Baile OPERATION ‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS OPERATION OPERATOR'S RESPONSIBILITY PERSONNEL SAFETY. START UP PROCEDURE. INPUTS WALKDOWN CHECKS SYSTEM LINE UP... WATER FILLING LIGHT-UP BAGASSE FIRING . PRESSURE RISING PRESSURE RISING CURVE SUPER HEATER COIL PROTECTION DURING PRESSURE RISING. OPERATION FUELS DISTRIBUTION .. GRATE SPEED, COMBUSTION AIR SECONDARY AIR PRESSURE SETTING . TRAVAGRATE.. OPERATION. SPEED CONTROL .. ESPt. STEAM TEMPERATURE CONTROL CHEMICAL DOSING SYSTEM BLOW-DOWN SYSTEM INTERMITTENT BLOW-DOWN (IBD)... CONTINUOS BLOW-DOWN (CBD).. AIR PRE-HEATER.. SOURCES OF TROUBLES AND PREVENTION FOULING... CORROSION .... wl) 9 Section € Page i‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. FIRES. DEAERATOR .. START UP.. OPERATION... SHUTTING DOWN... SOOT BLOWER ‘STEAM WATER ANALYSIS SYSTEM (SWAS)... ANTICIPATED BOILER PERFORMANCE DATA SHEET. FLUE GAS... reese DO’S AND DON'T S FOR BOILER. Do's DONTS.... oon OPERATING INSTRUCTION FOR IMPORTANT VALVES. WALK DOWN CHECK LIST DURING OPERATION NORMAL SHUTDOWN PROCEDURE .. SHUT DOWN PROCEDURES - LONG DURATION . SHUTDOWN PROCEDURES - SHORT DURATION EMERGENCY SHUTDOWN PROCEDURES .. BOILER START UP FLOW CHART. Section ¢ Page ii‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS OPERATION This section describes the startup and shutdown procedures of the boiler along with the operation, troubleshooting and safety points. ‘+ Procedures explained in this section apply for start up of a boiler already commissioned. Commissioning a new boiler call for several additional requirements, which are not explained here. ‘+ It is assumed that the boiler operators are fully fa feature described in section A. the design and construction + It is assumed that operators are trained in operation of similar Travagrate boilers and have been licensed to operate boilers by the concerned authorities. + The owner is encouraged to evolve standard operating procedures (SOP) based on the framework and recommendations that are explained in the subsections below. The SOPs have to be well understood by the utility managers and operators for safe and reliable operation. OPERATOR'S RESPONSIBILITY Boiler operator is responsible not only for the successful operation of the boiler and its related equipment, but also for the safety of all personnel involved. The operator must be aware of any operating conditions affecting the boiler or related equipment. Should be able to recognize hazardous conditions and to act properly to avoid injury. Even though operating procedures are normally given for each piece of equipment, a complete knowledge of all components their design, purpose, limitations and relationship with other components is must for the operators. Section C Page 1‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNTT OF MAWANA SUGARS PERSONNEL SAFETY Operating instructions usually deal primarily with the protection of equipment. Rules and devices for personnel protection are also essential. The items listed here are based on actual operating experience and point out some personnel safety considerations. 1. When viewing flames or furnace conditions always wear tinted goggles or a tinted shield to protect the eyes from harmful light intensity and flying ash or slag particles. 2. Do not stand in front of open ports or doors, especially when they are being opened. Furnace pulsations caused by firing conditions, soot blower operation, or tube failure can blow hot furnace gases out of open doors, even on suction-fired units. Aspirating air is used on inspection doors and ports of pressure-fired units to prevent the escape of hot furnace gases. ‘The aspirating jets can become blocked, or the aspirating air supply can fail. In some cases, the entire observation port or door can be covered with slag, causing the aspirating air ‘to blast slag and ash out into the boiler room. 3. Do not use open ended pipes for rodding observation ports or slag on furnace walls. Hot gases can be discharged through the open ended pipe directly onto its handler. The pipe can also become excessively hot. 4. When handling any type of rod or probe in the furnace — especially in coal-fired furnaces — be prepared for falling slag striking the rod or probe. The fulcrum action can inflict severe injuries. 5. Be prepared for slag leaks. Iron oxides in coal can be reduced to molten iron or iron sulfides in a reducing atmosphere in the furnace resulting from combustion with insufficient air. This molten iron can wash away refractory, seals and tube and leak out onto equipment or personnel. 6. Never enter a vessel, especially a boiler drum, until all stem and water valves, including drain and blow down valves, have been closed and locked or tagged. It is possible for steam and hot water to back up through drain and blow down piping, especially when more than one boiler or vessel is connected to the same drain or blow down tank. 7. Be prepared for hot water in drums and headers when removing manhole plates and manhole covers. 8. Do not enter a confined space until it has been cooled, purged of combustible and dangerous gases and properly ventilated with precautions taken to keep the entrance open. Station a worker at the entrance, notify a responsible person, or run an extension cord through the entrance. 9. Be prepared for falling slag and dust when entering the boiler setting or ash pit. 10. Use low voltage extension cords, or cords with ground fault interrupters. Bulbs on extension cords and flashlights should be explosion proof. LL. Never step into flyash. It can be cold on the surface yet remain hot and smoldering underneath for weeks. 12. Never use toxic or volatile fluids in confined spaces. 13. Never open or enter rotating equipment until it has come to a complete stop and its circuit breaker is locked open. Some types of rotating equipment can be set into motion with very little force. This type should be locked with a brake or other suitable device to prevent rotation. Section C Page 2\ ‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS 14, Always secure the drive mechanism of dampers, gates and doors before passing through them. w Section C Page 3‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS START UP PROCEDURE Prior to start the boiler, following input requirements to be satisfied. INPUTS Inputs required for startup are as follows: > Fuel > Feed water > Uninterrupted electric power supply for auxiliary equipment's Lighting for equipment’s, walk ways and field instruments Instrument air Plant air Cooling water Lubricant for the rotary equipment’s Chemical for feed and boiler water treatment Readiness of drainage and ash disposal system Fire fighting systern WALKDOWN CHECKS ~ Verify that the Nitrogen capping is removed and the unit is purged properly so as itis safe for man entry for inspection. Steam and water drums are clean and manholes are closed properly. Verify that the furnace S.H and convection bank are clear Verify that all access and inspection doors of furnace are tightly closed. Verify that the air duct to furnace and flue up to stack is clear and the manhole doors closed properly. Ensure the walkways are clear with out any obstruction. vvvy x SYSTEM LINE UP A, Process valve position during start-up Following valves to be kept in open position: » Air vent on steam drum. Start-up vent at S.H. steam outlet. Air vent on economiser outlet header Instrument air connections to all the instruments. Isolation valve for drum level gauge ‘Steam and water system pressure gauges/transmitters vvvvvy Section C Page 4‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. Following valves are to be kept in closed position: Main steam stop valve & by-pass valve SH header vents and drains Furnace bottom header drains Fumace Top header vents ‘Steam to soot blower root valve. Economiser drain 1BD/CBD Drum level Gauge drain valves Steam and water sample lines Spray water line vVvvvvvvyvyYY Field dampers are to be kept open/close as per the following instruction: > Keep the LD fan in/outlet dampers in open position. Verify the plenum, APH & ESP hopper, ash outlet gates are kept in open position. > Verify the main ash hopper outlet gates are in open position and the by pass chute gates are in closed position. > Submerged ash conveyor is filled with water so as the ash outlet chutes are immersed in water. > Open the LD fan inlet box drain plug during slow firing, due to low heating there is a possibility of condensation of fiue gases, which can be drained through this drain plug. > Close the FD Fan to APH inlet duct damper and open the APH by-pass duct damper. > Open the APH to plenum duct isolation dampers, > Ensure the chimney manhole is kept closed. y C. Verify the readiness of following equipment’s: LD., FD and S.A. fans Feed water transfer pump Feed water pump Travagrate with drive Twin drum feeders for bagasse Screw feeders for bagasse Rotary airlock valves Fuel handling system Ash handling system Chemical dosing system Soot blowers Section C Pages‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. D. Verify the readiness of following instruments: Control panel/OCs Control valves Motorized valves All the field and panel instruments. Damper actuators ‘Sensors seeees ‘Switch over the following controls in manual mode; Deaerator level and pressure. Furnace pressure Drum level Steam Temperature. Air flow Fuel flow CBD tank level Soot blower pressure control vvvvvvyY m ESP ‘Switch on the ash handling system one hour prior to light up. Open the isolation gate above the RAV and switch on the rotary airlock valves. Incase of pneumatic evacuation, open the isolation gate above the vessel. Switch on the rapping mechanism one-hour before the light up. Switch on the hopper and insulator heater four hours prior to light up. Check and ensure all the safety interlocks are tested prior to startup. vvvvyy . Others Verify all the soot blowers are in rest position. Ensure the test gags of safety valves are removed. Verify all the safety interlocks are working as per the desired logic/values. Ensure the availability of cooling water/seal air to the system, seesa Section C Page 6‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS H, Cold start-up: During cold startup at most care to be taken to ensure trouble free start-up and smooth operation of the boiler plant. > After completing the above pre start checks, ensure all the manholes in furnace, flues and ducting are closed and locked properly, except the wood-firing door. > Fil-up the fuel-bunker/silo with specified fuel. > Open the cooling water to boiler feed water pump, sample coolers and hydraulic drive oil cooler. > Fill up boiler with feed water, 50 mm below normal water level. WATER FILLING Caution: Feed water should be confirm to the specification. Prior to fill the water, keep the following valves in open position: + Air vent at economiser outlet header «Air vent on steam drum + Start up vent + Economiser drain Keep the following valves in closed position: + Furnace drain header outlet Furnace bottom headers drain Water drum drain/blowdown, CBD piping H.P Dosing piping Steam sampling line Main steam isolation and by-pass valve Attemperator spray water isolation Feed water control valve isolation Steam to soot blower Start the feed water transfer pump and admit the water through the filling line. OR Start the feed water pump as per the pump start up procedure, open the feed water flow control station by-pass valve gradually and feed the water to the boiler through the regular system. Feed water flow to be controlled in such a way that the electrical load on the pump motor is with in the operating limit also the pump outlet pressure is maintained. In this case, keep the ‘economiser drain in closed position wile line up the valves for water filling. Whenever the water flow from the economiser vent is free from air, close the vent valve. Continue water filling till the level in steam drum reaches 50mm below the normal operating limit and stop the pump, Section C Page 7‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS LIGHT-UP Stack around 200Kgs of firewood on the travagrate, light up the wood by kerosene soaked torch from out side the furnace through the wood firing door. (Firewood should be of small size- 2" x 500 mm long, without nail or packing metal strips, which may damage grate components). Maintain low and moderate fire initially and do not operate the fans at this stage, which may increase the furnace temperature rapidly. Whenever the fire is well spread over the grate, start the ID fan as per the Fan start up procedure. Continue the firing with the I.D fan in operation, at one stage the temperature will be stagnant, then start the F.D fan and increase the rate of fuel feeding. Maintain furnace pressure between (-) 2 to (-) 5 mmwe by adjusting the fan speed or fan ‘suction damper opening. Close the drum vent valve whenever the pressure reaches to 2kg/em? (g). Do not close the start up vent. Whenever the drum pressure reaches 5kg/cm? (g), stop the firing and reduce the boiler pressure to 2kg/cm? (g), quickly operate the I.B.D. and furnace bottom header drain valves, individually for Imin. In this operation, the sediments from the pressure part internals if any, may be removed. It also helps to reconfirm the drain pipe/valves are clear with out any obstruction/blockages. Maintain drum water level while doing the above operation. ‘After completion of hot draining operation re start the firing and increase the pressure. Open the continuous blow down valve (CBD) around 25% at this stage. At times, it may be require poking the fire during start up. Care should be taken while poking by ensuring sufficient negative draft inside the furnace.» Section ¢ Page 8‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS BAGASSE FIRING Whenever the boiler is ready for bagasse firing, start the S.A fan as per the fan startup procedure and maintain 200 to 300mmwe pressure at the pneumatic spreader air ducting. Then start the air-modulating damper. Keep the pneumatic spreader trajectory plate in horizontal position. Bagasse should be loose with moisture <50 %, and free from foreign materials like steel, stone, bricks, binding wire and wood etc. Presence of foreign material may jam the fuel feeders and damage the Travagrate grate and fuel feeder components, Start the bagasse carrier and fill up the silo. Prior to start the bagasse feeder, ensure the furnace temperature is adequate for the combustion of bagasse, otherwise there will be un-bumnt in the flue gas, which may create problem of choking the cinder re-firing system, APH tubes and ESP hoppers. Hence it is recommended to start the feeders whenever the furnace temperature is achieved >500° C. Whenever the required furnace temperature is achieved, start the screw feeders and run at minimum speed then start the twin drum feeder one by one and run at minimum speed, however it may require to operate the feeders intermittently depends on furnace conditions. Watch the furnace for fuel throw/spreading pattern and combustion. If the fuel is falling close to the front plate, increase the SA pressure at the spreader duct. Initially there will be heaps in the furnace, during such conditions, stop the feeder of the section where the fuel pile up on the travagrate and wait for the heaps to burn. Pocking may also require in such condition to disturb the heap for quick burning, Feeder can be started once the heaps are cleared. While viewing the furnace utmost care to be taken, as in the event of fuel feeding interruption there will be a possibility of furnace puffing. View the furnace condition through the peep hole in the access door at the travagrate front panel, it also advised to use safety goggle while viewing to avoid accident. During start-up, there will be mouth feeding and un-burnt in the bottom ash, due to low furnace temperature, which will be gradually reduced when the furnace temperature/load is increased. Furnace pressure is to be maintained between (-) 2 to (-) 5 mmwe, if the furnace pressure is too negative fine bagasse particles will either fire close to S.H. zone or fly as unburned. Firing at free board is to be avoided for the protection of S.H. coils from over heating. Page 9‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS PRESSURE RISING Close the drum vent valve when the pressure reaches to 2-kg/cm? (g). Keep the start up vent and SSH drain valves in open position. As the pressure increases, carefully watch the pressure part for free expansion/movements. Increase the boiler pressure as per the cold start up curve, rate of firing is to be varied as per the requirement, at times it may require to stop the feeders, but ensure that the feeding is not discontinued for a long time so as to maintain the furnace temperature. During pressure raising, keep the drum water level controller in manual or single element control mode, however furnace pressure control can be switched over to auto mode. Whenever the boiler pressure reaches close to the operating range make preparation for charging the main steam piping viz. opening the drain valves in the steam line. Open the by-pass valve of the main steam stop valve (MSSV) to warm up the steam line. Whenever the steam line is warm and condensate (if any) is removed, open the main steam stop valve (MSSV). Close the MSSV by- pass valve after the stop valve is opened fully. On confirming steady steam flow, take the drum level controller in to automatic control mode. It is advisable to keep a watch on the performance of the controller whenever it is put in to automatic control mode at least for one hour. If the steam flow varies more than 20% better to Keep it in manual mode till steady steam flow is ensured. Start up vent to be closed once the steam flow from the boiler is above 30% and the demand is steady with out any disturbance. ‘As the steam flow demand increases, required quantity of the fuel and airflow to be increased to maintain the boiler outlet steam pressure. During initial firing and load up to 60%MCR, both the fuel and airflow to be gontrolled manually through the respective controller. Whenever the steam flow from the boiler is increased more than 60% of MCR switch over the fuel flow controller in to auto mode along with the main steam pressure controller. Initially the airflow to be controlled manually for a period of two hrs, after taking the steam pressure Controller into auto mode. On confirmation of satisfactory working of controller switch over the air flow controller into automatic control mode along with the 02 trimming controller While loading the boiler care to be taken that the feed and boiler water parameters to be brought to the recommended limit before increasing the load beyond 50% of the MCR. Section C Page 10‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS PRESSURE RISING CURVE Pressurising Curve = a os 250} = fo |e gas $ Ee g Eus! z oa | | * as soo = as 5 = al ° 50 100 150 200 250 300 350 ~ Section C Page 11‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS SUPER HEATER COIL PROTECTION DURING PRESSURE RISING During boiler startup, rate of fuel firing and furnace conditions changes frequently which may resulting to vide variation in super heater steam temperature. During such situations if the super heater temperature is not controlled with in the safe limit, it may leads to the premature failure of the coil due to over heating. Hence, care to be taken while pressure rising to maintain the super heater steam temperature with in the safe limit by adjusting the fuel feed rate and sufficient flow through the super heater coil. To ensure cooling of super heater coil, it is mandatory to keep the start up vent valve full open till steady steam flow from the boiler is established, If required, firing may be reduced to maintain the temperature under control range. iso fuel sizing and moisture to be analysed prior to start the boiler as the quality of fuel plays an important role in super heater performance during startup and operation. If fines are more in fuel it may burn in free board and increase the super heater temperature. Hence, it is recommended to maintain fuel quality as per the specification for smooth and trouble free startup and operation. OPERATION Fuels distribution During first few days of operation, adjustment of Travagrate speed and spreader air pressure may require to bring the firing system to its fullest efficiency. For fuel spreading adjustment, system is provided with trajectory plate, air pressure control dampers along with air modulating dampers. Position of trajectory plate and air pressures setting depends on the fuel quality and firing conditions. To throw the fuel towards the rear wall, trajectory plate is to be kept horizontal and the air pressure to be adjusted so as the fuel spreading is beyond the grate centerline. Larger particle and high moisture fuels require high pressure air for spreading, however the air pressure to be reduced if the fuel is with low moisture and small size fiber. During start up, there will be mouth feeding of fuel close to the front wall, as the furnace temperature will be less during this period. Hence the fuel falling close to the front wall burning will be slow and looks like mouth feeding, this pile will be burnt and cleared as the boiler load increases, at times it may require to assist the fire by manual poking to clear the pile. GRATE SPEED il flow control valve located at the front of the hydraulic drive unit controls speed of the grate, By tuning the control knob, counter clockwise from ‘0’ setting, the speed can be increased from 0 to 13.7mtrs/ hour maximum, Section © Page 12‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. Quantity of fuel burnt and ash content of the fuel being fired determine the speed of the grate. Travagrate under high loads, burning fuel with a high ash content will require an accelerated grate speed to keep the ash bed level at an optimum height. Travagrate under lower loads, burning fuel with low ash content will require slow grate speed. Operator should adjust the drive speed accordingly, any adjustments should not be radical or made in rapid succession. The time between changing a setting and the effects could be several hours. COMBUSTION AIR For the complete combustion of fuel being fired, air is fed into the furnace from various sections. Primary air from FD fan through the Air per heater (APH), helps the combustion of fuel on the grate. Air flow to be adjusted according to the quantity of fuel feeding and bed ash thickness. The exact quantity of air requirements can be adjusted as per the excess air from the O2 measurement in flue gas and furnace conditions. During start-up Air Pre Heater (APH) is by-passed from airside, to avoid gas condensation because low gas temperature and tube corrosion. To maintain the APH tube metal temp. airflow through the APH is to controlled by adjusting the dampers provided in the F.D fan to APH and ‘APH by-pass ducts. These dampers are to be adjusted to maintain the gas temperature at APH outlet at 140°C, Over fire from SA fan is fed to furnace at various elevations, provides turbulence, which thoroughly mixes with volatile gases and fine fuels, thus assuring complete combustion. Dampers at the individual elevation ducts are to be adjusted to maintain the required air pressure to create good penetration into the furnace and vigorous air turbulence above the grate. Cinder re-firing system is also connected with the secondary air system and the required air pressure (250 to 350mmwc) to be maintained all the time i.e. after stabilising the coal firing and prior to run the coal feeding continuously. It is also required to keep the system clean and through always to ensure re-injection of cinder from flue gas. SECONDARY AIR PRESSURE SETTING Whenever the plant is stabilised and boiler loaded is around 60% MCR, adjust the secondary air pressure at various levels, as per the enclosed chart and record the same for future reference. Note that the air pressure at pneumatic spreader inlet is to adjusted according to the quality of bagasse viz. moisture and fibber size. Spreading of bagasse depends on the pressure at the spreader inlet and the position of trajectory plate. During plant commissioning the quality of bagasse varies frequently, under such condition there is always a possibility of chute jamming and mouth feeding of bagasse happens. To overcome such situations it is advisable to keep little high pressure at pneumatic spreader inlet. Section ¢ Page 13‘THERMAX BABCOCK & WILCOX PUNE, INDIA. PROJECT: TITAWI SUGAR COMPLEX UNIT OF MAWANA SUGARS SECONDARY AIR PRESSURE SETTING CHART FOR BAGASSE PITH DAMPER OPENING % [PF 250 10 350mm 35010 3s0mmme | > < 250 1 350mmwe 2500 350mmwe TO CINDER RECOVERY 7 SCUssyst=m |__| | BOOT TSM 4 4 THOT Emme — | 2 2 TPF 150 16 300mm 2|/a 3 3 + ae 100-125mmwe ms x OIL PRESSURE= —-mmWC Damper OP% or Speed = Section C Page 14‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. TYPICAL SECONDARY AIR PRESSURE SETTING FOR COAL FIRING Boiler front. = __» ‘TOP DUCT 200 to 250mmvve CINDER FIRING 300 to 350mmwe LOWER DUCT 100 to 150mmwe FINE THROW NOZZLE [J 200 10 400mmvve Pressure to be adjusted at site depends upon the fuel quality. When the fines are more in the fuel, fine through air nozzle pressure Is to be increased to throw the fuel far from front plate. Pressure provided is for reference only, actual setting will be carried out at site depends on the performance of fuel throw and firing performance. Section C Page 15THERMAX BABCOCK & WILCOX + TETAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS TRAVAGRATE Operation In stoker firing, part of the fuel is burned in suspension and remaining on the grate. Fuel is sprayed across the furnace by the series of fuel feeders with a uniform spreading action, Permitting suspension burning of the fine particles during travel. The larger pieces fall on the grate for combustion, forming a thin fast burning fuel bed. This method of firing fuel provides for extreme load fluctuation as ignition is almost instantaneous on increase of firing rate and the thin fuel bed can be burned out rapidly when required. Specifically designed air - metering grates for Under grate air, over fire air system, to reduce carbon loss. Combustion controls are furnished to coordinate fuel and air supply with load demand. The traveling grate has an extraordinary ability to burn any type of fuel with a wide range of burning characteristics with no limit on the ash content. An over fire air system is provided for successful suspension burning. This air mixes with the furnace gases and creates the turbulence required to complete combustion. To compensate for variation of the ash content in the fuel, the grate speed can be adjusted up to 13.7mtrs/ hour. The ash is continuously discharged over the front end of the grate into an ash hopper. Travagrate is extremely sensitive to load fluctuations since ignition is almost instantaneous on increase of firing rate and burn out of the thin fuel bed can be rapidly effected when desired. The grates employ the basic design concepts of high resistance with air metering to avoid blowholes through the thin bagasse pith bed. With pneumatic distribution feeding, fresh bagasse pith is distributed uniformly over the surface of the burning fuel bed. It is ignited from the fire bed beneath and burs upward. Thus the grates are always protected from high temperature by a layer of ash. Control of both the quantity and the distribution of combustion air are important and are generally done with the help of the damper at the fan inlet or by varying the speed. Speed control ' To control the speed of the grate, it is equipped with a flow control valve, which is located at the front of the drive. Turning its control knob anti clock wise increase the quantity of fluid flowing into the cylinder, thus making the piston travel at the faster rate. Increasing the rate of piston travel in turn increases speed of the grate. Turning the control knob clockwise will decrease the cil-flow and speed of the grate Capacity of the flow control valve and hydraulic system is such that the rotation of the drive shaft can be adjusted up to 45 foot per hour. The speed at which the drive should operate will depend ‘on the amount of fuel being burned and its ash content. Section ¢ Page 16‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS ESP Following care to be taken in ESP operation. + Monitor the gas inlet temperature during start up and low load operation, as the ESP to be charged once the gas temperature is increased above 125°C. * During start up, ESP to be charged 4hrs after the flue gas temperature is reached 125°C, this is to avoid mild explosions due to the presence of “CO” in flue gas, as “CO” generation is common during start up because of transient conditions. + If the boiler operation is not stable, it is advised to switch off the transformer, but keep the heater and rapping mechanism in operation. + It is recommended to switch off the ESP Transformer, if the ESP ash handling system is not in service. + Ensure proper functioning of insulator heater, presence of moisture can cause cracking of Insulator. * Check and confirm the healthiness safety interlocks. + Monitor the ESP gas outlet temperature. + Verify the normal operation of purge air fan and cleanliness of the suction filter. STEAM TEMPERATURE CONTROL ‘As the steam flow demand increases, the firing rate also increases which in turn rise the temperature of flue gas at super heater inlet. With the higher firing rate, the super heater steam temperature also increases considerably. To maintain the steam temperature to the desired limit, boiler is provided with a spray type attemperator between the outlet of primary super heater and inlet of secondary super heater headers. Water spray requirement is controlled through the controller and the control valve. Steam temperature controller to be switched over to auto mode when the steam flow increased to 60% of MCR. CHEMICAL DOSING SYSTEM + . To maintain the feed and boiler water concentration, boiler is provided with HP & LP dosing system. Dosing system should be started as soon as the boiler operation is stable, so as the recommended water limits can be achieved prior to load the boiler >50%MCR. Dosing requirement to be decided as per the analysis of the samples collected from the sources. At times the dosing may be stopped, during such situations, close the mixing tank outlet valve and open the flushing line valve, operate the pump for 2 hrs. In this process, the chemically concentrated water is replaced with the clear water; thus choking of piping can be avoided. Section © Page 17‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. BLOW-DOWN SYSTEM Dissolved and suspended solids entering into the boiler through feed water system remain in the boiler, as steam is generated continuously. During steaming process the solids retain the boiler which increase the concentration of boiler water gradually. There is a limit for the concentration level of solids in the boiler water depends on the operating pressure, exceeding the limit of Total Dissolved Solids (TDS) may produce undesirable foaming and carryover. To control the concentration limit, part of the water is to be drained off, and replaced with fresh water keeps the TDS level under control. Blow down rate is determined by the TDS of the boiler water, blow-down may be controlled either intermittently (IBD) or continuously (CBD). Intermittent Blow-down (IBD) Through this system blow-down is carried out intermittently to control the water concentration, whenever the drum level increase above the safe limit, to control the level water can be drained though this system. IBD is tapped from water drum Continuos Blow-down (CBD) Through this system a small portion was water is drained from boiler continuously, depends on the TDS level. Apart from maintain the concentration level, the heat from the drain is recovered as the flash steam from CBC tank is connected to the deaerator. Along with heat a portion of water also saved from CBD. Section C Page 18‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. AIR PRE-HEATER Air pre heater provided is of tubular type and the purpose is to recover a portion of the sensible heat from flue gases thereby improving combustion efficiency. The arrangement consists of tubes set vertically in a surrounding ductwork. The ends of the tubes are expanded into the supporting ‘tube sheets. The flue gas passes through the tubes while the incoming air for heating passes from the out side of the tubes. SOURCES OF TROUBLES AND PREVENTION Fouling Tubular heater elements are susceptible to fouling due to fly ash accumulation, particularly at the air inlet to the heater and near the exit of gas from Air Pre Heater. Dust build up on the gas side of the tubes can be detected by observing the following conditions, + Increased draft loss across the heater. + Increased gas temperature leaving the heater. ¢ Decreased air temperature at the APH outlet can often be prevented or minimized. Fouling can be prevented or minimized by proper operation of firing equipment and maintaining ‘APH tube metal temperature above the gas dew point limit. To minimise the dust deposit, APH is provided with air By-pass arrangement. As there will be gas condensation inside the tubes, during boiler start up due to low back-end gas temperature. Hence during start up the by pass damper to be kept open 100% open and the inlet damper to be kept closed. Opening of these dampers to be adjusted in such a way to maintain the gas outlet of APH at 140°C Corrosion When fly ash deposited in the gas path of cold end tubes, they often form a hard bonded material that acts as insulation. This insulation lowers the tube metal temperature until it approaches the incoming air temperature. This temperature is usually below the dew point of the flue gas, acid constituents within the ash, which become corrosive in the presence of moisture. Conditions causirfg corrosion can be minimized by keeping the tube surface free of deposits through proper combustion and by maintaining safe flue gas temp. i.e. 145°C at APH exit. Fires Tubular air-heater can be damaged or go out of shape by fires occurring in the gas passes. Generally these fires are caused by the deposition of large quantities of unburned combustible materials within tubes and on the tube sheets. Unbound fly ash may be deposited on the tube ‘surface during initial start up and on abrupt changes of firing rate, may ignite this deposits leading to damage of the tubes. Section C Page 19‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS APH fire is indicated by a very rapid increase in temperature of gas or air flowing from the APH. If this occurs, following steps should be taken. ¢ Discontinue firing immediately. ¢ Shut down all fans & dampers. ‘¢ Floor area of fire with CO? or suitable fire extinguisher. Ensuring complete combustion of fuel can prevent APH fires. DEAERATOR, ‘START UP It is recommended to charge the steam to the deaerator as soon the LP steam is made available, if the steam charging is done at boiler load conditions may cause thermal shock and water hammering due to imbalance in steam and water flow till the stabilisation of deaerator. Procedure for placing the deaerator in to service is as below: Open the vent valve on the vapor tank (DA-056). Open the deaerator level control valve and fill up the deaerator up to normal operating level. Check and ensure the water level indication is matching with the direct level gauge. Open the drains in the steam to deaerator pipeline and ensure the removal of condensate if any. + Open the pegging steam pipeline valve (tag no.DA-082) gradually and admit steam to the deaeraor. Whenever the water temperature rise above 60°C, open the deaerator pressure control valve (PCV-104) gradually, till steam starts flow out from the vapor tank. Adjust the valve opening to maintain the steam pressure as per the requirement. + During initial steam admission, it is recommended to control the feed water entry to deaerator, so as to maintain the balance in steam and water flow to avoid condensation and water hammering. ‘+ Steam and water flow to be increased simultaneously and appropriately to avoid thermal shock. + It also recommended to switch over the pressure and level control to auto mode as soon the deaerator pressure is achieved. sees OPERATION During the normal operation, vent valve (DA-056) should be closed as the required volume of steam will be vented out through the by-pass line with orifice. Also the pegging line isolation valve is kept in closed position whenever the deaerator pressure is stable, It also recommended to monitor the steam supply pressure and deaerator operating pressure to maintain required outlet water temperature. Section C Page 20‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. SHUTTING DOWN To isolate the deaerator from service; Close the steam to the deaerator. Open the vapor tank vent valve. Open the drain valves in the steam pipeline. Maintain water level as required. SOOT BLOWER Soot blower operation is depend on fuel type, steam flow, steam temperature and boiler arrangement. In general, frequency of cleaning may be determined by observing flue gas exit ‘temperatures raised from the boiler, economiser, air heaters, draft loss across the flue gas system and steam outlet temperature. It may be more economical on the other hand to operate soot | blowers as required rather than to adopt a fixed blowing schedule. This boiler is provided with, 4 nos. motorised long retractable and 14 nos. of motorised multi-jet rotary soot blowers. Superheater Zone ~ 4 (SB-1,2,3&4) + Super heater & B.B zone ~4 (SB-5, 6, 7&8) * Boiler Bank Zone —4 (SB-9, 10, 11 &12) * Economiser Zone —6 (SB-13TO 18) Soot blowing system is provided with a manual start up arrangement. Hence, during start up and normal/ operation, the soot blower control should be kept off or in manual mode along with the steam pressure control. Soot blower panel to be switched on and put into auto timer operation mode along with the steam pressure controller in auto mode, during soot blowing. It is recommended to operate soot blowers, whenever the steam flow from the boiler crosses 60%, While operating the soot blower, Prior to start up, furnace draft should be increased considerably to ensure sufficient draft to carry soot through the boiler. Secondly, open soot blower steam piping drain valve and steam trap valves. Keep the steam pressure control valve in auto mode and open the main steam valve & keep the drain open til all the condensed water is removed from the piping. Once the steam temperature reaches to the specified limit operate the blowers as per the order specified. On completion of blowing cycle main valve to be closed and the drain valve to be kept open to remove the condensate. Also the furnace pressure control to be made normal. Section ¢ Page 21‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. STEAM WATER ANALYSIS SYSTEM (SWAS) To monitor the steam, boiler water and feed water parameters like pH, conductivity, TDS, and silica system id provided with a SWA. Based on the analysis corrective action like chemical dosing and blowdown quantity can be decided. Start-up: Open the cooling water to sample cooler. Keep the drain valve in open position. Open the sample isolation valves graduaily and flush the piping till the dirt and sediments if any are removed so as to ensure a clean sample with out any contamination. After flushing, adjust the required sample flow rate and observe the temperature of the sample. On confirming temperature of the sample, collect the sample for analysis. During operation, periodically check the sample quantity and temperature. Also the quality of the cooling water to be monitored so as to avoid fouling and damages to the cooler coil Shutdown: Whenever the system needs to be shutdown, stop the sample first and run the cooling water for 30 minutes to cool the coil and keep the drain valve in open position to drain the sample trapped in between the system. Section C Page 22‘THERMAX BABCOCK & WILCOX PUNE, INDIA. PROJECT: TITAWI SUGAR COMPLEX UNIT OF MAWANA SUGARS ANTICIPATED BOILER PERFORMANCE DATA SHEET | se Description unit STEAM. Evaporation TPH ‘Steam Temperature @ Boiler Outlet [°C Drum operating pressure Kg/Cm= [Steam Pressure @ Boiler Outlet Ka/Cm |__| Primary SH Steam Inlet "CT Sec. SH inlet. °C. Sec. SH outlet 5C | | FEED WATER I I Eco inlet pressure Kg/Cm? Eco outlet pressure Kg/Cm’ Eco inlet temperature °C | Eco outlet temperature °C FLUE GAS es Flue Gas Temp. Leaving Furnace °C Flue Gas Temp. Leaving = | | Superheater Section __| * | | Flue Gas Temp. Leaving Convection °C Section Flue Gas Temp. Leaving Economizer | °C [ __ | Flue Gas at APH Out let |e f Temperature | Flue gas at furnace outlet [mmwe Flue gas at Boiler outlet mmwe Flue gas at Economiser outlet mmwe Flue gas at APH outlet mmwc Flue gas at ESP outlet mmwe [Flue gas at I.D. inlet mmwe L LAIR, [ ‘APH inlet. °C _ | ‘APH outlet EG | FD Fan outlet mmwe_| APH outlet mmwe_ | Under grate mmwe SA Fan outlet _ ‘mmwe | | 02 % Section Page 23‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA, UNIT OF MAWANA SUGARS DO’S AND DONT S FOR BOILER Do's + Clean the internals before closing the manholes of pressure parts furnace and ducting. ‘+ Maintain all instruments in good working condition ‘= Equipment safety interlocks should be always in line, ‘+ Maintain normal water level in boiler. + Maintain water quality as per the recommended limits. + All the contro! and isolation dampers must be in smooth operating condition. ‘© Maintain hydraulic drive oll pump pressure as per the recommended set pressure. ‘+ Pressure raising from cold start must be done as per the cold start up curve. ‘© Use proper lubricants recommended by the manufacturer schedule. ‘+ Start the equipment as per start-up sequence ‘+ Carry out regular soot blowing for boiler and economiser. + Operate the boiler within the recommended operation li + Boiler, Piping, Ducts, Feed water and Oil tank must be properly insulated. + Equipments maintenance should be done as per the manufacturer's schedule. + Maintain operation log sheets regularly. + Maintain the instrument air free from moisture and oil matters and the pressure as recommended. + Use proper valve gland packing to avoid leakage. ‘+ Use proper gaskets for flange joints. * Boller surroundings and equipments must be properly illuminated. ‘+ Incase of power failure close the steam stop valve and stop the fire immediately. Section C Page 24‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS: * Use genuine spares. Before starting rotary equipment’s ensure the following. Transfer pump Ensure the pump suction valve is wide open. Verify the suction pressure. Verify the cleanliness of the suction filter. Verify the bearing lubrication level. Free rotation of pump. inimum flow line vale wide open. Keep the pump discharge valve in close position: Feed water pump Ensure the pump suction valve is wide open. Verify the suction pressure. Verify the cleanliness of the suction filter. Ensure the availability of cooling water. Verify the bearing lubrication level. Free rotation of pump. Minimum flow and balancing leak off line vales are wide open. Keep the pump discharge valve in close position. ID Fan Ensure flue path duct and hopper manholes are closed. '* Close the fan suction and discharge damper fully. © Verify bearing lubrication. FD Fan + ID Fan in running condition + Close the fan suction damper ‘Verify bearing lubrication. SA Fan * ID, FD Fan in running condition + Close the fan suction damper © Verify bearing lubrication. Section C Page‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS DON'TS + Don't by pass any instruments and safety interlocks. + Don't use raw water as Boiler feed water. ‘Don't throw big size wooden logs inside the furnace for slow firing. * Don't run the Boiler with furnace in pressurized condition. * Don't increase the set pressure of the TRAVAGRATE hydraulic oil pressure beyond the recommended limit. + Don't allow super heater steam temp. to go beyond the designed limits. + Don't operate the furnace wall header drain valves while the Boiler is in operation, + Don't operate the boiler beyond the operation limits. + Don't leave the furnace door open while the boiler is in operation, + Don't mix up different lubricants. ‘= Don’t by pass compressed air, dryer, if any problem attend to it at the earliest * Don't throw water inside the hot furnace. * Avoid continuous operation of boiler at low loads (low back-end temperature) to protect Economiser, ESP and Air Pre-Heater corrosion. * Do not dose chemicals into the boiler in batch wise, they should be done on a continuous basis. * Do not open any of the ESP manholes, while the I.D. Fans in operation. + Do not charge the ESP at lower flue gas temperature (>120° C) Section € Page 26‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS OPERATING INSTRUCTION FOR IMPORTANT VALVES LOCATION OPEN CLOSE Economiser air | During boiler filling. After ensuring free water flow from vent en the vent. Steam drum | During water filling & |When the drum pressure vent. Start up. reaches to 2 kg/cm? during start + When the — drum _— | up. pressure drops 2kg/cm? | during shut down/box- | up. _ Start up vent During start up and also | After the boiler is connected to | when’ SH steam | load after ensuring 30% of MCR. __| temperature shoots up. | SH. Header drain | During start up after the boiler is connected to valve. the load Main steam by | Before charging the main | After the stop valve is opened | pass valve, steam line, fully. (After pipeline is heated up.) _ Main steam | After ensuring 100% | Whenever the boiler is to be stop valve. removal of condensate from _| isolated from the range. the steam piping. Also ensure the pipeline is heated up to the working | ‘temperature. TBD valve Open for emergency drum | After the drum level is brought level control and for sludge to normal level. | removal. | Water wall __| Open for draining the boiler | Valve should be kept closed | drains. | after kiling “the fire | always when fire inside the completely. boiler. CBD valve [Adjust the opening to | Close the valve if TDS of the | maintain the TDS of the | boiler water is maintained within | boiler water. its. Soot blower [Open before and _—_| Close after ensuring moisture steam line drain | completion of blowing cycle. _| free steam flow from the drain. valve. Section ¢ Page 27‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS WALK DOWN CHECK LIST DURING OPERATION Check for unusual noises from steam/water leakage, Check for unusual traces of water on floor, buck stay or leakage from casing joints. Look for valve and gland leakage. Discoloration, hot spots and bulging etc. on casing, ducts and hoppers. Check for steam and water leaks from connections and fittings to the drum. Watch the furnace for any clinker formation and bagasse pile up. If possible inspect the slagging condition of furnace walls and super heater coils through the observation ports. Walk around the furnace exterior and observe for any hot spots or gas leaks. Listen for any unusual noise around economiser which may indicate economiser leak (i.e. hissing noise) Inspect penthouse for gas leakage. Inspect wind-box/plenum hopper for any air leakage, signs of overheating that may indicate wind-box fires or hot gas re-circulation within the wind-box. Inspect all ash hoppers to make sure they are being emptied properly, Check around all air/flue ducts for signs of leakage. Check position of fan and field dampers. Check for any gas leakage from refractory sealing. Check for leakage from safety valves at normal operating pressure. Also note the safety valve blow off and shut off pressure. Check that the drain lines and drip pans are not plugged. Make note of any leaky valves and prepare maintenance schedule to repair them. Check to see that proper water level is being shown by the direct water level gauge. Check for water or steam leaks from ports or drain connections, which will cause a false water level in the gauge glass. Inspect the glass for discoloration or fouling, While doing routine operation of soot blowing, inspect for condensate, steam and leaks from the soot blowers.‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS WALK DOWN CHECK LIST DURING OPERATION Check for unusual noises from steam/water leakage, Check for unusual traces of water on floor, buck stay or leakage from casing joints. Look for valve and gland leakage. Discoloration, hot spots and bulging etc. on casing, ducts and hoppers. Check for steam and water leaks from connections and fittings to the drum. Watch the furnace for any clinker formation and bagasse pile up. If possible inspect the slagging condition of furnace walls and super heater coils through the observation ports. Walk around the furnace exterior and observe for any hot spots or gas leaks. Listen for any unusual noise around economiser which may indicate economiser leak (i.e. hissing noise) Inspect penthouse for gas leakage. Inspect wind-box/plenum hopper for any air leakage, signs of overheating that may indicate wind-box fires or hot gas re-circulation within the wind-box. Inspect all ash hoppers to make sure they are being emptied properiy, Check around all air/flue ducts for signs of leakage. Check position of fan and field dampers. Check for any gas leakage from refractory sealing. Check for leakage from safety valves at normal operating pressure. Also note the safety valve blow off and shut off pressure. Check that the drain lines and drip pans are not plugged. Make note of any leaky valves and prepare maintenance schedule to repair them Check to see that proper water level is being shown by the direct water level gauge. Check for water or steam leaks from ports or drain connections, which will cause a false water level in the gauge glass. Inspect the glass for discoloration or fouling, While doing routine operation of soot blowing, inspect for condensate, steam and leaks from the soot blowers.‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. NORMAL SHUTDOWN PROCEDURE For known reasons if the boiler is to be stopped for few hours or few days, it is suggested to follow the following procedures. If the shut down is only for few hours, it is not recommended to cool the furnace. If the shut down is for few days, it is recommended to cool the furnace. SHUT DOWN PROCEDURES - LONG DURATION > Reduce boiler load at the rate established by the turbine or as per process requirements until the minimum load point. > Reduce the steam flow by reducing the fuel feed rate and combustion airflow (primary). > In either manual or automatic operation, the airflow follows the fuel flow on decreasing load. > On confirming the zero demand of steam from boiler stop the fuel feeders, and close the main steam stop valve. Open the start-up vent valve till the boiler pressure drops to 85% of the operating pressure. And keep the boiler in hot banking for natural cooling. > Stop the boiler by shutting off the fuel feed systems as follows: Close the gate below coal bunker outlet above each feeder. Empty out the fuel feeders and stop the same. Keep the airflow to furnace till the all the remains over the great is cleared off. Continuously run the travagrate to dump all the remains over the grate surface. > When the flue gas temperature drops below 125°C remove the ESP from the service but keep the raping and heating system into service. Also the ash handling system into service for 4 to 6 hrs after switching of the 1.D. fan. > Keep the cooling water flow to the water cooled equipment till the body temperature drops to <50°C. > Once the drum pressure drops to 2Kg/cm*(g) open the drum air vent valve. > If the unit is to be shut for a short period, NO PERSONNEL WILL BE ADMITTED TO THE BOILER. If the operating personnel need to enter the unit, the boiler, economiser, air heater hoppers, and the ash collection equipment hoppers (ESP) must be emptied of any solids and the enclosure temperature cooled below 50°C. c Page 29‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS > All ash must be removed completely from the boiler and hopper and the boiler temperature must be below 50°c before personal are allowed to enter for maintenance or inspection. > Shut down all the auxiliary equipment at this time. This will include the feed water system, make-up system, ash removal systems, etc. > It is recommended that a positive pressure of nitrogen be maintained in the drainable components anytime the unit is out of service, whether the boiler is filed with or without water, for longer than two weeks. A nitrogen blanket should be maintained through a "T” fitting on the drum vent. SHUTDOWN PROCEDURES - SHORT DURATION ‘There may be situations the boiler may be kept under shutdown for small duration’s for some work outside the boiler plant or may be due to the failure of some auxiliary equipments. During such situations the following procedure may be followed, > Reduce the steam flow gradually and stop the steam outlet to the downstream equipments. > Stop the fuel feeding also stop the travagrate so as to keep some heat inventory to restart. > Stop the S.A, F.D and I.D fans. > Maintain the drum water level. > Boiler can be restarted with out any external assistance if it is restarted with in 4hrs time from shutdown, otherwise to retain the furnace temperature, firewood may be charged at regular intervals. The quantity wood firing may be controlled so as to avoid considerable ‘amount of pressure raise. > If the boiler needs to be kept under shut for overnight it can be kept hot by intermittent firing of coal or by manual charging of firewood. EMERGENCY SHUTDOWN PROCEDURES TYPES OF EMERGENCY SITUATIONS ‘The critical emergency situation in boiler plant is, low water situations, which directly affect the boiler pressure parts. EMERGENCY RESPONSE ACTIONS AND PRIORITIES Following are the required actions to be taken in response to the above emergency situations to ensure protection of the boiler pressure parts. Section C Pace 36PSY THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS. Loss of feed water supply. Start the stand-by boiler feed pump to restore the feed water supply to the boiler. If the feed water ump could not be started immediately, the following actions should be taken: > Fuel feeder, F.D and S.A fan will trip automatically though the drum level very low interlock (level switch/transmitter). It is mandatory to shut the unit down completely till BFP system is available. o ‘Stop all the steam and water outlet from the boiler. > If loss of feedwater is due to a power failure, start the emergency generator or switch over to alternate power source to restore the drum level. While suppiying water to drum during such situation the rate of flow should be controlled to avoid quenching. Failure of draft system ‘When the draft system fails, the boiler unit comes to a forced shut down, during such emergencies, the fuel feeder will trip through the F.D fan running interlock to start the DCF. During such situations maintain water level in the drum as the feed water pumping system is available, [As soon the draft system is ready for operation, switch the fan controls to manual mode and start the ID fan. Followed with F.D and S.A fan. Section C Page 31‘THERMAX BABCOCK & WILCOX PUNE, INDIA. PROJECT: TITAWI SUGAR COMPLEX UNTT OF MAWANA SUGARS. BOILER START UP FLOW CHART 1. Input ——— Fuel Feed water. Uninterrupted electric power supply for auxiliary equipment's. Lighting for equipment’s, walk ways and field instruments. Instrument air. Plant air. Cooling water. Lubricant for the rotary equipment’s. Chemical for feed and boiler water treatment. > Readiness of drainage and ash disposal system. Fire fighting system. vv a vvvyvy y 2, Walk down checks <->} > Nitrogen capping is removed and the unit is purged properly so as itis safe for man entry for inspection. Steam and water drums manholes are closed property. furnace S.H and convection bank are clear and all access / inspection doors are tightly closed. air duct to furnace and flue up to stack is clear and the manhole doors closed properly. > walkways are clear with out any obstruction. S Sy y 3. Equipment lineup <->} Valves to be kept in open position: Air vent on steam drum. Start-up vent at S.H. steam outlet. Air vent on economiser outlet header Instrument air connections to all the instruments. Isolation vaive for drum level gauge Steam and water system pressure gauges/transmitters vvvy vv Section C Paae 3?‘THERMAX BABCOCK & WILCOX PUNE, INDIA. PROJECT: TITAWI SUGAR COMPLEX UNIT OF MAWANA SUGARS Equipment lineup Valves to be kept in open position: > Air vent on steam drum, > Start-up vent at S.H. steam outlet. > Air vent on economiser outlet header » Instrument air connections to all the instruments. > Isolation valve for drum level gauge » Steam and water system pressure gauges/transmitters | a jd dampers open/close position during startup > LD fan in/outlet dampers in open position. > Plenum, APH & ESP hopper, ash outlet gates in open position. >» Main ash hopper outlet gates are in open position and the by pass chute gates are in closed position. > Submerged ash conveyor is filled with water. > Close the FD Fan to APH inlet duct damper and open the APH by-pass duct damper. > Open the APH to plenum duct isolation dampers. >_chimnev manhole is kent closed. Readiness of following equipment’s: .D., FD and S.A. fans. ¢ Feed water transfer pump. + Feed water pump. + Travagrate with drive. ‘+ Twin drum feeders for bagasse + Screw feeders for bagasse + Rotary airlock valves. ’ . . . Fuel handling system. ‘Ash handling system. Chemical dosing system. Soot blowers. Pace 33.‘THERMAX BABCOCK & WILCOX PUNE, INDIA. PROJECT: TITAWI SUGAR COMPLEX UNIT OF MAWANA SUGARS Equipment lineup Verify the readiness of following instruments: * Control panel/DCS Control valves Motorized valves All the field and panel instruments. Damper actuators Sensors x a Switch over the controls to manual mode; Deaerator level and pressure. Furnace pressure Drum level Steam pressure Steam Temperature. Air flow Fuel flow CBD tank level Soot blower pressure control ESP : > Switch on the ash handling system one hour prior to light up. > Open the isolation gate above the RAV and switch on the rotary airlock valves. > Incase of pneumatic evacuation, open the isolation gate above the | __ vessel > Switch on the rapping mechanism ‘one-hour before the light up. Switch on the hopper and insulator heater four hours prior to light up. Safety interlocks are tested prior to startup. v vVvvvvvvyy v e Section C Paae 34‘THERMAX BABCOCK & WILCOX PUNE, INDIA, PROJECT: TITAWI SUGAR COMPLEX UNIT OF MAWANA SUGARS 3. Equipment lineup < {>| 4. Water filling <—————__¥&______» y Start feed water transfer pump Others + Verify all the soot blowers are in rest position. ‘+ Ensure the test gags of safety valves are removed. Verify all the safety interlocks are working as per the desired logic/values. Ensure the availability of cooling water/seal air to the system. Switch on the RAV below ash hoppers and ash convevors. Valves to be kept in open position: + Air vent at economiser outlet header + Air vent on steam drum + Start up vent + Economiser inlet header drain Valves to be kept in closed position: © Furnace drain header outlet + Furnace bottom headers drain + Water drum drain/blowdown = CBD piping ‘+ H.P Dosing piping + Steam sampling line + Main steam isolation and by-pass valy + Attemperator spray water isolation + Feed water control valve isolation * Steam to soot blower +_Economiser outlet header drain + Ensure suction valve in open position. Verify the suction pressure. Verify cleanliness of the suction filter. Verify the bearing lubrication Verify free rotation of pump. Minimum flow line vale wide open. Pump discharge valve in close position. Start the pump,‘THERMAX BABCOCK & WILCOX PROJECT: TITAWI SUGAR COMPLEX PUNE, INDIA. UNIT OF MAWANA SUGARS * Admit the water through the common drain header, which is connected to economiser drain header. * Close the economiser outlet vent valve once the air is removed. + Fill the water up to 50mm below the normal water level, or * Ensure suction valve in open position. Verify suction pressure. Verify cleanliness of suction filter. Verify bearing lubrication. Confirm cooling water to shaft seal/gland. Verify free rotation of pump. © Minimum flow & balancing line valve wide open. + Pump discharge valve in close position. + Start the pump. Bere ___ * Close the economiser inlet header Grain valve. + Admit the water through the feed water control station by-pass valve. . * Close the economiser outlet vent valve once the air is removed. + Fill the water up to 50mm below the normal water level. vy Start feed water pump Section C Pane 6‘THERMAX BABCOCK & WILCOX PUNE, INDIA. PROJECT: TITAWI SUGAR COMPLEX UNIT OF MAWANA SUGARS A 4. Startup ¢——Y¥—__,} v Stack around 200kgs of ‘specified size firewood over the grate. Light up the firewood. Increase the firing rate gradually. Start ID Fan} Close the fan suction and discharge damper fully. Verify bearing lubrication. Confirm suction damper operation. Start the fan Start FD Fan Verify drum level. Verify ID Fan running Close the fan suction and discharge damper fully. Verify bearing lubrication. Confirm suction damper operation. Start the fan Start SA Fag Verify FD Fan running lose the fan suction and discharge damper fully. Verify bearing lubrication. Confirm suction damper operation. Start the fan. Furnace temperature >550°C Start air modulating damper Verify SA Fan running Close the fan suction and harge damper fully. Verify bearing lubrication. Confirm suction damper operation. Start the drive. Section C Page 37