Boiler Air Side System

1.0 Schematic Diagram

The schematic diagram of this system including the major components, manual and
actuated valves, and major instrumentations is located in Appendix A (See Figure 2).

2.0 Purpose
The purpose of the boiler airside system is to provide adequate air at predetermined
temperature for conveying coal to the combustion chamber and to provide sufficient air in order
to have an appropriate ratio of fuel and air for efficient combustion process.

3.0 Flow Path

3.1 Primary Flow Path

Two primary flow path of the system:
1. The primary air fan delivered a volume of air known as primary air into two
separate ways: (1) part of the volume of air goes to the tri-sector type air heater
and exits with an increase of temperature known as hot primary air, and (2) the
other extracted volume of air will not pass the tri-sector air heater and known as
cold primary air. After that, the primary cold and hot air will mix at specified
temperature and pass the coal mill to convey the coal to combustion chamber.
2. The Secondary air fan delivered a volume of air that passes the tri-sector type air
heater and continues to the wind box of the boiler for combustion.

After the combustion process, the very hot flue gas travel to the back pass of the
boiler and enter the tri-sector type air heater that is used for preheating both primary air
and secondary air. Consequently, the flue gas exits the boiler system and is being treated
by the other system in the power plant before it is thrown to the atmosphere.
 3.2 Secondary Path
The secondary flow path starts from the extraction of the primary air to the sealing
air fan prior to seal the coal mill.

4.0 Major Components

4.1 Primary Air Fan

The main function of this component is to convey the coal from the coal mill to the
burner of the boiler. Apart from that, the primary air is also used to dry the coal by the
application of proper mixing of cold and hot air to obtain the desire coal temperature. This
component is a double centrifugal type air fan and located outside of the boiler structure near
the forced draft fan.
The working principle of this component is to add kinetic energy to air as it strike
the impeller of the fan resulting to the increase in pressure and speed. The air will be
discharged to the air outlet port by the centrifugal force. Each boiler is provided with two (2)
by 50 % capacity during normal operation which is designed to meet the burning design coal
at BMCR load plus the seal air of all the coal mills and air leakage in the air preheaters.

4.2 Forced Draft Fan

The purpose of this component is mainly to deliver adequate volume of air in the
wind box which is known as secondary air create an efficient combustion process in the
furnace. The Secondary air is also used for minimizing the NOX of the flue gas by the
application of Secondary Over fired Air (SOFA) installed just above the burner in the boiler.

This component is an axial type force draft fan with variable pitch control which
moves air parallel to the axis of rotation. The air flow will pass the impeller and move spirally
resulting to the increase in kinetic energy and static pressure energy. The configuration of
this component is two (2) by 50% capacity for each boiler which is designed to meet the
 burning coal at BMCR load plus the air leakage in the air preheater. This Component is
located outside the boiler structure.

4.3 Induced Fan

This component is used as ventilator of the flue gas and to maintain the partial
vacuum pressure in the furnace to avoid back firing in the furnace. The fan works as the flow
gas enter the inlet box and the impeller does work on the flue gas. The outlet guide vanes
transform the spiral motion of the flue gas into axial flow and convert most kinetic energy into
static pressure energy needed by the system in the diffuser. The induced fan will deliver the
flue gas into the chimney. The configuration of this component is two (2) by 50 capacity for
each boiler. This component is located before chimney.

4.4 Tri-sector Type Preheater

This component is mainly used to preheat the primary air and the secondary air by
the utilizing the energy in the flue gas. The transfer of heat from the flue gas is achieved
through rotating elements specially formed of metal plates. This component has high
efficiency elements that are spaced and compactly arranged within sector-shaped
compartments of a radially divided cylindrical shell called the rotor. As the rotor slowly
revolves the mass of the elements alternately through the gas and air passages, heat is
absorbed by the element surfaces passing through the hot gas stream. The configuration of
the said component is two (2) by 50% capacity located inside the boiler below economizer.

5.0 Major Controls

5.1 Primary Air Fan

1. When primary air fan bearing temperature is 80, the high temperature alarm
will be sent. When the primary air fan bearing temperature is 90, the primary
air fan will trip.
 2. When primary air fan motor coil temperature is 110, the high temperature
alarm will be sent. When the primary air fan motor coil temperature is 135,
the fan will be tripped.

3. When primary air fan motor bearing temperature is 80, the high temperature
alarm will be sent. When the primary air fan motor bearing temperature is 90,
the primary air fan will be tripped.

4. When primary air fan bearing vibration amplitude is 4.6 mm/s, the big vibration
alarm will be sent. When primary air fan bearing vibration amplitude is 7.1
mm/s, the fan will be tripped.

Table 1. Major Controls & Setpoints

Description Instrument Low- Low Normal High High-
Low High
FD fan bearing
50~70 80 90
temperature
FD fan motor coil
50~70 110 135
temperature
FD fan motor
bearing 50~70 110 135
temperature

FD fan bearing 4.6

4.6 mm/s 7.1mm/s
vibration amplitude mm/s

5.2 Forced Draft Fan

1. The alarm of high temperature bearing is activating if the bearing temperature

of F.D. fan is 90 and F.D fan will trip if the bearing temperature of F.D fan is
100.

2. The alarm of high temperature motor coil is activating if the motor coil
temperature of F.D. fan is 110 and F.D fan will trip if the motor coil
temperature is 135.
 3. The alarm of high temperature motor bearing is activating if the motor bearing
temperature of F.D. fan is 85 and F.D fan will trip if the motor bearing
temperature is 95.

4. If the vibration value of F.D fan bearing is , the alarm of bearing with greatly
vibration is activating and F.D. fan will trip if the bearing vibration value of F.D
fan is 7.1 mm/s.

5. The stallout alarm of I.D. fan is activating if the stallout pressure difference of
I.D. fan is 50mbar and with being tripped after 15-second delay.

6. The alarm of low oil pressure will activate if the hydraulic oil pressure of F.D fan
is 2.5MPa and the low pressure alarm will send signal to startup the backup oil
pump if the hydraulic oil pressure of F.D. fan is 0.8MPa.

7. The alarm of low flow acts if the lubricating oil flow of F.D. fan is 3L/min.

8. The electric heater is put into service if the lubricating oil temperature of F.D fan
is 30 and should be stopped if the temperature is 40.

9. The alarm of high filter pressure difference acts if the filter pressure difference
of F.D. fan oil station is 0.15.

10. Tripping air preheater and I.D. fan can interlock-trip F.D. fan on the same side.

Table 1, Major Controls & Setpoints

Description Instrument Low- Low Normal High High-
Low High
Bearing
Temperature of 50~70 90 100
F.D Fan
Motor Coil
Temperature of 50~70 110 135
F.D Fan
 Table 1, Major Controls & Setpoints
Description Instrument Low- Low Normal High High-
Low High
Motor Bearing
Temperature of 50~70 85 95
F.D Fan

Bearing
4.6
Vibration of 4.6 mm/s 7.1mm/s
F.D. Fan mm/s

Hydraulic Oil 0.8MPa 2.5MPa 2.5~3.5

Pressure of F.
MPa
D Fan

Lubricating Oil
Temperauture 30 30~40 40
of F.D Fan

Lubricating Oil 3~25

3 L/min
Flow of F.D Fan L/min

5.3 Induced Fan

1. If the I.D. fan bearing temperature is higher than or equal to 70, the alarm of
high temperature bearing is activating. Start up the out-of-service cooling air fan
in Interlock way. And meanwhile, if the bearing temperature of I.D. fan is higher
than or equal to90, the alarm of high temperature bearing is activating and I.D.
fan will be tripped if the bearing temperature of I.D. fan is higher than or equal
to 100.

2. If the motor winding temperature of I.D. fan is higher than or equal to 110, the
motor winding will alarm because of high temperature. If I.D. fan bearing
temperature is higher than or equal to 135, I.D. fan will trip.

3. If the I.D. fan motor bearing temperature is higher than or equal to 90, the
bearing will alarm for high temperature and if the I.D. fan motor bearing
temperature is higher than or equal to 100, the I.D. fan will trip.
 4. If I.D. fan bearing vibration value is higher than or equal to 4.6mm/s, the bearing
will alarm because of strong vibration. If I.D. fan bearing vibration value is higher
than or equal to 7.1mm/s, the I.D. fan will trip.

5. If I.D. fan stalling differential pressure is higher than50mbar, I.D. fan stalling
alarm will be sent and I.D. fan trips after 15s delay.

Table 1, Major Controls & Setpoints

Description Instrument Low- Low Normal High High-
Low High

I.D. fan bearing 70 90 100

temperature

Motor.winding 110 110 135

temperature of ID.
fan

I.D. fan motor 90 90 95

bearing temperature

I.D.fan bearing 4.6

vibration 4.6 mm/s 5.6mm/s
mm/s

5.4 Tri-sector Air Preheater

1. Send fire alarm when rotor temperature reaches180.

2. Auxiliary motor will run automatically after main drive motor trips and an alarm
will be sounded. Air heater trips if auxiliary motor is not activated and alarm is
sent out.

3. Flue gas inlet damper, primary air inlet and outlet valves secondary air outlet
damper will automatically closed after air heater trips.
 Table 1, Major Controls & Set points
Description Instrument Low- Low Normal High High-
Low High
Upper bearing oil 70 85
temperature
Lower bearing oil 70C 55C
temperature
Inlet flue gas 387
temperature

6.0 Location of the Valves and Instruments

6.1 Instruments
Type of Instrument
DAS Pressure Transmitter
DAS Temperature Element
MCS Temperature Element
MCS Oxygen analyzer Transmitter
MCS Flow transmitter
Location
Outlet of the Primary Air Fan
Downstream of the Primary air
pipeline after it passes the air
preheater
Flue gas pipe line, before air heater
Flue gas pipe line, before Induce fan
Forced draft fan line after the
preheater
Downstream of the primary air fan
Before it enter the air heater
Primary air pipe line after it pass the
air heater
Flue gas Line before it enter the air
heater
Flue gas line before the bag house
Secondary air pipeline downstream of
the Forced Draft fan, before it enter
the air heater and after air heater
Flue gas line before it enter the air
heater
Secondary pipe line after it pass the
air heater
Before the burner
 6.2 Valves

Types of Valves Types of Instrument

MCS-Flow Control Valve
MCS -Pressure Control Valve
SCS- Isolating Damper
Before the burner (Control Damper)
Before the forced draft fan (Isolating
damper
Before the pressure control Valve
(Control Damper)
Before Induced Fan (Isolating
Damper)
After the primary air fan
Before and after of the air heater on
the primary air pipe line
After the Forced Draft fan
After the air heater on the secondary
air pipe line
Before the air heater on the Flue gas
line

7.0 Available Instruments to the Operator

The available instrument to field operator is very significant in the plant operation
wherein it is used for monitoring and verification purposes during the operation. Pressure
indicator is the instrument found for this system available to the operator.