BALRAMPUR CHINI MILL LTDs
(UNIT - HAIDERGARH)
WELCOME
By Pramod
yadav
POWER PLANT
TOPIC :-
Boiler
Operation
And
interlocks
WHAT IS A BOILER ?
Boiler is closed vessel in which the
heat produced by combustion of fuel
is transferred to feedwater to
generate steam. boiler is heat
exchanger
As per indian boiler Act 1923 boiler
mean any closed vessel exceeding
22.75 L in capacity
Major Boiler
Components
Steam Drum – Steam separation and
storage
Mud Drum – Sediment collection
Superheater – Increases steam temperature
Economiser – Preheats feedwater
Furnace – Fuel combustion chamber
Air Preheater – Heats combustion air
Water Walls, Riser Tubes – Heat transfer
surfaces
TECHNICAL DATA OF BOILER
(HCM)
Make : IJT( Isgec John Thompson)
Type : Water tube, Bi Drum, Membrane
wall, Bagasse fired,
Travelling grate, Natural
Circulation, Top supported,
Balanced draft boiler
Capacity : 120 TPH
Temperature : 515 ± 5°C
Design Pressure : 99.5 Kg/Cm² (g)
Working Pressure : 86 Kg/Cm²
WATER-STEAM FLOW
RO / DM
Steam Drum Primary SH
DM Storage
tank
From CEP
UGR
Mud Drum De-Super Heater
Feed water
tank
BOR-WELL Down Comer Secondary SH
Deaerator Header
Tank
Water Wall MSSV
Boiler feed
pump FURNACE
9 Ata
Steam Riser tube Common Header
HP Heater
FCV Station
Economiser
Importance of Boiler
TDS, pH, Silica control is essential
Feedwater
Poor water Quality
→ Scaling → Tube failure
Prevents corrosion, scaling, foaming
Regular Blowdown maintains water
chemistry
Use of DM/RO water recommended
Boiler Operating Cycle –
From Fuel to Steam
1. Fuel Feeding (Bagasse, Coal, etc.)
2. Combustion in Furnace
3. Heat Transfer to Water
4. Steam Generation in Drum
5. Steam Superheating
6. Steam Utilization (Turbine, PRDS, etc.)
FURNACE
The furnace is the most important part of
a boiler Its primary function is to provide
adequate space for fuel particles to burn
completely and to cool the flue gas to a
temperature at which the convective
heating surfaces can be operated safely.
HEAT TRANSFER
Transformation of energy
Chemical
Energy
Of fuel
Heat Energy
After combustion
Thermal Energy
In steam
Kinetic/Potential
Energy
At turbine inlet
Electrical Energy Rotational Energy
At Generator At turbine outlet
AIR/ FLUE GAS FLOW CHART
Mill Bagg. EL- Atmosphere
1
Atmosphere
SC-1/2 FD-Fan
Chimney
Bagg. silo APH
SA- Fan
ID- Fan
Drum feeder
Reselling
Hopper Boiler front
Air
Screw ESP
Furnace Boiler Rear
feeder Air
Secondary APH
SH
Primary SH Bank Zone Economiser
FD- FAN
Forced Draft Fans (FD) supply the air necessary
for fuel combustion by pushing air through the
combustion air supply system and into furnace.
These fans are located at the inlet of boiler to
push high pressure fresh air into combustion
chamber, where it mixes with the fuel to produce
positive pressure.
What is the use of ID Fan and FD Fan in boiler.
The primary difference between a forced draft and
induced draft is, FD fan forces outside air into the
heating system whereas ID fan draws flue gases
from the system out into the atmosphere.
ID FAN
Induced Draft Fans (ID) exhaust all gaseous
combustion products or flue gases from the boiler,
through dust collector and delivers it to the chimney
into the open atmosphere. Hence the ID fans are
usually located at the outlet of the boiler system
(between a dust collector and chimney)
SA FAN
The secondary air fans (SA fans) play an important
supporting role in power plants. The secondary
fan allows for complete combustion of the fuel
inside the furnace. As and when required the SA fan
is used to increase the air flow to improve the
efficiency and avoid wastage of fuel
WATER AND STEAM
CIRCULATION IN BOILER
BOILER STEAM DRUM
PRE-STARTUP CHECK
LIST
All blow-down and drain valve on boiler and water
wall should be in closed condition.
All boiler and super-heater filling valve should be
in closed condition.
Soot blower steam valve must be in closed
condition.
Main steam line stop valve should be in closed
condition.
Attemperator valve should be in closed condition.
Drum vents should be in open condition.
Super heater header drain should be in open
condition.
PRE-STARTUP CHECK
LIST
Availability of DM water and fuel :
Ensure that the level of DM water tank is above 90%.
Feed tank level must be above 70%.
Deaerator level must be above 60%.
Drum level must be in the range of 35-40%.
Wooden logs should be available ( 2-3 Ton).
High Speed Diesel should be available (5 Litres).
Waste cotton and cloth should be available .
Wasted oil and grease should be available.
Fire must be available.
Common Startup &
Shutdown
Challenges
Low Drum Level on startup → Air lock or
improper filling
Flame Failure → Check FD Fan, Fuel
Feed, Ignition system
Fast Pressure Rise → Attemperator
malfunction or firing imbalance
Delayed Bagasse ignition → Moisture
content or wet fuel
Proper sequencing of fans & dampers is
critical
CHECK THE FOLLOWING
INTERLOCKS
F. D. fan trip S.A. fan trip
S.A. fan trip All feeders trip
Dearetor level low low (10%) B.F.P. trip
Drum level low low (15%) Boiler trip
Furnace pressure high (+80 mmwc) Boiler trip
Furnace pressure low (-80 mmwc) Boiler trip
Steam temp high (560oC) Boiler trip
Both I.D. fan trip Boiler trip
CHECK THE FOLLOWING
INTERLOCKS
F. D. fan trip S.A. fan trip
S.A. fan trip All feeders trip
Dearetor level low low (10%) B.F.P. trip
Drum level low low (15%) Boiler trip
Furnace pressure high (+80 mmwc) Boiler trip
Furnace pressure low (-80 mmwc) Boiler trip
Steam temp high (560oC) Boiler trip
Both I.D. fan trip Boiler trip
Boiler Safety Interlocks –
Purpose & Function
Drum Level Low Low → Boiler Trip → Prevent
dry running
Furnace Pressure High → Boiler Trip → Avoid
rupture
Steam Temp High (560°C) → Trip → Avoid
superheater damage
Deaerator Level Low → BFP Trip → Prevent
pump cavitation
Both ID Fans Trip → Boiler Trip → Maintain
furnace draft
COLD STARTUP PROCEDURES
Put wooden logs on the travelling grate in layer by layer.
Waste cotton, oil and grease should be put above the
wooden logs.
High Speed Diesel should be sprayed over the wooden logs.
Put fire over the wooden logs.
Slow firing should be kept running for 2 hours while
maintaining furnace temperature of 150° C.
COLD STARTUP PROCEDURES
Air preheater (APH) bypass damper must be in
open condition.
After 2 hours fans should be start and bagasse
fired and furnace temperature must be gradually
risen and maintained till 350° C.
Drum pressure should be maintained at 3–5
Kg/cm² for 15-20 minutes.
Close the drum vent.
Bagasse feeding must be increased and maintain
furnace temperature till 450° C.
COLD STARTUP
PROCEDURES
Primary and secondary super heater vent should
be closed after 20 kg/cm²drum pressure.
When Drum pressure reaches 20 – 25 Kg/cm²,
crack open main steam stop valve and put steam
line, header and PRDS system in
charging(heating).
Furnace temperature should now be maintained
at 650°C by increasing bagasse feeding and air
flow.
Maintain firing with the help of oxygen
concentration of 3-5 %.
COLD STARTUP
PROCEDURES
Let the pressure and temperature rise gradually up to
working parameters.
Attemperation should be taken in line according to steam
temperature.
Start up vent valve should be closed when steam flow
exceeds 40 TPH.
All safety valves of Boiler set pressure should be done as per
IBR.
-First Supper heater safety valve set at 91.5 Kg/Cm² .
-Second Drum safety valve set at 99 Kg/Cm².
-Last drum safety valve set at 99.5 Kg/Cm² .
Boiler is now ready for full scale steam production.
Total time should be taken for cold startup approx. 6 Hrs.
Thank you for your
attention!
Feel free to ask any
questions
