29.11.

2014

Report On Site Visit To M/s Meghmani FineChem, Dahej

Main Objective
To assess the boilers 1,2 &3 performances during operation at maximum
available plant load. Also to study the operation of boiler # 3 during STG steam
trials by M/s Siemens.
Major Observations
1. Boiler # 3 was operated from 50 TPH (45% BMCR) load to 100 TPH (90%
BMCR) load for various tests in STG.
2. The boiler # 3 was not giving rated main steam temperature at desired
operating condition above 60% BMCR. In order to attain the rated main
steam temperature, the excess air levels had to be maintained above 60%
(O2 % > 7%).
3. The number of compartments in operation was also reduced to 3 at 50
TPH loading.
4. In order to attain main steam parameters at operating conditions,
its recommended to increase the refractory height on the water
walls of furnace during the next available opportunity.
5. Presently the Economiser outlet water temperature is being maintained
at 290 Deg. C against a saturation temperature of 309 Deg. C, Which is the
minimum allowed. This shall be monitored during all operating
conditions and if necessary the HP heater outlet water temperature
reduced further as required.
6. The boiler is forced to operate with 2 PA fans during start ups as the PA
header pressure could not be maintained. This is due to high flow rate of
air due to low bed height. This problem can be overcome by maintaining
850 900 mm WC PA header pressure during start ups.
Recommendations on Boiler controls based on operator feedback
1. During load throw off or when start up vent opened, the drum level in
3E control is not working in auto mode. This is due to the following
a. Presently the weightage for steam flow on 3E control (100% FCV)
is 80% and the drum level is 20% as per the current logic by M/s
CVL. When in an abnormal condition, the operator opens the start
up vent to maintain the boilers pressure, drops the steam flow.

Report By: A Prakash, Boiler Consultant

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 29.11.2014

So the drum level needs to be taken in manual mode to maintain

drum level.
b. A sudden reduction in steam generation is leading toshrinkage in
drum level.
To overcome this problem, during such events, provision shall be
given to switch the 100% FCV to 1E (auto ) control from 3E (auto)
control when there is a drastic loss of boiler load.
2. In STG 1&2, the hot well level control cannot be put in Auto mode until
the DM water make up to hot well valve is in Auto mode. But there is
no further logic for make up valve to maintain hot well level or the
deaerator level. So the operator takes the make up valve back to Man
mode once hot well level control valve is put in Auto mode. This logic
shall be modified as one of the below.
a. Operate the make up valve in Man mode only like in STG 3
logic. The operator shall decide when to open the make up valve
to either fill deaerator or hot well.
OR
b. Modify the logic by adding demand signals from both hot well level
and deaerator level. By creating new PID controllers for deaerator
level. The out put (MV) from deaerator level and the hotwell level
controllers shall be compared and which ever is higher shall be
selected to operate the make up valve. The running feed back of
CEP and hot well level if above set point, is interlocked so that in
such conditions, the valve shall remain closed.
3. The DCS HMI shall be given visual indications of LOLO, LO, HI & HIHI level
signals from electronic water level indicators (Hydrastep) on Boiler
Operation Page.
4. The CEP discharge pressure drops when the hot well level control valve is
opened fully. To avoid this, the valves output (High) shall be locked.
5. Its reported that there is puffing from mixing nozzles while firing dry
coal. By advancing the convergent nozzle further by 20 mm towards
mixing chamber, can reduce this problem.

Report By: A Prakash, Boiler Consultant

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