KILANG SAWIT LCSB LEPAR (KSLL)

KM 43 LEBUHRAYA TUN ABDUL RAZAK,

26300 GAMBANG,
PAHANG DARUL MAKMUR.

WELCOME

1
MILL BACKGROUND

— Started to be built in 1995

— Start operating commercially in1997
— Processing capacity : 60mt FFB/hr
— Owned by LKPP Corporation Sdn. Bhd.
(a subsidiary of the Pahang state
government)

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 ORGANIZATION CHART
MILL MANAGER
ZUL HILMEE B.SIRAN
(1ST Grade Steam Engineer)

ASST. MANAGER (MAINTENANCE) ASST. MANAGER (OPERATION)

RONNIE SHAZLAN B. SHAARI NOR IQBAL SHAFFIQ B. AZMAN

CHIEF CLERK
ROSLINA BT.
ABDOL RAZI

2ND CLERK

STORE FOREMAN ELECTRICAL LAB SUPERVISOR PROCESS BOILER

SUPERVISOR MOHD JAILANI CHARGEMAN BAHARI B.MD SUPERVISOR CHARGEMAN
SHUHAIMI B. B.JMOHD WAN AZMAN B AMIN 1. BAHARIN B. MUHA B.IBRAHIM
IBRAHIM JALALUDIN KASSIM ZAWAWI
2. AB RANI
BOILERMAN
TYPIST B.ABD HAMID

FITTERS FITTERS
(MECHANICAL) (ELECTRICAL) MANDUR

STORE APPREANTICE APPREANTICE LAB ATTENDANT OPERATORS FIREMAN

ATTENDANT
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Process Flow Chart FFB from Field
Reception
Sterilizer Condensate
Pressed EFB To Land
Screen Hot Water Sterilizer Ramp Application
Diluted Crude Oil EFB
Solids
Press
C.O. Vibrating Screen Press Cake
EFB
Thresher Depericarper
Undiluted
Waste
Crude Oil MPD
Recovery
DCO Tank Nut Silo
Plant Digester
EFB Liquor Fiber
Dirty Oil Cracker
Clarifier Screw Press
(Despatch)
Sludge Shell
Winnower
Sludge Tank Pure Oil Tank Shell
Light Shell
Phase Compartment Hydro Cyclone
1st & 2nd Stage Purifier
Desander Decanter

Boiler Kernel Silo

Decanter Vacuum Dryer
Heavy Phase
Decanter Waste Steam Bulk Kernel
CPO Storage Tank Turbine Silo
E.T.P
4
Crude Palm Oil Steam Electricity Palm Kernel
Final Discharge Shell
(BOD < 100 ppm) (Dispatch) (Dispatch) (Dispatch)
BOILER?

“A closed vessel used to generate

steam at a pressure above
atmospheric pressure, including
superheater and economizer
equipment and other equipment
attached to it”

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BOILER TYPES

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MAIN FUNCTION
◦ To convert the chemical energy in the palm
shell and fibre to heat energy in boiler
furnace.

◦ To transfer the heat energy to the water in

the water circuit of the boiler and convert it
to steam.

◦ To supply steam to the Power Station for

generating electricity.

◦ To supply steam for other process units in

the mill.

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ESSENTIAL FITTINGS

1. Safety valves 9. Low water fuel

2. Gauge glass cut off
10. Feed pump
3. Fusible plug
11. Inspector test
4. Low water alarm
gauge
5. Pressure gauge attachment
6. Blow-down valve 12. Registration
7. Main stop valve number
8. Feed check valve 13. Manufacturer
plate

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1. SAFETY VALVE
— Its function is to protect
the boiler shell from over
pressure and subsequent
explosion.

— The maximum set pressure

of the safety valve shall be
the maximum permissible
working pressure of the
boiler
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GAUGE GLASS
— Shows the current
level of water in the
boiler
— Should be tested
once / shift
— or as & when the
needs arises i.e in
emergency
(confirming low
water level
situation)
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GAUGE GLASS - TESTING PROCEDURE
— Steam & water cock in normal operation position.
Open drain cock gently, steam & water can be seen
flowing out from drainpipe
— Keep the drain cock in open position, close the
steam cock gently. Water will flow out vigorously
through the drainpipe. This step confirms that the
water passage is clear.
— Keep the drain cock in open position, open back the
steam cock. Steam and water will flow out through
the drainpipe
— Keep the drain cock in open position, shut the water
cock gently. Steam will rush through the gauge
glass and flow out through the drainpipe. This step
confirms that the steam passage is clear.
— Keep the drain cock open, open the water cock.
Both water and steam can be seen flowing out
through the drainpipe
— Close the drain cock and water level will rise in the
gauge glass to the normal working level, or Close
the drain cock and steam cock, water can be seen
filling up the whole length of the sight glass. Open
the steam cock, the water level will be pushed
down to its actual level.
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LOW WATER ALARM
— Give warning alarm
when the water level
is low
— Give warning alarm
when the water level
is high

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PRESSURE GAUGE
— Should be 150mm
dia.
— Should be marked to
indicate the normal
working pressure
and the maximum
permissible working
pressure

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BLOWDOWN VALVE
— Ejects the sludge or
sediment from the
bottom of the boiler
— To control TDS value
1800 - 2000ppm

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MAIN STOP VALVE
— To isolates / permits the
steam and its pressure
from / to the process or
plant.
— It should always be
opened slowly to
prevent any sudden rise
in downstream pressure
and associated
waterhammer, and to
help restrict the fall in
boiler pressure and any
possible associated
priming.

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FEED CHECK VALVE
— Under normal steaming
conditions the check
valve operates in a
conventional manner to
stop return flow from
the boiler entering the
feedline when the
feedpump is not
running.
— When the feedpump is
running, its pressure
overcomes the spring to
feed the boiler as
normal.

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REGISTRATION NO. &
MANUFACTURER NAMEPLATE

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BOILER OPERATION

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Make-up Water

Primary Secondary
Pretreatment Pretreatment

Process
Steam Header
Deaerator

Boiler Chemical
Turbine Feed
Systems
Feedwater

Blowdown
WATER TREATMENT PLANT
POLIMER

COAGULANT

SODA ASH TREATED WATER

TANK
STATIC MIXER CLARIFIER

RIVER WATER TANK

CLEAR WATER TANK SAND FILTER

WATER SOFTENER
— To soften the feed
water
— To reduced scale
formation

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WATER SOFTENER
Ca, Mg

Na, Na

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— Resin

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— Ion exchange
process
Calcium
Sodium Magnesium Calcium

Sodium Sodium
Calcium Magnesium
Sodium Sodium

Sodium Calcium
Sodium
Sodium

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DEAERATOR

— To remove O2 & dissolved gasses in

feed water to boiler

— 2 type of deaerator :
# thermal deaerator
# vacuum deaerator

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THERMAL DEAERATOR

— Operation
temperature min
950C

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O2 Solubility in Water
Oxygen - ppm
28
10 P.S.I.
24 5 P.S.I.
0
10" VAC
20

16

12

0
40 60 80 100 120 140 160 180 200 220 240
Temperature, ° F
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Relationship of Temp & O2
Content at Normal Temp

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VACUUM DEAERATOR
— Temp 75 – 800C
— Pressure -15inHg /
-400mmHg

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INTERNAL TREATMENT –
chemicals based
— To prevent scale formation on heating surface
& thereby prevent overheating & distortion.

— Oxygen scavenger - Remove the traces of

dissolve gasses which are the principle of
corrosion.

— To maintain the correct chemical balance in

boiler water.

— Alkalinity adjustment

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 DESIRABLE RESERVES IN
BOILER WATER
TDS 1800 - 2000ppm
Hardness 0 ppm
pH 10- 11.5

Alkalinity (P) 350 -800 ppm

Silica <= 150 ppm
Phosphate 30 -80 ppm
Sulfite 30 – 80 ppm
Iron, Fe < 0.3 ppm

Cycle 10- 15
Chloride <600 ppm

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PRELIMINARY CHECK
– Before Firing
— Check all valves – in close position.
— Check all fans casing, bearings, v-belts,
holding bolts, etc.
— Check water level in gauge glass (level ≈ ½).
Clean glass and guards.
— Visually inspect inside the furnace – the bed
is clean – fire bars & brickworks in order.
— Check blowdown valves are shut.
— Check feed water tank & fill as required
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START-UP
— Open blow down valve (2-3 short burst) until the level to
about ½.

— Feed & spread fibre evenly in furnace & set fire.

— Start up ID fan with damper about ¼ open

— Open the damper fully to allow the furnace to have full

natural draught.

— The fire must spread to all the fuel in the furnace and
normally it takes about 5 to 10 minutes

— Start secondary air fan & and the damper is adjusted to give
a balance draught inside the furnace. More fuel must then be
continuously fed into the furnace.
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START-UP (continue…)
— Once the boiler is at the operating pressure, check the
safety valves – ensure they are working properly no
sticking or jamming of valves. This can easily be
achieved by tapping the fulcrum arm of the valves. Also
check & test the gauge glasses.

— Open the drain valves of soot blowers and flush steam

through them. Once complete, operate the soot blowers
to clean the tubes. The sequence of operating the soot
blowers should be from front of furnace to back. The
boiler is now ready to supply steam to the powerhouse.

— It is always a good practice to open the main stop

valves gently, first by cracking it open, then wait for a
little while before open it fully.
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RUNNING
— Make sure that there is continuous supply of
fuel and water for the boiler.

— Ensure that the water level inside the drum is

always at half gauge glass. Where there is
feed regulator to control the water level, make
sure that it is working properly.

— NEVER ALLOW THE WATER LEVEL TO

DISAPPEAR FROM THE GAUGE GLASS.
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RUNNING (continue…)
— Feed in the fuel as and when necessary so that
the pressure in the boiler is maintained. Do not
over feed the boiler.

— Regulate the fuel to ensure that complete

combustion is achieved inside the furnace and
hence no black smoke is emitted from the
chimney.

— The furnace should be maintained around 0.3”

WG –ve pressure.
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RUNNING (continue…)
— Soot blow the tubes at four hours interval.

— Check and make sure that all the fans are

in good running condition during the
steaming time

— Regular blow-down of water from the boiler

is necessary (TDS 1800 – 2000 ppm)

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STOPPING
— The boiler can only be stopped after the steam turbine has been
stopped.

— About quarter to half an hour before the boiler is stopped, the fuel-
feeding rate must be reduced.

— Shut the main steam stop valve tightly. Stop all the fans.

— Pump in water to the drum till the gauge glass is at least three
quarter full, then shut the feed check valve.

— Rake out all the fire on the fire grate. Only keep some burning ash
on the fire grate. The purpose is to protect the refractory from
having too high a cooling rate. The furnace doors must be shut.

— Close the damper tightly. Keep the lights for the gauge glasses on.

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LOW WATER DRILL
— Low water is when the water level in the
gauge glass is less than quarter and is fast
disappearing (THE LIGHT PANEL GOES TO
RED, INDICATING 2ND LOW AND AUDIBLE
WARNING IS SOUNDED).

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LOW WATER DRILL (cont…)
Immediate action should be taken as follows:
è START UP AUXILLIARY FEED PUMP, RUNNING THE PUMP AT
MAXIMUM OUTPUT UNTIL NORMAL WORKING LEVEL IS
RESTORED.

è INVESTIGATE CAUSE OF LOW WATER AND RECTIFY.

è DO NOT STOP AUXILLIARY PUMP UNTIL MAIN FEED PUMP AND

CONTROLLER ARE OPERATING NORMALLY.

è IN THE UNLIKELY EVENT OF NOT BEING ABLE TO GET WATER INTO

THE BOILER DUE TO A COMBINATION OF CIRCUMSTANCES, THE
BOILER SHOULD BE SHUT DOWN IMMEDIATELY. AN EMERGENCY
SHUTDOWN SHOULD BE CARRIED OUT.

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EMERGENCY SHUTDOWN
— Stop the firing and draw out all the fire from
the furnace.

— Isolate the boiler by closing the main stop

valve. Feed check valve should remain open.

— Stop all Fans.

— Keep all fire doors and dampers fully open and

allow the furnace to cool with natural draught.
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EMERGENCY SHUTDOWN
(cont..)
There are instances when the water level has actually
disappeared from the gauge glass. Under such
circumstances, the following emergency procedure should
be instituted immediately:-

— Stop the feed pump & isolate the check valve at once.
— Draw out all the fire from furnace. Shut the main stop
valve
— Stop all the fans and open the damper fully and allow
the furnace to cool with natural draught.
— Investigate the causes for no water in gauge glass.
— NEVER PUMP IN ANY WATER INTO THE DRUM
DURING THIS TIME

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HIGH WATER ALARM
— Not a dangerous situation
— But it can cause priming, which can lead to
serious damage of turbines and steam
engines.
— Following steps should be taken:
è Slow down or stop the feed water pump.
è Blow down the boiler until the normal water level is indicated in
the gauge glass.

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BURST TUBE DRILL
In the event of tube failure due to local overheating or
mechanical defects, the following actions must be taken
immediately:-

— Stop firing and draw out all the fire from the furnace.
— Continue to run the feed pump at maximum output. If
the water level still cannot be maintained, start the
standby pump
— Isolate the boiler by shutting the main stop valve
— Stop all the fans, and the damper must be opened fully
to create maximum natural draught in the furnace to
cool it down.
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BOILER MAINTENANCE

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PREVENTIVE MAINTENANCE -
WEEKLY
— Clean the boiler furnace & ash pit

— Check all the fans for any abnormality i.e. ID Fan,

FD Fan, Secondary Fan and Fuel Feeder Fan. Clean
the fans impeller from any dust and re-grease all
the bearing.

— Check the ash conveyor shaft, ribbon, liner, hanger

bearing and drive unit. Rectify if necessary.

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PREVENTIVE MAINTENANCE -
WEEKLY (cont…)
— Check the Mobrey Water Alarm System, gauge
glass and blow-down valve for any leakage. Rectify
if necessary.

— Check the pendulum of fuel feeder chute and

rectify if necessary.

— Check the feed water regulating valve for

abnormality. Rectify if necessary

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PREVENTIVE MAINTENANCE –
every 15 month
— Preparation for DOSH inspection.

— Thoroughly clean the boiler internally & externally.

— Dismantle all fittings, man-hole & hand-hole.

— Overhaul all valves & other fittings – clean its

component thoroughly, grind the valve & valve
seat.

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PREVENTIVE MAINTENANCE –
every 15 month (cont…)
— Clean the boiler tube internally & externally.

— Check the tubes for any sagging.

— Clean the steam drum and mud drum internally

from any scale, pitting or corrosion.

— Check all fans for any abnormality. Carry out

balancing if necessary.

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PREVENTIVE MAINTENANCE –
every 15 month (cont…)
— Check furnace bricks and wall for any bulging.
Rectify if necessary.

— Paint the boiler externally. Reprint boiler

registration number & clean the manufacturer
plate.

— Prepare pre-inspection report

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PREVENTIVE MAINTENANCE –
every 15 month (cont…)
— Once inspection done by DOSH’s inspector has
completed, reinstall back all fittings and holes.

— Hydrostatic test - HT
(1.5 x designed pressure)
shall be conducted before
the boiler is putting back
into operation.

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PROBLEM IN BOILER

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 — Scale
— Corrosion
— Deposit
— Carry over

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SCALE
Due to high hardness in feed
water.
As a results:

èHeat transfer process will be

interrupted – less heat absorption

èReduced boiler efficiency.

èCreate overheating at heating

surface.

èTube blockage / burst.

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CORROSION
Due to presence of O2 & CO2

èO2 corrosion.
— Reaction:
◦ Fe -----> Fe2+ + 2e Anode
◦ 2e + 1/2O2 + H2O ---> 2(OH-) Cathode

— Will create pitting corrosion type

èCO2 corrosion
— Reaction:
CO2 + H2O <---> H2CO3
H2CO3 <---> H+ + HCO3- Pitting – O2 corrosion

— Carbonic acid will reduce pH &

corrodes the tubes

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DEPOSIT
Due to:

— high Total Dissolve Solids (TDS)

— Oxidized metal from corroded tubes

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CARRY OVER
Cause/type of carry over:

— Priming
— Foaming
— Misting
— Selective carry over

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CARRY OVER
è Priming
— A large amount of water enters the steam line due to:
# sudden demand of steam
# too high of boiler water level

è Foaming
— Presence of stable small air bubbles on surface of
boiler water due to:
# contamination of dissolved and undissolved
substances in water which cause the stability of
a thin layer of water around the vapor bubbles.

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CARRY OVER
è Misting
— The occurrence of wet layer on the boiler water due to:
# bursting of air bubbles on the surface of the water that
splashed water particles into the steam line.

è Selective Carry Over

— The occurrence of certain substances in the boiler
water i.e silica, vaporized and dissolved in the
steam.
— Occurs at high temperature & pressure where the
substance content exceeds the allowed limit.

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CARRY OVER EFFECT
— Priming
— Foaming WATER HAMMER
— Misting

— Selective Carry Over – DAMAGE THE FINS

OF STEAM TURRBINE
WHEEL

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PROBLEM IN BOILER - OTHERS
— Furnace collapse

— External corrosion due to soot accumulation on

tube nest

— Tube distortion due to water starvation (too

frequent of low water condition)

— Tubes burst - >30% from total nos of tubes,

rectification works to be carried out.

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PROCEDURE FOR TUBES
REPLACEMENT
◦ Submit drawing indicating all the location/position of the tubes to
be replaced and obtain approval from JKKP prior to
commencement of work.

◦ Using bending machine to perform cold bend of boiler tube as per

original design in compliance with BS1113.

◦ Dismantle the boiler casing and necessary brick wall to obtain

access into boiler tube.

◦ Dismantle all the relevant boiler tube.

1. Dye Penetrate Test to be carried out on the front and rear end plate to
ascertain crack free prior to installation of tube.
2. All the tube ends and holes at tube plate are to be clean to ensure
smooth and grease free surface.

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PROCEDURE FOR TUBES
REPLACEMENT – CONT…
◦ Install all the new tubes and expand by a special tool. All
expansion of tubes end into the drum shall comply to BS1113.

◦ After all tube are installed/expanded, hydrostatic test

(1.5xDesigned Pressure) will be carried out to ascertain that no
leak occurred.

◦ An official of hydrostatic test will be performed and witness by the

JKKP Officer.

◦ All brick wall, casing and refractory shall be reconstructed

accordance with its configuration after satisfactory of hydrostatic
test.

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 BOILERMAN &
STEAM ENGINEER
???

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TERIMA KASIH

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