(airy yor) Bharat Heavy Electricals Limited10, We 2 LB. 4, 15, 16. 7 18. 19. ‘GENERAL PRINCIPLES OF BOILER OPERATION TABLE OF CONTENTS INTRODUCTION PERFORMANCE FILLING AND VENTING STARTING-UP SHUTTING-DOWN WATER LEVEL WARMING UP AND EXPANSION AIR HEATER , SOOT BLOWERS STEAM-TEMPERATURE CONTROL SUPERHEATER AND REHEATER BLOW-DOWN TUBE FAILURES ; FURNACE EXPLOSIONS FLY ASH EROSION INSPECTION ‘LAY-UPS WATER WASHING TO REMOVE. DEPOSITS FROM OIL FIRING WATER TREATMENT © Ww 4 Bharat Heavy Electricals Limited1 GENERAL PRINCIPLES OF BOILER OPERATION INTRODUCTION . "General Principles of Bi basicoperation and care of large tangentially fired a natural Operation" are presented to acquint operators with irculation steam generating unit. Specific and detailed information regarding operation and maintenance bf the boiler components and auxiliary equipment supplied at this stallation will be found in other manuals for the respective equipment, Basic rules must be followed in the operation and maintenance of boilers and secondary equipment; the operator should be fami e If with the characteristics of this particular installation. This can only be accomplished by diligently observing, recording, checking and comparing data and details, Emergency conditions, resulting in unnecessary outages and repairs, can be avoided by a proper working knowledge and attention on the part of the operator. PERFORMANCE iv. ” ‘be employed to control the boiler water alk Allsteam generating equipment are designed for a specific purpose. When supplied with feed water at a specific temperature, the unit will deliver a definite quantity of steam at the design pressure and temperature. Operating at conditions which exceed the design limitations will shorten the fife of the boiler and its components. ‘The concentration of solids entrained in the steam leaving steam drum will depend to a great extent upon the quality of the fegdwater. Suitable ake-up water treatment and an adequate blawdown programme should inity and the concentration of silica, dissolved solids and suspended solids in the boiler water. ‘Adequate mechanical deaeration of the feedwater should be provided and steps shbuld be taken to control the'level of metallics oxides entering the boiler.in the feedwater. Refer to'the "Feedwater Treatment" section in this manual. ‘Tne quiatity of fuel consumed is generally measured pnd recorded. The means employed will depend uj the nature of the fuel and the equipment available for measuring. A representative fuel sample should be obtained periodically. The services of a competent laboratory should be employed to analyse the fuel with respect to chemical constituents, calorific value, viscosity (liquid fuels) and other physical characteristics which could hat an unfavourable influence on operation and efficiency. ‘An analysis of the flue gases leaving the boiter is favaluable as an index ‘of complete and economical combustion. Combustio: should be completed before.the gases leave the furnace. The best precentage of excess air to use will depend upon the nature of the fuel, the design of the fuel burning ‘equipment and other factors. The iost desirable excess air for different rates of evaporation must be established for each installation: The presence 1 Bharat Heavy Electricals Limited3 4 GENERAL PRINCIPLES OF BOILER OPERATION ‘of carbon monoxide (CO) in the flue gas indicates incomplete combustion, ‘The Orsat is the most reliable means of analysing flue gases and should be used as a check, even when other instruments are provided to furnish this data. For determination of the percentage of CO, CO, and O, gas samples should be obtained at the rear pass outlet upstream of the heater. v. When the heat transfer surfaces are kept clean, the temperature of the flue gases leaving the air heater and the draft loss through the unit wiil be substantially a constant for a given rating and percent excess air. This illustrates the desirability of keeping accurate records of performance from the start of operation. Operating data should be recorded in a form, that will facilitate the comparison of data taken under lar operating conditions. Wheir the equipment is new, standards should be established to serve as measures of satisfactory operation. Then if operating conditions deviate from this, established standard, steps can be taken to determine and correct the cause of the disctepancy, FILLING AND VENTING When filling the boiler, open the boiler vents and drains as noted on the "Valve Operating Diagram” in the “Unit Operating Procedures” section of this manual, Bring:the water upto the recommended operating level in th> gauge glass. If hot water (hot relative to the boiler metal temperatures) is uséd to fill the boiler take care; feed slowly to avoid severe temperature strains on the drums, headers ote : i STARTING-UP r In order to detect an incorrect firing condition may be detected promptly, it is important that the instruments used to monitor operating conditions are in good working order before lighting off. Draft readings, temperature readings,pressure readings and a reliable indication of how much excess air is being used are a prerequisite for intelligent operation. Prior to lighting off the unit, the drainable portions (headers, iniet, outlet and connecting links and piping) of the superheater should be drained through lines free from back pressure and vented at the outlet. The superheater drains should cordance with information.given on "Valve Operating Diagram" The superheater outlet drain (starting vent and drain) must remain open to ensure a flow of steam through the superheater to protect the elements from overheating uutil the unit has gone on the line and is carrying load. This drain valve may be throttled as the pressure increases, but must closed completely until the boiler is on the line. Refer to ‘Unit Operating Procedures’, for specific valve operation, 2 Bharat Heavy Electricals Limited5 GENERAL PRINCIPLES OF BOILER OPERATION During startups, when thereis ‘ni steam ‘flow through the.reheater, residual moisture in the reheater elemegt must be boiled off. ‘This is accomplished by opening the drains and/or vents on reheater headers and piping before the lighting off. The vents and atmosphetic drains must be closed prior to raising a vacuum in the condenser. Cold andjHot reheat line drains near the turbine, which connect with the condenser, should be kept open until the unit is under light load. During initial firing, prior to carrying load, the firing rate must be controlled to keep the furnace exit gas temperature below 540°C until the turbine is synchronized and steam flow through the superheater and rcheater is established, It is recommended that a temperature probe be inserted at the furnace outlet near the first gas touched superheat/reheat surface to enable continuous measurement of furnace exit gas temperatures, The time required to bring a boiler up to temperature and pressure will depend upon the temperature and pressure at which it is to operate. During initial start- up of a new boiler, the firing rate increase should be relatively slow to allow inspection for expansion movements and clearances. Subsequent start-ups can be done at a fastest rate but should not exceed a saturated steam temperature rise of 110°C per hour (Refer to Unit Startup Procedures, Publication No.2002) ‘or the furnace exit gas temperataure limitation stated above. Always make firing adjustments by hand during this period; never attempt to start up with the combustion control or feederwater equipment on “Automatic”. Prior to lighting off, check off, all instrumentation and safety interlocks to be sure they are in good working order. Verify proper operation of all instrulnentation, (gauges, transmitters, recordersetc.) during initial operation, SHUTTING DOWN Y The time requited and the procedures to be followed will depend on the nature of the shutdown (normal shutdown to cold, normal shutdown to hot standby emergency shutdown) and whether the unit is to be entered for inspection and/ or maintenance: Refer to Unit Operating Procedures Publication No. 2002 for detailed operating recommendations. The anticipated time of the outage should be considered during the shutting down process in determine the proper steps to be taken for laying up the unit for corrasion protection. “Refer to “Lay-up Procedures” in this manusl, Immediately after the unit is off the line (turbine atves closed) and all fires are. out, superheater and reheater drains are opened as required for the desired pressure reduction. If the unit is shutdown to cold, the drum vents shouid be opened when the pressure drops to 1.8 atg. If pressure parts inspection or maintenance is required, the water temperature shouldbe reduced to 93°C before draining the boiler. : 3 Bharat Heavy Electricals Limited6 GENERAL PRINCIPLES OF BOILER OPERATION Fans may be operated as required to achieve the desired rate of cooling. Refer to ‘Unit Operating Procedures' for precautions to be taken with airheaters. During any type of shutdown the co saturated steam temperature decrease ig Fate must not exceed 83°C per hour WATER LEVEL Before lighting a fire, the operator should check the water level in the upper drum by blowing down the water column and gauge glass. Usually slowly cracking the drain valve on high pressure gauges will suffice. A liberal blowdown will usually clear the drain valve seats of any foreign matter that may present. The gauge glass should be blown down several times at low pressure while warming up a new boiler, Routine checks of the water gauge should be made atleast once per shift while a boiler is in operation. (Refer to water gauge instructions for procedures, on checking level). If the action of the water-in the gauge is sluggish when the drain valve is opened or closed, investigate the cause and correct the condition immediately. To protect the gauge glass, blow downs should be kept to 8 minimum, during normal operation. During normal operation the waterlevél in the gauge glass should be observed periodically even though the boiler may be equipped with a reliable feedwater regulator and /or remote water level indicator. ' Whilejsteaming, the boiler shoul be protected from rapid changes in feedwater tempetature. The feedwater flow to the boiler should corressond rather closely ta the’steaming rate and should not be shut off completely while the boiler is being fired. : For the recommended water level and operating range refer to instruction on Steam Drum Internals. Unless there is information to the contrary, the water level should be carried near the centre of the gauge glass. The gauge glass centre fine is normally set to indicate normal level inside the drum at full pressure conditions. If the unit is operated at significantly reduced pressure, the level indicated at the gauge glass centre line will correspond to a lower than normal actual level inside the drum, due to the difference in temperature between the water in the glass and the water inside the drum. ‘Any adjustinent of the water fevel should be gradual. If the water level is too high, carryover or even priming may occur, especially if the steam demand is large and rapidly fluctuating. a Perhaps the most serious emergency that may be encountered is low water level. ‘As mentioned in previous patagraphs, the, water level must be watched continuously and water gauges should be checked periodically to ensure proper 4 Bharat Heavy Electricals Limited° GENERAL PRINCIPLES OF BOILER OPERATION operation. Protection of water level transmission lines should be provided to avoid freezing or other damages to these lines. Do not rely solely on high and low level alarms. If the water level falls out of sight in’ the water gauge, duc to failure of the feedwater supply ot neglect of the operator except in the care of momentary fluctuations that might occur with extraordinary changes in load, agpropriat: action should be taken at once to extinguish the fire. Any decision to continue to operate, ever if only for a short time at a reduced rating, would have to be made by someone in authority, thoroughly famitiar with the circumstances that Ted to the emergency and positively certain that the water level can be restored immediately without damaging the boiler. WARMING UP AND EXPANSION While the boiler is being brought upto pressure, provision should be made for gradually heating and adequately draining all cold steam piping from the beginning by opening all diain valves arcl by-p-sses (ii'stop valves nre provide Refer to "Valve Operating Diagram", During initial firing, periodically check ths expansion movements of the boiler and make sure the casing, headers, piping etc. move freely in respect to the structural steel. Expansion marks should be installed at suitable locations to facilitate inspection, (Refer to "Pressure Parts arrangement drawings and/or expansion movement diagrams" for this installation), Periodic checks should be made during the life of the unit tu determie that expansion movement continues to occur in a normal, uniform manner. All hongers on te unit and related piping should.be checked perictically for proper setsings end functioning. AIRHEATER ‘An abnormal inctease ia draft loss across the gas and/or air side of an air heater indicates that deposits are building up. Every precaution should be taken to keep the gas swept surfaces of the air heater clean. Operate the airheater soot blowers as frequently as necessary. Water washing equipment and/or other cleaning devices should be used as necessary to prevent air heater plugging. If oi! is being fired, make certain the fuel is being burned completely. Watch the temperature of the gas leaving the air heater, particularly when starting up the unit, Use airheater cleaning device to remove accumulations of combustible depasits. A sudden and abnormal increase in the gas outlet temprature woutd indicate that a fire has developed. In this event, the unit shoutd be shut down immediately and steps to be taken to quench the fire. Refer to “Airheater instructiuns” in and fire protection recommendation. manual for additional, specific cleaning $ Bharat Heavy Electricals Limited%» 10. G®UNERAL PRiNCIPLES OF BOILER OPERATION $$$ $$$ A steam coil aitheater is provided at the airheater air inlet to assist in the prevention of air heater cold end corresion. ‘The exit gas temperature will rise with increasing load and fail with decreasing load. If a log i: kept off the load, the exit gas temperature and soot blowing schedule, the operator will soon be able to recognise au abnorsially high or low exit gas temperature. If the exit gas temperature is below normal for the load at which the unit is being operated, took for very low excess air (verh high CO, , may be some CO and smoke). High exit gas temperature may be caused by such conditions as: High excess air, dirty water wails, secondary combustion, a dirty airheuter and/or a fire in SOOT BLOWERS ‘Soot blowers (if provided) should be opérated as often as necessary to keep the external heat transfer surfaces clean. A high economiser exit gas temprature and/or erratic steam temperature control action (see Note) may be an indication of the need for blowing soot. By recording and comparing this exit gas temperature at various loads.and furnace conditions, a proper soot blowing schedule can be established. [t will be found more difficult to use the soot blowers effectively if, during a periad of neglect, a considersble amount of fly ash or slag is allowed to build up. Never use soot blowers on a cold boiler. ‘Always be sure that the combustion rate is high ecough when blowing soot so that the fires are not extinguished. Refer to "Soot Blower Instructions” for details. : Note: The requirements of the steam tesiperature control system can be used as an indication of fouling in the furnace, superheater and reheater since desuperheater spray water quantity, fuel nozcle tilt movement ‘and gas recirculation quantity(if provided) quality refle.t the changes in tubé surface cleanliness. Ifthe soot blowing medium is steam , proper drainage of the soot blower piping, system is very important in preventing pressure parts erosion: There should be no water pockets whatever in the piping. A 8 mm x3 min hole is often drilled through the seat of the drain valve to permit continuous drainage of any condensate formed. Let the steam flow freely and long enovgh to heat the lines thoroughly before operating the soot blowers. STEAM TEMPERATURE CONTROL (with Tilting Tangential Firing) The function of the steam temperature control equipment is to maintain design superheat and reheat temperatures over the speci‘ied contrel rang. 6 Bharat Heavy Electricals LimitedGENERAL PRINCIPLES OF BOILER OPERATION Steaim temperatures should never be allowed to exceed the maximum vatues shown in the “Steam Temperature Vs evaporation" curve (see Unit Oprating Procedures), especially if steam temperature control equipment is programmed dqwn to a boiler rating below the control point. Damage to tubing may result dug to localized overheating, caused by poor distribution of steam flow at low loads, if the maximum values are exceeded. ‘The steam temperature control system may include any or all of the following, equipments: a) Fuel and Air Nozzle Tilts (Reheat temperature control). b) Spray water desuperheaters (superheat and reheat steam temperature control). If the steam temperature control system is provided by this company, specific instructions are included in this manual. Generally, the relationship between the control media is as follo i) Fuel and Air Nozzle Tits The fuel and air nozzles can be tilted through a 60° (1 rad) range, from 30°.(0.5 rad) up to 30° (0.5 rad) down Raising or lowering the flame provides, in effect, a furnace with an adjustable amount of heat absorbing surface. Note : In some units the coal nozles are designed to tilt through a S4° (0.9 rad)range, from 27° (0.45 rad) upto 27° (0.45 radjdown, ‘The nozzle tilt drive units in the four corners of a furnace should operate in unison (simultaneously) in response to control signals from the reheat steam temperature controller. An increase in reheat steam temperature beyond the control-set point moves the tilts down, and a decrease of steam temperature below the set point moves the tilts up in proportional increments. In order to relate steam temperature control with unit load conditions, a foad change signal is normally introduced into the master reheat temperataure controller, from steam flow or air flow transmitter. This permits corrective steam temperature control action in anticipation of a temperature correction demand imposed by the load change. When the nozzle tilts reach their minimum tilt and further reheat steam temperature reduction is required, control is automatically sequenced 10 the reheat desuperheater(s) (See below). 7 Bharat Heavy Electricals LimitedGENERAL PRINCIPLES OF BOILER OPERATION Desuperheaters ‘The reheater desuperheater(s) are normally provided for emergency use only, to reduce excessive reheat steam temperature, when nozzle tilt “ controithas reached its lower limit, The automaticcontrol signal to the spray water control valves is normally from the same source as the one actuating the nozzle tilt drives and/or gas recirculation control damper. The superheater desuperheaters are normally provided to maintain the design final superheater steam temperature. Desuperheate spray water control is generally a 3-element cascade system in which final steam temperature, intermediate (desuperheater outlet) steam temperature and load index (steam flow or air flow measurements) are applied to achieve Proper and fast control actions. Regardless of the means provided for controlling superheat and reheat steam temperatures, there are a number of factors which may produce abnormal steam temperatures, With a new or extremely clean coal or oil fired unit, it may be necessary to operate for a period of time before normal deposits build up on the furnace walls and some difficulty may be experienced in getting the predicted steam temperature. Abnormally low steam temperatures may also be produced by: a, + Insufficient excess air. b. Higher than rated feed water temperature. ¢. Lower than design reheater inlet temperature. 4. Excessive moisture carry over from the boiler. ©, A fouled superheater or rcheater externally or intetnally. f. Leaking desuperheater spray water valves. 8. Poorly adjusted control equipment, On the other hand the following conditions can produce steain temperatures abnormally high for a given rate of evaporation: h. A dirty furnace. i, Too much excess air. J. Lower than rated feed water temperature. k. Higher than rated reheater inlet temperature. 8 Bharat Heavy Electricals Limited4, GENERAL PRINCIPLES OF BOILER OPERATION 1. Irregular ignition or delayed combustion. Poorly adjusted control equipment The superheat steam temperature will drop suddenly and recover if the boiler is priming. The temperature fluctuations increase i frequency and severity as the total solids or alka ty in the boiler water increases, If the steam temperature is too low, the furnace walls should be cleaned only as necessary and in steps, using one wall blower, followed by operating for a period and then using another wall blower at another wall, Cleaning all the furnace walls at once may give an extremely low steam temperatuares; however, neglecting to clean the furnace may lead to other difficulties. If the steam semperatuare is generally too high, the furnace should be cleaned thoroughly and completely as often as necessary to keep the temperataure down. As slag develops in the furnace, the heat absorption rate of the furnace will be decreased materially and the steam temperature and overall performance of the unit will be affected. Continuously increasing steam temperature, with no change in steam output, indicates Progressive fouling of the furnace. “If slagging becom 2s acute, localiz-4 ash accumulations may obstruct portions of the superheater or reheater and produce high mass gas velocities in the free areas, with overheating a possibility. The operators should develop a suitable procedure for using the wall blowers to deslag the furnace. Soot blowers will give test results if the ash is not sticky. Frequent furnace inspection should be made to see that no slag accumulates around the windbox opening, since unsatisfactory flame conditions can result. Such accumulations, if found, should be removed promptly. . SUPERHEATER AND REHEATER (If Provided) Consideration for protecting the superheater and reheater is a controlling factor in determining how rapidly a controlled circulation unit should be brought up fo pressure. The saturated temperataure increase must not exceed 110°C per hour during startups. The superheater and reheater elements should be heated as evenly as possible and the maximum temperature of the flue gases entering the first gas touched superheater and/or reheater elements ("Furnace Exit Gas Temperature") should be carefully monitored and controlled during start-ups. The furnace exit gas temperatures are normally measured by means of a startup thermocouple probe traversing about half the width of the furnace. The point of maximum temperature must be determined each time the firing pattern is 9 Bharat Heavy Electricals Limited12, \ GENERAL PRINCIPLES OF BOILER OPERATION changed. The maximum furnace exit gas temperature should be limited to $40 °C until the turbine is under load and normal steam flow through the reheater is established. 1 ‘To assure cleaning the superheater clement loops of condensate, provision must be made for adequate flow of steam through the superheater while starting up. Drain and vent valves in the outlet headers and/or the main steam line should bbe opened before the unit is fired and kept open until the unit is steaming under load. These starting drains and/or vents may be throttled gradually as drum pressure incteases, provided sufficient flow through the superheater is ensured at all times. When the turbine is synchronized and carrying load an adequate steam flow will be ensured; the superheater start-up drains and/ or vents may be closed. All reheater drains should be opened before lighting off. As the boiler comes up in pressure, residual moisture in the reheater will be boiled off. Reheater drains connected to the condenser should remain open until the turbine generator is on the line and under light load. Vents or drains open to atmosphere should be closed before attempting to pull a vacuum in the condenser. It is advisable to operate a condenser circulating pump during the early stage of firing the boiler to prevent overheating of the condenser by hot vapour from the reheater drains. White carrying load, protection in the event of a sudden interruption of steam flow is provided by the superheater and ceheater safety valves which are set to “pop” before the drum safety valves. If the flow of steam from the boiler is suddenly stopped, the superheater and reheater safety valves will open first and re-establish the flow. It is imperative that all fuel be tripped immediately when such interruptions of steam flow occur. There will be no flow through the reheater unless the turbine is operating with steam flowing through it. Care must be exercised to avoid carry-over of water and solids to the superheater and turbine. Steam samples should be taken at frequent intervals detect evidence of carry-over. Steam conductivity recorders are commonly used for this purpose. Sampling connections are normally provided in the superheater connecting tubes, leaving the steam drum. Carry-over may be caused by abnormal high water level, especially if the steaming rate is high. 1f carry-over is suspected, steps should be taken immediately to investigate and eliminate the conditions causing this cacryover. If the investigation indicates that the cenrry-over is nat a result of impcoper water condition, the, steam drum internals and the water level control and indicating equipment should be inspected at the first possible opportunity. BLOWDOWN : i The continuous blowdown offers the best means for controlling and maint a relative constant concentration of soluble solids in the boiler water. ing 10 Bharat Heavy Electricals Limited13, GENERAL PRINCIPLES OF BOILER OPERATION The data on blowdown should be recorded. The amount of blowdown is best determined from a chemical analysis of water from the boiler. Since the water treatment system varies for each individual plant, a competent authority on water conditioning should: be engaged to prescribe suitable water treatment from analysis of the water supply and to furnish the necessary instruction for blowing, down, Natural circulation boilers are equipped with either downtake blow off valves or water wall supply drum drains which may be used for intermittent blowdown Service at any time. Never usé water wall inlet header drains for blowdown while the unit is steaming. These ate for draining only, when the uait is out of service. Unless the valve manufacturer's recommendations are contrary open the sealing valve (next to the boiler) and then the blowing valve (farthest from the boiler) and close in the reverse order, Never make the blowdown long enough to lose sight of the water in.the gauge glass. Check the valves for leaks, TUBE FAILURES In the event of a failure of one or more water carrying tube’ in a natural circulation boiler, the best method for shutting down the boiler dictated by the size of the failure, the ability to maintain normal water level in the boiler and the demands for the service of the boiler. If the failure is such that the water level can be maintained in the gauge glass by using the normal make-up system and the load conditions require continued operation, the boiler can be kept in service until it is more convenient to take it off the line to make the necessary repairs. While it is possible to operate for a considerable period of time under such conditions, there is always a chance of cutting other tubes. As long as the failure does not become one which involves the loss of water level in the gauge glass, the boiler should be shut down in the normal manner, in order that no equipment may be subjected to sudden temperatuare.changes. ’ if failure is such that the water level cannot be maintained in the gauge glass, thei the boiler should be shut down immediately. After a shutdown because of low water, every effort should be made to keep ihe water as near normal as Possible until the boiler is cool enough to drain, na superheater or reheater element should be investigated at the ¢: le time, and the unit should be shut down in a normal manner. » iest ‘These are recommendations only and are not intended to replace the judgement of the operators responsiblity for the operation’of the equipment. It must borne in mind that prolonged operation with leaking tubes may cut other tubes and make a major repair job out of what was a relatively simple and short one, but the time selected to take the unit off the line is solely the responsibility of the ‘operators as they are the only ones who know all the circumstances and the advantages and disadvantages of keeping the unit on the line, i W Bharat Heavy Electricals LimitedGENERAL PRINCIPLES OF BOILER OPERATION 14, FURNACE EXPLOSIONS Furnace explosions are generally a result of the fotlowing conditions: Unburned fuel may accumuiate in the furnace ina instance: The’ accumulation of unburned fuel in the furnace’ due, t combustion, loss of ignition or fuel vaive leakage, incomplete ‘The mixture of this unburned fuel vith air in explosive proportions, The application of sufficient heat to raise the temperature of a gortion of this mixture to the ignition point. mber of ways, for Through leaky main fuel or ignition fuel inlet valves on idle fuel compartments. If the fires are extinguished and the fuel is not shut off promptly. If the fuel is not burning as rapidly as it is entering the furnace. In start-up, difficulty is experienced in establishing ignition, Furnace explosions can be avoided by taking a few precautions such as: During a start-ups maintain a minimum air flow of 30% of full load air flow, to ensure an air rich furnace atmosphere and prevent accumulation of explosive mixtures.. Be sure that the main fuel and ignition fuel inlet-valves on idle fuel ‘compartments arg closed tightly and do not leak. It is advisable to remove idle guns from the guide pipes, to avoid dripping. Watch the fires so that the fuel may be shut off without delay if proper combustion is not maintained. If the fires are lost, trip all main and ignition fuel immediately. Close all trip and shut off valves. Purge the furnace for atleast 5 minutes after shut down with 30% (minimum) air flow, ‘Clean oil tanks of water and sludge periodically. « ' } When a boiler has been idle, purge the furnace for $ minutes with 30% of full load air flow, before putting ignitors in service.’ Bc sure that the warm up fuel firing rate is high enough to produce a flame not easily extinguished. 2 Bharat Heavy Electricals Limited15. GENERAL PRINCIPLES OF BOILER OPERATION Never attempt to light an oil or gas nozzle without the required ignition energy source. Be sure that steam for the steam atom: i and the oil is. heated and circulated to give the req} nozzles. Do not use heavy oil /mechanical atomising oil guns for boiling out, lighting off and warming up, preferably use light oil/steam atomizing guns. On coal fired units always use the required ignition energy source when placing any pulverizer in service. ~ vi. Regularly check proper function of any furnace safeguard supervisory system provided, including interlocks, trips ete, prior to any startup and periodically during normal operating periods. During outages thoroughly check out, inspect and maintain furnace safeguard supervisory system provided. FLY ASH EROSION Fly ash erosion is the abrasion of metal surfaces by residual ash pai in the flue gases. Erosion normally occurs in areas localised high flue gas velocities (See Note). ‘The degree of erosion is further related to the ash content (quantity and composition) of ihe fuel. Units firing coal with a high ash content of an abrasive nature are more subject to erosion, Note: Areas most commonly subject to erosion are screen tubes eonomiser and low temperature superheater termial tubes and bends, areas around sootblowers and wall deslaggers, gas duct work and induced draft fan { fan blades and housing). Boiter design parameters are based on conservative average flue gas velo: and normal coal ash percentages, to acl imum possibility of erosion, However, the possibility of localised erosion cannot be entirely avoided nor can the degree or location be predicted for cach installation. At is important that the unit be inspected for indications (See Note) of erosion, especially in areas mentioned above, whenever the opportunity presents itself but atleast during annual outages. When coal with a high ash content is fired, a definite periodic inspeetion programe must be established, Note: Indications of erosion are polished surface appearance, gouging holes in duct expansion joints (leaks) etc, Reduciion of tube diameters can be verified by micrometer readings. B Bharat Heavy Electricals Limited16. GENERAL PRINCIPLES OF BOILER OPERATION The effects of erosion can be controlled by protecting the affected arcas (pad welding installation of removable tube shields, refractory coating for example) or by dispersing the flue gas streams through the use of plate or wire mesh baffles (See Nore). Note: Extreme care must be exercised when installing baffles not 10 create new areas of erosion or to shift erosion from one area to another. The method of contral and/or correction depends on the degree and location of the erosion and only can be established after through evaluation of the local situation and some experimentation, The effectiveness of correction methods must be checked, In the event of extreme or unusual erosion problems, this company or its representative should be consulted. INSPECTION Whenever the boiler is shutdown, and the furnace is cool enough to enter, make an external inspection of the boiler, water walls, superheater, reheater, economiser and aisheater. Clean the firesides where necessary and examine all tubes for evidence of corrosion, erosion, swelling, warping, blistering, burning and cracking, ‘Swelling of superheater tubes indicates overhcating which may have been caused by bringing the boiler up to pressure too quickly, failure to vent the superheater sufficiently while the boiler is being brought-up to pressure, or scale on the internal surfaces due to carryover of water from the boiler. Slight warping is not serious if steps are taken at once to determine and eliminate the cause. i ‘ Check the condition of the furnace setting and check the casing and doors for Teaks. Periodic inspections should be made to examine the watersides of the boiler unit. : Before entering the drum, make sure that all valves in drum'connecting piping (feedwater, auxiliary steam, chemical feed, blowdown, drains, sampling gauge glass drains etc.) are closed tightly and properly tagged so that they will not be opened inadvertently. Remove the mankole covers and check the drum internals for tightness and cleanliness. Check the drum for corrosion and pitting. Oxygen pitting is a common form of corrosion that can be found in boilers, usually in the steam drum above the normal water level, but also found in tubes and headers, Remove a sufficient amount of handhole caps from each boiler and water wall header for inspection of the internal tube surfaces. Wash down the unit to remove any sludge. 4 Bharat Heavy Electricals Limited7, 18. GENERAL PRINCIPLES OF BOILER OPERATION Inspect and if necessary clegn oxtefnal heating surface of the economizer. 5 an See that the heating surfaces of the airheater are clean, Corrosion, if present, would appeat in the cooler portion of the heater, particularly where soot and dirt are allowed to accumulate. ' Make a thorough inspection of the firesides and clean as required. Check for misalignment of the soot blowers, Check fuel firing equipment (nozzles, ignitors, oil guns, scanners, linkage, dampers etc.) for cleanliness.and proper operation, If a furnace safeguard supervisory system is provided check out and exercise, where practicable, control valves, relays, interlocks etc. Annual inspection should be complete and include an internal and external examination of the entire unit. LAY-UPS When the unit is shut down for stand-by purposes and draining of the boiler is not required for maintenance or repairs, the boiler metals must be protected against corrosion. Refer to “Lay Up Procedures" in this manual, WATER WASHING TO REMOVE DEPOSITS FROM OIL FIRING Firing oil with ash content leads to troublesome ash deposits on the waterwall, supetheater and reheater surfaces. The ash contains varying amounts of vanadium, alkalines, sulphur, and other objectionable elements. It is composed of insoluble residue along with a bonding binder which adheres to the waterwall, superheater and reheater surfaces. This dansely bonded mass may not be completely removed by normal cleaning devices such as soot blowers. Periodic waterwashing of these surfaces may be required to loosen the binder and flush out the insoluble residue. Excessive ash on the waterwalls, superhicater or reheater have an adverse effect on boiler operation. When this accumulation plugs the passes in the superheater or reheater, operation of the unit is seriously hampered. Operating the unit with plugging is detrimental because : sed pressure losses. Full load operation may not be possible dus to inor from plugging. fi, "Laning" through the suipetheater and reheater can result in overheating elements in the open lanes. iii, Means of removing the wash water effluent from the boiler and its disposal ils Bharat Heavy Electricals LimitedGENERAL PRINCIPLES OF BOILER OPERATION iv. Suitable lances for washing between the elements in the-superheater and ,Feheater sections. ‘The boiler should be cooled to prevent temperature stresses in the pressure parts from the wash water. If the unit is cool enough so workmen can stay inside the furnace, it is cool enough to permit washing. It is preferable that the refractory retains some heat to aid in drying (from the inside) at the completion of the wash, The quantity-of wash water flow will vary, but means should be avuilable to supply up to 200 litres/min, Generally, higher pressures are desirable to dislodge deposits. The minimum pressure should be 21 kg/en?. Some treatment of the water can be beneficial but is not required, A wetting agent makes the ash deposits more soluble. Inhibitors are available to reduce the corrosive attack on metal parts by wash water made acidic from dissolved elements in the ash. Also, caustic or soda ash can be used to neutralize the wash water. Drains are provided in most boiler furnaces and in some flyash hoppers in rear passes. The drain openings should be cleaned out before the water ‘washing commences. A suitable means to dispose of the wash water should be provided before the washing commences, It is des able to blank off any windbox compartment openings from the furnace si before water washing, to avoid wetting metal pats of the windbox. Sinace the unit is equipped with airhe contact with a wash water effluent, w elements. + , means should be provided to prevent fh may cause plugging of the aicheater When washing, use-targe quantities of water so as to flush out the insoluble material and to dilute the acid forming elements in the ash, Rods or bars can be used to dislodge the more tenacious accumulations on the supetheater ‘or reheater elements. Care should be taken to avoid damage to tubing when using such rods or bars. It is extremely important, once washing is started, to clean the surfaces down to bare metal, Otherwise, corrosion is encouraged: the deposits which remain, accelerate plugging when the. unit returns, to service, ‘The amount of time required to waterwash a boiler, will of course, vary with the nature of deposits and preparations made for waterwashing. The minimum time experienced is about 8 hours. However, continuous washing should be planned, on an around-the-clock basis, until the boiler surfaces are clean. As soon as the boiler is washed, it should be dried out immediately. This will prevent corrosion of metal parts. Under no circumstances may the unit 16 ‘Bharat Heavy Electricals Limited19, GENERAL PRINCIPLES OF BOILER OPERATION be allowed to stand wet for. any appreciable time. Dry-out should consist of firing the boiler at a very low rate, just to maintain about 25 psi steam pressure for cight hours. Then, when the unit is dried out, it can be put back into service. If waterwashing is scheduled for an extended outage (more than one week), it should be done at the beginning of the outage and the unit should be dried out thoroughly to prevent corrosion caused by deposits absorbing moisture from the air during the outage. WATER TREATMENT The treatment of feedwater and the conditioning of boiler water are beyond the control of this Company. This Company does not assume the responsibility for water treatment and does not make specific recommendations for control purposes. Supplier warns against exceeding maximum limits of hardness in the feedwater for certain boiler types and of total solids, alkalinity and suspended solids concentrations in the boiler water. These limits are absolute maximums and should not be exceeded. In addition, the boiler water silica content should be limited for the particular operating pressure involved by reference to standard silica vaporization curves. ' ‘The successful operation of steam generating equipment depends upon a rigid control of feedwater and operating variables to assure freedom from scale formation and corrosion of water and steam contacted surfaces of the boiler. This control is very important in lower pressure boilers and becomes increasingly magnified at intermediate and higher pressure operation. Scale formation in boilers is prevented by providing a good make-up water to the feedwater system and by avoiding condensate contamination. At lower pressurés, a éuitable make-up may.be attained by cold or hot lime-soda process softeners or by zeolite combinations, At higher pressure, the make-up must be of condensate quality such as provided by evaporation or by demineralization. Corrosion of metal surfaces in contact with water and steam constitutes the major maintenance expense to the power industry. The condensate and feedwater must be free of dissolved corrosive gases and the pH of the water must be properly adjusted to prevent the attack of metal surfaces. ‘The oxygen content in the feedwater must be reduced to low levels by effective deaeration jn the condenser and in deaérating heaters, Care must be taken to prevent the introduction of air into heater drips which may be added to the condensate. Make-up condensate from storage tanks should not be added directly to the feedwater system without deacration. Minimum forced boiler outage time has been realized where the oxygen content has been reduced and held below 0.01 ppm. It is important to maintain a chemical ‘reducing environment in the boiler water and chemicals such as sulphite and hydrazine have been used effectively to achieve this. . 7 Bharat Heavy Electricals LimitedGENERAL PRINCIPLES OF BOILER OPERATION The pH of the feedwater must be controlled to prevent the dissolution of the iron and copper alloys in the pre-boiler system. These form corrosive products when introduced into the boiler and will contribute to the corrosion of boiler steam. generating surfaces. Oxides of iron and copper may permit the diffusion of boiler water to the heated surfaces of the unit and cause locally high concentrations of boiter water salines that result in the attack of the tube metal. The pick-up metals from pre-boiler surfaces can be minimized dy the addition of volatile alkatine chemicals that raise the pH of the feedwater. ‘The pH range of 8.3 - 9.5 have produced the best results. Volatile treatment offers the greatest assurance ugainst deposition in superheaters and turbines which might result from intermittent carry-over. The only disadvantage of this treatment is the fact that the boiler water is unbuffered and subject to relatively rapid changes in boiler water pH values if contamination should occur. Where the advantages of volatile control are to be pursued, special emphasis must be placed on quick detection of condenser leaks, and alarms must be available to alert the operators that such a condition exists. Volatile control should be used only when the dissolved solids content, in the boiler is less than 2 ppm; if a significant concentration of solids is present as a result of condenser leakage, solid treating chemicals such as trisodium . phosphate should be available for immediate injection of pH adjustment of the boiler water. Under no circumstances should a boiler be operated with a pH value below 7.0. If the boiler water pH cannot be maintained above this value with chemical feed and blowdown, the unit should be removed from service in an orderly fashion, i Close control of solids in the boiler water must be established to prevent carry-over of boiler water into the steam. The presence of oil, grease, high alkalinity, or other foam inducing solids cannot be tolerated. Itis evident that stringent control of operation and feedwater treatment must be applied to prevent trouble from scaling, corrosion and foaming. The control of boiler water is a prime prerequisite to good operation. A good chemical staff should be employed. The services of a competent consultant an be of value to supplement necessary technical data and information, NOTE : Protection of the boiler against corrosion should not be’ limited 10 actual operation of the unit. Rigid standards with respect to water conditioning should also be maintained duringt lay-up periods. For details on boiler lay-up refer ta the reconimended procedures elsewhere in the Manual. 18 Bharat Heavy Electricals Limited