O&Msec3 CFB Boiler Operation

Foster Wheeler International Engineering Labuhan Angin CFB Operations & Maintenance Manual
& Consulting (Shanghai) Co., Ltd.
SECTION 3
CIRCULATING FLUIDIZED BED
BOILER OPERATION
PROPRIETARY DATA
This document is the property of Foster Wheeler International Engineering & Consulting (Shanghai) Co.,
Ltd. and will be returned upon request or when no longer needed by the recipient. Information contained
herein may not be communicated to others nor may this document be copied in whole or in part without
the express written consent of Foster Wheeler International Engineering & Consulting (Shanghai) Co.,
Ltd.
Company: FWIEC Section: Three

TABLE OF CONTENTS
CIRCULATING FLUIDIZED BED BOILER OPERATION ............................... 1
INTRODUCTION ......................................................................................................................... 1
PRELIMINARY OPERATIONAL CHECK LIST ............................................................................ 4
COLD START........................................................................................................................................ 6
FILL THE BOILER .................................................................................................................... 6
COLD STARTUP VALVE ALIGNMENT CHART .............................................................................. 8
START FANS AND ADJUST AIR FLOWS ................................................................................. 10
STARTING THE INDUCED DRAFT FAN (IDF) .............................................................................. 10
STARTING THE HIGH PRESSURE BLOWER (HPB) ...................................................................... 11
STARTING THE SECONDARY AIR FAN (SAF) .............................................................................. 11
STARTING THE PRIMARY AIR FAN (PAF) .................................................................................... 12
AIR FLOW ADJUSTMENT............................................................................................................... 14
INSTALLING BED MATERIAL .............................................................................................. 15
INITIATE BOILER PURGE ........................................................................................................ 16
ELBOW DUCT BURNER LIGHT-OFF (DB) .......................................................................... 17
BOILER WARM-UP ................................................................................................................. 18
VALVE LINEUP FOR 25 PSIG STEAM DRUM PRESSURE ........................................................... 21
SOLID FUEL FIRING .............................................................................................................. 23
LIMESTONE FEEDING AND TRANSPORT SYSTEMS .................................................................. 26
BED ASH REMOVAL SYSTEM ......................................................................................................... 27
RAISE BOILER TO RATED CONDITIONS ............................................................................... 28
Btu COMPENSATION CONTROLLER .............................................................................................. 29
EXCESS O2 TRIM CONTROLLER ..................................................................................................... 29
NORMAL OPERATIONS .................................................................................................................. 30
FURNACE AND EMISSIONS .................................................................................................... 30
WATER CHEMISTRY AND STEAM PURITY ....................................................................... 32
ATTEMPERATION .............................................................................................................................. 33
ROUTINE INSPECTIONS .......................................................................................................... 33
BOILER SUPPORT .................................................................................................................... 34
BOTTOM ASH REMOVAL AND TRANSPORT ............................................................................... 34
SOOTBLOWING ........................................................................................................................ 34
NORMAL SHUTDOWN..................................................................................................................... 37
HOT SHUTDOWN .............................................................................................................................. 39
HOT RESTART................................................................................................................................... 40
TRANSIENT AND EMERGENCY OPERATIONS ........................................................................ 41
TRANSIENTS ........................................................................................................................... 41
HIGH OR LOW BED TEMPERATURES........................................................................................ 41
HIGH OR LOW DUCT BURNER FUEL SUPPLY PRESSURE ........................................................ 42
HIGH OR LOW BED INVENTORY ................................................................................................ 42
HIGH OR LOW STEAM DRUM WATER LEVEL............................................................................. 43
INTERMITTENT LOSS OF BED INVENTORY ................................................................................ 43
CONTINUOUS, GRADUAL LOSS OF BED INVENTORY .............................................................. 44
EMERGENCY SITUATIONS ..................................................................................................... 44
SUDDEN LOSS OF STEAM DRUM WATER LEVEL ...................................................................... 44
GRADUAL LOSS OF STEAM DRUM WATER LEVEL ................................................................... 44
EXCESSIVE BED TEMPERATURE ................................................................................................... 44
EMERGENCY SHUTDOWNS .................................................................................................... 45
Company: FWIEC PAGE ii Section: Three

STEAM DRUM WATER LEVEL CANNOT BE MAINTAINED ...................................................... 45

SUDDEN LOSS OF STEAM DRUM WATER LEVEL ...................................................................... 45
AIR-SIDE OR GAS-SIDE FAILURES................................................................................................. 45
LOSS OF SERVICE ............................................................................................................................ 46
RAPID LOSS OF BED INVENTORY FROM CIRCULATION ......................................................... 46
LOSS OF FLUIDIZING AIR TO Wall SEAL ...................................................................................... 46
TUBE LEAK DETECTION ...................................................................................................... 47
THERMAL CYCLING ................................................................................................... 49
SAND ANALYSIS ............................................................................................................. 50
SILICA CONCENTRATION ....................................................................................... 51
SYMBOLS & LEGEND P&ID 43-100429-5-6101............................................................................ 51
Company: FWIEC Section: Three

Foster Wheeler International Engineering Labuhan Angin Refining CFB Operations & Maintenance Manual
3.1 CIRCULATING FLUIDIZED BED BOILER OPERATION

INTRODUCTION
Placing a boiler in service requires careful consideration and ability to control safely all systems and
components. Your ability to operate will be tested when you experience an upset condition and/or loss of
a support system or component.
Any operation of the boiler must be accomplished with safety your

prime concern. As an operator, you should be thoroughly aware of
the status of the boiler and support systems before, during and after
Safety
any operation.
This section is to introduce you to the basic operating principles of a

First
Foster Wheeler Compact-Design Circulating Fluidized Bed boiler.
These basic operating guidelines should be supplemented with your
plant-specific operating instructions and guidelines as required by the owner/operator.
The material in this section is intended primarily to teach principles, not to provide
step-by-step details of operating your boiler. This manual should not replace
detailed operating procedures that may be prepared for your specific CFB boiler
installation.
Company: FWIEC PAGE 1 Section: Three

Foster Wheeler International Engineering & Labuhan CFB Operations & Maintenance Manual
Consulting (Shanghai) Co., Ltd.
Stroke all air flow dampers

Start fans and blowers, AUTO
Start 5-minute boiler purge
Furnace Ready signal from DCS
Duct burner light-off
Bed temperature >1100F (593C)
Start coal feeder
Bed temperature >1400F (760C)
Stop auxiliary burners
Raise load to 100% MCR

3.2 OPERATIONS

A. PRELIMINARY OPERATIONAL CHECK LIST
Most items listed here are simply common sense to an experienced operator. Unfortunately, they
become so common over a long period that they can be forgotten. They are provided here simply
as an overall reminder of items to check before beginning boiler startup.
1. Carefully inspect all parts for proper assembly and installation.
2. All auxiliary equipment must be in first-class operating condition and operated according
to the manufacturer's recommendations and instructions.
3. The steam drum water level sight glasses must be checked for installation according to
the manufacturer's drawings before preliminary operation. When the water level in the
steam drum is lowered below the lowest visible point on the sight glass, all water should
drain out of the glass. Any time a repair or change is made to the sight glass, proper
draining should be checked.
4. Blowdown lines from the water column and sight glasses must be piped to a safe area and
drain valves closed. The remote level indicator must be illuminated and clearly visible to
the operator from the operating floor.
5. Valves located between the steam drum and water column must be locked in the full open
position.
6. All operational vents, drains, relief valves, safety valves and instrument blowdown lines
must be readily accessible and properly piped to a blowdown system or other safe
location. If the boiler has a main steam vent valve or ERV, it is optional to open the
superheater vents on a cold startup.
7. Check that the remote steam drum water level indicators are operating and they compare
accurately with the local sight glass readings. This procedure should be carried out
regularly.
8. All safety valve hydrostatic test plugs must be removed and the safety valves must be in
proper operating condition. Safety valve and relief valve discharge pipes and drains
should be arranged and supported according to the safety/relief valve manufacturer's
recommendations and the ASME Boiler Codes.
9. Steam drum internals must be properly installed according to the manufacturer's drawings.
This will assure steam will not bypass the steam drum internals.
10. All temporary test connections and permanent plant instrumentation must be installed
with associated transmitters and indicators calibrated and available for operation.
11. Control system interlocks checked, verified and ready for operation.
12. All areas must have enough light to allow safe access and operation.
13. Dangerous obstacles have been removed, scaffolding used torn down. Walkways,
ladders or stairways should be in good condition.

14. Air and gas passages must be free from obstruction and the boiler can be thoroughly
purged by circulating air through the boiler.
15. The source of feedwater must be ample, uninterrupted and within the chemistry limits for
startup and boiler operation.
16. An ample supply of fuel (fuel oil and coal) and limestone must be available.
17. All access and observation doors must be closed. Check that no one is inside the boiler.
All equipment, tools and debris have been removed.
18. Steam drum door manway openings must be closed and properly sealed. Make certain
that the proper gasket material has been used to seal the drum ends.
19. All equipment subject to thermal expansion must be free of interference, such as
temporary scaffolding, ladders, debris and left over construction materials.
20. Elbow duct burner sight glasses and flame detectors must be clean and have purge air in
service.
21. Be familiar with the startup of the boiler and support systems before, during and after all
operations.
22. Equipment and system tag-outs reviewed and/or removed as necessary to support boiler
operations.
When you are sure that the above steps are fully understood and have been completed, then, and
only then, should operation of the boiler be started.

B. COLD START
This chapter provides detailed instructions to startup a cold, empty boiler and bring the boiler to full-load
output, 100% maximum continuous rating (MCR). This section defines basic steps and should be used
with your plant-specific operating procedures as established by the owner/operator. Check valve lineup
with the VALVE ALIGNMENT CHARTS later in the section.
B.1 FILL THE BOILER
The boiler is initially filled using the condensate storage transfer system to about 50 mm (-2")
below the normal water level, which is about 150 mm (6") below the centerline. The water
should be chemically treated to the proper chemical concentrations and pH for normal boiler
operation.
1.1 Open boiler drum level elements, sight glass block valves, pressure element block valves,
boiler steam drum chemical feed block valves, and level detector valves.
1.2 Verify boiler sight glass and water column drain valves are closed.
1.3 Open the boiler steam drum vent valve, 1HAD10 AA201.
1.4 Open the saturated steam vent valves (optional), 1HAD30 AA011, 1HAD30 AA012,
1HAD30 AA013 and 1HAD30 AA014.
1.5 Open all superheater steam drain valves finishing superheater drain valves, 1HAH40
AA001 and 1HAH40 AA002, superheater II wingwall drain valves, 1HAH30 AA001 and
1HAH30 AA002, and main steam line drain valves, 1LBA10 AA021 and 1LBA10
AA022.
1.6 Open the cross-over and HRA convection cage drain valves, cross-over drain valves,
1HAH11 AA001, 1HAH11 AA002, 1HAH12 AA001, 1HAH12 AA002, 1HAH11
AA003, 1HAH11 AA004, 1HAH12 AA003, 1HAH12 AA004, convection cage lower
header drain valves, 1HAH10 AA001 and 1HAH10 AA002.
1.7 Close the economizer inlet header drain valves, 1HAC10AA001, 1HAC10AA002,
1HAC10AA003 and 1HAC10AA004.
1.8 Close all boiler water-side drain valves, downcomer drain valves, 1HAD20 AA001,
1HAD20 AA002, 1HAD20 AA003, 1HAD20 AA004, 1HAD20 AA005, 1HAD20
AA006, 1HAD20 AA007, 1HAD20 AA008, 1HAD20 AA009, 1HAD20 AA010,
1HAD20 AA011, and 1HAD20 AA012.
1.9 Open the electromatic relief valve manual isolation valve (main steam line), 1LBA10
AA001.
1.10 Open ERV 1LBA10 AA203 at least 15%.
1.11 Drain any condensate from the main steam line by opening the main steam line drain
valves.

1.12 Open the continuous blowdown valve, 1HAD10 AA004, and intermittent blow-off valve,
1HAD10 AA202, 100% and check lineup to drain tank.
1.13 Verify all piping spring hangers are unpinned and at the cold setting.
1.14 Verify boiler feedwater temperature, 1LAB50CT001 (economizer inlet) and

1LAB10CT001 (economizer outlet) are within 112C (200F) of steam drum metal
temperatures, 1HAD10CT001, 1HAD10CT003, 1HAD10CT005, 1HAD10CT007(top)
and 1HAD10CT002, 1HAD10CT004, 1HAD10CT006, 1HAD10CT008 (bottom) and the
average when filing an empty steam drum.
1.15 Open economizer inlet feedwater supply block valve 1LAB50 AA204, and economizer
recirculating valve, 1HAD10 AA203.
1.16 Open boiler fill valve slowly and set up 10 to 15% feedwater flow to the boiler with
feedwater controls in manual.
1.17 Open economizer vent valves, 1LAB50 AA001 and 1LAB50 AA002, optional. When
all air is vented from the economizer, close the economizer vents.
1.18 Close the feedwater control valve when a few inches of water is seen in steam drum sight
glasses.
1.19 Blowdown the steam drum sight glasses, 1HAD10CL201 and 1HAD10CL502, and alarm
level elements, 1HAD10CL551 and 1HAD10CL552, using proper drain valves, 1HAD10
AA005, 1HAD10 AA006, 1HAD10 AA007, 1HAD10 AA010, 1HAD10 AA011 and
1HAD10 AA012.
1.20 Verify water level returns to the steam drum sight glass about where it was before
blowdown.
1.21 Verify sight glass level corresponds with remote indication in the control room and at the
steam drum level controller.
1.22 Open feedwater control valve and slowly add feedwater to the steam drum to raise the
water level.
1.23 Check steam drum sight glasses. Close the feedwater control valve when the steam drum
water level is at 1/3 of the sight glass or two inches (2") below the normal operating
water level. As water level rises, continue to verify level accuracy of the remote
indication in the control room.
Note: Water will expand as it is heated. This is called "swell." You should start with
a slightly lower-than-normal steam drum water level during startup.
1.24 Check boiler steam drum doors and external valves, fittings and connections for leaks.
Any leaks found must be corrected before proceeding with the startup.

COLD STARTUP VALVE ALIGNMENT CHART
Valve Description Valve Number Position

Boiler steam drum level gauge block valves 1HAD10 AA121, 1HAD10 AA Open
122, 1HAD10 AA 123, 1HAD10
AA 124, Left, 1HAD10 AA125,
1HAD10 AA126, 1HAD10
AA127, 1HAD10 AA128 Right
Boiler steam drum level detector block valves 1HAD10 AA129,, 1HAD10 Open
AA130, 1HAD10 AA131,
1HAD10 AA132 Left, 1HAD10
AA133, 1HAD10 AA134,
AA136 Right
Boiler steam drum pressure transmitter block 1HAD10CP001, Left, Open
valves 1HAD10CP002, Right
Boiler steam drum chemical feed block valves 1HAD10 AA014 and 1HAD10 Open
AA015
Boiler steam drum sight glass drain valves 1HAD10 AA005, 1HAD10 Closed
AA007, Left, 1HAD10 AA011,
1HAD10 AA012, Right
Boiler steam drum vent valve 1HAD10 AA201 Open
Saturated steam vent valves (optional) 1HAD30 AA011, 1HAD30 Open
AA012, 1HAD30 AA013,
1HAD30 AA014
Crossover steam drain valves 1HAD11 AA001, 1HAD11 Open
AA002, 1HAD11 AA003,
AA001, 1HAD12 AA002,
AA004
Main steam drain valves 1LBA10 AA021, 1LBA10 AA022 Open
HRA convection cage drain valves 1HAH10 AA001, 1HAH10 Open
AA002, 1HAH10 AA011,
1HAH10 AA012
Economizer inlet header drain valves 1HAC10 A001, 1HAC10 A002, Closed
1HAC10 A003, 1HAC10 A004

Boiler water-side drain valves 1HAD20 AA001, 1HAD20 Closed

AA002, 1HAD20 AA003,
AA005, 1HAD20 AA006,
AA008, 1HAD20 AA009,
AA011, and 1HAD20 AA012.
ERV manual isolation valve 1LBA10 AA001 Open
Startup vent valve or ERV 1LBA10 AA203 >15%
Continuous blowdown valve and intermittent CBD, 1HAD10 AA004, IBO, Open
blow-off valve 1HAD10 AA202
Finishing superheater drain valves, 1HAH40 AA001 and 1HAH40 Open
superheater II wingwall drain valves, and AA002, 1HAH30 AA001 and
main steam line drain valves, 1HAH30 AA002, 1LBA10 AA021
and 1LBA10 AA022
Note: SH vents can be opened (optional) if
ERV is not open

B.2 START FANS AND ADJUST AIR FLOWS
The fans are started in a set sequence for safe operation. The ID fans are started first to allow a
negative draft to be put on the boiler. The HP Blowers are started next to fluidize the wall seals
areas. The above grid air flow, SA and PA, is established next by starting the secondary air fans.
The bed is fluidized by the below grid and above grid air flows from the PA fans.
The following steps are used to start the ID, SA, PA fans and the HP blowers in their proper
sequence and to adjust air flows in preparation for the boiler purge.
Note: The sequence for starting fans is:
a. ID fans
b. HP blowers (Wall seal blower)
c. SA fans
d. PA fans
e. Adjust air flows, as necessary.
A. STARTING THE INDUCED DRAFT FAN (IDF)
1 Place bed temperature manual controller at 50%.
2 Place excess O2 trim bias controller at 50% and leave in manual.
3 Verify open upper SA nozzle air flow controller, 1HLA20 AA301, and lower PA
nozzle air flow controller, 1HLA10AA301, open greater than 25%.
4 Place ID fan inlet damper controllers, 1HNE10AA701 and 1HNE20AA301, at

minimum position, 0%.
5 Place ID fan outlet isolation damper, 1HNE10AA201 and 1HNE20AA201, at

open position.
6 Verify an Open Gas Path DCS signal through the ESP.
7 Verify ID fan controller is in Remote.
8 Verify no ID fan motors trouble
9 Verify no stop signal present.
10 Verify furnace pressure not low-low and no MFT
11 Verify ID fans/motor bearing temperatures not hig- high
12 Verify no ID fan failure to start
13 Verify no ID fan trip
. 14 Verify drum level not low-low

15 Verify fan motor stator winding temperature not high-high
16 Initiate a DCS start command to the ID fan A.
17 Verify ID fan A has started and vibration readings, electrical indications and
temperatures are normal, field verified by operator.
18 Repeat 16 to 17 for starting ID fan B.
19 Leave ID fan controllers in manual at minimum. If plant operating experience

shows that ID fan pressure control can operate in automatic mode through start of
the high pressure blowers, SA fan and PA fan, place the ID fan control in
automatic mode after starting the ID fans.
B. STARTING THE HIGH PRESSURE BLOWER (HPB)
1 Open HP (wall seal) air distribution valves on wall seals.
2 Verify manual valves of HP air at the stripper cooler solids transfer lines are
open.
3 Verify both ID fans are still running.
4 Verify wall seal blowers in Remote
5 Verify no wall seal blower motor trouble.
6 Verify no stop signal is present .
7 Verify wall seal blower motor winding temperature not very high.
8 Verify wall seal blower motor bearing temperature not very high.
9 Verify no wall seal surge.
10 Initiate a DCS start command to the HP blower A.
11. Verify HP blower A has started and vibration readings, electrical indications and
12. Open HP blower A outlet isolation valve 1HFW10AA201
13. Repeat 11 to 12 to start HP blower B.
14. Verify HP blower B has started and vibration readings, electrical indications and
15. Verify both HP blowers running and line pressure, 1HDW40CP001 increases high
enough to reset pressure switches, 1HDW40CP101 and 1HDW40CP102.
C. STARTING THE SECONDARY AIR FAN (SAF)

1 Place the SA fan inlet vane controls, 1HLB21AA301 and 1HLB22 AA301, at
minimum position, 0%.
2 Place the SA fan outlet isolation dampers, 1HLB21AA201 and 1HLB22 AA201,
at open position.
3 Verify the upper SA nozzle air flow controller, 1HLA20AA301, and lower PA
nozzle air flow controller, 1HLA10AA301, are in the minimum flow position.
4 Station operator at fan before starting.
5 Verify SA fan in Remote.
6 Verify no SA fan motor trouble.
7 Verify no stop signal present
8 Verify furnace pressure not high-high and no MFT
9 Verify SA fan/motor bearing temperature not high-high.
10 Verify no SA fan failure to start.
11 Verify No SA fan trip.
12 Verify ID fan is still running.
13 Verify drum level not low-low.
14 Verify SA fan/motor winding temperature not high-high.
15 Initiate a DCS start command to the SA fan A.
16 Verify the SA fan A starts, vibration readings, electrical indications and bearing
temperatures are normal.
17 Repeat 15 to 16 to start SA fan B.
18 Adjust SA fan pressure control, using SA fan inlet vane 1HLB21AA301 and
1HLB22 AA301 and DCS pressure controller to about 4.48 kPa (to be field-
verified) and put controller in automatic.
19 Adjust SA upper nozzle controller, 1HLA20AA301 to match DCS-generated

setpoint with the actual measured air flow. When minimum SA air flows are
made up, put flow controller in automatic to the air master.
20 Check the ID fan furnace pressure and controller for normal operation.
D. STARTING THE PRIMARY AIR FAN (PAF)

When starting the PA fan, the DCS operator must know whether there is bed in
the combustion chamber or not. Without bed material, there is no resistance to air flow
through the grid nozzles. When bed material is in the combustion chamber, windbox
pressure must increase to a point where there is enough pressure to force air up through
the grid nozzles and flow through the bed material.
1 Place the PA fan inlet vane flow controls, 1 HLB11AA301 and 1HLB12AA301,
to minimum position, 0%.
2. Place the PA fan outlet isolation damper, 1 HLB11AA201 and 1HLB12AA201,

to open position.
3 Verify the upper PA nozzle air flow controller, 1HLA10AA301, and PA air flow
to grid controller, 1HLA11AA301 and 1HLA12AA301, are in the minimum
flow position.
4 Station operator at the fans before starting.
5 Verify PA fan in Remote.
6 Verify no PA fan motor trouble.
7 Verify no stop signal present
8 Verify furnace pressure not high-high and no MFT.
9 Verify PA fan/motor bearing temperature not high-high.
10 Verify no PA fan failure to start.
11 Verify no PA fan trip
12 Verify drum level not lot-low.
13 Verify ID fans not stopped.
14 Verify SA fans not stopped,
15 Verify PA fan motor winding temperature not high-high,
16 Start the PA fan A.
17 Verify the PA fan A starts, vibration readings, electrical indications and bearing
temperatures are normal, verified by operator at the fan.
18 Repeat 16 to 17 to start PA fan B
19 Adjust PA fan pressure control, using 1HLB11AA301 and 1HLB12AA301 and

DCS pressure controller to about 12.45 kPa (to be field-verified) and put
controller in automatic.

20 Adjust PA upper nozzle controller, 1HLA10AA301 to match DCS-generated

setpoint with the actual measured air flow. When minimum PA air flows are
made up, put flow controller in automatic to the air master.
21 Slowly fluidize the bed by slowly increasing the PA-to-grid air flows,
1HLA11AA301 and 1HLA12AA301, in manual slightly higher than minimum.
After the bed has been fluidized (measured air flow indication), return PA-to-grid
air flow to minimum. Place PA air flow controls in automatic.
22 Adjust ID fan controller to control furnace pressure to 0.37Kpa (negative one-

half inch water column). When furnace pressure is stabilized, place ID fan
controller in auto.
F. AIR FLOW ADJUSTMENT (if necessary)
Air flow setpoints are generated by function generator curves programed into the DCS
(air master). Before an operator places any air flow controller in automatic, the operator
must first match the actual measured flow indication value to the generated setpoint value.
When both values are reading about the same, the operator can then place the controller
in automatic, bumpless transfer.
Verify SA fan pressure controller is in automatic and SA upper air flow control
damper is in automatic. Adjust, as required (to be field-verified).
Verify PA fan pressure controller in automatic and PA flow control dampers in

automatic.
TO PLACE THE AIR MASTER IN SERVICE:
1) All fans and downstream air flow dampers must be in automatic.

2) Place the air master in cascade (auto tracking).
3) The air master will now track the boiler master output that is tracking the total
fuel flow.

B.3 INSTALLING BED MATERIAL
Bed material inside the furnace is the medium that transfers heat from the duct burners, to the
primary air, up through the plenum or windbox, heating the bed
material. The hot bed material comes in contact with the
waterwalls and the heat goes from the bed material to the water
inside the waterwalls. The water inside the waterwalls gets hot,
produces steam bubbles. The hotter water and steam bubbles Have the fans in
move up inside the waterwalls to the steam drum. If the hot
water does not circulate inside the waterwalls, the water turns to
service when
steam and allows the metal of the waterwalls to overheat and installing bed
fail or rupture.
material
Startup bed material, about 60~70 tons, should be blown into
the combustion chamber using a lower combustion chamber
connection, if possible. When available, saved bed ash from the
previous shutdown is to be used to charge the bed.
3.1 Start feeding new bed material into the lower combustion chamber with all fans running.
This can be done before, during or after the 5-minute boiler purge.
Note: When installing bed material on a cold startup, it is permissible to fire DBs at a
very low firing rate, only. Do not exceed a firing rate of 30% until indicated
bed pressure is at least 10"w.c.
3.2 Check differential bed indications and actual bed pressure, level and density indications.
As bed volume increases, the bed pressure, level and density indications will also
increase.
3.3 Stop adding bed material to the combustion chamber when the furnace bed differentials,
1HBK10CP011 and 1HBK10CP012, and indicated bed pressure transmitters,
1HBK10CP004 and 1HBK10CP005, indicate enough bed material (about 4.5 - 5.5 kPa
bed pressure). Actual best quantity of bed material will be established during initial
boiler operation, after a series of test performed on boiler performance. This will be
equal to about 0.4 - 0.5 m (24-30") of static bed material if the fans were shut down and
the bed slumped. Also verify plenum (windbox) pressure when the PA fan is running
measured and transmitted to the DCS by 1HLA13CP001 and 1HLA13CP002. Windbox
or plenum pressure will also indicate an increase in bed material quantity.

B.4 INITIATE BOILER PURGE
In accordance with ASME boiler codes, the boiler must be purged before each cold startup, or
following an MFT when the bed temperature is less than 760C (1400F), or when all coalfeed
trips with less than 649C (1200F) and no duct burners are in service.
The boiler purge procedure and minimum permissives assure a clear air and gas flow path,
enough air flow to carry away combustible gases and assures all sources of fuel are isolated from
the combustion chamber or furnace.
The following interlocks are required to initiate a boiler purge:
During cold startup, before establishing ignition, or

After occurrence of a MFT, or
Bed temperature drops below 760C (1400F)
The following permissives will be required to initiate the 5-minute purge:
Total air flow > purge value (30%)

Duct burner A and B air flow > minimum
Primary air to left and right plenum air flow > purge value
Cold primary air to stripper cooler A stripper air flow > purge value
Cold primary air to stripper cooler A cooler 1 section air flow > purge value
Cold primary air to stripper cooler A cooler sections 2 and 3 air flow > purge value
Cold primary air to stripper cooler B stripper air flow > purge value
Cold primary air to stripper cooler B cooler 1 section air flow > purge value
Cold primary air to stripper cooler B cooler sections 2 and 3 air flow > purge value
No boiler trips
All sources of fuel proven off (coalsystem and fuel oil system).
The following permissive interlocks will be required for the boiler purge.
Boiler open gas path proven

ID fan running
Wall seal air pressure > minimum
SA fan running
PA fan running
ID suction pressure > minimum
All sources of fuel proven off
Compact separator exit gas temperature < maximum
Furnace pressure normal (not high-high or low-low)
Drum water level not high-high or low-low
No loss of bed ignition temperature
Air/Fuel ration > minimum
Instrument air header pressure > minimum
No DCS trouble
No operator emergency push-button trip
No boiler trips
Superheater protection not activated

4.1 Check all air flow indications to verify the total air flow required for a boiler purge
sequence.
4.2 Start the purge sequence timer in the DCS.
4.3 Assure all purge interlocks and air flows are maintained above the minimum values until
the purge timer has timed out.
4.4 Verify purge in progress light goes out and furnace ready signal light comes on when
purge is complete.
B.5 ELBOW DUCT BURNER LIGHT-OFF (DB)
There are two (2) oil-fired, fixed-position elbow duct burners (DB) with movable high energy (H.E.)
spark igniter to light-off the atomized fuel oil used during startup to assist in warming of a cold boiler, to
built pressure and to assist in warming up of cold bed before and during bed ignition.
5.1 Select remote operation at the local control panels for both burners. This will allow the
operator in the control room to have full control of those burners.
5.2 Verify the DBs are coupled and in place.
5.3 To open the main oil header safety shut-off valve (SSV) the following permissives must
be satisfied:
Verify Furnace Ready, at least the following conditions must be met.
No boiler MFT condition present

P.A. Flow on
Oil header pressure not low
Oil header shut-off valve (SSV) and individual burner safety shut-off valve (SSV)
closed
5.4 The main oil header safety shut-off valve (SSV) will automatically close on any one of
the following conditions:
Loss of furnace ready

Low oil pressure and any burner safety shut-off valve open
All burners safety shut-off valve closed
Any burner safety shut-off valve closed failure
5.5 Burner start sequence will be initiated on meeting the following conditions:
Oil permissive (oil header safety shut-off valve open and no oil header safety shut-off
valve closed condition present)
Oil pressure not high
Duct purge complete this condition will be generated in the following conditions are
met:
Oil safety shut-off valve closed
P.A flow on
Burner combustion damper and front wall damper are in purge position

Furnace ready
Instrument air pressure not low
Atomizing air pressure not low
Oil gun in place
No flame detected
Atomizing air pressure not low
Atomizing air valve closed
Scavenging air valve closed
5.6 Initiate a start command for the first DB from the control room. Verify:
Burner combustion damper and front wall damper opens (purge position)
Burner dampers go to light off position after 5 min purge completes
Atomizing valve opens
Burner ignitor inserts and energizes for 15 seconds, and burner oil shutoff opens
Flame is detected and proven by flame scanners
Damper position controls is release for modulation
5.7 Start second duct burner following same sequence.
5.8 Control heat input with both duct burners to follow proper heating (firing) rate using
thermocouples 1HLA11CT001 and 1HLA11CT002, right plenum, and 1HLA12CT001
and 1HLA12CT002, left plenum, input to the DCS.
Duct burners will be used to heat the bed to greater than 593C (1100F) and increase
boiler pressure according to the attached startup curve in preparation to shift over to
coalfiring.
Note: Before light-off of each burner, an operator should be positioned at the burner
front. During light-off, the operator should check that there are no fuel leaks.
After light-off, the operator should visually observe the condition of the flame,
checking for irregular flame patterns or flame impingement.
5.9 Burner shutdown sequence will be generated on any one of the following conditions:
Loss of oil permissives

Low oil pressure
Low instrument air pressure
Low atomizing air pressure
Oil gun not in place
Flame failure
The shut down sequence will close the fuel safety shut-off valve.
5.10 Oil gun scavenge (purge) will be initiated when the atomizing air pressure is not low.
The scavenging will be carried out when the duct burners are tripped and the purging is
completed. On initiation of oil gun scavenge, the ignitor will insert, the spark energized,.
the atomizing air valve and scavenge valve will be energized to open. On completion of
scavenge, all the valves will be de-energized to retract or close.
B.6 BOILER WARM-UP

A slow, gradual heating of the boiler will ease thermal stress on all boiler pressure parts and
refractory and allow the operator to complete the startup process without having automatic
shutdowns caused to too much heat input. The speed at which you heat the boiler will be limited
to heat rates. Foster Wheeler suggests that the starting heat rate be limited to a maximum of
112C (200F) change in flue gas temperature measured at the compact separator inlet
thermocouples, 1HDF10CT001, 1HDF10CT002 and 1HDF10CT003, compact separator #1, and
1HDF20CT001, 1HDF20CT002 and 1HDF20CT003, compact separator #2. Use the flue gas
temperature change per hour during the first three hours of startup.
Another heat rate used during startup, but not as accurate during the first three hours, is the
change is steam drum metal temperature. Thermocouples mounted on the top and bottom of the
steam drum generate the average metal temperature. Limit the metal temperature change to
between 28C (50F)/hr. and 56C (100F)/hr. in the averaged steam drum metal temperature.
If you choose to use the lower value, you may eliminate the chance of adverse drum swell and
boiler trips on uncontrolled steam drum water level change.
This will result in a quicker, smoother startup than if you used
the faster heat rate and have to slow the duct burner firing rate. Do not exceed
Foster Wheeler suggests a procedure used during startup that the Foster
will help reduce the reoccurring drum level trips that happen
when the water in the boiler swells. This procedure eliminates Wheeler's
adding water into the steam drum until the steam drum
pressure has reached about 560 kPa (200 psig). Operators
recommended
will adapt this technique for their boiler during the startup heat rate during
period when there are frequent restarts.
startup
Using this procedure, you start with a slightly lower than
normal (about -2" or -100 mm) water level in the steam drum.
As the boiler water expands, blowdown the swell using the
intermittent blowdown, the continuous blowdown and downcomer bottle drains, as necessary.
When the water level drops to about -100 mm to -200 mm (-2 to -4 inches), close the downcomer
bottle drains. The water in the boiler will continue to swell. Repeat this blowdown process as
necessary.
During this process, you must be aware that the water in the economizer tubes will evaporate as
that portion of the boiler heats up. When and if you have to add water to the steam drum, you
must remember to slowly admit feedwater to the boiler because the economizer section is dry and
hot. Feedwater added will immediately flash to steam and increase pressure inside the steam
drum. If you add a lot of feedwater to the economizer, that instantaneous production of steam
pressure will drive the steam drum water level down very quickly.
6.1 Adjust the duct burner firing rates to increase the hot compact separator inlet temperature
of 112C (200F) temperature change per hour or combustor bed temperature at rate of
28-56C (50F to 100F )/hr., as directed. Bed thermocouples may be covered with bed
material and not indicating actual temperature.
Steam used to heat the boiler pressure parts during startup will condensate and collect in
the lower bends of any superheater sections. This condensate will prevent cooling
steam flow through those superheater tubes until the condensate is drained or boiled dry.
During startup, superheater tubes with low or no steam flow will operate at the bed or
flue gas temperature, depending on location. This temperature must be limited to the
maximum design tube metal temperature of 482C ( 900F). This temperature limit is
maintained until a minimum of 10% steam flow is established through the boiler.
During the warm-up phase of this procedure, the boiler blowdown system must be placed
in operation. It is advisable to have the intermittent blowdown and continuous blowdown
open 100%. The downcomer bottle drains must be closed but available for use, as
necessary. The feedwater system must be available for makeup to the boiler.
Open the main steam stop bypass valve at the beginning of startup to allow the boiler and
main steam system to warm up together.
6.2 Check steam drum water level for swell. Use the intermittent blowdown and continuous
blowdown systems to help maintain steam drum water level and to blowdown floating
and suspended solids during startup.
6.3 Continuously check superheater metal thermocouple temperature indications on the

DCS during startup. If these indications exceed the high limit, you must reduce your
firing rate and blow down sections with high temperatures.
6.4 Check the temperatures around the combustion chamber, i.e., compact separators,
superheater, economizer and air heater air/flue gas temperatures (boiler temperature
profile) and assure the maximum recommended heat rates are not exceeded.
Note: The following steps will be performed at the proper pressures and temperatures,
but not necessarily performed in sequence.
6.5 Check steam drum pressure. When the pressure reaches 70 kPa (25 psig):
A. Close the steam drum vent valves and verify startup steam vent valve is open.
B. Close the superheater vent valves, if opened.
C. Leave superheater drains open.
D. Check boiler water chemistry continuously.
6.6 Check the steam drum water level. Verify that the remote and local steam drum water
level indicators are the same.
6.7 Establish steam flow path (main steam line vent or electromatic relief valve). Gradually
increase steam flow.
6.8 Admit main steam to main steam line (turbine) for turbine starting and loading as
required by turbine manufacturer.
6.9 Continue to increase boiler firing rate as required to raise boiler operating pressure and
temperature according to the recommended startup curve.

VALVE LINEUP FOR 25 PSIG STEAM DRUM PRESSURE
Valve Description Valve Number Position
Boiler steam drum vent valve 1HAD10AA201 CLOSED
Saturated steam vent valves (optional) 1HAD30AA011, 1HAD30AA012, CLOSED

1HAD30AA013, 1HAD30AA014
Crossover steam drain valves 1HAH11AA001, 1HAH11AA002, Open

1HAH11AA003, 1HAH11AA004,
1HAH12AA001, 1HAH12AA002,
1HAH12AA003, 1HAH12AA004

Main steam drain valves 1LBA10AA021 and Open

1LBA10AA022
HRA convection cage drain valves 1HAH10AA012, 1HAH10AA011, Open

1HAH10AA001, 1HAH10AA002
Startup vent valve or ERV 1LBA10AA203 >15%
Finishing superheater drain valves, 1HAH40AA001 and Open

superheater II wingwall drain valves, and 1HAH40AA002, 1HAH30AA001
main steam line drain valves, and 1HAH30AA002,
1LBA10AA021and
1LBA10AA022
Note: When you begin to develop pressure in the boiler steam drum, you will be instructed to
follow a pressure-raising curve rather than a temperature raising curve for
heat rates. Steam drum pressure is limited to about a 276 kPa (40 psig)/hour
ramp rate.

6.10 Open the superheater spray water (desuperheater) supply manual isolation valves and
place the steam temperature control system in automatic operation when outlet steam
temperatures are within 28C (50F ) of the design operating temperatures.
Note: Maintain final outlet steam temperature at least 11C (20F) above saturation
temperature and steam flow at or slightly above 10%.
6.11 Check the boiler outlet steam flow as steam is admitted to the main steam line.
6.12 Slowly close the startup valve while maintaining a minimum 10% steam flow for
superheater protection as steam use increases.
6.13 Close the superheater drains

completely when indicated steam 90 SECONDS 90 SECONDS
flow is greater than 10% of the
ON ON ON
boiler's rated steam flow (MCR).
6.14 Continue to close the startup valve

while maintaining greater than 10%
steam flow until it is completely 90 SECONDS 90 SECONDS
closed.
1 Burping Sequence
6.15 Continue to increase boiler firing rate to
reach initial conditions of steam temperature, steam pressure and bed temperature
according to the limitations of the startup curve.
Notes: (1) Maintain steam temperature above minimum superheat for turbine
operations according to turbine operating procedures if applicable.
This is generally 100 degrees of superheated steam.
(2) Control the firing rate to maintain less than 112C (200F)/hr.
compact separator inlet gas temperature increase.
B.7 SOLID FUEL FIRING -- Coal is solid fuel
At the Labuhan Project, four individual coalfeeders feed fuel to the front wall of the boiler.
Introducing coalto the boiler will increase temperatures and pressures very quickly. Before
starting any coalfiring, the boiler must be in stable controlled condition and there must be enough
bed inventory present in the boiler to support heat transfer and maintain the seal in the wall seals.
The operator must verify there is no MFT present, verify that bed temperature is greater than
595C (1100F) and plenum pressure greater than minimum.
When starting the first coalfeeder, Foster Wheeler recommends that the operator start the feeder
in manual mode and at minimum speed (generally about 10%). Run the first feeder for a
maximum of 90 seconds. Stop the first feeder for a maximum of 90 seconds. During the stop
time, verify that measured bed temperature increases and measured excess oxygen in the flue gas
decreases. Seeing temperatures increase and oxygen decrease is proof positive that fuel getting
into the furnace is igniting and burning. Repeat the process again verifying temperature increase
and oxygen decrease. If the process proves safe combustion of fuel, start the feeder for the third

time and leave running in manual at minimum speed. Start the remaining coalfeeders by starting
them in manual at minimum speed. Only burp the first feeder to prove good combustion of fuel.
Foster Wheeler suggests to put some fresh limestone into the bed if there is a need to slightly
increase indicated bed pressure or when starting up with a new bed. This is done by starting the
limestone feed system before the coalfeed system. When bed temperature reaches the
coalminimum temperature permissive, 593C (1100F) as indicated by the bed temperature
thermocouples (or depending on the ignition temperature of the coal/ ), coalfiring can begin.
7.1 Place all coalfeeder controls in manual.
7.2 Verify feeder is in remote.
7.3 Verify speed controllers of the feeders are set at zero.
7.4 Check all bed temperature indications on the DCS.
7.5 Open all coalfeeder silo outlet isolation valves (slide gates), 1HFB01AA001,
1HFB02AA001, 1HFB03AA001 and 1HFB04AA001.
7.6 Verify fuel feeder seal air to the coalfeeder high enough.
7.7 Open coalfeeder discharge valves to the combustion chamber, 1HFB01AA201,

1HFB02AA201, 1HFB03AA201 and 1HFB04AA201 on the front wall.
7.8 Run the coalfeeders in manual until fuel is present at the discharge end of the
coalconveyor belt inside the feeder. Flow switches inside the coalfeeders,
1HFB01CL101, 1HFB02CL101, 1HFB03CL101 and 1HFB04CL101 will generate this
signal to the DCS. Do not put fuel into the boiler at this point.
7.9 Place Btu compensation bias controller

in manual at 50% output, if available.
When starting the first
7.10 Remove any manual bias in the
individual coalfeeder controllers. coal feeder,always make
7.11 Verify the amount of excess oxygen in
sure O2 readings decrease
the flue gas, 1HNA10CQ001 and and bed temperatures
1HNA10CQ002, before starting the first
coalfeeder. increase
7.12 Start, manually at minimum speed
(~10%), the first front wall coalfeeder when bed temperatures are greater-than 593C
( 1100F) (or higher if required by the operator to provide a cushion for the bed
temperature permissive). Run the feeder ON for a maximum of 90 seconds and OFF for
the same value of time (90 seconds). This is called "burping" or "pulsing" the
coalfeeders. You must verify that bed temperatures increase at least 8C (15F) and
excess O2 in the flue gas decreases. Burp feed the fuel feed system three times. When
good ignition results are achieved, leave coalfeeder in continuous operation, at minimum
feeder speed, in manual control.

7.13 Start remaining coalfeeders one at a time, in manual at minimum speed, monitoring all
operating conditions.
When the coalfeeders are in operation, the operator must switch fuel sources, heat input
to the boiler. It is time to decrease the amount of fuel oil being used while increase the
amount of coal/. This action will make coalthe primary fuel and allow the operator to
establish full coalfiring. Once fuel oil use has been reduced to minimum, continue to
increase coalfiring for increase in heat input.
Note: Depending on operator responsibilities, you can put the limestone and ash
removal systems in service before firing coalif it helps in reducing startup
complications, i.e., too much bed material.
7.14 Slowly decrease the duct burner firing rates while increasing the fuel feed rate until the
duct burners are at minimum firing rate.
7.15 Stop the duct burners about 788-815C ( 1450-1500F) indicated bed temperature, one
at a time as bed temperature continues to increase. As each burner is shut down, it will
go through a purge cycle.
7.16 Adjust fuel feed rate manually, as necessary, to maintain bed temperature rise. As duct
burners are shut down and secured, place them in a standby condition, ready for use as
required.
PROCEDURE FOR PLACING FUEL MASTER IN SERVICE:
1) Match individual feeder control outputs to the fuel master output.
2) Place feeder controllers in auto to the fuel master.
3) Place the fuel master in cascade/auto.
4) The fuel master will now follow the boiler master output.

B.7 LIMESTONE FEEDING AND TRANSPORT SYSTEMS
There are two separate systems used to deliver the proper amount of limestone to the boiler. The
limestone feed system measures and amount of limestone and the limestone transport system
deliver the limestone to the boilers feed points.
7.17 Place the limestone feed system in operation depending upon bed requirements or
emission limitations.
1. Open the limestone manual isolation valves on the front wall of he boiler.
2. Start two of the three limestone blowers and verify line discharge pressure.
c. Open the limestone rotary airlock isolation valves, 1HFB11AA001,

1HFB12AA001, 1HFB21AA001 and 1HFB22AA001.
d. Verify operation of the limestone bin vent filter.
5. Start limestone rotary isolation valves, airlock rotary valves A1, A2, on
limestone feeder A, and B1 and B2 on limestone feeder B.
6. Open the limestone isolation gates at the silo, 1HFB10AA001and

1HFB20AA001.
7. Verify limestone feeder ready signals.
8. Start the limestone feeders in manual at minimum feeder speed.
9. Adjust limestone flow to maintain demand signal based on fuel flow and stack
emissions (SO2) monitor, 1HNE30CQ001.
10. Place limestone feeder controls in automatic when coalfeed and limestone feed
rates are above minimum and when boiler load is high enough.
OPERATION OF THE SO2 TRIM CONTROLLER:
1) This control loop trims the coaland limestone ratio signal to increase or decrease
limestone feed to match indicated measured SO2.
2) The main limestone feed demand signal is generated by multiplying measured

coalflow by a known factor depending on the amount of sulfur in the fuel, based
upon latest chemical analysis.
3) Adjust the SO2 controller output to match the signal on the limestone feeder
controller. Transfer controller from manual to auto.
7.18 Verify ESP ash removal operation and continuous emission monitoring (CEM) systems
are in service.

7.19 Verify baghouse ash removal operation and continuous emission monitoring (CEM)
systems are in service.
B.8 BED ASH REMOVAL SYSTEM
STRIPPER COOLER OPERATION
Two ash removal boxes (stripper coolers A and B) are attached to each sidewall. Stripper
coolers are used to classify and cool excess bed material removed from the furnace. Stripper
coolers are operated in a continuous mode as long as all the process indications are satisfied. An
emergency cooling water spray is used to reduce heat when needed.
1. Place the bottom ash removal system, stripper coolers, in service when the bed level, bed
density and or bed pressure starts to increase above the normal lower furnace pressure
indications. Actual numbers to be established during commissioning and startup.
Stripper cell fluidizing air dampers should never be closed to the point where air
flow is completely stopped. Air flows should be kept above minimum values to ensure
minimum classification.
1.1 Verify downstream ash transport system in service.
1.2 Verify cold primary fluidizing air to the stripper coolers.
1.3 Start the ash feeding fill sequence for the stripper cooler. Wall seal
blower air is started and helps push coarse bed material into and through the inlet
solids transfer line. When the measured amount of bed material in the stripper
cooler reaches a predetermined level, the wall seal blower air stops.
1.4 Check bed pressure, bed level or differential bed pressure.
1.5 Check stripper cooler temperatures to indicate filling of ash from the furnace.
1.6 Monitor stripper cooler differential pressure and watch for end of the fill cycle.
cold primary air classify the small particles of bed material and return them to the
furnace through two stripper cooler outlet lines.
1.7 Watch temperatures inside stripper cooler for proper operation. On initial high
temperature, water sprays are activated to speed the cooling process. When
temperatures decrease to a predetermined amount the water sprays stop.
1.8 When the temperature inside the stripper cooler reaches a predetermined amount
the ash drain valve under cooler section 3 will begin to turn and reduce the
amount of bed material in the stripper cooler to a minimum level. At that point,
the drain valve will stop operation. There must always be a small amount of bed
material in the stripper cooler. This will act as an insulation to keep hot incoming
bed material from the ash drain line and valve in cooler section 3.
c.

B.10 RAISE BOILER TO RATED CONDITIONS
Continue to raise temperatures and pressures shown on the boiler startup curve until all systems
have reached full operating temperatures and pressures with all controls in automatic operation.
Once boiler operation has become stable and steam flow is greater than 80% MCR, the operator
can place various controls in service to help improve boiler efficiency.
The most important of these is the control of excess oxygen in the flue gas. For safety, there
should always be more oxygen than is required. The CFB boiler is designed to operate with an
excess of oxygen, about 3.0 - 3.5% excess oxygen measured in the flue gas. Oxygen optimization
should only be considered when the boiler load is greater than 80% and load conditions are stable.
The second tool the operator has to improve boiler efficiency is the sootblowers. These cleaning
devices sweep the ash from the heat transfer surfaces in the HRA convection pass of the boiler.
This improves or reestablished good heat transfer and allows for better use of the heat generated
by the boiler.
10.1 Place the bottom ash removal system, stripper coolers, in service when the bed level,
density and or pressure starts to increase above 4.5 - 5.5 kPa (18-22" w.c.) or when the
lower combustion chamber bed differential indicated an increase in bed material. Based
on actual bed pressure measurements, this may be required before admitting coal
1. Verify ash transport system in service.
2. Verify wall seal fluidizing air to the wall seals.
3. Start the stripper cooler.
4. Check bed pressure, bed level or differential bed Always trend

pressure. indicated bed
5. Check stripper cooler temperatures to indicate pressure and
filling of ash from the combustion chamber.
quantity for
6. Monitor stripper cooler differential pressure. sudden
7. Watch temperatures inside stripper cooler for change
proper operation.
10.2 Slowly Close the boiler startup valve as boiler load continues to increase, assuring a 10%
minimum flow is maintained through the superheater. If steam flow drops below 10%,
the DCS activates safety control loops.
10.3 Check PA and SA measured air flows. Watch measured flow indication to setpoint.
10.4 Place the feedwater control in automatic when necessary.
10.5 Place the excess oxygen controller in automatic when boiler load exceeds 80% MCR and
at stable boiler load.
10.6 See Normal Operations for continued operation of boilers.

OPERATION OF THE Btu COMPENSATION CONTROLLER:
1) This control loop compares steam generated and the amount of coalit should take
to generate that amount of steam. When the Btu value of the coalchanges, this
control loop will raise or lower the coalflow to compensate without making any
change to the air flow.
2) This controller in automatic during operation. There is no manual access to this

controller. It is resident active in the DCS.
OPERATION OF THE EXCESS O2 TRIM CONTROLLER:
1) This control loop compares expected excess O2 in the flue gas to actual excess O2
based on boiler steam flow.
2) This controller should be left in manual at 50% output on the controller until
normal boiler operation has been established and boiler load is greater than 80%.
3) The output from this controller will trim or change the amount of air flow from
the SA nozzles.
4) Match process value and setpoint on controller. Then place controller in

automatic.

C. NORMAL OPERATIONS
This section provides general information and the basic guidelines for steady-state or controlled load
change operation of the Foster Wheeler Compact CFB boiler. These instructions should be used with your
owner/operator plant-specific operating procedures.
Operating checks and adjustments are performed to maintain efficient operation of the plant and prevent
any unscheduled plant shutdowns.
The primary technique for changing boiler load involves varying fuel feed rate and the corresponding
change in the air flow rate. Bed temperature may vary between 760C (1400F) and 899C (1650F) to
allow for small increments of change within a short time.
After reaching the desired steam flow rate, bed temperature should be reestablished at your plant's
normal bed temperature (about 871C (1600F)) and boiler load held steady by adjusting the coalfeed
rate. Always verify that the air flow tracks coalflow when in either manual or automatic control, and to
maintain a set safe excess oxygen value (greater than 3.0%).
C.1 FURNACE AND EMISSIONS
1.1 Check SO2 emissions from the boiler. The limestone feed rate must be adjusted, either
manually or automatically, to maintain an SO2 emission level at the stack that meets local
regulations. The SO2 value should not be allowed to be less than 75% of the standard for
a long period since this contributes to inefficient operation of the boiler.
1.2 Check NOx emissions from the boiler. NOx emissions are inherently low when the bed
temperature operating range of 788-899C (1450 to 1650F) is maintained. NOx
emissions increase as bed temperature increases.
1.3 Verify proper fluidizating of bed material and hot loop circulation. This is accomplished
by observing individual bed temperature thermocouples and flue gas temperatures
throughout the hot loop, checking that temperatures are consistent and normal within the
hot loop. Normal will become a known value with operating experience.
1.4 Increase the primary air flow and bed ash removal rate temporarily when it is determined
that part of the bed is not properly fluidized. When this increase in those activities does
not improve fluidization, it may be necessary to shutdown the boiler and inspect for
plugging of the grid nozzles, clinkers (aglomeration) in the combustion chamber, or
excessive coarse bed makeup.
1.5 Check the gas-side pressure differential throughout the HRA convection pass and the
economizer. Use the sootblower system to remove any build up of fly ash that might
have accumulated.
1.6 Inspect the coalfeed and limestone size distributions and feed systems for plugging or
bridging.
1.7 Check the bed density, bed level and bed pressure (fluidized bed material inventory) and
maintain it at its normal value. Bed maintenance may be required to maintain proper bed
material inventory, composition and SO2 control.

1.8 Monitor the windbox-to-bed-pressure differential continuously. When this changes

significantly from normal, check instrumentation for proper operation and the sensing
lines for plugs. If instrumentation is operating properly, shutdown the boiler and inspect
the air distribution grid.
1.9 Check the bottom ash removal system (stripper coolers) for proper operation. Check the
bed ash removal transport system for plugging periodically.
1.10 Check the accuracy and reading of the remote steam drum water level indicators to
assure they are reading the same as the local level gauges. This should be done daily on
new installations to assure plugging of the level gauges does not occur.
1.11 Check the accuracy of all excess oxygen analyzers with test gas as often as necessary.
Routine maintenance on these analyzers will help assure safe boiler operation.

C.2 WATER CHEMISTRY AND STEAM PURITY
2.1 Assure that the desired boiler water solids concentration and chemistry are maintained.
Improper boiler water chemistry can lead to tube fouling or corrosion of internal surfaces,
reducing the efficiency of the boiler and possibly resulting in overheating of tubes
leading to tube failure.
Note: Boiler chemical feed pumps are usually started when a steady feedwater flow to
the boiler is established and stopped when the feedwater pumps are stopped.
2.2 Avoid large quantities of solids or the injection of water treatment chemicals to the
feedwater before the economizer.
2.3 Strict control of oxygen content and pH in the boiler water and feedwater must be done
by daily sampling. Records for this information should be kept in a safe place.
2.4 Assure that steam purity is within maximum limits. For operation within design
conditions, the steam separator equipment in the steam drum will keep solids carry-over
within acceptable limits. Moisture carried over can include solids and other impurities
that may deposit on surfaces downstream of the boiler.
2.5 Adjust the steam drum continuous blowdown valve in the continuous blowdown system
when solids carry-over is being caused by excessive boiler water solids concentration.
CAUTION
These large valves should be opened slowly. When open, boiler inputs must
increase to maintain steady-state conditions. Too much blowdown reduces boiler
efficiency.
Always open the valve closest to the steam drum (root block valve) first and then close it
last to reduce wear on the valve seats.
2.6 Determine the required frequency of blowdown by checking the boiler water chemistry.
CAUTION
Drain valves on the lower waterwall headers should not be used for blowdown
purposes when the boiler is in operation. Improper use of these valves may
interrupt waterwall circulation and cause tube failure due to metal overheating.

C.3 ATTEMPERATION
3.1 Check intermediate (1A and 1B) and main steam (2A and 2B) temperature and
attemperation spray water flow. Verify that desuperheating does not lower the steam
temperature to within 11C (20F) of saturation temperature.
3.2 Verify a demand exist for attemperation (control of steam temperature).
3.3 Check that the controllers respond to their setpoints slowly. Over-feeding spray water
can lead to carry-over and or steam pressure swings.
C.4 ROUTINE INSPECTIONS (Operator Boiler Walk-Downs)
Foster Wheeler recommends that someone (an operator) walk down the boiler at least once every four
hours to visually inspect all equipment. A routine should be established during plant walk-downs to
inspect the boiler and auxiliary systems and equipment. A record of this frequent inspection will help
identify, repair and maintain the equipment in good, safe, operating conditon.
4.1 Check rotating equipment (motors, fans, feeders, conveyors, etc.) for proper lubrication,
cooling and vibration levels.
4.2 Check sootblower steam supply valves and piping. A leaking steam supply could steam-
cut boiler tubes in that area. Wasted steam also decreases boiler efficiency.
4.3 Check pipe hangers and buckstay bumper pads for signs of expansion problems that
could put unusual stress on boiler components.
4.4 Check steam drum water level sight glasses and columns, assuring they agree with
control room indications. Any leak should be reported and repaired immediately.
4.5 Inspect flues, ducts and boiler casings for hot spots, discoloration, flue gas smells and
structural integrity.
4.6 Check the boiler for unusual noises or vibrations. Early detection of a problem could
reduce down time and repair time.
4.7 Check indicated settings of dampers and manually adjusted air flows. Verify flows with
control room indications and operation.
4.8 Look for bed material/ash leaks. Small leaks soon become hot spots. Hot spots require
immediate attention. Most hot spots require a boiler shutdown to repair the problem.
4.9 Check valves and piping for leaks at flanges and valve stems. Investigate any standing
pools of water or oil.
4.10 Keep duct burner areas clean. Safety first!
4.11 Inspect all air drops and air nozzles on the boiler. Check for overheating, bed material or
flue gas leaks.
4.12 Check flame pattern and color when the duct burners are in service.

4.13 Check the stripper coolers for proper operation. Safety first! Be aware that air and water
are both used in stripping and cooling bottom ash.
C.5 BOILER SUPPORT
Several systems must support efficient boiler operation during normal operating conditions. The
stripper cooler systems remove ash to maintain proper combustor heat transfer, bed material
levels and temperatures. The sootblower system remove the build up of unwanted material (ash)
on HRA convection pass heat transfer surfaces. Operation of these two systems depend on
conditions in the boiler, load, quality of fuel and other variables.
C.6 BOTTOM ASH REMOVAL AND TRANSPORT
It is normal to keep the bottom ash removal system in standby until needed. The operation of the
stripper coolers works well with low-ash fuels such as coal . It is normal that the bottom ash
transport/transfer systems are in an automatic mode of operation.
The ash handling transport system empties the bottom ash, air heater and fly ash hoppers and
transports the ash to the ash silo(s). Operator action is usually required to unload the silo into the
trucks that haul the ash away.
C.7 SOOTBLOWING
Initiate a sootblowing cycle when the economizer exit flue gas temperature increases 17C (30F)
above normal or at least once every 24 hours to prevent baghouse/ash system overloading. The
recommended frequency of sootblowing will be determined during initial boiler operating period.
Before operating the sootblowers:
1. Initiate a cleaning cycle on the ESP and empty the fly ash hoppers. Sootblowing can
overload the fly ash system.
2. Verify that sootblower thermal drains are working.
3. Verify boiler load is above 50% of MCR.
4. Watch furnace pressure during the sootblower cleaning cycle. Too much steam may
cause furnace pressure to swing.
c. An operator should walk-down the sootblowing system while in operation looking for
leaking or other abnormal conditions.

Reduce fuel to the boiler @ 10%/min.

Blow soot above 50% MCR.
Bed temperature <760C (1400F),
auxiliary burner light-off.
Fuel feeders shutoff when empty.
Stop auxiliary burners.
Cool down boiler using fans and
blowers.
Open HRA doors for cool down.
Stop all fans and blowers.
Inspect boiler before entry by anyone .

D. NORMAL SHUTDOWN
This chapter describes the basic steps to reduce boiler load from 100% output (MCR) to cold shutdown
staying within cool-down limits. These instruction will assist the operator while using normal shutdown
procedures for your own boiler as supplied by the owner/operator.
1. Reduce coaland air input to reduce boiler load to about 50%. Normal bed temperatures
should be maintained.
Note: During shutdown, do not exceed a maximum temperature differential of 56C

(100F) between the steam drum top and bottom metal temperatures or greater
than 112C (200F)/hr temperature change in the flue gas temperature
measured at the compact separator inlets.
2. Place excess O2 bias controllers in manual at 50% output.
3. Clean HRA convection pass use the sootblowers before reducing load below 50%.
4. Check decreasing temperatures and maintain cooling

rates. Do not exceed
5. Continue to slowly reduce boiler load down to Foster Wheeler's
minimum, reducing coalfeed at 10% per minute or Recommended
less to 816C (1500F) bed temperature.
cool down rates
6. Maintain steam temperature above 11C (20F)
saturation temperature while decreasing load.
7. Place duct burners in service when bed temperature is less than 760C (1400F).
Continue to reduce coalfeed to minimum.
8. Empty coalfeeder belts and limestone feeders and lines with bed temperature above
649C (1200F).
9. Decrease duct burner firing rate while staying within decreasing temperature limits of
112C (200F)/hr combustion chamber gas temperature and 56C (100F)/hr boiler
metal temperature.
10. Maintain limestone feed in automatic until coalfeed is stopped.
11. Place steam drum water level controller in manual, as necessary.
12. Stop the coaland limestone feed to the boiler. Close all the manual limestone valves at
the boiler.
Note: If the boiler is being shutdown (cool-down) for maintenance and there is a
need to remove the bed, keep the stripper coolers in service as long as possible.
If the bed is to stay in the combustion chamber, stop the stripper cooler
operation.

13. Maintain steam drum water level near the upper limit of the steam drum gage glass
visibility during shutdown. Keep water level within limits of the sight glass.
14. Continue fluidizing the bed to cool the boiler at a maximum cooling rate of 56C
(100F)/hr on the pressure parts or 112C (200F) change in hot compact separator
inlet temperature. Use the duct burners to get the required rate of temperature decline.
15. Stop the duct burners when bed temperatures decrease below 425C (800F).
16. Continue full air flow through the boiler in automatic until the desired bed temperature is
reached, at least 400C (750F), lower if needed for maintenance, 38C (100F).
17. Close the primary and secondary air fan inlet control dampers. The dampers should be
closed slowly permitting the ID fan automatic damper control to maintain the furnace
pressure between 0.12Kpa and 0.25Kpa (0.5 and 1.0"w.c.).
18. Stop all fans after the PA and SA fan inlet control dampers are completely closed.
19. Close the ID fan inlet vanes.
20. Verify the high pressure blower stops 30 - 45 seconds after the ID fan stops.
21. Stop the chemical feed system and continuous blowdown system when the boiler feed
pump is stopped.
22. Continue to operate all ash removal transport systems until their respective hoppers are
empty.
23. Open all superheater and steam drum vents when the steam drum pressure has decreased
to about 25 psig (170 kPa) when the combustion chamber is to be opened for
maintenance.
Note: If the boiler is to be drained, you can begin force draining when steam drum
pressure has decayed to 100-170 kPa (15-25 psig). This pressure will help
"push" the water out a little faster. Check the drain system and check for
hammering. Boiler water should not exceed 121C (250F).
24. Do not allow any idle boiler that is open to atmosphere to remain partially filled with
water for any length of time. Fill the boiler completely with deaerated alkaline water
with oxygen scavenger added for protection against corrosion.
25. Apply a 35kPa (5 psig) nitrogen blanket to the steam drum through steam drum nitrogen
fill valve when steam drum pressure decays to 35 kPa (5 psig) when the boiler is to be
laid up wet.
26. If the outage will last several weeks or months or should weather prohibit filling the
boiler, drain and dry the boiler. Place shallow pans of unslaked lime or several pans of
silica gel in the steam drums to absorb moisture and maintain the internal surfaces in a
dry condition.

27. When the boiler is to be out of service for several days or longer, all ash, soot deposits
and bed material should be removed since moisture absorbed by these materials causes
corrosion.
28. Protect the boiler from freezing.
E. HOT SHUTDOWN
E.1 Planned - Bottling Up the Boiler
The boiler can be shutdown for short periods and held in a hot standby condition for up to,
about, eight (8) hours. Read the Bottling Procedure in the Appendix Section of either the O&M
Manual or Operator Training Manual.
When the bed is to be hot slumped or banked, the coalfeed is stopped and the fuel in the bed is
allowed to burn out. When the excess O2 indications in the flue gas increases to double the
normal full load reading (such as 3.5 to 7.0), the air flow to the combustion chamber should be
stopped to lessen bed heat loss by stopping the ID fan. This O2 increase suggests most of the
coalin the bed has been exhausted and the bed can be slumped without causing a clinker in the
bed.
The PA and SA fans will also stop. All fan inlet vanes and air control dampers are closed to
lessen the amount of heat lost. No fire is maintained or introduced into the furnace. The pressure
in the steam drum will decay after an initial slow, gradual increase during the first one to two
hours due to heat from boiler metals and refractory equalizing with water/steam-side. Maintain
normal water level in the boiler steam drum.
Note: A hot condition is one in which the average bed temperature is above 760C (1400F).
When the average bed temperature is below 760C (1400F), follow the Cold Startup
Procedure. The average bed temperature of a slumped bed must be read from the lower
set of bed thermocouples.
E.2 Unplanned
When the boiler is tripped from a load above minimum, where fans also stop, slumping the bed,
the boiler can:
1. Be restarted immediately following the hot restart guidelines,
OR
2. Remain down for "hot maintenance" without restarting fans until ready for restart.
In this case, the steam pressure increase during heat equalization will be higher
than during a planned hot shutdown.

F. HOT RESTART
To start up the boiler from a hot standby condition, proceed as follows:
1. Purge the boiler if the boiler tripped on an MFT. All steps should be accomplished as
quickly as possible to avoid reducing bed temperatures.
Note: On a hot restart following high load operation (above 80% MCR), it is
advised that you blowdown superheater drains. This is done by opening each
drain valve and closing the drain valve, one at a time. This is a precaution
against condensate collecting in the headers. Superheater vents are to remain
closed.
2. Start duct burners (DBs) and heat the boiler following the normal startup guidelines.
3. Check bed temperatures. When ignition occurs the bed temperatures will rise and the
normal coalfiring procedures can be followed.
Notes: When the bed temperature does not rise within three (3) pulses of feeding fuel,
stop feed fuel to the boiler. Purge the boiler and resume the normal startup
procedures.
Remember, when bed temperatures fall below 593C (1100F) the fuel feeder
start permissive will be lost and duct burners must be used to raise bed
temperature above the 593C (1100F) fuel feed permissive interlock.
If the fuel feeder trips with the bed temperature greater than 760C
(1400F), the duct burners should be placed in service to maintain bed
temperature if required.

G. TRANSIENT AND EMERGENCY OPERATIONS
This section discusses some, but not all, of the transients and emergencies that can occur during operation
of the CFB boiler. The information contained here is intended to provide general information for you
during such upsets. Transients are small problems. Emergencies are large problems.
Read Foster Wheeler "Safety and Operating Precautions" section for special limits and conditions that
may occur during transient and emergency operations. This information should not replace emergency or
abnormal response procedures that are specific to your plant.
G.1 TRANSIENTS
1.1 HIGH OR LOW BED TEMPERATURES
Never let the compact separator inlet temperatures exceed 1750F (954C).
Excessive heat may damage refractory or tube metal.
Check bed temperature thermocouples and associated instrumentation for proper

operation. If a problem is found, report it and have repairs made when possible.
Check gravimetric coalfeeders for proper operation, leaking, plugging, bridging and
normal coalfeed rate. If a problem is found, report it and have repairs made when
possible.
Check for proper operation of all fans and blowers. Verify setpoint and measured flow
indications. If a problem is found, report it and have repairs made when possible.
Check PA-to-grid, PA to plenum (windbox) air flows. Verify normal air split between
PA and SA air flow in automatic. If a problem is found, report it and have repairs made
when possible.
Check percent of excess oxygen in the flue gas. Verify normal operation of oxygen
analyzers. Verify calibration. If a problem is found, report it and have repairs made
when possible.
Check for proper steam drum water level. If necessary, blowdown gage glasses. Verify
normal operation of feedwater control valves. If a problem is found, report it and have
repairs made when possible.
Check stripper coolers for proper operation. Verify bed material is being conveyed in
and out of the stripper coolers. Verify air on the solids transfer line. If a problem is
found, report it and have repairs made when possible.
Check combustion chamber bed level, bed density and bed pressure indications. Verify
pressure taps are not plugged. Verify normal air flows and pressure to instruments.
Verify each individual differential pressure tap. If a problem is found, report it and have
Check for normal hot loop circulation temperatures. Check for deviation in normal
indications. Check the trend recordings of bed pressure and plenum pressure (windbox

pressure) for sudden changes. If a problem is found, report it and have repairs made
when possible.
G.1.2 HIGH OR LOW DUCT BURNER FUEL SUPPLY PRESSURE
Check fuel supply system for normal operation. If a problem is found, report it and have
G.1.3 HIGH OR LOW BED INVENTORY
Do not operate a Foster Wheeler CFB boiler without enough bed material in the
furnace to support heat transfer. If bed material inventory decreases below a preset
value (~32"w.c. windbox pressure), all coalfeeders will automatically stop.
Check that bed pressure taps are not plugged. Verify normal air flow and pressure to all
instruments. If a problem is found, report it and have repairs made when possible.
Check bed inventory transmitters and associated instruments for normal operation. If a
problem is found, report it and have repairs made when possible.
Check for proper operation of all fans and blowers. If a problem is found, report it and
have repairs made when possible.
Check for normal indication of pressures at windbox and grid. Verify air tight integrity
of ductwork. If a problem is found, report it and have repairs made when possible.
Check stripper coolers for proper operation. Verify bed material is being conveyed out
of the combustion chamber. If a problem is found, report it and have repairs made when
possible.
Check for normal operation of limestone feed system. Verify normal discharge pressure
and temperature of blower. Verify that all feed lines are warm (not plugged). If a
problem is found, report it and have repairs made when possible.
Check for normal coalfeed rates for the indicated boiler load. Verify that coalfeeders are
performing normally. If a problem is found, report it and have repairs made when
possible.

G.1.4 HIGH OR LOW STEAM DRUM WATER LEVEL
NEVER OPERATE (FIRE) ANY BOILER WITHOUT A VISIBLE WATER LEVEL

IN THE BOILER STEAM DRUM.
Check for proper operation of all steam drum instruments. Blowdown gage glasses.
Verify proper level by comparing local and remote water level indications. If a problem
is found, report it and have repairs made when possible.
Check for normal operation and line up of boiler feed pumps and associated piping.
Verify water level in deaerator. If a problem is found, report it and have repairs made
when possible.
Check for normal operation of all feedwater control valves and line up of piping. Verify
instrument air to all controllers are normal and free of moisture. If a problem is found,
report it and have repairs made when possible.
Check for normal operation of all steam flow and feedwater flow transmitters. Verify
valve line up. If a problem is found, report it and have repairs made when possible.
Check for evidence of a boiler tube failure. If a tube failure has occurred, follow
procedures outlined in Foster Wheeler's "Emergency Operation" fold out supplied with
your Operation and Maintenance Manual or your Training Manual.
Check for normal drain valve line up. Verify piping after the last block valve on each
system is not hot suggesting a leaking valve. If a problem is found, report it and have
G.1.5 INTERMITTENT LOSS OF BED INVENTORY FROM CIRCULATION - (Wall

seal surging or change in the rate of circulation of bed material in the hot loop)
Check for proper and normal fluidizing air flow to all wall seal fluidizing nozzles. If the
float inside the rotameter is stuck on the bottom of the glass, it is an indication of a
plugged nozzle. Applying service air to that nozzle may be necessary to unplug that
nozzle and reestablish fluidizing air flow. Too much fluidizing air flow for an extended
period can interfere with normal circulation. If a problem is found, report it and have
Check for normal operation and normal discharge pressure from high pressure blowers.
Verify that HP blower inlet filter is not plugged. If a problem is found, report it and have
Check for normal indications of bed inventory. See section H.1.3 above.
Check for normal operation of all fans. Check air flow indications. If a problem is
found, report it and have repairs made when possible.

G.1.6 CONTINUOUS, GRADUAL LOSS OF BED INVENTORY FROM

CIRCULATION
Check operation of bottom ash removal system. Verify normal operation and conditions
of bottom ash removal system. If a problem is found, report it and have repairs made
when possible.
Check for gas-tight integrity of combustion chamber. Walk-down the boiler looking for
bed material or gas leaks. If a problem is found, report it and have repairs made when
possible.
G.2 EMERGENCY SITUATIONS

G.2.1 SUDDEN LOSS OF STEAM DRUM WATER LEVEL
When the cause is known and immediately correctable before the water level in the steam
drum reaches the minimum allowable operating level, reestablish steam drum water level
to its normal operating value and continue boiler operation.
When the cause is not known and the water level in the steam drum drops below the
minimum allowable operating level (this situation could be the result of a tube failure),
start an immediate shutdown according to the emergency shutdown section of this
procedure.
G.2.2 GRADUAL LOSS OF STEAM DRUM WATER LEVEL
When you cannot maintain a normal steam drum water level, the load on the boiler must
be reduced and the cause of the problem corrected.
When it is impossible to maintain normal steam drum water level at the reduced load,
then the boiler must be taken out of service according to the normal shutdown procedure
until the cause(s) can be identified and corrected.
G.2.3 EXCESSIVE BED TEMPERATURE
When the bed temperature cannot be maintained below 954C (1750F), an immediate
adjustment in the air flow distribution must be started. Normally, increasing the primary
air flow to the grid and an equal reduction in secondary air flow will accomplish this.
A reduction in fuel feed and/or an increase in total air flow may be required to control
high temperatures. This reduces the bed temperature rapidly to reduce the high
temperature that, if allowed to continue, may reach the ash fusion temperature for the fuel
being burned. If the bed temperature cannot be controlled using the above procedure, the
boiler must be shutdown.

G.3 EMERGENCY SHUTDOWNS
G.3.1 STEAM DRUM WATER LEVEL CANNOT BE MAINTAINED
Remove boiler from service immediately by following Normal Shutdown or Emergency

Shutdown Procedure, as the situation dictates. Remove bed material during this
shutdown as quickly as possible from the boiler.
G.3.2 SUDDEN LOSS OF STEAM DRUM WATER LEVEL
Note: This procedure should also be followed on a loss of feedwater supply.
a. An automatic MFT will occur on low low steam drum water level. The primary
air fan will go to minimum flow condition. The secondary air fan will also go to
manual and drive the dampers to minimum position.
b. Cool the boiler to allow bed material removal and boiler inspection.
CAUTION
Wet bed material can solidify and could cause metal corrosion
in the furnace and should be removed as quickly as possible.
G.3.3 AIR-SIDE OR GAS-SIDE FAILURES
This procedure should be followed on a primary air fan, secondary air fan and/or induced
draft fan mechanical failure and the fan motor continues to run.
a. An MFT is started by a drop in air flow. A fan failure shuts off the fuel feed,
limestone feed and the bed material removal.
b. Fans and drives are interlocked to stop in the sequence below:
> PRIMARY AIR FAN MOTOR

> SECONDARY AIR FAN MOTOR
> INDUCED DRAFT FAN MOTOR
> HIGH PRESSURE BLOWER MOTOR
A trip of the ID fan will stop the primary air fan, then the secondary air fan and then the
HP blower after a 30-second time delay on the IDF.
c. Maintain normal steam drum water level.
d. Following control of the emergency situation, use the normal shutdown

procedure. After correcting the reason for the emergency shutdown, a normal
restart or hot restart, as applicable, can be initiated.

G.3.4 LOSS OF SERVICE of the following equipment will initiate an immediate automatic
boiler shutdown according to the emergency shutdown. (See Section 4 for a list of the
boiler main interlocks.)
a. Primary air fan not running.
b. Secondary air fan not running.
c. Wall seal header pressure less than minimum.
d. Induced draft fan not running.
G.3.5 RAPID LOSS OF BED INVENTORY FROM CIRCULATION (see previous section)
Check for rapid increase in air flow.
Check for rapid increase in flue gas temperature combined with air flow increase.
Check HP air pressure.
Check HP air flow rate to wall seal nozzles.
Note: If bed material loss persists, there may be a restriction in the wall seal or
compact separator downcomer from refractory failure or solids build up which
would require an internal inspection and possible repair.
G.3.6 LOSS OF FLUIDIZING AIR TO Wall SEAL
The wall seals should not require manual cleaning before a boiler restart
following a trip of the boiler and/or loss of the HP blower. Based on operating
experience, when there was difficulty of refluidizing the bed material in the wall seals
following an uncontrolled trip, service air was introduced at the nozzles. All the nozzles
have been designed with provisions for service air connection.
Although unlikely, if refluidization is not achieved, the following recommended restart

sequence should be followed.
Restart the ID fan.
Restart the HP blower.
Observe all wall seal rotameters for proper air flow. Blow out any that are low
in flow rate using service air.
Restart SA and PA fans and establish normal air flows.
Refire boiler and carefully observe bed pressure for normal operation. (The bed
pressure should drop only a few inches when increasing boiler load from minimum to full
load.)

Observe wall seal downcomer temperatures. These should follow bed

temperatures closely. If one does not follow bed temperature, then use service air on the
wall seal nozzles in an try to refluidize the wall seal.
If bed pressure drops rapidly during a load increase or earlier, then apply the
same technique of using service air until the wall seal(s) breaks free.
If this approach does not work, then it will be necessary to shutdown the boiler
and drain the wall seals.
H. TUBE LEAK DETECTION

Early detection of boiler pressure part leaks will prevent further damage to adjacent pressure parts and
circuits. Depending on the location of the leak, audible indication and visibility many not be possible on
an Foster Wheeler CFB boiler. However, other process indications can be used as evidence of a pressure
part leak.
The chart below outlines some locations and the possible indications.
ECONOMIZER COMBUSTION CONVECTION IN-FURNACE

CHAMBER CAGE & SH SUPERHEATERS
Steam flow, feedwater Steam flow, feedwater Steam flow, feedwater Steam flow, feedwater
flow split flow split flow split flow split
Water in air heater Reduction of bottom Reduction of bottom
hopper. Difficulty ash production ash production
pulling fly ash
Possible noise in back Seldom able to detect Able to detect noise in Seldom able to detect
pass any noise convection cage any noise
No change in compact Decreased compact No change in compact Decreased compact
separator inlet separator inlet separator inlet separator inlet
temperature temperatures temperature temperatures
No process effects Furnace pressure, drum Little or no process Furnace pressure may
detected level upset at onset of effect be upset at onset of
major leak major leak
No effect on spray No effect on spray Spray water may be Spray water may be
water water slightly effected slightly effected
ID fan, dust collector ID fan, dust collector ID fan, dust collector ID fan, dust collector
seldom affected seldom affected seldom affected seldom affected
Recommendations:
1. Develop a steam flow, feedwater flow, drum level trend that operates continuously.
2. Walk the boiler down regularly listening for unusual noises.
3. Shut down the boiler as soon as possible when a tube leak is suspected.
4. Remove bed material during the shutdown process.
5. Once the boiler is down, remove wet bed material immediately before it sets up.
A method of leak detection commonly used on any type of boiler is a chart or trend set up that includes
feedwater flow and steam flow. Whether the two lines on the chart line up or agree is not important.
What is important is the relative separation between the two displays. Obviously, a tube leak will
eventually show up as increase in feedwater flow without an increase in steam flow.
The next method is to monitor carefully process parameters. You must have a display with the boiler
temperature profile available upon demand. One of the features of the CFB process is that it is sensitive
to the presence of furnace leaks. The process will show the presence of a leak with much smaller flows
besides the feedwater/steam flow comparison.
For example, the first indication may be that the bottom ash removal rate will decrease, maybe enough to
shut the stripper coolers off entirely. You may then begin increasing the limestone feed rate to maintain
indicated bed pressure.
The second factor may be that the compact separator inlet temperatures will start to drop. Bed
temperatures will remain constant while the compact separator temperatures drop into the high 1400's.
This information, in conjunction with the bed loss, may confirm the presence of a tube leak.
Bed material loss is this case is caused by excessive velocity through the compact separators that results
in greatly increased bypassing of the compact separators. The lower compact separator flue gas
temperatures happen because furnace velocity may increase (resulting in better heat transfer) and the heat
absorption of the steam. Superheater spray flows may increase due to the higher HRA convection pass
velocity and other factors.
Economizer and HRA convection pass superheater leaks are more difficult to find because they will not
affect the process. Economizer leaks may eventually show up as water in either the ash hopper or
baghouse but superheater leaks will not.
It is very important to detect any leak as soon as possible. The longer any leak remains undetected, the
more damage that leak will cause.

I. THERMAL CYCLING
Thermal cycling in a CFB is defined as any cycle of temperature within the hot loop system from
the standard operating temperature (about 871C [1600F]) to a temperature of 371C (700F),
as measured by the bed temperature and compact separator inlet/compact separator flue gas
temperatures, below the standard operating temperature (about 871C [1600F]) and subsequent
return to the standard operating temperature, or a drop in the steam/water-side pressure that
results in greater than 139C (250F) change in the steam/water-side saturation temperature.
During these changes in temperature, considerable expansion and contraction of linings, tubes,
refractory, casing, etc. occurs. To lessen the potential damage that can be caused by thermal
cycling, you must minimize the number of cycles and the rate of temperature change during a
cycle.
The following are suggestions to reduce the effects of thermal cycling:
1. During a shutdown, do not allow the steam/water-side pressure to decay quickly. Allow
the steam-side pressure to decay naturally by keeping the boiler "bottled up."
2. In addition, try to reduce any rapid temperature declines (cool-down) caused by the air
and gas flows.
3. If possible, minimize the number of thermal cycles to eight (8) times a year with an
additional eight (8) times during an initial startup phase.
4. See the Safety and Operating Precautions section for allowable increases in boiler metal
temperatures versus time during a startup phase.

J. SAND ANALYSIS
The sand should be clean, natural feldspar-type sand that is round, uncrushed, washed, dry and double-
screened.
This kind of sand is normally used in foundries.
The following is a typical sand analysis:
percent
SiO2 70 - 85
Al2O3 5 - 15
Fe2O3 1-5
CaO 0.5 - 2.0
Na2O 1.0 - 2.0
K2O 2.0 - 3.0
Moisture 0.0 - 1.0
Note that pure quartz sand is not acceptable.
The recommended sand size distribution is:

100% less than 600 microns
Sand Flow Rate: 140-680kg/hr (300 1,500 lb/hr)

Bulk Density: 90 lb/ft3
Angle of repose: 40
Minimize alkali metal content.

K. SILICA CONCENTRATION
Prevention of volatilized silica carry-over requires control of boiler water silica below required limits
using continuous and/or intermittent blowdown procedures.
Silica will volatilize at varying concentrations and temperatures. As the steam drum pressure increases
and steam saturation temperature increases, lower amount of silica content is permitted to limit carry-over
of volatilized silica. The table below lists industry accepted maximum allowable limits of boiler water
concentrates for the prevention of carry-over:
Boiler Water
Steam drum Total Specific

Pressure Silica Alkalinity Conductance
(psig) (ppm SiO2) (ppm CaCO3) (micromhos/cm)
0-300 150 700 7000

301-450 90 600 6000
451-600 40 500 5000
601-750 30 400 4000
751-900 20 300 3000
901-1000 8 200 2000
1001-1500 2 0 150
1501-2000 1 0 100
These concentrations must be followed for operations at lower loads, such as turbine startup at low boiler
main steam outlet pressure.

O&amp;Msec3 CFB Boiler Operation

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

O&amp;Msec3 CFB Boiler Operation

Uploaded by

Copyright:

Available Formats

Foster Wheeler International Engineering Labuhan Angin CFB Operations & Maintenance Manual

& Consulting (Shanghai) Co., Ltd.

Company: FWIEC Section: Three

Company: FWIEC PAGE ii Section: Three

STEAM DRUM WATER LEVEL CANNOT BE MAINTAINED ...................................................... 45

Company: FWIEC Section: Three

3.1 CIRCULATING FLUIDIZED BED BOILER OPERATION

Any operation of the boiler must be accomplished with safety your

This section is to introduce you to the basic operating principles of a

Company: FWIEC PAGE 1 Section: Three

Stroke all air flow dampers

Company: FWIEC PAGE 2 Section: Three

Company: FWIEC PAGE 3 Section: Three

A. PRELIMINARY OPERATIONAL CHECK LIST

1. Carefully inspect all parts for proper assembly and installation.

Company: FWIEC PAGE 4 Section: Three

Company: FWIEC PAGE 5 Section: Three

B.1 FILL THE BOILER

1.10 Open ERV 1LBA10 AA203 at least 15%.

Company: FWIEC PAGE 6 Section: Three

1.14 Verify boiler feedwater temperature, 1LAB50CT001 (economizer inlet) and

Company: FWIEC PAGE 7 Section: Three

COLD STARTUP VALVE ALIGNMENT CHART

Valve Description Valve Number Position

Company: FWIEC PAGE 8 Section: Three

Boiler water-side drain valves 1HAD20 AA001, 1HAD20 Closed

Company: FWIEC PAGE 9 Section: Three

B.2 START FANS AND ADJUST AIR FLOWS

Note: The sequence for starting fans is:

A. STARTING THE INDUCED DRAFT FAN (IDF)

1 Place bed temperature manual controller at 50%.

2 Place excess O2 trim bias controller at 50% and leave in manual.

4 Place ID fan inlet damper controllers, 1HNE10AA701 and 1HNE20AA301, at

5 Place ID fan outlet isolation damper, 1HNE10AA201 and 1HNE20AA201, at

6 Verify an Open Gas Path DCS signal through the ESP.

7 Verify ID fan controller is in Remote.

8 Verify no ID fan motors trouble

9 Verify no stop signal present.

10 Verify furnace pressure not low-low and no MFT

11 Verify ID fans/motor bearing temperatures not hig- high

12 Verify no ID fan failure to start

13 Verify no ID fan trip

. 14 Verify drum level not low-low

Company: FWIEC PAGE 10 Section: Three

15 Verify fan motor stator winding temperature not high-high

16 Initiate a DCS start command to the ID fan A.

18 Repeat 16 to 17 for starting ID fan B.

19 Leave ID fan controllers in manual at minimum. If plant operating experience

B. STARTING THE HIGH PRESSURE BLOWER (HPB)

1 Open HP (wall seal) air distribution valves on wall seals.

3 Verify both ID fans are still running.

4 Verify wall seal blowers in Remote

5 Verify no wall seal blower motor trouble.

6 Verify no stop signal is present .

9 Verify no wall seal surge.

10 Initiate a DCS start command to the HP blower A.

12. Open HP blower A outlet isolation valve 1HFW10AA201

13. Repeat 11 to 12 to start HP blower B.

C. STARTING THE SECONDARY AIR FAN (SAF)

Company: FWIEC PAGE 11 Section: Three

4 Station operator at fan before starting.

5 Verify SA fan in Remote.

6 Verify no SA fan motor trouble.

O&Msec3 CFB Boiler Operation

O&Msec3 CFB Boiler Operation