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File Number
Contract No.
Version Editor Date Preliminary Date Auditor Date Translator Date Approver Date
auditor
st
1 version
nd
2 version
rd
3 version
th
4 version
AL2O3 % 19.72
Fe2O3 % 5.88
MgO % 3.00
SO3 % 6.12
K2O % 0.33
Na2O % 3.31
SiO2 % 52.96
TiO2 % 0.64
P2O5 % 0.25
Mn2O3 % 0.11
Total
1 μmol/L ≈2 During boiler running≤5.0μmol/L
hardness
μg/L
3 Iron ≤20
4 PH 8.8-9.3
c) Minimum temperature:25℃
The boiler is mainly consisted of three parts: membrane water wall furnace, two
steel plate type cyclone separator and one tail shaft cladded by steam cooling
enclosure wall.
The platen heating surfaces are arranged inside furnace: eight membrane
superheater tube bundles, four membrane reheater tube bundles and one water
cooling isolating wall. There are six coal feeders and four limestone inlets which
are arranged evenly along the the width direction of front wall water wall lower
part contraction section. The bottom of furnace is water cooling wind box
surrounded by bended water wall tube. There are two under bed air duct burners
in the primary air duct under furnace water cooling wind box; the burners are
equipped with high energy ignition device. Two ash coolers are set for the boiler.
There are two steel plate cyclone separators between furnace and tail convection
gas duct and one “U” material return valve is installed under the two cyclone
separators. The tail part is separated by enclosure wall and forms dual gas duct
structure in boiler depth direction. Two groups of low temperature reheaters are
installed in front gas duct; high temperature superheaters, low temperature
superheater are set in rear gas duct; the front gas duct and rear gas duct will
combine into one gas duct at the lower parts and the finned tube type
economizer and horizontal air heater is installed inside the one gas duct. The air
heater adopts light tube type and it is double inlet and double outlet along boiler
width direction. Two stage desuperheater is equipped in superheater system and
the reheater adopts gas baffle temperature regulating mode with emergency
spraying desuperheater and slight spraying desuperheater.
The boiler is arranged in bilateral symmetry and is hung on boiler steel frame.
DG440/13.8 type circulating fluidizing bed boiler is natural circulating boiler. The
water circulation of boiler adopts centralized water supply, distributed flowing in
and flowing out mode. The feed water flow in boiler drum water space and enter
into water wall and water cooling isolating wall inlet header through centralized
downcomer and connection pipe. Boiler water is heated to be steam and water
mixture when flows upward through furnace water wall, water cooling isolating
wall and enter into boiler drum to conduct water and steam separation through
the upper outlet header and steam and water outlet pipe. The separated water
returns to the water space of drum and conduct recirculation; the separated
saturated steam is leaded out from the steam connection pipe at the top of drum.
After the saturated steam is leaded out, it flows into tail convection gas duct side
wall enclosure upper header through saturated steam connection pipe, flows
downwards into side enclosure wall lower header through two sides side
enclosure wall; then it flows into front and rear enclosure lower header through
enclosure wall connection pipe, flows upwards into middle enclosure wall upper
header, flows downwards to middle enclosure wall lower header which is low
temperature superheater inlet header, flows upstream to cool down rear gas duct
low temperature superheater tube bundle, and then flows into boiler front platen
type superheater inlet header from the two sides connection pipe. It flows to the
high temperature superheater in the tail shaft rear gas duct through the two sides
connection pipe and the qualified superheated steam will be leaded out from the
two sides of high temperature superheater outlet header.
The exhausted steam from steam turbine HP casing flows into through tail shaft
front gas duct low temperature reheater inlet header; after flowing through two
groups of low temperature reheater, it flows out through low temperature reheater
outlet header and comes into boiler front platen type reheater inlet header from
the connection at the two sides of boiler. After it flows upstream to cool down
platen reheater, the qualified reheated steam is guided into steam turbine
intermediate pressure casing from the two sides of furnace upper platen type
reheater outlet header.
The material circulation of CFB boiler is achieved and maintained by the kinetic
energy of P.A fan, S.A fan and ID fan.
The air from primary air fan is divided into three way and then is delivered to
The gas and its carrying solid particles enters into cyclone separator through
separator inlet gas duct which is arranged in the rear wall of water wall. Most
material particles are separated by separator and the gas flow is leaded out
through cyclone separator center casing and flows into tail shaft gas duct through
separator outlet gas duct and enter into front and rear gas duct through the gas
window at the upper part of front enclosure wall and middle enclosure wall and
flow downwards and flush the horizontal convection heating surface tube bundle
arranged inside it to transmit the heat to the heating surface and then the gas
enters into dust suppressor after flowing through tubular air heater, finally it is
discharged to atmosphere after being extracted into chimney by induced draft fan.
There are three high head fluidizing fan for “U” valve material return device and
the output of each fan is 50%; in normal condition, two fans are in operation and
one for standby.
Boiler adopts balance ventilation and the pressure balance point is in the outlet of
furnace; there are governing baffle in the whole flue gas and air system in
convenience for the control and regulation during the operation.
2.2 Drum
2.2.1 Structure
The drum is in the boiler front top part and spans over the boiler in boiler width
direction. The drum is taken as the water receiver of boiler evaporation loop;
separating device and dosing pipe, feed water distributing pipe and blowdown
pipe are installed inside it..
There are manholes in the two ends of drum and the internal parts which could
be taken out from manhole conveniently.
The internal equipment includes water and steam separator, drying box, feed
water distributing pipe, continuous blowdown pipe, dosing pipe and so on.
The connecting box is set inside drum to avoid the boiler water and feed water
entering into drum and contacting with high temperature drum wall directly or
impacting the water, which will reduce drum wall temperature difference and heat
stress.
The downcomer hole, inlet water pore under drum water chamber wall and other
pores which may have temperature difference should adopt reasonable pore
structure type and water distribution type to avoid heat fatigue cracking
b) Platen superheater
The tube bundles of low temperature reheater is fixed on the tail enclosure
wall by fixed block and expand along with enclosure wall. The low pressure
steam from turbine is guided in from the two ends of low temperature
reheater inlet header, flows reversely in gas direction through low
temperature reheater tube bundle, enters into low temperature reheater
outlet header and then is guided out from the two ends of outlet header.
e) Platen reheater
There are altogether four platen reheaters which are arranged in furnace
upper near to furnace front wall; the reheater is membrane structure. Control
tube wall temperature is within 500 oC through regulating fuel feeding amount
when the boiler is started with no bypass system. The lower part of platen
reheater is covered by wearing resistance material and the whole platen
reheater expand from lower part to higher part.
The tail double gas duct baffle temperature regulation is the main regulating
method of reheated steam temperature. Adjust the openness of gas regulating
baffle in tail superheater and reheater parallel gas duct to control the gas amount
flowing through reheater side and superheater and regulate reheated steam
temperature based on the proportional relationship between gas amount and the
outlet temperature of reheated steam. The gas amount flowing through reheater
side will increase along with the decrease of boiler load, which could maintain the
reheated steam temperature at rated value in certain load range. In order to
increase the flexibility, there is a two stage desuperheater in reheating system;
the primary desuperheating is arranged in the connection pipeline between low
temperature reheater and platen reheater(one at either side), which is taken as
emergency spraying desuperheater; the secondary desuperheater is arranged in
the connection pipeline between low temperature reheater and platen
reheater(one at either side), which is taken as slight spraying desuperheater;
both of the above two stage spraying desuperheater could regulate the spraying
water amount at either side to eliminate the steam temperature difference at the
two sides.
2.3.3 Economizer
The economizer is set in the boiler tail gas duct and is finned tube structure. the
material is 20G light tube; it adopts double wound in-line arrangement. The
economizer tube takes conventional wearing protection measurements. The
restrict baffle is set between the inlet of economizer tube bundle and around wall
to avoid gas deflection; the feed water is guided in from the two ends of inlet
header, flows through economizer tube bundle and then is guided into boiler
drum from the right end of outlet header through connection tube.
The cyclone separator is rolled by steel plate and the internal side is laid with
wearing resistance, heat insulation layer.
b) The output of each set of ash coolers is 100% of the total slag amount of
boiler.
They could guarantee that the temperature of discharged slag is not more
than 150℃ no matter it is intermittent or continuous ash discharging and they
can operate for a long term. When one ash cooler stops or has fault, another
ash cooler could guarantee the boiler could operate for a long term under
BMCR working condition and the temperature of discharged slag is not more
than 150℃. When the two ash coolers fail to operate due to the fault, the
boiler could operate for one hour under BMCR working condition.
b) The material return port could distribute the return material in air distributor
plate evenly and local accumulation and overheating phenomenon will not
occur and it could also avoid the return back of secondary air.
b) There are two under bed air duct igniters in primary air air duct under
furnace wind box. The total thermal capacity is designed as 15% B-MCR
total input heat. The total heat capacity of above bed oil gun is designed as
35% B-MCR total input heat.
The under bed air duct igniter could increase the bed temperature to 600C
quickly and ensure the reliability of the ignition.
4.1 ID fan
e) The engaged operation personnel should take the following items as a key:
2) Check the conditions of equipment and system to see whether the rotary
equipment is flexible and the system leaks or not.
Hydrostatic test includes working pressure and overpressure test. The test
pressure for superheater and water wall tubes etc. is the rated working pressure
of steam drum; overpressure test pressure is as 1.25 times as the rated working
pressure of steam drum; the pressure of reheater should be calculated according
to the inlet working pressure, which overpressure is as 1.5 times as the inlet
working pressure.
b) After 1 year’s outage and before the boiler is put into operation.
a) Steam drum: steam drum and the fittings, man hole and pipe seats.
b) Feedwater system: economizer pipes and its inlet & outlet header, feedwater
pipes and economizer recirculating pipe section from economizer to the
steam drum connecting pipe, downcomer, water transferring pipe, water
cooling pipe of air distributor, water wall tube and its inlet & outlet header,
connecting pipe from upper header of water wall tube to steam drum,
water-cooled spacer and header.
b) Stop filling water when the level reaches -100mm of steam drum. Conduct
thorough inspection to check whether the expansion indication is normal
and take record. If abnormal, find out causes and handle them.
c) When filling water, close the air vent valve on the heating surface after water
d) Report to the main operator when closing air vent valve of HP superheater
and stop filling water. Conduct overall inspection.
f) Stop increasing the pressure when pressure reaches . Check the sealing of
water inlet valve, if no abnormality, increase pressure with the gradient no
more than 0.2MPa/min
h) After check, start to reduce pressure, gradually reduce feedwater flow till
feedwater governing valve is closed, and pressure should be reduced by
≯0.5MPa/min at each stage.
a) Disconnect drum local water level, drum safety valve and superheater safety
valve and close all valves connected to instruments except for pressure
gauges.
b) Continue to increase the pressure after receiving the instruction, and the
pressure should be increased by ≯0.1MPa/min at each stage.
a) When turbine HP steam exhaust valve, IP unite valve, Ⅰ/Ⅱ bypass and
water-spray attemperators are successfully isolated, open vent valves of hot
and cold reheaters, and close all reheater drain valves.
b) Start feedwater pump, open feedwater pump intermediate tap, and finally
open low temperature reheater emergency water-spray manual valve to
slowly supply water.
c) When vent valve water-spray lasts 1-2min, close vent valve. Check to
ensure everything is in good condition, and then perform pressure boosting
by desuperheating water regulation valve and controlling feedwater pump
rotation. Pressure should be increased by ≯0.1MPa/min at each stage.
d) Only demineralized water of good quality can be used for hydrostatic test.
Feedwater should be heated up to 20℃ in advance when steam drum wall
temperature and inlet water temperature are both less than 20℃; otherwise
pressure increasing cannot be performed.
f) Before hydrostatic test, turbine should be well isolated to prevent water from
entering turbine.
g) During hydrostatic test, readings on both remote pressure gauge and local
pressure gauge should be regularly calibrated. Pressure boosting should be
stopped in case of inaccurate pressure gauge reading. And pressure
boosting can be continued only after pressure gauge calibration to prevent
overpressure. Personnel should be designated locally to monitor feedwater
valve and pressure gauge.
5.3 Safety Valve Calibration
5.3.1 Purpose
To ensure boiler safe operation and prevent equipment damage due to
overpressure, boiler safety valve action value should be regularly calibrated
according to requirements to ensure reliable and accurate operations.
c) Chief shift operators as well as other involved personnel should do the work
under the command of shift leader.
d) I&C and boiler maintenance personnel should be responsible for safety valve
setting.
c) The complete calibration instruction and safety measures for safety valve
calibration should be formulated before the safety valve is calibrated. Special
personnel should be designated for directing the operation, and special
personnel for calibrating the valve.
d) Check all atmospheric steam discharge valve switches to ensure they work
freely and reliably.
h) In the process of on-load calibration, if safety valve does not reseat after
pop-up, decrease the pressure and take measures to make it reseat. When
pressure is decreased to such a degree that it cannot meet turbine
operation requirement, boiler should be shut down.
Valve and damper test should be performed: before newly built boiler is put into
service; before the boiler is put into service after maintenance; before each
start-up of boiler. Confirm that everything is ready for valve/damper test, that
valves or dampers are all completely closed, that the test will not affect operation
system. Related I&C and maintenance personnel should be on site.
Power should be on and air supply should start, and signal, opening degree
indication on control room CRT display should be accurate.
Check to ensure driving device works freely, valve opening direction is correct
and no pneumatic valve leakage.
During the test, there should be a good interaction between operation field and
control room, also there should be supervisor. Full opening, closing position
should be tested for correctness. Switch opening, closing time and angle should
be recorded.
Actuation connecting lever as well as pin should be tight, safe and unbent.
After test, results and potential troubles found should be recorded and reported to
personnel in charge.
5.5 Static Adjustment Test of I&C Adjustment System
Travel switch and torque switch should be adjusted and calibrated to ensure
correctness.
b) Actual driving test with working medium should be performed for main
protection interlock driving test, the test cannot be performed with signal
k) Low bed temperature in lower furnace (650℃ and combustors are not put
into service)
l) Low bed temperature in lower furnace (540℃ and no matter combustors are
o) Turbine trips.
b) Fuel oil OFT is activated, shut down fuel oil quick-shut-off valve, remove
igniter.
d) Switch desuperheating water regulating valve into manual position and shut
down desuperheating water holding valve.
f) Switch air volume control into manual position and keep the position.
g) If MFT is not caused by the air fan, all the fan control mode is in the manual
position. If not, the air fan control is conducted in interlock mode.
b) Oil inlet valve of any oil gun below bed is not at off position and main pipe oil
pressure of below bed oil is low.
c) Oil inlet valve or return oil valve of any oil below bed fail to close.
d) Oil inlet valve of oil gun below bed is not at off position and oil inlet quick
e) Oil inlet valve of any oil gun below bed is not at off position and quick closing
valve of below bed d oil return has been closed.
b) Oil inlet valve of any oil gun on bed is not at off position and main pipe oil
pressure below bed is low.
c) Oil inlet valve or oil return valve of oil gun on bed fail to close.
d) Oil inlet valve of any oil gun on bed is not at off position and oil inlet quick
closing valve has been closed.
e) Oil inlet valve of any oil gun on bed is not at off position and oil return quick
closing valve has been closed.
b) The pressure of supply oil main pipe is normal (The pressure of main pipe in
front of lower quick closing valve >3.2Mpa).
b) Supply oil main pipe pressure is normal (Main pipe pressure in front of upper
quick closing valve should more than 3.2Mpa).
6.1 Overview
Carry out individual or integral trial running and acceptance for related equipment
system of boiler after maintenance. The minor maintenance or other
maintenance acceptance should be carried out appropriately.
For boiler after major and minor overhaul, terminate all work permits before
startup and the related test should be carried out under the direction of the chief
engineer or the assigned person based on the actual condition of site. There are
tests such as boiler air-leakage, air-distribution plate resistance, hydrostatic test,
fluidization state inside furnace, safety valve action (Hot state), boiler MFT and
protection, opening/closing of all electrically-operated valves and governing
valves of boiler and interlock.
Carry out detailed checks for all equipment and systems before boiler startup.
After repairing boiler temporarily, important check should be checked for the
equipment system relating to the temporary maintenance items and the others
can be treated based on the standby boiler before boiler startup.
After receiving boiler startup command of shift leader, the foreman should inform
all posts in advance for check and preparation before ignition according to the
time and requirements.
All man-holes and sighting holes are complete and closed firmly.
Opening and closing of all flue gas duct, air passage damper and interlock
actuator is flexible with the correct indication and opening degree indication is
correct. After inspection, they should be at correct position.
All expansion indicators are correct with clear graduation and the initial value is
recorded.
The heat insulations support and hangers are safe and sound.
Put the auxiliary steam/industrial cooling water/ compressed air system into
service and the working medium parameters are normal.
The conditions for fuel oil system startup include: fuel oil begins circulating and
the fuel oil angle valve is opened. Start burners and the test on ignition gun action
are in good condition. The startup burner soot blowing is smooth. Put the fire
detector cooling air and startup burner sealing air into service.
The local water level meter is clear with correct normal water level, high/low
water level marks.
Check all valves of steam/water systems to ensure they meet the ignition
requirements.
Check the ignition transmitter and the control system power supply of flame
detector and burner.
Check pressure switch, relief valve and instruments to ensure they meet service
conditions and ready for startup.
Check the positions of all air dampers and valves/fittings are correct.
Check if all valves and holes are closed with good sealing. Make sure there is no
Check if the limestone system can be put into service and if there is enough
limestone in the limestone bunker.
Check if the coal feeder system can be put into service and if there is the enough
coal inside the coal bunker.
Check if the compressed air system can be put into service and if the flow of all
compressed air consumption equipment is reasonable.
Check if the soot blowing and sealing air system can be put into service and if the
flow of all air consumption equipment is within the range.
Check if the cooling water system can be put into service and if the flow of all
cooling water equipment is within prescribed range.
Check if there is enough bed material with high-quality in bed material system
and hopper.
Check to ensure pressure switch, relief valve and instrument meet service
conditions and are ready for start-up.
Check if all valves/holes are closed and if the air sealing check is finished.
Confirm there is no person working inside the equipment including no leakage of
all pipe systems, support and hangers in good condition.
Check if the locking device is removed on the constant-force hangers and spring
hangers.
Check if the feedwater system, including pumps can be put into service.
Check if the auto vent valve of reheater can be put into service.
Check if all soot blowers are in withdrawal position and if they can be put into
service.
Check if all water-spray desuperheaters inside the reheater system can be put
into service.
Check to ensure switches and instrument meet service conditions and ready for
start-up.
Check the interlock of primary air/secondary air systems and ensure they are in
enabled state.
Check all valves and holes are closed with good sealing and without person
working inside equipment.
Check if all air valves and cooling water valves and accessories are in enabled
state.
a) Check the material returner and the external heat exchanger fluidized air fan,
external heat exchanger system and air heater pipe bundles system, making
sure they meet the requirements.
c) Check if all holes and valves are closed and with good sealing and there is
no person inside the equipment.
c) Precautions: the speed of water feeding should be equal and slow. The
differential temperature of the upper/lower walls of steam drum should be
≤50℃.
b) Check and open the vent valve of boiler proper, drain valves of superheaters
and the drain valves of reheaters.
c) Check and put the drum water level meter, electric contact water level meter
and balancing vessel water level meter into service.
d) Get contact with the turbine personnel for starting water filling pump or
feedwater pump.
e) Use the feedwater bypass to forward water to the steam drum. Fully open
the electric valves before/behind the bypass governing valve and manually
adjust the opening degree of the bypass governing valve and control the
feeding flow.
g) When the drum water level reaches -100 mm, stop feeding water and open
the recirculation water valve of economizer. Thoroughly check there is no
leaking for the feedwater pipes and valves.
h) Record the expansion indicator of boiler once before and after feeding
water.
The tests for all electric valves/governing valves and I&C interlock protection
have been finished and with normal action.
The resistance test of air distributor is finished and the nozzles are not
obstructed.
The instrument and auxiliary compressed air system have been put into service
and the instrument compressed air pressure is in the prescribed limit.
The chemical department had prepared enough and high quality demineralized
water.
There is enough fuel oil and coal for ignition or coal has been fed into bunker.
The emergency power supply has been on for all rotating machines and I&C
power supply for all electric valves and protection has been on.
Prepare for putting the bottom heater into service based on the requirements.
Put the fuel oil system into service and starts oil circulation. The oil pressure is
within the prescribe limit
Put the soot blowing system of all measurements points into service. Carry out
ventilation and soot blowing for all measurements points.
a) Put all air fans into service for blowing the related pipes.
c) After purging, ignite the boiler. Meanwhile, manually start the flue gas duct
burner.
d) Before the first light oil burner is put into service and if the first light oil burner
cannot be ignited, carry out purging for the furnace and the flue gas passage
of downstream connection pipe to guarantee there is no explosive gas
mixture exiting in the combustion system. For the subsequent light oil burner
and all those light oil burners being put into service, the ignition cannot be
successful because of other emergency or the fault of any one light oil
burner, as will make the fuel flowing to the light oil burner which is going to
stop. But if there is still light oil burner in service, it is unnecessary to carry
out the purging. But the ignition interval should be extended
Any primary air fan in service and the damper is not closed yet.
Any secondary air fan in service and the damper is not closed yet.
Any ID fan in service and the damper are not closed yet.
b) Observe the burner and monitor oxygen change and regulate air volume to
ensure combustion stability.
c) Adjust the combustion power of the burner based on the temperature rise
and air chamber temperature condition and keep the temperature increasing
ratio of the boiler bed within 60-80℃/h. Control the outlet flue gas
temperature of the air duct burner at ≯920℃. The air chamber temperature
is less than 950℃ and note the drum wall temperature variance ratio is
△ t<50℃/h to prevent over-temperature of superheater/reheater mental
pipes.
d) After ignition is finished, immediately open the turbine bypass system and
slowly open the bypass valve as the steam pressure increases. If there is no
vacuum established on the turbine side, the low pressure bypass cannot be
put into service. But the electric steam discharge valve of reheater can be
opened.
e) When the steam drum pressure reaches to 0.2MPa, close the vent valve and
drain valve. Shut down superheater and reheater air exhaust valve and put
into service.
f) Put the drum continuous blowdown system into service based on the
chemical requirements and open the intermittent blowdown valve based on
the actual needs.
g) When the drum pressure reaches to 0.3-0.4 MPa, wash and calibrate the
local water level meter and carry out the intermittent blowdown once.
i) When the superheat steam flow is more than 10% B-MCR, all drain vales can
be closed based on the actual conditions.
j) Put desuperheating water into service based on the actual condition of steam
temperature. But before put the desuperheating water into service, carry out
backwashing for the desuperheaters to prevent temperature too low. If there
is steam in the reheater, and reheater temperature exceeds the rated value
causes by various factors, spray water to cool down for reheater protection.
l) Report the condition to the shift leader and get contact with the turbine
personnel for rolling turbine if the boiler main steam parameters cannot reach
the following values:
Main steam temperature is over 50℃ higher than the regulated range.
No serious fault of all equipments and boiler in normal operation with stable
combustion and normal water level
After bed temperature reaches 560℃, start up two coal feeders (one set is mounted
on left and right side of furnace area)and control the output at 10 t/h and keep
feeders operating for 2 minutes and then stop them. Watch the bed temperature
change: the bed temperature should begin to decrease and then increase. The
oxygen content of flue gas does not change at the beginning but later it will
decrease by several percent. Repeat the above process for three times and the
results are the same as the above. Based on the actual condition, put the coal
feeder into service under the proper coal flow. As the bed temperature and unit
load increase, put the coal feeder into service based on the above method. While
increases the flow of coal, the oxygen content will decrease and then gradually
increase the primary air flow to keep the minimum fluidization. Adjust the
b) Do not start the boiler if there is no monitoring on oxygen content of flue gas.
d) Before ignition, put cooling air of the fire detector into service. Do not cut off
the cooling air of fire detector after ignition and before shutdown.
e) Keep the temperature difference between the upper and lower walls of
steam drum less than 50℃ at all times
1) Steam drum wall temperature change ratio ≤50℃/h. it changes slowly at the
beginning, but fast later.
6) When steam drum pressure is ≤ 5 MPa, the increase ratio of the main steam
pressure is 0.02-0.05 MPa/min.
The warm startup is that the bed temperature is lower than that of feeding coal
and it is the startup method when the coal cannot be directly put into service
Before warm startup, checking and preparation are the same as that in the cold
startup. But the checking inside furnace and the interlock test are not necessary.
The purging operation of the warm startup boiler is the same as that the cold
startup.
After ignition, the steam drum pressure reaches 0.1~0.2 MPa and all vent valves
and drain valves are closed. Put high pressure or low pressure bypass into
service. Warm up the pipe for 15-20 min before putting the bypass into service.
During warming pipe, the steam discharging valve and drain valves of
superheater/reheater should be opened.
After boiler is tripped or when the fire is banked in furnace, if re-startup is needed,
it is not necessary to carry out the furnace purging before putting main fuel into
service when the bed temperature is higher than the permitted value. Then
quickly increase the air flow a little bit higher than the minimum operating air flow
and put the coal feeder into service. During the above process, the speed should
be quick and the air flow should be kept in a good range to prevent the bed
temperature lower than that when putting coal into service. During outage, if the
bed temperature has been lower than the permitted value of feeding coal, the
furnace purging must be carried out based on the regulations.
The inspection and preparation before boiler starts in hot state is the same as
that in cold state but the checking inside furnace and the interlock test are not
c) Shut down the under-bed burner inlet/returning oil quick shut-off valves.
d) The average bed temperature is higher than that when putting coal into
service.
e) The primary air flow to the air chamber is higher than the minimum fluidizing
air flow.
f) The coal spreading air and sealing air flow are both higher than the
minimum.
b) After the air fan is started up, boiler should be ventilated and purged if the
bed temperature is lower than that when putting coal into service. All purge
steps should be finished as soon as possible to prevent the bed temperature
from deceasing quickly.
c) If the coal fed is not burnt in 5 min, the hot startup fails. Stop feeding coal to
the burner and put the oil guns into service to increase the bed temperature
and re-feed the coal after re-purging.
d) After the oil guns are ignited, the bed temperature will increase. The
subsequent coal feeding can be carried out. With reference to the cold state
sliding parameters or actual condition, finish the startup process and the
subsequent operation to increase the unit load to the required level.
Control the temperature difference between upper and lower wall of drum no
more than 50℃. But if there is up tendency, immediately slow down pressure and
temperature increasing.
Carefully increase temperature and pressure based on the unit startup curve.
Monitor wall temperatures of superheater/reheater to prevent over-temperature.
Balance the feedwater and keep the normal water level of drum.
Keep the combustion in a good condition and reduce the thermal loss and
improve the boiler thermal efficiency.
Timely adjust the operation condition of boiler and keep all operation parameters
within optimal.
Strengthen monitoring operation and find and solve the equipment fault timely to
keep the boiler equipment in a safe and stable operation.
When the superheated steam pressure changes, timely analyze the cause for
flowability, so as to take corresponding measures and handle quickly, in case of
drastic pressure fluctuation.
Strengthen operating adjustment of coal feeder and limestone system to keep the
feeding of coal and limestone even and stable.
During normal operation, the steam pressure is adjusted by changing the feeding
coal flow. Keeps equivalent coal feeding quantity on all feeding coal lines. Do not
adjust the steam pressure by putting coal-feeder line into/outlet of service.
Normally, do not decrease the steam pressure by opening safety valve and
steam discharge valve.
Notice the relationship between the steam pressure, load and furnace pressure
differential. The furnace pressure differential means the particle concentration of
the dilute phase region, which plays an important role in controlling the steam
pressure and load.
b) Unstable combustion.
During normal operation, keep the steam temperature stable and watch the
steam temperature influence on the steam pressure and the feedwater pressure
influence on the desuperheating water flow and the feedwater temperature
The steam temperature can be raised by increasing the air flow but the air flow
should not be too big.
The steam temperature can be increased by soot blowing on the heat surface.
Report the situation to shift leader to decrease the load properly if the steam is
still over-temperature after adjustment.
Take the measurement of local water level meter as criterion and use the
secondary water level meter as the basis of monitor and adjustment. During
normal operation, there are two water level meters at least for the reference of
the operator.
Each shift should wash and calibrate the primary and secondary water level
meters. High/low water level alarm test should be carried out periodically to
guarantee reliable and correct operation.
When the feedwater is in automatic mode, carefully monitor its operation and
water level change. If the auto mode is not working, switch it to the manual
adjustment timely.
During operation, keep the water level within the prescribed limit and carefully
grasp the change pattern among steam flow, feedwater flow and feedwater
pressure to control the differential value of the feedwater flow and steam flow.
Regulate the water level timely when it changes.
When the boiler load is low, the feed water is adjusted in single-impulse way.
Make the inlet water equivalent to prevent large fluctuation of water level with
reference to the indication of feedwater flow and steam flow.
If the fake water level is caused by dramatic change of load, adjust the water
level correctly and timely based on the water level change tendency. Blind
operation should be avoided to prevent the water level accident of the steam
drum because of improper operation.
If the water level is too low because of low feedwater pressure or leakage on
heat surface, properly decrease the boiler load to keep the water level normal.
Strengthen monitoring and control of the water level under following conditions:
When the steam drum continuous blow down and intermittent blowdown is put
into service.
During operation, keep negative pressure of furnace normal value. For increasing
load, firstly increase the ID air flow and then increase the FD air flow and fuel
quantity. However, for decreasing load, firstly decrease the fuel quantity and FD
air flow and then decrease the ID air flow.
When the boiler load changes, firstly increase the air and then the coal, and then
decrease the coal and the air flow. Repeat the above sequence to achieve
“Less-Amount Many-Times” adjustment method and prevent the big fluctuation of
the bed temperature. Meanwhile, watch the corresponding relationship with the
furnace differential pressure under various loads. The furnace differential
pressure reflects the heat transfer of the dilute phase region.
During the boiler operation, watch the temperature and resistance change of all
parts at all times. If the flue gas temperature or the resistance is not normal,
check if it is caused by the air leakage or excess oxygen or coking or heat
surface leakage or abnormal combustion and take the measurement to solve the
abnormal condition. Then, check the air leakage of the boiler proper and all sight
holes and man-holes should be closed firmly. If found air leakage, take the
measures to block it.
During operation, watch the coal quality and take the corresponding adjustment
based on the quality.
The chemical operator on duty should analyze and tests the coal fed to the boiler,
ash slag and flying ash combustibles once in each shift. Inform the boiler
operators of test results to control the coal type change timely and achieve the
economic adjustment. Meanwhile control SO2 emission within prescribed limit.
Non-periodically carry out soot blowing for the measurement points of bed
pressure/temperature/furnace negative pressure to improve the accuracy of
indication and the combustion adjustment quality.
The high alarm of bed temperature is 955℃. When the temperature reaches
990℃, the main fuel should be cut off (MFT). The low alarm of the bed
temperature is 790℃. If the temperature is lower than 650℃, and the startup
burner is not put into service yet, the main fuel should be automatically cut off
(MFT). When the bed temperature is lower than 540℃, the main fuel is cut off
automatically, no matter whether the startup burner is put into service or not.
Monitor the inner temperature of furnace and the outlet flue gas temperature of
furnace at all times, in which it has a pre-warning function to monitor the bed
temperature.
Change the combustion quota of the dense phase to control the bed temperature,
which can be effectively controlled by changing the ratio of primary and
secondary air, discharged slag amount, feed coal quantity, returning material
quantity, ash flow of external bed, limestone quantity and change of the coal
particle.
Increase on the primary air flow can decrease the bed temperature and vice
versa.
Decrease on the feeding coal flow can reduce the bed temperature and vice
versa.
Increase on the returning material quantity can decrease the bed temperature
and vice versa.
Increase on ash flow of external bed can reduce bed temperature and vice versa.
During normal operation of boiler, keep the bed temperature within the prescribed
limit which should not exceed 4KPa based on the unit load. If the unit load is high,
the bed pressure should be high and vice versa. The bed pressure should be
kept within the range of 4-7KPa.(Decided based on commissioning result)
Change the discharged slag quantity, adjust the speed of ash cooler and keep
the bed pressure within the prescribed limit.
The bed pressure can be adjusted by changing the limestone quantity. If the bed
pressure is high, decrease the limestone quantity.
If the bed pressure is high, increase the primary air flow to make slag discharging
easy and strengthen slag discharging to decrease the bed temperature to be
within the prescribed limit.
Warm up the pipe for 30 min to make the level meter proper temperature stable
and then close the primary/secondary valves at turbine side as well as the
discharge valve.
Open the primary valves of steam/water side and then firstly 20% open
secondary valve of steam side and then 20% open the secondary valve of water
side.
Watch water level in the water level meter and slightly fluctuate. After the water
level meter is normal, alternatively open secondary valves on steam and water
sides to fully open position.
b) Close water valve, flush steam pipe and glass plate (tube).
c) Open water valve, close steam valve, flush water pipe and glass plate (tube).
d) Open steam valve, close water release valve, recover the operation of water
level gauge.
e) After flushing, it is required to compare the water level with that of the other
drum level gauge. If indication is abnormal, flush again. It is required to flush the
water level gauge slowly and apply protection in accordance with relevant safety
requirement.
7.10.4 Precautions:
a) Complete lighting on water level meter
d) Pay attention to the safety of personnel and equipment and operate slowly.
Do not face the sight hole of the water level meter and but stand by one side
of the meter. After operation, check the positions of all valves to make sure
the valves of water/steam sides are fully opened.
e) Do not use two water level meters flushing at the same time.
b) Strengthen flushing for water level meter if the water quality of the meter is
bad or scaled which cause the water level indication blur and dark image
display.
a) Slowly open the meter discharge valve. If the level drops a little, it indicates
the boiler is slightly full of water
b) If the water level does not decrease, close the valve of steam side. Wash the
pipes and valves on water side.
c) Slowly close the water discharging valve of the water level meter. If the water
level appears in the water level meter, it means there is still water inside the
steam drum, and the boiler is slightly lack of water.
d) If there is no water seen in the water level meter, it means that the water
level of steam drum has been decreased below the connection pipe of water
side, and it indicates boiler is seriously lack of water.
e) Close the valve of water side and open the water discharging valve. If there
is water level or the water level is decreasing, it indicates the boiler is
severely full of water.
The operator carries out the periodical blowdown with the supervision of chemical
personnel. During operation, fully open the primary valve first, and then open the
secondary valve. During closing, close the secondary valve first, then close the
primary valve and the blowdown time is 30s, which should not be too long to
prevent damage on water circulation.
Strengthen monitoring of the water level and communicate with the turbine
personnel to guarantee the water level of deaerator normal during blowdown.
Check all check valves before blowdown and stop blowdown if there is serious
fault or leakage threatening personnel safety. There should be enough lighting for
the blowdown site and with special tools. Do not directly face the valve.
Do not blow down two lines or two circulating loops at the same time. Do not use
bottom heating for blowdown.
Stop blowdown if the blowdown pipe has impact. Continue to blow down after
impact is solved.
Based on the predicted shutdown time, early remind the fuel operator on duty of
stopping feeding coal to the coal bunker and stopping feeding limestone to the
limestone silo.
Remind the personnel on each post to fully check all equipments under their
control and ask them to correctly record the detailed fault items in the “Equipment
Fault Log”.
Carry out full purging on the heat surface of boiler. (Before 50%BMCR)
Check the fuel oil system which should be in the standby state and carry out the
insertion and withdrawal test on the oil gun for putting the oil gun into service to
stabilize combustion in time. The purging system should be in good condition.
When boiler load decreases, watch and guarantee the differential pressure of
furnace not exceed the maximum value. Discharge the bed material from furnace
if necessary; otherwise it has the possibility to fail to set up the circulation when
restarting up boiler.
Stop the limestone feeder system and close all manual inlet valves.
During load decreasing, the temperature difference of the upper and lower drum
wall should be less than 50℃ and the decrease speed of the flue gas
temperature should be less than 1 ℃/min.
Decrease the electric load of unit to the minimum stable load and the boiler load
to 30%BMCR. Keep the minimum electric load operation of unit for 30min or so
as to cool down the refractory materials inside the cyclone gradually.
Gradually decrease the coal feeder output to zero and lower the material level of
coal bucker to the minimum safe store level or clean the coal from the coal
bucket. Close the outlet electric valve of the coal bucker and keep the coal feeder
running till the signal of cut-off coal supply alarm, and then stops the coal feeder
and close all outlet valves of coal feeder.
Monitor the oxygen content and bed temperature of furnace. When the oxygen
content increases dramatically and the bed temperature begins to decrease,
gradually reduce the output of air fan and reduce the supplying air flow of furnace.
But pay attention to adjust the primary air flow to guarantee good fluidization of
the bed material all the time.
After the flame is out, keep I.D fan, high pressure fluidization air fan, secondary
air fan, primary air fan running for 5min, and then purge the combustibles inside
the furnace.
If the boiler needs long-time outage or maintenance, continue using the air fan for
ventilation and cooling down of the boiler. Meanwhile use the ash cooler to
discharge the bed material. Before the flame is out completely, keep the pressure
of boiler bed not exceed 4KPa and cool down the unit as evenly as possible.
There is still steam generated within a time because of furnace wall and element
heat-storage, during which the water level of the drum should be kept at the
upper limit. Open the recirculation electric valve of economizer if the water is not
fed to the steam drum temporarily.
Stop the high pressure fluidization air fan after the material returner is cooled
down to the safe temperature.
There must be a special operator monitoring CRT if the water/bed material is not
discharged out yet and all rotating parts are not de-energized.
If the water/steam system of boiler needs to be ventilated, open the drain valve
when the steam drum pressure decrease to 0.5Mpa (The water temperature
should not exceed 120℃ during draining water) and open the vent valve when
the steam drum pressure decreases to 0.1MPa, discharge all water in boiler.
When the boiler load and parameters decrease, watch the coordination of boiler,
turbine and generator. Pay attention to the steam drum water level and steam
temperature.
Stop the limestone feeder system and close all manual inlet valves of boiler.
If the bed temperature is lower than 770℃, put the burner into service and retreat
ESP based on the actual condition. Continue decreasing the feed coal quantity to
the minimum till shutdown and open the steam discharging valve or the turbine
bypass based on the actual condition.
Gradually decrease the coal feeder output to zero and lower the material level of
coal bunker to the minimum safe store level or clean the coal from the coal
bunker. Close the electric outlet valve of the coal bunker and keep the coal
feeder running till the signal of cut-off coal supply alarm appears, and then stop
the coal feeder and close all outlet valves of coal feeder.
Decrease the combustion power of burner, but pay attention to control the
decrease speed of steam/flue gas temperature. The load should be reduced to
the minimum stable load, and keeps the boiler running under minimum load for
30 min. Cool down the refractory material of furnace gradually.
Stop burner, and flame is out. Close all fuel oil angle manual valves when the bed
temperature decreases to 540℃.
Latch off the turbine, stop the burner but keep the steam drum water level at
+150 or higher. Open the recirculation valve of economizer when stop feeding
water.
After stop supplying fuel and the ventilation lasts for 5min, stop all air fans and
close the corresponding electric inlet/outlet valves and governing dampers.
Continue running all ash removal systems till the ash hopper are empty. Stop
ESP and the ash removal and transmitting system based on the regulations.
During sliding parameters shutdown, control the decreasing speed of the main
steam pressure ≤0.05Mpa/min and that of the main steam temperature ≤1℃/min
and that of the reheat steam temperature ≯2~2.5℃/min.
After shutdown, keep the steam drum water level at +200mm or higher till the
steam temperature of drum is lower than 200℃.
There must be special operator monitoring CRT if the water/bed material is not
discharged out yet and all rotating parts are not de-energized.
b) Keep high bed material level and when bed temperature is 50℃ higher than
the normal operating temperature, stop the coal feeder before banking up.
c) When banking the fire, the heat accumulation of boiler is high. Watch the
steam drum water level and close the blowdown valves to keep a certain
water level. Open the electric recirculation valve of economizer.
d) When banking the fire, stop the coal feeder first, then stop the secondary air
fan and keep coal on the feeder belt.
e) After the coal feeder stops, quickly decrease the unit electric load based on
the boiler pressure to keep the main steam pressure a little higher at all
times and watch the oxygen content of the boiler outlet. When the oxygen
content increases to 13~15%, immediately stop I.D fan and trip the primary
air fan, secondary air fan by interlock. After banking up fire, quickly close the
damper to prevent the cooling air entering the furnace.
f) During the boiler shutdown for hot standby, keep the average bed
temperature at 650℃ or higher, follow the cold startup steps when the bed
temperature is lower than or equal to 650℃.
g) When boiler is shut down for hot standby, keep the boiler pressure. Close all
air fans and the related air dampers after finish sootblowing. Make the unit in
the hot standby state and ensure the materials have been discharged out
from the ash cooler. When the steam drum pressure decreases lower than
h) During boiler shutdown for hot standby, open the drain valve of main steam
header, the drain valves of main steam connection pipe and start water
supply system and keep the normal water level of steam drum during
combustion before raise fire combustion to guarantee the steam pressure
and the bed temperature.
i) If the fire banking time is longer, start to increase the temperature in the
midway. Re-bank up the fire after the bed temperature increases to normal
level.
b) Before hot startup, put the fuel oil system into service and carry out the oil
circulation. Once the hot startup fails, immediately put the burner into
service and shorten the startup time.
c) Start up ID fan, high pressure fluidizing air fan, secondary air fan, and adjust
the air flow to the ignition operation air flow. Subsequently, start up the coal
feeder, which should be operated quickly. If the bed temperature is higher
than 650℃, it is not necessary to carry out the blowdown. Watch the oxygen
content and bed temperature. After 5min, put the coal into service, it means
there is flame if the oxygen content decreases but the bed temperature
increases but if the oxygen content does not change and the bed
temperature has the decrease tendency, it means it is not fired yet. So stop
the coal feeder immediately and carry out purging on the furnace and then
start up the boiler based on the boiler cold startup steps.
d) When starting up air fans, communicate with the turbine personnel to slightly
open the high/low pressure bypass to achieve protection of the reheater.
Because the heat accumulation of the circulating fluidized boiler is big, the
heat exchange will take place between the hot bed materials and the heat
surface during starting up of air fans. Meanwhile, pay attention to steam
temperature. If it rises rapidly, cooperate with shift leader to adjust
combustion and desuperheating water.
f) Before starting up the air fan, carry out the ventilation and purging of boiler.
And then conduct the cold startup if the bed temperature is lower than 650℃.
All purging steps should be finished as soon as possible so as to prevent the
bed temperature from swift drop
g) After the oil gun is ignited, the bed temperature will increase and the coal
can be put into service based on the normal steps. The subsequent
operations should be finished with reference to the cold state sliding
parameter startup. Increase the unit load to the required value.
c) All water level meters are damaged and the water level of steam drum
cannot be monitored.
d) The severe pipe explosions of water wall, which make the normal water level,
fail to be maintained.
e) The main feedwater pipe, superheater and main steam pipes are exploded
and threaten the personnel and equipment safety.
g) The steam pressure is higher than the action value of the safety valve and
the safety valve refuses to act and the primary/secondary bypass and
atmospheric steam-discharge steam valve cannot relieve.
i) Re-combustion at the flue gas duct causing the discharge flue gas
temperature up to 250℃ or higher.
j) Furnace or flue gas duct is exploded which damage the equipment severely.
i) MFT acting conditions are met, but the protection failed to act.
m) I&C power supply is completely cut off, the boiler operation cannot be
monitored or controlled
c) All secondary water level meters are damaged and cannot be restored in
short time.
e) The boiler feedwater, boiler water and steam quality are severely over
normal parameters and cannot be restored after the measurement is taken.
f) Fluidization inside the furnace is worsened and cannot be restored after the
measurement is taken.
g) Partial power supply of I&C meters is off (flame is not out yet), and cannot be
restored in the short time.
h) The cyclone separator and bed temperature is 990℃ or higher for a long
time. The measurement adopted is ineffective, and there is a trend of going
up.
j) The furnace wall, cyclone separator, standing pipe, material returner and the
outside expansion joint of material U-beam are burnt to be red and will
possibly worsen.
k) If the ash cooler fails and it is hard to discharge slag. The problem is still
unsolved after multiple adjustments and the boiler cannot be guaranteed for
normal operation.
l) The material returner is blocked and external bed cone valve has leakage or
ash pluggage has not been eliminated, which is still unsolved after multiple
adjustments.
m) The superheat and reheat steam temperature or the metal wall surface
temperature exceeds the limit and it cannot recover to the normal range after
multiple adjustments are carried out.
n) There is a fire in the boiler house which threatens the equipment operation.
b) Cut off all automatic modes and manually adjust the water level of drum and
close all desuperheating water valves.
c) Report the situation to the shift leader and the department leader.
d) If the turbine has been latched off, timely put the primary and secondary
bypass into service and properly open the steam discharging valve.
f) If the secondary combustion happens in the flue gas duct, timely apply for
stopping all air fans after emergency shutdown, and firmly close all dampers
of the flue gas system and ventilation is forbidden.
g) If the leakage happens to the convection flue gas duct, keep the normal
water level of the steam drum.
h) Keeps the air fan running when the boiler is full of water. Restore the ignition
if the water level is back to normal.
i) If the boiler lacks water severely, the feeding time is decided by the chief
engineer.
j) If the leakage happens to the economizer and water walls, do not open the
recirculation valve of economizer.
k) If the heat surface is exploded and causes shutdown, keep one I.D fan
running till the steam is dried inside the furnace.
l) If the water wall and convection heat surface is exploded, apply for stopping
the shutdown after immediately stop the dust catcher.
n) After shutdown, record all expansion indications and the temperatures of all
heat surfaces based on the related regulations.
o) The other operations should be carried out based on the normal shutdown
and record the reason and treatment process after finishing treatment.
The steam drum pressure does not decrease to zero and the power supply of the
boiler equipment has not been cut off yet. The operator should continue
monitoring the panel.
Keep the water level of the steam drum in high level before the steam drum
pressure decreases to zero
Do not cut off the standby equipment interlock or carry out the maintenance on
the standby equipment without the shift leader’s approval.
Firmly close all dampers to decrease the heat loss of furnace during shutdown for
thermal standby.
Open ID fan damper and man hole for natural ventilation 4~6 hours after boiler
shutdown. Open the discharge water valve of the lower header when the steam
drum pressure decreases to 0.5MPa and open all vent valves of boiler proper
when the pressure decreases to 0.1MPa.
Start up the air fan for ventilation and cooling down at low flow 24hours after
boiler flameout. Based on the requirements, discharge the bed material. Watch
the temperature difference of upper and lower walls of steam drum which should
less than 50℃.
During shutdown and cooling down, slow down the cooling down operation when
the temperature difference of steam drum does not exceed the regulated value.
The quick cooling down is carried out based on the following method:
During shutdown, increase the discharged slag amount to decrease the storage
heat amount of boiler.
When the bed temperature decreases to 150℃, stop the high pressure fluidizing
air fan, primary air fan and secondary air fan. Open the man hole at the bottom of
the boiler wall to keep the ID fan running. Properly increase the furnace negative
pressure value based on the temperature decrease ratio.
8.8.1 General
a) In order to guarantee safe and economic operation of the thermal equipment
and prevent corrosion during the outage according to the related regulations
of Thermal Power Plant Shutdown (Standby) Thermal Equipment
Anti-corrosion Guide Rules SD223-87.
b) If the outage time exceeds one week, charge nitrogen for maintenance. If the
outage time is within one week, use the steam pressure method or
feedwater pressure method or residual-heat drying method. If the pressure
parts needs maintenance during outage, use the residual heat drying
method for maintenance.
b) When the steam drum pressure decreases to 0.1~0.2MPa, fully open the
vent valve of the drum proper to discharge out the boiler water. Use the
residual heat to dry the heat surface and remove the humidity from the boiler
till the air humidity of boiler reaches to standard. (The air relative humidity is
<70% or equal to the environment relative humidity).
c) During drying process, use the hot water sampler and vacuum pump to
extract the air inside the furnace for measurement.
d) Measure the humidity once every hour. The humidity should meet the
standard.
b) Stop filling water to the boiler till the water appears in the vent valve of the
superheater and the hydrazine concentration is 150~~200mg/L
d) During boiler protection, use the boiler water sampler to measure if the
solution content is satisfied.
e) Measure the hydrazine content and PH value once every week. Adjust them
if they are lower than the standard. Find out the cause and solve the
abnormal condition immediately.
f) Measure the hydrazine content and PH value once every week during
protection period.
g) The chemical solution has the corrosion influence on the copper parts, which
should be isolated.
h) After exit the boiler protection, strengthen backwashing from the boiler
proper to the superheater before ignition. Carefully control the ammonia
content of the steam at less than 2mg/kg to prevent the pipe corrosion by
ammonia.
i) The chemical solution is irritant and the hydrazine is poisonous, which should
be used with protection measurement on operators. Treat the solution to
satisfy the discharge standard before discharging the hydrazine solution.
b) When the drum pressure decreases to 0.3MPa, start filling nitrogen into the
boiler. In condition that the nitrogen pressure is kept within 0.3-0.5MPa,
open the water discharging valve. After the water in the boiler is discharged
using compressed nitrogen, close all the drain valves.
c) Check the boiler steam and water system thoroughly, tightly close all the air
valves and drain valves, feed water and main steam pipeline and its drain
valve, so as to keep the nitrogen system airtight
d) Use the nitrogen tank outlet regulating valve to control the pressure at
0.3MPa. When the pressure inside the boiler is lower this value, nitrogen
should be refilled into the boiler.
e) During the period of boiler with nitrogen, keep the nitrogen pressure inside
the boiler is higher than 0.03MPa (from indication of pressure gauge) and
the nitrogen purity is high than 98%. Meanwhile, the operating personnel on
shift should record the nitrogen pressure twice each shift.
a) Limit the spread of the accident, eliminate the accident source and remove
the danger to personnel safety.
b) Isolate the faulted equipment and make sure the non-faulted equipment is
operating normally.
c) Remove the fault as soon as possible, restart the equipment and the system,
adjust the operating parameter and recover the normal unit operation.
d) When fault occurs to the unit, all operating personnel should analyze
parameter variations and the fault detail. They should judge the cause and
the possible effect. Under the unanimous leadership of the supervisor and
team leader, the shifting personnel should try to solve the accident quickly
and properly, reduce the loss to minimal.
e) In a situation that the personnel and equipment safety is ensured, try to keep
the boiler in operation. Report the accident and the progress to the
engineers and related leaders at any time.
f) When the accident which is not listed in this manual occurs, the personnel in
charge should take measures for trouble-shooting as soon as possible
based on trouble shooting principles and their own experiences.
g) After the accident is solved, keep a detailed record on the accidents original
parameters and report it to the related leaders. Organize for accident
analyzing meeting and learn lesson from it.
o) Furnace pressure HH
p) Furnace pressure LL
q) Turbine trip
r) Logic control system powers off.
s) Fuel control system powers off (signal from automatic combustion control
system).
9.2.3 Solution
a) Check if the MFT action process is right or not immediately. If the protection
is triggered by mistake, reset the protection and restore the tripping power
equipment. Start the boiler under hot state and report to the shift leader at
same time.
b) Make sure fuel oil is cut off and desuperheating water is closed. Control the
going down speed of parameters. (For example, furnace negative pressure,
steam drum water level, steam temperature, steam pressure and bed
temperature).
c) Check tripping causes. Inform all posts to check equipment and systems.
Reset the tripping signals and equipment. Adjust total air quantity by about
30% for purging. Prepare for re-startup.
d) After the causes are found and eliminated. Purge the furnace for 5 min after
e) If the startup conditions could not be met in a short period of time, stop all
rotary equipment, and then perform according to the normal boiler shutdown
requirements.
9.3.1 Description
a) The steam drum water level indication is below the normal value and alarms.
If water level is -200 mm lower than the lowest allowable water level of
steam drum, alarm will be given; if lower than -280 mm, MFT will be
activated.
b) Feed water flow is abnormally less than the steam flow (when the water wall
or the economizer explodes, the feedwater flow will be the opposite)
c) When it is seriously short of water, the local water gauge indication is lower
than the visible water level; the superheated steam is abnormally high.
9.3.2 Cause
a) Feedwater automatic control fails or water level protection fails.
c) I&C instrument power failure, wrong indications of water level gauge and
steam & water flow meter causes operators to work in a wrong way.
Adjustment is not made after feedwater pump is started or operation is not
properly done when switching between feedwater lines.
d) Low feedwater pressure or adjustment is not made in time due to too much
steam flow added.
g) Too much load shedding and the steam exhaust valve or safety valve close
so quick.
h) Improper judgment on fake water level after safety valve is open which
opens the emergency discharge by mistake. After safety valve sit back, the
adjustment is not done in time.
j) Feed pump fails and its output falls. The operating pump trips, but the
standby pump does not start up by interlock. The standby pump is started up,
but the output isn’t adjusted timely.
9.3.3 Solution
a) When the water level is found lower than normal, check the water gauges to
see if their indications are right or not, according to the steam and water flow.
b) After confirm the water level is low, judge the causes, switch the automatic
water supply into manual, open the feedwater governing valve further or put
the auxiliary pipeline into operation for supplying more water. If the valves
are jammed, eliminate the problem timely.
c) When the steam drum water level is reduced to -50 mm, judge the causes.
Pay attention to that whether the automatic feedwater control can work
normally. If necessary, switch it to manual mode to increase feed water
amount.
d) Check whether the blowdown valve and water discharge valve are closed
tightly, damaged and has any leakage. Tightly close the water discharge
valves, blowdown valves and sampling valves.
f) If the water supply pressure is low, inform the turbine operator to increase
feedwater pressure or to start a standby feedwater pump. Reduce steam
drum pressure if necessary.
g) When water level is down to -280 mm, shut down boiler in emergency and
report to the shift leader.
b) If the steam drum is seriously full of water, local water gauge indication is
above the upper visible water level, steam temperature drops rapidly with
water attack sound. The poor sealing position of the pipe valves and flanges
9.4.2 Cause
a) Feedwater automatic control fails or water level protection fails.
c) I&C instrument power failure, wrong indications of water level gauge and
steam & water flow meter causes operators to work in a wrong way.
Adjustment is not made after feedwater pump is started or operation is not
properly done when switching between feedwater lines.
f) Improper operation when opening safety valve or air exhaust electrical valve
which is caused by fake water level.
g) Rapid recovery of combustion after boiler flameout, water level rises too fast
but improperly handled.
h) Serious boiler load fluctuations and water level adjustment is not made in
time.
i) When the feedwater bypass is switched to main line, the water supply
pressure and the steam drum pressure have a large difference, and
operation is improper.
9.4.3 Solution
a) When the water level is higher than normal, check the water gauges to see if
their indications are correct according to the steam and water flow.
b) After confirming the water level is high, judge the causes, switch the
automatic feedwater control into manual mode, close the feedwater
governing valve a little or exit the standby pipeline in operation to reduce
water flow. If the valves are jammed, eliminate the problem timely.
c) When the steam drum water level is up to +50 mm, judge the causes. Note if
the automatic feedwater control is easy to operate. Reduce feedwater
quantity manually if necessary.
d) If the hydraulic coupler fails, put the standby pump into operation
immediately. If the feedwater valve fails, eliminate the problem or adjust
steam drum water level through the feed pump hydraulic coupler.
f) If the main steam temperature drops too rapidly, cut off desuperheating
water supply and open drain valves of each stage superheater. Contact the
turbine operator to drain water of the main steam system and prepare for
emergency shutdown.
g) When the water level is up to +200 mm, shut down the boiler in emergent
and report to the shift leader. Discharge water further and pay attention to
water level changes.
h) After confirming that boiler is full of water, shut down the boiler in emergency
and inform turbine operator to pay attention to steam temperature changes.
i) Pay attention to water level changes. Stop discharging water after the water
level is restored to the normal. Check and confirm other conditions are met,
report to the shift leader, inform turbine and boiler operator for re-startup.
b) Blockage of water gauge steam collecting pipe or steam valve leakage and
water level too high.
c) Blockage of water gauge water collecting pipe or water valve leakage and
water level too lower.
d) Water level gauge steam and water connecting pipe is blocked and the
water level is too high.
e) The indication difference between water level gauges at the both sides is
large. Indications of the bi-color water level gauge, electric contact water
level gauge, and water level gauge of the DCS display doesn’t coincide.
9.5.2 Cause
a) Water slag and suspended matter in the steam drum come into the steam
and water connecting pipe.
b) The feedwater quality is bad and foreign matters accumulate at the primary
and secondary valves.
9.5.3 Solution
a) If the local bi-color water gauge leaks, disconnect it timely, close the valves
at the water and steam side, then inform the maintenance personnel.
Meanwhile, check if the indication of other bi-color water gauge is correct or
not.
b) When the local bi-color water gauge explodes, cut off the lighting of this
water gauge and then disconnect the water gauge.
c) If the local bi-color water gauges of the steam drum are all damaged, and
automatic feed water control is in place, high and low water level alarm and
water level protection are activated reliably, and water gauges of the electric
contact and equalizing reservoir are checked with the local water gauge not
long time ago. If they are confirmed reliable, the water gauges of the electric
contacts and equalizing reservoir can be used to monitor water level and
maintain boiler in operation for 2 hours. Pay attention to the balance
between the feedwater and steam flow, keep boiler load stable and isolate
the damaged water level gauge for maintenance.
d) If the local color water level gauges of the steam drum are all damaged,the
feedwater control is under automatic mode, and the High or low water level
alarm is not reliable, but the equalizing reservoir, or the electric contact water
level gauge had been calibrated recently, then it is allowed to run the gauges
for short time of 15-20 minutes.
e) Under the above mentioned situations, the water level gauge must be
repaired in emergency. Stabilize the load and pay attention to that the
feedwater flow and the steam flow should be balanced, during which the
blowdown work, water discharge and sootblowing work of boiler is not
allowed.
f) If all the local bi-color water gauges of the steam drum are damaged, the
automatic feed water control, high and low water level alarming and water
level protection are not reliable, and the water gauges of the electric contacts
and equalizing reservoir are also unreliable, the boiler should be shut down.
g) Once one water level gauge is repaired, ignition for re-startup can be
performed.
c) When it gets worse, the superheat steam temperature drops rapidly and
water impact will happen to steam pipeline, and steam will leak from the
flange.
9.6.2 Cause
a) Feedwater and boiler water quality deteriorate.
e) The steam and water separator is not good and operates overload for a long
time.
9.6.3 Solution
a) Report to the shift leader immediately, reduce boiler load and keep boiler in
stable operation condition.
b) Adjust the set value or switch from automatic to manual mode according to
the steam temperature condition. Reduce desuperheating water amount and
isolate the desuperheating water if necessary.
c) Drain water from the superheater system and inform the turbine operator of
draining water from the main steam system to prevent the deteriorated
steam from coming into turbine.
d) Inform the chemical operator to take sample and analyze boiler water. Then,
blow down to improve boiler water quality according to the results.
e) Open the continuous blowdown valves and blow down more regularly to
improve boiler water quality.
f) Change the feedwater control to manual mode. Keep the steam drum water
level at -50 mm, and then closely monitor the saturated steam quality.
h) Before boiler water quality improves, keep boiler in operation under low load
and it is forbidden to add load.
i) After the boiler water meets the requirements, increase the load slowly and
restore to normal operation.
b) There is abnormal sound at the leakage spot or steam leaks out from boiler
water wall or the spot is damp. Water flows out from the bottom of the flue
gas duct.
d) After leakage and pipe explosion, the flue gas temperature will be reduced
and the flue gas temperature difference at the both sides will increase. The
hot air temperature reduces and white smoke is seen from the stack.
e) If water leaks from the bottom of the flue gas duct, the ash handling device
could be blocked and the ash blowdown could not be smooth.
f) Serious pipe explosion, steam and water spray out from the nearby poor
sealing areas. Water level is hard to maintain, which leads to MFT.
9.7.2 Cause
a) Feedwater doesn’t meet the requirements, which causes scaling or corrosion
of the pipes.
h) The flue gas temperature difference is too high, leading to over temperature
of the partial pipe wall.
i) Flue gas corridor formed due to bad installation or maintenance performance,
9.7.3 Solution
a) Report to the shift leader timely. Monitor the adjustment and local inspections.
Pay attention to that if the damage situation deteriorates quickly.
c) When the damage is not very serious, supply more water for maintaining the
normal water level and operation under low load. Then, apply for boiler
shutdown.
d) When the pipe explodes seriously, the steam drum water level is hard to
maintain or the MFT protection is activated, the boiler should be shut down in
emergency.
e) One ID fan is used to maintain the furnace negative pressure. Stop it when
flue gas and steam in flue gas duct almost disappear. It is forbidden to
supply water to the boiler or open the electrically recirculating valve of the
economizer.
f) Before steam and water disappear in the flue gas duct, manhole is forbidden
to be opened for inspection.
g) After boiler shutdown, try to discharge ash from the ash hopper below the
dust remover and flue gas duct.
b) There is leaking sound in the furnace. When the pipe explodes, the furnace
negative pressure will become positive. The poor sealed spot of the boiler
wall leaks. The oxygen content will decrease.
d) Furnace bed temperature drops obviously. Flue gas temperature at the inlet
and outlet of the cyclone separator drops and temperature of returning
material at the leg position decreases.
e) The temperature difference of flue gas at the both sides is too wide. The
smoke exhaust temperature decreases and bottom ash is difficult to be
discharged.
f) Feed pressure increases and pressure difference between bed layers also
g) After pipe explosion, steam in the boiler is not completely exhausted. After
the boiler is cooled down, material on the bed is likely to be hardened.
h) White smoke (or steam) emits from the stack (or steam)
9.8.2 Cause
a) Feed water and boiler water is over limits for a long time, leading to the
scaling inside the piper inner wall, in which result in over temperature of pipe
wall or corrosion under the scaling.
b) Pipe external wall is worn severely. There is serious coking, and pipe
explode due to partial overheat.
c) Long time operation under low load or improper blowdown leads to bad
water circulation.
f) Boiler startup and shutdown are not operated according to the regulations.
Each part expands unevenly and large thermal stress is produced.
9.8.3 Solution
a) If there is leakage and the normal water level of the steam drum can be
remained and keep operation under low load, report it to the shift leader and
apply for boiler shutdown.
c) Check and pay attention to that if the damage situation expands rapidly or
not. Closely monitor water level, steam temperature, bed temperature and
bed ash discharge conditions. Adjust boiler negative pressure and bed
e) Reduce the primary and secondary air to ensure boiler negative pressure is
-100pa.
f) If the water wall is seriously damaged, after supplying more water, the steam
drum water level is still hard to maintain, shut down the boiler urgently.
g) One ID fan is in operation for exhausting steam and flue gas in the boiler.
h) After boiler is shut down, continue supplying water to maintain water level. If
the water consumption is too much and water level is hard to remain, stop
water supply accordingly.
9.9.1 Description
a) Unit load reduces suddenly, furnace negative pressure decreases or
becomes positive and the oxygen content drops.
c) Steam pressure decreases. Steam flow is abnormally less than feed water
flow.
d) Superheater explosion parts have abnormal sound. Flue gas leaks from the
poor-sealed position of boiler wall or enclosure wall.
e) Behind the leakage and pipe explosion, flue gas temperature decreases,
steam temperature and flue gas temperature difference increases and ID fan
current increases.
g) When the platen superheater leaks, bed pressure will fluctuates seriously,
bed temperature and separator inlet and outlet temperature decrease.
c) Pipes are not fixed firmly and tremble in operation for a long time.
d) The temperatures of main steam or pipes in operation are over limits for a
long time, which result in superheater over temperature for a long time.
e) During boiler startup, drain water is not enough or the desuperheating water
is improperly put into operation under low load. This cause water blockage,
and leads to partial overheat.
i) Pipe blockage by foreign matters leads to uneven steam flow, which results
in superheater partial pipe over temperature.
9.9.3 Solution
a) Report to the shift leader timely, monitor closely and pay attention to that if
the damage situation spreads rapidly.
c) When the pipe explodes seriously, shut down the boiler urgently so as to
avoid the accidents from spreading. Report to the shift leader and related
leaders.
d) Keep one ID fan in operation to exhaust steam in boiler and flue gas duct
after boiler shutdown.
e) Make up feedwater in small flow after boiler is shut down to keep a higher
water level of the steam drum. Open the economizer recirculation valve after
the water supply is stopped.
f) Steam in the boiler and flue gas duct almost disappears. Stop the ID fan for
natural ventilation.
9.10.1 Description
a) There is leaking sound at the pipe explosion places of the superheater.
Boiler negative pressure decreases suddenly or becomes positive. The
oxygen content decreases.
b) When cold reheater pipe explodes, flue gas or steam leaks from the
poorly-sealed places of the enclosure wall. when platen reheater pipe
explodes, flue gas or steam leaks from the poorly-sealed places of the
enclosure wall.
c) Reheat steam flow decreases abnormally and reheat steam pressure drops.
d) Behind the leakage and pipe explosion, flue gas temperature decreases,
steam temperature and flue gas temperature difference increases and ID
fan current increases.
9.10.2 Cause
a) Improper combustion adjustment, too wide flue gas temperature difference
at the both sides, and uneven heat leads to the partial pipe wall over
temperature for a long time.
c) Pipe external wall is worn or serious high temperature corrosion takes place.
d) Pipes are not fixed firmly and tremble in operation for a long time.
e) Reheat steam temperature or pipe wall temperature is over limit and in
operation for a long time, making the reheater pipe wall is in over
temperature condition for a long time.
f) During boiler startup, drain water is not enough or the desuperheating water
is improperly put into operation under low load, thus water is stopped,
leading to partial overheat.
g) Water wall scaling, and superheater ash blockage causes the increase of
flue gas temperature, and result in pipe wall over temperature.
i) Improper design and fabrication, uneven steam flow and too low flow rate.
l) During the startup, shutdown and load shedding process, the bypass system
isn’t put into operation timely, thus result in the pipe wall over temperature
without cooling.
m) Pipe blockage by foreign matters leads to uneven steam flow, which results
in superheater partial pipe over temperature.
9.10.3 Solution
a) Report to the shift leader timely. Monitor it more closely. Pay attention to that
if the damage situation is worsened or not.
c) When pipe explodes seriously, shut down the boiler urgently, prevent the
accidents from spreading. Report to the shift leader and related leaders.
d) Keep one ID fan in operation to exhaust steam in boiler and flue gas duct
after boiler is shut down.
e) When the steam in the boiler and the flue gas duct is almost disappeared,
shut down ID fans for natural ventilation.
9.11.1 Description
a) Safety valve doesn’t open when it reaches the action pressure.
c) After opening, the safety valve doesn’t reseat or reseats too fast.
9.11.2 Cause
a) Blockage of the safety valve.
b) If safety valve is open when it doesn’t reach action pressure, report to the
shift leader, keep boiler operation under reduced load, reduce steam
pressure to make the safety valve reseat as soon as possible. Contact the
maintenance personnel for maintenance. If it could not be solved under hot
state, apply for boiler shutdown based on the actual facts.
c) When the safety valve is open, the pressure is lower than the reseating
pressure but it doesn’t reseat, contact the turbine operator to reduce load.
Contact the maintenance personnel to take measures to make it reseat.
When the pressure is reduced and cannot meet turbine requirements, report
to the shift leader and apply for boiler shutdown.
c) When the bed temperature is too high, the fire is much brighter than that
under normal bed temperature, which is observed from the observation hole;
when the bed temperature is too low, the fire is darker than that under
normal bed temperature, which is observed from the observation hole;
d) Bed temperature too high leads to scaling of bed material, causes improper
fluidization. When it becomes serious, large scale of scaling may happen.
Bed temperature too low results in darker flame in combustion and may
cause fire accidents. When it becomes serious, the boiler may be out of
flame.
9.12.2 Cause
a) Wrong indication due to sudden changes of coal type or bed temperature
thermocouple failure.
d) Bottom ash fails to be discharged and the discharge amount is not properly
controlled, causes bed pressure deviated from the normal value.
f) Limestone supply is uneven, and causes bed temperature too high or too
low.
c) Adjust air and coal proportion. Increase primary air ratio properly and the
total air amount. Keep the oxygen content within the normal range.
d) Increase limestone amount, return ratio in the boiler properly or add bed
material by starting material feeding system.
f) Keep the bed temperature within normal range. If the ash cooler fails,
contact the maintenance personnel for repair.
b) If the coal feeding line fails, solve it and restore coal feeding timely.
c) Adjust primary, secondary air and air &coal proportion properly. Reduce
primary air amount of the air distributor properly. But good inner boiler
fluidization should be ensured. Control the oxygen content under the normal
range.
f) Bed temperature too low makes the combustion unstable, supply oil to
stabilize combustion and prevent MFT activation.
e) Air pressure of the water cooling air room is too high or too low.
9.13.2 Cause
a) Blockage of bed pressure measuring points or incorrect bed pressure
measured value.
f) Load is increased or reduced too fast and the adjustment is not carried out in
time.
g) Ash cooler failure.
h) Material crushing system fails and particle size changes greatly.
9.13.3 Solution
a) If the bed pressure is too high, discharge more bottom ash, reduce or stop
bed material or limestone feeding to the boiler. On the contrary, reduce
bottom ash discharge. Feed bed material to the boiler if necessary.
b) If bed pressure measuring points fail, inform the I&C personnel to handle it. If
the bed pressure measuring points are blocked, purge them with the
compressed air.
9.14.2 Cause
a) Power supply of coal feeder is off.
b) Coal feeder fails or the coal feeder is shut down by mistake.
c) Coal is wet and blocks up the coal chute, leading to activation of coal feeder
coal blockage switch. Coal feeder trips.
d) Coal bunker “bridging” or empty coal bunker.
e) MFT protection action results in coal feeder trip.
9.14.3 Solution
a) If the coal bunker is empty, contact coal handling personnel to supply coal.
b) If it is the coal bunker bridging, start the vibrator, the manual rapping also
should be carried out at the same time. If it is the coal bunker bridging and
could not be eliminated timely, it should be regarded as deviation of bed
temperature, flue gas temperature and steam temperature. Adjust coal
feeder amount in other coal bunker. If necessary, reduce the load and supply
oil to help combustion at the same time.
c) If the coal feeder trips, try to put it in to operation once. If successful, restore
the original working condition, thoroughly check and find out the tripping
causes. Increase coal amount in other coal feeders, report to shift leader and
check thoroughly, and treat it if necessary.
d) If the coal feeder trips and its operation could not be restored, close the
outlet valves of coal feeder so as to prevent hot flue gas from damaging coal
9.15.2 Cause
a) Auxiliary power electrical system of 6KV or 400V fails, which leads to
auxiliary equipment power failure.
b) Coal feeder fail and stop, which isn’t found out timely and leads to long time
coal interruption and bed temperature reduced to MFT activation value.
c) Material returning device and external bed return material work abnormally,
large amount of return feeding happens to pulse. If lots of bed materials
accumulated on the bed, it will cause flameout of burning coal due to sudden
oxygen loss.
d) When operates under low load, improper adjustment causes bed
temperature reduce to MFT activation value.
e) Coal property changes and is not adjusted timely.
f) Auxiliary equipment fails and trips, leading to MFT activation.
g) Main interlock protection of turbine, electrical and boiler is activated, leading
to MFT action.
h) Heating surface pipe explosion and water/steam leakage cause bed
temperature in the furnace decrease or intense furnace pressure fluctuation,
leading to MFT activation due to furnace pressure.
9.15.3 Solution
a) Stop coal feeder system and limestone system immediately. All automatically
controlled systems should be changed to manual control mode.
b) Put oil into operation to help combustion to increase bed temperature.
c) Reduce air amount, adjust circulating ash amount and cone valve opening.
Discharge some circulating ash or slag of external bed if necessary.
d) Reduce feed water amount and keep steam drum water level at -30mm.
e) Reduce or close desuperheating water according to steam temperature
down trend.
f) If the bed temperature meets the hot startup condition, perform the hot
startup immediately. If not, purge and perform the cold startup. It is forbidden
to supply coal blindly. Otherwise, secondary combustion or explosion or
coking will be caused.
9.16 Improper Bed Material Fluidization
9.16.1 Description
a) Uneven bed temperature, large bed pressure and bed density changes
significantly.
b) Serious air pressure fluctuation in the air chamber, so is the negative
pressure in furnace.
c) Large emission of NOx/CO and SO2.
d) Steam temperature and pressure and flow decreases.
e) Boiler is hard to take load.
9.16.2 Cause
a) Too much or too less bed material.
b) Too high or too low primary air proportion.
c) Fire-resistant and wear-resistant materials inside the boiler strip off and
block the air distribution plate.
d) Blockage of air nozzle.
e) Air fan fails or air damper is mis-operated by the operators.
f) Slag discharging system and bed material returning system fail.
g) Partial slag formation or load increase and decrease too fast.
h) Material particle size too big or small.
9.16.3 Solution
a) Adjust fluidizing air flow or pressure.
c) Air and coal proportion is too low and coal supply is too much for a long time
when boiler is in operation.
d) Primary air flow is too low, lower than critical fluidizing air flow. Bed material
cannot be fluidized normally.
e) When putting flue gas duct igniter into operation, air distribution is out of
proportion seriously or the combustion power is too high.
f) During igniting and pressure increasing, coal is added too fast and too much
or the air flow isn’t adjusted when adding the coal.
g) Bed temperature is too high, bed material fusion point is too low or the
coking is produced due to bad fluidization for a long time.
h) Coal property changes a lot, so does the lime stone content.
k) Air nozzles are damaged and slag leaks into air chamber, causing uneven
air distribution.
l) Slag is discharged too much, leading to too low bed pressure.
m) The slag isn’t discharged timely, causing bed material layer too thick.
n) Boiler is started for a long time and the air and oil mixture combustion is too
long. Particle bed temperature is too high.
o) Improper fire banking or slow fire banking startup causes the bed materials
fail to be fluidized, and leads to partial coking.
p) During boiler shutdown, the fuels and materials are not fully burnt and tar is
separated out, leading to LT coking.
9.17.3 Solution
a) Increase primary air flow of the coking area.
b) Increase bed material replacement, discharge bad fluidized bed material and
make up with fresh bed material.
c) Reduce bed temperature properly, especially during startup process to
prevent bed temperature from increasing rapidly.
d) If the fluidization condition of the boiler is poor or operation is carried out
under low load for long time, try to improve it in time.
e) Test coal property and limestone content timely.
f) After adjustment, if it still cannot be improved, apply for boiler shutdown.
9.18 Detonation
9.18.1 Description
a) There is a huge sound inside the furnace. When it becomes serious, the
furnace will be deformed.
b) Combustible materials accumulate in the flue gas duct. After ignition, the
combustible materials will be fired, leading to flue gas temperature over
limit.
9.18.2 Cause
a) Before ignition, the furnace isn’t sufficient ventilated for purging. Flammable
gas and materials are not discharged.
b) During startup process, when the temperature for coal feeding isn’t met, but
the coal is fed. The bed temperature doesn’t increase, coal supply isn’t
stopped but even increase coal supply amount blindly.c) During startup, the
pulse coal feeding isn’t performed, but coal is fed directly.
9.18.3 Solution
a) Before boiler startup, purge for enough ventilation to discharge flammable
gas and materials in the flue gas duct.
b) Before startup, perform the oil gun atomization test to avoid bad atomization,
which lead a large amount of oil accumulated in the ignition duct or in the
rear duct along with flue gas.
c) During the ignition, if the oil gun is out of flame, timely closes the oil valve.
Keep the fan in operation for 5 min, and then ignite the oil gun again.
d) If the oil gun mouth is blocked, oil gun has bad atomization condition. The
bed temperature is hard to increase and reach coal feeding temperature.
Stop the oil gun for cleaning or replacement and repeat ignition.
e) During ignition, open secondary air valve properly. This not only cools down
the secondary air port but also ensures adequate air ventilation of the dilute
zone, reduces and eliminates flue gas stagnation area and diminishes
flammable material accumulation timely.
f) Control coal feeding temperature properly. When the temperature is not
satisfactory for feeding coal, it is forbidden to add coal in advance.
Otherwise, coal will not be ignited and lots of flammable gas will be
separated and stored in furnace, separator and flue gas duct. Once there is
fire, detonation will happen. Even coking of equipment and beds will
happen.
g) Proportion of air with primary or secondary air should be adequate to
prevent incomplete burnt coal from being taken away and accumulating in
rear part of flue gas duct and horizontal flue gas duct. If the primary air is too
big, air rising speed will increase and coal volatile content is just separated
and the hard coke is blown up without combustion. If the secondary air is
inadequate, then disturbance will be decreased and the coal has no
adequate oxygen, thus the complete combustion conditions could not be
met.
h) Perform sootblowing on the rear part of flue gas duct periodically to take
accumulated combustible substance away.
i) Strictly control the coal particle size. Fine coal particles should not be too
much. Otherwise, the fine particles which haven’t been combusted will be
taken to the rear flue gas duct and settle down there.
j) During boiler ignition, oxygen content in the flue gas should be controlled
strictly and kept within 3~5%. During boiler load increase, add air first and
then the coal. When boiler load decreases, reduce coal first and then the air,
so as to stop boiler from operating under oxygen shortage working
k) During operation under low load, bed temperature should be well controlled.
It is forbidden to operate under low bed temperature condition.
l) During boiler banking, the coal supply must be stopped. When the bed
temperature tends to be stable or to decrease a little, the FD fan can be
stopped. Prevent too much coal in the bed material after boiler banking
from producing a large amount of flammable gas and dry pulverized coal.
9.19 Secondary Combustion at Rear Flue Gas Duct
9.19.1 Description
a) Negative pressure of flue gas duct and furnace fluctuates severely. Oxygen
amount reduces. Temperature of flue gas, working media and exhaust rises
abnormally. Black smoke emits from the stack.
b) Secondary combustion at air heater causes increase of primary and
secondary air temperature, even over the designed value.
c) Electric current of induced draft fan fluctuates and increases. Air and gas
duct that are not airtight may have smoke or spark. Anti-explosive valve will
be activated.
9.19.2 Cause
a) Air and coal ratio or primary and secondary air ratio is improperly distributed.
Incompletely combusted coal is carried away by gas flow and deposits in
rear and vertical flue gas duct.
b) Separating efficiency of the separator is low. Particle deposits in flue gas
duct with gas flow.
c) Under boiler start-up or emergency state, putting oil gun into service takes
longer. Oil and coal combust together, which causes incomplete combustion
of coal due to insufficient oxygen.
d) Sootblower fails or ash is not timely blown out. Deposited combustible
cannot be blown away.
e) There is too much fine particle in coal. Incompletely combusted particle is
carried away to flue gas duct and deposits.
f) Oil gun atomization is poor. Oil drop flows to flue gas duct and adheres to
heating surface.
g) Ventilation and purging are not done in cold or hot start-up.
h) Bed layer temperature or coal volatile is too low. Taking anthracite as an
example, due to longer combustion than black and brown coal, those
un-combusted will be carried away to flue gas duct and deposits if air
amount and speed is not adjusted timely.
i) Coal is fed when bed temperature has not reached feeding value.
Continuous coal feeding is conducted instead of pulse coal feeding, which
causes the coal carried away and deposit, thus secondary combustion at
rear flue gas duct happens.
9.19.3 Solution
a) When flue gas temperature rises abnormally, conduct combustion
adjustment and sootblowing in secondary combustion area.
b) Put steam extinguisher into operation at secondary combustion area.
9.20.3 Solution
a) Adjust primary air appropriately to lower the combustion area. Maintain good
fluidization of bed material.
9.21.2 Cause
a) Operate in long-time lower-temperature bed layer condition
b) Operate in condition that bed layer thickness is too high or too low, which is
unreasonable.
f) Impact of coal property: water content is larger, it’s required to absorb some
calories during combustion, bed layer temperature is kept as lower, the
combustion time is lengthened, the fly ash carbon content is increased; with
the ash content increasing or calories decreasing, fly ash carbon content
increases due to incomplete combustion.
g) If the separator efficiency is lower, the fly ash carbon content will be higher.
h) During cold sate startup, if the coal is supplied too early, the combustible
element cannot burn instantly.
9.21.3 Solution
a) In the premise that HP coking is not formed, it’s better to raise bed layer
temperature; make sure the separator inlet fume temperature is not too high,
in case of secondary combustion inside the separator.
b) In premise of sufficient total air flow and fluidization, reduce primary air,
c) Adjust ratio between upper and lower secondary air, increase the upper
secondary air and decrease the lower secondary air; when increasing upper
secondary air, try to reduce impact on lower bed temperature, so as to help
increasing bed temperature; keep primary air as proper index, keep bed
material well fluidized, make less adjustment; control oxygen content mainly
by adjusting secondary air ratio.
d) Control the slag exhaust volume properly, discharge the slag evenly, try to
keep the exhaust volume of each ash cooler consistent; do not discharge
slag continuously with a large volume; do not operate without discharging
slag for a long time.
9.22.3 Solution
a) If furnace is not seriously damaged, reduce load for further operation.
Increase furnace negative pressure. Pay much attention to furnace damage
situation.
b) If furnace is severely damaged, negative pressure cannot be maintained,
bed material spray by positive pressure or furnace frame is burned red, carry
out emergency shut-down and report to shift leader.
9.23 Air Chamber Slag Leakage
9.23.1 Description
a) Influence material fluidization, making the air chamber pressure increase
abnormally.
b) PA fan outlet pressure increases, which is easy to damage the primary air
duct.
b) Air nozzle declines or is seriously damaged, and the adjacent air nozzles
blow towards each other, causing air nozzle damage.
c) Air nozzle outlet flow rate is uneven, minor flow rate causes material to leak
into air chamber from air nozzle of lower rate.
9.23.3 Solution
a) When it is found that there is slag leakage, reduce air fan operations,
stabilize operation and timely report to shift leader.
b) When the slag leakage is serious, retain the operation, try to keep the load
stable, and prepare for applying for boiler shutdown.
c) When the slag leakage is serious, a large part of the ignition air duct has
been blocked, the bed material fluidization is uneven, apply for shutdown
immediately as required.
f) Furnace negative pressure decreases and that of flue gas duct increases.
9.24.3 Solution
a) When there is slight ash blockage, reduce coal feeding and slag discharge.
Reduce load and disturb by repeatedly switching and adjusting loosening air
and material returning air. Enhance slag discharge of material returning
device and its air chamber.
b) If air nozzle is blocked, anti-wear material fall off and coke is formed, shut
down for handling.
9.25 Drastic Decrease of Load
9.25.1 Description
a) Main steam pressure increases drastically. High steam pressure alarms.
Safety valve actuates if not timely handled.
b) Steam flow decreases dramatically.
c) Steam drum water level decreases first, and then rises. Water feeding
becomes less when it is in auto mode. Steam temperature rises.
9.25.2 Cause
a) Electric or power grid system fails.
b) Steam turbine or generator trips.
c) Mis-operation by operator.
d) Electrically-operated main stop valve is closed automatically.
9.25.3 Solution
a) According to steam pressure and pressure rising, open vent valve for
pressure relief and put LP bypass system of steam turbine into operation.
b) If safety valve is activated, check it after it seat back. Observe whether it is
tightly closed.
c) According to pressure rising, switch some governor into manual. Reduce
coal feeding or stop part of coal feeding for a short period. Strengthen
monitoring and adjustment of steam drum water level, steam pressure, bed
temperature, pressure and air amount.
d) According to bed temperature, if boiler minimum stable combustion cannot
be maintained, fire oil to support combustion. Reduce material circulation
9.26.3 Solution
Immediately reset all trip power switches.
Open the air vent valve of superheater, inform steam turbine operator to put primary
bypass, open air vent valve of reheater. Try the best to avoid safety valve working.
Shaft displacement, mm ≯4
10.14.2 Procedure
11.2.2 Cause
11.2.3 Solution
When two ID fans are in operation, one of them trips by fault:
a) If there is no abnormal phenomenon, like over-current, and main interlock
does not act, but the ID fan tripped, forcedly close CB of ID fan to re-operate
it. If the reclosing is ineffective, faulty fan should be put into stop mode
immediately and operator close its outlet-inlet dampers. Open other fan
dampers widely and increase its output, but over current is not allowed.
b) If there is over-current or any abnormal symptom, forced closing of CB is not
allowed. Main operator should regulate burning in time and keep burning
stable and furnace negative pressure normal.
c) Monitor ID fan output and reduce boiler load to 50%~60% of MCR. Regulate
air-coal ratio and keep stable operation.
When only one fan operates or tow ID fans trips at same time:
d) When MFT is activated, shut down boiler in emergency shutdown procedure
in time. Report it to shift leader.
e) When restoring, standby fan should be started first. If standby fan cannot
start or there is no standby fan, fans should be tripped at the same time.
Before trip, there are no abnormal symptom, such as over current or
mechanical defects. Find out the reason and recover operation as soon as
possible.
f) If the any one of the following situations happens, the fan should be stopped
immediately: rated current value is too big or vibration is too severe; bearing
temperature exceeds limit value; there is potential danger for equipment
damage and operation.
11.3.3 Solution
a) Fault fan trips and standby fan is started by interlock. If startup works
successfully, air pressure should be back to rated value immediately. At the
same time, fault fan should be put to OFF position immediately
b) If interlock startup of standby air fan is failed, manual startup should be
carried out immediately. If it still does not work and at the same time there
are no obvious electrical and mechanical faults, forced closing should be
taken. If the MFT protection is activated, emergency shutdown should be
carried out and shift leader should be reported.
11.4.2 Cause
a) Blade is seriously damaged and rusted or deposited with ash so that it loses
balance and result in vibration.
b) Bearing lubricant quality is poor or cooling water is cut off. Bearing
temperature rises and causes damages.
c) Impeller and its bearing are loose. Anchor screw is loose.
d) Fan is balanced or motor is not aligned when maintenance is carried out.
e) Protection malfunctions or activates because motor trips, emergency button
is pressed mistakenly or electrical fault happens.
11.4.3 Solution
11.5.2 Cause
11.5.3 Solution
When two ID fans are in operation, one of them trips by fault:
a) If there no over current or mechanical defects and MFT does not actuate
before the air fan tripped, forced closing of CB of air fan can be carried out
for restoring the operation. If the reclosing is ineffective, faulty fan should be
put into stop mode immediately and close its outlet dampers and inlet
dampers. Open another fan damper widely and increase its output, but over
current is not allowed. Monitor boiler bed temperature change closely.
b) If the tripped fan has over current or abnormal situations, forced closing is
not allowed. Chief supervisor should enhance another fan output and
guarantee good fluidization. Decrease ID fan output and increase secondary
air fan output. Decrease boiler load to 50~60% MCR and to the greatest
extent so as to maintain normal boiler bed temperature.
When only primary air fan operates or two running primary air fans trips at
same time:
c) When furnace comes to MFT, shut down the boiler in emergency shutdown
procedure. Report it to shift leader.
d) When restoring, standby fan should be started first. If standby fan failed to
start or there is no standby fan, the fan should be tripped at the same time.
Before trip, there are no abnormal symptom, such as over current or
mechanical defects etc. Find out the reason and restore operation as soon
as possible.
e) If the any one of the following situations happens, the fan should be stopped
immediately: rated current value is too big. Vibration is too severe. Bearing
temperature exceeds the limit value. There is potential danger for equipment,
stop the air fan urgently.
11.6.3 Solution
a) Regulate the output of normal coal feeder. Restore every parameter and put
bottom oil gun into operation if necessary.
b) Find out reason and eliminate faults rapidly.
c) If coal spreading air is less than the minimum, it should be regulated in time.
d) If coal feeder is interlocked to start under MFT protection operation, it should
be handled based on relevant regulation.
11.7.2 Cause
a) After ash cooler outage, slag with high carbon content burns in slag feed
chute and is coked inside the chute.
b) Before ash cooler is shut down, the speed is fast and slag feed chute
temperature is high and is in burnt red state. After ash cooler is shut down,
slag chute is cooled to shrink, thus slag inside chute is compressed. So this
results in blockage.
11.7.3 Solution
a) Rap slag chute to let blocked slag lump loose and fall.
b) Open slag chute inspection holes to release. When releasing, operator
should stand at side and enough retreat area should be reserved to prevent
danger from HP slag spraying.
c) Pay attention to bed pressure changes closely and transfer load to other ash
coolers. If necessary, emergency slag exit can be used to maintain bed
temperature in normal range.
d) Try best to maintain ash cooler continuous operation and avoid intermittent
slag discharge
e) Before ash cooler is out at every time, maintains operation at low speed for
certain period to cool the slag chute.
c) If leakage is serious, it will influence slag discharge. Besides, this will result
in ash cooler overload and trip.
11.8.2 Causes
a) Cooling water pressure for ash cooler is over limit.
11.8.3 Solutions
a) If water cooling tube bundle is leaking, stop ash cooler immediately and
close inlet-outlet valves for cooling water in time.
b) Increase slag discharge for other ash coolers and decrease boiler load
properly.
11.9.2 Solution
a) Stop ash cooler. Check damage situations of slag conveyor and find out
cause.
11.10.2 Solution
a) Check bearing damage carefully and add lubricant.
11.11.2 Cause
a) Positive pressure forms between limestone and furnace interface; if
intermittent limestone feeding is adopted, limestone is blocked by bed
material under positive pressure during not feeding.
c) Limestone particle is too big, thus the particles cause pipeline blockage
during moving.
b) There are foreign matters in oil gun so that atomization nozzle is blocked.
11.12.3 Solution
a) Before ignition, oil gun should be purged completely.
c) When flame detection time exceeds the prescribed time, there is ignition
failure signal. Oil gun input and output valve closes automatically.
11.13.1 Causes
a) Flame detector is in fault. There is flame for oil gun but flame detector cannot
detect it.
b) Oil gun ignition air is regulated improperly. Oil gun cannot ignite successfully
or flame is blown out after successful ignition.
e) Fuel oil contains excessive water or ignition or oil gun is in wrong position.
11.13.3 Solution
a) If ignition works well, but flame detector cannot detect flame. The flame
detector should be checked and repaired. If it cannot be repaired in short
term and ignition is demanded urgently, flame detector protection can be
defaulted under the condition that safety is guaranteed. On site, special
person should be there to monitor oil gun ignition
b) If oil gun ignition fails, ignition air proportion should be regulated again.
11.14.2 Causes
a) Oil gun atomization is abnormal and oil output is disorder.
c) Ambient air flow is too small for oil gun and it cannot control the flame.
11.14.3 Solutions
a) If there is problem for oil gun atomization, atomization nozzles should be
checked to see whether there is foreign matter or it is installed inversely.
11.15 Duct Ignition Burner Temperature Too High or Air Duct Catch Fire
11.15.1 Description
a) Temperature of air duct ignition burner is too high and sometimes it exceeds
1150℃.
b) Air duct metal casing is glow and when serious, there are sparks.
11.15.2 Causes
a) Flame is deflected or oil input is too much. The flame impacts refractory
directly.
c) The refractory are below the required standard and cannot bear high
temperature. Construction technology is below required standard or furnace
drying is not carried out according to heating curve so that refractory cannot
be cured normally.
d) Because boiler operates for a long time and the refractory are damaged and
drop off one after another.
11.15.3 Solutions
a) Before ignition, refractory should be checked carefully. If there are cracks
and material falloff, they should be repaired in time.
c) When the temperature of air duct ignition burner is too high, input of oil gun
should be decreased or the gun should be stopped temporarily.
e) When air duct ignition burner is burnt up, oil gun should be stopped
immediately and report shift leader to stop boiler.