high pressure boilers

HP BOILERS

Sr no

Parameter O V Unit alarm

1 Main steam pressure/Drum pressure

85 Kg/cm2

2 Main steam temperature 463 0c

3 Drum level 336 Mmwc

4 Oxygen 8.56 %

5 FD air 36.5 M3/hr

6 Furnace draft 0 Mmwc

7 ID Suction draft 26 Mmwc

8 FD Discharge dreaft 27 Mmwc

9 Pressure under grate 14 Mmwc

10 Draft Eco in 5 Mmwc

11 Draft eco out 40 Mmwc

12 Draft dust coo outlet 55 Mmwc

13 Secondary air pressure

14 Load ID 185 Amps

15 Load FD 24 Amps

16 FW temperature before Eco 131 0c

17 FW temperature after Eco 218 0c

18 Boiler outlet gas 377 0c

19 Eco outlet gas 197 0c

20 Air heater outlet gas 143 0c

21 Air heater outlet air 108 0c

Sr no

Parameter O V unit alarm

22 Primary SH before Attmpt. 354 0c

23 ESP outlet flue gas 129 0c

24 ESP 1A 20/135 Ma

25 ESP 1B 40/160 Ma

26 85/46 PRV open % 15

27 PDM tank temperature 50 0c

28 PDM tank level

29 Instrument air pressure

30 Ash Hooper level

31 Deaerator level

32 85/46 pressure 42.5 Kg/c2

33 CBD Conductivity

34 Deaerator water conductivity

35 Feed water Ph

OP

ER

AT

ING

P

AR

AM

ET

ER

S

HP BOILERS

AIR COMPRESSORS

NPP : KG KHOSLA MAKEDouble stage3H Y2TCERRPM : 650Pr. : 7 kg/cm2Cap : 5.89 m3/minPr 1 st stage : 2 kg/cm2pr 2 nd stage : 5.5 kg/cm2oil pr. : 2.5 kg/cm2

SPL : KG KHOSLA MAKEDouble stageAir comp no 4,5,6RPM : 800Pr. : 7 kg/cm2Cap : 51.41 m3/minPr 1 st stage : 2 kg/cm2pr 2 nd stage : 5.5 kg/cm2oil pr. : 2.5 kg/cm2

SPL : KG KHOSLA MAKESingle stageAir comp no 2RPM : 560Pr. : 7 kg/cm2Cap : 11.01 m3/minoil pr. : 2.5 kg/cm2

AIR COMPRESSORS

Air compressors in power house are situated as follows

1) 2 nos at old power plant

2) 2 nos at new power plant

3) 4 nos at specialty machine area

cooler

PROCESS

2.5 kg/cm2

Coating plant5 kg/cm2

AD AD

cooler

RECIEVERTANK

cooler

cooler

Pulp mill , spl machines , Clo2 plant, power house

5 kg/cm2

Air comp no 2,6,4,5

Motor load: 230-250 A

SPECIALITY PUMP HOUSE DETAILS

1 RUNNING 1 RUNNINGSHUT

250 M3/HR4 K/C285 A

M3/HR2-2.5 K/C265-70 A

3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21TUBE WELL LINES:

CO

AT

ING

PL

AN

T

AIR

CO

MP

RE

SS

OR

TW NO 9 / 6

55/ 150 LINE

NEW POWER HOUSE

PU

LP

MIL

L

10 KGTG

PULP MILL

7 KG BTH

rail clo2

SM

OPP office10KG STEAM HEADER

PRV 10/7

Dorr plant JMW APH

From

46/17/7 prv

ABL

LIME KLIN

AB

LD

AR

E.

OT

DEAERATOR

PDM

ABLFP

ABLSTEAMFP

85 KGSTEAMFP

EFP1EFP2

LAY OUT FEED WATER (HP) SYSTEM

TOHP BOILERS

TOABL BOILERS

ABLdeae. pump

Suction

Suction

HP BOILER 3 HP BOILER 2 HP BOILER 1

ECO ECO ECO

ABL

FR

OM

AB

L

PU

MP

HP BOILER AND ABL FEED WATER

OPERATING PARAMETRESSr no

Parameter O V

ABL FEED PUMP1 SUCTION PR 2.7

2 DISCHARGE PR 70 78

3 BALACING PR 3.0

4 ABL DEAERATOR WATER TEMP 100

5 DEAERATOR PUMP PR

6 DEAERATOR PUMP LOAD 13.5

7 BEARING TEMP MAX 60

HP FEED PUMP

1 WATER TEMP 108

2 FEED WATER COND 5-6

3 FEED WATER PH 9 -10

4 FEED PUMP SUC PR 1.3

5 DISCHARGE PR 100

6 BALANCING PR 1.4

7 PUMP NDE BEARING 40-45 70

8 PUMP DE BEARING TEMP 40-45 105

9 MOTOR WINDING 30-35

MOTOR BEARING DE 35-40 85

MOTOR NDE 90

21

Sr no

Parameter O V

HP FEED PUMP STEAM

1 RPM 2600

2 CONTROL OIL PR 2.3

3 LUB OIL TEMP 44

4 INLET STEAM PR 54

5 EXH STEAM PR 1.6-2.0

6 MOTOR LOAD 110

7 BOILER WATER COND 60-70 55 75

FLUE GAS PATH HP BOILER

BOILER 1 ST CYCLON 2 ND CYCLON 3RD CYCLON

SECONDARY AIR

TO GRATE

ECONOMISERAIR PREHEATER

FD AIR

HOT AIR OUT

ESP

SCREW CONVEYERS

TO SUBMURGED ASH BELT

RATED FLOW RATE: ID FAN :97524 M3/HR AND FD FAN : 51876 M3/HR (AIR DENSITY 1.20 KG/M3 AT 20 DEG CEL)

Sr no00

ASH CONTENT % COMUSTIBLE IN REFUSE INDIRECT BOILER

EFFICIENCY

SULPHER %

1.8

1 15 8-9 79.8-80.8

2 20 5-6 83-83.6

3 25 4.5-5 83.6-84.1

4 30 5.4-6.4 82.4-83.4

5 35 8-9.5 79.3-80

6 40 9.6-11.6 77.2-79

7 45 12-14 74.2-74.8

18

ASH CONTENT V/S EXPECTED BOILER EFFICIENCY

SAFETY VALVES SETTINGS

JMW BOILER: 51 , 50 , 48 (RHS,LHS,SUPER HEATER)

BOILER NO 1,2,3: 94.8, 93.6, 91.2 (RHS,LHS,SUPER HEATER)

BOILER NO 7: 51, 50, 48.5 (RHS,LHS,SUPER HEATER)

ABL BOILER

Sr no

Parameter O V

HP BOILER 1,2,3

1 EMERGENCY TRIP

2 ID FAN TRIPPED

3 FD FAN TRIPPED

4 SA FAN TRIPPED

5 COAL FEEDER 1 TRIPPED

6 COAL FEEDER 2 TRIPPED

7 COAL FEEDER 3 TRIPPED

COAL FEEDER 4 TRIPPED

1 STOKER TRIPPED

2 COAL FEEDRE NO 1 SPEED LOW

3 COAL FEEDRE NO 2 SPEED LOW

4 COAL FEEDRE NO 3 SPEED LOW

5 COAL FEEDRE NO 4 SPEED LOW

6 INST AIR PRESSURE VERY LOW

7 DRUM PR HIGH

8 DRUM PR VERY LOW

9 DRUM LEVEL VERY LOW

Sr no

Parameter O V

DRUM LEVEL HIGH

1 MAIN STEAM TEMP HIGH

2 MAIN STEAM TEMP LOW

3 AIR FLOW LESS THAN 30 %

4 FUEL PR LOW

5 AIR COMP 1 STOPPED

6 AIR COPMPRESSOR 2 STOPPED

7 DEAERATOR LEVEL LOW

EICM CERM RELAY MOTOR O/L

1 ESP1 FIELD 1 A TRIPPED

2 FIELD 1 B TRIPPED

3 ASH HOOPER LEVEL HIGH

4 RALV SC TRIPPED

5 ESP FIELD 1A 1B WORKING ALARM

6 O2 HIGH EXCESS AIR

7

8

9

OPERATING ALARMS ON PANEL

Sr no

Parameter

HP BOILER 1,2,3

1 MAIN STEAM HEADER PR LOW

2 86/46 LINE PR LOW

3 PDM PUMP 1 STOP

4 PDM PUMP 2 STOP

5 CBD1 COND LOW

6 CBD 2 COND LOW

7 CBD 3 COND LOW

DEAERATOR COND HIGH

1 FEED WATER PH LOW

2 FEED WATER PH HIGH

3

4

5

6

7

8

9

Sr no

Parameter

ABL BOILER

1 EMERGENCY TRIP

2 DRUM LEVEL LOW

3 DRUM LEVEL HIGH

4 FURNACE PRESSURE HIGH

5 FURNACE PRESSURE LOW

6 OVERHEAD TANK LEVEL LOW

7 DRUM LEVEL LOW

DRUM LEVEL VERY LOW

1 DRUM LEVEL HIGH

2 AIR FLOW LESS THAN 30 %

3 CONTROL PANEL SUPPLY FAIL BTH

4 CONTROL PANEL SUPPLY FAIL TG

5 DEAERATOR LEVEL LOW

6 ID FAN TRIP

7

8

9

OPERATING ALARMS ON PANEL

Sr no

Parameter

HP BOILER 1,2,3

1 ID SUCTION DRAFT MMWC

2 FD DISCHARGE DRAFT MMWC

3 APH INLET DRAFT MMWC

4 AIR PH OUTLET

5 ECON IN

6 ECON OUT

7 SA FAN

DEAERATOR LEVEL

1 APH OUTLET GAS TEMP

2 FURNACE DRAFT CONTROLLER

3 FEED WATER FLOW INTIGRATOR

4 STEAM FLOW INTIGRATOR

5 MAIN STEAM TEMP CONTROLLER

6 STEAM PR CONTROLLER

7 OXYGEN CONTROLLER

8 AIR FLOW CONTROLLER

9 DRUM LEVEL FEED WATER CONTROLLER

Sr no

Parameter

DEAERATOE PRESSURE CONTROLLER

1 DEAERATOR LEVEL CONTROLLER

2

3

4

5

6

7

1

2

3

4

5

6

7

8

9

OPERATING INSTRUMENTS ON PANEL