• THE IR-CFBC BED ASH COOLER UNIT

CONTROL PHILOSOPHY

PRESENTED BY
NASAR BABU .B
I & C ENGINEER
WCPM
IMPORTANCE OF BED MATERIAL IN FURNACE

 Bed material which is mixture of fine sand particles and

coal particles it’s very important while light up of any
furnace in industries, for even distribution of temperature.
The level of bed material is maintained to a certain level
for proper fluidization process. During the process of
feeding the system with coal, some particles remain un
burnt which increases the level of bed in turn effects the
process of fluidization.
 In general when Bed material in the Furnace reaches to a
certain level the Bed material should be drained for proper
combustion. For proper combustion in the Furnace the
material (Coal & Char) which is fed into is to be fluidized,
In order to achieve proper fluidization the level should be
maintained below 1350 mmwc (mille meter water
column). If the level of material in the furnace reaches
beyond the set point the material is to be drained.
 PROBLEM STATEMENT
 With the process of fluidization and feeding the
temperature of the Bed material reaches high around 800
degrees celcies. Previously the Bed material is drained
directly without using cooling process, in order to cool this
material water is sprinkled directly on to it, due to this lot
of dust is evolved which results atmospheric contamination
with unwanted gases and particles. This is hazardous to
health of people involved in draining and cooling of
material, to overcome this Bed ash Cooling system is
introduced
 WORK ALREADY DONE

 Instead of draining bed material directly into the atmosphere, in

the first stage the bed material is released into the bed ash
cooling system where the temperatures of the bed material falls
below 160 degrees celcies , and then the material is drained to
the silo, using ash handling system.
 Lower to mid shaft differential pressure shall be controlled in
between HIGH and LOW limit band, which shall be set by
process engg. (DPIC202) shall act as an ON/OFF control. Set
points of bed level to start bed as cooler AUTO sequence
START/ STOP with different boiler loads are as per FX202.
When (DPIC202) DP goes above High SP, the selected Ash
cooler sequence shall be started and bed material shall be
drained as per the ash cooler capacity. When (DPIC202) DP
goes below SP, the bed draining shall be stop. A dead band to
be provided to avoid cycling of the sequence
 PROJECT REQUIREMENTS
Development of the system which rigidities the desired
process requires the following
 PA air
The system should be provided with Purging Air which
provides free passing for un burnt particles from
furnace into the Bed ash cooling unit.
 ID fan
Top end of Bed ash cooler is enclosed with Duct of ID
fan, which guides the hot air into the APH and finally
passes the air into the atmosphere through stack.
 BAC fan
These are equipped for cooling the material inside bed ash
coolers. The air forced into unit will help in bringing down
the temperatures inside bed ash coolers.
 Temperature Sensor
Various tapings were provided for installing temperature
sensors, which are helpful in knowing the temperatures of
the bed material inside the unit.
 Level sensor
Bed ash cooling unit should be equipped with level sensors
at various points, for determining the percentage fill of bed
materials.
 Bottom Ash Conveying unit
Ash conveying units are mounted below the bed ash
coolers. This conveying unit will finally carry the bed
material into the silo.
Automation software's required
 In general Bed Ash Cooling Logic can be implemented
either by PLC or DCS. Here logic is implemented by
DCS. The graphical representation an Implementation
can be viewed with the help of SCADA. The logic
developed with DCS is interfaced to SCADA.
THANK YOU