GOVERNMENT POLYTECHNIC, NANDED

MICRO PROJECT
Academic year: 2020-21

TITLE OF THE PROJECT

MAINTENANCE PROCEDURE FOR PREVENTIVE AND
PREDICTIVE MAINTENANCE OF TYPICAL FBC
BOILERS AND ITS COMPONENTS.

Program: Mechanical Engineering

Program code: ME5I

Course: PPE Course code: 22566

Name of Guide: Shri P.B. Chavan

Government Polytechnic, Nanded 1

MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate
This is to certify that members of group 1683, 1663, 1666, 1676,1671 of 5th
Semester of Diploma in Mechanical Engineering of Institute, GOVERNMENT
POLYTECHNIC NANDED has completed the Micro Project satisfactorily in
Subject- PPE(22566) for the academic year 2020-21 as prescribed in the curriculum.

Place: Nanded

Date:

Subject Teacher Head of the Department Principal

Government Polytechnic, Nanded 2

Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________

Micro Project Evaluation Sheet (I Scheme )

Name of Course and Code :- Power Plant Engineering(22566)

Name Of Student :- (1) Sonone Omkar Digambar (1683),

Course Outcomes Achieved

• We known the how the maintenance procedure of FBC boiler is carried out.

Process Assessment Product Assessment Total Marks

Part A Project Project Part B- Project Individual
Proposal Methodology Report/ Presentation/ (10 )
(02 Marks ) ( 02 Marks) Working Model Viva
( 02 Marks ) ( 04 Marks )

Comments/Suggestions about team work/ leadership/Inter personal communication

For making this project we take every group member suggestion and their opinion. Any

Other Comment

We did hard work for preparation of this project reports.

Date Signature and Name of lecturer

Government Polytechnic, Nanded 3

Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________

Micro Project Evaluation Sheet (I Scheme )

Name of Course and Code :- Power Plant Engineering(22566)

Name Of Student :- (2) Shelke Ganesh Mariba(1676)

Course Outcomes Achieved

• We known the how the maintenance procedure of FBC boiler is carried out.

Process Assessment Product Assessment Total Marks

Part A Project Project Part B- Project Individual
Proposal Methodology Report/ Presentation/ (10 )
(02 Marks ) ( 02 Marks) Working Model Viva
( 02 Marks ) ( 04 Marks )

Comments/Suggestions about team work/ leadership/Inter personal communication

For making this project we take every group member suggestion and their opinion. Any

Other Comment

We did hard work for preparation of this project reports.

Date Signature and Name of lecturer

Government Polytechnic, Nanded 4

Government Polytechnic, Nanded

Mechanical Engineering Department

Academic Year (2020-21)
___________________________________________________________________________

Micro Project Evaluation Sheet (I Scheme )

Name of Course and Code :- Power Plant Engineering(22566)

Name Of Student :- (3) Patil chaitanya Kishor (1666)

Course Outcomes Achieved

• We known the how the maintenance procedure of FBC boiler is carried out.

Process Assessment Product Assessment Total Marks

Part A Project Project Part B- Project Individual
Proposal Methodology Report/ Presentation/ (10 )
(02 Marks ) ( 02 Marks) Working Model Viva
( 02 Marks ) ( 04 Marks )

Comments/Suggestions about team work/ leadership/Inter personal communication

For making this project we take every group member suggestion and their opinion. Any

Other Comment

We did hard work for preparation of this project reports.

Date Signature and Name of lecturer

Government Polytechnic, Nanded 5

Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________

Micro Project Evaluation Sheet (I Scheme )

Name of Course and Code :- Power Plant Engineering(22566)

Name Of Student :- (4) Panchal Balanced Ishwar (1663)

Course Outcomes Achieved

• We known the how the maintenance procedure of FBC boiler is carried out.

Process Assessment Product Assessment Total Marks

Part A Project Project Part B- Project Individual
Proposal Methodology Report/ Presentation/ (10 )
(02 Marks ) ( 02 Marks) Working Model Viva
( 02 Marks ) ( 04 Marks )

Comments/Suggestions about team work/ leadership/Inter personal communication

For making this project we take every group member suggestion and their opinion. Any

Other Comment

We did hard work for preparation of this project reports.

Date Signature and Name of lecturer

Government Polytechnic, Nanded 6

Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
___________________________________________________________________________

Micro Project Evaluation Sheet (I Scheme ) Name

of Course and Code :- Power Plant Engineering(22566)

Name Of Student :- (5) Prashant Kadam(1671).

Course Outcomes Achieved

• We known the how the maintenance procedure of FBC boiler is carried out.

Process Assessment Product Assessment Total Marks

Part A Project Project Part B- Project Individual
Proposal Methodology Report/ Presentation/ (10 )
(02 Marks ) ( 02 Marks) Working Model Viva
( 02 Marks ) ( 04 Marks )

Comments/Suggestions about team work/ leadership/Inter personal communication

For making this project we take every group member suggestion and their opinion. Any

Other Comment

We did hard work for preparation of this project reports.

Date Signature and Name of lecturer

Government Polytechnic, Nanded 7

Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
PART A
Micro Project Report
___________________________________________________________________________

Title of Micro-project: Develop maintenance procedure for preventive and predictive

maintenance of typical FBC boilers and its components.

1.Brief Introduction :- Coal fired boiler system generates approximately 38% of the electric
power worldwide and will continue to be major contributors in the future. New pulverized coal
fired systems routinely installed today generate power at net thermal cycle efficiency ranging
from 34% to 37% (higher heating value) while removing up to 97% of the combined,
uncontrolled air pollution emissions. A new generation of pulverized coal fired boiler technology
is currently under development which will permit generating efficiencies in excess of 42%. This
paper highlights some of today’s design improvements which target reduced emissions and
expanded operability, and explores some of the boiler design implications for the
ultrasupercritical conditions needed to achieve the high cycle efficiencies for the future.

2. Aim of the Micro-project :-

To study maintenance procedure for preventive and predictive maintenance of typical

FBC boilers and it’s Components

3. Action plan
S. Details of activity Planned Planned Name of
No. start date finish Date responsible
team members

1. Select the title of the microproject All members

2. Collected information about selected Sonone Omkar and
topic from internet Shelke Ganesh

Government Polytechnic, Nanded 8

3. Collect information about selected topic Panchal Balanand ,
from various reference books Patil Chaitanya and
Prashant Kadam
5. Make project report Sonone Omkar and
Shelke Ganesh

4. Resources Required
S. no. Name of Resource / material Specification Qty
1. Reference book. Power plant Engineering by PK 2
Nag and RK Rajput
2. Internet various websites. - -

Government Polytechnic, Nanded 9

Government Polytechnic, Nanded
Mechanical Engineering Department
Academic Year (2020-21)
PART B
Micro Project Report
___________________________________________________________________________

Title of Micro-project: Develop maintenance procedure for preventive and predictive

maintenance of typical FBC boilers and its components.

1.Brief Description

1.1 Definition
It is a closed vessel in which steam is produced from water by combustion of fuel. Boiler is an
apparatus in which thermal energy released by combustion of fuel is transferred into water which
vaporizes and gets converted into steam at the desired pressure and temperature.
1.2 Boiler Mounting
Mountings are the components used for the safety of boiler, the boiler requires the following
mountings a feed check valve to prevent the return of water from the boiler in base the feed
pump is to operating, a steam stop valve to regulate the flow of steam from the boiler, safety
valve (at least two) to protect the boiler from pressures higher than the designed valve, a blow
off valve to empty the boiler when needed and to discharge the mud and sediments that are in the
boiler. Water level indicator to show the water level inside the boiler, a pressure gauge to
indicate the pressure of steam in the boiler, fusible plugs to protect the boiler against low water
lever.
1.3 Boiler Accessories

Accessories are the auxiliary plants required for steam boilers for their proper operation and for
the increase of their efficiency. According to the principle of operation the steam separator is
classified as follows:
o Impact or baffle type o Reverse current type
o Centrifugal type

1.4 Boiler Efficiency

Boiler efficiency is the ratio of heat actually utilized in generation of steam to the heat supplied
by the fuel in the same period.
Boiler efficiency= ma (h-hf)/c
Where, ma = mass of water actually evaporated into steam per kg of fuel at the working pressure
Government Polytechnic, Nanded 10
C = calorific value of the fuel in kj/kg.
1.5 Heat Losses In A Boiler Plant
The following heat loss occurs in a boiler plant:
• Heat loss of flue gases
• Heat loss due to incomplete combustion
• Heat loss due to un burnt fuel
• Convection and radial losses
II. MECHANISM OF FLUIDIZED BED COMBUSTION
When an evenly distributed air or gas is passed upward through a finely divided bed of solid
particles such as sand supported on fine mesh, the particles are undisturbed at low velocity. As
air velocity is gradually increased, a stage is reached when the individual particles are suspended
in the air steam- the bed is called “fluidized”. With further increase in air velocity, there is
bubble formation, vigorous turbulence, rapid mixing and formation, of dense defined bed
surface. The bed of solid particles exhibits the properties of a boiling liquid and assumes the
appearance of a fluid- “bubbling fluidized bed”.At higher velocities, bubbles disappear, and
particle is blown out of the bed. Therefore, some amounts of particles have to be re circulated to
maintain a stable system- “circulating fluidized bed”. Fluidization depends largely on the particle
size and the air velocity. The mean solids velocity increases at a slower rate than does the gas
velocity. The difference between the mean solid velocity and mean gas velocity is called as slip
velocity. Maximum slip velocity between the solids and the gas is desirable for good heat
transfer and intimate contact. If sand particles in a fluidized state is heated to the ignition
temperature of coal, and coal is injected continuously into the bed, the coal will burn rapidly and
bed attains a uniform temperature. The fluidized bed combustion (FBC) takes place at about 840
to 950 degree Celsius. Since this temperature is much below the ash fusion temperature, melting
of ash and associated problems are avoided. The gas velocity is maintained between minimum
fluidization velocity and particle entrainment in the gas stream.FBC boilers
combustion progress requires the three “T”s that is time, temperature and turbulence. In FBC,
turbulence is promoted by fluidization. Improved mixing generates evenly distributed heat at
lower temperature. Residence time is many times greater than conventional grate firing. Thus an
FBC system releases heat more efficiently at lower temperatures.

2.1 Types of Fluidized Bed Combustion Boilers

There are three basic types of fluidized bed combustion boilers:
• Atmospheric classic fluidized bed combustion system (AFBC)
• Atmospheric circulating (fast) Fluidized bed combustion system (CFBC)
• Pressurized fluidized bed combustion system (PFBC)

Government Polytechnic, Nanded 11

2.2 General Arrangement of AFBC Boiler
AFBC boiler comprises of following systems:
• Fuel feeding system
• Air distributor
• Bed & in-bed heat transfer surface
• Ash handling system
2.3 Advantages of Fbc Boilers
o High Efficiency: FBC boilers can burn fuel with a combustion efficiency of over 95%
irrespective of ash content. FBC boiler can operate with overall efficiency of 84% (plus or
minus 2%)
o Reduction in Boiler Size: High heat transfer rate over a small heat transfer area immersed
in bed results in overall size reduction of the boiler.
o Ability to Burn Low Grade Fuel: FBC boiler would give the rated output with inferior
quality fuel. The boilers can fire coals with ash content as high as 62% and having calorific
value as low as 2,500 kcal/kg.
o Pollution Control: SO2 formation can be greatly minimized by addition of limestone or
dolomite for high sulphur coals. 3% limestone is required for every 1% sulphur in the coal
feed.
o Low Corrosion and Erosion: The corrosion and erosion effects are less due to lower
combustion temperature, softness of ash and low particle velocity (of the order 1m/sec)
o Less Excess Air: Higher CO2 in Flue Gas: The CO2 in the flue gases will be of the order of
14-15% at full load. Hence the FBC boiler can operate at low excess air only 20-25%.
o Simple Operation, Quick Start-Up: High turbulence of the bed facilitates quick start-up and
shut down. Full automation of start up and operation using reliable equipment is possible.

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Provision Of Automatic Coal And Ash Handling System: Automatic system for coal and ash
handling can be incorporated making the plant easy to operate comparable to oil or gas fired
installation
o High Reliability: The absence of moving parts in the combustion zone
results in a high degree of reliability and low maintenance cost.
o Reduced Maintenance: Routine overhauls are infrequent and high efficiency
is maintained for long periods.

III. OPERATION AND MAINTENANCE OF BOILER

3.1 Coal Handling Plant
In coal handling plant, raw coal that is brought from outside & bamboo dust is supplied to
griggly hoper whereby help of vibratory machine it is crushed into smaller parts. Then some
amount of bamboo dust is also mixed with charcoal and supplied to primary screen I & II with
the conveyor belt I & IA. In primary screen I&II coal size is checked (i.e. round 6-10 mm). If the
required size is obtained then it goes bunker of CF boiler. If size condition is not satisfied then
the coal goes to crusher I & II. When size is maintained if the coal size is not obtained to the
required size, then it goes to the secondary stages of coal sizing. The acceptable coal size is send
to the boiler through the help of conveyor belt IV.
3.2 Demineralization of Water
It means water is free from all minerals. This is done to various defects happens such as boiler
corrosion, formation of sludge and scale which may decrease the volume or capacity of the
boiler due to deposition of minerals on the walls of the boiler. It is to remove mineral content of
water, in this system raw water enters the hydrogen zeolite exchanger (cation removal) at the top
and flows to the anion exchanger and degasified and finally passes through silicon absorber.

IV. STARTING OF THE BOILER – LIGHT UP PROCEDURE FOR COLD

CONDITION
Preparation of furnace when the furnace is empty, check the following:
o Air Nozzle – nozzles hole are to be clean. Nozzle top to be intact.
o If nozzle are not clean the ore to be cleaned with air hose o Coal feed nozzle – the top
refractory is to be there Check the following:
o All the access doors to be closed o All personnel to be cleared
o All foreign material are to be removed from furnace & pressure parts o Starting
equipment & interlock are ok
o Check the following equipment for adequate lubrication and readiness for services
1) ID fan 2) FD fan

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o

3) PA fan 4) Feed pump

5) Fuel feeder 6) Dynamo drive system
o Banker (coal) to be full with 0-6 mm size coal and gates below the banker are in open
position and coal is available at feeder inlet
o Check instrument air above 3 kg/cm2pressure is available for instrumentation and
control.
o Start first ID fan with suction damper in closed position o Start FD fan with suction
dumper in closed position

4.1 Charging Bed Material o Keeping the individual damper of 3 compartments in open
position, furnace draft is to be maintained at 5 mm to 7 mm by slightly opening the ID fan
damper
o Open the furnace man hole and with 2 mazodoors the bed materials is to be charged into
the furnace, care to be taken that no empty bag slips into the furnace. After completely
charging the material it should be leveled by properly operating dampers of ID & FD
fans, then close dampers. Open the main holes on both sides of the furnace. o Take a 24v
hand lamp inside and measure the height of the bed in each compartment. The height of
bed in each compartment should be 300 mm to 310 mm. Then come out of the furnace
and keep the hand lamp on the bed coils(glowing)

4.2 Lighting Up of Boiler o Before lighting up of boiler fill the boiler with feed water up to
half steam drum level, at the time of taking water ensure that all air vents are in open
position and all drains are in closed position. Confirm the level of water in the drum by
seeing gauge glass levels.
o Keeping lighting swabs ready
o Keep open the furnace door and open the ID fan suction damper
o Light up one swab watch stick, light up all swabs one after one throw, then in all
directions in the startup Compartment
o In each compartment two thermocouples are provided to indicate feed temperature o It is
important to increase air flowing gradually to increase the top level temp. to 800 to
850 degree o When the bed temperature rises above 600 degree switch on PA fan, the
coal transport lines are to be closed and coal feed drain lines to the cleared
o Adjust PA fan suction damper to maintain header pressure in between 750 mm and 950
mm water column. Open the fuel transport air damper of the startup compartment. The
coal feed shall be kept at minimum at the beginning.

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4.3 Boiler Trip Due to Power Failure
If boiler trips due to power failure, take the following action:
Start stand by feed pump (on second power sources) o Restore drum water level by
controlling feed water on manual mode. If instrument air is not available first close the
isolation valves of the inlet of feed control valve and regulate
feed water through by pass valve, keep a constant watch on gauge glass level
o Close the inlet damper of ID and FD fan o Close the butterfly damper of wind box
o Close all steam outlets from boiler so that boiler is not depressurized immediately

4.4 Boiler Hot Startup Procedures o

Open the startup vent valve slightly o
Close all the compartment damper o
Start the ID fan, FD fan, PA fan
o Open slightly the wind box damper of no 1 so bed I fluidizes with minimum air ensure
that fluidization is uniform and satisfactory
o Adjust the ID fan damper to maintain the furnace pressure o Adjust the FD fan & PA
damper to get the required fan pressure o Start coal feeding without delay otherwise bed
may cool down rapidly o Gradually increase the coal feeding observing the rise in bed
temperature o Adjust the air flow and coal feeding observing the rise in bed temperature
o Take bed no 2 and other beds on line and connect the boiler process o Take feed
water control and furnace draft on auto mode o Charge the ESP if the flue gases
temperature is ok o Put the boiler into auto mode o Start ID fan, FD, fan PA fan
o If the bed level is too high drain the bed and bring down the bed height to around 300
mm by fluidizing the bed-1, spread some charcoal over the bed no-1, ignite the same
o Repeat the cold startup procedures listed in this manual and established the boiler.

4.5 Boiler Normal Shut Down Procedure

o Gradually reduce the steam load by reducing to the coal flow to the furnace
o Gradually reduce the air flow also to avoid fast cooling the bed
o Reduce the firing rate slowly to maintain the temperature drop around 250 per hour o
Cost of coal feeding to the combustor
o Do’s connect the boiler from range when steam pressure drop less than the required
pressure for process
o Open the startup vent slightly and depressurized the boiler gradually (if required)
otherwise close all the vent and drains fully without depressurizing

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o

o Switch off the ID fan if required. Keep ID & FD fan dampers are opened to allow the
gases to escape. o When the boiler pressure drops to 2 kg/cm2open the air vent of drum
o Maintain normal water level in the boiler

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o
If surface is required to be cooled quickly, fan may be kept running for sometimes,please note
that fast cooling leads for refractory damages, it is suggested to go for natural cooling.
V. DAILY MAINTENANCE CHECK LIST DURING OPERATION
o Check the correctness of water level in the control desk with direct level glass.
o Check the level indicator for proper illumination o Check the combustor for
proper fluidization through peep holes o Drain the bed do check for unusual
combustible in the bottom ash o Check fan unusual noise for steam/pumps o
Check vibration in rotary equipment o Check for air/gas leakage from dust &
flue o Check for hot spots bulging etc. on casting dusts etc o Check the position
of damper & cleanliness o Check the bearing for lubrication & cooling water
system o Check all alarm annunciations with respect to set position o Check for
water, oil along with instrument air o Check for any unusual smoke conditions

5.1 Do’s For Fbc Boiler

o Clear the materials before closing the man holes of pressure parts furnace & ducting.
o Maintain all instruments in good worker condition o All equipment interlocks
should be always in line. o Maintain normal water level in feed water tank,
deaerater tab & boiler o Maintain normal water quality as per the remedial limits. o
All dampers must be on smooth operation condition. o Pressure rising from cold
start must be done as per the cold start up curve. o All the duct joints must be leak
proof o Use proper lubricants recommended by the manufacture regularly o Boiler,
piping, duct, feed water & oil tank must be properly emulated.
o Servicing of equipment should be done as per the manufacturer’s schedule. o
Maintain proper operation log sheets regularly o Maintain the air face from
moisture & oily matter of the pressure as recommended.
o Come out regular closing of direct water level gauges glass on feed water tank,
Deaerator tanks & boiler drum.

5.2 Don’t’s For Fbc Boiler

o Don’t by pan any instrument of safety interlock o Don’t throw water as boiler
feed water. o Don’t throw big size, wooden logs inside the furnace for slow
firing o Don’t start any fan with suction damper in open condition
o Don’t start any pump with the delivery valve in open condition Don’t run the
boiler with furnace in pressurized condition
Don’t throttle the feed water pump balancing leak off value while the pump & in
operation

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o
o Don’t operate the furnace wall header drain valves while the boiler is in operation
o Don’t operate the boiler beyond the operation limits. o Don’t leave the furnace
door open while the boiler is in operation o Don’t mix up different lubricants o
Don’t by pass compressed air dryer, if any problem attend to it at the earliest o
Don’t throw water inside the hot furnace.

3. Course Outcomes

We known the how the maintenance procedure of FBC boiler is carried out.

4. Procedure Followed

1. First we were select the Title of the Microproject by making discussion.

2. Refer various books related to our microproject
3. Also visit to various websites for collecting information.
4. Make the Project report

5. Skill Developed / learning outcomes of this Micro-Project

In this micro project we study maintenance procedure for preventive and predictive
maintenance of typical FBC boilers and it’s Components .We become able to identify
each component of the Fluidized bed combustion boiler. Also the construction and
working of the FBC boiler is also understood.

Date of submission :- Name and signature of lecturer

Government Polytechnic, Nanded 18