ENMAS ANDRITZ PRIVATE LIMITED

TECHNICAL SERVICES POWER BOILER

CHENNAI, INDIA
BIRLA CELLULOSIC KHARACH (WB029M) 1 x 120 TPH AFBC BOILER

REPORT ON BIRLA CELLULOSIC SITE VISIT

Self has reached the site on 17-06-09 @ 7.00 PM and the elaborate operating
problems & issues has been discussed with Birla cellulosic operation team &
Maintenance team
The issues and root cause has been stated below
Problem
1. Refractory insulation at clinger seal box area has been eroded and the bed
material has been pops outside @ 16/06/09 11.10 pm with a Boiler load of
102-105 TPH and bed temp of 940-950 deg C. After this incident 1st
compartment has been slumped off and all other compartment where in
operation expect 6th compartment with boiler load of 72-74 TPH
Causes and suggested solution:
1. Erosion of refractory started from clinger door seal box area and the
boiler was under near full load operation from 04/06/09 to till this incident. It
has been observed that BCK personnels didnt place a refractory Brick lining at
clinger door area as it was clearly shown in Arrg. Of Refractory drawing.
Drg No:-00-72-01-3007/00
2. All other area of refractory will be cooled by water walls by conductive
heat transfer with tube. But areas like clinger door, where the heat transfer is
predominantly by radiation should be insulated with refractory brick lining.
Problem
1. BCK informed that some of the coal feeders were cant able to take in auto
mode

REPORT No: EAPL/WB029M/170609/01

DATE : 20/06/09

TECHNICAL SERVICES PB
ENMAS ANDRITZ PVT LTD

By: RAAJA REUBEN R

EXECUTIVE ENGINEER

ENMAS ANDRITZ PRIVATE LIMITED

TECHNICAL SERVICES POWER BOILER
CHENNAI, INDIA
BIRLA CELLULOSIC KHARACH (WB029M) 1 x 120 TPH AFBC BOILER
Causes and suggested solution:
1.

This problem was due to V/I converter on VFD panel, since the feeder

motor rpm is mandatory for auto mode. BCK wants all failed AMTECH supplied
VFD panels CANOPUS V/I converter to be replaced with MASIBUS V/I converter
2.

BCK replaced CANOPUS V/I converter of coal feeder with MASIBUS V/I

converter from LSF VFD panel and found OK.

3.

Expecting MASIBUS product from AMTECH 5nos for replacement.

4.

For disturb less operation, the feeding system should be provided with

Zero Speed Switch (already supplied ZSS was taken off as per BCK demand)
Problem
1. Issues on different capacity motor 1.1 KW/1.5 KW on coal feeder.
Suggested solution:
1.

Supplied 1.1KW & 1.5KW motor with same 1415 rpm doesnt make

difference.
Problem
1. While operating coal feeder 6A and 6B simultaneously, bed temperature
shoots up to 1000 deg C (on 6RHS top/ Bottom & 6LHS top temp) with a
same ref rpm like other feeders, So they are operating either 6A or 6B, that
too in lower rpm than other feeder.
Causes and suggested solution:
1.

All coal feeder rpm is to be checked, and it should be fine tuned like other

feeder. If it is found normal, the above mentioned bed thermocouple to be

checked.

Problem

REPORT No: EAPL/WB029M/170609/01

DATE : 20/06/09

TECHNICAL SERVICES PB
ENMAS ANDRITZ PVT LTD

By: RAAJA REUBEN R

EXECUTIVE ENGINEER

ENMAS ANDRITZ PRIVATE LIMITED

TECHNICAL SERVICES POWER BOILER
CHENNAI, INDIA
BIRLA CELLULOSIC KHARACH (WB029M) 1 x 120 TPH AFBC BOILER
1. While on >100%BMCR (126TPH) on 06/06/09 with drum Pressure of 57
Kg/cm2. The flow of the steam was recorded as 146TPH which is lasted for few
seconds, since flow is pressure compensated. Soon beyond the set value of
145TPH, the 3E has been switched over to manual mode. In response to that
drum level has a wide fluctuation and finally MFT acted for Drum level HH.
Suggested solution:
1.

Controller should have the provision to switch over from 3E to 1E while on

boiler normal operation itself. Providing a selection button for 1E/3E for 100%
CV in Boiler normal operation. If there is heavy fluctuation on drum level
because of above stated issue, operator can switch over 3E to 1E to avoid
fluctuation and followed boiler tripping.

Problem
1.

Safety valve passing

Response
1.

ENMAS will send an expert soon regarding this issue (as conveyed by Mr.

RMJ)
Problem
1.

APH side casing plate tears off and having heavy vibration

Response
1.

This will be attended while on forthcoming boiler shutdown schedule (as in

MOM on 09-06-09)

REPORT No: EAPL/WB029M/170609/01

DATE : 20/06/09

TECHNICAL SERVICES PB
ENMAS ANDRITZ PVT LTD

By: RAAJA REUBEN R

EXECUTIVE ENGINEER