Академический Документы
Профессиональный Документы
Культура Документы
: 2003-E-065-00
Date: 23.07.2012
D0 - 0 - 0 - 0
COMMISSIONING & OPERATION
Page 73 of 177
Issue Status: Controlled Copy Unauthorized copying not
D1 - 0 - 0 - 0
FILLING STEAM GENERATOR
Page 74 of 177
Issue Status: Controlled Copy Unauthorized copying not
The steam generator must only be filled with degassed and de-mineralized boiler water
(feed water specification are furnished to clients elsewhere). Approximately 36 m3 of
feed water is required to fill the boiler, up to centre of steam drum.
The status of various valves of the steam generator prior to filling water should generally
be:
D1.2.0.0
Sl.
Valve Name
No.
1.
Condition
Open
Open
station)
3.
4.
5.
Close
Close
Close
Furnace portion is filled usually by filling pump connections through furnace wall drain
header / Evaporator drain station. Start fill pump, open isolation and control valves on
filling pipe up to drain station and allow water to flow at the rate not exceeding approx.
20 TPH.
Close the vent valves on Economiser-I and Economiser-II soon after water flows full
throat from them. Close Economiser and evaporator drain valves.
After drum is filled and the water rises up to saturated steam header water will start
entering the super-heaters. As water starts flowing full from superheated vents close
them one by one. Thus superheated is now full of water. (This will only be required if
Boiler Hydraulic test is to be conducted).
Page 75 of 177
Issue Status: Controlled Copy Unauthorized copying not
a)
b)
c)
Valves at feed control station and spray control station are closed.
d)
e)
Start the feed pump and start topping up by keeping low feed line control valve crack
open (flow <20 TPH). Close vent valves on Economizer-I & II soon after water flows full
throat through them. As the water level in gauge glasses is approx. (-) 100 mmWC
close the low feed control valve and switch off the feed pump.
Page 76 of 177
Issue Status: Controlled Copy Unauthorized copying not
D2 - 0 - 0 - 0
START-UP CHECK LIST
Page 77 of 177
Issue Status: Controlled Copy Unauthorized copying not
All access doors on furnace, flue, ducts, fans etc. are closed properly.
2.
3.
All interlocks are checked & operating satisfactorily. Do not bypass any safety
interlock.
4.
5.
6.
7.
8.
9.
The bed level is normal and it is free from any foreign material.
10.
11.
12.
13.
14.
15.
16.
Slide gate on bed ash and cyclone ash drop pipes are in closed position and
operational.
17.
Bottom ash, cyclone ash and fly ash handling system are fully operational.
18.
19.
b)
c)
d)
e)
f)
g)
Page 78 of 177
Issue Status: Controlled Copy Unauthorized copying not
Drum vent
b)
c)
d)
e)
Page 79 of 177
Issue Status: Controlled Copy Unauthorized copying not
D3 - 0 - 0 - 0
SEQUENTIAL START-UP/SHUTDOWN &
BOILER SAFETY INTERLOCKS
Page 80 of 177
Issue Status: Controlled Copy Unauthorized copying not
SEQUENTIAL START-UP
Boiler auxiliaries have to be started in the following order so that safe light up is
achieved without any conflict with interlocks. Boiler is to be purged before light up from
the cold condition (cold start-up). For this purpose, a soft Timer shall be built in the
DCS, the setting of which can be adjusted. During the cold start-up, the setting of this
timer is to be set for 10 min., which is the purge cycle duration. Setting time of 10 min.
ensures about 3 volumetric changes of air in the Boiler and the air / flue gas path. This
setting has been followed in Cold Cyclone CFBC Boiler installations in Germany, which
yielded satisfactory results. This also meets NFPA requirement.
Under all condition of boiler starting it must be ensured that water level in steam drum is
approx. (-) 100 mm from NWL and coal feeders are not in operation. Also coal isolation
gates above siphon are in closed position.
D3.2.0.0
START-UP SEQUENCE
D3.2.1.0
The damper positions marked * thus below are only for starting-up of fans. The suction
and discharge dampers of ID, SA and PA fans are to be kept closed during the starting
of respective fans to isolate the system resistance. Once ID fan is started, followed by
SA fan, PA fan in a sequence, the discharge dampers of ID, SA and PA fans are fully
opened. The control dampers of SA and Tertiary Air local to the boiler are also to be
kept around 50% open. SA Fan speed is kept low i.e. about 10% of rated speed and
maintained during the light-up. Thereafter, speed of PA fan is gradually increased till the
minimum PA flow condition required for light-up is reached. The ID fan speed is slowly
increased with the VFD Control, commensurate with PA fans speed, basically to
maintain around (-) 30 to (-) 50 mm (may be around 10 mm during oil firing) Furnace
draft.
Page 81 of 177
Issue Status: Controlled Copy Unauthorized copying not
D3.2.1.1
STARTING LOGIC
ID FAN 1/2 will start after ID Fan start command is given from DCS only when the
following conditions are satisfied:
1.
Remote
2.
Not Tripped
3.
Control (1-IDF1/IDF2-YRE)
Available
4.
Not Operated
5.
Closed
6.
ID Fan (1-IDF1/IDF2-YBO)
Not running
7.
Closed
8.
Not high
9.
Not high
AND
11.
Running
OR
12.
Closed
Page 82 of 177
Issue Status: Controlled Copy Unauthorized copying not
If any one of the following signals is present ID Fan 1/2 will stop / trip
1.
From DCS
2.
Control (1-IDF1/IDF2-YRE)
Not Available
3.
Motor (1-IDF1/IDF2-XH)
Tripped
4.
High
5.
High
6.
Furnace Pressure
Very Low
7.
Very High
8.
Very High.
9.
Operated
Page 83 of 177
Issue Status: Controlled Copy Unauthorized copying not
Selected
2.
Control/MCC (1-SAF1/SAF2-XH)
Available
3.
No Fault
4.
Not Operated
5.
Closed
6.
Not Running
7.
Not high
8.
Not high
AND
9.
Any ID fan
Running
10.
Closed
11.
Furnace pressure
< max
12.
Furnace Pressure
>min
OR
13.
SA Fan 2/1
Running
SA Fan will stop /trip if any one of the following signals is present:
1.
Control/MCC (1-SAF1/SAF2-XH)
Not Available
2.
Fault
3.
HI HI
4.
HI HI
5.
ID fan 1 & 2
Not Running
6.
From CRT
7.
Stop command
8.
Very High
9.
Furnace Pressure
Very High
10.
Furnace Pressure
Very Low
11.
Drum Level
Very High
12.
Operated
Page 84 of 177
Issue Status: Controlled Copy Unauthorized copying not
Remote
2.
Control (1-PAF1/PAF2-XH)
Available
3.
Breaker (1-PAF1/PAF2-YBR)
Ready
4.
Closed
5.
PA Fan1/2 Vane(1-PAP-ZSC-00/02)
Minimum
6.
Not Running.
7.
Not high
8.
Not high
9.
Furnace Pressure
> Minimum
10.
Furnace Pressure
< Maximum
11.
Drum Level
< Maximum
12.
Drum Level
> Minimum
13.
Any ID fan
Running
14.
Any SA fan
Running
15.
TA flow
> Min
16.
SA flow
> Min
17.
Closed
OR
18.
Running.
20
Not Present
Page 85 of 177
Issue Status: Controlled Copy Unauthorized copying not
PA Fan 1/2 will stop / trip if any one of the following signals is present:
1.
From DCS
2.
Breaker (1-PAF1/PAF2-YBR )
Not Ready
3.
HI - HI
4.
HI - HI
5.
HI - HI
6.
HI HI
7.
8.
Not Healthy.
9.
Both SA Fans
Tripped
10.
Both ID Fans
Tripped
11.
Very high
12.
Boiler
Tripped
13.
SA Flow
< Minimum
14.
TA Flow
< Minimum
15.
PA Discharge Pressure
> Maximum
Page 86 of 177
Issue Status: Controlled Copy Unauthorized copying not
< max. 3
Furnace draft
> min. 2
Furnace draft
< max. 2
< max. 2
< max. 2
Drum level
> min. 2
Drum level
< max. 2
> min. 2
Bed temperature
> Min 1A
Page 87 of 177
Issue Status: Controlled Copy Unauthorized copying not
Before any fuel firing can take place a satisfactory Purge cycle must be completed. To
start a furnace Purge cycle the following conditions must be satisfied:
1.
Not low
2.
Any PA Fan
Running
3.
Not low
4.
Not low
5.
Not high
6.
Flame
Not On
7.
In closed position
8.
Not HI - HI
9.
Fully closed
10.
Scavenging on
No
11.
Not Low
12.
Not Low
13.
PA Flow
> Min
14.
Not Present
15.
Refractory Temperature
Not High
With all above conditions satisfied furnace purge ready lamp will be on. After
Purge start PB operated Furnace Purging will start and Furnace Purge ready lamp
will be off. Purge progress indication will be available in CRT and after a time delay
of 5 mins. Purge Complete indication will be available on CRT and Burner Ready
will be available when Purge is complete AND Oil Valve opening is > 25% and <
50% AND Oil Gun IN Position
Page 88 of 177
Issue Status: Controlled Copy Unauthorized copying not
Page 89 of 177
Issue Status: Controlled Copy Unauthorized copying not
Page 90 of 177
Issue Status: Controlled Copy Unauthorized copying not
D.
Selection (1-VFD02/03-XS)
CF 1 (1-VFD-02/03-XA)
Feeder 1/2 Outlet Date (1-FHS-ZSO-02/04)
Drive (1-VFD-02/03-XH)
Feeder.(1-VFD-02/03-XT)
Bed temp
Air protection
Boiler
Any PA fan
Fuel feeder Stop PB (DCS)
Trip coal feeder signal
Remote
Not running
Open
Healthy
Not Tripped
> Min 1A (2 out of 4 logic)
O.K.
Not tripped
Running
Not operated
Not present.
PA fan
Boiler
Bed temp
Fuel feeder 1 Drive(1-VFD-02/03-XT)
Fuel feeder 1 stop PB (DCS)
Drive (1-VFD-02/03-XH)
CF O/L gate (1-FHS-ZSC-02/04)
Bed Temperature
Siphon 1 / 2 Outlet temperature
Not running
Tripped
> 920deg C
Fault/Trip
Operated
Not Healthy
Closed
< Min 3
> Max (450 oC)
Page 91 of 177
Issue Status: Controlled Copy Unauthorized copying not
D3.3.0.0
TRIPPING SEQUENCE -
A.
Note:
OK
PA fan
Off / Trip
Close
Close
SA fan
Off / Trip
Close
Close
ID fan
Off / Trip
Close
Close
Page 92 of 177
Issue Status: Controlled Copy Unauthorized copying not
Selected
2. Drive (1-VFD07-XH)
Healthy
Not Running
> Min 1A
5. Air Protection
OK
6. Boiler
Not Tripped
7. BCF (1-VFD07-XA)
Not Running
8. PA Fan 1 or 2
Running
Not Operated
No Fault
Not Present
Not Operated
Bamboo Chip Feeder will stop / Trip if any one of the following input signals is present:
1. PA Fans 1 and 2
Not Running
2. Boiler
Tripped
3. Bed temperature
Operated
5. Drive (1-VFD07-XH)
Not healthy
6. Drive (1-VFD07-XT)
Fault
7. Bed temperature
< Min 3
8. Local Stop PB
Operated
Page 93 of 177
Issue Status: Controlled Copy Unauthorized copying not
D3.4.0.0
Sl.
No.
1.
2.
3.
4.
5.
Limits
Description
(Max/Min)
Set Value
Unit
min. 2
(-)150
max. 2
(+)100
min. 2
(-)510
mmWC
min. 2
11
kg/sec
min. 2
5.5
kg/sec
Drum level-I
min. 2
(-)320
Drum level- II
min. 2
(-)320
Drum level-I
max. 2
150
Drum level-II
max. 2
150
max. 2
max. 3
min. 1A
Furnace pressure
ID fan I inlet pressure
ID fan II inlet pressure
min. 3
mmWC
mm
940
920
> Ignition
Temp
350
Note:
1.
"Min .2" and "Max. 2" are limiting values of boiler trip.
2.
In the event of Boiler trip", (on account of reaching min 2/max 2 values) "Air/Flue
tripping sequence" should be initiated automatically. This will immensely help to
achieve quick start of boiler when normal condition is restored for restart.
3.
4.
Coal feeders (only) should trip if fluidised bed temperature exceeds "Max.
3" or drops below "Min. 3" once coal is charged.
5.
Set values mentioned for Bed Temp. (Sl. No. 5 above) are indicative and
shall be adjusted during commissioning.
6.
7.
Page 94 of 177
Issue Status: Controlled Copy Unauthorized copying not
Setting
Unit
Remarks
1.
+ 50
mm
High
2.
- 100
mm
Low
3.
Drum Pressure
130
4.
114
6.
540
High
8.
870
High
9.
High
10.
Low
11.
Bed Height
1200
mm
High
12.
Bed Height
800
mm
Low
13.
5 /2.5
14.
1660
mmWC
High
15.
600
mmWC
Low
16.
Furnace pressure
- 80
mmWC
Low
17.
Furnace pressure
+50
mmWC
High
18.
ID Fan 1 /2
Tripped
19.
PA Fan 1/ 2
Tripped
20.
SA Fan 1/ 2
High/ Low
Tripped
o
21.
22.
Tripped
23.
Low
25.
High
26.
Coal Feeder 1 / 2
Tripped
27.
Coal Feeder 1 / 2
No coal flow
28.
HGG
refractory temp.
29.
HGG
Flame failures
30.
HGG
Oil pressure
870
High
High
High
Page 95 of 177
Issue Status: Controlled Copy Unauthorized copying not
Setting
Unit
Remarks
Oil pressure
Low
32.
Low
33.
Low
34.
35.
High
Tripped
36.
37.
Kg/cm
Low
microns
38.
39.
Deaerator Level
40.
Kg/cm
mmWC
High
2
High
Low
Very Low
Page 96 of 177
Issue Status: Controlled Copy Unauthorized copying not
Setting
Unit
Remarks
+150
mm.
HI HI
-320
mm
LO LO
HI - HI
4. Bed Height
1400
mm
HI HI
5. Bed Height
500
mm
LO- LO
1750
mmWC
High
800
mmWC
LO-LO
8. Furnace Pressure
-150
mmWC
LO LO
9. Furnace pressure
+100
mmWC
HI HI
10. ID Fan 1 / 2
Tripped
11. PA Fan 1 / 2
Tripped
12. SA Fan 1 / 2
Tripped
<15
Kg/sec
Low
<2
Kg/sec
Low
<1
Kg/sec
Low
90
Deg C
HI-HI
90
Deg C
HI-HI
90
Deg C
HI-HI
11
mm/sec
High
11
mm/sec
High
11
mm/sec
High
480
Deg C
LO-LO
-550
mmWC
LO-LO
Page 97 of 177
Issue Status: Controlled Copy Unauthorized copying not
D4 - 0 - 0 - 0
HOT GAS GENERATOR - OPERATION
Page 98 of 177
Issue Status: Controlled Copy Unauthorized copying not
In CFBC Boiler, usually coal or lignite is the main fuel for normal operation.
It is
therefore necessary that the injected fuel falls in the surrounding which is conducive to
start its burning and is sustained. PF boilers have "Light-up" oil burners, likewise in
CFBC boiler, we have to raise the temperature of bed material, before charging main
fuel to a level which is, say 20C above the ignition temperature of fuel.
The HGG is mounted on cradle and suspended from Constant Load Hangers. HGG
outlet is fixed to the Airbox for initial heating of the bed material. The HGG is fed by
combustion air, i.e. primary air and dilution air from PA Fans. A set of dampers
regulates the air quantity suitably. Hot gas generators gradually raise the bed
temperature at a predetermined rate up to ignition temperature of the main fuel (coal).
D4.2.0.0
OPERATION OF HGG
Under "cold start" condition, Fans are started in the sequence ID, SA, PA. Furnace
draft is maintained at about (-) 30 mmWC keeping primary airflow just above fluidisation
level. Pre-requisites for starting HGG are:
25 mmWC
minimum
17 Kg/sec
minimum
One (1) Local Push Button Stations (LPBS), with various digital indicators, lamps & etc.,
are provided for the operation of the HGG, respectively. The burner management logic
and safety interlocks are built in the main DCS.
Page 99 of 177
Issue Status: Controlled Copy Unauthorized copying not
sufficient to maintain HGG outlet gas temperature at around 350 C initially. Gradually,
start raising the oil flow till it reaches around 900 kg/hr. Open dilution air damper such
O
that HGG outlet gas temperature rises gradually and does not exceed 850 C in any
case. This is important to have uniform thermal expansion of refractory bricks of HGG.
Main fuel (coal) is charged after temperature of bed material exceeds ignition
temperature of the fuel and all other boiler interlocks are fulfilled. Due to cold fuel,
initially there is slight "dip" in bed temperature. However, it picks up soon and after the
bed temperature exceeds 700C, gradually reduce the oil flow to about 250 kg/hr and
then smoothly trip the HGG.
The entire HGG operation can also be done in Auto mode from LPBS, where fuel flow
rate, airflow are regulated at predetermined ratio and also the HGG outlet temp. is
controlled at preset gradient. For further specific operational details of HGG, please
refer HGG suppliers Operation & Maintenance Manual.
Control circuit incorporates the operation logic & safety interlocks such as low fuel oil
pressure, low atomising air pressure; differential pressure across the HGG drops below
safe values, HGG gas outlet temperature exceeds safe operating limits, no-flame signal
from flame scanner etc. HGG must be tripped in the event of occurrence of one of the
above conditions.
In the event of such tripping, the whole cycle from clearing the
D5 - 0 - 0 - 0
COLD START-UP OF BOILER
During cold start-up of boiler, Hot Gas Generator (HGG) must be fired at minimum firing
rate i.e. about 150 kg/hr fuel oil flow. Also, HGG must be operated with high dilution air
in order to keep the HGG outlet temperatures low. Initially, Superheater drain valves
are kept open, along with drum and Superheater vent valves. When drum pressure
exceeds 2 kg/cm, drum vent valve and Superheater vent valves should be closed.
Once drum pressure reaches approx. 5 kg/cm, Superheater drain valves are kept
partially open for allowing steam flow through the Superheaters.
Adjust fuel oil flow rate, dilution air such that hot gas generator outlet temperature does
not exceed 600 C above the saturated steam temperature. At approximately 15 kg/cm
drum pressure, close all S/H drains and partially open start up vent valves such that
drum pressure increase is kept within permissible gradient 2 kg/cm (g) per minute. This
will allow steam flow through the super-heaters and final steam temperature will also
increase as per requirement. Overheating of superheaters must be avoided.
After fluidised bed temperature reaches about 20 OC above the ignition temperature of
main fuel (coal), charge the main fuel slowly through first stream. Initially, main fuel
feed should be minimum, say 10% of MCR requirement. There may be slight dip in
fluidised bed temperature initially, but in a few minutes the temperature will start
increasing. Gradually reduce oil flow of HGG as fuel firing stabilises. Slowly start the
second stream of main fuel.
established, HGG should be switched off gradually. The HGG Bypass damper should
also be opened gradually.
Increase in steam pressure and corresponding increase in steam temperature is
controlled by regulating the start-up vent valve but within permissible gradient i.e. 2
kg/cm2 per minute.
Initially, primary air is admitted through the Airpreheater bypass duct to minimise the
cold end corrosion of Airpreheater. Once the flue gas temperature at Airpreheater outlet
reaches approximately 130 C, Airpreheater is brought in to the service for heating PA &
SA and gradually airflow through Airpreheater by-pass duct is closed.
SEE "PRESSURE RAISING" & CHARGING MAIN FUEL" CHAPTERS ALSO.
D6 - 0 - 0 - 0
HOT START-UP OF BOILER
Boiler can be started without starting the HGG if the fluidised bed temperature is at least
20C above ignition temperature of the main fuel. This is possible after a short duration
shut down of boiler. Main fuel (coal) can be charged directly after all auxiliary fans have
started and bed fluidisation is maintained by ensuring minimum primary air flow.
Starting procedure and preconditions for boiler start-up shall be as explained in the
chapter SEQUENTIAL START-UP/SHUTDOWN & BOILER SAFETY INTERLOCKS
(CHAPTER D3-0-0-0).
Start coal feeding with minimum fuel flow (say 10% of MCR requirement) through one
stream. There may be slight dip in temperature of bed initially, but in a few minutes, bed
temperature will start increasing. Start now second stream of coal feed and allow it to
stabilise.
Increase in steam pressure and corresponding increase in steam temperature is
controlled by regulating the start-up vent valve but within permissible gradient i.e. 2
kg/cm2 per minute.
It should be noted that during hot start-up, bed material is likely to get cooled-down
rapidly when minimum primary airflow is established. Therefore, it is advisable to start
charging of fuel quickly while the bed temperature is sufficiently high.
D7 - 0 - 0 - 0
PRESSURE RAISING OF BOILER
D7.0.0.0
Boiler circulation should start soon after a fire is lit in combustor. Top headers and drum
should become warmer first followed by lower portion.
Close the steam drum vent when drum pressure is 2 kg/cmg. Superheater vents may
also be closed. Close Superheater inlet header drains at pressure 5 kg/cmg and open
the start up vent until the unit is put on load. Opening of start up vent should be
controlled to help raise the pressure in boiler and at the same time the super-heaters
are properly cooled.
In cases where the steam pressure is raised with intermittent firing, it is possible to
arrive at full operating pressure in steam drum and still have lower portion of furnace
relatively cool.
During pressure raising the water level will normally rise to the top of gauge glasses as
steam pressure is increased. This is due to expansion in volume of water due to heat
transfer and circulation. The excess water from system should be removed by blow
down.
accelerate circulation.
While giving the blow-down, do not keep the blow-down valves open for more than 20
seconds. The blow-down normally should be given with quick open/close operation.
Pressure and load limits of blow off valves operation are:
Up to 60 kg/cmg
100% load
60 to 85 kg/cmg
75% load
85 to 100 kg/cmg
50% load
Never
NEVER DRAIN THE BOILER WHEN THERE IS GLOWING SLAG OR ASH IN THE
COMBUSTOR OR FLUE GAS PASSES.
D8 - 0 - 0 - 0
CHARGING MAIN FUEL
D8.0.0.0
During start-up of boiler, as bed temperature approaches the near to the ignition
temperature of main fuel; preparation to start fuel firing has to be completed to enable
main fuel combustion quickly and reduce expensive oil burning.
2)
3)
4)
Once minimum bed temperature interlock is cleared, start the fuel feeder at lowest
speed. Initial charge of fuel may cause slight fall in bed temperature but soon bed
temperature starts rising and the coal feed also needs to be increased gradually. Bed
temperature, boiler pressure will now rise fairly fast and as Super-heater pressure
reaches the nominal (rated) value the main steam stop valve is opened to put the boiler
on load after warming up of MS line through by-pass valve.
As the bed temperature crosses 700 C level, gradually reduce oil flow through HGG
and simultaneously increase main fuel flow to maintain rising trend of bed temperature.
Finally, switch off HGG. Although the oil flow is reduced through HGG, total primary
airflow (combustion air plus dilution air) should not be reduced. In other words dilution
air should be increased to compensate decrease in combustion air linked to fuel oil
quantity.
Immediately after HGG switch off, open HGG by-pass damper full. HGG
Bypass Dampers maybe controlled to maintain equal airflow through both HGGs /
maintaining equal O2 % on both LHS & RHS of Flue Gas, if required.
Once the Boiler stabilizes on Coal, 20% Bamboo Chips, maybe fired by operating the
BCF. Necessary precaution maybe taken while firing bamboo chips by monitoring the
Flue Gas Temperature, to ensure complete ignition of Bamboo chips before exiting the
Furnace.
D9 - 0 - 0 - 0
STANDARD OPERATION AND LOAD VARIATION
D9.0.0.0
As the main fuel firing stabilises, the boiler pressure also gradually rises close to
nominal main steam pressure. First, open by-pass valve of main steam stop valve.
Allow steam to flow for sufficient time to warm up main steam piping. Then open main
steam stop valve and subsequently close by-pass valve.
2)
3)
Steam generation from the boiler can be increased or decreased smoothly by regulating
the following:
D9.1.0.0
1)
2)
Drum level
3)
Furnace draft
4)
5)
Operative behaviour of fuel and combustion air is shown in different diagrams referring
to temperature, pressure and mass flows. Adjusted values of primary, secondary and
tertiary air are maintained by operating personnel or automatic control circuits. The
values of fuel and air will also depend on the fuel characteristics and hence manual
intervention at times becomes necessary in control process.
DRUM LEVEL
Usually three element control, i.e. steam flow, feed flow and drum level, is responsible
to regulate feed water flow and maintain water level in drum reasonably steady.
Occasionally, pressure and temperature corrections are also applied in control circuits.
D9.3.0.0
FURNACE DRAFT
D9.4.0.0
Regulating the bed temperature of CFBC boiler can judiciously control emission of
pollutants, such as CO, NOx. Similarly, where desulphurisation of fuel (like lignite) is
desired by dosing limestone, the reaction takes place in fluidised bed.
And the
The
temperature of circulating ash drops to roughly 400 C during its vertically upward travel
as it enters cyclones. The circulating ash is separated in cyclone by centrifugal action
and it is returned to furnace via siphon. Increase or decrease of the quantity of cyclone
ash (at 400C) returned to bed (at approx. 850 C) will correspondingly decrease or
increase the bed temperature from its present level.
At siphon, the branch off for extracting the ash is provided which connects to cyclone
ash screw inlet. The speed regulation of cyclone ash screw cooler governs the bed
temperature.
Coal is charged only after bed temperature rises 20C beyond fuel ignition temperature.
Boiler is tripped in the event of bed temperature shooting up beyond 940C.
Coal feeders/BC feeders may be tripped if bed temperature exceeds 920C.
At higher load, say above 70% of MCR, mass flow of flue gas and heat absorption in
the Superheaters reach a stage where it is possible not only to achieve final rated
temperature, but it becomes necessary to cool the steam in stages to maintain final
temperature within close limits.
Stage-I Attemperator is interposed between Superheater-I & Superheater-II such that
Superheater-I outlet steam is cooled by the spray of water and enter Superheater-II at a
desired temperature. Stage-II Attemperator is interposed between Superheater-II and
Superheater-III such that steam entering the Superheater-III is cooled by the spray
water and the final steam outlet temperature is controlled to the desired value.
As the load increases, the quantity of water spray also increases. In the event of only
one spray nozzle, it is likely that at higher water flow, atomization of water may not be
proper, which may adversely effect on life of Attemperator. However, multi-spray nozzle
system incorporated in CFBC boiler ensures fine spray of water, within specific limits
through each nozzle, to achieve quick evaporation.
D10 - 0 - 0 - 0
ANTICIPATED PERFORMANCE CHARACTERISTICS
D10.0.0.0
Boiler Load
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0
10
20
30
40
50
60
70
80
90
100
110
Boiler Load (% )
30
Total Air
25
20
Primary Air
15
10
Secondary Air
5
Tertiary Air
0
0
10
20
30
40
50
60
70
80
90
100
Boiler Load %
Air Staging %
Fuel: Meghalaya Coal
110
100
Tertiary Air
90
Secondary Air
80
Air Staging %
70
60
Primary Air
50
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
4.00
3.50
Attemperator # 1
3.00
2.50
Attemperator # 2
2.00
1.50
1.00
0.50
0.00
60
65
70
75
80
85
90
95
100
105
2.40
2.30
2.20
2.10
2.00
1.90
1.80
1.70
1.60
1.50
1.40
1.30
1.20
1.10
1.00
0
10
20
30
40
50
60
70
80
90
100
110
Boiler Load %
20
19
18
17
16
15
14
DESIGN FUEL
13
12
11
10
9
PERFORMANCE
FUEL
8
7
6
5
4
3
2
1
0
0
10
20
30
40
50
60
70
80
90
100
110
5.4
5.2
5.0
4.8
4.6
4.4
O2 % Wet ( % by Volume)
4.2
4.0
3.8
3.6
3.4
3.2
3.0
2.8
2.6
2.4
2.2
2.0
15
20
25
30
35
40
45
Excess Air %
950.00
Screen Inlet
900.00
Bed Temperature
850.00
SH3 Inlet
800.00
SH2 Inlet
750.00
700.00
SH1 Inlet
650.00
600.00
550.00
Evaporator Inlet
ECO2 Inlet
500.00
450.00
Cyclone Inlet
400.00
350.00
AH Inlet
300.00
250.00
200.00
AH Outlet
150.00
100.00
50.00
0.00
60
65
70
75
80
85
90
95
100
45
40
35
M otor Spee d (R PM )
Bed Height = 80 mm
10
5
0
150
200
250
300
350
400
450
500
550
600
650
700
750
Flow (TPH)
Motor Speed = 750 RPM; Primary Reduction = 40:1 ; Secondary Reduction = 13:38
Fuel Flow (TPH) = (Bed Width) m x (Bed Height) m x (Fuel Density) T/m3 x 3.142 x (Sprocket PCD) m x (Feeder RPM) x 60
600
550
SH3 Out
SH2 Out
500
SH3 In
SH1 Out
450
SH2 In
400
Temperature (Deg C)
350
SH1 In
300
ECO2 Out
ECO2 In
250
ECO1 In
200
150
100
50
0
60
65
70
75
80
85
90
95
100
D11 - 0 - 0 - 0
NORMAL/STANDARD SHUT-DOWN
D11.1.0.0
In principle, the firing can be switched off at any boiler load without a special
preparation. Usually, generation of steam is gradually reduced to minimum load and
then shut down is initiated to bank the steam generator. Refer SEQUENTIAL STARTUP/SHUTDOWN & BOILER SAFETY INTERLOCKS (CHAPTER D3-0-0-0). While
pulling out the boiler from service sudden pressure and temperature drops must be
avoided so that pressure parts and non-pressure parts of boiler are spared from thermal
shocks.
D11.2.0.0
BOILER BANKING
Recommended sequence of activities for scheduled short shut down of the boiler is as
under:
1.
2.
3.
4.
5.
6.
7.
D11.3.0.0
1.
2.
Open drum & Superheater vents for residual evaporation at 2 kg/cm2 (g) pressure.
3.
Start fans and gradually cool furnace and boiler second pass till gas temperature at
inlet of cyclone reaches around 90 C.
4.
5.
6.
D12 - 0 - 0 - 0
EMERGENCY SHUT-DOWN
Boiler could be tripped on account of exceeding safe limits (Min.2 / Max.2 values of
boiler protection) during operation or manually by pressing of the "Emergency Trip
push button.
Should the pressure starts increasing, open "Start-up Vent" valve partially and reduce
the pressure slightly, say 4 to 5 kg/cm2. Let the boiler cool naturally or initiate forced
cooling, if required (only in emergency), and open drum and super-heater vents when
pressure falls to around 2 to 3 kg/cm2 (g).
Maintain the water level in drum between (+) 140 to (-)150 mmWC.
D13 - 0 - 0 - 0
REFRACTORY DRYING
INTRODUCTION
Refractory materials applied on furnace walls, air box as well as cyclones plays an
important role in boiler operation. The main objective of refractory is to prevent erosion
of surfaces especially of furnace and cyclones where expensive low castable is applied.
Besides, it prevents wastage of heat, and helps desired heat transfer in lower portion of
furnace. Natural drying will have no doubt removed part of the moisture in refractory.
Remaining moisture as well as chemically combined water has to be removed slowly so
that it is cured without giving rise to big cracks in settings.
D13.1.0.0
METHODOLOGY
The boiler is drained completely before both hot gas generators are lit up to start
refractory drying. In order to ensure slow heating from ambient temperature, oil guns /
sprayer plates of lower capacity say 250 litres (max) per HGG should be used. Keeping
the oil consumption at low level initially at around 100 Ltrs /hr, the rise in temperature of
flue gases at screen inlet can be maintained at about 20C/hr. The heat absorption of
pressure part steel is negligible unlike the water filled furnace walls. The temperature
gradient between air box to cyclone is also small. Once flue gas temperature reaches
approximately 110C, control the rate of oil consumption so that soaking can be done
for about 36 hours at this level. This will slowly evaporate the moisture.
Raise the temperature of flue gases by slow increase in oil consumption at the HGG so
that a gradient of 20C per hour is achieved from 110C up to 220C temperature. Soak
the refractory at 220C approximately for 18 hours.
Shut down the HGG and allow the natural cooling of refractory after 18 hours of soaking
at 220C. This marks the end of first phase of refractory drying.
Second phase of refractory drying is taken up at the commencement coal/lignite firing.
Raise the bed temperature with the help of HGG at the rate of 15C per hour when the
bed material is in furnace, which is filled with water. Soaking may be done for approx
12 hours maintaining bed temperature 500C to 550C.
330
275
Temp. in Deg.C
220
165
110
55
0
0
6 12 18 24 30 36 42 48 54 60 66 72 78 84
Time in Hours
D14 - 0 - 0 - 0
ALKALI BOIL OUT
PURPOSE
The cleaning of internal surfaces of furnace pressure parts is essential to ensure that
during normal operation of steam generation, steam is free from impurities/foreign
particles such as lubricants, oil, rust, sand, metal fragments and assorted debris which
are harmful for steam consumers e.g. steam turbine.
D14.2.0.0
CHEMICALS
The following chemicals should be added through steam drum manhole just before
commencement of heating by hot gas generators. Quantities are for each cubic metre
of water in the system.
Anhydrous Trisodium Phosphate (Na3PO4)
: 2 kg
OR
Crystalline Trisodium Phosphate (Na3PO4, 12H2O) : 5 kg
OR
Soda Ash (Na2CO3)
: 9 kg
1.5 kg to 2 kg of good detergent may also be mixed with water in addition to quantity of
one of the chemicals stated above.
~ 36 Te.
Provision should be made for double quantities of chemicals. Mostly, two charges of
chemicals may not be necessary.
D14.3.0.0
PROCEDURE
Start hot gas generators with fuel at minimum level. Soon after the HGG is switched on,
the boiler is thermally "Alive".
through out, the unit may indicate places where expansion strains are felt or where
warming up of headers and drum are not occurring uniformly. Keep close watch on
such undesirable developments. The following items should be observed:
1.
2.
Boiler circulation starts soon after a fire is lit in the combustor. Top headers
and drum will get warmer first to be followed by lower portion of furnace and
bottom headers. In case a particular header or a portion of it shows signs of
non-uniform heating, give number of short blows (max 20secs) through the
header drain /blow down valves until the circulation is observed/noted. Blow
down from each header should be roughly same quantity.
3.
4.
(Trams are already fixed at various levels and locations for monitoring thermal
expansion)
The steam generator is heated up with a firing capacity of approx. 3 to 5% MCR to
reach boiling condition and later on approx. 7% MCR up to about 30 Kg/cm2 (g) working
pressure. Both hot gas generators may be pressed in service for boil out operation.
Start up vent and Super-heater drain will be partially open to maintain pressure and
small circulation. The flue gas temperature at SH3 entry should not exceed 450-480C
(fuel quantity limitation).
maximum of sludge with minimum of risk of choking the blow down pipe work. Collect
Boiler water sample (CBD sample) for analysis of (a) Phosphate concentration, (b)
Alkalinity, and (c) Oil & Grease content in the sample. During the process, if the
phosphate concentration drops below 2000 ppm, doze additional chemicals through HP
dozing system to restore the original concentration.
Blow down lines should be hot. If not give them additional short blow down until they
become hot. Add clean warm water to bring back normal water level, bring the pressure
back to boil out pressure and continue boiling with steam venting.
After maintaining the drum pressure around 30 kg/cm (g) and normal circulation for
about 20 hours, shut down the HGG. Give blow down for longer period. Water level
should be restored and maintained until the boiler cools. When the boiler has finally
cooled, but before zero pressure is reached (say 6Kg/cm2) open all blow down and
drain valves to hot drain the boiler, economiser and super-heater. Open all air vents
when the pressure reaches 2 Kg/cm2. During emptying check that each drain and blow
down is running clear and it is not choked. On completion, feed a little water into the
boiler to wash out any remaining sludge.
Repeat blowing down and refilling the boiler at every two hours intervals. After alkali
boil out, periodically take blow down samples and analyse for oil content, silica, pH,
phosphate, suspended matter and clarity, if laboratory facilities are available. Continue
draining and refilling till quality of circulated water has conductivity within 50 micro-mho
of the incoming water. If analytical equipment is not available, charging and draining
water every two hours can be terminated when clarity or turbidity of drained water is
visibly same as the incoming water.
Inspect the interior of the steam drum, lower water wall headers and all other accessible
internal surfaces. Wash out any loose scale or other residue seen on internal surface of
the drum with high-pressure water hoses. The inspection nipples of furnace bottom
headers and economiser inlet header should be cut to examine bottom headers for left
over sludge/sediment. Remove all foreign material by washing with high-pressure water
hoses.
The inspection nipples should now be rewelded and post heat treatment
D15 - 0 - 0 - 0
STEAM LINE BLOWING
High velocity boiler steam is often used to clean the Superheaters and steam piping
which may contain mill scales, and any loose material that may damage the turbine
valves, blades or nozzles. Temporary exhaust piping is attached to the steam line near
the turbine so that the loose material can be discharged into the atmosphere without
allowing it to enter the turbine.
temporary piping is removed, fine mesh screens are often installed at the turbine inlet
and left in place during the preliminary operation or until inspections show no debris
collected on them.
Various piping and valve arrangements are used, but the basic scheme and
requirements are shown in a Figure-1 below.
One procedure for blowing is to raise the boiler pressure to a value slightly below the
design pressure of the temporary piping, gradually open the steam regulating valve
while increasing the firing rate to maintain pressure during the blow and gradually close
the regulating valve while reducing the firing rate.
In practice, usually the boiler pressure is raised to 40 kg/cm2. Trip the firing and quickly
open the blow off valve.
Allow drum pressure to drop down to approximately 20 kg/cm2 and quickly close the
blow off valve.
The interval between successive blows will be approximately 2 hours. In a day normally
about 6 to 8 blows maybe given with Overnight shutdown of the boiler for about 8 hrs.
This will help in loosening the Mill scale due to cooling and contraction.
All the permanent main steam piping must be insulated before commencing the steam
blowing operation.
All permanent hangers are in position and pressed in operation after floating.
All equipment and personnel around temporary steam piping/supports must be guarded
against any damage /injury.
The boiler pressure used for blowing out the line must not exceed, the design pressure
of the temporary piping, valves and flanges.
operating velocities can be obtained with low-pressure steam because of the great
change in specific volume of the steam. Other operators feel that temperature shocks,
along with high velocities are required to loosen scale inside the steam piping.
The colour of the steam discharged to the atmosphere can be used as an indication of
the debris being removed from the piping. The abrasion of aluminium target plates
(used in early stages and polished S.S. target plate is used at later stage) at the end of
the exhaust piping gives an indication of amount of debris removed during the blowing
operation. These target plates can be inspected for progressive abrasion after each
blow or they can be replaced after each blow.
In selecting the blowing pressure, it must be remembered that high velocities are easily
obtained with low pressure but changes in drum water level, on the other hand, are
minimized if higher blowing pressures are used.
purge
X Vpurge
Where,
Wpurge = Mass flow during purge condition. This shall be calculated using
Lapples equation for compressible fluids.
Vpurge = Specific volume of steam at purge parameters.
WMCR = Steam flow at MCR
VMCR = Specific volume of steam at MCR.
The value of DF at selected locations should be in the range 1.7 > DF > 1.3
D15.4.0.0 COMPLETION CRITERIA
Steam blowing can be declared complete only after ensuring cleanliness of target plates
mounted in the temporary exhaust pipe.
The highest velocity of steam being at the centre, the effectiveness of steam blowing is
judged by the absolute pitting on the Target plate in the central zone i.e. the area
th
The piping is considered clean if there are not more than five (5) pitting on the target
plate central zone and the edges are not deformed. Besides there should be no pitting
on the rim zone i.e. the area other than the central zone. This should be achieved on 3
consecutive plates.
D16 - 0 - 0 - 0
SETTING OF SAFETY VALVES
All safety valves are set for popping pressure and blow down before despatch from
manufacturer's works. However, possibility of slight disturbance from desired settings
cannot be ruled out on account of:
1)
Physical layout of inlet and outlet piping, drain connections and supports.
Incorrect layout may generate high stresses and back pressure.
2)
Ambient temperature.
3)
Quality of steam.
4)
5)
Use earmuffs when you are near to safety valves during adjustment.
2)
3)
4)
5)
Make sure that valve body and discharge elbow is free from external stresses
passed on from discharge piping. Safety valves escape piping supports must
be as per drawing.
6)
During the boiler hydraulic test at 1.5 times the design pressure the hydrostatic
plugs must be in place. In addition, gag all safety valves.
7)
Fix the gags on safety valves while raising the system pressure at
approximately 80% of design pressure. Similarly, gags should be removed at
approximately 80% of design pressure while releasing the system pressure. in
our case, design pressure is 120 kg/cm (g).
9)
Drain connections from body of safety valve, exhaust elbow, drip pan and
cover vent up to tundish should not have upward slope in any circumstances.
Ensure correct supporting arrangement for drain piping.
Successive floating of same safety valve in the event of unsatisfactory performance viz.
pop up pressure or blow down should be avoided. After the boiler pressure drops to
about 80% of pop up pressure (subsequent to safety valve floating) gags may be
interchanged and second safety valve (for its respective setting) may be tried. This will
save time and allow sufficient cooling of safety valve.
In any case ensure that at least one hour of cooling time is provided between
successive floating of same safety valve.
D16.4.0.0 DEFINITIONS
Set Pressure is that predetermined pressure above the working pressure of the boiler
that gives an adequate margin of pressure difference to prevent unnecessary
simmering. It is the pressure at which the first audible sound of escaping steam is heard
and Not the Pressure at which the valve lifts fully.
Full Lift Pressure is that pressure at which the valve has reached its maximum lift and
is usually within 3% excess of the set pressure.
D17 - 0 - 0 - 0
PRESERVATION OF BOILER
The advantages of efficient feed water and boiler water treatment during operation may
be lost if the same diligence is not applied to protect heat transfer surfaces during idle
periods. Protection from corrosion during storage becomes vitally important considering
the number of times the boiler and its auxiliary equipment will be idle during its life. To
minimize the possibility of corrosion, boilers to be put into the storage must be carefully
prepared for the idle period and closely watched during the outage.
There are two methods available for storing the unit i.e. dry storage and wet storage.
Although the wet storage procedure is preferred, factors such as availability of good
quality water, ambient weather conditions, length of storage period, auxiliary supply of
heat etc., may dictate that the dry storage procedure is more practical. When the unit is
required for standby service and must be held for sudden calls for operation and the unit
can be quickly made ready for placing in service, wet storage method is adopted.
D17.2.0.0 DRY STORAGE
When it is known that a boiler is to be idle for a considerable length of time and that a
brief period will be allowed for preparation to return it to service, the dry storage method
is recommended. In this method, the unit is emptied, thoroughly cleaned internally and
externally, dried, and then closed up tight to exclude both moisture and air. Trays of
lime, silica gel, or other moisture absorbent may be placed in the drums to draw off the
moisture in the air trapped by the closing up of the boiler.
1.
Fire the boiler according to the normal start-up procedure and establish 3.5
kg/cm (g) drum pressure. Secure the boiler and when the pressure decays to
1.5 kg/cm(g), drain immediately under air. As soon as possible, open the
drums to allow air to circulate for drying of all internal surfaces. This step is
included for a unit that has been in service and is to be placed into storage.
For a unit, that has never been in service, start with Step 2.
If the unit is full of water, drain the unit under air. All non-drainable boiler tubes
and super-heater tubes should be blown with compressed air. If an external
source of heat is available such as a steam coiled air heater, portable heaters,
etc., operate these heaters to assist in drying the internal surfaces. Install a
tray containing moisture absorbent (silica gel is preferred) into the drums. To
insure against overflow of corrosive liquid after the moisture has been
absorbed, the trays should not be more than 3/4 full of dry absorbent. The
amount of moisture absorbent can vary but one Kilogram per Tonne/hour
steam flow capacity is a suggested minimum.
3.
Attach a source of nitrogen to the steam drum vent, close all other vents and
drains and pressurize the boiler to 0.7 to 1.0 kg/cm(g) with nitrogen. The
amount of nitrogen required will vary according to the volume of the unit.
4.
With the boiler and super-heater pressurized, alternately open all boiler drains
(including super-heater) to purge air from the unit until pressure decays to zero.
It may be necessary to repeat this process several times to reduce the amount
of oxygen left in the unit to a minimum.
5.
The unit should now be stored under 0.3 to 0.7 kg/cm (g) nitrogen pressure
maintained at the steam drum.
6.
CAUTION:
THE UNIT SHOULD BE PROPERLY TAGGED AND THE APPROPRIATE WARNING SIGNS
ATTACHED NOTING THAT THE BOILER IS STORED UNDER NITROGEN PRESSURE AND
THAT COMPLETE EXHAUSTION OF THE NITROGEN MUST OCCUR BEFORE ANYONE
ENTERS THE DRUM. BEFORE ENTERING DRUM, TEST TO PROVE THAT THE OXYGEN
CONCENTRATION IS AT LEAST 19.5 PERCENT.
The advantage of employing the wet storage procedure is that the unit is stored
completely wet with the recommended levels of chemicals to eliminate a wet dry
interface where possible corrosion can occur. It is suggested that volatile chemicals be
used to avoid increasing the level of dissolved solids in the water to be used for storage.
The unit should be filled with deaerated, demineralised water treated with 200
ppm hydrazine (N2H4) for oxygen removal and sufficient ammonia (NH3) to
attain a pH of 10 (for demineralised water, this will require approximately 10
ppm ammonia).
2.
3.
Fill the unit with the treated demineralised water until flooding occurs at the
steam drum vent.
4.
5.
CAUTION:
THE UNIT SHOULD BE PROPERLY TAGGED AND THE APPROPRIATE WARNING SIGNS
ATTACHED NOTING THAT THE BOILER IS STORED UNDER NITROGEN PRESSURE AND
THAT COMPLETE EXHAUSTION OF THE NITROGEN MUST OCCUR BEFORE ANYONE
ENTERS THE DRUM. BEFORE ENTERING DRUM, TEST TO PROVE THAT THE OXYGEN
CONCENTRATION IS AT LEAST 19.5 PERCENT.
If storage continues into winter, ambient temperatures below the freezing point
of water create a real hazard to the boiler pressure parts and it will be
necessary to provide a means of keeping the unit warm to avoid damage.
7.
At some later date when the unit is to be placed into service, the boiler can be
drained to normal start-up water level and placed into operation.
In some cases, an expansion tank or surge tank above the drum and super-heater
elevation may be required to accommodate volume changes due to temperature
changes. The ammonia and hydrazine are not required for short period of storage of
less than two weeks; however, the nitrogen blanket is recommended for the steam drum
and super-heater.
Even with the above procedures, the possibility of corrosion must not be
underestimated.
damage.
Storage of the pre-boiler piping systems, whether it is wet or dry, can be handled in a
manner similar to those suggested for the boiler.
Nitrogen should be introduced through a "T" fitting or one vent (or drain) at each of the
following locations:
1.
Drum vents
2.
3.
The "T" fitting is to be installed between the pipe (or header) and the vent (or drain)
valve. The nitrogen inlet to the "T" should include a stop valve identical to the vent (or
drain) valve. The stop valve and "T" fitting should be a permanent addition to the
location listed.
The nitrogen required to seal the drainable components may be supplied from a
permanent nitrogen system or portable tanks located near the vent elevations. Due to
differences in plant layout, the owner should choose his own method of piping the
nitrogen, either from their permanent system for from portable tanks, to the vent (or
drain) locations listed.
CAUTION:
THE UNIT SHOULD BE PROPERLY TAGGED AND THE APPROPRIATE WARNING SIGNS
ATTACHED NOTING THAT THE BOILER IS STORED UNDER NITROGEN PRESSURE AND
THAT COMPLETE EXHAUSTION OF THE NITROGEN MUST OCCUR BEFORE ANYONE
ENTERS THE DRUM.
D18 - 0 - 0 - 0
WATER TREATMENT
established, the reaction virtually stops and does not resume until the film is disturbed or
removed. If the film is removed chemically or mechanically, the iron-water reaction
starts again to build up the protective oxide. This, of course, removes more iron from
the surface of the boiler parts and if allowed to continue will definitely thin the metal
parts. It is, therefore, very important to maintain boiler water chemistry within close
limits to prevent the chemical removal of the initial protective magnetic iron oxide film on
the internal metal surfaces.
The most common form of corrosion is that caused by the presence of oxygen in the
water-steam cycle. The most logical approach to the prevention of corrosion due to
dissolved oxygen is to eliminate the entrance of oxygen to the cycle as far as possible
and by expelling at the first opportunity the oxygen which has unavoidably entered the
cycle. The most common method of expelling oxygen is by deaerating the feed-water
from heaters or condenser.
It is of the utmost importance that this equipment should function over full load range of
the boiler. Oxygen concentrations at the deaerator outlet should be consistently less
than .007ppm. As a further assurance against the destructive effect of dissolved
oxygen, sufficient quantities of oxygen scavenging chemical compound should be
added to the feed-water after the deaerator to maintain a residual of chemicals in the
boiler water. The residual is an indication that all oxygen has been removed; it is also
available for upset conditions.
Reaction of hydrazine with dissolved oxygen produces nitrogen and water. Even
products of decomposition of hydrazine are volatile and tend to form, alkaline solutions
with water. This, therefore do not increase dissolved solids content in boiler water. The
reaction is of course dependant on hydrazine concentration, temperature and time. Due
to the volatility of hydrazine and its decomposition at elevated temperatures, only a
small residual (a few hundredths of a part per million) can be maintained in the boiler
water. It is apparent that with this small quantity of hydrazine available only minute
amounts of oxygen can be allowed to enter the boiler system.
These will re-dissolve at a point where condensation of steam occurs leading to acidic
condition in water circuit. Hydrazine is therefore preferred as oxygen scavenger in the
boiler operating in the region of 100 bars pressure.
In accordance with Table-I, feed-water pH should be controlled in the range of 8.5 - 9.5
to reduce iron and copper pick-up in the condensate - feed-water system. The most
common neutralizing chemicals used for controlling the pH of the condensate - feedwater are - Ammonia, Morpholine, Cyclohexylamine, and Hydrazine.
These chemicals are volatile alkalizers, which distil with the steam and neutralize trace
acids formed in the condensate.
--------
--------
N2
+ H2 + 2NH3
Experience has shown that the condensate pH, when using hydrazine, will stabilize in
the range of 8.5 -9.5 (due to the ammonia formation) depending upon the residual of
hydrazine maintained at the economiser inlet.
When feed-water or boiler water conditions are changed suddenly and drastically,
temporary upsets may be produced which can be troublesome. Therefore, any changes
such as an alteration in the feed-water treating practice, should be made gradually and
with close observation. When hydrazine feed is first started, initial dosage should be
small and changes in the iron and copper concentration in the feed-water should be
carefully monitored. If iron and copper concentration in the feed-water and boiler water
increase significantly, boiler blow-down should be increased.
Since it sometimes
requires days or weeks for conditions to stabilize, results must be observed over a
significant period before effects can be properly evaluated.
D18.5.0.0 CARRY-OVER
The trend toward higher steam pressures and temperatures resulting in higher operating
efficiencies imposes a great demand from steam purification equipment to eliminate
troublesome turbine deposits caused by carry-over.
Internal deposits vary in both their physical and chemical character. They differ in
degree, all are barriers to heat transfer and prevent complete wetting of the tube
surfaces with water. The result is always elevated tube metal temperature.
At one extreme are the very hard and dense deposits, which are impervious to water
and are poor heat conductors. When these form in high heat input zones, the results
are tube failures from overheating.
The failures may be the result of rapid localized overheating where considerable
swelling and thinning of the tube wall has occurred. If the failure is of the long term
overheating, there may be little or no swelling and thinning of the tube.
At the other extreme are soft and porous deposits, which allow boiler water to seep to
the tube surface. The result is a concentration of boiler water constituents at the tube
surface. If the constituents are scale forming, more scale will form. If they consist of
caustic, under deposit corrosion will take place.
Much of the art of feed-water treatment is devoted to the elimination of deposit forming
materials and the treatment of those minute quantities, which enter the boiler so as to
render them harmless.
possible, the deposit forming materials. Internal treatment handles the trace quantities,
which get past the pre-treatment equipment and also protects the boiler against
temporary upsets of the pre-treatment system, condenser leakage and contamination
from the condensate return system. In any case, internal boiler water treatment should
not be substituted for pre-treatment.
D18.8.0.0 PRE-TREATMENT
As operating pressures and percent make-up increase, it is imperative also to increase
the quality of the make-up water. As a guide for extended trouble free operation, the
feed-water quality limits indicated in Table-1 should be closely followed.
The type of pre-treatment necessary to obtain these limits depends almost entirely on
the quality and quantity of make-up water to the system. The type of pre-treatment may
include clarification and filtering, cold or hot lime soda, zerlite softening, demineralizers,
or evaporators.
For boilers operating in the pressure range of 70kg/cm(g) and above, more stringent
control is required to obtain the necessary feed-water quality.
There are various methods for the internal treatment of boiler water.
A blanket
recommendation of any one method is not realistic. The final decision as to the type of
treatment to be used in a particular boiler should be used on the raw water supply,
history of condenser leakage, the percent of make-up required, the nature of the
condensate returns, and other unique factors. A short summary of the recommended
internal water treatment methods is as follows:
D18.10.1.0 CONVENTIONAL TREATMENT
This type of treatment involves the addition of phosphate and caustic through the
chemical feed line to the steam drum. The caustic is added to the boiler water to
maintain the pH in the range of 10.2-11.2.
The primary purpose of phosphate addition to boiler water is to precipitate the hardness
constituents under the proper pH conditions. The calcium reacts with phosphate to
precipitate calcium phosphate as hydroxyapatite [calcium hydroxyapatite - Ca10 (PO4)6
(OH)2]. This is a flocculent precipitate tending to be less adherent to boiler surfaces
than simple tricalcium phosphate, which is precipitated below a pH of 10.2.
Also,
In this method of treatment, no free caustic is added to the boiler water. Figure 1
graphically shows the phosphate concentration versus the resulting pH when trisodium
phosphate is dissolved in water. Points on this Whirl-Purcell curve (mol ratio = 3.0)
indicate that all the phosphate exists as trisodium phosphate.
Recent laboratory tests show that the crystals, which precipitate from a solution of
trisodium phosphate at elevated temperatures, contains some disodium phosphate and
that the supernatant liquid contains sodium hydroxide. These same tests also indicated
that at mol ratios of 2.6 or less, free hydroxide did not form in the supernatant liquid. To
insure that no free caustic is present, we recommend a boiler water phosphate
concentration, which corresponds to a mol ratio of Na to PO4 of 2.6 as shown in Figure.
When using the regular commercial grades of chemicals, caution should be used in
calculating the weights to add to obtain the proper mol ratios since the phosphates are
in the form of Na3PO4 12H2O, Na2HPO4 7H2O. A mixture of 65 percent Na3PO4
12H2O and 35 percent Na2HPO4 7H2O corresponds to a mol ratio of Na to PO4 of 2.6.
In controlling the phosphate, should the pH be too low, it may be corrected by
increasing the ratio of trisodium to disodium phosphate. If the pH is high, this condition
may be corrected by decreasing this ratio. Figure 2 graphically shows the desired
phosphate concentration for a given operation pressure.
maintained at a value between 8.5 and 9.5 and the boiler water at a value between 9.0
and 10.0. As traces of impurities enter the cycle with the make up, the phosphate will be
precipitated producing free hydroxide.
For safe and efficient operation of boilers over 70 kg/cm (g) operating pressure it is
necessary to continuously monitor the water quality.
contamination entering the cycle is essential so that immediate corrective action can be
taken before the boiler and its related equipment is damaged.
Electrical conductance, the reciprocal of resistance, affords rapid means of checking for
contamination in a water sample. Electrical conductance of a water sample is the
measure of its ability to conduct an electric current, and can be related to the ionisable
dissolved solids in the water. A single instrument will measure and record important
conductivities of the cycle water, from as many as twenty locations in the system. This
electrical conductivity signal can be used to actuate alarm systems or operate
equipment in the water system. The micromho (1x10-6 mho) is normally the unit of
measurement. For most salts in low concentrations, 2micromho equal 1ppm
concentration when corrected to 25C.
Ammonia or amines used for pH control effect the conductivity. To obtain an accurate
indication of the solids, a cation ion exchanger is used to remove the volatile alkalizers
and convert the salts to their corresponding acids. The relationship is 7 micromho equal
1ppm concentration for most salts.
For boilers with operating pressures over 70kg/cm(g), cation conductivity of the
condensate should normally run between 0.2 to 0.5 micromho. A reading above this
limit indicates the presence of some condenser leakage or contamination from some
other source. The source of the contamination should be investigated and remedied at
the first opportunity.
Dissolved oxygen should be monitored at the condensate pump discharge and the
deaerator outlet.
scavenging and conventional or coordinated water treatment are used, the sulphite
chemical feed pumps are usually adjusted manually based upon the results of periodic
wet chemical analysis.
continuously and allows easy adjustment of the quantity as called for by routine
chemical analysis.
TABLE-1
Sl. No.
Description
Values
1.
pH
2.
Oxygen (ppm)
3.
Fe (ppm)
0.01
4.
Cu (ppm)
0.005 Max.
5.
SiO2 (ppm)
0.02 - 0.07
0.007 (Prefer 0)
Note:
*
Unit
Value
Conductivity at 25oC
Micro Siemens/cm
0.1
pH
9.0 10.0
Silica as SiO2
ppm
0.002
Phosphate as PO4
ppm
D19 - 0 - 0 - 0
LUBRICATION SCHEDULE
Sl.
No.
System /
Equipment
PA, SA and ID
Fans:
Duration of Change /
Top-up
Qty.
in
Litre
Trade Name of
Lubricant
Manufacturer
a. BPCL
b. Indian Oil
c. HPCL
d. Tide water
e. Caltex
a. Bearings
3.6
a. Enklo-100
b. Servo Syst-100
c. Parthan Ep-5/4
d. Apreslube- 90/86
e. Meropa-5/4
(ISO VG-100)
b. Coupling for
SA Fan PA
b. Complete grease
change after one
year
1.75
Kg
a. Servogem 2
a. Servogem
2
a.
b.
c.
d.
a. BP
b. Mobil
c. Castrol
d. Caltex
Coal Feeders
a. Motor Bearing
b. Pedestal
Bearing for:
i. Drive Sprocket
Shaft
ii. Trailing wheel
shaft
b. Gear Box
c. Tension
screws
& connected
nuts & bushes
d. Drive Transm.
Roller Chain
a. Every 3 months
b. Every 3 months
As
reqd.
c. Every 3 months
d. Every 3 months
Energrease HTG 2
Temp 78
Spheerol BNS
Thermotex EP 2
e. Every 3 months
NA
As
reqd.
NA
NA
Exxon Mobil
NA
Electrical
Actuators for
Dampers and
Valves
NA
NA
NA
0.2
Litres
a. Servosystem 460
a. Indian Oil
b. Enklo 460
b. HPCL
Pneumatic Slide
Gates for Bed,
Cyclone Ash:
a. Pneumatic
Actuator
b. Gates
a.
As and when
dismantled.
Whenever
excessive
operating torque
is experienced.
As
reqd.
Any std.
Manufacturer.
Electrical
Hoists:
As and when
dismantled or
whenever excessive
operating torque is
experienced or once
in a year.
As
reqd.
Servogem 2
OCL
HP Dosing
System:
Gear Reservoir of
the Pump
NA
Gears and
Bearing
b.
E1 - 0 - 0 - 0
BOILER GA DRAWINGS AND P&I DIAGRAMS
LIST OF DRAWINGS
Sr.
No.
1.
2.
3.
Drawing Name
G.A. of Boiler
Boiler Pressure Parts Assembly(FBB35)
Boiler Pressure Parts Assembly(FBB36)
Drawing No.
Rev.
PB-10969-0
PB-13961-0
PB-13963-0
PB-10970
4.
5.
PB-10971-1
6.
PB-10972-1
7.
P & ID of Fuel
PB-10973-2
8.
PB-10974-1
9.
P & ID of HP Dosing
PB-10975