Morupule B

Initial Assessment
of Boiler O & M
09 September 2013

AGENDA
INTRODUCTION
OPERATIONAL PHILISOPHY OF CFB BOILER WITH A OPEARTING MODEL
COMPARISON OF FEW DATA WITH EFFICIENT OPERATING PLANT
ASSESMENT OF MORUPULE B , BOILERS
EROSION IN CFB
OPERATIONAL READINESS & TRAINING NEED

INTRODUCTION Safety Share

SAFETY FIRST

Safety is a real concern at Morupule

B plant

No safety Guard on Ladder- Trip

hazard

Uneven gap between two stairs in

Boiler House Stair case, possibility of
trip hazards is high

Coal dust everywhere in Coal plant

Fire Hazard

OPERATIONAL PHILOSOPHY OF CFB

The system comprises of membrane water-cooled CFB combustor, high efficiency
hot cyclone separator, refractory lined solid circulation conduits, non-mechanical loop
seals and Superheater, Evaporator convective heat transfer surfaces located
downstream of the hot cyclone separator, called as FBHE or INTREX.
In specific cases, specially designed super heaters and / or evaporators are located
in the CFB combustor.
Fluidisation in the combustor is in fast-bed regime, with fluidizing velocity lying in the
region of 4.5 5 m/sec.
Since the plate type cyclones handle flue gas and solids at temperatures up to about
950 deg. C, the refractory lining for the cyclones are in multiple layers, designed for
abrasion resistance and heat insulation. Solids in the loop seal are fluidised by highpressure air.
By virtue of the difference in static head between the down comer and riser sections
of the loop seal , solids captured by the cyclone are recycled back to the CFB
combustor without any mechanical assistance / control equipment.
Fuel feed is through the membrane walls in the lower combustor.

OPERATIONAL PHILOSOPHY OF CFB

Solid recycle through the non-mechanical loop seals eliminates operation /
maintenance problems associated with J-valves valves, Seal Pot etc.
The cyclone separator captures particles greater than 70 microns for hot recycle
back to the CFB combustor. Only very fine particles, less than 70 microns, pass out
with flue gas to the convective heat transfer surfaces.
In view of this, the convective heat transfer surfaces do not encounter coarse
particles and are therefore, intrinsically protected against abrasion from coarse
particles.
This technology has experienced worldwide commercial success and has proven
record of high Combustion Efficiency, low unburnt carbon in Ash, efficient heat
transfer, trouble-free solid circulation, good emission control, wide fuel flexibility and
fast load response.
However, use of high quantum of refractory, associated maintenance of refractory,
high start-up time and maintenance of fabric type expansion joints (between
combustor and solid recycle devices) has sometimes been issues of concern.

OPERATIONAL PHILOSOPHY OF CFB

contd.

Video clip of CFB Operating Model

OPERATIONAL PHILOSOPHY OF CFB

contd.

How CFB works?

Video clip of a operating model

GOOD PRACTICE BOILER COMPARISON

PARAMETER

GOOD PRACTICE PLANT

(125MW)

MORUPULE B
(150 MW)

REMARKS

COLD START TIME TO 100%

TMCR (HR)

8~9

30 ~ 36

VERY LONG START TIMES

CBD OPENING (%)

NOT OPENED IF SILICA LEVEL

WITHIN LIMIT, MAY NEED
SOMETIMES

16 ~ 18 (OPENED
CONTINUOUSLY)

VERY HIGH WASTAGE

HIGH OPERATIONAL COST

LOWER BED TED TEMP.

(DEG C)

830 ~ 870

835 ~ 858

WITHIN LIMIT

CYCLONE INLET TEMP.

(DEG C)

860 ~ 900

855 ~ 872

TUNING OF BOILER NEEDED

CYCLONE OUT LET TEMP.

(DEG C)

900 ~ 950

838 ~ 862

TUNING OF BOILER NEEDED

UNBURNT CARBON IN FLY/

BOTTOM ASH (%)

1 ~ 2 / 0.2 ~ 0.5

6 ~ 7.5 / 2.3 ~ 6.5

VERY HIGH

MAKE UP WATER PER UNIT

(%)

1.2 ~ 1.5

NOT KNOWN
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Assessment of CFB at Morupule - B

1st generation CFB with Hot cyclone and FBHE
Very High Noise level & High Fan / Duct Vibration &
Failure
Higher Start up time
Higher Un-Burnt Carbon in Fly & Bottom Ash
High water consumptions due to high CBD (as high as
18%)
Frequent plugging of Ash discharge pipe from
combustor
Frequent Failure in FBHE
It goes without saying, all recommendations in this presentation to
be vetted by OEM and exercised (implemented) via appropriate EPC
contract (defects remedy) provisions. Similarly, engagement of the
O&M contractor to be carefully managed.

1st. Generation CFB HOT CYCLONE WITH FBHE

ADVANTAGE OF MORUPULE CFB BOILERS

FUEL FEED TO FRONT WALL WILL REDUCE THE CHANCE OF FAILURE OF

LOOP SEAL RETURN LEG EXPANSION JOINTS; UNLIKE OTHER BOILERS OF
SIMILAR DESIGN, WHERE FUEL IS FED TO LOOP SEAL

ISSUES:

MULTI LAYER REFRACTORY, HIGHER FAILURE FREQUENCY

SEVERAL CRACKS ON REFRACTORY SURFACE
RESTRICTED ACCESS TO FBHE, DIFFICULT FOR MAINTENANCE
FREQUENT FAILURE OF LOOP SEAL, CYCLONE INLET / OUTLET EXPANSION
JOINTS

RISK:

LOW AVAILIBILITY ON 1ST. ONE OR TWO YEARS

HIGHER COOLING / SHUT DOWN TIME
HIGH MAINTENANCE COST
TUBE FAILURE IF FAILED REFRACTORY NOT REPAIRED IN TIME
CEMENTING / CLINKER FORMATION IN THE EVENT OF TUBE LEAK IN FBHE /
COMBUSTOR

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1st. Generation CFB HOT CYCLONE WITH FBHE

PROPOSED RECOMMENDATION:
SHORT TERM
CRACK MAPPING OF ALL REFRACTORY SURFACE OF COMBUSTOR, FBHEs, CYCLONE; AT NEXT
EARLIEST OPPORTUNITY AND MONITOR ON EVERY SHUT DOWN
CLEAN ACCUMULATED BED MATERIALS BETWEEN REFRACTORY CRACKS AND FABRIC
EXPASION JOINTS BY AIR ON EVERY SHUT DOWN
REPAIR ANY CRACK MORE THAN ~10MM.
FOR FASTER COOLING DURING SHUT DOWN, KEEP ID FAN RUNNING AT MINIMUM, BACK PASS
ACCESS DOORS CAN BE OPENED WHILE FURNACE TEMPERATURE IS LESS THAN 300 DEG. C.
PROVIDE SAFETY BARRICADE SO THAT NO ONE CAN REACH NEAR THESE DOORS.
COMBUSTOR & CYCLONE DOORS CAN BE OPENED WHEN COMBUSTOR TEMPERATURE IS
LESS THAN 100 DEG. C, KEEPING ID FAN RUNNIG AT MINIMUM LOAD.
DO NOT ALLOW ANYONE TO ENTER INTO COMBUSTOR, BACK PASS, CYCLONE, LOOPSEAL,
FBHE UNTIL:

CYCLONE INLET AND OUTLET LEDGE HAS BEEN CLEANED

SYSTEM TEMPERATURE HAS REACHED AMBIENT
CONFINED SPACE ENTRY PERMIT IS AVAILABLE
OXYGEN LEVEL OF COFINED SPACE IS MORE THAN 20%

LONG TERM
REVIEW REFRACTORY AND ITS ANCHOR DESIGN
ADD 2 ~ 3 % SS NEEDLE WITH LOW CEMENT CASTABLE
LOW CEMENT CASTABLE INSTALLED IN 1M X 1M PANEL WITH EXPANSION PROVISION

11

VERY HIGH NOISE LEVEL & HIGH VIBRATION OF FANS & DUCT
ISSUE:

OUTRAGEOUS NOISE LEVEL

HIGH VIBRATION OF PA / SA FANS
DUCT DESIGN HAS SHARP BEND AT
THE DISCHARGE, HIGH TURBULENT
AIR FLOW
NO ROOT CAUSE ANALYSIS DONE
BY CNEEC

RISK:
HEALTH (HEARING DAMAGE) AND
SAFETY RISK
IMPACT ON DAY-TO-DAY
OPERATIONS OF PLANT
STRUCTURAL FAILURE OF DUCT
INSUFFICIENT AIR FLOW,
INEFFICIENT OPERATION OF BOILER

SHARP BEND IN FAN DISCHARGE DUCT

12

VERY HIGH NOISE LEVEL & HIGH VIBRATION OF FANS & DUCT
PROPOSED RECOMMENDATION:
SHORT TERM:

DO NOT TAKE OVER U #2 & #4 PRIOR TO RESOLUTION OF NOISE PROBLEM

(FANS AND DUCT)
CHECK FAN VIBRATION / DYNAMIC BALANCING OF FAN
CHECK FAN IMPELLER FOR ANY CRACKING
RECHECK ALIGNMET OF FAN AND MOTOR
INSTALL ACOUSTIC SOUND PROOF ENCLOSURE TO FAN; BEWARE, IMPROPER
DESIGN OF SUCH ENCLOSURE MAY INCREASE THE BEARING TEMPERATURE
OF FAN & MOTOR AND ALSO MAY INCREASE MOTOR WINDING TEMPERATURE

LONG TERM:

DO CFD (COMPUTATIONAL FLUID DYNAMICS) MODELLING OF FAN & DUCT

INSTALL DIVERSION PLATE (TURNING VANES) INSIDE THE DUCT IN STRATEGIC
LOCATION

13

HIGH START UP TIME

ISSUE

HIGH AND UNUSUAL DELAY IN START UP OF BOILER FROM COLD START

UP TO FULL LOAD (~36 HOURS TO ACHIEVE FULL LOAD).
TYPICALLY IT SHOULD NOT TAKE MORE THAN 9 HOURS (MAX). EVEN AS
PER CNEECS START UP CURVE IT SHOULD BE DONE BY 11 HOURS.
LONG TIME OPERATION WITH OIL, THUS HIGHER OIL CONSUMPTION
HIGH OPERATIONAL COST

REASON:

LOW CAPACITY OF BED MATERIALS SILO AND SYSTEM. SYSTEM

DESIGN FLAW
WRONG OPERATING SEQUENCE

14

HIGH START UP TIME

RECOMMENDATION:
SHORT TERM
OPTION - I

INVESTIGATE POSSIBILITY TO RENT SUCK

/ PUMPING TRUCK.
INSTALL Y CONNECTION ( WITH SS
BALL VALVE) ON SECONDARY AIR NOZZLE
AT STRATEGIC LOCATION NEAR
COMBUSTOR AND IN FBHE AT ACCESS
DOOR
PUMP IN BED MATERIALS IN COMBUSTOR
AND FBHE SIMULTANEOUSLY

OPTION II

FILL FBHE MANUALLY AS FAR AS

POSSIBLE BEFORE START UP

DURING START UP WHEN FEEDING BED
MATERIALS, START OPENING VALVE
BETWEEN LOOP SEAL AND FBHE BEFORE
~45% LOAD.

LONG TERM:
DESIGN AND INSTALL PIPE LINE FROM
BOTTOM ASH SILO TO BOILER (TO
CONNECT COMBUSTOR SA NOZZLES
Y CONNECTION).
AT FBHE DESIGN AND INSTALL 150 MM
PIPE NOZZLE TO CONNECT WITH
ABOVE PIPE

15

HIGH UNBURNT IN BOTTOM ASH & FLY ASH

ISSUE

HIGH UNBURNT CARBON IN BOTTOM ASH (AS HIGH AS 6.5 %) AS AGAINST 0.5%
(RECOMMENDED / GOOD PRACTICE).
MORUPULE BOILERS ARE SUPPLIED WITH BOTTOM ASH DRAIN SYSTEM, WHICH
IS AGAIN 1ST. GENERATION DESIGN AND UNBURNT IN BOTTOM ASH WILL ALWAYS
BE HIGHER
HIGH UNBURNT IN FLY ASH (AS HIGH AS 7.5%) AS AGAINST 2% (RECOMMENDED)

RISK

HIGHER COAL & LIMESTONE CONSUMPTION

INEFFICIENT BOILER OPERATION, OVERALL HEAT RATE PENALTY
HIGHER OPERATIONAL COST

16

HIGH UNBURNT IN BOTTOM ASH & FLY ASH

RECOMMENDATION
SHORT TERM:
TUNE THE BOILER OPERATING PARAMETERS
INCREASE BOILER UPPER TEMPERATURE
OPTIMISE OXYGEN LEVEL TO AROUND 3.5%
CHECK CYCLONE SOLID SEPARATION EFFICIENCY. THIS CAN BE DONE
COLLECTING SAMPLE FROM BOTTOM ASH, LOOP SEAL, ECONOMISER /
AIRHEATER/ FBHE / ESP HOPPERS, CHECK SIZE DISTRIBUTION OF ALL SAMPLES.
LONG TERM
IF CYCLONE SOLID SEPARATION EFFICIENCY IS NOT AS PER DESIGN, CYCLONE
DESIGN NEEDS TO BE IMPROVED BY CNEEC (DEFECT)
TO REDUCE UNBURNT IN BOTTOM ASH, IT IS HIGHLY RECOMMENDED TO
REPLACE BOTTOM ASH DRAINING SYSTEM WITH FLUIDISED BED ASH COOLERS /
STRIPPER COOLERS
REVIEW BUBBLE CAP GRID NOZZLE DESIGN OF COMBUSTOR AND REPLACE
THESE WITH BETTER DESIGN.
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HIGH WATER CONSUMPTION

ISSUE

PLANT WATER CONSUMPTION HIGHER THAN NORMAL

BOILER CONTINIOUS BLOW DOWN (CBD) IS OPENED ALL THE TIME

RISK

HIGH COST OF OPERATION

RECOMMENDATION

CLOSE CBD 100%. THIS SHOULD BE OPENED ONLY WHEN BOILER WATER
SILICA LEVEL, OR OTHER CONTAMINANTS ARE HIGH; AS ADVISED BY POWER
STATION CHEMIST
CHECK ALL DRAINS FOR ANY PASSING; AND FIX PASSING VALVES
IMMEDIATELY.

18

FREQUENT PLUGGING ASH DISCHARGE FROM COMBUSTOR

ISSUE

FREQUENT PLUGGING
LIMITS UNIT LOAD
HIGH UNBURNT CARBON IN BOTTOM ASH

RISK

COMBUSTOR BED PRESSURE INCREASES

MANUAL AIR LANCING / RODDING NEEDED TO
CLEAR PLUGGING IS A SAFETY HAZARD.

RECOMMENDATION

SHORT TERM:
INSTALL AIR CANON / AIR BLASTER
INSTALL METALLIC EXPASION JOINT BETWEEN
ASH COOLER AND ASH DISCHARGE PIPE

LONG TERM
REPLACE ASH COOLER WITH FLUID BED ASH
COOLERS / STRIPPER COOLERS

INSTALL AIR CANON / AIR BLASTER

19

FREQUENT FAILURE IN FBHE

IN ANY FBHE, FAILURE OF TUBES,
REFRACTORY, CEMENTING /
CLINKARISATION ARE COMMON ISSUES
ISSUE

FAILURE OF REFRACTORY DUE TO DESIGN &

APPLICATION OF REFRACTORY
EROSION OF TUBES
FREQUENT FAILURE OF TUBES

RISK

LOWER AVAILIBILTY OF UNIT

PRODUCTION LOSS
CEMENTING INSIDE FBHE
DAMAGING OF PRESSURE PART DURING
CLEANING (IF JACK HAMMER USED)
LONGER SHUT DOWN PERIOD

RECOMMENDATION
SHORT TERM:

START DRAINING OF BED MATERIALS AS MUCH AS

POSSIBLE IMMEDIATELY ON NOTICE OF TUBE
LEAK WHILE BOILER IN OPERATION
BARRICADE THE AREA WHERE HOT BED
MATERIALS ARE BEING DRAINED

TYPICAL ARRANGEMENT OF FBHE

20

FREQUENT FAILURE IN FBHE

RECOMMENDATION
SHORT TERM
REPLACE BOTH MANUAL VALVES
OF EACH LINE WITH ELECTRICAL
ACTUATOR OPERATION AND HOOK
UP THESE VALVE TO DCS
REPAIR REFRACTORY PROPERLY
WITH PROPER EXPANSION
PROVISSION
LONG TERM
AT PRESENT ALL DRAIN LINES ARE
CARBON STEEL, REPLACE THESE
LINE WITH SS PIPE.

REVIEW DESIGN AND LOOK FOR

POSSIBILITY TO REPLACE FBHEs
AND INSTALL RH & SH IN
COMBUSTOR

21

EROSION
EROSION OF PRESSURE PARTS IN
CFB IS A COMMON PROBLEM
CONCERNED AREA:

COMBUSTOR WATER WALLS

ABOVE REFRACTORY
ALL FOUR CORNERS OF
COMBUSTOR
CYCLONE INLET AND WHEREVER
GAS FLOW TURNS
AT BACK PASS : HANGER TUBES,
SH / RH /ECO BENDS AND TOP
BANKS
AT FBHE SH & RH

EROSION OF COMBUSTOR WATER

WALLS ABOVE REFRACTORY
22

EROSION (cont)
RECOMMENDATION

TUBE THICKNESS MAPPING OF

COMBUSTOR WATER WALLS UP TO A
HEIGHT OF 5M FROM REFRACTORY AT
EVERY 200MM DISTANCE. MONITOR
ANNUALLY.
TUBE THICKNESS MAPPING AT THE
ENTRY OF CYCLONE
ALL BENDS OF SH, RH, ECO AT
BACKPASS
INSTALL PROPERLY DESIGNED EROSION
PROTECTION SHIELD ON HANGER
TUBES, TOP BANKS OF SH, RH, ECO IN
BACKPASS (SEE PIC 1, DAMAGE OF
EROSION SHIELD AS NO PROVISION OF
THERMAL EXPANSION)
INSTALL EROSION SHIELD ON SH / RH IN
FBHE SHOWN IN THE PICTURE
23

EROSION
RECOMMENDATION (cont)

AFTER A FEW YEARS OF

OPERATION, WHEN TUBE
THICKNESS ABOVE REFRACTORY
REDUCES, REPLACE WATER
WALLS WITH NEW KICK OUT
DESIGN

24

OPERATIONAL READINESS & TRAINING

ISSUE
CFB TECHNOLOGY NEW TO BPC
INADEQUATE O&M MANUALS SUPPLIED BY BOILER VENDOR
INADEQUATE BPC OPERATION OR MAINTENANCE STAFF INVOLVED DURING
PRE- AND COMMISSIONING
NO KNOWLEDGE TRANSFER FROM CNEEC; MAINLY BECAUSE OF LANGUAGE
DIFFICULTIES AND WORKING RELATIONSHIP
NO SUFFICIENT MANPOWER IN BPC, MORUPULE B TO OPERATE & MAINTAIN
THE PLANT
NO RESOURCE PLANNING
RISK
HIGH OPERATIONAL COST (THROUGH O&M AGREEMENT)
100% DEPENDANCY ON CNEEC
DAY-TO-DAY O&M PHILOSOPHY / EXECUTION CURRENTLY VESTED IN
CONTRACTOR, SHOULD BE DRIVEN BY PLANT OWNER (WHOSE INTERESTS
ARE ALIGNED WITH A 25 YEAR LIFE)

25

OPERATIONAL READINESS & TRAINING

RECOMMENDATION
SHORT TERM

PRESENT OPERATION & MAINTENANCE TEAM MUST INVOLVE ITSELF WITH DAY TO DAY
BOILER OPERATION & MAINTENANCE ISSUES
O & M TEAM MUST WALKDOWN BOILER TWICE IN A SHIFT
ENSURE OPERATION TEAM IN CONTROL ROOM TO START LOGGING ALL PARAMETER
MANUALLY IN A LOG BOOK ON HOURLY BASIS
AS NO SIMULATOR IS AVAILABLE, MONITORS OF NON-OPERATING UNIT CAN BE USED AS
SIMULATOR, ISOLATING / RACKING OUT MCC PANEL OR PULLING OUT POWER FUSES, ETC
PREPARE COLOUR DRAWING / PROCESS FLOW DIAGRAM FOR EVERY SYSTEM AND
DISPLAY ON WALL OF CONTROL ROOM

LONG TERM

RECRUIT QUALIFIED OPERATORS AND MAINTENANCE TEAM ASAP

PREPARE GOOD O & M MANUAL BY THIRD PARTY WHO HAS GOOD EXPERIENCE ON SIMILAR
DESIGN CFB
TRAIN & ASSESS ALL OPERATION AND MAINTENANCE TEAM BY EXPERIENCED
CONSULTANT FOR CLASSROOM TRAINING
CONDUCT ON-THE-JOB TRAINING FOR ALL OPERATION & MAINTENANCE TEAM
ORGANISE SECONDMENT / TRAINING AT SIMILAR DESIGNED GOOD RUNNING PLANT
26

Q&A
ANY QUESTIONS?

Working at heights?

27