MHPS BOILERS
Boiler Light Up- Fuel Flow Demand
5. Fuel Flow demand generation from startup to full load is as

follows:
FUEL Initial Fuel Set Press Rising Steam Admiss Steam Admiss Steam Admiss Start up Fuel Common Fuel
SET Fuel Set Fuel Set-1 Fuel Set-2 Fuel Set-3 Set Set
COND BLU HPTB MIN STEAM GEN SYNCH MW > 20% HPTB MWD > 50%
POS IN ADMISSION TMCR CLOSED TMCR
FUEL
DEMAN Cold Mode- Cold Mode- Cold Mode- Cold Mode- Cold Mode- Cold Mode-
Cold Mode-
D 100 tph 110 tph 160 tph 170 tph Fx (BID) Fx (BID)
40 tph
Warm Warm Warm Warm Warm Warm
Warm
Mode- Mode- Mode- Mode- Mode- Mode-
Mode-40 tph
100 tph 115 tph 165 tph 175 tph Fx (BID) Fx (BID)
Hot Mode-
Hot Mode- Hot Mode- Hot Mode- Hot Mode- Hot Mode- Hot Mode-
40 tph
100 tph 115 tph 175 tph 185 tph Fx (BID) Fx (BID)
81 / 212
L&T-MHPS BOILERS
Boiler Pressurization & Temperature Rising
SH3
RH2
SH2
RH1 G
HPT IPT LPT LPT
SH1 HPTB system in-service
W W WDC M
M
S S
LX
D M
T M
DEA CP
WW LP4
M
M
BCP HP8
M
GSC
M
BR LP3
M
ECO HP7 M
T T
FX
FX
LP1/2 CPS
M
M
HP6
M
M M
Flash
Pipe
82 / 212
L&T-MHPS BOILERS
Schematic Diagram of Turbine By-Pass System
Hot Reheat Steam
Main Steam
HP TB Valve LP TB Valve
HP IP
SH
Turbine Turbine
RH
Boiler
BFP Outlet Condenser

Cold Reheat Steam
CP Outlet
To Deaerator
83 / 212
L&T-MHPS BOILERS
HP Turbine By Pass System
HP turbine bypass discharges high pressure steam from main

steam pipe to the cold reheat steam pipe to control the Main
steam pressure.
Functions:
1. Control of the boiler main steam line pressure during start-up

till dry Mode.
2. Enables the boiler to continue in service when turbine trips or
load shedding & FCB.
3. Facilitates the quick starting of turbine after a turbine trip by
supplying matching steam parameters.
84 / 212
L&T-MHPS BOILERS
HP Turbine bypass control
• When Main steam pressure reaches to 20 KSC, Hp turbine bypass
valve open to its minimum opening condition.
• After MS pressure reaches 80 KSC (for cold mode), the HPTB

valve will start controlling the pressure.
• After changeover to dry mode from Wet mode , HP TB control

valves are normally closed and operated as back up control for
Main Steam Pressure Control.
• In Dry mode of operation, the set pressure of HP bypass valve is

increased by 10 KSC from the set pressure of MSV to keep in back
up control.
85 / 212
L&T-MHPS BOILERS
HP Turbine bypass control
• In Dry mode of operation ,If steam pressure reaches the back-up

setting, the HP bypass valves will open and control the MS
pressure.
• When condenser vacuum pressure is low or HPTB valve outlet

temperature is very high, then HPTB control valve will be
forced to close.
• When Fast cutback (FCB) is in operation, the HPTB valve will

be forced to fully open.
86 / 212
L&T-MHPS BOILERS
Coal Mill In Service- During Pressurization & Temp Rising
6. Steps to take Coal Mill in Service
Steps -1: Confirm following pre-operating condition:
a. Coal bunker outlet valve in open condition
b. Confirm Coal Feeder “Coal ON” belt
c. Confirm Mill outlet valve & coal burner inlet valve full open
d. Confirm 1ry Cold Air Damper minimum position
e. Confirm line up of Mill reject system
f. Confirm Mill lube oil system is in operation
g. Confirm Mill Hydraulic System is in Operation
h. Confirm Mill Static Separator opening-40 %
i. Confirm Mill seal Fan is in operation & Individual Mill Seal air valve is in
open condition.
j. Confirm Coal Feeder Seal air valve is in open condition.
k. Confirm PA Header Pressure as per Fx
87 / 212
L&T-MHPS BOILERS
Coal Mill In Service- During Pressurization & Temp Rising
Steps -2: Operator shall put all the drives related to D coal burner in Auto
Step-3: Operator shall start “Coal Burner light Off BP” from SG-DCS
Step-4 : After Start PB, Mill-D warming starts

-Ensure Cold air gate Opens
-Ensure Cold air damper opening around 70 % for Mill Purge
-After 5 minute Mill Purge cycle, Hot Air gate opens
-After HAG Opens, HAD start opening as per Air flow control
-Mill outlet temp start increasing. When outlet temp >70 ◦C, warming process
completes.
Note: HAD controls the Mill inlet Air flow

CAD controls Mill outlet temperature
88 / 212
L&T-MHPS BOILERS
89 / 212
L&T-MHPS BOILERS
90 / 212
L&T-MHPS BOILERS
91 / 212
L&T-MHPS BOILERS
92 / 212
L&T-MHPS BOILERS
93 / 212
L&T-MHPS BOILERS
Purging will be
done for 5 min
at PA flow
more than 70%
flow.
94 / 212
L&T-MHPS BOILERS
Hot PA CD will
start opening
Hot PA& On Off
Warming damper
will be will be
started, opened
once once
the Onthe
Off purging is
dampercompleted.
is
opened.
95 / 212
L&T-MHPS BOILERS
When the pulv
O/l temp will
be more than
75 deg, Coal
feeder will be
started.
96 / 212
L&T-MHPS BOILERS
Coal Mill In Service
Steps -5: Firing Condition PB Start
-Ensure Coal Feeder gets ON. Initial Coal Feeding shall be as below:-
-Once grinding detection completes, Coal will be increases as per Combustion

demand.
97 / 212
L&T-MHPS BOILERS
Coal Mill In Service
98 / 212
L&T-MHPS BOILERS
Steam Admission- Schematic
SH3
RH2
SH2
RH1 G
HPT IPT LPT LPT
SH1
W W WDC M
M
S S
LX
D M
T M
DEA CP
WW LP4
M
M
BCP HP8
M
GSC
M
BR LP3
M
ECO HP7 M
T T
FX
FX
LP1/2 CPS
M
M
HP6
M
M M
Flash
Pipe
99 / 212
L&T-MHPS BOILERS
Synchronization- Schematic
SH3
RH2
SH2
RH1 G
HPT IPT LPT LPT
SH1
W W WDC M
M
S S
LX
D M
T M
DEA CP
WW LP4
M
M
BCP HP8
M
GSC
M
BR LP3
M
ECO HP7 M
T T
FX
FX
LP1/2 CPS
M
M
HP6
M
M M
Flash
Pipe
100 / 212
L&T-MHPS BOILERS
Turbine Rolling & Synchronization
7. Turbine Rolling & Synchronization procedure

shall be of Turbine Manufacturer / NTPC
Procedure.
101 / 212
L&T-MHPS BOILERS
Load Increase to 40 % Load
8. Load Increase to 40 % Load
Steps -1: 2nd Coal Burner warming starts
Step-2: Load is set to 25%
Step-3 : 2nd Coal Burner Firing starts

- Load gradually increases to 165 MW
- Fuel Flow is increases based on BID
- MS temp & RH temp control will starts if the temperature error becomes less than
or equal to Zero
- During this load-up , LPH & HPH shall be taken in service from Turbine controls
- During this time LDO master is in Auto control and Coal Master is in Manual
control
Load Hold Option is available during this period:
- Automatic load hold at 25 % TMCR is available for WET to DRY transfer.
- Manual Load hold is also available, but it is disabled between 20% to 30% load
up region. 102 / 212
L&T-MHPS BOILERS
WET to DRY Transfer
Step-4: WET to DRY Transfer
-WS level decreases as fuel firing increases

-BCP gets stopped at 4 Mtr level
-Mode judged to change to Dry Mode after BCP stops and WS inlet degree of
Superheat > 5 ◦ C
-After changeover to DRY mode, mode of operation shall be changed to CC-DRY
mode from BS Mode.
-WFR will be used for MS temp control.
-2ry SH will not only control MS temp but will also control 2DSDT
-1ry SH will control WS inlet degree of Superheat.
-Feedwater flow will be control as per BID.
-Boiler Pressure control will be achieved through correction in BID.
-BCP warming flow CV inlet MOV open and Control valve will control the WSDT
level at 8.0 mtr.
-WDC outlet valve –A closes automatically. 103 / 212
L&T-MHPS BOILERS
Wet / Dry Transfer
SH3
RH2
SH2
RH1 G
HPT IPT LPT LPT
SH1
W W WDC M
M
S S
LX
D M
T M
DEA CP
WW LP4
M
M
BCP HP8
M
GSC
M
BR LP3
M
ECO HP7 M
T T
FX
FX
LP1/2 CPS
M
M
HP6
M
M
M
M M
Flash
Pipe
(1) Wet/Dry Changeover Condition (Simplified)
BID > 30%

S DRY Mode
WS Inlet Super Heat
Ratio > 5 deg-C R
WET Mode
BCP Start
BR Valve
Full Close
MFT
Change-over timing
Synchronized depends on BCP
BID < 22% start/stop
WET Change Over Region DRY

22% 30% BID(%)
(1) Chart of Wet / Dry Mode
Startup Shutdown
WET DRY WET

TB Valve
Position
MW
20% 30% 100% 30% 20%
Steam Press
Control
TB Valve WFR BID WFR
TB Valve
Steam Press Close on Back up Press mode
Control
WFR
Not used Steam Steam Press
Degree of Superheat Control
Press Control
or Steam Temp. Control
Control
Comparison of Dry Mode and Wet Mode
Wet Mode (Circulation Mode)
Dry Mode (Once-Through Mode)
Same System 　as Drum Boiler
to to
SH Steam Turbine SH Steam Turbine
Water Water
Separator Separator
System Furnace Furnace

BCP
Schematics
BFP BFP
Eco Eco
BCP is out of service because BCP is in service to keep minimum

feed water flow is over minimum flow at furnace(25%ECR)
flow. (once-through operation)
Load 25% Load – 100% Load 0% - 25% Load

Temp. Control Water Fuel Ratio (WFR) Spray
Press. Control Feed Water Flow Water Fuel Ratio (WFR)
Load Increase to 40 % Load
Step-5: 3rd Coal Burner Comes in Service.
-3rd Mill warming starts
-Load set to 30%
-3rd Mill Firing starts
-MW increased to 30 %
-After 3rd Mill in service, Coal Master will come in Auto
-LDO master will come in standby mode. CV will start closing gradually. Guns need
to be taken out of service based on LDO header pressure.
-GH, EF & CD will be taken out of service one by one and Mill D, E & F shall be
loaded to compensate for the reduction of LDO flow.
-Load set to 40% and gradually MW increased to 40%
108 / 212
L&T-MHPS BOILERS
Load Increase to 50% Load
9.Load Increase to 50 % Load (4th Mill in Service & Fuel

changeover from Oil to Coal)
Steps:
- Load is set to 50%

-4th Mill warming starts
-4th Mill Coal Firing starts
-Load increased to 50 %
-Fuel changeover is also being done during this from Oil to coal (Exclusive coal
firing established during this).
-Oil gun shutdown sequence is shown in next slide
109 / 212
L&T-MHPS BOILERS
Shut down Sequence of Oil Burner during Load Up
SHUT-DOWN SEQUENCE OF OIL BURNER
(STEP1) IGNITOR
PI
BURNER VALVE
PI BURNER GUN
ATOMIZIZED AIR VALVE
110 / 212
L&T-MHPS BOILERS
(STEP2) IGNITOR
PI
BURNER VALVE
PI BURNER GUN
111 / 212
L&T-MHPS BOILERS
SHUT-DOWN SEQUENCE OF OIL BURNER (STEP2 :
60sec after) IGNITOR
PI
BURNER VALVE
PI BURNER GUN
112 / 212
L&T-MHPS BOILERS
PI
BURNER VALVE
PI BURNER GUN
113 / 212
L&T-MHPS BOILERS
PI
BURNER VALVE
PI BURNER GUN
114 / 212
L&T-MHPS BOILERS
PI
BURNER VALVE
PI BURNER GUN
115 / 212
L&T-MHPS BOILERS
(STEP6) IGNITOR
PI
BURNER VALVE
PI BURNER GUN
116 / 212
L&T-MHPS BOILERS
DIESEL OIL BURNER TRIP
BURNER GUN CONTINUE TO BE AT
INSERT POSITION.
PI
BURNER VALVE
PI BURNER GUN
117 / 212
L&T-MHPS BOILERS
Load up to 75 % & 100% Load
10. Load up to 75% (5th Mill in Service)
- Load set to 75%
- 5th Mill warming starts & thereafter Coal firing starts
- Load increased to 75%.
11. Load up to 100% (6th Mill in Service)
- Load set to 100%

- 6th Mill warming starts & thereafter Coal firing starts
- Load increased to 100%.
118 / 212
L&T-MHPS BOILERS
Coal Firing Sequence during Load up
 Coal Firing sequence during load-up is as follows:
Mill D Mill E Mill F Mill G Mill C Mill B
Note: In case of worst coal operation, Mill H shall be taken in service.
Load Band Vs No of Coal Mills
Design Coal Worst Coal
Load Band Used Mill No Load Band Used Mill No
Bef Synch- 10% TMCR 1 Bef Synch- 10% TMCR 1
10% - 25% TMCR 2 10% - 25% TMCR 2
25% - 30% TMCR 3 25% - 30% TMCR 3
30% - 50% TMCR 4 30% - 40% TMCR 4
50% - 75% TMCR 5 40% - 50% TMCR 5
75% - 100% TMCR 6 50% - 75% TMCR 6
- - 75% - 100% TMCR 7
119 / 212
L&T-MHPS BOILERS
Inerting & Clearing Time Chart for Mill Trip
Inerting & Clearing Time Chart (For Mill Trip):
Inert System-In Service
Inerting Start
Coal Burner (CF & Mill)
Mill Outlet Valve
Mill Purge Valve
Inert Steam Supply

Valve
Inert Steam Flow
120 / 212
L&T-MHPS BOILERS
Inerting & Clearing Time Chart for Mill Trip
Inerting & Clearing Time Chart (For Mill Trip):
Inert System-Out Of Service
Mill outlet valve will be opened in case of Furnace draft

pressure is negative
Coal Burner (CF & Mill)
Mill Outlet Valve
Mill Purge Valve
Inert Steam Supply

Valve
Inert Steam Flow
121 / 212
L&T-MHPS BOILERS
MODE OF OPERATION
 Modes Of Operation
1. BS Mode :
This mode is active during unit start-up. This mode remain active till HPTB gets closed
during dry mode of operation after which mode gets changed to CC Mode.
Pre-requisites;
- Feed water & Fuel Flow control must be in Auto.
Features:
- HPTB will control the Main Steam Pressure.
- Operator will manually control the MW from TG-DCS load setter
- BID is based on actual Feedwater flow
- Wet to Dry transfer will take place at 25% TMCR load
- Load setter faceplate is disabled in CMC HMI
122 / 212
L&T-MHPS BOILERS
MODE OF OPERATION
2. CC Mode :
This is the normal and main control mode for unit operation wherein boiler & turbine runs
in parallel coordinate mode. MWD is given to both boiler & turbine so that energy input
to boiler matches the energy output from turbine.
Pre-requisites;
- Feed water , Fuel Flow , Air flow & Furnace draft control must be in Auto.
Features:
- Turbine Governor will control the MW with Main steam Pressure correction
- BID will control the MWD with Main steam pressure correction.
- Load setter face plate is only enable in this mode in CMC HMI.
123 / 212
L&T-MHPS BOILERS
MODE OF OPERATION
3. BF Mode :
If the turbine master is changed to Manual during CC Mode , the operation mode changes to
BF mode.
Pre-requisites;
Features:
- Load setter face plate is only enable in TG-DCS
- Main Steam Pressure setter mode switches to Manual and Main steam pressure can be
set from operator face plate in CMC HMI of station DCS.
- Turbine Master is in Manual & BID is in auto.
- MS Pressure is controlled by BID with correction on Actual MW.
- Turbine governor controls actual MW
- MWD track the actual MW signal
124 / 212
L&T-MHPS BOILERS
MODE OF OPERATION
3. BF Mode :
Note: Turbine Master can be Put on “AUTO” mode when both the following conditions are
satisfied:
1. Any of the 3 turbine Controller “ON”- Load Controller / Initial Pressure Controller /
Position Controller.
2. DCS Operation Feedback received from TG-DCS

Operator can issue the “DCS Operation CMD ON” signal from S-DCS to TG-DCS
using the faceplate available in S-DCS HMI. TG-DCS shall select the DCS Operation
Mode based on this command and acknowledge the same by sending the “DCS
OPERATION ON FEEDBACK”.
125 / 212
L&T-MHPS BOILERS
MODE OF OPERATION
4. BI Mode :
In this mode, BID shall be in manual & Turbine master shall be in Auto. During runback or
FCB, this mode is selected automatically.
Pre-requisites;
Features:
- Turbine Master will control will the MS Pressure.
- BID will control the MW
- In case of runback or FCB, this mode is automatically selected and BID set points is set
automatically based on the target load specified for each runback.
- In case of normal mode/operation, BID can be set through Load setter face plate
available in S-DCS.
- MWD tracks the actual MW signal
126 / 212
L&T-MHPS BOILERS
MODE OF OPERATION
5. BM Mode :
Under dry condition, If feedwater control change to Manual, then BM mode is automatically
selected.
During Wet condition, if fuel control changes to Manual, then also BM mode is selected
automatically.
Features:
- BID tracks the actual MW in wet operation and is based on actual feed water flow in dry
mode of operation.
- MWD tracks the actual MW signal.
- MS Pressure is control by Turbine Master, if it is in Auto.
127 / 212
L&T-MHPS BOILERS
LOAD CHANGE RATE
 Load change rate
In auto mode (Normal mode of operation), Load change rate is as follows:-
± 1 % Per Minute (0% to 30% Load)

Load change rate is blocked i.e rate is forced to Zero when the load increase / decrease
block condition is active.
Increase Block Condition are as below:-

 Unit Master Upper Limit (Load upper limit / MW deviation high/ MS Pressure deviation
high)
 Frequency High
 BFP Upper Limit
128 / 212
L&T-MHPS BOILERS
LOAD CHANGE RATE
Increase Block Condition are as below:-
 Fuel flow upper limit
 Air flow upper limit
 Fuel Flow Feedwater demand decrease cross limit activated
 Feed water flow Fuel flow demand decrease cross limit activated
 Air flow Fuel flow demand decrease cross limit activated
Decrease Block Condition are as below:-

 Unit Master Lower limit (Load lower limit / MW deviation low/ MS Pressure
deviation Low)
 Frequency Low
 Fuel flow lower limit
 BFP lower limit
 Fuel Flow Feedwater demand increase cross limit activated
129 / 212
L&T-MHPS BOILERS
LOAD CHANGE RATE
Decrease Block Condition are as below:-
 Economizer Steaming Prevention Operate

 Fuel Flow Air flow demand increase cross limit activated
130 / 212
L&T-MHPS BOILERS
Operation & Control Timing Chart for Start-Up
Operation & Control Timing Chart for Start-Up
131 / 212
L&T-MHPS BOILERS
OPERATION CONTROLS
132
132
L&T-MHPS BOILERS
Start up Control of Boiler
• Wet Operation (1/3)
HPTB
SH3
HPT IPT G
SC2 SH2
RH1
From BFP
SC1 SH1 intermediate stage
RH2 RSC
Partially LPT
Evaporated
WS WS LPTB
WS Separate
DT COND
T
WDC
Furnace M
CEP
BCP
Drain is flown into ECO
BR Condensate
ECO inlet or Condenser. Polisher
BFP BFBP
HP LP
DEA
HTR HTR
133
133
L&T-MHPS BOILERS
• Wet Operation (2/3)
Steam Flow
Water Flow
through
SH3
Furnace
SC2 SH2 Steam
Flow Recirculation
SC1 SH1 Flow
W W
S S
25% Flow WET
W
S
D Load (%)
T WDC
Furnace
Recir.
BCP 25% Minimum
Flow Flow for
BR
ECO Furnace
BFP Protection
HP
HTR
134
L&T-MHPS BOILERS
Start up Control of
• Wet Operation Boiler
(3/3)
WDC A/B
SH3
SC2 SH2
SC1 SH1
W W α γ γ’ γ”
S S
W
S
D
γ”
LT FX
Furnace
T WDC W B
γ’ A
S WD
BCP START γ
BR BR C
D
ECO PI
△
FT
FX
T
BFP
HP α
HTR
135
L&T-MHPS BOILERS
• Dry Operation (1/2)
SH3
SC2 SH2
SC1 SH1
W W
S S
DRY
W
S
D Load (%)
T WDC
Furnace
Furnace
BCP
ECO
BR
Evaporated Feed Water Flow
BFP
= Steam Flow
HP
HTR
136
L&T-MHPS BOILERS
• Dry Operation (2/2)
WDC A/B
SH3
SC2 SH2
SC1 SH1
W W α γ
γ γ
S S ”
W No Level WSD
S T
D LT
” ’
γLeve
T WDC W
Furnace B
l
γ’ A
BCP S WD
γ
Stop BR C
BR
D
ECO
FT
Close T
BFP
HP α
HTR No Level
137
L&T-MHPS BOILERS
MS Temp. Control at Wet Operation
• Main steam Temperature is controlled by SH Spray during
Wet mode of operation.
• LHS line & RHS line can be

controlled separately.
• 2 stages of SH spray is employed

to control MS Temp.
138
138
L&T-MHPS BOILERS
1ry SH Spray Control Features:
The Main Features incorporated in 1ry SH Spray Control:
(1)Over injection Protection function.

(2)Min FW flow generation function
(3)Spray valve Minimum Opening Function
• 1ry SH Spray control valve will be in Forced close condition during

(1) MFT
(2) Steam Block Condition
139
139
L&T-MHPS BOILERS
Over Injection/ Steam Saturation Protection
•More water is injected and 2ry SH inlet steam temperature is less

than saturation temperature.
• Steam saturation/ over injection function is provided to prevent 1ry

SH spray control valve from driving the attemperator outlet temp
below the steam saturation point.
•If 2ry SH inlet Temperature is less than Water Separator saturation

Temperature + SH bias. The difference should not exceed 10 degree.
140
140
L&T-MHPS BOILERS
MS Temp. Control at Dry Operation
Steam temperature control by WFR
Once-through Boiler Feed water flow is kept at constant.
Once-through Section If fuel input is increased
Water Saturation Steam Saturation region is moved to left side and

superheat region is relatively long, and then
main steam temperature is elevated.
Burner Steam temperature is controlled by

water fuel ratio
(= ratio between fuel and water).
Disclaimer:
Drawings, models, data, pictures etc. used in the presentation are from LMB previous projects only, actual project specific
planning may vary based on final released documents. 141
L&T-MHPS BOILERS
RH Temperature Controls
RSV
2ry
RH ICV
1ry
RH
1.Deaerator
2. Soot Blwr 3.
Aux. Steam Hdr
142
142
L&T-MHPS BOILERS
RH Temperature Controls
 CRH temperature & pressure, and HRH pressure depend

on unit operating condition.
 HRH temperature controlled by

1. Back pass damper opening-- Main
2. Backup control: Burner Tilt
3. RH spray in emergency case.
143
143
L&T-MHPS BOILERS
RH Temperature Controls- Back Pass Damper
In Back
pass flue
gas split
into 2
streams
Back Pass
Damper
Down
stream of
damper
flue gas
144 rejoin
1st Pass Damper 2nd Pass Damper 144
L&T-MHPS BOILERS
RH Temperature Controls- Back Pass Damper
Control
• The SH/RH Gas Damper controls RH Steam Temperature
by adjusting the amount of flue gas passing through the
RH / SH to vary the amount of heat absorption in the RH.
• RH steam temperature depends on 1st pass damper opening .
• 2nd pass damper operates in counteracting manner.
145
145
L&T-MHPS BOILERS
RH Temperature Control- Burner Tilt
• Burner tilt is provided to enhance the controllability during load
change.
• Burner tilt is also used to control the RH steam temperature
imbalance.
• Right & Left side fire balls are relatively moved and control the
temperature imbalance.
• 1,2,7,8 Nozzles are tilting as a group & 3,4,5,6, Nozzles are also
tilting as a group.
• Burner Assy shall be kept at horizontal position when the
following conditions are satisfied.
1. All Coal feeder stop. 2. All LDO Burner valves closed 3. All
HFO burner valves closed
146
146
L&T-MHPS BOILERS
RH Temperature Controls- Reheater Spray
1. RH Spray is used only during
emergency condition ( When
Hot RH steam Temp goes
abnormal).
2. RH Spray valve is set as

Normal set point +
3degree( during Load
change) or 5 Degree
( Normal Operation).
3. When Gas damper is
saturated or not in auto, then
RH spray will control the RH
steam temp.
4. During MFT Spray valve is
Force close.
147
147
L&T-MHPS BOILERS
Air Flow Control
The set point is based on Air Flow demand (AFD) calculated as a
function of firing rate demand (FRD) and Boiler Input rate (BIR-Air)
and corrected to ensure complete combustion by monitoring for flue gas
oxygen and multiplying the demand with Air Fuel Ratio (AFR).
FDF bias station is provided to compensate load imbalance between

FDF(A) and FDF (B)
The AFD is cross-limited with total fuel flow to prevent fuel rich
condition in the furnace.
FDF blade pitch is controlled by a controller that receives an error

signal from the comparison of an air flow demand and an actual total
measured air flow which can be determined by adding the primary air
flow for each coal mill and the secondary air flow from FDF. 148
L&T-MHPS BOILERS
Air Flow Control
 FDF blade pitch demands are forced to maximum (100%) open
while both FDF are stopped so that natural ventilation of the furnace
could be done
 Stopped FDF blade pitch demand is forced to minimum (0%) open if

the other fan is running, to prevent reverse flow of the air through
the stopped fan
 The FDF blade demand is fed through a direction block interlock

which blocks demand change. The direction block interlock prevents
the FDF demand increase when the surging block function detects an
impending FDF surging condition 149
L&T-MHPS BOILERS
Furnace Draft Control
Purpose:
To maintain the furnace draft at constant negative value by modulating

IDF Blade Pitch.
Instrument Used:
Furnace Pressure Transmitters
Control Drives
IDF blade pitch control drive
150
L&T-MHPS BOILERS
Furnace Draft Control
 The PAF and FDF blade position is used as the feed forward
signal to improve response during a load change.
 Stopped IDF blade pitch demand is forced to minimum (0%) if the

other fan is running to prevent reverse flow of the stopped fan.
 The IDF blade demand is fed through a direction block interlock

which blocks demand change during furnace draft extremes or
when the Surge is detected 151
L&T-MHPS BOILERS
Fuel Flow Control
1. LDO Control :
LDO demand : Fuel Flow demand- Total Coal Flow
LDO fuel initially is in Pressure control Mode upto 2 Oil Burners

in Service
For more than 2 Oil burners- LDO FCV changes to Flow control
mode.
Note: Whenever Low header Pressure is detected, Flow control

mode is forced changeover to Minimum Pressure Control Mode
152
L&T-MHPS BOILERS
Fuel Flow Control
153
L&T-MHPS BOILERS
Fuel Flow Control
2. Coal Flow Control :
Total Coal Flow Demand : Fuel Flow demand- LDO Flow
Coal Master will be in Standby mode till 3 Coal Feeders in

service.
For more than 3 Coal burners- Coal Master will become auto. It
will divide the fuel demand equally among all running Coal Feeders.
Bias Option is there for an operator to adjust the feed rate of fuel
between running feeders.
Coal Flow demand will be as per BID + Calorie Correction. .

154
L&T-MHPS BOILERS
Fuel Flow Control
 In wet mode FF controls the MS Pressure.
 In Dry Mode, FF (WFR) controls the MS temperature
 Fuel Flow demand is generated based on BID
 WFR is added to the Fuel flow demand. WFR is generated based on

the Water separator inlet temp & Secondary super heater outlet
temp
 Fuel flow demand is cross limited with Feed water flow and Air
flow 155
L&T-MHPS BOILERS
Water / Fuel Ratio Control
 WFR takes care of heat absorption of actual heating value of fuel
& burner elevation in service
 WFR controls:
In Wet Mode :
Main Steam Pressure control after HPBP comes in the

back up control mode
In Dry Mode :
WS Inlet Superheat rate & MS temp 156
L&T-MHPS BOILERS
The Water/Fuel Ratio (WFR) demand is generated by the following
method.
 When the boiler is in WET mode, the Main Steam pressure is
controlled by the Fuel flow. Therefore in this case, the WFR
demand is adjusted to control the Main Steam Pressure.
 When the boiler is in DRY mode, the WFR demand controls the
Superheat Rate of the Main Steam temperature (Secondary SH
Outlet Steam temperature).
 In addition, to assist the Main Steam Temperature control, steam
temperature error of water separator inlet temp is added as FF
signal to Water/Fuel Ratio.
 Variable gain for the Water Separator Inlet steam superheat rate
and Secondary SH Outlet steam temperature is also provided to
change the control gain as per load demand
157
L&T-MHPS BOILERS
 WFR control the MS Pressure in wet mode and MS temperature in
dry mode till its upper and lower limit.
 Upper & Lower limit control is provided to judge the Calorific value
of Fuel.
 Whenever WFR comes to its lower or upper limit, then Calorie

correction is required.
 If WFR touches the lower limit – Calorific value need to be

increased.
 If WFR touches the upper limit- Calorific value need to be decreased.

158
L&T-MHPS BOILERS
Shutdown Sequence
1. Sixth Coal Burner shutdown
During unit load down “sixth coal burner shutdown” is initiated when MW load is set to
75%.
2. Fifth Coal Burner shutdown

During unit load down “fifth coal burner shutdown” is initiated when MW load is set to
50%.
3. Fourth Coal Burner shutdown

During unit load down “fourth coal burner shutdown” is initiated when MW load is set to
30%.
159 / 212
L&T-MHPS BOILERS
Shutdown Sequence
During unit load down “fourth coal burner shutdown” is initiated when MW load is set to
30%.
- During unit load down from 50% to 30%, Oil burner light up function starts when MW <
40%.
-One elevation of Oil burner light up take places.
-Coal Master will reduce coal flow automatically to compensate the increase of oil flow.
4.Third Coal Burner shutdown

During unit load down “third coal burner shutdown” is initiated when MW load is set to
20%.
- During unit load down from 30% to 20%, coal master will change from Auto to standby
mode after 3rd Mill Shutdown command initiated.
160 / 212
L&T-MHPS BOILERS
Shutdown Sequence
-Oil flow increases automatically
-MW decreases to 20% Load.
5.Second Coal Burner shutdown

-Unit load set to 15 %
-Second Coal burner shutdown activated.
6.Last Coal Burner shutdown

-Unit load set to 10 %
-Last Coal burner shutdown activated.
Coal Shutdown order is as follows:-
Mill B Mill C Mill G Mill F Mill E Mill D
161 / 212
L&T-MHPS BOILERS
Shutdown Sequence
7. Last Oil Burner shutdown
- Last Oil burner shutdown activates when the following conditions established:
 Generator Circuit breaker is open
 Not more than one elevation of Oil burner is in service.
- During this shutdown, the following control will be activated:-

- 1. Second set of oil burner shutdown (corner -2,6,4 &8)
- 2. Last set of oil burner shutdown (corner – 3, 7, 1 & 5)
With the last gun purge completed and all oil burner guns are retracted, this function is
completed, and then MFT is activated.
Recommended:
1. In case, long unit shutdown is planned, Operator should carry out all soot blower & wall
blower operation before unit shutdown.
162 / 212
L&T-MHPS BOILERS
163 / 212
L&T-MHPS BOILERS
Coal Flow min
command will be
given to Coal
feeder. After PA flow >
70% flow, Hot PA
On Off damper
Coal Burner
will be closed.
Purging will be
started when
coal flow is
minimum.
164 / 212
L&T-MHPS BOILERS
When Pulv O/L
temp < 55 deg,
Coal feeder will
be stopped.
165 / 212
L&T-MHPS BOILERS
166 / 212
L&T-MHPS BOILERS
167 / 212
L&T-MHPS BOILERS
Shutdown Sequence
8. For Hot Box up
- After MFT activates, Air & Gas system shall be shutdown and following condition
shall be kept:-
 All Fans blade pitch shall be closed
 All Fans Outlet damper / gate shall be closed
 All Boiler drain / vents shall be kept closed.
 All Sampling line isolation valves shall be closed.
 Boiler MSSV along with integral bypass valve shall be closed.
- Ensure following Drives are kept running:
 Both RAPH with GAS, SA & PA inlet and outlet dampers in closed condition
 Scanner Cooling Air Fan
 Fans Lube Oil Pumps (till Lube Oil temperature < 40 deg C)
 Fans Control Oil Pump (till control Oil temperature < 40 deg C)
168 / 212
L&T-MHPS BOILERS
Shutdown Sequence
9. For Natural Cooling
- After Air & Gas system shutdown, following condition shall be kept:-
 All Fans blade pitch shall be 100% opened.
 All Fans Outlet damper / gate shall be kept opened.
 All Boiler drain / vents shall be opened as per MS Pressure.
 All Sampling line isolation valves shall be kept opened.
 Boiler MSSV along with integral bypass valve shall be kept opened.
- Ensure following Drives are kept running:
 Both RAPH with GAS, SA & PA inlet and outlet dampers in closed condition till AH
inlet flue gas temperature < 100 deg C
 Scanner Cooling Air Fan till WS inlet temp < 90 deg C
 Fans Lube Oil Pumps (till Lube Oil temperature < 40 deg C)
 Fans Control Oil Pump (till control Oil temperature < 40 deg C)
169 / 212
L&T-MHPS BOILERS
Boiler Forced Cooling
10. For Forced Cooling
Purpose:
Forced cooling are intended for shortening the time for work after unit shutdown.
 Methods for Boiler Forced Cooling:

There are 3 factors to conduct Boiler forced cooling:
1. Reducing Pressure
2. Cooling by Feedwater
3. Cooling by Air flow
Sample figures is as shown in next slide:
170 / 212
L&T-MHPS BOILERS
10. For Forced Cooling
171 / 212
L&T-MHPS BOILERS
A.Boiler Forced Cooling (Incase of no inside work at Boiler)
1.After MFT, increase the air flow by bias operation
2.Turbine inlet drain valve is closed. HPBP valve is also closed if required
3.Supply feed water (25% TMCR). Start BCP in accordance with WSDT level.
4.Turbine inlet drain valve (other drain valves) is closed at less than main steam pressure
3 KSC.
5.BCP & MDBFP is stopped when WW outlet temperature and AH inlet gas temperature
becomes less than 90 & 100 deg C respectively.
6.Decrease the air flow bias. After “Zero bias”, A & G system to be shutdown
172 / 212
L&T-MHPS BOILERS
B.Boiler Forced Cooling (Incase of inside work at Boiler)
1.After MFT, increase the air flow by bias operation

2.Turbine inlet drain valve is closed. HPBP valve is also closed if required
3.Supply feed water (25% TMCR). Start BCP in accordance with WSDT level.
4.Turbine inlet drain valve (other drain valves) is closed at less than main steam pressure
3 KSC.
5.BCP & MDBFP is stopped when WW outlet temperature and AH inlet gas temperature
becomes less than 90 & 100 deg C respectively. Stop supplying steam into deaerator.
6.Open air vent and drain valve, and carry out boiler drain out.
7.When AH inlet gas temperature become less than 50 degree, decrease the air flow bias.
After “Zero bias”, A & G system to be shutdown
173 / 212
L&T-MHPS BOILERS
Air and Flue Gas System Shutdown
Furnace Decrease air flow

MFT Purge FDF-B
to Minimum (31%)
(5 Min)
IDF-A FDF-A Decrease air IDF-B

flow to 15%
RAPH shall be kept running till AH inlet flue gas temp < 100 deg C.
AC Scanner Air fan shall be kept running till WSDT inlet temp < 90 deg C.
Sequence of shutdown of Air & Flue gas system

174 / 212
L&T-MHPS BOILERS
Boiler Trip Condition
1. Boiler Trip PB Operated
2. All BFP Stop
3. All Flame Loss
4. All Fuel Loss
5. Unstable Combustion
6. Reheater Protection
7. Both FDF Stop
8. Both IDF Stop
9. Feed water flow very low (< 330 TPH)
10. Boiler Outlet Main Steam Pressure very high (> 284.2 KSC)
11. Furnace Pressure Very High (> 400 mmwc)
12. Furnace Pressure very low (< 400 mmwc)
175 / 212
L&T-MHPS BOILERS
Boiler Trip Condition
13. WW outlet temp very high
14. 1ry SH outlet steam temp very high
15. Boiler Metal Temp Very High
16. Air flow very low < 26% BMCR (< 641.9 tph)
17. WSDT level very high (> 14.4 mtr)
18. Turbine Trip with Condenser vacuum very low
19. S-DCS Failure
20. SG-DCS Failure
All above condition signal are given to the BPS with Hardwired signal from
local or through other system such as SG-DCS, S-DCS, TG-DCS, TPS etc.
To avoid unnecessary trip caused by a single instrument failure, 2 out of 3

voting logic is applied.
176 / 212
L&T-MHPS BOILERS
Boiler Trip Condition Explanation
1. Boiler Trip PB Operated
This is for emergency trip by the Operator. There are two no's of Push Button
located in Operator Console. Either of the button shall be pressed to trip the
boiler.
2. All BFP Stop
Boiler trip from ALL BFP STOP is given to prevent the damage of water wall
tubes due to extreme unbalance of water / Fuel ratio.
3. All Flame Loss
All Flame Loss –MFT is initiated when at least one Coal Feeder is in service with
either Furnace A Flame loss or Furnace B flame loss
177 / 212
L&T-MHPS BOILERS
4. All Fuel Loss
MFT is provided from “ALL FUEL LOSS” condition when all CF /MILL stopped and all
Oil burner valves closed.
5. Unstable combustion
This MFT is applicable for only Oil Firing. This is judged by following two condtions:
1. Oil Burner Header Pressure Low Low (< 5.2 KSC) for 3 sec.
2. Atomizing Air Header Pressure Low Low (< 3 KSC) for 3 sec.
6. Reheater Protection:
Boiler trip is initiated to protect the reheaters against burning in the case that excessive
boiler heat input is charged in the state of blocked steam across reheater.
Steam Block is Judged by following two condition -

- 1. TG MSV or TG- CV closed and Both HPBP CV closed
- 2. TG ISV or IP-CV closed and both LPBP CV closed
178 / 212
L&T-MHPS BOILERS
Reheater protection acts when following two condition establish:
1. If steam block condition persist for more than 10 sec for fuel more than 30%
BMCR
OR
2. If steam block condition persist for more than 20 sec for fuel more than 20%
BMCR
7. Air flow Very Low

MFT is initiated to prevent Fuel rich condition
8. WSDT Level High High

MFT is initiated to prevent water induction into Turbine
179 / 212
L&T-MHPS BOILERS
Special Operating Condition
1. Run Back:
It is provided when any major running equipment / auxiliaries gets trip during
plant operation so that overloading does not happen on other running
equipment. After runback, plant control automatically comes in BI Mode and
Load automatically reaches target load as specified for each auxiliaries.
Runback signals reset 10 minutes after BID reaches specified target load. This 10
minutes are given for plant stabilization.
Once runback signal resets, Operator can switch the Unit Mode based on actual
plant condition at that instant.
During runback, MFT logic is applicable as same as normal operation. Therefore

if any abnormal condition occur during runback, the unit does not runback, but
gets trip by MFT.
180 / 212
L&T-MHPS BOILERS
2. Fast Cut Back
FCB occur in an event of transmission line trouble or during sudden load throw
off when turbine generator either trips or comes to Islanding operation with
house load of 40 MW.
In order to swiftly reach to house load or “0” MW from normal load, Boiler
control rapidly decreases fuel flow, feedwater flow, air flow based on the BID
corresponding to target load.
FCB may occur during BID > 60 % , BID< 60% or during 20% to 30% BID.
When FCB occur during BID> 60%- Target load shall be 60% TMCR
FCB between 60% to 30% - Target load will be the last set point
FCB between 20% to 30%- Target load shall be 20% since boiler operation in
this transient Zone is not recommended.
181 / 212
L&T-MHPS BOILERS
Runback for Main Auxiliaries & FCB conditions are mentioned below:
Operation Cause of RB Target Load % Target Load Change Remarks

Status after Load rate
RB /FCB
1 x IDF IDF Trip 330 MW 50% 100% / min
1 x FDF FDF Trip 330 MW 50% 100% /min
1 x PAF PAF Trip 330 MW 50% 100% /min
1 x APH APH Trip 330 MW 50% 100% / min
1 x TDBFP 1 TDBFP Trip 396 MW (+66 60%(+10%, if 100% / min Under both TDBFP
MW, if MDBFP MDBFP ON) running
ON)
1 X TDBFP MDBFP Trip 396 MW 60% 100% / min 1 TDBFP+MDBFP

Operation
1 x MDBFP TDBFP Trip 198 MW 30% 100% / min 1 TDBFP+MDBFP

Operation
182 / 212
L&T-MHPS BOILERS
Runback for Main Auxiliaries & FCB conditions are mentioned below:
Operation Cause of RB Target Load % Target Load Load Change Remarks

Status after rate
RB /FCB
1 x CEP CEP Trip 330 MW 50% 100% /min
Mill 7 to 6 1 Mill trip 495 MW 75% 100% / min
Mill 5 to 4 (Best 1 Mill trip 330 MW 50% 100% / min

Coal)

(Worst Coal)
FCB (BID> Turbine trip OR 396 MW 60% 200% / min

60%) Generator
desynch
FCB (BID bet 132 MW 20% 20% /min
20 % to 30%)
183 / 212
L&T-MHPS BOILERS
Boiler Emergency
184 / 212
L&T-MHPS BOILERS
Objective
 To understand the Emergency
 Importance of learning emergency
 Personal characteristic for handling emergency
 To be prepared for handling emergency
185 / 212
L&T-MHPS BOILERS
Emergency
 Defection: An unexpected especially dangerous

happening or situation.
 Emergency is
 Unexpected
 Dangerous/Abnormal
 Starts slowly but Grow at a faster rate
 Requires immediate attention/prompt action
 If not properly/urgently handled can result in to
heavy loss.
186 / 212
L&T-MHPS BOILERS
How to Handle Emergency
 Control process to avoid the emergency (Prevention is
better than cure)
 Be cool and calm
 Act wisely and immediately
 Take proper actions
 Emergency preparedness will help in handling the
emergency
 Every body’s responsibility/Requires to work across the
boundary
 After handling the emergency analyze the action taken
and plan for the improvement
187 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Actuation of MFT
 Cause:
 Boiler Emergency PB Pressed
 Feed water flow very low
 Boiler Outlet steam pressure very High
 Loss of All Flame
 Loss of All Fuel
 Both FD Fan Stop
 Both ID Fan stop
 Furnace draft very high/ very Low: ±3.9kPa (3s) [±400mmAq]
188 / 212
L&T-MHPS BOILERS
 Cause: ( Cont..)
 Turbine Trip with Condenser vac. Very low or all CW Pumps trips
 Air flow very low
 Water wall outlet temperature very high
 Primary SH Outlet temperature very high
 S-DCS Failure
 SG-DCS failure
 Reheater protection : Gas temperature at secondary reheater inlet -
580℃ . 30%MCR(10s) 189 / 212
20%MCR(20s)
L&T-MHPS BOILERS
 Effect:
 All Fuel Oil Burner valves and Emergency shut off valves
Closes
 All Coal Feeders, Pulversizers and PA fan trips.
 Inert steam is supplied to pulversizers
 Turbine is tripped
 FDF, IDF and AH are kept running at 30 % air flow
 SH and RH desuperheater valves are closed.
 WSDT Level start Increasing
190 / 212
L&T-MHPS BOILERS
 Action:
 Check that the boiler had gone for the safe shut down.
 Check the running auxiliaries and ensure that they are running
steady
 Investigate the cause of the MFT and rectify the same.
 Restart the boiler after rectifying the cause
 Control WSDT level through WDC
191 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Tube Leakage
 Cause:
 Over Heating
 Erosion
 Blockage in tube
 Internal scale deposition due to poor Boiler Water

quality
192 / 212
L&T-MHPS BOILERS
 Effect:
 Makeup water flow increase.
 Feed water demand increase.
 Main steam pressure decrease.
 BID increase
 Main steam temperature increase.
 Flue gas flow increase./ID fan Loading increases
 Furnace Draft will go to positive side
 Tube leakage detection system will indicate the tube leakage
 Leakage Sound observed in the boiler
 Flue Gas temperature start decreasing 193 / 212
L&T-MHPS BOILERS
 Action:
 Reduce the load to maintain the Hotwell and Dearator

Levels.(adjust the load as per the make up)
Control the Furnace draft and if required reduce the load.
Check the furnace and find the location of the leakage.
Shut down the boiler and start the force cooling of the boiler.
194 / 212
L&T-MHPS BOILERS
Boiler Emergencies: ID Fan Trip
 Cause:
 Electrical relay operated
 Fan bearing Temperature High
 Motor Bearing temperature high
 Lub Oil pressure low.
 Related FD Fan or PA fan or AH tripped (Runback

operated)
195 / 212
L&T-MHPS BOILERS
Boiler Emergencies: ID fan Trips
 Effect:
 Related FDF stopped.
 Related PAF stopped.
 Change to one side air and gas system operation.
 IDF Runback operate
 Load set will set to 50 % Load
 Action:
 Confirm the stabilize of plant condition after RUNBACK.
 Find out the cause of trip rectify it
 Start the fan again and normalize the system
196 / 212
L&T-MHPS BOILERS
Boiler Emergencies: FD Fan Trip
 Cause:
 Fan or Motor Vibration High
 Related ID or PA fan tripped (Runback operated)
197 / 212
L&T-MHPS BOILERS
Boiler Emergencies: FD fan Trips
 Effect:
 Related IDF stopped.
 Related PAF stopped.
 FDF Runback operate
 Load Set to 50 % Load
 Action:
 Start the fan again and normalize the system
198 / 212
L&T-MHPS BOILERS
Boiler Emergencies: PA Fan Trip
 Cause:
 Fan or Motor Vibration High
 Related ID or FD fan tripped (Runback operated)
 Load set to 50% Load
 Effect:
 Pulverizer primary air flow decrease.
 Pulverizer/furnace differential pressure decrease.
 Pulverizer inlet hot air pressure decrease.
199 / 212
L&T-MHPS BOILERS
Boiler Emergencies: PA fan Trips
 Effect (Cont…)
 Other PAF blade pitch demand increase.
 Other PAF Motor current will increase
 Related FDF and IDF Trips.
 PAF Runback operate.
 Action:
 Control the Mill Inlet Air flow, If required trip 1 or 2 mill to
maintain PA header Pressure
 If Motor Current increases too much or stall alarm comes, take
PAF blade pitch in Manual mode for control
 Start the fan again and normalize the system 200 / 212
L&T-MHPS BOILERS
Boiler Emergencies: AH Motor Trips
 Cause:
 Gear Box Bearing Temperature High
 Motor Overload
 Effect:
 Related IDF / FDF and PAF stopped.
 AH-A air motor back-up start.
 AH Runback operate
 Load Set will change to 50% Load
201 / 212
L&T-MHPS BOILERS
Boiler Emergencies: AH Motor Trips
 Action:
 Confirm the AH air motor SOV open automatically.

 Confirm the stabilize of plant condition after
RUNBACK.
 If
air motor is not started Operate the AH manually.
 Find out the cause of trip rectify and normalize the
system
202 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Coal Feeder Trips
 Cause:
 No-Coal on Belt
 Discharge Chute Pluggage
 Local PB Operated
 Belt Motion Monitor
 Effect:
 Pulverizer hot air shut-off damper close.
 Change to BI and TF control mode.
 Runback Pulverizer operate.
203 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Coal Feeder Trips
 Action:
 Confirm the Coal feeder control system.
 Find out the cause of trip Rectify it and start the feeder again.
 Start the stand by pulverizer and its coal feeder.
204 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Seal Air Fan Trips
 Cause:
 Motor Current high
 Local PB Operated
 Effect:
 Stand by seal air fan starts on Auto and seal air header
pressure is maintained.
 If the stand by seal air fan had not started on auto, Seal air
header pressure drops Seal air DP decreases
 All mills trips on seal air DP low.
 Boiler MFT will happen
205 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Coal Mill Fire
 Cause:
 Coal accumulation in the mill or duct
 Effect:
 Pulv lower-upper house diff press increase.
 Primary air flow decrease.
 Pulv inlet air temp increase.
 Pulv/furnace diff press increase.
 Hot air gate close by outlet temp HH.
 Pulv trip by outlet temp HH of trip point.
206 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Coal Mill Fire
 Actions:
 Confirm the behavior of the plant process.
 Confirm the pulverizer stop safety.
 Confirm that an air line is cut off.
 Confirm that the inert steam is injected.
 Confirm whether pulverizer inlet and outlet temperature starts

to reduce.
207 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Condenser Tube Leakage
 Cause:
 Tube leakage
 Effect:
 CEP outlet water conductivity increases.
 Condenser hotwell conductivity increases.
 Chloride and other salt concentration will increase
 Boiler water quality may detoriate
208 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Condenser tube leakage
 Action:
 Confirm the conductivity.
 Maintain the CPU out let water quality.
 If required change the CPU stream and regenerate the stream.
 Find out the cause of trouble.
 Shut down the unit.
209 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Feed water flow reduced
 Cause:
 Tripping of BFP.
 Failure of Feed water controller
 Effect:
 Steam temperature increases.

 Steam Pressure decreases
 Load decreases
 Metal temperatures increases
 Fuel- Water ratio increases
 Degree of SH of water increases
210 / 212
L&T-MHPS BOILERS
Boiler Emergencies: Feed water flow reduced.
 Action:
 Increase the loading of the running BFP ( If one BFP had

Tripped)
 Start the stand by BFP if available.
 Take the Feed water control on Manual mode and control it, if
the controller is failed.
 Reduce the fuel input to match fuel-water ratio.
 Reduce the load to match the parameters.
211 / 212
L&T-MHPS BOILERS
THANK YOU
212 / 212
L&T-MHPS BOILERS

Starting, Operating and Emergency Procedures for Supercritical Boilers

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Starting, Operating and Emergency Procedures for Supercritical Boilers

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Supercritical Boiler Start

To economize and save running cost

Rise the Efficiency

Select the Elevated steam conditions

Supercritical pressure boiler

(1) Comparison with conventional drum type boiler

Initial cost : Higher

Pressure [MPa] Critical Pressure:

Drum Boiler The drum stably storage

Once-through Boiler at sub-critical

Water Saturation Steam

(4) Compared conceptual diagram

Once-through Boiler at sub-critical

Water Saturation Steam

Once-through Boiler at sub-critical Evaporation point is moved. It

Heat storage capacity is

(4) Compared conceptual diagram

Once-through Boiler at supercritical

Once-through Section Evaporation point is obscure.

(a) Steam temperature control

Once-through Boiler Feed water flow is kept at constant.

Once-through Section If fuel input is increased

Water Saturation Steam Saturation region is moved to left side and

Burner Steam temperature is controlled by

(b) Steam pressure control

A certain level of degree of superheat

Steam generation is quick increased

(A) No Spray 22 / 212

ECO ECO Spray water : From ECO outlet

(A) No Spray (B) Spray Injection 23 / 212

ECO ECO Spray water : From ECO outlet

Feed water flow : Constant

WW out 1SH 1ry DeSH 2SH 2ry DeSH 3SH

WW out 1SH 1ry DeSH 2SH 2ry DeSH 3SH

WW out 1SH 1ry DeSH 2SH 2ry DeSH 3SH

(f) Summary of comparison for main process control

Main parameters for main steam pressure / temperature control

Main steam Wet SH Spray

Main steam pressure setting (MPa)

Turbine governor opening (%)

Merit of the sliding pressure operation

Pre-Boiler Clean-up Operation Completion Criteria

pH (25°C) - 9.3 – 9.6

Combined HP heater WSDT ≤X

WSDT Iron ppb ≤ 100

Required Water Quality from Pressurisation to Synchronization

Deaerator outlet DO Ppb ≤ 10

Required Water Quality from Synchronization to Full Load

Deaerator outlet DO Ppb ≤7

Required Water Quality from COD onwards

Deaerator outlet DO Ppb ≤7

Dosing Points for AVT & CWT Mode of Operation

Ammonia (NH3) CPP O/L CPP O/L

Eco However, the steam generation is in low

To recover the possible heat loss, hot

Sr. No Parameters UOM BMCR TMCR

1 MS Flow Ton /Hr 2120 1918.6

2 RH Flow Ton / Hr 1680.1 1612.6

Sr. No Parameters UOM BMCR TMCR

9 ECO Temp ◦C 292.73 290

Press drop through

ATOMIZING MEDIUM VALVE FLAME ON ■ 　 15SEC