National Workshop on Efficient Operation and Maintenance of Boilers organized by National Productivity Council

at Visakhapatnam (AP)
Presented By: Vikas shrivastava & Akhilesh Tiwari under guidance of Mr. R N Yadav and Mr. A K Saxena
From JAYPEE SIDHI CEMENT PLANT, SIDHI, MP
EFFICIENT AND SAFE OPERATION OF BOILERS AND PREVENTION OF BOILER EXPLOSION
BY JAYPEE SIDHI CEMENT PLANT, SIDHI (M.P.)
PARAMETERS REQUIRED TO BE MAINTAINED STRICTLY FOR EFFICIENT OPERATION OF AFBC
BOILERS
ght/FD Air Pressure

BED HEIGHT/FD AIR PRESSURE

to 325 mm during initial light up of boiler.
500 mmwc to 600 mmwc.

of bed coils & low W.B. stops fluidization.

PRIMARY AIR PRESSURE
maintained 1000 to 1150 mmwc.
pressure is to be maintained approximately 500mmwc.
essure increases the bed coil erosion and carryover to enhance secondary combustion.
BED TEMPERATURE/FURNACE TEMPERATURE FOR AFBC/CFBC
Depends upon the type of fuel & firing method.

e fuel 800 to 850 Deg.C.

FUEL SIZE
firing with Indian/Imported coal following sizes are to strictly maintained as it will affect on performance of boiler.
Size: 0 to 8 mm
Less than 1 mm not allowed more than 20%.
Distribution: 1 to 5 mm 70%
5 to 8 mm -20%
0 to 1 mm 10%
NOTE: Lower the size of coal, higher the unburnt in fly ash, higher the size of coal, higher the erosion of bed coils and
blockage of fuel air pipe & clinkerization in boiler.
For STOKER FIRED BOILERS Size: 5 to 25 mm
Less than 5 mm not allowed more than 5%
Distribution: 5 mm to 15 mm-25%
15 mm to 25 mm-70%
0 mm to 5 mm -5%
NOTE: Lower the size of coal higher unburnt in fly ash & carryover through boiler.
PULVARIZED FIRED BOILERS
Pulverized coal size: mesh powder

m) and, for a bituminous coal

Size Distribution: 2% is +300 micro metre (m)

70-75% is below 75 microns
20% is about 75-100 microns
NOTE: Higher the size of pulverized coal below 100 mesh results unburnt in bottom ash.
BED MATERIAL SIZE & SPECIFICATION
o 2.36 mm
Distribution : 0.85 mm to 1.00 mm 10%
1.00 mm to 1.50 mm - 50%
1.5 mm to 2.36 mm - 40 %

Crushed fire bricks castables IS8 grade bricks or river silica sand
Fusion Temp. 1300 Deg.C Shape: Spherical Angular
Bulk Density 1050 Kg/M3 Silica : 65%
Al2O3 28% Fe2O3: 1.05%
PbO2 1.67 % MnO : Trace
MgO 0.23 % P2O5: 0.08 %
V2O 0.22 % K2O : 0.45 %
AIR TO FUEL RATIO

Theoretical Air Required: 4.31(8/3C+8(H-O/8)+S) Kg/Kg of fuel burnt.

To understand the basics of efficient boiler Operation, the combustion process must be understood. Stable combustion
Condition requires the right amount of fuels and Oxygen, combustion products are heat energy,CO2,water vapour,N2,Sox,Nox
and O2. In theory there is a specific amount of O2 needed to completely burn a given amount of fuel. In practice, burning
conditions are never ideal, Therefore excess air must be supplied to burn the fuel completely depending upon the type of fuel.
TYPICAL EXCESS AIR TO ACHIEVE HIGHEST EFFICIENCY FOR DIFFERENT FUELS
(Coal) boilers normally run about 15 to 20 %.

n about 10 to 15%.
OXYGEN AT BOILER OUTLET

probability of combustion of all fuels.

- O2% )x100

-.
of the combustion efficiency.
BOILER EMERGENCIES
a special emphasis on the safety aspect like boiler protection systems
controls and interlocks.
-low.
-high.
-high.
High.

ailure.

DRUM LEVEL LOW AND LOW-LOW

(sudden redn in load)

 level is within safe limit otherwise allow boiler to trip when the water level goes low-low limit to
protect the boiler pressure parts.
DRUM LEVEL HIGH AND HIGH-HIGH

increase in firing rate.

thrust pads.

rum level within safe limit and control the FCV.

TG.

FURNACE DRAUGHT HIGH AND

HIGH HIGH

furnace pressure.

it on manual mode and maintain furnace in suction.

trip on furnace draught high-high.
BED TEMP. HIGH
 failure.

trip to avoid clinker formation.

BED TEMP. LOW

r /screen/evaporator tube leakage.

running.

WATER WALL/SCREEN
TUBE/EVAPORATOR TUBE FAILURE

fluctuating draught.
 noticed and maintain the drum level.
SUPER HEATER TUBE FAILURE

quate steam flow and high gas temp. during hot start-up.

FW consumption than steam..

S.H. leakage noticed.

HIGH SUPER HEATER TEMP.

/load.

+ve turbine expansion.

y control.
LOW SUPER HEATER TEMP

ve.
stresses in S.H.

FLAME FAILURE

nace pressure high.

rge the boiler putting burner back and purge burner as per cycle time( minimum 5 minutes).

the healthiness of explosion vent & door.

FURNACE EXPLOSIONS

start-up of boiler.
 damage.

about 5 minutes. No cut short in purging allowed.

BOILER PRESSURE HIGH

e/prime mover trips.

nput & drum level.

lift.

of spring loaded safety valve.

PAH/SAH TUBE FAILURE

that tubes.
COAL FEEDER FAILURE
E:
 level.

the spray CV.

BOILER FEED PUMP FAILURE

level low.

maintain the drum.

Analyse and rectify the fault in the main feed pump & put it in auto.

LOSS OF FANS

-high.

ip.
 ) ACTIONS:

ID/FD/SA) after checking the cause of tripping and taking corrective actions.
EXPLOSIVE POWER OF BOILER
liberated by the explosion of Lancashire boiler 7.5 dia x 30 length, working at 7
Kg/CM^2 is sufficient to project it to a height of 3.29 KMS. Therefore hazards of boiler explosion may well be imagined.
hazards of 28.3 liters of water at 4.23 Kg/CM2 and sat.temp in a steam
boiler is equivalent to 0.45 Kg of gun powder.
Introduction to furnace explosions
In CFBC Boilers
explosion in the past, Apart from causing severe losses to the business
concerned, the occurrences have shaken the confidence of CPP professionals, however PF boilers are more prone to the such
type explosions than CFBC boiler but the Operation philosophy of PF boiler is clearly understood and established due to istory
of centuries.
er generation of technology and explosions avoidance measures are
not clearly understood by the operating Engineers.
TYPE OF EXPLOSIONS IN CFBC BOILERS
explosions caused by small particles of coal in the bed and in the free
board kept under suspension by fluidizing air fans.
and /or load carrying burners has also been reported.
DUST EXPLOSIONS
d . In a confined or nearly confined space, the explosions is
Characterized by relatively rapid development of pressure with flame propagation and the evolution of large quantities of heat
(coal) and reaction products. The required oxygen for this combustion is mostly supplied by the combustion air.
simultaneous presence of a dust cloud of proper concentration in air that
will support combustion and suitable ignition source.(Coal/HSD/LDO/FO).
gas explosions are called puffs or blow backs.
FIRE TRIANGLE AND EXPLOSION PENTAGON

FIRE TRIANGLE EXPLOTION PENTAGON

Ignition Source (Coal/LDO/HSD/FO) Coal/LDO/HSD/FO, Suspension Confinement Air or Oxygen Heat (Temp.) Air or
Oxygen Heat (Temp.)
Suspension and confinement must occur
simultaneously :.
 s pentagon like fire triangle, removing any ignition source one of these
requirements would prevent an explosions.
the explosion pentagon (Fuel, heat,
Oxygen, Suspension & Confinement) is important in preventing fires and explosions at any facility.
confinement, an explosion cannot occur, but a fire may occur. By
eliminating the fuel, the heat, or the Oxygen requirements, neither a fire nor an explosion can occur.
BASIC PHILOSPHY OF EXPLOSIONS
PREVENTION

seconds when there is no fire and coal should be added in a

small quantity at ignition temp of coal.
fired.
established and re-purging is surely done before restart.
concentration with explosive limits is never achieved.
operational and all protections and interlocks and fan drives
Sequence to be check in each shutdown as per OEM schedule/recommendations.
BOILER EXPLOSIONS PICTURES-BOILER FURNACE EXPLODED-BOILER STRUCTURES, BUILDINGS, &CABLE
GALLRIES COLLAPSED.
THE END