HANDLING OF BOILER DURING EMERGENCIES

BOILER EMERGENCIES
1)ONE ID FAN TRIPPED 2)ONE FD FAN TRIPPED 3)BOTH ID FANS TRIPPED 4) BOTH FD FANS TRIPPED 5) ONE PA FAN TRIPPED 6) BOTH PA FANS TRIPPED

7) COAL MILL TRIPPED 8)DRUM LEVEL VERY LOW 9)DRUM LEVEL VERY HIGH 10) ONE BFP TRIPPED 11)BOTH BFP TRIPPED 12) FURNACE DRAFT VERY LOW 13) FURNACE DRAFT VERY HIGH

HANDLING OF BOILER DURING EMERGENCY EMERGENCY OPERATIONS

Major emergency situations in Boiler and Auxiliary areas and suggested actions: 1. High Furnace Pressure Probable Reasons: One I.D. fan tripped or maloperation of control vanes of I.D,F.D,P.A. fans or closing of damper. Unstable furnace flame condition, Sudden starting of coal mill, Low windbox pressure (under normal F.D. fans loading conditions), Improper air distribution at elevations. Un-equal burner tilts at corners or Burner tilt in extreme up or Down. Fouling in Air heater, Air heater tripped. Furnace water seal broken, ES.P. or flue gas path manhole opened. Water wall tube rupture/leakage.

Action to be taken:
See that two mills are tripped or otherwise trip them. Take running I.D. fans control on manual & increase for loading. Check the cause of I.D. fan tripping and try to restart it, if everything is normal. Check gas dampers indication & draft reading along flue gas path. If some damper is closed try to open that damper. Take F.D. / P.A. fan control on manual. Check control damper operation. Adjust air flow.

Action to be taken:
Check air for correct flow. Check combustion regime, openings of Auxiliary air and fuel air dampers. wind box pressure. See cold air and hot air dampers. Watch Furnace flame. Trip Boiler if flame is very much unstable. Purge out explosive mixture by maintaining high air flow. Check Burner tilt at all corners is equal. Adjust Burner tilt between + 10 to -10 and check control air pressure. See air-preheaters are rotating. Restart tripped air preheater and do A.H. soot blowing. Check Furnace seal, water flow through seal trough overflow. Re-establish seal. Stop the boiler in case of tube leakage as soon as possible.

2. Furnace Pressure Low Probable Reasons: I.D. fan auto control failure. I.D. fan vane control mechanism failure causing vanes to open wide Sudden decrease in air input or tripping of one F.D. fan. Sudden tripping of one or more mills or choking of mills/raw coal feeder pipe . Partial flame failure

Action to be taken
Take I.D. fans control on manual & reduce load on I.D. fans Check I.D. fan control mechanism for proper functioning.
Check air flow, correct if necessary. After checking restart F.D. fan if it had tripped. Control the furnace pressure by adjusting I.D. fan vanes. Simultaneously try standby mill. Remove the choking of affected mill / Raw coal feed pipe. Take the oil gun i.nto service to establish flame that locations / corner. See the proper functioning of secondary air path damper.

3. Drum Level Low

Probable Reasons: Mal-operation of Feed Auto Control or Feed Regulator or Scoop auto.

Tripping of one of working feed pump (standby pump does not start). Sudden reduction of load. Sudden increase in firing e.g. starting of mills having sufficient coal left before previous stopping.

Tube rupture/puncture.

Inadvertent opening of low point drain valves or Emergency drum drain valve.

Action to be taken:
Take feed control valve on manual and increase feeding rate. Take scoop tube control on hand increase scoop tube position. Check that water flow through each pump does not exceed capacity. Check feed water control valve and tube control linkages. Starts reserve feed pump on tripping of running feed pump, if auto starting fails. Try to increase the load if not possible, reduce firing rate accordingly to control drum pressure.

Action to be taken:
Reduce firing rate by suitably adjusting the feed rate of running mills. Check water flow and compare with previous feeding rate and steam flow. High feed flow indicates tube failure. Inspect waterwall and economizer or any tubeleakage, If tube leakage observed stop the boiler as soon as possible,. Check drum drains and, low point drains for closing. Note: If drum level goes below gauge glass and low drum level trip protection fails, trip boiler at on low level.

4. High Drum Level Probable Reasons: Mal-operation of feed water control Sudden increase in load resulting in drum pressure drop. Sudden decrease in firing rate e.g. tripping of the running mills . B.F.P. scoop tube position suddenly increased

Action to be taken: Take feed control valve on manual and reduce feeding rate. Try to decrease the load as far as possible. Increase feeding range of running mills. Check differential pressure across feed control valve and maintain 5 Kg / cm2 by adjusting scoop tube position

5. Flame Failure At anElevvation

Probable Reasons: Closing of trip valves on H.O./ W.U. Oil / Igniter (Causing loss of ignition support energy) Where F.O. is being used as support fuel or when only oil is being used. Sudden decrease of mill feeder speeds to minimum. Too low or too high windbox pressure causing unstable combustion. Water wall tube failure. Malfunction of flame scanners due to supply failure or scanner air failure, slag or soot on scanner lenses etc. Burner tilt mechanism negative extreme due to air failure to power cylinders. Rapid load changes without adjusting airflow leading to improper combustion.

Action to be taken:
Do not attempt to introduce igniters or oil guns at elevation where No flame condition persist. Trip out the coal mills of feeding elevation where No flame conditions is persisting. Allow sometime for purging then introduce oil support adjacent to working mills until furnace flame is stabilized. Check that secondary air wind box dampers are modulating to maintain about 80m.m.wc wind box to furnace differential pressure. Check furnace for tube failure. If two elevations scanners show No flame trip the boiler manually Check burner tilt keep it between /+10 . Check furnaces flame condition.

6.0ne Fan Trips (Other in Service) Probable Reasons: It Is presumed that ID, FD, PA fan de-interlocking switches are on Interlock position. Fan Bearing temperature, high and/or Fan motor Bearing temperature high and/or Lube oil pressure for motor bearings low and/or Corresponding Air heater tripped (provided de-inter locking switch is on Interlock position) and/or. Motor protection operated.

Action to be taken:
Takes draft control or manual, and / or increase the loading on running fan and maintain furnace draft. Check corresponding fan is tripped through interlock. Take secondary airflow controls on manual and maintain correct airflow. Cut in oil burner adjacent to working mills. . Check drum level is controlled on auto if necessary, take drum level control On manual and maintain level. Check pulverizers in excess of 3 are tripped starting from bottom. Check that the load on the generator has reduced to 100 - 120 MW (partial load relay energized).

 Check that interconnecting dampers on air and flue gas side open and tripped fans are correctly isolated through interlocks. Check windbox pressure left and right is maintained normal (about 75 mmwc). Maintain steam temperature. Check furnace flames condition. Check that tripped pulverizers are correct isolated (hot air gates close, cold air dampers come to minimum). Investigate the cause of trip. Correct it & restart the tripped fan.

7. One Feeder Trips

Probable Reasons: Support energy is removed within 3 minutes of feeder and/or. No. coal flow alarm comes & low current relay picks up simultaneously. (Feeder shear pin given way) and/or. Mill trips and/or. Feeder motor supply fails.

Action to be taken:
Check that hot air gate closes & cold air damper opens full if pulverizer is running. Clear the mill of the coal before stopped. Stop the pulverizer if feeder cannot be restarted immediately. Check that running mills share the loading, thermal load is on auto. Reduce the load on generator and, maintain steam parameters. If 3 mills at less than 50% feeder speed or 2 mills are left in service, cut in oil gun adjacent to working mills. Check furnace draft, airflow and drum level is normal. Check flame is stable and scanners sense Flame on. Check that associated elevation fuel air damper close and windbox pressure is maintained 70 mmwc.

8. One Mill Trills

Probable Reasons: Mill discharge valves are closed and/or Loss of elevation D.c. supply for more than 2 secs and lor Support ignition energy is removed with 3 minutes of feeder starting and / or . Motor protection operates and / or One P.A. Fan trips (mill in excess of 3 will trip starting from bottom).

Action to be taken:
Check the running mills share the load if thermal load control of mills is on auto. Reduce the generator load if pressure starts dropping. Start reserve mill and take load. Check furnace draft is maintained normal. Check the correct airflow is maintained. Check that drum level is maintained normal. Check that tripped mill is isolated (hot air gate closed, cold air damper minimum open, feeder tripped).

9. Hang-up in Mill Probable Reasons: Choking of coal at inlet to mill. H-igh moisture in coal and / or Too much fineness in coal with moisture and / or Foreign material at RC feeder inlet

Action to be taken:
Check feeder trip on No Coal flow & low current protection. Check mill outlet temperature is less than 85C. Check mill hot air gate closes on mill outlet temperature high protection. Close hot air gate and check mill. Cold air damper opens full. Check the flame condition at the sick mill elevation. Trip the sick mill after clearing it coals.

 Increase the load on running mills if the thermal load control is on manual. Start reserve mill. Maintain steam pressure and temperature by reducing load. Check that furnace draft and airflow are normal. If 3 mills (or less) are in service with speed below 50% take oil support at elevation adjacent to running mills in service.

10. Water Wall Tube Leakage

Probable Reasons: Starved water walls due to very low drum level and/or Sustained flame impingement on water wall tubes and / or Blocked tube, scaling of tube, resulting in overheating of tube Metal, pitting, corrosion of tubes and/or Soot blower steam impingement (wet steam impingement or direct impingement of steam) and/or Circulation affected due to opening of low point drains.

Action to be taken:
Compare feed water flow and steam flow, assess the magnitude of tube leakage. Maintain drum level by increasing feed water flow. Inspect the furnace for tube leakage. If the tube leakage is minute then take the unit out as a planned shutdown to cold. If tube leakage is heavy & it is likely to damage other tubes or likely to disturb the flame stability trip out the unit.

 Keep close watch in furnace flame. As the load is being reduced try to locate burst tubes. Check economizer hoppers for water leakage steam noise etc. every shift. Check that furnace draft is maintained normal
.

11. Reheater /SuDerheater / Economizer Tube Failure Probable Reasons: Sustained high metal temperature due to waterwall Slagging or forcing boiler at the time of hot restart and / or Erosion on tubes due to high excess air, high ash content in coal, dislocated tubes, soot blowing and/or Blocked tubes causing overheating and/or

 Salt deposition due to high water level in drum. poor quality of water and/or Inadequpte flow due to open Superheater, Reheater drain and / or Fire side corrosion of tubes and / or Economizer tube can fail due to over heating if concentration of Fe, Cu is more in feed water, Steaming in economizer occurs causing salt deposition and harming the tubes
.

Action to be taken: As soon as leakage is detected start load reduction and trip out the boiler at the earliest possible time. Try to locate leak through manholes before boiler is depressurized.