2 x 115 TPH CFBC Boiler

UltraTech Cement Limited – APCW

Tadipatri
 FBC Boilers

 AFBC
- Atmospheric Fluidized bed combustion
 CFBC
- Circulating Fluidized bed combustion
 PFBC
- Pressurized Fluidized bed combustion
 CFBC
CFBC boilers are further classified with the
arrangement of cyclones.

– Hot Cyclone
• Hot flue gasses goes thr’ cyclone immediately after
furnace
• Flue gas path as below
=> Combustion zone => Free board => Cyclone
=> SH coils =>Evaporator => Economizer
=> Air pre heater => ESP

– Cold Cyclone
• Hot Flue Gasses passes thr’ cyclone after Eco-2.
• Flue gas path as below
 Combustion zone => Free Board
 SH Coils => Evaporator=> Eco-2
 Cyclone => Eco-1 => Air Pre Heater
 ESP
 CFBC Boiler principle
Cold Cyclone
 CFBC Boiler principle
Hot Cyclone
 CFBC
General Description of CFBC Boiler

 Use fluidized bed principle;

 Crushed (6~12 mm) fuel and limestone are injected into the lower furnace.
The particles are suspended in a stream of upwardly flowing air that enters
the bottom of the furnace through air distribution nozzles.
 Balance of combustion air is admitted above the bottom of the furnace as
secondary air.
 Combustion takes place at 800~950°C, with uniform combustion condition in
chamber;
 Fine particle (< 450 microns) are elutriated upward in furnace with flue gas
of 4~6 m/s.
 Particles are then collected by the solids separators and circulated back into
the furnace.
 Individual particles may recycle anything from 10 to 50 times
 Particles’ circulation provides efficient heat transfer to furnace walls and
longer residence
 time for carbon and limestone utilization.
 Advantages of CFBC
General Advantages

 Fuel Flexibility
 The relatively low furnace temperatures (815~925°C) are below ash softening
temperature of nearly all fuels;
 Therefore, furnace design is independent of ash characteristics
 Low SO2 Emissions
 Limestone is an effective sulfur sorbent in temperature range of 815~925 °C
 SO2 removal efficiency: >95%
 Low NOx Emissions
 Very low NOx emission
- Low furnace temperature
- Air staging to the furnace
 High combustion efficiency (even for difficult-to-burn fuels)
 Very long solids residence time in furnace due to re-circulation
 Vigorous solids/gas mixing in furnace
 These two compensate negative effect of low furnace temperature
 Process Flow Diagram

Eco-2
Evaporator Eco-1

SH-1 PA4
SA4
SH-2
SH-3 SA3

Screen PA3

PA2
SA2
Free Board
SA1
PA air
PA1

SA ID Fan
Air
PA
Air
Bed Level ESP

HGG1
Wind Box
PA air HGG2
 Boiler Spec.
• Steam TPH (MCR) - 115 TPH
• Outlet Pressure - 99 KG / CM2
• Steam Temperature - 540 +5 °C
• Feed water temperature - 210 °C
• Grate Area - 22.19 SQ. Mtr.
• Max Working Pressure (Des) - 119 KG / CM2
• Normal Working Press of drum - 105 KG / CM2
• Hyd. Test Pressure - 178.5 KG / CM2
 Heating Surfaces
Sl No Surface Area
1 Economiser-1 725
2 Economiser-2 759
3 Evaporator Bundle 440
4 Super Heater-1 595
5 Super Heater-2 295
6 Super Heater-3 153
7 Screen 168
8 Supporting Tube 220
9 Membrane Panel (Wall) 890
Total 4245
2
All Measurements are in M
 Boiler

• Drum Center - 44.35 Mtr

• Furnace Manhole - 10.35 Mtr

• SA air inlet - 12.875 Mtrs

• TA air inlet - 16.375 Mtr

• Man Hole Below screen - 27.450 Mtr

 Air Supply

• Primary Air - by PA fan

• Secondary Air - by SA Fan
• Tertiary Air - by SA Fan

• Flue Gas - by ID fan

 Water

Feed water Quality Requirements

Sl No Quality Parameter Unit Limits

1 pH 9.3 to 9.5

2 Oxygen ppb 7 (Prefer 0)

3 Fe ppb 10

4 Cu ppb 5

5 SiO2 ppm 0.02 to 0.07

 Water

Boiler Water Quality

Sl No Quality Parameter Unit Limits

1 Conductivity at 25° C 0.1

(Micro Siemens/cm)

2 pH 9 - 10

3 Silica as SiO2 ppb 2

4 Phosphate as PO4 ppm 2

 HGG

Diesel oil (HSD/LDO) from 20 KL storage tank,

will be pumped by Screw pumps with maximum press of
12 bar and 8 bar working pressure.

High pressure Oil will be sprayed (atomized) as

fine particles with atomization air and get fired.

Flame size & outlet temperature can be adjusted

by Combustion and dilution dampers of HGG.
 HGG Protections

• Initial Purging for 1.5 Minutes

• Air Protection - Minimum PA Air flow (>11.5 kg/s)
• Fuel Pressure (4 to 7 KG/CM2)
– <4 Low pressure tripping
– >7 High pressure tripping

• Atomization air pressure (>5 KG/Cm2)

– <5 Atom. Pressure low tripping

• Flame failure
• HGG outlet gas/air temperature (<900 °c)
 Nozzles & Bed

• No of Nozzles
• Bed Height – 800 mm
• Bed Material Size – 2 to 3
mm
 Basic Principle of CFBC

Fluidized bed
combustion (FBC) is a
combustion technology used in
power plants. Fluidized beds
suspend solid fuels on upward-
blowing jets of air during the
combustion process. The result is a
turbulent mixing of gas and solids.
The tumbling action, much like a
bubbling fluid, provides more
effective chemical reactions and
heat transfer. FBC plants are more
flexible than conventional plants in
that they can be fired on coal and
biomass, among other fuels.
 Coal Feeding

• Coal feeding
– 4 Nozzles
– Mixed feeding with Limestone , Recirculation ESP 1st & 2nd field fly ash
and Cyclone ash.
• Primary
– 50 to 60 % coal firing will be on Fluidized bed
• Secondary
– Remaining 40 to 50% coal firing will be on SA & TA inlet.
• Size requirement of Coal

Sl No Size Limit
1 -8 mm 100 %
2 -1 mm <35 %
First Pass – Steam and water

Drum

• Flue Gas path

Eco-2 – Free Board
– Screen
Evaporator – SH3
– SH2
SH1 – SH1
– Evaporator
SH2
– Economiser-2
SH3 – Cyclone
Screen

Flue Gas
 Cyclones

In cyclone separator, the suspended particles

are separated from the gas stream by the action of
centrifugal and gravitational forces. The dust laden
gas is introduced tangentially into the separation
chamber and thereby vortex flow is formed.
Consequently, in cyclone separators of small-
diameters, the separation of small suspended
particles are effected and thus high degree of
separation is achieved.
Cyclones

No Parameter Unit 100 % MCR

1 Gas Mass Flow at inlet Kg/s 23
2 Gas Temperature at inlet °C 410
3 Inlet Dust loading Kg/Nm3 2
4 Draught loss mmWC ~130
 Siphons

• Siphons are used for fluidizing,

cooling and diverting Ash from
cyclone to furnace.
 APH

FW Out
Tubes Arrangement
Eco-1 FW in

PA out
PA-4

SA out SA-4
- Flue Gas
SA-3 - PA/SA Gas

PA-3 Flue Gas path

PA-2 ╚ Eco-1
╚ PA4
SA-2 ╚ SA4
╚ SA3
SA air in SA-1 ╚ PA3
╚ PA2
PA air in PA-1 ╚ SA2
╚ SA1
╚ PA1
Flue Gas out to ESP
Boiler Cold start up
 Sequence of Operation
1. Start fans
 ID fan – Keep on Minimum RPM
 SA fans – Keep on 250 to 300 RPM
 PA fans – Keep just more than Minimum Fluidization level
2. Set Furnace pressure between -5 to -15 mmwc
 By adjusting the ID fan speed
 Set it on auto mode with set point -15
3. Start Oil Pump
 Max oil pressure 12 Kg/Cm2
 Minimum Oil pressure 4 Kg/Cm2
4. Start HGG
 Purging & Scavenging
5. Increase bed temperature to 500°
Note: Bed temperature for Coal feeding various as per the Fuel used (VM % of Fuel)
6. Start Coal Firing
7. Switch of HGG ( 600 °C and 700 °C )
8. Switch of Oil pumps
9. Continue Regular operation with coal firing
 Fan - Interlocks
• ID Fan
– Discharge Damper Closed condition
– Coal Feeder Discharge gate Closed
– Both Coal feeders are not running
• SA Fan
– ID fan running
– Suction damper of ID fan in open condition
– Discharge damper closed
– Furnace pressure
• PA Fan
– ID & SA fans are in running (minimum one from each)
– Discharge damper closed
– Furnace pressure (in between Min & Max)
– Drum Level (Between Min and Maximum limit)
– SA & TA flow (Between Min & Max)
 Boiler Protection

• Boiler air Protection

– Bed Temperature
– Furnace pressure
– Drum Level
– Primary air flow
– Siphon 1 &2 temperature
: 350 to 965 (3 out of 4)
: -150 to +100 (2 out of 3)
: -320 to +150 (2 out of 3)
: >11.0 kg/s
: < 450

• Boiler oil protection for HGG start up

– PA air Pressure
– PA flow : 17 Kg/s
– Atomization air pressure : > 7 Kg/Cm2
– Fuel oil pressure : < 7 Kg/Cm2
– Diff. air pressure across HGG : >25 mmwc
 HGG-Fuel Circuit

20 KL

Strainers

Pr.
Relief
Valve

To HGG Filters
 HSD/LDO Circuit - startup
• Pre - Checks
- Ensure HSD/LDO tank Oil level more than 0.7 Mtr.
- Drain Water from tank in case of longer storage

• Ensure following
- HSD pump suction strainers are clean.
- Discharge filters are clean.
- No leakages.

• Valves to be in open position

- Tank Suction
- Suction Strainer Inlet outlet valves
- Pump Inlet and outlet valves
- Pressure relief valve inlet, outlet valves & bypass valve
- Recirculation to tank inlet valve

• Valves to be in closed condition

- Filter inlet and outlet valves (only for starting)
- Unloading point suction valve
- Strainer and filter drain valves

• Safety Precautions
- Don’t rotate the Pump coupling with hand
- Take PTW while doing small checking or tightening jobs.
- Open valves gently while removing airlock on filters

• Removing air lock

- Remove air lock in suction filter
- Don’t remove air lock when tank level is less than the suction point of tank.
 Pumps
• Twin screw positive suction pumps should not be dry run, as
because the pump screws are not separately lubricated.

• The pumping oil media acts as a lubricating media.

• Dry run can reduce the life of screws, and it causes, reduction in
discharge pressure.

• Pumps inbuilt pressure relief valves should not be adjusted without

technical support.

• Reducing setting point of inbuilt pressure relief valve may cause

reduction in discharge pressure of pump as well as quantity of fuel
pumped.

• Ensure the pump rotating direction.

• Like Centrifugal pumps, this pumps should not be started with

discharge valves closed.
 Pumps

• Remove air from suction strainer.

• Remove air lock from discharge line.
• Top most point of Suction pipe line.
Note : Removing air lock from suction strainer will not remove the
air from the pump, because The suction line is elevated more
than the strainer top.

Pump Startup
1. After Completing all the checks of above
2. Start the pump, allow the oil to recalculate for a minute.
3. Open the discharge filter inlet and outlet valves
4. Slowly close the Bypass valve of Pressure control station
5. Pressure starts increasing on Boiler side.
6. Ensure pressure >7 KG/Cm2 (Usually 12 kG/CM2)
 HGG
Ctrl valve

Fuel

Compressed air

Atomizing air

Fuel Pressure - >7 KG/CM2

Normal Operation - 12 KG/CM2)
Fuel quantity - 900 KG/Hr per HGG
Normal Operation - 125 Kg/Hr min to 450 KG/Hr
Atomization air - Instrumentation air
Cooling & Sealing air - Service air from Inst. Comp.
 HGG
• Pre-Checks
– No Leakages
– All three fans are in operation
– Sufficient air purging for Boiler
– Spray nozzles of HGG are cleaned.
– Light up gun in service
– Alignment of igniter and fuel spray nozzle.
– Atomization air and service air compressors in operation
– Air supply valves are opened
– By pass damper in closed condition

• Ensure the following valves are in open condition

– Main Fuel supply valve to the boiler
– HSD inlet to HGG
– Flow meter inlet and outlet valves
– Control valves - Isolation valve
– Atomization air valve
– All sealing-cooling air valves (Partially open)

• Ensure the following valves are in closed condition

– Control valve
– Pneumatic shutoff valve
– Fuel Bypass to control valve.

• Ensure opening of Combustion and Dilution damper (Min 50 % )

 HGG start up
• Ensure air and Oil Protection
• Complete initial purging
• Keep Fuel control valve set point to 33 % open
• Give start command
– ignitor automatically inserted into HGG
– Ignitor generates sparks
– HSD shut of valve open and allows the HSD to flow to the spray gun nozzles
– Fuel Get automated with atomization air
– Automated fine particles comes contact with sparks and catches fire
– Ignitor keeps on generating sparks for 15 seconds.
– Flame sensor senses the fire and gives feed back.
– If Fuel does not catch fire, flame sensor fails to sense the flame and trips the system with
feed back of Flame failure alarm.
• Monitoring and controlling
– Fuel and atomization air pressure
– HGG outlet gas temperature
– Adjust Fuel control valve to control the temperature.
– Adjust combustion and Dilution damper to control the flame and temperature.
• Maintain HGG outlet temperature around 350°C for 1 hour, Then Raise to 850 ° C.
Note :
Keep 15 minutes gap between HGG1 & 2 for startup.
Raising of HGG outlet temperature Can be done after drum water temperature raises above Evaporation point.
 Safety Precautions

• Do not operate any valve, while HGG is in operation

• Do not force any interlocks on HGG
• Do not open air valve for cleaning.
• Keep open all the sealing air valves, closing the same may cause back fire.
• Operating HGG on manual mode should not be allowed. To do so, strict
vigilance and supervision to be provided.
• Do not operate, when system continuously trips on flame failure alarm,
which may cause a major disastrous (back fire).
• Scavenging of HGG while each tripping will reduce the risk of above.
• Fuel pressure should be always less than atomization air pressure, the
reverse of the above will cause back fire on air side.
• Scavenging of HGG will reduce the risk of Fuel fire
• Switch off/ do Emergency stop, whenever the flame failure and system is in
operation.
• Continuous monitoring is required.
 Coal Firing

• Maintain HGG outlet gas temperature around 850 °c till Bed temperature of
boiler reaches 500°c
• Start Coal feeder and sprinkle coal. (by starting and stopping)
• Coal feeder can be run continuously after O2 & Bed temperature response.
– If O2 % is reducing faster than normal, stop coal feeder to control bed
temperature.
– Coal feeding also increases the furnace pressure instantly
• When bed Temperature reaches 600 ° C, Reduce the HSD fuel control
valve and stop one HGG and Keep another one on slow firing.
• When Bed temperature reaches >700 ° c.
• Stop 2nd HGG.
• Precautions:
– Coal firing should be increased gradually, Faster increasing of coal feeding
increases bed temperature, as well as FG temperature.
– Increasing FG temperature without steam circulation on SH is not healthier
to the SH circuit.
 Other precautions - Oil firing
• Burner Refractory
– Burner Refractory is maintained under high temperature of HGG.
– It should not be cooled down suddenly.
– To avoid sudden cooling of burner ref. bricks, HGG by pass damper should be opened immediately after
HGG stoppage.

• Drum Level
– While boiler in oil firing, drum water level also increases with increase in water temperature (Swelling).
– Drum level should be controlled with IBD regularly.
– Close Drum vent, When drum pressure reaches more than 2 KG/CM2.

• Super Heater
– When drum pressure reaches 5 Kg/CM2, SH drains and Vents (If Opened) to be Partially closed.
– Closing drum vents and drains will shuts the steam circulation on SH tubes.
– To avoid SH tubes overheating, some amount of steam flow should be maintained on SH tubes.
– Start up vent should be kept partiallyu open to maintain this circulation on super heater coils
– Recommended Drum pressure increase is 2 KG/CM2 per minute.

• APH
– Initially PA air will be admitted through PA bypass duct to avoid cold end corrosion
– Once the Flue gas temperature reaches around 130 ° C, PA APH by pass damper can be closed gradually
and APH can be charged.
Boiler Cold startup

Coal Firing
 SOE Coal Firing
• Boiler Feed water pump operation
– Starting of Boiler feed water pump and Feed water line charging.

• Regularization of Coal Feeding

– Normalizing coal feeding and isolating oil firing

• Ash Recirculation (If Required)

– Ash recirculation from Siphon and ESP fields 1 and 2 recirculation to furnace

• APH Charging (If not done on Oil firing)

– Charging APH , closing bypass damper and maintaining 2 nd pass temperature.

• ESP Fields Charging

– Charging of ESP fields and All Ash handling systems

• Drum Level control

– Drum water level control and single element auto control

• Venting & Temp raising

– Usage of start up vent and raising of SH temperature to normal working range.

• Steam Charging
– Pressure raising and steam charging up to common header.

• Auto Control of Fans

– Auto control operation for PA & ID.
 BFP

Pre-Checks
– ACW pump in operation
– Cooling water supply valve to be in open condition
– Open All the cooling line valves.
– Open Main suction valve from Deaerator
– Ensure sufficient water level on Deaerator.
• Should be >1450 mm
• Maintain around 2000 mm (If possible) to meet the requirement of
startup vent.
– Keep Initial filling pump in auto mode operation, and Deaerator
level control set point set at 1300 mm for pump-1 and 1350 mm
for pump-2.
– Ensure all the suction and discharge pressure gauges and
pressure transmitters are in working condition.
 BFP
Starting of BFP

• Boiler feed water pump to be started with start up of boiler steam generation.

• Ensure the following before starting up BFP

– Ensure ACW pump is running

– Ensure water circulation on cooling water gauge glass.

– Ensure suction valve is open

– Discharge valve is in closed condition

– Balance leak off line valve is open.

– Minimum recirculation is ready for all respects.

– Suction pressure should be >1.5 Kg/CM2

– Remove air in the circuit by suction and discharge vent valves.

– Check oil levels of all gauge glass

• Give clearance to start the pump

• Ensure pump discharge pressure is around 150 KG/CM2

• Allow the water to circulate for 30 seconds.

• Open Discharge valve

 BFP

• Interlocks of BFP
– Suction pressure >1.2 KG/CM2

– Discharge Pressure >110 KG/cm2

– Deaerator level >600 mm (Trips on 600 mm)

• Safety Interlocks
– Balance leak off pressure <8 KG/CM2

– Should not be operated without discharge valve open and suction valves closed condition.

– Running BFP longer duration with recirculation will increase the temperature of feed water.

– Don’t open discharge valve immediately after pump start up.

• Discharge Valve opening

– Open discharge valve very slowly when pump discharge pipe is empty or low pressure.

– Slow operation of valve ensure gradual increase in pressure and reduces pressure hammering
on pipelines.
 Coal Feeding & APH charging

• Coal Feeding
– Initial Coal feeding should be started with 10% VFD command
– coal feeding of >20 % MCR rating load is required to maintain steady boiler operation.
– Ensure cyclone ash is re-circulated via siphon.
– If required, Open Minimal amount of purging air to control bed temperature raise.
– Ensure Free flow of coal from Bunkers.
– If not continuous flow,
1. Adjust Rod gates
2. Still no free flow, do Hammering

• APH Charging
– Ensure ESP inlet temperature is more than 120 °C.
– Gradually Close PA By Pass damper to charge APH.
– Charging APH on less temperature will increase the second pass corrosion.
– Extending oil firing up to APH charging will increase the boiler life.
• Safety Precautions
– Avoid coal feeder coal flow inspection when, back buffing occurs.
 ESP Fields

• Pre-checks
– Ensure Main Incomers are switched on.
– Ensure Heaters are on
– Ensure Purge air fans are in operation
– Ensure Flue gas temperature is more than 120 °C
– Ensure Fluidization air for ESP hopper is on.
– Ensure hopper poking pipe is properly closed
– Ensure conveying air pressure and instrument air pressure for dense weighers.

• Switch on Ash Conveying system

• Start Switching on fields
– one after another from Outlet end
– Maintain minimum duration of 5 minutes per field.
 Ash Recirculation

• Fly ash recirculation

– Ensure the following
• Fly ash silo BVP blower is in operation
• Purge air valve is opened and purging system is in operation.
• Ensure proper operation of Ash recirculation silo fluidization pads and fluidization air

– Start Fly ash recirculation screw feeder

– Open isolation gate for screw feeder.
– Fly ash recirculation from ESP Field-1 & 2 can be taken into circuits.
• To control bed temperature.
• To Control LOI on fly ash.

• Safety Precautions
– Avoid over filling of as recirculation
– Over filling causes back pressure on the ash conveying pipes which leads to
gasket failures
 Venting & Temp Raising

• Steam venting is done through start up vent

– To Maintain circulation on Boiler

– To increase the steam temperature

– To control the rate of raise of pressure in drum

• Don’t open start up vent manually.

• Open start up vent with Jogging will be a safe and good practice.

• Opening start up vent will effect the drum level.

• Keep control on IBD and Feed water control to maintain drum level.

• Safety Precautions
– Steam venting is a noise polluting operation.

– Ensure PPE’s (Ear plugs) to the operators on shop floor.

 Steam Charging
• Pre-checks
– Ensure all the main steam drain valves in open condition
– Allow condensate water (From Prev. Stoppage) to fully drain out

• Open Equalization valve of Main steam stop valve.

– Condensate water and wet steam starts coming out from all the drain valves.
– Close the drain valves partially, when dry steam comes out.
– Keep the valves crack open

• When all the valves are cracked down

– Ensure the pressure before MSSV and after MSSV is almost equal.
– Now open the MSSV slowly to charge the system.

• Safety Precautions
– Use proper PPE’s while opening and closing drain valves
– Condensate and wet steam is high temperature and high pressure causes injuries to health.
– Don’t check the drain condensate & steam with hand to check the wetness.
– Improper steam charging causes water hammering, may damage the entire system.
– Charging MSSV with improper Equilisation will suddenly increase the steam flow and which leads to drum
level hike and trips the boiler.
– Any abnormal sound from the steam pipes should be immediately conveyed to the control room.
 Valves Positions
Valves Hydro test Boil-Out Start-Up Operation
Start up Vent Close Close Open Close
MSSV Close Close Close/Open Open
Drum Vent Close(1) Close(2) Open Close
Feed Water Eco-1 Inlet Close Close Close Open
FCS Isolations Close Close Open Open
40/100 % Ctrl Valves Close Close Open Open/Close (3)
IBD Close Intermittent Close(4) Intermittent

CBD Close Close/Open Close Open

Chemical Dosing Close Close/Open Close Open
Water Walls Drain Close Close Close Close
Water Gauge Drain Close Close Close Close
Safety Valve Gag Free Free Free
Steam Gauge Shutoff Close Open Open Open

1. Opened, when filling with water. Closed when Drum Press >2 Kg/cm2.
2. Closed at 2 KG/Cm2 Pressure
3. Opened and controlled as per drum level
4. Opened Intermittently to maintain drum level during startup
 Major Equipments

Equipment Qty Cap KW Current RPM Temp Press

1 PA Fan 2 300 295 1500 45 1770 MMWC
2 SA Fan 2 75 78.6 1500 45 511 MMWC
3 ID fan 2 265 268 1000 160 -497 MMWc
4 Coal Feeders 2 7.5 15.6 725
5 Safety Valves Drum 2 46 TPH 113,114
6 Safety Valve SH 1 23 TPH 106.5
7 EMSV 1 17.25 106.5
8 HGG 2 900 Kg/Hr 850
9 BFP 3 135 TPH 750 48 2980 1444 MWC
10 Deareator 1 275 TPH 156° c 5.7
11 Cyclone Ash Screw Fdr 2 5.5 10 1455
12 Limestone Screw Feeder 1 5.5 TPH 3.75 6.9 1450
13 Compressor (Inst) 2 160
14 Compressor (Ash) 2 200
15 ACW Pumps 2 750 TPH 160 267 1485
16 DM water Makeup Pump 3 15 TPH 3.7 6.8 1450
17 Boiler Initial Filling Pump 2 25 TPH 18.5 32 2930 80 MWC