DEC CFBC Boiler Manual

PROJECT
8 X 135 MW LIGNITE THERMAL POWER PLANT

BHADARESH, DISTT. BARMER, RAJASTHAN - INDIA
OWNER
RAJ WEST POWER LIMITED (RWPL)

RAJASTHAN - INDIA
ENGINEERS
DESEIN PRIVATE LIMITED

NEW DELHI – INDIA
BTG SUPPLIER
DONGFANG ELECTRIC CORPORATION

CHENGDU – CHINA
ORIGINATOR
MANUFACTURER
DONGFANG BOILER GROUP CO., LTD.
ZIGONG – CHINA
Document No.: 39J – SM Rev.: A
Document Title :
OPERATION INSTRUCTION FOR CFB BOILER

Doc.No.: 39J-SM Operation Instruction for CFB Boiler Page 2 of 104 Rev. A
Document No. 39J-SM
OPERATION INSTRUCTION
FOR
CIRCULATING FLUIDIZED BED BOILER

( CFBB )
PREP.
CHKD.
EXAM.
APPD.
AUTD.
REVISION RECORD
REV. REV.SHEET
PAGE REV. REVISIONS REVISED
DATE. No.
All A First Issue
PREFACE
The Circulating Fluidized Bed (CFB) Boiler, whose model is DG440/13.73-II14, is
specially designed and manufactured by DONGFANG BOILER GROUP CO., LTD.
(DBC) for INDAI RAJ WEST POWER LIMITED POWER PLANT. The boiler is a
superhigh pressure 135MWe CFB boiler. This operation instruction is issued to assist
operators of DBC’s equipment in obtaining the best operation results.
This operation instruction is to be used as a guide for operational reference and shall
not take the place of Boiler Operation Specifications.
This operation instruction can only supplement the experience and judgments of
personnel in charge of operation. It shall be interpreted and applied after giving careful
consideration of the requirements of other relative equipment and for any particular
set of circumstances. This operation instruction does not purport to cover all details or
variations of equipment, including every contingency to meet during operation and / or
maintenance.
The recommendations contained in the operation instruction are prepared by DBC

based upon the knowledge and experience gained in the manufacture of CFB boilers,
and they represent our best experience and judgments at present. However, in the
application of this operation instruction to pre-operation, operation and maintenance
of equipment, DBC assumes no responsibility for any failure or incident resulted from
incorrect operation.
As the successful operation and performance depend greatly upon auxiliary systems,
this operation instruction contains some brief descriptions for several vital systems
such as coal feed system, air and gas system, bed material extraction system,
limestone feed system, etc. They shall be understood as the fundamental
requirements of the Boiler and could not be regarded as the sole principles for power
plant design.
Without permission, no one that is not involved in this Project is allowed to make any
copy of this operation instruction.
TABLE OF CONTENTS
DONGFANG BOILER GROUP CO., LTD. .................................................................................................... 1
SECTION 1 CONSTRUCTION DESCRIPTION ............................................................................8
1.1 Design Conditions...................................................................................................................................... 8
1.1.1 Boiler Specifications.............................................................................................................................. 8
1.1.2 Boiler Main Dimensions........................................................................................................................ 9
1.1.3 Fuel.......................................................................................................................................................... 9
1.1.4 Ash Characteristics ............................................................................................................................. 10
1.1.5 Limestone for Desulfurization............................................................................................................... 11
1.1.6 Igniter Type ,Fuel for Ignition and Combustion Support................................................................ 12
1.1.7 Feedwater Quality ............................................................................................................................... 13
1.1.8 Fountain ................................................................................................................................................ 13
1.1.9 Natural Conditions............................................................................................................................ 13
1.1.10 Operation Mode................................................................................................................................. 14
1.1.11 Draft Mode.......................................................................................................................................... 15
1.2 General Description Of DONGFANG Type CFB Boiler .......................................................................... 15
1.2.1 CFB Technology Description................................................................................................................ 15
1.2.2 DONGFANG Type CFB Boiler Process........................................................................................... 17
1.3 General Description of DG440/13.73-II14 ................................................................................................... 19
1.3.1 General Arrangement OF DG440/13.73-II14 Type CFBB ............................................................ 19
1.3.2 Boiler Steam and Water Flow Path .................................................................................................. 22
1.3.3 Boiler Gas and Air Flow Paths ............................................................................................................. 25
1.3.4 Combustion and Circulation Process of the Materials...................................................................... 26
1.3.5 Fuel and Limestone Feed Systems and Ash Removal System ...................................................... 28
1.3.6 Expansion System ................................................................................................................................. 28
1.3.7 Sootblowing System ........................................................................................................................... 29
1.4 Main Equipment of CFB Boiler.................................................................................................................... 30
1.4.1 Economizer .......................................................................................................................................... 30
1.4.2 Steam Drum and Drum Internals ...................................................................................................... 30
1.4.3 Furnace................................................................................................................................................. 30
1.4.4 Cyclone ................................................................................................................................................. 31
1.4.5 The Rear Pass ..................................................................................................................................... 32
1.4.6 LTS ........................................................................................................................................................ 32
1.4.7 Primary Desuperheater ...................................................................................................................... 32
1.4.8 PSH ....................................................................................................................................................... 33
1.4.9 Secondary Desuperheater ................................................................................................................. 33
1.4.10 HTS ........................................................................................................................................................ 33
1.4.11 Reheater Emergence Desuperheater ............................................................................................... 34
1.4.12 LTR......................................................................................................................................................... 34
1.4.13 Reheater Micro Spray Desuperheater .............................................................................................. 34
1.4.14 PRH........................................................................................................................................................ 34
1.4.15 Air Heater .............................................................................................................................................. 35
1.4.16 U Valve .................................................................................................................................................. 35
1.4.17 Ash Cooler.......................................................................................................................................... 36
1.4.18 Ignition System .................................................................................................................................. 36
1.4.19 Abrasion proof and refractory materials ........................................................................................ 37

1.4.20 Boiler Steel Structure........................................................................................................................ 38
1.5 Water Volumes Of Major Boiler Parts: ..................................................................................................... 38
SECTION 2 SAFETY PRECAUTIONS AND PREPARATION FOR OPERATION.........................40
2.1 SAFETY PRECAUTIONS ...................................................................................................................... 40
2.2 HYDROSTATIC TESTS........................................................................................................................... 43
2.3 SOLIDIFYING REFRACTORY MATERIALS ....................................................................................... 47
2.4 BOILING OUT........................................................................................................................................ 47
2.4.1 General ................................................................................................................................................. 47
2.4.2 Recommended Chemicals for Boiling Out....................................................................................... 48
2.4.3 Preparations for Boiling Out............................................................................................................... 49
2.4.4 Boiling Out Procedure......................................................................................................................... 52
2.5 FEEDWATER AND BOILER WATER TREATMENT .......................................................................... 54
2.6 CHEMICAL CLEANING OF ECONOMIZER AND STEAM GENERATING CIRCUIT..................... 55
2.6.1 General ................................................................................................................................................. 55
2.6.2 Determining the Need for Chemical Cleaning................................................................................. 55
2.6.3 Solvent System.................................................................................................................................... 56
2.6.4 General Cleaning Operations ............................................................................................................ 57
2.7 CHEMICAL CLEANING OF SUPERHEATERS & REHEATERS........................................................ 58
2.8 BOILER SYSTEM AIR TEST .................................................................................................................. 58
SECTION 3 OPERATION AND MAINTENANCE .........................................................................60
3.1 GENERAL................................................................................................................................................. 60
3.2 IMPORTANT PRECAUTIONS.............................................................................................................. 60
3.2.1 Furnace doors.................................................................................................................................... 60
3.2.2 Furnace Pressure Limits .................................................................................................................. 61
3.2.3 Drum Water Level and Temperature Difference........................................................................... 62
3.2.4 Safety Valve Adjustment .................................................................................................................. 63
3.2.5 Excess Air Requirements................................................................................................................. 63
3.2.6 Bed Temperature Profile .................................................................................................................. 64
3.2.7 Others.................................................................................................................................................. 65
3.3 COLD STARTUP PROCEDURE ........................................................................................................... 67
3.3.1 Preparation Prior to Startup ............................................................................................................. 67
3.3.2 Purging................................................................................................................................................ 71
3.3.3 Warming the Unit............................................................................................................................... 77
3.3.4 Start-up (Fuel Firing)......................................................................................................................... 81
3.4 HOT RESTART ........................................................................................................................................ 85
3.5 NORMAL OPERATION......................................................................................................................... 88
3.5.1 Combustion .......................................................................................................................................... 88
3.5.2 Boiler feedwater and steam quality .................................................................................................. 90
3.5.3 Sootblowing.......................................................................................................................................... 90
3.5.4 Spray Attemperation ........................................................................................................................... 91
3.5.5 Reheated Steam Temperature Regulation...................................................................................... 91
3.6 NORMAL SHUTDOWN ........................................................................................................................ 92
3.7 EMERGENCIES...................................................................................................................................... 95
3.7.1 Main Fuel Trip (MFT) .......................................................................................................................... 95
3.7.2 Emergency Operating Procedure ................................................................................................... 96
3.7.3 Overpressure Protection .................................................................................................................... 99

3.8 MAINTENANCE ...................................................................................................................................... 99
SECTION 4 ATTACHMENT........................................................................................................103
4.1 Boiler Performance data summary sheet(I) －Performance coal 100%B-MCR condition..................... 103
SECTION 1 CONSTRUCTION DESCRIPTION
1.1 Design Conditions
1.1.1 Boiler Specifications
Boiler capacity: under such conditions as firing performance coal or check coal
stated in item 1.1.3 and limestone stated in item 1.1.4 with the size distribution
specified in fig. 1.1~1.2, design Ca/S molar ratio, rated feed water temperature, rated
main steam temperature, rated pressure and acceptable steam quality, the boiler
maximum continuous rating is 440 t/h at least.
The boiler maximum continuous rating (BMCR) is corresponding to turbine regulating

valve whole open (VWO) condition.
Pressure, temperature and flow of main superheated steam, reheated steam and
feeder water of the CFBB can match with turbine parameters.
Boiler Type: DG440/13.73-II14
BMCR
Maximum Steam Flow 440t/h
Superheat Steam Outlet Pressure 13.73MPa(g)
Superheat Steam Outlet Temperature 540℃
Reheat Steam Outlet Temperature 540℃
Reheat Steam Outlet Pressure 2.57MPa(g)
Reheat Steam inlet Temperature 320℃
Reheat Steam inlet Pressure 2.73MPa(g)
Reheat Steam Flow 356.114t/h
Feedwater Temperature 248.6℃
Notes: Above mentioned (g) indicates gauge pressure.

1.1.2 Boiler Main Dimensions
Furnace Width (Between CL of Side Walls) 17170mm

Furnace Depth (Between CL of Front & Rear Walls) 7492mm
Elevation of Steam Drum CL 48370mm
Elevation of Boiler Top 54500mm
Boiler Width 31400mm
Boiler Depth 37100mm
1.1.3 Fuel
Performance coal in this project is asphaltite, a local reserve in the region. The coal
analysis data are as follows:
Item Symbol Unit Performance Coal Worst Coal

Sulfur as received Sar % 1.2 0.5
Hydrogen as received Har % 2.5 1.4
Carbon as received Car % 30 22.2
Nitrogen as received Nar % 0.3 0.3
Oxygen as received Oar % 9.3 7.6
Ash as received Aar % 11.7 30
Total Moisture Mt % 45 38
Volatile matter as dry
Vdaf % 25 20
and ash free
HHV as received Q Cal/kg 2900 2001
Coal Size Distribution：dmax=12mm；d50=1.8mm. (See Fig. 1.1：Coal Size
Distribution Curve).
Notes: To achieve optimum conditions for the CFB combustion process, the
solid fuel has to be prepared with respect to maximum particle size and
grain size distribution. The recommended coal size distribution is based on
both the balance of solid and emission, which can achieve optimum
combustion and a reasonable emission. Solid fluidizing velocity selection is
based on coal size, and fluidizing velocity defines furnace section. So the
coal size is a most important parameter. If the inlet coal size is too large, it
will affect stable operation of the ash-cooler and lead to higher carbon
content in bottom ash; on the contrary, it will lead to higher carbon content
in fly ash.
Fig. 1.1 Coal Size Distribution Curve
1.1.4 Ash Characteristics
Compositions of ash (with no limestone sophisticated)

Composition Symbol Unit Performance Coal
Silicon dioxide SiO2 % 50～70
Aluminum trioxide Al2O3 % 10～30
Ferric trioxide Fe2O3 % 2～6
Titanium oxide TiO2 % 1～2.5
Calcium oxide CaO % 0.56～10
Kalium oxide K2O % 0.05～0.3
Sodium oxide Na2O % 0～14.2
Magnesia MgO % 0.4～14.83
Sulfur trioxide SO3 % 0～10

Chlorid Cl % 0.01～0.25
1.1.5 Limestone for Desulfurization
Limestone is used in this project for desulfurization. Limestone analysis data are as
follows:
Composition Symbol Unit Value

Loss of combustion L.O.I ％ 42.4～43.2
Calcium Carbonate CaCO3 ％ 95～97
Sodium Carbonate MgCO3 ％ 0.3～0.75
Silicon dioxide SiO2 ％ 0.8～1.4
Aluminum trioxide Al2O3 ％ 0.4～0.6
Ferric trioxide Fe2O3 ％ 0.1～0.24
Calcium oxide CaO ％ 53.95～54.6
Magnesia MgO ％ 0.2～0.6
Limestone Size Distribution：dmax=1.5mm；D50=0.45mm. (See Fig. 1.2：
Limestone Size Distribution Curve).
Notes: After limestone powder is injected into the furnace, it is reacted with
SO2 and removes SO2, to guarantee the effective and economical operation
of boiler. The proper limestone size distribution is very important. If the
limestone particle is too coarse or too fine, it will affect the circulation
procedure. The too coarse particle will lead to increased limestone
consumption and will make bed temperature lower than normal value and
bottom ash quantity higher than design value; and the too fine limestone
particle will lead to its inadequate residence time in main circulating loop to
make limestone consumption increase and fly ash quantity higher than
design value.
Fig. 1.2 Limestone Size Distribution Curve
1.1.6 Igniter Type ,Fuel for Ignition and Combustion Support
The boiler is equipped with four (4) in-duct diesel oil burners , six (6) over-bed heavy
oil burners which are located at the side waterwall, The over-bed heavy oil burners
can be only used to support the combustion at low load.
The in-duct burners firing diesel oil are only used for the low load combustion
support.
The diesel oil analysis data are as follows:
Item Unit Value

Kinematic viscosity(40℃) cSt 2.5 to 15.7
Density (15℃) (approximation） kg/m3 850 - 870

o
Flash piont (min) C 66
o
Pour point (max) C 12(winter），21 (summer)
Water(max) % vol. 0.25
Sediment and Water (max) % wt 0.10
Sulphur (max) % wt 1.8

Item Unit Value

Ash (max) % wt 0.02
HHV（approximation） Kcal/kg 10,000
1.1.7 Feedwater Quality
Make-up water: one stage desalination and blend bed.
Boiler normal continuous blowdown rating: 0.3-1%
Boiler water and steam quality shall be in compliance with the requirements of
superhigh pressure boiler in the “Quality criterion of Water and Steam for
generating unit and Steam power equipment “ (GB/T12145-1999).
Item Feedwater
8.8~9.3
PH value
Full salinity /
hardness ≤2.0μmol/L
Hydrazine (N2H4) 10-50μg/L (Volatility treatment)
Dissolved oxygen (O2) ≤7μg/L
Fe ≤20μg/L
Cu ≤5μg/L
Oil ≤0.3mg/L
1.1.8 Fountain
The fountain of this power plant is from IGNP River .
1.1.9 Natural Conditions
Power plant address Bothya city of Rajasthan, Indian

height above sea level ～184m
Maximum daily average temperature in
40℃
May
Minimum daily average temperature in

12℃
December
Maximum daily temperature 34.5℃
Minimum daily temperature 20.7℃
Recoding Maximum temperature 48.9℃
Recoding Minimum temperature -1.7℃
Humidity 23～79
Maximum precipitation from July to
263mm
September
Annual wind speed 8.5kmm/h
Maximum wind speed 24km/h
Basic wind speed 47 m/s
Modulus K1 1.07
Seismic zone in India 1
Modulus K3 According to IS:875
1.1.10 Operation Mode
1) Load characteristic: The boiler will operated under normal load and can regulate
peak load. The boiler can meet double shift operation requirements.
2) Coal feeding system: Two-stage crushing plus screen system is adopted in this
project to satisfy requirements of coal size distribution.
3) Feed water regulating: Two (2) 100% BMCR motor-driven feed water pumps.
4) Bypass system: Two in-series stage bypass system with capacity of 60%BMCR.
5) Bottom ash removal: Bottom ash is discharged continuously or periodically

through ash cooler.
6) Air heater shall not be arranged in the inlet duct of air preheater.
7) The available average operating hours are more than 7500h per year.
8) Compressed air pressure: 0.5~0.7MPa; electric voltage: AC 400V/230V; DC 220V;

motor protection degree: IP54.
1.1.11 Draft Mode
Balanced draft is adopted for this boiler. The balance point of draft system is set at
the top of furnace (cyclone inlet).
1.2 General Description Of DONGFANG Type CFB Boiler
1.2.1 CFB Technology Description
As a cleaning coal combustion technology, the Circulating Fluidized Bed (CFB)

technology has been successfully used in boilers all over the world since 1980’s.
The various types of solid fuel combustion systems historically available, such as
stokers, pulverized fuel, and cyclone-fired boilers have distinct and specific
advantages and disadvantages. A few of the disadvantages that are common to each
of them in varying degrees are: Low residence time of fuel in the combustion zone
(except stokers) requires high combustion temperatures to assure adequate
combustion efficiency without excessive unburned carbon losses. High temperatures,
usually more than 980°C, contribute to the formation of nitrogen oxides, which are
environmentally objectionable. High combustion temperatures also dictate the use of
post-combustion treatment scrubbers for removal of sulfur dioxide (SO2). When the
combustion temperature is maintained between 850°C and 900°C, SO2 removal can
be accomplished by injecting limestone (CaCO3) directly into the furnace. The low
ash fusion temperature of many solid fuels goes against the adoption of conventional
combustion systems because the higher combustion temperatures result in the
formation of slag on boiler heat transfer surfaces. The need to overcome these
difficulties when using low-grade fuels has led to the development of fluidized bed
combustion systems. Presently, there are two distinct types of fluidized bed boilers in
commercial operation: bubbling bed and circulating bed.
1.2.1.1 Bubbling Bed
In the bubbling bed-type boiler, a layer of solid particles (mostly limestone, sand, ash
and calcium sulfate) are concentrated on a grid near the bottom of the boiler. This
layer is maintained in a turbulent state as low velocity air is forced into the bed from a
plenum chamber beneath the grid. Fuel is added to this bed and combustion takes
place. The combustion air velocity of is kept at a minimum value, but it is quite
enough to maintain turbulence in the bed. This velocity is not high enough to carry
significant quantities of solid particles out of the furnace. This turbulent mixing of air
and fuel results in a residence time of five seconds. The combination of turbulent
mixing and residence time permits bubbling bed boilers to operate at a furnace
temperature below 890°C. At this temperature, limestone is mixed with fuel in the
furnace to achieve over 90% sulfur removal. Boiler efficiency is the percentage of
total energy in the fuel that is used to produce steam. Combustion efficiency is the
percentage of complete combustion of carbon in the fuel. Incomplete combustion
results in the formation of carbon monoxide (CO) in the flue gas plus unburned
carbon in the solid particles leaving the furnace. In a regular bubbling bed boiler,
combustion efficiency can be up to 92%, with its unburned carbon loss component of
kept within the range of 2% to 5%. This is a good figure, but it is lower than that
achieved by pulverized fuel or cyclone-fired boilers. In addition, some fuels that have
very low volatile matter cannot be completely burned within the solids residence time
in bubbling bed-type boilers.
1.2.1.2 Circulating Fluidized Bed (CFB)
The need to improve the fluidized bed combustion efficiency (which also increases
overall boiler efficiency and reduces operating costs) and the desire to burn a wider
range of fuels has led to the development and application of the circulating fluidized
bed (CFB) boiler. Through the years, boiler suppliers have been increasing the size
of these high-efficiency steam generators. The CFB process offers the means for
efficiently burning a wide variety of fuels while maintaining low emissions. Fuel is fed
to the lower furnace where it is burned in an upward flow of combustion air. Fuel, ash,
and unburned fuel carried out of the furnace are collected by a separator and
returned to the lower furnace. Limestone, which is used as sulfur sorbent, is also fed
to the lower furnace. Furnace temperature is maintained in the range of 850°C to
950°C by suitable heat absorbing surface. This process offers the following
advantages:
Fuel Flexibility – The relatively low furnace temperatures are less than the ash
softening temperature for nearly all fuels. As a result, the furnace design is
independent of ash characteristics, which allows a given furnace to handle a wide
range of fuels.
Low SO2 Emissions – Limestone is effective sulfur sorbent in the temperature range
of 850°C to 950°C. SO2 removal efficiency of 95% or even higher has been
demonstrated along with good sorbent utilization.
Low NOx Emissions – Low furnace temperatures (850°C to 950°C) plus staging of air
feed to the furnace produces very low NOx emissions.
High Combustion Efficiency – The long solids residence time in the furnace resulting
from the collection/recirculation of solids via the cyclone, plus the vigorous solids/gas
contact in the furnace caused by the fluidization airflow, results in high combustion
efficiency, even with difficult-to-burn fuels. The unburned carbon loss component of
the combustion efficiency is typically in the range of 1% to 2%.
1.2.2 DONGFANG Type CFB Boiler Process
The major components of a DONGFANG CFB boiler are :
z The solids circulation loop, comprising the furnace, the cyclones, “U” valves.
z The rear pass.
In the CFB process, combustion and desulphurization take place within a large mass
of highly agitated fine ash particles bed at a relatively low temperature (close to 850 –
900°C) depending upon the fuel reactivity. This temperature is chosen to facilitate the
increase of combustion rate and desulphurization efficiency for the coal considered.
The bed temperature of this boiler is 897℃.
These particles or "solids" are held in suspension (fluidized) section by an upward

flow of air blown into the bottom of the furnace as the primary air through the
fluidization nozzles. The secondary air is fed into the furnace at two levels, thus
realizing staged combustion.
The bed completely fills the furnace volume (its density, high in the lower part, rapidly
decreases with height). The separation of solids from the gas solids stream at the top
of the furnace is ensured by means of cyclones.
The balance of solids is ensured by directly recirculating the solids separated from
the gas solids stream to the lower part of the furnace through material recycle
equipment (“U” valve). These “U” valves are installed to ensure that any gas flows
directly from the furnace to the cyclones.
The fluidization regime in CFB loop is characterized by very strong agitation and
mixing, high solids internal and external recirculation, high gas/solids slip velocity
and long residence time due to the high efficiency of cyclones.
All these result in excellent conditions regarding heat transfer and chemical
reactions.
The flexibility induced by the process allows burning a wide range of fuels
("opportunity fuels"), with a single design adopted.
Regarding depollution, the CFB boiler has very good performance due to the
following reasons:
The CFB boiler is able to remove sulfur dioxide directly in the furnace. This is
accomplished by contact between sulfur oxide and the calcium oxide contained in the
coal ashes or in the added limestone. The limestone is calcined in the furnace to
form calcium oxide (CaO) and then reacts with the SO2 to form calcium sulfate,
shown as follows:
CaCO3 Æ CaO + CO2

CaO + SO2 + ½ O2 Æ CaSO4
This reaction takes place preferably at 850-900°C, which can be kept under a wide
range of operating loads.
Further, the staged combustion and the relatively low combustion temperature
reduce NOx formation to a large extent.
So, CFB process offers:
z an intense internal mixing of the particles (fuel, limestone, hot ashes

constituting the bed)
z a homogeneous temperature in the bed
z a long residence time of the fuel in the furnace
z the possibility to keep the temperature within the optimum range of SO2
capture by the limestone
The combination of these characteristics offers the following advantages in terms of

performance:
z high carbon burnout
z high desulphurization efficiency
z low NOx emission
z high flexibility of operation.
1.3 General Description of DG440/13.73-II14
1.3.1 General Arrangement OF DG440/13.73-II14 Type CFBB
DG440/13.73-II14 CFB boiler adopts single drum, natural circulation, circulating

fluidized bed combustion and full enclosure structure, which is mainly composed by
membrane waterwall furnace, two plate cyclones and the rear pass.
The boiler adopts membrane wall furnace. Inside the furnace, eight platen
superheaters, four platen reheaters and one split waterwall are arranged. Six coal
feeders and four limestone feeding inlets are arranged on the lower front waterwall.
The bottom of the furnace is a water-cooled air plenum enclosed by the waterwall
tubes, connecting with the primary air ducts which are at each side of the boiler.
There are two induct burners in each PA duct. The burners are equipped with high
energy ignitor. And six over-bed burners are arranged above the grid for low load
combustion support. In the rear of the furnace, two rolling ash-coolers are arranged.
Between the furnace and the rear pass, two plate cyclones lined with refractory are
arranged. At the bottom of each cyclone, a non-mechanical “U”-valve seal device is
installed. The dual-element convection rear pass (double flue) is adopted for the
steam-cooled rear pass in the RH and SH area. The cold reheater is arranged in the
front flue and the hot superheater & cold superheater are arranged in the rear flue.
After that the two gas streams will become one stream and pass through economizer.
Then gas is divided into two streams to go through tubular air heater. The air heater
is of double in-let and out-let arrangement along the boiler width direction. Two stage
spray water will be adopted to the superheater system and damper regulation is
adopted to the reheater system. And emergency and micro spray water
desuperheaters are adopted for the safety guarantee of the reheater system.
The boiler is symmetrically arranged from right to left and is suspended or supported
from the boiler steel structure. The steel structure consists of columns, beams and
bracings.
Fig. 1.3 Side view of Boiler

Fig. 1.4 Plan View of Boiler
1.3.2 Boiler Steam and Water Flow Path
Single unit system is adopted in main steam, reheater steam and feeder water
system. And double in-let-and-out-let connection is adopted in main steam and
reheater steam pipe arrangement.
Feedwater is sent to the two sides of economizer inlet header in the rear pass. It
flows upstream and passes the horizontally arranged economizer tubes. Collected in
the outlet header of economizer, it is routed by the connecting pipe into the drum
from the drum head. In the period of boiler start-up, no continuous feedwater flows
into the drum. Economizer recirculation system can direct boiler water from the drum
to the inlet header of economizer, preventing water from steaming in the economizer
tubes.
Fig. 1.5 Steam and Water Flow
The DG440/13.73-II14 CFB boiler is of natural circulation. Boiler water circulation

system adopts centralized downcomers and decentralized feeders and risers. Water
from Economizer is directed into the water space of drum, then it enters into the
waterwall inlet header by the downcomers and feeders. Water is heated to the
mixture of steam/water and flows upward through the furnace waterwall and split
waterwall. Out of the waterwall outlet header, the mixture of steam/water is routed by
risers into the drum for steam/water separation. The split waterwall forms an
independent circuit with the separate feeder and riser for the safety and reliability of
water circulation. The separated water reenters the water space in the drum and
circulates again. The separated saturated steam is directed out from the steam
connecting pipe on the top of the drum.
Coming out of the drum, the saturated steam is directed to the upper header of the
side wall of the rear pass area by the connecting pipe. Then it passes the front, rear
walls and middle wall of the rear pass area and joins in the inlet header of low
temperature superheater (LTS). After flowing through the tubes of LTS, it is directly
induced into the platen superheater (PSH) in the upper furnace by the connecting
pipe. Passing the PSH, it returns to the high temperature superheater (HTS) in the
rear pass. At last, the steam with the rated pressure and temperature is directed out
from two ends of the outlet header of hot superheater.
The superheater system adopts spray desuperheating as a method for temperature

control and protection of heating surface tubes. The whole superheater system is
arranged with two stages of spray attemperation. The primary desuperheaters (on
the connection pipes of each side of the boiler) are arranged on the connecting pipe
from the LTS to the PSH for coarse adjustment. The secondary desuperheaters (also
on the connection pipes of each side of the boiler) are located on the connecting pipe
from the PSH to the HTS for fine adjustment. In the two stages of spray
attemperation, the quantity of spray water on each side can be adjusted
independently to eliminate the steam temperature difference on the right and left
sides.
The cold reheated steam coming from HP of turbine is induced into the low
temperature reheater (LTR) located in the front flue in the rear pass. After flowing
upward through two banks, it is directly induced into the platen reheaters (PRH) in
the upper furnace by connecting pipe. Heated by the PRH, the reheated steam with
the rated pressure and temperature is induced into MP of turbine.
The reheated steam temperature can be adjusted through regulating gas damper
located at the back of the double flue to adjust gas flow through RH flue. It’s a main
method to regulate RH temperature. The RH spray system is also used for faster
adjustment and the safety guarantee of the RH system. The whole reheater system
is arranged with two stages of spray attemperation. The primary desuperheaters (on
the connection pipes of each side of the boiler) are arranged on the inlet connecting
pipe of the LTR for emergence condition. The secondary desuperheaters (also on the
connection pipes of each side of the boiler) are located on the connecting pipe from
LTR to the PRH for faster and more precise adjustment. In the two stages of spray
attemperation, the quantity of sprayed water on each side can be adjusted
independently to eliminate the reheater steam temperature difference.
1.3.3 Boiler Gas and Air Flow Paths
Material circulation in the CFB boiler is started and maintained by forced-draft fans
(including primary and secondary air fans) and induced-draft fans.
Air from the primary air fan is sent into the furnace though three paths:
The first path: Hot air after the primary air heater enters into the water-cooled air
plenum at the bottom of furnace. The air coming out of nozzles on the air distributor
fluidizes bed materials. Gas and solid-phase flow is formed, which goes upward
through the furnace.
The second path: Hot air after the primary air heater is pressurized by the blower and
is directed as coal-distributing medium to the air-swept coal spouts.
The third path: Cold air induced before the primary air heater is used as the sealing
air for the belt coal feeders.
Air from the secondary air fan is sent to the furnace from the two layers of overfire
airports on the front and rear walls after the secondary air heater.
Gas and entrained solid particles exit the furnace from the outlet on the upper rear
waterwall and enter into the cyclone from the cyclone inlet flue. In the cyclone, most
of the solid particles are separated from the gas. Cleaned gas is induced out from the
discharge pipe (inner barrel) of the cyclone and directed to the rear pass by the
cyclone outlet flue. It flows into the rear pass from the inlet on the front wall and
sweeps across the LTR, HTS, LTS, economizer and air heater, transferring heat to
the heating surfaces. Then, the gas is routed through the dust collector and finally
sent into the stack by the induced-draft fan and emitted into the atmosphere.
The U-valve seal device is equipped with three blowers with high-pressure head. The
output of each blower is 50% of the total air needed of the U -valve seal device. In
normal operation, two blowers are in service and one blower is standby. The blowers
are of constant volume type. The air flow is adjusted through bypass pipe to the
primary air path.
The boiler is of balanced-draft type. The “balance pressure point” is located at the top
of the furnace.
Full enclosure structure is adopted to this boiler. The operation floor elevation is
9.0m.
Fig. 1.6 Diagram of Air and Gas Flow, Fuel, Limestone, Ash systems
1.3.4 Combustion and Circulation Process of the Materials
The cold start-up procedure of boiler is as follows:
Feed the start-up materials to the bed and “U” valves;
Start the in-duct burner and send the heated combustion air with the temperature of
870℃ to the furnace through the water-cooled air distributor for heating the start-up
materials.
As the bed temperature reaches 540℃ and remains stable, the crushed 0～12mm
coal particles are sent into the dense-phase zone of the furnace from the six coal
feeders and the crushed limestone particles for desulphurization are sent into the
furnace from the limestone feeding inlets.
Under the rated load condition, the primary air (about 40% of the total combustion air)
passes through the water-cooled air plenum and enters into the furnace as
combustion air and fluidizing medium of materials in the bed. The secondary air is
directed into the furnace from the two layers of overfire airports on the front and rear
walls to guarantee enough combustion air for coal particles and participate in the
adjustment of combustion. At the same time, the staged secondary air can produce
local reducing atmosphere in the furnace and inhibit oxidation of nitrogen in the fuel
so as to decrease generation of NOx.
At the bed temperature of 864℃, air fully mixes with fuel and limestone in the
dense-phase zone at the lower furnace. Firing of coal particles releases a part of
heat. CaCO3 is calcined to produce CO2 and CaO; the unburned coal particles are
entrained by gas in the diluted-phase zone at the upper furnace for further
combustion. The upper furnace is also a main desulphurizing zone, where CaO and
SO2 produced by combustion react to produce CaSO4.
The gas entraining rich solids passes through the furnace from two gas outlets on the
upper rear water wall. Then, it enters into two plate cyclones for the solids and gas
separation.
After leaving the plate cyclones and vortex finders, separated hot flue gas passes
through the refractory lined cross-over duct and enters into the top of the dual-flue
rear pass of the boiler. The flue gas splits and flows into the superheating section and
the reheat steaming section. The gas flow distribution of the two sections is decided
by dampers at the outlet of each section. As flue gas flows downward in this steam
cooled section, heat is transferred from the hot flue gas into the reheat steam and
superheat steam. The economizer is located directly below these steam sections. Air
heaters are located in the back of the rear pass. The horizontal tubular air heaters
are devices that heat primary/secondary air before it enters the boiler. Air is heated
as it passes inside the tubes, and the hot flue gas gives up its heat as it flows outside
the tubes. At the outlet of the boiler, gas temperature has decreased to about 149℃.
The separated solids by the cyclone are reinjected by means of the non-mechanical
“U”-valve seal device back to the furnace for circulating combustion.
On the rear wall of the lower furnace, two bed material drain ports are arranged. By
controlling the flow of ash extraction, the bed and furnace pressure profiles are kept
within the design limits to guarantee the good operation of boiler.
1.3.5 Fuel and Limestone Feed Systems and Ash Removal System
Six (6) coal feeders and four (4) limestone feed points are located at furnace front
wall. Four (4) bed material feed points for start-up are located in U-valve, which are
used to feed bed material when boiler start-up or to add bed material during
operation if necessary.
The bed ash from furnace is drained down to two (2) rolling ash coolers. A bed ash
removal system is connected to the rolling slag cooler ash outlet, the rear pass ash
drain (below air heater) and the ESP ash drain.
1.3.6 Expansion System
The expansion centers (fixed points) are designed according to the features of boiler
arrangement and supporting structure. This boiler has seven zero expansion points,
such as:
z The center line of furnace rear wall
z The center line of cyclone support (two points)
z The center line of u valve support (two points)
z The center line of rear pass front wall
z The center line of air heater support.
Each expansion system is expanded outwards from its fixed points through the
limitation and guide equipment. At the same time, the guide equipment of thermal
expansion will transfer wind and seism load to the steel structure.
The furnace waterwall and the rear enclosure wall expand downwards as they are all
hung onto the top plates. The furnace expands from the furnace center line (fixed
point) toward two sides through the expansion control devices. The rear pass heating
surfaces expands from boiler center line (fixed point) toward two sides through the
expansion control devices also. Material recycle equipment, cyclone and air heater
expand upwards from their supporting bases, and symmetrically expand onwards
and backwards, leftwards and rightwards.
There is a large temperature difference between furnace, Cyclone and “U” valve. And
the expansion ratios of the materials for these parts are not the same. So Cyclone
and U valve are supported on the corresponding steel structures respectively. Due to
their large expansion differences and huge dimensions, non-metal expansion joint is
adopted between furnace and cyclone. Metal expansion joints are adopted between
U valve orifice and furnace and between cyclone cone section outlet and U valve to
absorb expansion difference.
The expansion indicators shall be located inside the boiler proper.
1.3.7 Sootblowing System
A complete set of automatic sootblowing equipment is provided to clean the

superheater, reheater and economizer installed in the rear pass and the air heater
elements during operation of the boiler.
Steam for the sootblowers is taken from the outlet header of the low temperature
superheater. The tube socket specification is φ60×6. The steam parameter for
sootblower is 14.1MPa（g）and 487℃ at BMCR condition. There is a pressure
reducing station in the sootblowing system
The sootblowers are suitable for fully programmed operation or individual operation.
The blowing sequence can be optimized by the operator in such a way that the
overall sootblowing period is reduced to a minimum.
Taking into consideration the maximum prevailing flue gas temperature at the place
of installation, retractable blowers or rotating blowers may be used.
Long-retractable, part-retractable or rotating steam sootblowers are arranged on two

sides of the rear pass for cleaning the high temperature superheater, low
temperature reheater and economizer surfaces.
1.4 Main Equipment of CFB Boiler
1.4.1 Economizer
The economizer located in the rear pass consists of two (2) banks of φ42
spiral-finned tubes, which adopt two runs and in-line arrangement. The material of
tube is 20G.
Normal anti-abrasive methods are adopted to protect economizer tubes. Plates are
installed at the inlet of the ECO around the flue to make the gas distribute uniformly.
Feedwater enters the lower inlet header and flows upward through the outlet header,
and is piped to the feed end of the steam drum.
1.4.2 Steam Drum and Drum Internals
The steam drum is located in front of the upper furnace and across the width of
furnace. The steam drum serves as a container of series of steam-water separaters
and a water reservoir for the steam generation circuits. The drum contains
steam/water separating equipment and internal piping for distribution of chemicals to
the water, for distribution of feedwater and for blowdown. The inside diameter of
steam drum is 1600mm, and the straight section of its shell is 12.3m long.
1.4.3 Furnace
The furnace is a 17170mm width × 7492mm depth combustion chamber consisting

of front, rear, side waterwalls and split waterwalls.
At the bottom of the furnace, the front wall splits to form both the plenum floor and the
fluidized bed grid floor. Together with side walls, they form the water-cooled air
plenum. The water-cooled air plenum is lined with refractory to protect the tubes from
being eroded 870℃ high temperature gas. The grid floor is made up of internal
ribbed tubes (φ82.55) plus flat bar. Nozzles are fixed on the bar to insure the uniform
distribution of the primary air and the bed materials and at the same time, to sweep
coarse solid particles and sundries toward to the discharge port. The elevation of the
grid floor is 7000mm.
The furnace is divided into lower, middle and upper part. The longitudinal section
view of lower furnace is trapezoid-shaped as the lower front and rear wall intersects
with the horizontal plane at an angle of 72° . The tube spacing for front wall (and roof),
rear wall and side walls is 80 (φ60 tubes). Combustion occurres mainly in lower
furnace, where the bed material is most dense and most active. Total air and fuel
needed for the combustion are sent to the combustor through this part. Besides the
primary air is induced through the grid into the lower part, the staged secondary air is
also fed in.
Six (6) fuel feed points and four (4) limestone feed points are located on the front wall
of the furnace. The middle and upper waterwalls are also made up of membrane wall.
At the top of furnace, the front wall bends toward the rear wall to form the furnace
roof which terminates in the upper header.
Abrasion resistance material is laid on the lower high density zone waterwall and split
waterwall. And it is also laid on all the areas near the gas outlet of upper furnace.
1.4.4 Cyclone
2 cyclones with internal diameter 7.5m are arranged between the furnace and the
rear pass. They are made of carbon steel sheets lined with refractory material. The
upper part is columnar, and the lower part is coniform. Gas outlet (vortex finder) is of
columnar plate structure with open ends. Gas and solid is separated in the cyclone.
The clean gas leaves the cyclone through the vortex finder and the solids enter into
the material recycle equipment directly to be fed into the furnace again.
The vortex finder is made of RA-253MA, anti-abrasive high strength steel.
Purge air nozzle are located in the inlet duct of cyclone to avoid ash buildup during
low load operation or shutdown. The purge air is stopped when the boiler is operating
under normal condition. Purge air is from boiler compressed air.
1.4.5 The Rear Pass
The rear convection pass has a 11811mm×6350mm section. The upper part of the
rear pass is made up of enclosure wall superheater. The rear shaft is divided by the
middle enclosure wall into two sections (the front flue and the rear flue). Here, the
bottom elevation of enclosure wall is 36040mm, below which the rear shaft is clad
with steel plates. The rear pass houses the horizontal banks of air heater, convection
economizer, LTS, HTS and LTR.
All enclosure walls are connected through inlet and outlet headers. The rear pass
front wall top tube spacing is increased from 127mm to 381mm to form a flue gas
inlet passage. The front and rear wall top tubes bend toward the middle wall to form
the rear shaft roof. The tube specification of the front, middle, rear walls and side
walls is φ51, and the specification of hanging tubes for the front and middle wall
screens is φ 63.5.
1.4.6 LTS
LTS is located in the lower rear flue of the rear shaft, and consists of 92 pieces of
dual loop horizontal tubes (φ51) arranged in line across the width of the boiler
(counter to the gas flow).
The bank is fixed on the enclosure wall through the fixture and expands together with
the enclosure wall.
Normal anti-abrasive methods such as wearing plates are adopted to protect LTS
tubes. The distribution plates are also installed at the inlet of LTS around the flue to
make the gas distribute uniformly.
1.4.7 Primary Desuperheater
The primary spray water desuperheater is located in the steam connecting pipe
between LTS outlet header and PSH inlet header. The desuperheater is equipped
with a mixing liner and spray water piping. The liner is installed at the downstream of
the spray piping to protect the desuperheater shell from thermal shock. Instruments
are installed in spray water piping to measure the water flow and the water
temperature ahead of the desuperheater.
1.4.8 PSH
PSH (8 pieces) is arranged at the upper furnace near the front wall. PSH is
membrane wall construction with tube spacing of 63.5mm. Each platen consists of 43
tubes (12Cr1MoV, φ51). Below the elevation 23715mm, the platen superheater is
lined with refractory. The whole platen superheater expands upwards.
An outlet header (φ325) is located at the elevation 43666mm.
1.4.9 Secondary Desuperheater
The secondary spray water desuperheater is arranged in the steam connecting pipe
between PSH outlet header and HTS inlet header located at the rear wall of the rear
shaft. The superheated steam temperature is further controlled by the secondary
desuperheater. The construction of secondary desuperheater is basically the same
as that of the primary desuperheater.
1.4.10 HTS
Steam from the secondary desuperheater flows through connecting pipe into the
HTS, which is located at the upper rear flue of the rear shaft. The steam is introduced
into two ends of HTS inlet header and after flowing across HTS tube banks (counter
to the gas flow) goes into HTS outlet header, and then flows into the main steam pipe
from the two ends of the outlet header.
HTS is located in the upper rear flue of the rear shaft, and consists of 92 pieces of
dual loop horizontal tubes (φ51) arranged in line across the width of the boiler
(counter to the gas flow), which is divided into two banks (HTS1 and HTS2).
1.4.11 Reheater Emergence Desuperheater
The reheater emergence desuperheater is located in the upstream of LTR inlet

header to protect RH from excessive high temperature. The desuperheater is similar
to SH desuperheater. Instruments are installed in spray water piping to measure the
water flow and the water temperature ahead of the desuperheater.
1.4.12 LTR
LTR is located in the front flue of the rear shaft, and consists of 92 pieces of trinary
loop horizontal tubes (φ51) arranged in line across the width of the boiler (counter to
the gas flow).
The bank is fixed on the enclosure wall through the fixture and expands together with
the enclosure wall.
Normal anti-abrasive methods such as wearing plates are adopted to protect cold
reheater tubes. The distribution plates are also installed at the inlet of the cold
reheater around the flue to make the gas distribute uniformly. The first row of tubes
facing the gas is covered by wearing plates.
1.4.13 Reheater Micro Spray Desuperheater
The reheater micro spray desuperheater is located in the steam connecting pipe
between LTR outlet header and PRH inlet header, which is used to regulate reheater
steam temperature together with gas dampers. The desuperheater is similar to SH
desuperheater.
1.4.14 PRH
PRH is arranged at the upper furnace near the front wall, which consists of 4 pieces.
PRH is membrane wall construction with tube spacing of 89mm. Each platen
consists of 29 tubes (φ76mm). Below the elevation 28782mm, PRH is lined with
refractory. The whole PRH expands upward.
The specification of its inlet header is φ508mm, and the specification of its outlet
header is φ457.2mm.
1.4.15 Air Heater
The air heater adopts horizontal, in line and four-loop arrangement, which is located
in the lower part of the rear shaft. Air flows inside the tubes while gas flows outside
the tubes.
For each loop, 1-1/4 inch tubes are adopted to its upper two rows of tubes and the
right and the left sides of tubes, the other tubes are φ40mm tubes. Q215-A tubes are
used for the upper three tube banks, and 09CuPCrNi-A tubes are used for the lower
part of the fourth bank
The transverse spacing and longitudinal spacing of each tube bank are 80mm and
60mm respectively. The primary and secondary tube banks are arranged in two
parallel lines. Each two tube banks are connected by air duct to form two
independent paths. The primary air and the secondary air are supplied by
independent fans, and they go through their air ducts and heated by the flue gas
which flows across the tube banks. The primary and secondary air ducts are of
double inlet and outlet configuration and arranged along the width direction of the
boiler. The air temperature at the outlets is 290℃.
1.4.16 U Valve
The solids from the cyclone flow through U valve seal device. There are two U valves
which are arranged below the cyclone and supported on the beams of boiler steel
structure. The expansion joints are located between the cyclone to U valves and U
valves to the furnace. U valves have two functions: one is to reinject solids into
furnace continuously and steadily to realize the balance of materials; the second is to
provide sealing between the cyclone (negative pressure) and the furnace (positive
pressure).
The outlet duct of each U valve is divided into two parts. So the solids from each U
valve return to the furnace by two passes, ensuring that the solids return evenly.
The power source of solids reinjecting is from the pressure difference from gap of
solids levels between the vertical leg and reinjecting leg of U valve. Besides the
proper air distribution by the bottom plenum, the vertical leg is equipped with five (5)
layers of aeration nozzles for fluidizing solids in order to ensure that solids are
reinjected back to the furnace continuously and steadily. The fluidizing air for U valve
is supplied by the separate blowers with high pressure and small flow.
The vertical leg is equipped with pressure-measuring instrument. By means of

controlling the pressure differences, the solids level is strictly controlled so as to
prevent the furnace gas from back-flowing into the cyclone during pressure pulsating.
The start-up bed material inlets are arranged at the reinjecting leg of U valve.
Emergence discharge ports are located at the bottom of U valve, which are used for
maintenance and emergence condition.
The shell of U valve is made of steel plates. The inner diameter of U valve is
1510mm. To prevent the abrasion due to the gas current with high temperature and
high-density dust, U valve is lined with anti-abrasion and refractory materials.
1.4.17 Ash Cooler
On the rear wall of the furnace, two rolling ash coolers are arranged. Part of the spent
bed materials comes to the bottom of the furnace and are then drained to the ash
coolers through solids transfer pipes. The drain openings of the bottom ash in the
furnace are located at the elevation of 7196mm.
The installation and maintenance of ash cooler are shown in “INSTALLATION AND
MAINTENANCE MANUAL” provided by the ash cooler manufacture
1.4.18 Ignition System
Two kinds of start-up ignition equipment or over-bed ignition and in-duct ignition are
adopted for this boiler. 6 pieces of over-bed heavy oil burners with heat input of 15%
rated load are located on both the side and rear walls of the lower furnace. 4 pieces
of in-duct burners with heat input of 15% rated load are located in the primary air
ducts below the water-cooled air plenum.
The in-duct burners for startup heat the primary air to 870℃. Then the hot primary air
heats bed materials through air distribution device to ignition temperature. High
energy ignitor and flame scanner is provided for the burner.
1.4.19 Abrasion proof and refractory materials
Abrasion proof and refractory materials are required in all DONGFANG CFB boilers
to ensure the safe and reliable operation of the boilers.
Some parts of the CFB boiler are not pressure parts and are not cooled by the
circulating water and/or steam, but they are exposed to high temperature and high
velocity flue gas. These parts include typically cyclone, U valve etc., which are not
designed with heat transfer surface. So their inside surfaces are lined with two or
three layers of abrasion proof and refractory materials. The layer nearest to the outer
metal plate is insulating layer; the layer facing the gas is an abrasion-resistant layer.
Experience has shown that erosion in a CFB boiler can be reduced through proper
design of pressure parts and abrasion-resistant refractory coverage in key areas.
Abrasion-resistant and refractory materials selected for the protection of pressure
part also have low insulating characteristics, so the heat transfer and boiler
performance are not affected excessively. Refractory coverage of pressure parts in a
CFB boiler is primarily in the furnace. These areas include:
Lower furnace – The lower part of the furnace is considered as the portion that has
the highest density of bed material. The bed material is mixed with incoming fuel and
limestone and fluidized by the grid nozzle airflow. The smaller particles are entrained
in the upward flow while the bigger particles fall back to the grid floor. The particles in
this area have very abrasiveness. So abrasion-resistant and refractory materials
shall be laid from the grid floor to the juncture of the vertical wall and the bevel wall in
the combustor. Abrasion-resistant and refractory materials are laid on both the side
walls (including split wall) near the furnace outlet.
Penetrations and discontinuities – CFB boiler operating experience has shown

that erosion in the many locations of the furnace will not occur if there are no
discontinuities that would change the flow direction of the particles in the furnace.
Thus, the system is designed to eliminate unnecessary discontinuities. In the
locations where discontinuities must exist, such as platen surface penetrations and
the measure openings on the furnace, proper protection measures shall be taken
such as shielding or refractory coverage, or a combination of several protection
methods.
Furnace flue gas outlet – This area is subject to high velocity flue gas with bed
material, so proper protection measures shall be taken to prevent the tubes in this
area from being eroded.
1.4.20 Boiler Steel Structure
The boiler steel structure is of bolted and welded construction and full enclosure
arrangement. There are eight (8) main columns for supporting boiler. The columns
are connected to the foundation at the elevation of -500mm by reinforcing bars.
Horizontal beams and vertical supports are provided between the columns to
withstand the loads of boiler proper, wind and earthquake.
The major pressure parts of the boiler (steam drum, furnace waterwalls, rear pass
gas flue, etc.) are hung by hangers from the top plates. Other components of the
boiler, such as ash cooler, air heater, in-duct burner, cyclone etc. are all supported on
the horizontal beams or on the earth by supporting devices or reinforcements.
Platforms and stairs are located in the locations where maintenance or inspection
shall be performed during boiler operation.
1.5 Water Volumes Of Major Boiler Parts:
Part Name During Hydraulic test (m3) During Operation(m3)

Steam Drum 27.7 12.2
Waterwalls 87.3 87.3
Superheaters 35 0
Reheaters 44.2 0
Economizers 17.7 17.7
Total 211.9 117.2
Note: 1. The volume of waterwalls includes the volumes of downcomers, feeder pipes,
split waterwall and headers.
2. The volumes of superheaters, reheaters and economizers all include the
volumes of their headers and connecting pipes.

SECTION 2 SAFETY PRECAUTIONS AND PREPARATION
FOR OPERATION
2.1 SAFETY PRECAUTIONS
Safety is primary for any boiler operation.
The following descriptions are some of the general precautions which shall be
applied when a steam generator first comes into operation. They are intended to
supplement the experience and judgment of personnel in charge of operation and do
not cover all precautions which shall be observed.
The manufacturer has complied with the national code pertaining to the design and
fabrication of boiler. A newly erected unit, prior to being put into operation, must be
carefully inspected by the authority to assure that all components or parts accord with
the design requirements.
All boiler auxiliary facilities must be in the first class operating condition, and meet the
design operation conditions and can operate in accordance with the manufacturer’s
recommendations and instructions. Here is an initial start-up check list for boiler
auxiliary equipment.
NOTE
The following items shall be checked prior to start-up of the boiler.
1. All fans and blowers shall be operable. Lubrication systems shall be operable.
Equipment shall be able to operate within the allowable variation of vibration.
2. All dampers, controllers and actuators shall be subjected to internal and external
inspection. The boiler auxiliary equipment shall be operable under the full range of
operation conditions and shall be free of caking or jamming. It is confirm that all
dampers can actually move to the stipulated positions as per the control
requirements.
3. Ensure that the ash removal system is connected with the ash cooler and that the
ash cooler is well ready for operation.
4. All remotely operated valves and slide gates shall be operable, and their limit
switches shall be checked to ensure their proper installation, thus guaranteeing
the accurate position indications.
5. All conveyors shall be trial-operated to ensure their normal operation.
6. All flow elements shall be calibrated.
7. The over-bed/in-duct burners, flame detectors and interlocks shall be operable.
8. All thermocouples and pressure sensors shall be checked and calibrated to

ensure their normal operation.
9. All flues, ducts, pipes, chutes or conduits through which air, gas, water, steam or
solids flow shall be connected accurately and reliably.
10. All expansion joints shall be inspected to ensure that proper connections have
been made.
11. All dust catchers shall be checked to ensure their normal operation.
12. All electrical connections shall be inspected to ensure their proper erection and
good insulation.
13. The remote drum water level indicator shall be checked, comparing its readings
with the readings indicated by the local water level gauge. This process must be
done periodically.
z Before a new boiler is put into service, the following items shall be
checked:
1. The local drum water level gauge must be installed and checked in accordance
with the drawings prior to preliminary operation. When the water level of drum is
below the lowest visible point of the water level gauge, the gauge shall be drained.
Whenever gauge maintenance or replacement is done, it is necessary to verify
that its drain is normal.
2. Blowdown pipeline for water level gauge shall lead to the safe zone and drain
valves must be closed. The water level gauge must properly illuminated so that
that the operators on the operating floor can observe its readings sharply.
3. All vent, drain and blowdown pipelines shall be accessible and properly
connected with a blowdown tank or shall lead to other safe locations so as to
ensure the safety of personnel.
4. Valves that are located between the drum and equalizer and water level gauge
must be in the full open position.
5. All safety valve gags and hydrostatic test closure plates must be removed and
these valves must be in good condition. The steam discharge pipes of safety
valves shall be arranged and supported in accordance with the safety valve
manufacturer’s recommendations.
6. Drum internals must be properly installed in accordance with the drawings to

assure that there is no steam bypassing the internals.
7. All test interfaces, as deemed necessary, must be installed.
8. A leak test shall be conducted for the steam generator’s air and flue gas systems,
and all leaks shall be eliminated in accordance with Paragraph 2.8.
9. Heat emission zone of the boiler shall be insulated or roped off to ensure the
safety of personnel.
10. The thermal expansion of equipment shall not be disturbed by the temporary
scaffold, ladder, fragment and any construction material left.
z In addition to the above, the following items shall be thoroughly

checked each time before operation:
1. All necessary operating instruments, both permanent and temporary, must be

installed and correctly calibrated, and be able to operate reliably.
2. All areas must be sufficiently illuminated to guarantee the safety operation of

boiler.
3. All hazardous barriers shall be cleared away. Unobstructed walkways and

platforms as well as ladders or stairways shall be arranged in the locations where
operation and observation are performed.
4. Air and gas passages must be unobstructed and can be thoroughly purged by the
circulating air of the unit.
5. The boiler feedwater must be ample, uninterrupted and qualified once the unit is
put into operation.
6. An ample and reliable fuel /limestone supply shall be available.
7. All access and observation doors must be closed after it is ascertained that no
one is inside the unit.
8. Drum manholes must be closed and sealed properly.
After it is assured that the above precautions are fully understood and have been
complied with, subsequent operations such as “Drying Out”, “Boiling Out”, “Initial
Starting” and “Normal Starting” can be initiated.
2.2 HYDROSTATIC TESTS
The steam generating unit shall be subjected to a hydrostatic test after the erection of
pressure parts is completed. A hydrostatic test shall also be made upon the
completion of each general overhaul or any repair affecting pressure parts of the unit,
or at any time when it is desirable to perform leak inspection.
CAUTION
THE BOILER TO BE TESTED SHALL BE FILLED WITH TREATED

WATER.
If the unit is not to be put into service after the hydrostatic test, proper treatment shall
be done, namely 200～300ppm hydrazine plus sufficient ammonia or morpholine is
used to raise the pH to 10. If the unit is to be put into service within a short time, the
treatment may be done as per the normal operation procedures. It is strongly

recommended that the unit be filled with the demineralized water or condensed water
for the test.
If the inventory of demineralized water or condensed water is limited, certain parts of

the unit may be filled with treated potable water or other water free of corrosive and
suspended materials. This water is not to remain in the unit for wet storage because
only demineralized water or condensed water can be used for wet storage.
For the test of drainable parts, the water with chloride content of less than 50ppm and
temperature of less than 52℃ may be used. But these parts must be subsequently
be rinsed with condensed or demineralized water prior to operation.
The standard Supervision code for safety technology of steam generation boiler,
issued by the Labor Ministry of the People’s Republic of China, specifies that the unit
shall be subjected to a hydrostatic test prior to the first operation or upon the
completion of any repair or change of pressure part. The hydrostatic test of the
primary water-steam system covers most pressure parts including superheaters,
furnace and economizer (as a whole), and its test pressure is 1.25 times of the drum
design pressure. The hydrostatic test of the reheat steam system, also called the
secondary steam system, covers LRH and PRH, and the test pressure of the reheat
steam system is 1.5 times of the inlet working pressure of LRH. The water
temperature of all hydrostatic tests is 20～70℃ and shall be higher than the ambient
temperature. Before applying a hydrostatic test to the unit, a thorough internal and
external inspection shall be done to ensure the completion of the following items:
1. All sundries and tools have been removed.
2. No one is inside the unit.
3. The manometer has been correctly calibrated and erected on the drum outlet
piping, with valves open.
4. Any part which is designed not to withstand the hydrostatic test pressure is
properly isolated or blanked off from such pressure.
5. All valves are operable and in the right position.
6. All steam system spring hangers are pinned in the fixed position.
7. All safety valves are gagged; all power actuated relief valves are decoupled.
After the foregoing items have been carefully checked:
1. Verify that drum manholes are properly closed.
2. Close stop and check valves, all drain and blowdown valves and other valves for
any gage or other internal equipment which is designed not to withstand the
hydrostatic test pressure.
3. Open the vents on the highest point of each component or part of the unit.
4. Be sure that the water will not be frozen during test and the unit will not be
subjected to freezing conditions following the hydrostatic test.
5. If during hydrostatic test, the water temperature is above 50℃, it is necessary for
the operators close to the unit to be careful in order to avoid the possible scald
from water leakage.
6. Check that only authorized personnel are in the vicinity of the unit to be tested.
When starting to fill the unit with water, the water temperature shall be close to the
metal wall temperature of the drum. The temperature of all other pressure parts shall
not be less than 20℃.
CAUTION
WHENEVER THE HYDROSTATIC TEST PRESSURE EXCEEDS

5.1MPa, THE MINIMUM DRUM METAL WALL TEMPERATURE
AND WATER TEMPERATURE（20℃）MUST BE OBSERVED TO
INSURE THAT THE HYDROSTATIC TEST IS PERFORMED ABOVE
THE BRITTLE TO DUCTILITY TRANSITION TEMPERATURE FOR
THE METAL.
z To obtain this hydrostatic test temperature, the following procedures are

recommended (items 1 and 2).
1. If the boiler in-duct burner system cannot function, as may be the case for the
initial operation, any of the following methods (1), (2) and (3) is recommended.
(1) Use an external thermal source to heat so that the recommended

minimum temperature is obtained, as indicated by the drum surface
thermocouples.
(2) Use small oil and/or gas guns aimed through doors or resting on the grid
nozzles to raise the temperature to the recommended one. The boiler
tubes shall be kept away from the flame.
(3) If the medium temperature in the drum is below 20℃, saturated steam
may be fed into the drum through the drum blowdown or chemical feed
pipes to heat the water and the drum shell to the required temperature.
When the drum water level reaches the normal operating level, the
water shall be heated to a temperature 2 ～ 5℃ more than the
recommended temperature so that the final water temperature will not
be below the recommended minimum temperature.
2. If the boiler in-duct burner system can function, the following procedure is
recommended:
(1) After the unit water level reaches the normal water level, the in-duct
burners are ignited to raise the drum temperature to 2～5℃ more than
the recommended temperature.
(2) Switch off the in-duct burners and continue to fill the unit with water, and
at the same time inspect the drum drain pipelines and manholes for
leaks. Close the vent valves when water pours out of the vents located
at the highest points of the unit.
(3) Raise the pressure to the test pressure slowly. The recommended rate of
pressure rise shall not exceed 0.3MPa per minute to avoid the
occurrence of excessive pressure fluctuate.
(4) If the hydrostatic test pressure exceeds the design pressure, it is

necessary to reduce the pressure slowly. When the pressure is equal to
the operating pressure or the design pressure, the unit shall be
thoroughly inspected for leaks only at operating or design pressure. After
this inspection is completed, release pressure slowly at the
recommended rate of pressure release (not exceeding 0.3MPa per
minute), and open the vent and drain valves. Superheater system must
be thoroughly drained.
(5) If temporary manhole gaskets are used during the initial hydrostatic test,
they are to be replaced with proper gaskets before refilling the unit for
operation.
(6) Remove gags from safety valves and pins from spring hangers after the
test has been completed.
2.3 SOLIDIFYING REFRACTORY MATERIALS
All refractory materials shall be cured solidified and dried at the field by the erection
company in accordance with the refractory manufacturers’ recommendations to
assure that their actual performances meet the relative requirements.
2.4 BOILING OUT
2.4.1 General
Boiling out is a process to remove oil and grease inside the unit, and the cleaning
medium is usually a strong alkaline solution.
The presence of even very thin films of oil or grease or their decomposition products
on the boiler heating surfaces will seriously retard heat transfer. This film acts as a
dangerous heat insulating film and retards the rapid transmission of heat from the
metal to the boiler water. The resultant increase in metal temperature may cause
overheating and blistering of boiler tubes and even burst of tubes at high loads.
During the boiling out process, the gage glass may become badly discolored and
permanently etched. Our suggestion is that the customer has spare gage glass
fittings on hand. All the inoperable gage glasses shall be restored after boiling out
and chemical cleaning and before refilling the unit with water. The ordering and
replacement of gage glass shall be based on the manufacturer’s instruction.
The chemical shall be dissolved in water before being fed to the boiler and shall
never be fed to the boiler in the solid form. When handling corrosive materials, it is
necessary to ensure that the eyes, skin or clothing of the operator are bespattered by
them. When mixing these materials, it is recommended that goggles, rubber gloves
and cotton clothing be employed.
The chemical solution shall not be fed to the boiler in high concentration through the
regular chemical feed system because the high concentration solution may block up
the chemical feed piping and valves.
If the chemicals for boiling out must be injected to the boiler drum through the
chemical feed system, the solution concentration in the mixing tank shall be diluted,
namely 5% ahead of the chemical feed pump suction, and the pump and chemical
feed pipelines shall be flushed thoroughly after the pumping is completed.
2.4.2 Recommended Chemicals for Boiling Out
Alkaline chemicals such as soda ash and caustic soda are commonly used for boiling
out because these agents possess the ability to saponify the oils and greases to form
a soap compound that is easily removed through high pressure blowdown during the
boiling out process, and after the completion of boiling out, the unit shall be flushed
with cold water through a high pressure hose.
Phosphate (trisodium phosphate and disodium phosphate, accompanied by either

caustic soda or soda ash) may also be used as an agent to thoroughly clean the
internal surfaces of the boiler. In this connection, an embrittlement inhibitor and a
commercial “wetting agent” shall be added in the boiling-out solution.
It is known that intercrystalline cracking (caustic embrittlement ) is caused by the

caustic soda used during the relatively short period of boiling out. The alkaline
concentration developed in the boiler water during boiling out is much higher than
that of the standard boiler feedwater. Therefore it is a safe practice to add an
adequate concentration of an embrittlement inhibitor to the boiler water. Sodium
nitrate is the preferred agent for this purpose.
For the most effective removal of oil from boiler metal surfaces, it is recommended
that a “wetting agent” be mixed into the boiling out mixture. These agents increase
the “wetting power” of the water by reducing the surface tension so as to reduce the
adhesive capacity of oil or grease to a minimum degree. The combination of a
“wetting agent” and the regular boiling out chemicals will therefore break down the
oil-sludge bond so as to remove the oil and grease from the metal surfaces.
The following dosages of chemicals have proven successful on many units.
Trisodium Phosphate (crystalline) 5.25 g / kg of water

Soda Ash 1.0 g / kg of water
Sodium Nitrate 0.15 g / kg of water
Wetting Agent 0.10 g / kg of water
Refer to Item 1.5 for the total amount of water required for the unit.
If trisodium phosphate is not obtainable, it is permissible to adopt disodium

phosphate (anhydrous); however, the weight of this chemical shall be based on the
dosage of 2.5g/1kg of water.
NOTE
The following procedure is based on the assumption that a

trisodium phosphate solution (Na3PO4-12H2O) is used.
2.4.3 Preparations for Boiling Out
Prior to boiling out a boiler, the items previously outlined under “Safety Precautions”
and “Drying Out” shall be consulted and followed. Generally, drying out and boiling
out shall be performed simultaneously.
A careful cleaning and inspection of the interior and exterior surfaces of the boiler
and auxiliary equipment shall be performed for the purpose of removing all metal
scraps, borings, wood, tools, burr and other foreign materials. It is very important that
these materials be removed before boiling out. Otherwise, foreign materials inside
the boiler are likely to interfere with the operation of blowdown valves and future
operation of the boiler.
When the boiler is filled with water of high chemical concentration (such as water for
boiling out), no attempt shall be made to set safety valves until the initial start-up
phase during which the chemical concentration of the water inside the boiler is
approximate to the normal chemical concentration.
NOTE
The boiler can be charged with initial bed materials before or

after boiling out.
1. If charging is to be performed before boiling out, it shall be done in accordance

with the procedures specified in Section 3, Paragraph 3.3.
When a workman enters the furnace, the following proper precautions must be taken:
(1) Another workman is appointed to observe the progress of work beside the
furnace access door. The plant personnel shall be informed immediately if
any problem is found.
(2) All fuel and limestone feed equipment and fans shall be closed and a tablet
with indication of “No Operation - Someone Working in Furnace” shall
be placed.
(3) Anyone entering the furnace shall be provided with proper breathing
equipment and protection devices, as are required under a dusty work
environment.
(4) The furnace shall be cooled, well ventilated and inspected as per the
normal industry standard before someone enters it so that proper air
composition is realized.
2. Open the vent valves listed within Paragraph 3.3 so that air can be expelled when
filling the boiler with water. Isolate any device that could be damaged during
boiling out, such as water level gauge, remote level indicator, pressure connection
element and sensor. Filling the unit with water shall be accomplished by using the
feedwater pumping and piping systems normally used during boiler operation.
This will have a tendency to flush out the piping and auxiliaries in front of the
boiler.
3. Inject chemicals into the boiler feedwater pipeline at the downstream of the main
feedwater pump and at the upstream of the economizer by using the drain pipe of
the main feedwater pipeline or economizer drain pipe.
NOTE
Chemical injection shall be carried out only when water is

flowing in the main feedwater pipeline. Also, injection must be
completed well in advance of reaching the desired drum level so
that the chemicals in the boiler feedwater pipeline is flushed out
during the final stage of the boiler feedwater cycle .
4. Raise the water level so that the lowest water level in the bottom of the water level
gauge can be visible.
5. When the desired steam drum level is reached, close boiler feedwater flow control
by-pass valve.
NOTE
At this point, all steam drum valves, with the exception of

instrument connection valves and vent valves, shall be closed.
2.4.4 Boiling Out Procedure
1. Start the ID fans and combustion air fans in accordance with the fan
manufacturer’s instruction and the operation sequence outlined in Section 3,
Start-up Procedures.
2. Purge the boiler in accordance with Section 3, Start-up Procedures.
3. Set the combustion air damper to maintain sufficient air flow to the in-duct burner.
4. When in-duct burners run stably under low load, the firing rate shall be increased
as required so as to raise pressure.
NOTE
To protect the refractory and insulation materials inside the

drum and the cyclone from excessive thermal stress, the metal
differential temperature between the top and bottom of the drum
shall not exceed 50℃, and the temperature rising velocity of the
cyclone inlet shall not exceed 85℃/h during the start-up and
normal operation of the boiler.
5. Close the drum vent valves when the boiler pressure reaches 0.1MPa.
6. The in-duct burners keep on running until the boiling out pressure reaches the
value corresponding to the design pressure of this unit. (See Figure 2.1).
Boiling-Out Pressures（MPa)
4
3.5
3
2.5
2
1.5
1
0.5
0
0 5 10 15 20 25
Design Pressures（MPa)
Fig. 2.1 Recommended Boiling-Out Pressures for Different Design Pressures
7. The boiler feedwater pumps must be available during the operation of the unit.
8. Fire the in-duct burners intermittently as required to maintain the drum boiling out
pressure for at least eight (8) hours.
9. Raise the water level to approximately 51mm at the top of the gauge glass.
10. When the high water level and the drum boiling out pressure have been reached,
shut down the in-duct burners.
11. Start blowing down by opening the drum mass blow-off valve and the furnace
lower waterwall header drain valves. It is recommended that, when blowing down,
the root valve (closest to the boiler) shall be opened first and closed last. The
second valve in the pipeline shall be used to control the flow. An effective blowing
out can be accomplished by opening and closing these valves. This blowing out
shall last approximately 10 seconds.
12. A cooled water sample from the drum shall be tested to confirm its phosphate and
silica contents, pH value and total alkalinity and its chemical concentration shall
be also recorded.
13. If the water level in the drum falls to within 51mm above the bottom of the gauge
glass, refill the drum with water and fire the in-duct burners to maintain the drum
boiling out pressure.
14. Repeat Steps 11 and 12 once every four (4) hours for at least 24 hours until no oil
trace appears in the cooled boiler water sample. Repeat Step 13 if necessary.
After boiling out, when the boiler has been cooled and drained, the drum shall be
inspected and any sediment shall be removed. If necessary the headers shall be
inspected. If no inspection nipple is provided on a header, inspection may be
accomplished by cutting the stub of a feeder or riser tube of the header. If any foreign
material is found in a header, it shall be removed manually or flushed through a high
pressure water hose. Besides, it is necessary to assure that the metal internal
surfaces are free from oil adherence.
After the drum and headers have all been cleaned and inspected, the unit can be
sealed. New manhole gaskets shall be installed on the drum, and inspection nipple
caps or tubes cut for cleaning and inspection shall be replaced. The unit shall be
filled with either demineralized water or condensed water and subjected to
hydrostatic test under the pressure approximate to the hydrostatic test pressure. The
unit shall then be drained to reach the normal drum level.
2.5 FEEDWATER AND BOILER WATER TREATMENT
Feedwater and boiler water samples must be inspected to meet desired water quality
requirement.
The quality of feedwater shall be in compliance with the superhigh pressure water
quality specified by GB/T12145-1999 “Quality criterion of Water and Steam for
generating unit and Steam power equipment “. The treatment of feedwater and
the conditioning of boiler water are beyond the control of DBC. Therefore, DBC shall
not be responsible for damages due to corrosion or formation of scale or deposits or
caustic embrittlement caused by chemical conditions of the water. Fouling in boiler
tubes will impair heat transfer and result in overheating, thus affecting boiler
performance.
2.6 CHEMICAL CLEANING OF ECONOMIZER AND STEAM GENERATING
CIRCUIT
2.6.1 General
It is an effective means to clean modern high duty boiler units by using proper
chemical solutions. The cleaning performed prior to the initial operation of the boiler
or in a very short time thereafter, for the purpose of removing mill scales, provides a
thin, uniform protective coating of iron oxide and removes the material that may be
redistributed to the heat transfer areas from the unheated portions of the system. It is
beneficial to delay this type of cleaning short time after the initial operation because
considerable oxidation scales and materials containing silicon oxide may be carried
into the boiler from the feedwater and condensed water systems during the initial
operation, unless the feedwater and condensed water systems are also chemically
cleaned.
The need for removal of deposits produced during operation varies considerably
from plant to plant. It depends on the type of feedwater system used and the history
of water makeup and water quality. Because fouling produced during operation is
made up of a wide variety of materials, its removal may be much more complex than
the removal of mill scales. No boiler can operate reliably if fouling occurs to its heat
transfer surfaces.
2.6.2 Determining the Need for Chemical Cleaning
The need for a cleaning prior to operation will depend primarily on expected rusting
conditions of all cycle components during construction. Factors influencing rusting
conditions include storage measures and weather conditions at the plant site. Much
rust, loose mill scale sand materials containing silicon oxide are removed from the
boiler during the alkaline boiling out which must be performed on every unit. If the
other portion of the cycle circuit is not extensively cleaned, some materials will be
carried into the boiler. So cleaning may be performed further.
Deposits produced during operation are varied and quite complex and the maximum
tolerable amount is difficult to determine. Tube sampling test shall be performed each
year or every a year and the weight of deposits shall be measured. Generally,
ignoring the specific deposit composition, the deposits on the cold side of furnace
tubes of a unit reach 20 to 40 mg/cm2, chemical cleaning shall be performed during
the next maintenance.
2.6.3 Solvent System
Solvent selection is based on two primary considerations. The first is compatibility

between the solvent and tube material and the second is whether the solvent is
suitable for the removal of deposits. The two aspects are not independent each other
because the dissolution of deposits by the solvent may create corrosion of tube
material. But, this condition will not happen in the absence of deposits.
Mineral acid, such as hydrochloric acid, is commonly used as the solvent for the
removal of mill scales or deposits produced during operation. If copper is present in
the deposits, complex agent must be used, because copper will plate on the metal
surfaces in the acid solution. Solution strength will depend on the deposit analysis,
weight and structure.
When hydrochloric acid is used for cleaning prior to operation, the following
stipulations shall be observed:
Hydrochloric acid concentration 5% max. by wt.

Metal or solvent temperature 68℃
Solvent contact time 6 hours
Based on the cleaning
Inhibitor concentration
contractor’s spec.
The single or complex organic acid is also used as a solvent in combination with
various other materials. Although this solvent generally is less corrosive than the
mineral acid, a proper corrosion inhibitor and preliminary testing are still necessary.
In addition, because of the lesser dissolving capacity of the organic materials, some
means of circulation within the unit may be required to insure that there is no local
depletion of the solvent before the deposits are completely dissolved.
2.6.4 General Cleaning Operations
Chemical cleaning of a boiler shall never be performed by inexperienced personnel.

There is a great danger if the uncontrollable condition happens or improper material
is used. Careful planning is required to assure that the specified chemical conditions
are attained so that the conditions hazardous to life and property will not occur.
To make the unit reach the cleaning temperature, the unit may be filled with
condensed water or demineralized water and heated by one of the methods specified
in Paragraph 2.2. By using drum thermocouples, and temporary thermocouples if
necessary, monitor the unit temperature to assure that the temperature in each area
of the unit is not above the temperature limits required for the solvent system and
inhibitor used. The temperature limits must be specified by the solvent system
supplier. When the proper temperatures are attained, the water may be drained to
the storage vessel.
The solvent is pumped into the unit through the heated water that is stored and the
desired concentration is obtained by testing the concentrated solvent. Before
pumping the solvent into the unit, it is necessary to assure that the inhibitor is proper.
If the water temperature must be adjusted while refilling the unit with water, steam
shall be injected into the unit before the solvent pumping to avoid the corrosion of the
mixing equipment.
NEVER FIRE THE UNIT WHEN IT CONTAINS ACID AS INHIBITOR BREAKDOWN

MAY OCCUR.
After the solvent is pumped into the unit, it is necessary to regularly monitor the acid
strength, iron concentration, temperatures and any condition or constituent
necessary for control of the particular solvent system. When the cleaning is
completed, as determined by measuring the iron concentration, the solvent is
drained from the unit under a nitrogen blanket.
The unit may be filled with water and drained one or more times to flush the solvent
from the cleaned areas. The rinse water shall contain a ferrous complexing agent to
prevent the deposition of iron on the cleaned surfaces.
When the rinsing is completed, the unit is filled with an alkaline solution to neutralize
any residual solvent and passivate the metal surfaces to prevent after-rusting. The
alkaline solution may be heated prior to filling or the unit may be heated as per the
method stipulated in Paragraph 2.2 to attain the desired temperature.
Upon completion of the passivation, the unit shall be drained for inspection and all
temporary pipelines shall be removed.
2.7 CHEMICAL CLEANING OF SUPERHEATERS & REHEATERS
Chemical cleaning of superheaters & reheaters may be performed in these cases

when it is required for the particular cycle or by the user or when the deposits
produced under abnormal operating condition must be removed.
Chemical cleaning of superheaters & reheaters shall be in compliance with the

general principle regarding the suitability of solvent and the compatibility between the
solvent used and tube material, as required for steam generation circuit.
Superheaters & reheaters have the sections that are either non-drainable or ventless.
It is impossible to adopt the filling or soaking method to clean them. To assure that all
tubes can be filled with the solvent and flushed successfully, purging shall be
performed prior to introduction of the solvent. This may be accomplished by pumping
water at high flow rate or by purging with low pressure steam.
2.8 BOILER SYSTEM AIR TEST
Upon completion of erection, an air test shall be performed to detect air and flue gas
leaks in the boiler system. The leaks shall be eliminated to insure the tightness and
the safe operation of the system. A typical recommended procedure is as follows:
1. Install a closure plate at the ID fan inlet.
2. Close all access doors and observation ports.
3. Disconnect all instrument connections.
4. Open all channels to be tested.
5. Operate the FD fans to pressurize the system to 76.2mmH2O pressure.
6. Inspect the entire system by using suitable visual/audio devices. Soap films,
smoke bombs and sonic detectors are useful methods. They may be used
synthetically.
7. Identify all leaks.
8. Depressurize the system.
9. Repair all leaks.
10. If any leak is found, repeat the air test after completing the leak repair.
11. Remove closure plates, plugs and covers.

SECTION 3 OPERATION AND MAINTENANCE
3.1 GENERAL
1. The operators shall be thoroughly familiar with the functions and controls of the
boiler as well as its components and auxiliary equipment before operating the unit.
The descriptions given in this Paragraph shall not be deemed as the guidelines for
boiler operation. However, based on the descriptions given in this Paragraph and
in combination of relative auxiliary equipment instructions and knowledge derived
from unit initial operation, a detailed operation procedure can be prepared.
2. Circulation fluidized bed boiler is a reactor without obvious fireball inside. Inside
the boiler there are circulating solids with considerable thermal energy.
3. The operators shall be aware of the limitations imposed on the various parts of the
boiler and its auxiliaries and be alert to the actual operating conditions during
start-up and while operating as per system demands.
4. The boiler can be operated at a maximum continuous rating (BMCR) of 440t/h.

The superheater outlet superheated steam temperature is 540℃, its pressure is
13.73MPa.g, and the feedwater temperature is 248.6℃; the maximum continuous
rating (BMCR) of RH is 356.114t/h, its inlet pressure is 2.73MPa, its outlet
pressure is 2.57MPa.g, and its inlet temperature is 320℃ and outlet temperature is
540℃. The above mentioned parameters are based on firing the fuel specified in
Item 1.1.3, 1.1.4. Overload operation is forbidden.
3.2 IMPORTANT PRECAUTIONS
The critical precautions that the operators must follow and exercise during all phases
of operation of this unit are listed below.
3.2.1 Furnace doors
All doors at lower furnace must not be opened during normal unit operation to protect
personnel from any danger as this steam generating unit will have internal pressure
greater than atmospheric pressure.
3.2.2 Furnace Pressure Limits
Excessive negative or positive furnace pressure can result in serious damages to the
unit and auxiliary equipment.
The following controls shall be put into service and operable prior to start-up for
protection against excessive furnace pressure or draft.
(1) The furnace negative pressure, as measured at the balance point in the
furnace exit, shall be monitored constantly and automatically controlled within
the range of -127～-245Pa.
(2) The Main Fuel Trip (MFT) shall be set at the furnace outlet pressure of
±2489Pa (cyclone inlet), with a 5 seconds delayed.
(3) The FD and ID fan trips shall be set at the furnace pressure of ±3744Pa, with
no time delayed.
The following actions shall occur at Main Fuel Trip (MFT):
(a) Fuel feeders trip.
(b) Limestone system trip.
(c) In-duct and over-bed burners trip.
(d) Ash cooler trip.
(e) All air flow controls shall be switched to manual mode and hold at the
last position.
(f) FD fan controls shall be switched to manual mode and hold at the last
position. However, in case the trip is caused by FD fan failure, it shall be
controlled by its own logic.
(g) Output signal to combustion control shall limit ID fan automatic control to
insure that the furnace negative pressure is not beyond the limit.
(h) “Boiler Purge Requirement” logic control condition is set unless it is a

“Hot Restart” condition.
(4) The operator shall not allow the furnace pressure at the balance point to
exceed ±498Pa (alarm point).
(5) On trips of FD/ID Fans and all U valve blowers (MFT will be initiated), the bed
materials fall down and may burn. Access doors shall be closed. Air shall be
slowly fed into the unit to clear combustibles away from the unit.
NOTE
The operators shall keep it in mind that the unit in operation

maintains a considerable amount of stored energy even after the
MFT, so the drum water level and an adequate flow of steam to
control steam pressure shall be maintained at any time.
3.2.3 Drum Water Level and Temperature Difference
The normal drum water level is 76mm below the centerline of the drum. The alarm
water levels are set at 200mm below the normal water level and 125mm above the
normal water level and the trip water levels are set at 280mm below the normal water
level and 200mm above the normal water level.
NOTE
The lowest drum water level condition (280mm below normal

water level) or the highest drum water level condition (200mm
above normal water level) shall initiate the main fuel trip (MFT)
and the FD and ID fans trip. To protect the drum from undue
thermal stress, the metal temperature difference between the top
and the bottom of the drum shall be controlled within 50℃. The
drum metal temperature shall be monitored and indicated in the
control room.
3.2.4 Safety Valve Adjustment
Although, all the safety valves have been set by the valve manufacturer, they still
need to be rechecked under actual operating conditions during the boiler first startup
and rising pressure. If a safety valve does not act at the nominal pressure on its
nameplate or reseat properly, the valve shall be readjusted.
Warning: It is not allowed to change the setting value of any safety valve
without authorization.
3.2.5 Excess Air Requirements
Furnace excess air shall be carefully controlled to ensure the proper fuel-air ratio for
good combustion. During normal operation, the excess air factor shall be controlled
by measuring oxygen at the rear pass outlet. When the boiler operate at 100% MCR
load, the corresponding oxygen shall be controlled at approximately 3.051% (based
on a dry basis volume ratio). The relation between such oxygen amount and boiler
load is indicated in Figure 3.1.The above-mentioned measured value of oxygen
amount is only used for reference and shall be optimized by combustion adjustment.
Operation with the excess air less than the above specified value can be unfavorable
for good combustion and safe operation of the unit.
6
5
4
O2%
3
2
1
0
0 20 40 60 80 100
Boiler load %BMCR
Fig. 3.1 Volumetric O2 % in dry gas vs. Load %
3.2.6 Bed Temperature Profile
Normal operating bed temperature is 790～900℃ (measured by thermocouples on

the grid plate) which shall be monitored during operation and the boiler shall be
operated within this range. The high bed temperature alarm point is 955℃. A main fuel
trip is automatically initiated at 990℃. The lowest operating temperature for the bed is
790℃. The temperature is not allowed to drop below this level without fuel supporting.
The low bed temperature alarm during normal operation is 760℃. A main fuel trip is
automatically initiated at 650℃ unless the in-duct burners are in operation. The fuel
feeders will automatically trip off if the bed temperature drops below 540℃, whether
the in-duct burners operate or not.
After the staffs have gained enough experience, the boiler operation temperature can
be properly increased according to the requirements of combustion efficiency and
denitrifying efficiency of the power plant. But at any operation temperature, the
slagging and unstable combustion must be avoided.
3.2.7 Others
1. Inspection prior to startup
The following precautionary steps must be taken to insure reliable operation of the
unit:
(1) It is recommended to check the ash deposit condition at the rear pass heating
surfaces of the gas side at each boiler shutdown. The surfaces shall be cleaned
accordingly before boiler restart if any serious ash deposit is detected.
(2) Thermocouple are installed in various locations in the steam generating circuit to
monitor boiler startup conditions and help to determine the acceptable firing rate
during startup. The thermocouples are located at the following locations:
Steam Temp. Alarm

Part Location Total Qty
Limitation
12 (6 for
Steam Drum Top & Bottom
each)
PSH Outlet Tubes 80 545℃
LTS Outlet Tubes 6 450℃
HTS Outlet Tubes 20 573℃
650℃ (startup).
PRH Outlet Tubes 28
575℃(normal operation
These thermocouples are located in the places which are not eroded by flue gas.
Therefore, the temperature obtained is equal to the steam temperature. These and
other thermocouples shall be checked and made ready for service (including
indicators in the control room).
The unit can be operated continuously if the steam temperature is not beyond the
alarm limits indicated in the table above. To protect the safety of equipment, the
operators shall correct any condition which has caused an alarm.
To prevent plugging, rusting, oxidation and equipment failure, air used for the boiler
operation, whether for sealing, aspirating or atomizing, shall be free of dirt, oil and
water.
(3) All high and low furnace pressure safety interlocks shall be checked to ensure their
proper values and correct switching actions and be in service before starting the
induced draft fan.
(4) The sootblowing system shall be ready to operate. The sequence of operating the
sootblowers shall be from the top downward.
(5) Oxygen (O2) shall be monitored continuously during boiler operation. O2 levels
shall not fall below 3.5%, (based on a dry gas). It is recommended that the O2
analyzer be properly maintained and calibrated periodically as well as before any
startup. The O2 controller shall be held at the last value when its calibration is in
progress.
(6) It is strongly recommended that the reliability of all drum level indicators be
checked at least once a shift. This check shall cover all bi-color water gauges,
electrode water gauge and water level recorders. During this check, the drum level
can be changed to observe the responses of all indicators and gauge glasses.
(7)The furnace bed fluidizing velocity shall not be allowed to drop below 1.2m/sec (the
minimum velocity required to maintain proper fluidization). Refer to Figure 3.2.
350
Air Flow to Bed（mn /h×10 ）
3
300
250
3
200 600℃
750℃
150 900℃
100 1000℃
50
0
0 1 2 3 4 5 6
Fluidizing Velocity（m/s）
Fig. 3.2 Air Flow to Bed vs. Fluidizing Velocity

3.3 COLD STARTUP PROCEDURE
The operating sequence recommended to ensure a safe and proper startup is given
below. Modifications may be necessary as per subsequent operating experience. The
operation of auxiliary equipment shall refer to the manufacturer’ instruction.
Fig. 3.3 Curves of Cold Startup
3.3.1 Preparation Prior to Startup
NOTE
Inspection shall be made on the entire unit (including all parts

and auxiliary equipment) by at least two (2) people to verify that
they are well ready for start-up. For the initiation of the furnace
and U-valve bed material filling, see Paragraph 3.3.2.
1. Operation of the Purge System of pressure tap
The pressure tap purge system shall be put into operation. Blow a small amount of air
into the bed through the pressure taps. Periodically, the pressure taps shall be
manually purged with a blast of compressed air used for instrument. The frequency of
this purging must be determined by experience. Always close the appropriate valves
to protect the purge system’s instrumentation when the compressed air purge is to be
performed.
A similar procedure shall be used for all other pressure taps on the air and gas sides
of the boiler.
2. Make sure the test gags and/or plugs are removed from all safety valves.
3. Check the availabilities of fuel and main fuel for public utilities, power, and ignition.
Check the treated feedwater supply.
4. Check operation of all valves and dampers.
5. Check the start-up (over-bed & in-duct) burner and all boiler auxiliaries, assuring
that all of them are operable and that associated valves are in their proper open or
closed positions.
6. Check availability of thermocouples in representative locations to measure steam

drum metal temperatures.
7. Close all access doors and observation ports after it is proven that no one is inside
the unit. Remove the safety tag on the equipment to be put into service.
8. Set the boiler vent, drainage and instrument valves as per the following
stipulations before water feeding:
No. VALVE DESCRIPTION POSITION

1 HTS outlet Safety Valve Set at 14.39 MPa(g)
2 Steam Drum Safety Valve Set at 15.90 MPa(g)
3 Steam Drum Safety Valve Set at 16.38 MPa(g)
4 LTR inlet Safety Valve Set at 3.06 MPa(g)
5 HTR outlet Safety Valve Set at 2.772 MPa(g)
6 HTS PCV Valve Set at 14.25 MPa(g)
Electromagnetic Relief Valve Shut-off Open
7 Main Feed Stop Valve Closed

8 Main Feed Check Valve Automatic
9 Saturated Steam Pipe Vent Open
10 Drum Pressure Transfer shut-off Open
11 Drum Water gauge Shut off Open
12 Drum Water gauge drain Closed
13 Drum Chemical Feed Closed
14 Drum Emergency Discharge Closed
15 Drum Continuous Blowdown Closed
16 Drum Water Sampling Closed
17 Drum Pressure Instrumentation Valve Open
18 Saturated Steam Sampling Closed
19 Downcomer Drain Closed
20 Eco. recirculation stop valve Open
21 WW Lower Header Periodic Blowdown Closed
22 Rear Pass Roof Wall header Vent Open
23 Rear Pass Lower Header. Drain Open
24 PSH Inlet Header vent Open
25 PSH Intermediate Header Drain Open
26 PSH Outlet Header Vent Open
27 HTS Inlet Header Drain Open
28 HTS Outlet Header Vent Open
HTS Outlet Pressure Instrumentation
29 Open
Connection
30 HTS Outlet Discharge Open
31 LTR Inlet Header Drain Open
32 PRH Outlet Header Vent Open
33 PRH Outlet Discharge Open
PRH Outlet Pressure Instrumentation
34 Open
Connection
35 SH desuperheater Manual Stop valve Closed

36 RH desuperheater Manual Stop valve Closed
37 Stop valve in sootblower main pipe Closed
38 Main Feeder water bypass Stop valve Closed(*)
9. Fill the boiler with qualified water via By-pass Feed Control Valve to the
economizer system.
10. The temperature of the water shall be between 20℃～70℃ and shall not be
below the temperature of the drum metal. Close the vent valve which overflows.
11. Check the drum electrode water gauge operation conditions in the control room
and compare their values with local bi-colour water gauge readings.
12. Check whether all pressure and draft gauges have been calibrated and work
properly.
13. Check all safety interlocks for proper operation.
14. Verify that the drum level is visible in the bi-colour water gauges.
15. Check all lubricating and cooling systems for all driving facilities, make sure they
can meet the manufacturers’ technical requirements and all cooling mediums are
available for equipment that requires cooling.
16. The positions of dampers in the air ducts and gas flues, displayed in the control
room, are as follows. All fuel, limestone and other manual isolation and / or slide
gate dampers shall be set as follows.
No. DAMPER DESCRIPTION POSITION

1 ID Fan Inlet Vanes Open
2 Primary and Secondary FD Fan Inlet Vanes Open
3 Limestone Inlet Closed
4 Ash cooler Inlet duct Closed
5 Upper Secondary Air Open
6 Coal Feed Air Fan Inlet Manual Shut-Off Open
7 Coal Feed Air Fan By-Pass Shut-Off Closed
8 Coal Feeder Outlet Electromatic Shut-Off Open

9 Coal Feeder Inlet Electromatic Shut-Off Closed
10 In-Duct Burner & Furnace Fluidizing Air Open
11 U-Valve Upleg and Downleg Fluidizing Air Open
12 U-Valve Bottom Fluidizing Air Open
13 Lower Secondary Air Open
14 Coal Feeder Inlet Slide Gate Closed
15 U-Valve Blower Outlet Pressure Relief Open
16 Fuel Sweep Air Fan Open
17 Fuel Feeder Seal Air Open
17. The following operation sequence is recommended to ensure the safe and proper
start-up of the boiler. Modifications may be necessary as per subsequent
operating experience.
3.3.2 Purging
Prior to purge and igniting in-duct burner, it is essential to perform an internal

inspection for the combustion air duct at the downstream of the in-duct burner, and the
plenum to check the bed material leakage condition. All bed materials shall be
removed from the duct and the plenum to avoid the plugging of grid nozzles.
Immediately prior to each start-up or start-up after a main fuel trip (MFT), the furnace,
cyclones and rear pass heating surfaces must be purged (except for hot start-up ) as
per the following steps:
1. Ensure that no hot start-up condition exists. (The average bed temperature is
less than 650℃.)
2. Ensure that the boiler is in MFT state but no MFT condition exists.
3. Ensure that the fuel supply valve to the in-duct burner is closed.
4. Check that all limestone and fuel feeders are off and spent bed removal system
is off.
5. Start the induced draft (ID), forced draft (FD) and fuel feed sweep air fans and
two U-Valve blowers as per the following steps:
CAUTION
PRIOR TO STRATING A FAN, IT IS NECESSARY TO INSURE A

UNBLOCKED AIR FLOW PATH FROM THE FD FAN INLET TO THE
STACK TO PREVENT THE OCCURRENCE OF DAMAGES OF THE
FURNACE AND DUCTWORK DUE TO POSITIVE OR NEGATIVE
PRESSURE.
NOTE
The general sequence is to start the U-valve blowers firstly, then

the ID fan, the Primary and Secondary air fan and fuel feed
sweep air fans. Air flow is then set as per purge requirements
and all fans are switched to AUTO MODE. After the purging has
been accomplished, the fans shall be operable for subsequent
start-up.
(1) Ensure that all flue and duct dampers are in the positions specified in
Paragraph 3.3.1, Step 16.
(2) Start two U-valve blowers. Control the U-valve aeration rates within the
values listed in attached Table 3.1 (93℃).
Fig. 3.4 U-Valve Connections
Table 3.1： U-valve Aeration Rates

Operating condition Cold Hot
Temperature （℃） 93 843
Downflow leg Air Flow（Nm3/h）
NA Air Nozzles 1232.2 336.4
Aeration
A25~A28 43.9 72.1
Taps
Aeration
A21~A24 58.6 72.1
Taps
Aeration
A5~A8、A41 A43 A45 A47 58.6 72.1
Taps
Aeration
A33～A36 A42 A44 A46 A48 395.4 129.7
Taps
Subtotals： 1788.6 682.4
Upflow leg Air Flow（Nm3/h）
NB、NC Air Nozzles 1759.4 2084.9
Aeration
A13～A16 A17～A20 58.8 72.4
Taps
Aeration
A1~A4，A9~A12 58.8 72.4
Taps
Aeration
A29~A32，A37~A40 352.9 115.8
Taps
Subtotals： 2229.9 2345.5
Totals： 4018.6 3027.8
U-valve operation is automatically controlled by a program input to the system in the

pre-commissioning stage. Adjustment of air flows to the various aeration taps shall
not be necessary during unit operation. However, U-valve operation shall be
monitored closely to prevent the occurrence of abnormality or trouble at subsequent
start-up.
Verification of proper operation or minor adjustment of aeration flow rates shall be

performed in accordance with the following steps:
(a) Refer to Table 3.1, Fig.3.4 for proper operating parameters.
(b) Switch U-valve upflow leg / downflow leg plenum air flow controls to Auto
Mode.
(c) Switch U-valve blower pressure control valve to Auto Mode and check
whether it functions properly.
(d) Set shut-off valves to each aeration tap to a 65% open position.
(e) Switch upflow leg and downflow leg aeration flow controls to Auto Mode.
(f) Confirm air flow in each aeration tap line.
If there is no flow indication in any line, this trouble may be caused by plugging of the
tap, which shall be cleared by compressed air purge. No attempt to mechanically
dredge the line shall be performed when the unit is in service.
(g) Record aeration air flow rates and U-valve temperature and compare
them with the values in Table 3.1.
(h) Air flow rates that differ greatly from the values given in Table 3.1 shall be
adjusted until they are acceptable. Switch the aeration control to Manual
Mode. Adjust air flow as per 14Nm3/h increments while recording pressure
differentials. Set air flow based on the lowest stable pressure differential.
(i) It is necessary to shut down the unit to dredge multiple plugged or

inoperable aeration taps as soon as possible. The unit may keep on
operating for a short time provided the inoperable or plugged aeration tap
is found out and the horizontal or vertical taps adjacent to it are not
plugged. It is necessary to shut down the unit forcedly to avoid the
occurrence of plugging of U-valve when several taps are inoperable.
(j) Record U-valve aeration flows, pressures and temperatures under 40%,
60%, 80% and 100% BMCR respectively. If necessary, perform the
adjustment procedure stipulated in step (h).
(k) The adjustment above may be performed during boiler commissioning.

The U-valve has self-balance ability. Further adjustment may not be
needed in normal operation.
(3) Start the ID fan. Close the ID fan inlet control vanes and ID fan breaker to
start up the motor. Once the motor starts running and the speed reaches
the stipulated speed, the inlet control vanes shall be adjusted to control the
furnace pressure.
(4) Start the Secondary/Primary fan. Close the fan inlet control vanes and fan
breaker to start up the motor. Once the motor starts running, the inlet
control vanes shall be adjusted to control combustion. However, when
conducting this step, the secondary air fan shall be started firstly, and after
the completion of its startup, the secondary air flow shall be adjusted, and
then start the primary FD fan.
(5) Start one sweep air fan. Close the fuel feeding sweep air fan inlet control
damper and the fan breaker to start up the motor. Once the motor starts
running, the inlet control damper shall be put into operation, and at the
same time open the outlet shut-off damper.
(6) Adjusted automatically by the control system, the unit is ready for purge.
6. Charge the U-valves and furnace bed with initial materials as per the following
method:
(1) When each U-valve is charged with initial materials, a seal shall form between
its upflow leg and downflow leg. The materials shall be added through the
U-valve filling port. The U-valve blower must be in service to supply necessary
air during this operation, and the size of materials must be proper.
(2) The furnace bed shall be charged with initial bed materials, namely rough
limestone or burned material with 0～3mm particle size, until a still bed of
800mm depth forms. Stop charging when the bed pressure reaches 9420Pa.
7. Purge the unit with at least 25% (but not greater than 40%) total air flow for 5
minutes at least.
8. After the boiler has been completely purged, reset the master fuel trip (MFT)
state and perform the following actions:
(1) All secondary air control dampers shall be at minimum open position.
(2) Maintain the air flow equivalent to 1.2m/sec fluidizing velocity.
(3) Position the following parts or devices in the stipulated positions:
(a) Position the in-duct burner and furnace fluidizing air (to plenum) control
dampers in the stipulated positions for proper combustion air.
(b) Establish the minimum combustion air flow of 98439Nm3/h (Fig.3.2, 2m/s,
600℃) by adjusting FD fan inlet vanes.
(c) Ensure that the fuel supply and purging line of the in-duct burner are
unblocked.
(4) Put the steam coil airheater in service for cold end protection. Maintain the
average airheater cold end temperature of 80℃.
3.3.3 Warming the Unit
CAUTION
PRIOR TO IGNITION, A STILL BED OF 800MM DEPTH, WHICH IS

FILLED WITH BED MATERIALS, MUST FORM IN THE FURNACE
AND THE UNIT HAS BEEN PURGED. THE U-VALVE AND ASH
COOLER MUST ALSO BE CHARGED WITH BED MATERIALS.
700
Static Bed Height (mm)
600
500
400
300
200
100
0
0 1960 3920 5880 7840 9800
Bed Pressure Differential (Pa)
Fig. 3.5 Still Bed Height vs. Bed Pressure Differential
NOTE
Figure 3.5 and Figure 3.2 are curves of still bed height versus
bed differential pressure, and fluidizing velocity versus air flow,
respectively. Figure 3.2 may be used to obtain the fluidizing
velocity at a given bed temperature. While firing blended fuel, the
superficial fluidizing velocity shall not be allowed to drop below
1.2m/sec, the minimum superficial fluidizing velocity required to
maintain fluidization. These differential pressures shall be read
on the control room panel.
CAUTION
TO PROTECT THE REFRACTORY IN THE CYCLONE, THE

WARM-UP TEMPERATURE DIFFERENTIAL SHALL NOT EXCEED
85℃/h. MONITOR THIS TEMPERATURE DIFFERENTIAL
THROUGH TEMPERATURE INDICATORS AT CYCLONE INLET.
TO PROTECT THE DRUM FROM UNDUE THERMAL STRESS,

THE METAL TEMPERATURE DIFFERENTIAL BETWEEN THE TOP
AND BOTTOM OF THE DRUM SHALL NOT EXCEED 50℃.
1. Make sure the two recirculation shut-off valves from the economizer inlet to the
downcomer are open. First fully close the following drain valves and then open
them by 1/2 turn:
Rear Pass Lower Header Drains

PSH Intermediate Header Drains
HTS Inlet Header Drains
PRH Inlet Header Drains
LTS Inlet Header Drains
2. Turn off RH side damper and fully open SH side gas damper. At the same time,
check whether there is any accumulated water in RH. Some measures shall be
adopted to prevent the water from being carried into turbine. RH side gas damper
can be opened only after confirming there is steam flowing in RH.
3. The in-duct burner shall be ignited as per the manufacturer’s instruction. Observe
the ignition condition via the observation ports to ensure good combustion.
4. According to the manufacturer’s instruction, the limestone feeder system

(including limestone feed blowers) shall be put into service manually at a
minimum speed. Verify and monitor the operation conditions of rotating equipment
prior to and during start-up and during operation.
NOTE
Bed materials shall be added as required during operation.
5. Monitor the O2 to ascertain the complete combustion. According to the in-duct

burner manufacturer’s instruction, the in-duct burner gas flue wall temperature is
controlled below 950℃.
6. After the in-duct burner has been ignited, the automatic temperature control
system shall be put into service on the base of minimum firing rate.
7. Heat the bed materials and raise the drum pressure. Firing rate shall be regulated
to increase drum pressure and temperature at a rate not exceeding 85℃/h by
regulating the temperature control on the in-duct burner.
8. Adjust combustion to control the gas temperature at the in-duct burner outlet
below 950℃ at the rate not exceeding 30℃ every 20 to 30 minutes. (In-duct
burner is 15% MCR heat input.)
9. While the unit has been heated up and the drum pressure has been gained, the
drum metal temperature and drum level shall be checked.
10. Raise the bed temperature to 468℃ and maintain a combustion air flow of
98439Nm3/h. During the heating of the unit, the drum level will rise. Maintain the
drum level within the allowable range by the continuous blowdown valve and the
feedwater control valve. To maintain the drum level, the mass blow-off valve and
continuous blowdown valve may be used simultaneously if necessary.
NOTE
Under no circumstances shall downcomer or water wall drain

valves be used as blow- off valves.
11. When the drum pressure reaches 0.069～0.103MPa(g), close the following vent
valves:
Drum Vents (On transfer pipes between drum and rear pass)
rear pass Roof Wall Header Vents
PSH Inlet and Outlet Header Vents

PRH Outlet Header Vents

HTS Outlet Header Vents
12. Completely close the following drain valves:
Rear Pass Lower Header Drains

PSH Intermediate Header Drains
HTS Inlet Header Drains
PRH inlet Header Drains
LTR Inlet Header Drains
13. At this time, the drain valve(s) at the downstream of the HTS outlet header and
platen RH outlet header shall remain open to ensure that all water is drained from
the steam circuit.
14. After the drum pressure reaches approximately 0.17 MPa.g, recheck the
indications of the drum bi-colour water gauge by means of a short-term blowdown.
During the blowdown of the gauge glass / water column assembly, it is necessary
to check whether the low water level fuel trip functions to eliminate unnecessary
trip of the unit. Maintain the visible water level in the gauge glass. The water level
in the drum will rise due to swelling of water in the system. Drain the drum as
required by opening the drum continuous blowdown and / or emergency
discharge valves.
15. Switch the drum level control to Automatic Mode.
16. If the boiler water silica or salt content is above the recommended limit, the drum
water shall be drained by the drum continuous blowdown valve until it is kept
within the recommended limit and no further increase in pressure shall be
allowed.
17. Continue heating to build up the drum pressure and maintain the bed temperature
of 470℃. If necessary, feed limestone into the furnace during the warm-up of the
boiler to maintain the bed inventory, which is indicated by bed pressure signals.
18. If it becomes necessary to discharge water from the high temp. superheater, the
vent valve on the main steam connecting pipeline can be opened discontinuously.
However, this method may be used when the boiler pressure reaches 3.45MPa.g.
3.3.4 Start-up (Fuel Firing)
The following procedure shall be performed in combination of the boiler and main
steam piping (supplied by the other manufacturer), such that an unblocked flow path
can be maintained for the steam being produced by the circulating fluidized bed
boiler.
1. Put the ash handling system in service as per the manufacturer’s instruction.
2. Open the block valves for spray desuperheaters.
3. Switch the steam temperature control loop to Automatic Mode, with the desired
steam temperature set.
4. When the bed temperature is above 560℃, start two coal feeders (one at left side
and one at right side of the furnace) and adjust their capacity to 15% of the rated
capacity. Operate the two coal feeders under this capacity for 5 minutes and then
shut down them. Monitor O2 and average bed temperature (ABT) to establish a
total concept of time trend. During the first several minutes, the average bed
temperature shall decrease and then start increasing. O2 amount shall remain
steady initially and then begin to decrease before the average bed temperature
rises. Record a time cycle required for the complete burn-out of the fuel fed into
the furnace. This time cycle shall start from the fuel feeding to the occurrence of
the highest average bed temperature and lowest O2 amount. The time cycle may
be set based on the plant experience, but it may be changed with varied fuels.
With some low reactivity fuels and different unit designs used, it may be
necessary to change the time cycle of batch feeding.
The initial fuel feeding temperature of the boiler can be optimized through enough
experiments on the boiler and the fuel.
NOTE
Monitor each bed thermocouples during the above procedure.

Usually, the temperature at the feed points will decrease locally
while the temperature adjacent to thermocouples will increase
gradually.
5. Start two coal feeders again and adjust their capacity to 15% of the rated capacity.
Operate the two coal feeders under this capacity for 5 minutes and then shut
down them. Monitor the average bed temperature and O2 amount, restart the
feeders under 15% of the rated capacity prior to reaching the peak bed
temperature, and then add fuel for another 5 minutes.
6. Repeat Steps 3 and 4 to gradually increase the average bed temperature (ABT) to
760℃. Once a good coincidence relation between ABT and O2 amount forms, the
feeders can be put into normal operation. Boiler load can then be increased by
increasing feeder capacity. As ABT increases, the combustion rate for the batch
fuel feeding will also increase. This will actually cause a shortening of feeding
period. As the feeding rate increases, some measures must be taken to avoid the
excessive fuel feeding. If the unit has been overfed with fuel, several indicators
will show disproportionate changes. O2 amount will decrease rapidly, perhaps to
zero. ABT will rise sharply. The following actions can be done according to the
degree of excessive fuel feeding:
(1) Do not add fuel prior to the burn-out of the fuel fed into the furnace and
monitor the trends.
(2) Increase limestone or bed make-up feeding to absorb the increased heat
release.
(3) Lower the air supply to the bed to make the furnace kept in the insufficient
combustion condition.
7. As O2 amount continues to decrease and the bed temperature increases to 790℃,

the combustion air flow shall be increases gradually so that it is above
98439Nm3/h and, at the same time, the in-duct burner temperature shall be
decreased to 540℃. At this time, a certain air-fuel ratio shall be maintained.
In the initial start-up period, the protection of the RH is very important because there
is no steam in RH.
(1) Low Temp. RH is located in the front flue of the rear pass. Turn off RH side
gas damper, and watch metal temperature of LTR.
(2) Platen RH is located near the front wall in the upper furnace. The platen RH
inlet temperature and metal temperature shall be supervised and the inlet gas
temperature shall be below 650℃. If the wall temperature of PRH is below
650℃, short time dry firing for PRH is allowable.
(3) Put the by-pass system into operation on time.
(4) After the stable steam flow forms in RH, if the metal temperature of platen RH
is below the alarm value, the boiler could be operated as per normal steps.
8. The required reheating and superheating steam temperatures shall be maintained

during start-up by means of the following methods:
(1) After being desuperheated by the First and Secondary desuperheaters, the
temperature of the superheating steam entering the platen superheater and
HTSH shall has an overheating degree not less than 11℃. See Figure 3.6 for
this steam temperature limits.
(2) After the stable steam flow forms in the RH, the RH & SH side gas dampers
shall be adjusted to make the steam parameters meet the turbine
requirements
390
380
370
360
Steam temp.℃
350
340
330 Satur. Steam
320 ℃
310
300
290 The lowest
280 temp.after
270 spray Ts+11
260
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Drum Pressure(MPa)
Fig. 14 Minimum Limit of Steam Temperature after Spray attemperation
9. Warm, start up and synchronize the turbine when the proper steam pressure and
temperature are obtained.
10. After the turbine put into operation, turn on RH side gas damper to regulate RH
steam temperature (if RH inlet and outlet headers drain valves are in open
condition, close them immediately.)
11. After the turbine reaches synchronous speed and constant feedwater flow has
been maintained, or when the steam flow is greater than 7%, close the
economizer recirculating line shut-off valves.
The other feeders shall be put into service in the same way as the bed temperature
has been stabilized.
12. As the amount of steam delivered to the turbine reaches 10% of the boiler rated
capacity, close the drain valves at the downstream of the hot SH & RH outlet.
13. With the permission of operation conditions, switch the drum level, steam
temperature and air flow controls to Automatic Mode.
14. Gradually decrease the in-duct burner firing rate while gradually increase the fuel
feeding rate until the bed temperature is above 830℃ and O2 amount is stable. (If
necessary the over-bed burner can also be put into operation.)
15. Adjust the combustion air flow and fuel flow to establish the bed temperature of
864℃ while shutting down the in-duct burner, and maintain 3.093% O2.
16. During the normal operation, the limestone feeding rate will vary with the fuel
feeding rate proportionally. The ratio shall be adjusted according to the
concentration of SO2 in exhaust gas.
As mentioned before, Figure 3.5 is a graph of still bed height versus bed pressure
differential, which shall be checked and cold-tested prior to start-up or during trial
operation. While firing the fuel, the fluidizing velocity shall not be allowed to drop
below 1.2m/sec.
17. At this time, begin to operate the ash coolers discontinuously. The ash coolers
shall be charged slowly to allow the primary air flow to adjust the lower bed height
and allow the proper burn-out of solid carbon and adequate cooling of material so
that the components of the solids cooler will not suffer any undue thermal stress.
18. The unit load can now be raised to 100% (MCR) by using the boiler master control.
Observe the following guidelines:
(1) Do not operate the bed at a pressure differential greater than 710mmH2O or
less than 380mmH2O . The 380mmH2O limit is to protect the grid tubes from
overheating.
(2) Do not operate the boiler when the steam output is greater than 440t/h.
3.4 HOT RESTART
The boiler may be shut down for a period of time and held in the hot condition
(slumped but ready to operate again). When the boiler is to be hot slumped, the fuel
feeding shall be stopped and the O2 indicator at the boiler exit monitored. As soon as
the O2 amout starts to increase, stop the fluidizing air flow to the furnace and ash
coolers to minimize bed heat loss. This O2 amount increase indicates that most of the
fuel has been burned and the bed can be slumped by decreasing fluidizing air flow to
zero. The FD and ID and fuel feeding sweep air fans and the limestone feeding
system blowers shall be stopped. The U-valve blower shall remain in operation after
the fans and other blowers are shut down.
NOTE
To prevent damage to U-valve components, the U-valve blower

shall keep on operating until the valve has been cooled to the
temperature below 260℃.
All valves and air control dampers are closed to minimize heat loss. No firing is
maintained in the furnace; therefore, the pressure in the steam drum will decrease,
but proper drum level must be maintained.
NOTE
Figure 3.5 is a graph of still bed height versus bed pressure

differential. Figure 3.2 is a curve of fluidizing velocity versus air
flow. With the measured air flow, Figure 3.2 may be used to obtain
the superficial fluidizing velocity at a given bed temperature. While
firing the design fuel, the fluidizing velocity shall not be allowed to
drop below 1.2m/sec. A hot condition is one in which the average
bed temperature (after being slumped) is above 650℃. If the
average bed temperature is below 650℃, follow the procedures
described for a cold start-up in Paragraph 3.3.
To start up the boiler in a hot condition, the following procedure shall be followed:
1. Check water level in the drum. If necessary, make proper adjustment to reach
the normal drum water level (76mm below the drum centerline).
2. The fuel and limestone feeding systems and bed material extraction system
shall be operable.
3. Start two (2) U-valve blowers and set air flow to obtain proper fluidizing velocity.
Switch the blowers control to Auto Mode.
4. Start ID fan, FD fan and fuel feeding sweep air fans as per the procedures
described for a cold start-up in Paragraph 3.3.2.
CAUTION
IF LARGE AMOUNT OF UNBURNED CARBON EXISTS WITHIN THE

BED, THE COMBUSTION AIR FLOW MUST BE INCREASED
GRADUALLY IN ORDER TO PURGE THE BED AND ESTABLISH A
CONTROLLED BURNING RATE.
5. Adjust the combustion air to 25% MCR condition. When all fans are running,
proper air flow must again be established along with restart of the fuel feeding.
Since the bed temperature can drop rapidly, it is important to acquire proper air
flow and fuel feeding rate. Otherwise, the bed temperatures and O2 values will
not respond accordingly. If the unit does not respond to the proper feeding
rates of air and fuel, discontinue the hot start-up procedure and begin the cold
start-up methods. Purge the unit prior to igniting the in-duct burner.
6. During the hot restart, if solid fuel has been overfed into the bed and has not
fully combusted, a higher bed temperature will be again established, then the
bed temperatures may rise rapidly and O2 amount decrease rapidly. If this
happens, no further fuel feeding shall be performed until the bed has been
stabilized. If the temperature rise appears to be rapid enough to rise above
950℃, the following items shall be implemented in advance of achieving
950℃.
(1) Lower the air supply to the bed to starve the combustion process.
(2) If the unit is not stable, as indicated by O2 amount and bed temperature
trends, the in-duct burner shall be shut down.
NOTE
When re-establishing the air flow in a hot start-up condition, bed

temperatures may drop rapidly. Establish overfire air supply firstly
and then grid air supply to minimize heat loss.
7. Continue with hot restart as per the procedures listed in Paragraph 3.3.4, Steps
6 through 16.
NOTE
If the bed temperature does not rise after five minutes of the fuel
feeding, hot start-up fails. At this time, stop fuel feeding and purge
the unit, then star up the unit as per the normal cold start-up
procedure.
3.5 NORMAL OPERATION
3.5.1 Combustion
The fluidized bed boiler superheater outlet pressure shall be maintained within the
normal scope of 13.73MPa.g ± 0.1MPa during the normal operation except for
start-up and shutdown of the boiler.
1. The primary technique for changing the boiler load involves varying fuel feeding
rate and air flow. Bed temperature may be varied between 790℃ and 911℃. A
large increment of bed temperature within a short period of time is also
permitted. However, after obtaining the desired steam rate, the bed temperature
shall be kept at 864℃ and the boiler load shall be kept steady by adjusting the
bed inventory and combustion rate. When changing the boiler load, the bed
temperature shall be maintained at a constant value if possible. In all cases, it is
necessary to insure proper air fuel ratio and normal combustion.
2. To maintain normal combustion during operation, the excess O2 value shall be

monitored continuously. Fig. 3.1 shows the set excess O2 value under various
loads.
3. The SO2 emission from the boiler shall be monitored at all times. The limestone
feeding rate must be adjusted, either manually or automatically, to insure that
the SO2 emission level is in compliance with concerned regulations.
If the furnace temperature is within the normal range during operation, NOx emission
is inherently low. NOx emission will be increased as the furnace temperature is
increased. The NOx emission level shall be checked periodically through the
Continuous Emission Monitoring System (CEMS). Proper adjustment, if necessary,
shall be made to control the furnace temperature and secondary air distribution
through each level of air ports.
4. Periodically inspect the fluidized bed for even fluidization. A low temperature
measured by any of the lower bed thermocouples indicates loss of fluidization. If
a portion of the bed is not fluidized, increase bed air flow and temporarily
increase bed material extraction rate. If these measures do not improve
fluidization, it is necessary to shut down the boiler and perform inspection for
plugging of the air distribution grid, clinkers in the bed or large size solids
accumulation.
5. Continuously monitor the gas side pressure differential of the convection heat
transfer surface and periodically inspect the heat transfer surface for ash
accumulation.
6. Periodically inspect the fuel and limestone feeding systems for plugging,
improper sounds, vibration, lubrication and temperatures.
7. Continuously monitor the fluidized bed level and maintain it at its normal level by
adding limestone or increasing bed extraction rate. Bed material extraction is
required to maintain proper bed material inventory and SO2 control.
8. Continuously monitor the air distribution grid pressure differential. If this

differential decreases significantly, check instruments/meters for proper
operation and check sense lines for plugging. If instruments/meters operate
properly, shut down the boiler and inspect the air distribution grid.
3.5.2 Boiler feedwater and steam quality
1. It is necessary to assure that the desired boiler feedwater salt concentration and
chemical composition are maintained. Improper boiler feedwater can lead to
fouling or corrosion of internal surfaces, reducing the efficiency of the unit and
possibly resulting in overheating of tubes, even tube rupture.
2. It is necessary to assure that the moisture of steam from the drum is within the
permissible limit. When the boiler operates under the design conditions, the steam
separation equipment shall make the steam salt content kept within the
acceptable limit. The moisture carried by the steam includes salt and other
impurities which may deposit on the internal surfaces of tubes along the boiler
steam flow.
3. Opening or closing the continuous blowdown valves shall be determined by the

chemical characteristics of boiler water. When opening these valves, the boiler
thermal input shall be increased to keep the stable operation conditions. It is
necessary to note that the drain valves on the lower waterwall headers shall never
be used for blowdown purpose when the unit is in operation.
3.5.3 Sootblowing
All external surfaces of tubes and parts must be free of soot deposits to insure the
rated load and high efficiency operation of the boiler. Sootblowing shall be performed
as often as necessary to accomplish this purpose.
After the unit is put into service, operate the sootblowers to remove any soot deposits
which may be present. Sootblowing shall always be done on the pre-established
schedule basis regardless of the operating load; however, below 50% load the FD and
ID fans shall be in manual control during the sootblowing operation.
Sootblowing is considered as a part of the boiler operation and sootblowing process

shall be monitored to achieve an optimum cleaning result. Monitoring or inspecting the
following items will insure the establishment of the optimum sootblowing sequence:
(1) Properly operate the drain valves of sootblowing. The improper operation of
the drain valves will result in the occurrence of tube erosion within the
several feet scope along the sootblower travel, which is caused by water
droplets entrained in the steam being propelled against the tube surface.
(2) Check the blowing pressure setting of individual sootblower. Refer to the
manufacturer’s instruction for exact setting.
(3) During unit down time, visually inspect the rear convection pass for ash
accumulation.
(4) Monitor the high temp. superheater tubes and outlet steam temperatures.
(5) Monitor the changes in desuperheater spray flow.
(6) Monitor economizer and airheater exit gas temperatures.
(7) Monitor airheater air and gas side pressure differential variations.
(8) Monitor gas side system resistance through the rear pass.
Typically, when the sootblowing system is firstly commissioned, the aforementioned

boiler parameters are monitored and an optimized sootblowing sequence is adapted.
Periodic monitoring of the system can help prevent an unscheduled outage.
3.5.4 Spray Attemperation
It is necessary to insure that the temperature of the steam entering the PSH and HTS
inlet headers, after desuperheated by spray attemperation, is 11℃ more than the
saturation temperature at the inlet pressure of the transfer pipes.
3.5.5 Reheated Steam Temperature Regulation
The regulation of reheated steam temperature can be done by adjustment of control

damper at the outlet of dual-flue of the rear pass. The adjustment of the damper shall
be ordered, ensuring that the total opening of the damper is greater than 100%.
The total opening of the damper will vary according to the different fuel and load.
3.6 NORMAL SHUTDOWN
1. Normal shutdown involves reducing the unit load orderly, thus allowing the
turbine and boiler to be disconnected with no great temperature or pressure
fluctuate caused and at the same time keeping the unit at the hot standby
condition as much as possible. Unit load reduction can be accomplished
automatically by means of all AUTO controls.
2. The unit sootblowing shall be performed before reducing load and shutdown.
3. During shutdown, the metal temperature difference between the upper and lower
walls of the drum wall shall not exceed 50℃, and the temperature reducing
speed shall be less than 80℃/h, to prevent damages to the refractory in the
cyclone.
4. If necessary, control the superheater outlet temperature by regulating the

desuperheater spray water flow. Close the water shut-off valves when
attemperation is no longer required.
5. Check and maintain the normal drum water level.
6. Reduce the unit load to minimum stable load. Maintain the minimum unit load for
approximately 50 minutes to help cool the cyclone refractory.
7. Switch the boiler master control to Manual Mode.
8. Close all fuel silo hopper outlet shut-off valves and empty all fuel feeders (if an
extended shutdown is expected). Also, maintain the lowest safe fuel storage
levels in the storage silos.
9. Shut down the limestone feeder system.
10. Monitor the boiler oxygen level and bed temperature; when the oxygen amount
starts to increase and the bed temperature starts to decrease, close the air (to
plenum) control damper.
11. To avoid the fly ash accumulation, the purge for the cyclone inlet flue shall be
continuously performed when the load is below the minimum stable load until the
high-pressure blower for U-valve is stopped. The purging air is from hot SA duct.
The total flow of the purging air for one boiler is 2000Nm3/h.
12. When the load is reduced below approximately 10% of rated boiler capacity, open
drain valves of the main steam line and HTS outlet header. Pay attention to the
control of the furnace cooling rate. And these drain valves shall not be completely
closed off as long as steam is still generated during the process.
13. After flameout, keep the FD, ID and fuel feed sweep air fans in operation for at
least five minutes to purge the combustible matters.
14. If the boiler pressure needs to be maintained after shutdown, shut down the fans
after purging the unit. Close any associated fan dampers to retain heat. Be sure
that ash coolers are free of material. When the drum pressure has fallen below
the lowest set values of safety valves, and there is insufficient heat remaining to
pop the safety valves, close the drain valves of the HTS. The drain and vent
valves shall remain closed when there is no combustion in the unit.
15. Before igniting the unit to maintain steam pressure, the drain valves of HTS outlet
header main steam connecting pipeline must be opened. Keep the drain valves
open during firing and keep the feedwater supply system in operation as long as
steam is generating from the unit. Assure that the drum water level is close to the
normal level indication of the gauge glass during combustion.
16. Continue to cool down the unit by fans if the boiler is to be out of service for an
extended period or for maintenance, at the same time, remove bed materials via
the ash cooler. The drain valves at the downstream of the HTS outlet header may
be regulated along with other superheater drain valves to decrease the drum
pressure at the desired rate. Cool the unit as uniformly as possible. The residual
heat in the boiler setting and the boiler components will continue to generate
steam for a considerably long time. During this period, the boiler water level shall
be kept close to the upper limit of the gage glass. Once all bed materials are
removed from the unit, purge the boiler setting for five (5) minutes. The ash
cooler shall then be out of service. When the unit is cool enough for human entry,
the fans can be shut down.
17. Close the ash cooler inlet damper.
18. Stop the fuel feeding system. Shut down the FD, ID and fuel feed sweep air fans.
19. The U-valve blower shall remain in operation after the FD, ID and fuel feed sweep
air fans are shut down. To prevent damages to U-valve components, the U-valve
blower shall remain in operation until the valve has been cooled to below 260℃.
20. Shut down the ash system.
21. If the unit is to be drained, open all vents and drains when the drum pressure has
decreased to 0.1MPa.g. The boiler water temperature shall not exceed 120℃
when the unit is drained. When there is still a small amount of pressure in the unit,
draining the unit is preferred as the residual heat will assist in drying the internal
surfaces.
22. Superheater header drain and vent valves shall remain open during short outage.
23. During outage, it is not allowed that an idle boiler is partially filled with water for a
long time. Fill the boiler completely with deaerated alkaline water into which
hydrazine has been added as a protection against corrosion. If the outage will last
several weeks or months, or due to weather conditions, drain and dry the unit.
Place several shallow pans filled with a predetermined quantity of silica gel in the
drum to absorb moisture and maintain the internal surfaces in a dry condition.
When the unit is to be out of service for several days or longer, all ash and soot
deposits shall be removed because the moisture absorbed by ash or soot
containing sulfur will cause corrosion. It is advisable to sootblow the unit just
before taking it out of service, if possible.
3.7 EMERGENCIES
3.7.1 Main Fuel Trip (MFT)
On a main fuel trip, the following actions will take place:
1. Fuel feeders trip.
2. Limestone system trip.
3. In-duct and over-bed burners trip.
4. Ash cooler trip.
5. All air flow controls are switched to Manual Mode and kept at the last positions.
6. Fans controls are switched to Manual Mode and kept at the last positions unless
there is a fan trip when fan controls follow fan logic.
7. The signal is transmitted to the combustion controls to limit the automatic control
of ID fan, thus insuring that the furnace pressure is not above the set limit.
8. “Required Boiler Purge” logic is set unless the boiler is in the “Hot Restart”
condition.
z Any of the following conditions will cause a boiler main fuel trip (MFT).
1. Both MFT push buttons are pressed simultaneously.
2. The bed temperature is greater than 990℃ (signal from the Combustion Control
System).
3. Loss of logic control power.
4. The two ones of the three logics indicate the high high value of furnace pressure:
+2489Pa (with time delay).
5. The two ones of the three logics indicate the low low value of furnace pressure:
-2489Pa (with time delay).
6. The two ones of the three logics indicate the high high value of drum water level:
200mm above the normal water level (with time delay).
7. The two ones of the three logics indicate the low low value of drum water level:
280mm below the normal water level (with time delay).
8. ID fan trip.
9. Primary & Secondary fan trip.
10. The total air flow is low or less than 25% (with time delay) (signal from the
Combustion control System).
11. The Combustion Control System Power fails (signal from the Combustion Control
System).
12. The In-duct burner is out of service and the bed temperature is less than 650℃.
13. Two or more U-valve blowers trip.
14. Turbine trip.
15. The fuel feeding sweep air fans are out of service and the bypass is not opened
(with time delay).
16. The bed temperature is below 540℃.
3.7.2 Emergency Operating Procedure
z Tube Leakage
If such phenomena are found as high make-up water usage and abnormal deviation
between feedwater flow and main steam flow or tube leakage detected by audio or
visual inspection device, the unit must be shut down as quickly as possible to
minimize the moisture in the bed materials. The unit load shall be decreased as
quickly as possible and fuel feeding to the unit shall be stopped. Close the isolation
gates on all fuel feeders. Restart or continue to operate the ash coolers and the ash
removal system at a maximum rate.
Continue to operate fans and maintain the air flow to the furnace to keep the bed
materials moving into the ash cooler. Some air flow to the secondary air ports shall be
established to remove the moisture in the air ducts. Reduce the drum pressure as
slowly as possible and maintain the drum water level, if possible. Continue to cool the
unit and extract the bed materials until the unit is empty of bed materials and cool
enough for person to enter the unit. During cooling the unit, the temperature difference
between the upper and lower walls of the drum shall not exceed 50℃. The drum water
level shall be maintained until the boiler water temperature is reduced below 120℃;
then the boiler shall be drained. If the tube leakage happens in the furnace, it may be
necessary to start up the in-duct burner when removing the bed materials from the
furnace to evaporate the leaking water. If the bed is damp and its temperature drops
below 180℃, the bed materials may plug the ash handling system or stay within the
furnace. If the in-duct burner is utilized, it is important that the burner temperature
shall be kept below 315℃.
Before entering the unit for any reason, it is necessary for the maintenance personnel
to check that the safe temperature has been reached, perform gas sampling test for
safe level and wear proper protective clothing.
When the access to the bed is safe and all dischargeable bed materials are extracted,
the maintenance personnel shall enter the unit to assess the extent of the tube
leakage and amount of bed materials remaining. Any material, wet or dry, left in the
bed shall be removed as soon as possible before it has a chance to be solidified. The
solidified bed materials below the level of the grid nozzles need not to be removed.
However, the grid nozzles must be inspected, and any plugged nozzles shall be
dredged by means of cleaning rod and compressed air from below the nozzles under
insuring that no one is working on the opposite side of the nozzles.
z Excessive High Bed Temperature
The excessive high bed temperature can lead to clinkers (melt ash) and damages to
in-bed thermowell, thermocouples and grid nozzles, etc.
Excessive high bed temperature shall be avoided by increasing limestone feeding rate
and shutting down the ash coolers in an effort to increase the bed inventory and cool
the bed temperature. Load and fuel flow shall be reduced until the bed temperature
starts decreasing to avoid the formation of clinkers.
z Clinkered Bed
“Clinkers” in the bed are considered to be agglomerated masses of melt or cemented

ash which can be formed when firing fuel at low air/fuel ratio, elevated bed
temperatures or reduced superficial velocity. The risk of clinker forming is great when
the temperature exceeds 930℃.
If any of the above abnormal operating conditions is encountered, the operators shall
monitor the individual bed temperature thermocouple. If clinkers form, localized hot
spots will appear, followed by localized loss of fluidization and low bed temperature
zone. If it is confirmed that the isolated low bed temperature zone is not due to
instrument/meter failure or lack of fluidizing air, it may be suspected that there are
clinkers in the bed, and the unit shall be shut down according to the normal shutdown
procedure, with all possible bed materials extracted.
The actual cooling-down time is dependent upon the boiler load and bed temperature
during shutdown. Also, when the drum water temperature drops to 120℃, the unit can
be drained to aid cooling. During cooling-down, the maximum wall temperature
differential between the top and bottom of the drum shall not exceed 50℃. The
minimum air flow (equivalent to 1.2m/sec superficial velocity to the bed) shall be
maintained in order to cool the bed and ensure the transfer of loose bed materials to
the bed drain. When the unit is cool and no more bed materials can be removed
through the bed drain system, shut down the fans and make the necessary safety
preparations before the relative personnel enter the furnace. After entering the unit,
the personnel shall evaluate the extent of the clinkers. Small accumulations can be
broken up and removed. It is necessary to inspect that any damage happens to the
bed temperature thermocouples and grid nozzles. Any damaged thermocouple shall
be repair or replaced. All grid nozzles shall be inspected for plugging and dredged as
required.
3.7.3 Overpressure Protection
To prevent the occurrence of overpressure of boiler pressure parts due to

maloperation during operation, the unit shall be equipped with the following safety
valves and pressure relieving devices.
Description Location Qty. Set Pressure (MPa)

Safety Valve Steam Drum 1 15.9
Safety Valve Steam Drum 1 16.38
Safety Valve HTS outlet header 2 14.39
PCV Valve HTS outlet header 2 14.25
Safety Valve PRH outlet header 2 3.06
Safety Valve LTR inlet header 2 2.772
3.8 MAINTENANCE
1. During long-term boiler shutdown, the following items shall be followed:
CAUTION
DO NOT FILL THE BOILER WITH UNTIL ALL INTERNAL PRESSURE

PARTs INSPECTION AND/OR MAINTENANCE PROCEDURES ARE
COMPLETED. NITROGEN GAS PROTECTION SHALL BE USED
FOR THE IDLE BOILER. NITROGEN GAS FILLING SHALL BE
COMPLETED BY CONNECTING A NITROGEN SUPPLY OR
THROUGH A REGULATING VALVE TO A DRUM VENT.
If an idle boiler is not drained, the areas above the drum water level i shall be filled
with nitrogen gas through the above mentioned access on the drum. The nitrogen
gas blankets shall be established when the boiler pressure decreases to about
0.035MPa.g after shutdown. Maintain the nitrogen gas blankets during shutdown.
During this period, the boiler must be protected against freezing conditions. This may
be done by firing the in-duct burner shall be ignited to introduce low heat into the unit
to keep the temperature throughout the boiler above the freezing point.
If the weather or other conditions don’t allow the unit to be filled with water, it shall be
drained and dried. Place several shallow pans filled with a predetermined quantity of
silica gel in the drum to absorb the moisture and maintain the internal surfaces in a
dry condition.
2. When the unit is shut down for maintenance, the relative maintenance personnel
shall never enter the until it has been determined that all fuel shut off valves and
dampers are locked in the closed position. If there are some questions about their
tightness, it is recommended that the fuel lines be blanked off.
CAUTION
THERE ARE ACCESSIBLE AREAS IN THE BOILER THAT COULD

EXPOSE THE MAINTENANCE PERSONNEL TO HAZARDOUS
CONDITIONS. SOME OF THESE AREAS ARE THE PASSAGE
BETWEEN THE FURNACE AND THE CYCLONE INLET, WHERE
SOME OBJECTS COULD DROP INTO THE FURNACE AND
CYCLONE EXIT, THE U-VALVE, WHERE HOT BED MATERIALS
COULD ACCUMULATE, AND VIRTUALLY EVERY ACCESS DOOR,
WHERE BACK KICK OF AIR CURRENT COULD OCCUR. BEFORE
OPENING ANY ACCESS DOOR FOR ANY REASON, EXERCISE
EXTREME CAUTION TO GUARD AGAINST THESE DANGERS.
SHALL WEAR PROTECTIVE CLOTHING AND STAND AT THE SIDE
OF DOOR (DO NOT JUST FACE THE DOORS) WHEN OPENING
DOORS. DO NOT STAND JUST FACING THE DOORS. IT IS
NECESSARY TO USE SUITABLE BREATHING APPARATUS AND
SAFETY CLOTHING, IF NECESSARY, WHEN ENTERING THE
BOILER. IT IS NECESSARY FOR THE MAINTENANCE PERSONNEL
TO CARRY OR INSTALL ADEQUATE LIGHTING AND ALWAYS BE
AWARE OF IMMEDIATE SURROUNDINGS AFTER ENTERING THE
UNIT.
CAUTION
PROPER GAS SAMPLING TEST SHALL BE ACCOMPLISHED AND

PROPER O2 LEVELS SHALL BE ESTABLISHED.
3. Only approved safe types of lights and flashlights could be used when performing
inspection and working in the boiler.
4. During outage, the pressure parts and other internal surfaces shall be inspected if
possible. Unusual signs of wear or accumulations shall be investigated and their
causes eleminated.
5. Inspect each air distribution grid plate nozzle for plugging, and the plugged
nozzle must be dredged.
6. After inspection doors are opened for access, the used gaskets shall be replaced
with new ones.
7. During the overhaul period, the over-bed and in-duct burners shall be carefully
inspected for any damage and their maintenance or repair shall be performed in
accordance with the manufacturer’s recommendations.
8. Repair all leaking tubes as soon as possible. Leakage which is allowed to persist
can cause further damages because the water or steam which leaks from these
tubes will cut adjacent tubes.
9. Repair shall not be attempted on parts which are still subjected to pressure.
Repair of pressure parts shall be accomplished when the pressure has been
relieved and the system isolated.
10. Combustion control equipment and other control equipment such as feedwater
regulators and steam temperature controllers shall be kept in optimum
adjustment conditions at all times. The boiler efficiency depends upon the proper
functioning of these controls.
11. Check all fuel and limestone feeding pipelines and bed material extraction
pipeline for plugging, erosion, overheating, etc. Repair or replacement shall be
performed if necessary.
12. All valve and packing leakages shall be repaired during the outage period. This
will help prevent the occurrence of forced outage.
13. Thoroughly inspect the general conditions of all thermocouples and pressure taps,
and repair shall be performed for reliable operation if necessary.
14. Check the plenum floor for accumulation of spent bed materials due to back flow
of bed materials through grid plate air nozzles. Remove excessive bed materials.
15. Careful inspection of the boiler pressure parts shall be made to monitor any
erosion of tubes. Ultrasonic wall thickness measurements as well as tube outside
diameters shall be recorded on a regular basis (1～2 times a year). The areas to
be monitored include the furnace wall tubes, furnace outlet screen tubes, rear
pass outlet screen tubes, superheater tubes and economizer tubes.
16. The cyclone, U-valve, furnace roof and furnace exit refractory shall be inspected
on a regular basis and repaired if necessary.
SECTION 4 ATTACHMENT
4.1 Boiler Performance data summary sheet(I) －Performance coal 100%B-MCR condition
Boiler Parameters Desuperheating of SH：Spray water LHV HHV KCal/kg 2900

SH steam flow Dgr t/h 440 Primary stage D1 t/h 13.27 Fuel consumption Qf ×103kg/h 126.7
SH steam temp. Tgr ℃ 540 Secondary stage D2 t/h 6.63 Boiler efficiency η % 91.5
SH steam outlet pressure Pgr MPa.g 13.73 Spray water temp. ℃ 166.7 Limestone
Feed water temp. Tgs ℃ 248.6 Desuperheating of RH：Damper regulating (CaCO3)ar / % 96
Inlet Temp. at Air Heater Ta ℃ 38 Gas ratio of RH side % 45 (MgCO3)ar / % 0.525
Drum operation pressure Pgt MPa .g 15.1 Coal (Other)ar / % 3.475
RH steam flow Dzr t/h 356.114 Carbon Car % 30 Lst consumption / t/h 10.88
RH steam outlet temp. Tzr ℃ 540 Hydrogen Har % 2.5 Others
RH steam outlet pressure Pzr MPa .g 2.57 Oxygen Oar % 9.3 Tot Air flow Qa ×103mn3/h 463.1
3
RH steam inlet pressure Pjk MPa .g 2. 73 Nitrogen Nar % 0.3 Gas flow Qg ×10 mn3/h 570
RH steam inlet temp. Tjk ℃ 320 Total Sulfur Sar % 1.2 Bed temp. Tb ℃ 864
Moisture Mar % 45 Load：100%B—MCR
Ca/S / / 2.2 Ash Aar % 11.7 Performance coal
Gas. air and steam temperature profile

Item Symbol unit furnace Platen SH Cyclone Enclosure HTS LTS Platen RH Cold RH Eco. Air Heater
Gas inlet temp. Tin ℃ / / 865 844 776 649 / 815 515 315
Gas outlet temp. Tout ℃ / / 880 / 663 508 / 522 315 149
Media inlet temp. Tin ℃ 341 378 / 341 487 358 471 320 248.6 38
Media outlet temp. tout ℃ 341 502 / 358 540 394 540 471 319 290
Excessive air factors α / 1.17 / 1.17 1.17 1.17 1.17 / 1.17 1.17 1.17

DEC CFBC Boiler Manual

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PROJECT

8 X 135 MW LIGNITE THERMAL POWER PLANT

RAJ WEST POWER LIMITED (RWPL)

DESEIN PRIVATE LIMITED

DONGFANG ELECTRIC CORPORATION

DONGFANG BOILER GROUP CO., LTD.

OPERATION INSTRUCTION FOR CFB BOILER

Document No. 39J-SM

CIRCULATING FLUIDIZED BED BOILER

The recommendations contained in the operation instruction are prepared by DBC

1.4.19 Abrasion proof and refractory materials ........................................................................................ 37

3.7.3 Overpressure Protection .................................................................................................................... 99

SECTION 1 CONSTRUCTION DESCRIPTION

1.1 Design Conditions

1.1.1 Boiler Specifications

The boiler maximum continuous rating (BMCR) is corresponding to turbine regulating

Boiler Type: DG440/13.73-II14

Maximum Steam Flow 440t/h

Superheat Steam Outlet Pressure 13.73MPa(g)

Superheat Steam Outlet Temperature 540℃

Reheat Steam Outlet Temperature 540℃

Reheat Steam Outlet Pressure 2.57MPa(g)

Reheat Steam inlet Temperature 320℃

Reheat Steam inlet Pressure 2.73MPa(g)

Reheat Steam Flow 356.114t/h

Feedwater Temperature 248.6℃

Notes: Above mentioned (g) indicates gauge pressure.

1.1.2 Boiler Main Dimensions

Furnace Width (Between CL of Side Walls) 17170mm

Item Symbol Unit Performance Coal Worst Coal

Fig. 1.1 Coal Size Distribution Curve

1.1.4 Ash Characteristics

Compositions of ash (with no limestone sophisticated)

Sulfur trioxide SO3 % 0～10

1.1.5 Limestone for Desulfurization

Composition Symbol Unit Value

Fig. 1.2 Limestone Size Distribution Curve

1.1.6 Igniter Type ,Fuel for Ignition and Combustion Support

The diesel oil analysis data are as follows:

Item Unit Value

Density (15℃) (approximation） kg/m3 850 - 870

Water(max) % vol. 0.25

Sediment and Water (max) % wt 0.10

Sulphur (max) % wt 1.8

Item Unit Value

HHV（approximation） Kcal/kg 10,000

1.1.7 Feedwater Quality

Make-up water: one stage desalination and blend bed.

Boiler normal continuous blowdown rating: 0.3-1%

Hydrazine (N2H4) 10-50μg/L (Volatility treatment)

Dissolved oxygen (O2) ≤7μg/L

The fountain of this power plant is from IGNP River .

1.1.9 Natural Conditions

Power plant address Bothya city of Rajasthan, Indian

Minimum daily average temperature in

1.1.10 Operation Mode

5) Bottom ash removal: Bottom ash is discharged continuously or periodically

8) Compressed air pressure: 0.5~0.7MPa; electric voltage: AC 400V/230V; DC 220V;

motor protection degree: IP54.

1.1.11 Draft Mode

1.2 General Description Of DONGFANG Type CFB Boiler

1.2.1 CFB Technology Description

As a cleaning coal combustion technology, the Circulating Fluidized Bed (CFB)