ER/ 0734/ C F

Rev 00 00/ 30.06.09

ISGEC John Thompson

SECTION F STARTUP PROCEDURE FOR CFBC

BOILER
F.1 General checks

F.2 Cold Start-Up Sequence

Ensure that the boiler is ready to be fired

on slow fires and warmed through. The
rate of temperature increase must be
controlled as per the start up curve
provided in technical data sheet.

Close all air Flow Dampers

Water level will rise to glass due to

expansion and must thereafter be
maintained at this level.

Start PA Fan

Super-heater steam temperature must be

monitored constantly until pressure is
raised and flow is established through
superheater.

Start ID Fan
Start Wall Seal Blower
Start SA Fan
Start Boiler
Materials

Purge

adding

Bed

Open Air Vents and Start up Vents

Start the Startup Burner
Close Air vents at 3 bar
Raise bed pressure to 250 mmwc or
upto the established normal level
during
commissioning
&
Bed
Temperature to 550 - 600 Deg. C

Never allow the temperature

of
gases
entering
the
superheater zone to rise
above the normal working
steam temperature of the
superheater until a positive
flow of steam is established
through the open superheater
drain and vent valve.

Start Fuel feeder

Stop burner at 850 Deg. C
Gradually raise boiler load to 100%
MCR

F.3 Cold Start-Up Procedure

Following steps will be taken for bringing
boiler to range from cold condition.
Check all work permits are returned
from all agencies.

As
the
boiler
warms
up,
slight
adjustments to the air supply may be
necessary
to
maintain
satisfactory
combustion until the boiler is on load.
Keep a constant watch on all auxiliary
equipment, record the temperatures of
bearings associated with fans and pumps.
Any abnormal condition observed must
be
immediately
investigated
and
corrective measures taken.

1 x 190 TPH CFBC Boiler

M/s Arasmeta Captaive Power Co. Ltd., C.G.

No personnel is
Combustor,
duct
equipment.

working inside
or
on
any

All manholes, Doors are closed.

Fuel oil and coal, igniter, DM water,
chemicals for feed water are available
and handling system is healthy.
Check
healthiness
of
electrical
systems and instrumentation. Plant
and instrument air are ensured and
required pressure is developed.
1

ISGEC John Thompson

Confirm interlock and protection
systems are in line, Electric power for
instruments and other drives are
available.
Before lit up of the unit, full open
super heater header drains, vents and
main steam line drains. Keep drum
vents in open condition. Keep the
economizer drains and vents in close
condition. Drum drains should be in
closed condition. If Hydro test of
Boiler is carried out prior to the Boiler
startup, Convection cage bottom
header drains to be opened and water
should be drained out completely from
convection cage. After water has been
drained keep these valves crack open.
Check main Steam Stop Valve,
Economiser drain, CBD / IBD,
attemperator isolating valves etc. are
closed.
Ash coolers cooling water
system is in service.
Take water to drum upto 1/3rd of
gauge glass or (-) 75mmwc below
normal
water
level
in
level
transmitter.
Cold water (ambient
temperature) should be filled through
economiser inlet.
If Feed water
through BFP is above 60 0C, water to
be filled by initial filling line only
using DM Transfer pump (water
through initial filling line temp should
not exceed 60 0C), when the Boiler is
in cold condition.
Carry out DP test of the combustor
nozzles after the bed nozzles cleaning
and compare the readings with the
Earlier values available, the values
taken during the fresh boiler startup.
If Wind Box pressure is more than the
previous reading, the nozzle cleaning
job to be further carried out.
Check all the cooling water line I/L &
O/L Valves are in open condition.
Check the flow of C.W. to the sample
coolers, both side stripper cooler of
boiler and ash handling cooling
systems
Start Fuel oil pump.

1 x 190 TPH CFBC Boiler

M/s Arasmeta Captaive Power Co. Ltd., C.G.

ER/ 0734/ C F
Rev 00 00/ 30.06.09
Check all the fans suction / discharge
dampers are operating from control
room and then keep them in closed
condition.
All manual dampers
should be 100% open.
Keep all the selector switches on
Electrical Control panel on Remote
position.
Check the interlock of ID Fan in the
monitor, if found healthy, start ID
Fan, if not, check physically and make
it healthy then start ID Fan. Start
another ID Fan same way. Incase VFD
is provided, keep the speed to
minimum. Else keep the IGV of the
fans at minimum position.
Start Wall Seal Blower after checking
the interlock, keeping discharge
damper in open position and observe
the discharge pressure > 4000 mmwc
and it should not go beyond 4500
mmwc. If Wall seal blower discharge
pressure goes beyond 4500 mmwc, it
will result in blower vibrations and
failure. (If required the vent valve in
the wall seal blower outlet/ Pressure
control valve to PA duct to be opened
minimally to keep the pressure below
4500mmwc. Wall seal blower has a
safety valve in the discharge piping at
the back side; it is adjusted at 4500
mmwc. The settings of this safety
valve should not be disturbed. Always
keep the exhaust fan in wall seal
blower acoustic hood in running
condition to provide good ventilation
for the blower and the motor. Blower
should not be operated without
exhaust fan in running condition.
Check/ adjust the Loop seal settings.
Do not disturb the settings of the
valves. These settings are fixed for any
boiler load conditions.
Open the mobilizing air to stripper
cooler and physically check the air
flow thru the air slide. Check air slide
for any choking and remove the same
if any. This has to be done
Start scanner cooling air & open
suction damper.

ER/ 0734/ C F
Rev 00 00/ 30.06.09

ISGEC John Thompson

Check the interlock of SA Fan and
start the Fan. Maintain Furnace draft
by controlling ID fan
Check the interlock of PA Fan and
start the fan.

Check Start up
retracted position.

Burners

are

in

Verify no flame is there.

Verify oil, Scavenging valves are
closed and CAD damper opened above
80%.
Ensure that the Boiler inter locks are
satisfied.

NOTE:

Ensure that the Oil pump is running.

Maintain furnace draft around -5

mmwc during entire process of light
up and boiler loading. In case V F D
is provided, maintain the furnace
pressure by controlling fan speed

Ensure that the Oil Header Oil

pressure near burner is minimum 12
kg/cm2 (g) and atomizing air Pressure
is between 6 - 7 kg/cm2

If two fans are provided, keep stand

by fan damper closed to prevent
reverse rolling.

Start Boiler purge. After purge is

complete (5 minutes) reduce CAD
dampers to 20%

Oil manual Valve is opened.

Initiate Start Push Button.

Bed material installed. After obtaining
bed pressure of around 250 mmwc or
as established during commissioning,
boiler can be lit up. Bed material
quality and size to be maintained as
per Technical Data sheets.
Increase PA fan speed / IGV Opening
gradually upto 40% MCR. Maintain
SA fan air flow as per requirement of
burner and air bustles. Keep the
upper and lower SA dampers at
minimum.

Start purging of Boiler for a period of

10 minutes (minimum).
Start both the start-up burner as per
Procedure detailed below: Maintain oil
pressure at burner inlet / control
valve outlet at 1.5 Kg/cm2

STARTUP BURNERS
PROCEDURE

LIGHTING

UP

Burner will move to advanced

position
Igniter will be energized for 10 sec.
Oil Solenoid valve will open. On
flame monitor, Flame-On light will
glow as soon as flame is
established. In case flame is not
established, oil valve will close and
the system will be flushed with
compressed air in scavenging
cycle.
During each burner light up an
operator should be positioned at
the front of burner, to check oil /
air leakages. Visually observe the
flame
condition,
check
the
irregular flame pattern or flame
impingement etc.
The SA flow to the burner is to be
increased looking to the flame and
oil flow.
The burner to be taken off when
bed temperature (average) reaches
800OC.

There are two Start-up burners provided:

Check Burner local panel power is
ON.
Check oil, Air are properly connected.
1 x 190 TPH CFBC Boiler
M/s Arasmeta Captaive Power Co. Ltd., C.G.

ER/ 0734/ C F
Rev 00 00/ 30.06.09

ISGEC John Thompson

-

Do
Not
Exceed
Ijt
Recommended Heat Rate In
Start-Up

Close all air vents when

pressure is 2.5 kg/cm2.

drum
-

Close the super heater drains when

drum pressure reaches 5 kg/cm2.
Keep the main steam drain valve full
open and keep the startup vent open.
Keep
a
close
watch
on
bed
temperatures,
compact
separator
inlet/outlet temperatures and follow
COLD START UP CURVE.
When bed temperature is above 550
start coal feeder motor, check that
the sealing air to feeders and air to air
bustles are open.
0C,

Carry out coal

Procedure below:

feeding

as

per

Open the sliding valve between

coal feeder and entering point.
Manually start coal feeder when
average
bed
temperature
is
between 550- 600 0C.
Run the feeder at minimum speed
for 90 second and put it off. This
is called BURPING of coal feeder.
Verify bed temperature increases
at least 10 0C and Oxygen
percentage decreases.
Burp the coal feeder three times at
30 min. interval and leave coal
feeder in continuous operation on
minimum fuel feed. Ensure that
oxygen level during this time
should not fall below 5 %.
Once continuous increase in bed
temperature is observed, keep
watch on bed temperature and
Oxygen readings. Adjust air flow
and fuel feed to control the
parameters.
Follow AIR-FLOW Curve / chart
both for SA and PA and maintain
oxygen
percentage
as
per
Technical data sheets.

PROCEDURE FOR COAL FIRING

There must be enough bed inventory
before going for any solid fuel firing.
Indicated bed pressure should be 250300 mmwc and wind box pressure 900 to
1000 mmwc. This is required to support
proper heat transfer flame stability. If
required, bed pressure may be slightly
increased by adding bed material before
starting coal firing.
When average bed temperature indicates
550 0C (depending on ignition), coal firing
to be started in the following sequence:-

Put coal feeder in manual

Check
all
bed
temperature
indications.
Open Bunker Sliding valve and
rod gates (if not opened).
Check Sealing Air pressure at coal
feeder established.

1 x 190 TPH CFBC Boiler

M/s Arasmeta Captaive Power Co. Ltd., C.G.

Do Not Allow Excess Oxygen

percentage to go below 2 %
Do
not
Allow
Compact
Separator Inlet Temperature
to go More Than 1000 Deg. C.

Connect the boiler in range once the

rated pressure and temperature are
achieved. First Main steam by pass
valve to be opened. Ensure dry steam
coming out of Main steam line drain
valve.
After charging the header,
Main steam stop valve to be opened
gradually.

ER/ 0734/ C F
Rev 00 00/ 30.06.09

ISGEC John Thompson

While carrying out coal firing the
return leg temperature to be noted
down, it should not be 100 0C below
the bed temperature. If the return leg
temperature is less then air flow to
the lift and down legs to be
momentarily raised by using bypass
on the lift and down leg pipe line.
Care should be taken during this
process that if the wall seal blower
discharge pressure reduces below
tripping level of wall seal pressure for
more than 60 seconds then the boiler
will trip. The settings of the flow
control valve after the flow orifice of
wall seal blower line in lift leg and
down leg of RHS and LHS to be set
and should not be disturbed. If the
return leg temperature is less, it
indicates improper flow of return
material or the seal is empty. If the
return leg temperature is less than
mentioned above, it may also be due
to more air flow through the return
leg, the exact cause of the less
temperature to be analyzed and
attended.
Stop start up burners at 850 0C bed
temp.
Gradually steam load may
increased
depending
upon
requirement.

be
the

When steam generation is above 30%

of MCR put drum level control,
furnace pressure control and steam
temperature control in Auto and
observe the performance closely.

DO NOT KEEP THE BOILER IN

OPERATION if Ash handling
system fails and manual ash
removal from all hoppers is not
ensured. Failure of ash handling
system / ash accumulation in
the boiler can cause serious
damage to the boiler and its
auxiliaries.
For raising Furnace temp strictly
follow Boiler Cold start curve for
Cold start or Hot Start curve for
Hot start.

Bed ash to be removed through

stripper coolers when combustor
average bed pressure is more than
450 mmwc or as established during
commissioning. This can be put in
Auto operation soon after coal firing.

F.4

HOT START-UP

If the boiler has been on standby under

pressure and is required back in service.
Boiler is considered in Hot condition if the
following conditions are achieved:Boiler Main steam line pressure at the
time of restarting or taken in service
should be greater then 40 % of its
working pressure.

Close the start-up vent when 30%

MCR flow established and steam
temperature is achieved.

Bed temperature should not be less

then 550 0C.

Rapping mechanism and hopper

heaters of ESP and ASH conveying
system to be put in services. ESP
fields to be charged when air heater
outlet temperature is more than 120
0C and oil firing has been stopped.

To start the boiler from hot stand by

condition, following steps to be followed:HOT START-UP SEQUENCE
Start the fans as per the following
sequence:

1 x 190 TPH CFBC Boiler

M/s Arasmeta Captaive Power Co. Ltd., C.G.

ID Fan
Wall seal Blower
5

ER/ 0734/ C F
Rev 00 00/ 30.06.09

ISGEC John Thompson

F.5 DAILY CHECKS BY OPERATOR

SA Fan
PA Fan
Scanner cooling air

Being an operator it is important to

keep the boiler clean and safe.

Purge the boiler if bed temperature is

below. All proceedings to be done as
quickly as possible to avoid reducing
bed temperature.
Raise the PA Fan speed to attain 70%
MCR PA flow as quickly as possible
and set the PA Fan speed at required
position depending upon the bed
temperature.
Start the Startup Burner, if required
as per Start up Guidelines.
When bed temperature is 550
(average) Start Coal Firing.

0C

In case it is observed that bed

temperature is more than 600 OC.
directly Coal firing may be started,
setting the air at different zone as per
Air Flow curve / chart.

Following checks must be done once in

every shift:Both the Gauge glass to be checked
operating the drain valves. Compare
this with level transmitter reading.
Check all the drain, Air vent valves
etc. are closed.
No leakages from any man hole doors.
No Sand / bed material leakages from
combustor or convection cage.
No leakages from any flange joints on
Steam, water, air oil lines.
Wall seal air from Root Blower - no
disturbance on settings.
Check oil pump for smooth running.
Check all the bearings of all the fans,
motors etc.

NOTE:
On a hot restart to high load
operation about 70% (MCR) it is
advised to open and close each
drain valve of Primary and
Secondary / Final Superheater
headers one at a time as a
precaution against condensate
in headers.

Check coal feeder for smooth running,

sealing air is opened.
Sample of Feed, Boiler water and
steam to be collected and to be sent
for analysis.
Coal / Ash sample to be sent for
analysis.
Check
the
soundness
of
Ash
evacuation and Ash discharge system.
Check the soundness of all expansion
bellows
Check the boiler expansion is not
restricted.

In
case
on
coal
feeding,
temperature rise is not observed,
immediately
stop
the
coal
feeding and continue startup as
per cold startup procedure.

1 x 190 TPH CFBC Boiler

M/s Arasmeta Captaive Power Co. Ltd., C.G.

Check Steam drum man hole for any

leakages
Check oil level of oil lubricated Fan
bearings, if found low fill it upto the
required level.
Check coal dust/ ash etc. not
accumulated on Buck stays or
anywhere this may create any fire
hazards.

ER/ 0734/ C F
Rev 00 00/ 30.06.09

ISGEC John Thompson

Check Ash cooler
system is in service.

cooling

water

Check the deaerator O/L Feed Water

Temp.
Check oil level of all gear boxes e.g.
drag chain feeders, screw feeders,
RAVs, ESP rapping mechanism,
transformers etc.

F.6 HIGH PRESSURE (HP) AIR SYSTEM

(WALL
SEAL
BLOWER)
OPERATION PHILOSPHY
High pressure blower discharges a
larger volume of air at around 3000 to
4500 mmwc.
Most of the HP air is used to fluidize
the wall seal. The fluidizing air will
maintain flow of bed material through
wall seal by injecting air into the bed
material. This fluidized bed material
provides the seal between combustion
chambers positive pressure and the
compact separators negative pressure.
Static pressure near the bottom of the
compact separator will normally be
very close to atmosphere while
pressure at bed re-entry point may be
more than 200 mmwc. Some method
must be provided to seal against this
differential or the bed material in the
combustion chamber would flow
backward up the compact separator.
The wall seal fulfils this purpose by
acting as a U-tube that seals against
the different pressures that exists in
combustion chamber and bottom of
compact separator.
High pressure air is piped to the wall
seal to provide the mechanism for
keeping solid material moving through
the seal rather than allowing it to
settle and possibly cause a loss of
circulation. A loss of circulation or a
drastic change in the rate of
circulation of bed material can cause
a boiler upset.

1 x 190 TPH CFBC Boiler

M/s Arasmeta Captaive Power Co. Ltd., C.G.

Fluidizing of Wall seal area is

accomplished by taking high pressure
blower discharge air flow and
regulating that flow by use of manual
valves and Rota meters.
From Rota meters air is sent to a
series of manifolds that distribute that
air flow to many fluidizing nozzle on
the sides and floor on each Wall seal.
Typically, there are more fluidizing
nozzle on the lift side of the Wall seal,
the side at that point where the
circulating bed material must move
upward.
The high pressure air system, while
supplying a small percent of the total
air supplied to the boiler, nonetheless,
fulfills very crucial functions. Without
this air flow, the CFB boilers can not
operate.

OPERATION
During start up of the boiler, the high
pressure blower is started after the ID
fan and before the S.A. fan. The HP
blower does not have any control
damper to worry about. Flow control
is accomplished by manual valves at
the distribution headers. Outlet
isolation gate must be full open before
starting the blower.

NOTE:
Once the fluidizing nozzle air flow
on the compact separator Wall seal
have been set and balanced it
should not be necessary to adjust
them unless inspection of the Rota
meters indicates too little or too
much individual flow).

ISGEC John Thompson

ER/ 0734/ C F
Rev 00 00/ 30.06.09

During
normal
operation,
high
pressure air flows to wall seals
continuously; Operators need to
check distribution of HP air to all Rota
meters and the temp. at the wall seal
return leg at the bottom of the
compact separator to assure adequate
circulation of bed material to the
combustion chamber is occurring.
It must be remembered that high
temperature circulating bed material
is in the Wall seal during normal high
load operation.
Personal and
equipment safety should always be
used when working in that area.
Pressure
switch
and
pressure
transmitter mounted on the Wall seal
valve track are used to check the
pressure of the air at the valve rack.
If that pressure drops below at
present value, a boiler trip initiated by
DCS will happen.

1 x 190 TPH CFBC Boiler

M/s Arasmeta Captaive Power Co. Ltd., C.G.