INSTRUCTIONS

FOR THE
CARE AND OPERATION
OF
CIRCULATING FLUIDIZEDBED BOILER
(CFB)
 FOREWORD

The instructions are to be used as a guide for operational reference and

should not take the place of Boiler Operation Specifications.

These instructions are issued for the purpose of assisting operators in

obtaining the best possible results of HANGZHOU BOILER GROUP
CO.,LTD(HBG) equipment. The instructions can only supplement the
experience and judgment of those in charge of operation. They should be
interpreted and applied after due consideration for the requirements of other
equipment and for any particular set of circumstances. These instructions do
not purport to cover all details or variations in equipment nor to provide for
every possible contingency to be met in conjunction with operation and /or
maintenance.

The recommendations contained in these instructions are issued by HBG

based upon the knowledge and experience representing our best judgment at
the time of issuance. In offering these instructions for pre-operation, operation,
maintenance and safety, HBG assumes no responsibility for any failure or
incident resulted from incorrect operations.

The instructions involve quite a number of HBG’s technology, Without

permission, no one that is not involved in this Project is allowed to make any
copy of these Instructions.
 Contents
FOREWORD................................................................................................................2
1.CONSTRUCTION DESCRIPTION OF BOILER PROPER 锅炉本体构造说明.........7
1.1. Design Conditions..........................................................................................7
1.1.1. Boiler Specifications:.....................................................................................7
1.1.2. Boiler Main Dimensions.................................................................................7
1.1.3. Fuel................................................................................................................7
1.1.4. Optimum Size distribution for coal (shown in fig 1-1)Ash Analysis...............8
1.1.5. Limestone......................................................................................................9
1.1.6. Sand..............................................................................................................9
1.1.7. Igniter Type..................................................................................................10
1.1.8. Igniting Oil....................................................................................................10
1.1.9. Feedwater Quality........................................................................................11
1.1.10. make-up water.............................................................................................11
1.1.11. boiler water..................................................................................................12
1.1.12. Site Conditions:............................................................................................12
1.1.13. Operation Mode...........................................................................................13
1.1.14. Draft Mode...................................................................................................13
1.2. GENERAL DESCRIPTION OF BOILER......................................................13
1.3. GENERAL ARRANGEMENT OF THE BOILER..........................................14
1.3.1. Steam and Water Flow................................................................................14
1.3.2. Air and Gas Flow.........................................................................................16
1.3.3. Combustion Process...................................................................................17
1.3.4. Economizer..................................................................................................18
1.3.5. Steam Drum and Drum Internals.................................................................19
1.3.6. Furnace........................................................................................................20
1.3.7. Cyclone Inlet circuit......................................................................................22
1.3.8. Cyclone........................................................................................................22
1.3.9. Heat Recovery Area (HRA).........................................................................23
1.3.10. Low temp. superheater................................................................................24
1.3.11. Primary Attemperator...................................................................................24
1.3.12. Superheater Wing Wall................................................................................24
1.3.13. Secondary Attemperator..............................................................................25
1.3.14. High Temp. Superheater..............................................................................25
1.3.15. Air Preheater................................................................................................25
1.4. FUEL, LIMESTONE AND ASH REMOVAL SYSTEMS...............................26
1.5. CIRCULATING SOLIDS REINJECTION SYSTEM.....................................26
1.6. UNDER-BED BURNER...............................................................................26
1.7. BOILER PROPER STEEL STRUCTURE....................................................27
1.8. OPERATING PHILOSOPHY.......................................................................27
1.9. EXPANSION SYSTEM................................................................................28
1.10. WATER VOLUMES OF MAJOR BOILER PARTS:......................................30
2. SAFETY PRECAUTIONS AND PREPARATION FOR OPERATION..........31
2.1. SAFETY PRECAUTIONS............................................................................31
2.2. HYDROSTATIC TESTS...............................................................................34
2.3. DRYING OUT REFRACTORY....................................................................38
2.4. BOILING OUT..............................................................................................39
2.4.1. General........................................................................................................39
2.4.2. Recommended Chemicals for Boiling Out..................................................40
2.4.3. Preparations for Boiling Out........................................................................41
2.4.4. Boiling Out Procedure.................................................................................44
2.5. FEEDWATER AND BOILER WATER TREATMENT...................................46
2.6. CHEMICAL CLEANING OF ECONOMIZER AND STEAM GENERATING
CIRCUITS..................................................................................................................46
2.6.1. General........................................................................................................46
2.6.2. Determining the Need for Chemical Cleaning.............................................47
2.6.3. Solvent Systems..........................................................................................48
2.6.4. General Cleaning Operations......................................................................48
2.7. CHEMICAL CLEANING OF SUPERHEATERS..........................................50
2.7.1. General........................................................................................................50
2.8. STEAM-LINE BLOWING.............................................................................51
2.8.1. General........................................................................................................51
2.8.2. Initial condition.............................................................................................51
2.8.3. Precaution and matters need attention.......................................................52
2.8.4. Procedure of steam purging........................................................................53
2.8.5. Return to the raw condition..........................................................................54
2.9. BOILER SYSTEM AIR TEST.......................................................................54
3. OPERATION AND MAINTENANCE............................................................56
3.1. GENERAL....................................................................................................56
3.2. GENERAL PRECAUTIONS.........................................................................56
3.3. COLD START-UP PROCEDURE................................................................63
3.3.1. Preparation Prior to Start-up........................................................................63
3.3.2. Purging........................................................................................................67
3.3.3. Warming The Unit........................................................................................71
3.3.4. Start-up (Fuel Firing)...................................................................................75
3.4. HOT RESTART............................................................................................78
3.5. NORMAL OPERATION...............................................................................81
3.5.1. Firing............................................................................................................81
3.5.2. Water Chemistry and Steam Purity.............................................................83
3.5.3. SootBlowing.................................................................................................84
3.5.4. Spray Attemperation....................................................................................85
3.6. NORMAL SHUTDOWN...............................................................................85
3.7. EMERGENCIES..........................................................................................88
3.7.1. Main Fuel Trip (MFT)...................................................................................88
3.7.1.1. Any of the following conditions will cause a boiler main fuel trip (MFT)......89
3.7.2. Emergency Operating Procedures..............................................................90
3.7.2.1. Tube Leak....................................................................................................90
3.7.2.2. Excessive Bed Temperatures......................................................................91
3.7.2.3. Clinkered Bed..............................................................................................92
3.7.3. Overpressure Protection..............................................................................93
3.8. MAINTENANCE...........................................................................................93
4．Figure...................................................................................................................97
Fig。1-1 Optimum size distribution for coal...............................................................97
Fig。1-2 Sectional side elevation of boiler.................................................................98
Fig。1-3 Steam and water diagram of boiler.............................................................99
Fig。1-4 Gas and air diagram of boiler....................................................................100
Fig。1-6 Arrangement of downcomers....................................................................102
Fig。2-1 The boiling out pressure for different design pressure..............................103
Fig。3-1 Oxygen measurement of approximately % by volume on a wet basis.....104
Fig。3-2 Relationship between bed pressure and fluidizing velocity......................105
Fig。3-3 The minimum steam temperature after spray...........................................106
Fig。3-4 Relationship between bed pressure and height of static bed material.....107
Fig。3-5 Cold start curve 冷态启动曲线...................................................................108
Fig。3-8“J”Valve Piping Connection Drawing..........................................................111
5．Table112
Table 1 Thermodynamic Calculation Collecting Table for Coal rank COAL2 in Boiler
Design 112
Table 2. Boiler check coal rank COAL1 thermodynamic calculation collection table
116
Table 3. Boiler check coal rank COAL3 thermodynamic calculation collection table
120
Table 4. Flue Gas and Air Resistance Collection Table..........................................124
Table 5. Steam water Resistance Collection Table.................................................125
1.CONSTRUCTION DESCRIPTION OF BOILER PROPER

NG-130/10-M boiler is designed and manufactured for Siam Kraft Industry

Co., Ltd of Thailand.

The Boiler is a single furnace of coal-fired, outdoor, complete steel structures,

full membraned water cooling wall, circulating fluidized bed combustion, high
temperature steam-cooled volute type cyclone Separator for gas solid
separation, water circulation in natural way and flue gas system of balance
ventilation.

1.1. Design Conditions

1.1.1. Boiler Specifications:

Maximum Steam Flow 130t/h
Superheat Steam Outlet Temperature 510℃ +5-10
Superheat Steam Outlet Pressure 100bar(g)
Feedwater Temperature 170℃
Ambient Air temperature 30℃

1.1.2. Boiler Main Dimensions

Furnace Width (Between CL of Side Walls) 7200mm
Furnace Depth (Between CL of Front & Rear Walls) 4480mm
Elevation of Steam Drum CL 39200mm
Elevation of Boiler Top(Front/Rear) 38040/43200mm
Boiler Width (Z1 to Z1 Opposite) 10000mm
Boiler Depth (Z1 to Z4) 17860mm

1.1.3.Fuel
The boiler combusts with Coal 1 (Jorong Coal)，Coal 2 (Banpu Coal) or
Coal 3 (Sub-bituminous coal), and boiler performance with coal 2 shall be

analyzed separately with tests.

Ultimate Analysis (wt. % as received)

Symbol Design fuel Check fuel Check fuel

coal2 coal1 coal3
Carbon Car 62.21 48.73 62.74
Hydrogen Har 4.08 3.53 4.76
Oxygen Oar 6.09 14.03 8.89
Nitrogen Nar 1.01 0.48 1.02
 Sulfur Sar 0.72 0.11 1.32
Ash Aar 13.89 3.11 10.25
Moisture War 13.89 30 11
Proximate Analysis of the Coals (wt. %， air dry)

Design fuel Check fuel Check fuel

coal2 coal1 coal3
Volatile Matter (%) 40 51.2 40
LHV (Kcal/kg) 5831 4269 6024

1.1.4. Optimum Size distribution for coal (shown in fig 1-1) Ash

Analysis
Without limestone

ITEMS Units Design fuel Check fuel Check fuel

coal2 coal1 coal3
Ash softening point,
℃ ＞1200 ＞1200 ＞1200
reducing conditions
SiO2 % 46.68 31.6 49
Al2O3 % 36.19 37.21 37.7
Fe2O3 % 5.88 12.87 4.5
CaO % 1.4 9.07 2.2
MgO % 3.3 1.12 1.6
K2O % 0.43 0.89 0.5
Na2O % 0.49 0.27 0.4
SO3 % 2.04 4.33 1.2
TiO2 % 2.67 0.48 2.7
P2O5 % 0.8 0.05 0.2

1.1.5.Limestone
a. Limestone analysis (before calcined)

Item Unit Design date

CaCO3 % 90
 MgCO3 % 3.0

Moisture % 0.2

Inert % 1.0

Reactivity index / high

b. Optimum size distribution for limestone

- 100% < 750 um

- 80% < 500 um
- 50% < 300 um
- 10% < 150 um

1.1.6.Sand
Natural sand (feldspar) is used for start-up and make-up bed material.
The typical analysis is as follows:

Item Unit Data

SiO2 % 82.2
Al2O3 % 9.7
Fe2O3 % 1.8
CaO % 1.2
MgO % 0.4
Na2O % 1.9
K2O % 2.8
H2O % 0.1
loss of ignition % 0.95
Density kg/m3 1500
Softening point °C 1200
Optimum Size distribution for Inert

Particle size distribution

Weight ％ Unit Size

100% µm <1000
75% µm <450
50% µm <350
25 % µm <250
100 % µm >100
1.1.7.Igniter Type
under-bed Igniter (burner).

1.1.8.Igniting Oil

Unit Design Range

Fuel As-Received
Type light oil
Net calorific value MJ/kg 42.60 42.6-42.9
Total moisture % 0.05 0.0-0.05
Analysis of dry solids (%-weight)
Carbon, C % 86.08
Hydrogen, H % 13.71
Oxygen, O % 0.02
Nitrogen, N % 0.02 0.01-0.02
Sulfur, S % 0.15 0.05-0.15
Ash % 0.02
Specific weight, at
kg/m3 855 835-855
15°C
Viscosity, at 20 °C mm2/s 5.9 3-6

1.1.9.Feedwater Quality

Be in compliance with Requirement of High pressure water Quality in

the Quality Standards of Water and Steam for Thermal Power
and Steam Generating Units (GB12145).

Parameter Units Results

Hardness μmol/L ≤2.0
oxygen,O2 μg/L ≤7
total iron,Fe μg/L ≤30
copper, Cu μg/L ≤5
Na content μg/L /
should satisfy with
steam
requirement:≤20μg/kg
SiO2 content /
pH(250C) / 8.8-9.3
 Hydrazine μg/L 10-50
Oil mg/L ≤0.3
feedwater is used for spray control of steam temperature,the
feedwater TDS must not exceed 1 ppm.
TDS:mean total dissolved solids.

1.1.10. make-up water

Be in compliance with Requirement of High pressure water Quality in the

Quality Standards of Water and Steam for Thermal Power and Steam
Generating Units (GB12145).

Parameter Units Results

Hardness μmol/L ≈0
SiO2 content μg/L ≤20
0
conductivity(25 C) μS/cm ≤0.2

1.1.11. boiler water

Be in compliance with Requirement of High pressure water Quality in

the Quality Standards of Water and Steam for Thermal Power
and Steam Generating Units (GB12145).

Parameter Units Results

Total salt content mg/L ≤100

SiO2 content mg/L ≤2.00

PO34- content mg/L 2-10

pH(250C) / 9.0-10.5

conductivity(250C) μS/cm <150

1.1.12. Site Conditions:

Site
Elevation above sea level m 10
Ambient air
Pressure kPa 101.3
Temperature, average °C 30
Temperature, minimum °C 21
Temperature, maximum °C 38
Air temperature for boiler efficiency
°C 30
calculations
Relative Humidity
Performance design % 70
Minimum % 60
Maximum % 80
Wind Analysis
Maximum Wind Speed m/s 20
Wind direction / NE and SW
Maximum precipitation
Over 1 day period mm 80
Seismic intensity Grade 6
Field Classification / Grade II

1.1.13. Operation Mode

Constant or various pressure operation mode and the load change

rate may be greater than or equal to 7%/min.

1.1.14. Draft Mode

Balanced draft and pressure balance point is located at outlet of

furnace (inlet of cyclone separator).

1.2. GENERAL DESCRIPTION OF BOILER

This steam generator is a natural circulation, circulating fluidized bed

boiler and out-door arrangement.

The steam generator consists of a water-cooled furnace enclosure,

two (2) steam-cooled cyclone enclosures and one back pass
convective cage. The furnace and back pass cage are rectangular in
plan view while each cyclone is circular.

In the upper furnace, there are uniformly two (2) superheater wing
wall across the furnace width.
The back pass cage is made up of two parts, the upper part is a
steam-cooled convective heat recovery area (HRA) enclosure, the
lower part is a steel plate casing structure. the HRA contains high
temp. and low temp. superheaters, the casing structure contains
economizer and air preheater.

Between the low temp. superheater, superheater wing wall and high
temp. superheater there are two (2) stages water spray
attemperators to control final superheater steam temperature.

Fig. 1 － 2 consists of a sectional side elevation of boiler. The

elevation sketch locates the major steam generating components
and structural dimensions.

Heat to generate steam comes from the fluidized bed system. Initially
combusted bed materials are forced by flue gas upward through the
furnace and exit at the top to the two (2) steam-cooled cyclone
separators. Coarse hot bed material is separated from the flue gas in
the cyclones and sent back to the furnace via J-valves connected to
the bottom of the cyclones. The hot bed material re-enters the
furnace just above the grid plate to complete the circulation cycle
combustion. Flue gas exits via the outlet at the top of the cyclones
and enters the HRA through a gas screen near the top of the HRA
front wall. After flowing down the HRA, heating the HRA walls and
components, the hot gas leaves the steam generator through air-
preheater via the flue near the bottom of the HRA enclosure.

The circulating fluidized bed boiler is supported by other system,

including fuel and limestone feed systems, bottom ash drain cooler
and conveyer system, air and gas systems, control and
instrumentation systems.
1.3. GENERAL ARRANGEMENT OF THE BOILER

1.3.1.Steam and Water Flow

Fig. 1 － 3 shows that the steam generating circuitry consists of

economizer, one drum, furnace waterwalls, steam-cooled cyclone
inlet sections, steam-cooled cyclone separators, HRA steam
enclosure, low temp. superheater, superheater wing wall, high temp.
superheater and the piping.

Feedwater enters the economizer located in HRA through the lower

economizer inlet header (EL. 17700) located right side of the HRA
enclosure. The feedwater rises through four (4) serial-connected banks
of horizontal economizer tubes and is directed through an outlet header
and then through three 108×8 economizer pipes to the steam drum.

During start-up, when there is no feedwater flow to the drum, one

economizer recirculating system is provided to prevent the stagnant
water in tube steaming by recirculating drum water via the
downcomer to the pipes connected ahead of the economizer inlet
header.

The feedwater forms a water reservoir in the drum which is

connected to the lower inlet headers of the furnace walls via two (2)
drum downcomers and feeder tubes. The water flows upward
through the furnace wall tubes while being heated to a steam/water
mixture; the mixture then leaves through the furnace walls upper
outlet headers and re-enters the drum through riser tubes. The
steam drum separates the water from the entering steam/water
mixture and directs it back to the drum water reservoir for
recirculation to the furnace walls. The separated steam is dried and
flows out the steam lines at the top of the drum.
From the drum, the steam flows separately through two (2) 159×12
steam supply pipes to inlet headers of both side flue gas inlet
circuits, steam flows through the inlet circuits downwards into lower
outlet header, then steam is gathered into the upper ring header of
left cyclone via individual two(2) 159×12 pipes, Flow through the left
cyclone circular wall is downwards into the lower ring header. Then
the flow is directed through four (4) 159×12 transfer pipes to the
lower ring inlet header of the right cyclone enclosure, upwards into
upper ring header of right cyclone and finally four (4 )  159×12
transfer pipes carry the steam to the HRA front wall upper inlet
header at elevation of 40900. Flow in the HRA is down through the
HRA front wall up through both HRA side walls and then through the
roof and down the HRA rear wall.

Steam leaves at elevation 29930 the HRA rear wall lower header
which also serves as the low temp. superheater inlet header, steam
flow through the horizontal low temp. superheater tubes which is in
an upward direction counter to the flow of hot flue gas in the HRA
then to the low temp. superheater outlet header at elevation of
31440. From only left ends of low temp. superheater outlet heater,
steam flow via one (1)  273×20 transfer pipes which involve the
primary spray attemperators is directed to furnace front wall
superheater wing wall inlet header at elevation 17960. From the inlet
distributing header, the steam flows into two (2) upper furnace
superheater wing walls. Then through the superheater wing wall
outlet distributing headers at elevation 36200 the steam flows into
superheater wing wall outlet header. Between this header and high
temp. superheater inlet header located at HRA rear wall at elevation
32710, there is one (1) 325×25 transfer pipes which involve the
secondary spray attemperator. Steam flow through the horizontal
 high temp. superheater tubes is also in an upward direction to the
high temp. superheater outlet header at elevation 35710, finally the
satisfied main steam through six(6) Φ133×13 tranfer pipes is
gathered into the main steam contain header, and main steam leaves
the unit on the left side of boiler.

1.3.2.Air and Gas Flow

Circulation of the fluidized bed material is initiated and maintained by

forced draft (FD) fans ( including primary and secondary fans) and
one induced draft (ID) fan. Initially heated by air-preheater,
combustion air from primary fan is divided into three (3) paths. The
first is introduced into the plenum at the bottom of the furnace and
fluidizes the bed material through nozzles in the grid floor and
establishes solids circulation upwards through the furnace. In this
line, there are parallelly connected air bypass for boiler igniting
startup and low load stable fuel oil burner, The second is introduced
to three(3) air swept coal feeders to assist in transporting fuel into
furnace. The third is employed as sealing air for coal conveying belt.
However, the combustion air from the secondary FD fan is heated by
air-preheater and directed into furnace through secondary wind box
at upper furnace.

The flue gas and entrained solids exit the furnace, through two (2)
cyclone inlet circuits, to the two (2) cyclones where coarse solids are
separated from the gas stream which exits the top of each cyclone.
From the cyclones, the flue gas flows down through the HRA and
passes over the horizontal convection surfaces. Having given up its
heat to the steam circuits in the HRA, the gas passes through the
tubular air － preheater and enters the ESP for removal of fine
particulate. The cooled dust-free gas is then exhausted through the ID
 fan to the stack for release to atmosphere.

The air and gas flow paths through the steam generator are shown in
Fig. 1－4.

For J-valve, there are two (2) blowers each is for 100% capacity. one
(1) of the blowers are in operation and one stands-by. Excess air is
directed through by-pass line to the first path of primary air since each
J-valve blower is constant volume device.

Dampers are provided throughout the air and gas flow system to
obtain proper control, shut-off and isolation during operation and
shutdown.

1.3.3.Combustion Process

After the bed is initially charged, the under-bed burners are fired,
during a cold start-up, to preheat combustion air to the ignition point
of solid fuel. After entering the plenum, the air enters the fluidized
bed through an air distribution grid plate. This grid plate consists of
bell-shaped air nozzles inserted on the fins of a water-cooled grid
floor. The nozzles provide a uniform distribution of air throughout the
bed. The layer of refractory casting between the top of the grid plate
and the ends of the nozzles provides an anti-corrosion and insulation
layer which results in a lower grid plate operation temperature.

Within the fluidized bed, air mixes with the fuel and limestone
products to facilitate combustion and sulfur capture. Solids, swept up
in the furnace by air and flue gas, exit through furnace rear wall
openings and enter the cyclones. The coarser particles are
separated in each cyclone for reinjection to the furnace.

NOx formation is controlled and furnace temperature is properly

maintained due to staged combustion. introducing a portion of the air
 to burn the fuel in lower furnace and completing combustion in upper
furnace by introducing the remaining air as overfire air

1.3.4.Economizer

The economizer located in HRA consists of four (4) banks of 32×4

bare 20G tubes with an in-line arrangement on 90 longitudinal
spacing,. The first bank is 38 sections in wide direction with on 82
transversal spacing, which has four loop-in-loop tubes. The other
banks are 46 sections in wide direction with on 68 transversal
spacing, which have three loop-in-loop tubes. The economizer has
one inlet, one intermediate and one outlet header (each 219 OD).
Feedwater enters the right side lower inlet header at the elevation of
17700 and flows upward through the outlet header at the elevation of
28640, and is piped into the steam drum.

1.3.5.Steam Drum and Drum Internals

The steam drum is located at the top and across the width of the
furnace. the steam drum serves as a water reservoir for the steam
generation circuits. The drum contains steam separating equipment
and internal piping for distribution of chemicals to the water, for
distribution of feedwater and for blowdown of the water. Fig. 1 －
5shows the arrangement of the steam internal components.

Inner diameter of drum is 1600mm, length of straight drum body is

8.4m (excluding spherical end plate). The inner equipment is as
following:

Cyclone separators ----- total 32 sets in two rows in-line arranged.

corrugated moisture separators ---- total 21 sets.

Steel wire mesh separators ----total 21 sets.

Cleaning orifice ---- total 21 pieces.

 Feedwater inlet pipe ---- feedwater pipe is evenly introduced into
drum along drum body axially.

Continuous blowdown pipe ---- lacunaris, confluxed to two outlet

pipes to be drained.

Dosing pipe ---- lacunaris, confluxed to one outlet pipes in the middle
of drum.

The arc plate are mounted along whole straight section of drum,
forming a casing space at two sides of drum. Steam mixture introduced
from furnace rises enters the casing, and then goes into cyclone
separator for primary separation: separated water goes along wall
through discharge outlet into water space; while steam flows up
through cyclone separator top corrugated sheet separator into steam
space, and then through cleaning orifice, finally it is educed via steam
connecting pipe at the top of drum through wire mesh separator and
corrugated sheet separator. Water from economizer flows to cleaning
orifice plate through feedwater pipe and then into water space for next
primary circulating.

1.3.6.Furnace

The furnace is a 28770 high×7200 wide×4480 deep combustion

chamber consisting of front, rear and side walls. At the bottom of the
furnace, the rear wall splits to form both the plenum floor and the
fluidized bed grid floor, together with both side walls, they form the
water-cooled air plenum, the bottom of which is at the elevation of
3880. The elevation of the grid floor is 5980. At the top of furnace,
the front wall bends toward the rear wall to form the furnace roof
which terminates with an upper header. The elevation of the furnace
top is 36100. two (2) rear wall lower headers at the bottom of furnace
( elevation 3880, 4780) serve also as inlet headers for the plenum
 and grid floors ( formed by the rear wall tubes). There are one (1)
front wall upper headers and one (1) rear wall upper headers, all
located at elevation 36100. There are one (1) lower headers and one
(1) upper headers for each side wall , the lower headers of which are
at elevation 3480, the upper headers are at 35700. The furnace is
divided into upper part and lower part and the border of the division
is at elevation 12792.2. The longitudinal section view of lower
furnace is trapezoid shaped as the front and rear walls intersect with
the horizontal plane at a angle of 80  . The furnace depth, at
elevation 5980 where the grid floor is located, is 2200. Wearproof
material layers of 55 mm thickness are made to water wall of furnace
combustion area, and also made to rear wall, side walls, roof tubes,
all area near the gas outlet of upper furnace. The drum water is
connected to the circuitry via downcomer. Fig. 1 － 6shows the
arrangement of downcomers.

The tube spacing for front wall (and roof), rear wall and side walls is
80 ( 60×5 tubes). Front wall and rear wall are each comprised of
89 tubes, side walls are each comprised of 56 tubes. The grid floor is
made of 44 riffled tubes (Φ63.5X7.5) with tube spacing of 160. The
plenum floor is comprised of 44 finned tubes (Φ60×5) with tube
spacing of160. The furnace waterwall inlet and outlet headers are all

219×30, 20G.

Cross section ratios of inlet pipe, outlet pipe and riser of each circuit are
indicated in the following table. Cross section ratios of downcomer and
furnace water wall riser is 0.295.

Name Cross section ratio of Cross section ratio of

inlet pipe vs. furnace outlet pipe vs. furnace
water wall riser water wall riser
Front water wall 0.344 0.401
Rear water wall 0.344 0.401
Side water wall 0.365 0.365
 Three (3) fuel feed points are provided on the front wall of the furnace approximately

1200 above the grid floor. Two (2) limestone feed points are located respectively

within the front and rear wall 8420 above the grid floor. Secondary air ports are

arranged in two layers on the furnace front wall and rear wall as follows:

Furnace Wall Location Quantity Elevation

Front Wall 10 12080
Rear Wall 9 12080
Front Wall 6 8420
Rear Wall 4 9880
Rear Wall 6 8420
There are two(2) normal exkaust and one(1) emergency openings
located on the water grid floor, the two(2) bottom ash coolers are
connected to normal exhaust opening, ash coolers drain cooled ash
at the 1700 elevation, the emergency ash drain pipe(Φ219×10) outlet
is at the 1000 elevation.

Two (2) flue gas outlets center line is at the 32200 elevation near the
top of the rear wall.

1.3.7.Cyclone Inlet circuit

There are two (2) cyclone inlet circuits. Each cyclone inlet circuit
connects the rear wall flue gas outlet of the furnace to a
corresponding cyclone and is shaped to form a wide gas-tight tunnel
through which the flue gas can travel.

Each cyclone inlet circuit consists of steam cooled, refractory lined

tubes, connected by a lower header and an upper header at
elevation 34465 and 29930 respectively. There are total 26 tubes, 13
on each side per each cyclone inlet circuit. The tubes are 20GΦ51×5
and the inlet and outlet headers are 20G Φ219×30. Steam from the
drum is connected respectively by two (2) Φ159×12 transfer pipes to
 the inlet header of each cyclone inlet circuit. Steam then flows down
through the tubes of each circuit, in parallel fashion, to the outlet
headers which are connected to the left-hand cyclone upper inlet ring
header by transfer pipes.

1.3.8.Cyclone

Two (2) identical cyclones separate coarse particles from furnace

flue gas sending the fines out of the top into the HRA and allowing
the coarser particles to fall down corresponding J-valves for
recirculation back to the furnace.

The top half of the cyclone is volute shaped and the lower half is
conical (funnel shaped). The flue gas outlet are made of many
pieces, which shaped altogether to form an open ended cylinder
extending nearly half way down into the center of the cyclone. The
fines and flue gas enter the bottom of the cylinder and flow up to exit
the cyclone. The coarse particles drop down into the funnel which is
directly connected to the J-valve.

The entire cyclone enclosure is steam cooled and is of membrane

wall construction with a ring header at the bottom and a ring header
at the top. The wall tubes bend inward at the top to form a seal
between the cyclone tubes and the flue gas outlet cylinder.

Each cyclone consists of 114 tubes (Φ42×6). Each ring header is

273 O.D.

1.3.9.Heat Recovery Area (HRA)

The heat recovery area (HRA) means back pass cage, which is an
approximately 6295 wide×3025deep convection heat enclosure of
membrane wall and ends at the approximately 29930 elevation,
below which the remainder of the HRA is constructed of steel plate. A
 flue gas outlet is at the elevation of 6700, the bottom of the HRA is
formed into an ash hopper which allows a portion of the particles to
drop down before entering ESP and decreases the gas solids
concentration. The HRA houses the horizontal banks of convection
economizer, low temp. superheater and high temp. super-heater tube
surfaces.

All four walls are connected by inlet and outlet header. The HRA front
wall tube spacing increases from 95 to 285 near the top to form an
inlet screen for flue gas. The HRA rear wall tubing bends toward the
front wall near the top of the wall to form the HRA roof tubes. The
front and rear walls are each comprised of 65 tubes (Φ42×5, and the
14 support tubes in the front wall screen areΦ60×11) and each side
wall is comprised of 32 tubes (Φ42×5). The HRA front wall upper
header is Φ273X36,20G, low temp. superheater outlet header l is
Φ273X20,12Cr1MoVG, high temp. superheater inlet header l
isΦ325X25,12Cr1MoVG, high temp. superheater outlet header l
isΦ273X36,12Cr1MoVG, while other HRA superheater headers are
Φ219X30,20G.

1.3.10. Low temp. superheater

The low temp. superheater is located in the HRA and the inlet header
is at 29930 elevation, and consists of 16 loops of 2 loop-in-loop
horizontal tubes (Φ42X5 ) arranged in 65 sections across the width
of the unit, in counter to the gas flow. Along the steam flow, the first 8
loops are of 20G tubes, the other 8 loops are of 15CrMoG tubes. The
low temp. superheater outlet header ( 12Cr1MoVG, Φ273×20) is
located near the HRA rear wall at the 31440 elevation.
1.3.11. Primary Attemperator

The primary spray water attemperator is located in the steam transfer

pipe between the low temp. superheater outlet header and
superheater wing wall inlet header. The attemperator is equipped
with a mixing liner and spray water piping. The liner is installed at
downstream of the spray piping to protect the attemperator shell from
thermal shock. Instrumentation are installed in spray water piping to
measure the temperature before and after the attemperator to control
the water flow entering attemperator.

1.3.12. Superheater Wing Wall

There are two (2) pieces of wing wall arranged at upper furnace near
the front wall. The wing wall is membrane wall construction with tube
spacing of 63.5. Each piece consists of 25 tubes( 12Cr1MoV,

42×7). Below elevation 20540, wing wall is refractory lined. The

whole wing wall expands upward. An outlet header ( 325×25) is
located at the elevation 36200.

1.3.13. Secondary Attemperator

The secondary spray water attemperator is arranged in the steam

transfer pipe between the wing wall outlet header and the high temp.
superheater inlet header located at the HRA rear wall. The
superheated steam temperature is further controlled in the secondary
attemperator. The construction of secondary attemperator is basically
the same as the primary attemperator.

1.3.14. High Temp. Superheater

Steam from the secondary attemperator flows through transfer pipe

into the high temp. superheater located at upper HRA gas flue. The
 steam is introduced into one ends of high temp. superheater inlet
header at the elevation 32710 and counter flow with the gas through
the high temperature superheater loops into high temp. superheater
outlet header located at the elevation 35710, and then gather to the
main steam pipe via transfer pipes. The high temp. superheater
contains 20 loops of 2 loop-in-loop tubes (Φ42X6). The whole loops
are 12Cr1MoVG tubes. There are 65 sections across the width of the
HRA.

1.3.15. Air Preheater

The air preheater is of three circuits installed vertically behind the

HRA. The primary and secondary tube boxes are stagger-arranged,
the upper circuits are common 40×1.5 carbon steel tubes and the
lower circuit is vitreous enamel steel tube. The horizontal and
longitudinal spacing of the windbox are 65. Each three tube-groups is
connected by air duct to form independent paths. Primary and
secondary air are supplied by independent fan and directed through
the two air ducts and heated by flue gas which flows intersect with
the air. The primary and secondary air flow ratio is 52% and 48% of
total combustion air. The air temperature at the outlets is 185 ℃.

1.4. FUEL, LIMESTONE AND ASH REMOVAL SYSTEMS

Three (3) coal feed systems located at furnace front wall, Two (2)
limestone feed points located respectively at furnace front and rear
wall, two biomass gas gun located in lower secondary air ports,
one(1) inert material accession port located at the left of furnace. A
spent bed (ash) removal system is connected to the bottom ash
cooler outlet, the air preheater ash drain and the ESP ash drain.
1.5. CIRCULATING SOLIDS REINJECTION SYSTEM
This system is used to reinject heavy circulation solids particles from
the cyclone back into the furnace. It consists of two (2) J-valves(trap)
connected between the solids outlets of the cyclones and the solids
inlets on the furnace rear wall.

Each J-valve utilizes the bed material exiting the J-valve stand pipe
to “seal” the trap. This trap maintains proper flow direction of the
circulation bed towards the furnace with the motive force of the
difference pressure between upward and downward stream of the
trap. The air is supplied by high pressure blower.

1.6. UNDER-BED BURNER

two oil burners for start up is provided on both side of air plenum
below the grid floor. Combusted hot gas heats the primary air to
870℃ which in turn heats bed material through air distribution air
nozzles to ignition temperature. The burner utilizes mechanic oil
atomizing gun to get good combustion to prevent nozzle damage
resulted from oil re-burn in the air distribution device. Oil
consumption of each oil gun is 480kg/h; oil pressure is 1.96Mpa at
burner inlet. When oil is already fired air flow for each gun burning is
at least 9000Nm3/h. High energy ignitor and flame scanner is
provided for the burner.

1.7. BOILER PROPER STEEL STRUCTURE

The boiler steel structure is welded connection type and out-door
arrangement. There are eight (8) main columns for boiler supporting.
The columns are connected to the base-work （ foundation ） at the
elevation of +200mm by anchor bolts. Horizontal beams and vertical
supports are provided between columns to withstand the loads of boiler
 proper, wind and earthquake.

The major pressure parts of the boiler except steam drum are hung
by hangers from the top steel. Steam drum and other components of
the boiler, such as economizer, air preheater, under-bed burner,
loopseal, etc. are all stand on horizontal beams by supporting or
reinforcements.Platforms and stairs are provided where maintenance
or inspection is needed during boiler operation.

1.8. OPERATING PHILOSOPHY

The purpose of a fluidized bed boiler is to produce a required

quantity of steam, at the desired pressure and temperature by
burning fuel and operating at the optimum economic efficiency all in
an environmentally acceptable manner.

Load change with a fluidized bed steam generator is accomplished

by changing fuel and air flows, as same with any steam generator. A
fluidized bed steam generator differs in that it contains a solids
inventory in the form of lime and ash particles which constitute the
fluidized bed.

From the standpoint of combustion stability and NO x emission levels,

there is an allowable bed temperature variation and an optimum range
of bed temperature for SO2 capture. Outside this optimum range,
significant increases in limestone feed rates may be required to
maintain emission levels within acceptable limits. If load change
flexibility is required, the temperature should be maintained within a
specific range. This is accomplished by staged combustion and solids
loading control in the freeboard. Staged combustion serves two
purposes, the controlled combustion in the lower furnace help to
maintain the bed temperature in a suitable range for low NO x emission.

This unit utilizes fuel and limestone as the predominant bed material.
 At normal operating bed temperatures, limestone is easily calcined
( CO2 is liberated ) resulting in a material that partially reacts with
SO2 in the burning fuel to form calcium sulfate (gypsum).

1.9. EXPANSION SYSTEM

The expansion centers (zero expansion points) are designed

according to the features of boiler arrangement and supporting
structures. The orientation of furnace waterwalls, cyclone separators
and HRA expand from the top downwards as they are all hung to the
top steel. There are three expansion centers designed for the boiler:
the center line of furnace rear wall, the center line of cyclone, the
center line of HRA front wall. The furnace expands from furnace
center line ( zero expansion point) toward two sides due to
expansion control devices installed in two (2) steel structure levels at
the elevation of 26800 and17100 respectively. The HRA expands
from boiler center line (zero expansion point) toward two sides due to
the expansion control devices supplied at two (2) steel structure
levels at the elevation of 33630 and 30730 . Bed material reinjection
device(loopseal) and air preheater expand upward from their
supporting base, and uniformly to front, rear, right and left.
1.10. WATER VOLUMES OF MAJOR BOILER PARTS:
Part Name During Hydrotest During Operation

(m3) (m3)

Steam Drum 19 6.8

Waterwalls 31 31
Cyclones (including cyclone inlet circuit) 4 0
Superheaters 15 0
Economizers 10 10
Total 79 47.8

Note: 1. The volume of waterwall includes downcomers, feeder pipes,

and headers.
2. The volumes of cyclones, superheaters and economizers all include
their headers and transfer pipes.
2. SAFETY PRECAUTIONS AND PREPARATION FOR

OPERATION

2.1. SAFETY PRECAUTIONS

The following instructions are some of the general precautions which apply
when placing a steam generator into operation. They are intended to
supplement the experience and judgement of those in charge of operation
and cannot cover all precautions which should be observed.

The manufacturer has complied with the national boiler code (GB china
standard) pertaining to the design and fabrication of the unit. A newly erected
unit, prior to being placed into operation, must be carefully inspected by
authority to assure that all component parts are properly assembled.

All of the steam generator’s auxiliary equipment must be in first class

operating condition, suitable for operation at design conditions and operated
in accordance with the manufacturer’s recommendations and instructions. The
following is offered as an initial start-up check list for this auxiliary equipment.

NOTE

These checks should be completed prior to start-up of

the steam generator.

a. All fans and blowers shall be operated. Lubrication systems shall be

operable. Equipment shall be balanced and operate within vibration
tolerances.

b. All dampers, operators and actuators shall be subjected to internal and

external inspection. This auxiliary equipment shall be operated through
the full range of operation and shall be free of binding or jamming.
 Confirm that dampers actually move to the positions called for by the
controls.

c. Ensure that the ash removal system connection has been made to the
cooler and that the cooler is ready for operation.

d. All remotely operated valves shall be operated and limit switches

checked to ensure that proper installation has been accomplished,
thereby yielding accurate position indications.

e. All conveyors shall be operated to substantiate readiness.

f. All critical flow elements shall be calibrated.

g. The under-bed burners, shall be ready for operation with all safety
equipment verified operable, e.g., flame scanner, interlocks, etc.

h. All critical thermocouples and pressure transmitters shall be checked

for proper connections and to ensure that they are operable.
Calibrations shall be completed.

i. All flues, ducts, pipes, chutes or conduits through which air, gas, water,
steam or solids flow shall be connected securely; check to ensure that
proper flow paths have been maintained.

j. All expansion joints shall be inspected to ensure that proper

connections have been made.

k. The precipitator shall be checked to verify that the system is operating.

l. All electrical connections shall be inspected to ensure that they have

been properly installed and that all insulation is in good condition.

When preparing a new steam generator for service, see that the following is
done as required:

a. The drum level gage glasses must be checked and installed in

accordance with the drawings prior to preliminary operation.
 When the water level in the steam drum is lowered below the lowest
visible point of the gage glass, all water should drain out of the glass. Any
time a repair or change is made to the gage glass, this should be
checked.

b. Blowdown lines from water columns of drum level gage must be

properly piped and drain valves must be closed. The gage glasses
must properly illuminated and clearly visible to the operators from the
operating floor.

All vent, drain and blowdown lines must be readily accessible and properly
piped to a blowdown tank or other safe location so as not to endanger the
operator at any time.

Valves that are located between the steam drum and water column of water
gage must be in the full open position and locked.

All safety valve gags and hydrostatic test plugs must be removed and the
valves must be in proper operating condition. Discharge pipes and drains
should be arranged and supported in accordance with the safety valve
manufacturer’s recommendations.

Drum internal must be properly installed in accordance with the drawings to

assure that there will not be any steam bypassing the internals.

All test connections deemed necessary must be installed.

A leak test shall have been conducted on the steam generator’s air and flue
gas systems; all leaks shall be corrected in accordance with paragraph 2.8.

Expected hot areas of the steam generator shall be insulated or roped off to
provide suitable protection for personnel.

In addition to the above, the following items should be thoroughly checked

each time a steam generator is placed into operation:

a. All necessary operating instruments, both permanent and temporary,

 must be installed, operating properly and correctly calibrated.

b. All areas must be sufficiently illuminated.

c. No hazardous walkways, ladders or stairway should be used. Provide

substantial walkways and platforms where needed.

d. Air and gas passages must be free from obstruction and the unit
capable of being thoroughly purged by the circulation of air through the
unit.

e. The source of feedwater must be ample and uninterrupted once the

unit is in operation.

f. An ample fuel and limestone supply should be available.

g. All access and observation doors must be closed after it is ascertained

that no one is inside the unit.

h. Drum manhole openings must be properly closed.

When it is assured that the above precautions are fully understood and have
been complied with, then, and only then, should subsequent operations such
as“Drying Out”,“Boiling Out”,“Initial Starting”and“Normal Starting” be initiated.

2.2. HYDROSTATIC TESTS

The steam generating unit shall be subjected to a hydrostatic test when

erection of the pressure parts is completed. A hydrostatic test shall also be
made upon the completion of each general overhaul or repair affecting any
pressure part of the unit, or at other times when it is desirable to inspect for
leaks.

CAUTION

THE BOILER TO BE HYDROSTATICALLY TESTED

SHALL BE FILLED WITH TREATED WATER.
If the unit is not to be placed into service after the test, treatment
shall be with hydrazine in the range of 200 to 300ppm plus sufficient
ammonia or morpholine to raise the pH to 10. If the unit is to be
placed into service within a short time using the test water, the
treatment may be as for normal operation. It is strongly
recommended that the unit be filled with the demineralized water or
condensate system for the test.

If the quantity of demineralized water or condensate is limited,

certain sections of the unit may be filled with treated potable water or
other water free of corrosive and suspended materials. This water is
not to remain in the unit for wet storage as all wet storage should be
made with treated demineralized water or condensate.

Drainable sections may be tested with other than demineralized

water or condensate provided the chloride content of the test water is
less than 50ppm, the temperature is less than 52 ℃and that the
sections will subsequently be rinsed with condensate or
demineralized water prior to operation.

“The Steam Boiler Safety Supervisory Regulations”, stipulated by

the Labor Ministry of the People’s Republic of China, specifies that
the unit shall be subjected to a hydrostatic test with test pressure of
1.25 times the design pressure and test water temperature of 20 ～
70℃, which, however, shall be higher than the ambient temperature.
In order to satisfy with custom requirement, the hydrostatic test
pressure can be reached one and one-haif times the drum operating
pressure. This hydrostatic test is the test to be applied prior to the
unit is initially operated and after repairs or revisions are made to
pressure parts. Before applying a hydrostatic test on the unit, make a
thorough internal and external inspection to be absolutely sure that:
a. All foreign material and tools have been removed.

b. No one is inside the unit.

c. The pressure gage has been correctly calibrated and is connected

properly, with valves open, on the drum outlet piping.

d. Any part not designed to withstand the hydrostatic test pressure is

properly isolated or blanked off from such pressure.

e. All valves operate freely and seat properly.

f. All steam circuit spring hangers are pinned in a fixed position.

g. All safety valves are blanked or gagged.

When the foregoing have been carefully checked:

a. Verify that drum manhole are properly closed.

b. Close stop and check valves, all drain and blowdown valves and valves
to any gages or other integral equipment not designed to withstand the
hydrostatic test pressure.

c. Open vents on the highest points of each component part of the unit.

d. Be sure that the water will not freeze during test and the unit will not be
subjected to freezing conditions following the hydrostatic test. If
hydrostatic testing of a drum will be at temperatures above 49 ℃,
exercise care during close examination to avoid possible burns from
water leakage.

e. Check that only authorized personnel are in the vicinity of the unit to be
tested.

f. Start filling the unit with water, which should be relatively close in
temperature to that of the pressure parts, so that the temperature of
drum metal and water is in accordance with the following before
applying a hydrostatic test pressure. All other pressure parts must be at
a temperature of not less than 20℃.

CAUTION

WHENEVER HYDROSTATIC TEST PRESSURE IS IN

EXCESS OF 5.1Mpa, THE MINIMUM DRUM METAL AND
WATER TEMPERATURE （ 20℃ ） MUST BE OBSERVED
TO INSURE THAT HYDROSTATIC TESTING IS
PERFORMED ABOVE THE BRITTLE TO DUCTILE
TRANSITION TEMPERATURE FOR THE METAL.

To obtain this hydrostatic test temperature, the following procedures

are recommended ( items a and b).

(1) IF STEAM GENERATOR UNDER-BED BURNER SYSTEM IS

NOT
FUNCTIONING ( AS MAY BE THE CASE FOR INITIAL
OPERATION ), ANY ONE OF THE FOLLOWING METHODS
(1), (2), OR (3) IS RECOMMENDED. Heat from an external
source, to obtain the recommended minimum temperature as
indicated by the drum surface thermocouples.

(2) Use small oil and/or gas burners aimed through doors or
resting on the grid nozzles to raise the temperature to that
recommended. The burner flame should be kept away from
the boiler tubes.

(3) If the drum must be warmed above 20℃, the additional

temperature may be obtained by connecting a saturated
steam supply to drum blowdown or chemical feed line to heat
water and drum shell. Start out with drum at normal operating
level and heat the water to a temperature 2 ～ 5℃ above the
desired temperature so that subsequent water addition does
 not lower the final temperature below the recommended
minimum.

b. IF STEAM GENERATOR UNDER-BED BURNER SYSTEM IS

FUNCTIONING, THE FOLLOWING METHOD IS RECOMMENDED.

(1) After filling the unit to normal water level, fire the under-bed
burners to raise the drum temperature to 2 ～ 5℃ above that
recommended. Extinguish fires and continue to fill unit.
Inspect drains and manhole for leaks as the unit fills. Close
the high point vents when water issues from them.

(2) Raise pressure to the intended figure slowly to avoid shock.

The recommended rate of pressure increase should not
exceed 0.3Mpa per minute.

(3) If hydrostatic test was applied at pressure above design

pressure, reduce pressure slowly and thoroughly inspect unit
for leaks only at operating or design pressure. When
inspection is completed, release pressure slowly at the
recommended rate of pressure release not exceeding 0.3Mpa
per minute, open vents and drain. Superheater system must
be thoroughly drained.

(4) If temporary manhole gaskets were used during initial

hydrostatic test, they are to be replaced with proper gaskets
before refilling unit for operation.

(5) Remove blanks or gags from safety valves and pins from
spring hangers after test has been completed.

2.3. DRYING OUT REFRACTORY

All refractory should be cured and dried at the field by erection

company in accordance with the refractory manufacturers’
 recommendations to assure that the actual performance of refractory
shall meet our requirements.

2.4. BOILING OUT

2.4.1.General

Boiling out is the process of internally cleaning for the removal of oil
and grease, and the solvent usually consists of a strong alkaline
solution.

The presence of even very thin films of oil or grease or their

decomposition products on the boiler heating surfaces will seriously
retard heat transfer. This film acts as a dangerous heat insulating film
and retards the rapid transmission of heat from the metal to the boiler
water. The resultant increase in metal temperature may be sufficient
to cause overheating and blistering of boiler tubes and ultimate
failure at high loads.

During the boiling out process, the gage glass may become badly
discolored and permanently etched. We have supplied replacement
of mica and mica repair kit, Our suggestion is that Restore the
inoperable gage glass to its original condition after boiling out and
chemical cleaning, and before the next filling of the unit with treated
condensate. The gage glass manufacturer’s instructions should be
consulted for the identification and the replacement procedure.

The chemical should be dissolved in water before being added to the

boiler and should never be added to the boiler in solid form. In
handling caustic materials, care should be exercised to avoid contact
with the eyes, skin or clothing. When mixing this material, it is
recommended that goggles, rubber gloves and cotton clothing be
employed.
 The chemical solutions should not be added to the boiler in high
concentrations through the regular chemical feed system since these
high concentrations may plug the chemical feed piping and valves.

If the boiling out chemicals must be injected to the boiler drum

through the chemical feed system, the concentration should be
reduced to a five (5) percent solution in the mixing tank ahead of the
chemical feed pump suction, and the pump and chemical lines be
flushed thoroughly after the pumping is completed.

2.4.2.Recommended Chemicals for Boiling Out

Alkaline chemicals such as soda ash and caustic soda are commonly
used for boiling-out a unit since these agents possess the ability to
saponify the oils and greases and form a soap compound that is
easily removed by high pressure blowdown during the boiling out
process, and after completion of boiling out, by flushing with a high
pressure hose using cold water.

Phosphate has also been used as an agent to provide thorough

cleaning of internal boiler surfaces. Both trisodium phosphate and
disodium phosphate, accompanied by either caustic soda or soda
ash, have been used. In this connection, an embrittlement inhibitor
has been used in the boiling-out solution.

It is known that intercrystalline cracking ( caustic embrittlement ) has

been caused by the caustic soda used during the relatively short
boiling out period. the alkaline concentrations developed in the boiler
water during boiling out are quite high in comparison to standard
boiler water concentrations. It is safer practice therefore, to add an
adequate concentration of an embrittlement inhibitor to the boiler
water. Sodium nitrate is the preferred agent for this purpose.

For the most effective removal of oil from boiler metal surfaces, it is
 recommended that a“wetting agent”be incorporated in the boiling out
mixture. These agents increase the“wetting power”of the water by
reducing the surface tension and therefore reduce the adherent
characteristics of oils and greases to a minimum. The combination of
a “wetting agent”along with the regular boiling out chemicals will
therefore break down the oil-sludge bond and remove the oil and
grease from the metal surfaces.

The following chemical dosages have proven successful on many

installations and will clean a unit satisfactorily. The proportions of
each chemical should be accurately weighed before being placed in
the mixing tank.

The chemical charge should consist of the following proportions:

Trisodium Phosphate (crystalline) 5.25 1g/1kg of water

Soda Ash 1.0 1g/1kg of water
Sodium Nitrate 0.15 1g/1kg of water
Wetting Agent 0.10 1g/1kg of water

Refer to Item 1.10 for the amount of water required for normal filling
of this unit.

If trisodium phosphate is not obtainable, it is permissible to substitute

disodium phosphate (anhydrous); however, the weight of this
chemical should be based on 2.5g/1kg of water.

NOTE

The following procedure is based on the assumption

that a trisodium phosphate solution (Na3PO4-12H2O)
will be used.

2.4.3.Preparations for Boiling Out

Prior to boiling out a steam generator, the items previously outlined

 under“Safety Precaution”and“Drying Out”should be consulted and
followed. Generally, drying out and boiling out are combined as one
continuous operation.

A careful cleaning and inspection of the interior and exterior surfaces

of the boiler and auxiliaries should be made for the purpose of
removing all scrap metal, borings, wood, tools, rags and other
miscellaneous materials. It is very important that these material be
removed before the boiling out, otherwise, foreign material in the
interior boiler sections is likely to interfere with operation of blowdown
valves and future operation of the boiler.

No attempt should be made to set safety valves when the boiler

contains water of high chemical concentration such as that used for
boiling out purposes. The safety valves should be set when the boiler
contains water of approximately normal concentration during the
initial start-up phase.

NOTE

Initial charging of bed material can be accomplished

before or after boiling out.

a. If beds are to be charged at this time, add bed material, in accordance

with procedures specified in Section 3, Paragraph 3.3.

When workman enter the furnace, proper precautions must be taken

including:

(1) Station a second workman by the furnace access door to

observe the progress of work and immediately advise plant
personnel of any problems.

(2) All fuel and limestone feed equipment and fans should be
secured and tagged“Out of Service - Men Working in
 Furnace”.

(3) Anyone entering the furnace should be provided with proper

breathing equipment and eye protection as is required for a
dusty environment.

(4) The furnace should be cool, well ventilated and tested,

utilizing normal industry standards, for proper air constituents
before anyone enters it.

b. Open the vent valves indicated in the list within Paragraph 3.3. so that
air can be expelled as the boiler is being filled. Isolate gage glasses,
remote level indicators, pressure connections, sensitive
instrumentation and anything that could be damaged during boiling
out. Filling the unit should be accomplished using the feedwater
pumping and piping system normally used during boiler operation.
This will have a tendency to flush out the piping and auxiliaries ahead
of the boiler.

c. Inject chemicals into the boiler feed line downstream of the main feed
pump but upstream of the economizer. A main feed line piping drain or
economizer drain connection may be used for this purpose.

NOTE

Chemical injection should be carried out only when

main feedwater is flowing. Also, injection must be
completed well in advance of reaching the desired
drum level so that the chemicals in the boiler feedpipe
will be flushed out during the final stages of the boiler
fill cycle.

d. Raise the water level so that it is just visible in the bottom of the lower
gage glass.
e. When the desired steam drum level is reached, close boiler feedwater
flow control by-pass valve.

NOTE

At this point, all steam drum valves, with the exception

of instrument connections and vents, should be closed.

2.4.4.Boiling Out Procedure

a. Start the induced draft and combustion air fans in accordance with the
fan manufacturer’s instructions and in the sequence outlined in
Section 3, Start-up Procedures.

b. Purge the boiler in accordance with Section 3, start-up procedures.

c. Set the combustion air damper to maintain sufficient air flow to the
under-bed burner.

Establish stable firing at the burner fire rate.NOTE

To protect the drum from undue thermal stress, the

metal differential temperature between the top and
bottom of the drum should not exceed 50℃. Monitor
this temperature differential during start-up and normal
operation.

e. Close the steam drum vent valves when boiler pressure reaches
0.1MPa.

f. Continue to fire the under-bed burner or feed coal into the furnace
until the steam drum boiling out pressure reaches the value
corresponding to the design pressure for this unit. (See Figure 2－1).

g. The boiler feed pump must be kept available for operation should
make-up feedwater be required.
h. Fire the under-bed burner or feed coal into the furnace intermittently
as required to maintain steam drum boiling out pressure for at least
eight (8) hours.

i. Raise the water level to approximately 50mm from the top of the gage
glass.

j. When the high water level and steam drum boiling out pressure have
been reached, shut down the under-bed burner or interrupt coal
feeding.

k. Start blowing down each blow-off line by opening the drum mass
blow-off valve, furnace lower waterwall header drain valves. It is
recommended that, when blowing down these lines, the root valve
(closest valve to boiler) be opened first and closed last. The second
valve in the line should be used to control flow. A sufficient blow can
be accomplished by spinning the valve open and then spinning it
closed again (approximately 10 seconds.)

l. A cooled sample from the drum should be checked for phosphate, pH,
silica and total alkalinity and a record kept of the chemical
concentrations.

m. If the water in the steam drum falls to within 50mm from the bottom of
the gage glass, refill the steam drum and fire the under-bed burner or
feed coal into the furnace to maintain steam drum boiling out
pressure.

n. Repeat steps k and l once every four (4) hours for at least 24 hours
until all signs of oil have disappeared from the cooled boiler water
sample. Repeat step m. as required.

After boiling out, When the boiler has been cooled and drained, the
drum(s) should be inspected and any sediment removed. If the
quantity warrants, inspect headers. Where inspection nipples are not
 provided on headers, inspection may be accomplished by cutting a
feeder or riser tube at the stub and bending the tube out of the way. If
any foreign material is found in a header, It can be removed manually
or flushed with a high pressure water hose. In addition to checking
for sediment, inspection should assure that the metal internal
surfaces are free from oil adherence.

After the drum and headers have all been cleaned and inspected,
the unit can be closed. New manhole gaskets should be installed on
the drum and inspection nipple caps or tubes cut for cleaning and
inspection should be replaced.

2.5. FEEDWATER AND BOILER WATER TREATMENT

Feedwater and boiler water samples must be inspected to meet

desired water quality requirement.

The quality of feedwater should be in compliance with section 1.1.9

the high pressure water quality. The treatment of feedwater and the
conditioning of boiler water are beyond the control of HBG.
Therefore, HBG shall not be held responsible for damage due to
formation of scale or deposits or caustic embrittlement caused by
chemical conditions of the water. Sludge accumulations in tubes will
impair heat transfer and resulting in overheating and will affect boiler
performance.

2.6. CHEMICAL CLEANING OF ECONOMIZER AND STEAM

GENERATING CIRCUITS

2.6.1.General
The cleaning of modern high duty steam generators with chemical
solutions is an effective tool. A cleaning performed prior to initial operation
or a very short time thereafter, for the purpose of removing mill scale,
 provides a thin, uniform protective coating of iron oxide and removes, from
the unheated portions of the system, much material that may be
redistributed to the heat transfer areas. There is merit to postponing this
type of cleaning until after some short period of operation as considerable
iron oxide and silica-bearing materials may be carried into the steam
generator from the feedwater and condensate system during initial
operation, unless the feedwater and condensate system are also
chemically cleaned.

The need for removal of operational deposits will vary considerably

from plant to plant depending on the type of feedwater used and the
history of make-up and feedwater problems. Because of the wide
variety of materials that make up operational scales, their removal
may be much more complex than the removal of mill scale. No steam
generator can operate dependably if the heat transfer surfaces are
fouled with scale.

2.6.2.Determining the Need for Chemical Cleaning

The need for a pre-operational cleaning will depend primarily on how

much rusting of all cycle components can be expected to take place
during construction. Factors influencing this are storage precautions
and weather conditions at the plant site. Much rust, loose mill scale
and silica-bearing material will be removed from the steam generator
during the alkaline boiling out which should be performed on every
unit. If the rest of the cycle is not extensively cleaned, material will be
carried into the steam generator and cleaning may be warranted.

Deposits formed during operation can be quite varied and complex

and the maximum tolerable amounts are difficult to establish. Tube
samples should be removed from the unit on an annual or biannual
basis and the deposit weight measured. Generally, without reference
 to the specific deposit composition, a unit with 20 to 40 mg/cm 2 of

deposit on the cold side of the furnace tube should be considered

dirty enough for chemical cleaning at the next maintenance outage.

2.6.3.Solvent Systems

Solvent selection is made on the basis of two primary considerations.

The first is compatibility with the materials of construction and the
second is the suitability for removal of the deposits. The two are not
independent of each other since dissolution of deposit material by
the solvent may create corrosion conditions for a tube material that
would not be attacked by the solvent in the absence of the deposits.

Mineral acids, such as hydrochloric acid, are commonly used as the

solvent base for mill scale or operational deposit removal. If copper is
present in the deposits, complex agents must also be used, as
copper will plate on the boiler surfaces in the acid solution. Solution
strength will depend on the deposit analysis, weight and structure.

When using hydrochloric acid for a pre-operational cleaning, the

following is commonly used:

Hydrochloric acid concentration 5% max. by wt.

Metal or solvent temperature 68℃
Solvent contact time 6 hours
Inhibitor concentration Per cleaning contractor spec.

Organic acids, single or in mixture, and in combination with various

other materials are also used as solvents. While they generally are
less aggressive than the mineral acids, proper inhibition and
preliminary testing are still a necessity. In addition, because of the
lesser dissolving capacity of the organic materials, some means of
circulation within the unit may be required to insure against local
depletion of the solvent before the deposits are completely dissolved.
2.6.4.General Cleaning Operations

Chemical cleaning of a steam generator should never be attempted

by inexperienced personnel. There is danger of extensive damage
should conditions get out of hand or improper materials be used.
Careful planning is required to assure that the specified chemical
conditions are attained, that conditions hazardous to life and property
do not occur.

To bring the unit to cleaning temperature, the unit may be filled with
condensate or demineralized water and heated by one of the
methods specified in paragraph 2.2. Using drum thermocouples, and
temporary thermocouples if necessary, monitor unit temperature to
assure that there are no areas above the limits for the solvent system
and inhibitor used. The limits must be specified by the solvent
system supplier. When the proper temperatures are attained, the
water may be drained to storage.

The unit is then filled with solvent by pumping the stored heated
water back into the unit and metering in the concentrated solvent to
give the desired concentration. Before the solvent pumping is
started, it should be checked for proper inhibition. If the water
temperature must be adjusted while refilling the unit, steam should
be injected ahead of the solvent to avoid corrosion of the mixing
equipment.

NEVER FIRE THE UNIT WHEN IT CONTAINS ACID AS INHIBITOR

BREAKDOWN MAY OCCUR.

While the solvent is in the unit, the acid strength, iron concentration,
temperatures and any condition or constituent necessary for control
of the particular solvent system should be monitored on a regular
basis. When the cleaning is complete, as indicated by the leveling of
 the iron concentration, the solvent is drained from the unit under a
nitrogen blanket.

The unit may be filled and drained one or more times to flush the
solvent from the cleaned area. The rinse may contain an iron
complex agent to prevent precipitation of iron on the cleaned
surfaces.

When the rinsing is complete, the unit is filled with an alkaline

solution to neutralize any residual solvent and passivate the surfaces
to prevent after-rusting. The alkaline solution may be heated prior to
filling the unit or the unit may be heated as in paragraph 2.2 to attain
the desired temperature.

Upon completion of the passivation, the unit should be drained for

inspection and removal of any temporary piping .

2.7. CHEMICAL CLEANING OF SUPERHEATERS

2.7.1.General

Chemical cleaning of superheaters may be performed in those cases

where, because of particular cycle requirements, the operating
company elects to do a pre-operational cleaning or where an upset
operating condition creates deposits which must be removed.

The same general precautions regarding suitability of solvents and

compatibility of solvents with materials of construction, as required
for steam generation circuits must be observed.

Many superheaters contain sections that are either non-drainable or

non-ventable. This prevents a cleaning from being done by a fill and
soak method. To assure that all tubes can be filled with solvent and
then flushed successfully, all air must be purged from the circuitry
prior to introduction of the solvent. This may be accomplished by
 pumping water at high flow rates or by purging with low pressure
steam. The former method requires such high flow rates that, for any
but the smaller units, it is impractical. Steam purging for several
hours, followed by filling with hot water, in a manner to preclude entry
of air, and then displacement with solvent will permit a circulation
type cleaning with moderate pumping requirements.

2.8. STEAM-LINE BLOWING

2.8.1.General

Solids, such as scaling in the pipe, which is carried by steam

with extreme high velocity, can cause severe damages to the
blades and valves of turbine. Normally, need install a filter at the
inlet of the turbine and blow the superheater and the steam
piping before the first operation of the turbine. Steam-line
blowing is to clean all the solids in the pipe which will do
damage to the blades and valves of the turbine (ferric iron
oxide, rolling skin and some other external articles)Acceptance
gage

According to the acceptance goal value and the sampling of the

steam purity, which are the two successes, consider the steam
piping as purity.Prerequisite

a. Having continuous supply of feed water to make-up water lost in the period
of the steam purging.Check of electric drawings
b. Check of the duct pilot layout drawings
c. Finish the check of the meters
d. Test of the safety chains
e. Set and check the safety valves
f. Have finished the test of the boiler and all auxiliaries
g. Install the temporary purging piping, purging valve and silencer, also the
 check and pressure test
h. Strike all the temporary scaffolds, devices and some other unnecessary
equipments in the area of steam purging

2.8.2.Initial condition
a. Continuous communication has been established between device
operators, field persons and the master-control room
b. When the boiler runs in the condition which has lower steam pressure and
lower temperature for 5%-10% than required, the boiler and the
assistant system is steady. The required steam purging power is
determined by the following formula: R=(W/ Wr )2V/Vr( R: steam
purging power W: steam flow during the period of steam purging Wr:
the designed steam flow V: the specific volume in the inlet of the
superheater during the period of steam purging, is expressed by
cubic feet/pound). If we apply continuous purging method, R should
be 1.5—1.6 and for impulse or intermittent purging R should be 1.0—
1.2. Because the thermal impact and dynamic force generated by the
fast variation of the steam condition ( pressure and temperature )
accelerates the purging progress, intermittent method is better than
continuous method.
c. All valves on the steam piping, until all the temporary steam purging valves
is opened, all piping have been blowd and been preheated
d. Warning limit should be set in the adjacent area of steam purging and
temporary piping, and suspend the standards to prevent people enter
this area
e. All adjacent people have been informed

2.8.3.Precaution and matters need attention

a. Piping arrangement. The arrangement of the temporary piping should be

convenient to the purging of all steam piping located in the lower
 course of the boiler. All the temporary piping nozzles and valves
should have the same dimension as the piping need purging so as to
prevent the reduce expenditure. The temporary pipes which are used
to emit to the air should be consolidated so as to stand up with the
strong reacting force generated by the nozzles during the period of
ejecting. Purging should have only one direction to avoid hurt of
people or damage of objects which may cause by the carried material
with extreme high velocity. Whether silencer will needed depends on
its position and the silencer should be selected to meet the condition
of low pressure loss and high velocity. According to the cleanliness
the system, collectors and filters may need in the upper course of the
silencer to prevent blockage. The temporary piping should also
include the drain joints located in the low point and the upper course
of the purging valve. The outlet is used to heat and discharge
condensate liquid for the steam piping during the interval time of
steam purging. Also the safety valve may be needed for overpressure
protect, this depends on the pressure limit condition of the temporary
piping. All temporary piping near the work area should be isolated for
personal safety.
b. Valve. All selected temporary purging valves should have the function of
intermittent purging according to the high velocity. The steam valve
should be the type of quick-open and should have the remote control
structure which is suitable for this function. The steam purging valve
is not a part of the permanent system and this type of valve will be
damaged. The gate valve for hydraulic operation can open(about 3
seconds) or close(about 10 seconds) quickly. The purging valve
should be installed in the upper cause of the silencer

2.8.4.Procedure of steam purging

a. Rising pressure according to the normal pressure-rise curve and the

 marked condition to metal temperature and stop it until reach the
purging pressure. The purging pressure can be determined by
calculation of purging force.
b. When rise pressure, heat the temporary steam piping by the drain joint
located near the temporary steam purging valve
c. Set the water level a little lower than the normal level and then shutdown
the start-up burner
d. Open the steam purging valve quickly. When open the purging valve,
because the pressure of the steam drum falls down, the water level of
the steam drum will rise instantly and then falls down soon. Because
of this, the water level controller of the steam drum should be in
manual position. By doing this, when the operator can increase feed
water manually the moment he notices the falls of the water level of
the glass tube
e. Try your best to maintain the normal water lever, shutdown the steam
purging valve as soon as reaching the predetermined purging time.
The actual purging time is determined by the variation of the boiler
pressure and the water level of steam drum
f. In order to assure the water level of the steam drum be a constant, the
amount of feed water should be adjusted. When the purging valve is
shutdown, the water level of the steam drum will fall down
g. All piping which has been blowd should be drained
If necessary, do all the procedures again till the cleanliness is acceptable

2.8.5.Return to the raw condition

a. According to the requirement of liability, please make sure that the boiler
can generate steam
b. Isolation is for the temporary joints of the steam piping
c. Make sure that all temporary joints be drained, cooled and striked
d. Recover the piping and valves of the permanent devices to their raw
 condition.

2.9. BOILER SYSTEM AIR TEST

Upon completion of erection, an air test shall be performed to detect

any air and flue gas leaks in the boiler system. The leaks shall be
corrected to insure tightness and the safe operation of the system. A
typical recommended procedure is as follows:

a. Install a blanking plate at the ID fan inlet.

b. Close all access doors and observation ports.

c. Cap all instrumentation penetrations.

d. Open all passageways to be tested.

e. Operate the FD fan to pressurize the system to 80mmH 2O pressure.

f. Inspect entire system using suitable visual/audio method. Soap films,

smoke bombs and sonic detectors are useful and one or more should
be employed.

g. Identify all leaks.

h. De-pressurize system.

i. Repair all leaks.

j. If leaks were found, repeat the air test following leak repair.

k. Remove blanking plates and caps.

3. OPERATION AND MAINTENANCE

3.1. GENERAL

a. The operator should be thoroughly familiar with the function and

controls of the boiler, components and auxiliary equipment before
operating the unit. The information given in this section is not intended
to be a detailed procedure for operation of the steam generator but is
meant to serve as guide. This guide, together with the instructions of
the auxiliary equipment and with knowledge derived from initial unit
operation, can be used to develop a detailed operation procedure.

b. Circulation fluidized bed boilers are chemical process reactors,

without a defined fireball. The boiler fireside contains a circulating
solid inventory of considerable thermal energy.

c. The operator should be aware of the limitations imposed on the

various parts of the boiler and its auxiliaries and be alert to the actual
operating conditions during start-up and while operating per system
demands.

d. The boiler can be operated at a maximum continuous rating (MCR) of

130t/h superheated steam at 510℃ and 100bar(g) at the superheater
outlet with feedwater entering the unit at 170 ℃ while firing the fuel
specified in Item 1.1.3.

3.2. GENERAL PRECAUTIONS

The Critical precautions that the operator must observe and exercise
during all phase of operation of this unit are listed below.

a. All doors at lower furnace must not be opened during normal unit
operation to protect personnel from any danger as this steam
generating unit will have internal pressure greater than atmospheric
 pressure.

b. Furnace Pressure Limits

Exposure to excessive negative or positive furnace pressure can

result in serious damage to the unit and auxiliary equipment.

The following controls should be in service and operable prior to

start-up for protection against excessive furnace pressure or draft.

1. The furnace draft, as measured at the balance point in the

furnace exit, should be monitored constantly and automatically
controlled to be between -130～250Pa.

2. The Main Fuel Trip (MFT) should be set at 2500Pa pressure

in the furnace outlet (cyclone inlet) with a 5 second delay.

3. The FD and ID fan trips should be set at 3750Pa pressure in

the furnace area with no time delay.

On any Main Fuel Trip (MFT) the following occurs:

(a) Fuel feeders trip.

(b) Limestone systems trip.

(c) under-bed burners trips.

(d) Bottom coolers trip.

(e) All air flow controls transfer to manual mode and hold last
position.

(f) FD fan controls transfer to manual mode and hold last

position unless the cause is a fan trip. In that case, fan
controls follow fan logic.

(g) Output signal to combustion control limits ID fan automatic

control from going above the furnace draft limit.

(h) “Boiler Purge Required”logic is set unless it is a“Hot

 Restart”condition.

4. The operator should not allow the furnace pressure at the

balance point to exceed 500Pa (alarm point).

5. On loss of FD or ID Fans or all J valve blowers (MFT will be

initiated), the bed will collapse and the collapsed bed may
contain combustibles. Access doors should be left closed. Air
flow should be slowly re-established to purge combustibles
from the unit.

NOTE

At all times, the operator should remember that the unit

maintains a considerable amount of stored energy even
following an MFT. Drum level and an adequate flow of
steam to control pressure should be maintained at all
times.

c. Drum Water Level and Temperature Differential

The normal drum water level is 180mm below the centerline of the
drum. The alarms are set at 75mm below and 75mm above normal
water level and the trips are set at 120mm below and 120mm above
normal water level.

NOTE

A low low drum water level condition (120mm below

normal water level) or a high high drum water level
condition (120mm above normal water level) initiates a
main fuel trip (MFT) and the FD and ID fans are tripped
to protect the drum from undue thermal stress; the
metal temperature differential between top and bottom
 of the drum should not exceed 40℃. The drum metal
temperature should be monitored and indicated in the
control room.

d. Safety Valve Adjustment

All safety valves are set by the valve manufacturer but should be
rechecked under actual operating conditions as the boiler is being
brought up to pressure during initial operation. If a safety valve does
not lift at the pressure stamped on its nameplate or reseat properly,
the valve should be readjusted. It is not allowed to change the
settings of any safety valve without authorization.

e. Excess Air Requirement

Care should be exercised to ensure that the proper fuel-air ratio for
good combustion is maintained. The excess air requirement at 100%
MCR load is measured at the HRA outlet and corresponds to an
oxygen measurement of approximately 3.1% by volume on a wet
basis. (See Figure 3-1.) It is just for reference and should be set by
combustion adjustment. Operation with less than the specified
excess air can be detrimental from the standpoint of good
combustion and safe operation of the unit.

f. Bed Temperature Profile

Normal operating bed temperature is 790 ～ 920℃ (measured by

thermocouples on the grid plate). This temperature should be
monitored during operation and attempts should be made to operate
at this level. The bed high temperature alarm point is 955 ℃. A main
fuel trip is automatically initiated at 990 ℃. The minimum operating
temperature for the bed is 790℃. Do not allow temperature to drop
below this level without support fuel. The low bed temperature alarm
is 760℃. A main fuel trip is automatically initiated at 650 ℃ unless
 the under-bed burner is in operation. The solids fuel feeds will
automatically trip off line if the bed temperature drops below 540℃
regardless of burner operation.

g. Cyclone Tube Protection

If the unit experiences a trip, steam temperatures in the cyclone

tubes may tend to rise rapidly. Thermocouples have been installed
on cyclone wall tubes to monitor these temperature rises and
transmit them to the control system. If any one of these
thermocouples rises above 420℃, the control system automatically
opens the cyclone cooling steam vent to increase the cooling steam
through the cyclone tubes. The vent then automatically closes when
all of the thermocouples show temperatures below 410℃.

h. Readiness Inspection

The following precautionary steps must be taken to insure reliable

operation of the unit:

1. It is recommended that the heat recovery area (HRA) gas side

surfaces be inspected for particulate deposit accumulation each
time the boiler is taken out of service. The surfaces should be
cleaned accordingly before boiler restart if any serious
particulate accumulation is detected.

2. For purposes of monitoring start-up conditions during the life of

the boiler, thermocouple assemblies are installed in various
locations in the steam generating circuit. These thermocouples
are to be used as an aid in determining acceptable firing rates
during start-up. The thermocouples are located as follows:
 Thermocouples Location Total Alarm Limitation
Qty Steam Temp.
Steam Drum Top & Bottom 8
SH Wing Wall Outlet Tubes 1 500℃
Low Temp SH Outlet Tubes 1 450℃
High Temp SH Outlet Tubes 1 535℃
These thermocouples are located in a zone where flue gas does not
sweep over them; therefore, the temperature obtained will be equal
to the steam temperature. These and other thermocouples should be
checked and made ready for service (including control room
indications).

The unit can be operated continuously up to the steam temperature

limits indicated in the table above. To protect the equipment, the
operator should correct any condition which has caused an alarm.

In addition to the thermocouples mentioned above, there are 8

thermocouples per cyclone, 4 upper and 4 lower in left cyclone and 4
upper and 4 lower in right cyclone. All are located at equidistant
points in the roof tubes near the top ring headers and at equidistant
points in the gas-heated hopper tubes near lower ring headers.

There are also four (4) thermocouples in transfer pipes between the
right cyclone outlet and the HRA inlet.

3. To prevent plugging, rusting and oxidation and faulty operation

of equipment, air used on the boiler for operational purposes,
whether for sealing, aspirating or atomizing, should be free of
dirt, oil and water.

4. All high and low furnace pressure safety interlocks should be

checked for proper values and correct switching action and be
 in service before starting the induced draft fan.

5. The sootblower system should be ready to operate. The

sequence of operating the sootblowers should be from down to
up ,then from top downward as a sootblow circulation.

Eight(8) couples of sootblowers are installed in the HRA as

shown in the following listing, on both side for low and high S/H
and air-preheater, on rear side for economizer.

LOCATION TYPE ELEVATION QUANTITY

High Temp. S/H Long retracting 35700 2

Low Temp. S/H Long retracting 32630 2

Economizer IV Rotary 28740 2

Economizer III Rotary 25930 2

Economizer II Rotary 23030 2

Economizer I Rotary 20130 2

Air-preheater II Rotary 13400 2

Air-preheater I Rotary 10650 2

6. Oxygen (O2) is monitored continuously during operation of the

boiler. O2 levels should not fall below 3.1%, by volume on a wet
basis. It is recommended that the O 2 analyzer be properly
maintained and calibrated before any start-up and on a regular
scheduled basis, as dictated by industry standards. O 2
controller should hold last value when calibration is in progress.

7. It is strongly recommended that the reliability of all drum level

indicators be checked at least once a shift. This would include
all gage glasses, remote level indicators and level recorders.
This can only be done by changing drum level and observing
 the response of all indicators and gage glasses.

8. The furnace bed fluidizing velocity should not be allowed to

drop below 1.2m/sec (minimum velocity required to maintain
proper fluidization). Refer to Figure 3-2.

3.3. COLD START-UP PROCEDURE

The operating sequence recommended to ensure a safe and proper

start-up is given below. Modifications may be necessary as
subsequent operating experience dictates. Follow the manufacturers’
instructions for operating auxiliary equipment.

3.3.1.Preparation Prior to Start-up

NOTE

A general unit equipment patrol should be made by at

least two (2) people to verify that all equipment is ready
for start-up. See Paragraph 3.3.2 for initial bed charging
criteria.

a. Operation of the Pressure Tap Purge System

The pressure tap purge system should be put into operation.

Establish a low flow of air through the pressure taps into the bed.
Periodically, the pressure taps should be manually purged with a
blast of high pressure instrument air. The frequency of this purging
must be established by experience. Always close the appropriate
valves to protect the purge system’s instrumentation when the high
pressure purge is to be performed.

A similar procedure should be used for all other pressure taps on the
air and gas side of the steam generator.

b. Make sure the test gags and/or plugs are removed from all safety
 valves.

c. Check availability of utility services, power, ignition and main fuel, and
suitably treated feedwater.

d. Check operation of all valves and dampers.

e. Check the start-up (under-bed) burners and all boiler auxiliaries,

assuring that all are operable and that associated valves are in their
proper open or close positions.

f. Check availability of thermocouples in representative locations to

measure steam drum metal temperatures.

g. Close all access doors and observation ports after it is proven that no
one is inside the unit. Release all safety tags on equipment to be
placed in service.

h. Place the boiler vent, drain and instrument valves in the following
position. This list assumes the unit is empty.

VALVE DESCRIPTION POSITION QUANTITY

(PER BOILER)

Steam Drum Safety Valve Set at 118.9 bar 1

High temp SH outlet Safety Valve Set at 105 bar 1
Main Feed Stop Valve Closed 2
Main Feed Check Valve Automatic 1
Drum Steam Connection Vent Open 2
Drum Pressure Transfer shut-off Open 3
Drum Water gage Shut off Open 14
Drum Chemical Feed Closed 1
Drum Emergency Drain Closed 2
Drum Continuous Blowdown Closed 2
Drum Water Sampling Closed 2
Drum Pressure Instrumentation Valve Open 2
 Drum Steam Sampling Closed 2
Drum Auxiliary Steam Shut-off Closed 1
Downcomer Drain Closed 4
W/W Lower Header Periodic Blowdown Closed 12
Left Cyclone Upper Header
Automatic 2
Cooling Steam Vent

Cyclone Lower Ring Header Drain Open 4

HRA Front & Rear Wall Upper header Vent Open 4
HRA Front Wall, Rear Wall, Side Wall
Lower Header Drain Open 4
SH Wing Wall Inlet Header Drain Open 2
SH Wing Wall Outlet Header Vent Open 2
High Temp SH Inlet Header Drain Open 2
High Temp SH Outlet Header Vent Open 2
Main steam pipe Outlet Pressure
Instrumentation Connection Open 1
Attemperator moterized Shut-off Closed 2

i. Fill the boiler by admitting water, via By-pass Feed Control Valve, to
the economizer using water from the regular feedwater source.

j. The temperature of the water should be between 20℃ ～ 70℃ and

should not be below the temperature of the drum metal. Close the
vent valves as each vent shows water flow.

k. Check that the drum remote level indicators are operating in the
control room and that they compare accurately with local gage glass
readings.

l. Check that all pressure and draft gages are calibrated and functioning
properly.

m. Check all safety interlocks for proper operation.

n. Verify that drum level is visible in the gage glass.

o. Check that all lubricating and cooling systems for all driving facilities
meet the manufacturers’ technical requirements and all cooling
mediums are available for equipment that requires cooling.

p. Position dampers in the air ducts and gas flues as indicated below.
Damper positions are displayed in the control room. All fuel,
limestone and other manual isolation and / or slide gate dampers
should be closed at this time.
 DAMPER DESCRIPTION POSITION

ID Fan Inlet Vanes Open

Primary and Secondary FD Fan Inlet Vanes Open
Limestone Inlet Closed
Upper Secondary Air Open
under-bed Burner & Furnace Fluidizing Air Open
J-Valve Upleg and Downleg Fluidizing Air Open
J-Valve Bottom Fluidizing Air Open
Lower Secondary Air Open
Fuel Sweep Air Open
Fuel Feeder Seal Air Open

q. The following operation sequence is recommended to ensure safe

and proper start-up. Modifications may be necessary as subsequent
operating experience dictates.

3.3.2.Purging

Note

Prior to purge (and firing of under-bed burner ), it is

essential that an internal inspection of the combustion
air duct, downstream of the under-bed burner, and the
plenum, be made for back sifting of bed material. All
bed material should be removed from the duct and
from the plenum, to preclude grid nozzle plugging.
Immediately prior to each start-up and prior to starting
after a main fuel trip (MFT), the furnace, cyclones and
HRA must be purged (except the special procedure for
hot restart ). The following steps must be taken to
 prepare for the purge.

a. Ensure that no hot start condition exists (average bed temperature

less than 650℃).

b. Ensure that boiler is in MFT but no MFT conditions exist.

c. Ensure that the fuel supply valve to the under-bed burner is closed.

d. Check that all limestone fuel feeders are off and spent bed removal
system is off.

e. Start the induced draft (ID), forced draft (FD) and one J-Valve blower
as follows:

CAUTION

THE FOLLOWING PROCEDURE PROVIDES FOR A

CLEAR AIR FLOW PATH FROM THE FD FAN INLET TO
THE STACK DURING START-UP OF EACH FAN TO
PREVENT POSITIVE OR NEGATIVE PRESSURE
DAMAGE TO THE FURNACE AND DUCTWORK.

NOTE

The general procedure will be to start one (1) J-valve

blowers, the ID fan , the Primary and Secondary fan. Air
flow is then set to purge requirements and all fans put
on AUTO control. Purging will be accomplished and
fans will be left in operation for subsequent start-up.

1. Ensure that all flue and duct dampers are in the positions specified in

Paragraph 3.3.1, Step p.

2. Start one J-valve blowers. Set the J-valve aeration rates to correspond
to those values listed in attached table 6 and fig.3-8 for each J-valve.

J-valve operation is automatically controlled by a program input to the

system in the pre-commissioning stage. Adjustment of air flows to the
various aeration taps should not be necessary during unit operation.
However, J-valve operation should be monitored closely for
abnormalities following start-ups or upsets.

Verification of proper operation or minor adjustment of aeration flow

rates should be performed in accordance with the following:

(a) Refer to Table 1, Fig.3-5 Fig3-6 and Fig.3-7 for proper operating
parameters.

(b) Place J-valve upflow and downflow plenum air flow controls on
auto.

(c) Place J-valve blower pressure control valve on auto and check
that it is properly functioning.

(d) Set shut-off valves to individual aeration taps to a 65% open

position.

(e) Place upflow leg and downflow leg aeration flow control on
auto.

(f) Confirm flow in individual aeration tap lines.

A no-flow indication in any line may be plugging of the tap. Correct or

establish a clear line by a high pressure air purge. Do not attempt to
mechanically rod out the line with the unit in service.

(g) Record aeration air flow rates, and J-valve temperature and
compare to Table 6.

(h) Air flow rates that vary widely from values given in Table 6
should be adjusted to agree. Switch to a manual aeration
mode. Adjust air flow towards the tabulated value in 14Nm 3/h
 increments while recording pressure differentials. Set air flow at
lowest stable pressure differential.

(i) A unit shutdown will be necessary to clear plugged or

inoperable aeration taps as soon as possible. Continued unit
operation may be possible for a limited time provided the
inoperable or plugged aeration tap locations are known and that
horizontally or vertically adjacent taps are not plugged. Unit
shutdown is mandatory to avoid a plugged J-valve when
several taps are confirmed inoperable.

(j) Record J-valve aeration flows, pressures and temperatures at

unit loads of 40%, 60%, 80% and MCR. If necessary, perform
adjustment procedures as in step (h) above.

3. Start the ID fan. The ID fan inlet control vanes will close, the ID fan

breaker will close and the motor will start running. Once the motor is
proved running and up to speed, the inlet control vanes are released
to furnace pressure control.

4. Start the Secondary and Primary fan. The fan inlet control vanes will

close, the fan breaker will close and the motor will start running. Once
the motor is proved running, the inlet control vanes are released to
combustion control. However, the Secondary FD fan should be started
and adjust the air flow to minimum prior to start-up of the Primary FD
fan.

5. The control system will automatically adjust the unit to a“ready for

purge”condition.

f. Charge furnace beds with material as follows:

 1. The furnace bed should be charged with bed material , either rough

limestone or burned material of 0 ～ 6mm size, to a static bed depth of

400mm. Stop charging when bed pressure indicates 3500Pa.

g. Purge the unit with at least 25% (but not greater than 40%) total air
flow for at least 5 minutes.

h. After the steam generator has been completely purged, reset the
master fuel trip (MFT) and perform the following:

1. All secondary air control dampers should be at minimum open

position.

2. Position the following equipment in the indicated positions:

(a) Position the under-bed burner and furnace fluidizing air (to
plenum) control damper for proper combustion air.

(b) Establish combustion air flow at a minimum of 26600Nm 3/hr by

adjusting FD fan inlet vanes.

(c) Ensure that there is a supply of fuel available to the under-bed

burner and that purge air to the scanners is on.

3.3.3.Warming The Unit

CAUTION

PRIOR TO LIGHT-OFF, THERE MUST BE BED

MATERIAL IN THE FURNACE EQUIVALENT TO A
400mm STATIC BED AND THE UNIT MUST HAVE BEEN
PURGED.

NOTE
 the superficial fluidizing velocity should not be allowed
to drop below 1.2m/sec, the minimum superficial
fluidizing velocity required to maintain fluidization.

CAUTION

TO PROTECT THE DRUM FROM UNDUE THERMAL

STRESS, THE METAL TEMPERATURE DIFFERENTIAL
BETWEEN TOP AND BOTTOM OF THE DRUM SHOULD
NOT EXCEED 40℃. MONITOR THIS TEMPERATURE
DIFFERENTIAL ON THE DRUM METAL TEMPERATURE
INDICATORS.

a. Check that between economizer inlet and drum recirculation shut-off

valves are open.

Close fully and then open 1/2 turn the following drain valves:

Cyclone Lower Ring Header Transfer Pipe Drains

HRA Front wall Lower Header Drains
SH Wing Wall Inlet Header Drains

b. Following the burner instructions, light-off the under-bed burner.

Observe the light-off via the observation ports for good flame quality.

c. In the manual mode, place limestone feeder systems in service at

minimum speed per instructions. Verify and monitor tracking and
movement of rotating equipment prior to and during start-up and
during operation.

NOTE

Bed make-up is added as necessary during operation.

d. Monitor the O2 to ascertain complete combustion is taking place.

 Control mixture gas flue temperature below 900℃.

e. Having confirmed light-off in the under-bed burner, place on automatic

temperature control at various cooling air rate.

f. Heat the bed material and raise the drum pressure. Mixture gas flue
temperature should be regulated to increase drum pressure and
temperature at a rate not exceeding 50℃/hr.

g. While the unit is heating up and building drum pressure, check drum
metal temperature and drum level.

h. Raise the bed temperature to 450℃ while maintaining a combustion

air flow of 26600Nm3/hr. During the heating of the unit, the drum level
will rise. Maintain the drum level within range using the continuous
blowdown valve and the feedwater control valve. It may be necessary
to use the emergency release valve in conjunction with the continuous
blowdown valve to maintain drum level.

NOTE

Under no circumstances should downcomer or water

wall drain valves be used as blow- off valves.

j. When the drum pressure reaches 0.69 ～ 1.03bar, close the following
vent valves:

Drum Vents (On transfer pipes between drum and cyclone)

HRA Front Wall Upper Header Vents
HRA Rear Wall Upper Header Vents
SH Wing Wall Outlet Header Vents
Main steam Outlet Header Vents (On transfer pipes
between High Temp. SH and Main steam Outlet Header)

k. Close completely the following drain valves:

 Cyclone Lower Ring Header Drains
HRA Front Wall Lower Header Drains
SH Wing Wall Inlet Header Drains
High Temp. SH Inlet Header Drains

l. At this time, the drain valve(s) downstream of the main steam outlet
header should remain open to ensure that all water is drained from
the steam circuit.

m. After achieving approximately 1.7 bar in the drum, recheck the drum
water gage glass operation by a short blowdown. Maintain visible
water level in the gage glass. Water level in the drum will rise due to
swelling of water in the system. Blow down the drum as required by
opening the steam drum continuous blowdown and / or emergency
release valves.

n. Place the drum level control loop in automatic control in the single
element (drum level control) mode.

o. If the boiler water silica or solids contents is above the recommended

limit, the drum water should be blown down using the steam drum
continuous blowdown valve until the recommended limit is reached.
No further increase in pressure should be allowed until silica level is
below the respective pressure value.

p. Continue heating to build up boiler drum pressure and maintain bed

temperature of 450℃. If necessary, feed limestone into the furnace
during warm-up to maintain bed inventory indicated by bed pressure.

3.3.4.Start-up (Fuel Firing)

The following procedure must be integrated with the boiler and main
steam piping, such that a flow path is maintained for the steam being
produced by the circulating fluidized bed boiler.

a. Place the ash handling system in service following the own

 instructions.

b. Check that the spray control isolation block valves are open.

Place the steam temperature control loop on automatic with the

desired steam temperature setpoint.

c. Start three coal feeders and adjust to feed fuel into the furnace at 15%
capacity. Operate at this capacity for 5 minutes and then shut down
the feeder. Monitor O2 and average bed temperature (ABT) to
establish a trend over time. During the first several minutes, average
bed temperature should decrease initially and then start increasing.
O2 should remain steady initially and then begin to decrease
preceding average bed temperature rise. Establish a time interval
required to completely and safely combust the quantity of fuel just
fed. This time interval should be measured from the time of feed
commencement to the highest average bed temperature and lowest
O2. The time interval may be set by the field after having experienced,
but the duration may be changed with varying fuels. With some low
reactivity fuels coupled with varying unit designs, it may be necessary
to change the duration of batch feeding.

NOTE

Monitor individual bed thermocouples in conjunction

with the above procedure. A localized decrease in
temperature will usually be seen at the feed point with
gradual increases in temperature at adjacent
thermocouples.

d. Start the same feeder again at 15% capacity and batch feed fuel for
another 5 minute period. Shut down the feeder. Monitoring average
bed temperature and O2, restart the feeder at 15% capacity just prior
 to reaching peak bed temperature. Add fuel for another 5 minute
period.

e. Repeat steps c and d gradually increasing average bed temperature

(ABT) to 760℃. Once ABT and O2 are responding properly, the feeder
can be left in operation. Boiler load can then be increased by
increasing feeder capacity. As ABT increases, the combustion rate of
the batch feed fuel will also increase. This will actually cause a
shortening of duration time that the feed is left out of service. As the
feed rates increase, some caution must be taken not to overfeed the
unit. If the unit has been overfed with fuel, several indicators will
show disproportionate changes. O2 will decrease rapidly, perhaps to
zero. ABT will climb steadily in large increments. Several courses of
action can be followed dependent on the severity of overfed material:

1. Wait it out but do not introduce additional fuel; monitor the

trends.

2. Increase the limestone or bed make-up feed rates; this cooler

material will absorb the increased heat release.

3. Lower the air supply to the bed to starve the combustion

process.

f. As O2 continues to decrease and bed temperature increases to

790℃, gradually begin increasing combustion air flow above
26600Nm3/hr and, at the same time, lower under-bed burner gas flue
mixture temperature to 540℃. At this point, follow established feed
rates and air flow requirements.

g. Required superheat steam temperature should be maintained during

start-up by using the following:

The First and Secondary superheater attemperator inlet. It is

 important that the steam temperature entering the superheater tubes
downstream of the spray be not less than 11℃ above saturation
temperature. See Figure 3-3for this limiting steam temperature.

h. When the proper steam pressure and temperature are available,

warm, roll and synchronize the turbine.

i. After turbine synchronization and after constant feedwater flow is

being maintained, or when the steam flow is greater than 7%, close
the economizer to downcomer recirculating shut-off valves.

j. As the amount of steam delivered to the turbine approaches 10% of

the steam generator rated capacity, close the drain valves
downstream of the H/T superheater outlet.

k. When conditions permit, put drum level, steam temperature and air
flow on automatic control.

l. Gradually increasing fuel feed rate, until bed temperature is above

830℃ and O2 is stable.

m. Adjust combustion air flow and fuel flow to establish bed temperature
of 900℃ while removing the under-bed burner; maintain O 2 at 3.1%.

n. During normal operation, limestone feed rate will be varied, as

dictated by a ratio to the fuel feed. The ratio should be adjusted
according to the concentration of SO2 in exhaust gas.

As mentioned before, Figure 3-4 is a graph of static bed height

versus bed differential pressure and should be checked and cold-
tested prior to start-up or during trial operation. While firing the fuel,
the fluidizing velocity should not be allowed to drop below 1.2m/sec.

p. At this time begin operating the bottom ash coolers continually as

cooler instruction.

q. Unit load can now be raised to 100% (MCR) by using the boiler
 master control. Observe the following guide lines:

1. Do not operate the bed at a differential pressure greater than

500mmH2O or less than 200mmH 2O. The 200mmH2O limit is to
protect the grid tubes from overheating and bed material
fluidized from unstable.

3.4. HOT RESTART

The boiler may be shut down for a period of time and held in the hot
condition (slumped but ready to operate again). When the boiler is to
be hot slumped, the fuel feed should be stopped and the O 2 indicator
at the boiler exit monitored. As soon as the %O 2 starts to increase,
stop the fluidizing air flows to the furnace to minimize bed heat loss.
This O2 increase indicates that most of the fuel has been burned and
the beds can be slumped by decreasing fluidizing air flows to zero.
the FD and ID blowers and the limestone feed system are stopped.
The J-valve blower should remain in operation after the fans and
other blowers are shut down.

NOTE

To prevent damage to J-valve components, the J-valve

blower should remain on until valve cools to below
260℃.

All valves and air control dampers are closed so that a minimum
amount of heat is lost. No fire is maintained or introduced into the
furnace; therefore the pressure in the steam drum will decrease, but
proper drum level must be maintained.

NOTE

Figure 3-4 is a graph of static bed height versus bed

 differential pressure. Figure 3-2 is a curve of fluidizing
velocity versus air flow. With the measured air flow,
Figure 3-2 may be used to obtain the superficial
fluidizing velocity at a given bed temperature. While
firing the designed fuel, the fluidizing velocity should
not be allowed to drop below 1.2m/sec. A hot condition
is one in which the average bed temperature (after
being slumped) is above 650℃. If the average bed
temperature is below 650℃, follow the procedures
described for a cold start-up in Paragraph 3.3.

To start-up the boiler from a hot condition, proceed as follows:

a. Check water level in steam drum. If necessary, make

adjustments to bring water to normal level (180mm below drum
centerline).

b. Prepare fuel and limestone feed systems and bed material

extraction systems for operation.

c. Start one (1) J-valve blowers and set air flow for proper
fluidizing velocity. Place on Auto.

d. Start ID fan and FD fan per the procedures described for a cold
start-up, Paragraph 3.3.2.

CAUTION

IF LARGE AMOUNTS OF UNBURNED CARBON EXIST

OR ARE SUSPECTED WITHIN THE BED, COMBUSTION
AIR FLOW MUST BE INCREASED GRADUALLY IN
ORDER TO PURGE THE BED AND ESTABLISH A
CONTROLLED BURNING RATE.

e. Adjust combustion air for 25% MCR conditions. When all fans
 are running, proper air flows must again be established along
with restart of the fuel feeds. Since the bed temperature can
drop rapidly, it is important to acquire proper air flows and fuel
feed rates. Otherwise, bed temperatures and O 2 values will not
respond accordingly. If the unit does not respond to the proper
feed rates of air and fuel, discontinue the hot start-up procedure
and begin the cold start-up methods. Make certain to purge the
unit of combustibles prior to lighting the under-bed burner.

f. If during the hot restart solid fuel has been overfed into the bed
and has not fully combusted as a higher bed temperature is
again established, the bed temperatures may rise rapidly and
O2 decrease rapidly. If this should happen, no further fuel feed
should be added until the bed has stabilized. If the temperature
rise appears to be rapid enough to climb above 930 ℃, the
following should be implemented in advance of achieving
930℃.

1. Lower the air supply to the bed to starve the combustion

process.

2. If the unit doesn’t stabilize as indicated by O 2 and bed

temperature trends, the fluidizing air control damper
should be closed to smother the fire.

NOTE

When re-establishing air flows in a hot start condition,

bed temperatures may drop rapidly. Establish overfire
air (secondary air) first and then grid air to minimize
heat loss.

g. Continue with hot restart following procedures listed in

 Paragraph 3.3.4, steps f through q.

NOTE

if bed temperature does not rise within five minutes of

the fuel feed, ignition has not occurred. The feed must
be stopped, the unit purged and the unit started
following the normal cold start-up procedure.

3.5. NORMAL OPERATION

3.5.1.Firing

The fluidized bed steam generator superheater outlet pressure

should be maintained at its normal value of 100bar at all times during
operation with the exception of start-up and shutdown of the boiler.

a. The primary technique for changing the boiler load involves varying fuel
feed rate and air flow. Bed temperature may be varied between
790℃ and 920℃ to permit large increments of change within a short
period of time. However, after obtaining the desired steam rate, bed
temperature should be re-established at 900℃ and boiler load held
steady by adjusting bed inventory and firing rate. Normally when
changing load, the best method is to maintain the bed temperature at
a constant value if possible. In all cases, make sure that air flow
tracks fuel flow either manually or automatically, to maintain a set
excess O2 value.

b. The SO2 emissions from the boiler should be monitored at all times. The
limestone feed rate must be adjusted, either manually or
automatically, to maintain an SO2 emissions level at the stack that is
in compliance with concerned regulations.

NOx emissions are inherently low within the furnace at the normal
 temperature operating range. NOx emissions are increased as
furnace temperature is increased. The NO x emission level at the
Continuous Emission Monitoring System (CEMS) (stack) should be
checked periodically. Adjustments, if necessary, should be made to
operating furnace temperature and secondary air distribution through
various airport levels.

c. Periodically inspect the fluidized beds for even fluidization. A low

temperature at any of the lower bed thermocouples is an indication of
loss of fluidization. If a portion of the bed is not fluidizing, increase
bed air flow and temporarily increase bed material extraction rate. If
this increase does not improve fluidization, it may be necessary to
shut down the boiler and inspect for plugging of the air distribution
grid, clinkers in the bed or rock accumulation.

d. Continuously monitor the gas side pressure differential through the

convection heat transfer surface and periodically inspect the heater
transfer surface for buildup of ash material.

e. Periodically inspect the fuel and limestone feed systems for plugging,
improper sounds, vibration, belt tracking, lubrication and
temperatures.

f. Continuously monitor the fluidized bed level and maintain it at its normal
level by adding limestone or increasing bed extraction rate. Bed
material extraction will be required to maintain proper bed material
inventory and SO2 control.

NOTE

To minimize line expansion and other system stresses,

average temperature of ash leaving the cooler should
be maintained below 150℃. From an efficiency
 standpoint, cool the ash temperature as lower as
possible.

g. Continuously monitor the air distribution grid pressure differential. If this

differential decreases significantly, check instrumentation for proper
operation and sensing lines for plugging. If instrumentation operating
properly, shut down the boiler and inspect the air distribution grid.

3.5.2.Water Chemistry and Steam Purity

a. Assure that the desired boiler water salt concentration and chemistry are
maintained. Improper boiler water can lead to fouling or corrosion of
internal surfaces, reducing the efficiency of the unit and possibly
resulting in overheating of tubes leading to tube failure

b. Assure that moisture carryover from the drum is within permissible limits.
For operation within design condition, the steam separation
equipment will keep salt carryover within acceptable limits. Moisture
carried over can include salt and other impurities which may deposit
on surfaces downstream of the boiler.

c. The operation of the continuous blowdown valves should be determined

by monitoring the boiler water chemistry. Use of these valves will
increase input to the boiler for a given output. Note that drain valves
on the lower waterwall headers should never be used for blowdown
purposes when the unit is in operation.

3.5.3.SootBlowing

a. All external surfaces of tubes and elements must be kept reasonably

free of deposits if full capacity and efficiency are to be maintained.
Sootblowing should be used as often as necessary to accomplish
this.

b. After the unit is placed in service, operate the sootblowers to remove any
 deposits which may be present. Sootblowing should always be done
on the pre-established schedule basis regardless of the operating
load; however, below 50% load the FD and ID fans should be in
manual control during the sootblowing operation.

c. Sootblowing operations are considered a part of the boiler operations

and require frequent monitoring to achieve optimum cleaning.
Monitoring or inspecting the following will insure an early
establishment of the optimum sootblowing sequence:

1. Properly operate the drain valves of sootblowing. The result of

improper operation of the drain valves or trap is tube erosion
occurring within the first several feet of blower travel and is
caused by water droplets entrained in the steam being
propelled against the tube surface.

2. Check the settings of individual sootblower blowing pressures.

Refer to manufacturer’s instructions for exact settings.

3. During unit down time, visually inspect the furnace convection

passes for ash accumulations.

4. Monitor the high temp. (H/T) superheater final steam

temperatures.

5. Monitor the changes in attemperator spray flows.

6. Monitor economizer and airheater exit gas temperatures.

7. Monitor airheater air and gas side pressure differential

variations.

8. Monitor gas side system resistance through the HRA.

Typically, when the sootblowing system is first commissioned, the

aforementioned boiler parameters are monitored and an optimized
sootblowing sequence is adapted. Periodic monitoring of the system
 can help prevent an unscheduled outage.

3.5.4.Spray Attemperation

Do not desuperheat the steam entering the SH wing wall and H/T
superheater inlet header to less than 11 ℃ above saturation
temperature at the inlet pressure of the transfer pipes.

3.6. NORMAL SHUTDOWN

a.Normal shutdown involves reducing the load on the unit in an orderly

manner, thus allowing the turbine and boiler to be decoupled
without causing temperature and pressure swings, while at the
same time retaining as hot a unit as possible. Unit load reduction
can be accomplished with all control in AUTO.

b.Sootblowing before reducing load and taking unit out of service.

c.During shutting down, do not exceed an maximum temperature

difference of 40℃ between top and bottom of the drum.

d.Control, as necessary, the superheater outlet temperature by regulating

the attemperator spray water flow. Close the water shut-off valves
when attemperation is no longer required.

e.Check and maintain drum level at normal.

f. Reduce unit load to minimum stable. Maintain minimum unit load for
approximately 30 minutes to help cool cyclone refractory, otherwise
cyclone tube temperatures will rise to greater than 420 ℃. In such
case, opening the cyclone upper header vent system.

g.Transfer the boiler master control to manual.

h.close all fuel silo hopper outlet shut-off valves and run all fuel off the
feeders ( if an extended shutdown is expected). Also, empty the fuel
storage silos to their lowest safe levels.
i. Stop limestone feeder systems.

j. Monitor boiler oxygen levels and bed temperatures; when oxygen starts
to increase and bed temperatures start to decrease, closing off the
air (to plenum) control damper.

k.As the load is reduced below approximately 10 percent of rated boiler

capacity, open drain valves of the main steam line and H/T
superheater outlet header. Pay attention to the control of the
furnace cooling rate and these drain valves should not be
completely closed off as long as steam is still generated during the
process.

l. After all fires have been extinguished, leave the FD and ID fans in
operation for at least five minutes to purge the setting of
combustibles.

m. If pressure is to be maintained on the steam generator after being

taken out of service, shut down the fans after purging the unit.
Close any associated fan dampers to retain heat. Be sure bottom
ash coolers have been emptied of material. When the drum
pressure has fallen below the lowest set safety valves, and there is
insufficient heat remaining in the setting to pop the safety valves,
close the drain valves of the H/T superheater. The drain and vent
valves should remain closed when not firing the unit. Exception to
the foregoing may occur automatically by activation of cyclone tube
protection system.

n.Before firing a unit to maintain steam pressure, the H/T superheater

outlet header downstream drain valves must be opened. Keep the
drains open during firing and keep the feedwater supply system in
operation as long as steam is generating from the unit. Maintain
drum water level visible near normal level indication on the gage
 glass when firing.

o.If the boiler is to be out of service for an extended period or entered for
maintenance, continue to cool down the unit using the fans, while
removing bed material via the bottom ash cooler. The H/T
superheater outlet header downstream drain valves may be
regulated along with other superheater drains to decrease drum
pressure at the desired rate. Cool the unit as uniformly as possible.
The residual heat in the setting and the boiler components will
continue to generate steam for considerable time. During this
period, the boiler water level should be maintained near the upper
limit of gage glass visibility. Once all bed material is removed from
the unit, purge the boiler setting for five (5) minutes. The bottom ash
cooler should then be removed from service. When the unit is cool
enough for entry, the fans can be taken out of service.

p.Stop the feeder systems. Shut down the FD and ID fans.

q.The J-valve blower should remain in operation after the FD and ID f air
fans are shut down. To prevent damage to J-valve components, the
J-valve blower should remain on until valve cools to below 260 ℃.

r. Stop ash system.

s.If the unit is to be drained, open all vents and drains when the drum
pressure has decreased to 1bar. Temperature of the boiler water
should not exceed 120℃ when the unit is drained. Draining the unit
when there is still a small amount of pressure on the unit is
preferred as the residual heat will assist in drying the internal
surfaces.

t. Superheater header drain and vent valves should remain open during
short outages.

u.Idle boilers should not be allowed to remain partially filled with water for
 any appreciable length of time. Fill them completely with deaerated
alkaline water into which hydrazine has been added as a protection
against corrosion. If the outage will amount to several weeks or
months, or should weather prohibit filling the unit, drain and dry the
unit, placing shallow pans of a predetermined quantity of silica gel in
the drums to absorb moisture and maintain the internal surfaces in
a dry condition. When the unit is to be out of service for several
days or longer, all ash and soot deposits should be removed since
moisture absorbed by sulfur bearing ash or soot causes corrosion. It
is advisable to sootblow the unit just before taking it out of service, if
possible.

3.7. EMERGENCIES

3.7.1.Main Fuel Trip (MFT)

On a main fuel trip, the following actions will take place:

a.Fuel feeders trip.

b.Limestone systems trip.

c.under-bed burner trips.

d.Bottom ash cooler trip.

e.All air flow controls transfer to manual mode and hold last position.

f. Fan controls transfer to manual mode and hold last position unless the
cause is a fan trip, in which case, fan controls follow fan logic.

g.Output signal to combustion control limits ID fan automatic control from

going above the furnace draft limit.

h.“Boiler Purge Required”logic is set unless it is a“Hot Restart”condition.

3.7.1.1. Any of the following conditions will cause a boiler

main fuel trip (MFT).

1. Both MFT push buttons pressed simultaneously.

2. Bed temperature greater than 980℃ (from Combustion Control

System).

3. Loss of logic power.

4. Furnace pressure high high, +260mmH 2O (2 out of 3 logic) (with

time delay).

5. Furnace pressure low low, -260mmH 2O (2 out of 3 logic) (with

time delay).

6. Steam drum level high high, +120mm above normal ( with time
delay ) (2 out of 3 logic ).

7. Steam drum level low low, -120mm below normal ( with time
delay ) ( 2 out of 3 logic ).

8. ID fan tripped.

9. Primary & Secondary fan tripped.

10. Total air flow low, less than 25% (with time delay) (from
Combustion control System).

11. Combustion Control System Power failure (from Combustion

Control System ).

12. Total air/fuel ratio less than minimum (from Combustion Control
System).

13. under-bed burner not in service and bed temperature is less

than 650℃.

14. High furnace plenum pressure (with time delay) (from

 Combustion Control System).

15. Two J-valve blowers tripped.

16. Turbine trip.

17. Cyclone level high high (with time delay).

18. Start-up time exceeded.

3.7.2.Emergency Operating Procedures

3.7.2.1. Tube Leak

If a boiler tube leak is suspected (either through high make-up water

usage, abnormal deviation between feedwater flow and main steam
flow, or audio or visual inspection), the unit must be taken out of
service as quickly as possible, under a controlled shutdown, to
minimize moisture getting into the bed material. The unit load should
be ramped down as quickly as possible and all fuel feed to the unit
stopped. Close the isolation gates on all fuel feeders. Restart or
continue to operate the bottom ash coolers and ash removal system
at a maximum rate.

Continue to operate fans and maintain air flow to the furnace to keep
material moving into the bottom ash cooler. Some air flow to the
secondary air ports should be established to keep moisture out of
ducts. Reduce drum pressure as slowly as possible and maintain
drum level, if possible. Continue to cool the unit and extract bed
material until the unit is empty of bed material and cool enough to
enter. During cool-down, do not exceed a 40 ℃ differential
temperature between top and bottom of the steam drum. The drum
level should be maintained until the boiler water temperature is
reduced below 120℃; then the boiler should be drained. If the tube
 leak is in the furnace, it may be necessary to use the under-bed
burner while removing the bed material from the furnace to assist
with evaporation of the lost boiler water. If the bed is damp and drops
below 180℃, it may plug the ash handling system or stay within the
furnace. If the under-bed burner is utilized, it is important that the
burner temperature be kept below 315℃.

Before entering the unit for any reason, check that safe temperature
has been reached, conduct gas sniff test for safety levels and wear
proper protective clothing.

When access to the bed is possible and all bed material that is
possible to remove is extracted, enter the unit to assess the extent of
the tube leak and amount of bed material remaining. Any material,
wet or dry, left in the beds should be removed as soon as possible
before it has a chance to solidify. Solidified bed material below the
level of the grid nozzles need not be removed. However, the grid
nozzles must be inspected and any plugged nozzles cleaned out by
rodding with high pressure air from below the nozzles. Make certain
no one is working on the opposite side of the nozzle.

3.7.2.2. Excessive Bed Temperatures

Excessive high bed temperature can lead to clinkers (fused ash) and
damage to in-bed thermowell, thermocouples, grid nozzles, etc.

High bed temperature should be avoided by increasing limestone

feed rates and shutting down the bottom ash coolers in an effort to
increase bed inventory and cool bed temperatures. Load should be
reduced and fuel flow reduced, until bed temperatures start
decreasing to avoid the formation of clinkers.
3.7.2.3. Clinkered Bed

“Clinkers”in the bed are considered to be agglomerated masses of

fusing or cemented ash which can be formed when firing fuel with
low air/fuel ratios, elevated temperatures of bed or reduced
superficial velocity. The risk of forming clinkers is greater at
temperatures exceeding 920℃.

If any of the above abnormal operating conditions are encountered,

the operator should monitor the individual bed thermocouples. If
clinkers form, a localized hot spot will appear, followed by localized
defluidization and a zone of low bed temperatures. If it is confirmed
that the isolated zone of low bed temperatures is not due to faulty
instrumentation or lack of fluidizing air, a clinker is to be suspected
and the instructions for normal shutdown should be followed, the unit
taken out of service and all possible bed material removed from the
cell.

The actual cool-down time is dependent upon the boiler load and
bed temperature at the time of shutdown. Also, When the drum water
temperature drops to 120℃, the unit can be drained to aid cooling.
During cool down, a maximum of 40℃ differential temperature
between the top and bottom of the drum should not be exceeded.
Maintain minimum air flow, equivalent to 1.2m/sec superficial
velocity, to the bed for cooling and to ensure transfer of loose bed
material to the bed drain. When the unit is cool and no more bed
material can be removed through the bed drain system, shut down
the fans and make the necessary safety preparations to enter the
furnace. Enter the unit and evaluate the extent of the clinkers. Small
accumulations can be broken up and removed. Inspect for any
damage to the bed thermocouples and grid nozzles. Repair or
 replace as necessary. All grid nozzles should be inspected for
plugging and cleaned out as required.

3.7.3.Overpressure Protection

To protect the steam generator and associated equipment during

operation malfunction resulting in an over pressurization of pressure
parts, the following safety valves and relieving devices are installed
for the unit.

Description Location Qty. Set Pressure

(Bar)
Safety Valve Main steam header 1 105
Safety Valve Steam Drum 1 118.9

3.8. MAINTENANCE

a.During long-term boiler shutdowns, observe the following:

CAUTION

DO NOT FILL THE BOILER WITH NITROGEN UNTIL

AFTER ALL INTERNAL PRESSURE PART
INSPECTIONS AND/OR MAINTENANCE PROCEDURES
ARE COMPLETED. PROVISION SHOULD BE MADE
FOR NITROGEN PROTECTION OF THE IDLE BOILER
BY CONNECTING A NITROGEN SUPPLY, THROUGH A
REGULATING VALVE, TO A DRUM VENT.

If an idle boiler is not drained, the areas above the water level in the
drum should be filled with nitrogen through the above mentioned
access on the drum. The nitrogen cap should be established when
the pressure of the boiler being removed from service decreases to
 about 0.35Bar. Maintain the nitrogen cap during the shut down
period. During idle periods, the boiler must be protected against
freezing conditions. This may be done by firing the under-bed burner
with low heat input to maintain temperatures throughout the boiler
above freezing.

If weather or other conditions prevent leaving the unit filled, it should

be drained and dried. Place several shallow pans of a predetermined
quantity of silica gel in the drum to absorb moisture and maintain the
internal surfaces in a dry condition.

b. When the unit is shut down for repairs, it should never be entered until it
has been determined that all fuel shut off valves and dampers are
locked in the closed position. Should there be some questions about
their tightness, it is recommended that the fuel lines be blanked off.

CAUTION

THERE ARE ACCESSIBLE AREAS IN THE BOILER

THAT COULD EXPOSE PERSONNEL TO
HAZARDOUS CONDITIONS. SOME OF THESE
AREAS ARE THE FURNACE VESTIBULE AT THE
CYCLONE INLET, WHERE QUICK DROP-OFFS
INTO THE FURNACE AND CYCLONE EXIT, THE J-
VALVE, WHERE HOT BED MATERIALS COULD
ACCUMULATE, AND VIRTUALLY EVERY ACCESS
DOOR, WHERE BACK KICK COULD OCCUR.
BEFORE OPENING ANY ACCESS DOOR, FOR ANY
REASON, EXERCISE EXTREME CAUTION TO
GUARD AGAINST THESE DANGERS. WEAR
PROTECTIVE CLOTHING AND STAND TO ONE
SIDE (DO NOT JUST FACE THE DOORS) WHEN
 OPENING DOORS. USE SUITABLE BREATHING
APPARATUS AND SAFETY CLOTHING, AS
NECESSARY, WHEN ENTERING THE BOILER.
CARRY OR INSTALL ADEQUATE LIGHTING AND
ALWAYS BE AWARE OF IMMEDIATE
SURROUNDINGS WHEN INSIDE.

CAUTION

PROPER GAS SNIFF TESTING SHOULD BE

ACCOMPLISHED AND PROPER O2 LEVELS
ESTABLISHED.

c. Only approved safety types of lights and flashlights should be used when
inspecting and working in the boiler.

d. During outages, the pressure containing parts and other internal

surfaces should be inspected when possible. Unusual signs of wear or
accumulations should be investigated and the causes corrected.

e. Inspect each air distribution grid plate nozzle for plugging and clean out
as necessary.

f. When inspection door are opened for access, the used gaskets should
be replaced with new ones.

g. During overhaul periods, the under-bed burner should be carefully

inspected for any damage and maintenance repairs be made.

h. Repair all tube leaks as soon as possible. Leaks which are allowed to
persist can cause further damage due to water or steam cutting of
adjacent tubes.

Repairs should not be attempted on parts which are still subjected to

pressure. Repair to pressure parts should be accomplished when all
pressure has been removed and the system isolated.
 i. Combustion control equipment and other control equipment such as
feedwater regulators and steam temperature controllers should be
kept in optimum adjustment at all times. Efficiency depends upon the
proper functioning of these equipments.

j. Check all fuel and limestone feed piping and bed material extraction
piping for plugging, erosion, overheating, etc. Repair or replace as
necessary.

k. All valve and packing leaks should be repaired during the outage period.
This will help prevent forced outages.

l. Thoroughly inspect the general conditions of all thermocouples and

pressure taps and repair as necessary for reliable operation.

m. Check plenum floor for accumulation of spent bed material due to back
sifting through grid plate air nozzles. Remove material if excessive.

n. Careful inspection of the boiler pressure parts should be made to

monitor any erosion of tubes. Ultrasonic wall thickness measurements
as well as tube outside diameters should be recorded on a regular
basis (1 ～ 2 times a year). The areas to be monitored include the
furnace wall tubes, HRA inlet screen tubes, superheater tubes and
economizer tubes.

o. The cyclone, J-valve, furnace bottom/roof and furnace exit refractory

should be inspected on a regular basis and repaired as necessary.

4． Figure

Fig。 1-1 Optimum size distribution for coal

Fig。 1-2 Sectional side elevation of boiler
Fig。 1-3 Steam and water diagram of boiler
Fig。 1-4 Gas and air diagram of boiler
Fig。1-5 Drum internals
Fig。 1-6 Arrangement of downcomers
Fig。 2-1 The boiling out pressure for different design pressure
Fig 。 3-1 Oxygen measurement of approximately % by volume on a wet
basis
Fig。 3-2 Relationship between bed pressure and fluidizing velocity
Fig。 3-3 The minimum steam temperature after spray
Fig 。 3-4 Relationship between bed pressure and height of static bed
material
Fig。 3-5 Cold start curve 冷态启动曲线
Fig。3-6 Warm start curve

Fig。3-7 Hot start curve

Fig。 3-8“J”Valve Piping Connection Drawing
 5． Table

Table 1 Thermodynamic Calculation Collecting Table for Coal rank

COAL2 in Boiler Design

Boiler Specification
Name & sign Unit Result Name & sign Unit Result
Boiler rating vapour Rating steam outlet
t/h 130 ℃ 510
volume D temperature tgr
Steam outlet Drum working
Bar (g) 100 Bar (g) 111
pressure Pgr pressure Pgt
Feedwater Economizer inlet
℃ 170 Bar (g) 116
temperature tgs feedwater pressure Pgs
Continious Cooling air
% 2 ℃ 30
blowdown rate Ppw temperature tlk
Fuel Calculation
Name & sign Unit Result Name & sign Unit Result
As-received basis As-received basis
% 62.61 % 4.08
Cy Hy
As-received basis As-received basis
% 6.09 % 1.01
Oy Ny
As-received basis As-received basis
% 0.72 % 13.89
Sy Wy
As-received basis Combustionable
% 13.89 % 40
Ay group volatile
Low heating value Fuel check value
kcal/kg 5831 kcal/kg 5820
Qdwy Qv
Theoretic air value
Nm3/kg 6.43
VAirA
Furnace outlet
Boiler outlet excessive
excessive air / 1.2 1.25
air coefficient
coefficient
Temperature of
bottom ash Material circulation
℃ 200 21.2
discharged from ratio
furnace bottom
Carbon contents in Carbon contents in
% 5 % 1
fly ash bottom bottom ash
Limestone Features
Calcium carbonate Magnesium
% 90 % 3.0
CaCO3 carbonate MgCO3
Moisture % 0.2 Inertia index % 1.0
Desulfurazing
Ca/S Moore ratio / 2.5 % 83
efficiency
Heat Balance Calculation
Name & sign Unit Result Name & sign Unit Result
Loss due to chemical
Heat loss due to
% 5.29 incomplete combustion % 0.1
flue gas exhaust q2
q3
Loss due to
Loss due to heat
mechanical incomplete % 1.07 % 0.4
radiation q5
combustion q4
Decalescence in SO2 sulfation
% 0.39 % -0.37
calcining limestone radiation
Heat loss due to
Manufacturer
bottom ash % 0.04 % 0.25
margin
radiation q6
Calculated boiler heat Guaranteed boiler
% 93.09 % 92.8
efficiencyηgl heat efficiency
Calculated fuel
kg/h 15224 Fuel consumption B Kg/h 15389
consumption Bj
Limestone
kg/h 952 Total burnt air Mn3/h 118800
consumption
Inertia material kg/h 0
Flue gas at boiler
mn3/h 132400 Total bottom ash Kg/h 3071
outlet
Fly ash kg/h 2303 Bottom bottom ash Kg/h 768
Primary input air in
mn3/h 53500 Coaling input air Mn3/h 10000
furnace bottom
input air for
Secondary input air mn3/h 55300 Mn3/h 1150
returning material
Furnace
Name & sign Unit Result Name & sign Unit Result
Outlet flue gas
Bed temperatureθ" ℃ 899 ℃ 917
temperatureθ"
Boiler outlet discharge
Fly ash
Primary discharge
concentration at g/mn3 17.5 mg/mn3 1671
of SO2
boiler outlet
Discharge of SO2
mg/mn3 284
after desulfurization
Discharge Discharge
concentration of mg/mn3 <300 concentration of mg/mn3 <250
NOx CO
Desuperheater calculation
Name & sign Unit Result Name & sign Unit Result
Desuperhe
Desuperheater ating by Spraying water
℃ 170
type water temperature T
spray
Total water sprayed
by desuperheater T/h 7.4
△D
Water sprayed by
T/h 3.5
desuperheater I △D
Steam temperature at
Steam temperature at
℃ 409 desuperheater I outlet ℃ 388
desuperheater I inlet t1
t2
Water sprayed by
T/h 3.9
desuperheater II △D
Steam temperature at Steam temperature at
desuperheater II inlet ℃ 453 desuperheater II outlet ℃ 426
t1 t2
Heat transfer component calculating results collection
Wall
Screen High Low
enclosur
type Cyclone temp. Temp.
Name & sign Unit e
superhe separator superheat superhe
superhe
ater er ater
ater
Tube size mm φ42×7 φ42×6 φ42×5 φ42×6 φ42×5
Flue gas inlet
℃ / 917 867 822 668
temperature
Flue gas outlet
℃ / 867 / 668 576
temperature
Working medium
inlet ℃ 388 319 344 426 370
temperature
Working medium
outlet ℃ 453 344 370 510 409
temperature
Flue gas average
m/s / / / 11.7 10.3
velocity

Primary
Secondary
Economize Economizer Economize Economizer ducting
Name & sign Unit ducting air
r IV III r II I air
preheater
preheater
Tube size mm φ32×4 φ32×4 φ32×4 φ32×4 φ40×1.5 φ40×1.5
Flue gas inlet ℃ 576 466 389 313 260 /
temperature
Flue gas outlet ℃ 466 389 313 260 / 135
temperature
Working medium ℃ 240 214 188 170 30 30
inlet temperature
Working medium ℃ 275 240 214 188 185 185
outlet temperature
Flue gas average m/s 8.4 8.1 8.0 6.9 7.6 7.2
velocity
 Table 2. Boiler check coal rank COAL1 thermodynamic

calculation collection table

Boiler Specification
Name & sign Unit Result Name & sign Unit Result
Boiler rating vapour Rating steam outlet
t/h 130 ℃ 510
volume D temperature tgr
Steam outlet Drum working
bar(g) 100 bar(g) 111
pressure Pgr pressure Pgt
Feedwater Economizer inlet
℃ 170 bar(g) 116
temperature tgs feedwater pressure Pgs
Continious Cooling air
% 2 ℃ 30
blowdown rate Ppw temperature tlk
Fuel Calculation
Name & sign Unit Result Name & sign Unit Result
As-received basis As-received basis
% 48.73 % 3.53
Cy Hy
As-received basis As-received basis
% 14.03 % 0.48
Oy Ny
As-received basis As-received basis
% 0.11 % 30
Sy Wy
As-received basis Combustionable
% 3.11 % 51.2
Ay group volatile
Low heating value Fuel check value
kcal/kg 4269 kcal/kg 4274
Qdwy Qv
Theoretic air value
Nm3/kg 4.804
VAirA
Furnace outlet Boiler outlet excessive
/ 1.2 1.25
excessive air coefficient air coefficient
Temperature of
bottom ash Material circulation
℃ 200 20.1
discharged from ratio
furnace bottom
Carbon contents in Carbon contents in
% 5 % 1
fly ash bottom bottom ash
Limestone Features
Calcium carbonate Magnesium
% 90 % 3.0
CaCO3 carbonate MgCO3
Moisture % 0.2 Inertia index % 1.0
Desulfurazing
Ca/S Moore ratio / 2.5 % 30
efficiency
 Heat Balance Calculation
Name & sign Unit Result Name & sign Unit Result
Loss due to
Heat loss due to flue
% 6.03 incomplete chemical % 0.1
gas exhaust q2
combustion q3
Loss due to incomplete
Loss due to heat
mechanical combustion % 1.62 % 0.4
radiation q5
q4
Decalescence in SO2 sulfation
% 0.06 % -0.03
calcining limestone radiation
Heat loss due to
Manufacturer
bottom ash radiation % 0.05 % 0
margin
q6
Calculated boiler heat Guaranteed boiler
% 91.75 % /
efficiencyηgl heat efficiency
Calculated fuel
kg/h 20881 Fuel consumption B kg/h 20936
consumption Bj
Limestone
kg/h 160 Total burnt air mn3/h 121200
consumption
Inertia material kg/h 3764
Flue gas at boiler
mn3/h 142000 Total bottom ash kg/h 4732
outlet
Fly ash kg/h 3549 Bottom bottom ash kg/h 1183
Primary input air in mn3/h 54600 mn3/h 10000
Coaling input air
furnace bottom
Input air for
Secondary input air mn3/h 56600 mn3/h 1150
returning material
Furnace
Name & sign Unit Result Name & sign Unit Result
Outlet flue gas
Bed temperatureθ" ℃ 888 ℃ 900
temperatureθ"
Boiler outlet discharge
Fly ash
Primary discharge
concentration at g/mn3 25 mg/mn3 325
of SO2
boiler outlet
Discharge of SO2
mg/mn3 228
after desulfurization
Discharge Discharge
3
concentration of mg/m n <300 concentration of mg/mn3 <250
NOx CO
 Desuperheater calculation
Name & sign Unit Result Name & sign Unit Result
Desuperhe
ating by Spraying water
Desuperheater type ℃ 170
water temperature T
spray
Total water sprayed by
T/h 8.1
desuperheater △D
Water sprayed by
T/h 3.5
desuperheater I △D
Steam temperature at
Steam temperature at
℃ 410 desuperheater I outlet ℃ 389
desuperheater I inlet t1
t2
Water sprayed by
T/h 4.6
desuperheater II △D
Steam temperature at
Steam temperature at
℃ 452 desuperheater II outlet ℃ 421
desuperheater II inlet t1
t2
Heat transfer parts calculation result collection
Low
Wall High
Cyclone temperatur
Name & sign Unit wing wall enclosure temperature
separator e
superheater superheater
superheater
Tube size mm φ42×7 φ42×6 φ42×5 φ42×6 φ42×5
Flue gas inlet
℃ / 900 855 817 665
temperature
Flue gas outlet
℃ / 855 / 665 574
temperature
Working medium
℃ 389 319 344 421 367
inlet temperature
Working medium
℃ 452 344 367 510 410
outlet temperature
Flue gas average
m/s / / / 12.7 11.1
velocity
 Primary Secondary
Economize Economizer Economizer Economizer
Name & sign Unit ducting air ducting air
r IV III II I
preheater preheater
Tube size mm φ32×4 φ32×4 φ32×4 φ32×4 φ40×1.5 φ40×1.5
Flue gas inlet 574 467 392 316 262 /
℃
temperature
Flue gas outlet 467 392 316 262 / 141
℃
temperature
Working medium 245 218 190 170 30 30
℃
inlet temperature
Working medium 282 245 218 190 185 185
℃
outlet temperature
Flue gas average 9.1 8.8 8.6 7.5 8.3 7.8
m/s
velocity
 Table 3. Boiler check coal rank COAL3 thermodynamic

calculation collection table

Boiler specification
Name & sign Unit Result Name & sign Unit Result
Boiler rating vapour Rating steam outlet
t/h 130 ℃ 510
volume D temperature tgr
Steam outlet Drum working
bar(g) 100 bar(g) 111
pressure Pgr pressure Pgt
Economizer inlet
Feedwater
℃ 170 feedwater pressure bar(g) 116
temperature tgs
Pgs
Continious Cooling air
% 2 ℃ 30
blowdown rate Ppw temperature tlk
Fuel calculation
Name & sign Unit Result Name & sign Unit Result
As-received basis Cy % 62.74 As-received basis Hy % 4.76
As-received basis Oy % 8.89 As-received basis Ny % 1.02
As-received basis Sy % 1.32 As-received basis Wy % 11
Combustionable
As-received basis Ay % 10.25 % 40
group volatile
Low heating value Qdwy kcal/kg 6024 Fuel check value Qv kcal/kg 5990
Theoretic air value
Nm3/kg 6.587
VAirA
Furnace outlet
Boiler outlet excessive
excessive air / 1.2 1.25
air coefficient
coefficient
Temperature of
bottom ash Material circulation
℃ 200 22.3
discharged from ratio
furnace bottom
Carbon contents in Carbon contents in
% 5 % 1
fly ash bottom bottom ash
Limestone features
Calcium carbonate Magnesium
% 90 % 3.0
CaCO3 carbonate MgCO3
Moisture % 0.2 Inertia index % 1.0
Desulfurazing
Ca/S Moore ratio / 2.5 % 90
efficiency
 Heat balance calculation
Name & sign Unit Result Name & sign Unit Result
Loss due to chemical
Heat loss due to
% 5.26 incomplete combustion % 0.1
flue gas exhaust q2
q3
Loss due to
Loss due to heat
mechanical incomplete % 1.09 % 0.4
radiation q5
combustion q4
Decalescence in SO2 sulfation
% 0.69 % -0.71
calcining limestone radiation
Heat loss due to
Manufacturer
bottom ash % 0.04 % 0
margin
radiation q6
Calculated boiler heat Guaranteed boiler
% 93.14 % /
efficiencyηgl heat efficiency
Calculated fuel
kg/h 14726 Fuel consumption B Kg/h 14888
consumption Bj
Limestone
kg/h 1687 Total burnt air Mn3/h 116400
consumption
Inertia material kg/h 0
Flue gas at boiler
mn3/h 129900 Total bottom ash Kg/h 3123
outlet
Fly ash kg/h 2343 Bottom bottom ash Kg/h 781
Primary input air in
mn3/h 52400 Coaling input air Mn3/h 10000
furnace bottom
Input air for
Secondary input air mn3/h 54000 Mn3/h 1150
returning material
Furnace
Name & sign Unit Result Name & sign Unit Result
Outlet flue gas
Bed temperatureθ" ℃ 923 ℃ 883
temperatureθ"
Boiler outlet discharge
Fly ash
Primary discharge
concentration at g/mn3 17.9 mg/mn3 2988
of SO2
boiler outlet
Discharge of SO2
mg/mn3 298
after desulfurization
Discharge Discharge
3
concentration of mg/mn <300 concentration of mg/mn3 <250
NOx CO

Desuperheater calculation
Name & sign Unit Result Name & sign Unit Result
Desuperhe
Desuperheater ating by Spraying water
℃ 170
type water temperature T
spray
Total water sprayed by
T/h 7.2
desuperheater △D
Water sprayed by
T/h 3.5
desuperheater I △D
Steam temperature at
Steam temperature at
℃ 408 desuperheater I outlet ℃ 387
desuperheater I inlet t1
t2
Water sprayed by
T/h 3.7
desuperheater II △D
Steam temperature at Steam temperature at
℃ 452 ℃ 427
desuperheater II inlet t1 desuperheater II outlet t2
Heat transfer parts calculation result collection
Wall High Low
Cyclone
Name & sign Unit Wing wall enclosure temperature temperature
separator
superheater superheater superheater
Tube size mm φ42×7 φ42×6 φ42×5 φ42×6 φ42×5
Flue gas inlet
℃ / 883 866 820 668
temperature
Flue gas outlet
℃ / 866 / 667 575
temperature
Working medium
inlet ℃ 387 319 344 427 369
temperature
Working medium
outlet ℃ 452 344 369 510 408
temperature
Flue gas average
m/s / / / 11.7 10.2
velocity
 Primary Secondary
Economize Economizer Economize Economizer
Name & sign Unit ducting air ducting air
r IV III r II I
preheater preheater
Tube size mm φ32×4 φ32×4 φ32×4 φ32×4 φ40×1.5 φ40×1.5
Flue gas inlet ℃ 575 465 388 312 259 /
temperature
Flue gas outlet ℃ 465 388 312 259 / 135
temperature
Working medium ℃ 239 214 188 170 30 30
inlet
temperature
Working medium ℃ 274 239 214 188 185 185
outlet
temperature
Flue gas average m/s 8.3 8.0 7.8 6.8 7.5 7.1
velocity
Table 4. Flue Gas and Air Resistance Collection Table

Loop-seal
device
Secondary
Primary air Flue gas high
Coal rank Unit air
resistance resistance pressure
resistance
air
resistance
Coal 1 Pa 14000 9500 4000
Coal 2 Pa 13500 9000 3700 48000
Coal 3 Pa 13500 9000 3700
 Table 5. Steam water Resistance Collection Table

Superheater resistance： Unit：bar 11

Economizer resistance： Unit：bar 5

Table 6. “J”Valve Air Nozzle Charge Volume Temperature （℃）100890Descend
tube air flow （ Nm3/hr ） NANozzle button 15070A17~A20Charge

aperture3520A13~A16Charge aperture3520A1~A4Charge aperture5510A5~A8Charge

aperture2010Subtotal ： 295130Ascend tube air flow （ Nm3/hr ） NBNozzle button

12050A9~A12Charge aperture2010Subtotal：14060Total：435190