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OBJECTIVES
Production of steam at desired parameters and purity
Protection of pressure parts from corrosion, overheating, thermal stresses etc Prevention of furnace explosions
BOILER OPERATION
DIFFERENT PHASES
START UP PROCEDURES
CHECK AND ENSURE THAT All systems to be started are free from man and material and all work permits/line clears are returned. Local drum level indicator is in service. Furnace temperature probe is available for service All soot blowers are in retracted condition Safety valves gags/test plugs are removed.
CHECK AND ENSURE THAT Impulse safety valve/e.m.r. valve is in service position and its isolating valve is open. All drives of valves and dampers are in perfect condition and operetable from control desk. All control and interlock circuits are in healthy condition. Bottom ash hopper and seal trough are filled with water and adequate water supply is available
CHECK AND ENSURE THAT All ash hoppers are emptied and E.S.P.is cleaned and ready for operation. All sy.air dampers and burner tilt are freely operating and burner tilt is in horizontal position. All oil guns and spark plug assemblies are cleaned. All boiler,super heater,re heater drains and vents are in start up position.
BOILER FILLING
All vent valves on feed line, economiser,drum,headers and m.s.line are kept open. All drain and blow down valves are kept closed. Do not fill the water above the boiling point. Do not fill with excessive cold water. If possible fill with water 100c above boiler metal to avoid temp. stresses
BOILER FILLING
Open and close gauge glass cocks and drains on the water column to make sure that these connections are unobstructed and free. Fill till free jet of water comes out through economiser vent and drum vents. Bring down level in drum to normal by draining after closing economiser vent.
BOILER PURGING
CHECK THE FOLLOWING PURGE PERMISSIVES ARE SATISFIED
A.C.& D.C.power supply to F.S.S.S.is available Drum level is normal. Atleast one I.D.fan and one F.D.fan are in service Minimum 30% of full load airflow is maintained. All oil trip valves and nozzle valves are proven closed All auxiliary air dampers are modulating to maintain adequate windbox to furnace differential pressure All pulverisers and feeders are off All hot air gates are closed and cold air dampers are less than 5% open. All flame scanners sense no flame. No boiler trip command is present
BOILER PURGING
Satisfy purge permissives Give purge start command Purge on indicationcomes Purge complete indication comes
LIGHTOIL FIRING
Open ignitor oil trip valve Open light oil trip valve Select light oil firing in AB elevation Ensure elevation permissives Start one pair of oil guns Start second pair of oil guns Check 3 out of 4 L.O. guns are proven on in timed sequence
Control firing rate as per start up curve Close R.H.vents and drains Pull vacuum in condenser Take HP/LP by pass into service Close start up vent Maintain drum level by intermittently feeding Start feeding through low load FCV if drum level continue to recede Close economiser re circulation valve Monitor boiler expansion Ensure F.G. temp. after A.H.above acid dew point by regulating steam to SCAPH Raise steam to rolling parameters Turbine rolled,synchronised
TO S.H.ATTEMPERATION
TO S.H.ATTEMPERATION
DRAIN
DRAIN
F.C.V.
DRAIN
DRAIN
TO ECO.
DRAIN
DRAIN
DRAIN
ROUTINE CHECKS
Make a round of boiler to inspect Flame condition/ stability
ROUTINE CHECKS
Compare unit operating parameters with predicted readings.Any deviation should be reasoned and corrected Compare local instruments reading with remote instruments once a day.Any discrepancy to be corrected Maintain feed water,steam quality Ensure flow of sampling water is maintained Analyse F.G. through orsat apparatus once a day Check fineness of p.f.
ROUTINE CHECKS
Check pr.drop of F.G.,feed water temp before and after economiser, steam temp at various stages of S.H., metal temp. of S.H. and R.H. Carry out soot blowing as and when required Carry out soot blowing of A.H. once in a shift Ensure no choking in bunkers Maintain mill parameters Empty the bunker if the mill is taken for long shut down Ensure satisfactory operation of slag conveyors slag crushers,fly ash system
ROUTINE CHECKS
Control R.H. temp. by burner tilt Load pulverisers only to 80% Keep clean ignitor spark plugs,atomisers. Maintain H.O.and atomising steam temp.and pr. Parallel running fans are loaded equally Change over to stand by equipment of following aux. once a week
Seal air fan Hydrazine pump Coal mills Lub.oil pumps
Take all controls on manual mode By pass Turbine trip on Temp. protection Reduce speed of running R.C feeders gradually Ensure the firing rate is decreased in such a way that the rate of saturated steam temp drop at boiler drum is not exceeding the limits prescribed in the shut down curve (830 C per Hr ) all the time till the boiler is shut down
On further reduction of firing rate in the above manner at one stage the boiler will be running only with oil guns
BOILER IS COOLED
Internally Externally By Radiation
NATURAL COOLING
On tripping of the boiler bring the drum level to very high level and stop feeding After purging stop F.D.and I.D.fans All the dampers in air and flue gas path remain in open position Start up vent in open position Internal cooling takes place due to circulation of water inside tubes Top up water in drum when the level recedes
NATURAL COOLING
External cooling takes place by the air flow due to natural draught effect which is at a slow rate Also cooled by radiation When the pressure drops to 5kg/cm2 open the S.H.,R.H. vents When the pressure drops to 2kg/cm2 open the drum vents Natural cooling will take more time
FORCED COOLING
On tripping of the boiler bring the drum level to very high level and stop feeding After purging do not stop F.D.and I.D.fans Adjust air flow according to the cooling rate desired Ensure the saturated steam temperature drop is not more than 830C per hour
FORCED COOLING
Start up vent in open position Internal cooling takes place due to circulation of water inside tubes Top up water in drum when the level recedes External cooling takes place by the air flow at a faster rate according to air flow rate Also cooled by radiation
FORCED COOLING
When the pressure drops to 5kg/cm2 open the S.H.,R.H.vents When the pressure drops to 2kg/cm2 open the drum vents Boiler will be cooled at a faster rate in forced cooling Not healthy for boiler as it induces stresses in boiler tubes Used only in emergencies
BOX UP
On tripping of the boiler bring the drum level to very high level and stop feeding After purging stop F.D.and I.D.fans Keep all the vents and drains including start up vent in closed condition
As such there will not be any circulation and so no internal cooling
Keep all dampers in air and flue gas path in closed condition
As such there will not be any air flow through boiler and so no external cooling
BOX UP
Cooling can be only through radiation Heat inside the boiler can be retained for more time Adopted for keeping the boiler ready for hot start up on shut down