Hindalco Details PDF

DIVISION - A
STEAM GENERATING UNIT

VOLUME - A1
BOILER PERFORMANCE, LAYOUTS, PP, L&I & DUCTS
LIST OF CONTENTS
Location Description Ref. No. / Drg. No
TAB-1 BOILER PERFORMANCE

(1-97)
Contract Data Sheet CPT 1807
Predicted Performance Data CPT 1806
Boiler Performance Start up Curves CPT 1804
Boiler Start up Curve CPT 1803
Flow Measurement Device Characteristics and Data CPT 1805
Boiler Performance Curve CPT 1801
General Principles of Boiler Operation CPT 1808
Unit Operating Procedure CPT 1809
Valve Operating diagram CPT 1810
Air & Flue Gas Path Write Up CPT 1811
TAB-2 LAYOUTS
(98-117)
GA of Boiler Sectional Side Elevation 0-00-022-75947
GA of Boiler Sectional Plan 0-00-022-75948
Location of Furnace Openings & Buckstays 0-00-020-75145
Floor Plans M/s. BHEL
ID System Layout of Cold, Hot Air, Flue Gas Duct M/s. BHEL
Terminal Point Details 0-00-020-75144
TAB-3 PRESSURE PARTS

(118-124)
Drum Internal Details 0-04-124-01331
UMD for LTSH Coil Assy. 1-11-236-03208
UMD for Finish SH Coil Assy. 1-11-274-03209
UMD for RH Coils 1-16-275-01317
UMD for SH Vert. Platen Assy. 1-11-278-03210
0172 – 0177 HINDALCO-ADITYA VOLUME – A1 Page 1 of 2

DIVISION - A
STEAM GENERATING UNIT
VOLUME - A1
BOILER PERFORMANCE, LAYOUTS, PP, L&I & DUCTS
LIST OF CONTENTS
Location Description Ref. No. / Drg. No
Assy. of SH Desh 0-12-900-01485

RH Desuperheater 1-24-316-00874
TAB-4 PRESSURE PARTS ARRANGEMENTS

(125-157)
PPA-General Arrangement of Pressure Parts 0-00-027-45322
PPA-Down Comer Arrangement 0-00-027-45323
PPA-Expansion Movement Diagram 0-00-030-45321
Pressure Parts Write up M/s. BHEL
TAB-5 LINING AND INSULATION

(158-182)
Refractory & Insulation M/s. BHEL
Lining & Insulation Drawings M/s. BHEL
TAB-6 DUCTS
(183-227)
Scheme of Duct Arrangement M/s. BHEL
Duct Details M/s. BHEL
Duct Erection Drawings M/s. BHEL
Metallic Expansion Joints M/s. BHEL
TAB-7 HYDROSTATIC TEST PROCEDURE AND

(228-255) LUBRICATION CHART
Recommended Hydrostatic Test Procedure Pub. 2025

Recommended Lubrication Chart M/s. BHEL
0172 – 0177 HINDALCO-ADITYA VOLUME – A1 Page 2 of 2

TAB - 1
0172 - 0177 VOL - A1 TAB - 1 - 1
0172 - 0177 VOL - A1 TAB - 1 - 2
PREDICTED PERFORMANCE
(CONSTANT PRESSURE OPERATION)
SECTION DESCRIPTION SHEET No.
I FLOW 2
II TEMPERATURE 3
III PRESSURE (STEAM & WATER) 4
IV PRESSURES & DRAFTS (AIR & GAS) 5
V FUEL 6
VI MILL & BURNER PERFORMANCE 7
VII O2 • CO2 & EXCESS AIR 8
VIII HEAT BALANCE 9
The attached Performance Data are predicted only and are not to be construed as being
guaranteed except where the values coincide with guarantees stated under the performance
guarantee section.
CustomerlPlant: HINDALCO I ADITYA CPP, UNIT·1 to 6, 6x150 MW

ConlNo.: 0172-0177 Rev.OO Rev.01 Rev.02
L.
Engineer: SM ~ - 09.10.09
Reviewer: SV I.BSR \ tv'"v?" 09.10.09
Approver: SV I PSR '\-<>....I 09.10.09
BOILER PERFORMANCE &PROPOSALS CPT-1806
0172 - 0177 VOL - A1 TAB - 1 - 3

Both HP
Description Unit
HP Heaters in Heaters
out
100% VWO 100% 80% 60%
BMCR TMCR TMCR TMCR
150MW
150MW 120MW 90MW
Steam
Super heater outlet tlh 510.0 480.3 449.1 360.1 273.2 410.0
Re heater outlet tlh 407.1 411.2 384.5 310.5 237.4 390.5
Water
Feed water tlh 510.0 480.3 449.1 360.1 273.2 410.0
SH spray tlh 7.7 7.8 16.4 16.1 14.6 24.8
Air
Air heater outlet
tlh 144.0 136.4 131.0 93.0 88.8 117.8
(Primary)
Tempering air tlh 70.7 73.6 75.5 66.1 58.7 90.9
Air heater outlet
tlh 391.6 354.5 327.0 270.8 179.5 345.4
(Secondary)
Leakage air to
tlh. 32.0 32.0 32.0 32.0 32.0 32.0
boiler
Total Combustion
tlh 638.3 596.5 565.5 461.9 359 586.1
Air
Flue Gas
Flue gas at AH inlet tlh 707 661 627 512 398 650
Flue gas at AH
tlh 774.1 727.2 692.8 576.9 462.0 716.7
outlet
Fuel
Coal(HHV= 3400
tlh 111.9 104.5 99.1 80.9 62.9 102.7
kcaVkg)
ace o 1
Customer/Plant: HINDALCO / ADITYA CPP UNIT·1 to 6 6x15o MW
ContNo.: 0172-0177 Rev.oo Rev.01 Rev.02 Rev.03
I.
Engineer: SM ~ 09.10.09
Reviewer: SV / P..$R' V"-J~ 09.10.09
Approver: SV rPSR \}V 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 4

Description Unit Both HP

out
100% VWO 100% 80% 60%
BMCR TMCR TMCR TMCR 150MW
150MW 120MW 90MW
Steam
Sat. temp. in Drum °C 343 342 341 338 335 339
LTSH outlet °C 446 443 450 447 441 470
SH Platen inlet °C 435 433 426 417 406 421
SH Platen outlet °C 520 520 520 521 522 518
SH Finish inlet °C 520 520 520 521 522 518
SH Finish outlet °C 540 540 540 540 540 540
RH inlet °C 353.4 354.8 343.3 337.3 331.5 353.9
RH outlet °C 540 540 540 540 540 540
Water
Economizer inlet °C 242.0 244.2 240.6 230.6 218.2 155.3
Economizer outlet °C 290 291 290 281 271 241
Air
°C 25 25 25 25 25 25
Ambient
~H Outlet (Primary) °C 306 305 303 289 271 264
AH outlet (Seco-
°C 311 309 308 292 272 267
dary)
Gas
SH Platen inlet °C 1137 1129 1138 1105 1065 1107
RH Front inlet °C 1040 1030 1034 994 944 1011
RH Rear inlet °C 924 912 911 866 812 896
SH Finish inlet °C 815 801 796 754 705 788
LTSH Horz inlet °C 721 708 703 664 619 700
Economiser inlet °C 483 475 472 452 430 477
Airheater inlet °C 337 333 329 311 290 285
Airheater outlet
(Corrected)
°C 130 130 130 125 123 118
ace 0
Customer/Plant: HINDALCO / ADITYA CPP, UNIT-1 to 6, 6x150 MW
Cont.No.: 0172-0177 Rev.OO Rev.01 Rev.02 Rev.03
I
Enaineer: SM g". 09.10.09
Reviewer: SV / ~ lN~ 09.10.09
Approver: SV / PSR \R/ 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 5


out
100% VWO 100% 80% 60%
150MW 120MW 90MW
Pressure
Super heater 2
kg/cm (g) 139.0 138.3 137.5 135.59 134.09 136.61
outlet
Platen SH Outlet kg/cm" (g) 143.9 142.7 141.4 138.2 135.6 139.9
LTSH outlet kg/cm" (g) 149.4 147.6 145.7 141.1 137.4 143.6
Drum kg/cm"(g) 154.0 151.7 149.4 143.5 138.8 146.6
Economizer inlet kg/cm" (g) 157.3 154.9 152.3 146.1 141.1 149.4
Re heater inlet kg/cm"(g) 36.57 36.98 34.59 27.78 21.05 35.48
Re heater outlet . kg/cm" (g) 34.58 34.97 32.72 26.28 19.90 33.59
Pressure Drop
Super heater
kg/cm2 15.0 13.4 11.9 7.91 4.71 9.99
system
Re heater sys- 2
kg/cm 1.99 2.01 1.87 1.50 1.15 1.89
tem
Economizer 2 1.4 0.40
kg/cm 1.24 1.09 0.71 0.91
(Friction only)
ace 4 of 18
Customer/Plant: HINDALCO / ADITYA CPP, UNIT·1 to 6. 6x150 MW
ConlNo.: 0172-0177 Rev.OO Rev.01 Rev.02 Rev.03
.L
Engineer: SM ~-' 09.10.09

Reviewer: SV / ~ \hv~ 09.10.09
Approver: SV / PSR v \AI 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 6

Both HP
out
Description Unit
100% VWO 100% 80% 60%
150MW 120MW 90MW
Primary air
PA Fan inlet mmwc -14 -11 -11 -7 -6 -11
PA Fan outlet mmwc 833 827 824 794 790 815
Air heater inlet mmwc 818 813 810 785 782 801
Air heater outlet mmwc 770 769 769 763 761 769
Mill inlet mmwc 619 598 584 601 541 584
Mill outlet mmwc 250 237 228 236 199 224
Secondary air
FD fan inlet mmwc -20 -17 -14 -10 -5 -16
FD fan oulet mmwc 267 239 220 184 141 228
Air heater inlet mmwc 247 222 206 174 136 212
Air heater outlet mmwc 144 137 132 122 111 135
Wind box pressure mmwc 100 100 100 100 100 100
Gas
.
SH Platen inlet mmwc -5 -5 -5 -5 -5 -5

RH Inlet mmwc -6 -6 -6 -5 -5 -6
SH Finish inlet mmwc -11 -11 -10 -8 -7 -10
LTSH inlet mmwc -16 -15 -14 -11 -9 -14
Economizer inlet mmwc -26 -24 -22 -17 -13 -22
Air heater inlet mmwc -45 -41 -38 -28 -20 -38
EP inlet mmwc -155 -140 -128 -92 -62 -129
ID fan inlet mmwc -238 -216 -200 -146 -103 -201
ID fan outlet mmwc +40 +36 +33 23 +16 +33
Pace 5 of 18
CustomerlPlant: HINDALCO I ADITYA CPP, UNIT-1 to 6, 6x150 MW
ContNo.: 0172-0177 Rev.OO Rev.01 Rev.02 Rev.03
~
. ,.
Enaineer: SM 09.10.09
Reviewer: SV I P..sK Ij~~ 09.10.09
ADDrover: SV I PSR W 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 7

V. FUEL
The fuel data for design coal are as follows:
Description Unit Design Coal
Fuel
Proximate Analysis:
Fixed carbon % 28.0

Volatile matter % 22.5
Moisture % 12.0
Ash % 37.5
Grindability Index HGI 50
Higher Heating Value (HHV) kcal/kg 3510
Ultimate Analysis
Carbon % 38.6
Hydrogen % 2.6
Sulphur % 0.4
Nitrogen % 0.9
Oxygen % 8.0
Moisture % 12.0
Ash % 37.5
Page 6 of 18
Customer/Plant: HINDALCO / ADITYA CPP, UNIT·1 to 6, 6x150 MW
Cont.No.: 0172-0177 Rev.OO Rev.01 Rev.02 Rev.03'
\
Reviewer: SV / Pj)R' \Jr-J .r/,/j 09.10.09
Approver: SV / PSR \RI 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 8

Both HP
Description Unit HP Heaters in Heaters
out
100% VWO 100% 80% 60%
150MW 120MW 90MW
No.of mills in Operation 4 4 4 3 3 4
Air flow per mill t/h 53.7 52.5 51.6 53.0 49.2 52.2
Air temp. at mill inlet °C 217 211 206 185 178 165
Mill outlet temperature °C <--- 66 - 90 ---->
Fineness (thru' 200 % 70 70 70 70 70 70

mesh)
Burner tilt Deg -30 -21.3 -4.6 1.6 8.0 -30
Burners in operation BCDE BCDE BCDE CDE CDE BCDE
Pace 7 of 18
Customer/Plant: HINDALCO / ADITYA CPP, UNIT·1 to 6 6x150 MW
•
Enaineer: SM ~~A 09.10.09
Reviewer: SV / est( VV~ 09.10.09
Approver: SV / PSR \I W 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 9


Out
100% VWO 100% 80% 60%
150MW 120MW 90MW
Oxygen in gas at %
Economiser outlet 3.52 3.52 3.52 3.52 3.52 3.52
Carbon-di';oxide in %
gas at Economiser 16.34 16.34 16.34 16.34 16.34 16.34
outlet
Excess air in gas at % 20 20 20 20 20 20

Economiser outlet
Pace 8 of 18
Customer/Plant: HINDALCO / ADITYA CPP, UNIT·1 to 6. 6x150 MW
Engineer: SM ~_. 09.10.09

Reviewer: SV / P..sR \hJ~ 09.10.09
Approver: SV (PSR WI 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 10


Out
100% VWO 100% 80% 60%
150MW 120MW 90MW
Losses
Dry gas
% 4.897 4.833 4.854 4.708 4.746 4.284
H20 in fuel, surf, and inhe- % 2.174 2.1'71 2.172 2.167 2.168 2.151
rent
H20 from comb. of H2 % 4.209 4.205 4.206 4.196 4.199 4.166
H20 in air % 0.106 0.105 0.106 0.102 0.103 0.093
Unburnt Carbon % 1.500 1.500 1.500 1.500 1.500 1.500
Radiation % 0.214 0.229 0.241 0.293 0.375 0.231
Unaccounted & Manufac- % 1.561 1.566 1.571 1.593 1.630 1.562

turer margin
Total losses % 14.661 14.609 14.650 14.559 14.721 13.987
Heat credits % 0.228 0.266 0.271 0.267 0.289 0.273
Efficiency % 85.57 85.66 85.62 85.71 85.57 86.29
aae 0
Customer/Plant: HINDALCO / ADITYA CPP, UNIT·1 to 6, 6x150 MW
ContNo.: 0172-0177 Rev.OO Rev.01 Rev.02 Rev.03
•
Enaineer: SM ~ 09.10.09
Reviewer: SV / B8ff lV~ 09.10.09
Approver: SV / PSR \k/ 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 11

(SLIDING PRESSURE OPERATION)
SECTION DESCRIPTION SHEET No.
I FLOW 2
II TEMPERATURE 3
III PRESSURE (STEAM & WATER) 4
IV PRESSURES & DRAFTS (AIR & GAS) 5
V FUEL 6
VI MILL & BURNER PERFORMANCE 7
VII O2, CO2 & EXCESS AIR 8
VIII HEAT BALANCE 9
The attached Performance Data are predicted only and are not to be construed as being
guaranteed except where the values coincide with guarantees stated under the performance
guarantee section.
age 0
CustomerlPlant: : HINDALCO I ADITYA CPP, UNIT·1 to 6 6x150 MW
ConlNo.:0172-o177 Rev.OO Rev.01 Rev.02 Rev.03
L
Reviewer: SV I PSR--- h/6'-7 09.10.09
Approver: SV I PSR oW 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 12

Description Unit HP Heaters in
80%TMCR 60% TMCR

120MW 90MW
Steam
Super heater outlet t/h 337.9 270.2
Re heater outlet t/h 308.7 234.8

Water
Feed water t/h 337.9 280.2
SH spray t/h 14.8 13.5

Air
Air heater outlet (Primary) t/h 94.1 87.5
Tempering air t/h 65.1 59.7
Air heater outlet (Secondary) t/h 270.9 177.6
Leakage air to boiler t/h. 32.0 32.0
Total Combustion Air t/h 462.1 356.8

Flue Gas
Flue gas at AH inlet t/h 512 395
Flue gas at AH outlet t/h 577 459
Fuel
Coal(HHV= 3400 kcal/kg) t/h 81.0 62.5
age 0
Customer/Plant: : HINDALCO / ADITYA CPP, UNIT-1 to 6, 6x150 MW
ContNo. :0172-0177 Rev.OO Rev.01 Rev.02 Rev.03
I
Reviewer: SV / PBK \hJ~ 09.10.09
Approver: SV TpSR v W 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 13

Description Unit
HP Heaters in
80%TMCR 60% TMCR

120MW 90MW
Steam
Sat. temp. in Drum °C 325 306
LTSH outlet °C 447 444
SH Platen inlet °C 417 402
SH Platen outlet °C 518 521
SH Finish inlet °C 518 521
SH Finish outlet °C 540 540
RH inlet °C 345.7 348.2
RH outlet °C 540 540
Water
230.6 218.4
Economizer inlet °C
Economizer outlet °C 279 268
Air
°C 25 25
Ambient
AH Outlet (Primary) °C 287 267
AH outlet (Secodary) °C 289 268
Gas
SH Platen inlet °C 1080 1023
RH Front inlet °C 974 912
RH Rear inlet °C 853 791
SH Finish inlet °C 746 692
LTSH horz. inlet °C 657 609
Economiser inlet °C 446 418
Airheater inlet °C 308 286
Airheater outlet (Cor-
rected)
°C 123 122
aae 0
Customer/Plant: : HINDALCO / ADITYA CPP, UNIT·1 to 6, 6x150 MW
ConlNo.:0172-G177 Rev.OO Rev.01 Rev.02 Rev.03
t
'2'.a.... ,
Engineer: SM 09.10.09
Reviewer: SV / B8R ~V~ 09.10.09
Approver: SV / PSR \J \kI 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 14


80%TMCR 60% TMCR
120MW 90MW
Pressure
Super heater outlet kg/cm2 (g) 111.55 86.5
2
Platen SH Outlet kg/cm (g) 115 89.1
2
LTSH outlet kg/cm (g) 118.8 92.0
2
Drum kg/cm (g) 122.1 94.4
2
Economizer inlet kg/cm (g) 124.7 96.8
2
Re heater inlet kg/cm (g) 27.62 20.84
2
Re heater outlet kg/cm (g) 26.13 19.69
Pressure Drop
2
Super heater system kg/cm 10.5 7.9
Re heater system kg/cm2 1.49 1.15

Economizer (Friction 2
0.48
kg/cm 0.76
only)
aQe 0
Customer/Plant: : HINDALCO / ADITYA CPP, UNIT·1 to 6, 6x150 MW
ConlNo.:0172-Q177 Rev.OO Rev.01 Rev.02 Rev.03
I
Engineer: SM ~ A
09.10.09
Reviewer: SV / P..sR ~.\I~ 09.10.09
Approver: SV / PSR W 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 15

HP Heaters in
Description Unit 80%TMCR 60% TMCR
120MW 90MW
Primary air
PA Fan inlet mmwc -7 -6
PA Fan outlet mmwc 795 789
Air heater inlet mmwc 786 781
Air heater outlet mmwc 763 761
Mill inlet mmwc 602 539
Mill outlet mmwc 237 198
Secondary air
FD fan inlet mmwc -10 -5
FD fan oulet mmwc 184 139
Air heater inlet mmwc 174 134
Air heater outlet mmwc 122 110
Wind box pressure mmwc 100 100
Gas
SH Platen inlet mmwc -5 -5
RH Inlet mmwc -5 -5
SH Finish inlet mmwc -8 -7
LTSH inlet mmwc -11 -9
Economizer inlet mmwc -17 -13
Air heater inlet mmwc -28 -20
EP inlet mmwc -92 -61
ID fan inlet mmwc -146 -102
ID fan outlet mmwc 23 16
Page 14 of 18
Cont.No.:0172-o177 Rev.OO Rev.01 Rev.02 Rev.03
J.
Reviewer: SV / P.sK ~v~ 09.10.09
Approver: SV / PSR vV<J 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 16

v. FUEL
The fuel data for design coal are as follows:
Description Unit Design Coal
Fuel
Proximate Analysis:
Fixed carbon % 28.0

Volatile matter % 22.5
Moisture % 12.0
Ash % 37.5
Grindability Index HGI 50
Higher Heating Value (HHV) kcal/kg 3510
Ultimate Analysis
Carbon % 38.6
Hydrogen % 2.6
Sulphur % 0.4
Nitrogen % 0.9
Oxygen % 8.0
Moisture % 12.0
Ash % 37.5
age 0
I
Engineer: SM ~ , 09.10.09
Reviewer: SV /~. I~\f Q/y- 09.10.09
Approver: SV / PSR \I \RJ 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 17


80%TMCR 60% TMCR
120MW 90MW
No.of mills in Operation 3 3
Air flow per mill t/h 53.1 49.1
Air temp. at mill inlet DC 185 174
Mill outlet temperature DC <---- 66 - 90 ---->
Fineness (thru' 200 % 70 70

mesh)
Burner tilt Deg -12.5 -8.2
Burners in operation CDE CDE
Paae 16 of 18
ContNo.:0172-o177 Rev.OO Rev.01 Rev.02 Rev.03
Engineer: SM
Reviewer: SV / P.sK'
j
~--- 09.10.09
)II/;, 09.10.09
"-
Approver: SV / PSR R/ 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 18


80%TMCR 60% TMCR
120MW 90MW
Oxygen in gas at %
Economiser outlet 3.52 3.52
Carbon-di-oxide in %
gas at Economiser 16.34 16.34
outlet
Excess air in gas at % 20 20

Economiser outlet
aae 0 8
Customer/Plant: : HINDALCO / ADITYA CPP, UNIT·1 to 6. 6x150 MW
Engineer: SM ~
. 09.10.09
Reviewer: SV / B8R IVv y~ 09.10.09
Approver: SV / PSR \R/ 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 19


80%TMCR 60% TMCR
120MW 90MW
Losses
-
Dry gas
% 4.612 4.700
H20 in fuel, surf,and inherent % 2.163 2.167
H20 from combustion of H2 % 4.189 4.195
H20 in air % 0.100 0.102
Unburnt Carbon % 1.500 1.500
Radiation % 0.293 0.377
Unaccounted & Manufacturer % 1.593 1.631

margin
Total losses % 14.450 14.672
Heat credits % 0.267 0.290
Efficiency % 85.82 85.62
age 0
Customer/Plant: : HINDALCO / ADITYA CPP, UNIT·1 to 6. 6x150 MW
Enaineer: SM
.
~. 09.10.09
Reviewer: SV / P-Sf( ~"or- 09.10.09
ADDrover: SV / PSR \IV 09.10.09
0172 - 0177 VOL - A1 TAB - 1 - 20

0172 - 0177 VOL - A1 TAB - 1 - 21
0172 - 0177 VOL - A1 TAB - 1 - 22
0172 - 0177 VOL - A1 TAB - 1 - 23
0172 - 0177 VOL - A1 TAB - 1 - 24
0172 - 0177 VOL - A1 TAB - 1 - 25
0172 - 0177 VOL - A1 TAB - 1 - 26
Medium Hot secondary air
Location of airfoil Hot sec. air duct from AH outlet
to Wind box
2 (Two)
Flow per airfoil kg/h 195900

Medium pressure mmwc, 144
Medium temp. °c 312
Medium velocity m/s 19.5
Width mm 2450
Depth mm 2000
Duct eqt. dia de mm 2125
Transmitter dp mmwc 76.2 @ 195900 kg/h flow

Air-foil loss mmwc 19 @ 195900 kg/h flow
Upstream - min. 2de

Down stream - min. 1de
If the above straight length requirement is not possible due to layout restrictions, Duct Design is
to ensure 75% in upstream and 25% in down stream out of the total clear length available.
Customer / Plant: HINDALCO I ADITY A CPP, UNIT-l to 6, 6xl50MW

Cont. No.: 0172-0177 Rev. 0 Rev. 1 Rev. 2 Rev. 3
ISign Date Sign Date Sign Date Sign Date
Engineer: SM ~---, 08.10.09
Reviewer: SV / esR 1\\ ./ 08.10.09
Approver: SV / ysR )(IV"-"" 08.10.09
Boiler Performance & Proposals (FB)
0172 - 0177 VOL - A1 TAB - 1 - 27

AIR - FOIL FOR HOT SECONDARY AIR
CHARACTERISTIC CURVES
260 .CJ _C', ,..
.
ct' ,,<:> ~ ro<:> ~<:>
V"":
ro<:>
'P ,
,,,:po ~,:>o
/ " v" .....•. ,;'
// / // / / / /
240
220
I; // /:8v/ ~
,/
200 / II ~ ~ %V
V
180 / .~
~ ~
~
/
/
160
I/;,/ ~
~
~ 0
/
L.
~+J 140 ~ ~
3:
0
~ ~
If
If
~ 120
0:::
;(
/ j,
100 ~
'II/.
80 rI-
60
40
20
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140

PRESSURE DIFFERENTIAL mmwc
SHEET 2 OF 6
Customer/Plant: HINDALCO ADITYA CPP, UNIT-1 to 6, 6X150MW
Cont No : 0172-0177 Rev.1 Rev.2 Rev.3
Siqn. Date Siqn. Date Siqn. Date Siqn. Date
Enqineer SM ~ 08.10.09
Reviewer SV / ~ \\ r-f./ 08.10.09
/J
Approver SV / ~ 'J..\'-l 08.10.09

BOILER PERFORMA ~CE & PROPOSALS CPT- 1805
0172 - 0177 VOL - A1 TAB - 1 - 28

S is the straight length portion of the duct
Customer Plant: HINDALCOADITYA CPP, UNIT-1 to 6, 6X150MW
Date Si n. Date Si n. Date Si n. Date
En ineer 08.10.09
Reviewer 08.10.09
08.10.09
& PROPOSALS
0172 - 0177 VOL - A1 TAB - 1 - 29

Medium Hot primary air
Location of Airfoil Hot primary air duct at mill inlet
Number per mill 1 (One)
Flow per Airfoil kg/h 59330

Medium pressure mmwc 637
Medium temp. °c 221
Medium velocity m/s 15.4
Width mm 1260
Depth mm 1260
Duct eqt. Dia, de mm 1422
Transmitter, dp mmwc 76.2 @ 59330 kg/h flow

Airfoil loss mmwc 19 @ 59330 kg/h flow
Upstream - min. 1.5de

Down stream - min. 0.75de
If the above straight length requirement is not possible due to layout restrictions, Duct Design is
to ensure 75% in upstream and 25% in down stream out of the total clear length available.
Customer / Plant: HINDALCO I ADITY A CPP, UNIT-l to 6, 6xl50MW

Cont. No.: 0172-0177 Rev. 0 Rev. I Rev. 2 Rev. 3
(Sign Date Sign Date Sign Date Sign Date
Engineer : SM <;..K. ,1 08.10.09
Reviewer: SV / ~. /"'7/ 08.10.09
Approver : SV / ~ 11 ~v 08.10.09
Boiler Performance & Proposals (FB)
0172 - 0177 VOL - A1 TAB - 1 - 30

70
65
60
55
50
45
•... 40
.L:
"-.•..
~ 35
0
..J
l.L.
a::: 30
«
25
20
15
10
Customer/Plant: HINDALCO / ADITYA CPP, UNIT-1 to 6, 6x150MW

Siqn. Date Siqn. Date Siqn. Date Siqn. Date
Enqineer SM >!L .......• 08.10.09
Reviewer SV / ~ ~ n/Y/ 08.10.09
Approver SV / P~ 11'l 08.10.09
BOILER PERFORMAN:E & PROPOSALS CPT-1805
0172 - 0177 VOL - A1 TAB - 1 - 31

Customer Plant: HINDALCO ADITYA CPP, UNIT-1 to 6, 6x150MW
Dote Si n. Dote Si n. Dote Si n. Dote
En ineer 08.10.09
Reviewer 08.10.09
08.10.09
& PROPOSALS CPT-1805
0172 - 0177 VOL - A1 TAB - 1 - 32

PREDICTED PERFORMANCE CURVES
Rev. 00 Rev. 01 Rev. 02 Rev. 03

i n Date Si n Date Si n Date Si n Date
En ineer SM 11.08.09
Reviewer $V I PSR 1.08.09
A rover SV-I PSR 11.08.09
0172 - 0177 VOL - A1 TAB - 1 - 33

INDEX
SI.No. Description Rev Page
01 Load Vs SH/RH outlet steam temperature 00 1
02 Load Vs Excess air 00 2
03 Load V s Burner Tilt 00 3
04 Load Vs SH Spray 00 4
05 Load V s SH steam temperature after spray 00 5
06 Load Vs SH outlet pressure 00 6
07 Load Vs SH outlet flow 00 7
08 Load Vs Total air flow 00 8
CustomerI Plant: HINDALCO ADITYA CPP, UNIT-1 to 6, 6x150 MW

Cont.No.: 0172-0177 Rev. 00 Rev. 01 Rev. 02 Rev. 03
.Sian Date Sian Date Sign Date Sign Date
Engineer SM a -' 11.08.09
Reviewer $V I PSR' II L , I 11.08.09
Approver SV I PSR J '-..uv' 11.08.09
0172 - 0177 VOL - A1 TAB - 1 - 34

LOAD Vs SHIRH OUTLET STEAM TEMPERATURE
575
550
/'
'$ 525 / V/
V
£L
~
w
I
I
I
I
500
//
V
I-
~
L5
I-
If)
W
....J
475
I-
::>
0
I
a:::
........•.
I
If) 450
425
400
30 40 50 60 70 80 90 100
LOAD ---- 70BMCR .-
ShHf 1 of 8
Customer/Plant: HINDALCO ADITYA CPP. UNIT-1 to 6 6X150MW
Cont No : 0172-0177 Rev.O Rev.1 Rev.2 Rev.3
SUJn. Date Sian. Date Sign. Date Sign. Date
Engineer 5M ~ 11.08.09
Reviewer $V / P5Rr t 1 1_ ;11.08.09
Aoorover S¥ / P5R J 11.08.09
0172 - 0177 VOL - A1 TAB - 1 - 35

LOAD Vs EXCESS AIR
30
25
~
I
I
I
I
0:: 20
<
(f)
(f)
w
()
x
w
15
10
50 60 70 80 90 100
LOAD ---- %BMCR ••
Sh,,' 2 of 8
Customer /Plant : HINDALCO ADITYA CPP. UNIT-1 to 6. 6X150MW
Sian. Date Sian. Date Sian. Date Sign. Date
Enqineer 51.1 11.08.09
Reviewer gv / P5R\, I~
Approver $V / P5R) •...
,.~
~
11.08.09
11.08.09
0172 - 0177 VOL - A1 TAB - 1 - 36

LOAD Vs BURNER TILT
~
i=-10
a:::
w
z
a:::
::>
(D
-15
UNIT-1 fo 6 6X150MW
Re~1 Re~2 Rev.3
Si n. Date Si n. Date Si n. Date
En ineer SM
Reviewer S¥
A rover
BOILER
0172 - 0177 VOL - A1 TAB - 1 - 37

LOAD Vs SH SPRAY
15
L.
..c
.•...•.....
.•..
I
I
I
I
I
~
c:::
a.
(/)
10
Customer Plant: HINDALCO ADITYA CPP UNIT-1 fo 6 6X150MW

Cant No : 0172-0177 Rev.O Rev.1 Rev.2 Rev.3
Dote Si n. Dote Si n. Dote Si n. Dote
En ineer SM " 11.08.09
Reviewer $V 11.08.09
A rover 8V PSR 11.08.09
BOILER PERFORMANCE & PROPOSALS
0172 - 0177 VOL - A1 TAB - 1 - 38

LOAD Vs STEAM TEMP AFTER SPRAY
()
°1
I
I
I
I
w
a::
420
::>
!;;(
a::
w
Q.
~
W
f-
6X150MW
Rev.2 Rev.3
Si n. Date Si n. Date
En ineer SM
Reviewer W
0172 - 0177 VOL - A1 TAB - 1 - 39

LOAD Vs SHO PRESSURE
'"""'
0'1
'-" 137.0
E
u
...•••...
0'1
~
I
I
I
I
I
w
a:::
:::>
(/)
(/)
w
a:::
a..
o 134.5
I
(/)
6X150MW
Rev.2 Rev.3
Si n. Date Si n. Date
0172 - 0177 VOL - A1 TAB - 1 - 40

LOAD Vs SHO FLOW
450
'-
..c
.•..••....
.•..
I
I
I
I
~
0
-.J
l.L.
0
I
(/)
350
Customer Plant: HINDALCO ADITYA CPP UNIT-1 to 6 6X150MW

Si n. Date Si n. Date Si n. Date Si n. Date
En ineer SM /} 11.08.09
Reviewer ~ 11.08.09
A rover 8V PSR 11.08.09
BOILER PERFORMANCE & PROPOSALS
0172 - 0177 VOL - A1 TAB - 1 - 41

LOAD Vs TOTAL AIR FLOW
L..
.c:
.....•.•...
+J
I
I
I
I
:= 500
g
l.L.
a::
;{
-.J
~
0
~
Customer Plant: HINDALCO ADITYA CPP UNIT-1 fo 6 6X150MW

S' n. Date Si n. Date Si n. Date Si n. Date
11.08.09
11.08.09
11.08.09
& PROPOSAlS
0172 - 0177 VOL - A1 TAB - 1 - 42

GENERAL PRINCIPLES OF
BOILER OPERATION
Bharat Heavy Electricals Limited
0172 - 0177 VOL - A1 TAB - 1 - 43

HINDALCO / ADITYA CPP, UNIT-1 to 6, 6x150MW
------------------------------------------------------------------------------------------------------------
TABLE OF CONTENTS
1. INTRODUCTION 2
2. PERFORMANCE 2
3. FILLING AND VENTING 3
4. STARTING-UP 3
5. SHUTTING-DOWN 3
6. WATER LEVEL 4
7. WARMING UP AND EXPANSION 5
8. AIR HEATER 5
9. SOOT BLOWER 5
10. STEAM TEMPERATURE CONTROL 6
I. FUEL AND AIR NOZZLE TILTS 6
II. DESUPERHEATERS 6
11. SUPERHEATER AND REHEATERS 7
12. BLOW-DOWN 8
13. TUBE FAILURES 9
14. FURNACE EXPLOSIONS 9
15. FLY ASH EROSION 10
16. INSPECTION 11
17. LAY-UPS 12
18. WATER WASHING TO REMOVE DEPOSITS FROM OIL FIRING 12
19. FEED WATER TREATMENT 13
20. WATER IMPOUNDED BOTTOM ASH HOPPER 14
----------------------------------------------------------------------------------------------------------------
BHARAT HEAVY ELECTRICALS LIMITED Page 1 of 14
0172 - 0177 VOL - A1 TAB - 1 - 44

------------------------------------------------------------------------------------------------------------
GENERAL PRINCIPLES OF BOILER OPERATION
1. INTRODUCTION
The following “General Principles of Boiler Operation” are prepared to acquaint operators with
basic operation and care of large tangentially fired natural circulation steam generating units.
Specific and detailed information regarding operation and maintenance of the boiler components
and auxiliary equipment supplied at this installation will be found in other manuals for the
respective equipment.
Basic rules must be followed in the operation and maintenance of boiler and secondary
equipment. The operator should familiarize himself with the characteristics of this particular
installation. This can only be accomplished by diligently observing, recording, checking and
comparing data and details. Emergency conditions, resulting in unnecessary outages and
repairs, can be avoided by a proper working knowledge and attention on the part of the operator.
2. PERFORMANCE
i All steam generating equipments are designed for a specific purpose. When supplied with
feed water at a specific temperature, the unit will deliver a definite quantity of steam at the
rated pressure and temperature. Operating at conditions which exceed the design limits will
shorten the life of the boiler and its components.
ii. The concentration of solids entrained in the steam leaving steam drum will depend to a great
extent upon the quality of the feedwater. Suitable make-up water treatment and an
adequate blow down programme should be employed to control the boiler water alkalinity,
silica and concentration of dissolved and suspended solids in the boiler water. Adequate
mechanical deaeration of the feedwater should be provided and steps taken to control the
level of metallic oxides entering the boiler in the feedwater. Refer to ‘Feed water treatment’
section in this manual.
iii. The Quantity of fuel consumed is generally measured and recorded. The means employed
will depend upon the nature of the fuel and the equipment available for measuring. A
representative fuel sample should be obtained periodically. The services of a competent
laboratory should be employed to analyse the fuel with respect to chemical constituents,
calorific value, viscosity (liquid fuels) and other physical characteristics which could have an
unfavorable influence on operation and efficiency. These data should be used for making
necessary adjustment in operating parameters.
iv. An analysis of the flue gases leaving the boiler is invaluable as an index of complete and
economical combustion. Combustion should be completed before the gases leave the
furnace. The best percentage of excess air to use will depend upon the nature of the fuel,
the design of the fuel burning equipment and other factors. The most desirable excess air
for different rates of evaporation must be established for each installation. The presence of
carbon monoxide (CO) in the flue gas indicates incomplete combustion. The Orsat is the
most reliable means of analysing flue gases and should be used as a check even when
other instruments are provided to furnish this data. For determination of the percentage CO,
CO2 and O2 gas samples should be obtained at the rear pass outlet upstream of the air
heater.
v. When the heat transfer surfaces are kept clean, the temperature of the flue gas leaving the
air heater and the draft loss through the unit will be nearly a constant for the given rating and
percent excess air. This illustrates the desirability of keeping accurate records of
performance from the start of operation. Operating data should be recorded in a form, that
will facilitate comparison with data taken under similar operating conditions.
When the equipment is new, standards should be established to serve as measures of
satisfactory operation. Then if operating conditions deviate from this established standard,
steps can be taken to determine and correct the cause of the discrepancy
----------------------------------------------------------------------------------------------------------------
0172 - 0177 VOL - A1 TAB - 1 - 45

------------------------------------------------------------------------------------------------------------
3. FILLING AND VENTING
When filling the boiler, open the boiler vents as noted on the “Valve Operating Diagram” in the
“Unit Operating Procedures” section of this manual. Bring the water upto the recommended
operating level in the gauge glass. If hot water (hot relative to the boiler metal temperatures) is
used to fill the boiler, take care to feed slowly so as to avoid severe temperature strains on the
drums, headers etc.
4. STARTING UP
In order that an incorrect firing condition may be detected promptly, it is important that the
instruments used to monitor operating conditions are in good working order before lighting off.
Draft readings, temperature and pressure readings and a reliable indication of how much excess
air is being used are a prerequisite to intelligent operation.
Prior to lighting off the unit, the drainable portions (headers, inlet, outlet and connecting links and
piping) of the superheater should be drained through lines free from back pressure and vented at
the outlet. The superheater drains should be closed in accordance with information given on
“Valve Operating Diagram” for this installation. The superheater outlet vent (starting vent/drain)
must remain open to ensure a flow of steam through the superheater to protect the elements from
overheating until the unit has gone on line and is carrying load. This drain valve may be throttled
as the pressure increases, but must never be closed completely until the boiler is on the line.
Refer to ‘Unit Operating Procedures’ for specific valve operation.
During startups, when there is no steam flow through reheater, residual moisture in the reheater
element must be boiled off. This is accomplished by opening the drains and or vents on reheater
headers and piping before lighting off. The vents and atmospheric drains must be closed prior to
raising a vacuum in the condenser. Cold and Hot reheat drain lines near the turbine, which
connect with the condenser, should be kept open until the unit is under light load. During initial
firing, prior to carrying load, the firing rate must be controlled to keep the furnace exit gas
temperature below 540 deg.C until the HP-LP bypass is cut in and steam flow through the
superheater and reheater is established. It is recommended that a temperature probe be inserted
at the furnace outlet near the first gas touched superheater/reheater surface to enable continuous
measurement of furnace exit gas temperatures, before establishing flow through Reheater with
HP-LP bypass.
The time required to bring a boiler up to temperature and pressure will depend upon the
temperature and pressure at which it is to operate. During initial start-up of a new boiler the firing
rate must be limited and increase of firing rate should be relatively slow to allow inspection of
expansion movement and clearances. Subsequent start-ups can be done at a faster rate but
should not exceed the saturated steam temperature rise of 110 deg.C per hour (Refer to “Unit
Operating Procedures”) or the furnace exit gas temperature limitation stated above. Always
make firing adjustments by hand during this period: never attempt to start up with the combustion
control or feed water equipment on “Automatic”. Prior to lighting off, check all instrumentation and
safety interlocks to be sure they are in good working order. Verify proper operation of all
instrumentation (gauges, transmitters, recorders etc.) during initial operation.
5. SHUTTING DOWN
The time required and the procedures to be followed for shutting down the unit depend on the
nature of the shutdown (normal shutdown to cold, normal shutdown to hot standby, emergency
shutdown) and whether the unit is to be entered for inspection and/or maintenance. Refer to ‘Unit
Operating procedures for detailed operating recommendations.
The anticipated time of the outage should be considered during the shutting down process in
determining the steps to be taken for laying up the unit or corrosion protection. Refer to “Lay-up
procedures” in this manual.
----------------------------------------------------------------------------------------------------------------
0172 - 0177 VOL - A1 TAB - 1 - 46

------------------------------------------------------------------------------------------------------------
Immediately after the unit is off the line (turbine valves closed) and all fires are out, superheater
and reheater drains are opened as required for the desired pressure reduction. If the unit is
shutdown to cold, the drum vents should be opened when the drum pressure drops to 1.8 Kg/cm2
(g) . If pressure parts inspection or maintenance is required the water temperature should be
reduced to 93 deg.C before draining the boiler.
Fans may be operated as required to achieve the desired rate of cooling, refer to ‘Unit Operating
Procedures’ for precautions to be taken with air heaters.\
During any type of shutdown the cooling rate must not exceed the recommended saturated steam
temperature decrease (Refer “Unit Operating Procedures”).
6. WATERWALL
Before lighting a fire, the operator should check the water in the upper drum by blowing down the
water column and gauge glass. Usually slowly cracking the drain valve on high pressure gauges
will suffice. A liberal blow down will usually clear the drain valve seats of any foreign matter that
may be present. The gauge glass should be blow down several times at low pressure while
warming up a new boiler. Routine checks of the water gauge should be made at least once in a
shift while a boiler is in operation. (Refer “Direct/Remote Water Level Indicator Instructions” for
procedures on checking level). If the action of the water in the gauge is sluggish when the drain
valve is opened or closed, investigate the cause and correct the condition immediately. To
protect the gauge glass, blow downs should be kept to a minimum, during normal operation.
During normal operation the water level in the gauge glass should be observed periodically even
though the boiler may be equipped with a reliable feed water regulator and/or remote water level
indicator.
While steaming, the boiler should be protected from rapid changes in feed water temperature.
The feed water flow to the boiler should correspond fairly closely to the steaming rate and should
not be shut off completely while the boiler is being fired.
For the recommended water level and operating range refer to instructions on “Steam Drum
Internals”. Unless there is information to the contrary, the water level should be carried near the
center of the gauge glass. The gauge glass centre line is normally set to indicate normal level
inside the drum at full pressure conditions.
If the unit is operated at significantly reduced pressure, the level indicated at the gauge glass
centre line will correspond to a lower than normal actual level inside the drum, due to the
difference in temperature between the water in the glass and the water inside the drum.
Any adjustment of the water level should be gradual. If the water level is too high, carryover or
even priming may occur, especially if the steam demand is large and rapidly fluctuating.
Perhaps the most serious emergency that may be encountered is low water level. As mentioned
in previous paragraphs, the water level must be watched continuously and water gauges should
be checked periodically to ensure proper operation. Protection of water level transmission lines
should be provided to avoid freezing or other damages to these lines. Do not rely solely on high
and low level alarms.
If the water level falls out of sight in the water gauge, due to failure of the feedwater supply or
neglect of the operator, except in the case of momentary fluctuations that might occur with
extra-ordinary changes in load, appropriate action should be taken at once to extinguish the fire.
Any decision to continue to operate, even if only for a short time at a reduced rating, would have to
be made by someone in authority, thoroughly familiar with the circumstances that led to the
emergency and positively certain that the water level can be restored immediately without
damaging the boiler.
----------------------------------------------------------------------------------------------------------------
0172 - 0177 VOL - A1 TAB - 1 - 47

------------------------------------------------------------------------------------------------------------
7. WARMING UP AND EXPANSION
While the boiler is being brought up to pressure, provision should be made for gradually heating
and adequately draining all cold steam piping from the beginning by opening all drain valves and
by-passes (if stop valves are provided). Refer to “Valve Operating Diagram”.
During initial firing, periodically check the expansion movements of the boiler and make sure the
casing, headers, piping etc., move freely in respect to the structural steel. Expansion marks
should be installed at suitable locations to facilitate inspection (Refer Pressure Parts
arrangement drawings and/or expansion movement diagrams” for this installation). Periodic
checks should be made during the life of the unit to determine that expansion movement
continues to occur in a normal, uniform manner. All hangers on the unit and related piping should
be checked periodically for proper settings and functioning.
8. AIRHEATER
An abnormal increase in draft loss across the gas and/or air side of an air heater indicates that
deposits are building up. Every precaution should be taken to keep the gas swept surfaces of the
air heater clean. Operate the airheater soot blowers if provided as frequently as necessary.
Water washing equipment and/or other cleaning devices should be used as necessary to prevent
air heater plugging. If oil is being fired, make certain the fuel is being burned completely. Watch
the temperature of the gas leaving the air heater, particularly when starting up the unit. Use air
heater cleaning device to remove accumulations of combustible deposits. A sudden and
abnormal increase in the gas outlet temperature would indicate that a fire has developed. In this
event, the unit should be shut down immediately and steps be taken to quench the fire.
Refer to “ Airheater instructions” for additional specific cleaning and fire protection
recommendation.
An APH air bypass duct is provided to assist in the prevention of airheater cold end corrosion,
while firing oil during boiler startup.
The exit gas temperature will rise with increasing load and fall with decreasing load. If a log is
kept on the load, the exit gas temperature and soot blowing schedule, the operator will soon be
able to recognize an abnormally high or low exit gas temperature.
If the exit gas temperature is below normal for the load at which the unit is being operated, look for
very low excess air (very high CO2, may be some CO and smoke).
High exit gas temperature may be caused by such conditions as: High excess air, dirty water
walls, secondary combustion, a dirty air heater and/or a fire in the air heater.
9. SOOT BLOWERS
Soot blowers should be operated as often as necessary to keep the external heating surfaces
clean. A high economiser exit gas temperature and/or erratic steam temperature control action
(see note) may be an indication of the need for sootblowing. By recording and comparing this exit
gas temperature at various loads and furnace conditions, a proper soot blowing schedule can be
established. It will be found more difficult to use the soot blowers effectively if, during a period of
neglect, a considerable amount of fly ash or slag is allowed in build up. Never use soot blower on
a cold boiler. Always be sure that the combustion rate is high enough when blowing soot so that
the fires are not extinguished. Refer to “Soot Blower Instruments” for details.
Note: The requirements of the steam temperature control system can be used as an indication of
fouling in the furnace, superheater and reheater since desuperheater spray water
quantity and fuel nozzle tilt movement quantity reflect the changes in tube surface
cleanliness.
----------------------------------------------------------------------------------------------------------------
0172 - 0177 VOL - A1 TAB - 1 - 48

------------------------------------------------------------------------------------------------------------
Since the soot blowing medium is steam, proper drainage of the soot blower piping system is very
important in preventing pressure parts erosion. There should be no water pockets whatever in
the piping. Thermal Drain valve is Provided in the drain piping just below the lowest level of
sootblower to permit continuous drainage of any condensate formed until the steam temperature
reaches a predetermined level of superheat. Let the steam flow freely long enough to heat the
lines thoroughly before operating the soot blowers.
10. STEAM TEMPERATURE CONTROL(with Tilting Tangential Firing)
The function of the steam temperature control equipment is to maintain rated superheat and
reheat temperatures over the specified control range.
Steam temperatures should never be allowed to exceed the maximum values shown in the
“Steam Temperature Vs Load” curve especially if steam temperature control point. Damage to
tubing may result due to localized overheating, caused by mal distribution of steam flow at low
loads, if the maximum values are exceeded.
The steam temperature control system may include any or all of the following equipments:
i. Fuel and Air nozzle Tilts (Reheat temperature control)
ii. Spray water desuperheaters (superheat and reheat steam temperature control)
Generally the relationship between the control media is as follows:
i. Fuel and Air Nozzle Tilts
The fuel and air nozzles can be tilted through a predetermined angle up and down. Refer “Tilting
Tangential Burner Assembly”. Raising or lowering the flame provides, in effect, a furnace with an
adjustable amount of heat absorbing surface.
The drive units of nozzle tilt in the four corners of a furnace should operate in unison
(simultaneously) in response to control signals from the reheat steam temperature controller.
An increase in reheat steam temperature beyond the control set point moves the tilts down, and a
decrease of steam temperature below the set point moves the tilts up in proportional increments.
In order to relate steam temperature control with unit load conditions, a load change signal is
normally introduced into master reheat temperature controller from steam flow and/or air flow
transmitter. This permits corrective steam temperature control action in anticipation of a
temperature correction demand imposed by the load change.
When the nozzle tilts reach their minimum elevation and further reheat steam temperature
reduction is required, control is automatically sequenced to the reheat desuperheater(s). (Refer
Desuperheaters)
ii. Desuperheaters
The reheater desuperheater(s) are normally provided for emergency use only, to reduce
excessive reheat steam temperature, when nozzle tilt control has reached its lower limit. The
automatic control signal to the spray water control valves is normally from the same source as
that actuating the nozzle tilt drives.
The superheater desuperheaters are normally provided to maintain the rated final superheater
steam temperature. Desuperheater spray water control is generally a 3 element cascade system
in which final steam temperature, intermediate (desuperheater outlet steam temperature and load
index (steam flow or air flow measurements) are applied to achieve and fast control actions.
Regardless of the means provided for controlling superheat and reheat steam temperatures there
are a number of factors which may produce abnormal steam temperatures. With a new or
extremely cold or oil fired unit, it may be necessary to operate for a considerable period of time
before normal deposits build up on the furnace walls and some difficulty may be experienced in
getting the predicted steam temperature.
----------------------------------------------------------------------------------------------------------------
0172 - 0177 VOL - A1 TAB - 1 - 49

------------------------------------------------------------------------------------------------------------
Abnormally low steam temperatures may also be produced by:
1. Insufficient excess air
2. Higher than rated feed water temperature
3. Lower than rated reheater inlet temperature
4. Excessive moisture carry over from the boiler.
5. A fouled superheater or reheater surface externally or internally.
6. Leaking desuperheater spray water valves.
7. Poorly adjusted control equipment
On the other hand, the following conditions may produce steam temperatures abnormally high for
a given rate of evaporation.
1. A dirty furnace
2. Too much excess air
3. Lower than rated feed water temperature
4. Higher than rated reheater inlet temperature
5. Irregular ignition or delayed combustion
6. Poorly adjusted control equipment
The superheat steam temperature will drop suddenly and recover if the boiler is priming. The
temperature fluctuation increase in frequency and severely as the total solids or alkalinity in the
boiler water increases.
If the steam temperature is too low, the furnace walls should be cleaned only as necessary, in
steps, using one wall blower, then operating for a period and using another wall blower at another
wall. Cleaning all the furnace walls at once may give an extremely low steam temperature,
whereas neglecting to clean the furnace may lead to other difficulties.
If the steam temperature generally is too high, the furnace should be cleaned thoroughly and
completely as often as necessary to keep the temperatures down. As slag develops in the
furnace, the heat absorption rate of the furnace will be decreased materially and the steam
temperature and the overall performance of the unit will be affected. Continuously increasing
steam temperature, with no change in steam output, indicates progressive fouling of the furnace.
If slagging becomes acute, localised ash accumulations may obstruct portions of the superheater
or reheater and produce high gas mass velocities in the free areas with overheating becoming a
possibility. The operators should develop a suitable procedure, using the wall blowers to deslag.
Soot blowers will give best results if the ash is not sticky.
Frequent furnace inspection should be made to see that no slag accumulates around the wind
box openings. Since unsatisfactory flame conditions can result, such accumulations, if found,
should be removed promptly.
11. SUPERHEATER AND REHEATER
Consideration for protecting the superheater and reheater is a controlling factor in determining
how rapidly a natural circulation unit should be brought up to the rated pressure. The saturated
steam temperature increase must not exceed 110 deg.C per hour during startups.
----------------------------------------------------------------------------------------------------------------
0172 - 0177 VOL - A1 TAB - 1 - 50

------------------------------------------------------------------------------------------------------------
The superheater and reheater elements should be heated as evenly as possible, and the
maximum temperature of the flue gas entering the first gas touched superheater and/or reheater
elements (“Furnace exit gas temperature”) should be carefully monitored and controlled during
start-ups.
The furnace exit gas temperatures are normally measured by means of a startup temperature
probe traversing about half the width of the furnace. The point of maximum temperature must be
determined each time the firing pattern is changed. The maximum furnace exit gas temperature
should be limited to 540 deg.C until the turbine is under load and normal steam flow through the
reheater is established or HP-LP lines are charged.
To assure clearing the superheater element loops of condensate, provision must be made for
adequate flow of steam through the superheater while starting up. Drain and vent valves in the
outlet headers and/or the main steam line should be opened before the unit is fired and kept open
till the unit is steaming under load. These start-up vent/drains may be throttled gradually as drum
pressure increases, provided sufficient flow through the superheater is assured at all times.
When the turbine is synchronised and carrying load, an adequate steam flow will be assured and
the superheater start-up drains and/or vents may be closed.
All reheater drains should be opened before lighting off. As the boiler comes up in pressure,
residual moisture in the reheater will be boiled off. Reheater drains connected to the condenser
should remain open until the turbine generator is on the line and under light load. Vents and
drains open to atmosphere should be closed before attempting to pull a vacuum in the condenser.
It is advisable to operate a condenser circulating pump during the early stage of firing the boiler to
prevent overheating of the condenser by hot vapor from the reheater drains.
While carrying load, protection in the event of a sudden interruption of steam flow is provided by
the superheater and reheater safety valves which are set to “pop” before the drum safety valves.
If the flow of steam from the boiler is suddenly stopped, the superheater and reheater safety
valves will open and re-establish the flow.
It is imperative that all fuel be tripped immediately when such interruptions of steam flow occur.
Care must be exercised to avoid carry-over of water and solids to the superheater and turbine.
Steam samples should be taken at frequent intervals for the purpose of detecting evidence of
carry-over. Steam conductivity recorders are commonly used for this purpose. Sampling
connections are normally provided in the superheater connecting tubes leaving the steam drum.
Carry-over may be caused by abnormal high water level, especially if the steaming rate is high. If
carry-over is suspected, steps should be taken immediately to investigate and eliminate the
conditions causing this carryover. If the investigation indicates that the carry-over is not a result of
improper water condition, the steam internals and the water level control and indicating
equipment should be inspected at the first possible opportunity. Deposits of solid materials in
superheaters and reheaters are detrimental from heat transfer and corrosion stand point. Hence
introduction solid materials, either through carryover, or during filling operations must be avoided.
12. BLOWDOWN
The continuous blowdown offers the best means for controlling and maintaining a relatively
constant concentration of soluble solids in the boiler water.
The data on blowdown should be recorded. The amount of blowdown is best determined from a
chemical analysis of water from the boiler. Since the water treatment system varies for each
individual plant, a competent authority on water conditioning should be engaged to prescribe
suitable water treatment from analysis of the water supply and to furnish the necessary
instruction for blowing down.
Natural circulation boilers are equipped with downtake blow off valves and drum emergency
drain which may be used for intermittent blowdown service at any time. Never use water wall inlet
header drains for blowdown while the unit is steaming. These are for draining only when the unit
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0172 - 0177 VOL - A1 TAB - 1 - 51

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is out of service. Unless the valve manufacturer’s recommendations are contrary, open the
sealing valve (next to the boiler) and then the blowing valve (farthest from the boiler) and close in
the reverse order. Never make the blowdown long enough to lose sight of the water in the gauge
glass. Check the valves for leaks.
13. TUBE FAILURES
In the event of a failure of one or more water carrying tubes in a natural circulation boiler, the best
method for shutting down the boiler will be dictated by the size of the failure, the ability to maintain
normal water level in the boiler and the demands for the service of the boiler.
If the failure is such that the water level can be maintained in the gauge glass by using the normal
make-up system and the conditions require continued operation, the boiler can be kept in service
until it is more convenient to take it off the line and make the necessary repairs. While it is
possible to operate for a considerable period of time under such conditions, there is always a
chance of cutting other tubes. As long as the failure does not become one which involves the loss
of water level in the gauge glass, the boiler should be shut down in the normal manner, in order
that no equipment may be subjected to sudden temperature changes.
If the failure is such that the water level cannot be maintained in the gauge glass, then the boiler
should be shut down immediately. After a shutdown because of low water level, every effort
should be made to keep the water as near normal as possible until the boiler is cool enough to
drain.
A leak in a superheater or reheater element should be investigated at the earliest possible time,
and the unit should be shut down in a normal manner.
These are recommendations only and are not intended to supplant the judgment of the operators
responsible for the operation of the equipment. It must be borne in mind that prolonged operation
with leaking tubes may cut other tubes and make a major repair job out of what was a relatively
simple and short one, but the time selected to take the unit off the line is solely the responsibility of
the operators as they are the only ones who know all the circumstances, the advantages and
disadvantages of keeping the unit on the line.
14. FURNACE EXPLOSIONS
Furnace explosions are generally a result of the following conditions:
i. The accumulation of unburnt fuel in the furnace due to incomplete combustion, loss of ignition
or fuel valve leakage.
ii. The mixture of this unburnt fuel with air in explosive proportions
iii. The application of sufficient heat to raise the temperature of a portion of this mixture to the
ignition point.
Unburnt fuel may accumulate in the furnace in a number of ways, for instance:
1. Through leaky main fuel or ignition fuel inlet valves on idle windbox compartments.
2. If the fires are extinguished and the fuel is not shut off promptly.
3. If fuel is not burning as rapidly as it is entering the furnace.
4. In starting up, if difficulty is experienced in establishing ignition.
Furnace explosions can be avoided by taking a few precautions such as:
x During start-ups maintain a minimum air flow of 30% of full load air flow to ensure an air rich
furnace atmosphere and prevent accumulation of explosive mixtures.
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0172 - 0177 VOL - A1 TAB - 1 - 52

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x Be sure that the main fuel and ignition fuel inlet valves on idle fuel compartments are closed
tightly and do not leak. It is advisable to remove the idle guns form the guide pipes, to avoid
dripping.
x Watch the fires so that the fuel may be shut off without delay if proper combustion is not
maintained. If the fires are lost, trip all main and ignition fuel immediately. Close all trip and
shut off valves. Purge the furnace for at least 5 minutes after shut down with 30% (minimum)
air flow.
x Clear oil tanks of water and sludge periodically.
x When a boiler has been idle, purge the furnace before putting ignitors in service. Be sure that
the warm up fuel firing rate is high enough to produce a flame not easily extinguished.
Never attempt to light an oil or gas nozzle without the required ignition energy source. Be sure
that the oil is heated and circulated to give the required viscosity at the nozzles.
Do not use heavy oil/mechanical atomising oil guns for boiling out, lighting off and warming up,
preferably use light oil/steam atomising oil guns.
On coal fired units always use the required ignition energy source when placing any pulverizer in
service.
x Regularly check proper function of any furnace safeguard supervisory system provided
including interlocks, trips, etc, prior to any startup and periodically during normal operating
periods.
x During outages thoroughly check out, inspect and maintain furnace safeguard supervisory
system provided.
15. FLY ASH EROSION
Fly ash erosion is the abrasion of metal surfaces by residual ash particles carried in the flue
gases. Erosion normally occurs in areas where localised high flue gas velocities occur (See
note). The degree of erosion is further related to the ash content (quantity and composition) of the
fuel. Units firing with a high ash content of abrasive nature are more subject to erosion.
Note: Areas most commonly subject to erosion are:
Screen tube economiser and low temperature superheater terminal tubes and bends, areas
around soot blower and wall deslaggers, gas ductwork and induced draft fan (fan blades and
housing)
Boiler design parameters are based on conservative average flue gas velocities and normal coal
ash percentages, to achieve minimum possibility of erosion. However, the possibility of localised
erosion cannot be entirely avoided, nor can the degree or location be predicted for each
installation.
It is important that the unit be inspected for indications (See Note) of erosion, especially in areas
mentioned above, whenever the opportunity presents itself but atleast during annual outages.
When coal with a high ash content is fired, a definite periodic inspection programme must be
established.
NOTE: Indications of erosion are:
Polished surface appearance, gouging holes in duct, expansion joints (leaks) etc. Reduction of
tube diameters can be verified by micrometer readings.
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0172 - 0177 VOL - A1 TAB - 1 - 53

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The effects of erosion can be controlled by protecting the affected areas (pad welding installation
of removable tube shields, refractory coating etc.) or by dispersing the flue gas streams through
the use of plate or wire mesh baffles (See Note)
Note: Extreme care must be exercised when installing baffles not to create new area of erosion or
to shift erosion from one area to another.
The method of control and/or correction depends on the degree and location of the erosion and
only can be established after thorough evaluation of the local situation and some
experimentation. The effectiveness of correction methods must be checked. In the event of
extreme or unusual erosion problems, this company or its representative should be consulted.
16. INSPECTION
Whenever the boiler is shutdown, and cool enough to enter the furnace, make an external
inspection of the boiler, water walls, superheater, reheater, economiser and airheater. Clean the
firesides wherever necessary and examine all tubes for evidence of corrosion, erosion, swelling,
warping, blistering, burning and cracking.
Swelling of superheater tubes indicates overheating which may have been caused by bringing
the boiler upto pressure too quickly, failure to vent the superheater sufficiently while the boiler is
being brought-up to the full pressure, or scale on the internal surfaces due to carryover of water
from the boiler. Slight warping is not serious if steps are taken at once to determine and eliminate
the cause.
Check the condition of the furnace setting and check the casing and doors for leaks.
Periodic inspections should be made to examine the watersides of the boiler unit.
Before entering the drum, make sure that all valves in drum connecting piping (feed water,
auxiliary steam, chemical feed, blowdown, drains, sampling, gauge glass drain, etc.) are closed
tightly and properly tagged so that they will not be opened inadvertently. Remove the manhole
covers and check the drum internals for tightness and cleanliness.
Check the drum for corrosion and pitting. Oxygen pitting is a common form of corrosion that can
be found in boilers, usually in the steam drum above the normal water level, but is also found in
water drums, tubes and headers.
Remove sufficient amount of handhole caps from each boiler and water wall header for
inspection of the internal tube surfaces. Wash down the unit to remove any sludge.
Inspect and if necessary clean external heating surface of the economizer.
See that the heating surfaces of the airheater are clean. Corrosion if present, would appear in the
cooler portion of the heater, particularly where soot and dirt are allowed to accumulate.
Make a thorough inspection of the firesides and clean as required. Check for misalignment of the
soot blowers.
Check all boiler instrumentation for cleanliness and proper operation.
Check fuel burning equipment (Coal/air nozzles, ignitors, oil guns, scanners, linkage, dampers
etc.) for cleanliness and proper operation. If a furnace safeguard supervisory system is provided
check out and exercise, where practicable, control valves, relays, interlocks etc.
Annual inspection should be complete and include an internal and external examination of the
entire unit.
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17. LAY-UPS
When the unit is shut down for stand-by purposes and draining of the boiler is not required for
maintenance or repairs, the boiler metals must be protected against corrosion. Refer to “Lay Up
Procedures” in this manual.
18. WATER WASHING TO REMOVE DEPOSITS FROM OIL FIRING
Firing oil with high ash content leads to troublesome ash deposits on the waterwall, superheater
and reheater surfaces. The ash contains varying amount of vanadium, alkalines, sulphur and
other objectionable elements. It is composed of insoluble residue along with a bonding binder
which adheres to the water wall, superheater and reheater surfaces. This densely bonded mass
may not be completely removed by normal cleaning devices such as soot blowers. Periodic water
washing of these surfaces may be required to loosen the binder and flush out the insoluble
residue.
Excessive ash on the waterwalls, supeheater or reheater have an adverse effect on boiler
operation. When this accumulation plugs the passes in the superheater or reheater, operation of
the unit is seriously hampered. Operating the unit with plugging is determental because:
i Full load operation may not be possible due to increased pressure losses from plugging.
The increased pressure losses increase the head on the ID fan, resulting in reduced
capacity.
ii “Laning” through the superheater and reheater can result in overheating elements in the
open lanes.
iii Means of removing the wash water effluent from the boiler and its disposal.
iv Suitable lances for washing between the elements in the superheater and reheater
sections.
v Boiler efficiency will decrease due to reduced effectiveness of the coated heat transfer
surface.
Need for the water washing is indicated by increased pressure losses through the boiler. Other
indications are a reduction in steam temperature, increase in exit gas temperature, reduction in
capacity or the build up observed in a visual inspection.
The boiler should be cooled to prevent temperature stresses in the pressure parts from the wash
water. If the unit is cool enough so that workmen can stay inside the furnace, it is cool enough to
permit washing. It is preferable that the refractory retains some heat to aid in drying (from the
inside) at the completion of the wash.
The quantity of wash water flow will vary, but means should be available to supply up to 200
litres/min. Generally, higher pressures are desirable to dislodge deposits. The minimum
pressure should be 21 Kg/cm2(g).
Some treatment of the water can be beneficial but is not required. A wetting agent makes the ash
deposits more soluble. Inhibitors are available to reduce the corrosive attack on metal parts by
wash water made acidic from dissolved elements in the ash. Also, caustic or soda ash can be
used to neutralize the wash water.
Drains are provided in most boiler furnaces and in some fly ash hoppers in rear passes. The drain
openings should be cleaned out before the water washing commences. A suitable means to
dispose of the wash water should be provided before the washing commences.
It is desirable to blank off any windbox compartment openings from the furnace side before water
washing, to avoid wetting metal parts of the windbox. Since the unit is equipped with air heater,
means should be provided to prevent contact of wash water effluent, which may cause plugging
of the air heater elements.
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0172 - 0177 VOL - A1 TAB - 1 - 55

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When washing, use large quantities of water so as to flush out the insoluble material and to dilute
the acid forming elements in the ash. Rods or bars can be used to dislodge the more tenacious
accumulations on the superheater or reheater elements. Care should be taken to avoid damage
to tubing when using such rods or bars. It is extremely important, once washing is started, to
clean the surfaces down to bare metal. Otherwise, corrosion is encouraged: the deposits which
remain will accelerate plugging when the unit returns to service.
The amount of time required to water wash a boiler will, of course, vary with the nature of deposits
and preparations made for water washing. The minimum time experienced is about eight hours.
However, continuous washing should be planned, on an around-the-clock basis until the boiler
surfaces are clean.
As soon as the boiler is washed, it should be dried out immediately. This will prevent corrosion of
metal parts. Under no circumstances may the unit be allowed to stand wet for any appreciable
time. Dry-out should consist of firing the boiler at a very low rate, just to maintain about 1.7
kg.cm2(g) steam pressure for eight hours. Then, when the unit is dried out, it can be put back
into service.
If waterwashing is scheduled for an extended outage (longer than one week), it should be done at
the beginning of the outage and the unit should be dried out thoroughly to prevent corrosion
caused by deposits absorbing moisture from the air during the outage.
19. FEEDWATER TREATMENT
The treatment of feed water and the conditioning of boiler water are beyond the control of this
company. This company does not assume the responsibility for water treatment and does not
make specific recommendations for control purposes.
Supplier warns against exceeding maximum limits of hardness in the feed water and of total
solids and alkalinity concentrations in the boiler water. These limits are absolute maximums and
should not be exceeded. In addition, the boiler water silica content should be limited for the
particular operating pressure involved by reference to standard silica vaporization curves.
The successful operation of steam generating equipment depends upon a rigid control of
feedwater and operating variables to assure freedom from scale formation and corrosion of water
and steam contacted surfaces of the boiler. This control is very important for higher pressure
operation.
Scale formation in boilers is prevented by providing a good makeup water to the feed water
system and by avoiding condensate contamination. At higher pressure, the makeup must be of
condensate quality such as provided by evaporation or by demineralization.
Corrosion of metal surfaces in contact with water and steam constitutes the major maintenance
expense to the power industry. The condensate and feedwater must be free of dissolved
corrosive gases and the pH of the water must be properly adjusted to prevent the attack on metal
surfaces.
The oxygen content in the feed water must be reduced to low levels by effective deaeration in the
condenser and in deaerating heaters. Care must be taken to prevent the introduction of air into
heater drips which may be added to the condensate. Make up condensate from storage tanks
should not be added directly to the feed water system without deaeration. Minimum forced boiler
outage time has been realized where the oxygen content has been reduced and held below 0.01
ppm. It is important to maintain a chemical reducing environment in the boiler water and chemical
such as hydrazines have been used effectively to achieve this.
The pH of the feed water must be controlled to prevent the dissolution of the iron and copper
alloys in the pre-boiler system. These form corrosive products when introduced into the boiler
and will contribute to the corrosion of boiler steam generating surfaces. Oxides of iron and copper
may permit the diffusion of boiler water to the heated surfaces of the unit and cause locally high
concentration of boiler water salines that result in the attack of the tube metal.
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0172 - 0177 VOL - A1 TAB - 1 - 56

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The pick-up metals from pre-boiler surfaces can be minimized by the addition of volatile alkaline
chemicals that raise the pH of the feed water. The pH range of 9.1- 9.8 have produced the best
results.
Volatile treatment offers the greatest assurance against deposition in superheaters and turbines
which might result from intermittent carry over. The only disadvantage of this treatment is the fact
that the boiler water is unbuffered and subject to relatively rapid changes in boiler water pH values
if contamination should occur. Where the advantages of volatile control are to be pursued,
special emphasis must be placed on quick detection of condenser leaks and alarms must be
available to alert the operators that such a condition exists. Volatile control should be used only
when the dissolved solids content in the boiler is less than 2 ppm. If a significant concentration of
solids is present as a result of condenser leakage, solid treating chemicals such as trisodium
phosphate should be available for immediate injection for pH adjustment of the boiler water.
Under no circumstances should a boiler be operated with a pH value below 7.0. If the boiler
water pH cannot be maintained above this value with chemical feed and blowdown, the unit
should be removed from service in an orderly fashion. Refer to “Water Chemistry Guidelines for
High Pressure Boilers” enclosed in this manual.
Close control of solids in the boiler water must be established to prevent carryover of boiler water
into the steam. The presence of oil, grease, high alkalinity, or other foam inducing solids cannot
be tolerated.
It is evident that stringent control of operation and feed water treatment must be applied to
prevent trouble from scaling, corrosion and foaming.
The control of boiler water is a prime pre-requisite to good operation. A good chemical staff
should be employed. The services of a competent consultant can be of value to supplement
necessary technical data and information.
Note: Protection of the boiler against corrosion should not be limited to actual operation of the
unit. Rigid standards with respect to water conditioning should also be maintained during lay-up
periods. For details on boiler lay-up refer to the recommended procedures elsewhere in the
manual.
20. WATER IMPOUNDED BOTTOM ASH HOPPER (As applicable)
Ash level in the bottom ash hopper shall be monitored periodically through ‘S’ panel peep holes
and bottom ash view holes. After each deashing of bottom ash hopper complete evacuation of
hopper shall be ensured. Also after each wall blowing cycle during normal operation of the unit
the bottom ash hopper deslagging cycle shall be started. In case of any problem in the bottom ash
evacuation / clinker grinder operation the unit load shall be reduced suitably.
Always ensure the over flow water temperature at the bottom ash hopper at less than 60 deg.C to
avoid steaming, by suitably ensuring make up water flow.
Unit load shall not be raised in case of any problem in operation of ash hopper evacuation system.
BHEL do not recommend full accumulation of ash in the bottom hopper as the boiler is not
designed for taking this load and this is not a desirable operating condition for the safety of the
unit.
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0172 - 0177 VOL - A1 TAB - 1 - 57

HINDALCO / ADITYA CPP
UNITͲ1 to 6, 6x150MW
BHARAT HEAVY ELECTRICALS LIMITED
0172 - 0177 VOL - A1 TAB - 1 - 58

TABLE OF CONTENTS
Page No.
INTRODUCTION 1
IMPORTANT INSTRUCTIONS 3
1. PRE-OPERATIONAL PROCEDURES 8
1.1 CLEAN-UP 8
1.2 CHEMICAL CLEANING 8
1.3 BLOWING STEAM LINES 8
1.4 SETTING SAFETY VALVES 8
2. COLD START-UP 9
2.1 PREPARATIONS FOR LIGHTING OFF 9
2.2 INITIAL FIRING PRECAUTIONS 11
2.3 LIGHTING OFF 12
3. NORMAL OPERATION - UNIT LOAD CHANGES 17
3.1 DECREASING LOAD 17
3.2 INCREASING LOAD 18
4. NORMAL SHUTDOWN TO COLD 19
5. NORMAL SHUTDOWN TO HOT STANDBY 21
6. HOT RESTART 22
7. EMERGENCY PROCEDURES 23
7.1 REHEATER PROTECTION UPON LOSS OF LOAD 23
7.2 MASTER FUEL TRIP 24
7.3 LOW WATER LEVEL 25
7.4 HIGH WATER LEVEL 26
7.5 TUBE FAILURES 26
7.6 ASH HANDLING SYSTEM 27
8. CARE OF BOILERS DURING CONDENSER TUBE LEAKAGE 28
0172 - 0177 VOL - A1 TAB - 1 - 59

UNIT OPERATING PROCEDURES ADITYA CPP UNIT-1 to 6, 6x150MW
INTRODUCTION
The procedures outlined in this section of the manual are intended to serve as a guide
during initial stages of operation. The procedures include precautions which should be
observed and the proper operating sequences of the unit, the fuel firing equipment and
auxiliaries furnished by the company. Sequential procedures do not include detailed
reference to other equipment like feed pumps, condensate pumps, turbine etc.
Because the unit is only one part of the overall power station and since all equipment must
operate in unison, specific procedures and detailed values cannot be included in this
manual. As operating experience is gained and controls are fine tuned the units
characteristics and actual operating requirements will become evident to the operator.
Reference should be made to the Burner Management System (Furnace Safeguard

Supervisory System), Steam Temperature and Secondary Air Damper Control System and
other control sub loop instructions for further operating details.
Reference should be made to the manufacturer’s instructions regarding operational and

pre-operational procedures for their equipment.
Unit Description
The unit is a natural circulation, single drum, radiant reheat, balanced draft boiler with
tilting tangential burners. Firing equipment consists of remotely controllable HEA
Ignitors, air cooled oil guns and coal nozzles. The elevations of coal nozzles are supplied
with pulverised coal from Bowl Mills. Complete descriptions of the equipment provided
can be found in the respective instruction manuals.
There are 3 major circuits in the SG system are water & steam circuit, air & flue gas
circuit and fuel firing system.
Following are the associated control systems for the above.

x Unit monitoring
x Alarm & annunciation
x Interlocks & protection
x Auto control
Control equipment provided by BHEL includes Furnace Safeguard Supervisory System to

protect the pressure parts and flue gas system under extreme emergency conditions from
severe damages, Soot Blower Control System, Secondary Air Damper Control System,
Electromatic Relief Valve Control and other local pneumatic controls.
BHARAT HEAVY ELECTRICALS LIMITED 1
0172 - 0177 VOL - A1 TAB - 1 - 60

Safety valves are provided for the protection of critical equipments like Drum, piping etc
The various auxiliaries include two numbers rotary regenerative air preheaters, five nos. of
XRP 803 bowl Mills arranged at the rear of the boiler, two numbers axial reaction FD
Fans, two numbers axial reaction PA Fans, two numbers of radial ID Fans, two numbers
Seal Air Fans and two numbers Electrostatic Precipitators.
The Boiler is designed for control load operation from 60% TMCR to 100% BMCR.
Accordingly the SH / RH surface areas are designed to achieve the rated steam parameters
in the control range.
The steam output of the Boiler is termed as Boiler Load Index (BLI) and it is the
cumulative addition of flow in steam turbine, HP by pass lines and auxiliary PRDS lines
0172 - 0177 VOL - A1 TAB - 1 - 61

IMPORTANT INSTRUCTIONS - BOILER OPERATING PROCEDURES
DOs
A. PREPARATIONS FOR LIGHTING UP
1. CHECK AND REMOVE ANY FOREIGN MATERIAL FROM BOILER.

ENSURE ALL MANHOLES, ACCESS DOORS AND OPENINGS IN THE
BOILER AND DUCTING ALL SECURELY CLOSED.
2. REMOVE ANY RESTRICTION OBSTRUCTING THE BOILER EXPANSION.
3. ENSURE FURNACE HOPPER WATER SEALING.
4. ENSURE AVAILABILITY OF COMPRESSED AIR, POWER, CHEMICALS,

COOLING WATER ETC.,
5. KEEP ALL VENTS AND DRAINS AS PER VALVE OPERATING DIAGRAM.
6. ENSURE BURNER TILTING IS HORIZONTAL.
7. CHECK UP AND KEEP READY THE OIL PUMPING AND FIRING

EQUIPMENT AND SYSTEMS.
8. ENSURE CORRECT FUNCTIONING OF ALL INTERLOCKS AND

PROTECTIONS OF AUXILIARIES, DAMPERS AND VALVES.
9. CHECK UP THE WINDBOX FOR PROPER DAMPER POSITIONING.
10. CHECK UP CORRECT FUNCTIOINING OF ALL INSTRUMENTS.
11. KEEP ALL DAMPERS IN AIR AND GAS SYSTEM IN START UP

CONDITIONS.
12. CHECK AND ENSURE CORRECT FUNCTIONING OF FURNACE PROBE.
13. ENSURE ALL EQUIPMENTS ARE PROPERLY LUBRICATED AND KEPT

READY FOR START UP AS PER THEIR OPERATING INSTRUCTIONS.
14. FILL UP THE BOILER UPTO NORMAL LEVEL.
15. ENSURE FULL CLOSING OF ALL DESUPERHEATING SPRAY CONTROL

VALVES.
16. CHECK UP AND ENSURE THAT ALL INSTRUMENTATION AND

ASSOCIATED MECHANICAL EQUIPMENT ARE AVAILABLE FOR
SERVICE.
0172 - 0177 VOL - A1 TAB - 1 - 62

B. INITIAL FIRING
1. CHECK THAT NO BOILER TRIP CONDITION EXISTS.
2. ENSURE 30% AIR FLOW THROUGH BOILER.
3. COMPLETE THOROUGH PURGING OF FURNACE.
4. ENSURE ENOUGH OIL AND AIR PRESSURES ARE OBTAINED.
5. CHECK UP THAT ALL THE LIGHTED UP BURNERS ARE BURNING WELL

FREE OF SMOKE, PROPER ATOMISATION ETC.,
6. CHECK UP FOR GOOD FURNACE CONDITION.
IF THE FURNACE IS FOUND SMOKY ADJUST THE SECONDARY AIR

AROUND BURNER OR INCREASE THE TOTAL AIR FLOW IF REQUIRED.
7. SELECT THE BURNERS IN ROTATION TO HAVE UNIFORM HEATING.
8. CHECK FOR FREE EXPANSION OF FURNACE AND RECORD.
9. CHECK AND CONTROL FIRING RATE AS PER START UP CURVE.
10. CHECK AND MAINTAIN DRUM LEVEL ALWAYS NEAR NORMAL.
11. CHECK AND CONTROL BOILER WATER, FEED WATER AND STEAM
CONDITIONS AS RECOMMENDED.
12. DO FREQUENT SOOT BLOWING OF AIR PREHEATER DURING INITIAL

LIGHT UP AND START UP PERIOD.
13. KEEP AIR PREHEATER AIR BYPASS DAMPER IN SERVICE DURING

FUEL OIL FIRING.
0172 - 0177 VOL - A1 TAB - 1 - 63

C. NORMAL LOADING
1. INCREASE THE BOILER LOAD ONLY AS PER STARTUP CURVES.
2. START COAL FIRING ONLY WHEN SUFFICIENT IGNITION ENERGY IS

AVAILABLE.
3. COMMISSION ALL AUTOMATICS AS EARLY AND PRACTICABLE AS

POSSIBLE.
4. CHECK AND RECORD SUPERHEATER AND REHEATER METAL

TEMPERATURES.
5. CHECK AND MAINTAIN EQUAL WINDBOX PRESSURE ON ALL SIDES.
6. CHECK AND MAINTAIN THE FOLLOWING WITHIN LIMITS BY

PERIODIC ANALYSIS.
a. FLUE GAS ANALYSIS.
b. QUALITY OF FEED WATER, BOILER WATER/STEAM.
c. PULVERIZED COAL FINENESS.
7. DO FREQUENT SOOT BLOWING OF REGENERATIVE AIR PREHEATER

ESPECIALLY ON LOW LOAD TO AVOID AIRHEATER FIRE.
8. KEEP AIR PREHEATER AIR BYPASS IN SERVICE TILL THE

RECOMMENDED COLD END TEMPERATURE OF REGENERATIVE
AIRHEATER IS ACHIEVED.
9. MONITOR THE ASH LEVEL IN THE BOTTOM ASH HOPPER

PERIODICALLY THROUGH “S” PANEL PEEP HOLES AND BOTTOM ASH
HOPPER VIEW HOLES. ENSURE COMPLETE EVACUATION AFTER EACH
DEASHING CYCLE, AFTER EACH WALL BLOWING CYCLE
COMPLETION START THE BOTTOM ASH HOPPER DEASHING CYCLE.
IN CASE OF ANY PROBLEM IN CLINKER GRINDER OPERATION AT
BOTTOM ASH HOPPER THE CONTROL ROOM SHALL BE INFORMED TO
REDUCE THE LOAD SUITABLY.
10. ALWAYS ENSURE OVER FLOW WATER TEMPERATURE LESS THAN 60

DEG.C IN THE WATER IMPOUNDED BOTTOM ASH HOPPER TO AVOID
STEAMING BY ENSURING SUFFICIENT MAKE UP WATER FLOW
CONTINUOUSLY
0172 - 0177 VOL - A1 TAB - 1 - 64

D. NORMAL REDUCTION OF LOAD
1. REDUCE THE LOAD AS PER THE RECOMMENDED RATE.
2. CHECK AND ADJUST THE DESUPERHEATER SPRAY TO GET THE

DESIRED STEAM TEMPERATURES.
3. CHECK AND TAKE OUT THE CONTROLS ON MANUAL AT A POINT

WHETHER BETTER CONTROL CAN BE OBTAINED MANUALLY.
E. NORMAL SHUT DOWN TO COLD
1. REDUCE THE LOAD AS GRADUALLY AS POSSIBLE.
2. CHECK THAT NORMAL DRUM LEVEL IS MAINTAINED.
3. ENSURE ENOUGH PURGING OF FURNACE AFTER TRIPPING THE FUEL.
4. FILL UPTO + 150 MM ABOVE NORMAL LEVEL IN DRUM DURING

BOXING UP OF BOILER.
5. CHECK AND MAINTAIN DRUM LEVEL PERIODICALLY TILL IT COOLS

SUFFICIENTLY.
6. NOTE DOWN ALL MINOR MAINTENANCE WORKS LIKE VALVE

LEAKAGE, GLAND LEAKAGE ETC., AND ATTEND DURING SHUTDOWN.
7. RUN THE ID & FD FANS AND REGENERATIVE AIR PREHEATER TILL

THE AIR PREHEATER INLET FLUE GAS TEMPERATURE DROPS DOWN
TO 200 DEG.C.
0172 - 0177 VOL - A1 TAB - 1 - 65

DON’TS
A. INITIAL FIRING
1. DO NOT CONTINUE FIRING IF THE DRUM WATER LEVEL IS

DANGEROUSLY LOW.
2. NEVER INCREASE THE FIRING RATE SO AS TO CAUSE FURNACE

OUTLET TEMPERATURE MORE THAN 540 DEG.C, IF THERE IS NO FLOW
IN REHEATER.
3. DO NOT INCREASE THE RATE OF STEAM PRESSURE AND

TEMPERATURE RISE HIGHER THAN THE RECOMMENDED VALUES.
4. NEVER LIGHT UP OR CONTINUE FIRING IF REGENERATIVE AIR

PREHEATER IS NOT RUNNING.
5. DO NOT KEEP FURNACE PROBE INSIDE THE FURNACE IF FLUE GAS

TEMPERATURE EXCEEDS 540 DEG.C.
B. NORMAL LOADING
1. DO NOT INCREASE OR DECREASE THE RATE OF LOADING BEYOND

RECOMMENDED VALUES.
2. NEVER PUT THE MILL WITHOUT ESTABLISHING SUFFICIENT IGNITION

ENERGY.
3. NEVER OPERATE AT HIGHER STEAM TEMPERATURE THAN

RECOMMENDED IN THE START UP CURVES AS IT MAY HARM THE
SUPERHEATER AND REHEATER METALS.
4. DO NOT RAISE THE UNIT LOAD IN CASE ANY PROBLEM IN

OPERATION OF BOTTOM ASH EVACUATION SYSTEM.
5. TO ENSURE SAFETY OF THE BOILER AND AUXILIARIES, NO

INTERLOCK / PROTECTION SHALL BE BYPASSED
6. NO SAFETY VALVE SHALL BE GAGGED FOR THE SAFETY OF BOILER
0172 - 0177 VOL - A1 TAB - 1 - 66

1. PRE- OPERATIONAL PROCEDURES
1.1 Cleanup
Before initial firing and prior to each subsequent cold start-up, after maintenance
has been done on the unit, the furnace should be inspected and cleaned both
internally and externally. All foreign materials should be removed from the
pressure parts. Any grating, pipe lines, electric conduit, etc., that might restrict
normal expansion of the unit should be cleared. All personnel should be clear and
access doors closed. A complete check list should be prepared by the Operating
Department.
1.2 Chemical Cleaning
For procedures for boiling out and acid cleaning refer to “Acid Cleaning and
Steam Blowing. “Firing procedures are outlined under Section 2.3. Lighting off,
should be used as a guide when operating the fuel burning equipment.
1.3 Blowing Steam Lines
Prior to starting up a new unit or after major pressure parts repairs on an older unit,
the main steam lines and the reheater steam lines should be blown out to remove
scale and foreign matter there by preventing damage to the turbine. This should be
done after acid cleaning and prior to setting drum and superheater safety valves.
Consideration should be given to setting the reheater safety valves before
removing the temporary blow out piping.
Refer to instruction on Àcid Cleaning and Steam Blowing’ for recommended

operating procedures and precautions.
1.4 Setting Safety Valves.
Setting of the safety valves on the drum and superheater should be done prior to
turbine rolling. Refer to the safety valves manufacturer’s instructions for setting
procedures. A conservative firing rate should be maintained limiting the furnace
exit gas temperature to a maximum of 540 deg.C. If the reheater safety valves were
not set during the steam line blowing procedure, they may be set while the turbine
is carrying a light load, by closing down the intercept valves until a reheat steam
pressure is reached high enough to lift the reheater safety valves. (Consult the
turbine manufacturer’s instructions for allowable procedures). Popping pressure
and blow-downs should be adjusted to conform with design values.
0172 - 0177 VOL - A1 TAB - 1 - 67

2. COLD START UP
2.1 Preparations for Lighting Off
It is assumed that at this time the following preparatory work has been completed:
i. The unit has been chemically cleaned, that the steam lines have been blown, that
the safety valves have been set and that the unit has been filled to slightly above
the normal operating level with properly treated feed water. The feed water tank
should have been filed with water.
ii. All control systems have been checked and are available for service.
iii. All instrumentation and associated mechanical equipment have been checked and
are available for service. Check all safety interlock system prior to startup to
ensure proper functioning.
iv. The oil firing equipment has been checked out to assure proper functioning
Recheck items such as:
a. Oil guns inserted and properly coupled.(Check gaskets between unions).

b. All manual valves open.
c. All control valves closed.
v. The wind boxes have been checked for proper damper positioning, tilts at
horizontal, etc.
vi. The pulverizers and feeders have been checked and are available for service.
“Refer Mill starting sequence” under Mill Operating Procedure.
vii. The feedwater system, instrumentation and equipment, have been checked and are
available for operation. It is recommended that during start ups the feed water is
controlled remote-manually, until a continuous flow is established. See Section
2.3 “Lighting Off”. To avoid possibility of oxygen corrosion in the boiler, the use
of undeaerated feedwater (temperature less than 100 deg.C is not recommended.
viii. All air handling equipment have been checked and are available for service. All
air and gas duct dampers should be in the start up position. Refer to Notes and
caution below
a. I.D. Fan outlet shut off gate closed. Inlet regulating vanes/dampers are in
closed position during starting.
b. Keep the F.D. Fan outlet shut-off dampers closed. Keep the F.D. Fan
regulating Vanes/Blades in the minimum position.
c. Primary air fan outlet shut off and inlet control dampers closed.
d. Wind box (secondary) auxiliary air dampers open.
0172 - 0177 VOL - A1 TAB - 1 - 68

e. Scanner emergency air damper closed.
f. Pulveriser seal air fan shut off dampers open.
g. Air and gas dampers around airheater open.
NOTE:
1. Refer to the Fan Manufacturers’ instructions for operating details.
2. It is assumed that the unit will be started with both F.D.Fans and I.D.
Fans. If the unit is started with only one set of fans and airheaters,
the corresponding dampers associated with the equipment to be kept
open. Dampers associated with idle equipment should be closed.
CAUTION:
The I.D. Fans are capable of developing drafts in excess of the furnace design pressure.
Therefore, the operator must take care to establish and maintain an air flow path through
the unit prior to starting the I.D. Fan and prior to opening the I.D.Fan inlet damper by
ensuring that other dampers in the system are in the start up positions indicated above.
The I.D. Fan inlet damper must be kept closed until after the fan is started. This procedure
will minimize the possibility of developing excessive negative pressure in the unit during
the starting procedure.
The operator must take care to maintain the furnace draft within safe limit at all times.
He must be especially careful when draft and air low controls are in the “Manual mode.
He must be alert at all times for possible malfunctions of automatic control equipment
resulting in abnormal excursions in furnace pressure either negative or positive.
ix. Check that the airheaters have been prepared for service, than an adequate means
of extinguishing airheater fires is available and ready for use. Refer to Air
Preheater instructions for details.
x. Place the gas temperature probe intermittently for monitoring the FOT. It shall be
less than 540 Deg.C till RH is charged and accordingly the firing rate shall be
limited.
xi. The soot blowing equipment has been checked for proper operation and the system
is in the start up condition. (All blowers retracted, main steam supply valve open).
xii. All Desuperheater Spray Water Control Valves and block valves are closed
xiii. All Boiler, Superheater and Reheater drain and vent valves are in the start up
position. Refer to the Valve Operating Diagram.
xiv. The furnace gas temperature probe is in working order and available for service.
xv. The turbine generator is available for service and has been prepared for service as
described in the manufacturer’s instructions.
xvi. Cooling water and compressed air service is available.
0172 - 0177 VOL - A1 TAB - 1 - 69

2.2 Initial Firing Precautions
To Ensure a maximum safety margin during start-ups. It is mandatory that at least

30% of full load air flow be maintained in order to produce the following
conditions:
I. An air-rich furnace atmosphere. This precludes the possibility of an

accumulation of explosive mixtures in the event of poor or delayed ignition
after fuel is introduced in to the furnace.
II. High excess air through the air heater. This minimises the dilution of
combustion air by inerts, carried over by the air heater rotor.
Air flow should be increased when the boiler reaches a load where additional air is
required to maintain the rated operating excess air. Refer to Publication Tilting
Tangential Firing System” and air flow vs load curve.
During start-ups, lighting off is done with the lower ignitors and warm up oil guns.
Warming up can be accomplished with either the warm-up oil guns or fuel oil
firing. In either case, the required firing rate must permit operation of an entire
elevation of fuel nozzles without exceeding the furnace exit gas temperature
limitation as described in the following paragraph.
NOTE: To minimize the possibility of adverse visible stack emission it is

desirable to use the warmup oil guns till attained to atleast 35 Kg/cm 2 (g) drum
pressure and 177 deg.C secondary air temperature before firing pulverised coal.
When bringing the unit up to pressure and temperature, the saturated (steam
temperature rise must be limited to 110 deg. C per hour (See Note). The stat-up
curve (curve 1) shows the corresponding rate of drum pressure increase. The
capacity variation curve (curve 2) shows the capacity pressure relationship
required for proper waterwall circulation. At reduced drum pressure the steam
flow must not exceed the corresponding maximum allowable capacity (% design
capacity) shown on the curve.
During all start-ups the firing rate should be controlled to keep the maximum
furnace exit gas temperature below 540 deg.C (as measured by the furnace outlet
gas temperature probe) until adequate flow is established through RH by cutting in
the HP/LP Bypass. After rolling the turbine, the steam temperature and pressure
rise at the turbine throttle should at all times be in accordance with the limits
prescribed by the turbine manufacturer.
NOTE: It is recommended that during initial start of a new unit a relatively slow
rate of pressure increase be followed, in order to allow sufficient time for checking
expansion movements and to permit the operators to become familiar with the
characteristics of the unit and its auxiliaries. Once these characteristics have been
established, subsequent startups may be made at the fastest rate consistent with
maintaining the furnace exist gas temperature limitation of 540 deg.C until the
HP/LP Bypass is cut - in.
0172 - 0177 VOL - A1 TAB - 1 - 70

2.3 Lighting off
i. Start both air preheaters. Then start two I.D. Fans and two F.D. Fans. After
starting the F.D. Fan, open the shut - off dampers for minimum. 30% air flow by
blade pitch control (See Note below and ”Caution” under Section 2.1 “Preparation
for Lighting up”).
NOTE : Although it is sufficient to operate one set of fans until the turbines, carry
a light load, it may be desirable to light off with both sets of fans in order to avoid
unbalancing of the air flow when load is being carried. Refer to Note 2 in Section
2.1.
ii. Place the air preheater air bypass in service.
iii. Start the scanner and seal air fans.
iv. Adjust the fan and windbox dampers to permit a purge air flow of atleast 30% of
total air flow and a furnace draft of approximately 12.7mm wg. Refer to Section
2.2 Ìnitial Firing Precautions”.
v. When the fans are started, the secondary air damper control should adjust the
auxiliary air dampers to obtain approximately 37mm wg windbox to furnace
differential pressure. Check that all other purge permissives are satisfied.
vi. Initiate a furnace purge. Upon completion of purge cycle, check that all firing
prerequisites are satisfied.
vii. Place the temperature probe in service.
viii. Initiate a light off sequence of the lower elevation of ignitors and warmup oil guns.
Refer to the “Furnace Safeguard Supervisory System”. “Ignitor” and Air cooled
Oil Gun” Instructions for details.
During warming up period keep open the economiser recirculating line valve.
ix. Blow down the unit as required to maintain the drum water level in sight in the
gauge glass.
x. The firing rate should be controlled to keep the furnace exit gas temperature below
540 deg.C until steam flow through Reheater is established. Establish a slight flow
through superheater by opening its start-up vent. More superheater drains/vents
may be opened, if necessary, for increasing the steam temperature to match turbine
conditions.
NOTE: HP-LP By pass Station helps the unit to be quickly synchronised.
xi. Increase the firing rate as required within permissible limit of 110 deg.C hr. to
raise the pressure, if necessary with fuel oil.
0172 - 0177 VOL - A1 TAB - 1 - 71

xii. While the unit is heating up, frequent checks should be made of the boiler
expansion movements. Special attention should be given to expansion of the lower
part of the boiler relative to building steel. Expansion movements should be
recorded for comparison with future start-ups. Refer to the expansion movements
diagrams.
xiii. Maintain drum water level at normal and check boiler water concentrations and
constituents as frequently as required to maintain proper boiler water conditions.
xiv. Close the economiser recirculation valve when continuous feed water flow is
established.
xv. Before raising a vaccum in the condenser, make sure that all reheater vents or
drains that are open to the atmosphere are closed. Leave drains or vents connected
to HP drain flash tank open until the turbine is carrying a light load.
xvi. Open MSSV bypass first and later on MSSV fully after ensuring the drains in MS
line to atmosphere to flash tank opened. After sufficient pressure in MS line, with
drain to flash tank open in CRH & HRN lines, HP by pass shall be opened. The LP
by pass also shall be opened after ensuring the vacuum to establish flow in HP&LP
bypass system.
xvii. Steam dumping Operation: As the steam lines are charged after cleaning cycle of
steam blowing of critical pipings, the steam purity shall be achieved before
admitting steam to turbine for rolling. For the purpose, steam dumping operation
shall be continued in HP & LP by pass system and firing rate shall be raised for
quick loading of the turbine once it is synchronized.
xviii. As drum pressure increases, progressively throttle the final Superheater Outlet
Header vent (Start-up Vent) and other start-up drains used (main steam line drain,
turbine drains, etc.,). Sufficient steam flow must be maintained at all times to
assure clearing the superheater elements of condensate. Increase the firing rate as
necessary, without exceeding the furnace exit gas temperature limitation. Do not
close start-up vent completely until steam flow through the turbine is established.
The drains in Superheater steam colled wall rear outlet header and the side steam
cooled wall outlet header should be closed immediately after steam is admitted to
the turbine. Refer to figure Valve Operating Diagram.
xix. Start rolling the turbine as soon as the minimum permissible start-up pressure and
temperature, specified by the turbine manufacturer, are reached. Refer to turbine
manufacturer’s instructions.
xx. When bringing the turbine up to speed, the firing rate should be controlled to
prevent the furnace exit gas temperature from exceeding 540 deg. C. When the
turbine is up to speed, it may be synchronized. In no case should the firing rate
exceed than what is necessary to satisfy steam demand.
0172 - 0177 VOL - A1 TAB - 1 - 72

NOTE: If the unit is put on the line before design operating pressure is reached,
further increase of firing rate should be in accordance with the start-up rate. The
steam flow must not exceed the maximum allowable capacity shown in Figure 2.
xxi. If the unit was started with one set of fans then start the second set of fans.
xxii. Place additional level of oil guns in service as the load demands replace the warm-
up oil guns with load carrying guns after the first level of main oil guns are in
service and fire is stable.
xxiii. If coal was not fired previously (See Note) the pulverizer serving the lowest
elevation of coal nozzle (adjacent to the warm up oil guns) should be prepared for
operation so that it can readily be started at this time. Refer to Section `Furnace
Safeguard Supervisory System” for startup sequence and controls. Prior to placing
pulveriser in service, ensure that one of the P.A. fans developing adequate header
pressure is in service.
NOTE: If a pulverizer was started during the warming up period increasing load
requirements can be met by increasing feeder speed. When pulveriser is put into
service ensure that the corresponding seal air fan is also in service.
xxiv. When placing the first pulverizer in service, check that the pulveriser start
permissives (ignition energy, etc.,) are satisfied.
Refer to the Furnace Safeguard Supervisory System instructions. The coal fuel-air
dampers should remain closed until ignition is established. Check to see that the
nozzle tilts are horizontal. Place the second Primary Air Fan in service, if not done
previously.”
Start the pulverizer (See Note). Open the hot air shut-off gate and bring the
pulverizer up to the required operating temperature without coal. Place pulverizer
air flow and temperature control on Auto. When ready to fire coal, start the feeder
at minimum rating (Manual control). Ignition of the pulverised coal should take
place immediately. When the pulveriser is proven in service, the fuel air dampers
should open automatically. Maintain the fuel feed at a minimum consistent with
stable ignition. Watch the fires.
NOTE: If the Unit start-up follows a Master Fuel Trip, the pulverizers may not be
empty. It must be operated to clear it of excess coal before starting the feeder.
During this procedure the pulverisers discharge valves of all other idle pulverisers
must be closed in order to prevent blowing hot furnace gases back into the idle
pulverisers and coal piping (See “Emergency Procedures” in Section-7). When
most of the coal has been removed from the pulverisers the feeder can be started at
minimum speed and then adjusted to a speed selected to give a stable flame, or as
required to meet unit load requirements. Do not admit hot air to the pulveriser
until the feeder is started. Be sure that the ignition energy is established before
starting the pulveriser.
xxv. If ignition does not take place immediately after coal appears at the coal nozzles,
stop the feeder. Determine the cause of the ignition failure before attempting to
restart the feeder.
0172 - 0177 VOL - A1 TAB - 1 - 73

xxvi. Maintain proper coal/air temperature leaving the pulverizers. Regulate the hot and
cold air damper to hold between 75 deg.C and 90 deg.C at the pulveriser outlet. At
no time should this temperature exceed 95 deg.C. If it should exceed 95 deg.C the
hot air damper must be closed.
NOTE: Pulverizer start-up will cause a sudden and sharp increase of steam
pressure. This will level out rapidly as load is placed on the turbine.
Check the pulveriser oil temperature and turn on the water to the oil cooler when
the temperature approaches 65oC. The oil temperature should not exceed 70oC at
any time
xxvii. Place the adjacent pulverizer in service in a similar manner when the feeder rating
of the pulveriser has reached 80% of its maximum. When one mill is in service
and the other mill is introduced with the existing working mill as an ignition
permissive, care has to be taken to ensure that the feeder rating of the pulveriser
does not fall below 50% of its maximum failing which the ignitor permissive shall
no longer be available. The above caution is not applicable when an adjacent oil
elevation is in service which shall act as ignition support. The warm-up guns and
ignitors must remain in service until the feeder rating exceeds 50% of maximum.
When second pulverizer is provenin service, equalize the feed rate of the two
pulverizer.
NOTE: If the adjacent pulverizer is not available for service, place the other mill
serving the next closest elevation in service after ensuring ignition energy
availability and do not remove warm-up oil guns and ignitors from service until
two adjacent coal elevation are in service with feeder rating on associated
pulveriser in service greater than 50% of maximum.
xxviii. The Furnace Safeguard Supervisory System and Secondary Air Damper Controls
should close the auxiliary air dampers serving compartments adjacent to coal
nozzles which are out of service. When the boiler reaches 20% of full load
increase the wind box to furnace differential pressure to approximately 100 mmwc.
xxix. It is essential that the air flow to the furnace is sufficient for the firing rate at all
times, Automatic control equipment is normally arranged to maintain such a
balanced condition. The Oxygen measuring devices which are often tied in with
the air flow control should be checked periodically to assure continuous and
dependable operation.
xxx. Place additional pulverizers in service as the unit loading demands. The mill
serving the lowest available nozzle elevation not already in service should be
started when the feeder in service reaches approximately 80% of its maximum
rating.
xxxi. Place the Steam Temperature Controls and Combustion Controls on Àuto’ when
firing conditions are stable and the temperature and pressure control set points
have been reached. Refer to the control manufacturer’s instructions for specific
procedures.
0172 - 0177 VOL - A1 TAB - 1 - 74

xxxii. Adjust the feed water supply to the boiler as necessary to maintain normal water
level, as per drum level operating curve. Feed water control should be placed on
automatic as soon as possible and practicable when continuous feed water flow is
established.
xxxiii. As each pulverizer is placed in service, the required associated ignition energy
must be available. When the unit firing conditions are stabilised, all warm up oil
guns and ignitors may be taken out of service.
0172 - 0177 VOL - A1 TAB - 1 - 75

3. NORMAL OPERATION - UNIT LOAD CHANGES
During normal operation, with the unit on the line, changes in pulverizer loading
and/or the number of pulverisers in service may be required to accommodate unit
load changes. A wide range of load control can be achieved with the pulverizers
on automatic control.
3.1 Decreasing Load
If the unit load decreases to a point where the feeder rating of the pulveriser in
service is reduced to 50% of maximum, that mill should be taken out of service. To
remove the pulveriser from service, refer mill normal shutdown procedure.
To remove the pulveriser from service, proceed as follows.
1. Start the ignitors and /or warm up oil guns associated with the coal
elevation served by the selected pulverizer
2. Gradually reduce the feeder rating of the selected pulverizer to minium
3. When the feeder rating is at minium (approx.25%), close the hot air shut
off gate.
4. Allow the pulverizer coal -air temperature to drop to 45 deg.C and take
feeder out of service.
5. Allow the pulverizer to run for at least five minutes to ensure that it is
completely empty, then stop the pulverizer.
6. The associated ignitors and/or warm up oil guns may be shut down when
furnace conditions have stabilised
Additional pulverisers can be taken out of service in a similar manner when the
feeder rating drops to 50% of maximum,
Every effort should be made to keep adjacent pulverizer in service. If, due to
maintenance a pulveriser is not available, skipping the coal elevation served by
that pulveriser is permissible. Skipping of two coal elevations is not recommended
and is only permissible with the use of auxiliary supporting fuel oil (associated
warmup guns and ignitors).
If the unit load is reduced to a point where only two mills are required, auxiliary
supporting fuel adjacent to the coal nozzles in service must be placed in service to
assure positive ignition when the feeder rating drop to 50% or less.
NOTE: Auxiliary supporting fuel should be used at any time and under any
conditions in which, in the operators’ judgement in stabilisation of ignition is
necessary.
0172 - 0177 VOL - A1 TAB - 1 - 76

3.2 Increasing Load.
If after a load decreases when pulverizers have been taken out of service, should
the unit load increase to a point where the feeder rating of the pulveriser in service
exceeds 80% of maximum, an additional pulverizer should be placed in service as
follows:
a. Establish the ignition energy required for the coal elevation served by the
selected pulveriser end.
b. Start the pulveriser.
c. Open the hot air shut off gate & bring the pulverizer up to operating
temperature
d. Start the feeder corresponding to the pulveriser to be put into service at
minimum rating. (Refer to Bowl Mill instructions).
e. When the pulverizer is grinding & coal ignition has been established gradually
increase the feeder rating until the pulverizer loading equals that of the other
pulverizers I n service .Then place the pulverizers on auto.
f. The auxiliary supporting fuel (warm up oil guns) may be taken out of service
when furnace conditions have stabilized and atleast two pulveriser are in
service each with a feeder rating of atleast 50%.
g. Place additional pulverisers in service in the same manner as required by load
increase demand.
0172 - 0177 VOL - A1 TAB - 1 - 77

4. NORMAL SHUTDOWN TO COLD
The following procedures for normal shutdown are based on the assumption that
the unit is operating at full load on automatic control and that it is the intention to
reduce the pressure to zero and cool the boiler completely.
I. Gradually reduce load on the unit; reduce the firing rate in line with the decreasing
steam flow. Allow the pressure to drop with the reduction in load to accelerate
cooling. Reduce the steam temperature at the rate prescribed by the turbine
manufacturers.
Steam temperature control, combustion control and feedwater control may be left
on automatic mode until the point is reached when better control can be obtained
on manual mode.
ii. When the feeder rating on all pulveriser in service is reduced to 50% of maximum,
put the upper elevation of supporting fuel in service. Place the pulveriser
supplying the upper coal elevation on manual control. Gradually reduce the feeder
rating and when minimum flow is reached close the hot air shut off gate. Stop the
feeder when the coal-air mixture temperature has dropped to 45 deg.C.
Unless an emergency condition exists the pulverizer should always be emptied

before being stopped
iii. As pulverisers are taken out of service the secondary air damper control system
should close the associate windbox dampers and throttle other dampers as required
to compensate for the reduction in firing rate.
iv. Take the pulverizer supplying the next higher elevation of coal nozzles out of
service when the feeder rating on all remaining pulveriser reaches 40%. Continue
taking additional pulveriser at consecutive lower elevation(s) out of service in the
same manner. When down to the lowest two pulverizers the adjacent warm-up
guns must be placed in service prior to reducing the feeder rating of either
pulverizer to below 50% of maximum.
NOTE: It is recommended that the above consecutive elevation shutdown

sequence be followed. Firing coal at separated coal nozzle elevations without
auxiliary supporting fuel is not permitted.
v. Operate all soot blowers. Refer to manufacturer’s instructions.
vi. Reduce the air flow in line with fuel reduction until 30% of maximum air flow is
reached. Do not reduce the air flow below this rating until all fires are out and the
unit is off the line. See curve 3. To avoid firing instability during this period of
high relative air flow, the auxiliary air dampers at all elevations should be kept
open and reduce the windbox to furnace differential pressure to its lower setting.
vii. Check the expansion movement of the unit as load is being reduced.
viii. Close the desuperheater isolating valves.
0172 - 0177 VOL - A1 TAB - 1 - 78

ix. After the last pulveriser has been shut down, remove the warm-up guns and the
ignitors from service. Shut off the cooling water to the pulverisers. All fires
should be removed when the unit is off the line.
x. When the turbine load reduces to the minimum load, open HP & LP by pass
system for parallel dumping operation of the steam. Reduce the load further and
trip the turbine. Reduce the firing rate and reduce the pressure in Drum with steam
dumping continued in HP&LP bypass system. Box up the system at drum pressure
(required for rolling). The system can be force cooled as per the requirement as
given below. However, the SH vents and drains shall be opened at 10 KSC drum
pressure.
xi. Open the economiser recirculating valves.
xii. During the shutdown period if it is not required to enter the unit immediately a
slow rate of pressure and temperature decay may be desirable. This can be
accomplished as follows:
a. Purge the unit by running the induced draft and forced draft fans for atleast five
minutes (at 30% air flow) after the fires are extinguished.
b. Reduce the air flow through the unit to a minimum. Keep the fans and
airheaters in service until the unit has cooled to the desired temperature.
c. After stopping the fans, stop the airheater.
d. Keep the water level near normal in the gauge glass, add make up as required.
e. Open the drum vents when the unit pressure has decayed to 2 kg/cm2 (g).
* NOTE: Fans and Airheater should not be taken out of service until the
airheater gas inlet temperature has dropped to below 200 deg.C.
xiii. If it is desirable to accelerate the cooling process in order to permit entry into the
unit for maintenance, proceed as follows:
a. Purge the unit by running the induced draft and forced draft fans for atleast five
minutes (at a minimum of 30% air flow) after the fires are extinguished.
b. Continue running the fans to cool the unit at the desired rate. The airheaters
may be shutdown when the gas temperature at airheater inlet has dropped to
below 200 deg.C.
c. Maintain the water level near normal in the gauge glass.
xiv. Open the drum vents when the unit pressure has been reduced 2 kg/cm2 (g).
xv. If the boiler is laid up wet, refer to “lay-up Procedures” in Preservation of Boilers.
xvi The boiler water temperature should be reduced to atleast 90 deg.C before
draining.
0172 - 0177 VOL - A1 TAB - 1 - 79

5. NORMAL SHUTDOWN TO HOT STANDBY
It is assumed that the boiler will be shut down for a relatively short period of time
and existing pressure and temperature condition will be substantially maintained.
A procedure similar to that for normal shutdown should be followed except:
I. Do not reduce drum pressure in line with unit load reduction. The rate of pressure
drop should be much less than the rate followed during normal shutdown. When
the desired pressure at which the boiler is to be held is reached after the turbine is
off the line, the boiler may be bottled up closing all super-heater drains and vents.
Reheater drains and vents are kept open.
NOTE: If it is expected that the Unit will be restarted in a very short period of
time in which the turbine metal temperatures will not decrease appreciably, it may
be desirable to cool the turbine metal to below 425 deg.C by reducing the steam
temperature and pressure, while the unit load is being reduced. This will reduce
the steam/turbine metal differential temperature upon restart.
II. It is recommended that after all fires are extinguished (See Caution below) the I.D.
and F.D. Fans are kept running until the airheater gas inlet temperature has
dropped to below 200 deg.C (See Warning below). Close all gas duct, secondary
air duct and windbox dampers after the fans are shut down.
CAUTION : If it is known or suspected that combustible deposits are present in

the air heater elements, the airheater gas inlet temperature must be reduced to 200
deg.C before shutting down the F.D. Fans, I.D. Fans and airheaters. The airheaters
must be thoroughly cleaned to remove any combustible products before it is shut
down.
WARNING: If it is decided to shut down the fans with the airheater gas inlet
temperature above 200 deg.C the airheaters MUST be kept rotating. However
running an airheater with the gas inlet temperature above 200 deg. C and no air
flow through it will result in seal damage and subsequent excessive leakage during
operation (Refer to airheater instructions). The decision to bottle up the unit above
200 deg.C must be made with this in mind.
III. Keep the water level in sight in the gauge glass. As the unit cools and the water
shrinks, make up should be added intermittently to prevent the water from
dropping out of sight in the gauge glass.
NOTE: The operator should observe the gauge glass periodically so that he is
always aware of the actual drum level and can take the appropriate action to re-
establish water level when the unit is being restarted.
0172 - 0177 VOL - A1 TAB - 1 - 80

6. HOT RESTART
Assuming the boiler has been down for a comparatively short period of time and
considerable drum pressure was maintained, the following procedures should be used in
restarting the unit.
I. Make a general inspection of the boiler and check the points as mentioned under
normal start-up.
ii. If the airheater and fans were shutdown at reduced temperatures (See 5 Step (ii)
Normal Shutdown to Hot Standby), start the AH and fans as outlined under Sec 2.1
`Cold Start-up’. If the unit was bottled up hot with the airheaters still running, start
the fans in the normal sequence.
iii. Initiate a furnace purge and normal light off sequence of the warm-up oil guns.
iv. Open wide all superheater drains to allow complete draining of superheater
headers and/or elements. After draining, close all drains, except the superheater
steam cooled rear outlet header and side steam cooled wall outlet header drains and
the start-up drain vent (Main Steam Line Vents and drains). Keep the steam
cooled wall header drains slightly cracked open until steam is admitted to the
turbine. Keep the startup vent, drains open. Reheater drains and vents are open.
Open the desuperheater isolating valves. Desuperheater control valves must be
closed.
v. Close all reheater vents and atmospheric drains before pulling a vacuum in the
condenser. Reheater condenser drains may be left open until the turbine is under
light load. They may be closed soon after HPLP Bypass has been cut into
operation.
vi. When steam is admitted to the turbine for rolling, it is desirable to have a
minimum steam/turbine metal temperature differential. Take into service the HP &
LP bypass circuit at the earliest as shown in the startup curve. The firing rate shall
be increased suitably In order to reach the exit gas temperature limit it may be
desirable to put more oil guns to start a pulveriser at this time. Stabilize the firing
conditions to maintain the maximum furnace exit gas temperature without
exceeding it.
vii. Proceed as during normal start-up from cold, items (xxix). During a hot restart the
turbine metal temperature will normally require a rapid reloading of the unit and
this is achieved by closing the bypass as the turbine valve opens.
0172 - 0177 VOL - A1 TAB - 1 - 81

7. EMERGENCY PROCEDURES
7.1 Reheater Protection upon loss of load
Stoppage of steam flow through the reheater, when the entering gas temperature is
above 540 deg.C can result in overheating and damage to the reheater tubing. To
prevent this condition, the following measures must be taken:
A. Turbine Valve Closure
If a loss of load should cause the turbine valves to close, all fuel should be tripped
automatically either immediately or after a maximum time delay of ten seconds in
case the HP&LP bypass does not cut in.
Upon a Master Fuel Trip resulting from turbine control valve closure, an
immediate re-start is feasible in most instances, as the turbine is still rolling and
will be available to take steam as soon as the governor has the turbine speed under
control. See Note. If immediate turbine re-start is not possible and the turbine is
tripped, the reheater to condenser drains should be opened, as under `B’ below:.
NOTE: Refer to turbine manufacturer’s instructions for no-load operating

procedures and limitations.
B. Turbine Trip.
If a loss of load occurs in which the turbine is tripped, all fuel should be
automatically and instantaneously tripped in case the HP&LP bypass does not cut
in within specified time. The reheater safety valves will protect against
overpressure in the reheater. The vent should be opened to evacuate the steam in
the reheater.
C. Post Trip Procedures
Immediately following a Fuel Trip, the furnace must be purged. Any pulveriser
containing coal must be emptied as soon as possible. See Master Fuel Trip below:
To permit firing during start-up, prior to operating the turbine valves, the initiating
fuel circuits must be disarmed. They must be rearmed at a suitable point in the
startup sequence, such as when synchronising the turbine.
D. Turbine protection during restart.
Extreme care must be taken following a trip of the turbine and boiler to prevent
water from being introduced into the turbine upon unit restart. Water may be
collected in the main steam lines and cold reheat lines due to condensation. Refer
turbine manfuacturers instructions for specific precautions.
0172 - 0177 VOL - A1 TAB - 1 - 82

7.2 Master Fuel Trip
Under Conditions requiring a master fuel trip through normal interlocks or

operator’s action (manual trip), all fuel should be tripped instantaneously. If coal
was being fired the pulverizers should be tripped immediately. Tripping the
pulverisers will automatically trip the feeders and close the hot air shut off gate.
Refer to emergency shut down procedures in the instruction manual on “Bowl
Mills”. If oil was being fired, the warmup oil and ignitor trip valves and individual
nozzle shut off valves should be closed immediately.
The following steps should be taken immediately following an emergency fuel

trip:
I. Maintain the unit air flow at pre-trip value for atleast 5 minutes to purge the
system. If a hot restart is anticipated the air flow may be gradually reduced to light
off air flow (30% of full load air flow) during the purge period. For instructions
see Section 2.3 `Lighting Off”.
ii. If oil guns were in service when the fuel trip occurred, check to insure that all
individual shut off valves are closed. Oil guns should be removed, cleaned - See
Note 1 and 2 and reinstalled, to be ready for a restart of the unit.
NOTE 1. Refer to Burner Management System (Furnace Safeguard

Supervisory System) for emergency oil gun shut-down sequencing.
2. If immediate restart of the unit is anticipated, oil guns do not require
cleaning.
iii. If all auxiliary power sources are lost during a trip, upon restoration of power, start
the fans, airheaters (observe hot restart precautions in the Air preheater
Instructions) and purge the furnace for five minutes. For emergency tripping of
mills refer operating notice for mills.
iv. If pulverisers were in service when the fuel trip occured, all pulverizers containing
coal should be cleared of coal successively, as soon as possibble. Each pulverizer
should be unloaded in the following manner:
a) Close the discharge valves on all other idle pulverizers that contain coal. This
will prevent hot furnace gases from being carried back into these pulverisers.
b) Establish the required ignition energy for the pulveriser to be started (See
Note-1).
c) Start the pulverizer and allow it to clear itself of coal (See Note-2).
If the pulverizer will not be retained in service, stop the pulverizer after it is
completely cleared of coal. The pulverizer discharge valves should remain
open to allow a flow of cooling air through the empty pulverizer.
0172 - 0177 VOL - A1 TAB - 1 - 83

NOTE:
1. Refer to Unit cold start-up procedures and Burner Management System
(Furnace Safeguard Supervisory System) instructions for ignition energy
requirements and permissives.
2. If due to load conditions and/or requirements of Burner Management System

(Furnace Safeguard Supervisory System). It is impossible to establish ignition
permissive for all pulverizers and clear them of coal the discharge valves of all
idle pulverizer (including those still containing coal) should be opened to allow
a flow of cooling air through the pulverizer. The discharge valves should then
remain open until ready to unload and/or restart a pulverizer.
Each time an additional pulverizer is placed in service or unloaded any idle

pulverizers containing coal should again be temporarily isolated. See (iv) (a)
above.
3. Following a pulverizer trip under load the pulverizer should be operated with
cold air only until its feeder is started.
7.3 Low Water Level
If the water level falls out of sight in the water gauge, due to failure of the feed
water supply or neglect of the operator, except in the case of momentary
fluctuations that might occur with extraordinary changes in load, appropriate
action should be taken at once to trip the fuel. Any decision to continue to operate,
even if only for a short time at a reduced rating, would have to be made by some
one in authority who is thoroughly familiar with the circumstances that led to the
emergency and positively certain that the water level can be restored immediately
without damaging the boiler. In the absence of such a decision:
I. Trip all fuel immediately.
ii. Shut off all steam being discharged from the unit (trip turbine, steam driven
auxiliaries, etc).
iii. Simultaneously, if feedwater has become available and the operator is assured that
no pressure parts have been damaged, gradually increase (never decrease) the flow
of feed water to the boiler by `manual regulation. The purpose of handling the
feed in this manner is to avoid quenching pressure parts with relatively cold water
by raising the water level. The feedwater regulating valve should be closed
completely when the water in the drum can be maintained at the level desirable for
restarting the unit.
iv. Maintain a high air flow at first to hasten the cooling process.
v. If pressure parts damage is suspected, reduce the steam pressure gradually by

opening the superheater start up vents. Open the drum vents when the pressure
drops below 2 kg/cm2(g). As the boiler cools, reduce the air flow. Shut down the
fans as soon as the unit is cool enough for a man to enter following normal
0172 - 0177 VOL - A1 TAB - 1 - 84

draining procedures. Determine the cause of low water and examine the boiler for
the effects of possible overheating such as leaks and distortion of pressure parts.
vi. Repair any leaks, etc.,
vii. Hydrostatically test the boiler at working pressure before putting the unit back in
service.
7.4 High Water Level
Abnormally high water level should be avoided as it may lead to carry over and
even priming. If the water level rises above the recommended normal operating
range proceed as follows:
I. Reduce the water level immediately by opening the emergency blowdown

valves.
II. Reduce the steaming rate, if necessary and place feedwater control on
Manual.
If priming should occur, as indicated by rapid fluctuations in outlet steam

temperature, proceed as follows:
a). Reduce the steaming rate.
b) If the water level is abnormally high, reduce the level by opening the
emergency blowdown valves and place feed water control on Manual.
c) Investigate the water condition (alkalinity and solids).
d) Investigate the condition of the drum internals as soon as an opportunity is

available.
7.5 Tube Failure
Water Wall Tubes

In the event of failure of one or more water carrying tubes, the best method for
shutting down the unit will be dictated by the size of the failure, the ability to
maintain normal water level and the demands for the service of the unit.
The following instructions regarding tube failure are of a general nature. It must
be understood that conditions may arise which will require exercise of judgment
by the operators.
In case of a leak or tube failure which does not involve a serious drain on the feed
water supply, the water level should be maintained and unit taken out of service in
the normal manner. Refer to Normal Shut-down Procedures.
0172 - 0177 VOL - A1 TAB - 1 - 85

If the tube failure results in a loss of water so great that the water level cannot be
maintained with the feed water supply available, use the method outlined below:
a. Trip all fuel.

b. Shut off feed water to the boiler.
c. Maintain only enough air flow to carry the escaping steam up the stack.
d. Leave fans in service and pressure off the unit.
e. After the unit has cooled enough to permit a man to enter in, make a
thorough inspection of pressure parts for any indication of damage
resulting from loss of water level. After the necessary repairs have been
made, apply a hydrostatic test and obtain the approval of the proper
authorities before putting the unit back in service.
Economiser Tubes
An economiser tube leak can be detected by sound and/or increased make up water
requirements. The leak should be investigated at the earliest possible time and the
unit shut down in a normal manner. Water leaks in the economiser can cause
considerable erosion damage to adjacent tubes. Water carried over from an
economiser tube leak may cause plugging of hoppers and air heaters. Any
decision to continue operation with known leaks should be made with this in mind.
Superheater and Reheater Tubes.

A Superheater or Reheater tube failure can be detected by sound and/or increased
draft in Superheater or Reheater sections.
A small leak in a superheater or reheater element should be investigated at the

earliest possible time, and the unit should be shut-down in a normal manner.
Steam leaks in the superheater or reheater can cause considerable erosion damage
to adjacent tubes. Any decision to continue operation with known leaks should be
made with this in mind.
A major superheater or reheater tube failure may require an emergency unit shut-
down. The operator must use his judgment to access the seriousness of the failure
and its consequences and then decide what type of shut-down is required.
7.6 ASH Handling System
The ash handling system shall be properly maintained by operating personnel so as

to periodically evacuate the ash in Economiser, Airheater and ESP Hoppers. This
is to avoid ash build-up and consequent duct failures as Indian coals contain higher
percentage of ash. Sufficient care must be exercised to evacuate the Economiser
hopper ash periodically. This will reduce considerably the wear rate of AH
elements/ seals and load of ESP due to less ash carry over.
0172 - 0177 VOL - A1 TAB - 1 - 86

8. CARE OF BOILERS DURING CONDENSER TUBE LEAKAGE
Boiler water regime requires careful monitoring control and adjustment whenever
condenser tube leakage is suspected or confirmed. The condenser tube leakage
brings large amount of chlorides into the condensate and consequently into the
feed water. This is more predominant in sea water cooled power stations where
magnesium chloride and other forms of chlorides can leak in large quantities.
These are hardness salts and acid forming in nature due to hydrolysis reaction at
high temperatures. Whenever, the feed water gets contaminated by the cooling
water leakage from the condenser the following things happen to the boiler water
in the drum.
a. pH of boiler water drops rapidly due to the acid forming nature of condenser
leakage salts.
b. The phosphate level of boiler water drops down very low. This is due to the
reason that the residual phosphate is consumed by its reaction with hardness in-
leakage salts to form sludge constituents.
c. Conductivity of boiler water rises, due to increasing salt concentration brought

by condenser leak.
Under these circumstances, experience indicates accelerated corrosion of boiler

tubes and consequent tube failures can be caused, even if such operation is limited
only to few hours. In such a situation, the following course of action is
recommended. It must be realised that operation of the boiler with a condenser
leak requires extreme care and judgement. Failure to follow instructions would
lead to tube failure at a later stage.
1. Immediately start chemical injection pumps to maintain excess phosphate and

pH conditions in boiler water as below:
PO4 ----- 5 to 20 ppm
pH ----- 9.1 to 10.1
The phosphate and pH measurements in boiler water should be made every 30

minutes and the phosphate pump should be operated based on the
measurements to maintain the above regime. This would require extra dosage
of phosphate. This can be done either by increased running of the phosphate
pump at the maximum capacity or by increasing the strength of the phosphate
solution charged to the tank.
0172 - 0177 VOL - A1 TAB - 1 - 87

Some stations rely on dosing caustic soda (NaOH) in boiler drum under such
conditions to restore quickly boiler water pH. Caustic soda dosing should be
done with utmost care, as concentration of free hydroxide can lead to corrosion
of boiler tubes. In such cases caustic and phosphate (preferably disodium
phosphate) shall be dosed together and the pH and PO4 shall be closely
monitored such that pH for the corresponding phosphate residual does not fall
above the curve - 4. The region above the curve indicates the presence of free
hydroxide.
2. Increase blow down to the extent possible to keep the conductivity and
chlorides in boiler water within limits as below:
Specific electrical conductivity ----- 100 Siemens/cm (max.)

at 25 deg.C
Chlorides (as NaCl) ----- 4 ppm (max.)
3. Monitor the following at the interval of every 30 minutes.
a. Condensate sample either from ejector or from hot well - for

chlorides and conductivity.
b. Boiler water sample - for pH, phosphate, chlorides and

conductivity.
4. Isolate the condenser section one by one for locating the damaged section and
isolate and repair the damaged section. (If damaged condenser section cannot
be isolated and repaired, shut down the unit.
5. Do not continue to operate the unit if pH of boiler water cannot be maintained

above 9.6 or the conductivity below 30 micro Siemens/cm (i.e. total dissolved
solids below 15 ppm).
6. Avoid unnecessary use of desuperheater spray by (a) permitting reheater

temperature to fall or (b) reducing load.
7. If the unit is shut down for condenser repair, drain and flush the system to the
extent possible and establish wet lay-up of boiler unit and auxiliary equipment
during condenser repair.
0172 - 0177 VOL - A1 TAB - 1 - 88

., , '.',
." '
VALVE LOCATION VALVE BOILER COLD START UP BOXING UP HOT SHUT DOWN BOILER . REMARKS ".'
TAG FILLING START UP W1THCOOUNG EMPTYING

"". ,
I ECONOMISER AND ORCULAnNG SYSlEt.l '.,'.

~oml_ Inlet fHd Iln. filing E25 to E27 OPEN a.osE -- -- -- --
Economl_ Inl.t fHd Iln. cIroIn E15 II E16 a.osE a.OSE a.OSE a.osE a.OSE OPEN
Economr- outlet link _t E2J II E24 OPEN a.OSE a.OSE a.OSE a.osE OPEN
Drum _t 81,2.211l22 OPEN a.... •••••• pr-. > 2kg/cm2 a.OSE a.OSE a.OSE OPEN
L..... water waIIheocler cIroIn 8n to 884 a.OSE a.OSE a.OSE a.OSE a.OSE OPEN
Down-.. •. blow off 875 II 876 a.OSE Open to control drum I•••• a.osE a.OSE a.OSE OPEN
••••• lng oft.. lighting off.
Economl_ rec:lrcuIotion Iln. ..: E17 a.osE a.... wh.. contlnuoua fHd
wat.. IIow III eetabllohed.
a.OSE OOM wh•• contl-
noua fHd water
OPEN a.osE
now la eetabllohed
Drum _.,....cy droln 8112 II B63 a.OSE Open to control drum I•••• a.OSE a.OSE a.OSE OPEN Open to control drum I.... under _ •. g-.cy
•••• lng oft •. light off If operatlng condition
.-qulred In oddItion to down
com •. blow off.
II SUPERHEA1ER SYSlEt.l
SH roof Inl.t heocIer cIroIn 524 II S25 OPEN a.OSE a.OSE a.OSE a.OSE OPEN
SH roof outlet heocIer _t SllIlS9 OPEN OOM wh•• pr-. > 2kg/cm2 a.osE a.osE a.OSE OPEN
Fer Iongoutoga the baI •.••••• to be
SH ••• eteom coolecI wall outlet heocler cIroIn S2ll II 527, OPEN a.OSE a.OSE a.DsE OPEN OPEN Nitrogen copped
2 a.OSE a.osE
SH extencled ••• eteom cooled wall outl.t heocler _t 510 to 51J, OPEN OOM wh•• "..... > 2kg/cm clOSE OPEN
SH •.•••. ateam coolecI wall outl.t heocIer cIroIn 521111 S29 OPEN a.OSE a.osE a.osE OPEN OPEN
Plot.. SH Inlet link _t 515 •• 5111 OPEN OOM •••••• pr-. > 2kg/cm2 a.OSE a.osE a.OSE OPEN
F1n1llhSH Inlet link _t 517 •• 5111 OPEN OOM wh•• pr-. > 2kg/cm2 a.osE a.osE a.OSE' OPEN
F1n1llhSH outl.t heocIer _t 519 •• 520 OPEN OOM wh•• pr-. > '1!t.g/cm2 a.osE a.osE a.OSE OPEN
SH 8tcrtup _t S22 •• S2J OPEN· OOM wh.. now thro' HPI.P a.osE a.OSE OPEN OPEN
by •••• III .tobllllhed at
about 10 kg/cm2
MaIn ateam line cIroIn SlllI to 570 a.OSE OPEN a.OSE a.osE OPEN OPEN
SH cIroIn heocIer droln SJJ a.OSE a.OSE a.osE a.osE OPEN OPEN
SH filing Itl. 532 OPEN a.OSE a.osE a.OSE a.OSE a.OSE
III REHEA1ER SYS1Et.l

0172 - 0177 VOL - A1 TAB - 1 - 89
RH Inlet heocler _t R4 NA OOM before railing """"um In a.osE a.osE OPEN OPEN
condln_.
RH outlet heocIer _t R5 •• Rll NA OOM bef.... railing """"um In a.osE a.osE OPEN OPEN
condIn_.
Cold RH Iln. cIroIn NA OOM before railing """"um In a.OSE a.osE OPEN OPEN
Hot RH line cIroIn NA

•••••••
OOM before railing vacuum In a.osE a.osE OPEN OPEN
Customer/Plant HINDALCO / ADITYA CPP, UNIT .•..! to 6, 6x150MW

VALVE OPERATING INSTRUCTIONS ContNo 0172-0177 . Rev.O Rev.1 Rev.2 Rev.3
Sian. Date Sian. Date Sign. Date Siqn. IDate
ra;.._/
Enaineer SM 08.10.09
/1/ 08.10.09
..
Reviewer SV / P~ \1\
,
Approver SV /~SR
~C'7
08.10.09 .
AIR & FLUE GAS PATH
WRITE - UP
Refer the attachment (7 Sheets)
Customer/Plant: HINDALCO / ADITYA CPP, UNIT-1 to 6, 6x150MW

Cont. No. :0172-0177 Rev.OO Rev.01 Rev. 02 Rev.03
SiQn. Date SiQn. Date SiQn. Date Sign. Date
1 '-.---l
Reviewer:-W / PSR 1 .t
VlJI'
14.08.09
Approver: JiV / PSR ) 14.08.09
0172 - 0177 VOL - A1 TAB - 1 - 90

1.0 GENERAL
2.0 AIR SYSTEM
2.1 COMBUSTION AIR (SECONDARY AIR)
2.2 PRIMARY AIR
2.3 SCANNER COOLING AIR
2.4 SEAL AIR
3.0 FLUE GAS SYSTEM
4.0 ATTACHMENTS (3 sheets)
0172 - 0177 VOL - A1 TAB - 1 - 91

The total air flow through the unit is handled by two numbers of forced draft fans and
two numbers of Primary air fans. The flue gas produced in the furnace from
combustion of fuel is evacuated by two numbers of Induced draft fans. The schematic
diagram of air and flue gas system is enclosed, as attachment (3 sheets) and
described as below:
The forced draft fans supply the required secondary air and overfire air for
combustion. This air is preheated by secondary sector of two numbers of
Rotary Regenerative Trisector type air preheaters. Hot secondary air from
airpreheater is sent to wind box for combustion The air heater outlet ducts
are interconnected to provide balanced air flow to the furnace and also to
make it possible to operate the unit at the reduced rating with one fan in
service. Control of secondary air flow is done by FD fan blade pitch control.
Overfire air can be admitted to the furnace through the upper levels of
furnace windbox nozzles to assist in reducing the amount of NOx formed in
the furnace. Control of air flow to windbox is effected by FD fan blade pitch
control, while the distribution of secondary air to the windbox compartments
is controlled by "secondary air dampers". These are normally positioned by
the secondary air dampers control system. Two aerofoils are provided near
windbox to measure Hot secondary air flow. Refer Manuals on "Furnace
Safeguard and Supervisory System" and "Tilting Tangential Firing System"
for operating details.
Airpreheater air bypass is provided with damper control to maintain the

average cold end temperature of the Regenerative airheater elements to
prevent cold end corrosion during start up and also low load operation when
oil burners are in service.
The cold primary air fans supply the air required for drying the coal in
the bowl mills and for transporting the pulverised fuel from mill classifier
outlet to the coal burners. The primary air is heated in the Primary
sector of the two Tri-sector rotary regenerative airheaters.
0172 - 0177 VOL - A1 TAB - 1 - 92

To assure proper drying of coal in the mill, hot air must be available at
the required temperature. To achieve the required temperature at mill
inlet, part of the air (Tempering air) bypasses the air heater and is
mixed with the hot air coming out of the air heater. The primary air fan
blade pitch is modulated to maintain a predetermined pressure in the
pulveriser hot air bus duct.
Mill air flow is maintained by adjusting the hot air regulating damper
while the mill outlet temperature is maintained by adjusting the cold air
regulating damper. Venturi is provided in the mill inlet duct to measure
the individual mill air flow.
Boiler is provided with 16 numbers of Scanners (BHEL scan). Two numbers

of scanner air fans (one working + one standby) are provided to supply the
required air for cooling these flame scanners. The supply of air is taken from
FD fan discharge. The air is filtered and boosted to the required pressure by
the scanner air fans. Additionally an emergency air supply connection from
atmosphere is provided for supplying the cooling air to the scanners in case
both FD fans trip. Filter in the system helps to assure clean air for cooling.
a) Seal air for mills: To supply seal air for pulveriser journal and gear
housing, two nos. (1 working + 1 standby) of seal air fans are
provided. A shut off damper in the seal air duct at each pulveriser
can be closed when the pulveriser is out of service for maintenance.
The seal air fan suction is taken from cold PA bus duct before
airheater. Dynavane filter is provided at the inlet of seal air fans to
remove dust from air and thus assuring clean air supply for the
pulveriser journals and gear housing.
b) Seal air for feeders: Seal air for feeders is taken directly from cold
PA bus duct. The shut off valve is provided in the feeder seal air
duct to isolate the feeder for maintenance.
Seal air for PF coal pipes is taken from the cold PA bus duct. A
power operated valve in the seal air line operates in conjunction with
the pulveriser discharge valve to provide positive seal air pressure
in PF pipes when the discharge valve is closed.
0172 - 0177 VOL - A1 TAB - 1 - 93

The flue gases produced in the furnace as a result of combustion, travels upward in the
furnace, across the horizontal pass and downward through the second pass of the
boiler to the air preheaters.
In the airpreheaters, the residual heat of the flue gas is utilized to preheat the
secondary and primary air. The dust laden flue gases then pass through the
Electrostatic precipitator for dust removal.
Two numbers of Induced draft fans are provided to evacuate the flue gas from furnace
to the chimney. The 10 fans are provided with inlet damper and Variable Frequency
Drive (VFO).
Inter connecting duct is provided at the outlet of ESP so that the unit can be operated
at reduced rating even with one 10 fan in service. Shut-oft gates are provided at the
inlet and outlet of each 10 fan, to isolate anyone fan for maintenance while the
boiler/unit is in service
The FO fans and 10 fans are capable of maintaining balanced draft conditions in the
furnace over the entire load range of the boiler.
(I) Scheme of secondary air system
(II) Scheme of primary air system
0172 - 0177 VOL - A1 TAB - 1 - 94

HINDALCO I ADITYA CPP, 6 X 150MW
SCHEME OF SECONDARY AIR SYSTEM
2
S6
SUCTION FROM SUCTION FROM
ATMOSPHERE ATMOSPHERE
0172 - 0177 VOL - A1 TAB - 1 - 95
HINDALCO ,/ ADITYA CPP, 6 X 150MW
SCHEME OF PRIMARY AIR SYSTEM
< CD U 0 W
...J ...J ...J ...J ...J
...J ...J ...J ...J ...J
~ ~ ~ ~ ~
~ ~ ~ ~ ~
0 0
CL We:::
x-
~<
Ol (0
Q. Q.
IX)
sna ~I'v'lOH Q.
t
SUCTION FROM
P1
SUCTION FROM
tP2
ATMOSPHERE ATMOSPHERE
0172 - 0177 VOL - A1 TAB - 1 - 96
HINDALCO ! ADITYA CPP. 6 X 150MW
SCHEME OF FLUE GAS SYSTEM
"
....-..... ""',
l" >-
W
" ••
, z '
, :::::E ,
, I '
\,
'... ..... _-- "
U ,l
"<t
"<t
t' 10 ~
~
"<t "<t
t' ~
2" 2"
a.. a..
V> V>
W W
2' 2'
N N
~ t'
I")
t'
0172 - 0177 VOL - A1 TAB - 1 - 97
TAB - 2
0172 - 0177 VOL - A1 TAB - 2 - 98
0172 - 0177 VOL - A1 TAB - 2 - 99
0172 - 0177 VOL - A1 TAB - 2 - 100
0172 - 0177 VOL - A1 TAB - 2 - 101
0172 - 0177 VOL - A1 TAB - 2 - 102
0172 - 0177 VOL - A1 TAB - 2 - 103
0172 - 0177 VOL - A1 TAB - 2 - 104
LEGEND:
FLOOR PLAN AT EL.23550
FLOOR PLAN AT EL.20800 (MBL-3)
NOTE:
0164 T0 0169
0172 T0 0177
FLOOR PLAN AT EL.20800

& EL. 23550 (MBL-3)
0-00-021-75155 04
0172 - 0177 VOL - A1 TAB - 2 - 105
0172 - 0177 VOL - A1 TAB - 2 - 106
0172 - 0177 VOL - A1 TAB - 2 - 107
0172 - 0177 VOL - A1 TAB - 2 - 108
0172 - 0177 VOL - A1 TAB - 2 - 109
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0172 - 0177 VOL - A1 TAB - 2 - 112
0172 - 0177 VOL - A1 TAB - 2 - 113
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0172 - 0177 VOL - A1 TAB - 2 - 115
0172 - 0177 VOL - A1 TAB - 2 - 116
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TAB - 3
0172 - 0177 VOL - A1 TAB - 3 - 118
0172 - 0177 VOL - A1 TAB - 3 - 119
75
0172 - 0177 VOL - A1 TAB - 3 - 120

0172 - 0177 VOL - A1 TAB - 3 - 121
0172 - 0177 VOL - A1 TAB - 3 - 122
0172 - 0177 VOL - A1 TAB - 3 - 123
0172 - 0177 VOL - A1 TAB - 3 - 124
TAB - 4
0172 - 0177 VOL - A1 TAB - 4 - 125
0172 - 0177 VOL - A1 TAB - 4 - 126
0172 - 0177 VOL - A1 TAB - 4 - 127
HINDALCO-ADITYA
6 x 150 MW
Customer Nos. : 0172 to 0177
BOILER PRESSURE PARTS
Bharat Heavy Electricals Limited

Thiruchirapalli.
0172 - 0177 VOL - A1 TAB - 4 - 128

INDEX
1.0 Natural Circulation Boiler
2.0 Water Circuit

2.1 Description
2.2 Economiser
2.2.1 Description
2.2.2 Maintenance
2.3 Steam Drum Internals
2.3.1 Description
2.3.2 Maintenance
2.4 Water Cooled Furnace
2.4.1 Introduction
2.4.2 Welded Wall Construction
2.4.3 Bottom Construction
2.4.3.1 Open Hopper Type Bottom
2.4.4 Operation
2.4.4.1 Internal Deposits
2.4.4.2 Blow Down
2.4.4.3 Ash Deposits
2.4.4.4 Water Quenching of Furnace Bottom Tubes (Coal Fired Units only)
2.4.5 Maintenance
2.4.5.1 Inspection
2.4.5.2 Tube Repairs
3.0 Steam Circuit

3.1 Introduction
3.2 Superheater
3.3 Reheater
3.4 Protection and Control
3.5 Operation
3.5.1 Superheater
3.5.2 Reheater
3.6 Inspection
3.7 Maintenance
0172 - 0177 VOL - A1 TAB - 4 - 129

A-1 Desuperheater
A-1.1 General
A-1.2 Superheater Desuperheater
A-1.3 Reheater Desuperheater
A-1.4 Superheater / Reheater Spray Control Station
A-1.5 Blowout Procedure for Desuperheater Spray Water Lines
A-2 Water Level Testing with Water Level Sampling Cans

A-2.1 Introduction
A-2.2 Apparatus
A-2.3 Importance of True Water Level Indication
A-2.4 Theory of Water Level Indication
A-2.5 Prerequisites for Efficient Testing
A-2.6 Test Procedure
0172 - 0177 VOL - A1 TAB - 4 - 130

1.0 Natural Circulation Boiler

Natural Circulation Boiler is a boiler in which the circulation of water through the furnace
waterwalls is ensured by the density difference between water in the Downcomers and water-steam
mixture in the heated waterwall tubes.
2.0 Water Circuit

The water flow path through the Water Circuit is shown in Fig. 2.0.1. The components which
make up the flow path are numbered consecutively and are listed in Table 2.0.1. Where parallel flow
paths exist each circuit is numbered consecutively one after the other.
2.1 Description
Feed water entering the boiler through the Economiser components (01 to 07) mixes with the
Boiler water in the Steam Drum (08). Water flows from the Steam Drum (08) through the
Downcomers (09) to the Furnace Front Waterwall Lower Inlet Header (10), Furnace Rear Waterwall
Lower Inlet Header (11) and Furnace Side Waterwall Lower Inlet Headers (Left and Right) (12).
In the Furnace Waterwall Lower Inlet Headers, the Boiler water passes through the Furnace
Waterwall Tubes and the Economiser recirculating lines.
The water rises through the Furnace Waterwall Tubes where it absorbs heat. The Furnace
Waterwall Tubes consist of five parallel paths as listed.
Furnace Front Waterwall Tubes (13) to Furnace Front Waterwall Outlet Header (14)
Furnace Side Waterwall Tubes (15) to Furnace Side Waterwall Outlet Headers (16)
Furnace Rear Waterwall Tubes (17) with Furnace Rear Waterwall Hanger Tubes (18) to
Furnace Rear Waterwall Hanger Outlet Header (19)
Furnace Rear Waterwall Tubes (17) and Furnace Rear Arch Tubes (20) with Waterwall Screen
Tubes (21) to Waterwall Screen Outlet Header (22)
Furnace Rear Waterwall Tubes (17), Furnace Extended Side Waterwall Inlet Header Supply
Tubes (23) and Furnace Extended Side Waterwall Inlet Header (24) with Furnace Extended Side
Waterwall Tubes (25) to Furnace Side Waterwall Outlet Headers (16)
The resulting mixture of water and steam from the parallel paths collected in the
Waterwall Outlet Headers (14, 16, 19 and 22) is discharged into the Steam Drum (08) through the
Riser Tubes (26). In the Steam Drum (08), the steam and water are separated (Refer 2.3). The steam
from the separator follows the steam circuit (Refer 3.0). The water is returned to the water side of the
Steam Drum (08) for recirculation.
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0172 - 0177 VOL - A1 TAB - 4 - 131

  
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Figure 2.0.1
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0172 - 0177 VOL - A1 TAB - 4 - 132

Sl. No. Component Description

01. Economiser Inlet Lead
02. Economiser Inlet Header
03. Economiser Assemblies
04. Economiser Intermediate Header
05. Economiser Hanger Tubes
06. Economiser Outlet Header
07. Economiser Links to Steam Drum
08. Steam Drum
09. Downcomers
10. Furnace Front Waterwall Lower Inlet Header
11. Furnace Rear Waterwall Lower Inlet Header
12. Furnace Side Waterwall Lower Inlet Headers
13. Furnace Front Waterwall Tubes - Fusion Welded
14. Furnace Front Waterwall Outlet Header
15. Furnace Side Waterwall Tubes-Fusion Welded
16. Furnace Side Waterwall Outlet Headers
17. Furnace Rear Waterwall Tubes - Fusion Welded
18. Furnace Rear Waterwall Hanger Tubes
19. Furnace Rear Waterwall Hanger Outlet Header
20. Furnace Rear Arch Tubes - Fin Welded
21. Waterwall Screen Tubes
22. Waterwall Screen Outlet Header
23. Furnace Extended Side Waterwall Inlet Header Supply Tubes
24. Furnace Extended Side Waterwall Inlet Header
25. Furnace Extended Side Waterwall Tubes- Fin Welded

Riser Tubes from Furnace Front Waterwall Outlet Header, Furnace Side Waterwall
26. Outlet Headers, Furnace Rear Waterwall Hanger Outlet Header and Waterwall Screen
Outlet Header to Steam Drum.
Table 2.0.1 (Refer Fig. 2.0.1)
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2.2 Economiser
The function of the Economiser is to preheat the Boiler feed water before it is introduced into the
Steam Drum (08), by recovering heat from the flue gas leaving the Boiler. The Economiser is located
in the Second pass of the Boiler. It consists of parallel tube circuits originating from the Economiser
Inlet Header (02) and terminate at the Economiser Outlet Header (06) arranged in two banks in such a
manner that each bank is aligned with the bank above and/or below.
2.2.1 Description
Feed water is supplied to the Economiser inlet lead (01) via feed stop and check valves, which in
turn supplies the feed water to the Economiser Inlet Header (02). The feed water then flows through
the Economiser Assemblies (03), Economiser Intermediate Header (04) and Economiser Hanger
Tubes (05) to the Economiser Outlet Header (06). The feed water flow is upward through the
Economiser Assemblies (03) i.e. counter flow to the hot flue gases.
Most efficient heat transfer is hereby accomplished, while the possibility of steam generation
within the Economiser Assemblies (03) is minimized by the upward water flow. From the
Economiser Outlet Header (06) the feed water is passed through the Economiser Links (07) to the
Steam Drum (08).
2.2.2 Maintenance
Before starting up the Boiler and at each extended outage, the Economiser should be inspected
externally and if necessary cleaned. If the installation is new, accumulation of erection material
(wood, insulation, welding rods etc.) is not unusual. Large debris should be removed
manually, followed by washing down the Economiser by means of water.
Any exposed insulation should be kept in good condition at all times.
Access doors should be bolted tight. Check the doors occasionally for tightness.
The frequency with which soot blowers are used (if provided) depends entirely on local
conditions. When the Economiser is first placed in operation, the Economiser soot blowers should
be blown about once in every shift. Observation of the increase in draft loss between blowings will
determine how long an interval may be set as a standard. In many cases it has been found that
blowing the Economiser soot blowers once in a day or less is sufficient.
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2.3 Steam Drum Internals

The function of the Steam Drum Internals (Refer Fig 2.3.1) is to separate the water from the
steam generated in the furnace walls and to reduce the dissolved solids contents in the steam to a
value below the prescribed limit. Separation is generally performed in three stages. The first two
stages takes place in the Turbo Separators (Refer Fig 2.3.2) and the final stage take place at the top of
the Steam Drum (08) where the steam enters the Saturation Connecting Links (01) (Refer Table
3.0.1).
2.3.1 Description
Wet steam entering the Steam Drum (08) is collected in a compartment called as Separating
Chamber formed by internal baffles. From the shroud the steam is led through two rows of Turbo
Separators.
Each Turbo Separator consists of a primary stage and a secondary stage. The primary stage is
formed by two concentric cans. Spinner blades impart a centrifugal motion to the mixture of steam
and water flowing upward through the inner can, thereby throwing the water to the outside and
forcing the steam to the inside. The water is arrested by skim off lip above the spinner blades and
returned to the lower part of the Steam Drum (08) through the annulus between the two cans. The
steam proceeds up to the secondary separator stage.
The secondary stage consists of two opposed banks of closely spaced thin corrugated metal plates
which direct the steam through a tortuous path and separate the remaining entrained water.
From the secondary separators the steam flows upward to the third and final stage of separators. It
consists of rows of corrugated plated Dryer Assemblies extending throughout the length of the Steam
Drum (08) with a drain through between the rows. The steam flows with relatively low velocity
through the tortuous path formed by the closely spaced layers of corrugated plates. The remaining
entrained water is deposited on the corrugated plates. The water is not picked up again but runs down
the plates into the drain through. Suitably located drain pipes return this water to the water side of the
Steam Drum (08).
The fitting and alignment of drum internals are very important for its efficient performance. Any
misalignment with gap will lead to heavy carryover of impurities into steam which will get deposited
in the Superheater and turbines. The alignment should be checked (Refer 2.3.2) and drum internals
should be set right at every overhaul. In between also, it is desirable to check the drum internals fit up
during any shut down.
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0172 - 0177 VOL - A1 TAB - 4 - 135

2.3.2 Maintenance
A-2.3.2.1 While dismantling the drum internals during overhaul, match marks are to be
made so that the same sub assembly component goes back into the same
place during reassembly.
A-2.3.2.2 Check that there are no obstructions in safety valve nozzles, water gauge
nozzles, vent nozzles, pressure gauge nozzles and in all other nozzles
connecting pressure parts.
A-2.3.2.3 The separating chamber should be leak proof for efficient for efficient
performance of drum internals.
A-2.3.2.4 The steam water mixture that enters the separating chamber from the Riser
Tubes (26) should not leak. The mixture should flow only into turbo
separator. Make sure that the separating chamber covers all Riser Tubes (26)
through which steam water mixture enters the Steam Drum (08).
A-2.3.2.5 Make sure that the separating chamber has not developed any gap. The welds
at the joint should be complete and leak proof. Bulleted joints should be gas
tight.
A-2.3.2.6 Ensure tightness of the separating chamber by torch test. (Torch test is done
by keeping a light inside the chamber and inspecting all joints from outside to
ensure that no light passes through)
A-2.3.2.7 Make sure that all corrugated sheets of secondary separators and final screen
driers are free from foreign material. Take them out and blow air through
them to ensure free passage. The secondary separators should be secured
firmly to the primary separators.
A-2.3.2.8 The turbo separator should be ensured to be vertical.
A-2.3.2.9 Ensure that the dryer boxes are fixed with each other without any gap. The
gap if any shall not exceed 1 mm between the boxes.
A-2.3.2.10 Ensure that all bolted and screwed connections are tight.
A-2.3.2.11 After the fit up of drum internals is over, the inside of the drum should be
thoroughly cleaned and should be free from foreign materials.
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0172 - 0177 VOL - A1 TAB - 4 - 136

Figure 2.3.1
7|Page
0172 - 0177 VOL - A1 TAB - 4 - 137
Figure 2.3.2
8|Page
0172 - 0177 VOL - A1 TAB - 4 - 138

2.4 Water Cooled Furnace

Furnace is the primary part of boiler where the chemical energy available in the fuel is
converted in to thermal energy by combustion. Furnace is designed for efficient and complete
combustion. Major factors that assist for efficient combustion are Residence time of fuel inside the
furnace, Temperature inside the furnace and turbulence (which causes rapid mixing between fuel and
air). At present, water cooled furnaces are supplied for each type and size of Boiler.
Water cooled furnace has the following advantages
A-2.4.1 In furnace, not only combustion but heat transfer also takes place simultaneously
A-2.4.2 The maintenance work involved in repairing the fire bricks is practically
eliminated
A-2.4.3 Due to heat transfer in the furnace the flue gas temperature leaving the furnace is
reduced to the acceptable level to the Superheater surfaces.
A-2.4.4 Highest heat loading in the furnace is possible as heat transfer is simultaneously
removing heat. Hence total economy in surfacing is achieved.
2.4.1 Introduction
The following description and instruction cover the Welded Wall Construction used for furnace
and Bottom Construction most commonly used in a general way. Specific information on Welded
Wall Construction and setting can be found in the drawings included in the rear of this section.
2.4.2 Welded Wall Construction

Furnace Front Waterwall Tubes, Furnace Side Waterwall Tubes and Furnace Rear Waterwall
Tubes are made of 63.5 mm O.D tubes placed at 76.2 mm (typical) centers with each other. The
spaces between the tubes are fusion welded to form a complete gas tight seal.
Furnace Rear Arch Tubes are of 76.1 mm O.D placed at 114.3 mm (typical) centers. Fins are
welded in the spaces between the tubes to form a complete gas tight seal.
Furnace Extended Side Waterwall Tubes are of 63.5 mm O.D placed at 127 mm (typical) centers.
Fins are welded in the spaces between the tubes to form a complete gas tight seal.
Pourable insulation is normally used at each horizontal buck stay to form a continuous band
around the furnace there by preventing flue action of gases between the casing and waterwalls
Refer to the "Furnace Setting Arrangement" and "Typical Wall Construction" drawing for
specific information pertaining to setting insulation of Furnace Waterwalls.
2.4.3 Bottom Construction

The furnace bottom construction depends mainly on fuel and ash condition.
9|Page
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Bottom designs commonly used for coal fired units are of open hopper type, often referred to as
dry bottom type.
For gaseous and oil fuels closed hopper type, also referred to as wet bottom type is employed.
2.4.3.1 Open Hopper Type Bottom

In this type of bottom construction two sides of Furnace Waterwall Tubes, usually the Furnace
Front Waterwall Tubes and Furnace Rear Waterwall Tubes, slope down towards the centre of the
furnace to form the inclined sides of the bottom. Ash and/or slag from the furnace are discharged
through the bottom opening into an ash hopper directly below it. Depending on the height of the
furnace, six to fourteen inches clearance between the furnace and ash hopper is allowed for downward
expansion of the furnace walls. Leakage of air at this point is prevented by either a water seal
arrangement or a mechanical seal (expansion joint).
2.4.4 Operation
2.4.4.1 Internal Deposits
Since the design heat transfer rates in water cooled furnaces are normally high it is essential that
the tubes be kept free from scale formation and copper and iron oxides deposits. This is accomplished
by proper boiler water and feed water treatment (Refer "Water Treatment”)
Scale formation is the deposition of an insulating film on the waterside of the tube wall, which
raises the hot face temperature and may result in over heating of the tube section. Boiler water
treatment aims to eliminate deposition of scale forming components by substituting non-scale
forming components.
In High Pressure Boilers iron and copper oxides introduced from the pre-boiler system may lead
to internal corrosion in the areas of deposits and eventually cause tube failures. Feed water treatment
in this case performs corrosion control in the pre Boiler system.
Preoperational acid cleaning of the Boiler circuits contribute to internal cleanliness. Acid cleaning
of the Boiler after considerable operating time may be desirable, especially in Boilers subjected to
water conditions conducive to scale or oxide deposition.
2.4.4.2 Blow Down

Boiler blow down is used as a means of controlling Boiler water concentrations (solids and
alkalinity) and to remove sludge formation. The frequency of blowing down depends upon local
conditions, such as characteristics of the water, nature of feed water treatment, design and rating of
the Boiler, etc. In most cases the continuous blow down system is sufficient.
In extreme cases of sludge formation or in cases of poorly treated feed water with high solid
contents resulting in carryover, the Boiler may be blow down intermittently through the down take
10 | P a g e
0172 - 0177 VOL - A1 TAB - 4 - 140

drain or the Waterwall Inlet Header drains. In no case should the Waterwall Inlet header drains be
used for blowing down the Boiler while the unit is steaming.
At no time should conditions specified for an installation as to total dissolved solids alkalinity,
etc, be ignored or exceeded. The frequency and quantity of blow down should be in accordance with
instructions by a chemist or other competent authority. The responsibility for providing proper feed
water treatment and control rests with the operating force.
2.4.4.3 Ash Deposits (Slagging)

The amount and the rate of slagging depend mainly on the type of fuel burned. The furnace walls
cannot be entirely kept free from deposits, but should be kept "reasonably clean" (See NOTE 1).
Heavy local accumulations should be avoided by proper use of soot blowing equipment. The wall
blowers should not be used indiscriminately but only as required in the affected areas.
NOTE 1: During initial operation of a new unit, steam temperatures will tend to be
below design level because of the higher than normal heat absorption rate caused by extremely clean
furnace walls. The period of time required to establish "normal" deposits is called "seasoning" and is
common for coal fired units and certain oil fired units utilizing fuels with a high ash content. The
duration of the seasoning period varies, depending on the fuel (amount and nature of ash contents)
fired.
Gradual fouling of the furnace walls during commercial operation will cause increasing furnace
exit gas temperatures and high steam temperature, which may result in exceeding the range of steam
temperature controls. Wall blowers can be used to keep these controls within their operating range. In
natural circulation boilers localized slagging may also impair circulation, because of difference in
heat absorption rate between the clean and covered portions of a tube which results in overheating
and tube failure.
When changing over from coal firing to oil firing, or vice verse, it is recommended that the
furnace walls be cleaned thoroughly with existing soot blowing equipment, especially when the
substitute fuel will be used over an extended period of time. If experience indicates that extreme
depositing after changeover from oil to coal firing due to fuel ash characteristics, it may be necessary
to wash down the furnace walls prior to commencing operation on coal.
With straight gas fired units firing oil with low ash contents, there is no problem of slagging.
However, after extended operating time, dust or ash buildup on the furnace walls may gradually affect
exit gas temperatures, steam temperatures and controls. It is recommended that if such conditions
develop, the furnace walls be washed down whenever possible, to return the unit to its normal
condition.
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2.4.4.4 Water Quenching of Furnace Bottom Tubes (Coal Fired Units only)
Fatigue failure of fusion welded tubes in open hopper type furnace bottoms can occur when the
tubes are subjected to direct contact with relatively cold ash hopper water. Although ash hopper and
sluice system designs meet normal operating criteria, water quenching of furnace tubes can occur as a
result of unusual operating conditions or abnormal operating practices. Common conditions
conducive to water quenching are:
High ash pit water level, due to improper level control or overflow plugging.
Ash pit water level surging, due to clinker grinder vent non-operation, excessive pyrites and
or Economiser ash hopper discharge velocities.
Direct spray impingement on furnace tubes, due to misalignment of sluice jets and excessive
sluice water pressure.
Improper operation of jets during filling up the hopper after a periodic ash removal.
Conditions such as those listed above can be avoided by a proper inspection and maintenance
program.
2.4.5 Maintenance
2.4.5.1 Inspection
Routine inspections of Steam Drum, Headers and Furnace Wall Tubes should be done each time
after boiling out, initial acid cleaning, routine acid cleaning and final outages.
During these inspections, Steam Drum should be kept opened. Hand hole pipes removed from the
Headers. The condition of the Steam Drum Internals should be checked and internal surfaces
inspected for deposits. Furnace Wall Tubes should be spot checked and tube ends inspected internally
for deposits. Any deposits should be removed and Steam Drum, Headers and Furnace Wall Tubes
flushed out with clean water.
Furnace Wall Tubes should be examined externally for blistering, burning, corrosion, erosion and
cracking (Areas around soot blowers are susceptible to erosion). For this purpose the fire sides of all
exposed furnace tubes must first be thoroughly cleaned of slag and ash deposits.
On coal fired units the ash hopper should be inspected prior to initial operation of the unit for
proper installation and operation of the sluice system. Any condition observed as a potential cause of
water quenching of furnace bottom tubes (during normal or abnormal operating conditions) should be
corrected.
All inspections should be thorough and comprehensive in every detail. They should be made by a
competent personnel familiar with Boiler operation and maintenance and with water treatment
problems. A record of each inspection should be kept in a uniform manner so that results of any
change can be compared with former conditions.
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Inspections of tubes, as a result of tube failures or conditions expected to lead to failures should
be even more thorough. If the cause of the condition is not obvious or cannot be determined clearly,
such inspections should include metallurgical examinations of tube sections, chemical analysis of
deposits, etc.
2.4.5.2 Tube Repairs

A tube section that has failed, or which must be replaced because of danger of failure, can be
easily replaced. After removing the furnace wall insulation behind the failed area, the tube section is
removed by cutting across the tube, sufficiently above and below the failure and carefully cutting the
fin alongside the tube (The longitudinal cuts must extend beyond the perpendicular cuts sufficiently
to permit welding completely around the periphery of the tube when installing the new tube section).
Before inserting and rewelding a new tube section, the tube ends should be properly prepared for fin
welding. Fins between tubes must be replaced and made gas tight.
It must be recognized that it is impossible to include repair procedures (methods, welding
techniques, etc.) to cover all Pressure parts and associated structural components of a complex
modern steam generator. It is recommended that the company service or erection representative be
consulted for assistance in evaluating and repairing damaged Pressure parts and/or failures.
All repairs should be done by competent and qualified personnel and all welding should be in
accordance with the Indian Boiler Regulations.
13 | P a g e
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3.0 Steam Circuit

The course taken by Steam from Steam Drum (08) (Refer Table 2.0.1) to the Reheater Outlet
Header is shown in Fig.3.0.1. The components which make up the flow path are numbered
consecutively. Where parallel flow paths exist each circuit is numbered consecutively one after the
other.
3.1 Introduction
The steam from the Steam Drum (08) (Refer Table 2.0.1) flows through the Saturation
Connecting Links (01) to the Radiant Roof Inlet Header (02) and via Radiant Roof Tubes Front (03)
and Radiant Roof Tubes Rear (04) it reaches the Superheater Radiant Roof Outlet Header (05). Then
it passes to the Superheater Steam Cooled Side Wall Inlet Headers (06).
The Steam flow consists of three parallel paths from this point as listed.
A-3.1.1 Superheater Steam Cooled Side Wall Front Tubes (07) - Superheater Steam Cooled
Side Wall Outlet Headers (Front) (08) - Superheater Steam Cooled Front Wall Inlet
Header (09) - Superheater Steam Cooled Front Wall Tubes (10) - Superheater
Steam Cooled Front Screen Tubes (11) - Superheater Rear Roof Junction Header (12)
- Superheater Steam Cooled Rear Roof Tubes (13) - Superheater Steam Cooled Rear
Wall Tubes Upper (14) - Superheater Rear Horizontal Spaced Inlet Header (15)
A-3.1.2 Superheater Steam Cooled Side Wall Front Tubes (07) - Superheater Steam Cooled
Side Wall Outlet Headers (Front) (08) - Superheater Extended Side Steam Cooled
Wall Supply Tubes (16) - Superheater Extended Side Steam Cooled Wall Inlet
Header (17) - Superheater Extended Side Wall Tubes (18) - Superheater Extended
Side Steam Cooled Wall Outlet Header (19) - Superheater Extended Side Wall
Outlet Pipes (20) - Superheater Rear Roof Junction Header (12) - Superheater Steam
Cooled Rear Roof Tubes (13) - Super Heater Steam Cooled Rear Wall Tubes Upper
(14) - Super Heater Rear Horizontal Spaced Inlet Header (15).
A-3.1.3 Superheater Steam Cooled Side Wall Rear Tubes (21) - Superheater Steam Cooled
Side Wall Outlet Headers (Rear) (22) - Superheater Steam Cooled Rear Wall Inlet
Header (23) - Superheater Steam Cooled Rear Wall Tubes Lower (24) - Superheater
Rear Horizontal Spaced Inlet Header (15)
From the Superheater Rear Horizontal Spaced Inlet Header (15), the steam flows through the
Superheater Rear Horizontal Spaced Coils Upper, Middle and Lower Banks (25) to Superheater Rear
Vertical Spaced Assemblies (26) and then to Superheater Rear Horizontal Spaced Outlet Header (27).
Then the steam flows through the Superheater Links to Desuperheater (28) to Superheater
Desuperheater (29) and then via Superheater Links from Desuperheater (30) it flows to the
Superheater Pendant Platen Inlet Header (31).Then through the Superheater Pendant Platen
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Assemblies (32) it flows to the Superheater Pendant Platen Outlet Header (33) and via Superheater
Spaced Inlet Links (34) it flows to the Final Superheater Inlet Header (35).
The steam then passes through the Final Superheater Assemblies (36) to the Final Superheater
Outlet Header (37) from there it is taken via Superheater Outlet Leads (38) to the high pressure
section of turbine.
After passing through the high pressure stages of the turbine, steam is returned to the Reheater
circuit via the Cold Reheat Line. The Reheater Desuperheater is located in the Cold Reheat Line.
From the Cold Reheat Line the steam flows through the Reheater Inlet Leads (39) to the Reheater
Inlet Header (40) and then via Reheater Vertical Spaced Assemblies Front (41) it flows to the
Reheater Vertical Spaced Assemblies Rear (42) and gets collected at Reheater Outlet Headers (43).
From Reheater Outlet Headers (43) the reheated steam is taken out through the Reheater Outlet
Leads (44). The Reheated steam is returned to the intermediate pressure section of the turbine via the
Hot Reheat Line.
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 
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
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

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Figure 3.0.1
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SL. No. Component Description

01. Saturation Connecting Links
02. Radiant Roof Inlet Header
03. Radiant Roof Tubes Front-Peg Finned
04. Radiant Roof Tubes Rear-Peg Finned
05. Superheater Radiant Roof Outlet Header
06. Superheater Steam Cooled Side Wall Inlet Headers Left/Right
07. Superheater Steam Cooled Side Wall Front Tubes-Fin Welded
08. Superheater Steam Cooled Side Wall Outlet Headers Left/Right (Front)
09. Superheater Steam Cooled Front Wall Inlet Header
10. Superheater Steam Cooled Front Wall Tubes
11. Superheater Steam Cooled Front Screen Tubes
12. Superheater Rear Roof Junction Header
13. Superheater Steam Cooled Rear Roof Tubes-Fin Welded
14. Superheater Steam Cooled Rear Wall Tubes Upper
15. Superheater Rear Horizontal Spaced Inlet Header
16. Superheater Extended Side Steam Cooled Wall Supply Tubes
17. Superheater Extended Side Steam Cooled Wall Inlet Header
18. Superheater Extended Side Wall Tubes
19. Superheater Extended Side Steam Cooled Wall Outlet Header
20. Superheater Extended Side Wall Outlet Pipes
21. Superheater Steam Cooled Side Wall Rear Tubes-Fin Welded
22. Superheater Steam Cooled Side Wall Outlet Headers Left/Right (Rear)
23. Superheater Steam Cooled Rear Wall Inlet Header
24. Superheater Steam Cooled Rear Wall Tubes Lower-Fin Welded
25. Superheater Rear Horizontal Spaced Coils Upper and Lower Banks
26. Superheater Rear Vertical Spaced Assemblies
27. Superheater Rear Horizontal Spaced Outlet Header
28. Superheater Links to Desuperheater
29. Superheater Desuperheater
30. Superheater Links from Desuperheater
31. Superheater Pendant Platen Inlet Header
32. Superheater Pendant Platen Assemblies
33. Superheater Pendant Platen Outlet Header
34. Superheater Spaced Inlet Links
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35. Final Superheater Inlet Header

36. Final Superheater Assemblies
37. Final Superheater Outlet Header
38. Superheater Outlet Leads
39. Reheater Inlet Leads
40. Reheater Inlet Header
41. Reheater Vertical Spaced Assemblies Front
42. Reheater Vertical Spaced Assemblies Rear
43. Reheater Outlet Header
44. Reheater Outlet Leads
Table 3.0.1 (Refer Fig. 3.0.1)
3.2 SUPERHEATER
The Superheater system comprises of six basic sections
A-3.2.1 Roof Section
Furnace roof is formed by Radiant Roof Tubes Front (03) of 51 mm O.D and Radiant Roof Tubes
Rear (04) of 51 mm O.D tubes spaced at 114.3 mm (typical) between centers. The spaces between the
tubes are closed by peg fins welded with the tube. Second pass roof is formed by Superheater Steam
Cooled Rear Roof Tubes (13) of 44.5 mm O.D tubes spaced at 114.3 mm (typical) centers with the
space between the tubes closed by peg fin welded to the tube. All peg finned tubes are normally
backed with a castable refractory and skin casing which is seal welded to form a gas tight envelope.
Wherever the tubes are widely spaced to permit passage of Superheater elements, hanger tubes,
observation ports, soot blowers, etc. the space between the tubes and openings are closed with fin
material suitably so that a completely metallic surface is exposed to the hot furnace gases.
A-3.2.2 Second Pass Wall Section
Superheater Steam Cooled Side Wall Front Tubes (07) and Superheater Steam Cooled Side Wall
Rear Tubes (21) cover the sides of second pass. Superheater Steam Cooled Front Wall Tubes (10) and
Superheater Steam Cooled Front Screen Tubes (11) cover the front of second pass. Superheater Steam
Cooled Rear Wall Tubes Upper (14) and Superheater Steam Cooled Rear Wall Tubes Lower (24)
cover the rear of second pass. The second pass walls are formed by fin welded tubes of 44.5 mm O.D
tubes located at a pitch of 114.3 mm and 139.7 mm at different locations.
A-3.2.3 Steam Cooled Extended Side Wall Section
Superheater Extended Side Wall Tubes (18) cover the bottom and sides of Superheater Extended
Pass. It is formed by fin welded tubes of 44.5 mm O.D. located at a pitch of 127 mm (typical)
between centers.
A-3.2.4 Low Temperature Superheater Section
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The Superheater Rear Horizontal Spaced Coils Upper and Lower Banks (25) and Superheater
Rear Vertical Spaced Assemblies (26) are located in the second pass above the Economiser
Assemblies (03) (Refer Table 2.0.1).
A-3.2.5 Platen Section
The Superheater Pendant Platen Assemblies (32) is located in the furnace between the Furnace
Front Waterwall Tubes (13) (Refer Table 2.0.1) and the Reheater Vertical Spaced Assemblies Front
(41).
A-3.2.6 Final Superheater Section
The Final Superheater Assemblies (36) is located in the Superheater Extended Pass zone between
the Waterwall Screen Tubes (21) (Refer Table 2.0.1) and Superheater Steam Cooled Front Screen
Tubes (11).
3.3 REHEATER
The Reheater is composed of two sections
A-3.3.1 Front platen section
The Reheater Vertical Spaced Assemblies Front (41) is located in-between Superheater Pendant
Platen Assemblies (32) and Furnace Rear Waterwall Hanger Tubes (18) (Refer Table 2.0.1).
A-3.3.2 Finishing section
The Reheater Vertical Spaced Assemblies Rear (42) is located above the Furnace Rear Arch
Tubes (20) (Refer Table 2.0.1) between the Furnace Rear Waterwall Hanger Tubes (18) (Refer Table
2.0.1) and Waterwall Screen Tubes (21) (Refer Table 2.0.1).
For more details on the arrangement of Superheater and Reheater section refer to the contract
assembly drawing.
3.4 PROTECTION AND CONTROL

As long as there is fire in the furnace, adequate protection must be provided for the Superheater
and Reheater elements. This is especially important during periods when there is no demand for
steam, such as starting up and shutting down. During these periods of no steam flow through the
turbine, adequate flow through the Superheater is assured by means of drains and vents in the header,
links and Main Steam piping. Reheater drains and vents provide means to boil off residual water in
the Reheater elements during initial firing of the Boiler.
Safety valves on the Superheater Main Steam lines set below the low set Steam Drum safety valve
provide another means of protection by assuring adequate flow through the Superheater, if the steam
demand drops suddenly and unexpectedly. Reheater safety valves, located on the hot and cold reheat
piping serve to protect the Reheater if steam flow through the Reheater is suddenly interrupted.
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A power control valve on the Superheater Main Steam line set below the low set Superheater
safety valve is provided as a working valve to give an initial indication of excessive steam pressure.
This valve is equipped with a shut off valve to permit isolation for maintenance. The relieving
capacity of the PO Valve is not included in the total relieving of the safety valves required by the
boiler code.
During start-up, care must be taken not to overheat the Superheater or Reheater elements. The
firing rate must be controlled to limit the furnace exit gas temperature to 1000qF (See NOTE 2). A
thermocouple probe normally located in the upper furnace side wall should be used to measure the
furnace exit gas temperatures (See NOTE 3).
NOTE 2: The 1000qF gas temperature limitation is based on normal start-up condition, when
steam is admitted to the turbine at the minimum allowable pressure prescribed by the turbine
manufacturer. If turbine rolling is to be delayed and the steam pressure is permitted to build up, the
gas temperature limitation should be reduced to 950qF when the steam pressure exceeds two thirds of
the design pressure before steam flow through the turbine is established.
NOTE 3: Gas temperature measurements will be accurate only if a shielded aspirated probe is
used. If the probe consists of a simple bare thermocouple, there will be an error, due to radiation
resulting in a low temperature indication. At 1090qF actual gas temperatures, the thermocouple
reading will be approximately 50qF low. Unless very careful traverses are made to locate the point of
maximum temperature, it is advisable to allow another 50qF tolerance, regardless what type of
thermocouple probe is used
Thermocouples normally installed on various Superheater and Reheater terminal tubes, above the
furnace roofs, serve to give a continuous indication of element metal temperatures during start-ups
(Superheater) and when the unit is carrying load (Superheater and Reheater). In addition to the
Permanent thermocouples, temporary thermocouples provide supplementary means of establishing
temperature characteristics during initial operation.
Steam temperature control is provided by means of tilting windbox nozzles and spray in
Desuperheaters (Refer A-1).
3.5 OPERATION
Detailed instructions concerning the proper use and operation of the Superheaters, vent, drain vent
and drain valves, etc., are given in the section "Unit Operating Procedures". However, the following
rules can always be followed.
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3.5.1 SUPERHEATER
Make sure the Superheater back pass walls and steam lines are completely drained (especially
after a hydrostatic test), by opening inlet and Outlet Header drains and link vents before lighting off.
Close back pass inlet and Outlet Header drains down to a slightly open position after draining. Close
the link vents when they begin to steam. Close the back pass header drains immediately after rolling
the turbine, see “Unit Operating Procedures” Flow Diagram for exceptions.
The Main Steam line vents and drains serve as starting vents; they are kept open until the turbine
is under light load. These valves may be throttled as Steam Drum pressure increases, providing a
sufficient steam flow through the Superheater at all times, (Refer to start-up procedures in section
"Unit Operating Procedures"). Other Header and link vents should be kept open until the Steam
Drum pressure has reached to approximately 25 psi. The drain valves near the turbine should be
operated in conjunction with the start-up vents to provide additional steam flow and to drain and
warm the Main Steam line prior to turbine rolling.
3.5.2 REHEATER
All Reheater drains and vents should be opened before lighting off. The vents and drains must be
closed prior to raising a vacuum in the condenser. Drains connecting with the condenser may be left
open until the turbine is under light load.
3.6 INSPECTION
A regular inspection and maintenance program, conscientiously followed will assure continuity of
service and will avoid serious and expensive outages.
The Superheater and Reheater should be inspected when the boiler is out of service.
A-3.6.1 Check the element for alignment and any evidence of warping or bulging of unit
tubing. Replace tubing that shows serious warping, bulging, or other evidence of overheating.
A-3.6.2 Check supports, spacers and seal plates for proper location and condition. Repair or
replace promptly.
A-3.6.3 Check the inside surface of Steam Drum for any evidence of solids carryover. If
present, take immediate steps to eliminate cause. Manufacturer may be consulted with
for clarifications.
3.7 MAINTENANCE
It is essential that suitable arrangements are made to assure cleanliness of the external surfaces of
the Superheater and Reheater at all times. Fly ash and/or stag accumulations result in unequal gas
distribution, inefficient heat transfer and possible localized overheating. Suitably located soot blowers
operated in the proper cycle, normally provide adequate means of keeping surfaces clean.
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The external surface of Superheater and Reheater should be inspected regularly for cleanliness,
slagging must be kept to a minimum by proper use of soot blowers. Extreme build-ups must be
removed immediately. Lancing with compressed air is often effective in slag removal. Local slagging
may become a cause of overheating of element tubes possibly resulting in tube failures. Furthermore
it may restrict the gas flow, causing uneven heat transfer and creating further operating difficulties.
Proper feed water treatment and control of steam quality and carry-over are essential to assure
cleanliness of interior surfaces of Superheaters. Overloads, fluctuating load, high water level,
foaming, high concentrations, etc., all contribute to deposits on interior surfaces. Accumulation of
these deposits inside the tubes will lead to unit failures. Spray type Desuperheaters are installed,
therefore care must be taken to assure that condensate quality water is used to avoid carryover of
solids into the Superheater and Reheater and turbine blades. Periodic checks of steam pressure drops
across the Superheater and Reheater under identical load conditions usually indicate whether or not
solid deposits are present within the elements.
In the event of failure of one or more elements, it is better to check carefully to determine the
cause. The manufacturer may be consulted for repair procedures and proper means to prevent
recurrence. The attached unit material diagrams show the metal composition of various parts of
Superheater and Reheater elements and piping.
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A-1 DESUPERHEATER
A-1.1 GENERAL
Desuperheater is provided in the Superheater connecting link and the Reheater inlet leads to
permit reduction of steam temperature when necessary and to maintain the temperatures at design
values within the limits of the nozzle capacity.
Temperature reduction is accomplished by spraying water into the path of the steam through a
nozzle at the entry of the Desuperheater. The spray water comes from the Boiler feed water system. It
is essential that the spray water is chemically pure and free of suspended and dissolved solids,
containing only approved volatile organic treatment material, in order to prevent chemical deposition
in the Desuperheater and Reheater avoiding carryover of solids to the turbine.
Caution: During start-up of the unit, if Desuperheating is used to match the outlet steam
temperature to the turbine metal temperatures, care must be exercised so as not to spray down below a
minimum of 10qF above the saturation temperature at the existing operating pressure.
Desuperheating spray is not particularly effective at the low steam flows of start-up. Spray water
may not be completely evaporated but be carried through the heat absorbing sections to the turbine
where it can be the source of considerable damage. During start-up alternate methods of steam
temperature control should be considered.
The location of the Desuperheaters helps to ensure prevention of water carryover to the turbine. It
also eliminates the necessity for high temperature resisting materials in the Desuperheater
construction.
A-1.2 SUPERHEATER DESUPERHEATER

Two Spray Desuperheaters are installed in the connecting link between the Superheater low
temperature pendant Outlet Header and the Superheater division panel Inlet Headers.
A-1.3 REHEATER DESUPERHEATER

Two spray type Desuperheaters are installed in the Reheater inlet leads near the Reheater Inlet
Header.
A-1.4 SUPERHEATER / REHEATER SPRAY CONTROL STATIONS

A control valve linked to an automatic control drive regulates the flow of spray water supplied to
each Desuperheater. Valves should be provided on both sides of each control valve to permit isolation
when required. A bypass line provided with automatic control valve and the two isolating valves
should be used only in the event of an emergency or when an automatic control require maintenance.
Drain valves downstream of the control valves are used to relieve system pressure and drain the
control valve piping for maintenance.
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A block valve is installed in the supply line to each Desuperheater control station as an additional
shut off valve. These block valves must be interlocked to close when the Desuperheater control
valves are closed. The spray water control valves must be interlocked to close at turbine trip. Closing
the block valves will prevent water from entering the turbine through the cold reheat piping in the
event the Reheater spray water control valves. They prevent water from entering the Superheater
elements if the Superheater spray water control valves leak.
For schematic arrangement of Superheater / Reheater Spray Control Stations Refer “Scheme of
Water and Steam Circuits”.
A-1.5 BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES

The spray water lines should be blown out before using the Desuperheaters on a new unit and
after repairs on the spray water lines have been made. They may also be blown when there appears to
be any indication of plugging. Always have full pressure on the Boiler when blowing out the
Desuperheaters.
Each Desuperheater should be blown out in the following sequence
With the isolating valves closed, open the valves in the blowout connection and then open
the bypass valve for one minute.
With the bypass valve closed and the blowout valves open, open isolating valves and then
open the control valve for a minute (from the control station).
A-1.5.3 Close the isolating valves and control valve but leave the blowout connection
valves open for one more minute to clear the waste line before restoring the system to its
operating status.
NOTE 4: The blowout valves should be installed close to the spray water piping and with no
bends if possible.
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A-2 WATER LEVEL TESTING WITH WATER LEVEL SAMPLING CANS

A-2.1 INTRODUCTION
The Steam Drum of all large steam generators (Design pressure 2400 psi or higher) is equipped
with a water level sampling cans to permit establishing actual water level at high operating pressures,
for the purpose of checking water gauges and remote water level indicating equipment.
A-2.2 APPARATUS
Normally only four of the sampling can nozzles are connected with the test lines. The remaining
nozzles are capped off. A sufficient number of high pressure cooling coils should be available to
permit simultaneous sampling of at least two nozzles.
A conductivity cell (0.1 constant) should be installed in each sampling line. Conductivity values
may be monitored on a portable meter with switch box or by means of multiple point recorders.
Since approximate conductivity values will be adequate to distinguish between boiler water and
steam, temperature compensation is not required. All samples should be cooled to the same
approximate temperature.
A-2.3 IMPORTANCE OF TRUE WATER LEVEL INDICATION

The accurate measurement and control of water level is essential to optimum operation of a high
pressure boiler. Maintenance of water level higher than the required level reduces the free space in the
Steam Drum and may result in the malfunction of individual separators as they become submerged.
For safety reasons it is necessary to carry sufficient water in the Steam Drum to accommodate sudden
changes in load. It is important, therefore, to recognize the possible deficiencies in water level
indicators and the complications which may result because of these.
A-2.4 THEORY OF WATER LEVEL INDICATION

The use of a standard gauge glass to indicate water level is based on the principle that a depth of
water in an enclosed vessel will support an equal height of water in a visible, connected water
column. This principle is only valid when the density of the water in the vessel is the same as that in
the column.
In order to be visible to the operator, the relatively small amount of water in a gauge glass is
exposed to the cooler atmosphere outside the boiler and is thus subject to sub cooling. Because of the
greater density of this cooler water, it will support a proportionately greater height of water in the
Steam Drum. In high pressure boilers where the saturation temperature of the water is high, the
degree of sub cooling may be appreciable and thus introduces a significant error in the water level
indication. Compensated level controllers and remote indicators are not directly affected by this
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phenomenon; however, they are sometimes calibrated against the gauge glass zero reading and thus
reflect the same error.
Directly over a down comer, a vortex may exist which causes turbulence in this region. Water
level measurements in the affected zone are erratic and meaningless and hence should be restricted in
such zones.
A-2.5 PREREQUISITES FOR EFFICIENT TESTING

In order to obtain the maximum amount of reliable information, complete cooperation is required
between the test group and operating personnel in the performance of water level tests. Maximum
variations in Steam Drum level should occur at full load. So it is recommended that tests be
performed under steady full load conditions. Changing the load during the test period will provide
little additional information and will complicate interpretation of the data. It will be necessary to vary
the water level in uniform increments to observe the response of all indicators and to note the relative
position of the water level in the sampling can. Soot blowing should be avoided during the test period
since it may produce erratic water level.
Adequate cooling water is an absolute necessity for these tests. The nominal requirement is 2.5
gpm of cooling water per sample cooler. Since these tests will be performed adjacent to the Steam
Drum, service water pressure must be adequate at this level in the plant.
Since conductivity is the basis for distinguishing steam and water phases it is required that the
boiler water contain a reasonable amount of electrolytes. If the plant normally employs a "volatile" or
"low solids" boiler water control, it may be necessary to introduce sodium salts to the boiler water to
produce a minimum conductivity of 30 micro ohms.
A-2.6 TEST PROCEDURE

Connections should be available to permit sampling from the can at the following four points.
A-2.6.1.1 2" below normal water level (Refer Steam Drum internal drawing)
A-2.6.1.2 at normal water level
A-2.6.1.3 2" above normal water level
A-2.6.1.4 4" above normal water level
Samples from two probes on the can should be simultaneously condensed and monitored
for conductivity. Coolers should initially be connected to the points at and 2" above normal
water level, if these samples prove unsatisfactory, the coolers may be reconnected to either of
the other two connections available.
Water level in the boiler should be gradually reduced until all sample points indicate steam
conductivity (Refer NOTE 5) (less than 5 micro ohms). The condition should be maintained stable
for 15 minutes and the following data’s to be recorded.
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Conductivities of all sample points

Automatic level controller readings
Remote level indicator readings
Gauge glass readings
Time and load combination
Water level should be increased 1/2" based on the automatic level controller and this condition
should be maintained for 15 minutes. Repeat collection of data indicated in step A-2.6.3.
Repeat step A-2.6.4 until all sample points has been submerged in boiler water
(conductivity greater than 30 micro ohms).
If different circulating pumps combinations are to be checked, repeat steps A-2.6.3, A-2.6.4 and
A-2.6.5 with each individual.
NOTE 5: If this cannot be done without losing water level in the gauge glass then the samples
indicating boiler water should be shut off and the coolers reconnected to higher probe points.
Where the results of the test indicate extreme differences between actual water level and indicated
level, consideration should be given to compensate external water level indication, BHEL should be
consulted before such compensation are made.
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TAB - 5
REFRACTORY AND INSULATION
DESCRIPTION OF THE WORK:
This is a membrane wall construction type of boiler and

hence less refractory works is involved. At the portions of
ceiling, and other locations where the skin casing is provided,
castable refractory type-C is applied in between the gaps of
tubes and skin casing and also seal boxes. The outer side of
the combustion chamber, penthouse and all the equipments are
insulated with lightly bonded wool mattresses.
Drawings from 4-00-215-09435 to 4-00-215-09443 show

the configuration of various sections of the boiler.
Drawings 3-00-235-06262, 3-00-235-06264, 3-00-235-06267,

3-00-235-06268 2-00-235-06270 and 2-00-235-06271 show the typical
method of insulation for the auxiliaries.
LIST OF REFRACTORY AND INSULATION MATERIALS
Sl.No. Description Density Specification
01 Castable refractory Type-C 2100 Kg/M3 4-33-210-00793
02 Pourable insulation 650 Kg/M3 4-33-210-00794
03 LRB wool mattress 100 Kg/M3 4-33-021-00833

4-33-021-00834
CURING OF CASTABLE REFRACTORY
Refer Drgs. 4-00-205-08525 to 4-00-205-08527.
CURING OF POURABLE INSULATION
Refer Drgs. 4-00-205-08528 and 4-00-205-08529.
HINDALCO ADITYA-0172-0177
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Duct is a closed path to carry cold air, hot air and flue gas from one point /
equipments to other point/ equipments in a boiler system. It is generally of
square or rectangular in cross section and circular in some cases .It is
made up of plate 5 to 8mm steel plates.
Ducts for cold air path = 6 mm carbon steel plates.

Ducts for Hot air path = 8 mm carbon steel plates.
Gas ducts from Eco. to Chimney = 8mm thick CS
STIFFENERS are used to strength the duct walls to take the loads due to
pressure, self-weight, ash etc.,
Ducts are fabricated as walls and send to site to facilitate the

transportation. The duct walls are bridged at site to required cross section
by using flange field joints(FFJ), internal field joints(IFJ),external field
joints(EFJ).
TYPES OF JOINTS IN DUCTS :
FFJ - FLANGE FIELD JOINT
FJ - Field joint
IFJ - INTERNAL FIELD JOINT
Page 1 of 6
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SUPPORTS are used to support the Duct loads due to the self weight,
ash, wind and seismic, supports could be with or without internal supports
together with external supports. The internal supports could be pipe struts
mainly employed to form trusses for supporting various loads. These are
used for large sizes of panel
Types of Supports in Duct :

Ducts are supported either by bottom support or top support. The top
support is by using either fixed hanger support or spring hanger
support.
1). Bottom Support:
a . Fixed Type .
b . Sliding Type .
Normally hot air ducts and flue gas ducts will be provided with
sliding bottom supporting .
2). Top Support: (Hanger support) .

HANGER SUPPORTS:
a . Fixed hanger supports :
Used where the downward movement of the duct need not be
allowed .
b . Spring hanger supports *:
Used where Duct is allowed to move in the downward direction .
* Variable load hangers ( VLH ) .
Used when the ratio of hot load and cold load is less than 0.25 .
* Constant load hangers ( CLH ) .
Used when the ratio of hot load and cold load is greater than 0.25.
3). Restraints: (STOPS & TIES )

Used to take the horizontal loads on the ducts like
1 . Wind loads
2 . Seismic loads
3 . Expansion joint loads &
4 . Unbalanced pressure loads .
SHEAR TIES & PIN TIES: These are used to support the toggle section
inside the duct itself
EFFECT OF DUCT SUPPORTS & RESTRAINTS : Change in orientation

of Restraints may lead to unpredicted movements on Expansion Joints
which leads to premature failure
Page 2 of 6
0172 - 0177 VOL - A1 TAB - 6 - 187

Page 3 of 6
0172 - 0177 VOL - A1 TAB - 6 - 188
Page 4 of 6
0172 - 0177 VOL - A1 TAB - 6 - 189
ȱȱȱȱ Ǳȱ
ȱ
ȱ
0-00-260-88213 FD FAN TO AH DUCTING
1-00-260-20296
0-00-261-88816 PA FAN TO AH DUCTING
0-00-261-88817
1-00-261-20300
0-00-262-88224 TEMPERING AIR DUCT
1-00-262-05976
0-00-264-88788 HOT SEC AIR DUCT
0-00-264-88789
0-00-264-88790
0-00-264-88791
0-00-265-88804 HOT PRIMARY AIR DUCT
0-00-265-88805
0-00-266-88813 HOT AIR DUCT TO MILL
0-00-268-88296 GAS DUCT TO A.H
1-00-268-20010
1-00-268-20011
1-00-268-20012
1-00-268-20013
1-00-268-20014
1-00-269-05914 GAS DUCT A.H TO B.O.F
0-00-271-88820 BOF TO EP
1-00-271-20301
1-00-271-20302
0-00-272-88161 EP TO ID DUCTING
1-00-272-05939
0-00-273-89910 ID FAN TO CHIMNEY
0-00-273-89911 DUCTING (Unit – 1,3,4&6)
0-00-273-89912
0-00-273-89913
0-00-273-89908 ID FAN TO CHIMNEY
0-00-273-89909 DUCTING (Unit – 2&5)
1-00-273-20847
ȱ
ȱ
ȱ
Page 5 of 6
0172 - 0177 VOL - A1 TAB - 6 - 190

ȱ
ȱȱȱȱȱȱȱȱȱȱȱ ȱȱȱ Ȃȱ
ȱ
S.No Description Assembly Drg. No
1 (Hot sec flow meter) Air foil assy 0-48-207-35317
2 Mill Venturi meter 2-48-667-50265
ȱ
ȱ
ȱ
Page 6 of 6
0172 - 0177 VOL - A1 TAB - 6 - 191

0-00-260-88213
0172 - 0177 VOL - A1 TAB - 6 - 192

0172 - 0177 VOL - A1 TAB - 6 - 193
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0172 - 0177 VOL - A1 TAB - 6 - 200
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0172 - 0177 VOL - A1 TAB - 6 - 216
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0172 - 0177 VOL - A1 TAB - 6 - 218
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0172 - 0177 VOL - A1 TAB - 6 - 221
0172 - 0177 VOL - A1 TAB - 6 - 222
0172 - 0177 VOL - A1 TAB - 6 - 223
0172 - 0177 VOL - A1 TAB - 6 - 224
0172 - 0177 VOL - A1 TAB - 6 - 225
0172 - 0177 VOL - A1 TAB - 6 - 226
ȱ
METALLIC EXPANSION JOINTS
Expansion bellows are pieces, which by way of their construction can absorb the
thermal expansion of duct system without any detrimental effect.
These are made of thin sheets, the form of the bellows and sizes of the sheet determine
the quantum of expansion value that they can absorb effectively. In order to increase
the quantum of expansion that is to be taken at any one location multi bellow expansion
joints are used. Whenever the expansion bellows are in a deformed state ; they exert
action on the ducting system depending on the degree of deformation, which has to be
considered in the analysis of ducting. The metallic expansion bellows in FLUE GAS
SYSTEM are made up of corten steel and all other are made up of carbon steel.
Support load should not be transmitted through the expansion joint. Dents and holes are
not permitted in the expansion joint. During maintenance period ash and dirt if any
should be removed from the bellows.
Expansion bellows in Flue gas system are provided with internal liner plate to protect
Expansion bellow from erosion. They need to be inspected during annual overhaul for
any corrective work.
0172 - 0177 VOL - A1 TAB - 6 - 227

TAB - 7
0172 - 0177 VOL - A1 TAB - 7 - 228
0172 - 0177 VOL - A1 TAB - 7 - 229
0172 - 0177 VOL - A1 TAB - 7 - 230
0172 - 0177 VOL - A1 TAB - 7 - 231
0172 - 0177 VOL - A1 TAB - 7 - 232
0172 - 0177 VOL - A1 TAB - 7 - 233
0172 - 0177 VOL - A1 TAB - 7 - 234
0172 - 0177 VOL - A1 TAB - 7 - 235
0172 - 0177 VOL - A1 TAB - 7 - 236
0172 - 0177 VOL - A1 TAB - 7 - 237
0172 - 0177 VOL - A1 TAB - 7 - 238
0172 - 0177 VOL - A1 TAB - 7 - 239
0172 - 0177 VOL - A1 TAB - 7 - 240
0172 - 0177 VOL - A1 TAB - 7 - 241
0172 - 0177 VOL - A1 TAB - 7 - 242
0172 - 0177 VOL - A1 TAB - 7 - 243
0172 - 0177 VOL - A1 TAB - 7 - 244
0172 - 0177 VOL - A1 TAB - 7 - 245

RECOMMENDEDLUBRICATIONCHART

BHARATHEAVYELECTRICALSLIMITED
HIGHPREESUREBOILERPLANT
TRICHIRAPPALLI–620014.

STDPUBLNNo.:
REVISEDASON:01Ǧ08Ǧ2011.

0172 - 0177 VOL - A1 TAB - 7 - 246

Lubrication Schedule for Feeders & Raw coal gates
Equipment: 36” Inlet 7’ C.D. Gr. Feeder
Per Feeder Details
Position No. of Parts to be lubricated Recommended lubricants Method Qty/ Frequency Remarks
No. * Points IOC HP BP INDROL of Lub. feeder Of Change
Grease lubrication
For other instructions refer lubrication notes of Gravimetric feeder

01 2 Belt take up pulley
02 2 Belt take up screws
One month
03 2 COC Take up
5 Kg (For position No.01 to 14

04 12 Inlet span rollers
Ball bearing grease AP2

05 2 Tension roll shaft
By grease pump
Servogem EP2
06 2 Tension roll pivot
Lathax EP2
Lithon EP2
07 2 Weigh roller
08 2 Calibration shaft
09 4 Weigh span rollers
O & M manual
10 1 Belt drive pulley 3 months
11 1 COC drive shaft 3 months
12 1 Belt paddle switch shaft -
13 1 Discharge paddle switch -
14 2 Belt drive motor
0172 - 0177 VOL - A1 TAB - 7 - 247
15 2 COC motor
16 2 COC reducer 3 months
Oil lubrication
every 2500 hrs.

Oil filling plug
Castrol Alpha
17 Belt drive reducer housing 3 Ltr.
whichever is
6 Months or
of operation
Servomesh
Primary casing
earlier.
SP320
18 Belt drive reducer housing SP320 17 Ltr.

Main case
19 Clean out conveyor reducer
4.5 Ltr.
housing
* Refer to Lubrication diagram for Gravimetric feeder (Page 2 /4) Page No. 1/4
Lubrication Diagram for 36” Inlet 7’ CD Gravimetric Feeder
0172 - 0177 VOL - A1 TAB - 7 - 248
Page No. 2/4

Equipment : 36” Raw coal gates Per Gate Details
Position No. of Parts to be lubricated Recommended lubricants Method Qty/ Frequency Remarks
No.* Points IOC HP BP INDROL of Lub. Gate Of Change
Grease lubrication
For other instructions refer lubrication notes of

01 1 Gear 1:3
02 1 Pinion
Gravimetric feeder O & M manual

1 Kg (For position No.01 to 03)
03 16 Roller with nuts
Ball bearing grease AP2
By grease pump
Servogem EP2
Lathax EP2
Lithon EP2
6 Months
0172 - 0177 VOL - A1 TAB - 7 - 249
* Refer to Lubrication diagram for 36” R.C. Gate (Page 4/4)
Page No. 3/4

0172 - 0177 VOL - A1 TAB - 7 - 250
Lubrication Diagram For

36” Inlet Raw Coal Gate
Page No. 4/4

RECOMMENDEDLUBRICATIONCHARTFORWINDBOX
RECOMMENDEDLUBRICANT
FREQUENCY FREQUENCY
QUANTITY
SL.NO EQUIPMENTDESCRIPTION METHODOFFILLING OFOIL OF
(ANNUAL)
IOC HP BP CHANGE OBSERVATION
SprayTheSurfaceShouldBe
CoalBurners–PivotPins, CeracSp
Clean–SprayFromASeeNote2
01 NozzleTips,Nozzle 110(See SeeNote2 4Kg
DistanceOf150To300mmForA
AdjustableMechanisms Note1)
FewSeconds

Antisieze
PanelConnectingBoltsAnd
02 Compound Direct SeeNote3 3Kg
Nuts
Molysulf

NOTE1:M/s.CERACInc.Box597,Butler,Wisconsin–63007,USA
NOTE2:CERACSP110IsInitiallySprayedDuringAssembly.PartsAreToBeReͲSprayedDuringAnyDisassemblyAndReͲAssembly.
NOTE3:ApplyWheneverBoltAndNutsAreDismantled.

ESTIMATEDTOTALQUANTITYOFEACHLUBRICANT/ANNUALREQUIREMENT/WINDBOX
0172 - 0177 VOL - A1 TAB - 7 - 251
01. CeracSP110
02. AntiseizeCompoundMolySulf

BharatHeavyElectricalsLimited

RECOMMENDEDLUBRICATIONCHARTFORDUCTS,GATESANDDAMPERS

RecommendedLubricants
Frequency Qty
Sl.No. EquipmentDescription
OfChange PerBlr
10C HPBP BP
Bearings–Guillotin BharatMP
1 Servogem.HTxx Lithan3 3Years 10Kg
Gates Grease3
ShellTellus15
2 FilterCumLubricate Servospin12 1Year 5Litrs
Hp
CastrolAlphaSP68Of 1.25
3 Actuators Ͳ 2Years
Indrol–ServomeshSP68 Litrs
0172 - 0177 VOL - A1 TAB - 7 - 252

RECOMMENDEDLUBRICATIONFORLONGRETRACTABLESOOTBLOWERS
RECOMMENDEDLUBRICANT FREQUENCY FREQUENCY

QUANTITY
SL.NO EQUIPMENTDESCRIPTION METHODOFAPPLICATION OFOIL OF
(ANNUAL)
TravellingCarriage
01 Servomesh28 FillTheReservoir Annual 3Months 0.8Lit.
(AirBlowing)
Almasol1250
TravellingCarriage
02 OrServogem FillTheReservoir Annual 3Months 0.6Kg
(SteamBlowing)
HTXXX
03 Chain Servostem …… …… ……. 1
PowerPackRotaryAnd
04 Servomesh28 FillTheReservoir Annual 3Months 0.8Lit.
Traverse

NOTE1:AllTheChainAndChainLinksArePrelubricatedBySpecialTreatmentByWhichLubricationIsRequiredNormally.ButAsAndWhenSignOf
RustIsIdentifiedTwoFoldLubricationIsRecommended.FirstTheChainIsCleanedAndTrichloroethyleneIsAppliedOverSurfaces.(ThisIsUsedAsA
DegreasingAgentAndCarrierForPenetratingTheHeavyLubricant.Servosystem150IsAppliedAsASecondCoat).
NOTE2:LubricatingOilLevelsShouldBeCheckedAndMaintainedEveryMonth.
0172 - 0177 VOL - A1 TAB - 7 - 253
NOTE3:Almasol1250IsRecommendedOnlyWhenTheSootBlowingMediumTemperatureExceeds427°C.ForRecoveryBoilerIrrespectiveOf
TemperatureAlmasol1250IsRecommended


RECOMMENDEDLUBRICATIONCHARTFORFURNACETEMPERATUREPROBE–TYPEͲFTP–1E*
RECOMMENDEDLUBRICANT FREQUENCY FREQUENCY

SL. EQUIPMENT METHODOF QUANTITY
OFOIL OF
NO DESCRIPTION FILLING (ANNUAL)
3Months
01 POWERPACK Servostem68 Enklo68 BharatHydrol68 Reservoir Annual 1Litre
(SeeNote1)
02 Chain(SeeNote2) Servostem150 Enklo150 BharatHydrol150 ByBrush …… ……. 1Litre

*NO.VOFF/BOILER–2
NOTE1:LubricantOilLevelsShouldBeCheckedAndMaintainedEveryMonth.
NOTE2:AllTheChainLinksArePrelubricatedByaSpecialTreatmentByWhichNoLubricationIsRequiredNormally.ButAsAndWhenSignOfRustIs
Identified,TwoFoldLubricationIsRecommended.FirstTheChainIsCleanedAndThenTrichloroethyleneIsAppliedOverTheSurfaces.
Servoline150/Enklo150/Hydrol150isappliedasasecondcoatbybrush.
ESTIMATEDTOTALQUANTITYOFEACHLUBRICANT/ANNUALREQUIREMENTPERPROBE
0172 - 0177 VOL - A1 TAB - 7 - 254
Servosystem68(IOC)/Enklo68(HP)/BharatHydrol68(BP) …..1Litre
Servosystem150(IOC)/Enklo150(HP)/BharatHydrol150(BP) …..1Litre
RECOMMENDEDLUBRICATIONCHARTFORWALLBLOWERS
RECOMMENDEDLUBRICANT
FREQUENCY FREQUENCY
QUANTITY
SL.NO EQUIPMENTDESCRIPTION METHODOFFILLING OFOIL OF
BLOWER
Bharat
ServomeshSP Parthon
01 GearPackHousing AmocanOil Reservoir Annual 3months 0.5Lit.
460 EP460
460
BharatMP
02 Linkages Servogem3 Lithon3 ByBrush 2months 2months 0.1kg.
Grease3
ServomeshSP Parthon Bharat

03 RotaryGearBox Reservoir Annual 3months 0.5Lit.
460 EP460 Amoeam

NOTE1:LubricatingOilLevelsShouldbeCheckedandMaintainedEveryMonth.

ESTIMATEDTOTALQUANTITYOFEACHLUBRICANT/ANNUALREQUIREMENTPERBLOWER
0172 - 0177 VOL - A1 TAB - 7 - 255
01. ServomeshSP460(IOC)/ParthonEP460(HP)/BharatAmocanOil460(BP) ... 2Litres

02. Servogem3(IOC)/Lithon3(HP)/BharatMPGrease3 … 0.5kg


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DIVISION - A

STEAM GENERATING UNIT

Location Description Ref. No. / Drg. No

TAB-1 BOILER PERFORMANCE

TAB-3 PRESSURE PARTS

0172 – 0177 HINDALCO-ADITYA VOLUME – A1 Page 1 of 2

Location Description Ref. No. / Drg. No

Assy. of SH Desh 0-12-900-01485

TAB-4 PRESSURE PARTS ARRANGEMENTS

TAB-5 LINING AND INSULATION

TAB-7 HYDROSTATIC TEST PROCEDURE AND

Recommended Hydrostatic Test Procedure Pub. 2025

0172 – 0177 HINDALCO-ADITYA VOLUME – A1 Page 2 of 2

(CONSTANT PRESSURE OPERATION)

SECTION DESCRIPTION SHEET No.

III PRESSURE (STEAM & WATER) 4

IV PRESSURES & DRAFTS (AIR & GAS) 5

VI MILL & BURNER PERFORMANCE 7

VII O2 • CO2 & EXCESS AIR 8

VIII HEAT BALANCE 9

CustomerlPlant: HINDALCO I ADITYA CPP, UNIT·1 to 6, 6x150 MW

0172 - 0177 VOL - A1 TAB - 1 - 3

(CONSTANT PRESSURE OPERATION)

Feed water tlh 510.0 480.3 449.1 360.1 273.2 410.0

SH spray tlh 7.7 7.8 16.4 16.1 14.6 24.8

0172 - 0177 VOL - A1 TAB - 1 - 4

Description Unit Both HP

0172 - 0177 VOL - A1 TAB - 1 - 5

(CONSTANT PRESSURE OPERATION)

Description Unit Both HP

Engineer: SM ~-' 09.10.09

0172 - 0177 VOL - A1 TAB - 1 - 6

(CONSTANT PRESSURE OPERATION)

SH Platen inlet mmwc -5 -5 -5 -5 -5 -5

0172 - 0177 VOL - A1 TAB - 1 - 7

Fixed carbon % 28.0

0172 - 0177 VOL - A1 TAB - 1 - 8

No.of mills in Operation 4 4 4 3 3 4

Mill outlet temperature °C <--- 66 - 90 ---->

Fineness (thru' 200 % 70 70 70 70 70 70

Burner tilt Deg -30 -21.3 -4.6 1.6 8.0 -30

Burners in operation BCDE BCDE BCDE CDE CDE BCDE

0172 - 0177 VOL - A1 TAB - 1 - 9

(CONSTANT PRESSURE OPERATION)

Description Unit Both HP

Excess air in gas at % 20 20 20 20 20 20

Engineer: SM ~_. 09.10.09

0172 - 0177 VOL - A1 TAB - 1 - 10

Description Unit Both HP

H20 from comb. of H2 % 4.209 4.205 4.206 4.196 4.199 4.166

H20 in air % 0.106 0.105 0.106 0.102 0.103 0.093

Unburnt Carbon % 1.500 1.500 1.500 1.500 1.500 1.500

Radiation % 0.214 0.229 0.241 0.293 0.375 0.231

Unaccounted & Manufac- % 1.561 1.566 1.571 1.593 1.630 1.562

Total losses % 14.661 14.609 14.650 14.559 14.721 13.987

Heat credits % 0.228 0.266 0.271 0.267 0.289 0.273

Efficiency % 85.57 85.66 85.62 85.71 85.57 86.29