GENERAL DESCRIPTION OF AFBC BOILER

The “THERMAL SYSTEM HYDERABAD” is manufacturing a fluidised bed boiler

wit the following features.
1. Start up burner with LDO.
2. Under bed and over bed fuel feeding system.
3. Compartmentalisd combustion chamber.
4. Single drum water tube boiler.

The boiler is designed for 100% coal, 100% Rice husk and 50% coal 50% Rice husk
combination fuel also. With this combination of fuels it will produce the 60 TPH steam,
66kg/cm2 and 495°C +/- 5°C Temperature.

STARTING INTER LOCKS FOR THE BOILER

The boiler is provided with interlocks, for reliable operation. And none of this should be
by passed.

The observations and starting sequence of the boiler equipment as follows.

1. Check the DM water availability.

2. Check the power availability.
3. Check the steam drum level and confirm with the local level gauge.
4. Check the compressor air and cooling water.
5. Close the ID fan damper.
6. Start the ID fan.
7. Close the FD damper.
8. Start the FD fan.
9. Close the both PA discharge and suction dampers.
10. Start the PA fans as per requirement one by one.
11. Make sure the particular compartment ready to charge with fuel.
12. Start the fuel feeders with respect compartments.

The same sequence to be followed by shutdown the boiler also. After shutdown the boiler
the ID fan has to be run minimum 10-15 minutes to purge the boiler.

Air and gas flow

The purpose of ID fan to maintain the balancing draft in the furnace, and vent out the flue
gas. The FD Fan supplies the required air for the boiler combustion. Air is initially heated
by air heater and then, it is divided into primary air& secondary air. Air demand is
different for each fuel, and measuring the excess air ratio by determining Fuel
characteristics of Coal and rice husk. The net heat supply to the boiler the fluidized bed
through an air distribution grid plate. The grid plate consists of multiple air nozzles
inserted through the fins of panel grid floor. The orientation and configuration of the
nozzles is such that they inject air in a manner so that it transports the heavier bed
particles toward the bed drain, the airflow suspends the particles of sand and screened
bottom ash. Primary air from a dedicated fan is injected the fuel in to furnace through the
mixing nozzle below the bed to achieve a staged uniform combustion for each
compartment. Fluid suspension bed, entrained in a substantial upward flow of gas. The
net supply of heat on the fuel side the balance closes to the out put heat within +-5%.
This means that there is a good control of the accuracy of the air and fuel flows. The
thermal variations give reliable operation. The flue gas temperature before entering the
convection section of the boiler gradually reduce, the flue gas flows down through the
heat recovery area over the economizer and air heater finally flue gas vent out through
the ESP by ID fan to stack.

WATER-STEAM FLOW

The treated DM water enter in to the D/A. and it will be stored by maintain the DA level
by regulating the DA level control valve. From there it will connect to the BFP’s inlet.
BFP’s discharge feed water control valve is used to regulate, to maintain the boiler drum
level.

Boiler feed water enters the unit at the economizer, located at the bottom of the
convection heat recovery area, where it is preheated. From the economizer water rises to
the steam drum. From the steam drum water is distributed to the lower inlet headers of
the furnace walls, the idle pass walls, the heat recovery area enclosure and the evaporator
bank. Inside the water walls and the evaporator coil water flows upward and boils while
being heated. A steam-water mixture is collected at the upper outlet headers and sent to
the steam drum. The steam drum separates the water from the steam-water mixture and
directs it back to the drum reservoir for circulation to the water walls and evaporator
coils. The steam is dried and sent to superheaters. Superheating is sequentially carried out
to final superheater steam. The steam production is 60 t/h at 495° C and 66 kg/cm2. The
superheated steam drives a steam turbine.

STABILIZE COMBUSTION CONTROLS.

The combustion control System must accurately establish the correct fuel/air ratio to
optimize combustion efficiency. Combustion controls are designed to regulate fuel and
airflows to satisfy load demand, establish correct fuel/air ratio, and minimize the time
spent at inefficient firing conditions. Combustion controls are stabilized by making the
proper adjustments to the proportional band, integral, and rate settings to best respond to
the load conditions. It is common that the best settings for winter load conditions are not
best for summer conditions. The assistance of the control manufacturer may be required
to determine the best settings. Only trained and authorized personnel should change
settings.
OPTIMIZING CENTRAL PLANT EFFICIENCY

Optimizing Combustion Efficiency. With cost of fuel continuously increasing, the need
to operate central boiler plants efficiently becomes more important all the time.
Procedures for optimizing operating efficiencies are discussed. An operator should
review the elementary combustion principles and principles of steam and hot water
generation. To optimize boiler efficiency, the combustion efficiency must first be
optimized. Combustion efficiency is a function of the type of fuel burned, flue gas
Temperature, and the amount of excess air in flue gas. For a Given fuel, the operator
must take action to optimize combustion efficiency by maintaining as low a flue gas
temperature and excess air level as is possible.

Soot Blowing/Cleaning to Reduce Flue Gas Temperatures. Boilers equipped with

soot blowers should be operated as needed to maintain clean heat transfer surfaces. Once
a shift is the recommended interval when Rice husk or coal is being fired, although
experience may dictate a different interval for a particular unit. Note the flue gas
temperature before and after soot blowing. A reduction in temperature of 35 to 40
degrees, corresponds to an efficiency improvement of 1 percent. The specific
improvement at the actual temperatures and excess air levels at which you are operating.
For fire tube boilers not equipped with soot blowers, a record of flue gas temperatures at
the normal firing rate of the boiler should be kept a record.

Boilers are equipped with blow off lines at the lowest point in the water system.
These lines are necessary for draining and also to help control concentration of solids and
sludge. This concentration is determined by an analysis of the boiler water and should be
a routine part of operating procedure. Blow down a specific quantity of water each time,
usually a few inches as measured on gage glass. Frequency of blow down is based on
results of water analysis.
a) Blow down Procedure. Open the quick-opening valve or cock first. Then open the
slow-opening valve fully until the required quantity of water is discharged. Do not open
valves too rapidly, as undue stress or damage to blow off piping and connections may
result. Blow down when the boiler is banked or steaming at low rate is most effective in
removing sludge and solids. Bottom blow off connections must be used to remove
sludge.
b) Continuous Blow down. Surface blow off connections are also provided on most steam
boilers and when used on a continuous basis, are the most effective and economical
means of controlling dissolved solids. Recovery of some of the heat from the blow down
water can be accomplished by use of a heat exchanger. If continuous blow down is used,
the bottom blow down valves should still be used at intervals to prevent them from
becoming stuck or otherwise inoperative, and to remove sludge. The quantity and
frequency of manual blow downs are determined by the degree to which sludge
accumulates in mud drums and headers. Soot Blowers. Flue gases carry ash and soot that
act as insulators and, when deposited on boiler heating surfaces, reduce the rate of heat
transfer. The extent of soot deposit depends upon the fuel burned, completeness of
combustion, and the rating at which the boiler is operated. When coal-fired boilers are
operated at high rating, ash and slag may deposit on tubes to such an extent that gas flow
is restricted and draft loss through the boiler increases.

These lines are necessary for draining and also to help control concentration of solids and
sludge. This concentration is determined by an analysis of the boiler water and should be
a routine part of operating procedure. Blow down a specific quantity of water each time,
usually a few inches as measured on gage glass. Frequency of blow down is based on
results of water analysis.
a) Blow down Procedure. Open the quick-opening valve or cock first. Then open the
slow-opening valve fully until the required quantity of water is discharged. Do not open
valves too rapidly, as undue stress or damage to blow off piping and connections may
result. Blow down when the boiler is banked or steaming at low rate is most effective in
removing sludge and solids. Bottom blow off connections must be used to remove
sludge.
b) Continuous Blow down. Surface blow off connections are also provided on most steam
boilers and when used on a continuous basis, are the most effective and economical
means of controlling dissolved solids. Recovery of some of the heat from the blow down
water can be accomplished by use of a heat exchanger. If continuous blow down is used,
the bottom blow down valves should still be used at intervals to prevent them from
becoming stuck or otherwise inoperative, and to remove sludge. The quantity and
frequency of manual blow downs are determined by the degree to which sludge
accumulates in mud drums and headers.

SOOT BLOWERS.

Flue gases carry ash and soot that act as insulators and, when deposited on boiler heating
surfaces, reduce the rate of heat transfer. The extent of soot deposit depends upon the fuel
burned, completeness of combustion, and the rating at which the boiler is operated. When
coal-fired boilers are operated at high rating, ash and slag may deposit on tubes to such
an extent that gas flow is restricted and draft loss through the boiler increases. Fire tube
boilers to be cleaned while in operation by means of steam jets operated from outside the
boiler setting. Steam is applied to the pipe of a swinging-pipe soot blower with steam jets
directed into the boiler tubes. The soot blower is rotated to direct the jets into ash.

b) Ash Removal. Clean the fires at regular intervals at a time. Do not allow the bed to
become too thick or clinkers will form. Remove the ash deposit promptly from the ash pit
to prevent fires. These boilers should be operated in accordance with the manufacturer's
operating instructions.

c) Operation. Examine the drum level, wind box Pressure, furnace pressure and all drives
operating loads. Check the operation of fuel feeding mechanisms to ensure the fuel equal
distribution in the compartment. If wet fuel sticks in the fuel hopper, push it into the
feeder properly. Lubricate bearings frequently as per schedule in accordance with
manufacturer's requirements.
Prepare a spare parts inventory. Do not neglect to include small parts such as nuts, bolts,
shear pins, steam traps, Special Supplies. Lubricants and cleaning solvents are needed for
proper equipment operation and long life. Clean, properly lubricated equipment is
required for successful plant operation. Lubricants are frequently referred Because of the
extreme variations in equipment and service conditions, the types of lubricants required
for a given plant must be determined locally. Determine lubricant requirements from the
equipment manufacturers instructions, or advice from lubricant manufacturers.

INSPECTION AND PREVENTIVE MAINTENANCE

The general information and provide guidance to those responsible for maintenance of
boiler plant equipment. It establishes a system of maintenance assignments and records
sufficiently flexible to be applicable to most boiler plant installations. Although this
schedules most of the maintenance called for by manufacturers, it is not intended to take
the place of manufacturer's instruction details. Each plant must maintain for ready
reference and use a manufacturer's instruction file on installed equipment for
maintenance of plant equipment, guidelines for inspection and certification of boilers and
unfired pressure vessels, Repair, and alterations of boilers. Forced outages for repair or
replacement of equipment parts that have failed in service can be, and often are, very
costly. Through the application of proper operating procedures and careful inspection, it
is possible to increase the length of time over which a boiler can be carried on the line
before any repairs are required. This, in turn, will prolong the useful life of the equipment
and minimize forced maintenance. The principal causes of forced outages and excessive
maintenance are:
a) Sustained and frequent overloading of fuel burning equipment
b) Operating with improper airflow conditions
c) Fouling of external heating surfaces
d) Inadequate water conditioning
e) Improper lubrication
Reduce Radiation Losses. Inspect, maintain, and improve boiler, flue, and pipe
insulation. Improved insulation is often available and economically justified. Radiation
losses can be minimized by the proper selection of operating and standby boilers, and the
temperature at which standby boilers are maintained. For some plants operating with non-
critical load, a standby boiler need not be maintained in hot condition. Close the inlet and
outlet dampers of any standby boilers. This will help to minimize the natural draft
airflow, which will cool the boiler. Reduce Blow down Losses. Blow down is necessary
to control steam boiler water quality and minimize scale formation. Reduced scale
formation helps to maintain combustion efficiency near clean boiler levels and reduces
water side maintenance. Blow down is a form of preventive maintenance that should be
carefully controlled. Continuous blow down is recommended for steam boilers because
blow down heat exchangers can be used to recover much of the heat in the blow down
water by preheating makeup water. Automatic control of continuous blow down is also
recommended to improve the accuracy of the blow down procedure and help minimize
losses. Reduce Unburned Carbon Losses Ash reinjection systems are an important part of
a system, which must be maintained in good operative condition. Over fire air is also
very important on any system to obtain proper mixing of air and combustion gases.

Daily, weekly, monthly, quarterly, semiannually, and annually. Review the

manufacturer’s operating and maintenance instructions and add additional required items.
Along with and prepare a spare parts inventory. Do not neglect to include small parts
such as nuts, bolts, steam traps, gaskets, valve seats, and packing. Special Supplies.
Lubricants and cleaning solvents are needed for proper equipment operation and long
life. Clean, properly lubricated equipment is required for successful plant operation.

Lubricants. Lubricants are frequently referred to in par Because of the extreme variations
in equipment and service conditions. The types of lubricants required for a given plant
must be determined locally. Determine lubricant requirements from the equipment
manufacturers instructions, or advice from lubricant manufacturers.

The successful operation and maintenance of a boiler is greatly dependent on the

operation and maintenance of its auxiliaries. Boiler operation and boiler preventive
Maintenance involves inspection of the boiler operating conditions.
1) Daily (Check the following conditions and takes action as required)
 Water level.
 Steam pressure or water temperature stability.
 Flue gas temperature at two loads, compared to clean boiler temperatures.
 Flue gas oxygen levels at two loads, compared with baseline data.
 Water or steam leaks.
 Air leaks in casing, ducts, or setting.
 Water samples and analysis tests and continuous blow down.
 Blow down through the bottom blow down connection to remove sludge.
 Clean boiler exterior.
 Unusual noise or vibration.
 Electric motors for overheating.
 Hot bearings.
 Abnormal suction or discharge pressures.
 Abnormal leakage through glands/seals
 Abnormal vibration and noise.
 Abnormal pressure and flow conditions.
 Excessive or inadequate packing leakage.
 Check alignment of pump and driver with the unit at standstill and normal
operating temperature.
 Check shaft sleeves for scoring.
 Replace packing if required.
 Drain the oil from oil-lubricated bearings, flush, and refill with clean oil.
 Check grease-lubricated bearings. Do not over grease the bearings. When adding
grease, remove drain plug or use a safety fitting to prevent over greasing.
 Monthly. Inspect external gear and bearing housings for correct lubricant
condition. Establish lubrication requirements and schedule in accordance with
manufacturers
  Recommendations.
 Inspect for the following:
 Cleanliness.
 Overheating.
 Hot bearings.
 Correct lubrication.
 Proper operation of instruments and controls.
 Unusual noise or vibration.
 Continuous or excessive sparking at commutator or brushes.
 Loose belts, if provided.
 Establish lubrication and motor maintenance in accordance with manufacturer’s
recommendations.
 Inspect for the following:
o Cleanliness.
o Overheating.
o Hot bearings.
o Correct lubrication.
o Proper operation of instruments and controls.
o Unusual noise or vibration.
 Inspect for the following hourly:
o Abnormal speed.
o Improper stroke length.
o Defective operation of lubricator.
o Ineffective operation of governor.
o Improper action of the air chamber.
o Steam and water leaks.
 Establish lubrication requirements and schedule in accordance with
manufacturer’s instructions.

2) Monthly
(a) Lever test safety valves
(b) Check boiler drain valves for proper opening and closing.
(c) Check boiler room floor drains for proper function.
(d) Safety or safety relief valves.
(e) Water level gage function.

Check for correct operation of relief valve, steam pressure reducing valve, overflow,
controls, alarms, and steam pressure and temperature indicators. Report any malfunctions
immediately. Inspect for steam and water leaks. Repair immediately.
ANNUALLY.
Once a year, or more often under service conditions, clean the unit and inspect the
following:
 Spray valves for corrosion, erosion, scaling, and proper seating.
 Water discharge nozzles for clogging, corrosion, and wear.
 Trays (on tray type units). Remove and inspect for corrosion, warping, and
scaling.
 Oil separator. Inspect interior of heater for evidence of oil, corrosion, or scaling.
 Condition of relief, steam pressure reducing, float, vent, and overflow valves.
 Condition of gage glass, controls, alarms, and instruments.
 Condition of piping and valves.
 Vent condenser. Open and check for corrosion, wear and scaling.
 Condition of insulation. Check for cracks and peeling.
 Completely disassemble, clean, and inspect the pump. Check for the following:
 Excessive clearances.
 Hot and cold alignment.
 Corrosion or erosion of parts.
 Excessive wear of shafts, sleeves, bearings, and seals.
 Cracks, scrapes, wastage, or corrosion of gear teeth if provided.
 c) Annually. Completely disassemble, clean, and inspect the pump. Check for the
following:
 Wearing ring clearances according to manufacturer's instructions. Diametric
clearance between 0.005 and 0.025 inch is usual.
 Bearing wear and clearances. Overhaul if required, according to manufacturer’s
instructions.
 Shaft for scoring, corrosion, or wear at seals, and alignment.
 Impellers for corrosion, erosion, or excessive wear.
 Calibrate pressure gages, thermometers, and flow meters.
 Suction and discharge strainers for cleanliness.
 Monthly. Inspect for the following:
 Scoring of piston rods.
 Completely disassemble steam traps and inspect them carefully for the following:
 Establish lubrication and motor maintenance in accordance with manufacturer’s
recommendations.
 Inspect squirrel cage rotors for broken or loose bars. Check for loose or broken
fan blades.
(2) Thoroughly inspect ball, roller, and sleeve bearings for wear and dirt.
(3) Check and record insulation resistance.
(4) Check windings for dirt, moisture, cracks, and loose wedges.
(5) Check coupling alignment.