Power & Blowing Station

Boilers

SWARAJ ZODEY
Manager,
1

PBS Boilers
PRESENTATION MODULE
• Boiler Introduction
• Major Boiler Components
• Boiler startup procedure
• Important process description
• MFT details
• Targeted operation detail
• Routine operation
• Emergency identification & its handling
• Special instructions

2
INTRODUCTION
• M/S. Bhilai Steel Plant (BSP) expand its capacity from 4.0 MTPA to 7.0
MTPA, by adding one more Blast Furnace – 8.

• For critical power, air blast and process steam requirement of the 7.0 MT
stage, Power and Blowing Station expanded

• 3 X 150 TPH Gas fired Boilers

• 4 X 25 TPH CDCP Boilers
• 3 Nos. Steam Turbo-Blowers
• 1 X 25 MW Steam Turbo-Generator
• 1 X 14 MW TRT
3

• 1 X 4 MW BPTG
PURPOSE OF BOILER IN PBS
To provide the high pressure steam to

• 3 no. of Steam Turbo Blowers,

• 1 no. of 25 MW Steam Turbo Generator
• 15 ata and 12 ata Process steam.

4
DESIGN DATA FOR BOILER

Rated Capacity 150 tph

Steam Pressure 40 ata
Steam Temperature 450oC
Feed water Temperature 150oC
Boiler efficiency 89.4%
Exit flue gas Temperature 141oC

5
 COMBUSTION CONDITION
The boilers are designed for the following combinations (the ratios given are based on calorific values)

1. BF Gas – Upto100% MCR(Main Fuel)

with supplementary fuel (If required)
2. BOF Gas – Upto 50% MCR (Main Fuel)
3. BF Gas + BOF Gas – Upto 100% MCR (Main Fuel)
4. LDO – Upto 50% MCR (Supplementary Fuel)
5. COG – Upto 30%MCR (Supplementary fuel)
6. PCM – Upto 30%MCR (Supplementary fuel)
7. Combination Fuel (BF Gas +BOF Gas +CO Gas /LDO/PCM) - Upto 100% MCR

Note - Any point of time only one oil (LDO/PCM) will be fired

For boiler lightup and start up: LDO/COG

Boiler ignition device

HT spark and high frequency automatic high-energy electronic ignition devices are provided for LDO and COG burners.
6
BOILER EQUIPMENTS
ID fan 2 no.
FD fan 2 no.
HP dosing Pump 2 no. (1w/1s)
Agitators 2 no.
Dosing tank 1 no.
DM Buffer tank 1 no.
CBD tank 1 no.
IBD tank 1 no.
BFP 4 no. (2w/2s)
 WATER/STEAM FLOW DIAGRAM
Inlet Header
Drum LT Superheater
Recirculation line Outlet Header
Outlet Header

Upper Economizer De-superheater

Inlet Header
Water wall panel
Water wall panel
Water wall panel
Water wall panel
Water wall panel
Water wall panel
Water wall panel
Water wall panel
Center panel
Inlet Header

Evaporator
Outlet Header
HT Superheater
Lower Economizer
Outlet Header
Inlet Header

100% FWL
100% FWL Down comer
30% FWL Spray Water
Steam Collector
25% FWL
 AIR/FLUE GAS TEMPERATURE
REGIME Air Filter
1359 C (100 MCR)
o

1299oC (80 MCR) 355oC /

1250oC (60 MCR) 319oC /
285oC 30oC /
Boiler Furnace 30oC /
30oC
886oC /
FD fan
1299oC /
1250oC
Lower
280 C /
o Economizer 141oC /
263oC / 133oC /
238oC 123oC ID fan
Upper Lower
379oC / TAPH
353oC /
TAPH 182oC /
173oC /
314oC
162oC
867.7oC / 778.8oC / 141oC / Chimney
808oC / 722oC /
614oC / Upper 133oC /
570oC / 141oC /
738oC 660oC
382oC
Economizer 123oC
133oC /
123oC ID fan

30oC /
30oC /
30oC
Air Filter

HT LT Evaporator
Superheater Superheater
FD fan
 STEAM DRUM

Steam available in drum

above high water level
V= 10.64 m3
Internal Diameter 1600 mm
Drum Centre line Drum thickness 46 mm
High Water Level 25 mm Drum Length 11344 mm
Drum Material SA516 Gr.70
V3 = 9.77 m3 75 mm
Normal Water Level Geometrical volume 20.41 m3
V2 = 8.54 m3
Low Water Level
75 mm

V1 = 7.34 m3

10
 BOILER START UP CURVES
40

30

Pressure
(kg/cm2}
20

10

0
0 18 36 54 72 90
11 Time (mins)
 MAJOR ACTIVITIES TO START
BOILER
Open drum side vents
Open superheater
drains
Open recirculation
valve
Drum fill to lower level

Start second ID fan Start both FD fan Start one ID fan Start Scanner Air fan

Start furnace purge Start CO Gas purging CO gas U seal break Fire with CO gas

Open MSV @ Close drum side vents

Furnace temp 650 C
o BF gas line purging
10kg/cm2 @ 2kg/cm2

Boiler steam temp Boiler pressure slightly

BF gas U seal break Take BF gas in furnace
430oC + more than Header Prs

Close recirculation Close superheater

Charge attemperator Take Boiler in range
valve drains
 U- SEAL FILL & BREAK
13
PROCEDURE
 Seal Pot Vent
Seal Pot
Make up Seal Pot
water line Overflow
line
U-seal
Overflow
line
U-seal

Seal Pot
U-seal Make or
up water line Drip Pot

U-seal Drain
 SOP FOR BREAKING U-SEAL OF CO/BF GAS LINE
1. Ensure the manual bleeder after the COG/BFG U-seal is open.
2. Start steam purging between U seal and MOV and ensue steam is coming out
of the manual vent.
3. Start Purging in the COG/BFG line and ensure steam from vent lines of
COG/BFG.
4. Ensure drain valves of gas line to seal pot is open.
5. Ensure flow of make up water in the seal pots.
6. Ensure water is coming from overflow line of seal pots.
7. Remove the Blank plate fitted after the drain valve of U-seal.
8. Close the makeup water line manual valve.
9. Open the drain valve of the U-seal.
10. Close the Overflow manual valve.
11. Observe the discharge of the vent line, as soon as gas start coming along with
steam from the vent, close the manual vent valve.
12. Stop the steam purging between U-seal and MOV.
13. Line will be charge up to MOV.
 U-SEAL BREAK PROCEDURE

Detail:
Remove
Close
Open Purging
the
theblank
Drain
make
Purge
after
steam
up
valve
Steam
water
drain
ofvalve
valve
U-Seal
valve
valve.
and
and
manual
and
then overflow
Ventvent
valve.
valve
after U-Seal
valve of U-Seal.
SOP FOR FILLING U SEAL

1. Ensure gas line MOV is closed.

2. Ensure the overflow valve is open.
3. Close the seal drain valves.
4. Open incoming water line to U seal.
5. When water start coming from overflow line, adjust the water for
minimum continuous flow.
6. Open the steam purging SOV between U seal and MOV and then
open manual bleeder between U seal and COG MOV.
7. When pure steam is visible from the manual bleeder close purging
steam SOV.
8. Keep manual bleeder open.
 U-SEAL FILLING PROCEDURE

Detail:
Optionthe
Close
Open Overflow
the
to put
purging
manual
U-seal
steam
Drainvalve
valve
steam.
purging
vent
blank and
valve.
after
valve
Makeup
after
drain
water
the
valve,
filling
valve.
depend
of U-seal
on
by water.
lead time of next
fire
 PURGING & FIRING METHOD
19
FIRING BY COG

Guillotine Damper

MOV FCV
Trip
Valve

Gas U-seal

Boiler
Furnace

Detail:
TV CRV

Close
Open
Insert
Charge
Remove
Break the
thePilot
Guillotine
igniter
Start Purging COrod of
U-seal
valve
damper
and
gas and
fire
line
Blanking
Gas line byRetract
the
and Boiler Pilot Valve

the
stop igniter
purging
draining rod
the water
system
filled in U-seal
 COG Burner Detail
On DCS On Field or Inside Boiler

Igniter Rod Advance

Gas Gun Advance

Spark Command

COG Pilot Valve Open COG Corner Trip

Valve
Scanner Flame Detected
Flame Scanner
COG Corner Valves Opened
Pilot Valve/ Gun
Igniter Rod Retracted Igniter Rod

Gas Gun Retract Command

Corner Burner
EXPLODED
VIEW OF BF CORNER A CORNER
GAS LINE TO D
BOILER CRV

CTV
CORNER B CORNER
C

Guillotine MOV TV FCV

U-seal Damper
BF GAS
CHARGING IN
FURNACE Guillotine Damper

MOV FCV
Trip
Valve

Gas U-seal

EL. 6

Detail: EL. 4

Wait for
Break
Open
Start
Charge Purging
Guillotine
the
theUBF– seal
gas EL. 3

of Gas
damper
line
temperature
andline
stopbyof TV CRV

draining system
purging
furnace to
the650
water
o
C EL. 2

filled in U-seal Boiler

Furnace
Master Fuel Trip
Master fuel trip (MFT) is the core content of the boiler safety protection, FSSS system is the most important safety
feature. MFT action, quick cutting off all fuel into the furnace, which cut off all Gases and Oil input to ensure the
safety of the boiler to prevent accidents or limit the further expansion of the accident.

Action occurred by it
• Close of LDO/PCM Trip valve and all Oil Nozzle Valves, thus cutting off total oil supply.
• It also ensures the closure of COG/BFG gas trip valves and Corner valves

Master fuel trip occurs due to

• Both ID fans are off
• Both FD fans are off
• Instrument air pressure low low
• Drum level high high for more than 10 seconds
• Drum level low low for more than 10 seconds
• Furnace pressure high high
• Furnace pressure low low
• Loss
24 of all fuel supply
• Unit flame failure
• Air flow <30%
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure
HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure
HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure
HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure
HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure
HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure HH

Loss of all fuels Furnace Pressure HH

Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Master Fuel Trip
Elevation 1 Elevation 3 Elevation 5 Instrument Air
ID fan – A stop
&
ID fan – B stop Elevation 2 Elevation 4 Elevation 6
Air flow < 30%
Unit Flame Failure
FD fan – A stop
&
FD fan – B stop
Furnace Pressure LL

MFT Furnace Pressure LL

Drum Level HH 2/3
Furnace Pressure LL
Drum Level HH
2/3
Drum Level HH Furnace Pressure HH
Furnace Pressure
Loss of all fuels HH
Drum Level LL 2/3
Elevation 1 Elevation 3 Elevation 5 Furnace Pressure HH
Drum Level LL
2/3 Elevation 2 Elevation 4 Elevation 6
Drum Level LL
Primary Goal of DCS operator
By following the all safety norms for man and machine, maintain the main
steam collector pressure between

36 – 37 kg/cm 2

37
DCS operator monitor and maintain
Monitor and maintain some important parameters

 Steam temperature, pressure and flow.

 Furnace Oxygen, temperature and draft.
 Feed water pressure, flow and temperature
 Drum level
 Attemperator water flow
 Fuel flow and pressure
 Instrument air pressure, scanner air pressure and purge steam pressure.

38
Operator action perform
Major actions perform by operator during normal operation

 Regulating the gas flow

 4 regulating valves of CO gas
 12 regulating valves of BF gas
 Furnace draft and oxygen
 24 corner air dampers
 2 ID fan inlet air dampers
 2 FD fan inlet air dampers

39
Operator routine job & special tasks
Important routine jobs performed

 Gas line inspection

 Boiler proper inspection
 ID/FD fan inspection

Special task performed

 HP dosing in Boiler
 IBD to the boiler
 LDO system control and monitor
40

 LDO unloading process

Operator schedule job
 Compressed Air system inspection
 LDO line checking & tank inspection
 Fire Fighting system line check of Boiler
 SWAS Panel inspection for Boiler
 Purging line change over job of Boiler
 HP dosing pump oil top up and change over job
 Feed water line change over job of Boiler
 Full PBD of Boiler
 Attemperator line change over job of Boiler
 Seal pot flushing of gas line of Boiler
 Soot blowing of Boiler
 Heating Surface Area inspection of Boiler
 ID/FD fan greasing job of Boiler
 Gauge glass flushing of Boiler
 CEMS inspection of Boiler
41
POSITIVE

ROUTINE OPERATION
42

NEGATIVE
 Critical Parameter
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
43 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
Main Steam Pressure Vs Header Pressure

Boiler Under load Boiler in stable mode Boiler Over load

36 – 37 kg/cm2
 Boiler Under load
Action perform:
• Increase the Gas Flow

Alert for:
Collector 1 Pressure
DRUM FURNACE
OXYGEN Collector 2 Pressure
LEVEL DRAFT
45

36 – 37 kg/cm2
Reason
• Gas Pressure may dropped
• Turbine load may increased
• Process steam demand may increased
• Any Boiler may reduce load tripped
 Boiler Over load
Action perform:
• Reduce the Gas Flow

Alert for:
Collector 1 Pressure
DRUM FURNACE
OXYGEN Collector 2 Pressure
LEVEL
46
DRAFT

36 – 37 kg/cm2
Reason
• Gas Pressure may increased
• Process steam demand may reduced
•Turbine may tripped or demand dropped
• Any Boiler may taken in range
 Boiler performer
In the month of December 2020 to January 2021
A performance report prepared through out the shift.

Mr. Kamal Sirmor perform 88% best operation to maintain the Header pressure
between 36-37.5 kg/cm2.

Worst
47 performance observed 13%
 EMERGENCY IDENTIFICATION
48
& ITS HANDLING
 ID Fan Trip
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
49 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – One ID fan trip
Step 1: Reduce the BF gas
Step 2: Reduce ID fan load & both FD fans load
Step 3: Reduce CO gas to maintain the Oxygen %
Step 4: Inform to Shift In-charge or Station Engineer
Step 5: Restrict the Boiler load approx. 85 tph
Step 6: Identify the cause
 Action Plans – Both ID fan trip
MFT initiated automatically and both FD fan stop
Step 1: Check BF & CO gas MOV start closing
Step 2: Close the CO gas and BF gas trip valve
Step 3: Close MSSV of Boiler. Open Start up vent
Step 4: Manually operate feed water line to control drum level
Instruction: Do not open Man hole of boiler
Step 5: Inform to Shift In-charge or Station Engineer
Step 6: Identify the cause
 FD fan Trip
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
52 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – One FD fan trip
Step 1: Reduce one FD fan load & both ID fan load to maintain furnace
pressure
Step 2: Reduce CO gas immediately
Step 3: Reduce BF gas with maintaining furnace pressure
Step 3: Inform to Shift In-charge or Station Engineer
Step 4: Restrict the Boiler load 85 tph
Step 6: Identify the cause
 Action Plans – Both FD fan trip
MFT initiated automatically
Step 1: Check MOV start closing
Step 2: Close the CO gas and BF gas trip valve
Step 3: Stop one ID fan
Step 4: Close MSSV of Boiler. Open Start up vent
Step 5: Manually operate feed water line to control drum level
Step 6: Inform to Shift In-charge or Station Engineer
Step 7: Identify the cause
 Scanner Air fan Trip
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
55 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – Scanner Air fan trip
If DC scanner air fan also not start.
Step 1: Try to start DC scanner air fan manually from DCS
Even it not start
Step 2: Move furnace draft to negative side
Step 3: Immediately open the service air line manual valve continuously
coordinating with DCS operator to maintain pressure of 450 mmWC – 550
mmWC.
Step 4: Once it achieve, again maintain the furnace pressure
Step 5: Inform to shift In-charge; Coordinate with Eletrical Shift incharge
Step 6: Inspection team check the burner scanners
Step 7: Identify the cause
 BFP Trip
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
57 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – One BFP trip
If BFP in auto mode not start than One BFP in operation
Step 1: Reduce total load of Boiler – 7, 8 & 9 to 250 tph.
Step 2: Monitor Feed line pressure should not reduce to 62 kg/cm2
Step 3: Inform to Shift In-charge or Station Engineer
Step 4: Identify the cause
 Action Plans – Both BFP trip
No signal of Feed water line pressure increase and drum level continuously
falling.
Water level not seen in gauge glass
Step 1: Close Trip valve of both CO gas & BF gas.
Step 2: Close MSSV of Boiler
Step 3: Inform to Shift In-charge or Station Engineer
Step 4: Start Boiler inspection

Progressively go in shut down procedure of Boiler

 LDO pump trip
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
60 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – LDO pump trip
Do not start another LDO pump
Step 1: Click Stop button of all running burners.
Wait till purge completed
Step 2: Clearance from shift in-charge, start another pump
Step 3: Fire the LDO burner as per SOP
Step 4: Identify the cause
 BF Gas MOV trip or Trip Valve Close
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
62 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – BFG MOV or TV close
Step 1: Immediately maintain the furnace pressure.
Step 2: Reduce the load to approx. 45 tph
Step 3: Try to maintain the Steam temperature
Steam temperature should not go below 400oC
Case 1: Identify the issue, if resolved than purge the BF gas line after MOV
and take BF gas in Boiler
Case 2: If issue not resolved and temperature maintained than continuously
run the boiler.
Case 3: If issue not resolved and temperature still in falling trend below
400oC, immediately close MSSV and open start up vent and wait for further
instruction from Shift In-charge.
 CO Gas MOV trip or Trip Valve
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
64 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – COG MOV or TV close
Step 1: Furnace temperature should more than 650oC

Case 1: If issue resolved, Purge the CO gas line after MOV and take CO gas
in furnace.
Case 2: If issue not resolved than shut down the boiler as per SOP.
 MSV or Header Valve Trip
Drum Drum Condensa BF gas CO gas
LDO Flow
Level Pressure te Flow Flow Flow

Steam Steam Steam BF gas CO gas LDO

Flow Temp Pressure Pressure Pressure Pressure

Feed Feed
Instrument
Water Water FD fan A
CBD Flow Collector Pressure rate change Oxygen Air
Header 1 Header 1 Air Flow
Kg/cm2/min Pressure
Flow Pressure
Feed Feed
Purge Collector 1 Pressure Scanner
Water Water Furnace FD fan B
66 Steam Air
Header 2 Header 2 Collector 2 Pressure Pressure Air Flow
Pressure Pressure
Flow Pressure
 Action Plans – MSV closed
Step 1: Close the Trip valve of BF gas
Step 2: Manage the furnace draft
Step 3: Open the warm up vent
Step 4: Reduce the CO gas to 3000 Nm3/hr immediately
Step 5: Manage Air flow
Step 6: Manually operate the feed water system
Step 7: Inform to shift In-charge or station engineer.
Step 8: Identify the cause
 Action Plans – Low BF pressure
Pressure of BF gas at 335 mmWC
Step 1: Avoid increase the BF gas flow
Step 2: Try to increase the CO gas flow
Step 3: If steam pressure not maintain than inform to shift in charge or
station engineer.

Monitor BF gas pressure should not go below 335 mmWC.

 Action Plans – Low CO pressure
Pressure of CO gas at 190 mmWC
Step 1: Avoid increase the CO gas flow
Step 2: Try to increase the BF gas flow
Step 3: If steam pressure not maintain than inform to shift in charge or
station engineer.

Monitor CO gas pressure should not go below 190 mmWC

 Special Instruction
• Use PPEs when you are on field.
• During routine shift start inspection, at least two person go to field.
• In case, gas found more than 500 ppm, try to immediately left that field
area and inform to shift in-charge.
THANK YOU
 MAJOR ACTIVITIES TO BOILER SHUTDOWN
Close the Charge the purging Close Trip valve of BF
Reduce the Boiler load
Attemporator valve system gas

Close Trip valve of

Close MSV Close MOV of COG Close MOV of BF gas
COG

Close both header Open recirculation

Open Warm up vent Start Gas line purging valve
valve of Steam

Close manual valve of Drum temperature Open superheater

Open drum side vents
Feed water line <100oC drains

Stop one ID and FD Drum temperature < Open Manhole of

fan 70oC Stop ID & FD fan
Boiler

Close recirculation Close superheater

Charge attemperator Take Boiler in range
valve drains