Report on CFBC Modifications after /during Commissioning Bed Ash Coolers: The bed ash coolers installed for

r bed ash draining was of dense phase pnuematic system with separate transporter installed on LHS and RHS of the boiler bottom. The hot bed material in the furnace chamber flows outward through a 100mm hole provided on LHS and RHS wall of the Boiler structure into a small fluidising chamber connected external to furnace chamber. The small fluidising chamber is enclosed with cooling water circulation and air nozzles for fluisidisation. The denser bed ash material will retain in the chamber and lighter particles along the fluidisation air are diverted as secondary air. The cooled denser particles are collected in to the transporter and conveyed to the Silo. Since the coal used was of F-Grade, the system was not sufficient to discharge the collected bed ash. The operators used to drain the bed ash through bypass tapping. As the content is 48% in F-Grade, any surge in bed temperatures caused clinker formation and this clinker used get struck up in the 100mm hole provided. It was a tedious job to clear the jam and bring the system to normal. This is causing limitation of boiler generation. Modification/Correction: The dense pnuematic system was replaced with rotary drum with direct tapping from the furnace for cooling the bed ash. The rotary drum is provided with indirect heating with cooling water and the outlet of rotary drum is falling into a portable bunker connected to a dense phase pnuematic system. After modification, there is no rise in bed pressure or restriction in Boiler generation. Main Steam Temperature: The designed main steam temperature at main steam stop valve is 525deg.C and maximum achieved steam temperature at main steam stop valve was 485deg.C during normal operation. It was not achieved even after putting soot blower into operation. Modification/Correction: Additional loop of superheat coil was installed in the super heater zone. Necessary modifications were also carried out in feed water circuit. Plenum chamber coil Failure: The combustion chamber is constructed with water coils connected with skin plate which is called plenum chamber. The top part of the wind box is constructed with one of these water coils. The air nozzles for fluidisation are installed on the top part of the wind box in between water coils of the entire volume. During normal operation of the boiler, the air nozzles used to fail and creating a jet of air impinge on the plenum water coils. These water coils are failing frequently. Modification/Correction: The entire top half of the plenum chamber water coils are covered with castable refractory so that any failure of air nozzle will not lead to coil failure. This experiment has worked out and there was no failure of coils in plenum chamber. Economiser Tube Failure: The economiser was provided with soot blower for clearing the soot deposited on the economiser coils. Over a period of time, there was leakage from economiser coil. The coil failed location was inspected and found that the soot blower steam is impinging on the coil causing it fail over a period of time. Modification/Correction: Deflectors were arranged near the economiser coil to avoid direct impingement of steam on to the coil. S.V.NAGESH Head Technical Cubex Energy Pvt Ltd 9962666980