Boiler Manual 3x135MW

REV.
INSTRUCTION FOR BOILER OPERATION
MODEL OF PRODUCT
NAME OF PRODUCT
SERIES
No.
SG-420/13.9-M2305
420t/h
420t/h Circulating Fluidized Bed Boiler
2305-1-8603
PREPARED BY
DATE 2015-04-27
CHECKED BY
DATE 2015-04-27
REVIEWED BY
DATE 2015-04-27
APPROVED BY
DATE 2015-04-28
2015 4
,
THIS DRAWING OR DOCUMENT BELONGS TO SBWL AND MAY NOT BE REPRODUCED OR DISCLOSED TO ANY THIRD
PARTY IN ANY FORM WITHOUT THE PRIOR WRITTEN PERMISSION OF SBWL..
Instruction For Boiler Operation
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Table of Contents
INSTRUCTION ....................................................................................................................... 5
1 GENERAL CONDITIONS OF BOILER ............................................................................. 6
1.1 BRIEF INTRODUCTION OF BOILER ..................................................................................... 6
1.2 MAIN TECHNICAL PARAMETERS OF BOILER ..................................................................... 7
1.3 MAIN PERFORMANCE INDEXES OF BOILERDESIGN COAL, TMCR WORKING CONDITION
.............................................................................................................................................. 8
1.4 FUEL ................................................................................................................................ 8
1.5 LIMESTONE (IN BRIEF) ..................................................................................................... 9
2. COMMISSIONING TEST OF BOILER ............................................................................. 9
2.1 IMPORTANCE OF BOILER COMMISSIONING ........................................................................ 9
2.2 PREPARATION BEFORE BOILER OVERALL STARTUP ........................................................ 10
3. HYDROSTATIC TEST ..................................................................................................... 10
3.1 TEST REQUIREMENTS ..................................................................................................... 10
3.2 MAINTENANCE AFTER HYDROSTATIC TEST .................................................................... 11
4. WATER TREATMENT (IN BRIEF) ................................................................................ 11
5BOILER DRY-OFF ......................................................................................................... 11
5.1 PURPOSE OF BOILER DRY-OFF ........................................................................................ 11
5.2 PREPARATION REQUIRED BEFORE BOILER DRY-OFF AND CONDITIONS............................ 12
5.3 BOILER DRY-OFF METHODS AND PROCESS ..................................................................... 12
6. COLD AERODYNAMIC FIELD TEST OF BOILER ...................................................... 16
6.1 TEST PURPOSE ............................................................................................................... 16
6.2 MAIN CONTENT OF TEST ................................................................................................ 17
6.3 AIR VOLUME CALIBRATION OF PRIMARY, SECONDARY AND BRANCHED AIR DUCTS ....... 17
6.4 TEST OF EMPTY-BED RESISTANCE FEATURES ................................................................. 17
6.5 TEST OF CRITICAL FLUIDIZATION AIR VOLUME .............................................................. 18
6.6 FLUIDIZATION QUALITY TEST ........................................................................................ 18
7. RECOMMENDED PROCEDURE FOR CHEMICAL CLEANING ................................ 18
7.1 PREPARATION FOR CLEANING ........................................................................................ 19
7.2 FLUSHING WITH CLEANSER UNDER AMBIENT TEMPERATURE ......................................... 20
7.3 MATTERS NEEDING ATTENTION ..................................................................................... 21
8STEAM PIPELINE PURGING PROCEDURE............................................................... 21
8.1 STEAM PURGING PURPOSE ............................................................................................. 21
8.2 RESPONSIBILITY ............................................................................................................ 21
8.3 GENERAL RULES ............................................................................................................ 22
8.4 MATTERS NEEDING ATTENTION ..................................................................................... 23
8.5 OPERATION PROCEDURE ................................................................................................ 24
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8.6 PURGING OF MAIN STEAM PIPELINE................................................................................ 25

8.7 PURGING OF REHEATER INLET PIPELINE ......................................................................... 25
9. NORMAL PRINCIPLES FOR BOILER OPERATION ................................................... 25
9.1 GENERAL RULES ............................................................................................................ 25
9.2 WATER FILLING AND VENTING ...................................................................................... 26
9.3 STARTUP ........................................................................................................................ 26
9.4 BOILER SHUTDOWN ....................................................................................................... 27
9.5 WATER LEVEL ............................................................................................................... 28
9.6 BOILER WARM-UP AND EXPANSION ............................................................................... 29
9.7 AIR PREHEATER ............................................................................................................. 29
9.8 SOOT BLOWING .............................................................................................................. 29
9.9 REGULATION OF STEAM TEMPERATURE ......................................................................... 30
9.10 SUPERHEATER AND REHEATER .................................................................................... 30
9.11 BLOW-OFF ................................................................................................................... 32
9.12 TUBE DAMAGE ............................................................................................................. 32
9.13 FURNACE EXPLOSION................................................................................................... 33
9.14 FLY ASH WEAR ............................................................................................................ 34
9.15 INSPECTION ................................................................................................................. 34
9.16 MAINTENANCE OF BOILER AND FREEZING PREVENTION ............................................... 35
10 BOILER OPERATION PROCEDURE ............................................................................ 36
10.1 STARTUP AND OPERATION OF BOILER .......................................................................... 36
10.2 PREPARATION BEFORE BOILER STARTUP ...................................................................... 37
10.3 COLD/WARM-STATE STARTUP ...................................................................................... 38
10.4 HOT-STATE STARTUP OF BOILER .................................................................................. 42
10.5 REGULATION DURING NORMAL OPERATION OF BOILER ................................................ 43
10.6 SHUTDOWN OF BOILER................................................................................................. 47
10.7 SLAG-COOLING SYSTEM............................................................................................... 50
10.8 MAINTENANCE OF BOILER DURING SHUTDOWNREFERRING TO 9.16 MAINTENANCE OF
BOILER AND FREEZING PREVENTION ................................................................................ 50
11 HANDLING OF COMMON ACCIDENTS OF BOILER ............................................... 50
11.1 EXCESSIVELY HIGH OR LOW BED TEMPERATURE.......................................................... 50
11.2 EXCESSIVELY HIGH OR LOW BED PRESSURE ................................................................. 51
11.3 WATER WALL TUBE LEAKAGE AND CRACKING ............................................................ 51
11.4 TUBE BLASTING OF SUPERHEATER ............................................................................... 52
11.5 COKING ON BED SURFACE ............................................................................................ 53
11.6 POWER INTERRUPTION OF SYSTEM ............................................................................... 54
11.7 WATER SHORTAGE ACCIDENT...................................................................................... 54
11.8 WATER FULLNESS ACCIDENT ....................................................................................... 55
11.9 WATER ATTACK OF PIPELINE ....................................................................................... 55
12 APPENDIX ....................................................................................................................... 57
12.1 FIGURE 1 BOILER DRY-OFF HEATING/COOLING RATE ............................................... 57
12.2 FIGURE 2 COLD-STATE STARTUP CURVE.................................................................... 58
12.3 FIGURE 3 WARM-STATE STARTUP CURVE .................................................................. 59
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12.4 FIGURE 4 HOT-STATE STARTUP CURVE ...................................................................... 60

12.5 FIGURE 5 SHUTDOWN CURVE .................................................................................... 61
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Instruction
Combining the experience in design, manufacture and operation of dozens of
ultra-supercritical circulating fluidized bed boiler, the 420t/h class circulating fluidized bed
boiler is completely designed by Shanghai Boiler Works Co., Ltd, which is developed by
Shanghai Boiler Works Co., Ltd using advanced technology of circulating fluidized bed.
This instruction for boiler operation, based on the design features of circulating
fluidized bed boiler, introduces the utilization requirements, operation procedures and
matters needing attention of the boiler body. The various contents of the instruction are basic
requirements proposed for the boiler utilization process to ensure the safe operation and
service life of the boiler. The boiler startup and shutdown procedures are closely related to
the other units of the boiler, e.g. turbine, various auxiliary equipment, control system, etc.
Therefore, the specific operation specifications for the complete set of generator unit to
match with the boiler shall be prepared by the user with reference to the applicable
specifications of the industry. This instruction is only for information when the user prepares
boiler startup and operation specifications.
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1 General conditions of boiler

1.1 Brief introduction of boiler
SG-420/13.9-M2305 circulating fluidized bed boiler is an ultra-supercritical
intermediate reheat, natural circulation boiler with single drum, which is designed and
manufactured by Shanghai Boiler Works Co., Ltd using advanced technology of circulating
fluidized bed. Balanced draft, centralized downcomer and water-cooling cyclone separator
are adopted in the boiler, and 2 slag discharge tubes and 1 accident slag discharge tube are
arranged at the bottom of furnace combustion chamber. Membrane waterwall is adopted in
furnace and the lower part uses refractory furnace lining. The boiler has 4 coal feeding points
and 4 limestone feeders, which are all set at the front wall. For this boiler, on-bed startup
ignition mode is adopted. Totally 4 high-power ignition oil guns (2 for each of the left and
right side walls respectively) are arranged on the bed. Convection heating surface is arranged
in the boiler rear pass and two-stage water spray temperature adjustment is adopted in
superheater. Reheater mainly uses flue gas damper temperature adjustment, supplemented by
accident water spray device.
1.1.1 Steam-water system of boiler
The steam-water system of the boiler includes tail economizer, boiler drum, evaporation
heating faces (furnace water wall and water-cooling panel), rear pass enclosure superheater,
platen superheater cold and hot section, high-temperature superheater and reheater. The
steam flow diagram is as follow:
Saturated steam Left and right side wall enclosure superheater Front wall
enclosure superheater, suspension pipe superheater Furnace roof enclosure superheater
Back wall enclosure superheater Separation wall enclosure superheater Platen
superheater cold section Primary desuperheater Platen superheater hot section
Seconadry superheater High-temperature superheater Main steam outlet
There are four tube groups set in the reheater primary arrangement. After heated by
heating surface, reheat steam is led into steam turbine intermediate pressure cylinder by two
457 pipes.
1.1.2 Flue gas and air system of boiler
Balanced ventilation is adopted for the boiler. The pressure zero point of the furnace is
provided in the inlet gas duct of the cyclone separator. The circulation of the material in the
circulating fluidization bed is started and maintained by the air delivery fans (including
primary and secondary air fans) and the induced draft fans. The burning air coming out of
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the primary air fan is heated in the steam air heater and primary air preheater. Then one route
enters the primary air chamber in the bottom of the furnace and the bed material is fluidized
through the wind cowl on the air distribution board, forming solid circulation going upwards
through the furnace. For the second route, an air pipe is led from the primary air duct to the
furnace coal falling tube as coal spreading air. For the third route, a stream of high-pressure
cold air is led from the cold air duct behind the outlet of the primary air fan as the sealing air
for the furnace coal falling tube and coal feeder. After the secondary air is heated by the air
heater and secondary air preheater, a certain number of branch tubes are led from the
secondary air chamber. The air enters the furnace combustion chamber from front and back
wall of the furnace and upper dense-phase zone as two layers. Meanwhile, the secondary air
is also used for ignition of the on-bed oil guns and oil gun cooling.
After the gas with solid particles left the furnace, it tangentially enters the cyclone
separator through two inlet duct respectively. Coarse particles are separated from the gas in
the separator, and gas enters rear pass through separator center cylinder. After cooled by
heating surface, the gas enters dust collector through tubular air preheater to remove fine
particles and finally discharges into the atmosphere through stack by induced draft fan.
One stream of the high-pressure fluidization air is used as fluidization air for the
U-shaped material-returning machine, and another stream is used as lubrication air for the
separator, vertical tube of material-returning machine and material returning tube.
1.1.3 Circulating material return system
Water-cooling cyclone separator U-shaped material-returning machine (vertical
pipe, fluidization chamber, material-returning leg) Furnace
1.1.4 Two slag discharge tubes and one accident slag discharge tube are arranged at the
bottom of the furnace.
1.1.5 Oil system
The boiler is provided with 4 on-bed startup burners (output is 41950kg/h). Simple
mechanical atomization mode is adopted for the oil guns.
1.2 Main technical parameters of boiler
VWO working
BMCR working
condition
condition
t/h
407.232
420
MPa(g)
13.9
13.9
Boiler parameter
Unit
Superheater outlet steam flow

Superheater outlet steam pressure
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Superheater outlet steam temperature
543
543
Reheater steam flow
t/h
351.108
351.108
Reheater inlet steam pressure
MPa(g)
2.757
2.757
Reheater outlet steam pressure
MPa(g)
2.632
2.632
Reheater inlet steam temperature
319.6
319.6
Reheater outlet steam temperature
543
543
Feedwater temperature
252.1
252.1
1.3 Main performance indexes of boilerDesign coal, TMCR working condition

Item
Unit
Value
93.29
92.5
g/Nm3
14
Computational efficiency of boiler (as

per net calorific power)
Guaranteed efficiency of boiler (as per
net calorific power)
Solid incomplete combustion heat loss
Dust discharge concentration at
preheater outlet
1.4 Fuel
1.4.1 Analysis of coal quality
Item
Symbol
Unit
Design coal
As-received carbon
Car
46.3
As-received hydrogen
Har
3.5
As-received oxygen
Oar
12.1
As-received nitrogen
Nar
0.9
As-received sulfur
Sar
0.6
As-received ash content
Aar
6.6
Total moisture
Mar
30
Dry ash-free basis volatile
Vdaf
50.65
As-received gross calorific value

HHV
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Kcal/kg
4500
1.4.2 Ignition and combustion supporting oil

Light diesel oil is adopted in this project as ignition and combustion supporting oil. The
analysis data of the oil are as follows.
1.5 Limestone (in brief)

If limestone is needed, analysis will be carried on.
2. Commissioning test of boiler
2.1 Importance of boiler commissioning
Commissioning test of boiler is an important part of the overall quality inspection of the
main engine and its corollary equipment, including design, manufacture, installation,
commission and preparation for production. It is also an important procedure to guarantee
the safe, reliable and economical operation of the boiler in the future. The following
purposes should be achieved through the start-up commissioning. To inspect the installation
quality of the boiler, auxiliary equipment and control system, etc. To ensure that the surface
of inner pipe is clean and there is no debris in the pipe. To get preliminary understanding of
operating characteristics of the boiler and main auxiliary equipment. To inspect the
rationality and reliability of boiler control and protection system. To preliminarily inspect
full load operation capacity of boiler and auxiliary equipment. To discover important defects
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exist in boiler and auxiliary equipment, in order to take effective measures in time. To train
the operating personnel concerned about equipment performance and primary adjustments of
operation, which lays a good foundation for pilot production and commercial operation.
2.2 Preparation before boiler overall startup
Besides separated commissioning of the main equipment of each system, hydrostatic
test, dry-off, cold aerodynamic characteristic test, boiler body cleaning, steam pipeline
purging, boiler ignition test, boiler safety valve setting, auxiliary equipment interlock
protection test and boiler main protection test should be done before the boiler overall
startup commissioning. A complete inspection of boiler proper and its steam-water system,
flue gas and air system, combustion system, relevant auxiliary equipment, thermal control,
chemical water treatment equipment and site environment should be carried out according to
the commissioning program, operating standard and boiler operation instruction before cold
start, to meet the requirements of boiler safe startup.
3. Hydrostatic test
Hydrostatic test should be carried out according to the requirements of relevant boiler
regulations.
3.1 Test requirements
3.1.1 Test pressure
The test pressure of boiler overall (excluding reheater system) hydrostatic test is 1.25
times as much of the operating pressure of the boiler drum.
Reheater will have a separate hydrostatic test at 1.5 times the operating pressure of
reheater inlet.
3.1.2 Water temperature
The recommended water temperature of the hydrostatic test water is 2070
3.1.3 Water quality
Water for hydrostatic test shall be desalted water or condensate water, which has 10ppm
ammonia and 200ppm hydrazine treatment, and its Cl- is <0.2mg/L. PH value within 9~10 is
preferred.
Caution: The definition of desalted water or condensate water is that visible solids is
less than 1ppm, and the concentration of organic compound is almost zero (or minimum
measured value level).
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For hydrostatic test, the water treated with solid chemical shall
be avoided. Solid substances may deposit in the superheater and
reheater. This is harmful in view of both heat conduction and
Caution
corrosion.
3.1.4 Others
Hydrostatic test in accordance with the test pressure and water temperature specified
in ASME standard is allowed.
3.2 Maintenance after hydrostatic test
After passed the hydrostatic test, visa application needs to be done. It should be
determined whether to discharge water in time according to site actual condition. If the
interval between hydrostatic test and chemical cleaning is within 30 days, boiler can
maintain the status of being filled with water to prevent air from getting inside during this
time. If the interval between hydrostatic test and chemical cleaning is more than 30 days,
water needs to be discharged in time and anti-corrosion measures should be taken according
to the relevant provisions. For instance, to fill boiler with nitrogen through nitrogen fill inlet
with the pressure of 2134kPa. All hydrostatic test plugs and locking device of safe valves
should be removed, before the startup of the unit.
4. Water treatment (in brief)
Water treatment and boiler water are out of our companys control range, thus, power
plants need to follow the boiler industry standards in actual operation. It is extremely
important that the successful operation of boiler depends on strict control of feedwater and
flexible operation, which avoids corrosion and scaling on the metal surface where water and
steam contact.
5Boiler dry-off
5.1 Purpose of boiler dry-off
The inner surfaces of the furnace and duct are all coated with large quantity of
wear-resistant bricks, insulation bricks and wear-resistant refractory insulation casting
materials. Though these wear-resistant materials have been dried naturally in air (normally
more than 3 days), certain quantity of free water content still remains in the whole refractory
materials. If the materials are put into operation directly without boiler dry-off, the water
content will evaporate as heated to cause the volume to expand, generating certain pressure
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that results in cracking, deformation and damage of the refractory materials, or even
peeling-off of the wear-resistant materials in severe case. Therefore, before the boiler is put
into operation officially, it is necessary to dry off the boiler with controlled heating method.
Meanwhile, boiler dry-off can accelerate the physical/chemical variation process of the
boiler wall materials, making the performances stable so that it can work for long term under
high temperature.
5.2 Preparation required before boiler dry-off and conditions
1)
The installation work for the boiler proper, material returning system and gas/air
system is completed. The construction of the wear-proof refractory materials is
completed. The air leakage and air pressure test is passed.
2)
Open the door holes in the various positions and allow it to dry naturally for more than
72 hours.
3)
Carry out internal inspection of the furnace, flue gas/air duct, cyclone separator,
material returning device, etc. Remove the foreign matters.
4)
Temporary exhaust valve is installed on the top cover of the cyclone separator, and
temporary partition is installed in outlet duct of the separator.
5)
The fuel oil system is installed. All the jobs such as hydrostatic test and instrument test
have been completed. Oil can be supplied normally to the boiler startup burners.
6)
The boiler expansion indicator has been installed completely, and the pointer has been
adjusted to zero position.
7)
The installation, trial operation and calibration of all the thermodynamic instruments
and electrical instruments have been completed, and they are ready for putting into
service.
8)
Feed chemically demineralized water into the boiler to normal level or 50mm below
the normal level, and flush the level gauge until it is clean.
5.3 Boiler dry-off methods and process

The wear-resistant refractory materials are mainly arranged in the locations such as
furnace air distribution board, furnace cone part, water-cooling panel of the upper part of the
furnace, the lower surface of the platen superheater ,and the wall-penetrating part, cyclone
separator (including outlet duct), and the material-returning machine. Though these
wear-resistant materials have been dried naturally in air (normally more than 72 hours),
certain quantity of free water content still remains in the whole refractory materials.
Therefore, before the boiler is put into operation officially, it is necessary to dry off the
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boiler with controlled heating method. The boiler dry-off curve of wear-resistant refractory
materials should be made by insulating material manufacturer, user and boiler manufacturer.
This instruction recommends the dry-off methods which uses extra burner to heat CFB
boiler. In this method, extra burners are arranged through the manhole doors and observation
eyes in the furnace and gas ducts at the positions laid with wear-resistant refractory materials
for heating and temperature control, the heat source generated is hot gas, which will not
flush the refractory insulation materials directly or generate local high temperature.
Moreover, with this method, it is easier to control the furnace and the gas duct at different
temperature.
Drying of the refractory materials is only a stage for accomplishing the engineering
plan. However, for CFB boiler, it is a very important link. This job is usually implemented
and accomplished by the refractory material installer by providing with temporary burners.
Once the refractory material drying procedure starts, it must proceed continuously as
per the temperature control curve without interruption until the boiler dry-off is completed.
This is critical for drying the refractory materials thoroughly and for ensuring the
performances of the refractory materials.
After a period of insulation, the furnace temperature cooled down is about 370. The
continuous time for heating and cooling of refractory material is expected to be 5~6 days.
5.3.1 Progress should meet the requirement of boiler dry-off
1) Hydrostatic test is finished.
2) All exhaust pipes and drain pipes are connected to atmosphere and drainage system.
3) All water-steam pipe hangers are correctly installed at the cold state position.
4) The stack which allows gas exhausting is completed.
5) Electric precipitator flue is available. Piping system of furnace outlet, rear pass,
economizer, air preheater, electric precipitator and stack is finished.
6) Blind flange shall be installed at the bottom of the furnace hopper or ash treatment
equipment shall be installed to prevent gas from escaping out.
7) The rear gas duct door hole shall be closed.
8) The soot blower shall be installed at the soot blower hole or the hole shall be blocked
temporarily to prevent gas from escaping out.
9) Install temporary exhaust valve on the cyclone separator top cap, and temporary
separation wall at separator outlet flue.
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10) The door holes in the furnace and separator shall be closed to prevent heat from
escaping out of the door hole.
11) Feed water into the boiler drum to the normal operation level.
12) Adjust the main steam exhaust and drain valve before starting boiler dry-off.
13) Drum exhaust door
Open/Pressure up to 175Pa Close
14) Main steam exhaust/drain
Open
15) Startup exhaust valve
Open 25%
16) Reheater exhaust/drain
Open
17) Adjust the openness of the fan inlet movable vane to be consistent with that of the
baffle.
18) Primary air fan inlet movable vane
5%-10%
19) Secondary air fan inlet movable vane
5%-10%
20) Induced draft fan inlet movable vane
5%-10%
21) Secondary air fan upper/lower baffle
Close
22) During the drying of refractory materials, maintain the steam drum at normal water
pressure.
23) During the boiler dry-off, monitor the temperature of the gas entering the preheater
24) During the boiler dry-off and temperature holding, inspect the boiler and the rear gas
duct for expansion.
25) During the boiler dry-off, record all the boiler expansions.
5.3.2 Requirements for power plant to cooperate in boiler dry-off
1) Boiler water supply, replenishing, chemical dosing system and temporary oil supply
system should be connected before boiler dry-off. Water quality is qualified during
boiler dry-off.
2) During the boiler dry-off, the water supply system or the temporary water supply system
is reliable for use, and ensure there is sufficient qualified water.
3) During the boiler dry-off, the blow-off system is put into operation effectively, and the
water is discharged after the boiler dry-off.
5.3.3 Boiler dry-off equipment, control, instruments and services
1Burner, purging and ignition device for temporary heating.
2Oil supply pipe diameter for the burner of each set is 15 inches.
3Computer control system.
4K-type thermocouple.
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5Recorder for recording the temperature of each thermocouple.

6Operating personnel 24 hour uninterrupted shift.
7Provide boiler dry-off report (including summary, copy and electronic edition of original
boiler dry-off record)
5.3.4 Duration
1) Preparation time is about four weeks from the delivery of boiler dry-off equipment.
2) About one week to install pipe to burner position.
3) About three day for equipment startup preparation.
5.3.5 Other requirements
1) Elevator/crane for lifting boiler dry-off machine (800kg).
2) Compressed air used during boiler dry-off (3m3/h/burner0.25Mpa), atomized fuel oil.
3) Electric power 18kw/220/380 volt power, 50100kg/h fuel 14 boiler dry-off machine.
4) Oil supply pipe connected to boiler dry-off machine, use hose for the tube at about 15
inches near the end the boiler.
5) Set aside a plane space of 3 inches 3 inches for temporary boiler dry-off machine area.
5.3.6 Position of burner and thermocouple for boiler dry-off
Burner arrangement
1) Four boiler dry-off machine are arranged in the furnace. Two of them are vertically
placed, and two are placed at 45.
2) Two boiler dry-off machine are arranged at the material returning tube of the furnace.
3) Two boiler dry-off machine are arranged in the material returning machine, one dry-off
machine for each.
4) Two boiler dry-off machine are arranged at the furnace outlet/separator inlet.
One dry-off machine for each separator inlet pipe.
There are totally ten boiler dry-off machine.
5.3.7 Auxiliary fuel supply
1) Fuel oil
Oil tank to store sufficient fuel oil in order to meet the demands of boiler dry-off.
Pump to transport oil to boiler area through pump and oil pipeline.
Booster pump (if needed) booster pump is needed when the output of fuel feed pump
is not enough.
2) Temporary fuel system
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Storage area temporary storage area is arranged beside the boiler or between two
boilers.
Temporary storage tank this is sign on and beside temporary storage tank (truck oil
tank)
Temporary pipeline from storage tank to boiler area and then to the connection of
temporary burner.
In addition, where there is oil return line, there is isolating valve.
5.3.8 Boiler dry-off heating/cooling rate (see Figure 1).
5.3.9 Temperature rising requirements for the first startup
After the boiler dry-off with dry-off machines is completed, all the dry-off machines
and the related devices shall be removed. When the complete-group startup conditions are
met and the boiler is started for the first time, in order to protect refractory material, boiler
main oil gun should be used to heat up as per the curve below. To meet the requirements of
heating curve, the oil quantity for the oil guns and the number of oil guns put into use shall
be controlled strictly.
Temp.
50/h rises to
500, keep at
500 for 2 hours
670
Operating Temperature
25-30/h
to130
50/h to 360,
keep at 360 for 2
hours
300
200
50/h
to 300
130
50/h rises to
670, keep at 670
for 4 hours
Tubes
must be
filled
with
water
Rise to Operating
Temperature
Keep at 300
for 6 hours
0
0:00
12:00
24:00
Timehour
6. Cold aerodynamic field test of boiler

6.1 Test purpose
The purpose of cold aerodynamic field test is for preliminary adjustment prior to the
initial ignition. Through the cold-state test, understand and master the in-furnace gas flow
characteristics and the features of the various air volume regulation devices and flow
distribution, inspect the air distribution evenness of the air distribution board and the
empty-bed resistance of the fluidized bed and the material layer resistance features, find the
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critical fluidization air volume, and provide with references for the hot-state operation of the
boiler to ensure the combustion safety of the boiler, to prevent coking on the bed and to
protect the equipment from being damaged.
Cold aerodynamic characteristic test is the foundation and
reference basis for boiler startup commissioning, boiler
combustion adjustment and boiler safe and economical
Caution
operation. It should be done in accordance with the relevant

regulations. Relevant data collection should be done as well.
6.2 Main content of test

Furnace ventilation circuit test
1)
Performance examination of primary/secondary air fans and high-pressure fluidization

air fan;
2)
Test of coal feeder air quantity distribution features;
3)
Calibration for measuring devices of primary/secondary air volume and fluidized air
volume of material-returning machine;
4)
Determination of the regulation features of the various air door baffles;
5)
Determination of the air volume of material-returning machine and lubricating air;
6)
Test of startup burner air volume and baffle openness features;
7)
Determination of empty-bed resistance and material layer features of fluidized bed;
8)
Air distribution uniformity test of air distribution board;
9)
Critical fluidization air volume test;
10) Feeding features of pneumatic coal feeding device;

11) Material-returning machine air volume flow features;
12) Necessary purging air volume of equipment;
6.3 Air volume calibration of primary, secondary and branched air ducts
For all the air ducts where flow measurement devices are arranged, air volume
calibration shall be carried out.
6.4 Test of empty-bed resistance features
For test of empty-bed resistance features, i.e. air distribution board resistance test, start
the induced draft fan and the primary air fan with no bed materials laid on the air distribution
board, and record the primary air chamber pressure and the lower bed pressure in the
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in-furnace dense-phase zone. The difference between the two is the resistance of the air
distribution board. Draw the relationship curve between the primary air volume and the air
distribution board resistance in cold state. Through temperature correction, the relationship
curve between the primary air volume and the air distribution board resistance in hot state
can be obtained. During the operation of the boiler, if failure occurs at the bed pressure
measurement point, the quantity of on-bed materials can also be judged on the basis of the
relationship curve between air chamber pressure & air volume and air distribution board
resistance, thereby reducing the operation blindness.
6.5 Test of critical fluidization air volume
The various cold-state measurement tests before this test are carried out with no bed
materials filled. The critical fluidization air volume refers to the minimum air volume
necessary for the bed materials to turn from fixed state to fluidized state. It is the minimum
primary air volume during the operation of the boiler. Method for determine the critical
fluidization air volume: Select 0~1mm or 0~1.5mm river sand or CFB boiler slag as bed
materials. Add bed materials to static height of 1100 mm (sand) or1200mm (ash). Increase
the primary air volume. On the initial stage, the bed pressure increases gradually along with
the increment of primary air volume. When the air volume exceeds a certain value, continue
to increase the primary air volume and the bed pressure will increase no longer. This air
volume value is the critical fluidization air volume. In addition, the critical fluidization air
volume can be determined by reducing the primary air volume gradually. Record the air
volume and bed pressure values and draw the relationship curve between primary air volume
and bed pressure.
6.6 Fluidization quality test
The bed materials, when being in fluidized state, can result in MFT of the induced draft
fan manually, causing the primary air fan to stop air delivery suddenly. Enter the furnace to
observe the flatness of the bed materials. If the bed face is found to be not flat or even
swell, remove the bed materials in this zone, find the causes and take countermeasures in
time.
7. Recommended procedure for chemical cleaning
Before a new boiler is put into operation, the inner surfaces of pressured parts
(including economizer) shall be cleaned to remove any residual substances. In addition to the
inner surfaces of the boiler, the boil front system shall also be cleaned to remove the same
substances.
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There are various kinds of chemical cleaning. Users can choose the appropriate method
according to relevant standards.
This chapter only introduces the cleaning method with low-temperature low-foam
cleanser by virtue of out-laid circulating pump for forced circulation. It is an effective, quick
and economical cleaning method.
The concentration recommended by merchant should be checked, since commercial
cleanser concentration is changed (for example, diluted with water). Normally, the
recommended cleanser concentration is 0.6 percent by volume at 21 ambient temperature
(i.e. to add 1L cleanser into 167L water). If the boiler is cleaned at above 65.6, the
recommended cleanser concentration is 0.3 percent by volume.
7.1 Preparation for cleaning
1) All the water/steam separation devices in the steam drum have been removed.
2) Provide with a temporary circulating pump with a capacity of 14 t/h to circulate the
solution in the furnace. This pump shall suck the solution from the bottoms of the
furnace lower header and of the evaporation screen header. The solution is discharged
from the economizer inlet header. The size of the pipes from the pump to such positions
on the boiler shall match. All the high-pressure pipes connecting to the boiler and all the
auxiliary pipes connecting to the auxiliary pump must be flushed before they are
connected to the boiler and pump. To prevent from short circuit of solution, the
downcomer of the steam drum shall be plugged or be provided with throttle orifice.
3) To minimize the foreign substance carried from the boiler front system to the boiler, the
boiler front system shall also be cleaned similarly.
4) During the cleaning, all the boiler instrument tubes (except for level gauge connection
tubes) shall be isolated.
5) Provide with a temporary pipe at the lower header and/or circulating pump suction to
connect with the chemical cleaning nozzle. This pipe is used to introduce the cleanser.
6) Provide with a temporary or permanent drainage pipe with sufficient size, which can
drain the water out rapidly in 60 minutes to satisfy the boiler acid cleaning requirements.
The size of permanent drainage valves and pipes connecting to boiler bottom should
meet the requirements of 80% assumed pressure drop when passing double valves and
pipes 80% assumed pressure drop, 20% pressure drop discharges through temporary
pipes. The normal boiler drainage system can be put into use, if the cleanser can be
smoothly discharged.
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7) Provide with a sampling connection complete with valve, and attach an appropriate tag.
8) Before cleaning, remove the residues in the boiler drum and header mechanically as
long as possible. Check all the bolt sealing components in the boiler drum.
9) All the pressured parts must be checked carefully for any blockage. If any, carry out
necessary hydrostatic test. Inspect the blow-off pipes and dosing pipes inside the boiler
drum and make sure the interiors are smooth and clean.
10) During the cleaning, the operators on duty shall be familiar with the normal combustion
and operational procedures, as well as preventive actions, and learn safety operation
procedures for cleaning. This is very important. Special care shall be employed when
taking any measures that may cause leakage. Take appropriate measures to protect the
personal safety in case of any accidental leakage event.
11) Desalted water is used to fill reversely the SH to ensure that the SH is fulfilled, for ease
of observing the increase of drum water level.
7.2 Flushing with cleanser under ambient temperature
Fill the boiler, evaporation screen and economizer with water until the bottom water
level of the level gauge is in visible range. Through the temporary chemical pipeline, inject
the cleaning liquor slowly. Again add water until the water level is higher than the boiler
centerline by 50mm. Once this water level is established, start the temporary circulating
pump. Monitor the vent valve of the boiler drum and confirm that no foam is formed. Add
necessary anti-foaming agent. If the water level is high and cannot be seen, blowdown is
needed. On the other hand, blowdown capacity should be limited to avoid the water level
being too low to be seen. The combinableness and surfactivity of cleanser can be used for
cleaning, and its recipe can be changed according to the needs of contamination control.
Timing sampling of boiler water should be done, and the existence and turbidity of
grease matter should be inspected. Quantitative determination of grease matter should be
done to meet the requirements of monitoring and controlling.
Fill the evaporate panel and economizer with clean water to the top of glass water
gauge. After the boiler is fully filled, desalted water is used to fill reversely the SH through
header until water overflows into the drum. Drain the boiler, evaporate panel and
economizer as before.
Inspect the interiors of the steam drum. If inspection discloses that the cleanliness is not
satisfactory, repeat the cleaning procedure.
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7.3 Matters needing attention

1) Discharge of the cleanser does not need to be done under the presence of nitrogen.
Nitrogen is a nontoxic gas, but is unfavorable for human respiration. If nitrogen-filling
is adopted for draining the boiler and a man needs to enter it after the drainage,
appropriate ventilation must be carried out before a man is allowed in.
2) If the boiler will be left free for a couple of days after the cleaning, the boiler and the
superheater need to be maintained as described in the maintenance procedure.
3) Before the counter-flushing of the superheater is completed, perform chemical analysis
for the water used (conductivity, pH and chlorine) to confirm that no pollution exists.
4) After the cleaning and before the ignition of the boiler, the water in the superheater and
steam pipeline shall be sampled, analyzed and inspected for any contamination.
5) If cleanser overflows into the superheater due to carelessness during the chemical
cleaning, carry out thorough counter-flushing with sufficient flow before ignition is
allowed in order to ensure that the various contaminants are all removed.
6) In the chemical treatment process, take special care to prevent the cleanser from doing
harm to human being.
7) Inspect the steam drum and remove any loose deposit from the inner surface of the
steam drum.
8) Inspect the openable lower header and evaporation screen header, and flush with clean
water.
8Steam pipeline purging procedure
8.1 Steam purging purpose
The purpose of purging the main steam piping systems and reheating steam piping
systems of a newly built unit is to remove all foreign matters left in the superheater, reheater
and steam pipes after installation. If foreign matters enter into steam piping systems or steam
turbine during initial operation, it will cause major accident.
For old units, after the overhaul of main pressure parts, the possibility of foreign
matters entering into systems also exists. Thus, it is necessary to consider purging steam
pipelines.
8.2 Responsibility
Because purging of steam pipeline is mainly to protect the steam system devices against
any damage, the responsibility of steam purging effect depends on the user.
The design, fabrication and installation of any temporary piping system for the purpose
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of steam pipe purging, as well as the protection against over-pressure or over-temperature,

are all the responsibilities of the user.
Because the water level of the steam drum fluctuates greatly
during the purging, the operator shall do the preparation work
sufficiently in advance to avoid any steam drum overflow or
water shortage accidents. Pipe purging can cause certain
Warning
damage to the boiler. So the number of purging times shall be

minimized while meeting to the applicable examination
standards.
8.3 General rules

To achieve the best purging effect, when purging the steam pipelines, the steam flow
conditions of system should equal to normal operation conditions at maximum load. Because
the purging conditions when discharging into the atmosphere is unlikely to be repeatedly in
accordance with operation conditions, equivalent operation conditions is expected to be
achieved, i.e. steam flow when purging under low pressure multiplies velocity is normal
operation conditions at full load. The flow rate that may be obtained must be determined on
the basis of the whole system, including the flow resistance of the temporary pipes. This is
usually determined by the designer in charge of the purging system.
Purging by component is important in the system. Purging each component separately
is especially important for flushing the reheater, because in this way, foreign matters will not
transport or deposit from one component to another. Large foreign matters will stay in the
reheater inlet header instead of passing through reheating tubes and cause blockage of
reheating tubes if superheaters and reheaters are flushed at the same time. After the boiler
being put into operation, it will cause overheating and tube failure of reheating tubes.
Therefore, temporary pipeline arrangement is recommended, which purges the foreign
matters in main steam pipelines to the atmosphere and purges the foreign matters to the
atmosphere before the cold reheating pipelines being connected to heater inlet header. Until
then, steam is allowed to be let into the reheater to purge reheater pipelines.
Normally a shutoff valve is installed in the temporary pipeline as purging valve. With
this arrangement, the superheater and the rising steam part of the temporary pipeline can
always be kept at the steam drum pressure when purging is not performed.
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If a cut-off valve is installed in the main steam pipeline of the boiler, if the design of
valve allows such operation mode, this valve can also be used as purging valve.
For any component with more than one route of steam pipeline, it is necessary to
consider installation of temporary pipeline so that every route of pipeline could be purged
independently. In this case, make sure to resolve the flow unbalance and expansion problems
at the connections of the pipeline system.
The cleanliness of the components being purged is shown by the target plate provided
at the outlet of the purging pipeline on the final stage of the purging.
The pitting level of the target plate after the purging is used to determine the purging
cycle of certain components.
8.4 Matters needing attention
1) The purging process may result in abnormal and severe conditions for the boiler and
steam pipeline. During every purging cycle, tremendous and quick temperature change
will occur. This change causes much severer damage as compared with normal
operation. In the thick-wall parts of the system such as boiler drum, header and pipeline,
excessive thermal stress may be generated. Therefore, during the purging, such
conditions shall be considered carefully. While meeting the system cleanliness
conditions, the number of purging times shall be minimized.
2) Close the startup burner, keep primary air fan operating and reduce the temperature
fluctuation of extreme temperature refractory surface.
3) As compared with the boiler body, the design pressure of the temporary purging pipeline
is lower. In the whole purging operation process, over-pressure of the purging pipeline
must be avoided. The operators shall monitor continuously the pressure in the temporary
pipeline to avoid over-pressure.
4) During the steam purging operation, it is very difficult for the steam not to carry water
from the steam drum into the superheater. Therefore, in this process, the boiler water
shall be subjected to non-volatile chemical treatment to prevent solid substances from
depositing on the superheater.
5) Main fuel and limestone sliding doors should be closed.
6) To avoid local densification of hot gas, the wind cowl of the material-returning machine
shall be covered with ash or sand completely or use a high-pressure fluidization fan.
7) To protect the fluidization wind cowl against any damage due to the flame of startup
burners, the primary air shall flow through the fluidization cap of the furnace.
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8) To ensure that the hot gas will not leak out of the furnace, the furnace shall be operated
in vacuum state (-50Pa).
9) To make the tubes in furnace and convection pass heating surface overheated or
dry-burned, the gas temperature of the furnace and cyclone separator shall be kept below
538.
8.5 Operation procedure
Due to the requirement for low ignition rate, the fluid bed may be not started during
steam purging. Fire the startup burner steadily, and assume that burner adjustment is good,
dust collector is not necessary.
To avoid excessively high thermal load that may cause thermal corrosion of the
refractory material, the mean rising rate of the steam drum water temperature shall not
exceed 50/h. Start up induced draft fan firstly, then start up primary fan and secondary fan,
thus the startup procedure begins. As long as the material-returning machine nozzle is cover
by ash or sand, the high-pressure fluid fan in not necessary.
Start the boiler as per cold-state startup procedure in normal way. Formal suggestion
and regulation about fuel burning equipment, air treatment equipment, drainage and exhaust
shall be followed. If the boiler start up in normal operation mode, for any newly-built boiler,
steam purging is the first thing to do to make boiler on fire at any effective speed. Thus, high
attention shall be paid to startup and purging. After all the equipment are inspected and the
expansion displacement indicator is monitored closely, the boiler unit must be started at a
relatively slow rate. After the boiler is fired, the furnace and cyclone separator outlet gas
temperature shall be controlled within 538. During the operation, the matters needing
attention for any new unit also apply here.
During the purging, the boiler drum water level will fluctuate sharply. When the
temporary discharge valve is opened, the boiler drum water level rises quickly and may
exceed the visible range of the glass gauge. Along with the purging progress, the boiler drum
water level may re-appear and drops beyond the visible range. Therefore, before purging
starts in each time, it is very important to establish the boiler drum water level at or slightly
higher than the normal operation level. Before purging starts in each time, small quantity of
feed water flow must be established. Moreover, to prevent from excessively low water level,
increase the feed water flow once the water level drops to the visible range.
When the boiler drum pressure achieves the set value (normally 4.15MPa) and can
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generate the purging flow required, the purging process can start.
8.6 Purging of main steam pipeline
1) Turn off or hold startup burners. Open the temporary discharge valve gradually. Purge
through the superheater and main steam pipelines and discharge through the temporary
discharge pipe (refer to Matters needing attention). The initial purging is normally
carried out under depressurization in order to inspect the supporting and fixing devices
of the temporary piping system.
2) When the steam drum pressure drops to about 1.38MPa, close the temporary discharge
valve and re-ignite the unit to establish the purging conditions.
3) Repeat the above operation cycle until the inspection to the flushing target plate on the
final stage shows that the cleanliness is qualified.
8.7 Purging of reheater inlet pipeline
1) Turn off or hold startup burners. Open the temporary discharge valve gradually. Purge
through the superheater and main steam pipelines and discharge and the pipes
temporarily connected to the reheater and exhaust through temporary discharge pipe
(refer to Matters needing attention). Important note: The initial purging is normally
carried out under depressurization in order to inspect the supporting and fixing devices
of the temporary piping system.
2) When the steam drum pressure drops to about 1.38MPa, close the temporary discharge
valve and re-ignite the unit to establish the purging conditions.
3) Repeat the above operation cycle until the inspection to the flushing target plate on the
final stage shows that the cleanliness is qualified.
9. Normal principles for boiler operation
9.1 General rules
All the boiler equipment are designed for specific purpose. When feed water of
specified temperature is supplied, the boiler will generate certain volume of steam at the
deigned pressure and temperature. Operation beyond the conditions limited by the design
will shorten the life of the boiler and of the other components.
The total solid substance content in the outlet steam depends largely on the quality of
the feed water. Appropriate makeup water treatment device and appropriate blow-off
procedure shall be used to control the alkalinity, silicon content, dissolved solid substance
and suspended solid substance of the boiler water.
The fuel consumption shall be measured and recorded. The method used depends on the
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fuel property and the equipment used for measurement. Representative fuel samples shall be
taken regularly to analyze the chemical component, calorific value, viscosity (liquid fuel)
particle size distribution and other physical features of the fuel. All these can cause effect on
the operation and efficiency.
As an index for measuring the economical efficiency of boiler operation, the discharged
gas analysis of the boiler is of important value. The combustion shall be completed before
the gas departs from the cyclone separator. Adoption of the optimal excess air factor depends
on the fuel properties, design of fuel combustion equipment and other factors. And, the
optimized excess air factors shall be established under different loads.
When the heat conduction surface is kept clean, at the given percentages of steam and
excess air, the gas temperature at the outlet of the preheater and the resistance of the gas
passing through the gas duct shall generally be kept constant. To record these operation data
starting from the startup is necessary. The operation data shall be recorded in the tables in
order to compare with the data obtained under the various similar operation conditions.
Standard value for judging the operation satisfaction shall be established when the
equipment is new. In this way, when the operation conditions deviate from the standard,
steps shall be taken to determine and correct the cause of the deviation.
9.2 Water filling and venting
When the boiler is filled with water, open the vent valve of the boiler as specified. Fill
water to the operation level in the glass level gauge. If hot water is adopted (relative to the
temperature of the boiler metal), take care to feed water slowly in order not to cause
temperature stress at the steam drum, header, etc.
9.3 Startup
In order to detect the abnormal firing conditions quickly, the instruments used for
monitoring the operation conditions before ignition shall be in sound working status.
Reliable display of the ventilation resistance readouts, temperature & pressure readouts and
excess air quantity is indispensable for safe operation.
Prior to the ignition, the drainable parts of the superheater (connection pipelines and
tubes of header, inlet and outlet) shall be drained from the outlets through piping drainages
with no back pressure. The superheater outlet drainage valves (exhaust valve and drain valve)
shall be kept in open state in order to ensure that there is steam flowing through the
superheater to prevent from over-temperature of the pipe fittings until the unit is integrated
into the grid.
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When the pressure rises, the drainage valve can be throttled, but shall not be shut
completely. Refer to the operation instructions of the valve (Refer to instruction for valve
operation).
During the startup, burning rate should be controlled to keep the highest gas temperaure
of rear pass under 538 (inspected by the temperature element in cyclone separator and
rear pass) until ranked with turbine. After turbine running, the rise of turbine throttle valve
steam temperature and pressure shall always comply with the regulations made by the
turbine manufacturers.
When a new boiler unit is started for the first time, the combustion rate must be
controlled. The increment of combustion rate shall be maintained at a relatively slow rate in
order to inspect the expansion displacement and clearance. The later startup rate can be
relatively quicker, but the temperature rise of the saturated steam shall not exceed 93
(refer to boiler startup procedures) or the limited gas temperature of cyclone separator outlet
mentioned above. The temperature rise of the saturated steam can be slow depending on the
heating rate of the insulation material, refer to the instructions of the insulation material
manufacturer. In this period, combustion regulation is normally carried out manually. Never
try to start up with the combustion control or feed water equipment in automatic status.
Prior to the ignition, check all the equipment and safety interlock devices and make sure
that they are in excellent working state. During the initial operation, determine the
appropriate operation modes of all the instruments (gauge, transmission, recording, etc.)
9.4 Boiler Shutdown
The time and procedure required for boiler shutdown depend on the character of
shutdown (normal shutdown till cold state, normal shutdown till hot standby and accident
shutdown.) and whether to inspect or repair. It observes the detailed operational procedures
for unit operation.
Decide the service steps for boiler shutdown to be taken on the basis of the expected
shutdown time. Refer to the shutdown service procedure in this instruction manual.
Along with the boiler off-line (turbine valves closed) and complete flameout, the drain
valves of the superheater and reheater shall be opened as required for the desired pressure
drop. If the boiler is shut down to cold state and when the steam drum pressure drops to
around 0.17 MPa, the vent valve of the steam drum opens. If it is necessary to inspect or
repair the pressured components, lower the water temperature to 93 before discharge
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water.
Whatever shutdown mode is chosen, cooling rate cannot make saturated-steam
temperature drop exceed 85 per hour.
9.5 Water level
Prior to the ignition, the operator shall check the steam drum water level with the water
meter column and level gauge blow-off method. Normally, slowly opening drain valve of
high pressure gauge is enough. Normally, an unblocked blow down can clean the foreign
matters probably exist on drain valve seat. When warm up the new unit, the gauges shall be
blown off for several times under low pressure and verify the consistency of remote and
local level gauges. During the operation of boiler, the water level gauges shall be inspected
once per shift (refer to the instructions for the water level gauges). If the water in water
gauge is stagnant when open or close the drain valve, investigate for the cause and correct
the conditions immediately. To protect the glass of the water level gauges, the blow-off
volume shall be kept to minimum during the normal operation.
During the normal operation, the water level of the water level gauge shall also be
observed regularly even if the boiler may be provided with reliable water level regulator or
remote water level indicator.
The boiler should prevent the rapid change of feedwater temperature when evaporating,
and that water passes through the boiler should match the steam evaporation rate.
Feedwater flow should not be closed all when the boiler is fired.
The centerline of the water level gauge indicates the normal water level inside the boiler
under full pressure work conditions. If the boiler is usually required to operate under
lowered pressure, the water level indicted by the centerline of the water level gauge will be
lower than the actual one in the boiler drum. It is because that there is temperature
difference between water in water gauge and drum. Any water level regulation shall be
carried out slowly. If the water level is excessively high, carryover of water in steam, even
steam-water, co-boiling may occur, especially in the case of great and quick fluctuation of
steam. The most severe danger that may be encountered is low water level. As mentioned
before, water level shall be continuously observed, and water gauge shall be checked
regularly to ensure the normal operation. The protection of water level transmission
pipelines shall be provided to avoid the freeze or other damage, instead of relying on
high-low water alarm.
Due to the water supply failure or due to the negligence of operator, if the water level is
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out the visible range of the gauge, except the instant water level fluctuation caused by rapid
and sharp variation of load, proper action shall be taken immediately to flame out the boiler.
9.6 Boiler warm-up and expansion
When the pressure of the boiler is raised, it is necessary to take measures in the
beginning to open all the drain valves and bypasses (if any) to drain the cold steam pipes
sufficiently.
During the initial ignition, check the expansion conditions of the boiler regularly and
make records, and make sure that the guard plates, headers and pipes can expand freely
relative to the steel structure. The expansion indicator shall be installed at appropriate
position to facilitate inspection (refer to the arrangement diagram or expansion displacement
diagram of pressured components). During the service life of boiler, inspect its expansion
regularly to determine whether the expansion is normal and uniform. All the hanger rods and
the related pipes shall be inspected regularly for their appropriate displacement and function.
9.7 Air preheater
Abnormal increment of the ventilation resistance in the gas side or air side of the air
preheater indicates that the ash blockage is increasing and various measures shall be taken
immediately. Especially when the unit is started, observe closely the temperature of the gas
departing from the air preheater and make sure that the fuel has actually been burnt
completely. The sharp and abnormal increment of gas outlet temperature will show that there
is a fire in the preheater. In case of such accident, shut down the boiler immediately and take
measures to extinguish the fire.
9.8 Soot blowing
The soot blowers shall be put into operation as needed to keep the surfaces of the
heating faces clean. Excessively high gas temperature at the economizer outlet or abnormal
steam temperature regulation action may indicate the necessity of soot blowing. Through
recording and comparison of the exhaust gas temperatures and furnace conditions under
different loads, an appropriate soot blowing periodical table can be obtained. Practice proves
that effective soot blowing is very difficult after quite a lot of fly ash and slag accumulates
due to a period of omission. Pay attention to the information of the steam temperature
control system. These parameters can show the dirt level of the superheaters because the
quantity of desuperheating spray water reflects the variation of the cleanliness of the tube
surfaces.
If soot blowing medium is steam, appropriate drainage of soot blowing system is
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important to the prevention of pressure parts erosion. In no case should plash be in the
pipeline. Normally, a hole at the drain valve can continuously discharge the water. Before
the soot blower put into operation, steam shall be used to purge freely, and enough long time
is needed to heat the pipelines.
9.9 Regulation of steam temperature
Steam side regulates through firing in the furnace and control furnace outlet gas
temperature to regulate and keep outlet steam temperature. The medium side normally keeps
final superheater and final reheater design temperature with desuperheating water. Only
when the outlet temperature of reheater cannot be kept within the specified range of outlet
temperature, spray desuperheating is used.
Whatever method is used to control the temperatuer of superheater and reheater, there
are some factors which may cause abnormal fluctuation of steam temperature:
Causes for abnormal low steam temperature:
1) Insufficient excess air;
2) Feed water temperature higher than design value;
3) Boiler fuel carries excessive moisture;
4) Contamination on superheater/reheater outer surface or inner surface;
5) Spray desuperheating valve leakage;
6) High water level of drum, steam carries water;
7) Control regulating equipment is not well-adjusted;
In addition, the following conditions may cause abnormal over-temperature of the
steam:
1) Heat conduction of furnace lower than designed
2) Excessive excess air;
3) Feed water temperature lower than the design value;
4) Irregular ignition or delayed combustion;
5) Control regulating equipment is not well-adjusted.
9.10 Superheater and reheater
Protection of the superheater and reheater is an important controlling factor when
deciding how to make natural circulation boiler quickly carry pressure. During the startup,
the saturated steam temperature rising shall not be more than 93C per hour. Heating rate of
saturated steam temperature maybe slow according to thermal insulation material, referring
to thermal insulation material characteristics specification. The heating of the superheater
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and reheater shall be as even as possible, and the maximum temperature where gas flows
through the superheater tubes (gas temperature at outlet of cyclone separator) shall be
monitored and controlled.
The gas temperature at outlet of cyclone separator is usually measured with the
thermocouples installed in the outlet gas duct of the cyclone separator. The maximum
temperature at outlet of cyclone separator shall be limited at 538, until the turbine carries
loads and the reheater establish normal steam flow.
To ensure that the condensation water in superheater coil is removed, steam flow
through the superheater shall have appropriate flow when start up. Before the ignition and
firing of the boiler, the drainage valves and vent valves in the outlet headers and/or main
steam pipes shall be opened and shall be kept open until the boiler generates steam and is
loaded. When the boiler drum pressure increases, these startup drainage valves and/or vent
valves can be throttled gradually to make sure that sufficient steam flows through the
superheater throughout the startup. When the turbine is in line with load and appropriate
steam flow is ensured, the startup drainage valves and/or vent valves of the superheater can
be closed.
All drain valves of reheaters shall be open before ignitions. When boiler pressure rises,
the moisture left in the reheater evaporates. Before turbine and electric machine synchronize
and carry loads, the drain valves of reheater connecting to condenser shall keep open. The
exhaust valves and drain valves open into the atmosphere shall be closed before the
condenser starts suction and forms vacuum.
The gas temperature around superheater and reheater surface is very high when the unit
carries loads. The sudden interruption of cooling steam flow will cause the damage
superheater and reheater due to overheating. Therefore, when steam flow is interrupted, all
fuels shall be cut off. If normal steam flow is passively interrupted, the safety valves at
superheater outlet which provide protection shall be open, and steam flow shall be
established again. These safety valves shall take off before the safety valves of drum. The
safety valves of reheater will be open to reduce the pressure of reheater steam trap.
Carefully prevent water or solid matter from flowing into the turbine. Sampling analysis
shall be done regularly and frequently to inspect the condition of steam carrying water. The
record of steam conductivity is used for this purpose. Sampling tube is normally set at the
steam connection pipe from drum to superheater. Steam carrying water may be caused by
abnormal high water level, especially when the evaporation capacity is high. If the condition
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of steam carrying water is doubtable, take measures immediately and investigate to remove
the causes that result in steam carrying water. If the research show that steam carrying water
is not caused by poor water quality, internal device of steam-water separation, water level
control and indicating equipment where problem may probably occur shall first inspected.
From the heat conduction and corrosion point of view, deposition of solid substances on
the superheater and reheater is harmful. Under the presence of chemical substance like
caustic alkali and chlorine, stainless steel pipes of superheater and reheater are much more
likely to be eroded. Therefore, whether during carrying or filling water (hydrostatic test,
chemical cleaning), solid matter shall be prevented from getting inside.
9.11 Blow-off
Continuous blow-off is the best method to control and keep the relative stable
concentration of the soluble solid substances in the boiler water. The blow-off data shall be
recorded. Total blow-off quantity is better to be determined according to the boiler water
chemical analysis. Because each power plant has a different water treatment system, person
in charge of water condition shall specify the water treatment system according to the
feedwater analysis and give necessary instruction of blow-off.
However, the blow-off quantity will affect the heat loss and water supplement volume
of the boiler, so he total blow-off quantity should preferably be determined on the basis of
the chemical analysis of the boiler water. Regular blow-off should be conducted under low
load as can as possible, and the water level in the boiler drum should be monitored strictly to
control the blow-off quantity.
Natural circulation boiler is equipped with down drain valve or water wall header drain
valve, which can be used for interrupted blow-down at any time. Drain valves of lower water
wall header are only used for blow-down when the boiler shut down. Unless valve
manufacturer has opposite recommendation, normally, sealing valve (near the boiler) is the
first to be open, and then the exhaust valve (far away from the boiler). Do the reverse
process when closing the valves. Never make blow-off time so long that the visible water
level in water gauge will disappear. The valve leakage shall be checked often.
9.12 Tube damage
For the tube damage of boiler, one or more, whether boiler shutdown is needs shall be
determined on the basis of the damage level, the ability of maintaining normal water level of
the boiler and the boiler load requirements.
If normal feedwater system can keep water level at visible range of water gauge, and
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load condition requires to keep operating, the boiler can keep operating until the chance of
shut-down for necessary overhaul. Under such circumstance, other tubes are often damaged
when the boiler operate for quite some time. When the tube damage is more than one and
affect the water gauge losing water level, the boiler shall be shut down in normal mode. The
purpose is to prevent all equipment from suffering sudden temperature change.
Low water level, various measures shall be taken to make water level approach the
normal level until the boiler is fully cooled down and allowed for drainage.
When leakage of superheater or reheater components happens, it shall be analyzed as
soon as possible. The boiler shall be shut down in normal mode.
The above information is only for suggestion, and cannot take the place of the correct
judgment of the stokers responsible for operating these equipment.
Bear in mind that prolonging the operation of the tubes with leakage may cause the
damage to adjacent tubes and increase maintenance works, exceeding the former short scope
of maintenance.
9.13 Furnace explosion
Furnace explosion is usually result of the following conditions:
1) Unburned fuel accumulates in the furnace due to incomplete combustion.
2) The mixture of unburned fuel and air achieves the explosive proportion.
3) There is sufficient heat to improve such part of mixture to the ignition temperature.
The unburned fuel accumulates in the furnace in several modes, e.g.:
1) It leaks into the combustion zone through the ignition fuel inlet valve.
2) If the flame has died out, the supply of fuel is not cut off immediately.
3) The furnace entering the furnace is not burnt quickly and immediately.
4) There is difficulty in ignition during the startup.
Furnace explosion can be avoid if a little attention is paid.
1) Maintain a certain amount of air volume during the startup to ensure that there is enough
air in the furnace which prevent the explosive mixture accumulation. Make sure that the
main fuel valve and ignition fuel inlet valve to the combustion zone are closed tightly
with no leakage.
2) Take care to observe the ignition of the fuel. When finding any abnormal combustion,
cut off the fuel supply with no delay. Close all the cutoff valves. Blow the furnace with
30% air volume (minimum) for at least 5 minutes after the boiler is shut down.
3) Remove the water, mud and slag from the oil tank regularly.
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4) It is absolutely unallowable to ignite the oil burner when the ignition energy source
needed is lost. Ensure that the air in air atomization oil gun is dry, do not use heavy
oil/mechanical atomization oil gun for boiling out, ignition and boiler warm-up, while
light oil/ air atomization or heavy oil/steam atomization oil gun is preferred.
5) Prior to any startup and during the normal operation, inspect the functions of the furnace
safety supervision system regularly, including interlock, tripping, etc.
6) During the downtime of the furnace, regulate, inspect and maintain the furnace safety
control system thoroughly.
9.14 Fly ash wear
Fly ash wear refers to the wear of the residual ash particles carried over in the gas to the
metal surfaces. Wear normally occurs in local zones with high gas speed. The wear level is
related to the ash content of the fuel (quantity and component). Firing coal with high wear
characteristics and high ash content makes boiler wear a main problem.
Caution: Wear usually occurs in: the end and bend of economizer tube and
low-temperature superheater and around soot blowing area, gas duct and induced draft fan
(fan blade and shell).
The boiler design parameters are based on conservative mean gas velocity and normal
coal-ash ratio to achieve the minimum wear possibility. However, the possibility of local
wear is inevitable. For each boiler, neither the wear level nor the local wear area can be
forecasted.
9.15 Inspection
After the boiler is shut down and cooled and can be assessed, perform external
inspection to the water wall, cyclone separator, superheater, air preheater and deduster.
Check for any wear, corrosion, expansion, blister, bending, over-burning or crack.
Expansion of the superheater/reheater tubes indicates the overheating which may be
caused by fast boiler pressure rise. When boiler pressure rises, exhaust in superheater is not
enough, or incrustation is generated on tube inner surface due to the moisture carried by the
boiler. Measures shall be taken to eliminate the reasons resulting in bending though mild
bending is not serious. Check the guard plates and door holes for any leakage. Boiler water
side condition shall be inspected regularly, in freezing weather, for instance, the inner
inspection during drainage, be careful, not to let water left in the pipeline or valve seat,
especially during the boiler downtime, the gate valve on vertical pipe shall be kept open, in
case of getting frozen and damage to valve seat. Some condensation water will be left in the
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section of superheater and reheater panel where water cannot be drained, and measures shall
be taken to prevent getting frozen.
Before entering the steam drum, make sure that all the valves in the steam drum
connection pipes are closed tightly (feed water, auxiliary steam, dosing pipe, blow-off,
drainage, sampling, level gauge drainage, etc.). Open the manhole cover to inspect the
tightness and cleanliness of the interiors of the steam drum. Inspect the steam drum for
corrosion and surface pit. Oxidized pit is a common form of corrosion, and normally occurs
in the steam drum above the normal water level, and sometimes in the tubes and lower
headers. Open sufficient number of hand hole covers in the various headers of the water wall
to remove the dirt.
Check the heating face of the preheater for cleanliness. If there is corrosion, it should
occur in the cold end part of the preheater, especially in the places where ash and filth tend
to accumulate.
Inspect the gas side thoroughly and clean it as necessary. Check if the soot blower is
deflective. Inspect the equipments such as coal spreading trough, igniter, oil gun, scanning
air fan, connection rod and air door for cleanliness and damage, and carry out operation and
flexibility inspection. For the FSSS system, inspect and test the control valve, relay,
indication lamp, interlock, etc.
9.16 Maintenance of boiler and freezing prevention
9.16.1 Principle for boiler maintenance
After the boiler is shut down, whether for standby or for overhaul, implement the
corrosion prevention work carefully.
1) When equipment in service is switched for short-term standby, the pressured
components have no overhaul work and it is ready for startup at any time, mostly
heating pressurization method is adopted for the maintenance.
2) When the equipment in service is subjected to heavy repair or small repair or is switched
for standby of more than 10 days, normally drainage under pressure afterheat afterheat
drying method is adopted for the maintenance.
3) When the equipment in service is switched for long-term standby of more than 1 month,
hydrazine & ammonia solution method shall be adopted for the maintenance. If the
pressured components of the boiler are relatively tight, ammonia filling method can
be adopted for the maintenance.
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4) Cold boiler shall not be switched to dry type corrosion prevention. If it is necessary,
ignite and raise the pressure to 30% of the rated pressure and then reduce the pressure.
Adopt the afterheat drying method for the maintenance.
9.16.2 Maintenance method
Select the maintenance method according to the maintenance principle. The
maintenance and operation can be implemented depending on the specific conditions of the
power plant with reference to the applicable specifications of the power authorities.
9.16.3 Freezing prevent for boiler
The freezing prevention measures shall be checked before winter begins. No pipe is
allowed to be bare. Anti-freezing and heating devices for each part of pipeline proper shall
be put into operation. Heating tubes of fuel line are in operation whole year and cannot be
overhauled in winter. Water in gauge pipe shall be drawn off. Hole door and damper of spare
boiler shall be closed, and measures shall be taken to prevent cold air from entering into the
boiler in overhaul.
In winter, during the shutdown of boiler, adopt dry-type maintenance as can as possible,
and air heater shall be put into use when the wall temperature of superheater is below
20.
If there is water in the boiler, water shall be fed in and drawn off when the temperature
of boiler water is below 10.
10 Boiler operation procedure
10.1 Startup and operation of boiler
For boiler startup, firstly put into use the on-bed startup burners. Heat the bed materials
to the coal feeding temperature. After coal is fed, according to the temperature rising and
pressure rising rate, increase the air volume and fuel quantity gradually so that the boiler
achieves its rated load. In the ignition and temperature rising process, it is necessary to
control the temperature variation rate at all the flue gas side temperature measuring points to
be lower than 135/h, to limit the saturation temperature variation rate to be lower than
93/h, to control the temperature difference between the upper and lower walls of the steam
drum to be less than 50, to control the temperature variation rate of drum metal wall to be
lower than 55/h.
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10.2 Preparation before boiler startup

10.2.1 Inspection and cleaning before boiler startup
Before initial ignition and every cold startup or after service of the boiler, the interior
and exterior of furnace shall be inspected and cleaned. And all foreign maters shall be
removed completely from the pressure parts, all pipes and conduit tubes, which may limit
the normal expansion of the boiler, shall be removed. All person shall leave, and all doors
and openings shall be closed. Check whether the indication of the boiler drum water level
gauge is consist with the reading of local glass water level gauge, whether there is any block
at air distribution boards of the furnace and material-returning machine, and inspect and start
the atomization nozzle of the burner. And all these check shall be prepared by the
departments which is in charge of operation. Be familiar with the startup and operational
procedures for boiler and auxiliary machines.
10.2.2 Steam pipeline purging
For a new boiler or a boiler the main pressure parts of which has been repaired, the
purging of main steam pipeline and reheating steam pipeline shall be done before startup to
remove the rust and foreign matters in order to avoid the damage ti turbine. The purging of a
new boiler shall be done after pickling and before the setting of drum and reheater safety
valve. Before removing the temporary purging pipeline, whether it is needed to set reheater
safety valve shall be taken into consideration.
10.2.3 Safety valve setting
The setting of drum and reheater safety valve shall be done before the flushing of
turbine. During ignition and firing, combustion rate shall be kept to limit the highest
temperature of cyclone separator outlet to be below 538. When the turbine carries loads,
the setting of reheater safety valve shall be done. Until reheat steam pressure is high enough
to make reheater safety valve is activated through closing intermediate valve. The popping
pressure and closing pressure shall be consistent with design value. The setting procedure
refers to the specification of safety valve manufacturer.
10.2.4 Boiler dry-off
Before the startup of the new unit or after the repair of thermal insulation material, the
pipelines of furnace, cyclone separator, material-returning machine and connection which
has thermal insulation material inside shall have an appropriate dry-off according to the
thermal insulation material characteristics and design requirements.
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10.2.5 Filling bed materials into boiler

Before the CFB boiler is started, inert substances (appropriate sand particles or CFB
bed ash) are loaded into the furnace as bed materials. Used CFB bed ash is optimal due to its
excellent fluidization features. To ensure appropriate heat transfer and system insulation,
sufficient bed materials must be introduced. Each boiler needs about 200t bed materials
(including the furnace and material-returning machine). The particle size of the bed materials
loaded shall meet the particle size limits allows by the design. If no ash is unloaded from the
system or if the bed materials exist before the operation, no further loading is needed.
10.3 Cold/warm-state startup
When the turbine high pressure rotor probe temperature is lower than 100, or when
the boiler starts up in cold state with no pressure, it is called cold-state startup. When the bed
temperature (the average temperature shown in the middle-level thermocouple) is lower than
680, coal cannot be put into the furnace directly; instead, it is necessary to purge the
furnace according to the cold-state startup mode and then to put the startup burners into
service to increase the be bed temperature. The startup mode in such state is called
warm-state startup. In case of cold-state or warm-state startup, the furnace must be purged.
Only after the purging is completed can the startup burners be put into service. After the
furnace temperature is raised to above 575 (the average temperature shown in the
middle-level thermocouple), put sold fuel gradually until the fuel is ignited. After the oil
guns are retracted completely, the bed temperature shall be no less than 680.
In addition to the preparation work to meet the startup conditions, the cold-state startup
process of the boiler can generally be divided into several steps, i.e. air fan startup, and
furnace purging, boiler ignition and temperature/pressure raising, turbine rolling and velocity
raising, unit combination to grid and adding initial load, increment of unit load to rated load,
etc.
10.3.1 Boiler feed water (in brief)
The boiler feed water quality must conform to the requirements of the specifications.
When feeding water into the boiler, control the water feeding speed and feedwater
temperature strictly.
10.3.2 Air fan starting
The air fan starting sequence is: induced draft fan high-pressure fluidization air fan
secondary air fan primary air fan limestone air fan.
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10.3.2.1 Starting of induced draft fan

Induced draft fan is the first air fan in circulating fluidization air and gas system during
boiler start-up. Before the induced draft fan is started, its inlet baffle is regulated to the
minimum position to avoid over-current of the motor of the induced draft fan during the
startup. After the induced draft fan is started, check the outlet baffle which shall be open,
note that the vibration indication value of the air fan bearing, the voltage and current values
and the temperature should be within the specified range. Open the vane control baffle at the
inlet of the induced draft fan slowly. Put the furnace vacuum (separator outlet) control to
automatic. Monitor the furnace pressure. Subsequently, the air volume of the induced draft
fan will regulate the control baffle automatically for operation, maintaining appropriate
furnace pressure at the outlet of the combustion chamber.
If tripping or downtime of induced draft fan for any reason occurs during boiler start-up,
primary air fan and secondary air fan shall be shutdown.
10.3.2.2 Starting of high-pressure fluidization air fan
During boiler start-up, after the induced draft fan is started, start the high-pressure
fluidization air fan and check the air volume of every chamber of the material returning
valve.
10.3.2.3 Startup of secondary air fan
Before the secondary air fan is started, the inlet baffle of the secondary air flow shall be
closed to avoid overload of the motor of the fan.
10.3.2.4 Startup of primary air fan
During boiler start-up, start up the primary air fan after the startup of induced draft fan,
high-pressure fluidization air fan and secondary air fan. Before the primary air fan is started,
the inlet baffle of this fan, the primary air duct baffle in the downstream and the baffle of
start-up burner shall be regulated to the minimum position in order to avoid overload of the
motor of the fan during the startup.
After the primary air fan is in operation, open the vane control baffle at the inlet of the
primary air fan slowly, and monitor the furnace pressure.
10.3.2.5 Startup of limestone air fan
The startup and shutdown of limestone air fan refers to the manual provided by the
manufacturer.
10.3.3 Ignition fuel system leakage test and furnace purging
Before ignition, fuel system leakage test and furnace purging of 5min must be carried
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out. The furnace purging air volume shall, as a minimum, be more than 30% of the total air
volume under the rated load. For the detailed purging steps when the boiler is started up or
shut down, refer to the boiler operational procedures provided by FSSS suppliers.
10.3.4 Boiler ignition startup and temperature/pressure raising
Before the ignition of startup burner, cold/warm-state boiler shall have periodic purging
according to the permissive ignition condition of start-up burner.
1) Electrify the electrostatic precipitator
2) Start up the induced air fan.
3) Put the furnace pressure control to automatic, and keep the furnace pressure at -125Pa.
4) Start up the high-pressure fluidization air fan, ensure that there is at least one
high-pressure fluidization air fan under operation.
5) Start up the secondary air fan.
6) Start up the primary air fan, ensure that there is at least one primary air fan under
operation.
7) Put the boiler air flow to automatic. Adjust the set value of total air flow to be no less
than 30% of the air flow at full load. Inspect all equipment until they meet furnace
purging. Control the primary, secondary air volume at 50% of air volume at rated load.
Cut off all material feeding system. Ensure that the main interlock of the boiler is
normal and there is no possibility of tripping.
8) Start furnace purging for at least 5 minutes.
9) Check if all the ignition allowable conditions of the startup burners are met according to
the completion of purging cycle.
10) Close all secondary air nozzle baffles to specified halted state, and open these baffles
successively with the increase of boiler load. Keep high-pressure fluidization air fan
under operation.
11) Firstly, put one startup burner into operation at the minimum combustion rate, and
observe the flame features. Regulate the fuel oil / air volume rate, the fuel oil pressure
and the atomization pressure continuously to make the air volume match with the fuel
quantity. Then, with the same method, start the other startup burner on the diagonal
boiler wall. According to the temperature raising requirements, put the other startup
burners into operation gradually.
12) The increase of start-up burner load shall accord with start-up curve. The furnace
heating rate as measured with the middle-level thermocouples shall not exceed 135/h.
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13) Along with the increasing furnace temperature, the temperature difference between
material-returning machine and upper furnace shall be kept with 38, in order to
prevent the damage of heat insulating material of cyclone separator and material
returning machine. When the temperature of material-returning machine is 38 or
much lower than upper furnace, primary air volume shall be added as needed to reduce
temperature difference.
14) When the steam drum pressure achieves 0.17MPa, close the steam discharge valve and
vent valve in the boiler drum connection pipe.
15) Along with the increasing boiler drum pressure, regulate the drainage of the superheater
outlet header gradually or start other discharge valves or drainage valves. During the
startup, sufficient steam flow must be maintained to remove the condensate on the
superheater components.
16) Blow the boiler off as necessary during boiler warm-up. Maintain the water level within
the visible range during the blow-off.
17) Maintain the water level of boiler drum at normal valve, and inspect the concentration
and composition of boiler water as needed, to maintain qualified boiler water condition.
18) Before the condenser forms vacuum, make sure that the exhaust valves and drain valves
open into the atmosphere is closed. Only keep exhaust valves and drain valves
connecting to the condenser open until the turbine carries loads.
19) Roll the turbine by flushing once the lowest allowable pressure and temperature
specified by turbine manufacturer is realized. Refer to the specification provided by
turbine manufacturer.
20) Before rated speed is reached, burning rate shall be controlled to prevent the gas
temperature of cyclone separator being above 538, to protect boiler reheater. When
rated speed and synchronization is reached, the limit of the gas temperature of cyclone
separator being lower than 538 can be canceled. However, burning rate can never
exceed the requirements of steam rising.
If the boiler synchronizes before design operation pressure is reached, startup rate
requirements shall be followed when further increase the boiler burning rater.
Caution: The operator shall report alarm when steam-carrying water and water entering
into the turbine are detected. For example:
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Temperature of main steam or reheat steam pipelines suddenly drops without rhyme or
reason.
2.
Steam line vibrates and causes water shock.
3.
Abnormal vibration and expansion reading record shown in turbine monitoring

equipment.
Operating personnel shall take necessary measures to prevent water from entering and
damaging the turbine. Refer to the specification provided by turbine manufacturer.
21) When bed temperature (average temperature of middle-level thermocouple) achieves

575, the first coal feeder can be started manually to load coal at the minimum rate.
After coal is loaded, observe the variation of bed temperature. When the bed
temperature rises gradually while the oxygen quantity decreases continuously, it can be
identified that the coal is in combustion. To spread the fuel evenly on the bed face,
firstly load coal through the middle coal feeding tube. Now attention shall be paid to the
air quantity in the coal feeding tube. If the bed pressure is low and the air quantity is
small, the dampers in the two sides can be turned down appropriately. However, in the
beginning when coal is loaded, increase or decrease gradually depending on the
combustion conditions in the furnace. For further heating and temperature rising, follow
the demands of the startup curve. When bed temperature achieves 760, reduce
gradually the output of the oil guns of the on-bed burners. After the on-bed burners are
completely taken out of service, the bed temperature is no less than 680.
22) Once all parameter is realized, automatic control system can be started up. However,
boiler load cannot be lower than 50% (about 50% of gas flow).
23) The air volume entering into the furnace shall always meet the requirements of fuel rate.
Automatic control system is used to maintain such balance. The measurement of O2
combined with air volume control shall be inspected regularly to ensure the continuous
reliable operation.
24) When burning condition is stable and the temperature and pressure has reached design
value, steam temperature control and burning control shall be put to automatic.
25) Regulate feedwater to normal water level as needed. Once continuous water feeding is
set, put water feeding control to automatic.
10.4 Hot-state startup of boiler
The so-called hot-state startup refers to the startup by feeding coal directly into the
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boiler when the bed temperature(average temperature measured by the lower thermocouple)
is more than 650. If the bed temperature is higher than the allowable coal feeding
temperature after the fan is started, it is not necessary to purge the furnace or to put the
startup burners into operation. After feeding coal directly and igniting with the coal feeder at
the minimum rotary speed, the boiler can be brought to the full load rapidly. It is also not
necessary to consider the limit in temperature rising rate for the wear-resistant refractory
materials in the furnace. This is because there is quite high accumulation of heat in the
furnace and cyclone separator in this time.
10.5 Regulation during normal operation of boiler
The boiler will be put to automatic control during operation, however opertaing
personnel shall pay attention to the operating condition of the unit to ensure the safety and
economics of boiler operation and to the control of emmssion in fuel gas. Steam flow,
temperature and pressure parameter of superheater and reheater shall be kept within the
allowable range of normal operation.
10.5.1 Regulation of boiler load
The regulation of boiler load is mainly achieved by changing the coal feeding quantity
and the corresponding air volume. When the load increases, increase the air volume firstly
and then increase the coal feeding quantity. On the contrary, when the load decreases, reduce
the coal feeding quantity firstly and then reduce the air volume in order to keep the oxygen
content in the tail gas unchanged. When the boiler load increases, the bed temperature will
rise. On the contrary, when the boiler load drops, the bed temperature will decrease. The
temperature level in the whole furnace also varies along with the variation of load, and the
variation tendency is as same as that of the bed temperature.
When the boiler load increases, while increasing the fuel quantity and air volume, also
increase the bed material quantity through the dosing system to improve the height of the
bed layer. When the boiler load decreases, while reducing the fuel quantity and air volume,
also discharge the large-particle bed materials in the furnace through the slag discharge
system to reduce the height of the bed layer. In this way, when the bed temperature
fluctuates within a relatively small range, the load can be increased or reduced steadily to
ensure the stable operation of the boiler.
It is required that, when the boiler load varies within a small range, the purpose of
increasing or reducing the load through change of bed temperature by increasing/reducing
the fuel quantity and air volume only while the bed pressure for normal operation is
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maintained. However, because the bed temperature is restricted by multiple factors, the
variation amplitude is limited.
10.5.2 Regulation of bed temperature of boiler
The design value of the bed layer temperature of the boiler is 892 under the rated
load. Considering the load variation and the requirements in other aspects, the bed layer
temperature is controlled at 850~910. When the bed temperature exceeds this range, it
must be regulated in time.
Regulate the bed temperature by changing the ratio of primary air to secondary air.
When the primary air volume is increased or the secondary air volume is reduced, the bed
temperature will decrease. Conversely, the bed temperature will increase.
By increasing the quantity of bed materials to improve the circulation of the materials,
the bed temperature can be increased. By increasing the slag discharge quantity to reduce the
bed pressure and the quantity of bed materials, the bed temperature will rise.
If the mean size of the bed materials is excessively large, relatively speaking, the
useable materials that can participate in the internal and external circulations of the boiler
will decrease, causing the boiler to operate at relatively high bed temperature. By increasing
the slag discharge quantity, removing the bed materials with larger particle size and adding
qualified bed materials through the dosing system, the bed temperature can be recovered to
the normal level.
10.5.3 Regulation of water level
To maintain normal water level of boiler drum is the most importance to ensure safe
operation of the boiler. Too high water level will result in steam carrying water, thus worse
the steam quality, and too low water level will disrupt the water circulation, even serious
water shortage will occur. If the feed water volume doesn't match the evaporation volume,
water shortage or water overflow accident will occur within couple of minutes. The water
shall be supplied balancedly and continuously as can as possible, to maintain normal water
level in boiler drum.
When the boiler runs under low load, the water level in the boiler drum shall be slightly
higher than the normal level to avoid low water level due to increment of load. On the
contrary, when the boiler runs under high load, the water level in the boiler drum shall be
slightly lower than the normal level to avoid high water level due to decrement of load.
However, the variation range shall not exceed the allowable value.
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10.5.4 Regulation of steam temperature

Primary and secondary spray type desuperheater are set respectively between platen
superheater cold section, platen superheater hot section and high-temperature superheater in
superheater system, to regulate steam temperature, primary for coarse control and secondary
for fine tuning.
Reheater regulate steam temperature mainly by gas damper, supplemented by
emergency water spray device.
The steam temperature is regulated with water spray. The operators shall pay close
attention to the water spray quantity and the steam temperature before and after water spray
to ensure that the desuperheated steam temperature should be higher than the saturation
temperature under such pressure by 11.
10.5.5 Control of SOx emission quantity
If the control of SOx emission quantity is not needed, please skip this section.
The SOx emission quantity is normally controlled by controlling limestone feed rate
automatically and manually, i.e. to increase or decrease the mole ratio of calcium and sulfur.
However, many other factors like bed temperature, limestone granularity will affect the
desulfurization efficiency of a CFB boiler.
Changing the limestone quantity of qualified granularity can control SOx emission
quantity. Within a certain range, with the increase of limestone quantity, SOx emission
quantity is significantly decreased.
It is generally acknowledged that the desulfurization efficiency of desulfurizer is the
best when bed temperature is at 850910, which is also the bed temperature range of
boiler normal operation. Therefore, control of bed temperature during boiler operation is also
the control of SOx emission quantity.
The time of limestone staying in the furnace determines the utilization rate of limestone.
On the premise of boiler operation conditions unchanged, the time of limestone staying in
the furnace depends on limestone granularity. Therefore, the appropriate selection of
limestone granularity is essentially important. In addition, the CaO formed by limestone
decomposition and the CaSO4 formed by sulphate chemical combination are excellent bed
material.
The structure characteristics of limestone will also affect the desulfurization efficiency.
10.5.6 Control of NOx emission quantity
The NOx generated by the circulating fluidized bed boiler is mainly fuel type NOx, i.e.
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the nitrogen oxides generated from the organic nitrogen compounds in the fuel which are
oxidized in the combustion process. For the fluidized bed boiler, the NOx emission quantity
is controlled through control of bed temperature and segmental combustion.
When the bed temperature is controlled in 790~900, the NOx emission quantity is the
lowest.
The primary/secondary air ratio affects the NOx emission. While the bed temperature
and the normal combustion in the furnace are guaranteed, regulating the primary/secondary
air ratio within a certain range can bring the NOx emission to a relatively low level.
10.5.7 Protection of reheater
Turbine bypass shall remain hot stand-by during boiler normal operation, in order to
protect the reheater heating surface when unexpected accidents such as turbine tripping
happen. CFB boiler is different from conventional PC boiler, when accidents such as turbine
tripping happen and cause MFT, huge heat storage still exists in the furnace and the
temperature is high in the furnace, even higher than the anti-oxidation temperature of tube
material. Therefore, bypass is needed to start up to make a certain amount of steam flowing
through superheater and reheater to cool the heating surface.
10.5.8 Re-fluidization of bed materials
When the accumulated or excessive bed materials due to relatively low air volume (e.g.
during boiler startup) cause the condition that the bed materials in local area on the air
distribution board are not fluidized, increase the primary air volume in a pulsed way to
fluidize them.
Preconditions:
1) The boiler load is below 70%.
2) The bed pressure is about 11~12KPa.
3) The openness of the inlet baffle of the primary air fan is less than 35%.
4) The various control systems of the boiler have been coordinated properly.
Procedure:
1) Control the primary air fan baffle to increase from the current position to 70%~80%.
2) When the fan pressure increases and the primary air volume increases, return the
primary air fan baffle to the original position.
3) Observe the variation of bed temperature in the non-fluidized area.
4) Repeat this step for no more than 3 times at an interval of 10 minutes. If there is no
effect, stop this operation.
,
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5) Recover the normal control.

10.5.9 Use and maintenance of bed temperature thermocouple
Bed temperature is the average temperature of each thermocouple at different place of
the bed. If the temperature of a thermocouple differs by more than 170 from average
temperature, the temperature will not be included in the calculation.
Bed temperature thermocouple passes through wear-resisting material layer for about
150mm. If the length is exceeded, the wear will be increased and the service life will be
shortened.
10.5.10 Maintenance of bed temperature measuring equipment
Bed temperature measuring equipment is different from conventional pressure
measurement. Purging air shall be arranged, because pressure measuring point and pressure
measuring pipeline can be easily blocked by fluid bed material.
In order to remove the accumulated bed material at pressure measuring hole, purging
shall be continuous. It is realized by zero transferring at site.
Instruction: Pressure measuring holes shall be inspected on by one for blockage before
boiler is put into operation. Because of the error of construction, the distance between each
hole and air distributor may deviate from design location and causes large pressure
difference of each measuring point during boiler operation, thus affect the correct operation
of operating personnel.
10.6 Shutdown of boiler
10.6.1 Normal shutdown to cold state
The following steps for normal shutdown are based on the assumption that the boiler
unit is operating under full load in automatic control mode and are for the purpose of
reducing the steam pressure to zero and cooling the boiler down completely.
1) Gradually lower the unit load, and lower the boiler combustion rate accordingly with the
decrease of steam flow.
With the decrease of load, steam pressure is allowed to fasten the cooling. Gradually
reduce the fuel and air volume, lower the load to 50% and maintain the stability of bed
temperature.
In the process of lowering load, maintain the temperature between drum upper and
lower wall below 50. The decline speed of furnace temperature measured by
thermocouple of second layer shall not exceed 135/h. Following shutdown to cold state
,
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furnace temperature drop curve.

Steam temperature drop speed shall be in line with the requirements of turbine
manufacturer.
Steam temperature control, combustion control and water feeding control can keep
using automatic way until manual way is better, change into manual way.
Caution: During and after shutdown, carefully prevent water from entering into main
steam pipeline, hot reheat pipeline and cold reheat pipeline, in order to prevent the damage
to turbine in future restart. Water may come from:
1 Overflow into superheater from drum because of high water level.
2 Enter into superheater from desuperheater because of desuperheating control
valve open or leakage.
2) Reduce the coal feeding quantity
When the middle-level thermocouples show that the temperature is near 680, put the
startup burners into service. Control the boiler reducing rate according to the shutdown curve.
When the middle-level thermocouples show that the temperature is below 680 without
startup burners running or when startup burners is in operation and the middle-level
thermocouples temperature is lower than 630, coal feeding must be stopped. Once coal
feeding is stopped, close the limestone feeding system.
When feeding fuel oil to the startup burners, interrupt the power supply for the electric
precipitator as needed.
The primary air fan, secondary air fan, induced draft fan and high-pressure fluidization
air fan are kept running to cool the furnace and the material-returning machine.
3) When unit load decreases, operate all soot blower for one time.
4) When the load decreases, inspect the expansion displacement of the boiler.
5) The feed-water flow required is lower than the actual min. control value, to set the
feed-water control to and keep the water level in the visible range. Use the intermittent
blow-off as necessary.
6) After the vent valve and drainage valve at the superheater outlet and reheater are fully
opened, close the turbine stop valve. To further reduce the pressure, open the other
drainage valves in the superheater system as demanded. Open the steam pipeline and
turbine drain valve in accordance with the requirements of turbine manufacturers.
7) When the unit pressure drops to around 0.17MPa, open the vent valves of the drum.
,
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8) If the boiler to be emptied, boiler water temperature shall be below 90 before

drainage.
9) When an appropriate operating temperature is realized for boiler shutdown, continue to
purge the furnace, cyclone separator, material-returning leg and material-returning
machine for around 30mins to protect the refractory materials, then shut off the air fan.
10) The stop subsequence of fans: primary air fan-- secondary air fan-- induced air
fan--high-pressure fluidized air fan.
10.6.2 Normal boiler shutdown to hot standby
Boiler shutdown time is short (below 8 hours) and certain pressure and temperature are
maintained. Furnace bed temperature shall be kept higher than the allowable temperature of
pulverized coal ignition during operation as far as possible. The pressure of superheater
pipeline shall be reduced to an expected value, and it shall be kept by using superheater
outlet exhaust valve or reheater protection system.
The procedure similar to that for normal shutdown to cold state shall be observed
except for the following conditions:
With the decrease of unit load, do not lower the drum pressure. The pressure decrease
rate shall be much smaller than the rate of normal boiler shutdown. Referring to the
instruction of steam turbine manufacturer.
Keep the water level of glass water gauge within the visible range. When the boiler
shrinks because of water cooling down, add water from time to time to avoid the visible
water level in the water gauge disappearing.
Note: Operating personnel shall observe the water level of water gauge regularly, to
know the actual drum water level. Thus, when the unit needs to restart, the drum water level
can be established by taking appropriate measures.
1) Gradually reduce fuel and air volume, lower the load to 50% and keep the stability of
bed temperature.
2) When the fluidized bed boiler is to be damped down in hot state, stop coal feeding after
the boiler load is reduced to the minimum load.
3) After the main fuel is cut off, continue to keep induced air fan, secondary air fan, primary
air fan and high-pressure fluidized air fan in operation so that the volatile and combustible
substances remaining on the bed could be burnt out. Then stop the primary air fan.
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Under the condition that the coal powder ignition is allowed, maintain the bed
temperature as high as possible.
4) Turn off the secondary air fan when the gas temperature of cyclone separator is lowered
to 538. Continue with the purging with high-pressure fluidization air fan for 10
minutes to remove the combustible gas in the material returner and the solid substances
in the cyclone separator, material returner and material-returning leg. Then turn off the
induced draft fan and close the baffles in all the air ducts to minimize the heat loss in the
furnace.
5) The boiler can be re-started in hot-state or warm-state mode depending on the bed
temperature.
10.7 Slag-cooling system
There are slag notches at the bottom of the furnace. Bottom slag enters into slag cooler
through slag notches, and is discharged after being cooled. Discharge quantity is controlled
by variable frequency motor speed, and inlet quantity is controlled by the pressure
difference between the inlet air pressure of hot primary air chamber at the bottom and
furnace outlet air pressure. Slagging begins when bed pressure is beyond 13.5Kpa
(tentative, the specific value is determined after site commissioning).
Parameter and operation instruction of slag cooler sees also the slag cooler instruction.
10.8 Maintenance of boiler during shutdownReferring to 9.16 Maintenance of boiler and
freezing prevention
11 Handling of common accidents of boiler
11.1 Excessively high or low bed temperature
Phenomenon:
1) High or low bed temperature displayed;
2) High bed temperature alarm;
3) Elevated or reduced load.
Cause:
1) Excessively coarse or fine particle size of coal fed;
2) Measurement failure of bed temperature thermocouples;
3) Abnormal function of coal feeder;
4) Imbalance of primary-secondary air ratio;
5) Failure of slag discharge system;
,
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6) Limestone system doesnt run normally.

Countermeasures:
1) Inspect the bed temperature thermocouples;
2) Check if the operation and control of the coal feeder are normal;
3) Distribute the air reasonably, and regulate the primary-secondary air ratio;
4) Adjust the particle size of the coal fed into the furnace;
5) If necessary, increase the slag discharge quantity and add bed materials of appropriate
particle size.
11.2 Excessively high or low bed pressure
Phenomenon:
1) Excessively high or low display of CRT interface; Excessively high or low display of
bed pressure;
2) Bed pressure high or low alarm;
3) Severe increment of slag discharge load of slag cooler, or slag discharge almost stopped;
4) Excessively high or low pressure at bottom of air box.
Cause:
1) Bed pressure measurement failure;
2) Slag cooler failure, with excessively low or high slag discharge quantity;
3) Abnormal fuel and limestone quantity;
4) Abnormal primary air volume;
5) Excessively quick increment/decrement of boiler load, or excessive change of coal
quality.
Countermeasures:
1) In case of high bed pressure, increase the slag discharge quantity of the slag cooler,
reduce the coal feeding quantity, and stop adding sand into the furnace. In case of low
bed pressure, reduce the slag discharge quantity of the slag cooler, increase the coal
feeding quantity as necessary, or add sand into the furnace appropriately.
2) Check the bed pressure measurement points. Remove any failure found.
3) If, after the above treatment, the bed pressure is still below 7.5Kpa, the boiler shall be
shut down.
11.3 Water wall tube leakage and cracking
Phenomenon:
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1) In case of slight cracking or weld leakage, hiss of steam can occur and the feed water
flow increases slightly;
2) In case of severe conditions, obvious popping and steam spraying sound appears at the
tube cracking place, the negative pressure in the furnace turns positive, the feed water
flow becomes abnormally higher than the steam flow, and keeping of water level
becomes difficult in severe case.
3) Atomization phenomenon occurs in the non-tight boiler wall places;
4) In severe case, the current of the induced draft fan increases and white steam is emitted
from the chimney;
5) The bed temperature and the temperature at the inlet/outlet of the cyclone separator
decrease.
Cause:
1) The quality of boiler water and feed water exceeds the standard for long term, causing
scaling in the tubes, increment of local thermal resistance and over-temperature;
2) The water circulation is not good, resulting in local over-temperature;
3) Unqualified tube material, poor welding quality, or severe wear of external wall of
tubes;
4) Severe shortage of water in the boiler, blind and abrupt water feeding, or too fast water
feeding;
5) Severe over-pressure of the boiler.
Countermeasures:
1) Shut down the boiler in emergency and stop feeding water into the boiler;
2) Keep the induced draft fan in operation. Discharge the steam in the boiler. If the bed
temperature reducing rate is beyond the allowable value, stop the induced draft fan. Stop
the primary and secondary air fan, keep the induced draft fan in operation, and remove
the steam in the boiler. If the bed temperature decreasing rate exceeds the allowable
value, stop the induced draft fan;
3) After the boiler shutdown, remove the bed materials in the boiler as quickly as possible;
4) Proceed with the other operations as per the normal boiler shutdown procedure.
11.4 Tube blasting of superheater
Phenomenon:
1) There is steam spraying sound, and the feed water flow is more than the steam flow;
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2) The furnace vacuum reduces or turns positive, and the pressure of the superheated steam
decreases.
Cause:
1) Scaling on the inner wall of the tube or blockage of the tube with foreign materials,
resulting in deteriorated heat conduction;
2) Wear of outer wall of tubes, or high-temperature corrosion;
3) The steam temperature or wall temperature exceeds the limit for long term;
4) Unqualified tube material, improper welding quality, or improper steam soot blowing.
Countermeasures:
1) If the tube blasting is not severe, it is allowed to operate for a certain period. However,
reduce the load appropriately and prepare for shutdown.
2) In case of severe tube blasting;
1. With the induced draft fan running, control the bed temperature decreasing rate not
to exceed the specified value;
2. Maintain small quantity of feed water and keep normal water level;
3. Proceed with the other operations as per the normal boiler shutdown procedure.
11.5 Coking on bed surface
Phenomenon:
1) The temperature indicated by one or more thermocouples has large difference from the
mean (the difference>100);
2) Air chamber pressure increases while the bed pressure is normal;
3) One or several bed pressure indicates are static read-outs instead of fluctuating read-outs
during normal operation.
Cause:
1) Excessively high bed temperature of the boiler, or excessively low fusion point of the
bed materials;
2) Improper air/coal ratio for long term during the boiler operation;
3) Excessive blockage of fluidization air nozzles before boiler startup, or foreign materials
such as refractory material remaining in the boiler.
Countermeasures:
1) If it can be judge that the coking cause is Item 3, the only selection is to shut down the
boiler for treatment.
2) Also re-fluidization of bed materials can be referred to 10.5.8;
,
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3) If it the condition does not improve after the regulation, shut down the boiler
immediately.
11.6 Power interruption of system
Phenomenon:
1) The water level in the steam drum is relatively low or is invisible;
2) Collapse of the bed materials in the furnace bed face or in the bed face of the material
returning valve;
3) Power interruption causes all the auxiliary machines to stop.
Countermeasures:
1) Close the main steam valve and open the atmosphere vent valve of the superheater.
Avoid tripping of the safety valve as long as possible. Control the steam flow at
approximately 2kg/s;
2) Open the connection between the drainage of the economizer and the concentrated
downcomer so that the water of the economizer could be supplemented into the water
wall;
3) Because of the high heat accumulation in the boiler, open the baffles of the various air
ducts to reduce the temperature level in the boiler at the maximum speed;
4) Once the external power supply is restored and water is loaded into the steam drum, if
the temperature difference between the economizer outlet water and the steam drum
wall exceeds 112, stop supplying water into the economizer and the steam drum;
5) For startup of the boiler, the warm-state startup or hot-state startup method can be
adopted depending on the bed temperature conditions.
11.7 Water shortage accident
Phenomenon:
1) Boiler drum water level lower than the normal level or invisible in the sight glass;
2) The water level alarm gives low-level alarm signal;
3) The steam flow becomes higher than the actual effective feed water flow suddenly.
Cause:
1) The operators do not monitor the water level strictly due to carelessness;
2) Equipment accident, e.g. malfunction of automatic water feeding, or blockage of level
gauge resulting in false water level;
3) Leakage of boiler drainage or blow-off system, or excessive drainage;
4) Tube blasting of boiler feed water pipeline or heating face.
,
2305-1-8603
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Countermeasures:
1) Firstly, compare the indication conditions of all the level gauges to judge the
truthfulness of the water shortage accident and the water shortage extent;
2) If relatively severe water shortage is caused by severe failure of electrical equipment,
judge quickly and request for instructions for emergency shutdown;
3) When water shortage is not serious, generally, there is no failure which may affect the
operation of boiler, such shortage is caused by improper operation probably. Water
supply shall be enhanced by manual operation to restore normal water level.
11.8 Water fullness accident
Phenomenon:
1) Water level is invisible at the sight glass of the level gauge, and the boiler water
becomes dark;
2) The water level alarm gives high-level alarm signal;
3) The superheated steam temperature drops and the salt content of the steam increases;
4) The feed water flow becomes higher than the steam flow suddenly.
Cause:
1) The operators omits in monitoring the water level;
2) The automatic regulation of feed water fails, or the feed water pressure is excessively
high.
Countermeasures:
1) Firstly, compare the indication conditions of multiple level gauges to judge the
truthfulness of the water fullness accident and the water fullness extent;
2) Turn the automatic feed water regulation to manual feed water regulation;
3) For slight water fullness, regulate manually and reinforce the blow-off and drainage;
4) For severe water fullness, if the regulation is ineffective, apply for emergency shutdown
immediately.
11.9 Water attack of pipeline
Cause:
1) Sufficient pipe warm-up or drainage was not carried out before the steam is fed into the
steam pipeline, or air remains in the pipeline;
2) The check valve of the feed water pump opens and closes from time to time, resulting in
instable water pressure.
Countermeasures:
,
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P 56/61
In case of water attack in the steam pipeline, start the drainage valve of the superheater
system. Drain sufficiently and vent the remaining air out of the pipeline. For the feed water
pipeline, stabilize the water pressure and eliminate the air.
2305-1-8603
P 57 / 61
12 Appendix
12.1 Figure 1
Boiler dry-off heating/cooling rate
,
THIS DRAWING OR DOCUMENT BELONGS TO SBWL AND MAY NOT BE REPRODUCED OR DISCLOSED TO ANY THIRD PARTY IN ANY FORM WITHOUT THE PRIOR WRITTEN PERMISSION
OF SBWL..
12.2 Figure 2
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Cold-state startup curve
,
OF SBWL..
12.3 Figure 3
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P 59 / 61
Warm-state startup curve
,
OF SBWL..
12.4 Figure 4
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P 60 / 61
Hot-state startup curve
,
OF SBWL..
12.5 Figure 5
2305-1-8603
P 61 / 61
Shutdown curve
,
OF SBWL..

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INSTRUCTION FOR BOILER OPERATION

Instruction For Boiler Operation

Instruction For Boiler Operation

8.6 PURGING OF MAIN STEAM PIPELINE................................................................................ 25

Instruction For Boiler Operation

12.4 FIGURE 4 HOT-STATE STARTUP CURVE ...................................................................... 60

Instruction For Boiler Operation

Instruction For Boiler Operation

1 General conditions of boiler

Instruction For Boiler Operation

Superheater outlet steam flow

Instruction For Boiler Operation

Superheater outlet steam temperature

Reheater steam flow

Reheater inlet steam pressure

Reheater outlet steam pressure

Reheater inlet steam temperature

Reheater outlet steam temperature

1.3 Main performance indexes of boilerDesign coal, TMCR working condition

Computational efficiency of boiler (as

As-received ash content

Dry ash-free basis volatile

Instruction For Boiler Operation

As-received gross calorific value

1.4.2 Ignition and combustion supporting oil

1.5 Limestone (in brief)

Instruction For Boiler Operation

Instruction For Boiler Operation

Instruction For Boiler Operation

5.3 Boiler dry-off methods and process

Instruction For Boiler Operation

Instruction For Boiler Operation

Open/Pressure up to 175Pa Close

14) Main steam exhaust/drain

15) Startup exhaust valve

16) Reheater exhaust/drain

19) Secondary air fan inlet movable vane

20) Induced draft fan inlet movable vane

21) Secondary air fan upper/lower baffle

Instruction For Boiler Operation

5Recorder for recording the temperature of each thermocouple.

Instruction For Boiler Operation

6. Cold aerodynamic field test of boiler

Instruction For Boiler Operation

operation. It should be done in accordance with the relevant

6.2 Main content of test

Performance examination of primary/secondary air fans and high-pressure fluidization

Test of coal feeder air quantity distribution features;

Determination of the regulation features of the various air door baffles;

Determination of the air volume of material-returning machine and lubricating air;

Test of startup burner air volume and baffle openness features;

Determination of empty-bed resistance and material layer features of fluidized bed;

Air distribution uniformity test of air distribution board;

Critical fluidization air volume test;

10) Feeding features of pneumatic coal feeding device;

Instruction For Boiler Operation

Instruction For Boiler Operation

Instruction For Boiler Operation

Instruction For Boiler Operation

7.3 Matters needing attention

Instruction For Boiler Operation

of steam pipe purging, as well as the protection against over-pressure or over-temperature,

damage to the boiler. So the number of purging times shall be