BI-DRUM BOILER THERMAX Chapter 3: EQUIPMENT DATA 3.1 GENERAL Type of System : Atmospheric Fluidised Bed Combustion.

Type of Boiler : Bi drum, Water tube Type of Furnace : Membrane wall Type of feeding system : Under Bed Type of water circulation : Natural Type of draft system : Balanced Type of support : Bottom Supported Type of installation : Indoor installation No. of units : One 3.2 PARAMETERS OF BOILER Ambient Temperature : 40 oC (design & performance) Relative Humidity : 60%. Flue gas temperature at the : 160 170 oC Chimney inlet 3.3 INBED COILS Tube size : 50.8 mm O.D x 6.35 mm thk. Tube material specification : BS 3059 PART-1 SEAMLESS, GR 320. 3.4 FURNACE Water Wall construction : Membrane panel Water Wall tube size : 63.5 mm OD x 3.66 mm thk. Water wall tube material : BS 3059 PART1 ERW GR 320. Water wall fin thickness : 6.0 mm Water wall fin material : IS 2062 Header size : OD 219.1 mm x 12.7 mm thk Header material : SA 106 Gr.B 3.5 DRUMS Steam Drum Water Drum Internal diameter mm : 1234 750 Material of construction : SA 516 Gr.70 SA 516 Gr.70 Type of dished ends : Semi Ellipsoidal Semi Ellipsoidal Length (approx.) mm : 3900 3900 Thickness of shell mm : 22 16 C&H HEATING DIVISION 15 BDFB-240/CD23/88

BI-DRUM BOILER THERMAX 3.6 AIR PRE HEATER Location : After Economiser Arrangement and type : Staggered tubes, cross counter flow Tube size : 63.5 mm O.D x 2.04 mm thk. Tube material specification : BS 6323 ERW Part V Flow medium -Inside tubes : Flue Gas -Outside tubes : Air Casing material specification : 3 mm thk, IS 2062 3.7 DUCTING Air ducting thickness : 4.0 mm thk Flue gas ducting thickness : 5.0 mm thk Plate material specification : IS 2062 3.8 FORCED DRAFT FAN Fan Make : THERMAX Fan Support : Simply supported Qty Nos. : 1 (One) Flow m3/min. : 545 Static head (mmWC) : 725 @ 40 C Medium : Air Temperature C Operating : 40 Fan speed rpm : 1450 Connected Power : 110 kw 3.9 PRIMARY AIR FAN Fan Make : THERMAX Fan Support : Simply supported Qty Nos. : 1 (One) Flow m3/min. : 110 Static head (mmWC ) : 700 @ 160 C Medium : Air Temperature C Operating : 160 Fan speed rpm : 2980 Connected power : 37 kw C&H HEATING DIVISION 16 BDFB-240/CD23/88

BI-DRUM BOILER THERMAX 3.10 INDUCED DRAFT FAN Fan Make : THERMAX Fan Support : Simply supported Qty Nos. : 1 (One) Flow m3 / min. : 830 Static head (mm WC) : 200@ 160 C Medium : flue gas Temperature C Oper/Design : 160 Fan speed rpm : 980 Connected Power : 55 kW 3.11 FEED PUMP Quantity Nos. : 2 (one working, one standby) Make : Grundfos Capacity m3/hr : 30 Pressure head mlc : 243 Medium : Boiler feed water Feed water temp. C : 105 / 125(When the fuel is Kutch Lignite) Connected Load KW : 37 kW .g. asbestos hand gloves, ear mufflers, transparent eye protective goggles and first aid kit. Note: - If control valves/isolating valves to be kept in on line position, while steam flushing, keep their position to 100% open to avoid damage to seat of the valves or accumu lation of dirt. 3._____________________________ C&H HEATING DIVISION 27 BDFB-240/CD23/88 c). Procedure: . Start ID Fan and FD fan as per the sequence for the fan start-up procedures. . Ensure that the PA fans I/L and O/L dampers are kept closed to avoid air leaka ge through the fans . Close all the air tapings to other locations like burner, Over fire air, ESP p urge, bed ash cooler (if any) etc. from FD fan. . Close all the wind box (compartments) dampers, except the start-up compartment No.1. . Start passing air through compartment 1, adjust the ID fan and FD fan flow con trol dampers to get 2e high resulting in higher pressure drop through air nozzles. C&H HEATING DIVISION 28 BDFB-240/CD23/88

BI-DRUM BOILER THERMAX ______________________________________________________________________________ C&H HEATING D5.C / hr reaching 100 .C and hold temperature for 4-6 hr. at 100. C for soaking refractory castables. If the temperature falls, increase the firing rate and maintain the required temperature. Raise temperature of flue gas at boiler outlet again @ of 25. C/hr to 125. C and Hold temperature for 4 to 6 hr for soaking of refractory castables. Once the above heating schedule is over refractory may be cooled down with natur al cooling (with FD, PA & IDengineer. . After visual checks, close all access to the boiler unit internals. . Following minimum controls and requirements are necessary for boiler operation . . Good working Drum level gauge glass with illuminator assembly. . Boiler drum pressure gauge. . Safety/relie test of boiler to be completed to the maximum working pressure. Quantity of Chemicals for alkali boil-out (Per boiler, per boil out) CHEMICALS QUANTITY (kg) Hydrous tri-sodium phosphate (Na3PO4 12H2O) 120.0 Anhydrous di-sodium phosphate (Na2 HPO4) 60.0 Wetting agent (Surfactant/Detergent) 10.0 8. PROCEDURE FOR SAFETY VALVE SETTING OBJECTIVE The objective of this procedure is to outline the procedures involved in setting the safety valves to the designed set pressures before allowing the boiler to go for commercial st eaming.

should be able to recognize hazardous conditions and to act properly to avoid injury. Even though operating procedures are normally given for each piece of equipment, a complete knowledge of all components their design, purpose, limitations and relationship with other components is must for the operators. 5.1 BOILER OPERATION AFBC PHILOSOPHY . Fluidized . The water level in a natural circulating boiler must be within limits during o peration and must be so indicated to the operator. The gauge glass, when correctly installed and

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BI-DRUM BOILER THERMAX ______________________________________________________________________________ C&H HEATING DIVISION 40 BDFB-240/CD23/88 Water should be filled up at a very slow feed rate to ensure removal of entrappe d air from the pressure parts. Air vents should be closed one by one only after ensuring that the entire air in that system has been released. This is indicated when the water flowing out of the air vent achi eves a constant flow pattern for at least 3 to 5 minutes. After the system is filled and water comes out from the last air vent, the BFW P ump discharge valve should be shut & BFW Pump switched off. PROCEDURE FOR BED MATERI . Limit the bed temperature to maximum of (refer the boiler light up procedure). . Boiler bottom drains should never be operated while boiler is in service. 5.7 LOG SHEET . Even though the sophisticated boiler and auxiliaries control systems are provi ded, it is suggested to record the boiler parameters during start up and during normal oper ation. . Log sheet to be filled once in every hour during boiler operation. . If the FD fan and ID fan are in running condition, for data entry purposes the boiler is considered in operation. . Feed water and boiler water quality to be recorded in the log sheet once in ei ght hours. Detailed log sheet for boiler start up, boiler operation, water quality is enclo sed here with for information. . During start up . Ensure that the chimney manhole door is closed. FUEL HANDLING SYSTEM . Check & ensure the availability of dry fuel of recommended size in the bunker. . Ensure that drives and Control systems are ready for service. Horizontal & Ver tical fuel feed lines are clear. FLY ASH HANDLING SYSTEM (if Applicable) . Fly ash handling system for hopper below boiler bank should be kept ready for operation.

BI-DRUM BOILER Check and assure that there is sufficient storage of fuels in the bunker and nor mal water level in the drum. Clean the bed and the nozzle holes prior to bed material charging ,Fil l river sand of specified size in the combustor about 250 to 300 mm from the distributor plate t op. Start the FD fan and open the fan damper gradually to level the sand bed. Check the fluidizat ion uniformity by obser / movements. When the drum pressure reaches 2 kg/cm2 (g), quickly operate the I.B.D. valve fo r 10 sec. In this operation the sediments and rust dislodged from the pressure part internals due to thermal expansion can be removed. It also helps to reconfirm the drain pipe/valves are c lear with out any obstruction/bl Alkalinity adjustment and film formation are closely related. The pH value of fe ed water should be maintained greater than 9.6 to reduce the corrosion effects caused by the rea son mentioned above. The required alkalinity of feed water is adjusted by adding soda ash caus tic soda or trisodium phosphate. The calcium hardness, alkalinity and pH are inter-related v ariables in scale control. Calcium carbonate is one of the most troublesome deposits responsible f or scale formation. installing steam purifier, lowering water level in the boiler and maintains cons tant load on boilers. The recommended residual of such chemicals in boiler water is given in Table 1 Table 1 Hardnes temperature, the boiler should be shut-down at the earliest by regular procedure for main BOILER SAFETY . HANDLING OF DAMPERS ON AIR DUCTS . THE HAND OPERATED DAMPERS IN THE AIR DUCT WILL BE VERY HOT. . WHILE HANDLING THE DAMPERS / PORTS PROTECTIVE GLOVES SHOULD BE WORN AND ENOUGH ATTENTION TO BE GIVEN. HANDLING OF SOLID PILES . ALWAYS BE CAUTIOUS OF PILES OF COMBUSTION PRODUCTS. . THE SURFACE OF PILED MATERIAL MAY BE COOL IN THE SURFACE WHILE JUST BELOW THE SURFACE STILL MAY BE VERY HOT. . MATERIAL IN A PILE CAN STAY HOT FOR SEVERAL DAYS.

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