0049 Unit Operation Proceddure

UNIT OPERATING PROCEDURE
Contents
1.0 INTRODUCTION ......................................................................................................... 2
2.0 PLANT START-UP ...................................................................................................... 3
3.0 COLD START -UP ..................................................................................................... 10
4.0 HOT /WARM RESTART ........................................................................................... 17
5.0 INCREASING THE LOAD ........................................................................................ 19
6.0 CFB SYSTEM............................................................................................................. 20
7.0 WATER / STEAM SYSTEM ..................................................................................... 31
8.0 LIGNITE FEEDING SYSTEM .................................................................................. 41
9.0 SOOT BLOWER SYSTEM ....................................................................................... 45
10.0 BED ASH SYSTEM ................................................................................................... 47
11.0 LIMESTONE FEEDING SYSTEM........................................................................... 50
12.0 SEAL AND PURGE AIR SYSTEM .......................................................................... 52
13.0 PLANT MAINTENANCE ........................................................................................... 53
14.0 REFRACTORY........................................................................................................... 57
15.0 MAINTENANCE OF EXPANSION JOINTS........................................................... 57
16.0 OPERATION UPSETS ............................................................................................. 57
17.0 PLANT SHUT-DOWN ............................................................................................... 65
1.0 INTRODUCTION
1.1 The operating manual covers a functional description of the plant, information
on the sequence of operations and functional logic of the individual plant
components as well as separate descriptions of the individual units and their
maintenance.
It is beyond the scope and intent of the operating manual to provide
instructions for all the possible operations and control actions, which may be
required for the operations of the boiler system. It should be noted that the
present operating instructions are no substitute for the thorough instructions of
the operating personnel into the details of plant operation.
The supplier does not assume any responsibility for damage resulting from
faulty operation of the plant.
Proper plant operation presupposes continuous plant supervision by skilled
operators and effective communication between the control room personnel
and the operators in all major plant areas.
It is prohibited to deactivate or bridge safety systems such as electric
interlocks and flame monitoring systems nor is it allowed to deactivate
individual functions of these systems.
Moreover, the latest editions of the relevant national regulations and/or
company’s in-plant regulations have to be taken into account, as specific
operation instructions of the respective items.
1.2 DUTIES OF THE OPERATING PERSONNEL
The duties of the operating personnel comprise the checks and preparatory
work for plant startup, actual plant startup as well as supervision of plant
operations, shutdown and maintenance.
When changing shifts, care has to be taken that the personnel of the relevant
shift does not leave its working place before plant operation has been taken
over by the next shift, i.e. the new shift has to be properly informed of all
events which occurred during the previous shift.
Shift logs should contain the following minimum information broken down by
type of activity and indicating the time when this activity was performed:
1. Functional checks.
2. Startup
3. Shutdown
5303&5304 NLC – Barsingsar Page 2 of 72
4. Abnormal operating conditions such as abnormal noise generations,
leakages, pressures, temperatures, excessive vibrations etc.
5. Failure of major components and
6. Instrument readings.
If the plant operators identify operating upsets or other irregularities, these
should, if possible, be immediately remedied and reported to the supervisor.
Plant monitoring and control instruments have to be read at regular intervals
during plant operation and the readings entered into the shift log.
The supplier retains the right to revise or supplement the operating
instructions, if this seems to be expedient in the light of new operating
experience.
The operating manuals submitted to the plant owner should be treated with
due care to make sure that they are available whenever they are needed. In
this connection, special care should be exercised to ensure that individual
pages or chapters are not taken out of the manuals.
The plant owner is requested to inform the supplier of any new operating
results so that the original operating manual can be revised and/or
supplemented accordingly.
2.0 PLANT START-UP
2.1 PREPARATION:
2.1.1 CFB FIRING SYSTEM
The combustor is empty. All units are out of operations. The pre
commissioning work should be started in due time (about 24 hours) before the
scheduled startup.
Before proceeding to startup, make sure that the following pre-commissioning
work is carried out and/or the following requirements are satisfied:
Check that all units, equipments, piping, ducting and adjacent areas are free
from foreign mater.
Check that all openings are properly closed.
Check boiler, air and flue gas ducting for gas leakages; check expansion
movement of boiler and associated piping, set pipe hangers.
Make sure that all plant components are properly insulated.

Check all units for full functionability; this also includes preparing the electrical
drives for starting.
Check that all valves and dampers are workable; grease spindles and adjust
stuffing boxes.
Subject all remote-controlled elements (such as butterfly valves, shutoff
valves, gate valves) to a cold test.
Set all relief valves.
Check and adjust the cooling water and compressed air systems.
Commission the power supply
Check oil levels, clean strainers and filters.
Test and calibrate all instruments; inspect and set limit and position indicating
switches.
Calibrate rotary valves.
All oil-lubricating systems are ready for operation.
The measuring and control system has been checked, is ready to start and
has been set to MANUAL.
Instrument air supply to the individual components has been checked and all
valves in the instrument air lines are open.
ALL LOCAL switches are set to REMOTE.
Inspection doors and openings are closed and have been checked for tight
sealing and that nobody is inside.
Seal air is available.
The seal air supply piping to the individual consumers has been checked and
the required air rates adjusted:
Electrostatic precipitator is ready for operation.
The steam supply system is ready for operation and the requisite steam piping
to the individual consumers has been drained.
The steam tracer or electrical tracing of the oil system is ready for operation
and activated.
The valve positions (steam) on the oil lances and burners have to be checked
to ensure that no steam condensate can enter the lances and/or the burners.
All lances and burner tips are cleaned.
Local check of startup burners/oil lances and oil station.
Clean the flame monitor nozzles.
Clean all sight glasses.
Check the valve positions in the sealair lines (all valves must be open
considering the commissioning instructions).
The purge air system is ready for operation and the individual purge air rates
have been adjusted.
Check purge air supply to the individual consumers especially to the oil lances
operator consoles,
Introduce the cleaned oil lances into the empty CFB combustor, connect the
oil and steam hosing and make sure that seal and purge air supply is
established.
2.1.2 WATER / STEAM SECTION
The boiler is free from leaks (hydrotest has been successfully completed).
The stuffing boxes of the water/steam valves have been leak-checked.
The system is properly insulated and the insulation is free from damage.
The locking devices on the constant and spring hangers have been removed.
Valve positions in the boiler feedwater, steam and condensate system have
been checked.
Drains and vents are checked and ready for operation.
Feedwater is available in sufficient quantity and adequate quality.
Feedwater pumps are ready for operation (see manufacturer’s operating
instructions).
The boiler feed water and blow-down control are ready for operation.
Blocking devices have been removed from the safety valves.
Reheater and superheater start-up vent valves are ready for operation.
Instrument air supply to the safety valves in the boiler drum and superheater
section is established.
HP-Bypass including attemperator is ready for operation.
LP-Bypass including attemperator is ready for operation, if any. Spraywater
valves are ready for operation.
All soot blowers are in REST position; operation is checked prior to start-up.
2.1.3 FUEL AND LIMESTONE FEEDING SYSTEMS, ASH DISCHARGE
SYSTEMS
Oil system is ready for operation. The electrical tracing is switched on.

Lignite feed system is ready for operation.
Lignite bunker is filled above the minimum level.
The layer height on the lignite feeder has been adjusted to suit the type of
lignite.
The oil filters are cleaned. The oil pumps are maintained.
Valves in the instrument air lines are open.
Valves in the purge air and seal air lines are open.
The limestone silo is filled with limestone of the specified quality.
The purge air and bin aeration systems are ready for operation and activated.
Ash discharge system ready for operation.
2.1.4 MOTOR DRIVEN EQUIPMENT
The following pre-operational checks on motor driven equipment should be
applied as minimum requirements:
Make sure both driving and driven equipment are correctly lubricated before
start-up.
Run-in and vibration test all motors, uncoupled before first run.
Turn drive shafts for all fans and blowers by hand if size permits, to make sure
impellers rotate without bumping or rubbing.
Start the following equipment a few revolutions with drives to check for correct
rotation without bumping or rubbing:
a. Rotary valves for lignite, ash and limestone
b. Feeders for lignite
Check all motor operated valves for correct function and minimum possible
position (open/close).
2.1.5 STARTUP PREREQUISITES
The boiler and firing system are ready for operation.
The startup prerequisites listed under are fulfilled and the requisite checks
have been carried out.
2.2 FILLING OF BOILER SECTION
Prior to startup, the boiler has to be filled with boiler feedwater up to the
normal water level. Boiler filling is carried out manually.
The boiler feedwater must conform to the specified quality standards.

2.3 FILLING THE CFB COMBUSTOR AND FLUID BED HEAT EXCHANGER
WITH BED MATERIAL
If the CFB combustor is empty, it has to be filled with bed material prior to
start-up to protect the nozzles from direct exposure to the flame during start-up
operation. Moreover, the combustor has to be at least partially filled to permit
controlled combustion in the ash bed. Oil and lignite firing in a combustor
without sufficient ash inventory would cause uncontrollable temperature peaks
resulting in damage to the nozzles, thermocouple sleeves and also possibly to
the refractory. Moreover, the ash in the CFB-system could melt or sinter. For
this reason, authorization for oil or lignite firing is subject to a minimum p (ash
inventory).
Although filling of the fluid bed heat exchanger is not absolutely required
before restarting the plant, this is recommended to ensure a sufficient supply
of bed material in order to attain steam generation rates over 120 t/h (= 30 %
full load) within the shortest possible time.
Whenever possible, ash from the combustion system should be used for bed
build-up, as this is best-suited material. If ash is not available, quartz sand with
a size distribution of 90 – 95% between 50 and 300 m can be used for bed
buildup. Quartz sand is highly abrasion resistant and relatively insensitive to
the temperature peaks occurring during startup operation. However, generally,
any kind of burned-out ash will be suitable for start-up operation provided that
it has the necessary size range, a very low moisture content and not too low
softening point.
Filling the CFB Combustor
The bed material silo will be filled with starting material (sand or ash). Filling
of the CFB combustor is accomplished gravimetrically via the bed ash rotary
valve from the bed material silo into the combustor.
The inventory of the stationary bed in the combustor should be about 1 m of
ash. This corresponds to a p of 120 to 150 mbar across the CFB combustor
without pressure loss of grate. A bed height of about 1 m ensures reliable
preheating operation at a sufficient heating rate. If the steam generating
capacity is to be increased, it may become necessary to charge additional ash
after changeover to oil firing (normal operation) in order to maintain the
required p. Additional ash has to be charged in any way when proceeding to
lignite firing.
Filling the Fluid Bed Heat Exchangers (FBHE)
Filling of the FBHEs during normal operation by feeding ash from the recycling
cyclone takes a long time as the ash inventory of the FBHEs are considerably
higher than that of the CFB combustor. Therefore it is recommended that the
FBHEs will be filled with bed material or with system ash prior to start-up.
In principle, bed build-up in the FBHE can be accomplished by feeding
circulating combustor ash via the cyclone and spiess valve and directly from
the combustor.
Feeding directly from the combustor into the bundle chamber happens every
time the primary air fan is started, as there is a direct opening between the
combustor and the bundle chambers. However the empty chambers have to
be filled via the spiess valve.
For feeding via the spiess valve, the FBHE blowers for the bundle, the empty
champers and the primary air fan have to run during the first filling operation.
The spiess valve must be open. Moreover, the bed inventory in the CFB
combustor has to be complemented by charging ash until a sufficient bed has
been established in the FBHE. Filling operation requires the operator
attendance, as the air inlet dampers to the individual FBHE empty chambers
have to be adjusted until the FBHE is filled.
Adjustment of the above air rates will ensure that the start-up material flowing
into empty chambers from the sealpots is gradually moved to the bundle
chambers by the air stream. At first, the air rate in the empty chamber will drop
(assuming that the FBHE was completely emptied previously). This is
indicative of an increasing material bed and hence an increased resistance to
be overcome by the air flow. As a result, the air rates in the remaining empty
chambers will increase accordingly. Therefore the air flows through these
chambers have to be continually readjusted to the original levels by slightly
throttling the air inlet dampers to these empty chambers. After the FBHE has
been filled, repeat the same procedure for the second FBHE, the third FBHE
and finally for the fourth FBHE.

Once the maximum filling level has been attained in the last FBHE, the bed
material feeding can be stopped.
Important Note:
When readjusting the air inlet dampers for the FBHE empty chambers during
FBHE filling, care should be taken to ensure that at least one of the dampers
is fully open. In principle, all dampers should be set to the maximum possible
opening position as long as the air rates remain stable. Throttling of the air
inlet dampers without there being any impermissible fluctuations in the air flow
will result in an excessive pressure increase and hence cause the safety valve
to respond. Once the safety valve has been activated, the air flow to the
FBHEs is interrupted and the material in the empty chambers is not longer
fluidized as the air is blown off via the safety valve. In such a case, the air inlet
dampers have to be set to a wider opening angle to prevent the pressure relief
valve from venting the air to atmosphere.
2.4 PLANT START-UP
2.4.1 GENERAL
On the one hand, the boiler should be started up as quickly as possible to
save both time and money while on the other, care has to be taken to ensure
gentle operating conditions to prevent damage to the refractories in the CFB
combustor, cyclones, sealpots and the fluid bed heat exchangers and the
water/steam circuit, in particular the superheaters in the convective pass and
FBHEs.
For plant start-up, a distinction is made between
-cold start-up,
-warm restart,
-hot restart.
The criterion for this classification are the lower and middle combustor
temperature. The term "hot restart" refers to temperatures above 700 °C,
where a restart directly with lignite is possible. The term "warm restart" refers
to temperatures above 600 °C, where the use of bed lances is required for
restart, and the term "cold start-up" refers to temperatures below 600°C,
where the use of the start-up burners is required for restart.
As a rule, the maximum permissible temperatures, temperature gradients and
pressure increases stated in the following chapters shall not be exceeded.
Moreover, the manufacturer's operating instructions for the individual units
have to be taken into account.
2.4.2 NON-STATIONARY OPERATING CONDITIONS
Following non-stationary operating conditions can occur:
a) Heating-up to operating temperature after long shut-down (> 60 h),
b) Heating-up after short shut-down (<60 h),
c) Cooling-down (by heat loss) during short operating upset (< 60 h),
d) Controlled shut-down within 12 h and
e) Purging after trip of bed lances (for the next attempt of heating-up).
Heating-up and cooling-down should be done with a temperature gradient of:
50 to 100 °C/h
For detail of gradients refer to refractory manuals.
Heating-up time for the FBHEs could be reduced according to its control
characteristic.
3.0 COLD START -UP
The term "Cold Start-up" refers to all start-up procedures requiring ignition of
the start-up burners. In this start-up procedure, the temperature at the
combustor nozzle grate is staying below 600°C after the start of the primary air
fan.
Cold start-up proceeds in seven steps:
- Starting the I.D. Fan and SealAir Blower
- Starting the Combustion Air Supply
- Purging,
- Heating up operation using the start-up burners,
- Combined oil lance/start-up burner operation,
- Changeover to oil lance/lignite firing,
- Lignite firing (normal operation).
3.1 Start-up Prerequisites
- The boiler and firing system are ready for operation.
- The start-up prerequisites listed in section"2. General Conditions for
Start-Up" are fulfilled and the requisite checks have been carried out.
3.2 Start-up Preparations for Purging and Lighting-up
Preparations for Purging and Lighting-up
Prior to boiler start-up the following preparations have to be completed:
- The unit has been chemically cleaned, the steam line has been blown, the
safety valves have been set and the unit has been filled to the normal
operating level with adequately treated feedwater.
- The soot blowing equipment has been checked for proper operation and the
system is in the start-up condition.
- The attemperator spray water control and isolation valves are closed.
Attemperator manual spray water shut-off valves are open.
- All boiler superheater, reheater, drain and vent valves are in the start-up
position, as required for proper venting and draining.
- Feedwater control valves closed (manual control). Steam stop valve at

turbine inlet and/or turbine throttle valve closed. Drum water gauge valves
open (locked open).
Before starting the fans for boiler start-up the following conditions should be
fulfilled.
1. Start the oil circuit at least 2 hours before the planned start-up time
Circulating oil pump 1 or 2 ON
2. Main steam stop valve OPEN
3. Superheater and reheater venting valves OPEN *
4. Superheater and reheater drain valves OPEN *
5. HP-Bypass AUTO/OPEN
6. Reheater Start-up vent valve or LP-Bypass AUTO/OPEN
7. Attemperator control valves CLOSED
8. Oil pump1or2 ON
9. Oil pump bypass CLOSED
* if water/steam system is not pressurized
Note:
The HP-bypass open and put to Auto mode for temperature and pressure
control. The main steam stop valve, located before the HP-bypass tapping
point at the HP-steam line, has to stay always open to guarantee a steam flow
to the reheater system via the HP-bypass for cooling the reheater.
Starting the Combustion Air Supply
When these preparations have been completed, the combustion air supply to
the boiler is started by starting the function group "Fans and Blowers".

After completion of the function group "Fans and Blowers" purging of the plant
may be started.
3.3 Boiler Purge
Boiler Purge is required by standards applicable to CFB boilers to ensure that

there are no explosive gases in the combustor or ducts prior to first ignition of
a start-up burner. During boiler purge a flow of air through the boiler enclosure
and associated air and flue gas ducts will effectively remove any combustibles
with air:
- One PA fan, one SA fan, One ID fan and all blowers shall be operated to get
also the respective ducts purged.
- Total purge air flow rate shall be higher than 113 kg/s.
- Purging time shall be 22 minutes (for a 3 fold volume change). The purging
time starts once the required purging air flow is reached.
If the purging time is not finished, the timer for the boiler purge will be started
again once the air flow is less than required minimum purge air flow.
In order to fulfill respective safety requirements the voltage of the ESPs must
be turned down during purging to eliminate any ignition source.
After purging is completed the starting of the start-up burners is permitted for
30 minutes. When this time is expired, the purging has to be repeated.
After 4 failed ignitions a complete boiler purge is required. The following
restrictions are valid:
If the oil line is purged after the ignition, this will count as an additional failed
ignition trial (because fuel is fed to the combustor).
During the ignition attempts the overall purge air flow rate shall never be
reduced below 22.0 kg/s (25 % MCR according to NFPA requirements).
Between the ignition attempts a waiting time of at least 1 minute must be kept.
The "ready for ignition" condition is available for 30 minutes once boiler purge
is finished. If it is not possible to light up the start-up burner within this period
of time, purging must be repeated.
3.4 Heating-Up Operation for Cold Start-Up
The steam generator is equipped with two LDO/heavy oil-fired start-up

burners. After purging is completed the Start-up burners are ready for ignition.

Starting up the Start-up Burners
Starting of the start-up burners is subject to the condition that the bottom
section of the CFB combustor and seal pot are filled with inert material (ash or
quartz sand). Otherwise, uncontrolled temperature peaks will cause damage
to the nozzles, thermocouple sleeves and possibly also to the refractory lining.
To start heating-up operation one of the two start-up burners is put into
operation. If the burners are not lit up within the safety time, ignition operation
will be automatically stopped.
Detailed description for burner operation see section Oil Firing System - Start-
Up Burners" .
In case only one burner is in operation and trips, the unit has to be purged
prior to putting again one burner into operation.
Heating-up Operation
- The heating-up procedure to be adopted depends on whether the combustor

is started up from the
- cold (combustor middle temperature < 600°C) or
- warm (combustor lower temperature> 600°C) condition. (see Section
"Warm Start-up")
- Above 600°C the burner(s) may be started without proceeding purge.
In the case of a cold start-up, the heating curve shown in the diagram
"Predicted Cold Start-Up", should be observed. The firing rate will
automatically be increased according to start-up burner fuel oil and air flow
control loop. Temperature gradient is limited by the output signal of the
temperature controller.
Up to a temperature level of 400°C, the maximum allowable temperature

gradient for heating up the CFB combustor is 80 to 100 °C/h (the reference
temperature is always the combustor middle temperature).
Exceptions are possible, for example, for Dry-Heating or for the first start-up
after the refractory lining has been repaired or replaced.
In any case heating-up gradients given in the refractory suppliers

recommendation should be followed.
After a temperature of about 600°C has been attained at the combustor middle
and lower temperature, the oil lances can be started.
Oil Lance Operation during Heating-up Operation
Once all interlocks are satisfied, the bed lances can be started immediately.
For operation of the oil lances see Section "Oil Firing System".
When starting a bed lance, the oil flow rate should be closely observed: if the
oil rate does not rise, this is indicative of a lance blockage. In such a case, the
affected lance has to be once again stopped, inspected locally and, if required,
cleaned. After stopping of one lance, another lance has to be immediately
started by the operator to prevent a temperature drop in the CFB combustor.
After the bed lances have been put into service, it is essential to keep an eye
on the combustor temperatures, for
- the combustor bottom temperature must not fall below 600°C.
- the lower combustor temperature should rise noticeably after the bed lances
have been started (max. time allowed for the temperature rise 5 min.).
If these two conditions are not met, the bed lances have to be once again
stopped as reliable combustion is not ensured.
After stopping or tripping of the bed lances, they have to be blown out with
steam. Steam blowing is carried out automatically as long as the lower bed
temperature stays above 600 °C.
After the bed lances have been successfully ignited, heating up of the
combustor is continued until a lower or middle combustor temperature of more
than 700°C has been attained. Then lignite feeding should be started for
further increase of load. The temperature for the permissive will be optimized
during initial stages of operation.
3.5 Cold Start-Up of Boiler (Water/Steam Side)
Lighting up and Steam Flow Control
- Blow down the unit as required to maintain the water level in sight in the
gauge glass.
- Close the drum vents when the drum pressure reaches 2 kg/cm 2(g).
- The finishing superheater and reheater inlet header drain must never be
completely closed until the steam outlet temperature of the superheater and
reheater is 15°C superheated.
- To protect the backpass superheater and reheater, maintain the gas

temperature at the cyclone outlet below 540°C until adequate superheater
steam flow is established. Use primary air and burner firing rate for control.
- As system pressure increases, progressively throttle the superheater and

reheater drain and vents (main steam line drain, turbine drains, backpass
drains, superheater and reheater outlet vent). Sufficient steam flow must be
maintained at all times to ensure proper cooling of the superheater and
reheater elements. The pressure raise is controlled by the HP-bypass
according to the heating-up curve regarding an maximum allowed pressure
gradient of 1 bar/min to limit the thermal stresses on the pressure parts.
- The HP-bypass and reheater outlet vent valve, alternatively the LP-bypass,
must remain open to ensure steam flow through the backpass superheater
and subsequently reheater to protect the elements from overheating until the
turbine is synchronized.
- While the unit is heating up, make frequent checks of the boiler expansion
movements.
Note:
For the first start-up of a new unit it is recommended to apply a slower rate of
pressure increase so as to allow sufficient time for checking expansion
movements and to permit the operators to become familiar with the
characteristics of the system and its auxiliary equipment. It is advisable to
make marks to check the expansion movements at various places and to
record the expansions hourly.
- Maintain drum water level at normal and check boiler water concentrations
and constituents as frequently as required to maintain proper boiler water
conditions.
- Adjust the feedwater supply to the boiler as necessary to maintain normal

water level. Feedwater control should be set to AUTOMATIC as soon as
possible and practicable when continuous feed water flow is established.
- Turbine rolling and synchronization may be accomplished as soon as the
minimum permissible start-up pressure, temperature and load specified are
reached. The HP- and LP-bypass are then closed accordingly. Refer to tur-
bine instructions.
- Set the steam temperature control and combustion controls to "AUTO" when

firing conditions are stable and the temperature and pressure control set
points have been reached. Refer to the control manufacturer's instructions
for specific procedures.
CAUTION
Operators should be alert to detect the symptoms of water carry over from the
boiler and introduction of water into the turbine such as:
A. A sudden unexplained drop in steam temperature in the main steam line.
B. Vibration in the steam piping resulting from water hammer.
C. Abnormal vibration and differential expansion readings from the turbine
monitoring instruments.
Operators must be prepared to take actions necessary to prevent turbine
damage when detecting the introduction of water. Refer to turbine
manufacturer's instructions for specific actions to be taken.

4.0 HOT /WARM RESTART
Hot Restart
A hot restart can be carried out if the lower or middle combustor temperature
is > 700°C still after starting of primary air fan. Such condition normally exists
after a brief shutdown so that the plant can be started up with the lignite
directly, i.e. start-up burner operation is not necessary.
Warm Restart
A warm restart can be carried out if, after starting of the primary air fan and
after having adjusted minimum primary air flow rate, the lower or middle
combustor temperature is above 600°C, i.e. the lances can be taken into
operation without start-up burners being in operation.
The oil lances shall be started immediately once the minimum primary air flow
is exceeded.
4.1 Preparations for Hot/Warm Restart
Local
Set cooling water flow to spiess valve to 5 m3/h.
Control Room
Fuel supply system in start position
Oil control valve (lances) in start position
Electrostatic precipitator ready for operation
CFB combustor air dampers CLOSED
Vane control of primary and secondary air fan CLOSED
Drum water level >MIN
Check that interlock conditions for starting the induced draft fan are satisfied:
. Flue gas pressure control set to MANUAL
I.D. fan vane control CLOSED
Now I.D. fan interlocks are satisfied
Oil circulating pump 1 or 2 ON
Oil pump 1 or 2 ON
4.2 Fuel Oil Lance Operation
After the preparations for warm start-up have been completed, proceed to the
start-up of the fuel oil lances. The requisite start-up steps should be carried out
speedily to prevent the lower/middle combustor temperature from dropping
below the interlock temperature. Especially after starting of the primary air fan,

the temperature in the combustor ash inventory tends to drop rapidly.
If the combustor temperature is falling below 600°C, starting of the bed lances
is no longer possible. The plant has to be purged once again and heated up
with the aid of the start-up burners.
To avoid purge conditions it might be advisable to start at least one start-up
burner prior to the lances in case of a warm/hot start-up.
To put the bed lances into service, proceed as detailed below making sure that
one of the I.D. fans has been proved ready for starting and that the vane
control is in CLOSED position:
- Start function group (FG) "I.D. Fan 1" or "I.D. Fan 2"
- Put all relevant FGs to automatic mode
- Select P.A. and S.A. fan to be started first.
- Manual start of FG "Fans and Blowers".
Note:
If difficulties occur after starting the primary air fan and the bed lances and the
startup burners cannot be immediately put into service, the fan should be once
again stopped and the fault remedied. This will prevent the ash in the
combustor from cooling down.
Now all interlocks are satisfied and authorization for bed lance operation
should be given.
- Start FG "Bed Lance 1" and, if required, other bed lances.
Whenever starting a bed lance, observe the oil flow. If the oil flow does not rise
when connecting a lance, check the relevant lance locally but start the next
lance without delay.
- Start limestone feeding
- Start bottom ash system
- Start filter ash system
- Start fly ash system
- Start lignite feeding
For warm start-up the maximum temperature in the combustor middle should
never exceed 950°C and the heating-up gradient (reference temperature,
combustor middle temperature) should be 80 to 100 °C/h at a maximum.

4.3 Changeover to Lignite Firing or Hot Restart
Changeover to lignite firing constitutes the last step in the start-up procedure
before the plant reaches normal operating conditions. When firing lignite, the
plant is on normal operation. To get the permissive to change to lignite firing
the interlocks (temperature) have to be satisfied.
Now the start-up program is completed and the plant is on normal operation.
Depending on the load requirements and the lignite feed rates, the oil feed to
the lances can be reduced and the lances successively put out of service. The
lances have to be blown out with steam after having been taken out of
operation.
In case of a Hot Restart, lignite feeding without any lance operation is possible
in case the permissive to allow for lignite operation are satisfied.
4.4 Hot Restart (Water/Steam Side)
The HP-bypass and reheater outlet vents or alternatively the LP-bypass, if
applicable, will be opened to relieve excess pressure and to provide sufficient
cooling of the superheater and reheater during the hot standby. If the
necessary criteria for a hot restart are satisfied, the following procedure should
be followed:
It is desirable to have the steam temperature match the turbine metal
temperature when steam is admitted to the turbine for rolling.
To protect the backpass superheater and reheater, establish always min. flow
to ensure proper cooling.
The HP-bypass and reheater outlet vent valve must remain open to assure a
flow of steam through the backpass superheater and reheater to protect the
elements from overheating until the turbine is synchronized.
5.0 INCREASING THE LOAD
5.1 Starting Up the Fluid Bed Heat Exchanger
After the boiling point temperature in the FBHE water/steam systems has been
attained, the FBHEs are ready for start-up.
About 1/2 h before taking into operation of the FBHE with the evaporator
bundle a drain in the downcomer or evaporator inlet header should be opened
to ensure a proper circulation in the evaporation system guaranteeing a
sufficient cooling of tubes before coming in contact with hot ash.

Once ash circulation from the CFB combustor via the cyclone is established,
heating up of the FBHEs can be commenced. For this purpose, the FBHE
blower is started and the spiess valve is slightly opened (5 %) and the
temperature level of the FBHE ash is gradually raised.
Special care has to be taken not to start all FBHEs at a time. At starting any
FBHE blower there will usually occur a fast transfer of a large amount of ash
from the FBHE to the combustor, resulting in an increase of combustor ash
inventory and primary air pressure. Allow the primary air flow controller to
adjust the primary air flow as required.
As the fluid bed heat exchangers are being filled with ash after opening of the
spiess valves, the ash inventory of the CFB combustor will decrease again. If
required bottom ash from the bottom ash silo has to be fed to the CFB
combustor to maintain the actual p (excluding pressure loss of the nozzle
grates) across the CFB combustor above 150 mbar.
5.2 Increasing the Load above 50 %
When the boiler load has reached 50% the second P.A. Fan, S.A. Fan and ID.
Fan have to be started before the load can be increased further.
6.0 CFB SYSTEM
Operation Requirements
The CFB system serves the following functions:
Environmentally acceptable combustion of solid fuels and liquids in the CFB

combustor by staged combustion air addition thus ensuring suppression of
NOx formation and a high carbon burnout over the following load ranges:
Solid fuel firing 30 to 100 % load
Oil firing 0 to 45 % load
In-situ capture of the major part of the gaseous pollutants S02, HCI and HF
due to long retention time of the solid fuel and limestone in the system.
Maintaining of a constant temperature of 850°C in the combustor over a load

range from 50 % to about 100 % by controlling the ash flow to the fluid bed
heat exchanger via the spiess valve, thus ensuring:
a) an optimum temperature for reaction of the limestone with the SO 2, HCI and
HF, a temperature well below the ash softening.
b) Ensuring optimum conditions for heat transfer in the CFB combustor and

fluid bed heat exchanger (FBHE) over the entire load range by controlling the
ash recirculation rate, irrespective of whether solid fuels, oil or a solid fuel/oil
mix is being fired.
Preheating of the refractory-lined equipment through the circulating bed
material, which is preheated by oil burners when the system is started up from
the cold condition.
Mechanical Arrangement
The CFB combustor, cyclones, fluid bed heat exchangers and pertaining seal
pots form an integral system and constitute the main components of the
circulating fluidized bed combustion system.
In the CFB combustor, the lignite is burnt in an circulating fluidized bed. In the
process, the solid particles (ash), are continuously carried out of the
combustor with the flue gas. The flue gas leaving the combustor is routed to
the recycling cyclones where the solids are separated and returned to the
combustor via the fluidized seal pots. The seal pots provide a pressure seal
between the cyclones and the CFB combustor. The cyclone is operating with a
high collection efficiency. Only the fine ash particles are carried with the flue
gas into the convective pass.
These fine particles are collected in the electrostatic precipitators.
Part of the ash collected in the cyclones is drawn off via the spiess valves at
the seal pots and routed directly to the empty chamber of the fluid bed heat
exchangers. In the FBHE, the thermal content of the hot ash is put to the
effective use for steam superheating, reheating and steam generation. The
cooled ash is returned directly to the combustor.
6.1 CFB Combustor
The CFB combustor is rectangular. The downward tapering combustor bottom
section ensures an almost constant gas velocity (iso-kinetic conditions) over
the entire combustor height when applying staged combustion air supply. A
nozzle grate equipped with air nozzles forms the bottom of the CFB combus-
tor. The nozzles are arranged offset against each other. The nozzle grate and
the combustor bottom section up to a height of 9 m are pinned and lined with a
refractory castable to protect the tubes from the reducing atmosphere (air
deficiency).

The combustor has gas tight welded membrane-walls forming part of the
overall evaporator heating surface.
During full load operation (lignite firing), about 38 % of the total combustion air
is fed as primary air via the nozzle grate at the combustor bottom. The
remaining air - except the fluidizing air for the FBHEs, sealpots and ash
coolers - is fed as secondary air to the combustor. The secondary air enters at
the burner and the upper secondary air level to the combustor.
6.2 Nozzles
The nozzle grate forms the bottom of the CFB combustor. Each nozzle
consists of a nozzle tube provided with a cap to prevent ash spillage through
the grate. The object of the nozzles is to ensure optimum distribution of the
primary air over the combustor cross section, a prerequisite for stable
combustion.
The windbox of the nozzle grate is equipped with a windbox ash discharge
valve to permit the removal of ash particles which may enter the windbox
through the nozzles during plant start-up and shut-down. To a minor extent
this occurs also during normal operation, therefore the windbox for primary air
has to be drained regularly.
Excessive spillage during normal plant operation or start-up is indicative of
nozzle wear or damaged nozzle heads. In such a case, it is up to the plant
management to decide whether the plant should be shut down for nozzle
inspection.
If considerable spillage is observed during normal operation, an inspection
should be carried out as soon as possible as the accumulation of ash in the
windbox could lead to bad fluidization in the combustor and it poses an
increased risk of wear in the windbox.. Ash spillage during the start-up phase
is less critical and will noticeably decrease once stable operating conditions
are established (defined air flow through the nozzles). The back sifted ash
shall be drained once per day and after start-up.
6.3 Primary Air Supply
The preheated primary air is fed to the CFB combustor ensures:
the circulation of the bed material which is dependent on the velocity of the
primary air both on solid fuel firing and oil firing,
combustion under reducing conditions in the primary combustion zone in
complete combustion conjunction with the secondary air
The primary air is fed load-controlled to suit the requirements of material
circulation with regard to heat transfer in the CFB combustor (influence of the
solids circulation rate on heat transfer) and a sufficient ash supply to the FBHE
via the spiess valves
Primary air rate adjustment is accomplished by means of vane control of the
primary air fan.
6.4 Secondary Air Supply
For staged combustion secondary air is fed to the combustor at two secondary
air levels:
Level 1 (burners): 2 start-up burners
Level 2 (top): 6 injection nozzles
The secondary air is preheated in the tubular air heater and controlled in such
a way that a preset air to fuel ratio is attained in the CFB combustor.
6.5 Other Air Supply
Other air streams entering the CFB combustor and thus participating in the
combustion process are:
fluidizing air to ash coolers, fluidizing air to seal pots,
fluidizing air to FBHEs,
seal and purge air.
transport air for limestone feeding as part of the seal and purge air
These air streams are compressed in rotary piston blowers and injected into
the CFB combustor.
6.6 Total Air Rate
The total air rate is computed by totaling the rates of individual air streams. In
this connection it should be noted that air streams of rotary piston blowers, i.e.
seal pot blower, FBHE blower, ash cooler, seal and purge air blower are
included in the summation as a fixed value.
At 100 % MCR:
Primary air through nozzles 57.5 kg/s
Primary air through oil lances 0.6 kg/s
Upper SA- levels 59.1 kg/s
Burner level 19.7 kg/s
Fluidizing air of the FBHE's 5 x 2.1 kg/s
Fluidizing air of the seal pots 2 x 0.6 kg/s
Fluidizing air of ash coolers 2.1 kg/s
Seal and purge air for various purposes 1.8 kg/s
For combustor temperature monitoring, several thermocouples are provided
along the height of the combustor:
Lower combustor temperature: 4 thermocouples, at about 1.2 m above grate;
these measurements are hooked up to the interlock system and will trip the
lignite system if the temperature falls below 650°C and at 590 °C oil bed
lances will be tripped. In each case, the lower temperature reading of 3 in-
struments will cause the respective fuel system trips.
As the temperatures across the combustor may slightly differ from each other,
all combustor lower temperatures should not fall below 650°C during lignite
operation.
Combustor middle temperature: 4 thermocouples, installed at a level of about
6 m above the nozzle grate; these temperature measurements form part of the
interlock conditions for preheating operation. The load of the start-up burners
is controlled by this temperature.
During normal operation deviations of the combustor middle temperature from
the set point are corrected by modulating the spiess valves thus varying the
ash flow to the FBHE 2,3 and 4 . When the combustor middle temperature is
rising over the set point the spiess valves will open automatically, to increase
the ash flow to the FBHEs. As the ash is cooled in the FBHEs and returned to
the combustor, this leads to a decrease of combustor temperature. When the
combustor temperature is decreasing below the set point the spiess valves will
close automatically, to decrease the ash flow to the FBHEs. As the amount of
ash cooled in the FBHEs and returned to the combustor is decreasing, this
leads to an increase of combustor temperature.
Remark:
The temperature of the reheated steam after reheater 1 located in FBHE 1 is
controlled by the spiess position. This temperature is controlled independently
of the combustor temperature controlled by FBHE 2, 3 and 4.
Combustor outlet temperature: 2 thermocouples, installed at the flue gas duct
from the combustor to the recycling cyclones. During full load operation this
temperature will be about 850-870 °C. At lower loads and especially in the
load range where FBHE is not in operation anymore, this temperature will drop
below the combustor middle temperatures (reason: heat transfer to the
evaporator heating surfaces).
Cyclone outlet temperatures: this temperatures (6 thermocouples, three at the

outlet of each cyclone, should not exceed 950°C.
Falling below the minimum primary air rate of 16 kgls will automatically trip the
firing system.
6.7 Excess Air Ratio
The excess air ratio applied for lignite firing in the upper load range is about 20
%. Approx. 38 % is fed to the combustor as primary air via the nozzle grate.
During part-load operation below a load of 50 % the excess air rises to about
80 % at 30 % load. The excess air ratio will be automatically calculated as a
function of the load signal. Control of the excess air ratio is accomplished by
varying the lignite mass flow.
6.8 Temperatures in the CFB Combustor
Due to the high ash circulation rate in the circulating fluidized bed system and
the resulting excellent heat and mass transfer conditions, combustion
proceeds at a temperature level of about 850°C. Under full-load operating
conditions, there is a uniform temperature of 850 °C across the entire height of
the CFB combustor. In the load range from about 50 % to 100% this
temperature is effectively controlled via the ash flow to the FBHE, i.e. the ash
flow through the spiess valve.
At lower loads the FBHEs are out of operation and combustor temperatures
fall accordingly.
During normal operation a combustor middle temperature of about 850°C is
controlled by means of spiess valves, thus ensuring optimum capture of the
sulfur by the limestone additive and minimum NOx formation.
In no case the flue gas temperatures should exceed 950°C in order to remain
clearly below the ash softening point. Due to the temperature rise occurring in
the cyclone (post-combustion effect), the cyclone outlet temperature is critical
and the Boiler Protection 1 will be activated when this temperature exceeds
950°C.

Within the load range of 50 % to 100 %, i.e. the FBHEs are in operation and
the combustor middle temperature is roughly constant. At loads below 50 %
the combustor temperature will drop with the load and the temperatures in the
combustor decrease towards the combustor top.
temperature at full load is higher than the combustor outlet temperature and
drops with decreasing load below the combustor middle temperature. The
temperature rise due to post-combustion is in the range of about 20°C to 50
°C at full load; at lower loads, it is clearly below this level.
6.9 Differential Pressure and Pressure Profile across the CFB Combustor
The differential pressure across the CFB combustor is measured and
indicated at four points:
P combustor with grate, with one measuring point being provided in the
primary air line upstream of the windbox and the other at the combustor top.
Accordingly, the p combustor with grate shows the total of the following
pressure losses:
- primary air inlet and windbox,
- nozzle grate and
- combustor, consisting mainly of the solids inventory.
P combustor total, is a calculated value. It is derived from the measurement
P combustor with grate and corrected by the pressure loss of the windbox
and nozzle grate which will be measured during commissioning. Hence the p
combustor total is indicating the pressure loss of the combustor, which is
mainly the pressure loss due to the solids inventory of the combustor. There-
fore this pressure is used to control the ash discharge via the combustor
spiess valves to the ash coolers to maintain a good operation performance
over the whole load range.
P combustor at SUB-level with one measuring point arranged at about 2 m
above the nozzle grate. Hence, the P combustor at SUB-level is indicating the
total pressure at height of the burners and ash return ducts:
P combustor upper, with the upper tapping at the combustor top, at about
26m above nozzle grate, and the lower tapping at about 14m above nozzle
grate. The P combustor upper is indicating the total pressure drop across the
water wall, giving an indication on the amount of ash carried by the flue gas at

the combustor top. Hence this parameter is a reference for the ash circulation
rate. A low P in this area shows of a low ash circulation rate, a high P
indicates a high ash circulation rate.
The P value recommended for normal operation at MCR is about 4 mbar. It is
falling when the load is decreased.
Solids Inventory
The solids inventory of the combustor is changing with the boiler load due to
the storage capacity of seal pots and FBHEs. When the boiler load is
increased to MCR conditions the flow of ash through the seal pots and through
the FBHEs is also rising. This is leading to a higher level of ash in the seal
pots and FBHEs. Thus these are storing some of the circulating ash which
results in a decrease of solids inventory in the CFB combustor.
When the load is decreased to minimum, the level of ash in the seal pots and
in the FBHEs is going down again to the minimum levels. Hence the ash is
returning to the combustor resulting in an increase of solids inventory and p
combustor (total).
Care should be taken to ensure that the p combustor (total) stays always
within the range.
P combustor (total) min. 100 mbar at MCR
max. 220 mbar at minimum load
Exceeding the range for p combustor (total) should be avoided at any time by
discharging ash from the CFB-system to ensure proper fluidization of the bed
material. If the p combustor (total) exceeds the given range the pressure of
the primary air could rise the design limits of the primary air fan which could
lead to unstable air supply and bad fluidization
If the p combustor (total) falls below about 80 mbar , the ash bed will become
so dilute that uniform temperatures across the combustor can no longer be
maintained and plant operation becomes unstable. In this case bed material
has to be added to the combustor from the bed material silo.
Having a constant p combustor (total) while the p combustor upper and P
combustor at SUB-level are decreasing, is an indicator for coarsening of the
bed ash in the combustor bottom section due to lumps, stones or coarse ash

introduced with the lignite feed. In this case ash from the combustor should be
extracted only via the combustor spiess valve and not via the FBHE spiess
valve. Furthermore the lignite crusher setting should be checked.
The coarsening of bed ash is a gradual process, and there is sufficient time to
take corrective action.
CAUTION
The CFB combustion system is operated at a certain overpressure and at high
temperatures. Therefore it should never be attempted to open any devices
(manholes, inspection openings, connecting lines, clean out openings,
instrument elements etc.) during operation of the fluidization system due to
safety reasons. Opening of any device is only permitted once the entire
system has been proven to be pressure less. Violation of this caution may lead
to leaking of hot flue gases and ash to the surrounding area or environment
which may result in serious damage of equipment or severe injuries to
operating or maintenance personnel.
6.10 Recycling Cyclones
General
The hot, ash-laden flue gases leave the combustor top through the side walls
and enter the recycling cyclones. The recycling cyclones are completely
refractory lined vessels consisting of a cylindrical top section and a conical
bottom section tapering downward.
The recycling cyclone collects nearly all ash particles from the flue gas. This
circulating ash is returned to the combustor via the seal pots. Only a fraction of
fine ash particles is leaving the cyclone together with the flue gas. Sealing of
the recycling cyclones against the pressurized combustor vessel is provided
by the seal pots located in the ash return line from the cyclone to the
combustor. The vortex finder installed at the gas outlet of the recycle cyclones
effectively improves solids separation and hence material circulation and
solids management of the CFB -system.
Post Combustion
When firing lignite, the temperature of the flue gas will rise by passing the
cyclone due to the post-combustion of unburned carbon contained in the ash
particles. Care should be taken to ensure that the maximum temperature
downstream of the recycling cyclone outlet does not exceed 950°C.
Temperatures above this level will cause a trip of fuel and combustion air
systems.
6.11 Seal Pot
The water cooled seal pots with an erosion resistant lining, downstream of the
recycling cyclones are fluidized with air and are ensuring a pressure seal be-
tween the recycling cyclones and the CFB combustor.
The ash discharged from the cyclones is returned via the seal pots to the
combustor. A branch stream of the ash is flowing from the seal pots via the
spiess valves to the fluid bed heat exchangers. The ash rate is controlled by
the spiess valves located at the seal pots depending on boiler load and
combustor temperature.
For emptying the seal pot wind box from ash spillage through the fluidizing
nozzles, wind box drain valves are provided.. These valves should be
operated at regular intervals, at least once per day.
The seal pot fluidizing air is supplied by the seal pot blowers, to the two legs of
a seal pot. The air rates to the individual seal pot legs can be adjusted by
means of locally operated dampers, however, they stay fully open during
normal operation.
Air distribution to the nozzles is accomplished by wind boxes located

underneath the seal pots.
6.12 Fluid Bed Heat Exchangers
The fluid bed heat exchangers are arranged downstream of the recycling
cyclones and supplied with ash via the spiess valves from the seal pots.
The FBHEs have water-cooled membrane walls, refractory lined in the bottom
area, and consist of the following 2 chambers which are separated from each
other by weirs:
Chamber 1: empty chamber to steady the ash flow entering the FBHEs,
Chamber 2 : chamber equipped with a bundle:

FBHE 1 has a reheater bundle, RH 1
FBHE 2 has a superheater bundle, SH2B.
FBHE 3 has a superheater bundle, SH2A
FBHE 4 has an evaporator bundle.

In the chambers the ash is fluidized by means of a constant airflow admitted
via nozzle grates supplied by rotary piston blowers. As the ash is passing
through the FBHEs, the ash is cooled down.
The four empty chambers have one common rotary piston blower. The
fluidizing air flow rate to the empty chambers can be adjusted by dampers.
Care should be taken to ensure that the air rate per empty chamber does not
fall below a minimum value of 0,45 kg/s for proper fluidization.
The temperatures in the individual chambers are monitored. Should the
temperature in one chamber drop while all other operating parameters remain
constant, the fluidizing air supply has to be checked.
If the temperature in the empty chamber is decreasing, check also the ash
discharge via the spiess valves. If the ash flow is poor or if there is no ash flow
at all, open and close the spiess valve once and set it back to its original
position.
Every rotary piston blower is equipped with a safety valve to protect the blower
from high pressure. If the safety valve of the blower for the empty chambers
responds during operation, check the position of the dampers and the
fluidizing air rates and open the dampers to bring the fluidizing air pressure
back to normal values. Opening of the safety valves during operation due to
high pressure should be avoided at any time.
Start-Up
The blower for the fluidization of the empty chamber will be started after the
primary air fans. To put a FBHE into operation, the blower for this FBHE has to
be started to fluidize the bundle chamber. Then the spiess valve has to be
opened slowly while observing the temperature rise in the empty chamber and
the bundle chamber. Thus the FBHE is heated up slowly. When the spiess
valve is opened, the FBHE starts to store some of the circulating ash which
leads to a decrease of combustor inventory and p combustor (total).
About half an hour before the FBHE 4 with the evaporator bundle will be put
into operation the bundles should be heated up by draining the downcomer or
inlet header to ensure proper circulation and sufficient cooling of the bundle
tubes when they come in contact with hot ash.
For emptying the FBHE windbox from ash spillage through the fluidizing

nozzles, windbox drain valves are provided. These valves should be operated
at regular intervals, at least once per day.
6.13 Abnormal Operation
A sudden pressure drop of the ash inventory in the combustor, ( P
combustor)' or a pressure increase of the pressure at the bottom of a cyclone
are an indication, that a cyclones is probably blocked. Additional indications
are low pressure of the seal pot fluidizing air and falling temperatures in the
seal pot. Having this situation the boiler shall be tripped to avoid overfilling of
the cyclones.
For further abnormal operations see also section "Operating Upsets".
7.0 WATER / STEAM SYSTEM

Process Description
Operation Requirements
The circulating fluidized bed boiler operates according to the natural circulation
principle.
The water flow path is shown on the schematic flow diagram for the water and
saturated steam circuits.
The economizer - evaporator - superheater - reheater system serves the
following functions:
1. Withdrawal of the amount of heat from the different areas in the CFB
system as required to achieve:
- a flue gas temperature of about 870°C at the CFB outlet,
- a flue gas temperature of about 285°C at the outlet of the convective
pass
- an ash temperature of approx. 550°C at the FBHE outlet.
2. Heating up of the feedwater, with an economizer inlet temperature of
235° C, and generation of SH- and RH-steam at a constant
temperature of 540°C over a broad load range.
3. The HP Bypass shall cool safely the reheater system during station
black-out, startup, turbine trip, etc.
4. Withdrawal of the residual heat:
- on normal shutdown of the boiler system or

- on power failure/black out .
In this case the boiler is supplied by the emergency BFW pump.
The water/steam system consists essentially of the following equipment:
- Economizer
The economizer is located below the horizontal low-temperature superheater
assemblies, in the lower section of the convective pass (backpass). It is
composed of banks of parallel bare tube elements, arranged in horizontal rows
in such a manner that each row is in parallel with the row above and below. All
tube circuits start at the inlet header and terminate at the economizer outlet
header.
- Steam Drum
The steam drum is partly bottom supported and standing on the main
downcomers, located beside the combustor. The balance weight of the drum
is carried by constant load hangers.
- Evaporator
The evaporator consists of
- the evaporator bundles in the FBHE 4
- the water-cooled membrane walls of the combustor, FBHEs and seal pots
The membrane walls are welded gas-tight, stiffed with buckstays and partly
refractory lined for insulation and erosion protection.
- Superheaters
The superheater is composed of three basic stages or sections:
a low-temperature section as
steam cooled hanger tubes for bundle support in the backpass
membrane wall of the convective pass and
SH I bundle, located above the economizer in the convective pass
the medium-temperature sections SH2A located in FBHE 3,
the medium-temperature sections SH2B located in FBHE 2,
a finishing, high-temperature section SH3 in the convective pass,
- Reheaters
The reheater is composed of two basic stages or sections:
a low-temperature section as RHI bundle located in a FBHE 1

a finishing, high-temperature section as RH2 bundle located in the convective
pass between SH 3 and SH I bundles
- Spray Type Attemperators
Three spray type attemperators are provided for maintaining the related steam
temperature:
The first is installed in the connecting line between low-temperature

superheater (SHl) and FBHEs (SH2A & B). Steam enters the superheater
attemperator from the outlet header of the low-temperature superheater and
passes on to the inlet header of FBHE.
The second is installed in the connecting line between FBHE and high-
temperature superheater. Steam enters the superheater attemperator from the
outlet header ofFBHE 2 and passes on to the inlet header of the high-
temperature superheater (SH3).
The third is installed in the connecting line between reheater 1 in FBHE 1 and
reheater 2 in the backpass. Steam enters the reheater attemperator from the
outlet header of reheater 1 and passes on to the inlet header of the reheater 2.
Normal Operation
Economizer
Feedwater enters the boiler through the economizer, and is mixed with boiler
water in the steam drum. The function of the economizer is to preheat the
boiler feedwater before it is introduced into the drum by recovering some of
the heat of the flue gases leaving the combustor. The feedwater flow through
the economizer is upward in countercurrent with the hot flue gas. This ensures
efficient heat transfer.
Feedwater is supplied to the economizer inlet header via boiler feedwater stop
valve, check valve and feed water control valves for full load and low load
valve for part load. Please note that the boiler feedwater pumps should not be
started having the boiler feedwater isolation valves, the manual valves or the
boiler feedwater stop valve closed.
To avoid steaming of the economizer and to receive a quick temperature
increase of the flue gases beyond the due point during start-up, a economizer
recirculation line is installed. During normal operation the shut off valve, will be

closed. Only during start-up with cold boiler feedwater the economizer
recirculaion line could be opened.
Steam Drum
The steam drum supplies the evaporator with water via the downcomers and
separates the water and steam returning from the evaporator. The steam
leaves the drum to the superheaters.
It is of utmost importance to keep the drum level within the normal range to
guarantee sufficient cooling for the evaporator. The drum level is controlled by
the feedwater control valves. If the drum level is falling below the minimum
level the boiler will trip
If the drum level is rising above the maximum level, the emergency blow down
drain will be opened automatically and the boiler feed water flow must be
reduced manually. If the drum level is rising further, the boiler feed water
supply must be stopped manually to avoid carry-over ftom water in the
superheaters.
- Continuous Blow Down
Continuous boiler blow down is used as means of controlling boiler water
quality (solids and alkalinity). The frequency and quantity of continuous
blowdown should be adjusted according to the quality of boiler water and
boiler feed water.
Evaporator
The evaporator is composed of different sections, supplied with water from the
drum via several downcomers to the lower evaporator headers. The lower
headers assure proper distribution of the water to the evaporator sections.
Several water flow paths exists parallel to the combustor water walls as the
FBHEs and seal pots are also water cooled with membrane type walls.
From the lower headers of the combustor, the water rises through the upper
combustor waterwall tubes, being heated up in the process. The plenum grate
tubes, front wall tubes, rear wall tubes, and side wall tubes, form parallel flow
paths. The resulting mixture of water and steam is collected in the waterwall
outlet headers and is discharged into the steam drum through the riser tubes.
Separate downcomers for the fluid bed heat exchanger (FBHE) supply water
to the FBHE inlet headers, through the FBHE walls and the evaporator bundle

in FBHE 4, to the FBHE outlet headers, through the FBHE riser tubes to the
steam drum.
During normal operation the evaporation in the evaporator bundle in FHBE 4 is
controlled by the amount of hot ash passing through the Spiess Valve for
FBHE4. The Spiess Valve position is adjusted according to the main steam
flow. Furthermore the Spiess Valve is controlling the combustor temperature
together with the Spiess Valves for the FBHE 2 and FBHE 3.
As this boiler has a water cooled and integrated seal pot the seal pot has its
own, separate seal pot downcomers which supply water to the seal pot inlet
headers, through the seal pot assemblies, to the sealpot outlet headers,
through the sealpot riser tubes to the steam drum.
- Start-up
Before a FBHE is put into service and the spiess valve is opened, care has to
be taken to insure that the water in the FBHE evaporator system (FBHE-walls
and FBHE evaporator bundle) has reached boiling temperature. This is
required to ensure proper water circulation and sufficient cooling of the tubes
once they come in contact with hot ash.
Therefore the drains of the FBHE evaporator system should be opened about
1/2 h before the FBHE is fed with hot ash, to drain the cold water and fill the
FBHE evaporator with hot water from the drum.
Superheater
The course taken by steam from the steam drum to the superheater finishing
outlet headers is shown on the Schematic Flow Diagram for the superheater.
The main steam route from steam drum to main steam line is as follows:
- backpass hanger tubes in backpass (SH1) - backpass walls in backpass
(SH1)
- L T SH bundle in backpass (SH1)
- Attemperator 1 for temperature control - MT SH bundle in FBHE 3 (SH2A)
- MT SH bundle in FBHE 2 (SH2B)
- Attemperator 2 for temperature control
- HT SH bundle in backpass (SH3)
Superheated steam from the final superheater flows to the turbine via the main
steam line. During turbine trip the SH steam flows via HP-Bypass to the RH
system.
Sufficient cooling must be provided for the superheater elements as long as
there is fire in the combustor. This is especially important during periods when
the turbine is not in operation like start-up and shut-down. During these
periods care has to be taken to adjust a minimum steam flow through the
superheater by the HP-bypass valve.
The boiler pressure is controlled by the HP-bypass valve during start-up and
shut-down and by the turbine during normal operation. Care has to be taken to
keep the pressure gradient for the superheater always within the permitted
limits.
To keep the pressure of the HP system within the limits, safety valves on the
superheater main steam line with set point below the low set point of drum
safety valve are provided.
The HP-bypass valve has the task to take over the steam from the turbine and
to control the steam pressure, in case of turbine trip. As the HP-bypass valve
has only a steam flow capacity equivalent to 60% boiler load, two SH-Start-up
vent valves on the superheater main steam line are provided .In case of a
turbine trip at loads higher than 60% they take the balance steam flow and
control the HP steam pressure, thus avoiding actuating of the HP safety
valves. As the reheater needs cooling during turbine trips the HP-Bypass shall
be opened with priority, whereas generally actuation of safety valves and SH
vent valve shall be avoided.
- Spiess Valves
During normal operation the heat transfer to the SH2A bundle in FHBE 3 is
FBHE3. The heat transfer to the SH2B bundle in FHBE 2 is controlled by the
amount of hot ash passing through the Spiess Valve for FBHE2.
The Spiess Valve position is adjusted according to the boiler load.
Furthermore the Spiess Valves are controlling the combustor temperature
together with the Spiess Valve for FBHE 4. In addition to this, the Spiess Valve
for FBHE 3 is also controlling the SH2A outlet temperature and the Spiess
Valve for FBHE 2 is also controlling the SH2B outlet temperature.
- Start-up
During start-up superheater and main steam lines have to be vented and

drained.
The drain valves and vent valves near the turbine should be opened, too, to
provide additional steam flow and to drain and warm the main steam line prior
to turbine rolling.
For a cold start-up care has to be taken for proper venting and draining of the
superheaters.
During start-up the superheater vents should be kept open until about 2 bar(g),
with the HP-Bypass open. Above 2 bar(g) the superheater vents may be
closed, and the HP-Bypass and the RH start-up vent valve are controlling the
system pressure and the steam flow through the SH and RH system. They are
kept open until the turbine is under light load. The HP-Bypass valve may be
throttled to increase drum pressure, providing a sufficient steam flow through
the superheater is assured at all times.
Reheater
The reheat steam route is as follows:
- L T RH bundle in FBHE 1 (RHI)
- Reheater Attemperator for temperature control
- HT RH bundle in backpass (RH2)
Reheated steam from the finishing reheater flows to the turbine via the steam
line. The reheat steam temperature is controlled by the FBHE solids flow
(spiess valve). Only during load changes a small amount of de superheater
spray water is injected at the reheater desuperheater located between the two
reheater sections.
During turbine trip the depressurized and attemporated steam in the HP-
Bypass flows through the RH system either via LP-Bypass to condenser or via
RH start-up vent valve to atmosphere, which is to be opened in case of trip or
overflow of LP-Bypass.
As long as there is fire in the combustor, adequate cooling must be provided

for the reheater elements in backpass and FBHE. This is especially important
during start-up and shut-down. During these periods adequate flow through
the reheater is assured by HP-Bypass.
To ensure steam flow through the RH system the main steam stop valve, has
to stay always open, because the tapping point for the HP-Bypass is located

downstream of the stop valve. Closing of the main steam stop valve would
lead to a starving of steam of the reheater system causing severe damages or
destruction of the reheater bundles at higher temperatures.
Safety valves on cold reheater steam line have a set point above the low set
point of safety valves provided at the hot end are only for emergency cases for
RH protection against overpressure.
- Spiess Valves
During normal operation the heat transfer to the RHI bundle in FBHE 1 is
FBHE I. The Spiess Valve position is adjusted according to the main steam
flow. Furthermore the Spiess Valve is controlling the RH I outlet temperature.
- Start-up
During start-up reheater and main steam lines have to be vented and drained.
The drain valves and vent valves near the turbine should be opened, too, to
provide additional steam flow and to drain and warm the main steam line prior
to turbine rolling.
During start-up the reheater vents should be kept open until about 2 kg/cm 2(g),
with the RH start-up vent valve open. Above 2 kg/cm2(g) the reheater vents
may be closed, and the RH start-up vent valve is controlling the system
pressure. The steam flow through the RH system is controlled by the HP-
Bypass valve. The RH start-up vent valve and the RH start-up vent isolation
valve are kept open until the turbine is under light load.
The RH vent valve may be throttled to increase reheater pressure, providing a

sufficient steam flow through the reheater is assured at all times.
During start-up the LP-Bypass valve may be used as an alternative for the RH
start-up vent valve, if RH steam can be passed to the condenser.
Attemperator
Attemperators are provided in the superheater and reheater connecting line to
permit reduction of steam temperature when necessary to maintain the
temperatures at design values within the limits of the nozzle capacity.
Temperature reduction is accomplished by spraying water into the path of the

steam through a nozzle at the attemperator inlet. The spray water comes from

the boiler feedwater system. It is essential that the spray water is chemically
pure and tree of suspended and dissolved solids, containing only approved
volatile organic treatment material, in order to prevent chemical deposition in
the attemperator and carryover of solids to the turbine.
CAUTION:
To gain proper evaporation of the spray water the attemperator outlet
temperature should be kept always at least 10°C above the saturation
temperature of the steam at the actual operating pressure.
- Control Valve
A control valve linked to closed loop steam temperature control regulates the
spray water flow supplied to each attemperator. During normal operation the
DCS takes care of this measure also during station blackout as DCS and the
block isolation valves are both linked to UPS. Motorized block valves are
installed in the supply line to each attemperator control valve as an additional
shut-off valve. The block valves are interlocked to be closed if the steam
temperature is falling below the evaporation temperature.
Spray water for the superheater attemperators is taken from boiler feed pump
discharge.
HP-bypass
During start-up, operation upsets and turbine trips the HP-bypass will open to
guarantee at all circumstances a flow of desuperheated and depressurized
steam through the reheater system for cooling purposes. The HP-bypass
prevents also the opening of the HP safety valve by limiting the boiler
pressure, thus ensuring always a sufficient steam flow through the reheater
system.
Abnormal Operation Low Water Level
There is a low drum level alarm and low drum level boiler trip.
If the feedwater pumps are not available for service, the emergency diesel
feedwater pump should be put in service.
When feed water is once again available and the operator is assured that no
pressure parts have been damaged, the flow of feedwater to the boiler should
be slowly increased (never rapidly increased) by manual regulation. The
purpose of handling the feed in this manner is to avoid quenching pressure

parts with relatively cold water by raising the water level and on the other
hand, to avoid overheating additional pressure parts.
High Water Level
If the drum level is rising above the maximum level, the emergency blow down
drain will be opened automatically and the boiler feed water flow must be
reduced manually. If the drum level is rising further, the boiler feed water
supply must be stopped manually to avoid carry-over from water in the
superheaters.
Operators should be alert to detect the symptoms of water carry-over from the
boiler and introduction of water into the turbine, such as:
A. A sudden unexplained drop or fluctuation of the steam temperature in the
main steam lines,
B. Vibration in the steam piping resulting from water hammer or
C. Abnormal vibration and differential expansion readings from the turbine

supervisory instrumentation.
Operators must be prepared to take the actions necessary to prevent turbine
damage upon detecting the introduction of water. Refer to the turbine
manufacturer's instructions for measures to be taken.
Loss of Power Station Blackout
Upon a loss of all electrical power, the main turbine stop valves will close and
the HP-bypass will open immediately together with the RH start-up vent valve.
The emergency boiler feedwater pump will be put into service automatically to
maintain drum water level.
Initially, the required BFW feed rate will be about 15 % of the feed rate at full
load conditions. As the system cools down, the BFW feed rate can be reduced
subsequently later, always keeping the normal drum level. Only when the
temperature in the combustor has dropped below 450°C and the drum level is
on the normal level, BFW feeding can be stopped.
The HP-Bypass is operated for depressurizing slowly the SH system. The

purpose of depressurizing the SH-system is to cool the backpass
superheaters and reheaters which receive radiation from the hot refractory of
the cyclone outlet duct.to cool the superheater and reheater bundles located in

the FBHE, as there heat penetrating from the hot ash to the bundles.
A superheater depressurization rate of about 7-10 bar/h should be followed
until the flue gas temperaure at combustor outlet falls below 450°C.
Tube Damage - General
It should be noted that tube damage is not easy to detect unless major
feedwater or steam leakage occur. Whenever there is reason to suspect tube
damage, the shift supervisor shall be informed and the corrective action
coordinated. Please refer to Chapter Operation Upsets for details regarding
leak detection and emergency procedures.
8.0 LIGNITE FEEDING SYSTEM
8.1 Operation Requirements

The solid fuel feed system serves the following functions:
Feeding of the crushed fuel to the CFB combustor as a function of the load.
8.2 Process Description
The solid fuel feed system serves the following functions:

Feeding of the crushed fuel to the CFB combustor as a function of the load.
The lignite feeding system consists essentially of the following equipment:
two lignite bunkers
two emergency outlets
each bunker is provided with shut-off gates to enable bin shut-off for repair
work,
two solid fuel discharge conveyors
two rotary air lock feeder two provide a pressure-tight seal against the feed
points and
two master fuel trip valves
8.3 Normal Operation Lignite Bunker
The bins are fed with run-off-mine lignite already crushed to a maximum
particle size of 15 mm. Each bin is equipped with one discharge cone,
provided with 5 shut-off gates to enable bin shut-off for repair work. A
minimum seal leg of about 3 m is required. If the corresponding weight is lower
than a minimal value (about 25 t), the feed line is automatically tripped.

To ensure proper bin filling, the discharge position of the reversing conveyor is
to be varied so as to uniformly distribute the lignite over the entire bin cross
section.
The lignite feeding trains can be started if the lower and middle combustor
temperature is above 700°C and boiler protection level 3 is not activated.
Further it is to guarantee that the oxygen content of the flue gas measured in
the backpass stays above 1 %. Otherwise all fuel feeding systems will be get
tripped.
8.4 Solid Fuel Discharge Conveyors
Solid fuel discharge conveyors (troughed chain conveyors) withdraw the solid
fuel from the bins and carry it on their upper strand to the reversing pulley from
where it is transported on the lower strand in the opposite direction. The lignite
is uniformly discharged into the feed chute to the rotary valve. The height of
the material layer in the upper strand, which will be determined in the course
of plant commissioning, is adjusted and indicated locally (basic position - 160
mm). If the solid fuel feed rate has to be re-adjusted during operation, this is
exclusively done by synchronous resetting of the conveying speed of all
troughed chain conveyors. The solid fuel extraction chain conveyor is powered
by a frequency-controlled motor. Control and monitoring systems are provided
for: the height of the material layer on the solid fuel discharge conveyor, the
chain tension in the form with inductive proximity switches on the take-up
units, zero speed monitoring and the speed at the take-up shaft.
Crushing of the solid fuel is needed to ensure a particle size distribution as
required for the CFB combustor:
Medium size fraction
D50 = 800 - 1000 µm
8.5 Rotary Air Lock Feeder
The rotary air lock feeder provides a pressure seal and a protection against
flashback.
The rotary air lock feeder is controlled by a two speed motor. It switches to fast
speed if the solid fuel discharge conveyor is working with more than 60 % of
his capacity and will switch to slow speed if the solid fuel discharge conveyor

is working with less than 40 % of his capacity. If there is any blockage in the
rotary air lock feeder the whole lignite train is stopped. Then an operator can
try to remove the blockage by reversing shortly the direction of rotation from
the DCS. After removal of the blockage the lignite train can be started again.
The rotary valve has three separate purging air loops:
Loop I leads to the angular air spaces at the shaft seals. It is to prevent
ingress of lignite breeze which may leads to premature of the seals.
Loop II purges the side walls of the rotor. It is to prevent lignite from getting
between the walls of the rotor and those of the casing in order to forestall
caking and possible freezing.
Loop III leads to the rotor pockets at the shaft level. It is to ensure that gases
cannot get from the combustor into the lignite conveying system upstream of
the rotary valve.
In case of a trip of the seal and purge air blower the coal feeding lines shall be
tripped and the lignite gate valves closed to avoid overheating of the rotary
valves.
8.6 Master Fuel Trip Valves (Lignite gate valves)
The master fuel trip valves are cooled by purge air. This is to ensure a proper
protection against the temperature of the circulating ash of up to 850 °C.
Maintenance of one coal feeding line during operation of the CFB boiler is only
allowed if the lignite feeding line is isolated by positive means from the boiler.
8.7 Safety Equipment
To ensure a pressure seal of the lignite trains against the CFB combustor and
to protect the same against a flashback, a rotary air lock feeder as well as an
electrically actuated master fuel trip valve are arranged upstream of the line at
the seal pot under the recycling cyclone.
During lignite operation with the master fuel trip valve open, the rotary air lock
feeder in conjunction with the seal and purge air feeding via the limestone
feeding line is acting as a pressure seal.
The master fuel trip valve is closed in the following cases:
1. during trip of boiler or
2. lignite feeding lines are not in operation.

In case of a trip of the seal and purge air blower the lignite feeding lines shall
be tripped to avoid overheating of the lignite feeding system, especially of the
rotary airlock feeder.
In case of a fire in the extraction chain conveyors the bunker gate valves shall
be closed first and it should be tried to empty the burning lignite via the air lock
feeder in the boiler. If the disposal of the burning fuel in the boiler is not
possible the fire shall be extinguished with huge amounts of water or
alternatively with nitrogen supplied for example from gas bottle feeds via the
tapping points in the conveyor. In all cases of fire the fire service shall be
informed immediately and the relevant safety rules shall be obeyed.
In case of fire in the lignite bunker the bunker gate valves shall be closed first
and the operation personnel shall flood immediately the bunker with water to
extinguish the fire. Afterwards the mixture of water and lignite shall be drained
via the emergency outlet to the ground. It shall be avoided to feed the wet
lignite/water-mixture to the boiler.
Before revisions or longer shut downs the extraction chain conveyors shall be
emptied completely to avoid difficulties during start-up due to sticky lignite.
Therefore the bunker gate valves can be closed during operation and the
extraction chain conveyors will stay in operation until the chain conveyors are
completely empty. Depending on the speed it may take up to 16 minutes to
clean the lines completely.
In case of a trip of one lignite line, the other lignite line will automatically take
over the duty of the tripped one to keep the load constant.
If there is a blockage in the rotary air lock feeder, it is possible to reverse the
direction of rotation. By changing the rotation direction of the rotary air lock
feeder for a short time, the rotary air lock feeder blockage can possibly be
removed.
In case the lignite lines should be emptied fully, it will take, depending on the
load about 10 - 15 minutes for clearing the lignite lines after having closed the
bunker shut - off gate valves.

8.9 Analysis of the Lignite
Proximate Analysis of the Lignite for Guarantee (as received basis)

Moisture % 39.13
Ash % 26.11
Fixed carbon % 16.50
Volatile matter % 18.26
Gross calorific value kcal/kg 2600

Ultimate Analysis of the Lignite for Guarantee
Moisture % 39.13
Ash % 26.11
Carbon % 26.50
Hydrogen % 1.91
Sulphur % 0.80
Nitrogen % 0.51
Oxygen (by difference) % 5.04
At normal operation the rotary valve is operated at low speed. Only in case of
a trip of one lignite line the high speed mode will be envisaged. Preferred
mode of operation is 2 x 50 % per lignite train.
9.0 SOOT BLOWER SYSTEM

The flue gas, leaving the cyclones, seal pot and FBHE, is dust loaden. This fly
ash is very fine and therefore hardly able to trickle. Therefore, deposits of
loose dust are to be expected on the heating surfaces of the convective pass
and the air preheater.
For cleaning of the heating surfaces of the convective pass and of the air
preheater, there are sootblowers provided. All blowers are provided with an
electric drive. Steam is used as blowing medium.
9.2 Mechanical Arrangement
The sootblower system consists essentially of the following equipment:
Manual shut-off valve,
Motor operated shut-off valve,

Sootblower steam control valve,
A safety valve,
Soot blowers with electric drive in the convective pass,
Soot blowers with electric drive at the air preheater
Two motor operated valves, and non return flaps,
9.3 Normal Operation
The purpose of the soot blowers is to clean the heat transfer surfaces in
backpass and airheater ensuring an economic flue gas temperature within
design range and a low CO content in the flue gas. This is to keep the overall
efficiency of the boiler.
Normally the operators shall run the soot blowing programme once or twice
per shift or when exceeding a flue gas temperature of 145°C. The soot
blowing intervals are depending on the load. At least once per shift (8h) the
soot blowing program shall be run.
The soot blower steam is taken behind superheater 1. By opening the motor
operated shut-offvalve, and the manual shut-offvalve, the steam line to the
sootblowers is open. The soot blower steam control valve, is reducing the
steam to the required pressure. The steam is fed to two separate lines, one to
sootblowers in the convective pass, and one to the sootblowers in the air
preheater.
The sootblower system is pressure and temperature controlled and is
equipped with a safety valve.
Every sootblower sequence begins with the preheating of the steam line
system. The sootblowers have a top to bottom sequence; first backpass and
then airheater.
If the steam pressure is high enough, the motor operated valves at the end of
each sootblower line, are opened. Now the steam can heat up the system.
If the temperature, measured in backpass sootblower steam drain, is high
enough, the motor operated valves will be closed. Now, the steam is in a slight
superheated condition and sootblowing of the backpass can begin.
If the temperature, measured in airheater sootblower steam drain , is high

enough, the motor operated valves will be closed. Now, the steam is in a slight

superheated condition and sootblowing of the airheater can begin.
After sootblowing the motor operated valve, is closed and so the steam line is
closed.
For drainage, there is a bypass at the at the end of the sootblower lines. The
condensation water is led to the drains and vented by lines.
In case of failure of the steam system or during station black out all
sootblowers are to be extracted either manually or automatically to avoid
overheating of sootblowers.
In case of an operation upset the cooling media as steam or air shall not be
stopped when the sootblowers lances are inserted to avoid overheating.
During plant shut-down sootblowing shall be performed to facilitate the
inspection of the backpass and air prehater now widely ash deposit tree.
10.0 BED ASH SYSTEM

The bottom ash system serves the following functions:
1. Intermittent discharge of the bottom ash from the CFB combustor in the
case of an unpermissible p-increase on solid fuel firing
2. Emptying of the CFB system to permit the plant to be entered for
inspection.
3. Cooling down of the bottom ash to 150°C under normal conditions, in
the second chamber of the ash cooler by means of cooling water. The
cooling water rate to the ash coolers is being controlled by the water
outlet temperature.
4. The coarse ash is cooled in the first chamber using fluidizing air as a
cooling medium.
5. The fluidizing air is directly returned to the CFB combustor via the
venting line serving as part of the combustion air (secondary air).
6. Manual and periodical extraction of the coarse particles by the bottom
drains of the ash cooler.
The bed ash discharge system consists essentially of the following equipment:
two combustor spiess valves,
one FBHE spiess valve, controlling the ash flow from FBHE 2 to ash
cooler 2,
two independent ash coolers, each having a vent line to the combustor,
and manual bottom drains,
the ash cooler 2 has two ash feed ducts, one from the combustor, and
one from FBHE 2,. FBHE 1 has only one ash feed duct from the
combustor,
one rotary piston blower for fluidizing each ash cooler,
one airlock feeder (rotary valve) for each discharge train, for dosing
ash to the ash handling system and sealing purposes.
10.3 Bed Material Feeding
The bed material feeding system is placed between the bed material silo and
the combustor.
It consists essentially of the following equipment:
bed material silo
manual shut -off gate, air lock feeder
pneumatic shut-off valve
pneumatic shut-off valve for seal and purge air
ash feeding pipe
The individual ash discharge route can be selected as required. The ash
discharge train with ash cooler 2 should be preferred having two ash inlet
ducts, one from the FBHE 2 and one from the combustor. The circulating ash
from the FBHE has a temperature of about 500°C instead of 850 °C as the
combustor bottom ash. Hence the overall efficiency of the CFB system can be
increased by mixing circulating and bottom ash thus reducing also the
demand of cooling water.
Extraction of the coarse ash from the combustor, about 26 t/h for guarantee
lignite, is absolutely necessary to keep the required ash inventory in the
combustor indicated by a proper pressure profile.
During normal operation only one ash cooler is in operation but the other
should be started regularly to avoid overfilling due to backsifting ash from the
vent line.

Prior to emptying the whole CFB combustor, both ash coolers should be put in
operation to permit a quick deashing and a proper cooling of the extracted ash
to 150 °C even at the elevated discharge rate of 32 t/h.
From time to time, depending on the ash content of the fuel and the
adjustment of the lignite milling system the very coarse ash particles (d > 4
mm), have to be discharged from the empty chamber. The coarse ash is
withdrawn from the empty chamber directly routed to a nearby container. The
coarse ash from the bundle chamber can be withdrawn directly via bottom ash
drains below the ash cooler. A regular extraction of the coarse ash ensures a
proper fluidization and avoids an enrichment of coarse particles in the bundle
chamber disturbing the heat transfer to the cooling bundle. In the beginning
this extraction shall be done at least once per shift until the operating
personnel have enough operating experience with the plant and the fuels.
Having a bulk density of 1,500 kg/m3, the ash causes a p of about 350 mbar
at maximal filling of the ash cooler.
From the second chamber of the ash cooler, the bottom ash is discharged by
means of rotary air lock valve, placed at the overflow of the ash cooler. The
rotary air lock valve running with a constant speed serves the dual purpose of
discharging the bottom ash avoiding overfilling of the conveyor and providing
a pressure-tight seal both during shutdown and during operation.
10.5 Bed Material Feeding System
Ash feeding to the combustor is only allowed when the PA flow is higher than
minimum to ensure a proper ash distribution in the combustor. The constant
gravimetric ash feeding rate of about 10 t/h is controlled by an airlock feeder.
The maximum allowed ash inventory of the combustor, indicated by a p
measurement, shall always be below 250 mbar.
The necessary air for bin aeration taken from the seal and purge air system
are uniformly distributed over the entire circumference of the bin cone. The
purge air can be controlled by a pneumatically activated valve. The necessity
of a continuous bin aeration will be checked during commissioning.
Bed Ash Discharge

In case of difficulties with the ash discharge train in duty the standby line shall

be started manually from the control room.
If ash cannot be withdrawn anymore from the CFB combustor, plant operation
can be continued until the maximum permissible pComb of 250 mbar is
attained in the CFB combustor. A pressure of more than 250 mbar should be
avoided under all circumstances to avoid the trip of the radial primary air fans
due to high backpressure in the combustor. Without any ash discharge from
the combustor the plant can be operated for approx. another 1-2 hours. A
pComb> 250 mbar is to be avoided also to be able to restart the primary air
fans after a shut-down or trip of the CFB boiler.
10.7 Bed Material System
In case of a trip or blockage of the bed material feeding system the limestone
can also be used alternatively as bed material substitute for a short time.
Please refer to relevant chapters for operation of the limestone system.
Having ash flow problems from bed material silo to combustor an increased
amount of seal and purge air can be used to clean the ash feeding lines to the
combustor. This purge air supports the ash flow.
10.8 Specification of the Bed Material
100 % < 1000 m

80 % 180 - 200 m
50 % 150 - 170 m
Bulk density 1500 kg/m3
11.0 LIMESTONE FEEDING SYSTEM

Limestone Feeding
From each limestone silo, the limestone is fed to the combustor via rotary
valves with a capacity of 14 t/h limestone each. The number of rotary valves in
operation is selected as required.
The rotary valves are feeding on a common chute. The chute is purged
continuously by seal and purge air, of about 600 Nm 3/h for each line,
supporting at the same time the gravimetric limestone transport to the seal pot.
However the main purpose of the seal and purge air is to cool the master-fuel-

trip valve, below the rotary valve for the lignite feeding.
During normal operation of the plant preferably both limestone feeding

systems should be operated to guarantee an even distribution: of limestone
and a low Sulfur / Limestone - ratio. The limestone is automatically fed via
rotary air lock feeders with variable speed, control being accomplished as a
function of the SO2 content.
The feed lines and number of airlock feeders per line are preselected
manually. Aeration air from the seal and purge air system is fed into the silo
cone. The necessity of a constant fluidization will be checked during
commissioning. Speed-controlled rotary air lock feeders act as final control
elements for SO2 control: The rotary air lock feeders are exclusively used for
feeding and metering of the limestone to limestone feeding line. The rotary air
lock feeders do not have any sealing function (minimum wear). The pressure-
tight sealing against the CFB system in case of a trip of the feeding lines is
ensured by the valve in each line and not by the airlock feeder. Hence in case
of a longer standstill the valves shall be closed to avoid backflow of flue gases
to the limestone system.

In case of a failure of the waste air system and/or overpressure in the silo the
fluidizing air and transportation air is stopped.
On failure of one feed line, the operating system is automatically keeping the
required emission level using the pre-selected feeding capacity. In case this is
not sufficient additional rotary valves are to be started manually.
The failed limestone line is shut off by means of the valves, when both rotary
valves are tripped or when the seal and purge air flow is too small. In this case
also the shut-offvalve/s, are closed to prevent backflow of flue gases in the
seal and purge air system.
In case of repair work on the limestone feed system during plant operation, the
manual shut-off valve shall be closed in addition. The limestone silo can be
checked during plant shut-down having the shut-off valves closed. Before
entering the limestone silo it has to be checked for dangerous gases and dust
deposits. During residence of personnel in the silo there shall always be a

guard outside of the silo. After completion of the repair work, the manual shut-
off valve can be opened again.
11.3 Design Criteria
By limestone addition, the fuel-borne sulfur is captured to such an extent that
the flue gas discharged to atmosphere reliably meets the stipulated SO2
emission limits without requiring any additional treatment.
Due to the broad range of part-load operation and the greatly varying sulfur
contents of the different solid fuels, limestone consumption varies
considerably.
12.0 SEAL AND PURGE AIR SYSTEM

Process Description
The seal and purge air system has the function to supply air for:
- avoiding unwanted ash deposits
- cooling purpose
The seal and pure air system consists essentially of the following equipment:
- one rotary piston blowers for seal and purge air, and one stand-
by blower.
The seal and pure air is supplied to the following consumers:
- sight glass for spiess valves at combustor and FBHEs
- sight glass for combustor
- bed material silo fluidisation
- limestone silo fluidisation
- lignite rotary valves
- start-up burners
During normal operation only one seal air blower is in operation. The
other blower is in stand-by.
The consumption of seal and purge air of the consumers is adjusted
during commissioning.
The seal air blower is started by the FG "I.D. Fan 1/2".

Trip of one Seal Air Blower
In case of trip of one seal air blower the stand-by blower will come
automatically in operation.
Decrease of Seal and Purge Air Pressure
If the pressure of the seal and purge air is decreasing below 600mbar
with one seal air blower in operation, the stand-by blower will start in
addition automatically.
13.0 PLANT MAINTENANCE
13.1. General
The following section describes a number of checks for the CFB steam
generator, which should be carried out at regular intervals to ensure proper
operation of all plant units and components, avoiding damage and preventing
equipment failures.
NOTE:
The present check list is limited to some selected plant components, which
have proved to require special attention. The following instructions should not
be considered to provide a complete checking routine nor are they a substitute
for the necessary inspection of the overall plant according to operating and
maintenance manual of respective vendors of subsystems. A lubricating chart
based on the manufacturers' instructions should be followed.
13.2. Blowing out of Wind boxes
Each wind box is provided with blowout devices to remove ash introduced
during operation as a result of grate spillage.
Blowout should be carried once per shift. Blowout is required in any case
before and after restarting plant.

13.3. Soot Blowing
Soot blowing is required, if one of the following conditions occurs in the plant:
- Excessive temperature at electrostatic precipitator inlet

- CO concentration downstream of the induced draft fan > 350 vppm (dry
basis, 6 % O2)
- last soot blowing operation carried out more than 8 hours ago.
Once per shift, the soot blowers should be checked for leaks while in
operation.
13.4 Maintenance and Inspections for the Water/Steam System
Maintenance - Combustor
Inspections
Routine inspections of combustor wall tubes, drums and headers should be
made each time after boiling-out, initial acid cleaning, routine acid cleaning
and during annual outages.
During these inspections, drums should be opened and handhole plates

removed from headers. The state of the drum internals should be checked
and internal surfaces inspected for deposits. Tubes should be spot checked
and tube ends inspected internally for deposits. Any deposits should be
removed and headers, drums and tubes flushed out with clean water.
Combustor tubes should be examined externally for blistering, burning,
corrosion, erosion and cracking. For this purpose, the fire sides of all exposed
combustor tubes must first be thoroughly cleaned of slag and ash deposits.
All inspections should be thorough and comprehensive in every detail. They

should be made by competent personnel, familiar with boiler operation and
maintenance and with water treatment problems. A record of each inspection
should be kept in a uniform manner so that results of any change can be
compared with former conditions.
Inspections of tubes, as result of tube failures or conditions expected to lead
to failures, should be even more thorough. If the trouble source is not obvious
or cannot be determined clearly, such inspections should include metallurgical
examinations of tube sections, chemical analysis of deposits, etc.

Tube Repairs
A tube section that has failed, or which must be replaced because of danger
of failure, can in most cases easily be replaced. After removing the combustor
wall insulation behind the failed area, the tube section is removed by cutting
across the tube, sufficiently above and below the affected area and carefully
cutting the web alongside the tube. The longitudinal cuts must extend beyond
the perpendicular cuts sufficiently to permit the new tube section to be welded
around the complete periphery. Webs between tubes must be replaced and
made gas-tight. Before inserting and welding a new tube section, the tube
ends should be properly prepared for welding.
It should be noted that it is impossible to include repair procedures (methods,
welding techniques, etc.) to cover all pressure parts and associated structural
components of a complex modern steam generator. It is recommended that
this company's local service or construction representative shall be consulted
for assistance in evaluating and repairing damaged pressure parts and/or
failures.
Maintenance - Superheaters
It is essential that suitable arrangements be made to assure cleanliness of the
external and internal superheater surfaces at all times. Fly ash accumulations
result in non-uniform gas distribution, inefficient heat transfer, and possibly
localized overheating. Suitably located soot blowers operated in the proper
cycle normally provide adequate means of keeping surfaces clean.
Proper feed water treatment and control of steam quality and carry-over are
essential to assure cleanliness of superheater surfaces. Overloads, fluctuating
loads, high water level, foaming, high solids concentrations, etc. all contribute
to deposits on interior surface.
Accumulation of these deposits inside the tubes will lead to unit failure. When
spray-type attemperators are installed care must be taken to ensure that
condensate quality water is used to avoid carry-over of solids into the
superheater's turbine blades. Periodic checks of steam pressure drop across
the superheater at unchanged load conditions usually indicate whether or not
solid deposits are present within the elements.
In the event of failure of one or more elements it is well to check carefully to
determine the cause. The manufacturer may be consulted for repair
procedures and proper means to prevent recurrence.
Inspection - Superheaters
A regular inspection and maintenance program, conscientiously followed, will
do much to assure continuity of service and to avoid serious and expensive
outages.
1. The superheater should be inspected when the boiler is out of
service.
2. Check the elements for alignment and any evidence of erosion,
warping or bulging of unit tubing. Replace tubing that shows
serious erosion, warping, bulging or evidence of overheating.
3. Check supports, spacers and seal plates for proper location and
condition. Repair or replace promptly.
4. Check inside surface of the steam drum for evidence of solids
carryover. If present, take immediate steps to eliminate cause.
When in doubt consult the manufacturer.
Maintenance - Reheaters
It is essential that suitable arrangements be made to assure cleanliness of the
external and internal reheater surfaces at all times. Fly ash accumulations
result in non-uniform gas distribution, inefficient heat transfer, and possibly
localized overheating. Suitably located soot blowers operated in the proper
cycle normally provide adequate means of keeping surfaces clean.
Proper feed water treatment and control of steam quality and carry-over are
essential to assure cleanliness of reheater surfaces. Overloads, fluctuating
loads, high water level, foaming, high solids concentrations, etc. all contribute
to deposits on interior surface. Accumulation of these deposits inside the tubes
will lead to unit failure. When spray-type attemperators are installed care must
be taken to ensure that condensate quality water is used to avoid carry-over of
solids into the turbine blades. Periodic checks of steam pressure drop across
the reheater at unchanged load conditions usually indicate whether or not
solid deposits are present within the elements.
In the event of failure of one or more elements it is well to check carefully to
determine the cause. The manufacturer may be consulted for repair
procedures and proper means to prevent recurrence.

Inspection - Reheaters
A regular inspection and maintenance program, conscientiously followed, will
do much to assure continuity of service and to avoid serious and expensive
outages.
1. The reheater should be inspected when the boiler is out of
service.
2. Check the elements for alignment and any evidence of erosion,
warping or bulging of unit tubing. Replace tubing that shows
serious erosion, warping, bulging or evidence of overheating.
3. Check supports, spacers and seal plates for proper location and
condition. Repair or replace promptly.
14.0 REFRACTORY
Inspections
At the annual boiler revisions an inspection of the refractory lining has to be
caried out.
Thereby all refractory lined areas have to be inspected and checked for wear
or cracks. All expansion joints have to be checked for clearance.
All variations of the refractory should be recorded in an inspection report and
marked in the corresponding drawings for later reference.
15.0 MAINTENANCE OF EXPANSION JOINTS
Expansion joints have to be cleaned. Compressed ash and loose ceramic

wool have to be removed.
The joints have to be filled up again with ceramic wool. For detailed
instructions refer to the refractory vendor documentation.
16.0 OPERATION UPSETS
16.1. General
The major tasks of the plant operating personnel can be summarized as
follows:
Early detection of operation upsets,
Location of operation upsets,
Taking the necessary measures to prevent consequential damage and
Taking corrective measures to remedy the trouble source.
If the plant is shut down in due time, the outage will always be shorter than in

the case of plant tripping with the resulting damage.
In the case of operation upsets where the plant operators do not have a clear
picture of the actual operating conditions, they should not run any risk and trip
the plant.
Do not open any man doors, pressure tabs, or other openings for inspection
while the CFB is in operation. The plant operates at overpressure and hot
gases or ash may exit.
Extreme care has to be taken when handling hot ash.
Failure of individual units normally initiates to take the second train or standby
unit into operation or decrease load. If the automatic control system fails,
manual interventions become necessary.
In the following, the various alarms provided are described and instructions
are given for measures to be adopted in the case of tube rupture and ash
leakages. For other operation upsets please refer to the relevant vendor
supplied operation and maintenance manuals for the equipment. .
16.2 Tube Damage in the Water/Steam System
Whenever there is reason to suspect tube damage, the shift supervisor should
be informed and the corrective action coordinated.
It should be noted that tube damage is not easy to detect unless major
feedwater or steam leakages occur and the effects described below are
observed. Minor tube damage may remain undetected for long periods and
become conspicuous only during plant shutdowns.
The corrective measures described below are generally applicable irrespective
of the extent of the tube damage.
16.2.1 Tube Damage in the CFB Evaporator Water Walls
The following symptoms can be normally recognized:
Excessive boiler feed water rate relative to the steam rate due to a damaged
evaporator. In case the difference of 10 t/h in mass flow between steam and
boiler feedwater is recorded for more than 5 minutes, a tube damage can be
assumed.
Possible temperature drop in the CFB combustor and the downstream flue gas
path. Possible load decrease due to reduced steam production.
Possible decrease in the drum water level, despite maximum boiler feedwater
rate.
Increased delivery rate of the induced draft fan due to higher flue gas rate.
Increase in the temperature downstream of the evaporator.
Pressure surge on the flue gas side due to a sudden increase in volume and
response of the pressure relief damper in the flue gas path.
Possible trip of the fans and blowers due to excessive flue gas pressure.
Possible fast reduction of oxygen content in the flue gas.
Corrective Measures
Set boiler feed water control to MANUAL, depressurize the boiler, increase
boiler feedwater rate to prevent a temperature rise and overriding of the
maximum permissible temperatures; observe the temperatures; maximum
boiler feedwater rate to the drum.
Shutting down the lignite and/or oil feed systems and the FBHE blowers.
Lower the combustor temperature to < 500°C as quickly as possible by
restarting or continuing fan/blower operation.
Close the spiess valves to ash coolers if the lower combustor temperature
drops below 150°C. Later ash shall be drained via emergency ash drains to
containers.
Continue shut-down operation followed by cooling operation as described
under section "Shut-Down for a longer Period". If the boiler is tripped by the
boiler protection, start the fans and blowers (I.D.Fan, S.A.Fan, P.A.Fan and
Seal Pot Blowers) again when possible.
Before draining the water from the individual evaporators, the flue gas
temperature upstream of the cyclone outlet should be below 300°C (to limit
thermal stresses and resulting damage due to overheating).
16.2.2 Tube Damage in the FBHE Evaporator and Seal Pot
The following symptoms can be normally recognized:

- Fast temperature drop in the respective seal pot or FHBE chamber.
- Excessive boiler feed water rate relative to the steam rate due to a
damaged evaporator. In case that the difference of 10 t/h in mass flow
between life steam and boiler feedwater is recorded for more than 5
minutes a tube damage can be assumed.
- Pressure surge on the flue gas side due to an abrupt increase in the
flue gas volume and, possibly, actuation of the pressure relief valve in

the flue gas path.
- Possible trip of the fans and blowers due to excessive flue gas
pressure.
- Possible load capacity decrease due to reduced steam production.
- Possible temperature drop in the CFB combustor and the downstream
flue gas path.
- Increased delivery rate of the induced draft fan due to higher flue gas
rate.
- Increase in the temperature downstream of the evaporator. Drum water
level drops despite maximum boiler feed water feed.
Corrective Measures
- Set boiler feed water control to MANUAL, depressurize the system,
increase boiler feedwater rate to prevent a temperature rise and
overriding of the maximum permissible temperatures; maximum boiler
feed water rate to the drum.
- Shutting down the lignite and/or oil feed systems. Close spiess valve
immediately.
Start the FBHE blower manually and try to keep the material in the FBHE
chambers fluidized by all means as long as the chamber temperature is above
150°C. This will prevent cementing of the ash in the area of the FBHE tube
bundles.
In case of severe tube leakage and chamber temperatures below 150°C the
FBHE blower should be tripped to avoid flash evaporation of water fed to the
combustor resulting in a severe overpressure of the system with the risk of
deforming pressure parts. In this case water shall be drained together with the
ash via the ash discharge into containers. . The grate ash drainpipes are to be
filled with specified bed material (refer section 10.8) during initial startup and
every instance of ash discharge, as they would facilitate easy discharge of ash
from the chamber
Continue shut down operation followed by cooling operation as described
under section "Shut-Down for a longer Period".
Before draining the water from the evaporator, the flue gas temperature at the
cyclone outlet should be below 300°C to prevent excessive thermal stresses.
16.2.3 Tube Damage in Superheaters 1/2 and in Reheater 2 (Convective Pass)
Symptoms of Tube Damage
- Conspicuous noise in the area of the tube rupture.
- Serious tube damage: load decrease and excessive boiler feedwater
rate relative to the steam rate, taking into account the attemperator
spray rates.
Corrective Measures
Shut down and cool the plant adopting the standard procedure as
described under section "Shut-Down for a longer Period".
16.2.4 Tube Damage in the FBHE Superheaters 2A/B and Reheater 1
- Conspicuous noise in the area of the FBHEs.
- Possible load decrease and excessive boiler feedwater consumption
relative to the steam rate taking into account the attemperator spray
rates.
- The leakage in the reheater section can be detected by mass flow
differences indicated by balancing the turbine (HP and MP section)
considering the spray water demand.
Corrective Measures
- Shut down and cool the boiler (see section "Shut-Down for a longer
Period").
- Close the spiess valve.
- Start the FBHE blowers and fluidize the ash in the FBHE chambers to
prevent it from hardening (cementing); try to empty the FBHEs into the
combustor.
16.2.5 Tube Damage in Economizer

- Load decrease and increased boiler feedwater rate relative to the
steam rate, taking into account the attemperator spray rates.
- Temperature increase downstream evaporator up to HP steam outlet.
- Increased power consumption of I.D. fans.

Corrective Measures
- Shut down and cool the plant adopting the standard procedure as
described under section "Shut-Down for a longer Period".
- Shut-off lignite and limestone feeding systems.
- Lower the combustor temperature to < 500°C as quickly as possible by
restarting or continuing fan/blower operation.
- Lower boiler pressure by means of HP-Bypass valve (2 bar/min).
- Boiler feed water control to "MANUAL".
16.3 High Water Level
Abnormally high water level should be avoided as it may lead to carry-over
and even priming. If there is an indication of priming (by rapid fluctuation in
outlet steam temperature) proceed as follows:
Reduce the steaming rate
If the water level is abnormally high, reduce the level by opening the
intermittent blow down valves and place feed water control on manual
Investigate the water condition (alkalinity and solids)
Investigate the condition of the drum internals as soon as an opportunity
arises.
16.4 Ash Leakages on the CFB Combustor, Fluid Bed Heat Exchangers and Seal
Pots
Depending on where the leakage occurs, different corrective measures can be
adopted. Incase of considerable ash leakage the plant has to be shut down
immediately. Leakages should be immediately reported to the shift supervisor
and the boiler house shall be evacuated.
16.5 Failure of Boiler Feedwater Pump
In case the Boiler Feedwater Pump is tripped, the standby Boiler Feedwater
Pump has to take over full operation latest after 60 seconds. However the
boiler will trip at low drum level. If the Feedwater Pumps are not available the
Emergency Boiler Feedwater Pump has to be started.
16.6 Station Blackout
In case of a "station black out" the boiler trips and the supply of combustion air
is stopped immediately as well as the Boiler Feed Water (BFW) supply. All
relevant control instruments and actuators are linked to the UPS system,

hence the DCS stays in operation during station black out.
The stored latent heat of ash inventory, refractory in the lower part of the
combustor and the brick lining in the cyclones is continuously released to the
evaporator surfaces of the combustor by different ways:
- direct heat transfer from the refractory lining of the combustor's lower
part to the evaporator membrane wall covered by the refractory,
- heat radiation from the surface of the ash inventory, which has fallen
down to the bottom of the combustor, to the evaporator walls of the
combustor's upper part,
- heat radiation from the brick lining of the cyclones through the inlet
openings back to the evaporator water walls of the combustor,
- superposition of the above mentioned heat radiation by natural

convection to the evaporator walls,
- the ash inventory which fell down onto the bottom of the combustor
after shut down starts to insulate itself after having settled. For the later
restart of the boiler it is important to know, that after starting the
fluidization the bed's latent heat, stored in the ash inventory at the
bottom of combustor, is immediately transferred to the evaporator walls
of the combustor.
As a result of the above there will be intense evaporation and superheating in
FBHEs and backpass in the first phase of a station black out. The boiler has to
be de-pressurised with a gradient of about 8-10 bar/h to cool the superheater
and reheater bundles. Later the steam flow is continuously decreasing due to
loss of latent heat in refractory, bricks, ash inventory and due to the self-
insulation effect of the ash.
The diesel driven Emergency Boiler Feed water Pump shall be in operation
latest 1 minute after trip of the Boiler Feedwater Pumps. Initially a minimum
Boiler Feed Water rate of about 15 % of the full-load rate will be required, with
the specified depressurization gradient. Boiler Feed Water supply has to be
continued for about 6 hours. During this period, the rate can be gradually
decreased.
Boiler feed water supply may be stopped when a temperature of < 450°C has
been reached in the combustor and in the second pass.
The blow down valve is to be closed or shall be closed in failsafe conditions.
As long as evaporation is going on in the water walls of the combustor
sufficient cooling of all boiler parts, which are exposed to heat radiation and
convection, is ensured. The water losses shall be compensated by feeding
feedwater with the diesel driven Emergency Boiler Feedwater Pump to the
drum, via economizer, keeping the required drum level.
The preheated boiler feedwater is extracted from the deaerator. Due to the
limited size of the deaerator, cold boiler feedwater is to be fed to the deaerator
with the boiler make-up water pump, connected to the EPS. Cold boiler
feedwater shall not be fed directly to the drum via economizer but via the
boiler filling line connected to the combustor wall inlet headers to avoid a
thermal shock and strain for the drum.
Difficulties with Emergency Boiler Feedwater Pump
In case it is not possible to start the Emergency Boiler Feedwater Pump this
may lead to a severe damage of the combustor evaporator tubes due to
overheating. Therefore all efforts have to be made to get the Emergency Boiler
Feedwater Pump running as soon as possible.
In case the Emergency Boiler Feedwater Pump is not starting, the damage to
the boiler may be limited by reducing the boiler pressure with a gradient of
about 1 bar/minute once the water level in the drum is no longer indicated or
visible. This is done to increase the evaporation and steam flow to provide
cooling for the combustor evaporator tubes.
Provisions for Station Blackout
In order to be able to operate and protect the boiler and its components
properly during station black out the following arrangements are foreseen:
- Main steam stop valve /and its bypass valve for operation as required.
- SH start-up vent valves and SH start-up vent isolation valves are to be
operated to control the pressure and the pressure increase after closing of the
steam stop valve at inlet of turbine avoiding working of the safety valves.
- RH start-up vent valves and RH start-up vent isolation valves for venting
the generated steam to atmosphere and control of the steam flow through the
reheater system in accordance with the HP-bypass.

- HP-bypass valve shall operate as safety valve for the HP-system opening
immediately to cool the reheater system controlling at the same time the
pressure decrease of the SH system. HPBP hydro pumps are connected with
EPS since the HYD accumulator is capable for initial operations of the HPBP
valve.
- DCS and PLC are connected to EPS to take care of the Emergency shut
down system (ESD), Process control system (PCS) and Operation monitoring
system (OMS) for a proper monitoring and control of the boiler conditions.
- Emergency cooling water pumps and isolation valves for the change over
between normal and emergency services to guarantee a proper cooling of the
spiess rods sticking in hot ash.
- Make-up water pump to ensure sufficient reserve for filling of the deaerator
and to the emergency feed pump.
- Blow-down valve for closing avoiding uncontrolled drainage of the drum.
- All spiess valves to operate as required.
- Emergency feed pump discharge isolation valves in Feed control station,
SH & RH spray and HPBP spray lines to effect the change over from normal to
emergency flow.
- SH & RH attemperator valves’ (UPS instrument air operated) isolation
/bypass valves to maintain SH RH temperature within safe limits.
In case there is no EBFP, to reduce the chance of superheating of the
evaporator walls the boiler pressure has to be reduced at 1 bar/min, in order to
achieve more water evaporation, resulting in longer cooling of the evaporator
tubes. Further the drum shows a lower temperature, which is advantageous in
case of feeding cold BFW at restart.
Linked to Instrument Air (One Time Consummation):
Limestone isolation valve to avoid backflow of hot flue gases into the bunker.
Bed material isolation valve to avoid backflow of hot flue gases into the
bunker.
17.0 PLANT SHUT-DOWN
17.1. Shut-down for Subsequent Hot/Warm Restart
17.1.1 Firing System
If the plant is to be restarted from hot/warm condition after a short outage, care
has to be taken to ensure that the respective combustor temperatures do not
fall below the interlock temperature. For this purpose, the following "shut-
down" procedure should be adopted:
- When reducing the load in the course of the plant shut-down, care
should be taken to ensure that the pressure difference across the
overall combustor does not exceed maximum pressure. If required, ash
has to be discharged since otherwise problems will be encountered in
fluidizing the ash bed when restarting the plant.
- Reduce the plant load to approx. 40 %.
- Switch off the second set of P.A.Fan, S.A.Fan and I.D.Fan.
- Shut down the fluid bed heat exchanger by closing the spiess valves
and stopping of the blowers for the FBHE bundle chambers. The
blowers for FBHE bundle chambers should be stopped quickly after
closing of the spiess valves to avoid overfilling of the combustor with
ash.
- If the specified HP steam temperature can no longer be maintained or
drops below the required turbine inlet temperature, the HP-bypass has
to be opened and the turbine has to be disconnected. After that, system
pressure is controlled by the HP-bypass and reheater start-up vent or
alternatively LP-bypass.
- Shut down the plant making sure that
- Shortly before plant shut-down the respective combustor should be
raised to temperatures 880 ° C,
- After that,
Either shut down lignite and limestone feeder and continue fluidization
for about 2 min at a reduced air rate,
- Or
Shut down lignite and limestone feeder and, at the same time, activate
the fuel oil lances; increase the temperature at the combustor bottom to
about 880 °C;
- After the lances have been shut off, a steam blowing cycle is
automatically initiated. Once the oil lances are out of operation,
continue fluidization at minimum primary air rate for about 30 s.
- Then shut off the fans and blowers by putting the FG "Fans and
Blowers" to standstill. Thereafter the I.D.Fan and the Seal and Purge air
are kept in operation for about 30 min. (to be finally adjusted during
commissioning and then switched off with the FG "I.D.Fan".
- Because of the high heat storage capacity of the boiler itself, the
refractory lining and the ash, evaporation will still continue for a while
after the system has been shut down.
As this would lead to a pressure rise in the system, the pressure has to be
controlled only via the HP-bypass. During this period, boiler feed water has to
be fed. Also after the pressure has ceased to rise, the HP-bypass shall not be
fully closed to guarantee further cooling of the reheater system.
As a rule, the ash temperatures in the CFB combustor should be raised prior
to shut-down in order to facilitate restarting.
17.1.2 Water/Steam Side
It is assumed that the boiler will be shut down for a relatively short period of
time and existing pressure and temperature conditions will be substantially
maintained. A procedure similar to that for normal shut-down (see section
"Shut-Down for a longer Period") should be used except as follows:
Note:
The intention of the following procedures is to keep the bed material and
combustor and cyclone refractories near full operating temperature to facilitate
restart and to prevent loss of refractory service life by reducing the number of
heating/cooling cycles. The backpass superheater and reheater tubing,
however, must be protected from radiation produced by the hot cyclone outlet
refractory by partial depressurization and ensuring steam flow through the
tubes at all times during the shut-down.
Gradually reduce load on the unit; reduce the firing rate in line with the
decreasing steam flow. Allow the pressure to drop via the turbine or
alternatively via HP-bypass while following the required rates of cooling for the
drum and turbine.
Note:
If it is expected that the unit will be restarted in a very short period of time, in
which the turbine metal temperatures will not decrease appreciably, it may be
desirable to cool the turbine metal parallel with the steam temperature, by
reducing the steam temperature and pressure, while the unit load is being

reduced. This will reduce the steam/turbine metal differential temperature
upon restart.
Operate the HP-bypass to maintain superheater outlet pressure and steam

flow through the superheater and reheater elements.
CAUTION
Care must be exercised to prevent water from entering the main steam line(s),
to the turbine from any source during and after the shut -down process. The
purpose is to prevent possible water damage to the turbine during a
subsequent restart. Possible sources of water are:
- Overflow from the drum into the superheater as a result of high water
level.
- Water entering the superheater and reheater through the attemperator
in superheater, reheater and HP-bypass due to open attemperator
control valves or possible valve leakage with the feed pumps running.
After the turbine has been taken off line, ensure the continuance of steam flow
through the superheater and reheater by operation of the HP-bypass valve
and reheater outlet vent valve. Metal temperatures in the back pass upper
cavity should be closely monitored throughout shut-down to ensure the tubing
is receiving adequate cooling steam flow.
Keep the water level in sight in the gauge glass. As the unit cools and the
water shrinks, make-up water should be added intermittently to prevent the
water from dropping out of sight in the gauge glass.
Note:
The operator should observe the gauge glass periodically so that he is always
aware of the actual drum level and can take the appropriate action to re-
establish water level when the unit is being restarted.
Shut the superheater and reheater attemperator block valves when the
temperatures have dropped below the normal operation temperatures.
17.2. Shut-down for a longer Period
17.2.1 Firing System
The shut-down procedure for a planned prolonged outage and subsequent
cold start-up of the plant is basically the same as that for a hot restart except
that the combustor temperatures has to be decreased according to the
gradients for the refractory (80-100K/h). Decreasing the temperature slowly is
important for the quality and durability of the refractory. When a combustor
temperature of 650°C is reached the oil lances or burners should be started
for controlled cooling of the combustor. At combustor temperatures of about
400°C the burners may be switched off.
After the firing system has been shut down, the plant is cooled by controlled
air blowing.
When reducing the load in the course of the plant shut-down, care should be
taken to ensure that the pressure difference across the overall combustor
does not exceed maximum pressure. If required, ash has to be discharged
since otherwise problems will be encountered in fluidizing the ash bed when
restarting the plant.
If the CFB combustor is to be emptied, continuous ash discharge via the
combustor bottom ash discharge system should be commenced during cooling
operation.
If the FBHE is to be emptied as well, the ash from the individual FBHE
chambers should be displaced to the CFB combustor by continuously running
the blowers.
After the ash in the FBHE is cooled to a temperature below 100°C and the
FBHE blower has been shut down, the remaining ash has to be discharged via
the bottom discharge openings in the individual chambers. For this purpose,
down pipes are connected to the bottom discharge openings and the ash is
collected in containers for possible re-use.
If required, the boiler is depressurized at the specified rate via the HP-bypass.
Once a pressure of I to 2 bar is attained, the vent on saturated steam side can
be opened.
Prior to opening the manhole doors, adequate measures have to be taken to
collect the ash trickling out of the manholes when removing bricks. When
opening the manhole doors, make sure that the negative pressure in the boiler
system is maintained via the I.D. fan.
Next the combustor is cooled to ambient temperature by sucking in air (I.D.
fan, if required).
Prior to entering any equipment it has to be ensured that there are no ash
deposits above manholes and connected ducts and chutes. Especially the ash
in the cyclone inlet ducts has to be removed (e.g. by air lances using
pressurised air) prior to entering the combustor.
Before carrying out an internal inspection of the plant, check that the cyclones,
the cyclone outlets, the seal pots and the FBHE are free from dust cornices.
All fans and blowers shall be disconnected from the mains.
17.2.2 Water/Steam Side
The following procedures for normal shut -down assume that the unit is
operating at full load on automatic control and the intention is to reduce the
pressure to zero and cool the boiler completely.
Gradually reduce load on the unit; reduce the firing rate in line with the
decreasing steam flow. Allow the pressure to drop with the reduction in load to
accelerate cooling. Reduce the steam temperature at the rate prescribed by
the turbine manufacturer. Reduce the combustor temperature by following the
start-up curve in reverse given by the refractory supplier.
Steam temperature control, combustion control and feedwater control may be
left on automatic until the point is reached at which better control can be
obtained on manual.
CAUTION
Care must be exercised to prevent water from entering the main steam line(s)
to the turbine from any source during and after the shut-down process. The
purpose is to prevent water damage to the turbine during a subsequent restart.
Possible sources of water are:
- Overflow from the drum into the superheater as a result of high water
level.
- Water entering the superheater and reheater through the attemperator
in superheater, reheater and HP-bypass due to open attemperator
control valves or possible valve leakage with the feed pumps running.
Operate all soot blowers.
Check the expansion movements of the boiler as it is being cooled.
Immediately after the turbine is off line and HP-bypass is in operation the
steam can be vented to atmosphere via reheater vent valves or to the
condenser via LP-bypass. At lower pressures and steam temperatures slightly
above the evaporation point the superheater and reheater vents and drains
shall be opened carefully. These vents and drains should be partially opened
to maintain some steam flow through the superheater and reheater until the
cyclone outlet temperature falls below 480 °C. Open steam line and turbine
drains as described by the turbine manufacturer.
Keep the water level in sight in the gauge glass. As the unit cools and the
water shrinks, make-up should be added intermittently to prevent the water
from dropping out of sight in the gauge glass.
Note:
The operator should observe the gauge glass periodically so that he is always
aware of the actual drum level and can take the appropriate action to re-
establish the water level when the unit is being restarted.
Close attemperator-isolating valves.
Open the drum vents when the unit pressure has decayed to 2 bar(g).
If the boiler is to be emptied completely, the boiler water temperature should
be reduced to at least 95 °C before draining.
17.3. Emergency "OFF"
In emergency cases, the steam generator can be shut down via the
"EMERGENCY OFF" button. Boiler feed water supply and cooling of the
superheater and reheater bundles is maintained in the same way as described
under "Normal Shutdown for Subsequent Hot Starting".
"EMERGENCY OFF" represents Boiler Protection Level 1. Pressing of the
"EMERGENCY OFF" button causes all main fans and blowers to stop.

0049 Unit Operation Proceddure

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UNIT OPERATING PROCEDURE

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- Feedwater control valves closed (manual control). Steam stop valve at

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Boiler Purge is required by standards applicable to CFB boilers to ensure that

The steam generator is equipped with two LDO/heavy oil-fired start-up

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- The heating-up procedure to be adopted depends on whether the combustor

Up to a temperature level of 400°C, the maximum allowable temperature

In any case heating-up gradients given in the refractory suppliers

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- As system pressure increases, progressively throttle the superheater and

- Adjust the feedwater supply to the boiler as necessary to maintain normal

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Environmentally acceptable combustion of solid fuels and liquids in the CFB

Maintaining of a constant temperature of 850°C in the combustor over a load

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Cyclone outlet temperatures: this temperatures (6 thermocouples, three at the

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Air distribution to the nozzles is accomplished by wind boxes located

Chamber 2 : chamber equipped with a bundle:

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For further abnormal operations see also section "Operating Upsets".

7.0 WATER / STEAM SYSTEM

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The first is installed in the connecting line between low-temperature

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As long as there is fire in the combustor, adequate cooling must be provided

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The RH vent valve may be throttled to increase reheater pressure, providing a

Temperature reduction is accomplished by spraying water into the path of the

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C. Abnormal vibration and differential expansion readings from the turbine

The HP-Bypass is operated for depressurizing slowly the SH system. The

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8.1 Operation Requirements

8.2 Process Description

The solid fuel feed system serves the following functions:

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Proximate Analysis of the Lignite for Guarantee (as received basis)

Fixed carbon % 16.50