05start Up Rev1

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
START-UP CFBT-582-1 1
Osasto - Department Kohde - Subject Sivu - Page
Power Generation RAPP PB3 PROJECT 1 (22)

Systems CFB MULTIFUEL BOILER
TABLE OF CONTENTS
5. START-UP............................................................................................................. 2
5.1 Start-up of boiler plant in general........................................................................... 2
5.2 Start-up of feed water system................................................................................ 4
5.2.1 Feedwater pumps .................................................................................................. 4
5.3 Start-up of the flue gas system .............................................................................. 5
5.3.1 Start-up of the electrostatic precipitator ................................................................. 5
5.4 Start-up of the air system....................................................................................... 6
5.4.1 Starting the fans..................................................................................................... 6
5.4.2 Starting steam coil preheater ................................................................................. 8
5.4.3 Boiler purge ........................................................................................................... 8
5.5 Start-up of the burners........................................................................................... 9
5.5.1 Start-up of the oil burners .................................................................................... 10
5.6 Boiler pressure increase ...................................................................................... 12
5.7 Starting steam generation of the boiler ................................................................ 14
5.8 Start-up of the fuel feeding system ...................................................................... 16
5.9 Limestone feeding ............................................................................................... 17
5.10 Start-up of fluidized bed....................................................................................... 18
5.10.1 Cold start-up..................................................................................................... 18
5.10.2 Hot start-up ...................................................................................................... 20
5.10.3 Adjustment of fuel feeding air........................................................................... 20
5.10.4 Adjustment of secondary air............................................................................. 20
5.11 Start-up of bottom ash removal ........................................................................... 21
5.12 Start-up of sootblowing ........................................................................................ 22
1 2005 - 08 - 30 Tuomo Keinonen

0 2005 - 01 - 10 Tuomo Keinonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder 1\05start-up_rev1.doc
This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005

5. START-UP
5.1 Start-up of boiler plant in general
Start-up of the plant can be divided into separate parts which

operation principles are described in more detailed in the system
descriptions.
Boiler start-up is generally carried out in the following order:
1. Start-up of the feedwater system

• Filling of the feedwater tank and preparation of deaerated water
• Start of feeding dosing chemicals
• Bringing feedwater pumps to service and filling of the boiler.
2. Bringing boiler water-steam circuit to service

• Drum level to control
• Water and steam samplings are brought to service
• Pressure increase within the limits of start-up velocity curve
3. Bringing the flue gas system to service

• Flue gas fans are brought to service
• Furnace draft control to automatic.
4. Start-up of the loopseal compressor system
5. Start-up of the boiler air system

• The primary air and secondary air fans are brought to service,
primary air and secondary air pressure control to automatic.
• The steam air preheaters to service
6. Start-up preparations of the oil system

• The oil station to service
• Heating circulations to burners on (when using heavy fuel oil).
7. Purging of the boiler furnace and flue gas ducting

• Boiler purging through upper secondary air level and through
start-up burners before the ignition of the burners or start-up of
fluidization.

8. Starting the oil firing

• First the pressure of the boiler is increased with oil
• Heating of the sand bed using start-up burners (Diesel oil
recommended when bed temperature is below 250 °C)
• Drum pressure increase velocity according to the start-up curve.
9. Bringing the coal and bark systems to service

• Filling of the coal silos
• Filling of the biofuel silo preferably with dry bio fuel, which suits
best for start-up
• Testing of the rotary feeders, belt, drag and screw conveyors.
10. Starting of fluidized bed combustion

• Bed temperature by support oil firing to minimum 500°C
(average value of three temperature measurements), so that
coal ignites
• Periodical controlled bark feeding is possible when bed
temperature is between 300°C and 400°C and at least one start-
up burner is on (average value of three min. temperature
measurements).
• Continuous bark feeding with support oil firing above 400°C
(average value of three min. temperature measurements)
• Continuous coal or bark feeding without support oil firing above
600°C (average value of three min. temperature measurements)
• Observe whole time carefully that solid fuel ignites and burns
properly.
• At least one start-up burner must be in operation until the bed
temperature is over 600 °C (average value of three min.
temperature measurements).
11. Start-up of ash removal

• Switch the ESP hopper heating elements on at latest 36 hours
before solid fuel combustion.
• Bringing the fly ash conveyor system to service after oil or fluid
bed firing has been started
• Bringing the electrostatic precipitator to service at the beginning
of the solid fuel firing period

• Start-up of bottom ash removal after fluidized bed combustion

has been started in accordance with the requirements set by the
bed condition. It is recommended to start regular bottom ash
removal latest one day after the start of fluidised bed combustion
12. Start of sootblowing

• When the flue gas end temperature is increasing or the pressure
difference across the heat transfer banks increases.
• When needed, but however it is recommended to start the
sootblowing sequence (all sootblowers) at least once per day.
5.2 Start-up of feed water system
5.2.1 Feedwater pumps
Feedwater pumps (283P001-003 and P018) should be started with

automatic start-up sequence. Start-up shall be carried out according
to pump supplier's operating instructions.
Checks prior to starting

− The feed water tank and feed water system are filled and vented
− The corresponding valve (2830045, 0062, 0079, 0167) in the
inlet pipe is completely open
− The valve in discharge pipe is closed
− The manual shut-off valves in the minimum flow pipes are open
− The manual shut-off valves in the balance water pipes are open
− The cooling water system is in operation and manual valves
open
− All temperature indications are within the allowed values
− Check the oil levels in pumps; fill if required
− Check the oil level in the lubrication unit of feedwater pumps; fill
if required
− Check possible leakages of all pipes, flanges and threaded
connections

Starting
Should warning signals or problems occur during starting or

performance test, proceed as described in the supplier's operating
instructions
− Switch the drive on

− Check the temperature and smooth running of the bearings
− Check the pump pressures
− Make sure that the minimum flow control valve is working
correctly (flow-generated noise/minimum flow pipe gets hot).
− Check the seal components
− Open slowly the discharge valve until it is completely open
− Control the operating behavior of the pump set permanently
5.3 Start-up of the flue gas system
1. Start the flue gas fan (283K002 or 283K003) as follows:

• Open the shut-off damper HS-1363 or HS-1374 (depending on
which ID fan is started) before the ESP.
• Set the inverter control of the fan to minimum setting.
• Start the fan.
• Open the shut-off damper HS-1373 or HS- 1384 (depending on
which ID fan is started) after the fan.
2. Set the furnace draft control (PIC-1276) to automatic with a set

value of abt. -0.1 … -0.2 kPa, depending on the situation.
• Start another flue gas fan when needed
5.3.1 Start-up of the electrostatic precipitator
Start the electrostatic precipitator when solid fuel firing is started.
1. Start the dust-conveying system.

2. Start the rappers.

Start of precipitator rectifiers from the control centre:
3. Turn the rectifier main switches in position “1”.

4. Start the rectifiers from the starting switch on the control panel.
The rectifier must be switched to local control and the current
potentiometer must be set at a value of 100 %
After start, check from the meters that the precipitator voltage rises
at least up to 20 kV and the precipitator current at least up to 100mA
See also the supplier's operating instructions.
5.4 Start-up of the air system
5.4.1 Starting the fans
Start the fans in following order:
1. Start both loop seal compressors (283K009 and 283K010) and

set the air pressure control on automatic (setpoint of pressure
about 35 kPa). Set flow controls on automatic and in cold boiler
start-up set the flow in down-leg side (FIC-1448, FIC-1458 and
FIC-1467) 0.3 Nm3/s in loop seals and in up-leg side (FIC-1445,
FIC-1455 and FIC-1464) 0.75 Nm3/s in loop seals.
Later in hot condition or if it is a hot boiler start-up set the flow in

down-leg 3 x 0.2 Nm3/s and in up-leg 3 x 0.3 Nm3/s.
Air pressure after the compressors is regulated by the rotation

speed of the compressors.
During the cold boiler start-up both loop seal compressors are
needed but in hot condition it is possible to run only with one
compressor while the other one is stand-by.
NOTE! It is very important that air flow to loop seal is big enough
to prevent the bed material accumulation in the loop
seals.

2. Start the secondary air fan 1 or 2 (283K007 or 283008) and set

the pressure control of the fan on automatic.
The secondary air flow is regulated by control dampers

(FIC1297...FIC1300).
3.
The primary air fan is started as follows:
Start-up conditions
• Main interlocks valid, secondary air fan, loop seal air

compressors and flue gas fan are running
• Inlet vanes are in minimum position
• Primary air fan dampers HS-1416 and HS-1422 are closed
Fluidizing air fans can be started before boiler purge, but keep the
fluidizing air dampers HS-1416 and HS-1422 closed until bed
material is needed to fluidize (= when oil or solid fuel firing starts).
The fluidizing air flow is adjusted by dampers FIC-1313 and FIC-

1317 at least to its minimum value in terms of fluidization, which is
2 * 30 Nm3/s (interlock 2 * 27 Nm3/s).
Fuel feeding or burners cannot be started before the start-up of

primary air fans.
• After start-up the primary air amount can be adjusted using the
inlet vane and air control dampers. The needed fluidizing air
amount is dependent on boiler load.
• The primary air amount affects to bed temperature and amount
of circulating particles. Primary air is also used for the cooling of
the fuel feeding screws and chutes.
• Normally control dampers are kept almost fully open and inlet
vanes are used to control the pressure.
Observe the separate operating, maintenance and service

instructions given by the fan supplier.

5.4.2 Starting steam coil preheater
Steam coil air preheater for primary air (283E078) is taken to service
as follows:
• Be sure that all low pressure steam manual valves to the
preheaters are open and control valve (TV-1414) is closed
• Manual drain valves must be opened including bypass valve so
condensate can get into the condensate tank
• Open slowly steam control valve (TV-1414) approx. 15 %
• Control all time the material temperature
• When condensate line is warm enough close the bypass valve.
• Put both control valves on automatic and set point 120 ...130 oC
5.4.3 Boiler purge
Conditions for furnace purge are as follows:
• flue gas fan is running

• secondary air fan is running
• purge air amount is sufficient.
• ESPs are switched off
Normally the boiler is purged through the upper secondary air

nozzles and start-up burners by an automatic purge sequence
program. If purge must be done manually, proceed as follows:
• Open the upper secondary air dampers and the control dampers
of the burner air .
• Set the secondary air flow to the purge value, (interlocking limits
for upper secondary air flow 8,5 + 8,5 Nm3/s and 6,5 Nm3/s
through each burner)
• Lower secondary air dampers are closed
• Fluidizing air dampers must be closed
• ESP switched off
• Start the purge time counting 8 min manually
• Set off purge.
After purge has been completed firing can be started within 10

minutes, if boiler safety interlock is otherwise in order.

No purge is needed before starting fuel feeding if at least one of the

burners is already in operation or if fluidized combustion is going on,
i.e. the fluidized bed temperature is > 600°C and fluidizing air
amount exceeds the minimum value.
NOTE! Demand for purge becomes more important, particularly at

boiler shutdown in the middle of fluidized combustion, if
there is accumulation of unburnt fuel inside the bed. In that
case the purge of the furnace bottom should be started
manually by means of secondary air as soon as possible.
Do not start the use of fluidizing air before combustible,
explosive gases have been removed from the boiler.
5.5 Start-up of the burners
The ignition of the burner is normally done as a so-called sequence

start-up, the functions of which are described in the section
“Automation and Control”. If the burner is started from the local
control box, the operator must take the same measures as described
in connection with the sequences.
The matters to be taken into consideration in connection with the

start-up of the burners are described generally below.
Before the start-up of the burner make sure that sand has been
added onto the fluidized bed grate at least 200 mm above nozzles in
order to protect the fins and nozzles in the bottom against excessive
radiation.
Before starting the first burner the fluidizing air flow must be set to
2 * 30 Nm3/s .
Any of the burners (burner 1...6) in the boiler can be started first.
The first start-up burner must be ignited by local control and with a
gas/electric igniter. The ignition of other burners can be done either
by local control or as a group control from the control room. At start-
up after shutdown, the control of start-up on the field is, however,
recommended for all burners, so that the appropriate operation of
the equipment can be secured. This also concerns the case when
the operator finds something abnormal in the operation of the
burner.

5.5.1 Start-up of the oil burners
Regardless of which burner is in question, start-up must always be

carried out in the same operational order. The measures are listed
below:
• The "Burner ready for ignition” text indicates that the interlock
conditions are fulfilled and that the purge has come to an end
allowing the ignition of the first burner (burners) during 10
minutes (2 ignition attempts).
• Choose the place of control and the fuel to be used (switches).
• Push the cleaned oil lance into the burner (limit switch).
• Open the oil and atomizing steam or air shut-off valves prior to
the burner valve group.
• Set the burner air flow to the ignition position, abt. 3,0 Nm3/s.
The lamp in the local control box indicates that the oil conditions
are met.
• Set the oil control valve to the ignition set value ( dependent on
fuel quality)
• Check the validity of the following conditions for each burner

− Oil temperature is >110°C
− Oil pressure is >3bar
− Combustion air amount >2.5 Nm3/s
− Atomizing steam pressure is >7bar
• Also check that
− Atomizing steam is superheated
− Cooling air is in operation
− Ignition air pressure is > 5 kPa
− Ignition gas pressure is 6kPa-60kPa
• Push the lance into firing position by means of an actuator (limit

switch).

• When using heavy oil then open the atomizing steam valve and
heat the lance for abt. 10 s (it can be heated also by blowing
steam through the lance).
• Start the ignition device (own flame detection unit).
• Open oil quick-closing valves (safety time during ignition 5

seconds and during operation 1 s and close the recirculation
valve by the same switch operation).
• When there is a flame burning steadily, pull out the ignition

device.
• Set the burner air to automatic control and check the set value of
the oil/air ratio.
• Check that there are no oil leaks in the burner and the shape of
the flame is normal.
• The output of the burner is regulated if necessary either

manually or automatically.
NOTE! When start-up burners are in operation, the bed must be

in the fluidized condition with an air flow of at least
2*30 Nm3/s, so that the burner flame will not melt the
surface of the sand.
When bed temperature is below 250 °C it is

recommended to use diesel oil.

5.6 Boiler pressure increase
At the initial stage of pressure increase the burner must be changed

so that there is a burner in operation on both sides of the furnace
during the first one (1) hours. The burners must be changed so that
the furnace is heated symmetrically. The pressure increase velocity
is controlled by means of burner capacity and start-up valves. Follow
boiler thermal expansion during the whole pressure increase
process.
Note during pressure increase
• Start-up of the boiler is not allowed to do faster than is presented

in the pressure increase curve. Also control that thermal
expansion takes place as planned.
• When starting the boiler for the first time or after repair of
refractory, proper drying and heating of refractory (according to
separate supplier’s instructions) must be taken care of.
• The manual shut-off valves of the boiler drain lines can be fully
opened periodically, to make sure that impurities, if any, have
been removed from the boiler at the beginning of heating (do not
do this at a pressure exceeding 4 bar.)
• The connection valves of the loopseal MUST BE FULLY

OPENED always when the boiler pressure is below 60 bar
and oil or fluidbed combustion is on.
• When heating is started, water, if any, is drained out from the

superheaters through the drain lines. The manual valve in the
drain line of the main steam line is left slightly open. It is very
important to drain the superheaters, if the boiler has been purged
many times consecutively. In this kind of situation the formation
of condensate inside the superheaters is most intensive.

• Observe the surface temperature measurements of the

superheaters (Specially in the secondary superheaters). There is
a sudden temperature rise when the water leaves the
superheater tube. It is not allowed to exceed the given maximum
temperatures of the tube materials. If the temperature rises too
high, the boiler load must be decreased or the steam circulation
of the superheaters must be added by opening the start-up
valve.
• Make sure that the start-up valves are ready for operation and
open the shut-off valve when the drum pressure starts to rise.
The start-up control valve must be opened abt. 10% at the
beginning and it can be used for controlling the pressure
increase velocity of the boiler (max. 0.4°C / min).
• When the drum pressure starts to rise, throttle the vent valves of
the drum. When the pressure has risen to 3 bar, close the vent
valves totally.
• Increase the oil flow and when the need arises, start more
burners (the start-up valve must be always at least 15-20%
open). Oil firing has to be divided evenly between as many
burners as possible.
• Particularly:
− observe steam temperatures
− observe material temperatures of the superheaters
− observe the drum water level
− observe material temperatures of the cyclones
− open the start-up valve accordingly
− no not exceed allowed pressure rise velocity
− take care of sufficient fluidization compared to burner load
(observe bed material temperatures)
NOTE! The loopseals connection valves must be closed when

boiler pressure is over 60 bar and material temperatures of
the cyclones are close to drum operation temperature.

NOTE! Temperature rise in cyclone water circulation must be

checked from material temperature measurements of the
cyclones. The difference between the measurements
should be within 10-20°C.
• The drum water level tends to rise during the pressure rise when
cold water expands due to heat. Therefore it might be necessary,
particularly at the beginning, to lower the water level through the
motor driven drain valve (avoid using if boiler pressure is more
than 40 bar).
• There is a need to drain the superheaters, particularly during the

start-up after wet preservation
• The drain valves of the superheaters should not be closed fully

until the pressure has risen above 10 bar.
5.7 Starting steam generation of the boiler
The high-pressure steam produced in the boiler is led to steam

turbine header or to the pressure reduction station of the plant.
Before the steam can be led to the turbine, make absolutely sure by
laboratory tests that the steam quality corresponds to the
requirements set by turbine manufacturer.
During start-up the operators must note the following points:
1. The pressure and temperature of the high-pressure steam is

raised according to the start-up curve
• at the same time the main steam pipe is heated by keeping
the by-pass valve of the main steam valve open during the
pressure increase.
• check that manual shut-off valve is open.

• in case the material temperatures of the superheaters tend

to rise too high, the steam flow is increased via the start-up
valve and/or reduction station.
• observe the removal of condensate from the main steam line
before increasing the steam flow.
2. The main steam valve is opened very slowly

• the by-pass of the main steam valve has to be open to heat
the main steam line and to balance the pressure between
the boiler and steam net
• By throttling the start-up valve at the same time the boiler
pressure is kept constant and slightly higher than that of the
high-pressure grid.
3. The by-pass of the main steam valve is normally kept closed

during operation.
4. At the same time control drum water level.
5. When the steam production has started, gradually raise the set
value for the drum level control so that it becomes normal (±30
mm).
6. Before starting to increase the boiler load, make sure that all the
manual shut-off valves, including the double valves, in the drain
and venting lines are closed.
7. When the boiler water circulation is established and the boiler is in

normal operation, bring continuous blowdown from the drum to
service (amount abt. 1-2% of the steam generation in question).
• Check that shut-off valve in vent pipe is open
• Place the level control of the continuous blow-down tank on
automatic and make sure that the manual valves in the
condensate line are open.
• The set value for level control should be kept at <0.3 m, so
that the water coming from the continuous blowdown line will
not flow below the water level and let impurities containing
steam flow into the feedwater tank along with the vent.

5.8 Start-up of the fuel feeding system
The start-up of the fuel feeding equipment can be carried out either
one by one, beginning from boiler wall, or it can be started by group
control.
Start-up is possible if the following conditions are fulfilled:
• Boiler interlock for fluidized bed firing is "OK"

− boiler safety interlock OK
− bed is fluidized with a sufficient air amount (> 2*30 Nm3/s)
− Loopseal compressor air flow sufficient 3 x 0.2 Nm3/s and
FC1814) and 3 x 0.3 Nm3/s
− bed temperature > 600°C or if at least one oil burner is on
and bed temperature > 500°C
− Bed temperature < 980 °C
Regardless of whether the start-up is carried out by individual or

group control, the order of starting the devices is as follows:
• check that manual maintenance dampers below rotary feeders

in the fuel chutes are open
• motor driven slide gate dampers are not closed
• check that cooling air for feeding screws and fuel chutes is
available
• wall screws are started
• rotary feeders are started
• the metering screws are started at the minimum speed
• the drag conveyors are started at the minimum speed
• the mixing screw is started at the minimum speed
• one of the coal silo reclaimers is started at the minimum speed
• also the screw reclaimer in the biofuel silo can be started.

The operators must observe the following things when the fuel
feeding system is brought to service:
• in the beginning (TBed = 500-600 °C) only periodical fuel feeding

is possible when firing coal
• in the beginning it is recommended to use only one line at the
time
• start-up is usually carried out at the minimum velocity of the
equipment
• the ignition of the fuel must be carefully observed as described in
connection with the start-up of fluidized bed firing
• the control loops must be on automatic so that the fuel and air
controls are corresponding
• when the fluidization is stable and bed temperature increases
both fuel feeding lines can be operated at the same time
• uninterrupted fuel feeding is possible when bed temperature has
increased above 600 °C.
• fuel feeding without oil firing support is possible when bed
temperature has increased above 600 °C. However it is
recommended to keep at least one burner on until bed
temperature increases to about 700 °C.
• the fuel flow control can be taken in operation
5.9 Limestone feeding
The silo must be filled with dry limestone before start-up. When
starting the system, the starting order is as follows.
• the limestone feeding air compressor (238K014) is started, the
manual shut-off valves (2831481 ... 2831486) must be open
• the feeding line must be dried with feeding air about 10 min.
before starting limestone feeding
• the hopper filling automatic is taken in service
• limestone feeding screws and rotary valve below injection hopper
are started
• the limestone flow is controlled by screw speed.

5.10 Start-up of fluidized bed
5.10.1 Cold start-up
In the start-up the bed temperature should be raised so high that

stable firing with a solid fuel is possible without using burners.
The start-up of the fluid bed takes place by means of the burners
and solid fuel.
During the oil firing period the bed must also be fluidized with
sufficient amount of air. The air amount depends on burner load.
Start-up order
• Go through the general interlock conditions and start-up

measures for the boiler (purge, drum water level, etc.).
• Allowed start-up time after the purge period is 10 minutes, during

which the first burner must be ignited.
• Start the primary air fans and bring the bed into a fluidized
condition with an air amount as small as possible
Note! If the loopseals are not yet filled with sand, the circulating
bed material will fill them. The bed depth must be kept
inside given range (abt. 500 - 550 mm) by adding sand from
the silo.
• During the bed temperature raise to be performed by start-up

burners the bed is fluidized with an air flow of abt. 2 * 30 Nm3/s.
• Ignite the other burner, when the pressure increase curve allows
it.
• Control during start-up that the burners do not melt the bed sand.

• Start feeding the fuel periodically into the bed at a small capacity
when the sand temperature is over 500°C. (Make sure that fuel
ignites).
• With cold bed (abt. 300°C) the required flow of fluidizing air can
be even 2 * 40 Nm3/s, so that the whole bed is fluidized. During
the breaks in fuel feeding the air flow should be decreased, so
that the bed is not cooled too much.
NOTE! It is recommended to supervise the bed temperature trend

lines to see the direction of changes made.
• When the fluidized bed temperature exceeds 600 °C, the fuel
feeding conveyors can be operated continuously at minimum
feed, following the rate of rise of temperatures.
• Follow the fluidization of the bed through the sight glasses. Also
follow the bed temperatures. The bed is properly fluidized when
all bed temperature measurements give nearly the same
reading. In case of temperature differences the bed can be
mixed with a larger amount of fluidizing air. At start-up it is
normal that there are differences in temperatures but when the
start-up proceeds, the temperatures normally stabilize along with
better fluidization.
• During start-up observe carefully that no unburned fuel

accumulates in the bed and that there is enough oxygen (QI-
1346, QI-1348 and QI-1359), 3-5% and CO (QI-1345, QI-1358
and QI-1347) is within the measuring range.
• When the bed temperature increases the burner load can be

gradually decreased and when temperature is about 700 °C
burners are not any more needed

5.10.2 Hot start-up
In this connection hot start-up refers to the situation when the

temperature of the fluidized bed is minimum 600 °C, which makes
the ignition of coal possible. Start-up is carried out in the same way
as in the case of cold boiler, except for the stages before the
temperature of 600°C. The start-up time is extremely short, the bed
temperature can be raised to 700°C in 1-3 hours, if the boiler
pressure is high enough.
NOTE! Because in a hot start-up the bed temperature is over

600 °C it is not necessary to start the burners. In that case it
is not even necessary to purge the boiler but it is
recommended.
5.10.3 Adjustment of fuel feeding air
The air flow is adjusted as follows:

• Check that air dampers 2831240 and 2831241 on the primary air
duct are open
• the valves 2831290 ... 2831295 are opened and adjusted so
much that fuel chutes and wall screws get enough cooling.
• Also 2831642 must be opened to cool the rotary feeders and to
prevent flue gas back flow from the furnace.
5.10.4 Adjustment of secondary air
The secondary air is brought above the fluidized bed from all walls of
the boiler through the secondary air ports. The secondary air is
divided to two different levels. The air split between these levels
depends on boiler load and fuel properties.
The secondary air flow is automatically adjusted according to boiler

load and the controller’s set point is corrected by flue gas O2
measurement. The air flow is regulated by means of the control
dampers FIC-1297 (lower right side) FIC-1299 (lower left side), FIC-
1298 (upper right side) and FC-1300 (upper left side).

The secondary air system is dimensioned so that the air pressure

before the air ports with full load is about 2 kPa.
By means of the secondary air fan speed, the pressure is kept in the
correct range by sliding the set value (PIC-1296) according to air
amount requirement.
5.11 Start-up of bottom ash removal
Practically most of the ash generated in coal and sludge firing is

grounded in a bed into fine dust and leaves the boiler as fly ash.
Stones and other material which is too coarse for fluidization coming
with the fuel remains at the bottom of the grate and must be
removed through the bottom ash system.
Need for coarse material removal depends essentially on the

impurities mixed in the fuel.
In the fluidized bed, natural sieving takes place so that the

unfluidized coarse ash and sand sink to the bottom of the fluidized
bed and can be removed through the ash chutes to the conveyors.
The boiler has 12 ash removal chutes which are equipped with
manual and pneumatically operated gate valves. Manual valves are
used to close the passage of sand to the pneumatic gate valves
during maintenance work. The manual valves are normally open
while the pneumatic ones are normally closed. Through the chutes
bottom ash is periodically led to dry-type water cooled screw
conveyors and after that drag conceyor (283C043).
When the ash removal is started, make first sure that:

• the cooling water circulation of the conveyors functions normally
• the ash conveyor runs smoothly without any unusual sound; see
what has been said in the conveyor supplier's instructions.
The ash is removed from different parts of the grate by opening

pneumatic valves one at a time for a short period.

After the ash removal has been stopped, the drag conveyor must be
in operation and cooling water line open until all the coarse material
taken to the conveyor has been cooled enough.
NOTE! When discharging hot material from the bed it must be let to
cool sufficiently in the removal chute before it enters the
conveyor, so that the bottom ash conveyor is not damaged
locally. (Sand temperature can be over 900 °C). Removal
system is not designed for continuous operation in hot
condition.
5.12 Start-up of sootblowing
The sootblowing demand of the boiler is essentially determined by

the fuel used. It is concluded from flue gas pressure difference
measurement and also from the increase in the flue gas outlet
temperature .
Sootblowing is started and carried out as sequence operation. It can

also be carried out as a single operation.
The operating principle of the sequence:
• After the sootblower group has been chosen, start a sootblowing

automatic, which takes care of the heating and drain of the
sootblowing lines before sootblowing is started.
• The subsequent sootblower starts up, when the preceding

sootblower lies in end position and has stopped.
• Stopping and drain is taken care of by sootblowing automatics.

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Asiakirjan nimi - Name of Document Tunniste - Identification Rev.

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 1 (22)

1 2005 - 08 - 30 Tuomo Keinonen

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 2 (22)

5.1 Start-up of boiler plant in general

Start-up of the plant can be divided into separate parts which

Boiler start-up is generally carried out in the following order:

1. Start-up of the feedwater system

2. Bringing boiler water-steam circuit to service

3. Bringing the flue gas system to service

4. Start-up of the loopseal compressor system

5. Start-up of the boiler air system

6. Start-up preparations of the oil system

7. Purging of the boiler furnace and flue gas ducting

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 3 (22)

8. Starting the oil firing

9. Bringing the coal and bark systems to service

10. Starting of fluidized bed combustion

11. Start-up of ash removal

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 4 (22)

• Start-up of bottom ash removal after fluidized bed combustion

12. Start of sootblowing

5.2 Start-up of feed water system

5.2.1 Feedwater pumps

Feedwater pumps (283P001-003 and P018) should be started with

Checks prior to starting

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 5 (22)

Should warning signals or problems occur during starting or

− Switch the drive on

5.3 Start-up of the flue gas system

1. Start the flue gas fan (283K002 or 283K003) as follows:

2. Set the furnace draft control (PIC-1276) to automatic with a set

5.3.1 Start-up of the electrostatic precipitator

Start the electrostatic precipitator when solid fuel firing is started.

1. Start the dust-conveying system.

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 6 (22)

Start of precipitator rectifiers from the control centre:

3. Turn the rectifier main switches in position “1”.

See also the supplier's operating instructions.

5.4 Start-up of the air system

5.4.1 Starting the fans

Start the fans in following order:

1. Start both loop seal compressors (283K009 and 283K010) and

Later in hot condition or if it is a hot boiler start-up set the flow in

Air pressure after the compressors is regulated by the rotation

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 7 (22)

2. Start the secondary air fan 1 or 2 (283K007 or 283008) and set

The secondary air flow is regulated by control dampers

• Main interlocks valid, secondary air fan, loop seal air

The fluidizing air flow is adjusted by dampers FIC-1313 and FIC-

Fuel feeding or burners cannot be started before the start-up of

Observe the separate operating, maintenance and service

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 8 (22)

5.4.2 Starting steam coil preheater

5.4.3 Boiler purge

Conditions for furnace purge are as follows: