SEMINAR REPORT ON

210 MW LMW WIND-BOX DESIGN & OPERATION

(For Induction Level Training Course for Engineers)

2008 SUBMITTE B!

ASHOK D. WALKOLI Junior Engr. (Gen) K-45 Batch

COURSE DIRECTOR Mr. P.D. Deshmukh (E.E.) E.E.)

COURSE CO-ORDINATOR Mr. M.H. Deshpande (Dy.

KORADI TRAINING CENTER

MSPGCL, KORADI, NAGPUR.

"C#$%&LE 'ME$T
I am very glad to express my deep sense of gratitude and whole hearted thanks to Mr( C( S&"M! (C('(M() and Mr( B(U( &"')M"*E (S(E) for giving me encouragement and necessary facilities for carrying out this seminar. I am also thankful to Mr( +( ( ES)MU#) (E(E() Course Director & Mr. M()( ES)+"$ E ( ,( E(E() Course Co-ordinator who has provided me this opportunity to do the same. Last ut not the least! I would like to thank all the related people who helped me in the duration of my seminar.

"S)%# ( &"L#%LI -r(Engr( ('en) #./0 Batc1

KORADI TRAINING CENTER

MSPGCL, KORADI, NAGPUR.

I$ E2
34 C%MBUSTI%$ "$ &I$ .B%2 "I* 24 C%MBUSTI%$ "I* S!STEM 54 FUEL BU*$I$' S!STEM 6 SUBS!STEMS /4 SEC%$ "*! "I* S!STEM 6 IST*IBUTI%$ 04 %+E*"TI%$ %F &I$ .B%2 74 +*% UCTS %F C%MBUSTI%$ S!STEM 84 I$ST*UME$T"TI%$ L%'ICS 84 +*%BLEMS &IT) &I$ .B%2 94 C%$CLUSI%$

34 C%$T*%L %F &I$ B%2 "I* T% B%ILE* 6 C%MBUSTI%$ T)E%*! Coal is fired in to the furnace where com usti le matter in the coal reacts with "xygen from the com ustion air. Chemical reaction causes release of heat energy. #s a result of com ustion$ %lue gases and ash is also generated$ which are removed from the furnace y I.D. %ans. #sh is separated from flue gases in &lectrostatic 'recipitator and flue gases are released in to atmosphere. %ly ash is evacuated from &(' )oppers and disposed off to ash und. (ulphur present in the coal reacts with "xygen producing ("* and ("+ gases$ which mix with moisture$ forming (ulphuric acid$ which has a due point of ,*-. C. If flue gas temperature drops elow due point temperature$ condensation of (ulphuric acid take place causing corrosion of the steel work. )ence flue gas temperature is maintained around ,+/. C to ,0-. C at #ir 'reheater outlet. %lue gases at the temperature of ,+/.C to ,0-.C are then released to atmosphere. 1his causes loss of heat energy$ and the loss is called 2Dry %lue 3as Loss4. 1his loss is minimum if 5uantity of flue gas released is minimum. 6uantity of flue gas produced is proportional to 5uantity of com ustion air supplied. %or complete com ustion of fuel$ certain minimum air is re5uired and there are thus limitations in reducing the air 5uantity. Com ustion system of 7oiler is designed to achieve complete com ustion of all the fuel with 2optimum4 air supply. Com ustion system design also takes care that flue gas temperature shall remain within ,+/. C to ,0-. C at #ir 'reheater outlet. 1o develop a understanding of the com ustion process is the o 8ective of this write up. (ome of the terms commonly used in com ustion theory are defined as follows. Initiation of Co:;ustion in ;oiler9 %or com ustion to take place there are three essential re5uirements %uel$ #ir and Ignition. Ignition energy re5uirements for coal are high and can not e met y low energy devices such as electrical spark plugs etc. )ence coal is never fired at start up of the oilers. "n the other hand$ LD" :Light Diesel oil; is used to initiate start up of the 7oiler

as its ignition energy re5uirements can e fulfilled with the help of &lectrical spark$ o tained from spark plugs. <hile LD" com ustion is in progress$ )%" :)eavy fuel oil; is fired. 1he sparking induced in the spark plug along with the heat energy released from the com ustion of LD" is sufficient for igniting )%". Coal firing can e started only after the oiler pressure has reached a predetermined value. "il support is continued till oiler reaches /-= of rated output. "nce the 7oiler Load is more than /-=$ the intense radiation in the furnace can provide the necessary ignition energy for coal. #t this stage$ oiler is said to e operating in sta le condition. %ollowing discussions are applica le for com ustion theory under sta le operating conditions of the 7oiler. Co:;ustion s,ste:9 Com ustion system is designed for carrying complete com ustion of coal$ at re5uired rate and within limited space the furnace. 1he salient re5uirements for the com ustion systems are9 3) >ery high rate of fuel admission re5uired for achieving re5uired evaporation rate. (team flow for *,- M< 7oilers is ?@- 1onsA hr and for /-- M< oiler$ it is ,/*0 tons A hr. 1he fuel firing rate for these oilers are ,+/ 1A)r and +-- tons A hr respectively. Coal particles do not stay in the furnace for more than , or * seconds. )ence$ com ustion system shall e a le to complete com ustion of all the fuel within this time. 1he time for which coal remains in com ustion Bone is called Cesident 1ime. 2) Dn urnt car on should not exceed -./ = to ,.- = of fly ash to achieve high 7oiler efficiency. 5) >olume of %lue gas generated shall e minimum possi le. #s the flue gas is discharged in to atmosphere at ,+/. C$ small volume of flue gas means small heat losses. /) #ll these o 8ectives shall e achieved keeping the furnace siBe as small as possi le for achieving low capital costs. 0) #ll coal particles shall e a le to mix with the "xygen in the com ustion air eing supplied to the furnace. 7) #ir surrounding every coal particle shall contain enough "xygen for its complete com ustion.

)ow the com ustion system achieves these o 8ectives can e known y studying com ustion mechanism. Co:;ustion :ec1anis:4 Co:;ustion of single solid Fuel <article in "ir9 Com ustion is a chemical reaction etween fuel and oxygen. 1ime re5uired for completion of this reaction is known as reaction time$ and it consists of! ,; 1he time taken y "xygen in the surrounding air$ to reach the fuel *; 1ime taken y fuel to react with "xygen. "xygen from air reaches to the fuel particles y a phenomenon called Diffusion. Diffusion takes place ecause of difference in concentration of "xygen in air and concentration of oxygen in the gas film on the surface of urning fuel particle.

<hen fuel particle is ignited$ "xygen from air that is in close contact with particleEs surface reacts with the fuel. 1his produces flue gases and the "xygen from the air in contact with particleEs surface gets consumed. 1his leads to reduction in "xygen concentration at surface. (ince "xygen concentration in the atmospheric air is approx. *+= y mass that is much more than that in the gas film around the particle$ oxygen from air starts diffusing towards the surface of the fuel particle and reaction continues till all the com usti le matter in the fuel is exhausted. 1he various factors controlling the rate of reaction are ,. 1he rate at which "xygen diffuses through the 3as %ilm. *. 1he rate at which "xygen diffuses through the ash layer formed on the surface of the urning particle. +. 1he rate at which reaction of oxidation of com usti le material is taking place. Co:;ustion of Coal in Boiler furnaces4

1he process takes place at #tmospheric 'ressure and at very high temperature of ,*-Degrees C or higher and is Diffusion controlled. 1he furnace also contains mixture of %lue gases$ fly ash and #ir eing supplied. 1he process of com ustion progresses in two steps9 ,; Delivery of "xygen from the air :which is one of the constituent of mixture of the gases present in the furnace; to the surface of Coal particles y Diffusion *; Chemical reaction taking place at the surface. 1he rate of com ustion is controlled y the rate of Diffusion of "xygen. %or o taining very high rate of diffusion of "xygen from air to fuel particles$ it is necessary that fuel particles must always remain surrounded y air re5uired for complete com ustion of the particles. (ince the furnace contains mixture of air$ coal particles and flue gases$ the pro a ility of coal particles remaining in contact with air is very high provided following re5uirements are fulfilled9 ,. (mall siBe of the 'articles9 Coal is pulverised to very fine siBe in coal mills thus increasing the surface area of per unit mass of coal. #s small particle needs small mass of air for its complete com ustion$ it needs to e surrounded y small siBe of air sphere. In well-mixed furnace$ it is possi le to fulfill this condition. Coal is pulverised to Mean average 'article siBe of @/ microns. :Corresponding to *---mesh siBe;. @-= of coal particle should pass through *---mesh sieve and retention y /--mesh screen shall not exceed ,=. *. Dryness of Coal particles9 'ulverised coal is transported to %urnace through coal pipes using 'rimary air. Coal is dried in the coal mill with the help of high temperature primary air. 1he mixture temperature at coal mill outlet is maintained at @/. C$ which prevents condensation of water vapor in the coalA air stream. >elocity of coal A air mixture in the pipes is +/ mAsec which avoids separation of particles from stream. +. >elocity of air A coal mixture in pipes9 1o achieve well-mixed furnace$ e5ual mass of coal should e fired from all corners. %or making the velocity of airA coal mixture e5ual in all pipes$ orifices are provided on the pipes.

Coal contains >olatile matter that mainly comprises of gases such as Methane$ )ydrogen Fitrogen$ "xygen and moisture. <hen coal particles enter the furnace$ due to intense radiation present$ its temperature starts increasing$ causing its expansion >olatile Matter comes out from the particle and starts urning. "xygen in the 'rimary air gets consumed in the com ustionof volatile matter. (ince volatile matter is gaseous in nature$ it mixes easily with the air and hence its com ustion is very rapid. 1he solid particles$ which are now devoid of >olatile Matter$ are known as soot particle. Com ustion air re5uirement for soot particles is fulfilled y secondary air. (econdary air fans are used for this$ discharge of which is connected to #ir preheaters$ where air temperature is increased to +*/. C. 1his air then flows to <ind 7ox$ from where it is admitted to the furnace through dampers called auxiliary air dampers. %or ensuring the air-rich and well-mixed furnace$ secondary air is admitted from the specified locations and with specified velocity. 1he velocity of admission of secondary air is 0- m Asec. 1he secondary air dampers are named after the elevation on the oiler as follows9

FUEL FI*I$' S!STEM

FF F EF E E Front &all C C BC B "B " "" )F% Burner %il Fla:e Scanner )E" Igniter (3) +lan (Corner esignation) (/) "ir a:<er E" F" End "ir Fuel "ir Coal Burner Fire Ball Scanner LF%=)F% Burner E" F" (2) (5)

T,<ical Corner "rrange:ent for a Tangentiall, Fired S,ste:

Dampers #$ 7$ C$ D$ % and %9 1hese are also called %uel air dampers. 1he opening of these dampers is modulated as per mill loading. 1hese dampers supply the secondary air for com ustion of coal and hence open only for those coal elevations$ which are in service. Dampers #7$ CD and &%9 %or the oil elevations in service$ these dampers modulate as per the oil pressure. %or the elevation where oil guns in not in service$ these dampers modulate to maintain %urnace-<ind ox Differential 'ressure as per the following curve9 Dampers ##$ 7C$ D&$ %%9 1hese dampers modulate to maintain %urnace-<ind ox Differential 'ressure as per the following curve9

1ur ulence9 1ur ulence in the furnace results in well-mixed furnace where the gas mixture is homogeneous. 1angential corners firing result in highly tur ulent furnace. >ortex formed in the furnace due to corner firing causes particles to travel in a helical path$ thus increasing the resident time. Firing s,ste: 1he firing system adopted for koradi unit is of direct firing tangential system with the fuel air mixture from the fuel preparation plant directly carried to the respective urners without having any intermediate storage ins. 1he tangential tilting urners are located at the four corners with six fuel

elevation$ corresponding to the six owl mills. In this tangential firing system furnace itself acts as a urner ensuring good tur ulence and complete com ustion inside the furnace at a fairly low flame temperature level. 1his also results in minimum emission of Fitrogen "xide orF"*. 1he urners are e5uipped with tilting mechanism to ena le the tilting of the urner y a range of G+- in order to achieve a finer control in reheat system temperature at part load conditions. 1he urner wind ox selected for H"C#DI unit is designed to fire a wide range of Indian coals. Depending on the type of coals to e fired the num er of mills and there y the num er of fuel elevation in operation will vary from 0 to? at MCC load condition. It may e noted that there are two elevation of oil guns sandwiched with coal compartment for the purpose of start up and warm up re5uirement. 1he capacity of each oil gun is */= of MCC. )owever when oth elevations are in operation$

the maximum load per elevation is to e maintained at ,*./=. 1he oil heating and pumping units are siBed for a total */= MCC capacity. 1he wind ox is provided with 0 num ers of ignitors and + num er of flame scanners per corner of location as indicated in the sketch attached. 1hese scanners and ignitors are linked with the furnace safeguard system :%(((; installed in this unit to ensure safer com ustion.

24 C%MBUSTI%$ "I* S!STEM( 1he unit uses two forced draft :%D; fans$ two primary air :'#; fans$ and two induced draft :ID; fans. 1he %D fans force com ustion air through the air heater then into the wind ox and steam generator for com ustion. 1he %D fans are axial flow fans that are driven y single-speed electric motors. 1he '# fans force com ustion air through the air heater then through the pulveriBers$ where the pulveriBed coal is removed efore delivery to the urners. 1he '# fans are centrifugal fans driven y single-speed electric motors.

1he steam generator operates at essentially atmospheric pressures. 1he ID fans develop the pressure differential necessary to remove the com ustion gas from the steam generator. 1he fans propel the flue gas through the air heater$ particulate removal system$ flue gas desulfuriBation system and up the stack. 1he ID fans are axial flow fans driven y single-speed electric motors.

"I* 6 FLUE '"S S!STEM

To "ir Cooled 'uns Scanner "ir Fans Fro: F Fans To )ot +" )eader To Cold +" )eader +" F"$ "

+" F"$ B

&I$ %2 " ") " FU*$"CE + T $ S ) * ) F I $ S ) L T S ) E C % ES+ " I Fan " C1i:ne, I Fan B ") B ES+ B

&I$ B%2 B

F F"$ "

F F"$ B

Si:<lified +rocess iagra:

54 FUEL BU*$I$' S!STEM "$ SUBS!STEM 1he primary function of fuel urning system in the process of steam generation is to provide controlled$ efficient conversion of the chemical energy of the fuel in to heat energy which is then transferred to the heat a sor ing surface. (atisfactory oiler operation re5uires energy and se5uence so that the furnace never can contain an explosive mixture$ flow and processing of fuel$ air ignition energy and the products of com ustion

Su; s,ste:s 1he fuel urning system should function so that the fuel and air input is ignited continuously and immediately upon its entry into furnace. 1he total fuel urning system re5uires to do this consist of su systems for #ir handling fuel handling ignition com ustion product removal main urners and oiler furnace "ir 1andling 1his su system should e capa le of supplying properly air to the main urners on a continuous and uninterrupted asis. It should e capa le of providing the re5uired air fuel ratio over the entire range of the urning. 1he total air re5uired for com ustion is divided into primary air and secondary air. 1he primary air is that portion of the total air which is sent to the mill. 1he air dries the coal in the mill as the coal is getting pulveriBed$ transports the accepted coal particles to the furnace$ and supplies oxygen for the com ustion of volatiles. 1he secondary air otherwise also known as auxiliary air helps complete com ustion.

1he pressure variation in air and gas path is shown in following diag.

'ressure >ariation
Pressure Variatio i Air & Gas Pat! at "u## Loa$
3000 2500 2000 1500 1000 500 0 -500 -1000 -1500 -2000 -2500

Pressure &Pa'

10

11

12

%D %an Duct (C#') Duct #')

Duct <ind 7oiler #') &(' ID %an 7ox

Pat! E#e%e t (a#)u#ate$ &21* MW' Desi+ &210 MW'

/4 SEC%$ "*! "I* S!STEM "$

IST*IBUTI%$

1he secondary air which is handled y the %D fan passes through the regenerative air heater and to the wind ox connecting duct which supplies the secondary air to a pair of wind oxes. 1he secondary air is divided into two parts namely primary air and auxiliary air. %uel air is that air which immediately surrounds the fuel noBBles. (ince this air provides a covering for the fuel noBBles$ this air is is also called as Mentle air.

#uxiliary air is admitted through compartments a ove and elow the fuel noBBles. Dampers are provided in the wind ox compartment so that the correct 5uantities of air to the individual compartment can achieve etter com ustion in the furnace.

In order to ensure safe light off conditions the proportional purge air flow :at least +-= of the full load air flow; is maintained during the entire warm up period until the unit load has reached a point where the air flow must e increased to accommodate further load increase. 1he +-= air flow is maintained in order to ensure an air rich furnace atmosphere with enough air for good com ustion. #fter the unit is online the total amount of air flow is a function of the unit characteristics of the fuel fired and the amount of excess air re5uired.

1he function of the wind ox compartment dampers is to proportionally affect the air distri ution as follows

Secondar, air distri;utio: # ove +-= MCC close auxiliary air dampers ad8acent to non-operating fuel noBBles to ensure good distri ution of air around operating noBBles. Inade5ueate air around operating fuel noBBles will lead to sweeping of flames around the wind ox $ noBBle tips there y overheating and deforming the noBBle tips. # cooling air 5uantity of / to ,-= is ade5uate through non-operating fuel air and auxiliary air noBBles$ larger cooling air 5uantity may increase the excess air or reduce the secondary air availa le closet to the operating fuel noBBles and affect com ustion unfavora ly.

%uel air supplied around the air noBBle$ is 5uantity and velocity can influence the flame front greately. 1he fuel air dampers controlling its velocity and its relative 5uantity w.r.t. aux. can e ad8usted to keep the flame front +--mm away from the fuel noBBles to keep it ade5uately cool at /--c.

# fuel air auxiliary air ratio of 0-9?- or 0/9// has een found more suita le than earlier adopted ratio of *-9I- or +-9@- for furnace operation. etter performance and slag free

"pening up the fuel air dampers or closing down the auxiliary dampers increases the air flow around the fuel noBBles. Closing down the fuel air dampers or opening the auxiliary dampers decreases the air flow around the fuel noBBles.

1he correct proportioning of secondary air etween the fuel compartment and auxiliary compartment depends on the the furnace. Fuel air da:<er control urning characteristics of the fuel. It influences the degree of mixing the rapidity of com ustion and the flame within

#ll the fuel air dampers are normally closed. 1hey open at a definite time interval after the associated feeders are started. 1hese dampers are to e modulated with reference to the amount of fuel fed to that elevation of fuel noBBles. 1he fuel air dampers opening can e effectively used for the control of flame front position. 1hey are fully open when oth %D fans are off. %or damper operation the pneumatic operated power cylinders are provided as follows

"u>iliar, air da:<er control During the furnace purge period and initial operation of the unit :up to +-= loading; all elevations of auxiliary dampers modulate to maintain a predetermined wind ox to furnace differential. #ll these dampers are modulared on elevation asis. <hen the unit load exceeds +-= loading the wind ox to furnace differential in dampers which are time se5uence starting with upper elevation and progressing to lowest elevation. 1he optimum wind ox dampers settings for particular unit depend on the condition that is present on the particular unit. In general$ the factors which determines the setting are Ignition sta ility Ignition point relative to fuel noBBles "verall com ustion condition in furnace.

04 %+E*"TI%$ %F &I$ .B%2 "M+E*S #ll auxiliary air dampers shall e open for oiler purge to ensure uniform purge. #ll wind ox dampers except non-operating fuel air dampers shall modulate to maintain,/ to +@mm. differential pressure etween wind ox and furnace up to +-= oiler load to keep proper air distri ution around operating fuel noBBles. #ll operating elevations of air dampers and their ad8acent auxiliary air dampers shall modulate to maintain ,-- to ,/-mm :as specified; wind ox to furnace differential pressure on full load. 1he primary air pulveriBed coal noBBles admit fuel at almost a fixed velocity of *@ mAsec$ over an elevation load range of /- to ,--=. 'rimary air flow through mill has to e reduced corresponding to a velocity of not less than *- mAsec. in p.f. pipe to ensure sta le flame at low loads. 1he fuel air :%.#.; supplying %.#. around primary noBBles shall e ad8usted to get a sta le flame a out +--mm outside the noBBles. More fuel air shifts the flame front further away and makes the flame unsta le and conse5uently haBardous situation develop. Low fuel air results in urning within the noBBles and hence overheating and detoroation of the noBBles and the conse5uent detoriation of the com ustion process and even impingement of flame leading to failure of the oiler tu ing$ the life of oiler noBBles is also considera ly reduced. Large 5uantity of fuel air i.e. 0- to 0/= secondary air as against *- to +-= secondary air sent around the fuel noBBles has helped to improve the urner performance and solve slagging condition in the furnace. More air is forced to flow through fuel air noBBles y opening the fuel air damoers more and simultaneously closing in the auxiliary air dampers. #fter +-= oiler load the auxiliary air dampers ad8acent to operating fuel noBBles may e opened gradually to hold maximum wind ox to furnace over ?-= to ,--= oiler load range instead of ramping up the differential presuure at +-= oiler load :to ensure smooth operation and o tain etter performance;.

74 +*% UCTS %F C%MBUSTI%$ S!STEM

LetEs first see details a out the fuel i.e. coal to know the com ustion products. T,<e and classification of Coal4 Coal is classified as per its composition in different grades. 1he #(1M :#merican society for 1esting and Materials; have graded the coal in following different grades! ,; #nthracite Coal9 1his is the highest grade of coal. It contains high percentage y mass of fixed car on$ ranging etween I?= to JI= on dry$ mineral free asis and a low volatile matter$ generally *= to ,0= y mass. It is a shiny lack$ dense hard$ rittle coal. It is slow urning and have a Calorific >alue @?-- Hcal A Hg *; 7ituminous Coal9 It is a road class of coal containing 0?= to I?= of fixed car on y mass and *-= to 0-= y mass of >olatile Matter. Its calorific value ranges etween ?--- HcalAkg to I--- Hcal A kg. the coal is easily com usti le and is most suita le for com ustion in pulveriBed form. +; (u 7ituminous Coal9 1his is a class of coal that has lower heating value than that of ituminous coal. Its C.>. ranges etween 0/-- to ?0-- Hcal A kg. 1his coal is also suita le for com ustion in pulveriBed form. %ixed Car on ranges etween 0-= to /-=$ >olatile matter ranges etween *-= to +-=. 0; Lignite9 It is the lowest grade of coal. It is rown in color and remnants of wood fi ers are visi le in this coal. It originates from resin rich plants and hence contains very high inherent moisture :+-=; and volatile matter. Its heating value is +/-- HcalA Hg to 0?-- HcalA kg /; 'eat 9 It is not an I(1M coal. It is considered as the first step in coal formation. It contains decomposed organic matter and minerals and J-= moisture. It is not useful for 'ower generation. 7ut due to its a undance in some countries$ it is used for heating and in some other industries In India$ coal is graded as per its calorific value. Different

gradations are

"nal,sis of coal9 1here are two types of coal analysis$ 'roximate and Dltimate. Dltimate analysis9 Dltimate analysis gives information a out the various constituents of coal. # typical ultimate analysis on dry asis is given elow.

'roximate analysis9 It is easier to carry out proximate analysis and it gives useful information for coalEs use in steam generators. It determines the mass percentage of %ixed car on$ #sh$ >olatile Matter and Moisture. 1ypical proximate for an Indian coal is as follows9

Calculation of "ir re?uire:ent for co:;ustion of Coal4 1heoretical air re5uirement for complete com ustion of coal can e known if the constituents of coal are known. Dltimate analysis gives the information a out the Car on$ )ydrogen$ (ulphur$ "xygen and Fitrogen present in coal. 1heoretical air re5uirement$ also called (toichometric air re5uirement$ for complete com ustion of , Hg of coal can e computed as follows.

Car;on ;urnt to Car;on i %>ide4 (u stance9 C G "* K C"* #tomic or molecular weight9 ,* G +* K 00 <eight in Hg , G *.?@ K +.?@ G I-@@ Hcal heat release Car;on ;urnt to Car;on Mono %>ide4 (u stance9 *C G "* K * C" #tomic or molecular weight9 *0 G +* K /? <eight in Hg , Hg G ,.+++ K *.+++ G *0++Hcal heat release Car;on Mono o>ide ;urnt to Car;on i %>ide (u stance9 *C" G "* K * C"* #tomic or molecular weight9 /? G +* K II <eight in Hg *.+++ G ,.+++ K *.?@ Co:;ustion of ),drogen4 (u stance9 *)* G "* K * )*" #tomic or molecular weight9 + G +* K +? <eight in Hg , Hg G J K J G +0000 Hcal heat release Sul<1ur Burnt to Sul<1ur i %>ide4 (u stance9 ( G "* K ("* #tomic or molecular weight9 +* G +* K ?0 <eight in Hg , Hg G , K * G ,**J Hcal heat release "xygen supplied for com ustion is o tained from the atmospheric air$ which is composed of following elements9 &lement 'ercentage 'ercentage y volume y weight "xygen *-.J, *+.,/ Fitrogen @J.-J @?.I/ "nly "xygen takes part in com ustion reactions and Fitrogen passes without chemical change.

B"SIC C%MBUSTI%$ C)EMIST*!

Co:<lete ("ir) %>,gen %2 Fuel )2 C

)e at

Flue 'as

+roducts )2% C%2

Inco:<lete %>,gen %2 Fuel

)e at

Flue 'as

)2 C

+roducts )2% C%2 C% )2 C

%t1er Co:;usti;les . Sul<1ur to Sul<1ur %>ides $on.co:;usti;le . $itrogen to $itrogen@$itrous %>ides "s1

T1eoretical air re?uire:ents for co:;ustion4 %or supplying , Hg of "xygen$ :,--A *+.,/; Hg i.e. 0.+* Hg of air is re5uired. (ince , Hg of car on re5uires *.?@ kg of "xygen$ air re5uired will e *.?@ L 0.+* K ,,./+ Hg of air. #ir re5uirements for com ustion of other constituents is also given y9 Hg of air re5uired K ,,./+ C G +0./?:) - ,AI "; G 0.+* ( <here C$ )$ " and ( are Car on$ )ydrogen$ "xygen and (ulphur contents in the coal in 'ercent y weight$ given y Dltimate analysis of coal. In 'ulveriBed Coal fired furnace$ for complete com ustion$ *-= excess air is supplied$ which is over and a ove the calculated theoretical air re5uirement. 7y measuring "xygen in %lue 3ases$ &xcess air supply can e measured. +./= of "xygen in %lue 3as at &conomiser "utlet ensures that oiler is eing supplied with *-= &xcess air. )owever$ complete com ustion can e achieved with supply of *-= excess air only when following parameters are also maintained

,. &5ual firing rate from all the corners of the oiler. Maintaining the orifice plates in coal pipe in proper condition can ensure this. 1he temperature of coal A air mixture at Mill outlet should also e maintained at @@ C. 1his ensures proper dryness of fuelA air mixture. *. Coal 'article siBe9 (iBe of coal particles from all the coal mills should confirm to9 @-= particles should pass through *-- Mesh sieve$ not more than -./= particles shall e retained y /--mesh sieve +. Correct operation of all (econdary #ir dampers$ ensures air rich well mixed furnace. 0. Maintaining the %urnace <ind ox D' as per the manufacturerEs recommendations. 1his ensures that the secondary air flows in to the furnace at design velocity. /. &nsuring the airtight furnace$ y eliminating the atmospheric air entry in to the furnace from inadverantly open peepholes$ damaged gaskets of 'eepholes and Manhole doors etc. 1he atmospheric air entering in the furnace$ called tramp air$ does not take part in the com ustion and inflates the "* in flue gas reading$ thus reducing the com ustion air. It also aids late com ustion of un urnt car on particles in the )oriBontal pass$ leading to excessive heat pick up in convective superheaters. ?. Monitoring the Car on mono oxide :C"; in flue gases further help optimiBation of the com ustion process. Incomplete com ustion due to poor air supply :i.e. deficit air supply; leads to large concentration of C" in flue gas. 1he curve elow shows that C" concentration increases stiffly even for a small reduction in air re5uired for complete com ustion. Maintaining ,-- ''M C" in flue gas y controlling the secondary air flow ensures that com ustion air supply is optimum and hence losses are minimum.

In s1ort4 +roducts of Co:;ustion S,ste: 1his su -system should e capa le of removing furnace gases over the entire operating range of fuel urning system while maintaining the furnace pressure within design limitations. # primary function is to remove inert com ustion product so that the furnace fuel air input can e continuously and immediately ignited. Controls are provided for the operation of dampers in the flue gas system. #lso the analysis of C"*$ o* and co in the product of com ustion is very valua le in determining the com ustion efficiency and air infiltration. 1here is no perfectly relia le means of measuring the air actually admitted to the furnace and the only means of determining the amount of such air is from the analysis of products of the com ustion called flue gas.

84 I$ST*UME$T"TI%$ L%'ICS F%* raft control 6 &ind.;o> +*ESS( C%$T*%L

Draught Control

<ind ox 'ressure Control

84 +*%BLEMS F"CI$' &IT) &I$ .B%2 (S" C) "M+E*S

,. *. Fo output from the panel. ,. *. +. Check the control panel for proper functioning. Check the power supply and the healthiness of cards in the panel. Confirm data transfer etween console$ IA" cards and processor.

"utput not varying. Check the signal to the output cards separately and esta lish it. Check the output cards separately. Check the field ca ling for earth faults$ short circuits and proper polarity. Check for any overriding protective interlocks : e.g$ ID-%D fans off$ M%1$ furnace to <7 D' high.;

+. 0.

Damper opening not matching with the demand &nsure correct air supply to the IA' :current to pressure ; transmitters. Check the ca ling for polarity$ healthiness of connections Check the current input and signal output at the IA' outlet port. Check the signal tu ing for leakages. Conduct pressure decay test if dou t persists. Check the damper separately for mechanical freeness. Check the power cylinder air supply for proper 5uality and pressure. #fter ensuring proper signal and power air supplies to the actuator$ check its response :output air pressure;. Check the setting of the air lock relay on the actuator. (ervice the actuator. %ailure of #uto control of #uxiliary damper

 Check the furnace to <7 diff pressure transmitters for proper functioning. Check for high mismatch etween measured values. Confirm that #LL the dampers are responding properly and the damper position in all corners of the same elevation are matching. Check the response of the D' when dampers are manually ad8usted. #d8ust the ias to get suita le D' demand. Check the healthiness of reference signal used to generate D' demand : oiler load index; Check for any over riding interlocks. Check the secondary air system for proper status. If the oxygen = is not maintaining proper please check for leakages in oiler.

In alanced draft oilers am ient air leaks into the oiler through furnace ottom$ various openings in the furnace convective pass and leaking manholes. #ir ingress into *nd pass where gas temperatures are high enough$ supports secondary com ustion. #ir ingress from convective pass or downstream ducts$ where the temperatures are low$ 8ust dilutes the flue gas and increases its volume. 1he cold

air entering from furnace ottom results in lesser hot airflow through air heaters there y affecting oiler efficiency. #ir entering after com ustion completion i.e. from penthouse roof$ second pass expansion 8oints and from ducts upstream air heaters$ shall account for the difference in "* level etween the furnace exit and economiBer exit. #irflow control is ased on "* measurement at air heater inlet in coal-fired oilers. %or a specified level of "*$ any air ingress efore this section would result in reduced level of "* actually taking part in com ustion in the furnace$ there y increasing the un urnt car on and car on monoxide levels.

/.

%ailure of %uel air dampers.

Check that no override commands are present. Check that the reference input : e.g '# flow; is "H. Check the damper operation in manual. 1une the parameters to suit the firing regime.

94 C%$CLUSI%$ %or proper operation of wind ox oxygen measurement plays ma8or role$ so it should proper. Cegularly checking of furnace air leakages is necessary. (ome new installation should prefer to reduce the losses and increase the efficiency.
3AInstallation %f Fa;ric E><ansion Co:<ensator "t +ri:ar,B Secondar, "ir uct "nd Furnace.&ind Bo> uct BacCground In a coal ased power plant '# & %D fans supply primary and secondary air re5uired for com ustion. 1his air is heated in air pre heater to a temperature of +--.C. 1he hot secondary air is supplied to the oiler from wind ox. 1he 8oints of air preheater with primary and secondary air ducts and 8oints of the wind ox are exposed to high wear and tear and results in heavy leakage of hot dust laden air. 1he surroundings ecome very hot and difficult to work. 1here is huge heat loss also. %;servations 1here was severe ash A hot #ir leakages in all four corners from wind ox & primary$ secondary hot air leakages from expansion ellows. Tec1nical 6 Financial anal,sis ,. M( plate of + mm thickness welded from inside the wind ox to cover the metallic expansion ellow to avoid direct contact of hot secondary air.

*. %a ric expansion ellow provided from outside the wind ox to cover metallic expansion ellow. +. %a ric expansion ellow provided at #') outlet duct in primary & secondary metallic expansion ellow. 0. Investment of Cs. ,*.+0 Lakhs &nergy (aving Cs. ,,* .,* LakhsAyear. I:<act of i:<le:entation ,. 1o reduce respective fan loading. (aving &nergy. *. 1o reduced the ash accumulation around furnace and #') guide earing area$ there y improving e5uipment life and relia ility. +. 1o reduce hot air leakages around furnace and #') guide earing area$ there y preventing loss of energy. 0. Cost savings of Cs ,,*.,* lakhs. 'er year for oth units.

2A"rrange:ent of se<arate over fire air s,ste: for co:<lete co:;ustion 1his arrangement is given in new power plants and it really helps to complete com ustion