CPP Pocket Manual

POCKET MANUAL
CAPTIVE POWER PLANT

(UNIT NO: 31)
(OPM/02/CPP/006)
BHARAT OMAN REFINERIES LTD.

AGASOD, BINA, M.P.
BHARAT OMAN REFINERIES LTD., BINA
POCKET MANUAL CPP
Pocket Manual
(CAPTIVE POWER PLANT)
OPM/02/CPP/006
Prepared By Reviewed By Approved By

Designatio Manager-CPP VP - P&U Head - P&U
n
Name Atul Shrivastava Sanjeev Verma Rampal Singh
Signature
Date
DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 2

POCKET MANUAL CPP
DOC. REV. DETAILS OF REMARK

S.N. DATE
NO. NO. AMMENDMENTS

POCKET MANUAL CPP
QUALITY, ENVIRONMENTAL, OCCUPATIONAL, HEALTH

& SAFETY (QEHS) POLICY

POCKET MANUAL CPP
ENERGY (EnMS) POLICY

POCKET MANUAL CPP
PREFACE
This pocket manual of CPP has been prepared with the objective
that it will serve as a ready reckoner for the operating personnel of
the unit. Particularly, it is intended to benefit the new entrants to
CPP.
The operating procedures for normal operation, handling of various

emergencies and other standing instructions etc. are available in
each production unit in the form of various manuals & documents.
The information available in all these documents put together is by
and large, very comprehensive & exhaustive. However operating
personnel at times find these not very handy for use in the field. A
need has been felt to compile the critical aspects of all operating
procedures in the form of a Pocket Manual which will serve as a
quick reference. It may be mentioned here that this pocket manual
is intended to supplement the existing manuals and not to replace
them.
While all attempts have been made to make this Pocket Manual
useful and user friendly, suggestions for further improvements are
welcome.

POCKET MANUAL CPP
CONTENTS
S.N. TOPIC PAGE NO

1 Introduction 08
2 Process Flow 12
3 Principal of CFBC 13
4 Process Description 15
5 Design Basis & Battery Limit Conditions 29
6 Normal Operating Parameters & Alarm Values 33
7 Design basis of steam, power & BFW system 35
8 Cooling Water Treatment package 48
9 Equipment Details 53
10 Interlocks 73
11 Start-up & Shutdown 81
12 Emergency Procedure 86
13 Standing Instruction & SOPs 117
14 Coal handling plant (CHP) 138
15 Annexure 164
15.1 PA System locations 165
15.2 Fire protection & Safety Shower location 166
15.3 Important Contact Numbers 168
15.4 Emergency Siren Codes 168
15.5 Power Distribution Diagram 170
15.6 MCP locations 171
Fire Water network with Hydrant location
15.7 172
layout
15.8 List of Assembly points 173

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1.0 INTRODUCTION
M/S Bharat Oman refineries limited (BORL) is setting up a pet
coke/coal based power plant and it is capacity 99 MW power
generation by 3 Nos of steam turbines and 825 TPH capacity of
steam generation by 3 Nos of circulating fluidized bed combustion
(CFBC) boilers in captive power plant refinery at Bina in the state
of Madhya Pradesh, India.
Power Generation capacity

Total capacity 99 MW
3Nos X 33MW Steam turbines
3Nos X 275 TPH Boilers
Type of Station Pet coke/Indonesia coal based
Cogeneration thermal power plant
Technical parameters of steam turbines (3 Nos)
Type and Make of Turbine: Extraction Condensing Steam
Turbine BHEL, Make
Capacity of each turbine 33000 KW
Specified initial steam pressure 106 ata
Specified initial steam temperature 5050C

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Controlled Extraction (LP) 7 ata at a flow of 43.12
65.0 TPH
Uncontrolled Extraction (MP) 25.5 ata at a flow of 2.33
13.0 TPH
Uncontrolled Extraction (HP) 50.0 ata at a flow of 9.7
20.0 TPH
Exhaust pressure 0.1145 Kg/cm2 (a) at
exhaust flow of 95.55 TPH
Technical Parameters of Boilers (3Nos)
Type of Boiler Circulating fluidized bed combustion

(CFBC) BHEL, Make
Design Fuel Pet coke
o
Steam Temp at MSSV Outlet 515 C
Steam Press at MSSV Outlet 110 Kg/cm2(g)
Flow at MSSV Outlet 275 TPH
Feed Water temp 110oC
Predicted fuel consumption 30 TPH @ 100% MCR
Lime Stone Consumption 28 TPH (max)

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Design Steam Parameters for PRDS
VHP Steam to HP Header
Flow 0 258 TPH
Inlet Temp 510oC
Outlet Temp 390oC
Inlet Press 110Kg/cm2 (g)
Outlet Press 42 Kg/cm2 (g)
HP Steam to MP Steam Header

Flow 0 238 TPH
Inlet Temp 402oC
Outlet Temp 340oC
Inlet Press 42 Kg/cm2 (g)
Outlet Press 19.5Kg/cm2 (g)
MP Steam to LP Steam Header
Flow 0 150 TPH
Inlet Temp 340oC
Outlet Temp 225oC
Inlet Press 19 Kg/cm2 (g)
Outlet Press 5.0 Kg/cm2 (g)
Normal Design Steam Parameters for Process

HP Steam to Refinery
Flow 21.9
Temperature 390oC

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Pressure 41 ata
MP Steam to Refinery
Flow 78 TPH
Temperature 280oC
Pressure 19 ata
LP Steam to Refinery
Flow 58 TPH
Temperature 225oC
Pressure 6 ata
Refinery Overview

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2.0 PROCESS FLOW

Below is the diagrammatic indication of process flow:

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CHEMICAL INJECTION
All dosing facilities are skid mounted system. Following chemical

dosing facilities are specified in CPP.
1. Morpholine: The feed water / condensate pH is maintained by

the use of morpholine for boiler water.
2. Hydrazine: Oxygen is removed by thermal deaeration at the
deaerator from the system continually. Hydrazine is generally used
as a chemical scavenger to remove the left over oxygen.
3.0 PRINCIPLE OF CIRCULATING FLUIDISED BED
TECHNOLOGY: -

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Solid fuel combustion in a Circulating Fluidized Bed (CFB)
boiler system takes place in a vertical chamber called the
Combustor, in which the fluidization and combustion of solid
fuel are performed. Properly sized solid fuel is fed into the
combustor and is burned at a relatively low temperature.
Limestone as per specified size is introduced into the
combustor to capture the sulphur dioxide released when
specific emission levels are to be complied with.
The circulating inventory of combustor primarily consists
of combustibles, ash, gypsum and excess calcined limestone.
The mean size of combustor inventory is in the range of 100
-200 microns. The combustor inventory is fluidized by primary
air introduced through a nozzle grate at the bottom of the
combustor and by the flue gas generated which flows upwards
with a relatively high fluidizing velocity (5-7 m/s). The entire
combustor contains suspended solids of a high concentration,
which decreases continuously towards the top. The flue gases
entrain a considerable portion of solid inventory from the
combustor.
These entrained solids are separated from the gas in
recycling cyclone(s) provided after the combustor and are
continuously returned to bed by a recycle loop. The very high
internal and external circulating rates of solids, characteristic of
the Circulating fluidized Bed, result in consistently uniform
temperatures throughout the combustor and the solids recycling
system.
There is a large difference between gas velocity and solids
velocity. The difference in velocities is called the slip velocity.
Solids residence times are in the order of 20-30 minutes. These
long residence times compared with small particle size and

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efficient heat and mass transfer, result in high combustion
efficiency. Also, in combination with these conditions,
comparatively lower combustion temperature allow the
decomposition of limestone and the subsequent formation of
gypsum, as well as the reduction of the sulphur dioxide
concentration in the flue gases to extremely low levels.
Combustion air is introduced into the combustor through two
stages. About 40-50% of the combustion air is passed as primary
fluidizing air through the grate nozzles at the bottom pf the
combustor and the balance is admitted as secondary air thorough
ports at the walls of the combustor.
The combustion proceeds in two zones: a primary reducing zone
in the lower section of the combustor and complete combustion
is achieved through the use of excess air in the upper part of the
combustor. This staged combustion at controlled low
temperatures, effectively suppresses NOx formation.
4.0 Process Description:-

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The CFB combustor, cyclones, fluid bed heat exchangers
and pertaining seal pots form an integral system and constitute the
main components of the circulating fluidized bed combustion
system. In the CFB combustor, the solid fuel is burnt in a circulating
fluidized bed. In the process, the solid particles (ash) are
continuously carried out of the combustor with the flue gas. The flue
gas leaving the combustor is routed to the recycling cyclones where
the solids are separated and returned to the combustor via the
fluidized seal pots. The seal pots provide a pressure seal between the
cyclones and the CFB combustor. The cyclone is operating with
high collection efficiency. Only the fine ash particles are carried
with the flue gas into the convective pass. These fine particles are
collected in the electrostatic precipitators (see description of the flue
gas system).
Part of the ash collected in the cyclones is drawn off via the spiess
valves at the seal pots and routed directly to the empty chamber of
the fluid bed heat exchangers. In the FBHE, the thermal content of
the hot ash is put to the effective use for steam superheating,
reheating and steam generation. The cooled ash is returned directly
to the combustor.

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Maintaining of a constant temperature in the combustor over a load
range specified by controlling the ash flow to the fluid bed heat
exchanger via the spiess valve, thus ensuring:
a. An optimum temperature for reaction of the limestone

with the SO2, HCI and HF.
b. a temperature well below the ash softening.
c. Ensuring optimum conditions for heat transfer in the CFB
combustor and fluid bed heat exchanger (FBHE) over the
entire load range by controlling the ash recirculation rate,
irrespective of whether solid fuels, oil or a solid fuel/oil
mix is being fired.
d. Preheating of the refractory-lined equipment through the
circulating bed material which is preheated by oil burners
when the system is started up from the cold condition.
CFB Combustor:-
The CFB combustor is rectangular. The downward tapering
combustor bottom section ensures an almost constant gas velocity
(iso-kinetic conditions) over the entire combustor height when
applying staged combustion air supply. A grate equipped with
nozzles forms the bottom of the CFB combustor. The nozzles are

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arranged offset against each other. The nozzle grate and the
combustor bottom section are pinned and lined with a castable
refractory to protect the tubes from the reducing atmosphere (air
deficiency). The combustor has gas tight welded membrane-walls
forming part of the overall evaporator heating surface. During full
load operation (solid firing), about 40% of the total combustion air
is fed as primary air via the nozzle grate at the combustor bottom.
The remaining air - except the fluidizing air for the FBHEs, seal
pots and ash coolers - is fed as secondary air to the combustor. The
secondary air enters at the burner and the secondary air injection
nozzles into the combustor.
Nozzles:-
The nozzle grate forms the bottom of the CFB combustor. Each
nozzle consists of a nozzle tube provided with a cap to prevent ash
spillage through the grate. The objective of the nozzles is to ensure
optimum distribution of the primary air over the combustor cross
section, a pre-requisite for stable combustion. The wind-box of the
nozzle grate is equipped with a wind-box ash discharge valve to
permit the removal of ash particles which may enter the wind-box
through the nozzles during plant start-up and shut-down.

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To a minor extent this occurs also during normal
operation, therefore the wind- box for primary air has to be drained
regularly. Excessive spillage during normal plant operation or start-
up is indicative of nozzle wear or damaged nozzle heads. In such a
case, it is up to the plant management to decide whether the plant
should be shut down for nozzle inspection. If considerable spillage
is observed during normal operation, an inspection should be carried
out as soon as possible as the accumulation of ash in the
wind-box could lead to bad fluidization in the combustor and it
poses an increased risk of wear in the wind-box.
Ash spillage during the start-up phase is less critical and

will noticeably decrease once stable operating conditions are
established (defined air flow through the nozzles). The back-sifted
ash shall be drained once per day and after startup.
Primary Air Supply:-
The preheated primary air is fed to the CFB combustor and

Circulation of the bed material which is dependent on the velocity of
the primary air both on solid fuel firing and oil firing, Combustion
under reducing conditions in the primary combustion zone in
complete combustion conjunction with the secondary air

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The primary air is fed load-controlled to suit the requirements of
material circulation with regard to heat transfer in the CFB
combustor (influence of the solids circulation rate on heat transfer)
and a sufficient ash supply to the FBHE via the spiess valves. For
further details please refer to section "Combustion Air System"
Secondary Air Supply:-
The secondary air consists of following air streams:-
Secondary Air (from fan)

- Fluidizing Air of the FBHEs
- Fluidizing Air of the Seal-pots
- Fluidizing Air of the ash coolers
- Seal and purge air supplied for various purposes
The secondary air from the fan is passed through air heater before it
is divided into different streams to supply to lower and upper
secondary air levels. The flow rates are controlled by respective
secondary air dampers. During start-up the air-heater is preheated by
steam cooled air heaters by admitting steam to keep the air heater
tube temperatures above the dew point temperatures or alternately
bypassing air through the secondary air bypass duct by opening the
secondary air bypass damper manually to keep the flue gas

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temperature above the acid and water dew points. The secondary air
fan maintains specified secondary air pressure controlled by the inlet
guide vane controller of the fan.
Total Air Flow rate:-
The total air flow rate is computed by totaling the rates of individual
air streams. In this connection it should be noted that air streams of
rotary piston blowers, i.e. seal pot blower, FBHE blower, ash cooler,
seal and purge air blower are included in the summation as a fixed
value.
At 100 % MCR:
Primary air through nozzles
Primary air through oil lances
Upper & Lower SA- levels
Burner level
Fluidizing air of the FBHE's Fluidizing air of the seal pots
Fluidizing air of ash coolers
Seal and purge air for various purposes
Recycling Cyclones:-
The hot, ash-laden flue gases leave the combustor top through the
side walls and enter the recycling cyclones. The recycling cyclones

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are completely refractory lined vessels consisting of a cylindrical
top section and a conical bottom section tapering downward.
The recycling cyclone collects nearly all ash particles from the flue
gas. This circulating ash is returned to the combustor via the seal
pots. Only a fraction of fine ash particles is leaving the cyclone
together with the flue gas. Sealing of the recycling cyclones against
the pressurized combustor vessel is provided by the seal pots located
in the ash return line from the cyclone to the combustor. The vortex
finder installed at the gas outlet of the recycle cyclones effectively
improves solids separation and hence material circulation and solids
management of the CFB -system.
Seal Pot:-
The seal pots with an erosion resistant lining, down-stream of the
recycling cyclones are fluidized with air and are ensuring a pressure
seal between the recycling cyclones and the CFB combustor. The
ash discharged from the cyclones is returned via the seal pots to the
combustor. A branch stream of the ash is flowing from the seal pots
via the spiess valves to the fluid bed heat exchangers. The ash rate is
controlled by the spiess valves located at the seal pots depending on
boiler load and combustor temperature.

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The seal pot fluidizing air is supplied by the seal pot blowers, to the
two legs of a seal pot. The air rates to the individual seal pot legs
can be adjusted by means of locally operated dampers; however,
they stay fully open during normal operation. Air distribution to the
nozzles is accomplished by wind boxes located underneath the seal
pots.
Fluid Bed Heat Exchangers (FBHE):-
The fluid bed heat exchangers are arranged downstream of the

recycling cyclones and supplied with ash via the spiess valves from
the seal pots.
The FBHEs have refractory lined walls, and consist of the following
chambers which are separated from each other by weirs:
Empty chamber to steady the ash flow entering the FBHEs, Bundle
chamber equipped with Heat transfer bundles:
In the chambers the ash is fluidized by means of a constant airflow
admitted via nozzle grates supplied by rotary piston blowers. As the
ash is passing through the FBHEs, the ash is cooled down. The
fluidizing air flow rate to the empty chambers can be adjusted by
dampers. Care should be taken to ensure that the air rate per empty
chamber does not fall below a minimum value specified in alarm &
trip settings for proper fluidization.
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Economizer:-
Feed water enters the boiler through the economizer, and is mixed
with boiler water in the steam drum. The function of the economizer
is to preheat the boiler feed water before it is introduced into the
drum by recovering some of the heat of the flue gases leaving the
combustor. The feed water flow through the economizer is upward
in counter current with the hot flue gas. This ensures efficient heat
transfer.
Feed water is supplied to the economizer inlet header via boiler feed
water stop valve, check valve and feed water control valves for full
load and low load valve for part load.
Please note that the boiler feed water pumps should not be started
having the boiler feed water isolation valves, the manual valves or
the boiler feed water stop valve closed.
Steam Drum:-
The steam drum supplies the evaporator with water via the down
comers and separates the water and steam returning from the
evaporator. The steam leaves the drum to the super heaters. It is of
utmost importance to keep the drum level within the normal range to
guarantee sufficient cooling for the evaporator. The drum level is

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controlled by the feed water control valves. If the drum level is
falling below the minimum level the boiler will trip If the drum
level is rising above the maximum level, the emergency blow down
drain will be opened automatically and the boiler feed water flow
must be reduced manually. If the drum level is rising further, the
boiler feed water supply must be stopped manually to avoid carry-
over from water in the superheaters.
Evaporator:-
The evaporator is composed of different sections, supplied with

water from the drum via several down comers to the lower
evaporator headers. The lower headers assure proper distribution of
the water to the evaporator sections. From the lower headers of the
combustor, the water rises through the upper combustor water wall
tubes, being heated up in the process. The grate tubes, front wall
tubes, rear wall tubes, and side wall tubes, form parallel flow paths.
The resulting mixture of water and steam is collected in the water
wall outlet headers and is discharged into the steam drum through
the riser tubes.
Separate down comers for the fluid bed heat exchanger (FBHE)
supply water to the FBHE inlet headers, the evaporator bundle, and
to the FBHE outlet headers, through the FBHE riser tubes to the

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steam drum.
During normal operation the evaporation in the evaporator bundle in
FHBE is controlled by the amount of hot ash passing through the
Spiess Valve for FBHE
SOLID FUEL FEEDING SYSTEM:-
The bunkers are fed with solid fuel already crushed to specified
particle size. Crushing of the solid fuel is needed to ensure a particle
size distribution as specified for the CFB combustor.
Each bunker is equipped with discharge cone, provided with shut-
off gates to enable bunker shut-off for repair work. A minimum
specified seal height of solid fuel in the bunker is required to be
maintained. If the corresponding weight is lower than a minimal
value, the feed line is automatically tripped.
To ensure proper bunker filling, the discharge position of the
reversing conveyor is to be varied so as to uniformly distribute the
fuel over the entire bin cross section.
The solid fuel feeding trains can be started if the lower and middle
combustor temperature is above the solid fuel admission
temperature and boiler protection level 3 is not activated. Further it
is to guarantee that the oxygen content of the flue gas measured in

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the back pass stays above 1 %. Otherwise all fuel feeding systems
will be get tripped.
Start Up Burners:-
The start-up burners are required for heating up the combustor

together with the refractory lining and ash inventory when the plant
is started from cold conditions. The burners consist of a central
tubular jacket accommodating the retractable burner gun.
The start-up burner gun is connected to the oil, atomizing air and
steam supply systems by flexible hoses.
The start-up burners are lighted-up by means of a separate ignition

lance, equipped with a high-voltage lighter igniting the propane
pilot flame. The igniter flame is monitored by the igniter flame
scanner. The igniter rod is cooled by igniter air taken from the flame
scanner cooling air.
Each burner has in addition a peep hole enabling the operator to

check the igniter and the burner flame locally.
Bed Lances:-
The bed lances are required for heating-up procedure, if combustor

temperature is above self ignition temperature of oil fired and for

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maintaining plant load in case of operation upsets in the solid fuel
feeding system.
The bed lance system consists of bed lances, installed above the
nozzle grate with atomizing system. The oil flow to all bed lances is
controlled by means of one common control valve. The oil flow rate
fed to the combustor is the difference of oil flow upstream the oil
control valve and the oil flow in the oil return line. Atomizing media
and oil are supplied via separate pipes to the nozzle head where the
fuel oil is atomized.
BED ASH SYSTEM:-
The bottom ash system serves the following functions: Bed Ash
Discharge
1. Intermittent discharge of the bottom ash from the CFB combustor
in the case of an impermissible p-increase on solid fuel firing.
2. Emptying of the CFB system to permit the plant to be entered for
inspection.
3. Cooling down of the bottom ash to 150C under normal
conditions, in the bundle chamber of the ash cooler by means of
cooling water. The cooling water rate to the ash coolers is being
controlled by the water outlet temperature.
4. The coarse ash is cooled in the first chamber using fluidizing air
as a cooling medium.
5. The fluidizing air is directly returned to the CFB combustor via

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the venting line serving as part of the combustion air (secondary
air).
6. Manual and periodical extraction of the coarse particles by the
bottom drains of the ash cooler.
BED MATERIAL FEEDING:-
The bed material feeding system is placed between the bed material
bunker and the combustor.
Ash feeding to the combustor is only allowed when the PA flow is

higher than minimum to ensure a proper ash distribution in the
combustor. The constant gravimetric ash feeding rate is controlled
by an airlock feeder. The maximum allowed ash inventory of the
combustor, indicated by a p measurement, shall always be below
220 mbar.
LIMESTONE FEEDING SYSTEM:-
From each limestone bunker, the limestone is fed to the combustor

via rotary valves. The number of rotary valves in operation is
selected as required. The rotary valves are feeding on a common
chute. The chute is purged continuously by seal and purge air,
supporting at the same time the gravimetric limestone transport to
the seal pot.

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5.0 Design Basis:-
PROPERTIES OF COAL
Parameters Result
Carbon 59.08 %
Sulphur 0.17 %
Ash 6.80 %
Hardgrove Grindabiity Index 46
Oxygen 29.04 %
Nitrogen 0.90 %
Hydrogen 4.01 %
Total Moisture 26.09 %
Gross Calorific Value (GCV) 4682 Kcal/Kg
Initial Deformation Temperature 1262OC
Size (%) 100 %
Other Important parameters:-

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PET COKE FUEL:-

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6.0 Normal Operating Parameters:-
Steam & Power Requirement of the Refinery
MP HP
LP Steam Power
Description steam steam
(TPH) (MW)
(TPH) (TPH)
Normal 64 86 24 78.3

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7.0 DESIGN BASIS OF STEAM, POWER & BFW

SYSTEM FOR BORL REFINERY

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7.1 STEAM INTRODUCTION:-
The steam shall be produced in the captive power plant.

The fuel to CPP will be coke. Steam is consumed in the
refinery at three levels, viz. High Pressure (HP) Steam,
Medium Pressure (MP) Steam and Low Pressure (LP) Steam.
Steam is also generated at all three levels within process
units/facilities
Steam is used in the various units mainly for the following

purposes:
- Process use (Chemical reaction, Stripping steam

etc.)
- Steam drives for some of the
compressors/pumps
- As heating medium for steam heated
exchangers
- Fuel oil atomization
- Steam tracing of lines (congealing service)/ Tankage
heating
- De-aeration
- Intermittent requirement like snuffing, soot
blowing, purging etc.
- Air conditioning units for control rooms.
7.2 STEAM SCENARIOS

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Various governing operating scenarios within the refinery have
been identified and are listed below:
Case No. Case Description

Case-I All units running normal, Normal demand
Case-II HGU+HCU/DHT down others running normal with
DCU peak
Case-III DCU down, all others running normal
Case-IV HGU+HCU/DHT operating at 50 % turn down, others
running normal.
Following tables give the consumption / generation figures or

steam in various units at HP, MP and LP levels.
7.3 STEAM REQUIREMENTS

Table - HP STEAM REQUIREMENTS (TPH)

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Notes:
1. Steam requirement of HGU shall be met by internal

generation.
2. HP to LP extraction turbine drive is considered for
emergency cooling water pump of RGC. This pump shall
be maintained on slow roll as hot standby with 2 TPH of
HP to LP steam extraction & will come on line during
normal CW failure with 7.0 TPH of HP to LP extraction.

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Table - MP STEAM REQUIREMENT (TPH)
Notes:
1. Two soot blowers operating in one unit at any one
time each consuming 4.5 T/Hr. of MP steam is considered.
2. Purging requirement considered is 0.6 T/hr per pass,
not considered simultaneous with soot blowing steam.
3. No decoking steam is required as the decoking will
be carried out mechanically.
4. Intermittent demands of CDU/VDU, DCU & CCR
includes 9.0 TPH of soot blowing steam.
5. 0.5 TPH of MP steam considered as continuous
requirement for tracing of vaporized naphtha lines.
6. Peak intermittent demand of 11.2 TPH for coke drum
heating.
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7. There is no import / export of MP steam to sulphur
block. Sulphur block MP steam is let down to LP level and
consumed within sulphur block.
8. 52 TPH MP Steam generation is without auxiliary
firing in Incinerator i.e. 40 TPH from waste heat boilers
and 12 TPH from incinerator. 70 TPH steam generation is
based on 30 TPH of steam generation in incinerator with
auxiliary firing.
Table - LP STEAM REQUIREMENT (TPH)
Notes:

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1. One furnace has been considered to be snuffed at a
time. A peak of 14 T/hr. of LP steam during CDU/VDU
shut down has been considered.
2. Snuffing steam 8.0 TPH is not included. 1.8 TPH
LP steam generation from LO pump drives considered.
3. 1.0 TPH of LP steam from extraction turbines
driven pump and 11.2 TPH Diesel product generator.
4. Snuffing steam requirement for all the heaters
5. HP to LP extraction turbine in cooling water
system.
6. Snuffing steam for the large heater.
7. 70 TPH, MP steam generation in waste heat
boilers and incinerator with auxiliary firing is
considered. Out of which after internal consumption
63.3 TPH of MP steam is let down to LP level for
consumption within sulphur block.
8. Incase of HGU/HCU down, ARU shall be
operating at 30 % capacity. And SRU operating with one
chain and auxiliary firing in Incinerator
7.4 POWER SYSTEM

Power is used in various units for the following main purposes:

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a) For driving motors to run various rotating
machinery (pumps, compressors, blowers, etc.)
in the complex
b) For meeting the power demand of instruments
in the entire complex
c) For plant lighting and other miscellaneous
purposes, etc.
Tables below give the power requirement of various units:
Table - POWER REQUIREMENTS (KW)
Power demand for combined utilities and offsite (in KW)

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7.5 Total Power and Steam Requirements:-

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The following table gives the total Power and steam requirements
for various scenarios.
Table- Total Power and Steam Requirements

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The following table gives the total Power and steam supply from
CPP
Table- Power and Steam supply from CPP
7.6 SULPHUR BLOCK STEAM REQUIREMENTS:
As sulphur block is generating MP steam and MP steam

consumption in sulphur block is less, the balance MP steam
shall be letdown to LP level to meet the LP steam requirement
within sulphur block. There is no import / export of MP steam
to sulphur block.
To meet the LP steam requirement of sulphur block, LP steam

line for 27.0 TPH to sulphur block is considered from CPP. Also,
additionally HP steam line of 24.0 TPH to sulphur block is
considered to meet the LP steam requirements. Necessary
PRDS is provided within Sulphur block.

POCKET MANUAL CPP
7.7 BOILER FEED WATER: - Boiler Feed Water Requirements:
Table gives the boiler feed water requirements of various process

units and the Captive Power Plant (CPP).
Table - Boiler Feed Water Requirement (TPH)
BFW requirements from CPP vendor: As the HP and LP BFW

requirements are significantly low; the import from CPP shall be
only MP BFW. Quantity of MP BFW import from CPP shall be 170
m3/hr. (design) on continuous basis.
HP BFW requirement shall be met from HGU.
Condensate return to CPP area shall be normally 110 m3/hr. at

650C. However, system shall be designed for zero condensate
return to CPP.

POCKET MANUAL CPP
7.8 BOILER FEED WATER QUALITY:
7.9 BATTERY LIMIT CONDITIONS (At consumer battery limits)

POCKET MANUAL CPP
7.10 BATTERY LIMIT CONDITIONS (At CPP battery limit)

POCKET MANUAL CPP
8.0 CPP Cooling Water Treatment Package:-

The cooling water system envisaged to cater the cooling water
demand for CPP is provided with a dedicated cooling tower to meet
the internal demand of cooling water as well as the cooling water
requirement for compressed air system, nitrogen system, CPU/DM
plant and MCR.
The CPP cooling water system includes cooling towers,

cooling water circulating pumps, cooling water treatment facilities
viz. chemicals dosing for quality control, anti scalent, corrosil for
anti corrosion and Biocide for Anti bacteria. Cooling tower is having
12 identical cells with the capacity of 3075 m 3/hr each (10 operating
+ 2 stand by). Cooling water circulating pumps is having 4
recirculating water pumps (3W+1S) capacity of 7700 m 3/hr each
and 3 emergency cooling water pump ( capacity- 126 m 3/hr ) for
CFBC Boiler and 3 cooling water pumps for Refinery capacity of
2400 m3/hr.
Two side stream filters are provided in the cooling tower

to reduce the total suspended solid from the recirculation water.
In recirculating cooling Water systems, following levels of

inhibitors/ chemicals shall be maintained.
POCKET MANUAL CPP
1 pH 7.58.0
2 Total phosphate as PO4 1518mg/l (continuous)
3 Orthophosphate as PO4 78mg/l (continuous)
4 Organophosphonate (HEDP+PBTC) as 56mg/l (continuous)

PO4
5 Zinc as Zn 11.5mg/l (continuous)
6 Polymeric Dispersant ( min. 40% basis) 25mg/l (continuous)
7 Biodispersant ( 100% basis ) 4mg/l (continuous)
8 Copper inhibitor (TTA) (100% basis) 1.01.5mg/l (continuous)
9 Hypo dosing (8%) 1.01.5mg/l (continuous)

POCKET MANUAL CPP
10 QUAT (min. 40%) (Shock dose 50 mg/l (Shock dose)

alternately )
11 MBT (min. 10%) (Shock dose 50 mg/l (Shock dose)

alternately )
12 DBNPA (min. 10% ) (Shock dose 50 mg/l (Shock dose)

alternately )
HEDP : Hydroxy Ethylidene diphosphonic acid

PBTC : Phosphono butane Tri Carboxylic acid
TTA : Tolytriazole
QUAT : Quaternary Ammonium Compounds
MBT : Methylene BisThiocynate
DBNPA : Di Bromo Nitrilo Propionamide
All non oxidizing biocide shall be added as shock dose alternatively

once in fortnight i.e. one dose/fortnight. The Contractor may
recommend the higher concentration of above inhibitors/chemicals
to achieve the guarantee as per the clause 7.5. The operating range

POCKET MANUAL CPP
of all inhibitors including copper inhibitor should be specified by
Contractor in AnnexureI. All formulations supplied by Contractor
shall contain max recommended levels of inhibitors/dosing levels
specified above & based on filtered values as given below & as per
the SOR by Contractor. The evaluation of bid will be made based on
the quantity of chemicals calculated & specified by Contractor as
per the SOR & dosing levels as per AnnexureI. The Hypo dosing
shall be based on minimum dosing of 1.0 mg/l (8%) to obtain FRC
of 0.300.60 mg/l in CWS subject to maximum of 1.50 mg/l (100%).

POCKET MANUAL CPP

POCKET MANUAL CPP
Pump Lube oil Details:-

POCKET MANUAL CPP
9.0 EQUIPMENT DETAILS

POCKET MANUAL CPP
9.1 Process Data of Furnace:-

POCKET MANUAL CPP
9.2 Induced Draft (ID) Fan:-

POCKET MANUAL CPP
9.3 Secondary Air (SA) Fan:-

POCKET MANUAL CPP
9.4 Primary Air (PA) Fan:-

POCKET MANUAL CPP

POCKET MANUAL CPP

POCKET MANUAL CPP

POCKET MANUAL CPP

POCKET MANUAL CPP

POCKET MANUAL CPP

POCKET MANUAL CPP
9.6 Boiler feed water booster pump:-

POCKET MANUAL CPP
9.7 Technical Data of Cooling Water Pump:-

POCKET MANUAL CPP
9.8 Deaerator Design Data:-

POCKET MANUAL CPP
9.9 Steam Turbine Generator (STG):-
Maximum Output 33000 KW

Design Rating 33000 KW
Speed Turbine (6) 5000 rpm
Inlet Press before stop valve 106.0 Kg/cm2 abs
Inlet temp before stop valve 505.0oC
Controlled Extraction press 7.0Kg/cm2 abs
Exhaust press 0.1145Kg/cm2 at exhaust flow of
95.5t/hr.

POCKET MANUAL CPP
9.10 PUMP DETAILS:-

POCKET MANUAL CPP
9.11 Ejector Details

Main Ejector:-

POCKET MANUAL CPP
Starting Ejector:-
9.12 LIST OF CONTROL VALVES:-

POCKET MANUAL CPP

9.13 PSV DETAILS
S. Tag No. Service Description Line No. P&ID No. Normal Normal Normal Range
N0 Flow Pressure Temperature
1 PSV-1121A VHP to HP Header 8-VHP-1108 31-02617 228.4 110 510 0-130 Kg/cm2
2 PSV-1121B VHP to HP Header 8-VHP-1108 31-02617 228.4 110 510 0-130 Kg/cm2
3 PSV-1184A Turbine drive1 Outlet 10-SM-1124 31-02617 48 19.5 340
4 PSV-1184B Turbine drive1 Outlet 10-SM-1124 31-02617 48 19.5 340
5 PSV-1194A Turbine drive1 Outlet 10-SM-1125 31-02617 48 19.5 340
6 PSV-1194B Turbine drive1 Outlet 10-SM-1125 31-02617 48 19.5 340
7 PSV-1144A 9-PRD-1140 Outlet 6-SM-1117 31-02617 0.35 210 110 0-220 Kg/cm2
8 PSV-1207A HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
9 PSV-1207B HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
10 PSV-1207C HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
11 PSV-1207D HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
12 PSV-1207E HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
13 PSV-1207F HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
14 PSV-1207G HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
15 PSV-1207H HP to MP Steam header 16-SH-1211 31-02618 219.5 42 402.5 0-50 Kg/cm2
16 PSV-1205A ACW pump to MP steam header 8-SM-1216 31-02618 68 19.5 340 0-30 Kg/cm2
17 PSV-1205B ACW pump to MP steam header 8-SM-1216 31-02618 68 19.5 340 0-30 Kg/cm2
18 PSV-1222A MP to LP Steam Header 20-MPS-1217 31-02618 68 19.5 340 0-30 Kg/cm2
19 PSV-1222B MP to LP Steam Header 20-MPS-1217 31-02618 68 19.5 340 0-30 Kg/cm2
20 PSV-1315A VHP BFP to LP steam Header 6-SL-1317 31-02619 66.6 5 181.5 0-10 Kg/cm2
21 PSV-1315B VHP BFP to LP steam Header 6-SL-1317 31-02619 66.6 5 181.5 0-10 Kg/cm2
22 PSV-1413A VHP BFP-1 Suction Pressure 16-WB-1407 31-00781 292.3 3.5 110
23 PSV-1413B VHP BFP-2 Suction Pressure 16-WB-1408 31-00781 292.3 3.5 110
24 PSV-1413C VHP BFP-3 Suction Pressure 16-WB-1409 31-00781 292.3 3.5 110
25 PSV-1413D VHP BFP-4 Suction Pressure 16-WB-1410 31-00781 292.3 3.5 110

10.0 LIST OF INTERLOCKS
ALARM & TRIP SET POINTS OF BOP AREA:-

SET POINT LIST OF CFBC BOILERS:-
SL.NO. DESCRIPTION SET POINTS REMARKS

1 DRUM LEVEL VERY HIGH (+) 240 MMWC TRIP
2 DRUM LEVEL HIGH (+) MMWC ALARM
3 DRUM LEVEL VERY LOW (-) 240 MMWC TRIP
4 DRUM LEVEL LOW (-) MMWC ALARM
5 FURNACE PRESSURE VERY HIGH TRIP
6 FURNACE PRESSURE HIGH ALARM
7 FURNACE PRESSURE VERY LOW TRIP
8 FURNACE PRESSURE LOW ALARM
9 WALL SEAL BLOWER DISC. PRESSURE LOW <3000 MMWC TRIP
10 WALL SEAL BLOWER DISC. PRESSURE HIGH >7000 MMWC ALARM
11 TOTAL PA FLOW LOW <40 T/Hr ALARM
12 TOTAL PA FLOW HIGH ALARM
13 PA PRESSURE IN WINDBOX LOW <459 MMWC ALARM
14 FG TEMP AT COMPACT SEP.I/L HIGH >1000 Deg.C. TRIP
15 BED PRESSURE HIGH (AVG) 900 MMWC ALARM
16 BED PRESSURE LOW (AVG) 250 MMWC ALARM
17 BED TEMPERATURE HIGH (AVG) 950 Deg.C. ALARM
18 BED TEMPERATURE LOW (AVG) 750 Deg.C. ALARM
19 BED TEMPERATURE VERY LOW (AVG) 600 Deg.C. ALARM
20 FUEL OIL PRESSURE AT P/P DISCH. LOW < 10 Kg/Cm2 ALARM
21 FUEL OIL PRESSURE AT P/P DISCH.HIGH > 15 Kg/Cm2 ALARM
22 INSTRUMENT AIR HEADER PRESSURE LOW < 4.5 Kg/Cm2 ALARM
23 FUEL OIL HEADER PRESSURE LOW < 6 Kg/Cm2 ALARM

24 BURNER-1 OIL PRESSURE LOW < 3.5 Kg/Cm2 ALARM

25 BURNER-2 OIL PRESSURE LOW < 3.5 Kg/Cm2 ALARM
26 BURNER-1 ATOMISING AIR PRESSURE LOW < 4 Kg/Cm2 ALARM
27 BURNER-2 ATOMISING AIR PRESSURE LOW < 4 Kg/Cm2 ALARM
28 DRUM PRESSURE HIGH 85 Kg/Cm2 ALARM
29 MAIN STEAM PRESSURE HIGH 70 Kg/Cm2 ALARM
30 MAIN STEAM TEMPERATURE HIGH 510 Deg.C. ALARM
31 MAIN STEAM TEMPERATURE LOW 470 Deg.C. ALARM
32 MAIN STEAM FLOW AT BOILER O/L HIGH 155 T/Hr ALARM
33 FLUE GAS DP ACROSS SH HIGH ALARM
34 FLUE GAS DP ACROSS ECONOMISER HIGH ALARM
35 FLUE GAS DP ACROSS AIR HEATER HIGH ALARM
36 FLUE GAS DP ACROSS ESP HIGH ALARM
37 ID FAN_A MOTOR BEARING TEMPERATURE HIGH 80 Deg.C. ALARM
38 ID FAN_A MOTOR WINDING TEMPERATURE HIGH 100 Deg.C. ALARM
39 ID FAN_A MOTOR BEARING TEMP. VERY HIGH 90 Deg.C. TRIP
40 ID FAN_A MOTOR WINDING TEMP. VERY HIGH 110 TRIP
41 ID FAN_A BEARING TEMP. HIGH 80 ALARM
42 ID FAN_A BEARING TEMP. VERY HIGH 90 TRIP
43 ID FAN_B MOTOR BEARING TEMPERATURE HIGH 80 Deg.C. ALARM
44 ID FAN_B MOTOR WINDING TEMPERATURE HIGH 100 Deg.C. ALARM
45 ID FAN_B MOTOR BEARING TEMP. VERY HIGH 90 Deg.C. TRIP
46 ID FAN_B MOTOR WINDING TEMP. VERY HIGH 110 TRIP
47 ID FAN_B BEARING TEMP. HIGH 80 ALARM
48 ID FAN_B BEARING TEMP. VERY HIGH 90 TRIP
49 PA FAN_A MOTOR BEARING TEMPERATURE HIGH 80 Deg.C. ALARM
50 PA FAN_A MOTOR WINDING TEMPERATURE HIGH 100 Deg.C. ALARM
51 PA FAN_A MOTOR BEARING TEMP. VERY HIGH 90 Deg.C. TRIP

52 PA FAN_A MOTOR WINDING TEMP. VERY HIGH 110 TRIP
53 PA FAN_A BEARING TEMP. HIGH 80 ALARM
54 PA FAN_A BEARING TEMP. VERY HIGH 90 TRIP
55 PA FAN_B MOTOR BEARING TEMPERATURE HIGH 80 Deg.C. ALARM
56 PA FAN_B MOTOR WINDING TEMPERATURE HIGH 100 Deg.C. ALARM
57 PA FAN_B MOTOR BEARING TEMP. VERY HIGH 90 Deg.C. TRIP
58 PA FAN_B MOTOR WINDING TEMP. VERY HIGH 110 TRIP
59 PA FAN_B BEARING TEMP. HIGH 80 ALARM
60 PA FAN_B BEARING TEMP. VERY HIGH 90 TRIP
61 SA FAN_A MOTOR BEARING TEMPERATURE HIGH 80 Deg.C. ALARM
62 SA FAN_A MOTOR WINDING TEMPERATURE HIGH 100 Deg.C. ALARM
63 SA FAN_A MOTOR BEARING TEMP. VERY HIGH 90 Deg.C. TRIP
64 SA FAN_A MOTOR WINDING TEMP. VERY HIGH 110 TRIP
65 SA FAN_A BEARING TEMP. HIGH 80 ALARM
66 SA FAN_A BEARING TEMP. VERY HIGH 90 TRIP
67 SA FAN_B MOTOR BEARING TEMPERATURE HIGH 80 Deg.C. ALARM
68 SA FAN_B MOTOR WINDING TEMPERATURE HIGH 100 Deg.C. ALARM
69 SA FAN_B MOTOR BEARING TEMP. VERY HIGH 90 Deg.C. TRIP
70 SA FAN_B MOTOR WINDING TEMP. VERY HIGH 110 TRIP
71 SA FAN_B BEARING TEMP. HIGH 80 ALARM
72 SA FAN_B BEARING TEMP. VERY HIGH 90 TRIP

11.0 NORMAL START-UP
Start up of the unit involves the following consecutive phases:

11.1 SHUT DOWN FOR HOT START UP

11.2 NORMAL SHUT DOWN:
1. Reduce load of solid fuel feeding system to minimum according to
refractory temperature gradient.
2. At combustor temperature slightly above release temperature of
solid fuel firing, start up burner and lances stop solid fuel feeding.
3. Reduce load of burners and lances to minimum according to
refractory temperature gradient.
4. All fans and blowers are in peration, for cooling of the combustor
according to the requirements of refractory.
5. Start soot blowers for cleaning tube bundles in convective pass
discharge ash of convective pass, ESP, etc.
6. Stop start up burner
7. Reduce load on lances & stop lances wait some minutes for cooling
down.
8. Stop the following fans & blowers
a. FBHE blowers
b. Primary and Secondary air fans
c. Seal pot blower
d. Stop ash cooler blower(s)
e. Stop purge and seal air blower
f. Stop ID fan and auxiliary system.
9. Special attention for drum water level, convective passes
10. Temperatures and co emission in flue gas.
11. Drum pressure reduction or run id fan at minimum flow.

12. Check if temperatures are stable or falling.
12.0 EMERGENCY PROCEDURE
FOR
CFBC BOILER

12.1 GENERAL
When the safe routing operation is interrupted emergency
procedures are sometimes required to overcome the potential hazards.
If continuation of unit operations on limited basis is impractical the
unit must be shut down as safely as possible.
The following instructions regarding operation upset and tube
failures are of a general nature. It must be understood that
conditions will arise that require the judgment of the operators.
Emergency can result from equipment failure and from interruption of

utilities. Certain features have been designed into the plant to
minimize the likelihood of emergencies.
In case of not clear operation upsets the boiler shall be tripped to

avoid damages to persons and the plant itself.
As during emergency there is no time, emergency procedure must be
learnt beforehand. The steps to be taken during various
emergencies are given below.
1. Boilers protection.
2. Power failure
3. Tube leakage
4. Trip of PA fan
5. Trip of SA fan
6. Pet coke feeder-1.
7. Trip of FBHE blower 1
8. Trip of purge & seal blower 1

9. Trip of seal pot blower 1
10. Emergency procedure for turbine system
1. BOILER PROTECTION LOGIC:-
DESCRIPTION:
In CFBC boiler the Boiler Protection is grouped as follows
A. Boiler Protection I Master protection

B. Boiler Protection II Protection during Start up Burners / Bed
lances operation
C. Boiler Protection III Protection during Lignite firing
D. SG Cool down Logic: Protection for the boiler tubes on
boiler trip / station blackout conditions.
A. Boiler Protection I:
This is the top most level of protection for the boiler, and when
this condition occurs total boiler will trip. i.e. tripping of all
auxiliaries and pet coke feeders except ID Fan, and ID Fan IGV
Control force to auto.
However, ID fan also will trip if boiler protection I is actuated due

to ID Fan inlet pressure is in very low condition.
Boiler Protection I will be actuated when any of the following
condition emerges:
1) Emergency PB press
2) Feed water tank level very low

3) Drum level very low (<-225mm)
4) ID fan trips or their speed very low (<150)
5) ID fan outlet dampers close
6) Instrument Air pressure very low (4.5 kg/cm2)
7) All Boiler feed pumps trips
8) Flue gas Pressure v. high at Convective pass inlets
(> 30 mbar)
9) Flue gas Pressure v. low at inlet to ID Fan (< 40
mbar).
10) Combustor middle temperature v. high (> 950o C).
11) Combustor lower temperature v. high (> 950o C).
12) Cyclone I outlet temperature v. high (> 950o C)..
13) Cyclone II outlet temperature v. high (> 950o C).
14) Total cooling water flow very low.
15) All ACW pumps trips.
16) Main steam temperature very high (>540oC)
17) Turbine - Bypass valve not open within 2 seconds
when turbine trips.
18) Main steam stop valve not open when SH steam
pressure > 20 bar
B. Boiler Protection - II
This protection ensures the safe operation of the SUBs and Bed
lances. When BP-II actuates it will trip all the burners. Boiler
Protection-II is sub-divided as BP II (SUB) and BP-II (Lances).
Boiler Protection-II (SUB) is the protection for Start up Burner

operation. BP-II (SUB) is actuated when any of the following
condition emerges:
1) Boiler Protection I acted.

2) No. of failed ignition > 4

3) SUB Emergency PB press
4) Secondary air flow for SUB-I or SUB-II < 2.7
Kg/sec.
5) PA flow <15 Kg/sec.
6) Combustor DP < 70mbar.
When BP-II (SUB) acted the working SUB(s) will be put off.
Boiler Protection II (Lances) is the protection for bed lances

operation.
The BP-II (Lances) will be acted in any of the following

conditions.
1) Boiler Protection-I is acted

2) Combustor temperature middle <550oC
3) PA flow <16 Kg/sec.
4) Combustor DP < 70mbar.
5) Lances Emergency PB press.
When BP-II (Lances) acted all the working Lances will be put off.
C. Boiler Protection - III

This protection ensures safe operation of petcoke firing.
When BP-III is actuated it will trip all drives related to
petcoke feeding and lime stone feeding system and also
closes the Boiler MFT i.e. Master fuel trip valves (petcoke
Gate I and II).
BP-III will be acted at any of the following conditions:
1. BP-I is acted.
2. BP II is acted.
3. Combustor middle temperature < 650oC.

4. Combustor lower temperature < 650oC
2. Emergency procedure for Power failure :-

On power failure, in which case the emergency BFW pump has
to remain in operation. The drive of the emergency BFW feed
pump has to be designed in such a way, that pump operation is
also ensured in the case of a complete power failure (blackout)
of the power plant. Initially the required BFW feed rate will be
approxxx.15% of the feed rate at full load conditions. As the
system cools down, the BFW feed rate can be reduced
subsequently later. The preheated boiler feed water is
extracted from the deaerator. Due to the limited size of the
deaerator, cold boiler feed water is to be fed to the deaerator
with the boiler make-up water pump, connected to the EPS.
Cold boiler feed water shall not be fed directly to the drum via
economizer but via the boiler, filling line connected to the
combustor wall inlet headers to avoid a thermal shock and strain
for the drum.
In case of difficulties with the emergency BFW pump one
means of reducing the chance for superheating in the evaporator
walls would be to reduce the boiler pressure, about 1 bar/min, in
order to achieve more water evaporation, resulting in longer

cooling of the evaporator tubes. Further, the drum would
show a lower temperature, which would be advantageous in
case of feeding cold BFW as restart. This means are feasible
if the black out would not last longer than approximately 6 hours.
Due to the rapidly decreasing release of heat from the
combustors refractory and due to the self-insulation effect of
the ash inventory it may happen in case of non operation of the
emergency boiler feed water pump that evaporation stops after
the water level has fallen below the area in the upper part of the
combustor, which is exposed to long lasting radiation heat from
the cyclones. This would mean that cooling of this area by
evaporated water/steam would no longer take place resulting
in a deformation of the water walls in the upper part of the
combustor exposed to radiation. Deformation of the water wall
would mean a preferred location for erosion immediately
after start-up. Hence, this condition shall be avoided at all
circumstances.
Upon a loss of power, the main turbine stop valves will shut
and the HP-Bypass will open immediately together with the
LP-By pass or RH start-up vent valves. The emergency
boiler feed water pump shall be put in service to maintain drum
water level. The following steps should be taken.

The HP-Bypass is operated depressurizing slowly the
SH system.
The purpose for depressurizing is to protect the back
pass superheaters from radiation from the hot cyclone
outlet duct refractory.
Depressurization provides adequate steam flow to cool
the back pass and FBHE
superheater while, at the same time, lowering the tube
stresses. The superheater depressurization rate of about 7-10
bar/hr should be followed down to approx. 50 bar(g) until the
flue gas temperature at combustor outlet falls below 450C.
Thereafter maintain the pressure constant to avoid unnecessary
loss of stored water.
Low Water Level
If feed water is once again available and the operator is assured
that no pressure parts have been damaged, the flow of feed
water to the boiler should be slowly increased (never rapidly
increased) by manual regulation. The purpose of handling the
feed in this manner is to avoid quenching pressure parts with
relatively cold water by raising the water level and on the other
hand, to avoid overheating additional pressure parts.
The most preferred treatment for the pressure parts is filling of

the boiler via the boiler filling line. The feed water-regulating
valve should be closed completely when steam flow from the
unit has ceased completely. If pressure parts have been
damaged, refer to the Tube failure description in O&M manual.
NOTE:
If the feed water pumps are not available for service, the
emergency diesel feed water pump should be put in service
supplying feed water in the manner outlined above.
If pressure parts damage is suspected, reduce the steam
pressure gradually by opening the superheater start-up drain.
Open, the drum vents when the pressure drops below 1.7 bar
(g) Shut down the I D fans as soon as the unit is cool
enough for a man to enter.
Empty the boiler when the drum metal temperatures is
below 95C, following the normal draining procedures.
Determine the cause of low water and examine the boiler for the
effects of possible overheating such as leaks and distortion of
pressure parts.
Repair any leaks, etc.
Hydrostatically test the boiler at working pressure before
putting the unit back in service.
High Water Level

There will be a high drum water level alarm and a high drum
level master fuel trip. Abnormally high water level should be
avoided as it may lead to carry over and even priming. If there
is an indication of priming (by rapid fluctuation in outlet
steam temperature) proceed as follows:
Reduce the steaming rate.
If the water level is abnormally high, reduce the level by

opening the intermittent blow-down valves and place feed
water control on manual.
Investigate the water condition (alkalinity and solids).
Investigate the condition of the drum internals as soon

as an opportunity arises.
3. Emergency procedure for tube leakage:-
It should be noted that tube damage is not easy to detect unless

major feed water or steam leakage occur and the effects
described below are observed. Minor tube damage may
remain undetected for long periods and become conspicuous
only during plant shut downs.
Whenever there is reason to suspect tube damage, the shift

supervisor shall be informed and the corrective action coordinated.

The following instructions regarding tube failures are of a general
nature. For details, refer to O&M manual. It must be understood
that conditions will arise that require the judgement of the
operators.
Water wall Tubes and Evaporator bundle tubes.
Excessive boiler feed water rate relative to the life steam rate due
to a damaged evaporator. In case that the difference of 10 t/hr in
mass flow between main steam and boiler feed water plus
desuperheater spray water is recorded for more than 5 minutes
a tube damage can be assumed.
Possible temperatures drop in the CFB combustor and the downstream
flue gas path.
Possible load decrease due to reduced steam production.
Possible decrease in the drum water level despite maximum
boiler feed water rate.
Increased delivery rate of the induced draft fan due to higher

flue gas rate.
Increase in the temperature downstream of the evaporator.
Pressure surge on the flue gas side due to a sudden increase in
volume and response of the pressure relief damper in the flue gas path.
Possible trip of the fans and blowers due to excessive flue gas pressure.
Possible fast reduction of oxygen content in the flue gas.
IMMEDIATE EXPECTED OR DESIRABLE OPERATOR

ACTION.
In the event one or more water carrying tubes fail, the best method
for shutting down the unit will be dictated by the size of the failure,
the ability to maintain normal water level and the demand for the unit t
In case of a leak or tube failure, which does not involve a serious
drain on the feedwater supply, the water level should be maintained,

and the unit taken out of service in the normal manner.
Try to avoid blowing the safety valves.

Operate the soot blowers if conditions permit.
Control feed water to the boiler manually, maintaining a high level
in the water gauge. To speed cooling, boiler pressure can be
reduced by opening the superheater drains.
When the drum pressure drops to 1.7bar (g), open the drum vent valve.
Allow the boiler to cool at least to 95C (drum metal temperature)
before draining.
In case of a tube failure which results in a loss of water so great
that the water level cannot be maintained with the feed water
supply available, after making every effort to keep the water level
as near to normal as possible, use the method outlined below:
Shut off feed water to the boiler to avoid shocking the drum with
cold water. Drop pressure from the boiler rapidly by using the
vents or the emergency relief valve.
After the combustor has cooled enough to permit a man to
enter, make a thorough inspection of all pressure parts for any
Indication of damage. After the necessary repairs have
been made, conduct a hydrostatic test and obtain the approval
of the proper authorities before putting the unit back in service
16.2 Water wall Tubes and Evaporator bundle tubes.
Symptoms of Tube Damage

Load decrease and increased boiler feed water rate relative to the
life steam rate, taking into account the desuperheater spray rates.
Temperature increase downstream evaporator up to HP steam
outlet.
Increased power consumption of the ID fans.
Immediate expected or desirable operator action.
An economizer tube leak can further be detected by
conspicuous noises and/or increased make up water requirements.
The leak should be investigated at the earliest possible time and
the unit shut down in a normal manner. Water leaks in the
economizer can cause considerable erosion damage to adjacent
tubes.
Water carried over from an economizer tube leaks may cause
plugging of hoppers. Any decision to continue operation with
known leaks should be made with this in mind. If a leak is
suspected in the economizer, reduce PA airflow until the upper
combustor differential pressure measurement reads zero and then
bring unit down as leak dictates
16.3 Superheater Tubes
Symptoms of Tube Damage:
Conspicuous noise in the area of the tube rupture.
Serious tube damage: load decrease and excessive boiler feed

water rate relative to the main steam rate, taking into account the
desuperheater spray rates.

A small leak in a superheater element should be investigated at
the earliest possible time, and the unit should be shut down
in a normal manner. Steam leaks in the superheater can cause
considerable erosion damage to adjacent tubes. Any decision to
continue operation with known leaks should be made with this in
mind.
A major superheater tube failure may require an emergency
unit shut down. The operator must use his judgement to
assess the seriousness of the failure and its consequences and
then decide what type of shut down is required.
CAUTION:
Operators should be alert to detect the symptoms of water

carry over from the boiler and introduction of water into the
turbine such as:
A. Sudden unexplained drop in the steam temperature in the

main steam lines.
B. Vibration in the steam piping resulting from water hammer or
C. Abnormal vibration and differential expansion readings

from the turbine
supervisory instrumentation.

Operators must be prepared to take the actions necessary to
prevent turbine damage upon detecting the introduction of
water. Refer to the turbine manufacturers instructions for
measures to be taken.
4. EMERGECY PROCEDURE FOR TRIP OF PA FAN:
PA FAN-1 will trip, when any one of the following occurs
Emergency push buttons activated.

Boiler Protection 1 activated.
All three Seal Pot Blowers tripped.

Both Purge & Seal air Blowers tripped.
SA fan tripped.
Motor protection acted.
Motor winding temp v. high (4-TE-5303-5308).
Fan / motor bearing temp v. high (4-TE-5301, 5302,
5309 & 5310).
Fan bearing vibration V.high (3-VT-5301,5302).
Local / Remote stop PB pressed.
SA FLOW < 10 kg / s with 30 sec ON Delay
Lube oil system Pressure v. low with 10 sec ON-Delay
(for pump start)
Immediate expected or desirable operator action
If PA If PA fan is tripped, all fuel systems will get tripped

automatically as they are interlocked.

The FBHE blowers except the empty chamber blower
shall be switched off immediately to avoid overfilling
of combustor.
In case of a trip of PA fan the shut-off valve downstream
the tripped fan is to be closed to avoid back flow of
fluidizing air resulting in a reverse rolling of the fan.
This should be avoided.

Decrease load accordingly.
3. OPERATING LOGIC
Start up Operation
Before starting the system all the following conditions should be

satisfied.
Permissive
PA FAN IGV closed (4-ZT-5301)

Any two Seal Pot blowers running
ID FAN running
Any one Purge & seal air blower running
SA FAN running
Any one FBHE EC Blower running
Boiler protection 1 not acted
Lube oil system Pressure O.K.
Lube oil tank level not low.
SA FLOW > 10 kg/s
Sequence

Primary air flow controller to MANUAL mode and
output signal to minimum position (Operator guidance
for achieving IGV close).
Switch on PA FAN lube oil pump-1 or 2 on
Switch on PA FAN
PA FAN IGV control/ Primary air flow controller,
switching to auto, if required, done by Manual.
5. EMERGECY PROCEDURE FOR TRIP OF SA FAN:-
SA FAN will trip, when any one of the following occurs
Boiler Protection 1 activated.

All three Seal Pot Blowers tripped.
Both Purge & Seal air Blowers tripped,
Motor protection acted
Motor winding temp v. high (4-TE 5303 TO 08)
Fan / motor bearing temp v. high (4-TE-5301, 02, 09 &
10)
Fan bearing vibration v. high (4-VT-5301, 5302)
Local / remote stop PB pressed
Lube oil system Pressure v. low with 10 sec ON-Delay
(for pump start)

In case of a trip of SA fan the shut-off valve
downstream the tripped

fan is to be closed to avoid back flow of fluidizing air
resulting in a reverse rolling of the fan..
Decrease load accordingly.
OPERATING LOGIC
Start up Operation

satisfied.
Permissive
SA FAN IGV closed (4-ZT-5302)

Any two Seal Pot blowers running
ID FAN running
Any one Purge & seal air blower running

Boiler protection 1 not acted.
SCAPH I/L &O/L dampers open OR SCAPH
B/P damper open
Lube oil system Pressure O.K.
Lube oil tank level not low.
Sequence
Secondary air pressure controller to MANUAL

mode and output signal to minimum. (operator
guidance for ensuring IGV close).
Switch on SA FAN

SA FAN IGV control / Secondary air pressure
controller, switching to auto, If required, done
by manual.
6. EMERGECY PROCEDURE FOR PETCOKE FEEDER:
Running PETCOKE feeder system-1 will trip, when any one of the
following occurs.
Boiler Protection 3 acted
Boiler Protection 1 acted

DP combustor < 90Mbar(3HHC01CP011)
Combustor temp (LOWER 2 OF 3) < 650 C(4-
TE-5360,5361,5362)
Combustor temp (MIDDLE 2 OF 3) <650 C(4-
TE-5363,5364,5365)
PA FLOW < 16 cu,m / sec. .(4-FT-5302)
Both P&S Air Blowers tripped.

PA fan tripped.
- SA fan tripped.
PETCOKE gate-1 closed
PETCOKE AL feeder-1 stopped

1. The PETCOKE Drag link Feeders are provided with VFD

control for smooth speed control. Control, monitoring and

protection signal interfaces between DCS and VFD panel to be
established.
2. The PETCOKE AL feeder-1 is provided with a two speed a.c.
motor, normally running with slow speed, and will switched to
fast speed automatically when all the following conditions
satisfied.
a. Boiler load > 60 %
b. PETCOKE feeder-1 speed control in auto
c. PETCOKE feeder 2 tripped
3. This PETCOKE AL feeder direction of rotation can be

reversed momentarily by manual command. This may be used
to clear the jamming, by reverse rotation of the feeder
whenever the feeder tripped due to jamming. To enable this
operation, all the permissive of the AL feeder are bypassed
during reverse rotation. Reverse run is recommended for short
duration only, still such time of holding the manual reverse
command.
4. Provision will be made at DCS for monitoring and reverse
operation.
The PETCOKE FEEDER -1 system consists essentially of the

following equipments
A. PETCOKE GATE VALVE-1

B. PETCOKE AL FEEDER-1 PURGE VALVE
C. PETCOKE AL FEEDER -1
D. PETCOKE DRAG LINK FEEDER-1
OPERATING LOGIC
Start up Operation

satisfied.
Permissive

PD COMBUSTOR > 70Mbar
COMBUSTER TEMP (LOWER 2 OF 4) >700 C(4-TE-
5360,5361,5362)
COMBUSTER TEMP (MIDDLE 2 OF 4) >700 C(4-TE-
5363,5364,5365)
PA FLOW > 17cu,m / sec.(4-FT-5302)
Any one PURGE&SEAL AIR BLOWER in service
Any two Seal Pot blowers in service
Any one empty chamber blowers in service
PA fan in service
SA fan in service
Put PETCOKE feeder-1 speed control in manual &
minimum.
Sequence
Open pet coke gate (MFT)

Open purge valve to pet coke AL feeder
Switch on pet coke AL feeder-1 (slow speed)
Switch on pet coke drag link feeder-1
7. EMERGECY PROCEDURE FOR TRIP OF FBHE

BLOWER 1:-

Running Blower will trip, when any one of the following occurs.

Inlet filter DP high.
Local / Remote stop PB pressed.
Boiler Protection 1 acted.
ID FAN tripped.
Both P&S Air Blowers tripped.
Both SP Blower 1 & 1-2 tripped.
Both EC Blower 1 & 2 tripped.
FBHE BLOWER -1 out let damper closed (4-ZSC-
5308).
FBHE BLOWER -1 safety relief valve (4-ZSC-5307)
not closed for >2 sec.
FBHE BLOWER -1 on & zero speed switch acted (4-
SS-5308).
Motor protection relay acted.
1. Out of three FBHE Blowers (1, 3, 1-3) the

blower1-3) is standby, which will be started automatically in
case of any one of the two running blowers (1 or 3) tripped.
2. The stand by blower (1-3) will substitute for
the first tripped blower only.
3. In case of a trip of one of the rotary blowers for the FBHE

bundle or empty chambers and difficulties in starting the
respective stand-by blower the boiler load should be reduced
immediately by about 30% MCR and the respective spies

valve shall be closed fully to avoid overfilling of the
bundle chamber. The immediate load reduction is required
to avoid a boiler trip due to actuating of boiler protection.
At this load, a repair of the damaged blowers should be
possible keeping the boiler in operation.
OPERATING LOGIC
Start up Operation

satisfied.
Permissive

Any one ID FAN in service.
Any one PURGE&SEAL AIR BLOWER in
service.
SEAL POT BLOWER 1 1-2 in service.
SEAL POT - FBHE-1 SPIESS VALVE
controller in HAND & MINIMUM.
Any one EC BLOWER in service.
FBHE BLOWER-1 INLET FILTER DP NOT
HIGH
Sequence
Following actions will happen when start command issued by
manual/auto.

FBHE BLOWER -1 outlet gate open (4-ZSO-5308).
FBHE blower 1-3 outlet gate-1 close (4-ZSC-5309).
Switch on FBHE BLOWER 1 .
8. TRIP OF PURGE & SEAL BLOWER 1:-
Running Purge & Seal Air Blower-1 will trip automatically, when
any one of the following occurs.
o Emergency push buttons activated

o Inlet filter DP high.
o Boiler Protection 1 acted.
ID FAN tripped .
P&S blower-1 on & its zero speed switch acted (4-SS-
5301).
P&S blower-1 safety relief valve not closed for >2 sec
(4-ZSC-5337).
P&S blower-1 out let damper closed (4-ZSC-5338).
P&S blower-1 Motor protection acted.
P&S blower-1 Motor winding temp v. high (4-TE-5325
TO 5330).
P&S blower-1 Motor bearing temp v. high (4-TE-5323
& 5324).
Local stop PB pressed.

1. H.T. Motor winding, motor bearing temp. Very high trip
signals shall be derived from respective signals.

2. Out of two PURGE & SEAL AIR Blowers one is standby,
which will be started automatically in case of the running
blower tripped.
3. Provision is for selecting any one as standby / running
EQUIPMENTS APPLICABLE
The PURGE & SEAL AIR BLOWER-1system consists

essentially the following equipments
PURGE&SEAL AIR BLOWER1

PURGE&SEAL AIR BLOWER1 OUTLET
DAMPER
Blower inlet Filter DP Switch
OPERATING LOGIC
Start up Operation
satisfied.
Permissive
ID FAN should be in service.

P &S blower 1 selected for running
(P&S blower-2 in standby)
Blower inlet filter DP not high
Sequence

Following actions will happen when start command issued by
manual/auto.
Open outlet gate of P&S blower-1(4-ZSC-5338).
Switch on P&S blower-1.
9. TRIP OF SEAL POT BLOWER 1:-
Running Blower-will trip automatically, when any one of the

following occurs.

Inlet filter DP high .
Local / remote stop PB pressed.
Boiler Protection 1 acted.
ID FAN tripped
Both P&S Air Blowers tripped .
Seal pot blower 1 on & zero speed switch acted (4-SS-
5305).
Seal pot blower 1 out let damper closed (4-ZSC-5326).
Seal pot blower-1 safety relief valve not closed for >2 sec
(4-ZSC-5325).
EMERGENCY PROCEDURE FOR TURBINE SYSTEM
HOT WELL LEVEL DROPPING FAST:-

Over feeding to deaerator
Excessive dumping to CWP Discharge
Make up pumps not running or tripped.

Make up control valves got struck in close position.
Level transmitters reading erratic.
Load reduced at fast rate.
Water loss due to boiler tube leakages & blow down.
Feed line drains open.
Non availability of makeup water
Plant response:-
Hot well level low alarm will come
Both make up control valves opens fully.
Stand by makeup pump starts at -100mm.
If hot level drops to minimum CEP's will trip
Parameters of concern/Adverse effects:-

Hot well level.
Condensate ST level.
Start the make up pumps if not started in auto.

Strat emergency make pump..
Check all the hot well level transmitters are reading same
or not.
Condensate storage tank level can be reduced to bring up
the hot well level.
If any blow downs & drains are open close it.

Check for any leakages in the system & try to isolate if
possible.
If DMST level is low take other tank in service
HOT WELL LEVEL RISING FAST

Excessive make up due to control valve struck in open
position.
PRDS charged from other unit & gland steam Inlet line
drain open to flash tank.
Condenser tube leakage.
Both CEP's tripped.
Sudden load changes.
Plant response
Hot well level high alarm will come
If CEP is running and Stand by CEP get started
Very high level will lead to water entry in to vacuum
pump suction pipe & condenser vacuum will drop
If level is very high it will increase load on condenser
springs
Parameters of concern/Adverse effects
Condenser vacuum.
Hot well level.
Condensate conductivity

Check make up control valves are closed, if required
close motor operated isolation valves.

Open blow down.
If condensate conductivity is raising (swas), conductivity
to be checked in lab.
Maintain drum PH & conductivity by starting Phosphate
pump & giving blow down
Check all the hot well level transmitters are reading same
or not.
Final correction activity
If condenser tube leakage is confirmed, reduce load & isolate
that section of water box and release for maintenance
DEAERATOR LEVEL VERY HIGH:-

Over feeding to deaerator may be due to
malfunctioning of control valve.
Tripping of feed pumps.
Transmitters faulty.
Plant response
Deaerator level high alarm will come
Extraction valve will close on high level.
Hammering in Deaerator at very high level

Deaerator level.
Deaerator pressure & feed water temperature

Immediately reduce the feeding to deaerator by taking
level control on manual.
Check all the transmitters are reading OK

Deaerator drain to DMST or IBD tank can be opened
from local.
If CBD is connected to CBD tank then close CBD valve.
The moment level becomes normal charge deaerator
extraction
Normalize the deaerator level & put on auto.
DEAERATOR LEVEL VERY LOW:-

Condensate transfer pump tripped.
Malfunctioning of level control valve.
Deaerator drain open.
Leakages in condensate system.
Transmitters reading erratic.
Plant response
Deaerator level low alarm will come
At very low deaerator level boiler feed pumps will trip.

Deaerator level.
Drum level.

If control valve is faulty then open bypass valve.
If required stand by CST Pump can be started & also hot
well make up pump can be started.
Close CBD & other drains.

If level is not raising reduce load & boiler firing
Check all the transmitters are reading OK.
Check for any system leak/drains open & arrest it

Find out cause for level drop & normalize system.
13.0 STANDING INSTRUCTIONS AND SOPs:-

General Guidelines:
1. All plant persons should wear all mandatory PPE.

2. Trained Manpower should be involved in all critical
operation.
3. Follow signboards instruction where applicable.
4. Proper /Clear communication to be ensured.
13.1 Start Up ID Fan Operation:-

1. Check that all permits are returned and all access doors
are closed.
2. Check that fan as well as motor bearings are properly
lubricated.
3. All relevant Interlocks and protection should be
checked.
4. Ensure ACW pump is running with normal header
pressure. Ensure cooling water is charged for fan bearing
cooling.
5. Put the back pass pressure controller, IGV & Speed
controllers in MANUAL mode.
6. Close the IGV to 0% and put minimum output value for
speed controller.
7. Open inlet & outlet gates of either of ESPs (or both) and
check for their limit switch feedbacks at DCS.
8. Keep Open the ID fan outlet gate and check for the limit
switch feedbacks at DCS.
9. Switch ON ID fan from DCS, after taking proper
clearance from field engineer.
10. Increase the fan RPM to more than 150 rpm.
11. Check for any abnormal noise, vibration level and
bearing temperature.
12. Manually open IGV as per the convective pass inlet
pressure.
13. Take lube oil cooler in service as soon as the temperature
starts increasing.
14. Put the back pass pressure & ID fan speed controller in
Auto mode once IGV opens fully.
13.2 Soot Blowing Operation

The flue gas, leaving the cyclones, seal pot and FBHE, is dust

laden. This fly ash is very fine and therefore hardly able to
captured. Therefore, deposits of loose dust are to be expected on
the heating surfaces of the convective pass and the air heater.
For cleaning of the heating surfaces of the convective pass and of
the air heater, there are soot blowers provided. All blowers are
provided with an electric drive. Steam is used as blowing medium.
The soot blower system consists essentially of the following
equipment:
- Manual shut-off valve, Motor operated shut-off valve,
- Soot blower steam control valve,

- A safety valve,
- Soot blowers with electric drive, in the convective
pass and at the air heater
- Motor operated valves, and non return valves,
By opening the motor operated shut-off valve, and the manual

shut-off valve, the steam line to the soot blowers is open. The soot
blower steam control valve reduces the steam to the required
pressure. The steam is fed to two separate lines, one to soot
blowers in the convective pass, and one to the soot blowers in the
air heater. The soot blower system is pressure and temperature
controlled and is equipped with a safety valve.

The purpose of the soot blowers is to clean the heat
transfer surfaces in back pass and air heater ensuring an economic
flue gas temperature within design range and a low CO content in
the flue gas. This is to keep the overall efficiency of the boiler.
Normally the operators shall run the soot blowing
sequence once or twice per shift or when exceeding the specified
flue gas temperature. The soot blowing intervals are to be adjusted
depending on the load. At least once per shift (8hr) the soot
blowing sequence is recommended to be run.
13.3 STARTING PUGRE & SEAL BLOWER:-
1. Check that all permits are returned and check that blower
as well as motor bearings are properly lubricated.
2. ID fan should be in running condition before starting the
blower. Please ensure.
3. Check that motor bearing temperature transmitters are
showing healthy reading at LOCAL & DCS.
4. Ensure boiler protection 1 is not acted.
5. Ensure Blower inlet filter DP is showing normal value
and ensure that all the switches like Zero speed switch
and SRV switches are normal and outlet gates of both the
blowers are close.
6. Issue blower START command in manual mode from
DCS. P&S Blower will be started after the limit switch
OPEN feedback of outlet damper is received on DCS.
bearing temperature.

8. Check suction filter DP is showing normal value and Put
the standby blower in AUTO mode.
13.4 STARTING FBHE EMPTY CHAMBER BLOWER:
1. ID, one P&S blower, two seal pot blowers should be in

running condition before starting the FBHE EC blower.
Please ensure.
2. Check that motor bearing temperature transmitters are
showing healthy reading at LOCAL & DCS.
3. Ensure boiler protection 1 is not acted.
and SRV switches are normal.
5. Check that outlet gates of both the blowers are close.
6. Emergency push button should be in released condition.
Ensure electrical RTS is available at DCS.
7. Check the condition of the V-belts.
8. Open the isolation gate valves at the wind box of all the
FBHEs around 50%.
9. Issue blower START command to any one FBHE EC
Blower in manual mode from DCS. Blower will be
started after the limit switch OPEN feedback of outlet
damper is received on DCS.
10. Check for any abnormal noise, vibration level, bearing
temperature And oil leakages and Check suction filter
DP is showing normal value.
13.5 BED MATERIAL FILLING:
1. Ensure Bed material bunker level is sufficient.

2. PA flow should be >15kg/s (54 TPH). Please ensure the
convective pass inlet pressure to be maintained around 0
to +1 mBar.
3. Check that bed material discharge gate is close.
4. Open the bed material gate valve below the bunker
around 30%.
5. Open the bed material pneumatic gate valve below the
RAV.
6. Open the Purge & Seal air SOV.
7. If Bed material RAV is not in service then open isolation
valve manually.
13.6 STARTING FBHE BC BLOWERS:
1. ID fan & any one P&S air blower, two Seal Pot blowers
& one EC blower should be in running condition before
starting the blower. Please ensure..
and SRV switches are normal.
3. Check that outlet gates (08 no.) of all FBHE BC blowers
are close.
4. Issue START command in manual mode from DCS to
FBHE BC blower # 1. Blower will be started after the
limit switch OPEN feedback of outlet damper is received
on DCS.
bearing temperature and Check suction filter DP is
showing normal value.
6. Start FBHE BC blower #2, #3 & #4 following the same
procedure.

13.7 BOILER PURGE OPERATION:
Purge is applicable at any one of the following conditions:
a) Before the first startup of the SUB,

b) After four successive unsuccessful starting of the first
burner (SUB I or II),
c) Burner start beyond 30 min. from the completion of the
purge.
d) Boiler start up when combustor temperature < 600 C.
1. Total purge airflow, @ min. 70.85 kg/s is to be flown for

15.5 min. time (to ensure three fold of volume change).
2. During boiler purge all blowers (except spare blowers)
will RUN.
3. Please ensure that any protection / interlock are not
bypassed.
4. Boiler protection 1 not acted.
5. Combustor (lower) temp. < 600 C.
6. ESP I & II Off.
7. ID, SA, PA, Any one P&S air Blower, Any one FBHE
EC blower and Both AC blower are in service.
8. Purge Ready signal will be available* only when the
total air flow is >280 TPH.
9. Purge START command (manual).
10. Purge Ready signal will be automatically generated,
when any of the following conditions occurs
a. Purge reset command or Purge Failed when
combustor temp < 6000C
b. 30 min. elapsed after purge completed & any one
SUB or Lances in service
c. More than four consecutive unsuccessful light up of

Burners (SUB-I or II), within 30 min. after the
completion of purge.
11. Put Back pass pressure controller in AUTO.
12. SET SUB-1 & SUB-II Comb. Air Controller to MAX.
13. SET PA & SA FAN IGV Controller to MAX.
14. If total purge airflow rate > 77.72 kg/s, only then
Combustor PURGE TIMING ON. Also FBHE PURGE
TIMER ON.
15. PURGE IN PROGRESS signal on.
16. After 70 sec. FBHE PURGE COMPLETED signal ON.
17. After 930 sec. PURGE COMPLETED signal ON, and
also 30 min. hold on timer ON.
18. Following actions will occur automatically, when
PURGE TIME COMPLETED (15.5 min.) or failed or
RESET COMMAND given.
19. SET SUB-1 & SUB-2 Comb. Air Controller to MIN.
20. SET SA & PA FAN IGV Controller to MIN.
Protection:
1. Running PURGE operation will trip and PURGE

FAILED indication / signal will be ON, when any one of
the following conditions occurs before PURGE
COMPLETION.
2. Emergency push buttons activated.
3. PURGE RESET PB pressed.
4. Boiler Protection 1 acted.
5. Both P&S Air Blowers tripped.
6. Any two SP Blowers 1 / 1-2 / 2 tripped.
7. Both EC Blower 1 & 2 tripped.
8. SA & PA FAN tripped.
9. Any one FBHE blowers tripped.
10. Both Ash Cooler blowers tripped.

If combustor temperature > 600 deg. C, Hot start up can be done
without combustor purge.
If startup of the SUB is delayed more than 30 min. from purge
complete, again purge to be done.
During purge the ESP should be kept off to avoid light up of any
residual fuel.
Fans IGV Positions once auto set at min. / max. shall be released
to manual access for any further adjustment
13.8 START UP OF FUEL OIL BURNERS:-
Before starting the SUB all the following conditions should be

satisfied
1. HSD & atomizing air are lined up as per the Doc. No.
BORL/CPP/PRO/SOP001.
2. LPG is lined up as per the Doc. No.
BORL/CPP/PRO/SOP 002.
Permissive
1. Boiler protection 1 not acted.

2. COMBUSTOR LOWER TEMPERATURE < 600oC.
3. ESP -I & II Off.
4. ID FAN in service.
5. Any one Purge & Seal air Blower in service.
6. SA FAN in service.
7. SUB-I combustion air damper not close.
8. PA FAN in service and PA FLOW > MIN. (4-FT-
5302).
9. Purge completed or combustor temperature >300
degC or SUB-2 in service signal available.
10. LPG pressure o.k. (4-pt-5701)

11. HSD pump running
12. HSD pump outlet pressure controller in auto
13. HSD pressure o.k. (4-pt-5501)
14. Atomizing air pressure o.k. (4-pt-5504)
15. sub-1 scvange valve closed (4-sv-5506)
16. Check for the SUB 1 & 2 READY TO START
signal is available on LOCAL / DCS.
START UP PROCEDURE
Following actions will happen when SUB-I START command
given
1. HSD pump outlet pressure. Controller auto.
2. Sub gun advanced.
3. Set sub comb. Air damper controller to auto.
4. LPG vent valve close.
5. LPG master trip valve open.
6. LPG burner trip valve open.
7. LPG pilot on (flame scanner).
8. Sub atomizing air trip valve open.
9. Sub atomizing air pressure controller auto.
10. HSD master trip valve open.
11. Sub HSD bnr trip valve open.
12. HSD flame on (senced by scanner).

13. LPG master trip valve close.
14. Sub LPG burner trip valve close.
15. LPG pilot off (3hjq21 aa010).
16. LPG vent valve open (3hjg10 aa035).
17. Loading of sub by flow controller auto / manual (3hjf10
aa010).
Following actions will occurs automatically, when SUB 1 or 2
STOP command given or TRIP occurs
1. Sub-1 HSD BNR trip valve close.
2. Sub-1 HSD long recirculation valve open.
3. Sub-i scavange valve open.
4. After scavange time over sub-i scavange vlv close.
5. Sub-1 atomizing air trip valve close.
Protection
1. Burner will trip and trip indication / signal will ON,
when any one of the following Conditions occurs
2. Emergency push buttons activated
3. Boiler Protection 1 acted.
4. Boiler Protection 2 acted
5. Both P&S Air Blowers tripped
6. ID FAN tripped
7. SA FAN tripped

8. PA FAN tripped
9. Respective fuel HSD PRESSURE V. High
10. Flame failure
Note
- If combustor temperature>6000C, Hot start up can be

done without SUB in service.
- If startup of the SUB is delayed more than 30 min. from
purge complete, again purge to be done
- SUB can be started independently irrespective of other
SUB is in operation with HSD
- Operation of FO master trip valve and long re-
circulation valve of each SUB are by remote manual
13.9 STG COLD START UP OPERATION:
1. Start the MOP and check whether the required pressure

(9 to 10Kg/cm2) is being developed or not.
2. Check the interlocks and the auto changeover of the
MOP, AOP & EOP.
3. Check the interlocks and the auto changeover of the AC
JOP & DC JOP.
4. Initial fill the hot well by using the DM make up valve
and fill the hot well up to or above 1200 mmWC
5. Open the suction and discharge valves of the CEP 1 & 2
and open the canister vent of both the CEPs. Open the
mechanical seal cooling water line as per requirement.
6. Ensure the DPTs and the Discharge PTs of the CEPs
are in line.

7. Start the CEP 1 and see that the Recirculation valve is
kept open above 45% so that minimum circulation of the
CEPs are achieved and same procedure is to be
followed for the stand by CEP also.
8. After checking the auto changeover of the CEPs
maintain the hot well level at around 900 mm WC.
9. Open the following valves
- Main steam line drain above the flash tank.
- Main steam line motorized drain line before the TSSV.
- Keep the TSSV in open condition as it is not operable.
- Warm up vent valve.
- Ejector auxiliary steam line drain valve.
- All the drain lines before the QC NRVs of all the three
extraction.
- All the drain lines of the STG casing
10. Open the integral bypass valve of the STG main steam
line isolation valve at the PRDS floor full open and
simultaneously charge the Auxiliary steam line by
opening the control valve 5%.
11. Wait until the main steam pressure &temperature comes
up to 350oC/100Kg/cm2 before and after the TSSV and
the auxiliary steam temperature comes up to 200 oC and
pressure up to 10.5Kg/cm2.
12. Slowly open the auxiliary steam isolation valve of the
Starting ejector and after opening the steam valve then
open the air valve.
13. Close the vacuum breaker valve.
14. Charge the gland steam line by opening the gland steam
isolation valve and the upstream isolation valve and
simultaneously open the drain line in between the two
isolation valves.
15. Gland steam condenser start up procedure:-

- Open the steam line isolation valve and charge the line
- Open the ejector isolation valve downstream of the main
isolation valve
- Open the gland steam line coming from the turbine gland
- Open the GSC drain line going to the condenser stand
pipe
16. After achieving the vacuum of -0.4 Kg/cm2, charge the
gland steam line by opening the gland steam C/V and
maintain the gland steam pressure of 850 mmWC.
17. When the vacuum of -0.85Kg/cm2 is achieved with the
ejectors then go for the cold rolling of the STG. But if
the required vacuum is not achieved then the main
ejector is to be taken in line along with the starting
ejector.
Main ejector Start up procedure:-

- Open the steam line isolation valve slowly
- Open the airline isolation valve slowly
- Then open the Rota meter vent valve of the respective
ejector
- Open the first stage drain line of the respective Ejector
- Open the second stage drain line before and after the
strainer which is going to the stand pipe of the condenser
- Ensure the atmospheric drain lines to be kept fully
closed
13.10 TDBFW PUMPS OPERATION:

1. Check that the de-aerator is filled to normal working
level.

2. Check that control air and electrical supplies are
available for instrumentation, leak of equipment and
valves.
3. Check that booster pump and feed pump drain valves are
shut.
4. Check that recirculation and isolation valves are opened.
5. Check that all instrument tapping points and isolating
valves are open and that all drain equalizing valves are
shut.
6. Open the feed pump drive end and non-drive end
mechanical seal cooler circulation water inlet and outlet
isolating valves.
7. Check that pump set discharge isolation valve is open.
8. Crack open the pump set suction isolation valve.
9. Open the booster stage air vent valve and vent any
trapped air and gases from the pump casing.
10. Shut the booster pump air vent valve when water issues
freely from it.
11. The interconnecting pipe work and the boiler feed pump
discharge pipe work should also be primed and vented.
12. Vent the feed pump mechanical seals and cooler.
13. Fully open the pump set suction isolating valve.
14. Ensure that clarified cooling water and raw water are
available for pump set.
15. Open the clarified cooling water inlet and outlet isolating
valves for feed pump mechanical seal coolers.
16. Prepare the drive motor for starting.
START UP PROCEDURE
LUBRICATION SYSTEM OF BFP

1. The FOLS has two LOPs each separately driven by
motor. One pumps acts as auxiliary to another. One of
the lop shall be started to supply lubricant to BFP
bearings, gear box and booster pump.
2. In case pressure is not built up by the first LOP within
two minutes of starting, the second pump starts
automatically and the first LOP shall be stopped
manually only after adequate pressure is built up.
3. By adjusting the relief valve lube oil pressure at pump
discharge is to be set 2.5 kg/cm2 (g).
4. In case lube oil pressure falls below 1.2 kg/cm2 (g) ,
Lube oil pressure low alarm is initiated and if lube oil
pressure further drops to O.8 kg/cm2 (g) ,BFP will be
tripped immediately.
5. One of the LOPs shall be kept in running condition for
standby BFP.
TURBINES START UP PROCEDURE:
1. Open warm up vent

2. Open the casing drain
3. Slowly open the isolation valve connecting to HP line to
turbine inlet.
4. Gradually raise the pressure and temperature steam at
ESV inlet.
5. Steam temperature during warming of valve chest should
be 300 C more than the saturation temperature of steam
corresponding to steam pressure (refer to warming up
curve DRG.NO.:4-301-00-70631).
6. During speeding up to 500 RPM minimum 100o C
superheat is to be maintained.

7. For cold start up soaking time at 500 RPM is 20 min.
then speed is raised to 1800 RPM within 10 min. Idle
hold time at this RPM is 50 min ,then to the rated 4380
rpm.
8. For warm & hot start up as per the Woodward 505
governors.
9. Turbine warm up vent and casing drains should be
closed as per the requirement.
STARTING TDACW PUMP OPERATION:-
1. Check all drain of HP, MP lines and turbine casing are in

open condition.
2. Slowly charge HP, MP lines and put on line heating.
3. Ensure no hammering in steam line.
4. Engage the over speed tripping lever.
5. Ensure the governor is set at minimum position.
6. After line heating open HP,MP isolation valve of
TDACW fully
7. Open Turbine leak off line to LP header line.

8. Give open command to Turbine trip Valve.
9. Open manual discharge valve of pump.
10. Vent the Pump discharge line properly.
11. Have close monitoring on Pump discharge pressure.
12. Slowly raise the turbine rpm.
13. When pump discharge pressure is more than the ACW
header pressure, Start opening the discharge MOV.
14. After opening of discharge MOV raise the RPM to 3600
15. If ACW header pressure increases throttle the
interconnecting valve between ACW and ECW header.

16. One MDACW should be put on Auto stand by.
17. After stabilization of TDACW pump give stop command
to running MDACW Pump
18. Put TDACW discharge MOV on remote and Auto
selection.
19. Close all line drains and casing drains.
SOLID MATERIAL HANDLING:-
1. Start the drive motor & run belt continuously for no

load.
2. Carry out a thorough check of all fasteners and free
running of idlers.
3. Check for excessive heating of bearings, gearbox and
motor.
4. Start loading the conveyor gradually to attain maximum
specified capacity.
5. Check for proper discharge cogging of chutes, central
feeding on succeeding conveyor.
6. The voltmeter and watt readings should be taken on
proper interval.
STARTING SEQUENCE
FEEDING FROM PCC 1:

1. Initially operator shall manually move the travelling
tripper at required position.
2. Open feeder gate 3A & 3B.
3. Start drive motors of PCC 5A & 5B.

6. Start drive motors of PCC 3C & 3D.
7. Start vibrating screen A & B.
8. Start crushers A & B.
10. Adjust feed diverter control as per requirement.
11. Start drives motor of PCC 2.
12. Finally start PCC 1
IN THE ABOVE SEQUENCE DUST EXTACTION SYSTEM

AND MAGNETS WILL START WITH THE RESPECTIVE
EQUIPMENTS.
FEEDING FROM PCC 7:

2. Start drive motors of PCC 6A & 6B
3. Open feeder gate 3A & 3B
5. Open feeder gate 2A & 2B
13.11 SAMPLING, GAUGING & DRAINING

CONTENTS
SAMPLE SCHEDULE

SAMPLES, SAMPLING AND TESTING
TANK GAUGING
GAUGE GLASSES
SAMPLE SCHEDULE
All routine samples like boiler blow down, CT supply &
return header, feed water, steam, condensate etc. to be
drawn as per instruction of shift in-charge and sent to
laboratory.
SAMPLES, SAMPLING & TESTING
Samples must at all time be on grade to the

specifications stated. Should there be any difficulty in
maintaining this, the shift in-charge should contact the
day-staff for guidance.
Careful watch must be kept on laboratory results. If

results are doubtful, checks should be made immediately.
But in no case should results be ignored and no action is
taken.
Careful sampling is necessary for effective quality

control. Care should be taken on the following points:

Samples should be representative of what is
contained in the tank.
Clean bottles and cans should be used.
Sample bottles should not be used for any

purpose other than sampling.
Sample labels should always be used for

identifying and specifying tests on samples.
It should be made certain that samples are sent

to the laboratory at the correct time according
to the schedule.
It is essential that the results of any sample sent be

recorded in the lab analysis book. Shift In-charge should
pass over an account of results pending to the next shift
so that inquiries for results can be made.
Special Samples
Whenever a sample out of the routine is sent for analysis

the shift in-charge should inform the shift chemist in
advance.
Special samples must be restricted to a minimum.
GAUGE GLASSES

Gauge glasses are provided on vessel and equipment to have an
absolute control on level and to ensure that level instruments are in
good working condition. All level gauge glasses should therefore
be maintained clean and in working order all the time and levels in
equipments and vessels should be checked to ensure safe working
levels without placing absolute reliance on instruments.
If for maintenance purpose any gauge has to be removed,

it should be fitted back as soon as possible.
Whenever a level instrument is handed over for

maintenance a marking must be made on the gauge glass
to serve as an operating guide for the normal level in the
vessel.
While draining a gauge glass, care should be taken to see

that the liquid does not spill over and cause a fire hazard.

14.0 COAL HANDLING PLANT
(CHP)
14.1 Introduction:
The CHP (Coal handling plant) is given for transporting the materials
coal/pet coke via the shortest distance between the required loading

and unloading points. They are very flexible in their capabilities of
receiving material from one or more locations and for delivering it to
points or areas, as required by plant flow sheets. Belt conveyors are
more acceptable than other means of transporting bulk materials;
they neither pollute the air nor deafen ate ears. They operate quietly,
often in their own enclosures which desirable can be located above
the confusion and safety hazards of surface traffic or in small tunnels-
out of sight and hearing.
Maintenance cost for belt conveyors are extremely low compared
with most other means of transportation bulk materials. Usually they
schedule inspection and lubrication. The maintenance also very easy
to do, such as tightening ate belt, increasing the belt length or
reducing the belt length etc.
14.2 Technical Data:-
Pet Coke System

EQUIPMENT RATED CAPACITY DESIGN CAPACITY
(TPH) (TPH)
PCC-1 300 320
PCC-2 300 320
PCC-3A/3B 150 170
PCC-4A/4B 150 170
PCC-5A/5B 150 170
PCC-6A/6B 150 170
VIBRO FEEDER VF-1 300 320
DOBLE ROLL CRUSHER 300 320
STACKER/RECLAIMER 300 320
VIBRO FEEDER VF-2A/2B 150 170
VIBRATING SCREN VSC-A 150 170

&B
Rated and design capacity
14.3 LIME STONE SYSTEM

RATED & DESIGN CAPACITY
EQUIPMENT RATED CAPACITY DESIGN

(TPH) CAPACITY (TPH)

WAGON TIPPLER 15 TIPPLING 20 TIPPLING
APRON FEEDER 825 950
STACKER 825 950
RECLAIMER 280 320
VIBRATING SCREEN 140 160

LSVC A & B
L S CRUSHER LCR A & 140 160

B
MILL LSM 1 &2 56 62
PNEUMATIC CON. 56 65
SYSTEM PCS A&B
LSC-1 825 950
LSC-2 825 950
LSC-3 825 950
LSC-4A/4B 140 160
LSC-5A/5B 140 160
LSC-6A/6B 56 65

BELT CONVEYOR START UP PROCEDURE
PRECHECKS
Check that all permits are returned.

Ensure that all parts of belt conveyor are free any
undesired material before starting .
Conveyor frame work must be checked for perfect
alignment, movement
Ensure proper lubrication is available at all drives.
Ensure that direction of motor is correct.
Check the lubrication oil level of the gear box
START UP PROCEDURE
Start the drive motor & run belt continuously for no load.
Carry out a thorough check of all fasteners and free
running of idlers
Check for excessive heating of bearings, gearbox and
motor.
Start loading the conveyor gradually to attain maximum
specified capacity.
Check for proper discharge cogging of chutes, central
feeding on succeeding conveyor.
The voltmeter and watt readings should be taken.
STARTING SEQUENCE:
A. FEEDING FROM PCC 1:

8. Start vibrating screens A & B.
12. Start drive motor of PCC 2
13. Finally start PCC 1.
EQUIPMENTS.
FEEDING FROM PCC 7:

8. Start vibrating screen A & B.
12. Start drive motor of PCC 2
13. Start DRC
14. Finally start PCC 7.
15. Start LSC 2.

16. Start LSC 1

EQUIPMENTS.
OPERATION OF STACKER / RECLAIMER (PETCOKE /

LIMESTONE)
1. Introduction
The rail mounted Slew able Stacker cum Reclaimer
machine is used for handling limestone with following
characteristics:-
Bulk Density --- 1.04 t/Cu. M.
Grain Size --- (-) 200 mm.
Angle of Repose --- 35 deg.
It travels through the maximum length of 255m across the
stockpile (refer TRF civil information drawing 162 00-08 12019).
The machine is suitable for serving two parallel stockpiles, each on
either side of the track rails. For pile configuration, refer GA of
Stacker Reclaimer bearing TRF Drawing No. 164 -00-00 1 6061C.
Maximum height of stockpile shall be 6.00 Meters. at approx. 35
angle of repose.

The boom of the machine, used for both Stacking and
Reclaiming with the help of flap gates, can luff up and down and
slew through 105.
2. Modes of Operation from Equipment control point of view

There are the following modes to control machine
operation:
a. Local mode is envisaged only for maintenance / testing purpose
of individual equipment. Operation will be possible from a Local
Control Station (LCS) located near the motors / drives of the
individual mechanism.
Operation in this mode is possible only if the Local /
Remote switch on the respective LCS is selected in Local position.
In this mode, only the equipment safely interlocks that are
hardwired in the MCC or drive circuit are effective.
Operations in this mode are generally without PLC.
b. Remote mode shall always be selected during continuous

operation/ positioning of the machine from operators cabin. In
Remote mode, both in Auto and Manual, all operations shall be
done from the touch screen. Long travel, Luff and slew motion
shall be controlled through a joystick. In Remote mode, the
operator has two options, viz. AUTO or MANUAL. The

AUTO/MANUAL mode is selected on the HMI.
i. Manual mode primarily to be used for start-up functions and

Positioning.
The operator can select Manual mode from the HMI and
operate the machine by starting one drive at a time in sequence.
Safety and sequential interlocks for each drive are provided in the
PLC. In manual mode, there is no automatic sequencing between
the movements of different parts of the machine.
In this mode, luffing, slew and long travel will be done with joy
stick with interlock.
ii. Auto mode is meant for continuous stacking or reclaiming

operation. In automatic mode or AUTO mode, used
during continued stacking or reclaiming operation, the sequence of
operations is decided by the PLC based feedback from various
field devices and sensors. In case AUTO mode is selected on the
HMI for Stacking or Reclaiming by pressing the soft-key Auto
start, the drives will start in an automatic sequence one after the
other without operators intervention.
3. Modes of operation from the Process point of view:

The mode in which the machine will operate from the
process point of view is decided at the Material handling Control
Room (MHCR). The mode of operation is confirmed at the HMI
and subsequently the machine can operate in the selected mode
only.
The modes of operation from the process point of view are as
follows:
a. Stacking mode
Under stacking mode of operation, the following are
done in sequence:
i. MHCR operator sends the request for stacking.
ii. The stacker cum reclaimer machine operator acknowledges the

request by selecting Stacking mode through HMI on the CD.
iii. MHCR operator informs the stacker cum reclaimer operator

over voice communication about the stock pile where the material
is to be stacked.
iv. The operator moves the machine, with long travel, slew and luff
selected in Remote Manual mode, to the desired point of the yard
by luffing up / down or slewing the booms as to clear the existing

stock pile and inform MHCR that the machine is ready to operate
in desired stockpile.
v. He slews the boom through a joystick and put the same over the
pile so that the material discharged from the boom falls at the
center of the pile.
vi. He will then position the boom to the desired height
vii. He will then start the Boom conveyor. The status will be
communicated to the MHCR operator through a digital signal and
telephone together. .
The equipment shall be kept at one defined place over the rail
track.
The discharge boom will then be lowered to the minimum sensed

by the lower end limit switch. Stockpile building operation will
start; once the material reaches the desired stockpile the discharge
boom will be luffed up automatically from time to time, in pre-
determined amount set by the PLC software, on receipt of signal
from the pile-sensing probe. The operation will continue till a pile
of predetermined height is built-up and end limit switch top is
actuated.

However the travel limit will be set as per the pile length set by the
Operator.
Under AUTO mode of operation, Boom Luffing, Long travel and

Slew drive have to be operated in sequence.
Under Manual mode of operation, the operator will

actuate Long travel joystick to enable the equipment to move
forward / reverse by a predetermined distance, seen by him at the
HMI as feedback from the position encoder. This operation will
continue till travel end limit switch for stacking is actuated, i.e.
pile end is reached.
b. Direct feeding mode

On receipt of command from MHCR, machine operator selects
direct feeding mode. For this operation the flap gate position is
altered so that the material discharged from the tripper falls into
the central chute of the stacker/ reclaimer.
C. Reclaiming mode
The reclaiming operations will normally be started from
one end of pile. Two (2) modes of reclaiming mode are envisaged,
the block module mode and the benching mode and the Stacker
cum reclaimer shall be controlled as detailed in the following

paragraph. Luffing operation will be guided by rotary cam limit
switches.
Block Module mode of reclamation

In block module mode, the reclaiming operation shall
start from one end of the stockpile. On Receipt of a request from
the operator of the MHCR, the machine operator will bring the
equipment at one end of the coal stockpile; position the boom in
MANUAL mode by luffing up / down and or slewing the boom.
After positioning, he will inform MHCR operator Machine
selected in reclaiming mode and Ready to start at desired
stockpile. On receiving this information, MHCR operator will start
the conveyor system with the yard conveyor starting in the end.
The machine receives the information Yard conveyor running. The
machine operator can then start the Boom conveyor.
The operator will then bring the bucket wheel at suitable
working position on stockpile from where he intends to start
reclaiming.
The equipment will then be started in Auto mode, which will start
the bucket wheel drive and the slew speed will get varied
automatically through PLC software to maintain a constant
reclaiming rate.

After the material is reclaimed from the first / starting
block (measured by zero reading on the belt scale at the boom
conveyor), the equipment will be advanced automatically to give a
fresh cut for material reclamation by slewing operation and the
process described above will continue. After a predetermined
number of advancements to be set during commissioning at site (3-
5, generally), the equipment will be traveled back to clear off the
pile.
The boom will be lowered and the equipment will be
traveled back to clear off the pile. The boom will be lowered and
the equipment will be moved forward so that it gets engaged with
the next block for continuing with the reclaiming process.
When material from all the layers in a block is
reclaimed, the operator, in Manual mode, traverses the reclaimer
back to clear off the pile, raises the boom and then moves the
equipment forward for starting reclamation of the next block.
Process of reclamation is repeated till MHCR operator informs
machine operator to stop reclaiming
Benching mode of reclamation
In the benching mode operation, the material will be
reclaimed out of the stockpile starting from the top bench and by
automatically controlled movement of the long travel drives (to

maintain fixed reclaim rate) over the full length of the pile. This
operation shall be carried out in the Auto mode.
After full length of pile is reclaimed, the boom of the
equipment will be slewed to touch the material of the same bench
and above mentioned procedure will be followed in reverse
direction. After reclaiming the first bench, the boom is lowered to
the next bench and the reclaiming process continued as described
earlier.
Reclaiming Rate Indications will be provided on the operators
console.
4. General Permissive in Remote Mode:

The general Starting Permissive for any movement of
Stacker reclaimer in Remote Mode under normal conditions are:
Transformer winding temperature not high
6.6 kV LBS ON
415V MCCB in MCC ON
Emergency end limit switches for Long Travel, Slew and luff not
actuated
Wind Speed normal (Fault condition is annunciated on CD
Wind Speed High)
Boom not anchored
Boom not on pile, detected by the level sensing probes

Lubrication systems are operational
Emergency Stop PB not actuated
All drives in Remote mode
6. Emergency Stop:
The mushroom head, lockable, rotate to release type Emergency
Stop (Estop) stations are strategically located at different parts of
the machine. Pressing this button gets the topmost priority of
operation and stops the machine irrespective of the mode of
operation.

COAL MILL STARTING PROCEDURE:-

Coal mill Stop procedure:-

15.0 ANNEXURES

PA (PUBLIC ADDRESSING) SYSTEM LOCATION:

Fire Protection System List:-
Fire Protection System in CPP
SN Plant Equipment Tag System Type

1 CPP (STG) TR -21
2 CPP (STG) TR -22
3 CPP (STG) TR -23
4 CPP (STG) TR -24
5 CPP (STG) TR -25
6 CPP (STG) TR -26
7 CPP (STG) GT -1
HVWS
8 CPP (STG) GT -2
9 CPP (STG) GT -3
10 CPP (MHL) TR -27
11 CPP (MHL) TR -28
12 CPP (132 KVA) TR -1
13 CPP (132 KVA) TR -2
14 CPP (132 KVA) TR -3
Foam Pourer
15 CPP (HSD Tank) Foam Pourer System
MVWS
16 CPP (HSD Tank) HSD Tank
Safety Shower Location in CPP

Sr. No. Area/Location
1 Near Chemical House: Cooling Tower
2 Near Control Room
3 Boiler # 1: ground floor
4
Boiler # 2: ground floor
5 Boiler # 3: ground floor

IMPORTANT TELEPHONE NO.
S.N. IMPORTANT TELEPHONR NO.
1 FIRE 6666
2 AMBULANCE 6111
3 SECURITY 6100
4 CONTROL ROOM (CPP PANEL) 6691
5 RSM 6604
LIST OF REFINERY ASSEMBLEY POINTS:

Power Distribution Diagram:-

Manual Call Point (MCP) Location in CPP

Fire Water Network with Hydrant syatem in CPP:-


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POCKET MANUAL

CAPTIVE POWER PLANT

BHARAT OMAN REFINERIES LTD.

(CAPTIVE POWER PLANT)

Prepared By Reviewed By Approved By

DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 2

DOC. REV. DETAILS OF REMARK

DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 3

QUALITY, ENVIRONMENTAL, OCCUPATIONAL, HEALTH

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ENERGY (EnMS) POLICY

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The operating procedures for normal operation, handling of various

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S.N. TOPIC PAGE NO

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Power Generation capacity

Specified initial steam pressure 106 ata

Specified initial steam temperature 5050C

DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 8

Technical Parameters of Boilers (3Nos)

Type of Boiler Circulating fluidized bed combustion

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HP Steam to MP Steam Header

Normal Design Steam Parameters for Process

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DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 11

2.0 PROCESS FLOW

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All dosing facilities are skid mounted system. Following chemical

1. Morpholine: The feed water / condensate pH is maintained by

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4.0 Process Description:-

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DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 16

a. An optimum temperature for reaction of the limestone

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DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 18

Ash spillage during the start-up phase is less critical and

Primary Air Supply:-

The preheated primary air is fed to the CFB combustor and

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Secondary Air Supply:-

The secondary air consists of following air streams:-

Secondary Air (from fan)

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Total Air Flow rate:-

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Fluid Bed Heat Exchangers (FBHE):-

The fluid bed heat exchangers are arranged downstream of the

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The evaporator is composed of different sections, supplied with

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SOLID FUEL FEEDING SYSTEM:-

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The start-up burners are required for heating up the combustor

The start-up burners are lighted-up by means of a separate ignition

Each burner has in addition a peep hole enabling the operator to

The bed lances are required for heating-up procedure, if combustor

DOCUMENT NO. : BORL/OPM/02/CPP/006, Rev. 0 Page 27