O - M Manual Vol 1 CFBC Boiler (Bg013)

Cethar Vesse ls Lt d
Utilit y Division
Shree Cement Limit ed

85 T P H CF BC Boi l er ( BG 0 13)
INDEX
VOLUME I
BOILER COMPONENTS AND OPERATION

1.0
CONTRACT DATA SHEET
2.0
INTRODUCTION TO CFBC BOILER
3.0
GENERAL DESCRIPTION OF CFBC BOILER
4.0
BOILER PRESSURE PARTS
5.0
NON PRESSURE PARTS
6.0
SYSTEM DESCRIPTION
7.0
REFRACTORY
8.0
WATER CHEMISTRY GUIDELINES
9.0
STARTING OF INDIVIDUAL EQUIPMENT
10.0
BOILER START-UP PROCEDURE AND OPERATION
11.0
SHUTDOWN PROCEDURE
12.0
PRESERVATION OF BOILER
13.0
PROCEDURE FOR HYDROSTATIC TESTING
14.0
PROCEDURE FOR ALKALI BOIL-OUT
15.0
PROCEDURE FOR STEAM BLOWING
16.0
DOS AND DONTS
17.0
TROUBLE SHOOTING
18.0
QUICK REFERENCE
Page 1 of 1 52
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VOLUME II

MECHANICAL, ELECTRICAL AND INSTRUMENTATION DOCUMENTS
(BG013)
1.0 MECHANICAL DOCUMENTS
2.0 ELECTRICAL DOCUMENTS
3.0 INSTRUMENTATION DOCUMENTS
VOLUME III
FANS & BLOWER

1.0 FANS
2.0 LOOP SEAL BLOWER
VOLUME IV
VALVES
1.0 MANUAL VALVES
2.0 CONTROL VALVES
3.0 FIXED NOZZLE DE-SUPERHEATER
4.0 MOTORISED VALVE
5.0 SAFETY VALVES
6.0 KNIFE EDGE GATE VALVE
VOLUME V
ELECTRICAL AND INSTRUMENTATION VENDOR MANUALS

1.0 ELECTRICAL
2.0 INSTRUMENTATION
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VOLUME VI
INSTRUMENTATION VENDOR MANUALS
VOLUME VII
FUEL FEEDING AND BED ASH COOLING SYSTEM
VOLUME VIII START UP BURNER SYSTEM
VOLUME IX
ELECTRO STATIC PRECIPITATOR
VOLUME X
DRAWINGS
1.0 GENERAL ARRANGEMENT (ELEVATION)
2.0 GENERAL ARRANGEMENT (PLAN)
3.0 GENERAL ARRANGEMENT (SECTIONAL SIDE VIEWS)
4.0 P&ID DIAGRAM FOR FUEL FEEDING, AIR & FLUE GAS SYSTEM
5.0 P&ID DIAGRAM FOR FEED, STEAM LINE, BLOW DOWN TANK
6.0 LEGEND, SYMBOLS & TAGGING PHILOSOPHY
7.0 GENERAL ARRANGEMENT (FANS)
8.0 GENERAL ARRANGEMENT (REFRACTORY)
9.0 GENERAL ARRANGEMENT (EXPANSION MOVEMENT)
10.0 GENERAL ARRANGEMENT (FEEDER)
11.0 ELECTRICAL DRAWINGS
VOLUME XI
VARIABLE FREQUENCY DRIVE
Page 3 of 1 52
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TABLE OF CONTENTS
VOLUME 1: BOILER COMPONENTS & OPERATION
1.0
CONTRACT DATA SHEET ------------------------------------------------------------- 009
2.0
INTRODUCTION TO CFBC BOILER ------------------------------------------------ 012

2.1
Atmospheric Fluidised Bed Boiler -------------------------------------- 012
2.1.1
Characteristics of BFB Boiler --------------------------------------------012
2.1.2
Characteristics of CBFC Boiler ------------------------------------------013
2.2
Advantages of CFBC Boiler ----------------------------------------------015
3.0
GENERAL DESCRIPTION OF CFBC BOILER ----------------------------------- 016
4.0
BOILER PRESSURE PARTS ---------------------------------------------------------- 018

4.1
Steam Drum ----------------------------------------------------------------- 018
4.1.1
Drum Internals -------------------------------------------------------------- 019
4.1.2
Installation ------------------------------------------------------------------- 021
4.1.3
Data Sheet for Steam Drum -------------------------------------------- 022
4.2
Down Comers and Risers ------------------------------------------------ 023
4.2.1
Data Sheet for Downcomers and Risers ---------------------------- 023
4.3
Combustor (Furnace)-------------------------------------------------------024
4.3.1
Distributor Grid---------------------------------------------------------------024
4.3.2
Lower Part --------------------------------------------------------------------024
4.3.3
Upper Part --------------------------------------------------------------------025
4.3.4
Data Sheet for Combustor ----------------------------------------------- 026
4.4
Hot Cyclone Separator and Loop seal ---------------
4.5
Vortex Finder ---------------------------------------------------------------- 028
4.6
Cross Over Duct (Cyclone Outlet Chamber-COC) ---------------- 028
4.7
Super Heaters --------------------------------------------------------------- 029
4.7.1
Primary Superheater ------------------------------------------------------ 029
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(Prelim inary)
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4.7.1.1 Data Sheet for Primary Superheater ---------------------------------- 030

4.7.2
De-superheater ------------------------------------------------------------- 031
4.7.2.1 Data Sheet for De-superheater ----------------------------------------- 032

4.7.3
Wingwall (radiant) Superheater ----------------------------------------- 033
4.7.3.1 Data Sheet for Wingwall (radiant) Superheater -------------------- 035

4.7.4
Final Superheater ---------------------------------------------------------- 036
4.7.4.1 Data Sheet for Final Superheater ------------------------------------- 037
5.0
6.0
4.8
Economiser ------------------------------------------------------------------ 038
4.8.1
Data Sheet for Economiser ---------------------------------------------- 039
NON PRESSURE PARTS ---------------------------------------------------------------040

5.1
Tubular Air Pre-heater ----------------------------------------------------- 040
5.1.1
Data Sheet for Tubular Air Pre-heater -------------------------------- 040
5.2
Electro Static Precipitator ------------------------------------------------- 041
5.3
Bed Ash Cooler ------------------------------------------------------------- 041
SYSTEM DESCRIPTION ---------------------------------------------------------------- 042

6.1
Air System ------------------------------------------------------------------- 042
6.1.1
Primary Air System -------------------------------------------------------- 042
6.1.1.1 Primary Air Distribution --------------------------------------------------- 043

6.1.2
Secondary Air System ---------------------------------------------------- 044
6.1.2.1 Secondary Air Distribution ----------------------------------------------- 044

6.2
Solid Fuel Feeding System ---------------------------------------------- 046
6.3
Start-up Burner System --------------------------------------------------- 047
6.4
Flue Gas System ----------------------------------------------------------- 048
6.4.1
Combustor -------------------------------------------------------------------- 048
6.4.2
Hot Cyclone Separator -------------------------------------------------- 049
6.4.3
Convection Section (Back Pass) --------------------------------------- 049
6.4.4
Induced Draft Fan (ID) ---------------------------------------------------- 049
6.5
Feed Water System ------------------------------------------------------- 050
6.6
Steam System -------------------------------------------------------------- 050
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6.6.1
Main Steam Piping --------------------------------------------------------- 051
6.7
Ash Collection System ---------------------------------------------------- 052
6.7.1
Bed Ash Collection -------------------------------------------------------- 052
6.7.2
Fly Ash Collection System ----------------------------------------------- 053
6.8
Bed Material Feeding System ------------------------------------------- 053
6.9
Soot Blowing System------------------------------------------------------ 054
7.0
REFRACTORY ----------------------------------------------------------------------------- 055
8.0
WATER CHEMISTRY GUIDELINES ------------------------------------------------- 056

8.1
Prelude ------------------------------------------------------------------------ 056
8.2
Water Treatment ----------------------------------------------------------- 056
8.2.1
External Treatment -------------------------------------------------------- 056
8.2.1.1 Pre-treatment --------------------------------------------------------------- 057

8.2.1.2 Demineralisation ------------------------------------------------------------ 057
8.3
Internal Treatment --------------------------------------------------------- 057
8.3.1
Oxygen Removal ----------------------------------------------------------- 058
8.3.2
LP Dosing -------------------------------------------------------------------- 058
8.3.3
HP Dosing -------------------------------------------------------------------- 058
8.3.4
Silica Control -----------------------------------------------------------------059
8.3.5
Feed Water / Boiler Water Quality --------------------------------------059
9.0
STARTING OF INDIVIDUAL EQUIPMENT -----------------------------------------064
10.0
BOILER START-UP PROCEDURE AND OPERATION ------------------------ 084

10.1
Preliminary Operational Check List ------------------------------------ 086
10.2
Cold Start --------------------------------------------------------------------- 089
10.2.1 Filling the Boiler ------------------------------------------------------------- 090

10.2.2 Starting the Fans & Adjusting Air Flows ------------------------------ 092
10.2.3 Filling Bed Material -------------------------------------------------------- 095
10.2.4 Initiating Boiler Purge ----------------------------------------------------- 096
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10.2.5

Lighting up Start-up Burner ---------------------------------------------- 099
10.2.6 Boiler Warm-up ------------------------------------------------------------- 100

10.2.7 Solid Fuel Firing ------------------------------------------------------------ 103
10.2.8 Raising Boiler to Rated Condition -------------------------------------- 104
11.0
SHUT DOWN PROCEDURE ------------------------------------------------------------108

11.1
Normal Shutdown ---------------------------------------------------------- 108
11.2
Planned - Boxing up the Boiler ----------------------------------------- 110
11.3
Unplanned Shutdown ----------------------------------------------------- 111
12.0
PRESERVATION OF BOILER --------------------------------------------------------- 113
13.0
PROCEDURE FOR HYDROSTATIC TESTING ----------------------------------- 117
14.0
PROCEDURE FOR ALKALI BOIL-OUT -------------------------------------------- 119
15.0
PROCEDURE FOR STEAM BLOWING ---------------------------------------------122
16.0
DOS AND DONTS -----------------------------------------------------------------------126
17.0
TROUBLE SHOOTING ------------------------------------------------------------------ 132

17.1
High or Low Bed Temperatures ---------------------------------------- 132
17.2
High or Low Bed Pressure ----------------------------------------------- 133
17.3
High or Low Steam Drum Water Level ------------------------------- 134
17.4
Loss of Bed Inventory from Circulation ------------------------------- 135
17.5
Emergency Situations ---------------------------------------------------- 136
17.5.1 Sudden Lose of Steam Drum Level ----------------------------------- 136

17.5.2 Gradual Loss of Steam Drum Water Level -------------------------- 136
17.5.3
Excessive Bed Temperature -------------------------------------------- 136
17.6
Emergency Shutdown ----------------------------------------------------- 137
17.6.1
Steam Drum Water Level cannot be Maintained ------------------- 137

Page 7 of 1 52
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17.6.2 Sudden Lose of Steam Water Level ----------------------------------- 137

17.6.3 Air side or Gas side Failure ---------------------------------------------- 137
17.6.4 Loss of Service ------------------------------------------------------------- 138
17.6.5 Rapid Loss of Bed Inventory -------------------------------------------- 138
17.6.6 Loss of Fluidising Air to Loop seal ------------------------------------- 139
18.0
QUICK REFERENCE CHART --------------------------------------------------------- 141

18.1
Check List before Start-up ----------------------------------------------- 141
18.1.1 Boiler Water Filling --------------------------------------------------------- 141

18.1.2 Starting ID Fan -------------------------------------------------------------- 142
18.1.3 Starting Loop seal Blower ------------------------------------------------ 142
18.1.4 Starting SA Fan ------------------------------------------------------------- 143
18.1.5 Starting PA Fan ------------------------------------------------------------- 143
18.1.6 Air Settings, all Fans ON ------------------------------------------------ 144
18.1.7 Adding Bed Material ------------------------------------------------------- 144
18.1.8 Before Start-up Burner Light-up ---------------------------------------- 145
18.2
Cold Start-up ---------------------------------------------------------------- 145
18.2.1 Starting of Start-up Burner ----------------------------------------------- 145

18.2.2 Raising of Steam Pressure ---------------------------------------------- 146
18.2.3 Starting of Solid Fuel Firing ---------------------------------------------- 147
18.2.4 Maintaining Solid Fuel Firing -------------------------------------------- 148
18.3
Normal Operations --------------------------------------------------------- 149
18.3.1 Maintaining Bed Material Inventory ------------------------------------ 149

18.3.2 Bed Ash Removal System ----------------------------------------------- 149
18.4
Normal Shutdown -----------------------------------------------------------150
18.4.1 Solid Fuel Shutdown ------------------------------------------------------ 150

18.4.2 PA, SA, ID Fans and Loop seal Blower Shutdown----------------- 151
18.4.3 Boiler Shutdown ------------------------------------------------------------ 152
18.4.4 Quick Cool-Down for Outage -------------------------------------------- 152
Page 8 of 1 52
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1.0

CONTRACT DATA SHEET

CONTRACT DATA SHEET
WORK ORDER NO: BG013
PURCHASER : M/s SHREE CEMENT LIMITED

BOILER TYPE : 85TPH CFBC BOILER
CONSULTANTS: 1.M/s SPB PROJECTS AND CONSULTANCY LTD., CHENNAI.

MAIN FUEL
: PETCOKE + FLYASH (225TPD)
GCV
ALTERNATE FUEL : 100% PETCOKE / 100%F GRADE COAL / 54% F GRADE COAL
Kcal /
+ 46% FLYASH / 100% LIGNITE / 55% LIGNITE + 45% FLYASH
kg
PROPOSED FUEL:
C%
H2 %
S%
N2 %
O2 %
H2 O %
ASH %
FLY ASH (225 TPD) +

PETCOKE
52.36
0.81
2.54
0.12
0.58
13.65
29.94
4569
100% F GRADE COAL
38.50
2.90
0.50
0.79
5.62
10.00
41.69
3890
PET COKE
84.34
2.66
7.93
0.39
1.91
2.00
0.77
7936
100 % LIGNITE
43.08
3.30
4.00
0.88
8.74
30.00
10.00
4500
54%F GRADE COAL+46%

FLYASH
38.40
1.40
0.33
0.38
2.71
14.54
42.23
3476
55% LIGNITE+45%
FLYASH
40.53
1.54
1.96
0.41
4.07
24.00
27.51
3672
FUEL FIRING EQUIPMENT : DRAG CHAIN FEEDER
MAIN FUEL
Nos.
CONTROL
A. SMALL DRAG CHAIN FEEDERS --- 4

B. MAIN DRAG CHAIN FEEDERS --- 2
A. VARIABLE FREQUENCY DRIVE --- 4 NOS
B. CONSTANT SPEED DRIVE --- 2 NOS
F GRADE COAL / LIGNITE / PETCOKE / 54%F

GRADE COAL+46% FLYASH / 55%
LIGNITE+45% FLYASH DRAG CHAIN
FEEDER
COMMON FEEDERS FOR MAIN &
ALTERNATE FUELS
-
A. MAIN DRAG CHAIN FEEDER- 28500 / feeder

B. SMALL DRAG CHAIN FEEDER- 28500 / feeder
CAPACITY kg/h
FRONT WATER WALL
FRONT WATER WALL
COMBUSTOR
TYPE: BALANCED DRAFT
WIDTH, mm
HEIGHT, mm
DEPTH, mm
VOLUME,m3
4442
25040
4442
472
BOILER
NATURAL CIRCULATION
START-UP OIL
OIL TANK CAPACITY,m
CONSTRUCTION : FUSION WELDED WALLS
FUEL HEAT INPUT Mkcal/h : 62.9

DESIGN :
kg/cm 2(g)
LDO
3
15
No. of BURNERS
2
12.37
BURNER CAPACITY , Mkcal / hr
SECTION
STAGE
PRESSURE
kg/cm2 (g)
LOCATION
START-UP
FIRING SYSTEM
ALTERNATE FUEL
PETCOKE + FLY ASH (225 TPD) - DRAG CHAIN

FEEDER
TYPE
FINAL SUPERHEATER OUTLET: 88.0
TYPE OF FLOW
H.S AREA
m2
PRIMARY SUPERHEATER
COUNTER FLOW
619.67
WINGWALL(RADIANT) SUPERHEATER
II
PARALLEL
111.50
Page 9 of 1 52
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FINAL SUPERHEATER
III
COUNTER FLOW
326.28
DE-SUPERHEATER
ONE
FIXED NOZZLE TYPE
ECONOMISER
ONE
COUNTER TUBE
1208
AIR HEATER
3 BLOCKS
COUNTER FLOW
xxxx
---
BOILER AUXILIARIES
DESIGN CONDITION
PUMPS &
FANS
TYPE
MAKE
MOTOR RATING
DRIVE
Nos.
FLOW
m3/s
PRESS.
mmWC
TEMP
C
CONTROL
SPEED
rpm
KW
PA FAN
CENTRIFUGAL
CVL
18.85
1570
50
MOTOR
1492
400
DOL
SA FAN
CENTRIFUGAL
CVL
14.11
884
50
MOTOR
1485
180
DOL
ID FAN
CENTRIFUGAL
CVL
49.20
547
165
MOTOR
992
350
VFD / DOL
LOOP SEAL
BLOWER
POSITIVE
DISPLACEMENT
BLOWER
KAY
0.355
4000
80
MOTOR
1455
22
DOL
SOOT BLOWERS
LOCATION
SUPERHEATER
TYPE
MAKE
NOS.
MEDIUM
LONG RETRACTABLE SOOT BLOWER
SITSON
S.H STEAM
ROTARY SOOT BLOWER
SITSON
S.H STEAM
---
-----
---
----
ECONOMISER
AIR HEATER
DUST COLLECTORS
DESIGN CONDITIONS (Flyash+Petcoke )
DUST
COLLECTOR
MAKE
FIELD
ESP
CVL
NOS.
INLET DUST
CONCENT.
gm/ Nm3
FLUE GAS
FLOW
TPH
FLUE GAS FLOW m3/s
PRESSURE
LOSS
mmWC
O / L DUST
CONCENT.
mg/ Nm3
48.92
109.9
37.65
25
xxx
(with all fields
in service)
PIPING
PIPE LINES
MAIN STEAM
HOT REHEAT
COLD REHEAT
FEED WATER
SIZE Dia.x t
(mm x mm)
Matl. Spec
219.1 X 25.4 mm
NA
NA
168.3 X 14.27 mm
No. of LINE
---
---
BOILER MOUNTINGS
LOCATION
STEAM DRUM
MAIN STEAM LINE
SAFETY
VALVES
SOOT BLOWER
CBD
BED ASH COOLER
BI-COLOUR
WATER LEVEL
INDICATOR
STEAM DRUM
MODEL
MAKE
Nos.
1727 WB
BHEL
SET
PRESSURE
kg/cm2(g)
105/108
1727 WD
1811 HC6X20
BHEL
94.0
23
BHEL
21.0
1.52.5
SIZE
inches
23
---
TYCO
7.0
1.52.5
1 G1 2 JOS-H-E-25-CIBR-SPL
TYCO
5.0
1.0x2.0
4119F
YARWAY
---
---
Page 1 0 of 152
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MAIN PARAMETERS
FUEL
53% PETCOKE + 47% FLYASH
STEAM
DESCRIPTION
FLOW AT FINAL SUPERHEATER OUTLET
PRESSURE AT FINAL SUPERHEATER OUTLET
TEMPERATURE AT FINAL OUTLET
FLUE
GAS
FUEL HEAT INPUT TO BOILER
UNIT
100% BMCR
60% BMCR
TPH
85.0
51
88
88
520
520
Mkcal/h
62.9
37.6
kg/cm (g)
0
FEED WATER TEMPERATURE
210
210
AMBIENT AIR TEMPERATURE
40
40
COMBUSTION AIR TEMPERATURE
213
207
FUEL QUANTITY
TPH
13.73
8.23
COMBUSTION AIR QUANTITY
TPH
102.22
61.20
QUANTITY
TPH
111.74
66.90
150
130
TPH
3.029
1.815
82.00
82.13
TEMPERATURE AIR HEATER OUTLET

LIME STONE QUANTITY
EFFICIENCY (GUARANTEED)
C
C
Page 1 1 of 152
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2.0 INTRODUCTION TO CFBC BOILER

In this section fluidised bed technology and evolution of the CIRCULATING FLUIDISED
BED COMBUSTION (CFBC) boiler, its operating principle and advantages are generally
described.
2.1
Atmospheric Fluidised Bed Boiler
An atmospheric fluidised bed boiler operates with higher combustor gas velocities that vary
only between the minimum fluidisation and the entrainment velocities. (Refer to fig-1). If
higher air velocity is used in fluidised bed the bed material is entrained and the unburned
particles are carried over from the combustor and lost in the gas stream. When the air
velocity is lower the bed is slumped causing localized hot spots. Hence to sustain stable
operation of the bed, it must be ensured that air velocity is maintained between fluidisation
velocity and particle entrainment velocity.
Atmospheric fluidised bed boiler is further classified as BFB and CFB boiler.
2.1.1 Characteristics of BFB Boiler
Low fluidising velocity

Dense bed depth with submerged heat transfer tube bundles.
A free board region with water-cooled membrane walls.
The solid fuel feeding to the fluidised bed is carried out either with a pneumatic under-bed
feed system or an over-bed pneumatic spreader.
The under-bed feed system is normally used in larger size boilers. The solid fuels are sized
to 5 to 6 mm before conveying to the combustor with the high velocity air through the air
box and distributor plate.
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With the over-bed system the solid fuel are conveyed mechanically to the pneumatic
spreaders through the drag chain feeder, which distributes / spreads the fuel evenly into the
combustor.
In fluidised bed boilers only a small percent of the ash or non combustible solids are
drained through the bottom and the remaining are collected as fly ash. The separation of fly
ash from the flue gas is accomplished by bag house or mechanical dust collector.
2.1.2 Characteristics of CFBC Boiler
A CFBC boiler consists of combustion chamber, hot cyclone separator, convection section
(back pass) and bed ash coolers. Compared to bubbling fluidized bed, the relatively higher
fluidizing velocity adopted in CFBC boiler causes the dense mixture of solids to move up
through the combustion chamber.
Solids move at lower velocity than the gas. This
phenomenon, the taller combustion chamber of a CFBC boiler and re-circulation of bed
material, result in a longer residence time for the fuel particles in the combustion chamber.
The long residence time facilitates complete combustion of the fuel particles.
Primary air is admitted to the combustor through the air box and nozzles mounted on the
bottom grid panel. The primary air is used mainly for fluidisation and meets part of
combustion air requirement. Secondary air is admitted at various levels of the combustion
chamber for staged combustion, as fuel particles move up. Heat is continuously transferred
to the membrane water wall of the combustor maintaining the furnace temperature.
Start-up burners are used for initial heating up of the bed material. Once the bed
temperature reaches above fuel ignition temperature, solid fuel is introduced. The bulk
density of the bed varies along the height of the combustor. Heavier particles stay in the
lower region of the combustor and the lighter particles move up and enter the circulation
path of the hot loop.
Page 1 3 of 152
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The hot loop comprises of the combustor, hot cyclone separator, return leg and loop seal,
back to the combustor. When the particles break down into finer size, they are carried out
of the hot loop (circulating path) with the flue gas as fly ash into the back pass of the boiler.
The bed ash is transferred through the bed ash cooler for cooling before discharge.
FIG-1
Page 1 4 of 152
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2.2 Advantages of CFBC Boiler
1. Water Cooled Hot Cyclone separator

2. Higher degree of fuel flexibility
3. High combustion Efficiency
4. Low SOx Emissions
5. Low NOx Emissions
6. Good Turn Down Ratio
7. No Need for In-Bed Tubes, which are Subject to Erosion
8. Smaller Combustor Cross Section
9. Fewer Fuel Feed Points
10. Elimination of Slagging
11. High Availability
12. Easy to Operate and Maintain
Page 1 5 of 152
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3.0

GENERAL DESCRIPTION OF CFBC BOILER
The CFBC boiler supplied is a top supported, single drum, natural circulation and balanced
draft type (Refer General arrangement drawings No. BG013-00-02-0-002 & BG013-00-020-003).
The boiler is designed to operate with either 53% Petcoke + 47% Fly ash, 100% Petcoke,
100% F Grade coal, 54% F Grade coal + 46% Fly ash, 100% Lignite or 55% Lignite + 45%
Fly ash as the fuel. The combustor is provided with two numbers of opening for fuel feeding
and one number for the bed material feeding. Main fuel bunker of capacity 250 m and
Auxiliary fuel bunker of capacity 250 m are provided for storing the solid fuels. A separate
bunker of capacity 60 m and 50 m are provided for storing the lime stone and bed
material respectively. Two numbers of main drag chain feeders and four numbers of box
feeders of drag chain type are provided for fuel feeding and a rotary air lock valve is
provided for lime stone and bed material feeding.
Two numbers of burners for Light Diesel Oil (LDO) firing are provided for start up of the
boiler. The burners are mounted one each on left and right side walls of the combustor.
The boiler is provided with 1 x 100% Primary Air (PA) fan, 1 x 100% Secondary Air (SA) fan
for supplying the required air for fluidization and combustion. The flue gas coming out of the
combustor passes through the hot cyclone (water cooled) where the coarser particles are
separated and returned to the combustor. 2 x 100% Loop seal blowers (One working + One
stand by) are provided for fluidizing the solids in the seal pot and returning the coarser
particles back to the combustor. The flue gas with fine ash is carried over to the back pass
through the steam cooled cross over duct (cyclone outlet chamber).The back pass is also
of steam cooled wall enclosure construction housing the primary and final super heaters.
The super heater consists of three stages namely primary convective super heater, wing
wall (radiant platen) super heater in the upper portion of the combustor and final convective
super heater. A single stage Fixed nozzle spray type de-superheater is located in between
primary and wing wall super heaters to maintain the rated super heated steam temperature
between 60% and 100% MCR.
Page 1 6 of 152
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The economizer is located below the super heaters in the gas path within duct casing.
Tubular air pre-heater is located after the economizer in multi blocks for heating both
primary and secondary air.
The flue gas then passes through Electro Static Precipitator (ESP) before exiting through
the Chimney. 1 x 100% ID fan is provided after ESP for maintaining the balanced draft in
the boiler.
Two numbers of bed ash coolers are provided one on each side of the combustor for
cooling the bed ash to facilitate further handling.
All necessary piping complete with valves and fittings are provided. Refer to P&ID BG01300-09-1-010, BG013-00-09-2-014, BG013-00-09-3-015, and BG013-00-09-3-080.
All necessary ducting complete with dampers and gates are also provided. Refer to P&ID
BG013-00-09-2-012 and BG013-00-09-2-013
All necessary instruments, logics and controls are provided for the safe and reliable
operation of the boiler.
Page 1 7 of 152
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4.0
Boiler Pressure Parts
4.1
Steam Drum

The steam drum is made up of carbon steel plate, welded construction, with a cylindrical
shell and dished ends. Manholes with hinged covers are provided at each end of the drum.
The following nozzles are provided in the steam drum as per the P&ID BG013 00 09
1 010.
01.
Local Pressure Gauge
- 1 No.
02.
Remote Pressure Gauge
- 1 No.
03.
Air Vent
- 2 No.
04.
Safety Valve
- 2 Nos.
05.
Direct Level Gauges
- 2 Nos.
06.
Auxiliary stub
- 1 No.
07.
Level Transmitter
- 3 Nos.
08.
Pressure Transmitter
- 1 No.
09.
Continuous Blow down Connection
- 1 No.
10.
Intermittent Blow down Connection
- 1 No.
11.
HP Dosing Connection
- 1 No.
12.
Downcomer Pipe
- 4 Nos.
13.
Riser Pipe
- 11 Nos.
14.
Feed Pipe
- 1 No.
15.
Steam Outlet
- 2 Nos.
Page 1 8 of 152
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The steam-water mixture, entering the drum from combustor and water cooled hot cyclone
separator top headers, is collected in the separating chamber of the drum. A portion of the
water is drained off through the perforated continuous blow down pipes at this point of
high solids concentration. The blow down line is provided with a motorized operated
angle type blow down with isolation valve. Two numbers of spring loaded safety valves are
mounted on the drum. The drum safety valves are set to open when the drum gets
pressurised above the set point. Drum level is measured to control the feed water flow.
Drum level is indicated by the local water level gauges and a digital remote level indicator
at the operating floor. The motorized Intermittent blow down valve with isolation valves is to
be used for emergency drain when the drum level shoots up abnormally.
4.1.1 Drum Internals
The boiler drum is provided with efficient internals for separation of steam from steam water
mixture.
The drum internals, turbo separators and a set of screen box, provide simple and efficient
system to produce high quality steam.
The feed water manifold located inside the drum helps to distribute the water evenly
through out the drum length. The turbo separators and screen box separates the generated
steam from the water and removes moisture from the steam before it leaves the boiler. The
turbo separators equipped with a corrugated plate assembly at its outlet provides primary
and secondary separation of water from steam. These separators are vertically mounted in
the steam drum so that the steam rises out at the top and the water falls back into the water
space. Refer to fig-2
Screen box mounted above the turbo separators, further remove moisture from the steam
by changing the direction of steam flow several times before leaving the steam drum.
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FIG - 2
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4.1.2 Installation
The following instructions are to be adhered to for the proper functioning of drum.
01.
Refer the drum internal drawing incase of dismantling and reassembling of drum
internals.
02.
To prevent moisture from bypassing the screen box and mixing with dry steam, as it
leaves the drum, all the joints in the box assemblies must be absolutely seal welded,
wherever indicated. All bolts are to be assembled with two washers, one under the
nut and the other under the head. Please note that joints which are bolted are to be
made as tight as possible and not to be seal welded.
03.
The joints in the partition baffles need not be absolutely tight but should be made as
tight as possible. Buckles on bent flanges which do not clamp properly should be
hammered together between the bolts and corners drifted together.
04.
All bolted joints are to be retightened after the initial bolting.
05.
U - Bolts on the feed header should allow for free expansion.
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4.1.3 Data Sheet for Steam Drum
Drum
Internal diameter, mm
1371
Shell / Dished Head, mm
80 / 80
Length of the Drum, mm
4470
Shell / Dished Head
SA516 Gr. 70
Design Pressure, kg/cm (g)
105
Design Temperature, C
314
No. off
18
Size, mm
300
No. of modules
12
Size, mm
574 307
Thickness of the Drum
Material of Construction
Internals
A)
Turbo Separator
B) Screen box
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4.2

Down Comers and Risers
The water from drum flows through
down comers to the combustor & hot cyclone
separator I/L headers, loop seal bottom headers, water cooled hot cyclone separator O/L
headers and hot cyclone separator inlet duct bottom header(s).
Risers carry steam water mixture from outlet headers to drum.
4.2.1 Data Sheet
Downcomers
COMBUSTOR
WATER COOLED
WATER COOLED
SEPARATOR
SEPARATOR I/L DUCT
No. off
Pipe Size (NB)
300
150
100
Pipe Material
SA 106 Gr. B
SA 106 Gr. B
SA 106 Gr. B
WATER COOLED
WATER COOLED
SEPARATOR
SEPARATOR I/L DUCT
Risers
COMBUSTOR
No. off
Pipe Size (NB)
150
150
100
SA 106 Gr. B
SA 106 Gr. B
SA 106 Gr. B
Pipe Material
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4.3

Combustor (Furnace)
The entire combustor is a gas tight enclosure with completely water cooled tubes.
The main components of the combustor are:
the water-cooled distributor grid
the water-cooled lower part (with refractory lining)
the water-cooled upper part
4.3.1 Distributor Grid
The bottom of the combustor is provided with widely spaced water cooled tubes as
distributor grid. Stainless steel air nozzles are mounted on the membrane fins. The primary
air from the air box flows through these nozzles for fluidising the bed material as well as
fuel and supporting combustion. The design feature of these nozzles and the gas pressure
across the system with admission of minimum air flow avoids any back shifting of bed
material to the air box when the unit is operating at low loads.
4.3.2 Lower Part

The lower combustion chamber is made of water cooled membrane wall enclosure and
refractory lined for protection against erosion and chemical attack because of reducing
conditions. A special care is taken at the combustor refractory zone with a kick - out
(back bump) design to minimize the erosion at the refractory interface with the tube panels.
It is in this area that the main combustion takes place. The bed is denser here and very
turbulent. All combustion air and fuel are brought into the combustor in this area. In
addition to the primary air through grid, secondary air is fed at about 2 m above the grid.
Secondary air completes the staged combustion with minimum Nox formation. Start-up
burners are located above the grid. All the penetrations for bed temperature and pressure
measurements are located in this area.
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4.3.3 Upper Part
The upper part of the combustor is also made of water-cooled membrane walls. This is the
area in which the heat is transferred from the flue gases and bed material to the boiler
water. As the walls are water-cooled, the temperature of the tubes is constant throughout
the combustor and corresponds to the saturation temperature at the boiler drum pressure.
Gas inlet channel from the combustor to hot cyclone is lined with a thin layer of refractory.
The combustor tubes are of seamless construction and welded to the headers. The
combustor is designed for positive pressure operation and accordingly suitable buck stays
and tie bars are provided. The entire combustor assembly, hot cyclone separator and back
pass are supported from the top. Hence, there is no differential thermal expansion between
the combustor and hot cyclone separator. The complete combustor assembly is designed
for natural circulation. Saturated water from the drum is circulated through the down
comers to the combustor bottom headers. Wing wall / radiant superheater are located in
the upper part of the combustor. These are fin welded tubes, positioned parallel to the gas
flow path.
Following are the openings provided in the combustor for the combustion process.
1. Fuel feeding
2. Bed material feeding
3. Solids return from loop seal
4. Secondary air inlet
5. Start-up burner openings
6. Wing wall (radiant) superheater panels
7. Gas outlet to hot cyclone separator
8. Bottom ash transfer to bed ash coolers
9. Hot air return line from Ash coolers to combustor
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10. Temperature and pressure instrument penetrations

11. Provision for sky climber rope guide in the roof panel
12. Man hole opening
The openings are provided with suitable seal box arrangement to ensure that there is no /
minimised leakage outside because of the pressurised condition inside the combustor.
4.3.4 Data Sheet for Combustor
Bottom Headers
Size
NB 250 ( 273.1 32)
Material
SA 106 Gr.B
Size
NB 250 ( 273.1 32)
Material
SA 106 Gr.B
Size
NB 250 ( 273.1 32)
Material
SA 106 Gr.B
Size, mm
51.0 4.5
Material
SA 210 Gr.A1
Side wall Top Headers
Roof & Rear Wall Top Header
Combustor Tubes
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4.4

Hot Cyclone Separators and Loop Seal
The hot cyclone separator (water cooled) is a gas tight circular enclosure manufactured
from membrane panels (similar to combustor tube construction).
The hot cyclone
separator is lined inside with a thin layer of abrasion resistant refractory. The primary
purpose of the hot cyclone separator is to separate the hot coarser solids carried along
with the flue gas so that they can be returned back to the lower combustor through the loop
seal system. Ash that is separated in the hot cyclone separator flows down the hot
cyclone separators return pipe to the loop seal. This acts as a seal preventing the back
flow of flue gas from the combustor through the hot cyclone separator. The ash in the
loop seal is fluidised by high pressure air coming from the high-pressure loop seal blower
through the nozzles located on the bottom.
Like the combustor, the hot cyclone separator and loop seal system is also designed for
natural circulation system. Saturated water from the steam drum is taken to the inlet
headers of hot cyclone separator and loop seal by separate down comers and feed pipes.
The steam-water mixture from the loop seal and hot cyclone separator wall tubes is
collected in the upper separator headers and returned to the steam drum via riser pipes for
further steam water separation in the drum. The entire hot cyclone separator and loop seal
assembly is top supported and would expand downward with the combustor and the back
pass.
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4.5

Vortex Finder
Hot combustion gases, with the entrained solids, fuel and ash, leave the top of the
combustor and enter into the hot cyclone separator. The flue gas and ash are drawn
through a fixed center pipe attached to the top of the hot cyclone separator, a device
called a vortex finder that causes the gas-ash mixture to change direction. Coarser
material is separated from the flue gases by centrifugal force. This SS 310 cylinder hangs
down into the area and causes the horizontal-traveling flue gas and bed material to make a
90-degree turn to flow up and out of the hot cyclone separator. This change in direction
helps separate and size the coarser bed material from the fine bed material, fly ash. The
smaller fly ash particles entrained with the flue gas leave the top of the hot cyclone
separator and enters the boiler's convection section (back pass). The hot cyclone
separators itself is made of water-cooled membrane waterfall tubes or pipes and are lined
on the inside with refractory.
4.6
Cross Over Duct (Cyclone Outlet Chamber COC)
After leaving the hot cyclone separator, the flue gas fly ash mixture is drawn into and
through the steam-cooled refractory-lined crossover ducts. Saturated steam from the steam
drum passes through this crossover section. The tubes that make up the steam-cooled
crossover duct are 44.5mm O.D. and made from SA-210 Gr.A1 metal. Building this
ductwork using steam piping reduces the weight and the amount of refractory necessary to
protect the area. The crossover ducts connect the hot cyclone separator to the convection
section (back pass) of the boiler.
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4.7

Superheaters
4.7.1 Primary Superheater

Saturated steam from the drum flows through steam cooled walls and then the cross over
duct (cyclone outlet chamber) gets slightly superheated and led to primary superheater,
which serves to completely dry and superheat the saturated steam. Primary Superheater is
a convective type superheater section located in the back pass enclosure (steam cooled
walls). Steam through this section flows counter to the gas flow through single bank
arrangement. The superheater inlet and outlet headers are located horizontally on the rear
side of the steam cooled wall enclosure. Both the inlet and outlet headers are drainable.
The convection superheater consists of 33 parallel paths and the complete superheater
assembly is supported by the hanger tubes from the economiser intermediate headers.
The first row of the superheater assembly is provided with an erosion shield of stainless
steel material to protect the tubes against erosion. Baffle plates are welded to the front and
rear of steam cooled wall at entry of each bank to protect the bends against erosion.
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4.7.1.1

Data Sheet for Primary Superheater
Inlet Header
No off
One
Size
NB 200 (219.1 25.4)
Material
SA 106 Gr.B
Number of Parallel Paths
33
Number of Banks
Type of Heat Transfer
Convection
Size , mm
44.5 5
Material
SA 210 Gr.A1 & SA 213 T11
Transverse Pitch, mm
104
Longitudinal Pitch, mm
89
Type of Support
Support Lug, with Slider Arrangement on hanger
Tubes
Tube
Outlet Header
Size
NB 250 (273.1 32.00)
Material
SA 335 P11
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4.7.2 De- superheater

De-superheater is located in the interconnecting piping between the primary and wing wall
(radiant) superheaters. De-superheating is carried out to control the rated steam
temperature over the control load range. This is done by means of fixed nozzle de-superheater using feed water. The spray water is regulated through a spray control valve, with
the feed water tapped off from a point upstream of the feed water control valve, by
monitoring steam temperature after the de-superheater.
Please refer the quality of spray water under section feed water quality.
The de-superheater is fitted with a renewable liner to take care of erosion from the
spray water stream, thus protecting the main de-superheater shell.
Excessive noise
from de-superheater usually indicates a worn-out liner and may suggest for replacement of
the liner.
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4.7.2.1

Data Sheet for De-superheater
No. off
One
Size, mm
NB 250 (273.1 25.4)
Material
SA106 Gr.B
Liner Size, mm
180 3.15
Liner Material
SA240 Gr.304
No. of Spray Nozzles
One
Spray Nozzle Material
SS 304
Spray Nozzle Body Material
SS 304
DESH Inlet Link Size
NB 200 (219.118.26)
DESH Inlet Link Material
SA 335 P11
DESH Outlet Link Size
NB 200 (219.118.26)
DESH Outlet Link Material
SA 335 P11
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4.7.3 Wingwall (radiant) Superheater

The wing wall or intermediate superheater is a radiant type superheater made up of
multiple panels located in the upper left part of the combustor. Steam from the primary
superheater is distributed to the radiant wall superheater panel inlet headers, passes
through the panels to the outlet headers. The differential expansion of the superheater
panel walls relative to the combustor wall is accommodated with an expansion joint at the
combustor roof penetration.
The lower portion of the walls is protected from possible
erosion by abrasion resistant refractory. Weld overlay is carried out immediately following
the refractory on the tube. Refer fig -3
The wing wall (radiant) superheater, the inlet and outlet headers are suspended from top
hangers through spring supports. Coils are placed vertically at the direct radiant zone.
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FIG - 3
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4.7.3.1 Data Sheet for Wingwall (radiant) Superheater

Inlet Link
No. off
One
Pipe Size, mm
NB 200 (219.118.26)
Material
SA 335 P11
No. off
One
Size, mm
NB 150 (168.318.26)
Material
SA 335 P11
Number of parallel paths
2 25
Tube Size, mm
38.1 4.06
Tube Material
SA 213 T 11
Type
Finned Panel
Distance between panels, mm
1216
Tube Pitch, mm
51
Type of Support
Top & bottom Supported
No. off
One
Size, mm
NB 150 (168.318.26)
Material
SA 335 P11
Inlet Header
Superheater
Outlet Header
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4.7.4 Final Superheater

The superheated steam from wingwall (radiant) superheater outlet passes to the final
superheater for further superheating.
The final superheater is located in the back pass of the boiler as the first convective heat
transfer section. The final superheater is of horizontal, convective and in-line arrangement.
All superheater elements are provided complete with spacers, and support hangers.
The first row of the superheater assembly is provided with an erosion shield of stainless
steel material to protect the tubes against erosion. Baffle plates are welded to the front and
rear of steam cooled wall at entry of each bank to protect the bends against erosion.
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4.7.4.1 Data Sheet for Final Superheater

Inlet Link
No. off
One
Pipe Size, mm
NB 200 (219.118.26)
Material
SA 335 Gr.P11
No. off
One
Size, mm
NB 250 ( 273.125.4)
Material
SA 335 Gr.P11
Number of Parallel Paths
17
Number of Banks
Two
Type of Heat transfer
Convection
Tube Size, mm
44.5 6
Tube Material
SA 213 T11 / SA 213 T 22
208
Longitudinal pitch, mm
89
Arrangement
3 Start
No. off
One
Size, mm
NB 250 ( 273.1 36)
Material
SA 335 Gr.P 22
Inlet Header
Coils
Outlet Header
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4.8

Economiser
The economiser is located back pass of the boiler in between the primary superheater and
the tubular air pre-heater. The purpose of the economiser is to pick up the heat from the hot
flue gases before entering the steam drum. Feed water flows through the tubes arranged
horizontally for counter flow heat transfer in the gas flow path.
The economiser is of bare tube, in line, horizontal, serpentine type arrangement in multiple
banks. The economiser tubes are supported by straps. The final economiser bank tubes
are welded to the intermediate headers. Hanger tubes connect the intermediate header to
the economiser outlet header located at the boiler roof.
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4.8.1 Data Sheet for Economiser

Feed Pipe:
No. off
One
Size
NB150 (168.3 14.27)
Material
SA 106 Gr.B
No. off
One
Size
NB 200 (219.1 18.26)
Material
SA 106 Gr.B
No. of Parallel Paths
60
No.of Banks
Three
Tube Size, mm
38.1 3.66 Thk
Tube Material
SA 210 Gr.A1
76
Longitudinal Pitch, mm
76
Flow Arrangement
Cross Flow
Coil Arrangement
In-Line Arrangement
Type of Support
Hanger Tube Support
No. off
One
Size
NB 200 (219.1 25.4)
Material
Carbon Steel (SA 106 Gr.B)
No. off
One
Size
NB 150 (168.3 14.27)
Material
Carbon Steel (SA 106 Gr.B)
Inlet Header:
Coils
Outlet Header:
Outlet Link:
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5.0
NON PRESSURE PARTS
5.1
Tubular Air Pre-Heater
A tubular, multi-pass air heater system with air through tube design is located below
economiser. The air pre-heater is made of three blocks. Each block is divided into two
paths, one for the primary air and other for the secondary air. The air heater tubes are
arranged horizontally between tube sheets. The flue gas flows outside the tubes
exchanging heat in cross flow manner. The primary air and secondary air are supplied by
the primary air fan (PA) and secondary air fan (SA) through dedicated air ducting
interconnection between blocks.
5.1.1 Data sheets for Tubular Air Heater
Tube
Type
Tubular Air Heater with air through tubes & gas over tubes
Size
NB 50 ( 60.3 2.34)
Material
IS 1239
Sheet Material
IS 2062 GR A
Sheet Thickness, mm :
20
Support
Bottom Supported
Transverse Pitch
90
Longitudinal Pitch
80
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5.2

Electro Static Precipitator (ESP)
Electrostatic
from the
Precipitator is the most effective method for removal of ash/dust particles
flue gases. The
Electrostatic Precipitator basically consists of a large steel
chamber housing the emitting and collecting electrodes. High voltage DC supply is applied
between the emitting electrode and collecting electrode. The emitting electrode is
connected to the negative terminal. The collecting electrode is connected to the positive
terminal and earthed. When flue gases pass through the chamber, because of the high
DC voltage applied across the emitting and collecting electrodes, the ash/dust particles
get ionised and are attracted to the collecting electrode. Due to periodic hammering,
ash/dust drops down in the hoppers, which is then removed and disposed off.
The outlet duct of the electrostatic precipitator is connected to the inlet of the ID fan. ID fan
is provided with power cylinder operated regulation dampers and manual outlet discharge
damper.
For more details of operation and maintenance of ESP refer Volume - X
5.3
Bed Ash Cooler
The CFBC boiler is provided with two (2) numbers of water cooled bed ash coolers. The
combustor and the bed ash coolers are connected by separate ash transfer pipes at the
bottom. The hot air coming out of the bed ash coolers are connected back to the
combustor. The ash coolers are located on either side of the combustor.
The bed ash cooler chambers are constructed out of fin welded membrane type panels on
all four sides and separated into three individual compartments with refractory walls inside.
The ash cooler is supported from the combustor as well as from the fuel feeder floor beam
through constant spring hangers and thereby minimising any differential thermal expansion
at the connections between the combustor and the ash cooler. A rotary valve is provided at
the discharge of the ash cooler to regulate the ash flow rate to maintain the combustor bed
pressure.
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Necessary arrangement for poking is also provided in case of any blockage in the ash
transfer pipe.
6.0
SYSTEM DESCRIPTION
6.1
Air System
The primary and the secondary air fan constitute the combustion air system. The primary
air fan is employed primarily for supplying air for fluidisation of the fuel / bed material. The
secondary air fan is used for supplying air for combustion in the combustor and assisting
the fuel feeding. For distribution of the primary and secondary air, refer to P&ID BG013 - 00
09-2 - 012
6.1.1 Primary Air System
Primary air is drawn from atmosphere by 1100% capacity centrifugal fan. Primary air (PA)
is used to fluidise the fuel / bed material in the combustor by passing the air flow up through
the air box on the floor of the combustor. Primary air further helps in combustion of fuel.
The primary air is heated (heat exchanged from flue gas) in the primary air heater in
convection / back pass section before entering combustor. Hot primary air passes through
the air box and the grid nozzles creating high velocity air flow that causes the fuel / bed
material fluidized. Note that there is a minimum primary air flow required to fluidise the bed
and prevent back flow of the material through the nozzles. Hence, at low load operation of
the boiler, the minimum primary airflow has to be maintained constant. Primary air fan
control is via inlet damper control according to the required airflow demand. The air flow is
measured by the aerofoil in the inlet duct.
During start-up of the boiler, the PA fan is started after the ID fan, Loop seal blower and SA
fans are started. Before starting the fan, the inlet damper of PA fan is to be kept closed to
avoid overloading of the fan motor. The PA fan along with SA and ID fans is used for
purging the boiler before start-up burner light-up.
For more details on fans, refer to Volume IV
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6.1.1.1 Primary Air Distribution

The hot primary air (PA) is distributed to the combustor grid though the air box and the air
nozzles located at the combustor bottom. (Refer to Fig-4)
The cold primary air is drawn before the air pre-heater and supplied to the bed ash cooler
through the air box and air nozzles for fluidising the ash.
FIG- 4
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6.1.2 Secondary Air System

Secondary air is drawn from atmosphere by 1100% centrifugal fan and preheated in the
air heater in convection section (back pass) before entry to the combustion chamber. Hot
secondary air is brought into combustor at 2 elevations (2 nos. entry at lower elevation and
10 nos. entry at higher elevation) for staged combustion, and to reduce NOx emission. Hot
secondary air is also supplied to air bustle to assist fuel flow into the combustor. The
secondary air flow shall be controlled to optimise the excess air in flue gas and there by the
boiler efficiency through O2 trimming at economiser outlet. O2 is kept ~3.5 % to ensure
proper combustion.
The SA fan along with PA and ID fans is used to purge the boiler prior to start-up burner
light-up.
For more details on fans, refer to Volume - IV.
6.1.2.1 Secondary Air Distribution

The distribution of the Secondary air is as per the P&ID BG013 00 09 2 012
The secondary air is distributed to the boiler for meeting the various functions as follows:
1. Cold secondary air to oil gun assembly for cooling.
2. Cold secondary air to the fuel feeders for sealing.
3. Hot secondary air for start-up burners and combustor.
4. Hot secondary air through the air bustles in fuel feeding chutes to facilitate free
flow of fuel to the combustor (refer to fig -5)
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FIG- 5
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6.2

Solid Fuel Feeding System
The fuel feed system is as per the P&ID BG013-00-09-3-11. Main bunkers of total capacity
250 m are provided for storing the solid fuels. The capacity of lime stone bunker is 60 m &
the bed material bunker is 50 m. Each bunker is provided with two number of hoppers
except bed material bunker with SS plate lining for approximately 2 meters height at the
tapered portion for free flow of the solid fuels. The outlet of the hoppers are connected to
small drag chain feeders (box feeder) through the rod gate and chain morris wheel
operated slide gate connected in series for isolating the bunker. The fuel flows due to
gravity into the small drag chain feeder which is driven by a geared motor and controlled by
the VFD for delivering the required quantum of fuel to the main drag chain feeder and
finally into the combustor through two fuel feed inlets. Air bustles are provided at each of
the fuel discharge line to the combustor from the main drag chain feeder. The air bustles
assist free flow of fuel into the combustor and to arrest the reverse flow of hot gases into
the fuel feeders, thus preventing any fire hazard. The secondary air flow for the air bustle is
set through the regulating damper and flow measurement provided at the upstream of the
air bustle. Additional air sealing is accomplished by providing regulated supply of cold
secondary air to the main drag chain feeder for providing effective sealing of hot gases
entering the feeders. The main drag chain feeders are designed to withstand 2 PSI
pressure. For details of the drag chain feeders, refer to the manual in Volume - VIII
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6.3

Start-up Burner System
The start up oil firing system is designed for burning light diesel oil (LDO). Start up
Burners are provided to heat up the bed material up to a temperature at which the solid fuel
ignites so that solid fuel feeding can start. Two (2) numbers of start up burners are
mounted, one each on left and right side walls of the lower combustor. Each burner is
designed for 12.37 Mkcal of heat input. The start up oil system comprises LDO tank of
capacity 15m3 with 2nos. of gear oil pump (1W + 1S) and suction strainer. The startup
burner, pumping and firing system, air piping, valves, fittings & instruments are per the
P&ID BG013-09 - 00-3-017.
The details of the startup oil firing system with associated equipment, BMS controls and
logics are elaborately described in Volume IX
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6.4

FLUE GAS SYSTEM
6.4.1 Combustor
The combustor forms the chamber within which the combustion of fuel takes place and
products of combustion (flue gases) are generated. (Refer to Fig-6) The taller combustion
chamber and re-circulation of bed material result in a longer residence time for the particles
facilitating complete combustion of the fuel particles. As the hot flue gases move up the
combustor, heat is transferred to the water walls and wing wall (radiant) superheater
sections before exiting the combustor. (Refer to P&ID BG013-00-09-2-013)
FIG- 6
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6.4.2 Hot Cyclone Separator
Flue gases leaving the top of the combustion chamber enters the hot cyclone separator
through the cyclone inlet. Once the gas solids enter the hot cyclone separator, the gas
travels upwards through the vortex finder and enters the cross over duct (cyclone outlet
chamber) and further down the convection section (back pass) of the boiler.
6.4.3 Convection Section (Back Pass)
The flue gases pass through the convection section (back pass) of the boiler vertically
downwards across various heat transfer sections viz. final superheater, primary
superheater, economiser and air pre-heaters. Heat transfer from the flue gases to above
sections is purely by convection. The flue gases then pass through the ESP, ID fan and
chimney to the atmosphere.
6.4.4 Induced Draft Fan (ID)

One number 100% centrifugal type induced fan coupled to a motor is provided in the boiler
for the purpose of purging initially and maintaining a balanced draft during normal
operations. The flue gas from the boiler is drawn through ID fan, and evacuated / discharged to the atmosphere through the chimney. The ID fan inlet damper opening / position is
controlled according to the pressure at the top of the combustor which is the balance point
(slightly negative pressure, -10 mmWC).
Flue gas is analyzed for O2 at the Economiser outlet to monitor the efficiency of combustion process and CO analyser at the outlet of air heater for monitoring the CO level in the
flue gas. Sox, Nox and particulate may be checked periodically through the analyzer test
pockets provided, according to the requirement. For more details on ID fan refer to manual
in Volume - IV
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6.5

Feed Water System
One number common de-aerator system is provided for supplying the feed water to the
both boilers (Unit IV & Unit V). Three numbers of electrical motor driven boiler feed
pumps are provided at the outlet of the de-aerator cum storage tank.
The feed water from the feed pump is heated at the HP heaters before entering the
economiser.
One (1) x 100% pneumatic feed control valve, (1) x 100% motorized bypass feed control
valve and one (1) x 30% pneumatic feed control valve are provided to regulate the boiler
feed water flow. During boiler start-up up to 30% load, the feed flow rate is controlled by
30% feed control valve. When boiler exceeds 30 % load, the 100% feed control valve
regulates the feed water flow rate to maintain the drum level at the desired set point.
Motorised isolation valves are provided at the upstream side of each feed control valve and
manually operated valves are installed on down stream of each control valve for
maintenance purpose. Motor operated control valve of 100% capacity is also provided in
the bypass line with isolation valve at the upstream and manual isolation valve at the down
stream to take care of feed water regulation during the maintenance of 100% feed control
valve.
6.6
Steam System
The steam system is as per the P&ID BG013-00-09-1-010. The feed water enters the
economiser and the heat is exchanged with the flue gas and enters the steam drum. After
leaving the drum, the saturated steam is led to the back pass. The back pass enclosure is
constructed of a gas tight, steam cooled membrane walls clamped with buck stays and tie
bars. Steam from the drum enters the steam cooled wall distribution header through steam
cooled wall left and right top and bottom headers, flows down the steam cooled wall front
side header and through the cross over duct (cyclone outlet chamber). The cross over duct
(cyclone outlet chamber) assembly is also completely steam cooled with similar gas tight
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membrane panel arrangement. The saturated steam passes through the primary
superheater, de-superheater, wingwall and final superheater for superheating the steam.
The de-superheater is a fixed spray type located between the primary and wingwall
superheater controls the steam temperature to the rated value. The sensing element TE5202 / TE-5204 which is mounted on the discharge link of primary superheater and the
main steam line respectively monitors and control the main steam line temperature to the
rated value.
6.6.1 Main Steam Piping

The main steam piping is supplied from final superheater outlet header up to main steam
stop valve. From main steam stop valve outlet steam is let into the turbine through common
distribution header. Steam flow nozzle is provided in the main steam pipe to measure the
steam flow. Adequate number of steam drains is provided in the bottom most level of the
pipes and air vent provided in the top most elevation of the pipe. The main steam pipe is
provided with the following.
01.
Safety Valve with silencer
- 1 no.
02.
Startup Vent valve with silencer
- 1 no. (Motorised)
03.
Startup vent isolation valve
- 1 no.
04.
Pressure Transmitter
- 1 nos.
05.
Flow nozzle with Transmitter
- 1 nos.
06.
Pressure Gauge (Local)
- 1 no.
07.
Pressure Gauge (Remote)
- 1 no.
08.
Sampling Stub (SWAS)
- 1 no.
09.
Temperature Element (T/C)
- 1 no.
10.
Main Steam Stop Valve
- 1no.
11.
Drain stub
- 1 no.
12.
Air Vent stub
- 1 no.
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13.
Auxiliary stub
- 1 no.
14.
Temperature gauge
- 1 no.
Main Steam Pipe

Size
219.1 25.4 mm
Material
SA 335 Gr.P 22
6.7
Ash Collection System
6.7.1 Bed Ash Collection
The CFBC boiler is provided with two numbers of water cooled bed ash coolers. The ash
coolers are located on either side of the combustor. Refer to P&ID BG013-00-09-2-014.
The bed ash coolers are provided to collect and cool the bed ash to approximately 265C
so that the ash can be handled by ash disposal equipment.
The ash is cooled by a part of the fluidising air taken from the primary air fan system and
the hot air from the cooler is fed back to the combustor for sensible heat recovery from the
ash. The ash is cooled from approximately 950C to 265C by this system. Further if the
temperature is in excess of 300C at the 3 rd compartment, the emergency water spray is
activated by the interlock to cool down the ash before discharge.
The cooling water circuit to the bed ash coolers is connected in series i.e. the cooling water
enters and leaves the first bed ash cooler and then passes through the second bed ash
cooler before coming out of the system. Necessary provision to bypass the cooling water
inlet to either of the bed ash coolers is also provided. The cooling water coming out of the
bed ash cooler is cooled and re-circulated using dedicated cooling tower.
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A rotary air lock valve is provided at the discharge of each ash cooler to regulate the ash
discharge rate depending on the combustor bed pressure.
6.7.2 Fly Ash Collection System
The fine ash that is carried by the flue gas from the hot cyclone separator outlet is
collected at various sections of the boiler such as air heater hoppers, and ESP hoppers.
Ash collected from these hoppers are handled by a separate system to the ash silo.
6.8
Bed Material Feeding System
The bed material feeding system is as per the P&ID BG013-00-09-3-011.The bed material
bunker capacity is 50 m for storing the required bed material. The bunker outlet is provided
with a slide gate for isolation of bed material flow to the rotary feeder provided for feeding
the bed material to the combustor. The rotary feeder is also provided with slide gate type
isolator at the outlet for maintenance purpose.
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6.9 Soot Blowing System
Three number of long retractable soot blowers (LRSB) are provided in superheater section
of the boiler, one each in primary superheater, final superheater and between primary and
final super heater. And two more motorised rotary soot blowers (MRSB) are also provided
in the economiser section in the boiler.
Soot Blower is a mechanism consisting of Soot Blower head mounting box, element &
intermediate or end supports. Soot Blowers head is a simple gear train which rotates the
spindle and in turn element. The function of Soot Blowers is to keep the Boiler clean & are
not expected to remove slag and old deposits which are the result of previous
neglect. Steam passes through the head and element throughout nozzles, cleaning
the loose soot deposited on Boiler Tubes and Super Heater coils and Economiser.
For more information on soot blowing system pls refer volume -
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7.0 Refractory
Refractory is applied in CFBC boilers to mainly provide erosion protection of the boiler. The
detail of the areas where refractory is applied is as shown in fig - 7.
For more details on refractory application, refer to G.A drawing enclosed in Volume XI
FIG 7
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8.0 WATER CHEMISTRY GUIDELINES
8.1
Prelude
Water Chemistry Guidelines provided in this write up is intended to help operating staff to
achieve maximum efficiency and improve boiler availability at optimum cost. Boiler outage
statistics, world wide, indicate that more than 75 % is attributed to cycle chemistry
deviations, particularly during startup, shut down and lay up cycles. These guidelines are
derived based on general cycle chemistry followed word wide and our own experience. It
may be noted that these are only GUIDELINES and NOT SPECIFICATION. However,
customer, on his own or on the advice of the consultant may opt his own system, but with
no obligation to M/s Cethar vessels (P) Ltd.
8.2
Water Treatment
Water is treated to meet the requirements of the boiler under use, as stipulated in the
Guidelines. The main purpose of water treatment is to achieve the required steam quality,
as dictated by the turbine manufacturer or the process requirement. Minimising corrosion /
deposition and blow down are the other objectives of the water treatment design. Ultimately
these achievements will lead to higher boiler availability and optimum efficiency. Water
treatment is carried out in two stages External Treatment and Internal Treatment.
External treatment is intended to remove suspended and dissolved solids while internal
treatment is meant for minimizing solids carry over into steam and corrosion of heat
exchangers.
8.2.1 External Treatment
Raw water is treated, initially to remove organic matter and suspended solids in a process
called pre-treatment and then to remove dissolved solid and silica using Demineraliser
Plant to get ultra pure water required for boiler application.
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8.2.1.1 Pre-treatment
Pre treatment is carried out to remove organics and suspended solids. Organics, basically
organisms like algae, is removed by on-line chlorination using suitable chemicals.
Incomplete removal of organics will cause fouling of anion resins of the demineraliser, apart
from fouling mechanical filters. Care should be taken to minimise excess chlorine either by
on-line control or by removal using activated charcoal beds, prior to de-mineralisation.
Excessive chlorine will destroy the organic resins used in demineraliser plants. When
allowed to get into boiler circuit, they may decompose to gaseous hydrocarbons, which
may cause damage to the super heater metallurgy. Some organics may even cause
foaming in the drum, affecting steam purity. Suspended solids are removed by a process
called Flocculation, sedimentation and de-cantationin a carefully designed pre-treatment
plant. The quality of water produced is normally consistent with that of demineraliser plant
design.
8.2.1.2 Demineralisation
Demineralisation is achieved by ion-exchange process or in combination with a Reverse

Osmosis plant. Residual chlorine, suspended solids and dissolved solids are removed
charcoal bed, sand filters and Rom plant / ion exchange resins respectively. The out put
quality of the demineralised water is designed to meet the make up / boiler feed water
requirements.
8.3
Internal Treatment
Ultra pure Demineralised water is used in boiler to produce steam of high purity. Though
the pH of DM water is 7 0.2, considered neutral at ambient conditions, it is still corrosive
at elevated temperatures. Also the dissolved oxygen, which is not removed during demineralisation, process will cause, will cause pitting corrosion in the pre boiler circuit,
particularly in economisers. In order to reduce corrosion, internal treatment is carried out in
two stages viz. LP stage and HP stage.
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8.3.1 Oxygen Removal
Dissolved Oxygen level in de-mineralised water varies from 6 to 8 ppm under ambient
conditions of temperature and pressure. This is required to be reduced to less than 0.007
ppm in order to minimise pitting corrosion. Oxygen removal is carried out in two Stages
using mechanical and chemical means. De-aerator suitably designed to meet the boiler
requirements, including startups and emergency operations like excessive make up due to
high drum levels or solids / silica etc will reduce the oxygen levels between 0.05 to 0.1
ppm. Further it is reduced to 0.007 ppm level using hydrazine hydrate.
8.3.2 LP Dosing
LP dosing is done at the inlet of economized, preferably at the suction head of feed pump.
A mixture of Hydrazine (0.5 % solution of hydrazine in DM water and Ammonia (calculated
quantity to maintain 0.5 ppm in feed water) is used for this purpose. Morpholine or cyclo
hexylamine can also be used instead of ammonia. While ammonia increases the feed
water pH to the required level (90.2) hydrazine will scavenge residual oxygen from deaerator the required level of 0.007 ppm. Alternatively, ammonia and hydrazine can be
dosed independently to achieve precise control of these chemicals.
8.3.3 HP Dosing
Tri-sodium Phosphate solution (1% TSP in DM water) is dosed directly into the drum to
further increase the boiler water pH to the specified level (100.2). The phosphate residual
to be maintained in the boiler water is given in the Table -1 under Boiler Water quality.
However achieving the desired pH is of paramount important than maintaining phosphate
levels. A co-ordinated phosphate curve is given in FIG-8 to help maintain pH-PO4 levels
avoiding free hydroxide in boiler water. Another means of controlling free hydroxide is by
measuring P and M alkalinity with a thumb rule that 2P M. Normally the P & M alkalinity
levels to be maintained in Boiler Water are 10% and 20% of Boiler water solids,
respectively.
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8.3.4 Silica Control
Silica carryover in high pressure boiler is more controlled by distribution law than
mechanical carryover in high pressure boilers. Hence the silica level in steam is a function
of boiler water silica and the drum operating pressure. pH also plays an important role in
keeping silica in solution. Boiler water silica to be maintained for the required steam silica of
0.02 ppm versus drum operating pressure is given in Fig 9. Two different curves are given
for 2 ranges of pH to be maintained in Boiler Water. Any excess silica build up of silica in
Boiler Water is removed by blow down. However the best way to minimise blow down is to
control silica and solids ingression through boiler input, viz make up water.
8.3.5 Feed Water / Boiler Water Quality
In order to achieve the required steam quality and minimise corrosion, both in boiler and
pre-boiler systems, the qualities of feed water and boiler water are to be defined precisely.
Table 1 gives the data for a High Pressure boiler working above 60 kg/cm2 (g) pressures. It
is needless to emphasis the need for maintaining good make up water quality, feed & boiler
water quality, HP / LP dose control and optimum operating parameters in de-aerator to
achieve maximum efficiency and plant availability.
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TABLE - 1
WATER QUALITY REQUIREMENT FOR SINGLE DRUM BOILERS
Drum Operating Pressure (kg/cm(g))
Above 60
Feed Water:
Specific Electrical Conductivity At 25C Measured
After Cation Exchanger In The H+ Form And After Co2
Removal.
ms/cm
max.
0.5
Total Iron
ppm
max.
0.01
Total Copper
ppm
max.
0.01
Total Silica
ppm
max.
0.02
Oxygen
ppm
max.
0.007
Hydrazine Residual
ppm
max.
0.01 - 0.02
pH @ 25C (Copper Alloy Pre-Boiler System)
ppm
8.8 - 9.2
pH @ 25C (Copper Free Pre-Boiler System)
9.0 - 9.4
Permanganate
ppm
max.
Nil
Hardness
ppm
Nil
Total Co2
ppm
Nil
Oil
ppm
Not Allowed
Total Dissolved Solids
ppm
Not More Than 100
Specific Electrical Conductivity At 25C
ms/cm
Not More Than 200
Phosphate Residual
ppm
15 - 25
Boiler Water
pH @ 25C
max.
Silica
(See Note : 8)
ppm
Page 6 0 of 152
9.8 - 10.2
Silica Level Less Than
0.02 ppm In Steam
Leaving The Drum.
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Notes
1. All the measurement of feed water shall be made at high pressure heater outlet or
economiser inlet.
2. The recommended pH in feed water can be obtained by dosing ammonia morpholine or

any volatile amine. The concentration of volatile chemical in the feed water should not
exceed 1 ppm (expressed as ammonia).
3. If the pH of boiler water falls below the recommended range, it will considerably
increase silica carry over in
steam and hence suitable lower Silica level should be
maintained in boiler water to maintain less than 0.02 ppm in steam leaving the drum.
4. The phosphate and pH are recommended in accordance with co-ordinated phosphate

curve to prevent presence of free hydroxide in boiler water. If the recommended
pH is consistently obtained phosphate residual can be maintained near lower limits.
5. Water levels in drum should be maintained within limits during all operational modes
i.e., Start-up, load fluctuation and normal operation.
6. The alignment of drum internal should be checked and ensured to be in order at least
once in every year.
7. It is needless to emphasise that correct sampling, accurate measurements with the use
of reliable instruments
at adequate intervals and proper logging of reading go a long
way in ensuring trouble free operation of boilers.
8. To be controlled on the basis of silica in boiler water and drum pressure and boiler
water pH relationship to maintain less than 0.02 ppm in the steam leaving the drum.
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FIG-8
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FIG-9
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9.0

STARTING OF INDIVIDUAL EQUIPMENT
The electrical drives are provided with interlocks for safe startup and reliable operation. The
interlocks should not be bypassed. Before the fans are started the suction dampers are
checked for smooth operation.
The sequence of starting the equipments is as follows:
*** Check the water level gauge for start-up level (-250mm) in steam Drum.
01.
Start the ID fan.
02.
Start the Loop seal blower.
03.
Start the SA fan.
04.
Start the PA fan.
The individual equipment can be started through DCS or from Local Push Button or VFD
panels (LPBS/VFD panel/MCC).The Local / Remote selection is provided in DCS. Switch
on the power supply to the motor control centre (MCC) panel. The fuses of individual motor
controls shall be checked for continuity. Three phase supply of 415 V 50 Hz with allowable
percentage of variation shall be ensured before switching on the equipment.
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Interlocks
ID Fan (LTM 5303) (Drawing No. BG013-00-09-3-056)
CFBC boiler is provided with 1 x 100% ID fan with inlet damper at the suction for combustor
pressure control.
Permissives:
Before starting the ID fan, the system shall ensure the following conditions.
1. Steam drum level not low

2. Steam drum level not high
3. ID fan bearing temperature not high at DE and NDE
4. ID fan motor bearing temperature not high at DE and NDE
5. ID fan motor winding temperature (R,Y,B) not high.
6. ID fan suction damper in minimum position or ID fan running.
7. ID motor not overloaded
Operation:
The ID fan can be started / stopped by remote operation from DCS. On selection
of local operation from DCS the ID fan can be started / stopped from VFD panel or from
LPBS at field. On selection of the control in local operation except the motor overload
condition all other permissives / interlocks are bypassed. ID fan is started by initiating a
start command. ID fan suction damper can be opened after starting the ID fan. The ID fan
can be stopped any time from DCS/LPBS/VFD Panel during the normal course of operation
(remote/local).
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Trip Condition:
The ID fan trips on following conditions when the drive is selected in remote
operation.
1. If any of the above mentioned permissives failed

2. ID fan motor overload
The ID fan motor trips on motor overload and stop command, irrespective to the
mode of operation
Failure to start the VFD within 5 secs from initiation of start push button rests the
logic
Loop seal Air Blower (LTM 5305 & LTM 5305) (Drawing No. BG013-00-09-3-057&058)
CFBC boiler is provided with 2 x 100%(1W + 1S) loop seal blower for supplying high
pressure air to the return leg of the hot cyclone separator for fluidising the solids and ash
transfer line collected between the combustor and bed ash cooler.
Any one of the loop seal blower can be selected to start as per the requirement.
Before starting the loop seal blower, the system shall ensure the following conditions.
Permissives:
1. Steam drum level not low

2. Steam drum level not high
3. loop seal blower motor not overloaded
4. ID fan motor running
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Operation:
The loop seal blower can be started / stopped by remote operation from DCS.
On selection of local operation from DCS the loop seal blower can be started / stopped
from MCC or from LPBS in the field. On selection of the control in local operation except
the motor overload all other permissives / interlocks are bypassed. Seal pot blower is
started by initiating a start command. The operation of the equipment can be stopped
anytime from DCS/LPBS/MCC during the normal course of operation (remote/local).
Trip Condition:
The loop seal blower motor trips on following conditions when the drive is selected
in remote operation.
1. If any of the above mentioned permissives failed
The loop seal blower motor trips on motor overload and stop command,
irrespective of the mode of operation.
The loop seal blower fan continues to run for 30 secs, even after ID fan is stopped
/ tripped to fluidize and ensure the leg return of the hot cyclone separator is free
from accumulation.
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SA Fan (LTM 5302) (Drawing No. BG013-00-09-3-059)
The CFBC boiler is provided with 1 x 100% SA fan with suction damper for combustion air
control.
Before starting the SA fan, the system shall ensure the following conditions.
Permissives:
1. ID fan motor running

2. Loop seal air blower I or II running.
3. Loop seal air blower I or II air pressure not low.
4. Furnace pressure not high.
5. SA fan suction damper In minimum position or SA fan running.
6. Steam drum level not low.
7. Steam drum level not high.
8. SA fan DE and NDE bearing temperature not high.
9. SA fan motor DE and NDE bearing temperature not high
10. Drive motor not overload.
Operation:
The SA fan can be started / stopped by remote operation from DCS. On

selection of local operation from DCS the SA fan can be started / stopped from MCC or
from LPBS at field. On selection of the control in local operation except the motor overload
all other permissives / interlocks are bypassed. SA fan motor is started by initiating a start
command. The SA fan suction damper can be opened after starting the SA fan. The SA fan
can be stopped anytime from DCS / LPBS / MCC during the normal course of operation
(remote/local).
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Trip Condition:
The SA fan motor trips on following conditions when the drive is selected in
remote operation.
1. If any of the above permissives fails
2. Trip initiated from boiler trip push button in DCS. (Ref BG013-00-09-3-061)
3. ID fan motor tripped.
4. Loop seal air blower motor tripped.
The SA fan motor trips on motor overload, irrespective of the mode of operation.
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PA Fan (HTM 5301) (Drawing No. BG013-00-09-3-060)
The PA fan 1 x 100 % is provided with the suction damper for fluidising the bed material in
the combustor.
Before starting the PA fan, the system shall ensure the following conditions.
Permissives:
1. ID fan motor running.

2. SA fan motor running.
3. Loop seal air blower I or II running.
4. Furnace pressure not high.
5. PA fan suction damper in minimum position or PA fan running.
6. Steam drum level not low.
7. Steam drum level not high.
8. PA fan bearing temperature not high at DE and NDE
9. PA fan motor bearing temperature not high at DE and NDE
10. PA fan motor winding temperature (R,Y,B) not high.
11. HT panel breaker not tripped
Operation:
The PA fan can be started / stopped by local / remote operation from DCS. On
selection of local operation from DCS the PA fan can be started / stopped from HT panel or
from LPBS at field through a dedicated open / close breaker. PA fan motor is started by
initiating a start command through a close coil. The PA fan suction damper can be opened
after starting the PA fan. The PA fan can be stopped from DCS / LPBS / HT panel during
the normal course of operation (remote / local).
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Trip Condition:
The PA fan motor trips on following conditions when the drive is selected in
remote operation.
1. If any of the above mentioned permissives failed.

2. Trip initiated from boiler trip push button in DCS. (Ref BG013-00-09-3-061)
The PA fan motor trips on HT panel breaker tripped and by breaker open command
from DCS / LPBS / HT panel, irrespective of the mode of operation.
Boiler trip & Fuel trip (Drawing No. BG013-00-09-3-061)

The Boiler will be tripped when boiler trip push button is initiated (or) when the following
conditions occur.
a)
b)
c)
d)
Furnace pressure very high.

Drum level very low.
Drum level very high.
ID fan not running.
NO BOILER TRIP:
When the above condition comes to normal state no boiler trip permissive is granted.
Fuel feeder trip is enable when any of the following conditions occurs,
a) Boiler trip.
b) Seal pot(Loop seal) air blower-I and Seal pot(Loop seal) air blower-II not running.
c) SA Fan motor not running.
d) Air box pressure < 1000 mmwc
e) PA Fan motor not running.
Boiler Purging (Drawing No. BG013-00-09-3-062)
The following are the condition to be satisfied for boiler purging.
a)
b)
c)
d)
All Sources of Fuels off.

Primary air flow > minimum.
Secondary air flow > minimum.
No Boiler trip.
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Once all the above conditions are satisfied by pressing the purge start push
button from the DCS, purging is carried out for 5 minutes. Once the boiler
purging is completed the purge completed signal is taken to DCS as burner start
permissive.
However during the process of purging if any of the permissive fails, the purging
should be repeated again for 5 minutes before admitting the fuel. Purging of the
furnace is required to keep the furnace clear for the combustible gases before
starting of the boiler or starting after any boiler trip condition.
NOTE: All feeders stopped and LOTV trip valve close is considered as all sources of fuels
off.
Main Drag Chain Feeder I & II : (GM 5405 & GM 5406) (Drawing No. BG013-00-09-3063 & 064)
Two numbers of main drag chain feeders (constant speed geared motor driven) are
provided for conveying the fuel into the combustor.
Before starting the main drag chain feeder motors, the system shall ensure the following
conditions.
Permissives:
1. Main drag chain feeder I & II geared motors not overloaded.

2. PA fan motor running.
3. Knife edge gate I & II opened.
4. Zero speed switches not actuated.
5. Air box pressure > 1000 mmWC.
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Operation:
The main drag chain feeder motor can be started / stopped by remote operation
from DCS. On selection of local operation from DCS the drag chain feeder motor can be
started / stopped from MCC or from LPBS at field. On selection of the control in local
operation except the motor overload all other permissives / interlocks are bypassed. The
main drag chain feeder motor is started by initiating a start command. The main drag
feeder motor can be stopped from DCS / LPBS / MCC during the normal course of
operation.
Trip Condition:
The main drag chain feeder motor I & II trips on following conditions when the drive is
selected in remote operation.
Note:
1. If any of the above mentioned permissives failed or fuel tripped or Temperature at
fuel line I & II high or knife edge gate I & II closed.
2. The main drag chain feeder motor I & II can be stopped, irrespective to the mode
of selection.
3. Failure to start the drive within 5 secs from the initiation of start push button
resets the logic.
The main drag chain feeder motor I & II trips on motor overload, irrespective to
the mode of selection.
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Drag Chain Feeder I & III(GM 5401 & GM 5403)

(Drawing No. BG013-00-09-3-065)
Two numbers of drag chain feeders (VFD driven) are provided for conveying the fuel into
the main drag chain feeder I.
Before starting the small drag chain feeder motor, the system shall ensure the following
conditions.
Permissives:
1. Drag chain feeder I & III geared motors not overloaded

2. Main Drag chain feeder motor (GM 5405) running.
Operation:
The drag chain feeder motor can be started / stopped by remote operation from
DCS. On selection of local operation from DCS the drag chain feeder motor can be started
/ stopped from the VFD panel or from LPBS at field. On selection of the control in local
drag chain feeder motor is started by initiating a start command. The drag chain feeder
motor can be stopped from DCS / LPBS / VFD panel during the normal course of operation.
Trip Condition:
The drag chain feeder motor I & III trips on following conditions when the drive is selected
in remote operation.
Note:
1. If any of the above mentioned permissives failed or fuel tripped.
2. The drag chain feeder motor I & III can be stopped, irrespective to the mode of
selection.
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3. Failure to start the VFD within 5 secs from the initiation of start push button
resets the logic.
The drag chain feeder motor I & III trips on motor overload, irrespective to the
mode of selection.
Lime stone feeder I (GM 5407)

(Drawing No. BG013-00-09-3-081)
One number lime stone feeder (VFD driven) are provided for conveying the fuel into the
main drag chain feeder I.
Before starting the lime stone feeder motor, the system shall ensure the following
conditions.
Permissives:
1. Lime stone feeder geared motor not overloaded

Operation:
The lime stone feeder motor can be started / stopped by remote operation from
DCS. On selection of local operation from DCS the lime stone feeder motor can be started /
stopped from the VFD panel or from LPBS at field. On selection of the control in local
lime stone feeder motor is started by initiating a start command. The lime stone feeder
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Trip Condition:
The lime stone feeder motor trips on following conditions when the drive is selected in
remote operation.
Note:
2. The lime stone feeder motor can be stopped, irrespective to the mode of selection.
resets the logic.
The lime stone feeder motor trips on motor overload, irrespective to the mode of
selection.
Drag Chain Feeder II & IV (GM 5402 & GM 5404)

(Drawing No. BG013-00-09-3-066)
Two numbers of drag chain feeders (VFD driven) are provided for conveying the fuel into
the main drag chain feeder II.
Before starting the small drag chain feeder motor, the system shall ensure the following
conditions.
Permissives:
1. Drag chain feeder II & IV geared motors not overloaded

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Operation:
The drag chain feeder motor can be started / stopped by remote operation from
DCS. On selection of local operation from DCS the drag chain feeder motor can be started
/ stopped from the VFD panel or from LPBS at field. On selection of the control in local
drag chain feeder motor is started by initiating a start command. The drag chain feeder
Trip Condition:
The drag chain feeder motor II & IV trips on following conditions when the drive is
selected in remote operation.
Note:
2. The drag chain feeder motor II & IV can be stopped, irrespective to the mode of
selection.
resets the logic.
The drag chain feeder motor II & IV trips on motor overload, irrespective to the
mode of selection.
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Lime stone feeder II (GM 5408) (Drawing No. BG013-00-09-3-082)
One number lime stone feeder (VFD driven) are provided for conveying the fuel into the
main drag chain feeder II.
Before starting the lime stone feeder motor, the system shall ensure the following
conditions.
Permissives:
1. Lime stone feeder geared motor not overloaded

Operation:
The lime stone feeder motor can be started / stopped by remote operation from
DCS. On selection of local operation from DCS the lime stone feeder motor can be started /
stopped from the VFD panel or from LPBS at field. On selection of the control in local
lime stone feeder motor is started by initiating a start command. The lime stone feeder
Trip Condition:
The lime stone feeder motor trips on following conditions when the drive is selected in
remote operation.
Note:
2. The lime stone feeder motor can be stopped, irrespective to the mode of selection.
resets the logic.
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The lime stone feeder motor trips on motor overload, irrespective to the mode of
selection.
Bed Material Feeder (GM 5409): (Drawing No. BG013-00-09-3-067)
For bed material feeding into the combustor a rotary type feeder with geared motor is
provided.
This motor is provided with a local / remote selector switch in DCS. The operator has an
option to start / stop the bed material feeder motor from MCC panel / LPBS or DCS
The motor can be started from local / remote, if the motor is not on overload trip condition.
The motor trips on overload condition, irrespective of mode of operation.
Caution: Please check inventory of bed material before starting this bed material feeder
after any trip and hot re-start.
Gear Oil Pump motor I & II (LTM 5801 & LTM 5802): (Drawing No. BG013-00-09-3067)
The gear oil pump is provided for pumping LDO from the day tank to the burners during the
initial firing for light-up.
This motor is provided with a selectable Local / Remote switch in DCS. The operator has
an option to start / stop the oil pump motor from MCC panel / LPBS or DCS, when the
motor is not on overload trip condition.
The motor trips on overload condition irrespective of the mode of operation.
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Bed Ash Cooler Ash Discharge Feeders (GM 5901 & GM 5902)
(Drawing No. BG013-00-09-3-070)
A rotary air lock type ash discharge feeders with geared motor is provided at the outlet of
each bed ash cooler. These motors are controlled through VFD for discharging the ash
during the normal course of operation.
These motors are provided with a local / remote selector switch in DCS. The operator has
an option to start / stop the motors from VFD panel / LPBS or DCS.
The motors can be started from local / remote, if the motor is not overloaded.
The motor trips on overload, irrespective of mode of operation
Knife Edge Gate-I Solenoid Valve (SOV5401) : (Drawing No. BG013-00-09-3-076)
A pneumatic power cylinder operated knife edge gate valve is provided at the outlet of Main
drag chain feeder - I.
Knife edge gate valve shall be opened / closed manually from the DCS.
Knife edge gate valve will be closed, when the temperature at fuel line is high.
The open and close feed back indication of PCD-5401 will be available in DCS through
reed switches ZSC-5401 & ZSO-5401.
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Knife Edge Gate-II Solenoid Valve (SOV5402) : (Drawing No. BG013-00-09-3-077)
A pneumatic power cylinder operated knife edge gate valve is provided at the outlet of Main
drag chain feeder-II.
Knife edge gate valve shall be opened / closed manually from the DCS.
Knife edge gate valve will be closed, when the temperature at fuel line is high.
The open and close feed back indication of PCD-5402 will be available in DCS through
reed switches ZSC-5402 & ZSO-5402.
Bed Ash Cooler I Solenoid Valve (SOV 5101) & (SOV5301) :
(Drawing No. BG013-00-09-3-078)
Cooling water SOV (SOV 5101) shall be opened when bed ash temperature TE5304
reaches above the set point or the steam flow signal increases greater than 50% of load
and it closes when the temperature reduces below the set point & the steam flow signal
reduces less than 50% of load.
Service air SOV (SOV 5301) shall be opened when cooling water SOV
(SOV 5101)
closes.
Service air SOV (SOV-5301) & Cooling water SOV (SOV 5101) can also be opened /
closed manually from the DCS.
The close feed back indication for cooling water SOV (SOV 5101) will be available in DCS
through limit switches ZSC 5101.
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Bed Ash Cooler Ii Solenoid Valve (SOV 5102) & (SOV5302) :

(Drawing No. BG013-00-09-3-079)
Cooling water SOV (SOV 5102) shall be opened when bed ash temperature TE 5305
reaches above the set point or the steam flow signal increases greater than 50% of load
and it closes when the temperature reduces below the set point & the steam flow signal
reduces less than 50% of load.
Service air SOV (SOV 5302) shall be opened when cooling water SOV
(SOV 5102)
closes.
Service air SOV (SOV 5302) & Cooling water SOV (SOV 5102) can also be opened /
closed manually from the DCS.
The close feed back indication for cooling water SOV (SOV 5102) will be available in DCS
through limit switches ZSC 5102.
Long Retractable Soot Blower (LRSB 5201, 5202 & 5203) & Motorised Rotary soot
blower(MRSB 5201 & MRSB 5202) (Drawing No. BG013-00-09-3-071 to 75)
Three numbers of long retractable soot blowers (LRSB) are provided in superheater section
of the boiler, one each in primary superheater, final superheater and between primary and
final super heater and two numbers of Motorised Rotary Sootblowers(MRSB) are provided
in the economiser zone.
Soot blowers (LRSB & MRSB) shall be started by selecting either in Local or from
Remote mode.
When Remote mode is selected from DCS, Soot blower shall be operated either in
sequence by selecting Auto sequence mode by energizing a multi-lead timer in DCS or the
same shall be operated individually by selecting Manual mode in DCS.
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Soot blower motor will be started when the following Permissive are satisfied.
a) All the blowers home position limit switches are in initial position.
b) Soot blower steam pressure not low.
c) Soot blower motor TOLR not actuated.
d) Soot blower motor stop push button not actuated.
e) Soot blower motor not in Bypass mode.
Soot blower shall be tripped when soot blower motor TOLR is actuated (or) Soot
blower motor stopped.
Long retractable soot blower (LRSB) shall be wired such that the motor can be
forwarded / Retracted either from DCS/LPBS/MCC.
Motorised rotary soot blower motor shall be wired such that the motor can be
started/stopped either from DCS/LPBS/MCC.
Note:
If any of the soot blowers are bypassed, the corresponding multilead timer also skipped to
start the next selected soot blower without any time delay.
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10.0

BOILER START- UP PROCEDURE AND OPERATION
Introduction
Start-up and operation of the boiler requires experience and understanding of all systems
and auxiliaries.
Any operation of the boiler must be accomplished with safety as prime concern. The
operator should be thoroughly aware of the status of the boiler and support systems before,
during and after any operation.
This section is to introduce you to the basic operating principles of CETHAR Circulating
Fluidised Bed Boiler. These basic operating guidelines should be supplemented with the
plant-specific operating instructions and guidelines as required.
The material in this section is intended primarily to brief the principles, and to provide stepby-step details of operating the CETHAR CFBC boiler.
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START-UP SEQUENCE
CHECK ALL AIR FLOW DAMPERS
START INDUCED DRAFT FAN
START SEAL POT (LOOP SEAL) BLOWER
START SECONDARY AIR FAN
START PRIMARY AIR FAN
START 5-MINUTE BOILER PURGE
START START-UP BURNERS
RAISE BED TEMPERATURE > 600C
START FIRST FUEL FEEDER
START SECOND FUEL FEEDER
REDUCE OIL FIRING & INCREASE SOLID FUEL FEED
RAISE BED TEMPERATURE > 760 C
STOP START-UP BURNERS
RAISE BOILER TO RATED 100% MCR
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Operations
10.1
Preliminary Operational Check List
Please check up the following before boiler startup and ensure that the boiler startup
procedure and all support systems are understood for proper operation.
1.
Carefully inspect all parts for proper assembly and installation.
2.
All auxiliary equipment must be in good operating condition and operated as per
the manufacturers recommendations and instructions according to this O&M
manual.
3.
The steam drum water level gauges must be checked for installation according to
the manufacturers drawing before preliminary operation. When the water level
in the steam drum is lowered below the lowest visible point on the level gauge, all
water should drain out of the glass. Any time a repair or change is made to the
level gauge, check for proper draining.
Ensure the steam legs of the level
gauges are not insulated for proper measurement / indication.
4.
Blow down lines from the water column and level gauges are taken to a safe
location. Ensure the drain valves are closed.
5.
Valves located between the steam drum and drum level gauge water column,
level transmitters etc, must be kept in the full open position.
6.
All operational drains, and drain lines from vents, relief valves, safety valves and
instrument drain lines must be readily accessible and properly connected to a
blow down system or other safe location.
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7.

Check that the steam drum water level indication in DCS and compare accurately
with the direct water level glass reading.
8.
All safety valve hydrostatic test plug must be removed and the safety valves must
be in proper operating condition. Safety valve and relief valve discharge pipes
and drains should be arranged and supported according to the safety relief valve
manufactures recommendations and IBR codes.
9.
Steam drum internals must be properly installed according to the manufacturers

drawings. This will assure steam - water mixture will not bypass the steam drum
internals.
10.
All temporary test connections and permanent plant instrumentation must be

installed with associated transmitters and indicators calibrated and available for
operation.
11.
Control system and safety interlocks are checked.
12.
Adequate lighting is provided for safe operation.
13.
Ensure all scaffolding removed, walkways and stairways are cleared from
obstacles.
14.
Air and gas path are cleared from obstruction.
15.
The feed water supply must be adequate without interruption and as per the
water quality recommended.
16.
Adequate supply of fuel (oil / Petcoke + Fly ash / Petcoke / F grade coal + Fly
ash / F grade coal / Lignite + Fly ash / Lignite) must be available.
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17.

Ensure availability of adequate bed material as per the recommended

specification.
18.
Ensure all equipment, tools and debris have been removed, and no one is inside
the boiler and all access doors are closed.
19.
Steam drum manhole openings are closed and properly sealed.
20.
All equipment subject to thermal expansion must be free of interference, such as

temporary scaffolding, debris and left over construction materials etc and should
be ensured for free expansion.
21.
Ensure burner view port and flame scanner are clean, and cooling air is available
for flame scanner.
22.
Ensure concurrent approval taken from all concerned before starting of any
equipment, to support boiler operations.
When the above check points are completed, then the boiler can be started.
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10.2

Cold Start
This section provides detailed instructions to startup the boiler from cold condition and to
bring it to maximum continuous rating (MCR). Refer Fig-10
This section defines basic steps and these basic operating guidelines should be
supplemented with the plant-specific operating instructions and guidelines as required.
START UP CURVE
START UP / COOLING CURVE FOR CFBC BOILER
100.0
90.0
70.0
DRUM PRESSURE IN kg/cm (g)
80.0
AFTER REFRACTORY
APPLICATION
(COLD)
SUBSEQUENT START
(COLD)
60.0
50.0
40.0
30.0
20.0
10.0
0.0
0
TIME IN hours
FIG 10
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10.2.1

Filling the Boiler
The boiler is initially filled using the boiler fill pump through the common drain header to the
start-up level about -250mm below normal water level. The water should be chemically
treated to the proper chemical concentrations and pH for normal boiler operation, as per
the water quality requirement specified in this manual.
Following activities are to be carried out:
1. Open boiler Direct Water Level Gauge (DWLG) root valves, and level transmitter
isolation valves.
2. Verify boiler Direct water level gauge (DWLG) and its water column drain valves are
closed.
3. Open boiler steam drum vent valves.
4. Open the saturated steam vent valves.
5. Close the economiser inlet header drain valves.
6. Close all boiler drain valves.
7. Open all super heater vent valves.
8. Drain any condensate from the superheaters by opening the superheater drain valves.
9. Drain any condensate from the main steam line by opening the main steam line drain
valves.
10. Open the startup vent isolation valve.
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11. Adjust the startup vent control valve to its minimum open position.
12. Open economiser vent valves. When all air is vented from the economizer, ensuring
water is issuing out of the vent valves, close the vent valves.
13. Close fill-line isolation valve when the water level is seen in steam drum DWLG.
14. Drain steam drum DWLG.
15. Verify water level returns to the steam drum water level gauge about where it was
before draining.
16. Verify level seen in direct water level gauge corresponds with remote indication in DCS
17. Open the fill-line isolation valve and slowly raise the water level in the steam drum.
18. Check steam drum water level. Close the isolation valve when the steam drum water
level is at about -250 mm below the normal operating water level. As water level rises,
continue to verify level accuracy of the remote indication in the control room.
Note:
Water will expand as it is heated. This is called swell. Start with lower-thannormal steam drum water level (-250 mm) during startup.
19. Check boiler steam drum doors and external valves, fittings and connections for leaks.
Any leaks found must be corrected before proceeding with the startup.
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10.2.2 Starting the Fans and Adjusting Air Flows
The following steps are used to start the ID, SA, PA, and the loop seal blowers in their
respective sequence and to adjust air flows in preparation for the boiler purge.
Note: The sequence for starting fans is:
a)
a.
ID fan
b.
Loop seal blower
c.
SA fan
d.
PA fan
e.
Adjust air flows, as required.
Starting the Induced Draft (ID) Fan

1. Place O2 trim controller at 50 percent and leave in manual mode.
2. Place ID fan inlet damper control at closed position.
3. Verify open flow path through the boiler to atmosphere.
4. Verify no stop signal is present on the ID fan.
5. Verify bearing temperatures are normal.
6. Initiate a start command to the ID fan.
7. Verify ID fan is started and check for any abnormal vibration, electrical indications
and temperatures are normal.
8. Leave ID fan controller in manual mode at minimum.
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b)

Starting the Loop seal Blower.

1. Open loop seal air valves to the ash transfer line to the bed ash coolers.
2. Verify loop seal air valves to the down leg fluidising nozzles are open (about 30
percent).
Note: During the initial stages of startup of the boiler when bed and solid fuel have been
introduced into the combustor, these flows will be adjusted for optimum loop seal
material fluidisation (circulation) by startup engineers.
3. Verify ID fan is running.

4. Verify no stop signal is present on the loop seal blower.
5. Initiate a start command to the loop seal blower.
6. Verify the loop seal blower is started.
7. After the loop seal blower is started, adjust valves to the required air flow setting as
per the respective flow indication in the rotameters.
c)
Starting the Secondary Air (SA) Fan

1. Place the SA fan inlet control damper at closed position.
2. Place the startup burners SA flow control damper at the minimum position.
3. Adjust the combustion chamber SA nozzle control damper to about 20 percent open.
4. Open the solid fuel feed air bustles pneumatic dampers.
5. Open and adjust the fuel feeder pressurisation SA damper to about 30 percent open.
6. Verify the loop seal blower is running.
7. Check combustor pressure.
8. Verify no stop signal is present on the SA fan.
10. Initiate a start command to the SA fan.
11. Verify the SA fan is started, check for any abnormal vibration, electrical indications
and bearing temperatures are normal.
12. Adjust Secondary air flow control to minimum xx TPH.
13. Check combustor pressure.
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d)

Starting the Primary Air (PA) Fan
1. Place the PA fan inlet control damper to closed position.

2. Verify SA fan is running.
3. Check combustor pressure. Adjust combustor pressure to -10 mm WC if ID fan
control is in manual mode.
4. Verify no stop signal is present on PA fan.
6. Start the PA fan.
7. Verify the PA fan is started, check for any abnormal vibration, electrical indications
and bearing temperatures are normal.
8. Fluidise the bed by increasing the PA-to-grid air flows slightly higher than minimum
(above xx TPH). After the bed has been fluidised, return PA-to-grid air flow to
minimum. Place Primary air flow controls in minimum and in automatic.
9. Adjust ID fan controller to control combustor pressure at -10 mm WC (negative ten
mm of water column).
When combustor pressure is stabilised, place ID fan
controller in auto mode.
e)
Air Flow Adjustments
1. Verify SA air flow damper control in automatic. Adjust, as required.

2. Verify PA air flow damper control in automatic. Adjust, as required.
Note: Minimum PA-to-grid air flow will be maintained when in auto.
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10.2.3 Filling Bed Material
Bed material, river sand as per specification, should be fed into the combustion chamber
using the bed material feeder.
1. Start filling bed material into the lower combustion chamber with all fans running.
This can be done before, during or after 5-minute boiler purge.
Note:
When filling bed material on a cold startup, it is advisable that the startup
burner is not started up to 200 mmWC of bed pressure, and the startup
burner to be operated at load not exceeding 30% up to 250 mmWC of bed
pressure and stop the bed material feed when the bed pressure reaches 300
to 350 mmWC.
2. The initial bed material fill to the combustion chamber could be either sand, or saved
bed material from other boilers. The preferred choice is sand as per the
specifications as follows
Use sand with an approximate bulk density of 1500kg/m3, the initial quantity of material
required is 14200 Kg.
Bed material distribution:
100% less than - 600 microns

0% less than
- 60 microns
3. As the bed pressure is the indication of the accumulated bed material in the
combustion chamber, this phenomena can be noticed while filling the bed material.
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4. Stop adding bed material to the combustion chamber when bed pressure reaches
300 to 350 mmWC. This will be equal to about 600 to 750 mm of bed material if the
fans were shut down and the bed slumped.
10.2.4 Initiating Boiler Purge
The boiler purging has to be initiated when any one of the following condition occurs.
The boiler must be purged before each cold startup,

All fuel feeders trip and the bed temperature is less than 7600C,
Bed temperature less than 6000C and no startup burner in service.
The purging process assures enough air flow to drive out combustible elements from
the combustion chamber.
The following permissives are required to initiate a boiler purge:

Purge Air Flow Requirements
Minimum 30% to 40% of total air flow on Cold Start

Minimum 30% to 40% of total air flow on Hot Restart provided bed temperature is
less than the fuel ignition temperature.
Purge Permissives
ID fan running
SA fan running.
Loop seal blower is running.
PA fan running.
Minimum 30% to 40% of total air flow on Cold / Hot restart (Purge not
required if the bed temperature is more than the fuel ignition temperature
during hot restart)
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Ensure (manually) fuel feed-point discharge isolating gates are closed.
All fuel feeders off.
Start-up burner trip valve is closed.
1. Check all air flow indications to verify the total air (PA+SA) flow required for a boiler
purge.
2. Start 5 minute (300 secs) boiler purge.
3. Assure all purge interlocks and air flows are maintained above the minimum purge air
flow rate until the purge timer (300 seconds) has timed out.
4. Verify purge in progress indication goes out and combustor ready indication comes on
in DCS when purge is completed.
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INCREASING

1000oC
DECREASING
940oC
900oC
860oC
820oC
TEMPERATURE
LATCH
760oC
STOP SOLID
FUEL FEED
700oC
SOLID FUEL
PERMISSIVE
600oC
560oC
520oC
480oC
440oC
BED TEMPERATURE
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10.2.5 Lighting up of Start-up Burner
1. Select local / remote operation of the burners from the remote BMS control panel.
2. Check oil pressure is adequate.
3. Verify the manual block valve is open.
4. Open the burner oil supply header trip valve from local / remote panel.
5. Verify the start-up burners are installed in position.
6. Verify the atomising and cooling air supplies are kept in service.
7. Combustor ready / purge completed indication is on.
8. Air flows are above the minimum (30% of SA), light-up value. This will be further tuned
during commissioning
9. Scavenging to be done.
10. Initiate a start command for the first start-up burner.
11. High Energy Arc (HEA) Ignitor advances and ignites spark for 15 seconds before
retracts to its home position.
12. When the scanner detects the flame the burner is permitted for continuous operation.
13. If the flame is not established within 25 seconds, burner trip will be automatically
initiated and burner start-up procedure has to be repeated.
14. Start the other start-up burner as necessary for bed material heating.
15. Adjust both start-up burner air flows as required.
16. Start-up burners will be used to heat up the bed material to 6000C. On reaching 7600C
both the start-up burners will be stopped
Note: Before light-up of each burner, an operator should be positioned at the burner front.
During light-up, the operator should check there are no oil leaks. After light-up, the
operator should visually observe the condition of the flame, checking for irregular
flame patterns or flame impingement.
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10.2.6 Boiler Warm-up
The procedure given below will help to eliminate / reduce the nuisance
tripping of the boiler due to swelling of water in the steam drum. This warm-up
procedure eliminates adding water into the steam drum until the drum has reached
about 7 to 14 kg/cm. Operators to adopt this technique during the cold start-up
period. Using this procedure, start with lower than normal (-250 mmWC) water level
in the steam drum. As the boiler water expands, blow down using the blow down
valve to avoid swelling. When the water level drops to about -250 mmWC, close the
blow down valve. The water in the boiler will continue to swell. Repeat this blow
down process as necessary. During this process, the water in the economiser tubes
will evaporate as that portion of the boiler heats up. In order to avoid steaming in
economiser during start-up, ensure that adequate quantity of water flow through
economizer is maintained. A slow, gradual heating of the boiler will relieve thermal
stress on all boiler pressure parts and refractory. During start-up, the heat rate shall
be limited to 1500C / hr. change in temperature at the hot cyclone separator inlet.
If you choose to use the lower value, you may eliminate the chance of
adverse drum swell. This will result in rather a quicker, smoother startup avoiding
boiler trips on uncontrolled steam drum water level.
1.
Adjust the start-up burner firing rates to increase the hot separator inlet temperature
of 1500C/hr temperature change, as directed.
During the warm-up, the boiler blow down system must be placed in operation. It is
advisable to have the continuous blow down valve crack open. The feed water
system must be available for makeup to the boiler. Open the main steam stop
integral bypass valve at the beginning of startup to allow the boiler and main steam
system to warm up together if required.
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2.

Check steam drum water level for swell. Use the intermittent blow down system to
help maintain steam drum water level.
3.
Check the combustion chamber, separator, superheater, economiser and air heater
air/flue gas temperatures (boiler temperature profile) and assure the maximum
recommended heat rates are not exceeded.
Note: The following steps shall be performed at the recommended pressures and
temperatures, but not necessarily performed in sequence.
Check steam drum pressure. When the pressure reaches 2 kg/cm (g)
Close the steam drum vent.
Close the superheater vents.
Check boiler water chemistry continuously.
Leave superheater drains open.
Note:
It is recommended to adopt a slow and gradual pressure rise rate (limited to
0.2 kg/cm2/minute) during initial stages of a start-up and after reaching 50% of rated
drum pressure, a faster pressure rate (limited to 2.5 kg/cm/minute) is permitted as
shown in the start-up curve.
4.
Check the steam drum water level. Verify level seen in direct water level gauge
corresponds with remote indication in DCS.
5.
Check for any steam leaks.
6.
Open the main steam stop valve when ready to admit steam to the main steam line.
7.
Continue to increase boiler firing rate to raise boiler operating pressure according to
the recommended startup curve.
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8.

Open the spray water (de-superheater) supply manual isolation valve(s) and place
the steam temperature control system in automatic operation when outlet steam
temperature is within 200C of the operating temperature.
Note: Maintain final outlet steam temperature at least 100C above saturation
temperature and steam flow slightly above 10 percent.
9.
Check the boiler outlet steam flow as steam is admitted to the main steam line.
10.
Slowly close the startup vent valve and superheater drains.
11.
Continue to increase boiler firing rate to reach the required steam temperature and
pressure.
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10.2.7 Solid Fuel Firing
Before starting solid fuel firing, there must be adequate quantity of bed material
present in the boiler to support heat transfer and maintain the seal in the loop seal.
When bed temperature reaches the solid fuel minimum temperature permissive,
600oC as indicated by all bed thermocouples, solid fuel firing can begin.
1.
Place the solid fuel feeder controls in manual.
2.
Check all bed temperature indications for 600oC temperature permissive.
3.
Open the feeder pressurisation air manual isolation valves to the main drag chain
feeder.
4.
Adjust the drag chain feeder seal air flow slightly above the minimum requirement.
5.
Start the main drag chain feeder and then the box feeders associated with that.
6.
Open the solid fuel bunker outlet isolation rod and slide gates.
7.
Open solid fuel feeder discharge gates to the combustion chamber.
8.
Remove any bias in the solid fuel feeder controllers.
9.
Start, manually, the first fuel feeder when bed temperatures are greater-than 600oC
(or higher if it is required to provide a cushion for the bed temperature permissive).
Run the feeder for a maximum of 90 seconds and stop the feeder for 90 seconds.
This is called pulsing the solid fuel feeders. Check that bed temperatures increase
at least 10oC and excess O2 decreases. Pulse the fuel feeders three times. When
these results are achieved, leave solid fuel feeders in continuous operation, on
manual control.
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10.
Note:

Start the second fuel feeder
Bed ash removal systems can be put in service before firing solid fuel if it helps in
reducing startup complications.
11.
Slowly decrease the start-up burner firing rates while increasing the fuel feed rate
until the start-up burners reach zero firing rate.
12.
Stop the start-up burner's at 740-760oC indicated bed temperature, one at a time as
bed temperature continues to increase.
13.
Adjust fuel feed rate manually, as necessary, to maintain bed temperature rise. As
start-up burners are retracted, place them in a standby condition.
10.2.8 Raising Boiler to Rated Condition
Continue to raise the boiler pressure as shown on the boiler startup curve until all
systems have reached full operating parameters with all controls in automatic
operation.
1. Place the bed ash removal system in service when the bed pressure starts to
increase above 650 to 700 mmWC. Based on actual bed pressure
measurements, this may be required before admitting solid fuel.
Verify ash handling system in service
Start bottom ash rotary feeders
Check bed pressure.
Check bed ash drain discharge temperatures.
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Adjust bed pressure controls as necessary to maintain normal bed

pressure.
Verify loop seal fluidising air to return leg.
2. Slowly close the boiler startup vent valve as boiler load continues to increase.
3. Check PA and SA flows.
4. Place the feed water control in automatic as necessary
5. Place oxygen controller in automatic when boiler load exceeds 70 percent

MCR.
6. See NORMAL OPERATION for continued operation of boilers.
a.
Operation of the Excess O2 Trim Controller:

1)
This control loop compares expected excess O2 in the flue gas to

actual excess O2 based on boiler steam flow.
2)
This controller should be left in manual at 50 percent output on the controller,

until normal boiler operation has been established and boiler load is greater
than 70 percent.
3)
The output from this controller will change the amount of air flow through the
SA nozzles.
4)
Match process value and set point on controller. Then place controller in auto
mode.
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b.

De- superheaters
1. Check intermediate and main steam temperature and de-superheater spray water
flow. Verify that de-superheating does not lower the steam temperature to within
10oC of saturation temperature.
2. Verify a demand exist for de-superheater (control of steam temperature).
3. Check that the controllers respond to their set points.
c.
Routine Inspections (Operator Walk-Downs)
1. Check rotating equipment (motors, fans, fuel feeders, ash discharge feeder etc.) for
proper lubrication, temperature and vibration levels.
2. Check hanger supports, boiler guides and buck stay corner links etc., as per the
attached expansion movement G.A diagram in volume -XI for signs of expansion
problems that could put unusual stress on boiler components.
3. Check steam drum water level gauges to ensure the level matching with control
room indications.
4. Inspect air and flue gas ducting and boiler casings for hot spots, discolouration, flue
gas leakage and structural deformation.
5. Check the boiler for abnormal noise or vibrations. Early detection of a problem could
reduce down time.
6. Check indicated settings of dampers and corresponding manually adjusted air flows.
7. Look for bed material and ash leakage.
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8. Check valves and piping for any leakage at flanges and valve stems. Investigate any
standing pool of water or oil.
9. Ensure burner area clean.
10. Check flame pattern and colour when the burners are in service.
d.
Bed Ash Removal
It is normal to keep the bed ash cooler rotary air lock feeders in continuous operation
(semi automatic mode) to maintain proper bed pressure.
Note:
Normal hot loop circulation is balancing the input to the combustion chamber (fuel)
and output (bed ash and fly ash). Control of bed pressure is done slowly over
time.
Hence, bed ash discharge feeders should not be started or operated
in auto mode.
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11.0
SHUT DOWN PROCEDURE
11.1
Normal Shutdown

This section describes the basic steps to reduce boiler load from 100 percent (MCR) to cold
condition as given below.
1.
Reduce fuel and air input to reduce boiler load to 50 percent. Normal bed
temperatures should be maintained.
2.
Place O2 controllers in manual at 50 percent output.
3.
Check decreasing temperatures and maintain cooling rates.
4.
Continue to reduce the load slowly down to minimum, reducing fuel feed rate at 10
percent per minute or less till reaching 760oC bed temperature.
5.
Maintain steam temperature above 10oC saturation temperature while decreasing

load.
6.
Continue to reduce solid fuel feed to minimum.
7.
Empty solid fuel feeder conveyor with bed temperature above 650oC and stop the
fuel
8.
Note:
feeders.
Place steam drum water level controller in manual, as necessary.
If the boiler is shutdown for maintenance and there is a need to remove the bed
material, keep the bed ash discharge feeder in service. If the bed material is to be
retained in the combustion chamber, stop the bed ash discharge feeders.
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9.

Maintain steam drum water level near the upper limit of the steam drum gauge glass
visibility during shutdown.
10.
Continue fluidising the bed to cool the boiler at a maximum cooling rate of 150oC / hr
change in separator inlet gas temperature.
11.
Continue air flow through the boiler until the desired bed temperature is reached, at
least 400oC or lower if needed for maintenance.
12.
Close the primary and secondary air fan inlet control dampers. The dampers should
be closed slowly permitting the ID fan automatic damper control to maintain the
combustor pressure between -10 and -25mm WC.
13.
Stop all fans after the PA and SA fan inlet control dampers are completely closed.
14.
Stop ID fan after closing the ID fan inlet vanes.
15.
Verify the loop seal blower stops 30 seconds after the ID fan stops.
16.
Stop the chemical feed system and continuous blow down system when the boiler
feed pump is stopped.
17.
Continue to operate all ash discharge feeders until their respective bed ash coolers
are empty.
18.
Open all superheater and steam drum vents when the steam drum pressure has
decreased to about 2 kg/cm (g).
Note: If the boiler is to be drained, begin draining when steam drum pressure has decayed
to 1-2 kg/cm (g). This pressure will help Push the water out a little faster. Check
the drain system and check for hammering.
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19.

Do not keep any idle boiler that is open to atmosphere to remain partially filled with
water for any length of time. Fill the boiler completely with deaerated alkaline water
with oxygen scavenger added as a protection against corrosion.
Apply Nitrogen blanketing at 0.3 kg/cm(g) pressure through steam drum nitrogen
filling valve when steam drum pressure decays to 0.3 kg/cm(g) when the boiler is to
be laid up wet.
When the boiler is to be out of service for several days or longer, all ash,
and bed material should be removed to avoid corrosion due to moisture absorbed by
these materials.
11.2
Planned Boxing up the Boiler
The boiler can be shutdown for short periods and held in a hot standby condition for about
eight (8) hours. When the bed is to be hot slumped, the coal feed is to be stopped and the
fuel in the bed be allowed to burn out. When the excess O2 indication in the flue gas
increases to double the normal full load reading (such as 3.5 to 7.0), the air flow to the
combustion chamber should be stopped to lessen bed heat loss. This O2 increase suggests
most of the fuel in the bed has been combusted and the bed can be slumped without the
formation of clinker material in the bed. The fans are then stopped. All fan inlet vanes and
air control dampers are closed to lessen the amount of heat lost. No fire is maintained or
introduced into the combustor. The pressure in the steam drum will decay after an initial
slow, gradual increase during the first one to two hours due to heat from boiler metal and
refractory equalising with water / steam side.
Note: A hot condition is one in which the average bed temperature is above
760oC. When the average bed temperature is below 760oC, follow the Cold Startup
Procedure. The average bed temperature of a slumped bed shall be read from the
bed thermocouples.
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11.3

Unplanned Shutdown
When the boiler is tripped from a load above minimum, where fans also stop, slumping the
bed, the boiler can:
1.
Be restarted immediately following the hot restart guidelines.

(or)
2.
Remain shutdown for hot maintenance without restarting fans until ready for
restart. In this case, the steam pressure increase during heat equalisation will be
higher than during a planned hot shutdown.
For startup of the boiler from a hot standby condition, proceed as follows:
1. Purge the boiler if the boiler tripped on boiler trip interlock. All steps should be
accomplished as quickly as possible to avoid reducing bed temperatures.
Note: On a hot restart following high load operation (above 80% MCR), it
is advisable to blow down and drain the superheaters. This is done by opening
each drain valve and closing the drain valve, one at a time. This is a precaution
against condensate collecting in the headers. Superheater vents are to remain
closed.
2. Start start-up burners and heat the boiler following the normal startup guidelines.
3. Check bed temperature. When ignition starts, the bed temperature will rise and the
normal solid fuel firing procedures can be followed.
Note:
When the bed temperature does not rise within three (3) pulses of fuel feed, stop
the feeders. Purge the boiler and resume the normal startup procedures.
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4. Remember, when bed temperatures fall below 600oC, startup burners must be used
to raise bed temperature above the 600oC.
5. If the fuel feeder trips with the bed temperature greater than 760oC, the startup
burners should be placed in service to maintain bed temperature, if required.
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12.0

PRESERVATION OF BOILER
Introduction
Boiler corrosion is well managed during regular operation. However, during boiler shut
down period, preservation of boiler to prevent corrosion and subsequent problems
becomes mandatory .Atmospheric corrosion of ferrous materials proceeds rapidly in the
presence of oxygen and moisture.
The oxides produced are detrimental and can be
transported to critical heat transfer areas. Also, through the wall, oxygen will cause pit type
corrosion. In todays boilers with their numerous complex circuits and bends, it is usually
impossible to completely dry a boiler in preparation for storage. Draining all circuits (if
drainable) while hot may temporarily dry the surfaces.
However, unless dry air is
continuously circulated to eliminate all the water vapour from the unit, re-condensation will
again result in moist conditions. To overcome this, wet lay-up procedure is recommended,
which normally offers the most positive method of protection for pressure part components
in modern boilers.
Lay-up Method
This method employs filling up the boiler with treated water and keeping the unit
pressurized. Superheaters shall be filled first using the filling line provided in the common
drain header for steam circuit and the saturated steam link in the drum shall be plugged.
Filling up of water in superheater and its links shall be ensured by observing the water leak
through the air vent provided in the links. Once this is ensured water can be filled through
the filling line provided in the common drain header. The entire system shall be pressurized
to 5Kg/cm (g). Feed water pump may be used for this purpose. Water conforming to
recommended specification furnished in earlier section, is to be used for filling. In addition,
nitrogen blanketing is also to be carried out wherein the boiler is filled with water treated
for pH and O2 and sealed with nitrogen at a pressure of 0.3 Kg /cm(g) to avoid air
ingress.
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Figure -11 shown below describes the general arrangement of the rig up required for
nitrogen blanketing. Nitrogen cylinders can be employed for this purpose. The nitrogen
supply can be connected to the drum vent and superheater vent.
Wet Method
If the boiler is likely to be out of service for more than a few days, but may be needed for
steaming at short notice, all parts, including the economiser and superheater should be
completely filled with properly treated water. It is most important that pockets of air are
not allowed to remain in the boiler and that there should be no leakage. While
completely filling the boiler with water, sufficient hydrazine should be added to combine
with the dissolved oxygen and leave an excess of 100 to 200 mg / liter of hydrazine as
N2H4. In addition, ammonia should be added to ensure that a pH value of 9.0 to 10 is
maintained. Distribution of these chemicals throughout the bulk of the water should be
ensured by filling with a premixed solution, by use of a circulating pump or by
heating the boiler when partially filled and then topping up with treated water. It is
recommended that the aircock on the drum should be connected to a surge tank
located at a higher level. This compensates for any volumetric change and ensures a
positive pressure thus preventing admission of oxygen to the unit. This tank should be
covered and oxygen scavenger and ammonia be dosed as required.
Alternatively, pressure on the system may be maintained by using a small pump. The
oxygen scavenger reserve and the pH value or alkalinity should be checked regularly and
additional treatment chemicals added, as necessary and distributed to maintain the
treatment levels within the recommended range. Any additional water added to the
boiler
should
contain
the
appropriate
quantities
of
treatment
chemicals. When
required for service, the boiler should be drained down to normal working level
before firing. Phosphate or other conditioning reserves should be re-established as
soon as possible.
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This method of storage is recommended only if there is no likelihood of frost damage

occurring. Wet storage is not recommended for periods of longer than 2 or 3 months
unless the treated water is circulated regularly in all parts of the boiler including the
economiser and
superheater.
Wet
storage tends to promote
condensation
of
atmospheric moisture and hence corrosion in the flue gas side. Where this results in
some trouble, dry storage is resorted to.
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FIG-11
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13.0

PROCEDURE FOR HYDROSTATIC TESTING
The system components have been hydrostatically tested to 1-1/2 times the boiler design
pressure in the factory.
However, the complete system, along with all interconnecting
piping should be hydrostatically tested before start-up to comply with code requirements
and to check for leaks that might have resulted during shipping and handling. The boiler
and process lines must be completely vented in order to fill them with water.
The following is a recommended procedure for hydrostatic testing:
1. Open the steam drum vent valve and close steam outlet valve.
2. The boiler safety valve stubs are plugged with end plates and sent as a dummied stub.
Hence these end plates have to be cut and removed after hydro-test and the safety
valves are to be butt welded.
3. For subsequent hydro test if any and for every annual hydro-testing, gag the safety
valves in accordance with safety valve manufacturers recommendations. In lieu of
gagging, the safety valves may be removed and replaced with test plugs or blind plates.
4. Isolate pressure switches, gauge glasses or control components which are not intended
to be subjected to a hydrostatic test.
5. Fill the system with treated water in accordance with recommended CVLs water quality.
The temperature of water to be used shall be between 20C and 50C.
6. Once the system is filled and the pressure is approximately 1 kg/cm, close all vents.
The pressure may then be increased gradually to the test pressure requirement of the
steam boiler inspecting agency. No pressure parts shall be subjected to more than 1-1/2
times the design pressure rating of the boiler.
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7. Examine the system for any leaks.
If no leaks are visible, hold the system in a
pressurised static condition for a period of 1/2 hour to satisfy the code requirements.
8. After that the pressure shall be reduced to maximum allowable working pressure
and maintained for sufficient time to permit close visual inspection for leakage of
pressure parts.
9. Upon completion of the test, release pressure slowly through drain valves in the water
and steam circuit. Then fully open the vents and drains when the pressure drops to 1
kg/cm(g). Particular care must
be given to make sure that
parts
not
normally
containing water during operation are drained free of water. The system should be
drained fully after hydrostatic testing to prevent freezing, if the unit is installed in a cold
weather area, and to minimize corrosion of the metal surfaces.
10. If temporary hand hole or manhole gaskets were used for the test, they should be
replaced with regular service gaskets before returning the unit for operation. Gaskets
should never be reused. Replace gauge glass if necessary and make sure that the
gauge cocks are open. Remove all blanks or gags from safety valves and install safety
valves, if removed.
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14.0
PROCEDURE FOR ALKALI BOIL-OUT
1.
Check if boiler erection work is completed with all assemblies, valves, fittings and
necessary instrumentation.
2.
Ensure that the pre-commissioning activities are carried out as per the
commissioning check list.
3.
Boiler auxiliaries such as fans, feed pumps should have been trial run and made
ready for operation.
4.
All instruments except one drum level transmitter and drum pressure transmitter
(DCS indication) are to be isolated prior to alkali boil-out.
5.
Ensure that steam drum internals have been fixed in position.
6.
Check if all the refractory and insulation work are completed.
7.
Check if all scaffolding, temporary supports, debris are cleared.
8.
Ensure that refractory curing is completed.
9.
Check if suitable fire fighting equipments such as Co2 or foam type fire
extinguishers, sand buckets, etc, are available at convenient places.
10.
Check if boiler chemical feeding system is ready for operation.
11.
Check if sufficient quantity of chemicals is available. Based on the water volume of

the boiler chemicals required can be estimated. If water volume of the boiler is Q M3
each chemical required will be 4 x Q kgs. The same quantity of chemicals will be
required for each boil out.
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12.
For alkali boil-out sodium carbonate and trisodium phosphate are used.
13.
Prepare 20% concentrated solution of the chemicals separately in a tank and the
solution is charged into the boiler through the nozzles (either auxiliary steam top
nozzle or Air vent nozzle) into the steam drum manually by means of a funnel.
14.
After the addition of required quantity of chemicals, the nozzles are covered with the
cover flange and water is filled up to the normal operating level.
15.
Light up the boiler and raise the steam pressure gradually to 5 kg/cm2(g) as
per the operating procedure prescribed in this manual and maintain the pressure
for a minimum period of 12 hours.
16.
Tighten all glands and flange joints.
17.
Raise the firing rate to achieve the boiler loading similar to the normal loading rate of
the boiler during start-up.
18.
Samples are to be taken every two hours and analysis is to be carried out to
determine the following:
19.
a)
pH value
b)
Alkalinity
c)
Phosphate
d)
Oil
e)
Silica
Ensure that the alkali boil-out is carried out in 3 stages and fresh chemicals are to be
used before each stage.
20.
Ensure that the pressure is maintained in the boiler for each stage alkali boil-out as
follows:
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DURATION
I stage
- 5 kg/cm2 (g)
- 12 hours.
II stage
- 7 kg/cm2 (g)
- 12 hours.
III stage
- 10 kg/cm2 (g)
- 12 hours.
(Ensure that the pressure of the boiler is raised gradually for alkali boil-out).
21.
Each stage of boiling can be terminated when the content of oil in the boiler water
maintains a steady value. However final reading of oil should be less than 5ppm.
22.
After completion of alkali boil-out, shut down the boiler and allow the boiler to cool
down gradually.
23.
Drain the boiler after the drum pressure reaches atmospheric pressure. Water jets
shall be used to clean the headers.
24.
After complete draining of the boiler, clean the entire boiler by filling up of the water
and draining it at least once.
25.
The hand hole pipes of all headers preferably at bottom most point are to be cut
and inspected and cleaned out of any foreign material.
26.
After inspection and cleaning, weld the end caps to their position and hydro test the
boiler to working pressure.
27.
Now the boiler is ready for steam blowing.
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15.0

PROCEDURE FOR STEAM BLOWING
Steam Blowing
Steam blowing is an established practice for the purpose of physically removing any
substance which remain deposited in the superheater and associated pipe lines. These
substances are mainly scales and loose minerals that might have been entrapped during
manufacture, storage and erection at site.
Principle
The principle of steam blowing is to give thermal shock and dislodge the scales. These
scales will be subsequently driven out by the dynamic velocity of the expanding steam.
Before starting the boiler for steam blowing the following points are to be ensured:
1. Alkali boil out is completed.
2. All the instruments calibration are completed and safety interlocks are in line, except
water level interlock which is to be isolated temporarily.
3. NRV and flow nozzle should not be fitted initially and thermowell in steam line is to be
removed.
4. All the spring hangers in steam line are loaded properly.
5. Temporary steam line is erected and anchored properly for steam blowing.
6. Target plate fixing arrangement to be kept ready.
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7. Required target plates are to be machined and kept ready to fix when required. Target
plates shall be of aluminum material.
Procedure:
The method of steam blowing is as below:
1. Start the boiler and raise the boiler pressure above 35 kg/cm (g). The bed temperature
shall be maintained at about 800-950C.
2. Quickly open the main steam stop valve (or the temporary blowing valves if provided).
In order to maintain the flow to atmosphere the main steam stop valve is to be kept
open till the steam pressure drops down close to 15 kg/cm(g).
3. Slowly reduce the firing rate and slump the boiler. The main steam stop valve shall be
closed when the boiler pressure reaches 15 kg/cm(g).
4. After one hour, the boiler shall be restarted and the bed temperature shall be
maintained at about 800 - 950C.
The steam blowing shall be once again started when the pressure reaches 35 kg/cm(g).
By the above procedure, the scale adhering to the contours get cracked due to temperature
difference and get removed during subsequent blows.
Scheme of Blowing
Temporary discharge piping which lead the steam to the atmosphere shall be welded
downstream of main steam line must be properly supported and anchored.
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Operational Precautions
1. Normally the steam blowing operation is the first occasion to fire the unit at significant
rate. The unit must be brought up much slower while all equipments are checked and
expansion movements are monitored closely.
2. During blowing, water level in drum gauge glass may fluctuate very widely. Feed
regulating station must be checked for proper remote operation. Sufficient quantity of
DM water availability must be ensured.
3. Flue gas temperature at the inlet of convection (back pass) superheater must be
restricted to 450C.
4. Temporary discharge piping which should be at least equal to the diameter of piping to
which it is connected must be well supported to withstand reaction forces during steam
blowing.
5. Discharge piping should be so diverted that personnel and equipments are not
endangered. The area should be cordoned off.
6. After three free blows, target plate can be fixed.
7. Based on target plate condition as recommended by the turbine supplier blow can be
continued or terminated.
8. During blowing, sufficient time duration should be given between blows to attain better
thermal shock to discharge the scale and other deposits in pressure parts and steam
line.
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9. After clearing the steam blowing, boiler to be stopped and steam line to be cooled to
complete the welding of NRV and flow nozzle and thermowell fixing in main steam line.
10. Temporary steam line to be removed and permanent line to be connected with TG.
11. After completion of the job, the boiler is ready for safety valve floating.
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16.0

DOS AND DONTS
Operating instructions deal with equipment protection and safe operating devices for
personnel protection. The dos and donts listed here are based on operating experience.
They are included to make the operating personnel more safety conscious and
knowledgeable of the process.
Before performing installation or maintenance on equipment, turn off electrical power

to that equipment and its controls to avoid electrical shock and remote starts. Follow
the companys tag-out and personnel entry procedure.
Never try to open the access doors when the boiler is in operation and furnace under
pressure.
Ear protection should be worn when operating, maintaining, and adjusting or

inspecting any equipment on the boiler island or when near the equipment.
Always use low voltage hand lamps with proper earthing.
Never open or attend rotating equipment until that equipment has come to a
complete stop after switching off the power supply. Follow locking or tagging
procedure according to the plants safety code and procedures. Rotating equipment
should be locked with a brake or locking device to prevent rotation before personnel
entry.
Never direct air or water stream into an accumulation of hot bed ash or fly ash. Much
of this ash will become airborne and pose a breathing hazard. If ash is in smoldering
condition this action, could result in a fire or explosion.
Never reach over or under any rotating machinery. Clothing can be caught on the
rotating equipment and pull into the rotating machinery.
Keep all work areas clean.
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Post appropriate CAUTION, DANGER, or WARNING signs and barriers as required

to alert non working personnel to the work being performed.
Only qualified and authorized personnel, should service equipment.
DO NOT TAMPER WITH OR BYPASS ANY INTERLOCKS. BYPASSING AN

INTERLOCK MAY CAUSE EQUIPMENT DAMAGE OR SERIOUS PERSONNEL
INJURY.
Report and set right immediately any safety hazard found.
Always replace electrical junction box covers or mechanical equipment covers

immediately after service. This action prevents foreign matter from entering the
equipment and assures safe operation.
Use an approved filtering dust mask or respirator when entering dust laden areas
(ash or fuel) of the boiler. Always avoid breathing the fine dust.
Do not disconnect a hose unless you have made sure that the source is isolated
(closed) and all pressure has been released from the hose.
Before releasing equipment after service, verify that all tools, parts and debris have
been removed and equipment returned to operating condition.
Do not open a steam drum manhole door without emptying the steam drum.
Hot water, steam or vapour may be present in drum, headers or lines. One should
be alert when opening manhole door or connections. Do not enter until the closed
space has been thoroughly ventilated.
Never enter a pressure vessel until all valves have been closed and locked or
tagged depending on the plants safety code. It is possible for steam, hot water and
chemicals to back up through drain and blow down piping. Vent valves connected to
a nitrogen system should also be closed, locked or tagged.
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Do not enter a confined space until it has been cooled, purged of gases and properly
ventilated. Precautions should be taken to keep the entrance open. Lock out all
related systems. A combustible gas detector should be used to confirm a safe
atmosphere.
When entering confined spaces like Combustion chamber, hot cyclone separator,
solids return leg or convection pass (back pass) pass be prepared for any falling
material. Always wear Personnel protective equipment like helmet, goggles, safety
shoes etc.
Always lock the drive mechanism of dampers, gates and doors before passing
through them.
Never step into accumulations of bottom ash or fly ash as they may be cold on the
surface yet remain hot underneath.
Never use toxic fluids in confined spaces.
Before entering the combustion chamber after a boiler shutdown, have all fuel
manual and automatic isolation block valves are closed.
Standby personnel shall be positioned outside a confined space to assist in case of

emergencies and can rescue the individuals inside the confined space.
When entering either the hot cyclone separator inlet or hot cyclone separator
outlet, be aware of the chance of falling through the vortex finder or separator cone.
Keep area well lighted before personnel entry. Always wear a safety belt or harness,
helmet and protective eye wear.
Do not wear contact lenses without protective eye wear near boiler. Small airborne
particles can cause eye damage.
Do not enter the solids return leg without installing a cover over the solids return leg
down-comer at the base of the lower conical section of the hot cyclone separator.
Installing this cover will prevent material from falling on you.
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Do not enter any area of the boiler, combustor or convection pass (back pass)
without visual confirmation that there is no accumulation of hot bed material
anywhere in the hot cyclone separator, solids return leg or crossover duct.
Do not operate a CFBC boiler without properly calibrated O2 analyzer in service.

Measuring excess air in the flue gas is a primary safety consideration in avoiding a
fuel rich condition in the combustor.
Do not operate a CFBC boiler without installing the bed material except in special
circumstances like alkali boil-out and also never more than 25 percent rated firing of
startup fuel. Never fire solid fuel without adequate bed material inventory. With no
bed material circulating in the combustion chamber there is no heat transfer.
Additionally, there will be no seal in the solids return leg between the positive
pressure in the lower combustion chamber and the negative pressure at the hot
cyclone separator outlets. This can allow reverse gas flow up through the solids
return leg and down-comer.
Whenever the primary air fan is started the operator must increase PA-to-grid air
flow above minimum for several minutes to fully fluidise bed material in the
combustion chamber.
Do not operate a CFBC boiler with too much bed material (greater than 900 mmWC
bed pressure). There will be a tendency for grid nozzles to plug at lower boiler
loads.
On a cold startup the rate of change in combustion chamber exit gas temperature
measured at the hot cyclone separator inlet should be limited to 150oC/hr.
You must have all fans in service when installing bed material. This will allow even
distribution of bed material and help in establishing the seal in the solids return leg.
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Do not use a torch when cutting into steam generator pressure parts. Slag from the
cutting will fall into the pressure part and could cause plugging or damage. Use a
reciprocating saw to cut and remove the pressure part. Torch cutting also ruins the
metallurgical structure and grain patterns in the area of the torch cut destroying
important information that might be needed to determine the cause of a pressure
part failure.
Refractory retains heat for long periods following a shutdown. When approaching a
refractory area, be prepared for hot surfaces and hot bed material in that area. Small
stainless steel needles are embedded in the refractory to help hold it together.
Always wear gloves to protect your hands when inspecting the boiler.
During initial startup and commissioning of the boiler there may be surface falling of
refractory. Surface falling is caused by bed material getting into cracks during each
thermal cycle and, as the refractory cools down, it contracts. This action causes the
surface refractory to fall off.
After completion of refractory repairs there may be up to a 24-hour air cure

depending upon repair material before applying heat. This time can be used to
remove scaffolding, closing man ways and loading bed material. For more details on
refractory application and curing, refer the supplier O&M attached in volume - VIII
Newly installed refractory contains moisture. If the heat rate of the boiler is too fast,
moisture can cause steaming and explosive falling may happen.
If, after continuous operation, the boiler is to be drained, reduce steam drum
pressure by venting or allowing pressure to decay. The draining process may start
when steam drum pressure decreases to approximately 2 kg/cm (g) the drum will
cool faster if left full during cool-down.
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Cooling air flow is required through all startup burners not in service. The air flow will
prevent bed material collecting in the startup burner opening. The air flow reduces
heat distortion at the startup burner diffuser, and prevents combustible (explosive)
gases from accumulating in burners not in service.
Normal practice before shutting down the boiler for a planned outage is to empty all
the fuel off the solid fuel feeders. Close the bunker isolation gates and allow the fuel
on the drag chain feeders to empty into the boiler while on solid fuel > 650oC. If the
fuel feeders cannot be emptied before a shutdown, it is recommended that the fuel
be run off the feeders as soon as possible.
All air flow dampers should have their shaft marked with the position of the damper
blades. This will provide damper blade orientation during startup and normal
operation.
The high pressure loop seal blower that supplies air to the solids return leg fluidising
nozzles must run for 30 seconds after all the other fans including ID fan have
stopped. This feature is included in the CFBC boiler interlock logic. This will reduce
the chance of material plugging the solids return leg down leg.
Gas-side and water-side of the boiler should be protected against corrosion during
shutdown periods. Refer recommended procedure for boiler preservation attached in
this section.
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17.0
TROUBLE SHOOTING
17.1
High or Low Bed Temperatures
Never let the Hot cyclone separator inlet temperatures exceed 1000oC. Excessive
heat may damage refractory or tube metal.
1. Check bed thermocouples and associated instrumentation for proper operation. If a
problem is found, report it and have repairs made when possible.
2. Check the fuel feeders for proper operation and normal fuel feed rate. If a problem is
found, report it and have repairs made when possible.
3. Check for proper operation of all fans and blowers. If a problem is found, report it
and have repairs made when possible.
4. Check PA-to-grid air flow. Be sure of normal air distribution between PA and SA air
flow. If a problem is found, report it and have repairs made when possible.
5. Check percentage of excess air in the flue gas. Be sure of normal operation of
oxygen analyzer. If a problem is found, report it and have repairs made when
possible.
6. Check bed ash discharge feeders for proper operation. Verify bed material is being
conveyed out of the combustion chamber. If a problem is found, report it and have
repairs made when possible.
7. Check combustion chamber bed pressure. Verify pressure taps are not plugged.
Verify normal purge/seal air flow to instruments. If a problem is found, report it and
have repairs made when possible.
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8. Check for normal hot loop circulation temperatures. Check for deviation in normal
indications.
Check
the
trend
recording
of
bed
pressure
for
sudden
changes. If a problem is found, report it and have repairs made when possible.
17.2
High or Low Bed Pressure
Operate CFBC boiler with enough bed material in the combustion chamber to
support heat transfer.
1. Check that bed pressure taps are not plugged. Verify normal seal air flow to all bed
pressure transmitters. If a problem is found, report it and have repairs made when
possible.
2. Check
bed
pressure transmitters
and
associated
instruments
for
normal
operation. If a problem is found, report it and have repairs made when possible.
3. Check for proper operation of all fans and blower. If a problem is found, report it and
have repairs made when possible.
4. Check for normal indication of pressures at airbox and grid. Verify air tight integrity of
ductwork. If a problem is found, report it and have repairs made when possible.
5. Check bed ash discharge feeders for proper operation. Verify bed material is being
conveyed out of the combustion chamber. If a problem is found, report it and have
6. Check for normal fuel feed rates for the indicated boiler load. Verify that solid fuel
feeders are performing normally. If a problem is found, report it and have repairs
made when possible.
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17.3

High or Low Steam Drum Water Level
Never operate the boiler without a visible water level in the boiler steam drum.
1. Check for proper operation of all steam drum instruments. Blowdown remote water
level gauge and direct water level gauge. Verify the drum level by comparing local
and remote water level indications. If a problem is found, report it and have repairs
made when possible.
2. Check for normal operation and line up of boiler feed pumps and associated piping.
Verify water level in de-aerator. If a problem is found, report it and have repairs
made when possible.
3. Check for normal operation of feed water control valves and line up of piping. Verify
instrument air to all control valves are normal and free of moisture. If a problem is
4. Check for normal operation of steam flow and feed water flow transmitters. Verify
valve line up. If a problem is found, report it and have repairs made when possible.
5. Check for evidence of a boiler tube failure. If a tube failure has occurred, take
necessary steps to stop the boiler and arrest the leakage.
6. Check for normal drain valve line up. Verify piping after the last block valve is not hot
suggesting a leaking valve. If a problem is found, report it and have repairs made
when possible.
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17.4

Loss of Bed Inventory from Circulation
1. Check for proper and normal fluidising air flow to all loop seal fluidising nozzles. If
the float inside the rotameter is stuck on the bottom of the glass, it is an indication of
a plugged nozzle. Applying service air to that nozzle may be necessary to unplug
that nozzle and re-establish fluidising air flow. Too much fluidising air flow for an
extended period can interfere with normal circulation. If a problem is found, report it
and have repairs made when possible.
2. Check for normal operation and normal discharge pressure from high pressure loop
seal blower. Verify that loop seal blower inlet filter is not plugged. If a problem is
3. Check for normal indications of bed inventory.
4. Check for normal operation of all fans. Check air flow indications. If a problem is
5. Check operation of bed ash discharge system. Verify normal operation and
conditions of bed ash discharge system. If a problem is found, report it and have
6. Check for gas-tight integrity of combustion chamber. Walk-down the boiler looking
for bed material or gas leaks. If a problem is found, report it and have repairs made
when possible.
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17.5

Emergency Situations
17.5.1 Sudden Loss of Steam Drum Water Level

When the cause is known and immediately correctable before the water level in the
steam drum reaches the minimum allowable operating level, reestablish steam drum
water level to its normal operating value and continue boiler operation. When the
cause is not known and the water level in the steam drum drops below the minimum
allowable operating level (this situation could be the result of a tube failure), start an
immediate shutdown according to the emergency shutdown section of this
procedure.
17.5.2 Gradual Loss of Steam Drum Water Level

When you cannot maintain a normal steam drum water level, the load on the boiler
must be reduced and the cause of the problem corrected. When it is impossible to
maintain normal steam drum water level at the reduced load, then the boiler must be
taken out of service according to the normal shutdown procedure until the cause(s)
can be identified and corrected.
17.5.3 Excessive Bed Temperature

When the bed temperature cannot be maintained below 1000oC, an immediate
adjustment in the air flow distribution must be started. Normally, increasing the
primary air flow to the grid and an equal reduction in secondary air flow will
accomplish this.
A reduction in fuel feed and / or an increase in total air flow may be required to
control high temperatures. This reduces the bed temperature rapidly to reduce the
high temperature that, if allowed to continue, may reach the ash fusion temperature
for the fuel being burned. If the bed temperature cannot be controlled using the
above procedure, the boiler must be shutdown.
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17.6

Emergency Shutdown
17.6.1 Steam Drum Water Level cannot be Maintained

Remove boiler from service immediately by following Normal Shutdown or
Emergency shutdown Procedure, as the situation dictates. Remove bed material
during this shutdown as quickly as possible from the boiler.
17.6.2 Sudden Loss of Steam Drum Water Level
An automatic trip will occur on low low steam drum water level. The primary and
secondary air fan will go to trip condition and drive the dampers to minimum position.
Cool the boiler to allow bed material removal and boiler inspection.
CAUTION:
Wet
bed
material
can
solidify
and
could
cause
metal
corrosion
in
the boiler and should be removed as quickly as possible.

17.6.3 Air side or Gas side Failures
This procedure should be followed on a primary air fan, secondary air fan
and / or induced draft fan failure.
1. An alarm is initiated by a drop in air flow. PA fan failure shuts off the fuel feed, and
the bed material removal.
2. A trip of the ID fan will stop the secondary air fan and the primary air fan and then
the Loop seal blower after a 30-second time delay.
3. Maintain normal steam drum water level.
After correcting the reason for the emergency shutdown, a normal restart or hot
restart, as applicable, can be initiated.
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17.6.4 Loss of Service of the following will initiate an immediate automatic shutdown of the
boiler according to the emergency shutdown.
Primary air fan not running.
Secondary air fan not running.
Loop seal blower not running.
Induced draft fan not running.
17.6.5 Rapid Loss of Bed Inventory from Circulation
Check for rapid increase in air flow.
Check
for
rapid
increase
in
flue
gas
temperature
combined
with
air
flow
increase.
Check loop seal air pressure.
Check loop seal air flow rate to nozzles.
Note: If bed material loss persists, there may be a restriction in the loop
seal or hot cyclone separator downcomer from refractory failure or solids build up
which would require an internal inspection and possible repair.
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17.6.6 Loss of Fluidising Air to Loop seal
The seal pots (loop seal) should not require manual cleaning before a boiler restart
following a trip of the boiler and / or loss of the loop seal blower. Based on operating
experience, when there is difficulty of refluidising the bed material in the loop seal
following an uncontrolled trip, service air is introduced at the nozzles provided at the
side walls in down leg and lift leg.
Although unlikely, if refluidisation is not achieved, the following recommended restart

sequence should be followed.
Restart the ID fan.
Restart the Loop seal blower.
Observe all loop seal rotameters for proper air flow. Blowout any rotameter that is low
in flow rate using service air.
Restart SA and PA fans and establish normal air flows.
Restart boiler and carefully observe bed pressure for normal operation (The bed
pressure should drop only a few mmWC when increasing boiler load from minimum to
full load.)
Observe loop seal downcomer temperature. This should follow bed temperature
closely. If this does not follow bed temperature, then use service air on the loop seal
nozzles provided at side walls in down leg and lift leg in an attempt to refluidise the
loop seal.
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If bed pressure drops rapidly during a load increase or earlier, then apply the same
technique of using service air until the loop seal chocking is cleared.
If this approach does not work, then it will be necessary to shutdown the boiler and
empty the loop seal.
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18.0
QUICK REFERENCE CHART
18.1
Check List before Start-up
18.1.1 Boiler Water Filling

Operator Checks
Operator Actions
Adequate supply of clean, DM water is Open manual steam drum vent valves all
available.
the way.
Ensure chemically treated feed-water is Close all boiler drain valves.

used for filling.
Open all superheater vents and drains
Steam drum doors and valves are leak

free.
Open drum level gauge and transmitter
Operator stationed at boiler steam drum.

Ensure local
all the way.
drum
level
gauges
isolation valves.
are Fill water to 1/3rd of steam drum level
reading the same as remote (DCS) level
gauge or -100mm of NWL. Verify level in
indicator.
DCS.
Place de-aerator and boiler feed pump
ready for start-up.
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18.1.2 Starting ID Fan

Operator Checks
Ensure
Operator Actions
clearance
mechanical,
department
electrical
for
initial
from Place inlet damper closed and controls
obtained
and
instrument
running
of
the Interlocks ready for ID fan start.
equipment.
Start ID fan. Verify fan motor roll.
Instrumentation in place and operational

Fan damper closed, coupled and read to
start.
in manual.
Place the ID fan draft pressure controller

in manual.
Adjust combustor pressure controller as
Check combustor draft when starting ID
needed
Fan.
18.1.3 Starting Loop seal Blower

Operator Checks
Ensure
clearance
mechanical,
department
Operator Actions
electrical
for
initial
from Check the Interlocks are satisfied prior, to
obtained
and
instrument
running
of
Loop seal blower fan start.
the Start loop seal blower fan. Verify fan
equipment.
motor roll.
Instrumentation in place and operational.
Adjust the air flow valve by looking at the
Fan coupled and ready to start.
rotameter reading to ensure sufficient
Verify for effective sealing of return leg to
fluidization in the return leg.
the combustor.
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18.1.4 Starting SA Fan

Operator Checks
Ensure
Operator Actions
clearance
mechanical,
department
electrical
for
initial
from Place inlet damper closed and controls in
obtained
and
instrument
running
of
manual.
the Interlocks ready for SA fan start.
equipment.
Start SA fan. Verify fan motor roll.
Instrumentation in place and operational.

Fan closed, coupled and ready to start.
Place SA flow controllers in automatic

when minimum flows are met.
Check combustor draft when starting SA
Adjust combustor pressure controller as
Fan.
needed.
18.1.5 Starting PA Fan

Operator Actions
Operator Checks
Ensure
clearance
mechanical,
department
electrical
for
initial
from Place inlet damper closed and controls
obtained
and
instrument
running
of
equipment.
in manual.
the Interlock ready for PA fan start.

Start PA fan. Verify fan motor roll.
Instrumentation in place and operational

Fan closed, coupled and ready to start.
Monitor combustor draft and adjust

controller as necessary
Check combustor draft when starting PA Place PA flow and controls in automatic.
fan
Place ID fan in auto.
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18.1.6 Air Settings, all Fans ON

Operator Checks
Operator Actions
Verify ID fan controls set to maintain -10 Verify all air flow controls are in
mmWC
automatic
Verify SA fan Flow control and air flows
and
maintaining
minimum
flow.
Initiate a 5-minute boiler purge when
are normal and in automatic.

Verify PA Flow control and flows are
normal and in automatic
main interlocks are ready.

Observe the purge complete indication
Verify total air flow is greater than
(DCS)
Monitor all air flows during boiler purge.
minimum necessary for purge.
Monitor all boiler trip conditions in

preparation for combustor ready signal.
18.1.7 Adding Bed Material

Operator Checks
Operator Actions
System in place for adding bed material

Verify all fans are running at minimum air
Start adding bed material to combustion

chamber
Monitor feeding of bed material
settings
Verify adequate supply of bed material Fire the startup burners at minimum to
available
pre-warm boiler, as necessary.
Verify all indicated bed pressure taps are Stop feeding bed material when bed
reading about 300-350mmWc
pressure is 300-350mmWc.
Check the startup burners are ON
Isolate bed material conveying lines, &

feeding system.
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18.1.8

Before Start-up Burner Light-up
Operator Checks
Operator Actions
All boiler flue and duct hangers, spring Verify all pre-firing conditions satisfied.
hangers in cold position
Boiler purge complete.
Temporary scaffold and equipment clear off Adequate

boiler, flues and ducts.
startup
fuel
supply
available
for
Drum level slightly low for startup to allow Startup burner fuel pressure regulated
swell when water gets heated.
as necessary.
Drum vents and superheater vents are Operator stationed at individual start-up
open. Also superheater drains are kept
burner to monitor light-up.
open.
All plant personnel ready for boiler
Through
boiler
walk
down
has
been
startup.
completed.
18.2 Cold Startup
18.2.1 Starting of Start-up Burner

Operator Checks
Complete
all
Operator Actions
pre-firing
operations. Check that startup burners are coupled and in
Ensure all prerequisites are satisfied.
the retract position.
Open all manual fuel shut-off valves
Complete boiler purge requirements.
Verify interlocks satisfied.
Start the first startup burner at minimum firing
Verify
all
properly.
instruments
are
working
rate and visually check condition of flame.

Start the other burner at minimum firing rate
and visually check condition of flame.
Fire startup burners to get to 600oC bed
temperature.
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Continue to fire startup burners until bed

temperature reaches 760oC.
Follow recommended firing rates during all
cold startups
18.2.2 Raising of Steam Pressure

Operator Checks
Monitor
rate
Operator Actions
of
change
in
flue
gas Close drum vents and SH vents at

2Kg/cm(g) drum pressure
temperatures and boiler pressure
Monitor actual hourly changes in boiler Blow down steam drum to maintain
temperature and pressure.
normal drum water level.
Monitor startup burner operations.

Monitor loop seal return leg temperatures for
differences.
Place feed water and drum level

controls in automatic when steam flow
is indicated.
o
Place Electrostatic precipitator in service as Control firing rate to less than 150 C /
hr at hot cyclone separator inlet
required.
temperature change.
At 7 kg/cm(g)
drum pressure, throttle
SH drains. Keep them cracked open.

Add feed water to the drum only if it is
essential until over 14 kg/cm (g). Blow
down to maintain drum level.
Close all superheater drains.
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18.2.3 Starting of Solid Fuel Firing

Operator Checks
Operator Actions
Verify solid fuel feed systems are Maintain startup burner firing rate as per
ready for normal operation with fuel on
the drag chain feeders.
the start-up curve.

Open solid fuel feeder silo isolation
Monitor startup burners
valves
Start bed ash removal system when
pressurization valves.
drag
chain
feeder
Start the first solid fuel feeder in manual
needed.
Continuously
and
monitor
bed
temperatures, bed pressure and loop

seal return temperatures.
at minimum. Pulse-feed the first solid

fuel feeder three times.
Place remaining solid fuel feeders in
service at minimum in manual
Reduce
startup
burner
firing
rates
slowly. Increase solid fuel feed to

maintain temperature ramp rate. Watch
excess O2 all the time.
Shutoff
startup
burners
when
bed
temperature is stable at greater than

760oC.
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18.2.4 Maintaining Solid Fuel Firing

Operator Checks
Monitor
boiler
Operator Actions
temperature
profile.
Normal bed temperature 880-950oC
Place the controls in automatic as

necessary.
Maintain boiler steam flow within rated
Place oxygen trim control in automatic

when boiler load is stable and above
limits. Do not Over fire!
70%.
Monitor O2 level for excess air.

Monitor boiler steam temperatures.
Place bed ash removal system in

service as needed
Monitor excess oxygen indications.

Place
steam
temperature
control
stations in service as needed.

Monitor excess oxygen indications as

measured in the flue gas. Keep within
calibration limits. If not, have them
recalibrated.
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18.3 Normal Operations

18.3.1 Maintaining Bed Material Inventory
Operator Checks
Bed pressure and
indicating
properly
Operator Actions
bed temperature Verify solid fuel size distribution by
around
the
combustion chamber
sampling as fired fuel.

Verify
Monitor bed ash removal operation for
and
change
in
solid
fuel
composition, i.e. Ash content.
any problems. Monitor bed ash drain Improper bed material can result in high
temperatures.
bed temperatures, high or low bed
Monitor split between bed pressure and
airbox pressure.
pressures, high or low hot cyclone

separator inlet temperatures.
Watch
bed
ash
for
abnormal
composition and size.
18.3.2 Bed Ash Removal System

Operator Checks
Operator Actions
Monitor ash drain outlet temperatures.
Keep the bed ash discharge feeders in
Monitor cooling water pressure and flow
continuous operation.
Check operation of bed ash discharge Always observe safety precautions

when around the bottom ash center
feeder.
Verify that isolation gate is not partially
closed.
drains or ash conveying system.

Respond to bed ash drain problems as
soon as they happen.
Low bed pressure reduce bed ash
removal rate.
High bed pressure increase bed ash
removal rate.
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18.4 Normal Shutdown

18.4.1 Solid Fuel Shutdown
Operator Checks
Operator Actions
Monitor excess O2.
Reduce solid fuel feed at 10%
Continuously monitor flue gas temperature,

boiler pressure and rates of change.
Monitor boiler temperature profile.
minute
to
760oC
indicated
bed
temperature.
Place solid fuel, O2 trim control in
manual before stopping solid fuel
feeders.
Monitor excess oxygen content in
the flue gas.
Empty solid fuel drag chain feeders
and lines before 760oC
At 10% MCR, take drum level control
to manual, close main steam valve,
open
startup
vent
to
control
pressure.
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18.4.2 PA, SA, ID Fans and Loop seal Blower Shutdown

Operator Checks
Operator Actions
Monitor boiler temperature profile
Keep all fans running at minimum until
Check boiler drum water level
boiler is cooled
If taking boiler out of service, empty all fly If entering boiler, keep fans running to
35oC indicated bed temperature.
ash and bottom ash hoppers.
Maintain proper cooling rates with air
flows
Remove bed material if rapid cool-down
is desired
Leave water in boiler for quicker cooldown
At desired temperature, stop fans in
sequence, PA, SA, and ID. Or stop the ID
fan. Verify Seal pot blower runs for 30
seconds after ID fan is stopped.
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18.4.3 Boiler Shutdown

Operator Checks
Operator Actions
Monitor and maintain drum water Maintain normal steam drum water level at all
level
times.
Monitor steam drum pressure
Stop boiler chemical feed pumps when boiler
Check for normal boiler movement
feed pump is off.

At 1.5 kg/cm pressure. Open drum and
during cool-down.
Check position of spring hangers
superheat vents all the way.

If bottling up the boiler, keep drum pressure
around the boiler.
high, close air dampers, keep normal water

level in the steam drum.
Apply nitrogen blanket if boiler will be out of
service for a long time or empty boiler.
Verify all auxiliary equipment is shutdown at
the proper time.
18.4.4 Quick Cool-Down for Outage

Empty bed from combustion chamber as quickly as possible. Keep bottom ash discharge
feeders in service until until the ash is removed out from the bed ash cooler..
Keep fans ON until combustion chamber temperatures drop quickly.
STOP all fans in the normal manner.
Open all combustion chamber and hot cyclone separator / loop seal doors.
Start ID fan and Seal pot blower only.
Increase combustor draft to 25 mmWC to facilitate fast cool down.
Observe all safety rules. Do not rush the process.
Page 152 of 15 2
(Preliminary)

O - M Manual Vol 1 CFBC Boiler (Bg013)

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Cethar Vesse ls Lt d

Shree Cement Limit ed

BOILER COMPONENTS AND OPERATION

CONTRACT DATA SHEET

INTRODUCTION TO CFBC BOILER

GENERAL DESCRIPTION OF CFBC BOILER

BOILER PRESSURE PARTS

NON PRESSURE PARTS

WATER CHEMISTRY GUIDELINES

STARTING OF INDIVIDUAL EQUIPMENT

BOILER START-UP PROCEDURE AND OPERATION

PROCEDURE FOR HYDROSTATIC TESTING

PROCEDURE FOR ALKALI BOIL-OUT

PROCEDURE FOR STEAM BLOWING

DOS AND DONTS

Shree Cement Limit ed

MECHANICAL, ELECTRICAL AND INSTRUMENTATION DOCUMENTS

FANS & BLOWER

ELECTRICAL AND INSTRUMENTATION VENDOR MANUALS

Shree Cement Limit ed

INSTRUMENTATION VENDOR MANUALS

FUEL FEEDING AND BED ASH COOLING SYSTEM

VOLUME VIII START UP BURNER SYSTEM

ELECTRO STATIC PRECIPITATOR

VARIABLE FREQUENCY DRIVE

Shree Cement Limit ed

VOLUME 1: BOILER COMPONENTS & OPERATION

CONTRACT DATA SHEET ------------------------------------------------------------- 009

INTRODUCTION TO CFBC BOILER ------------------------------------------------ 012

Atmospheric Fluidised Bed Boiler -------------------------------------- 012

Characteristics of BFB Boiler --------------------------------------------012

Characteristics of CBFC Boiler ------------------------------------------013

Advantages of CFBC Boiler ----------------------------------------------015

GENERAL DESCRIPTION OF CFBC BOILER ----------------------------------- 016

BOILER PRESSURE PARTS ---------------------------------------------------------- 018

Steam Drum ----------------------------------------------------------------- 018

Drum Internals -------------------------------------------------------------- 019

Installation ------------------------------------------------------------------- 021

Data Sheet for Steam Drum -------------------------------------------- 022

Down Comers and Risers ------------------------------------------------ 023

Data Sheet for Downcomers and Risers ---------------------------- 023

Lower Part --------------------------------------------------------------------024

Upper Part --------------------------------------------------------------------025

Data Sheet for Combustor ----------------------------------------------- 026

Hot Cyclone Separator and Loop seal ---------------

Vortex Finder ---------------------------------------------------------------- 028

Cross Over Duct (Cyclone Outlet Chamber-COC) ---------------- 028

Super Heaters --------------------------------------------------------------- 029

Primary Superheater ------------------------------------------------------ 029

Shree Cement Limit ed

4.7.1.1 Data Sheet for Primary Superheater ---------------------------------- 030

De-superheater ------------------------------------------------------------- 031

4.7.2.1 Data Sheet for De-superheater ----------------------------------------- 032

Wingwall (radiant) Superheater ----------------------------------------- 033

4.7.3.1 Data Sheet for Wingwall (radiant) Superheater -------------------- 035

Final Superheater ---------------------------------------------------------- 036

4.7.4.1 Data Sheet for Final Superheater ------------------------------------- 037

Economiser ------------------------------------------------------------------ 038

Data Sheet for Economiser ---------------------------------------------- 039

NON PRESSURE PARTS ---------------------------------------------------------------040

Tubular Air Pre-heater ----------------------------------------------------- 040

Data Sheet for Tubular Air Pre-heater -------------------------------- 040