Boiler Manual Thermax 150 TPH IRCFBC

THERMAX LIMITED PROJECT: RSPL LIMITED.
BOILER AND HEATER GROUP JAMNAGAR, GUJARAT

PUNE, INDIA PROJECT NO.: PC 0531/32/33
SECTION OVERVIEW ............................................................................................................ 1
1 BOILER START UP .......................................................................................................... 4

1.1 START-UP OF A COLD BOILER ........................................................................................ 4
1.1.1 SYSTEM LINE UP ...................................................................................................................... 5
1.1.2 WALK-DOWN CHECKS ............................................................................................................... 5
1.1.3 FILLING OF WATER IN THE BOILER ......................................................................................... 16
1.1.4 FANS START UP PROCEDURES ................................................................................................ 18
1.1.5 BUBBLE CAP dP TEST .............................................................................................................. 20
1.1.6 BED MATERIAL FILLING .......................................................................................................... 21
1.1.7 COLD LIGHT UP OF BOILER .................................................................................................... 22
1.1.8 COAL FIRING:......................................................................................................................... 25
1.1.9 PETCOKE FIRING .................................................................................................................... 26
1.1.10 COLD PRESSURE RAISING CURVE............................................................................................ 28
2 LOAD OPERATION ........................................................................................................ 29
2.1 BED TEMPERATURE CONTROL ..................................................................................... 31
2.2 SOLID INVENTORY CONTROL ...................................................................................... 39
2.2.1 Solid Mass Control (Total Inventory Control) ............................................................................. 39
2.2.2 Solids Particle Size Control ....................................................................................................... 48
2.3 BED ASH ALKALI CONTROL .......................................................................................... 50
3 BALANCE OF PLANT START UP (BOILER) ..................................................................... 51
3.1 DEAERATOR CHARGING (CUSTOMER SCOPE) ................................................................ 51
3.2 SWAS SYSTEM ............................................................................................................ 52
3.3 DOSING SYSTEM......................................................................................................... 52
3.4 ASH HANDLINGSYSTEM ............................................................................................... 52
3.5 AIR PRE HEATER ......................................................................................................... 53
3.6 ELECTRO STATIC PRECIPITATOR (ESP) ........................................................................ 53
3.7 BED ASH COOLER (BAC) .............................................................................................. 54
3.8 BED ASH RERCYCLE SYSTEM ........................................................................................ 56
4 CONTROLS.................................................................................................................... 58
3.9 FURNACE PRESSURE CONTROL .................................................................................... 58
3.10 DRUM LEVEL CONTROL ............................................................................................... 58
3.11 SUPER HEATER STEAM TEMPERATURE CONTROL .......................................................... 59
3.12 AUTO COMBUSTION .................................................................................................... 59
3.13 EXCESS AIR - O2 CONTROL .......................................................................................... 59
3.14 BED LEVEL CONTROL .................................................................................................. 59
3.15 BED TEMPERATURE CONTROL ..................................................................................... 60
3.16 U BEAM TEMPERATURE CONTROL ................................................................................ 60
3.17 PRIMARY AIRFLOW CONTROL ...................................................................................... 60
3.18 OFA FLOW CONTROL................................................................................................... 60
4 EMISSION CONTROL .................................................................................................... 61
5 HOT STARTUP............................................................................................................... 64
SECTION B PAGE I
6 WARM START UP .......................................................................................................... 66
7 WINDBOX STEAM PURGING......................................................................................... 68
8 WINDBOX CO VENTING................................................................................................ 69
9 WING WALL PROTECTION ........................................................................................... 70
10 MASTER FUEL TRIP (MFT) ............................................................................................ 70
11 TROUBLE SHOOTING CHART ........................................................................................ 72
12 DO’S AND DONT ‘S........................................................................................................ 79
13 WALK DOWN CHECK LIST DURING OPERATION .......................................................... 81
14 BOILER SHUTDOWN ..................................................................................................... 82

14.1 NORMAL SHUTDOWN PROCEDURE ............................................................................... 82
14.2 EMERGENCY SHUTDOWN SEQUENCE............................................................................ 85
14.3 ACTION DURING TUBE FAILURE ................................................................................... 86
15 BOILER / EQUIPMENT SAFETY & LIMITATIONS .......................................................... 88
15.1 PERSONNEL SAFETY PRECAUTIONS.............................................................................. 90
SECTION B PAGE II
SECTION OVERVIEW
This section describes in brief about IR-CFBC operation philosophy, Boiler start-up, Shutdown,
Emergency procedures & Safety aspects of the boiler.
Note
• Procedures explained in this section apply for start up of a boiler already commissioned.
Commissioning a new boiler calls for several additional requirements, which are not
explained here.
• It is assumed that the boiler operating team is fully familiar with the design and construction
features described in section A.
• It is assumed that operators are trained in operation of similar IRCFBC boilers and have
been licensed to operate boilers by the concerned authorities.
• Owner is encouraged to evolve standard operating procedures (SOP) based on the
framework and recommendations that are explained in the subsections below. The SOPs
have to be well understood by the utility managers and operators for safe and reliable
operation.
OPERATOR’S RESPONSIBILITY
Boiler operator is responsible not only for the smooth operation of the boiler and its related
equipments, but also for the safety of all the personnel involved. Operator must be aware of any
operating conditions affecting the boiler or related equipments and should be able to recognize
hazardous conditions and to act properly to avoid injury/ damages.
Even though the operating procedures are normally given for each piece of equipment, but
complete knowledge of all components, their design, purpose, limitations and relationship with
other components is must for the operators.
SECTION B PAGE 1
IRCFBC WORKING PHILOSOPHY

In 1970s, fluidized-bed combustion technology was first applied to large-scale utility boilers to
explore new ways of burning solid fuels, especially high-sulphur coal, in an environmentally
acceptable and efficient manner. In concept, fluidized bed burns fuel in an air-suspended mass
(or bed) of particles. By controlling bed temperature and using reagents like Limestone as bed
material, emissions of Nitrogen oxides (NOx) and Sulphurdioxide (SO2) can be controlled.
Additional benefits of fluidized-bed combustion include wide fuel flexibility and the ability to
combust fuels such as bio-mass or waste fuels, which are difficult to burn in conventional
systems because of their low heating value, low volatile matter, high moisture content or other
challenging characteristics. In coal- fired boiler, fuel is burned in an air-suspended bed of
limestone and inert ash particles where SO2 is absorbed by the limestone and NOx formation is
limited by lower bed operating temperatures and staged combustion. This technology is now
used in a 'variety of industrial and utility boiler applications.
FLUIDISING PROCESS
Fluidising process induces an upward flow of a gas through a stacked height of solid particles.
At high gas velocities, the gas/solids mass exhibits liquid-like properties, thus the term fluidized
bed.
The following example illustrates the fluidizing process.
Furnace Furnace Furnace Furnace
AIR PLENUM AIR PLENUM AIR PLENUM AIR PLENUM
Static bed Minimum fluidisation Fluidising bed Turbulent bed

Fig-1A Fig -1B Fig-1C Fig-1D
Fig. 1A shows illustration of furnace with an air supply plenum at the bottom an air distributor
that promotes even air flow through the bed and a chamber filled with Bed Material or other
granular material.
If a small quantity of air flows through the air distributor into the Bed Material, it will pass
through the voids of an immobile mass of Bed Material. For low velocities, the air does not exert
much force on thebe Material particles and they remain in place. This condition is called a fixed
bed and is shown in Fig. 1B.
By increasing the air flow rate/velocity, the air exerts greater forces on the bed material and
reduces the contact forces between the bed material particles caused by gravity. By increasing
the airflow further, the drag forces on the particles will eventually counterbalance the
gravitational forces, and the bed material particles become suspended in the upward stream.
SECTION B PAGE 2
Point where the bed starts to behave as a fluid is called as minimum fluidization condition.
Increase in bed height is insignificant when compared with the non-fluidized case (fig 1B).
As the airflow increases further, the bed becomes less uniform, bubbles of air start to form,
and the bed becomes violent. This is called a bubbling fluidized bed (BFB), shown in Fig. 1C. At
this stage the volume occupied by the air/solids mixture increases substantially.
By increasing the airflow further, the bubbles become larger and begin to coalesce; forming
large voids in the bed. This condition is called a turbulent Fluidized bed Fig. 1D
As the velocity of air is further increased (around 6 m/s), a condition is reached wherein the
whole of bed material is in circulation from furnace to a collection chamber (U beam hopper)
and back to furnace resulting in a uniform temperature profile throughout the furnace. Because
the whole bed is in continuous circulation internally, this boiler is called Internal
Recirculation Circulating Fluidized Bed Combustion (IR-CFBC) boiler as described in Fig
Fig ( Solid Flow in IR – CFBC BOILER)
In circulating beds, more particles are blown from the bed than bubbling bed. The particles are
then collected back by a particle separator and recycled to the furnace. Residence time of the
particle is determined by the collection efficiency of the particle separator and the solids
circulation rate. As the result of the recirculation process, the effective particle residence time
greatly exceeds the gas residence time.
SECTION B PAGE 3
1 BOILER START UP
This chapter describes the boiler start up and load operation
BOILER START UP SEQUENCE

• System Line up
• Walk-down checks and valve/damper line up
• Filling of water in the boiler
• Bed material filling in the combustor
• Cold start-up of the boiler
During cold start up of the boiler, equipment should be sequentially started, as per
the requirements; the start up sequence may be as follows
• I.D. Fan
• P.A. Fan
• S.A. Fan
• Feed Water Pump (as per requirement)
• Start up burners
• Fuel handling system
• Fly ash handling system
• ESP
• LP & HP dosing system
• Bed material feeding system
• Bed ash drain system
1.1 START-UP OF A COLD BOILER
Boiler start-up can be termed as cold start-up when there is no pressure or when pressure is
less than 2 Kg/cm2 (g) in the steam drum.
In a cold start up, possibilities of some inspection or maintenance works having been done is
presumed. A walk down check is required and the boiler and its auxiliaries are to be prepared
meticulously for a start up from the control room. Before a walk down check ensure that all
work permits have been returned, safety tags are removed and permission from maintenance
department is available for boiler.
Sequence to be followed to bring the boiler into service during cold start up is as below.
SECTION B PAGE 4
1.1.1 SYSTEM LINE UP

• Power supply: Ensure that the power supply is switched 'ON' and available for all the
feeders in MCC and for all panels.
• Operating station – PLC/DCS is ensured for readiness and emergency push buttons are
released, if activated.
• As instrument air is necessary for the operation of most of the valves and actuators, charge
the instrument air header, the branch lines and instruments supply lines elsewhere. Root
valves of all instruments (Pressure gauges, Pressure transmitters, DP transmitters, Level
gauges, etc.) must be kept open and their drains if any are to be kept closed. They are not
separately listed.
Ensure that all the field instruments are lined up mechanically / electronically.
1.1.2 WALK-DOWN CHECKS

Using powerful torches or low voltage inspection lamps inspect the furnace, other generating
sections, auxiliaries, flue and air ducting of the boiler and ensure the following:
BOILER
• Furnace, superheater areas are clear. All maintenance personnel have been removed and
no scaffolding or inspection devices have been left inside.
• Furnace floor, water walls, enclosure panels are clean and there is no evidence of any
water drips, slag or any other deposits.
• Steam drum is clean and manholes are closed properly.
• Confirm the furnace drain header valves are in closed position.
• Confirm that superheaters header drain valves are in open position and vent in closed
positions.
• Isolation valves from furnace and superheater drain header to the blowdown tank are
open.
• Verify that all access doors, inspection doors of furnace and wind box are tightly closed.
• Verify that all peepholes have been tightly closed and sealing/ cooling air connections are
intact and the air valves are open.
• Verify that the air duct, windbox, economiser, air pre-heater, dust collecting equipments
and flue gas ducts are clear and that all maintenance personnel have been withdrawn.
Ensure that the manhole doors are closed properly.
• Verify that the safety valves are not gagged.
• Verify that the illuminators of local level gauges are 'ON'. Inlet valves from steam and
waterside is open and their drain valves are closed.
• Verify whether the Nitrogen purging valve is opened (connected to the steam drum). If it is
open, it has to be closed just before boiler light up, when air vents are opened.
SECTION B PAGE 5
Description Tag No. Status

Furnace drain header valves FD-1001 to FD-1008 Closed
DR-1011/EM-1041
Superheater header drain valves Closed
DR-1013/EM-1042
Superheater header vent valves SH-1021/1022 Closed
Drain valve before MSSV DR-1016/EM-1016 Open
Drain valve after MSSV DR-1018/EM-1017 Closed
Furnace common drain header to the blowdown tank valve FD-1009 Open
SH common drain header to the blowdown tank valve DR-1022 Open
Nitrogen purging valve to steam drum SD-1043/1044/1045 Close
ECONOMISER
• Verify the internal is clean and all the manholes are closed with proper sealing.
• Ensure drain and vents are kept in position as described below.
Top header vent ECO-1001/1002 Open
Drain valve of top header ECO-1005/1006 Closed
Drain valve of bottom header ECO-1003/1004 Closed
STEAM DRUM
Ensure that valves are kept in position as described below
Drum vent valve SD-1039/1040 Open
CBD line isolation valve ( near drum) CBD-1001 Open
Motorised CBD valve EM-1007 Close
CBD isolation valve CBD-1003 Close
CBD line sampling isolation valve SAM-1003 / 1004 Close
HP dosing line isolation valves HP-1025 Open
IBD line isolation valve ( near drum) IBD-1001 Open
Motorised IBD valve EM-1006 Close
IBD isolation valve IBD-1003 Close
All drains and vents of standpipes provided for level -
Close
transmitters, indicator & gauges
All root valves for instruments - Open
SECTION B PAGE 6
SUPERHEATER SECTION
Saturated steam sampling line isolation valve SAM-1005/1006 Close
Windbox steam purging valve HCV-1019 Open
Windbox steam purging ON/OFF valves UV-1015/1016 Close

PS-1001/1002/1003 Open
Steam trap valves in steam purging line to windbox
Bypass- PS-1004 Close
SH-1003/1004
Saturated steam header vent valves Close
SH-1001/1002
DR-1003 / EM-1044
Superheater enclosure panel drain valves Open
DR-1001 / EM-1043
Superheater enclosure panel vent valves SH-1005/1006 Open
Wing wall inlet drain valve (RHS) DR-1005/ EM-1045 Open
Wing wall outlet vent valve (RHS) SH-1007/1008 Open
Wing wall outlet drain valve (RHS) DR-1007 / EM-1046 Open
Wing wall outlet drain valve (LHS) DR-1009 / EM-1040 Open
Wing wall outlet vent valve (LHS) SH-1009/1010 Open
Attemperator-1 header vent valve DSH-1026/ 1027 Open
Primary superheater-2 inlet header drain valve DR-1011/ EM-1041 Open
Attemperator-2 header vent valve DSH-1028/ 1029 Open
Secondary Superheater outlet header drain valve DR-1013/ EM-1042 Open
Secondary Superheater outlet header vent valve SH-1021/ 1022 Open

-
All root valves for instruments Open
MAIN – STEAM LINE

Ensure that following drain and vents are kept in position as described below.

Start-up vent motorised isolation valves EM-1018 Open
Superheated steam sampling line isolation valve SAM-1007/1008 Close
Main steam drain line isolation valve before MSSV DR-1016 / EM-1016 Open
Main steam drain line isolation valve after MSSV DR-1018 / EM-1017 Open
SECTION B PAGE 7

Main steam stop valve EM-1015A Close
MSSV bypass valve EM-1015B Close
FEED WATER PUMPS (CUSTOMER SCOPE)

• Ensure the pump and motor coupling alignment.
• Verify the bearing lubrication is done properly.
• Verify the free rotation of the pump by hand.
• Verify the open close feedback of individual pump suction valves.
• Verify the coupling guards are installed properly.
• Verify the suction strainers are clean and secured in its place at correct orientation.
• Ensure the pump seal & bearing cooling water pressure.
FEED WATER AND SPRAY WATER LINE

• Select the drum level and feed water flow controllers in manual mode and close the control
valves.
• Select steam temperature controller in manual mode with 0% output.
Ensure that following valves for drain and vents are kept in position as described below,

FEED WATER CONTROL STATION
100% Flow Control Valve (FCV) FCV-100B Close

100% FCV upstream isolation valve EM-1003A Close
100% FCV upstream bypass isolation valve EM-1003B Open
100% FCV downstream isolation valve BFW-1024A Close
100% FCV downstream bypass isolation valve BFW-1024B Open
100% FCV control station drain valves BFW-1018/1019 Close
30% Level Control Valve (LCV) LCV-1001A Close
30% LCV upstream isolation valve EM-1004 Open
30% LCV downstream isolation valve BFW-1025 Open
30% LCV control station drain valve BFW-1020/1021 Close
100% bypass FCV Valve EM-1001C Close
SECTION B PAGE 8

100% bypass FCV upstream isolation valve EM-1005A Close
100% bypass FCV upstream bypass isolation valve EM-1005B Close
100% bypass FCV downstream isolation valve BFW-1026A Close
100% bypass FCV downstream bypass isolation valve BFW-1026B Close
100% FCV bypass control station drain valves BFW-1022/1023 Close
ATTEMPERATION CONTROL STATION
Attemperator –I
Attemperator-1 control valve ( TCV) TCV-1010A Close
Temperature Control Valve (TCV) upstream motorised
EM-1013 Open
isolation valve
TCV downstream isolation valve DSH-1009 Open
Attempertion-1 control station drain valves DSH-1007/1008 Close
TCV bypass valve EM-1010B Close
Isolation valve at upstream of bypass valve DSH-1010 Open
Isolation valve at downstream of bypass valve DSH-1012 Open
Attemperator-II
Attemperator-II control valve ( TCV) TCV-1011A Close
Temperature Control Valve (TCV) upstream motorised
EM-1014 Open
isolation valve
TCV downstream isolation valve DSH-1019 Open
Attemperation-II control station drain valves DSH-1007/1008 Open
TCV bypass valve EM-1011B Close
Isolation valve at upstream of bypass valve DSH-1020 Close
Isolation valve at downstream of bypass valve DSH-1022 Open
SECTION B PAGE 9
START UP BURNER
• Verify that the igniters and burner fuel line flexible hoses are connected to the respective
nozzles properly.
• Verify power cables are connected to the igniters.
• Verify that the flame scanners are installed properly, cooling air hoses are connected and
valves are open.
• Verify that the air dampers at individual burners are at pre-set start-up position and air
supply to actuator is available.
• Verify physically in PLC/DCS that the fuel shutoff valves are fully closed.
• Spark gap is set at 2-3 mm. Gap between the burner tip to the swirler must be maintained as
per the drawing.
• Check the operation of gun forward and retract movement.
• Gun nozzles are clean without any blockages.
Ensure valve line-up as below:

LDO SUPPLY LINE
Manual isolation valve LDO-1301 Open
Isolation valves at upstream and downstream of oil LDO-1302/LDO-1308
Open
pumps LDO-1303/LDO-1309
Isolation valve at pump outlet LDO-1314/1317 Open
Close
Isolation valves for boiler 2&3 LDO-1101/1201
(Open as required)
Isolation valve LDO-1001 Open
Oil flow control valve FCV-1078 Close
Manual isolation valve in upstream and downstream
LDO-1002/1003 Open
of flow control valve
Bypass valve to flow control valve LDO-1004 Close
Solenoid operated shut off valve UV-1070 Open
Solenoid operated shut off valve at oil return line
UV-1079 Open
from header
Manual isolation valve at oil return line from header LDO-1009/1315 Open
Manual isolation valves at oil return line from boiler 2 Open as per
LDO-1109/1209
&3 requirement
Isolation valves at common header to individual
LDO-1006/1007/1008 Open
burners
UV-1071A
Solenoid operated shut off valves at individual
UV-1071B Close
burner
UV-1071C
SECTION B PAGE 10

COMBUSTION AIR TO BURNER
To be opened
Combustion air flow control damper FCV-1022
before purging
Isolation dampers at individual burner inlet FCV-1075A/B/C Open
ATOMISING AIR TO BURNER
Isolation valve at atomizing air line AA-1011 Open
UV-1072A
UV-1072B Close
burner
UV-1072C
IA-1019
Isolation valves at individual burner (Clearing media) IA-1023 Close
IA-1027
UV-1073A
UV-1073B Close
burner (Clearing media)
UV-1073C
NOTE:
a. Manual operated fuel isolating valves are to be verified for shut. These valves have to be
opened just before firing.
b. All root valves for instruments should be open.
ID, PA & SA FANS

• Check that the fan inspection doors are closed.
• Ensure that the bearing lubrication is done properly.
• Check that the coupling and guards are installed properly for safety purpose.
• Ensure that the control damper actuator is properly fixed to the operating lever and air
supply is open to actuator.
• Ensure the DOR as marked on fan.
Ensure following damper position before taking any fan in service.
Shut off damper at PA fan O/L duct EM-1021A/1021B Close
Shut off damper at SA fan O/L duct EM-1020A/1021B Close
Guillotine damper at ID fan I/L EM-1037A/1037B Close
Control damper at ID fan I/L duct HCV-1037A/1037B Close
Guillotine damper at ID fan O/L EM-1038A/1038B Close
SECTION B PAGE 11
STEAM AND WATER SAMPLING SYSTEM

• All sample lines isolation valves are to be kept closed. Samples can be taken into service as
boiler is pressurised.
• Ensure a slight bleeding through the sample line as the boiler is pressurized to 2 bar to
avoid choking of the line.
Ensure following valve position before taking any sample cooler in service
DESCRIPTION TAG NOS. Status
Cooling water inlet and outlet isolation valve to CWS-078A/B/C/D

Open
sample coolers CWR-079A/B/C/D
Feed water sampling isolation valve SAM-1001/ 1002 Close
Blow down water sampling isolation valve SAM-1003/ 1004 Close
Saturated steam sampling isolation valve SAM-1005/ 1006 Close

Superheated steam sampling isolation valve SAM-1007/ 1008 Close
COMBUSTOR & WINDBOX

• Verify the bubble caps holes are clear without any blockages.
• Verify the furnace wall refractory is intact without any swelling/damage.
• Verify burner throat, coal feed chute opening and fly ash recycle port refractory are intact
without any swelling/damage.
• Verify the healthiness of bed thermocouples.
• Verify the wind-box is clean and manholes are secured properly with seal rope/gasket.
• Confirm the OPEN-CLOSE operation of wind-box dampers (FCV-1026A/B)
• Confirm the OPEN-CLOSE operation of CO evacuation wind-box dampers (UV-1027)
• Verify the wind-box pressure indicator isolation vales are in open position.
• Verify the cleanliness of bubble cap, lower furnace and shaft dP transmitter impulse piping.
Confirm the OPEN-CLOSE operation of continuous purging SOV (UV-1040).
• Verify the bed drain lines are clear without any blockages.
• Ensure the wind box drain lines are close.
Ensure floor panel joints are leak proof. Ensure damper/valve line-up as below:
DESCRIPTION TAG NOS. Status
Wind-box dampers FCV-1026A/B Close
CO evacuation wind-box dampers UV-1027 Close
All root valves of instrument - Open
SECTION B PAGE 12
FUEL FEEDING SYSTEM –DRAG CHAIN FEEDER

• Verify the bearing condition and lubrication is done properly.
• Verify the gear box normal oil level of DCF.
• Confirm the tightness of the drive chain for DCF.
• Confirm the tightness of the feeder chain (DCF).
• Adjust the DCF load depth control plate to the desired limit.
• Ensure the healthiness of bunker level transmitter.
• Confirm the feeder discharge chutes are clear without any blockages.
Ensure following valve /damper position before boiler startup
DCF inlet slide gate SG-1001/1002/1003 Open
DCF seal air hand operated damper HD-1011/1013/1015 Open
Coal spreading air hand operated damper HD-1012/1014/1016 Open
Close;
KGV at DCF outlet UV-1031/1032/1033
(Open before start-up)
BED MATERIAL AND LIMESTONE FEEDERS
• Verify the bearing condition and lubrication is done properly.

• Verify and confirm the clearance between the casing and rotor blades.
• Verify all the flange joints are leak proof to avoid air ingress.
• Confirm the tightness of the drive chain for RAV.
• Confirm the outlet chutes are clear without any blockages.
• Ensure the operation of the slide gate valve at RAV inlet & outlet.
• Ensure the healthiness of bunker level transmitter.
Ensure following valve /damper position before boiler startup
Bed material rotary feeder inlet slide gate valve SG-1010/1011 Open
Bed material rotary feeder outlet slide gate valve SG-1012/1013 Open
Limestone rotary feeder inlet slide gate valve SG-1004/1005/1006 Open

Limestone rotary feeder outlet slide gate valve SG-1007/1008/1009 Open
SECTION B PAGE 13
MDC & BED MATERIAL RECYCLE SYSTEM

• Verify that internals are clean without any damages.
• Verify that hopper manholes are secured properly with seal rope.
• Ensure system flange joints are leak proofs.
• Verify that air slides are clear without any blockages at air and ash side & the inspection
doors and plugs are secured properly.
• Verify that all the fluidizing air hose pipes are connected to Airslide.
• Verify and ensure the healthiness of level switches at MDC hoppers.
• Ensure the smooth operation of rotary air lock valves
Ensure following valve /damper position before boiler start-up

MDC hopper bypass Knife Gate Valve (KGV) UV-1061B/1062B Close
Close
MDC hopper discharge KGV before RAV UV-1061A/1062A
(Open before starting RAV)
Close
Hot PA air Shut off damper UV-1060
(Open after SA fan start)
Hot PA to MDC airslide - hand operated
HD-1031/1032 Open
ON-OFF damper
PA-1013 to PA-1015
Airslide isolation valve Open
PA-1021 to PA-1023
Fly ash recycle discharge hand operated slide
KGV-1004/1005 Open
gate valve
BED ASH DRAIN & COOLING SYSTEM

• Verify that bed drain pipes are clear without blockages.
• Verify the smooth operation of bed drain SGV.
• Verify the condition of expansion bellow.
• Verify the ash cooler bubble caps for damages and cleanliness.
• Verify that manholes & all the flange joints are secured properly with seal rope.
• Verify and ensure healthiness of level, pressure and temperature indications.
• Ensure purge air to BAC LT is lined up.
SECTION B PAGE 14
Ensure following valve /damper position before boiler start-up

Bed ash cooler inlet regulating gate valve LCV-1050/1053/1056 Close
Bed ash cooler bypass hand operated slide gate valve KGV-1001/1002/1003 Close
Bed ash cooler outlet KGV UV-1052/1055/1058 Close
SA cooling air to BAC- hand operated isolation damper HD-1021/1022/1023 Open
SA cooling air on/off damper H SAD-212/213 Open
SA cooling air solenoid operated shut off damper UV-1051/1054/1057 Close
Hot air to ash separator- hand operated damper HD-1024/1025/1026 Pre-set Open
AIR PREHEATER (PA & SA)

• Ensure the soundness of the tube expansion near tube sheet.
• Verify tube ends are clean without erosion.
• Verify the tubes are clear without any blockages.
• Verify the tubes are in good condition without damage.
• Confirm the manholes are properly closed with seal rope.
• Confirm PA APH outlet pressure relief door is properly seated and locking bolt released.
Check following position of damper at Air Pre Heater.
PA APH I/L damper HCV-1025A Close
PA APH bypass damper HCV-1025B Open
SA APH I/L damper HCV-1023A Close
SA APH bypass damper HCV-1023B Open
SECONDARY AIR TO OFA
SA to OFA flow control damper FCV-1024 Open partial
OFA front and rear header hand operated Open – to be adjusted
HD-1001/1002
damper during commissioning
ELECTRO STATIC PRECIPITATOR (ESP)

• Conduct air load testing to assess the condition of electrical system.
• Switch ON the insulator and hopper heaters 4 hrs prior to boiler light up.
• Switch ON the rapper mechanism 2 hrs prior to light up.
SECTION B PAGE 15
• Switch ON the ash handling system below the hopper prior to solid fuel firing.
• Ensure all access doors are closed with proper sealing rope to avoid air infiltration.
• Access door mechanical key close interlock is activated.
Note: Refer ESP supplier’s manual for safe operation detail.
GENERAL CHECKLIST
• Ensure that the battery limit valves are open and the inputs are available
• Ensure availability of instrument air and service air at rated pressure.
• Ensure all the measuring and monitoring instruments are installed at position.
• Ensure that all the measuring and monitoring instruments root valves are open.
• Availability of sufficient quantity of feed water as per recommended quality
• Power up the feeders at MCC.
• Availability of LDO up to terminal point isolation valve.
• Ensure cooling water supply to the various equipments.
• Fuel bunker is filled up with specified fuel.
• Bed material and limestone bunker is filled with specified quality of material
• Availability of initial filling and makeup bed material.
• Availability of chemical for feed and boiler water treatment.
• Availability of lubricants for normal operation.
• Ash handling system is ready for normal operation.
1.1.3 FILLING OF WATER IN THE BOILER
It is recommended to use specified quality of feed water through the filling line for initial water
filling of the boiler.
Before filling water into boiler ensure following drain & vent position as described below.

Initial filling line to furnace drain header FD-1015 Open
DR-1011/EM-1041
DR-1005/EM-1045
DR-1007/EM-1046
All superheater drains Close
DR-1009/EM-1040
DR-1011/EM-1041
DR-1013/EM-1042
SECTION B PAGE 16

SH-1007/1008
Superheater vents SH-1009/1010 Close
SH-1021/1022
Economiser bottom header drain valve ECO-1003/1004 Open
Economiser top header drain valve ECO-1005/1006 Close
Open- To be closed
Economiser top header vent valves ECO-1001/1002
after removal of air
Downcomer drain valves FD-1001 to FD-1008 Open
SD-1039/1040
Drum vent Open
SD-1043/1044
Start-up vent MS-1012/EM-1018 Open
Hydro-test connection and furnace drain HY-1001/1002
Close
header valves FD-1011/1012
Furnace drain header outlet valve to BD tank FD-1009 Close
CBD & IBD isolation valves EM-1007 / EM-1006 Close
Following cares to be taken before starting water filling in boiler

• Water analysis report for the quality of water being filled up should be available and confirm
to the specifications.
• Direct water level gauge, level transmitters and RWLG/EDLI should be on-line.
• Pressure gauges at economiser headers, steam drum & main steam line should be inline.
• Main steam stop valve (EM-1015A) shall be kept closed.
NOTE: Gate valves should never be throttled. As per requirement, they may be either fully
open or fully closed.
PROCEDURE
• Ensure feed water for boiler fill up is available at boiler filling line.
• Open the filling line isolation valve (FD-1015) and fill up the boiler.
• Water will start flowing from all bottom headers and starts rising in boiler & economiser.
• Close economiser top header vent valve as soon as free flow of water start coming out and
air is expelled completely.
• Keep vigilance and allow water to fill in steam drum up to 30% drum level (NWL = 25 mm
above drum center line).
• Close filling line isolation valves (FD-1015) and all the downcomer drain valves
(FD-1001 to FD-1008) and economiser bottom header drain valves (ECO-1003/1004).
SECTION B PAGE 17
Caution:
While filling the water care should be taken to maintain the metal temperature
above 21°C to avoid brittle fracture, hence the water temperature must be
maintained to meet this requirement.
1.1.4 FANS START UP PROCEDURES

ID FAN START-UP PROCEDURE
Pre requisites
• Walk down checks are confirmed.
• All the interlocks are in service (Refer drive logic – volume 3)
• Ensure all work permits are closed.
Procedure for ID fan start

• Check that start permissive is available
• Start the ID fan from DCS.
• Observe the motor current readings.
• Observe fan and motor bearing temperature and motor winding temperature.
• Open ID fan inlet damper.
• Adjust the fan speed through VFD to maintain negative furnace pressure (-5mmWC).
PA FAN START-UP PROCEDURE

Pre requisites
• All the interlocks are in service (Refer drive logic – volume 3)
• Ensure PA APH bypass damper in open condition.
Procedure for PA fan Start

• Start the PA fan from DCS.
• Observe the motor current and vibration readings.
• Adjust the fan speed through VFD as per requirement.
• Ensure CO vent (UV-1027) is forced closed and bed ash cooler to APH (UV-1041) force
open condition.
• Maintain furnace pressure (-5 mmWc).
SECTION B PAGE 18
• Verify furnace DPT purging shut off valve (UV-1041) open automatically through logic.
• PA air flow to wind box to be adjusted by wind box damper (FCV-1026A/B) as per
process requirement.
SA FAN START-UP PROCEDURE

Pre requisites
• All the interlocks of fan are in service (Refer drive logic – volume 3)
• SA APH bypass damper must be in open position (HCV–1023B).
Procedure for SA fan Start

• Start the SA fan from DCS
• Observe the motor current readings.
• Immediately after the SA fan start up PA air to MDC airslide will open automatically
through logic.
• Adjust the fan speed through VFD as per requirement.
• Maintain furnace pressure (-5 mmWC) negative.
SECTION B PAGE 19
1.1.5 BUBBLE CAP dP TEST

Objective
The objective of this test is to find out the pressure drop across the bubble cap at different air-
flow and to establish the base details for boiler operation at part / full load.
Pre-Requisites
• Ensure that the bed is empty without any bed material.
• Verify the bubble cap for any physical damages or any blockages and replace the damaged
bubble cap if any and clear the blockage by pinning.
• Verify the floor panel seal welding for any cracks /damage and rectify the defect if any.
• Ensure that the manhole doors / inspection doors are properly secured and tightened on the
air / gas ducting.
Procedure
• Start ID & PA fans as per the fan startup procedures.
• Maintain furnace draft of – 5 mmH2O by modulating ID fan I/L damper or ID fan speed
through VFD.
• Note down the windbox pressure and bubble cap cold dP corresponding to 45%,60 %
,75% and 100 % MCR PA Fan air flow.
PA AIR FLOW (TPH) Bubble cap dP (mmH20) Windbox pressure (mmH20)

45%
60%
75%
100%
• At ideal condition there should not be any variation beyond ± 5% of predicted bubble cap
dP at corresponding air flow.
• If the dP is more than the acceptable limit, reasons to be identified and rectified.
• Repeat the above procedures at least two times to ensure the correctness of reading. If the
result is within limit, then the system is ready for bed material filing.
SECTION B PAGE 20
1.1.6 BED MATERIAL FILLING
Note: Bed material size and chemical property must be maintained strictly as per the
specification for smooth start up and efficient operation. (Refer section A)
Procedure:
• Ensure specified bed material is filled in bed material bunker.
• Start the ID fan as per fan start-up procedure (refer section 1.1.4)
• Adjust the furnace pressure to –2 to – 4mmH2O.
• Start PA fan as per fan start-up procedure (refer section 1.1.4)
• Maintain the PA air flow to windbox (35.5 TPH) sufficient enough to fluidize by adjusting PA
fan speed through VFD and spread bed material uniformly in the entire combustor.
• Open DCF outlet KGV (UV-1031/1032/1033). DCF may be operated if required.
• Ensure the isolation gate above (SG-1010/1011) and below (SG-1012/1013) the rotary feeder
are open.
• Switch ON the rotary feeders at bed material bunker outlet and operate at minimum speed
and start filling the bed material to the furnace.
• Bed material filling should be done in batches; it should not be in one stretch as it may cause
accumulation of material at the drop point and restrict the fluidisation of bed material and
spreading.
• Bed material shall be filled up-to 600 mm heights above the bubble cap, which is to be verified
physically.
• Prior to confirm the bed height, it is recommended to fluidize the bed thoroughly to spread the
material uniformly. Adjust the PA air flow suitably to ensure uniform distribution of the bed
materials evenly across the combustor.
• Record the minimum fluidization windbox pressure, lower dP and PA air flow as these are the
guiding parameter during cold startups.
PRECAUTIONS TO BE TAKEN BEFORE FILLING THE BED MATERIAL FOR BOILER

RESTART
Whenever there is tube failure in the furnace there are chances of bubble caps holes getting
blocked with bed ash / bed material. The intensity of blockage depends upon the ash properties
and nature / intensity of tube failure.
Hence it is required to ensure the cleanliness of bubble cap holes before filling the bed material.
It is recommended to do bubble cap pressure drop test, before boiler cold startup.
WARNING
If the bubble caps are not cleaned properly, fluidization may affect and back shifting of bed
material into windbox and erosion of bubble cap at the vicinity of choked bubble caps.
SECTION B PAGE 21
1.1.7 COLD LIGHT UP OF BOILER

• Ensure that all prerequisites stated above (walk down checks, valve and damper line up,
system line up ,water filling, bubble cap dP test and bed material filling) are completed and
boiler safety interlocks are tested and in operation.
Start-up sequence for ID fan, PA & SA fan:
• ID fan should be started first followed by PA & then SA fan
• Start the ID fan as per start-up procedure (refer section 1.1.4)
• Once ID fan is started, maintain furnace pressure at (-) 3 to (-) 5mmH2O by adjusting the flow
control damper/ fan speed.
• Once ID fan operation and furnace pressure is stabilized, PA fan can be started after satisfying
start up permissive.
• Start the PA fan as per fan start up procedure (refer section 1.1.4)
• With the above condition, permissive shall be generated for starting the SA fan.
• Start the SA fan as per fan start- up procedure (refer section 1.1.4)
• Stabilize all the fans and furnace pressure for normal operation.
BURNER STARTUP
Before starting the burner, operator should get acquainted with the burner management
system, logic and positions of valves are verified in accordance with system line up checks
(Section 1.1.2). In addition pre start up checks is to be ensured as mentioned below.
PRE- START-UP CHECKS FOR BURNER

• Opening/closing of combustion damper for all the burners are smooth with complete travel.
• Verify cooling air to flame scanners are available as per the recommendation.
• Verify the operation of LDO flow control valve (FCV-1078) opening and closing.
• All instruments for measurement of LDO pressure, flow and temperature are in service.
BURNER START-UP PROCEDURE

Start oil pump as per the start up procedure & maintain the rated oil pressure at main fuel trip
valve (MFT) inlet.
Before starting the burner, the pre-interlocks, main interlocks purge interlocks & oil firing
permissive are to be satisfied as per BMS logic.
SECTION B PAGE 22
FURNACE PURGING
• Whenever the Pre interlocks are satisfied, the system is “Ready for purging” and is
indicated by the glow of lamp “Purge ready to start”.
• For purging, maintain PA air flow as per the minimum fluidisation (established during bed
material filling) or > 45% of the max PA air flow (>45.6 TPH) whichever is higher and SA
air flow > 30% of the max SA air flow (>33.6 TPH) by adjusting the fan speed /damper
opening.
• Initiate the purge start from DCS. At this stage “Purge in progress” indication will appear.
After the pre set time i.e. 5 mins, purge complete indication will appear.
• After completion of purging windbox air sleeve damper moves to start up position.
• Normalize the PA & SA air flow for burner start up.
MFT Reset:
On completion of purging all conditions for MFT (refer vol. 3 BMS logic) need to be satisfied for
MFT Relay to be reset.
OIL FIRING
With MFT Reset, permissive shall be available for start the oil burner.
• Open main fuel shut off valve (UV-1070) and set the oil flow control valve (FCV-1078) to the
start up position (to be determined during commissioning/burner trials).
• Whenever Main fuel control valve /shut off valve opens, short recirculation valve (if
provided) closes & oil circulation starts through long recirculation line.
• “Burner ready to start” indication will appear. Initiate burner start command to the
selected burner.
• Whenever the burner start command is initiated the following actions takes place.
Oil gun of the respective burner goes to insert position (Firing Position).
Burner Atomising Air valve (UV-1072A) for that burner opens.
Igniter of the respective burner goes to the insert position.
With igniter insert position proved, igniter is energised for spark generation.
Igniter will be in energized condition for 15 sec.
Selected burner shut off valve will open & Oil re-circulation valve will be closed. (Once
first burner is established, the re-circulation valve will continue to remain close)
• Main flame will be established & “Burner-on” indication will be generated.
• Stabilise the burner operation & adjust the oil firing rate as per requirement.
• Number of burners operation can be decided as per requirement.
SECTION B PAGE 23
CAUTION:
If the burner fails to light up, find out the cause of failure. Do not attempt repeatedly
to light up the burner unless the fault is established. Repeated failures in lighting of
the burner may cause accumulation of un-burnt fuel and make a threat of explosion.
BOILER PRESSURING
• Increase the burner oil pressure by increasing oil flow after burner light up, according to the
pressurizing curve.
• Maintain the furnace pressure around -3 to –5 mmH2O and normal water level in drum.
• Whenever the steam drum pressure reaches about 2kg/cm2, close the steam drum vent
valve (SD-1039/1040).
• Whenever the pressure reaches to 3kg/cm2 close the superheater header drain valves (DR-
1009/EM-1040/Dr-1011/EM-1041/DM-1013/EM-1042) & wing wall drain valves
(DR-1005/EM-1045/DR-1007/EM-1046).
• Intermittently fluidize the bed at regular intervals, so as to avoid over heating of bed
material.
• Along with the boiler pressurization raise the bed temperature gradually.
CAUTION:
• Firing rate to be adjusted in such a way to maintain the flue gas temperature
at “U” beam inlet at 450ºC till 20% of MCR.
• Monitor and maintain the steam drum metal differential temperature
at 25°C by modulating the firing rate.
SECTION B PAGE 24
1.1.8 COAL FIRING:

Whenever the bed temperature reaches around 5500C - 6000C initiate the coal firing.
• Prior to start the fuel feeders, ensure seal air to the coal feeder & coal feed pipes are open
and maintain the required pressure (> 500mmH2O).
• Start drag chain feeder (DCF-001) with minimum coal flow (1.5-2.2 TPH) and admit the fuel
into the furnace.
• Observe the bed temperature carefully, if there is no change in the bed temperature after
admitting the coal, discontinue the coal feeding and increase the bed temperature to 6500 C
by over bed burner.
NOTE: Do not stop the PA to combustor after initiating coal firing.
• Again start drag chain feeder with minimum coal flow and admit the fuel to the furnace.
• If the bed temperature starts increasing steadily after coal firing and O2 level in flue gas start
reducing then continue the coal feeding.
• Monitor the bed temperature raise closely, whenever the bed temperature reaches 7500 C,
start the second DCF at minimum coal flow.
• Adjust the over bed burner oil flow suitably to have a control on the bed temperatures.
• Raise the bed temperature around 8000 C by adjusting the fuel feeding rate (LDO & Coal) and
airflow (Combustor & Burner) suitably.
• Whenever the bed temperature reaches above 8000 C, switch-off the over bed burners one by
one gradually.
Caution :
After switching off the burners, to cool the burner components exposed to high
temperature and to avoid back shifting of bed material into burner windbox and
air ducting sufficient air pressure has to be maintained at the burner windbox. i.e.
550 mmH2O.
• Raise the bed temperature to around 920 – 940°C by adjusting the coal feeding rate and
airflow suitably. However PA air flow should not be less than corresponding to minimum
bubble cap dP, set during commissioning.
Note: If the bed temperature continues to rise even after switching off the over bed burners,
increase the primary air flow, and regulate the coal feed rate and admit fresh bed material to have
a control on bed temperature.
• Whenever the coal firing is established, increase the OFA flow and maintain the pressure of
250 mmH2O at the OFA ducts at boiler front and rear.
• Monitor the O2 level in flue gas carefully and it should not be dropped below 6%. If the O2
level drops below 6% increase the primary air without further increase in coal flow rate.
• Maintain the furnace pressure normal i.e. (-) 3 to (-) 5 mmH2O.
SECTION B PAGE 25
• Raise the drum pressure upto rated pressure in accordance with the enclosed boiler cold start
up pressure raising curve.
• Adjust the fuel feed rate, primary and secondary air flow according to the fuel firing rate to
maintain the boiler outlet pressure and bed temperature.
• For lignite firing follow the above procedure.
1.1.9 PETCOKE FIRING

• Start the fans as per the start up procedure
• Switch on the start up burners as per the procedure
• Maintain low oil flow to the burners
• Admit primary air to windbox, airflow should be equal to or more than the minimum fludizing
air. At this stage air flow may not be continuous, it may be intermediate.
• Gradually increase the oil flow and bed temperature.
• Whenever the bed temperature increased above 650°C OR maintain the furnace temperature
above 850°C. start one of the fuel feeder at minimum speed and admit petcoke.
• During petcoke firing, primary air to the windbox should be ON and the air flow should be
maintained. Higher volume of air flow should be avoided as it will cool the bed also blow off
the bed material. Lower airflow may leads to partial bed fludisation and back shifting.
• Observe the bed temperature. If the temperature start increasing, continue the petcoke
feeding, if not discontinue the petcoke feeding and increase the bed temperature by
increasing the oil flow to the start up burners.
• Start the petcoke feeder and observe the bed temperature. Once the bed temperature is in
increasing trend, increase the petcoke feeding rate.
• Whenever the bed temperature, increased above 800 °C, gradually reduce the oil flow to the
burners and switch off the burners when the bed temperature raised above 920 °C
• Care should be taken to maintain the furnace middle dP between 600 to 700mm, start feed
the limestone or make up bed material to maintian the lower dP.
NOTE:
• Carryout flue gas analysis regularly for SOx in flue gas. Depend upon SOx % in flue gas
adjust the lime stone feeding to bed.
• Do not use recycled bed ash during petcoke firing
• Limestone quantity may depends on the limestone quality and sulphur content in the fuel
being fired.
• Frequent start and stop of boiler may lead to clinkering, hence avoid the frequent stopages
SECTION B PAGE 26
Boiler Tripping During Petcoke Firing

1. Boiler to be restarted quickly, failing which may leads to bed smouldering with residual
petcoke if any.
2. During restart after tripping, start the firing with LDO and stabilize the boiler, admit petcoke
whenever the bed conditions are satisfied.
Boiler load throw off during petcoke firing

1. Reduce the fuel feed rate to maintain the boiler outlet pressure.
2. Reduce the PA air to windbox by 10% from the operating airflow
3. Maintain the bed temperature above 850 °C by modulating the fuel flow.
If required start the LDO firing suitably.
CAUTION:
• Once the coal/lignite/petcoke firing is initiated there will be a sharp rise in the bed
temperature, should be controlled by reducing the over bed burner oil flow and increasing the
primary air flow suitably.
• Monitor the O2 level leaving the economiser carefully during coal/lignite/petcoke firing, it
should not be allowed to drop below 6%. If the O2 level falls below 6%, do not continue to
increase the main fuel feeding rate. Instead, increase the primary air to the bed slightly.
Furnace draft controls should have been tuned to maintain furnace draft to set point, and it is
recommended that the draft controls to be in auto mode, if the draft controls not be in auto,
adjust the ID fan dampers/speed to maintain furnace draft set point. Once the forced draft air
supply has been increased and furnace draft adjusted, main fuel feed rate can be increased
and continue with the monitoring of the O2 level. Adjust the OFA flow and ID fan speed to
maintain the acceptable O2 level in the flue gas.
• Maintain normal water level in the drum.
• Boiler pressure to be raised in accordance with boiler cold start up curve.
• Start-up vent valve (EM-1018) should be in full open condition during pressure rising and till
the steady flow of steam from the boiler.
• Immediately after stabilising the coal/lignite/petcoke firing, operate all the bed drain valves
intermittently to avoid choking of bed drain pipes due to gas condensation and clinker
formation at bed drain mouth.
• Firing rate to be adjusted in such a way to maintain the flue gas temperature at “U” beam
inlet at 480ºC till 20% of MCR steam flow is established.
• Monitor and maintain the steam drum metal differential temperature at 25°C by modulating
the firing rate.
SECTION B PAGE 27
1.1.10 COLD PRESSURE RAISING CURVE
Cold Start Up Curve

130.0
325 120.0
300 110.0
275
100.0
250
90.0
Sat Temp. (deg C)
Pressure Kg/cm2 (g)

225
80.0
200
70.0
175
60.0
150
125 50.0
100 40.0
75 30.0
50 20.0
25 10.0
0 0.0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
Time in min
Saturated Steam Temperature Drum Pressure
SECTION B PAGE 28
2 LOAD OPERATION
Mode of Operation:
During low load operation i.e. < 60% MCR, the boiler operation may be semi CFBC mode.
Along with the increase in load i.e.> 60% MCR, the combustion mode shifts to CFBC mode.
Load ramp up:

It is recommended to raise the load gradually but not more than 3 % of MCR/ minutes.
During load ramp up sufficient inventory is made available to control the bed temperature
fluctuations beyond safe limit.
Once the boiler load reaches above 60% MCR, switchover the following controlls in
automatic control mode
• PA & SA APH outlet pressure
• PA flow to windbox
• OFA flow to furnace
Once all above loops are stabilized take coal flow in auto mode.
CAUTION:
• During cold start-up primary & secondary air preheater to be bypassed to

avoid cold end corrosion. Whenever the boiler backend flue gas temperature
increases to 140ºC or depend upon sulphur dew point, APH to be taken in line.
Opening of APH inlet (HCV-1023A & HCV-1025A) & bypass damper (HCV-1023B & HCV-
1025B) to be adjusted in such a way to maintain the gas outlet of APH to 140ºC or
above sulphur dew point temperature. Opening and closing of APH inlet (HCV-
1023A & HCV-1025A) & bypass damper (HCV-1023B & HCV-1025B) will be initiated in
auto mode based on the ESP inlet flue gas temperature (above 140 ºC) set point.
• While loading the boiler, care to be taken that the feed and boiler water
parameters to be brought to the recommended limit before increasing the
steam flow beyond 50% of the MCR.
• While increasing the firing rate always increase the air flow first and then
increase the fuel.
While loading the boiler following conditions are to be ensured to achieve the desired output;
Input:
• Ensure the fuel being fired is as per the design specification i.e. coal size distribution,
proximate & ultimate analysis.
• Adequate quantity of specified bed material /inert should be available, sieve size
distribution and bulk density must be as per design specification.
• Adequate quantity of specified feed water & fuel should be available.
SECTION B PAGE 29
Fuel
Quality of fuel is to be maintained to ensure availability and efficiency of the boiler.
Hence, it is essential to maintain the fuel as per the design limits. Following needs to
be monitored during operation.
♦ Fuel sieve analysis
♦ Fuel moisture
♦ Presence of shale and stones
♦ Heat value
♦ Ash content in fuel
Bed material
For CFBC boiler operation bed material plays an important role as it is responsible for
maintaining the furnace shaft dP and temperatures as per steam flow demand.
Following to be monitored & maintained during operation:
♦ Sieve size distribution
♦ Chemical properties
♦ Bulk density
♦ Fusion temperature
♦ Iron content
Steady state operation and control philosophy
The intend of this write-up is to guide /enable the boiler operator to apply the control
principles described herein to specific cases characterized by peculiar fuel and sorbent
properties, equipment and measurement/control systems configurations. The steady state
operation control philosophy described herein is to limited specific areas.
Boiler performance i.e. load, power consumption, furnace temperature, combustion

efficiency, gaseous emissions, etc. is depends on the variables like
• Fuel properties
• Air/fuel ratio
• Bed and furnace temperatures
• Bubble cap dP, middle dP/ Furnace primary zone dP and upper dP/Shaft dP must be
maintained as per load demand.
• Excess air (O2) level in flue gas must be maintain as per steam load.
• Bed drain control
• MDC recycle control
• Make up material/ bed material control
• Solid particle size control
• Air & Gas temperature profile
• Emissions
SECTION B PAGE 30
2.1 BED TEMPERATURE CONTROL

Bed temperature is a function of,
• Operating load
• Furnace inventory/shaft dP / Upper dP
• Furnace primary zone dP/ Middle dP
• Bed ash chemical composition
• Excess air
• Moisture in fuel
The controlled variable is the bed (primary zone/lower furnace) temperature. Bed temperature
is controlled primarily by manipulating the furnace operating parameter viz. shaft differential
pressure/upper dP (DPT-1049 A/B) primary air ratio (PAR - fraction of the primary air in the
total combustion air) and excess air.
Bed temperature and primary air flow changes with the boiler load, hence the temperature
control method varies depending on load as mentioned below;
1. Steady state operation at 70 to 100% of MCR load
a) The shaft differential pressure and primary air ratio are the main parameters controlling
the lower furnace temperature in this load range.
b) An increase in the shaft dP/upper dP will increase the heat transfer thereby reducing
furnace temperature. However low shaft dP/upper dP will decrease the heat transfer
thereby increase in furnace temperatures.
The required shaft dP/upper dP is adjusted if the lower furnace temperature deviates
from its target value. Shaft dP/ upper dP is increased when the lower furnace
temperature is above its target value and decreased in the opposite case.
Shaft dP/upper dP cannot be increased when middle dP/ Furnace primary zone dP (DPT-
1048A/B) or windbox pressure (PT-1026) are at or above their maximum limits.
Shaft dP/upper dP is increased by increasing multiclone dust collector (MDC) ash recycle
RAV (M-1049A/1049B) speed provided at each MDC ash hopper discharge.
The MDC recycle increases the solid inventory to the furnace thereby retaining more
circulating material in the CFB system. It also reduces the overflow of solids from the
MDC hoppers.
When burning fuels with low solids input (e.g. low-ash coal) or incase of abnormally low
MDC efficiency (worn out collection elements), Shaft dP/upper dP control via MDC
recycle control might not be possible, during such situations make-up bed material to be
feed to maintain the required Shaft dP/ upper dP (see make-up material control below).
In case of Shaft dP/ upper dP decrease the opposite actions are taken.
SECTION B PAGE 31
c) If the primary zone temperature cannot be controlled by the MDC recycle rate within the
limits of the shaft dP /upper dP, or when MDC recycle and/or make-up rate is limited,
use one or a combination of the following means to bring the primary zone temperature
to the desired range:
Increasing primary air ratio results in MDC recycle and shaft dP/upper dP increase
which enhances the heat transfer in the furnace shaft and reduces the primary zone
temperature. The reverse is also true.
The range of primary air ratio and the rate of change of primary air ratio are limited
by middle dP/ Furnace primary zone dP (DPT-1048A/B), primary air ratio cannot be
increased when middle dP/ Furnace primary zone dP is at its minimum limit, and
cannot be decreased when middle dP/ Furnace primary zone dP is at its maximum
limit.
The effect of PRIMARY AIR RATIO on the primary zone temperature may be
enhanced or mitigated by its influence on the fuel burnout distribution. For some
fuels a PRIMARY AIR RATIO increase tends to increase the primary zone
temperature due to the increase of fuel burnout in the lower furnace prevailing over
the diluting effect of greater primary air flow. For other fuels the opposite is true.
Other areas affected by changing PRIMARY AIR RATIO include NO, and CO
emissions, carbon utilization and CO burnout in the U-beams. The result of a
PRIMARY AIR RATIO change is fuel specific and needs to be determined
during the boiler tuning. Changes of PRIMARY AIR RATIO should be done
slowly and within a limited range.
SECTION B PAGE 32
Boiler Air Flow Curves - Imported Coal

120
PA Air Flow (TPH); SA Air Flow (TPH)
100
Total PA fan air
80 flow
60
Total SA fan air
flow
40
20
0
0 10 20 30 40 50 60 70 80 90 100
Steam Flow (%)
Total PA fan air flow
Boiler Air Flow Curves - Lignite

160
140
120
100 Total PA fan air

flow
80
60 Total SA fan air

40 flow
20
0
0 10 20 30 40 50 60 70 80 90 100
Steam Flow (%)
Total PA fan air flow
SECTION B PAGE 33
Boiler Air Flow Curves - Petcoke

160
140
120
100
80
60 Total PA fan air

flow
40
Total SA fan air
20 flow
0
0 10 20 30 40 50 60 70 80 90 100
Steam Flow (%)
Total PA fan air flow Total SA fan air flow
Note: This is an indicative curve may change during operation based on fuel being fire and
operating condition.
Changing the fuel feed rate is an emergency short term means to prevent
temperature excursions in the primary zone and will cause a subsequent load
change.
The effect of fuel feed rate change on the lower furnace temperature also depends
on the type of fuel. When low-reactivity fuels are burned (like anthracite or Petcoke)
and the carbon content in the primary zone is high, the response of the temperature
to the fuel feed rate is slow. In this case changing of the fuel feed rate is not
effective for a short term temperature control. Higher reactivity solid fuels, such as
coals and lignite, which have more volatile content that burns quickly, will result
greater short term fuel feed rate change effect on the lower furnace temperature.
Changing of the bed particle size is a long term means used to change both the
furnace temperature and pressure differential.
The effects of the particle size distribution of circulating solids are explained as
below.
SECTION B PAGE 34
In addition to the quantity of solids in the furnace, the size of the particles also has a
significant impact on furnace heat transfer. In general, the finer the particles, the
higher the heat transfer rate. Typically, the mean size of the particles in the lower
furnace is from 250 to 350 microns and the mean size in the upper furnace is from
100 to 200 microns.
For the furnace of a CFB boiler to operate properly, the quantity of particles as well
as the size of the particles in the furnace must match the design values. If the
quantity of solids in the furnace is less than the design value, or if the size of the
particles is too coarse, the furnace operating temperature will exceed the design
value, and it will be necessary to limit boiler load to maintain the furnace
temperatures to within their design values.
The quantity of particles or solids in the furnace is measured by the gas side
pressure drop of the middle dP/ Furnace primary zone dP and shaft dP/ Upper dP. It
is also necessary to achieve the proper split between the lower bed pressure drop
and the shaft pressure drop.
A higher content of smaller particles in circulating solids results in the higher furnace
heat transfer and lower furnace temperature.
Bed particle size distribution change may be effected by modifying the sieve size for
fuel feed, sorbent (limestone), fresh inert bed material (crushed refractory) and
recycle bed ash feed to the boiler. Bed particle size distribution can also be changed
by rate of MDC ash recycle and bed drain.
SECTION B PAGE 35
2. Steady state operation at boiler load less than 70% of MCR
The control strategy is similar to that for 70-100% MCR load range with addition of excess
air (EA) as a means of the lower furnace temperature control.
With load decrease, the influence of the shaft dP/ Upper dP (and its controlling variables)
reduces, due to overall reduction of solids circulation rate. Excess air and primary air ratio
are increased as load is reduced below 70% MCR to control the lower furnace temperature
through the effect of dilution and to maintain furnace solids circulation and heat transfer to
furnace surface at lower loads. MDC recycle plays a lesser role at lower loads as a
controlling variable.
Shaft dP/ Upper dP, excess air (EA) and primary air ratio targets for the boiler load range
are established during process tuning taking into consideration of lower furnace
temperature, solids inventory control, superheater temperature control requirements and
emission limits. These parameter may be adjusted automatically or maintain by the operator
within the established limits.
Considerations for using the fuel feed rate and bed particle size for lower furnace
temperature control are similar to those described above for the 70 to 100 % load
operation.
The following describes the role of the major controlling variables during partial load
operation:
a) MDC Recycle Rate (MDCR)

During 50 to 70% load, MDC Recycle rate is used to control Shaft dP/ Upper dP at the set
point level, but should not be reduced below a preset minimum value.
If the minimum MDC Recycle rate limit is reached, other controls i.e. primary air ratio,
excess air should takeover. Below 50% load MDC Recycle feed rate is limited hence lower
furnace temperature is controlled by primary air ratio and excess air.
b) Primary Air Ratio

The effect of primary air ratio on the lower furnace temperature is fuel specific. For any fuel
at a given load, typically there will be some value of primary air ratio that produces a
maximum value for the lower furnace temperature. When primary air ratio is reduced from
that point, the temperature decreases due to the prevailing effect of reduced fuel burnout in
the lower furnace; and when primary air ratio is increased from that point, the temperature
decreases due to the prevailing effect of dilution with air. The point of primary air ratio
corresponding to the maximum temperature depends on the fuel type, boiler load and the
level of excess air (EA). When EA increases, the point of maximum primary zone
temperature moves in the direction of lower primary air ratio and may be outside of
practically achievable Primary Air Ratio value. For the lower reactivity fuels, the point of
maximum temperature moves towards higher primary air ratio values. Changes of primary
SECTION B PAGE 36
air ratio for the primary zone temperature control are limited due to effects of primary air
ratio on carbon utilization, NOx, and CO emissions, and solids inventory in the primary zone.
The allowable span of the primary air ratio adjustment for the temperature control within
the boiler load range is determined during boiler commissioning tuning.
c) Excess Air (EA)

Typically, changes of EA have a predictable effect on the primary zone temperature. With an
EA increase, the temperature decreases due to the effect of dilution and greater solids
entrainment enhancing heat transfer in the furnace. Normally, an EA change is used for the
lower furnace temperature control when all other temperature control means are exhausted.
This is due to the strong effect of EA on boiler efficiency and NOx emission. The role of EA
as a means of the lower furnace temperature control increases with the load decrease.
Note:
• During part load operations combustion control may have to be operated in manual
mode
• At any given time the primary air should not be reduced below purge air requirement.
Bubble cap dP should be always above 260 mmH2O
• O2% in flue gas must be maintained as recommended.
• Total air (PA + SA) flow should not be reduced below the minimum air flow at any point
of time after coal firing.
• In case of sudden bed temperature rise, reduce the coal feed rate to control the bed
temperature till the temperature become normal. The coal flow will be reduced
automatically through the drive logic if the controls are in automatic mode. Rate of fuel
flow change may be decided at site as per the operating conditions.
• While firing multiple fuels if the fuel configuration change happens there will be bed
temperature fluctuation hence the fuel configuration must be in a control manner to
avoid such situations.
SECTION B PAGE 37
O2 level Curve - Imported Coal

20.00
18.00
16.00
14.00
O2 level in %
12.00 O2 Level
10.00
8.00
6.00
4.00
2.00
0.00
0 10 15 20 30 40 50 60 70 80 90 100
Steam Flow in %
O2 level Curve - Lignite

20.00
18.00
16.00
14.00
O2 level in %
12.00 O2 Level
10.00
8.00
6.00
4.00
2.00
0.00
0 10 15 20 30 40 50 60 70 80 90 100
Steam Flow in %
SECTION B PAGE 38
O2 level Curve - Petcoke

20.00
18.00
16.00
14.00
O2 level in %
12.00 O2 Level
10.00
8.00
6.00
4.00
2.00
0.00
0 10 15 20 30 40 50 60 70 80 90 100
Steam Flow in %
operating condition
2.2 SOLID INVENTORY CONTROL

The solids inventory control comprises two interrelated components:
Solids Mass Control (Total inventory Control)

The solids mass control is accomplished online using sorbent (or inert material) feed rate,
bed drain purge, multiclone purge and MDC recycle rate
Solids Particle Size Control

Solids size control is accomplished online by using bed drain purge and MDC recycle and
offline by modifying the sieve size for fuel feed, sorbent (limestone), fresh inert bed
material (crushed refractory) and recycle bed ash feed to the boiler. Bed particle size
distribution can also be changed by rate of MDC ash recycle and bed drain.
2.2.1 Solid Mass Control (Total Inventory Control)

The total solids inventory consists of the following components:
I. Furnace inventory
II. MDC hopper inventory
III. Bed material makeup silo inventory
a) Total solids inventory built-up in the furnace is depend on the following factors:
The inventory input into the furnace which is determined by:

- ash content of the fuel being fired
SECTION B PAGE 39
- limestone feed rate and quality required for SO2 control

- volume of makeup bed material feed to furnace
The inventory losses from the furnace that consist of:

- solids lost along with flue gas leaving MDC
- solids lost from the MDC hopper over flow
- Useful solids lost from the bed drain.
Internal recirculation flows that consist of:

- Solids flow to the U-beams and recycle from U-beams and MDC recycle flow to
the furnace.
Solids feed size distribution and attrition / decrepitating properties which determine the
size distribution of particles over their time of residence in the CFB process.
b) Solids may be categorized according to behavior of particles of different sizes in CFB

process as follows:
Coarse particles that are predominantly settle in the lower furnace. These particles do
not reach U-beams and leave the furnace only with the bed drain purge.
Coarse and fine circulating particles form most of the circulating inventory. Coarse
circulating particles (>300 microns) are collected completely by U-beams, and leave the
system with the bed drain only. Fine circulating particles (<300 microns) passing through
U-beams are completely collected by the MDC and leave the system with the bed drain
and MDC ash hopper purge.
Fine particles that are essentially not collected by U-beams are collected by the MDC and
are not retained in the dense bed. Fine particles 70 - 100 microns (normally) & 100-150
microns (occasionally) leave the system through the MDC ash hopper purge and exit with
the gases leaving the MDC.
c) During steady state conditions the amount and size distribution of solids fed and then
transformed in the CFB process are balanced with solids losses.
The following governs distribution of solids flows within the system and solid losses:
The solids flow at U-beam inlet is maintained for the furnace temperature control.
The inventory of coarse particles in the primary zone is controlled by the bed drain rate.
When no bed drain recovery/recycle is provided, useful solids particles are drained
through the bed drain together with coarse particles. A certain minimum bed drain rate is
needed for most fuels to insure purging of the oversized bed material that includes shales
and stones to maintain the bed bulk density 1000 - 1100 Kg/m3 and lower furnace dP/
middle dP/ Furnace primary zone dP.
SECTION B PAGE 40
Flow and size distribution of solids passing the U-beams depend on the solids flow at the
U-beam inlet and the U-beam efficiency. This solids stream consists of fine particles and
fine circulating particles not collected by the U-beams.
Fine circulating particles and some of the fines are collected by MDC. When the solids
inventory in MDC hoppers increases to the high level, the excess quantity including both
the fine circulating and fine particles, is lost through the MDC ash hopper drain. The fine
circulating particles that are recycled back to the furnace leave the system through the
bed drain.
Fine particles escapes from the MDC are collected by ESP.
If the inventory/solids generation in the boiler is lower than required and to make up the
losses while burning fuels with low solids (e.g. low-ash and low-sulfur coal), addition of a
make-up material (limestone, crushed refractory) may be required to maintain the solids
inventory for CFB unit operation. To reduce the amount of the fresh makeup material, bed
ash & fly ash recycle system may be used depends upon the quality of ash material. With
bed ash and fly ash recycle arrangement, no useful solids will be lost from the system
except the ash that is leaving MDC to ESP.
SECTION B PAGE 41
2.2.1.1 Furnace Inventory Control

The most important inventory control area is the furnace inventory control. The furnace
inventory control includes three controlled variables:
• Shaft inventory measured by the Shaft dP / Upper dP (DPT-1049A/B)
• Primary zone inventory measured by the middle dP/ Furnace primary zone dP
(DPT-1048A/B)
• Total furnace inventory, i.e. the sum of the primary zone and shaft inventory
The control actions and their interrelation are described below:
i) Shaft Inventory Control

The furnace inventory control requirements are determined primarily by the shaft
inventory (or Shaft dP/Upper dP) needed for the furnace temperature control which is
controlled by changing MDC recycle or primary air ratio, as has been described in the
Furnace Temperature Control section (Section 2.1). Changes of Shaft dP/Upper dP are
SECTION B PAGE 42
interrelated with the inventory in MDC hoppers. For example, when MDC recycle is
increased to increase Shaft dP/Upper dP, according to the lower furnace temperature
control, the solids are transferred from MDC hoppers to the furnace. When MDC recycle
is reduced to decrease Shaft dP/Upper dP, the inventory is not recycle to the furnace
then it will be collected in the MDC hopper whenever the hopper level is above its high
limit will be purge out through the overflow.
When primary air ratio and/or excess air is increased, it results in transfer of some
solids inventory from the primary zone to upper zone. Subsequently, the solids flow at
the U-beam inlet increases thus increase the furnace heat transfer and reduce the
furnace temperature to some extent.
ii) Primary Zone Inventory Control

The primary zone inventory (middle dP/ Furnace primary zone dP) is controlled by bed
drain flow in case of self-sufficient solid built up in the furnace. If not make up bed
material/limestone to be added as required to maintain the dP. Middle dP/ Furnace
primary zone dP must not be allowed to drop below a minimum level which is required
for adequate fuel-solids mixing and proper combustion conditions in the primary zone.
Typically, minimum middle dP/ Furnace primary zone dP shall not be less than 600
mmH2O.
Also middle dP/ Furnace primary zone dP shall not be above 800 mmH2O at full load.
The middle dP/ Furnace primary zone target dP and maximum dP values are
established as functions of boiler load and normally increase with the load reduction as
well as consideration of reduction/ optimization of the primary air fan power
consumption established during boiler tuning.
iii) Total Furnace Inventory Control

When total furnace inventory reaches its predetermined maximum limit, bed drain flow
increases to control total furnace inventory regardless of the middle dP/ Furnace
primary zone dP level. If, in this situation middle dP/ Furnace primary zone dP falls
below Minimum level 600 mmH2O, boiler load shall be reduced suitably to avoid
problems with combustion.
SECTION B PAGE 43
Boiler dP Curve- Indian Coal

(Typical Indicative Curve)
1000
900
Bubble Cap dP (mmwc); Furnace Primary Zone dP
800
(mmwc);Upper Furnace/Shaft dP (mmwc)
Furnace Primary
700
Zone dP
600
500
400
Bubble Cap dP
300
200 Upper Furnace/

Shaft dP
100
0
10 20 30 40 50 60 70 80 90 100
Load (%)
Bubble Cap dP Furnace Primary Zone dP Upper Furnace/ Shaft dP
operating condition
SECTION B PAGE 44
2.2.1.2 Bed Drain Control

During boiler operation, higher size ash particles get collected in the bottom of the bed
which will increase the bed bulk density. Whenever the bulk density increase more than
design limit it warrants increase in primary air to keep the bed fluidizing and maintain
the bed temperature. Hence bed ash bulk density must be measure at regular interval
and drain the bed ash to maintain bed bulk density i.e.<1200Kg/m3. While draining the
bed ash along with courser particles fine particles also drained out. To maintain the
required bed height and furnace inventory ash recycle from the MDC to be increased or
from make-up bed bunker.
Gradual increase in wind box pressure and middle/ lower furnace dP without increasing
the PA flow indicates the increase in bed bulk density / bed height. To have a control
on the bed height the bed need to be drained periodically through the ash coolers.
The bed drain flow is controlled by varying the frequency of operation of bed ash
coolers. Cooler operation depend upon the pre-determined middle dP/Furnace primary
zone dP/ total dP.
Cooler operation can be classified as follows
• Manual Mode
• Semi-Automatic Mode
• Automatic Mode
Manual Mode: In manual mode of operation, each valve of the ash cooler has to be
operated individually using their respective Open Push button in a sequence. All ash
cooler valves (except Bed drain valve) remain open for a preset time and closes
automatically after the timer is elapsed. The protection interlocks are in line during
manual mode of operation.
Semi Automatic Mode: In Semi Automatic Mode, each valve of the ash cooler operates
in automatic predetermined sequence. However the start of the sequence shall be
triggered individually using their respective cooler sequence command from DCS.
Automatic Mode: In Automatic Mode, each valve of the ash cooler operates in
automatic predetermined sequence. However the start of the sequence shall be
triggered through preset middle dp/Furnace primary zone dP.
Refer section 3.7 for detailed BAC operation.
2.2.1.3 MDC Recycle (MDCR) Control

The functions of the MDC solids recycle in a CFB process are:
Maintaining the inventory of circulating material in the furnace as required for

desirable furnace heat transfer by reducing the loss of useful circulating particles
to the ESP.
SECTION B PAGE 45
Controlled feeding of inventory from MDC to furnace as per the bed temperature and
Shaft dP/Upper dP.
Prior to initiate the MDC recycle system lineup the dampers & valve as described in walk-
down checks section 1.1.2.
OPERATIONAL SEQUENCE
• PA hot air inlet damper UV-1060 will open in auto when SA fan starts.
• Maintain PA air pressure at airslider, 200-250mmWC more than wind box pressure
• Open the MDC RAV inlet KGV (UV-1061A/1062A).
• Start corresponding MDC RAV.
• Ash will start sliding into the furnace via airslide. Monitor airslide skin
temperature.
• Run MDC RAV as per boiler load requirement.
• Monitor and maintain the bed temperature and main steam pressure as per load
condition.
MDC recycle is controlled by changing the speed of RAV installed at the MDC hoppers
discharge. A target MDC recycle value, preset as a function of boiler load, is adjusted
by demand to provide a set point for the recycle RAV control.
The MDC Recycle control is subject to the following limits:
i) MDC recycle shall not exceed its maximum limit, except for a limited time (not longer
than a predetermined period) if needed for the control purposes. The value of the
maximum limit is determined based on process performance requirements (heat
transfer, combustion efficiency and sorbent utilization) and an acceptable erosion rate
of convection heating surfaces which depends on the solids loading in flue gases. After
a predetermined time limit is reached, MDC recycle shall be ramped down to its
maximum limit, and other means of the bed temperature control shall be employed.
ii) MDC recycle shall not be below its minimum limit, which is a preset empirical
function of boiler load. The minimum limit is established based on combustion/sorbent
utilization considerations. This limit is applied only when MDC hopper level is at or
above its high limit i.e. MDC solids are being purged.
iii) MDC recycle cannot be increased when middle dP/ Furnace primary zone dP or Total
dP are at their respective maximum level and it cannot be decreased when middle dP/
Furnace primary zone dP is at or below its minimum limit.
iv) MDC recycle is reduced when MDC hopper level is at or below its low limit. In this
case MDC recycle is actually controlled by the requirements of the MDC hopper level
control.
SECTION B PAGE 46
v) MDC recycle shall be stopped if MDC hopper level reaches its “Low-Low" value. In
such a case the operator would be required to reduce boiler load or feed bed inventory
from the make-up bunker and take measures to correct this abnormal condition.
Caution:
Do not allow wet / moist ash to enter airslide.
In case of tube failure, isolate the MDC outlet RAV immediately and drain
the ash through the bypass arrangement.
2.2.1.4 MDC Hopper inventory Control

At a steady state condition, in case MDC hopper level is at or above its high limit, solids
are purged from MDC hoppers through the over flow connection. When MDC recycle is
increased to control shaft dP/Upper dP, MDC hopper level drops below its high limit and
the purge stops. If MDC hopper level reaches or goes below its low limit, rate of MDC
recycle is to be reduced until MDC hopper level is above its low limit.
If Low-Low level occurs, the corresponding MDC RAV will trip and the addition of make-
up material is needed to maintain the furnace inventory at the target level. The
addition of make-up material should bring Shaft dP/Upper shaft dP to the required level
with MDC hopper level not exceeding its high limit, i.e. no solids are purged from MDC
hopper. In this case MDC hopper level is maintain between its high and low limits by
balancing the make-up material flow rate (feed from inert bed silo and/or adjustment
to limestone feed rate) and bed drain flow, while maintaining the desirable Shaft
dP/Upper shaft dP value. In certain cases the transition to the make-up feed mode can
be avoided by changing limestone size distribution/properties or coal size distribution
(mainly, for high-ash coals). In this case, the input of circulating particles shall be
increased, and inputs of coarse and fine particles shall be reduced.
2.2.1.5 Make-up Material Control

When burning low-ash and low-sulfur coal or in case of abnormally low MDC efficiency
(worn out collection elements), solids input with fuel ash and limestone may be less
than solids losses from the system i.e. total of solids in gas leaving from MDC to ESP
and bed drain purge. In this case, addition of make-up material from an inert bed silo
may be used. The necessity of the make-up feed is signaled by reduction of Shaft
dP/Upper shaft dP and low level in MDC hoppers, as described above (section
2.2.1.4).The make-up feed rate shall be governed by boiler control system as needed
for shaft differential pressure and lower furnace temperature control while avoiding
solids purge from MDC hoppers.
The inert bed silo should be maintained in as full status as possible by storing recycle
from bed drain material (classified and/or sieved). If solids input to the silo with all
recycled streams is less than the make-up requirement the silo is to be filled with solids
from some external source, e.g. with purchased bed material with the proper physical
and chemical properties, to provide continued supply of material needed for adequate
furnace inventory control.
SECTION B PAGE 47
2.2.1.6 Limestone Feed Control

The limestone feed rate is established in proportion to the measured fuel flow to
provide the expected Ca/S ratio for the target SO2 capture. The limestone input is
corrected based on the difference between the measured and target SO2 values. Close
watch of these values should he maintained to avoid excessive limestone consumption.
While limestone feed rate affects overall solids inventory, and thus can be used as a
means for solids inventory control, such a use is generally discouraged. This is due to
typically higher cost and lesser effect on the solids inventory than that of properly sized
spent bed material or sand. Another potentially detrimental impact of overfeeding
limestone on boiler performance is its catalyzing effect on oxidizing nitrogen
compounds released with fuel volatiles to NOx.
2.2.2. Solids Particle Size Control

Adjustment of the solids size may be needed when the furnace temperature and/or
solids inventory cannot be maintained within the allowable limits using control actions
as described above.
Bed material size and distribution of particles of different sizes in a CFB system depend
on:
1) Fuel, limestone and make up Bed material size distribution and attrition
characteristics.
For low ash coal and Petcoke, the fuel size distribution may not have a strong
effect on the size of circulating bed material. Fuel sizing may affect the content
of oversized particles (shale’s & stones) in the dense bed.
For high ash coal, the coal ash makes up a considerable part of the circulating
inventory as well as non-entrainable particles. In this case, coal sizing may
strongly influence the bed particle size distribution.
Limestone size distribution has a major effect on the inventory size for low ash
coals and Petcoke.
Inert make-up material sizing has a major effect when the make-up is needed
for the inventory control.
2) CFB system parameters:

U-beam efficiency
Multiclone dust collector efficiency
Multiclone recycle rate
Bed drain rate
SECTION B PAGE 48
Bed material sizing affects CFB operation as follows:

1. Increasing the input fraction of coarse (larger than 600 microns) and coarse
circulating (300-600 micron) range particles results in increased primary zone dP for
a given MDC recycle rate.
2. Input fraction and mean size of coarse and fine circulating (74 to 300 micron)
particles has a strong influence on the mean size of solids circulating through the
furnace. Reduction of the solids mean size allows achieving higher heat transfer in
the furnace (lower furnace exit gas temperature) for the same furnace pressure
differential.
3. Increasing the input fraction of fine particles (smaller than 75 micron) increases the
convection pass solids loading and solids losses to the final dust collector (ESP) and
should be minimized.
4. Increasing the MDC purge, by reducing MDC recycle flow, results in coarser bed
inventory circulating through the furnace. The reverse is also true.
5. Rate of bed drain/frequency will change the size of solids in the dense bed and
therefore, will affect relationship between the middle dP/ Furnace primary zone dP
or the total furnace inventory.
SECTION B PAGE 49
2.3 BED ASH ALKALI CONTROL

(REFER FOR BIOMASS AND LIGNITE FUELS ONLY)
Bed chemistry needs to be monitored as the fuel bound alkalis like Fe2O3, Na2O, K2O etc. may
cause fouling of heat transfer sections and result in low heat pick-up and loss in efficiency. Also
whenever the iron volume in bed ash exceeds the limit, the bed will become heavy which may
call for higher windbox pressure operation. With higher windbox pressure than specified there
will be fast erosion of bubble cap & furnace wall refractory. Whenever the alkali concentration
increases more than safe limit there could be possibility of bed agglomeration. Hence serious
attention to be given for the control of alkali elements during normal operation the boiler plant.
Following are the guideline for the bed chemistry control
1. Regular analysis of bed ash for Fe2O3, Na2O, K2O Sieve analysis, bulk density etc.
2. Minimise the concentration of alkali in the bed by draining the concentrated bed ash and
additional of fresh bed material.
3. Analyse bed ash for following parameters to decide draining frequency and rate;
♦ Iron Oxide (Fe2O3) : < 4%
♦ Na2O + K2O : < 5%
♦ Bed ash sieve distribution should be 100% less than 500 microns
♦ Bed ash bulk density should be :<1200Kg/m3
SECTION B PAGE 50
3 BALANCE OF PLANT START UP

• Deaerator charging
• SWAS system
• LP/ HP Dosing
• Ash handling system
• Air preheater
• ESP
• Bed Ash Cooler
• Bed Ash Recycle system
3.1 DEAERATOR CHARGING (CUSTOMER SCOPE)

The procedure for placing the deaerator in service is outlined below:
It always recommended that the deaerator has to be taken in line as soon as the LP
steam is made available from source. It is also recommended to take deaerator in
operation, as soon as the boiler firing is stabilised, so that the risk of corrosion and pitting
of economiser is minimised.
• Line up all the instruments on deaerator system.
• Open the vent valve at the vapour tank to atmosphere.
• Fill the deaerator slowly through the makeup water inlet connection by opening the
deaerator level control valve. Watch the water level in the level gauges and ensure that
the gauges are indicating the correct water level. Cross check with the level indication
available at control room through the level transmitter. Stop the water supply to the
deaerator when normal water level has reached.
• Charge the steam up to the pressure control valve to warm up the line and keep the
steam readily available for charging into deaerator. Once, water level has attained NWL,
slowly admit the steam into deaerator through the pegging steam line. Whenever the
water temperature reaches 60 to 70 0C, deaerator is ready for charging the steam
through main supply line.
• Maintain the level before admitting the steam through the main supply line. Level may
be maintained well above the very low level and below the center line of the tank. Due
to direct scrubbing of steam with warm or cold water there may be little hammering or
vibration in the storage tank. By keeping the low water level, quantity of water in the
storage tank will be less and less steam will be required initially to heat it. Thus vibration
or hammering can be reduced while pressurizing the deaerator. Keeping low water level
will have to be done manually watching the level in the direct level gauge and by
maintaining the water intake manually, as the level transmitter will be out of its range.
• Charge steam gradually by opening the pressure control valve, water will be heated up
and steam will start coming out of the vent. Whenever the steam vapour start flows
increase the steam flow (slowly) and maintain the pressure as per the desired value.
• Along with steam, increase water flow simultaneously but gradually. Objective is to
maintain Normal Water Level and to increase deaerator pressure up to the required
SECTION B PAGE 51
value. Once there is considerable rise in temperature, admitting of steam in more

quantity will not cause hammering in the deaerator.
• Water and steam intake should be synchronized so that at no point of time deaerator
pressure shall go beyond the pressure above the desired limit and to vacuum pressure.
More steam flow will lead to increase in deaerator pressure and less steam flow than the
requirement for the water flow will lead to condensing of steam and will result into
reduction in deaerator pressure, even to vacuum pressure.
• As the deaerator pressure increases the water temperature will start increasing. If the
water outflow from deaerator is faster, then the temperature rise will be faster.
• Once the level and pressure are reached the set values the controllers can be put into
auto. Temperature will reach automatically to the operating value.
In the event of taking the deaerator into line, if abnormal hammering or vacuum
situation is created, stop admitting the steam and repeat the whole charging process.
3.2 SWAS SYSTEM
Prior to taking sample in the system, process lines need to be flushed; also these lines
need to be flushed on periodic basis during operation.
Prior to passing the process samples through the sample coolers ensure specified quality
of cooling water at rated pressure is circulated through the sample coolers.
3.3 DOSING SYSTEM
Before start of the boiler, ensure the dosing systems valves are lined up as per “System
Line up procedure”. Also ensure that pump suction filters are clean.
Prepare recommended concentration solution of Trisodium Phosphate (5%) in HP. &
Hydrazine solution in LP Dosing tank.
Start the dosing pumps and adjust the dosing rate based on water analysis report, aim is
to maintain recommended water chemistry in feed & boiler water. Operate tank stirrer
periodically.
Refer supplier instruction manuals for safe operation and maintenance of
dosing system.
Caution: Whenever dosing is to be stopped, flush the dosing piping upto steam
drum and deaerator by pumping fresh water for cleaning the pump internals
and piping.
3.4 ASH HANDLING SYSTEM

Fly ash handling system shall be started one hour prior to solid fuel firing, whereas bed
ash handling system can be operated as per process requirement.
Ref. Ash handling system O & M manual for details.
SECTION B PAGE 52
3.5 AIR PRE HEATER

When the boiler backend flue gas temperature increase above 140 °C or depend upon
sulphur dew point, APH to be taken in line. Opening of APH inlet (HCV-1023A/1025A) &
bypass damper (HCV-1023B/1025B) to be adjusted in such a way to maintain the gas
outlet of APH above 140ºC or above sulphur dew point temperature.
Opening and closing of APH inlet (HCV-1023A/1025A) & bypass damper (HCV-
1023B/1025B) will be initiated in auto mode based on the ESP inlet flue gas temperature
(above 140 ºC) set point.
APH Tubular heater elements are susceptible to fouling due to fly ash accumulation,
particularly at the cold air inlet to the air heater and near the exit of flue gas from Air Pre
Heater, sometimes also observed corrosion due to condensation of the flue gas, acid
constituents within the ash, which become corrosive in the presence of moisture & fire
occurring in the gas path by the deposition of large quantities of unburned combustible
materials within tubes and on the tube sheets. Above conditions can be minimised by
keeping the tube surface free of deposits through proper combustion and by maintaining
safe flue gas temp. i.e. above 140ºC at APH exit.
CAUTION:
Ensure the evacuation of ash from the APH ash hopper regularly; if the Ash is
allowed to build up inside the hopper, the hopper may lead to plugging of APH
tubes and tube failure due to gas condensation and corrosion.
Apart from failures the efficiency of APH will be deteriorated which results into
reduction in efficiency.
3.6 ELECTRO STATIC PRECIPITATOR (ESP)

Rapping mechanism should be started one hour prior to start the firing.
Hopper and insulator heater should be “Switched ON” prior to start-up of boiler & the
temperatures to be maintained as specified in supplier manual.
ESP shall be charged after attaining the required flue gas temperature at 140ºC or depend
upon sulphur dew point. Opening percentage of APH inlet damper (HCV-1023A/1025A) &
bypass damper (1023B/1025B) will be adjusted through auto logic in such a way to
maintain the gas outlet of APH at 140ºC or above sulphur dew point temperature.
However in case of disturbance in normal operation of the boiler, it is advised to switch off the
transformer.
Ref. ESP O & M manual for details.
SECTION B PAGE 53
3.7 BED ASH COOLER (BAC)

Ash coolers are provided to cool the bed ash to the desired temperature prior to dispose
to ash handling system.
Ash cooler can be operated either in manual or in auto mode.
Bed Ash cooler sequence will be initiated in auto mode based on the middle shaft dP set
point. Number of cooler in operation shall be selected by the operator. Cooler can be
selected for manual operation as per the operator convenience.
Prior to initiate the bed ash cooler sequence lineup the dampers & valves as described in
walk-down checks section 1.1.2.
Note:
For detail Bed Ash Cooler logic and write-up, refer Volume-3
MANUAL OPERATION
While initiating the cooler Manual operation following sequence is to be followed:
• Open Cooling Air Valve (UV-1051/1054/1057) to BAC (Secondary air from SA fan). This
valve will close after cooling cycle time of 25 minutes. (Will be set during
commissioning).
• To open cooling valve, following interlocks shall be satisfied.
a. Close PB for cooling valve is not actuated
b. Manual mode is selected.
• When Cooling Air Valve ‘Open Feedback’ is available, open bed ash drain valve
(LCV-1050/1053/1056). To open bed ash drain valve, following interlocks shall be
satisfied.
a. Cooling air valve is open.
b. Furnace drain valve close P.B. (HSC-1051) is not operated.
c. Manual mode is selected (HAS-1051).
d. Ash cooler bed level not high.
e. Emergency Stop not operated
• Regulating Furnace drain valve (LCV-1050/1053/1056) shall be opened in three steps,
First 15 sec at 100% opening then next 15 sec at 30% opening and further 15 seconds
at 100% opening. (will be set during commissioning).
• Bed drain valve will close after a specified third pulse timer (15 sec, will be set during
commissioning).
• Since the cooling air valve is in open condition, bed ash inside cooler will be cooled.
• Whenever the ash temperature is dropped safe enough for disposal (<160 °C), ash
cooler drain line KGV (UV-1052/1055/1058) should be opened to dump the ash to the
SECTION B PAGE 54
handling system. This valve close after a specified time interval (2mins). To open cooler
drain valve, following interlocks shall be satisfied.
a. Manual mode is selected
b. Furnace drain is closed and cooling air valve open
c. Ash cooler temperature is less than 160°C.
d. Ash cooler drain valve close P.B. not operated.
e. Ash cooler bed level not low
f. Emergency stop not operated.
• Once the bed draining from the cooler is completed the cooling air valve will close.
NOTE:
1. Ensure the ash handling system is lined up and in healthy operating conditions.
AUTO OPERATION
Bed drain and bed ash cooling sequence will initiate automatically to maintain the following
conditions:
• Middle dP/ Furnace primary zone dP set point (760 mmH2O - Set during commissioning
trials)
NOTE:
1. Operator to select the coolers to be operated in auto mode as per process
requirement.
2. Ensure the ash handling system is lined up and in healthy operating conditions.
For Bed Ash Cooler auto sequence, following interlocks to be satisfied.

a. Auto mode is selected
b. Sequence is reset (to ensure that previous cycle had successfully completed in
auto Mode)
c. Emergency trip PB is not pressed.
d. “Auto Sequence start PB (HSB-1051) is pressed by Operator” OR “Auto Seq. Start
from Furnace Bed level control is high”.
During Auto sequence following operations takes place:

• Cooling air to ash cooler damper (UV-1051/1054/1057) will open for cooling cycle time
of 25 minutes (Will be set during commissioning).
• After a specified time delay, regulating furnace drain valve (LCV-1050/1053/1056) shall
be opened in three steps, First 15 sec at 100% opening then next 15 sec at 30%
opening and further 15 seconds at 100% opening. (will be set during commissioning).
SECTION B PAGE 55
• Bed drain valve will close after a specified third pulse timer (15 sec, will be set during
commissioning).
• Cooling air to ash cooler damper remains open till the ash temperature drops to desired
limit.
• Whenever the ash temperature drops to safe disposal limit (<160 Deg°C), ash cooler
KGV (UV-1052/1055/1058) opens automatically to dump the ash to the handling system.
This valve closes after a specified time interval 2 mins. (Will be set during
commissioning).
• Once the bed ash draining from the cooler is completed the cooling air valve
(UV-1051/1054/1057) will close.
• The entire bed ash cooling system will be operated from the DCS in sequence on
selection of BAC and auto-start command.
SEMI-AUTO SEQUENCE
In semi auto mode operator to initiate bed drain and cooling sequence start command
instead of auto-start command through logic and the sequence will be completed through
auto logic.
CAUTION
• Do not open Access doors on the bed drain system unless it is isolated and
depressurized
• Ensure the evacuation of ash from the Ash cooler outlet duct swirler and APH ash
hopper regularly, failing may cause mal operation/ non operation of ash cooler.
3.8 BED ASH RERCYCLE SYSTEM

During imported coal firing it is not possible to maintain the solid concentration in furnace due
to the low ash content in the coal. Hence we need to add recycled bed ash to maintain the
required solid concentration. In order to facilitate addition of bed ash, a recycling system has
been provided.
Above system will be operated only when imported coal is fired. However the system has the
flexibility to capture bed ash while firing Lignite, which can be stored and utilized as and when
required.
GENERAL PRINCIPLE OF OPERATION:
The operation of the system is quite simple. In level probe mode, level sensing probe provided
in the product buffer / reject buffer hopper above transfer vessel shall sense the presence of
material in the hopper and initiate the conveying cycles. Dome valve shall open and allow the
material to gravitate into the transfer vessel for a preset time & then close automatically. On
closure of dome valve, its seal get inflated and signals the conveying air injection into the
transfer vessel. The vessel gets pressurized and material resistance help pressure build up and
SECTION B PAGE 56
conveys the material through steel piping to the destination silo. When conveying is completed,
the pressure drops down and is sensed by the control system, the air supply to the system is
stopped and the cycle is completed. The transfer vessel is ready for the next cycle.
The total system is made automatic by use of level probe in destination silo to control the
transfer of material. Complete system is flexible enough and programmable and automatically
operated through a PLC based central control panel.
OPERATION
During imported coal firing diverter valves will be operated to pass the ash in to the Feed Bin.
Same shall be operated by level switch contact through PLC. At any time flow from only 2
conveying lines will be diverted to the intermediate silo.
Ash flow to the intermediate silo will continue till the intermediate silo level reaches high. When
intermediate silo level reaches high, ash entering to the intermediate silo has to be stopped and
will be taken in to the bed ash silo.
Start permissive will be provided to RAV & vibrating screen, based on the intermediate silo level
and fresh bed material make-up silo level healthy. Standby system can be started by operator in
case of problem in the working system. Thus 500 micron size bed ash is collected in the Product
buffer hopper.
Pneumatic conveying of the ash from buffer hopper will be controlled based on the level high
signal from the buffer hopper & will continues till the fresh bed material make-up silo level
reaches high. Fresh bed material make-up silo high level trip is provided to trip the rotary
feeder below the intermediate silo, vibrating screen & ash conveying vessel.
Pneumatic conveying of the ash from Reject Hopper will be controlled based on the level high
signal from the Reject Hopper & will continue till the bed ash silo level reaches high.
SECTION B PAGE 57
4 CONTROLS
Boiler is provided with various controls to ensure safe, efficient and reliable operation of the
plant. This section provides brief description of various control loops, for detail refer vol-3
section under control schematic narrative.
Following are the major control loops employed in the boiler plant operation;
• FURNACE PRESSURE
• DRUM LEVEL
• S.H. STEAM TEMPERATURE
• AUTO COMBUSTION
• EXCESS AIR CONTROL
• BED LEVEL CONTROL
• BED TEMPERATURE CONTROL
• U-BEAM TEMPERATURE CONTROL
• PRIMARY AIRFLOW CONTROL
• OFA FLOW CONTROL
Caution: Though the controls monitor the operation in auto mode, control room
operator must be alert and vouch for any upset and disturbances in the process to
save the boiler from tripping and damage.
3.9 FURNACE PRESSURE CONTROL

Function of the control loop is to maintain the furnace pressure at the desired limit, during the
boiler operation. Signal from the pressure controller modulate the ID fan speed or fan inlet
damper opening to maintain the furnace draft. Control can be operated either in manual or
automatic mode depends on the process requirement. Furnace pressure set point for auto
control can be varied depends on the process requirement. Control to be switched over to auto
mode after the stabilization of firing. During bed activation, slumping and disturbed operating
conditions, control may be switched over to manual mode as the air and gas flow may vary
drastically & abruptly during such conditions.
3.10 DRUM LEVEL CONTROL

Function of the control loop is to maintain the drum water level at the desired limit, during the
boiler operation. Signal from the level controller modulate the 30% or 100% feed water flow
control valve opening (depends on the valve selection i.e. 100%) to maintain the drum level.
For drum level control, two types of controls are provided in the boiler, i.e. single element and
three element controls. Single element control is employed during cold startups and steam flow
less than 30% of MCR flow conditions. Three element controls is a fine control, which work
effectively on higher and steady load conditions. Three element controls can be switched over
to auto mode after steady and steam flow is ensured. Both 30% and 100% control valves can
be operated either in manual or automatic mode depends on the process requirement.
SECTION B PAGE 58
3.11 SUPERHEATER STEAM TEMPERATURE CONTROL

Function of this control loop is to maintain the final steam temperature at the desired limit
during the boiler operation. Two stage attemperation is provided between PSH-I outlet & PSH-II
inlet & PSH-II outlet & SSH inlet for the fine control of main steam temperature. Signal from the
temperature controllers modulate the attemperator spray control valve (TCV-1010A/1011A)
opening to maintain the steam temperature. Control can be operated either in manual or
automatic mode depends on the process requirement. Steam temperature set point for auto
control can be varied depending on the process requirement. Controllers to be switched over to
auto mode after the steady steam flow (>60% MCR) is established. During disturbed operating
conditions, controllers may be switched over to manual mode as the steam temperature may
vary drastically & abruptly during such conditions.
3.12 AUTO COMBUSTION

Function of the control loop is to maintain rated pressure of final steam during the boiler
operation. Signal from the pressure controller regulate the air flow & fuel feed rate to maintain
the desired steam pressure. Control can be operated either in manual or automatic mode
depends on the process requirement. Pressure set point for auto control can be varied depends
on the process requirement. Control to be switched over to auto mode, whenever the steam
flow is increased above 60% MCR and boiler operation is stable. However close observation
may be required as it may be difficult to maintain the final steam pressure as per the predicted
values during upset conditions like heavy bed, continuous variation in fuel quality and
fluctuating steam demands. If required controller can be switched over to manual mode as per
the process requirement.
3.13 EXCESS AIR - O2 CONTROL

Function of the control loop is to maintain the excess air at the desired limit during the boiler
operation. Signal from the O2 controller regulate the fan speed to supply the required air flow
to maintain the excess air depends on the steam flow and fuel being fired. Control can be
operated either in manual or automatic mode depends on the process requirement. O2% set
point for auto control can be varied depends on the steam flow and quality of the fuel being
fired. Control to be switched over to auto mode whenever the steam flow is increased above
60% MCR and boiler operation is stable. However close observation may be required as it may
be difficult to maintain the O2 as per the predicted values during upset conditions like heavy
bed, moist fuel and fluctuating steam demands.
3.14 BED LEVEL CONTROL

Function of the control loop is to maintain the required bed level during the boiler operation.
Signal from the bed level control initiate the bed ash cooler operation and stop the cycle as per
the preset time. Ash cooler operation/sequence can be activated either in manual or automatic
mode depends on the requirement. Bed level set point for auto control may be varied depends
on the steam flow. Control can be operated in auto mode, however close observation of the
furnace and drained bed material may be required to optimize the draining frequency.
SECTION B PAGE 59
3.15 BED TEMPERATURE CONTROL

Function of the control loop is to maintain the bed temperature as per the steam flow & fuel
being fired. Signal from the bed temperature control regulate the speed of MDC ash recycle
RAV (M-1049A/B) & air flow to furnace.
If bed temperature reaches to its alarm limit, the alarm shall be activated; fuel feeders will
rundown by 5% every 5 minutes following the alarm till the bed temperature comes to the
normal value. Fuel feeder shall get trip if bed temperature reaches to very high limit. (1000 °C)
3.16 U BEAM TEMPERATURE CONTROL

Function of the control loop is to maintain the U Beam temperature as per the design limit.
Signal from the average U Beam temperature control regulate the speed of the fuel feeder.
If U beam temperature reaches to its alarm limit, U beam high alarm shall be activated; fuel
feeders will rundown by 5% every 5 minutes following the alarm till the even temperature
comes to the normal value. Fuel feeder shall be tripped if the average U Beam temperature
raised to high limits.
3.17 PRIMARY AIRFLOW CONTROL

Function of the control loop is to maintain the required PA flow to windbox during the boiler
operation. Once the boiler load reach above 60% MCR switchover the PA flow to windbox
controllers to automatic control mode. In auto control PA to windbox control dampers
(FCV-1026A/B) will regulate primary air flow as per remote set point generated by steam load
demand.
3.18 OFA FLOW CONTROL

Function of the control loop is to maintain the required OFA flow during the boiler operation.
Once the boiler load reach above 60% MCR switchover the OFA flow to furnace controllers to
automatic control mode. In auto control OFA control damper (FCV-1024) will regulate OFA flow
as per remote set point generated by steam load demand along with Oxygen (O2) trimming.
SECTION B PAGE 60
4 EMISSION CONTROL
To control emissions from boilers and combustion processes to the desired limits, boiler
operation needs to be optimized. Emission gases includes sulfur dioxide (S02), nitrogen oxides
(NOx), carbon monoxide (CO), hydrocarbons and particulate matter.
CONTROL OF SULFUR DIOXIDE EMISSIONS
SULPHUR DIOXIDE CONTROL – WHY?

When gaseous SO2 combines with moisture it forms dilute solution of sulphurous acid (H2SO3).
Sulphurous acid can easily oxidize in the atmosphere to form sulphuric acid (H2SO4). Dilute
sulphuric acid is a major constituent of acid rain and also lead to sulphur dew point corrosion on
boiler downstream equipments like: APH, ESP, ID Fan etc.
SULPHUR DIOXIDE CONTROL

When sulfur bearing fuels are burned, most of the sulfur is oxidized to SO2, a gas, which
becomes one of the constituents of the flue gas. When limestone is added to the bed, it
undergoes a transformation called calcination to form lime (CaO), a solid, which in turn
reacts with the SO2 in the flue gas to form calcium sulfate (CaSO4). The calcination reaction
is endothermic and is described by:
CaC03 (s) + 193Kcal/kg (of CaCO3) - >CaO(s) + CO2 (g)
Once formed, solid CaO reacts with gaseous SO2 and oxygen to form CaSO4 according to
the following exothermic reaction:
SO2 (g) + 1/2 02 (g) + CaO (s) - > CaSO4 (s) + 1696Kcal/kg (of S)
The resulting calcium sulfate is a chemically stable solid at CFBC operating temperatures and
is removed from the system for disposal. Sulfur dioxide reductions of 90% are typically
achieved in a CFBC boiler with calcium to sulfur (Ca/S) molar ratios of 2 to 2.5, depending on
the sulfur content of the fuel and the reactivity of the limestone.
In general the lower the sulfur concentration in the fuel, the greater the calcium to sulfur
molar ratio must be for a given SO2 removal efficiency. For removal requirements greater
than 90%, the amount of limestone needed must be increased, and for removal efficiencies
less than 90 percent less limestone is required.
The quantity of limestone fed to the boiler depends upon the physical properties & reactivity
of limestone, sulphur content in fuel and boiler operating parameters corresponding to SO2
concentration in the flue gas leaving the stack.
SECTION B PAGE 61
CONTROL OF NITROGEN OXIDES EMISSIONS

NOx emissions in CFBC boilers are influenced by various factors including nitrogen and volatile
matter in the fuel, furnace temperature, excess air & bed stoichiometry.
The nitrogen oxides that are present in flue gas come from two sources: the oxidation of
nitrogen compounds in the fuel and the reaction between the nitrogen and oxygen in the
combustion air. It is common to refer to the nitrogen oxides in the flue gas as NOx, where
the subscript “x” implies the presence of several different nitrogen/oxygen compounds. The
NOx formed by oxidizing fuel nitrogen compounds is referred to as fuel NOx and the NOx
formed from the nitrogen and oxygen in the combustion air is called thermal NOx, because
it is a product of a high temperature process (above 1482 °C).
The relatively low combustion temperature helps reduce NOx formation. As a result of the low
temperatures at which a fluidized bed operates, thermal NOx makes a minor contribution to
overall emissions. CFBC boilers are also designed to suppress the amount of fuel NOx
formed. This is accomplished by optimizing amount of combustion air through the windbox
(furnace bubble caps) and adding the remainder of the combustion air to the furnace above
the dense bed by way of the over fire air ports (secondary air). As a result of this staged air
admission process, some of the fuel nitrogen compounds released in the lower zones of the
furnace decompose into molecular nitrogen rather than forming fuel NOx. This air admission
process is referred to as staged combustion.
The degree of air staging is a function of the fuel, and the ratio of primary air to secondary
air. It is established when the boiler is designed to provide for both good combustion
efficiency and low NOx formation. In practice, the primary to secondary air ratio may be
adjusted, to a limited degree, to arrive at the best combination of fuel burnout and NOx
emissions.
CONTROL OF CARBON MONOXIDE AND HYDROCARBONS EMISSIONS

Maximum conversion of carbon monoxide to carbon dioxide in the furnace is achieved by
providing adequate mixing of fuel and air, furnace temperature and turbulence for the gas.
The design of furnace and the combustion air system (PA &SA) allows considerable residence
time & control, variation in the pattern of air distribution of the furnace. Like NOx, the primary
to secondary air split influences the burnout of CO and hydrocarbons, and may be adjusted
for the best results.
CONTROL OF PARTICULATES EMISSIONS

The particulates in a CFBC boiler system come from three sources: the fuel ash, make up
bed material and the limestone added for sulfur dioxide control. The ash contained in the
coal is released during the combustion process. Some of this ash remains in the fluidized
bed furnace and is discharged by way of the bed drain system. The remaining ash leaves
the boiler along with flue gas.
SECTION B PAGE 62
Coarse Fly ash is collected from the hopper below MDC and recycled back to furnace. Fine
fly ash in the flue gas after air heater is removed in the ESP to control the particulate
emission from the boiler.
SECTION B PAGE 63
5 HOT STARTUP
Average Bed Temperature ≥ 600°C (Imported coal / Lignite)
After boiler tripping, if average bed temperature is ≥ 600DegC, boiler can be restarted directly
with solid fuel feeding.
Note:
1. Windbox needs to be purged with steam as per the Windbox steam purging procedure”.
However air purging is not required if average bed temperature is ≥ 600DegC.
Below mentioned sequence to be followed to bring back the boiler into service during hot
startup.
• After completion of windbox steam purging, normalize the dampers in air and gas circuit.
• Normalize the drum level.
• Drain the bed through the bypass gate and observe for any large amount of unburnt/fresh
coal, if so continue the drain until clear bed material flows from the drain. If no unburnt coal
is observed in the drain, close the drain.
• Bring back all the fan and fuel feeder drives to the minimum speed/flow setting.
• Start the ID Fan, PA fan and SA fan as per fan start-up sequence described in boiler cold
start up procedure.
• Start PA fan and keep the PA air flow to windbox damper in close position.
• After PA fan, start the SA fan and normalise the DCF Seal air pressure (>425mmH2O).
• Open the PA air flow damper to windbox, adjust the PA flow to windbox 45 % of MCR
quickly and start the coal feeding.
• In case, bed temperature drops below 600°C, oil burner support can be taken to increase
the bed temperature before starting the coal firing.
• Open the start-up vent valve (EM-1018)
• Start the fuel feeders.
• Observe the rise in bed temperature.
• Stabilize the coal firing & normalize the boiler operation.
• Adjust the fuel and airflow to maintain the flue gas temperature at “U” beam inlet at 480ºC
till 20% of MCR steam flow is established through the superheater coils.
• Raise the boiler pressure to the rated pressure as per ‘Hot pressurization curve’.
Whenever the boiler rated pressure is attained, connect the boiler to CSDH.
SECTION B PAGE 64
Hot Start Up Curve
140.0
350
325 120.0
300
275
100.0
250
Sat Temp. (Deg C)
Pressure kg/cm2(g)
225
80.0
200
175
150 60.0
125
100 40.0
75
50 20.0
25
0 0.0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
Time in min
SECTION B PAGE 65
6 WARM START UP
Average Bed Temperature ≤ 600°C
OR
Average Bed Temperature ≥ 200°C
After boiler tripping, if average bed temperature is <600°C and ≥200°C, boiler cannot be
started directly with solid fuel feeding.
Note: Windbox needs to be purged with steam as per the Windbox steam purging procedure”.
Apart from steam purging, Furnace purging also need to be carried out as per “Furnace Purging
Procedure” (Refer section 1.1.6)
Following sequence may be followed to bring back the boiler into service.
• After completion of wind box steam purging, normalize the dampers in air and gas circuit.
• Start the ID fan, PA fan and SA fan as per fan start-up sequence described in boiler cold
start up procedure.
• Prior to start the burner; confirm the bed height to be 600 mm. If it is more, drain the bed
material and maintain bed height of 600 mm above the bubble cap.
• Carry out furnace air purge as per furnace purging procedure. Normalize the dampers in air
and gas circuit.
• Normalize the drum level.
• Open the startup vent valve (EM-1018)
• Start the over bed burner as per burner start up procedure.
• Adjust the oil flow and airflow to raise the bed temperature.
• Once the required bed temperature is attained, initiate the solid fuel firing as per the
procedure (refer section 1.1.8).
• Raise the boiler pressure as per warm start up curve.
• Whenever the boiler rated pressure is attained, connect the boiler to CSDH
SECTION B PAGE 66
Warm Start Up Curve

130.0
325 120.0
300 110.0
275 100.0
250
90.0
225
Sat Temp. (Deg C)
Pressure Bar (a)

80.0
200
70.0
175
150 60.0
125 50.0
100 40.0
75 30.0
50 20.0
25 10.0
0 0.0
0 20 40 60 80 100 120 140 160 180 200 220 240
Time in min
SECTION B PAGE 67
7 WINDBOX STEAM PURGING

During boiler tripping, there may a possibility of CO gas formation due to un-burnt fuel settled
at furnace bottom travels to the windbox through the bubble caps. CO gas is flammable when
sufficient air and temperature is made available, hence utmost care to be taken while re-
starting the unit in hot condition.
Post boiler trip i.e. blackout condition or PA fan trip condition, windbox need to be purged by
steam injection to remove the combustibles gas trapped inside the windbox if the average bed
temperature is higher than 200°C.
Steam purging can be initiated automatically by a preset timer or by operator interface.

Purging steam is sourced from saturated steam header from steam drum outlet.
System line up prior to initiate the purging:

• Ensure the steam trap station valves (PS-1001/1002/1003) provided in steam purging
line to windbox are open and bypass drain valve (PS-1004) is close.
• Ensure the flow control valve (HCV-1019) is kept open at the preset condition (during
commissioning trials).
Operation sequence
• The windbox damper (FCV-1026A/B) force closes automatically through control logic
during MFT condition.
• The steam purge valves (UV-1015/1016) opens. (Automatically through control logic
after 5 minutes of black out condition OR PA trip condition).
• Observe the windbox pressure and should be < 1100-1200mmH2O.
• The steam purging is carried out for 5 min.
• After 5 min the steam purge valves (UV-1015/1016) closes (automatically through
control logic).
• In case of over pressurisation of windbox >2000mmH2O, the steam purge valves
(UV-1015/1016) will close automatically through windbox pressure controller.
• The sequence will repeat every 10 minutes until bed temperature is less than 200°C or
main steam pressure is less than 3 kg/cm2 OR the unit is started.
• Windbox dampers (FCV- FCV-1026A/B A/B) are released for normal operations on PA
fan run feedback.
SECTION B PAGE 68
8 WINDBOX CO VENTING
To evacuate CO gases accumulated if any; inside the windbox during boiler tripping & blackout
windbox steam purging venting system is provided. To ensure complete evacuation of CO gases
from the windbox, system is also provided with a gas venting system through flue path to
chimney.
In case of boiler blackout or tripping of the PA fan, windbox venting will be initiated
automatically through logic by opening dampers (UV-1027) at windbox vent duct to APH
hopper. This damper position will prevail until restart of the PA fan.
After PA fan run feedback is available, damper (UV- 1027) at windbox vent duct to APH hopper
will close automatically through control logic after 7 mins of PA fan run feedback.
NOTE:
Ensure the evacuation of ash from APH ash hopper regularly; failing may lead to
stopping the evacuation of gases from the windbox.
SECTION B PAGE 69
9 WING WALL PROTECTION
During black plant condition/boiler tripping, establish steam flow through the steam cooled
section to protect steam cooled section from overheating.
For wing wall protection emergency vent valve UV-1017 is provided which will open
automatically through logic during boiler tripping if the Furnace Exit Gas Temperature (FEGT) at
“U” beam inlet is above 480°C. Bleed steam flow will be stopped once the FEGT / U beam
temperature drops to 480°C.
There are two modes of control
A) Auto Mode
B) Manual Mode
A) Auto Mode:
In case of boiler tripping if the Furnace Exit Gas Temp at “U” beam inlet is above 480 °C. and
tripping of the PA fan, the wing wall protection valve / Emergency vent valve (UV-1017) opens
automatically & remains open until the restart of PA fan OR Furnace Exit Gas Temp (Average U
beam) reduces below 480 °C
The valve will open to ensure 5 % MCR steam flow through wing wall and superheater coils.
B) Manual Mode:
In manual mode, wing wall protection valve/ emergency vent valve (UV-1017) can be force
open by the operator satisfying the operating conditions. As a precaution an alarm is provided
when valve is operated manually.
Note: Advice to keep the controls in automatic mode to avoid manual error.
10 MASTER FUEL TRIP (MFT)

The Master Fuel Trip (MFT) system logic continuously monitors the BMS & boiler control
system interlocks. The MFT system is control system logic when activated; the MFT shall stop
all fuel feeders & associated system to the boiler within a period that does not allow a
dangerous situation in boiler.
The following interlocks are monitored continuously throughout the operation of the unit:
• Furnace draft High-High

• Furnace draft Low-Low
• Total boiler air flow Low-Low
• Bed temperature High-High
• Primary air fan running
• Secondary air fan running
• Induced draft fan running
• Drum level Low-Low
• Drum level High-High
SECTION B PAGE 70
• Emergency push button operated from local & remote

• Instrument air pressure not very low.
SECTION B PAGE 71
11 TROUBLE SHOOTING CHART

The following chart is to be used for solving problems arising during operation.
PROBLEMS PROBABLE REASONS SOLUTION
1) Igniter spark not available 1) Verify spark gap, insulation condition of
electrode, cleanliness of electrode tip,
electrode damage, transformer power
supply and continuity checking.
2) Scanner not sensing flame 2) Verify scanner alignment with respect
to flame, cleanliness of scanner lens,
flame shape, power supply to scanner.
3) Inadequate oil flow 3) Verify the oil flow & pressure.
Unable to 4) Furnace pressure too low 4) Adjust the ID fan speed / damper
start burner position to maintain furnace pressure
(-) 5mmH2O.
5) gun insert position feedback not 5) Verify gun is inserted and position
available feedback is available.
6) Air sleeve damper min position 6) Verify that damper operation is smooth
feedback not available and limit switch feedback is available
7) Oil control valve start position (min) 7) Verify control valve opening in DCS is
feedback not available in accordance with start up position.
1) Very low bed inventory / Bed level 1) Maintain the bed level / inventory
(middle dP) (middle dP) as per the steam flow.
2) Very High bed inventory / Bed level 2) Maintain the bed level / inventory
(middle dP) (middle dP) as per the steam flow.
3) Inadequate fly ash recycling 3) Verify the MDC ash hopper level,
operation of RAV, condition of airslide
porous sheet, air pressure at airslide.
4) Use of non specified fuel 4) Use only the design fuel
5) Fuel rich bed 5) Adjust the air to fuel ratio as per the
load
Unable to 6) Higher oil firing rate. 6) Modulate oil flow rate
control bed
temperatures 7) Inadequate combustion airflow 7) Adjust the air flow through windbox
through windbox. suitably
8) Measurement error 8) Verify the condition of thermocouple
and cross check the readings at field.
9) Quality of bed material 9) Maintain silica & alumina content in
make-up bed material.
10) Improper bed material size 10) Use only the recommended size bed
distribution material
11) Collection of Shale & stones in bed 11) Restrict the shale and stones feeding
to boiler along with fuel. Increase bed
ash draining frequency and maintain
fuel sieve size suitably.
SECTION B PAGE 72
1) Very low bed inventory / Bed 1) Maintain the bed level / inventory
level (middle dP) (middle dP) as per the steam flow.
2) Inadequate fuel supply 2) Maintain the fuel feeder speed as per
the operating load
3) Low feed water temperature 3) Maintain the feed water temperature
as specified
4) Use of non specified fuel 4) Use only the design fuel
Unable to load
5) Fuel chocking in the feeding 5) Inspect the feed system for chock and
the boiler
system clear as required
6) Non availability of fly ash recycle 6) Ensure that ash recycling system is
system available for operation
7) Inadequate combustion air 7) Verify the bubble caps chocking, air
supply to furnace. leakage from air path, verify damper
positions, & verify & maintain the air
flow according to steam load.
1) High furnace dP 1) Maintain the bed level / inventory as
per the steam flow.
2) Air flow more than required 2) Adjust the air flow as per the
operating load
3) High bed ash Bulk density 3) Drain the coarse ash settled at
Windbox bottom furnace periodically and
pressure high maintains the bulk density below
1200 kg/m3.
4) Bubble cap chocking 4) Verify the dp across the bubble cap
and inspect & clean the bubble caps
5) Measurement error 5) Verify the transmitter calibration for
correct reading
1) High ash content in fuel than in 1) Use only design fuel

design fuel.
2) Coarse fuel size i.e. top size is 2) Maintain fuel sieve size distribution
more than specified. as specified.
Frequent bed 3) Improper bed material size 3) Maintain bed material sieve size
draining distribution distribution as specified
4) Presence of high volume of shale 4) Restrict the shale and stones
and stones in fuel feeding to boiler along with fuel.
5) Sorbent quality 5) Maintain limestone quality as
specified.
1) Fuel not burning properly. 1) Maintain bed temperature to suit

Sudden
the fuel being fired.
quenching of
2) Inadequate fuel feeding. 2) Verify the fuel flow & feeding rate
bed
3) Very high combustion air flow 3) Maintain the combustion air flow as
per the load conditions.
SECTION B PAGE 73

4) Higher volume of fines in fuel. 4) Maintain fuel size distribution as
recommended.
5) High moisture in fuel 5) Ensure fuel quality as per design.
6) Tube leakage in furnace 6) Verify and attend the tube leakage if
any.
1) High bed level 1) Maintain the bed level / inventory as
per the steam flow.
2) Air flow less than required 2) Adjust the air flow as per the bed
level
3) High bed ash bulk density 3) Maintain the bulk density below
1200 kg/m3.
Bed not
4) Bubble cap chocking 4) Verify the dp across the bubble cap
fluidizing
and inspect & clean the bubble caps
5) Packed bed. 5) Manually agitate the packed portion
of bed.
Caution: All the fans must be
6) Wet bed material switched off.
6) Verify the bed material for moisture
prior to admitting to furnace.
1) Bed temperature more than 1) Maintain the bed temperature as per
specified. the fuel being fired.
2) Low fusion temperature of fuel 2) Maintain the fuel as per design
being fired
3) Higher volume of alkalis in bed 3) Periodically analyze the bed ash for
Bed
ash. alkali concentration and dilute the
agglomeration
alkali concentration by draining bed
(clinker)
ash and adding fresh bed material.
4) Fluidization/airflow not adequate 4) Maintain the bed for bulk density
and air flow.
5) Fuel rich bed 5) Maintain air to fuel ratio
6) Very high bed inventory / Bed 6) Maintain the bed level / inventory
level (middle dP) (middle dP) as per the steam flow
1) High lower furnace dP 1) Maintain the dP as specified
2) Low bunker level 2) Maintain the bunker level
3) Inadequate seal air pressure 3) Maintain the seal air pressure to
furnace connections as specified (50
Back firing / mm pressure above the middle dP)
Furnace 4) Flue gas path blockage 4) Verify the systems for pressure drop
puffing & take corrective action
5) Insufficient induced draft 5) Maintain ID fan speed / damper
opening
6) Tube leakage 6) Check for tube leakage and rectify
the same if any.
Inadequate fly 1) No ash collection in MDC hopper 1) Verify for damaged MDC internals
ash recycle to and replace if any. Maintain the fuel
SECTION B PAGE 74

furnace quality and size distribution. Ensure
that MDC bypass drain is operated
as per logic.
2) Chocking of airslide porous sheet 2) Verify and clear the airslide porous
sheet.
3) Damaged porous sheet 3) Verify and replace the damaged
porous sheet
4) Insufficient air pressure at 4) Maintain air pressure across the

airslide airslide as specified
5) RAV (M-1049A/B) at MDC outlet 5) Ensure the RAV (M-1049A/B) at
not functioning MDC outlet is in operation and the
isolation gates are open.
Unable to 1) Feed pump suction filter partial 1) Verify dP across the pump suction
maintain boiler chocking filter and if required clean the filter
water level 2) Malfunctioning of feed water 2) Verify and rectify the control valve
control valve operation
3) Control valve blockage 3) Verify and clear the blockage if any
4) Economiser steaming 4) Maintain the feed water & flue gas
temperature at economiser as
specified. Maintain continuous water
flow through economiser.
5) Tube leakage 5) Verify and rectify tube leakage if
any.
6) Low feed pump discharge 6) Verify and maintain pump operating
pressure speed. Maintain feed water
discharge flow as per design.
7) Boiler steam flow more that MCR 7) Do not overload the boiler.
condition
8) Measurement error 8) Establish and rectify faulty
measurement if any.
9) Frequent fluctuation in load 9) Maintain the load fluctuation within
± 5% of MCR.
10) Passing through IBD, CBD, and 10) Verify all the drain lines for passing
other drain valves of valves and rectify.
11) Steam vapor lock 11) Maintain the deaerator pressure

and temperature.
12) Pressure part leakage 12) Check for tube leakage and rectify
the same if any.
1) Low load operation 1) Bypass APH during low load
Low backend operation
temperature 2) APH in service at low load 2) Bypass APH during low load
operation
SECTION B PAGE 75

3) APH leakage 3) Verify for APH tube leakages and do
the repairs as required.
4) Blocking of APH tubes 4) Inspect and clean the tubes as
required. Ensure the evacuation of
ash hopper and bypass the APH
during startup and low load to avoid
gas condensation and ash
accumulation.
5) Change of fuel 5) Use fuel as per design
6) Low Feed water temperature 6) Maintain economiser temperature as
per design
1) APH in bypass mode 1) Modulate the APH bypass damper to
maintain the required back end
temperature.
2) Blocking of APH tubes 2) Inspect and clean the tubes as
required. Ensure the evacuation of
Ash hopper and bypass the APH
High back end during startup and low load to avoid
temperature gas condensation and ash
accumulation
3) High excess air 3) Maintain the combustion air flow as
per operating load
4) Internal / external fouling of 4) Check the feed water and fuel
pressure parts quality
5) Change of fuel quality 5) Use fuel as per design
1) Water carry over 1) Maintain normal level in drum,
water chemistry, integrity of drum
internal & avoid frequent load
fluctuation above ± 5% of MCR.
2) High water level operation 2) Maintain normal water level
3) Attemperator spray water quality 3) Maintain feed water quality as
specified
High TDS in 4) Frequent / High load fluctuation 4) Maintain the load fluctuation within
steam ± 5% of MCR.
5) High boiler water TDS 5) Maintain boiler water chemistry by
proper chemical dosing and regular
blow-down.
6) Faulty / defective drum internals 6) During boiler outage check the
integrity of steam purifier assembly.
7) Sample contamination in sample 7) Check the sample cooler for any
cooler leakage.
1) Water carry over 1) Maintain normal level in drum,
Low steam water chemistry, integrity of drum
temperature internal & avoid frequent load
fluctuation above ± 5% of MCR.
SECTION B PAGE 76

2) Improper tuning of steam 2) Tune the steam temperature
temperature controller controller for optimum performance.
3) Faulty measurement of steam 3) Check the thermocouple and
temperature transmitter for range, accuracy and
termination.
4) Internal / external fouling 4) Check the feed water and fuel
quality
5) Low load operation 5) Maintain boiler load in SH
temperature control range.
6) Change of fuel quality 6) Use fuel as per design
7) Passing of attemperator Control 7) Verify the control valves and rectify
valve/ bypass valve if required.
1) High firing rate low mass flow 1) Maintain fuel firing rate as per
operating load. Startup vent
opening must be controlled as per
firing rate. Check and clear startup
vent valve blockages if any.
2) High excess air 2) Maintain air to fuel ratio as per
operating load.
3) Change of fuel 3) Use fuel as per design
High steam 4) Stagnant combustion. 4) Verify bed for proper fluidization.
temperature 5) Improper tuning of steam 5) Tune the controller for optimum
temperature controller performance.
6) Measurement error 6) Check the thermocouple and
transmitter for range, accuracy and
termination.
7) High furnace inventory 7) Maintain FEGT & furnace inventory
as per operating load.
8) Blocking of spray nozzle and 8) Verify and clean the spray nozzle
control valve and control valve as required.
1) Partial blockage of bubble cap 1) Ensure the bubble caps are clear
holes. without any blockages. Partial
blockages disturb the air flow
pattern and may erode the bubble
cap.
2) Uncontrolled bed drain through 2) Bed must be drained through the
bypass. bed ash cooler. During emergency
Erosion of
bypass drain may be used but in
bubble cap
controlled manner.
3) Entry of foreign material along 3) Avoid Entry of foreign material into
with coal. bunker, as the impact of foreign
material fall may damage the
bubble cap at the vicinity of coal
feed nozzle.
4) Presence of high percentage of 4) Periodically check the iron
SECTION B PAGE 77

iron in the bed concentration in the bed and adjust
the rate of draining frequency to
maintain the iron concentration <5
% in bed ash
5) Low bed level during cold startup 5) Maintain the bed level at 600mmwc.
(Oil firing) With low bed bubble cap may
exposed to the direct impingement
of the burner flame and the bubble
cap at the vicinity of the burner
flame may damage due to
overheating.
6) Inadequate air flow during cold 6) Maintain the required air flow along
startup (Oil firing) with the rate of oil flow and bed
temperature increase. With low air
flow bubble caps at the vicinity of
the burner flame may damage due
to overheating as the bed material
may be displaced /blown away by
the flame jet.
1) High middle dP 1) Maintain the bed level / inventory
(middle dP) as per the steam flow.
2) Porous sheet damage 2) Verify and replace the porous sheet
if required. Maintain the iron
Flue gas concentration <5% fly ash as higher
leakage from concentration may erode the porous
airslide and sheet.
RAV 3) Defective flange joints 3) Repair the flange joints with proper
seal rope and high temperature
sealant.
4) RAV casing and blade clearance 4) Maintain the RAV blade and casing
more than required clearances (0.5mm).
1) High middle dP 1) Maintain the bed level / inventory
Burner (middle dP) as per the steam flow.
windbox over 2) Inadequate cooling air flow and 2) Maintain the burner windbox air
heating pressure to burner wind box pressure (50mm above the furnace
middle dP )
1) Higher middle dP 1) Maintain the bed level / inventory
(middle dP) as per the steam flow.
Back shifting 2) Low air flow during load 2) Adjust the air flow as per the bed
of bed operation level
material 3) Low air flow during hot start up 3) Maintain 45 % of MCR air flow
during hot startups
4) Damaged bubble caps 4) Verify and replace the bubble caps
if required
SECTION B PAGE 78

5) Floor panel welding failure 5) Check and re-weld the panel joints.
6) Bed drain pipe Weld failure 6) Check and re-weld the pipe joints.
12 DO’S AND DONT ‘S

DO’S
• Maintain fuel quality and size distribution as per the specification.
• Use the bed material (fresh and recycle ash) quality and size distribution as per the
specification.
• Maintain bed ash chemistry and bulk density as per the design limits.
• Maintain feed and boiler water chemistry as per the specification.
• Maintain cooling water chemistry and pressure as per the specification.
• Use lubricants as per the equipment manufacturer recommendation.
• Maintain all instruments and interlocks are in service.
• Maintain the instrument air free from moisture and oily matters and the pressure as
recommended.
• Ensure all ash hoppers are emptied regularly.
• Economiser ash hopper need not to drain during normal operation. To be drained during
annual shutdown inspection and maintenance.
• Maintain seal air pressure at furnace openings as recommended (50 mmH2O) pressure
above the middle dP.
• Maintain burner & scanner cooling air to over bed burners.
• Operate the boiler within the recommended operating limits.
• While increasing the firing rate always increase the combustion air flow first and then
increase the fuel. While reducing firing rate always reduce fuel first and then reduce the
combustion air.
• Monitor & maintain the O2 level in flue gas as per the operating load.
• Maintain the “U beam” temperature as per the design limits.
• Keep the stand by auxiliaries ready for operation.
• Chemical dosing systems as per recommendation.
• Boiler surroundings and equipment must be properly illuminated.
• Ensure the walkways and surroundings are clear without obstruction for free movement.
• Maintain boiler operation log data regularly.
• Use genuine spares.
• Maintenance of auxiliaries & mountings should be done as per the manufacturer’s schedule.
SECTION B PAGE 79
• Verify that furnace refractory is intact without any damages during boiler outage.
• Inspect the bed bubble caps for any damages & replace as required during boiler outage.
• During outages preserve the boiler & auxiliaries as per preservation procedure.
• Inspect the floor panel for any leakages & rectify if required during boiler outage.
DONT’S
• Don’t bypass any instruments and safety interlocks.
• Don’t throttle the feed water pump balancing leak off valve while the pump is in operation.
• Don’t operate the furnace header drain valves while the boiler is in operation.
• Don’t open the furnace manhole during boiler operation.
• Economiser ash hopper need not to drain during normal operation.
• Don’t leave the boiler control room / Panel unattended.
• Don’t allow unauthorized persons to operate the boiler and associated equipments.
• Avoid continuous operation of boiler at low loads (low backend temperature) to protect
downstream equipments from dew point corrosion.
• Don’t operate the boiler below the recommended steam outlet pressure.
• Don’t load the boiler beyond rated capacity.
• Don’t operate boiler on very low & very high steam drum level.
• Don’t use non specified fuels.
• Avoid frequent starts & stops of the boiler.
• Don’t restart boiler after tripping until the cause is identified and rectified.
• Don’t carry out any maintenance without proper work permits and safety compliance.
SECTION B PAGE 80
13 WALK DOWN CHECK LIST DURING OPERATION

The boiler operator is responsible not only for the successful operation of the boiler and its
related equipments, but also responsible for the safety of operating personnel and the
equipment.
• Check for unusual noise from steam / water leakage.
• Check for unusual traces of water on floor, buckstay or leakage from casing joint.
• Look for valve and gland leakage.
• Discoloration, hot spots and bulging etc. on casing, duct and hopper.
• Check for steam and water leak from connection and fitting to the drum.
• Walk around the furnace exterior and observe for any hot spot, bed material & gas
leakage.
• Listen for any unusual noise around economiser which may indicate economiser leak.
• Inspect penthouse for gas leakage.
• Inspect windbox for any air leakage.
• Inspect all ash hoppers to make sure they are being emptied properly.
• Check around all air/flue ducts for sign of leakage.
• Check for ash leakage from bed drain bypass line.
• Check for ash leakage from airslide (Bed ash & fly ash recycle).
• Verify seal air pressure at various furnace connections.
• Check for coal spillage in handling and feeding system.
• Check for damaged insulation and cladding.
• Check for oil leakage from bearing / gear box seals.
• Check for feed water pump shaft seal leakages.
• Check for system / equipment cooling water inlet & outlet temperature.
• Check for leakage from safety valves at normal operating pressure. Also note the safety
valve blow off and shut off pressure. Check that the drain line and drip pan of safety
valves are not plugged.
• Check to see that proper water level is being shown by the direct water level gauge. Check
for water or steam leaks from ports or drain connections, which will cause a false water
level in the gauge glass. Inspect the glass for discoloration or fouling.
SECTION B PAGE 81
14 BOILER SHUTDOWN
Boiler shut down can be of two types:
• Planned / Normal shut down, where the operator gets advance notice and adequate time
to shut down the boiler in an orderly manner.
• Boiler Trip on interlock protection (MFT Condition) or emergency shutdown by the
Operator.
14.1 NORMAL SHUTDOWN PROCEDURE
• Reduce load at the rate established by the turbine, until the turbine is at its minimum load
point.
• During the period of load reduction, operator should maintain continuous steam flow
through the superheater.
• Steam flow is decreased by reducing fuel feed rate and combustion air flow (primary and
secondary) either manual or automatic operation. While pressure reduction, flue flow to be
reduced first followed with corresponding air flow however the air flow should not be
reduced below the purge air or minimum fluidisation air flow whichever is higher to prevent
solids shifting back.
• Trip the turbine and bring the boiler down by shutting off the following feed systems:
Stop the limestone/ make up bed material rotary feeder & MDC ash recycle rotary
feeder along with load reduction.
Stop the fuel feeders.
If the unit is to be shutdown for maintenance, the coal bunker isolation gate valves
(H-1001/1002/1003) should be closed prior to shutting down the fuel feeders, the
fuel feeders should continue to run for at least 5 minutes after isolating the bunker
to empty the DCF and fuel feeding chute.
• The operator should adjust the start-up vent (EM-1018) so as to provide at least 20%
steam flow to protect the superheater from overheating until the flue gas temperature
entering the U-beams is below 480°C.
• Switch off the ESP whenever the backend temperature drops below 140°C but never OFF
the rapping system of ESP instantly.
• De-energize the overbed burners if in service.
• Stop HP / LP dosing.
• Close the CBD valve (EM-1007).
• Close the sample lines.
• Maintain normal water level.
• Verify the IBD valve (EM-1006) is closed.
SECTION B PAGE 82
NOTE: If the unit is shut down for a short period of time AND NO PERSONNEL WILL BE
ADMITTED TO THE BOILER, store the solids inventory in the MDC ash hopper & leaving enough
bed material in the furnace to provide at least 600mm bed height.
• Whenever the gas temperature entering U-beams has cooled below 480°C, steam flow is no
longer needed to cool the superheater. Now close the start up vent valve (EM-1018).
Increase the air flow to 100% MCR through the primary and secondary air ports to cool the
bed ash temperature to 200°C.
• Stop the fans and allow boiler to cool naturally. SHUT DOWN THE SA FAN BEFORE
SHUTTING DOWN THE PA FAN, TO PREVENT FLOW OF HOT AND COMBUSTIBLE GASES
INTO THE WINDBOX. Shut down the ID fan and keep the fan damper open position.
• Whenever the steam drum pressure drops to 2-kg/cm2 (g), open the steam drum vent
(LHS (SD-1039/1040) and the start-up vent (EM-1018).
• Pressure reduction should not be faster than the boiler depressurization curve (attached
below)
CAUTION
IF PERSONNEL NEED TO ENTER THE UNIT, ALL SOLIDS MUST BE REMOVED COMPLETELY
FROM THE BOILER INCLUDING THE FURNACE, U-BEAM ZONE, SUPERHEATER PASS FLOOR,
MDC HOPPERS, ESP AND WINDBOX. THE BOILER TEMPERATURE MUST BE AMBIENT, AND THE
FOLLOWING EQUIPMENT/SYSTEMS BE LOCKED OUT BEFORE PERSONNEL ARE ALLOWED TO
ENTER FOR MAINTENANCE OR INSPECTION: FEED WATER SYSTEM, ID, PA & SA FANS,
BURNERS & IGNITERS, SOLID FUEL FEEDERS, LIMESTONE FEED SYSTEM, MAKEUP BED
MATERIAL SILO.
SECTION B PAGE 83
Typical Indicative Curve for Boiler Shutdown

110.0
100.0
90.0 Using high temp FW, increase water level to

6" below top of drum and hold between 6"
80.0
Reduce pressure by
Drum pressure in Kg/cm2 (g)
70.0
fanning slowly with 300
Stay on this side of curve
60.0
Open Superheater drains to equalize
temp of the drum shell (3 rounds)
50.0
Shut off air heaters Open Drum Vent at
40.0
2 Kg/cm2 (g)
30.0 Close pressure
Superheater Maintain
20.0 drains high water
10.0 level until
zero press.
0.0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850
Time in minutes
SECTION B PAGE 84
14.2 EMERGENCY SHUTDOWN SEQUENCE

Emergency shutdown is initiated as a result of equipment failure OR due to MFT conditions.
Four types of major emergencies are discussed in this section:
A) Types of Major Emergency Situations

1. Loss of feed water supply - Boiler feed pump(s) system is not available.
2. Loss of draft – PA/ SA fans and/or induced draft (ID) fan is not available.
3. Loss of both water supply and draft - Black plant with the boiler trip and isolated
from the power grid, with only emergency power available. This is the most critical
emergency situation.
4. Loss of solid fuel feed to furnace- If draft and feed water supply equipment remain
in service, this situation may be resolved quickly enough to prevent emergency
shutdown.
B) Emergency Response Actions and Priorities:
Following actions need to be taken for emergency situations mentioned above.

• Close main steam stop valve (EM-1015A)
• Stop HP / LP dosing.
• Close the CBD valve (EM-1007)
• Close the sample lines.
• Verify the IBD valve (EM-1006) is closed.
During black plant condition establish steam flow through the emergency vent valve (UV-1017)
quickly to prevent safety valve lifting, which once lifted will compound loss of water. With the
consideration that steam venting will quickly commence followed by water supply to the drum.
• Boiler trip during load operation, especially due to loss of feed water supply to the
boiler; immediate response should be to restore feed water supply through emergency
boiler feed water pump. The goal is to maintain safe water level; if not in the normal
operation range, at least up to the minimum visibility of drum direct level gauge glass.
The target is to restore a water feed to the drum within 5 to 7 minutes of the trip.
• Generally, loss of feedwater supply to the drum will result in low water which trip the
fuel will feed system. Should the loss of the entire main BFP system occur, it is
recommended if possible to trip the fuel feed system (main and auxiliary fuel) before
low water trip occurs. This may help to conserve drum water inventory as preparations
are made to restore water flow to drum.
• Establish steam flow through the superheaters through start up vent (EM-1018) and
emergency vent valve (UV-1017) immediately after tripping to protect steam cooled
section from overheating. Though there is loss of water due to venting through startup
SECTION B PAGE 85
vent valve/emergency vent valve; controlled venting of small amount of steam may
reduce pressure rise and prevent lifting of safety valves to the large extent.
NOTE: BLEED STEAM FLOW WILL BE STOPPED ONCE THE FEGT / U BEAM
TEMPERATURE DROPS TO 500°C.
• Ensure ID fan dampers (HCV-1037A/1037B) are open to facilitate evacuation of gases
from the furnace.
• Windbox steam purging and venting should be online during blackout.
START-UP AFTER EMERGENCY SHUTDOWN

Investigate the cause of trip and eliminate the problem prior to restart. While restarting the
boiler after a Master Fuel Trip has occurred or after the furnace has been boxed up, depending
upon the bed temperature follow the start up procedure as mentioned above.
14.3 ACTION DURING TUBE FAILURE

Operating the boiler with known tube leak is not recommended. Steam or water escaping from
a small leak can damage other tubes by impingement and cause a chain reaction of tube
failures. Large tube leaks can be dangerous as the boiler water level may go below the safe
limit, fire may put-off, and the boiler casing may be damaged. In addition, it could create a
hazard to personnel due to undesirable reactions of the steam with the reducing zone gases
carbon monoxide, hydrogen and other toxic and combustible gases. In situations where the
pressure part leak has occurred outside the furnace / flue gas path, extreme caution must be
exercised. Steam leak jets can be invisible until cooled enough for a condensation cloud to
form. Personnel contact with a steam jet can result in serious injury. Small leaks can sometimes
be detected by the loss of water in the cycle or system or by the noise from the leak. If a leak is
suspected, the boiler should be shut down as soon as possible. After the exact location of the
leak or leaks has been determined, proper repair procedures may be initiated.
SECTION B PAGE 86
Following are the typical failure reasons & corrective action.
Failure Reason for failure Action

1) Erosion
2) Failure of refractory
3) Failure from weld defect
Failure of water 4) Partial blockage and Stop the boiler as per shut down
wall tube starvation procedure depending upon the
5) Failure because of weld nature of failure.
metal penetration at Cool the boiler
furnace wall. Inspect the failure
1) Erosion Analyze the reason for failure
2) Failure from weld defect Restore the system after proper
Failure of
3) Partial blockage and repair / replacement
superheater
starvation In case of economiser coil failure
coils
4) Overheating is suspected immediately drain
5) Thermal shocks the economiser outlet ash hoper
1) Erosion so as to avoid water carry over
2) Failure from weld defect to MDC airslide as moist ash may
Failure of
3) Corrosion chock the porous sheet
economiser coil
4) Steaming
SECTION B PAGE 87
15 BOILER / EQUIPMENT SAFETY & LIMITATIONS

The CFBC boiler is quite different from the conventional boilers mainly due to the presence of
large volume of hot bed material and a pressurized furnace. The purpose of this section is to
familiarize operating and maintenance personnel about the equipment and personnel safety
procedures to be followed, whether the boiler is operating or shut down.
The operator must be aware of any operating conditions affecting the boiler or related
equipment, should able to recognize hazardous conditions and act properly to avoid injury and
damage. Even though operating procedures are given for each system, it is expected that the
operating personnel should acquire complete knowledge of all components - their design,
purpose, limitations and relationships with other components / systems.
• The reducing atmosphere in the lower furnace due to the staged combustion results in the
presence of relatively high concentrations of carbon monoxide, hydrogen and other toxic
and combustible gases. Operating personnel should be aware of the potential safety hazard
of gases leaking from the pressurized lower furnace. The operator/owner is responsible for
the installation of gas monitors and development and implementation of safety procedures
to alert the operating personnel about the leakage of harmful gas & hot bed material from
the lower furnace and attachments such as the fuel feed system and MDC fly ash recycle
connections.
• Operating the boiler with low feed water temperature along with high excess air will
result in exceeding metal temperature. During such conditions load must be bring down
immediately, if this temperature cannot be brought under control by other means.
• In case of tube leakage, which can be identified by hearing the noise from the boiler
surroundings and cross checked by difference in steam and water flow, gas and steam
temperature, the boiler should be shut-down at the earliest depends upon the nature of
failure for inspection & repair work. Otherwise large number of tubes may fail due to
steam impingement & erosion.
• Entry of wet steam into superheater will results in thermal shock. Austenitic steel is
worst affected due to stress corrosion in this case. Hence temperature after the
de- superheater should be maintained well above the saturation point.
• Always use deaerated, de-mineralised water for boiler feeding with the recommended
feed water quality.
• Feed water temperature must also be maintained as per design by heating the water in
deaerator. Low feed water temperature during low load operation will result in external
corrosion of economiser.
• Steaming in economiser is harmful to economiser unless otherwise it is designed as
steaming type and hence steaming should be prevented by passing water through
economiser continuously when there is fire in boiler.
• Carryover of salts in steam occurs either due to mechanical or vapour carry over from
steam drum. Efficient drum internals can only reduce mechanical carry over. Silica is
SECTION B PAGE 88
always carried over in vaporous form. Continuous monitoring of sodium and silica in
steam is desirable.
• Before operating a boiler, ensure complete knowledge of water chemistry.
• Whenever boiler is started after a shutdown of more than 3 days, check all safety
interlock before boiler start up for proper functioning.
• Superheater drain valve (DR-1011/EM-1041, DR-1013/EM-1042) should be operated as
per recommendations.
• The steam drum should normally be filled up to 30% drum level (NWL = 25 mm above
drum centre line).
• Firing should be limited depends upon the steam flow & furnace exit gas temperature
for protection of superheater during start-ups.
• Once the boiler is boxed up after shutdown, the water level in the steam drum must be
raised to the very top of the drum. Filling the drum like this will prevent excessive
temperature differentials along the drum wall during natural cooling.
• While raising pressure on boilers, a technique of continuous firing should be developed if
possible, since intermittent firing may result in re condensation in the tube loops.
• Where spray type attemperator is fitted, it is very important that control of steam or
superheater tube metal temperature is not attempted by the use of the spray during
pressure raising. This can lead to the entry of spray water into the secondary
superheater tube loops. Temperature must be controlled by modulating the rate of firing
and steam venting.
• Operate the boiler with recommended dP i.e. bubble cap dP, lower furnace and upper
furnace dP this is to prevent back shifting of bed material into windbox blocking fly ash
recirculation from airslide and damages to the airslide components.
• Establish steam flow through the superheaters through startup vent (XV-1018) and
emergency vent valve (UV-1017) immediately after tripping to protect steam cooled
section from overheating.
• Ensure the availability of fuel / make up bed material in the bunkers.
• Never allow gas to accumulate anywhere, other than in a tank or lines which form a part
of a fuel supply system.
• Purge the furnace completely before introducing any light or spark.
• Light up the burner with help of igniter & not from any other source.
• Ensure operation staff alerts to all abnormal conditions.
SECTION B PAGE 89
15.1 PERSONNEL SAFETY PRECAUTIONS

Boiler operator is responsible not only for the successful operation of the boiler and related
equipments, but also for the safety of all personnel involved. Operator must be aware of any
operating conditions affecting the boiler or related equipments, be able to recognize hazardous
conditions and act properly to avoid injury and damages.
Personnel protection is an important part of proper operation. Listed below are some of the
items foreseen as potential safety hazards:
• Do not attempt to open the furnace doors or observation ports during boiler operation
without observing the proper safety procedure. The furnace is under pressure, and
improper handling of doors or openings will lead to severe injury and may result in
death. High concentrations of harmful gases such as carbon monoxide, carbon dioxide,
hydrogen sulfides, sulfur dioxide and nitrogen oxides are the major known components.
The hot gases and hot solids will escape from the furnace doors, ports and other
openings if the instructions given in the safe handling of doors are not followed. The
observation port located on the large access door in the lower furnace must not be
opened during operation of the boiler. Access doors must never be opened when the
boiler is in operation.
• Always use a full face mask with tinted glass to protect the eyes and face from hot
gases, harmful light rays, and ash particles when viewing furnace conditions.
• Do not stand directly in front of the open ports or doors especially when they are being
opened. The solids in the furnace, windbox (if any), dust collector hopper, air heater
hopper and the final particle separation unit (ESP) hopper remain hot for extended
periods of time. When opening doors, even when the unit is shutdown, care must be
taken to avoid injury from the avalanche effect of the solids accumulated behind the
doors.
• Furnace pulsations caused by firing conditions or upset conditions such as tube failure
can blow hot furnace solids and gases out of open doors, even on the negative pressure
point near the U-beams. Use aspirating air before opening the inspection doors and
ports to prevent the escape of hot furnace gases and hot solids to protect against
furnace pulsation. Ensure that the aspirating air lines are not blocked or the aspirating
air supply is not fail/interrupted.
• Since observation ports are connected with aspirating air it will be quite noisy, hence ear
protection should be worn whenever these doors are opened.
• Wear protective gloves when working around boiler doors and openings.
• Do not use open-ended pipes for rodding observation doors or ports. Hot gases and
solids can be flow out through the open-ended pipe directly onto its handler. The pipe
can also become excessively hot. Use solid rods made of non-combustible material and
wear protective gear (gloves, safety glasses, and gas mask).
SECTION B PAGE 90
• Never enter vessels, especially boiler drums, until all the steam and water valves,
including the drain and blowdown valves, have been closed, locked and tagged. It is
possible for steam and hot water to back up through the drains and blowdown piping
especially when some of boiler drains are connected together. When vent valves are
connected to a nitrogen system, these valves should also be closed, locked and tagged.
• Do not enter a confined space until it has been cooled below 48°C and properly
ventilated. Completely drain and clean all the solids from the bed, U-beam zone, super
heater enclosure, dust collector hoppers, economiser and the air preheater ash hoppers.
• Use low voltage extension cords and light bulbs with properly connected grounds. Bulbs
on extension cords and flashlights should be explosion proof.
• Never open or enter the rotating equipment until it has come to a complete stop and its
circuit breaker is locked open. Some types of rotating equipment can be set into motion
with very little force. This type should be locked with a brake or locking device to
prevent rotation.
• Be prepared for falling ash when entering the boiler furnace by wearing a facial mask,
helmet and covered tight goggles to protect the eyes.
• Never step into fly ash or drained bed material. It can be cold on the surface but remain
hot smoldering underneath for longer period of time.
• Verify and ensure the drive mechanism of dampers, gates, and doors are secured/locked
before passing through them.
• Watch for hot water in drum and headers while opening the manhole and hand hole
covers.
• Never use toxic fluids, such as cleaning solvents, in confined spaces without adequate
ventilation. Follow Occupassional Safety & Health Administration (OSHA) -recommended
procedures for handling such material in confined spaces.
• Never direct an air or water stream into an accumulation of fly ash in a confined area. If
the fly ash is smoldering, the disturbance by air / water jet could result in an explosion.
WARNING
THE U-BEAMS, U-BEAM BOTTOM AND SIDE BAFFLES AND ATTACHMENTS ARE MADE OF
AUSTENITIC STAINLESS STEEL. EXPOSURE OF AUSTENITIC STAINLESS STEEL TO OPERATING
TEMPERATURES EXPERIENCED IN THIS AREA HAS BEEN FOUND TO SIGNIFICANTLY REDUCE
THE AMBIENT OR ROOM TEMPERATURE IMPACT STRENGTH OF THE MATERIAL. DUE TO THE
REDUCED AMBIENT OR ROOM TEMPERATURE IMPACT STRENGTH, FRACTURE FAILURE OF
THE STAINLESS STEEL MAY OCCUR UPON APPLICATION OF SUDDEN IMPACT LOADS WHEN
THE BOILER IS NOT IN OPERATION. THEREFORE, SHARP BLOWS OR IMPACTS TO THE U-
BEAMS, BOTTOM AND SIDE BAFFLES AND ATTACHMENTS MUST BE AVOIDED WHEN DOING
SECTION B PAGE 91
CLEANING, MAINTENANCE OR REPAIR WORK ON, OR IN THE VICINITY OF, THE BEAMS.
PROCEDURES MUST BE DEVELOPED BY THE OPERATOR FOR PREVENTING ANY IMPACTS TO
THE U-BEAMS, BOTTOM AND SIDE BAFFLES AND ATTACHMENTS SUCH AS HAMMER BLOWS
OR BLOWS FROM IMPACT HAMMERS OR CHISELS. WHEN MAKING REPAIRS TO, OR
OTHERWISE MODIFYING THE U-BEAMS, BOTTOM AND SIDE BAFFLES AND ATTACHMENTS,
REPAIR AND INSPECTION PROCEDURES MUST BE USED WHICH ELIMINATE ANY CRACK TYPE
STRESS RISERS OR CONCENTRATORS SUCH AS PLATE CRACKING, LACK OF WELD FUSION OR
OTHER WELD DEFECTS.
BED MATERIAL USED IN THE OPERATION OF THIS EQUIPMENT MAY CONTAIN FREE
CRYSTALLINE SILICA. REPEATED INHALATION OF RESPIRABLE FREE CRYSTALLINE SILICA
DUST MAY CAUSE LUNG INJURY. RESPIRATORS SHOULD BE WORN WHEN WORKING IN
CONFINED AREAS WHERE ADEQUATE VENTILATION IS NOT APPARENT OR AVAILABLE AND
WHERE BED MATERIAL PARTICLES ARE PRESENT IN THE ATMOSPHERE IN AMOUNTS IN
EXCESS OF ALLOWABLE LEVELS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH
ADMINISTRATION (OSHA). THESE CONDITIONS MAY EXIST IN AREAS SUCH AS TANKS,
HOPPERS AND BOILERS. APPROPRIATE VENTILATION SHOULD BE PROVIDED AND
PROTECTIVE EQUIPMENT SHOULD BE WORN IN COMPLIANCE WITH STANDARDS
ESTABLISHED BY OSHA. PROCEDURES SHALL BE DEVELOPED BY THE OPERATOR FOR
MEASURING ATMOSPHERIC LEVELS OF BED MATERIAL/SILICA AND FOR RESPIRATOR USE.
POSSIBLE EMERGENCY AND ROUTINE USES OF RESPIRATORS SHOULD BE ANTICIPATED AND
PLANNED FOR. WARNING: LIMESTONE USED IN THE OPERATION OF THIS EQUIPMENT IS
CONVERTED TO LIME DURING THE CALCINING PROCESS WHICH OCCURS IN THE FURNACE.
CALCIUM OXIDE (LIME) IS A STRONG ALKALINE DEHYDRATING MATERIAL WHICH UPON
CONTACT WITH SKIN AND EYES WILL CAUSE IRRITATION OR PERMANENT DAMAGE TO THE
EYES.
INHALATION OF LIME DUST MAY CAUSE COUGHING, SNEEZING AND INFLAMMATION OF THE
RESPIRATORY SYSTEM. RESPIRATORS AND TIGHT PROTECTIVE EYE GOGGLES SHOULD BE
WORN WHEN WORKING IN CONFINED AREAS WHERE ADEQUATE VENTILATION IS NOT
APPARENT OR AVAILABLE AND WHERE LIME PARTICLES ARE PRESENT IN THE ATMOSPHERE
IN AMOUNTS IN EXCESS OF ALLOWABLE LEVELS ESTABLISHED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA). THESE CONDITIONS MAY EXIST IN AREAS
SUCH AS TANKS, HOPPERS AND BOILERS. APPROPRIATE VENTILATION SHOULD BE
PROVIDED AND PROTECTIVE EQUIPMENT SHOULD BE WORN IN COMPLIANCE WITH
STANDARDS ESTABLISHED BY OSHA. PROCEDURES SHALL BE DEVELOPED BY THE OPERATOR
FOR MEASURING ATMOSPHERIC LEVELS OF LIME AND FOR RESPIRATOR USE. POSSIBLE
EMERGENCY AND ROUTINE USES OF RESPIRATORS SHOULD BE ANTICIPATED AND PLANNED
FOR.
SECTION B PAGE 92
Proper handling of bed drains

• The material flowing through a bed drain may tend to fluctuate. The interruption may be
due to momentary hang-ups or furnace pressure pulsations or pluggage of the bed drain
at the bed floor level. Whatever the cause, the result is sudden surges of gas and
sparks. These surges and pressure pulses can be dangerous to the personnel taking
drain samples and to people working on the bed drains and ash coolers.
• Sampling should not be done in such a way that there is an open path from the drain
line or the furnace to the atmosphere. The material surges and pressure pulses can
cause material to splash out of drain ports or spurt out of the opening and miss the
collecting vessel/container. The samples should be obtained from the cooled ash
downstream of the metering/isolating valves.
• Never attempt to rod out a plugged bed drain with the unit in service or with any bed
material in the furnace. When it starts to flow it will spew out and will not stop until the
furnace is empty. Pocking of bed drains should be done from the top (bed side). Clear
the area underneath of all personnel.
• Probes connected to bed ash drain system should be tightly fitted and secured in the
respective ports to minimize the blowout of material from the furnace.
• Do not leave any rod or probe in the furnace for long. It will heat up quickly making it
difficult to handle and hazardous when removed.
• Never look directly into the port or stand directly in front of the open port. If there is a
pressure fluctuation in the furnace, hot bed material can suddenly and unexpectedly
spurt out.
• The access door/inspection port cover will probably be hot. Protective gloves and
glasses should be worn at all times.
• Secure and lock the manhole and observation port cap any time the port is not in use,
even for short periods of time.
• Never use anything that may burn or melt, such as plastic or rubber, to temporarily
block the port. It will contact the hot gas and the result will be fire with noxious or toxic
fumes.
• Always wear insulated gloves and covered tight protective safety glasses when using
these ports. It is also advised to wear long sleeve shirts.
• Properly dispose of all combustible material from the port area. If any hot material blows
out from the boiler it presents a potential fire hazard.
SECTION B PAGE 93
• Turn on the aspirating air. Be SURE aspirating air is “ON” before you open the port
door. If the aspirating air is not “ON”, a stream of hot furnace gas and bed material will
blow out of the boiler.
• Open the port cap slowly.
• If the port is blocked by ash or bed material, rod it out with a long (greater than 6') solid
steel rod. DO NOT USE PIPES.
CAUTION
THE ASPIRATING AIR WILL BE BLOWING MATERIAL OUT AND WHEN THE PLUG IS CLEARED
THE ASPIRATING AIR CAN BLOW A FEW PARTICLES OF BED MATERIAL OUT IN YOUR
DIRECTION. DO NOT TURN OFF THE ASPIRATING AIR UNDER ANY CIRCUMSTANCES. THE
OPERATOR SHOULD ENSURE THE ASPIRATING AIR SOURCE IS RELIABLE AND NOT SUBJECT
TO BEING INADVERTENTLY TURNED OFF AT A REMOTE POINT.
• When inserting a probe in the port, stand as far back as you can. The aspirating air
WILL be blowing a few particles of hot bed material out of the port. Also, if a pressure
pulse occurs in the furnace, some bed material can blowout.
• When extracting the probe, again stand well back. The probe, even if water-cooled, will
be HOT. Any un-cooled portions of the probe such as a tip or filter will be at furnace
temperature.
• After using a port, close the door first, and then turn off the aspirating air. NEVER,
under any circumstances, leave a port door open and unattended, even for short
periods. A pressure pulse in the furnace can cause bed material to blow out
unexpectedly. The aspirating air can be left on to keep the port clear if it will be used
again in a few minutes. Do not leave the aspirating air on permanently.
Proper Handling of Solids Piles

Always be cautious of piles of bed material or any solids or ash accumulated anywhere inside
the boiler. The surface of piled material may be cool while but just below the surface it may still
be very hot. Bed material in a pile can stay hot for several days, even though the unit has been
cooled down. Any pile of solids found outside the boiler (from sampling, leaks, or spilled from
port) should always be assumed to be hot even though the outer surface is cool.
Proper Use of Ports in the U-beam Zone

• The ports located along the side walls of the U-beam zone and any additional
observation ports there should be treated with great caution when the unit is in
operation, or even when cold. The material collected by the U-beams is highly aerated
and hot when the boiler is in operation causing the solids material to flow like water out
of any opening. Therefore, the ports must be treated the same as described above
under "PROPER HANDLING OF FURNACE PORTS & OBSERVATION DOORS -
PRESSURIZED ZONE", "PROPER USE OF PORTS", AND "PROPER USE OF OBSERVATION
DOORS".
SECTION B PAGE 94
• Operation of the ports immediately after shutting down the boiler must be treated the
same as if the boiler were still operating. Any residual material inside the U-beam zone
such as that collected on the convection pass floor, U-beam segments and attachments,
etc. will remain aerated and hot for a considerable period of time after the boiler is shut
down. Sufficient waiting time must be allotted for the material to de-aerate and cool
down. A minimum of 48 hours should be allowed between shutting down the boiler and
opening a port if aspirating air for the port is not operable.
• The ports in the U-beam zone should be opened only when needed. Do not leave open
ports unattended.
• Penetrations in the U-beam zone such as pressure taps should NEVER be opened when
the boiler is in service.
PROPER HANDLING OF THERMOCOUPLES AND THERMOWELLS
Repair or changing of thermo wells during boiler operation is absolutely prohibited, particularly
in the positive pressure zone of the boiler. Changing thermocouples embedded within thermo
wells during boiler operation is not a recommended procedure. However, if the need arises,
when for example only one thermocouple is in operation in a particular zone, then the following
procedure must be followed.
When replacing thermocouples (TC) located in the furnace, always recall that the furnace is
pressurized and that the thermo well may be an open path to the pressurized furnace. Slowly
and carefully disconnect the thermocouple from the well. If you encounter resistance in
removing the thermocouple, or solids start to flow out of the well, it is an indication that the
thermo well has eroded and is packed with ash and bed material. Abort the attempt to replace
the thermocouple and refasten it until the boiler is off line and cooled. If no resistance is
encountered, then carefully remove the faulty thermocouple and replace it. Always wear
protective glasses and eye protection and always stand to one side when working on the TC.
NEVER look into a TC well opening. It is advised that if a TC is removed from the well, the
opening should be plugged with a steel plug or cap. Never use plastic or rubber. These can melt
or burn resulting in fire with noxious or toxic fumes.
PROPER HANDLING OF ACCESS DOOR
Never open an access door while the unit is operating.
Any access door can have large amount of material built up behind it even after the bed has
been drained. This material will fall out when the door is opened. Bed material can stay hot for
many days even after boiler shutdown.
Open the door slowly and always stand to the side of the opening.
SECTION B PAGE 95

Boiler Manual Thermax 150 TPH IRCFBC

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THERMAX LIMITED PROJECT: RSPL LIMITED.

BOILER AND HEATER GROUP JAMNAGAR, GUJARAT

SECTION OVERVIEW ............................................................................................................ 1

1 BOILER START UP .......................................................................................................... 4

6 WARM START UP .......................................................................................................... 66

7 WINDBOX STEAM PURGING......................................................................................... 68

9 WING WALL PROTECTION ........................................................................................... 70

10 MASTER FUEL TRIP (MFT) ............................................................................................ 70

11 TROUBLE SHOOTING CHART ........................................................................................ 72

12 DO’S AND DONT ‘S........................................................................................................ 79

13 WALK DOWN CHECK LIST DURING OPERATION .......................................................... 81

14 BOILER SHUTDOWN ..................................................................................................... 82

IRCFBC WORKING PHILOSOPHY

Furnace Furnace Furnace Furnace

AIR PLENUM AIR PLENUM AIR PLENUM AIR PLENUM

Static bed Minimum fluidisation Fluidising bed Turbulent bed

Fig ( Solid Flow in IR – CFBC BOILER)

BOILER START UP SEQUENCE

1.1.1 SYSTEM LINE UP

1.1.2 WALK-DOWN CHECKS

Description Tag No. Status

Description Tag No. Status

Saturated steam sampling line isolation valve SAM-1005/1006 Close

Windbox steam purging valve HCV-1019 Open

Windbox steam purging ON/OFF valves UV-1015/1016 Close

Secondary Superheater outlet header drain valve DR-1013/ EM-1042 Open

Secondary Superheater outlet header vent valve SH-1021/ 1022 Open

MAIN – STEAM LINE

Description Tag No. Status

Description Tag No. Status

FEED WATER PUMPS (CUSTOMER SCOPE)

FEED WATER AND SPRAY WATER LINE

Description Tag No. Status

100% Flow Control Valve (FCV) FCV-100B Close

Description Tag No. Status

Ensure valve line-up as below:

Description Tag No. Status

ID, PA & SA FANS

STEAM AND WATER SAMPLING SYSTEM

DESCRIPTION TAG NOS. Status

Cooling water inlet and outlet isolation valve to CWS-078A/B/C/D

Saturated steam sampling isolation valve SAM-1005/ 1006 Close

COMBUSTOR & WINDBOX

FUEL FEEDING SYSTEM –DRAG CHAIN FEEDER

BED MATERIAL AND LIMESTONE FEEDERS

• Verify the bearing condition and lubrication is done properly.

Limestone rotary feeder inlet slide gate valve SG-1004/1005/1006 Open

MDC & BED MATERIAL RECYCLE SYSTEM

Description Tag No. Status

BED ASH DRAIN & COOLING SYSTEM

Ensure following valve /damper position before boiler start-up

AIR PREHEATER (PA & SA)

ELECTRO STATIC PRECIPITATOR (ESP)

1.1.3 FILLING OF WATER IN THE BOILER

Description Tag No. Status

Description Tag No. Status

Following cares to be taken before starting water filling in boiler

1.1.4 FANS START UP PROCEDURES

Procedure for ID fan start

PA FAN START-UP PROCEDURE

Procedure for PA fan Start

SA FAN START-UP PROCEDURE