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Power plant and calculations

Power plant and calculation site basically includes the detailed study of power plant operation and maintenance, its related all
calculations and thumb rules. It also involves detailed troubleshooting guides for operation and maintenance of power plant
Motorised

processes and equipments. Motorised

Track
Track

Trolleys Trolleys

Track Gauges,

Designers and

Alumicarts,

Manufacturers

Portable &

of Railway
Handheld

Engineering
Lighting, Remote

Tools and
Monitoring, Hand

Equipment Tools

22-Most likely Question Answer Guide

for Boilers troubleshooting

Motorised

Track Trolleys

Designers and

Manufacturers of

Railway Engineering

Tools and Equipment

TOP-6 BEST POWER PLANT O&M BOOKS

1.What are
the emergencies that are expected to happen in boiler operation?

Emergencies that can happen

in boilers operation are:

Boilers tubes leakage

Failure
of feed water control station
Unbalanced
draft in furnace
Furnace
explosion
Blow
down valve failure
Feed
water pumps failure
Secondary
combustion in super heaters and ESP

Also read 16-Perfect reasons for increasing the fuel consumption of

Boilers

2.List out the

potential reasons for boiler tubes failure.
 Reasons for boiler tubes
failure:
Failure
due to overheating
CLOSE ADS Failure
due to internal scales CLOSE ADS

Failure
due to aging
Failure
due to uneven expansion
Failure
due to ash and flue gas erosion
Failure
due to material defects
Failure
due to internal and external tube corrosion

Motorised
Improper
or effected circulation due to opening/passing of low point drains Motorised
Motorised

3.List down
the sequential action taken after boiler tube leakage to restore the boiler.
Track
Following activities are
done to restore the boiler: Track Trolleys Track

Trolleys After
tube leakage, Shutdown the boiler as soon as possible Trolleys
Allow to cool
the boiler continuously by circulating feed water
If
necessary start fast cooling by keeping ‘ON’ ID and FD fans
After
cooling the boiler, identify the leakage tube/coil
Drain
the water up to the leakage point
Designers and

Find
out the root cause of leakage Track Gauges,

Designers and
Manufacturers of

If
leakage is minor like pin hole, crack then weld the tube (follow welding Alumicarts,

Manufacturers
procedure) Railway Engineering
Portable &

of Railway
If
leakage is major like fish mouth damage, then replace the damaged part Tools and Equipment Handheld

Engineering
Allow
to cool the joint for two hours Lighting, Remote

Tools and
Fill
up the boiler and carryout hydraulic test at 1.25% of maximum operating Monitoring, Hand

Equipment pressure Tools

After
ensuring the joint is free from leakage, drain the boiler up to normal drum
level
Start the boiler as
per start up procedure
It's all about HP heaters

4.What are the

reasons for boiler drum level fluctuation?

Possible reasons for drum

level fluctuations are:
Sudden
loading and unloadingof Boiler
Fluctuation
in steam pressure
Safety
valve sudden pop up
Priming
and foaming
Failure
of drum level controller
Leakage
or passing of blow down valves
Uncontrolled
firing rate Motorised

Leakages in tubes or coils

IBR acts, regulations & forms used

Track Trolleys
5.How do you
handle a boiler, if steam drum safety valve lifts before lifting of super
heater
line safety valve?

Drum safety valve lifting

may cause failure of super heater coils due to less steam flow to
coils. In
such cases maintain sufficient steam flow to super heater coils by maintaining
drum
Designers and

level normal by allowing more feed water flow into drum. And reduce the
firing rate and drum
pressure for re-seating drum safety valves quickly. Manufacturers of

Railway Engineering

Procedure for Boiler Gauge glass line up

Tools and Equipment

6.What are the

possible reasons for furnace draft fluctuations?

Following are the some

reasons for furnace draught fluctuation:
Unbalanced
draft
Fuel
moisture variation
Sudden
load change
Failure
of ID, FD fan
Flue
gas path choke up generally in APH
Air
and flue gas leakages
Loose or
improperly fitted fans guide vanes.

7.What action
you will take if boiler blow down valve fails?

Following immediate
actions shall be taken during boiler blow down valve failure:
Allow
more feed water flow and maintain drum level normal.
 Reduce
the boiler load and check the quantity of water flowing through the blow
down
line.
If
the water loss is less and acceptable run the boiler till upcoming planned
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shutdown, If it is more than acceptable, shutdown the boiler and get done the
repair
work of valve.

Why do the Boilers explode???

8.What are the

main causes for boilers explosion?

Motorised

Major causes of boilers

explosion:
Motorised
Motorised

Unbalanced
draft i.e. high positive pressure
Track
Secondary
combustion Track Trolleys Track

Trolleys Bypassing
the boiler protections and interlocks Trolleys
Overheat
Scale
and corrosion of pressure parts

9.What
are the causes of higher flue gas outlet temperature of boiler? And how do you
troubleshoot? Designers and

Track Gauges,

Designers and
Improper
Heat Transfer in Economizer, APH: Clean
Economiser coils and APH Manufacturers of
Alumicarts,

Manufacturers
tubes regularly, maintain flue gas temperature as per
manufacturer guide.
Railway Engineering
Portable &

of Railway
Accumulation
of Soot on Super Heater Coils, Economizer: Operate soot blowers
regularly.
Tools and Equipment Handheld

Engineering
Lighting, Remote

Burning
of Higher Moisture Content Fuel: Limit
the moisture content of fuel.
Tools and
Monitoring, Hand

Higher
Economizer Feed Water Inlet Temperature: Reduce steam flow to HP/LP
Equipment heaters. Tools
Excess
Heating Surface of Boiler: Modify
the boiler pressure parts design in
consultation with manufacturers and
designers.

10.What are the

problems you do come across during sudden load cutoff on boiler? How do
you
troubleshoot?

During sudden load cut off

following abnormal operation may take place:
Drum
Level Low: Increase
feed water flow proportionally.
Safety
Valve Lift: Drum
level starts to rise, so control feed water flow. In case of
drum safety valve
lift there may be chances of failure of super heater coils due to
less steam
circulation (starvation of coils), so utmost care must be taken to
maintain
drum water level.
Furnace
Draft May Become Unbalance: Maintain
furnace draft by controlling ID and
FD fan speed manually.
Higher
Attemperation: Reduce
firing rate and attemperator water flow. Motorised

Questions & Answers on AFBC Boilers

Track Trolleys
11.List down
the causes and remedies of higher fuel consumption of boiler.

More fuel combustion is

manly is due to:
Incomplete
Combustion: Achieve
proper and complete combustion, limit excess air
and fuel moisture. Maintain
3Ts of combustion.
Low
Economizer Inlet Feed Water Temperature: Increase bleed steam to HP and Designers and

LP heaters.
Manufacturers of

Formation
of Soot on Heat Transfer Surfaces: Operate
soot blowers regularly at
rated pressure and temperature. Railway Engineering

12.Why does the

boiler backfire? Tools and Equipment
Back firing of boiler is
due to:
Unbalanced
draught
Reduced
speed of ID fan or more speed of FD fan
Improper
locking of fans damper (which may disturb in fan running due to air
pressure)
Sudden
trip of ID fan or closing of damper
High
moisture fuel
More
excess air
Jamming
of APH
Reasons for Boiler back fire

13.List out the

reasons for more unburnt in ash.

Excess unburnt is due to:

Incomplete
combustion
Insufficient
combustion air
 More
moisture content fuel
Not
meeting 3T’s of combustion
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working of cinder reinjection system CLOSE ADS
Lower
GCV fuel
High
ash content in fuel
Low
over fire air

14.What
are the trouble shoots during boiler start up?

Motorised
Boiler
Flue Gas Ducts Explosion: Before
light up purge the boiler properly. Motorised
Motorised

Trouble
to Achieve Furnace Temperature: Maintain
balanced draught (slightly
Track
positive). Track Trolleys Track

Fluctuation
in Drum Level: Maintain
drum level by taking feed water control valve in
Trolleys manual. Do not allow the drum
level to go high (>90%) or less (<20%). Trolleys
Tripping
of ID Fan or FD fans Due to Draught Fluctuation: Maintain furnace draft in
manual mode
until boiler load reaches more than 30% of MCR.
High/Low
Steam Temperature: Maintain
attempteration in manual and keep open
attemperator isolation valves.
Flue gas condensation
in APH: By pass the APH for FD air flow to Designers and

Track Gauges,

Designers and
avoid flue gas condensation. Manufacturers of
Alumicarts,

Manufacturers
Railway Engineering
Portable &

of Railway
15.How
do you troubleshoot the formation of clinker? Tools and Equipment Handheld

Engineering
Lighting, Remote

Clinker formation can be

avoided by following ways:
Tools and
Monitoring, Hand

Using
low moisture coal
Equipment Tools
Maintaining
proper air fuel mixture
Achieving
proper combustion
Using
coal with no foreign materials
Avoiding
frequent startups and stops
Use
coal with high ash fusion temperature
17.How
do you reduce the auxiliary power consumption of Boiler?

Maintain
proper air fuel mixture so that speed of ID, FD fans and fuel feeding
system
can be optimized.
Avoid
using high moisture coal as it requires more air for combustion.
Use
VFDs to fuel feeding system.
If
boiler is running on load less than <30% shutoff the stand by fans.
Tune
the feed water control valve for maximum opening to reduce the speed of
Boiler
feed pump.
Motorised

Viva Questions & answers for preparation of BOE exam & interview
Track Trolleys
18.What
are the possible reasons for higher main steam temperature?
Failure
of Attemperator control valve
More
boiler load
More
heat transfer in super heater zone due to more velocity of flue gas
More
firing rate
Low
Economiser inlet feed water temperature Designers and

High
moisture fuel Manufacturers of

More
excess air Railway Engineering

Low
drum level Tools and Equipment
Leakage
of super heater coil

Boiler calculations for Boiler operation engineer (BOE) exam

19.What are the

effects of high and low drum levels?

High drum level:

Results
into carryover of water into super heater coils which may damage coils due
to
high thermal shock.
Can
damage safety valve seats.
Disturbs
circulation ratio.
Carry
over with sharp fall in super heater temperature.
Water may enter
turbine and serious damages to turbine may occur
Super
Heater deposit and fouling.
Turbine Deposit
and increase in specific steam consumption.

Low drum level may results

less steam flow to super heater coils. 
20.How
do you control boiler corrosion rate?
Maintain
pH of water in the desired range to control corrosion.
 O2 in feed water should be
controlled within 0.007 ppm, primarily by good
deaeration, supplemented by
Oxygen scavenger dozing.
Condenser
leak should be immediately detected and acted upon.
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DM
water storage tank should be properly sealed.
Condensers
and heaters should be air-tight.
Proper
wet lay-up of units during shut downs.
21.How do you
identify the leakage of economizer tube? What is its effect?
 An economizer tube leakage
can be detected by sound or increased make up water
requirements. The leak
should be investigated at the earliest possible time and the unit to be
Motorised

shut
down in a normal manner. Water leaks in the economizer can cause considerable
erosion Motorised
Motorised

Track
damage Track Trolleys Track

to adjacent tubes. Water carried over from an economizer tube

leak may lead to cold
end corrosion also. 

Trolleys22.What are the

reasons for lifting of steam drum safety valve and how do you bring the Trolleys
boiler
to normal operation?

Drum safety valve may lift

due to following reasons:
Excessive
fuel firing rate.
Sudden
decrease in steam load. Designers and

Track Gauges,

Designers and
Manufacturers of

Faulty setting
of safety valve. Alumicarts,

Manufacturers
Railway Engineering
Portable &

of Railway
The following actions have
to be taken to bring boiler into normal operation: Tools and Equipment Handheld

Reduce
fuel-firing rate.
Engineering
Lighting, Remote

Tools and
Open
the start up vent valve. Monitoring, Hand

EquipmentObserve
the steam flow of the super heater. If there is no flow, trip the boiler. Tools
Maintain the
steam drum level.

Questions & Answers on Boiler safety valves

Motorised

Track Trolleys

Available @ Flipcart/Amazon/Notion press

Designers and

Manufacturers of

Factors considered for Boiler Engineering/Design

Railway Engineering

Boiler Feed Pumps Design factors & Pump Capacity calculation

Tools and Equipment

Challenging situations & troubleshooting during boiler light up & start

up

Boiler safety valves overhauling steps

at
July 12, 2020

Labels:
Boiler

1 comment:
Balaji M 19 August 2020 at 12:15

Nice
 Reply

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Enter comment

Hi all,

This article is written based on practical experience..If liked, share with others, or any suggestions
leave in comment box.

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