First boiler light up

A K Das DGM(OS) NTPC Ltd

Points of discussion
Parameters General preparation before boiler light up System readiness for first light up Protection and interlock

Parameters
Parameter Unit Predicted

Load
Total fuel Superheater O/L pressure Drum pr First stage pressure Reheater I/L pressure Reheater O/L pressure Super heater O/L steam flow Feed water flow Superheater spray flow Reheater spray flow

MW
MT Kg/sqcm Kg/sqcm Kg/sqcm Kg/sqcm Kg/sqcm T/hr T/hr T/hr T/hr

500
344 176.7 191.3 157.44 43 41 1498.5 1488.5 13 0

Parameters
ECO I/L temp degC 253

ECO O/L temp

Superheater O/L temp Reheater O/L temp Flue gas temp at Pri APH I/L Flue gas temp at Pri APH O/L Flue gas temp at Sec APH I/L Flue gas temp at Sec APH O/L PA fan O/L pr Primary air flow Sec air flow Total air flow

degC
degC degC degC degC degC degC mmWC T/hr T/hr T/hr

324
540 540 338 127 338 127 830 652 993 1847

O2%

3.6

Preparation for 1st BLU

System readiness for the SIX main systems to be ensured 1. Air system 2. Gas system 3. Water system 4. Fuel system 5. Steam system 6. FSSS

Preparation for 1st BLU

Trial run of all auxiliaries (Except Mills) Availability of instruments, interlocks and protections needed Refractory and insulation work completed Availability of DM water Communication at different locations Sufficient illumination Functioning of chemical lab

Preparation for 1st BLU

Ensure fire fighting system Ensure sufficient stock of fuel oil, lubricants & commissioning spares Working instructions and log sheets

Preparation for 1st BLU

Remove all loose construction materials around boiler Cut off temporary supports , construction platforms not envisaged in the drgs All valves marked with tag no All lines identified by painting by colour code Inspect water WW,SH, RH,Eco,APH ,ducts

Preparation for 1st BLU

Retractable soot blowers must be in withdrawn conditions Instrument tapping point valves must be open Drum level signaling and instruments should be made operational

READINESS FOR FIRST BOILER LIGHT UP

BOILER PROTECTIONS

FSSS
Furnace Safeguard and Supervisory System:

- A fully digital control system which governs mandatory

requirements related to safe startup and safe shutdown of the boiler - Includes main boiler permissives and protections - Includes heavy oil and light oil firing interlocks - Includes permissives and protections (digital logic) related to mills and feeders

TO HAVE ALL THE MFT (03) DPUS HEALTHY. MFT CIRCUIT IS READY.

TO ENSURE NO BOILER TRIP IS PRESENT.

TO PREVENT FUEL TO BOILER.

TO HAVE PROPER AIR FLOW FOR REMOVAL THE UNBURNT FUEL LEFT IN THE FURNACE

NO FLAME IN FURNACE

BOILER PURGE
A 9 minute mandatory cycle in which FD and ID fans are run with 30 to 40% air flow, with NO Fuel input to the

furnace, to ensure the removal the unburnt fuel left over in

the furnace area after the last master fuel trip

BOILER FSSS PROTECTIONS

Three contacts each for Individual ID Fan are generated in corresponding VFD circuit when the electronic speed is sensed to be less than minimum (i.e. 90 rpm)

BOILER FSSS PROTECTIONS

Three contacts each for Individual FD Fan are generated in corresponding 11kV MCC Motor Feeder Panel

BOILER FSSS PROTECTIONS

TO FACILITATE OPEARTOR TO TRIP BOILER MANUALLY IN IMPENDING SERIOS CONDITION. BOTH HARDWIRED & SOFT TRIP.

BOILER FSSS PROTECTIONS

All elevations voted no flame (no delay) AFTER any feeder is proven in service for 2 seconds. An elevation is said to vote for no flame if the feeder is not proven, OR if 3/4 oil guns are not in service AND 2/4 fireball flame is not sensed

BOILER FSSS PROTECTIONS

All oil and coal inputs to the boiler are sensed as closed or OFF (no delay) i.e. - All LONV closed OR LOTV closed + All HONV closed OR HOTV closed + All Feeders OFF (after any LONV/HONV opens partially)

BOILER FSSS PROTECTIONS

All oil and coal inputs to the boiler are sensed as closed or OFF (no delay) i.e. - All LONV closed OR LOTV closed + All HONV closed OR HOTV closed + All Feeders OFF (after any LONV/HONV opens partially)

BOILER FSSS PROTECTIONS

Boiler ON AND All BCW OFF (OR)

2/3 running BCWPs sense DP less than 10 psi=0.67 ksc (5 sec delay)

BOILER FSSS PROTECTIONS

Boiler ON AND Drum Pressure > 8 ksc AND Flow through reheater tubes is interrupted (10 sec delay). To maintain flow through reheater, both MS to CRH and HRH to condenser paths should be not fully closed. Either HP Turbine path or HPBP path should be not fully closed AND LP Turbine path or LPBP should be not fully closed

BOILER FSSS PROTECTIONS

Furnace Pressure Very high > +150 mmwc 2 out of 3 logic from 3 pressure switches

BOILER FSSS PROTECTIONS

Furnace Pressure Very low < -175 mmwc 2 out of 3 logic from 3 pressure switches

BOILER FSSS PROTECTIONS

Drum Level Very High 250 mm for 10 sec

2 out of 3 logic. 1 from electronic water level indicators (eg. Hydrastep) and 02 from transmitters limit value (average of left and right)

BOILER FSSS PROTECTIONS

Drum Level Very High -375 mm for 05 sec

2 out of 3 logic from 2 electronic water level indicators (eg. Hydrastep) and transmitter limit value (average of left and right)

BOILER FSSS PROTECTIONS

Loss of 220V DC in MFT circuit for more than 2 sec.

Loss of 220V DC generates software protection

BOILER FSSS PROTECTIONS

Loss of 24V DC in 2 out of 3 MFT panels. Loss of 24V DC generates hardwired protection.

BOILER FSSS PROTECTIONS

Total air flow (secondary near windbox + primary to individual mills) is less than 30% of full load rated flow I.e. 540 TPH (no delay)

BOILER FSSS PROTECTIONS

All BFPs OFF with 10 sec delay.

03 contacts generated in Station C&I logic and then hardwired to MFT panels. TDBFP trip is sensed as Trip Oil pressure V Low OR ESV Closed.

BOILER FSSS PROTECTIONS

Both Secondary Air Heaters OFF with 5 sec delay

3 contacts generated in Station C&I logic and then hardwired to MFT panels. Air Heater OFF is sensed as Electric Motor OFF AND Air Motor OFF i.e. Solenoid valve exit pressure low.

BOILER FSSS PROTECTIONS

Loss of both communication networks in 2 out of 3 MFT processors OR Processor failure in 2 out of 3 processors OR Processor outputs frozen in 2 out of 3 processors

OIL FIRING LDO

OIL BURNER ELEVATION AB ONLY

FUEL OIL SYSTEM MIMIC

HEAVY OIL FIRING MIMIC

Coal firing MIMIC

MFT trip logic diagram

REHEATER PROTECTION LOGIC

FSSS COMMISSIONING PROCEDURE