Cethar Vessels Limited M/s.

Orient Cement
Utilit y Division 11 4 TP H CFBC Boi l er (BG 1 29 )

TABLE OF CONTENTS

VOLUME 1 : BOILER COMPONENTS & OPERATION

1.0 CONTRACT DATA SHEET

2.0 INTRODUCTION TO CFBC BOILER

2.1 Atmospheric Fluidised Bed Boiler
2.1.1 Characteristics of BFB Boiler
2.1.2 Characteristics of CFBC Boiler
2.2 Advantages of CFBC Boiler

3.0 GENERAL DESCRIPTION OF CFBC BOILER

4.0 BOILER PRESSURE PARTS

4.1 Steam Drum
4.1.1 Drum Internals
4.1.2 Installation
4.1.3 Data Sheet for Steam Drum
4.2 Down Comers and Risers
4.2.1 Data Sheet for Downcomers and Risers
4.3 Combustor (Furnace)
4.3.1 Distributor Bottom Grid
4.3.2 Lower Combustor
4.3.3 Upper Combustor
4.3.4 Data Sheet for Combustor
4.4 Water cooled Cyclone and Loop Seal
4.4.1 Vortex Finder
4.4.2 Data sheet for water cooled cyclone
4.4.3 Data sheet for loop seal
4.5 Steam cooled wall (back pass)
4.5.1 Data sheet for Steam cooled wall
4.6 Cyclone Outlet Chamber

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 11 4 TP H CFBC Boi l er (BG 1 29 )

4.6.1 Data Sheet For Cyclone Outlet Chamber

4.7 Super Heaters
4.7.1 Primary Superheater
4.7.1.1 Data Sheet for Primary Superheater
4.7.2 De-superheater
4.7.2.1 Data Sheet for De-superheater
4.7.3 Wingwall (radiant) Superheater
4.7.3.1 Data Sheet for Wingwall (radiant) Superheater
4.7.4 Final Superheater
4.7.4.1 Data Sheet for Final Superheater
4.8 Economiser
4.8.1 Data Sheet for Economiser

5.0 NON PRESSURE PARTS

5.1 Tubular Air Pre-heater
5.1.1 Data Sheet for Tubular Air Pre-heater
5.2 Bed Ash Cooler

6.0 SYSTEM DESCRIPTION

6.1 Air System
6.1.1 Primary Air System
6.1.1.1 Primary Air Distribution
6.1.2 Secondary Air System
6.1.2.1 Secondary Air Distribution
6.2 Solid Fuel Feeding System
6.2.1 Limestone Feeding System
6.2.2 Bed Material Feeding System
6.3 Start-up Burner System
6.4 Flue Gas System
6.4.1 Combustor
6.4.2 Water Cooled Cyclone Separator
6.4.3 Convection Section (Back Pass)
6.4.4 Induced Draft Fan (ID)

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 11 4 TP H CFBC Boi l er (BG 1 29 )

6.5 Water System

6.5.1 De-aerator System
6.5.2 Feed Water System
6.6 Steam System
6.6.1 Main Steam Piping
6.7 Ash Collection System
6.7.1 Bed Ash Collection
6.7.2 Fly Ash Collection System
6.8 Dosing System
6.8.1 LP Dosing System
6.8.2 HP Dosing System

7.0 REFRACTORY

8.0 WATER CHEMISTRY GUIDELINES

8.1 Prelude
8.2 Water Treatment
8.2.1 External Treatment
8.2.1.1 Pre-treatment
8.2.1.2 Demineralisation
8.3 Internal Treatment
8.3.1 Oxygen Removal
8.3.2 LP Dosing
8.3.3 HP Dosing
8.3.4 Silica Control
8.3.5 Feed Water / Boiler Water Quality

9.0 STARTING OF INDIVIDUAL EQUIPMENT

10.0 BOILER START-UP PROCEDURE AND OPERATION

10.1 Preliminary Operational Check List
10.2 Cold Start

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 11 4 TP H CFBC Boi l er (BG 1 29 )

10.2.1 Filling the Boiler

10.2.2 Starting the Fans & Adjusting Air Flows
10.2.3 Filling Bed Material
10.2.4 Initiating Boiler Purge
10.2.5 Lighting up Start-up Burner
10.2.6 Boiler Warm-up
10.2.7 Solid Fuel Firing
10.2.8 Raising Boiler to Rated Condition

11.0 SHUT DOWN PROCEDURE

11.1 Normal Shutdown
11.2 Planned - Boxing up the Boiler
11.3 Unplanned Shutdown

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

17.1 High or Low Bed Temperatures
17.2 High or Low Bed Pressure
17.3 High or Low Steam Drum Water Level
17.4 Loss of Bed Inventory from Circulation
17.5 Emergency Situations
17.5.1 Sudden Lose of Steam Drum Level
17.5.2 Gradual Loss of Steam Drum Water Level
17.5.3 Excessive Bed Temperature

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Utilit y Division 11 4 TP H CFBC Boi l er (BG 1 29 )

17.6 Emergency Shutdown

17.6.1 Steam Drum Water Level cannot be Maintained
17.6.2 Sudden Lose of Steam Water Level
17.6.3 Air side or Gas side Failure
17.6.4 Loss of Service
17.6.5 Rapid Loss of Bed Inventory
17.6.6 Loss of Fluidising Air to Seal Pot (Loop Seal)

18.0 QUICK REFERENCE CHART

18.1 Check List before Start-up
18.1.1 Boiler Water Filling
18.1.2 Starting ID Fan
18.1.3 Starting Seal Pot (Loop Seal) Blower
18.1.4 Starting SA Fan
18.1.5 Starting PA Fan
18.1.6 Air Settings, all Fans ON
18.1.7 Adding Bed Material
18.1.8 Before Start-up Burner Light-up
18.2 Cold Start-up
18.2.1 Starting of Start-up Burner
18.2.2 Raising of Steam Pressure
18.2.3 Starting of Solid Fuel Firing
18.2.4 Maintaining Solid Fuel Firing
18.3 Normal Operations
18.3.1 Maintaining Bed Material Inventory
18.3.2 Bed Ash Removal System
18.4 Normal Shutdown
18.4.1 Solid Fuel Shutdown
18.4.2 PA, SA, ID Fans and Seal Pot (Loop Seal) Blower Shutdown
18.4.3 Boiler Shutdown
18.4.4 Quick Cool-Down for Outage

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

1.0 CONTRACT DATA SHEET

CONTRACT DATA SHEET WORK ORDER NO: BG129

PURCHASER : M/s. ORIENT CEMENT

BOILER TYPE : CFBC BOILER - 114TPH CONSULTANT : M/s. FICHTNER CONSULTING ENGINEERS (INDIA) PVT. LTD.
MAIN FUEL : 100% COAL MIDDLING
ALTERNATE FUEL: 20% DRY CAKE+80% COAL MIDDLING
PROPOSED FUEL: 20% FINES+80% COAL MIDDLING
GCV
5% RICE HUSK+95% COAL MIDDLING
Kcal / kg
5% WOOD CHIPS+95% COAL MIDDLING
C% H2 % S% N2 % O2 % H2O % ASH %

100% COAL MIDDLING 28.00 2.42 0.23 0.48 9.92 5.94 53.01 2670

20% DRY CAKE+80% COAL

27.82 2.30 0.28 0.48 8.67 7.93 52.51 2672
MIDDLING
20% FINES+80% COAL
30.12 2.48 0.27 0.53 9.28 6.35 50.98 2873
MIDDLING
5% RICE HUSK+95% COAL
28.36 2.51 0.23 0.51 10.86 6.08 51.45 2695
MIDDLING
5% WOOD CHIPS+95%
28.45 2.51 0.23 0.50 10.78 6.50 51.04 2699
COAL MIDDLING
FUEL FIRING EQUIPMENT : DRAG CHAIN FEEDER
A FOR ALL ALTERNATE FUELS - DRAG
100% COAL MIDDLING-DRAG CHAIN FEEDER L
TYPE CHAIN FEEDER & BOX
M & BOX FEEDERS T FEEDERS
A E
I 1. SMALL DRAG CHAIN FEEDERS - 4 R COMMON FEEDERS FOR MAIN &
Nos.
N 2. MAIN DRAG CHAIN FEEDERS -2 N ALTERNATE FUELS
A
1. VARIABLE FREQUENCY DRIVE - 4
CONTROL F T -
2. CONSTANT SPEED DRIVE - 2
U E
E 1.MAIN DRAG CHAIN FEEDER-31000 KG/HR F
L PER FEEDER U
CAPACITY kg/h -
2.SMALL DRAG CHAIN FEEDER-15500 PER E
FEEDER L
LOCATION FRONT WATER WALL FRONT WATER WALL
CONSTRUCTION : FUSION WELDED
COMBUSTOR TYPE: BALANCED DRAFT
WALLS

WIDTH, mm HEIGHT, mm DEPTH, mm LOCATION

FRONT WATER WALL
5278 23500 5278 COMBUSTOR
BOILER NATURAL CIRCULATION DESIGN : 106.5kg/cm2(g)
START-UP OIL LDO P
R
E
OIL TANK CAPACITY (85 & 43 S
START- 170 TPH),m3 S
UP
No. of BURNERS 2 U FINAL SUPERHEATER OUTLET: 87
FIRING
R
SYSTEM
MIN -7.7, MAX-30.8 E
BURNER CAPACITY , Mkcal / kg/
hr cm2
(g)
SECTION STAGE TYPE OF FLOW H.S AREA m2
PRIMARY SUPERHEATER I COUNTER FLOW 668.30
WINGWALL(RADIAL) SUPERHEATER II PARALLEL 68.79
FINAL SUPERHEATER III COUNTER FLOW 511.45
DE-SUPERHEATER ONE VARIABLE NOZZLE TYPE ---
ECONOMISER ONE COUNTER TUBE 2313.889
AIR HEATER 3 BLOCKS COUNTER FLOW 2866.4

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

BOILER AUXILIARIES
MOTOR
DESIGN CONDITION
RATING
PUMPS & MAK
TYPE Nos. DRIVE CONTROL
FANS E
FLOW PRESS. TEMP SPEED
KW
m3/s mm WC C rpm
DIRECT
HYDRAULIC
COUPLED
BOILER FEED COUPLING
CENTRIFUGAL KSB 2 132 --- 159.9 WITH 2925 680
PUMP WITH SCOOP
HYDRAULIC
TUBE
COUPLING
PA FAN RADIAL CVL 2 11.92 1594 50 1480 270 IGV

SA FAN RADIAL CVL 2 10.35 891 50 DIRECT 1480 132 IGV

COUPLED

ID FAN RADIAL CVL 2 33.29 432 155 980 200 MLD

SEAL POT
POSITIVE 18. BUTTERFLY
(LOOP SEAL) KAY 2 0.26 4000 80 BELT 1455
DISPLACEMENT 5 VALVE
BLOWER
SOOT BLOWERS & TEMPERATURE PROBES
LOCATION TYPE MAKE NOS. MEDIUM
SUPERHEATER
ECONOMISER NA
AIR HEATER
DUST COLLECTORS
DESIGN CONDITIONS (DOLOCHAR)
DUST INLET DUST FLUE GAS PRESSURE O / L DUST
MAKE FIELD NOS. FLUE GAS FLOW
COLLECTOR CONCENT. FLOW LOSS CONCENT.
m3/s
gm/ Nm3 TPH mmWC mg/ Nm3

CYCLONE --- --- --- --- --- --- --- ---

50 (N FIELDS)
ESP CVL 4 1 99 235.2 49.5 25 100 (N-1
FIELDS
PIPING

PIPE LINES MAIN STEAM HOT REHEAT COLD REHEAT FEED WATER

SIZE Dia.x t 168.3mm X

219.1mm X 23.01mm
(mm x mm) Matl. NA NA 18.26mm
Spec
No. of LINE 1 --- --- 1
BOILER MOUNTINGS
SET
SIZE
LOCATION MODEL MAKE Nos. PRESSURE kg/
inches
cm2(g)
STEAM DRUM HCL-76w-1BR-SPL TYCO SANMAR 2 106.5/109.7 2'' X 6''
MAIN STEAM LINE HCL-R-68w-1BR-SPL TYCO SANMAR 1 96.19 2.5'' X 6''

SAFETY VALVES CBD JOS-H-E-15-C-1BR-SPL TYCO SANMAR 1 7 3'' X 4''

DE-AERATOR JOS-H-E-15-C-1BR-SPL TYCO SANMAR 1 7.36 6'' X 8''

BED ASH COOLER JOS-H-E-15-C-1BR-SPL TYCO VALVES 1 --- 1.5'' X 3''

BI-COLOR
TYCO VALVES &
WATER LEVEL STREAM DRUM 4119F-4595F 2 5.0 ---
CONTROL
GAUGE
ELECTRONIC
TYCO VALVES &
WATER LEVEL STEAM DRUM YARWAY 3000 1 --- ---
CONTROL
INDICATOR

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

MAIN PARAMETERS
FUEL 100% COAL MIDDLING

DESCRIPTION UNIT 100% BMCR 60% BMCR

FLOW AT FINAL SUPERHEATER OUTLET TPH 114 68.4

2
STEAM PRESSURE AT FINAL SUPERHEATER OUTLET kg/cm (g) 88.60 86.4
0
TEMPERATURE AT FINAL OUTLET C 520 5 520 5

FUEL HEAT INPUT TO BOILER Mkcal/h 82.699 49.211

0
FEED WATER TEMPERATURE C 205 205
0
AMBIENT AIR TEMPERATURE C 30 30
0
COMBUSTION AIR TEMPERATURE C 175 171

FUEL QUANTITY TPH 30.973 18.431

COMBUSTION AIR QUANTITY TPH 217.296 128.248

QUANTITY TPH 149.135 88.745

FLUE
GAS 0
TEMPERATURE AT BOILER EXIT C 140 127

EFFICIENCY BASED ON HHV % 84.4 84.52

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

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 fuel feeders
are sized to 5 to 6 mm before conveying to the combustor with the high velocity air through
the air box and distributor plate.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.

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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 of 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.
The hot loop comprises of the combustor, hot cyclone separator, return leg and seal pot
(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.

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Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

FIG-1

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Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

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

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

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. BG129-00-02-0-001, BG129-00-02-0-
002, & BG129-00-02-0-003).

The boiler is designed to operate with either 100% Coal Middling or combination of Coal
Middling and Dry cake / Fines/ Wood chips/ Rice husk as the fuel. The combustor is
provided with two numbers of opening for fuel feeding and one number for the bed material
feeding. Twin bunkers of capacity 440 m3 and 440 m3 are provided for storing Coal
Middling and Dry cake / Fines/ Wood chips/ Rice husk respectively. Also a bunker capacity
of 250 m3 is provided for storing Limestone. A separate bunker of capacity 7.2 m3 is
provided for storing the bed material. Four numbers of main drag chain feeders and eight
numbers of box feeders of drag chain type are provided for fuel feeding and two nos. of
rotary air lock valve is provided for bed material feeding.

Two numbers of burners for High Speed Diesel (HSD) 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 2 x 60% Primary Air (PA) fan, 2 x 60% 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% Seal pot (Loop seal) blower is
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.

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Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

The economizer is located below the super heaters in the gas path within duct casing.
Tubular air pre-heater is located below the economizer in multi blocks for heating both
primary and secondary air.

The flue gas then passes through a mechanical cyclone type dust collector (for pre
collection) and then Electro Static Precipitator (ESP) before exiting through the Chimney.
2 x 60% 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 BG129-
00-09-1-010, BG129-00-09-1-023, BG129-00-09-3-011, BG129-00-09-1-014, BG129-00-
09-3-015, BG129-00-09-4-016, BG129-00-09-4-017, BG129-00-09-2-018, BG129-00-09-3-
019.

All necessary ducting complete with dampers and gates are also provided. Refer to P&ID
BG129-00-09-3-011, BG129-00-09-2-012, BG129-00-09-2-013,

All necessary instruments, logics and controls are provided for the safe and reliable
operation of the boiler.

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 Cethar Vessels Limited M/s. Orient Cement
Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

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 Drawing No.
BG129-00-09-1-010.

01. Local Pressure Gauge - 1 No.

02. Remote Pressure Gauge - 1 No.

03. Air Vent & N2 Capping Stub - 1 No.

04. Safety Valve - 2 Nos.

05. Direct Level Gauges - 2 Nos.

06. Level Transmitter - 3 Nos.

07. Electronic Drum Level Indicator - 1 No.

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 - 3 Nos.

13. Riser Pipe - 14 Nos.

14. Feed Pipe - 1 Nos.

15. Steam Outlet - 2 Nos.

16. Metal Temperature Measurement - 4 Nos.

The steam-water mixture entering the drum from combustor and water cooled cyclone top
headers is collected in the separating chamber of the drum. A portion of the water is

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Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

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 angle type blow
down with isolation valves. Two numbers of spring loaded safety valves are mounted on
the drum. The drum safety valves are set to open when the drum gets pressurized above
the set point. Drum level is measured to control the feed water flow. Drum level is
indicated by the local drum water level gauges. 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 contains turbo separators and screen boxes provide
simple and efficient system 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 boxes are used to separate the steam from steam -water mixture
before it leaves from the drum. The turbo separators equipped with a corrugated plate
assembly at its outlet provides with 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. Screen boxes are mounted above the
turbo separator which helps to remove the remaining water particles from the steam using
the method of changing the direction of steam flow several times before leaving the steam
drum. Refer FIG-2.

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Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

FIG-2

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Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

4.1.2 Installation
The following instructions are to be adhered for the proper functioning of drum.

01. Dismantling and reassembling of drum internals if necessary, please study and
follow the drum internals arrangement in the drawing.

02. To prevent water particles 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 re-tightened after the initial bolting.

05. U - Bolts on the feed header should allow for free expansion.

4.1.3 Data Sheet for Steam Drum

Drum

Internal diameter, mm : 1371

Thickness of the Drum

Shell / Dished Head, mm : 75 / 70

Length of the Drum, mm : 6500

Material of Construction
Shell / Dished Head : SA 515 GR 70 / SA 515 GR 70

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Utilit y Division 1 14 TP H CFBC Boi l er (BG 1 29 )

Design Pressure, kg/cm (g) : 106.50

Design Temperature, C : 315

Internals
A) Turbo Separator

No. off : 24

Size, mm : 220

B) Screen box

No. of modules : 18

Size, mm : 574 X 307

4.2 Down Comers and Risers

The boiler water from steam drum flows through down comers to the combustor, water
cooled cyclone bottom headers, loop seal bottom headers & water cooled cyclone inlet
duct header. Risers carry steam-water mixture from respective outlet headers to steam
drum.

4.2.1 Data Sheet

Downcomers

COMBUSTOR WATER COOLED

CYCLONE
No. off 2 1
Pipe Size (NB) 300 200
Pipe Material SA 106 GR B SA 106 GR B

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Risers

COMBUSTOR WATER COOLED

CYCLONE
No. off 12 2
Pipe Size (NB) 150 150
Pipe Material SA 106 GR B SA 106 GR B

4.3 Combustor (Furnace)

The entire combustor is a gas tight enclosure with completely water cooled tubes.
The main components of the combustor are:

water-cooled distributor bottom grid

water-cooled lower combustor (with refractory lining)

water-cooled upper combustor

4.3.1 Distributor bottom 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 fluidizing 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 combustor

The lower combustion chamber is made of water cooled membrane wall enclosure
and refractory lined for protection against erosion and chemical attack. A special care is
taken at the combustor refractory zone with a kick - out (back bump) design to minimize

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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.

4.3.3 Upper combustor

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 water cooled 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, water cooled cyclone and
back pass are supported from the top. Hence, there is no differential thermal expansion
between the combustor and water cooled cyclone. 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 super heaters 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

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6. Wing wall (radiant) super heater panels

7. Gas outlet to water cooled cyclone

8. Bottom ash transfer to bed ash coolers

9. Hot air return line from Ash coolers to combustor

10. Temperature and pressure instrument penetrations

11. Provision for sky climber rope guide in the roof panel

The openings are provided with suitable seal box arrangement to ensure that there is no
leakage outside because of the pressurized condition inside the combustor.

4.3.4 Data Sheet for Combustor

Bottom Headers

Size : NB 250 (273.1 X 32 THK.)

Material : SA 106 GR B

Side wall Top Headers

Size : NB 200 (219.1 X 25.40 THK.)

Material : SA 106 GR B

Roof & Rear Wall Top Header

Size : NB 250 (273.1 X 32 THK.)

Material : SA 106 GR B

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Combustor Tubes

Size, mm : 51 X 4.50 THK

Material : SA 210 GR A1

4.4 Water cooled Cyclone and Loop Seal

The water cooled cyclone is a gas tight circular enclosure manufactured from membrane
panels (similar to combustor tube construction). The water cooled cyclone is lined inside
with a thin layer of abrasion resistant refractory. The primary purpose of the water cooled
cyclone 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 water cooled cyclone and flows down to the loop seal. This acts as a seal
preventing the back flow of flue gas from the combustor through the water cooled cyclone.
The ash in the loop seal is fluidized by high pressure air coming from the high-pressure
loop seal blower through the nozzles located on the bottom.

Like the combustor, the water cooled cyclone and loop seal system is also designed for
natural circulation system. Saturated water from the steam drum is taken to the inlet
headers of water cooled cyclone and loop seal by separate down comers. The steam-
water mixture from the loop seal and water cooled cyclone wall tubes is collected in the
upper water cooled cyclone headers and returned to the steam drum via riser pipes for
further steam water separation in the drum. The entire water cooled cyclone and loop seal
assembly is top supported and would expand downward with the combustor and the back
pass.

4.4.1 Vortex Finder

Hot combustion gases, with the entrained solids, fuel and ash, leave the top of the
combustor and enter into the water cooled cyclone. The flue gas and ash are drawn
through a fixed center pipe attached to the top of the water cooled cyclone , a device called
a vortex finder that causes the gas-ash mixture to change direction. Coarser material is

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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 water cooled cyclone. This change in direction helps
separate and size the coarser bed material from the fine bed material and fly ash. The
smaller fly ash particles entrained with the flue gas leave the top of the water cooled
cyclone and enters the boiler's convection section (back pass).

4.4.2 Data sheet for water cooled cyclone

Bottom Headers

Size : NB 150 (168.3 X 14.27 THK.)

Material : SA 106 GR B

Top Headers

Size : NB 150 (168.3 X 18.26 THK.)

Material : SA 106 GR B

Water cooled cyclone Tubes

Size, mm : 44.5 X 4 THK.

Material : SA 210 GR A1
4.4.3 Data sheet for loop seal
Inlet Headers

Size : NB 100 (114.3 X 13.49 THK.)

Material : SA 106 GR B

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Loop seal Tubes

Size, mm : 44.5 X 4 THK.

Material : SA 210 GR A1

4.5 Steam cooled wall (back pass)

The steam cooled wall is a gas tight enclosure with completely steam cooled membrane
walls tubes. This is the area in which the heat is transferred from the flue gases to the
steam inside the tubes. The steam cooled wall tubes are of seamless construction and
welded to the headers. The steam cooled wall is designed for negative pressure operation
and accordingly suitable buck stays and tie bars are provided. The steam cooled wall
assembly is supported from top by means of hanger rods. The complete steam cooled wall
assembly is designed for natural circulation. Saturated steam from the drum is passed
through the super heater links to steam cooled wall side panels. The steam is collected in
front wall and goes to cyclone outlet chamber. Finally the steam enters the roof header,
rear wall panels and gets slightly superheated and led to primary super heater. Primary &
final convection super heaters are located in the steam cooled wall enclosure.

4.5.1 Data sheet for Steam cooled wall

Inlet Link

No. off : Two

Pipe Size, mm : NB 150 (168.3 X 10.97 THK)

Material : SA 106 GR B

Front middle & top Header

Size : NB 250 (273.1 X 25.40 THK.)

Material : SA 106 GR B

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Side wall Top Headers

Size : NB 200 (219.1 X 18.26 THK.)

Side wall Top

Material : SA 106 GR B
Headers

Side wall Bottom Headers

Size : NB 200 (219.1 X 18.26 THK.)

Material : SA 106 GR B

Front wall Bottom Header

Size : NB 200 (219.1 X 18.26 THK.)

Material : SA 106 GR B

Steam cooled wall Tubes

Size, mm : 38.1 X 4.50 THK

Material : SA 210 GR A1

4.6 Cyclone Outlet Chamber

After leaving the water cooled cyclone, the flue gas fly ash mixture is drawn into and
through the steam-cooled refractory-lined cyclone outlet chamber. Saturated steam from
the steam drum passes through this cross over section. The tubes that make up the steam-
cooled cyclone outlet chamber is 44.5mm O.D. and made from carbon steel material.
Building this ductwork using steam piping reduces the weight and the amount of refractory

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necessary to protect the area. The cyclone outlet chamber connect the water cooled
cyclone to the convection section (back pass) of the boiler.

4.6.1 Data sheet for cyclone outlet chamber

Bottom Headers

Size : NB 150 (168.3 X 14.27 THK.)

Material : SA 106 GR B

Side Headers

Size : NB 200 (219.1 X 18.26 THK.)

Material : SA 106 GR B

Top Headers

Size : NB 200 (219.1 X 18.26 THK.)

Material : SA 106 GR B

Connecting Links

No. off : One

Pipe Size, mm : NB 150 (168.3 X 10.97 THK)

Material : SA 106 GR B

Cyclone outlet chamber Tubes

Size, mm : 44.5 X 4.50 THK.

Material : SA 210 GR A1

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4.7 Superheaters

4.7.1 Primary Superheater

Saturated steam from steam drum flows through steam cooled walls and then the 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 cross to the gas flow through multiple banks 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 specified no. off 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.

4.7.1.1 Data Sheet for Primary Superheater

Inlet Header

No off : One

Size : NB 200 (219.1 X 18.26)

Material : SA 106 GR B

Tubes

Number of Parallel Paths : 49

Number of Banks : 2

Type of Heat Transfer : Convection

Size, mm : 44.5 X 5 THK & 44.5 X 4 THK

Material : SA 210 GR A1 & SA 213 T11

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Transverse Pitch, mm : 104

Longitudinal Pitch, mm : 89

Type of Support : Support lug with Slider Arrangement on

hanger tube.

Arrangement : 2 Starts

Outlet Header

Size : NB 250 (273.1 X 28.58 THK)

Material : SA 106 GR B

4.7.2 De- superheater

De-superheater is located in the interconnecting piping between the primary and final
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 X 25.40 THK)

Material : SA 106 GR B

Liner Size, mm : 180 x 3.15 THK

Liner Material : SA 240 GR 304

No. of Spray Nozzles : One

Spray Nozzle Material : SA 479 GR 304

Spray Nozzle Body Material : SA 479 GR 304

DESH Inlet Link Size : NB 200 ( 219.1 X 15.09 THK )

DESH Inlet Link Material : SA 106 GR B

DESH Outlet Link Size : NB 200 (219.1 X 18.26 THK)

DESH Outlet Link Material : SA 106 GR B

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 ( 219.1 X 15.09 THK )

Material : SA 106 GR B

Inlet Header

No. off : One

Size, mm : NB 200 ( 219.1 X 23.01 THK )

Material : SA 106 GR B

Superheater

Number of parallel paths : 4 X 18

Tube Size, mm : 38.1 X 4.06 THK

Tube Material : SA 213 T11

Type : Finned Panel

Distance between panels, mm : 912

Tube Pitch, mm : 51

Type of Support : Top Supported

Outlet Header

No. off : One

Size, mm : NB 250 ( 273.1 X 25.40 THK )

Material : SA 335 GR P11

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4.7.4 Final Superheater

The superheated steam from primary 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, in-
line arrangement and steam flows cross to the flue gas flow. 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.

4.7.4.1 Data Sheet for Final Superheater

Inlet Link

No. off : One

Pipe Size, mm : NB 200 (219.1 X 15.09 THK)

Material : SA 335 GR P11

Inlet Header

No. off : One

Size, mm : NB 250 (273.1 X 25.40 THK)

Material : SA 335 GR P11

Coils

Number of Parallel Paths : 25

Number of Banks : 2

Type of Heat transfer : Convection

Tube Size, mm : 44.5 X 6 THK & 44.5 X 7.10 THK

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Tube Material : SA 213 T11 / SA 213 T22

Transverse Pitch, mm : 208

Longitudinal pitch, mm : 89

Arrangement : 3 Starts
Outlet Header
No. off : One

Size, mm : NB 300 (323.9 X 40 THK)

Material : SA 335 GR P22

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 by horizontally for cross flow to 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 above the boiler roof.

4.8.1 Data Sheet for Economiser

Feed Pipe:
No. off : One

Size : NB 150 (168.3 X 18.26 THK)

Material : SA 106 GR B

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Inlet Header:
No. off : One

Size : NB 200 (219.1 X 18.26 THK)

Material : SA 106 GR B

Coils
No. of Parallel Paths : 65

Tube Size, mm : 38.1 X 3.66 THK

Tube Material : SA 210 GR A1

Transverse Pitch, mm : 80

Longitudinal Pitch, mm : 96

Flow Arrangement : Cross Flow

Coil Arrangement : In-Line arrangement

Type of Support : Strap support

Outlet Header:
No. off : One

Size : NB 200 (219.1 X 18.26 THK)

Material : SA 106 GR B

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Outlet Link:

No. off : One

Size : NB 150 (168.3 X 10.97 THK)

Material : SA 106 GR B

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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 in third pass.
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 x 2.34 thk)

Material : Block-I (Top) , Block II & III (Middle & Bottom)

IS 1239

Sheet Material : IS 2062 Gr.A

Sheet Thickness, mm : 20 THK

Support : Bottom Supported

Transverse Pitch : 90

Longitudinal Pitch : 80

5.2 Bed Ash Cooler

The CFBC boiler is provided with two (2) integrated water cooled bed ash coolers designed
to handle 100% of the bed ash flow. The ash coolers are located on either side of the main

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furnace. The coolers are provided to cool the furnace bed ash to approximately 300 C so
that the ash can be handled by mechanical ash disposal equipment. The bed ash cooler
have the following advantages.

1. Hot mechanical screws, valves and other moving parts in the hot temperature zone are
eliminated and so there is a very low maintance need.

2. The ash is cooled by a part of the fluidizing air taken from the primary air system with the
hot air coming out of the bed ash coolers is fed back to the furnace for the sensible heat
recovery from the ash.

3. A gain in the efficiency through the reinjection of fine bed material/limestone and fuel
plus recovery of heat in the ash.

4. 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.

5. Cooling coils are also provided in second of the bed ash cooler compartments to further
cool down the ash temperature. The plain cooling coils are arranged in-line, with bends
outside the fluidization zone. The cooling water can be taken from the condensate system
or from condenser cooling water system depending on the requirement.

6. The ash cooler is supported from the top externally in such a way that there is
minimizing differential thermal expansion between the furnace 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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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 BG129-00-
09-2-012.

6.1.1 Primary Air System

Primary air is drawn from atmosphere by 260% 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. The primary air is also supplied to the bed ash
cooling system.

During start-up of the boiler, the PA fan is started after the ID fan, Seal pot (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 III

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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.
Bypass duct is provided between cold air duct and hot air duct for bypassing the air pre-
heater

FIG-4

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6.1.2 Secondary Air System

Secondary air is drawn from atmosphere by 260% 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 (5 nos. entry at lower elevation and
12 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-III.

6.1.2.1 Secondary Air Distribution

The distribution of the Secondary air is as per the P&ID No BG129-00-09-2-012.

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)

Bypass duct is provided between cold air duct and hot air duct for bypassing the air pre-heater

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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 BG129-00-09-3-011. Twin bunker of total capacity
880 m is provided for storing the solid fuels Coal Middling and Dry cake / Fines/ Wood
chips/ Rice husk . The capacity of Coal Middling bunker is 440 m & Dry cake / Fines/
Wood chips/ Rice husk bunker is 440 m. Each bunker is provided with two numbers of
hoppers 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 four 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 manual damper and rotameter provided at the upstream of the air bustle.
Additional air sealing is accomplished by providing regulated supply of cold secondary air
through the Rotameter 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 - III

6.2.1 Limestone Feeding System

250 m^3 Capacity Lime stone bunker is provided. In Limestone feeding system, the
limestoneis withdrawn from the respective bunker through the variable speed Rotary Air
lock Valve ( RAV ) to the fuel main drag chain feeders by means of gravity flow. After
mixingwith fuels in the main drag chain feeders, it flows to the combustor (furnace) through
air bustle by respective feed chutes.

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6.2.2 Bed Material Feeding System

The bed material feeding system is as per the P&ID BG129-00-09-3-011. The bed material
bunker capacity is 6 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.

6.3 Start-up Burner System

The start-up oil firing system is designed for burning High Speed Diesel (HSD). 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 14.1 Mkcal/hr of heat input. The start up oil system comprises HSD tank of
capacity 43m3 with 2nos. of gear oil pump and suction strainer provided common for both
114 TPH boilers. The startup burner, pumping and firing system, air piping, valves, fittings
& instruments are per the P&ID-BG129-00-09-2-018.

The details of HSD Tank and pumping system are available in Volume-VII of BG129 O&M
Manual. The details of the startup oil firing system with associated equipment, BMS
controls and logics are elaborately described in Volume-VII.

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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 BG129-00-09-2-013.

FIG-6

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6.4.2 Water Cooled Cyclone Separator

Flue gases leaving the top of the combustion chamber enters the water cooled cyclone
separator through the cyclone I/L duct. Once the gas solids enter the water cooledcyclone
separator , the gas travels upwards through the vortex finder and enters the cyclone
outlet chamber (COC) 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 pre dust collector,
ESP, ID fan and chimney to the atmosphere.

6.4.4 Induced Draft Fan (ID)

Two number 60% 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 / dischar-
ged to the atmosphere through the chimney. The ID fan inlet damper opening / position is
controlled according to the pressure at the top 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 combus-
tion process. SO2 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 - III

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6.5 Water System

6.5.1 De-aerator System

The de-aerator system is provided for removing non condensate gases like Oxygen from
the feed water to the boiler for preventing oxidation in boiler pressure part components.
The de-aerator system consists of vertical de-aerating chamber called header and
horizontal feed water storage tank. (Ref: P&ID-BG129-00-09-1-023.

The condensate and make up water entering the de-aerating chamber is sprayed through
spray nozzles as fine droplets. These fine droplets fall through tray stack for heat and
mass transfer as they come into contact with the steam resulting in release of non
condensate gases which are carried by the steam moving upwards.

The condensate after leaving de-aerating header enters into feed water storage tank from
where it goes to common boiler feed pumps. LP Steam enters the feed water storage tank
and then goes into de-aerating header where part of the steam gets condensed and
remaining steam along with non condensate gases goes out of the de-aerator.

The LP steam is used for de-aeration of the water. The pressure inside de-aerator tank is
measured and the LP Steam inlet to the de-aerator is controlled to maintain the pressure
by regulating the NB 100 size pressure control valve under normal operation of the turbine.

The level in the de-aerator tank is maintained by controlling the flow from the condensate
storage tank using the level control valve, However if the level is increased beyond control
and on reaching the high level set point, the solenoid activated over-flow on/off valve will
open to drain out the excess water to maintain the level. If the water level is increased
beyond high-high level setpoint, the extraction line MOV shall be closed and for low-low
level the boiler feed pump (BFP) shall be tripped.

The de-aerated water is pumped using two (2) numbers of electrically driven feed pumps
(1W + 1S). These pumps are of multistage, ring section, centrifugal type, complete with
suction strainer, balancing chamber, necessary valves and instruments. A suction strainer
is provided at the inlet of the pump to prevent debris in feed water entering the pump.
Balancing leak off arrangement is provided for the pumps to reduce the axial thrust on the

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bearing. Balancing leak off line is connected back to the de-aerator storage tank. The
delivery line of the pump is provided with auto recirculation valve, one line from the auto
recirculation line connected back to de-aerator storage tank while the other line is going to
the common feed water discharge header. The recirculation arrangement prevents
abnormal temperature rise within the pump by establishing a minimum flow through the
pump, whenever the feed water drawn by the boiler is less than the permissible minimum
flow through the pump. For more details on feed pump refer to Volume-III provided in 114
TPH CFBC Boiler O&M Manual.

6.5.2 Feed Water System

Individual de-aerator system is provided for supplying the feed water for each 114 TPH
boilers. Two 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. The de-aerator, boiler feed pumps with associated
piping, valves & fittings and instrumentation are provided as per the P&ID BG129-00-09 -
1-023.

The feed water from the feed pump is heated at the HP heaters before entering the
economiser. The de-aerator, boiler feed pumps with associated piping, valves & fittings and
instrumentation are provided as per the P&ID BG129-00-09-1-023.

One (1) x 100% pneumatic feed control valve, one (1) X 100% bypass pneumatic control
valve and one (1) x 40% pneumatic feed control valve are provided to regulate the boiler
feed water flow. During boiler start-up up to 40% load, the feed flow rate is controlled by
40% feed control valve. When boiler exceeds 40 % 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. Manual regulating valve of 100% capacity is also provided in the
bypass line with motorized isolation valve at the upstream and manual isolation valve at the

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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 BG129-00-09-1-010. 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 back pass upper side wall headers, flows down the
side walls, up the front and rear walls 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 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 variable spray type located between the primary and wingwall
superheater controls the steam temperature to the rated value. The sensing element
11TE06 / 11TE12 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 common silencer - 1 no.

02. Startup Steam Vent with common silencer - 1 no. (Motorised)

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03. Startup Steam Vent valve - 1 no. (Motorised)

04. Pressure Transmitter - 1 no.

05. Pressure Gauge (Local) - 1 no.

06. Pressure Gauge (Remote) - 1 no.

07. Sampling Stub - 1 no.

08. Temperature Element (T/C) - 1 no.

09. Drain valve (motorised) - 1 no.

10. N2 filling stub - 1 no.

11. Temperature gauge - 1 no.

12. Temperature test pocket - 1 no.

Main Steam Pipe

Size : 273.1 X 28.58 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 BG129-00-09-1-014.
The bed ash coolers are provided to collect and cool the bed ash to approximately 250C
so that the ash can be handled by ash disposal equipment.

The ash is cooled by a part of the fluidizing air taken from the cold primary air system and
the hot air from the cooler is fed back to the combustor for sensible heat recovery from the

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ash. Cooling coils are also provided in the second and third compartments of bed ash
cooler for further cooling of ash. The ash is cooled from approximately 950C to 250C by
this system. Further if the temperature is in excess of 300C at the 3rd 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. 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. Out of three compartments, first compartment
is provided with sparger header arrangement instead of distributor plate. This will help to
remove the higher sized ash particles from first compartment itself. Hence the fluidization
of ash particles can be improved. This will enhance the smooth transition of ash particles
from first compartment to succeeding compartments without de-fluidization.

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 (supplied by others) to
the ash silo.

6.8 Dosing System

6.8.1 L.P Dosing System

LP dosing system, Hydrazine (N2H4) is dosed to feed water at the inlet of feed pumps (or)
inlet of feed water tank to scavenge the last traces of dissolved oxygen in feed water. The
LP dosing system is as per the P&ID No BG129-00-09-4-016.

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To ensure proper dosing, a residual concentration of Hydrazine (0.01 to 0.02 ppm)

is usually maintained in the feed water. The correct treatment level may vary depending
on operating conditions like water characteristics and boiler pressure.

Description

DM water or condensate is mixed with concentrated Hydrazine using motorised agitator in

mixing cum storage tank and further stored in that tank. Prepared chemical is dosed to
feed water using 2 x 100% capacity reciprocating pumps (1W + 1S). The dosing rate from
reciprocating pump can be varied by adjusting the stroke of the plunger through a scaled
knob. At pump discharge a pressure gauge is provided in the common delivery line to read
the chemical discharge pressure. One pressure relieving valve is provided to safeguard the
pump against high pressure. Necessary isolation valves are provided to isolate the pump.
One NRV is provided in the pump outlet to prevent the back flow of water to the pump.

Procedure

When the boiler is under normal operation, chemical is dosed at a particular rate and feed
water sample is analysed for residual hydrazine of 0.01 to 0.02 ppm. Based on analysis,
the dosing rate is to be increased or decreased to get the required residual hydrazine in the
feed water. Once the required residual hydrazine is obtained, the stroke and chemical
concentration, ratio of water & concentrated N2H4, shall be recorded and should not be
varied unless there is any change in the feed water quality.

Handling and Storage

1. Avoid contact with skin and eyes.

2. Chemical solution if prepared should be made in a covered tank. Since the chemical
solution can absorb oxygen from the atmosphere, not more than one day requirement
should be prepared at a time.

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6.8.2 H.P Dosing System

HP dosing system, trisodium phosphate solution is dosed to steam drum to precipitate

the dissolved salts forming hardness. These precipitated sludge is removed through blow
down. To ensure proper dosing of phosphate, recommended amount of residual
phosphate is maintained in the boiler water. The amount of required residual phosphate
can be obtained from pH - phosphate co-ordination curve (refer to fig-8) which depends on
the pH value of boiler water. The HP dosing system is as per the P&ID No BG129-00-09-4-
017.

Description:

Trisodium phosphate diluted solution is prepared using DM water in a mixing tank and
stored at storage tank. Water is thoroughly mixed with chemicals using motorised agitator.
Prepared chemical is dosed to drum using 2x100% capacity common reciprocating pumps
(1W+1S) - one pump per boiler. The dosing rate from reciprocating pump can be varied by
adjusting the stroke of the plunger through a scaled knob. Please refer the P&ID No
BG129-00-09-4-017 for valves, fittings & instruments.
Pressure relieving valve is provided to safeguard the pump against high pressure.
Necessary isolation valves are provided to isolate the pump. NRV is provided in the pump
outlet to prevent the back flow of water to the pump.

Procedure

When the boiler is under normal operation chemical is dosed at a particular rate and boiler
water sample is analysed for phosphate. Based on analysis, the dosing rate is to be
increased or decreased to get the required phosphate (PO4). Once the required phosphate
level is obtained, the stroke and chemical concentration (Ratio of water/PO4) shall be
recorded and should not be varied unless there is any change in the feed water quality.
This should not be varied unless there is any change in the boiler water quality.

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Handling and Storage

1. Avoid contact with skin and eyes.

2. Avoid extremes of temperature.
3. Replace caps securely after use.
4. Maximum storage limit is 2 years.

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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-IX.

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 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 Demineralization

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 de-
mineralisation, 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 de-
aerator 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/cm 2 (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

Boiler Water

Total Dissolved Solids ppm Not More Than 100

Specific Electrical Conductivity At 25C ms/cm Not More Than 200

Phosphate Residual ppm 15 - 25

pH @ 25C max. 9.8 - 10.2

Silica ppm Silica Level Less Than 0.02 ppm

(See Note : 8) 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 I & II.

02. Start the loop seal blower.
03. Start the SA fan-I &II.
04. Start the PA fan-I & II.

The individual equipment can be started through DCS or from Local Push Button or VFD
panels (LPBS/VFD panel).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.

Interlocks
ID FAN:
CFBC boiler is provided with 2 x 60% ID fan with inlet damper at the suction for combustor
pressure control.

ID Fan - I (13LTM05) - (Drawing No. BG129-00-09-3-076)

Permissives:
Before starting the ID fan - I, the system shall ensure the following conditions.

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1. Steam drum level not low

2. Steam drum level not high
3. ID fan I motor winding temperature not high
4. ID fan-I motor bearing temperature not high @ D.E
5. ID fan-I motor bearing temperature not high @ N.D.E
6. ID fan-I running / ID fan-I suction damper (RPC & guillotine) is closed
7. ID fan-I motor is ready
8. ID fan-I motor not tripped
9. ID fan-I delivery damper (guillotine) is open.
10. ID fan-I running / ID fan-II running / ID fan-II delivery dampers (guillotine) closed.

Operation:
ID fan-I motor shall be started in Remote or from Local mode in DCS by selecting either
VFD mode (or) Bypass mode (DOL) from VFD panel. ID fanI motor will be started when
the above Permissive are satisfied. When ID fanI motor attains the rated speed, its
suction damper will be opened fully. The ID fan-I can be stopped any time from DCS/LPBS/
VFD Panel during the normal course of operation (remote/local).

Trip Condition:
The ID fanI motor shall be tripped, when any one of the above Permissive is failed except
Drum level low and high.

ID Fan - II (13LTM06) - (Drawing No. BG129-00-09-3-077)

Permissives:
Before starting the ID fan - II, the system shall ensure the following conditions.

1. Steam drum level not low

2. Steam drum level not high
3. ID fan II motor winding temperature not high
4. ID fan-II motor bearing temperature not high @ D.E
5. ID fan-II motor bearing temperature not high @ N.D.E
6. ID fan-II running / ID fan-II suction damper (RPC & guillotine) is closed

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7. ID fan-II motor is ready

8. ID fan-II motor not tripped
9. ID fan-II delivery damper (guillotine) is open.
10. ID fan-II running / ID fan-I running / ID fan-I delivery dampers (guillotine) closed.

Operation:
ID fan-II motor shall be started in Remote or from Local mode in DCS by selecting either
VFD mode (or) Bypass mode (DOL) from VFD panel. ID fanII motor will be started when
the above Permissive are satisfied. When ID fanII motor attains the rated speed, its
suction damper will be opened fully. The ID fan-II can be stopped any time from
DCS/LPBS/VFD Panel during the normal course of operation (remote/local).

Trip Condition:
The ID fanII motor shall be tripped, when any one of the above Permissive is failed except
Drum level low and high.

loop seal Blower-I (13LTM11) - (Drawing No. BG129-00-09-3-078)

CFBC boiler is provided with 2 x 100% 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.

Permissives:
Before starting the loop seal Blower-I, the system shall ensure the following conditions.

1. Steam drum level not low

2. Steam drum level not high
3. loop seal Blower-I motor not tripped
4. loop seal Blower-I motor is ready
5. ID fan I (or) ID fan-II motor running

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Operation:
Loop seal blower-I motor shall be started by selecting either in Remote or from Local mode.
Loop seal blower-I motor will be started when the above Permissive are satisfied (or) it
shall be automatically started when Loop seal blower-II pressure is low. Loop seal blower-I
motor can be started/ stopped either from DCS / LPBS panel.

Trip Condition:
Loop seal blower-I motor shall be tripped, when any one of the above Permissive is failed
except Drum level low and high (or) when ID fanI and ID fan- II is stopped (or) Loop seal
blower-I running & its Pressure low and Loop seal blower-II running &its pressure not low.

The loop seal blower-I motor continues to run for 30 secs, even after ID fan is stopped /
tripped to fluidise and ensure the leg return of the hot cyclone separator is free from
accumulation.

loop seal Blower-II (13LTM12) - (Drawing No. BG129-00-09-3-079)

Permissives:
Before starting the loop seal Blower-II, the system shall ensure the following conditions.

1. Steam drum level not low

2. Steam drum level not high
3. loop seal Blower-II motor not tripped
4. loop seal Blower-II motor is ready
5. ID fan I (or) ID fan-II motor running

Operation:
Loop seal blower-II motor shall be started by selecting either in Remote or from Local
mode. Loop seal blower-II motor will be started when the above Permissive are satisfied
(or) it shall be automatically started when Loop seal blower-I pressure is low. Loop seal
blower-II motor can be started/ stopped either from DCS / LPBS panel.

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Trip Condition:
Loop seal blower-II motor shall be tripped, when any one of the above Permissive is failed
except Drum level low and high (or) when ID fanI and ID fan- II is stopped (or) Loop seal
blower-II running & its Pressure low and Loop seal blower-I running &its pressure not low.

The loop seal blower-II motor continues to run for 30 secs, even after ID fan is stopped /
tripped to fluidise and ensure the leg return of the hot cyclone separator is free from
accumulation.

SA FAN:
The CFBC boiler is provided with 2 x 60% SA fan for combustion air control.

SA Fan I (13LTM03) - (Drawing No. BG129-00-09-3-080)

Permissives:
Before starting the SA fan - I, the system shall ensure the following conditions.
1. SA fan-I motor ready.
2. SA fan-I motor not tripped
3. SA fanI motor running (or) SA fan-I suction Damper closed.
4. SA fan-I delivery damper (Guillotine) open.
5. SA fanI motor running (or) SA fanII motor running (or) SA fanII delivery
damper (Guillotine) close.
6. ID Fan-I running.
7. Loop seal blower-I (or) Loop seal blower-II running.
8. Loop seal blower-I (or) Loop seal blower-II air pressure not low.
9. Furnace pressure not high high.
10. SA fan-I bearing temperature at DE & NDE not high high.
11. SA fan-I motor bearing temperature at DE & NDE not high high.
12. SA Fan-I motor winding temperature not high high.
13. Drum level not low.
14. Drum level not high.

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Operation:
SA fan-I motor shall be started by selecting either in Remote or from Local mode in
DCS. SA fan-I motor will be started when the above Permissive are satisfied. When SA
fan-I motor attains the rated speed, its suction damper will be opened fully. SA fan-I
motor can be started/ stopped either from DCS / LPBS panel.

Trip Condition:
SA fan-I motor shall be tripped, when any one of the above Permissive is failed except
Drum level low and high (or) Boiler tripped (or) ID fanI is stopped (or) Loop seal
blower-I and Loop seal blower-II stopped (or) Loop seal blower-I and Loop seal blower-
II air Pressure low.

NOTE: When the loop seal blower pressure is low continuously for more than 3 sec, the
trip is initiated to stop the SA fan -I.

SA Fan II (13LTM04) - (Drawing No. BG129-00-09-3-081)

Permissives:
Before starting the SA fan - II, the system shall ensure the following conditions.
1. SA fan-II motor ready.
2. SA fan-II motor not tripped
3. SA fanII motor running (or) SA fan-II suction Damper closed.
4. SA fan-II delivery damper (Guillotine) open.
5. SA fanII motor running (or) SA fanI motor running (or) SA fanI delivery
damper (Guillotine) close.
6. ID Fan-II running.
7. Loop seal blower-I (or) Loop seal blower-II running.
8. Loop seal blower-I (or) Loop seal blower-II air pressure not low.
9. Furnace pressure not high high.
10. SA fan-II bearing temperature at DE & NDE not high high.
11. SA fan-II motor bearing temperature at DE & NDE not high high.
12. SA Fan-II motor winding temperature not high high.
13. Drum level not low.
14. Drum level not high.

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Operation:
SA fan-II motor shall be started by selecting either in Remote or from Local mode in
DCS. SA fan-II motor will be started when the above Permissive are satisfied. When
SA fan-II motor attains the rated speed, its suction damper will be opened fully. SA fan-
II motor can be started/ stopped either from DCS / LPBS panel.

Trip Condition:
SA fan-II motor shall be tripped, when any one of the above Permissive is failed except
Drum level low and high (or) Boiler tripped (or) ID fan- II is stopped (or) Loop seal
blower-I and Loop seal blower-II stopped (or) Loop seal blower-I and Loop seal blower-
II air Pressure low.

NOTE: When the loop seal blower pressure is low continuously for more than 5 sec, the
trip is initiated to stop the SA fan - II.

PA FAN:
The CFBC boiler is provided with 2 x 60 % PA fan for fluidizing the bed material in the
combustor.

PA Fan - I (13HTM 01) - (Drawing No. BG129-00-09-3-082)

Permissives:
Before starting the PA fan - I, the system shall ensure the following conditions.

1. PA fan-I Breaker in Service.

2. PA fan-I Trip circuit healthy.
3. PA fan-I motor ready.
4. PA fan-I delivery damper open.
5. PA fanI motor running (or) PA fan-I suction Damper close.
6. PA fanI motor running (or) PA fanII motor running (or) PA fanII delivery
damper close.
7. ID Fan-I running.
8. SA fan-I running.
9. Loop seal blower-I (or) Loop seal blower-II running.
10. Furnace pressure not high high.
11. PA fan-I bearing temperature at DE & NDE not high high.

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12. PA fan-I motor bearing temperature at DE & NDE not high high.
13. PA fan-I motor winding temperature not high high.
14. PA fan-I motor vibration at DE & NDE not high high.
15. Drum level not low.
16. Drum level not high.

Operation:
PA fan-I motor shall be started by selecting either in Remote or from Local mode in
DCS. PA fan-I motor will be started when the above Permissive are satisfied. When PA
fan-I motor attains the rated speed, its suction damper will be opened fully. PA fan-I
motor can be started/ stopped either from DCS / LPBS panel.

Trip Condition:
PA fan-I motor shall be tripped, when any one of the above Permissive is failed except
Drum level low and high (or) Breaker fault (or) Boiler tripped (or) ID fanI stopped (or)
SA fanI stopped (or) Loop seal blower-I and Loop seal blower-II stopped.

PA Fan - II (13HTM 02) - (Drawing No. BG129-00-09-3-083)

Permissives:
Before starting the PA fan - II, the system shall ensure the following conditions.

1. PA fan-II Breaker in Service.

2. PA fan-II Trip circuit healthy.
3. PA fan-II motor ready.
4. PA fan-II delivery damper open.
5. PA fanII motor running (or) PA fan-II suction Damper close.
6. PA fanII motor running (or) PA fanI motor running (or) PA fanI delivery
damper close.
7. ID Fan-II running.
8. SA fan-II running.
9. Loop seal blower-I (or) Loop seal blower-II running.
10. Furnace pressure not high high.
11. PA fan-II bearing temperature at DE & NDE not high high.
12. PA fan-II motor bearing temperature at DE & NDE not high high.
13. PA fan-II motor winding temperature not high high.

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14. PA fan-II motor vibration at DE & NDE not high high.

15. Drum level not low.
16. Drum level not high.

Operation:
PA fan-II motor shall be started by selecting either in Remote or from Local mode in
DCS. PA fan-II motor will be started when the above Permissive are satisfied. When
PA fan-II motor attains the rated speed, its suction damper will be opened fully. PA fan-
II motor can be started/ stopped either from DCS / LPBS panel.

Trip Condition:
PA fan-II motor shall be tripped, when any one of the above Permissive is failed except
Drum level low and high (or) Breaker fault (or) Boiler tripped (or) ID fanII stopped (or)
SA fanII stopped (or) Loop seal blower-I and Loop seal blower-II stopped.

Interlock for boiler trip- (Drawing No. BG129-00-09-3-084)

The Boiler is tripped, when boiler trip push button is pressed (or) when the
following conditions occur.
1. Furnace pressure high high.
2. Furnace pressure low low.
3. Drum level low low.
4. Drum level high high.
5. ID fan-I (or) ID fan-II not running.
6. Instrument air header Pressure low.

No Boiler Trip:
When the above conditions come to normal state no boiler trip permissive is granted.
Fuel feeder trip is enable when any of the following conditions occurs,

1. Boiler trip.
2. Loop seal blowers-I and II not running.
3. SA Fan-I (or) SA Fan-II not running.
4. PA Fan-I (or) PA Fan-II not running.

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5. Air box pressure < 1100 mmwc

Interlock for boiler purging - (Drawing No. BG129-00-09-3-085)

The following are the condition to be satisfied for Boiler Purging.
1. All Sources of Fuels off.
2. Primary air flow > 30% of total mass air flow.
3. Secondary air flow > 30% of total mass air flow.
4. No Boiler trip.

Once all the above conditions are satisfied by pressing the purge start PB 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.

All feeders stopped and LOTV trip valve close is considered as all sources of fuels off.

Interlock for main drag chain feederI (14GM05) - (Drawing No. BG129-00-09-3-086)
Two numbers of main drag chain feeders are provided for conveying the fuel into the
combustor.

Permissives:
Before starting the main drag chain feeder motor, the system shall ensure the following
conditions.
1. Main drag chain feederI motor ready.
2. Zero speed switch not actuated.
3. PA FanI and PA FanII motor running.
4. Air box pressure >1100 mmwc.
5. Knife edge gate-I opened.

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6. Main drag chain feederI motor TOLR not actuated.

7. Bed temperature > 400C.

Operation:
Main drag chain feederI Geared motor shall be started by selecting either in Remote (or)
from Local mode in DCS. The Main drag chain feederI Geared motor will be started when
the above Permissive are satisfied. The Main drag chain feederI Geared motor can be
started / stopped either from DCS/LPBS panel.

Trip Condition:
The Main drag chain feederI Geared motor shall be tripped, when any one of the
above Permissive is failed (or) fuel trip (or) Temperature at fuel line high.

This write-up is applicable for Main drag chain feederII Geared motor (14GM06)
(Drawing No.BG129-00-09-3-087).

Interlock for drag chain feederI : (14GM01)-(Drawing No. BG129-00-09-3-088)

Two numbers of small drag chain feeders are (VFD driven) provided for conveying the fuel
into the main drag chain feeder -I

Permissives:
Before starting the drag chain feeder motors, the system shall ensure the following
conditions.

1. Respective main drag chain feeder motor (14GM05) running

2. Zero speed switch is not activated.
3. Drag chain feeder-I motor ready
4. Drag Chain FeederI Geared motor not tripped

Operation:
Drag chain feederI Geared motor shall be started by selecting either in Remote or from
Local mode. The Drag chain feederI Geared motor will be started when the above
Permissive are satisfied when Remote mode is selected from VFD panel. The Drag chain
feederI Geared motor motor can be started / stopped either from DCS/LPBS/VFD panel.

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Trip Condition:
The Drag chain feederI Geared motor shall be tripped, when any one of the above
Permissive is failed (or) fuel trip (or) Main drag chain feeder-I motor stopped.

This similar logic is applicable for

i) DRAG CHAIN FEEDERIII GEARED MOTOR (14GM03)VFD & 14ZSS03.
ii) LIME STONE FEEDER FEEDERI GEARED MOTOR (14GM07)VFD.
LIME STONE FEEDER-I motor should start only when Main drag chain feeder-I motor
is running.

Interlock for drag chain feederII : (14GM02)-(Drawing No. BG129-00-09-3-089)

Two numbers of small drag chain feeders are (VFD driven) provided for conveying the fuel
into the main drag chain feeder -II

Permissives:
Before starting the drag chain feeder motors, the system shall ensure the following
conditions.
1. Respective main drag chain feeder motor (14GM06) running
2. Zero speed switch is not activated.
3. Drag chain feeder-II motor ready
4. Drag Chain FeederII Geared motor not tripped

Operation:
Drag chain feederII Geared motor shall be started by selecting either in Remote or from
Local mode. The Drag chain feederII Geared motor will be started when the above
Permissive are satisfied when Remote mode is selected from VFD panel. The Drag chain
feederII Geared motor motor can be started / stopped either from DCS/LPBS/VFD panel.

Trip Condition:
The Drag chain feederII Geared motor shall be tripped, when any one of the above
Permissive is failed (or) fuel trip (or) Main drag chain feeder-II motor stopped.

This similar logic is applicable for

i) DRAG CHAIN FEEDERIV GEARED MOTOR (14GM04)VFD & 14ZSS04.
ii) LIME STONE FEEDER FEEDERII GEARED MOTOR (14GM08)VFD.

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LIME STONE FEEDER-II motor should start only when Main drag chain feeder-II
motor is running.

Interlock for Non-Inching Starters - (Drawing No. BG129-00-09-3-090)

Motorised valves shall be Opened / Closed either through DCS / LPBS when the following
conditions are satisfied.

Permissives:
1. Motorised valve motor is ready

2. Motorised valve motor not tripped

3. Torque switches (open) not actuated for open command.

4. Torque switches (close) not actuated for close command.

5. Limit switches (open) not actuated for open command.

6. Limit switches (close) not actuated for close command.

7. Stop command not actuated

Motorised valves shall be wired such that it can be stopped either from DCS / LPBS.

The above logic is applicable for 10LTM11, 10LTM15, 10LTM16, 10LTM17, 10LTM18,
11LTM01, 11LTM03, 11LTM04, 18LTM01, 18LTM03, 18LTM04, 18LTM05, 18LTM06,
10LTM02 & 10LTM03 motorised valves.

Interlock for Inching Starters - (Drawing No. BG129-00-09-3-091)

Motorised valves shall be Opened / Closed either through DCS / LPBS when the following
conditions are satisfied.

Permissives:
1. Motorised valve motor is ready

2. Motorised valve motor not tripped

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3. Torque switches (open) not actuated for open command.

4. Torque switches (close) not actuated for close command.

5. Limit switches (open) not actuated for open command.

6. Limit switches (close) not actuated for close command.

The position of these valves will be available in DCS through position transmitter
provided in the valves.
Motorised valves shall be wired such that it can be stopped either from DCS / LPBS.
The above logic is applicable for 11LTM02 and 18LTM02 motorised valves.

Interlock for Deaerator over flow MOV (10LTM01) (Drawing No. BG129-00-09-3-092).
Motorised valve shall be operated from DCS / LPBS / automatically (through logic function)
if the following permissives are satisfied.
1. Motorised valve motor is ready.
2. Motorised valve motor not tripped

Operation:
On sensing high level in deaerator by the respective level switch the motorised valve opens
to drain out the excess level from the deaerator, provided the permissives are satisfied and
open torque / limit switches are not activated.
When the normal level is sensed by the level switch the motorised valve closes provided
the permissives are satisfied and close torque / limit switches are not activated.

Deaerator over flow Motorised valves shall be wired such that it can be stopped either from
DCS / LPBS.

Interlock for feed pump motor-I (10HTM 01) (Drawing No. BG129-00-09-3-093).
Two number of feed water pumps 2 x 100 % (1W+1S) are provided which supplies the
required feed water to boiler.
Before starting the feed water pumps, the system shall ensure the following conditions.

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Permissives:
1. Differential pressure across the feed pump suction strainer not high.
2. Feed pump-I Breaker in service.
3. Boiler Feed Pump-I motor ready.
4. Deaerator level normal.
5. Deaerator tank level not low low.
6. Feed pumpI bearing temperature at DE & NDE not high high.
7. Feed pumpI motor bearing temperature at DE & NDE not high high.
8. Feed pumpI motor winding (R, Y, B) temperature not high high.
9. Feed pumpI motor vibration at DE & NDE not high high.
10. Fluid coupling lube oil pressure is not low low (A off delay timer is introduced for
initial start (or) Feed pump-I running.
11. Feed pump-I Trip circuit healthy
12. Scoop tube in minimum position.

Operation:
Feed pump-I motor shall be started by selecting either in Remote or from Local mode
in DCS. Feed pump-I motor will be started when the above Permissive are satisfied.
Feed pump-I motor can be started/ stopped either from DCS / LPBS panel.

Trip Condition:
Feed pump-I motor shall be tripped, when any one of the above Permissive is failed except
Differential pressure across the feed pump suction strainer is high (or) fluid coupling Lube
oil temperature is High High (or) Lube oil pressure low low (or) Breaker fault.

This similar logic is applicable for

i) FEED PUMP-II MOTOR (10HTM02) (Drawing No. BG129-00-09-3-094).

HP Dosing pump motor:

Two HP dosing pumps are provided for boiler (1W+1S)

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Interlock for HP Dosing Pump-1 (10LTM23): (Drawing No. BG129-00-09-3-095)

Permissives:
Before starting the HP Dosing pump-I motor, the system shall ensure the following
conditions.
1. HP Dosing Pump-I motor ready.
2. HP Dosing tank level not low low.
3. HP Dosing Pump-I motor not tripped

Operation:
HP Dosing Pump-I motor shall be started by selecting either in Remote or from Local
mode. The HP Dosing Pump-I motor will be started when the above Permissive are
satisfied. HP Dosing Pump-I motor can be started /Stopped either from DCS or LPBS.

Trip Condition:
The HP Dosing Pump-I motor shall be tripped, when any one of the above Permissive is
failed.

This similar logic is applicable for

i) HP Dosing Pump-II motor (10LTM24).

Note: Failure to energise the contactor within 5 secs from the initiation of start push
button resets the logic.

Interlock for HP Dosing Agitator motor (10GM02): (Drawing No. BG129-00-09-3-096)

The agitator is part of the HP dosing tank.

The agitator motor can be started when following condition are satisfied.
Permissives:
1. Agitator Motor is ready.
2. Agitator motor not tripped

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Operation:
HP Dosing Agitator Geared motor shall be started by selecting either in Remote or
from Local mode in DCS. The HP Dosing Agitator Geared motor will be started, when
the above Permissive are satisfied. HP Dosing Agitator Geared motor shall be wired,
such that motor can be started /Stopped either from DCS / LPBS.

Trip Condition:
The HP Dosing Agitator Geared motor shall be tripped, when any one of the above
permissive is failed.

LP Dosing pump motor:

Two LP dosing pumps are provided for boiler (1W+1S)

Interlock for LP Dosing Pump-1 (10LTM21): (Drawing No. BG129-00-09-3-097)

Permissives:
Before starting the LP Dosing pump-I motor, the system shall ensure the following
conditions.
1. LP Dosing Pump-I motor ready.
2. LP Dosing tank level not low low.
3. LP Dosing Pump-I motor not tripped

Operation:
LP Dosing Pump-I motor shall be started by selecting either in Remote or from Local
mode. The LP Dosing Pump-I motor will be started when the above Permissive are
satisfied. LP Dosing Pump-I motor can be started /Stopped either from DCS or LPBS.

Trip Condition:
The LP Dosing Pump-I motor shall be tripped, when any one of the above Permissive is
failed.

This similar logic is applicable for

i) LP Dosing Pump-II motor (10LTM22).

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Note: Failure to energise the contactor within 5 secs from the initiation of start push
button resets the logic.

Interlock for LP Dosing Agitator motor (10GM01): (Drawing No. BG129-00-09-3-098)

The agitator is part of the LP dosing tank.

The agitator motor can be started when following condition are satisfied.

Permissives:
1. Agitator Motor is ready.
2. Agitator motor not tripped

Operation:
LP Dosing Agitator Geared motor shall be started by selecting either in Remote or from
Local mode in DCS. The LP Dosing Agitator Geared motor will be started, when the
above Permissive are satisfied. LP Dosing Agitator Geared motor shall be wired, such
that motor can be started /Stopped either from DCS / LPBS.

Trip Condition:
The LP Dosing Agitator Geared motor shall be tripped, when any one of the above
permissive is failed.

Interlock for Bed Ash Cooler Ash Discharge Geared motor (07GM01)
(Drawing No. BG129-00-09-3-099)
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.

Permissives:
1. Bed ash cooler-I ash discharge Geared motor motor ready.
2. Bed ash cooler-I ash discharge Geared motor motor not tripped
3. Zero speed switch not actuated.

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Operation:

Bed ash cooler ash discharge Geared motor-I shall be started by selecting either in
Local or from Remote mode in DCS. The Bed ash cooler ash discharge Geared
motor-I will be started when the above Permissive are satisfied when Remote mode is
selected from VFD panel. Bed ash cooler ash discharge Geared motor-I shall be wired,
such that motor can be started / Stopped either from DCS / LPBS/VFD panel.

Trip Condition:
The Bed ash cooler ash discharge Geared motor-I shall be tripped, when any one of
the above permissive is failed.
This write-up is applicable for
Bed Ash Cooler Ash Discharge geared motor-II (07GM02)-VFD.

Note : Failure to energise the contactor within 5 secs from initiation of start push button
rests the logic.

Interlock for common Gear Oil Pump-I (19LTM01): (Drawing No.BG129-00-09-3-100):

Common gear oil pump is provided for pumping HSD from the day tank to the burners
during the initial firing for light-up. This pump is common for both BG129 & BG130 boilers.

Permissives:
4. Gear oil pump-I motor ready.
5. Gear oil pump-I motor not tripped

Operation:
Gear oil pump-I motor shall be started by selecting either in Remote or from Local
mode in DCS. The Gear oil pump-I motor will be started, when the above Permissive
are satisfied. Gear oil pump-I motor shall be wired, such that motor can be started
/Stopped either from DCS / LPBS.

Trip Condition:
The Gear oil pump-I motor shall be tripped, when any one of the above permissive is
failed (or) HSD oil tank level low low.

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This write-up is applicable for Gear oil pump-II motor (19LTM02).

Interlock for ID fanI delivery damper (Guillotine) (Drawing No. BG129-00-09-3-101).

Delivery damper (guillotine) can be opened / closed from DCS / LPBS as desired and
selected from DCS remote / local selector switch provided the following permissives are
satisfied.
1. ID Fan I delivery damper motor ready.
2. ID Fan I delivery damper not tripped

ID Fan I delivery damper(Guillotine) shall be opened when both ID Fan-I and ID Fan-II
stopped & shall also be closed by initiation of interlock when ID Fan-I is stopped/tripped
and ID Fan-II running.

ID Fan I delivery damper (Guillotine) shall not be opened, when motor ready feedback is
not satisfied (or) TOLR is actuated (or) Open limit switch is actuated (or) Open torque
switch is actuated (or) ID Fan-I and ID Fan-II are not stopped.

ID Fan I delivery damper (Guillotine) shall not be closed, when motor ready feedback is
not satisfied (or) TOLR is actuated (or) Close limit switch is actuated (or) Close torque
switch is actuated (or) ID Fan-I is not stopped/tripped and ID Fan-II not running

This write-up is applicable for

ID Fan II delivery damper (Guillotine) (Drawing No. BG129-00-09-3-102)

Interlock for SA fanI delivery damper (Guillotine) (Drawing No. BG129-00-09-3-103).

Delivery damper (guillotine) can be opened / closed from DCS / LPBS as desired and
selected from DCS remote / local selector switch provided the following permissives are
satisfied.
1. SA Fan I delivery damper motor ready.
2. SA Fan I delivery damper not tripped

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SA Fan I delivery damper(Guillotine) shall be opened when both SA Fan-I and SA Fan-II
stopped & shall also be closed by initiation of interlock when SA Fan-I is stopped/tripped
and SA Fan-II running.

SA Fan I delivery damper (Guillotine) shall not be opened, when motor ready feedback is
not satisfied (or) TOLR is actuated (or) Open limit switch is actuated (or) Open torque
switch is actuated (or) SA Fan-I and SA Fan-II are not stopped.

SA Fan I delivery damper (Guillotine) shall not be closed, when motor ready feedback is
not satisfied (or) TOLR is actuated (or) Close limit switch is actuated (or) Close torque
switch is actuated (or) SA Fan-I is not stopped/tripped and SA Fan-II not running

This write-up is applicable for

SA Fan II delivery damper (Guillotine) (Drawing No. BG129-00-09-3-104)

Interlock for PA fanI delivery damper (Guillotine) (Drawing No. BG129-00-09-3-105).

Delivery damper (guillotine) can be opened / closed from DCS / LPBS as desired and
selected from DCS remote / local selector switch provided the following permissives are
satisfied.
1. PA Fan I delivery damper motor ready.
2. PA Fan I delivery damper not tripped

PA Fan I delivery damper(Guillotine) shall be opened when both PA Fan-I and PA Fan-II
stopped & shall also be closed by initiation of interlock when PA Fan-I is stopped/tripped
and PA Fan-II running.

PA Fan I delivery damper (Guillotine) shall not be opened, when motor ready feedback is
not satisfied (or) TOLR is actuated (or) Open limit switch is actuated (or) Open torque
switch is actuated (or) PA Fan-I and PA Fan-II are not stopped.

PA Fan I delivery damper (Guillotine) shall not be closed, when motor ready feedback is
not satisfied (or) TOLR is actuated (or) Close limit switch is actuated (or) Close torque
switch is actuated (or) PA Fan-I is not stopped/tripped and PA Fan-II not running

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This write-up is applicable for PA Fan II delivery damper (Guillotine) (Drawing No.
BG129-00-09-3-106)

Interlock for ID fanI Suction damper (guillotine) (Drawing No. BG129-00-09-3-107).

Suction damper (guillotine) can be opened / closed from DCS / LPBS as desired and
selected from DCS remote / local selector switch provided the following permissive are
satisfied.
1. ID Fan I suction damper motor ready.
2. ID Fan I suction damper not tripped.

ID Fan I suction damper(Guillotine) shall also be opened when ID Fan-I running & it shall
also be closed by initiation of interlock when ID Fan-I stopped/tripped.

ID Fan I suction damper(Guillotine) shall be tripped, when motor ready feedback is not
satisfied (or) TOLR is actuated (or) Open limit switch is actuated (or) Close limit switch is
actuated (or) Open torque switch is actuated (or) Close torque switch is actuated.
This write-up is applicable for
ID Fan II suction damper (Guillotine) (Drawing No. BG129-00-09-3-108)

Interlock for ID fan-I suction damper (13RPC12A) (Drawing No. BG129-00-09-3-109).

ID fan-I suction damper shall be opened from DCS (or) when ID fan-I and ID fan-II is
stopped.
ID fan-I suction damper shall be closed from the DCS (or) when ID fan-I stopped and ID
fan-II is running.
The open and close feed back indication of suction damper will be available in DCS
through limit switches 13ZSC12A.

This similar write up is applicable for

i) ID FAN-II SUCTION DAMPER (13RPC12B)
(Refer drawing No. BG129-00-09-3-110).
ii) SA FAN-I SUCTION DAMPER (13RPC02A)
(Refer drawing No. BG129-00-09-3-111).
iii) SA FAN-II SUCTION DAMPER (13RPC02B)
(Refer drawing No. BG129-00-09-3-112).

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iv) PA FAN-I SUCTION DAMPER (13RPC01A)

(Refer drawing No. BG129-00-09-3-113).
v) PA FAN-II SUCTION DAMPER (13RPC01B)
(Refer drawing No. BG129-00-09-3-114).

Interlock for ON /OFF PCD at knife edge gate-1 (14SOV01) (Drawing No. BG129-00-
09-3-115).
Knife edge gate valve shall be opened / closed manually from the DCS.
Knife edge gate valve shall be closed by initiation of interlock, when the temperature at
feeder outlet is sensed high.
The open and close feed back indication of 14PCD01 will be available in DCS through reed
switches 14ZSC01 & 14ZSO01.

This similar write up is applicable for KNIFE EDGE GATE-II SOLENOID VALVE
(14SOV02)
(Refer drawing No. BG129-00-09-3-116).

Bed Ash Cooler-I On / OFF valve (01SOV01 & 02SOV11)

(Drawing No. BG129-00-09-3-117).

During the normal operation and when the bed ash temperature is below the set point and
the boiler load is below 50%, the service air solenoid (02SOV11) is in operation.
The Cooling water SOV (01SOV01) opens on initiation of interlock when bed ash
temperature (07TE05) reaches above the set point & when the steam flow signal is greater
than 50% of load. It closes when the temperature reduces below the set point & the steam
flow signal reduces less than 50% of load.
Service air SOV(02SOV11) is open when cooling water SOV (01SOV01) is closed and
viceversa.
Service air SOV (02SOV11) & Cooling water SOV (01SOV01) can also be opened / closed
manually from the DCS.
This similar write up is applicable for BED ASH COOLER-II SOLENOID VALVES
(01SOV02) and(02SOV12) with (07TE10)(Refer drawing No. BG129-00-09-3-118).

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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 step-
by-step details of operating the CETHAR CFBC boiler.

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START-UP SEQUENCE

CHECK ALL AIR FLOW DAMPERS

START SEAL POT (LOOP SEAL) BLOWER

START SECONDARY AIR FAN

START PRIMARY AIR FAN

START INDUCED DRAFT 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.

7. Check that the steam drum water level indication in DCS and compare
accurately with the direct water level glass reading.

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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 and dolochar/coal) must be available.

17. Ensure availability of adequate bed material as per the recommended

specification.

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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.

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.

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START UP / COOLING CURVE FOR CFBC BOILER

100.0

90.0

80.0

70.0
(g)
DRUM PRESSURE IN kg/cm

AFTER REFRACTORY
2

SUBSEQUENT START APPLICATION

60.0 (COLD) (COLD)

50.0

40.0

30.0

20.0

10.0

0.0
0 1 2 3 4 5 6 7 8 9 10
TIME IN hours

START UP CURVE
FIG-10

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:

Open boiler Direct Water Level Gauge (DWLG) root valves, and level transmitter
isolation valves.

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Verify boiler direct water level gauge (DWLG) and its water column drain valves are
closed.

Open boiler steam drum vent valves.

Open the saturated steam vent valves.

Close the economiser inlet header drain valves.

Close all boiler drain valves.

Open all super heater vent valves.

Drain any condensate from the superheaters by opening the superheater drain
valves.

Drain any condensate from the main steam line by opening the main steam line
drain valves.

Open the startup vent motorised isolation valve.

Adjust the startup vent control valve to its minimum open position.

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.

Close fill line isolation valve when the water level is seen in steam drum DWLG.

Drain steam drum DWLG.

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Verify water level returns to the steam drum water level gauge about where it was
before draining.

Verify level seen in direct water level gauge corresponds with remote indication in
DCS

Open the fill-line isolation valve and slowly raise the water level in the steam drum.

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-than-
normal steam drum water level (-250 mm) during startup.

Check boiler steam drum doors and external valves, fittings and connections for
leaks. Any leaks found must be corrected before proceeding with the startup.

10.2.2 Starting the Fans and Adjusting Air Flows

The following steps are used to start the ID, SA, PA fans and the seal pot (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. ID fan-I / ID fan-II
b. Seal pot (Loop seal) blower
c. SA fan-I / SA fan-II
d. PA fan-I / PA fan-II
e. Adjust air flows, as required.

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a) Starting the Induced Draft (ID) Fans

Common procedure for ID fan-I and ID fan-II:

1. Place O2 trim controller at 50 percent and leave in manual mode.

2. Place ID fans 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 fans.
5. Verify bearing temperatures are normal.
6. Initiate a start command to the ID fans.
7. Verify ID fans are started and check for any abnormal vibration, electrical indications
and temperatures are normal.
8. Leave Furnace Pressure controller in manual mode at minimum.

Note : ID fan-II to be started after starting the ID fan-I

b) Starting the Seal Pot (loop seal) Blower.

1. Open seal pot (loop seal) air valves to the ash transfer line to the bed ash coolers.
2. Verify seal pot (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 seal pot
(loop seal) material fluidisation (circulation) by startup engineers.

3. Verify ID fan-I / ID fan-II are running.

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

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Note: Seal pot (loop seal) blower-II is started automatically when Seal pot (loop seal)
blower-I running & its pressure is low.

c) Starting the Secondary Air (SA) Fans

Common procedure for SA fan-I and SA fan-II:

1. Place the SA fans 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 manual dampers.
5. Open and adjust the fuel feeder pressurisation SA damper to about 30 percent
open.
6. Verify the seal pot (loop seal) blower is running.
7. Check combustor pressure.
8. Verify no stop signal is present on the SA fan.

9. Verify bearing temperatures are normal.

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 29 TPH.

Note : SA fan-II to be started after starting the SA fan-I

d) Starting the Primary Air (PA) Fan

Common procedure for PA fan-I and PA fan-II:

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.

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4. Verify no stop signal is present on PA fan.

5. Verify bearing temperatures are normal.
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 32 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.

Note : PA fan-II to be started after starting the PA fan-I

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.

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.

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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 1680kg/m3, the initial quantity of material
required is 11230 Kg.

Bed material distribution:

100% less than - 600 microns

75% less than - 250 microns

50% less than - 180 microns

25% less than - 130 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.

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

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.
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-I / ID fan-II running
Seal pot (loop seal) blower is running.
SA fan-I / SA fan-II running.
PA fan-I / PA fan-II 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)
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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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

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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.

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 10 0C 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.

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 seal pot (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.

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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.

10. Start the second fuel feeder

Note: 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.

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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.

Adjust bed pressure controls as necessary to maintain normal bed
pressure.

Verify seal pot (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.

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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.

b. De- super heaters

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)

2. Check rotating equipment (motors, fans, fuel feeders, ash discharge feeder etc.) for
proper lubrication, temperature and vibration levels.

3. Check hanger supports, boiler guides and buck stay corner links etc., as per the
attached expansion movement G.A diagram in volume - IX for signs of expansion
problems that could put unusual stress on boiler components.

4. Check steam drum water level gauges to ensure the level matching with control
room indications.

5. Inspect air and flue gas ducting and boiler casings for hot spots, discolouration, flue
gas leakage and structural deformation.

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6. Check the boiler for abnormal noise or vibrations. Early detection of a problem could
reduce down time.

7. Check indicated settings of dampers and corresponding manually adjusted air flows.

8. Look for bed material and ash leakage.

9. Check valves and piping for any leakage at flanges and valve stems. Investigate any
standing pool of water or oil.

10. Ensure burner area clean.

11. 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 feeders.

8. Place steam drum water level controller in manual, as necessary.

Note: 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.

9. Maintain steam drum water level near the upper limit of the steam drum gauge glass
visibility during shutdown.

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10. Continue fluidising the bed to cool the boiler at a maximum cooling rate of 150 oC / 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 seal pot (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.
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.

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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 O 2 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.

11.3 Unplanned Shutdown

When the boiler is tripped from a load above minimum, where fans also stop, slumping the
bed, the boiler can:

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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.

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 760 oC, 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.
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.

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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 / litre 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.
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 CVPLs 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.

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.

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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 are 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.

12. For alkali boil-out sodium carbonate and trisodium phosphate are used.

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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/cm 2(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:

a) pH value
b) Alkalinity
c) Phosphate
d) Oil
e) Silica

19. 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.

7. Required target plates are to be machined and kept ready to fix when required. Target
plates shall be of aluminum material.

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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.

Operational Precautions

4. 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.

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5. 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.

6. Flue gas temperature at the inlet of convection (back pass) superheater must be
restricted to 450C.

7. 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.

8. Discharge piping should be so diverted that personnel and equipments are not
endangered. The area should be cordoned off.

9. After three free blows, target plate can be fixed.

10. Based on target plate condition as recommended by the turbine supplier blow can be
continued or terminated.

11. 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.

12. 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.

13. 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.

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.

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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.

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 r
elated systems. A combustible gas detector should be used to confirm a safe
atmosphere.

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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.

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.

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Do not operate a CFBC boiler without properly calibrated O 2 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.

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.

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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-IX

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.

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)
ases 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

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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 seal pot (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 1000 oC. 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.

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.

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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
repairs made when possible.

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.

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 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.

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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
found, report it and have repairs made when possible.

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.
17.4 Loss of Bed Inventory from Circulation

1. Check for proper and normal fluidising air flow to all seal pot (loop seal) fluidising
nozzles. If the float inside the rotameter is stuck on the bottom of the glass, it is an I
ndication 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 seal
pot (loop seal) blower. Verify that seal pot (loop seal) blower inlet filter is not
plugged. If a problem is found, report it and have repairs made when possible.

3. Check for normal indications of bed inventory.

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4. Check for normal operation of all fans. Check air flow indications. If a problem is
found, report it and have repairs made when possible.

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
repairs made when possible.

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.

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.

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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.

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.

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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 Seal pot (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.

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.

Seal pot (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 seal pot (loop seal) air pressure.

Check seal pot (loop seal) air flow rate to nozzles.

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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.

17.6.6 Loss of Fluidising Air to Seal Pot (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 seal pot (loop seal) blower. Based on
operating experience, when there is difficulty of refluidising the bed material in the seal pot
(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 Seal pot (loop seal) blower.

Observe all seal pot (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 seal pot (loop seal) downcomer temperature. This should follow bed temperature
closely. If this does not follow bed temperature, then use service air on the seal pot (loop
seal) nozzles provided at side walls in down leg and lift leg in an attempt to refluidise the
seal pot (loop seal).

Observe seal pot (loop seal) downcomer temperature. This should follow bed temperature
closely. If this does not follow bed temperature, then use service air on the seal pot (loop

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seal) nozzles provided at side walls in down leg and lift leg in an attempt to refluidise the
seal pot (loop seal).
If bed pressure drops rapidly during a load increase or earlier, then apply the same
technique of using service air until the seal pot (loop seal) chocking is cleared.
If this approach does not work, then it will be necessary to shutdown the boiler and empty
the seal pot (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
available. all 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. all the way.

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

Ensure local drum level gauges are reading transmitter isolation valves.

the same as remote (DCS) level indicator. Fill water to 1/3rd of steam drum level
gauge or -100mm of NWL. Verify level
in DCS.

Place de-aerator and boiler feed pump

ready for start-up.

18.1.2 Starting ID Fan

Operator Checks Operator Actions
Ensure clearance obtained from mechanical, Place inlet damper closed and
electrical and instrument department for initial controls in manual.
running of the equipment. Interlocks ready for ID fan start.
Instrumentation in place and operational Start ID fan. Verify fan motor roll.
Fan damper closed, coupled and read to Place the ID fan draft pressure
start. controller in manual.
Check combustor draft when starting ID Adjust combustor pressure controller
Fan as needed

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18.1.3 Starting Seal Pot (Loop Seal) Blower

Operator Checks Operator Actions

Ensure clearance obtained from Check the Interlocks are satisfied prior, to
mechanical, electrical and instrument Seal pot (loop seal) blower fan start.
department for initial running of the Start seal pot (loop seal) blower fan.
equipment. Verify fan 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.

18.1.4 Starting SA Fan

Operator Checks Operator Actions

Ensure clearance obtained from Place inlet damper closed and controls
mechanical, electrical and instrument in manual.
department for initial running of the Interlocks ready for SA fan start.
equipment.
Start SA fan. Verify fan motor roll.
Instrumentation in place and operational.
Place SA flow controllers in automatic
Fan closed, coupled and ready to start. when minimum flows are met.
Check combustor draft when starting SA Adjust combustor pressure controller as
Fan. needed.

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18.1.5 Starting PA Fan

Operator Checks Operator Actions
Ensure clearance obtained from Place inlet damper closed and controls
mechanical, electrical and instrument in manual.
department for initial running of the Interlock ready for PA fan start.
equipment.
Start PA fan. Verify fan motor roll.
Instrumentation in place and operational
Monitor combustor draft and adjust
Fan closed, coupled and ready to start. controller as necessary
Check combustor draft when starting PA Place PA flow and controls in
fan automatic.

Place ID fan in auto.

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 and maintaining minimum

Verify SA fan Flow control and air flows flow.

are normal and in automatic. Initiate a 5-minute boiler purge when

Verify PA Flow control and flows are main interlocks are ready.

normal and in automatic Observe the purge complete indication

Verify total air flow is greater than (DCS)

minimum necessary for purge. Monitor all air flows during boiler purge.

Monitor all boiler trip conditions in

preparation for combustor ready signal.

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18.1.7 Adding Bed Material

Operator Checks Operator Actions
System in place for adding bed material Start adding bed material to combustion

Verify all fans are running at minimum air chamber

settings Monitor feeding of bed material

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.

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 Adequate fuel supply available for
off boiler, flues and ducts. startup
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.

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18.2 Cold Startup

18.2.1 Starting of Start-up Burner
Operator Checks Operator Actions
Complete all pre-firing Check that startup burners are coupled and in the
operations. Ensure all retract position.
prerequisites are satisfied. Complete boiler purge requirements.
Open all manual fuel shut- Start the first startup burner at minimum firing rate and
off valves visually check condition of flame.
Verify interlocks satisfied. Start the other burner at minimum firing rate and
Verify all instruments are visually check condition of flame.
working properly. Fire startup burners to get to 600oC bed temperature.

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 Operator Actions
Monitor rate of change in flue Close drum vents and SH vents at
gas temperatures and boiler 2Kg/cm(g) drum pressure
pressure Blow down steam drum to maintain normal
Monitor actual hourly changes drum water level.
in boiler temperature and Place feed water and drum level controls in
pressure. automatic when steam flow is indicated.
Monitor startup burner Control firing rate to less than 150 o C / hr at
operations. hot cyclone separator inlet temperature change.
Monitor seal pot (loop seal) At 7 kg/cm(g) drum pressure, throttle SH
return leg temperatures for drains. Keep them cracked open.
differences.
Add feed water to the drum only if it is
Place Electrostatic precipitator essential until over 14 kg/cm (g). Blow down to
in service as required. 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
ready for normal operation with fuel on per the start-up curve.
the drag chain feeders. Open solid fuel feeder silo isolation
Monitor startup burners valves and drag chain feeder

Start bed ash removal system pressurization valves.

when needed. Start the first solid fuel feeder in

Continuously monitor bed manual at minimum. Pulse-feed the first

temperatures, bed pressure and seal solid fuel feeder three times.

pot (loop seal) return temperatures. 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 Operator Actions
Monitor boiler temperature profile. Place the controls in automatic as
Normal bed temperature 880-950oC necessary.

Maintain boiler steam flow within Place oxygen trim control in

rated limits. Do not Over fire! automatic when boiler load is stable

Monitor O2 level for excess air. and above 70%.

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 Operator Actions
Bed pressure and bed temperature Verify solid fuel size distribution by
indicating properly around the sampling as fired fuel.
combustion chamber Verify and change in solid fuel
Monitor bed ash removal operation for composition, i.e. Ash content.
any problems. Monitor bed ash drain Improper bed material can result in
temperatures. high bed temperatures, high or low bed
Monitor split between bed pressure and pressures, high or low hot cyclone
airbox pressure. 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

Monitor cooling water pressure and flow in continuous operation.

Check operation of bed ash discharge Always observe safety precautions

feeder. when around the bottom ash center
drains or ash conveying system.
Verify that isolation gate is not partially
closed. 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, minute to 760oC indicated bed

boiler pressure and rates of change. temperature.

Monitor boiler temperature profile. 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 Seal Pot (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 If entering boiler, keep fans running to
fly ash and bottom ash hoppers. 35oC indicated bed temperature.

Maintain proper cooling rates with air

flows

Remove bed material if rapid cool-down

is desired

Leave water in boiler for quicker cool-

down

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.

during cool-down. At 1.5 kg/cm pressure. Open drum and

Check position of spring hangers superheat vents all the way.

around the boiler. If bottling up the boiler, keep drum pressure

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 / seal pot (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.

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