BLR Manual - All - R1 PDF

San Miguel Consolidated Power Corporation
Reheat Type Coal Fired CFB Boiler

Malita, Davao Del Sur, Philippines
(2) 150 MW CFB Units
Utility Boiler
Contract No. MPP-130108-01/02/03
Design and Operation Manual
Circulating Fluidized Bed Steam Generator

Instruction Manual
Supplied by:
Formosa Heavy Industries Corp.
Consisting of:
Design and Operation Manual
Maintenance Manuals
Proprietary Notice:
This manual contains proprietary data of FHI.

No disclosure, reproduction, or use of any part
May be made without written permission of FHI.
Date of Issue: August 2015

CFB BOILER DESIGN AND OPERATION MANUAL
CAUTION: Before performing any procedures, users of this

manual must read all information contained in the Instructions
to User in Part 1 of Volume 1.
GENERAL NOTE: This instruction manual has been prepared

to serve as a guide in operation and maintaining the specific
equipment for which it was issued. It is not intended to cover
all possible variations in equipment, nor to provide solutions to
specific problems which may arise. Should additional
information be required, this company or our field
representatives should be contacted.
It must be recognized that no amount of written instruction can
replace intelligent thinking and reasoning be equipment
operators and maintenance personnel, especially under
unforeseen conditions. It is the responsibility of the equipment
operators or maintenance personnel to become thoroughly
familiar with the specific equipment covered in this manual,
along with the pertinent control and auxiliary equipment, to
ensure proper functioning, satisfactory performance and
personnel safety.
Maintenance, operation, and performance of any equipment not
specifically covered in this manual is the sole responsibility of
the plant maintenance and operating personnel.
CFB BOILER OPERATION MANUAL
PART 1 - INTRODUCTION
TABLE OF CONTENTS
TITLE SECTION
INSTRUCTION TO USER .............................................................................................................. 1

DESIGN AND OPERATION MANUAL ALPHABETICAL INDEX ................................................... 2
DESIGN AND OPERATION MANUAL AMENDMENT RECORD SHEET ...................................... 3
1-0-1
SECTION 1 - INSTRUCTIONS TO USER
TABLE OF CONTENTS
TITLE PAGE NO.
GENERAL NOTICE .......................................................................................................... 1-1-1
USE OF WARNINGS, CAUTIONS, AND NOTES ............................................................. 1-1-2
MANUAL ORGANIZATION ............................................................................................... 1-1-3

Design and Operation Manual .................................................................................... 1-1-3
Maintenance and Vendor Manual ............................................................................... 1-1-3
CONVERSION FACTORS ................................................................................................ 1-1-4

Length........................................................................................................................... 1-1-4
Area............................................................................................................................... 1-1-4
Volume .......................................................................................................................... 1-1-4
Temperature ................................................................................................................. 1-1-4
Weight........................................................................................................................... 1-1-4
Density.......................................................................................................................... 1-1-5
Pressure ....................................................................................................................... 1-1-5
Flow Rates ................................................................................................................... 1-1-5
Concentration .............................................................................................................. 1-1-5
Velocity ......................................................................................................................... 1-1-6
Heat ............................................................................................................................... 1-1-6
Power ............................................................................................................................ 1-1-6
Torque........................................................................................................................... 1-1-6
Miscellaneous .............................................................................................................. 1-1-6
AMENDMENT RECORD SHEET...................................................................................... 1-1-7
1-1-i
INSTRUCTIONS TO USER
CAUTION: Before performing any procedures, us-

ers of this manual must read all information con-
tained in the following paragraphs.
GENERAL
NOTICE
This instruction manual has been prepared to serve as a
guide in operating and maintaining the specific equip-
ment for which it was issued. It is not intended to cover
all possible variations in equipment, nor to provide solu-
tions to specific problems which may arise. Should addi-
tional information be required, Formosa Heavy Industries,
or its field representatives should be contacted.
It must be recognized that no amount of written instruc-

tion can replace intelligent thinking and reasoning by
equipment operators and maintenance personnel, espe-
cially under unforeseen conditions. It is the responsibility
of the equipment operators or maintenance personnel to
become thoroughly familiar with the specific equipment
covered in this manual, along with the pertinent control
and auxiliary equipment, to ensure proper functioning,
satisfactory performance and personnel safety.
Maintenance, operation, and performance of any equip-

ment not specifically covered in this manual is the sole
responsibility of the plant maintenance and operating
personnel.
1-1-1
USE OF
WARNINGS,
CAUTIONS,
AND NOTES
This publication includes WARNINGS, CAUTIONS and
NOTES at appropriate locations to point out safety relat-
ed or other important information.
WARNING: An operating or maintenance procedure

or practice which, if not strictly observed, can result
in personal injury or death.
CAUTION: An operating or maintenance procedure

or practice which, if not strictly observed, can result
in damage to or destruction of equipment, or signifi-
cant loss of safety functions.
NOTE: An operating or maintenance procedure or

practice which should be highlighted.
Although the WARNING hazards are related to personal

injury, and the CAUTION hazards are associated with
equipment or property damage, it should be understood
that operation of damaged equipment could, under cer-
tain operational conditions, result in degraded system
performance or a loss of safety function, leading to per-
sonal injury or death. Therefore, plant operation and
maintenance personnel must fully comply with all
WARNING and CAUTION notices.
1-1-2
CFB BOILER DESIGN OPERATION MANUAL
MANUAL
ORGANIZATION
Design and
Operation
Manual
This manual covers the design and operation of the For-
mosa Heavy Industries manufactured products. When
necessary, reference has been made to the general op-
eration of specific vendor supplied auxiliary equipment.
Information in the Design and Operation Manual is bro-
ken down into sections covering the general systems
which make up the steam generator. Each section is then
divided into tabs covering specific pieces of equipment or
subsystems.
Maintenance
and Vendor
Manual
This manual covers the maintenance of the Formosa
Heavy Industries manufactured products as well as de-
sign, operation and maintenance information supplied by
the vendors for their equipment. Information in this man-
ual is broken down into sections covering the general
systems which make up the steam generator. Each sec-
tion is then divided into tabs covering specific pieces of
equipment or subsystems. Every attempt has been
made to make these sections and tabs correspond to
those in the Design and Operation Manual.
In some cases, when a vendor, such as a valve manufac-

turer, has equipment in more than one system, the asso-
ciated vendor information may only appear in one section.
1-1-3
CONVERSION
FACTORS
The following conversions factors, which generally apply
to the design, operation, and maintenance of steam gen-
erating equipment have been provided as a convenience
to the users of this manual.
Length
1 ft = 0.3048 m 1 m = 3.281 ft
1 in. = 25.4 mm 1 mm = 0.03937 in.
1 µm = 39.37 x 10-6 in.
Area
1 ft2 = 0.0929 m2 1 m2 = 10.76 ft2
Volume
1 ft3 = 0.0283 m3 1 m3 = 35.314 ft3
1 ft3 = 28.32 L 1 L = 0.0351 ft3
1 gal = 3.785 L 1 L = 0.2642 gal
1 in3 =16.39 cm3 1 cm3 = 0.0610 in3
Temperature
t°F = 1.8 t°C + 32 t°C = 5/9 (t°F - 32)
Weight
1 lb = 0.4536 kg 1 kg = 2.2046 lb
1 lb = 4.536 x 10-4 metric ton 1 metric ton = 2204.6 lb
1 U.S. ton = 1 metric ton =
0.9072 metric ton 1.1023 U.S. ton
1-1-4
Density
1 lb/ft3 = 16.02 kg/m3 1 kg/m3 = 0.0624 lb/ft3
1 ft3/lb = 0.0624 m3/kg 1 m3/kg = 16.02 ft3/lb
1 ft3/lb = 62.43 L/kg 1 L/kg = 0.01602 ft3/lb
Pressure
1 psi = 0.0703 kg/cm2 1 kg/cm2 = 14.223 psi
1 lb/ft2 = 4.882 kg/m2 1 kg/m2 = 0.2048 lb/ft2
1 atm = 14.696 psi 1 psi = 0.0680 atm
1 atm = 406.8 in. w.g.
1 psi = 6.895 kPa 1 kPa = 0.145 psi
1 MPa = 145 psi
1 in. w.g. = 0.249 kPa 1 kPa = 4.016 in. w.g.
1 in. Hg = 3.377 kPa 1 kPa = 0.296 in. Hg
1 mm Hg = 0.1333 kPa 1 kPa = 7.502 mm Hg
1 psi = 0.0689 bar 1 bar = 14.50 psi
1 bar = 401.4 in. w.g.
Flow Rates
1 lb/hr = 1 metric ton/hr =
4.536 x l0-4 metric tons/hr 2205 lb/hr
1 lb/hr = 0.4536 kg/hr 1 kg/hr = 2.205 lb/hr
1 lb/hr-ft2 = 1 kg/sec-m2 =
0.00136 kg/sec-m2 737 lb/hr-ft2
1 ft3/min = 1 m3/sec =
4.72 x l0-4 m3/sec 2119 ft3/min
1 ft3/sec = 0.0283 m3/sec 1m3/sec = 35.314 ft3/sec
1 gal/min = 0.227 m3/hr 1 m3/hr = 4.40 gal/min
Concentration
1 lb/(106 Btu) = 1 kg/(106 kcal) =
1.8 kg/(106 kcal) 0.556 lb/(106 Btu)
1 grain/ft3 = 2.29 g/m3 1 g/m3 = 0.437 grain/ft3
1-1-5
Velocity
1 ft/sec = 0.3048 m/sec 1 m/sec = 3.28 ft/sec
1 ft/min = 0.00508 m/sec 1 m/sec = 196.85 ft/min
Heat
1 Btu = 0.252 kcal 1 kcal = 3.97 Btu
1 Btu/lb = 0.556 kcal/kg 1 kcal/kg = 1.80 Btu/lb
1 Btu/lb-°F = 1 kcal/kg-°C 1 kcal/kg-°C = 1 Btu/lb-°F
1 Btu/hr = 0.252 kcal/hr 1 kcal/hr = 3.97 Btu/hr
1 Btu/hr-ft2 = 1 kcal/hr-m2 =
2.712 kcal/hr-m2 0.369 Btu/hr-ft2
1 Btu/hr-ft3 = 1 kcal/hr-m3 =
8.89 kcal/hr-m3 0.112 Btu/hr-ft3
1 Btu/hr-ft2-°F = 1 kcal/hr-m2-°C =
4.89 kcal/hr-m2-°C 0.204 Btu/hr-ft2-°F
1 Btu = 1.055 kJ 1 kJ = 0.948 Btu
1 Btu/lb = 2.326 kJ/kg 1 kJ/kg = 0.430 Btu/lb
1 Btu/lb-°F = 1 kJ/kg-°C =
4.19 kJ/kg-°C 0.239 Btu/lb-°F
1 Btu/hr-ft2 = 3.154 W/m2 1 W/m2 = 0.317 Btu/hr-ft2
1 Btu/hr-ft3 = 1 W/m3 =
10.353 W/m3-ft3 0.0966 Btu/hr-ft3
1 Btu/hr-ft2-°F = 1 W/m2-°C =
5.678 W/m2-°C 0.176 Btu/hr-ft2-°F
Power
1 hp = 0.746 kW 1 kW = 1.341 hp
1 Btu/hr = 0.293 W 1 W = 3.413 Btu/hr
Torque
1 ft-lb = 0.138255 kgf-m 1 kg-m = 7.233011 ft-lb
1 ft-lb = 1.355818 N-m 1 N-m = 0.737562 ft-lb
Miscellaneous
1 ft2/1000 cfm = 1 m2/m3/sec =
0.197 m2/m3/sec 5.08 ft2/1000 cfm
1-1-6
AMENDMENT
RECORD
SHEET
The Instruction Manual Amendment Record Sheet locat-
ed in Part 1, Section 3 of the Design and Operation con-
tains a complete listing of those items that have been
added to, or have replaced information in the respective
manual. Upon initial issue of these manuals, the lists
may contain items which were not included because they
were not available at the time of delivery. However, their
delivery is anticipated and appropriate locations have
been provided for them in the manual as indicated in the
index. When they are shipped, the shipment date will be
added to the amendment record sheet, and a new sheet
will accompany the delivery.
Whenever additional or revised information is added to

the manuals, a new record sheet will be issued. As
shown, the sheet will list each item sequentially, indicate
its location by Volume, Part, Section and Tab number, as
applicable and give a brief description of the information
and any special instructions required, such as the re-
moval or repositioning of existing information. When a
new amendment sheet is issued, the old sheet should be
removed and destroyed.
1-1-7
SECTION 2 - DESIGN AND OPERATION MANUAL

ALPHABETICAL INDEX
PART 1- INTRODUCTION
PART 2- STEAM GENERATOR DESIGN AND OPERATION
PART 3- WATER SYSTEM
PART 4- STEAM SYSTEM
PART 5- AIR AND FLUE GAS SYSTEM
1-2-1
SECTION 3 - DESIGN AND OPERATION MANUAL

AMENDMENT RECORD SHEET
(PART 1, SECTION 3)
AMENDMENT
RECORD SHEET
The following Instruction Manual Amendment Record Sheet contains
a complete listing of those items that have been added to, or have
replaced information in this manual. Upon initial issue of this manual,
this list may contain items which were not included because they
were not available at the time of delivery. However, their delivery is
anticipated and appropriate locations have been provided for them in
the manual as indicated in the index. When they are shipped, the
shipment date will be added to the amendment record sheet, and a
new sheet accompany the delivery.
Whenever additional or revised information is added to the manual, a

new record sheet will be issued. As shown, the sheet will list each
item sequentially, indicate its location by Volume, Tab and Section
number, as applicable, and give a brief description of the information
and any special instructions required, such as the removal or
repositioning of existing information.
When a new amendment sheet is issued, the old sheet must be

removed and destroyed and the new amendment sheet inserted
in its place.
1-3-1
Design and Operation Instruction Manual Amendment Record Sheet
Item Part Sect. Tab Description Date
10
11
12
13
14
15
1-3-2
PART 2 - STEAM GENERATOR DESIGN AND OPERATION
TABLE OF CONTENTS
TITLE SECTION
FOREWORD ................................................................................................................... 1
EQUIPMENT ARRANGEMENT ...................................................................................... 2
CFB GENERAL DESCRIPTION ..................................................................................... 3
DESCRIPTION OF PLANT EQUIPMENT ....................................................................... 4
STEAM GENERATOR DESCRIPTION ........................................................................... 5
CFB PROCESS DESCRIPTION ..................................................................................... 6
DESIGN DATA ................................................................................................................ 7
OPERATIONAL PROCEDURES .................................................................................... 8
PRESSURE PARTS ARRANGEMENT........................................................................... 9
GENERAL ARRANGEMENT ........................................................................................ 10
2-0-1
SECTION 1 - FOREWORD
TABLE OF CONTENTS
TITLE PAGE NO.
FOREWORD ................................................................................................................. 2-1-1
GENERAL OVERVIEW ................................................................................................. 2-1-1
CFB PROCESS OVERVIEW ........................................................................................ 2-1-2

CFB BOILER................................................................................................................. 2-1-2
BOILER AND RELATIVED EQUIPMENT ..................................................................... 2-1-4
2-1-i
FOREWORD
FOREWORD
Formosa Heavy Industries Corporation is providing for San Miguel

Consolidated Power Corporation, two sets of Circulating Fluid Bed
Boilers, each capable of firing coal to produce high quality steam at a
Maximum Continuous Rating of 460,000 kg/hr, 130 ata and 541°C at
the superheater outlet.
With an adequate back end cleaning system the gases discharged
from the unit will meet the project requirements, being essentially free
of SO2, NOX, CO, and particulate.
Every effort has been made to have the information in this manual
correct for the San Miguel Consolidated Power Corporation operation.
However, it is impossible to describe each and every operating condi-
tion that might occur, therefore, it is necessary for the operators to
become completely familiar with the equipment provided and its ca-
pabilities and to use good judgment in its operation and care.
GENERAL
OVERVIEW
A circulating fluidized bed boiler and its auxiliaries contain all the
fundamental parts found in any fossil fired steam generation system.
The are circuits for:
Fuel – Prepared coal is carefully metered into the preheated furnace
where it begins conversion to oxides of carbon, hydrogen, sulfur and
nitrogen. Start-up and supplemental fuel firing is also provided for.
Air – Several air circuits are used for combustion transport, and fluid-
ization of fuel and combustion products.
Water – Furnace with a steam drum, water cooled wall tubing and
an economizer.
Steam – Superheated steam is produced in circuits at both the top
of the furnace (Radiant) and in the superheater backpass (Convec-
tive) section. Reheated steam is produced in circuits located in the
reheater backpass (Convective) section.
2-1-1
Flue Gas – Multiple auxiliary systems address operational needs for

blending in other minerals that keep the coal combustion process
moving. Still other auxiliaries address the need for efficient opera-
tion within challenging emission standards.
CFB PROCESS
OVERVIEW
What makes the CFB system unique is the way in which the typical
boiler circuits are arranged. The circuit arrangement include the fol-
lowing major systems:
- Feed Systems for Coal, Sorbent and Inert
- Diesel Oil Heat Input Systems for Start-up
- Combustion and Fluidizing Air Supply
- Circulating Fluidizing Bed Combustion Heat Exchanger
- Ash Collection and Conveying System
- Utility Systems for Oil Supply, Air Supply, Cooling Water, Service
Air and Instrument Air.
CFB BOILER
Formosa Heavy Industries Corporation are creating two Circulating
Fluid Bed Boilers where:
Fuel Input – Crushed fuel, inert bed material (sand) and sorbent
(limestone) introduced by air into the furnace which has been pre-
heated to a minimum operating temperature with start-up burners.
Air Input – Primary air is introduced into the furnace plenum, passes
up through the fuel, inert bed material (sand) and sorbent (limestone)
bed fluidizing the mixture and supporting combustion of the fuel. The
air velocity through the bed is high enough that particles are sus-
pended in the air stream. A small portion of hot primary air is admit-
ted to the fuel feed chutes. Secondary air is introduced at a level
above the plenum grate so that the combustion process is essentially
completed as the suspended particles are carried up through the
furnace and over into the recycle cyclones.
Ash Extraction – The recycle cyclones remove a major portion of
the hot ash particles from the flue gas stream. This hot ash settles
into the siphon seals. A fluidizing air blower keeps the ash fluid and
2-1-2
fee-moving in the siphon seals and allows it to be returned to the

combustion chamber. Ash is continuously withdrawn from the com-
bustion chamber with four water cooled screw ash coolers. The ash
is then transferred from the screw ash coolers to the rest of the ash
system.
Efficiency – Relatively clean gases from the recycle cyclones enter
the convective pass of the steam generator where they pass over
the horizontal superheater, reheater and economizer elements.
The flue gas then enters the rotary air heater where it transfers its
heat to the primary and secondary air systems. The PA fan sup-
plies primary air at a relatively high pressure. Flow is through the
primary side of the air heater where the air is preheated before it is
introduced to the furnace plenum.
Emissions Output – Flue gas, which, thanks to the CFB processes
is already low in polluting combustion by-products, continues to the
backend gas cleaning equipment for removal of residual particulate
and then to the ID Fan and the stack. With an adequate back end
cleaning system the gases discharged from the unit will meet the
project requirements, being essentially free of SO2, NOx, CO, and
particulate.
2-1-3
BOILER AND
RELATED
EQUIPMENT
Description (Quantity per Boiler):

Furnace (1)
Steam Drum (1)
In-Furnace Evaporator Panels (6)
In-Furnace Superheater Panels #1 (7)
In-Furnace Superheater Panels #2 (7)
Furnace Grate (1)
Recycle Cyclones (2)
Seal Pots (2)
Backpass with Division Wall - RH Pass and SH Pass (1)
Reheater Bank - RH Pass (4)
Finishing Superheater - SH Pass (3)
Economizer Bank - RH Pass (1)
Economizer Bank - SH Pass (3)
Economizer Bank - Common Duct (1)
DownComer & Riser & Links & Headers (1)
Start-up Burners (4)
Hot Primary Air Duct from Air Heater (1)
Hot Primary Air, Furnace Inlet Connections (4)
Hot Secondary Air Duct from Air Heater (1)
Hot Secondary Air Duct to Furnace Front (1)
Hot Secondary Air Duct to Furnace Rear (1)
Hot Secondary Air Duct, Furnace Inlet Nozzles (22)
Rotary Air Heater (1)
Back Pass Soot Blowers (28)
Air Heater Soot Blowers (2)
Start-up Burner Air Supply Ducts (4)
Fluidizing Air Blowers (2)
Ash Screw Coolers (4)
Bottom Ash Transfer System (1)
2-1-4
ESP (1)
Induced Draft Fan (1)
Stack (1)
Safety Valves Sec. I and Sec. VIII
Solid Fuel Feed System:

- Fuel Silos (3)
- Fuel Silo Outlet Shutoff Valves (3)
- Gravimetric Feeders (3)
- Fuel Feed Isolation Valves (3)
- Fuel Feed Chutes (6)
- Fuel Feed Nozzles (6)
Sorbent (Limestone) Feed System: (Continuous)
- Sorbent Silo (1 for One Boiler, One Outlet)
- Silo Outlet Maintenance Gate (1)
- Roto Feeder & Vessels (1)
- Dome Valves & relating valves (1)
- All required Pneumatic Piping
- Flow Splitters (5)
- Isolation Valves (8)
- Feed Nozzles (8)
- All required Motors for equipment
Inerts (Sand) Feed System: (Batch Type)
- Sand Silo (1)
- Silo Outlet Maintenance Gate (1)
- Dome Valves & relating valves (1)
- All required Pneumatic Piping
- Flow Splitters (1)
- Isolation Valves (2)
- Feed Nozzles (2)
- All required Motors for equipment
2-1-5
SECTION 2 - EQUIPMENT ARRANGEMENT
TABLE OF CONTENTS
TITLE PAGE NO.
EQUIPMENT ARRANGEMENT ........................................................................................ 2-2-1
2-2-i
EQUIPMENT ARRANGEMENT
EQUIPMENT
ARRANGEMENT
The General Arrangement drawings of boiler provided for client
show the equipment arrangement within the CFB boiler island.
The components shown on the General Arrangement Drawings from
north to south are:
1. The solid fuel feeding system, which includes (per boiler):
a. Three solid fuel silos, each with an isolation valve.
b. Three gravimetric feeders with inlet chutes and outlet hop-
pers.
c. Three fuel feed isolation valves.
d. Six fuel nozzles.
The gravimetric feeders charge the fuel from the fuel silos
through the isolation valves into the furnace front wall openings.
2. The furnace with the steam drum, the furnace waterwalls and
furnace plenum.
3. The start-up over-bed burners are located in the east and west
side walls of the furnace and are accessible from the FL+8,800
mm elevation platform.
4. The water cooled screw ash coolers are located off the floor of
the furnace.
5. Two parallel recycle cyclones.
6. The siphon seals are directly attached to the recycle cyclone sol-
ids outlets and are located on the FL+15,200 mm elevation plat-
form, discharging the recycle ash into the combustion chamber.
7. Two fluidizing air blowers located below the siphon seals at
ground level.
8. The convective backpass which contains heat absorbing surfac-
es, superheater, reheater and economizer.
9. The Ljungstrom rotary air preheater.
10. The sorbent (limestone) silo and feeding system is located in
east side of boiler island for unit 1 and in west side of boiler is-
land for unit 2.
11. The inert (sand) feeding system is located in the last bay of boil-
er structure. The primary and secondary air fans are below the
Ljungstrom air heater on the ground level.
2-2-1
12. The flue gas cleaning equipment, the ID fan and the stack are at
the south side of the unit on the ground level.
2-2-2
SECTION 3 - CFB GENERAL DESCRIPTION
TABLE OF CONTENTS
TITLE PAGE NO.
CIRCULATING FLUID BED (CFB) COMBUSTION SYSTEM .......................................... 2-3-1
2-3-i
CFB GENERAL DESCRIPTION
CIRCULATING FLUID BED

(CFB) COMBUSTION
SYSTEM
The Circulating Fluid Bed (CFB) technology is a highly efficient pro-
cess for gas/solids reactions. Complete with proven components for
production of steam, this technology is applied to combustion of wide-
ly varying solid fuels. Fuel flexibility and the capability for load follow-
ing are major features of this technology.
Combustion in the CFB takes place in a vertical chamber called the
furnace. The fuel and sorbent are fed into the furnace, fluidized, and
1 burned at temperatures of approximately 850°C~900°C. The sorbent
is fine grained limestone which reacts with the sulfur dioxide released
from the burning fuel to form calcium sulfate (gypsum). The bed ma-
terial in the furnace consists primarily of mineral matter from the fuel,
gypsum, and excess calcined lime.
The bed material is fluidized with primary air introduced through a
grate at the bottom of the furnace and also by the combustion gases
generated. Secondary air is added to the lower section of the furnace
to achieve complete and staged combustion.
The suspended solids form a concentration gradient throughout the
furnace which decreases gradually toward the two outlets at the top.
The combustion gas entrains a considerable portion of the solids in-
ventory from the furnace. Solids are separated from the gas in two
recycle cyclones and are continuously returned to the bed via recycle
loops.
Because of the high slip velocity between gas and solids, the solids
proceed through the furnace at a much lower velocity than the gas.
The longer residence and contact times, coupled with the small parti-
cle sizes and high heat and mass transfer rates achieved, result in a
high combustion efficiency. These conditions also allow both the
complete decomposition of the limestone and the subsequent capture
of the SO2 at very low calcium to sulfur molar ratios.
Combustion air is fed to the furnace at two levels. Roughly sixty per-
cent of the combustion air is introduced as primary or fluidizing air
through the grate at the bottom, and the balance is admitted as sec-
ondary air through multiple ports in the side walls. Combustion thus
takes place in two zones: a primary reducing zone in the lower sec-
tion of the furnace followed by an appropriately adjusted excess air
oxidizing zone in the upper section. This staged combustion, at con-
trolled low temperatures, effectively controls NOX formation and pro-
vides conditions to most efficiently capture SO2 at low calcium to sul-
fur molar ratios.
2-3-1
Heat for steam generation is removed from the system in three areas:
1. In the primary loop, where heat is removed from the solids circu-
lating in the CFB system. Heat removal is achieved by:
a. Heat absorbing surface in the water walls of the furnace;
b. Pendant superheater and evaporator heat absorbing surfac-
es located in the upper furnace region.
2. In the convective pass (backpass), where heat is removed from
the flue gas exiting the recycle cyclones. Heat removal is
achieved by superheater, reheater and economizer surfaces.
After the convective pass, the gases are further cooled in an air heater.
From the air heater, the flue gases are cleaned in the flue gas cleaning
equipment and vented via an induced draft fan to the stack.
2-3-2
SECTION 4 - DESCRIPTION OF PLANT EQUIPMENT
TABLE OF CONTENTS
TITLE PAGE NO.
FUEL SYSTEM ................................................................................................................. 2-4-1
Coal Storage and Feed System Description ............................................................. 2-4-1
Component Description .............................................................................................. 2-4-1
Coal Silos................................................................................................................. 2-4-1
Coal Silo Isolation Valves ........................................................................................ 2-4-1
Acoustic Flow Monitors ............................................................................................ 2-4-1
Coal Gravimetric Feeders ........................................................................................ 2-4-2
Furnace Isolation Slide Gate Valves ........................................................................ 2-4-2
SORBENT (LIMESTONE) INJECTION SYSTEM DESCRIPTION ................................... 2-4-2
Component Descriptions ............................................................................................ 2-4-3
Sorbent (Limestone) Silo ......................................................................................... 2-4-3
Sorbent (Limestone) Silo Outlet Fluidizing Device ................................................... 2-4-3
Sorbent (Limestone) Silo Isolation Gate .................................................................. 2-4-3
The "RotoFeed" Machine System ............................................................................ 2-4-3
Flow Proportioner (Splitter) ...................................................................................... 2-4-5
Line Isolation Valve and Injection Feed Nozzles ..................................................... 2-4-5
INERT (SAND) INJECTION SYSTEM DESCRIPTION ..................................................... 2-4-5
Component Descriptions ............................................................................................ 2-4-5
Inert (Sand) Silo ....................................................................................................... 2-4-5
Inert (Sand) Silo Isolation Gate ................................................................................ 2-4-6
DensPhase Pneumatic Conveying System ............................................................. 2-4-6
Isolation Valve and Injection Feed Nozzles ............................................................. 2-4-6
CIRCULATING FLUIDIZED BED FURNACE ................................................................... 2-4-7
Circulating Fluidized Bed System Description ......................................................... 2-4-7
Component Description .............................................................................................. 2-4-8
Lower Refractory Lined Furnace Section/Plenum and Grate .................................. 2-4-8
Upper Waterwall Furnace Section ........................................................................... 2-4-9
In-Furnace Pendant Evaporator Panels................................................................... 2-4-9
SOLIDS RECYCLE SYSTEM ........................................................................................... 2-4-9
Solids Recycle System Description ........................................................................... 2-4-9
Component Description ............................................................................................ 2-4-10
Recycle Cyclones .................................................................................................. 2-4-10
Standpipes (Siphon Seal Inlet Duct) ...................................................................... 2-4-10
Siphon Seal Pots ................................................................................................... 2-4-10
Solids Return Ducts to Furnace ............................................................................. 2-4-10
AIR/GAS SYSTEM .......................................................................................................... 2-4-10
Air/Gas System Description ..................................................................................... 2-4-10
Component Description ............................................................................................ 2-4-11
Primary Air Fan ...................................................................................................... 2-4-11
2-4-i
TABLE OF CONTENTS
TITLE PAGE NO.

Secondary Air Fan .................................................................................................. 2-4-11
Induced Draft Fan................................................................................................... 2-4-11
Fluidizing Air Blower ............................................................................................... 2-4-11
BURNER SYSTEM .......................................................................................................... 2-4-12
Burner System Description ....................................................................................... 2-4-12
Component Description............................................................................................. 2-4-12
Start-up Burners ..................................................................................................... 2-4-12
HEAT TRANSFER SYSTEMS ......................................................................................... 2-4-12
Heat Transfer System Description............................................................................ 2-4-12
Convective Backpass ............................................................................................. 2-4-12
Ljungstrom Air Preheater ....................................................................................... 2-4-13
AIR POLLUTION CONTROL SYSTEM ........................................................................... 2-4-13
Air Pollution Control System Description ................................................................ 2-4-13
Convective Backpass/Ljungstrom Air Preheater .................................................... 2-4-14
Electrostatic Precipitator ......................................................................................... 2-4-14
ASH REMOVAL SYSTEM ............................................................................................... 2-4-15
Ash Removal System Description ............................................................................ 2-4-15
Bottom Ash Removal System ................................................................................. 2-4-15
Fly Ash System ...................................................................................................... 2-4-16
Bottom Ash Combustor Bed Drain Valves.............................................................. 2-4-16
Water-cooled Screw Ash Cooler Ash Removal ...................................................... 2-4-16
2-4-ii
DESCRIPTION OF PLANT EQUIPMENT
FUEL SYSTEM
Coal Storage and

Feed System
Description
Fuel is extracted from the coal silo and isolation valves at variable
rates, as required by the operation of the boiler, by gravimetric
feeders. From the feeders, the coal is fed, via three parallel feed
systems, into six (6) furnace front (north) wall openings. Each feed
system consists of a feeder outlet hopper and miscellaneous duct-
work. Each feed system is designed to handle 45% of the MCR
boiler fuel requirements.
Component
Description
Coal Silos
The solid fuel preparation and feed system empties into three (3)
coal silos. Each coal silo has one hopper and isolation valve which
discharges coal into the associated gravimetric feeder.
Coal Silo Isolation

Valves
Three (3) coal silo isolating valves are furnished (one per train) to
isolate each fuel train from each coal silo outlet. The knife gates
utilize a rack and pinion drive arrangement to allow for closure
against a full silo. Each valve is equipped with a manual gearbox
with a chain wheel operator and chain.
Acoustic Flow
Monitors
An acoustic flow monitor is mounted in each of the downspouts be-
low the coal silo isolation valve outlets to detect material flow or
flow interruption in the downspouts.
The flow monitor unit consists of two subassemblies; a detector
probe which mounts on the downspout, and a control unit suitable
for wall mounting in a convenient location. The detector probe in-
cludes a stainless steel alloy tip, which protrudes through the
downspout wall into direct contact with the moving material. The
control unit includes the required electronics, alarm relay, compara-
2-4-1
tor circuitry, and LED indication to advise alarm status. Adjustment

and calibration are accomplished at the control unit.
Coal Gravimetric
Feeders
The coal silo hoppers discharge the solid fuel into the three (3) en-
closed pressurized gravimetric feeders. One feeder is provided for
each of the three fuel feed trains. The feeders are furnished with a
variable speed ac drive and controller, to regulate the fuel feed to
the furnace by varying the belt linear speed.
The feeders each have a 1,150 mm wide belt. The center feeder is
6,201 mm and the outboard feeders are 7,061 mm inlet to dis-
charge length. They are designed for 0.21 kg/cm2(g) internal pres-
sure and are provided with drag chain scavengers driven with sepa-
rate ac motors to recover any fuel spillage at the bottom of the
feeder housing.
Other features furnished with the fuel feeders include: Access
doors at each end of the feeders, glass observation ports, internal
lights, provisions for coal sampling, and switches for sensing (zero
speed, starvation, belt tracking and discharge pluggage).
Furnace Isolation
Slide Gate Valves
Three (3) pneumatically operated slide gate valves (one per train)
are furnished to isolate each fuel train from the furnace for mainte-
nance shutdowns and to protect the feeder from hot furnace gas-
ses should the pressurization of the feeder become inadequate for
any reason. The valve gate is provided with a single cylinder ac-
tuator.
As a safety feature, three fail-safe packages (one per valve) are
supplied to automatically shut down the valve in the event of a
power failure. Each fail-safe package includes an air accumulator,
air filter/regulator/lubricator, open/close limit switches, pressure
switches, air feed control valve, and solenoid and check valves.
SORBENT
(LIMESTONE)
INJECTION SYSTEM
DESCRIPTION
One (1) sorbent (limestone) feed system is provided for each boiler.
The sorbent (limestone) material from the sorbent (limestone) daily
silo is injected into the furnace at eight (8) points, to control the SO2
emissions at the stack outlet.
Prepared sorbent (limestone) material from the sorbent (limestone)
daily silo flows through the sorbent (limestone) silo hopper with flu-
idizing devices to the “Rotofeed” system. The “Rotofeed” system
dispenses limestone through conveying pipework to the boiler unit
2-4-2
via one 4-way splitter and four 2-way splitters, providing 8 injection
points at the boiler.
A isolation valve is provided at each nozzle ( each injection points ),
to isolate the feed system from the furnace for maintenance pur-
poses.
Component
Descriptions
Sorbent (Limestone)
Silo
The prepared sorbent (limestone) silo, one per boiler, stores pre-
pared sorbent (limestone) material. The silo has one (1) outlet, hav-
ing a maintenance slide gate located at the silo hopper outlet, for si-
lo isolation and maintenance of equipment below.
Sorbent (Limestone)
Silo Outlet Fluidizing
Device
Silo hopper fluidizing device are provided at the hopper of the
sorbent (limestone) silo for the purpose of ensuring steady sorbent
(limestone) flow from the silo to the vertical downspout. The source
of fluidizing air is from one air receiver near silo. Action of fluidizing
device will be an interlock with “Rotofeed” system.
Sorbent (Limestone)
Silo Isolation Gate
A manually operated isolation gate (one per system) is provided in
the piping between the sorbent (limestone) silo and the “Rotofeed”
system for the purpose of isolating the conveying system from the
storage silo. Actuation of the gate is through a rotary screw shaft by
a manual wheel.
The “Rotofeed”
machine system
The “Rotofeed” machine consists of two pressure vessels, a volu-
metric feeder and a compressed air distribution manifold. The volu-
metric feeder will be driven through a gearbox by a standard induc-
tion motor. The electrical supply to the motor will be from a variable
frequency / voltage inverter drive (VFD), which will enable the “Ro-
tofeed” feeder speed and hence material output of the “Rotofeed” to
be controlled. The “Rotofeed” feeder speed is measured and used
to calculate material output. Thermal switches incorporated into the
feeder motor will provide an indication of motor overheating and pro-
tection within the VFD will stop the motor in the event of an overload.
The pressure vessels are arranged vertically with the dispensing
vessel located beneath the lock vessel. The inlet to each vessel is
provided with a Materials Handling air operated Dome Valve. These
2-4-3
valves incorporate an inflating seal to provide air tight closure. The

dispensing vessel is used to provide a constant supply of material to
the volumetric feeder. When material is being injected, the dispens-
ing vessel will be pressurised. The lock vessel is used to periodically
replenish the dispensing vessel with material by providing a pressure
lock between the high pressure environment of the dispensing ves-
sel and the limestone silo. In this way, injection of material to the
process can be continually maintained.
At rest the Dome Valves will be closed and the lock vessel will be
empty. When the low level switch in the dispensing vessel becomes
uncovered, a filling cycle will be initiated and will proceed as follows.
The vent valve will open and allow residual pressure in the lock ves-
sel to be vented. A pressure switch will detect the pressure in the
lock vessel. Providing it has subsided at the end of the venting peri-
od the lock vessel inlet Dome Valve will be opened and material will
be gravity fed from the feed silo into the lock vessel. During lock
vessel filling, the lock vessel equalisation valve will be opened intro-
ducing air into the base of the lock vessel to prevent consolidation of
the material.
The dispensing vessel inlet Dome Valve will then be opened and
material will flow under gravity from the lock vessel into the dispens-
ing vessel. To assist the discharge, air will be introduced into the
lock vessel through the pressure equalisation valve. During this peri-
od the balance valve will be open to allow displaced air from the dis-
pensing vessel to be routed back into the lock vessel. After a pre-set
time material transfer from the lock vessel to the dispensing vessel
will be deemed to be complete and the lock vessel pressure equali-
sation valve, dispensing vessel inlet Dome Valve and balance valve
will all be closed.
When the pressure switch connected to the Dome Valve seals indi-
cates that the valves have closed and sealed the filling cycle will be
complete and will be repeated when the dispensing vessel level
switch once again becomes uncovered.
The conveying air will enter the boiler unit along with the limestone
material and will leave the boiler along with the other process gases.
It is important that the feed hopper into which the Rotofeed vents is
fitted with a vent or filter to allow the air released from the Rotofeed
during venting to be safely vented.
The controls will monitor the time taken for the fill cycle and an alarm
will be raised if the time taken is significantly longer than a pre-set
norm. The controls will also monitor the conveying air pressure and
will activate an alarm if it goes abnormally high.
A level switch fitted to the lock vessel will signal that the lock vessel
has filled. When this occurs, the lock vessel inlet Dome Valve and
the vent valve will be closed. The pressure in the lock vessel will
begin to increase. When the lock vessel pressure becomes equal to
the dispensing vessel pressure as indicated by the differential pres-
2-4-4
sure switch, the lock vessel pressure equalisation valve will be

closed.
Flow Proportioner
(Splitter)
Each flow proportioner (splitter) (five per system) is provided with
abrasion-resistant contact surfaces and an balancing shoe, for sys-
tem balancing.
Line Isolation Valve

and Injection Feed
Nozzles
Each system has eight (8) end of line isolation valves [one (1) per
injection point]. There are a total of eight (8) injection nozzles per
boiler for these units. Prior to opening the valves, the operator
should ensure that the “Rotofeed” system main conveying air sup-
ply valve is open and that the air supply is healthy. A conveying gas
flow is required to prevent combustor gasses back feeding into the
conveying line.
INERT (SAND)
INJECTION SYSTEM
DESCRIPTION
One (1) inert (sand) feed system is provided for each boiler. The
material from the inert (sand) silo is injected into the furnace at two
(2) points when needed.
Sized inert material from the inert (sand) silo flows through the inert
(sand) silo outlet maintenance gate, will be discharged by gravity to
the DensPhase transport vessel of inert (sand) feed system. The
material will then be pneumatically conveyed through steel pipework
to the boiler.
A compressed air from dry plant air system provides conveying air
which transports the inert material/air mixture through conveying
pipe, and then injected into the return line of each seal pot. A isola-
tion valve is provided at end of injection line, to isolate the feed sys-
tem from the seal pot for isolation and maintenance purposes.
Component
Descriptions
Inert (Sand) Silo

The inert (sand) silo is located near backpass and supported by its
own steel structure nearby boiler steel structure. One per boiler unit,
stores inert (sand) material. Inert (sand) is fed to the silo by pneu-
matic conveying system located in sand unloading station or in bot-
tom ash recycle system. The silo has a lined bottom, fluidizing de-
vice and carbon steel barrel section. One (1) outlet, having a
maintenance slide gate located at the silo outlets, for silo isolation
2-4-5
and maintenance of equipment below. Each silo will include required

access doors, opening(s) for silo fill system. The silo will also include
the required connections for level measurement devices.
Inert (Sand) Silo

Isolation Gate
A manually operated isolation gate (one per system) is provided in
the piping between the inert (sand) silo and the DensPhase pneu-
matic conveying system for the purpose of isolating the conveying
system from the storage silo. Actuation of the gate is through a rota-
ry screw shaft by a manual wheel.
DensPhase
Pneumatic Conveying
System
The DensPhase pneumatic conveying system consists of inlet dome
valve, DensPhase vessel, vent valve, air bypass valve and outlet ball
valve density stabilisers and associated valves.
Inert (sand) will fall under gravity from silo into the DensPhase vessel.
During filling the vent will remain open to allow displaced air to be re-
leased from the vessel. After a time delay or when the level switch in
the DensPhase vessel indicates that the vessel has filled, the vent will
be closed. After a short timed delay to allow the vessel to completely
fill, the inlet dome valve will be closed. When the inlet dome valve and
vent valve have both closed and sealed, the outlet ball valve will be
opened and air will be introduced into the vessel and the material will
be discharged into the pipeline and conveyed to the furnace.
During material transfer, the bypass air will be closed. Air will also be
introduced at points along the conveying pipe via the density stabi-
lisers to ensure smooth conveying. When the material has been
discharged into the boiler, signalled by a drop in conveying pressure,
the conveying air valves and outlet Dome valve will be closed and
the bypass air will be opened. The vent will be re opened and the
cycle is complete.
Isolation Valve and

Injection Feed
Nozzles
Each system has one (1) isolation valves . There are a total of two
(2) injection nozzles per boiler for these units.
2-4-6
CIRCULATING
FLUIDIZED BED
FURNACE
Circulating Fluidized
Bed System
Description
Fuel combustion in the Circulating Fluidized Bed (CFB) system takes
place in the vertical combustion chamber. Properly sized fuel and fi-
ne grained sorbent (limestone) are fed into the furnace and burned
1 at a relatively low temperature (850°C~900°C). The fine grained
limestone captures the sulfur dioxide released when the fuel is
burned. The bed material in the furnace consists primarily of coal
ash, gypsum, excess calcined limestone and inerts. The mean par-
ticle size of the bed material is in the range of 100 to 300 microns.
The bed material is fluidized by primary air introduced through a
nozzle grate at the bottom of the bed, and by the gas generated dur-
ing combustion. The gases flow upward with a relatively high veloci-
ty filling the entire furnace with suspended solids. They have high
concentration at the fluidizing bed but decrease continuously to-
wards the top of the furnace. The combustion gas entrains a con-
siderable portion of the solids in the furnace and carries them over to
recycle cyclones where the entrained solids are separated from the
gases. Some solids are continuously returned to the bed by a recy-
cle loop.
Because of the high slip velocity between the gas and solids, the sol-
ids proceed through the furnace at a much lower velocity than the
gas. Solids residence times on the order of minutes are obtained for
each cycle of solids circulation. The long residence and contact
times, coupled with the small particle sizes and efficient heat and
mass transfer rates, produce a high combustion efficiency. These
aforementioned effects in combination with temperature allow both
the decomposition of limestone and the subsequent formation of
gypsum.
Combustion air is introduced into the furnace at two levels. About
sixty percent of the combustion air is passed as primary fluidizing air.
Preheated to approximately 287°C, it enters the furnace through a
grate assembly and plenum located at the bottom of the furnace.
The balance of the air is admitted as secondary air, also preheated
to approximately 302°C, entering the furnace via multiple ports lo-
cated in the front and rear walls of the furnace. The combustion pro-
ceeds in two zones: a primary reducing zone in the lower section of
the furnace, and complete combustion using 20% excess air in the
upper section. This staged combustion, at controlled low tempera-
tures, effectively suppresses NOx formation.
Flue gas resulting from the combustion of the fuel, and the entrained
solids, exit the furnace at essentially the furnace temperature via two
outlets located in the upper portion of the rear wall and is ducted into
the two parallel recycle cyclones designed to remove about 99% of
the solids entrained by the gas from the combustion chamber. The
2-4-7
solids separated by the recycling cyclones are collected in two air

fluidized siphon seal pots and are returned directly into the furnace.
Heat for steam generation is removed from the system in three ways:
1. By the furnace waterwalIs.
2. Furnace pendant superheater and evaporator located in the
upper furnace region.
3. The convective backpass, using the sensible heat of the flue
gas and entrained solids.
NOTE: Furnace temperature is affected by coal

1 property and particle size distribution of coal, lime-
stone and make-up bed material. 850°C~900°C in
principle is for normal operation and up to 950°C
furnace temperature is also allowed for long term
operation according to different kinds of coal prop-
erty and material situations. If furnace temperature
is above 900°C, it shall contact commissioning su-
pervisor of Formosa Heavy Industries for final
check.
Component
Description
The CFB combustion chamber is of rectangular single grate design
(15,506.7 mm wide x 7,683.5 mm deep) and consists of two sec-
tions:
Lower Refractory
Lined Furnace
Section/Plenum and
Grate
Fuel combustion proceeds in two furnace zones: a primary reducing
zone in the lower section, and final combustion at 20% excess air in
the middle and upper section. Primary fluidizing air, representing
roughly 60% of the total air to the furnace, is supplied under pres-
sure from the primary air fan through the plenum and grate assem-
bly at the bottom of the furnace.
The plenum is located in the lower most portion of the furnace. Pri-
mary air is injected into the plenum. The plenum consists of un-
cooled duct plate on two sides and the floor. The roof of the plenum
is made of finned waterwall tubes with holes in the fins to accommo-
date fluidizing air nozzles.
The fluidizing grate consists of:
1. The roof of the plenum described above.
2-4-8
2. Capped Fluidizing Nozzles consists of nozzle tubes, inner

nozzle tube, nozzle heads. Nozzle tubes and inner nozzle
tubes are made of stainless steel. The Nozzle heads are
made heat resistant cast metal, with 8 hole outlets. The di-
ameter and quantity of holes is based on the required pres-
sure drop of nozzles. The nozzles are spaced on approxi-
mately 14” centers in an evenly distributed grid.
3. A refractory lining.
The lower furnace consists of waterwalls that are refractory-lined to
a height of about 7,748 mm from the grate.
Multiple ports are provided in the refractory-lined section for solids
return from the cyclones, secondary air inlet ports, start-up burners
and manholes. Instrument nozzles are located, as required, both in
the refractory-lined and unlined waterwall sections of the furnace.
The refractory lining in the lower furnace section serves three pur-
poses. First, the heat loss is minimized, thus allowing for faster hot
restarts. Second, the possible corrosion effects of the reducing envi-
ronment are eliminated and third, protection against fluidized bed
erosion is afforded.
Upper Waterwall
Furnace Section
The upper section is rectangular in design and is made up of evap-
orative waterwalls, maintained in place by a grid of buckstays. This
upper waterwall section, combined with the lower furnace section.
Water is supplied to the waterwalls by use of a lower ring header.
The solids density gradient decreases as the stream moves up
through the upper furnace. At the top of the furnace section, the
stream exits through two openings in the rear wall and proceeds to
the recycle cyclones.
In-Furnace Pendant
Evaporator Panels
The In-Furnace evaporator panels (C-23) are located in the upper
furnace front wall area opposite to the cyclone inlet openings. They
consist of six (6) 63.5 mm O.D. tube fin-welded assemblies.
SOLIDS RECYCLE
SYSTEM
Solids Recycle
System Description
Flue gas with entrained solids enter the two parallel recycle cy-
clones where about 99% of the solids are captured. The collected
solids flow downward into a standpipe, ending in two refractory
lined, air fluidized siphon seal pots. The siphon seal pot arrange-
2-4-9
ment returns the solids separated by the cyclones through an in-

clined, refractory lined duct to the lower furnace section.
Component
Description
Recycle Cyclones
Two (2) recycle cyclones are provided for this system. The cy-
clones are fabricated from 10 mm thick carbon steel and are refrac-
tory lined. The cyclones have an inside diameter of 7,900 mm and
an overall height of approximately 24,542, including the domes. An
expansion joint is provided between the cyclone top and the dome.
At this same elevation, a vortex finder made of abrasion and heat
resistant alloy steel is supported by twelve (12) equally spaced lugs
around the vortex finder perimeter.
Standpipes (Siphon
Seal Inlet Duct)
Two (2) standpipes are provided. Each pipe is refractory lined,
1,450 mm diameter inside the refractory lining, and is provided with
an expansion joint.
Siphon Seal Pots

Two (2) refractory lined siphon seal pots are provided with fluidizing
air nozzle grid and air distributors. Fluidizing air is supplied by a flu-
idizing air blower.
Solids Return Ducts to

Furnace
Two (2) solids return duct sections are supplied. The ducts are
made of carbon steel, refractory lined with a 1,015 mm diameter in-
side refractory and are provided with an expansion joint.
AIR/GAS SYSTEM
Air/Gas System
Description
The combustion air is supplied to the CFB furnace in two main
streams: primary fluidizing air and secondary air.
Primary fluidizing air is introduced through a plenum and grate as-
sembly located at the bottom of the lower refractory furnace section.
The balance is admitted as secondary air through various ports in
the front and rear walls of the furnace, as vented fluidizing air for the
siphon seals and as transport air for the limestone feed. Various
purges, pressurization and other fluidizing air flows also contribute to
the combustion air. The flow of air into the furnace is integrated and
recorded and is automatically proportioned to the fuel rate to main-
tain the required excess air ratio for combustion. The gas flow
2-4-10
through the system is generated by the induced draft fan. The in-
duced draft fan, located downstream of the ESP and upstream of
the stack, pulls the gas through the system and forces the resulting
clean gases into the stack for dispersal into the air.
Component
Description
Primary Air Fan

One (1) primary air fan supplies fluidizing air to the furnace grate
and the fuel feed systems. Flow is inlet vane controlled by combus-
tion airflow control. The primary air flows first through the Ljung-
strom air preheater and is then ducted to the furnace.
Secondary Air Fan

One (1) secondary air fan supplies air to the secondary air manifold
and the start-up burners via the Ljungstrom air preheater. Flow is in-
let vane controlled by combustion airflow control.
Induced Draft Fan

There is one (1) induced draft fan. As indicated previously, this fan
is located between the ESP and the stack and is used to pull the
CFB combustion gases through the system and push them out
through the stack.
Fluidizing Air Blower

One (1) fluidizing air blower and one (1) 100% spare blower are pro-
vided for fluidizing the solids in the siphon seal pots.
Fluidizing air is used at the cyclone and seal pot to circulate the sol-
ids (ash) back to the furnace (combustor). The fluidizing air is sup-
plied through a multi-stage centrifugal type air blower. At normal load
the fluidizing air blower is expected to supply up to approximately
22,700 kg/hr at 5,230 mmH2O.
The ductwork from the fluidizing air blower supplies fluidizing air to
one CFB at the following locations:
a. Cyclone hoppers, cyclones, eight nozzles per cyclone.
b. Seal pot inlets, seal pots, eight nozzles per seal pot inlet.
c. Seal pots, four nozzles in vertical leg of each seal pot inlet
d. Seal pot, four nozzles in bottom of each seal pot
e. Seal pot, two nozzles in vertical leg of each seal pot outlet.
f. Seal pot return duct, two ducts to combustor six nozzles in each
g. Sealing air to expansion joint located on each seal pot return
chute.
2-4-11
BURNER SYSTEM
Burner System
Description
The CFB burner system is composed of start-up burners.
The start-up burners are used for preheating the unit. These burn-
ers operate with air supplied from the secondary air fan and are re-
tracted when the temperature in the furnace reaches approximately
700°C.
Component
Description
Start-up Burners
The start-up burner system consists of four (4) automatically re-
tractable start-up burners for firing diesel oil, with a high energy arc
igniter and a burner management system. The burners are located
on the east and west side walls of the furnace. Start-up and shut
down is independent for each burner. The minimum turndown of
each burner is approximately 20% of its maximum rated capacity.
Combustion air is supplied from the secondary air system and the
fuel/air ratio is controlled for each burner.
HEAT TRANSFER
SYSTEMS
Heat Transfer
System Description
The heat transfer systems are of two kinds. The first is those parts of
the process where heat is introduced into the system. This type of
process is provided by the Burner & Fuel Feeder System (see
“Burner & Fuel Feeder System” section).
The second kind is where heat is removed from the system. These
types of processes are:
1. Furnace Waterwalls (see “Furnace” section).
2. Furnace Pendant Superheater and Evaporator (see “Super-
heater” and “Furnace” sections).
3. Convective Backpass/Superheater/Reheater/Economizer.
4. Air Preheater.
Component
Description
Convective Backpass
Flue gas enters the convective split backpass after exiting from the
recycle cyclones which reduce the solids carry-over to the convec-
2-4-12
tive section. Heat is transferred from the flue gas to the steam and
water circuits which are made up of superheater, reheater and
economizer surfaces.
The hot gases pass through a steam cooled superheater enclosure
and division wall, and across the horizontal reheater section and the
horizontal finishing superheater section in each pass of split back-
pass respectively. The hot gases then pass across the horizontal
plain tube economizer sections located in RH pass and SH pass. Fi-
nally, the hot gases leaving each pass merge back one stream and
then across horizontal plain tube economizer located in common
duct. Heat is recovered from the flue gas before entering the Ljung-
strom air preheater, where remaining heat is transferred to the pri-
mary and secondary air systems.
Ljungstrom Air
Preheater
Primary and secondary air leaving the PA Fan and SA Fan respec-
tively are heated by the Ljungstrom Air Preheater. Flue gas leaving
the Ljungstrom Air Preheater is cooled to 135°C.
The Ljungstrom regenerative air preheater design is a highly efficient,
rotating modular element, compact heat exchanger. The design has
three sections: one for flue gas, one for primary air, and one for sec-
ondary air.
The Ljungstrom Air Preheater is located below the convective back-
pass, and consists of a rotor drive unit electrically driven geared as-
sembly mounted to the rotor hub drive shaft. This drive assembly
provides the facility of main AC electric drive and standby air drive
(used for maintenance and loss of power), two (2) retractable soot-
blowers (one on the air preheater gas inlet side and one on the air
preheater gas outlet side), stationary washing devices, fire detection
device and rotor support bearing/ steady bearing with oil bath.
AIR POLLUTION
CONTROL SYSTEM
Air Pollution Control

System Description
Air pollutants caused by the combustion of most fuels fall into two
categories: gaseous and particulate. Gaseous pollutants such as
NOX and SO2 are controlled within the CFB unit via low temperature
combustion and limestone injection for SO2 removal. The particu-
lates carried from the CFB are captured by the recycle cyclones (for
solids recirculation), the solids dropout section beneath Ljungstrom
air preheater and ESP.
2-4-13
Component
Description
Convective Backpass
/Ljungstrom Air
Preheater
Gases from the CFB pass through the recycle cyclones where the
majority of particulates in the gas are removed. The gases then en-
ter and pass through the various sections of the convective split
backpass. Convective split backpass is split to two gas passages by
steam cooled division wall which is parallel to front steam cooled wall
and rear steam cooled wall of backpass. The two gas passages, one
is RH pass located closest to the cyclone outlet ducts and all reheat-
er sections are located in the pass. The other is SH (superheater)
pass located near rear steam cooled wall and finish superheater
sections and economizer sections are located in the pass. As a re-
sult of the low velocity design of the backpass, additional particulate
recovery occurs at the bottom of the Ljungstrom air preheater which
has four (4) hopper outlets.
Electrostatic
Precipitator
For cleaning the flue gas the electrostatic precipitator will be used to
meet the particulate emission requirement 50 mg/Nm3 at 6% O2 vd.
An electrostatic precipitator has one inlet duct through which the
gases pass uniformly at a velocity of 1~1.5 m/s. The duct is formed
by parallel rows of vertically mounted collecting plates and a number
of discharge electrodes vertically suspended between the collecting
plates. Five cells and two ash hopper per cell are designed. Every
ash hopper will be connected to the transmitter vessel of fly ash re-
moval system.
The high negative voltage applied to the electrically insulated dis-
charge electrodes creates a strong electrical field between the dis-
charge electrodes and the earthed collecting plates. As the voltage
is raised, electrical breakdown of the gas which close to the elec-
trode surface take place. This breakdown, called “corona”, produces
large numbers of gas ions. The negative gas ions produced charge
the dust particles suspended in the gas, then the negatively charged
particles migrate towards the collecting plate where they are depos-
ited.
These particles build up a layer of dust on the collecting-plate sur-
face which is dislodged by rapping.
The inlet dust loading – 23.8 g/Nm3 as dry base will be introduced to
ESP chamber, the outlet dust concentration shall be less than 50
mg/Nm3. Over 99.7% high collecting efficiency will be reached base
on above operation condition.
2-4-14
ASH REMOVAL
SYSTEM
Ash Removal
System Description
One of the many reasons for a CFB being very efficient is because it
effectively utilizes ash and ash recirculation for added heat transfer.
Fluidized ash is circulated up through the combustor giving off heat
to the combustor waterwalls. Heavier, more coarse ash is recirculat-
ed through the cyclones and seal pot and back into the bottom of the
combustor. Fluidizing air and the injection of inert sand helps this
heavier ash return to the combustor and plenum. A majority of the
ash will follow this recirculating path before eventually exiting the
CFB through a bottom ash removal path (ash screw coolers). A
smaller portion of the ash is expected to be so fine that it remains in
laminar flow streams in the flue gas to travel out through the back-
pass with the flue gas.
Ash is removed from the system in three places: the water-cooled
screw ash coolers, Ljungstrom air preheater gas outlet hoppers, and
the ESP hoppers.
Fly Ash : Ash entrained within the flue gas passing through the
backpass is considered to be fly ash. Some of the fly ash will attach
to the superheater, reheater and economizer tubes. Long and par-
tial retract sootblowers will dislodge this sintered material. Some of
the fly ash will attach to the Ljungstrorm Air heater plate surfaces.
Retract AH sootblowers will dislodge this dust and any sulfate based
compounds. Ash hoppers located below air heater will collect any fly
ash that drops out of the flue gas flow. Ash collected in air heater
hoppers is removed by the ash handling system.
Bottom Ash : While the CFB uses ash recirculation as a basis for
heat transfer. The ash be circulated is derived from the combustion
of the solid fuel plus limestone and sand. The ash will be removed
from the bottom ash system will be chemical compounds based on
the sorbent and sulfate compounds plus a small amount of the inert
sand and fuel ash
Component
Description
Bottom ash removal

system
Bottom ash is removed through four(4) bed drains located in the bot-
tom of the combustor. Each bed drain is connected to a single screw,
water cooled screw conveyor that continuously removes the bottom
ash from the combustor to bottom ash removal system. The ash re-
moval system will deliver bottom ash to bottom ash silo.
2-4-15
Fly ash system

Ljungstrom Air Preheater/ Particulates collected in the gas outlet
hoppers, and the ESP hoppers are removed by the pneumatic fly
ash conveying system to fly ash silo
Bottom Ash
Combustor Bed Drain
Valves
The 304.8 mm inlet slide gate valve is located in the plenum exit
above the water cooled screw conveyors. The inlet valve is either
pneumatically or manually operated (hand wheel) knife gate valve.
They provide isolation of the water cooled screw conveyor from the
combustor bed when the screw conveyor requires servicing. Special
material is used to survive the high inlet temperatures
Water-cooled Screw
Ash Cooler Ash
Removal
Bottom ash is removed from boiler bottom with four water cooled
single screw conveyors per boiler. Each water cooled single screw
conveyor is equipped with one infeed chute.
The operation and capacity of all water cooled single screw convey-
ors are controlled from bottom ash handling automation system. The
capacities must be checked and adjusted during commissioning with
actual material.
Water cooled screw conveyor is equipped with single screw and mo-
tor. The meaning of the water cooled screw is to cool the ash coming
from the boiler. Water circulations must be always on, when bottom
ash is removed.
Water circulation must be closed (manually) within approx. 15
minutes after screw conveyor is stopped to avoid the condensation
inside the screw. This time can be reduced to 5 minutes in situations
when the conveyor is empty. The capacity of screw conveyor can be
regulated with frequency converter. Both screws are equipped with
independence frequency converters.
Furnace ash passes through the water-cooled screw ash coolers to
the ash handling system.
2-4-16
SECTION 5 - STEAM GENERATOR DESCRIPTION
TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION ........................................................................................................... 2-5-2
WELDED WALL CONSTRUCTION .............................................................................. 2-5-2
SETTING MATERIALS ................................................................................................. 2-5-3
OPERATION ................................................................................................................. 2-5-4

Internal Deposits ...................................................................................................... 2-5-4
Blowdown ................................................................................................................. 2-5-4
MAINTENANCE ............................................................................................................ 2-5-5

Inspections ............................................................................................................... 2-5-5
Tube Repairs ............................................................................................................ 2-5-6
GUIDELINES FOR HANDLING OF SILICA DUST ....................................................... 2-5-6

Introduction .............................................................................................................. 2-5-6
Classification of Silica Dust .................................................................................... 2-5-7
Harmful Effects of Dust ........................................................................................... 2-5-7
Installation and Removal ......................................................................................... 2-5-8
Silicosis .................................................................................................................... 2-5-8
Other Diseases ......................................................................................................... 2-5-9
Threshold Limit Value (TLV) ................................................................................... 2-5-9
Medical Requirements ........................................................................................... 2-5-10
Industrial Hygiene Measurements ........................................................................ 2-5-10
Abatement of Personnel Exposures .................................................................... 2-5-10
Ventilation .......................................................................................................... 2-5-10
Protective Equipment ......................................................................................... 2-5-11
2-5-1
STEAM GENERATOR DESCRIPTION
INTRODUCTION
The following description and instructions cover in a general way the
upper furnace wall design used. Specific information on wall con-
struction and furnace setting can be found in the contract pressure
part arrangement and the insulation and refractory drawings.
WELDED WALL
CONSTRUCTION
The furnace walls are composed of 63.5 mm O.D. tubes on 88.9 mm
centers. The space between the tubes is fin welded to form a com-
plete gas tight seal.
The convective split pass (backpass) steam cooled side walls are
composed of 44.45 mm O.D. fin welded tubes on 114.3 mm centers.
The backpass front wall, roof wall and rear wall are composed of
50.8 mm O.D. fin welded tubes on 114.3 mm centers. The division
wall runs parallel to front and rear backpass walls and is composed
of 50.8 mm O.D. fin welded tubes on 114.3 mm centers. Screen
tubes come from division steam cooled wall tube and bare type with-
out fin welded at upper cavity of the convective split backpass. The
purpose is gas stream be able to across division wall and enter SH
pass.
Where tubes are spread out to permit passage of superheater, re-
heater and economizer elements, screen tubes, sootblowers, etc.,
the spaces between the tubes and openings are closed with fin ma-
terial so a completely metallic surface is exposed to the hot furnace
gases.
All finned tubes are backed with a plastic refractory and skin casing
which is seal welded to form a gas tight envelope.
Poured insulation and plastic refractory are used at each horizontal
buckstay to form a continuous band around the furnace thereby pre-
venting flue action of gases between the casing and waterwalls. At
2-5-2
vertical buckstays and corner angles, loose mineral fiber insulation is

packed in to a density of 160 kg/m3.
The setting (insulation) of the furnace walls consists of total 125 mm
of mineral fiber batt insulation installed in two layers (inner layer is 50
mm；outer layer is 75 mm). The setting of the backpass consists of
total 150 mm of mineral fiber batt insulation installed in two layers
(inner layer is 50 mm；outer layer is 100 mm). The setting is impaled
on pins and held in place at the corners with junior mesh expanded
metal. A ribbed galvanized outer casing completes the setting.
Refer to the contract Insulation, Refractory, and Outer Casing draw-
ings for additional specific information pertaining to this installation.
SETTING
MATERIALS
All setting materials used to insulate the walls and ducts of Formosa
Heavy Industries units contain organic binders. Mineral fiber batt
and blanket insulation is composed of rock or slag fibers and organic
binders. Mineral fiber block insulation is composed of rock or slag fi-
bers, inorganic binder and a small amount of organic binder.
The organic binder and oil used in the manufacture of these materi-
als usually dissipates as smoke when the unit is heated for the first
time. The intensity of the smoke will vary with the type of organic
binder used in the product and the rate of temperature increase.
On initial start-up of the unit, mineral fiber products may be heated

rather quickly to 177°C. From 177°C to the unit operating tempera-
ture the insulation temperature should not increase more than
55.6°C per hour. At 232°C the insulation will smoke. The smoke
should subside after the unit has been at operating temperature for
approximately four hours.
Hot air or gas over 177°C should not be allowed to enter ducts sud-
denly during the initial start-ups. Dampers should be open to allow
the duct temperatures to increase with the furnace temperature.
Loss of the organic binder as smoke does not affect the insulating
qualities of the mineral fiber batts, blankets and blocks. The incre-
mental temperature increase less than 55.6°C/hr is required only the
2-5-3
first time a unit is brought up to operating temperature, and subse-

quent start-ups may be at a normal rate.
OPERATION
Internal Deposits
Since the design heat transfer rates in water cooled furnaces are
normally high, it is essential that the tubes be kept free from scale
formation and copper and iron oxides deposits. This is accom-
plished by proper boiler water treatment.
NOTE: Refer to “Feedwater Treatment”.
Scale formation is the deposition of an insulating film on the water

side of the tube wall, which raises the hot face temperature and may
result in overheating of the tube section. Boiler water treatment aims
to eliminate deposition of scale forming components by substituting
non-scale forming components.
In high pressure boilers iron and copper oxides introduced from the
preboiler system may lead to internal corrosion in the areas of de-
posits and eventually cause tube failures. Feedwater treatment in
this case comprises corrosion control in the preboiler system.
Blowdown
Boiler blowdown is used as a means of controlling boiler water con-
centrations (solids and alkalinity) and to remove sludge formation.
The frequency of blowing down depends upon local conditions, such
as: character of the water, nature of feedwater treatment, design and
rating of the boiler, etc. In most cases the continuous blowdown sys-
tem is sufficient.
In extreme cases of sludge formation, or in cases of poorly treated
feedwater with high solids contents resulting in carry-over, the boiler
may be blown down intermittently through the downtake drain or the
lower ring header drains. In no case should the waterwall header
drains be used for blowing down the boiler while the unit is steaming.
2-5-4
At no time should the conditions specified for an installation as to to-

tal dissolved solids, alkalinity, etc., be ignored or exceeded. The fre-
quency and quantity of blowdown should be in accordance with in-
structions by a chemist or some other competent person. The re-
sponsibility for providing proper feedwater treatment and control
rests with the operating force.
MAINTENANCE
Inspections
Routine inspections of furnace wall tubes, drum and headers should
be made each time after boiling-out and during annual outages.
During these inspections drums should be opened and handhole
plates removed from headers. The condition of the drum internals
should be checked and internal surfaces inspected for deposits.
Tubes should be spot checked and the tube ends inspected internal-
ly for deposits. Any deposits should be removed and headers, drums
and tubes flushed out with clean water.
Furnace tubes should be examined externally for blistering, burning,
corrosion, erosion and cracking (See Note). For this purpose the fire
sides of all exposed furnace tubes must first be thoroughly cleaned
of ash deposits.
NOTE: Areas around sootblowers are susceptible

to erosion.
All inspections should be thorough and comprehensive in every de-

tail. They should be made by competent personnel, familiar with
boiler operation and maintenance and with water treatment problems.
A record of each inspection should be kept in a uniform manner so
that results of any change can be compared with former conditions.
Inspections of tubes, as a result of tube failures or conditions ex-
pected to lead to failures, should be even more thorough. If the
cause of the condition is not obvious or cannot be determined clearly,
such inspections should include metallurgical examinations of tube
sections, chemical analysis of deposits, etc.
2-5-5
Tube Repairs
A tube section that has failed, or which must be replaced because of
danger of failure, can in most cases easily be replaced. After remov-
ing the furnace wall insulation behind the failed area, the tube sec-
tion is removed by cutting across the tube, sufficiently above and be-
low the failure and carefully cutting the web alongside the tube (See
Note). Before inserting and rewelding a new tube section the tube
ends should be properly prepared for welding.
NOTE: The longitudinal cuts must extend beyond
the perpendicular cuts sufficiently to permit welding
completely around the periphery of the tube when
installing the new tube section. Webs between
tubes must be replaced and made gastight.
It must be recognized that it is impossible to include repair proce-
dures (methods, welding techniques, etc.) to cover all pressure parts
and associated structural components of a complex modern steam
generator. It is recommended that Formosa Heavy Industries’ ser-
vice or construction representative be consulted for assistance in
evaluating and repairing damaged pressure parts and/or failures.
All repairs should be done by competent and qualified personnel and
all welding should be in accordance with the Recommended Rules
for Repairs of Power Boilers by the National Board of Boiler and
Pressure Vessel Inspectors.
NOTE: If repaired tube is located in boiler furnace
grinding of welding region to make a smooth and
vertical furnace water wall with an angle of impact
approximating zero is necessary to prevent wearing
on welded zone due to high particle loads in the
furnace. The criteria of grinding and vertical angle is
shown on the drawing of pressure parts.
GUIDELINES FOR
HANDLING OF
SILICA DUST
Introduction
These guidelines are provided to alert our customers to the potential-
ly harmful health effects and the risk of serious disease caused by
2-5-6
the inhalation of silica dust. The developing medical and scientific

evidence strongly suggests that as the amount and/or duration of sil-
ica dust inhalation increases, the risk of serious and possibly fatal
respiratory and other diseases also increases. Even a minimal inha-
lation of silica dust may pose a health hazard. These guidelines also
provide information which may assist you in implementing, monitor-
ing and evaluating your own industrial hygiene and dust control pro-
grams to minimize potentially harmful personnel exposures. While
Formosa Heavy Industries cannot assure that these procedures will
eliminate risk, they should tend to reduce the risk.
Classification of
Silica Dust
Free silica is uncombined silicon dioxide (SiO2). Silicates contain sil-
icon and oxygen combined with other elements in a more complex
molecule. With the exception of asbestos and some talcs, silicate
dusts should not ordinarily cause disabling lung conditions like those
produced by free silica.
It is uncombined or free silica that is most important in industrial dust
exposure. To evaluate an exposure properly, the percentage of un-
combined silica must be determined by petrographic analysis, pref-
erably by x-ray diffraction or infra-red techniques.
Harmful Effects of
Dust
It has been generally stated that the size of the offending dust parti-
cles is of extreme importance in determining the concentration of
particles that may be suspended in the air. The size of particles also
determines the depth to which these particles penetrate into the lung
along with the quantity that may become deposited and retained.
The particulates less than 10 microns in size are potentially the most
harmful. Generally, when airborne particles are substantially larger
than 10 microns in diameter, they are not of great concern because
they are unable to penetrate into the lung where they could be dam-
aging. Instead they are collected and removed by the nasal passag-
es or upper respiratory system.
Also, it has been generally stated that the duration of dust inhalation
is of extreme importance. Persons who for many years have contin-
2-5-7
uously inhaled free silica dust have a great likelihood of contracting a

silica related or caused disease. Those who only intermittently in-
hale the dust have less risk of injury. In addition, those persons who
smoke will increase the risk which otherwise exists.
Installation and
Removal
It is important to be aware that exposure to silica dust can occur dur-
ing installation of products that contain free silica as well as during
tear-out/removal and repair of facilities where products containing
free silica have previously been installed.
Protective measures should be taken during both installation and
tear-out and repair operations.
Silicosis
Inhalation of silica dust can produce rapidly-developing (acute) or
chronic silicosis - a disabling lung disease. Typically, the lung tissue
reacts to the presence of silica particles by forming fibrous matter
around the particle. Evidence suggests that particles below one mi-
cron (one-millionth of a meter) in size may be the most dangerous
since they may penetrate deeper into the lungs in high concentra-
tions. In rapidly-developing silicosis, symptoms appear 8 to 18
months after the first exposure. Chronic silicosis, the type usually
encountered in industry, generally is produced 5-20 years after the
chronic silica inhalation.
Silicosis is generally classified in three separate stages by medical
authorities.
The first stage of the disease produces no disability. The affected
man can carry on his work as well as ever. Frequently, the individual
is not aware that anything is wrong, and the disease is revealed only
by opaque nodular shadows on a chest x-ray coupled with a known
exposure to crystalline free silica.
In the second stage, respiration may be affected in some persons
but not in all by any means. Labored breathing on heavy exertion
usually is noted first, and a dry cough also may be present.
The third stage can develop after the second stage even though the
individual has been removed from exposure to silica dust. However,
2-5-8
the progress of the disease will be slower without continued dust ex-
posure. Breathing may become severely labored. The worker is far
below normal physically and is susceptible to respiratory diseases.
Chest x-ray may show an enlarged heart as a result of the body's at-
tempts to overcome the resistance of restricted blood vessels in the
lungs. Pulmonary tuberculosis and emphysema are frequent com-
plications.
Other Diseases
In addition to causing silicosis, the inhalation of silica dust can oth-
erwise weaken the lungs and their natural cleansing process. As a
result, the inhalation of silica dust may be a contribution factor lead-
ing to other respiratory diseases. Medical and scientific analysis is
continuing, and the total effect of silica inhalation is not known.
What is known strongly indicates that silica inhalation is hazardous to
health.
Threshold Limit
Value (TLV)
TLV's or Threshold Limit Values of mineral dusts are time weighted
average concentrations considered permissible for exposures of
eight hours per day, five days per week that are published by the
American Conference of Governmental Industrial Hygienists (ACGIH)
and have been promulgated as standards of OSHA.
These values have been obtained from the experience of many

groups in industry and from laboratory studies on animals. They are
reviewed annually and changed as necessary on the basis of experi-
ence. Copies of TLV's may be obtained by writing to:
American Conference of Governmental Industrial Hygienists
Building D-7
6500 Glenway Avenue
Cincinnati, OH 45211-4438
Phone: (513) 661-7881
For maximum safety, ALSTOM/FHI does not recommend the inhala-
tion of any silica dust.
2-5-9
Medical
Requirements
An effective medical control program for exposed personnel will help
prevent occupational diseases. Such a program can also serve as a
check on engineering controls because symptoms of exposure in a
group of workers could indicate inadequate controls.
Examinations should be performed by or under the supervision of a
licensed physician and should be given to all personnel prior to their
assignments to areas in which airborne concentrations of dust may
exceed the permissible exposure limits.
These examinations should include as a minimum the following:
1. Medical and occupational history.

2. Chest x-ray.
3. Pulmonary function studies.
4. Physical, including body weight, height and age.
Industrial Hygiene
Measurements
Personnel dust exposures should be evaluated by dust measure-
ments and a step-by-step analysis should be made to determine the
conditions under which personnel are exposed to silica material. A
standard procedure using personal sampling pumps should be em-
ployed in silica dust sampling. Sampling Data Sheet #S315 found in
the "NIOSH* Manual of Sampling Data Sheets" may be used to
sample respirable silica dust.
*National Institute for Occupational Safety and Health/U.S. Dept of
Health, Education and Welfare
Abatement of
Personnel
Exposures
Ventilation
The primary means of controlling airborne dust is through use of
proper ventilation. For detailed information refer to the ACGIH publi-
cation, "Industrial Ventilation, a Manual of Recommended Practices".
2-5-10
Protective
Equipment
Respiratory protection should be used by personnel working in dust
environments where the ventilation system is inadequate or non-
operational. A combination of both proper ventilation and respiratory
protection would tend to eliminate most risks.
For details on use of respirators refer to the ANSI standard, Z88.2-
1969 "Practices for Respiratory Protection".
2-5-11
SECTION 6 - PROCESS DESCRIPTION
TABLE OF CONTENTS
TITLE PAGE NO.
COAL, SORBENT, AND INERT FEED SYSTEMS ........................................................... 2-6-1

Coal Feed System ........................................................................................................ 2-6-1
Sorbent (Limestone) Injection System ....................................................................... 2-6-1
Inert (Sand) Injection System ...................................................................................... 2-6-2
CFB COMBUSTION (HEAT GENERATION) .................................................................... 2-6-2
COMBUSTION AND FLUIDIZING AIR SUPPLY .............................................................. 2-6-4
ASH COLLECTION AND CONVEYING SYSTEM ............................................................ 2-6-5
AUXILIARY HEAT INPUT SYSTEMS ............................................................................... 2-6-5

Start-up Burner System ............................................................................................... 2-6-5
UTILITY SYSTEMS ........................................................................................................... 2-6-6

Diesel Oil Supply .......................................................................................................... 2-6-6
Air Supply ..................................................................................................................... 2-6-6
Cooling Water ............................................................................................................... 2-6-6
Service Air .................................................................................................................... 2-6-7
Instrument Air ............................................................................................................... 2-6-7
2-6- i
PROCESS DESCRIPTION
COAL, SORBENT, AND

INERT FEED SYSTEMS
Coal Feed System

The coal feed system consists of three parallel trains, each capable
of a maximum fuel feed rate of 40,000 kg/hr.
Fuel is withdrawn from the coal silo, via coal silo shutoff valves, di-
rectly to the Gravimetric Feeders. The feeders are controlled by
the boiler capacity control system and according to the preselected
ratio. The fuel is then fed via pneumatically operated knife gate
valves and fuel feeding chutes to furnace front wall openings. The
fuel gravimetric feeders are also pressurized with cold primary air
via 6” diameter piping connections. Each pressurizing system con-
tains valves and instrumentation. Cold primary air also provides
purge air below each furnace isolation slide gate valve.
Sorbent (Limestone)
Injection System
There is one sorbent (limestone) silo which services one boiler. The
sorbent (limestone) silo is located in east side of boiler island for
unit 1 and in west side of boiler island for unit 2. One silo has one
(1) outlet. Silo hopper is equipped with a fluidizing device, isolation
gate valve and “rotofeed” continuous sorbent injection system.
Prepared sorbent (limestone) from the silo flows through the silo
outlet maintenance gate, fluidizing device, silo isolation gate, inlet
Dome Valves, lock vessel and dispensing vessel to variable speed
of volumetric feeder. Conveying air from dry plant air system pro-
vides high pressure conveying air which transports the sorbent
(limestone)/air mixture to the flow proportioners (splitters). The flow
proportioners divide the mixture into eight(8) streams which are
then injected into the furnace through injection feed nozzles. A iso-
lation valve is provided at each nozzle to isolate the feed system
from the furnace for isolation and maintenance purposes.
2-6-1
The pneumatic sorbent (limestone) feed system is controlled pro-

portional to the fuel feed (and such sulfur feed rate) and the
sorbent (limestone) feed rate is adjusted depending on the SO2
level in the stack flue gas.
Inert (Sand) Injection

System
There is one inert (sand) material silo per boiler, located near the
backpass and supported by boiler steel structure. One silo has
one (1) outlet to connect inert (sand) feed system.
Sized inert material from the inert (sand) silo flows through the in-
ert (sand) silo outlet maintenance gate, through the inlet dome
valve (pneumatic), and the Densphase transport vessel of feed
system. An compressed air from dry plant air system provides
conveying air which transports the inert material/air mixture into
the return duct of each seal pot nozzles. A isolation valve is pro-
vided at each nozzle to isolate the feed system from the seal pot
for isolation and maintenance purposes.
CFB COMBUSTION
(HEAT GENERATION)
The furnace chamber design is of the single grate arrangement.
Fuel combustion in the circulating fluid bed system takes place in

the vertical combustion chamber. Properly sized fuel and fine
grained sorbent (limestone) is fed into the furnace and is burned at
1 a relatively low temperature (850°C~900°C). The fined grained
limestone captures the sulfur dioxide released when the fuel is
burning. The bed material in the furnace consists primarily of fuel
ash, gypsum, and excess calcined limestone. The mean particle
size of the bed material is in the range of 100-300 microns.
The bed material is fluidized by primary air introduced through the

grate nozzles at the bottom of the bed and by the gas generated
during combustion. The air and gas flows upwards through the
furnace with a relatively high velocity filling the entire furnace with
suspended solids. The solids have a high concentration at the flu-
idizing bed and decrease continuously towards the top of the fur-
nace. The combustion gas entrains a considerable portion of the
solids in the furnace and carries them over to where the entrained
2-6-2
solids are separated from the gas in the recycle cyclones. Some
solids are continuously returned to the bed by a recycle loop. The
very high internal and external circulating rates of solids, character-
istic of a circulating fluid bed, result in consistently uniform temper-
atures throughout the furnace and the solids recycle system.
Because of the high slip velocity between gas and solids, the solids
proceed through the furnace at a slower velocity than the gas. Sol-
ids residence times in the order of minutes are obtained for each
cycle of solids circulation. The long residence and contact times,
coupled with the small particle sizes and efficient heat and mass
transfer rates, produce a high combustion efficiency. The afore-
mentioned effects in combination with temperature allow both the
decomposition of limestone and subsequent formation of gypsum.
Combustion air is introduced into the furnace at two levels. About

60 percent (at MCR) of the combustion air is passed as primary flu-
idizing air through the furnace grate and as sealing air through coal
feeding chutes, and the balance is admitted as secondary air
through multiple ports in the front and rear walls of the furnace and
as fluidizing air via solids air return ducts to the furnace. The com-
bustion proceeds in two zones; a primary reducing zone in the low-
er section of the furnace, and complete combustion using excess
air in the upper section. This staged combustion, at controlled low
temperatures, effectively suppresses NOX formation.
Preheated primary combustion air enters the furnace chamber

through the grate assembly and windbox located at the bottom of
the furnace. Preheated secondary air enters the furnace via multi-
ple ports located in the front and rear walls of the furnace. Flue gas
resulting from the combustion of the fuel, and the entrained solids,
exit the furnace at combustion temperature via two outlets located
in the upper portion of the rear wall and is ducted into the two par-
allel recycling cyclones designed to remove about 99% of the solids
entrained by the gas from the combustion chamber. The flue gas
is ducted from each of the two recycle cyclones via refractory-lined
connecting ducts to the backpass.
The solids separated by the recycling cyclones are collected in two

air fluidized seal pots. The solids are returned directly into the fur-
nace at essentially the furnace exit temperature. Fluidizing air from
2-6-3
the fluidizing air blower is used for fluidization of the cyclone solids
outlet cones, seal pots, and seal pot return ducts.
Heat for steam generation is removed from the system in three

ways.
1. First, by the furnace membrane water walls, and roof of the

furnace. Most of the heat is provided by the vertical furnace
walls.
2. Second, heat is removed in a conventional convective split

backpass using the sensible heat of the flue gas and entrained
solids.
3. Third, by pendant superheater and evaporator heat absorbing

surface located in the upper furnace region.
COMBUSTION AND
FLUIDIZING AIR SUPPLY
Combustion air is supplied to the CFB furnace in two main streams.
Air is passed through the bottom grate as primary fluidizing air.
The balance is admitted as secondary air through various ports in
the front and rear walls of the furnace, as fluidizing air for the si-
phon seals (seal pots) and as transport air for the limestone feed.
Various purges and fluidizing airflows also contribute to the com-
bustion air.
The flow of air is automatically proportioned to the fuel feed rate in

order to maintain the required excess air ratio for combustion.
The following list gives an overview of the airflows contributing to

the combustion air from blowers and fans supplying the air. The
values in parenthesis are the predicted percentages of total com-
bustion air at MCR conditions for each air supply system when fir-
ing the performance fuel.
1. Primary air fan in operation - Air to the furnace grate via the
Ljungstrom air preheater, cold and hot purge air for solids feed-
ing. Flow inlet vane controlled by combustion air flow control
(60%).
2. Secondary air fan in operation - Air to secondary air manifold

and start-up burner via the Ljungstrom air preheater. Flow inlet
vane controlled by combustion airflow control (36%).
2-6-4
3. One fluidizing air blower in operation - Air to siphon seal (seal

pot) fluidizing air, constant flow (3%).
4. One limestone feed system in operation - Limestone injection,

constant flow (approximately 1%).
ASH COLLECTION AND

CONVEYING SYSTEM
Some ash discharge points are connected to furnace. In order to
maintain a constant solids inventory in the furnace/cyclone system,
it is necessary to control the system bottom ash flow.
Solids are removed from the circulating fluid bed system as follows:
1. Fine fly ash at the Ljungstrom air preheater and flue gas clean-
ing equipment hopper outlets.
2. Coarse bottom ash from the furnace grate via ash screw cooler
outlets.
Ash is discharged from the furnace grate via 8.625” OD pipes and
ash discharge gate valves into four trains of single screw, water-
cooled ash coolers. Each ash cooler train is arranged at a slight
incline to horizontal.
Ash in the ash cooler train is cooled to 200°C~250°C by means of

water cooled screw flights and trough in the screw type ash coolers
before being discharged for collection and handling.
Special ash drains are provided on the furnace windbox and are in-
tended for use only when the unit is essentially cooled down. Dur-
ing normal operation the ash temperatures will range up to 900°C.
AUXILIARY HEAT INPUT

SYSTEMS
Start-up Burner System

The start-up burner system consists of four automatic retractable
start-up burners for firing diesel oil, with high energy arc igniter and
a burner management system.
Start-up burners are located on the east and west side walls of the
furnace. Each of the start-up burners has a firing capacity of
35.8x106 kcal/hr. Start-up and shutdown is independent for each
2-6-5
burner. The minimum turndown for each burner is 20% of its rated
capacity.
Combustion air for the start-up burners is supplied from the sec-
ondary air fan via the Ljungstrom air preheater.
UTILITY SYSTEMS
Diesel Oil Supply

Diesel oil is supplied at a net heat value of 10,221 kcal/kg from die-
sel oil pump. The supply conditions at the start-up burner piping
train before control valve is 10.2 kg/cm2(g) and before burner inlet
is 5.1 kg/cm2(g) at max. load.
Compressed air will be provided to burner for atomization. The

supply condition of compressed air at control valve is 7 kg/cm2(g)
and at burner inlet at max. burner load is 6 kg/cm2(g).
The diesel oil firing rate for each of the start-up burners is set by
the operator via hand indicating controller in conjunction with the
burner total diesel oil and total air summer (totalizer) control system.
Air Supply
Combustion air is supplied by the the secondary air fan to the start-
up burners. Protective purge air is also supplied by the secondary
air fan to cool burners when not in use.
Combustion air to the furnace is supplied by the primary air fan and
the secondary air fan via the furnace bed (via the Ljungstrom air
preheater).
Fluidizing air and grease air for cyclone and seal pot is supplied by
fluidizing air blower
Cooling Water
Cooling water coming from closed circuit cooling system is supplied
at a temperature of 37°C and a pressure of 4 kg/cm2(g), and is
used for services such as generator air cooler, T/G oil cooler, ash
screw coolers, F.A. blower, compressors, dryers, boiler feed water
pump, air heater and fans etc.
2-6-6
Service Air
Service air from plant air system (compressor station) is provided at
ambient air temperature and a pressure of 4~7 kg/cm2(g), dry, at a
2°C dew point temperature. The service air system is provided to
supply the various consumers within the plant, which are not sup-
plied from the instrument air system.
The transportation air for fly ash, limestone, sand and bottom ash
recycle system will also be integrated to the service air system,
surely buffer tanks are necessary for separate system.
Service air users are also as follows:
- Start-up burner
- Limestone feed system
- Sand feed system
- Ash cooler
- Bottom ash recycle system
- Service air station
Instrument Air
Instrument air is provided for controls at ambient air temperature, a
pressure of 4~7 kg/cm2(g), dry-oil and dust free, at a 2°C dew point
temperature.
The instrument air distribution system from air compressor located

in compressor room provides the demand for all instrument air with-
in the plant. Piping branches are connected to the ring main header
as possible via isolating valves and supply air to the necessary
equipments.
The system is designed on the basis of a dry, oil-free, filtered air

supply being provided from the compressor and dryer equipment
located somewhere suitable.
Instrumentation is limited to the provision of a single pressure

transmitter to monitor the air pressure in the source.
2-6-7
SECTION 7 - DESIGN DATA
TABLE OF CONTENTS
TITLE TAB NO.
DESIGN DATA ................................................................................................. 2-7-TAB_1-1
CONTRACT DATA SHEET .............................................................................. 2-7-TAB_2-1
PREDICTED PERFORMANCE DATA ............................................................. 2-7-TAB_3-1
PREDICTED PERFORMANCE AND STARTUP CURVES .............................. 2-7-TAB_4-1
2-7-1
TAB 1 - DESIGN DATA
TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION ............................................................................................... 2-7-TAB_1-2
DESIGN CONCEPT .......................................................................................... 2-7-TAB_1-2
LIST OF TABLES
TITLE PAGE NO.
Table 1. Boiler Pressure Parts 2-7-TAB_1-3
2-7-TAB_1-1
DESIGN DATA
INTRODUCTION
The steam generator is designed to produce superheated steam at
specified temperatures and pressures, when supplied with feedwa-
ter at a specific temperature. Operation of the steam generator at
any condition that exceeds the design limitations will shorten the
life of the boiler and its auxiliary equipment. Specific design param-
eters are outlined on the Predicted Performance sheet (Tab 3).
When the equipment is new, specific operating parameters should
be established which will serve as a standard for satisfactory boiler
operation. Then, if this specific “standard” or “normal” operating
condition is exceeded, steps can be taken to correct any devia-
tion(s) which may result in unsatisfactory boiler operation.
Emergency conditions may result in unnecessary boiler outages,
repairs or injuries. Plant personnel must be trained in safe boiler
operation and to make diligent recordings in the appropriate boiler
operation data logs.
Plant operation and maintenance standards should be followed by
plant personnel for both the boiler and the auxiliary equipment.
Plant personnel should become thoroughly familiar with the specific
design characteristics of the boiler and the associated auxiliary
equipment. This can only be accomplished if plant personnel dili-
gently observe, record, check and verify all pertinent data obtained
during normal boiler operation.
DESIGN CONCEPT
At maximum continuous rating (MCR), the Formosa Heavy Indus-
tries two CFB Type Reheat Boiler (steam generators) are each de-
signed for an evaporation rate of 460,000 kg/hr at a superheater
outlet pressure of 129 kg/cm2(g) and temperature of 541°C. The
design feedwater temperature is 245.4°C.
2-7-TAB_1-2
Table 1. Boiler Pressure Parts
CIRCUIT
NUMBER REQ'D DESCRIPTION
NUMBER
C-1 1 1676.4 I.D. STEAM DRUM
C-2 4 355.6 O.D. FURNACE DOWNCOMER
C-3 1 406.4 O.D. FURNACE LOWER FRONT INLET HEADER
C-4 174 TBS 63.5 O.D. FURNACE FRONT/ROOF FIN WELD PANELS
C-5 1 273.1 O.D. FURN FRONT/REAR UPP OUTLET HDR
C-6 26 168.3 O.D. FURN FRONT/REAR/ROOF RISERS
C-7 86 TBS 63.5 O.D. FURN FLOOR FIN WELD PANELS
C-8 1 406.4 O.D. FURNACE LWR REAR INLET HDR
C-9 174 TBS 63.5 O.D. FURN REAR FIN WLD PNLS
C-10 2 219.1 O.D. FURN OUTLET RING HDR
C-11 2 406.4 O.D. FURN LWR SIDE INLET HDR
C-12 172 TBS 63.5 O.D. FURN SIDE FIN WLD PNLS
C-13 2 273.1 O.D. FURN UPP SIDE OUTLET HDR
C-14 14 168.3 O.D. FURN SIDE RISERS
C-21 6 219.1 O.D. EVP. DOWNCOMER
C-22 6 273.1 O.D. EVP. INLET HDR
C-23 6 PNLS 63.5 O.D. EVP. FIN WLD PNLS
C-24 6 273.1 O.D. EVP. OUTLET HDR
C-25 12 168.3 O.D. EVP. RISERS
E-1 1 273.1 O.D. ECONOMIZER #1 INLET HEADER
E-2 115 TBS 50.8 O.D. ECON. #1 PLAIN TUBE ASSY
E-3 1 273.1 O.D. ECON. #1 OUTLET HEADER
E-4 1 273.1 O.D. COMMON LINK FROM ECON. #1
E-5 1 273.1 O.D. LINK TO ECON. #2-S IN SH PASS
E-6 1 273.1 O.D. ECON. #2-S INLET HDR
E-7 106 TBS 50.8 O.D. ECON. #2-S PLAIN TUBE ASSY
E-8 1 273.1 O.D. LINK TO ECON. #2-R IN RH PASS
E-9 1 273.1 O.D. ECON. #2-R INLET HDR
E-10 106 TBS 57.2 O.D. ECON. #2-R PLAIN TUBE ASSY
E-11 1 323.9 O.D. ECON. #2 JUNCT HDR
E-12 1 273.1 O.D. LINK TO ECON. #3 IN SH PASS
E-13 1 273.1 O.D. ECON. #3 INLET HEADER
E-14 106 TBS 50.8 O.D. ECON. #3 PLAIN TUBE ASSY-LOWER
E-15 106 TBS 50.8 O.D. ECON. #3 PLAIN TUBE ASSY-UPPER
E-16 1 323.9 O.D. ECON. #3 OUTLET HEADER
E-17 1 219.1 O.D. ECON. #3 LINK TO STEAM DRUM
S-1 8 168.3 O.D. SATURATED LINKS FROM STEAM DRUM
S-2 2 273.1 O.D. BKPASS UPP SIDE INLET HDRS
S-3 116 TBS 44.5 O.D. BKPASS SIDE FIN WLD PNLS
S-4 2 323.9 O.D. BKPASS LWR SIDE OUTLET HDRS
2-7-TAB_1-3
Table 1. Boiler Pressure Parts
CIRCUIT
NUMBER REQ'D DESCRIPTION
NUMBER
S-5 1 323.9 O.D. BKPASS LWR FRT INLET HDR
S-6 107 TBS 50.8 O.D. BKPASS FRONT FIN WLD PNLS
S-7 2 273.1 O.D. BKPASS GAS INLET RING HDR
S-8 107 TBS 50.8 O.D. BKPASS ROOF FIN WLD PNLS
S-9 107 TBS 50.8 O.D. BKPASS REAR FIN WLD PNLS
S-10 1 323.9 O.D. BKPASS LWR REAR OUTLET HDR
S-11 5 168.3 O.D. LINKS TO DIVISION WALL
S-12 1 273.1 O.D. BKPASS DIVISION WALL INLET HDRS
S-13 107 TBS 50.8 O.D. BKPASS DIVISION WALL
S-13 53 TBS PER ROW 50.8 O.D. BKPASS SCREEN TUBES
S-15 1 273.1 O.D. BKPASS DIVISION WALL OUTLET HDR
S-16 2 273.1 O.D. LINKS TO IN-FURN SH PANEL
S-17 1 406.4 O.D. SH PNL #1 INLET HDR
S-18 7 PNLS 44.5 O.D. SH FIN WLD PNL #1 INLET
S-19 7 273.1 O.D. SH PNL #1 JUNCT HDRS
S-20 7 PNLS 44.5 O.D. SH FIN WLD PNL #1 OUTLET
S-21 1 355.6 O.D. SH PNL #1 OUTLET HDR
S-22 1 355.6 O.D. LINK TO SH DESUPERHEATER #1
S-23 1 355.6 O.D. SH DESUPERHEATER #1
S-24 1 355.6 O.D. LINK TO SH PNL #2
S-25 1 355.6 O.D. SH PNL #2 INLET HDR
S-26 7 PNLS 44.5 O.D. SH FIN WLD PNL #2 INLET
S-27 7 273.1 O.D. SH PNL #2 JUNCT HDRS
S-28 7 PNLS 44.5 O.D. SH FIN WLD PNL #2 OUTLET
S-29 1 406.4 O.D. SH PNL #2 OUTLET HDR
S-30 1 406.4 O.D. LINK TO SH DESUPERHEATER #2
S-31 1 406.4 O.D. SH DESUPERHEATER #2
S-32 1 406.4 O.D. LINK TO LINK S-33
S-33 2 355.6 O.D. LINKS TO BP FINISH SH
S-34 1 406.4 O.D. FINISH SH INLET HDR
S-35 212 TBS 50.8 O.D. FINISH SH ASSY-LOWER
S-36 212 TBS 50.8 O.D. FINISH SH ASSY-INTERM.
S-37 212 TBS 50.8 O.D. FINISH SH ASSY-UPPER
S-38 1 406.4 O.D. FINISH SH OUTLET HDR
R-2 1 406.4 O.D. REHEATER INLET HDR
R-3 318 TBS 57.2 O.D. RH ASSY-LOWER
R-4 318 TBS 57.2 O.D. RH ASSY-LOWER INTERM.
R-5 318 TBS 57.2 O.D. RH ASSY-UPPER INTERM.
R-6 318 TBS 57.2 O.D. RH ASSY-UPPER
R-7 1 508 O.D. REHEATER OUTLET HDR
2-7-TAB_1-4
CONTRACT DATA SHEET
FORMOSA HEAVY INDUSTRIES
Contract No. MPP-130108-01/02/03
Project Description
SUPPLIER Formosa Heavy Industries Corporation.
USER San Miguel Consolidated Power Corporation, Malita, Davao Del Sur, Philippines
CONS. ENGINEER N.A.
Steam Generator Specifications

STEAM GENERATOR Designation Circulating Fluidized Bed Boiler
Pressure Oper. S.O.: 129 kg/cm2(g)

Turbine Throttle: 125 kg/cm2(g)
MCR 460,000 kg/hr
Plant Elevation N.A.

Associated Equip. Boiler design & proper, start-up burner system, coal feed system, limestone
pneumatic feed system, inert pneumatic feed system, fans, fly ash system,
bottom ash system, associated FBSS instrumentation and controls,
sootblowers, etc.
COMBUSTOR Description Balanced Draft
Dimensions Width 15,506.7 mm

Front to Rear 7,683.5 mm
Heating Surface 1,510 m2
Total Volume 4,000 m3
SUPERHEATER Description Convective Pass
REHEATER Description Convective Pass
ECONOMIZER Description Bare Tube Convective Pass
AIR HEATER Description Rotary Type Air Preheater
FUEL BURNING EQUIPMENT Description CFB Furnace w/Gravimetric Coal Feeders, Diesel Oil Start-up Burners
FUEL PERFORMANCE COAL Ash Fusion Grindability HHV / LHV

Temp. °C (kcal/kg)
42.97% Carbon, 2.75% Hydrogen, 11.42% 4,008 / 3,662
Oxygen, 0.59% Nitrogen, 1.49% Sulfur, 6.82%
Ash, 33.96% Water,
Operating Conditions
MCR
KG STEAM PER PRIMARY 460,000
HOUR ACTUAL REHEAT 181,867
STEAM TEMP (°C) SUPERHEATER 541
LEAVING REHEATER 541
REHEAT DATA ENTERING TEMP (°C) 370
ENTERING PRESS. (kg/cm2g) 36.6
FEEDWATER TEMP. °C 245.4
TEMP. GAS FROM AIR HEATER (°C) Uncor. 135
OVERALL EFFICIENCY (%) *Guaranteed, LHV 90.9
2-7-TAB_2-1
Formosa Heavy Industries Corp.
CFB Type Reheat Boiler
Unit 1 and Unit 2
San Miguel Consolidated Power Corporation
Malita, Davao Del Sur, Philippines
FHI Contract no. : MPP-130108-01/02/03
Predicted Performance
Load MCR
Fuel Coal
Evaporation kg/hr 460,000
Feedwater Temperature °C 245.4
Feedwater Temperature Leaving Economizer °C 303
Superheater Outlet Temperature °C 541
Superheater Outlet Pressure kg/cm2(g) 129
Superheater Pressure Drop kg/cm2(g) 16
Reheating Steam kg/hr 181,867
Reheater Inlet Temperature °C 370
Reheater Inlet Pressure kg/cm2(g) 36.6
Reheater Outlet Temperature °C 541
Reheater Outlet Pressure kg/cm2(g) 35.1
Reheater Pressure Drop kg/cm2(g) 1.5
Economizer Pressure Drop kg/cm2(g) 3.5
Gas Temperature Entering Air Heater °C 322

Gas Temperature Leaving Air Heater, Uncorrected °C 135
Gas Temperature Leaving Air Heater, Corrected °C 128.4
Primary Air Temperature Entering Air Heater °C 45
Secondary Air Temperature Entering Air Heater °C 39
Primary Air Temperature Leaving Air Heater °C 285.8
Secondary Air Temperature Leaving Air Heater °C 301.6
Ambient Air Temperature °C 35
Excess Air Leaving Economizer % 20
Fuel Fired kg/hr 89,000
Efficiency, LHV % 90.9
2-7-TAB_3-1
TAB 3 - PREDICTED PERFORMANCE
*NOTES:
These performance figures are predicted only and are not to be construed as being
guaranteed except where the points coincide with the guarantees.
Operation of this unit in excess of the above specified Maximum Continuous Rating (MCR)
may result in damage to the equipment and/or increased maintenance.
The fuel specifications on which the guarantees are based are as follows:
RAW MATERIAL SPECIFICATION
Solid Fuel Specification
Type: Coal
% Passing
Size Distribution Enter Boiler Size(mm) By Weight
6.0 – 9.0 Top Size (99% passing)
0.7 – 1.5 D - 50
Less Than 0.1 5% (max.) fines
Higher Heating Value (HHV), kcal/kg (A.F.B.) 4,008

Higher Heating Value (HHV), kcal/kg (A.F.B.) 3,662
Ultimate Analysis: As Fired, % Weight
Carbon 42.97
Hydrogen 2.75
Nitrogen 0.59
Sulfur 1.49
Ash 6.82
Oxygen 11.42
Water 33.96
100.00
2-7-TAB_3-2
TAB 3 - PREDICTED PERFORMANCE
Limestone Specification
Type: Limestone
% Passing
Size Distribution Size(mm) By Weight
0.8 – 1.5 Top Size (99% passing)
0.3 – 0.5 D - 50
Chemical Composition: Performance Limestone

Dry Basis, % Weight
CaCO3 93.66
MgCO3 0.61
H2O 0.72
Inerts 5.01
100.00
Attrition Index: Not to exceed 25
Moisture Content < 1% (for pneumatic conveying)
Sand Specification
Type: Sand
Size Distribution Size(mm) By Weight

Less Than 0.6 Top Size (99% passing)
0.15 – 0.30 D - 50
Moisture Content < 1% (for pneumatic conveying)
• Sphericity Factor: Greater than 0.85 (Sphericity factor is the degree of

deviation from spherical shape with a 1.0 representing a perfect sphere).
This requirement is necessary to ensure that proper shape for good
fluidization and to reduce erosion potential by providing a more rounded
particle.
• Acid-soluble alkali content as NA2 + K2: Below 0.5% by weight.
• Chlorides: Below 0.05% by weight.
• Fusion temperature ≧1250℃
2-7-TAB_3-3
TAB 4 - PREDICTED PERFORMANCE AND STARTUP

CURVES
LIST OF FIGURES
TITLE FIGURE NO.
Maximum Allowable Rate of Pressure Change for Normal Startups & Shutdowns 1
Start-up Curves (Cold Startup) 2
Start-up Curves (Warm Startup) 3
Start-up Curves (Hot Startup) 4
Start-up Curves (Cold Shutdown) 5
Steam Temperature vs % Load 6
Percent Oxygen vs Load 7
Furnace Temperature vs % Load 8
Overall Furnace DP vs Load 9
Superheater Spray vs % Load 10
Superheater Outlet Pressure vs % Load 11
Air flow vs Load 12
Fuel Flow & Sorbent Flow vs Load 13
2-7-TAB_4-1
MAXIMUM ALLOWABLE RATE OF PRESSURE CHANGE
FOR
NORMAL START-UPS AND SHUTDOWNS
(NATURAL CIRCULATION UNITS)
PSIG PSIG
[kPa (gauge)] [kPa (gauge)]
[20685]
[17238] [16548]
[13700]
[13790]
[13798]
[10343]
[10343]
[6895]
[6895]
[5516]
D
R
U [4137]
M
P [2758]
[3448]
R
E [2069]
S
S [83° C]
U [1379]
R
E
- [110° C]
P
S [689]
I
[552] [690]
G
[414]
[276] [345]
[207]
[138]
Figure 1
FORMOSA HEAVY INDUSTRIES CORPORATION
SMC-150MW RH-CFB BOILER
COLD STARTUP
900 110
Furn. Temp.
** : Period from turbine rolling to sychronize depends on turbine warm-up suitation 100
800
SUPERHAETER OUTLET PRESSURE,, Kg/Cm2 G
Boiler load 90
700
SH./ R.H OUTLET TEMPERATURE, °C
80
FURNACE TEMPERATURE, °C
600
70
BOILER LOAD, %
500 SH / RH Out.
60
Temp.
400 50
40
300
30
200
S.H. pressure 20
100
10
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Shutoff Full Load -

Roll** Turbine** Turbine Start Startup Boiler
5 Min. Purge Turbine Syn. IP/HP Coal Burners
Fire Burners Transfer
TIME, HOURS
WARM STARTUP
900 110
Furn. Temp. Furn. Temp.
100
800 Boiler 8 - 56 HOUR
SHUTDOWN
Boiler Load
SUPERHEATER OUTLET PRESSURE, Kg/Cm2 G
Load
90
700
S.H. / R.H. OUTLET TEMPERATURE, °C
80
600 SH/RH SH/RH

Out. Temp. Out. Temp. 70
LOAD, % MCR
500 60
400 50
40
300
30
200
SH Outl.
SH Out. Press. Press. 20
100
10
0 0
-3.00 -2.00 -1.00 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00
TIME, HOURS
Start Roll Turbine Turbine Start Shutoff Full Load

Shut off Fuel, 5 Min. Purge Coal
Reducing Fuel Turbine Syn. IP/HP Burners Boiler
Fire Burners
Transfer
Turbine
Syn.
HOT STARTUP
900 110
Furnace Temp. Furnace Temp.
100
800
Boiler Load Boiler Load
90
700
< 8 HOUR
80
SUPERHEATER OUTLET PRESUE, Kg/Cm2 G
SHUTDOWN
600
SH/RH OUTLET TEMPERATURE, °C
BOILER LOAD, % MCR

70
SH/RH Out. Temp.
500 SH/RH Out. Temp.
60
400 50
40
300
30
200
20
SH. Out. Press. SH. Out. Press.
100
10
0 0
-3.00 -2.00 -1.00 0.00 1.00 2.00 3.00 4.00 5.00
Start Fans, Start
Begin Blowers Oil
Reducing Shut off Fuel, Burnerl Turbine Full Load TIME, HOURS
Fuel Trip Turbine Turbine Syn & HP/LP Start Shutoff
Roll Coall
Transfer. Burner
BOILER COLD SHUTDOWN
900 120
Furnace Temp.
800
100
Boiler Load
700
SUPERHEATER OUTLET PRESSUR,(Kg/cm2 G)
600 80
SH/RH OUTLET TEMPERATURE (°C)
FURNACE TEMPERATURE (°C)
BOILER LOAD, % MCR

500 SH/RH Outlet Temp.
60
400
300 40
200
SH Outlet Press. 20
100
0 0
-2.00 -1.00 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
TIME, HOURS
Begin Shutdown, Start Shut off Shut off
Start Reducing Fuel Burners Solid Fuel Burners
SH & RH STEAM TEMPERATURE VERSUS LOAD FOR DESIGN COAL
542
540
538
536
STEAM TEMPERATURE, °C
534
532
530
528
526
524
522
20 30 40 50 60 70 80 90 100
BOILER MCR STEAM FLOW, %
O2 VERSUS LOAD BASED ON DESIGN COAL
14
12
FLUE GAS VOLUME OXYGEN LEVEL DRY BASE, % O2
10
0
30 40 50 60 70 80 90 100
FURNACE AVERAGE TEMPERATURE VERSUS LOAD (DESIGN COAL)
900
850
FURNACE FLUE GAS OUTLET TEMPERATURE, °C
800
750
700
650
600
550
30 40 50 60 70 80 90 100
OVERALL FURNACE PRESSURE DROP VERSUS BOILER LOAD
2300
HIGH LIMIT
2100
OVERALL FURNACE PRESSURE DROP MMH2O
1900
1700
NORMAL
1500
OPERATION
1300
LOW LIMIT
1100
900
700
500
0 10 20 30 40 50 60 70 80 90 100
SUPERHEATER SPRAY VERSUS LOAD FOR DESIGN COAL
3.00
2.50
SUPERHEATER SPRAY, % MAIN STEAM FLOW
2.00
1.50
1.00
0.50
0.00
30 40 50 60 70 80 90 100
SUPERHEATER OUTLET PRESSURE VERSUS BOILER LOAD
150.0
140.0
SUPERHEATER OUTLET PRESSURE, Kg/cm2G
130.0
120.0
110.0
100.0
90.0
80.0
70.0
60.0
0 10 20 30 40 50 60 70 80 90 100
AIR FLOW VERSUS BOILER LOAD FOR DESIGN COAL
700
600
AIR FLOW RATE TO FURNAC TONS/HR
500
400
TOTAL AIR TO BOILER
300
PRIMARY AIR EXCLUDING AH LEAKAGE
200
100 SECONADRY AIR EXCLUDING AH LEAKAGE
0
0 10 20 30 40 50 60 70 80 90 100
SMC-150 MW RH-CFB BOILER
DESIGN COAL FLOW & SORBENT FLOW VERSUS BOILER LOAD
100
90
COAL FLOW
80
FUEL & SORBENT FLOW, T/HR
70
60
50
40
30
20
10
LIMESTONE FLOW
0
30 40 50 60 70 80 90 100

SECTION 8 - OPERATIONAL PROCEDURES
TABLE OF CONTENTS
TITLE TAB NO.
SAFETY PRECAUTION
HYDROSTATIC TESTING ............................................................................................. 1
WATER WEIGHTS ........................................................................................................ 2
FEEDWATER TREATMENT.......................................................................................... 3
LAY-UP PROCEDURES ................................................................................................ 4
RECOMMENDED CHEMICAL CLEANING PROCEDURES ......................................... 5
PRINCIPLES OF BOILER OPERATION ....................................................................... 6
STEAM LINE BLOWING PROCEDURES ..................................................................... 7
START UP CHECK OUT ............................................................................................... 8
UNIT OPERATING PROCEDURES .............................................................................. 9
SAFETY VALVE ADJUSTING ..................................................................................... 10
2-8-1
SAFETY
PRECAUTION
The following instructions are the general instruction for precaution

which apply when placing a boiler into operation. They are intended
to supplement the experience and judgment of those in charge of
operation and can't cover all precautions which should be observed.
A newly erected unit, prior to being placed into operation must be

carefully inspected to assure that all component parts are properly
assembled.
It is the purchaser's responsibility to see that the unit has been

inspected by his insurance inspector and, if required, approved by
government inspectors.
All auxiliary equipments must be inspected first and shall be

operated in accordance with the recommendation or instruction of
each maker.
Before a new unit in service, following be accomplished as required :
a. When the water level in the drum is lowered below the lowest
visible point of the gage glass, all water should drain out of the
glass. Any time a repair or change is made to the gage glass,
this should be checked.
b. Blowdown lines from water column and gage glasses must be

properly piped and drain valves closed. The gage glasses must
be properly illuminated and clearly visible to the operator from
the operating floor.
c. All drain and blowdown lines must be readily accessible and

properly piped to a blowdown tank.
Drain valves of multiple boilers should not be connected

together.
d. Information from each steam pressure gage must be visible to

the operator from the operating floor and gages must be
correctly installed with intermediate line valves open.
2-8-2
e. All safety valve gage must be removed and valves in proper

operating condition. Discharge pipes, vents and drains should
be arranged and supported in accordance with the safety valve
maker's recommendations.
f. Drum internals must be properly installed in accordance with

drawings to assure that there will not be any steam by-passing
the internals.
g. All necessary test connections must be installed.
In addition to the above, the following items should be thoroughly

checked each time a boiler is placed into operation.
a. All necessary operating instruments, must be installed,

operating properly and correctly calibrated.
b. All necessary areas must be sufficiently illuminated.
c. No hazardous walkways, ladders or stairways should be used.

Provide substantial walkways and platforms where needed.
d. Air and gas passages must be free from obstruction and unit
capable of being thoroughly purged by the circulation of air
through the unit.
e. The source of feed water to boiler and make-up water to the

cycle must be sufficient, constant and well quality once the unit
is in operation.
f. A sufficient and constant fuel supply should be available.
g. All access and observation doors must be closed after it is

confirmed that no personnel are inside of the unit.
h. Manhole openings must be closed and properly made up.
2-8-3
TAB 1 - HYDROSTATIC TEST PROCEDURES
TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION ............................................................................................... 2-8-TAB_1-1
PRELIMINARY.................................................................................................. 2-8-TAB_1-1
FILLING ............................................................................................................ 2-8-TAB_1-2
FILL WATER..................................................................................................... 2-8-TAB_1-2
EXTERNAL CHECK ......................................................................................... 2-8-TAB_1-3
HYDROSTATIC TESTING ................................................................................ 2-8-TAB_1-4
POST HYDROSTATIC TEST PROCEDURES ................................................. 2-8-TAB_1-6
2-8-TAB_1-i
HYDROSTATIC TEST PROCEDURES
INTRODUCTION
After installation of all pressure parts, except those omitted during
chemical cleaning (see Chemical Cleaning Procedures), the unit is
subjected to the required initial hydrostatic test of 1-1/2 times the
unit design pressure. Depending on insurance requirements, hy-
drostatic test of pressure parts repairs are commonly made at the
normal operating pressure or the design pressure.
NOTE: The boiler, superheater, reheater and econ-

omizer are hydrostatically tested as a unit.
Hydrostatic test procedures depend to a great extent on local con-

ditions and provisions. Procedures for initial hydrostatic testing
must be in accordance with Boiler Code requirements. Specific ini-
tial hydrostatic testing procedures can be supplied, if necessary, by
this Company's Construction Services Department. The following
basic rules should always be followed:
PRELIMINARY
1. Before starting to fill the waterwalls, superheater and reheater
make sure all drums and headers are cleared of foreign mate-
rial. Close all drains. Open all vents normally used when filling
the unit (such as superheater link vents, reheater link vents,
economizer link vents, drum vents).
2. Prior to any hydrostatic test above the normal operating pres-
sure, hydrostatic test plugs must be installed in all safety valves
in accordance with the manufacturer's instructions. If the hy-
drostatic test pressure is at or below the normal operating
pressure it may be sufficient to merely gag the safety valves.
Refer to the safety valve manufacturer's instructions.
2-8-TAB_1-1
FILLING
1. Fill the superheater (See Fill Water Below) through a suitable
outlet connection (such as the final superheater outlet header
drain or vent) until all elements are filled and the water over-
flows into the steam drum.
2. Cease filling through the superheater outlet connection when
the water overflows into the steam drum. Close superheater fill
and vent connections.
3. Proceed filling the boiler (See Fill Water, below) through the
normal filling connections. Keep filling until water overflows
from the drum vents. Then close all vents.
FILL WATER
It is the responsibility of the customer to provide properly treated
water, as specified below, at ambient temperature but in no case
less than 21°C and max. 50°C. If the proper type of water is not
available, the Formosa Heavy Industries Co-Generation depart-
ment should be contacted for further information. Once the super-
heater has been filled, take water samples from each available su-
perheater vent or drain and analyze them to verify the absence of
contamination.
Type of water to be used:
1. Superheater and Reheater (drainable and nondrainable sec-
tions): Fill with treated condensate or treated demineralized wa-
ter (See Note). The treatment shall include 10 ppm ammonia.
This treated water will have a pH value of approximately 10.
NOTE: Demineralized or condensate quality water

is defined as containing no more than 1 ppm inden-
tifiable solids and essentially a zero concentration
(or lowest detectable level) of organic material.
2-8-TAB_1-2
CAUTION: THE USE OF FILL WATER TREATED

WITH SOLID CHEMICALS SHOULD BE AVOID-
ED. DEPOSITS OF SOLID MATERIALS IN SU-
PERHEATERS CAN BE DETRIMENTAL FROM
HEAT TRANSFER AND CORROSION STAND-
POINTS. SUPERHEATERS CONTAINING STAIN-
LESS STEEL TUBING ARE PARTICULARLY
VULNERABLE TO STRESS CORROSION
CRACKING IN THE PRESENCE OF SUCH CHEM-
ICALS AS CAUSTICS AND CHLORIDES.
2. Remainder of boiler unit: Fill with treated condensate or treated

demineralized water or, if not available, with a clean source of
filtered water treated with 10 ppm ammonia.
NOTE: The use of oxygen scavengers in the hydro

fill (or lay-up) water is not necessary. If the hydro fill
water remains in the boiler for an extended period
of time (see Lay-up Procedures), it is important to
establish and maintain a nitrogen cap to prevent air
ingress.
CAUTION: If potable water (TDS < 500 ppm, Cl <

100 ppm) is used in any of the procedures prior to
the steam blow operation, the unit cannot be fired
or heated until this water has been drained and the
components rinsed with demineralized water. The
final rinse should not contain more than 5 ppm so-
dium and 5 ppm chlorides.
EXTERNAL
INSPECTION
Before applying a hydrotest on a unit, make a thorough internal and

external inspection to be absolutely sure that :
1. All foreign material and tools have been removed.
2. No personnel are inside of the unit.
2-8-TAB_1-3
3. Pressure gages have been correctly calibrated and are con-

nected properly with intermediate line valves open.
4. All safety valves are blanked or gagged if the hydrotest pres-
sure is near to or will exceed the lifting pressure of any safety
valve.
5. Any part not designed to withstand the hydrates pressure is
properly isolated or blanked off from such pressure.
6. All steam circuit spring hangers are pinned in a fixed position.
7. All valves operate freely and seat properly.
8. When the foregoing have been carefully checked:
9. Close all manholes.
10. Close stop and check valves, all drain and blowdown valves to
any gages or other integral equipment not designed to with-
stand the hydrotest pressure.
11. Open vents on the highest points of each component part of
the unit.
12. Be sure that the water will not freeze during test and that non-
drainable portions of the unit will be freeze protected following
the hydrotest.
13. Never put a hydrotest of more than design pressure on a unit
that is at or near operating temperature.
14. Check that only authorized personnel are in the vicinity of the
unit to be tested. All personnel should remain a minimum of six
meters away from any pressure parts during the test.
HYDROSTATIC
TESTING
1. Apply hydrostatic test in accordance with Boiler Code require-
ments.
2. Raise pressure to the intended figure slowly to avoid shock.
The recommended rate of pressure increase should be 1 ~ 3
kg/cm2(g) but not exceed 3 kg/cm2(g) per minute.
The unit must be maintained at full hydrostatic pressure test
level for a duration of time that satisfies qualified inspectors.
3. If hydrotest was applied at pressure above design pressure,
reduce pressure slowly and thoroughly inspect unit for leaks
2-8-TAB_1-4
only at operating or design pressure. When inspection is com-

pleted, open vents and drains, release pressure slowly (same
as raising pressure but no more than 5 kg/cm2(g) per min.).
All drainable portions of the unit not intended to contain water
during operation must be drained.
CAUTION: HYDROSTATIC TEST PRESSURE

SHOULD NOT BE APPLIED TO THE BOILER IF
THE METAL TEMPERATURE OF PRESSURE
PARTS IS BELOW 21°C TO BE KEPT TO PRE-
VENT THE METAL FROM BEING BRITTLE AND
DUCTILE TRANSITION.
2-8-TAB_1-5
NOTE :
For Boiler plus Superheater
Design Pressure : 153.5 kg/cm2(g)
Hydrotest Pressure : 230.25 kg/cm2(g)
Hold Points and Check :
1st : 10 kg/cm2(g), hold and field check
nd
2 : 50 kg/cm2(g), hold and quick field check
3rd : 153.5 kg/cm2(g), hold 1~2 hr for thorough check
th
4 : 230.25 kg/cm2(g), hold 15 min. no field check
5th : 153.5 kg/cm2(g), hold 1~2 hr for thorough
check
For Reheater
Design Pressure : 45 kg/cm2(g)
Hydrotest Pressure : 67.5 kg/cm2(g)
Hold Points and Check :
1st : 10 kg/cm2(g), hold and field check
2nd : 45 kg/cm2(g), hold 1~2 hr for thorough check
3rd : 67.5 kg/cm2(g), hold 15 min. no field check
4th : 45 kg/cm2(g), hold 1~2 hr for thorough check
POST
HYDROSTATIC
TEST
PROCEDURES
1. Introduce nitrogen through the drum vent to pressurize the unit
to approximately 0.35 kg/cm2(g).
2. Remove all hydrostatic test plugs and gags from the safety
valves prior to starting up the unit.
NOTE: Since there is generally some time delay
between the hydrostatic test and the initial boiling
out of the boiler, the unit should remain full of water,
air should not be allowed to enter.
2-8-TAB_1-6
NOTE: If there is a chance of freezing, the water in

the drainable circuits can be displaced by nitrogen
and the unit can be laid-up under nitrogen pressure.
Temporary heating equipment should be provided
to keep the nondrainable superheater elements
above freezing temperature.
2-8-TAB_1-7
TAB 2 - WATER WEIGHTS
TABLE OF CONTENTS
TITLE PAGE NO.
WATER WEIGHTS ........................................................................................... 2-8-TAB_2-1
2-8-TAB_2-i
WATER WEIGHTS
WATER WEIGHTS SUMMARY*
kgs at 15.5°C
Components* Entirely Filled (Hydro) kgs
Economizer: 55,379
[Includes water in all Economizer
Components, starting at the econo-
mizer inlet and ending at the drum
end of the economizer outlet links]
Steam Drum: 31,784

(Includes water in Steam Drum only)
Furnace: 74,477
(Includes water in all Furnace Com-
ponents, starting at the inlet end of
the downcomers and ending at the
drum end of the riser tubes)
Evaporator: 13,994
(Includes water in all Evaporator
Components, starting at the drum end
of the evaporator downcomers and
ending at the drum end of the evapo-
rator risers)
Superheater:
[Includes water in all Superheater
Components, starting at the drum end 75,760
of the superheater connection tubes
and ending at the superheater outlet]
Reheater:
[Includes water in all Reheater Com- 60,068
ponents, starting at the reheater inlet
header and ending at the reheater
outlet header]
Total 311,462
Prepared Water : 358,181 within15% margin
2-8-TAB_2-1
TAB 3 - WATER TREATMENT
TABLE OF CONTENTS
TITLE PAGE NO.
WATER TREATMENT...................................................................................... 2-8-TAB_3-1
LIST OF FIGURES
TITLE FIGURE NO.
Silica in Boiler Water Relationship with Drum Pressure ............................ 2-8-TAB_3-1
Criteria for Maintaining Boiler Water Concentrations ................................. 2-8-TAB_3-2
Recommended Coordinated Phosphate Curve ........................................... 2-8-TAB_3-3
2-8-TAB_3- i
WATER TREATMENT
WATER
TREATMENT
The treatment of feedwater and the conditioning of boiler water are
beyond the control of this company. This company does not as-
sume the responsibility for water treatment and does not make spe-
cific recommendations for control purposes. This is in accordance
with the practice established by the American Boiler and Affiliated
Industries Standards Committee. However, reference should be
made to the company’s Proposal, which warns against exceeding
maximum limits of hardness in the feedwater for certain boiler types
and of total solids, alkalinity and suspended solids concentrations in
the boiler water. These limits are absolute maximums and should
not be exceeded. In addition, the boiler water silica content should
be limited for the particular operating pressure involved by reference
to standard silica vaporization curves.
The successful operation of steam generating equipment depends
upon a rigid control of feedwater and operating variables to assure
freedom from scale formation and corrosion of water and steam con-
tacted surfaces of the boiler. This control is very important in lower
pressure boilers and becomes increasingly magnified at intermediate
and higher pressure operation.
Scale formation in boilers is prevented by providing a good makeup
water to the feedwater system and by avoiding condensate contami-
nation. At lower pressures, a suitable makeup may be attained by
cold or hot lime-soda process softeners or by zeolite combinations.
At higher pressure, the makeup must be of condensate quality such
as provided by evaporation or by demineralization.
Corrosion of metal surfaces in contact with water and steam consti-
tutes the major maintenance expense to the power industry. The
condensate and feedwater must be free of dissolved corrosive gas-
2-8-TAB_3- 1
es and the pH of the water must be properly adjusted to prevent the

attack on metal surfaces.
The oxygen content in the feedwater must be reduced to low levels
by effective deaeration in the condenser and in deaerating heaters.
It is recommended that deaerating heaters be kept pressurized to
0.7 to 1.1 kg/cm2, minimum, equivalent to 116°C to 121°C water
temperature, during all operational modes (start-up, load production,
shutdown). During standby periods, the appropriate Formosa Heavy
Industries recommended lay-up procedure should be followed. Care
must be taken to prevent the introduction of air into heater drips
which may be added to the condensate. Makeup condensate from
storage tanks should not be added directly to the feedwater system
without deaeration. Minimum forced boiler outage time has been re-
alized where the oxygen content has been reduced and held below
0.01 ppm. It is important to maintain a chemical reducing environ-
ment in the boiler water and chemicals such as sulfite have been
used effectively to achieve this.
The pH of the feedwater must be controlled to prevent the dissolu-
tion of the iron and copper alloys in the preboiler system. These form
corrosive products when introduced into the boiler and will contribute
to the corrosion of boiler steam generating surfaces. Oxides of iron
and copper may permit the diffusion of boiler water to the heated
surfaces of the unit and cause locally high concentrations of boiler
water salines that result in the attack on tube metal.
The pickup metals from preboiler surfaces can be minimized by the
addition of volatile alkaline chemicals that raise the pH of the feed-
water. Ammonia and various amines, added to maintain a pH range
of 8.8 to 9.2, have produced the best results.
The philosophy of control of boiler water pH varies widely in the in-
dustry. The caustic-based pH system, the coordinated phosphate/pH
control and the volatile treatment method have all been successfully
applied; however, the latter two methods of control are preferred in
higher pressure boilers.
Volatile treatment offers the greatest assurance against deposition in
superheaters and turbines that might result from intermittent carry-
2-8-TAB_3- 2
over. The only disadvantage of this treatment is the fact that the
boiler water is unbuffered and subject to relatively rapid changes in
boiler water pH values if contamination should occur. Where the
advantages of volatile control are to be pursued, special emphasis
must be placed on quick detection of condenser leaks, and alarms
must be available etc, alert the operators that such condition exists.
Volatile control should be used only when the dissolved solids con-
tent in the boiler is less than that shown in the attached table. If a
significant concentration of solids is present as a result of condenser
leakage, solid treating chemicals such as trisodium phosphate
should be available for immediate injection of pH adjustment of the
boiler water. Under no circumstances should a boiler be operated
with a pH value below 7.0. If the boiler water pH cannot be main-
tained above this value with chemical feed and blowdown, the unit
should be removed from service in an orderly fashion.
Close control of solids in the boiler water must be established to pre-
vent carry-over of boiler water into the steam. The presence of oil,
grease, high alkalinity, or other foam inducing solids cannot be toler-
ated.
It is evident that stringent control of operation and feedwater treat-
ment must be applied to prevent trouble from scaling, corrosion and
foaming. While caustic embrittlement is no longer a serious problem
in the industry, care should be taken in the operation of lower pres-
2
sure boilers [below 63.3 kg/cm ] to prevent its occurrence by
maintenance of proper alkalinity-to-nitrate ratios. The necessity for
its application can be determined by means of a Bureau of Mines
Embrittlement Detector.
The control of boiler water is a prime requisite for good operation. A
good chemical staff should be employed. The services of a compe-
tent consultant can be of value to supplement necessary technical
data and information.
2-8-TAB_3- 3
NOTE: Protection of the boiler against corrosion

should not be limited to actual operation of the unit.
Rigid standards with respect to water conditioning
should also be maintained during lay-up periods.
For details on boiler lay-up refer to the recom-
mended procedures elsewhere in the Manual.
2-8-TAB_3- 4
Figure 2-8-TAB_3-1
Figure 2-8-TAB_3-2
Figure 2-8-TAB_3-3
TAB 4 - LAY-UP PROCEDURES
TABLE OF CONTENTS
TITLE PAGE NO.
PRE-OPERATIONAL PERIOD ........................................................................ 2-8-TAB_4-1
POST BOIL-OUT PERIOD ............................................................................... 2-8-TAB_4-2
SHORT OUTAGE PERIOD .............................................................................. 2-8-TAB_4-2
LONG OUTAGE ............................................................................................... 2-8-TAB_4-2
2-8-TAB_4- i
LAY-UP PROCEDURES
PRE-
OPERATIONAL
PERIOD
When the boiler is ready for the hydrostatic test, proceed as follows:
1. Fill the superheater with condensate or demineralized water
containing 10 ppm (10 mg/kg) of ammonia and 200 ppm (200
mg/kg) of hydrazine. The pH value of the solution should be
approximately 10.0. The condensate is added at the super-
heater outlet to overflow into the boiler drum.
2. When the condensate overflows from the superheater into the
boiler drum, the addition of condensate at the superheater can
be stopped and the unit filled as described in step 3.
3. Fill the boiler through the normal filling connections with hydra-
zine treated water. Close boiler drains and open boiler vents as
during normal filling procedures.
4. At the conclusion of the hydrostatic test, with the boiler and su-
perheater filled to overflowing, pressurize the unit to 0.2 to 0.35
2
kg/cm (g) gage with nitrogen.
a. If freezing is a problem, the water in the drainable circuits
can be displaced with nitrogen and the unit is layed up un-
der nitrogen pressure. Auxiliary heat may be applied to
keep the non-drainable sections from freezing.
b. With drainable superheaters all surfaces can be laid up un-
der nitrogen pressure.
5. Boilers without stop valves in the main steam line should have
the outlet isolated by means of a blank flange, or equivalent, so
that a small positive pressure can be applied.
2-8-TAB_4-1
POST BOIL-OUT
PERIOD
If the operation of the boiler is delayed after boiling out it should be
filled as follows:
Introduce condensate containing about 10 ppm (10 mg/kg) of am-
monia and 200 ppm (200 mg/kg) of hydrazine to the boiler and su-
perheater and pressurize the unit with nitrogen.
SHORT OUTAGE
PERIOD
No draining. If the boiler is shut down for a period of three to four
days, and the boiler pressure will drop to atmospheric pressure:
Introduce nitrogen through the boiler drum vent and superheater
outlet header drain/vent, as the unit is cooled, when the steam
pressure drops below 0.35 kg/cm2(g). Maintain a total pressure
0.35 kg/cm2(g) due to nitrogen. Admission of air through atmos-
pheric vents should be avoided.
LONG OUTAGE
Boiler not opened for repair work. Where the boiler is removed
from service for a prolonged shutdown, as a seasonal outage of a
month or longer:
1. Fill the superheater, adding the condensate to the outlet of the
nondrainable sections. Then proceed with filling the boiler with
a condensate 10 ppm (10 mg/kg) of ammonia and 200 ppm
(200 mg/kg) of hydrazine.
The treated condensate can be displaced with nitrogen or the entire
unit can be laid up wet under nitrogen pressure depending upon the
temperature of the surrounding area. Maintain a nitrogen pressure
of 0.2 to 0.35 kg/cm2(g) gage on the undrained sections of the unit,
where possible. If the main steam line is not equipped with a stop
valve, steps should be taken to blank off the line so that the boiler
can be pressurized.
2. If freezing weather conditions arise during the outage, means
must be provided to keep the elements above freezing temper-
ature.
2-8-TAB_4- 2
NOTE: If the use of hydrazine (N2H4) can't be ac-

ceptable as agent per local regulation, alternate
agent for oxygen scavenger is necessary. Owner
shall contact water chemical supplier to obtain per-
mit substitute agent. The condensate or demineral-
ized water containing concentration of the substitute
agent shall have an effectiveness similar to hydra-
zine (N2H4) described in previous paragraphs.
NOTE: When the unit is to be put in service, it will

be necessary to bring the water level to normal and
open the drum and superheater vents before light-
ing off. To conserve nitrogen supply used in pres-
surizing the unit, shut off the supply before opening
the vents.
2-8-TAB_4- 3
TAB 5 - RECOMMENDED CHEMICAL CLEANING PROCEDURES
TABLE OF CONTENTS
TITLE PAGE NO.
FOREWORD ..................................................................................................... 2-8-TAB_5-1
PREPARATION FOR BOILING OUT ............................................................... 2-8-TAB_5-1
RECOMMENDED CHEMICALS FOR BOILING OUT ...................................... 2-8-TAB_5-3
BOILING OUT PROCEDURE ........................................................................... 2-8-TAB_5-4
DRAINING & RINSE ......................................................................................... 2-8-TAB_5-5
2-8-TAB_5-i
RECOMMENDED CHEMICAL CLEANING PROCEDURES
FOREWORD
Boiling out is the process of chemical cleaning for the removal of oil
and grease, and the solvent usually consists of a strong aqueous al-
kaline solution. Oils and greases previously introduced in manufac-
turing and for the purpose of providing protection during the storage
of tubes and other pressure parts for extended periods of time must
be removed prior to unit operation.
The presence of even very thin films of oil or grease or their decom-
position products on the boiler heating surfaces will seriously retard
heat transfer. The resultant increase in metal temperature may be
sufficient to cause overheating and blistering of boiler tubes, and ul-
timate failure at high loads.
During the boiling out process, the gage glass may become badly
discolored and permanently etched. FHI suggests that the customer
have, on hand at the job site, replacement kits for all gage glasses. If
not applicable, enough drain for gauge glass be necessary. The
gage glass manufacturer's instruction also should be consulted.
The chemicals should be dissolved in water before being added to
the boiler and should never be added to the boiler in solid form. In
handling caustic materials, care should be exercised to avoid contact
with the eyes, skin or clothing. When mixing this material, it is rec-
ommended that goggles, rubber gloves and cotton clothing be em-
ployed.
The chemical solutions should not be added to the boiler
through the regular chemical feed system since these high
concentrations may plug the chemical feed piping and valves.
Chemical solutions should always be added by means of an external
blend/fill pumping system or feed from manhole of drum.
PREPARATION
FOR BOILING OUT
Prior to boiling out a boiler, the items previously outlined under
"safety precautions" and "drying out" should be consulted and fol-
2-8-TAB_5-1
lowed. Generally, "drying out" and "boiling out" are combined as one
continuous operation.
A careful cleaning and inspection of the interior and exterior surface
of the boiler and auxiliaries should be made for the purpose of re-
moving all scrap metal, borings, wood, tools, rags and other miscel-
laneous materials. It is very important that these materials be re-
moved before boiling out, otherwise foreign material in the interior
boiler sections is likely to interfere with the operation of blowdown
valves and future operation of the boiler.
It is considered undesirable to attempt to set safety valves when the
boiler contains water of high chemical concentration such as that
used for boiling out purposes. The safety valves should be set when
the boiler contains water of approximately normal concentration for
steam generation.
The boiler should be filled to a point about 300 mm below the bottom
of the steam drum manhole(See Note Below). The unit should be
filled through the passage normally used during operation. Water
should be supplied from the condensate storage tank, through de-
aerator feedwater pump, boiler feed pump, and connecting piping
through the feedwater heaters, to the economizer through the main
feedwater pipe, through the economizer and into the boiler drum. If
this filling procedure is followed, it will flush all the piping and auxilia-
ries ahead of the boiler, and eliminate fouling of the boiler surfaces
with contaminants after the boiler has been properly cleaned. Flush-
ing the feedwater supply system also reduces the quantity of silica
found in boiler water during the initial period of operation.
All superheater drains and vents and boiler steam drum vents
should be opened wide after filling the boiler. Close all access and
observation doors. Check the firing equipment and the feedwater
system to be sure they are in correct operating condition. Pressure
gages, correctly calibrated, should be mounted in locations readily
visible to the operator.
One (1) pressure gage should be located at the boiler steam drum
and another located at the firing aisle, each indicating "steam drum
pressure".
When using oil for boiling out, the oil piping should first be checked
for leaks. Fans should be operated for several hours during which
2-8-TAB_5-2
time they should be checked for excessive vibration, hot bearings

and stability. Fan dampers should be checked for tight closure and
full opening over their required range of travel. Fan linkages should
be checked to assure that all cotter pins are inserted in linkages and
the fan linkage is free of any "lost motion" (excessive motion).
NOTE: If chemical solutions should be feed from
manhole of drum. The boiler should be filled to a
point about 300 mm below the bottom of the steam
drum manhole, then refill water to drum until normal
water level which is 254 mm down from the drum
centerline water level after close manhole of drum.
RECOMMENDED
CHEMICALS FOR
BOILING OUT
Strong alkaline detergent solutions are commonly used for boiling
out a unit since these agents posses the ability to saponify the oils
and greases and form a soap compound that is easily removed by
high pressure blowdown during the boiling out process.
For the most effective removal of oil from boiler metal surfaces, it is
recommended that a "wetting agent" be incorporated in the boiling
out mixture. These agents increase the "wetting power" of the water
by reducing the surface tension and therefore reduce the adherent
characteristics of oils and greases to a minimum. The combination of
a "wetting agent" along with the regular boiling out chemicals will
therefore break down the oil-sludge bond and aid in the removal of
oil and grease from the metal surfaces.
There are wide variations in the composition of boiling out chemicals
which can be employed. Alkaline formulations based on the use of
trisodium phosphate, disodium phosphate and a small amount of de-
tergent (wetting agent) are recommended. A suggested formulation
for preoperational boil-out of a unit is as follows :
1) 4 kg of Na2HPO4 (Na2HPO4-7H2O ) PER 1000 kg OF WATER
2) 8 kg of Na3PO4 (Na3PO4-12H2O ) PER 1000 kg OF WATER
3) Degreaser or detergent ( 0.05% to 0.1% by volume )
2-8-TAB_5-3
BOILING OUT
PROCEDURE
The boiler should be lit off in accordance with the start-up procedure
contained in the operation and maintenance section of this manual.
After furnace purge, RH pass damper close at min. opening and SH
pass damper open at full opening.
Fire at minimum capacity until steam issues forcibly from the steam
drum vent. At this time, close the drum vent and all superheater
vents and drains except those on the superheater outlet header.
Slowly raise the pressure on the unit as attached figure as possible
and always keeping furnace exit temp. below 535℃. To protect re-
heater tube, the proper boiling out pressure based upon the design
pressure of the unit is 30~35 kg/cm2(g).
The specified pressure for boiling out is necessary to provide com-

plete circulation throughout the unit and develop boiling out water
temperatures sufficient for complete removal of greases and oils
present on the metal surfaces.
Deaerator feed water pump and boiler feed pumps should be ready
for operation for delivery of make-up water to the boiler steam drum.
After the prescribed boiler steam drum pressure has been obtained,
this should be maintained for eight (8) to ten (10) hours. After the
hold time of 8-10 hours shut down all start-up oil burner that are in
service and blow down the lower water headers and evaporator
header via drain valves on these header. Blowdown until the drum
pressure drops to 25 kg/cm2(g) or when the drum level drops to low
level of -445mm.
Refill the boiler with Condesate quality water via the normal boiler
feed system until the drum is back to normal level. All feed water to
the drum must be < 93 DegC differential.
Once the drum level is back to the normal level re-fire the boiler and
raise the drum pressure back to 30-35 kg/cm2(g). Reduce the firing
rate to hold the drum pressure at 30-35 kg/cm2(g) for 4 hours.
After the hold time of 4 hours shut down all start up oil burners that are in
service and blow down the lower headers and Evaporator headers via
drain valves on header. Blowdown until the drum pressure drops to 25
kg/cm2(g) or when the drum level drops to low level of -445mm.
2-8-TAB_5-4
Repeat the above procedure every four hours until all signals of oil
have disappeared from a cooled boiler water sample.
After each blowdown period, a cooled sampled should be checked
for PH and phosphate concentration if possible and shall test for oil
and silica concentration.
The times of each blowdown, valve cycles and chemistry data
should be recorded on a blowdown data sheet until the concentra-
tion of tested blow down water is :
Oil <= 3ppm
Silica<= 5 ppm
DRAINING & RINSE
Draining
- Once the Oil and Silica are with-in the acceptable limits allow the
unit to cool down slowly and once the drum reached 1.5
kg/cm2(g) open its vents.
- Open all drains on the lower header point and drains on the
evaporator panel point and allow to drain completely.
- Open all low point drain valves on the steam circuits point.
Rinse -
- Fill boiler to top of drum level gauge.
- Following complete draining of the alkaline solution, the boilers is
to be filled to the top of the gauge glass with rinse water via
normal boiler filling.
- Backfill the Superheater
- Backfill the superheater via the bypass valve of secondary super-
heater desuperheater spray station until the superheater spills
over into the drum and the drum level increases approximately 1”
(25mm).
- Draining the Boiler.
- Drain the rinse water through,
Lower header drain valves
Economizer drain valves
2-8-TAB_5-5
Evaporator drain valves

Superheater panel drain valve
Finish superheater drain valves
Superheater outlet drain valves.
CAUTION: The use of fill water treated with solid

chemicals should be avoided. Deposits of solid
materials in superheaters can be detrimental from
heat transfer and corrosion standpoints. Super-
heaters containing stainless steel tubing are par-
ticularly vulnerable to stress corrosion cracking in
the presence of such chemicals as caustics and
chlorides. The quality of the fill water should be
verified immediately prior to its introduction into the
superheater circuits.
rinse water to be condensate quality with ammonia

dosing toa pH of 9.5 to 10.5
After the boiling out period, when the boiler has been cooled and
drained, the steam drum should be inspected and any sediment
removed by hand. If the quantity warrants, inspect lower furnace
headers, through inspection nipples.
If any foreign material is found in a lower furnace header, it can be
removed by hand or flushed with a high pressure water hose, In
addition to checking for sediment, inspection should assure that the
metal internal surfaces are free from oil adherence.
After the drum and headers have all been cleaned and inspected,
the unit can be closed. New manhole gaskets should be installed
on the drum and any inspection nipple caps or tubes cut for clean-
ing and inspection should be replaced. The unit should be filled
with either demineralized water or condensate and subjected to a
hydrotest pressure approximately that of normal operating pressure.
The unit should then be drained to normal operating drum level.
The superheater should also be drained thru headers drain system.
2-8-TAB_5-6
Perform an internal inspection of the steam drum. The detergent

flush should be repeated if the inspection indicates unsatisfactory
cleaning.
2-8-TAB_5-7
TAB 6 - PRINCIPLES OF BOILER OPERATION
TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION .......................................................................................................... 2-8-TAB_6-1
PERFORMANCE ......................................................................................................... 2-8-TAB_6-1
FILLING AND VENTING .............................................................................................. 2-8-TAB_6-2
STARTING UP ............................................................................................................. 2-8-TAB_6-3
SHUTTING DOWN....................................................................................................... 2-8-TAB_6-4
WATER LEVEL ............................................................................................................ 2-8-TAB_6-4
WARMING UP AND EXPANSION ............................................................................... 2-8-TAB_6-6
AIR HEATERS ............................................................................................................. 2-8-TAB_6-6
SOOT BLOWERS ........................................................................................................ 2-8-TAB_6-7
STEAM TEMPERATURE CONTROL........................................................................... 2-8-TAB_6-7
DESUPERHEATER ..................................................................................................... 2-8-TAB_6-8
SUPERHEATER .......................................................................................................... 2-8-TAB_6-8
BLOWDOWN ............................................................................................................. 2-8-TAB_6-10
TUBE FAILURES ....................................................................................................... 2-8-TAB_6-10
FURNACE EXPLOSIONS .......................................................................................... 2-8-TAB_6-11
FLY ASH EROSION................................................................................................... 2-8-TAB_6-12
INSPECTION ............................................................................................................. 2-8-TAB_6-14
LAY-UPS ................................................................................................................... 2-8-TAB_6-15
2-8-TAB_6-i
PRINCIPLES OF BOILER OPERATION
INTRODUCTION
The following "General Principles of Boiler Operation" are prepared
to acquaint operators with the basic operation and care of large
natural circulation steam generating units. Specific and detailed in-
formation regarding operation and maintenance of the boiler com-
ponents and auxiliary equipment supplied at this installation will be
found in other sections of this manual.
Basic rules must be followed in the operation and maintenance of
boilers and secondary equipment; the operator should familiarize
himself with the characteristics of this particular installation. This
can only be accomplished by diligently observing, recording, check-
ing and comparing data and details. Emergency conditions, result-
ing in unnecessary outages and repairs, can be avoided by a prop-
er working knowledge and attention on the part of the operator.
PERFORMANCE
1. All steam generating equipment is designed for a specific pur-
pose. When supplied with feedwater at a specific temperature,
the unit will deliver a definite quantity of steam at the design
pressure and temperature. Operating at conditions which ex-
ceed the design limitations will shorten the life of the boiler and
its components.
2. The concentration of solids entrained in the steam leaving the
steam drum will depend to a great extent upon the quality of the
feedwater. Suitable make-up water treatment and an adequate
blowdown program should be employed to control the boiler
water alkalinity, silica and concentration of dissolved and sus-
pended solids in the boiler water. Adequate mechanical deaera-
tion of the feedwater should be provided and steps taken to
control the level of metallic oxides entering the boiler in the
feedwater. Refer to the "Feedwater Treatment” section of the
manual.
3. The quantity of fuel consumed is generally measured and rec-
orded. The means employed will depend upon the nature of
the fuel and the equipment available for measuring. A repre-
2-8-TAB_6-1
sentative fuel sample should be obtained periodically. The ser-

vices of a competent laboratory should be employed to analyze
the fuel with respect to chemical constituents, calorific value,
viscosity (liquid fuels) and other physical characteristics which
could have an unfavorable influence on operation and efficien-
cy.
4. An analysis of the flue gases leaving the boiler is invaluable as
an index of complete and economical combustion. Combustion
should be completed before the gases leave the cyclone. The
best percentage of excess air to use will depend upon the na-
ture of the fuel, the design of the fuel burning equipment and
other factors. The most desirable excess air for different rates
of evaporation must be established for each installation. The
presence of carbon monoxide (CO) in the flue gas indicates in-
complete combustion. The Orsat is the most reliable means of
analyzing flue gases and should be used as a check even when
other instruments are provided to furnish this data. For deter-
mination of the percentage CO, CO2 and O2 gas samples
should be obtained at the rear pass outlet upstream of the air
heater.
5. When the heat transfer surfaces are kept clean, the tempera-
ture of the flue gases leaving the air heater and the draft loss
through the unit will be substantially a constant for a given rat-
ing and percent excess air. This illustrates the desirability of
keeping accurate records of performance from the start of op-
eration. Operating data should be recorded in a form that will
facilitate comparison with data taken under similar operating
conditions.
When the equipment is new, standards should be established to
serve as measures of satisfactory operation. Then if operating
conditions deviate from this established standard, steps can be
taken to determine and correct the cause of the discrepancy.
FILLING AND
VENTING
When filling the unit, open the boiler vents as noted in the "Unit
Operating Procedures” section of this manual. Bring the water up
to the recommended operating level in the gage glass. If hot water
(hot relative to the boiler metal temperatures) is used to fill the unit
2-8-TAB_6-2
use care; feed slowly to avoid severe temperature strains on the

drums, headers, etc.
STARTING UP
In order that an incorrect firing condition may be detected promptly,
it is important that the instruments used to monitor operating condi-
tions are in good working order before lighting off. Draft readings,
temperature and pressure readings and a reliable indication of how
much excess air is being used are a prerequisite to intelligent oper-
ation.
Prior to lighting off the unit, the drainable portions (headers, inlet,
outlet and connecting lines and piping) of the superheater should
be drained through lines free from back pressure and vented at the
outlet. The superheater drains should be closed in accordance with
information given in the Unit Operating Procedures for this installa-
tion. The superheater outlet drain ("starting vent and drain”) must
remain open to assure a flow of steam through the superheater to
protect the elements from overheating until the unit has gone on the
line and is carrying load. This drain valve may be throttled as the
pressure increases, but must never be closed completely until the
unit is on the line. Refer to Operating Procedures for specific valve
operation.
During all start-ups, the firing rate should be controlled to keep the
maximum backpass entering gas temperature below 535°C
(1000°F) (as measured by the cyclone to backpass gas tempera-
ture elements) until the turbine is synchronized. After rolling the
turbine, the steam temperature and pressure rise at the turbine
throttle should at all times be in accordance with the limits pre-
scribed by the turbine manufacturer.
The time required to bring a unit up to temperature and pressure
will depend upon the temperature and pressure at which it is to op-
erate. During initial start-up of a new unit the firing rate must be lim-
ited, and increase of firing rate should be relatively slow to allow in-
spection of expansion movements and clearances. Subsequent
start-ups can be done at a faster rate but should not exceed a satu-
rated steam temperature rise of 110°C (200°F) per hour (refer to
Unit Startup Procedures) or the cyclone exit gas temperature limita-
tion stated above. The saturated steam temperature rise could be
lower depending upon the refractory heat-up rates. Refer to the re-
2-8-TAB_6-3
fractory manufacturer’s instructions. Always make firing adjust-

ments by hand during this period; never attempt to start up with the
combustion control or feedwater equipment on ”Automatic”.
Prior to lighting off, check all instrumentation and safety interlocks
to be sure they are in good working order. Verify proper operation
of all instrumentation (gauges, transmitters, recorders, etc.) during
initial operation.
SHUTTING DOWN
The time required and the procedures to be followed for shutting
down the unit depend on the nature of the shutdown (normal shut-
down to cold, normal shutdown to hot standby, emergency shut-
down) and whether the unit is to be entered for inspection and/or
maintenance. Refer to Unit Operating Procedures for detailed op-
erating recommendations.
The anticipated time of the outage should be considered during the
shutting down process in determining the steps to be taken for lay-
ing up the unit or corrosion protection. Refer to Lay-Up Procedures
in this manual.
Immediately after the unit is off the line (turbine valves closed) and
all fires are out, superheater drains are opened as required for the
desired pressure reduction. If the unit is shut down to cold, the
drum vents should be opened when the drum pressure drops to 25
psig. If pressure parts inspection or maintenance is required, the
water temperature should be reduced to 95°C (200°F) before drain-
ing the boiler.
Fans may be operated as required to achieve the desired rate of
cooling.
During any type of shutdown, the cooling rate must not exceed
85°C (150°F) per hour saturated steam temperature decrease.
WATER LEVEL
Before lighting a fire, the operator should check the water level in
the steam drum by blowing down the water column and gage glass.
Usually slowly cracking the drain valve on high pressure gages will
suffice. A liberal blowdown will usually clear the drain valve seats of
any foreign matter that may be present. The gauge glass should
be blown down several times at low pressure while warming up a
new unit. Routine checks of the water gauge should be made at
least once a shift while a unit is in operation. If the action of the wa-
2-8-TAB_6-4
ter in the gage is sluggish when the drain valve is opened or closed,
investigate the cause and correct the condition immediately. To
protect the gage glass, blow downs should be kept to a minimum,
during normal operation.
During normal operation the water level in the gage glass should be
observed periodically even though the boiler may be equipped with
a reliable feedwater regulator and/or remote water level indicator.
While steaming, the boiler should be protected from rapid changes
in feedwater temperature. The feedwater flow to the boiler should
correspond fairly closely to the steaming rate and should not be
shut off completely while the furnace is being fired.
The recommended water level and operating range is indicated in
the section "Drum lnternals”. Unless there is information to the con-
trary, the water level should be carried near the center of the gage
glass. The gauge glass center line is normally set to indicate nor-
mal level inside the drum at full pressure conditions. If the unit is
operated at significantly reduced pressure the level indicated at the
gauge glass center line will correspond to a lower than normal ac-
tual level inside the drum, due to the difference in temperature be-
tween the water in the glass and the water inside the drum. Any
adjustment of the water level should be gradual. If the water level
is too high, carryover or even priming may occur, especially if the
steam demand is large and rapidly fluctuating.
Perhaps the most serious emergency that may be encountered is
low water. As mentioned in previous paragraphs, the water level
must be watched continuously and the water gauges should be
checked periodically to ensure proper operation. Protection of wa-
ter level transmission lines should be provided to avoid freezing or
other damages to these lines. Do not rely solely on high and low
level alarms.
If the water level falls out of sight in the water gauge, due to failure
of the feedwater supply or neglect of the operator, except in the
case of momentary fluctuations that might occur with extraordinary
changes in load, appropriate action should be taken at once to dis-
continue fuel firing. Any decision to continue to operate, even if on-
ly for a short time at a reduced rating, would have to be made by
someone in authority, thoroughly familiar with the circumstances
2-8-TAB_6-5
that led to the emergency and positively certain that the water level
can be restored immediately without damaging the unit.
WARMING UP AND
EXPANSION
While the unit is being brought up to pressure, provision should be
made for gradually heating and adequately draining all cold steam
piping from the beginning by opening all drain valves and bypasses
(if stop valves are provided).
During initial firing, periodically check the expansion movements of
the unit and make sure the casing, headers, piping, etc., move
freely in respect to the structural steel. Expansion markers should
be installed at suitable locations to facilitate inspection (refer to
Pressure Parts Arrangement drawings and/or Expansion Movement
Diagrams for this installation). Periodic checks should be made
during the life of the unit to determine that expansion movement
continues to occur in a normal, uniform manner. All hangers on the
unit and related piping should be checked periodically for proper
settings and functioning.
AIR HEATERS
An abnormal increase in draft loss across the gas and/or air side of
an air heater indicates that deposits are building up. Every precau-
tion should be taken to keep the gas swept surfaces of the air heat-
er clean. Operate the air heater soot blowers as frequently as nec-
essary.
If oil is being fired make certain the fuel is being burned completely.
Watch the temperature of the gas leaving the air heater, particularly
when starting up the unit. Use air heater cleaning device to remove
accumulations of combustible deposits. A sudden and abnormal in-
crease in the gas outlet temperature would indicate that a fire has
developed. In this event, the unit should be shut down immediately
and steps be taken to quench the fire.
The exit gas temperature will rise with increasing load and fall with
decreasing load. If a log is kept of the load, the exit gas tempera-
ture and soot blowing schedule, the operator will soon be able to
recognize an abnormally high or low exit gas temperature.
If the exit gas temperature is below normal for the load at which the
unit is being operated, look for very low excess air (very high CO2,
maybe some CO, and smoke).
2-8-TAB_6-6
High exit gas temperature may be caused by such conditions as:

high excess air, dirty combustor water walls, secondary combustion,
dirty air heaters and/or fire in the air heaters.
SOOT BLOWERS
Soot blowers should be operated as often as necessary to keep the
external heating surfaces clean. A high economizer exit gas tem-
perature and/or erratic steam temperature control action (See Note)
may be an indication of the need for blowing soot. By recording and
comparing this exit gas temperature at various loads and furnace
conditions, a proper soot blowing schedule can be established. It
will be found more difficult to use the soot blowers effectively if, dur-
ing a period of neglect, a considerable amount of fly ash or slag is
allowed to build up. Never use soot blowers on a cold unit. Refer to
Soot Blower instructions for details.
NOTE: The requirements of the steam temperature
control system can be used as an indication of foul-
ing in the superheater since desuperheater spray
water quantity reflects the changes in tube surface
cleanliness.
If the soot blowing medium is steam, proper drainage of the soot

blower piping system is very important in preventing pressure parts
erosion. There should be no water pockets whatever in the piping.
A 5mm (3/16 in.) hole is often drilled through the seat of the drain
valve so as to permit continuous drainage of any condensate
formed. Let the steam blow freely long enough to heat the lines
thoroughly before operating the soot blowers.
STEAM
TEMPERATURE
CONTROL
The function of the steam temperature control equipment is to
maintain design superheat temperature over the specified control
range.
Steam temperature should never be allowed to exceed the maxi-
mum values shown on the "Steam Temperature vs Evaporation”
curve (See Unit Operating Procedure), especially if steam tempera-
ture control equipment is programmed down to a boiler rating below
the control point. Damage to tubing may result due to localized
2-8-TAB_6-7
overheating, caused by maldistribution of steam flow at low loads, if

the maximum values are exceeded.
If the steam temperature control system is provided by this compa-
ny, specific instructions are included in this manual.
DESUPERHEATER
A superheater desuperheater is provided to maintain the design fi-
nal superheater steam temperature. Desuperheater spray water
control is generally a 3-element cascade system, in which final
steam temperature, desuperheater outlet steam temperature and
load index (steam flow or airflow measurements) are applied to
achieve proper and fast control actions.
Regardless of the means provided for controlling superheat tem-
perature, there are a number of factors which may produce abnor-
mal steam temperatures.
Abnormally low steam temperatures may be produced by:
1. Insufficient excess air.
2. Higher than design feedwater temperature.
3. Excessive moisture carryover from the boiler.
4. A fouled superheater, externally or internally.
5. Leaking desuperheater spray water valves.
6. Poorly adjusted control equipment.
On the other hand, the following conditions can produce steam
temperatures abnormally high for a given rate of evaporation:
7. Lower than design furnace heat transfer.
8. Too much excess air.
9. Lower than design feedwater temperature.
10. Irregular ignition or delayed combustion.
11. Poorly adjusted control equipment.
The superheat steam temperature will drop suddenly and recover if
the boiler is priming. The temperature fluctuations increase in fre-
quency and severity as the total solids or alkalinity in the boiler wa-
ter increases.
SUPERHEATER
Consideration for protecting the superheater is a controlling factor
in determining how rapidly a natural circulation unit should be
brought up to pressure. The saturated temperature increase must
not exceed 110°C (200°F) per hour during startups. The saturated
steam temperature rise could be lower depending upon the refrac-
2-8-TAB_6-8
tory heat-up rates. Refer to the refractory manufacturer's instruc-

tions. The superheater elements should be heated as evenly as
possible and the maximum temperature of the flue gas entering the
first gas touched superheater elements (“Cyclone Exit Gas Tem-
perature") should be carefully monitored and controlled during
startups.
The cyclone exit gas temperatures are normally measured by
means of thermocouples located in the cyclone outlet ducts. The
maximum cyclone exit gas temperature should be limited to 535°C
(1000°F) until the turbine is under load and normal steam flow
through the superheater is established.
To assure clearing the superheater element loops of condensate,
provision must be made for adequate flow of steam through the su-
perheater while starting up. Drain and vent valves in the outlet
headers and/or the main steam line should be opened before the
unit is fired and kept open until the unit is steaming under load.
These starting drains and/or vents may be throttled gradually as
drum pressure increases, provided sufficient flow through the su-
perheater is assured at all times. When the turbine is synchronized
and carrying load an adequate steam flow will be assured, the su-
perheater start-up drains and/or vents may be closed. While carry-
ing load, protection in the event of a sudden interruption of steam
flow is provided by the superheater safety valves which are set to
"pop” before the drum safety valves. If the flow of steam from the
unit is suddenly stopped, the superheater safety valves will open
and re-establish the flow. It is imperative that all fuel be tripped im-
mediately when such interruptions of steam flow occur.
Care must be exercised to avoid carry-over of water and solids to
the superheater and turbine. Steam samples should be taken at
frequent intervals for the purpose of detecting evidence of carryover.
Steam conductivity recorders are commonly used for this purpose.
Sampling connections are normally provided in the superheater
connecting tubes, leaving the steam drum. Carry-over may be
caused by abnormal high water level, especially if the steaming rate
is high. If carry-over is suspected, steps should be taken immedi-
ately to investigate and eliminate the conditions causing this carry-
over. If the investigation indicates that the carry-over is not a result
of improper water condition, the steam drum internals and the water
2-8-TAB_6-9
level control and indicating equipment should be inspected at the

first possible opportunity.
Deposits of solid materials in superheaters can be detrimental from
heat transfer and corrosion standpoints. Superheaters containing
stainless steel tubing are particularly vulnerable to stress corrosion
cracking in the presence of such chemicals as caustics and chlo-
rides. Therefore, introduction of solid materials, either through car-
ry-over, or during filling operations (hydrostatic testing, chemical
cleaning) must be avoided.
BLOWDOWN
The continuous blowdown offers the best means for controlling and
maintaining a relative constant concentration of soluble solids in the
boiler water.
The data on blowdown should be recorded. The amount of blow-
down is best determined from a chemical analysis of water from the
boiler. Since the water treatment system varies for each individual
plant, a competent authority on water conditioning should be en-
gaged to prescribe suitable water treatment from analysis of the
water supply, and to furnish the necessary instructions for blowing
down.
Natural circulation boilers are equipped with either downtake blow
off valves or water wall supply drum drains which may be used for
intermittent blowdown service at any time. Never use lower water
wall header drains for blowdown while the unit is steaming. These
are for draining only, when the unit is out of service. Unless the
valve manufacturer's recommendations are contrary, open the seal-
ing valve (next to the boiler) and then the blowing valve (farthest
from the boiler) and close in the reverse order. Never make the
blowdown long enough to lose sight of the water in the gage glass.
Check the valves for leaks.
TUBE FAILURES
In the event of a failure of one or more water carrying tubes in a
boiler, the best method for shutting down the boiler will be dictated
by the size of the failure, the ability to maintain normal water level in
the boiler and the demands for the service of the boiler.
If the failure is such that the water level can be maintained in the
gauge glass by using the normal make-up system and the load
conditions require continued operation, the boiler can be kept in
2-8-TAB_6-10
service until it is more convenient to take it off the line and make
the necessary repairs. While it is possible to operate for a consid-
erable period of time under such conditions, there is always a
chance of cutting other tubes. As long as the failure does not be-
come one which involves the loss of water level in the gauge glass,
the unit should be shut down in the normal manner, in order that no
equipment may be subject to sudden temperature changes.
If failure is such that the water level cannot be maintained in the
gauge glass, then the unit should be shut down immediately. After
a shutdown because of low water, every effort should be made to
keep the water as near normal as possible until the boiler is cool
enough to drain.
A leak in a superheater element should be investigated at the earli-
est possible time, and the unit should be shut down in a normal
manner.
These are recommendations only and are not intended to supplant
the judgment of the operators responsible for the operation of the
equipment. lt must be borne in mind that prolonged operation with
leaking tubes may cut other tubes and make a major repair job out
of what was a relatively simple and short one, but the time selected
to take the unit off the line is solely the responsibility of the opera-
tors as they are the only ones who know all the circumstances, the
advantages and disadvantages of keeping the unit on the line.
FURNACE
EXPLOSIONS
Furnace explosions are generally a result of the following conditions:
1. The accumulation of unburned fuel in the furnace due to in-
complete combustion.
2. The mixture of this unburned fuel with air in explosive propor-
tions.
3. The application of sufficient heat to raise the temperature of a
portion of this mixture to the ignition point.
Unburned fuel may accumulate in the furnace in a number of ways,
for instance:
4. Through leaky auxiliary fuel inlet valves on idle fuel firing
equipment.
5. If the fires are extinguished and the fuel is not shut off promptly.
6. If the fuel is not burning as rapidly as it is entering the furnace.
2-8-TAB_6-11
7. In starting up, if difficulty is experienced in establishing ignition.

Furnace explosions can be avoided by taking a few precautions,
such as:
8. During start-ups maintain a minimum air flow, to ensure an air
rich furnace atmosphere and prevent accumulation of explosive
mixtures.
9. Be sure that the auxiliary fuel inlet valves on idle fuel firing
equipment are closed tightly and do not leak.
10. Watch the furnace temperatures so that the fuel may be shut
off without delay if proper combustion is not maintained. If the
furnace temperature firing permit is lost, trip all main and igni-
tion fuel immediately. Close all trip and shutoff valves. Purge
the furnace for at least 5 minutes after shutdown with 30% of
MCR airflow.
11. Clear oil tanks of water and sludge periodically.
12. Never attempt to light an oil burner without the required ignition
energy source. Be sure that air for the air atomizing oil guns is
dry.
Do not use heavy oil/mechanical atomizing oil guns for boiling
out, lighting off and warming up, preferably use light oil/air at-
omizing or heavy oil/steam atomizing oil guns.
Always use the required auxiliary fuel energy source before fir-
ing any coal.
13. Regularly check proper function of the control system provided,
including interlocks, trips, etc., prior to any startup and periodi-
cally during normal operating periods.
14. During outages thoroughly check out, inspect and maintain any
control system provided.
FLY ASH EROSION
Fly ash erosion is the abrasion of metal surfaces by residual ash
particles carried in the flue gases.
Erosion normally occurs in areas of localized high flue gas veloci-
ties (See NOTE). The degree of erosion is further related to the ash
content (quantity and composition) of the fuel. Units firing fuel with
a high ash content of abrasive nature are more subject to erosion.
2-8-TAB_6-12
NOTE: Areas most commonly subject to erosion

are: economizer hanger tubes, economizer, and low
temperature superheater terminal tubes and bends,
areas around soot blowers, gas ductwork and in-
duced draft fan (fan blades and housing).
Unit design parameters are based on conservative average flue gas

velocities and normal fuel ash percentages, to achieve minimum
possibility of erosion. However, the possibility of localized erosion
cannot be entirely avoided, nor can the degree or location be pre-
dicted for each installation.
It is important that the unit be inspected for indications (See NOTE)
of erosion, especially in the areas mentioned above, whenever the
opportunity presents itself, but at least during annual outages.
When fuel with a high ash content is fired, a definite periodic in-
spection program must be established.
NOTE: Indications of erosion are: polished surface
appearance, gouging holes in duct expansion joints
(leaks), etc. Reduction of tube diameters can be
verified by micrometer readings.
The effects of erosion can be controlled by protecting the affected

areas (pad welding, installation of removable tube shields, refracto-
ry coating, etc.) or by dispersing the flue gas streams through the
use of plate or wire mesh baffles (See NOTE).
NOTE: Extreme care must be exercised, when in-
stalling baffles, not to create new areas of erosion
or to shift erosion from one area to another.
The method of control and/or correction depends on the degree

and location of the erosion and can only be established after thor-
ough evaluation of the local situation and some experimentation.
The effectiveness of correction methods must be checked. In the
event of extreme or unusual erosion problems, this Company or its
representative should be consulted.
2-8-TAB_6-13
INSPECTION
Whenever the unit is shut down, and cool enough to enter, make
an external inspection of the unit, waterwalls, cyclone, superheater,
economizer, air heater and baghouse or ESP. Clean the firesides
where necessary and examine all tubes for evidence of corrosion,
erosion, swelling, warping, blistering, burning and cracking.
Swelling of superheater tubes indicates overheating which may
have been caused by bringing the unit up to pressure too quickly,
failure to vent the superheater sufficiently while the unit is being
brought up to pressure, or scale on the internal surfaces due to car-
ryover of water from the steam drum. Slight warping is not serious
if steps are taken at once to determine and eliminate the cause.
Check the condition of the unit setting and check the casing and
doors for leaks.
Periodic inspections should be made to examine the watersides of
the furnace. When draining the boiler for internal inspection during
freezing weather conditions, care must be taken that no water re-
mains trapped in piping or above valve seats. Especially gate
valves in vertical piping should remain open during the outage to
prevent damage to the valve seats due to freezing. Some conden-
sate will remain in non-drainable superheater loops. Means (some
source of heat) must be provided to prevent freezing.
Before entering the drum, make sure that all valves in drum con-
necting piping (feedwater, auxiliary steam, chemical feed, blow-
down, drains, sampling, gauge glass drains, etc.) are closed tightly
and properly tagged so that they will not be opened inadvertently.
Remove the manhole covers and check the drum internals for
tightness and cleanliness.
Check the drum for corrosion and pitting. Oxygen pitting is a com-
mon form of corrosion that can be found in boilers, usually in the
steam drum above the normal water level, but also in tubes and
headers.
Remove a sufficient amount of inspection plugs from each boiler
and waterwall header for boroscope inspection of the internal tube
surfaces. Wash down the unit to remove any sludge.
Inspect and if necessary clean the external heating surface of the
economizer.
2-8-TAB_6-14
See that the heating surfaces of the air heater are clean. Corrosion,
if present, would appear in the cooler portion of the heater, particu-
larly where soot and dirt are allowed to accumulate.
Make a thorough inspection of the furnace and clean as required.
Check fuel burning equipment (ignitors, oil guns, scanners, linkage,
dampers, etc.) for cleanliness and proper operation. If a fluidized
bed supervisory system is provided, check out and exercise, where
practicable, control valves, relays, interlocks, etc.
Annual inspection should be complete and include an internal and
external examination of the entire unit.
LAY-UPS
When the Unit is shut down for stand-by purposes and draining of
the boiler is not required for maintenance or repairs, the boiler met-
als must be protected against corrosion. Refer to Lay Up Proce-
dures in this manual.
2-8-TAB_6-15
TAB 7 - STEAM LINE BLOWING PROCEDURES
TABLE OF CONTENTS
TITLE PAGE NO.
PURPOSE ........................................................................................................ 2-8-TAB_7-1
RESPONSIBILITY............................................................................................ 2-8-TAB_7-1
GENERAL ........................................................................................................ 2-8-TAB_7-1
PRECAUTIONS................................................................................................ 2-8-TAB_7-3
OPERATING PROCEDURES .......................................................................... 2-8-TAB_7-4

Main Steam Lines........................................................................................ 2-8-TAB_7-5
Cold Reheat Lines....................................................................................... 2-8-TAB_7-5
Hot Reheat Lines......................................................................................... 2-8-TAB_7-6
2-8-TAB_7-i
STEAM LINE BLOWING PROCEDURES
PURPOSE
The purpose of blowing the main steam lines and reheater steam
lines prior to starting up a new unit is to remove any foreign material
remaining in the superheater, reheater and steam piping after erec-
tion is completed. Considerable damage could result if such for-
eign material was allowed to enter the plant steam system or tur-
bine during initial operation.
On older units the need for steam line blowing should be consid-
ered following major pressure parts repairs, where the possibility of
introduction of foreign material into the system exists.
RESPONSIBILITY
Since prevention of damage to the plant steam system or turbine is
the prime concern, the responsibility for determining the effective-
ness of the steam line blowing operation rests with the purchaser.
During the steam line blowing process the unit should be operated
in accordance with Formosa Heavy Industries recommended pro-
cedures, with all control systems and protective interlocks function-
ing.
The responsibility for the design, fabrication and installation of any
temporary piping system used for the purpose of steam line blowing,
as well as its protection against overpressure or overtemperature
rests with the purchaser.
GENERAL
Ideally, to obtain optimum cleaning, the flow conditions in the sys-
tem during steam line blowing should equal those during normal
operation at maximum load. Since it is impossible to exactly dupli-
cate these conditions when blowing through the piping to atmos-
phere, it is desirable to produce equivalent conditions by using low-
er pressure steam with a flow rate such that the product of steam
flow times velocity will equal that under normal full conditions. The
determination of the total obtainable flow quantity must be based on
flow resistances in the entire system, including the temporary piping.
2-8-TAB_7-1
This determination is normally made by the designer of the blowing

system.
It is important that the system be blown in sections and that each
section be blown separately, so that foreign material is not trans-
ported from one section and deposited in the next. This is particu-
larly important when blowing the reheater. If the reheater were to
be blown immediately in series with the superheater, material too
large to pass through the reheater tubes would remain lodged in
the reheater inlet header and cause blockage of reheater tubes,
with resulting overheating and failure of reheater tubing when the
unit goes into operation. For this reason it is recommended that the
temporary piping be arranged such that the main steam lines can
be blown to atmosphere first, secondly that the cold reheat lines be
blown to atmosphere before they are connected to the reheater in-
let header, and that steam be admitted only then to the reheater for
blowing through the hot reheat lines.
The temporary piping is normally equipped with a shutoff valve
which is used as a blowing valve (See Note). With this arrange-
ment, the superheater and the upstream portion of the temporary
piping are maintained at drum pressure at all times when not actu-
ally blowing.
NOTE: If the unit is equipped with a main steam
stop valve, this may be used as a blowing valve, if
the valve design permits this type of service.
When more than one steam line is provided in any section, consid-
eration should be given to arranging the temporary piping so that
each line may be blown separately. lf this is done, the piping sys-
tem should be investigated to insure that flow unbalances and ex-
pansion stresses at connections do not become a problem.
An indication of the cleanliness is obtained by impact specimens,
installed in the blowoff piping during the final blows. Suitably
mounted and supported, polished square bar stock has been used
effectively for this purpose. The degree of pitting of the specimen
surface following a blow is used to determine the end point of the
blowing cycle for the particular section.
2-8-TAB_7-2
PRECAUTIONS
1. The process of steam line blowing imposes abnormal and se-
vere conditions upon the boiler and steam piping. Large, rapid
temperature changes occur during each blowing cycle. This
cycling of temperature is far more severe than is incurred in
normal operation. Thermal stresses may be excessive in the
heavy wall portions of the system such as drums, headers and
piping. It is prudent to consider this fact when performing the
blowing procedure and to limit the number of blowing cycles
(“blows”) to the minimum consistent with cleaning the system.
2. Before starting the steam blowing process, the start-up burners
should be turned off. The P.A. fan should remain in service.
This will minimize the extreme fluctuations in refractory face
temperatures, and a repurge of the unit may not be necessary.
3. Since the temporary steam line blowing piping may be de-
signed for lower pressure than the boiler, care must be used to
prevent overpressuring this piping during the entire steam line
blowing operation. The pressure in the temporary piping should
be monitored continuously and operators be alert to prevent
overpressure.
It is recommended that a means of overpressure protection be
provided in the temporary piping, such as, safety valves set at
the design pressure of the temporary piping.
4. It is difficult to avoid carryover from the steam drum to the su-
perheater during the steam line blowing operation. Therefore,
boiler water should not be treated with non-volatile chemicals
during this process, to avoid deposits of solid materials into the
superheater.
5. Ash drain shut-off valves to the ash screw coolers should be
closed, and the drains should be filled with ash or sand.
6. Main fuel and limestone slide gates should be closed and seal-
ing air provided downstream of slide gates.
7. The seal pot nozzles should be completely covered with ash or
sand in order to protect them from localized hot gases, when
F.A. blower is not in service.
2-8-TAB_7-3
8. The primary air should be flowing through the furnace fluidizing

nozzles in order to avoid damaging the fluidizing nozzles from
the start-up burner flame.
9. The lower furnace should be operated at a slightly negative
-5.1mm W.G. (-0.2" W.G.) pressure to ensure that hot gases do
not leak out of the furnace.
10. To minimize the possibility of damage to the in-furnace and
convective pass tubing, the furnace and cyclone outlet tem-
peratures should be kept below 535°C.
OPERATING
PROCEDURES
The standard steam blow can be employed without fluidizing the
bed, due to the low firing rate required. The start-up burners should
be fired as evenly as possible. Assuming the burners are well-tuned,
the baghouse can be bypassed if baghouse is selected as a flue
gas cleaning device.
Raise the drum water temperature at an average rate less than
55°C per hour, in order to avoid firing too hard and causing local-
ized hotspots on the refractory. Start-up should begin with the rota-
ry AH and the ID fan, followed by the PA fan and the SA fan. The
fluidizing air blower is not required provided the seal pot nozzles
have been covered with ash or sand and can therefore remain out
of service.
The unit is started in the normal manner, following the Cold Startup
Procedures. All normal recommendations and limitations with re-
spect to fuel firing equipment, air handling equipment, drains and
vents, etc. should be followed, as if the unit were being started for
normal operation. As for any new unit, the steam blowing operation
is the first occasion that the unit is fired at any significant rate.
Consequently, the startup as well as the steam line blowing must
be conducted with great care. The unit must be brought up slowly,
while all equipment is checked and expansion movements moni-
tored closely. The 535°C furnace and cyclone exit gas temperature
limitation must not be exceeded when the unit is fired. The same
general precautions taken on any new unit for this period of opera-
tion apply equally here.
2-8-TAB_7-4
The drum level will be subjected to extreme fluctuations during the

blows. As the temporary blowoff valve is opened, the drum level will
rise rapidly and may go out of sight in the gauge glass. As the blow
progresses the drum water level will re-appear and may drop out of
sight. Therefore, it is important that the drum level be established
at or slightly above normal operating level before the start of each
blow. A small amount of feedwater flow should be established be-
fore the start of each blow and the feedwater flow should be in-
creased as soon as the water level drops back in sight, in order to
prevent excessive low water level.
When the drum pressure reaches the value calculated to produce
the desired blowing flow quantity [normally up to 42 kg/cm2(g)*], the
blowing process can be started:
NOTE: *Not to exceed normal operating pressure.
Especially for reheat steam line, the normal operat-
ing pressure maybe is below than 42 kg/cm2(g).
Main Steam Lines

1. The start-up burners should be turned off. Gradually open the
temporary blowoff valve, to blow through the superheater, main
steam line and out the temporary blowoff piping (Refer to Pre-
cautions).
NOTE: IMPORTANT. The first blow should always
be done at reduced pressure, in order to check out
the temporary piping system, its supports and an-
chors.
2. When the drum pressure has dropped to approximately 14

kg/cm2(g), close the temporary blowoff valve and refire the unit
(See Precautions) to reestablish blowing conditions.
3. Repeat the above cycle until it is considered that cleaning is
satisfactory (Refer to Precautions) as indicated by inspection of
impact specimens during the final blows.
Cold Reheat Lines
steam line, temporary tie to the cold reheat line and out the
temporary blowoff piping (Refer to Precautions).
2-8-TAB_7-5

chors.

Hot Reheat Lines
steam line, temporary tie to the cold reheat line, reheater, hot
reheat line and out the temporary blowoff piping (Refer to Pre-
cautions).
chors.

2-8-TAB_7-6
TAB 8 – START UP CHECK OUT
TABLE OF CONTENTS
TITLE PAGE NO.
BOILER MECHANICAL ................................................................................... 2-8-TAB_8-1
FLUE & GAS DUCT ......................................................................................... 2-8-TAB_8-3
FANS & BLOWER ........................................................................................... 2-8-TAB_8-4
START-UP BURNER SYSTEM........................................................................ 2-8-TAB_8-6
FEEDER ........................................................................................................... 2-8-TAB_8-8
ASH COOLER ................................................................................................ 2-8-TAB_8-10
BURNER CONTROL AND FUEL SAFETY.................................................... 2-8-TAB_8-11
SOOTBLOWER ............................................................................................. 2-8-TAB_8-11
SPRAY SYSTEMS ......................................................................................... 2-8-TAB_8-13
SAFETY VALVES .......................................................................................... 2-8-TAB_8-13
ALARMS, TRIPS & INTERLOCKS ................................................................ 2-8-TAB_8-14
INSTRUMENTATION & CONTROL ............................................................... 2-8-TAB_8-15
2-8-TAB_8-i
START UP CHECK OUTLINE
BOILER
MECHANICAL
Drum Internals
Inspect the drum internals for correct assembly and cleanliness. In-
sure that those internals are installed correctly.
Drum Centerline
Transfer the drum centerline to structural steel and to the gauge
glasses.
Drum Gauge Glass Check
Check the drum gauge glass installations and forward a detailed
sketch of same to FHI office. Verify the drum centerline. Insure that
the drum internal connections to the gauge glass are clear.
Drum Level Alarms & Trips
Set up the drum level alarms and trips.
Inspect Anti-Erosion Protection
Inspect all refractory and/or baffles to prevent erosion, to insure cor-
rect installation.
Vibration Baffles
Inspect the anti-vibration baffles for correct locations and support, if
installed.
Inspect Dead Air Spaces
Inspect the dead air spaces for tube interferences, sag support in-
stallations and cleanliness.
Furnace Inspection
Inspect the furnace to insure refractory and fluidizing nozzles correct-
ly installed, all fin welding is complete, and site welding is grinding to
meet requirement of design, and construction materials have been
removed.
Inspect Bottom Ash drain
Insure that bottom ash drain is installed correctly and will not inter-
fere with boiler expansion.
Refractory Inspection
2-8-TAB_8-1
Check to insure that the proper refractory has been correctly poured
at lower furnace, bottom of S/H panel, all ports, access doors, soot-
blower openings and seals.
Burner Throats & Seals
Check that the refractory for the burners has been correctly poured,
both the burner throats and the seal cans behind each burner.
Expansion Interferences & Measurements
Walk down the unit looking for expansion interferences. Insure that
all interferences are corrected prior to initial firing. Mark all bumpers
and guides for future measurement of boiler expansion during opera-
tion.
Check Boiler Seals
Ascertain that all boiler seals are correctly installed and have the cor-
rect refractory where applicable.
Feed Stop & Check Valves
Insure that the valves are clean and in proper operating condition.
Stroke each valve and set up the open and closed positions. Verify
that the valves are installed for the proper direction of flow of the
feedwater.
Drain & Vent Inspection
Trace all boiler drain and vent piping for proper routing an interfer-
ences. Insure that all valves are stroked and are operable.
Chemical Feed System
Check that the pump set is in operating condition. Stroke all valves in
the system and set limit switches as supplied. Insure piping is routed
correctly, supported adequately, and will not interfere with boiler ex-
pansion. Verify that chemical feed discharge pipe in the economizer
outlet is correctly installed. Operate the system with water only to
check for leaks and proper operation.
Ash Removal System
Check that ash removal system is correctly installed. Verify that sys-
tem is sized to handle the expected ash loading for the fuel burned.
Insure that the ash removal system will not interfere with boiler ex-
pansion.
Spring Hanger Settings & Stops
Check all spring hangers for correct installation, remove all spring
stops and record cold set point of each hanger. Adjust those hangers
which are not at the correct initial cold set point.
2-8-TAB_8-2
Ash Hopper Loads & Drains

Check all ash hoppers for ash. Insure that a method of draining the
ash hoppers is available.
Insulation & Lagging
Check that all boiler parts are insulated and lagged according to con-
tract specifications. Specifically check for insulation behind the buck-
stays.
Recheck Spring Hangers After Steam Flushing
Check the cold set point of the spring hangers after the steam flush-
ing operation is complete. Reset all hangers to the cold position as
needed.
Take Boiler Expansion Data
Take boiler expansion measurements at the various stages of start-
up as indicated.
The purpose of blowing the main steam lines and reheating steam
line prior to starting up a new unit is to remove any foreign material
remaining in the superheater, reheater and steam piping after erec-
tion is completed. Considerable damage could result if such foreign
material was allowed to enter the plant steam system or turbine dur-
ing initial operation.
On older units the need for steam line blowing should be considered
following major pressure parts repairs, where the possibility of intro-
duction of foreign material into the system exists.
FLUES & DUCTS

External Flue & Duct Inspections
Inspect all flues and ducts externally for correct routing by compari-
son to the assembly drawing.
Insulation & Lagging of Flues & Ducts
Ascertain that all flues and ducts are correctly insulated and lagged
according to contract specifications.
Flue & Duct Supports
Check all flue and duct supports for tightness and snug-up where
necessary.
Trusswork Inspections
Verify the correct installation of all trusswork in the flues and ducts.
Replace any damaged members found. Clean out construction de-
bris.
2-8-TAB_8-3
Expansion Joints
Check that all expansion joints are installed correctly, that movement
limits have correct clearances, and that all shipping bolts/straps have
been removed.
Damper Checkout
Check all flue and duct dampers for correct installation. Operate all
dampers normally to insure free and easy movement, prior to operat-
ing with the actuator.
Mark Damper Blade Shaft Ends
Insure that all damper blade shaft ends are clearly marked to indi-
cate their actual position externally to the unit.
Adjust Damper Limit Switches
Adjust the open and closed limit switches for each damper, insuring
that the correct open and closed position of the damper blades is
achieved.
Control Room Indication
Connect damper actuators and operate locally and from the control
room. Verify that the open and closed positions indicate properly in
the control room.
Damper Operation During Trip
Check the correct operation (full open, full close or stop) of all damp-
ers following a trip.
Flues & Ducts Available
The flues and ducts are available for air flow tests and subsequent opera-
tion.
FANS & BLOWERS
The majority of the work on the fans will be performed under the di-
rection of a service representative of the fan manufacturer.
Check Foundations
Insure that all foundations for fans & blowers and bearings are built
according to manufacturer's specifications.
Internal Inspections
Inspect the interior of each fan & blower for correct installation. In-
sure rotor is installed for correct rotation.
Inlet Screens and Silencer
Insure that fan inlet screens are installed correctly. Insure that blower
inlet filter and silencer are installed correctly.
2-8-TAB_8-4
Dampers & Vanes

Inspect the fan and blower dampers and vanes, insure that each is
free and does no interfere with fan housing or piping, connect damp-
er/vane actuators and set open and closed limit switches to their
proper positions. Insure correct operation and indication of dampers
in the control room.
Inspect Bearings
Inspect and clean all bearings and add new oil to the proper level af-
ter closing. Check the journal condition in the bearing zone. Record
the type of oil used in each bearing and insure that is meets the
manufacturer's specification.
Lube Oil & Cooling Water Piping
Check that the lube oil and cooling water piping is installed correctly
and has no leaks. All connections to the bearings should be with flex-
ible hose.
Flush Cooling System
Insure that cooling water supply is available. Flush the cooling water
system and prove bearing oil reservoir has no water accumulation.
Check Wiring
Insure that all actuators, limit switches, and motors are wired correct-
ly. Insure all motors are properly grounded.
Verify Motors & Cables
Verify that the motors function properly (also motor heaters if sup-
plied), and the cables from the breaker to the motor.
Thermocouples
Insure that the bearing thermocouples, motor heaters, and winding
thermocouples are connected correctly, if installed.
Check Motor Direction Of Rotation
Insure that the main drive motors and turning gears have the correct
direction of rotation.
Rotate Fan By Hand-Clearances
Rotate the fan rotor by hand to check clearances. Measure and rec-
ord rotor to inlet cone dimensions.
Run Motors
Operate the fan/blower motor according to manufacturer's specifica-
tion. Check thermocouples, no load amps, bearings and oil levels,
motor ventilation, etc.
2-8-TAB_8-5
Align & Couple

Align and couple the fan to the main drive motor. Record alignment
readings and insure that the coupling grease meets the manufactur-
er's specification.
Coupling Guard
Install the coupling guard.
Alarms, Trips & Interlocks
Check that the fan/blower and motor alarms, trips, and interlocks are
connected, calibrated and tested.
Momentary Fan Fun-Check Lubrication
Start the fan and let it reach normal operating speed. Then shutdown
the fan and check for correct oil ring rotation, if installed, during coast
down.
Run Fan/Blower-Establish Bearing Temperatures
Start the fan/blower and run the fan under load for sufficient time to
establish bearing temperatures. Record operating data on the
fan/blower and forward to the fan manufacturer, if necessary. Do any
rotor balancing as needed at this time.
Actual Alarms & Trips
Check all alarms, trips and interlocks on the fan and motor for correct
operation.
START-UP
BURNER SYSTEM
The majority of the work on the start-up system will be performed
under the direction of a service representative of the start-up burner
system manufacturer.
Check Piping Layout
Insure that the physical piping layout is correct.
Check Atomizing and Cooling System
Check the valve blocks assembly functions properly. Check that
cooling air flow rate and pressure should be as manufacturer's re-
quirement.
Clean & Purge Piping
Clean the oil system piping and purge all piping by compressed air or
steam.
Check Wiring
Check the burner system wiring from the control room to each indi-
vidual burner.
2-8-TAB_8-6
Check Voltages
Insure that the correct voltage is supplied to the system prior to en-
ergizing.
Check Oil Pump Station
Verify that the oil pump station is installed correctly and are ready for
operation.
Check Physical Installation
Check physical installation of each burner. Insure that the burners
are installed correctly.
Burner Centering
Insure that each burner is centered in its burner throat.
Check Ignitor and oil gun Installation
Check the physical installation of each burner ignitor and oil gun. In-
sure that the ignitor and oil gun are in the correct position when ex-
tended and retracted. Check and adjust the control valves.
Set Limit Switches
Adjust the limit switches for the extended and retracted position of
each ignitor and oil gun. Insure control room indication corresponds
to actual ignitor and oil gun positions. Adjust the limit switches on the
control valves.
Check-Out Dampers
Stroke all burner dampers and mark open and closed positions. Es-
tablish initial settings for all dampers based on contract specification.
Operate each damper locally and from the control room to insure
proper control and indication.
Check & Set Scanners
Insure that the flame detectors are installed correctly and the initial
sighting position has been set.
Check Shut-down & Light-Off Interlocks
Insure that the interlocks for the unit shut-down and for ignitor light-
off are installed and armed.
Control Room Indication
Verify that the control room indication of all ignition system functions
is complete and operable.
2-8-TAB_8-7
Local Ignitor and Oil Gun Interlock Run Test

Locally operate each ignitor and oil gun without fuel to insure correct
operation. Operate each burner from the control room without fuel.
Simulate Ignitor Trips & Alarms
Simulate the alarms and trips for the burner and verify that each indi-
vidual burner actuates correctly under the various conditions.
Test Fire
Test fire each burner both locally and from the control room. Insure
correct control room indication. Adjust flame detectors as needed.
FEEDERS
The majority of the work on the feeders will be performed under the
direction of a service representative of the feeder manufacturer.
Proper Storage Procedures
Ascertain that the proper storage procedures, as recommended by
the feeder manufacturer, have been followed prior to installation of
the feeder. This includes rotation of drive motors, rollers, inspections,
and greasing at regular intervals.
Flexible Connections
Insure that there are flexible connections above and below each
feeder.
Seal Air
Check that seal air is connected to a clean air supply.
Lubricant of Drain & Refill Reducers
Drain and refill all gear reducers with fresh lubricant to the proper
level.
Install Speed Controller
Install each feeder speed controller according to manufacturer's rec-
ommendations.
Check Wiring
Check the wiring of the feeder and its controls and insure that the in-
put signals are available and correct.
Ground Lug
Verify that the ground lug is connected in order to prevent possible
shock hazard.
Open Doors
Open all of the feeder doors to afford access during check-out.
Internal & External Inspections
2-8-TAB_8-8
Inspect the feeder both internally and externally and remove any
construction debris at this time.
Block Belt Scraper
Block the belt scraper in a position so that it does not contact the belt,
prior to bumping the feeder motors.
Adjust Belt Tension
Check the feeder belt tension and make any initial adjustments re-
quired.
Adjust Cleanout Chain
Adjust the cleanout conveyor chain tension.
Check Idler Rollers
Insure that the feeder idler rollers are free to rotate.
Bump Motors
Bump all motors to insure that all are operational and rotating in the
proper direction.
Adjust Discharge Limit Switch
Adjust the discharge limit switch of each feeder to actuate at the rec-
ommended distance from the feeder end plate.
Preset Controls
Preset and calibrate the feeder controls prior to the initial run-in. In-
sure that manufacturer's recommendations are followed strictly.
Run Feeder
Place each feeder in service and insure it operates correctly. Insure
that coal cannot enter the feeder for these initial run-ins.
Set Up Speed Controller
Adjust the feeder speed controller and calibrate the load cell accord-
ing to manufacturer's recommendations.
Check Belt Tracing
Insure that the belt tracks correctly.
Re-adjust Belt Tension
During the initial test runs, the feeder belt tension may require ad-
justment.
Shutdown Feeder & Close Doors
Following the recommended run-in time, remove the feeder from
service and close all access doors.
Check Feeder Calibration
2-8-TAB_8-9
Verify the correct calibration of the feeder controls when it is first

placed in service with coal. Periodically check the feeder belt tension
to insure it is correctly adjusted.
ASH COOLER
The majority of the work on the ash cooler will be performed under
the direction of a service representative of the fan manufacturer.
Check conveyor
Insure that there are no foreign objects inside the conveyor and that
the conveying elements are free to move.
Inspect Bearings
Inspect the condition of the bearing gaskets and bearings for lubrica-
tion.
Lube Oil Quantity
Check the quantity of lube oil in gear reducers, see instructions of
manufacturer.
Check Motor Direction Of Rotation
Insure that the main drive motors have the correct direction of rota-
tion, if the cables have been wired.
Covers and Doors.
Insure that all covers and shields are imperforate and their right posi-
tions and that all manholes and service doors are closed.
Check Wiring
Check the wiring of the cooler and its controls and insure that the in-
put signals are available and correct.
Preset Controls
Preset and calibrate the cooler controls prior to the initial run-in. In-
sure that manufacturer's recommendations are followed strictly.
Check that the cooler and motor alarms, trips, and interlocks are
connected, calibrated and tested.
Start & Stop Sequence
Insure that the start/stop sequence is right.
2-8-TAB_8-10
BURNER
CONTROLS &
FUEL SAFETY
Check Local Cabinets
Check all local cabinets for correct installation, material supply, and
weather tightness.
Check Wiring
Insure that the wiring from the control room to each burner is correct.
Insure Proper Voltages
Check that all supply voltages are correct prior to energizing the sys-
tems.
Check and verify that all alarms, trips and system interlocks are con-
nected and are operable.
Simulate Control Functions
Simulate all of the system control functions, including alarms, trips
and interlocks.
Simulate Light-Off
Simulate a boiler light-off to insure all permissive, alarms, trips, and
interlocks operate correctly.
Simulate Oil Firing
Simulate boiler normal operation on oil firing and test all permissive,
alarms, trips, and interlocks.
SOOTBLOWER
The majority of the work on the sootblowers will be performed under
the direction of a service representative of the sootblower manufac-
turer.
Check Wiring & Voltages
Check the system wiring from the control room to each sootblower
and insure that supply voltages are correct prior to energizing the
system. Check motor grounds.
Check Local Control Boxes
Ascertain that all local control boxes are installed and wired correctly
and are weather tight.
Check Control Room Panel
Ascertain that the control room panel is correctly installed and wired.
Check Piping Installation
Verify that the physical layout of all sootblower piping is correct.
2-8-TAB_8-11
Check Piping Supports

Verify that the sootblower piping supports are installed correctly, are
adequate, and that they allow for boiler and piping expansion.
Leak Test
Perform a leak test on the sootblower piping and correct any leaks
found. Perform a hydrostatic test if required.
Clean Piping
Clean out the sootblower system piping by blowing down with steam
or compressed air. Insure that the thermal drain valves are removed
prior to blowing down.
Mechanical Check Each Blower
Check each sootblower to verify correct installation. Clean and ten-
sion the chains properly.
Blower Wiring & Rotation
Check each sootblower for correct wiring of motor and limit switches
and verify the correct direction of rotation of the nozzle.
Inspect/Clean Drain Valves Supply
Inspect and clean the intervals of the system drain valves supplied
and reassemble following blowdown of the piping.
Drain Valve Controls
Calibrate the thermocouples for all automatic drain valves.
Drain Valve Operation
Insure that all automatic drain valves operate correctly.
Operate Each Blower Manually
Operate each sootblower by hand to check for mechanical clearanc-
es and limit switch adjustments. Also, adjust the sootblower medium
angle valve linkages.
Energize System
Energize the system and check for correct supply voltages to each
blower.
Operate Each Blower Locally
Place each sootblower in service from its local control box. Insure
that limit switches operate correctly.
Operate Manually From Control Panel
Operate each sootblower in the manual mode from the control panel.
Automatic Operation
Operate the system in the automatic sequence mode to insure cor-
rect operation.
2-8-TAB_8-12
Inspect & Adjust Pressure Reducing Station

Insure that the pressure reducing station is installed correctly. In-
spect and clean the PRV valve internals. Adjust the initial control set-
tings and warm-up circuit. Set the safety valve after inspecting and
cleaning.
Adjust Sootblower Pressure
Adjust the blowing pressure of each sootblower once boiler operation per-
mits use of the sootblowers.
Establish Blowing Frequency Schedules
After sufficient operating experience, establish recommended soot-
blowing frequency schedules to control slag.
SPRAY SYSTEMS
Check Piping & Supports
Check that the spray system physical piping layout is correctly in-
stalled and supported.
Leak Test
Perform a leak test on the system. Also, perform a hydrostatic test as
required.
Clean Piping
Insure that all spray water piping has been cleaned.
Inspect Spray Control & Stop Valves
Insure that all spray control and stop valves function well.
Stroke Valves & Set Limit Switches
Stroke all of the valves manually and from the control room. Adjust
the open and closed limit switches. Insure proper control room oper-
ation and indication.
Check & Calibrate Thermocouples
Check that thermocouples are installed at appropriate points in the
system, that they are connected correctly, calibrated, and indicate in
the control room.
SAFETY VALVES
The majority of the work on the safety valves will be performed under
the direction of a service representative of the safety valve manufac-
turer.
Remove Hydro Plugs
Remove the hydrostatic test plugs.
2-8-TAB_8-13
Clean Internals
Clean all valve internals per recommendations of the service repre-
sentative.
Lap Seats
Lap the seat of each safety valve as directed by the manufacturer's
representative, if necessary.
Assemble Valves
Assemble each valve following the inspections. Use molikote or
equivalent on all bolts to each future maintenance.
Remove Shipping Stops
Remove the shipping blocks from the safety valve springs.
Discharge Clearances
Insure that the expansion clearances between the discharge and ex-
haust piping are adequate. Also, check that exhaust piping supports
are installed correctly to allow for differential expansion.
Drains
Insure that the proper safety valve drains are installed and routed to
a safe location.
Set Safety Valves
Set the safety valve lift pressures.
Real Lift Pressures & Blow-down Tests
Raise boiler pressure and check the actual lift pressure of each safe-
ty valve. Also, check that the blow-down is correct.
ALARMS, TRIPS &
INTERLOCKS
Boiler Purge
Insure that all interlocks for a boiler purge are armed and operating.
Also, check that the proper unit trips hinder a successful boiler purge.
Drum Level
Check that drum level high and low level alarms and trips are set cor-
rectly and annunciate in the control room.
Start-up Burner System
Ascertain that all burner system alarms, trips and interlocks are func-
tioning, Especially check light-off permissive.
Furnace Draft
Check that the furnace draft alarms and trips are correctly calibrated
and armed.
2-8-TAB_8-14
Damper Operation
Insure that all damper interlocks are correctly connected.
Fans and Blowers
Insure that all fan and blower start-up permissive are armed to pre-
vent improper operation of the fans and blower. Verify all fan and
blower alarms and trips.
Fuel Safety
Ascertain that the fuel safety system is properly designed for the in-
tended service and that all system alarms, trip and interlocks are
functioning correctly.
Manual Trip
Test the manual emergency boiler trip to insure it operates correctly.
INSTRUMENTATION
& CONTROL
Metals Temperatures
If applied, insure that all metal temperature thermocouples are cor-
rectly located and installed. Check each thermocouple for correct
operation prior to final terminations are made. Also, check that each
thermocouple indicates properly in the control room. Insure that
alarm points for high metal temperatures are set correctly and an-
nunciate.
Air & Gas Temperatures
Verify that all air and gas temperature thermocouples are correctly
installed and connected to indicate in the control room.
Furnace Temperature
Insure that the furnace temperature probes are available and indi-
cated in the control room.
Air & Gas Pressures
Check that all points of measurement of air and gas pressures
throughout the unit are connected to indicate in the control room and
are calibrated correctly.
Fans and Blower
Verify that all pertinent instrumentation on fan operation is correctly
installed and indicating in the control room. Insure that the fan and
blower controls function correctly in both the manual and automatic
modes.
2-8-TAB_8-15
Air Flow
Insure that an indication of primary and secondary air flow is correct-
ly calibrated to indicate in the control room.
Cooling Water
Check that the instrumentation and control of cooling water is cor-
rectly installed and the correct alarms annunciate on loss of cooling
water.
Auxiliary & Atomizing Air
Both the local and control room instrumentation for auxiliary and at-
omizing air should be checked for correct installation. Insure that
controls for both systems function from the control system.
Drum Pressure & Level
Insure proper indication of the drum pressure and drum level in the
control room and locally at the drum. Verify the calibration of the var-
ious instruments. Check that the drum level controls are functioning.
Feedwater
Ascertain that an indication of feedwater is available in the control
room and that controls of feedwater flow and quality are functioning.
Advise your Regional Manager as to whether or not the feedwater
flow measurement includes spray water flow.
Flow, Pressure, Spray Temp.-SH/RH
Check for the proper installation and calibration of the indications of
flow, pressure, and spray water temperature for both the superheater
and reheater.
Start-Up Burner
Insure that there is proper indication in the control room and locally
of all burner system functions and pertinent operating data, such as
nature gas pressure, air pressure, etc.
Oxygen Analyzer
Verify that the oxygen analyzer is connected, calibrated and availa-
ble for service.
Steam Temperature Controls
Check that the attemperation valve and biasing damper controls are
connected and function correctly both in the hand and automatic
modes. Insure that there is control room indication of steam tem-
peratures before and after each spray station.
Sootblowers
2-8-TAB_8-16
Verify that the controls and instrumentation for the sootblower sys-
tem are available for service.
Coal Feeders
Insure that there is control room indication of coal feeder operating
conditions and that all controls are connected and are available for
service.
Controls Automated
As unit operation permits, test the boiler controls in the automatic
mode of operation.
2-8-TAB_8-17
TAB 9 - UNIT OPERATING PROCEDURES
TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION .............................................................................................. 2-8-TAB_9-1
UNIT DESCRIPTION ........................................................................................ 2-8-TAB_9-1
PRE-OPERATIONAL PROCEDURES ............................................................. 2-8-TAB_9-2

Cleanup ........................................................................................................ 2-8-TAB_9-2
Chemical Cleaning ...................................................................................... 2-8-TAB_9-2
Blowing Steam Lines .................................................................................. 2-8-TAB_9-2
Setting Safety Valves .................................................................................. 2-8-TAB_9-2
Refractory Cure ........................................................................................... 2-8-TAB_9-3
Unit Charging .............................................................................................. 2-8-TAB_9-3
COLD / WARM START-UP .............................................................................. 2-8-TAB_9-5

Preparation for Lighting-Off and Purging ................................................. 2-8-TAB_9-5
Initial Firing Precautions ............................................................................ 2-8-TAB_9-9
Steam Temperature and Pressure Control (Prior to Unit Synchronization) ...............
.................................................................................................................... 2-8-TAB_9-10
Air Preheater Protection During Unit Start-Ups On Oil ......................... 2-8-TAB_9-10
Lighting-Off - Cold / Warm Start .............................................................. 2-8-TAB_9-11
NORMAL OPERATION - UNIT LOAD CHANGE ........................................... 2-8-TAB_9-17

Decreasing Load ....................................................................................... 2-8-TAB_9-17
Increasing Load ........................................................................................ 2-8-TAB_9-17
NORMAL SHUTDOWN TO COLD ................................................................. 2-8-TAB_9-17
NORMAL SHUTDOWN TO HOT STANDBY ................................................. 2-8-TAB_9-20
HOT RESTART .............................................................................................. 2-8-TAB_9-22
EMERGENCY PROCEDURES ...................................................................... 2-8-TAB_9-23

Reheater Protection Upon Loss of Load ................................................ 2-8-TAB_9-23
Turbine Valve Closure .............................................................................. 2-8-TAB_9-24
Turbine Trip ............................................................................................... 2-8-TAB_9-24
Post Trip Procedures................................................................................ 2-8-TAB_9-24
Turbine Protection Upon Loss of Load................................................... 2-8-TAB_9-25
Master Fuel Trip ........................................................................................ 2-8-TAB_9-26
Low Water Level ....................................................................................... 2-8-TAB_9-26
High Water Level ....................................................................................... 2-8-TAB_9-27
2-8 -TAB_9-i
TITLE PAGE NO.
Tube Failures ............................................................................................ 2-8-TAB_9-28

Water Wall Tubes and Evaporator Panels ........................................ 2-8-TAB_9-28
Economizer Tubes .............................................................................. 2-8-TAB_9-29
Superheater and Reheater Tubes ...................................................... 2-8-TAB_9-29
Loss of Power ........................................................................................... 2-8-TAB_9-29
Loss of PA Fan .......................................................................................... 2-8-TAB_9-29
Loss of SA Fan .......................................................................................... 2-8-TAB_9-30
Loss of Fluidizing Air Blower................................................................... 2-8-TAB_9-30
Loss of Induced Draft Fan ........................................................................ 2-8-TAB_9-31
2-8 -TAB_9-ii
UNIT OPERATING PROCEDURES
INTRODUCTION
The procedures outlined in this section of the manual are intended
to serve as a guideline for manual and automatic operation. The
procedures include precautions which should be observed and the
proper operating sequences of the unit.
The procedures contained in this section of the manual describe
the proper operating sequences to ensure a safe and orderly start-
up and shutdown of the boiler. These procedures will also provide
temperature values to serve as a guideline to protect the refractory
as well as the boiler proper. As operating experience is gained and
controls are fine-tuned, the unit characteristics and actual operating
requirements will become evident to the operator.
Reference should be made to the controls description located
elsewhere in this manual for further operating details.
Reference should be made to the detailed manufacturers’ instruc-
tions found elsewhere in this manual for auxiliary equipment sup-
plied by them regarding operational and pre-operational procedures.
UNIT DESCRIPTION
The unit is a balanced draft, natural circulation, circulating fluid bed
(CFB) boiler.
The furnace is of a water - wall design with the lower portion refrac-
tory lined. Convective pass flue gas biasing dampers are provided
for reheat steam temperature control. There are six(6) coal feed
openings located on the furnace front wall. There are four (4) start-
up burners - two (2) located on each side wall. There are eight (8)
limestone feed points, six (6) on the furnace front wall and one (1)
in each seal pot return duct.
2-8 -TAB_9-1
PRE-OPERATIONAL
PROCEDURES
Cleanup
Before initial firing and prior to each subsequent cold start-up, after
maintenance has been done on the unit, the furnace and auxiliary
equipment should be inspected and cleaned both internally and ex-
ternally. Any foreign material should be removed from the pressure
parts. Any grating, pipe lines, electric conduit, etc., that might re-
strict normal expansion of the unit should be cleared. All personnel
should be clear and access doors closed. A complete check list
should be prepared by operating personnel.
Chemical Cleaning
Specific procedures for boiling out elsewhere in this manual. Firing
procedures as outlined under “Lighting Off-Cold / Warm Startup”
should be used as a guide when operating the fuel firing equipment.
Blowing Steam
Lines
Prior to starting up a new unit or following major pressure parts re-
pairs on an older unit, the main steam lines and the reheater steam
lines should be blown out to remove scale and foreign matter,
thereby preventing damage to the turbine. This should be done af-
ter chemical cleaning and prior to setting boiler and superheater
safety valves. Consideration should be given to setting the reheater
safety valves before removing the temporary blow out piping.
Refer to “Steam Line Blowing Procedures” elsewhere in this manual
for recommended operating procedures and precautions.
Setting Safety
Valves
Setting of the safety valves on the drum and superheater should be
done prior to turbine rolling. Refer to the safety valve manufactur-
er’s instructions for setting procedures. A conservative firing rate
should be maintained, limiting the cyclone exit gas temperature to a
maximum of 535°C in order to protect the superheater pressure
parts and associated equipment, including the safety valves, during
setting of the safety valves. The reheater safety valves may be set
after reheater steam line blowing or while the turbine is carrying a
light load, by closing down on the intercept valves until a reheat
2-8 -TAB_9-2
steam pressure is reached that is high enough to lift the reheat

safeties. Refer to safety valve manufacturer’s instructions. Popping
pressure and blowdowns should be adjusted to conform with design
values.
Refractory Cure
Prior to starting up a new unit, or following any refractory repair, the
furnace, cyclone, seal pot, and connecting refractory ductwork must
be properly cured in accordance to the refractory supplier’s instruc-
tions.
Unit Charging
Prior to starting up of the CFB system an inert material (properly
sized sand or CFB bed ash) must be introduced into the furnace
and seal pots:
NOTE: Sand or bed ash can be used as inert mate-
rial. It is preferable to use bed ash as its softening
temperature is higher than 1250°C. Bed ash with
1200°C softening temperature or below is not rec-
ommended. Bed ash can come from the bottom
ash sized from vibration screen in bottom ash han-
dling system. For new unit or unit start-up after
overhaul, fresh sand with high fusion temperature
such as silica sand as inert material is recommend-
ed to prevent agglomeration of inert material during
start-up period with oil firing or co-firing of oil and
coal.
Sufficient material must be introduced in order to allow for proper

heat transfer and warming of the system. Approximately 100 tons
of inert material is needed for the furnace and seal pots. It is not
necessary to charge the unit if the system was not drained of ash
and/or bed material which accumulated during prior operation. Ad-
ditional bed material may have to be supplied to the CFB system
during start-up only to maintain proper heat transfer and warming of
the system.
2-8 -TAB_9-3
INERT BED MATERIAL PARTICLE SIZE DISTRIBUTION
CURVE NO. 1
2-8 -TAB_9-4
COLD / WARM
START-UP
A cold or warm start is considered to be when the temperature of
the fluidized bed at the startup burner elevation is below 700°C and
a purge cycle must therefore be included. The temperature of the
slumped bed prior to fluidization at the lowest thermocouple eleva-
tion provides an indication only (not a permissive) whether or not a
purge cycle may be required. Cold or warm start-up includes purg-
ing the unit, heating up the furnace with the startup burners above
550°C, introducing solid fuel with the start-up burners operating,
and final heat-up solely with solid fuel, above 700°C on solid fuel
only.
NOTE: Permissive temperature for coal burning
depends on coal property. Above permissive tem-
perature is according to design coal property. Any
burning coal is different from design coal, permis-
sive temperature must be tested during commis-
sioning or start-up.
Preparation for
Lighting-Off and
Purging
It is assumed that at this time the following preparatory work has
been completed:
1. The unit has been chemically cleaned, that the steam lines
have been blown, that the safety valves have been set, that the
unit has sufficient bed material, and that the unit has been filled
to slightly above the normal operating level with properly treated
feedwater.
CAUTION: The differential temperature between
economizer water outlet temperature and drum
metal temperature must never exceed 110°C. This
is to avoid thermal shocking the drum.
2. All control systems have been checked out and are available
for service.
2-8 -TAB_9-5
NOTE: Check all safety interlock systems prior to

startup to insure proper functioning. Exercise the
systems by creating the actual interlock activating
conditions. Simulate the activating condition if the
actual condition cannot be created.
3. All instrumentation has been checked out, calibrated and is

available for service.
4. Cooling water system has been checked out :
a. Cooling water pump is in service
b. Stand-by cooling water pump is ready in stand-by.
c. Assure cooling water is available for auxiliary equipment
before run these equipment.
d. Check cooling water go to places where need cooling water.
e. Assure sufficient cooling water for auxiliary equipment.
5. Plant air and instrument air system
a. Open isolation valves of air piping.
b. Compressor is running and air is available.
c. Dryers are in service.
d. Air pressure reaches required value.
6. The fuel firing equipment, coal and diesel oil, has been checked
out are available for service.
7. The limestone equipment has been checked out to assure
proper functioning.
8. All mechanical and auxiliary equipment and systems have been
checked out and are available for service.
9. The feedwater system, including instrumentation and equip-
ment, has been checked out and is available for operation.
a. Assure make-up water level in ultra-water tank is normal.
b. Condenser make-up pump running is stable.
c. If heating steam for deaerator is available, heat-up deaera-
tor and storage tank to suitable temperature.
d. Feed make-up water to deaerator storage until proper water
level.
e. Control proper pressure in deaerator.
f. Start-up vent of deaerator is open.
g. Inlet valve of BFP shall be open before start up pump.
2-8 -TAB_9-6
h. Outlet valve of BFP is close before start up pump.

i. Assure manual valve on minimum flow line and balance line
is open.
j. Boiler feed pump start up in accordance with manufacture’s
instructions.
k. After BFP with direct driver is start-up, when pump reach
full speed, open outlet valve of pump
If BFP with hydraulic coupling is start-up, when pump reach
min. speed, open outlet valve of pump.
It is recommended that during startups the feedwater be con-
trolled remote-manually, until a continuous flow is established.
To avoid the possibility of oxygen corrosion in the boiler, the
use of deaerated feedwater is recommended. Refer to the
“Water Treatment” instructions elsewhere in this manual.
10. All air and gas handling equipment has been checked out and
is available for service. All air and gas duct dampers should be
in the startup position. (Refer to Notes and Caution below).
a. ID Fan inlet control vanes closed.
b. PA Fan inlet control vanes open 25% or above.
c. SA Fan inlet control vanes open 25% or above.
d. Secondary air port dampers open.
e. Convective backpass flue gas biasing dampers on both su-
perheat and reheat side specified open to ensure even
heating of both parallel passes.
NOTE: Refer to the Fan manufacturer’s instruc-
tions for operating details.
2-8 -TAB_9-7
CAUTION: The I.D. Fan is capable of developing a

draft in excess of the furnace design pressure.
Therefore, the operator must take care to establish
and maintain an air flow path through the unit, prior
to starting the I.D. Fan and prior to opening the I.D.
Fan inlet control vanes, by insuring that other
dampers in the system are in the startup positions
indicated above and all secondary air port dampers
are open.
I.D. Fan inlet control vanes should be kept closed
until after the fan is started. This procedure will min-
imize the possibility of developing excessive nega-
tive pressure in the unit during the starting proce-
dure.
The operator must take care to maintain the fur-
nace draft within safe limits at all time, and must be
especially careful when draft and air flow controls
are in the “Manual” mode. The operator must be
alert at all times for possible malfunctions of auto-
matic control equipment resulting in abnormal ex-
cursions in furnace pressure, either negative or
positive.
11. The soot blowing equipment has been checked for proper op-
eration and the system is in the startup condition (all blowers
retracted, main steam supply valves isolation open.)
12. All Desuperheater Spray Water Control Valves are closed.
13. All Boiler, Superheater and Reheater drain and vent valves are
in the start-up position. Feedwater regulating valves closed
(manual control). All boiler drain and blowdown valves closed.
Main steam stop valve and/or turbine throttle valve closed.
Drum vent open. Water gauge valves open (locked open). Su-
perheater and Reheater header drains and vents and main
steam line drains open (see Note below).
2-8 -TAB_9-8
NOTE: Open all superheater header vents and

drains. Close all reheater vents just before raising a
vacuum in the condenser. Keep reheater drains
open (to condenser) until turbine is lightly loaded. If
reheater drains do not connect with the condenser,
close them just before raising a vacuum in the con-
denser.
CAUTION: Prevent possible water damage to the

turbine by using extreme care to eliminate all water
from the main steam line, cold and hot reheat lines
and superheater and reheater elements and head-
ers before the turbine is rolled. Refer to the turbine
manufacturer’s instructions.
14. The furnace and seal pots should be pre-charged with bed ma-
terial in order to maintain proper bed differential pressures.
Sized sand as bed material is highly recommended.
15. The turbine - generator is available for service and has been
prepared for service as described in the manufacturer’s instruc-
tions.
Initial Firing
Precautions
During start-up, warming up the unit to solid fuel firing conditions is
accomplished with the start-up burners.
When bringing the unit up to steam pressure and temperature, the
saturated steam temperature rise must be limited to 110°C, per
hour (see Note). The “Maximum Allowable Rate of Pressure
Change for Normal Startups and Shutdowns” curve shows the cor-
responding rate of drum pressure increase.
NOTE: It is recommended that during initial start of
a new unit a relatively slow rate of pressure in-
crease be followed, in order to allow sufficient time
for checking expansion movements and to permit
the operators to become familiar with the character-
istics of the unit and auxiliaries.
2-8 -TAB_9-9
During all start-ups the firing rate should be controlled to keep the
maximum cyclone exit gas temperature below 535°C until the tur-
bine is synchronized. After rolling the turbine, the steam tempera-
ture and pressure rise at the turbine throttle should at all times be in
accordance with the limits prescribed by the turbine manufacturer.
NOTE: For the first few start-ups, until the refracto-
ry has seasoned, the furnace heat-up rates should
be limited to 65°C per hour. Once the unit has sea-
soned, the furnace heat-up rates can be increased
to follow the startup curves.
STEAM
TEMPERATURE AND
PRESSURE
CONTROL (PRIOR
TO UNIT
SYNCHRONIZATION)
During start-up of this unit, the HP and LP turbine steam bypass
system can be used to control steam temperature and pressure as
required to the turbine, and convective pass flue gas biasing damp-
ers can also put in service to assist steam temperature control if
necessary. Refer to the turbine supplier’s operating procedures for
this system’s details. Once the turbine/generator has been syn-
chronized and reheat flow has been established to the boiler re-
heater, the convective pass flue gas biasing dampers can be put in
service to control reheat steam temperature to the turbine as re-
quired.
AIR PREHEATER
PROTECTION
DURING UNIT
START-UPS ON OIL
It is strong recommendation to have the air preheater soot blowing
system continuously in service when firing oil to start up a boiler.
This measure is intended to help avoid air preheater fires due to
accumulation of oil vapor on heat transfer surfaces or ash particles
in the air preheater baskets. Retractable soot blowers are installed
at the cold end and hot end of the air preheater on the gas side.
2-8 -TAB_9-10
These soot blowers are primarily designed to reduce and/or control

ash build-up in the air preheater heat transfer surface elements.
They are not cleaning devices such as the stationary wash down
nozzles.
Steam is the preferred soot blowing media. However, on some

units auxiliary steam sources are not available when starting a unit,
and nor-mal soot blowing steam requirements are not reached until
a later stage in the start-up process. In those cases, compressed
air is an acceptable alternate blowing media, though less effective
than steam.
For those units where either auxiliary steam or compressed air is

available for cold starts on oil, the fire detection system must be ac-
tivated before the air preheater is activated. This system will identi-
fy any possible start of a fire in the air preheater. Special attention
must be given to the readings of gas and air temperatures leaving
the air preheater. An unusual increase in any of these tempera-
tures must be investigated immediately. Any indication of an air
preheater fire must be investigated immediately because once a
fire is well under way it can not be stopped before the air preheater
is severely damaged.
For unit loads below 10% MCR steam flow, unnecessary high fluc-
tua-tions in furnace draft [more than ± 6.35mm w.g. (± 0.25" w.g.)]
should be avoided. Also, any steam that is available can and
should be used for air preheater soot blowing as long as sufficient
steam pressure is available (per sootblower instruction manual).
When this minimum steam pressure has been reached, continuous
cold end and hot end blowing should be initiated and continued un-
til 10% MCR steam flow is reached. After that air preheater soot
blowing can be reduced to intermittent operation, once every four to
eight hours or as required, depending on the fuel being fired.
Lighting-Off - Cold /
Warm Start
Before a cold or warm unit can be fired, a purge cycle is required to
obtain start-up burner ignition permit.
2-8 -TAB_9-11
1. Start the air preheater. Refer to the air preheater instructions

for operating details
2. Start the induced draft (ID) fan (see caution under item 10,
“Preparation for Light-Off and Purging”).
3. Set furnace pressure controller to “Auto”.
4. Start the fluidizing air (FA) blower.
5. Start the secondary air (SA) fan.
6. Start the primary air (PA) fan.
7. The PA fan should be set to maintain a minimum airflow of
about 50% of its full load air flow. The SA fan is controlled to
meet startup burner air flow demand when the burners are in
service. Set all secondary air nozzle dampers closed to limit
stop. These dampers will be sequentially opened as boiler load
is increased. The fluidizing air blower is to remain in service.
8. Adjust fan inlet vanes and all secondary air nozzle dampers to
permit a purge air flow of at least 30% of full load air flow. Re-
fer to “Initial Firing Precautions”. Check that all requirements to
initiate a furnace purge are satisfied.
9. Initiate a furnace purge. Purge for at least five (5) minutes.
10. Upon completion of the purge cycle, check that all start-up
burner ignition permits are satisfied.
11. After completion of the furnace purge, the biasing damper in
reheater pass close to minimize opening position.
12. Light off one start-up burner. Leave the burner at minimum fire.
Then start another burner on the opposite side wall and leave
the burner at minimum fire. Once all burners are in service, in-
crease load on all four burners simultaneously to meet startup
curves.
13. The furnace heat-up rate as measured by the thermocouples
located at the same elevation as the startup burners should not
exceed 153°C per hour. ( If the refractory maker have an dif-
ferent limit for temperature rising, the furnace temperature
rising will follow refractory maker’s instruction )
2-8 -TAB_9-12
NOTE: For start-ups during commissioning, the re-

fractory has to be seasoned, the furnace heat-up
rates should be limited to less than 65°C per hour.
The furnace heat-up rate is measured by the ther-
mocouples located at the same elevation as the
start-up burners. This lower rate is recommended to
allow the refractory to season and to prevent any
damage from occurring due to faster than recom-
mended furnace heat-up rates. Once the unit has
seasoned, the furnace heat-up rates can be in-
creased to follow the startup curves.
14. As the furnace temperature increases, the temperature at the
seal pots should be maintained to within 55°C of the upper fur-
nace temperature (burner elevation), to prevent damaging the
cyclone and seal pot refractory. When the seal pot tempera-
tures drop 55°C or more below the upper furnace temperature,
the PA flow should be increased as required to reduce the dif-
ferential to or below 55°C, or the rate of heat-up should be re-
duced.
15. Close the drum vent valve when the drum pressures reaches 2
kg/cm2(g).
16. As the drum pressure increases, progressively throttle the su-
perheater outlet header drain and/or other start-up vent and
drains used. Sufficient steam flow must be maintained at all
times to assure clearing the superheater elements of conden-
sate and to provide cooling of tubing during startup.
17. During the warming period, blow down the unit as required to
maintain the water level in sight in the gauge glass.
18. While the unit is heating up, frequent checks should be made of
the boiler expansion movements. Special attention should be
given to lower part of the boiler relative to building steel. Ex-
pansion movement should be recorded for comparison with fu-
ture start-ups.
19. Maintain drum water level at normal and check boiler water
concentrations and constituents as frequently as required to
maintain proper boiler water conditions.
2-8 -TAB_9-13
20. Before raising a vacuum in the condenser, make sure that all
the appropriate vents or drains including all reheater vents or
drains that are open to atmosphere are closed. Leave drains or
vents connected to the condenser open until the turbine is car-
rying a light load.
21. Start rolling the turbine as soon as the minimum permissible
start-up pressure and temperature, specified by the turbine
manufacturer, are reached. Refer to turbine manufacturer’s in-
structions.
22. When bringing the turbine up to speed, the firing rate should be
controlled to prevent the cyclone exit gas temperature from ex-
ceeding 535°C to protect the boiler superheater and reheater.
When the turbine is up to speed, it may be synchronized and
the 535°C cyclone exit gas temperature limit may be discontin-
ued. In no case should the firing rate exceed that which is nec-
essary to satisfy steam demand.
NOTE: If the unit is put on the line before operating
pressure is reached, further increase of firing rate
should be in accordance with the start-up rates.
2-8 -TAB_9-14
CAUTION: Operators should be alert to detect the

symptoms of water carryover from the boiler and
introduction of water into the turbine such as:
a. A sudden unexplained drop in steam tempera-

ture in either the main steam or hot reheat line.
b. Vibration in the steam piping resulting from wa-
ter hammer.
c. Abnormal vibration and differential expansion
readings from the turbine supervisory instru-
mentation.
Operators must be prepared to take actions neces-
sary to prevent turbine damage upon detection of
water introduction. Refer to turbine manufacturer’s
instruction for specific actions to be taken.
23. Solid fuel firing can begin at a minimum flow rate when the fur-
nace temperature at the startup burner elevation reaches
550°C. As further heat input is required to follow the startup
curve, solid fuel flow should be increased. When the furnace
temperature at the startup burner elevation reaches 700°C, the
start-up burners firing rate can be reduced while increasing the
solid fuel firing rate to maintain and increase the furnace tem-
perature. When the furnace temperature at the start-up burner
elevation reaches 750°C, the start-up burners can start to re-
move from service. This removal temperature may be adjusted
based on actual operating experience. When removing a burn-
er from service, allow the furnace temperature to recover. Fol-
low the start-up curve for increasing furnace temperature.
24. At the full coal firing, start limestone feeding system. Limestone
powder is introduced to furnace depending on the SO2 re-
quirements.
25. It is essential that the air flow to the furnace is sufficient for the
firing rate at all times. Automatic control equipment is normally
arranged to maintain such a balanced condition. The O2 meas-
uring devices, which are often tied in with the air flow control,
should be checked periodically to assure continuous and de-
pendable operation.
2-8 -TAB_9-15
26. Place the steam temperature controls and combustion controls

on “Auto” when firing conditions are stable and the temperature
and pressure control set points have been reached. Refer to
the control manufacturer’s instructions for specific procedures.
27. Adjust the feedwater supply to the boiler as necessary to main-
tain normal water level. Feedwater control should be placed on
automatic as soon as possible and practicable after continuous
feedwater flow is established.
CAUTION: To prevent agglomeration of limestone

or bed material in lower furnace due to local hotspot
during boiler start-up, normal operation or shut
down period, following operation situations must be
avoided.
a. Limestone shall not be able to introduce to
boiler until all start-up burners out service and
full coal firing. Also recommend to stop lime-
stone to boiler when start-up burner is in ser-
vice during normal operation or period of shut
down.
b. Long time co-firing of oil and coal shall not al-
low during boiler start-up, normal operation or
shut down period. Co-firing time shall not be
over than 8-10 hrs. During co-firing of oil and
coal, operator shall monitor furnace tempera-
ture and bed differential pressure frequently.
Any abnormal condition in these parameters,
perhaps agglomeration of bed material is oc-
curred. Boiler shall shut down to check bed ma-
terial situation in furnace.
c. To switch coal firing to only oil firing and keep
oil firing for long time operation without drain
out all bed material isn’t allowed.
d. Limit to increase firing rate (follow start-up
curve) during transient period of oil firing
changed to coal firing.
2-8 -TAB_9-16
NORMAL
OPERATION - UNIT
LOAD CHANGE
During normal operation the unit will be controlled automatically.
The operator will have to pay special attention to the unit’s opera-
tion to ensure that the flue gas emissions limits are not exceeded,
and that the superheater and reheater steam flow, temperature,
and pressure are maintained.
Decreasing Load
To reduce load, reduce the steam flow to the turbine. This is ac-
complished by decreasing the fuel flow to the furnace. Adjust the
solid fuel rate and/or take out of service an operating fuel feeder.
Increasing Load
To increase load, increase the steam flow to the turbine. This is ac-
complished by increasing the solid fuel flow to the furnace. Adjust
the fuel rate and/or place another fuel feeder in operation.
CAUTION: Some backsifting of bed material from
the furnace into the air plenum beneath the furnace
may occur during startup or periods of operation
below 50% load where primary air flow is signifi-
cantly reduced below the full load value. If the ple-
num is not periodically drained of this material,
amounts sufficient to impact PA fan performance
and possibly damage the plenum support structure
may accumulate. It is therefore recommended that
the plenum drains be operated once per shift during
these periods of low primary air flow operation.
Draining of the plenum is not normally required dur-
ing periods of operation above 50% load.
NORMAL
SHUTDOWN TO
COLD
The following procedures for normal shutdown to cold are based on
the assumption that the unit is operating at full load on automatic
control and that it is the intention to reduce the pressure to zero and
cool the boiler completely.
2-8 -TAB_9-17
1. Gradually reduce load on the unit by reducing the firing rate in

line with the decreasing steam flow. Allow the steam pressure
to drop with the reduction in load to accelerate cooling. Follow
the “Maximum Allowable Rate of Pressure Change for Normal
Start -Ups and Shutdowns” curve.
A reduction in furnace temperature as measured by thermo-
couples located at the startup burner elevation should not ex-
ceed 153°C per hour. Follow the “Shutdown To Cold” curve for
decreasing furnace temperature. ( If the refractory maker
have an different limit for temperature reducing , the fur-
nace temperature reducing will follow refractory maker’s
instruction )
Reduce the steam temperature at the rate prescribed by the
turbine manufacturer.
Steam temperature control, combustion control and feedwater
control may be left on automatic until the point is reached
where better control can be obtained on manual.
CAUTION: Care must be exercised to prevent wa-
ter from entering the main steam line, the hot re-
heat line and the cold reheat line to the turbine from
any source during and after the shutdown process.
This is to prevent possible water damage to the tur-
bine during a subsequent restart. Possible sources
of water are:
a. Overflow from the drum into the superheater as
a result of high water level.
b. Water entering the superheater or reheater
through the desuperheater due to open desu-
perheater control valves or possible valve leak-
age with the feed pumps running.
2. Reduce solid fuel firing. As the furnace temperature at the start-

up burner elevation approaches 750°C, the start-up burners
can be placed in service to control the cool down of the unit ac-
cording to the shutdown curve. Solid fuel flow must be discon-
tinued when the furnace temperature at the start-up burner ele-
vation drops below 700°C without the startup burners in service
2-8 -TAB_9-18
or drops below 550°C with burners in service. The limestone

system shall be shut down when any start-up burners is in-
service.
If start-up burners in service, shut off the start-up burners when
their maximum turndown is reached. Keep the primary air, sec-
ondary air, induced draft fans, and fluidizing blower in operation
to cool the furnace and seal pot beds.
The air preheater should not be taken out of service until the
air preheater gas inlet temperatures have dropped below
120°C.
NOTE: With the air preheater stopped and the fans
running, deposits of flyash may accumulate in the
air preheater and cause a rotor unbalance
3. While reducing load on the unit, operate all sootblowers. Refer

to manufacturer’s instructions.
4. Check the expansion movement of the unit as load is being re-
duced.
5. Place feedwater control on manual when feedwater flow re-
quirements are below practical control minimum. Keep water
level in sight. Use intermittent blowdown as necessary.
6. Close the turbine stop valves after opening wide the superheat-
er outlet vents and drains and all reheater vents and drains.
Open other drains in the superheater system as required for
further pressure reduction. Open steam line and turbine drains
as described by the turbine manufacturer.
7. Close the turbine stop, all fuels will stop automatically, HP/LP
bypass will be opened to protect reheater if its conditions are
satisfied to open.
8. Open the drum vents when the unit pressure has decayed to 2
kg/cm2(g).
9. If the boiler will be emptied, the boiler water temperature should
be reduced to at least 90°C before draining.
10. Shut-off all fans and blower when a suitable temperature for
working in the unit is reached..
11. Shut off the air preheater. Refer to manufacturer’s instructions.
12. If the boiler is laid up wet, refer to “Lay-Up Procedures”.
2-8 -TAB_9-19
NOTE: When turbine is stop, if cyclone exit flow

gas temperature is still higher than 535°C and
HP/LP bypass is not open, PA fan will be stopped
automatically and reheater biasing damper will be
close to minimize opening and SH biasing damper
will be full open to prevent reheater tubes
WARNING: If the fans are shut down with an air

preheater gas inlet temperature above 120°C, the
air preheater must be kept rotating until the flue
gas temperature below 120°C to prevent the rotor
jamming due to excessive expansion and cause ro-
tor sitting stationary in high heat levels. (Refer to air
preheater instructions)
NORMAL
SHUTDOWN TO
HOT STANDBY
It is assumed that the boiler will be shut down for a relatively short
period of time (8 hours or less) and existing pressure and tempera-
ture conditions will be substantially maintained. The intention of this
procedure is to keep the furnace bed temperature as much above
the solid fuel firing permissive as possible. The superheater and
reheater circuits should be depressurized to a desired pressure at
which the boiler is to be held via the HP and LP turbine steam by-
pass system and should have some flow at all times.
A procedure similar to that for normal shutdown to cold should be
followed except:
1. Do not reduce drum pressure in line with unit load reduction.
The rate of pressure drop should be much smaller than the rate
followed during normal shutdown. Refer to the turbine manufac-
turer’s instructions.
2-8 -TAB_9-20
CAUTION: Care must be exercised to prevent wa-

ter from entering the main steam line, the hot re-
heat line and the cold reheat line to the turbine from
any source during and after the shut down process.
This is to prevent possible water damage to the tur-
bine during a subsequent restart. Possible sources
of water are:
a. Overflow from the drum into the superheater as

a result of high water level.
b. Water entering the superheater or reheater
through the desuperheater due to open desu-
perheater control valves or possible valve leak-
age with the feed pumps running.
2. Keep the water level in sight in the gage glass. As the unit
cools and the water shrinks, make up should be added intermit-
tently to prevent the water from dropping out of sight in the
gage glass.
NOTE: The operator should observe the gage
glass periodically to always be aware of the actual
drum level so that he can take the appropriate ac-
tion to reestablish water level when the unit is being
restarted.
3. Trip the main fuel. Keep the ID fan, SA fan, PA fan and fluidiz-
ing blower operating to remove volatiles and burn the remaining
fuel in the bed. This typically is indicated by an increase in oxy-
gen level and a drop in bed temperature. Then shut off the PA
fan to maintain the highest possible bed temperature above sol-
id fuel firing permissive.
4. After the cyclone exit gas outlet temperature is cooled to 535°C
(in order to protect the backpass tubing) and air preheater gas
inlet temperature below 120°C, then the SA fan can be shut-off.
Run the FA blower for another 10 minutes to purge the seal
pots of combustible gases, and to remove solids from the cy-
clones, cyclone stand legs, and seal pots. After the fluidizing
2-8 -TAB_9-21
blowers are shut off, then the induced draft fan should be shut
off and the secondary air nozzle dampers closed.

CAUTION: If combustible deposits are present

in the air preheater elements, the air preheater
gas inlet temperature must be reduced to 120°C
before the SA fan, ID fan and air preheater are
shut down. The air preheater must be thorough-
ly cleaned to remove any combustible products
before it is shut down.
HOT RESTART
Assuming the boiler has been down for a comparatively short peri-
od of time (8 hours or less) and considerable drum pressure was
maintained, a hot restart may be possible. A hot restart is consid-
ered to be when the temperature of the fluidized bed at the startup
burner elevation is above the purge bypass permit temperature
700°C therefore eliminating the requirement for a purge cycle. The
following procedures should be used in restarting the unit :
1. Make a general inspection of the boiler and check the points as
mentioned under normal cold start-up.
2. If the air preheater is shut down, when restart the air preheater,
must refer to the air preheater instructions for restart require-
ment of operating details.
3. Start the air preheater if all required conditions in air preheater
instructions are satisfied.
4. Start the ID fan, FA blower, and SA fan.
5. Open wide all superheater drains to allow complete draining of
superheater headers and/or elements. After draining, close all
drains except the Superheater Backpass Lower Front Inlet
Header and Backpass Outlet Header Drains and the start-up
drains (Main Steam Line Vents and Drains). Keep the Back-
2-8 -TAB_9-22
pass Header drains slightly cracked open until steam is admit-

ted to the turbine. Keep the start-up drains open. Reheater
drains and vents are open.
CAUTION: Prevent possible water damage to the
turbine by using extreme care to eliminate all water
from the main steam line, cold and hot reheater
lines and superheater and reheater elements and
headers before the turbine is rolled. Refer to the
turbine manufacturer’s instructions.
6. Start the PA fan. Start the start-up burners if needed to keep

the furnace temperature at the burner elevation above the coal
permissive.
NOTE: If steam isn’t admitted to the turbine before
start PA fan and/or burners, HP/LP bypass shall put
in-service to supply cooling steam to reheater and
RH biasing damper in minimize opening position,
when cyclone exit flue gas temperature above
535°C.
7. Start solid fuel firing, providing the furnace temperature at the

burner elevation is above the coal permissive of 700°C without
the burners in operation or above 550°C with the burners in
service. After full coal firing, start-up limestone feeding system
and add limestone to meet SO2 requirements.
8. Continue the startup by following the procedures listed under
“Lighting-Off - Cold / Warm Start” after solid fuel is introduced.
EMERGENCY
PROCEDURES
Reheater Protection
Upon Loss of Load
Stoppage of steam flow through the reheater when the cyclone exit
gas temperature is above 535°C can result in overheating and
damage to the reheater tubing. To prevent this condition, the follow-
ing measures must be taken:
2-8 -TAB_9-23
Turbine Valve
Closure
If a loss of load should cause the turbine valves to close, all fuel is
tripped automatically. If HP and LP bypass are available, PA flow
shall reduce instantaneously, then leave the fans and blower on to
reduce the gas and solid temperatures below the above mentioned
temperatures. If HP and LP bypass aren’t available to in service,
PA fan shall stop automatically. And the convective pass flue gas
biasing dampers can be closed on the reheater side and opened on
the superheater side to minimize the flow of hot flue gases over the
reheater. Leave SA fan and ID fan on to reduce gas temperature
below the above mentioned temperature.
If an immediate restart is possible, as the turbine is still rolling and
will be available to take steam as soon as the governor has the tur-
bine speed under control (See note below). If immediate turbine re-
start is not possible and the turbine is tripped, the reheater conden-
ser drains should be opened.
NOTE: Refer to turbine manufacturer’s instructions
for no-load operating procedures and limitations.
Turbine Trip
If a loss of load occurs in which the turbine is tripped, all fuel should
be automatically and instantaneously tripped.
Boiler operation procedure is as same as above described in tur-
bine valve closure.
The reheater safety valves will protect against over pressure in the
reheater. The reheater condenser drains should be opened to
evacuate the condensed steam in the reheater. Depressurize the
reheater circuit.
Post Trip Procedures

Immediately following a Fuel Trip, the furnace must be purged for at
least 5 minutes.
See Master Fuel Trip.
To permit firing during start-up, prior to opening the turbine valves,
the initiating fuel trip circuits must be disarmed. They must be re-
2-8 -TAB_9-24
armed at a suitable point in the start-up sequence, such as when

synchronizing the turbine.
Turbine Protection
Upon Loss of Load
Extreme care must be taken following a trip of the turbine and boiler
to prevent water from being introduced into the turbine upon unit
restart. Water may collect in the main steam line and cold reheat
lines from condensation. Water may be introduced into the super-
heater due to overflow from the steam drum (inadvertent high water
level). Water may be introduced into the superheater and/or re-
heater through the desuperheater due to open or leaking spray wa-
ter control valves.
Inadvertent introduction of water into the steam lines must be pre-
vented. Adequate draining of lines must be assured prior to open-
ing the turbine stop valves.
CAUTION: Operators should be alert to detect the
symptoms of water carryover from the boiler and
introduction of water into the turbine, such as:
a. A sudden unexplained drop in the steam

temperature in the main steam or hot reheat
lines.
b. Vibration in the steam piping resulting from

water hammer.
c. Abnormal vibration and differential expansion

readings from the turbine supervisory instru-
mentation
Operators must be prepared to take the actions
necessary to prevent turbine damage upon detec-
tion of water introduction. Refer to the turbine
manufacturer’s instructions for specific actions to be
taken.
2-8 -TAB_9-25
Master Fuel Trip

Under conditions requiring a master fuel trip through normal inter-
locks or operator action (manual trip), all fuel should be tripped in-
stantaneously.
The following steps should taken immediately following an emer-
gency fuel trip:
1. Maintain the unit air flow at pre-trip value or reduce air flow per
reheater tube protection requirement, for at least 5 minutes to
purge the system. If a hot restart is anticipated the air flow may
be reduced to light-off air flow (30% of full load air flow) during
the 5 minute purge.
2. Check to insure that all individual fuel shut off valves are closed.
3. Depending on the mode of operation when the Master Fuel Trip
occurs, refer to the previous operating procedures for “Normal
Shut Down - To Cold” or “Normal Shut Down - To Hot Standby”.
NOTE: Refer to the Fluid Bed Supervisory System
instructions for emergency fuel shutdown sequenc-
ing.
Low Water Level

If the water level falls out of sight in the water gauge, due to failure
of the feedwater supply or neglect of the operator, except in the
case of momentary fluctuations that might occur with extraordinary
changes in load, appropriate action should be taken at once to trip
the fuel. Any decision to continue to operate, even if only for a short
time at a reduce rating, would have to be made by someone in au-
thority who is thoroughly familiar with the circumstances that led to
the emergency and positively certain that the water level can be re-
stored immediately without damaging the boiler. In the absence of
such a decision:
1. Trip all fuel immediately. Then shut-off the PA fan.
2. Shut off all steam being discharged from the unit (trip turbine,
close HP and LP turbine steam bypass valving, trip steam driv-
en auxiliaries, etc.). The convective pass flue gas biasing
damper must be closed on reheater side and opened on super-
heater side.
2-8 -TAB_9-26
3. Keep ID fan, SA fan, and fluidizing air blower on. Shut-off fluid-
izing air blower when cyclone, cyclone stand leg and seal pots
are clear of solids.

4. Shut-off the SA fan; then shut-off the ID fan as soon as the unit
is cool enough for personnel to enter.
5. If pressure parts damage is suspected, reduce the steam pres-
sure gradually by opening the superheater start up drains.
Open the drum vents when the pressure drops below 2
kg/cm2(g). Drain the boiler when the drum metal temperature is
90°C following normal draining procedures. Determine the
cause of low water and examine the boiler for the effects of
possible overheating such as leaks and distortion of pressure
parts.
6. Repair any leaks, etc.
7. Hydrostatically test the boiler at working pressure before putting
the unit back in service.
High Water Level
Abnormally high water level should be avoided as it may lead to
carryover and even priming. If the water level rises above the rec-
ommended normal operating range proceed as follows:
1. Reduce the water level immediately by opening the intermittent
blowdown valves.
2. Reduce the steaming rate, if necessary, then place feedwater
control on Manual.
2-8 -TAB_9-27
If priming should occur, as indicated by rapid fluctuations in outlet

steam temperature, proceed as follows:
3. Reduce the steaming rate.
4. If the water level is abnormally high, reduce the level by open-
ing the intermittent blowdown valves and place feedwater con-
trol on manual.
5. Investigate the water condition (alkalinity and solids).
6. Investigate the condition of the drum internals as soon as an
opportunity is afforded.
Tube Failures
Water Wall Tubes and
Evaporator Panels
In the event of failure of one or more water carrying tubes in a natu-
ral circulation boiler, the best method for shutting down the unit will
be dictated by the size of the failure, the ability to maintain normal
water level and the demands for the service of the unit.
The following instructions regarding tube failures are of a general
nature. It must be understood that conditions may arise which will
require exercise of judgment by the operators.
During the shut down, drain bed ash as quickly as possible while
maintaining primary air flow. Remove as much bed ash as possible
in order to minimize the amount of wet bed ash.
In case of a leak or tube failure which does not involve a serious
drain on the feedwater supply, the water level should be maintained
and the unit taken out of service in the normal manner. Refer to
“Normal Shut-Down - to Cold” Procedures.
If the tube failure results in a loss of water so great that the water
level can not be maintained with the feedwater supply available,
use the method outlined below:
1. Trip all fuel. Then shut-off PA fan.
2. Shut off feedwater to the boiler.
3. Maintain only enough air flow to carry the escaping steam up
the stack, and cool cyclone exit gas temperature below 400°C.
4. Refer to “Normal Shut-Down To Cold” section for shut-down
procedure
5. After the unit has cooled enough to permit a person to enter it,
make a thorough inspection of pressure parts for any indication
2-8 -TAB_9-28
of damage resulting from loss of water level. After the neces-

sary repairs have been made, apply a hydrostatic test and ob-
tain the approval of the proper authorities before putting the unit
back in service.
Economizer Tubes
An economizer tube leak can be detected by sound and/or in-
creased make up water requirements. The leak should be investi-
gated at the earliest possible time and the unit shut down in a nor-
mal manner. Water leaks in the economizer can cause considera-
ble erosion damage to adjacent tubes. Water carried over from an
economizer tube leak may cause plugging of hoppers and air pre-
heaters. Any decision to continue operation with known leaks
should be made with this in mind.
Superheater and
Reheater Tubes
A small leak in a superheater or reheater element should be inves-
tigated at the earliest possible time, and the unit should be shut-
down in a normal manner. Steam leaks in the superheater or re-
heater can cause considerable erosion damage to adjacent tubes.
Any decision to continue operation with known leaks should be
made with this in mind.
A major superheater or reheater tube failure may require an emer-
gency unit shutdown. The operator must use his judgment to as-
sess the seriousness of the failure and its consequences and then
decide what type of shut down is required.
Loss of Power
1. Trip the turbine
2. Depressurize the superheater or reheater circuits.
3. Maintain drum water level.
4. Open all dampers to remove heat from Furnace, Cyclone and
Back pass.
Loss of PA Fan
1. Trip fuel, limestone feed and startup burners (if in use).
2. Shut off the secondary air fan after the cyclone gas outlet tem-
perature cools to 535°C.
3. Shut off the fluidizing air blower after purging the cyclones, cy-
clone stand legs, and seal pots.
2-8 -TAB_9-29
4. Shut off the induced draft fan.


Loss of SA Fan
1. Trip fuel and limestone feed, PA Fan, and startup burners (if in
use).
2. Shut off the fluidizing air blower after purging the cyclones, cy-
clones stand legs, and seal pots.
3. Shut off the induced draft fan after the cyclone exit gas temper-
ature has been reduced to 535°C.
Loss of Fluidizing Air

Blower
1. Trip fuel and limestone feed. Shut-off PA Fan, and startup
burners (if in use).
2. Shut off SA and ID fans after the cyclone exit gas temperature
has been reduced to 535°C.
3. Depressurize the superheater and reheater circuits.
2-8 -TAB_9-30
5. Open all dampers to remove heat from Furnace, Cyclone, and

Backpass.

Loss of Induced
Draft Fan
1. Trip turbine. Trip fuel and limestone. Shut-off PA fan, SA fan
and fluidizing air blower.
2. Depressurize the superheater and reheater circuits.
4. Open all dampers to remove heat from Furnace, Cyclone and
Backpass.

2-8 -TAB_9-31
PART 3 - WATER SYSTEM
TABLE OF CONTENTS
TITLE SECTION
WATER AND SATURATED STEAM CIRCUITS ................................................................. 1
STEAM DRUM INTERNALS ............................................................................................... 2
ECONOMIZER .................................................................................................................... 3
3-0-1
SECTION 1 - WATER AND SATURATED STEAM CIRCUITS
TABLE OF CONTENTS
TITLE PAGE NO.
DESCRIPTION .............................................................................................................. 3-1-1
3-1-i
WATER AND SATURATED STEAM CIRCUITS
DESCRIPTION
The circulating fluidized bed boiler utilizes natural circulation in the
water cooled circuits of the furnace and pendant evaporative panels.
The water flow path can be followed on the referenced Flow Diagram
for the Water and Steam Circuits (Combustor Circuitry). The ele-
ments which make up the flow path are essentially numbered con-
secutively. Where parallel flow paths exist, first one and then the
other circuits are numbered.
Feedwater enters the unit through the economizer elements (E-1)
through (E-17) (Economizer Circuitry refers to Part 3, Section 3), and
is mixed with boiler water in the steam drum (C-1). Water flows from
the drum (C-1) through four(4) downcomers (C-2) to the lower ring
headers (C-3) (C-8) (C-11). The ring headers assure proper distribu-
tion of the water to the furnace waterwalls.
From the ring header the water rises through the upper furnace wa-
terwall tubes where it absorbs heat. The front wall tubes and roof
tubes (C-4), rear wall tubes (C-9), and side wall tubes (C-12) form
parallel flow paths. The resulting mixture of water and steam collects
in the waterwall outlet headers (C-5) (C-13) and is discharged into
the steam drum (C-1) through the riser tubes (C-6) (C-14).
A water flow path exists parallel to the furnace waterwalls. Six(6)
separate downcomers (C-21) supply water to the evaporative panel
inlet headers (C-22) located at the upper furnace front wall. The wa-
ter continues into the evaporative fin welded panels (C-23) where it
absorbs heat. The resulting mixture of water and steam collects in
the evaporative panel outlet headers (C-24) and is discharged into
the steam drum (C-1) via riser tubes (C-25). In the steam drum the
steam and water are separated (see "Drum lnternals”), the steam
goes to the superheater (see “Superheater”) and the water is re-
turned to the water side of the steam drum to be recirculated.
3-1-1
Flow Diagram View Of Combustor Circuitry
3-1-2
SECTION 2 - STEAM DRUM INTERNALS
TABLE OF CONTENTS
TITLE PAGE NO.
DESCRIPTION .................................................................................................................. 3-2-1
OPERATION ..................................................................................................................... 3-2-3

General ......................................................................................................................... 3-2-3
3-2-i
STEAM DRUM INTERNALS
DESCRIPTION
The function of the steam drum internals is to separate the water
from the steam generated in the waterwalls of the furnace and to re-
duce the dissolved solids contents of the steam to below the pre-
scribed limit. Separation of steam from water in the drum is general-
ly performed in three stages, with the first two stages occurring in the
turbo-separators, and the final stage taking place at the top of the
drum just before the steam enters the connecting tubes.
The steam water mixture entering the drum (C-1) from the riser
tubes (C-6) (C-14) (C-25) is collected in the chamber formed by in-
ternal baffles (refer to the referenced flow diagrams of combustor for
element numbers). At the lower end of the baffles the steam water
mixture is forced upward through two rows (37 per row) of turbo sep-
arators (refer to Figure 1).
Each turbo separator consists of a primary stage and a secondary

stage (refer to Figure 2).
The primary stage is formed by two concentric cans. Spinner blades
impart a centrifugal motion to the mixture of steam and water flowing
upward through the inner can, thereby throwing the water to the out-
side and forcing the steam to the inside. The water is arrested by a
skim-off lip above the Spinner blades and is returned to the lower
part of the drum through the annulus between the two cans. The
steam proceeds up to the secondary separator stage.
The secondary stage consists of two opposed banks of closely
spaced thin, corrugated metal plates which direct the steam through
a tortuous path and force entrained water against the corrugated
plates. Since the velocity is relatively low, this water does not get
picked up again, but runs down the plates and off the second stage
lips at the two steam outlets.
From the secondary separators the steam flows uniformly and with
relatively low velocity upward to the series of screen dryers, consist-
3-2-1
ing of 38 screen sections, extending in layers across the length of

the drum. These screens perform the final stage of separation.
In order to avoid unnecessary boiler outages due to leakage in drum
internals, it is important to carefully supervise the replacement of all
internals that have been disturbed during inspections, etc. Leaks
may be due to a variety of conditions. A bolted flange may not be
tight, consecutive flanges may not be in line, and bolts may be over-
looked and omitted.
Briefly, instructions for the installation of drum internals may be
summed up, as follows:
1. Study the drum internal drawing and learn the purpose of the various
internal parts.
2. To prevent moisture from bypassing the top screen dryer and mixing
with the dry steam as it leaves the drum, all of the joints in the dryer
assembly must be absolutely tight. Seal welding, where indicated on
the drawings, must be carefully done. All bolts are to have two
washers, one under the nut and one under the head. Joints which
are bolted only and not seal welded are to be made as tight as pos-
sible.
3. 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 up tight should be hammered together between the
bolts and corners drifted together.
4. All bolted joints are to be retightened after the initial bolting.
5. The use of Apexior on flanged joints and bolt threads preserves the
bolts and helps to fill up small holes and cracks.
6. Gaskets shalI not be used.
7. Joints in feed piping are to be absolutely tight. “U” bolts on the feed
piping should allow for feed pipe expansion.
The arrangement of the steam drum internals is shown on the at-
tached Arrangement Drawings.
3-2-2
OPERATION
General
Operation of the steam drum is directly related to overall boiler oper-
ation. Therefore, operating procedures pertaining to the steam drum
are discussed in detail in the Unit Operating Procedures included in
this Manual.
3-2-3
Fig. 1 Typical Steam Drum Internal
3-2-4
Fig. 2 Typical Turbo Separator
3-2-5
SECTION 3 - ECONOMIZER
TABLE OF CONTENTS
TITLE PAGE NO.
DESCRIPTION .............................................................................................................. 3-3-1
OPERATION ................................................................................................................. 3-3-2
MAINTENANCE ............................................................................................................ 3-3-2
FLOW DIAGRAM VIEW OF ECONOMIZER CIRCUITRY ............................................ 3-3-3
3-3-i
ECONOMIZER
DESCRIPTION
The function of the economizer is to preheat the boiler feedwater be-
fore it is introduced into the steam drum, by recovering some of the
heat of the flue gases leaving the furnace. The economizer water
flow path can be followed on the referenced Flow Diagram for the
Water and Steam Circuits (Economizer Circuitry).
There are three economizer sections located in the convective back-
pass. First economizer section is a common economizer (as Eco.1)
located directly above the Ljungstrom rotary air preheater. It is com-
posed of one(1) bank of 115 parallel bare tube assembly (E-2) ar-
ranged in horizontal rows in such a manner that each row is in line in
relation to the row above and below.
Second economizer splits into two parallel economizers (as Eco.2-R
& Eco.2-S) located in each rear passes and above each flue gas bi-
asing dampers respectively. The Eco.2-R is located in reheater
backpass and composed of one(1) bank of 106 parallel bare tube
assembly (E-10) arranged in horizontal rows. The Eco.2-S is located
in superheater backpass and composed of one(1) bank of 106 paral-
lel bare tube assembly (E-7) arranged in horizontal rows.
Third economizer (as Eco.3) is located in superheater backpass and
below finish superheater banks. It is composed of two(2) banks of
106 parallel bare tube assemblies (E-14 & E-15) arranged in horizon-
tal rows.
Feedwater is supplied to the economizer inlet header (E-1) via feed
stop and check valves. The feedwater flow is upward through the
economizer, that is, counterflow to the hot flue gases. Most efficient
heat transfer is hereby accomplished, while the possibility of steam
generation within the economizer is minimized by the upward water
flow.
From the common economizer tube assembly (E-2), heated water
splits into two parallel paths and flows through each parallel econo-
3-3-1
mizers (E-7 & E-10) in each backpass respectively, and then recom-
bines at junction header (E-11). The combined heated water flows
through Eco.3 assemblies (E-14 & E-15) via link E-12, with counter-
flow to the hot flue gases, and to the economizer outlet header (E-
16). The heated feedwater is then led to the steam drum (C-1) via
the economizer outlet link (E-17).
OPERATION
Operation of the economizer is not independent of the rest of the
boiler. Therefore, operating procedures for the economizer are dis-
cussed in detail under Unit Operating Procedures.
The frequency with which soot blowers are used depends entirely on
local conditions. When the economizer is first placed in operation,
the economizer soot blowers should be blown about once every shift.
Observation of the increase in draft loss between blowings will de-
termine how long an interval may be set as a standard. In many cas-
es, it has been found that blowing the economizer soot blowers once
a day or less is sufficient. For further details, refer to the Soot Blow-
ing Philosophy section located in Part 5, Section 2.
MAINTENANCE
Before starting up the furnace and at each extended outage the
economizer should be inspected externally and if necessary cleaned.
If the installation is new, accumulation of erection material (wood, in-
sulation, welding rods, etc.) is not unusual. Large debris should be
removed manually, followed by washing down the economizer banks
by means of a hose and water.
Any exposed insulation should be kept in good condition at all times.
Access doors should be bolted tight. Check the doors occasionally

for tightness.
3-3-2
Flow Diagram View of Economizer Circuitry
3-3-3
PART 4 - STEAM SYSTEM
TABLE OF CONTENTS
TITLE SECTION
SUPERHEATER.................................................................................................................. 1
SUPERHEATER DESUPERHEATERS .............................................................................. 2
REHEATER ......................................................................................................................... 3
4-0-1
SECTION 1 - SUPERHEATER
TABLE OF CONTENTS
TITLE PAGE NO.
DESCRIPTION .............................................................................................................. 4-1-1

Superheater .............................................................................................................. 4-1-1
Steam Flow ............................................................................................................... 4-1-1
Protection and Control ............................................................................................ 4-1-2
DESIGN DATA .............................................................................................................. 4-1-4
OPERATION ................................................................................................................. 4-1-4

General ..................................................................................................................... 4-1-4
MAINTENANCE ............................................................................................................ 4-1-4
INSPECTION................................................................................................................. 4-1-5
FLOW DIAGRAM OF SUPERHEATER STEAM CIRCUITS ......................................... 4-1-6
4-1-i
SUPERHEATER
DESCRIPTION
The arrangement, tube size and quantity of the Superheater ele-
ments are shown on the Pressure Part Arrangement drawings. The
steam flow path can be followed on the referenced Flow Diagram for
the Superheater Steam Circuits (refer to Fig. 1).
Superheater
The Superheater is composed of four basic stages or sections; Fin-
ishing Horizontal Sections (S-35), (S-36) and (S-37), #1 and #2 Fur-
nace Panel Sections (S-18), (S-20), (S-26) and (S-28) and the con-
vective pass (Backpass) Enclosure Wall, Division Wall and Roof
Sections (S-3), (S-6), (S-8), (S-9) and (S-13).
The Finishing Sections are located above No.3 Economizer Horizon-
tal Section (E-15) and consist of three(3) banks (S-35), (S-36) and
(S-37) of 106 [50.8mm O.D. tube] assemblies spaced on 114.3mm
centers.
#1 and #2 Furnace Superheater Panel Sections (S-18), (S-20), (S-26)
and (S-28) are located in the upper front furnace area opposite the
cyclone inlets. They consist of seven(7) [44.45mm O.D. tube] fin-
welded assemblies spaced on 622.3mm centers from the centerline
of the furnace for each sections.
The Convective Pass (Backpass) Enclosure Wall and Roof Sections
form the sidewall (S-3) constructed of fin welded panels of 44.45mm
O.D. tubes, front wall (S-6), roof (S-8) and rear wall (S-9) constructed
of fin welded panels of 50.8mm O.D. tubes. The division wall (S-13)
of the vertical gas pass splits convective pass into two parallel gas
passes and it is constructed of fin welded panels of 50.8mm O.D.
tubes.
Steam Flow
The course taken by steam from the steam drum to the superheater
finishing outlet header can be followed on the referenced Flow Dia-
gram for the Superheater Steam Circuits. The elements which make
4-1-1
up the flow path are essentially numbered consecutively. Where

parallel flow paths exist, first one and then the other circuit is num-
bered. The main steam flow path is:
Steam Drum (C-1) - saturated steam superheater (SH) connecting
tubes (S-1) - backpass upper sidewall inlet headers (S-2) - backpass
sidewall tubes (S-3) - backpass lower sidewall outlet headers (S-4) -
backpass front wall inlet header (S-5) - backpass front wall tubes (S-
6) - backpass gas inlet ring header (S-7) - backpass roof tubes (S-8)
- backpass rear wall tubes (S-9) - backpass rear wall outlet header
(S-10) - connecting link to division wall (S-11) - backpass division
wall inlet header (S-12) - backpass division wall tubes (S-13) - back-
pass division wall outlet header (S-15).
The steam flow path to furnace SH panel circuit from the backpass
division wall outlet headers (S-15) is:
Connecting link to furnace SH panel #1 (S-16) - SH panel #1 inlet
header (S-17) - SH panel #1 inlet assemblies (S-18) - SH panel #1
junction header (S-19) - SH panel #1 outlet assemblies (S-20) - SH
panel #1 outlet header (S-21) - connecting link to superheater desu-
perheater #1 (S-22) - SH desuperheater #1 (S-23) - connecting link
from SH desuperheater #1 (S-24) - SH panel #2 inlet header (S-25) -
SH panel #2 inlet assemblies (S-26) - SH panel #2 junction header
(S-27) - SH panel #2 outlet assemblies (S-28) - SH panel #2 outlet
header (S-29).
The steam flow leaving furnace SH panels continues to:
Connecting link to SH desuperheater #2 (S-30) - SH desuperheater
#2 (S-31) - connecting link from SH desuperheater #2 (S-32) - finish-
ing SH inlet header (S-34) - finishing horizontal SH lower assembly
tubes (S-35) - finishing horizontal SH intermediate assembly tubes
(S-36) - finishing horizontal SH upper assembly tubes (S-37) - finish-
ing SH outlet header (S-38) - main steam line to turbine.
Protection and
Control
As long as the unit is being fired or in the hot condition, adequate
protection must be provided for the Superheater elements. This is
especially important during periods when there is no demand for
steam, such as when starting up and when shutting down. During
4-1-2
these periods of no steam flow through the turbine, adequate flow

through the superheater is assured by means of drains and vents in
the headers, links and main steam piping.
A safety valve on the superheater main steam line set below the low
set drum safety valve, provides another means of protection by as-
suring adequate flow through the superheater if the steam demand
should suddenly and unexpectedly drop.
During all start-ups, care must be taken not to overheat the super-
heater elements. The firing rate must be controlled to keep the fur-
nace and cyclone exit gas temperatures from exceeding 535°C.
Thermocouples located at the cyclone inlets and exits should be
used to measure the gas temperatures.
NOTE: With a simple bare thermocouple meas-

urement, there will be an error, due to radiation, re-
sulting in a low temperature indication. At 535°C
actual gas temperature, the thermocouple reading
will be approximately 28°C low. Unless very careful
traverses are made to locate the point of maximum
temperature, it is advisable to allow another 28°C
tolerance, regardless what type of thermocouple
probe is used.
NOTE: The 535°C gas temperature limitation is

based on normal start-up conditions, where steam
is admitted to the turbine at the minimum allowable
pressure prescribed by the turbine manufacturer.
Should turbine rolling be delayed and the steam
pressure be permitted to build up, the gas tempera-
ture limitation should be reduced to 510°C when the
steam pressure exceeds two-thirds of the design
pressure before steam flow through the turbine is
established.
Steam temperature control is provided by means of desuperheaters.

Refer to appropriate section elsewhere in the manual for details.
4-1-3
DESIGN DATA
Design information for the superheater is contained in Table 1 in Part
2, Section 7, Tab 1 of this manual.
OPERATION
Operation of the superheater is not independent of the rest of the
steam generator. Therefore, operating procedures for this compo-
nent are discussed in the section "Unit Operating Procedures", lo-
cated in Part 2, Section 8, Tab 9. However, basically the following
rules can always be followed:
General
Make sure the superheater convective pass walls and main steam
lines are completely drained (especially after a hydrostatic test), by
opening inlet and outlet header drains before lighting off. Close the
backpass lower header drains immediately after rolling the turbine,
see “Unit Operating Procedures” for exceptions.
The main steam line vents and drains serve as starting vents. They
are kept open until the turbine is under light load. These valves may
be throttled as drum pressure increases, providing a sufficient steam
flow through the superheater is assured at all times (refer to start-up
procedures in the section "Unit Operating Procedures"). The drain
valves near the turbine should be operated in conjunction with the
startup vents to provide additional steam flow and to drain and warm
the main steam line prior to turbine rolIing.
MAINTENANCE
It is essential that suitable arrangements are made to assure cleanli-
ness of the external and internal surfaces of the Superheater at all
times. Ash accumulations result in unequal gas distribution, ineffi-
cient heat transfer, and possible localized overheating. Suitably lo-
cated soot blowers operated in the proper cycle, normally provide
adequate means of keeping surfaces clean.
Proper feedwater treatment and control of steam quality and carry-
over are essential to assure cleanliness of interior surfaces of super-
heaters. Overloads, fluctuating load, high water level, foaming, high
solids concentrations, etc., all contribute to deposits on interior sur-
faces. Accumulation of these deposits inside the tubes will lead to
4-1-4
unit failure. When spray-type desuperheaters are installed, care

must be taken to assure that condensate quality water is used to
avoid carry-over of solids into the superheater and the turbine blades.
Periodic checks of steam pressure drop across the superheater, un-
der identical load conditions, usually indicate whether or not solid
deposits are present within the elements.
In the event of failure of one or more elements, it is well to check
carefully to determine the cause. The manufacturer may be consult-
ed for repair procedures and proper means to prevent recurrence.
INSPECTION
A regular inspection and maintenance program, conscientiously fol-
lowed will do much to assure continuity of service and to avoid seri-
ous and expensive outages.
1. The superheater should be inspected when the boiler is out of
service.
2. Check the elements for alignment and any evidence of warping
or bulging of unit tubing. Replace tubing that shows serious
warping, bulging, or other evidence of overheating.
3. Check supports, spacers and seal plates for proper location and
condition. Repair or replace promptly.
4. Check inside surfaces of the steam drum for evidence of solids
carryover. If present, take immediate steps to eliminate cause.
When in doubt, consult the manufacturer.
4-1-5
S-15
S/H PANEL NO.2
D/A #2
S-31
S/H PANEL NO.1
Fig. 1 Flow Diagram Of Superheater Steam Circuits
4-1-6
SECTION 2 - SUPERHEATER DESUPERHEATERS
TABLE OF CONTENTS
TITLE PAGE NO.
DESCRIPTION .............................................................................................................. 4-2-1
CONTROL STATION .................................................................................................... 4-2-2
MAINTENANCE ............................................................................................................ 4-2-2
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES ............ 4-2-3
4-2-i
SUPERHEATER DESUPERHEATERS
DESCRIPTION
Two (2) spray type superheater desuperheaters are provided on
each unit. One (S-23) is located in the connecting link between the
in-furnace superheater panel #1 outlet header (S-21) and the in-
furnace superheater panel #2 inlet header (S-25). The second su-
perheater desuperheater (S-31) is located in the connecting link be-
tween the in-furnace superheater panel #2 outlet header (S-29) and
the finishing superheater inlet header (S-34) to permit reduction of
steam temperature when necessary and to maintain the tempera-
tures at design values within the limits of the nozzle capacity.
Temperature reduction is accomplished by spraying water into the
path of the steam through a nozzle at the entering end of the desu-
perheater. The spray water comes from the boiler feedwater system.
It is essential that the spray water be chemically pure and free of
suspended and dissolved solids, containing only approved volatile
organic treatment material, in order to prevent chemical deposition in
the superheater and carry-over of solids to the turbine.
CAUTION: During start-up of the unit, if desuper-
heating is used to match the outlet steam tempera-
ture to the turbine metal temperatures, care must
be exercised so as not to spray down below a min-
imum of 11°C above the saturation temperature at
the existing operating pressure. Desuperheating
spray is not particularly effective at the low steam
flows of start-up. Spray water may not be complete-
ly evaporated but be carried through the heat ab-
sorbing sections to the turbine where it can be a
source of considerable damage. During start-up
alternate methods of steam temperature control
should be considered.
4-2-1
The location of the desuperheaters helps to ensure against water

carry-over to the turbine. It also eliminates the necessity for high
temperature resisting materials in the desuperheater construction.
CONTROL
STATION
A pneumatically operated control valve linked to an automatic control
drive regulates the flow of spray water supplied to each desuper-
heater. A manually operated isolation valve is located both upstream
and downstream of each control valve to permit isolation when re-
quired. One pneumatically operated bypass control valve with small
amount of spray water capacity will be used to control main steam
temperature rising which is required in turbine start-up period. Also
additional one bypass manual valve in a bypass line around the au-
tomatic control valve should be used only in an emergency, or when
the automatic control valves may require maintenance. Blowoff
valves downstream of the control valve are used to relieve system
pressure and drain the control valve piping for maintenance.
A pneumatically operated block valve is installed in the supply line to
each desuperheater control station as an additional shut off valve.
These block valves must be interlocked to close when the desuper-
heater control valves are closed. The spray water control valves
must be interlocked to close upon a turbine trip. Closing the block
valves will prevent water from entering the superheater elements if
the superheater spray water control valves should leak.
Spray water for the superheater desuperheater is taken from the
boiler feed pump discharge.
MAINTENANCE
Each desuperheater is fitted with a renewable liner to take the wear
of erosion from the spray water stream, thus protecting the main
desuperheater shell. Excessive noise from within a desuperheater
usually indicates a worn liner. Sufficient clearances should be pro-
vided around the desuperheaters for replacing liners ( refer to Fig.1).
4-2-2
BLOWOUT
PROCEDURE FOR
DESUPERHEATER
SPRAY WATER
LINES
The spray water lines should be blown out before using the desuper-
heaters on a new unit and after repairs on the spray water lines have
been made. They may also be blown when there appears to be any
indication of plugging. Always have full pressure on the boiler when
blowing out the desuperheater.
Each desuperheater should be blown out in the following sequence:
1. With the isolating valves closed, open the valves in the blowoff
connection and then open the bypass valve for 1 minute.
2. With the bypass valve closed and the blowoff valves open, open
the isolating valves and then open the control valve for 1 minute
(from the control station). Close the isolating valves and the con-
trol valve but leave the blowoff valves open for another minute to
clear the waste line before restoring the system to its operating
status.
NOTE: The blowout valves should be installed

close to the spray water piping and with no bends
intervening, if possible.
4-2-3
Fig.1 - Desuperheater Arrangement
4-2-4
SECTION 3 - REHEATER
TABLE OF CONTENTS
TITLE PAGE NO.
DESCRIPTION .............................................................................................................. 4-3-1

Reheater ................................................................................................................... 4-3-1
Steam Flow ............................................................................................................... 4-3-1
Protection and Control ............................................................................................ 4-3-1
DESIGN DATA .............................................................................................................. 4-3-2
OPERATION ................................................................................................................. 4-3-2

General ..................................................................................................................... 4-3-3
MAINTENANCE ............................................................................................................ 4-3-3
INSPECTION................................................................................................................. 4-3-3
FLOW DIAGRAM OF REHEATER STEAM CIRCUITS ................................................ 4-3-5
4-3-i
REHEATER
DESCRIPTION
The arrangement, tube size and quantity of the Reheater elements
are shown on the Pressure Part Arrangement drawings. The steam
flow path can be followed on the referenced Flow Diagram for the
Reheater Steam Circuits (refer to Fig. 1).
Reheater
The Reheater is composed of one section located in front pass of the
convective split backpass and consists of four banks of 57.2 mm O.D.
tube assemblies spaced on 114.3mm centers.
Steam Flow
The course taken by steam from the cold RH inlet lead to the hot RH
outlet lead can be followed on the referenced Flow Diagram for the
Reheater Steam Circuits. The Reheater steam flow is as follows:
Reheater inlet desuperheater (R-1) - Reheater inlet header (R-2) -
Reheater horizontal spaced lower, lower intermediate, upper inter-
mediate and upper assemblies (R-3), (R-4), (R-5) and (R-6) - Re-
heater outlet header (R-7). Reheat steam from the Reheater outlet
header (R-7) goes to the turbine via the "hot" reheat line.
Protection and
Control
As long as the unit is being fired or in the hot condition, adequate

protection must be provided for the reheater elements. This is espe-
cially important during periods when there is no demand for steam,
such as when starting up and when shutting down. Reheater header
drains and vents provide means to boil off residual water in the re-
heater elements during initial firing of the boiler.
Reheater safety valves, located on outlet piping, serve to protect the
Reheater if steam flow through the reheater is suddenly interrupted.
During all start-ups, care must be taken not to overheat the reheater
elements. The firing rate must be controlled to keep the cyclone exit
4-3-1
gas temperature entering the backpass from exceeding 535°C.

Thermocouples located at the cyclone exits should be used to
measure the gas temperatures.
NOTE: With a simple bare thermocouple meas-
urement, there will be an error, due to radiation, re-
sulting in a low temperature indication. At 535°C
actual gas temperature, the thermocouple reading
will be approximately 28°C low. Unless very careful
traverses are made to locate the point of maximum
temperature, it is advisable to allow another 28°C
tolerance, regardless what type of thermocouple
probe is used.
NOTE: The 535°C gas temperature limitation is

based on normal start-up conditions, where steam
is admitted to the turbine at the minimum allowable
pressure prescribed by the turbine manufacturer.
Should turbine rolling be delayed and the steam
pressure be permitted to build up, the gas tempera-
ture limitation should be reduced to 510°C when the
steam pressure exceeds two-thirds of the design
pressure before steam flow through the turbine is
established.
Steam temperature control is provided by means of a desuperheater

and gas biasing dampers which control the flow of flue gas across
the reheater.
DESIGN DATA
Design information for the reheater is contained in Table 1 in Part 2,
Section 7, Tab 1 of this manual.
OPERATION
Operation of the reheater is not independent of the rest of the steam
generator. Therefore, operating procedures for this component are
discussed in the section "Unit Operating Procedures", located in Part
4-3-2
2, Section 8, Tab 9. However, basically the following rules can al-

ways be followed:
General
All Reheater drains and vents should be opened before lighting off.
The vents and drains to the atmosphere must be closed prior to rais-
ing a vacuum in the condenser. Drains connecting with the conden-
ser may be left open until the boiler is under light load.
MAINTENANCE
It is essential that suitable arrangements are made to assure cleanli-
ness of the external and internal surfaces of the reheater at all times.
Ash accumulations result in unequal gas distribution, inefficient heat
transfer, and possible localized overheating. Suitably located soot
blowers operated in the proper cycle, normally provide adequate
means of keeping surfaces clean.
Proper feedwater treatment and control of steam quality and carry-
over are essential to assure cleanliness of interior surfaces of re-
heaters. Overloads, fluctuating load, high water level, foaming, high
solids concentrations, etc., all contribute to deposits on interior sur-
faces. Accumulation of these deposits inside the tubes will lead to
unit failure. When spray-type desuperheaters are installed, care
must be taken to assure that condensate quality water is used to
avoid carry-over of solids into the reheater and the turbine blades.
Periodic checks of steam pressure drop across the reheater, under
identical load conditions, usually indicate whether or not solid depos-
its are present within the elements.
In the event of failure of one or more elements, it is well to check
carefully to determine the cause. The manufacturer may be consult-
ed for repair procedures and proper means to prevent recurrence.
INSPECTION
A regular inspection and maintenance program, conscientiously fol-
lowed will do much to assure continuity of service and to avoid seri-
ous and expensive outages.
1. The reheater should be inspected when the boiler is out of ser-
vice.
4-3-3
2. Check the elements for alignment and any evidence of warping

or bulging of unit tubing. Replace tubing that shows serious
warping, bulging, or other evidence of overheating.
3. Check supports, spacers and seal plates for proper location and
condition. Repair or replace promptly.
4. Check inside surfaces of the steam drum for evidence of solids
carryover. If present, take immediate steps to eliminate cause.
When in doubt, consult the manufacturer.
4-3-4
Fig. 1 Flow Diagram Of Reheater Steam Circuits
4-3-5
PART 5 - AIR AND FLUE GAS SYSTEMS
TABLE OF CONTENTS
TITLE SECTION
AIR AND FLUE GAS SYSTEM ........................................................................................... 1
SOOT BLOWING PHILOSOPHY........................................................................................ 2
5-0-1
SECTION 1 - AIR AND FLUE GAS SYSTEMS
TABLE OF CONTENTS
TITLE PAGE NO.
AIR FLOW ..................................................................................................................... 5-1-2

Primary Air ................................................................................................................ 5-1-2
Secondary Air ........................................................................................................... 5-1-2
Fluidizing Air ............................................................................................................ 5-1-3
FLUE GAS FLOW ......................................................................................................... 5-1-3
5-1-1
AIR AND FLUE GAS SYSTEMS
AIR FLOW
Air flow through each unit is handled by one primary air (PA) fan, one
secondary air (SA) fan, and two fluidizing air (FA) blowers (one oper-
ating continuously and one installed spare). The air is utilized for:
1. Combustion and bed fluidization - Primary air.
2. Combustion and bed fluidization - Secondary air.
3. Fluidization and grease air - Fluidizing air.
Primary Air
One (1) primary air (PA) fan supplies combustion air and fluidizing air
to the furnace grate, purge air to the gravimetric fuel feeders, sealing
air to the fuel chutes between the furnace isolation slide gate valve
and the furnace, and fuel chute sweep air. Primary air used for com-
bustion bed fluidization and fuel chute sweep air is preheated by
means of the Ljungstrom type air preheater. Primary air used for
purge and sealing air is taken from the cold air duct leaving the PA
fan.
Control of the primary air flow is obtained by positioning the PA fan
inlet guide vanes. These vanes are controlled by a control loop as-
sociated with the DCS.
Secondary Air
One (1) secondary air fan supplies combustion air and fluidizing air
to the furnace and combustion air to the start-up burners. The sec-
ondary air that is preheated by means of the Ljungstrom type air
preheater enters the furnace via multiple ports located in the front
and rear walls of the furnace and through the start-up burners.
Control of the secondary air flow is obtained by positioning the SA
fan inlet guide vanes. These vanes are controlled by a control loop
associated with the DCS.
5-1-2
Fluidizing Air
Two (2) 100% capacity fluidizing air (FA) blowers are installed, with
one blower operating continuously and the other an installed spare.
Fluidizing air is used to fluidize the seal pots and to provide grease
air to the cyclone cones and seal pots.
A check valve is located at each blower discharge to prevent back-
flow of furnace gases and ash if the blower is out of service. During
normal operation the blower flow is determined by the system re-
sistance. When there are solids in the seal pots, the system re-
sistance due to the solids level will be constant over the load range.
FLUE GAS FLOW
Flue gases travel upward in the furnace, through the cyclones and
then downward through the backpass to the Ljungstrom type air pre-
heater. In the air preheater, the residual heat of the flue gases is utilized
to preheat the primary and secondary air streams. From the air preheater,
the flue gases are drawn by the one (1) induced draft (ID) fan
through the backend flue gas cleaning equipment and are dis-
charged to the stack.
5-1-3
SECTION 2 - SOOT BLOWING PHILOSOPHY
TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION ............................................................................................................... 5-2-1
OPERATIONS ................................................................................................................... 5-2-1
TYPES OF ASH DEPOSITS ............................................................................................. 5-2-2
BLOWER LOCATIONS..................................................................................................... 5-2-2

Superheater and Reheater Area ................................................................................. 5-2-2
Economizer and Air Heater ......................................................................................... 5-2-3
5-2-I
SOOT BLOWING PHILOSOPHY
INTRODUCTION
The soot blowing system for this unit has been designed on the
basis of specific parameters. That is, in determining the number
and type of blowers, blower location and operating sequences, the
characteristics of the fuel to be burned, the configuration of the
heat-absorbing surfaces of the boiler and past experience with this
type of unit, were taken into account.
However, it is impossible to predict the performance of the soot

blowing equipment for all operating conditions and for each indi-
vidual unit. Factors such as variation in fuel characteristics, load
changes, fluctuations in furnace temperatures and air flow condi-
tions can greatly affect the soot blowing requirements. Therefore,
operation of the soot blowers must be continuously evaluated
and reviewed on the basis of changing operating conditions.
OPERATIONS
Soot blowers are provided to fulfill a need. Operating practices
should be modified as the needs change. For this reason, ample
flexibility is provided in the system to enable manual selective op-
eration in addition to fully automatic control.
Intelligent use of the soot blower system offers the following ad-
vantages:
1. It can prevent troublesome accumulations of ash deposits that,

in turn, may cause additional unit operating problems.
2. It provides for maximum cleaning of the heat absorbing sur-
faces.
In addition, minimizing the number of blowing cycles will save val-

uable blowing medium. More efficient, selective use of the
equipment will result in reduced maintenance.
5-2-1
There are several indicators of ineffective use of the soot blowing

equipment, such as response of steam temperature control,
changes in draft loss, etc. The best way to monitor the effec-
tiveness of soot blowing is by frequent heat absorption sur-
faces observation. If operation of a blower or a series of blowers
does not produce the expected results, the heat absorption sur-
faces area involved should be observed and the blower(s) in ques-
tion checked.
Blowing pressures should be checked periodically (approximately

every six months) to determine whether they have changed from
their initial effective settings.
TYPES OF ASH
DEPOSITS
To determine if proper cleaning is taking place, the operator

should have a basic knowledge of the types of ash deposits that
can build up in the various parts of the unit.
Sintered or dust-like ash deposits or buildups are prevalent on

convection surfaces, such as superheater elements, and in the
back pass.
BLOWER LOCATIONS
Superheater and
Reheater Area
Using the retractable blowers in the convection superheater and

reheater areas should remove accumulated surface deposits.
This will improve heat absorption in these sections. If the steam
temperature controls are on automatic, this should cause the
spray water flow to increase. Selective blowing of retractable
blowers in the superheater and reheater zones can also be uti-
lized to balance superheater and reheater outlet temperatures. In
any case, draft loss across convection surfaces should be closely
observed. Increased draft loss indicates an advanced plugging
condition. If a plugging condition is allowed to progress too far, it
5-2-2
may be impossible to clean the convection surfaces except by re-

moving the unit from service for water washing.
Economizer and Air

Heater
The economizer blowers and air preheater soot blower should be
blown to provide maximum unit efficiency consistent with reason-
able blowing medium consumption. Constant blowing of the econ-
omizer and the air preheater would assure that these surfaces
stay clean, but the economics of blowing medium consumption,
maintenance of equipment, and metal erosion rates must be con-
sidered. A “happy medium” should be determined by observing
the fouling rate, cost of blowing medium, and blowing effective-
ness.
Efficient use of soot blowers can help counter other operational

problems with the unit. For instance, it may be desirable to re-
duce soot blowing of the economizer in order to cause an increase
of the flue gas temperature to the air preheater.
Formosa Heavy Industries Engineers are available to assist you in

determining which blowers should be blown, how often, and why.
Generally, the best soot blowing policy is to determine the mini-
mum amount of soot blowing required to keep the unit clean
enough to avoid operational problems.
5-2-3

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San Miguel Consolidated Power Corporation

Reheat Type Coal Fired CFB Boiler

Circulating Fluidized Bed Steam Generator

Formosa Heavy Industries Corp.

This manual contains proprietary data of FHI.

Date of Issue: August 2015

CAUTION: Before performing any procedures, users of this

GENERAL NOTE: This instruction manual has been prepared

INSTRUCTION TO USER .............................................................................................................. 1

SECTION 1 - INSTRUCTIONS TO USER

TITLE PAGE NO.

GENERAL NOTICE .......................................................................................................... 1-1-1

USE OF WARNINGS, CAUTIONS, AND NOTES ............................................................. 1-1-2

MANUAL ORGANIZATION ............................................................................................... 1-1-3

CONVERSION FACTORS ................................................................................................ 1-1-4

AMENDMENT RECORD SHEET...................................................................................... 1-1-7

CAUTION: Before performing any procedures, us-

It must be recognized that no amount of written instruc-

Maintenance, operation, and performance of any equip-

WARNING: An operating or maintenance procedure

CAUTION: An operating or maintenance procedure

NOTE: An operating or maintenance procedure or

Although the WARNING hazards are related to personal

In some cases, when a vendor, such as a valve manufac-

Whenever additional or revised information is added to

SECTION 2 - DESIGN AND OPERATION MANUAL

PART 2- STEAM GENERATOR DESIGN AND OPERATION

PART 3- WATER SYSTEM

PART 4- STEAM SYSTEM

PART 5- AIR AND FLUE GAS SYSTEM

SECTION 3 - DESIGN AND OPERATION MANUAL

Whenever additional or revised information is added to the manual, a

When a new amendment sheet is issued, the old sheet must be

Design and Operation Instruction Manual Amendment Record Sheet

Item Part Sect. Tab Description Date

PART 2 - STEAM GENERATOR DESIGN AND OPERATION

EQUIPMENT ARRANGEMENT ...................................................................................... 2

CFB GENERAL DESCRIPTION ..................................................................................... 3

DESCRIPTION OF PLANT EQUIPMENT ....................................................................... 4

STEAM GENERATOR DESCRIPTION ........................................................................... 5

CFB PROCESS DESCRIPTION ..................................................................................... 6

DESIGN DATA ................................................................................................................ 7

OPERATIONAL PROCEDURES .................................................................................... 8

PRESSURE PARTS ARRANGEMENT........................................................................... 9

GENERAL ARRANGEMENT ........................................................................................ 10

TITLE PAGE NO.

FOREWORD ................................................................................................................. 2-1-1

GENERAL OVERVIEW ................................................................................................. 2-1-1

CFB PROCESS OVERVIEW ........................................................................................ 2-1-2

BOILER AND RELATIVED EQUIPMENT ..................................................................... 2-1-4

Formosa Heavy Industries Corporation is providing for San Miguel

Flue Gas – Multiple auxiliary systems address operational needs for

fee-moving in the siphon seals and allows it to be returned to the

Description (Quantity per Boiler):

Solid Fuel Feed System:

SECTION 2 - EQUIPMENT ARRANGEMENT

TITLE PAGE NO.

EQUIPMENT ARRANGEMENT ........................................................................................ 2-2-1

SECTION 3 - CFB GENERAL DESCRIPTION

TITLE PAGE NO.

CIRCULATING FLUID BED (CFB) COMBUSTION SYSTEM .......................................... 2-3-1

CFB GENERAL DESCRIPTION

CIRCULATING FLUID BED