Title of Micro-project: Develop maintenance procedure for preventive and

predictive maintenance of typical FBC boilers and its components.

1. Brief Description

1.1 Definition

It is a closed vessel in which steam is produced from water by combustion of fuel. Boiler is
an apparatus in which thermal energy released by combustion of fuel is transferred into water
which vaporizes and gets converted into steam at the desired pressure and temperature.

1.2 Boiler Mounting

Mountings are the components used for the safety of boiler, the boiler requires the following
mountings a feed check valve to prevent the return of water from the boiler in base the feed
pump is to operating, a steam stop valve to regulate the flow of steam from the boiler, safety
valve (at least two) to protect the boiler from pressures higher than the designed valve, a blow
off valve to empty the boiler when needed and to discharge the mud and sediments that are in
the boiler. Water level indicator to show the water level inside the boiler, a pressure gauge to
indicate the pressure of steam in the boiler, fusible plugs to protect the boiler against low
watar lever.

1.3 Boiler Accessories

Accessories are the auxiliary plants required for steam boilers for their proper operation and
for the increase of their efficiency. According to the principle of operation the steam
separator is classified as follows:

• Impact or buffle type

• Reverse current type
• Centrifugal type

1.4 Boiler Efficiency

Boiler efficiency is the ratio of heat actually utilized in generation of steam to the heat
supplied by the fuel in the same period

Boiler efficiency = ma (h-hf)/c

Where, ma = mass of water actually evaporated into steam per kg of fuel at the working
pressure

C-calorific value of the fuel in kj/kg.

1.5 Heat Losses In A Boiler Plant

The following heat loss occurs in a boiler plant:

• Heat loss of flue gases

• Heat loss due to incomplete combustion

• Heat loss due to un burnt fuel

• Convection and radial losses

II. MECHANISM OF FLUIDIZED RED COMBUSTION

When an evenly distributed air or gas is passed upward through a finely divided bed of solid
particles such as sand supported on fine mesh, the particles are undisturbed at low velocity.
As air velocity is gradually increased, a stage is reached when the individual particles are
suspended in the air steam- the bed is called "fluidized". With further increase in air velocity,
there is bubble formation, vigorous turbulence rapid mixing and formation, of dense defined
bed surface. The bed of solid partieles exhibits the properties of a boiling liquid and assumes
the appearance of a fluid. "bubbling fluidized bed". At higher velocities, bubbles disappear,
and particle is blown out of the bed. Therefore, some amounts of particles have to be re
circalated to maintain a stable system- "circulating fluidized bed”. Fluidization depends
largely on the particle size and the air velocity. The mean solids velocity increases at a slower
rate than does the gas velocity. The difference between the mean solid velocity and mean gas
velocity is called as slip velocity. Maximum slip velocity berween the solids and the gas is
desirable for good heat. transfer and intimate contact. If sand particles in a fluidized state is
heated to the ignition temperature of coal, and coal is injected continuously into the bed, the
coal will burn rapidly and bed attains a unifonm temperature. The fluidized bed combustion
(FBC) takes place at about 840 to 950 degree Celsius. Since this temperature is much below
the ash fusion temperature, melting of ash and associated problems are avoided. The gas
velocity is maintained between minimum fluidization velocity and particle entrainment in the
gas stream.FBC boilers combustion progress requires the three "T"s that is time, temperature
and turbulence. In FBC, turbulence is promoted by fluidization. Improved mixing generates
evenly distributed heat at Lower temperature. Residence time is many times greater than
conventional grate firing. Thus an FBC system releases heat more efficiently at lower
temperatures,

2.1 Types of Fluidized Bed Combustion Boilers

There are three basic types of fluidized bed combustion boilers;

• Atmospheric classic fluidized bed combustion system (AFBC)

• Atmospheric circulating (fast) Fluidized bed combustion system (CFBC)

• Pressurized fluidized bed combustion system (PFBC)

2.2 General Arrangement of AFBC Boller

AFBC boiler comprises of following systems.

• Fuel feeding system

• Air distributor

• Bed & in-bed heat transfer surface

• Ash handling system

2.3 Advantages of Fbc Boilers

o High Efficiency: FBC boilers can burn fuel with a combustion efficiency of over 95%
irrespective of ash.content. FBC boiler can operate with overall efficiency of 84%
(plus or minus 2%)
o Reduction in Boiler Size: High heat transfer rate over a small heat transfer area
immersed in bed results in overall size reduction of the boiler.
o Ability to Burn Low Grade Fuel: FBC boiler would give the rated output with inferior
quality fuel. The boilers can fire coala with ash content as high as 62% and having
calorific value as low as 2,500 kcal/kg.
o Pollution Control: SO2 formation can be greatly minimized by addition of limestone
or dolomite for high sulphur coola. 3% limestone is required for every 1% sulphur in
the coal Feed.
o Law Carrosion and Erosion: The corrosoin and erosion effects are less due to lower
combustion temperature, softness of ash and low particle velocity (of the order
1m/sec)
o Less Excess Air: Higher CO2 in Flue Gus; The CO2 in the flue gases will be of the
order of 14-15% at full load. Hence the FBC boiler can operate at low excess air only
20-25%.
o Simple Operation, Quick Start-Up: High turbulence of the bed facilitates quick start-
up and shut down. Full automation of start up and operation using reliable equipenent
is possible.

Provision Of Automatic Coal And Ash Handling System: Automatic system for coal and ash
handling can be incorporated making the plant easy to operate comparable to oil or gas fired
installation

o High Reliability; The absence of moving parts in the combustion zone results in a
high degree of reliability and low maintenance cost.
o Reduced Maintenance: Routine overhauls are infreqiant and high efficiency is
maintained for long periods.
III. OPERATION AND MAINTENANCE OF BOILER

3.1 Coal Handling Plant

In coal handling plant, raw coal that is brought from outside & bamboo dust is supplied to
griggly hoper whereby help of vibratory machine it is crushed into smaller parts. Then some
amount of bamboo dust is also mixed with charcoal and supplied to primary screen I & II
with the conveyor belt I & IA. In primary screen I&II coal size is checked (i.e round 6-10
mm). If the required size is obtained then it goes bunker of CF boiler. If size condition is not
satisfied then the coal goes to crusher I & II When size is maintained if the coal size is not
obtained to the required size, then it goes to the secondary stages of coal sizing The
acceptable coal size is send to the boiler through the help of conveyor belt IV.

3.2 Demineralization of Water

It means water is free from all minerals. This is done to various defects happens such as
boiler corrosion, formation of sludge and scale which may decrease the volume or capacity
of the boiler due to deposition of minerals on the walls of the boiler. It is to remove mineral
content of water, in this system raw water enters the hydrogen zeolite exchanger (cation
removal) at the top and flows to the anion exchanger and degasified and finally passes
through silicon absorber.

IV. STARTING OF THE BOILER LIGHT UP PROCEDURE FOR COLD

CONDITION

Preparation of furnace when the tumace is empty, check the following;

• Air Nozzle - nozzles hole are to be clean. Nozzle top to be intact

• It nozzle are not clean the ore to be cleaned with air hose Coul feed nozzle-the top
refractory is to be there Check the following;
• All the access doors to be closed
• All personnel to be cleared
• All foreign material are to be removed from furnace & pressure parts
• Starting equipament & interlock are ok
• Check the following equipment for adequate lubescation and readiness for services

1) ID 2) FD lan
3) PA fan 4) Feed pump.
5) Fuel feeder 6) Dynamo drive system

• Banker (coal) to be full with 0-6 mm size coal and gates below the banket are in open
position and coal is available at feeder inlet
• Check instrument air above 3 kg/cm2pressure is available for instrumentation and
Control
• Start first ID fan with suction damper in closed position
• Start FD fan with suction dumper in closed position
4.1 Charging Bed Material
• Keeping the indivishtal damper of 3 compartments in open position, furnace draft is to
be maintained at 5 mm to 7 mum by slightly opening the ID fan damper
• Open the lurrace man hole and with 2 mazodoors the bed materials is to be charged
into the furnace, care to be taken that no empty bag slips into the furnace. After
completely charging the material it should be leveled by properly operating dampers
of ID & FD fans, then close dampers. Open the main holes on both sides of the
furnace.
• Take a 24v hand lamp inside and measure the height of the b bed in each
compartment. The height of bed in each compartment should be 300 mm to 310 mm.
Then come out of the furance and keep the hand lamp on the bed coil (glowing)

4.2 Lighting Up of Boller

• Before lighting up of boiler fill the boiler with feed water up to half steam drum
level, at the time of taking water ensure that all air vents are in open position and all
drains are in closed position. Confirm the level of water in the drum by seeing gauge
glass levels.
• Keeping lighting swabs ready
• Keep open the furnace coor and open the ID fan suction damper
• Light up one swab watch stick, light up all swabs one after one throw, then in all
directions in the startup Compartment
• In cach compartiment two thermocouples are provided to indicate feed temperature it
is important to increase air flowing gradually to increase the top level temp, to 800 to
850 degree
• When the bed temperature rises above 600 degree switch on PA fan, the coal
transport lines are to be closed and coal feed drain lines to the cleared
• Adjust PA fun section damper to maintain header pressure in between 750 mm and
950 um water column. Open the fuel transport air damper of the startup compartment.
The coal teed shall be kept at minimum at the beginning.

4.3 Boiler Trip Due to Power Failure

If boiler trips due to power failure, take the following action;

Start stand by feed pump (on second poer source)
• Restore drum water level by controlling teed water on manual mode. It instrument air
is not available titst close the inolation valves of the inlet of feed cantrol valve and
regulate
feed water through by pass valve, keep a constant watch on gauge glass level
• Close the inlet damper of ID and FD fan Close the butterfly damper of wind box
• Close all steum outlets from boilet so that boiler is not depressurized immediately
4.4 Boiler Hot Startup Procedures

• Open the startup vent valve slightly

• Close all the compartment damper
• Start the ID fan, FD fan, PA fan
• Open slightly the wind box damper of no 1 so bed 1 fluidizes with minimum air
ensure that fluidization is uniform and satisfactory
• Adjust the ID fan dumper to maintain the faurnace pressure
• Adjust the FD tan & PA damper to get the required fan pressure
• Start coal feeding without delay otherwise bed may cool down rapidly
• Gradually mercuse the coal feeding observing the rise in bed temperature
• Adjust the air flow and coal feeding observing the rise in bed temperature
• Take bed no 2 and other beds on line and connect the boiler process
• Take feed water control and furnace draft on auto mode
• Charge the ESP if the flue gases temperature in ok
• Put the boiler into auto mode
• Start ID fan, FD, fan PA fan
• If the bed level is too high drain the bed and being down the bed height to around 300
mm by fluidizing the bed-1, spread some charcoal over the bed no-1, ignite the same
• Repeat the cold startup procedures listed in this manual and established the boiler

4.5 Boiler Normal Shut Down Procedure

• Graduully reduce the steam lead by reducing to the coal flow to the furnace
• Gradually reduce the air flow also to avoid fast cooling the bed
• Reduce the firing rate slowly to maintain the temperature drop around 250 per hour
Cost of coal feeding to the combustor
• Do's connect the boiler from range when steam pressure drop less than the required
pressure for process
• Open the startup vent slightly and depressurized the boiler gradually tif required)
otherwise close all the vent and drains fully without depressurizing
• Switch off the ID fan if required. Keep ID & FD tan dampers are opened to allow the
gases to escape
• When the boiler pressure drops to 2 kg/cm2open the air vent of drum
• Maintain normal water level in the boiler
• If surface is required to be cooled quickly, fan may be kept running for sometimes
please note that fast cooling leads for refractory damages, it is suggested to go for
natural cooling.

V. DAILY MAINTENANCE CHECK LIST DURING OPERATION

• Check the correctness of water level in the control desk with direct level glass.
• Check the level indicator for proper illumination
• Check the combustor for proper fluidization through peep holes
• Drain the bed do check for unusual combustible in the bottom ash
• Check fan unasual noise for steam/pumps
• Check vibration in rotary equipment
• Check for air gas leakage from dust & flue etc
3. Course Outcomes

We known the how the maintenance procedure of FBC boiler is carried out.

4. Procedure Followed

1. First we were select the Title of the Microproject by making discussion.

2. Refer various books related to our microproject
3. Also visit to vanous websites for collecting information.
4. Make the Project report

5. Skill Developed/learning outcomes of this Micro-Project

In this micro project we study maintenance procedure for preventive and predictive
maintenance of typical FBC boilers and it's Components. We become able to identify each
component of the Fluidized bed combustion boiler Also the construction and working of the
FBC boiler is also understood.