2X500 MW Neyveli New Thermal Power Project (NNTPP) Neyveli, Tamilnadu, India

Employer’s and Contractor’s Information / Project Name
2x500 MW NEYVELI NEW THERMAL POWER

PROJECT (NNTPP)
NEYVELI, TAMILNADU, INDIA

Space for Stamping (Review and Validation status - if needed)
Participant
Scale Other Document Code (if any)
Responsible dept. Created by Checked by Approved by Format

CC-CM T. Wende C. Hotze H. Nagel A4
Originator Document Type Project Document Code
NLC/01/B/G1-04-0300/OI/105
Title, Subtitle Document Status
Unit 01 Released
Identification number
Operating Manual 148760_00108_7105

GE Boiler Deutschland GmbH Rev. Date Lang. Sheet
Oil Firing
00 01.08.17 En 1/28
© General Electric 2016. All rights reserved. Please consider the environment before printing this document
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
SYSTEM OPERATING MANUAL
OIL FIRING
REVISION HISTORY
Revision history
Rev. Revision Date Created by Checked by Approved by Description
00 01.08.2017 T. Wende C. Hotze H. Nagel 1st issue
Originator Identification number Rev. Date Lang. Sheet

GE Boiler Deutschland GmbH 148760_00108_7105 00 01.08.17 En 2/28
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
INDEX
1 PART 1 – General ................................................................................................................ 8

1.1 Purpose of the document ................................................................................................................... 8
1.2 Purpose of the system ........................................................................................................................ 8
1.3 Health and safety ................................................................................................................................ 8
1.3.1 General safety instructions ............................................................................................................ 9
1.3.2 System specific safety instructions .............................................................................................. 11
1.4 System delimitations ......................................................................................................................... 12
2 PART 2 - Control panel operating instructions ................................................................13
2.1 Function description.......................................................................................................................... 14
2.1.1 Fixing of airflows to the oil burner ................................................................................................ 15
2.2 Preparation for starting ..................................................................................................................... 16
2.3 Start-up ............................................................................................................................................. 16
2.3.1 Oil burner release ........................................................................................................................ 16
2.3.2 Oil burner start ............................................................................................................................. 17
2.3.3 FG Oil burner (FG OIL BURNER 01HJA11) ............................................................................... 18
2.4 Operation .......................................................................................................................................... 19
2.4.1 Normal automatic operation ........................................................................................................ 19
2.4.2 Controls in oil firing system .......................................................................................................... 19
2.4.2.1 Pressure control Fuel oil burner (P CTRL FUEL OIL 01HJF00DP) ....................................... 20
2.4.2.2 Secondary Air Flow control (F CTRL SA OIL BNR L 1 LE 01HJL11DF) ............................... 20
2.5 Shutdown .......................................................................................................................................... 21
2.5.1 Burner Trip ................................................................................................................................... 21
3 PART 3 - Field operations ..................................................................................................23
3.1 Recommissioning ............................................................................................................................. 23
3.2 Preparation for starting ..................................................................................................................... 24
3.2.1 Basic position of valves and dampers ......................................................................................... 24
3.3 Start-up ............................................................................................................................................. 26
3.4 Operation .......................................................................................................................................... 26
3.5 Shutdown .......................................................................................................................................... 27
4 PART 4 – Special operation ...............................................................................................28
4.1 Alarms description and troubleshooting ........................................................................................... 28
4.1.1 Alarm list ...................................................................................................................................... 28

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
LIST OF REFERENCE DOCUMENTS

System Alarm Sheets:
Operation instructions Boiler alarm sheets NLC/01/G4-01-0300/111

Operation instructions Boiler Protection alarm sheets
NLC/01/G4-01-0300/112
Operation instructions Air / Flue gas alarm sheets NLC/01/G4-01-0300/113
Operation instructions Water / Steam alarm sheets NLC/01/G4-01-0300/114
Operation instructions Coal Firing alarm sheets NLC/01/G4-01-0300/115
Operation instructions Oil Firing alarm sheets NLC/01/G4-01-0300/116
Operation instructions Sootblower & Water Lance Blower alarm sheets
NLC/01/G4-01-0300/117
Operation instructions Ash Handling alarm sheets NLC/01/G4-01-0300/118
System Design Manual:

Operation Instructions Boiler NLC/01/G4-01-0300/101
Operation Instructions Boiler Protection NLC/01/G4-01-0300/102
Operation Instructions Air / Flue Gas NLC/01/G4-01-0300/103
Operation Instructions Water / Steam NLC/01/G4-01-0300/104
Operation Instructions Coal Firing NLC/01/G4-01-0300/105
Operation Instructions Oil Firing NLC/01/G4-01-0300/106
Operation Instructions Sootblower & Water Lance Blower
NLC/01/G4-01-0300/107
Operation Instructions Ash Handling NLC/01/G4-01-0300/108
Firing system process design NLC/00/B/G2-X2-1000/ER/101

Pre-control curves of the firing system NLC/00/B/G2-X2-2000/DM/063
Piping & Instrumentation Diagram (P&ID):
P&ID Eco and Evaporator NLC/00/B/G2-X7-11--/FD/001

P&ID Superheater NLC/00/B/G2-X7-11--/FD/002
P&ID Reheater NLC/00/B/G2-X7-11--/FD/003
P&ID Drain and Venting Station NLC/00/B/G2-X7-11--/FD/004
P&ID Condensate System NLC/00/B/G2-X7-11--/FD/005
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
LIST OF REFERENCE DOCUMENTS

P&ID Combustion Air Distribution NLC/00/B/G2-X7-11--/FD/021
P&ID Furnace Air and Flue Gas NLC/00/B/G2-X7-11--/FD/022
P&ID Coal Burner NLC/00/B/G2-X7-11--/FD/023
P&ID Oil firing, Ignition and support NLC/00/B/G2-X7-11--/FD/024
P&ID Burner Valve Arrangement NLC/00/B/G2-X7-11--/FD/025
P&ID Sootblower NLC/00/B/G2-X7-11--/FD/030
P&ID Water Lance Blower NLC/00/B/G2-X7-11--/FD/031
P&ID Wet ash conveying system NLC/00/B/G2-X7-11--/FD/061
P&ID Beater wheel bearing lubrication mill 1 NLC/00/B/G2-X7-11--/FD/250
P&ID Air canon bunker mill 1 NLC/00/B/G2-X7-11--/FD/300
P&ID Gear coupling oil circuit NLC/00/B/BK-02-03--/851
Manual from supplier and partners:
To be completed during commissioning by BHEL

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS

List of abbreviations:
Standard:
- BCM Lignite quality with maximum calorific value and minimum moisture content
- BHEL Bharat Heavy Electricals Limited
- BMCR Boiler maximum continuous rating
- FC Function Control
- FG Function Group
- DC Lignite quality for guarantee calculations (design coal)
- DCS Digital control system
- FG Function Group
- LI Lahmeyer International
- LTG Longitudinal travelling grate
- NCV Net calorific value
- SG Sub Group Control
- SSC Submerged scraper conveyor
- TMCR Turbine maximum continuous rating
- WCA ESP Lignite quality with the minimum calorific value and 10% ash content for
designing ESP
- WCA.S Lignite quality with the minimum calorific value and the maximum ash content
and maximum sulphur content for designing WFGD
- WCM Lignite quality with minimum calorific value and maximum moisture content
System specific:
- FGRD Flue gas resuction duct
- KKS Tag numbers (Kraftwerkskennzeichnungssystem - German abbreviation)
- OFA Over fire air
- P&ID Piping and instrumentation diagram
- PC Pulverized coal
- WFGD Wet flue gas desulphurization
KKS description:
- HBK Furnace

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS
Symbols:
 Display the corresponding mimic
 See the corresponding section
 Cross check when the action is completed
Note indicates an important instruction or the best practices
Timing note indicates long duration activity which should be initiated early
enough to avoid extended downtime.
Freeze protection note indicates instruction to be followed in order to protect
the system against freezing risks.
Caution is used to alert against imminent or potential mechanical damage to
the equipment.
Warning is used to alert of imminent or a potential danger, which could result in
death or serious injury.
Note
Changes from previous revisions of this operation instructions document are highlighted in
yellow allowing easy-to-follow document updates.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 1 - GENERAL
1 PART 1 – General
1.1 Purpose of the document
The operation manual of the Oil firing system provides the operator a detailed description for the
system specific design and explains the necessary aspects for the operation modes of the boiler
(start-up, operation and shut-down).
➢ PART 1. This first part gives general information about the system.
➢ PART 2. The second part gives the System Operating Manual for the control panel
operator.
➢ PART 3. The third part gives the System Operating Manual for the field operator.
➢ PART 4. The fourth part gives the system special operating instructions for both
operators.
1.2 Purpose of the system

The ignition- and start-up burners are required for unit start-up and for the ignition of the pulverized
coal burners. Light diesel oil (LDO) according to IS 1460 and heavy fuel oil (HFO) according to
IS1593 will be utilized. Eight oil burners are installed, two on the middle axis of each furnace wall at
the height of the pulverized coal nozzles. The oil burner level 2 is connected to the HFO system,
level 1 to the HFO system and the LDO system as well. Air is used as atomizing medium for LDO
and steam as atomizing medium for HFO.
1.3 Health and safety
The safety instructions included in this operator’s manual, which may cause
dangers to persons in case of any non-observance, are specially marked
with the general danger symbol.
Any discovered failures and malfunctions should be immediately notified to

the responsible superior. Any plant components, which were shut down by
means of an emergency shutdown, may only be switched on again upon
instruction as well as after the elimination of the cause of the shutdown and
inspection of the plant component on site.
Any danger areas caused by disturbances must be delimited, identified and
monitored. These danger areas may only be entered upon instruction of the
responsible person and after the performance of the necessary safety
measures.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 1 - GENERAL
1.3.1 General safety instructions
The site Health and Safety Instructions shall be read and fully understood before performing any
actions detailed within the whole System Operating Manual.
The operator shall also comply with the Special Precautions mentioned herewith.
HAZARDS POTENTIAL CONSEQUENCES MEASURES
Organizational • Personnel injuries Any maintenance work
deficiencies • Component damages may only be started, after
the responsible person
has laid down the
required safety measures
as one part of the Permit-
to-work procedure,
checked the performance
of the relevant measures
and released the place of
work. After completion of
the work any safety
measures may only be
cancelled upon
instruction of the
responsible person. As a
rule, a written release
procedure shall be
required for such work.
Hydraulic • Injuries due to high pressure leakages All pipes, hoses, valves
• Injuries due to loose connections and screwed connections
• Risk of fire in case of relevant oil leakages are to be checked for any
in the area of hot surfaces damage and leakages at
regular intervals, and any
damaged parts are to be
replaced. Prior to
disassembly the motor is
to be disconnected and
all pressure pipes and
accumulators in the
hydraulic circuit are to be
depressurized. Any
hydraulic oil splashing
out under pressure may
lead to serious injuries,
burns and fires.
Any maintenance and

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 1 - GENERAL

repair of hydraulically and
pneumatically operated
plants may only be
performed by specially
trained personnel who
are familiar with the
plants.
Oil, grease and • The inexpert handling of the stated Manufacturer’s data
chemical substance substances may cause damage to health. (safety data sheet) and
the operating instructions
must be checked prior to
use and the prescribed
protective measures
need to be reached.
Noise • Hearing disorders for operator personnel Noise reduction
• Personnel can get into dangerous situations measures need to be
because of not hearing acoustic warning defined
Sign giving orders need

to be installed to indicate
where it is necessary to
wear noise reduction
equipment
Fire risk due to • Damages to persons (burnings, The employees must be
- deposit of asphyxiation due to CO, …) trained in the handling of
combustible dust or • Damages to Equipment that leads to plant combustible substances
whirl-up of dust unavailability or ignition sources and
- leakages of pipes the behaviour after the
with comustible outbreak of a fire.
media
- storage and
handling of
combustible media
in improper way
- missing safety
measures for
welding, burning
and soldering work
(hot work permit)
Environmental • The non-observance of environmental In particular, the relevant
damages protection measures during the operation of safety data sheets and

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 1 - GENERAL

the plant as well as in case of maintenance operating instructions for
and inspection work can cause hazardous materials are
environmental exposures to be observed when
handling dangerous
substances.
1.3.2 System specific safety instructions

If any of the following hazard is observed by the field operator or any other person, he has to
inform immediately the unit control panel operator, who must ask the concerned maintenance
specialist in order to take appropriate measures and/or corrective actions for the personnel
protection and equipment integrity as soon as possible:
Causing damage of • Damaged components may cause When working in and
equipment unplanned outages and lead to dangerous around the system no
operating states (e.g. cracking by tools, materials, lamps or
vibrations, …) similar may remain in the
ducts in order to avoid
any damage to the plant.
Uncovered moving • In case of contact with uncovered turning Any protective covers,
equipment equipment the risk of getting pulled in by e.g. protection against
rolling up clothing etc. is high accidental contact of
coupling or linkages must
be fitted in a safe and
correct manner. Any
obstructions by other
installations or auxiliary
structures (e.g. scaffolds)
are to be removed before
the operation of the plant.
In this respect, the boiler
expansion is to be
observed.
Electrical danger • Electrical shocks in case of structure under For the inspection and
voltage performance of any work
at components of the
system, only electrical
components with the
protective measure
„protective extra-low
voltage‟ or „protective

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 1 - GENERAL

separation‟ are to be
used.
Hot working places • During the inspection of hot ductings and Working times and
(thermal danger) components the physical exercise of the recovery times of the
persons can greatly be increased. personnel must be
monitored, laid down and
observed according to
the according the safety
rules and safety laws of
this country.
1.4 System delimitations

The attached list of system components with the associated KKS numbers is not complete, but
comprises the components, which are required for the description of the systems and need to be
descripted by GE.
▪ Heavy fuel oil 01HJF
▪ Light fuel oil 01HJF
▪ Slop oil 01HJF80
▪ Fuel oil burner 01HJA
▪ Atomizing- & purge steam 01HJM
▪ Instrument air 01HJX
▪ Atomizing air 01HJS
▪ Cooling air 01HJQ

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS
2 PART 2 - Control panel operating instructions

Contents:
Instructions to the CONTROL PANEL operations.
➢ Displays to observe and control
➢ Instructions for start-up preparation.
➢ Instructions for start-up.
➢ Instructions for operation.
➢ Instructions for shutdown.
The oil firing system is started by the group control
To insert during commissioning

Screenshot of DCS screen with system overview,
Main Air & Flue gas function groups
and the linked DCS screen to operate the sub systems
Figure 1: DCS screenshot with marked up controls for air & flue gas system
The equipment of air & flue gas system within the engineering scope of GE is operated by the
following functional groups, sub groups and (preselection) function controls:

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
2.1 Function description

The ignition- and start-up burners are required for unit start-up and for the ignition of the pulverized
coal burners. Light diesel oil (LDO) according to IS 1460 and heavy fuel oil (HFO) according to
IS1593 will be utilized. The minimum oil firing capacity is 7.5% BMCR heat input capacity for LDO
and 30% BMCR heat input capacity for HFO. Eight oil burners are installed, two on the middle axis
of each furnace wall at the height of the pulverized coal nozzles. The oil burner level 2 is
connected to the HFO system, level 1 to the HFO system and the LDO system as well. Air is used
as atomizing medium for LDO and steam as atomizing medium for HFO.
Each of the eight oil burners comprises the following equipment:

• the burner wall box including the core air tube
• the front plate with the attachments for the ignition
• the core air damper (01HJL11AA051, 01HJL12AA051, 01HJL21AA051, 01HJL22AA051,
01HJL31AA051, 01HJL32AA051, 01HJL41AA051, 01HJL42AA051)
• the oil gun and swirl insert of the core air
• supervision and monitoring device of the burner
• HV igniter
Each oil burner is supplied by hot air. The hot airflow is measured and controlled individually by a
venturi nozzle (01HJL11CF001 / 01HJL12CF001, 01HJL21CF001 / 01HJL22CF001,
01HJL31CF001 / 01HJL32CF001, 01HJL41CF001 / 01HJL42CF001) and a control damper
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

(01HJL11AA451, 01HJL12AA451, 01HJL21AA451, 01HJL22AA451, 01HJL31AA451,
01HJL32AA451, 01HJL41AA451, 01HJL42AA451). In case the related oil burner is out of
operation, the control damper adjusts the required cooling airflow. An additional mechanically
locking device prevents the control damper from accidentally closing. The hot airflow of one burner
is divided up into two flows:
• core airflow that is approximately 10 % of the total hot airflow to the oil burner
• circumferential airflow that is approximately 90 % of the hot total airflow to the burner
The core air tube is mounted centrally in the burner wall box. The air split between core and
circumferential air is fixed by a manually operated damper that throttles the core airflow. The core
air is swirled by a fixed swirl vane assembly that is arranged inside the core air tube. Near the
burner mouth, the outside of the core air tube is equipped with an annular baffle plate. Thus the
circumferential air is swirled in the burner mouth to improve the mixing and ensuring a stable
ignition close to the burner. The oil gun is arranged in the center of the burner. The atomization is
done by means of either atomizing pressurized air (for LDO) or steam (for HFO). The high voltage
igniter, the flame detector and the inspection flap are located around the gun.
The total oil firing capacity is controlled by means of varying the oil pressure upstream the
operating burners by varying the position of the control valve that is arranged in the return flow
pipeline. The oil flow of each burner is measured individually. The part load mode of the oil burners
is used during the start-up phase of the individual oil burners to reduce the load jumps of the total
oil firing capacity. The part load mode can be used for the regulation of the required oil capacity as
well. The corresponding burner airflow of each burner is pre-controlled in dependence of the
individual oil flow. The pre-controlled value of the airflow to the individual oil burner can be adjusted
manually by the operator either by presetting a value or by modifying the pre-controlled value by a
constant value that is added or subtracted of the pre-controlled value.
2.1.1 Fixing of airflows to the oil burner

The set point of the burner airflow during the start-up process of one oil burner is 26800 m³/h STP
per burner, which corresponds to a stoichiometry of 1.3. The stoichiometry is pre-controlled
dependent on the air temperature downstream RAPH in order to keep the velocity in the secondary
air cross section of the oil burner on a high level (pre-control curve 1.48760/00030-7063-5.18). In
case the local air ratio of one oil burner falls below 0.6 or the secondary air flow to one oil burner is
less than 8900 m³/h STP, the individual oil burner is shut down automatically. An alarm is issued.
In case an oil burner is out of operation, the required burner cooling airflow is precontrolled
dependent on the total firing capacity (pre-control curve 1.48760/00030-7063-5.5.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
2.2 Preparation for starting

The following sections describe which preparatory measures have to be taken in order to establish
readiness of the oil firing for start-up.
All necessary preparations for bringing the manual valves & dampers into the right position for
starting of the oil burner are listed in the sections 3.2 and following.
▪ Oil-, steam- cooling air -, instrument air supply available

▪ I&C equipment ready, in particular flame scanner
▪ All electric drives shall be ready for operation.
▪ All protection interlocks (level, flow, pressure, stall, temperature, vibration, etc.) have to
be operational.
▪ Remote and local measuring equipment needs to be activated.
▪ Existing leaks have to be repaired.
▪ Junction boxes and pneumatic system enclosure need to be properly closed, to avoid
ingress of dust.
▪ Check the instruments availability.
▪ Check that functions group are switch off.
▪ Check releases conditions for start-up.
▪ Clear and acknowledge all alarms.
2.3 Start-up
➢ Check that the preparation for start-up of the system is done
 PART 3 - Field operations - 3.2 Preparation for starting
An Oil burner can be started only, if the Oil burner Release signal from FG Boiler Protection
is available.
2.3.1 Oil burner release

The general oil burner start release is available, if following conditions are met:
Light fuel oil (LFO) release:
➢ P instrument air (01HJX01CP001-CP003) > MIN (= 4kg/cm²)
➢ P steam supply (01HJM01CP001-CP003) > MIN
➢ Air/Fluegas System ON
➢ General Ignition release EXISTS

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

Heavy fuel oil (HFO) release:
➢ P instrument air (01HJX01CP001-CP003) > MIN (= 4kg/cm²)
➢ P purge air (01HSJ01CP001-CP003) > MIN
➢ Air/Fluegas System ON
➢ General Ignition release EXISTS
2.3.2 Oil burner start

The Oil burner is in general started in the following sequence:
1. The oil pressure control valve is switched to auto mode

2. The secondary air damper is switched to auto mode and the ignition setpoint is selected
3. The oil gun is inserted
4. The ignitor is inserted
5. The ignition transformer is switched on
6. The quick closing oil valve are opened
7. The ignition transformer is removed out of operation
The burner has two Ignition Safety Time. They are 5 and 11 seconds respectively. 5 seconds are
allowed, if the oil pipes are filled up to the burner oil gun. 11 seconds are allowed if the scavenge is
completed which means the oil pipes between the valves and the gun nozzle are not filled. Out of
this 11 seconds, 6 seconds are used for filling the oil pipe between the quick closing oil valve and
the oil gun.
The start-up program allows two attempts for each burner. i.e. the steps (1) through (7) are
followed in the sequence to start the burner. If in case after step (7) the burner-flame is not
established, steps (4) through (6) are repeated immediately following the first attempt.
The burner start is deemed successfully established, if after the expiring of Ignition Safety
Time:
➢ the corresponding flame scanner detects flame
➢ a proper air fuel ratio is maintained
➢ the oil supply valves are kept opened
 Burner ON signal
Once the signal Burner ON is established, if the burner switches off, a Burner Trip signal is
generated which shutdown the burner. But each of this attempt is counted in the fail start counter in
boiler protection logic.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

2.3.3 FG Oil burner (FG OIL BURNER 01HJA11)
Step Command Setpoint Remark / waiting for

01 CTRL DAMP SA 01HJL11AA451 AUTO
CTRL SA FOBNR 01HJA11EW001 SP IGN ON
02 P-V INSR OILGN LVL 1 LE BNR 01HJA11AA151 AUTO
03 P-V QCV PRNG ST LVL 1 01HJM11AA152A Digital Input HFO selected
04 P-V QCV ATM ST LVL 1 LE 01HJM11AA151A Digital Input Steam purging 20 sec
05 P-V QCV PRNG ST LVL 1 LE BNR Digital Input

1HJM11AA152A
P-V QCV ATM AIR LVL 1 LE BNR Digital Input
01HJS11AA151A
P-V INSR IGN LVL 1 LE BNR OPEN
01HJA11AA152A
06 Waiting time
07 IGN L 1 LE BNR Digital Input Energizing of ignitor

01HJA11AV010
08 SAFETY TIME LFO LVL 1 LE BNR ON

01HJA11AA156A
IGN L 1 LE BNR Digital Input
01HJA11AV010
SAFETY TIME HFO LVL 1 LE BNR ON
01HJA11AA154A
P-V INSR IGN LVL 1 LE BNR Cmd Open
01HJA11AA152A
09 Waiting time 3 sec (1st oil filling

step)
10 P-V INSR IGN LVL 1 LE BNR Cmd Open

01HJA11AA152A

01HJA11AV010
P-V INSR IGN LVL 1 LE BNR Cmd Open
01HJA11AA152A

01HJA11AV010
P-V INSR IGN LVL 1 LE BNR Cmd Open Start oil supply
01HJA11AA152A
SAFETY TIME HFO LVL 1 LE BNR ON
01HJA11AA154A
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

SAFETY TIME LFO LVL 1 LE BNR ON
01HJA11AA156A
13 Waiting time to establish flame
14 Check if flame is detected
15 Sequence completed or fail

start counted
2.4 Operation
2.4.1 Normal automatic operation

During operation of the unit the operator has to check all operation parameters of the systems
periodically, to make sure the steady operation of the plant is ensured and to be able to determine
disturbances and malfunctions as soon as possible.
Note
 ➢ Check for alarms
➢ Check for warnings
➢ Check for all important parameters (temperature, pressure, level, …)
➢ Request the field operator to carry out in the field, the routine checks following the
instructions given in Part 3:
 PART 3 - Field operations - 3.4 Operation (Routine checks)
2.4.2 Controls in oil firing system
General
All characteristic curves and Setpoints mentioned in the following
paragraphs have to be adapted during the commissioning period to achieve
favorable emission limits and good preconditions for combustion.
General
Additionally implemented pre-control curves during commissioning phase
need to be implemented in this document before finalization.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

2.4.2.1 Pressure control Fuel oil burner (P CTRL FUEL OIL 01HJF00DP)
The fuel oil pressure control valves 01HJF60/70A401 are used to control the fuel flow by
controlling the fuel oil pressure. The pressure of the fuel oil is basically controlled between the min
and max allowed oil pressure so as to have proper combustion. The first oil burner is started with
predetermined Ignition Pressure. Once 1 burner was taken into operation, the pressure set point is
transferred to the main pressure control.
The main pressure control receives the demand signal from the master fuel controller. The flow
demand is selected based on whether the fuel oil is the leading fuel or lignite is selected as the
leading fuel.
During oil is leading fuel, the controller acts as follows:
The total coal flow signal is deducted from the setpoint signal and the deviations is sent to the
setpoint integrator of the fuel oil flow controller. This demand signal is compared to the total
measured flow and the difference is compared with the allowed pressure. The function generator is
used to ensure that during any time of operation sufficient amount of secondary air is available for
proper combustion. The input to the function generator is the secondary air flow.
Control variables
➢ Light fuel oil supply pressure 01HJF70CP001 and 01HJF70CP002
➢ Heavy fuel oil supply pressure 01HJF60CP001 and 01HJF60CP002
Actuator
➢ Light Fuel Oil Pressure Control valve 01HJF70A451
➢ Heavy Fuel Oil Pressure Control valve 01HJF60A451
Setpoint Variable
Setpoint total fuel oil flow from Master fuel Controller 01HFY00DF002
2.4.2.2 Secondary Air Flow control (F CTRL SA OIL BNR L 1 LE 01HJL11DF)

The secondary air flow to the oil burner is controlled to meet the air requirements for proper
combustion.
During the normal oil burner operation the air flow is set according to the heavy resp. light fuel oil
flow to the burner.
When the oil burner is out of operation the air flow is set according to the total firing rate to ensure
sufficient cooling of the burner nozzle.
The deviation between the measured air flow and the set point for the cooling air flow if the burner
is out of operation is considered false air in the secondary master air flow controller
01HHL00DF001.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

Control variable
➢ Flow secondary air level 1 left oil burner 01HJL11CF001/002
Actuator
➢ Control damper secondary air level 1 left oil burner 01HJL11AA451
2.5 Shutdown
During oil burner shut down, the start-sequence is followed in the reverse order provided the
release for oil burner or scavenging release is available. The sequence is as follows:
1. The quick closing oil valves are closed.
2. Secondary air is switched to auto mode.
3. Ignitor is inserted.
4. Ignition transformer is switched on and kept on until the first stage scavenging is
completed.
5. Scavenge valves are opened.
6. Once the scavenge is completed, the scavenge valves are closed.
7. The oil gun is retracted
The scavenging is done in two stages. During the Stage 1, the oil in the pipe is scavenged and
burnt. During this time, the ignitors are switched on to assist combustion and the secondary air
damper is taken into auto mode. This process takes around 30 seconds. Once the first stage
scavenging is completed, the ignitors are retracted and the secondary air dampers are closed. The
second stage of scavenging follows with a process time of approx. 300 seconds. This is done to
make sure all the residues are removed out of the Oil pipes and Oil gun.
A burner shut down is automatically initiated following a Burner Trip provided the release
conditions for a scavenge cycle are satisfied.
2.5.1 Burner Trip

The burner is tripped if during operation any one or more of the following conditions occur:
1. Individual flame scanner sees no flame
2. Air fuel ratio is lower then the preset value for a preset tolerance time
3. Air flow is lower than the MIN value
4. If the oil burner release signal failed due to Boiler Trip
5. If the oil valves or the oil gun leaves the open/advance position
6. If the emergency switch from the individual local control cabinet is actuated
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

7. Boiler trip is initiated

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 3 – FIELD OPERATIONS
3 PART 3 - Field operations

Contents:
Instructions to the FIELD OERATIONS.
➢ Instructions for recommissioning.
➢ Instructions for start-up preparation.
➢ Instructions for start-up.
➢ Instructions for routine checks during operation.
➢ Instruction for shutdown.
3.1 Recommissioning
Note
The decision to recommission may be triggered by a long time outage or numerous
 instruments and drives failures on the system.

Follow reference document instruction for recommissioning of the instruments and
components (e.g. pneumatic valve & damper drives, ignitor, etc.)
For the recommissioning of the boiler after a trip of the unit the operator has to make sure that
▪ all failures and disturbances that caused the trip have be resolved,
▪ all automated dampers & valves are in AUTO mode,
▪ all system function groups, sub control groups etc. are properly reinitiated, to be able to
start up the boiler in automatic mode
▪ and all manual dampers & valves are in operation position according to section 2.2 and
following.
After a longer outage accompanied by maintenance work at oil firing or system specific
components it needs to be checked that:
▪ all manholes or inspection openings of the system and its components are safely
closed again
▪ all piping and ducting supports must be deblocked and ready for operation
▪ all insulation on piping, ducting and components must be reinstalled to prevent
personnel hazards due to hot surfaces
▪ all relevant work permits are closed and given back to permit office
▪ manual (control/throttle) valves & dampers are adjusted to the right position according
to the valve list in the following chapter
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

3.2 Preparation for starting
Note
The instructions below have to be followed in cooperation with the local control panel
operator.
The following sections give the instructions to the field operator in order to prepare the systems for
start-up. The tasks described in this section shall be executed in parallel with those of the “control
panel preparation for starting” section.
➢ Wait that local control panel operator has performed the following section and request
field operator actions:
 PART 3 - Field operations - 2.2 Preparation for starting
➢ Perform the following check lists.
➢ Confirm to the local control panel operator that line up is done.
3.2.1 Basic position of valves and dampers

KKS – No Description Position Add. information
HFO-supply
01HFJ60AA001 Isol. Vlv HFO supply open
01HFJ60AA002 Isol. Vlv HFO supply open
01HFJ60AA004 Isol. Vlv HFO return line open
01HFJ60AA052 Throttle Vlv HFO return Approx. To be adjusted during
line 30% commissioning
01HFJ61AA002 Isol vlv return drain closed
LFO supply
01HFJ70AA001 Isol. Vlv LFO supply
01HFJ70AA002 Isol. Vlv LFO supply
01HFJ70AA004 Isol. Vlv LFO return line open
01HFJ70AA052 Throttle Vlv LFO return Approx. To be adjusted during
line 30% commissioning
01HFJ71AA001 Isol vlv return drain closed

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

Atomizing air supply
01HJS01AA001 Isol. Vlv atm air supply open
01HJS01AA601 Drain vlv closed
Instrument air supply

01HJX01AA001 Isol. Vlv instr air supply open
Steam supply
01HJM01AA001 Isol. Vlv steam supply open
01HJM01AA002 Isol. Vlv steam supply open
01HJM01AA003 Throttle vlv supply bypass closed
01HJM01AA601 Drain vlv open
01HJM01AA602 Drain vlv closed
01HJM01AA603 Isol. vlv cond trap open
01HJM01AA604 Isol. Vlv Warm-up line open
01HJM01AA605 Isol. vlv cond trap open
01HJM01AA606 Drain Vlv Warm-up line closed
01HJM01AA607 Drain vlv cond trap closed
Burner 41
Instrument air
01HJX41AT001 Inlet filter open
Atomizing air
01HJS41AA051 Throttle vlv inlet Approx. To be adjusted during
75% commissioning
Cooling air
01HJQ41AA001 Ball vlv cooling air open
steam
01HJM41AA601 Isol. Vlv drain line open
01HJM41AA602 Isol. Vlv drain line Closed
open
01HJM41AA603 Isol. Vlv drain cond trap
01HJM41AA051 Throttle vlv steam supply Approx. To be adjusted during
50% commissioning
Oil
01HJA41AA001 Ball vlv HFO supply open For HFO operation
01HJA41AA011 Ball vlv LFO supply open For LFO operation
Secondary air

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

01HJL41AA051 Secondary air Approx. To be adjusted during
50% commissioning
3.3 Start-up
Note
operator.
➢ Confirm that the local control panels for ignitors and flame scanner are ready for operation
and that all equipment is set to auto mode
➢ Check cleanness of flame scanner
➢ Checks moving equipment start-up (any abnormal vibration, noise or overheating,

leaks…)
➢ Check oil lines for leackages
➢ Check media-supply lines for leackages (air + steam)
➢ Carry on a routine check as per following chapter:
 PART 3 - Field operations - 3.4 Operation routine checks
3.4 Operation
Note
Recommended periodicity for routine checks: (finally to define by plant operator)

1/8h (Once per shift) or 1/24h (Once per day of operation).
Warning
A systematic inspection of the equipment should be made, for faults and signs of
deterioration. Any defects or abnormalities should be reported for attention/
correction.
It’s recommended to the boiler operators to do a walkdown on the boiler in regular intervals to
check the components for proper conditions for boiler operation.
The following checks of the boiler are based on experiences of the operation of comparable plants
In due course the checks are to be adapted to new operational experiences.
General checks:
➢ Check cleanliness and tightness of the pipe network.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING

o Leaks, in particular at oil system
o Loose pipework supports,
o Loose, damaged or oil soaked thermal insulation,
o Vibration
➢ Check instrument panels for :
o Damage to the panel and mounted instrumentation,
o Obviously faulty indications,
o Faulty alarm/indication lamps (where test facility is provided).
➢ Check plant/valve mounted instrument for :
o Damage to instruments or to pipework and cabling,
o Plausibility of pressure and temperature indications
o Obviously faulty indications.
➢ Check for abnormal noises
3.5 Shutdown
Note
operator.
➢ The shut down of the oil firing system or individual oil burner is explained in chapter 2.5
and initiated by the control room operator
➢ In case the outside operator observes potential hazards on an oil burner, he can
shutdown the individual burner by activating the emergency button
➢ After a walk down at the system according to chapter 3.4 the field operator should confirm
to the control room operator the proper shut off of all equipment

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
OIL FIRING
PART 4 – SPECIAL OPERATION
4 PART 4 – Special operation

Contents:
Instructions to the CONTROL PANEL AND FIELD OPERATORS.
➢ Alarms description and troubleshooting
4.1 Alarms description and troubleshooting

Alarms can be issued by different systems and function groups of the air & flue gas system. In the
following tables the designed alarms are listed and described. The list needs to be completed
during commissioning with the final thresholds and may additionally defined alarms and warnings
in the DCS system.
4.1.1 Alarm list
KKS Description interlock criteria Remark / action

Pressure Steam Supply Oil in case P < MIN: check oil supply
01HJM01CP001 Firing > MIN > 10 kg/cm² lines + pumps
T ST SPL OIL FIRING > MIN in case T < MIN: check supply lines,
01HJM01CT901 1 > 120 °C valves

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

2X500 MW Neyveli New Thermal Power Project (NNTPP) Neyveli, Tamilnadu, India

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2x500 MW NEYVELI NEW THERMAL POWER

NEYVELI, TAMILNADU, INDIA

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Operating Manual 148760_00108_7105

Originator Identification number Rev. Date Lang. Sheet

1 PART 1 – General ................................................................................................................ 8

Originator Identification number Rev. Date Lang. Sheet

LIST OF REFERENCE DOCUMENTS

Operation instructions Boiler alarm sheets NLC/01/G4-01-0300/111

System Design Manual:

Firing system process design NLC/00/B/G2-X2-1000/ER/101

Piping & Instrumentation Diagram (P&ID):

P&ID Eco and Evaporator NLC/00/B/G2-X7-11--/FD/001

LIST OF REFERENCE DOCUMENTS

Manual from supplier and partners:

To be completed during commissioning by BHEL

Originator Identification number Rev. Date Lang. Sheet

LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS

Originator Identification number Rev. Date Lang. Sheet

LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS

 Display the corresponding mimic

 See the corresponding section

 Cross check when the action is completed

Note indicates an important instruction or the best practices

Originator Identification number Rev. Date Lang. Sheet

1.2 Purpose of the system

1.3 Health and safety

Any discovered failures and malfunctions should be immediately notified to

Originator Identification number Rev. Date Lang. Sheet

Originator Identification number Rev. Date Lang. Sheet

HAZARDS POTENTIAL CONSEQUENCES MEASURES

Sign giving orders need

Originator Identification number Rev. Date Lang. Sheet

HAZARDS POTENTIAL CONSEQUENCES MEASURES

1.3.2 System specific safety instructions

Originator Identification number Rev. Date Lang. Sheet

HAZARDS POTENTIAL CONSEQUENCES MEASURES

1.4 System delimitations

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

2 PART 2 - Control panel operating instructions

➢ Instructions for start-up preparation.

➢ Instructions for start-up.

➢ Instructions for operation.

➢ Instructions for shutdown.

The oil firing system is started by the group control

To insert during commissioning

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

2.1 Function description

Each of the eight oil burners comprises the following equipment:

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

2.1.1 Fixing of airflows to the oil burner

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

2.2 Preparation for starting

▪ Oil-, steam- cooling air -, instrument air supply available