1. The trouble shootings of a CFBC Boiler 1.

1 The too high or too low bed temperature Phenomenon: The displayed bed temperature is high or low. The alarm for the high bed temperature The load increase or reduce. Reason: The fuel particles may be oversize or downsized. The measuring fault of the thermocouple. The fuel feeder not in working condition. The mismatch of the PA and SA distribution. Bed ash cooler system fault. Limestone feeding system not functioning. Measurements: Check the thermocouple for the bed temperature measuring. Check the fuel feeder performance as well as its controls. Adjust the air distribution of the PA and SA. If the bed temperature is too low and results in the unstable combustion the oil gun should be functioned to provide the supporting combustion. 1.2 The bed pressure is high or low Phenomenon: The alarm is sent for the high or low bed pressure The bed ash cooler discharge load is seriously increased or the discharge stops. The air box pressure is too high or too low. Reason: The bed pressure measuring fault. The bed ash cooler fault ( discharge volume is more or too less ) The feeding of the limestone and the fuel is not proper. The PA volume is not proper. The boiler load increasing is too fast or the fuel quality variation is too large. Measurements: If the bed pressure is high and then increase the discharge volume of the bed ash cooler and reduce the fuel feeding quantity. If the bed pressure is too low and then reduce the discharge volume of the bed ash cooler and if required to increase the fed quantity of the limestone or sand. Check the bed pressure measuring points. If the bed ash discharging fault could not be solved whereas the bed pressure is larger than 8 KPa and the boiler should be shutdown. 1.3 The water wall tube bursts Phenomenon: If the tube is minor burst and the welding portion leakage happens the steam leakage sound will happen and the feed water volume will be slightly increased. If the tube burst is serious there is the obvious cracking sound and the steam sound

and the furnace pressure will become positive instead of negative and the feed water flow is abnormally larger than the steam flow. Reason: The boiler water and the feed water quality is not up to the mark for a long time and has resulted the fouling inside the tube and the further resulted in increasing of the resistance locally to form the local over heated. The water circulation is not proper and results in the local over heated. The tube material may not be qualified or the welding quality is poor or serious erosion happens on the outer wall of the tube. Measurement: When the water wall damage is not serious: a Increase the feed water flow to maintain the drum water level and then operate the boiler at lower load or shutdown the boiler as per the normal procedures. b If the combustion is not stable the oil burner should be started to provide the support. If the water wall is seriously damaged and not possible to maintain the normal water level: a Emergency shutdown the boiler and stop the feed water supply to the boiler. b Maintain the operation of the ID fan to remove the steam inside the boiler and if the bed temperature decreasing speed is beyond the permissible value and then stop the ID fan. c After the shutdown of the boiler immediately remove the bed material. d The other operations left please refer to the shutdown of the boiler under normal shutdown procedures) 1.4 The superheater tube burst Phenomenon: There is the sound of the steam spout and the feed water flow is larger than the steam flow. The furnace negative pressure decreases or changes to positive pressure and the superheated steam pressure decreases. Reason: The fouling happens inside the furnace or the foreign substances chocked the tube to affect the heat transmission. The erosion happens on the outer wall of the tube or the corrosion happens due to high temperature. The steam temperature or the wall temperature is beyond the limit for long time. The tube material quality is not up to mark or the welding quality may have problem or the soot blowing is not functioning properly. Measurement: If the tube burst is not serious and then it is permitted to operate the boiler for a certain time but the load should be reduced and prepare for the shutdown. If the tube burst is seriously:

a Maintain the operation of the ID fan to control the bed temperature decreasing speed not to be beyond the specified value. b Maintain the feed water supply as less as possible to maintain the normal water level. c Other operations according to normal cases. 1.5 Slag formation on the bed Phenomenon: The indicated value of one or more thermocouples has large difference with the average value ( with the difference of more than 100 degree Celsius ) Under the normal bed pressure the air box pressure increases. The reading of the indication value of one or more bed pressure keep still but not the fluctuation reading during the normal operation. There is the white color flash in the bed and the slag formation can be seen from the peephole. When the slag formation becomes serious it is difficulty to deliver the load. Reason: The bed temperature is too high or the bed material melting point is too low. During the operation of the boiler the air supply and the coal supply does not match for a long time. More numbers of the air nozzles for fluidization are chocked before the startup of the boiler or there maybe the left inside of substances of the refractory pieces, etc. Measurement: To increase the PA volume. To suitable reduce the bed temperature. The precaution should be given to that the increasing of the bed temperature should not the too fast. After the adjustment and if there is no improvement the boiler should be shutdown. 1.6 The firing inside the flue gas duct Phenomenon: The discharge temperature of the flue gas is abnormally increasing. When the horizontal glue gas duct is firing and the oxygen content in the flue gas will be decreased and the main steam temperature will be abnormally increased. When the vertical flue gas duct is firing the PA and SA air temperature will be increased and the outlet water temperature will be increased at the outlet of the economizer. The furnace negative pressure fluctuation is more. The fire comes out from the portion of the flue gas duct which is not properly sealed. Reason: The air and fuel supply ratio is not proper. During the startup the oil gun atomization is not proper. Measurement: Start the soot blowing to the flue gas duct heating surface and if required to reduce the load. If the above measurement does not help and the discharge flue gas temperature is increased 200 degree Celsius and then the boiler has to be emergency shutdown.

Stop all the air fans and close the combustion and the flue gas, air supply system. Maintain the continuous feed water supply to the boiler. 1.7 The feed water shortage Phenomenon: The drum water level is lower than the normal water level or the water level is not visible from the window. The water level alarm sends the low level signal. The steam flow is larger than the actual effective feed water flow in s sudden. Reason: Due to the negligence of the operator the monitor of the water level is not followed. The fault of the water supply equipment, like failure of the auto water feeding adjustment or the water level gauge chocked to form the fake water level. The leakage of the drain and blowdown system of the boiler is more or the discharge is more. The feed water pipe or the heating surface tubes burst. Measurement: First cross-check all the water level gauges to verify the authenticity of the water level or the seriousness of the shortage. If found that the feed water shortage is serious and then the boiler maybe emergency shutdown. If the shortage is not serious which may not affect the operation of the boiler and then manually operated the feeding of the water to resume the water level? 1.8 The overflow of the drum Phenomenon: The water level is not visible and the drum water is not clear. The water level alarm send the high water level signal. The superheated steam temperature decreases and the salt content in the steam increases. The feed water flow is larger than the steam flow in a sudden. Reason: The negligence of the operator to monitor the water level. The auto feed water adjustment failure or the feed water pressure is more. Measurement: First cross-check all the water level gauges to verify the authenticity of the water level or the seriousness of the shortage. Changeover the auto feed water adjustment to manual feed water adjustment. If the overflow is not serious manually adjust the same by increase the blowdown volume, drain volume and the emergency water release. If the overflow is serious and the manual adjustment is not helpful and then emergency shutdown the boiler. 1.9 The water impact on the piping Reason: The pipes are not properly heated and drained before carrying the steam or there is

the air left inside the piping. The intermittent close and open of the BFP to create the unstable water pressure. Measurement: In case of the water impact, open the drain valve of the superheater system to smooth the drainage and timely release the air from inside the superheater piping system. For the feed water piping, the water pressure should be stabilized and the air should be released completely. 1.10 The breakage of the fuel supply Reason: The bunker is chocked. The feeder fault. The fuel feeding pipes are chocked. The furnace back pressure is too high. Measurement: Check the Oxygen value from the meter and if found it is obviously higher than the normal value firstly check if there is any breakage of the fuel supply (if found that the bed temperature is continuously decrease and then verify the breakage of the fuel and it will be too late). Conduct the routine check and locate the location of the breakage of the fuel and at the same time increase the speed of the fuel feeder to maintain the total feeding quantity. If the back pressure of the furnace is too high and then increase the discharge of the bed ash cooler. 1.11 The main fuel trip MFT The MFT incurs along with the following activities: 1 The cutoff of the main fuel 2 The cutoff of the lime stone supply system 3 The cutoff of the under bed ignition system 4 All the air volume control to be changed over to manual mode and maintain the same. 5 All the air fans control to be changed over to manual mode subject to the cutoff of the air fans itself is not realized. If the air fans itself trip and then the logic control will be followed. 6 The output signal of the combustion control will limit the ID fan auto control to ensure that the furnace pressure is not beyond the limit. 7 If the boiler is at the condition for hot restart the logic for the specified soot