Boiler Operating Rules.pdf

KMPCL
KMPCL
KMPCL
KMPCL 6
6
6
6 x
x
x
x 600
600
600
600 MW
MW
MW
MW Subcritical
Subcritical
Subcritical
Subcritical Coal-fired
Coal-fired
Coal-fired
Coal-fired Power
Power
Power
Power Plant
Plant
Plant
Plant Project
Project
Project
Project
KSK
KSK
KSK
KSK Mahanadi
Mahanadi
Mahanadi
Mahanadi Power
Power
Power
Power Company
Company
Company
Company Limited
Limited
Limited
Limited
6
6
6
6 x
x
x
x 600
600
600
600 MW
MW
MW
MW Thermal
Thermal
Thermal
Thermal Power
Power
Power
Power Project
Project
Project
Project Nariyara,
Nariyara,
Nariyara,
Nariyara, Chhattisgarh,
Chhattisgarh,
Chhattisgarh,
Chhattisgarh, India
India
India
India
S
S
S
SEPCO
EPCO
EPCO
EPCO ELECT
ELECT
ELECT
ELECT IC
IC
IC
IC POWER
POWER
POWER
POWER CONSTRUCTION
CONSTRUCTION
CONSTRUCTION
CONSTRUCTION CORP.
CORP.
CORP.
CORP.
No. Boiler Operating Rules Total 175 pages
Boiler
Boiler
Boiler
Boiler Operating
Operating
Operating
Operating Rules
Rules
Rules
Rules
SEPCOI
Drafted by:
Reviewed by:
Approved by:

1
Content
Content
Content
Content
Part 1 Brief Introduction of Boiler Equipment................................................................................................ 1
Chapter 1 Main Design Features and Specifications of Boiler................................................................1
Chapter 2 Boiler Technical Specifications and Performance Parameters of Main Components............. 5
Chapter 3 Calculated Data Table Of Boiler Thermal Performance..........................................................8
Chapter 4 Induced Draft Fan................................................................................................................. 12
Chapter 5 Forced Draft Fan................................................................................................................... 16
Chapter 6 Primary Air Fan.....................................................................................................................19
Chapter 7 Air Preheater..........................................................................................................................22
Chapter 8 Pulverizing System................................................................................................................23
Chapter 9 Air Heater..............................................................................................................................28
Chapter 10 Air Compressor and Its Dryer............................................................................................. 29
Chapter 11 Boiler Water Circulation Pump........................................................................................... 33
Chapter 12 Flame Check Cooling Fan...................................................................................................34
Chapter 13 Startup Boiler...................................................................................................................... 35
Chapter 14 Soot Blowing System..........................................................................................................37
Part 2 Startup and Shutdown of Boiler.......................................................................................................... 39
Chapter 1 Rules & Conditions of Unit Startup...................................................................................... 39
Chapter 2 Boiler Cold Start................................................................................................................... 41
Chapter 3 Hot Start................................................................................................................................ 52
Chapter 4 Very Hot Start........................................................................................................................53
Chapter 5 Boiler Shutdown....................................................................................................................54
Chapter 6 Normal Shutdown of Boiler..................................................................................................57
Chapter 7 Boiler Cooling.......................................................................................................................58
Chapter 8 Precautions for Boiler Shutdown.......................................................................................... 59
Chapter 9 Boiler Shutdown Preservation...............................................................................................60
Part 3 Operation & Maintenance of Boiler....................................................................................................63
Chapter 1 Operation Adjustment........................................................................................................... 63
Chapter 2 Unit Operation Mode............................................................................................................ 67
Chapter 3 Operation Mode of Boiler Water Circulating Pump System.................................................70
Chapter 4 Operation Mode of Pulverizing System................................................................................ 71
Chapter 5 Monitoring of Parameters in Normal Operation................................................................... 72
Chapter 6 Boiler Periodic Working System Schedule........................................................................... 74
Part 4 Boiler Interlocking Protection and Test...............................................................................................75
Chapter 1 Boiler Interlocking Protection...............................................................................................75
Chapter 2 Boiler Test Procedures...........................................................................................................79
Part 5 Handling of Boiler Unit Trouble......................................................................................................... 87
Chapter 1 Rules for Trouble Handling...................................................................................................87
Chapter 2 Boiler Accident Shutdown.................................................................................................... 89
Chapter 3 Boiler MFT........................................................................................................................... 91
Chapter 4 Loss of Service Power...........................................................................................................92
Chapter 5 Loss of Service Air Supply....................................................................................................93
Chapter 6 Automatic load shedding.......................................................................................................94
Chapter 7 Overfeed of Water into Drum................................................................................................96
Chapter 8 Water Shortage of Drum........................................................................................................97

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Chapter 9 Surge of Forced Draft Fan and Induced Draft Fan................................................................98
Chapter 10 Tripping of Air Preheater.....................................................................................................99
Chapter 11 Leakage of Boiler Heating Surface................................................................................... 100
Chapter 12 Secondary Combustion of Boiler Tail Flue.......................................................................101
Chapter 13 Abnormalities of Steam Parameters.................................................................................. 102
Chapter 14 Unit Load Swinging.......................................................................................................... 104
Chapter 15 Unit Load-rejection........................................................................................................... 105
Chapter 16 Auxiliary Equipment Fault................................................................................................106
Chapter 17 Fire Disaster...................................................................................................................... 110
Chapter 18 DCS Fault..........................................................................................................................112
Chapter 19 Operation Measures for Pulverizing System.....................................................................113
Chapter 20 Anti-accident Measures against Furnace Explosion..........................................................115
Part 6 Startup and Shutdown of Boiler Auxiliary Equipment......................................................................117
Chapter 1 General Rules for Auxiliary Equipment..............................................................................117
Chapter 2 Startup and Shutdown of Air Preheater...............................................................................122
Chapter 3 Startup and Shutdown of Induced Draft Fan.......................................................................125
Chapter 4 Startup and Shutdown of Forced Draft Fan.........................................................................128
Chapter 5 Startup and Shutdown of Primary Air Fan.......................................................................... 131
Chapter 6 Startup and Shutdown of Air Compressor...........................................................................133
Chapter 7 Startup and Shutdown of Fire Check Cooling Fan..............................................................137
Chapter 8 Startup and Shutdown of Fuel Oil System.......................................................................... 138
Chapter 9 Treatment of Fuel Oil System Accidents.............................................................................144
Chapter 10 Startup and Shutdown of Pulverizing System...................................................................147
Chapter 11 Startup and Shutdown of Drum Two-color Water Gauge..................................................151
Chapter 12 Startup and Shutdown of Air Heater................................................................................. 153
Chapter 13 Operation of Boiler Sootblower........................................................................................ 155
Chapter 14 Startup and Shutdown of Boiler Water Circulating Pump.................................................158
Appendix:.................................................................................................................................................... 163

1
Part
Part
Part
Part 1
1
1
1 Brief
Brief
Brief
Brief Introduction
Introduction
Introduction
Introduction of
of
of
of Boiler
Boiler
Boiler
Boiler Equipment
Equipment
Equipment
Equipment
Chapter 1 Main Design Features and Specifications of Boiler
1.1 Model: SG-2069/17.47-M921, manufactured by Shanghai Boiler Works Co., Ltd.
1.2 The boiler is subcritical pressure intermediate primary reheat control circulation boiler with swing type
temperature adjusting, four corners arrangement, tangential firing, positive pressure direct firing
pulverizing system, single furnace, II-type outdoor arrangement, all-steel overhung construction, dry-ash
furnace and balanced ventilation. The furnace is 21,082mm in width and 17,829.5mm in depth, the furnace
roof elevation is 77,300mm, the drum center line elevation is 78,300mm and the furnace roof plate girder
bottom elevation is 85,800mm. The boiler roof adopts metal fully sealed structure and is set with big cover
casing made up of Φ51×6 membrane water wall. The furnace bottom ash hopper is at an angle of 55º, the
furnace bottom sealing is water seal, there are division wall, rear platen and platen reheater arranged on the
upside of furnace and there are wall radiant reheater mounted on the front wall and side walls, the furnace
lower header elevation is 9000mm. The horizontal gas pass is 8548mm in depth, made up of the extension
of water wall and rear flue gas pass and has last stage reheater and last stage superheater arranged inside.
The rear flue gas pass is 13908mm in depth and has low temperature superheater and economizer mounted
inside.
1.3 The furnace has three LP boiler circulating pumps mounted at the front of boiler and two trisector
regenerative Ljungstrom air preheater mounted at the rear with rotor diameter of 14.236m, the rotor rotates
reversely, and the angular degree of primary air division is 50°.
1.4 The boiler adopts positive pressure direct firing pulverizing system equipped with 7 sets of
HP1103DYN type medium speed coal mill, which is amounted at the front of boiler. 6 coal mills are with
MCR load and 1 is for standby. Direct-flow burner is arranged on four corners with tangential firing and the
outlet of each coal mill is connected to one layer pulverized coal spray by 4 pulverized coal piping. The
upper most burner nozzle center line elevation is 37500mm, which is 23000mm away from the bottom of
platen and the lowest burner nozzle center line elevation is 27440mm, which is 5934mm away from the
furnace hopper angle. The burner wind box on each corner has five layers of startup and
combustion-supporting oil gun torch, three layers of heavy oil gun torch and two layers of light oil gun
torch.
1.5 Steam temperature governing mode: Superheated steam temperature governing mainly depends on
spray temperature governing except for the affect of burner nozzle sway. It is equipment with two stages of
spray attemperator, the first stage attemperator is arranged on the division wall superheater inlet pipe for
controlling the steam temperature getting into the division wall superheater; the second stage attemperator
is arranged on the final stage superheater inlet pipe for controlling the outlet steam temperature of final
stage superheater. The maximum design water spray capacity of first stage attemperator is 206t/h and that
of the second stage attemperator is 40t/h.
The reheat steam temperature governing mainly adopts titling burner nozzle angle to change the height of
flame center and thus to change the furnace outlet flue gas temperature. The swing angle of primary air
nozzle is ±20° and the swing angle of secondary air nozzle is ±30°. As the reheaters are arranged at the
furnace outlet high temperature flue gas area, the temperature governing to swing nozzle is of relatively
large sensitivity. Temperature governing can be done by increasing excess air coefficient when the load is
lower than the certain value. Furthermore, there are two emergency water spray attemperator at the reheater

2
inlet, of which the nozzle is Monok nozzle, controlling the reheated steam inlet steam temperature at
emergency status. The attemperator is arranged on the wall type reheater inlet pipeline with maximum
design water spray capacity of 90t/h.
1.6 This boiler has 5%BMCR startup bypass system as the method of controlling superheated steam
pressure and temperature when boiler starts up to shorten startup time. When the boiler starts up in cold
state, the medium temperature in this system should be the saturation temperature under the pressure of
4.14MPa and the drain valve are fully opened. Increase the superheating steam temperature by increasing
the furnace combustion rate to quicken startup speed. When the boiler starts up in hot state, the drain valve
should be also opened to exhaust the condensate in the superheater system, therefore, the pipeline design
pressure and temperature behind the motor-operated valve is the same as that of the enclosure superheater.
The superheated steam temperature is controlled by furnace combustion rate and the superheated steam
pressure is controlled by drain valve during startup; close this drain valve after synchronization of steam
turbine.
1.7 The boiler adopts dry ash extraction and the furnace ash hopper bottom slag extracting adopts
mechanical slag extracting
1.8 There are 80 wall type soot blower in the furnace part, 44 long retractable soot blower on the upper part
of furnace and convection pass area and 1 retractable soot blower on the flue gas inlet and outlet end of
each preheater; all soot blowers will be program control during operation.
1.9 There are 16 spring safety valve in the boiler proper part, of which 6 are at the drum, 2 at the
superheater outlet, 6 at the reheater inlet pipe and 2 at the reheater outlet pipe. 3 power discharge valves are
installed at the superheater outlet to reduce take-off times of safety valve.
1.10 This boiler has the expansion center. The whole boiler will expand by taking the expansion center as
the base point during operation, the vertical expansion zero point of boiler is set on the top of big cover
casing, the expansion zero point in depth and width direction of boiler is set at the furnace center. Three
layers of guiding device are set in the height direction of furnace to control the expansion direction of
boiler heating surface and horizontal load of boiler.
1.11 The length of drum shell straight part is 26216mm, which is made by rolling of steel plate with inner
diameter ofΦ1743mm; the two ends adopt spherical heads; the total length is 28585mm including heads;
the drum shell and head adopt the materials of SA-299. The drum shell upper part is welded with 29Φ159
saturated steam extraction pipe base and 87Φ159 steam-water leading-in pipe base and is equipped with
auxiliary steam tube and air vent pipe base. The shell bottom is welded with 6 pieces of downcomer and 3
pieces of feed water pipe base. The head has manhole, 6 safety valve pipe base with 3 on each side, 8
couples of water level monitoring pipe base for connecting 2 two-color water level gages, 4 water level
balance containers and 2 electrode pitting water level gauges. The normal water level of drum is 220mm
below center line.
1.12 Each side of furnace outlet has one non-cooled flue gas probe; the flue gas probe extend to the furnace
to monitor the furnace outlet flue gas temperature during boiler startup stage. The highest measured
temperature of flue gas probe is 600℃, therefore, when the flue gas temperature reaches 538℃, alarm will
be given and flue gas probe will drop out automatically. Then decrease fuel amount to prevent burning of
wall type reheater for overheat. Flue gas probe model is TS-O with travel of 7000mm.
1.13 Operating mode of boiler: the boiler has base load and is of peaking capability. The lowest load of
stable flame without fuel is not higher than 40% of boiler maximum continuous rating in fuel design of

3
burning, under which the boiler can operate stably and safely in a long time.
1.14 Boiler steam water process:
1.14.1 Boiler water circulation process:
E1, E2 Economizer inlet pipeline F8 Circulating pump F22 Water cooling screen pipe
E3 Economizer inlet header F9 Pump outlet valve F23
Water cooling screen pipe
outlet header
E4 Economizer piping F10 Pump outlet pipeline F24
Screen pipe outlet header
extraction pipe
E5
Economizer hanging pipe inlet
header
F11
Lower boiler barrel admitting
pipe base
F25 Side lower boiler barrel
E6 Economizer hanging pipe F12 Front boiler barrel F26 Side wall water wall
E7
Economizer hanging pipe outlet
header
F13 Front water wall F27
Extension side wall water
wall
E8 Economizer outlet connecting pipe F14 Front water wall upper header F28
Side wall water wall upper
header
F1 Boiler F15
Front water wall extraction
pipe
F29
Side wall water wall
extraction pipe
F2 Downcomer base F16 Rear lower boiler barrel F30 Exhaust pipe
F3 Downcomer F17 Rear water wall F31 Recirculating inlet base
F4 Confluence header inlet three-way F18 Rear water wall hanging pipe F32 Recirculating pipeline
F5 Confluence header F19 Hanging pipe outlet header F33 Recirculating valve
F6 Confluence header outlet three-way F20
Hanging pipe header
extraction pipe
F34 Recirculating pipeline
F7 Pump induction stub pipe F21 Rear arch water wall pipe F35 Recirculating outlet base

4
1.14.2 Primary steam system
1.14.3 Reheated steam system process
Wall enclosure system bypass pipe
Ceiling bypass pipe
Drum Saturated steam
outlet pipe
Ceiling pipe
inlet header
Ceiling
pipe
Ceiling pipe
outlet header
Rear flue gas
pass ceiling
pipe
Rear flue gas
pass rear wall
pipe
Rear flue gas
pass rear wall
lower header
Rear flue gas pass side
wall lower header
(rear)
Rear flue gas pass
rear end side wall
pipe
Rear flue gas
pass front wall
pipe
Rear flue gas pass
front wall lower
header
Rear flue gas pass extension
side wall lower header
Rear flue gas pass side wall
lower header (front)
Rear flue gas pass
extension side wall pipe
Rear flue gas pass front
end side wall pipe
Rear flue gas
pass side wall
upper header
Low temperature
superheater inlet
connecting pipe
Horizontal low
temperature superheater
inlet header
Horizontal low
temperature
superheater
Vertical low
temperature
superheater
Vertical low temperature
superheater outlet header
Superheater
division wall
Division wall
inlet header
First stage attemperator
outlet connecting pipe
Superheater first
stage attemperator
First stage attemperator
inlet connecting pipe
Division wall
outlet header
Connecting pipe between
division wall and rear platen
Rear platen inlet
header
Superheater
rear platen
Rear platen
outlet header
Final stage
superheater
Final stage superheater
inlet header
Second stage attemperator
outlet connecting pipe
Superheater second
attemperator
Superheater outlet conduit
Second stage
attemperator inlet
connecting pipe
Final stage superheater
outlet header
(Cold reheater pipeline)
Reheater spray
attemperator (Cold reheater pipeline)
Wall type reheater
inlet header
Front wall
radiation reheater
Side wall
radiation reheater
Wall type reheater
outlet header
Connecting pipe from wall type reheater outlet
header to reheater front platen inlet header
Reheater front platen
inlet header
Reheater front
platen
Final stage
reheater
Final stage reheater
outlet header
Reheater outlet
conduit

5
Chapter 2 Boiler Technical Specifications and Performance Parameters of Main
Components
2.1 The evaporation capacity under BMCR is 1.02 times as the admission capacity under turbine VWO.
Main parameters table of TMCR working condition and BMCR working condition:
Name Unit BMCR TMCR
Superheated steam flow t/h 2069 1878
Steam pressure at superheater outlet MPa (g) 17.47 17.31
Steam temperature at superheater outlet ℃ 541 541
Reheated steam flow t/h 1751 1598
Steam pressure at reheater inlet MPa (g) 3.97 3.69
Steam pressure at reheater outlet MPa (g) 3.76 3.50
Steam temperature at reheater inlet ℃ 332 325
Steam temperature at reheater outlet ℃ 541 541
Economizer inlet feed water temperature ℃ 282 277
2.2 Heating surface structure dimension
Heating surface name
Outside
diameter
Transverse
pitch
Longitudina
l pitch
Heating
area
Number of
row
Number
of piece
mm mm mm m2
Wall type reheater 60 63.5 0 623.4 1 558
Division wall superheater 57 3012 67 1616.8 6 60
Platen superheater 70/63 1016 73 1764.7 20 18
Platen reheater 63 508 73 3177 40 20
Final stage reheater 63 254 114 3476 82 10
Final stage superheater 51 190.5 102 5025 108 6
Low temperature superheater 57 142 114 17615 147 5
economizer 42 100 90 21926 209 4
Trisector preheater
Rotor diameter is 13492m; heating surface height is 2185; primary air sector
50°; reverse
2.3 Coal quality
The coal of this project is India soft coal of high ash content and low heat value.
Design coal type Worst coal type Best coal type
A) Technical analysis
Fixed carbon 31.00% 27.00% 42.00%
Volatile matter 22.00% 18.00% 27.90%
Ash content 36.00% 40.00% 21.00%
Moisture 11.00% 15.00% 9.10%
Gross calorific value as received basis (kCal/kg) 4200 3800 4900
B) Elemental analysis
Carbon 43.10 % 38.00 % 53.90 %
Hydrogen 2.85 % 2.50 % 3.00 %
Nitrogen 0.9 % 0.50 % 1.20 %
Sulfur 0.4 % 0.60 % 0.30 %
Moisture 11.0 % 15.00 % 9.10 %
Oxygen 5.75 % 3.40 % 11.50 %
Ash content 36.00 % 40.00 % 21.00 %
Fixed moisture 6% 7%
Gross calorific value as received basis (kCal/kg) 4200 3800 4900
C) Deformation temperature 1170 ℃ 1170 ℃ 1170 ℃
Softening temperature 1300 ℃ 1300℃ 1300 ℃
Flow temperature 1400 ℃ 1400℃ 1400℃
D) Grindability coefficient 50 45 55

6
2.4 Ignition & combustion-supporting oil
2.4.1 The ignition method of this combustion system is three-stage ignition, that is, the high-energy ignitor
ignites the light oil, the light oil ignites the heavy oil and then the heavy oil ignites the pulverized coal. The
burner secondary air nozzle is equipped with 2 layers of total 8 light oil gun and adopts mechanical
atomization method. The fuel used is light oil when the boiler starts up to 10%BMCR; the
combustion-supporting oil is heavy oil during low load operation and the boiler heavy oil system output is
30%BMCR. The ignition unit adopts high-energy electric spark ignitor.
The design output of light oil gun/heavy oil gun: 12/42 t/h(oil)
2.4.2 Oil quality performance data
Light oil characteristic data table:
Name Unit Average value
Kinematic viscosity (at 38℃) cst 2.5-15.7
Pour point ℃ Summer : ≮12, winter: ≮18
Mechanical impurities ℃ >66
Closed cup flash point % ≮1.8
Sulphur content % ≮0.25
Water content % ≮0.02
Ash content % ≮1.5
Heavy oil characteristic data table:
Characteristic HFO
Acidic, inorganic 0.1
Ash, mass percent % 11000cal/g
Gross calorific value >66℃
Flash point, min ≮180cst
Kinematic viscosity at 50℃ (cst), max ≮0.25
Residue, mass percent (%), max ≮4.5
Sulphur, total mass percent (%), max ≮1.0
Water content, mass percent (%), max ≮2．5
Asphalt mass percent (%), max
2.5 Boiler steam water quality
Normal blowdown rate of boiler (BMCR) is 10.5 t/h counted as per 0.5 %.
It is strictly required to control the boiler feed water and boiler water according to the following quality
standards for the purpose of guarantee qualified steam quality
2.5.1 Quality standard table for boiler feed water:
Item Unit Guaranteed value
PH value (25℃) 9.0~9.6
Hardness μmol/l ~0
Dissolved oxygen (O2) μg/l ≤7
Iron (Fe) μg/l ≤20
Copper (Cu) μg/l ≤5
Oil mg/l ≤0.3
Hydrazine (N2H4) μg/l ≤30
Conductivity 25℃ μs/cm ≤0.3
Silicon dioxide Comply with the standards

7
2.5.2 Quality standard table for boiler water:
PH value (25℃) 9~10
Hardness μmo l/l ~0
Total salt content mg/l ≤20
Silicon dioxide (SiO2) mg/l ≤0.25
Chloride ion CL-1 mg/l ≤1
Phosphate radical mg/l 0.5~3
2.5.3 Quality standard table for steam:
Iron (Fe) μg/kg ≤20
Copper (Cu) μg/kg ≤5
Sodium (Na) μg/kg ≤10
Silicon dioxide (SiO2) μg/kg ≤20
Conductivity (25℃) μs/cm ≤0.30
2.6 Site weather and geographic condition
The region that this project construction site located has the features of high temperature and high humidity.
Extreme max temperature: 48℃
Extreme min temperature: 8℃
Design temperature: 8~50℃ (performance guaranteed value is below 34.5℃)
Design temperature of electrical equipment: 50℃
Relative humidity:
Design: 60%
Mean annual precipitation: 1500mm
Earthquake intensity: Grade VII (as per IS-1893 located at zone-II)
Number of annual operation hours of boiler: above 30 years

8
Chapter 3 Calculated Data Table Of Boiler Thermal Performance
Performance data (Design coal type)
A. Design parameters
No. Item Unit BMCR TMCR HPHO* 80%TMCR 60%TMCR 40%BMCR
1 Main steam flow rate t/h 2068.6 1877.9 1640.2 1474.2 1105 836.4
2 Superheated steam outlet pressure Mpa 17.47 17.31 17.14 15.24 11.55 8.82
3
Superheated steam outlet
temperature
℃ 541 541 541 541 541 529
4 Reheated steam flow rate t/h 1751.4 1597.9 1612.6 1272.6 968.5 748.1
5 Reheated steam inlet pressure Mpa 3.95 3.69 3.83 2.93 2.22 1.65
6 Reheated steam outlet pressure Mpa 3.74 3.50 3.63 2.78 2.10 1.56
7 Reheated steam inlet temperature ℃ 332.1 324.8 333.3 316.6 321.3 313.8
8
Reheated steam outlet
temperature
℃ 541 541 541 541 541 514
9 Feed water pressure Mpa 19.24 18.82 18.36 16.38 12.45 9.55
10 Feed water temperature ℃ 280 275 183 261 245 229
11 Attemperating water temperature ℃ 182 179 182 170 159 148
12
Superheater water spray quantity
(first stage)
t/h 31.0 68.7 179.0 110.7 98.7 72.8
13
Superheater water spray quantity
(second stage)
t/h 0.0 0.0 0.0 0.0 0.0 0.0
14 reheater water spray quantity t/h 0.0 0.0 0.0 0.0 0.0 7.4
15 Boiler barrel pressure Mpa 18.84 18.46 18.02 16.06 12.17 9.28
16 Boiler barrel temperature ℃ 361.2 359.5 357.5 348.1 326.3 306.3
17
Exhaust gas temperature (before
correction)
℃ 139.5 138.0 117.0 134.5 125.5 112.5
18
Exhaust gas temperature (after
correction)
℃ 135.0 133.0 113.5 129.0 119.5 105.5
B Heat loss and heat load
1
Heat loss carried off by exhaust
dry flue gas
% 4.18 4.12 3.23 3.96 3.57 3.17
2
Heat loss carried off by the
moisture in fuel
% 1.64 1.64 1.61 1.63 1.62 1.61
3
moisture produced by hydrogen
burning
% 3.76 3.76 3.7 3.75 3.7 2 3.69
4
moisture in air
% 0.17 0.17 0.13 0.16 0.15 0.13
5 Heat loss due to unburned fuel % 1.5 1.5 1.5 1.5 1.8 2
6 Heat loss due to radiation % 0.17 0.22 0.21 0.26 0.34 0.43
7 Inestimable heat loss % 0.35 0.35 0.35 0.35 0.35 0.35
8 Manufacturer margin % 0.7 0.7 0.7 0.7 0.7 0.7
9 Total loss % 12.47 12.46 11.43 12.31 12.25 12.08
10 High heat efficiency % 87 53 87.54 88.57 87.69 87.75 87 92
11 Fuel consumption t/h 345.6 318.7 324.8 259.9 202.0 155.7
12 Burner operating layer 6 6 6 5 4 3
13 Excess air coefficient 1.25 1.25 1.25 1.25 1.25 1.25

9
C Steam temperature
No. Item Unit BMCR TMCR HPHO* 80%TMCR 60%TMCR 40%TMCR
1
Wall type reheater inlet
temperature
℃ 332 325 333 317 321 303
2
Wall type reheater outlet
temperature
℃ 371 366 372 363 371 353
3
Furnace roof superheater inlet
temperature
℃ 361 359 358 348 326 306
4
Furnace roof superheater outlet
temperature
℃ 363 362 361 352 332 313
5
Division wall superheater inlet
temperature
℃ 398 393 382 378 358 338
6
Division wall superheater outlet
temperature
℃ 443 440 428 432 424 411
7
Rear platen superheater inlet
temperature
℃ 443 440 428 432 424 411
8
Rear platen superheater outlet
temperature
℃ 499 499 493 501 505 501
9 Platen reheater inlet temperature ℃ 371 366 372 363 371 353
10 Platen reheater outlet temperature ℃ 468 468 470 470 477 458
11
Final stage reheater inlet
temperature
℃ 468 468 470 470 477 458
12
Final stage reheater outlet
temperature
℃ 541 541 540 540 540 515
13
Final stage superheater inlet
temperature
℃ 499 499 493 501 505 501
14
Final stage superheater outlet
temperature
℃ 541 541 541 541 541 529
15
Steam cooled pipe inlet
temperature
℃ 363 362 361 352 332 313
16
Steam cooled pipe outlet
temperature
℃ 364 362 362 353 334 316
17
LV superheater straight part inlet
temperature
℃ 394 396 413 400 398 384
18
LV superheater straight part outlet
temperature
℃ 404 407 429 414 415 402
19
Reversing chamber economizer
hanging pipe inlet temperature
℃ 323 320 275 310 296 279
20
hanging pipe outlet temperature
℃ 325 322 279 312 299 282
21
Reversing chamber enclosure tube
inlet temperature
℃ 364 362 362 353 334 316
22
outlet temperature
℃ 365 364 364 356 339 322
23
LV superheater horizontal part
inlet temperature
℃ 365 364 364 356 339 322
24
outlet temperature
℃ 394 396 413 400 398 384
25
temperature
℃ 323 320 274 310 295 279
26
temperature
℃ 323 320 275 310 296 279
27 Economizer inlet temperature ℃ 282 277 185 262 246 231
28 Economizer outlet temperature ℃ 323 320 274 310 295 279

10
D Flue gas temperature
1
Furnace outlet flue gas
temperature
℃ 1045 1033 1018 983 911 841
2
Wall type reheater inlet
temperature
℃ 1327 1330 1311 1312 1235 1165
3
Wall type reheater outlet
temperature
℃ 1327 1330 1311 1312 1235 1165
4
Furnace roof superheater inlet
temperature
℃ 1327 1330 1311 1312 1235 1165
5
Furnace roof superheater outlet
temperature
℃ 1327 1330 1311 1312 1235 1165
6 Division wall superheater inlet ℃ 1327 1330 1311 1312 1235 1165
7
Division wall superheater outlet
temperature
℃ 1143 1134 1115 1088 1017 949
8
Rear platen superheater inlet
temperature
℃ 1143 1134 1115 1088 1017 949
9
Rear platen superheater outlet
temperature
℃ 1045 1033 1018 983 911 841
10 Platen reheater inlet temperature ℃ 1045 1033 1018 983 911 841
11 Platen reheater outlet temperature ℃ 932 918 908 867 800 730
12
Final stage reheater inlet
temperature
℃ 923 909 899 858 791 721
13
Final stage reheater outlet
temperature
℃ 837 823 816 777 721 657
14
Final stage superheater inlet
temperature
℃ 813 799 793 753 697 634
15
Final stage superheater outlet
temperature
℃ 731 718 714 682 639 592
16
Steam cooled pipe inlet
temperature
℃ 731 718 714 682 639 592
17
Steam cooled pipe outlet
temperature
℃ 724 711 707 674 632 584
18
LV superheater straight part inlet
temperature
℃ 724 711 707 674 632 584
19
LV superheater straight part outlet
temperature
℃ 686 674 673 640 599 554
20
hanging pipe inlet temperature
℃ 686 674 673 640 599 554
21
hanging pipe outlet temperature
℃ 678 667 665 633 593 548
22
inlet temperature
℃ 678 667 665 633 593 548
23
outlet temperature
℃ 662 651 649 616 575 529
24
inlet temperature
℃ 662 651 649 616 575 529
25
outlet temperature
℃ 488 481 484 459 431 399
26
temperature
℃ 488 481 484 459 431 399
27
temperature
℃ 486 478 482 457 428 397

11
28 Economizer inlet temperature ℃ 486 478 482 457 428 397
29 Economizer outlet temperature ℃ 342 336 279 316 292 269
30 Preheater inlet temperature ℃ 342 336 279 316 292 269
31
Preheater outlet temperature
(corrected)
℃ 135 133 114 129 120 106
E Average velocity of flue gas
1
Rear platen superheater flue gas
velocity
m/s 8.7 8.0 8.0 6.3 4.6 3.3
2 Platen reheater flue gas velocity m/s 9.5 8.7 8.8 6.8 5.0 3.6
3
Final stage reheater flue gas
velocity
m/s 12.0 11.0 11.1 8.6 6.3 4.5
4
Final stage superheater flue gas
velocity
m/s 11.5 10.5 10.6 8.2 6.1 4.3
5
Horizontal part low temperature
superheater flue gas velocity
m/s 9.9 9.3 9.5 7.3 2.7 3.9
6 Economizer flue gas velocity m/s 8.5 7.8 7.6 6.2 4.6 3.4
F Flue gas flow rate
No. Item Unit BMCR TMCR HPHO* 80%TMCR 80%TMCR 60%TMCR
1
Primary air flow rate entering
preheater
Kg/h 580183 556376 680792 510512 450868 400738
2 Preheater secondary air flow rate Kg/h 1790510 1619370 1589234 1238461 936317 643036
3
Flue gas flow rate entering
preheater
Kg/h 2699532 2489411 2537100 2030083 1575601 1113196
4
Attemperating primary air flow
rate
Kg/h 211248 218808 164304 215424 156888 95400
5
Primary air flow rate out of
preheater
Kg/h 399460 377456 500792 332672 276988 226498
6
Secondary air flow rate out of
preheater
Kg/h 1771070 1599570 1567994 1219021 915797 621796
7 Flue gas flow rate out of preheater Kg/h 2899692 2688131 2738340 2227363 1770001 1308676
8
Air leakage quantity from air to
flue gas
Kg/h 200160 198720 201240 197280 194400 195480
9
Air leakage quantity from primary
air to secondary air
Kg/h 23040 22320 21600 21600 19440 19800
10
Air leakage quantity from
secondary air to flue gas
Kg/h 42480 42120 42840 41040 39960 41040
11
Air leakage quantity from primary
air to flue gas
Kg/h 157680 156600 158400 156240 154440 154440
G Air temperature
1
Preheater inlet primary air
temperature
℃ 44.5 44.5 44.5 44.5 44.5 44.5
2
Preheater inlet secondary air
temperature
℃ 37.3 37.3 37.3 37.3 37.3 37.3
3
Preheater outlet primary air
temperature
℃ 302.0 298.5 245.0 287.0 269.5 244.5
4
Preheater outlet secondary air
temperature
℃ 312.0 307.5 254.5 294.0 275.0 249.0

12
Chapter 4 Induced Draft Fan
4.1 General introduction of induced draft fan
Model: fixed blade adjustable axle induced draft fan
Quantity: each boiler is equipped with 2 sets.
Operating mode: 2 sets of fan operate in parallel.
Adjusting mode: fixed blade adjustment.
Arrangement mode: horizontal symmetric arrangement, vertical inlet air and horizontal outlet air.
Single set of fan is of 60%BMCR of boiler capacity.
4.2 Induced draft fan parameters requirements:
4.2.1 Parameters of fan at each working condition point:
No.
Working condition
Coal type Parameters
TB
working
condition
BMCR working condition
TMCR working
condition
Design coal type Check coal type Design coal type
1 Fan inlet volume flow rate (m³/s) 690 547 549 500
2 Fan inlet static pressure (Pa) -6580 -5220 -5205 -5065
3 Fan inlet flue gas temperature (℃) 150 134.5 130.0 132.1
4 Fan inlet medium density (kg/m³) 0.741 0.779 0.785 0.785
5 Inlet flue gas dust content (mg/Nm³) ≤230
6 Fan static pressure rise (Pa) 7479 5983 6057 5593
Instruction:
① TB (test bl℃k), the air quantity and air pressure of this working condition point is the check point of fan
capacity.
② B-MCR is the max continuous output working condition of boiler, which is the check point of fan
efficiency.
③ TMCR is equivalent to 93.37% B-MCR working condition of boiler.
4.2.2 Technical data of induced draft fan:
No. Item Unit Induced draft fan
1 Fan model G158/343
2 Fan regulating device model 8000Nm 4~20mA
3 Impeller diameter mm 3430
4 Bearing material 42CrMo
5 Hub material 15MnV
6 Blade material 15MnV
7 Impeller series Level 1
8 Blade number of each stage Piece 18
9 Blade adjustable range Degree -70~+30
10 Bore and stroke of hydraulic cylinder mm/mm N/A
11 Rotor weight kg ~7500
12 Rotor moment of inertia Kg.m2
6524
13 Fan first critical speed r/min >956

13
14 Air inlet box material/wall thickness /mm Q235/6
15 Casing material/wall thickness /mm Q235A/16
16 Diffuser material/wall thickness /mm Q235/6
17 Fan bearing type Roll
18 Bearing lubrication type Thin oil
19 Bearing cooling type
Forced oil circulation + cooling
wind
20 Bearing bush cooling water volume t/h N/V
21 Fan rotation direction (view form motor side) Anticlockwise
22 Muffler resistance Pa ------
23 Fan total weight kg ~55000
24
Max lifting weight/max lifting height in
installation
kg ~25000
m >3.8 (start from fan axial)
25
maintenance
Kg ~7500
m >3.8 (start from fan axial)
4.2.3 Fan performance data
Working condition
Item
Induced draft fan
TB condition BMCR condition TMCR condition
Fan inlet volume flow rate (m3/s) 690 547 500
Fan inlet mass flow rate (kg/s) 511.29 426.11 392.5
Fan inlet temperature (℃) 48 48 48
Inlet air density (kg/m3
) 0.741 0.779 0.785
Fan inlet total pressure (Pa) -6580 -5220 -5065
Fan inlet static pressure (Pa) -6580 -5220 -5065
Fan outlet total pressure (Pa) 968 818 583
Fan outlet static pressure (Pa) 968 818 583
Fan total pressure rise (Pa) 7548 6038 5648
Fan static pressure rise (Pa) 7548 6038 5648
Fan outlet wind temperature (℃) 161.63 143.55 140.98
Fan accessory loss (Pa) Included in efficiency loss Included in efficiency loss Included in efficiency loss
Fan total pressure efficiency (%) 85.06 83.7 79.2
Fan shaft output (kW) 5949 3857 3485
Fan speed (r/min) 745 745 745
4.2.4 Integrated data table of supporting motor
No. Parameter name Unit Induced draft fan
1 Model STMKS900-8
2 Electromotor type Three phase squirrel cage asynchronous motor
3 Rated power kW
6250
J=6524 kgm2

14
4 Rated voltage kV 11
5 Rated current A 393
6 Rated power Hz 50
7 Rated speed rpm 745
8 Number of poles 8
9 Degree of protection IPW55
10 Insulation level F
11 Cooling mode IC81W
12 Installation mode IMB3
13 Working system S1
14 Efficiency %
Efficiency at rated load % 96.0
3/4Efficiency at rated load % 95.6
1/2Efficiency at rated load % 94.2
15 Power factor
Power factor at rated load 0.88
Power factor at 3/4 rated load 0.85
16 Maximum torque/rated torque 2.2
17 Locked rotor torque/rated torque 0.45
18 Locked rotor current/rated current 6.0
19
Accelerating time and starting time
(under rated load working condition)
s 17
20 Motor moment of inertia Kg.m2
21 Noise dB(A) 85
22 Vibration amplitude at bearing pedestal mm 0.076
23 Bearing vibrating velocity mm/s
24 Stator temperature rise K 70
25 Number of phases Three
26 Temperature measuring element Pt100
27 Bearing model Domestic sliding
Bearing model trademark 46# steam turbine oil L-TSA
Bearing lubrication type Forced thin lubricating oil
Bearing cooling mode Oil cooling
28 Motor weight Kg 45000
29 Bearing lubricating oil flow (L/min) 16
30 CT mode ratio/accuracy level Confirmed by design liaison meeting
31 Rotating direction Confirmed by fan manufacturer
32 Threading pipe adaptor box
33 Threading pipe inlet
34 Allowed locked rotor time s 41
35 Starting torque
36 Min starting torque
37 Recommended lubricant 46# steam turbine oil L-TSA

15
38
Resistance and temperature detector & model
for stator use
Pt100
39 Bearing temperature detector & model Pt100, bimetal thermometer
4.2.5 Main technical data of oil system
1 Flow rate l/min 40 (shared by fan and motor)
2 Pressure MPa 0.4
3 Oil quality trademark N46 or N68
4 Oil tank material/volume /m3 Q235/0.6
5 Oil filter filtering precision μ 25
6 Oil cooler water quantity 2.5
7 Oil cooler water pressure MPa
8 Oil cooler model Plate type
9 Oil pump model Gear pump
10 Oil pump number Set 2
11 Oil pump speed r/min 1470
12 Oil pump power 5.5
13 Quantity of oil tank electric heater Set 1
14 Power of oil tank electric heater KW 3
4.2.5 Cooling water data table
Equipment Equipment name
Water quality
requirement
Water pressure
requirement
Water
temperature
requirement
Water
quantity
requirement
Induced
draft fan
Lubricating oil station
cooling water flow rate
Common
industrial water
1MPa 38 6.3 T/h

16
Chapter 5 Forced Draft Fan
5.1 Overview: Model: moving blade adjustable axle induced draft fan.
Quantity: each set of boiler is equipped with 2 set.
Operating mode: 2 sets of forced draft fan operate in parallel, single set of fan can meet the requirement of
boiler 60% BMCR working condition air quantity.
Adjusting mode: moving blade adjustment.
Arrangement mode: horizontal & symmetry arrangement, vertical inlet air and horizontal outlet air
The forced draft fan bearing adopts rolling bearing and oil bath lubrication. The motor bearing adopts
rolling bearing and grease lubrication and adopts water cooling mode.
5.2 Requirements of forced draft fan parameters
5.2.1 Parameters of fan at each working condition point (the initial data):
No.
Working condition
Parameters
TB working
condition
BMCR working
condition
TMCR
Design coal
quality
Design coal
quality
Design coal
quality
1 Fan inlet Flow rate (m3
/s) 303 275 248
2 Fan inlet cross section static pressure (Pa) -950 -875 -823
3 Fan inlet temperature (℃) 48 48 48
4 Fan static pressure rise (Pa) 4584 3820 3688
5 Inlet air density (kg/m3) 1.038 1.038 1.038
5.2.2 Technical data of forced draft fan
No. Item Unit forced draft fan
1 Fan model ANN-2575/1250C
2 Fan regulating device model 5t hydraulic cylinder
5 Hub material Forging steel
6 Blade material Cast aluminum alloy
9 Blade adjustable range Degree 30~85
10 Bore and stroke of hydraulic cylinder mm/mm 250/96
11 Rotor weight kg 3597
12 Rotor moment of inertia Kg.m2
387
13 Fan first critical speed r/min 1287
14 Air inlet box material/wall thickness /mm Q235A/6

17
No. Item Unit forced draft fan
16 Diffuser material/wall thickness /mm Q235A/6
17 Fan bearing type Rolling bearing
18 Bearing lubrication type Oil bath lubrication
19 Bearing cooling type Natural cooling
20 Bearing bush cooling water volume t/h /
21 Fan rotation direction (view form motor side) Clockwise
22 Muffler resistance Pa 150
23 Fan total weight kg 16087
24 Max lifting weight/max lifting height in installation
kg 7620
m 3.7
25 Max lifting weight/max lifting height in maintenance
Kg 1600
m 3.7
5.2.3 Fan performance data
Working condition
Item
Forced draft fan
TB working
condition
B-MCR working
condition
TMCR working
condition
Fan inlet volume flow rate (m3
/s) 303 275 248
Fan inlet mass flow rate (kg/s) / / /
Inlet air density (kg/m3
) 1.038 1.038 1.038
Fan accessory loss (Pa) Included Included Included
Fan total pressure efficiency (%) 85 87.3 88.0
Fan shaft output (kW) 1636.8 1209.1 1042.2
Fan speed (r/min) 990 990 990
5.2.4 Technical data of electromotor:
Item Unit Secondary fan motor
Model STMKS500-6 (tentative)
Rated power kW 1800
Rated voltage kV 11
Synchronous speed r/min 1000
Startup current A 690
Rated current A 115
Frequency Hz 50

18
Main features
Efficiency 95.8
Power factor 0.88
Locked rotor torque 0.5
Locked rotor current 6.0
Max torque 2.0
Insulation level F/B
Weight kg 18000
Cooling mode Air water cooling
5.2.5 Main technical data of oil system
No. Item Unit Value (forced draft fan hydraulic pressure)
1 Flow rate l/min 10~12
2 Pressure MPa 8.0
3 Oil quality trademark ISO VG 32
4 Oil tank material/volume /m3 Low carbon steel spray paint/0.203
5 Oil filter filtering precision μ 10
6 Oil cooler water quantity 0.24
7 Oil cooler water pressure MPa 0.2~0.4
8 Oil cooler model Plate type
9 Oil pump model Gear pump
10 Oil pump number Set 2
11 Oil pump speed r/min 1430
12 Oil pump power 2.2
13 Quantity of oil tank electric heater Set 2
14 Power of oil tank electric heater kW 1.0
5.2.6 Forced draft fan cooling water data table
Equipment name
Water quality
requirement
Water pressure
requirement
Water temperature
requirement
Water quantity
requirement
Lubricating oil station
cooling water flow rate
/ / / /
HP oil station cooling
water flow rate
/ 0.4~0.6Mpa <40℃ tentative

19
Chapter 6 Primary Air Fan
6.1 Overview:
Model: moving blade adjustable axle induced draft fan.
Quantity: each set of boiler is equipped with 2 sets.
Operating mode: 2 sets of primary air fan operate in parallel, single set fan can meet the requirements of
boiler 60%BMCR working condition air quantity.
Adjusting mode: moving blade adjustment.
Arrangement mode: horizontal & symmetry arrangement, vertical inlet air and horizontal outlet air
The bearing adopts rolling bearing and forced lubrication. The motor bearing adopts domestic sliding
bearing and forced lubrication and the motor adopts water cooling mode.
6.2 Primary air fan parameter requirements
6.2.1 Parameters of fans at each working condition point:
No.
Working condition
Parameters
TB working
condition
B-MCR working
condition
TMCR
Design coal
quality
Design coal
quality
Design coal
quality
1 Fan inlet Flow rate(m3/s) 178 162 156
2 Fan inlet cross section static pressure(Pa) -550 -458 -446
3 Fan inlet temperature (℃) 48 48 48
4 Fan static pressure rise (Pa) 13500 11180 10829
5 Inlet air density (kg/m3) 1.044 1.044 1.044
6.2.2 Technical data of primary air fan
No. Item Unit Primary air fan
1 Fan model ANT-2062/1250N
2 Fan regulating device model 10t hydraulic cylinder
5 Hub material Forging steel
6 Blade material Cast aluminum alloy
9 Blade adjustable range Degree 10~55
10 Bore and stroke of hydraulic cylinder mm/mm 250/96
11 Rotor weight kg 4117
12 Rotor moment of inertia Kg.m2 674
13 Fan first critical speed r/min 1938
14 Air inlet box material/wall thickness /mm Q235A/5
16 Diffuser material/wall thickness /mm Q235A/5
17 Fan bearing type Rolling bearing
18 Bearing lubrication type Forced lubrication
19 Bearing cooling type Forced cooling
20 Bearing bush cooling water volume t/h
21
Fan rotation direction (view form motor
side)
Clockwise
22 Muffler resistance Pa 150

20
No. Item Unit Primary air fan
23 Fan total weight kg 15797
24
installation
kg 4320
m 2.8
25
maintenance
Kg 2640
m 2.8
6.2.3 Performance data of primary air fan
Working condition
Item
Primary air fan
TB working
condition
BMCR working
condition
TMCR working
condition
Fan inlet volume flow rate (m3/s) 178 162 156
Fan inlet mass flow rate (kg/s) / / /
Inlet air density (kg/m3) 1.044 1.044 1.044
Fan accessory loss (Pa) Included Included Included
Fan total pressure efficiency (%) 87 88.0 88.0
Fan shaft output (kW) 2653.2 1993.9 1861.7
Fan speed (r/min) 1490 1490 1490
6.2.4 Technical data of primary air fan motor:
Item Unit Primary air fan motor
Model STMKS560-4 (tentative)
Rated power kW 2800
Rated voltage kV 11
Startup current A 1038
Rated current A 173
Frequency Hz 50
Main features
Efficiency 95.6
Power factor 0.89
Locked rotor torque 0.5
Locked rotor current 6.0
Max torque 2.2
Insulation level F/B
Weight kg 21300
Cooling mode Air water cooling
6.2.5 Main technical data of primary air fan oil system
No. Item Unit
Value (Hydraulic oil
station)
Value (Lubricating oil
station)
1 Flow rate l/min 10~12 15~18
2 pressure MPa 8.0 1.5~2.0
3 Oil quality trademark ISO VG 32 ISO VG 46
4 Oil tank material/volume /m3 Low carbon steel spray
paint/0.203
Low carbon steel
spray paint/0.369
5 Oil filter filtering precision μ 10 10
6 Oil cooler water quantity 0.24 0.6
7 Oil cooler water pressure MPa 0.2~0.4 0.2~0.4

21
No. Item Unit
Value (Hydraulic oil
station)
Value (Lubricating oil
station)
8 Oil cooler model Plate type Plate type
9 Oil pump model Gear pump Gear pump
10 Oil pump number Set 2 2
11 Oil pump speed r/min 1430 1430
12 Oil pump power 2.2 0.75
13 Quantity of oil tank electric heater Set 2 2
14 Power of oil tank electric heater kW 1.0 1.0
6.2.6 Data of primary air fan oil station cooling water
Equipment name
Water quality
requirement
Water pressure
requirement
Water temperature
requirement
Water quantity
requirement
Lubricating oil station cooling
water flow rate
/ 0.4~0.6Mpa <40℃ Tentative
HP oil station cooling water
flow rate
/ 0.4~0.6Mpa <40℃ Tentative

22
Chapter 7 Air Preheater
7.1 Air preheater data parameters
Name Height
Component
thickness
Component
material
Heat transmission
component
Hot section layer 1000 mm 0.8mm SPCC-SD
Hot section intermediate layer 880 mm 0.8mm SPCC-SD
Cold section layer 305 mm 1.2mm corten-A
Inner diameter of
rotor
14236 mm
Actuator
Model of speed reducer SGW600-01A
Main motor Y225S-4B3 37KW 1480 r/min
Auxiliary motor Y160M-4B5 11KW 359 r/min
SGZJ11-4
right angle
speed reducer
Air motor
INGERSOLL-
RAND
7.5 HP 103 r/min
Main speed reducing ratio 123.835
Output shaft speed Main transmission 11.95 r/min
Rated output torque 57500 N·m
Pedestal bearing Spherical roller thrust bearing 294/710EF
Guide bearing
Biserial centripetal spherical roller bearing
23192
Oil circulation
system
Guide bearing, pedestal bearing
thin oil station
Model: ℃S-8E
Electromotor: Y9OL-4 1.5KW
Three-screw pump: 3GR30X4-1.6/1.0
Double cylinder oil filter: SXU-A100
Tubular oil cooler: GLC2-1.3
Soot blower Retractable sootblower

23
Chapter 8 Pulverizing System
8.1 Brief introduction of pulverizing system
Model: HP1103DYN type medium speed coal mill cold primary fan positive pressure direct firing pulverizing
system; each boiler is equipped with 7 medium speed coal.
Fineness of coal: Design coal type and check coal type meet the requirements of the following coal fineness
that is R90= 18.38% and uniformity index ≥1.2.
Boiler (BMCR) coal consumption: 345.7 t/h (Design coal type)
386.7 t/h (Check coal type, worst coal)
294.5 t/h (Check coal type, best coal)
Theoretical air quantity (dry air): Design coal type 4.41 Nm3/kg
Check coal type 3.95 Nm3
/kg
Furnace outlet excess air ratio (B-MCR): 1.14 (tentative)
8.2 Coal feeder
8.2.1 Model: electronic weighing coal feeder.
Quantity: each set of coal mill is equipped with 1 set of coal feeder.
Continuous coal feed rate: 10~100 t/h
Measuring accuracy: ±0.25%
Control accuracy: ±0.5%
Raw coal granularity: ≤30mm
The noise should be lower than 85dB (A) at the position 1m away from the shell during normal operation
of coal feeder.
8.2.2 Technical data table of coal feeder of
No. Item Unit Supplied by manufacturer
1 Coal feeder model EG2490
2 Output range t/h 115
3
Coal feeding distance (coal feeder inlet and outlet central
line distance)
mm 3100
4 Inlet coal chute length/diameter (outer dia.) / wall thickness mm/mm/mm 1405/φ629/8
Outlet coal chute length/diameter (outer dia.) / wall
thickness
mm/mm/mm 5400/φ610/8
5 Coal inlet flange inner dia. (coal inlet gate inner dia.) mm φ629
Coal outlet flange inner dia. (coal outlet gate inner dia.) mm φ610
6 Main driven motor model JRTKAF87100L4
Power kW 3.0
Power supply 415
7 Cleaning chain motor model JRTSF77R37D71D4
Power kW 0.37
Power supply 415
8 Engine body seal
Seal wind pressure (differential pressure with pulverizing
mill inlet)
Pa +500
Seal air quantity Nm3/min 12
9 Model and power of inlet & outlet coal gate drive motor kW 1.1
AUMA/ROTORK

24
8.2.3 Technical data of coal feeder motor
Item Unit Data
Model KF87-DV100L4 (SEW)
Rated power kW 3
Rated voltage kV 415
Startup current A 4~7 times
Rated current A 6.4
Frequency Hz 50
8.3 Coal mill
8.3.1 Mill inlet coal granularity: ≤30 mm
Boiler (BMCR) coal consumption: 345.7 t/h (design coal type)
386.7 t/h (Check coal type, worst coal)
294.5 t/h (Check coal type, best coal)
Drying medium temperature of coal mill inlet: the max temperature of air preheater outlet primary air is
326.7 ℃ (design coal type B-MCR working condition, tentative).
Medium temperature of coal mill outlet: <75 ℃.
Pulverized coal moisture: 80% of air drying machine moisture.
Pulverized coal pipeline number of each set of coal mill: 4.
8.3.2 Technical data table of coal mill
No. Item Unit
1 Model HP1103/Dyn
2 Separator model Dynamic separator
3 Ground roll loading mode Spring variable load
4 Base mode Cement fixed base
5 Primary air inlet dimension mm×mm 743×2438
6 Central coal chute dimension/wall thickness mm/ mm Φ610/10
7 Pulverized coal pipeline interface dimension/wall thickness mm/ mm Φ734/17
8 Volume of slagoff box m3 1.0
8.3.3 Coal mill performance data
No. Item Unit Design coal type Worst coal Best coal
1 Output of coal mill (R90= 18.38 %)
Maximum output t/h 87.2 80.2 93.3
Calculated output t/h 57.62 64.45 57.3
Guaranteed output (consider that 10% of output
decrease)
t/h 78.48 72.18 83.9
Minimum output t/h 19.62 18.045 23.3

25
No. Item Unit Design coal type Worst coal Best coal
2 Ventilation quantity of coal mill
Maximum ventilation quantity kg/s 36.3
Calculated ventilation quantity kg/s 31.4 33.48 30.7
Ventilation quantity under guaranteed output kg/s 34.8
Minimum ventilation quantity kg/s 22.7
3 Drying medium temperature of coal mill inlet ℃ 188 240 178
4 Rotated speed of coal mill r/min 30.0
5
Ventilation resistance of coal mill (including
segregator and coal dust distributor box)
Maximum ventilation resistance Pa ≤5000
Ventilation resistance (guaranteed output) Pa 4608
Calculated ventilation resistance Pa 3740 4250 3577
6 Seal air system of coal mill
Seal air quantity of coal mill m3
/min 100
Seal air pressure of coal mill (or the difference
with primary air pressure)
Pa >2000
7
Unit power consumption of coal mill (BMCR
working condition) (including oil station and
dynamic separator motor)
kW.h/t 11.4 11.77 10.5
Unit power consumption under guaranteed
output (including oil station and dynamic
separator motor)
kW.h/t 10.2 11.46 9.5
8 Unit wear rate of coal mill g/t 2.5 on average
9 Life of main parts
Grinding roller sleeve h ≥10000
Mill bowl back block h ≥10000
Seal part of grinding roller bearing h ≥20000
Other main seal parts h ≥20000
Stone coal scraper h ≥20000
10 Material of easy wear parts
Grinding roller sleeve Cemented carbide
Mill bowl back block Abrasion resistant cast iron
Stone coal scraper Overlay welding wear-resistant steel plate
11 Air delivery of seal fan/ pressure head m3/h /Pa 64032/6481
Motor power of seal fan KW 185
8.3.4 Summary table of main electromotor performance parameters

26
No. Parameter name Unit Value
1 Model YHP630-6
2 Electromotor type Squirrel cage asynchronous motor
3 Rated power kW 850
4 Rated voltage V 11000
5 Rated current A 62.5
6 Rated power Hz 50
7 Rated speed r/min 985
8 Number of poles 6
9 Degree of protection IP54
10 Insulation level F
11 Cooling mode IC611 (air-air cooling)
12 Installation mode IMB3 (vertical)
13 Working system S1 (continuous)
14 Efficiency %
Efficiency at rated load % 93
Efficiency at 3/4 rated load % 92.5
Efficiency at 1/2 rated load % 90
15 Power factor
Power factor at rated load 0.79
16 Maximum torque/rated torque 2.0
17 Locked rotor torque/rated torque 2.8
18 Locked rotor current/rated current 6.3
19
Accelerating time and starting time
(under rated load working condition)
S 2
20 Motor moment of inertia kg.m2
120
21 Noise dB(A) 85 (at 1.5m)
22 Vibration amplitude at bearing pedestal mm /
23 Bearing vibrating velocity mm/s 2.8
24 Stator temperature rise K 80
25 Number of phases 3
26 Temperature measuring element Pt100
27 Bearing model Rolling bearing
Bearing model trademark 3# lithium based grease
Bearing lubrication type Grease lubrication
Bearing cooling mode Natural cooling
28 Motor weight kg 9700
29 Bearing lubricating oil flow (m3/s) /
30 CT mode ratio/accuracy level /
31 Rotating direction Bidirection
32 Terminal box Subject to the official drawing
33 Terminal box inlet (dimension, quantity) Subject to the official drawing
34 Allowed locked rotor time s 3
35 Figuration drawing and drawing number
36 Starting torque 2.8Me
37 Min starting torque /
38 Recommended lubricant 3# lithium based grease
39
Stator temperature measuring element quantity
and model
6 pc/pt100
40
Bering temperature measuring element quantity
and model
2 pc/pt100
41 Vibration meter interface

27
8.3.5 Integrated data table of other supporting equipment
No. Item Unit
1 Actuator
Speed reducer (Model) KMP340
Transmission mode
Spiral bevel gear and planet gear second stage vertical
transmission
Transmission ratio 32.435
Lubrication cooling device (Model) OWTS10 (double pump)
Oil pump flow rate l/min 228
Motor power KW 11
Normal oil supply pressure MPa 0.15~0.35
Cooling water quantity m3/h 17
Cooling water pressure MPa 0.4
Oil tank electric heater/quantity 6
Rated voltage V 415
Rated power KW 1.7kW/set
Oil return pipe electric heat tape/quantity N/A
Rated voltage V /
Rated power KW /
Lubricating oil trademark ISO VG 320
2 Lubricating oil station device (Model) OWTS10
Oil pump flow rate l/min 228
Motor power KW 11
Normal oil supply pressure MPa 0.15~0.35
Oil tank electric heater/quantity 6
Lubricating oil trademark ISO VG 320
8.4 Data table of coal mill cooling waters
No. Equipment name
Water quality
requirement
Water pressure
requirement
Water temperature
requirement
Water quantity
requirement
1
Lubricating oil
station cooling water
Demineralized water 0.4MPa <41℃ 17m3
/h/set coal mill
8.5 Seal fan performance parameters
Seal fan (Model) 9-26 type 16D-4
Rated air flow m3
/h 64032
Rated hoisting head pressure Pa 6481
Seal fan motor (Model) Y355M2-6
Rated power KW 185
Rated speed r/min 960
Rated voltage V 415
Air filter (Model) 60M
Chamber number of each set 16
Air capacity of each chamber M³/h 4245
Resistance Pa 1370
Filtration index (particle diameter≥5um filter ratio) 95%

28
Chapter 9 Air Heater
9.1 Installation location of air heater: outdoor
Installation and operating conditions: it is used for heating secondary air when the ambient temperature is
low.
Arrangement mode: the secondary air heater is equipped on the forced draft fan outlet vertical air duct.
Quantity: each set of boiler is equipped with 2 sets of secondary air heater.
9.2 Technical data table of air heater:
No. Item Unit Secondary air heater
1 Model of air heater —— GNWCS-1.6/350-620
2 Number of sheets in parallel connection Sheet 2
3 Number of sheets in series connection Sheet 1
4 Air heater design pressure MPa 1.6
5 Air heater design temperature ℃ 350
6 Air heater draining pressure MPa 0.4~0.6
7 Air heater draining temperature ℃ Saturation temperature 159
8 Air heater inlet air temperature ℃ 8
9 Air heater outlet air temperature ℃ 20
10 Air heater air side resistance Pa <150
11 Air heater heat exchange area m2 620
12 Air heater interface dimension mm 8571 X5130
13 Air heater thickness mm 450
14 Air heater arrangement mode ——
Horizontal installation of horizontal vertical
air duct
15 Air heater weight kg 4.5
16 Adjusting mode Steam adjustment

29
Chapter 10 Air Compressor and Its Dryer
10.1 Overview of air compressor
Purpose of equipment: for supplying compressed air for instrument use of the whole factory and
maintenance use.
Allocation of equipment: heat engineering of this project is equipped with w compressed air rooms for
guaranteeing the compressed air for instrument and maintenance use. 1 compressed air room has 3 sets of
unit and is equipped with 4 sets of screw oil-free air compressor and 2 sets of screw slight oil air
compressor.
Design temperature: 8~50℃.
10.2 (instrument use) Main technical specifications of oil-free screw air compressor:
Model: SM250
Compressing medium: air
Air delivery: ≥ 41.5 m3/min (normal air is 101.3KPa (absolute), 20℃)
Exhaust pressure: ≥0.85Mpa
Exhaust temperature: ≤ cooling water temperature +8 ℃
Exhaust auto control range: 0%-100%
Adjusting mode: ON/OFF;
Max design temperature of Ingersoll Rand: 50℃
Indoor indraft and water cooling.
Quantity of equipment: 8 set (there are 6 sets of boiler in the whole factor, every 3 sets of boiler is
considered as one unit; each unit has 4 sets, of which 3 for operation and 1 for standby)
10.3 (Maintenance use) main technical specifications of oil injection screw air compressor:
Model: ML350
Compressing medium: air
Air delivery: ≥ 60.7 m3/min (normal air is 101.3KPa (absolute), 20℃)
Exhaust pressure: ≥0.75Mpa
Exhaust temperature: ≤cooling water temperature +8 ℃
Exhaust auto control range: 0%-100%
Adjusting mode: ON/OFF; air flow adjustment; ACS auto adjustment
Max design temperature of Ingersoll Rand: 50℃
Indoor indraft and water cooling.

30
Equipment quantity: 4 set (whole factory)
10.4 Performance data table of air compressor
No. Items Unit
Screw air compressor 40 Nm3/min 60 Nm3
/min
1 Model SM250 ML350
2 Type Oil-free screw Oil injection screw
3 Dimension (length×width×height) mm 3048 x 1930 x 2438 4650×1930 ×2146
4 Installation mode S1 S1
5 Adjusting mode ON/OFF;
ON/OFF; air flow adjustment;
ACS auto adjustment
6 Rated air capacity Nm3
/min 41.5 60.2
7 Rated exhaust pressure MPa (g) 0.85 0.75
8
Compressor speed
Male rotor of first stage rotor
Male rotor of second stage rotor
rpm 8292
13945
2185
9 Exhaust temperature ℃ Water temperature+8 Water temperature+8
10 Outlet air pressure dew point temperature ℃ Water temperature+8 Water temperature+8
11 Noise (at 1m) dB (A) 76 82
12 Weight kg 4306 7670
13 Rotor material
first stage: Carbon steel
second stage: stainless steel 304
Carbon steel
14 Oil content of exhaust ppm 0 3
15 Guaranteed service life Year 30 30
16 Cooling mode Water cooling Water cooling
17 Cooling water consumption t/h 19.1 18.2
18
Heat exchange area (the cooler area should
have 20% margin)
m2
19 Lubricating oil trademark/oil mass
IR-SL200
91L
Super cooling agent /204L
20 Shaft power of compressor KW 252.8 315
21 Rated air capacity KW 252.8 315
No load KW 53.2 64.3
Air compressor weight kg 4306 7670
22
Name/weight of the largest component for
maintenance
Motor/1890 Motor/1960
Clearance height of min maintenance m 2 2
Model & place of origin of screw and
motor bearing
SKF/ Sweden SKF/ Sweden
10.5 Air compressor motor data table
No. Motor Unit Oil-free 40 Nm3/min Slight oil 60 Nm3
/min
1 Quantity Set 1 1
2 Manufacturer Wuxi Hwada Motor Co., Ltd.
3 Motor model Squirrel cage motor
4 Degree of protection IP54 IP54
5 Speed/number of magnetic pole Piece 1475 4 1482
6 Full load output power of motor KW 287.5 345
7 Frame Y400 Y400
8 Weight 1860 7670
9 Number of motor electric heater 2 2
10 Voltage/power of motor electric motor 220v/200W 110v/200w

31
10.6 Overview of air compressor dryer
10.6.1 Equipment model: micro heat regeneration type after-treatment device (no air remover).
Purpose of equipment: for purifying the whole factory instrument use compressed air.
Installation site of equipment: indoor.
Allocation of equipment: this project is totally equipped with 8 sets of 45Nm3/min instrument use
compressed air drying and purifying device and 2 sets of 12Nm3/min instrument use air drying and
purifying device.
Design temperature: 8~50℃.
10.6.2 Main technical specification (instrument use 45Nm3
/min compressed air drying and purifying
device)
a. Model: SLAD-45MXF
b. Quantity: 8 sets.
c. Inlet compressed air pressure: 0.86Mpa (g).
d. Rated treated air delivery: ≥45Nm3
/min.
e. Inlet compressed air temperature: ≤45℃.
f. Inlet compressed air oil content: 0mg/m3.
g. Granularity of dust in outlet air: ≤1μm.
h. Regenerated air consumption: ≤5%.
j. Temperature of pressure dew point: ≤-40℃.
h. Water removal rate of dryer: ≥95%.
10.6.3 Main technical specification (maintenance use 65Nm3
/min compressed air drying and purifying
device)
a. Model: SLAD-65MXF.
b. Quantity: 4 sets.
c. Inlet compressed air pressure: 0.86Mpa(g).
d. Rated treated air delivery: ≥65Nm3/min.
e. Inlet compressed air temperature: ≤45℃.
f. Inlet compressed air oil content: <5mg/m3.
g. Granularity of dust in outlet air: ≤1μm.
Oil content of outlet compressed air: <1mg/m3.
h. Regenerated air consumption: ≤5%.
j. Temperature of pressure dew point: ≤-40℃.
h. Water removal rate of dry: ≥95%.

32
Chapter 11 Boiler Water Circulation Pump
Boiler water circulation pump
Model HLAV2×300-480/1C
Design temperature of pump
and insulator
365.3℃
Design pressure 20.56MPa Test pressure 30.84MPa
Dependable flow of single pump operation 3939m³/h Inlet pressure 194.36kg/ cm2
Total head 29.6m NPSH 19.5m
Boiler water circulating pump motor
Model Rated power 500kW
Rated voltage 11000V Rated current 43A
Rated speed 1465 r/min Start current 279A
Start time 1.4S Motor winding insulation PE2/PA
Design pressure 205.6kg/ cm2
g Design temperature 90℃
Maximum working
temperature
Alarm 63℃ Insulation level Y
Trip 66℃
Cooling water of boiler water circulating pump motor
Unit Cooling water Boiler water
Heat exchange content KJ/h 307700
Discharge ratio L/min 409 175
Inlet temperature ℃ 38 50
Outlet temperature ℃ 41 43
Design pressure kg/ cm2
g 10 205.6
Design temperature ℃ 50 90
Test pressure kg/ cm2
g 15 308.4
Normal discharge 10 m³/h Water supply pressure 0.2~0.4 MPa
Suspended matter content ≤5 PPm PH value 8~9.5

33
Chapter 12 Flame Check Cooling Fan
Flame check cooling fan
Model 9-19-NO.5.6A -18.5KW Max inlet temperature
Air flow rate 4200-7800 m3/h Rated air pressure of fan 7kPa
Turning
Flame check cooling fan motor
Motor model Y160-2 Rated current 35.5A
Motor power 18.5 kW Voltage 415V
Speed 2900r/min Manufactured by Wannan motor

34
Chapter 13 Startup Boiler
13.1 Equipment name: fuel oil startup boiler
Model: fuel oil, micro positive pressure, ready package and outdoor arrangement
Model: SZS35-1.2/320-YC
Boiler efficiency is not lower than 91%
Operating mode: continuous operation
Induced draft fan is not set.
13.2 Operating parameters of fuel oil startup boiler
Item Unit Value
Rated steam flow rate t/h 35
Rated pressure MPa 1.2
Rated temperature ℃ 320
Fuel Light oil
13.3 Main technical parameters of startup boiler
Item Unit Parameters Remark
Max continuous evaporation capacity BMCR T/h 35
Rated steam capacity T/h 35 Overload 110%
Rated steam pressure MPa (g) 1.2
Rated steam temperature ℃ 320
Rated inlet water temperature ℃ 20
Hot wind temperature ℃ 20
Heat exchange area M2 665 Whole boiler
Exhaust gas temperature ℃ 160
Heat efficiency % 92.4
Boiler computational efficiency % 92.4
Boiler guaranteed efficiency % 91.2
Boiler max continuous blowdown rate % 3
Boiler max air leakage rate % 0
Superheated steam temperature deviation ±15
Operating time at 10% boiler overload 15
Burner model and arrangement mode
Mechanical atomization
front wall arrangement
Furnace pressure ±10KPa
Max withstand
pressure
Furnace volume 52
Furnace basic size (depth×width×height)
2160x11370x2210
(on average)
Drum working pressure 1.32MPa
Min load of boiler 30%
Net weight of boiler T 88
Boiler full water weight T 110
Weight of largest hoisting element for
maintenance
2t
Burning mode
Micro positive pressure
chamber burning

35
Burning djusting mode Proportional control
Fuel LDO
Burner oil pressure
Burner fuel valve unit
inlet oil pressure
3.0-3.5MPa
Fuel consumption kg/h 2730
Superheater temperature adjusting mode Plate type attemperating
Water wall material SA-106 Gr.B
Superheater material SA213-T12
Total electric power kW 270
Oil pump kW 16.5
Lighting and maintenance kW 30+50
Feed water pump kW 55
Fan kW 110 Supplied alone
Furnace volume 52
Max transportation dimension m 13x4.7x4.4
Chimney height m 20
Chimney diameter and wall thickness m 1.2m t12

36
Chapter 14 Soot Blowing System
Soot blower of boiler is to keep the heating surface clean and produce good heating effect. The whole soot
blowing system has two parts of boiler proper heating surface sootblowing and preheater sootblowing. The
boiler proper part has 80 furnace soot blowers arranged in the furnace part, 44 long retractable soot blowers
arranged at the upper part of furnace and convection pass area. The outlet end of each set of preheater flue
gas side is equipped with 1 retractable soot blower; the sootblowing steam of proper part is received by the
division wall superheater outlet header with steam temperature 443℃ and pressure 18.20MPa (gauge); the
preheater sootblowing steam is received by rear platen superheater outlet header with temperature 501℃
and pressure 17.8MPa (gauge); they will get into each soot blower passing through pressure reducing valve;
there is automatic drainage point in the pipeline and sootblowing control of boiler is realized by DCS; the
system design always take into consideration that 2 long retractable, 2 furnace soot blower and 2 air
preheater are put into operation at the same time; the long retractable type and furnace soot blower on the
opposite side of wall has 1 soot blower putting into operation respectively or it can be set as user requires.
14.1 Soot blowing system of boiler proper
The soot blowing system of boiler proper is equipped with one set steam pressure reduction station; the
sootblowing steam gets into two division wall superheater outlet headers and get together, then passes
through 2″ pneumatic file pressure reducing valve for reducing pressure, the setting value is 2.94MPa
(30kgf/cm2) and temperature is about 330℃; the optimum application value is determined by various
situations after soot blower is put into operation and this pressure should be regulated by user as needed.
There is a manual stop valve and a motor-operated stop valve at the pressure reducing valve front pipeline
for closing steam source
A safety valve is set on the pressure reducing valve rear pipeline to prevent steam overpressure. There is
also pressure measuring point on the pipeline to monitor the pressure reducing valve outlet pressure. The
sootblowing steam is divided into two ways to get to the furnace soot blower after pressure reduction and
the long retractable soot blower is used for purging steam. Flow switch is set on each blowing pipe and
connected with program control; the set value of flow switch contact is to keep the minimum cooling flow
rate required by soot blower. Drain water system is set in the blowing pipeline to ensure proper dryness of
sootblowing; the proper sootblowing part has 4 drain points, of which 2 in furnace soot blower and long
retractable soot blower; each drain point drain pipeline has one motor-operated stop valve for temperature
control and water drainage and the open and close set value of the valve is 300℃; the horizontal pipeline
should keep 0.025m/m slope at least to ensure thorough drainage.
Note: The final setting values of steam pressure and drainage temperature subject to the instruction of soot
blower manufacturer.
14.2 Soot blowing system of preheater
The steam of air preheater sootblowing comes from rear platen superheater outlet header; the pressure will
be reduced by passing 1.5″ pneumatic film pressure reducing valve, of which the setting value is 2.94MPa
(30kg/cm2) and temperature is about 420℃ (this value can be regulated according to the operating
conditions). There is also stop valve in the front of pressure reducing valve and safety valve and pressure
measuring point, etc. behind the valve. The steam divides into two ways in the header pipe and then gets
into the air preheater soot blower. This system has one drain point for temperature control and drainage; the
drain valve is motor-operated stop valve, of which the open and close set value is 350℃; the superheat

37
degree of temperature controller should be set as high as possible in the building site when setting
temperature.
Note: The final setting values of steam pressure and drainage temperature subject to the instruction of soot
blower manufacturer.
There is also soot blower auxiliary steam pipeline on the header pipe; the auxiliary steam comes from the
auxiliary steam mains arranged by the design institute with steam pressure of 0.95~1.1MPa (gauge pressure)
and temperature of 325~360℃; the steam passes gets to the blowing pipeline by passing through the stop
valve and check valve; the switching conditions of auxiliary steam and normal steam valve:
(1) The pressure reduction station of air preheater sootblowing steam source will open for supply
sootblowing steam when the boiler load is larger than 30%MCR.
(2) The auxiliary steam source valve will open for supplying auxiliary steam when the boiler load is smaller
than 30%MCR or in startup stage.
Note: the switching conditions of final auxiliary steam and normal steam valves subject to the materials of
supplier.
Main design parameters of soot blowing
No. Items Soot blower of furnace Long retractable soot blower Air preheater soot blower
1 Model V04 PS-LL PS-AT
2 Travel (mm) 255 10600 970
3 Purging angle 3600 3600 Vertical
4
Effective purging radius
(mm)
2500 1500~3500 2000
5
Travel speed of blowing
pipe (m/min)
0.5 2.0 1.44
6
Rotation speed of
blowing pipe (rpm)
2.7 24 24
7 Purging time (s) 50 606 Undetermined
8 Working time (s) 55 630 Undetermined
9
Steam consumption
(kg/min) (single unit)
82 170 80
10 Motor model M2QA71M4B M2QA90S4A M2QA90S4A
10-1 Power (kW) 0.25 1.1 0.55
10-2 Speed (rpm) 1400 1390 1400
10-3 Insulation level F F F
10-4 Level of protection IP55 IP55 IP55
11
Recommended purging
pressure (MPa)
1.0~1.5 1.0~1.5 1.0~1.5

38
Part
Part
Part
Part 2
2
2
2 Startup
Startup
Startup
Startup and
and
and
and Shutdown
Shutdown
Shutdown
Shutdown of
of
of
of Boiler
Boiler
Boiler
Boiler
Chapter 1 Rules & Conditions of Unit Startup
1.1 Startup rules
1.1.1 Shift engineer directs the normal startup of unit and takes charge of the centralized control staff to
start up according to the instruction, and specialist engineer in Operation Department take charge of the
technical supervision and technical director on site.
1.1.2 Check the reports for the relevant equipment & system abnormal action, completion and oil
qualification are complete prior to startup after the overhaul or minor maintenance of unit.
1.1.3 Verify that all the check & maintenance work of unit have been finished completely, all the
worksheets are taken back, sanitation on site is accorded with the standard, the relevant temporary work
platform of check & maintenance is dismantled and check and acceptance of cold state is qualified.
1.1.4 Transmission test of each valve is done by Department of production technology that takes charge of
unified coordination and arrangement and Operation Department that cooperates after the overhaul and
minor maintenance of unit.
1.1.5 Contact the thermal technical staff to do the interlock and protection test work of relevant equipment
and system and keep records.
1.1.6 All kinds of record lists and vibration gauge, thermo detector and listening rod etc. instruments &
tools prior to startup shall be prepared ready.
1.1.7 All the level meters are bright and clean and each signal primary valve of relevant pressure gauge,
flow gauge and protection gauge is opened.
1.1.8 Contact the thermal technical staff to supply power to all the thermo technical instrument, signal and
protection device of main control.
1.1.9 Check that oil level of each rotating equipment bearing is normal, oil circulation is normal, oil
pressure is normal and oil quality is qualified.
1.1.10 All the motor-operated valves, governing valves and modulating dampers are powered on and
display status is accorded with the practice.
1.1.11 Power on after verifying the insulation of all electrical equipment is qualified and grounding line of
enclosure is in good condition.
1.1.12 Hydraulic test of boiler needs to be done after overhaul or minor maintenance of unit or finishing
displacing the heating surface that leaks.
1.1.13 Check that expansion indicator shall be put into operation and record the original value.
1.2 Selection of unit start mode
1.2.1 The unit starts up in cold start mode when the boiler and steam turbine are in cold state.
1.2.2 The unit starts up in hot start mode when the boiler and steam turbine are in hot state.
1.2.3 The unit selects pressure boosting rate and temperature rising rate in cold start mode and impulse time
of unit and unit warm-up time of initial load is selected in hot start mode when the boiler is in cold state but

39
the steam turbine is in hot state.
1.2.4 Division of unit boiler startup condition
1.2.4.1 Boiler cold state: shutdown time is more than 36 hours without pressure of boiler.
Boiler hot state: shutdown time is less than 10 hours.
1.2.4.2 The time from ignition of boiler to unit with full load (BMCR) (matching with steam turbine)
Start state Cold Warm Hot
Time <8 hours <2.5 hours <0.75 hours
1.2.5 Division of startup condition of unit steam turbine
Startup mode Definition of startup mode
Cold state
Shutdown for more than 36h (mental temperature reduces to lower than 40% of the
testing point temperature with full load, T<305℃)
Warm state
Shutdown for 10~36h (mental temperature reduces to between 40% and 80% of the
testing point temperature with full load, 305℃≤T<420℃)
Hot state
Shutdown within 10h (mental temperature reduces to higher than 80% of the testing
point temperature with full load, 420℃≤T<490℃)
Very hot state
Shutdown within 1h (mental temperature is close to the testing point temperature with
full load, 490℃<T)

40
Chapter 2 Boiler Cold Start
2.1 Check & preparations prior to boiler start
2.1.1 All the check & maintenance work that influence the start of unit has been finished and work sheets
have been finished according to the relevant rules. Safety measures are removed, and the operators have
known the condition of check & maintenance and device improvement clearly.
2.1.2 Interlock & protection test of each main unit & auxiliary equipment has been finished and qualified;
baffle of each motor valve, pneumatic valve and air valve has been finished adjusting and testing and their
switch directions are right; the auxiliary equipment that is checked & maintained has been normal through
trial run part by part.
2.1.3 Any faults in each part that obstruct expansion are to be checked and removed and each expansion
indicator is mounted on correct position. Messes and rubbish around boiler were removed to guarantee the
platform, stairs and railing complete and firm and there are no sundries in the passage and around the
equipment obstructing the operating and passing.
2.1.4 All the system connections are in good condition and all pipeline supports are firm and pipeline
insulation is complete. The hangers of steam-water pipeline, air and flue gas duct and burner etc. are
complete and bear pressure evenly, and spring hanger has been in normal working condition.
2.1.5 Temporary fence, signboard of each site and temporary cover plate of all kinds pipelines have been
dismantled.
2.1.6 Each site illumination of workshop inside and outside is in good condition and accident illumination
system is in normal condition that can be put into operation at any moment.
2.1.7 Centralized control room and local control panel & cabinet are complete and all kinds of indicating
recorder, alarm device and operation & control switch are in complete and good condition.
2.1.8 Plant fire-fighting system is put into operation normally and fire-fighting device is complete.
2.1.9 All kinds of relevant operating power source, control power source and instrument power source shall
be powered on and in normal condition.
2.1.10 All the primary and secondary valves of local measurement device are opened and meters indicate
correctly.
2.1.11 Verify the setting value is correct and put it into “AUTO” after the adjustment & test of
local-mounted control device is finished.
2.1.12 Communication between each post is smooth.
2.1.13 Special tool, instrument, gauge and all kinds of record paper of unit startup and work sheet that are
used in startup have been prepared; the staff has been arranged well.
2.1.14 Control & monitor systems such as DCS, DAS, FSSS, BMS, D-EHG, MEH, HITASS, TSI, PRP,
ASS and bypass etc. are put into normal operation; each parameter indication on the CRT is correct.
2.1.15 Each manhole valve of boiler proper and air & flue gas ducts is closed tightly; all the air valves and
flue pipe baffles are opened and closed flexibly; local switch position of baffle shall be accorded with the
indication of meter, and spring support of proper and steam water pipe is in good condition without

41
expansion obstacles.
2.1.16 Each sootblower of boiler exits from the boiler to be in standby condition.
2.1.17 Furnace gas temperature probe exits to be in standby condition.
2.1.18 All valves are to be check for on the correct start-up position, no leak, operate flexibly, the
motor-operated and pneumatic actuator operates normally, and the opening extent indication is in
accordance with actual position.
2.1.19 The steam drum water gauge pointer is complete, indicates correctly and is lighted well, the water
level videotaping system works normally.
2.1.20 TV Taking lens of furnace flame is in good condition and cooling air is put into operation.
Combustion system shall be checked with the doper position, furnace front oil system and burner wind-box.
Ash & slag handling system and boiler water circulating pump and control system can be put into operation
normally.
2.1.21 Check the actuating device, sealing clearance and lubricating cooling system of rotary air preheater
and each indicator is in normal position. Confirm sealing clearance sector panel of air preheater hoists to
maximum and hotspot detection system is put into operation well.
2.1.22 The following parameters shall be monitored and adjusted with emphasis when the unit starts up:
Steam drum pressure and temperature difference between upper wall and lower wall of steam drum; main
& reheated steam temperature & steam pressure;
Furnace negative pressure; furnace air flow; opening of adjustable vane of induced draft fan & air blower;
Opening of guide vane of primary air fan; flue gas temperature of each section of flue gas duct; hot primary
& secondary air temperature;
Outlet air powder temperature & primary air flow of pulverizing mill;
2.2 Test rules prior to start
2.2.1 Test and trial run of device must be presented with a written application by maintainer and can be
performed only when it is approved by shift engineer and test command is issued.
2.2.2 Device test is coordinated by maintainer in charge and is matched operation by operator and relevant
staff is on site.
2.2.3 Test method of device is divided into two kinds: static state and dynamic state; when it is static state
test, boiler running with above 11kV is only supplied test power source, 2.215V LV power source is given
dynamic power source; when it is dynamic state test, both operation & dynamic power source are
connected.
2.2.4 The above test is carried out after the overhaul or minor maintenance of unit. Some tests can be
carried out separately after the check & maintenance as required. Dynamic state test can only be carried out
after the static state test is qualified.
2.2.5 Oil pump and air & flue gas baffle position etc. shall satisfy the conditions of program control
requirement prior to the protection & interlock test. Test can be carried out only when the relevant
conditions are forced to be satisfied by thermo technical staff.

42
2.2.6 Test operation of each interlock, protection and accident button shall be accurate and reliable; audible
and visual alarm and CRT menu condition indication are normal.
2.2.7 Motor-operated valve, control valve and air valve baffle are qualified through teste.
2.2.8 Test requirements:
2.2.8.1 The system that has been put into operation and the motor valves & control valves that are under
pressure cannot be tested.
2.2.8.2 Both remote control and local control shall be tested for the servo mechanism that has local control
and remote control and have specially-assigned person record the time of opening and closing and test
condition.
2.2.9 Test method:
2.2.9.1 Full open and full close test of remote & local control shall be carried out for all the motor valves
and air valve baffle according to the test card, the opening indication and local indication shall be accordant,
the motor-operated valve and damper baffle with intermediate stop should be normal at the intermediate
stop position.
2.2.9.2 Pneumatic control device shall operate flexibly without air leak or abnormal phenomena.
2.2.10 Opening and closing and accident button tests (static)
2.2.10.1 Start all the equipment separately, and they are good as verified in the opening and closing test,
then resume their closing position.
2.2.10.2 Stop all the auxiliary equipment with the accident button on site respectively, and the
corresponding auxiliary equipment should trip and audible and visible signal alarm should be normal.
2.3 Operations prior to impulse starting in cold start
2.3.1 System put-in
Put in the following systems gradually and check that it is in normal operation according to the check card
and the relevant content in chapter Start and Stop of Auxiliary equipment & System of Unit. The balance of
load distribution of each section shall be considered comprehensively when it puts into the system.
2.3.1.1 Fire fighting water system;
2.3.1.2 Plant-service compressed air system;
2.3.1.3 Auxiliary steam system is put into operation;
2.3.1.4 Industrial cooling water system;
2.3.1.5Open cooling water system;
2.3.1.6 Closed cooling water system;
2.3.1.7 Boiler slag hopper water seal system;
2.3.1.8 Lubricating oil system of each auxiliary engine;
2.3.1.9 Fuel system;
2.3.1.10 Boiler bottom water seal system;

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2.3.1.11 Demineralized cooling water system;
2.4 Water filling and heating of deaerator
2.4.1 Water tank of deaerator is made up with water up to normal level and contact the chemical staff to
feed chemical to the deaerator.
2.4.2 Verify that turning gear of main unit is put into operation normally.
2.4.3 Start up the electrically driven feed pump or booster pump of steam pump and put the auxiliary steam
of deaerator into operation to heat, adjust the auxiliary steam to pressure control valve of deaerator to make
the water temperature of deaerator rise slowly, which is close to the steam drum wall temperature as much
as possible. Make adjustment and open the deaerator to start exhaust to guarantee qualified dissolved
oxygen.
2.4.4 Water filling and deflating of feed pump
2.5. Boiler water filling
2.5.1 Filling water prior to startup of boiler shall be checked according to the check operation card and
carried out after the startup conditions are met.
2.5.2 If the boiler had water originally, ask for instruction from the shift engineer according to the chemical
assay result to confirm whether drain off water or not.
2.5.3 Start up the electrically driven feed pump to start filling water to the boiler.
2.5.4 The temperature difference between boiler water filling temperature and steam drum wall temperature
should be <90℃ and water quality must be qualified.
2.5.5 Verify that boiler water circulating pump has been put into continuous flushing water.
2.5.6 Verify that the startup conditions of electrically driven feed pump are met.
2.5.7 Start up the electrically driven feed pump to check that its motor current is normal.
2.5.8 Open the recycle valve of economizer to make the feed water enter the lower header of water wall,
which is convenient for exhausting air.
2.5.9 Adjust the rotating speed of electrically driven feed pump and control the feed water flow 30~60t/h
and the entire time of water inlet is that summer is >2 hours and winter is >4 hours.
2.5.10 Reduce the rotating speed of electrically driven feed pump to make the water level rise to +200mm
slowly when water level appears in the water level gauge of steam drum.
2.5.11 Close the outlet valve of electrically driven feed pump to stop filling water.
2.5.12 Inch for exhaust of boiler water pump when the water level of steam drum is high.
2.5.13 Close the air valve on the top of steam drum and start up B boiler water pump.
2.5.14 Stop boiler water circulating pump B and fill water to +200mm when the water level of steam drum
reduces to minimum visible water level.
2.5.15 Start up the boiler water circulating pump A and then start up boiler water circulating pump B & C
after the water level is stable.

44
2.5.16 Contact the chemical staff to feed chemical to the steam drum.
2.5.17 Check that all the spray water control valves and stop valves of spray type attemperator are closed.
2.5.18 Check that all the drain valves and vent valves are in the position of opening.
2.5.19 Open the drain valve of superheater.
2.6 Put-in of air & flue gas system of boiler
2.6.1 Check and verify that boiler proper, each manhole valve of air & flue gas dust and fire observation
valve are closed tightly and bottom water seal is put into operation normally.
2.6.2Start up the pneumatic motor of air preheater A & B and after rotation is normal, start up the
electromotor of air preheater A & B and confirm the pneumatic motor is stopped, put the pneumatic motor
to “AUTO”. Confirm the air & flue gas baffle has been opened. Put the upper & lower bearing oil pump
interlock of air preheater into operation, adjustment device of sealing clearance exits “AUTO” and
clearance is to maximum position.
2.6.3 Start up the induced draft fan of one side and check everything is normal. Open the adjustable vane
slightly to adjust the furnace negative pressure to be about -50Pa and put the adjustable vane into “AUTO”.
2.6.4 Start up the air blower on the same side to check that everything is normal.
2.6.5 Start up the induced draft fan of the other side to check that everything is normal; adjust the furnace
negative pressure to about 50Pa and put the adjustable vane into automatic.
2.6.6 Start up the air blower on the other side to check that everything is normal.
2.6.7 Adjust the furnace negative pressure to be about -50Pa and total air flow ≥30%MCR by adjusting the
opening of adjustable vane of induced draft fan & air blower.
2.6.8 Adjust the auxiliary air baffle to make the pressure difference between big bellow and furnace about
381MPa.
2.6.9 Put the swinging burner to horizontal level.
2.6.10 Start up one fire detector fan and put the standby fan into standby.
2.6.11 Put the air heater into operation as required.
2.7 Oil leakage test
2.7.1 Trigger the oil leakage test simultaneously as the furnace purging starts.
2.7.2 Allowable conditions of oil leakage test:
2.7.2.1 Oil supply pressure is normal;
2.7.2.2 There is no fire in the whole furnace;
2.7.2.3 All the doper solenoid valves are closed;
2.7.2.4 No MFT trip condition;
2.7.3 Oil (light fuel) leakage test shall be carried out according to the following steps when all the
conditions are met:

45
2.7.3.1 Control valve of fuel oil inlet is put into operation manually and open the control valve of fuel oil
inlet;
2.7.3.2 Open the fast valve of oil inlet and oil return to fill the pipeline with oil, and close the fast valve of
oil return after delaying 10 seconds.
2.7.3.3 If the oil header pressure does not reach the set value in 40s, oil charge fails and the test breaks off;
or after the oil pressure is reached, header oil charge succeeds and close the oil inlet fast closing valve.
2.7.3.4 Start the oil pressure monitoring process for 3 minutes. If the oil header pressure is lower than the
setting value (light oil pressure is lower than 3.5Mpa and heavy oil pressure is lower than 1.9MPa) in the
process, it indicates there is leak in pipeline and the test is broken off; if not, open the oil return valve 3
minutes later and pipeline leaks oil, close the oil return valve after the oil pressure is lower and start the oil
pressure monitoring process for 3 minutes. If the front & rear differential pressure of oil inlet fast valve is
lower than the setting value (uncertain) in the process, it indicates there is leak of oil inlet fast valve and the
test is broken off; if not, the whole test is successful after 3 minutes.
2.7.3.5 In addition, bypass oil leakage can be tested, which is forced to generate the normal condition of
check leakage test.
2.7.4 If test is in failed in the process of test, inform the thermodynamic staff and maintainer to check and
re-test after treatment.
2.7.5 Conduct the oil leakage test of heavy fuel oil system according to the above conditions and sequence.
2.8 Furnace purge
2.8.1 Conditions for purging furnace:
(1) There is air blower in operation;
(2) There is induced draft fan in operation;
(3) All the oil angle fast valves are closed;
(4) Fuel trip valve is closed;
(5) No MFT command
(6) All the coal feeders are stopped;
(7) All coal mills have been stopped;
(8) Steam drum level is normal;
(9) All the fire detectors indicate no fire;
(10) Air volume is appropriate;
(11) Fire detection cooling air is normal
(12) Preheater is in operation;
(13) Cottrell stops operation;
(14) Baffle of secondary air valve is in the adjustment position;
(15) Oil leak test is finished.

46
(16) Power source of FSSS system is normal;
(17) Power source of MCS system is normal;
(18) S SOFA baffle is closed;
(19) Primary air fan is shut down;
2.8.2 Verify all the conditions for purging furnace are provided.
2.8.3 Press the key of “Purging Request” on the LCD screen and the timing purging of 5 minutes will be
started. “Purging” signal is appeared on the LCD screen.
2.8.4 If any one purging condition is not met in the timing purging process for 5 minutes, break off purging.
It can be re-started purging after all the purging conditions are met again.
2.8.5 “Finish Purging” signal is appeared on LCD screen and first trip signal of MFT is reset automatically
after the timing purging of 5 minutes is finished. Slag handling system of boiler is put into operation; ash
conveying system is put into operation.
2.9 Ignition of boiler
2.9.1 Main protection of boiler and supervision TV of furnace flame shall be put into operation and local
flue gas temperature probe shall be put into operation to make the probe enter the furnace manually or
remote control as ruled prior to ignition of boiler.
2.9.2 Open the inlet header of roof tube and drain valve of superheater and open the recycle valve of
economizer.
2.9.3 Start the ignition of light doper of BC layer after verifying that all the ignition conditions are met.
2.9.4 If the ignition of boiler I sin failure, it must re-purge the furnace and ignite again.
2.9.5 Verify the oil recycle valve shall be closed automatically after ignition of the first doper.
2.9.6 Keep the gas temperature of furnace outlet lower than 538℃ after confirming ignition is successful.
2.9.7 Verify ignition for three times is in failure, it can be re-ignited after furnace re-purging.
2.9.8Observe the firing condition locally after ignition and verify the oil atomization is in good condition
and air distribution is proper. If some doper is found no fire, close the oil supply solenoid valve of this
doper immediately and exit operating position. It can be re-put into operation after purging.
2.9.9 Verify that recycle valve of economizer is opened when feed water flow is less than 25%.
2.9.10 Maintain the normal water level of steam drum and drain off contamination of boiler as required
according to the quality of boiler water.
2.9.11 Put air preheater into operation to continue sootblowing after ignition of boiler.
2.9.12 When all the permissive conditions are met, igniters of two coal seams can be allowable logically to
ignite once if header pressure is normal.
a) All the permissive conditions are met and the oil header pressure of AB layer is normal;
b) All the permissive conditions are met and the oil header pressure of BC layer is normal;
c) All the permissive conditions are met and the oil header pressure of CD layer is normal;

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