Distance - Design of Circulating Fluidized Bed Boilers: Design of Circulating Fluidized Bed (CFB) Boiler Components, Furnace Design, CFB Boiler Design with External Fluid Bed Heat Excganger, CFB Boiler Design Without Cyclone, Design of Water Wall, Su

Course Code: MEC090d

ARE YOU:

Looking for professional development but do not have the time to take off from work?
Looking for refresher course on specific engineering topics and cannot find an intensive course to serve your needs?
This may be your ideal Professional Development course!

Find out more on how the Professional Development Distance Program may work for you - Click here

Duration:

This course is approximately 4-5 weeks in duration.

Learning Method:

The PDDP program is more of a self-guided learning style.
You are required to read the notes and materials given, complete the follow-up assignments on your own, send in your questions prior to your 1 hour webinar meeting (if required) and be involved in live discussion via the internet.
Once you have completed the course, you will receive a certificate of completion

Introduction

This seminar will provide a comprehensive understanding of the design of circulating fluidized bed (CFB) boilers. The design of all CFB boiler components and equipment including furnace, cyclones, economizers, superheaters, reheaters, loop seals, expansion joints, refractory, and L-valves will be covered in detail. All potential operating problems and major operating problems, corrective actions and maintenance required for CFB boilers will be covered thoroughly. This seminar will focus on designing CFB boilers that have the highest efficiency, and maximum longevity and capacity factor. All the common problems encountered in CFB Boilers will be discussed in detail. This includes thermally induced failures, anchor system induced failures, water walls tube failures, NMEJ damages, clinker formation, refractory damages, APH tube chock-up, erosion and corrosion. The solutions to each of these problems will be presented. All repair and refurbishment methods, preventive and predictive maintenance required for CFB boilers will be covered in-depth.

Several studies have confirmed that CFB boilers are the best method for power generation. This is due to their fuel flexibility, and lowest electricity cost among all types of boilers. This technology is in great demand due to various other advantages such as lower emissions as compared to other types of boilers and has a carbon footprint well below the norms laid down by the World Bank emission requirements. This seminar is a MUST for anyone who is involved in the design, operation or maintenance of circulating fluidized bed boilers, because it covers how these boilers are designed and provides guidelines and rules that ensure the CFB boilers have great performance. This seminar will also provide up-dated information in respect to the design of supercritical once-through CFB boilers and ultra supercritical CFB boilers.

Who Should Attend

Engineers of all disciplines
Managers
Technicians
Maintenance personnel
Other technical individuals

Seminar Outcome

Circulating Fluidized Bed Boiler Design: Gain a thorough understanding of the best design methods of circulating fluidized bed boilers.
Design of Circulating Fluidized Bed Boiler Components and Systems: Learn all the techniques used to design CFB boiler equipment and systems including furnace, cyclones, economizers, superheaters, reheaters, loop seals, expansion joints, refractory, and L-valves.
Design of Circulating Fluidized Bed Boiler to Achieve Highest Efficiency, and Best Performance and Economics: Gain a thorough understanding of all the methods used to design CFB boilers having the highest efficiency, longevity and capacity factor as well as best economics.
Circulating Fluidized Bed Boiler Equipment: Learn about various equipment of circulating fluidized bed boilers including: furnaces, cyclones, economizers, superheaters, reheaters, ammonia injection systems, electrostatic precipitators, polishing dry scrubbers, fuel and sorbent feeding systems, bottom ash handling and extraction systems and materials.
Circulating Fluidized Bed Boiler Environmental Emissions: Learn about the monitoring and control of environmental emissions from circulating fluidized boilers.
Circulating Fluidized Bed Boiler Instrumentation and Control Systems: Learn about the latest instrumentation and control systems of circulating fluidized bed boilers.
Circulating Fluidized Bed Boiler Reliability and Testing: Increase your knowledge of predictive and preventive maintenance, reliability and testing of circulating fluidized bed boilers.
Circulating Fluidized Bed Boiler Selection and Applications: Gain a detailed understanding of the selection considerations and applications of circulating fluidized bed boilers.
Circulating Fluidized Bed Boiler Maintenance: Learn all the maintenance activities required for circulating fluidized bed boilers, to minimize their operating cost and maximize their efficiency, reliability, and longevity.
Circulating Fluidized Bed Boiler Refurbishment, and Life Extension Methods: Learn about life cycle cost, profitability, refurbishment, and life extension methods for all types of circulating fluidized bed boilers.
Circulating Fluidized Bed Boiler Commissioning: Understand all the commissioning requirements of circulating fluidized bed boilers.
Circulating Fluidized Bed Boiler Codes and Standards: Learn all the codes and standards applicable for circulating fluidized bed boilers.

Training Methodology

The instructor relies on a highly interactive training method to enhance the learning process. This method ensures that all the delegates gain a complete understanding of all the topics covered. The training environment is highly stimulating, challenging, and effective because the participants will learn by case studies which will allow them to apply the material taught to their own organization.

Special Feature

Each delegate will receive a copy in digital format of the following materials written by the instructor:

“POWER GENERATION HANDBOOK” published by McGraw-Hill in 2012 (800 pages)
Design of Circulating Fluidized Bed Boiler manual (600 pages)

The PDDP Distance Education program works as follows:

Once you register for this course, you will be sent a login username and password for our online distance website.

You will receive the course notes in hard copy through the online website, you will receive a set of notes each week covering the course material.
A one hour video-conference session will be conducted by your instructor each week (if required). The objective of this session is to assist in solving the assignments, as well as answer student questions that should be sent to instructor early enough prior to the meeting time. In addition with being able to communicate with the instructor, you will also be able to communicate with other students in the same class and watch their questions being answered as well. (A high speed internet connection is strongly recommended for this feature).
Each set of exercises can be completed and submitted by the indicated date and your completed exercise will be marked online and and returned by your instructor.
To gain the most from your course, it is highly recommended that you participate fully in all discussions and exercises. Please remember that each course has a form of quiz or exercise at the end to test your understanding of the material. You will be informed of these dates when you receive the course schedule.

*Course commencement date is subject to instructor availability.

Philip Kiameh

Philip Kiameh, M.A.Sc., B.Eng., D.Eng., P.Eng. (Canada) has been a teacher at University of Toronto and Dalhousie University, Canada for more than 24 years. In addition, Prof Kiameh has taught courses and seminars to more than four thousand working engineers and professionals around the world, specifically Europe and North America. Prof Kiameh has been consistently ranked as "Excellent" or "Very Good" by the delegates who attended his seminars and lectures.

Prof Kiameh wrote 5 books for working engineers from which three have been published by McGraw-Hill, New York. Below is a list of the books authored by Prof Kiameh:

Power Generation Handbook: Gas Turbines, Steam Power Plants, Co-generation, and Combined Cycles, second edition, (800 pages), McGraw-Hill, New York, October 2011.
Electrical Equipment Handbook (600 pages), McGraw-Hill, New York, March 2003.
Power Plant Equipment Operation and Maintenance Guide (800 pages), McGraw-Hill, New York, January 2012.
Industrial Instrumentation and Modern Control Systems (400 pages), Custom Publishing, University of Toronto, University of Toronto Custom Publishing (1999).
Industrial Equipment (600 pages), Custom Publishing, University of Toronto, University of Toronto, University of Toronto Custom Publishing (1999).

Prof. Kiameh has received the following awards:

The first "Excellence in Teaching" award offered by the Professional Development Center at University of Toronto (May, 1996).
The "Excellence in Teaching Award" in April 2007 offered by TUV Akademie (TUV Akademie is one of the largest Professional Development centre in world, it is based in Germany and the United Arab Emirates, and provides engineering training to engineers and managers across Europe and the Middle East).
Awarded graduation “With Distinction” from Dalhousie University when completed Bachelor of Engineering degree (1983).
Entrance Scholarship to University of Ottawa (1984).
Natural Science and Engineering Research Counsel (NSERC) scholarship towards graduate studies – Master of Applied Science in Engineering (1984 – 1985).

Prof. Kiameh performed research on power generation equipment with Atomic Energy of Canada Limited at their Chalk River and Whiteshell Nuclear Research Laboratories. He also has more than 30 years of practical engineering experience with Ontario Power Generation (formerly, Ontario Hydro - the largest electric utility in North America).

While working at Ontario Hydro, Prof. Kiameh acted as a Training Manager, Engineering Supervisor, System Responsible Engineer and Design Engineer. During the period of time that Prof Kiameh worked as a Field Engineer and Design Engineer, he was responsible for the operation, maintenance, diagnostics, and testing of gas turbines, steam turbines, generators, motors, transformers, inverters, valves, pumps, compressors, instrumentation and control systems. Further, his responsibilities included designing, engineering, diagnosing equipment problems and recommending solutions to repair deficiencies and improve system performance, supervising engineers, setting up preventive maintenance programs, writing Operating and Design Manuals, and commissioning new equipment.

Later, Prof Kiameh worked as the manager of a section dedicated to providing training for the staff at the power stations. The training provided by Prof Kiameh covered in detail the various equipment and systems used in power stations.

Professor Philip Kiameh was awarded his Bachelor of Engineering Degree "with distinction" from Dalhousie University, Halifax, Nova Scotia, Canada. He also received a Master of Applied Science in Engineering (M.A.Sc.) from the University of Ottawa, Canada. He is also a member of the Association of Professional Engineers in the province of Ontario, Canada.

Advantages of CFB Boilers, Components of CFB Boilers, Typical Arrangements of CFB Boilers, Hydrodynamics in CFB Boilers, Combustion in CFB Boilers, Heat Transfer in CFB Boilers, Design of CFB Boilers, CFB Boiler Operation, Maintenance of CFB Boilers, CFB Boiler Safety, Control Systems of CFB Boilers, Common Problems and Solutions of CFB Boilers

Advantages of circulating fluidized bed combustion
Circulating fluidized bed combustion technology
Development of circulating fluidized bed boilers
Components of CFB boilers: wind box and grid nozzle, bottom ash drain, HP blower, cyclone separator, evaporative or superheat wing walls, fuel feeding system, refractory, solid recycle system (loop seal), wall tubes, kick out, limestone and sand system
Typical arrangements of CFB boilers
Hydrodynamic in CFB boilers: particle classification, regimes of fluidization, fast fluidization, hydrodynamic regimes in a CFB boiler, Hydrodynamic structure of fast beds,
Combustion in CFB boilers: coal properties for CFB boiler, stage of combustion, factors affecting combustion efficiency, combustion in CFB, biomass combustion
Heat transfer in CFB boilers: gas to particle heat transfer, heat transfer in CFB boiler
Design of CFB boilers: design and required data, combustion calculations, heat and mass balance, furnace design, cyclone separator
CFB boiler operation: Requirements before starting, grid pressure drop test, cold start procedure, fill boiler procedure, start fan, boiler interlock, purge, start-up burner, drum and DA low level cut off, boiler warm-up, normal operation, normal shutdown, hot shutdown, hot restart,
Malfunction and emergency: bed pressure, bed temperature, circulation, tube leak, drum level
Maintenance of CFB boilers: Requirements before maintenance work, overview boiler maintenance, windbox inspection, furnace inspection, kick-out inspection, superheat (wingwalls), superheat (omega tube), roof inspection, inlet separator, steam drum, separator, outlet separator, screen tube, superheat tube, economizer inspection, air heater
Basic boiler safety: warnings, general safety precaution, equipment entry, operating precautions
CFB boiler control systems: Basic control, furnace control, main pressure control, main steam pressure control, drum level control, feed tank control, solid fuel control, HP blower control, primary air control, secondary air control, oxygen control, fuel oil control
Boiler commissioning procedure
Common problems and solutions of CFB boilers: wear problems in the boiler furnace, wastage in the boiler, thermally induced failures, anchor system induced failures, water wall tube failures (near lignite and subentry area), water wall tube failures at penthouse, main causes of tube failures, remedial actions, NMEJ failures, fitting of dust seal trap, clinker formation, remedial action taken, refractory damage, areas of major refractory damages, refractory damage in cyclones, APH tube chock-up, refractory failures at start-up burner and lignite entry area, chock-up in HP section

Design of a Circulating Fluidized Bed Boiler, Heat and Mass Transfer in a CFB Boiler, Furnace Design, CFB Boiler Configuration, CFB Design with External Fluid Bed Heat Exchanger, CFB Design Without Cyclone, Design of Heating Surfaces, Example of a Thermal Design of a CFB Boiler, Design of CFB Components

Design of a CFB boiler
Stoichiometric Calculations in a CFB boiler
Heat and Mass Transfer in a CFB boiler
Heat Balance
Calcination loss
Sulfation credit
Unburnt carbon loss in ash
Dry flue gas loss
Moisture loss
Division of solid stream (bed ash vs. fly ash)
Control of particle size distribution in bed
Furnace design
Furnace cross section
Width and depth ratio
Furnace openings
CFB boiler configuration
CFB boiler without external heat exchanger
CFB design with external fluid bed heat exchanger (FBHE)
Design with internal fluid bed heat exchanger
CFB design without cyclone
Cooled cyclone versus hot cyclone
Design of heating surfaces
Disposition of heating surfaces
Effect of fuel type
Biomass fired CFB boiler
Waste fired CFB boiler
Heat absorption in external heat exchanger (EHE)
Heat absorption in the furnace and back pass of the boiler
Energy and mass balance around CFB loop
Example of thermal design of a CFB boiler
Design of CFB components
Types of non-mechanical valves
Principle of operation of non-mechanical valves
L-valve, V-valve
Loop seal (seal pot or J-valve)
Design of L-valve
Maximum solid flow rate through L-valve
Practical consideration
Design of loop seal
Pressure balance
Size of loop seal
Design of loop seal
Pressure balance
Size of loop seal
Intrex with J-valve
Grate or fluidizing air distributor
Types of distributors
Design methods
Fluidizing air distributor for CFB
Nozzle plate design
Practical considerations
Plenum air loss
Sealing distributor
Attrition
Back-flow of solids

Material Selection for a CFB Boiler, Corrosion and Erosion Potential in a CFB Boiler, Design Considerations of Refractory Lining, Potential Operating Problems with CFB Boilers, Failure or Degradation of Boiler Components, Design and Construction of CFB Boilers, Reduced Performance of the Total CFB Boiler or Specific Components, Prevention of Erosion and Corrosion in CFB Boilers, Maintenance Solutions to Common Problems Found in CFB Boilers, Supercritical Once-through Internal Recirculation-Circulating Fluidized-Bed (IR-CFB) Boilers for Power Generation, Ultra Supercritical Fluidized Bed (CFB) Boilers

Material Selection for a Circulating fluidized bed boiler
Pressure part materials in a CFB boiler
Corrosion potential in a CFB boiler
Erosion potential in a CFB boiler
Selection of tube materials
Commonly used materials in a CFB boiler
Carbon and alloy steels
Subcritical CFB boilers
Supercritical CFB boiler
Refractory and insulations
Properties of refractory material
Design considerations of refractory lining
Anchors
Areas of refractory use in a CFB boiler
Refractory application
Expansion joints in a CFB boiler
Material-related problems in a CFB boiler
Lower combustor
Water-cooled cyclones
Potential operating problems with CFB boilers: blockage of feed lines, loss in efficiency, material degradation, solid leakage, fouling, and agglomeration
Major Operating Problems in CFB Boilers
Failure of CFB Boiler Components
Degradation of CFB Boiler Components
Reduced Performance of the Whole CFB Boiler or Specific Components
Design and Construction of the Boiler
Options for Reduction in Erosion in CFB Boilers
Corrosion Inside CFB Boilers
Erosion-Corrosion
Fouling and Deposit Formation Inside CFB Boiler
Prevention of High Temperature Corrosion in CFB Boiler
Use of Additives to Prevent High-Temperature Corrosion in CFB Boiler
Reduction of Flue Gas Temperature at the Furnace Outlet
Use of Corrosion Resisting Alloys
Avoidance of Simultaneous Occurrence of High Gas Temperature and High Wall Temperature
Avoidance of Contact of High Wall Temperature and Corrosion Agents
Refractory Failure
Thermally Induced Failures
Anchor Failures
Erosion Failures
Maintenance Issues
Design Audit
Material Audit
Preventive and Remedial Measures for Fireside Corrosion
Preventive Maintenance for Refractory
Operating Issues
Safety Issues
Wind-box Explosion
Reduced Boiler Performance
High Furnace Temperature
Excess Emission of NOx and SO2
Bed Agglomeration
Fouling
Loop-seal Problems
Methods used to improve the heat rate of circulating fluidized bed boilers
Supercritical Once-Through Internal Recirculation-Circulating Fluidized Bed Boilers (IR-CFB) Boilers for Power Generation
Supercritical once-through circulating fluidized bed with in-bed heat exchanger (IBHX)
Supercritical once-through circulating fluidized bed design study
Ultra supercritical circulating fluidized bed boilers

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