Circulating Fluidized Bed Furnace: General Description In the circulating fluidized bed boiler, a stream of fine particles is repeatedly

circulated through the furnace. The circulating flow is called the circulating bed. The fuel is fed into front wall of the primary zone which operates substoichimetrically. The fuel is fed by the drag chain feeders to the fuel feed pipe from where it is pneumatically pushed into the furnace, at the boiler front. The circulating bed flow rate is such that a relatively high solids loading is maintained above the primary zone. At this loading, a phenomenon called plasma flow occurs in which clusters of solids form, flow downward against the flow of the gas, and then disperse with the solids being re-entrained to form clusters again. This plasma flow and the high solid loading means that there is a high rate of heat transfer between the circulating bed and the furnace walls. The flue gas, with the circulating bed entrained, flows from the furnace to the Ubeam separator where the circulating bed material is removed from the flue gas. The hot particles in the gas first strike the first / second row of `U' beams placed at top of the furnace just before furnace exit. Most of the particles after striking on `U' beams loose their velocity and drop down straight into the furnace thus achieving internal re-circulation system. Most of the particle re-circulation takes place by in first phase of internal re-circulation. The particles escaped through first two rows of U- beams further go and strike the other three rows of U beams placed in first convection pass of furnace at the top. The rear wall membrane panel upcoming from bottom of the furnace is connected to rear wall top header. A screen panel enclosing the 3 rows of U beams forms a cavity just below the 3 rows beam section. The particles collected in that cavity flows back to furnace by gravity through the openings provided in rear wall panel. Thus, achieving the second phase of internal recirculation. Primary Zone The B&W design IR-CFB Boiler incorporates a bottom section, or primary zone. This section, which includes a common fluidized bed zone at the bottom of the furnace, is located below the elevation of the secondary air ports. Primary air is introduced through bubble caps in the water-cooled floor of the bottom section of the furnace. This bottom section serves several purposes:

The low fluidization velocity and the location of fuel introduction into the common area of the bed result in increased particle residence time, providing good mixing at all loads. Furnace bed temperature can be maintained essentially constant over the entire load range. This results in optimum temperatures for combustion and emissions reduction even at low loads. The shape of the primary zone, together with the introduction of fuel and re-injected material in this zone, promotes the necessary lateral as well as vertical mixing in the bed at all times.

Steam Generator The CFB boiler is arranged with a single furnace shaft. The enclosure surface of the furnace, particle separator and super-heater enclosure pass is made up of water-cooled membrane tubes. Super-heater and economizer surfaces are located in the convection pass. Air Flow A tubular air heater heats air from the PA & SA fan separately. The primary air (PA fan) is directed to a wind-box at the bottom of the furnace. Two air connections are provided in the wind box to distribute the air with common control damper. The secondary air from the tubular air heater flows to the distributing nozzles located at two levels across the width of the furnace above the primary zone on both the front wall and rear wall. Dampers are supplied to vary the proportions of the secondary air to the front and rear distributing nozzles. The primary air is introduced into the bottom of the furnace through bubble caps. The secondary air is introduced into the furnace through nozzles penetrating the membrane walls. Gas Flow and Solids Flow The flue gas generated plus entrained solids pass from the furnace to the Ubeam separators. Nearly all the entrained solids are collected in the U-beam separator and fall back into the furnace. The flue gases continue through the convention pass, air heater, ESP and ID fan. Solids collected in the hopper below MDC are re-injected into the furnace to further enhance combustion efficiency. The Hot Particle capture in MDC and External Re-circulation System:

The particles escaped from the series of U beams travels with flue gas pass through MDC, through the plain tube inline economizer and multi-tubular air heater tubes, takes a turn to reach inlet of ESP. A hopper provided at the bottom of APH collects some amount of particles. Mechanical dust collector (MDC) is located down stream of economizer. Fly ash particles collected in the MDC will be conveyed to the furnace through air slides for better control of furnace temperature profile. Water and Steam Flow Feed water enters the unit at the economizer inlet, flows through the economizer banks in the convection pass to the outlet headers and then to the feed water inlet connection in the drum. Water is then withdrawn from the drum through supplies to feed the enclosure walls and division wall. Steam water mixtures from the various circuits flow through heaters and riser tubes to the drum. Good circulation is maintained at all loads. INSTRUMENTATION & CONTROLS: Field instruments as listed in our offer are included in TBW's scope and TBW shall furnish detailed scheme for control loops to purchaser. TBW shall furnish control logics & write ups for panel instruments to enable customer to select proper system. The start up burner controls shall be of Microprocessor based (DCS based). Other instrumentation shall be as defined in our offer. The following controls shall be considered to provide design & engineering. The instruments which are in TBW scope of supply are also indicated below under respective control loop.

a) Firing rate control b) Air flow control - Aerofoil at the suction/discharge of PA fan. - Damper at suction of PA fan. - Pneumatic power actuators. - Airflow transmitter. - Cabling from transmitter to local Junction box

- Isolation damper for each compartment for On- Off control to be used during slumping of bed. - Air piping from one point to converter/actuators c) Fuel flow control - Variable speed drive for Drag chain feeders. - Panel for above drives. - Steam pressure transmitter - Cabling from transmitter to local Junction box. d) Furnace draft control - Damper at the ID fan inlet - Pneumatic power actuator - Furnace draft transmitter - Cabling from transmitter to local Junction box. - Air piping from one point to converter/actuators e) Boiler drum level control - Drum level transmitter - Pneumatic control valve - Flow element in feed water & final steam line - Steam flow transmitter - Feed water flow transmitter - Cabling from transmitter to local Junction box. - Air piping from one point to converter f) Superheated steam temperature control. - Temp. element before & after attemperator. - Temp. Transmitter - Attemperation water flow control valve - Cabling from transmitter to local Junction box. - Air piping from one point to converter g) Bed temperature indication / interlocks - 2 Nos. temp. elements for each bed. - Necessary relays for interlock - Cabling from transmitter to local Junction box. h) Bottom ash discharge control i) Start up vent control

- Motorized valve in start up vent steam line. j) U Beam temperature control alarms and trips. k) Upper shaft temperature control. Supervisory instruments Pressure gauges Temperature gauges/Thermocouples U beams metal temperature IMPULSE PIPING & FITTINGS: Necessary impulse piping & fitting for measurement in pressure parts and non- pressure parts shall be provided. Impulse piping in pressure parts shall be seamless and of carbon steel/alloy steel material. Impulse piping in nonpressure parts shall be of carbon steel material. For draft gauges, 15 mm NB CS pipes to be used from the process tapping point up to control panel bottom and from there 8 mm/12 mm copper tubing to be used up to draft gauges. BOILER PRESSURE PARTS: 1. DRUM: The drum will be manufactured in accordance with the Indian Boiler Regulations. The drum will be radio graphed, stress relieved and hydrostatically tested. Each drum will be equipped with manholes and gaskets. A continuous blow down connection with an internal pipe is provided on the steam drum for continuously removing solids during the operation. Nozzles for safety valves, air vent, water level gauges, pressure gauges, are provided. For removing moisture, steam drum is equipped with drum internals like girth baffle, cyclone type primary separators and secondary scrubbers. For uniform distribution, perforated feed water pipe, and continuous blow down pipe are provided. The boiler offered is top supported. 2. FURNACE: The boiler furnace is in machine welded membrane wall construction. The furnace tubes will be manipulated from carbon steel tubes. The furnace side wall tubes are suitably bent for providing the spreaders, peepholes, access doors, and will be welded at top and bottom to respective side wall

top and bottom headers. The roof tubes will be suitably staggered to allow super heater coils to pass through. The headers shall be manufactured from seamless pipes. The headers shall be provided with drain connections, air vent connection and hand holes for inspection as required. 3. FURNACE DIVISION WALLS: Inside the furnace water cooled division wall is provided. 4. ECONOMISER: The economizer shall be bare tube continuous inline type with inlet and outlet headers, enclosed second pass. Necessary drains, vents, temperature, pressure gauges, etc. shall be furnished as per Indian Boiler Regulation requirement. 5. SUPERHEATER: The super heaters are provided in two sections i.e. primary & secondary. The super heater assembly is designed to raise the steam temperature as specified. The main outlet is from secondary super heater. 6. ATTEMPERATOR: Spray type interstage attemperator is provided. The final steam temperature shall be maintained within 5C over specified load range on both the conditions. 7. RISERS & DOWNCOMERS: Generously sized riser and feeder pipes are provided to ensure positive circulation at all loads. 8. BOILER MOUNTINGS & FITTINGS: The complete mountings, fittings, valves, etc. shall be provided. The scheme of valves & fittings shall be furnished as per P&I diagram enclosed with this proposal. 9. DRAFT SYSTEM: The boiler is designed for balanced draft operation and adequately rated ID and PA fans are provided. The boiler is equipped with ID fan and PA fan along with necessary interconnecting air and gas ducting, dampers etc.

The ID fan shall be of heavy duty construction radial tip / back ward curved construction, self aligning spherical roller bearings, inspection door, drain, inlet box and guard. The impeller is provided with tip liners and dynamically balanced. The ID fans shall be with multi louver damper control. The rpm of ID fan shall be less than 1000. The PA fan is centrifugal type with suitably sized impeller. The fan impeller shall be dynamically balanced and is complete with inspection door, foundation bolts and guard. The PA fan shall be provided with silencer to meet the noise level. The RPM of PA fan shall be 1500 rpm. The control damper shall be pneumatically operated. Secondary air fan shall also be provided for over fire air arrangement. PA, ID & SA fan shall be directly coupled to Motors. 10 AIR PRE- HEATER: A tubular air pre heater is provided as the last stage of heat recovery unit. The shell and tube side fluid shall be combustion air and flue gas respectively. The air pre heater tubes shall be fitted into the tube sheets on both sides. Entire air Pre-heater shall be supported in a structural steel frame and enclosed within welded steel casing.

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STRUCTURAL STEEL: Steelwork will be provided to support of the boiler & auxiliaries. The supporting steel structural will be fabricated from rolled steel section / plate section along with suitable galleries, staircases, ladders and platforms.

12.

DUCTING: All air and flue gas ducting within terminal points shall be provided complete with stiffeners, dampers, expansion joints and supports as required. The air ducting and flue gas ducting shall be fabricated from MS plates.

13.

BOILER SETTING: Boiler setting materials shall be furnished as follows: Standard refractory bricks/tiles, castable refractory as required to suit the boiler temperature.

Mineral wool insulation for boiler, hot ducts, hot lines, economizer, all piping in TBW scope of supply etc. 0.5 mm aluminium sheeting for the main boiler block, economizer, and APH etc. 14. HOPPERS: Bottom drum, economizer, air pre heater hoppers shall be furnished. The hoppers with valley angle of 55 - 60 shall be constructed of MS plate suitably stiffened as required. The vertical free elevation of flange bottom all hoppers shall be as listed in scope of supply description. 15 16. STRUCTURAL / DUCTING/HOPPER: SAMPLE COOLERS We shall supply sampling points with isolation valves & sample coolers or SWAS as described for the following services. i) Main steam ii) Drum water III) Feed water iv) Saturated steam. 17. FUEL FEEDING & FIRING SYSTEM Boiler is equipped with the fluid bed combustor with feed technique consisting of: OVER BED FEEDING: Fuel bunker along with surge hopper above drag chain feeders shall be provided. VFD driven Drag chain feeders are provided below the surge hopper. These feeders will finally discharge the fuel through chutes to the furnace. BOILER TURNDOWN: Boiler turn down shall be achieved by varying the fuel feed rate and adjusting the furnace inventory levels. FLUIDISING NOZZLE: The design of air and fuel nozzles shall prevent in-bed spouts/eruptions, which may impinge on in-bed tubes and erode the same. Besides, the

nozzle design shall permit effective fluidization at lower loads with shutting down of some compartments. Fluidizing nozzles shall have suitably sized stem portion extending from the bed plate to the furnace side and shall be fitted with bubble caps of stainless steel material to facilitate uniform distribution of air and fuel. 18. SECONDARY AIR SYSTEM High-pressure secondary over fire air tapped from SA fan discharge is injected into the furnace through heat resistant nozzles mounted on the front and rear walls. The system is complete with ducting and manually operated air control dampers. 19. FLUID BED COMBUSTOR Water -cooled distributor plate fluid bed combustor with SS bubble cap fluidizing nozzles. Drain pipes shall periodically remove the ash / stones collected. Drain pipes shall be provided, with ash cooler system. The outlet of flue gas from the ash cooler is connected to APH hopper. 20. ASH HANDLING. Bed drain lines shall be provided for combustor and below hoppers for fly ash for removing the bed ash generated while firing the fuel as listed in design basis. As per the scope matrix, description of scope of supply, ash handling system shall be provided. 21. CHEMICAL DOSING This shall consist of one set for HP dosing (chemical injection pumps (variable stroke plunger type). Each dosing system will have one no. mixing tank with stirrer each (motorized), piping, fittings, motors for pumps etc. The chemical dosing pumps will be connected by piping from mixing tank to pump and then to steam drum. Necessary valves, fittings, etc. shall be provided. 22. BLOWDOWN TANK: Common Blow down tank shall be provided for CBD & IBD lines. 23. BOILER FEED WATER PUMPING STATION Shall be as discussed in the offer.