high pressure boilers
DESCRIPTION
Air compressors Pump house Steam header Feed water System Operating Parameters Fuel Gas path Ash content vs fuel efficiency Operating alarms operating instruments on panelTRANSCRIPT
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