TM

INSTALLATION, OPERATION &

MAINTENANCE MANUAL FOR
FLUIDISED BED COMBUTION (FBC)
STEAM BOILER

HEATEX INDUSTRIES LIMITED.

Regd. Office & Works:
BLOCK NO.436, OPP.T.M.PATEL PROCESSING, NR.PALSANA CHOKDI,
N.H.NO.8, PALSANA, DIST. SURAT - 394315.(GUJARAT)INDIA.
Ph.No.:91-2622-265430,265436 Fax:91-2622-265422
E-Mail:info@heatexindustries.com
Website:www.heatexindustries.com

1
 INDEX

A. Installation

B. Operation &Control

1. General Information
2. Bed Material
3. Starting
4. Running Attention
5. Stopping

C. Operation Instruction of Valves

D. Description of the Steam Generation System

E. Do’s and Don’ts for Boiler

F. Emergency Procedure

G. Operational Precaution for Safety

[A] INSTALLATION:

The Boiler dispatched from our factory is normally in open trailer. During
transportation cares should be conform proper supporting to avoid vibration.
The boiler also should be lifted for loading or unloading or shifting from one
position to another position only by using with lifting lugs.

 UNLOADING

Unloading of this kind heavy material generally used crain or hydra. If it not to
use in any critical places rollers, wooden slabs or some kind should be placed be
near the frame of the boiler and wooden cases and it should be carefully guided
for unloading and shifting. Under no circumstances the Boiler and accessories
should be dropped or turned to any other position other than marked on the
cases.

It is advisable to unload the Boiler as close as possible to the Boiler House,

preferably just outside the main door of the Boiler House, on some kinds or
pipes, so that pushing the Boiler into the Boiler house for positioning it on the
foundation is easier. The soil at the place of unloading should be hard enough to
bear the weight of the Boiler or Crain to prevent it from sinking. Like wise, when
the boiler is being shifted to the boiler House, the approach road to the boiler
house should also be made of hard ground.

 RECEIVING AND INSPECTION

On receipt to of the boiler ,please, check that all items as per delivery Challan
have been received. For ease of checking ones e to PACKING SLIP is sent along
with the transporter and one set is mail id to one of the packing case in
aluminum sheet with clear marking of PACKINGSLIP.

By careful inspection, determine whether any damage/loss has occurred in

transit, in spite of proper checking and loading of each equipment at our factory
before.

Heatex Surat /Insurance co. must be notified immediately incase of any lost or
undelivered parts, or transit damage for corrective action, as the case may be.

Timely assistance from or Regional/ Area offices will be available.

 STORAGE

If installation of equipment is delayed and storage is made outdoors, provide

reasonable weather protection as dictated by the climate and period of
exposure. Please note that packing case life is maximum 3 months.
 Electrical components, motors and bearings should be tightly covered to
preventing rain of water / moisture and if the equipment of its parts are to be
stored out doors for any length of time it should be completely covered with a
tarpaulin. Periodically the unit should be inspected to make sure no damage,
such as corrosion, is occurring.

When a equipment is stored or installed within a building still under

construction, the entrance of dirt and construction material to the tank, motors,
feed pump, OPH, fans and electrical components should be prevented. The
critical components should be covered and sealed, preferably they should be
stored in covered building to prevent damage and corrosion.

Whenever an assembled rotating equipment such a fans, pumps, gearboxes, is

store main idle for any extended number of days, extra precaution has to be
taken to avoid rusting and jamming of bearings. The equipment can be rotated
manually once a week in the following sequence to prevent jamming.

180 degrees clockwise, then 90 degrees anticlockwise, then 180 degrees

clockwise etc.

 FOUNDATIONS

A rigid, level foundation is vitally essential for smooth, quite operation, good
performance and low maintenance cost of the Boiler and other equipment. An
improperly constructed or inadequate foundation may cause vibration and
possible misalignment of the equipment.

Special attention must be given to insure a permanently solid support for the
rotating equipment and bearing supports.

ALL FOUNDATIONS MUST BE FLAT, LEVEL AND RIGID

The height of any foundation should be minimum 100 mm above the finish floor
level unless otherwise specified in foundation drawing of your boiler.This is to
prevent the structure of equipment from spilled water, oil, corrosive chemicals
etc. which may corrode and reduce the life of equipment and foundation bolts.

An allowance must be made for a minimum of (25mm) 1 inch of shimming and

grouting when determining the top surface of the foundation.

Generally speaking, concrete foundations should have a minimum weight of six

to eight times the total weight of the equipment. Consult your civil engineering
expert for designing the foundations based on soil condition of your plant and
live weight of the foundation.

The foundation layout and floor loading for designing foundations of various
equipment’s.

Given in foundation details / General Arrangement drawing of the Boiler.

Important Note: In horizontal installation of unit a M.S. plate of 10 mm thickness
should be grouted in foundation as shown in general arrangement drawing. This is
necessary to facilitate free thermal expansion movement of Boiler during operation.

PREFERABLY THE FOUNDATION WORK SHOULD BE COMPLETED PRIOR TO

ARRIVAL OF BOILER TO SAVE TIME ININSTALLATION

 HANDLING

If a hoist/crane is employed in handling the equipment’s extreme care

should be taken to prevent distortion or damage to any part of equipment. The
handling of large sized equipment’s will be require extra precaution in this
respect. Use lifting hooks or eyes where provided.

It is advisable to use a spreader type sling when handling equipment.

Boiler requires careful assembly and alignment at site. Each equipment should
be moved to its foundation as a unit, with care being taken to prevent of the
equipment.

After the foundation holes in the unit are lined up with anchor bolts in the
foundation, The equipment should be lowered over the anchor bolts.

Since the Boiler, APH, feed water pump, Dust collector, Bag filter are mounted
on separate foundations much care and attention to alignment is required to
match their inlets and outlets.

Prior to placing the equipment’s on the foundations, the location of anchor

bolts should be checked against the drawing to ensure that there holes are
placed correctly. During erection all parts should be carefully checked to see
that they physically match and are incorrect position as indicated in the General
Arrangement drawing.

Lashing hooks are provided for units exported outside India, these are to be cut-
off once unit is finally placed on foundation.

 GROUTING AND LEVELING

For preventing the rotating equipment from distortion vibrations etc. proper care
needs to be taken on selection of anchor bolts ,its size, shape and length and on
proper leveling.

Anchor bolts in concrete should be L or T shaped, and should be placed in pipe

or sheet metal sleeves approximately (50 mm) 2” larger in diameter then the
anchor bolts to allow for adjusting the bolts in case they moves lightly when
concrete is poured.

Where some adjustment is required to level the unit, leveling should be done
taking top plate and boiler shell as reference.
 For leveling large area shims should be placed under the boiler frame/pedestal
before tightening the anchor bolts. Distortion of the equipment may occur when
the bolts are not tightened equally or if short thick shims providing only limited
surface contact are used.

 BOILER ROOM

The unit and its surroundings can be kept clean if the installation is done on a
raised slab or platform. The slab must be cast out of a non-combustible material
like concrete and properly leveled.

A minimum clearance of 1000 m (3.3”) is required for any machinery as per

FACTORY ACT. The front clearance should be at least 1200 mm (4’) to allow
adequate room for movement, operation and maintenance. Space should be
provided for the coil to be lowered on the floor. The͞ “I” beam should be fixed
exactly over the center of the unit shell. A hand operated chain pulley block
with travelling trolley of the capacity mentioned for various models should be
mounted on “I” beam. If the span is longer, structural engineers may be
consulted. An electrical hoist with a travelling trolley is recommended for
quicker and easier operations.

If sufficient height in this room is not available, shifting the entire unit to a place
with adequate vertical clearance may be considered.

This room should be properly ventilated, preferably by large windows on all sides
in order that the surrounding temperature does not exceed 40°C to 45°C.For
this purpose, it is also necessary to insulate the chimney as shown in the
drawing. It is to be noted that in case of artificial ventilation, extraction of air by
exhaust fans is not recommended as this may create negative pressure in the
room, which can be detrimental to the proper operation of the unit.

Please make sure that while installing the unit, regulations of fire insurance
association, etc. are strictly adhered to.
 LIST OF EQUIPMENTS FOR INSTALLATIONOF UP TO 12TPH
CAPACITY

Equipments Capacity Quantity

Sr.No.

01 Crane 100 Tone 1 No.

02. Hydra 20 Tone 1 No.

03. Spanner Ring type 3/16” to 2” 1 set

04. Spanner Fix type 3/16” to 2” 1 set

3/16” to 5/8” 1 set
05. Allen key
2 mm to 16 mm 1 set
06. Screwdriver 8” ,12”, 24” 1 set

07. Tester 12” 1 No.

08. Tie-belt 10meter 2 Nos.

09. Hammer 10Kgs 1 No.

5meter 1 No.
10. Measure tape
15meter 1 No.
11. Level bottle 1 No.

12. Water level tube 1 No.

[B] Operation & Control

1. General Information

AFBC PHILOSOPHY

Fluidised Bed Combustion (FBC) technology has distinct advantages for burning solid
fuels and recovering the energy to produce steam.

The process features a mixture of particles suspended in upward flowing gas stream the
combination of which exhibits fluid like properties. Combustion takes place in the bed
with high heat transfer to the furnace and low combustion temperatures. Key benefits of
this process are fuel flexibility and reduced emissions.

The following example will help to visualize the fluid bed process. Assume a container
with air supply through fluidizing air pipes at the bottom, that promotes even air flow
through the bed, and an upper chamber filled with sand. If a small quantity of air flows
through the fluidizing air pipe into the bed, it will pass through the voids of an immobile
mass of sand. For low velocities the air does not exert much force on the sand and they
remain in place. This condition is called a fixed bed or static bed.

By increasing the flow rate, the air exerts greater forces on the sand and thereby reduces
the contact forces between the sand particles caused by gravity. By increasing the air
flow further, a point is reached where the drag forces on the particles counter balance
the gravity forces and sand particles become suspended in the up flowing air stream. The
point where the bed starts to behave as a fluid is called the minimum fluidization
condition.

As the air increases further, the bed becomes less uniform, bubbles of air start to form
and the bed becomes violent. At this condition the bed is in expanded condition. This is
called bubbling fluidized bed and this phenomena occurs at atmospheric condition.
Hence, it is called as an Atmospheric Fluidised Bed.

The bed at static condition or at minimum Fliudised condition will be heated by charcoal
to the fuel ignition temperatures preferably above 500 deg C. Then fuel will be
introduced into the bed. The combustion takes place in the Atmospheric Fluidised Bed.
Hence, the combustion is called Atmospheric Fluidised Bed Combustion (AFBC).

FLUIDISED BED COMBUSTION

The fuel in the bed will burn and impart heat to the whole volume of the fuel when the
solid particles in the fluidised bed are preheated to the ignition temperature of the fuel.
At steady state operation, the bed contains about 0.5 to 2% of carbon while the rest is
inert material. A large amount of heat is extracted by the bed coils immersed in the bed
to maintain the combustion temperature lower that the ash fusion temperature and
thereby avoid agglomeration. Under such conditions the heat transfer to bed coils are
very high due to rapid mixing of particles.
 ADVANTAGES OF FBC BOILERS

1. Considerable reduction in boiler size is possible due to high heat transfer rate
over a small heat transfer area immersed in the bed.

2. Low Combustion temperature of the order of 750 0 – 900 0 C facilitates burning of

fuel with low ash fusion temperature, prevents NOx formation, reduces high
temperature corrosion and erosion, and minimizes accumulation of harmful
deposits due to low volatilization of alkali components.

3. High sulphur coals can be burnt efficiently without much generation of Sox by
feeding limisestone continuously with the fuel.

4. The unit can be designed to burn a variety of fuels including low grade coals like
floatation slimes and washery rejects without much sacrifice in operation
efficiency because only about 1% by wt. Of carbon content in the bed can sustain
the fluidised bed combustion.

5. High turbulence of the bed facilities quick start-up and shut down

6. Fuel automation of start-up and operation using simple reliable equipment is

possible.

7. Inherent high thermal storage characteristics can easily absorb fluctuations in fuel
feed rate.
2. Bed Material

IMPORTANCE OF BED MATERIAL QUALITY & QUANTITY

1. Before programming for a light-up, it is necessary that the recommended quantity

of bed material is procured according to the specifications. The bed material to be
stocked at least for 10 startups.

2. If the bed materials are procured from a refractory supplier, ensure only
refractory bricks are crushed to make bed material. Mix up of insulation bricks is
not allowed.

3. The fusion temperature of the bed material has to be above 1400 0 C. if the fusion
temperature is lower, clinkering will occur in the bed.

4. It is important that the bed material is procured according to the size

recommended. Oversize particles do not fluidize well and fine powder will fly
away. Also the fine powder puts off charcoal fire while fly away. Also the fine
powder puts off charcoal fire while start up. (Because fine bed material quickly
transfers heat to the bed coils

5. In a coal fired boiler, the ash produced from coal partly accumulates in the bed
and the same is drained to maintain a constant recommended bed height in the
fluidized bed. This ash drained from the bed can also be screened and the
screened ash can be used as bed material. In an agro fuel fired boiler, the bed
material will not be generated and hence bed material has to be procured for daily
consumption.

6. A coal fired fluidized bed in operation contain good amount of fines and coarse
particles, which are due to varying coal particle size on crushing. Hence for every
light up (except hot restart) fresh bed material is to be used. This is essential for a
smooth and quick start up.

7. When the bed material is procured from a refractory supplier, the size of the bed
material is to be specified up mentioning the upper serve no. 8 and lower sieve no.
20. The material has to pass, through sieve no. 8 and to stay on sieve no. 20.
 BED MATERIAL

REQUIRED PER START UP: 2.5 TONNES (APPROX.)

CRUSHED REFRACTORY – CHEMICAL ANALYSIS

Sl. No. Chemical Composition Percentage

1. SIO2 68
2. A12O3 28
3. Fe2O3 1.05
4. TIO2 1.67
5. MnO TRACES
6. CAO 0.54
7. MgO 0.23
8. P2O5 0.08
9. Na2O 0.22
10. K2O 0.45
11. BULK DENSITY APPROX – 1050 kg/m3

CRUSHED REFRACTORY SIZE : 100% > 0.85 mm & < 2.38 mm

SHAPE : PREFERABLY SUB ANGULAR / SPHERICAL

Fusion Temp. : > 1400 0 C

 USE AND IMPORTANCE OF CHARCOAL

1. Charcoal is selected as the start up fuel, mainly because of its high heat content,
rapid burning characteristics and low ignition temperature.

2. Charcoal is required for lighting up of the boiler. A fixed quantity of charcoal is

burnt in the fluidized bed to raise the bed temperature in the start up
compartment. Once the bed temperature is raised further fuel is fed to establish
combustion of fuel in the fluidized bed.

3. Good quality charcoal is a must for easy light up. Ensure charcoal is dry and not
already burnt. Heavier charcoal is an indication of good quality. Tamarind wood
charcoal is the best because it burns for more time and the calorific value is about
6600 kcal / kg.
4. Charcoal should be dry for rapid burning. Wet charcoal should not be used in any
case. Ensure the charcoal in stock is also dry.

5. The charcoal should not contain powder or bigger lumps. The charcoal shall be
sized to 15 – 25 mm. Fine charcoal burns easily and does not contribute much for
heating the bed. Bigger lumps would cause clinker formation, as the lumps do not
easily fluidize.
 BED MATERIAL FILLING

 The bed material can be filled by entering the furnace. For start up purpose, the
bed height shall be 175 mm – 200 mm above the air nozzle top level. I.e around
275 to 300 from DP

 The bed material below the nozzle level remains static all the time. This is not to
be counted as the bed height.

 Uniform spreading can be done by admitting fluidising air through the bed. The
air should be sufficient enough to fluidise bed.

 The bed height can be measure after physically after putting off the airflow.

 Alternatively the bed height can be found out by pressure drop across the fluidised
bed.

Since the bulk density of the bed material is around 1000 kg/m3, the pressure drop
across the bed in mm is the bed height in mm.

Though the normal operating bed height is 300 mm, initial bed material filling is done
only upto 175 – 200 mm.

In the case of compartment start up the bed material shall be filled as explained below :

Fill the bed material to a height of 175 mm in all the compartments. Fluidise all the
compartments together provided the fan motor Amperes are below the limits. If not
possible, fluidise two compartments together for leveling. Then the next compartment
can be fluidised separately. The start up compartment is to be fluidised separately.
When this is done a portion of the bed material spills to the adjacent compartment and
forms a mount along the edge of the compartment. Further bed material is to be added
to the start up compartment so that the bed height of 175 – 200 mm is maintained.
3. Starting

BOILER LIGHT UP

The lighting of the boiler is to be done with the help of charcoal and kerosene. The light
up is to be done only for a single compliment. After stabilizing with a single
compartment fire is transferred to other compartments as per the procedure explained
separately.

PREPARATIONS:

1. Inspect the boiler prior to starting and check the following:

- All access doors are closed.
- All personnel cleared
- All foreign materials are removed from furnace and pressure parts
- Starting equipment & inter locks are in position
- Boiler is filled with soft water above the low level limit

2. Check the following equipments for adequate lubrication and readiness for service:
- Fans and drives
- Feed pumps and drives
- Fuel feeders and controllers

3. Check dry fuel (0-6) mm is available in the bunker, the gates below the bunker are
open and fuel is available at feeder inlet.

4. Check the instrument air is available at the required pressure (of 7 kg/cm2) for
instrumentation and control.

5. Check the following valves in the Boiler shell / drum are closed.
- Feed control valve and its bypass valve
- Blow down valve
- Main steam stop valve
- Drain valves of water level gauge

6. Check the following valves are kept open

- Air vent on top of drum / shell
- Water level gauge, pressure gauge and liquid level transmitter /
limiter isolation valves.
- Valves before and after the feed control valve in the feed line
- Valves on the feed line connecting to the feed pumps in operation.

7. Check the bed material is filled in the furnace and fluidisation study is complete.
 BOILER FILLING

Before starting the filling up, keep the vent on the shell / drum open and close the blow
down and drain valves. The filling up is done by running the feed pumps but the rate of
flow is controlled by means of feed control valve. During the filling up check the
operation of blow down valve and drain valves and then close them. The boiler is filed up
completely till water comes through the shell / drum vent and is drained to bring the
water level to low-level alarm limit.

FLUIDISATION STUDY

 During the fluidisation studies, except for large compartments the fuel transport
air need not be introduced, as it would disturb the bed. The P.A fan is not being
operated.

 Observe the fluidisation of the start up compartment by varying the air flow
gradually. Mark the position of dampers when the bed material begins to fluidise.
In the case of pneumatically operated dampers, note the input signal “psi” from
the manual loaders

 The on set of fluidisation may also be observed by plotting the bed pressure drop
against the air flow.

 Set the air flow at 5 mm pressure

 Measure the air box pressure, P1 mm WC

 Add the gas plenum pressure P2 to P1

(P1 + 1 P2) is the pressure drop across the distributor plate and bed.

 Subtract P3 mm WC, which is the pressure drop across DP alone which is

measured in DP study.
i.e (P1 + 1 P2) – P3 would be the pressure drop across the bed

 The pressure drop across the bed is thus obtained for various air flows. The
readings may be plotted in a graph as shown.

 The airflow at which fluidisation starts are noted. This value is to be maintained
for the purpose of mixing at the time of start up

 Once the fluidisation study is completed, the fans shall be switched off and boiler
shall be taken for light up
The boiler light up is done using charcoal and kerosene as explained below :

 A fixed quantity of dry charcoal is spread uniformly over the start up compartment

 A fixed quantity of kerosene mixed charcoal is spread uniformly over the dry
charcoal layer

 The fire is initiated using swab

 Further by proper airflow control, fire can be spread and the heat released by
charcoal is utilized to heat the bed material to a temperature above the ignition
temperature of the fuel.

 In the process of preheating bed material the required fluidisation velocity is

maintained in the bed by suitably opening the FD Fan inlet damper.

 Further the fuel feed rate is adjusted to maintain a bed temperature of 800 0 C to
850 0 C

 The charcoal of size below 15 mm shall not be accounted for the above quantity

 Keep the ID Fan damper open at the time of lighting up. this would reduce the
possibility of furnaces puff.

 Initiate the fire busing number of swabs. Throw the swabs in such a way that the
fire spreads uniformly over the entire furnace. If the spreading of the fire is non
uniform sprinkle some kerosene choked charcoal and throw it to the locations
where fire is not there. Unless the fire is more or less present over the entire
surface, it is advised not to proceed with the light up. Unless the top layer or
charcoal gets ignited, further charcoal would not get ignited.

BED TEMPERATURE AND AIR FLOW CONTROL

The thermocouples are located in such a way that they are well utilized for start up

The top level bed thermocouple is located at a height to read the temperature just at the
burning charcoal layer. The bottom level thermocouple is located to read the bed
material temperature at a height of 100 mm from nozzle level.

After the introduction of fire, top level thermocouple temperature will go up. It is very
important to increase the airflow gradually in order to increase the top level temperature
to 800 0 C to 850 0 C. At first the ID fan damper opening alone allows some leakage air.
Further opening of FD Fan damper will add some more air to increase the bed
temperature. Now close ID Fan and FD Fan inlet dampers. Start ID Fan then FD Fan.
Open ID Fan and FD Fan Inlet dampers step by step to increase the top level
temperature to 800 0 C to 850 0 C. Till this period the bottom level thermocouple would
not have show increase in temperature. Once the top level temperature reaches 800 –
850 0 C, the burning top layer of charcoal shall be mixed with rest of the bed. The
mixing is done by increasing the air flow so as to fluidise the bed. The mixing air flow
should not be higher than that of the airflow established during the fluidisation study.
For this purpose the markings made on damper positions shall be used.
If the mixing is done at higher airflow, the burning charcoal will spill into the adjacent
compartment. More than the loss of charcoal in the start up compartment, the bed
height will reduce in start up compartment. This would lead to defluidisation, as the air
would tend to bypass at bed heights lower than 100 mm.

The duration of mixing shall be between 20 – 30 seconds. During the mixing process,
the top level temperature would start reducing. At the same time, bottom level
temperature would begin to rise.

Soon after the mixings completed the airflow shall be brought to a minimum. Open the
man hole door and visually ensure through mixing has been done. If top layer charcoal
had not been disturbed at some places, mixing shall be carried out once again.

After ensuring thorough mixing, the airflow shall be brought down to minimum and then
shall be increased in steps. The airflow shall be increased gradually so as to raise the
bed temperature. The airflow shall be brought up to MCR airflow in process of raising
bed temperature above 600 0 C.

Once the bed temperature shoots above 600 0 C, the fuel transport lines are to be
dechoked and fuel flow shall be established.

 Switch on the PA Fan (if provided)

 Open the fuel transport air dampers of the start up compartment

 Check the suction at the mixing nozzle. If suction is not available, open the
respective bottom drain gates of fuel pipes to dechoked, if any. After the choking
of fuel feed pipe is cleared close the gates.

 In the case of larger compartments it is advisable to initiate minimum airflow in

fuel pipelines just before mixing process to avoid choking of the fuel lines.

 Adjust the PA Fan suction damper, to maintain the header pressure in between
700 to 900 mm of WC.

Initiate the fuel flow by switching on the fuel feeders. The fuel flow shall be kept minimal
at the beginning. At the time of fuel feed inflation, the charcoal might not have burnt
fully. Hence it is most important to initiate fuel feed gradually.

Excess fuel feed will increase the bed temperature uncontrollably. Thought the bed
temperature can be controlled by increasing the airflow, it is advisable to take care at the
time of fuel feed inflation.

Stabilize the start up compartment operation with a bed temperature of 650 0 C and with
the MCR airflow.

 On the water level watch the shell level. If the level goes down switch on feed
pump and regulate the feed control valve. ON / OFF operation of feed pump
should be avoided to the extend possible, if the feed pump is auto operated, keep
 the selector switch in auto mode. Here again regulate the feed control valve to
avoid frequent start / stop of the pump.

 Close the drum / shell vents at 2 kg/cm 2 pressure if the boiler is provided with
superheater. This is done so that superheater coils are cooled better by more
steam flow through them. Ensure the vents, start up vents, drains are open in
superheater lines. The condensate in superheater coils ad main steam pipe
should have been removed earlier. In the case of non drainable sections of
superheater coils it is possible that condensate leads to water hammer.

 In cases of powercut during start up after the mixing it will not be possible to
assesss how much charcoal is burnt out. It is advised to cool thoroughly and
drain the bed material in star up compartment and do a fresh light up.

 Fluidise the bed minimally. Check the bed temperatures, if the bed temperature is
more than 400 0 C add dry charcoal to the bed. The charcoal should be thrown
uniformly over the entire bed. Observe the rise in temperature. If there is no
improvement in bed temperature it is better to cool the bed. Never allow the bed
to be static in this method. If the bed is static, clinker formation will start.
 COMPARTMENTAL TRANSFER

The start up with one compartment is recommended for the following reasons :

1. Gradual loading of Pressure Parts

2. Reduction of Charcoal for start up
3. Load variation

The compartment transfer means activating a static (cold) compartment of the furnace
adjacent to the activated compartment. This is done just by admitting the fluidizing air
to the compartment to be activated and mixing the cold material with hot material of the
operating compartment.

Before activating a static compartment, the airflow in the fluidizing compartment shall be
increased to 120% of the MCR airflow, and the fuel feed rate shall be correspondingly
increased to maintain the bed temperature at 900 0 C.

Now open the compartment air damper of the adjacent compartment, which is to be
activated. The cold bed material in this compartment would begin to mix up with that of
hot bed material in the operating compartment. The bed temperature in new
compartment would begin to rise.

The bed temperature in operating compartment shall be once again brought up to 900 0

C before another attempt is made.

By following the process of mixing the bed material of the compartment to be activated
with that of the operating compartment, on one or many attempts, the activation can be
completed. The bed temperature of the new compartment shall be brought to atleast 600 0
C before fuel feeding is commenced.

The primary air lines in the new compartment shall be opened and the fuel feeding can be
commenced and the bed temperature shall be brought to 800 0 C with MCR fluidizing
airflow condition. Care shall be taken not to drop the temperature of operating
compartment below 600 0 C in the process of activating adjacent compartment.

If by mistake, the temperature of the operating compartment drops below 600 0 C, it

becomes necessary to raise the temperature using charcoal. The charcoal should be
sprayed over the entire compartment. Charcoal should be mixed with the bed keeping the
bed minimally fluidised. The charcoal if burns under static condition, the chance of
clinkering is high.
4. Running Attention

NORMAL OPERATION

LOAD CONTROL :

The steam generation needs to be matched with that of demand to avoid venting of steam.
If the steam drawn from the boiler is less compared to steam generated then the pressure
would rise and thus resulting in lifting of safety valve. Frequent lifting of safety valve will
damage the safety valve seat. Steam generation can be varied by slumping compartments
or by varying the fluidisation air flow or by varying the bed temperature or by varying the
bed height.

Load variation of 70% to 100% may be obtained by varying the bed temperature. The bed
temperature can be reduced upto 700 0 C and can be increased to 900 0 C based on
demand. For this purpose the fuel fed rate needs to be varied. Further turndown is also
possible by reducing the fluidisation airflow but not to the extent of defluidisation of the
bed. In such cases the airflow through primary air lines should never be reduced. Only
the fluidisng airflow should be reduced. Further load control is done by slumping the
compartments. The compartments can be slumped only from either ends of the bed.
Incase of two compartments any compartment may be slumped. In case of three
compartments only first or third compartment is to be slumped, before the middle
compartment is slumped.

Slumping of the compartment is to be done as explained here. Bring down the fuel rate to
minimum and switch off the feeder. Wait till the bottom bed temperature comes around
850 0 C and then close the fluidising air damper of the compartment. Then close the flue
transport air line dampers. When the fluidising air through a compartment is cut off, the
air through the other compartments would increase. This airflow shall be adjusted by
throtting inlet damper of FD Fan. Further draft in the furnace shall be adjusted by
throtting of ID Fan inlet damper.

Reactivation of a compartment shall be done in the following sequence. Open the fuel
transport airline valves first and ensure the required air pressure is available in the PA
Fan header. If the line is choked, choke shall be removed by using the drain gates of the
fuel transport lines. Then open the fluidising air damper and set the FD Fan inlet damper
for the required MCR airflow. If the bed temperature is above 600 0 C fuel feed shall be
initiated and the bed temperature shall be brought to the required operating
temperature.

In case the temperature of the bed is less than 600 0 C immediately after fluidisation, the
compartment shall be started in the manner explained in the compartment transfer
method.

During one compartment operation, the bed height cannot be increased, as the bed is not
contained on one side. This is applicable to some extent to two compartments operation
also maximum variation is possible in all compartments operation as the bed is totally
contained in all four sided by the furnace water wall.
 DYNAMICS IN FLUIDISED BED

The height of the fluidised bed needs to be increased after the activation of all
compartments in order to meet the steam demand. In the case of coal firing, the bed height
automatically increases due to generation of ash from coal burning. The ash which is
retained in the bed, if not drained, will accumulate to an extent that the airflow through the
bed starts coming down below the MCR airflow. The height of bed is not to be allowed to
increase beyond the recommended bed height, which is about 300 mm to 400 mm. The
bed height is indirectly measured by means of air box pressure as explained in the earlier
sections. Other than the purpose of maintaining required bed height, the bed drain gates
are to be operated for removing higher size particles. When there are deviations from the
specified fuel feed size, i.e. minus 6 mm, the higher size particles would begin to settle
down at the air nozzle level. Similarly when agro fuel is used stones ingress with fuel would
lead to settling of stones.

The bed drain is to be operated frequently to drain the higher size particles, if the drain is
not operated frequently the fluidisation will be upset causing clinker formation. In the case
of fuels (Agrowastes), which do not generate bed ash, bed material requires to be added
frequently in order to compensate for loss of bed material by attrition and subsequent
elutriation. Hence sufficient stock of bed material is to be maintained.

ASH REMOVAL

The ash should be drained from all collection points. Failure to remove the ash will result
in choking of flue gas path.

INGRESS OF FOREIGN MATTER IN FUEL

Ingress of cotton waste, waste cloth, coconut shell, mango seed etc will block the fuel flow
from the chute into the feeder. This is indicated by the drop in bed temperature (provided
the feed rate of the feeder is not increased).

The above mentioned problems can be eliminated, if a screen is provided I the fuel handling
system. Feeder tripping due to foreign material is a great nuisance and at times it may lead
to boiler shut down. In case of coal, it becomes necessary to provide a magnetic separator
to separate out the tramp iron from the coal. This not only protects the crusher, but also
prevents to damage to the feeder.

At times it may so happen that the foreign matter may block the fuel transport line.
When there is no airflow in the fuel transport line, the bed material from the bed enters
the fuel feed nozzle and leads to choking of the line. The choking should be removed by
slumping the bed and by opening the drain gates. Also the foreign matter should be
removed from the mixing nozzle opening the plug of the mixing nozzle.
5. Stopping

NORMAL SHUTDOWN TO COLD

Reduce the fuel feed rate and stop the fuel feeders. Maintain the same airflow to cool bed
faster. If the steam is not drawn from the boiler, open the air vent to reduce pressure. If it
is not necessary to enter the boiler for maintenance, slow rate of pressure and temperature
decay is desirable switch off the fans after the bed has cooled down to 500 0 C. Switching
off the fans should be in the order of FD and ID Fans. If it is desirable to accelerate the
cooling process in order to permit entry into the unit for maintenance, the fans could be
continued to run at the same rate until temperature reaches 100 0 C. During the process
maintain normal water level in the boiler. After the bed temperature reached 100°C open
the blow down valve and drain the boiler. (The boiler water temperature must be reduced
atleast 90 0 C before draining). Drain the bed material. This can be done by opening the
gates below the drain points, collect this bed material, sieve and reuse for subsequent light
ups.

NORMAL SHUTDOWN TO HOT STAND BY

If the boiler has to be shut for a relatively short period (minimum of 2 hours) follow the
procedure given below.

1, Switch of the fuel feeder, FD, PA & ID Fans instantaneously. The PA line dampers
and fluidising air dampers need not be closed. But FD & ID Fans dampers must be
closed.

2. Do not reduce the boiler pressure in line with unit load reduction. When the desired
pressure at which the boiler is to be held is reached after the boiler is off the line, the
boiler may be up by closing the main steam valve.

3. Keep the water level in sight in the gauge glass and add make up rate as required.

HOT START UP

After a shut down for a brief period, follow the steps given below to restart the unit.

1. Open the air vent. Check fluidising air damper and PA damper are ‘OPEN’.

2. Keeping the ID & FD Fan dampers in the closed position

3. Start ID & FD and PA Fans in quick succession.

4. Start the fuel feeders with speed setting knob at minimum position

5. Gradually open ID and FD Fan dampers to maintain airflow D.O of 30 mm and gas
plenum pressure of 10 mm.
6. Increase the speed of fuel feeders and watch the bed temperatre

7. IF the bed temperature is slowly increasing then increase fuel feed and air flow in
line with load requirement.

8. If the bed temperature is not increasing, stop the fuel feeders.

9. IF the bed temperature is below 600 0 C throw charcoal through access door, till
temperature reaches 600 0 C. This has to be carefully done. This may be required
if more than one hour has lapsed after shutting down.

10. If the bed temperature is less than 300 0 C, cool the bed and start the boiler
following ‘normal startup from cold’ procedure.

Qty. of charcoal shall be 20 kg per m2 area of bed and kerosene

Shall be 10 kg per m2 area of bed.

 BED LEVEL CONTROL / ASH DRAINING

During boiler operation, bed ash accumulates inside the bed and should be drained at
regular intervals to maintain adequate bed levels for effective fluidisation for good
combustion and to meet the required steam demand.

Pressure drop across the bed will increase with the accumulation of bed ash. This will
reflect on increase in wind box pressure. Gradual increase in wind box pressure (without
increasing the FD or PA flow) indicates the accumulation of bed ash. Consequently,
quantity of air flow through the bed, wind box pressure may have to be maintained at
higher level at the expense of high pressure drop. This in turn will increase the power
consumption of FD Fan.

Apart from wind box pressure indicators, bed level indicators also provided for the bed
compartments. This gives the bed height in fluidising condition. It is essential to
maintain the bed height around 400 – 420 mm by regularly drain the bed ash. If the bed
height is too low, boiler load cannot be increased to the rated capacity. At this condition
sieved sand as per the size specified or sieved bed ash or crushed refractory or lime stone
may be used as a bed make up material to maintain the bed level to the requirement.

Rate of accumulation of bed ash depends on coal size distribution. With higher
percentage of lines in the coal, ash accumulation in the bed will be less. Coal with very
less percentage of fines contributes for high bed ash accumulation. Apart from sizing,
ash content in the coal also decides the ash accumulation levels in the bed.

Along with the coal stones / shells also enters the furnace and accumulates in the
furnace bottom which also increases the wind box pressure. Bed draining to be done
frequently to remove the accumulated stones / shells to keep the bed healthier to avoid
clinker formation and for trouble free operation.

So considering the actual bed, fuel conditions and foreign matter operator should act
accordingly to maintain the required bed level for trouble free operation. If required bed
material to be added for healthier conditions.
C. OPERATING INSTRUCTION FOR IMPORTANT VALVES

Sl. No. Location Open Close

1. Shell Air Vent Open during boiler filling, Close during boiler
boiler startup & durin pressure raising after
pressure reducing g attaining 2 kg/cm2
attaining 2 kg/cm2- after shell pressure
shell in the
2. Economiser air vent (if Open during boiler filling Close after ensuring
applicable) free water flow from
the vent.
3. Side Wall top Open during filling & start up. Close when the shell
header and shell Open when the shell pressure pressure reaches 2
vent drops 2 kg/cm2 during shut kg/cm2 during
down. startup
4 Start up Vent Open during start up and also Close after the boiler
when SH steam temp. shoots is connected to the
up load.
5. Sec. SH drain valve (if Open during start up Close after the boiler
applicable) is connected to the
load
6. Main steam by pass Open before charging Close after the main
valve the main steam line steam stop valve is
fully opened. (after
pipe line is heated up)
7. Main steam stop valve Open after ensuring 100% Close whenever the
removal of condensate from boiler is to be isolated
the steam piping. Also ensure from the range.
the pie line is heated upto the
working temperature
8. Main steam line drain Open before charging the Close after ensuring
valves main steam line moisture free steam
flow from the drain.
9. IBD Valve Open for emergency shell level Close after the shell
control and for foreign level is brought to
removal. normal level.
10. Water wall header Open for draining the boiler Valve should be kept
drains after killing the fire closed always when
completely. fire inside the boiler.
11. CBD Valve Adjust the opening to Close the valve if TDS
maintain the TDS of the boiler of the boiler is within
water. the limits.
12. Soot blower steam line Open before operating the Close after ensuring
drain valve (if system moisture free steam
provided) flow from the drain.
13. Soot blower Open after the pipe line is Close after soot
branch steam valve heated upto the blowing operation.
working temperature
D. DESCRIPTION OF THE STEAM GENERATOR

GENERAL

This boiler is a Shell type, natural circulation, water and flue tube, balance draft, bottom
supported construction, equipped with Atmospheric Fluidised Bed combustion system
having in-bed evaporator coils with under bed fuel feeding system.

As a complete unit the boiler plant is equipped with the following circuits.
 Feed water
 Pressure parts
 Steam
 Blow down
 Sample coolers
 Combustor
 Combustion Air
 PA fans and ducting
 Fuel bunker & Fuel feeding system
 Flue gas
 Bed ash handling
 Refractory and insulation
 Electrical and instrumentation

WATER STORAGE TANK AND FEED PUMP SYSTEM

Feed water system consists of the following :

 feed water storage tank
 Feed water pump

FEED WATER PUMP

Feed pump station consists of following:

 Pump suction piping
 Cooling water system
 Pump discharge piping
 Minimum flow and balancing leak-off(spillback) piping

PUMP SUCTION PIPING

water from the tank is connected to the suction of the feed water pump through this
piping. From the tank, water flows to the pumps suction header through the isolation
valve. Both feed-water pumps are separately connected to the common suction header
through a isolation valve. To avoid the entry of foreign particle suction filters are
provided before the inlet of each pump. Both pump suction piping are provided with
pressure indicators.

DISCHARGE PIPING

Both pumps are separately connected to the common discharge header through
minimum re-circulation valves and discharge valves. Both pump discharge pipings are
provided with a pressure indicator.
 FEED WATER CONTROL STATION

There is a feed water control station provided on the feed water line to maintain the boiler
shell level during all loads.
Manual isolation valves are provided before and after the 100% feed control valves. In
addition to this bypass valve is also provided.

PRESSURE PARTS

Boiler is of bottom supported construction. Boiler is combo water and flue tube boiler,
multi pass shell and main down comers. Shell is supported with saddle support.

SHELL

The Shell is a fusion welded type, provided with manholes and hand holes. Tube sheet
fixed at the ends. The downstream of Shell is heat recovery unit located.

CONSTRUCTIONAL DETAILS

S.NO. DESCRIPTION SIZE MATERIAL

1. Shell plate SA 516 Gr 70
2. Tube sheet plate SA 516 Gr 70

PROVISION IN SHELL FOR MOUNTINGS

SHELL RH SIDE & LH SIDE CONNECTIONS / OPENINGS

 Feed water connection

 Direct level gauge connection on both sides
 Level transmitter connection
 Continuous blow down connection
 Manhole
 Chemical dosing connection

MOUNTINGS ON SHELL

 Safety valve stubs – 2 Nos.

 Pressure gauge connections
 Pressure transmitter connections
 Air vent connection

SHELL INTERNALS

SHELL internals provided very high quality steam (99.9% dryness) to the process.
Shell receives water / steam mixture from the water wall panels through the raiser tubes.
The water-steam mixture flows upwards to flow through the internals with Perforated
sheets. In this flow water which is heavier is separated from steam and trickle down to
mix with water in the shell.
Feed water pipe – 1 no. is installed in the shell with holes. This will ensure the uniform
distribution of feed water in the entire steam shell to maintain the shell level.

Continuous blow down pipe – 1 no. in installed in the shell to maintain the boiler water
concentration at the specified levels.

Chemical dosing pipe – 1 no. is installed in the shell for dosing the HP dosing chemical
which helps to maintain the required pH, phosphate levels in the boiler water.

FURNACE WATER WALLS

RH SIDE & LH SIDE WALLS

The furnace water walls are of membrane type, totally water-cooled, gas and pressure
tight construction. LHS wall, RHS wall, Front wall and rear wall forms part of furnace.

There are man holes and peep holes provided in the panel for easy entry in to the
combustor zone and for furnace observation.

BOILER BLOW DOWN SYSTEM

INTERMEDIATE BLOW DOWN

During boiler light up and occasionally during load fluctuations the boiler shell level will
increase. During operation the boiler water concentration also will go up. Intermediate
blow down valve is provided to maintain the shell level during upset conditions, maintain
the shell water concentrations and to remove the accumulated sludge/muck from the
water shell.

IBD is taken from water shell. Blow down line is provided with manual isolation valves
and blow down valve. Blow down is connected to BD tank through NRV.

CONTINUOUS BLOW DOWN

Continuous blow down system is provided on the CBD line to maintain the boiler water
concentrations. CBD line is taken from steam shell and provided with isolation valves
and blow down valves. The line is terminated to blow down tank through NRV.

Connection is provided for sample cooler along with suitable piping and isolation valve.

BLOW DOWN TANK

Blow down tank is provided as a receiver to collect the entire waterside and steam side
drains.
BD tank is fitted with the following
1. Gauge glass with isolation valves.
 2. A drain valve along with over flow seal.
3. A exhaust pipe to relieve all the steam from the blow down tank
without pressurizing the tank.

FLUE GAS SYSTEM

Boiler is equipped with a motorized Induced draft (ID) fan of 100% MCR capacity.
After the combustion of fuel, flue gases are generated in the combustor. The flue gases at
high temperatures leave the furnace and enters the free board zone above the combustor,
then to the convection bank, the tubular air heater, Dust collector, ID fan and to the
chimney.

REFRACTORY AND INSULATION

Combustor and other areas of the boiler are covered with refractory (where ever required)

ELECTRICAL AND INSTRUMENTATION

Suitable electrical components with safety systems are provided for boiler auxiliaries.
Suitable control systems are provided for trouble free / safe operation of the boiler
and auxiliaries with suitable safety interlock systems.
E. DO’S AND DONT’S FOR BOILER

DO’S
 Clean the internals before closing the man holes of pressure parts furnace and
ducting.
 Maintain all instruments in good working condition.
 All equipment interlocks should be always in line.
 Maintain normal water level in Feed water tank and boiler.
 Maintain water quality as per the recommended limits.
 All dampers must be in smooth operating condition.
 Pressure raising from cold start must be done as per the cold start up curve.
 All the duct joints must be leak proof.
 Use proper lubricants recommended by the manufacturer regularly.
 Start the equipments as per the sequence.
 Clean all ash hoppers regularly.
 Carry out regular soot blowing for boiler and economiser (if provided).
 Regularly clean feed water and transfer pump suction strainers.
 Operate the boiler within the recommended operation limits.
 Boiler, Piping, Ducts, Feed water and Steam piping must be properly insulated.
 Servicing of equipments should be done as per the manufacturer’s schedule.
 Maintain proper operation log sheets regularly.
 Maintain the instrument air free from moisture and oily matters and the
pressure as recommended.
 Carry out regular cleaning of direct water level gauge glass on Feed water tank,
and boiler shell.
 Use proper valve gland packing to avoid leakage.
 Use proper gaskets for flange joints.
 Regularly maintain Refractory construction.
 Boiler surroundings and equipments must be properly illuminated.
 Operate the blow down valves as per recommendation.
 Boiler surroundings and equipments must be properly illuminated.
 In case of power failure close the steam valve and stop the fire immediately.
 If the water level goes up above the limits operate the intermittent blowdown
valve immediately and maintain the water level to normal.
 Use genuine spares.

Before starting these equipments ensure the following :

FEED WATER PUMP

 Ensure proper water level in the tank

 Open suction valve fully
 Open re circulating valve fully (if applicable)
 Open balancing line valve fully (if applicable)
 Close the discharge valve fully
 Ensure cooling water supply to stuffing box (if provided)
 Check lubricating oil level
ID FAN

 Close suction damper fully

  Check lubrication

FD FAN

 ID fan in running condition

 Close suction damper
 Check lubrication

PA / SA FAN

 ID & FD fan in running condition

 Close suction damper
 Check lubrication

DONT’ S

 Don’t by pass any instruments and safety interlocks

 Don’t use raw water as Boiler feed water
 Don’t throw big size wooden logs inside the furnace for slow firing
 Don’t start any fan with suction damper in open condition
 Don’t start any pump with the delivery valve in open condition
 Don’t run the Boiler with furnace in pressurized condition
 Don’t throttle the feed water pump balancing leakoff valve while the pump
is in operation.
 Don’t operate the furnace wall header drain valves while the Boiler is in
operation
 Don’t operate the boiler beyond the operation limits
 Don’t leave the furnace door open while the boiler is in operation
 Don’t mix up different lubricants
 Don’t throw water inside the hot furnace
 Don’t alter the equipment maintenance schedule
 Don’t leave the instrument control panel unattended
 Don’t allow unauthorized persons to operate the boiler and associated
equipments
 Avoid continuous operation of boiler at low loads (low back end
temperature) to protect economiser and air pre heater corrosion
 Do not dose chemicals into the boiler in batch wise, they should be done on
a continuous basis
F. EMERGENCY PROCEDURE

At emergency conditions it is advisable to initiate the following actions to safe guard men
and equipments,

UNABLE TO MAINTAIN THE SHELL LEVEL

CAUSES
 Too much load fluctuations
 Tube leakage in the furnace tubes

ACTION
 Take the shell level control loop into manual mode
 Reduce the water level immediately by operating the intermittent blow down to
maintain the shell level if it is high
 Reduce steam discharge rate, if necessary
 Start the stand by compressor if required
 Analyze the water quality (alkalinity and solids)

FURNACE PUFFING & BACK FIRING

CAUSES
 Uncontrolled feeding of fuel on to the combustor
 Uncontrolled auxiliary fuel feeding
 Malfunctioning of furnace draft control system
 Sudden increase in FD fan air
 Tube rupture

ACTION
 Take the furnace draft and air flow control system into manual mode and
maintain the furnace pressure
 Never increase fuel/auxiliary fuel/air flow suddenly
 In case of tube failure take the boiler out of service immediately

BOILER EXPLOSION

CAUSES
 Accumulation of fuel in the furnace

a. Due to incomplete combustion

b. Due to loss of ignition
c. Due to fuel valve leakages
d. Due to frequent valve leakages
e. Due to frequent startups

 With the mixture of unburnt fuel with air in explosive proportions and the
application of heat sufficient enough to raise the temperature of mixture to
ignition point.

ACTION
 Trip the firing systems immediately
 Evacuate the furnace to the possible extend
 Analyze the reasons for explosion and rectify the system

BOILER IMPLOSION

CAUSES
 Sudden tripping of fuel to furnace
 Too negative furnace draft due to failure of furnace pressure control system.

ACTION
 In case of sudden fuel trip take the draft control system into manual mode and
maintain the furnace pressure
 Start the fuel feeding system if possible
G. OPERATIONAL PRECAUTIONS FOR SAFETY

INTRODUCTION

The handling and burning of any fuel is potentially hazardous. Some fuels ignite more
rapidly than others. Safe handling and operation demands knowledge of the
characteristics of the fuel and careful observance of necessary precautions.

 Operating the boiler with low feed water temperature along with high excess air
will result in exceeding metal temperature. There should be no hesitation to bring
down the load on the boiler if this temperature cannot be brought under control
by other means.
 The raising and lowering of steam parameters should be restricted to the value
given in the starting diagram. Exceeding these value will result in reduced fatigue
life of pressure parts.
 In the case of tube failure which can be identified by hearing the noise in the
boiler gallery and cross checked by difference in steam and water flow, gas and
steam temperature, the boiler should be shutdown at the earliest by regular
procedure for maintenance work. Otherwise large number of tubes may fail due
to steam erosion and impingement.
 Boiler washing (when the unit is shutdown) can be done effectively by using hot
water. Immediately after washing, the surfaces should be dried.
 Always use deaerated de-mineralised water for boiler feeding with the
recommended feed water quality.
 Feed water temperature must also be maintained at the highest level possible
either with the help of feed water heaters or heating the water in the feed tank.
Low feed water temperature obtained during low load operation will result in
external corrosion of economiser.
 The economiser circulation system if provided should be kept in service when
there is fire in the boiler with no feed flow.
 Carry over of salts in steam occur either due to mechanical or vapour carry over
from steam shell. Efficient shell internals can only reduce mechanical carry over.
Silica is always carried over in vaporous form. Continuous monitoring of sodium
and silica in steam is desirable.
 Before operating a boiler, ensure complete knowledge of water chemistry.
 Whenever boiler is started after a shutdown of more than 3 days, check all safety
interlocks before boiler start up for proper functioning.
 Super heater drain valve should normally be filled upto the point when water is
showing in the bottom part of the gauge glass. This is to allow for the swell on
heating and to reduce any blowing down resulting from this cause to a minimum.
 Once the boiler is boxed up, the water level in the steam shell must be raised to
the very top of the shell. Filling the shell like this will prevent excessive
temperature differentials along the shell wall. The water is then shut-off and the
boiler is allowed to cool.
 When starting from cold, the drains on both the inlet and outlet superheater boxes
should be wide open (if applicable)
 Ensure the availability of fuel / sand / recycle ash in the bunkers.

PROPER HANDLING OF ACCESS DOOR

 Never open an access door while the unit is operating.

  Open the door slowly and always stand to the side of the opening.
 Look at the cavities through the door before entering into the boiler. Have
sufficient bright light available at all times when personnel are in the furnace and
or in convection pass.

BE SURE THAT A SOLID GROUND IS AVAILABLE FOR SAFE LANDING OR USE

STEP LADDER.

PROPER HANDLING OF THERMOCOUPLES

 Repair or changing of thermocouple / thermowells during boiler operation is

absolutely prohibited, particularly in the positive pressure zone of the boiler.
However if the need arises, always recall that the furnace is pressurized and that
the thermowell may be an open path to the pressurized furnace. Slowly and
carefully disconnect the thermocouple from the well.
 If you encounter resistance in removing the thermocouple, it is an indication that
the thermowell has eroded and is packed with ash. Abort the attempt to replace
the thermocouple and refasten it until the boiler is off and the line cooled.
 If no resistance is encountered then carefully remove the faulty thermocouple
and replace it.
 Never look into the thermowell opening

SAFETY PRECAUTIONS
 Do not attempt to open the boiler doors or observation ports without observing
the proper safety procedure.
 Always use a full-face mask with tinted glass.
 Do not stand directly in front of open ports or doors especially when they are
opened.
 Use sealing air when opening the doors / observation ports.
 Use ear protection devices, whenever it is necessary
 Wear protective gloves when working around the boiler.
 Do not use open ended pipes for rotting observation doors or ports.
 Do not enter a confined space until it has been cooled below 30 C and properly
ventilated.
 Completely drain the solids from the bed , hoppers etc. while entering.
 Use always low voltage extension cords and light bulbs with properly
connected ground.
 Never open or enter the rotating equipment until it has come to a complete stop
and circuit broken i.e. open.
 Never step into fly ash. It can be cold on the surface yet remain hot and smolder
underneath for extended period of time. Always secure the drive mechanism of
dampers, gates and doors before passing through them.
 Watch for hot water in shell and headers when removing manhole and
manhole covers.
 Never direct an air or water stream into an accumulation of fly ash in a confined
area.