WELCOME

PRESENTATION
ON
BOILERS &
AUXILIARIES
P M G V SRINIVAS
SUPDT (Operation)

STAGE # 1 BOILER
DRUM

BURNERS

DOWN COMERS

LFO

WATER WALL

HFO

ECONOMIZER

COAL

SUPER HEARTER
PRIMARY SH
PLATEN SH
PENDENT SH
REHEATER

Boiler Auxiliaries

ID FAN
FD FAN
APH
MILLS & LUB OIL PUMPS
PA FANS & FLOP
FEEDERS
COC
SEAL AIR FAN
SCANNER AIR FAN
LPDOSING PUMPS
HP DOSING PUMPS
ESP

SCAPH
BOTTOM ASH HOPPER
CLINKER GRINDERS
SOOT BLOWERS
WATER WALL (24)
LRSB (8)
APH (4)

POWER PLANT SCHEMES

WATER AND STEAM CIRCUIT
AIR AND FLUE GAS CIRCUIT
FUEL CIRCUIT
COOLING WATER CIRCUIT
ASH WATER CIRCUIT

MS TO HPT

HRH TO IPT

DRUM
ECONOMISER

PLATEN SH1

PRI. SH
ECONOMISER

CRH FROM
HPT

BOILER DRUM AND CONNECTIONS

Designed Pressure

182 Ksc

Designed temperature

3560C

Length

21344 MM.

Thickness

110 MM.

Material

AM6O

situated at 46.4 MT elevation

NO.
1
2.
3.

SET PR.
l82Ksc
l84Ksc
l86Ksc

RELIEVING CAPACITY
148.3T/H
149.1T/H
212.1T/H

FD FAN

Volume Flow Rate at MCR 96.5 NM3/Sec.

Total PR. (MMWC)
675
Fan Efficiency %
78.7
Motor Rating KW
1400
Rated Speed RPM
740
Type of Coupling
CLAW
Type of Bearing
Sleeve Oil
Method of Lubrication
Ring

REGULAR CHEKS:
1) Oil levels of all bearings.
2) Cooling water flow to the bearing jackets.
3) Air supply to IGV, discharge damper,
tempering air damper.
4) Pressurised air leakage if any.
5) Oil leakages from bearings.
6) Abnormal sound from fan, motor and bearings.
7) Motor hot air temp. & earth strip connection

CHECKS BEFORE START:

1) Emergency Push Button (EPB) should be in
released condition.
2) IGV should be in closed condition.
3) Discharge damper should be in closed condition.
4) Bearings Temperatures should be normal.
5) All man holes in the air duct should be in closed
condition.
EMERGENCY
When any FD fan trips the closure of the discharge
damper of tripped fan should be ensured at local.

INDUCED DRAFT FAN

Volume flow rate (NM3/Sec.)

107.5

Total PR. (MMWC)

210

Fan Efficiency %

78.5

Motor Rating KW

1200

Rated Speed RPM

720

Type of Coupling
Type of Bearing

CLAW
Sleeve Oil

REGULAR CHECKS:
1) Oil levels of all bearings.
2) Cooling water flow to the bearing jackets and
oil cooler.
3) Scoop oil temp. & pr. (normal values are 400C & 0.4 ksc)
4) Flue gas leakage if any.
5) Oil leakages from bearings.
6) Abnormal sound from fan, motor and bearings.
7) Motor hot air temp. & earth strip connection

CHECKS BEFORE START:

1)
2)
3)
4)

EPB should be in released condition.

IGV should be in minimum position.
Scoop oil temp. & pr. should be adequate.
All man holes in the flue gas duct should be in
closed condition.

3.4 EMERGENCY
When any ID fan trips corresponding FD fan also
trips, hence closure of discharge damper of
tripped FD fan is to be ensured at local.

COAL MILLS
REGULAR CHECKS:
- Lighting & cleanliness in surroundings.
- Loading system oil & Gas pressures, multipliers
plunger position. loading oil tank level, loading oil
pump healthiness loading cylinder oil leakages,
loading cylinders cotter pins position. nitrogen gas
cylinders position.
- Lube oil pressure before and after filter. oil
leakages. gearbox oil level & quality.
-PF leakages if any from mill body, seal, salient
blocks, classifier, PF v/vs, PF pipes etc.
- Hot air leakages if any. from PA inlet duct inspection
doors, expansion bellow, mill inspection doors and
reject chutes.
-

Abnormal sound from mill, gearbox, motor if any.

Mill seal air damper position, seal air differential pressures.
Lube oil coolers water & oil leakages.
Checking the readiness of the standby mill

NORMAL OPERATIONS:
1.Loading system pressurisation when gas pressure is low.
Ensure close position of other mills regulator valves.
Open manual isolating v/v of Nitrogen cyl. discharge line.
- Open regulator v/v then open precharge v/v.
- Ensure pressure gauges v/vs open position.
- Ensure open position of v/v to cylinders.
- Open Nitrogen v/v to cylinder slowly and keep a precharge
gas pressure of 40 Ksc for a few minutes so that nitrogen gas
pressure is maintained around 36 ksc.
- Close Nitrogen cyl. outlet v/v and discharge line manual v/v.
- Close precharge v/v and regulator v/v.
- Pressurise the loading oil system by pumping the loading oil
pump to maintain a pressure of 7 ksc more than gas pressure.

If Multiplier plunger is out, operated loading oil pump to

push the plunger in
2. Supervision of reject gates operation and rejects
3. removal once in an hour.
3. Lube oil filter changing over on as per requirement
(when after filter pressure is low or before filter
pressure is high) with concurrence from UCB.
4. Making standby mill ready
- Ensure boxing up of Mill.
- Check Reject Gate operation and close reject
chambers doors.
- Ensure loading gas pressure of 36 ksc and oil
pressure of 43 ksc.

- Mill oil coolers water lines should be in charged

condition.
- Open seal air valves.
- Ensure C&I whether the connections are through
or not.
- Ensure Healthiness of all gauges.
- Release EPB of mill & LOP and inform UCB.
5.
Doing local run of mill when required.
6.
Giving necessary feed backs to the UCB engineer
when mill is taken in to service (Like PF valves position,
lube oil pressures, abnormal sounds, PF/air leakages,
reject passage healthiness etc).

START / STOP FROM UCB.

1.For taking milling system into service.
- Take oil support in associated burners (HFO/LFO)
- Start PA fan and load it to 40 t/h.
- Raise the mill outlet temperature to 800 C (by
regulating CAD/HAD position).
- Start Mill.
- Start feeder and load it upto 15 t/h with
corresponding increase in PA flow (PA flow = 21+coal
flow in t/h).
- Cut out oil gun pairs one by one after establishing
PF auto indication and flame scanner readings are
O.K.
- Mill loading can be raised to required value with
corresponding raise in air flow

FOR STOPPING THE MILL

Reduce feeder speed to minimum gradually, with a
corresponding reduction in air flow in mill.
Keep the mill outlet temp. setting to slightly lower
value than normal.
Ensure healthiness of flame scanner readings in
other mills.
Stop feeder and maintain an air flow of 40 t/h. Allow
the mill to get empty which is indicated by reduction in
mill current and mill outlet temperature rise. Stop mill
after reducing air flow to minimum.
Stop PA fan and keep PF valves closed.
Close isolating damper of PA fan (if neccessary)
only after fan comes to stand still.

SAFETY:
- Fire fighting equipment readiness is to be checked
and ensured before permitting any gas cutting or welding
work.
- If smoke is observed from reject chamber, clear the
reject passages immediately to avoid fire.
- Oil/PF/hot air leakages are to be arrested on priority
as these may pose fire hazard & pollute the area.
- Coal accumulated (reject coal mill local run coal etc.)
near mill should be transported to identified place.
- All safety precautions to be taken before doing local
run of mill to avoid accidents.
- personal protection equipment (helmet, safety shoes
dust mask etc.) are to be used religiously by all personnel
working in mills area.

EMERGENCIES:
Abnormal sound from mill /gear box Stop the milling
system and get it attended.
Both reject passages chocked Stop the milling system
and get the reject passages cleared (if there is no fire or
any other abnormality, mill can be run for a few hours with
both reject passages chocked)
Reject passage fire
Keep the reject gate and door open for a few minutes to
flush out clinkers from passage. If fire is not getting off,
milling system is to be stopped and reject passage to be
cleared.
Fire inside running mill - Reduce or cut off the air flow to
mill and dump the mill with coal by increasing the feeder
speed.
Loading system pressures not maintaining due to
leakages

PA FAN

Type of PA fan

: Radial Flow, centrifugal type

Motor

: 6.6 KV (HT) - 400 KW

Shaft speed

: 1480 RPM

Design capacity

: 12.9 NM3 /SEC

Volume flow Rate

: 10.3 NM3/SEC

Total pressure

: 1130 MMWC

Fan Efficiency

: 80%

REGULAR CHECKS:
1. Return oil flow from fan bearings.
2.

Cooling water flow to the bearing jackets.

3.

Hot air leakage from fan and duct.

4.

Oil leakage from the bearings.

5. Abnormal sound from motor, fan and bearings.

6.

Forced lub oil tank level.

7. Air Supply to IGV.

CHECKS BEFORE START:

1. EPB should be in released condition.
2. Mill PF valves should be in closed condition.
3. FLOP should be running and LOP dish pressure should
not be more than 1.0 KSC to avoid oil spillage from
bearings.
4. All bearings temperature should be normal.
5. All manholes in the hot air duct upto mill should be in
closed condition.

BO1TOM ASH HOPPER SPECIFICATIONS:

1) Hopper Capacity

: 160 tons

2) Hydro ejector capacity

: 60 T/HR.

3) Frequency of deashing

: 4 hrs.

4) Ash water ratio

: 1:4

5) Water pressure required

: 8 ksc

6) Bottom hopper flushing duration

: 40 Mm.

7) Cap. of BA HP pumps

: 600 M3 /hr at 7.5ksc

CLINKER GRINDER SPECIFICATIONS:

Capacity of grinder
60 T/HR
Speed of grinder
55 RPM
Dia of roller
318 MM
No. of grinders
4 Nos.
Type of grinders
Double roller
Weight of grinder
170 kgs.
Seal water quantity
2 M3 /hr/grinder
Clinker grinder motor rating
7.5 KW
Fuse rating
32 Amps
Power supply source
Boiler MCC
Clinker grinders A&C Module No.
R5.3 & R 5.4
Clinker grinder B&D Module No.
F11.3 & F 9.4

BOTTOM ASHING PROCEDURE:

1) Open the line discharge valves of corresponding
grinders (AD or BC)
2)
Open corresponding ejector HP water valves.
3)
Get the bottom ash HP pump started from UCB.
4)
Check the water pressure (Normally 7/8 Ksc.)
5)
Fill the hydro-pneumatic tank with water.
6)
Check the control air pressure is normal and
charge the hydro- pneumatic tank by opening air valve.
7)Start the clinker grinders.
8)Open hopper gate fully by opening water valve at
hydro tank outlet.
9)
Check the pressure in discharge line located
after disch. Valve.
10)
To ensure ash evacuation open the sample valve
which is located in disch. Line (Mixture of ash and
water should come.)

11) Monitor evacuation of ash by viewing through side, front

& rear view glasses.
12)
When hopper is empty air suction takes from grinder
overflow line. Then open hopper flushing valves in pairs
starting from top to bottom (one in each pair).
13). Ensure that no accumulation of ash on hopper slope
portion by viewing through view glasses. After ensuring
hopper is clear stop the flushing.
14)
Close both hopper gates by changing the air valve
position
15) Open grinder flushing valve and wait for overflow to come
from overflow line, then close and stop both grinders.
16)Open both hopper filling valves and close both ejector
valves.
17) Close the filling valves after ensuring overflow hopper
overflow line (Note Before closing filling valve keep open
atleast one ejector valve
18)Inform to UCB about the bottom ashing details.

ROUTINE CHECKS:
1) Ensure both ash hoppers with full of water (slight
overflow should always come from over flow line.)
2) Seal trough level to be ensured by ensuring over
flow from seal trough over flow line.
3) Ensure all 4 hopper gates are in closed condition.
4) Ensure correct oil level of CG fluid coupling .
5) Monitor bottom ash pit level. If level is more
dewatering to be done.
6) Keep refractory cooling water crack open to avoid
over heating.
7) Ensure adequate lighting at bottom ash hopper
area.

ELECTROSTATIC PRECIPITATOR
FUNCTION OF DIFFERENT AUXILIARIES:
GD SCREEN : It is a perforated steel plate for uniform gas
distribution across the ESP.
HOPPER HEATER : To prevent any dampening of the ash
inside the hopper.
COLLECTOR RAPPER : To dislodge ash accumulated on
the collector plates.
EMITTER RAPPER : To dislodge ash accumulated on the
emitters.

AIR FLUSHING FAN :

1. To supply warm air to heat the insulator and prevent
possible condensation to avoid flash over and
consequent damage to the insulators.
2. To supply air with light pressure inside insulator to
creat air barrier against the dirty gas crossing the
precipitator
AIR HEATERS :
To maintain temp of air coming from air flushing fan.
ROTARY FEEDERS :
As maximum ash collection is in the zero and 1st fields, hoppers
are provided with the rotary feeders. Ash is mixed with water and
through open channel sent to ash slurry pump house. Ash is fed
from hoppers by gravity / vibrator.

SPECIFICATIONS:
1.
2.
3.
4.
5.

Manufacturer
Flakt Italiana SPA
SP Collecting plate Area (SQ M2/M3/SEC)
147.68
Total power consumption
370 KW
Efficiency without anyone field in service 98.16%
Hopper storage capacity (Ash den. 750 /M3)
8/80/250/700
Hrs.
6. Ash collection rates with 4 fields in service
1 - 84%
2 - 10.5%
3 - 3.3%
4 - 1.2%

TAKING ESP INTO SERVICE :

1. Check that coal firing is started in the boiler and ash
handling system is taken into service.
2. Switch on heater for the shaft and support insulators.
Check up current drawn by heating elements from meters
on aux panel.
3. Ensure that LT switchgear is charged.
4. Rapping mechanism for emitting and collecting
electrodes is to be taken into service after starting ID fan.
5. The high voltage switch is to be put in 'ON' position.
6. Check that all interlocking keys are kept in normal
condition.

7.

Put LT main switch in 'ON' position.

8. Switch on the breaker in control cubicle.

9. Set the selector switch in manual position. The
manual control should be kept at minimum.
10. Switch on the rectifier unit by pressing start push
button on rectifier control cubicle.
11. Increase the manual setting gradually so that
working current is reached. Take care to see that
spark rate is min.
12. Voltmeter and ammeter should show steady
readings.
13. Put the selector switch on auto.

SHUTTING DOWN OF ESP :

1. Make sure that coal firing is stopped and boiler is
being shutdown.
2. Switch off high voltage for all rectifies.
3. Switch off LT motor main switch.
4. Put the high voltage disconnecting switch in 'OFF'
position.
5. Keep rapping, vibration and heating systems in
service for 12 hours.
6. After 12 hours switch off all the rapping motors and
heating elements

ROUTINE CHECKS:
ZERO METER LEVEL :
1. ESP and economiser hopper chockages.
2. Healthiness of rotary feeders.
3. HP/LP pressure.
4. Ash leakages.
5. Channels free of ash
6. Mixing chamber water overflow to be ensured
7. Carbon particles in ash scale.
8. Collector and emitter rapper healthiness.
9. Ash trench water nozzle healthiness

ESP CONTROL ROOM:

1.
2.
3.
4.

Air conditioner healthiness.

All fields primary and sec voltages and currents.
Chattering in any relay.
For all fields whether all rappers are starting and
stopping as per sequence or not.
5. No rapper motor should be continuously kept on or off.

ESP PASS ISOLATION

Close inlet and outlet dampers of the particular pass.
2. Switch off HT for all fields of the pass.
3. Keep aux in service till the PTW is issued.
4. Keep Outlet damper open by 10-15% along with 2-3
manholes for cooling the pass.
5. Keep step all auxiliaries.
6. Issue P&W after isolating electrical supplies and
cooling of ESP elements.

AIR PREHEATER
ROUTINE ACTIVITIES:

1.

2.
3.

4.
5.

6.

7.

8.
9.

Check the oil levels in the top & bottom bearings through the
guage glasses.
Checking coIling water supply to both bearings.
Check oil level in the drive gear box of main motor &
auxiliary motor.
Check the gas inlet, air outlet & air bypass dampers position.
Check whether air receiver is charged, drain the condensate
of air receiver & check the line up of solenoid valve for air
motor. The air pr. required is 6 Ksc.
Check the line up of APH Soot blowing steam either from
main steam or from aux. steam.
Follow up APH soot blowing &ensuring proper draining of
condensate from soot blowing steam circuit during blowing.
Check whether bearing temp. & vibration are normal.
Visual inspection of the air - preheater through view glass at
the bottom with the help of light inside.

EMERGENCY ACTIVITIES:
1. In case of air - preheater tripping ensure full closure of air
outler & gas inlet dampers.
2. In case of total power failure ensure starting of air motor. In
case air motor fails to operate, the air - heater is to be rotated
manually with the help of a handle.
3. In case of fire in the air - heater ensure full closure of air
outlet & gas inlet dampers. After stopping of ID & FD fans
send water through fire fighting line until the fire is
extinguished & rotor is cooled completely

SCANNER AIR BOOSTER FAN

START UP CHECKS:
1.
2.
3.
4.
5.

Both suction filters should be in charged

condition.
Fan suction damper is the open condition.
Fan discharge damper is in close condition.
Discharge damper air connection is through.
Emergency push button is in released condition.

 ROUTINE CHECKS:
1.
2.
3.
4.
5.
6.

Both suction filters are incharged condition.

Running fan discharge damper is in fully open
condition.
Standby fan EPB is in released condition.
Scanner fan discharge header pr. is normal.
Standby fan discharge damper is in closed
condition.
All individual scanners cooling air isolating valves
are in open condition

BURNER FRONT
200 MW boiler is a front fired boiler having 24 burner
assemblies i.e. 6 burner assemblies at 4 different elevations

Operation:
On clearance for Boiler light up, initially
igniters will be taken into service by giving
on command to oil guns at UCB. Sequence
of operations as follows.
1. steam purge v/v closes,
2. Guns insert,
3. Igniters insert,
4. Igniter v/vs open,
5. Initiation of spark by spark rods.

DESIGN VALUES
Calorific Values.
Coal
4300 Kcal/kg.
Oil
11000 Kcal/kg.
Maximum consumption.
Coal.
115T/hrs. (Good coal), 131T/hr (worst coal)
Capacity of oil guns:
HFO
LFO

0.5 kl/Gunhour. at 7 kg/cm2

0.8 kl/Gunhour.)

REGULAR CHECK UPS AND ROUTINE ACTIVITIES

- Check all air registers are open for running mills
- Check igniters and oil guns are in retracted position for
all running mills.
- Check steam purge valve open for all burners except for
oil guns which are in service.
- If any oil leakage observed close the individual valves
and inform to UCB.
- Check coal and steam leakages if any and inform UCB.
- Replace oil guns with cleaned oil guns as per schedule to
maintain free oil flow.
- Check availability of fire protection system located at
Burner floor.
- Ensure Good House keeping.
- Ensure pipe sampling points checking for coal pipe
chokage verification:

DOs & DONTs

Dos : Before operating any oil or steam valves it is to be
confirmed from UCB.
- Personal protection equipment should be used
while working at Burner front.
- Check regularly fire fighting Apparatus readiness.
Donts
- Do not allow gas cutting and welding without fire
fighting equipment availability.
- Do not allow any maintenance persons
without work permit

SEAL AIR FAN

STARTUP CHECKS:
1.
2.

Check that bearings of the fan are greased.

Check that oil level in the bearing sump is
normal.
3. Check that discharge damper is in closed
condition.
4. Check that discharge damper is in auto position
& air connection to the damper is through.
5. Check that stop push button of the fan is in
released condition

ROUTINE CHECKS:
1.
2.

Check the bearing oil level.

Check the bearing temperature of the fan & the
motor bearing.
3. Check for any abnormal sound in the fan or the
motor.
4. Check the discharge header pr. of seal air fan.
5. Check for any leakage in the discharge line of
seal air fan.

GRAVIMETRIC FEEDER
START UP CHECKS:
1. Check that oil level in the drive gear box of feeder &
clean out conveyor is normal.
2. Ensure that feeder is completely boxed up condition.
3. Ensure that bunker gate is fully opened condition.
4. Check that seal air valve to the feeder is in open
condition.
5. Check that feeder local / remote switch is in remote
position & clean out conveyor is on position.
6. Ensure that clean out conveyor shearpin is in intact
condition.
7. Ensure that feeder view glass is in clean condition.
8. Ensure that light provided inside feeder is available.

SOOT BLOWING SYSTEM

Group 1.

24 blowers

Water walls

Group 2.

8 blowers

Final RH

Group 3.

8 blowers

Final SH

Group 4.

12 blowers

Primary SH

Group 5

8 blowers

Primary RH

Group 6

12 blowers

Economiser

Group 7.

4 blowers

Air Preheater

 CHECKS AND PRECAUTIONS:

1. Ensure the steam flow from the drain at
zero meter before starting the soot
blowing
2. When blower does not retract UCB is to be
informed and blower is to be retracted
manually after ensuring supply isolation.
3. In case blower is jammed steam valve is to
be isolated.
4. After wall blowing ensure that all blowers
are retracted

CHEMICAL DOSING
WHY CHEMICAL DOSING IS REOUIRED?

The water used in boilers for steam generation is

deminaralised water, generated in DM plant.
Corrosion in boiler tubes is caused by
dissolved gases mainly O2 & CO2, these gases
can be absorbed by water any time through,
condenser tube leakages, feed water suction
leaks and from makeup water. Various salts
such as carbonates, sulphates and chlorides
of calcium and Magnesium can enter into the
steam and water cycle due to cooling water
leakage in the condenser, and cause scale
formation

LP DOSING
Hydrazine (N2H4) & Ammonia Solution will be pumped in
to the deaerator. After mechanical deaeration the left out
dissolved gases will be removed by adding hydrazine
solution in deaerator with LP dozing pump. The chemical
equation as follows.
N2H4 +O2 ------------ N2 +2H2O

DAILY ROUTINE CHECK UPS:

1) Check the pump gear box oil level ------------If level
is low inform to UCB
2) Check for any gland leakage -------------- If any gland
leak inform to UCB
3) Pump is not discharging ------------- Do the line flushing
with DM water to release line choke if any.
4) Check the pump shear pin is intact ----------- If not inform
to UCB.
5) Check for any abnormal sound from pump & motor ______ if any
abnormal sound is observed inform to UCB, stop the pump and
start spare pump if available.
6) If dosing tank level is low ---------------- Transfer chemical solution
from preparation tank to dosing tank.
7) If preparation tank level is low Inform to UCB, inturn UCB will
inform to DM plant for chemicals addition in preparation tank.

USAGE OF AUX. STEAM IN BOILER

& TURBINE

1.

To SCAPH

2.

To APH sootblowing

3.

To HFO atomisation

4.

To HFO tracing steam

5.

To Turbine pre-heating

6.

To Turbine Seal Steam

7.

To Ejectors

8.

To Deaerator Pre-heating & bleeding

ROUTINE ACTIVITIES AND CHECKS

1.
2.
3.
4.
5.
6.
7.
8.

Check for line up of APRDS steam side if it

is available.
Check for line up of spray water line.
Check for line up of oil lines for all sulzer
valves.
Check for all drain lines are isolated & no
passing of drain lines.
Check for any steam or water leakage.
Check for any oil leakage from the system.
Check for any passing of safety valves.
Check for line-up / isolation of aux. steam
supply to different auxiliaries as per
requirements.

ISOLATION OF APRDS STATION

1.

Isolate the first valve at main steam side

F001.

2.

Isolate manual valve F005 between APRDS

station & aux. steam header.

3.

Isolate spray water line manual valves.

4.

Open all drain lines in the APRDS station.

5.

Isolate oil lines in the control valves if

required.

CHARGING OF APRDS STATION :

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Check that all control valves & Movs in

APRDS station are in closed condition.
Crack open drain lines in APRDS station.
Crack open first isolating valve From main
steam line F00l.
Check for flow through drains & close all
drain lines.
Check for any leakages or abnormality, if
nothing Open fully FOOl valve.
Fully open F005 valve.
Open spray water isolating valves.
Open MOV F002 & manual valve after control
valve F550, if closed.
Check for line up of oil lines for all control
valves.
Check for supply in OSU & oil pump is
running