Basic & Intermediate Boiler Training CoursePrincipal Parts of a Boiler Furnace — Energy Conversion Heating Surfaces — Absorption of Heat from the Furnace Steam/Water Separators — Separate Water from Feedwater Supply — Provides the Water as the medium for conversion to steam e Draft Equipment — Fans for supplying air for combi and removal of flue gas e Fuel Supply — Provides the energy source e Control Equipment — Controlling Start, Operation, Shutdown and Safe Tripping of PlantBoiler Mountings © Boiler Mountings are attached devices which perform specific tasks associated estan mato bee Com . e They may include: — Safety Valves and Escape Pipework — Maintain Operating Pressure — Water Level Control Devices — Control Water Levi to Setpoint — Water Level Indication Devices — Provide confirmation of Water Level — Pressure Gauges — Indicate Boiler PressureBoiler Mountings — Boiler Stop Valve — Provide a ri Steam Supply ; — Boiler Vent Valve — Allow for Ventin on Filling and Emptying — Blowdown Valves — Water Quality Cont through Blowdown — Expansion System — To allow safe expansi and contraction of the Boiler — Explosion Doors/Discs — Minimise damage in! the event of explosionTypical Boilers Fire Tube BoilerTypical Boilers Water Tube Boiler Section7 radu El : [i] — steam Riser | Oowneomer y aFeedwater System e A typical Feedwater System a the sted evar eles — Incoming Supply —Town or Raw Water — Water Conditioning Plant —Water Softening Plant or Demineraliser — Feedwater Tank — May include a Preheater — Feedwater Pumps — Feedwater Control Valve and Isolation Valves — Chemical Injection System — Added Chemicals condition the ae — Feedwater Sampling Point — Blowdown Valve/sDraft System e A typical Draft System comprises the following: — Air Intake q — Forced Draft Fan — Supplies Combustion Ai also force flue gases from the Boiler if no Indu Draft Fan — Induced Draft Fan — Maintains a negative pressure the furnace and removes flue gases (May not be fitt to all boilers) — Damper Control to Regulate Air Flow & Isolate Air and Gas SystemsMUS) ReN VSI 00) Oe Gaynerle noms Aon mee nly ekesmt este) oa titea Gas Supply Line with Isolation Valves ‘ Gas Block and Bleed Valves — Ensure Safe isolatio1 OPE MAO Umoe Stel me Bal Pressure Reducing Station — To reduce supply pressure Aone T item CaS cd Pressure Modulating Valve Pressure Monitoring Devices — To ensure Pressure Reducing Teton Ree etre me oe te bean Tees RC Coa (meme (anc Flame Scanner — to monitor the flame and shutdown the boiler ii Voi iaey ie iva ertRS O vel Control System i alin || Fup off \ First low atm | y | 1 sacond tow alarm Protection tubes jTopic Five — Typical Maxitherm Boiler and Associated Equipment e A Typical Boiler and Associated Equipment consists of: — 6MW Maxitherm 2 Drum Watertube Boiler SAV EUrmse oncom Ba Toa Th] 4 — Feedwater Preheater — Feedwater Tank — 2 Boiler Feedwater Pumps — Feedwater Control Valve and Bypass Valve — Chemical Injection Pumps and Tanks — Blowdown Valve and Blowdown Tank — Boiler Main Stop Valve and Steam System to the Factory De MOLES Cny — Forced Draft Air System — PLC and Associated Operator InterfaceMain Gas Isolation Valve Eo aa Pilot Gas Peete Esolation ValveGas Supply a Pt one ~~ ral wit Fal "Burner FrontBurner Front _Softener and C!sxe (oyHeat ExchangerFeed PumpsFeedwater Control ValvePreparation for Start-Up e Work Area Clean and Tidy e All Lighting Serviceable e Town Water Available e Gas Supply Available e Power Available e@ PLC Available @ Operator Interface AvailableAlarms e Alarms are displayed on the Alarm Screen of the Operator Interface Computer e Alarms should first be silenced, the and acknowledged before rectifying see e Once the fault is rectified the alarm shou be clearedBoiler Start-Up 5. Tf water level is low, top up water level Switch the Feedwater Control Swi the Motor Control Centre to FILL Press RESET, the Feed Water Pumps will start and the Boiler will fill.Boiler Start-Up ie Once the water level is over half way on the gauge glass, turn the switch 01 left from Fill to AUTO. Switch the Burner On/Off switch on far right to ON. The Forced Draft Fan will start and the Purge Cycle will commence.Boiler Start-Up 10. Once the Purge is complete the Burner . Shut the Vent Valve on the Steam D: will now start up automatically and,hold at Low Fire until the pressure rea ea on top of the boilerBoiler Start-Up Ds . Walk and Check the Steam Supply When pressure reaches 400 kPa a the Boiler Main Steam Stop Valve (V very slowly) Open the Auto Blowdown Valve. Pipework and ensure it is draining correctly via the various Steam Traps an sDye-statsyBoiler Operational Checks e Boiler checks should be BBLS g eons Company Policy e Boiler / Water Treatment / oot yt DEA el lee.e e A general inspection of the Boiler and Steam Supply Piping and Valving in the Plant is also recommendedBoiler Shutdown 1. Ensure Burner is on low fire. If not, Shut Main Steam Stop Valve. 2. Switch Burner On/Off Switch to 3. The boiler will then shutdown.Boiler Shutdown ce Shut the Boiler Main and ey Gas Inlet Isolation Valves j Shut the Auto Blowdown Valve Check that water level is over 1/2 w steam drum, if not switch the FILL / OFF / AUTO switch to FILL, connec we eas Ten MU eiev amBoiler Shutdown 7. When water level is 2 way Salo FILL / OFF / AUTO Switch to s. Shut Feedwater Isolation Valve.Emergency Shutdown e What is an Emergency Shutdown? SP OM neem NTC NAIR Cee LTE! e There is a major system failure and the B Pot ita Be Rome mei srol(e OTe ileken erin eo CosetieH — A large leak in the Feedwater System — A large leak in a Steam Line SUN meL TeleEmergency Shutdown e How is an Emergency Shutdown performed? q fo a ae a ale Switch the Burner On/Off Switch to Shut the Boiler Main Gas Inlet Valve Shut the Boiler Main Steam Stop Valve Shut the Boiler Blowdown Valve Secure the area around the leak as required Log the event and monitor the BoilerWhere to Get More Information e NOHSC — NOHSC 1006 (2001) CPI TOMNIETerTeely Sera SLUR C VEC HENLE BICC Tew (Olmak Equipment Operation and Maintenance — AS 2593 Australian Standard for Unattende Boilers