AFBC Boiler cold start-up procedure

Pre Start Up inspection:

1. All man hole doors are closed.

2. All drives ID, FD, PA fans, drag chains, pocket feeders are in proper running condition.
3. All pneumatic dampers ID, FD, PA suction/discharge dampers and FD, PA
compartmental dampers are in proper working condition.
4. All interlock & protections are in line.
5. Check availability of coal of appropriate size (4mm to 6mm).
6. Check availability of charcoal of specification
 Size: 15-25 mm. & C.V: 6000-6600 Kcal/kg.
7. Check availability of bed material of below mentioned specification:
 Size: 0.85mm to 2.36mm.
 Particle density: 2000 kg/cu.m.
 Bulk density: 1000 kg/cu.m.
 Chemical composition:
Alumina: 35% to 45%
Silica: 65% to 55%
 Fusion temperature: 1400 deg.C
8. Check availability of kerosene. Approx. 25 lts. reqd. per start up.
9. Check availability of DM water and boiler feed pump running.

Preparing for Start Up:

1. Before filling bed material into the furnace FD nozzles must be cleaned by admitting
maximum FD air into the furnace by opening FD compartmental dampers (PA dampers
remaining closed) for 10-15 minutes.
2. Fill bed material into the furnace so that bed height should be about 220-240mm above
air nozzles or 280-300mm above DB plate. The bed material below the air nozzles
remains static all the time and should not be counted as bed height.
3. Uniformly spread the bed material by admitting sufficient fluidizing air through the bed
and bed height can now be measured physically after putting off the air. During fluidizing
PA dampers should remain closed.
4. After uniform spreading of bed material and maintaining required bed height start
fluidizing the start-up compartment by varying the air flow gradually so that bed material
begins to fluidize.
5. Slowly increase the air flow so that small bubble formation takes place over the bed
material and incoming air escapes the bed as small bubbles. Note down the air flow at
this stage known as bubbling stage.
6. Again increase the air flow so that the bed becomes turbulent and complete mixing of top
and bottom layer of bed material takes place. Note down the air flow at this stage. This is
the amount of air required for mixing during start-up.
7. Now stopped the fans and boiler can be taken for start-up.
 8. Maintain drum level about 40%.
9. Drum vent, super heater vent, startup vent and main steam line drain should be kept open.

Start-up procedure:

1. Desired quantity of dry charcoal is spreaded uniformly over the bed in the startup
compartment.
2. Desired quantity of kerosene mixed charcoal is spreaded over the dry charcoal.
3. Initiate the fire using kerosene soaked cotton.
4. After spreading of fire over the total bed area start ID, PA, FD fans as per sequence and
open their discharge dampers then suction dampers (assuming VFD control).
5. Open compartmental PA and FD damper and maintaining furnace draught 0 to -1 mmwc.
give very nominal air flow for charcoal ignition & fire establishment in startup
compartment.
6. Now check physically and ensure when flame is in bluish condition mixing should be
done with mixing air flow for 20-30 seconds maintaining furnace draught at 0 to -1
mmwc.
7. After giving the mixing air flow should be reduced to bed minimum fluidization
condition.
8. Now bed temperatures will start rising and after getting bed temperature more than fuel
ignition temperature, (at about 550*C for indian coal) the fuel feeding can be started with
minimum feed rate.
9. Before start of feeding ensure PA lines are clear and PA header pressure is maintained at
800 mmwc( slightly more than wind box pressure).
10. Keep wind box pressure at about 280-300 mmwc.
11. Regulate fuel feed rate depending upon the temperature of the bed so that the temperature
becomes stable at 850-900 deg.C
12. Close drum air vent at 2.5 Kg/cm2(g) pressure.
13. Close super heater drain at 18Kg/cm2(g) pressure.
14. Open MSSV(Main steam stop valve) after the prior & proper charging through equalizer
valve.
15. Close startup vent after MSSV fully open.

Precautions during start-up:

1. If mixing is done at higher air flow, the burning charcoal and bed material will spill into
the adjacent compartment and bed height will reduce in the startup compartment.
2. If mixing is done at lower air flow, the burning charcoal and bed material will not mix
properly. The charcoal will burn top layer of bed material leading to clinker formation.
3. If fuel feeding is started too early before attaining fuel ignition temperature, incoming
fuel will not burn and accumulate in the furnace and may lead to clinker formation.
4. Lower bed height and less air flow can lead to higher temperatures and bed material can
be charged to limit the rising temperature.
 5. In any case bed temperatures should not be allowed beyond 950 deg.C. So charcoal
mixing , the time of feeding, and air flow setting should be done properly.
6. During start-up drum level will fluctuate due to thermal action in water and should be
maintained accordingly.

Compartmental transfer:

1. After stabilizing the 1st compartment open the PA line damper of 2nd compartment and
ensure the lines are clear.
2. Open the FD line damper of 2nd compartment and increase the air up to fluidization level.
Compartmental mixing can be done at 55-60 mmwc. air flow and higher according to
requirement as cold bed would require more air to fluidize.
3. At the time of mixing the bed temperature of the running compartment will go down and
that of mixing compartment of will rise. At the time of mixing the bed temperature in the
running compartment should not be allowed to go below fuel ignition temperature and
mixing should be stopped accordingly and air flow to be normalized.
4. The process of mixing should be repeated several times till the bed temperature in the
mixing compartment attain fuel ignition temperature.
5. The mixing compartment can now be taken in line by starting the feeding with sufficient
air flow. Air flow can be maintained at 45-50 mmwc. and wind box pressure at 370- 380
mmwc.
6. Adjust the fuel feeding such that the bed temperatures in both compartments become
stable at 850-900 deg.C

Note : Kindly note that Startup of any AFBC Boiler is skilled jobs which may be vary as
per situational requirement. Best practice is that always follow manufacturer
recommendations. Following parameters must be maintain at normal level during
startup time of any AFBC Boiler :
1. Drum level (50%)
2. Boiler pressure(<working pressure)
3. MS temperature(Less than rated steam temp)
4. Bed temp (<950*C).
5. Furnace draft(-5mmwc)
6. Bed height(<400mm)
7. PA header pressure (800mmwc to 1200mmwc)