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Boiler Operations Theory PDF
Boiler Operations Theory PDF
CHAPTER – 7
BOILER OPERATION
Chapter – 7
BOILER OPERATION
DESCRIPTION
Sl.No.
7.1 Filling water in economiser and boiler
DESCRIPTION
a) Feed Water
b) Feed Water piping
c) Economiser
d) Boiler and Mountings
e) Drum gauge glasses
f) Water filling into boiler
g) Valves opening before water filling
h) Valves closing before water filling
i) Steam drum water level
j) Safety valve and its escape piping
a. Feed Water
Boiler feed water should preferably be de-aerated and shall be dosed with oxygen
Scavenger. When filling the unit for service, care should be taken to only use properly
treated and de-aerated water so that correct operating conditions will exist from the start
suitable for the avoidance of scale, corrosion and other difficulties caused by improperly
conditioned water. Make sure that the unit is filled with water and chemicals in
accordance with the instructions.
Caution
If feed water is not de-aerated, special attention should be paid so as to prevent
pitting & corrosion in the drum due to oxygen dissolved in feed water. So chemical
for oxygen scavenger is to be fed from steam drum manhole in such conditions.
c. Economiser
Open the air vent valves, economiser inlet stop valve
Make sure that there is no foreign matter in the gas path of the economiser tube
surface
When a flow of water has been established through the economiser, shut its air vent
valve
Check if drum internal fittings are arranged in right position. Special care should be
taken to check looseness of connection, sludge in openings or holes, and damage of
packing.
Replace damaged packing for manhole with new one. Confirm the tightness of cover.
Caution:
• Do not over tighten the valves by applying excessive leverage as it may lead to
permanent damage of valve & its seat
• Do not fill super heaters by filling the drum. Always prefer back filling of super
heaters to avoid contaminants from drum being carried into super heaters.
If hot water is used to fill the boiler and economiser, extreme care must be taken to
feed slowly and vent thoroughly so that no pressure is built up by the resultant flashing
into steam. To avoid excessive localized heating or chilling of the boiler drum it is
recommended that the temperature of the water used should be no more than about 28
deg. C above or below the temperature of the boiler steam drum.
Check the water level gauges and water column by opening all valves attached at
least once a day periodically.
Caution: Do not gag safety valve if hydro test pressure is more than 10 % of valve
set pressure. Always Hydro plug the safety valve while hydro testing above this
pressure .
DESCRIPTION
i. Introduction
a. Hydraulic Test
b. Safety Interlocks and Alarms
c. Utilities
d. Checking Furnace, Air and Gas Passages, Access Doors,
Safety Valves, Valves and Pressure Gauges
iii. Fuel
a. Fuel Supply
b. Fuel Burning Equipment
c. Burner Operation Procedure (Typical)
d. Burner Operation
o Burner Start Procedure
o Burner Stop Procedure
o Trouble Reset Operation
Burner trouble reset
e. Precautionary Measure
Clean Burner
Check Burner Position
Uniform Combustion
Optimize Air Flow
Check Adequate Air
Ascertain Suitable Air Supply
Check Fuel Oil Pressure
i) Introduction
a. Hydraulic Test
For a new boiler or after maintenance job in pressure parts, hydraulic test is carried
out after taking water in the economiser and boiler to check that there is no water leakage
from any pressure part.
Warning: Do not hydro test boiler at pressures more than 1.5 times of it maximum
working pressure.
c. Utilities
Check prior to start up that the following utilities are available
1. Instrument Air
2. Electric Power
3. Demineralised water
4. Cooling water
5. Plant Air
6. Lubricant oil and / or grease.
7. Availability of Fuel oil
8. Chemicals for boiler water and boiler feed water treatment.
Check that all blow down and drain valves can be used effectively.
d. Checking Furnace, Air and Gas Passages, Access Doors, Safety Valves, Valves
and Pressure Gauges.
Remove all structural timber from the furnace and from the gas passages
especially from locations where the gas temperature may reach the point at which the
wood will burn or glow.
The reason for this is that a glowing member may be the cause of igniting explosive
gases which can accumulate with careless handling of the combustion equipment while
firing at low rates of boiling out.
Ascertain cleaning and arrangements in the furnace and gas passage are perfect.
Open and close all the covers for cleaning, and confirm they are in good order.
All access doors on boiler, ductwork and auxiliaries are closed.
Check boiler, economiser, expansion joints and their supports and confirm that
thermal expansion during operation will not be restrained.
Ascertain that the safety valve is free from drain or accumulated rainwater. Confirm
that stoppers or cover plates used for hydraulic test have been removed.
Confirm that each position of the valves, such as feed water, steam, fuel Oil and drain
valves is in good order. These should operate freely
iii) Fuel
a. Fuel Supply.
Ensure that sufficient quantity of fuel is available. Check the fuel oil header
pressure.
Check the burner in accordance with “Instruction Manual” issued by the burner
manufacturer.
Inspect the burner shield. Confirm electric source is supplied.
Check the flame detectors, and confirm the normal action of the electric circuit.
For further details, refer to “ Instruction manual of burner “.
d. Burner Operation
2. Start the fuel oil pump (A/B) with the following permissive to be satisfied
• Fuel oil tank level normal
• Header pressure low
• Suction strainer DP is normal
3. The header trip valve shall be opened with “ Oil firing start” push button.
4. Open the Burner Air fan Damper valve set the required head Pressure of 200mmwc.
5. Press “ Burner Start (burner 1 or 2) push button which causes the following valves to
open
• Atomising air trip valve opened (HV – 379A / 379B)
• Burner air damper is opened (HV – 375A / 375B)
• Fuel oil trip valve opened (HV – 368A / 378B)
• Portable Ignitor to be positioned in the burner.
• Instantaneously operator has to ignite the ignitor.
6. Burner start is completed,“ Lightup successful if flame sensed by flame sensor.
7. If Ignition trail time is elapsed and flame is not sensed “Lightup failure sensed by
flame sensor.
e. Precautionary Measures
Clean Burner
Always clean the burner possibly after every operation so as not to accumulate the
carbon on the burner nozzle and throat tile.
Uniform Combustion
Check the fuel valve open / close time and record it. Confirm the burner performance
in accordance with the instruction book.
Uniform combustion is desirable to prevent excessive local combustion load,
fluctuation of combustion gas temperature or explosion.
Check the operation of burner dampers and record the damper open / close time.
Insufficient amount of air flow tends to cause pulsating combustion, which may result in
damage of refractory materials and inner casing if this condition continues for a long time.
Ascertain Suitable Air Supply
Suitable supply of airflow for combustion is essential. Even in case that automatic
control system is furnished, ascertain its sure function.
Insufficient combustion airflow may cause the following troubles:
Decrease in boiler efficiency due to incomplete combustion.
Dangerous secondary combustion due to the accumulation of unburnt gas.
Decrease in boiler efficiency and evaporation rate due to excessive accumulation of soot
on the heating surface.
Too much combustion airflow may cause the following troubles:
Decrease in combustion gas temperature in furnace, resulting in decrease in boiler
efficiency and evaporation rate due to decrease in radiant heat absorption in the furnace.
Increase in heat loss due to the increase in combustion gas flow rate and exhaust gas
temperature.
Note:
If bed temperatures start to decrease rapidly in some area, this indicates that
fluidization has been lost in this area and the airflow must be increased to re-fluidize
the area and restore the bed temperatures. This will unfortunately also reduce the
leading bed temperatures, but this is unavoidable.
u. When all the bed temperatures are greater than the coal ignition temperature, the coal
feeders should be run continuously at minimum coal flow.
v. Shut off the oil burners at 650° C bed temperature, set boiler to automatic control.
w. When all the bed temperatures are above 500° C, increasing or decreasing the coal
and airflows can control the rate of rise. As coal firing increase, reduce the oil burner
firing rate, maintaining a steady bed temperature rise to about 920° C and allow the
bed temperatures and the boiler generally to stabilize.
x. Float the boiler on to range, when steam flow is observed shut the superheater drain
and commission the automatic feed water control. When feed water is being supplied
continuously, open the economizer inlet valve.
y. Monitor the bed closely to ensure that fluidization is not lost in any area. Fluidization
will be significantly uniform in all corners of the furnace.
z. Remove the burner guns and clean the tips as per recommendation.
Warning:
• Do not allow burner flame to impinge on to the bed coils. The bed coils
are to be fully submerged by filling bed material before start – up to
avoid flame impinging.
• Always make sure that the start – up vent is open during start – ups & a
minimum flow of steam is established through the super heaters after
closing of air vents to avoid over heating of super heaters.
• Always maintain water level between NWL to Low alarm limit to prevent
over heating / carryover of drum water level.
Caution:
Do not operate the boiler with compartments slumped for long duration
without giving any mixing of slumped compartment as it may result in
clinker formation.
DESCRIPTION
a) General
b) Chemicals
c) Economiser
d) Firing
i) Refractory Inspection
a) General
When the boiler is new or after extensive repair to the pressure parts is done any oil
or grease remained internally must be boiled out.
During the initial boiling out process, or after major repairs are done to refractory
materials, the drying out shall be carried out to dry the refractory bricks and castables.
When the refractory bricks and castables are new, the drying out must not be started
within 24 hours after the completion of the refractory work.
Before proceeding with boiling out of boiler, remove as completely as possible any oil
or other foreign materials by wiping out the end of the tubes, the headers and drums
using rags, make sure no rag is left in the pressure parts as a tube may be blocked and
the poor circulation will result in the tube failure.
b) Chemicals
The pressure parts should be boiled out with a dilute solution of tri-sodium phosphate
(Na3 PO4) to remove grease and loose mill scale from the internal surfaces. If tri-sodium
phosphate is not available, Soda ash (Na2 CO3) may be used. Suggested quantities of
these alternative chemicals to be added to the boiler water for boiling out are given below
in kgs per ten tons of water.
The water content in the boiler upto normal water level NWL or upto Steam Drum
centerline is 60 kl. The crystalline form of tri-sodium phosphate is preferred because it
dissolves more easily in water than the anhydrous form.
Open the boiler steam drum manhole door. See that there is about 150 mm depth
of water in the bottom of the drum. Dissolve the chemical in hot water in a suitable tank,
and transfer the solution into the drum using a portable hand pump or by HP dozing
pump, admitting the solution through the manhole while slowly feeding the drum with
water. This procedure will ensure that the solution is thoroughly distributed.
If the solution were poured into an empty boiler drum, the whole quantity would
disappear into the nearest boiler tube.The chemical injection pump may be used to
introduce the boiling out chemicals.
After closing the drum manhole door, add water to bring the water level into the gauge
glasses.
c) Economiser
Economiser, during the boiling out procedure, should be handled in the same manner
as during the starting-up period; i.e. the procedure and precautions for the operation of
the air cocks, drains, feed valves, etc., called for in the starting-up instructions, should
apply during boiling out period.
d) Firing
Before lighting the fire, it is recommended as earlier mentioned that the following
precautions should be taken
a) Remove all structural timber from the furnace and from the gas passages, especially
from locations where the gas temperature may reach the point at which wood will burn
or glow. The reason for this is that a glowing member may be the cause of igniting
explosive gases which can accumulate with careless handling of the combustion
equipment while firing at low rates during the period of boiling out.
b) Check that all blow-down and drain valves can be used effectively.
c) Make sure that the drum gauge glasses are in good working order.
d) Make sure that the fuel burning equipment can be operated in strict accordance with
all recognized rules of safety applying to the particular fuel to be used for the boiling
out process.
e) Make sure that the unit is filled with water and chemicals in accordance with the
foregoing instructions.
f) Before lighting up, completely purge the setting of all combustible gas by pulling air
through the setting for at least five minutes at the rate approximately one fourth of the
requirement for maximum capacity of the unit.
g) Start burner at minimum firing rate and keep the steam saturation temperature rising
rate within 1°C per minute. This limitation should be duly kept under consideration
during all the three days of boiling out period. Precaution should be taken against the
spall and crack of refractory caused by intense combustion.
After the fire has been lit, it is important to hold them continuously at the minimum
rates consistent with the boiling out process. It is especially important from the
standpoint of safety to maintain stable combustion conditions for the avoidance of
puffs or perhaps, a serious explosion. In this connection, should the fire be
accidentally or purposely extinguished, it is absolutely necessary to purge the setting
completely for at least five minutes before re-lighting.
Caution-
The drying out and boiling out periods may give rise to hazards unless very great
care is taken to observe the safety rules applying to the type of firing supplied. In
particular, experienced operators only should be used and it is recommended that
they should have adequate training and opportunity to become familiar with the new
equipment before commissioning begins.
• Drum shall be filled with DM water and taken to super heaters back filling. Filling
and flushing shall simultaneously be carried out till the clarity of the flushing is
equal to incoming DM Water.
• After flushing super heaters, drum level shall be brought to normal operating level.
• During pressure raising and holding at 5 Kg/cm2, sufficient flushing and draining
through all bottom drains shall be made, a composite sample shall be collected
and pH, conductivity and oil content in the composite sample shall be analyzed
and recorded.
• Boiler pressure shall be raised to 10 Kg/cm2and pressure raising and holding at
10Kg/cm2 shall be over a period of 8 hours. During pressure raising and holding at
10 Kg/cm2, sufficient flushing and draining through all bottom drains shall be
made, a composite sample shall be collected and pH, conductivity and oil content
in the composite sample shall be analyzed and recorded.
• Filling and draining shall be made with DM water through all bottom drains either
individually or collectively depending up on the site conditions. Once pH,
Conductivity,Oil content (less than 5 ppm) and clarity of the water is satisfactory,
flushing and draining shall be stopped.
• Boiler shall again be filled and taken to super heaters and super heaters also filled
and drained and the flushing shall be checked for pH, Conductivity and clarity.
Once they are satisfactory, filling and draining of super heaters shall be stopped
and boiler shall be drained completely through all bottom drains including
economizer.
• After complete draining of boiler water, Steam drum and Water drum shall be
opened. Internals kept inside the Steam drum shall be taken out, cleaned
thoroughly and kept ready for assembling. Debris collected inside the steam and
water drums shall physically be removed, thoroughly cleaned and internals
assembled in the steam drum and both the drums shall be closed and kept ready
for steam blowing.
• Inspection stubs of all bottom headers shall be cut on both sides, inspected,
collected debris removed, cleaned, inspection stubs welded back and kept ready
for steam blowing.
NOTE:
Water holding capacity is 68M3
Tri Sodium Phosphate requirement for the Alkali Boil out shall be 200 Kgs.
(Minimum).
At any time of Alkali Boil out up to a pressure of 20 Kg/cm2, TSP concentration
shall not be below 50% of the original concentration.
Collect the sample of the RHS, LHS, Front and Rear bottom headers as well as
drum water and send to lab for analysis of pH and conductivity.
Allow the boiler to cool naturally.
Day 2
Repeat the activities of 1st day and raise the steam pressure to 10 Kg/cm g. as per
the chemical boil out curve.
Maintain the pressure at 10 Kg/cm g. for 8 hrs.
Take the thermal expansion readings.
Quick blow down to be given from the bottom headers after shutting the burners at
the end of boil out period.
Collect water samples from bottom headers and drum and analysis for pH,
Conductivity, oil traces and Iron pick-ups.
Allow the boiler for natural cooling in the night.
Day 3
After ensuring the steam drum has cooled sufficiently, start rinsing the drum and
pressure parts to get the required pH in the drum water as given in the procedure
of the alkali boil out.
Rests of the activities like stub cutting for checking cleanness of the headers as
well as to water hose for cleaning if required is to be performed.
All the internals in side the steam drum are to be taken out and mechanically
cleaned and water hosed before fitting inside the steam drum.
Hydrazine concentration shall be maintained between 250 to 300 ppm and pH adjusted to
10.5 with the help of Ammonia, if necessary. After establishing necessary concentration
of Hydrazine and pH, circulation shall be stopped and steam drum drained to normal
water level.
During steam blowing operation chemistry of feed water, boiler water and steam
shall be maintained with the help of Hydrazine and Ammonia.
Feed Water pH shall be maintained between 8.8 and 9.0, boiler water pH shall be
maintained between 9.2 and 9.4 & steam pH shall be maintained between 8.8 and 9.0.
Dosage of Tri Sodium Phosphate through HP dosing system shall be avoided and
drum level shall be maintained at the lowest level possible.
After attaining steam purity during steam blowing operation system is ready for
giving steam for turbine rolling.
If turbine rolling is delayed, fire shall be killed and drum pressure shall be allowed
to drop to 5 Kg/Cm2 and boiler shall be hot drained and all the vents shall be
opened.
With this operation, internals of the boiler would have been passivated. If
necessary, drum manhole shall be opened and inspected for jet-black coating of
magnetic oxide (Fe3 O4).
To confirm the magnetic oxide coating, after opening the drum manhole, coating
from the accessible area shall be scrapped and tested with magnet wrapped with
paper. If the coating is magnetic, entire scrapped material shall be attracted
towards magnet.
During initial period of steam being taken to turbine rolling, the chemistry of feed
water, drum water and steam shall be maintained with the help of Hydrazine and
Ammonia.
Afterwards, drum water chemistry shall be maintained with Tri Sodium Phosphate
(HP Dosing) and feed water pH shall be maintained with Hydrazine and if
necessary, feed water chemistry shall be adjusted with the help of small dosage of
Ammonia.
The following procedure is in close accordance with ASTM D 1178 and accuracy of
this method is 1 ppm.
COLLECTION OF SAMPLES
Samples shall be collected through individual drains through all bottom headers and a
composite sample shall be prepared and used for analysis of oil and grease. The sample
shall be collected in a thoroughly cleaned Stainless steel / Plastic Bucket.
LIST OF EQUIPMENTS:
500 / 250 ml glass separating funnel
500/250 ml glass measuring cylinder
25 ml glass measuring cylinder
Glass funnel
100 ml glass beaker
Desiccator
pH meter
Chemical Balance (0.1 mg accuracy)
Air Oven
LIST OF CHEMICALS:
Chloroform AR
Sodium Sulphate Anhydrous AR
1:4 Sulphuric Acid AR / Concentrated Hydro Chloric Acid AR
Universal Indicator Solution
GF / A filter paper (Pore size 1.6 micron) No. 1 filter paper
PROCEDURE:
Composite sample collected shall be filtered through GF / A filter paper. The clarity of
the filtered water shall be as good as DM water. 500 / 250 ml of composite filtered sample
shall be taken for analysis and 10 ml of 1:4 Sulfuric Acid / hydrochloric acid shall be
added to the above sample to make the solution distinctly acidic.
This shall be ensured by testing a fraction of the sample either with pH meter or with
universal indicator solution. 25 ml of Chloroform shall be added to the separating funnel
and shaken well (care shall be taken that no grease or oil is applied on the stopcock or
the stopper of the separating funnel). The separated chloroform layer at the bottom of the
separating funnel shall be allowed to pass through Anhydrous Sodium Sulphate taken in
no.1 filter paper in glass funnel and filtered chloroform shall be collected in a pre weighed
100 ml glass beaker.
The addition of chloroform to the sample shaking it and filtering it through anhydrous
sodium sulphate shall be made at least twice and all the filtered chloroform shall be
collected in the same pre weighed beaker. Finally Sodium Sulphate is given wash 25 ml
of fresh chloroform and this will also be collected in the same beaker. The glass beaker to
the chloroform shall be kept in a water bath and shall be allowed to evaporate completely.
This beaker shall than be kept inside an air oven at 105 Deg. C and allowed it to cool in
desiccator and weighed.
The above experiment shall be carried out with the DM water and the results shall be
taken as a blank and this shall be subtracted from the sample.
The results shall be reported in mg/l (ppm).
Open the drum manhole door to permit inspection and washing Fit the internal feed
pipe, chemical feed pipe etc., and prepare the safety valves for testing and setting. The
drum internal fittings should be inspected carefully, great care being taken to see that the
joints between the individual fittings and the drum are tight at all points. The pressure
parts may then be closed up and filled with suitable water, ready for raising pressure for
testing the Safety valves set pressures.
i) Refractory inspection
Before going into the gas passage for inspection, sufficient ventilation is essential to
avoid the danger due to the combustible or harmful gas.
After drying out, go into the gas passage, and inspect the refractory materials on the
drying condition, any crack and excessive contraction. Normally, small crack is no
problem for operation. But if excessive cracks are found, put the ceramic fibre into the
crack. Clean up the gas passage after the inspection. Be certain that no cloth or foreign
material remain inside.
DESCRIPTION
a) Introduction
e) Precautions
a) Introduction
When a boiler and its associated steam piping have been erected, there is a
possibility that debris, such as welding beads and dirt may have been left in the tubes and
piping. In addition, these parts may have an internal coating of oxide or mill scale, which
will flake off during initial temperature changes. Failure to remove the debris results in
increased erosion, turbine blade damage and rapid deterioration of turbine efficiency.
To avoid any hazard of such material causing obstruction or damage to machinery, it
is recommended that arrangements be made to blow the piping systems to atmosphere
before the final connections are made and steam is passed to the plant. This blowing
through is done with steam, which is exhausted through adequate sized, open-ended low-
pressure temporary piping. The steam blowing operation cleans the system and provides
the steam of requisite purity for the plant.
This low-pressure temporary piping must be connected as near as possible to the
terminal point of the section of the system being purged. In some cases an appropriate
valve cover may be removed and the temporary piping led off the valve chest. The run
should be as short as possible consistent with steams discharging freely to atmosphere
without causing danger to personnel or damage to structure and equipment.
If a basket type strainer is installed in the steam piping it must be removed prior to
steam blowing and subsequently replaced.
The precautions listed below must be strictly observed.
The diameter of temporary discharge piping shall not be less than the diameter of the
respective line to be steam blown. The spool pieces should have an opening equal to the
diameter of the respective temporary pipeline the temporary discharge piping and
supports shall be capable to withstand steam-blowing parameters.
For both procedures, experienced observation can determine when sufficient blowing
through has been effected. Clean metal target plates are rigidly secured in the path of the
discharging steam at a suitable distance from the pipe end.
These are placed in position for evaluation of debris carryover along with the steam
after the initial few blows when the steam is visibly clean. After each blow the target
plates are inspected for any pitting by the debris.
Target plate assembly is located in the temporary exhaust pipe and placed nearest to
the permanent pipe work. Availability of sufficient number of target plates is to be
ensured. Stainless steel plates having mirror finish shall be used in final blows. In
preceding blows target plates of aluminium shall be used. Further blows are given until
they indicate that no debris remains in the piping. It is a standard practice to limit the
number of blows to 6 to 8 per day at an interval of 2 hours between 2 consecutive blows
and with an overnight cooling.
A complete record of the events and observations are to be maintained.
e) Precautions
To prevent excessive strain on pressure parts and danger to personnel, the
following precautions must be strictly observed.
1. The securing arrangements of permanent piping must be complete, or adequate
temporary bracing installed. For thermal expansion of pipes, proper allowance must
be given. First test steam blow should be given at lower pressure and the temporary
piping should be surveyed for proper expansion and supports.
9. All the permanent pipelines and temporary pipelines passing through working area
should be insulated before the blowing.
10. All permanent hangers and supports for various lines are to be erected and set for
proper values as per design figures. All locks and restraints are to be removed from
pipelines.
11. Provision should be made for tightening of flanges of holding arrangements for target
plates. Spare gaskets for flanges are to be kept ready.
12. In addition to usual light up instruments, provision is to be made for monitoring /
recording pressure and temperature at outlet of boiler and before temporary exhaust.
13. The area around the exhaust point should be cordoned off. For warning sound, prior
to blow, siren or PA system can be utilized.
14. Effective communication and lighting system should be ensured at the vulnerable
areas.
15. Boiler should be ready in all respects including
16. Chemical cleaning of the pressure parts internals should be complete prior to steam
blowing
17. All drain connecting piping are to be left open to atmosphere and are not to be
connected permanently to drain vessel to ensure proper and quick draining. After
checking drain pots for choking, the drain lines are to be connected permanently to
vessels after steam blowing.
Description
a) Introduction
a) Introduction
Two numbers safety valves are provided on the steam drum, having a combined
relieving capacity of 75 % of the peak load steam generation. One number of safety valve
provided in main steam line, having a relieving capacity of 25 % (at 520 °C) of the peak
load steam generation.
During the inspection of the boiler after boiling out, the safety valve escape pipes
must be inspected to confirm that they are led to safe points of discharge and are
properly secured, and that the safety valve drains are clear. Also see that the expansion
chambers have the correct clearance so that when the pressure parts are hot they do not
foul the safety valve exhaust pipes.
Before the boiler is put into service and after the pressure parts of a new boiler have
been boiled out and it is otherwise ready for steaming, the safety valves should be
“floated “ with the main steam stop valve closed, to make sure that the valves lift and
close satisfactorily at the specified pressures.
c) Ensure that the escape piping is rigidly held at a point near the expansion joint.
Cold settings of the escape piping may be included on the drawings sketch, as these
dimensions will be of benefit whenever it is necessary to remove valves or escape
piping.
If attention is paid to the above points, no trouble should arise either with valve
operation or expansion joint leakage.
As there can be no definite assurance of the latter it may be necessary to erect
protective barriers local to expansion joints, where leakage could be of danger to
personnel.
DESCRIPTION
a) Preliminary Checks
b) Firing Equipment
c) Use of Drains
e) General Check – Up
f) Water Level
g) Steam Supply
a) Preliminary Checks
Before commencing to raise pressure in a boiler, make sure that all auxiliary
equipment is in working order and test the controls. The steam drum water level for boiler
tripping is set at –200 mm. Water is taken in the steam drum just above this level. Test
the water level by opening and closing the drain cocks. The cause of any sluggish
movement of the water should be investigated.
See that the keys of all blow down and drain valves are removed. Open the air cocks
and drains connected to the steam line before the main steam stop valve MSSV. Operate
all dampers and set them in the correct position. Remove any combustible material in
contact with steam pipes or ducts, as later it may ignite and cause trouble.
Test feed lines and make sure that the economiser is full by feeding some water into
the boiler via the economiser to raise the water level in the gauge glass by about 10 mm.
Afterwards close only the regulating valve so that water is readily available. See that the
valve admitting feed direct to the drum is closed and that the automatic feed valve is in
the fully open position and ready for setting. Before the boiler goes into operation when
there is continuous flow of water through the economiser, water should be taken
intermittently through the economiser to avoid overheating of its tubes during pressure
raising, alkali boil out or setting of safety valves etc.
See that access doors on the boiler are closed and that steam and water valves and
pressure gauge cocks are workable and correctly set. Run the fan and prepare the firing
equipment for service.
b) Firing Equipment
The fuel burning equipment should be placed in service in accordance with the
instructions for the type of system installed, and with rigid observance of all the
recognized rules of safety applying to the fuel to be used. The boiler settings should be
purged with 25% MCR airflow as mentioned in Art. 7.4 for light up.
The rate of firing should be adjusted to produce an increase in saturation temperature
not greater than 67°C/hr. Follow allowable pressure arising rate by manually regulating
fuel flow rate and adjust opening of main steam vent valve in order to keep the limitations
i.e. maximum temperature rising rate is 67°C/hr by supervising the steam pressure rising.
c) Use of Drains.
The boiler outlet steam line drain must be kept open during the whole pressure
raising period to ensure a flow of steam through the steam line
4. Test the water connection by closing the steam valve and allowing water to escape to
drain until satisfied that the water connection is clear.
5. Open the steam valve.
6. Close the drain valve, when the water should return promptly to its true level in the
gauge glass. Any sluggishness in the movement of the water may indicate that the
steam connection or the water connection is partially choked and the level may be
false.
The operating engineer should satisfy himself that each boiler operator fully
understands how to test the water gauge.
e) General Check Up
Confirm that all newly made hand hole cap joints and manhole door joints have been
fully tightened, and keep all joints under observation during the pressure raising period.
When pressure is being raised, the expansion of water may make it necessary to blow
out some water to prevent the water level from rising above the gauge glasses
It will be found advantageous to put the distant level indicator into service while
pressure is being raised, so that it will be ready for use, and the boiler feeding can be
seen and controlled from the firing floor, when the boiler commences to deliver steam. It
must be remembered that the most reliable indication of the water level is obtained from
the direct - on gauge glass, and the distant water level indicator should be checked
against this when commissioned.
The high and low water alarm should be put into commission in accordance with the
commissioning instructions and should be checked by raising and lowering the water
level. When the alarm is correctly set, it should give audible warning if the water level
rises or falls, to ± 100 mm for high and low water level respectively. Considering the
drum Centerline at 0mm level and the normal water level being also at 0 mm level.
f) Water Level
As the pressure builds up, the water level in the boiler gauge glass will rise due to
the expansion of the heated water. When water level rises higher than the upper range
i.e., +100 mm in the water level gauge, blow off the boiler water by opening the
continuous blow line valve so that water level can be kept within the range of the gauge,
preferably near the normal water level i.e., 0mm which coincides with the steam drum
center line.
OPERATION & MAINTENANCE MANUAL Page.No. 120
ENMAS GB POWER SYSTEMS
(A Division of GB Engineering Enterprises Pvt. LTD)
Chennai – 600 018 INDIA
Open the feed water flow control valve isolating valves. With the rise of steam
pressure, supply the feed water by opening feed water flow control valve to supplement
the exhaust steam lost through air vent valve, drain valve and steam vent valve by
adjusting feed water flow control valve. The intermittent feeding of water will also prevent
the overheating of the economiser tubes. Extreme care must be taken that the level is not
Abnormally high when the boiler is cut in, as there would be danger of the water
being carried over into the steam line.
The main steam stop valve should be opened gradually. Otherwise, such action of
water carrying over to steam line would cause undue temperature strains in the steam
line and possibly damage the steam driven equipment. As a precautionary measure the
water level should never be allowed to rise to the extreme top of the glass during the
starting –up period, and the boiler should be blown down to half glass shortly before line
pressure is reached.
g) Steam Supply
The boiler is put into service by following procedures as described in part 7.9
DESCRIPTION
d) Firing Control
d) Firing Control
When the boiler goes on load, the rate of firing should be adjusted to maintain
pressure and meet the steam demand without lifting the safety valves.
It is advisable to steam a new unit on light load for a period to prove its reliability and
to allow the operators to become familiar with the controls. Full use should be made of
this period to ensure that the instruments are working satisfactorily and to try out all
steam consumer services.
DESCRIPTION
e) Dampers
g) Bed management
Warning:
1. At any point of time do not increase the boiler-firing rate beyond the MCR
heat input of the boiler.
2. Do not operate boiler with drum level below Low Low trip level.
3. Do not operate water wall header & down comer drains when firing is on
If the draught loss through the boiler increases noticeably while the boiler is in
service, an inspection of the gas passes should be made at the first opportunity, to
locate and remove any deposits from the gas passages.
Quick drop of main steam temperature is often the indication of carry over. In this
case, reduce the boiler load and investigate the reason of the quick drop in order to
prevent further trouble with the main steam line and others.
The cause may be an excessive rise of drum water level, rapid load change,
excessively high salt content of boiler water or contamination of oil into boiler.
Breakage of Glass
When the glass is broken, close the isolating valve as soon as possible. Take
the broken glass very carefully and blow off small particles of glass by slightly opening
the isolating valves with the drain valves open.
Replacing of Glass
It is advised that steam and water valves for the replaced water level gauge
should be opened very slowly to prevent breakage or crack of the glass due to thermal
shock. Steam and water shall be supplied into the gauge in the following manner.
1. Warm up the glass by slightly opening the steam valve and the drain valve.
2. Close the drain valve after slightly opening the water valve.
3. Gradually open the steam and water valves to full open.
In order not to damage the glass of the level gauge, uniform and gradual
tightening of all the bolts is essential.
High and low water alarm should be tested at least once a week by raising and
lowering the boiler water level. The external alarm should be blown through only as
stated in the maker’s instructions.
Warning: If feed water & drum water quality parameters show deviation from the
specified parameters and immediate steps to be taken to find out the probable
reason for it and suitable corrective action to be taken. Shut the boiler
immediately if the deviation is more than 10 % than specified to prevent damage
to boiler pressure parts.
e) Dampers
It is essential that dampers be moved from their set position at least once every
seven days, not only during boiler outages but also during prolonged operating
periods. This will ensure that damper spindles do not become seized in their bearings.
g) Bed Management
It may be noted that the particle density of the bed material if is high will result in
low fluidization of the bed, will result in lower expanded bed height and the higher back
pressure in mixing nozzle. Low expanded bed will result in low pickup in bed coils and
high bed temperatures at lower boiler loads. This operating condition with actual bed
level LOW (shallow bed operation) will result in higher pickup of heat in Primary super
heaters higher rate of erosion and higher un – burnt carbon loss.
The following steps are to be adopted for better bed management and to maintain
optimum the bed material properties.
Check bed material Bulk density, particle density and particle distribution at least
once in a day. The following steps to be adopted to maintain the bed.
Regularly drain the bed based on bed chemistry and particle size. Use of Re –
cycling of bed material should be avoided and if recycling is being done, sieve the
drained bed material with 8 mesh & 18 mesh sieve. The optimum size of bed particle is
0.85 mm to 2.3 mm before it being used for topping up.
Add fresh material to maintain the bed chemistry (Al2O3 & SiO2 % to be maintained)
as per the recommendations. Always maintain Fe2O3 content in the bed less than 3% .
Check the Fe content in bed material once in a while (Say once in a week).
While procuring new bed material specify the parameters with Al2O3 - 55 – 65 %,
SiO2 - 35 – 45 %, particle size - 0.85 mm to 2.3 mm, the bulk density as Less than
1200 Kg/ M3 , Fusion temperature - > 1200 Deg C and Crushed from IS – 8 grade
refractory.
Always maintain coal size less than 6 mm. If any time larger size coal goes into the
furnace due to problems in coal handling plant, increase the bed drain frequency till
the bigger pieces are drained – off from the bed to maintain good fluidization.
1. Feed water to the boiler through the economizer to just above the low-level
interlock set point.
2. Open the final steam drain valve carefully.
3. Start the ID fan and select the furnace pressure control to “AUTO”.
4. Start the feeder cooling system.
5. Start the FD fan and open the inlet dampers to provide the minimum fluidizing
air flow.
6. Start the coal feeders with minimum coal flow. Check the coal is ignited (See
cold start note).
7. Ensure that the pressure-raising rate does not exceed the Babcock pressure-
raising curve.
If the boiler steam pressure has dropped below about 35 Kg/cm2, it will probably
not be possible to regulate the firing at a suitably low firing rate. The pressure must
therefore be maintained above 35 Kg/cm2 for a hot start.
8. Float the boiler online and establish automatic feed water control. Shut the final
drain valve.
9. Allow the bed temperatures and combustion to stabilize and when the entire
bed temperature rise to about 850° C, set the boiler on automatic control.
• Check for steam or water leaks from valves, connections and fittings
• Check for air / flue leakage from wind box, boiler casing and ducting
• Walk around the furnace exterior and observe for any hot spots or gas leaks.
• Check for passing from safety valves at normal operating pressure. Check that
the drain lines and drip pans are not plugged
• Check to see that proper water level is being shown by the direct water level
gauge. Check for water or steam leak from ports or drain connections, which will
cause a false water level in the gauge glass. Inspect the glass for discoloration
or fouling
• Pressure raising from cold start must be done as per the cold start up curve
• Maintain the instrument air free from moisture and oily matters and the
pressure as recommended
• Carry out regular cleaning of direct water level gauge glasses of Boiler drum
• If the water level goes up above the limits operate the intermittent blow down
valve immediately and maintain the water level to normal
• Maintain the feed water temperature at economizer inlet and flue gas
temperature at economizer outlet as recommended
k) DON’TS
• Don’t leave the furnace door open while the boiler is in operation
• Don’t mix up different lubricants
• Don’t alter the equipment maintenance schedule
• Don’t leave the control panel unattended
• Don’t allow unauthorized persons to operate the boiler and associated
equipments
• Do not dose chemicals into the boiler in batch wise, they should be done on a
continuous basis
The handling and burning of any fuel is potentially hazardous. Some fuels ignite
more readily than others do. Safe handling and operation demands knowledge of the
characteristics of the fuel and careful observance of necessary precautions.
Because of the rapid diffusion of gas, any leak of gas into an enclosed space may
result in an explosive mixture of air and gas.
One of the requirements of good combustion is intimate mixing of fuel and air. In
case of gaseous fuels such mixtures are potentially explosive and can be expected to
ignite from a single spark. Therefore these mixtures must never be allowed to exist
except inside the combustion chamber
• Never allow fuel to accumulate anywhere, other than in lines that form a part of a
fuel supply system.
• Steps should be taken immediately to clean or purge the area thoroughly and then
locate the source. Carry out routine checks to detect leaking fuel.
• Purge the furnace completely before introducing any light or spark during burner
operation.
• Maintain a positive airflow through the bed into the furnace and up the stack
• Operating the boiler with low feed water temperature will result in corrosion of
economizer coils.
• The raising and lowering of steam parameters should be restricted to the value
given in the start – up curve. Exceeding these values will result in reduced fatigue
life of pressure parts.
• In case of tube failure, which can be identified by hearing the noise in the boiler
gallery and increase in draught pressure, flue gas and steam temperature, and the
boiler should be shutdown at the earliest by regular procedure for maintenance
work. Otherwise large number of tubes may fail due to steam erosion and
impingement.
• Whenever boiler is started after a shutdown of more than 3 days, check all safety
interlocks before boiler start up for proper functioning.
• The steam drum should normally be filled up to the point when water is showing in
the bottom part of the gauge glass. This is to allow for the swell on heating and to
reduce any blowing down resulting from this cause to a minimum.
• Once the boiler is boxed up, the water level in the steam drum must be raised to
the very top of the drum. Filling the drum like this will prevent excessive
temperature differentials along the drum wall. The water is then shut-off and the
boiler is allowed to cool.
While raising pressure on boilers, continuous firing is recommended, since
intermittent firing may result in re-condensation in the tube loops.