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BOILER OPERATION

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

Cold start Hot start


CARE DURING NORMAL RUNNING

Load changes Routine checks


OPERATION UNDER ABNORMAL CONDITIONS SHUTDOWN PROCEDURES

To cold To hot stand by

BOILER COLD START


MAJOR ACTIVITIES Pre checks Boiler filling Starting draught system Charging steam to scaph Boiler purging Light up with oil (L.D.O.) Switching over to H.F.O.firing Raising the parameters Switching over to P.F. firing Loading the boiler

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.

PRE CHECKS FOR BOILER LIGHTUP

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

PRE CHECKS FOR BOILER LIGHTUP

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.

PRE CHECKS FOR BOILER LIGHTUP

PRE CHECKS FOR BOILER LIGHTUP


CHECK AND ENSURE THAT All de super heater spray control valves are in closed condition and available for service. Fire fighting system is ready. Adequate fuel oil quantity is stored. Raw coal bunkers are filled. D.M. water tank is filled.

PRE CHECKS FOR BOILER LIGHTUP


CHECK AND ENSURE THAT Bearing cooling water system is started. Compressed air from instrument air and service air compressors are available and air pressures are adequate.

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.

STARTING DRAUGHT SYSTEM


Lineup lub.oil system of all fans and air heaters and take them into service Lineup flue gas path Lineup air path Start air heater A Start air heater B Start one I.D. fan Start corresponding F.D. fan Raise load on I.D.&F.D. to maintain 30% of full load air flow through Boiler and necessary furnace draught Start scanner air fan Draught system ready for light up

STARTING DRAUGHT SYSTEM

LINE UP FLUEGAS PATH


Ensure all man hole doors are closed Ensure ESP hoppers are sealed Ensure sufficient flow through furnace water seal Establish power supply to all flue gas path dampers Establish power supply to all flue gas path instruments Close suction and discharge dampers of both I.D.fans Keep I.D.fan control devices in minimum position Keep open flue gas inlet and outlet dampers to both air heaters

LINEUP AIR PATH


Ensure all air path man hole doors are closed Establish power supply to all air path dampers Establish power supply to all air path instruments Close discharge dampers of both F.D.fans Keep F.D.fan control devices in minimum position Keep open sy.air inlet and outlet dampers to both air heaters

STARTING AIR HEATERS


Check support bearing and guide bearing lub. oil systems are in service. Check air and flue gas paths are lined up. Check air heater water wash lines are closed. Check service air supply to air heater is available. Establish electric supply to air heater motor. Start the motor. Observe whether motor current is normal. Observe for rubbing/abnormal noise at local. Open water inlet and outlet valves in lub. oil systems. Start second air heater as above

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

ON LIGHTUP WITH LIGHT OIL


Ensure adequate light oil / atomising air pressure Check boiler expansion is free Control firing rate in such away that steaming starts only after 45 minutes Keep economiser re circulation valve open When drum pressure reaches 2 kg/cm2close drum vents Control firing rate according to start up curve and FOT not exceeding 5400c Start closing S.H. vents and drains except start up vent Increase steam pressure Warm up main steam lines

HEAVY OIL FIRING


Ensure auxiliary steam lines are charged Ensure atomising steam lines are charged Ensure H.O.system is started through re circulation SCAPHcorresponding to F.D.in service is charged Open H.O. trip valve Ensure CD elevation permissives Start one pair of CD elevation guns Start second pair Ensure minimum 3 out of 4 corners are proven on Change over to H.O. firing in AB elevation

HEAVY OIL FIRING



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

FEED WATER FROM H.P.HEATER DRAIN DRAIN

TO ECO.

DRAIN

DRAIN

DRAIN

FEED REGULATING STATION

PREPARATION FOR COAL FIRING


Check boiler water quality Maintain boiler water pH through phosphate dozing Ensure silica level and TDS are in permissible levels Start scrapper conveyor and slag crusher Check E.S.P. rapping mechanism in service Start one P.A.fan Start seal air fan Keep S.H/R.H spray control system ready

STARTING COAL FIRING


Ensure mill ready permissives for mill A Make ignition energy availableto mill A Start mill A Open hot air gate Start R.C.feeder A Increase feeder speed gradually Maintain drum level Maintain furnace draught Switch on E.S.P.hopper heaters Control firing rate according to start up curve

STARTING COAL FIRING


Prepare for starting mill B when first mill is loaded to 50% Start mill B in same way as mill A Start R.C.feeder B and equalise loading in both feeders Control firing rate by reducing oil firing rate Change over to 100% F.C.V. when low load feed control valve is more than 80% open Increase air flow proportional to boiler load when load crosses 30% Control S.H. temp.by attemperation and R.H.temp.by burner tilting Gradually increase boiler load

WHEN BOILER LOAD APPROCHES 50%


Start second I.D.fan Equalise loading on both i.d.fans Start second F.D.fan Equalise loading on both F.D.fans Take SCAPH of second F.D.into service Ensure adequate wind box to furnace differential pressure is maintained Start second P.A.fan Equalise load on both P.A.fans

GOING TO FULL LOAD


Start third mill when first two mills are loaded to 80% Start third R.C.feeder Equalise loading on all three mills Start fourth mill when first three mills are loaded to 80% Start fourth R.C.feeder Equalise loading on all four mills Increase boiler loading to full load

ON NEARING FULL LOAD


Feed control valve can be put on auto S.H/R.H steam temp. control on auto Furnace draught control on auto E.S.P. fields are charged Oil firing can be stopped when boiler load is more than 6o% and more than two mills are in service at minimum 50% loading and atleast two adjacent mills are in service Steam to SCAPH s cut off when flue gas outlet temperature more than 1500c

ROUTINE CHECKS
Make a round of boiler to inspect Flame condition/ stability

Pressure parts for leakage


Leakage in air/flue gas paths Running auxiliaries for abnormal noise vibration,high bearing temp. etc. Maintain hourly log. Identify deviations and take corrective actions

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

Reversal of light up procedure

BOILER SHUT DOWN PROCEDURE

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

BOILER SHUT DOWN PROCEDURE


Maintain drum level and furnace draught Take oil support at the adjacent elevation to the top coal elevation in service Trip the top elevation R.C.feeder when its speed nears to minimum Share the load on other feeders Run the mill corresponding to the feeder tripped for some more time till it is cleared of coal Stop the mill and isolate it

BOILER SHUT DOWN PROCEDURE


Reduce load further by reducing speed of feeders, tripping the feeder after taking oil support etc. When the load drops below 50% stop one F.D.fan, one I.D.fan Ensure the tripped fans suction and discharge dampers are fully closed Reduce load further by reducing speed of feeders, tripping the feeder after taking oil support etc

BOILER SHUT DOWN PROCEDURE


When the load drops below 30%
Change over to low load feed control valve Ensure the wind box to furnace Diff. Pr. is changed to low set point Maintain air flow to the boiler at 30 to 40% of full load air flow on further reduction of load

On further reduction of firing rate in the above manner at one stage the boiler will be running only with oil guns

BOILER SHUT DOWN PROCEDURE


When the load drops below 10% trip the boiler through protection Ensure all the oil valves are fully closed Carry out boiler purging Do not stop the air heaters till the gas inlet temperature drops to 1000C Carry out cooling of the boiler on the method desired

COOLING THE BOILER ON SHUT DOWN


METHODS OF COOLING
NATURAL COOLING FORCED COOLING BOX UP

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

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