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INTRODUCTION BOILER EMERGENCY CONTROL PROCEDURE Objective of the emergency control i) Maintain equipment in maximum state of reliability.

ii) Minimize personnel casualties and secondary damage to vital machinery. Three steps in emergency operations i) Minimization of equipment damage. ii) Restoring bac the equipment in service. iii) !arrying out the necessary repairs. BOILER EMERGENCIES i) "oiler trip out #M$T). ii) %isturbance in boiler drum &ater level. iii) 'ater pumps failure. iv) (igh &ater level v) !arry over. vi) Reheater protection upon loss of load vii) Minor tube lea age. viii) Major tube burst. ix) $.%. fan failures. x) ).%. fan troubles. xi) $urnace explosion. xii) (igh furnace pressure. IMPORTANT BOILER SAFETIES )) Master $uel trip #M$T). ii) *artial fuel trip. iii) *urge.

BOILER TRIP + boiler trip command #M$T) stops all fuel inputs by tripping +ll of the pulverizer +ll feeders +ll oil guns +ll ignitor !loses the ignitor, light oil and heavy trip valves + boiler trip command #M$T) is initiated by any of the follo&ing conditions being present. -oss of unit %.!. po&er #for more than . sec) -oss of +.!. po&er at any elevation #for more than . sec) in service / no feeder established. -o& drum &ater level. (igh drum &ater level "oth $.%. fans are off "oth ).%. fans are off 0nit air flo& is less than 12 3 of full load air flo& before boiler loading has been above 12 3 -o& furnace pressure. (igh furnace pressure Turbine trip -oss of all fuel 0nit flame failure #trip) Manual trip "oth the trip push buttons on the control console depressed. Loss of fuel Trip circuit becomes on once a minimum of three of the four igniters at any elevation are proved on. Once the trip circuit is on, loss of fuel trip &ill occur if 4 +ll feeders are off +nd

5ither the igniter trip valve is not open or more than one of the four igniter valves are not open at any elevations +nd 5ither the heavy oil trip valve is not open or more than one of the four heavy oil nozzle valves are not open at all elevations +", !% and 5$ +nd 5ither the light oil trip valve is not open or more than one of the four heavy oil nozzle valves are not open at all elevations +", +nd 0nit +! po&er is not available Unit flame failure %uring light up and until any main fuel either coal or heavy oil is in service at a fire ball condition, the optical flame scanner do not ta e part in overall flame failure protection system unit flame failure signal is initiated &hen there is no fireball conditions at all elevations and either any feeder is on or any heavy oil nozzle valve is not closed at any elevation # +" or 5$ ) &here less than three of the four associated igniters are proven O6 5levation no fireball condition -oss of +! po&er failure for more than . sec 6earest oil elevation less than1 no nozzle valves, oil guns and igniter are proven 5levation7s both coal feeders are off Trip valve operation Trip valve is to cut off oil supply to furnace in M$T condition *ermissive to open trip valves +ll the igniter valves are proven closed )gniter oil supply pressure is adequate "oiler trip circuit is reset The trip valve closed automatically On boiler trip #M$T) conditions

)gniter oil pressure going lo& &hen any of the )gniter valve is open for more than t&o seconds light oil trip valve permissive for opening "oiler trip circuit is reset +ll &arm8up oil nozzle valves are closed 'arm up fuel supply pressure is adequate light oil trip valve Tripping conditions "oiler trip out conditions 'arm up fuel pressure is lo& for more than . sec, any &arm up oil nozzle valve is not closed 'arm up air to oil differential pressure is lo& for more than . sec (eavy oil trip valve permissive for opening "oiler trip circuit is reset +ll (eavy oil nozzle valves are closed (eavy fuel supply pressure is adequate light oil trip valve Tripping conditions "oiler trip out conditions (eavy fuel pressure is lo& for more than . sec &hen either recirculation valve is closed or any (eavy oil nozzle valve is not closed 9team to (eavy oil differential pressure is lo& for more than . sec arious !oiler "ontrol s#stem -ight oil pressure control (eavy oil pressure control (eavy oil temperature control *ulveriser temperature control *ulveriser air flo& control !ombustion control *rimary air pressure control Total air flo& control

+uxiliary air damper control $uel air damper control (eavy oil 4 'arm up oil damper control $urnace draft control. superheater steam temperature control Reheater steam temperature control +uxiliary *R%9 pressure control +uxiliary *R%9 temperature control %rum level control !"% expander level control

BOILER INTERLOC$ SYSTEM Control % Interlo"& for Air 'eater 6o interloc provided can be started from local:M!!:remote independently Tri((in) interlo"& On motor protections "earing temperature ; <2 ! Control % Interlo"& for I*D* fan One of the air heater is running 6o bearing temp high indication should persist 6o lub oil pressure lo& indication should persist %ischarge damper should be closed =ane position should be minimum Tri((in) interlo"& ).%. fan + / " should trip on "earing temperature high occur >.>. Common O(erational Pro!lems of Boiler % Au+iliaries? Fre,uent tri(s on flame failure

>. .. 1. @. A. B. <.

!hec for proper combustion !hec for correct total air flo& !hec for correct coal air ratio !hec for correct &ind box to furnace %* !hec for proper functioning of 9+%! !hec for healthiness of flame scanners !hec for flame failure circuit in $999 Main Steam-'R' steam tem(erature lo.-/i)/0

>. .. 1. @. A. B. <. C.

!hec for correct total air flo& !hec for correct burner tilt position !hec for correct feed &ater temperature at 5conomiser inlet !hec for slagging:scaling #external) on &ater &all, 9( / R( tubes Operate &all blo&ers:-R9" at regular interval as per requirement !hec for inside scaling in &ater &alls / 9(:R( tubes !hec for cho ing of 9(:R( attemperator nozzles:passing of 9(:R( spray control valves !hec for any undesired steam outlet due to passing of safety valves, drain valves, vent valves

Tri((in) of !oiler on R' (rote"tions 1ue to "losure of 'P-LP B#(ass 1urin) start u(s0 >. .. 1. @. A. B. Maintain stable combustion 9tudy R( protection logic )nitially eep (*:-* "ypass valves on manual mode. +fter stable combustion and sufficient flo& only they should be put on +uto !hec for proper functioning of these valves on Manual and +uto7 !hec protection closing circuit for any malfunctioning Maintain correct (* "ypass do&nstream temperature

Tri((in) of Unit on /i)/-lo. 1rum le2el 0 >. .. 1. @. A. B. <. C. D. !hec for sudden opening:lea age of &ater&all:economiser tube !hec for tripping of any one of running "$*s !hec for malfunctioning of drum level auto control !hec for closure of any valve in feed &ater circuit !hec for opening of (* "ypass valve on fast opening mode. !hec for sudden thro& off:raising of load !hec for tripping of t&o:three coal elevations simultaneously !hec for disturbance in combustion !hec for malfunctioning of drum level transmitters

Fre,uent tu!e failures 0 >. .. 1. @. A. B. <. C. D. >2. +void sudden stress to boiler tubes Maintain rate of pressurisation:de8pressurisation as recommended during hydraulic test of boiler Maintain rate of rise:drop of temperature as recommended during start8 up:shut do&n #follo& start up curve) Monitor drum:9(:R( metal temperatures during start up:shut do&n %O67T T+E5 M)--9 )6TO 95R=)!5 06-599 $-O' )9 59T+"-)9(5% T(RO0F( R5(5+T5R Maintain proper &ater chemistry regime as per recommendations. !hec for tube thic ness for any erosion. )n case of erosion, tubes must be replaced !hec for deposits:scales inside the tubes. )f found, contact "(5- for further analysis and chemical cleaning. !hec for possibility of cho ing !hec for foreign materials:obstructions in the connected headers

3*3*4*

Boiler 1rum (ressure 1ro((in) su11enl# 0 >. .. 1. @. A. B. <. !hec for interruption of coal to the furnace due to cho ing in the burner !hec for tripping of feeder:mill !hec for disturbed combustion inside furnace !hec for any boiler tube lea age !hec for opening of boiler drains, vent, safety valves !hec for cho ing in mills:drop in air flo& through mill !hec for malfunctioning of auto control of !M!:$uel master control

Su11en re1u"tion of loa1 0 >. .. !hec &hether it is momentary due to grid disturbance or due to

malfunctioning of turbine governing system !hec for drum pressure. )f the trend is increasing, ta e appropriate measures to stabilize drum pressure by reducing:cutting off fuel input to furnace. )f necessary, cut off mills, one by one. 1. @. A. !hec for drum level. 9ee &hether auto control is able to maintain drum level. Other&ise ta e it on manual control. !hec for furnace draft !hec for secondary air flo&, oxygen in flue gas.

'i)/ Flue Gas tem(erature at AP' outlet 0 >. .. 1. @. A. B. <. !hec for excess +ir and total +ir flo& !hec for fineness of coal !hec for fouling of &ater &alls, superheaters, reheaters etc. !hec for proper heat transfer in +ir preheaters !hec for dampers position of +ir preheaters !hec for "urner tilting system and bring it do&n&ards. 9&itch over to lo&er elevation mills.

C. D. >2.

!hec for proper +ir distribution and functioning 9+%! !hec for lea ages through peep holes, manholes, seal &ater trough etc. !hec for tube failures.

>.>.><. 'i)/ e+"ess Air flo. 0 >. .. 1. @. A. B. <. !hec the +ir flo& distribution and functioning of 9+%! !hec the combustion !hec the fouling of superheater, reheater and (T9( surfaces !hec for air ingress through peep holes, manholes, seal trough etc. !hec the reliability of air flo& and O. measurements !hec the fineness of coal and functioning of mills. 9et for proper air flo& and O. in +utomatic combustion control.

Me"/ani"al S#stem ? Pressure Parts ? 5ater 5all tu!e failure 0 >. .. 1. @. A. B. <. C. D. !hec for deposits inside the tube. +nalyse the deposits. !hec for indications for overheating of the failed tube and the nearby tubes. !hec the tube thic ness of the failed tube and also nearby tubes. !hec the healthiness of nearby &all blo&ers for steam passing !hec for possibility of cho ing:loss of adequate flo& through the tube )n case of scales:chemicals deposits:Rust contact "(5- for further analysis and chemical cleaning !hec for foreign materials:obstructions in &ater &all ring headers !hec for possibility of failure of &eld joint !hec the orifices of the tubes in the ring header in case of controlled circulation boilers.

3*6*3*3*

Su(er/eater-Re/eater-E"onomiser-Tu!e failure0 >. .. 1. @. A. B. <. C. D. >2. !hec for indications for overheating of the failed tubes and the nearby tubes !hec for failure of &eld joint !hec the tube thic ness of the failed tube and the nearby tubes !hec the healthiness of nearby long retractable soot blo&er for steam passing !hec for possibility of cho ing:loss of adequate flo& through the tubes !hec for foreign materials:obstructions in the connected headers !hec the tube material for usage of proper grade material )n case of scales:chemicals deposits:rust contact "(5- for further analysis and remedial measures !hec the spacing and alignment of coils around the failed tube !hec the availability:healthiness of tube shields:cassette baffles

Interlo"& an1 Safet# Re,uirements*


9afety controls are needed to protect a)ainst !oiler e+(losions an1 im(losions. )nterloc and other safety requirements for boilers are given in the follo&ing +merican 9ociety of Mechanical 5ngineers #+9M5) and 6ational $ire *rotection +ssociation #6$*+) standards. 'here local or state code requirements differ from the +9M5 and 6$*+ codes, the more stringent code requirements must prevail. G +9M5 !9%8> Controls and Safety Devices for Automatically Fired Boilers G 6$*+8CA2> Standard for Single Burner Boiler Operation G 6$*+8CA2. Standard for the Prevention of Furnace Explosions/ mplosions in !ultiple Burner Boilers G 6$*+8CA21 Standard for Pulveri"ed Fuel Systems

Safet# Interlo"&s* 9afety interloc s are required but not limited to those listed belo&. +dditional safety interloc s may be required to fulfill applicable state and local codes for the boiler fuel type used. G *repurge )nterloc 4 *revents fuel from being admitted to a furnace until the furnace has been thoroughly air8purged to remove residual combustibles. G (igh 9team *ressure )nterloc 4 $uel is shutoff upon abnormally high boiler steam pressure. G -o& +irflo& )nterloc 4 $uel is shutoff upon loss of airflo& from the combustion air fan or blo&er, the induced draft fan or the forced draft fan. G -o& $uel 9upply )nterloc H$uel is shut off upon loss of fuel supply pressure. The loss of fuel supply pressure &ould result in unstable flame conditions. G -oss of $lame )nterloc 4 +ll fuel is shut off upon loss of flame in the furnace or to an individual burner in the furnace. G $an )nterloc 4 9top forced draft upon loss of induced draft fan. G -o& 'ater )nterloc 4 9hut off fuel on lo& &ater level in boiler drum. G (igh !ombustibles )nterloc #optional) 4 9hut off fuel on highly combustible content in the flue gases. G *ost *urge )nterloc 4 !ontinues fan operations to remove residual combustibles from the furnace prior to shutting do&n the fans. De1i"ate1 Safet# S#stem* The safety shutdo&n system must be dedicated and independent of the one used for boiler control. $or example, if *-! controllers are utilized, the design must contain a *-! for safety shutdo&n that is separate and independent of the one used for boiler control. S(e"ial Consi1erations* 9pecial attention should be maintained throughout

the boiler design to prevent the follo&ing safety hazards. G 5quipment must be designed to protect against electrical shoc from exposure to control po&er. G "oiler control must assure a sufficient quantity and duration of pre8purge airflo& through the boiler prior to ignition to prevent boiler explosions. G "oiler control must assure a sufficient quantity and duration of post8purge airflo& through the boiler during shutdo&n to prevent boiler explosions. G "oiler control must assure a sufficient quantity of combustion air and prevent excessive fuel during boiler operation to prevent boiler explosions. G "oiler control must limit the number of retries &hen igniting the boiler pilot. The industry standard is to allo& three attempts at achieving pilot ignition prior to necessitating a boiler purge cycle.

CONTROL LOOPS0 GENERAL* *rovide controls in accordance &ith applicable codes. CONTROL LOOP TYPES* + single control loop includes a controlled variable sensor, controlled variable transmitter, controller, automatic8manual control station, and final control element. !ontrol loops used for boilers may be of the pressure, temperature, liquid level type, or flo& type. Pressure* *ressure control loops may be used for the control of boiler pressure or fuel oil pressure. $or the control of boiler pressure, the final control element regulates fuel flo& to the boiler in response to boiler drum steam pressure. $or the control of fuel oil pressure, the final control element is usually a pressure reducing control valve that regulates in response to do&nstream pressure. Tem(erature* Temperature control loops may be used for the control of steam temperature from boilers or fuel oil temperature from fuel oil heaters. Le2el* -iquid level control loops may be used for the control of boiler drum &ater level. Flo.* $lo& control loops may be used for the control of fuel flo& into the boiler burners, burner draft airflo&, feed &ater into a boiler, or steam flo& out of a boiler. AIR TO FUEL7RATIO* $urnish controls to automatically provide the proper fuel to air ratio over the entire boiler operating range from maximum turndo&n to Maximum !ontinuous Rating #M!R). *rovide cross8limited #lead8lag) controls bet&een air and fuel to increase airflo& before increasing fuel flo& and to decrease fuel flo& before decreasing airflo&. !onsider full metering controls, &hich measure directly both airflo& and fuel flo&, for all boilers &ith capacities greater than A..C gigajoule:h #A,222,222 "tu:h). !onsider an oxygen analyzer, for trim only, for all boilers &ith capacities greater than

.A.1. gigajoule:h #.@,222,222 "tu:h). !onsider !O trim for all boilers &ith capacities greater than A..<A gigajoule:h #A2,222,222 "tu:h), especially coal fired boilers. 5valuate the energy savings of these measures and provide all those that are life cycle cost effective per 5xecutive Order >1>.1. + typical cross8limited #lead8lag) boiler control system &ith oxygen trim for a single fuel is used. Alarms* $urnish alarms to announce the approach of unsafe conditions. *rovide shutdo&ns to shut the equipment do&n under unsafe conditions. BOILER DRUM LE EL* *rovide controls to al&ays maintain the boiler drum level &ithin the boiler manufacturerIs specifications under all operating conditions. Three types of control systems used in boiler plants are single element, t&o element and three element. T/ree Element Control* + three element control system utilizes a level transmitter, the amount of steam flo& from the boiler and the amount of &ater into the boiler to maintain control of the boiler drum &ater level. 6ote that although not sho&n, the steam flo& from the boiler is usually compensated for pressure and temperature. + three element control system corrects the problems associated &ith a t&o element control system and provides the best method of compensating for variable loads. BOILER DRUM LE EL MEASUREMENT AND CONTROL *roper operation of %rum -evel Measurement and !ontrol circuit is very crucial for uninterrupted operation of "oiler. *rinciple of measurement and three8element control of "oiler %rum -evel is explained in this &rite up. -iquid level measurement can be carried out by measuring the head exerted by liquid column. T/ree Element Drum Le2el Control 0

T/ree

)n this control, $eed $lo& transmitter measures feed flo& and its output is connected to the computing relay to &hich is connected steam flo& signal. %ifference bet&een steam flo& and feed flo& is then fed to drum -evel control, to &hich drum level signal is also connected. 9ince actual measurement of feed flo& is carried out, this control circuit gives very stable and high quality performance. %rum level control circuits used in *o&er *lants no& a days control the feed flo& by varying the $eed *ump scoop instead of $eed !ontrol valve on loads above 123 INDI IDUAL ITEM RE8UIREMENTS Controllers* "oilers use three types of controllers. These are digital #e.g. microprocessor or computer based), analog, and pneumatic. 0se the follo&ing guidelines in selecting the type of controller to be used? G 0se the type of controller that is the most economical and reliable.

G $or plants &ith many control loops use digital type of controllers. G $or the expansion of existing controls &ithin a plant use the existing technology. This may be either digital, analog electronic, or pneumatic controllers. G 0se pneumatic controllers in hazardous areas. G +void use of pneumatic controllers in the control room. G 'hen using digital control avoid depending on a single or a fe& control devices for the entire plant &ithout having a bac up. + redundant controller might not be required if only a single controller controls one loop. (o&ever, if a single controller controls a large number of loops then provide redundancy so that if the controller fails another controller &ill automatically ta e over. Pro"ess Controllers* *rocess controllers use one or several of the follo&ing control modes? G On8off G *roportional G )ntegral #also called reset) G %erivative #also called rate) Most digital controllers have all of the above control modes included. They are also usually provided &ith anti8reset &indup. +nalog and p neumatic controllers often do not include all three control modes or anti8reset &indup. Control Mo1es* )n general, use the follo&ing control modes for the indicated control loop. G $lo& 88 0se proportional plus integral. G -evel 88 0se proportional plus integral. G *ressure and Temperature 88 0se proportional plus integral. 0se proportional plus integral plus rate &hen the application requires a quic response time

Alarms* *rovide the follo&ing minimum alarms. G !ontroller failure G (igh8high alarm G (igh alarm G -o& alarm G -o&8lo& alarm Features* *rovide the follo&ing features as a minimum. G *roportional, integral and derivative control modes G +nti8reset &indup G +utomatic:manual and manual:automatic bumpless transfer G !hange configuration &ithout shutting do&n the control loop G %isplay configuration data &ithout interfering &ith the operation of the controller. Failure Res(onse* *rovide the follo&ing minimum actions on controller failure. G The controller should s&itch to manual operation, hold its last output signal, and send out an alarm sho&ing controller failure if a bac up controller is not provided. G The control should automatically s&itch over to the bac up controller and send out an alarm sho&ing controller failure if a bac up controller is provided. Pro)ramma!le Lo)i" Controllers* *rogrammable logic controllers #*-!s) are usually programmed in the electrical ladder diagram format. Other formats are also used. 'hen specifying *-!s include the follo&ing features. G *rovide a controller that can be programmed in the electrical ladder diagram format &hen many logic steps are involved. G )nclude provisions so that the controller can be programmed and the program read &ithout disturbing its operation.

De1i"ate1 Alarms* *rovide a separate &indo& that includes all dedicated alarms associated &ith an area. Typical dedicated alarms are summarized in Table B8.. Flame Dete"tors* *rovide the flame detector best suited for the fue l and flame. $or gas fired boilers al&ays use an ultraviolet #0=) self8chec ing flame scanner. %o not use a flame detector that is activated by hot refractory. *rovide a separate flame detector for each burner. -ocate the flame detector so that it &ill be activated only by its o&n burner and not by an adjacent burner or hot refractory. RECOMMENDED BOILER INSTRUMENTATION BOILER CONTROL PANEL INDICATORS9 RECORDERS AND TOTALI:ERS* The instrumentation in Table B8> represents the minimum recommended requirements for a boiler plant. This instrumentation selection is based primarily on boiler operation safety concerns. Refer to 6$*+ CA2., Standard for the Prevention of Furnace Explosions/ mplosions in !ultiple Burner Boilers for further instrumentation concerns for boiler plants in the >1.>C gigajoule:h #>.,A22,222 "tu:h) or above range and +9M5 !9%8>, Controls and Safety Devices for Automatically Fired Boilers for boiler plants belo& >1.>C gigajoule:h #>.,A22,222 "tu:h). The indicators and recorders can be either dedicated or shared devices. Totalizers must be dedicated devices. 9hared device selection may be either by means of pushbuttons, a selector s&itch, or by entering commands on a eyboard. *rovide the follo&ing in the display of information associated &ith a shared device. G 6ame of process variable G )nstrument number G 0nits G *rocess variable value 9tore the process data in a storage device such as a computer dis or tape if a dedicated recorder or totalizer is not provided. -abel the computer dis or tape as to process variable, instrument number, date, time, and units. The time label must include

hours, minutes, and seconds. 9tore the data so that it can be retrieved selectively. )n selective retrieval as a minimum include the name of process variable, instrument number, date and desired time interval. )nclude maximum and minimum points and alarms &ith the data to be recorded. *rovide a dedicated printer or printer:plotter on &hich the recorded and totalized data can be presented on paper on demand. %ata storage, retrieval, and printing must meet federal, state, and local environmental documentation requirements. +n instrumentation item is not applicable if the equipment that it services is not included in the plant. $or example, if an air preheater is not provided then an air preheater outlet temperature indicator does not have to be furnished. BOILER CONTROL PANEL ALARMS AND S'UTDO5NS* The alarms and shutdo&ns in Table B 8. represents the minimum recommended requirements for a boiler plant. These &ere selected based primarily on boiler operation safety concerns. Refer to 6$*+ CA2., 9tandard for the Prevention of Furnace Explosions/ mplosions in !ultiple Burner Boilers for further information for boiler plants in the >1.>C gigajoule:h #>.,A22,222 "tu:h) or above range and +9M5 !9%8>, Controls and Safety Devices for Automatically Fired Boilers for boiler plants belo& >1.>C gigajoule:h #>.,A22,222 "tu:h). *rovide a separate &indo& in an annunciator system for each dedicated alarm. *rovide a dedicated common trouble alarm &indo& to &hich the non8dedicated alarms are &ired. )nclude a first8out listing to sho& &hich device connected to the common trouble alarm tripped first. *rovide instrumentation to sho& &hich device shut the equipment do&n first during a system shutdo&n. +n alarm or shutdo&n is not applicable if the equipment that it services is not included in the plant. $or example, if the boiler is gas fired only, a lo& fuel oil pressure alarm is not required. Refer also to paragraphs 1 8A and @8..B. BOILER CONTROL PANEL CONTROLLERS* *rovide controllers as required for the proper operation of the boiler plant. !ontrollers required for a typical

boiler plant include steam header pressure #plant master and boiler master), boiler drum &ater level #feed&ater flo&), fuel flo&, combustion air flo& and boiler furnace draft. BOILER PROTECTIONS AND FURNACE SAFEGUARD AND SUPER ISORY SYSTEM There are three distinct systems for the Operation and !ontrol of "oiler in .>2 M' and A22 M' "oilers. These are >. Measurement and process control system for the control of "oiler *rocesses. This system is provided mainly for measurement and of mechanical properties such as *ressure, temperature, $lo& and level of &ater and steam. $uel and +ir flo& control, $urnace %raft control, %rum level control, coordinated master pressure control etc are some of the controls and measurements included in this system, .. "oiler )nterloc system is mainly used for the sequential and interloc ing !ontrol of )% fans, $% $ans and *+ $ans and some other equipment of the "oiler. 1. $urnace 9afeguard and 9upervisory 9ystem, popularly called $999, continuously monitors the operations related to fuel admission and some other vital parameters to ensure safety of the "oiler. Fenerally furnace oil or any ind of fuel is susceptible to explosion hazards. Majority of explosions occurs during start up, shout do&n and lo& load operations. There are many steps that must be follo&ed by the operator to admit fuel in to the furnace safely and properly. )f left to the judgement of the operators, there is a high probability of error. +dequacy of ignition energy is an important factor &hich should not be left for to operator interpretation. )n high capacity boilers, &here fuel input rate is very high, major furnace explosions can result from the ignition of unburnt fuel accumulated in first > or . seconds. (uman reaction time to such situations is inadequate. !onsidering these facts a proper "urner Management 9ystem, called $999 is installed in the "oilers. 5very operation related to fuel admission is accomplished through $999. 9ystem -ogic allo&s fuel admission only if it is safe. The system logic also senses any li elihood of dangerous situation and preempts fuel admission is such situations. Through $999, startup operations, routine operation and &ithdra&al of the "oiler are initiated and supervised. $ollo&ing table sho&s the "oiler tripping initiated through $999.

#i.e. &hen full load feed line is in service). )n some of the .>2 M' plants, drum level controller controls the @< "$* 9coop position &here as another controller is used to maintain the %* across control valve. 9chematic diagram is as sho&n in fig. C. Fi)* ;

)n most of the ne&er plants, $eed !ontrol valve is full open. This avoids energy loss in throttling of control valve. Three8element control output is fed to "$* 9coop and it is the only control point to achieve feed flo& regulation. )n such cases, !ontrol !ircuit for maintaining %* across valve is not required. +s there is a limitation &hich does not allo& scoop position belo& 123, at lo& drum pressure belo& 1A g:cm. #encountered during startups) -o& load feed line is provided &ith control valve for regulation of feed flo&. )n such instances, %rum level controller output is fed to the feed control valve instead of "$* scoop. 'hen $ull -oad feed line is ta en in to service, three8element control &ith "$* scoop regulation is ta en in to service.

Re1u"tion in Boiler Tu!e Failures 3*< Intro1u"tion0 )n )ndian po&er sector, coal based thermal po&er generating stations operate as base load stations and they provide major chun of the demand. (ence their availability is highly desirable. These po&er plants have to undergo certain regulatory outages as &ell as outages for necessary maintenance. These outages are termed as planned outages. +nd all the other outages, &hich cause unit outage, are forced or unplanned outage. + typical classification of forced outage is sho&n belo&. +s it is clear that the major reason for forced outage is tube lea age in boiler pressure parts.

+ coal based thermal po&er plant of the size of %T*9 &ould loss its availability by about >.BA 3, if it experiences one tube lea age every B months in each of its unit. This &ould be equivalent to a direct generation loss of <. M0s and a direct revenue loss of Rs..>A Million for %T*9. 5ach start up of boiler : turbine after attending the problem &ould result in consumption of large quantity of oil, coal and %M &ater. The start : stop due to the frequent tube lea ages &ould affect the long8term life and performance of boiler and turbine. +nd in case of frequent lea ages

boiler parameters may also be need to be restricted to lo&er value compared to design parameters and this &ould result in continuous loss in heat rate. 6*< Root Cause of Tu!e Failures0 The boiler pressure parts are subjected to very high steam pressures and flo& internally and high temperatures and abrasive environment externally. (ence they are li ely to fail and cause a forced outage. )ndia has huge reserves of coal that can be used for po&er generation. "ut the quality of coal is poor due to very high proportion of highly abrasive ash content. The ash content is as high as @A 3 in )ndian coals. The inherent nature of po&er generation process is such that the boiler pressure parts get a continuous exposure to&ards high temperature flue gases containing abrasive ash. This erosion leads to tube thinning process, &hich ultimately results in boiler tube rupture causing a forced outage. Classifi"ation of Tu!e Failure Causes0+ typical classification of boiler tube failure causes is sho&n belo& This picture sho&s clear majority of tube failure cases due to erosion and &elding

failures.

"ut the &elding failures for the jobs done during erection &or in past is not preventable during the O / M phase. 9o &e have ta en preventive measures for &elding joints being made at our end. 'e ensure >22 3 radiography and use of highly s illed high8pressure &elders. This has resulted in no &elding joint failure of the joint made at our site since >DD<. (ence the focus gets shifted to&ards prevention and control of erosion related failures.

Initial Inno2ati2e Strate)# for Erosion Re1u"tion0 The cause of erosion is no&n and &e undertoo some preventive measures right at the beginning of the operations of %T*9. 'e pioneered the concept of blending the lo& quality8high ash )ndian coal &ith high quality imported coal having very lo& ash proportion. Thereafter &e also improved the quality of available )ndian coal by establishing a coal &ashery near pithead and &ashing the lo& quality )ndian coal and reducing its ash proportion by about >2 3. +nd again blended this better quality )ndian coal &ith high F!= 4 -o& ash imported coal. *age These efforts gave us good results and this is evident from the statistics of tube failure cases for %T*9 vis8J8vis that of 6T*! 4 a leader in )ndian po&er generation sector. 6T*! mainly uses indigenous coal having high ash content. +nd even after rigorous preventive measures the rate of tube failures is high #refer fig? 1). This clearly sho&s advantage of use of blended coal over the use of )ndian coal. +nd no& the practice of coal blending is being adopted by progressive utilities all over the country. The innovative practice of coal blending &as started &ay bac in >DDB and it has given very good results for %T*9.

Pre2ention of Erosion = Con2entional Te"/ni,ues0 There are prevalent industry &ide practices of erosion prevention or reduction. >. Thic er tubes

.. 9hielding Te"/nolo)# of ' OF Pro"ess0 Sele"tion of t/e (ro"ess0 )n mar et there are many technologies available for surface coating. >. 'ire $lame spray .. +rc &ire spray 1. *o&der $lame spray @. *lasma spray "ut, in the above8mentioned surface coating technologies, temperature used for the spraying as &ell as base metal temperature goes more than B22K !, &hich may lead to change in microstructure of the metal.

P/ase I0 )n %T*9, &ater &all tubes near burner panel are the most erosion prone area. Of the total number of tube lea ages due to erosion, B23 occur in &ater &all tubes. (ence &e replaced these eroded tubes by surface coated tubes during overhaul of 0 L >and . during their respective overhauls. !ost incurred during the implementation of *hase8) &as Rs ..1 Million. P/ase II0 The second most erosion prone area is economiser tube. Of the total number of tube lea ages due to erosion, >A3 occur in economiser tubes. +s above phase 4 > replacement is sho&ing very good results, &e are planning to replace eroded economiser tubes by surface coated tubes during the next proposed overhaul.

CONCLUSION0
$rom the trend sho&n #$ig8<) here it is very clear that there has not been a single tube lea age since .221 in the areas &here it &as highly probable due to high erosion patterns observed in past. The strategy of tube coatings has helped us &ith improving our availability#$ig8D) and also maintaining the high loading factor#$ig8>2).

'e have been able to operate %T*9 units at a record availability and loading factor and maintain yearly plant loading factor at more than >22 3 &ith lo&est heat rate#$ig8C) in )ndia since .2218 2@. The resultant heat rate is lo&er by ..A@ 3 from the base value of .1.2 Ecal: E'( in .22>82.. The project of providing additional protection to boiler tubes in vulnerable areas can be very easily replicated across the industry. )t can be applied to large utility boilers as &ell as smaller industrial boiler the benefits to the consumer &ould be immense as mentioned earlier. * Dire"t Benefits0 #a) )n case of a tube lea age %T*9 looses revenues of Rs. >C Million for this loss of generation. This loss of generation needs to be bought from external sources at a much higher rate than the

generation cost of %T*9. (ence prevention of one tube lea age helps the company to continue to provide subsidy or lo&er tariff to retail consumers. #b) +lso start up after each tube lea age consumes on an average >. <A Eilo -itters oil .. A2 Tonnes of coal These resources are consumed &ithout generating electricity. (ence it is a direct loss. This direct loss costs are more than Rs > million for %T*9. +lso these processes generate additional green house gases. (ence prevention of one tube lea age provides benefit in terms of >. -o&er tariff to consumers .. -esser pollution / resource conservation to society at large SLD>Steam lea& 1ete"tor?0 9-% detects the tube lea age in various zones in the furnace.)t uses ultrasonic technique to detect the tube lea age.>B to >C 9-%7s are placed at various locations in the furnace,the signals from the above 9-%7s are brought in the *lant control room for monitoring the steam lea in the tubes. Re1u"tion of Boiler E+it Flue Gas Tem(erature The )ndian po&er sector has al&ays been operating in the deficit regime. The customer has been facing the brunt of the impact. The po&er costs and availability of quality po&er are the major issues for the customer. +nd the suppliers have been charging for availability and reliability. )n the regions &here players other than state electricity boards are supplying the po&er directly to the end user, they have been charging a premium for the consistent supply. (ence the po&er availability, quality and ultimately the cost are the three issues, &hich the customer has been dealing &ith to control his o&n costs. )n )ndia, the coal based thermal po&er plants are the bac bone of the po&er generation sector. Out of total generation more than <2 3 is being met by the coal based thermal plants. The soaring cost, unreliability of supply, dependency on other countries has made oil and gas po&er plants not viable. +lmost all of existing oil and gas8based po&er plants are either idle or running &ith reduced capacity. 6on8fossil : rene&able energy based po&er is considered an alternate due

to its environmentally clean po&er and non8exhaustive primary energy source. "ut commercially and economically it is not viable due to high capital investment. (ence efficiency of the coal8based po&er plant plays a major role in the costs of po&er available for consumption. The basic coal based po&er generation plants operate on the modified Ran ine cycle. (ere there is a lot of scope for inefficiencies. Or inversely there is a lot of scope for improvement in the operating efficiency.

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