STEAM GENERATOR

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AIR FLUE GAS

Air flue gas

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TRAINING BOOK

Note:

This training book provides a detailed overview of all training topics. It was issued with the intention to
support the trainees with basic and detail knowledge about coal fired steam generators and the ap-
plied technique. However it must be read in conjunction with the project specific descriptions, drawings
and manuals of the steam generator manufacturer.

Depending on the training class, slides applied for training might differ from those shown in this docu-
ment.

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1- introduction ( -02-99-IB07-00001-)

The air and flue gas system includes the following main components (twice in each case):
forced draught fan (FDF),
primary air fan (PAF) and
induced draught fan (IDF),
steam-heated air heater (SAH)

flue gas-heated air heater (RAH),

pulse jet fabric filter (PJFF).

table: D.01.a
D.o1.a air- and flue gas system
02-9

air- & flue gas system

PA-fan
air in 02-99-IB13-01 fig: D 5.2.2-1
FD-fan
SAH
combustion air
ID-f

RAH PFJJ

boiler
ID-f
SAH

FD-fan

PA-fan RAH = flue gas heated

SAH = steam heated ai
hot primary air PFJJ = pulse jet fabric f

cold primary air

3
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2- air control (02-99-IB07-01 5.2.3.2)

The total air control of the boiler plant is a function of the boiler load
The structures are built for primary air control (mill operation) as well as
for combustion air control (the oil and coal burners, the secondary- and tertiär air ,
the core air, the lateral air, the cooling air and the over fire air system )

2.1- the primary air system

takes care of the operation of the mills. table D.02.a

combustion & primary air system
P&I 06-01-Ib01-01

The system consists of the hot - and the cold primary air system.

The air volume required for the combined drying and pulverising in the mill and
for the transport of the pulverised fuel to the burners is taken in by two radial flow
primary air fans. (6 0HFE 01/02 AN001) branched off from the FD-fan pressure
lines before the steam air heaters.

5
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The hot primary air ,responsible for the transport of the coal dust/air mixture, is heated up in
the flue gas-air preheaters, the cold primary air , responsible for the classifier temperature
control , is bypassing the flue gas-air preheaters.

For each pulveriser a hot and cold air branch are linked together to a common primary air
supply line (6 0HFE 10-50 BR020). In each branch a control damper is arranged.
The PA mass flow required for drying and transporting the pulverised fuel is adjusted
by hot air damper control (6 0HFE 10-50 AA001) mill.

table D.02.b
the primary air system
02-99-IB13-01 MS 5.2.2.1-1

The cold air dampers (6 0HFE 11-51 AA001) are controlling the mill outlet temperature.
They also take over the flow control for start-up and shut-down the pulverisers.

7
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2.2- the combustion air system Page 17 of 67 - pt 4.2 –see 02-99-IB13-00001

The task for the combustion air is to supply the air to the oil and coal burners,
the secondary- and tertiär air , the core air, the lateral air, the cooling air and the
over fire air system .

table: D.02.c
combustion air system
section of P&I 06-01-IB01-01

The combustion air , transported by two parallel arranged FD fans , is first

heated up in a steam air heater (SAH - 6 0HLC 10/20 AC001) to prevent
the flue gas air preheaters from dropping below the dew point on the cold flue gas side.
The combustion air is then further heated up in the flue gas-air preheaters, designed in four
sectors as so called “Quart-Sector Air Preheater”. (RAH - 6 0HLD 10/20 AC001),
to approx 370 °C at boiler full load.

Downstream of the air preheaters the four combustion air lines are interconnected ,
Each of these single lines are equipped with double blade shut-off dampers, (6 0HLA
17/19/18/20-AA101). These dampers are opened permanently at a double-line mode of op-
eration of the firing system.

9
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The FD fan controls the pressure after air preheater , see table D.02.d

table D.02.d
combustion air pressure = f (boiler load)
fig. 02-99-IB13-01 D.5.2.1-2

In the combustion air line temperature measurements (6 0HLA 22/23 CP001-003) are in-
stalled for the correction of the OFA- and burner air flow measurements.
These signals also serves as starting release for the first pulveriser ,
signal: hot air temperature > 150 °C (default value).
see-06-03-IB01-01/02 – combustion air level 10/30/50 or 20/40

2.3- burner air control (02-99-IB13-01 S.41)

the firing plant is designed for the operation with staged air supply, which means, that the combustion

air is not only introduced into the furnace by the core air, the secondary- and tertiär air and the pri-

mary air to the 30 burners, but also but also by additional lateral air nozzles and overfire double ports.

11
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table C.05.b primary air control+

HHL AA101
OFA air flow OFA control damper
CF 902 HHL 17-20
over fire air HLA 70/80 BR010/020
M AA 101

12x OFA-double nozzles HHL-AA001

HHA 71-76 81-86 AV001 control damper combustion air HHL - CF 001
M HLA22/23

BR010
burner trimming plate combustion air flow
BR013

table: D.02.e
HHA AV 001 tertiary air
HHL – AA101
secondary air 3x shut off damper
P für FD-fan control
open / close
core air
M
pulverised fuel line

HHE CG 301
control damper AA121
sources P&I´s combustion air control
06-03-IB01-01 burner elevation air
HHL AA503 35-99-IB01-01 mill 10
M BR015

3-way valve
AV002
06-01-IB01-01 air system
06-99-IB01-01 firing system general view diagrams
diagrams:
HHE 11-16 AA101 lateral air
02-99-IB13-01 02-99-IB07-01
2x3 /level
BP 501
35-99-IB13-01
02-99-IB13-01 02-99-IB07-01 35-99-IB13-01
M GZ HFE CG301

HFE – AA501
manuell operated
mill HFC
HFE21 AA101 mill
quick closing damper
primary air flow HFE10 AA001control damper for coal flow
M hot primary air
M
cold primary air

CT 001 & CP 001 for HFE11 AA001 control damper for classifier temp.
pa-flow correction
purging air for coal feeders 0,4 kg/s

The six burners of each level (e.g. 6 0HHA 11-16 AV001) are connected via individual lines
each (e.g. 6 0HHA 11-16 BR010) with the secondary air ducts .
Air flow measuring devices (6 0HHL 11-16 CF001). and control damper (e.g. 6 0HHA 11-16
AA001) are installed in each individual air line to the burners.
The extraction of lateral air (e.g. 6 0HHL 11-16 BR016) and core air (e.g. 6 0HHL 11-16
BR014) takes place between flow measurement and control damper.
Lateral air- as well as core air quantities are only dependent on system pressure,
not on the boiler load.

table D.02.f
furnace sketch
02-99-IB07-01 page10

13
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2.3.1- lateral air (side wall air)

The lateral air lines is branched off (6OHHL 11-16 BR016) between combustion air flow measure-

ment (OHHL CF001) and combustion air control damper (OHHA AA001)

and is therefore dependent on combustion air system pressure, not on boiler load.
Low-oxide flue gas atmosphere in the burner zone close to the boiler walls, will be avoided
by concentrated lateral air injection
The lateral air is injected via separate nozzles (e.g. 6 0HHA 11-16 AV002), 2x3 per burner
level, into the furnace close to the side walls.

The lateral air dampers are controlled in groups and moved into a defined OPEN or
CLOSED (=COOLING) position.
Depending on the firing capacity or boiler load these dampers (e.g. 6 0HHL 11-16 AA101)
are in a constant “open” position.
Only In case of boiler loads < 40 % the dampers are “closed” or in “cooling position”
(20% open).

If needed , the lateral air dampers may be activated , level per level, depending on
boiler load (e.g. closing of lateral air dampers of upper burner levels at loads < 60%.)

2.3.2- core air (02-99-IB13-01 & 02-99-IB07)

The core air is branched off (6OHHL 11-16 BR014) between combustion air flow measurement

(OHHL CF001) and and combustion air control damper (OHHA AA001)

and is therefore dependent on combustion air system pressure, not on boiler load.
The core air is centrally injected via the core air pipe into the furnace.

In case the burner level is not in coal operation ( mill quick closing damper OHFE Aa101) is
closed, primary air tube is cooled through “3-way” cooling air shut off damper
(OHHE 11-16 AA101)

15
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2.3.3- the over fire air system (ofa) (02-99-IB13-01 & 02-99-IB07)

A total of 12 OFA double nozzles (OHHA 71-76 AV001) ,situated on the front and rear wall
above the upper burner level, are supplied with combustion air upstream the combustion air
flow measurement (OHHL CF001) and are controlled by the OFA controll damper (OHHL
80/81 AA101) and the OFA flow measurement (CF 901/902)
The over fire air flow is measured and controlled for 3 ports each.
The OFA double nozzles are designed with an inside and an outside cross-section, the out-
side cross section can be throttled manually by means of a sliding cone
The OFA control is load dependent , influenced by an oxygen control and required for the
complete combustion.
At boiler full load the OFA is injected to the furnace at an average velocity of approx. 50 m/s.

17
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3- combustion air balance

The total air amount depends on the boiler load, the fuel quality , the stoichiometric air
amount and the excess air. (see table D.03.a and D.03.b)

table: D.03.a
total air amount Lo against boiler load
see: 02-99-IB13-01

next table

table: D.03.b
air fuel ratio f (boiler load)
see: 02-99-IB13-01

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.3.1- air balance at 100 % BMCR (02-99-IB07-01)

example: 100% boiler load with 4 out of 5 mills e.g 24 burners in operation

system remarks

100 % boiler load kg/s steam 635,5 = 2228 t/h

100% firing capacity MW 1866

NCV of coal MJ/kg 17.871

coal mass flow kg/s 104,44 = 1866 : 17.871

total air mass flow kg/s 770,3 fuel air ratio 1,2

over fire air system kg/s 81,4

lateral air kg/s 19,26

cooling air kg/s 40,57 for level out of operation

The sum of over fire- and lateral air (for levels in operation) and cooling air (level out of operation) addes up to
141,22 kg/s . The remaining burner air will be therefore add up to: 770,3 minus 141,22 = 629,08 kg/s.

burner capacity MW 77,8 24 burner in operation

NCV of coal MJ/kg 17.871 77,8 : 17.871 =

coal mass flow /burner kg/s 4,35 X 24 = 104,44 kg/s at full load

burner air mass flow/burner kg/s 26,21 fuel air ratio 0,98

total burner air mass flow kg/s 629,08 = 24 x 26,21

primary air (incl sealing air) kg/s 169,47 = 24 x 7,06

tertiary air kg/s 280,38 = 24 x 11,7

secondary air kg/s 168,68 = 24 x 7,02

core air kg/s 10,55 = 24 x 0,44

21
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3.1.1- summary (02-99-IB07-01)

The summary of all air mass flows should add up to the total air mass flow.

The air mass flows are divided in

.1. the burner air,
consisting of the primary air, the secondary - , tertiary- and core air .

.2 the lateral air

.3. the ofa air system
above items for the levels in operation and, for the burner level out of operation
.4. the cooling air mass flow of primary air, the secondary - , tertiary- and core air
(40,57 kg/s see above) as well as the lateral air (3,6 kg/s) is taken into consideration
for combustion air control

total air mass flow kg/s 770,3

over fire air system kg/s 81,4

lateral air kg/s 19,26

cooling air kg/s 40,55

primary air kg/s 169,45

tertiary air kg/s 280,36

secondary air kg/s 168,67

core air kg/s 10,55

23
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table: D.03.d
combustion air balance at 100% BMCR
see 02-99-IB07-01

table: D.03.e
DS burner air balance
see 02-99-IB07-01 p. 10&14

25
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4- the flue gas system (see 02 99 ib13 01 s.27-30 & P&I: 06-09-IB01-01)

Due to the combustion of the pulverised fuel in the furnace (6 0HBK01) a flue gas flow with a
thermal content is used for the generation and superheating of the load-dependent steam
flow in the various heating surfaces.

D.04.a flue gas system symplified table: D.04.a

see 02-99-IB13-01 S.27-30 & P&I: 06-09-IB01-01

fluegas system (symplified)

CT 001-003 CP 001
see 02-99-IB13-01
OHNA 11/21 CQ 001-003 OHNA 13/23
AA101 M-M
125 °C

390 °C
O²-CQ001-003 fluegas air preheaters control damper
OHLD 10/20 AC001 OHNA 12/22 fabric filter
P for ID-Fan control AA451/452 OHDD 10-40
OHBK40 CP901l AT 001

M-M

1420 °C
ID-Fan double blade
radiation pyrometers OHNC 10/20 shut off damper
AN001 OHNA 14/24
AA 101

FD-Fan

PA-Fan

In this connection maximum flue gas temperatures of up to 1420°C on average occur in the
combustion zone at full firing capacity which is cooled down to 1200°C on average when
leaving the furnace. Successive the flue gas is cooled down in the superheater, reheater and
economiser to the boiler outlet temperature of approx. 390°C. While in the furnace the heat
transfer was effected for more than 90 % by radiation, in the superheater section the heat
exchange takes places predominantly by convection.
Additionally to the standard flame monitoring by single burner flame detectors, the furnace is
equipped with 12 radiation pyrometers (6 0HBK01 CR 001-012) which are arranged on two
levels on each sidewall.

27
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At the boiler outlet (HBK area), directly upstream of reheater 1 (RH 1) three analogous
pressure measurements (6 0HBK40 CP001-003) are arranged which in a 2 out of 3 selection
monitor the flue gas pressure in the boiler. In case of exceeding the higher or lower limit
values the boiler protection with or without switching-off of the fans is triggered after
prealarming.
The measured values are displayed in the control room as well as their mean value
(6 0HBK40 CP901). The mean value of two additional analogous pressure measurements
with a smaller measuring range (6 0HBK40 CP004-005) are used as actual value for the ID
fan control.
The flue gas is taken out of the furnace by two parallel operating axial ID fans (6 0HNC 10/20
AN001) with variable pitch control via a common flue gas duct (6 0HNA10 BR010) and
afterwards divided into two trains (6 0HNA 11/21 BR010) upstream the flue gas air
preheaters (6 0HLD 10/20 AC001).

In each line upstream of the air preheater the flue gas oxygen content (6 0HNA 11/21
CQ001-003) is measured with three probes. All measured values are displayed in the control
room. The 2 x 3 O2 measurements as well as their mean values are used for the calculation
of emission values, for combustion air control as well as the lambda monitoring and
protection of the boiler plant.
A further measurement is the temperature system measurement. Three temperature sensors
with different lengths are distributed over the duct up and downstream of each air preheater.
The temperature measured values (6 0HNA 11/21 CT001-003 / 6 0 HNA 12/22 CT001-003)
are displayed in the control room.

Subsequently the flue gases passed the air preheaters which cooled down by heat transfer
to the combustion air to approx. 125°C at full load.
The equipment of the air preheaters and their operation modes are detailed summarised in a
separate process description B114116-06-13-IB13-00001.
When a maximum admissible flue gas temperature downstream the air preheater is
exceeded the appertaining ID fan is switched off and all shut-off dampers of this flue gas
train are closed.

29
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If the temperature of the flue gas increases over 125°C, two control dampers, which are
arranged at the duct in each line (6 0HNA12 AA 451/452 and 6 0HNA22 AA 451/452) will
controlled open to cool down the fluegas with ambient air. See also the P&I Diagrams
B114116-13-02-IB01-00001 and B114116-13-02-IB01-00002.
In the flue gas duct trains (6 0HNA 12/22 BR010) there are additional three O2
measurements (6 0HNA 12/22 CQ001-003) arranged to determinate the oxygen content in
the flue gas downstream the air preheaters. Furthermore a pressure measurement (6 0HNA
12/22 CP001) monitors the negative pressure during phase 2 in one train ventilate operation.
Subsequently the flue gases are dedusted in one fabric filter in each train (6 0HDD
10/30/20/40 AT001). A triple pressure measurement (6 0HNA 13/23 CP001-003) respectively
arranged in both flue gas trains (6 0HNA 13/23 BR010) downstream of the fabric filter
monitors the maximum admissible negative pressure upstream of the ID fan for the
protection of the fabric filter. The measurements are processed in the boiler protection
system (2 out of 3).
Downstream of each ID fan a triple analogue pressure measurement (6 0HNA 14/24 CP001-
003) is installed to monitor the undisturbed flue gas path. These measured values are
displayed in the control room and processed in the boiler protection system too (2 out of 3).
In each train a gas-tight double blade shut-off damper fed with sealing air (6 0HNA 14/24
AA101) is located directly downstream the measurements. During normal operation these
dampers are moved in the open position. In case of ID fan disturbance and/or single-train
operation the appertaining damper downstream of the fan is closed and the corresponding
sealing air supply unit is switched on. The differential pressure between sealing air and flue
gas duct is measured and indicated in the control room. In case of dropping below a limit
value an alarm is triggered and the stand-by fan of the sealing air supply unit is switched on.
In addition to that the closed position of the damper is monitored with three binary position
indicators (6 0HNA 14/24 CG302/304/306). In case of a default an alarm is triggered off in
the control room and the damper in the connected sealing air supply line is closed.
The equipment of the ID fans and their operation modes are detailed summarised in a
separate process description for the ID fan B114116-06-12-IB10-00001.

31
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Downstream of the ID fans (6 0HNA 14/24 BR010) both trains are connected to a common
duct (6 0HNA30 BR010) where the cleaned flue gases are led to the atmosphere via the
stack (TPLOSS-02-07-01 “Supplement ESKOM“). The emission measurements (6 0HNE 10
CP001/CT001/CQ001-006 TPLOSS-02-07-02 “Supplement ESKOM“) are accommodated in
the supply line to the stack.

table: D.04.b
flue gas system
see: 06-09-IB01-01

33