Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Overview Of Boiler Commissioning And Startup

Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.

Chapter : Instrumentations For additional information on this subject, contact

File Reference: PCI20107 J.L. Sprague
Engineering Encyclopedia Instrumentations
Overview Of Boiler Commissioning And Startup

Contents Pages

INFORMATION .................................................................................................................. 1

INTRODUCTION................................................................................................................ 1

MAJOR EVENTS PRIOR TO BOILER COMMISSIONING............................................... 2

Hydrostatic Testing ................................................................................................... 2
Chemical Cleaning..................................................................................................... 2
Steam and Air Blows................................................................................................. 2
Refractory Curing...................................................................................................... 2
MAJOR STARTUP PROCESS AND INSTRUMENTATION TASKS DURING
BOILER COMMISSIONING............................................................................................... 3
Major Startup Processes............................................................................................ 3
Feedwater System.......................................................................................... 3
Air System..................................................................................................... 3
Fuel System ................................................................................................... 4
Instrumentation Tasks ............................................................................................... 4
Calibration ..................................................................................................... 4
Loop Checks ................................................................................................. 5
Functional Checks.......................................................................................... 5
BOILER AIR-TO-FUEL CHARACTERIZATION AND O2 CURVE GENERATION........ 6
Air-to-Fuel Characterization...................................................................................... 6
Gas and Oil.................................................................................................... 6
O2 Curve Generation ................................................................................................. 6
CONTROLLER PARAMETERS ......................................................................................... 7
Gain .......................................................................................................................... 7
Integral...................................................................................................................... 8
Derivative.................................................................................................................. 9
Methods of Tuning...................................................................................................10
Closed Loop Technique............................................................................................10
Open Loop Technique ..............................................................................................10

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Engineering Encyclopedia Instrumentations
Overview Of Boiler Commissioning And Startup

SEQUENCE FOR PLACEMENT OF CONTROLLERS IN AUTOMATIC AND

MAJOR TUNING PARAMETERS .....................................................................................11
Auxiliary or Independent Loops................................................................................11
Fuel Pressure and Temperature.................................................................................11
Deaerator Level........................................................................................................11
Furnace Pressure ......................................................................................................11
Drum Level ..............................................................................................................11
Air Flow...................................................................................................................11
Fuel Flow .................................................................................................................11
Oxygen.....................................................................................................................11
Steam Temperature ..................................................................................................12
Boiler Pressure .........................................................................................................12
GLOSSARY........................................................................................................................13

Table of Figures Pages

Figure 1. O2 Curve .................................................................................................... 6

Figure 2. Tuning Parameter Proportional Gain........................................................... 8
Figure 3. Tuning Parameter Integral .......................................................................... 9
Figure 4. Tuning Parameter Derivative .....................................................................10

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Engineering Encyclopedia Instrumentations
Overview Of Boiler Commissioning And Startup

INFORMATION

INTRODUCTION

This module discusses hydrostatic testing, chemical cleaning, steam blows, and refractory curing.
This module discusses major startup processes and instrumentation tasks such as installation,
calibration, loops checks, and functional checks. This module discusses boiler air-to-fuel
characterization for gas and oil and O2 curve generation. This module also discusses tuning
parameters, gain, integral, and derivative.

The sections of this module include:

• Major Events Prior to Boiler Commissioning.
• Major Startup Process and Instrumentation Tasks During Boiler Commissioning.
• Boiler Air-To-Fuel Characterization and O2 Curve Generation.
• Tuning Procedures.
• Sequence for Placement of Controllers in Automatic and Major Tuning Parameters

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Overview Of Boiler Commissioning And Startup

MAJOR EVENTS PRIOR TO BOILER COMMISSIONING

Hydrostatic Testing

Prior to boiler startup, hydrostatic testing is done by pressurizing the boiler with high pressure
water through the boiler to test for leaks.

Chemical Cleaning

Chemical cleaning is done by adding chemicals to the boiler to remove oil, grease, and impurities.

Steam and Air Blows

High pressure steam blows and high pressure air blows are done to remove foreign/trapped
material from the boiler.

Refractory Curing

Refractory must be cured by heating at a certain rate based upon the manufacturer's recommended
rate of heating refractory, to prevent the refractory from cracking and spalling.

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Engineering Encyclopedia Instrumentations
Overview Of Boiler Commissioning And Startup

MAJOR STARTUP PROCESS AND INSTRUMENTATION TASKS DURING BOILER

COMMISSIONING

Major Startup Processes

The following systems must be checked prior to boiler startup: feedwater system, air system, fuel
system, and the air heaters and bypass systems.

Feedwater System

The boiler must be filled with condensate for proper operation. To fill the boiler with condensate,
make sure all the appropriate valves are open and closed.

Fill the boiler by first adding all startup chemicals. Next open the two block valves on the boiler
filling line. While opening the valves, observe the discharge pressure of the boiler feedpumps.
Check the high and low water level alarms and trip of the boiler. Refill the boiler until a water
level of approximately one inch is visible in the water level sight glasses. When the boiler is filled,
close the filling line block valves at the steam drum.

To pressurize the boiler feedwater system, crack open the block valve on the main feedwater lead
line and permit piping to heat. To build pressure open the block valve at the header. When water
from the drain is satisfactorily hot and indicates pressure above static head, close the drain and
permit the pressure to rise. When the pressure in the inlet line equals that in the feedwater header,
open the header block valve completely. Do the same to pressurize the auxiliary feedwater
system.

Air System

To start the forced draft fan, open the burner air registers by pressing the "Open air registers"
push buttons. Start the forced draft fan according to applicable OEM instructions.

To start the draft fan, open drains on the steam inlet line and the steam exhausts line. Open
slightly the block valve on the exhaust steam lead line. Open the open drain valve and verify an
increase of water/steam drainage.

Open the header block valve completely and the steam inlet line block valve slightly and allow the
line to heat until only dry steam is being discharged from the drain. Throttle the drain valve and
permit pressure to build. Open all appropriate valves.

Make certain cooling water is available at oil coolers. When the turbine case has reached the
appropriate temperature, fully open the steam exhaust valve. Reset the turbine overspeed trip
lever. Crack open the trip throttle valve. Continue to open the trip throttle valve as shaft speed
increases and observe the governor and bearing oil pressures that must rise as the speed increases.

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Overview Of Boiler Commissioning And Startup

Open the trip throttle valve until the governor overrides the valve and then open the trip throttle
valve completely. Check all appropriate oil pressures. Check operation of carrier rings in each
forced and induced draft fan pedestal bearing. Close drains on steam lead lines.

Fuel System

To start up the boiler, the following events must occur.

• Establish air purge permissives
• Purge the Furnace

Air purge will be initiated by manual operation of the "Purge Start" push-button after all
permissives have been established.
• Purge of Pilot and Main Manifold Headers

A purge of the main and pilot headers is required in order to ensure that the air is removed from
the system so that the fuel gas is well above upper explosion limits prior to burner ignition.
• Pilot Burner Testing (Ingitor)

For the purpose of the pilot burner test, a pilot test push button is provided on each burner plate,
operation of which will initiate the pilot burner light-off sequence and completes to the end of the
pilot proving period. This testing facility is inhibited once the burner is firing. A complete periodic
operational testing of each Ingitor must be made.
• Light off First Burner
• Light off Subsequent Burners

Instrumentation Tasks

Calibration

Each instrument, Valves, Dampers, and Conventional Transmitters, is to be calibrated over the
full operational range and prove instruments to be within manufacturer's guaranteed accuracy.
Wherever possible this is done with the instrument in place.

In general, calibration in at least three points of the scale range is checked and instrument
manufacturer's printed instructions for calibration and adjustments are followed.

Before calibration, instrument range, scale, pressure rating, electrical supply , and signal range are
checked to make sure that they are in accordance with specification.

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Loop Checks

Simulate Input – Simulate the input using a proper device for calibration (e.g., transducer, hand-
held calibrator, 4-20 ma transmations).

Verify Proper Input Indication – To verify proper input indication, dummy a signal in to verify that
the correct signal has been received by the distributed control system from the field instrument.

Verify Proper Output Indication – Use a meter or stroke the actual device to verify the output in the
field from the distributed control system.

Verify Proper Response – Verify proper response by checking output direction (open/closed).

Functional Checks

Verify Internal Control Logic and Control Parameters–By simulation, test the internal control
logic and control parameters. For example, if deaerator pressure goes down, put the controller in
automatic, and the deaerator steam supply valve should open, (i.e., verify controller action -
direction).

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BOILER AIR-TO-FUEL CHARACTERIZATION AND O2 CURVE GENERATION

Air-to-Fuel Characterization

Gas and Oil

Using design data for Maximum Continuous Rating (MCR) and actual load data, operate the
boiler in manual and characterize fuel to air in equal percentages to obtain equal amounts of fuel
and air across the load range for any combination of fuel, (i.e., scalable fuel to air).

O2 Curve Generation

Sometimes the boiler manufacturer supplies the O2 curve. Even so, it must be validated. Figure 1
illustrates a typical O2 curve.

7
Percent Oxygen % - Influe

0 10 20 30 40 50 60 70 80 90 100
Steam Flow % (load)

Figure 1. O2 Curve

For O2 curve generation, look at various loads of the boiler, and manually adjust fuel and air to a
point where CO and opacity are good (within limits). This will determine the minimum operating
O2 measurement over the load range of the boiler. The objective is to increase overall efficiency.

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CONTROLLER PARAMETERS

This section briefly describes controller tuning parameters and tuning constants. For more
information, refer to Controller Tuning & Control Loop Performance (Course Handout 9).
The chart below summarizes tuning parameters gain, integral, and derivative.

Name Symbol Units Alias Symbol Units Conversion

Factor
Gain K ---- Prob. Band PB ---- PB = 100/K
Integral T1 or TI Min. per Reset I Repeats per I = 1/T1
Repeat minute
Derivative T2 Min. Rate. TD Minute T2=TD

Gain

Figure 2 illustrates tuning parameter proportional gain. For proportional control, the output is
some proportion to the change in error or deviation of the process variable from the setpoint. The
K factor, proportional gain, or simply gain is a measure of how sensitive the output change will be
to a given error. Gain is frequently expressed in terms of percent proportional band, PB, which is
related to the proportional gain: PB = 100/K.

"Wide bands" (high percentage of PB) correspond to less "sensitive" controller settings, and
"narrow bands" (low percentages) correspond to more sensitive controller settings.

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Error (E)
+50%

0% Tim e

-50%
O utP ut
+50%

0% Tim e
PG = .5
+50% PG = 1.0

Output = K (E) + M
K = Proportion Gai n
M = Constant which is value
of output when E = 0

Figure 2. Tuning Parameter Proportional Gain

Integral

Figure 3 illustrates the tuning parameter integral. The integral parameter is synonymous with the
term reset. The adjustable parameter associated with the integral mode is the integral time T1, or
reset rate I = 1/TI. Assume a step change in setpoint at a point in time as shown in figure 3,
integral mode sensing there is an error, begins to change the output at a rate proportional to that
error. Integral action changes the output at some rate as long as the error is not zero.

It will be seen that after an interval of time, T1, an increase in output equal to the original
proportional change has taken place. This is called the integral time. When time is used to express
reset action, it is called integral time. Quite commonly, its reciprocal is used, in which case it is
called reset in "Repeats per minute" abbreviated R/M or RPM. Clearly this term refers to the
number of times per minute that the reset action is repeating the output change produced by
proportional control alone.

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Error (E)
50%

0 T im e
1 2 3 4

-50%

.5K
OutPut
0 T im e
1 2 3 4 T1 = 1.0 Min
T1 = 2.0 Min
-.5K
K t
Output = (E) d t + M
T1 0
K = Proportion Gain
T1 = Integral Time
M = Constant

Figure 3. Tuning Parameter Integral

Derivative

It seems reasonable to take additional control action based on the rate of change of error. Thus
we establish a mode under which there is output movement proportional to the rate of change of
error or process variable. Note that this additional correction exists only while the error is
changing. It disappears when the error stops changing even though there may still be a large value
of error.

This tuning parameter, derivative, is illustrated in figure 4. The derivative is most commonly
referred to as rate, because its output is based on the rate of change of the input variable. The
adjustable parameter associated with the derivative is TD (rate) or T2 (derivative time.)

Assume that error is changing at a constant rate as shown in figure 4. Rate action contributes an
immediate valve increment proportional to the rate of change of error.

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Error (E)
50%

0 T im e
1 min 2 3 4 5

-50%
OutPut
.5K

0 Time
1 min 2 3 4 5
TD = 1 Min
-.5K TD = 2 Min

Output = K (TD) (dE) + M

dt
K = Proportion Gain
TD = Derivative Time or Rate
M = Constant

Figure 4. Tuning Parameter Derivative

Methods of Tuning

The widely used tuning methods were first developed and published by Ziegler and Nichols. They
present two methods, closed loop and open loop. The closed loop method is more frequently
used.

Closed Loop Technique

Refer to page 2 of Controller Tuning & Control Loop Performance (Course Handout 9) for a
description of the closed loop method of tuning.

Open Loop Technique

Refer to page 3 of Controller Tuning & Control Loop Performance (Course Handout 9) for a
description of the open loop method of tuning.

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SEQUENCE FOR PLACEMENT OF CONTROLLERS IN AUTOMATIC AND MAJOR

TUNING PARAMETERS

Auxiliary or Independent Loops

Put the auxiliary or independent loops into automatic first, because they are not coupled to the
system.

Fuel Pressure and Temperature

Put the fuel pressure and temperature loops into automatic to be as responsive as they can, to not
implode the boiler, and to maintain stable flow across the furnace prior to tuning the flow
controller.

Deaerator Level

Put the deaerator level loop into automatic to maintain constant head to the boiler feedpumps
before tuning the drum level.

Furnace Pressure

Tune the furnace pressure so that it does not interfere with air flow, which will be tuned later.

Drum Level

Next, drum level needs to be in commission prior to tuning air and fuel because shrink and swell
occurs during fuel and air flow tuning.

Air Flow

Once the drum level, fuel pressure and temperature have been tuned, we start on the heart of the
combustion control system. Put air flow in automatic and tune it first so that when fuel is tuned
later, air can lead/lag fuel as necessary.

Fuel Flow

Once air flow is placed in automatic, place fuel flow in automatic, and tune to respond to load
changes.

Oxygen

Place the oxygen loop in automatic for supervisory control, tuning it for slow moving BTU
changes.

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Steam Temperature

Now that the whole combustion control system is in automatic, steam temperature may be placed
in automatic and tuned.

Boiler Pressure

Once all controllers are in automatic, tune the boiler pressure (master controller) to adjust to load-
to-load changes.

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GLOSSARY

air heater Heat transfer apparatus through which air passes and is
heated by a medium of higher temperature, such as the
products of combustion (flue gases) or steam.
automatic Having the power of self action.
boiler A device used to change water into steam when heat is
applied to the boiler.
boiler feed pumps Supplies high pressure feedwater to the drum.
BTU British Thermal Unit.
bypass system Term used to denote the load and startup system of a once-
through or supercritical steam generator.
Carbon Dioxide (CO2) A product of the complete combustion of carbon.
Carbon Monoxide (CO) A product of the incomplete combustion of carbon.
combustion controls Used to control the burning fuel in a furnace to produce
heat at the best combustion efficiency.
deaerator A device used to extract air from water. Since this device
uses steam for impact extraction of air in the boiler water
(condensate) it is also considered a feedwater heater. A
deaerator may be referred to as a direct contact heater
meaning direct contact of the extraction steam with the
condensate.
derivative A control action in which the output is proportional to the
rate of change of the input.
drum level controls Controls associated with the regulation of the water level in
the boiler.
fuel A combustible substance used to produce heat by burning.
furnace Combustion chamber of a boiler.
gain The gain of a closed loop system, expressed as the ratio of
the output change to the input change at a specified
frequency.
hydrostatic test A test of the pressure retaining component of a device using
cold water. For boilers, the test pressure is usually 1-1/2
times the boiler design pressure. For valves, the test

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pressure is 1-1/2 times the cold working pressure rounded

off to the next highest 25 psig increment. This test checks
components and/or systems for structural integrity.
integral A control mode measured in repeats per minute and used to
reduce the error between the set point and the process
variable to zero.
opacity The quality that makes an object impervious to light.
refractory A heat resisting material which provides protective
insulation inside the boiler.

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