Transcript

1. 1CFB Boiler Design, Operation and Maintenance By Pichai

Chaibamrung

2. 2Content Day11. Introduction to CFB2. Hydrodynamic of

CFB3. Combustion in CFB4. Heat Transfer in CFB5. Basic
design of CFB6. Operation7. Maintenance8. Basic Boiler
Safety9. Basic CFB control

3. 3Objective To understand the typical arrangement in

CFB To understand the basic hydrodynamic of CFB To
understand the basic combustion in CFB To understand the
basic heat transfer in CFB To understand basic design of
CFB To understand theory of cyclone separator Know
Principle Solve Everything

4. 41. Introduction to CFB1.1 Development of CFB1.2 Typical

equipment of CFB1.3 Advantage of CFB

5. 51.1 Development of CFB 1921, Fritz Winkler, Germany,

Coal Gasification 1938, Waren Lewis and Edwin Gilliland,
USA, Fluid Catalytic Cracking, Fast Fluidized Bed 1960,
Douglas Elliott, England, Coal Combustion, BFB 1960s,
Ahlstrom Group, Finland, First commercial CFB boiler, 15MWth,
Peat

6. 61.2 Typical Component of CFB Boiler

7. 71.2 Typical Component of CFB Boiler Wind box and grid

nozzle primary air is fed into wind box. Air is equally distributed
on furnace cross section by passing through the grid nozzle.
This will help mixing of air and fuel for completed combustion

8. 81.2 Typical Component of CFB Boiler Bottom ash drain

coarse size of ash that is not take away from furnace by
fluidizing air will be drain at bottom ash drain port locating on

grid nozzle floor by gravity. Bottom ash will be cooled and

conveyed to silo by cooling conveyor.

9. 91.2 Typical Component of CFB Boiler Blower supply high

pressure air to fluidize bed material in loop seal so that it can
overflow to furnace Rota meter Supplying of HP blower to loop
seal

10. 101.2 Typical Component of CFB Boiler Cyclone separator

located after furnace exit and before convective part. use to
provide circulation by trapping coarse particle back to the
furnace Fluidized boiler without this would be BFB not CFB

11. 111.2 Typical Component of CFB Boiler Evaporative or

Superheat Wing Wall located on upper zone of furnace it can be
both of evaporative or SH panel lower portion covered by
erosion resistant materials

12. 121.2 Typical Component of CFB Boiler Fuel Feeding

system solid fuel is fed into the lower zone of furnace through
the screw conveyor cooling with combustion air. Number of
feeding port depend on the size of boiler

13. 131.2 Typical Component of CFB Boiler Refractory re

factory is used to protect the pressure part from serious erosion
zone such as lower bed, cyclone separator

14. 141.2 Typical Component of CFB Boiler Solid recycle

system (Loop seal) loop seal is located between dip leg of
separator and furnace. Its design physical is similar to furnace
which has air box and nozzle to distribute air. Distributed air
from HP blower initiate fluidization. Solid behave like fluid then
over flow back to the furnace.

15. 151.2 Typical Component of CFB Boiler Kick outkick out is

referred to interface zone between the end of lower zone

refractory and water tube. It is design to protect the erosion by

by-passing the interface from falling down bed materials

16. 161.2 Typical Component of CFB Boiler Lime stone and

sand system lime stone is pneumatically feed or gravitational
feed into the furnace slightly above fuel feed port. the objective
is to reduce SOx emission. Sand is normally fed by gravitation
from silo in order to maintain bed pressure. Its flow control by
speed of rotary screw.

17. 171.2 Typical Arrangement of CFB Boiler

18. 181.3 Advantage of CFB Boiler Fuel Flexibility

19. 191.3 Advantage of CFB Boiler High Combustion

Efficiency- Good solid mixing- Low unburned loss by cyclone, fly
ash recirculation- Long combustion zone In situ sulfur
removal Low nitrogen oxide emission

20. 202. Hydrodynamic in CFB2.1 Regimes of Fluidization2.2

Fast Fluidized Bed2.3 Hydrodynamic Regimes in CFB2.4
Hydrodynamic Structure of Fast Beds

21. 212.1 Regimes of Fluidization Fluidization is defined as

the operation through which fine solid are transformed into a
fluid like state through contact with a gas or liquid.

22. 222.1 Regimes of Fluidization Particle

Classification<130<180<250<600CFB1Size
(micron)<590<25025%>420>100100%<840<45050%75%100%
Distribution<1190<550<1680<1000BFBCFB2

23. 232.1 Regimes of Fluidization Particle Classification

24. 242.1 Regimes of Fluidization Comparison of Principal

Gas-Solid Contacting Processes

25. 252.1 Regimes of Fluidization Packed Bed The pressure

drop per unit height of a packed beds of a uniformly size

particles is correlated as (Ergun,1952)Where U is gas flow rate

per unit cross section of the bed called Superficial Gas Velocity

26. 262.1 Regimes of Fluidization Bubbling Fluidization Beds

Minimum fluidization velocity is velocity where the fluid drag is
equal to a particles weight less its buoyancy.

27. 272.1 Regimes of Fluidization Bubbling Fluidization Beds

For B and D particle, the bubble is started when superficial gas
is higher than minimum fluidization velocity But for group A
particle the bubble is started when superficial velocity is higher
than minimum bubbling velocity

28. 282.1 Regimes of Fluidization Turbulent Beds when the

superficial is continually increased through bubbling fluidization
bed, the bed start expanding, then the new regime called
turbulent bed is started.

29. 292.1 Regimes of Fluidization

30. 302.1 Regimes of Fluidization Terminal Velocity Terminal

velocity is the particle velocity when the forces acting on particle
is equilibrium

31. 312.1 Regimes of Fluidization Freeboard and Furnace

Height- considered for design heating-surface area- considered
for design furnace height- to minimize unburned carbon in
bubbling bed- the freeboard heights should be exceed or closed
to the transport disengaging heights

32. 322.2 Fast Fluidization Definition

33. 332.2 Fast Fluidization Characteristics of Fast Beds- nonuniform suspension of slender particle agglomerates or clusters
moving up and down in a dilute- excellent mixing are major
characteristic- low feed rate, particles are uniformly dispersed in
gas stream- high feed rate, particles enter the wake of the other,

fluid drag on the leading particle decrease, fall under the gravity
until it drops on to trailing particle

34. 342.3 Hydrodynamic regimes in a Flower Furnace below

SA: Turbulent or bubbling fluidized bed Furnace Upper SA: Fast
Fluidized Bed Cyclone Separator :Swirl Flow Return leg and lift
leg :Pack bed and Bubbling Bed Back Pass: Pneumatic
Transport

35. 352.4 Hydrodynamic Structure of Fast Beds Axial Void

age Profile Bed Density Profile of 135 MWe CFB Boiler (Zhang
et al., 2005)Secondary air is fed

36. 362.4 Hydrodynamic Structure of Fast Beds Velocity

Profile in Fast Fluidized Bed

37. 372.4 Hydrodynamic Structure of Fast Beds Velocity

Profile in Fast Fluidized Bed

38. 382.4 Hydrodynamic Structure of Fast Beds Particle

Distribution Profile in Fast Fluidized Bed

39. 392.4 Hydrodynamic Structure of Fast Beds Particle

Distribution Profile in Fast Fluidized Bed

40. 402.4 Hydrodynamic Structure of Fast Beds Particle

Distribution Profile in Fast Fluidized Bed Effect of SA injection
on particle distribution by M .Koksal and F.Hamdullahpur
(2004). The experimental CFB is pilot scale CFB. There are
three orientations of SA injection; radial, tangential, and mixed

41. 412.4 Hydrodynamic Structure of Fast Beds Particle

Distribution Profile in Fast Fluidized Bed No SA, the suspension
density is proportional to solid circulation rate With SA 20% of
PA ,the solid particle is hold up when compare to no SO
Increasing SA to 40%does not significant on suspension density
above SA injection point but the low zone is denser than low SA
ratio Increasing solid circulation rate effect to both lower and

upper zone of SA injection point which both zone is denser than

low solid circulation rate

42. 422.4 Hydrodynamic Structure of Fast Beds Effects of

Circulation Rate on Void age Profile higher solid recirculation
rate

43. 432.4 Hydrodynamic Structure of Fast Beds Effects of

Circulation Rate on Void age Profile higher solid recirculation
rate Pressure drop across the L-valve is proportional to solid
recirculation rate

44. 442.4 Hydrodynamic Structure of Fast Beds Effect of

Particle Size on Suspension Density Profile- Fine particle - - >
higher suspension density- Higher suspension density - - >
higher heat transfer- Higher suspension density - - > lower bed
temperature

45. 452.4 Hydrodynamic Structure of Fast Beds Core-Annulus

Model- the furnace may be split into two zones : core and
annulus Core- Velocity is above superficial velocity- Solid move
upward Annulus- Velocity is low to negative- Solids move
downward core annulus

46. 462.4 Hydrodynamic Structure of Fast Beds Core-Annulus

Model core annulus

47. 472.4 Hydrodynamic Structure of Fast Beds Core Annulus

Model- the up-and-down movement solids in the core and
annulus sets up an internal circulation- the uniform bed
temperature is a direct result of internal circulation

48. 483. Combustion in CFB3.1 Coal properties for CFB

boiler3.2 Stage of Combustion3.3 Factor Affecting Combustion
Efficiency3.4 Combustion in CFB3.5 Biomass Combustion

49. 493.1 Coal properties for CFB Boiler Properties- coarse size
coal shall be crushed by coal crusher- sizing is an importance

parameter for CFB boiler improper size might result in

combustion loss- normal size shall be < 8 mm

50. 503.2 Stage of Combustions particle of solid fuel is injected

into an FB undergoes the following sequence of events:Heating and drying- De volatilization and volatile combustionSwelling and primary fragmentation (for some types of coal)Combustion of char with secondary fragmentation and attrition

51. 513.2 Stages of Combustion Heating and DryingCombustible materials constitutes around 0.5-5.0% by weight of
total solids in combustor- Rate of heating 100 C/sec 1000
C/sec- Heat transfer to a fuel particle (Holder 1989)

52. 523.2 Stages of Combustion De volatilization and volatile

combustion- first steady release 500-600 C- second release
800-1000C- slowest species is CO (Kearns et al., 1984)- 3 mm
coal take 14 sec to devolatilze at 850 C (Basu and Fraser,
1991)

53. 533.2 Stages of Combustion Char Combustion2 step of

char combustion1. Transportation of oxygen to carbon surface2.
Reaction of carbon with oxygen on the carbon surface3 regimes
of char combustion- Regime I: mass transfer is higher than
kinetic rate- Regime II: mass transfer is comparable to kinetic
rate- Regime III: mass transfer is very slow compared to kinetic
rate

54. 543.2 Stage of Combustion Combination Phenomena

During Combustion Volatile release cause the particle swell
Volatile release in non-porous particle cause the high internal
pressure result in break a coal particle into fragmentation Char
burn under regime I, II, the pores increases in size weak
bridge connection of carbon until it cant with stand the
hydrodynamic force. It will fragment again call secondary
fragmentation Attrition, Fine particles from coarse particles
through mechanical contract like abrasion with other particles

Char burn under regime I which is mass transfer is higher than

kinetic transfer. The sudden collapse or other type of second
fragmentation call per collative fragmentation occurs

55. 553.3 Factor Affecting Combustion Efficiency Fuel

Characteristics the lower ratio of FC/VM result in higher
combustion efficiency (Makansi, 1990), (Yoshioka and
Ikeda,1990),(Oka, 2004) but the improper mixing could result in
lower combustion efficiency due to prompting escape of volatile
gas from furnace.

56. 563.3 Factor Affecting Combustion Efficiency Operating

condition (Bed Temperature)- higher combustion temperature --> high combustion efficiency High combustion temperature
result in high oxidation reaction, then burn out time decrease.
So the combustion efficiency increase. Limit of Bed temp-Sulfur
capture-Bed melting-Water tube failure

57. 573.3 Factor Affecting Combustion Efficiency Fuel

Characteristic (Particle size)-The effect of this particle size is not
clear-Fine particle, low burn out time but the probability to be
dispersed from cyclone the high-Coarse size, need long time to
burn out.-Both increases and decreases are possible when
particle size decrease

58. 583.3 Factor Affecting Combustion Efficiency Operating

condition (superficial velocity)- high fluidizing velocity decrease
combustion efficiency because Increasing probability of small
char particle be elutriated from circulation loop- low fluidizing
velocity cause de-fluidization, hot spot and sintering

59. 593.3 Factor Affecting Combustion Efficiency Operating

condition (excess air)- combustion efficiency improve which
excess air < 20%Excess air >20% less significant improve
combustion efficiency. Combustion loss decrease significantly
when excess air < 20%.

60. 603.3 Factor Affecting Combustion Efficiency Operating

Condition The highest loss of combustion result from elutriation
of char particle from circulation loop. Especially, low reactive
coal size smaller than 1mm it cannot achieve complete
combustion efficiency without fly ash recirculation system.
However, the significant efficiency improve is in range 0.0-2.0 fly
ash recirculation ratio.

61. 613.4 Combustion in CFB Boiler Lower Zone PropertiesThis zone is fluidized by primary air constituting about40-80% of
total air.- This zone receives fresh coal from coal feeder and
unburned coal from cyclone though return valve- Oxygen
deficient zone, lined with refractory to protect corrosion- Denser
than upper zone

62. 623.4 Combustion in CFB Boiler Upper Zone PropertiesSecondary is added at interface between lower and upper zoneOxygen-rich zone- Most of char combustion occurs- Char
particle could make many trips around the furnace before they
are finally entrained out through the top of furnace

63. 633.4 Combustion in CFB Boiler Cyclone Zone

Properties- Normally, the combustion is small when compare to
in furnace- Some boiler may experience the strong combustion
inthis zone which can be observe by rising temperature in the
cyclone exit and loop seal

64. 643.5 Biomass Combustion Fuel Characteristics- high

volatile content (60-80%)- high alkali content sintering,
slogging, and fouling- high chlorine content corrosion

65. 653.5 Biomass Combustion AgglomerationSiO2 melts at

1450 CE eutectic Mixture melts at 874 CS interring tendency of
fuel is indicated by the following(Hulkkonen et al., 2003)

66. 663.5 Biomass Combustion Options for Avoiding the

Agglomeration Problem- Use of additives- china clay, dolomite,

kaolin soil- Preprocessing of fuels- water leaching- Use of

alternative bed materials- dolomite, magnetite, and aluminaReduction in bed temperature

67. 673.5 Biomass Combustion Agglomeration

68. 683.5 Biomass Combustion Fouling- is sticky deposition

of ash due to evaporation of alkali salt- result in low heat
transfer to tube

69. 693.5 Biomass Combustion Corrosion Potential in

Biomass Firing- hot corrosion- chlorine reacts with alkali metal
from low temperature melting alkali chlorides- reduce heat
transfer and causing high temperature corrosion

70. 704. Heat Transfer in CFB4.1 Gas to Particle Heat

Transfer4.2 Heat Transfer in CFB

71. 714.1 Gas to Particle Heat Transfer Mechanism of Heat

Transfer In a CFB boiler, fine solid particles agglomerate and
form clusters or stand in a continuum of generally up-flowing
gas containing sparsely dispersed solids. The continuum is
called the dispersed phase, while the agglomerates are called
the cluster phase. The heat transfer to furnace wall occurs
through conduction from particle clusters, convection from
dispersed phase, and radiation from both phase.

72. 724.1 Heat Transfer in CFB Boiler Effect of Suspension

Density and particle size Heat transfer coefficient is proportional
to the square root of suspension density

73. 734.1 Heat Transfer in CFB Boiler Effect of Fluidization

Velocity No effect from fluidization velocity when leave the
suspension density constant

74. 744.1 Heat Transfer in CFB Boiler Effect of Fluidization

Velocity

75. 754.1 Heat Transfer in CFB Boiler Effect of Fluidization

Velocity

76. 764.1 Heat Transfer in CFB Boiler Effect of Vertical

Length of Heat Transfer Surface

77. 774.1 Heat Transfer in CFB Boiler Effect of Bed

Temperature

78. 784.1 Heat Transfer in CFB Boiler Heat Flux on 300 MW

CFB Boiler (Z. Man, et. al)

79. 794.1 Heat Transfer in CFB Boiler Heat transfer to the

walls of commercial-size Low suspension density low heat
transfer to the wall.

80. 804.1 Heat Transfer in CFB Boiler Circumferential

Distribution of Heat Transfer Coefficient

81. 815 Design of CFB Boiler 5.1 Design and Required

Data 5.2 Combustion Calculation 5.3 Heat and Mass
Balance 5.4 Furnace Design 5.5 Cyclone Separator

82. 825.1 Design and Required Data The design and required
data normally will be specify by owner or client. The basic
design data and required data are; Design Data :- Fuel ultimate
analysis - Weather condition- Feed water quality - Feed water
properties Required Data :- Main steam properties - Flue gas
temperature- Flue gas emission - Boiler efficiency

83. 835.2 Combustion Calculation Base on the design and

required data the following data can be calculated in this stage
:- Fuel flow rate - Combustion air flow rate- Fan capacity - Fuel
and ash handling capacity- Sorbent flow rate

84. 845.3 Heat and Mass Balance Fuel and sorbent Unburned
in bottom ash Feed water Combustion air Main steam Blow

down Flue gas Moisture in fuel and sorbent Unburned in fly ash
Moisture in combustion air Radiation Heat input Heat output

85. 855.3 Heat and Mass Balance Mass Balance Fuel and
sorbent bottom ash Solid Flue gas Moisture in fuel and sorbent
fly ash Make up bed material bottom ash Fuel and sorbent
Make up bed material Solid in Flue gas fly ash Mass output
Mass input

86. 865.4 Furnace Design The furnace design include: 1.

Furnace crosses section2. Furnace height3. Furnace opening1.
Furnace cross section Criteria- moisture in fuel- ash in fuelfluidization velocity- SA penetration- maintain fluidization in
lower zone at part load

87. 875.4 Furnace Design2. Furnace height Criteria- Heating

surface- Residual time for sulfurcapture3. Furnace opening
Criteria- Fuel feed ports- Sorbent feed ports- Bed drain portsFurnace exit section

88. 885.5 Cyclone Separator 6.1 Theory 6.2 Critical size of

particle

89. 895.5 Cyclone Separator The centrifugal force on the

particle entering the cyclone is The drag force on the particle
can be written as Under steady state drag force = centrifugal
force

90. 905.5 Cyclone Separator Vr can be considered as index

of cyclone efficiency, from above equation the cyclone efficiency
will increase for :- Higher entry velocity- Large size of solidHigher density of particle- Small radius of cyclone- low value of
viscosity of gas

91. 915.5 Cyclone Separator The particle with a diameter

larger than theoretical cut-size of cyclone will be collected or
trapped by cyclone while the small size will be entrained or

leave a cyclone Actual operation, the cut-off size diameter will

be defined as d50 that mean 50% of the particle which have
diameter more than d50 will be collected or captured.

92. 926. Operation

93. 93Content6.1 Before start6.2 Grid pressure drop test6.3

Cold Start6.4 Normal Operation6.5 Normal Shutdown6.6 Hot
Shutdown6.7 Hot Restart6.8 Malfunction and Emergency

94. 946.1 Before Start all maintenance work have been

completely done All function test have been checked
cooling water system is operating compressed air system is
operating Make up water system Deorator system Boiler
feed water pump Condensate system Oil and gas system
Drain and vent valves Air duct, flue gas duct system

95. 956.1 Before Start Blow down system Sand feeding

system Lime stone feeding system Solid fuel system Ash
drainage system Control and safety interlock system

96. 966.2 Grid Pressure Drop Test For check blockage of grid
nozzle Furnace set point = 0 Test at every PA. load
Compare to clean data or design data Shall not exceed 10%
from design data Perform in cold condition Pw Pb FIPf= 0

97. 976.3 Cold Start Fill boiler Boiler Interlock Start up Burner
Feed Solid Fuel Boiler Warm Up P urge Start Fan Feed Bed
Material Raise to MCR-100 mm normal level D,HP,SA,PA Low
level cut off300 STb 150-200 C30-50 mbar, Tb 550-600 C

98. 98Fill Boiler-Close all water side drain valve-Open all air
vent valve at drum and superheat-Open start up vent valve 1015%-Slowly feed water to drum until level 1/3 of sigh glass

99. 99Start Fan1.Start ID.Fan2.Start HP Blower3.Start

SA.Fan4.Start PA. Fan

100. 100Boiler Interlock Emergency stop in order Furnace P. <

Max (2/3) ID. Fan running HP Blower start Drum level > min
(2/3) SA. Fan running PA. Fan running HP. Blower P. > min PA.
Flow to grid > min Trip Solid Fuel Flue gas T after Furnace <
max Trip Soot Blower Trip Oil Trip Sand Trip Lime Stone Trip
Bottom Ash

101. 101Purge To carry out combustible gases To assure

all fuel are isolated from furnace Before starting first burner
for cold start If bed temp < 600 C or OEM recommend and no
burner in-service Total air flow > 50% 300 sec for purging
time

102. 102PurgeNFPA85: CFB Boiler purge logic

103. 103Start up burner Help to heat up bed temp to

allowable temperature for feeding solid fuel Will be stopped if
bed temp > 850 C Before starting, all interlock have to
passed Main interlock Oil pressure > minimum Control air
pressure > minimum Atomizing air pressure > minimum

104. 104Start up burnerNFPA85 - Typical burner safety for CFB

boiler

105. 105Drum and DA low level cut-off Test for safety

During burner are operating Open drain until low level
Signal feeding are not allow Steam drum low level = chance
to overheating of water tube DA low level = danger for BFWP

106. 106Boiler warm up Gradually heating the boiler to

reduce the effect of thermal stress on pressure part, refractory
and drum swell Increase bed temp 60-80 C/hr by adjusting
SUB Control flue gas temperature <470 C until steam flow
>10% MCR Close vent valves at drum and SH when pressure
> 2 bar Continue to increase firing rate according to
recommended start up curve Operate de-super heater when
steam temperature are within 30 C of design point Slowly

close start up and drain valve while maintain steam flow > 10%
MCR

107. 107Feed bed material Bed material should be sand

which size is according to recommended size Start feed sand
when bed temp >150 C Do not exceed firing rate >30% if bed
pressure <20 mbar otherwise overheating may occur for
refractory and nozzle Continue feed bed material unit it reach
30 mbar

108. 108Feed solid fuel Must have enough bed material

Bed temperature > 600 C or manufacturer recommendation or
refer to NFPA85 Appendix H Pulse feed every 90 s Placing
lime stone feeding, ash removal system simultaneously
Slowly decrease SUB firing rate while increasing solid fuel feed
rate Stop SUB one by one, observe bed temperature
increasing Turn to auto mode control

109. 109Rise to MCR Continue rise pressure and

temperature according to recommended curve until reach
design point Drain bottom ash when bed pressure >45-55
mbar Slowly close start up valve Monitor concerning
parameters

110. 1106.4 Normal Operation Increasing- manual increase

air flow- manual increase fuel flow- monitor excess oxygenmonitor steam pressure Decreasing- manual decrease air
flow- manual decrease fuel flow- monitor excess oxygenmonitor steam pressure Changing Boiler load (manual)

111. 1116.4 Normal Operation Furnace and emissionmonitor fluidization in hot loop- monitor gas side pressure dropmonitor bed pressure- monitor bed temperature-monitor wind
box pressure- monitor SOx, Nox, CO Furnace and Emission
Monitoring

112. 1126.4 Normal Operation Bottom ash drain- automatic or

manual draining of bottom ash shall be judged by
commissioning engineer for the design fuel.- when fuel is
deviated from the design, operator can be judge by themselves
that draining need to perform or not.- bed pressure is the main
parameter to start draining Soot blower- initiate soot blower to
clean the heat exchanger surface in convective part- frequent of
soot blowing depend on the degradation of heat transfer
coefficient.- normally 10 C higher than normal value of exhaust
temperature Bottom ash and Soot Blower

113. 1136.4 Normal Operation Boiler Walk Down- boiler

expansion joint- Boiler steam drum- Boiler penthouse- Safety
valve- Boiler lagging- Spring hanger- Valve and piping- Damper
position- Loop seal- Bottom screw- Combustion chamber- Fuel
conveyor

114. 1146.4 Normal Operation Sizing Quality- crushed coal,

bed material, lime stone and bottom ash sizing shall be
periodically checked by the operator- sieve sizing shall be
performed regularly to make sure that their sizing is in range of
recommendation

115. 1156.5 Normal Shut Down1. Reduce boiler load to 50%

MCR2. Place O2 control in manual mode3. Monitor bed
temperature4. Continue reducing load according to shut down
curve5. Maintain SH steam >20 C of saturation temperature6.
Start burner when bed temperature <750 C7. Empty solid fuel
and lime stone with bed material >650 C8. Decrease SUB firing
rate according to suggestion curve9. Maintain drum level in
manual mode10. Stop solid fuel, line stone, sand feeding
system

116. 1166.5 Normal Shut Down11. Maintain drum level near

upper limit12. Continue fluidizing the bed to cool down the
system at 2C/min by reducing SUB firing rate13. Stop SUB at

bed temperature 350 C14. Continue fluidizing until bed

temperature reaches 300 C15. Slowly close inlet damper of PAF
and SAF so that ID Fan control furnace pressure in automatic
mode16. Stop all fan after damper completely closed17. Stop
HP blower 30 S after IDF stopped18. Stop chemical feeding
system when BFWP stop19. Continue operate ash removal
system until it empty

117. 1176.5 Normal Shut Down20. Open vent valve at drum and
SH when drum pressure reach 1.5-2 bar21. Open manhole
around furnace when bed temp < 300 C

118. 1186.6 Emergency Shutdown Boiler can be held in hot

standby condition about 8 hrs Hot condition is bed temp >650
C otherwise follow cold star up procedure Boiler load should
be brought to minimum Stop fuel feeding Wait O2 increase
2 time of normal operation Stop air to combustion chamber to
minimize heat loss

119. 1196.7 Hot restart Purge boiler if bed temperature < 600
C Start SUBs if bed temperature > 500 C Monitor bed
temperature rise If bed temperature does not rise after pulse
feeding solid fuel. stop feeding and start purge

120. 1206.8 Malfunction and Emergency Bed pressure Bed

temperature Circulation Tube leak Drum level

121. 121Bed Pressure Bed pressure is an one of importance

parameter that effect on boiler efficiency and reliability.
Measured above grid nozzle about 20 cm.PwPbFIPf= 0

122. 122Bed Pressure Effect of low bed pressure- poor heat

transfer- boiler responds- high bed temperature- damage of air
nozzle and refractory Effect of high bed pressure- increase
heat transfer- more efficient sulfur capture- more power
consumption of fan

123. 123Bed Pressure Cause of low bed pressure- loss of

bed material- too fine of bed materials- high bed temperature
Cause of high bed pressure- agglomeration- too coarse of bed
material

124. 124Bed Temperature Measured above grid nozzle

about20 cm Measured around the furnace cross-section It
is the significant parameter to operate CFB boiler

125. 125Bed temperature Effect of high bed temperatureineffective sulfur capture- chance of ash melting- chance of
agglomeration- chance to damage of air nozzle

126. 126Bed temperature Cause of high bed temperaturelow bed pressure- too coarse bed material- too coarse solid
fuel- improper drain bed material- low volatile fuel- improper air
flow adjustment

127. 127Circulation Circulation is particular phenomena of

CFB boiler. Bed material and fuel are collected at cyclone
separator Return to the furnace via loop seal HP blower
supply HP air to fluidize collected materials to return to furnace

128. 128Circulation Effect of malfunction circulation- No

circulation result in forced shut down- high rate of circulationhigh circulation rate need more power of blower- low rate of
circulation

129. 129Circulation Cause of malfunction circulationinsufficiency air flow to loop seal nozzle- insufficient air pressure
to loop seal- plugging of HP blower inlet filter- blocking or
plugging of loop seal nozzle-

130. 130Tube leak Water tube leak- furnace pressure risebed temperature reduce- stop fuel feeding- open start up valvedont left low level of drum- continue feed water until flue gas

temp < 400 C- continue combustion until complete- small leak

follow normal shut down

131. 131Drum level sudden loss of drum level- when the cause
is known and immediately correctable before level reach
minimum allowable. Reestablish steam drum level to its normal
value and continue boiler operation-if the cause is not known.
Start immediate shut down according to emergency shutdown
procedure

132. 132Drum level Gradual loss of drum level- boiler load shall
be reduced to low load- find out and correct the problem as
soon as possible- if cannot maintain level and correct the
problem, boiler must be taken out of service and normal shut
down procedure shall be applied.

133. 1337. Maintenance

134. 134Before maintenance work Make sure that all staff are
understand about safety instruction for doing CFB boiler
maintenance work Make sure that all maintenance and safety
equipments shall be a first class

135. 135Overview Boiler Maintenance Refractory and tube are

the main area that need to be checked

136. 1366.1 Wind box Inspection Inspect sand inside wind

box after shutdown Drain pipe Crack Air gun pipe
Refractory Crack, wear and fall down inspect by
hammer(knocking) if burner is under bed design Drain pipe

137. 1376.2 Furnace Inspection Nozzle : Wear Fall-off

Refractory Crack, wear and fall down inspect by hammer
knocking if burner is under bed design Feed fuel port
Wear Crack Burner Refractory Burner Feed Fuel Nozzle

138. 1386.2 Furnace Inspection Limestone port Crack

Deform Refractory damage at connection between port and

refractory Secondary & Recirculation Airport Crack

Deform Refractory damage at connection between port and
refractory Bed Temperature Check thermo well
deformation Check wear Secondary & Recirculation Air port

139. 1396.3 Kick-Out Inspection Refractory Wear Crack

and fall down by hammer(knocking) Water tube Wear
Thickness

140. 1406.3 Kick-Out Inspection Water Tube: Thickness

measuring Erosion at corner CO Corrosion due to
incomplete combustion at fuel feed side. Defect from weld
build up Water tube sampling for internal check every 3 years
Inside water tube inspect by bores cope welded build up
excessive metal because use welding rod size bigger than tube
thickness

141. 1416.4 Superheat I (Wing wall) Water Tube:

Thickness measuring Erosion at tube connection
Refractory Crack and fall down by hammer(knocking)
Guard Crack fall down

142. 1426.4 Superheat I (Omega Tube) Offset Water Tube:

Thickness measuring Erosion at offset tube SH tube
Thickness measuring Omega Guard Crack fall down
Omega Guard Offset Water Tube

143. 1436.5 Roof Water Tube: Thickness measuring

Erosion Refractory Crack, wear and fall down by
hammer(knocking)

144. 1446.6 Inlet Separator Water Tube: Thickness

measuring near opening have more erosion than another tube
because of high velocity of flue gas Refractory Crack, wear
and fall down by hammer(knocking)

145. 1456.7 Steam Drum Surface : Surface were black by

magnetite Deposits Deposits at bottom drum need to check
chemical analysis Cyclone Separator Loose Demister
Blow down hole Plugging U-Clamp Loose Deposits at
bottom drum

146. 1466.8 Separator Central Pipe: Deformation

Crack Refractory Wear at impact zone due to high impact
velocity Crack and fall down by hammer(knocking)

147. 1476.9 Outlet Separator Water Tube Tube

Thickness Erosion Outlet Central Pipe:Support or Hook
RefractoryCrack and fall down by hammer(knocking)

148. 1486.10 Screen Tube Water Tube Thickness

measuring upper part of screen tube at corner have more
erosion than another area because of high velocity of flue gas
Guard Loose Refractory Crack and fall down by
hammer(knocking)Weld build up or install guard to prevent tube
erosion upper part of screen tube at corner have more erosion

149. 1496.11 Superheat Tube Tube Thickness

measuring High erosion between SH tube and wall Steam
erosion due to improper soot blower Guard Fall down
Crack

150. 1506.12 Economizer Water Tube Thickness

measuring High erosion between economizer tube and wall
Steam erosion due to improper soot blower Guard Fall
down Crack Guard Install guard to prevent tube erosion

151. 1516.13 Air Heater Tube Cold end corrosion due to

high concentrate SO3 in flue gas Steam erosion due to
improper soot blower Inlet air heater Cold end corrosion due to
SO3 in flue gas

152. 1528. Basic Boiler Safety

153. 153WarningOperating or maintenance procedure which, if

not as described could result in injured death or damage of
equipment

154. 154General safety precaution Electrical power shall be

turned off before performing installation or maintenance work.
Lock out, tag out shall be indicated All personal safety
equipment shall be suit for each work Never direct air water
stream into accumulation bed material or fly ash. This will
become breathing hazard Always provide safe access to all
equipment ( plant from, ladders, stair way, hand rail Post
appropriate caution, warning or danger sign and barrier for
alerting non-working person Only qualify and authorized
person should service equipment or maintenance work

155. 155General safety precaution Do not by-pass any boiler

interlocks Use an filtering dust mask when entering dust
zone Do not disconnect hoist unless you have made sure that
the source is isolated

156. 156Equipment entry Never entry confine space until is

has been cooled, purgedand properly vented When entering
confine space such as separator, loop sealfurnace be prepared
for falling material Always lock the damper, gate or door
before passingthrough them Never step on accumulation of
bottom ash or fly ash. Itsunderneath still hot Never use toxic
fluid in confine space Use only appropriate lifting equipment
when lift or moveequipment

157. 157Equipment entry Stand by personnel shall be

positioned outside a confinespace to help inside person incase
of emergency Be carefully aware the chance of falling down
when entercyclone inlet or outlet. Don not wear contact lens
with out protective eye nearboiler, fuel handing, ash handing
system. Airborne particlecan cause eye damage Don not

enter loop seal with out installing of cover overloop seal

downcomer to prevent falling material fromcyclone

158. 158Operating precautionsCFB boiler process Use planks

on top of bed materials after boiler is cooleddown. This will
prevent the chance of nozzle plugging Do not open any water
valve when boiler is in service Do not operate boiler with out
O2 analyzer Do not use downcomer blown donw when
pressure > 7bar otherwise loss of circulation may occure Do
not operate CFB boiler without bed material When PA is
started. PA flow to grid must be increase toabove minimum limit
to fully fluidized bed maerial Do not operate CFB boiler with
bed pressure > 80mbar.This might be grid nozzle plugging

159. 159Operating precautions on cold start up the rate of

chance in saturated steam shall not exceed 2 C/min On cold
start up the change of flue gas temp at cyclone inlet shall not
exceed 70 C/min Do not add feed water to empty steam drum
with different temperature between drum metal and feed water
greater than 50 C All fan must be operated when add bed
material

160. 160Operating precautions Refractory when entering

cyclone be aware a chance of falling down Refractory retain
heat for long period. Be prepared for hot surface when enter this
area An excessive thermal cycle will reduce the life cycle of
refractory After refractory repair, air cure need to apply about
24 hr or depend on manufacturer before heating cure Heating
cure shall be done carefully otherwise refractory life will be
reduced

161. 161Operating precautions Solid Fuel Chemical analysis

of all solid fuel shall be determined for first time and compared
with OEM standard Sizing is important Burp feeding shall
be performed during starting feeding solid fuel instead of
continuous feeding

162. 1629. Basic CFB Boiler Control

163. 163 Basic control Furnace control Main pressure

control Main stream pressure control Drum level control
Feed tank control Solid fuel control Primary air control
Secondary air control Oxygen control

164. 164Basic control Simple feedback control PRIMARY

VARIABLEXTKA T Af(x)SET POINTPROCESSMANIPULATED
VARIABLE

165. 165Basic control Simple feed forward plus feedback

control PR IM ARY VARIABLEXTYTSECO NDARYVARIABLEA
T Af(x)MANIPULATED VARIABLEPROCESSSET POINTK

166. 166Basic control Simple cascade control PRIMARY

VARIABLEXTZTKKSET POINTA AT PROCESS
f(x)MANIPULATED VARIABLESECONDARYVARIABLE

167. 167Basic control COSPPVPID Control Mode of PID-MAN

(Manual)-AUT (Automatic)-CAS (Cascade) Signal to open0-15
m3/h0-100% (closed open) 4-20 mA Electrical signal 4-20 mA
Eng. Unit 0-15 m3/h Percent 0-100 % 0-100%

168. 168Feed water control LTPTPIDPID Make up water

Heating steam Pressure-Manual mode 0-100% heating steam
valve position-Auto mode, specify pressure set pointTemperature compensation Level-Manual mode 0-100% make
up water valve-Auto mode, specify level set point-Temperature
compensation-Protection, high level over flow

169. 169Drum Level control DP feed water pump Control valve

A, SPM, 0-100%Main steam flow Main steam Pressure Manual
mode, 0-100%control valve Auto mode, specify drum level.
Automatically adjust valve Protection-lower limit-2/3 principle10 s delay-Close steam valve for low level

170. 170Main steam pressure control SPPVFFCO

171. 171CombustionCalculationSA SPPA SP Total air SP Total

Fuel SPFuel1 SP Fuel3 SPFuel2 SPPA. Fan Conveyor1
Conveyor2 Conveyor3SA.FanX -Main steam Pressure

172. 172Solid Fuel Control MWTPID Cascade Auto Manual

Manual : speed of coal conveyor is specified by operator Auto :
operator specify fuel flow load Cascade: fuel flow set point
calculated by main steam pressure control

173. 173Primary air control MPIDFT Auto Cascade PV Manual

Manual: position of damper is specified Auto: desired air flow is
specified by operator Cascade: set point is calculated from
master combustion Flow (interlock) > minimum PA wind box P >
minimum PA running

174. 174Secondary air control MPID Auto Cascade Manual

FTFTPT Manual Manual PID Auto Cascade Lower SA Upper
SAFTPV

175. 175HP Blower Control Pressure is controlled by control

valve Control valve is connected to primary air It will
release the air to primary air duct if pressure higher than set
point If operating unit stop due to disturbance or pressure fall
down, stand by unit shall be automatically started Pressure
should be higher than 300 mbar, boiler interlock Pressure <
350 mbar parallel operation start

176. 176Furnace Pressure

controlMPIDPTAutoFurnacepressureManualPIDManualAuto2/3
furnace P < max (35 mbar)

177. 177Lime stone control Lime stone can be control by

lime stone/ fuel flow ratio SO2 feedback control Manual
feed rate

178. 178Fuel oil control MA Pressure control Pressure control

valve Flow control valve Auto Manual

179. 179Referenced Prabir Basu , Combustion and gasification

in fluidized bed, 2006 Fluidized bed combustion, Simeon N.
Oka, 2004 Nan Zh., et al, 3D CFD simulation of hydrodynamics
of a 150 MWe circulating fluidized bed boiler, Chemical
Engineering Journal, 162, 2010, 821-828 Zhang M., et al, Heat
Flux profile of the furnace wall of 300 MWe CFB Boiler, powder
technology, 203, 2010, 548-554 Foster Wheeler, TKIC refresh
training, 2008 M. Koksal and F. Humdullahper , Gas Mixing in
circulating fluidized beds with secondary air injection, Chemical
engineering research and design, 82 (8A), 2004, 979-992