Boiler Preparations,

Start up,
Loading,
&
Withdrawl
Preetam singh
 Operati on Of Boilers
1. P r e s t a r t C h e c k s
2. S t a r t i n g o f A u x i l i a r i e s
3. B o i l e r L i g h t u p P r o c e d u r e
4. B o i l e r W a r m i n g u p P r o c e d u r e
5. W a t e r / S t e a m q u a l i t y & B l o w d o w n
6. L o a d i n g o f B o i l e r a s p e r R e q u i r e m e n t
7. S o o t b l o w i n g o f F u r n a c e & A i r H e a t e r
8. B o t t o m a s h , E c o n o m i s e r , A i r p r e h e a t e r & E S P a s h r e m o v a l
9. R o u t i n e O & M c h e c k s d u r i n g o p e r a t i o n o f B o i l e r
10. W i t h d r a w a l o f B o i l e r
11. S h u t t i n g o f A u x i l i a r i e s
12. O p e r a t i o n t o b e c a r r i e d o u t d u r i n g A C s u p p l y f a i l u r e
13. B e s t p r a c t i c e s a d o p t e d d u r i n g o p e r a t i o n o f B o i l e r
14. T r o u b l e s h o o t i n g & o t h e r O & M i s s u e s
15. E m e r g e n c i e s r e l a t e d t o B o i l e r O p e r a t i o n
 1.
Boiler Prestart Checks
 Boiler Start-Up PRE CHECK
1. Ensure all permits on boiler, air cycles A/H’s, flue gas
path, Air/Gas dampers, ESP, ECO. / Air heater hoppers
are cleared.
2. Ensure all manholes in Furnace / Air heater/ ESP & Air
cycles are properly closed.
3. Ensure no material is obstructing the normal expansion.
4. Ensure DM/GS water & both I/A & S/Air system is in
service.
5. Both Air cycle lubricating oil system is in service &
standby LOP’s are available.
6. Ensure B/ASH hoppers seal trough is charged &
overflow is maintained.
7. Ensure ESP path safety diaphragms / doors are close
& Gas dampers GD 5,6,7,8 are open
 Boiler Start-Up PRE
CHECK
8. ESP rapping motor mechanism is available & in
service / Bag Filter is Ready.
9. Make support & shaft insulators ON.
10.Ensure all required instrumentation is available &
ready.
11. Ensure both drum G/Glasses are available.
12.Establish communication between Boiler. Drum
level staff & PCR staff.
13.Ensure all isolating valves are open i.e.
phosphate dosing /CBD /EBD /Drum level
transmitter/ Pr. Gauges root valves/ Sampling
valves.
 Boiler Start-Up
Ensure the following conditions
• Boiler outlet valves MS 103/104 are closed &
drains are open.
• All Soot blowers are out & soot blower line is
isolated.
• Boiler vents (Drum, Eco. R/H, S/H, Start up) &
S/H drains are open.
• All ring header drains and main drain closed.
• All Feed station control valves trials are taken
& available.
• Boiler filling line from ELP is through. Both
DM101,102 valves are open.
 Boiler Start-Up
Ensure the following conditions
• Eco. Recirculation & inlet valve E2 is open.
• Ensure trial of Aux. Air dampers, coal dampers
are taken.
• Ensure Burner tilt trial is taken & is at Zero or
horizontal
• position.
• Ensure all flame scanners, HEA igniters are
cleaned & ready.
• LDO pump is ready on recirculation & all
Elevation guns are in position. Soot blower
operation.
 2.
Starting of Auxiliaries
 Boiler Auxiliaries
1 Air Pre Heater
2 ID Fan
3 FD Fan
4 PA F a n
5 Seal Air Fan
6 Igniter Air Fan
7 Scanner Air Fan
8 Soot Blower
9 Coal mill
10 Bottom Ash Disposal System
11 ESP
12 Bag Filter
13 Fly Ash Evacuation
14 Fly Ash Slurry Disposal
15 Slurry Pump
16 Clear Water & Boo ster Pump s (U-5)
17 Oil Handling Plant
18 Boiler Furnace Safe Guard & Supervisory System – FSSS
 3.
Boiler Light up Procedure
 Boiler Start-Up
1. Start boiler filling through ELP & fill up to normal
level i.e. 3 ports.
2. Start both A/H one by one & ensure top, bottom
LOP’s are in service.
3. Start one or both Air cycles one by one & adjust
furnace draft to – 10 mms of water column & Wind
box pr. to furnace Diff. Pr. To 20 mm of WC.
4. Keep total airflow slightly higher than 30% by
opening ID/FD IGV’s & put ID FANS on AUTO
control.
5. Start Scanner air fan & ignitor fan check its
dampers are open. Emergency (atmospheric)
damper should be closed. Check scanner air fan
discharge is maintained at 350 to 400 mms of wc.
 Boiler Start-Up
6. Furnace is to be purged as per FSSS logic
scheme by 5 min. timer in purge cycle.
7. Reset Boiler. Trip command.
8. Select light oil on control desk & maintain LDO
pr. At firing floor to 7/8 Kg/cm2 by adjusting pump
recirculation.
9. Give ON command to 1/3 or 2/4 oil guns. Start
push button & confirm the guns are proven & the
flame is bright & long from firing floor operator.
 4.
Boiler Warming up
Procedure
 Boiler Warmin g u p
10. Heat boiler slowly at the rate of 10 kg/cm2 in one

hour initially and 20 kg/cm2 afterwards after

closing the S/H vents at @ 2 kg/cm2.
11 . A s p e r r e c o m m e n d a t i o n s f r o m c h e m i s t b l o w d o w n
at 10/20/30 kg/cm2 shall be monitored after
k i l l i n g t h e f i r e o n l y a n d t h r o u g h r i n g h e a d e r.
12. Blow down in normal running condition is with out
fire killing.
14. At 35/40 kg/cm2 Boiler is ready to deliver steam
but we can’t ensure quality of steam and
hence b efo r e s e nd ing to Tur b ine q ua lity a n d
degree of super heat shall be maintained by
HP/LP bypass system.
 5.
Water/Steam quality
&
Blow down
B o i l e r W a t e r Q u a l i t y, S t e a m Q u a l i t y & B l o w d o w n

1. H e a d e r B l o w d o w n
2. C B D
3. C h e m i c a l D o s i n g
 6.
Loading of Boiler as per
Requirement
 Operation Of Boilers

• The load control range

• The steady regime of boiler operation

• The allowable boiler range

• The unsteady regime of boiler operation

 The Load Control Range

• The automatic control system of a boiler

responds quickly to the load without the

interference of the operating personnel.

• The lowest limit is from 40-50% of rated

load.. Smaller boilers not used for power

stations have much lower control range

 The Allowable Load Ranges

The allowable load ranges include loads

from limit of control range to the lowest

load at which the boiler can function steadily

The Unsteady Regime of Boiler Operation
• Load variation and fluctuation of steam
parameters occur due to internal or
external disturbances
• Internal disturbances are variations in
F l o w r a t e / Te m p e r a t u r e
• Fuel consumption rate
• Combustion air flow rate
 The Unsteady Regime of Boiler Operation

• External disturbances are variations in:

Steam pressure

• Load of the turbo-alternator

• The degree of opening of start-up and shut

down device.
 7.
Soot blowing of
Furnace
&
Air Heater
 8.
Bottom ash, Economiser,
Air preheater
&
ESP ash removal
 9.
Routine O&M checks
during
operation of Boiler
 10.
Withdrawal of Boiler
 11.
Shutting of Auxiliaries
 12.
Operation to be carried out
during
AC supply failure
 13.
Best practices adopted
during
operation of Boiler
 Factors Aff ecting Boiler
Performance
1. Pe r i o d i c a l c l e a n i n g o f b o i l e r s
2. Pe r i o d i c a l s o o t b l o w i n g
3. Pro p e r w a t e r t re a t m e n t p ro g r a m m e
a n d b l o w d o w n c o n t ro l
4. D r a ft c o n t ro l
5. E xc e s s a i r c o n t ro l
6. Pe rc e n t a g e l o a d i n g o f b o i l e r
7. S t e a m g e n e r a t i o n p re s s u re a n d
t e m p e r a t u re
8. B o i l e r i n s u l a t i o n
9. Q u a l i t y o f f u e l
Layout of a Pulverized Fuel Power Plant
December 25, 2024 PMI Revision 00 32
December 25, 2024 PMI Revision 00 33
BOILER DRUM DESCRIPTION

34
December 25, 2024 PMI Revision 00 35
36
37
38
39
WATER AND STEAM CIRCUIT

40
41
42
43
44
45
December 25, 2024 PMI Revision 00 46
December 25, 2024 PMI Revision 00 47
PERFORMANCE GUARANTEE TEST

OF

PULVERISERS (BOWL MILLS)

BOWL MILL
CONTENTS
• GRINDING PROCESS IN THE MILL
• GENERAL
• MILL PARAMETERS WHICH DETERMINE THE
PERFORMANCE
• EFFECT OF PARAMETERS
• MILL OPTIMISATION FOR
• UBC IN FA & BA DEPENDS ON
• MILL CAPACITY DEPENDS ON
 1.0 GRINDING PROCESS IN THE MILL

P.F. TO BOILER
RAW COAL

HEAVY
PARTICLES CLASSIFIER

P.F.+AIR
HOT AIR GRINDING ZONE
DRYING & GRINDING

REJECTS
 Boiler Auxiliaries

PATH
D
I/L VAN
D
I/ O/L
I/L BF O/L L
GD1 GD3 ID-A

A/H -A
GD1 GD1
0
367 C 0
147 C PATH C
IDB
C

GD
21
I/L O/L
ESP
FLUE GAS FROM COMBUSTION

11240C
10120C 7870C 7110C 4600C
PLATEN

REHEATER

UPPER BANK

ECONOMISER

CHIMNEY
HORI. S/H

HORI. S/H
S/H

CHIMNEY
FINAL

LOWER
BANK
S/H

PATH
CHAMBER

B
B
IDA
GD2 I/L ESP O/L
GD4

GD
22
A/H -B
GD1

3670C 1470C
BF I/ O/L
L
A I/L VAN
I/L O/L
PATH A

FLUE GAS PATH

KTPS/OP-II(U-6) /DRG-606
 Boiler Auxiliaries
SURAY LINES FROM BFP DIS

}
SHH -3L

SHH -5L

SHH -6L

DESU
DESU
SHH - 10

SHH - 13
SHH - 12
SHH - 9

SHH - 11
SHH - 4
SHH - 1

SHH - 8
SHH - 2

SHH - 7
SHH -3R

SHH -5R

SHH -6R
PLATEN
SUPER
HEATER

FOR SOOT BLOWING

TO SB 2

S
SAMPLE

SHH-14
CV
BP MS
S S MS 103 104 S S
COMBUS ION BP MS
MS 104
CHAMBER 103
S.60
S.61
S.62
S.67

S.64

AS 101 S MS 105A
S.70
TO PRDS
HORI. PASS
BOILER DRUM S.71 S.61 L/RETRACT
MS 105B UDT UDT
S
S.69

S.71

S.65
S.63

S MS 102 S S
S S MS 101
DRAIN HDR
MS 106B MS 106A
SECOND ESV ESV UDT
S B 62 PASS L/
UDT
FILLING LINE

RETRACT
FROM BLR

TO FLASH TANK
S B 63
C.B.D.

SB 22 S SB 23 MAIN STEAM FLOW

S
EXPR .

KTPS/OP-II(U-6) /DRG-608
DRAIN
TO
 Boiler Auxiliaries SURAY LINES FROM BFP DIS

}
5L
SH
H-
SHH-3L

SHH-6L

DESU
DESU
SHH - 10

SHH - 13
SHH - 12
SHH - 11
SHH - 9
SHH - 1

SHH - 8
SHH - 2

SHH - 7
SHH - 4
SHH-3R

SHH-6R
PLATEN
SUPER

5R
SH
HEATER

H-
FOR SOOT BLOWING
TO SB 2

S
SAMPLE

SHH-14
CV
BP MS
S S MS 103 104 S S
COMBUS ION BP MS
103 MS 104
CHAMBER
S.60
S.61
S.62
S.67

S.64
AS 101 S MS 105A
S.70
TO PRDS
HORI. PASS
BOILER DRUM S.71 S.61 MS 105B UDT UDT
S.69

S.71

S.65
S.63

L/RETRACT
S
S MS 102 S S
S S MS 101
DRAIN HDR
MS 106B MS 106A
FILLING LINE

SECOND
FROM BLR

ESV ESV UDT

S B 62 PASS L/
RETRACT UDT
TO FLASH TANK
C.B.D.

S B 63

MAIN STEAM FLOW

DRAIN
EXPR.

SB 22 S S SB 23
KTPS/OP-II(U-6) /DRG-608
TO
Boiler Auxiliaries
RHS R/H. SPRAY LHS R/H. RHS S/H. SPRAY LHS S/H.
TO TO
DESUPERHETER
R/H HDR. NO. 1
(AFTER SHH-10)

S84 S90
R39 R45 S81 S87

R38 S80 S83 S86 S89

R44

S82 S85 S88

R37 R43 S79

R-34 S74

MAIN FEED
LINE
BP S74
OPEN TO
ATMOSPHER

TO BLR
DRAIN
EXPANDER

SH AND RH SPRAY CONTROL

KTPS/OP-II(U-6) /DRG-609
 TO SEAL
TO SCAN. FAN 
To IGN. FAN
AIR FAN AD 22  

IGV
 
SUCT. FROM ATM. AD 14
AD 19 AD 16 PA-B
  

HOT AIR
DAMPER

AD 21  SCAPH 


GATE
AD 11 AD 9 AD 4
  FD-B
A

O/L
I/L D 
  AD 2
 

IGV
BF
BDP

A/H B
W/B  GD14
B

   GD10 ID FAN-
B GD 2 GD O/L
I/L B
4 GD18 
  ESP

CHIMNEY
C GD13 GD16 GD20
GD  GD  GD22
 
C
COAL MILLS

COMBUSTION
CHAMBER 6 9 O/L
I/L
  GD  B  GD15 GD19
5 ESP
1 
D

  GD GD12
DUCT

 GD O/L ID FAN- GD21

W/B GD 8 I/L
3 GD17 A
  B AD-1

IGV
BF
HOT AIR DUCT
AIR
E

  GD A GD11 
AD 3 FD-A
  7
SCAPH
A/H A

   AD-13
AD 10
COLD

AD 8

IGV

F

  AD 20 AD 15 
  PA-A
DAMPER

AD 18
COLD

GATE
AIR

TO SEAL
AIR FAN
AIR PATH AND FLUE GAS PATH
KTPS/OP-II(U-6) /DRG-605
The Direct Method Testing
The Indirect Method Testing
Best practice of Boiler operation - Availability increase

Light up to load raising

• Ensure pre-light-up walk down check for free thermal
expansion of boiler to avoid tube failure
• Ensure recording of thermal expansion at 40 Kg/cm2 drum
pressure before proceeding further and at full load - to keep
furnace configuration & fire ball intact, to avoid vibration,
tube failure etc
• Ensure the free second pass rear side ward expansion- Rear
SCW expansion is maximum towards chimney – 80 mm for
210 MW
• Ensure Blow down of water wall low point drains at 5, 10,
15…. till 40 Kg/cm2 of drum pressure for better control on
water chemistry & minimizing water wall internal deposits –
to avoid tube failure
Best practice of Boiler operation - Availability increase

• Ensure the drum metal temperature difference not to

exceed 50 Deg. C – to avoid boiler life reduction
• Ensure early charging of HP bypass lines as per warm,
hot and cold start-up curves
• Ensure Critical piping drain pot level switch
functioning and auto control of the level – to avoid
hammering in MS/CRH/HRH and Boiler outage
• Ensure the allowable rated pressure rise– to avoid
boiler life reduction
• Ensure no gagging of any Safety valves during
operation – safety requirement
 Best practice of Boiler operation - Availability increase
Wall soot Blower & LRSB operation
• Ensure Wall soot blowing cycle per shift - effective heat transfer
• Ensure soot blowing steam pressure as per OEM recommendation; lower
the pressure than the recommended the less effective is the cleaning
• Regular operation of LRSBs – frequency to be decided based on
experience and parameters
• Ensure the operation of LRSB at goose neck once in a day
• Increase the wall soot blowing cycle as well as bottom ash evacuation
cycle according to ash content in the coal – to avoid built-up os ash/slag in
Water wall/BAH
Fly-Ash Evacuation
• Ensure regular Eco hopper ash evacuation
• Ensure ESP ash hopper evacuation records with duration
• Maintain Agitating air temperature – to avoid rat hole formation in ash
hoppers
Best practice of Boiler operation - Availability increase
Avoiding slagging /ash accumulation in WW/BAH for the following
conditions
• Ensure the inert content in the coal (moisture and volatile matter) not to
exceed 62 % for pulverized fuel fired boiler
• Ensure the ash content in the coal not to exceed 53 %;
• Ensure proper Mill fineness (70% thro 200 mesh & , 2% remaining in 50
mesh)
Prevention of Steam Explosion in Bottom Ash Hopper (BAH)
• Ensure the de-ashing of the BAH even at low load once in a shift.
• Ensure the BAH over flow line kept open continuously such that the over
flow water temp. not to exceed 60 Deg. C
• Ensure no leakages in the BAH - to keep normal water level and to avoid
low bottom ash hopper level as it leads to bottom ash hopper explosion,
accumulation, etc.
 Best practice of Boiler operation - Availability increase

Water chemistry
• Ensure the chemical regime of pre-boiler as per
OEM
• Ensure the drum water pH within the range as
recommended by OEM; it can be controlled to
the accuracy of 0.1
• Ensure the de-aerator pressure as per OEM for
the effective control of Oxygen %
• Ensure Oxygen ppb < 10 at condensate outlet
• Ensure SS tubes for LP heaters to avoid pre-
boiler corrosive products
 Best practice of Boiler operation –
Optimum Efficiency & Less APC through Optimization

Concerned areas

• Good Combustion
– Pulverized fuel firing
– SADC
• Steam and water regime
• Air and flue gas
Best practice of Boiler operation - Optimum Efficiency & Less
APC through Optimization
Good Combustion
SADC & Burner Tilt
• Limit max. opening of the fuel air damper (FAD) in SADC according to
volatile matter % in the coal; for <30 % volatile matter, max. of 20 %
opening for auto control
• Ensure >30% opening of the AAD ( Aux. Air Damper) in SADC shall be
for coal firing operation.
• Ensure >70 mmWC WB to furnace DP during coal fire operation
• Ensure 21 – 24 m/sec velocity of the pulverized fuel at coal nozzle tip.
• Ensure the secondary air velocity in WB in the range 45 – 50 m/sec.
• Ensure equal opening of all four corner SAD as per control room signal
 Best practice of Boiler operation - Optimum Efficiency & Less
APC through Optimization

Good Combustion
SADC & Burner Tilt
• Ensure equal tilt in all corners
• Ensure Secondary air only for the working elevations
• Ensure the achieving offire ball concept to have effective
combustion
• Ensure the fire ball in the furnace center; not in the upper or lower
furnace
• Ensure the operation of Bottom Mills with upper tilt & Top Mils
with bottom tilt
• Ensure equal SA flow between left & right- to avoid shifting of the
flame to one side
• Ensure equal SA flow between corners
 Best practice of Boiler operation - Optimum Efficiency & Less
APC through Optimization
Pulverized fuel firing

• Ensure the hot air damper >80 % opening at full load for the mill
with max feeder speed; accordingly PA header pressure shall be
maintained - to reduce auxiliary power consumption
• Ensure Mill outlet temperature in the range 90 to 95 Deg. C –
more Boiler Efficiency
• Ensure Mill variable air flow curve implementation for bowl Mill
• Ensure optimised Seal air pressure
• Ensure dummy flange /Gun dummy plug for the guide pipe in case
of no scanner/oil gun – to avoid less scanner header pressure
 Best practice of Boiler operation - Optimum Efficiency & Less
APC through Optimization
Steam & Water cycle
• Ensure and follow HBD at any control load
• Ensure the rated parameters (pressure, temperature) at any control load –
optimum efficiency
• Ensure the controlled sliding pressure mode of operation for
– Less APC
– Longer life
– Fast response
• Ensure no leakages in system to reduce make up
• Ensure the use of MS- PRDS; Avoid CRH PRDS on continuous basis
• Ensure minimum Re-heater spray level thro operation of Burner Tilt - for
optimum heat rate
• Ensure less Super heater thro SB cycle- for optimum heat rate
• Hook up ERV operation of RH during turbine trip to avoid RH protection trip
 Best practice of Boiler operation - Optimum Efficiency & Less
APC through Optimization
Difference between sliding pressure & Constant pressure
Description SP CP
HPT CV opening % 90 As per load
HPT CV opening % in Pure sliding pressure 100 As per load
Lower mechanical stress for Boiler tubes at part load Yes No

Less aux Power consumption at lower load Yes No

Increase in Boiler life Yes No
Quenching effect in HPT CV No Yes
All critical piping & HPT/LPT casing are at the same temperature Yes No

Step load in % of TMCR 15% 7.5%

Ramp load per minute in % of TMCR 7.5 3.5
Upgraded Material requirement in same Boiler section yes No
 Best practice of Boiler operation - Optimum Efficiency & Less
APC through Optimization
Air & Flue Gas path
• Never exceed the APH flue gas outlet temp. than the predicted value - it will
increase the AH leakages across air to flue gas side
• Ensure Boiler air ingress <5 % - all peep holes, man holes, test pockets, shall be
closed with new gaskets
• Ensure the total combustion (primary air+ secondary air + boiler air ingress) <
120%
• PA+SA+ Boiler AI = 120% Stoichometric air=3.5% O2 at APH inlet in Flue Gas side
• Ensure the O2 trimming circuit for control of FD fan air flow to maintain the
excess air level <20% Execess Air (EA)
• Ensure CO monitoring at APH inlet for maintaning the EA level <15% or at10%
• Monitor APH pressure drop continuously for choking
 Best practice of maintenance
• Neat & tight – the pass word for the maintenance.
• Conduct Air leak test even for 4 days shut down and
• Ensure no leakages in Wind box as it is under negative pressure
after SAD
• Ensure the following in hydraulic test (HT) after any repair :
– Ensure the use of hydrostatic plug for HT at > lowest SV set pressure
– Ensure <10 Kg/sq.cm per minute rate of pressure rise upto 80 % of HT
pressure
– Ensure <2 KSC per minute rate of pressure rise after 80 % of HT pressure
– Ensure <2 KSC per minute rate of pressure drop for de-pressurisation
– Ensure water temp in the range 21 deg C to 49 deg C
– Ensure the gagging of SV at 80 % of the HT pressure (with hand tighten)
– Ensure the boiler feed pump not be used for fillingas well as pressurising –
inadvertent pressure rise damages the safety valve stem.
 Best practice of maintenance
• Ensure SADC damper shall be under preventive maintenance (PM) schedule
(once in a week frequency)
• Ensure scanner cleaning in PM schedule
• Ensure the scanner filter cleaning in PM schedule
• The boiler temporary supports shall be removed after any shut down
• Check Vertical alignment bands (VAB) for dislocation/intactness for horizontal
SH
• Ensure Erosion Mapping for the pressure parts in FG path – Burner panel
straight & transition tubes, WSB area, horizontal SH, Eco, Screen tubes,
Extende water wall/steam cooled wall etc
• Ensure Proper Reaction supports for SV & ERV in critical piping
• Ensure WSB protrusion inside the furnace as per OEM
• Ensure LRSB rear hinged support for accomodation of Boler expansion at the
point
• Ensure airvent valve installation after puppet valve – to drain condensate
 Best practice of maintenance

AIR PREHEATER (APH) – Water Washing and Dry out

• Ensure APH water washing till drain water pH approaches 5.
• Ensure dry out with FD fan and ID fan in association with SCAPH
• Ensure closure of Air outlet dampers and flue gas inlet dampers
• Ensure inspection of middle basket for through cleaning. For the purpose,
remove three cold end basket at 120 Deg. apart..
• Ensure no wear out & looseness of elements
• Ensure seal setting values as per OEM.
• Ensure no bypassing of air/flue gas across APH
• Ensure full coverage of all elements by AH soot blower
• Ensure the opening of drain line to atmosphere after IV in water washing &
fire fighting line
• – to avoid water entry on account of passing
• - to keep the nozzles clean in header inside the APH
• Ensure AHSB steam pressure as per the O&M
 Performance Testing of Boilers
Sample Input Parameters - 1
1 Unit load MW 210
2 FW Flow at Econ inlet T/hr 650.70
3 Wet bulb Temp 0
C
4 Dry Bulb Temp 0
C
5 Barometric Pressure mmHg 750.30
6 Total Coal Flow T/hr 130.59
7 Unburnt C in BA % 5.00
8 Unburnt C in FA % 1.00
9 Radiation & Unaccounted Losses % 2.00
10 % Fly ash to Total Ash % 80.00
11 % Bottom ash to Total ash % 20.00
 INPUT PARAMETERS - 2
Proximate Analysis of Coal
12 Moisture AD % 4.85
13 Moisture AF % 12.80
14 Ash AD % 35.97
15 Ash AF % 32.96
16 Volatile Matter AD % 26.39
17 Volatile Matter AF % 24.19
18 Fixed Carbon AD % 32.79
19 Fixed Carbon AF % 30.05
20 Gross Cal. Value AD Kcal/kg 4464.00
21 Gross Cal. Value AF Kcal/kg 4445.00
 Sample Inputs
22 Ave FG O2 APH in % 3.50
23 Ave FG CO2 APH in % 15.80
24 Ave FG CO APH in PPM 39.00
25 Ave FG O2 APH Out % 5.00
26 Ave FG CO2 APH Out % 14.30
27 Ave FG CO APH Out PPM 50.00
28 Ave. FG Temp APH in 0
C 300.00
29 Ave. FG Temp APH Out 0
C 140.00
30 Air to APH in 0
C 31.00
31 Air APH out 0
C 290.00
32 Total Primary Flow T/hr 330.00
33 Total Air Flow L 0
C 360.00
34 Total Air Flow R 0
C 360.00
35 Design Ambient / Ref air Temp 0
C 30.00
 14.
Trouble shooting
&
other O&M issues
 1COMMON
. F r e qOPERATIONAL
u e n t t r iPROBLEMS
p s o n OFf lBOILER
a m e& fAUXILIARIES
ailure
1. Check for proper combustion
2. Check for correct total air flow
3. Check for correct coal air ratio
4. Check for correct wind box to furnace
DP
5. Check for proper functioning of SADC
6. Check for healthiness of flame
scanners
7. Check for flame failure circuit in FSSS
 COMMON
2. Furn a c e d r aOPERATIONAL
f t f l u c t u a t iPROBLEMS
o n s a l o nOF
g BOILER
w i t h f&
l aAUXILIARIES
me scanner

flickering:

1. Check for proper functioning of draft control on `Auto’

2. Check for disturbed flame condition

3. Check for proper functioning of CMC/Fuel master control

on Auto

4 . C h e c k f o r p r o p e r f u n c t i o n i n g o f PA h e a d e r p r e s s u r e a u t o

control

5. Check for proper functioning of secondary air flow auto

Control

6. Check for proper functioning of SADC on auto control

7. Check for furnace trough sealing

3 . M a i n COMMON
Steam/H R H s t e a mPROBLEMS
OPERATIONAL t e m p e rOF
a tBOILER
u r e l o&wAUXILIARIES
/high:
1. Check for correct total air flow
2. Check for correct burner tilt position
3. Check for correct feed water temperature at Economizer
inlet
4. Check for slagging/scaling (external) on water
wall,SH/RH tubes
5. Operate wall blowers/LRSB at regular interval as per
requirement
6. Check for inside scaling in water walls & SH/RH tubes
7. Check for choking of SH/RH attemperator
nozzles/passing of SH/RH spray control valves
8. Check for any undesired steam outlet due to passing of
safety valves, drain valves, vent valves
4 . H i g hCOMMON
unburn t c a r b o n PROBLEMS
OPERATIONAL i n f l y a sOF
h /BOILER
b o t t o&mAUXILIARIES
ash:
1. Check for proper and stable combustion
2. Check for plugged coal pipes and ensure equal
distribution in all four coal pipes
3. Check and adjust the fineness of coal
4. Maintain adequate total air flow (secondary air flow +
PA f l o w )
5. Maintain proper oxygen in flue gas. Cross check UCB
instruments with local sampling
6. Ensure that burner tilt of all four corners is at same
position.
7. Maintain correct mill outlet temperature.
8 . Tun e SAD C a s p e r r eq u ir em en t to op tim iz e fla me
condition
9. Carryout clean air flow test/hot traverse if required
1 0. C h e c k a n d o p timis e b a ll c h a r ge ( O n ly for Tub e mills )
11 . C h e c k a n d r e p l a c e w o r n o u t m i l l l i n e r s
12. Check for proper mill clearances
1 3. Ma inta in p r op e r mill le v el ( O n ly fo r Tub e m ills )
14. Check classifier/reject chute for bypassing of coal air
mixture
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES

5 . Tr i p p i n g o f b o i l e r o n R H p r o t e c t i o n s d u e t o
closure of HP/LP Bypass during start ups:
1. Maintain stable combustion
2. Study RH protection logic
3. Initially keep HP/LP Bypass valves on
manual mode. After stable combustion and
sufficient flow only they should be put on Auto
4. Check for proper functioning of these valves
on Manual and Auto’
5. Check protection closing circuit for any
malfunctioning
6. Maintain correct HP Bypass downstream
temperature
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES
6. Unit load not increasing to rated load :
1. Check for correct parameters of main steam/HRH steam i.e. pressure,
temperature, flow
2. Check for correct quantity of coal
3. Check for proper combustion/flame condition
4. Check for correct total air flow/Oxygen and CO in flue gas
5. Check for calorific value, fixed carbon, ash content, moisture etc. of coal
6. Check for correct feed water temperature at economiser inlet
7. Check for correct fineness of coal
8. Inspect mill and replace worn out liners and internals
9. Check for correct mill output and take remedial measures to get
optimum output
10. Check for any boiler tube leakage
11. Check for undesired steam outlet due to passing of safety valves, drain
valves, vent valves.
12. Attend all valve leakages
13. Check for very dirty furnace due to deposition of slag/scale on water
wall/SH/RH tubes
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES
7. High stack Emission :
1. Check for functioning of all ESP fields
2. Check for correct total air flow, Oxygen and CO in flue gas
3. Check for correct flue gas temperature at ESP
4. Check for proper rapping frequency
5. Check for proper current settings
6. Check for proper gas flow distribution in the pass during
shut down
7. Check for proper fixing of deflector plates of hoppers during
shut down
8. Check for eroded guide vanes/splitters during shut down
9. Check for proper fixing of screen plates during shut down
10. Check for proper closure of manhole doors, inspection
doors etc. to prevent air ingress
11. Check for proper functioning of ash handling system
12. Check for high ash content in coal
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES
8. Tripping of Unit on high/low drum level :
1. Check for sudden opening/leakage of water
wall/economiser tube
2. Check for tripping of any one of running BFPs
3. Check for malfunctioning of drum level auto control
4. Check for closure of any valve in feed water circuit
5. Check for opening of HP Bypass valve on fast
opening mode.
6. Check for sudden throw off/raising of load
7. Check for tripping of two/three coal elevations
simultaneously
8. Check for disturbance in combustion
9. Check for malfunctioning of drum level transmitters
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES
9. Frequent tube failures :

1. Avoid sudden stress to boiler tubes

2. Maintain rate of pressurisation/de-pressurisation as recommended during
hydraulic test of boiler
3. Maintain rate of rise/drop of temperature as recommended during
start-up/shut down (follow start up curve)
4. Monitor drum/SH/RH metal temperatures during start up/shut down
5. DON’T TAKE MILLS INTO SERVICE UNLESS FLOW IS ESTABLISHED THROUGH
REHEATER
6. Maintain proper water chemistry regime as per recommendations.
7. Check for tube thickness for any erosion. In case of erosion, tubes must
be replaced
8. Check for deposits/scales inside the tubes. If found, contact BHEL for
further analysis and chemical cleaning.
9. Check for possibility of choking
10. Check for foreign materials/obstructions in the connected headers
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES
10. Boiler drum pressure dropping suddenly :
1. Check for interruption of coal to the furnace due to
choking in the burner
2. Check for tripping of feeder/mill
3. Check for disturbed combustion inside furnace
4. Check for any boiler tube leakage
5. Check for opening of boiler drains, vent, safety
valves
6. Check for choking in mills/drop in air flow through
mill
7. Check for malfunctioning of auto control of CMC/Fuel
master control
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES

11. High DM Water make up :

1. Check for any boiler tube leakage
2. Check for leakages from glands and
bonnets of valves
3. Check for passing of safety valves
4. Check for passing of drain valves
5. Check for passing of vent valves
6. Check for optimum opening of CBD valves
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES

12. Boiler water silica level High :

1. Check for proper DM water quality
2. Check for correct chemical regime in boiler drum
3. Check that CBD valves are operative
4. Check the CBD lines for any possible choking
5. Check for any condenser tube leakage
6. Check for proper opening of CBD valves
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES

13. Sudden reduction of load :

1. Check whether it is momentary due to grid disturbance or due to
malfunctioning of turbine governing system
2. Check for drum pressure. If the trend is increasing, take appropriate
measures to stabilize drum pressure by reducing/cutting off fuel input to
furnace. If necessary, cut off mills, one by one.
3. Check for drum level. See whether auto control is able to maintain drum
level. Otherwise take it on manual control.
4. Check for furnace draft
5. Check for secondary air flow, oxygen in flue gas.
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES

14. Ash build up in bottom ash hopper and water walls :

1. Check for proper functioning of bottom ash evacuation system

2. Check for proper functioning of clinker grinder system

3. Check for proper functioning of scrapper conveyor wherever provided

4. Check for any choking of ash evacuation/disposal pipes

5. Don’t allow building up of ash level in case of non-functioning of ash

evacuation and associated systems.

6. In case problem is persisting and ash level has started building, boiler

must be stopped and ash/clinker is to be removed.

 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES

15. High Flue Gas temperature at APH outlet :

1. Check for excess Air and total Air flow
2. Check for fineness of coal
3. Check for fouling of water walls, super heaters, reheaters etc.
4. Check for proper heat transfer in Air preheaters
5. Check for dampers position of Air preheaters
6. Check for Burner tilting system and bring it downwards.
7. Switch over to lower elevation mills.
8. Check for proper Air distribution and functioning SADC
9. Check for leakages through peep holes, manholes, seal water trough etc.
10. Check for tube failures.
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES
16. Low Boiler efficiency :
1. Check for excess air flow
2. Check for the reasons for high air preheater outlet flue gas temperature
3. Check for higher unburnt carbon in bottom ash and fly ash
4. Check for proper combustion and high `CO’ in flue gas
5. Check insulation/refractory to arrest heat loss
6. Check for entry of excess water/moisture alongwith coal. Arrest where
possible.
7. Check the fineness of coal
8. Check for proper Air distribution and functioning of SADC.
9. Check for steam/water leakages and tube failures.
 COMMON OPERATIONAL PROBLEMS OF BOILER & AUXILIARIES

17. High excess Air flow :

1. Check the Air flow distribution and functioning of SADC
2. Check the combustion
3. Check the fouling of superheater, reheater and LTSH surfaces
4. Check for air ingress through peep holes, manholes, seal
trough etc.
5. Check the reliability of air flow and O2 measurements
6. Check the fineness of coal and functioning of mills.
7. Set for proper air flow and O2 in Automatic combustion
control.
 15.
Emergencies related to
Boiler Operation
 Steam Generators (Boiler)
Testing
• Cold testing
• H y d r o s t a t i c Te s t i n g
• Welding testing
• Hot testing
• Flow measurement
• Te m p e r a t u r e m e a s u r e m e n t
• Dryness fraction of steam leaving the
drum
Pre-checks For Hydraulic Test of
•
Boiler
Ensure all men & material like scaffolding. Platforms
are removed from Boiler after shutdown.
• Clearance from Boiler after maint. Dept. for hydraulic
test
• Boiler outlet valves are closed & Ms line drains to unit
flash tank are open.
• Ensure availability of ELP & DM make up pumps Ensure
overhead DM tank & UDT levels are normal.
• Confirm all 3 Mtr water wall ring header drains are
open & final drains on header is closed.
• Check ELP filling line valve on ring header is open &
DM 1 & 2 are close.
• Confirm Boiler Drum to Economiser recirculation valve
is open.
• B o i l e r D r u m , E c o n o m i s e r, s u p e r h e a t e r v e n t s a r e o p e n
and super header drains are close.
 Boiler Filling
• Start ELP for boiler filling after clearance
from B/M and chemist.
• On sufficient venting at approximately 3
K g / c m 2 p r e s s u r e , d r u m , E c o n o m i s e r, s u p e r
heater vents must be closed.
• Boiler drum pressure will rise gradually upto
12 to 30 Kg/cm2 within 1 ½ hours.
• Check for leakages from valves, glands and
tubes at this pressure.
• When no leakages are reported close all
ring header valves along with ELP filling
valve, run ELP on recirculation.
 BOILER HYDRAULIC TEST
• C h e c k F S T l e v e l a n d a v a i l a b i l i t y o f B F P.
• After clearance start one BFP with due
intimation to other units.
• Raise pressure gradually to 50
Kg/cm2.holding this pressure inspect boiler
for any leakages from manholes.
• if no leakages are found again raise pressure
to 130 Kg/cm2 and hold it for 10 min. for
carrying out physical checks of boiler from
manholes.
• After clearance from B/M and if no leakages
are reported, depressurise the boiler by
u n l o a d i n g B F P g r a d u a l l y a n d t h e n s t o p B F P.
• After attaining 4 to 5 Kg/cm2 open boiler
drum, Economiser and S/H vents.
 SAFETY PRECAUTIONS

• Boiler house area must be clean and all

debris removed from boiler house
after shutdown.

• Sufficient lighting be available at

elevation for carrying out physical check
for boiler leakages.
 Pre-checks for Re-Heater Hydraulic Test
• Ensure all related permits are cancelled.
• Ensure DM/GS water systems are I/S.
• Ensure UDT is available for service & chemicals are dozed by S/C
• Ensure FST is available & filled up at 2600 mm.
• One ELP is to be made ready along with its discharge line
connected to CRH drain valve (modification work so that DM water
can be filled in R/H circuit).
• Ensure one BFP is available.
• Feed station valves & Eco.inlet valves are closed.
• DM 1 & 2 valves are closed.
• All instrumentation in R/H side are closed.
• Ensure all S/H side spray S79 to S90 are closed.& drain valves are
closed. R/H drain valve is initially open.
• Close HP/LP bypass spray BD isolating. Valve (FW 155) PRDS
spray-isolating valve are closed.
RH Hyd. Test ENSURE FOLLOWING
• Both IV are to be dummied.
• Ensure CRH/HRH & MS line hangers
supports are locked.
• Ensure R/H vents are open.
• Ensure CRH NRV’s are closed.
• Ensure HPH6 steam extraction valve ES-4 is
closed & after drain is open. ES4 line drain
before ES4, which is connected, to drain
before ES1 (HPH-7 FC NRV) is blocked.
• Ensure CRH/HRH/ Drain cycle HP bypass
station /HRH drains are closed.
RH Hyd. Test ENSURE FOLLOWING
• Ensure ES 6/7 closed & line drain before ES7 are
open.
• Ensure LP bypass station valve is closed & drains
before LP bypass are closed.
• Drains before HP bypass are opened.
• All main steam valves should be closed & drains on
MS lines ( also inspection drains) are open. Drains
between ESV & MSV are open.
• Ensure transfer/ casing drains of LPT/IPT are open.
• Ensure that Condenser/ UDT levels are constant
during R/H filling to confirm that the valves are not
passing. R/H safety valves to be gauged.
 START OF HYDRAULIC TEST
• Start ELP for filling & check UDT level drop & amperes of
ELP.
• Check for leakages at turbine side & specially check IV
dummy.
• Close R/H spray drain & then R/H vents after sufficient
deaeration.
• Check the leakages through B/M & get clearance for further
pressure raising.
• Start BFP & put on recirculation at minimum possible
pressure (55 kg/cm2 )
• Open CRH valves S-74, R-34, R-38 & R-44.& watch R/H
pressure raise to 35 Kg/cm2 & check leakages & take
appropriate action.
• Stop BFP & depressurise the R/H line & completely drain.
• Ensure CRH/HRH/ MS lines hanger supports are released
by maint. Staff.
 Energy conversion taking place in the thermal power
plant
Generator is
Chemical Steam is
Heat energy coupled to
Energy is converts water admitted Turbine, where
converted to to high to Turbine mechanical
Heat Energy pressure, high through energy is
by temperature pipes. converted to
combustion steam. (in electrical energy.
Of fuel in Boiler)
Boiler.
In Turbine, steam
expands as it is passed
Pump Steam exhausted through number of
delivers from turbine nozzles. Heat energy
condensed is thus converted to
condenses in kinetic energy.
water from Condenser,
Condenser rejecting
back to unavailable heat
Steam is then passed over
Boiler. energy.
blades, arranged on shaft of
Turbine. Shaft rotates & Kinetic
energy is thus converted to
mechanical work
107
 Rankin Cycle
• The Carnot Cycle is theoretically most efficient, but it is having
practical difficulties.
• For steam power plant, practically thermal cycle used is Modified
Rankine cycle.
3-3’ – BFP raises pressure from p2 to p1
T
3’-4 – Heating In feed heaters & eco
T1 4 1 4 -1 – Heating In boiler
p1 1-2 – Work done in Turbine from p1 to p2
3’ 2-3 – Heat Rejection In Condenser

T2 2
3 p2

S
Rankine Cycle with Super heating, Reheating &
Feed Heating
Basic Power Plant Cycle

110
Thank
You