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01 Prevention and Safe Clearing of Ash Build Up in Boiler Bottom Ash Hoppers PDF
01 Prevention and Safe Clearing of Ash Build Up in Boiler Bottom Ash Hoppers PDF
COS-ISO-00-OGN/OPS/SYST/001
Approved for
Implementation by ……………………………………………………..
GM(K)
Date: ……22/01/2007
Prevention and Safe Clearing of Ash Build-up in Boiler
Bottom Ash Hoppers
INDEX
1.0 Introduction 1
8.0 Review 12
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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers
3.1 Coal parameters used for evaluating coal-ash behaviour as they affect
furnace slagging are:
* ash-fusibility temperatures
* base/ acid ratio (More basic nature implies more tendency for slagging)
* iron/calcium ratio
* silica/alumina ratio
* iron/dolomite ratio
* dolomite percentage
* ferric percentage
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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers
The figure below shows a typical cross section of a water wall slag deposit
that has reached a maximum steady-state thickness.
i) Primary deposits that result from the settling of the finer fractions (smaller
than 30 microns) of fly ash. This type of primary deposit is loose in structure
and does not provide cohesive or adhesive bonds.
ii) Primary deposits that result from the selective deposition of certain reactive
components of the ash (iron, calcium, or alkalies). These components can be
present in the deposit in high concentrations as oxides and/or sulphur
compounds, leading to the formation of low-melting eutectic mixtures. This
type of deposit is denser in structure and has stronger cohesive and adhesive
bonds.
The figure 1 showing the cross-section of a typical water wall slag deposit has
a slag surface that has reached a maximum steady-state thickness.
The rate at which glass droplets fuse together is directly dependent upon the
time available for bonding to develop, and is inversely proportional to the
viscosity of the melt, i.e., the more fluid the droplets are the more readily they
will run together thus strengthening the mechanical bonding in the deposits,
and ultimately thick slabs may built up, reducing the heat transfer efficiency
of the boiler surfaces.
This section discusses the operational techniques that the operator can use to
control slagging. Although the predominant factors affecting ash deposition
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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers
are the amount and composition of coal ash; boiler operating conditions have
also been demonstrated to affect deposition.
The operating variables that influence slagging are:
(i) furnace temperature
(ii) excess air
(iii) fuel fineness
(iv) secondary air distribution
(v) distribution of coal
(vi) air fuel ratio
Changing any one, however, will not eliminate operating problems
completely. Although the individual variable affects boiler performance, they
must be studied collectively to determine the effectiveness of a given
programme.
i) Furnace Temperature
Bottom Ash hoppers are designed to carry the ash for about two hours (with
scrapper conveyor system). However the carrying capacity in terms of time
depends on various factors like coal firing rate, ash content in coal, bottom
ash/fly ash ratio etc. During BAH equipment maintenance , the BAH gates
are normally closed and if the work is likely to get prolonged ( more than
four/two hours ) , bottom ash hopper deasing must be started after every
four/two hours with proper care alerting all working personnel in the vicinity ,
to avoid further ash build up inside the BAH. The operation staff will be in
continuous touch with maintenance staff during BAH work..
Falling slag / hard clinkers also can cause accumulation inside the bottom ash
hopper as they will block the hopper gates and prevent free flow of ash. These
may lead to incomplete deashing also as the clinkers remain undetected inside
the hopper.
6.1 The ash build-up can be of two types from ash removing
strategy perspective:
A. Build-up during normal unit operation with bottom ash gates wide open.
B. Build-up during / after scrapper conveyor maintenance activities with
bottom ash gates in closed condition.
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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers
ii) To prevent build up in bottom ash hopper and to start deashing in time,
peep holes above bottom ash hopper (at 10.5 / 7m m in case of 500/200
MW units) on both side view glasses are to be regularly inspected for
any sign of build up by local supervisor/Unit Controller. This is to be
recorded in the log book. This observation is to made preferably three
hours after completion of deslagging.
i) In case slag deposits / ash build-up are not getting cleared by normal
deashing, it is to be cleared immediately by poking / flushing with a
high pressure water jet/ lances through peep holes (availability of fire
hoses, nozzles etc. should be ensured always).
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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers
ii) If massive slag deposits are observed, unit load should be restricted to
the minimum, with oil support and all efforts must be made to remove
slag in a running condition.
iii) Shift Charge Engineer is fully empowered to reduce load under such
conditions.
iv) Manhole in the furnace mounted above Z-panel should be opened only
when unmanageable ash build up is there. Efforts should first be made
to dislodge ash through peep holes with the help of lancers and fire
water. Whenever such operation is carried out, persons not connected
with the job should not be present around and below that area. While
opening the manhole door near Z-panel for removing the ash build up
inside the boiler, care should be taken by providing the wire mesh
cover near the manhole door of Z-panel. Due to this the furnace will
not be completely exposed to the poking people and minimizing the
unsafe conditions.
v) Activities like manual poking of bottom ash hopper and area above Z-
panel of furnace should be carried out in consultation with operation,
boiler mechanical maintenance, ash handling maintenance and Safety
Departments, ensuring all safety measures like Personal Protective
Equipments, operating parameters have been taken care of. Operating
staff should take extra care to ensure that the furnace does not get
pressurized during such activity.
vi) Whenever manual poking of bottom ash hopper and area above Z-
panel of furnace is being done through manhole etc. no mill is to be
stopped or cut in, and soot blowing is not to be carried out, as it causes
sudden detachment and fall of clinkers.
vii) Concerned persons involved in ash / slag / clinker removing activities
should stand at safe distance from bottom ash hoppers so that risk of
splashing ash / hot water causing injuries is minimised. Water lances
should have sufficient long metallic pipes so that cleaning is done
from a safe distance.
viii) A practice of carrying out one job only at a time, i.e., either clearing of
bottom ash hoppers or clearing of slag formation above Z-panel is to
be adhered to.
ix) During clearing of ash build-up, special care and lot of patience is
required to be taken for avoiding over loading leading to failure of
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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers
scrapper conveyors since any such failure increases total time for ash
removal considerably. So, specific precautions to be taken during slag
/ clinker removing activities.
x) No direct control on rate of ash falling on scrapper conveyor is
available to concerned O&M staff. If suddenly heavy amount of ash /
slag / clinkers fall on scrapper conveyor (S/C), it may lead to over
loading / failure of S/C. Apart from this, sudden falling of ash is also
dangerous for people working in near by areas since splashed ash/hot
water can reach up to considerable distances.
xi) Due precaution is to be taken by restricting no. of water lances in use
at a time & their point of application so that risk mentioned above is
minimised. All concerned people must move to safe distances when
there is chance of sudden ash falling in large amount. The surrounding
area shall be kept free of debris for this.
xii) Personal Protective Equipments (PPE) are to be used by personnel,
supervising and executing the job of deashing. The PPE includes
safety helmets with face shield, gum boots, fire retardant hand gloves
and fire resistant overall suit. All Personal Protective Equipments
(PPE) are to be kept in common place like shift maintenance room in a
separate box for easy availability during the emergency of chockage
removal for saving time.
xiii) All efforts should be made to avoid the practice of by-passing the
clinker grinders and dumping the slurry on boiler floor to be manually
removed later. If required bypassing may be resorted to with additional
water jetting arrangements.
xiv) If all actions fail to remove/dislodge the massive slag deposits, the unit
should be taken under shut down for removal of clinkers/ slag
accumulated in the furnace. Immediately after unit shut down bottom
ash hopper is to be flooded with water to avoid hard clinkers formation
from burning slags. In no case unit is to be run with uncontrolled and
unmanageable slag deposits or without bottom ash evacuation.
xv) While shutting down Unit, sufficient care needs to be taken to avoid
overheating of boiler tubes. Boiler is not to be drained and drum level
is to be maintained.
xvi) If build up has taken place during or after maintenance on scraper
conveyor, the rate of bottom ash gates opening is VERY CRITICAL
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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers
for controlling loading on S/C. The gates are to be opened only in 5%-
10% increment in order to avoid overloading of S/C and splashing of
ash in near by areas.
xvii) After each incremental opening of gates, S/C is to be seen physically
for amount of ash being handled by it. Once, there is reasonable
reduction from peak amount of ash being carried away by S/C then
only further opening of gates is to be carried out.
7.4 Other Precautionary Measures
i) Since BAH gates and Hyd, punp (Stg-I) & VC feed gates and Oil
pump units (Stg-II) are very critical items their reliability must be
ensured .
ii) In Stg.II , Winches meant for shifting Scraper conveyor are to be
regularly checked and maintained for their availability.
iii) In Stg.II , Routine trial of standby scrapper conveyors / clinker
grinders shall be carried out regularly as per the schedule.
iv) In case any of the above critical equipments is under break down it
must be attended at the earliest.
8.0 REVIEW
This LMI shall be reviewed by the GM(K) , on a 3-yearly basis or as
necessary.
Document for Distribution to:
1. GM(K)
2. AGM(O&M)
3. DGM(O/EEMG/MM-ash)
4. DGM(TS)
5. Sr.Mgr.(Safety)
6. SCE
7. All UCBs
8. O&M Library
9. Local intranet – soft copy