From

J.B.Suhag
V.P.(Western Region)
Ribo Industries Pvt. Ltd. -Ahmedabad
1
EFFICIENT,SAFE
& EMERGENCY
OPERATIONS OF
BOILERS
2
EFFICIENT OPERATION OF
BOILERS

3
 THE PARAMETERS REQUIRED TO BE
MAINTAINED STRICTLY IN AFBC BOILER
FOR EFFICIENT OPERATION
1. Bed Height / F.D. Air Pressure

2. Primary Air Pressure

3. Bed Temperature / Furnace Temperature

4. Fuel Size

5. Bed Material Size & Specifications

6. Air & Fuel Ratio

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 1. BED HEIGHT / FD AIR PRESSURE
• Static height for AFBC boiler is to be maintained
250 to 300mm during initial light up of boiler.
• Expand bed height for AFBC boiler is to be
maintained 500 to 600 mmwc.
• FD air discharge pressure is to be maintained 600
to 650mmwc
• Windbox or airbox pressure is to be maintained
500 to 600mmwc
NOTE :- High W.B. pressure increases the erosion of
bed coils & low W.B. stops fluidization.

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 2. PRIMARY AIR PRESSURE

• P.A. fan air headerpressure for AFBC boiler is to

be maintained 1000 to 1150 mmwc.

• Diff. of Primary Air Pressure & F.D. Wind Box

pressure is to be maintained approximately
500mmwc.

Note :- High P.A. Pressure increases the high bed

coil erosion and carryover.
Low P.A.pressure cause the blockage of P.A.
lines and puffing in boiler and also chances
of clinkerisation. 6
3. BED TEMP. / FURNACE TEMPERATURE

• Depends upon the type of fuel & firing method.

• For (Indian Coal) bed temp. in FBC/AFBC/CFBC is

to be maintained 850 Deg.C to 900 Deg.C.

• For Imported Coal bed temp. in FBC/AFBC/CFBC

is to be maintained bed 875 Deg. C to 925 Deg.C.

• For lignite bed temp. in FBC/AFBC/CFBC is to be

maintained 800 C to 850 C.

• For Petcock bed temp. in FBC/AFBC/CFBC is to be

maintained 875 C to 950 C.
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• For Rice husk and other Bio-mass fuel bed
temp. in FBC/AFBC/CFBC is to be maintained
850 C 900 C.

• For Stoker firing furnace temperature is to be

maintained 1100 C to 1200 C.

• For Pulverized Fuel firing furnace temperature

is to be maintained 1100 C to 1300 C.

• For oil & gas fuel firing furnace temp.is to be

maintained 1100 to 1500 C.

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 4.FUEL SIZE
When firing with Indian/Imported coal following
sizes are to be strictly maintained as it will affect
on performance and efficiency of boiler.
• For FBC / AFBC / CFBC Boiler.
Size : 0 to 8 mm,
less then 1mm not allowed more then 20%
Distribution : 1 to 5mm – 70%
5 to 8mm – 20%
0 to 1mm – 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.
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• For Stoker fired Boiler

Size : 5 to 25mm,
less then 5mm not allowed more then 5%

Distribution : 5mm to 15mm – 25 %

15mm to 25mm – 75%
0 to 5mm – 05%

Note: Lower the size of coal higher unburnt in

flyash & carryover through Boiler.

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• For Pulverized Fired Boiler.

Raw Coal Feeder Inlet – 0 to 25mm( higher size

will be effected by pulverizer (Pulverizer Inlet)
performance and more rejection )

Pulverized Coal Size – 200 mesh powder

Size Distribution : 150 – 200 - 60%

100 – 150 - 30%
75 - 100 - 10%

Note: Higher the size of pulverized coal below 100

mesh results unburnt in bottom ash.
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5. BED MATERIAL SIZE & SPECIFICATIONS

Bed Material Size :-

Size:0.85mm o 2.36mm (not below 0.85mm)

Distribution : 0.85 mm to 1.0mm –10%

1.0 mm to 1.5mm – 50%
1.5 to 2.36 mm – 40%

Note: Higher the size of bed material cause higher

erosion of bed coils & lower size cause wastage
through ash from boiler.

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Bed Material Specifications :
Crushed Fire Bricks Castable IS8 grade Bricks or River Silica
Sand

Fusion Temperature : 1300 Deg. C.

Shape : Spherical Angular
Bulk Density : 1050 Kg/m3
Silica (SiO2) : 68 %
Al203 : 28 %
Fe203 : 1.05%
PiO2 : 1.67%
MnO : Trace
CaO : 0.54%
MgO : 0.23%
P2O5 : 0.08%
A2O : 0.22%
K2O : 0.45%
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 6. AIR & FUEL RATIO
• Theoretical Air For Combustion :-

Theoretical Air Required = 4.31 {8/3 C (H-O/8)+S} gram/gm

of Fuel
• Excess Air :-

To understand the basics of Efficient Boiler Operation, the

combustion process must be understood. Stable combustion
conditions requires the right amounts of fuels and oxygen. The
combustion products are heat energy, carbon dioxide, water vapor,
nitrogen, and other gases (excluding oxygen). In theory there is a
specific amount of oxygen needed to completely burn a given
amount of fuel. In practice, burning conditions are never ideal.

Therefore, more air than ideal must be supplied to burn all fuel
completely. The amount of air more than the theoretical
requirement is referred to as excess air.
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Theoretical Maximum Co2 for various fuels
Sr.No. Fuel Maximum CO2 %
1. Bitominious Coal 18.6
2. Coke 19.7
3. Anthracite 19.5
4. Lignite 19.0-19.5
5. Peat 19.5-20.1
6. Fuel Oil 15.3
7. Natural Gas 11.8

Theoretical Air x Theoretical CO2 = Actual Air x Actual CO2

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Typical excess air to achieve highest efficiency
for
different fuels are
• Power plant boilers normally run about 10 to 20 %
• Fuel Oil Fired boilers may run as low as 5 to 15%.
• Natural gasfired boilers may run as low as 5 to
10%
• Pulverized coalfired boilers may run with 15 to
20%
• Gas turbines run very lean with up to 300%

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• Oxygen
To ensure atcomplete
Boiler Outlet :-
combustion of the fuel used,
combustion chambers are supplied with excess air.
Excess air increase the amount of oxygen and the
probability of combustion of all fuel.

When fuel and oxygen in

the air are in perfectly
balance - the combustion
is said to be
stoichiometric. The
combustion efficiency will
increase with increased
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excess air, until the heat loss in the excess air is larger
than the heat provided by more efficient combustion.

Carbon dioxide (CO2) is a

product of the combustion
and the content in the flue
gas is an important
indication of the
combustion efficiency.

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 SAFE & EMERGENCY
OPERATION OF BOILERS

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BOILER EMERGENCY & SAFE OPERATIONS
Various Emergency situations during operation with a special emphasis on
the safety aspect like boiler protection systems controls and interlocks.
1. Drum level low and low-low
2. Drum level high and high high
3. Furnace Draft high and high high
4. Bed Temperature High
5. Bed Temperature Low
6. Water wall / screen tube / evaporator tube failure
7. Super heater tube failure
8. High super heater temperature
9. Low Super heater temperature
10. Flame Failure
11. Furnace Explosion
12. Boiler pressure high
13. Coal feeder failure
14. PAH / SAH tube failure
15. Boiler feed pump failure 20
16. Fan Failure
1. DRUM LEVEL LOW AND LOW-LOW:-
(A) CAUSE :-
1. Failure of boiler feed pump.
2. Failure of drum level controller.
3. Inadvertent opening of C.B.D.
4. Extraordinary change in load. (Sudden reduction in load)
5. Water tube failure.
(B) EFFECT :-
1. Boiler may damage badly.
(C) ACTION :-
1. Run the boiler if drum level is within safe limit (Lo alarm and lo-lo alarm
came). If it goes beyond safe limit allow boiler to trip.
1a. Attempt to control with feed valve.
1b. If feed valve is stuck up open parallel line valve or bypass valve.
1c. Take care while increasing feed flow that running B.F.P. do not trip on
feed flow high.
1d. If low level is due to tripping of feed pump start stand by pump, if it is on
manual.
2. If water level is below safe level, allow to trip the boiler on drum level
lo-lo to protect the boiler drum and tubes.
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2. DRUM LEVEL HIGH AND HIGH HIGH :-
(A) CAUSE
1. Failure of drum level controller.
2. Extra ordinary increase in load
3. Sudden increase in firing rate.
(B) EFFECT:-
1. Water may enter turbine and serious damages to turbine may occur.
2. Joint valve on main steam pipe work leaks.
3. Carry over with sharp fall in super heater temperature
(C) ACTION :-
1. Run the boiler if drum level is within safe limit (drum level high and high high alarm
came). If goes beyond limit allow boiler to trip.
• Attempt to control with feed valve.
• If feed valve is stuck up close isolating valve.
• Attempt to control drum level by opening C.B.D.
• Close Economizer inlet valve and allow feed pump to run in recirculation.
• If above measures fail trip the feed pump.
2. If level is due to sudden rise in load. If high level rises above normal level allow
boiler to trip on drum level high high.
• If main steam temperature drop takes place open steam pipe drains.
• Trip the turbine / prime mover when steam
temperature falls. 22
3. FURNACE DRAFT HIGH AND HIGH HIGH
(A) CAUSE :-
1. Due to faulty operation of fan control.
2. Disturbed combustion
3. Un-controlled fuel entry
(B) EFFECT:-
1. Boiler may damage due to high furnace pressure.
2. Weak parts of furnace (ductings and enclosures) may
explode due to high furnace pressure.
(C) ACTION :-
1. If it is due to faulty operation of I.D./P.A./S.A. fan
control, take it on manual and maintain the furnace in
suction.
2. If furnace pressure has increased beyond limit allow
boiler to trip on furnace draught high high. 23
 4. BED TEMP. HIGH :-
(A) CAUSE :-
1. High CV and low ash coal used.
2. Low P.A. flow / S.A. flow
3. Sudden change in load
4. Faulty bed temp thermocouple
5. Ash recirculating system trouble
(B) EFFECT :-
1. Chances of clinker formation
2. Chances of refractory failure
3. Chances of screen tube failure
(C) ACTION :-
1. Control bed temp by recirculation ash through recirculation feeder.
2. Start sand feeder if bed height permits.
3. Increase P.A. flow up and increase S.A. flow.
4. Reduce the load by cutting coal feeder.
5. Coal feeders trip, if temp rises above limit and allow boiler to trip, if temp exceeds
beyond safe limit to save bed from clinkerisation.
6. Check the bed temp thermocouple.
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 5. BED TEMP LOW :-
(A) CAUSE :-
1. High PA with respect to load / high SA flow w.r.t. load.
2. Low CV high ash coal used.
3. Coal interruption or coal feeder trips or overfeeding of coal into furnace.
4. Recirculation ash feeder speed may increase.
5. Faulty bed temp. thermocouple.
6. Water tube / screen tube / evaporator tube failure.
(B) EFFECT :-
1. Boiler steam flow will reduce.
2. Super heater temp drops.
3. Furnace draft will fluctuate.
(C) ACTION :-
1. Reduce P.A. Fan flow, if excessive / reduce S.A. flow, if excessive.
2. Reduce speed of recirculation ash feeder.
3. Stop bed material supply, if running.
4. Check bed temp thermocouple.
5. Check any leakage sound from furnace. 25
6. Check coal feeder and coal supply.
6. WATER WALL / SCREEN TUBE /
EVAPORATOR TUBE FAILURE
(A) CAUSE :-
1. Starved water wall.
2. Block tube, eroded tube, pitted tube, salt deposits.
3. Circulation affected due to open low point drains.
(B) EFFECT :-
1. Hissing steam leakage noise from boiler.
2. Unstable flame fluctuating draught.
3. Bed temperature drops sharply.
4. High feed water flow for given steam generation / increase in make up water.
5. Increase in I.D. Fan loading.
6. Below screen temperature drops sharply.
7. Flue gas outlet temperature decreased.
(C) ACTION :-
1. Every shift check low point drain valve are fully closed.
2. Every shift check the furnace listen furnace to detect steam noise.
3. At first diagnostics of tube failure, start load reduction; trip out unit before damage
become serious. Quicker shutdown reduces extensive damage.
4. Try to locate tube at low level.
5. Don’t allow the drum level to go beyond a danger level.
6. Start another BFP, if drum level is not maintained by running BFP. 26
 7. SUPER HEATER TUBE FAILURE :-
(A) CAUSE :-
1. Sustaining high metal temp due to water wall slagging or inadequate steam
flow and high gas temp during hot start.
2. Erosion on tubes due to high excess air.
3. Blocked tubes.
4. Starvation of tubes.
5. Salt deposition due to high water level in drum. Poor quality of spray water.
(B) EFFECT :-
• Hissing noise notices.
• Flue gas temp drops.
• High feed water consumption compared to steam flow.
• Over loading on I.D. Fan.
• Erosion of other tubes and damages to other SAH tubes.
(C) ACTION :-
1. As soon as leakages noticed start reducing the load and trip the boiler.
2. Listen the SH region for steam leakage.
3. Try to locate leakage through manholes before the boiler is depressurized.

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8. HIGH SUPER HEATER TEMP
(A) CAUSE :-
1. High excess air.
2. Low feed water temp HP Heater not in service at constant firing /
load.
3. Sudden increase in firing rate to increase steam pressure.
4. In adequate spray.
5. Lodging of soot on the water walls considerably.
(B) EFFECT :-
Rise in (+ve) positive turbine expansion.
1. Creep rate increase in tube metal, turbine parts, steam piping.
(C) ACTION :-
1. Check feed water temp. If HP heaters are available, put in service and if
not reduce the load.
2. Slow down firing rate.
3. Reduce excess air, if more.
4. Check Spray control 28
 9. LOW SUPER HEATER TEMP. :-
(A) CAUSE :-
1. Dirty super heater
2. Inadequate air flow.
3. High Spray
4. Too high feed water temp.
5. Sharp increase in load and pressure drop.
6. High Drum level.
(B) EFFECT :-
1. Turbine expansion may be negative.
2. May induce thermal stresses in S.H.
(C) ACTION :-
1. Check air flow – increase, if necessary.
2. Reduce spray, if more.
3. Check feed water temp.
4. Avoid sharp rise in load to boiler pressure drop.
5. If, it is due to high drum level – allow unit to trip and open main steam drains.

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 10. FLAME FAILURE :-
(A) CAUSE :-
1. Dirty Oil / Gas Burner
2. Faulty Flame Scanner
3. Failure of Blower
4. Furnace Pressure High
5. Low Combustion Air
(B) EFFECT :-
1. Boiler will trip on flame failure
2. Chances of furnace explosion, if unburnt oil / gas / coal mixture entered in furnace.
3. Boiler steam pressure may fall down.
4. Super Heater Steam Temp. drop sharply.
5. Variation observed in drum level.
(drum level low)
(C) ACTION :-
1. Purge the boiler before putting burner back and purge burner as per cycle time given by supplier.
2. Check the flame scanner and clean the photocell, if found dirty.
3. Check the sparking circuit and high voltage transformer supply.
4. Check spark plug, if found dirty, clean it and set the gap.
5. Clean the burner tip, if nozzles (holes) are found chocked.
6. Check the air blower and maintain air fuel ratio.
7. Check the explosion doors, close it if opened. 30
11. FURNACE EXPLOSION
(A) CAUSE :-
1. Accumulation of unburnt fuel during lit up / start up of
boiler.
2. Improper burning.
3. Inadequate air.
4. Secondary combustion.
(B) EFFECT :-
1. Furnace explosion can cause extensive damage.
(C) ACTION :-
1. Always purge the boiler with 40% full load air for about
five minutes. No cut short in purging allowed.
2. Adjust fuel air ratio.
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OVERVIEW OF UTILITY BOILER
OVERVIEW OF UTILITY BOILER
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
12. BOILER PRESSURE HIGH
(A) CAUSE :-
1. Sudden drop in load / steam flow.
2. Un-controlled fuel entry.
3. Turbine / prime mover trips.
(B) EFFECT :-
1. Disturbance in drum water level.
2. Safety valves may life if pressure rise is up to that extent.
3. Boiler may trip on high pressure.
(C) ACTION :-
1. Open start up vent valve.
2. Control fuel input and drum level.
3. Check coal feeder feeding rate.
4. Adjust the load on unit, if it has dropped.
5. If TG / prime mover has tripped first, allow boiler to trip but
safety valve may lift.
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 13. COAL FEEDER FAILURE :-
(A) CAUSE :-
1. Electrical supply failed
2. V.F.D. fault
3. Bed temperature high
4. Furnace draft high
5. Furnace draft low
6. Drum level high
7. Drum level low
(B) EFFECT :-
1. Boiler pressure may fall down
2. SH steam temp fall sharply.
3. Bed temp. will decrease.
4. Variation in furnace pressure (LOW)
5. Variation in drum level (Low)
(C) ACTION :-
1. Control boiler pressure by reducing load on turbine / prime mover or process.
2. Control super heater steam temp by closing spray valve.
3. Reduce PA / SA flow to control bed temp.
4. Control furnace draft and drum level.
5. Check electrical fault or emergency stop push button & restart coal feeder.
6. Check VFD fault, if any.
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7. Restart coal feeder after checking cause of failure.
 14. PAH / SAH TUBE FAILURE
(A) CAUSE :-
1. Erosion of tube.
2. Corrosion of tube.
(B) EFFECT :-
1. Flue gas temp after APH will fall down.
2. Increases in O2 percentage at ESP inlet.
3. PA / SA Fan overloaded.
4. Bed temp may be increased.
(C) ACTION :-
1. Control flue gas temp by passes PAH.
2. Reduce coal feeding to maintain O2 percentage.
3. Control bed temp.
4. If leakage of tubes are more stop the boiler
and plug / replaced.

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15. BOILER FEED PUMP FAILURE :-
(A) CAUSE :-
1. Motor protection relay operates
2. Lube oil temperature high
3. Discharge flow high
4. Motor bearing temperature high
5. Deaerator level low
6. BFP suction pressure low
(B) EFFECT :-
1. If standby pump is available, it will start on auto or start it manually.
2. If standby pump does not start on auto & manual, drum level may go very low, which
may trip the boiler.
(C) ACTION :-
1. Start the stand by pump, if it does not start on auto. Adjust the load to maintain the drum
level as well as to prevent the tripping of this pump on high feed water flow.
2. See the proper operation of recirculation valve and C.W. Valve.
3. Analyze and rectify the fault in the main feed pump. Put it on auto.
4. Restore the bus supply, if it has lost and make the pump available.
5. Check the deaerator level and if it falls below safe limit, stop the feed pump,
immediately.
6. Check the BFP suction strainer and clean it, if found chocked. 47
 16. LOSS OF FANS
(1) ID FAN FAILURE
(A) CAUSE :-
1. Electrical motor protection
2. Fan bearing temp becomes high high
3. Motor bearing temp becomes very high
4. Drive fault (MCC fault)
5. Boiler trip
(B) EFFECT :-
1. Furnace may get pressurized
2. Boiler will trip on boiler furnace pressure high.
(C) ACTION :-
1. Check emergency or field stop.
2. Rectify electrical fault, if any.
3. Check cause for boiler trip & normalize it.
4. Check fan / motor-bearing temp.
5. Restart I.D. Fan after checking cause of tripping and taking corrective
actions.
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 (2) P.A. FAN FAILURE :-
(A) CAUSE :-
1. Electrical motor protection.
2. Fan bearing temp. becomes high high.
3. Motor bearing temp. becomes very high.
4. MCC fault.
5. Boiler trip.
6. Run feed back off.
7. ID Fan trip.
8. SA trip.
(B) EFFECT :-
1. Boiler will trip on
a. Furnace draft low
b. P.A. flow low.
(C) ACTION :-
1. Rectify electrical fault, if any.
2. Check cause for boiler trip and normalize it.
3. Check fan / motor-bearing temp.
4. Restart the P.A. Fan after checking the cause of tripping and 49
taking corrective actions.
 (3) S.A. FAN FAILURE:-
(A) CAUSE :-
1. Electrical motor protection.
2. Fan bearing temp becomes high high.
3. Motor bearing temp becomes very high.
4. MCC fault.
5. Boiler trip.
6. Run feed back off.
7. I.D. Fan trip.
(B) EFFECT :-
1. Boiler will trip on low furnace draft.
(C) ACTIONS :-
1. Rectify electrical fault, if any.
2. Check cause for boiler, trip & normalize it.
3. Check fan / motor-bearing temp.
4. Restart the S.A. Fan after checking the cause of tripping
50
and taking corrective actions.
51