An Experience With CFBC Boiler Tube Failures PDF

March 16, 2013
CFBC BOILER TUBE FAILURE DIAGNOSIS REPORT
By K.K.Parthiban, Venus Energy Audit System
Agenda for visit
The visit was made on 13th to 14th March 2013 to diagnose the various tube failures experienced in
the CFBC boiler. The CFBC boiler was supplied by CVL about an year ago. The boiler rated
parameters are 115 TPH, 108 kg/cm2a, 540 deg C with feed water temperature at 210 deg C. The
boiler experienced failures at locations below:
 Radiant superheater bottom tube failure and secondary damage at nearby waterwall.
 Roof tube failure close to the radiant superheater outlet.
 Furnace wall tube failure close to kink – date of failure – 9th March 2013
 Furnace wall tube failure close the panel to panel joint at 16 m level- 12th March 2013
The visit was made for diagnosing the failure.
TUBE FAILURE DIAGNOSIS
The tube samples were not available for the first two failures. However for the remaining two
failures (9th March 2013 and 12th March 2013), the tube samples were available. Both the samples
photographs are enclosed in annexure 3 & 4. The location of failures is marked in the drawings and
enclosed in annexure 3 & 4. Thickness survey was done near the failed zone and at the kick off zone
and are presented in annexure 5.
First failure- radiant SH bottom tube failure- See annexure 1
The refractory choice for radiant superheater bottom should be suitable for rapid heat cycles and for
high sulfur duty. Accmon 40 / Accmon 60 do not meet this requirement. Generally plastic
refractories are applied for critical locations. In many plants, plastic refractory is considered when
the high alumina castable with cement binder gives way. The failure cause is the refractory failure
only. See annexure 1. Similar failures were experienced at another plant. See photo in annexure 1. In
case the failure is repeated, the density of studs has to be increased so that the phoscast refractory can
hold to the studs well.
Second failure – Roof tube failure- See annexure 2
The failure at roof is due to high air ingress through the leakage developed at sealbox. Such failures
are seen at many plants.
The radiant Superheaters are hung from roof panels. The radiant SH panels are hung close to the
front wall. This is not an area of high dust concentration. It is seen that the sealbox design is not leak
proof. Normally expansion bellows are provided between radiant superheater and the roof panel, as
the radiant superheater expands upwards. See annexure 2, for a drawing showing the fabric bellows
at another plant. Few other observations are noted on review of the drawings. These are highlighted
in the annexure 2.
The radiant SH outlet sealbox height is only 75 mm as against 150 mm shown in another drawing.
When the sealbox height is 150 mm at the inlet, it can’t be lesser at the outlet. It is seen that coir rope
is used around the radiant SH inside the sealbox. This will burn off in first firing itself, leaving the
flue gas to fill inside the sealbox. The sealbox would warp and crack at the welds.
It is advised to change the sealbox design and provide an expansion bellow as per our drawing
enclosed with this report. The metallic bellow design is suggested, since the ID fan draft is already
less in this boiler and positive sealing is a must.
Third failure- furnace wall tube failure- See annexure 3
The boiler maker has provided refractory for furnace tubes at waterwall corners. This is not a feature
for boilers of other makes. See photographs in annexure 3. If there had been any extra refractory,
guiding the bed material towards the nearby tube, then this failure occurs. Typical failures are
enclosed in the annexure 3. It is necessary to check that the refractory is as per drawing. As per
drawing the studs holding the refractory should have been on the fins. But in the failed tube, it is
seen that the studs are welded on to the tube. It is recommended to go for thickness mapping on a
regular basis with a separate team at every shut down opportunity. This will help to prevent localized
erosion failures and know if there is any permanent correction to be made or not.
As of now, it is advised to trim any excess refractory by checking with a template gauge. See the
drawings enclosed with this report. It is advised to check the entire length of refractory and correct
this.
Both corner refractory and the kick off zone refractory are to be checked with gauges.
Fourth failure - furnace wall tube failure- See annexure 4
The location of failure was at the front wall. The location is marked in the drawing and enclosed in
the annexure 4. The failure was at the field weld joint at 16 m level, and adjacent to corner
refractory. The fin cutting made at field joints is not seal welded from inside the furnace. The
incomplete weldment has allowed the localized erosion. The fin to fin weld has overlaps, which is
also a reason for localized erosion. The tube to tube out of line can also cause erosion. This is to be
checked using a steel scale. It is advised to carry out seal welding from inside and grind off the
excess reinforcement. There are some plates welded along the corner refractory. Such a detail is not
done at other plants. It is necessary to check the tubes adjacent to these plates. This is due to the
reason that the distorted plates can direct the bed material towards the furnace tube.
The cause for the failures can be due to excess refractory in the corner. The distorted plate could
have caused the localized erosion. The studs are wrongly welded on the tube instead of on the fins.
Thickness survey at the kick off zone indicated comparatively higher thickness as compared to tubes
in this field joint area. It is advised to make platform all around and carryout the seal run from inside
and grind off any excess weldment. This work would call for good planning of manpower, tools and
tackles. MIG welding may take less time as compared to arc welding. Carbide tip cutter with flexible
shaft grinding machine may be required. It is advised to carry out a mock up trial and estimate the
time taken for a meter length of weld. Based on this work study, the estimate for total work has to be
arrived at.
General guidance to reduce erosion rate of CFBC furnace
CFBC boiler furnace wall tubes erode in a gross manner and in localized manner.
 The gross erosion will be due to presence of stones / high iron content / high bulk density of bed
inventory. This can be seen up to a length of 2 meter above the lower furnace refractory.
 Localized erosion can occur at places at following locations.
o Where refractory contour is projecting in way to divert the bed material towards the fin to
tube zone.
o Where any foreign material is left behind after the erection. This can divert the material
locally to a tube.
o Where any fin to fin joint is out of plane.
o Where tube to tube is out of plane.
o Where refractory at kink zone is excess than that of what is required.
o Where radiant SH sealbox refractory is terminated. There may be erosion at the refractory
edges.
o Where another sealbox refractory is projecting in to the furnace.
It is advised to look for such spots regularly and take corrective action. Localized erosion can be
accelerated by the high bulk density bed material / high iron bed material. The sky climber will be
required for quick & detailed inspection of the furnace wall tubes.
OTHER OBSERVATIONS
Inadequate margin in ID fan
During the visit it was informed that the ID fan margin was practically not available. On review it
was found that for design purpose the fuels selected were on air dried basis. As fired moisture
contents are not seen in the fuel specification. Indonesian coal moisture normally ranges from 28% to
40%, whereas the fuel moisture considered is 15.2%. This takes away little margin.
The fan flow requirements were calculated and presented in annexure 6. For the case of Indonesian
coal with 40 % moisture, the MCR gas flow for 20% EA condition will be 28.56 m3/s, whereas the
ID fan is selected for 33.63 m3/s. There is margin available. But this is not available when the
oxygen content increases to 9% due to air ingress or due to other operational reasons. When the air
flow is adjusted for 9% O2 in flue gas, the excess air will be 75%. The MCR gas flow then becomes
42 m3/s as compared to available flow of 39.7 m3/s. Since the head at design point is 543 mmWC,
the fan is able to cope up with present gas flow at 120 TPH steam generation. The air ingress may be
too high disrupting the fan capacity. The air ingress at Radiant SH sealbox has to be arrested as it
leads to secondary combustion and thus many parameters are affected. See annexure 6 on fan sizing
for different fuels. At present the boiler seems to be operating on high excess air. This can be due to
loss of fines from upper furnace and due to air ingress.
Air nozzle failures
The design of air nozzle is not as per the current practice. The present air nozzle does not get
adequate cooling air at the top. The air nozzle has four tier holes. Only one fourth of the air comes to
top for cooling. Hence the top plate oxidizes and simultaneously the oxide scales get stripped too.
After thinning the nozzles fail. It is suggested to increase the pitch between nozzles as per drawing
no. The air nozzle shall be modified as per drawing no. The nozzles supplied for other customers by
Cethar are similar to Chinese design. See the photographs in annexure 7.
Duct size checking
The duct sizing is checked for adequacy for the air required / flue gas produced in the case of
Indonesian coal with 40% Excess air. The results are presented in annexure 7.
Regular thickness mapping
Tube thickness checking needs to be documented for future reference. Like bed coils of AFBC
boiler, CFBC boiler would also erode. It is necessary to know the pattern of erosion in the boiler and
take necessary action. The tube thickness meter shall be with a curvature probe suitable for tube OD
of 38.1 mm – 51 mm. The thickness range has to be 2 - 6.5 mm. The additional probe shall be
procured.
ESP outlet duct
It is better to avoid a T duct when the gas is divided among two ID fans. Instead it should be made of
2 x 90 deg bends. This helps to save power in ID fan. See suggestion vide drawing.
Effect of air ingress at roof
Air ingress at roof panel can cause a localized secondary combustion and upset the gas temperature
profile. Due to this secondary combustion the boiler exit temperature can be higher. Also the
superheater spray can be more. At present nearly 80 deg C is being dropped at two desuperheater put
together. Loss of fines from furnace can cause high combustion temperatures. Fines in upper furnace
help for heat transfer to furnace wall tubes.
High gas temperature at ESP inlet
It is seen that the gas temperature is as high as 160 deg C as against 140 deg C. The primary APH is
being bypassed to control the bed temperature. It may be necessary to fine tune the PA air flow &
bed height to get the lowest bed temperature. Overloading the boiler can also have an effect. Once
the air ingress at roof is arrested, there may be improvement in this.
Lower feed water temperature
Feed water temperature after HP heater is seen to be 201 deg C as against 210 deg C. This also leads
to overloading the boiler. The turbine extraction conditions have to be checked with that of design.
If the inlet steam temperature is less, then feed water temperature will be less. Also check the level
control valve setting.
Higher moisture as compared to design
At present 40 - 45% moisture coal is being fired as against the design moisture of 13.5 % in the
Indonesian coal. The flue gas quantity is more due to the steam in the flue gas. The efficiency of the
boiler is less with high moisture coal. This calls for burning additional coal and thus the flue gas flow
is more. A 40% moisture coal will have a boiler efficiency of 83.2 % as compared to 28% moisture
coal with a boiler efficiency of 86%.
Bed material requirement
It is learnt that considerable bed material is required in order to maintain iron content & bulk density
under limits. Iron content should not cross 15% by weight. Bulk density can be 1350 kg/m3 at the
maximum. Using high ash coal will solve the problem of high bed material consumption and the
high bulk density. Recycling of drained bed material is permitted after the removal of iron by a
magnetic separator.
Usage of low ash coal with iron content in ash
Indonesian coals have less ash. The iron content in ash can be as high as 20%. This gets concentrated
in the furnace and increases the iron content. Higher ash content of nearly 10% helps to prevent iron
accumulation in the bed. This is due to the reason that the bed ash generation will also be more and
the draining will be more and hence concentration of iron is not seen.
Procurement of right type of coal
A simple criterion is the ash softening temperature. It has to be above 1200 deg C under reducing
condition. This will automatically be low iron coal. While procurement of coal, the ash report must
be scrutinized and the coal must be selected.
Measurement of iron in fly ash
Measurement of iron in fly ash helps to know whether the ash is harmful or not. If the fly ash iron
content is in the increasing trend, it means the iron input is more. When using several coals, this
number must be monitored. Iron can be tested by a permanent magnet.
Lean bed height measurement
The lean bed height can be measured close to kick off zone. This helps to know the lean bed height.
The ash content in coal being fired may be so less, that it does not compensate for the loss of
material from furnace. It is learnt that bed material is being used to a large extent in this boiler. The
loss of fines from roof will also increase the bed material requirement.
Condensate pH
At present condensate pH is around 9.2. It may be necessary to increase the pH further by dosing
morpholine or Cyclohexylamine at TG exhaust. This is due to the reason that the ACC tubes may
undergo corrosion. It is advised to inspect ACC tubes from inside the ACC duct. See some good and
bad ACC tubes. It is possible to check silt density index after CEP to know whether ACC tubes are
undergoing pH corrosion or not. In annexure 7, some photographs showing ACC corrosion are
presented.
Keeping water below the ACC structure
The performance can be studied by measuring the tube temperatures with IR camera with and
without water. There may be some benefit. The heat pick up by water vapor will contribute for
maintaining lower air exit temperature.
Inspection of steam drum / deaerator tower / deaerator storage tank / condensate tank / ACC tubes
and ACC duct
The above are to be inspected when there is a normal shut down without any forced cooling by cold
water. From the color of the inside surface one can understand corrosion of metal. Magnetite layer is
grey in color. See photo in annexure 7.
Loop seal fan VFD and air flow measurement
At present loop seal is operating at constant speed. There may be excess air flow at loop seal
disturbing the seal and down leg. The rotometers provided at loop seal air pipe are to be lowered for
visibility. The loop seal blower has to be operated with a VFD to regulate the air required for
maintaining the seal and the bed material transfer. If VFD is not planned at least there has to be a
dump valve to send part of the air to PA duct.
Difference between the DCS oxygen reading and the portable meter reading
The data on O2 readings between DCS and Field were seen. The field readings are higher by 5%.
There can be problem in the sensor or there can be air ingress at measurement points.
ID fan discharge damper removal
The ID fan discharge dampers are only pressure killers in case it is not used for maintenance. There
may be some gain in head, if the dampers are removed.
Fly ash sieve analysis
ESP first field ash must be analyzed for size. It is advised to procure sieve shaker and sieves with 25,
50,75 and 100 microns mesh openings. On regular analysis, one can come to know of fines loss from
furnace. If fines are lost, there can be loop seal plugging / vortex finder distortion.
Explosion doors in the furnace
Explosion doors are advised to avoid furnace damage during any furnace explosion. Furnace
explosion can be sensed by using CO analyser. Fuel accumulations in the fuel chute can cause
explosive situations. Explosion door provision will call for pressure part modifications.
K.K.Parthiban.
ANNEXURE 1: PHOTOS & COMMENTS RELATED TO FIRST FAILURE AT
WINGWALL SUPERHEATER.
Photo 1: It is learnt that the radiant SH bottom refractory got dislodged in the first few months of
operation. This has led to erosion of the radiant SH. There had been secondary damage to furnace
walls. Improper selection of refractory and improper casting method and inadequate anchor density
can cause this problem. Phosphate bonded high alumina castable is the right choice. The stud density
shall be as per AFBC boiler bed coil if the refractory failure is seen again.
Photo 2: There was no photo available for the radiant SH failure. This is a typical failure at wingwall
SH at another plant due to improper anchors and wrong selection of refractory.
ANNEXURE 2: PHOTOS AND COMMENTS RELATED TO SECOND FAILURE AT ROOF
PANEL
Photo 1: The second failure was reported to have taken place at the roof panel close to the radiant SH
sealbox. This is due to break down of sealbox and the resultant air ingress.
Photo 2: These are the additional views of the sealbox. The sealbox height should have been 150 mm
as per another drawing. The coir rope would burn off in no time and the hot gases would be filled
inside the sealbox. This leads to high heat input. The sealbox will naturally fail due to this. For this
reason there had been flue gas leakages. Ideally the sealbox should be fully filled with castable.
Already there is a sleeve to protect the SH coils. That is the reason that the roof tubes failed instead
of SH tubes. Modifications are suggested in the sealbox. An expansion bellow shall be used to ensure
positive sealing. This is required as the SH coils expand upwards due thermal expansion. A drawing
is given.

Photo 3 & 4: Two different details are seen between Cethar drawings. The sealbox height is 150 mm.
There is no coir rope detail in this. Incidentally this is the better detailing as compared to coil rope
case. It is advised to increase the sealbox height to 150 mm and pour fresh castable refractory. It is
advised to install the metallic expansion bellow as per enclosed drawing. The space should be filled
with ceramic blanketing.
Photo 5: The above drawing is taken from the Chinese boiler. They have provided fabric expansion
bellow for positive sealing of the sealbox. Fabric joints stand a chance of bursting on furnace back
pressure. Hence fabric joint is not suggested here.
ANNEXURE 3 : PHOTOS AND COMMENTS RELATED TO TUBE FAILURE AT KICK
OFF ZONE AT FRONT WATERWALL
Photo 1: The third failure was at kick off zone. This boiler is provided with corner refractory from
top to bottom. The failed tube was close to the corner refractory.
Photo 2: Detail K shows the typical corner refractory detail which is provided from top to bottom of
the furnace walls. If the refractory contouring is improper, there can be localised diversion of the bed
material towards to the fin to tube area. This results in localised erosion. There are no anchors on the
tubes. The anchors are only on the fins.
Photo 3: The above is the failed tube available at plant. The erosion is seen to have originated at the
tube to fin joint zone. The studs are seen welded on the tube instead of on fins. With this, the
refractory contouring would not be as per engineering requirement. If there was any excess
refractory, then the erosion will be localised.
Photo 4: It was seen that two tubes are removed from the failed area. This extended refractory will
again cause erosion. There should be no hooks. Any excess weldment at tube to tube joint, fin to fin
joint and fin to tube joint are to be removed. The purpose of providing kick off zone is lost.
Photo 5: The above is the detail of refractory at kick off zone given by boiler maker for this project.
This is likely to cause erosion. The detail given for some other projects by the same boiler maker is
as below.
Photo 6: The above are the details of kick off zone refractory in some other projects by the same
boiler maker. This detail will ensure less erosion rates at kick off zone.
Photo 7: This photo shows the high erosion rate when the refractory is excess. This is from a
Chinese boiler.
Photo 8: The above are some failures in CFBC furnace wall failures, as the erection debris is left
behind by the erector. The material gets diverted to localised spots and cause failure.
ANNEXURE 4: PHOTOS AND COMMENTS RELATED TO FOURTH TUBE FAILURE AT
16 M LEVEL NEAR CORNER REFRACTORY
Photo 1: The location of the 4th failure is marked in the drawing. The failure was close the field joint
area and next to the corner refractory. See further photos below.
Photo 2: The photo shows the tubes after removal. The first tube close to refractory had burst. There
is plate welded nearby. This location is just below the field joint (panel to panel joint).
Photo 3: The photo shows the tube that burst open near the corner refractory.
Photo 4: It can be seen that the fin to fin joint is not as per recommendations. The fin weld should
have been done from furnace side.
Photo 5: The third tube from the failed tube also thinned down. During thickness measurement this
was identified.
Photo 6: Close inspection of the fin joints revealed that the fin welding is not from inside. There is
overlap of fin. The welds are not dressed. All the above requirements are seen in the drawings. The
water marks show the pattern of material flow during normal operation.
Photo 7: These drawings are taken from the pressure part drawings of the boiler supplier. We can see
that the fin joints can have a negative offset of 1.6 mm at the maximum. Positive offset is not
allowed. Similarly tubes to tube joint can be with 1 mm offset. The bottom tube can go inside but not
outside. The fin to fin joint is to be made from combustor side.
Photo 8: The third tube which showed sign of erosion near the fin. The fin to fin weld was made
from outside only. This is the area where the fins are slit at shop for field matching of the tube to
tube butt weld joint.
Photo 9: The erection note says that the inside welds between panels are to be flush ground smooth.
Any projection leads to drifting of the bed material towards the fin base causing thinning down of
tube.
Photo 10: It is seen that SS plates are welded at the fins along the corner refractory. This is not
continuous. It is also seen in warped condition since it is not cooled well. It can cause localised
erosion of the tubes since it is warped. These SS plates are not provided in other boilers of Cethar.
Photo 11: As per the drawing of Cethar, the SS plate is to be welded to the tube. The erection is not
as per drawing. However this is not a good idea. Only refractory must be shaped to the required
profile. It is advised to make a gauge and check entire corner refractory. See drawing attached with
the report.
Photo 12: This is a photo taken in the furnace elsewhere at the panel to panel joint. The fin to fin
weld is not done and not dressed too. The adjacent corner refractory is seen haphazard. Even the
tubes are seen to be out of plane.
Photo 13: As per the drawing the fin to fin weld at field joint area should have been seal welded from
inside. It is seen that the fin to fin welding is not proper and the seal welding was done from outside.
Photo 14: The photo shows the slits made at factory for the purpose of tube matching at field joint.
The weld has to be full penetration weld. The second side is also to be seal welded.
ANNEXURE 5: REPORT ON THICKNESS SURVEY
ANNEXURE 6: FAN SELECTION CHECK CONSIDERING THE HIGH MOISTURE
COAL
EWS 604
PROJECT : Rengaraj Ispat- Indonesian coal-20% EA

INPUTS FOR COMBUSTION CALCULATIONS
AIR & GAS CALCULATIONS
Ta Ambient temperature 40 Deg C

P1 Relative humidity 60 %
Ma Moisture in dry air ( from tables) 0.02851 kg/kg
E Excess air 20 %
Te Boiler outlet gas temperature 140 Deg C
El Site elevation 200 Metres
P Flue gas pressure 5 mmwc
Moisture Moisture Moisture

8 40 23.46
Indian coal Indonesian coal Australian coal

Std As fired Std As fired Std As fired
Carbon 26.09 25.08 53.94 38.17 51.38 51.38
Hydrogen 2.15 2.07 4.13 2.92 3.63 3.63
Oxygen 4.31 4.14 10.06 7.12 14.59 14.59
Sulphur 0.26 0.25 0.45 0.32 1.09 1.09
Nitrogen 0.89 0.86 0.28 0.20 1.1 1.10
Moisture 4.3 8.00 15.2 40.00 23.46 23.46
Ash 62 59.60 15.94 11.28 4.75 4.75
100 100 100
Gross GCV of fuel 2500 2403.34 5165 3654.48 4206 4206.00
95.7 92 84.8 60 76.54 76.54
Weight ratio 0.00 100.00 0.00

Actual weight 0 23450 0
Heat input ratio 0.00 100.00 0.00
Efficiency on 100% firing 82.00 83.00 85.95
0.00 83.00 0.00
Heat output ratio 0.00 100.00 0.00
Constituents of fuel
FUEL Fuel Mix
C Carbon 38.17 % by wt
H Hydrogen 2.92 % by wt
O Oxygen 7.12 % by wt
S Sulphur 0.32 % by wt
N Nitrogen 0.20 % by wt
M Moisture 40.00 % by wt
A Ash 11.28 % by wt
100.01
GCV Gross GCV of fuel 3654.48 Kcal /kg
INPUTS FOR EFFICIENCY CALCULATIONS
Design by: Approved by

Name: Name:
Sign: Sign:
EWS 604
HLS1 Carbon loss ( calculated ) 0.51 %
HLS6 Radiation loss ( assumed ) 0.5 %
HLS7 Manufacturer margin (assumed ) 0%
Locations
A1 % Ash collection at location 1 Bed 20 %
A2 % Ash collection at location 2 ESP 80 %
T1 Temperature of ash at location1 900 Deg C

INPUTS FOR BOILER DUTY CALCULATIONS
**Adjusted for heat duty Steam generation rate Nett 115000 Kg/h
Main steam pressure 107 kg/cm2 g
Main steam temperature 540 Deg C
Feed water inlet temperature 210 Deg C
Superheater Pressure drop 10 kg/cm2 g
Saturated steam flow from drum 0 kg/h
Boiler efficiency Calculated 83.16
Boiler efficiency 83.00 %
INPUTS FOR AIR,GAS DUCT,CHIMNEY SIZING CALCULATIONS
Flue gas ducting Gas temp

Airheater outlet 140 Deg C
Air ducting Air temp
INPUTS FOR FAN SIZING CALCULATIONS
PA air / Total air 60 %

SA air / total air 40 %
Fan sizing
PA fan capacity (% MCR ) 50 %
PA fan efficency 80 %
ID fan capacity (% MCR) 50 %
ID fan efficency 80 %
SA fan capacity (% MCR ) 50 %
SA fan efficiency 80 %
PA fan design head 1400 mmwc

SA fan design head 1100 mmwc
ID fan design head 320 mmwc
Margin on PA fan flow 20 %

Margin on SA fan flow 20 %
Margin on ID fan flow 20 %

Name: Name:
Sign: Sign:
EWS 604
FAN SIZING CALCULATION Date & time: 3/18/13 8:18 PM
PROJECT : Rengaraj Ispat- Indonesian coal-20% EA

Site elevation = 200 metres
Gas temp at Airheater outlet = 140 deg C
Air temp at Airheater air inlet = 40 deg C
Airheater outlet = 200 deg C
Fan details PA air / Total air = 60

SA air / total air = 40
PA fan capacity (% MCR ) = 50 %
PA fan efficiency = 80 %
ID fan capacity (% MCR) = 50 %
ID fan efficiency = 80 %
SA fan capacity (% MCR ) = 50 %
SA fan efficiency = 80 %
PA fan design head = 1400 mmwc

SA fan design head = 1100 mmwc
ID fan design head = 320 mmwc
Flue gas generated per kg of fuel = 7.147 kg/kg

Molecular wt of flue gas = 28.27
Actual Fuel burnt rate = 23,450 kg/h
Wet air required per kg of fuel = 6.262 kg/kg
Margin on PA fan flow = 20 %

Margin on SA fan flow = 20 %
Margin on ID fan flow = 20 %
FAN SIZING CALCULATIONS

Calculations of volumetric gas flow rate
Wet flue gas produced per kg of fuel = 7.147 kg/kg

Fuel firing rate = 23,450 kg/h
Wet flue gas flow rate = 7.147 x 23,450 kg/h
= 167597.15 kg/h
Molecular wt of flue gas = 28.27 from air & gas calc
K, altitude correction factor = 0.977
Flue Gas volume flow rate at 0 deg C = 167597.15 x 22.4 / ( 28.27 x 0.977 )
= 135,923.41 Nm3 /hr
Flue Gas volume flow rate at 0 deg C = 37.76 Nm3 / sec
Boiler exit temperature, deg C = 140 Deg C
Design by: Approved by:

Name: Name:
Sign: Sign:
EWS 604
Gas flow at boiler exit temperature = ( 37.76x ( 273 + 140 ) / 273 )m3 /sec
= 57.12 m3 /sec
Calculations of volumetric Air flow rate

Wet air flow rate = 6.262 x 23,450 kg/h
= 146843.9 kg/h
Molecular wt of wet air = 28.50
K, Altidue correction factor = 0.977
Wet air volume flow rate at 0 deg C = 146843.9 x 22.4 / ( 28.50 x 0.977)
= 118,131.17 Nm3 /hr
Wet air volume flow rate at 0 deg C = 32.81 Nm3 / sec
Air temp at Airheater air inlet = 40 Deg C
Hence, Volumetric Air flow rate = ( 37.76x ( 273 + 40 ) / 273 )m3 /sec
Volumetric air flow rate = 37.62 m3 /sec

PA fan sizing
MCR PA flow for combustion = 37.62 x 60 / 100 m3/s
= 22.572 m3/s
MCR airflow of PA fan = ( 22.572x 50 / 100 ) m3/s
MCR airflow of PA fan = 11.286 m3/s
Design Flow for PA fan = 11.286 x ( 100 +20 ) / 100 m3/s
= 13.54 m3/s
= 48744 m3/h
PA fan Design head = 1400 mmwc
Assumed PA fan efficiency = 80 %
PA fan operating power required = 100 x 13.54 x 1400/ ( 101 x 80 ) kw
= 234.6 kw
Minimum motor power required = 1.15 x 234.6 kw
Minimum motor power required for PA fan = 269.8 kw
SA fan sizing
MCR SA flow for combustion = 37.62 x 40 / 100 m3/s
= 15.048 m3/s
Total SA air flow = 15.048 m3/s
MCR airflow of SA fan = ( 15.048x 50 / 100 ) m3/s
MCR airflow of SA fan = 7.524 m3/s
Design Flow for SA fan = 7.524 x ( 100 +20 ) / 100 m3/s
= 9.03 m3/s

Name: Name:
Sign: Sign:
EWS 604
SA fan Design head = 1100 mmwc
Assumed SA fan efficiency = 80 %
SA fan operating power required = 100 x 9.03 x 1100/ ( 101 x 80 ) kw
= 122.9 kw
Minimum motor power required for SA fan = 141.3 kw
ID fan sizing
ID fan capacity (% MCR ) = 50 %
MCR gas flow produced = 57.12 m3/s
MCR gas flow of ID fan = ( 57.12x 50 / 100 ) m3/s
MCR gas flow of ID fan = 28.56 m3/s
Design Flow for ID fan = 28.56 x ( 100 +20 ) / 100 m3/s
= 34.272 m3/s
= 123379.2 m3/h
ID fan Design head = 320 mmwc
Assumed ID fan efficiency = 80 %
ID fan operating power required = 100 x 34.272 x 320/ ( 101 x 80 ) kw
= 135.7 kw
Minimum motor power required for ID fan = 156.1 kw
Results summary
PA fan Existing SA fan Existing ID fan Existing
MCR flow m3/s 11.29 7.52 28.56
Design flow m3/s 13.54 14.90 9.03 11.10 34.27 33.63
Design flow m3/h 48744 53640 32508 39960 123379 121050
Design head mmwc 1400 1377 1100 1377 320 1377
Design temperature Deg C 40 40 140
Assumed effciency % 80 80 80
Operating power kw 234.6 122.9 135.7
Min motor power kw 269.8 141.3 156.1

Name: Name:
Sign: Sign:
EWS 604
PROJECT : Rengaraj Ispat- Indian coal


E Excess air 20 %

8 40 23.46

Carbon 26.09 25.08 53.94 38.17 51.38 51.38
Hydrogen 2.15 2.07 4.13 2.92 3.63 3.63
Oxygen 4.31 4.14 10.06 7.12 14.59 14.59
Sulphur 0.26 0.25 0.45 0.32 1.09 1.09
Nitrogen 0.89 0.86 0.28 0.20 1.1 1.10
Moisture 4.3 8.00 15.2 40.00 23.46 23.46
Ash 62 59.60 15.94 11.28 4.75 4.75
100 100 100
Gross GCV of fuel 2500 2403.34 5165 3654.48 4206 4206.00
95.7 92 84.8 60 76.54 76.54
Weight ratio 100.00 0.00 0.00

82.00 0.00 0.00
FUEL Fuel Mix
A Ash 59.60 % by wt
100.00

Name: Name:
Sign: Sign:
EWS 604
Locations



Fan sizing



Name: Name:
Sign: Sign:
EWS 604
FAN SIZING CALCULATION Date & time: 3/18/13 8:18 PM
PROJECT : Rengaraj Ispat- Indian coal







= 160469.478 kg/h
= 127,526.39 Nm3 /hr

Name: Name:
Sign: Sign:
EWS 604
= 53.58 m3 /sec

= 146321.02 kg/h
= 117,710.53 Nm3 /hr

PA fan sizing
= 22.494 m3/s
= 13.50 m3/s
= 48600 m3/h
= 233.9 kw
SA fan sizing
= 14.996 m3/s
= 9.00 m3/s

Name: Name:
Sign: Sign:
EWS 604
= 122.5 kw
ID fan sizing
= 32.148 m3/s
= 115732.8 m3/h
= 127.3 kw
Results summary
MCR flow m3/s 11.25 7.50 26.79
Design flow m3/s 13.50 14.90 9.00 11.10 32.15 33.63
Design flow m3/h 48600 53640 32400 39960 115733 121050
Design head mmwc 1400 1377 1100 1377 320 320

Name: Name:
Sign: Sign:
EWS 604
PROJECT : Rengaraj Ispat- Australian coal


E Excess air 20 %

8 40 23.46

Carbon 26.09 25.08 53.94 38.17 51.38 51.38
Hydrogen 2.15 2.07 4.13 2.92 3.63 3.63
Oxygen 4.31 4.14 10.06 7.12 14.59 14.59
Sulphur 0.26 0.25 0.45 0.32 1.09 1.09
Nitrogen 0.89 0.86 0.28 0.20 1.1 1.10
Moisture 4.3 8.00 15.2 40.00 23.46 23.46
Ash 62 59.60 15.94 11.28 4.75 4.75
100 100 100
Gross GCV of fuel 2500 2403.34 5165 3654.48 4206 4206.00
95.7 92 84.8 60 76.54 76.54
Weight ratio 0.00 0.00 100.00

0.00 0.00 85.95
FUEL Fuel Mix
A Ash 4.75 % by wt
100.00

Name: Name:
Sign: Sign:
EWS 604
Locations



Fan sizing



Name: Name:
Sign: Sign:
EWS 604
FAN SIZING CALCULATION Date & time: 3/19/13 5:32 AM
PROJECT : Rengaraj Ispat- Australian coal







= 180038.904 kg/h
= 142,830.83 Nm3 /hr

Name: Name:
Sign: Sign:
EWS 604
= 60.03 m3 /sec

= 161117.81 kg/h
= 129,614.07 Nm3 /hr

PA fan sizing
= 24.762 m3/s
= 14.86 m3/s
= 53496 m3/h
= 257.5 kw
SA fan sizing
= 16.508 m3/s
= 9.90 m3/s

Name: Name:
Sign: Sign:
EWS 604
= 134.8 kw
ID fan sizing
= 36.018 m3/s
= 129664.8 m3/h
= 142.6 kw
Results summary
MCR flow m3/s 12.38 8.25 30.015
Design flow m3/s 14.86 14.90 9.90 11.10 36.02 33.63
Design flow m3/h 53496 53640 35640 39960 129665 121050
Design head mmwc 1400 1377 1100 1377 320 320

Name: Name:
Sign: Sign:
EWS 604
PROJECT : Rengaraj Ispat- Indonesian coal- high excess air operation


E Excess air 75 %

8 40 23.46

Carbon 26.09 25.08 53.94 38.17 51.38 51.38
Hydrogen 2.15 2.07 4.13 2.92 3.63 3.63
Oxygen 4.31 4.14 10.06 7.12 14.59 14.59
Sulphur 0.26 0.25 0.45 0.32 1.09 1.09
Nitrogen 0.89 0.86 0.28 0.20 1.1 1.10
Moisture 4.3 8.00 15.2 40.00 23.46 23.46
Ash 62 59.60 15.94 11.28 4.75 4.75
100 100 100
Gross GCV of fuel 2500 2403.34 5165 3654.48 4206 4206.00
95.7 92 84.8 60 76.54 76.54
Weight ratio 0.00 100.00 0.00

0.00 83.00 0.00
FUEL Fuel Mix
A Ash 11.28 % by wt
100.01

Name: Name:
Sign: Sign:
EWS 604
Locations



Fan sizing



Name: Name:
Sign: Sign:
EWS 604
FAN SIZING CALCULATION Date & time: 3/19/13 5:35 AM
PROJECT : Rengaraj Ispat- Indonesian coal- high excess air operation







= 243689.28 kg/h
= 197,565.21 Nm3 /hr

Name: Name:
Sign: Sign:
EWS 604
= 84.03 m3 /sec

= 222157.23 kg/h
= 178,718.31 Nm3 /hr

PA fan sizing
= 34.146 m3/s
= 20.49 m3/s
= 73764 m3/h
= 355.0 kw
SA fan sizing
= 22.764 m3/s
= 13.66 m3/s

Name: Name:
Sign: Sign:
EWS 604
= 186.0 kw
ID fan sizing
= 50.418 m3/s
= 181504.8 m3/h
= 199.7 kw
Results summary
MCR flow m3/s 17.07 11.38 42.015
Design flow m3/s 20.49 14.90 13.66 11.10 50.42 33.63
Design flow m3/h 73764 53640 49176 39960 181505 121050
Design head mmwc 1400 1377 1100 1377 320 320

Name: Name:
Sign: Sign:
ANNEXURE 7: PHOTOS AND COMMENTS RELATED TO OTHER OBSERVATIONS
Photo 1: The air nozzles are seen to get oxidised and eroded. It is learnt that at every boiler stoppage
there are some worn out nozzles. This design is already changed by the boiler supplier, based on our
feedback at Jaibalaji, Durgapur.
Photo 2: The photo shows the design of air nozzles used in CFBC boiler in India. The nozzles are
somewhat similar in all cases. The air inlet pipe is close to the air nozzle head. The air hits the top
and travels down. This keeps the head cooled better.
Photo 3: There is the current air nozzle design adopted by Cethar.
.
Photo 4: This is another air nozzle design by BHEL. The air is released from bottom. The head is
cooled better.

Photo 5: The fan sizing is compared here. We can see for the current operating condition, there can
be limitation in volume flow rate of ID fan.
Photo 6: The T duct at ESP outlet is not a good feature. This results in turbulence at this place. If the
duct is modified as per the drawing given, there will be improvement over draft loss.
Photo 7: This is the check on duct sizing for Indonesian coal.
Photo 8: ACC corrosion due to low pH. Like this ACC tube inside has to be visually checked.
Photo 9: This is a curve produced by EPRI scientists after extensive tests with ACC corrosion.
Before raising pH, SDI must be tested. After raising the pH SDI must be tested. The pH can be
boosted by dosing morpholine at TG exhaust. Dissolved iron does not reveal this corrosion much.
Photo 10 & 11: The corrosion products of steel can be seen in the steam drum of the photo at the
bottom. The top photo shows the steam drum with proper feedwater and boiler water chemistry. The
grey color layer is magnetite layer.
ANNEXURE 8: LIST OF DRAWINGS
1. P1156-00-01-4-001 Rev00- Gauge for Corner Refractory

2. P1156-00-01-4-002 Rev00- Gauge for Kick off zone Refractory
3. P1156-00-01-3-003 Rev00- Air nozzle layout
4. P1156-00-01-3-004 Rev00- Air nozzle
5. P1156-00-01-2-005 Rev00- Seal box & Expansion joint at RSH outlet
6. P1156-00-01-3 -006 Rev00- T-Duct for ESP outlet

An Experience With CFBC Boiler Tube Failures PDF

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An Experience With CFBC Boiler Tube Failures PDF

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March 16, 2013

CFBC BOILER TUBE FAILURE DIAGNOSIS REPORT

By K.K.Parthiban, Venus Energy Audit System

Agenda for visit

The visit was made for diagnosing the failure.

TUBE FAILURE DIAGNOSIS

First failure- radiant SH bottom tube failure- See annexure 1

Second failure – Roof tube failure- See annexure 2

Third failure- furnace wall tube failure- See annexure 3

Fourth failure - furnace wall tube failure- See annexure 4

General guidance to reduce erosion rate of CFBC furnace

Inadequate margin in ID fan

Duct size checking

Regular thickness mapping

ESP outlet duct

Effect of air ingress at roof

High gas temperature at ESP inlet

Lower feed water temperature

Bed material requirement

Usage of low ash coal with iron content in ash

Procurement of right type of coal

Measurement of iron in fly ash

Lean bed height measurement

Keeping water below the ACC structure

Loop seal fan VFD and air flow measurement

ID fan discharge damper removal

Fly ash sieve analysis

Explosion doors in the furnace

PROJECT : Rengaraj Ispat- Indonesian coal-20% EA

Ta Ambient temperature 40 Deg C

Moisture Moisture Moisture

Indian coal Indonesian coal Australian coal

Weight ratio 0.00 100.00 0.00

INPUTS FOR EFFICIENCY CALCULATIONS

Design by: Approved by

T1 Temperature of ash at location1 900 Deg C

INPUTS FOR AIR,GAS DUCT,CHIMNEY SIZING CALCULATIONS

Flue gas ducting Gas temp

PA air / Total air 60 %

PA fan design head 1400 mmwc

Margin on PA fan flow 20 %

Design by: Approved by

INPUTS FOR FAN SIZING CALCULATIONS

Fan details PA air / Total air = 60

PA fan design head = 1400 mmwc

Flue gas generated per kg of fuel = 7.147 kg/kg

Margin on PA fan flow = 20 %

FAN SIZING CALCULATIONS

Wet flue gas produced per kg of fuel = 7.147 kg/kg

Design by: Approved by:

Calculations of volumetric Air flow rate

Wet air required per kg of fuel = 6.262 kg/kg

FAN SIZING CALCULATIONS

Design by: Approved by:

Design by: Approved by:

PROJECT : Rengaraj Ispat- Indian coal

Ta Ambient temperature 40 Deg C

Moisture Moisture Moisture

Indian coal Indonesian coal Australian coal

Weight ratio 100.00 0.00 0.00

INPUTS FOR EFFICIENCY CALCULATIONS

Design by: Approved by