1

BABCOCK BOILER UAN WEST 1 TO 6

Operation Manual Prepared By Ashek Ullah

Table of Contents
A. BOILER 1 TO 6 : 1. TECHNICAL DATA 2. START UP PROCEDURE
i. ii. iii. COLD WARM HOT

3. FIRING SYSTEM
i. ii. NATURAL GAS CRUDE OIL

4. SHUT DOWN PROCEDURES

i. ii. NORMAL EMERGENCY SHUT DOWN

5. OPERATION OF SOOT BLOWING SYS. 6. INTER LOCKS 7. ALARMS & PROTECTIONS

8.

ISOLATION BOILER MAJOR AUXILIARY EQUIPMENTS

i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. BOILER FEED WATER PUMPS BOILER F.D. FANS COOLING AIR FANS LP GAS REDUCING STATIONS CRUDE OIL TRANSFER PUMPS BURNER CRUDE OIL PUMPS BOILER GAS / CRUDE OIL BURNER BOILER FW CONTROL VALVES DEAERATOR STEAM REDUCING STATION SH ATTAMPERATER SPRAY WATER BOILER WASTE DRAIN PUMS. MAJOR OVERHOLING BOILER TUBE LEAK

3 A - 1.BOILER TECHNICAL DATA:

(For individual unit only)

BOILER (1 6) TECHNICAL DATA:

DESIGN DATA OPERATING DATA PRESENT DATA

A. BOILER - : Max. Continuous loading Min. stable loading Design pressure Drum pressure Super Heater Outlet temp Super heater Outlet press Feed water Inlet temp.

= 365 t /h = 73 t / h = 86,4 bar = 80,8 bar 0 .=490 C = 66.7 bar 0 = 140 C

B) FIRING EQUIPMENTS -:
Note- it is possible to operate the Boiler either with N. Gas or Crude oil or N. Gas and Crude oil during the same time : but not in same burner. 1. Natural Gas Burner -: Type of Burner =6 multi speed lances Number of Burner= 9 nos. Design net calorific values -: a) 10450 K.cal / Nm3 b) 11000 K. cal / Nm3 Cap. Of burner Nozzle 3083 Nm3 / h Min. Gas press. Before burner 0.05 bar Max. Gas press. Before burner 1 . 2 bar Turn down ratio of burner 1 to 4 2. Type of Burner = Swirl parallel flow Type of Nozzle = Number of Burners Design net calorific value= Cap. of burner Nozzle =3253 kg / h Min. Crude oil flow before burner= 5.0 bar Max. Crude oil flow before burner= 16.0 bar Excess Air ( O2 ) Turn down ratio of burners = Atomizing air press. before burner Auto. steam press. outlet Red. station Auto steam temp. before burner 3. Ignition burner -: Type = High voltage ignito. NO. of Burner 4. LP Gas Station - : Inlet Press. Out Let press. Capacity of each station Number of Station
15 / 10 YELN 385243 100

9 nos. 9989 K. cal/ kg

at 100 % load = 1 % at 50 % load = 1 % at 20 % load = 3 ,4 % 1 to 4 = 6.0 bar 13.5 bar o 225 C Drug. 400 - 43 Ex / D - 2L 400 9 nos. 6 to 8 bar 4.0 bar 30 ,00 Nm3 2 nos.

Note- to be able to start the boiler from cold with crude oil burner 7, 8 & 9 with atomizing Air.

4 C. Pumps & Fans

1. Boiler Feed water Pump: (RL111A1,RL12A1 & RL13A1) Flow Nor. Head Req. Power Speed NO. of Pump Max. Amps. Flow Nor. Head Req. Power Speed Max. Amps. NO. of Pump Flow Nor. Head Req. Power Speed NO. of pump Flow Nor. Head Speed NO. of pump Flow Nor. Head Speed NO. of pump 200 m3 / h 1120 m WC 803 kW 2980 r.p.m. 3 nos. 120 A 270 t / h 110 m WC 104.85 kW 1450 r.p.m. 240 A 2 nos. 70 m3 / h 49.6 m WC 14.86 kW 2900 r.p.m. 2 nos. 100 t / h 50 m WC 2900 r.p.m. 3 nos. 90 to 110 t / h 8 to 10 m WC 1450 r.p.m. 2 nos.

2. Clean drain pump (RU11A1 & RU12A1)

3. Service water pump ( VG

4. Make up water pump ( UA

5. Waste drain pump ( RT

6. Waste drain pit over flow pump ( ?

7. Crude oil burner pump (NM21A1 & NM22A1)

Flow Nor. Head Req. Power Speed NO. of Pump Flow Nor. Head Req. Power Speed NO. of Fan Max. Amps. Flow Nor. Head Req. Power Speed NO. of fan

8. FD Fan (NG11A & NG12A1)

9. Cooling Air Fan ( NK51A1 & NK52A1)

36.9 m3 / h 18.3 bar 47 kW 2960 r.p.m. 2 nos. 62 Nm3 /sec (223700 Nm3 / h) 827 m WC 578 kW 1490 r.p.m. 2 nos. 80 A 1073 Nm3 / h 106.5 m WC 25 kW 2965 r.p.m. 2 nos.

5 A 2, BOILER START UP: According to the boiler temperature, distinguish three start- up modes: i. ii. iii. Cold Start : it may be classified either boiler evaporator & superheater temperature as environment level or start up after periodical inspection or overhauling. Warm Start : after down time of 24 hours, the boiler pressure of approx. 10 bars and evaporator & superheater temperature approx. 180 oC. Hot Start : after a downtime of 8 hours, the boiler pressure approx. 40 bars and evaporator & superheater temperature approx. 300 oC. If necessary, boiler will be re-fed as low water level. The FW temperature amounts to approx. 100 o C.
2 1. a. PREPARATION TO START UP: -

Before start up the boiler check that the following items are fulfilled: All maintenance or inspection works at boiler or auxiliaries has to be completed and all work permits must be cancelled. ii. Combustion chamber, flue gas passes and flue gas ducts are cleaned and all manholes are closed. iii. Boiler drum cleaned and both manholes are properly tied. Level indicators are cleaned. iv. The soot blowers should be in their retracted position. v. All auxiliaries of the unit must be ready for operation e.g. all oil levels at pumps, motors and gears are checked and topped up. vi. All dampers, vanes etc. are greased. vii. All safety instructions have to be checked about proper and exact functioning e.g. safety & relief valves. viii. All by pass valves in regulating loops should be closed and all regulating valves checked about proper working conditions. ix. All chemical analysis has to be in working order, cation filters are regenerated etc. x. The isolating valves of all indications or transmitters impulse line must be open. xi. All electric breakers should be in working place. xii. The T.V. cameras for boiler furnace and drum level indication are ready for service but the furnace camera kept in operation before 1st burner fire.( N / A ) xiii. Check waste water drain pumps and grease pots are filled xiv. Check service water pumps; related water basin & over head tank. xv. Check instrument air compressors , dryers & reserve tank. xvi. Check service air compressors & reserve tank. xvii. Check emergency diesel air compressors. xviii. Check make up water pumps
xix. Check instrument air supplied all consumers. xx. Power supplied to burners cubicle HB1-4 switch ON.

i.

6
2 1. . PREPARATION TO START UP: a. CONDITION OF THE MOTERIZE VALVE

Circuit breakers of the motorized valve

FW Stop valve - 1 FW Stop valve - 2 FW Stop valve - 3 FW Control valve - 1 FW Control valve - 2 FW by pass valve - 3 FW inter Connection valve Main FW stop valve to boiler Start up stop valve Start up Control valve Attamp. spray water valve - 1 Attamp. spray water valve - 2 Drum drain valve SH - 1 drain valve SH - 2 drain valve SH - 3 drain valve Boiler HP steam stop valve & by pass valve Boiler blow down valve Spray water inter connection valve RL41G201 RL42G201 RL43G201 RL41G401 RL42G401 RL43G401 RL70G201 NA 1G201 NA70G201 NA70G401 NA51G401 NA52G401 NC15G401 NC 33G401 NC 40G401 NC 49G401 NA49G201 RZ16G401 RL73G401 Working position Working position Working position Working position Working position Working position Working position Rack out Working position Working position Working position Working position Working position Working position Working position Working position Working position Working position Working position

Valve position Closed Closed Opened Closed Closed Closed Closed Closed opened Opened 50 % Closed Closed Closed opened opened opened Closed Closed Closed

7
b. CONDITION OF THE HAND OPERATED VALVE

HAND OPERATED & MOTOR OPERATED VALVE POSITION Supporting tube outlet header drain valve ( SH 1) Super Heater - 2 drain valve HP steam line SH 3 outlet drain valve Evaporator drain valves Evaporator header drain valves Economizer drain valves Boiler drum drain valve Saturated steam header vent valve Economizer inlet vent valves Attamp. - 1 vent valve Superheater 3 vent valve Feed water supply line to Distiller valve
NC 33 G 1 NC 40 G1 NC 49 G 1 NC 23 G11 upto NC23 G 71 NC 91 G 81 / 82 NC 6 G 1 / G2 NC 15 G 1 NC 28 G1 / G2 NC 2 G1 / G2 NC 38 G 1 / G 2 NC 46 G 1 / G 2 RL 80 G 1 RL 72 G 1 RL 73 G 1 RL 53 G 1

Remarks

Open Open open Open Closed Closed Closed 2 turns open 2 turns open 2 turns open 2 turns open Closed Closed Closed Closed Closed Closed Closed Closed Closed Open Open Open slowly , after venting over, valves closed Open fully Open stepwise upto 15 % Open partially.

Isolating valves of Spray water control valves

RL 53 G1 NA 54 G1 NA 55 G1 / G2 NA 56 G1
NA 56 G2 NA 51 G1 / G2 NA56 G1 / G2 RL- 70 G1 RL - 30 G8 RL - 40G7 RL 43 G201 RL43G401 RL 60 G5 / G6 NC 1 G1/ G2 RL 43 G401

Isolating valves of Spray water control valves Vent FW line up to FW control station FW Stop valve ( by pass station) FW control valve ( by pass station) Vent FW line before Eco. 1 inlet ( direct vent) Boiler filling valves at 0 meter level Control FW flow through control valve Watch FW tank level Watch economizer venting Watch boiler drum level locally & TCR Closed evaporator drain valves FW Stop valve ( by pass station) FW control valve ( by pass station) FW main stop valve to boiler Fill up the boiler drum up to > HH

Open slowly Flow approx. 30 t / h Maintain normal level. after venting NC 2 G1 / 2 completed closed vent valves When low level alarm disappeared ( > 100 mm) closed RL43 G401 & filling valves NC1 G1 / 2
NC 23 G11 up-to NC23 G 71 RL 43 G201 RL43G401 NC 1G201 RL 43 G201 RL 43G401

Closed Closed fully Closed fully Elec. CB rack in & open Open full Open stepwise up to 15 % kept operation level ( - 200 mm)

Open the boiler drain valve

8 A 2. 2. BOILER FEED WATER TANK FILLING UP : 2.2.1 Inform Lab. boiler start up program , & prepared to fill the boiler feed water tank up to normal level ~ 2.6 m:Before filling the FW tank, check the following valves are in their correct position or not. drain valve of FW tank closed, vent valve of deaerator 1 turn opened. over flow valve must be closed & Selection in AUTO position. all isolating valves of level transmitters etc. must be opened. It may fill FW tank either with the direct make up water filling valve (UA2G201) or with turbine condensate pumps if the condensate water conductivity as usable condition.

2 2. 1. FEED WATER PUMP START UP: After FW tank level filled: 2.3. Prepared to start any one FW pumps ( RL 11, 12 & 13A1): i. FW pumps suction, lubricating oil & gland sealing water filters should be cleaned & installed. ii. Checked all filters P iii. pump & suction filter drain valves closed iv. Suction filters & sealing water filters properly vented. v. Pumps suction side manual valves (RL11, 12,13G1) are fully opened. vi. Isolating valves of all pressure switches & pressure transmitters opened. vii. Pumps discharge by pass manual valves (RL21G2/G3, 22G2/G3, 23G2/G3) Closed. viii. Pumps motorize discharge isolating valves (RL 21, 22 & 23G201) Closed. ix. Pumps balancing water isolating valves (RL24, 26,28G2) opened. x. Pumps minimum flow manual isolating valves (RL25, 27,29G2) opened. xi. Sealing water isolating valve open. xii. Oil levels in the lube oil tanks are normal. xiii. Lub. Oil pumps oil discharge line isolating valve opened.

9
xiv. A/C & D/C Lube oil pumps, FW pumps & discharge valves Elec. Circuit breakers are in working position. xv. Start a / c lube oil pump from TCR xvi. Check lube oil pressure & flow each for bearing. xvii. Lube oil coolers cooling service water isolating valves opened & check cooling water flow through the lube oil coolers. xviii. EM push buttons of the FW pumps released. xix. FW pumps Selector switch in TCR. xx. Start one of the FW pumps, watch amp. meter xxi. FW pump discharge by pass valve (RL21G2/3, 22G2/3, and 23G 2/3 gradually open; wait for pressure equalization ~ 130 bars. xxii. Pumps discharge valves (RL21, 22 & 23G201) open step by step. xxiii. Pumps discharge by pass valves (RL21G2/G3, 22G2/G3, 23G2/ G3) closed. xxiv. Start one of the reserve pumps a/c lube oil pump & Select the FW pump in AUTO.

10 A - 2. 3. PREPARE TO FILL UP BOILER: PRE CONDITIONS: ONE FW PUMP INSERVICE & THE FOLLOWING MOTORIZED VALVES C.V ARE IN WORKING POSITION. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. FW stop valves 1, 2 & 3 ( RL41,42 & 43G201). FW control valves RL41, 42 & 43G401. Start up stop valve NA70G201 Start up Control valve NA70G401 Spray water Valve (attempt.)NO.1 & NO.2 NA51 & 52G401 Drum drain valve NC15G401 SH NO. 1,2 & 3 drain valves NC33/40G401,NC49G401. HP steam stop valve of boiler and by pass valve Boiler blow down valve RZ16G201. Spray water valves RL72, 73G401. Open slowly vent valves RL70G1 & RL30G8 in the FW control station, if water continuously flowing out, close vent valves. open fully FW stop valve RL43G201 Open step wise FW control valve RL43G401~ 15 % Open FW vent line valves RL60G5 & G6. before economizer NO.1 , when water continuously flowing out, close vent valves. Open stepwise boiler filling valves NC1G1 & G2 Control FW flow approx. 30 t / h through RL43G401. Watch FW tank level, maintain its normal level by feed valve. Check economizer vent valve NC2G1 & G2, if water continuously flowing out, close vent valves. watch boiler drum level indicator, when low level signal disappeared, ( - 100 mm) * some times it was observed that, drum filled upto HH level for hydraulic test & later drain excess water . closed FW line valve RL43G401 Close filling valve NC1G1 & G2 Close evaporator drain valves , NC23G11 to NC23G72 Boiler FW main stop valve RL60G201 C.B. rack in & open Maintain drum level - 200 mm; open RL43G201 fully & throttle FW flow approx. 30 t / h through valve RL43G401.

11. 12. 13. 14. 15. 16. 17.

18. 19. 20.

11

BOILER FILLING UP FLOW DIAGRAM

12 A 2. 4. Cold Start-up of the Boiler

I. by NATURAL GAS -:

Conditions: 1. 2. 3. 4. boiler filled starting level ( - 200 mm) Main Gas Red. Station in operation ( HP Gas .Red. station) One Condensate pump in service. One Feed Water pump in service.

Check all manholes on boiler and air ducts are closed. Check instrument air supplied to all consumers. power supplied to burners cubicle HB1-4 switch ON. HP Gas Red. Station outlet press. ~ 7.00 bar.

13

LP GAS RED. STATION 5. Open inlet valve of both LP gas red. station NN2G1 & NN7G1. 6. Closed valve in nitrogen and vent lines. 7. Fill LP gas red. Station and waiting for press. equalization ~ 6.0 bar, by opening the by pass valve NN3G4 and NN8G4. 8. Open natural gas quick closing valve (NN8G401, NN3G401) by pressing the hand levers. An switch ON the Stop valve 9. Check proper function of LP gas red. Station valves. by opening the vent valve ( NN5G1, NN10G1) pressure drop, and watch press. after red. Station valve at ~ 3.9 bar and 4.0 bars respectively; then close the vent valves. 10. Open outlet valve of LP gas red. Station (NN3G1, NN8G1). 11. Check the position of natural gas control valve (NN20G401. It must be close position. 12. Open the natural gas relief valve, NN34G801 from TCR desk. 13. Circuit breakers of Cooling air fans working position. and EM. Push button released & Select Switches in TCR position. 14. Check all cooling air valves to photo cell are opened. 15. Start one of the cooling air fan. NK51A1 or NK52A1 from TCR desk. cool Air press. Low signal disappear nd 16. Select 2 Cooling air Fan NK52A1 to AUTO position. 17. Tripped the running fan by pressing EM. Push button from local , Sel. Auto stand by will take place 18. Release EM. Push button & Sel. he Fan NO. in AUTO position ; nd st Press EM button of the 2 running fan, after tripped 1 one will take place. 19. Prepare the FD Fan NO.1 & NO.2. Check the oil level. Check the function of the fans dampers and vanes. put circuit breakers in working position. Make sure that, hand operated dampers in the air ducts are opened. Released EM. Push buttons of the both Fans. Sel. Switch of both Fans in TCR position. 20. Start of the FD fans from TCR desk on AUTO program or MAN Selection for purging. 21. Purging Program: (Time Setting 160 Seconds & rate of air volume 2950 m3 / min or 177,000 m3 / hr.)
[ Boiler purging means, clear the boiler furnace & down stream flue gas paths upto chimney inlet by a sufficient volume of air to get rid ( make free) of undesirable elements in order to safe guard the equipment against any explosion]
PRECONDITIONS:-

Connecting the interlock setting of the boiler main protection & firing interlocks systems established. i. Emergency push buttons released. ii. Control air pressure > min. iii. Boiler release existing means that the following interlocks are fulfilled . a) Furnace pressure < min. b) Drum level between < HH & > LL c) Fuel air ratio < HH d) F.D. Fan 1 or 2 in operation. e) All oil quick closing valves are closed. f) All natural quick closing valves are closed. g) No purge program existing or any burner in service.

14
Press push button Preventing ON Air dumpers of all burners will open. 22. when all burner dampers are in open position ; start to open FD Fan vane 3 and bring the air flow to ~ 200,000 nm / h. signal Preventing running ' appears. after 160 seconds signal Preventing finish will appears & Ready for ignition period will start . TIME SETTING 10 minutes. 3 reducing the air flow by closing FD fan vane to 15 %; with air flow of approx. 45,000 nm / h, and burners Ready for Ignition signal will appears at each of the nine burners. 25. Open the natural gas Main Stop valve. Open natural gas isolating valves infront each burners. and check gas press. before burners must be at ~ 0.11 to 0.15 bars. 23. Starting the first burner from bottom row with natural gas burner.
PRECONDITIONS: -

To get Burner Ready signal the following interlocks have to be fulfilled: a. Boiler Release existing when the below conditions a to g are fulfilled.
i. ii. iii. iv. v. vi. vii.

Furnace pressure < min. Drum level between < HH & > LL Fuel air ratio < HH F.D. Fan 1 or 2 in operation. All oil quick closing valves are closed. All natural quick closing valves are closed. No purge program existing or any burner in service.

b. c.

Boiler air purge terminated. 3 Ignition air flow > min ( 45,000 Nm / h )either one burner in operation ( min. air flow signal is taken from FD Fan vane position) b. Gas regulating valve in close position. c. One flare in operation. d. Burner natural gas pressure before burner, > min.min. ( 0.02 bar) [ NN18P2] e. Burner natural gas pressure before burner < max. max. ( 0.3 bar) [ NN18P4] f. Gas relief valve open. g. Photocell is not picking up any stray light.

wait until Flame signal appears; observe the air damper is moving to open position, then close natural gas relief valve from TCR. [Note: - incase of some disturbance: air dampers of all burners open automatically; and purging has to be repeated, by increasing the air flow to ~ 200,000 Nm 3 / h.] 27. Increase air flow to > 45,000 Nm / h, ( FD fan guide vane must be > 18 % open) start burner No.9. after flam appeared Check the stability and brightness of the flame by the flame intensity indicator and TV combustion monitor screen, also locally through furnace side glass. 3 nd Increase the combustion air flow to 50,000 Nm / h. in preparation to start 2 burner. 3 Start burner No. 7, observe the firing sequence, gas flow will be double i.e. 2200 Nm / h. 3 Immediately increase air flow upto 50,000 Nm / h. and gas pressure by opening the gas control valve. nd In case fails to start 2 burner or any other one, wait for at least 5 min. before making further attempts to start the burner & continuously observe the flame in side the combustion chamber. Observe the 02 flue gas in recorder.
3

15
Watch all figure ( drum metal , super heaters temperature, flow and pressure rate; 28. When the drum pressure reached 2 ~ 3 bars; Close the vent valves of super heaters and drum. Increase the press. & temp. of the boiler by corresponding controlling air flow and gas press. gas flow respectively the number of burners in operation. Note: While fire rate increase, always increase air flow first before increasing gas. While decrease firing rate, gas flow reduce first later air flow reduce. 3 3 During start up time maintain 20Nm of air flow for each 1Nm of natural gas. Firing rate will be increase when steam temp. tends to be steady. During start up stage always maintain continuous feed water flow through economizer coils. o Watch waste drain basin level & temperature should not exceed > 60 C. 29. When SH NO.1 steam out let temperature app. ~ 300 C press. about 5 bar, Then close step by step throttle all Super heaters drain valves according their metal temperature. Keep an eye super heaters multi point metal temperature. After 30 min. 3 30. Increase the combustion air flow to 70,000 Nm / h also increase N.G. pressure to 0.7 bars, gas flow approx. 4,000 Nm3 / h. 3 3 31. After 40 min. increase air flow 80, 00 Nm / h & gas press. to 0.8 bar (gas flow around 4300Nm /h). 32. 3 rd burner 8 start : rd before start 3 burner, prepare the attemperators station for service to maintain required temperature.( drain valves close , isolating valves opened & properly vented). 3 33. Air flow increase to 90,000Nm / h, adjust gas pressure to 0.6 bars, corresponding gas flow about 5,000 Nm3 / h. The fire rate must be kept in a limit, press. not more than & press. 1.5 bars / min. o The super heater metal temp. normal increasing rate 5 C / min, 34. When boiler outlet steam press. reach 10 bar :Start heating up the HP line RA-1 by gradually opening motorize by pass valve NA50G201. As required, open by pass valves to Turbine (RA2G202) & Distiller (RA4G2) also deaerator When press. Equalized. Start opening HP steam main valve NA49G201 and close by pass valve RA50G201. As soon as steam consumption increase steam pressure tends to come down. Gradually close start up control valve NA70G401 & observe boiler load not be < 72 t / h at any time. Firing rate increase according steam consumption (turbine & distiller). 35. Start opening the FW tank HP Red. Station.( isolating valves are opened) and spray water control valves for heating up FW tank.( isolating valves are opened) monitor continuously for the proper fuel air ratio, when gas pressure reaches 0.9 bar put one more gas burner in service. 36. when drum press. reach 30 ~ 35 bars :as require, start turbine Hogging Ejector. to start falling up vacuum in condenser, main steam valve to turbine RA2G201 slowly open; open steam valve RH32G1 to deaerator. 37. when boiler steam pressure about 40 bar adjust FW flow to 50 ~ 70 t / h. increase press. and temp. and steam flow to turbine and distiller as required. 38. when boiler load reached 80 t / h. Change-over the FW control valve, by pass RL43G401 to main control RL41G401 or RL42G401. Open FW controller stop valve behind the main control valve; Open main Control valve slowly and close the by pass valve; observe FW flow & drum level.
o

16
39. when boiler load reach approx. 100 t / h; o bring boiler steam parameters to 50 bars and temp. 420 C, Proceed to put into AUTOMATIC CONTROL LOOP of the boiler as per following sequence: FFED WATER CONTROL LOOP COMBUSTION CONTROL LOOP ( FUEL) COMBUSTION CONTROL LOOP ( AIR) BOILER LOAD CONTROL LOOP SPRAY WATER CONTROL LOOP FW and combustion control valves to AUTO (Gas, contr. valve & FD Fan vane). 40. when boiler load reach approx. 180 t / h, nd start the 2 FW pump. 3 41. when air flow reach approx. 170,000 Nm / h , nd start the 2 FD Fan; nd then open 2 FD fan vane until, both fans are equalized, nd select the 2 FD Fan vane control to automatic position 42. Bring steam parameters of boiler up to operating values; o press. 65 bars & temp. 490 C, by increasing the number of burners firing respectively with load.

17

A 3.2. COLD START UP OF THE BOILER

II. BY CRUDE OIL WITH ATOMIZING AIR & ATOMIZING STEAM:

CONDITIONS: i. At least one crude tank filled. ii. One crude oil transfer pump running. iii. one transfer pump selected to AUTO start iv. one service air compressor running v. Boiler filled up to normal starting level. vi. condensate pump running for mechanical sealing of the FW pump vii. One feed water pump running.

1. Open hand isolating vale OUS 70G1 from service air main ring line to boiler. 2. Open hand isolating valve OUS70 G2 service air to atomizing air. indication Atomizing air pressure Low signal disappears. 3. Bring anti vibration rings into oil position on burner 7, 8 & 9. 4. Preparations before start of the 1st burner
i. All manholes on the boiler and air ducts closed. ii. Instrument air connected to all consumers. iii. Power supply to the burner cubicles switch ON iv. Circuit breakers of cooling air fan (NK51, NK52A1) working position. v. Both cooling air fans emergency push buttons released. vi. All cooling air valves to the fotocell are open. vii. Start one cooling air fan Cooling air pressure Low signal disappears viii. Check cooling air fans performance one by one. ix. Both FD fans Circuit breakers in working position & Selector switches are TCR position. x. Dampers & vanes circuit breakers are in working position. 5. Circuit breakers of crude oil booster pumps (NM21A1 & NM22A1) are working position. 6. One oil filter in normal position, other one cleaned & properly filled. 7. Open suction, discharge and minimum flow valves at each pump : (NM1G1,NM21G1,NM22G1NM23G1,NM24G1,NM25G1,NM26G1, NM34G1,NM34G2) 8. open hand valves ( NM27G1 & NM27G2) before & after relief valve 9. Close by pass valve (NM27G1) of the pressure relief valve. 10. Close crude oil control valve ( NM32G401 11. Open controllers hand isolating valves (NM32G1 & NM32G2). 12. Close crude oil by pass valve (NM33G1). 13. Open hand isolating valve (NM31G1 & NM31G2) before & after crude oil start up valve. 14. Open crude oil flow meter isolating valves (NM34G1 & NM34G2). 15. Close by pass valve (NM35G1) of crude oil flow meter. 16. Close hand isolating valves (NM41G1 49G1) before each burner. 17. Close oil return valve (NM51G801). 18. Through by pass valve (NM52G1) throttled oil flow approx. 6 t / h. 19. open 2 turn by pass valve (NM92G1) of the atomizing steam trap. 20. open atomizing steam control station outlet valve (NM62G4). 21. close by pass valve (NM63G1 & G2) of the atomizing steam control valve 22. open 2 turn by pass valve (NM94G1) of the atomizing steam trap. 23. open slowly to 100 % isolating valve (NM62G1) infront reducing station. watch pressure & temperature. O temperature after reducing station approx. 200 C. open fully atomizing steam control station inlet & outlet valves (NM62G1 & G2 ) pressure approx. 13.5 bars. 24. Open steam trap isolating valves (NM91G1 & G3).

18
25. close atomizing steam trap by pass valves (NM92G1 & NM94G1). 26. Start crude oil booster pump ( NM21A1 or NM22A1) : Release EM. Push buttons both pumps (BM21& 22A1). Selections are in TCR. Start one pump deliver pressure approx. 23 bars. Both pumps performance test will be carry out one by one. Physically check that all oil & atomizing steam hoses are properly connected. Open hand isolating valves at each burner. After opening the atomizing steam hand isolating valves on burner 7, 8 , & 9 Atomizing medium Low signal must disappear. Close by pass valve to oil return, watch oil flow will be 0 t / h. Watch oil pressure before oil QCV of burner, approx. ~ 6.0 bar. 27. Both FD fans dampers & vanes check function by opening & closing. i. Both FD fans oil level check. ii. Open all hand operated dampers (NG30, 31,40,41,50 & 51G1) in the air ducks. iii. EM push buttons released. iv. Start one of the FD Fan from TCR on AUTO program Select AUTO program > Press release button & ON button of the fan > when running up time of the starting FD Fan is over > damper will open automatically. v. Press push button Preventing ON air dampers of the all burners will open, if they are not yet open. vi. When above air dampers are open position open air vane and check air flow. 3 Air flow > 200,000 Nm / h. Signal Preventing Running appears. After 160 seconds signal Preventing Finish will appear. 28. Air flow approx. 55,000 Nm3 / h.: Start oil burner 8 from TCR and wait until the flame signal appears and damper is moving in the open position. 29. Watch all figures (drum level, feed water tank level, temperature, flow, pressure, also feed water flow through economizer. 30. when drum pressure reaches 2.5 to 3 bar - close vent valves of the drum & super heater. 31. increase air flow to 65,000 Nm3 / h.: 3 Start oil burner NO.7, after start burner NO.7, increase air flow to 80,000 Nm / h. 32. Start burner NO.9, After the signal flame appears and the air damper open stop burner NO.8. 3 After stopping burner NO.8, reduce air flow to 65,000 Nm / h. 33. When drum pressure 10 15 bar start heating up steam lines. 34. Watch atomizing steam pressure & temperature before burner 7, 8 & 9. 35. Burner atomizing medium change over from air to atomizing steam : When atomizing steam pressure is higher than atomizing air pressure the non-return valves in atomizing lines will be closed automatically by the atomizing steam pressure and the change over period starts. Closing all atomizing air valves starts within 10 minutes time delay. After the 10 minutes the atomizing air valves will be closed automatically and the signal Atomizing steam press Low Low disappears. 36. Start other burners and & watch all parameters , increase pressure and temperature of boiler by correspondingly controlling oil flow and air flow respectively the number of burners in operation. Working sequences of the oil system: After pressing ON button start the burner the Ready signal disappearing oil lance will be inserted air damper is moving into ignition position. When the oil lance is inserted the atomizing steam valve is opening for heat up the oil lance and pushes the accumulated condensate out of the atomizing steam system. When the pre-purging or pre-heat time is over and the air damper is in ignition position the power for the electric igniter is switch on and the igniter starts move into the operation position. After igniter established the safety ignition time starts ( 5 second) and the oil valve opens if the following criterias are fulfilled : -

19
i. ii. iii. iv. v. vi. air damper ignition position. Oil operation released No order OFF appeared Air flow > min. Atomizing steam valve open Oil lance inserted.

The fuel air mixture will ignite on the sparks of the igniter and fotocell must pick up the flame within the safety ignition time. If this done, then the signal Flame will appear and the air damper is moving into operation. After the expiry of the safety ignition time the igniter is retracted and the power switched off. If the fotocell is not picking up the flame within the safety time the oil quick closing valve will close again and the signal oil burner distur-bance and oil burner purge will be appearing. The oil lance will be retracted. The burner OFF or disturbance signal has to be cancelled by pressing the burner OFF push button. 3 Is no other gas or oil burner in operation the automatic furnace purge will start as soon as air flow is above 200,000 n m / h. When the preventing of the boiler is finished the burner may be re-started or steam purge. If you want to start oil burner, press oil ON button, if you want to steam purge the burner press the OFF button.
STEAM PURGE SEQUENCE OF AN OIL BURNER: -

Steam purge with igniter May be oil valve opened & photocell did not pickup the flame, with pressing the OFF push button the steam purge can be started The signal purge of lance is indicating that the steam purge is taking place. The air damper is moving into ignition position and the power for the ignition will be ON when the photocell criterias are fulfilled: i. Stem purge release exists ii. Steam purge memory is set. iii. No flame is existing iv. Oil valve is closed v. No burner in ON or OFF program vi. When the push button burner off was pressed vii. When the return signal of the open position of atomizing steam and purge steam is there, the first purge program starts. The oil which was remaining in the oil lance will be blown out and ignited at the sparking igniter. When the time for the 1 purge program is over the air damper is closing, the igniter retracting, the power for igniter switch off. Is no burner in operation, the boiler has to be air purged before ignite the next burner. If the preventing finished, the signal Ready for ignition is appearing & required criterias are fulfilled. if the second steam purge will not be interrupted with give a new ON signal, the steam purge valve stays open until also the time of second purge will be over. Steam purge with out igniter: If one oil burner will be switched off during normal operation by pressing the OFF push button, the atomizing steam valve is closing the steam purge valve will open too and till remaining oil is burnt with the existing flame.

20

21
A 3. 1. Boiler 1 to 6 FIRING SYSTEM CHANGE OVER
I. NATURAL GAS TO CRUDE OIL

Conditions: at least one crude oil tank is filled. one transfer pump is running and one transfer pump selected to AUTO position. Crude oil line properly vented & an oil flow 5 to 10 t / h is circulating each boiler ( which prevent that wax or other part of the oil can settle in the pipe & choke the strainers and oil gun nozzles. All valves should be in their normal operation condition. All oil lances installed in the retracted position and atomizing steam hoses are connected. The nitrogen buffer system has to be filled with nitrogen, during normal operation the pressure should be > 21 bars. Preparation of crude oil sys. 1. circuit breaker of the booster pump in working position; NM21A1 - crude oil booster pump No.1 NM22A1 - crude oil booster pump No.2 2. one filter in normal and other stand by one cleaned & filled (NM1B10). 3. open the following suction, discharge & minimum flow valves of both crude oil booster pumps:
NM1G1 NM21G1 NM22G1 NM3G1 NM13G2 NM23G1 NM25G1 NM2G1 NM24G1

4. Hand valve before and after press. relief valves, NM27G1 open, NM27G2 open, by pass valve of pressure relief valve NM28G1 closed. 5. crude oil control valve NM32G401 open; and hand isolating valve NM32G2 open. Crude oil control valve, by pass valve NM33G1 - close. 6. Hand operated isolating valve before and after the crude oil start-up valve NM31G1 and NM31G2 open. 7. crude oil flow meter before and after isolating valve NM34G1 and NM34G2 open. by pass valve NM35G1 of the flow meter close. 8. Hand isolating valve before each burner NM41 to NM49G1 close. 9. oil return pneumatic valve NM51G801 close. by pass valve NM52G1 to oil return : throttle crude oil flow approx. 6 t / h. 10. by pass valve of steam trap of atomizing steam valve NM92G1 open 2 turns. 11. Hand operated isolating valves before and after steam trap NM91G1 & G3 open. 12. Atomizing steam control station outlet valve NM62G4 - open. 13. By pass valve of atomizing steam control valve NM63G1 & G2 close. by pass valve of the steam trap NM94G1 open 2 turns isolating valve NM62G1, in front Red. Station open slowly to full. isolating valve NM62G2 before Red. Station open slowly. and watch pressure and temp. 14. Temperature reaches after Red. Station approx. ~ 200 o C. stepwise open valve NM62G2 fully and watch press. approx. 13.5 bar. 15. by pass valve of steam trap of atomizing Red. Station drain valve NM94 & 92G1 close. and watch temp. after Red. Station approx. 245 o C. 16. Release EM. Push buttons of both crude oil booster pumps.

22
Select booster pumps NM21, NM22A1 in the TCR position. 17. start one of the booster pumps from TCR. and watch the crude oil control valve approx. 23 .00 bar. 18. Select stand by crude oil booster pump to AUTO, and check AUTO start up. trip the running pump by EM. push button. stand by pump start automatically. 19. Repeat the same other crude oil booster pump. 20. make sure that, all oil and atomizing steam hoses are connected, and open the oil hand isolating valve in front of each burner. 21. close by pass valve to oil return valve. and watch oil flow, 0.0 t / h. watch press. before oil quick stop valve of burners approx. 6 ~ 7 bar. Note: -Start-up oil pressure is 7.0 bars.

23 A 3. 1. BOILER FIRING SYSTEM CHANGE OVER

II. CRUDE OIL TO NATURAL GAS

Conditions: - : Boiler load 200 t / h, with 9 burners in operation. HP Gas Red. Station in service. LP Gas Red. Station in service. 1. Set flue gas 02 % vol. to 3 %. by increasing the fuel / air ratio set point, in TCR Desk. 2. check LP gas Red. Station, if already in operation. 3. open the main gas stop valve NN17G801. and gas relief valve from TCR desk 4. open full the gas hand operated isolating valve in front of the burners. 5. check natural gas press. before the burners, 0.11 ~ 0.15 bar. 6. stop crude oil burner NO. 7 by pressing OFF push button in TCR desk. after steam purge of the burner has taken placed- : and oil lance retracted,start gas burner NO. 7 , when FLAME signal appears , Close the natural gas relief valve. And increase the gas pressure to approx. 0.7 bars, by opening the gas control manually. Note: boiler combustion and load control remain in AUTO mode.

valve

7. stop crude oil burner NO. 9 , after purge time over & oil lance retracted :start gas burner NO. 9 , when FLAME signal appears, increase the gas press. to approx. 0.6 bar ~ 0.7 bar, by opening gas control valve. 8. stop oil burner NO. 8, after purge time over & oil lance retracted :start gas burner NO. 8, when FLAME signal appears, increase gas press. Kept Natural gas Contr. Valve AUTO 9. stop oil burner NO. 5, after purge time over & oil lace retracted :start gas burner NO. 5, when FLAME signal appears, increase gas press. repeat the steps for next all other burners. 10. when the oil control valve NN32G401 has reach 20% opening position,change the control valve from AUTO to MANUAL position. 11. stop the next oil burner, after purging time over & oil lance retracted:-. start the gas burner 12. when last oil burner remain in service, close the oil control valve manually, and keep one oil burner on oil start up valve; and keep one oil burner on oil start up valve; watch the gas press. , not more than 1.0 bar. 13. stop the last oil burner ;when purge time over and oil lance retracted , the firing is completely changed to gas firing. 14. change 1st the position of stand by oil pump , which in AUTO to Manual selection,then stop the crude oil running pump. 15. open the oil return valve. 16. close the atomizing steam valve. 17. close the hand isolating oil valves before each burner.

24
A 3. 2. BOILER HOT START UP: CONDITIONS: I. The boiler pressure is approx. 40 bar II. All unit auxiliaries still are in service 1. Prepare to start feed water pump after fulfilled pre-conditions. if the feed water temperature is 100 0C and FW tank pressure less, fed make up water to FW tank to get the feed water temperature down or take steam through inter-connection steam line from other unit before that arrange spray water for reducing stations. 2. Pressurized feed water line, if it was already pressure less upto boiler main feed water valve NA01 GG201. 3. Prepare the natural gas system as cold start up process. 4. Start FD Fan with auto program 5. Start feeding the boiler until drum level reach 200 mm. 6. Open hand isolating valves of drain & super heater drains. 7. open the motorized valve some steps until steam is coming out of the drains , watch the change of the flowing noise. 8. When steam is coming, close motorized valves again, approx. after 2 to 5 minutes. 9. The feeding through the economizer is important because , steam bubbles get out of the economizer. Therefore feed with a flow of about 50 t/ h for at least about 10 mins. 10. If drum level higher than 200 mm, it will be equalized by using after the start of the 1st burner the drum drain valve. 11. When the boiler furnace is air purged , drum level at start up position , start up stop valve open . 12. Hand isolating valve before burner open 13. Burner ready for ignition signal appeared , then boiler is ready to start the 1st burner 14. After burner fired, open start up regulating valve approx. 15 %. 15. Open super heater drain valves 10 steps. 16. When the temperature is approx. 300 o C close the drain of 2nd super heater completely. 17. And the drain of the 3rd one to 5 steps . 18. Watch the temperature of the feed water after economizer 3 outlet. Keep the temperature below the saturated steam temperature. 19. Regulate the feed water flow accordingly. 20. As soon as the steam temperature respectively the super heaters metal temperature. 21. Start the 2nd burner. 22. This means 7 & 9 in service and NO.8 out of service. 23. Further procedure are same as cold start up .

25
A - 3.3. BOILER WARM START UP:

26
A 4. 1. BOILER NORMAL SHUT DOWN PRCEDURES: 1. Reduce the boiler load by reducing turbine or distiller to minimum. keep turbine load on 25 MW, then either start shut down distiller or transfers to other available unit. after shut down distiller, close following valves : RA04G1, HP steam valve to distiller. RL80G1 , spray water valve to distiller RM90G201, return condensate water valve from distiller to FW tank. Inform Lab. About boiler shut down program. when boiler load reduced to approx.~ 100 t / h, Change all boiler close loop AUTO control to manual mode. FW control valve RL41 / 42 G401. Fuel gas control valve. Boiler (load) Master control. FD fan 1 & 2 vane control. Stop one FW pump. when boiler load reduce to < 90 t / h, change FW main controller to by pass control valve, check the gas pressure, stop some burner, if needed, to keep 0.5 bar gas press. by reducing the firing rate, ( at 3 burners remain in service), keep air flow at 90,000 nm 3 /h. when attempt. Spray water valve have reached to 5 % opening position, change the control valves to manual position.

2. 3.

4.

5.

6. when boiler load reduce further 70 ~ 80 t / h: start opening the start up regulating valve approx. 25 %. And keep FW flow about 50 ~ 70 t / h through economizer. 7. when turbine load ~ 5 MW, trip the turbine, the quick transformer will work in the moment, when the generator breaker is open. Open direct drain valve of the steam strainer, before turbine Q.C.valve (RA2G10&G11). 8. when 3 burners are remain in service ( 7,8 & 9) , reducing the firing rate stepwise by closing the natural gas regulating valve until the :start up regulating valve will take over at 0.15 bar gauge pressure. 9. close continuous blow down valve to increase boiler drum level up to + 200 mm. 10. stop burner NO.9. and close the natural gas regulating valve, as by pass regulating valve taking over,( which is capable of taking 2 burners in service), keep burners 7 & 8 in operation, and adjust the air flow to 75,000 Nm 3 / h. 11. open by pass valve of the boiler HP steam and close HP steam valve of the boiler. 12. Stop the last two burners 7 & 8 one by one , which close in parallel the main natural gas stop valve. Then open the gas relief valve.

27
13. when boiler drum level in + 200 mm, close the FW controller by pass valve, RL43G401. 14. stop the remaining FW pump. then close the HP by pass valve of the boiler. 15. close make up water valve to condenser. 16. Change the cold. condenser level control valve RM30G401 and RM35G410 to manual; and close both valves. 17. wait up to Shaft turning gear start. 18. stop the running condensate pump 19. start purging the boiler furnace : by increasing the air flow to ~ 200,000 nm 3 / h, by opening the FD fans vane control for approx. 3 min. as purge finish signal appears. 20. stop the FD fan one by one, by closing the vanes and air dampers respectively, and stop the motor. Keep cooling air fan in service, until boiler is cold. 21. close the boiler main natural gas valve. 22. close all the hand isolating valves in front of the burners. 23. close the gas auto shut off valves of each LP gas Red. stations from local : by opening the hand lever. 24. close hand operated isolating valves of the sample points at SH and drum drains. 25. when boiler press. drop to 10 bar : open the drum and SH drains. 26. when boiler press. drop to 2. 5 3.0 bar : open the drum and SH vents.

28
A - 4. 2. BOILER EMERGENCY SHUT DOWN:

29 A 5. BOILER SOOT BLOWE SYTEM: -

. Preparation to start up: Check which to be carried out prior to operation of the soot blowers.
i. drain by pass valve NV41G1 open o ii. contact thermometer set point 200 C iii. the following sealing & cooling air valves must be open at all soot blowers NV61G1, NV71G1, NV62G1, NV72G1, NV63G1, NV73G1, NV69G1, NV74G1, NV65G1, NV75G1, NV66G1, NV67G1.
SOOT BLOWER 7 TO 10 NV53G1, NV54G1, NV55G1, NV56G1

iv. Steam hand isolating valves should be open at each soot-blower NV21G1 to NV26g1 & NV31G1 to NV34G1 v. all soot blowers have to be in their retracted position, if not pull them into the retraced position with the hand lever. [indication in TCR panel OFF when the control voltage is switched ON and the soot blowers are pre-select.] vi. impulse lines of pressure switch NV1P3 & NV1P and pressure indication must be open. vii. The safety valve should not be blocked viii. Steam pressure > 40 bar. ix. Main switch of the cubicle HC 01 is switch ON
b. OPERATION OF THE SOOT BLOWER SYSTEM: -

The following criterias have to be fulfilled either Manual or Automatic operation : i. ii. iii. iv. control voltage switch ON ( key switch at soot blower panel in TCR) drain valve ( NV4G201) closed main hand isolating valve ( NV1G1) closed. Motorized isolating valve ( NV1G201) closed.

30
v. vi. vii. viii. All soot blowers in their retracted position All soot blowers are pre-selected to operate in the correct sequence. No fault indication appeared of soot blowers 1 - 9 & main valve or drain valve. When the boiler is in operation the key switch in the control cubicle has to be selected to the position with pressure If during the COLD boiler the function of the soot blower system has to be tested the key switch has to be selected to the position without pressure.

a. AUTOMATIC OPERATION OF THE SOOT BLOWERS: [ all remote control operating switches are arranged in TCR Cont. Panel, from where Selection AUTO / MAN / LOCAL & Operation will be carry out] Sequence of the operation: ix. Open the drain valve manually from TCR Contr. Panel x. Open main valve main valve from TCR Contr. Panel xi. Open the main isolating valve , for heating up the line. xii. Cancelled the PRESSURE LOW indication by pressing the button. o If the temperature is above 200 C the drain valve is close automatically. xiii. Close main valve manually. xiv. When closed indication appeared of the main valve xv. Pre- select AUTOMATIC ( Soot blower panel) xvi. Press Automatic Start button. xvii. Main drain valve will open (Flush light during the operation, steady light , when the valves are in open position) xviii. When open signal appeared, open main hand isolating valve NV1G1 slowly to heat up the steam lines. xix. When the steam pressure is > 8 bars , the signal Pressure Low in TCR can be cancelled by pressing the Alarm OFF push button. xx. The steam lines automatic vent valves ( NV1G4 & NV3G1) are closing in the moment , when the line pressure is > 0.5 bar. xxi. When the steam temperature is > 200 oC the drain valve is closing automatically ( warm up time is app.1 hr.) xxii. When drain valve closing indication appeared, the soot blowers are starting according to sequence 7 10 & 1 6. xxiii. Flushing signal ON is appearing during inserting and retracting. xxiv. When soot blower is back in the retracted position the signal ON & OFF is appearing. xxv. When the last soot blower has reached again the retracted position the signal END appears and main steam valve closes automatically. xxvi. With operating the push button END signal END and START and ON will be cancelled at each blower. xxvii. The drain valve kept closed. xxviii. The soot blower system is ready to be started again. xxix. After completed of the soot blower, close again the hand operated isolating valve NV1G1. xxx. When soot blowing line is nearly 1 bar the vent valves NV1G4 & NV1G3 open automatically. b. MANUAL OPERATION OF THE SOOT BLOWERS:
FROM TCR SELECTION

i. ii. iii. iv. v. vi. vii. viii. ix.

SOOT BLOWERS SELECTION FROM TCR, Sequence of the operation procedures: Open the drain valve by pressing the push button OPEN in TCR When drain valve opened full, Open main steam valve also . Open steam hand isolating valve , heat up the steam line. Cancelled PRESSURE LOW signal If the temperature is > 200 oC , the drain valve closing automatically. st When drain valve closed, start 1 shoot blower manually with pressing the push button ON. nd st The 2 blower should only be started after the 1 one has reached its retraced position. By this way complete other

31
c. MANUAL OPERATION OF THE SOOT BLOWERS: FROM LOCAL SELECTION

Select soot blowers in LOCAL , now it is able to operate the system from Locally by ON button during local operation it is not possible to open the drain valve from TCR. When last soot blower has been operated the main steam valve can be closed from TCR , close push button. After close the manual hand isolating valve

OPERATION STEAM PARAMETERS SETTING MINIMUM STAEM PRESSURE----------- = 8 BAR. o MINIMUM STAEM TEMPERATURE---- = 200 C. SAFETY VALVE OPENING PRESS.-----= 40 BAR STAEM PRESS. AFTER REG. VALVE -= 20 BAR. BLOWING PRESSURE-------------------- = 10 BAR. ALARM STEAM PRESS. > HIGH --------= 30 BAR

32 A - 6. BOILER PRESSER SWITCHES & INTERLOCKS: a. PRESSURE & LIMIT SWITCHES: AK NO. NG11A2 NG12A2 NR01P02 NA16L03 NA16L03 NN17F01 NM01F01 UE80P1 NK6P1 NN37P1 NN35P1 NN16P03 NN18P2 NN18P3 NN14P4 US90P4 NM67P2 NM77P3 NM78P3 NM79P3 NM21P01 NM22P01 NM27G401 NM31G401 NM19G401 NN3G401 NN8G401 NN3G401 NN8G401 NN6G101 NN11G101 EQUIPMENT FD Fan 1 Vane Position FD Fan 2 Vane Position Furnace press. Drum Level Low Low Drum Level High High TRIPPING VALUES 12% 12% 400 mm WC - 320 mm WC + 320 mm REMARKS

Control Air press. L L Cooling air press. Gas press. Torch Gas press. Torch Gas press. After LP Red. Station Burner N. Gas Press. Start Gas press. High Burner N. Gas press. Low Auto. Air press. Low Auto. Steam press. Low Auto. Medium press. Auto. Medium press. Auto. Medium press. Crude oil press. before pump Crude oil press. before pump Crude oil Relief valve Starting oil Reg. Valve Starting oil Reg. Valve LP Gas Reg. valve LP Gas Reg. valve LP Gas Quick closing valve LP Gas Quick closing valve LP Gas Red. Station safety valve LP Gas Red. Station safety valve

3,5 bar 20 m. bar 3 , 5 bar 3 , 5 bar 3 , 0 bar 20 m bar 0 , 3 bar 0, 2 bar 4 , 0 bar 8 , 0 bar 4 , 0 bar 4 , 0 bar 4 , 0 bar 1 , 5 bar 1 , 5 bar 23 , 0 bar 5. 0 bar 0 , 10 bar 4 , 0 bar 3 , 9 bar 5 , 1 bar 5 , 1 bar 4 , 5 bar 4 , 5 bar Opening Set value Opening Set value

b. TIME SETTINGS: Air purge time of Boiler Furnace & Fuel Gas press. Ready for ignition period Opening time of oil burner QCV Opening time of gas burner QCV Purge time of gas burner QC v/v Safety time gas burner Safety time of oil burner First stage burner oil purge 2nd stage burner oil purge Safety time photo Photocell Closing time ( time ) QCV gas Closing time QCV crude oil Time delay NM21P01 Time delay NM22P01 Time delay NM16l03 ( Boiler Drum) Time delay Fuel / Air ratio 160 sec. 10 mins. 2 sec. 1.5 , 2 sec 30 sec. 3 sec. 5 sec. 60 sec. Alarm Setting 90 sec. 1 sec. 1 sec. 1 sec. 3 sec. 3 sec. 1 sec. 10 sec. with min. air flow 200,000 N m3 / h Remarks

33 A. - 7. : BOILER ALARMS & PROTECTIONS: -

a. FLOW MEASUREMENTS:
AK NO. NG11G401 NG12G401 NG20F01 RL11F01 RL12F01 RL13F01 RL11F02 RL12F02 RL13F02 RL11F03 RL12F03 RL13F03 DESCRIPTION Position of Comb. Air fan damper Position of Comb. Air fan damper combustion air flow lube oil flow FW P/P NO.1 lube oil flow FW P/P NO.2 lube oil flow FW P/P NO.3 sealing water flow FW P/P NO.1 sealing water flow FW P/P NO.2 sealing water flow FW P/P NO.3 sealing water flow FW P/P NO.1 sealing water flow FW P/P NO.2 sealing water flow FW P/P NO.3 ALARM INTERLOCKING / PROT. 18 % 18 % S = 2000, 000 Nm3 / h L = 40 l/min L = 40 l/min L = 40 l/min L=7,5 l / min L=7,5 l / min L=7,5 l / min L=7,5 l / min L=7,5 l / min L=7,5 l / min

L = 40 l/min L = 40 l/min L = 40 l/min L=7,5 l / min L=7,5 l / min L=7,5 l / min L=7,5 l / min L=7,5 l / min L=7,5 l / min

b. LEVEL MEASUREMENTS: NA16L03 NA16 L01 RH03 L01 RH03 L05 RH03 L06 RH03 L07 RH03 L08 RM33 L02 RT01 L01 RT01 L01 RU01 L01 RU01 L02 RU01 L03 RU01 L04 VF10,30 & 50 L01 VF17, 37 & 57 L01 RZ16L01 Boiler drum level Boiler drum level Feed water tank level HH = +320 mm LL = - 320 mm H = + 100 mm L = - 100 mm HH =2940 mm LL = 700 mm LL = 700 mm LL = 700 mm H = 2800 mm L = 25OO MM H = 13. 5 m. L = 10 , 0 m. Z = HH = +320 mm Z = LL = - 320 mm

Z = HH =2940 mm Z = LL = 700 mm Z = LL = 700 mm Z = LL = 700 mm

Feed water tank level Cold cond. storage tank level Waste drain basin level Grease switch 300 sec. time delay Clean drain tank level Clean drain tank level Clean drain tank level Clean drain tank level Service water Basin unit (1 - 2 ) Service water elevated tank L Continuous blow down flash vessel- L

S = 10 m Z = 1 , 0 m. S = 1380 mm S = 1960 mm Z = 2160 mm

H = 1800 mm L = 1350 mm S = 1920 mm S = 1650 mm Z = 1420 mm H = 1700 mm L = 1100 mm L = 2900 mm H = 130 mm Z = 900 mm

34

c.

PRESSURE MEASUREMENTS: Boiler drum press. Boiler outlet press. Boiler outlet press. Combustion air press. Cooling air press. Fuel oil filter P Fuel oil before fuel oil pump Fuel oil after control valve Fuel oil after control valve Fuel oil before pump NO.1 Fuel oil before pump NO.2 Atomizer steam after cont. V / V Atomizer steam after cont. V / V Atomizer medium before burner-7 Atomizer medium before burner-8 Atomizer medium before burner-9 Natural gas P. filter Red.stin-1 Natural gas P. filter Red.stin-2 Natural gas press. after Red. station Burner N. gas press. after control valve Burner starting N. gas press. after cont. V. N. gas press. after contr. Valve burner starting N. gas press. after c.v burner starting N. gas press. after c.v Ignition gas press. for torch equipment -1 Ignition gas press. for torch equipment -2 Flue gas press. Flue gas press. Steam press. before soot blower Deaerator steam press. Boiler FW P/P NO. 1 suc. Filter P FW P/P NO. 1 LUB.OIL Filter P Boiler FW P/P NO. 2 suc. Filter P FW P/P NO. 2 LUB.OIL Filter P Boiler FW P/P NO. 3 suc. Filter P FW P/P NO. 3 LUB.OIL Filter P FW P -1, press. Between NRV & stop valve FW P -2, press. Between NRV & stop valve FW P -3, press. Between NRV & stop valve Atomizer air pressure Service water line pressure H = 70, 0 bar L = 62, 0 bar L = 10.0 mbar L = 20.0 m bar H = 0, 4 bar L = 2 , 0 bar LL = 3 , 0 bar H = 18 ,0 bar L = 6 , 0 bar LL = 1 , 5 bar LL = 1 , 5 bar LL = 8 , 0 bar L = 10 , 5 bar L = 4 , 0 bar L = 4 , 0 bar L = 4 , 0 bar H = 0 , 68 bar H = 0 , 68 bar LL = 3 , 0 bar LL = 0,02 bar HH = 2 .0 bar HH = 0, 3 bar H = 1 , 6 bar L = 0 , 3 bar L = 3 , 5 bar L = 3 , 5 bar H =34 ,2 mbar HH=39,2 mbar H = 30,0 bar L = 8 , 0 bar H = 3 , 0 bar L = 2 , 3 bar H = 0 , 25 bar H = 0.294 BAR H = 0 , 25 bar H = 0.294 BAR H = 0 , 25 bar H = 0.294 BAR L= 70 BAR L= 70 BAR L= 70 BAR L = 8.0 bar L = 3.2 bar HH = 84 , 8 bar H = 82 , 8 bar Z=73,7 bar Z=69,0 bar

NA16 P02 NA49 P01 NA49 P03 NG20 P01 NK01 P01 NM06 P06 NM02 P01 NM04 P02 NM04 P03 NM21 P01 NM22 P01 NM67 P02 NM67 P03 NM77 P03 NM78 P03 NM79 P03 NN02 P01 NN07 P01 NN16 P03 NN18 P02 NN18 P03 NN18 P04 NN18 P05 NN18 P06 NN35 P01 NN37 P01 NR01 P01 NR01 P02 NV01 P03 RH03 P03 RL11 P02 RL11 P05 RL12 P02 RL12 P05 RL13 P02 RL13 P05 RL21P03 RL22P03 RL23P03 US90P01 OVF 20,40 & 60P01

S = 3 , 0 bar

Z = 1 , 5 bar Z = 1 , 5 bar Z = 8 , 0 bar Z = 4 , 0 bar Z = 4 , 0 bar Z = 4 , 0 bar

S = 2.0 BAR S = 2.0 BAR

Z = 3 , 0 bar Z = 0,02 bar Z = 0 ,3 bar Z = 2 .0 bar

Z = 3 , 5 bar Z= 3 , 5 bar Z =39,2 mbar Z = 8 , 0 bar

L= 70 BAR L= 70 BAR L= 70 BAR Z = 8. 0 bar S = 3.2 bar

35 d. CHEMICAL MEASUREMENTS: NA29Q01 NA49Q01 NC16Q01 NR01Q01 NR01Q02 RL01Q01 RL01Q02 RL01Q03 RM30Q01 RM90Q01 RU01Q01 Saturated steam conductivity Sup. heated steam boiler outlet Drum water conductivity Flue gas C0 Flue gas 02 Feed water 02 Feed water pH Feed water conductivity Main condensate Cond. From desalination plant Clean drain conductivity H = 0.5 s / cm H = 0.5 s / cm H = 50 s / cm H = 0.05 s / cm H=3% H = 0.5 g / l H = 9.5 L = 8.5 H = 0.5 s / cm H = 0.5 s / cm H = 0.5 s / cm H = 1.0 s / cm

e. TEMPERATURE MEASUREMENTS: NG11T03 NG12T01 NG12T02 NG12T03 NM04T01 NV04T01 RA02T01 FD fan 1, motor Winding Temp. FD fan 2, motor Winding Temp. FD Fan 2, motor Winding Temp. FD Fan 2, motor Winding Temp. Fuel oil Temp. Condensate after Soot blower Live steam Temp. before turbine Boiler drum Dif. Temperature RA02T02 RH30T02 RL11T03 RL12T03 RL13T03 RL11T04 RL12T04 RL13T04 RL11T05 RL12T04 RL13T04 RL11T07 RL11T08 RL11T09 RL12T07 RL12T08 RL12T09 RL13T07 RL13T08 RL13T09 OVF20,40 & 60T01 Live steam Temp. before turbine EXTR.-3 Temp. , to FW tank FW Pump 1, HP Bearing Temp FW Pump 2, HP Bearing Temp FW Pump 3, HP Bearing Temp FW Pump 1, LP Bearing Temp FW Pump 2, LP Bearing Temp FW Pump 3, LP Bearing Temp FW Pump 1, Thrust Bearing Temp FW Pump 2, Thrust Bearing Temp FW Pump 3, Thrust Bearing Temp FWP 1, MOTOR WINDING Temp. FWP 1, MOTOR WINDING Temp. FWP 1, MOTOR WINDING Temp. FWP 2, MOTOR WINDING Temp. FWP 2, MOTOR WINDING Temp. FWP 2, MOTOR WINDING Temp. FWP 3, MOTOR WINDING Temp. FWP 3, MOTOR WINDING Temp. FWP 3, MOTOR WINDING Temp. Service water Temp. H = 125 O C H = 125 O C H = 125 O C H = 125 O C H= 50 O C S = 200 O C H = 497 C L= 475 O C H = T 20O C HH = 509
O O

H = 300 O C H = 75 O C H = 75 O C H = 75 O C H = 75 O C H = 75 O C H = 75 O C H = 75 O C H = 75 O C H = 75 O C H = 125 O C H = 125 O C H = 125 O C H = 125 O C H = 125 O C H = 125 O C H = 125 O C H = 125 O C H = 125 O C H = 46
O

Z = HH = 509 O C , turbine trip Del time 20 min. Z = 85 O C Z = 85 O C Z = 85 O C Z = 85 O C Z = 85 O C Z = 85 O C Z = 85 O C Z = 85 O C Z = 85 O C Z = 85 O C

Z = 46

f. FUEL / AIR RATIO & TRANSMITTER FAULT: Fuel / air Ratio: HH = 1: 0.8 = 1. 25 H = 1: 0.9 = 1. 11 L = 1 : 1.15 = 0.8696

Transmitter fault adjustment SET to 10 % Minimum Load for automatic operation 100 t / h = 27.5 %

36
A - 8. ISOLATION OF BOILER MAJOR AUXILLIARY EQUIPMENTS.
8.I. Boiler Feed water Pump. 1. Stop the pump and emergency push button pressed in or put in SWG position in TCR. 2. The 6.0 K.V. circuit breaker is racked out or in test position and the space heater MCB is switch off & tagged. 3. Discharge motorized valve and bypass manual valve are closed, 380 volt C.B. rack out and valves are chain locked. 4. Suction manual valve closed and chain locked and strainer drain & vent valves are open. 5. Sealing water line valve to pump is closed. 6. Balancing line valve is closed and chain locked. 7. Minimum flow line valve is closed and chain locked. 8. AC / DC lube oil pumps are stopped and C.B's. are rack out or in SWG position in TCR, their EPB are pushed in. 9. Open the pump body drain valve. 10. All instrument attachment to the pump are to be removed by IMD. NOTE: If motor is not overhaul, space heater should be on. Boiler Feed water Pump Motor. 1. The Pump is stop and 6 K.V. C.B. is racked out and earthed. 2. AC / DC lube oil pump is off, E.P.B. is pushed in and put in SWG position in TCR. 3. Space heater MCB is switch off and tag. 4. Pump and motor to be decoupled by MMD 5. Lube oil line to motor to be removed by MMD. 6. All instrument attachment to motor to be removed by IMD. 8.2 . Force Draft Fan. 1. Stop the fan and emergency push button is pressed in or put in SWG position in TCR. 2. 6.0 K.V. circuit breaker is racked out or in test position and the space heater MCB is switch off & tagged. 3. F.D. fan air damper and vane are in closed position and their 380 volts circuit breakers racked out. 8.3. Cooling Air Fans. 1. Stop the fan and emergency push button pressed in or put in SWG position in TCR. 2. 380 volts circuit breaker is racked out or in test position and the space heater MCB switch is off & tagged. 8.4. Burner Crude Oil Pumps. 1. Stop the pump and pressed in the emergency push button or put in SWG position in TCR. 2. 380 volts circuit breaker racked out or in test position and space heater MCB switch off & tag. 3. Suction and discharge manual valves are closed and chain locked. 4. Open the pump drain and vent. 8.5. Burner Crude Oil Strainers/Filters. 1. The strainer/filter is in standby position. 2. Its vent and drain are open.

37
8.6 . Boiler F.W. Control Valves. 1. The feed water control valve to be isolated is in standby position. 2. Both isolating valves (inlet and outlet) are closed and chain locked. 3. Outlet isolating valve 380 volts motor, circuit breaker is racked out or in test position. 4. Drain valve before the control valve must be opened. 8.7. Deaerator Steam Reducing Station. 1. The deaerator steam reducing station to be isolated is in standby position. 2. Both isolating valves (inlet and outlet) are closed and chain locked. 3. The pressure and temperature controllers 380 volts motors circuit breakers are racked out or in test position. 4. Drain and vent valve before the control valve must be opened. 5. Spray water manual isolating valve is closed. 8.8. Superheater Attemperators Spray water. 1. The superheater attemperators spray water to be isolated is in by-pass position (by-pass valve is open). 2. Both isolating valves (inlet and outlet) are closed and chain locked. 3. The spray water control valve 380 volts motor circuit breaker is racked out or in test position. 4. Drain valve after the control valve must be opened. 8.9. Boiler Waste Drain Pump. 1. Stop the pump and pressed in the emergency push button or put in SWG position in TCR. 2. Its 380 volts circuit breaker is racked out or in test position and the space heater MCB is switch off & tagged. 3. The Discharge manual valves is closed and chain locked. BOILER OVERHAULING ISOLATION PROCEDURE:
O

1. 2. 3. 4. 5. 6. 7. 8.

Boiler is shut down, drained and vented. Boiler temperature is 50 C All feedwater pumps are out of service. Isolated according to the above isolation procedure. Both F.D. fans are out of service. Isolated according to the above isolation procedure. LP Gas reducing stations 1 and 2 are out of service, isolated and purge by Nitrogen gas. The cooling air fans are out of service and isolated according to procedure stated above. Fuel oil pumps are out of service and isolated. The H.P. steam valve and its by-pass are closed, chain locked and their motors C.Bs. are switch off. The H.P. steam interconnection valve and its by-pass are closed, chain locked and their motors C.Bs. are switch off. 9. F.W. interconnection valve and its by-pass are closed, chain locked and their motors C.Bs. are switch off. 10. Make-up water valve to feed water tank is closed, chain locked and their motors C.Bs. are switch off.

38 A - 10. Boiler abnormal operation & Trouble shooting: TROUBLE SHOOTING

Process plants operate maximum days of the month to cover the overall costs. The remaining days of the month operate to make profit. If the process is down for some days, then the company cannot cover the costs and no profit has been made. So, respective persons must quickly and successfully solve any problems that occur. Sometimes the problems occur during startup, sometimes just after a maintenance turn-around, and sometimes unexpectedly during usual operation. A trouble shooting problem is one sometimes occurs that is unexpected to such an extent that it is perceived that some corrective action may be needed. The trouble occurs somewhere in a system that consists of various pieces of interacting equipment run by the people. The corrective action requires may be: to initiate emergency shut- down procedures. to forget the situation : it will eventually correct itself, to return the situation to safe-park and identify and correct the cause and try to prevent a reoccurrence, to identify and correct the cause while the process continues to operate under current conditions.

Now a days widely use and familiar with the word trouble shooting.
WHAT IS THE TROUBLE SHOOTING ?

Trouble shooting is the process used to diagnose the fault safely & efficiently, decide on corrective action and prevent the fault from reoccurring. Characteristics of a Trouble Shooting Problem: The problems share four common characteristics: the problems differ in their seriousness and when they occur. This problems share mainly the following four characteristics: a) exhibit symptoms of deviations from the expected, b) have tight time constraints, c) are constrained by the physical plant layout & d) involve people. a) exhibit symptoms of deviations from the expected: the symptoms may suggest fault on the plant or they might be caused by trouble upstream or downstream. The symptoms may be false and misleading because they result from faulty instrument or incorrect sampling. These kinds of symptoms might not reflect the real problem. b) the tight time constraints related to safety and economics. The symptoms indicative of a potential explosion or major leak in the system. We should initiate immediate shut-down and emergency procedure. c) The process configuration constrains a trouble shooter. The process is fabricated in a given way. The valves, lines and instruments are in fixed locations. We may want to measure or sample, but no easy way is available We have to work within the existing process system. d) sometimes the cause of the problem is people. Someone may not have followed the expected procedure and was unwilling to admit error. Someone may open the bypass valve in the belief that the process operates better that way. The alarm may have turn OFF. The orifice plate may have been put in backwards. When emergencies arise, due to logical, physical or fault causes, analyze and identify the causes, decide on the most applicable action, and proceed quickly. It is essential that an operator know the plant thoroughly to handle emergencies. Proper knowledge of the plant not only will make it possible to act wisely but also will give the operator the necessary confidence. Learn what constitutes safe practices and how they are applied to plant. Do not shut down unless it is absolutely necessary, but do not hesitate to shut down rather than resort to unsafe practices. When emergencies of this nature arise, quick and decisive action is important, and a through knowledge of the plant and a pre-considered line of action are essential. Study the various means available sources and utilize them in proper way. When any problem arises, it might be some causes and several solutions in our hand, which one perfect and applicable it is depending on experience & broad knowledge regarding the subject.

39
In the processing plant several problems & difficulties are arising, all of them are not possible to add due to our limitation; only some of them difficulties and their causes show bellows: -

Plant difficulties encountered in operation:

A. Oil firing A summary of the difficulties that may encountered in operating oil fired plant are as follows:1. Failure of the oil to flow to the pumps due to inactive venting of the tank. 2. Clogged strainers caused by sludge deposits in the tank 3. Failure of pumps to operate due to air leaks in the suction line. 4. Vapor formation in the pump suction line as a result of too high temp. in tank. 5. Oil too heavy to flow to the pumps because of insufficient heating 6. Faulty atomizing caused by: a. too low an oil temperature. b. carbon formation on burner trips. c. worn burner trips d. too low oil pressure. e. insufficient steam or air. 7. Smoke, poor combustion, and flames striking furnace walls caused by: a. faulty atomization of oil. b. incorrect adjustment of air supply. c. automatic control not functioning properly. 8. Fire hazard and unsightly appearance caused by leaks in the pump discharge line. B. Boiler water level: Thought should be given to the procedure to be followed if difficulty is experienced in maintaining the water level in the boiler. Small oil / gas fired boilers equipped for automatic operation have low water fuel-cutoff devices. In the event of low water, the fuel valve automatically closed and the water level restored. However, industrial and utility plant shutdown must be avoided if at all possible. Alarms are provided, but in the event of high or low water, the operator must decide on the action to be taken. When the water level in the drum drops below the minimum required as specified by the boiler designer, stop the fuel and air supplies. Priming & foaming are caused by boiler water high in solids, high capacities, high water level, or a combination of these. Foaming is serious, since it makes it difficult to determine the water level. Priming can result in a mixture of steam and water in steam lines, causing water hammer, which may result in rupture of the piping system. When this trouble develops, reduce the capacity and blow the boiler down through the surface blow off, if one is provided; otherwise, use the main blow off. If the priming becomes so serious that the water level can no longer be detected, close the steam valve long enough to determine the correct level. Blow down the gauge glass and water column to make sure the water level indicated is correct. If conditions do not return to normal, take the boiler out of service. C. Boiler tube failure: Stop the fuel feed and proceed to reduce combustion. Maintain water level unless this affects the feed water supply. This is a matter that requires instant decision on the part of operator, and the correct action depends on the size of the leak and available reserve supply of water. The pressure should be reduce as quickly as possible to prevent the blow of water and steam from cutting other tubes. Except for the fact that tube failures cause boiler outage, they are not considered serious. Operating a boiler with tube leak, escaping water or steam that can cut other tubes by impingement and cause a chain reaction of tube failures. With the loss of water or steam, a tube failure can change boiler circulation and possible cause overheating in the circuits, which can lead to further failures. Small leak can be detected at times by loss of water from the system, by the loss of chemicals from a drum type boiler or by noise that is created by the leak. Damage of boiler tubes are normally recognized by the following signs: a. Pressure increase in combustion chamber. b. Increase of difference between water & steam flow. c. Changing in flue gas temperature without changing load.

40
d. Blowing noise in the boiler. e. Steam at chimney exit. If above reason appeared, shut down the boiler normal way. If serious leaking, stop boiler by pressing emergency button. D. Incase of more then one burner tripping, put muster control immediately on Hand Control. Reduce load according to still available burner load. 8 6 3 burner up to 100 % load approx. = 360 t/h burner up to 70 % load approx. = 240 t/h burner up to 30 % loads approx. = 120 t/h.

When trouble is over, change Hand control to AUTO. E. If all burners are tripped, turbine will trip due to inter lock. If inter lock is not operating, trip turbine with emergency button. F. Break down of oil / air ratio control or gas/air ratio control. Change master control to Hand. Change oil / air ratio respectively gas /air ratio (air flow & fuel flow) keep the plant running. Keep sufficient air by observing 02. 4. Break down temperature control, change immediately from AUTO to Hand ( manual position) if temperature dropping too far ,quickly trip the turbine. Abnormally low steam temperatures may also produce by: b. Insufficient excess air. c. Higher then design feed water temperature. d. Excessive moisture carries over from the boiler. e. A fouled super heater externally & internally. f. Leaking spray water valves. g. Poorly adjusted control equipment. On the other hand following conditions can produce steam temperature abnormally high: a. dirty furnace b. Too much excess air c. Lower than design feed water temperature. d. Irregular ignition or delayed combustion. e. Poorly adjust control equipments. If temperature exceeds maximum allowed value reduce burner load immediately. G. Failure of the fuel supply: - low capacity, too much primary/ combustion air and disturbance from blowing soot may result in loss of ignition when fuel is burned in suspension. If the equipment is supplied with a flame detector the fuel feed will be shut off automatically. H. Safety valve leak: - even pressure lower than for which it is set, try to free it by operating the lift levers. If this fails to stop the leak, the valve must be repaired or replaced. Never attempt to stop a leaking safety valve by blocking or fighting the spring. I. Gauge glass breaks: -shut off the flow of steam and water. While the gauge glass is out of service, check the water level by using the try cock. Before inserting the new gauge glass, blow out the connections to make sure that no broken pieces remain in the fitting, and check the glass and gasket for the correct length and size. Pull up the packing slowly and not to tightly to avoid breaking the glass. When the new glass is in position, open the top or steam valve first and allow the drain valve to remain open. This permits steam to circulate through the glass, gradually heating the entire surface to a uniform temperature. Then partly open the lower valve. After the water has reached the normal level, open the lower valve. After the water has reached the normal level, open both valves all the way. When the lower valve is first opened, the glass is subjected to a vibration in temperature that may result in breakage.

41
BURNER NOT FIRE Possible Causes: 1. 2. 3. 4. 5. 6. 7. Pilot not burning. Main gas valve solenoid coil burned out. Water level too low or no water in sight glass. Honeywell operating pressure switch defective. Broken wire in burner circuit. Loose or broken probe in water column. Scale build-up on probe and/or water column.

Corrective Action: 1. 2. 3. 4. 5. Check the gas supply. Replace solenoid coil. Replace gas valve. Replace operating pressure switch. Check wiring for loose or broken connection.

BURNER NOT SHUT OFF Possible Causes: 1. Pressure switches not operating. 2. Faulty operating mechanism on gas valve. 3. Broken wire in burner circuit (shorted to ground). Corrective Action: 1. Replace pressure switch. 2. Replace gas valve. 3. Check for electrical short circuit and repair. PILOT BURNER NOT BURNING OR NOT STAY LITGHT Possible Causes: 1. 2. 3. 4. 5. 6. 7. Pilot burner orifice plugged or dirty. Ignition wire burnt or shorting out. Igniter lance cracked or broken. Igniter lance misaligned. Ignition module defective. Pilot solenoid valve not opening. Pilot regulator plugged or broken.

Corrective Action: 1. 2. 3. 4. 5. 6. Clean pilot burner orifice. Replace igniter. Replace pilot safety relay. Re-align igniter to the center of the pilot assembly. Replace ignition module. Replace pilot solenoid valve.

7. Clean or replace pilot regulator.

42 PRE-IGNITION OR POOR LIGHT OFF

Possible Causes: 1. Pilot in wrong location in relation to main burner. Dirty main burner orifices. Corrective Action: 1. Clean pilot burner and orifice without enlarging. 2. Locate pilot burner so that top of burner is 1/2 above and 1/2 to the side of main burner. 3. Clean burner caps with drill bit. Consult factory for proper drill bit size. Caution: be careful to avoid any increases in orifice size. 4. Adjust barometric damper in stack. Check for collapsed stack or restriction in stack. PUMP NOT PERFORMING PROPERLY Possible Causes: 1. 2. 3. 4. 5. 6. 7. No water being supplied to suction side of pump. Plugged strainer screen. Check valves worn or leaking. Pump leaking at shaft. Pump out of adjustment. Air lock. Vapor lock. 2.

Corrective Action: 1. 2. 3. 4. 5. 6. Clean lines connecting float tank to water jacket on 9.5, 10 & 15 HP models. Remove and clean pump intake strainer screen. Clean lines from water jacket to pump. Repair or replace check valves. Replace shaft seal and O ring in pump. Adjust pump impeller. With pump running, carefully loosen hex nut on angle check valve to bleed air from system. Tighten hex nut when water starts escaping. 7. If vapor lock is caused by leaking check valves, replace check valves. If vapor lock is caused by too high a temperature in the return tank, check all steam traps for proper operation and repair as required.

PUMP MOTOR WILL NOT RUN Possible Causes: 1. 2. 3. 4. Starter relay defective. Broken electrical connection. Motor burned out. Inter lock block to start the pump

Corrective Action: 1. 2. 3. 4. Replace starter relay. Release the pump from inter lock blocking Check wiring for loose or broken connection. Repair or replace motor.

43
POOR BOILER PERFORMANCE (Low steam pressure or slow recovery) Possible Causes: 1. 2. 3. 4. 5. Low water condition in boiler. Insufficient fuel supply to burners. Defective operating pressure switch. Calcium deposits, (boiler scale) in water tube assembly. Soot formation on water tube assembly.

Corrective Action: 1. 2. 3. 4. 5. 6. Clean burners. Replace operating pressure switch. De-scale boiler or replace plugged water tube assembly. Remove soot from tubes by means of soot blowers. Improper fuel air ration. Fuel oil / gas caloric values are poor for improper combustion.

SIGHT GLASS GASKETS LEAK Possible Causes: 1. Gaskets deteriorated. 2. Fittings improperly aligned. Corrective Action: 1. Boiler shut down and allow cooling down. 2. Replace gaskets. 3. Loosen nuts, carefully align sight glass fittings and tighten nuts.