111455-O&M-Manual (Sec 3)

OPERATION AND MAINTENANCE MANUAL
SECTION 3
OPERATION AND MAINTENANCE
3.1 GENERAL
a. The operator should be thoroughly familiar with the function and controls of the
steam generator components and auxiliary equipment before operating the
unit. The information given in this section is not intended to be a detailed
procedure for operation of the steam generator, but is meant to serve as a guide
together with the instructions of the auxiliary equipment manufacturers and with
knowledge derived from initial unit operation.
b. Circulating fluidized bed boilers are chemical process reactors, without a defined
fireball, which behave differently than conventional boilers. They involve
considerable inertia of solids inventory and thermal energy.
c. The operator should be aware of the limitations imposed on the various parts of
the boiler and its auxiliaries and be alert to the actual operating conditions
during start-up and while operating per system demands.
d. Inert bed material such as sand can be used for initial start-up of the unit. It is
recommended to use saved, spent bed material for subsequent start-ups. The
startup bed material should be blown into the lower furnace area with the PA,
SA and ID fans running. Bed material should be added until the static pressure
of the bed is 4.5-5.5 KPa (18”– 22” w.g.)
e. The saved bed material should be sampled during any outage to check for any
hardened material or for sticky conditions due to absorbed moisture. Hydrated
bed material can break apart during start-up and increase fine bed material
carryover. The bed static pressure should be monitored during each restart of
the unit to see that the bed level is being maintained. If bed static pressure
decreases below the minimum value of 4.5 KPa (18”w.g.), additional start-up
material should be added.
3-1
(111455 Sec. 3)
SECTION 3
3.2 PRECAUTIONS
a. Exposure to excessive negative or positive pressures can result in serious

damage to the unit and auxiliary equipment. Furnace draft is monitored
constantly and automatically controlled. Alarm and MFT set points must be
implemented. When a particular induced draft (ID), primary air (PA) and/or
secondary air (SA) fans(s) is to be started, the corresponding inlet control vanes
and outlet isolating (shut-off) dampers (if supplied) should be closed. However, if
there are multiple fans, the dampers (and vanes) on the companion idle fans
should be open to assure a clear air flow path (between ID, SA or PA fan inlet and
stack) exists when starting the fans.
b. All safety valves are set by the manufacturer but should be rechecked under
actual operating conditions as the unit is being brought up to pressure during
initial operation. If a safety valve does not lift at the pressure stamped on its
nameplate or reseat properly, the valve should be readjusted. In some localities,
it is required that only certain authorized personnel may change or adjust safety
valve settings or that changes in safety valve settings be witnessed by authorized
personnel. Consult governmental and insurance requirements before changing
the setting of any safety valve.
On installations where the safety valve relieving pressure exceeds 8.274 MPa(g)
(1200 psig), it is recommended that checking and adjusting of safety valve
settings prior to initial operation be performed by the valve manufacturer service
engineer. A hydraulic or pneumatic device is recommended, if approved by the
inspecting authority, to assist in testing valves on 8.274 MPa(g) (1200 psig) or
higher installations. This device eliminates the need for raising boiler pressure
above normal and minimizes the possibility of valve seat damage during testing.
c. Care should be exercised to insure that proper fuel-air ratio for combustion is
maintained. The Summary Performance Sheet in Section 1 indicates the
minimum excess air requirements. Operation with less than the minimum
expected excess air can be detrimental from the standpoint of combustion,
emission performance and safe operation of the unit.
d. For purposes of monitoring start-up conditions during the life of the boiler,
permanent thermocouples are installed to measure metal temperature of various
tubes. These thermocouples are located in the unheated portion of the tubes
before they enter the outlet headers. The locations and quantities are as follows:
primary superheater (10), intermediate superheater (16), finishing superheater (7),
Reheater I (10) and Reheater II (10). There are two (2) thermocouples on each
cyclone outlet. There are six (6) thermocouples on the steam drum. All these
thermocouples are to be used as aids in determining acceptable firing rates
during start-up.
e. The unit can be operated up to the temperature limits indicated in the table
below. To protect the equipment, the operator should correct any condition which
has caused an alarm to sound.
3-2
(111455 Sec 3)
SECTION 3
Section Location of Maximum Maximum

Temperatur Long Term Short
e Temperature Term
Measureme Temperatu
nt re*
Primary Superheater Tubes to Outlet 487C (909F) 498C (928F)
Header
Intermediate Tubes to Outlet 596C (1105F) 604C (1119F)
Superheater Header
Finishing Superheater Tubes to Outlet 600C (1112) 611C (1132F)
Header
Reheater I Tubes to Outlet 613C (1135F) 627C (1161F)
Header
Reheater II Tubes to Outlet 610C (1130F) 621C (1150F)
Header
* Short term means a period not exceeding 4 hours per day.
f. To prevent plugging, rusting, oxidation and faulty operation of equipment, service

air used on the steam generator for operational purposes, whether for sealing,
aspirating, or atomizing, should be free of dirt, oil and water.
g. All high and low furnace pressure safety interlocks should be checked for proper
values and correct switching action and should be in service before starting the
induced draft fans. The automatic furnace draft control equipment should be
checked and ready for service before starting the induced draft fans.
h. Carbon monoxide (CO) should be monitored continuously during operation of the

steam generator. Foster Wheeler recommends that CO monitoring equipment be
permanently installed for this purpose.
i. It is strongly recommended that the reliability of all drum level indicators be

checked at least once a shift. This would include all gage glasses and remote
level indicators. A water level indicator connection that is being used to control
water level should not be blown down until the control is switched to another
water level controller or feedwater control is put on manual.
j. On commonly operated valves, such as superheater drains and vents, care

should be taken maintain the integrity of the root valves. These valves should
never be in a throttled position, and it may be beneficial to leave them open and
only close the end valves. The root valve would then only be closed for end valve
maintenance or downstream line maintenance. Both valves on waterwall wall
drains can be left closed.
In all cases, end valves should be closed before closing root valves and opened
only after opening the root valve in order to minimize potential root valve seat
damage.
3-3
(111455 Sec 3)
SECTION 3
k. Any of the following operating conditions require mandatory MFT. The flow rates
and ratios are initial values and may be modified during commissioning.
Condition/Situation Status Type of Trip

Drum Level Low-Low -203 mm MFT
Drum Level High-High +203 mm MFT
Furnace Pressure High +2.49 KPa MFT
Furnace Pressure High-High +3.48 KPa Primary/Secondar
y Fans Trip
Furnace Pressure Low -2.49 KPa MFT
Furnace Pressure Low-Low -3.48 KPa Induced Draft
Fans Trip
Loop seal Header Pressure Low- 25 KPa MFT
Low
Superheater/Waterwall Protection Cyclone MFT
Temp.>1000F and
Steam Flow <10%
Cyclone Temperature > Maximum 1000C MFT
Primary Air Flow < Minimum 158.0 t/h MFT
Instrument Air Pressure Low-Low (Set in Field) MFT
Total Air Flow < Minimum 157.8 t/h MFT
Air Fuel Ratio Low-Low 4.08 MFT
No SA Fan in Service True MFT
No PA Fan in Service True MFT
No ID Fan in Service True MFT
Furnace Bed Temperature High- 982C MFT
High
Furnace Bed Temperature Low 649C MFT
Loss of all Fuel True MFT
BMS/DCS Communication Failure True MFT
Emergency MFT Pushbuttons True MFT
Initiated
3-4
(111455 Sec 3)
SECTION 3
3.3 START-UP PROCEDURE
The operating sequence recommended to ensure a safe and proper start-up is given
below. Modifications may be necessary as subsequent operating experience dictates.
Follow the manufacturer's instructions for operating auxiliary equipment. Tag numbers
are indicated for Boiler 1. Boiler 2 will have 12 prefix.
3.3.1 Preparation Prior to Start-Up
a. Make sure that test gags are removed from all safety valves.
b. Check availability of utility services, power, ignition and main fuel, and
suitably treated feedwater.
c. Check operation of all valves and dampers. Check that control equipment
functions properly.
d. Check the start-up burners and auxiliaries assuring that all are operable
and that associated valves are in their proper open or closed positions and
that the fuel supply will be adequate. Check that atomizing mediums are
available, as necessary, for the start-up burners.
e. Check availability of thermocouples in representative locations to measure

tube metal temperature distribution across the superheaters in the
unheated zones near the outlet headers. Check availability of
thermocouples to measure steam drum metal temperature.
f. Close all access doors and observation ports after it is ascertained that no
one is inside the unit.
g. Place the steam generator vent and drain valves in the following positions:
Tag No. Description Position

11LBA70-AA307 ERV Isolation Open
11LBA70-AA306 Startup Vent Valve Isolation Open
11LBA70-AA201 Startup Vent Valve >15%
11HAD20-AA343 Drum Vent Root Valves Open
11HAD20-AA346
11HAD20-AA106 Drum Vent End Valves (Motor Open
11HAD20-AA107 Operated)
11HAD30-AA002 Drum Nitrogen Blanket Closed
11HAD30-AA001 Drum Riser Vent Root Valve Open
11HAD30-AA101 Drum Riser Vent End Valve (Motor Open
Operated)
3-5
(111455 Sec 3)
SECTION 3

11HAD20-AA341 Drum Pressure Gages Open
11HAD20-AA371
11HAD20-AA344
11HAD20-AA345
11HAD20-AA372
11HAD20-AA309 Drum Water Level Gage Shut-Off Open
11HAD20-AA310 (Lock Open)
11HAD20-AA311
11HAD20-AA312
11HAD20-AA319
11HAD20-AA320
11HAD20-AA321
11HAD20-AA322
11HAD20-AA357
11HAD20-AA358
11HAD20-AA359
11HAD20-AA360
11HAD20-AA355 Drum Water Level Gage and Closed
11HAD20-AA002 Electric Water Column Drains
11HAD20-AA327
11HAD20-AA333
11HAD20-AA331 Drum Chemical Feed Open
11HAD20-AA332
11HAD20-AA001 Drum Mass Blow-Off (Root Valve) Open
11HAD20-AA105 Drum Mass Blow-Off (End Valve) Closed
(Motor Operated)
11HAD20-AA010 Drum Continuous Blowdown (Root Open
Valve)
11HAD20-AA359 Drum Water Sampling Closed
11HAD20-AA351 Drum Remote Level Water Column Open
11HAD20-AA352 Shut-Off (Lock Open)
11HAD20-AA353
11HAD20-AA354
11HAD20-AA323
11HAD20-AA324
11HAD20-AA325
11HAD20-AA326
3-6
(111455 Sec 3)
SECTION 3

11HAD20-AA303 Drum Level Control Transmitter Shut- Open
11HAD20-AA304 Off
11HAD20-AA305
11HAD20-AA307
11HAD20-AA306
11HAD20-AA308
11HAD20-AA315
11HAD20-AA317
11HAD20-AA316
11HAD20-AA318
11HAD20-AA313 Drum Water Level Gage Temperature Open
11HAD20-AA314 Equalizer
11HAD20-AA329
11HAD20-AA330
11HAD30-AA003 Drum Steam Sampling Closed
11HAD30-AA004
11HAD30-AA005
11HAD30-AA006
11HAD30-AA007 Drum Steam Sampling Shut-Off Closed
11LCQ10-AA101 Drum Continuous Blowdown (End Closed
Valve)
11HAD10-AA004 Furnace Front Wall Header Drain Closed
11HAD10-AA005 Root Valves
11HAD10-AA102 Furnace Front Wall Header Drain End Closed
11HAD10-AA103 Valves (Motor Operated)
11HAD10-AA007 Furnace Rear Wall Header Drain Closed
Root Valve
11HAD10-AA106 Furnace Rear Wall Header Drain End Closed
Valve (Motor Operated)
11HAD10-AA003 Furnace RS & LS Wall Header Drain Closed
11HAD10-AA006 Root Valves
11HAD10-AA101 Furnace RS & LS Wall Header Drain Closed
11HAD10-AA104 End Valves (Motor Operated)
11HAH10-AA001 HRA Wall Drain Root Valves Open
11HAH10-AA002
11HAH10-AA005
11HAH10-AA102 HRA Wall Drain End Valves (Motor Open
11HAH10-AA103 Operated)
11HAH10-AA101
11HAH10-AA003 HRA Vent Root Valve Open
11HAH10-AA104 HRA Vent End Valve (Motor Open
Operated)
11HAH21-AA002 Primary Superheater Outlet Header Closed*
11HAH22-AA002 Pressure Connection (Before Spray)
3-7
(111455 Sec 3)
SECTION 3

11HAH21-AA302 Primary Superheater Pressure Open
11HAH22-AA302 Transmitter
11HAH21-AA301 Primary Superheater Outlet Manifold Open
11HAH22-AA301 Vent Root Valves
11HAH21-AA102 Primary Superheater Outlet Manifold Open
11HAH22-AA102 Vent End Valves (Motor Operated)
11HCB10-AA001 Sootblower Steam Shut-Off Open
11HAH21-AA003 Primary Superheater Inlet Manifold Open
11HAH22-AA003 Drain Root Valves
11HAH21-AA101 Primary Superheater Inlet Manifold Open
11HAH22–AA101 Drain End Valves (Motor Operated)
11HAH21-AA004 Primary Superheater Inlet Header Open
11HAH21-AA005 Vent Root Valves
11HAH21-AA006
11HAH22-AA004
11HAH22-AA005
11HAH22-AA006
11HAH21-AA104 Primary Superheater Inlet Header Open
11HAH21-AA105 Vent End Valves (Motor Operated)
11HAH21-AA106
11HAH22-AA104
11HAH22-AA105
11HAH22-AA106
11HAH30-AA001 Intermediate Superheater Inlet Open
11HAH30-AA002 Manifold Drain Root Valves
11HAH30-AA102 Manifold Drain End Valves (Motor
Operated)
Thru Header Vent Root Valves
11HAH30-AA014
Thru Header Vent End Valves (Motor
11HAH30-AA003 Intermediate Superheater Outlet Open
11HAH30-AA004 Manifold Vent Root Valves
11HAH30-AA103 Intermediate Superheater Outlet Open
11HAH30-AA104 Manifold Vent End Valves (Motor
Operated)
11HAH31-AA001 Finishing Superheater Inlet Vent Root Open
11HAH32-AA001 Valves
11HAH31-AA101 Finishing Superheater Inlet Vent End Open
11HAH32-AA101 Valves (Motor Operated)
11HAH40-AA001 Finishing Superheater Outlet Header Open
11HAH40-AA002 Drain Root Valves
3-8
(111455 Sec 3)
SECTION 3

11HAH40-AA101 Finishing Superheater Outlet Header Open
11HAH40-AA102 Drain End Valves (Motor Operated)
11LBA70-AA304 Main Steam ERV Pressure Switch Open
11LBA70-AA305 Shut-off
11LBA70-AA301 Main Steam Pressure Transmitter Open
11LBA70-AA302 Shut-Off
11LBA70-AA303 Main Steam Nitrogen Valve Closed
11LAB50-AA001 Feedwater Stop Valve Open
11LAB50-AA002 Boiler Fill Connection Closed
11LAB50-AA003
11LAB50-AA004 Feedwater Sample Valves Closed
11LAB50-AA005
11HAC10-AA001 Economizer Inlet Drain Root Valves Closed
11HAC10-AA002
11HAC10-AA101 Economizer Inlet Drain End Valves Closed
11HAC10-AA102 (Motor Operated)
11LAB50-AA301 Economizer Inlet Pressure Gage Open
11LAB50-AA302 Shut-Off
11HAC11-AA001 Economizer Vent Root Valves Open
11HAC12-AA001
11HAC11-AA101 Economizer Vent End Valves (Motor Open
11HAC12-AA101 Operated)
11LBC71-AA001 Reheater I Inlet Header Drain Root Open
11LBC71-AA002 Valves
11LBC71-AA101 Reheater I Inlet Header Drain End Open
11LBC71-AA102 Valves (Motor Operated)
11LBC72-AA001 Cold Reheat Drain Root Valve Open
11LBC72-AA101 Cold Reheat Drain End Valve (Motor Open
Operated)
11LBC71-AA201 Reheater I Inlet Control Valve Open
11LBC72-AA201 Reheater I Bypass Control Valve Closed
11LBC73-AA301 Reheater Outlet Pressure Transmitter Open
11LBC73-AA302 Isolation Valves
11LBC73-AA001 Reheater II Inlet Header Drain Root Open
11LBC73-AA002 Valve
11LBC73-AA101 Reheater II Inlet Header Drain End Open
11LBC73-AA102 Valve (Motor Operated)
11LBC73-AA002 Reheater I Outlet Vent Root Valve Closed
11LBC73-AA102 Reheater I Outlet Vent End Valve Closed
(Motor Operated)
11LBC73-AA003 Reheater II Outlet Vent Root Valve Closed
11LBC73-AA103 Reheater II Outlet Vent End Valve Closed
(Motor Operated)
11LAE11-AA001 First Stage Spray Inlet Shut-Off Open
11LAE12-AA001
3-9
(111455 Sec 3)
SECTION 3

11LAE11-AA202 First Stage Spray Control (Pneumatic Closed
11LAE12-AA202 Operated)
11LAE11-AA201 First Stage Spray Block (Pneumatic Closed
11LAE12-AA201 Operated)
11LAE11-AA002 First Stage Spray Outlet Shut-Off Open
11LAE12-AA002
11LAE11-AA003 First Stage Spray Drain Valves Closed
11LAE11-AA004
11LAE12-AA003
11LAE12-AA004
11LAE13-AA001 Second Stage Spray Inlet Shut-Off Open
11LAE14-AA001
11LAE13-AA201 Second Stage Spray Block Closed
11LAE14-AA201 (Pneumatic Operated)
11LAE13-AA202 Second Stage Spray Control Closed
11LAE14-AA202 (Pneumatic Operated)
11LAE13-AA002 Second Stage Spray Outlet Shut-Off Open
11LAE14-AA002
11LAE13-AA003 Second Stage Spray Drain Closed
11LAE13-AA004
11LAE14-AA003
11LAE14-AA004
11LAE20-AA001 Reheater Spray Inlet Shut-Off Open
11LAE20-AA201 Reheater Spray Block (Pneumatic Closed
Operated)
11LAE20-AA202 Reheater Spray Control Pneumatic Closed
Operated)
11LAE20-AA004 Reheater Spray Outlet Shut-Off Open
11LAE20-AA002 Reheater Spray Teltale Closed
11LAE20-AA003
* These valves may be open if permanently connected to pressure reading devices.
The initial open position of the drain valves will drain the primary
superheater, intermediate superheater,finishing superheater and heat
recovery area walls. These sections must be drained so that subsequent
flow of steam will not be blocked by water or condensate.
h. Fill the unit by admitting water to the economizer inlet header using water
from the regular feedwater source. The temperature of the water should
not be more than 200F above or below the temperature of the pressure
parts.
When air is vented from the economizer, close the economizer vent
valves, 11HAC11-AA101 and 11HAC12-AA101.
3-10
(111455 Sec 3)
SECTION 3
Fill the unit until water in the steam drum is just visible in the bottom of the
gage glass. Operate the water column and gage glass blowdown valves
to assure that water returns promptly in the gage glass when the valves
are closed.
i. Check that the remote water level indicators and steam drum pressure
gages are operating.
j. Check that lubricating and cooling systems for all drive units are as
specified by the manufacturer. See that cooling water is available as
necessary.
k. Check that all pressure and draft gages are calibrated and functioning
properly.
l. Check all safety interlocks for proper operation.
p. Check boiler steam drum doors and external valves, fittings and
connections for leaks. Any leaks found must be corrected before
proceeding with the startup.
q. The following operating sequence is recommended to insure a safe and

proper start-up. Modifications may be necessary as subsequent operating
experience dictates. Follow the manufacturer's instructions for operating
auxiliary equipment.
3.3.2 Start Fans and Adjust Flows
The fans are started in a set sequence for safe operation. The sequence for
starting the fans is ID fan, HP blower, SA fan and then PA fan. The ID fan is
started first to allow a negative draft to be put on the boiler. The HP Blower is
started next to fluidize the loop seal areas. The above grid air flow, SA and PA,
is established next by starting the SA fan and then the PA fan. The bed is
fluidized by the PA fan.
CAUTION
A CLEAR AIR FLOW PATH MUST BE MAINTAINED FROM

THE PA FAN INLET TO THE STACK DURING STARTUP OF
EACH FAN TO PREVENT POSITIVE OR NEGATIVE
PRESSURE DAMAGE TO THE FURNACE AND DUCTWORK.
a. Starting the Induced Draft Fan (by others)
Ensure DCS permissive to start all fans.
1. Verify an open gas path through the stack.
2. Verify open upper SA nozzle air flow controller, and lower PA nozzle
airflow controller, open greater than 25%
3-11
(111455 Sec 3)
SECTION 3
3. Verify ID fan startup criteria, and start ID fans in accordance with ID fan
instructions (by others).
4. Place ID fan controller in automatic with a furnace set point of -125 Pa (-

0.5” w.g.)
b. Starting the High Pressure Blower (by others)
1. Ensure the HP blower manual discharge valves and air distribution

valves on the loop seals are open.
2. Verify HP air isolation valves at the stripper cooler solids transfer lines
are open.
3. Verify manual valves at the loop seal nozzles are open and that the
isolation valves for the loop seal nozzle flow indicators are open.
4. Verify ID fan is running.
5. Verify HP blower startup criteria, and start HP blowers in accordance
with HP blower instructions (by others).
6. Verify the HP blower starts and verify line pressure, 11HHL12CP001,
increase pressure high enough to clear the low pressure trip switches,
11HHL12CP101 and 11HHL12CP102.
7. If necessary, adjust loop seal nozzle flow rates using the manual valves
and flow indications. These rates are set during commissioning and do
not normally require adjustment.
c. Starting the Secondary Air Fan (by others)
1. Place the SA fan inlet vane control at minimum position, 0%.
2. Place the SA nozzle air flow controller, 11HLB24CG001, and the PA

air flow controllers, 11HLB14CG001, 11HLB16CG001 and
11HLB18CG001 in the minimum flow position.
3. Verify HP blowers are running and pressure is adequate.
4. Verify ID fan is running.
5. Check furnace pressure and controller for proper operation.
7. Verify SA fan startup criteria, and start SA fans in accordance with SA
fan instructions (by others).
8. Adjust SA fan pressure control to about 2.49 KPa (10” w.g.) (to be field
verified) and put controller in automatic.
9. Adjust SA controller, 11HLB24CG001, to match the DCS-generated
set point with the actual measured air flow. When the minimum SA air
flow is made up, put flow control in automatic to the air master.
10. Place the secondary air heater steam coil (SCAH) air heater in service.
Be sure to vent system and pre-warm all piping. The averaged cold
3-12
(111455 Sec 3)
SECTION 3
end temperature set point can be adjusted a little higher than normal
during startup to help provide heat to the boiler. Once the bed
temperature approaches 260C (500 F), the set point can be adjusted
to its normal value. When the averaged cold end temperature is above
normal set point without using the SCAH remove it from service.
d. Starting the Primary Air Fan (by others)
When starting the PA fan, the DCS operator must know whether there is bed
in the combustion chamber or not. Without bed material, there is no
resistance to air flow through the grid nozzles. When bed material is in the
combustion chamber, windbox pressure must increase to a point where
there is enough pressure to force air up through the grid nozzles and flow
through the bed material.
3. Adjust the PA-to-windbox plenum dampers, 11HLB16CG001 and

11HLB17CG001 to about 25% open.
4. Verify SA fan is running.
5. Check furnace pressure. Adjust furnace pressure to -125 Pa (-0.5”
w.g.) if ID fan is still in manual mode.
6. Verify PA fan startup criteria, and start PA fans in accordance with PA
fan instructions (by others).
7. Adjust PA fan pressure control, using DCS pressure controller to the
function generated set point (to be field-verified) and put controller in
automatic.
8. If there is existing bed material in the furnace, slowly fluidize the bed
by increasing the PA-to-grid air flows, 11HLB16CG001 and
11HLB17CG001, in manual slightly higher than minimum. After the
bed has been fluidized (measured air flow indication), return PA-to-grid
air flow to minimum. Place PA air flow controls in automatic.
9. Adjust ID fan controller to control furnace pressure at -125 Pa (-0.5”
w.g.). When furnace pressure is stabilized, place ID fan controller in
auto.
10. Start the other PA fan in the same manner.
e. Air Flow Adjustment (if necessary)

Air flow set points are generated by function generator curves programmed
into the DCS (air master). Before an operator places any air flow controller
in automatic, the operator must first match the actual measured flow
indication value to the set point value. When both values are reading about
the same, the operator can place the controller in automatic.
1. Verify SA fan pressure controller in automatic and SA air flow control
dampers are in automatic. Adjust as required (to be field verified).
3-13
(111455 Sec 3)
SECTION 3
2. Verify PA fan pressure controller in automatic and PA air flow controls in

automatic.
f. Put Air Master in Service
3.3.3 Installing Bed Material
Startup bed material should be blown into the combustion chamber using a
lower combustion chamber connection, if possible. When available, saved bed
ash from the previous shutdown can be used to charge the bed.
1. Start feeding new bed material into the lower combustion chamber with all
the fans running. This can be done before or after purging the boiler.
NOTE
When installing bed material on a cold startup, it is

permissible to fire over bed burners at a very low firing
rate, only. Do not exceed a firing rate of 30% of the
burner maximum firing rate until indicated bed pressure is
at least 2.49 KPa (10” w.g.). A boiler purge must be
completed before starting the burners.
2. Check bed pressure indications. As bed volume increases, the bed

pressure indications will also increase.
3. Stop adding bed material to the combustion chamber when indicated bed
pressure transmitters, 11HBK10CP007 and 11HBK10CP009, reach 4.48-
5.48 KPa (18-22” w.g.). This will be equal to about 610-762mm (24-30”) of
static bed material if the fans were shut down and the bed slumped. Also
verify plenum (windbox) pressure as measured by 11HLB16CP001 and
11HLB16CP002.
3.3.4 Initiate Boiler Purge
In accordance with NFPA 85 Boiler and Combustion Systems Hazards Code,

the boiler must be purged before each cold startup or startup following an MFT
when the bed temperature is less than 760C (1400F), or when all solid fuel feed
trips with less than 649C (1200F) and no above bed burners are in service.
The boiler purge procedure and minimum permissives ensure a clear air and
gas flow path and enough air flow to carry away combustible gases.
1. Check all air flow indications to verify that the air flows are above the
requirement for purging.
2. Ensure all fuel streams to the boiler are shut-off.
3. Start the purge sequence timer in the DCS.
3-14
(111455 Sec 3)
SECTION 3
4. Ensure all purge interlocks and air flows are maintained above the minimum
purge airflow rate until the purge timer has timed out.
5. Verify the purge in progress indication goes out and the purge complete
indication comes on when the purge is complete.
3.3.5 Startup Burner Light-off
Sequence for light-off of the over bed startup burners (SUB’s) will include
adjusting air flows (if necessary). The Eight (8) SUB’s are by others. The
following procedures are general. See SUB documentation (by others) for detail
system information and procedures.
1. Open any manual burner inlet dampers.
2. Verify manual shut-off valves for oil and atomizing air at the main skid and
individual burner skids are open.
3. Verify the SUB’s are coupled and in place.
5. Verify burner start permissives are met.
6. Start the first SUB in accordance with the manufacturer’s instructions.
7. Put each of the remaining burners in service in the same manner.
8. Increase heat input to the burners to heat up the bed and increase the boiler
pressure.
CAUTION
TO PROTECT THE DRUM FROM UNDUE THERMAL

STRESS, THE METAL TEMPERATURE DIFFERENTIAL
BETWEEN THE TOP AND BOTTOM OF THE DRUM
SHOULD NOT EXCEED 111C (200F). MONITOR THIS
TEMPERATURE DIFFERENTIAL ON THE DRUM METAL
TEMPERATURE INDICATORS.
3.3.6 Boiler Warm-up
A slow gradual heating of the boiler will ease thermal stress on all boiler
pressure parts and refractory and allow the operator to complete the startup
process without having automatic shutdowns caused by too much heat input.
The speed at which a boiler is heated is referred to here as “heating rate”.
Foster Wheeler suggests that the starting heating rate be limited to a maximum
of 111C (200F) per hour change in the flue gas temperature measured at the
cyclone inlet thermocouples. This heating rate should be used during the first
three hours of startup.
3-15
(111455 Sec 3)
SECTION 3
Another heating rate used during startup, but not as accurate during the first
three hours, is the change in steam drum metal temperature. Thermocouples
on the top and bottom of the steam drum generate the average drum metal
temperature. The average metal temperature change of these thermocouples
should be limited to 111C (200F) per hour. The saturated steam temperature
change can also be used as an indication of steam drum temperature change
rate.
Foster Wheeler suggests a procedure to be used during startup that will help
reduce the occurrence of drum level trips from swelling of the water in the drum.
The initial drum level is established slightly lower than normal (about 51mm (-
2”)). As the boiler water expands, the mass blowdown, continuous blowdown
and downcommer bottle drains are used as necessary to eliminate the swell.
When the water level drops to about -51 to -102mm (-2 to -4 inches), close the
downcommer bottle drains. The water in the boiler will continue to swell.
Repeat this blowdown process as necessary.
During this process, the water in the economizer tubes will evaporate as that
portion of the boiler heats up. When and if feedwater has to be added to the
steam drum, it has to be slowly added slowly because the economizer section is
dry and hot. Feedwater added will immediately flash to steam and increase
pressure inside the steam drum. If feedwater is added too rapidly, the
increased pressure will drive the drum level down quickly.
1. Adjust the SUB firing rates to increase cyclone inlet flue gas temperature at
a rate of 111 C/hr (200 F/hr). An alternative is to increase the combustor
bed temperature at 28 to 55 C/hr (50 to 100 F/hr).
Steam generated during startup will condense and collect in the lower bends
of any superheater sections. This condensate will prevent cooling steam
flow through these tubes until the condensate is drained or boiled dry.
During startup superheater tubes with low or no steam flow will be at the bed
or flue gas temperature depending on location. This temperature must be
limited to the maximum design temperature of 487C (909F) until a minimum
of 10% steam flow is established through the boiler.
During the warm-up phase of this procedure, the boiler blowdown system
must be placed in operation. It is advisable to have the mass blowdown and
continuous blowdown open 100%. The downcommer bottle drains must be
closed, but available for use, as necessary. The feedwater system must be
available for makeup to the boiler.
2. Check the steam drum water level for swell. Use the mass blowdown and
continuous blowdown systems to help maintain steam drum water level and
to blowdown floating and suspended solids during startup.
3. Continuously check superheater metal temperature indications, on the DCS

during startup. If these indications exceed the high limit, the firing rate must
be reduced.
3-16
(111455 Sec 3)
SECTION 3
4. Check the temperatures around the combustion chamber, cyclone,

superheater, and airheater and assure the maximum recommended heating
rates are not exceeded.
NOTE
The following steps will be performed at the proper

pressures and temperatures, but not necessarily
performed in sequence.
5. Check steam drum pressure. When the pressure reaches 172 KPa (25
psig):
a. Close the steam drum vent valves,11HAD20-AA106, 11HAD20-AA107

and 11HAD30-AA101.
b. Close the following superheater vent valves:
11HAH10-AA104 HRA Vent End Valve

(Motor Operated)
11HAH21-AA102 Primary Superheater Vent
11HAH22-AA102 End Valve (Motor
11HAH22-AA104
11HAH30-AA103 Intermediate Superheater
11HAH30-AA104 Vent End Valve (Motor
11HAH30-AA005 Thru Operated)
11HAH30-AA014
11HAH31-AA101 Finishing Superheater Inlet
11HAH32-AA101 Vent End Valve (Motor
Operated)
c. Leave superheater and reheater drain valves open.
d. Check boiler water chemistry continuously.
6. Check the steam drum water level. Verify that the remote and local
steam drum water level indicators are the same.
7. Establish steam flow path (main steam line vent or electromatic relief valve).
Gradually increase steam flow.
8. Admit main steam to main steam line (turbine) for turbine starting and
loading as required by turbine manufacturer.
9. Continue to increase boiler firing rate as required to raise boiler operating

pressure and temperature according to the appropriate startup curve.
NOTE
3-17
(111455 Sec 3)
SECTION 3
Boiler load is increased in accordance with the demands and

limitations of the turbine bypass system, turbine and other plant
equipment. Foster Wheeler has supplied Harbin with necessary
information for the development of startup curves, but the final
curves are by Harbin.
3-18
(111455 Sec 3)
SECTION 3
10. At 100 psig, Close fully and then bump open approximately ½ turn the
following drain valves:
11HAH10-AA101 HRA Wall Drain End Valves

11HAH10-AA102 (Motor Operated)
11HAH10-AA103
11HAH21-AA101 Primary Superheaater Drain
11HAH22-AA101 End Valves (Motor Operated)
11HAH30-AA102 Drain End Valves (Motor
Operated)
11HAH40-AA101 Finishing Superheater Drain
11LBC72-AA101 Reheater Drain Valves (Motor
11LBC71-AA101 Operated)
11LBC71-AA102
11LBC73-AA101
11LBC73-AA102
11. Open the superheater spray water (desuperheater) supply manual isolation
valves , 11LAE11-AA001, 11LAE11-AA002, 11LAE12-AA001, 11LAE12-
AA002, 11LAE13-AA001, 11LAE13-AA002, 11LAE14-AA001 and 11LAE14-
AA002, if they are not already open and place the steam temperature
control system in automatic operation when outlet steam temperatures are
within 28C (50F) of the design operating temperatures.
NOTE
Maintain final outlet steam temperature at least 11C (20F) above

saturation temperature and steam flow at or slightly above 10%.
12. Check the boiler outlet steam flow as steam is admitted to the main steam
line.
13. Put the turbine bypass system (by others) into service.
14. Slowly close the startup valve, 11LBA70-AA201, while maintaining a

minimum 10% steam flow for superheater protection as steam use
increases.
NOTE
When the flow rate and pressure are sufficient for the turbine
bypass system (by others) to control boiler pressure the turbine
bypass system can be brought into service. This may be at less
than 10% flow.
3-19
(111455 Sec 3)
SECTION 3
15. Close the superheater and reheater drains completely when indicated steam
flow is greater than 10% of the boiler's rated steam flow (MCR).
11HAH10-AA101 HRA Wall Drain End Valves

11HAH10-AA102 (Motor Operated)
11HAH10-AA103
11HAH21-AA101 Primary Superheaater Drain
11HAH30-AA102 Drain End Valves (Motor
Operated)
11HAH40-AA101 Finishing Superheater Drain
11LBC72-AA101 Reheater Drain Valves (Motor
11LBC71-AA101 Operated)
11LBC71-AA102
11LBC73-AA101
11LBC73-AA102
16. Continue to close the startup valve while maintaining greater than 10%
steam flow until it is completely closed.
3.3.7 Increasing Load and Two Boiler Operation
Continue to increase boiler firing rate to reach initial conditions of steam

temperature, steam pressure and bed temperature according to the
limitations of the startup curve.
NOTE
Operate the boiler and turbine bypass system (by others) to

establish proper steam conditions for rolling and synchronizing
the steam turbine. If the companion boiler is in service, its load
must be held at or reduced to the matching steam conditions.
Maintain steam temperature above minimum superheat for
turbine operations according to turbine operating procedures if
applicable.
NOTE
Control the firing rate to maintain less than 111 C/hr (200 F/hr)
cyclone inlet gas temperature increase.
Each boiler and its associated bypass system should be operated in a manner
that establishes steam conditions suitable for rolling and synchronizing the
steam turbine. Additionally, the bypass system provides a means to start up
either boiler while raising the pressure and steam temperature of the second
3-20
(111455 Sec 3)
SECTION 3
boiler to match the pressure and temperature of the first boiler (which is already
providing steam to the turbine) and blend the two steam flows in a controlled
manner.
When two boilers are in operation their steam outputs do not have to be
maintained on an equal basis. Therefore, the reheat steam flows may or may
not be equal but should always be in proportion to the amount of main steam
generated in order to keep the energy input to a boiler in balance with the
energy removed. To aid in this endeavor, a steam flow balancing valve is
placed at the inlet to the individual boiler reheat systems. The control system
for these valves modulates the flow of reheat steam to a boiler so that it will be
equal to the amount of high pressure steam generated by that boiler corrected
by the ratio of total reheat steam flow to total main steam flow. To minimize the
pressure drop through the reheater, the control system modulates one valve at
a time (the boiler with the lower load) while maintaining the other at the 100%
open position.
Before bringing the second boiler on line it will be typically isolated via the
turbine main steam and reheat isolation valves. The boiler is then fired at a rate
matching its normal warm up curves until pressure and steam temperature
begin to approach conditions produced by the first boiler. This may or may not
include operation with the solid fuel system in service. The isolation valves can
then be opened so steam may begin to be blended with the operating boiler
supplying the turbine. This operation can be effectively carried out whether the
turbine controls are in manual or automatic (Inlet pressure Control (IPC).
3.3.8 Solid Fuel Firing
The solid fuel feed system is by others. This system should be put into service
in accordance with instructions from the solid fuel system supplier. Introducing
solid fuel to the boiler will increase temperatures and pressures very quickly.
Before starting any solid fuel firing, the boiler must be in stable controlled
conditions and there must be enough bed inventory present in the boiler to
support heat transfer and maintain the seal in the loop seals.
Foster Wheeler suggests putting some fresh limestone into the bed if there is a
need to slightly increase indicated bed pressure or when starting up with a new
bed. This is done by starting the limestone feed system (see Section 3.3.8)
before the solid fuel feed system. When bed temperature reaches the solid fuel
minimum temperature permissive, 595C (1103F) as indicated by the bed
temperature thermocouples (or depending on the ignition temperature of the
solid fuel), solid fuel firing can begin. Verify air flow to the fuel chute air bustles
and adjust flow rate, if necessary. Verify and take note of the amount of excess
oxygen in the flue gas, 11HNA10CQ001 and 11HNA10CQ002, before starting
the first solid fuel point. Start the fuel feeders in accordance with system
supplier’s instructions.
When starting the first solid fuel feed point, Foster Wheeler recommends that
the operator feed fuel for a maximum of 90 seconds and then stop the fuel feed
3-21
(111455 Sec 3)
SECTION 3
for a maximum of 90 seconds. During the stop time, verify that measured bed
temperature increases and measured excess oxygen in the flue gas decreases.
Seeing temperatures increase and oxygen decrease is proof positive that fuel
getting into the furnace is igniting and burning. Repeat the process again
verifying temperature increase and oxygen decrease. If the process proves
safe combustion of fuel, the fuel feed can be kept running in manual at the
minimum rate. Start the remaining solid fuel points in manual at minimum feed
rate. Only “burp” the first feeder to prove good combustion of fuel.
In addition to the dry coal feed system, there is a slurry fuel feed system (by
others). If slurry feeding is to be used, start the slurry feed system in
accordance with the supplier’s instructions. Slurry feed is limited to 20% by
weight of the solid fuel input. Dry solid fuel feeding should be started and bed
conditions stable before slurry is introduced.
When the solid fuel feeding is in operation, the operator must switch fuel
sources. The amount of fuel oil being fired should be decreased while
increasing the amount of solid fuel. This action will make solid fuel the
primary fuel and allow the operator to establish full solid fuel firing. Once fuel oil
use has been reduced to minimum, continue to increase solid fuel firing for
increase in heat input.
NOTE
Depending on operator responsibilities, the limestone and ash

removal systems can be put in service before firing solid fuel if it
helps in reducing startup complications, i.e., too much bed
material.
1. Slowly decrease the above bed burner firing rates while increasing the fuel
feed rate until the startup burners are at minimum firing rate.
2. Stop the startup burners at about 788-815C (1450-1500F) indicated bed

temperature, one at a time as bed temperature continues to increase. As
each burner is shut down, it needs to go through a purge cycle.
3. Adjust fuel feed rate manually, as necessary, to maintain bed temperature

rise. As the above bed burners are secured, place them in a standby
condition, ready for use as required.
4. Place Fuel Master in service with the following procedure:
a. Match individual feeder control outputs to the fuel master output.

b. Place feeder controllers in auto to the fuel master.
c. The fuel master will now follow the boiler master output if it is in
automatic.
3.3.9 Limestone Feeding System
There are two (2) separate feed systems (by others).
3-22
(111455 Sec 3)
SECTION 3
Place each limestone feed system in operation depending upon bed

requirements or emission limitations. Start the limestone feed system in
accordance with the system supplier’s instructions.
7. Adjust limestone flow to maintain demand signal based on solid fuel flow
and SO2 monitor.
8. Place limestone feeder controls in automatic when solid fuel feed and
limestone feed rates are above minimum and when boiler load is high
enough.
OPERATION OF THE SO2 TRIM CONTROLLER:
1) This control loop trims the solid fuel/limestone ratio signal to increase or
decrease limestone feed to match indicated measured SO2.
2) The main limestone feed demand signal is generated by multiplying

measured fuel flow by a known factor depending on the amount of sulfur in
the fuel.
3) Transfer controller from manual to auto.
3.3.10 Raise Boiler to Rated Conditions
Once boiler operation has become stable, the operator can place various
controls in service to help improve boiler efficiency. Continue to raise
temperatures and pressures shown on the boiler startup curve until all systems
have reached full operating temperatures and pressures with all controls in
automatic operation.
The most important of these is the control of excess oxygen in the flue gas. For
safety, there should always be more oxygen than is required. The CFB boiler is
designed to operate with an excess of oxygen, about 3.0 - 3.5% excess oxygen
measured in the flue gas. Oxygen optimization should only be considered when
the boiler load is greater than 60% MCR and load conditions are stable.
The second tool the operator has to improve boiler efficiency is the sootblowers
(by others). These cleaning devices sweep the ash from the heat transfer
surfaces in the HRA convection pass of the boiler. This improves or
reestablishes good heat transfer and allows for better use of the heat generated
by the boiler.
1. Place the bottom ash removal system (by others) in service when the bed
level and or pressure starts to increase above 4.5 - 5.5 kPa (18-22" w.c.).
2. Slowly close the boiler startup valve as boiler load continues to increase,
assuring a 10% minimum flow is maintained through the superheater. If
steam flow drops below 10%, the DCS activates safety control loops.
3-23
(111455 Sec 3)
SECTION 3
3. Check PA and SA indicated airflows. Watch for large variations in flow

indication to controller set points.
4. Place the feedwater control in automatic when necessary.
5. Place the excess oxygen controller in automatic when boiler load exceeds
60% MCR and at stable boiler load.
6. See Normal Operations for continued operation of boilers.
3-24
(111455 Sec 3)
SECTION 3
OPERATION OF THE Btu COMPENSATION CONTROLLER:
This control loop compares steam generated and the amount of solid
fuel it should take to generate that amount of steam. When the Btu
value of the solid fuel changes, this control loop will raise or lower the
solid fuel flow to compensate without making any change to the
airflow/fuel flow stoichiometric relationship.
OPERATION OF THE EXCESS O2 TRIM CONTROLLER:
1) This control loop compares expected excess O2 in the flue gas to

actual excess O2 based on boiler load as indicated by steam flow.
2) This controller should be left in manual at 50% output on the

controller until normal boiler operation has been established and
boiler load is greater than 60%.
3) The output from this controller will trim or change the amount of
secondary airflow.
4) Place controller in auto.
3-25
(111455 Sec 3)
SECTION 3
3.4 NORMAL OPERATIONS
This section provides general information and the basic guidelines for steady-state or
controlled load change operation of the Foster Wheeler CFB boiler. These instructions
should be used with your owner/operator plant-specific operating procedures.
Operating checks and adjustments are performed to maintain efficient operation of the
plant and prevent any unscheduled plant shutdowns.
The primary technique for changing boiler load involves varying fuel feed rate and the
corresponding airflow rate.
After reaching the desired steam flow rate, bed temperature should be reestablished at
the plant's normal bed temperature and boiler load held steady by adjusting the solid
fuel feed rate. Always make sure that air flow tracks solid fuel flow when in either
manual or automatic control, to maintain a set excess O2 value (greater than 3.0%).
3.4.1 Furnace and Emissions
1. Check SO2 emissions from the boiler. The limestone feed rate must be
adjusted, either manually or automatically, to maintain an SO2 emission
level at the stack that meets local regulations. Feeding limestone at
greater rates than required will negatively impact NOx production and
increase ash handling demands.
2. Check NOx emissions from the boiler. NOx emissions are inherently low
when the bed temperature operating range of 788-899C (1450 to 1650F)
is maintained. NOx emissions increase as bed temperature increases.
3. Verify proper fluidization of bed material and hot loop circulation. This is
accomplished by observing individual bed temperature and pressure and
flue gas temperatures throughout the hot loop, checking that temperatures
are consistent within the hot loop.
4. Check the gas-side temperatures to monitor the cleanliness of the heat

transfer surfaces. Use the sootblower system to remove any build up of
ash that might have accumulated.
5. Inspect the solid fuel feed and limestone feed systems for plugging or
bridging.
6. Check the bed pressure (fluidized bed material inventory) and maintain it
at its normal value.
7. Check the bottom ash removal system for proper operation. Check the
ash removal transport system for plugging periodically.
8. Check the accuracy and reading of the remote steam drum water level
indicators to assure they are reading the same as the local level gauges.
3-26
(111455 Sec 3)
SECTION 3
This should be done daily on new installations to assure plugging of the

level gauges does not occur.
9. Check the accuracy of all excess oxygen analyzers with test gas as often
as necessary. Routine maintenance on these analyzers will assure safe
boiler operation.
3.4.2 Water Chemistry and Steam Purity
1. Assure that the desired boiler water solids concentration and chemistry are
maintained. Improper boiler water chemistry can lead to fouling or
corrosion of internal surfaces, reducing the efficiency of the boiler and
possibly resulting in overheating of tubes leading to tube failure.
NOTE
Boiler chemical feed pumps are usually started when a

steady feedwater flow to the boiler is established and
stopped when the feedwater pumps are stopped.
2. Avoid large quantities of solids or the injection of water treatment

chemicals to the feedwater before the economizer.
3. Strict control of oxygen content and pH in the boiler water and feedwater
must be maintained daily.
4. Assure that steam purity is within maximum limits. For operation within
design conditions, the steam separator equipment in the steam drum will
keep solids carry-over within acceptable limits. Moisture carried over can
include solids and other impurities that may deposit on surfaces
downstream of the boiler.
5. Adjust the steam drum continuous blowdown valve in the continuous

blowdown system when solids carry-over is being caused by excessive
boiler water solids concentration. Always open the valve closest to the
steam drum (root block valve) first and then close it last to reduce wear on
the valve seats.
CAUTION
THESE LARGE VALVES SHOULD BE OPENED

SLOWLY. WHEN OPEN, BOILER INPUTS MUST
INCREASE TO MAINTAIN STEADY-STATE
CONDITIONS. TOO MUCH BLOWDOWN
REDUCES BOILER EFFICIENCY.
6. Determine the required frequency of blowdown by checking the boiler

water chemistry.
CAUTION
3-27
(111455 Sec 3)
SECTION 3
DRAIN VALVES ON THE LOWER WATERWALL

HEADERS SHOULD NOT BE USED FOR
BLOWDOWN PURPOSES WHEN THE BOILER IS
IN OPERATION. IMPROPER USE OF THESE
VALVES MAY INTERRUPT WATERWALL
CIRCULATION AND CAUSE TUBE FAILURE DUE
TO METAL OVERHEATING.
3.4.3 Attemperation
1. Check main steam temperature and attemperation spray water flow.

Verify that desuperheating does not lower the steam temperature to within
11C (20 F) of saturation temperature.
2. Verify a demand exists for attemperation (control of steam temperature).
3. Check that the controller responds to its setpoint slowly. Over-feeding

spray water can lead to excessive carry-over.
3.4.4 Routine Inspections (Operator Boiler Walkdowns)
Foster Wheeler recommends that an operator walk down the boiler at least once
every four hours. A routine should be established during plant walk-downs to
inspect the boiler and auxiliary systems and equipment.
1. Check rotating equipment (motors, fans, feeders, ash conveyors, etc.) for
proper lubrication, cooling and vibration levels.
2. Check sootblower steam supply piping. Thermal drains should be working

correctly to remove condensate.
3. Check pipe hangers and buckstay bumper pads for signs of expansion
problems that could put unusual stress on boiler components.
4. Check steam drum water level sight glasses, assuring they agree with
control room indications. Any leak should be fixed immediately.
5. Inspect flues, ducts and boiler casings for hot spots, discoloration, flue gas
smells and structural integrity.
6. Check the boiler for unusual noises or vibrations. Early detection of a

problem could reduce down time and repair time.
7. Check indicated settings of dampers and manually adjusted airflows.

Verify flows with control room operations.
8. Look for bed material/ash leaks. Small leaks soon become hot spots. Hot
3-28
(111455 Sec 3)
SECTION 3
spots require immediate attention. Most hot spots require a boiler

shutdown to repair the problem.
9. Check valves and piping for leaks at flanges and valve stems. Investigate
any standing pools of water or oil.
10. Keep burner areas clean. Safety first!
11. Inspect air drop nozzles. Check for overheating, bed material or flue gas
leaks.
12. Check flame pattern and color when the SUB’s are in service.
13 Check the ash levels in all the hoppers.
3.4.5 Bottom Ash Removal
The bottom ash removal system is by others. It should be operated in

accordance with supplier’s instructions.
3.4.6 Sootblowing
Initiate a sootblowing cycle when economizer exit flue gas temperature

increases 17C (30F) above normal or at least once every 24 hours to prevent
ESP/ash system overloading. The frequency of sootblowing is determined
during the initial operating period.
Before operating the sootblowers:
1. Initiate a cleaning cycle on the ESP and empty the fly ash hoppers.
Sootblowing can overload the fly ash system.
2. Verify that sootblower thermal drains are working.
3. Verify boiler load is above 50% of MCR.
4. Watch furnace pressure during the sootblower cleaning cycle.

Too much steam may cause furnace pressure to swing.
3.4.7 Flyash Reinjection
Flyash reinjection is used to minimize the amount of limestone that is required.

A rough estimate of the split between bottom ash and fly ash is 35% bottom ash
and 65% flyash. However, the only ash that gets reinjected is the flyash.
Recirculating the unreacted limestone in the flyash improves limestone
utilization.
The flyash reinjection feeder is set at a constant speed that is determined from
experience with the boiler operation. After stable operation is achieved, flyash
reinjection is started at a minimum flow rate and limestone consumption and
3-29
(111455 Sec 3)
SECTION 3
bed temperatures are observed. If limestone consumption is decreased, the

flyash reinjection can be increased in steps until there is no effect on limestone
consumption. If, however, bed temperature starts to decrease due to the better
heat transfer of the finer flyash particles, the rate of flyash injection should be
reduced. In this manner, an optimum rate of flyash reinjection is determined.
3-30
(111455 Sec 3)
SECTION 3
3.5 NORMAL SHUTDOWN
This section describes the basic steps to reduce boiler load from 100% output (MCR) to
cold shutdown staying within cool-down limits. It should not be used in place of a
detailed procedure for your own boiler as supplied by the owner/operator.
1. Reduce solid fuel and air input to reduce boiler load to about 50%. Normal bed
temperatures should be maintained.
NOTE
During shutdown, do not exceed a maximum temperature

differential of 111C (200F) between the steam drum top and
bottom metal temperatures or greater than 111 C/hr (200 F/hr)
temperature change in the flue gas temperature measured at the
cyclone inlets.
2. Place excess O2 trim controller in manual at 50% output.
3. Use the sootblowers to clean HRA convection pass before reducing load below
50%.
4. Check decreasing temperatures and maintain cooling rates.
5. Continue to slowly reduce boiler load down to minimum, reducing solid fuel feed
at 10% per minute or less to 816C (1500 F) bed temperature.
6. Maintain steam temperature at least 11C (20F) above saturation temperature

while decreasing load.
7. Place SUB’s in service when bed temperature is less than 760C (1400F).
Continue to reduce solid fuel feed to minimum.
8. Empty solid fuel feeder belts and limestone feeders and lines with bed
temperature above 649C (1200F).
9. Decrease SUB’s firing rate while staying within decreasing temperature limits of
111 C/hr (200 F/hr) combustion chamber gas temperature and 111 C/hr (200
F/hr) boiler metal temperature.
10. Place steam drum water level controller in manual, as necessary.
11. Stop the solid fuel and limestone feed to the boiler.
12. Maintain steam drum water level near the upper limit of the steam drum gage
glass visibility during shutdown.
13. Continue fluidizing the bed to cool the boiler at a maximum cooling rate of
111C//hr (200 F/hr) on the pressure parts or 111 C/hr (200 F/hr) change in hot
cyclone inlet temperature. Use the SUB’s to get the required rate of
3-31
(111455 Sec 3)
SECTION 3
temperature decline.
14. Stop the SUB’s below 454C (850F) bed temperature.
15. Continue air flow through the boiler in automatic until the desired bed
temperature is reached, at least 427C (800F), lower if needed for maintenance,
38C (100F).
16. Close the primary and secondary air fan inlet control dampers. The dampers
should be closed slowly permitting the ID fan automatic damper control to
maintain the furnace pressure between -125 and -250 Pa (-0.5 and -1.0"w.g.).
17. Stop all fans after the PA and SA fan inlet control dampers are completely
closed.
18. Close the ID fan inlet vanes.
19. Verify the high pressure blower stops 30 - 45 seconds after the ID fan stops.
20. Stop the chemical feed system and continuous blowdown system when the
boiler feed pump is stopped.
21. Continue to operate all ash removal transport systems (by others) until their
respective hoppers are empty.
22. Open all superheater and steam drum vents when the steam drum pressure has
decreased to about 62 kPa (25 psig) when the combustion chamber is to be
opened for maintenance.
NOTE
If the boiler is to be drained, draining can begin when steam drum

pressure has decayed to 37-62 kPa (15-25 psig). This pressure
will help "push" the water out a little faster. Check the drain
system and check for hammering. Boiler water should not
exceed 121C (250F).
23. Do not allow any idle boiler that is open to atmosphere to remain partially filled
with water for any length of time. Fill the boiler completely with deaerated
alkaline water with oxygen scavenger has been added as a protection against
corrosion.
24. Apply a 13 kPa (5 psig) nitrogen blanket to the steam drum through steam drum
nitrogen fill valve when steam drum pressure decays to 13 kPa (5 psig) when
the boiler is to be laid up wet.
25. If the outage will last several weeks or months or should weather prohibit filling
the boiler, drain and dry the boiler. Place shallow pans of unslaked lime or
several pans of silica gel in the steam drums to absorb moisture and maintain
the internal surfaces in a dry condition.
3-32
(111455 Sec 3)
SECTION 3
26. When the boiler is to be out of service for several days or longer, all ash, soot
deposits and bed material should be removed since moisture absorbed by these
materials causes corrosion.
27. Protect the boiler from freezing.
3-33
(111455 Sec 3)
SECTION 3
3.6 HOT SHUTDOWN
3.6.1 Planned – Bottling up the Boiler
The boiler can be shutdown for short periods and held in a “hot standby”
condition for approximately eight (8) hours.
When the bed is to be hot slumped, the solid fuel feed is stopped and the fuel in
the bed is allowed to burn out. When the excess O 2 indications in the flue gas
increases to double the normal full load reading (such as 3.5 to 7.0), the air flow
to the combustion chamber should be stopped to lessen bed heat loss by
stopping the ID fan. This O2 increase suggests most of the solid fuel in the bed
has been exhausted and the bed can be slumped without the formation of
clinker material in the bed.
The fans are then stopped. All fan inlet vanes and air control dampers are
closed to lessen the amount of heat lost. No fire is maintained or introduced
into the furnace. The pressure in the steam drum will decay after an initial slow,
gradual increase during the first one to two hours due to heat from boiler metals
and refractory equalizing with water/steam-side. Maintain normal water level in
the boiler steam drum.
NOTE
A hot condition is one in which the average bed temperature is

above 760C (1400F). When the average bed temperature is
below 760C (1400F), follow the Cold Startup Procedure. The
average bed temperature of a slumped bed must be read from
the lower set of bed thermocouples.
3.6.2 Unplanned
When the boiler is tripped from a load above minimum, where fans also stop,
slumping the bed, the boiler can:
1. Be restarted immediately following the hot restart guidelines, if practical.
OR
2. Remain down for "hot maintenance" without restarting fans until ready for
restart. In this case, the steam pressure increase during heat equalization
will be higher than during a planned hot shutdown.
3-34
(111455 Sec 3)
SECTION 3
3.7 HOT RESTART
To startup the boiler from a hot standby condition, proceed as follows:
1. Purge the boiler if the boiler tripped on an MFT. All steps should be accomplished
as quickly as possible to avoid reducing bed temperatures.
NOTE
On a hot restart following high load operation (above 80% MCR), it

is advised that superheater drains be blown down. This is done by
opening each drain valve and closing the drain valve, one at a
time. This is a precaution against condensate collecting in the
headers. Superheater vents are to remain closed.
2. Start SUB’s and heat the boiler following the normal startup guidelines.
3. Check bed temperatures. When ignition occurs, the bed temperatures will rise
and the normal solid fuel firing procedures can be followed.
NOTE
When the bed temperature does not rise within three (3) pulses
of feeding fuel, stop fuel feed to the boiler. Purge the boiler and
resume the normal startup procedures.
Remember, when bed temperatures fall below 595C (1103F) the

fuel feeder start permissive will be lost and the SUB’s must be
used to raise bed temperature above the 595C (1103F) fuel feed
permissive interlock.
If a fuel feeder trips with the bed temperature greater than 760C
(1400F), the SUB’s should be placed in service if required to
maintain bed temperature.
3-35
(111455 Sec 3)
SECTION 3
3.8 TRANSIENTS AND EMERGENCY OPERATIONS
This section discusses some, but not all, of the transients and emergencies that can
occur during operation of the CFB boiler. The information contained here is intended to
provide general information for you during such upsets. Transients are small problems.
Emergencies are large problems.
Read Foster Wheeler "Safety and Operating Precautions" section for special limits and
conditions that may occur during transient and emergency operations. This information
should not replace emergency or abnormal response procedures that are specific to
your plant.
3.8.1 Transients
3.8.1.1 High or Low Bed Temperatures
CAUTION
NEVER LET THE CYCLONE INLET

TEMPERATURES EXCEED 982C (1800F).
EXCESSIVE HEAT MAY DAMAGE REFRACTORY
OR TUBE METAL.
Check bed temperature thermocouples and associated instrumentation

for proper operation. If a problem is found, report it and have repairs
made when possible.
Check gravimetric solid fuel feeder for proper operation, leaking,

plugging, bridging and normal solid fuel feed rate. If a problem is
found, report it and have repairs made when possible.
Check for proper operation of all fans and blowers. Verify setpoint and
measured flow indications. If a problem is found, report it and have
repairs made when possible.
Check PA-to-grid, PA to plenum (windbox) air flows. Be sure of normal

air split between PA and SA airflow. If a problem is found, report it and
have repairs made when possible.
Check percent of excess air in the flue gas. Be sure of normal

operation of oxygen analyzers. Verify calibration. If a problem is
Check for proper steam drum water level. If necessary, blowdown

gage glasses. Verify normal operation of feedwater control valves. If a
problem is found, report it and have repairs made when possible.
Check ash removal systemfor proper operation. If a problem is found,

report it and have repairs made when possible.
3-36
(111455 Sec 3)
SECTION 3
Check combustion chamber bed pressure indications. Verify pressure

taps are not plugged. Verify normal airflows and pressure to
instruments. If a problem is found, report it and have repairs made
when possible.
Check for normal hot loop circulation temperatures. Check for

deviation in normal indications. Check the trend recording of bed
pressure for sudden changes. If a problem is found, report it and have
3.8.1.2 High or Low Startup Burner Fuel Supply Pressure
Check fuel supply system for normal operation. Verify system piping
integrity. Check strainers for plugging. Check for leaks. If a problem
is found, report it and have repairs made when possible.
3.8.1.3 High or Low Bed Inventory
CAUTION
DO NOT OPERATE A FOSTER WHEELER CFB

BOILER WITHOUT ENOUGH BED MATERIAL IN
THE COMBUSTION CHAMBER TO SUPPORT
HEAT TRANSFER. IF BED INVENTORY
DECREASES BELOW A PRESET VALUE 0F 8.87
KPa (35"W.C.), AS INDICATED BY WINDBOX
PRESSURE, ALL SOLID FUEL FEED WILL STOP.
Check that bed pressure taps are not plugged. Verify normal airflow
and pressure to all instruments. If a problem is found, report it and
Check bed inventory transmitters and associated instruments for

normal operation. If a problem is found, report it and have repairs
made when possible.
Check for proper operation of all fans and blowers. If a problem is

Check for normal indication of pressures at windbox and grid. Verify

air tight integrity of ductwork. If a problem is found, report it and have
Check bed ash removal system for proper operation. Verify bed
material is being conveyed out of the combustion chamber. If a
Check for normal operation of limestone feed system. Verify normal

discharge pressure and temperature of blower. Verify that all feed
lines are warm (not plugged). If a problem is found, report it and have
3-37
(111455 Sec 3)
SECTION 3
Check for normal solid fuel feed rates for the indicated boiler load.
Verify that solid fuel feeders are performing normally. If a problem is
3.8.1.4 High or Low Steam Drum Water Level
CAUTION
NEVER OPERATE (FIRE) ANY BOILER WITHOUT

A VISIBLE WATER LEVEL IN THE BOILER
STEAM DRUM.
Check for proper operation of all steam drum instruments. Blowdown

gage glasses. Verify proper level by comparing local and remote water
level indications. If a problem is found, report it and have repairs made
when possible.
Check for normal operation and line up of boiler feed pumps and
associated piping. Verify water level in deaerator. If a problem is
Check for normal operation of all feedwater control valves and line up
of piping. Verify instrument air to all controllers is normal and free of
moisture. If a problem is found, report it and have repairs made when
possible.
Check for normal operation of all steam flow and feedwater flow
transmitters. Verify valve line up. If a problem is found, report it and
Check for evidence of a boiler tube failure. If a tube failure has

occurred, make the necessary repairs.
Check for normal drain valve line up. Verify piping after the last block
valve on each system is not hot suggesting a leaking valve. If a
3.8.1.5 Intermittent Loss of Bed Material from Circulation

(Loop seal surging or change in the rate of circulation of bed material
in the hot loop)
Check for proper and normal fluidizing airflow to all loop seal fluidizing
nozzles. If there is no flow indication, it is an indication of a plugged
nozzle. Applying service air to that nozzle may be necessary to unplug
that nozzle and reestablish fluidizing airflow. Too much fluidizing
airflow for an extended period can interfere with normal circulation. If a
3-38
(111455 Sec 3)
SECTION 3
Check for normal operation and normal discharge pressure from high
pressure blowers. Verify that HP blower inlet filter is not plugged. If a
Check for normal indications of bed inventory. See section 3.8.1.3

above.
Check for normal operation of all fans. Check airflow indications. If a

3.8.1.6 Continuous, Gradual Loss of bed Inventory from Circulation
Check operation of bottom ash removal system. Verify normal

operation and conditions of bottom ash removal system. If a problem
is found, report it and have repairs made when possible.
Check for gas-tight integrity of combustion chamber. Walk-down the

boiler looking for bed material or gas leaks. If a problem is found,
report it and have repairs made when possible.
Check for tube leak in bed area.
3.8.2 Emergency Situations
3.8.2.1 Sudden Loss of Steam Drum Water Level
When the cause is known and immediately correctable before the

water level in the steam drum reaches the minimum allowable
operating level, reestablish steam drum water level to its normal
operating value and continue boiler operation.
When the cause is not known and the water level in the steam drum
drops below the minimum allowable operating level (this situation could
be the result of a tube failure), start an immediate shutdown according
to the emergency shutdown section of this procedure.
3.8.2.2 Gradual Loss of Steam Drum Water Level
When a normal steam drum water level cannot be maintained, the load
on the boiler must be reduced and the cause of the problem corrected.
When it is impossible to maintain normal steam drum water level at the

reduced load, then the boiler must be taken out of service according to
the normal shutdown procedure until the cause(s) can be identified and
corrected.
3.8.2.3 Excessive Bed Temperature
When the bed temperature cannot be maintained below 954C (1750F),

an immediate adjustment in the airflow distribution must be started.
3-39
(111455 Sec 3)
SECTION 3
Normally, increasing the primary airflow to the grid and an equal

reduction in secondary airflow will accomplish this.
A reduction in fuel feed and/or an increase in total airflow may be

required to control high temperatures. This reduces the bed
temperature rapidly to reduce the high temperature that, if allowed to
continue, may reach the ash fusion temperature for the fuel being
burned. If the bed temperature cannot be controlled using the above
procedure, the boiler must be shutdown. A MFT will occur if the
average bed temperature and 18 of 22 bed thermocouples are above
960C (1760F)
3.8.2.4 Loss of Regenerative Air Heater Rotation Because of Binding
The regenerative air heater is by others. The following information is to

supplement instructions provided by the air heater supplier. In the
event of discrepancies, follow the instructions provided by the air
heater supplier.
WARNING
STOPPAGE OF ROTATION CAN BE CAUSED BY A FIRE

IN THE AIR HEATER. IF DUCT IS NOT UNDER POSITIVE
PRESSURE, CAUTIOUSLY OPEN A DOOR IN THE GAS
INLET OF THE AIR HEATER. FIRE RESISTANT
PROTECTIVE CLOTHING, GLOVES AND A FACE SHIELD
SHOULD BE WORN DURING THIS INSPECTION. IF
THERE IS NO INDICATION OF A FIRE, CONTINUE TO
ADMIT AMBIENT AIR THROUGH THE OPEN DOOR, AND
OTHERS IF AVAILABLE, TO COOL THE AIR HEATER
SUFFICIENTLY TO MAKE ROTATION POSSIBLE. THE
AIR MOTOR IS MORE POWERFUL FOR TURNING THE
AIR HEATER ROTOR THAN THE ELECTRIC MOTOR. IF
FIRE IS DETECTED IN THE AIR HEATER WHEN THE
DOOR IS OPENED, IMMEDIATELY FOLLOW THE
INSTRUCTIONS IN 3.8.2.5 "AIR HEATER FIRE".
3.8.2.5 Air Heater Fire
The regenerative air heater is by others. The following information is to

supplement instructions provided by the air heater supplier. In the
event of discrepancies, follow the instructions provided by the air
heater supplier.
CAUTION
AN AIR HEATER FIRE STARTS AS A SOOT AND/OR OIL

DEPOSIT FIRE. IF IT IS NOT EXTINGUISHED
IMMEDIATELY, THE METAL PARTS, PARTICULARLY
3-40
(111455 Sec 3)
SECTION 3
THE BASKETS, IGNITE. AS A METAL FIRE, IT CANNOT

BE EXTINGUISHED BY SMOTHERING. AT THIS STAGE,
IT MUST BE EXTINGUISHED BY WATER QUENCHING TO
REDUCE THE TEMPERATURE OF THE BURNING METAL
BELOW THE IGNITION TEMPERATURE. THIS IS BEST
ACCOMPLISHED BY APPLYING LARGE QUANTITIES OF
WATER. FOR THIS PURPOSE, THE AIR HEATER MUST
HAVE AN ADEQUATE WATER SUPPLY AVAILABLE FOR
CONNECTION TO THE INTERNAL DELUGE SYSTEM, IF
PROVIDED, OR TO LOCAL FIRE NOZZLES. THE
CONNECTIONS SHOULD BE OF THE QUICK-CONNECT
TYPE AND ARE IN ADDITION TO THE AIR HEATER
WATER WASH SYSTEM. PROVISIONS FOR DRAINAGE
OF THESE LARGE QUANTITIES OF WATER MUST BE
MADE AT SUITABLE LOCATIONS IN THE CONNECTING
FLUES AND DUCTS. ALL DRAINS MUST BE OPEN
BEFORE ALLOWING WATER TO ENTER THE AIR
HEATER.
THIS SYSTEM SHOULD BE BROUGHT INTO FULL

OPERATION AT THE FIRST SIGN OF AN AIR HEATER
FIRE AS INDICATED BY ABNORMAL AIR OR GAS
TEMPERATURES, OBSERVATION, HOT SPOTS OR BY A
FIRE DETECTION SYSTEM.
(1) Isolate the air heater

(2) Open all drains
(3) Admit the deluge water
CAUTION
DRAINS SHOULD BE PROVIDED FOR AIR HEATER

HOPPER, FAN HOUSINGS, DUCTS AND ANY OTHER
ADJACENT EQUIPMENT THAT COULD BE AFFECTED.
3-41
(111455 Sec 3)
SECTION 3
3.9 EMERGENCY SHUTDOWNS
3.9.1 Steam Drum Water Level Cannot Be Maintained
Remove boiler from service immediately by following Normal Shutdown or

Emergency Shutdown Procedure, as the situation dictates. Remove bed
material during this shutdown as quickly as possible from the boiler.
3.9.2 Sudden Loss of Steam Drum Water Level
NOTE
This procedure should also be followed on a loss of feedwater

supply.
1. An automatic MFT will occur on low-low steam drum water level. The
primary air fan will go to minimum flow condition. The secondary air fan
will also go to manual and drive the dampers to minimum position.
2. Cool the boiler to allow bed material removal and boiler inspection.
CAUTION
WET BED MATERIAL CAN SOLIDIFY AND COULD

CAUSE METAL CORROSION IN THE BOILER AND
SHOULD BE REMOVED AS QUICKLY AS POSSIBLE.
3.9.3 Air-Side or Gas-side Failures
This procedure should be followed on a primary air fan, secondary air fan and/or
induced draft fan mechanical failure and the fan motor continues to run.
1. An MFT is started by a drop in airflow. A fan failure shuts off the fuel feed,
limestone feed and the bed material removal.
2. Fans and drives are interlocked to stop in the sequence below:
1) Primary Air Fan Motor

2) Secondary Air Fan Motor
3) Induced Draft Fan Motor
4) High Pressure Blower Motor
A trip of the ID fan will stop the primary air fan, then the secondary air fan.
3. Maintain normal steam drum water level.
4. Following control of the emergency situation, use the normal shutdown

procedure. After correcting the reason for the emergency shutdown, a
3-42
(111455 Sec 3)
SECTION 3
normal restart or hot restart, as applicable, can be initiated.
3.9.4 Loss of Service
Loss of service of the following equipment will initiate an immediate automatic

boiler shutdown according to the emergency shutdown.
a. Primary air fan not running.
b. Secondary air fan not running.
c. Loop seal header pressure less than minimum.
d. Induced draft fan not running.
3.9.5 Rapid Loss of Bed Inventory From Circulation
Check for rapid increase in airflow.
Check for rapid increase in flue gas temperature combined with airflow increase.
Check HP air pressure.
Check HP airflow rate to loop seal nozzles.
NOTE
If bed material loss persists, there may be a restriction in the loop

seal or cyclone downcomer from refractory failure or solids build
up which would require an internal inspection and possible repair.
3.9.6 Loss of Fluidizing Air to Loop Seal
The loop seals should not require manual cleaning before a boiler restart
following a trip of the boiler and/or loss of the HP blower. Based on operating
experience, when there was difficulty of refluidizing the bed material in the loop
seals following an uncontrolled trip, service air was introduced at the nozzles.
All the nozzles have been designed with provisions for service air connection.
Although unlikely, if refluidization is not achieved, the following recommended

restart sequence should be followed.
Restart the ID fan.
Restart the HP blower.
Observe all loop seal flow indications for proper airflow. Blow out any nozzles
that are low in flow rate using service air.
3-43
(111455 Sec 3)
SECTION 3
Restart SA and PA fans and establish normal airflows.
Re-fire boiler and carefully observe bed pressure for normal operation. (The
bed pressure should drop only a few inches when increasing boiler load from
minimum to full load.)
Observe loop seal downcomer differential pressure. If this pressure rises above
normal level, it may indicate a loss of flow through the loop seal. Also observe
loop seal downcomer temperatures. If this temperature drops from normal
levels it may indicate loss of fluidization in the loop seal. If either condition
occurs, use service air on the loop seal nozzles to try to refluidize the loop seal.
If bed pressure drops rapidly during a load increase or earlier, then apply the
same technique of using service air until the loop seal(s) breaks free.
If this approach does not work, then it will be necessary to shutdown the boiler
and drain the loop seals.
3-44
(111455 Sec 3)
SECTION 3
3.10 LEAK DETECTION
Early detection of boiler pressure part leaks will prevent further damage to adjacent
pressure parts and circuits. Depending on the location of the leak, audible indication
and visibility may not be possible on a Foster Wheeler CFB boiler. However, other
process indications can be used as evidence of a pressure part leak.
The chart below outlines some locations and the possible indications.
ECONOMIZER COMBUSTION CONVECTION IN-FURNACE

CHAMBER CAGE & SH SUPERHEATERS
Steam flow, Steam flow, Steam flow, Steam flow,
feedwater flow split feedwater flow split feedwater flow split feedwater flow split
Water in air heater Reduction of bottom Reduction of bottom
hopper. Difficulty ash production ash production
pulling fly ash
Possible noise in Seldom able to Able to detect noise Seldom able to
back pass detect any noise in convection cage detect any noise
No change in Decreased cyclone No change in Decreased cyclone
cyclone inlet inlet temperatures cyclone inlet inlet temperatures
temperature temperature
No process effects Furnace pressure, Little or no process Furnace pressure
detected drum level upset at effect may be upset at
onset of major leak onset of major leak
No effect on spray No effect on spray Spray water may be Spray water may be
water water slightly effected slightly effected
ID fan, dust collector ID fan, dust collector ID fan, dust collector ID fan, dust collector
seldom affected seldom affected seldom affected seldom affected
Recommendations:
1. Develop a steam flow, feedwater flow, drum level trend that operates
continuously.
2. Walk the boiler down regularly listening for unusual noises.
3. Shut down the boiler as soon as possible when a tube leak is suspected.
4. Remove bed material during the shutdown process.
5. Once the boiler is down, remove wet bed material immediately before it sets up.
A method of leak detection commonly used on any type of boiler is a chart or trend set
3-45
(111455 Sec 3)
SECTION 3
up that includes feedwater flow and steam flow. Whether the two lines on the chart line
up or agree is not important. What is important is the relative separation between the
two displays. Obviously, a tube leak will eventually show up as increase in feedwater
flow without an increase in steam flow.
The next method is to monitor carefully process parameters. You must have a display
with the boiler temperature profile available upon demand. One of the features of the
CFB process is that it is sensitive to the presence of furnace leaks. The process may
show the presence of a leak with much smaller flows than a typical feedwater/steam
flow comparison.
For example, the first indication may be that the bottom ash removal rate will decrease.
You may then begin increasing the limestone feed rate to maintain indicated bed
pressure.
The second factor may be that the cyclone inlet temperatures may start to drop. Bed
temperatures will remain constant while the cyclone temperatures drop. This
information, in conjunction with the bed loss, may confirm the presence of a tube leak.
Bed material loss in this case is caused by excessive velocity through the cyclones that
results in greatly increased bypassing of the cyclones. The lower cyclone flue gas
temperatures occur because furnace gas velocity may increase, resulting in an
increase in heat transfer. Superheater spray flows may increase due to the higher
HRA convection pass gas velocity and other factors.
Economizer and HRA convection pass superheater leaks are more difficult to find
because they will not affect the process. Economizer leaks may eventually show up as
water in either the ash hopper or baghouse but superheater leaks will not.
It is very important to detect any leak as soon as possible. The longer any leak
remains undetected, the more damage that leak will cause.
3-46
(111455 Sec 3)
SECTION 3
3.11 THERMAL CYCLING
Thermal cycling in a CFB is defined as any cycle of temperature within the hot loop
system from the standard operating temperature (about 871C [1600F]) to a
temperature of 371C (700F), as measured by the bed temperature and cyclone
inlet/cyclone flue gas temperatures, below the standard operating temperature and
subsequent return to the standard operating temperature, or a drop in the steam/water-
side pressure that results in greater than 139C (250F) change in the steam/water-side
saturation temperature. During these changes in temperature, considerable expansion
and contraction of linings, tubes, refractory, casing, etc. occurs. To lessen the potential
damage that can be caused by thermal cycling, you must minimize the number of
cycles and the rate of temperature change during a cycle.
The following are suggestions to reduce the effects of thermal cycling:
1. During a shutdown, do not allow the steam/water-side pressure to decay quickly.

Allow the steam-side pressure to decay naturally by keeping the boiler "bottled
up."
2. In addition, try to reduce any rapid temperature declines (cool-down) caused by

the air and gas flows.
3. If possible, minimize the number of thermal cycles to eight (8) times a year with an
additional eight (8) times during an initial startup phase.
4. See Section 2.1.3 for allowable increases in boiler metal temperatures versus
time during a startup phase.
3-47
(111455 Sec 3)
SECTION 3
3.12 SAND ANALYSIS
The sand should be clean, natural feldspar-type sand that is round, uncrushed,
washed, dry and double-screened. This kind of sand is normally used in foundries.
Minimize alkali metal content.
The following is a typical sand analysis:
percent
SiO2 70 - 85
Al2O3 5 - 15
Fe2O3 1-5
CaO 0.5 - 2.0
Na2O 1.0 - 2.0
K2O 2.0 - 3.0
Moisture 0.0 - 1.0
Note that pure quartz sand is not acceptable.
The recommended sand size distribution is:
100% less than 600 microns

Sand Flow Rate: 200 - 2,000 lb/hr

Bulk Density: 90 lb/ft3
Angle of repose: 40 °
3-48
(111455 Sec 3)

111455-O&M-Manual (Sec 3)

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OPERATION AND MAINTENANCE MANUAL

OPERATION AND MAINTENANCE

a. Exposure to excessive negative or positive pressures can result in serious

Section Location of Maximum Maximum

f. To prevent plugging, rusting, oxidation and faulty operation of equipment, service

h. Carbon monoxide (CO) should be monitored continuously during operation of the

i. It is strongly recommended that the reliability of all drum level indicators be

j. On commonly operated valves, such as superheater drains and vents, care

Condition/Situation Status Type of Trip

3.3 START-UP PROCEDURE

3.3.1 Preparation Prior to Start-Up

e. Check availability of thermocouples in representative locations to measure

Tag No. Description Position

Tag No. Description Position

Tag No. Description Position

Tag No. Description Position

Tag No. Description Position

Tag No. Description Position

* These valves may be open if permanently connected to pressure reading devices.

l. Check all safety interlocks for proper operation.

q. The following operating sequence is recommended to insure a safe and

3.3.2 Start Fans and Adjust Flows

A CLEAR AIR FLOW PATH MUST BE MAINTAINED FROM

a. Starting the Induced Draft Fan (by others)

Ensure DCS permissive to start all fans.

1. Verify an open gas path through the stack.

4. Place ID fan controller in automatic with a furnace set point of -125 Pa (-

b. Starting the High Pressure Blower (by others)

1. Ensure the HP blower manual discharge valves and air distribution

c. Starting the Secondary Air Fan (by others)

1. Place the SA fan inlet vane control at minimum position, 0%.

2. Place the SA nozzle air flow controller, 11HLB24CG001, and the PA

d. Starting the Primary Air Fan (by others)

3. Adjust the PA-to-windbox plenum dampers, 11HLB16CG001 and

e. Air Flow Adjustment (if necessary)

2. Verify PA fan pressure controller in automatic and PA air flow controls in

3.3.3 Installing Bed Material

When installing bed material on a cold startup, it is

2. Check bed pressure indications. As bed volume increases, the bed

3.3.4 Initiate Boiler Purge

In accordance with NFPA 85 Boiler and Combustion Systems Hazards Code,

2. Ensure all fuel streams to the boiler are shut-off.

3. Start the purge sequence timer in the DCS.

3.3.5 Startup Burner Light-off

1. Open any manual burner inlet dampers.

3. Verify the SUB’s are coupled and in place.

5. Verify burner start permissives are met.

6. Start the first SUB in accordance with the manufacturer’s instructions.

7. Put each of the remaining burners in service in the same manner.

TO PROTECT THE DRUM FROM UNDUE THERMAL

3.3.6 Boiler Warm-up

3. Continuously check superheater metal temperature indications, on the DCS

4. Check the temperatures around the combustion chamber, cyclone,

The following steps will be performed at the proper

a. Close the steam drum vent valves,11HAD20-AA106, 11HAD20-AA107

b. Close the following superheater vent valves:

11HAH10-AA104 HRA Vent End Valve

c. Leave superheater and reheater drain valves open.

d. Check boiler water chemistry continuously.

9. Continue to increase boiler firing rate as required to raise boiler operating

Boiler load is increased in accordance with the demands and

11HAH10-AA101 HRA Wall Drain End Valves