NTPC LTD KORBA

Ref.: OPERATION GUIDANCE NOTE :

COS-ISO-00-OGN/OPS/SYST/001


LOCATION MANAGEMENT INSTRUCTION

LMI/OGN/OPS/SYST/001

Rev. No.:2 Date: January 07




Prevention and Safe
Clearing of Ash Build-up in
Boiler Bottom Ash Hoppers






Approved for
Implementation by ..
GM(K)

Date: 22/01/2007



Prevention and Safe Clearing of Ash Build-up in Boiler
Bottom Ash Hoppers



INDEX


Sl. No. Contents Page No.

1.0 Introduction 1
2.0 Superseded Documents 1
3.0 Coal-Ash Slagging 1
4.0 Control of Slagging 3
5.0 Continuous Removal - Bottom Ash Hopper 6
6.0 Reasons for Ash build-up 6
7.0 The means of Preventing and Clearing Ash build-up 7
8.0 Review 12



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LMI/OGN/OPS/SYST/001 Rev. No.: 2
Prevention and Safe Clearing of Ash Build-up in Boiler Bottom Ash Hoppers

NTPC Limited, Korba

Prevention and Safe Clearing of Ash Build-up in Boiler
Bottom Ash Hoppers
1.0 INTRODUCTION :
This LMI based on OPERATION GUIDANCE NOTE : COS-ISO-00-
OGN/SYST/001 , Rev. No.:2 , Dated: December 2005 , identifies the need to
exercise great care to avoid slag formation in the boiler furnace which results
in poor heat transfer of furnace walls, large slabs of fused ash, blocking of
clinker grinders & ash slurry pumps and choking of ash disposal lines. The
LMI also covers safe means to clear ash build up in case it so happens.
Operating experience has shown that excessive slag formation or improper
bottom deashing leads to build-up of bottom ash to a height of 16-18 meters in
the furnace bottom, forcing unit shutdown which could last several days.
Build-up of this magnitude can also result in catastrophic failure of boiler
support system.
2.0 SUPERSEDED DOCUMENTS -
LMI/OPN/008 based on Operation Guidance Note Ash Build-Up in Boiler
Bottom Ash Hoppers : OGN/OPS/SYST/001 Issue: 1 dated August 1994
3.0 COAL-ASH SLAGGING
Slagging occurs when fused or solidified molten material forms on surfaces
exposed to high radiant heat fluxes and gas temperatures.
3.1 Coal parameters used for evaluating coal-ash behaviour as they affect
furnace slagging are:
* ash-fusibility temperatures
* base/ acid ratio (More basic nature implies more tendency for slagging)
* iron/calcium ratio
* silica/alumina ratio
* iron/dolomite ratio
* dolomite percentage
* ferric percentage
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The figure below shows a typical cross section of a water wall slag deposit
that has reached a maximum steady-state thickness.
Figure 1. Cross section of a typical furnace-wall slag deposit
Molten to semi-molten coal-ash slag deposits will not form on clean water-
wall tubes since, upon approaching relatively cooler tube surface, the slag
particles become less adhesive because of rapid cooling in the wall-adjacent
area. Accordingly, coal-ash deposition is a two-stage process. A primary layer
of deposit first forms on the water wall tube surface. The resulting rise in the
surrounding surface temperatures subsequently allows the adherence of rigid
plastic secondary deposits.



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NTPC Limited, Korba

3.2 Mechanism of Coal-Ash Slag Deposition
The following two types or primary deposits are most commonly
observed:
i) Primary deposits that result from the settling of the finer fractions (smaller
than 30 microns) of fly ash. This type of primary deposit is loose in structure
and does not provide cohesive or adhesive bonds.
ii) Primary deposits that result from the selective deposition of certain reactive
components of the ash (iron, calcium, or alkalies). These components can be
present in the deposit in high concentrations as oxides and/or sulphur
compounds, leading to the formation of low-melting eutectic mixtures. This
type of deposit is denser in structure and has stronger cohesive and adhesive
bonds.
During the deposition, there is a transitional stage where the plastic
secondary deposits begin to stick on the primary layer. These secondary
deposit/droplets of low viscosity molten glass are strengthened by time and
increasing temperatures. The temperature at which the secondary deposits
begin to form corresponds to approximately 950 degree C. The transition
from primary to secondary deposit is a function of the immediate gas
temperature outside the deposit.
3.3 Deposit Structure and Maximum Thickness
The figure 1 showing the cross-section of a typical water wall slag deposit has
a slag surface that has reached a maximum steady-state thickness.
The rate at which glass droplets fuse together is directly dependent upon the
time available for bonding to develop, and is inversely proportional to the
viscosity of the melt, i.e., the more fluid the droplets are the more readily they
will run together thus strengthening the mechanical bonding in the deposits,
and ultimately thick slabs may built up, reducing the heat transfer efficiency
of the boiler surfaces.
4.0 CONTROL OF SLAGGING
This section discusses the operational techniques that the operator can use to
control slagging. Although the predominant factors affecting ash deposition
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NTPC Limited, Korba

are the amount and composition of coal ash; boiler operating conditions have
also been demonstrated to affect deposition.
The operating variables that influence slagging are:
(i) furnace temperature
(ii) excess air
(iii) fuel fineness
(iv) secondary air distribution
(v) distribution of coal
(vi) air fuel ratio
Changing any one, however, will not eliminate operating problems
completely. Although the individual variable affects boiler performance, they
must be studied collectively to determine the effectiveness of a given
programme.
Effect of each operating variable is considered as follows :-
i) Furnace Temperature
Higher the furnace temperature on account of improper combustion,
poor heat absorption in the walls or sometimes due to higher load,
greater the potential for slagging. Load reduction can reduce the
potential for slagging but this is not always possible, because the
rated output may be necessary to meet power generation. Changes in
excess air, fuel fineness, and secondary air distribution are less
drastic methods for minimising slagging.
ii) Excess Air
In a reducing atmosphere, the ash fusion temperature reduces. Here
the Fe
2+
ions will increase at the expense of more highly oxidized
Fe
3+
ions. The ferrous ions act as a flux and this reduces the initial
deformation temperature of ash.

If slagging is a problem with high
iron coals, furnace deposits can be reduced drastically by increasing
the amount of excess air. As a rule-of-thumb, the higher the fusion
temperature, the drier the slag in the furnace, and the easier it is to
remove.


iii) Fuel fineness
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Slagging conditions often can be improved by control of the
pulveriser fineness. Since coarse particles take longer to burn, hence
these burn away from the intended zone of combustion. They are
more prone to producing slag. High retention on +50 mesh often
increases slagging tendencies. This is better accomplished by
maintaining air/fuel ratio at designed level.
iv) Secondary air distribution
Basically, the objective is to provide a good mixing of fuel and air so
that combustion is efficient, and local zones with reducing
atmosphere are avoided. In units with tangential firing, for example,
slagging can be reduced by optimising secondary air flow to fuel
compartments. It is accomplished by regulating fuel air and
combustion air distribution. The extent of Fuel air damper opening
can be decided depending upon the amount of volatile matter in coal
(Higher the Volatile Matter, lesser can be the opening). In changing
coal profile, such dampers have to be readjusted to get efficient
combustion. Fuel air dampers of a non running mill (especially
bottom mills) should be kept closed as they cause an increase in
furnace temperature. Generally any major temperature mismatch of
steam and flue gas (Left/right) should warrant a check up of SADC
system.
(v) Fuel distribution
Improper distribution of coal, due to eroded coal burner nozzles/
nozzle tips/ impellers will affect the combustion and hence increase
the furnace temperature.
vi) Other Operational measures
Failure to remove deposits at the proper time may result in chain
reaction of deteriorating events. For example, excessive furnace
slagging can result from not using the wall blowers at proper
intervals. This condition imposes higher gas temperatures in the
convective section of the furnace because of the reduced rate of heat
absorption. The attemperation levels indicate the level of deposits in
a boiler for a constant steam temperature. High attemperation flow
denotes a high deposit on the boiler tubes. Thus it is best to do soot
blowing whenever such a situation arises.
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NTPC Limited, Korba

Using programmed soot blower systems, ash deposits on the furnace
walls can be minimised. Waiting too long between operations can
seriously hamper the effectiveness of soot blowers. Observation of
furnace conditions at least twice per shift helps eliminate unexpected
problems. Because the soot blower system is so important for
reliable, full capacity operation of a coal-fired unit, this equipment
must be maintained in good operating condition.
After overhauling of boiler / maintenance of furnace, the boiler should be
inspected and loose material if any, is to be removed from furnace / bottom
ash hopper. Falling of loose materials in the bottom ash hopper will obstruct
ash flow inside the hopper / full closing of feed gates / jamming of clinker
grinder / increase the time of deashing, etc.
6.0 REASONS FOR ASH BUILD-UP
Bottom Ash hoppers are designed to carry the ash for about two hours (with
scrapper conveyor system). However the carrying capacity in terms of time
depends on various factors like coal firing rate, ash content in coal, bottom
ash/fly ash ratio etc. During BAH equipment maintenance , the BAH gates
are normally closed and if the work is likely to get prolonged ( more than
four/two hours ) , bottom ash hopper deasing must be started after every
four/two hours with proper care alerting all working personnel in the vicinity ,
to avoid further ash build up inside the BAH. The operation staff will be in
continuous touch with maintenance staff during BAH work..
Falling slag / hard clinkers also can cause accumulation inside the bottom ash
hopper as they will block the hopper gates and prevent free flow of ash. These
may lead to incomplete deashing also as the clinkers remain undetected inside
the hopper.

6.1 The ash build-up can be of two types from ash removing
strategy perspective:
A. Build-up during normal unit operation with bottom ash gates wide open.
B. Build-up during / after scrapper conveyor maintenance activities with
bottom ash gates in closed condition.


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7.0 THE MEANS OF PREVENTING AND CLEARING ASH BUILD-UP
7.1 Routine observations:
i) On getting indications of slagging or high furnace exit temperature, the
combustion related parameters (mentioned earlier) are to be checked and
necessary corrective actions taken accordingly.
ii) To prevent build up in bottom ash hopper and to start deashing in time,
peep holes above bottom ash hopper (at 10.5 / 7m m in case of 500/200
MW units) on both side view glasses are to be regularly inspected for
any sign of build up by local supervisor/Unit Controller. This is to be
recorded in the log book. This observation is to made preferably three
hours after completion of deslagging.
7.2 During Operation:
i) Observation is to be made from the BAH view glasses for deposition
of bottom ash, if any, in the hopper. A typical empty hopper
demonstrates intermittent flame. View glass cleaning water supply
should be ensured regularly. If view glasses are not clean , the same
may be got cleaned by shift mech.mtce.
ii) Utmost care is to be taken to ensure that the entire bottom ash is
evacuated from the bottom ash hopper and there is no build up of ash
over Z-panel of furnace. Any abnormality must be reported to SCE
and Head (Operation). Both the furnace and bottom ash hopper must
be inspected at least twice a shift for any ash build up in these
locations.
iii) It is to be ensured that the inspection view glasses/peepholes are easily
accessible and a clear view maintained.
7.3 In case of ash build up
i) In case slag deposits / ash build-up are not getting cleared by normal
deashing, it is to be cleared immediately by poking / flushing with a
high pressure water jet/ lances through peep holes (availability of fire
hoses, nozzles etc. should be ensured always).
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ii) If massive slag deposits are observed, unit load should be restricted to
the minimum, with oil support and all efforts must be made to remove
slag in a running condition.
iii) Shift Charge Engineer is fully empowered to reduce load under such
conditions.
iv) Manhole in the furnace mounted above Z-panel should be opened only
when unmanageable ash build up is there. Efforts should first be made
to dislodge ash through peep holes with the help of lancers and fire
water. Whenever such operation is carried out, persons not connected
with the job should not be present around and below that area. While
opening the manhole door near Z-panel for removing the ash build up
inside the boiler, care should be taken by providing the wire mesh
cover near the manhole door of Z-panel. Due to this the furnace will
not be completely exposed to the poking people and minimizing the
unsafe conditions.
v) Activities like manual poking of bottom ash hopper and area above Z-
panel of furnace should be carried out in consultation with operation,
boiler mechanical maintenance, ash handling maintenance and Safety
Departments, ensuring all safety measures like Personal Protective
Equipments, operating parameters have been taken care of. Operating
staff should take extra care to ensure that the furnace does not get
pressurized during such activity.
vi) Whenever manual poking of bottom ash hopper and area above Z-
panel of furnace is being done through manhole etc. no mill is to be
stopped or cut in, and soot blowing is not to be carried out, as it causes
sudden detachment and fall of clinkers.
vii) Concerned persons involved in ash / slag / clinker removing activities
should stand at safe distance from bottom ash hoppers so that risk of
splashing ash / hot water causing injuries is minimised. Water lances
should have sufficient long metallic pipes so that cleaning is done
from a safe distance.
viii) A practice of carrying out one job only at a time, i.e., either clearing of
bottom ash hoppers or clearing of slag formation above Z-panel is to
be adhered to.
ix) During clearing of ash build-up, special care and lot of patience is
required to be taken for avoiding over loading leading to failure of
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scrapper conveyors since any such failure increases total time for ash
removal considerably. So, specific precautions to be taken during slag
/ clinker removing activities.
x) No direct control on rate of ash falling on scrapper conveyor is
available to concerned O&M staff. If suddenly heavy amount of ash /
slag / clinkers fall on scrapper conveyor (S/C), it may lead to over
loading / failure of S/C. Apart from this, sudden falling of ash is also
dangerous for people working in near by areas since splashed ash/hot
water can reach up to considerable distances.
xi) Due precaution is to be taken by restricting no. of water lances in use
at a time & their point of application so that risk mentioned above is
minimised. All concerned people must move to safe distances when
there is chance of sudden ash falling in large amount. The surrounding
area shall be kept free of debris for this.
xii) Personal Protective Equipments (PPE) are to be used by personnel,
supervising and executing the job of deashing. The PPE includes
safety helmets with face shield, gum boots, fire retardant hand gloves
and fire resistant overall suit. All Personal Protective Equipments
(PPE) are to be kept in common place like shift maintenance room in a
separate box for easy availability during the emergency of chockage
removal for saving time.
xiii) All efforts should be made to avoid the practice of by-passing the
clinker grinders and dumping the slurry on boiler floor to be manually
removed later. If required bypassing may be resorted to with additional
water jetting arrangements.
xiv) If all actions fail to remove/dislodge the massive slag deposits, the unit
should be taken under shut down for removal of clinkers/ slag
accumulated in the furnace. Immediately after unit shut down bottom
ash hopper is to be flooded with water to avoid hard clinkers formation
from burning slags. In no case unit is to be run with uncontrolled and
unmanageable slag deposits or without bottom ash evacuation.
xv) While shutting down Unit, sufficient care needs to be taken to avoid
overheating of boiler tubes. Boiler is not to be drained and drum level
is to be maintained.
xvi) If build up has taken place during or after maintenance on scraper
conveyor, the rate of bottom ash gates opening is VERY CRITICAL
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for controlling loading on S/C. The gates are to be opened only in 5%-
10% increment in order to avoid overloading of S/C and splashing of
ash in near by areas.
xvii) After each incremental opening of gates, S/C is to be seen physically
for amount of ash being handled by it. Once, there is reasonable
reduction from peak amount of ash being carried away by S/C then
only further opening of gates is to be carried out.
7.4 Other Precautionary Measures
i) Since BAH gates and Hyd, punp (Stg-I) & VC feed gates and Oil
pump units (Stg-II) are very critical items their reliability must be
ensured .
ii) In Stg.II , Winches meant for shifting Scraper conveyor are to be
regularly checked and maintained for their availability.
iii) In Stg.II , Routine trial of standby scrapper conveyors / clinker
grinders shall be carried out regularly as per the schedule.
iv) In case any of the above critical equipments is under break down it
must be attended at the earliest.

8.0 REVIEW
This LMI shall be reviewed by the GM(K) , on a 3-yearly basis or as
necessary.



Document for Distribution to:

1. GM(K)
2. AGM(O&M)
3. DGM(O/EEMG/MM-ash)
4. DGM(TS)
5. Sr.Mgr.(Safety)
6. SCE
7. All UCBs
8. O&M Library
9. Local intranet soft copy