Operating and Maintenance Manual JDW Dm12227 Boiler

DESCON ENGINEERING LIMITED
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Title : OPERATING AND MAINTENANCE MANUAL
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Client : United Sugar Mills Limited

Project Title : DDW-SH-140066
Project Number : DM.12227
Document Number : DM.12227-000-B91-800
Revision : 00
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02-12-13 00 First issue MZI KA FB

Date Rev Description of revision Prepared By Checked By Approved By
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DM.12227-000-B91-800 Operating and Maintenance Manual Page 1 of 1

OPERATING & MAINTENANCE MANUAL
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Project No : DM.12227
Designer : Descon Engineering Limited
Manufacturer : Descon Engineering Limited
Document No. : DM.12227-000-B91-810
Date : 02 Dec 2013
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Descon Engineering Limited
Lahore Manufacturing Business Area
2Km Defence Road off, 24th Km
Multan Road, Chung Lahore, Pakistan.
Telephone +92-42-7540361-6
http://www.descon.com
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Introduction Descon
Engineering Limited
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Revision : 00
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DM.12227-000-B91-820 Introduction Descon Engineering Limited Page 1 of 5

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TABLE OF CONTENTS
1. Introduction …………………………………………………………. 3
1.1 General Instructions ………………………………………………… 3

1.2 Technical service ……………………………………………………. 3
1.3 Correspondence Address ………………………………………….. 4
1.4 Office Address ……………………………………………………….. 5
1.5 Design Approval ……………………………………………………… 5
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1. INTRODUCTION
1.1 General Instructions
The Instruction Manual describes the operation and maintenance of the

DESCON Boiler. The Instruction Manual is not so complete that it describes all
possible operations of the Boiler Plant. The Instruction Manual cannot replace
the absolutely necessary education of the operating personnel. Descon does
not undertake any responsibility for damage arisen due to an operation, which
is not laid down in the Manual or due to a faulty operation of the plant in which
the operation has taken place because the Instruction Manual does not contain
instructions. DESCON reserves the right to revise the Manual if new
experiences make it necessary. The buyer is asked to inform DESCON about
important new operational results experienced by him so that the Instruction
Manual is extended.
Note:- It is not allowed to disconnect or in any other way, fully or partially, put
the safety devices out of function.
1.2 Technical Service
The equipment you have purchased from DESCON has been custom designed
to your requirements and is capable of delivering superior performance and
reliability when properly used and maintained. To this end, it is in general
advisable that a DESCON Technical Service Engineer is available to start-up,
adjust and maintain your equipment to ensure optimum performance.
Should problems arise with your DESCON, we urge you to utilize our service
consultation staff available to help you by telephone without charge. Many
problems can be solved in this manner saving both downtime and expense.
If you do call for consultation, please have available:
1. All DESCON prints, electrical and/or mechanical, that relates to your
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problem. All necessary prints are included in each instruction book.
Familiarize yourself with these prints before calling.
2. A brief written description of the problem, along with related indications
that you can refer to.
3. DESCON numbers of your equipment. These are shown on all prints in
the manuals.
4. A purchase orders number in the event that parts or a service engineer is
required.
5. A shipping address, preferably for air freight service.
6. A telephone no, where we can readily contact you if we have to call back.
Consultation service and all requests for a service engineer can be made by
asking for DESCON Technical Service Department.
Office hours are 09.00 a.m. to 18.00 p.m. (local time), Monday to Friday,
except national holidays.
To facilitate scheduling of our Service Engineers, we require a minimum of two

(2) weeks advance Notice. In emergency cases, we will do our best to get a
man to your plant as soon as possible
1.3 Correspondence Address
Technical Service Section- Operations Boilers Department

Multan Road, Chung, Lahore, Pakistan
Telephone : +92 - (0)42 35966680-6 ext 252
Fax : +92 - (0)42 35966687-8
E-mail : boilerservices@descon.com
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1.4 Office Address

Multan Road, Chung
Lahore, Pakistan
1.5 Design Approval
Before a new boiler installation is permitted to be commissioned, it shall be

subjected to inspection by the supervising or approval authority.
Since inspections have been made during designing and constructing, these
will be limited to the welding work done on site, the hydrostatic test and the
correct functioning of accessories and auxiliary equipment.
The requirements of the approval authority with respect to the preparation are
to be met & co-operation is to be given to facilitate tests.
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Introduction to Direct Fired

Boiler
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Revision : 00
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DM.12227-000-B91-830 Introduction to Direct Fired Boiler Page 1 of 20

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TABLE OF CONTENTS
1. Introduction direct fired boiler……………………………………………………... 3
2. Boiler components………………………………………………………….……….. 3
3. Process description of the direct fired boiler…………………..………………. 6
3.1 General description……………………………………………..…………………..... 6

3.2 Combustion air flow path…………………………………………………………….. 7
3.3 Exhaust gas flow path...………………………………………..…………………..... 8
3.4 Water / steam flow path ………………………………………..…………………..... 9
4 Construction of the direct fired boiler………………………………….............. 11
4.1 General …………….……………………………………………..…………………..... 11

4.2 The water cooled firing room ……….…………………………..…………………..... 11
4.3 Super heater section……………………………….………………………………….. 12
4.4 Evaporator flags………………………………………………………………………... 12
4.5 Economizer section………….………………………………………………..……….. 13
4.6 The steam drum ……………………………………………………………………….. 13
4.7 The boiler pipe frame............................................................................................ 14
4.8 Flue Gas Air preheater………………………………………………………………… 16
4.9 Steam air preheater……………………………………………………………………. 17
4.10 Fly Ash Arrestor………………………………………………………………………… 18
4.11 Deaerator……………………………………………………………………………….. 18
4.12 Accessibility ……………………………………………………………………………. 19
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1. INTRODUCTION DIRECT FIRED BOILER
The Descon Direct Fired Boiler is designed to transfer heat from flue gasses to feed
water in order to produce desired flow of superheated steam.
Boiler is fed with Bagasse (fuel) through seven front Bagasse feeders.
The boiler capacity is 140 TPH at maximum steam pressure of 66 bar (g) and
temperature of 485 °C.
The boiler is a natural circulation boiler with proven performance in several applications.
Experience, which was collected in these applications, has been adapted into the
present design.
2. BOILER COMPONENTS
The boiler is equipped with the following main sections / parts:
- Boiler parts comprises of:
• Water cooled membrane Wall furnace

• Super heaters Section
• Evaporators Flags
• Steam drum
• Flue gas/Air preheating section
• Economizer section
• Steam air preheater
• All required internal interconnecting piping, including main steam line up to
main steam stop valve
- Deaerator system for Boiler comprises of
• Deaerator storage vessel
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• Dome arrangement for deaeration/oxygen removal
• Internal steam sparger pipe
• All required interconnecting piping
- Three(3) BFW pumps (3X50% with VFD) & with electric motor driven and equipped with
recirculation valve of adequate quantity)
- Steam air preheater for preheating air to approx 100 C. Including vessel for condensate
storage.
- Bagasse firing system for boiler comprises of:

• Conveyors (client scope) for conveying Bagasse to the seven Bagasse
silos.
• Bagasse silos, vertically installed above each drum feeder for ensuring a
storage time of approx 2,5 minutes for full load operation in case of
disturbance in Bagasse supply.
• Seven Bagasse feeders comprising of one drum feeder for controlling the
fuel flow and one screw feeder for transporting the bagasse from outlet
feeder into the chute. Only the drum feeder is provided with VSD motor.
• Chutes for conveying Baggase from Bagasse feeder to inlet of Air
Spreader
• Spreader system comprising of two spreader fans (one standby/both
electric driven) , seven rotary air valves electric motor driven (one
operating and one as standby) from a common shaft and one static
spreader per feeding system to spread the fuel equalized over the grate
for efficient fuel combustion.
• One dumping grate, divided in 7 separate sections (one for each feeder).
Each section is splitted in 2 parts, each part operated through its own
pneumatic cylinder/actuator. Each dumping grate section is provided with
its own air supply through its own hopper installed underneath the
dumping grate section. The air to each section can be blocked by its own
air damper (pneumatic operated) installed at the air inlet of the hopper.
• One over firing system. Air nozzles are installed at a pitch of 180 mm in the
front and rear walls of furnace. On 3 levels in the front wall and at 4 levels
in the rear wall. The air is supplied through a separate air box for each
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level. At the inlet of each air box a manual trim damper is installed for
controlling the air supply
− Combustion air/flue gas system for boiler comprising of:
• Two primary forced draught (PFD) fans for feeding the primary air to
the grate and the secondary/over firing air to the secondary air fans.
Each air fan provided with Variable speed electric drive. The air
suction from an common air inlet duct which is vertically installed and
provided with venturi for air flow measurement and raincap with bird
screen Two Secondary forced draught (SFD) fans with Variable speed
electric drive for feeding the air at higher pressure to the over firing
system.
• Two ID fan for all seven Bagasse feeding systems with Variable speed
electric drive to control the furnace outlet pressure.
− Soot blower system for cleaning all heating surfaces, including pressure
regulator and drain system and control system for fully automatic operation.
− Air and flue gas ducting/casing for boiler. All ducting provided with metallic
expansion bellows for absorbing the expansions of the ducting. The secondary
air duct supplying the air from the flue gas/air preheater to the over firing system
is provided with a venturi for air flow measurement. The primary air section of the
flue gas air preheater is provided with a small air bypass duct with pneumatic
operated air damper for controlling the primary air temperature towards the
dumping grate.
- Fly ash arrestor of the multiple cyclone type is installed directly under the
economizer outlet
- Dry Ash collecting system, comprising of hoppers with air rotary valves
- Dry ash collecting system is installed at outlet of each hopper underneath each
grate section. At hopper outlet a slide gate valve and at its outlet chute a sliding
plate is installed.
- Stairs, ladders and platforms (including support structure)
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- Main stack including platforms, insulation, emission sample ports and anti vibration
belongings.
- Chemical dosing system including pumps, vessel, electric mixer etc.
- Steam/water sampling system comprising of Six (6) sample coolers.
- Local instrumentation comprising of instrument block valves, flow measuring

devices, thermo-wells, transmitters, switches, pressure and temperature gauges,
level glasses etc.
- Valves and fittings, including control valves, safety valves, start-up blow off valves,
blow down- valves , check valves and main steam stop valves
- Insulation for all hot components
- Refractory in furnace front wall to accommodate the spreader system and at small
areas around inspection doors, peephole and headers. Further refractory is installed
in each hopper underneath the grate.
3. PROCESS DESCRIPTION OF THE DIRECT FIRED BOILER
3.1 General description
The Descon direct fired boiler is specifically designed for Biomass fuel Bagasse
abundantly available in sugar industries.
Direct-fired boilers can be operated on a wide range of fuels, and have found their
application in the chemical, Petro-chemical, paper and food industry functioning either
as a primary steam generator or operating as a back-up unit.
The boiler can be operated efficiently from approx. 42 TPH (Min stable Load) up to
140 TPH. The base fuel of the boiler is Bagasse; the combustion of fuel takes place in
a water-cooled combustion room.
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The process is completed with all necessary equipment to ensure a safe and reliable
operation of the plant, under the demand that the boiler will only be tripped as ultimate
measure at the most extreme conditions.
3.2. Combustion Air flow path
For schematic view refer to the Combustion Air path of the boiler shown in P&IDs.
Combustion air is supplied by two FD-fans (PFDF-01 & PFDF-02) and being lead to
the Steam Air pre-heater (SAH-02) where heat is provided to the combustion air from
the low pressure steam provided by client. Before entering the steam air preheater the
air is splitted in 2 streams, primary and secondary/over firing air.
The primary air flows first through the lower section of the steam air preheater where it
is heated till approx 100 C and then through the lower section of the flue gas/air
preheater where it is heated till approx 200 C by the flue gases coming from the boiler/
Economizer 03 section. In case the air temperature rises above 200 C the air will be
partly bypassed over those air preheater sections and mixed with the heated air. The
heated air will be finally fed through a duct to each dumping grate section.. The air
supply to each section can be blocked by a pneumatic actuated air damper installed at
the inlet of each hopper under the grate. The secondary/over firing air is fed to the
secondary Air fans (SAF-01 & SAF-02). The secondary/over firing air at outlet of
secondary air fans (SAF-01 & SAF-02) is fed to the upper section of the Steam air
heater (SAH-01) and heated till approx 100 C, and then heated in the upper section of
the Flue gas air preheater (APH-01), by the flue gases leaving the lower section of the
flue gas air preheater. From there the secondary/over firing air is fed into the furnace
through the over firing Nozzles installed above the grate in the furnace front and rear
wall.
The firing of fuel (Bagasse) with combustion air takes place in a water-cooled furnace.
Any unfired Baggase components which settles down in the furnace grating area are
removed by operation of the dumping grates as per requirement.
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3.3. Exhaust gas flow path
For schematic view refer to the Flue Gas path of the boiler shown in P&IDs.
In the furnace the fuel is spread equally over the dumping grate by the seven fuel
spreaders. To equalize the fuel over the depth of the furnace the spreader air
amount is changed by the help of a rotary air valve installed at spreader air inlet of
each fuel spreader. To improve the combustion the flue gasses are mixed above
the grate with the secondary/over firing air through air injection nozzles. Those
nozzles are installed at 4 different levels in the furnace rear wall and at 3 different
levels in the furnace front wall. The air supply to each level can be set by an air
trim damper. The furnace is sized such that the combustion will take place before
the flue gasses are leaving the furnace in the top. From the outlet the flue gases
enters in the second pass and flow downwards through the heating surfaces of the
boiler. First the flue gasses passes through the secondary and primary super
heaters (SH-01,SH-02) then convection bank and enter ECO-3. At bottom of boiler
the flue gasses are leaving the boiler and flow upwards through the Flue gas Air
Preheater (APH-01) and economizer (ECO-02). At the top it turns and flows again
downwards through the economizer 1 (ECO-01) and into the fly ash arrestor for
removal of the fly ash in the flue gases. At the bottom of each vertical pass hoppers
are provided for accumulation of the fly ash particles Boiler is equipped with soot
blowers series starting from superheater to the economizer section to remove the
soot accumulated on the heating surfaces during operation.
Two Induced draught fans (IDF-01 & IDF-02) are dedicated to control the furnace
outlet pressure and to pass the flue gases into the stack (ST-01) section. Finally
the flue gasses are led to the atmosphere via stack (ST-01).
During operation primary, secondary and ID fans should be in operation. In case of

a trip the second fan remain in operation while the inlet or outlet damper will be
closed automatically in order to prevent back flow over this tripped fan.
IN CASE OF A TRIP OF A PRIMARY AIR OR ID FAN THE CAPACITY OF THE
BOILER WILL BE REDUCED AUTOMATICALLY TO 55% LOAD. IN CASE OF A
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TRIP OF THE SECONDARY FAN THE UNIT CAN RUN FURTHER AT 100 %
LOAD.
3.4. Water/Steam flow path
For schematic view refer to the Water / Steam flow path of the boiler shown in P&IDs.
Makeup water along with condensate enters into dome of sieve tray type deaerator
where oxygen is removed from water by deaeration using steam supplied from client
steam distribution header. The Boiler feed water then enters the inlet header of
economizer-01, 02 & 03 respectively. In the economizer section the BFW is heated up
to a certain approach temperature before it enters the steam drum.
The natural circulation system of the boiler will take care for evaporation of the water in
the evaporator sections of the boiler for producing the required steam amount.
In the boiler drum a steam purification system is installed consisting of baffles and
demister. The arrangement is such which ensures absolutely dry steam to the super
heater even during change in boiler loads. The steam leaves the steam drum
through several pipes installed over the length of the steam drum in order to
guarantee an equal distribution of steam over the demister and the superheater
tubes. The superheater is splitted in 2 sections the primary and secondary section.
The steam enters the primary superheater first and flows in cross counter flow
through the superheater tubes and is collected in the outlet header. From there it
flows through a desuperheater line in which the steam will be desuperheated by
injecting BFW into the steam up to the required steam temperature of 485 C at outlet
of boiler. At the outlet of the desuperheater piping the steam is distributed over the
inlet header of the secondary superheater where the steam flows in cross parallel
flow through its tubes into its outlet header. From here the steam flows into the
steam outlet line of the boiler.
Further for removal of unwanted particles there are further two arrangements available
first one is the continuous blow down, that is taken from the steam drum & the
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intermittent blow down that is taken from the right hand side header & left hand side
header and the lower header of the suspension tubes.
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4. CONSTRUCTION OF THE BOILER AND OTHER MAIN PARTS
4.1 General
For details refer to Descon’s general arrangement drawings of the pressure parts.
The direct fired boiler is of corner tube type.
This is a water tube boiler of the single drum type which has a pre-separation system
of the water and steam mixture in its risers before entering the steam drum.
The water separated in those risers will be led by multiple downcommers installed at
each boiler wall to the lower distribution headers. This guarantees an even distribution
of the water over all heating surfaces.
Due to those downcommers the boiler can be bottom supported and expand freely
upwards.
Further this system reduces the size of the steam drum as the water and steam
mixture has already a certain pre-separation.
The boiler is totally of an integrally welded construction.
4.2 The water cooled firing room
The combustion process takes place in the furnace, which is constructed out of water
cooled membrane walls, with exception of the bottom front wall section just above the
grate. This section is refractory lined and the outside casing is not insulated in order to
guarantee expansion free connections of bagasse spreaders and chutes.
All walls are fully welded resulting in a completely gas tight enclosure.
The dimensioning of the firing room and the mixing of air with flue gasses through the
over firing nozzles ensures a complete combustion of the fuel and a homogeneous
temperature-profile of the flue gas when it enters into the heating surfaces.
The water-cooled firing room is completely drainable.

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Peepholes are fitted at the side and front wall of the furnace in order to facilitate
observation of the combustion. Several access doors (manholes) provide the
possibility to enter boiler for inspection purposes
4.3. Super heater section
When leaving the furnace (radiant part of the boiler) the flue gasses are led to the
superheater section, which is located, In the top of the 2nd pass. Superheater section
comprise of primary and secondary super heater. Both consist of plain tubes, arranged
in-line. The tubes are horizontally installed and supported by a suspension screen and
in the boiler rear wall. By placing the superheater behind the furnace rear wall the
superheater tubes are protected against the direct flame radiation. The primary
superheater is arranged in counter flow and the secondary superheater in parallel flow
in order to keep the metal temperatures low.
The superheater headers are installed outside the boiler casing. The tubes are welded
to pipe pieces, welded into the casing to make the casing gastight. The casing is
protected by installing between the boiler rear wall tubes and the casing a layer of
refractory and ceramic wool. In order to take care between the expansions of the
superheater outlet header and casing of boiler rear wall the headers are welded to the
drum downcommers at sufficient distance from the casing.
The superheaters are fully drainable and provided with 2 retractable soot blowers for
cleaning the heating surfaces during operation.
4.4 Evaporator flags
The evaporator is of the flag type, arranged horizontally in-line. The flags consist of 4
parallel streams at water side and are connected to the boiler rear wall. The water to the
flag tubes is fed and the steam is released to the steam drum by the tubes of this boiler
rear wall.
The flags are supported by those boiler rear wall tubes and at the other side by the
furnace rear wall tubes.
The heating surfaces are cleaned by 4 rotary soot blowers during operation.
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4.5 Economizer section
The Economizer is splitted in 2 sections as explained before. The Economizer consists

of plain tubes, arranged in-line and counter flow.
The economiser 1 is installed in uncooled carbon steel casing in the low temperature
zone downstream the flue gas air preheater. The economiser 2 is installed inside the
boiler membrane wall casing as its flue gas temperatures are too high. This economiser
2 is supported by a separate steel structure installed on the bottom distributors of the
pipe frame where it can slide freely.
The economiser coils are all supported with expansion provisions by bended strip on
beams installed inside the casing in the flue gas stream.
The headers are arranged inside the casing in the flue gas flow to guarantee maximum
flexibility and are supported/guided by the casing
The positioning of the Economizer provides easy access for inspection, cleaning,
replacement and repair. The Economizer headers comprises of drain & vent nozzles
and inspection nipples.
The economisers are fully drainable and provided with 4 rotary soot blowers in
economiser-03 & 3 rotary soot blowers for Economizer-02 with the economiser1 is
provided with 4 semi-retractable soot blowers during operation in order to increase it
cleaning efficiency as these are the last heating surfaces of the boiler.
4.6 The steam drum
The steam drum is dimensioned according to the rules as standard applied by Descon
for direct fired boilers and the mechanical design is done in accordance to the
applicable boiler code.
The drum is a part of the tube frame construction and the BFW coming from the
economizer is sparged along the length of the drum below the normal water level.
The design of the drum provides a good hold-up time between Level Low Alarm (LAL)
and Level Alarm Low Low Trip (LALL) at maximum steam production and no boiler feed
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water being supplied to the drum.
The separation of the water/steam mixture takes place in the steam drum by means of
a baffle plate arrangement in combination with a final purification unit i.e. demister pad.
The demister pad is built up of 2 layers of fine stainless steel mesh of different density.
The baffles, demister and the multiple steam outlet nozzles are installed over the entire
length of the steam drum in order to guarantee an even distribution over all those parts.
This design of the drum guarantees more than adequate degrees of steam purification.
These design requirements guarantee a safe and a reliable boiler operation.
4.7 The boiler pipe frame
The boiler is fully bottom supported through its pipe frame which is part of the boiler
evaporator system. This means that the boiler is expanding freely upwards and sliding
freely from one fixed point in all direction over the boiler steel structure.
The pipe frame is shown in below sketch.
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Downcom
mers
suspension
tubes
Evaporator
flags
The blue arrow shows the water flow from the steam drum and riser system through the
downcommers to the lower water distribution headers which supply the water to the
heating surfaces (membrane wall tubes and flags). The suspension tubes for supporting
the superheater tubes are fed by 2 independent downcommers directly from the steam
drum in order to avoid any unbalance due to their low water requirement.
The dotted red lines show the heating surfaces of the evaporator system.
The water/steam mixtures are collected in the riser collector headers as shown in below
sketch. In those collectors the steam water mixture is pre-separated before entering the
steam drum.
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80% steam/ 20% water flowing in top of steam drum
Water steam mixture from

heating surfaces
Water trough downcommers to heating surfaces
The bottom distributors also serve as "mud drum". Intermittent blow down lines are
connected to these headers. The intermittent blow down should be opened once every
eight hours for approx. 10 seconds, in order to remove any sludge that may have been
collected in the bottom distribution headers.
The lower longitudinal distributors are equipped with flanges in order to facilitate
waterside inspection / cleaning.
The boiler water quality is maintained by the continuous blowdown, which is taken from
the drum. When the boiler feed water quality is maintained as prescribed, the
continuous blowdown can be restricted to a minimum.
In order to heat the boiler drum evenly and to prevent excessive thermal stress and the
consequent damage from it, it is recommended not to exceed a boiler water
temperature increase rate as mentioned in the startup procedure (usually 1°C/min).
4.8 Flue gas air preheater
The flue gas airpreheater is installed directly at boiler outlet.

The flue gasses are passing vertically around the tubes, which are arranged horizontally
and in line. The air is passing through the tubes in one pass. The air side is splitted in 2
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parts. The lower part of the tubes is fed with the grate air. The upper part with over firing
air, the tubes are expanded into tube sheets. The tube sheet at the inlet is welded into
the casing. The one at outlet is sliding and provided with a seal of ceramic rope. The
sealing arrangement is such that air cannot leak into the flue gas side, however only into
the atmosphere.
The air is heated to approx 100 C in a steam airpreheater before entering the flue gas
airpreheater. Due to this high air temperature the tube wall temperature of the tubes is
always above dew point temperatures, which prevent the carbon steel tubes from
corrosion.
The flue gas air preheater is provided with 3 rotary soot blowers for cleaning the heating
surfaces during operation.
4.9 Steam air preheater
The steam air preheater is installed at air inlet of the flue gas airpreheater. The air is
heated by LP steam supplied from the process (client scope).
The steam airpreheater consist of finned tubes which are installed horizontally and
staggered arranged. The finned tubes have aluminium L shape fins. The finned tubes
are welded in-between tube sheets. The LP steam is fed into the tubes from a steam
distribution box welded to the tube sheet and flows in one pass through the tubes (all
tubes in parallel arrangement). The condensate is collected in a condensate collector
box welded to the tube sheet at outlet side. From there the condensate flows into a
condensate vessel which is installed directly under the steam air preheater. The
condensate vessel collect the condensate and prevent due to its size that condensate
cannot be collected in the air preheater tubes.
The condensate level is controlled by a condensate control valve installed at
condensate vessel outlet which feed the condensate by condensate pumps into the
condensate tanks
The steam airpreheater is same as for the flue gas airpreheater splitted in 2 parts. The
lower part for the grate air and the upper part for the over firing air. Also from
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steam/condensate side the air preheater is splitted and provided with individual inlet and
outlet valves.
At Air outlet side the air preheater is connected with the inlet of the flue gas air
preheater. To absorb the expansions between those 2 parts a double seal of ceramic
rope is installed. The sealing arrangement is such that air cannot leak into the flue gas
side, however only into the atmosphere.
4.10 Fly ash arrestor
Approx 80% of the ash will flow with the flue gasses as fly ash through the heating
surfaces and will be for approx 90% caught in a fly ash arrestor of the multi cyclone
type.
The cyclones are all installed in one horizontal plane. The flue gasses flow from the
economizer directly downwards into the cyclones. The flue gasses entering the
cyclones from the top and are forced into a swirl by the cast iron swirler installed at its
inlet. By the swirl the fly ash is forced by the centrifugal force to collect against the outer
wall of the cyclone and fall down into the hopper installed underneath the cyclones. The
clean flue gasses are turning at the lower side of the cyclone and flow upwards through
the inner tube of the cyclones. The flue gasses are collected in multiple boxes in the flue
gas inlet section and are connected with the flue gas outlet of the of the fly ash arrestor.
The condition of each cyclone can be checked from the flue gas inlet side.
4.11 Deaerator
The deaerator is of the tray type. The trays are all installed in several levels in a dome
installed vertically on top of the storage vessel.
The condensate and demin water are mixed at the outlet of flash vessel FV-02 in the
and from there combined fed towards the deaerator.
At the inlet of the dome the water is evenly distributed over the top tray. From there the
water flows with low velocity over the perforated plate and falls at the end in the
downcommer which connects the upper tray with its lower tray. In the same way the
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water flows over the other trays and into the downcommers till it flows into the storage
vessel through pipes under the water surface in the storage vessel.
The steam for heating and deaerating the water is fed into the storage vessel through a
steam distribution header which consists of multiple sparger pipes. The multiple
spargers guarantee that steam is distributed in the bottom side evenly over the entire
length of the storage vessel. This ensures removal of the remaining dissolved gasses
from the water deaerated in the tray type deaerator.
The steam distribution header is provided with a pressure equalisation line at its inlet in
order to avoid any back flow of water through the distribution pipe/spargers into the LP
steam line.
The steam leaves the water surface and flows into the bottom opening of the tray type
deaerator. There the steam flows in counter flow upwards through each tray and
gradually heat up and deaerate the water.
The removed gasses are collected in the top of the deaerator and are vented with some
steam into the atmosphere through a vent line installed at top of the dome. The flow is
fixed by an orifice.
The trays are all of stainless steel and bolted to strips welded to the dome outer shell.
The rest is all of carbon steel. The dome and storage vessel are externally insulated.
The dome is and vessel are accessible through a man way.
4.12 Accessibility
Routine inspection, maintenance and conservation can be carried out via platforms &
stairways. Even though repairs or replacement of tubes will probably not be required,
module sections can be repaired and/or partly replaced within reasonable time.
All the air and flue gas ducting are provided with stainless steel expansion joint in
order to absorb the expansions of all boiler parts.
Several access doors (manholes) at all levels are provided for entrance to all
sections/parts for inspection purposes.
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All heating surfaces are completely drainable. The boiler can therefore be chemically
cleaned on both water and steam side when water conditions are out of control and
excessive scale has formed.
Chemical cleaning of the boiler is a highly specialized process and should be carried
out by specialized firms only and after consulting the boiler manufacturer first steam
side when water conditions are out of control and excessive scale has formed.
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Technical Data Boiler
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Revision : 00
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DM.12227-000-B91-840 Technical Data Boiler Page 1 of 6

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TABLE OF CONTENTS
1. Technical data boiler ………………………………………………..………………. 3
2. Mechanical data pressure parts ……………………..……………………….... 5
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1. TECHNICAL DATA BOILER
Boiler-section
Nominal main steam pressure : 66 Bar(g)

Nominal main steam output : 140 t/h
Peak steam output for 3 hrs per 24 hrs : 154 t/h
Main steam temperature : 485 °C
BFW temp. normal : 105 °C
Heating surface boiler
Furnace EPRS Area : 557 m2

Evaporators : 973 m2
Superheater ( 1st stage) : 690 m2
Superheater ( 2nd stage) : 276 m2
Economizer 3 : 309 m2
Air Preheater (Grate air section) : 719 m2
Air Preheater (OFA air section) : 540 m2
Steam Air Heater (Grate air section) : 1907 m2
Steam Air Heater (OFA air section) : 1090 m2
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Boiler volume water/steam side (approx)
Boiler fully filled (excl. economizer) : 96 m3

Boiler filled up to NWL (excl. economizer : 85,7 m3
Water content in economizers : 20 m3
Design data
Design code boiler : ASME SEC l Edition 2010

Design pressure main steam line : 76 Bar(g)
Design pressure super heaters : 76 Bar(g)
Design pressure economizer 1 : 84 Bar(g)
Boiler volume flue gas side (Approximately)
- Boiler section including pre-heater, 2100 m3

-Economizer and inlet outlet duct
- Main stack 187 m3
2. Mechanical data pressure parts
Description : Suspension Super heater Super heater

Tubes 01 02 01
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Rows deep : 1 8 20 -
Pitch (mm x mm) : 100 x 200 114 x100 114x100
No. Of tubes 50 800 2000
Tube diameter : 50.8 38.1 38.1 mm
Tube wall thickness : 4.5 4.5 3.5/ 4.5 mm
Tube material : A192 T22 T11/ T22 -
Fin type : - - - -
No of fins : - - - m-1
Fin diameter : - - - mm
Fin thickness : - - - mm
Fin material : - - - -
Finned /bare length : 3000 3000 3000 mm
Header diameter : - 219 219 mm
Header material : - A -335 Gr.P22 A -335 -
Gr.P22/ P11
Description : Eco-02 Evaporators Steam Air

preheater
(Grate/OFA)
Type
Rows deep : 16 24 28/16
Pitch (T mm x L mm) : 85 x 65 110 x 100 85/74
No. of tubes 928 2424 504/ 288
Tube wall thickness : 3.2 3.5 2.6 mm
Tube material : SA -192 SA -192 A-178A -
Fin type : - - Solid -
No of fins per meter : - - 250 m-1
Fin height : - - 12.7 mm
Fin thickness : - - 0.4 mm
Fin material : - - Al-1060 -
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Inlet Header diameter : 168.3 - - mm
Inlet Header wall : 14.5 - - mm
thickness : A 106 B - -
Description : Air preheater Eco-03 Eco-01
Rows deep : 16+12 10 66

Pitch (mm x mm) t & l : 165 x 120 120 x 100 85 x 65
No. Of tubes 644 230 3828
Tube wall thickness : 2.5 3.5 3.2 mm
Tube material : A -178 SA -192 SA -192
Fin type : - - - -
No of fins : - - - m-1
Fin Height : - - - mm
Fin thickness : - - - mm
Fin material : - - - -
Header diameter : - 168.3 mm

Header wall thickness : - 14.5 mm
Outlet Header material : - A 106 B A 106 B -
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Operating Data Boiler
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Revision : 00
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DM.12227-000-B91-850 Operating Data Boiler Page 1 of 9
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TABLE OF CONTENTS
1. OPERATING REFERENCE DATA BOILER …………………….. 3
1.1 Environmental conditions ……………………………………………. 3

1.2 Bagasse data …………………..……………………………………… 3
2. OPERATING DATA BOILER ………………………………………… 4
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1. OPERATING REFERENCE DATA BOILER
Calculations are based on normal operating and reference conditions as follows:
1.1 Environmental conditions
The boiler will be located indoor, average conditions:
Ambient temperature : 4-45 °C

Ambient pressure : 1.014 Bara
Relative humidity 20-95 %
1.2 Bagasse data
Bagasse Analysis (% Dry Basis)

:
C : 47.0 %
H : 6.5 %
S : 0.03 %
O (by Diff) : 44.0 %
N : 0.00 %
Moisture : 52.0 %
Ash : 2.5 %
Cl : 0.01 %
LHV : 1764 Kcal/Kg
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2.0 Operating data boiler fired with Bagasse
100% MCR
Load Case
Fuel data :
Bagasse flow 62.68 t/hr
Flue gas composition:
N2 56.60 Vol%
O2 3.50 Vol%
CO2 11.38 Vol%
H2O 27.84 Vol%
Ar 0.66 Vol%
SO2 0.01 Vol%
Main steam data :
Main steam production 140 TPH
Main steam pressure(At stop valve) 66 Barg
Main steam temperature 485 °C
Flue gas side:
-flue gas pressure in furnace -1 mbar

-flue gas flow 227060 Nm3/hr
-at inlet of super heater 02 872 °C

-at inlet of Boiler bank 583 °C
-at inlet of ECO-03 429 °C
-at inlet of Air preheater 384 °C
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-at outlet of ECO-01 143 °C
Water/steam side:
-water pressure intlet ECO-01 80 Barg

-pressure in steam drum 70,6 Barg
-steam pressure at boiler outlet 66 Barg
-at inlet of Economizer 01 105 °C
-at Outlet of Economizer 01 176 °C
Air data :
Ambient air flow 168338 Nm3/h

Ambient air temperature for performance 30 °C
Air temperature before firing 200 °C
Load Case OFF

season
Fuel data :
Fuel flow rate 45.5 T/hr
Flue gas composition:
N2 57.15 Vol%
O2 3.97 Vol%
CO2 11.07 Vol%
H2O 27.84 Vol%
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Ar 0.67 Vol%
SO2 0.01 Vol%
Main steam data :
Main steam production 101.8 TPH
Main steam pressure 66 Barg
Flue gas side:
-Flue gas pressure in furnace -1 mbar

-Flue gas flow 168595 Nm3/hr

Water/steam temperature:
-water pressure outlet BFW pump 81 Barg

-Pressure in steam drum 68.5 Barg
-Steam pressure at boiler outlet 66 Bar
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Air Data:
Ambient Air flow 117738 Nm3/hr
30
Ambient Air temperature °C
200
Air temperature before firing °C
43-86
Relative humidity %
Load Case 60% MCR
Fuel Data:
Bagasse flow rate 39.3 T/hr
Flue gas composition
N2 58.63 Vol%
O2 5.24 Vol%
CO2 10.22 Vol%
H2O 25.22 Vol%
Ar 0.69 Vol%
SO2 0.01 Vol%
Main steam data :
Main steam production 84 TPH
Main steam pressure 66 Barg
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Flue gas temperature:
-Flue gas pressure in furnace -1 mbar

-Flue gas flow 157932 Nm3/hr

-at Stack 128 °C
Water/steam temperature:
-water pressure outlet BFW pumps 80 Barg

-Pressure in steam drum 67.7 Barg
-steam pressure at Boiler outlet 66 Barg
Air Data:
Ambient Air flow 113167 Nm3/hr

Ambient Air temperature 30 °C
Air temperature before firing 195/185 °C
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Technical Data Auxiliary

Equipment
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Document Number : DM.12227-B91-000-860
Revision : 00
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DM.12227-B91-000-860 Technical Data Auxiliary Equipment Page 1 of 10
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TABLE OF CONTENTS
1 Combustion air system ………………………..…………………………………. 3
1.1 Primary forced draught fan ………….……………………….…………………….. 3

1.2 Secondary forced draught fan …………………………………………….……….. 3
1.3 Induced draught fan …………………………………………………………….…... 4
1.4 Spreader Fan………………………………………………………………………… 4
2 BFW Pumps ………………………………………………………………………….. 5
3 Safety Relief Valves ………………………………………………………………. 5
4 Deaerator ……………………………………………………………………….…….. 6
5 Chemical dosing system……………………………………………………….…... 7
5.1 High pressure chemical dosing system………………………………………….. 7

5.2 Low pressure chemical dosing system……………………………………….…... 7
6 Remaining equipments ………………………………………………………….…. 8

7 Condensate storage Vessel………………………………………………………... 9
8 Blow Down Tank…………………………………………………………………….. 9
9 Bagasse Feeders…………………………………………………………………… 9
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TECHNICAL DATA AUXILIARY EQUIPMENT
1. COMBUSTION AIR SYSTEM
1.1 Primary Forced Draught Fan
Manufacturer Fan : GRUBER HERMANOS

Type : Centrifugal
Number : 2
Inlet air flow design : 29.24 m3/s
Inlet temperature design : 25-30 °C
Static differential pressure : 270 mm .w.g
Fan speed : 985 rpm
Manufacturer Motor : ABB

Type : Induction
Driver Type : VFD
Number : 2
Motor power : 132 KW
Absorbed Power : 95 KW
Electrical supply motor : 400 VAC / 3PH / 50Hz
1.2 Secondary Air Fan

Type : Centrifugal
Number : 2
Inlet temperature : 25-30 °C
Fan Speed : 1430 rpm
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Type : Induction
Driver Type : VFD
Number : 2
1.3 Induced Draught Fan

Type : Centrifugal
Number : 2
Inlet temperature : 150 °C
Fan Speed : 740 rpm

Type : Induction
Driver Type : VFD
Number : 2
1.4 Spreader Fan

Type : Centrifugal
Number : 2
Inlet temperature : 25-30 °C
Fan Speed : 1470 rpm
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Number : 2
Motor power : 55 KW
2. BFW PUMPS
Manufacturer Pump : KSB

Type : Centrifugal
Number : 3 X 50%
Design pump capacity : 91.36 m3/h each
Design pump head : 125 barg
Medium temperature : 105 ~ 128 °C
Pump speed 2982 rpm
Manufacturer Pump Motor : Siemens

Driver type : VFD
Type : Induction
Number : 3
Motor power : 500 kW
Absorbed power : 376 kW
3. SAFETY RELIEF VALVES
Location : Deaerator
Manufacturer : Bopp & Ruther
Type : Open bonnet
Number : 1
Medium : Saturated steam
Set pressure : 1.5 barg
Discharge temperature : 130 °C
Capacity : 13 t/h
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Location : Steam to Soot blowers
Type : Open Bonnet
Number : 1
Medium : Low pressure SH Steam
Set pressure : 25 Bar(g)
Capacity 16.4 t/h
Location : Boiler Steam Drum

Type : Semi Nozzle+Full lift
Number : 2
Medium : saturated steam
Set pressure : 76 & 78 Bar(g)
Discharge temperature : 291 & 293 °C
Capacity (Each) 58 t/h
Location : Super Heated steam line

Type : Semi Nozzle+Full lift
Number : 1
Medium : Superheated steam
Set pressure : 71 Bar(g)
Capacity 53.9 t/h
4. Deaerator
Manufacturer Descon Engg. LTD

Type of contactor Tray
Number 01
Design Code ASME Sec VIII div I
Mode of Operation Continues Off season
Operating conditions Season 104.8 tph
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Boiler feed water flow 144.2 tph 0.2 bar g
Operating pressure 0.2 bar g 105 °C
Operating Temperature 105 °C 30(46) °C
Condensate Return 100~115 °C
Temp. 1.5 bar g
Heating Steam Pressure 1.5 bar g 128 °C
Heating steam Temp. 128 °C
Design pressure 1 bar g

Design Temperature 120 °C
Storage Volume of 80.9 m3
vessel
(total)
Hold up time for 270 tph 20 min
5. CHEMICAL DOSING SYSTEM
5.1 High Pressure Chemical Dosing
Manufacturer : Etatron D.S

Number of Pumps : 02
Type : Piston type
Liquid : 1 % sol Tri Sodium Phosphate
Pump Max. Flow : 10 Lit/h
Pump Max. Pressure : 95 Barg
Working Temp : 0 ~ 50 °C
Stroke : 100 % Adjustable
Motor Power : 0.25 KW
Motor Type : IP55
Motor RPM : See Product Manual
Electric Supply : 230-400 V / 3 phase / 50 Hz
Tank Capacity : 230 Liters
Tank Material : Polyethylene
Tank quantity : 01
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Accessories : Motorized Mixer
5.2 Low Pressure Chemical Dosing

Type : Diaphragm Pump
Liquid : 5 % solution of Ammonia
Stroke : 100 % automatic Adjustable
Motor Power : 0.18 Watt
Tank quantity : 01
5.3 Low Pressure Chemical Dosing

Type : Diaphragm Pump
Liquid : 0.1 % solution of O2 Scavenger
Stroke : 100 % Adjustable
Motor Power : 0.18 Watt
Tank quantity : 01
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6. REMAINING EQUIPMENT
For all other equipment, instruments, valves and fittings we refer to the applicable sub-
suppliers Documentation
7. CONDENSATE STORAGE VESSEL
Flash Vessel diameter : 1000 mm

Flash Vessel Length : 2000(1500) mm
Volume of Flash Vessel : 1.2 m3
Design Pressure : 1(3) Barg
Design temperature : 120(150) C
Design code : ASME Sec VIII DIV. I
8. BLOW DOWN TANK
Tank diameter : 1400 mm

Tank length : 2800(2100) mm
Volume of Blow down tank : 3.23 m3
Design Pressure : 1 Barg
Design Temperature : 120 °C
Design code : ASME Sec VIII DIV. I
9. Bagasse feeders
Type : Double roller with pneumatic spreader
Number : 7 sets
Type of control : VSD
Feeding Capacity : 15 tph each
Twin Rollers speed : 23 rpm (max)
Motor power for twin rollers : 7.5 KW
Speed Reduction gear box output : 75 rpm (max)
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Mode of bagasse spreading : By Spreading roller
Speed of spreading roller/ drum : 18 rpm (max)
Motor power : 4 KW
Speed Reduction gear box output : 75 rpm (max)
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Boiler Start up Procedure
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Revision : 00
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DM.12227-000-B91-870 Boiler Start Up Procedure Page 1 of 16

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TABLE OF CONTENTS
1. Introduction…………………………………………………………………… 3
2. Qualification of operating Personnel…………………………………….. 3
3. Preparation Before Operation……………………………………………… 4
3.1 Boiler air / Flue gas side………………………………………………………. 4

3.2 Boiler water / Steam side…………………………….……………………..… 5
4. Filling of Water Tube Boiler ………………………………………………... 6
4.1 General………………………………………………………………………….. 6
4.2 Water filling to Deaerator & Boiler………………………………...………….. 7
4.3 Preparation of Bagasse Feeding System………………...………..………….. 8
5. Starting up the boiler plant…………………….……………………………. 9
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1. INTRODUCTION
The start-up procedure is divided in three steps:

• Preparations, see section 3
• Filling of the boiler see sections 4
• Starting-up the boiler plant, see section 5
The fittings, instruments and valve numbering mentioned in this procedure are shown
on Descon’s P&IDs.
During commissioning, the Water Tube Boiler (WTB) and its connecting piping should
be carefully checked to see that it can expand freely in the manner and direction
intended in the design.
2. QUALIFICATIONS OF OPERATING PERSONNEL
Before taking charge of boilers, qualified operators must fully understand their duties.
They must have a clear conception of the purpose of the equipment, its operating
characteristics and its exact relationship to other equipment of the plant. Safety
should be first considered for boiler operation.
They must be fully familiar with what the equipment is capable of doing and
equally important, what it is not capable of doing.
This must include knowledge of the normal operating ranges of pressure,

temperature and Flow of the equipment and must include knowledge of the hazards
that accompany abnormal operating conditions and the corrective actions that must
be taken.
Therefore, the operator should fully understand this manual as well as other technical
reference literature. Mis operation of boiler may result in a dangerous mishap or
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accident such as a severe explosion or may result in water shortage if something
goes wrong. Therefore, careful monitoring, checking and maintenance are required.
Take one-hourly readings of each part temperature, flow rate, pressure, water level,
boiler water pH, boiler water conductivity, motor load etc. This would ensure proper
operation of the unit and would also help in preventing major mishaps from occurring.
When bottleneck in an operation occurs, immediate counter-action / trouble-shooting

must be taken to prevent any consequent accidents from happening.
3. PREPARATIONS BEFORE OPERATION
Before the first start-up or after long shut down of the boiler installation it is required
to perform the following procedures first:
• Hydraulic test
• Alkaline boil out procedure
• Water flushing procedure of the Boiler and steam piping.
Before boiler start-up, water, power, air for control use, fuel, lubrication oil and
cooling water should be confirmed to have been secured and ready for use. For
starting of plant, valves, dampers and other equipment should be carefully checked
and confirmed that normal starting position is okay. Especially checking and
confirmation of water level by water level gauge should be made a habit, at least
twice per shift. Before the startup of the boiler installation it is required to perform the
following procedures:
• Make sure that the boiler has been inspected / maintained as per procedure.
• Make sure all auxiliary parts of the boiler installation have been inspected as
mentioned in the sub-vendor documentation.
• Make sure that all temperature-, pressure-, and level control set points of steam
drums and main steam lines are as specified.
• Confirmation Items including water level gauge before Boiler Operation.
• Make sure Power supply for all motors and panels is available.
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• Make sure sufficient Feed water storage is available.
• Make sure sufficient fuel supply is available.
• Make sure that cooling water for Fan bearings is available.
• Make sure that Instrument air for the pneumatic equipments/control valves is
available.
• Make sure that Valve condition is correct as per P&IDs.
• Make sure Pumps and Fans are ready for operation.
• All controls which include Main pressure controller, combustion air control,
Furnace draught control, Boiler Drum level control, steam temperature control,
Deaerator level control, and Deaerator pressure control are all in manual mode.
• Pressure gauge should be checked by high accuracy test gauge. Before installing
pressure gauge, make sure that water is in the siphon pipe.
3.1. Boiler air / flue gas side
Generally speaking, open all block valves upstream instruments in air/ flue gas path.
• Make sure all inspection doors are closed and bolted.

• Make sure duct drains are closed except the main stack drain.
• Peephole protection plates are lowered.
3.2. Boiler water / steam side
Generally you can say that you have to open all block valves upstream instruments,
and level instruments/gauge glasses and close all drain, and vent valves of
instruments and level gauge glasses in the water/steam path.
The control valves should be set on following modes.

• Main pressure controller Manual
• Combustion air controller Manual
• Furnace draft control Manual
• Boiler drum level controller Manual
• Steam temperature controller Manual
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• Deaerator level controller Manual
• Deaerator pressure controller Manual
• Bagasse feeders control(VSD) Manual
• Boiler feed water pump speed control Manual
• Condensate storage vessel level control Manual
Also make sure that the inspection doors from the steam drum and deaerator storage
tank / feed water tank are closed and bolted. All valves will be in Open or Close
positions as shown on P&ID’s.
Note: Make sure that all piping subjected to possible freezing (when not in operation
and not provided with tracing) is drained completely in order to avoid any damage
(e.g. drain lines instrumentation, sample lines etc.
Now water tube boiler is ready to be filled
4. FILLING OF WATER TUBE BOILER
4.1. General
It is essential that operator maintain a strict daily routine and it is strongly

recommended that a comprehensive log sheet covering all related parameters be
maintained. Plant operator must have three senses alert.
• Hearing ----------- Leaks or bearing / malfunctioning

• Smell ------------ burning, hot bearing / malfunctioning
• Touch ------------- Undue vibration or temperature
It must be recognized that all boilers and auxiliaries systems require operator’s
attention during start up. Special care must be exercised in the manipulation of feed
& fuel system to protect against damaging of the boiler to ensure personnel safety.
First it should be checked that all piping and vessels are cleaned on the waterside.
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Secondly, a feed water analysis shall be made before the boiler is filled, to be sure
that the quality is in accordance with Descon requirements.
We refer to “Water chemistry”; see this document for more detailed information.
The next procedures can be followed provided that BFW is of high quality and
available.
Before start up it would be preferable to have available low pressure steam for
heating up the deaerator and the combustion air through the steam air preheater.
If this is not available then it is recommended to heat up the steam line towards the
steam/turbine and process as fast as possible and to supply steam through the
bypass stations towards the deaerator and the steam air preheater.
4.2. Water filling to Deaerator & boiler
Before feeding water to boiler, it should be first confirmed that sufficient water
quantity is available in condensation tank, and the water feeding to deaerator is
started. Regarding pump operation and handling of attached valves, please refer to
each valve handling manual.
A: Procedures of water feeding to deaerator.

• Inlet and outlet valves of deaerator level and pressure control valve are opened.
• Air vent valve of deaerator is fully opened.
• Fill the deaerator with water till just 100 mm above Lowest water level by driving
of deaerator make up water pump. During filling dose also some ammonia. In
case level was already higher then do not increase further. Keep it always
below NWL.
• The BFW pumps and its piping are completely filled and vented up to the
economizer. The economizer will be filled till the same level as the water level
in the deaerator.
• With regard to steam supply to deaerator, gradually open the steam pressure
control valve slightly and then raise steam pressure slowly to 0.2 bar(g). When
the subject pressure is achieved, put the pressure controller on AUTO.
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• Then fill the deaerator slowly further by opening slightly the deaerator level
control valve LCV100 and also dose some ammonia.
• After completion put the level control valve on automatic
• Deaerator is now ready for operation.
Remarks: Condensate strainer is choked sometimes at the beginning of operation,

therefore, if such tendency is seen, its cleaning is necessary.
If the steam is not available then for heating up then fill the deaerator till NWL and
start the boiler. After steam is made available then slowly heat up the water by
opening the steam pressure control valve slightly and open further after there is no
hammering observed.
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B: Procedures of Boiler Water Feeding
In the beginning of boiler operation, dust or welding waste are carried along with
water. In case of initial operation of pump, flush piping adequately and closely
monitor the suction pressure during operation to prevent any likelihood of cavitation
in the pump.
Ensure the following points are followed:
• Deaerator outlet valve is opened.

• Feed water pump inlet and outlet valve is opened (after air venting of pump).
Minimum flow valve is opened. Cooling water is confirmed if required for pump
bearings.
• Boiler drum level control LCV-101C and steam temperature control valve TCV-
603 A/B upstream and downstream valves are opened.
• The boiler feed water control valve LCV-101C and the steam temperature
control valve TCV603 A/B are fully closed
• Boiler feed water stop valve and air vent valves are opened.
• Economizer drain (when water is draining then close) and vent valves are
opened, till complete air venting.
• The main steam stop valve and its bypass is closed.
• The soot blowing steam pressure control valve and its bypasses are closed.
• The vent and drain valves in steam lines/system including the start up valve
SVV-600 are opened.
• The BFW Pump is started at its lowest speed of 1500 rpm and boiler water
flows over the minimum flow valve back into the deaerator. Check the proper
operation of the BFW pumps for 10 minutes. Then put the speed control on
automatic for pressure control over BFW control valve LCV101 A/B/ (setpoint
15 bar).
• Then the Boiler can be filled feeding is started by slightly opening of the boiler
feed water control valve LCV-101C.
Pump outlet pressure and motor current figures are checked so that pump and motor
are operating at normal conditions without the risk of over-loading. In this case,
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automatic level control of drum cannot be executed. The level control is done by
manual control.
• Close BFW control valve LCV-101C when drum water level is just above L.A.L.,
so that there is room for expansion when the water is heated.
• If the water level in the steam drum is too high, this can be corrected by
draining water through the intermittent blow down valves.
• The filling rate depends on the temperature of feed water; the boiler should be
filled slowly if its temperature is at higher side to prevent over stressing of the
steel components.
C: Initial Chemical Charging
At the initial stage of filling the boiler with water, inject sufficient amount of chemical
to maintain the correct pH of Boiler Water. Carry out the initial charging of the
chemical by the following method:
• Prepare the eye-guard, gas mask and gloves in order to prevent from injury.
• Required chemicals should be dissolved with water by using PE drums.
The boiler system is now filled and is ready for start.
4.3. Preparation of Bagasse Feeding System
Bagasse burning does not accompany dangerous operation as in the case of heavy
oil burning, however, boiler operator should take precaution against abnormally
distributed flame or furnace inside explosion.
Bagasse supplied to bagasse feeder by bagasse conveyor is conveyed to the

pneumatic spreader through chute by bagasse feeder driven by variable speed drive.
Following checks should be made to ensure smooth running of bagasse feeders.
1. Bagasse conveying equipment (Client’s portion): Before starting bagasse
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conveying unit, the client shall ensure that foreign materials as steel piece, stone,
wooden tips etc, and any other material apart from bagasse are completely
removed and that full safety of workers is ensured.
2. The surrounding of bagasse conveyor may become dirty by scattering of fine
bagasse, which may be ignited by fire seed from boiler furnace. Therefore, proper
surrounding cleaning should not be neglected.
3. The flue gas inside the furnace should be completely purged.
4. All the foreign matter on fire grate should be completely removed.
5. The dumping grates and its air inlet dampers should be checked for smoothly
operation.
6. The dumping grate should be covered with wood for ignition of bagasse
7. Driving equipment should be perfectly ready.
8. The air dampers under the grate should be opened
9. First induced draught fan should be started with minimum speed followed by start
up of secondary forced draught fans and finally the primary forced draught fans.
Finally also the spreader air fans and the rotary air valves in the spreader air lines.
10. Put the furnace draught control on automatic
11. Check if the spreader air is also supplied to the peepholes and sootblower wall
boxes for sealing and cooling.
5. STARTING UP THE BOILER
The boiler plant & all auxiliary plants must be controlled by a boiler attendant during
commissioning. Be especially careful with the operation of the BFW & the combustion
plant to avoid damage to the plant and to increase the security of the personnel.
The objective of the start-up is to bring the boiler from cold conditions up to normal
operating condition following a start-up sequence.
The DFB shall be started up as followed; every step shall be confirmed and/or
checked automatically or by the operator.
The start-up of the boiler shall be done in accordance with the boiler start-up curve
(See start up curve chapter).
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The following conditions shall be present before a ‘start-up’ is initiated.
• All manually operated valves (drain-, block-, and vent valves etc.) shall be in the
correct position (to be confirmed by commissioning engineer).
• The following external system shall be healthy and available:

- Boiler feed water supply system available (pumps running) and healthy
- Sealing / Cooling air system healthy and available
- Condensate water pumps of condensate storage vessel available and healthy
- Steam supply to steam air preheater available and all valves in its system open.
• For the DFB system, the following conditions shall be set / present
- BFW control valve LCV-101C closed.
- Drum vent valve V507/508 open
- Superheated steam start up vent valve SVV-600 open
- Superheated steam line drain valves open
- BFW pump(s) started and supply system healthy and available
• Check water level of steam drum (level > L.A.L.), increase if necessary by
opening BFW control valve LCV-101C gradually. The drum water level shall be
maintained preferable 100 mm above lowest water level. If filled up to NWL then
drain it till 100 mm below NWL. During the complete startup of the boiler the
level in the steam drum should be kept low. When the pressure is raised till
approx 3 barg then the water level can be raised slowly till NWL
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Start up Of Bagasse burning equipment
Following sequence is followed for start up of the bagasse burning equipment.

• Start Baggase conveyor.
• Bagasse twin Feeder VSD should be set on Manual mode.
• The drum of the bagasse feeder can be started
• Start the ash removal valves under boiler 2nd pass, air-preheater and cyclones.
• Set the FD fan and over firing fan slowly to 25% speed and control the furnace
pressure by increasing the speed of the ID fan. The boiler will be purged for 5 minutes.
After purge set fans again at min speed of 50 rpm.
• Preparation for ignition of wood can be started.
• Close first the air dampers under the grate
• Ignition of wood through front doors of grate.
The following confirmations are required before ignition of bagasse / supply of

bagasse for ignition.
• Is the furnace inside having minus draft pressure?

• Is the draft at each point correct?
Ignition for bagasse can be started as follows

• After wood is ignited and furnace is warmed up the air dampers under the grate
can be opened.
• Now the bagasse twin roll feeders can be started at low speed one by one.
• When the firing is stable then increase slowly the bagasse amount and grate air
amount.
• The bagasse should be fired in suspension. Means burning on the grate should
be minimized. When this condition is reached then leave the boiler running in
this condition and warm up the boiler slowly.
• The boiler heat input should be limited to approx 15% during start up. It could
be wise to run with only 3 dumping grate section during start up (section 3, 4
and 5 and to leave the air dampers of section 1 and 7 closed.
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• The steam start-up valve SVV-600 should be left fully open. At the moment the
steam pressure increases to slow then the firing can be increased slowly by
putting the other dumping grate sections in operation.
• Close the steam vents when the pressure is increased to 5 barg. Same for the
drains in the steam lines/superheaters.
• During the warming up the bypass valve in the main steam line can be left open
for heating up the steam lines into the process/towards the steam turbine.
However, ensure that all drain and, vent valves are kept open till 5 barg steam
pressure and all steam traps are working properly. When the boiler is on its
steam pressure and the steam lines are all heated up and pressurized the main
steam stop valve can be opened.
• During the warm up increase the over firing air up to 30% till 40% and check the
combustion. During the commissioning the trim dampers of each over firing air
duct are set. Do not change those from their position.
• When the firing is at approx 30% the combustion air and furnace draft control
can be put on automatic
• By closing slowly the steam start up valve SVV-600 the steam pressure can be
increased further to the operating pressure. When operating pressure is stable
then put steam start up valve in automatic for controlling the steam pressure.
• During the start up the steam temperature will increase too far and de-
superheating water will be required. Control the steam temperature at inlet of
superheater-02 at 350 C during the start up. When the boiler is on its operating
pressure then increase the steam outlet temperature to 485 C slowly and finally
put it on automatic.
• During the start up the boiler pressure is increasing while the Boiler feed water
pump runs still at 1500 rpm. The BFW pump discharge pressure will be approx
27 barg. During the start up the pressure difference over the BFW control valve
LCV-101C should be maintained at minimum 5 bar by the speed adjustment of
the BFW pumps (the VFD control). However, the parameter for this control is
taken from the pressure difference between the steam drum pressure PT501
A/B and BFW pump discharge pressure PT103. At 100% MCR this value
should be approx 15 bar. Therefore set the pressure difference control from
start on automatic with min speed of 1500 rpm and a pressure difference of 15
bar.
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• When the boiler is running stable then put the continuous blow on automatic
control.
• When the boiler is on pressure then open the intermittent blow down valves
each for 20 seconds and continue it for each shift.
• After the boiler is in operation then start the steam blowing sequence by putting
it on automatic control.
• Burning condition of bagasse fluctuate according to shape, content and
burning rate. During normal operation, condition of furnace inside is closely
checked so that optimum air distribution is obtained
• During the warm up of the boiler increase the over firing air up to 30% till 40%
and check the combustion. During the commissioning the trim dampers of each
over firing air duct are set. Do not change them from their position.
• Steam supply should be started after the boiler starting operation has been
completed and the boiler has entered into normal operation, while, water
feeding against lowering of drum water level should be ready.
• The load can be increased by increasing the speed of the feeders.
• When the steam system is ready then the boiler pressure control can be put on
automatic.
• During the increase in steam supply to the steam system the start up valve will
close slowly depending on the steam flow towards the steam system.
The important precaution in case of steam supply is the smooth handling of valve
without sudden operation. Next mentioned cases may be caused by sudden handling
of the valve.
• Drum water level is forced up by abrupt load fluctuation of boiler and carry over
may occur.
• When much high temperature steam is supplied to piping or machinery of cold
state at starting, excessive thermal stress may occur and cause various
problems.
• Water hammering may occur, which causes damage of flange or gasket and is
not easily settled.
The “Start-up” of the DFB is now completed.

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NOTE: Boiler pressure shall be increased according to the Temperature-Pressure

curve (Start Up Curve) or more slowly. Too much high speed increasing pressure
damages the boiler and Superheater by the strong thermal expansion force caused
by unbalanced temperature.
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Boiler Start up Curve
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TABLE OF CONTENTS
1. Start Up Curve……………………………………………………………………… 3
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1. BOILER START UP CURVE
307. 5 75
287 70
266. 5 65
246 60
TEMPERATURE (°C)
PRESSURE (barg)
225. 5 55
205 50
184. 5 45
164 40
143. 5 35
123 30
102. 5 25
82 20
Saturation Temp curve 15

61. 5
41 10
Pressue curve
20. 5 5
0
30 90 150 210 270 287 330
60 120 180 240 300 360
187 Minutes
TIME (min)
Ramp Rate : 1 °C / min
Temperature : 287 °C
Pressure : 70 barg
Time : 3 Hours 7 min (187 minutes)
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Pre-Service Inspection /
Pre-Commissioning
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Revision : 00
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TABLE OF CONTENTS
1. Handling…………………………………………….…………………………….… 3
2. Installation………………………………………….………………………………. 3
3. Pre-service inspection / pre-commissioning…………………………………. 3
3.1 General…………………………….………………………………………………… 3
3.2 External………………………………………..……………………………………. 4
3.3 Combustion chamber……………..………………………………………………… 4
3.4 Bagasse Feeder……………..…….……………………………………………… 5
3.5 Combustion Air……….…………..………………………………………………… 5
3.6 Pre-commissioning checks ……………………………………….……………..… 5
3.7 Thermal hazards……….………………………………………………………….… 6
3.8 Boiler feed water and piping ………………………………………….………….… 7
3.9 Steam piping ………………………………………….…………………………..… 7
3.10 Drain piping ………………………………………….…………………………….… 8
3.11 Water column ………………………………………….………………………….… 8
3.12 Safety valve ………………………………………….…………………………….… 8
3.13 Safety controls ………………………………………….………………….……..… 9
3.14 Soot blowers………………………………….……………………………….……… 9
3.15 Drum internals………………………………………………………………….……… 9
3.16 Air Preheater ………………………………………….…………………………….… 9
3.17 Fly Ash arrestor ………………………………………….……….………………….. 10
3.18 Feed water pumping and control………………………………………….……… 10
3.19 Summary…………………………...……………………………………….……… 10
3.20 Pre-service inspection checklist…………………………………………….……… 10
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1. HANDLING
The DESCON Boiler is thoroughly designed, structurally sound, some parts of boiler
are shop assembled Unit that has been continually checked and inspected during
assembly. When the Boiler’s components are received at the Plant, it should be
inspected for signs of damage prior to accepting the shipment or releasing the
shipper.
The units should be inspected after each phase of installation so that, in case
damage has occurred, claims for repairs may be submitted to the responsible party.
If there is any doubt as to the condition of Boiler/its component, a service technician
should be called for to advice about the condition and possible repairs.
2. INSTALLATION
The Boiler structure will simply be positioned at the base plates. A foundation layout
diagram is provided to allow proper design and construction of the foundations that
will receive the Boiler. The Boiler is welded to the foundation plate by the front saddle
and the rear saddle is free to slide on the foundation plate, to allow for thermal
expansion. There is one manhole provided at the steam side of the Boiler.
If there are questions about the installation or foundation, please refer them to
Operations Boiler Department of Manufacturing Business Area of DESCON
ENGINEERING LIMITED.
3. PRE-SERVICE INSPECTION/PRE-COMMISSIONING
3.1 General
Before commissioning operating or maintaining this equipment it is essential that all

personnel involved have read and thoroughly understood this instruction manual;
when installation of the Boiler has been completed, and before putting it into
operation, the entire system should be inspected. This inspection can serve two
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functions. First, a thorough inspection will show whether or not the equipment
installers have done a satisfactory job and can be released from the job site.
Secondly if any of the components is damaged, defective or improperly installed, a
thorough inspection will reveal the discrepancy immediately, rather than allow a
delay in the starting-up & operation later.
The following discussion and the component checklist in this section are intended as
an inspection guide. After every component in this checklist is inspected and proved
operational, the Boiler will be ready to operate. The inspection should also cover any
related equipment furnished by others to ensure that the total system is ready to
function
3.2 External
Any sign of damage which occurred enroute, should be thoroughly inspected. The
area around the Boiler should be checked to ensure that no attachments are
preventing the unit from expanding.
Any obvious signs of components miss-assembly should be listed, and the list should
be signed by the equipment installer or Incharge of the installation. This inspection
list should constitute a request for correction of the improper conditions.
3.3 Combustion chamber
The main access to the furnace area on firebox is through the man way doors. The
furnace interior should be inspected for any signs of damage to the refractory,
grating and covered. Refractory does have hairline cracks, which will not cause
trouble, but cracks over 1/8 inch wide can cause problems by allowing leakage of hot
gases to the steel casing. Any damage to the refractory on insulation should be
repaired before the main flame is lit.
The tube banks which make up the furnace walls should be tight and in good
alignment. If there are any gaps between the refractory wall of rear side, the gas
flow can short circuit from the furnace into the convection zone and destroy the
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performance of the steam generator as well as cause possible damage. All fixed and
movable fire grating with their respective gaps for air flow must be checked. Change
the fire grate if required.
Baggase distributor / spreader must be clear for baggase feed. Baggase feed
chutes and feeding system must be checked in all respects.
3.4 Bagasse Feeder (Burner)
Baggase burners comprise of Baggase twin roller feeders with controlled variable
speed drive motor and gearbox. Drive shaft is driven through chain sprockets. This
feeder feeds Baggase to pneumatic distributors / spreader through a steel chute. Oil
level in gearbox of feeder drive and greasing of bearings, drive chain and spur gear
must be proper. Turning of shaft and picker roller by hand must be free and without
binder of scraping. The motors rotation must coincide with the shaft and picker roller
shaft respectively. The shafts movement, motor rotation and motors starter can be
tested by momentarily energizing the electric circuit. If rotation is proper and
movement is free then continue to free run for a period of time and check the bearing
and mountings.
For smooth over all operation also check the following.
− Check bagasse intake chute and damper
− Check baggase feed chute to pneumatic distributor / spreader.
− Check pneumatic spreader installation and lever operation for proper angle
adjustment for baggase.
− Check air damper and pressure indicator for pneumatic spreader.
3.5 Combustion Air
The rate of air flow is controlled by frequency control of speed of FD and overfiring
air fans for Bagasse firing and furnace pressure is controlled by frequency control of
speed of I.D. fan Section. F.D. fan is used to fluidize the baggase burning in the
furnace. Turning of fans motor and shaft by hand should be free and without binding
on scraping. The motor rotation must coincide with the fan wheel rotation which is
marked on the housing. The fan movement, motor rotation, and motor starter can be
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tested by momentarily energizing the electrical circuit to the motor. If fan rotation is
proper and movement is free, then continue to run the fan for a period of time and
check the bearings and mountings for excessive vibration and smooth overall
operation.
Also check air intake duct installation at FD fan. Check for freedom of movement,
range of movement, and closure tightness by operating the drive manually on control
linkage.
3.6 Pre-commissioning checks
− No foreign object is in the Boiler.

− Boiler, Boiler feed water suction, discharge lines, steam drains and all utilities
lines are properly installed and flushed.
− All connection are made with joints rings and retightened.
− Manhole covers are fitted with joints and secure.
− All electrical connection have been made, all wiring is secure, supply is available,
and check that all circuits are functioning correctly.
− Blow Down valves Closed.
− Stop Valve closed.
− Ducting doors and cleaning doors secure.
− Exhaust gas outlet to chimney unobstructed.
− Is the system wired correctly?
− Are all pressure switches & solenoid valves functional?
− Are the motor directions correct?
− Is the Boiler filled with Water to NWL?
− Is the feed water pump ready for operation?
3.7 Thermal hazards
Thermal Hazards are intrinsic in Boiler as some of hot surfaces are not insulated that
is Manhole access doors etc. Plant should be located in an isolated area and only
entered by authorized staff
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3.8 Boiler feed water and piping
It is of paramount importance that water of suitable quality is available. More damage

is done to boiler by failure to properly treated water than any other cause. It is
strongly advised to obtain services of a reputed water treatment specialist. The feed
water piping should be examined to see if all the joints are tight and that the valves
are in the proper orientation. The direction of flow through the check valves should
be towards the Boiler. If any type of leak is reported attend it without any delay. Make
no attempt to operate associated plant when gas is escaping and isolate hot water
supplies.
3.9 Steam piping
All steam piping should be inspected for such things as;
• Securely bolted flanges.

• Properly oriented globe and check valves.
• No open ports.
• Correct installation of gauges and proper actuation of vent and drain valves.
• Check all orifices, metering devices for proper installation.
• On heating steam lines, ensure that steam condensate traps and drains are
installed properly.
• All drain lines should be inspected from the connections on the steam
generator to the blow down pit or tank
• There should be no shut-off on obstructions between the steam generator
and the pit or flash tank.
Items which normally have drain provisions are:

• Steam generator drum.
• Furnace headers.
• Water gauge glass.
• Heating steam condensate.
• Soot blowers.
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3.10 Drain piping
All drain lines should be inspected from the connection on the Boiler. There should
be no shut-offs or obstructions between the Boiler and the collection tank. The
collection tank should be installed to comply with any local codes or insurance
recommendations. Items which normally have drain provisions are:
Boiler’s water column, level gauge glass and safety valves.
3.11 Water column
As the water columns & water level gauges are so important to the operation of a
Boiler, they must be carefully inspected. The connecting piping must be complete
and free of leaks. With a water column there are several control devices which could
have been furnished, such as;
• Low water level alarm (this signals when water level is dropping to the danger
point).
• Low Low water level cut-off (this shuts the steam generator down before the
water level is low enough to do any over heating or damage to the boiler).
• High water level alarm (this warns the operator before the level gets high enough
to cause loss of steam purity and water carryover).
• High High water level (this closes the Boiler shut off valve before the level gets
high enough to cause loss of steam purity and water carryover).
Any of the above devices, which are furnished, should be checked for proper
actuation. The normal water level is usually maintained at the center of the gauge
glass.
3.12 Safety valves
Safety valves should be checked to make sure that there are no blockages or shut-
offs on the outlets. The vent pipes should not be supported from the valves, because
the weight of the pipes could cause the valves body to distort or expand. The valves
should be preset in accordance with the manufacturer’s valve identification.
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3.13 Safety controls
Before inspecting the safety control circuit, examine all components and make
preliminary adjustments as per the manufacturer’s advice. Normal safety controls
include items such as:
Excess steam pressure limit switch, flameproof safe guards, water level alarms and
cut-offs, plus any of the special controls furnished to fulfill the Boiler’s system
requirements. When carrying out maintenance, particularly when dealing with plant
which may be operated under automatic control, switch off electric panel. Check
extra low, low level and high level while filling. Then normalize level at required
condition.
3.14 Soot Blowers
Check that the soot blowers’ pressure requirements of the steam for cleaning and
purging air are adjusted as per requirements. Check the angle of rotation on the
lance to ensure cleaning within the proper convection lanes. Lubricate to the
manufacturer’s recommendations.
3.15 Drum Internals
The drum should be opened for inspection prior to operation. Bolts and brackets on
the internal distribution pipes and demister pads should be checked for tightness.
Baffle plates sections should be checked to see that there are no wide openings.
BFW distributor header should be checked for obstructions. Any large amounts of
dirt, scale, on debris should be removed.
3.16 Air Preheater
1. Flue gas and combustion air paths must be checked for proper sealing.
2. Installation of multi-jet stationary soot blower must be properly tightened.
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3.17 Fly Ash Arrestor
Check flue gas path, cyclones, guide vane and baffles for proper installation.
3.18 Feed water pumping and control
Before starting pump check:

- Free rotation of shaft.
- Pump rotates in the correct direction.
- Suction line has been purged of air and is full of water
- The water controls and over load units are correct and connections are sound
3.19 Summary
A thorough inspection will reveal any obvious damage on improper installation of

component equipment. When all of the items contained in this checklist have been
reviewed and the entire system has been inspected, you may proceed with the
preparation for service.
Caution:-
Do not attempt to fire the steam generator until all systems have been
checked and are operational.
3.20 Pre-service inspection check list
Actuator Igniter
Air-purge Instruments
Air Ducts Insulation
Air Heater Limit switches
Bearing & Seals Linkage
Blow down Lubrication
Blow off Manifold-Gas
Bolts – Base hold down Man ways-Drum
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Bolts-Flange Observation ports
Bypass Ducts Outlet-Smoke
Bypass Feed Water Pneumatic Cylinders
Casing Outer Piping
Casing Seal Pressure gauges
Chemical feed Refractory
Combustion equipment Safety Valves
Controls Soot Blowers
Compressor Air Level Control switch
Dampers Gear Box
Drains Wiring
Drives / Couplings Wind-box (If fitted)

Drum Internals Stack
Expansion provisions Steam Lines
Expansion joints Steam Purifier
Fans (ID, FD & SA) Temperature gauges
Feed water system Thermo-couples
Gasket/Felts Thermo-meters
Furnace Traps
Grating Tubes
Pneumatic Spreader Valves
Feeder Vanes
Baggase Carrier Water column
Gauges Level Gauges
(Please examine installation of equipments with respect to P&I diagrams and

installation instructions).
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Boiler in Operation
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Revision : 00
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TABLE OF CONTENTS
1. Introduction ……………………………………………………………………. 4
2. Maintenance during Operation ……………………………………………… 5
3. Water levels ……………………………………………………………………. 5
4. Combustion controls ………………………………………………………… 5
5. Blow-down …………………………………………………………………….. 6
6. Flame pattern …………………………………………………………………. 6
7. Temperatures …………………………………………………………………. 6
8. Soot blowers …………………………………………………………………… 7
9. Ash removal operation …….………………………………………………… 8
10. Data ……………………………………………………………………………… 9
11. Operator’s maintenance ……………………………………………………… 9
11.1 Each Shift ……………………………………………………………………… 10

11.2 Daily ……………………………………………………………………………. 10
11.3 Periodically …………………………………………………………………….. 10
11.4 Preventive Maintenance ………… …………………………………………... 10
11.4.1 Tubes ……………………………………………………………………….….. 11
11.4.2 Flue Gas Side……………………………………………………………….….. 11
11.4.3 Steam drum………… …………………………………………………….….. 11
11.4.4 Preventive maintenance schedule ……………………………………………. 11
11.5 Annual Checks …………………………………………………………………… 14
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12. Safety ……………………………………………………………………………. 14
12.1 General safety ……………………………………………………………..…… 14

12.2 Requisite for the safe operation of the boiler unit ………..………………. 15
12.3 Safety practices and procedures …………………………..………………. 15
12.3.1 For boiler operators …………………………………………………………. 15
12.3.2 In the event of fire …………………………………………………………… 15
12.3.3 General house keeping …………………………………………………….. 16
12.3.4 For maintenance operations ……………………………………………….. 16
12.3.5 Routine maintenance work ………………………………………………… 16
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1. INTRODUCTION
Boiler operation can be done both on automatic and in upset cases on manual
control. Manual control is possible by switching the auto/manual station. Before
changing over the boiler operation should be steady. However, it is recommended to
keep the boiler on automatic in order to keep it running smoothly.
While the boiler is pressurized, manholes and bolted flanges may start to leak. If this
is the case, then the bolts are to be tightened cross-wise. During steady state
operation, the water levels of the steam drums must be kept at normal level.
Be sure that the water level never falls under the lowest admissible level, indicated
by the level gauges.
If it ever falls under low-low level or should there be doubt about it, and in case it
appears to be impossible to increase the level by adding feed water, immediately
shut down the boiler (if not tripped already automatically).
All alarm and locking devices are to be tested and checked at regular intervals, as
indicated in the sub-suppliers documentation.
Check instruments and valves for leakage.
The steam pressure shall never rise above the maximum allowable pressure
This value is indicated on the name plate and by a red line on the pressure gauges.
When exceeding this pressure, the safety devices must react at once. Therefore, it is
of great importance to check their condition and operation at frequent intervals.
NO CHANGE WHATSOEVER OF THESE DEVICES OR THEIR SETTING IS

PERMITTED
In particular, overloading or putting out of action of these devices is regarded to be a

serious offence against the applicable Boiler Code.
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A good quality of boiler and feed water is a prerequisite to a trouble-free functioning
of the boiler. Therefore, analyses shall be made at regular intervals as mentioned in
the water requirements section of this manual.
In the event all safety interlocks have failed and the safety relief valve of the steam
drum opens to atmosphere, the steam flow through the super heaters and main
steam line is strongly reduced. This may lead to serious damage of the super heaters
due to overheating. Therefore the fuel flow has to be reduced immediately until the
relief valve(s) close again and there is sufficient steam flow through the super
heaters.
2. MAINTENANCE DURING OPERATION
In case of maintenance during operation, sample lines and all other lines that might
contain stagnant water should be purged completely in order to avoid freezing of the
line section.
When ambient temperature < +5°C, then valve has to be opened in order to avoid
freezing of intermittent blow down line.
3. WATER LEVELS
Safe and reliable operation of the Boiler depends on routine monitoring of the control
and safety systems. The feed water rate and the combustion controls must be
continually checked whether the system is operated automatically or an operator is in
attendance. Proper water level in the Boiler must be maintained. If the water reaches
too high a level, the steam purity is endangered. If the water level reaches too low a
point, the unit is in danger of overheating. The level is automatically controlled by the
feed water control system.
4. COMBUSTION CONTROLS
The combustion controls, mainly the air fuel ratio, and the overfiring trim dampers
should be adjusted and monitored for optimum performance and efficiency. Not only
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poor combustion means fuel loss, but the convection zone of unit will become fouled
and heat transfer will drop, causing excess exit gas temperature. However, you
should avoid an air rich adjustment on the air-fuel ratio because this can lead to flame
instability and an increase in nitrogen oxide emission (NOX).
5. BLOW-DOWN, CHEMICAL DOSING AND WATER STEAM ANALYSIS
The water condition of the water in deaerator and boiler should be maintained in an
optimal condition. Therefore the water and steam analysis should be performed on a
daily basis as written in the section. The dosing rates should be adjusted as per the
results of the analysis. Also the condition of the dosing units should be regular
checked.
The blow-down rate must be adjusted according to the boiler feed water and boiler
blow down specifications. The water column and water gauge glass should be blown-
down at the beginning of each shift. This schedule will ensure two things:
First, the sludge or sediment will not have a chance to accumulate in the column or
glass. Any accumulation can cause a wrong level indication. Second, the Boiler
attendant, by observing blow-down and return of liquid to glass, will be assured of
proper actuation of one of the most important safety devices of the unit.
6. FLAME PATTERN
The flame pattern within the furnace is important to achieve anticipated performance.
Improper flame pattern can result in carbon built-up on the Furnace and tube
surfaces, which will restrict heat transfer and result in high exit gas temperatures and
loss in efficiency.
7. TEMPERATURES
While unit is in operation, a constant check should be run on all temperature

indicators. A drop in steam pressure / capacity will indicate a variance from
performance. This may appear as a rise in boiler exit gas temperature, a drop in fuel
gas feed temperature or pressure, or a drop in feed water temperature. As stated
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several times in this Manual, a rise in exit gas temperature means carbon fouling of
the surfaces, improper flame position or miss-adjusted air-fuel ratio.
8. SOOT BLOWERS
The carbon content of the gas normally coats the tubes causing a decrease in
the rate of thermal transfer. For this reason the units are equipped with soot
blowers. These soot blowers should be operated at least every shift or at
least daily as per temperature rise trend in the boiler in flue gas path.
However unnecessary prolonged duration and number of times of soot blower
application without requirement may also result in damage to tubes. If the
pressure drop over the smoke side of the boiler should exceed the value
measured at the delivery test, the interval must be increased until the value is
re-established unless it is not due to other reasons, e.g. improper flame
pattern. Insufficient soot blowing of the tube surfaces on a schedule makes
the cleaning operation that much harder, when blowing is eventually done.
Always remember that soot build up on tube surface directly affects the
efficiency of the steam generator.
The convection part soot blower should be used as frequently as necessary to

keep the convection tubes as clean as possible. Soot blower element
alignment should be checked regularly to prevent cutting of tubes by steam
from the soot blower elements. It should also be checked that the soot
blowers are blowing with the right steam pressure as stated in the manual. In
general, the recommended pressure for the proper operation of soot blowers
should be followed. The soot blower steam line is erected with drain valves
and keeping warm provision to allow steam to flow through the line for
warming up purpose. The soot blower supply valve is opened slightly, while
the steam line is warming up. 20 minutes are normally sufficient for warming
up the steam line. It is very important that the line is free of water before soot
blowing to prevent cutting of tubes. After that the boiler is blown out from
front to rear. It is also important to have the right pressure for scavenging air
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to prevent corrosion gases from getting into the soot blower tubes and
damaging them. It is necessary to have the boiler at min 50 % load when
soot blowing to avoid that the flame is blowing out and to increase the effect
of soot blowing. The boiler should always be soot blown properly before it is
taken out of service. The boiler should be cleaned from superheater section
to the Economizer section step by step. See also the instruction from soot
blower supplier.
Soot blower operation is preferable to be performed during light loads. The operation
procedures are as follows:
- Soot blowing steam pipe drain valve is opened for drainage of drain.
- Soot blowing operation is started, after drain valve is fully opened for more than
3 minutes.
- Soot blowing operation is performed from upper stream side to downstream side
according to gas passing direction.
After completion of soot blowing, steam stop valve is closed and the drain valves are
fully opened for complete drainage of steam condensate mix. After soot blowing,
draft and temperature of each portion are checked and the effect is investigated.
When condensate droplet is mixed with soot blow steam, water tube may be
damaged; therefore, sufficient drainage is vitally necessary.
9. ASH REMOVAL OPERATION
Periodical ash removal is performed for hopper bottom minimum twice per shift.
The operation of this portion is made automatic with exception of ash removal from
hopper.
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By selecting the appropriate dumping grate section from the panel the complete
section will be dumped in approx 15 seconds (feeder will be stopped and air damper
will be closed and dumping starts). After dumping the ash collected in the hopper
needs to be dumped immediately /as fast as possible. The lower sliding plate of the
chute should be installed before the slide valve under the hopper will be opened.
After closing the slide valve the sliding plate can be removed in order to dump the
ash into a trolley. When the slide valve is closed the operator should directly push the
button for automatic opening of the air damper and starting the feeder. The section is
then in operation again.
10. DATA
Boiler room personnel should be instructed to follow a precise schedule of data

collection. Not only is this data a useful record of system’s performance, but also the
operator will become accustomed to seeing the proper figures on his data chart on
regular intervals (preferably on hourly basis) and when something drifts off the norm,
he will spot the drift and correct the system accordingly.
11. OPERATOR’S MAINTENANCE
A conscientious maintenance program should be applied. The following list is by way

of suggestion. A schedule for regular minor maintenance is best complied once
operating experience is gained.
Regular cleaning and checking for correct plant operation will be required at intervals,
which will depend on the frequency of load conditions. This criterion will affect
maintenance frequency.
As experience of operation is build up the schedule should be altered to suit.
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11.1 Each Shift
• Check Bagasse feeding system.

• Blow down water column and gauge glasses.
• Water quality check must be done once per shift.
• Blow down is applied based on BFW and boiler blow down results.
• All level gauges must be drained.
• Operate soot blowers.
11.2 Daily
• Make a general inspection of whole plant, checking security and operation of all
dampers and associated linkage.
• Ensure that there is no leakage on flue gas, water and steam lines.
11.3 Periodically
• Clean & inspect inside of furnace fireboxes for deterioration of refractory or insulation.
• Conduct water level alarm check by blowing down the boiler.
11.4 Preventive Maintenance
While operating the Boiler, if anything happens where obvious damage may occur by
continuing to operate, load should be reduced and the unit is taken out of service as
soon as possible. Inspection should be made to assess the problem. If there are
questions about the condition of the unit, contact the DESCON’S OPERATIONS
BOILER DEPARTMENT, Problems which may arise during the operation of the
Boiler, can be separated into two categories:
The first are “Operational problems” & the second are “Maintenance Problems. The
first category has been discussed in the beginning of the Manual. In this section, the
second category will be dealt with. Keep in mind the basic axiom that preventive
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maintenance is the best tool towards avoiding problems that ultimately cause untimely
shutdowns and loss of production.
11.4.1 Tubes
At every outage, if possible, check the waterside of the tubes for scale build-up. If a
scale deposit is formed on the tube surfaces, heat cannot pass effectively into the
water. The scale causes the steel tubes to become overheated and they could blister
or swell to the point of rupturing.
Preventing scale build-up requires close cooperation with a reputable water treatment
laboratory, and close surveillance of the feed water system. To remove this scale
build-up from the tube surfaces, a mechanical tube cleaner can be used, but chemical
cleaning has been found to be more effective. If the chemical cleaning method is
used, it is advisable to hire professional personnel as the Process Engineers, if
handled incorrectly, can damage the metal.
11.4.2 Flue gas side
Check for corrosion layers and carbon deposits. If required wire brushing can be
executed.
11.4.3 Steam drum
During on-line service, the water should be blown down once on every shift or three
times per day. The blow-down will keep sediment or sludge from fouling the float or
the electrodes. When the Boiler is out of service for annual inspection, dismantle the
Steam drum and clean the internals thoroughly.
11.4.4 Preventive maintenance schedule
In order to ensure the normal operation in fail safe mode the Preventive
Maintenance Schedule for boiler should strictly be followed for checks which ever
are applicable.
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Preventive Maintenance Schedule for boiler is consists of following checks.
• Operational Checks
• Electromechanical Checks
• Safety & Security Checks / Confirmations/ Interlocking on boiler & aux plant.
• Drainage and Purging.
A generalized preventive maintenance schedule for water tube boiler to ensure

normal operation in fail safe mode
Sr. Per 3
Description Daily Weekly Month Yearly Remark
No Shift month
1 Operational Checks X
2 Fuel Gas Pressure X
3 Feed Water tank X
4 Intermittent Blow down X
5 Scum/CBD X
6 Feed water Analysis X
7 Flame Formation High Fire X
8 Flame Formation Low Fire X
9 Motor Skin Temperature X
10 Bearing Temperature X
11 Drum Level Locally X
12 Drum Pressure X
13 Steam Leakages X
14 Filter Cleaning Fuel Gas X
16 Filter Cleaning Instrument Air X
17 Strainer Cleaning Water Line X
18 Strainer Cleaning Steam Line X
19 Lamps Indicators Test X
20 House Keeping X
21 Motors any abnormal observation X
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22 Electromechanical Checks
23 Bearings Grease X
24 Gaskets X
25 Moving Parts lubrication X
26 Nut Bolt Tightness X
27 Electrical Loose Connection X
28 Check By Pass Electrical X
Check by Pass across the control

29 X
Valve
Greasing And Lubrication of
30 X
Valves
Greasing And Lubrication of Nut
31 X
Bolts
32 Passivation of Anti Rust X
33 Boiler Drum Internal X
34 Economizer X
Safety and Security

35
Checks/Confirmation
36 Safety Valves Lift X
Steam Pressure Switch High Limit/

37 X
alarm +Trip
Drum Water Level High
38 X
limits/alarm
Drum Water Level Low
39 X
limits/alarm
Drum Water Level Low Low limits/
40 X
alarm +Trip
Fuel Gas Pressure Switch High
41 X
Limits
Fuel Gas Pressure Switch Low
42 X
Limits
45 Flame Sensor X
46 Drainage and Purging
47 Level Gage Glass X
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48 Level Electrode Bottle X
49 Instrument Air filter Regulators X
50 Hydrastep
51 Instrument Calibration X
52 Flue Gases Path Cleaning X
Initial Initial
Name Name
11.5 Annual Checks
• Overhaul all equipment mounted on boiler.

• Drain, inspect and clean all water and gas spaces.
• Obtain services of a boiler inspector for inspection of unit.
• Check and overhaul water level control units.
• Check all internals sealing arrangement of butterfly valve of dampers.
• Replace gland packing of all valves and do lapping if any valve is passing.
• Reset PSV’s on bench.
12. SAFETY
12.1 General safety
− It is a requirement by law that a manufacturer and or supplier of equipment

ensures that the equipment manufactured is at such a standard so as to be
operated and maintained in safely.
− It is also a requirement by law and suitable for intended function that the
purchaser and user of the equipment, ensures that the installation,
commissioning, operation and maintenance of said equipment is carried out by
competent persons.
− Where the competency of the person is in doubt then appropriate training shall
be provided or obtained.
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− It is also a requirement by law that the operator and maintenance persons ensure
that they are adequately trained to carry out their responsibility on the said
equipment and that they are given suitable training where required.
− It is also a requirement by law that the operations and maintenance departments
act in a safe manner and take due care of their own and others safety during the
execution of their duties.
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12.2 Requisite for the safe operation of the boiler unit:
− The Boiler shall be housed in an adequately ventilated space.

− Suitable firefighting equipment shall be situated in the building.
− The area around the boiler should be kept clean and free of all debris
− Do not leave control panels and junction box door covers open during “power on”
and operation. If it is necessary to do so for fault diagnosis and rectification, then
suitable notices should be posted around the area indicating same and the work
should only be conducted by personnel suitably qualified by training and expertise,
ensuring that the doors and cover are replaced as soon as possible.
− Ensure that all hot pipes ducts are suitably insulated.
− A set of practices and procedures should be developed for any maintenance work
to be carried out, and should include permit to work control procedures.
12.3 Safety practices and procedures:
12.3.1 For boiler operators
In the event of the failure:

− The unit is to be shut downed completely.
− Notices are to be posted indicating that unit is not to be restarted
− Notify maintenance personnel of problem
12.3.2 In the event of fire:
− Switch off all electrical supplies.

− Notify the appropriate fire authority within the company. Learn and use fire
extinguishing devices in case of emergency.
− Shut off all ventilation systems.
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12.3.3 General house keeping:
− Ensure that all water leaks are stopped and the spillage is cleaned away
and that any leaks have been rectified.
− Ensure that no debris exists around the boiler and any associated
equipment.
− Ensure that the space is adequately ventilated at all times.
− Monitor at regular intervals the operational functions of the unit.
− Be aware of the water treatment plant and chemicals used.
− Observe safety precautions at all times.
12.3.4 For maintenance operations:
− Use a permit to work procedure. This ensures that all necessary persons
are notified and that appropriate precautions are in place.
− Always ensure that electrical supplies are isolated and are locked off with
notice of name and department.
− Post notices around indicating work taking place.
12.3.5 Routine maintenance work:
− Obtain permit to work as appropriate to the type of work being undertaken.

− Switch and lock off all appropriate supplies such as Exhaust Gas, Water,
Steam and Electricity.
− Post notices to indicate work being undertaken and associated hazards.
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Boiler Shut down Procedure
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TABLE OF CONTENTS
1. Introduction………………………………………..…………….……………………….. 3
2. Planned shut down………………….…………………………………………………… 3
3. Eemergency shut down……………….……………………………..………………… 4.
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1. INTRODUCTION
There are two types of shut down namely:

- Planned shut down for maintenance / inspection
- Emergency shut down (After boiler trip)
2. PLANNED SHUT DOWN
The procedure for a planned shut down is a fully operator action, the following steps
have to be taken:
1. The boiler load is decreased to its minimum and the pressure control is put on
manual.
2. The block valves upstream the steam start up valves are opened and the steam
blow off valve is put on automatic for steam pressure control.
3. The main steam stop valve and its bypass can be closed.
4. Then the following steps prior to stopping firing in furnace or boiler shut down.
• Baggase supply from Baggase conveyor is stopped
• Baggase gate is closed.
• The steam drum level control is put on manual and the BFW control valve is put
on minimum opening of 10%. The water level in steam drum will drop now
• Baggase feeder is set at a minimum revolution & remainder Baggase in
Baggase chute and feeder portion is removed.
• Finally Baggase feeder is stopped.
• Close the BFW control valve completely.
• When no fire is seen in the furnace & it is ensured that all burnable are removed
from the boiler system, take the combustion air control and furnace draught
control on manual and shut-down fans in the following sequence,
- First Secondary FD & Spreader air fan are stopped.
- Then Force draught fan will be stopped.
- And finally Induced draught fan will be stopped.
- Finally close the air dampers under the grate to avoid further rapid
cooling down of boiler
• To heap up Baggase in chute after closing the gate is effective for high air seal
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effect; however, precaution against fire accident (by backfire) should be taken.
5. Prior to shutting the steam generation down, operate the soot blowing
equipment more than normal.
6. After shutdown put all controls on manual and close all control valves
7. Stop BFW pumps and condensate drain pumps.
Note: Depending upon the time for unit closure decision will then be made as to which
preservation technique will be more applicable for the unit out of service.
3. EMERGENCY SHUT DOWN.
The emergency shut down is executed by pressing the emergency shut down button or
is executed due to a boiler trip signal. The result is that the safeguarding system (BMS)
will immediately stop the heat input to the boiler by initiating the following trip signal, the
sequence is as follows,
1. Bagasse feeders stop

2. Secondary FD & Spreader air fan are tripped.
3. Force draught fan will be tripped.
4. And finally Induced draught fan will be tripped.
5. Air dampers under grate to be closed
6. Main steam steam stop valve and its bypass valve to be closed. The start-up
valve remains on pressure control.
7. BFW control valve to be closed.
Once these immediate actions are taken by the system further actions as in case of
planned shut-down are to be followed.
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Note
• Further the procedure for preservation after a boiler shut down is described in
lateral chapter of this manual.
• Also the procedure for maintenance or inspection after a boiler shut down is
described in lateral chapter of this manual.
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Safety
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TABLE OF CONTENTS
1. Precautions……………………….………………………………………………… 3
2. Boiler Access……………………………………………………………………… 4
3. Valves…………………..…………………………………………………………. 4
4. Instrumentation……..………………………………………….………………… 5
5. Instrument line blow down……………..……………………………………… 5
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1. PRECAUTIONS
Boiler Safety is everyone’s business. This section’s purpose is to inform the

operator’s of the potential risks associated with the operation & maintenance (O&M)
of Descon’s Boiler.
NOTE:
• This section contains suggestions for safe operation & maintenance of

Descon’s Boiler.
• This section shall not be considered as a safety standard or procedure.
• Minimum requirements are presented for the benefit of the reader, but this
section is not intended to be all inclusive.
Proper installation, operation, & maintenance are essential for safe & reliable boiler
operation. The performance of the required tasks for boiler O&M will require
personnel to be in the proximity of high temperature & pressure fluids.
Precautions taken should include, but not be limited to, hearing protection, eye
protection, protective clothing (i.e., gloves, hard hats, long sleeve shirts) as required
for the task being performed.
Due to the various circumstances & conditions in which plant personnel may be
working & the consequences of each, Descon cannot possibly evaluate all conditions
that may injure personnel or equipment.
Nevertheless, Descon is offering the following safety precautions for plant personnel
information only. When replacing instrumentation, always isolate the instrument with
the root valves & remove pressure with instrument vent or blow off line.
CAUTION: Do not try to repair an instrument when under pressure.
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2. BOILER ACCESS
Some precautions needed to be checked are,
• Entering ductwork / boiler casing through access doors during an outage for
routine maintenance/ inspections, operators should ensure that the
environmental check has been made for man safe entry conditions.
• Temperature & environmental gases should not be tainted with exhaust fumes
or other gases detrimental to personnel.
• When entering the cavity, look around to be sure there are no loose liner panels
or other boiler components overhead.
• Extended outages for major boiler upgrades or maintenance require a lock out
of the complete boiler from operation. Under no circumstances should the unit
have any chance of operation when personnel are inside the boiler for
inspection or maintenance.
• After safe entry has been gained, ensure proper lighting & ventilation
installation to perform the task.
• When entering steam drums, operators should mechanically ensure that drum
access doors cannot be unintentionally closed trapping personnel inside. And
water and steam stop valves are closed and locked at close position.
• In inclement weather, operators should be aware of slick grating on the
platforms which are external to the boiler enclosure.
• Operators should be alert for grating not properly fastened down. Loose grating
can result in tripping hazards.
• When boiler is in operation, never touch an exposed piece of process pipe or
tubing without first testing for temperature.
NOTE: Discolored casing areas are indicative of hot spots. And can indicate
insulation system failure.
3. VALVES
Never repack or perform maintenance while the valve is under pressure unless a
special procedure exists (i.e., setting of safety valves) & qualified personnel are
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performing the task. Always be sure that all safety relief valves are in working order
prior to start-up.
CAUTION: Boiler operation with any safety relief valve non operational could cause
serious injury & excessive damage to the boiler pressure parts.
4. INSULATION
Repair damaged insulation & lagging as soon as possible, particularly in areas where
personnel could be injured (i.e., near aisles, areas reached from platforms, ladders,
stairs, grade, etc.). The insulation specified is non asbestos bearing rock wool or
ceramic wool.
5. INSTRUMENT LINE BLOW DOWN
When blowing down an instrument sensing line, hot water & steam will be discharged.
Instrument sensing lines (normally not insulated) would be heated to high
temperatures. The area should be safe guarded until lines have cooled.
NOTE Excessive blow down of transmitter lines will expose the transmitters to
excess temperature & cause premature failure.
CAUTION: Operating gauge glass valves incorrectly can cause damage to glass
ports & results in serious injury. When examining high pressure steam Lines for leaks,
extreme care should be used, particularly if the leak is heard but not seen.
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Boiler Inspection Procedure
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TABLE OF CONTENTS
1. Introduction……………………….………………………………………………… 3
2. Purpose of inspections…………………………………………………………… 4
3. Frequency of inspection…………………………………………………………. 5
4. Cause of deterioration………………………………………….………………… 5
5. General preparatory work for inspection……………………………………… 5
5.1 Inspection before cleaning …………………………………………………….…... 6

5.2 Final inspection after cleaning …………………………………………………….. 6
6. Boiler records……………………….……………………………………………… 6
6.1 Construction records…………………………………………..……………………. 7

6.2 Field notes……………………………….…………………………………………… 7
6.3 Historical records…………………………………………………………………….. 7
6.4 Boiler Log sheet records…………………………………………………………….. 7
7. Reports ……………………………………………………………………………… 8
8. Conclusion ………………………………….………………………………………. 8
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1. INTRODUCTION
Before a boiler installation is inspected, amongst other things, the following

conditions are to be fulfilled:
- The boiler must be drained and sufficiently cooled down. During cooling down the
pressure in the boiler will drop.
- The main steam pipe shall be isolated from the main grid by means of a blind flange
(spectacle blind).
- All connections for feed water, drain, steam shall also be insulated by means of stop
valves and blind flanges or they shall be disconnected. (Only in case a second
boiler is in operation).
- If client employs an own safety inspection department, this one shall give a
"declaration of no objection" before the installation is entered.
- Good ventilation shall be provided, for example by opening the inspection doors.
- In view of risk of explosion, no open fire shall be used for illumination at boiler
inspection. Portable lamps and electric cables must comply with local regulation, be
earth connected and be in good condition. Voltage shall not be higher than 42 V.
Daily inspection
- All man ways must be free from obstacles.

- The access to the inspection doors shall be free.
- Check whether all peepholes are clean and clear.
- Remove all loose dirt or other foreign matters, from the piping as well as from the
connecting flue gas ducts.
- Check the connecting pipe work and flue gas ducts for good condition, fittings etc.,
sealing’s and expansion pieces for proper operation.
Yearly inspection
- It is recommended to clean the boiler on the waterside.

- Sludge that might have been left behind must be removed through the manhole.
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- The drum and its internals shall be inspected for, and when necessary, shall be
cleaned from traces of grease, oil and the like.
- If a little scale deposit is found, the tri-sodium phosphate dose of the feed water
must be increased. If the deposits are heavy, the boiler must be chemically cleaned
(consult for that matter specialised enterprises).
- Bolts and nuts must be greased with molycote, graphite or another heat resisting
lubricant, after each inspection.
- For the inspection requirements of the other equipment we refer to the attached
instructions of the sub suppliers.
- Check the boiler for cracks, pitting, corrosion, erosion, deposits and possible traces
of leakage, on the flue gas as well as on the water side.
- On the flue gas side the boiler shall be thoroughly cleaned. This can be done by
rinsing with water, mechanical means or chemical methods. In the latter case, it
shall be checked that possible left chemicals are sufficiently neutralized.
2. PURPOSE OF INSPECTIONS
The reason for having an inspection of a boiler is to determine by comparison with

the initial inspection at the time of construction or with basic records the effect that
corrosion, erosion and other factors have had on the equipment.
It also helps to maintain the safety and efficiency of continued operation and
forecasts maintenance and replacement based on the indicated rate of deterioration.
In the same way all subsequent inspections are compared with preceding inspection
of the same specific purpose.
Regular inspections make it possible to predict the repairs or replacement that will be
required at the next scheduled shutdown-period by reviewing the data accumulated
at regular inspections and by continual awareness of actual conditions.
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3. FREQUENCY OF INSPECTION
Minimal interval between inspections is usually set by local law or by insurance

carrier. However, government and insurance company inspectors will concern
themselves only with the pressure parts of the boiler to make sure that the boiler
condition is still within the requirements of the boiler law and/or in an insurable
condition.
The plant inspector however must be concerned not only with this part, but also with
related non-pressure parts including furnace, flue gas ducts, stacks, steam drum
internals and all other auxiliary equipment.
The frequency of inspection will also be determined by actual operation conditions,

water quality, and quality of fuels and so on, as well as climatic conditions and
location of boiler on the plant (near cooling towers and or sea water funnels).
4. CAUSES OF DETERIORATION
1. Overheating
2. Poor water quality
3. Carry over
4. Corrosion fireside and waterside
5. Improper use of cleaning tools
6. Improper water tightness of casing
7. Improper maintenance, alignment, lubrication and so on
8. Excessive vibration
5. GENERAL PREPARATORY WORK FOR INSPECTION
Before the inspection, the tools needed for inspection should be checked for
availability, proper condition and accuracy. This includes tools and equipment for
safety.
Minimal required tools for inspection:
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- Portable lights + flashlight

- Scraper or knife
- Inspectors hammer
- Inside/outside callipers
- Pit depth cage
- Note book
- Wire brush
- Thickness measurement equipment
- Small mirror
- M.P.I. equipment.
Inspections should be carried out in two steps
5.1 Inspection before cleaning
The location, amount, physical appearance and analysis of mud, sludge or scale
deposits will provide information about the effectiveness of the feed water treatment,
blow down operation.
This inspection will also be helpful in determining which parts of the boiler require the
closest inspection.
5.2 Final inspection after cleaning
This inspection will be very helpful in determining the quality of cleaning being carried
out and to see whether the objectives are met or not before giving final go ahead..
6. BOILER RECORDS
Separate records should be kept for each boiler. A complete boiler record file should
consist of:
Construction records
Field notes
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Historical records
Log sheet records
6.1 Construction records
Construction records should consist of:

- Drawings, specifications, design data and any information relative to the
construction or repair of the boiler.
6.2 Field notes
Field notes should consist of:
- Records made in the field

- All measurement and inspection results
- Records of all repairs
- Description of any unusual condition encountered during operation
6.3 Historical records
Historical records should consist of:
- All data accumulated for a boiler since the time of its construction.
- Records of all measurements, repairs and replacements.
- Service conditions.
- Copies of all inspection reports.
6.4 Boiler log sheet records
Boiler log sheet records should consist of:

- All data of boiler and auxiliaries equipments operating parameters since the time of
its construction.
- All data of rotary equipments associated with boiler operation.
- Analysis of water and flue gas side.
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7. REPORTS
Inspection reports should be clear and complete.
All unusual conditions observed should be reported fully, incorporated by sketches,

diagrams and photographs.
8. CONCLUSION
All above mentioned information concerning inspection is based on experience and

only for general use.
For a more detailed maintenance and inspection program based on your particular
boiler, Descon Technical Service Department will be pleased to assist you.
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Tube Repair Procedure
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TABLE OF CONTENTS
1. Introduction ………………………………………………………………......………. 3
2. Procedure …………………………………………………………………………….. 4
2.1 Dig procedure ………………………………………………………………………… 4

2.2 Plug off procedure …………………………………………………………………... 7
3 Calamities …………………………………………………………………………… 8
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1. INTRODUCTION
In case of leakage of any of the boiler tube/ module, Descon shall be contacted to
define a repair Plan. The plan of action will have to be defined at that moment, since
it is not possible to provide a detailed repair plan in advance as the details of the
repair are very much depending on the actual location of the leak.
However in general following can be said.
There are various options of repair. Basically this consists of a repair in the area of
the upper or lower header. Because in case of leakage to a tube this shall be
repaired by simple welding at the location of the leak, or if this is not possible the
repair to tubes will be done by replacing the damaged sections by new tube spools.
This results in cutting and welding close to, or at the header.
Depending on the location of the leaking tube and the design data of the boiler it
sometimes is worth to consider plugging of the tube.
Drawing is available and the people are qualified for their activities.
Procedures for entering a confined space should be available and used (see also
Inspection and maintenance procedure).
Repairs in the middle of the module banks are more complicated because of limited
access. Suppose if in a boiler the maximum number of tube rows is 24, which means
worse case will be a leak in tube 12 (b/w the tube bundle). In this case it should be
decided whether to repair the tube by the so-called "dig procedure", to lift or lower a
module, or to plug off the tube.
Basically the main option for direct fired boilers is the dig procedure. The plugging off
procedure is the solution that should be decided for when the dig procedure is not
possible or to time/cost consuming.
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But as said before Descon shall be contacted to define a detailed plan of action,
because experience has learned that there are more options available outside the
mentioned main options, all depending on circumstances and actual location of the
repair.
Both procedures will be described hereafter.
2. PROCEDURES
2.1 Dig procedure
This is the normal conventional procedure, which consists of cutting the tubes that
are in front from the place of access until the damaged tube is reached. This is a well
proven repair method which is very suitable for repairs that are not too far into the
module bank.
Example of dig procedure when leak is found (worst case) in row 8 on the front side
of tube, which means that we have to dig access to the leak spot by cutting tube
spools from row 1 up to 6, see also figure 1.
Number of tubes to be cut:

- 4 tubes from row 1
The exact amount of tubes will differ from case to case, depending on the place
where the leak is found on the tube (front, rear, left or right side).
Tube length to be cut:

- 1250 mm from row 1
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After repair of leak, the tubes of the preceding row can be used for repairing the
following row, which means that only tubes from row 1 should be replaced by new
tubes (either finned tubes or bare tubes).
Actual sequence of work:
1. Locate leak.
2. Cut sufficient tubes by grinding, to create access for repair work (at least 100 mm of
tube should stay on header).
3. Repair leak and carry out NDE as required.
4. Remove fins from tubes by grinding over a length of approximately 100 mm from
bevel ends.
5. Bevel tube ends in boiler according welding preparation.
6. Measure the actual length between bevel ends and bevel the required spools.
Actual spool length should be the measured length minus one welding opening,
see also figure.
7. Fit up one spool at one end and weld complete. Dye penetrant examination on root
and capping run.
8. Prepare fit up on the other end of spool after cooling down of first weld (to prevent
stresses in the tube due to shrinkage of weld).
9. Weld spool end & dye penetrant on root and capping run.
10. X-ray both welds.
11. Repeat step 6 through 10 for rest of tubes.
12. Hydro test boiler according test procedure.
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FIGURE 1 DIG CUTTING PROCEDURE /
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2.2 Plug off procedure
Procedure for plugging off tubes is as follows (see also sketch below):
1. Remove outside cladding and insulation on boiler roof and cut about 1 m2 of boiler
roof casing just on top of leaking tube.
2. Take exact measurement of leaking tube to header end.
3. Mark location of tube on top of header.
4. Cut a patch in header (approx. 200 x 100 mm).
5. Repeat 2, 3 and 4 also for bottom header.
6. Identify and/or confirm leak spot in relevant tube.
7. Drill a hole ø 5 mm in leaking tube to prevent overpressure in tube after plugging.
8. Prepare plugs with diameter = inside diameter of hole in header – 1 mm and
thickness = wall thickness of header and a bevel angle of 30°.
9. Weld plugs in header according WPS welding procedures.
10. Smooth up internal header surface and carry out dye penetrant examination.
11. Prepare patch and window of header.
12. Install and tack weld patch.
13. Check fit-up.
14. Weld window complete in accordance with WPS welding procedures.
15. Dye penetrant examination on root and capping run.
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16. Carry out UT, Ultrasonic Testing examination if possible.
17. Hydro test boiler.
18. Reinstall boiler casing and insulation.
3. CALAMITIES
In case of calamities when a great amount of tubes must be replaced on the same
header it can be decided to pull the complete header with tubes and to do the repair
outside the boiler. In this case we would recommend consulting Descon technical
service department for more detailed procedures based on the specific job.
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Preservation Procedure
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TABLE OF CONTENTS
1. Introduction……………………………………………………….………............... 3
2. Dry storage………………………………………………………………………..…. 3
3. Wet storage……………………………………………………………………….…. 4
4. Preservation on the flue gas side……………………………………………….. 5
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1. INTRODUCTION
When a boiler is taken out of service, the boiler should be cooled down until the water
is below the atmospheric boiling point, but not below 80 °C, the boiler should be
emptied and flushed out.
An inspection should be made to determine what repair work is necessary and what
mechanical and chemical cleaning should be done. A decision should then be made
on whether to employ dry storage or wet storage. Since freshly cleaned metal
surfaces are much more vulnerable to storage corrosion than surfaces that have
operational oxides on them, it is much preferable to delay chemical cleaning until the
boiler is ready to be returned to service.
2. DRY STORAGE
This procedure may be preferable for boilers out of service for extended periods of
time or in locations where freezing temperatures may be expected during stand-by.
1. The boiler should be thoroughly dried, since any moisture left on the metal surface
would cause corrosion to occur on long standing. After drying, precautions should
be taken to preclude entry of moisture in any form, from steam and feed lines.
2. For this purpose, moister-absorbing material, such as silica gel at a rate of approx
2.7 kg per m3 boiler volume may be placed on trays inside the drum to absorb
moisture from the air. The manholes should then be closed and all other
connections on the boiler tightly blanked. The effectiveness of the materials for such
purpose and need for their renewal may be determined through regular internal
boiler inspections.
It is usually desirable in the case of large utility boilers to simply drain the boiler
completely, applying nitrogen continuously during draining operation and maintain a
pressure of nitrogen greater than atmospheric throughout the draining and
subsequent storage period.
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3. WET STORAGE
Particularly useful if the stand-by boiler may be required for service at short notice or
if it is impractical to employ a dry storage procedure. The method is not generally
employed for boilers which may be subjected to freezing temperatures.
Several alternative procedures have been employed:
The empty boiler should be closed and filled to the top with water, conditioned
chemically to minimize corrosion during stand-by. Water pressure greater than
atmospheric should be maintained within the boiler during storage period.
1. For a short storage period, condensate of feed water containing approximately 200
ppm sodium sulphite may be used. If superheater is drainable it can be filled with
the same treated water by overflowing from boiler.
2. The boiler can now be filled through the feed water or other filling line with
condensate feed water or clean service water treated with hydrazine and
additional volatile alkali. If the storage period is expected to exceed three months,
the concentration of hydrazine should be doubled.
3. If preferred, the boiler may be filled using feed water or condensate treated with
sodium sulphite as described in point 1 after first filling superheaters with
condensate treated with hydrazine and additional volatile alkali.
As an alternative, the boiler may be stored with water at normal operating level in the
drum and topped-up with nitrogen maintaining a pressure of nitrogen greater than
atmospheric throughout the storage period. To prevent in-leakage of air, it is
necessary to supply nitrogen at the vents before the boiler pressure falls to zero as
the boiler is coming off line. If boiler pressure falls to zero, the boiler should be fired
to re-establish pressure; superheaters should be thoroughly vented to remove air
before nitrogen is added. All partly filled steam drums and superheater headers
should be connected in parallel to the nitrogen supply. If nitrogen is supplied only to
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the steam drum the nitrogen pressure should be greater than the hydrostatic head of
the longest vertical column of condensate that could be produced in the superheater.
4. PRESERVATION ON THE FLUE GAS SIDE
It shall be checked that no acid constituents (H2SO4) from the flue gases are found
on the tube walls and other boiler parts, to prevent corrosion with all its
consequences.
So it is understood that the boiler must be very carefully cleaned on the flue gas side,
and as to that, cleaning right after taking out of service, when still warm, is the best
procedure. Especially tube banks should be carefully cleaned to prevent serious
damage as a result of Sulphur corrosion.
Further, the cleaned surface must be treated with an acid free preservative.
After cleaning a small container with a moister-absorbing material, such as silica gel
@ 2.7 kg / m3 of boiler volume may be placed inside the combustion chamber to
absorb moisture from the air. The manholes should then be closed and all other
connections on the boiler tightly blanked. The effectiveness of the materials for such
purpose and need for their renewal may be determined through regular internal boiler
inspections.
For preservation of the other equipment, we refer to the applicable instructions of the
sub-suppliers.
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Water Washing Procedure
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TABLE OF CONTENTS
1. Water Washing…..………………………..………………..………………........... 3
2. Washing Sequence & Drying Out……………………………………………….. 4
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1. WATER WASHING
When burning certain low grade fuels and if the quality of combustion is allowed to
deteriorate, the lanes between the super heater tubes may become slagged up with
bonded deposits which cannot be removed by normal soot blowing.
As nearly all the slag formed consists mainly of a non - soluble base bonded by a
relatively water soluble binder, the use of water under pressure will accomplish the
following dual purpose:
a. Loosening the binder, and

b. Flushing away the loosened insoluble deposit
Water washing must be continued and without break until all deposits are removed;
otherwise remaining dissolved deposits will harden. It should be realized that once
deposits start building up, especially on Superheater tubes surface, the subsequent
build-up is rapid, therefore, water washing should be carried out at the first
opportunity.
A wetting agent (e.g BEROL 563 or equivalent, efficient hydrotroping agent for
cleaning and degreasing), can also be used to a great advantage before the actual
water washing starts. Generally, the required solution comprises of the following
chemicals:
BEROL 563 : 25 liters

Soda ash (Na2CO3) : 10 Kg
Common salt (NaCl) : 10 Kg
Make-up Water : 500 liters
When a wetting agent is used it is sprayed on the deposits with a suitable type of
spray designed to prevent waste of solution by dripping off. The spraying should be
continued until the deposit is thoroughly wetted or until the deposit drips, no longer
absorbing solution. In some cases, particularly with the hardening type of deposits, it
may be an advantage to allow the wetting agents to soak in for several hours, but
careful observation should be made to ensure that no drying-out occurs.
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Normal water washing should then be carried out as follows:-
- Supply fresh water at a temperature of approximately 65-70°C.

- Deliver the hot water to a lance at pressure between 14-17 bar.
- Direct the jet of water into the slagged sections so as to most expeditiously
remove the accumulation. Every endeavor should be made to insert the lance
upwards and downwards through the vertical and diagonal lanes to wash all
slagged sections at close range with the water jet.
- Dry out the unit.
- A relatively high pressure, 14 / 17 bar, and a temperature of 65-70 °C must be
maintained in order to obtain the best results.
A 1” and 2” diameter steam hose, preferably wire bound, is ideal for carrying the
water to the nozzle. The lance or nozzle itself is usually made up from odd lengths of
¼” pipe. From one to four 1/8” dia. holes should be drilled along the pipe near the
end.
At times it may be more convenient for reaching certain areas to drill only one ¼” dia-
hole at the end of the pipe at a desired angle so that the spray is directed out of the
end of the pipe to reach those points; a thin flat lance for penetrating into the banks
of tubes can also be extremely useful. In addition, several types of nozzles may be
required for any one boiler. However, as the equipment is extremely simple, each
operator may best determine for himself the set-up that is most suited to his
individual needs.
2. WASHING SEQUENCE & DRYING OUT
When cleaning the whole boiler unit, water washing should normally start at the top
of the economizer / super heater / boiler tubes and work down systematically. Water
dripping down from the top banks tends to soften the slag accumulations in the areas
below those being washed thus making the cleaning job faster and easier when
these lower areas are reached.
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During water washing the accumulation of water is removed via the permanent drains
fitted, which must be kept clear. Water washing can commence as soon as the unit is
cool enough for personnel to enter. The time required for water washing one boiler
will depend on the extent and nature of deposits.
Once water washing has started it must be continued until washing of all surfaces
has been completed and all deposits removed, otherwise some types of deposits
when wetted and allowed to dry will harden and become more difficult to remove.
With old or stubborn deposits a sustained period of water washing may be found
necessary; alternatively, a cleaning specialist should be called in to carry out water
washing with a special high pressure jet, operating with a water pressure of greater
than usually 27.5 bar
After water washing all deposits which have been removed from the tubes must be
thoroughly washed away. The unit must be dried out immediately upon completion of
the washing procedure. Using a very light fire it will usually be found to take between
8-12 hours to thoroughly dry out the boiler. Provided the unit is dried out immediately
upon completion of the water washing no damage will occur to the brick work. The
necessity of lighting up and drying out after water washing cannot be too strongly
stressed, and it might be found more convenient to carry out water washing before
the boiler is out of commission and being unable to immediately light up the boiler.
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Boil Out / Dry Out

Procedure
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TABLE OF CONTENTS
1. General……………………………………..………………..………………........... 3
2. Hydrostatic testing….…………………………………………………………….. 3
3 Drying out procedure (If applicable)….………………………………………… 4
4. Alkaline boil out…………………..………………………………………………… 5
4.1 General……………………………………………………………………………..… 6
4.2 Resources and equipment…………………………………….…………..……….. 7
4.3 Preparation…………………………………………………………………………... 8
4.4 Chemical introduction activities…………………………………………………….. 9
4.5 Chemicals…………………………………………………………………………….. 9
4.6 Procedure…………………………………………………………………………….. 10
4.6.1 Economizer and Superheater …………………………………………………..… 11
4.6.2 Deaerator (Integrated)…………………………………………………………….... 11
4.6.3 Post boil out activities……….…………………………………………………….… 11
5. Boil out preparation check list …………………………………………………. 13
6. Boil out procedure check list……………………………………………………. 14
7. Valve positioning…………………………….……………………………………. 15
8. Chemical data for boil out…………………….……………………………………. 16
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1. GENERAL
When the pre-service inspection is complete, and when all problems have been
rectified, then the system can be subjected to its final series of tests before putting it
into service
2. HYDROSTATIC TESTING
All Descon boilers are hydro-statically tested in the works. However, the unit along
with any steam header or inter-connecting piping should be re-hydro-tested before
starting up, if required. The steam and water lines must be completely vented in
order to fill them with water. Proceed as follows:-
1. Open the vent valves on the Boiler and gag the safety valves.
2. Isolate any pressure switch or control, which is not intended to be subjected to
the hydro-test pressure.
3. Fill the system with treated water. The water should be at room temperature
(20 ºC recommended). If the water is over 37ºC, fill the system slowly to avoid
any thermal shocking.
4. Once the system is filled, the pressure may be increased to a maximum of 1.5
times the design limit of the system, or to the requirements of the local steam
Boiler inspecting agency.
Caution:
Do not over-pressurize the system.
5. Examine the system for any leaks. If no leaks are visible, hold the system in a
pressurized static condition for a period long enough to satisfy both yourself and
the inspector, that the system is tight.
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3. DRYING OUT PROCEDURE (IF APPLICABLE)
The drying out of the refractory in the steam generator is very important to ensure
proper performance of the refractory once the system is in service.
Proceed as follows:
1. Undue stresses will be aerated within Boiler shell if the heating be uneven. To
eliminate this, following procedure should be adopted. Fill the unit with water to
slightly below the normal water line and leave the vent valve in the steam drum
open, until steam vapors start to come out after firing. The warming up period
should be as long as possible and is recommended that Boiler be operated
continuously at low load.
2. The firing rate in the boiler should be low at to enter the boiler system at low flow
rate for periods of five minutes on and five minutes off, in accordance with the
demands for heating up the system. This intermittent operation should continue
for minimum two hours or until moisture vapors stop coming from the stack.
Caution: Heating rate should not be faster than startup curve.
3. By now the refractory should be cured and the system can be boiled out. Boiling
out can be done concurrently with drying out.
4. During this process make sure that steam is flowing through vent.
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4. ALKALINE BOIL OUT
Purity of the pressure part surface of the boiler is of great importance to all boilers.
With increasing heat transfer, increasing steam pressures and the resulting higher
steam saturation temperatures, the purity of the surface becomes more and more
important.
Contamination at the pressure side of the boiler can result in damaged boiler tubing,
or can result in carry over of loose particles into the steam system. These can then
form deposits on the turbine blades or can cause damage to the superheater tubes
and if steam is used in the food processing directly, it can contaminate /poison it.
Oil and grease from deposits on the boiler tubing surface form a barrier to heat
transfer which may result in damage to these tubes due to local overheating.
Especially with boiler functioning with natural circulation, which is the case with this
type of tube banks
Residues of oil may lead to foaming which, in its turn, causes water to mix with the
steam, resulting in unreliable water level readings and the formation of deposits in
the superheater.
In order to remove oil, grease and rests of paint, the boiler is subject to a boil out to
be carried out by a qualified commissioning engineer.
Descon prefers an alkaline boil-out procedure for chemical cleaning of the boiler.
This procedure will be described below.
Other chemical cleaning methods could be followed, procedures for that are
depending on the type of chemical cleaning.
For project typical data refer to procedure data sheet document.
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4.1 General
The alkaline boil out is a widely applied, common way of initial boiler cleaning. From
a pure chemical point of view alkaline solutions are not capable of removing the most
common iron oxides like hematite and magnetite as being present in new boilers. For
this reason the appearance of the surface of a drum will show no significant change
upon alkaline boil-out.
The total effectiveness of the cleaning method is difficult to measure directly and is
highly depending of a number of factors, not all in the hand of the commissioning
engineer. The initial condition of the boiler with respect to the amounts of rust and/or
mill scale present can not be influenced. In addition large amounts of foreign material
like sand or metal parts from mechanical activities (welding, drilling) are not removed
with alkaline boil out and have to be removed from the system in a different way.
For an optimal result the commissioning engineer has to control the following three
process parameters:
1. The alkaline condition during boil out (pH preferably > 10) serves two objectives:
the removal of the organic fats and oils, and protection of the boiler inside wall for
acid corrosion. It has to be considered that a boil out often is carried out using non-
deaerated water in combination with air pockets in the system. In general, an
unwanted situation with respect to corrosion which destructive effect will be
amplified in neutral or acidic conditions.
2. The effectiveness of an alkaline boil out is strongly dependent on temperature. It
can be assumed the boil out will have little to no effect if the temperature remains
below 85 °C. An increased affectivity can be obtained by increasing the
temperature. In practice the temperature has to be chosen at approx. 135 °C.
Lower temperatures will require longer boil out times.
3. Time is the third process parameter influencing the quality of this cleaning
technique. The solving of the organic deposits from the boiler is a time dependent
process and therefore more complete with longer process time.
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A boil-out has to be performed one or two times during an uninterrupted period of 8

hours at the stated alkalinity and temperature (pH: 10, T: 100 - 135 °C min.).
The applied chemicals are responsible for two main effects: keep the pH at the
desired value & provide a chemical condition in which the organic components will
remain solved. The presence of Na Phosphate & Nitrate will minimize the existence
of 'free' caustic, which is responsible for caustic embitterment, a type of corrosion.
Due to liquid turbulence and the possible application of changing temperatures a

certain part of loose or semi loose rust and mill scale will be removed from tubes and
drum walls. This material will be collected in areas with the lowest liquid velocities.
These parts shall be carefully cleaned and flushed after boil out.
4.2 Resources and equipment
The following manpower shall participate:

• Qualified commissioning engineer (1),
• Field boiler operator (1),
• PLC / DCS Boiler operator (1),
• Fitters (2).
The following (temporary) equipment and/or systems shall be available:

• Temporary equipment as used for the steam flushing procedure for new
boilers
• Spare manhole gaskets
• Pressure measurements drum and steam header
• pH measuring after flushing
• Chemicals
• Cover sheeting
• Water for remedial washing and cleaning
• Safety clothes, signs and equipment
• Feed water system
• Drain system or disposal trucks
• Heat source: burner
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• Control and safeguarding system

• All other tools and equipment as required by the commissioning engineer
4.3 Preparation
Before supplying water and heat to the boiler the following conditions (but not limited
to) have to be fulfilled:
In General:
- The boiler must be completely inspected; the pressure part as well as the flue
gas part, and all foreign items should be removed. Then the blind flanges,
manholes and other openings at the flue gas part of the boiler must be closed.
Fit gaskets.
- All the equipment to be used, including water and chemicals etc., should be
checked and ready for use.
- The responsible operators have read and understood the procedures for filling,
boil-out etc. They are familiar with the operation of the installation. One day
for instruction, checking the equipment and preparing the installation must be
accounted for.
- All valves and cocks are tested for smooth operation and they are
appropriately set.
- All, for this part of the starting-up procedure required, controls, safeties etc.
are tested and approved for. Of great importance here are all the monitoring
instruments in the control room and at the boiler.
- All relevant procedures are complete and present at the installation site.
- All legal and operational requirements are fulfilled and the necessary permits
are present. In written form is laid down who is responsible for this aspect.
- All the above mentioned conditions apply to the complete installation, thus for
the boiler, burner, equipment to be operated by a third party etc.
- Boiler operation shall be manually.
For Safety:
- Barrier off area around and under steam drum.
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- Only personnel involved in this operation are allowed in immediate boiler area.
- Confirm that sufficient water flow is available for remedial washing & cleaning.
- Grating of drum platform at location of filling point to be covered with sheeting
to prevent spilling to the lower area.
- Chemicals to be carried up to the steam drum in containers of max. 25 liters.
4.4 Chemical introduction activities
- Personal protective equipment to be worn, (Goggles and plastic / rubber

gloves as described in the product information.
- Chemicals to be poured into the drum carefully, to make sure that no
chemicals will be spilled.
- After completion of filling the drum, manholes should be closed.
- Empty chemical drums should be dealt with as described in supplier’s
instruction.
- Sheeting on grating should be removed and cleaned by water flushing.
- Barriers to be removed.
4.5 Chemicals
For the alkaline boil out the following chemicals shall be applied
• NaOH, Sodium Hydroxide 2.0 gram/ liter

• Na2NO3, Sodium Nitrate 1.5 gram/ liter
• Na3PO4, Sodium phosphate 1.0 gram/ liter
Chemicals will be added into the drum one by one at a low temperature (maximum
50°C) through the manhole.
The total amount to be added of each chemical has to be calculated from above
table and is only depending of boiler part volumes:
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Alternative compositions can be considered based on supplier’s recommendations

and procedures, but will always be subject to approval of Descon process
department.
Cautions
- Chemicals should be mixed thoroughly outside of unit and inserted in the

form of slurry.
- Do not add the chemicals to boiler until ready to perform the boil out. If
chemicals are added in a stagnant concentration or if chemicals lay dormant
for any length of time, they adhere to steam surfaces and may cause
corrosion problems.
4.6 Procedure
- Fill the boiler with warm or cold water up to about 100 mm below the level of
the opened manhole in the drum. The temperature of the water should not
exceed about 50 °C, because at higher temperatures the evaporation of the
hot water will hinder the operator to add the chemicals. If the water has not
yet reached this temperature, the temperature should be raised by extra heat
input (gas turbine or burner).
- Add the required chemicals in the steam drums and close the manholes.
- Fill the steam drums with water until the boil out start-up level.
- Start the heat input, as per start-up procedure, and raise the pressure of the
boiler slowly to the boil out pressure level.
- Adjust the valves according to the valve position table at the end of this
chapter.
Cautions
The pH of the boiler water is high, so be careful with opening the start-up/vent valve.
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- At boil out pressure level the heat input shall be stopped (burner or diverter)
or minimized (GT). To prevent condensation in the superheater the start-up
valve shall be left slightly open.
- The drum level shall be maintained above the Low Alarm level. Boiler feed
water shall be added as required.
- When the pressure drops to the boil out relief pressure level the heat input
shall be introduced again to raise the pressure till the boil out pressure level.
Repeat these steps for approximately 8 hours.
- After 8 hours the heat input can be stopped completely (if not already
stopped) and the boiler should be drained completely as fast as possible. For
an optimal effect it is preferable that the plant drain system shall be used and
the disposals shall be mixed with wastewater. In case trucks will be used a
cool down period will be required.
- After draining the boiler should be filled again with boiler feed water. The
superheaters and boiler have to be flushed.
- The flushing of the boiler parts is complete when the pH of the drained water
is equal to the pH of the boiler feed water.
4.6.1 Economiser and superheater
During the boil-out procedure, economizer and superheater should be dealt with in
the same way as during the start-up period. Therefore the procedure and precautions
for the operation of the air cocks, drains, feed water valves etc., as called for in the
start-up instruction or requirements, should be applied for during the boil out.
4.6.2 Deaerator (integrated)
In case an integrated deaerator is installed the steam drums shall be filled and
isolated from the feed water system to protect the boiler feed water pumps.
4.6.3 Post boil-out activities
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- When the boiler has cooled down, open all manholes and blind flanges of the
bottom headers. Check the drum and the headers for possibly present
residues of mud. If the boiler is not completely free of grease and oil, decide
to boil-out the boiler again.
- Flush the drum entirely clean with a fire hose. Let the water and possible
loose parts flow through the drains / intermittent blow down connections. The
quality of the flushing water used must be the same as or better than the feed
water quality, see Requirements for water treatment and quality.
- Flush all bottom headers. Sludge and dirt, which cannot be removed with
flushing, should be dealt with by a scraper (a stick with a half-moon like blade
connected at its end). If the building-out length next to the headers is not
sufficient, then use scrapers, which can be disassembled, in two or more
parts.
- Mount all flanges and manholes using new gaskets. Make sure that thread of
bolts and nuts are supplied with a heat resistant anti sticking paste.
- After final inspection the boiler can be boxed up again and is ready for
blowing-through of the superheater.
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5. BOIL OUT PREPARATION CHECK SHEET
Accepted Accepted Accepted

Item Activity
Descon Client Others
System has to be freed of loose dirt (all

1) accessible parts) and rinsed with cold water
(tap water quality)·
Assure the availability of water for remedial

2)
washing and cleaning during boil out
Plant drain systems and/or disposal trucks

3) are available for draining the boiler after
boil out.
Heat input (GT/diverter or burner) is

4)
available at low load
If installed, diverter/damper to be functional

5)
(manually or automatically)
Feed-water system is available and/or

6)
isolated from BFW pumps.
Required safety precautions have been

7)
taken.
Assure the availability of the appropriate

8)
chemicals.
Assure the drum water temperature at

9)
approx. 50°C
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6. BOIL OUT PROCEDURE CHECK SHEET
Item Activity Accepted Accepted Accepted

Descon Client Others
1) Open one manhole of the drum and add the
liquid and solid chemicals into the boiler
drum.
2) Close the manhole and fill the drum till the
boil out start up level.
3) Heat up the boiler by starting heat input
according the normal GT or burner start up
procedure.
4) Increase drum pressure according the start-
up curve by increasing the heat input.
5) When boiler pressure reach the boil out
pressure level, either shut the heat input
down or maintain the heat input as low as
possible.
6) Slowly decrease boiler pressure to the boil
out relief pressure and restart heat input as
per above and increase boiler pressure up
to the boil out pressure level again.
7) Continue this activity (step 5 and 6) for a
minimum of 8 hours.
8) During the boil out maintain the water level
of the boiler drum between low level and
high level.
9) When boil out is complete, blow-down the
boiler completely as fast as possible. Allow
boiler to cool down.
10) Rinse boiler with boiler feed water till
conductivity and/or pH meets specification.
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11) When the boiler has cooled down, open all

manholes.
12) Check the drum for possibly present rests
of mud.
13) If the boiler is not completely free of grease
and oil, decide to boil out the boiler again
14) Mount all flanges and manholes using new
gaskets. Make sure that thread of bolts and
nuts are supplied with a heat resistant anti
sticking paste.
15) After final inspection the boiler can be
boxed up and is ready for blowing-through
(steam blow) of the super-heater.
It must be ensured that all water is removed and rinsing with pure water as a
protection against corrosion takes place.
7. VALVE POSITION
TABLE – 1
Valve Hydro Boil out Dry out Operation
Main Steam Shut Off Close Close Close Open
Feed Water Valve (2) Open Open Open Open
Drum Vent (1) Open / Close Open Par. Open Close
Safety Valve(s) Gag Free Free Free
Continuous blow Down (3) Close Close Par. Open Open
Water Column Drain Close Close Close Close
Water Gauge Drain Close Close Close Close
Steam Gauge Shut Off (4) Open Open Open Open
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(1) This valve should be opened to fill the boiler with water.
(2) This valve should be opened as needed to control water level.
(3) This valve should be opened only on emergency needs.
(4) Use a test gauge until after boil-out.
8. CHEMICAL DATA FOR BOIL OUT
Drum water pH >10
Drum water filling

approx. 50°C
temperature
Drum water boil out temperature between 100 – 135°C
Drum water boil out start-up level NWL
2 barg
(In case boiler Op pressure < 5 Barg)
Boil out pressure
5 barg
(In case boiler Op pressure > 5 Brag)
Boil out relief pressure NA
Boil out period 8 hours
Volume Boiler system

Approx = 65 m³
(based on NWL)
NaOH, Sodium Hydroxide

= 2.0 gram/ liter = 130 Kg
Na2NO3, Sodium Nitrate
Chemical required (approx) Typical
= 1.5 gram/ liter = 98 Kg
Na3PO4, Sodium phosphate
=1.0 gram/ liter = 65 Kg
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Steam Blow Procedure
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Revision : 00
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DM.12227-000-B91-935 Steam Blow Out Procedure Page 1 of 15

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TABLE OF CONTENTS
1. Introduction……………………………………………………….………............... 3
2. Objective………………………………………………………………………..…. 3
3. Method and Effectiveness…………………..……………………………….…. 3
4. Resource & Equipment………..……………………………………………….. 5
5. Temporary Arrangement……………………………………………………..…. 6
6. Preparation……………………………………………………………………….…. 7
7. Safety……………………………….……………………………………………….. 9
8. Conditions……………………………………………………………………….…. 9
9. Sequence …………………………..……………………………………………….. 8
10. Procedure………………………………………………………………………..…. 11
11. Target Acceptance……………………………………………………………..…. 12
12. Check list….………………………………………………………………………..…. 14
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1. INTRODUCTION
Solid particle erosion of critical steam turbine components is known to be caused by

deposits from the supplying steam systems. These deposits consist of mill scale from
initial tube formation, weld slag and debris introduced during construction and steam
side corrosion products formed during operation.
It is normal practice to clean the steam systems by high velocity steam flushing, so
called steam blow. .
Note: Boiler subjected to steam flushing or steam blow to be carried out by a

qualified commissioning engineer.
2. OBJECTIVE
A steam blow consists of heating & blowing steam through, & cooling the related
piping. Method used to remove weld-bead deposits, pipe slag, iron oxides & other
foreign materials from steam power piping & boiler super heater surfaces.
The inherent design of the process equipment allows steam to be supplied from the
boiler with the incorporation of temporary piping, materials & silencer (as per contract
if required) to satisfy steam blow operations.
3. METHOD AND EFFECTIVENESS
The proposed steam blowing method is based on cleaning the steam system
continuous with steam produced in the boiler at low pressure and letting it flowing
uninterrupted through the steam system with very high steam velocities. During the
blowing normal attemporation methods are used to thermal shock the steam cycle,
using both existing interstage attemporation systems. Boiler feed water is injected at
prescribed levels to reduce the steam temperature to an arbitrarily defined limit of 25
C above the saturation temperature, and then held at these lower temperatures for a
period of 30 till 60 minutes.
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In figure 1 the system is presented.
Figure 1: steam blow system
The continuous steam blowing method is effective when there are no steam pass
restrictions available in the system and the steam velocities are kept high. The
system should be fully open. Downstream the target plate a quencher will be placed
to reduce the steam temperature to 130 C in order to reduce the steam velocity and
to avoid any sonic shock wave at the steam outlet. A steam muzzler is place at the
end of the temporary piping to separate/collect the heavy deposits before steam is
blown into the atmosphere.
The effectiveness of steam blow cleaning is determined by observing a polished

target (plate) located in the temporary piping. Solid particles carried by the steam
impact the target & produce pits in its surface. The target is then analyzed by visual
observation, in which the amount & size of all pits are determined. Several target
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_______________________________________________________________
plates needs to be installed during operation to observe the progress of the steam
blow cleaning. A decision is finally made with regard to the line being adequately
clean, thereby signifying the termination of the particular steam blow.
The total steam blowing duration is normally one day, however, depending on the
condition of the piping it could be extended till 2 or 3 days.
4. RESOURCES & EQUIPMENT
The following manpower shall participate in each shift:

• Field boiler operator (1),
• DCS boiler operator (1),
• Fitters (2).
The following equipment is required

• Temporary steam line with target plate insert (see figure below)
• Temporary vent steam quencher with water valves and supply hoses from raw
water supply
• Temporary steam muzzler with drain hose of 6 inch into drain system
• Pressure measurements drum & steam header (DCS)
• Temperature measurements at outlet de-superheaters (DCS)
• Pressure gauge just upstream the target plate
• Spare gaskets flow elements
• Safety signs & equipment
• Full fuel, feed water, boiler and steam system including controls and
safeguarding systems
• Heat source: Bagasse
• All other tools & equipment as required by the commissioning engineer
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5. TEMPORARY ARRANGEMENT
TARGET PLATE DESIGN
Flange for removing

target plate
Cross section A‐A
Flow direction
Target plate polished

at both sides
steam blow cleaning of HRSG and steam
system
• The main steam line should be steam blown as far as possible i.e close to
battery limit.
• What cannot be steam blown needs to be fully mechanically cleaned.
• The main steam stop valve at battery limit could have provisions for removing
the internals, installing covers for protecting the outlet & installing special cover
plates.
• The temporary blow off piping of steam line should be same as the steam line.
Down streams the target plate it can be reduced. The material of blow off line
can be of A106 GrB.
• Install the target plate approx few meters down streams the connection with the
permanent piping. Minimize the blow off line length between steam line & target
plate to avoid the impact of debris from the temporary blow off pipe.
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• The target plate assembly is special designed to allow target plate installation
during the steam blow in order to avoid any shutdown of the boiler.
• Pressure value during steam blow off to be taken at boiler outlet & target plate.
• The material of target plate can be copper (Cu) or steel. Preferred is carbon
steel with Brinell hardness of 110 HB
• Criteria area should be 40 * 40 mm.
• The Brinell hardness of the target plate should be measured and be written on
the plate outside the criteria area.
• The temporary blow off steam lines & its supports should be engineered careful
because during the steam blow high reaction forces could occur in case of a
operator failure.
• All the orifices, demisters and pressure reduction stations should be removed to
avoid any damage of those parts during the steam blow
• It is preferred to have also low pressure steam available for the deaerator and
air steam preheater. If this cannot be made available then it can be taken from
the safety valve nozzle of the steam drum. Specially the operation of the
deaerator at operating temperature of 105 C is essential in order to avoid
built up of fly ash in cyclones and its hopper (the flue gasses will
condense due to the very low flue gas temperature of 50 C in case of
feeding the boiler with cold water).
6. PREPARATION
Before supplying water & heat to the boiler the following conditions (but not limited to)
have to be fulfilled:
• The boiler must be completely inspected; pressure part as well as the flue gas
part, & all foreign items should be removed. Then the blind flanges, manholes &
other openings at the flue gas part of the boiler must be closed. Fit gaskets.
• All the equipment, e.g. target plates, temporary lines, temporary valves,
temporary quencher and muzzler, etc. to be used should be checked & ready
for use.
• The responsible operators have read / understood the procedures for filling,
start-up, steam blow, etc. & are familiar with operation of the installation.
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_______________________________________________________________
• One day for instruction, equipment checking & preparing the installation must
be accounted for.
• All valves & cocks are tested for smooth operation & they are appropriately set.
• All, for this part of the starting-up procedure required, controls, safeties etc. are
tested & approved for. Of great importance here are all the monitoring instru-
ments in the control room & at the boiler.
• No instrument securities except PSV’s are available to protect the system.
• All relevant procedures are complete & present at the installation site.
• All legal & operational requirements are fulfilled & the necessary permits are
present. In written form is laid down who is responsible for this aspect.
• All the above mentioned conditions apply to the complete installation, thus for
the boiler, burner, equipment to be operated by a third party etc.
• The procedure for the boil out has been completed & approved.
• Hydro static test of boiler has been carried out.
• Boiler feed water supply is available.
• Ammonia and dosing unit are available.
• The raw water for quenching the steam is available
• Plant air is available at target plate assembly to keep overpressure and avoid
steam leakage through target plate assembly
• PSVs of steam drum (dismantled when steam extraction is required) and steam
line are installed.
• Level gauge on steam drum installed and working correctly. NWL, LWL, LLWL,
HWL and HHWL are marked on the gauge.
• Boil-out of system has been carried out prior to steam blowing.
• Boiler is completely inspected and boxed up.
• Start-up vent valve is isolated from the main steam line and will remain closed
during the whole activity.
• Target plates for steam blowing are available
• Temporary spool for steam blowing is connected with the system and its
supports are in order.
• The spring hangers in the steam lines are de-blocked. Should be functioning
well to allow the unrestricted expansion of the piping system.
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The following equipment shall be removed prior to the procedure:
o Steam flow elements, e.g. orifice plates needs to be removed, (Venturi suitable
for steam blowing).
o Demister in steam drum should be removed.
o The main steam shut-off valves in steam lines should be fully open.
o The internals of check valves in steam lines should be removed.
o The sample steam nozzles should be removed.
o Thermocouples not used shall be removed from steam lines (welded ones not)
o Control valves installed in the steam lines, remove internals including seats
o Close isolation valves on steam header instrumentation such as pressure
transmitters, gauge lines, etc and remove other sensitive in-line equipment
7. SAFETY:
• Only personnel involved in this operation are allowed in immediate boiler area.
• All personnel involved in the blowing activity should have proper PPEs.
• In case of misoperation high reaction forces are sustained within the temporary
pipe work system, therefore, certain minimum safety precautions must be
implemented.
• Barrier off local area to the temporary pipe work & exhaust also appropriate
warning notice positioned to prevent inadvertent entry of unauthorized persons.
8. CONDITIONS
• The CFR factor should be greater then 1 throughout the system.

CFR = (Mc2 * Vc”) / (Mmcr2 * Vmcr”)
Mc is the mass flow rate during steam blow in tph
Vc” is the specific volume of steam during steam blow in m3/kg
Mmcr is the mass flow rate at maximum continuous operation in tph
Vmcr” is the specific volume of steam during maximum continuous operation in
m3/kg
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• By reading the pressure and temperature in main steam line and the BFW flow
at boiler inlet during the steam blow the CFR value can be determined. Note:
during this measurement the steam supply from steam drum to deaerator and
steam air preheater (when this temporary line is installed) should be closed in
order to have the proper reference flow for the steam flow.
• In the HP main steam the operating parameter are: M= 140 tph; pressure at
boiler outlet 66 barg and 485 C, specific volume of 0,0493 m3/kg
• Expected is a steam drum pressure of 5,8 barg with steam flow of 35 tph, 2,4
barg and 400 C at boiler outlet. Steam temperature controlled by boiler de-
superheater station at 400 C. Specific volume is then 0,941. The CFR factor is
1,28 at main steam line.
• The bagasse consumption will be approx 20 tph
• Boiler pressure increase upto required pressure will be as per startup curve.
9. SEQUENCE:
The boiler will be operated continuously at a fixed load which depends on the CFR
value obtained in the main steam line at boiler outlet.
When the CFR factor is reached then maintain the boiler for 1 hour at its load.
Then start to thermal shock the steam system by lower the steam temperature at the
outlet of each de-superheater to 25 C above its saturation temperature. Means 180 C
at de-superehater outlet of boiler and 160 C at de-superheater outlet downstreams
the pressure reducing station. Maintain the thermal shock for 15 minutes and then
stop for one hour. Perform this thermal shock 3 times.
Start and finalize this thermal shock procedure for the upstream system first and then
the downstream system.
Cycle also the in line valves to clear the debris. Each valve should be partially closed
(approx 70% closed) and returned to full open. Perform this from upstream to
downstream installed valves.
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10. PROCEDURE
• Follow the procedure for Filling and starting up of system.

• Maintain the steam outlet temperature at maximum 400 C.
• The main steam valve and its bypass should be fully open.
• The start-up valve will be not used.
• The steam can be vented without any restriction into atmosphere
• When steam is extracted from steam drum for the deaerator and steam air
preheater then use the steam first for heating up the deaerator slowly. Do this
slowly otherwise there will be damage in the deaerator. Keep the block valves
of the steam air preheater closed. After the deaerator is heated up then slowly
open the block valves of the steam air preheater. Start first with the grate
section air. When this is fully in operation then the overfiring air. Check very
carefully that the pressure at steam air preheater does not raise above 3
barg.
• During the warming up check all flanges, drains, steam traps and repair as
necessary.
• While pressure is increasing above atmosphere introduce quench water slowly.
Avoid too fast opening of quench water valve as then a lot of drain water will be
sprayed out of the muzzler. Specially observe the noise from the muzzler and
reduce it sound level slowly.
• Periodically blow down all drip legs in the flow path for 10 minutes. Any drip
legs that become clogged are to be back blown with oil free compressed air.
• Check at 35 tph steam production the CFR value
• Then start after one hour the thermal shockes as described above in section 9.
• Cycle the valves as described above in section 9
• Then start after one hour the insertion of the target plate.
• Leave it 20 minutes in the line. Record the readings of the steam pressures at
steam drum, main steam outlet and at target plate. Also read the BFW flow
(with steam supply from steam drum to deaerator and steam air preheater
closed shortly for 5 minutes with stable water level in steam drum). Also read
the steam temperature at boiler outlet.
• When cleanness is not satisfactory then install the next target after 1 hour
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.
• If target plate is clear (as per acceptance criteria). Stop the blow off activity.
• Stop the boiler as per shutdown procedure. Close the main steam stop valve
and its bypass directly after boiler stop and let is slowly cool down.
11. TARGET ACCEPTANCE
0.8
= allowable zone
Size of
Scars
(Ø mm
0.3
2 No. of scars 5
Judgment on result of steam flushing shall be done by the following:
• The material of target plate can be copper or polished steel. Preferred is carbon
steel with Brinell hardness of 110 HB.
• Dimension: 25 mm x diam. blow off line
• Criteria area should be 40 * 40 mm
• The judgment time to be 20 minutes of steady load and CFR factor should be
larger then 1.
• The Brinell hardness of the target plate should be measured and be written on
the plate outside the criteria area.
• During the test the pressure and temperature at boiler outlet and at temporary
steam blow pipe should be recorded.
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• After 1 hour of having ended the procedure for thermal shock of system, a
polished target plate should be inserted.
• Allowable size & number of scars on the surface of the test piece shall be in
accordance with table shown below.
• The acceptance criteria for carbon steel plate is:
o No pit of larger then 1 mm
o Less then 4 pits of size larger then 0,5 mm
o Less then 10 pits of size larger then 0,2 mm
o The pit surrounding should not be raised above the target surface
o During the purging the number of pits should reduce clearly.
• Finally a total of 3 consecutive targets must be obtained to conclude the
cleanness.
Activity Descon Client Others

tem
System has to be freed of loose dirt (all accessible
parts) & rinsed with cold water (tap water quality)·
Confirm that the boiler has been alkaline or acid
cleaned
Confirm that all flow elements, & valve internals as
described in this procedure have been removed.
Start-up isolating valve is closed. Spring hangers are
de-blocked
Confirm that feed water flow elements have been
installed & are functional
Confirm that the boiler is completely boxed up, &
sufficient boiler feed water is available for the agreed
period of flushing.
Confirm that all equipment, e.g. target plates are
available.
Required safety precautions have been taken.
Fuel feeding system is available & ready to start.
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12. CHECK LIST
Steam flushing- Preparation check sheet
Steam flushing - Procedure check sheet
Activity Descon Client Others
Fill and start up the boiler as per start up procedure. Leave

the main stam stop valve and its bypass fully open
Confirm all drain valves at steam line are open.
Heat up the boiler according to the start-up curve using

temporary vent assembly.
Heat up the deaerator to operating pressure of 0,2 barg
slowly. This is important to avoid condensation of fly ash at
economiser outlet and blocking in hopper under cyclones.
Continue heating up boiler to flushing/blowing conditions.
Drum pressure of approximately steam blow pressure
level. Drum level control as per start-up procedure
Check the CFR factor and start the steam blow
During steam blow

- record drum / steam header/target plate pressure
plus main steam temperature and BFW flow
- maintain drum level steady at normal water level
Start after 1 hr the thermal shocks
After ending thermal shocks start the valve cycling
After 1 hour steady load after valve cycling install a target

plate
Repeat steps again after 1 hour (using target plate) until
judgement criteria has been satisfied for last 2 successive
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blows. Only install target plates when successful blow is
expected.
After successful blowing stop the boiler as per shutdown
procedure and close the main steam stop valve and its
bypass
After acceptance of target plates reinstate flow elements,
valve internals, etc.
Reinstall the pressure reducing station and its piping.
Check if the pipe is fully mechanically cleaned. Inspect also
the pipe which is cleaned by steam blowing
Check the des-superheater nozzles used during the steam
blow.
Prepare boiler for final commissioning.
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Water chemistry control
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Revision : 00
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DM.12227-000-B91-940 Water Treatment & Water Requirement Page 1 of 14

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TABLE OF CONTENTS
1. OBJECTIVES AND SCOPE 3
2. WATER CONSULTANT 3
3. WATER TREATMENT 3
3.1. Chemicals 3
3.2. Physical 4
4. WATER AND STEAM REQUIREMENTS 9

4.1. Boiler feed water requirements 9
4.2 Boiler water requirements 9
4.3. steam purity requirements for condensing steam turbines 10
5. ANALYSIS TO BE CARRIED OUT AT THE BOILERPLANT 11
6. GENERAL RECOMMENDATIONS FOR SAMPLING WATER 11
7. INSTRUCTIONS FOR ANALYSIS 13

7.1. Determination of pH: 13
7.2. Determination of the conductivity at 25 C. 13
7.3. Determination of silica 13
7.4. Determination of the total hardness 13
7.5. Determination of phosphate 13
7.6. Determination of iron 13
7.7. Determination of oxygen 14
Appendix A: Determination of silica

Appendix B: Determination of the total hardness
Appendix C: Determination of Phosphate
Appendix D: Determination of iron
Appendix E: Determination of oxygen
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.
1. OBJECTIVES AND SCOPE
The main objective of water chemistry control is to insure the long term integrity of the
materials of construction and the successful operation of the boiler-turbine cycle.
This guideline refers to normal plant operation. Higher impurity levels may be encountered
during commissioning and early operating period until the final cleanliness of the system
has been achieved.
Boiler water chemistry control is based on the following considerations:

General and specific corrosion protection of the pressure parts surfaces in the event of
contamination ingress
Achieving the required steam purity
2. WATER CONSULTANT
Boiler feed water is beyond the control of the boiler manufacturer. Each plant location has
distinctive water sources and issues. For this reason, it is recommendation of Descon that
a competent consultant that specializes in boiler water be engaged to advise the owner
on most economical conditioning of water supply for boiler use.
Present day water conditioning will supply water that when used with internal chemical
treatment will give many years of trouble free boiler operation. The expense of a water
consultant is an insurance against scale deposits and/or corrosion that could result in
tube losses and extended boiler outages.
Boiler water must meet certain minimum requirements in order to prevent scale,
excessive sludge, corrosion, and foaming. In the attached file some general information is
offered to assist the operator in determining a reasonable quality for the boiler(s).
3. WATER TREATMENT
3.1 Chemicals
Ammonia
Ammonia is supplied in the condensate / make-up water supply line to the deaerator feed
water tank. It increases the pH value of the boiler feed water up to a pH value of 9.2- 9.5.
The ammonia is used to prevent condensate system corrosion. By adding the neutralizing
amine, the condensate pH can be elevated to a desired range (e.g., 9.2 till 9.5). Amines
also used for condensate acid neutralization and pH elevation. The ability of any amine to
protect a system effectively depends on the neutralizing capacity; and recovery ratio,
basicity, of the particular amine. They form a protective film on metal surface to protect it.
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Note: Ammonia will lead to corrosion of Copper. In case this materials is installed in the
steam and condensate system of the sugar mill then an alternative amine should be taken
in order to avoid corrosion.
Oxygen Scavenger / Hydrazine
Oxygen Scavenger is supplied in the feed water line between the feed water tank and feed
water pumps when the oxygen level at outlet deaerator is above 20 ppb.
The O2 scavenger chemical scavenges oxygen and reduces corrosion in the feed water
circuit - protecting the equipment against damage and reducing the potential for
unscheduled downtime. These treatments also reduce the amount of metal oxides entering
the boiler to maintain clean boiler tube surfaces and improve fuel efficiency.
Phosphate
Phosphate is injected in the feed water line between the economizer and the drum or
directly into drum. The phosphate reduces the remaining hardness still present in the boiler
water, by changing it in to a more or less harmless sludge which can be blown-off through
the blow down valves. The amount of phosphate to be dosed is based on the pH value of
the boiler water measured.
3.2 Physical
Dissolved Solids and Oxides.
The guidelines address the influence of both dissolved and suspended (i.e. oxides)
solids. Since the feed water is used for de-superheating (steam temperature control), its
level of dissolved solids must be limited in order to prevent fouling of steam touched
surfaces as well as achieve steam purity requirements. It should also be recognized that
metallic oxides transported to the boiler (or superheater/turbine) by feed water can foul
these surfaces such that damage and/or efficiency losses may occur.
Boiler feed water normally contains impurities, even though water treatment takes
place. It is necessary to control the maximum level of impurities in the water content
of the boiler.
These impurities are normally measured as mg/l`. Passing the water through a
Demi- water treatment Plant reduces the impurities to minimum required levels.
Phosphate dosing
The boiler water quality and respective treatment is designed to prevent corrosion and
deposits in the boiler as well as to produce steam with a sodium content not to exceed
specification limits. Therefore, a low level sodium phosphate treatment has been selected.
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Below Figure 1 is a plot of phosphate vs. pH. This type of strong alkaline treatment
provides good buffering capabilities in the event of impurity ingress.
Figure 1: Phosphate treatment zones
Phosphate treatment with a sodium to phosphate ratio of 3 is applied as standard boiler

water treatment. This treatment can be modified during periods of contaminant ingress to
address either caustic or acid producing salts.
The pH value (@25°C) is corrected from the contribution of ammonia (Figure 2 below) and
solely dependent on the phosphate concentration. The solid red line is the upper boundary
for the saturated steam sodium concentration in HP boilers with a mechanical carry-over
approaching 0.2%.
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Figure: 2
pH is referred to a reference temperature of 25°C. These curves are approximations with

sufficient accuracy for daily use. It is assumed that the feed water pH is solely governed by
the ammonia content . Typical distribution ratios for feed water ammonia to boiler water
ammonia have been used.
Cation Conductivity.
The cation conductivity specification values do not include the influence of carbon dioxide.
During normal operating conditions, levels of 0.06-0.2 μS/cm in the boiler feed water can
be achieved. Higher values are observed during startup. Carbon dioxide, having entered
the system with air during shutdown, is dissolved in the water. It requires some time until it
is purged from the system. The removal rate depends on the efficiency of the deaeration
devices (deaerator, condenser), as well as on cycle water pH. At cold start, normal
specification values are usually obtained within a few hours for base loaded plants.
Attached figure 3 shows the relation between the amount of ammonia injected, the pH
value and the conductivity. Also the influence of CO2 in the water is shown.
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Figure 3: conductivity before and after cation exchange en pH at 25 C of low concentrated

solution of ammonia and CO2 for pH values of 5 till 10
To keep the conductivity level of the water in the boiler below the allowable
maximum it is necessary to drain off or “blow down” the boiler to replace the
increasing, highly concentrated water, with a low concentration, i.e., the feed water.
Careful monitoring and maintenance of demi-water quality and all chemical injection
dosage is very important to control the water and steam qualities. Shift wise
laboratory analysis and effective conclusion to make timely decision is very critical,
especially in high pressure boiler.
Continuous blow-down
Steam hardly carries along any solids (salts) and silica so the concentration in the boiler drum
water increases. These salts and sludge cause "foaming and carry-over". The operator has to
find an optimum between the continuous blow-down percentage and the maximum allowed
conductivity (after cation filter) and/or silica content in the boiler water, to achieve the required
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boiler water and steam quality. The continuous blow down flow is approximately 1 % of the
MCR steam flow.
General formula for calculating blow down percentage
qb = ((1- qr/qs)x(Sm /Sb-Sm)) x 100 %

qb = Blow down percentage based on steam output.
qr = boiler feed water amount t/hr
qs = Steam output t/hr
Sm = Total conductivity (after cation filter) or silica content in
boiler feed water
Sb = Max. conductivity (after cation filter) or silica content
allowed in boiler water
Intermittent blow-down
The intermittent blow-down is taken from the bottom of steam drum. Every 8 hours once inter-
mittent blow-down valve has to be opened for approximately 30 seconds.
The un-dissolved solids and sediments are removed by this blow down.
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4. WATER AND STEAM REQUIREMENTS
4.1 Boiler feed water requirements
Boiler feed water requirements Boiler feed water
Conductivity after cat-ion

exchange 25 C MicroS/cm 0.2 max
pH 25 C 9.0 min
Hardness CaCO3 mg/kg n.d max
Carbon-dioxide CO2 mg/kg n.d max
Silica SiO2 mg/kg 0.02 max
Oxygen O2 mg/kg 0.02 max
Iron Fe mg/kg 0.03 max
Copper Cu mg/kg 0.005 max
Permangate KMnO4 mg/kg 3.0 max
Oil / Grease mg/kg n.d. max
Sensory perception clear, odourless,
colourless
4.2. Boiler water requirements
Conductivity after cation

Exchange 25C S/cm 150 max
pH 25C 9.5 – 10
Silica SiO2 mg/kg 4
Phosphate PO4 mg/kg 6
Hydrazine N2H4 mg/kg Traces max
Sensory perception Clear, no differing
odour or colour
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4.3. steam purity requirements for condensing steam turbines
The steam at outlet of boiler should meet following requirements in order to avoid any
fouling in the steam turbine
Standard value Normal

operating value
Conductivity at 25°C downstream of a
strongly acidic sampling cation exchanger S/cm < 0,2 0,1
continuous measurement at the sampling
point
Silica mg/l <0,02 0,005
Total iron Fe mg/l <0,02 0,005
Total copper Cu mg/l <0,003 0,001
Sodium Na mg/l <0,01 0,002
Sensory perception clear, clear, odourless,
odourless, colourless
colourless
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5. ANALYSIS TO BE CARRIED OUT AT THE BOILERPLANT
A complete laboratory has to be equipped for measuring frequently following parameter:.
Parameter Boiler Feed Water in steam Superheated

water drum steam
pH daily daily -
Conductivity daily daily daily
Silica daily daily -
Total hardness daily - -
Phosphate - daily -
Iron Weekly - -
Oily matter Weekly - -
Oxygen monthly - -
Sensory daily daily daily
perceptions
Conductivity after - - daily
cation exchange
Obviously, the same requirements have to be made to the demineralised water as to the
condensate . Concerning the demineralised water, daily pH, conductivity and silica have to
be determined.
The returning condensate has to be controlled daily on the presence of oily matter and
sugar traces.
6. GENERAL RECOMMENDATIONS FOR SAMPLING WATER
Chemical control of boiler water may fail to achieve good results, unless the samples taken for
testing properly represent the period of time and the quantity of water involved.
All containers for collecting samples should be kept clean and should be rinsed several times
with the water to be sampled before final filling.
The container should then be kept closed to avoid contamination with O2 - CO2 or dirt.
Before taking samples, make sure that sample coolers have been adjusted to a sample flow
of approx 30 l/h and cooled down to a water temperature as low as possible and not more
then.50 C.
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Analysis reports should be clear and complete and at least have following information:
a. Sample description
b. Sample location
c. Sampling date
d. Sampling time
e. Analyses results
f. Analyses method
g. Min. /max. requirements
h. Recommended corrective action.
Some of the important parameters should be recorded in a monthly curve (pH, conductivity
and O2).
The results of laboratory analyses should be checked for correctness and accuracy on
regular intervals.
Results of the test should always be checked by comparison with preceding test results
and expected design data.
This will give an indication if samples have been taken in correct way and have not been
exchanged.
Test results will be used as guidelines for daily operation. It might be useful to evaluate the
test results over a longer period at regular intervals together with the inspection results as
described in “Inspection and maintenance procedure”.
As a result of this evaluation it should be decided if corrective actions are required.
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7. INSTRUCTIONS FOR ANALYSIS
The following instructions for determinations are detailed.
7.1. Determination of pH:
Hydrogen ions give a potential difference to a glass electrode/reference electrode-system,

which is a measure for the pH. This potential difference is measured by an electronic
voltmeter, equipped with a pH-scale.
The determination of the pH has to be carried out as soon as possible after taking the
sample
The pH-meter has to be calibrated according to the manual of the pH-meter. Standard
solutions for this calibration are available at the suppliers of chemicals
The execution of the pH-measurement: measure the pH as indicated un the manual; the
measurement has to be carried out at room temperature.
7.2. Determination of the conductivity at 25 C.
The conductivity is a measure of the concentration of the salts, dissolved in the water.
 The measurement of the conductivity has to be carried out at room temperature

 Measure the conductivity as indicated in the manual. Measuring the conductivity it is
important to watch the temperature of the water sample. For the sample of boiler
feed water and boiler water this temperature must be 25 C
 There are conductivity meters available, at which there exists a correction for a
deviating temperature. In other cases the measurement has to be carried out at 25
C.
 For the steam sample the sampled water has to be led over a cation exchange filter
to take out the ammonia.
7.3. Determination of silica:
See appendix A
7.4. Determination of the total hardness:
See appendix B
7.5. Determination of phosphate:
See appendix C
7.6. Determination of iron:
See appendix D
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7.7. Determination of oxygen:
See appendix E
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Safety valve testing

procedure
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Revision : 00
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TABLE OF CONTENTS
1. Introduction……………………….………………………………………………… 3
2. General….….……………………………………………………………………… 3
3. Resources & equipment…..…………………………………………………………. 3
4. Preparation……….……..………………………………………….………………… 4
5. Safety…………………………………………..……………………………………… 5
6. Procedure……….……..………………………………………….………………… 5
7. Terminology…….……..………………………………………….………………… 6
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1. INTRODUCTION
To protect the boiler against exceeding the design pressure under inadvertent upset
conditions the boiler is equipped with steam safety relief valves on drums & SH
steam lines as per boiler design code.
In normal practice & also required by most boiler codes to test the steam safety relief
valve for new boilers & after replacement or maintenance. Also the boiler is subjected
to a safety valve test to be carried out by a qualified commissioning engineer.
2. GENERAL
Testing or floating safety relief valve is a relatively straightforward operation. Process

should not be rushed & provided sensible precautions are taken to avoid any problem
occurrence. All boiler protection will be active throughout the safety valve testing.
Boiler will be started as per normal start up procedure. Once the boiler pressure
reaches about 80% of its nominal value the first safety valve will be gagged. The
sequence of testing will be Drum followed by Main steam safety valve. To test the
drum safety valves, the safety relief valve of the corresponding SH line shall be
blocked by means of gags to allow the pressure to rise to test pressure levels.
Where more than one drum safety valve is installed for the particular pressure
system, the safety valve with the higher plated set pressure will be tested first, with
the other drum valve(s) gagged.
3. RESOURCES & EQUIPMENT
The following manpower shall participate:

• Client Engineer to witness & provision of resources.
• Clients boiler operator (2),
• DCS boiler operator (1),
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• Fitters (2).
The following (temporary) equipment &/or systems shall be available:

• Spanner for adjusting set pressure.
• Spanner for removing of blow down ring securing plug.
• Screw driver, Gags
• Telephone/ radio head set link with control room
• Pressure measurements drum & steam header (DCS)
• Calibrated pressure gauge near safety valve
• Safety signs & equipment
• Feed water system
• Heat source: Bagasse
• Control & safeguarding system
• All other tools & equipment as required by the commissioning engineer
4. PREPARATION
Before supplying water & heat to the boiler the following conditions (but not limited to)
have to be fulfilled:
• The boiler must be completely inspected the pressure part as well as the flue
gas part, & all foreign items should be removed.
• The blind flanges, manholes & other openings at the flue gas part of the boiler
must be closed. Fit gaskets.
• All the equipment, e.g. drains, vent & blow-off lines, silencers, pressure gauges,
etc. to be used should be checked & ready for use.
• The responsible operators have read & understood the procedures for filling,
startup, steam blow, etc. They are familiar with the operation of the installation
(One day for instruction, checking the equipment & preparing the installation
must be accounted for).
• All valves & cocks are tested for smooth operation & they are appropriately set.
• All parts of the starting-up procedure required, controls, protection systems etc.
are tested & approved. Of great importance here are all the monitoring
instruments in control room & at boiler.
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• All relevant procedures are complete & present at the installation site.
• All legal & operational requirements are fulfilled, necessary permits are present.
• In written form is laid down who is responsible for this aspect.
• All the above mentioned conditions apply to the complete installation, thus for
the boiler, equipment to be operated by a third party etc.
• The boil out & Flushing procedures have been completed & approved.
• Procedures for commissioning of controls have been completed & approved.
• Install calibrated pressure gauge near safety relief valve.
• Check safety valves mechanically to ensure correct installation & that
hydrostatic plug are removed.
5. SAFETY
• Only personnel involved in this operation are allowed in the immediate boiler area.
• No personnel to be in the vicinity of the silencers, except observer at safe distance.
• A direct communication link between valve location & control room to be set up.
Adjustment to the safety valves should be undertaken by a competent person.
• Escape routes should be unobstructed
• Barrier off area local to the temporary pipe work & exhaust & appropriate warning
notice positioned to prevent inadvertent entry of unauthorized persons.
6. PROCEDURE
• Maintain or control the boiler drum level as per start up procedure, e.g. minimum flow
through economizer, start level is just low alarm, raise set point to NWL, etc.
• Start the heating according the normal procedure & follow the normal boiler start up
procedure described in the O &M manual.
• Raise the pressure slowly to approx. 85% of set pressure safety relief valve. Install
gags to the not tested safety relief valve(s) in the same system.
• Raise pressure until set pressure. As boiler pressure approaches set pressure the
designated start-up valve should be closed until cracked open to enhance the
requisite valve to open cleanly. Maintain under all circumstances some flow through
super heaters.
• Record set pressure for opening
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• Open start-up valve to reduce the pressure.
• Record reseating pressure.
• Reduce pressure to 85 % of set pressure.
• Confirm pressures are in accordance with design. If not, adjust set pressure or blow
down.
• Repeat steps until adjustment is satisfactory.
• Raise the pressure slowly to approx. 85% of set pressure safety relief valve for next
safety valve.
• If all safety valves have been tested the boiler can be connected to the system & is
ready for final commissioning &/or performance test.
7. TERMINOLOGY
• Working pressure: Actual pressure at which the installation operates

• Design pressure: Maximum allowable working pressure of the system
• Set pressure: Pressure predetermined by the user at which the valve disc must
begin to lift
• Maximum relieving pressure: Sum of set pressure & over pressure in accordance
with regulations
• Over pressure: Increase of set pressure expressed in units of pressure for which the
required capacity is guaranteed
• Accumulation: Over pressure expressed as a percentage of set pressure
• Reseating pressure: Pressure at which the valve closes after discharging
• Blow-down: Difference between set pressure & reseating pressure, expressed as a
percentage of the set pressure
• Back pressure: Any pressure on the discharge side of the safety valve
• Cold differential test pressure: Static pressure at which the valve is set to open on
the test bench & which takes account of corrections, required by operating conditions,
e.g. temp.& back pressure.
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Title : OPERATING AND MAINTENANCE INSTRUCTIONS
Auxiliary Equipments
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Revision : 00
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DM.12227-000-B91-950 O & M Instructions of Auxiliary Equipments 1 of 21

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TABLE OF CONTENTS
1. Introduction auxiliary equipments……………………………………………….. 4
1.1 Auxiliary equipments components……………………………..…………………..... 4

1.2 Process description of the auxiliary equipments………………………………….. 5
1.3 Construction of the auxiliary equipments ………………………..………….…….. 7
1.4 Safety ………………………..…………….………………………………………….. 7
2. Technical data auxiliary equipments ……………………………………..…….. 9
3. Pre-service inspection and commissioning ………………………………….. 10

3.1 Introduction ……………………………………………………..…………………..... 10
3.2 Piping ………………………………………………………………………………….. 10
3.3 High & low water alarms …………………………………………………………….. 11
3.4 Safety valves ………………………..…………….………………………………….. 11
3.5 Auxiliary equipments internals ………….………………………………………….. 11
3.6 Summary……………………..…………….………………………………………….. 11
3.7 Pre-service inspection checklist ………….………………………….…………….. 12
4. Preparation for service commissioning ………..………..…………………….. 13

4.1 Preparation for service ………….………………………………………………….. 13
4.2 Warning & items requiring special attention ……………………….…………….. 13
4.3 Registration of data ………….…………………………………………….……….. 13
4.4 Observation during auxiliary equipments operation …………………………….. 13
4.5 Water column & water gauge ………….………………………………………….. 14
5. Start up of Auxiliary equipments…………………..…………………………….. 14

5.1 Introduction …………………….………….………………………………………….. 14
5.2 Preparation for start up ………….………….……………………………………….. 15
5.3 Start up the feed water tank……….……………………………………………….... 15
5.3.1 Items required special attention ..………………………………………………. 16
5.4 Shut down the deaerator……………….……………………………………………. 16
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5.5 Start up and shut down of sample coolers ……………………………………….. 17
6. Auxiliary equipments inspection and maintenance ……………….……….. 17
7. Preservation procedure ………………………..…..…………………………….. 18

7.1 Dry preservation ………………….……….……………………………….……….. 18
7.2 Entering auxiliary equipments (If applicable) …………………………………….. 19
8. Safety requirements …………………………..……………………..…………….. 19

8.1 General Safety …………………….……….………………………..……….……….. 19
8.2 Pre-requisite for the safe operation of auxiliaries equipments………….……….. 20
8.3 Safety practices and procedures ………………………………..………………….. 20
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1. INTRODUCTION AUXILIARY EQUIPMENTS
Deaerator
The Descon feed water deaerator is designed to extract oxygen out of the feed water
by using steam. When this is done the deaerator is at the same time used as
mixer/Preheater Extracting oxygen is of essential need in systems where water is
used. Small amounts of oxygen cause great corrosive activity in the system. Steam
is injected under the water level.
A Sieve Plate / Tray Type thermal de-aerator with proven performance in specific
application of stripping, eliminates dissolved oxygen from boiler feed water in order to
protect the boiler from corrosion.
Deaerated water from feed water tank/deaerator goes to boiler through boiler feed
water pumps via Economizers where further rise in temperature occurs due to heat
transfer between water and flue gases.
Sample coolers
Descon Sample Coolers are Spiral type heat exchangers designed to reduce high
temperature liquid/steam samples to safe, usable temperatures for analysis. Cooling
water is used as cooling media to reduce sample temperature. The counter flow
design efficiently cools the tube side fluid.
1.1 Auxiliary equipments components
The auxiliary equipments are equipped with the following main parts:
- Auxiliary equipments system comprising of:
• Auxiliary equipments
• All required interconnecting piping
• Stairs, ladders and platforms (If placed at an elevation)
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• Local instrumentation comprising of instrument block valves, thermo
wells, transmitters, switches, pressure and temperature gauges,
level gauges.
• Valves and fittings including control valves and safety valves.
1.2 Process description of the auxiliary equipments
Deaerator
Deaerator is designed to remove oxygen from feed water by using steam.

When this is done the deaerator is at the same time used as a mixer/Preheater.
Removing oxygen is of essential need in systems where water is used. Small
amounts of oxygen cause great corrosive activity in the system. Steam is
injected under the water level.
The deaerator constitutes a specific application of stripping, which removes

dissolved oxygen from boiler feed water in order to protect the boiler from
corrosion. This deaerator operates on two fundamental principles:
• The solubility of a gas in water is a non-explicit decreasing function of

temperature.
• The concentration of gas by weight dissolved in a liquid at a given
temperature is proportional to its partial pressure in atmosphere above the
liquid.
The Demin water enters into the top most tray section of deaerator dome. The
steam enters into the deaerator storage vessel through a sparger pipe. The
operation of deaerator is based on physical deaeration, which takes place in
two steps:
- Pre-deaeration in which Demin water and condensate is passed across

steam through the sieve tray section of dome.
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- Final deaeration in the water tank, where steam is brought in close contact
with the water. After that boiler feed water flows across the baffle and
reaches final section having outlet nozzle with vortex breaker.
The sieve trays and internal steam sparger are specifically designed to
deaerate the incoming water.
Intermittent controlled manual bottom blowdown
The recommended method of removing sludge is based on intermittent valve.

When valve opens a localized low pressure area forms around the blow off
opening and boiler sludge rushes out at high velocity giving boiler a short blow.
The discharge of sludge and precipitated solids at valve full open position takes
approximately 2 seconds. In order to ascertain the blow down frequency the
operating data of blow down valve and drum water quality has to be taken in
account.
Blowdown water will pass into a metal blow down vessel situated above ground.
The size of the vessel is determined by the flowrate of blow down water that
enters the vessel when the blowdown valve is opened.
Sample coolers
The operation of sample cooler is based on the heat transfer principle in which
the hot fluid which may be blow down water, boiler feed water, saturated steam,
Superheated steam sample are cooled down through heat exchange with
cooling water as cooling agent. The sample coolers are designed in such a way
that they provide sample at ambient condition. If sample of above streams are
not cooled they will evaporate as they are at a higher pressure than
atmosphere and will therefore provide with higher TDS values as a result of
flashing of steam.
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1.3 Construction of auxiliary equipments
Deaerator
We refer to Descon Drawings. (DM.12227-000-B15-000) for general arrangement of

deaerator
The Deaerator storage vessel is constructed of carbon steel and it consists of a

cylindrical shell provided with two dish ends. The deaerator dome is
constructed of carbon steel with sieve trays of stainless steel.
The interior consists mainly of steam sparger, for injection steam under water
level specific baffle and sieve trays with water pipes.
Deaerator is equipped with two man holes one for sieve trays and one man
hole for storage vessel to facilitate the inspection of the sieves and deaerator
internals.
Sample coolers
We refer to Descon Drawings. (DM.12227-000-B15-011) for general

arrangement of sample coolers.
The Sample coolers are constructed of carbon steel shell and stainless steel tube
coils and it consists of a cylindrical shell in which there is a jacket of tube coils.
The samples from different sampling points enter into tube side of coil where
they are cooled down by circulating water in shell side. The sample cooled to
ambient condition is discharged at the sample collection point.
1.4 Safety
When the blow down tank require an internal inspection be sure that the blow
down tank is empty and at ambient temperature before open the manhole to
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enter the vessel. Also check the sufficient oxygen contents in the vessel and
vessel has proper lighting arrangement.
Similarly when sample cooler or feed water tank require an internal inspection
be sure that the sample cooler or feed water tank is empty and at ambient
temperature before open the equipments.
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2. TECHNICAL DATA AUXILIARY EQUIPMENTS
Deaerator
Design code ASME Section VIII, Edition 2010
Design pressure Barg 1.0
Design temperature °C 120
Operating pressure barg 0.2
Operating temperature °C 105
Diameter Dome (ID) mm 1500
Diameter Shell (ID) mm 3200
Shell thickness mm 12
Length (T/T) mm 9000
Material Sieve Trays [-] SS-304
Material storage tank [-] A-36
Gross volume (Tank) m3 80.9
Mixed water (Demin & condensate) flow rate Kg/Hr 140000

Mixed water temperature C 86
Mixed water pressure Barg 0.8
Saturated steam flow rate Kg/Hr 4800~9100

Saturated steam temperature ºC 128
Saturated steam pressure after control valve Barg 0.4-0.73
Boiler feed water flow rate Kg/Hr 144200

Boiler feed water temperature ºC 105
Sample coolers
Design code Manufacturer standard.
Design pressure (tube side / shell side) Barg 130 / 10
Design temperature (tube side / shell side) °C 495 / 50
Operating pressure (tube side / shell side) Barg based on sample / 3
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Operating temperature (tube side / shell side) °C based on sample / 33
Shell diameter (ID) mm 108.2

Length (T/T) mm 640
Material [-] SS 304
Coil diameter (ID) mm 4.9
Material [-] SS-304
Sample flow Kg/hr 30

Sample outlet temperature ºC 60
Sample outlet pressure Barg atmospheric
Cooling water inlet flow Kg/Hr Based on sample

Cooling water inlet temperature ºC 33
Cooling water inlet pressure Barg 3~3.5
3. PRE-SERVICE INSPECTION AND COMMISSIONING
3.1 Introduction
When installation of the auxiliary equipments has been completed, and before
it is put into operation, the entire system should be inspected. The following
discussion and the components check list in this section are intended as an
inspection guide. When every component in this checklist has been inspected
and proven operational, the auxiliary equipments will be ready to operate. The
inspection should also cover any related equipment furnished by others to
ensure that the total system is ready to function.
3.2 Piping
The piping should be examined to see if all of the joints are tight and that the
valves are in the proper orientation. Check the control valve regulator
assembly to determine that control linkage is operating properly.
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All piping should be inspected for such things as:
Securely bolted flanges, properly oriented check valves, no open ports, correct
installation of gauging and proper actuation of vent and drain valves. There
should be no shut-offs or obstructions between the service lines and auxiliary
equipments.
3.3 High & low water alarms
As the safety equipment for high and low water level alarms, boiler feed water
outlet from deaerator and Demin water + Condensate inlet level control is so
important for the operation. The high and low water levels at which the high
and low water level alarms respectively are set to come into operation on this
deaerator at their respective set points.
3.4 Safety valves
Safety valve should be checked to make sure that there is no blockage on the outlet.
The valve should be pre-set in accordance with the required set points.
3.5 Auxiliary equipments internals
The man way of auxiliary equipments should be opened for inspection prior to
operation. Bolts and nuts on the internal distribution pipe should be checked for
tightness. Any large amounts of dirt, scale, or debris should be removed.
3.6 Summary
A thorough inspection will reveal any obvious damage or improper installation of

component equipment. When all of the items contained in this checklist have been
reviewed and the entire system has been inspected, you may proceed with the
preparation for service.
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3.7 Pre-service inspection checklist
Blow down Man way

Bolts-Flange Piping
Pressure Gauges Controls
Safety Valve Drains
Drives / Couplings Steam Lines
Temperature Gauges Thermo-couples
Vents Traps
Valves Water Column
Gauges Water Gauge
Wiring Instruments
Insulation
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4. PREPARATION FOR SERVICE COMMISSIONING
4.1 Preparation for service
When the pre-service inspection is complete, and when all problems have
been corrected, then the system can be subjected to its final series of tests
before putting it into service.
4.2 Warning & items requiring special attention
The following is not allowed during start-up or commissioning:

• Do not put the inlet streams of auxiliary equipments into use without having
ascertained that there is no air left in the supply piping and that the piping
is only filled with water for liquid inlet streams and make sure that there is
no condensates left in the steam inlet streams.
• Never warm up the auxiliary equipments with the level above the normal
water level (N.W.L) at start.
• Never take the auxiliary equipments into full operation at once. Especially
when starting there is the danger of a hammering in the auxiliary
equipments due to two phase formation.
4.3 Registration of data
Auxiliary equipments personnel should be instructed to follow a precise

schedule of data collection. Not only this data is a useful record of the system
performance, but the operator will become accustomed to seeing the proper
figures on his data chart, and when something un-useful happens, he will
detect it immediately and correct the system accordingly.
4.4 Observation during auxiliary equipments operation
• If the water level for one reason or another irregular feeding / discharging,
etc. approaches the “highest / lowest water level”, the level should be
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corrected by manual operation of the inlet, outlet, bypass, Overflow valves
or drain valve.
• The water level indicators are to be blown through daily. The blowing
through must be of short duration – about one half to one second, in order
to protect the glasses.
• The pressure gauge is to be checked regularly, and the “O” point to be
checked. The check is to be carried out with a checking pressure gauge at
least once every six months.
• Blowing off the safety valve should be avoided.
4.5 Water column & water gauge
The water column and water gauge glass should be blow down at the
beginning of each shift. The three times a day schedule will ensure two things:
• The sludge or sediment will not have a chance to accumulate in the
column or glass.
• Any accumulation can cause an erroneous level indication.
5. START UP OF AUXILIARY EQUIPMENTS
5.1 Introduction
This start up should be read in conjunction with boiler start up procedure and
Process control narratives.
The auxiliary equipments start up procedure is divided into two steps:
- Preparation for start up

- Starting up the auxiliary equipments
During commissioning the feed water tank/deaerator and its connecting piping
should be carefully checked to see it can expand freely in the manner and
direction intended in design.
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5.2 Preparation for start up
1. Before proceeding to the commissioning of the auxiliary equipments, all

connecting pipelines, all flange connections of the various fittings and
accessories are to be properly secured. Next, check that the inside of the
auxiliary equipments is free from all stray nuts, bolts, tools, etc.
2. The auxiliary equipments must be perfectly clean and all bolts firmly secured
against backing off and loosening.
3. All apparatus to the auxiliary equipments (valves, gauge glass cocks, etc)
should be in perfect condition and be in the right position (open or shut) while
the connecting lines and pipes to and from the auxiliary equipments are to be in
good working order. Refer to boiler start up procedure.
4. The H.W.L., N.W.L. and L.W.L. levels (High-, Normal-, Low Water Level) in the
auxiliary equipments should be made visible on the sight glass.
5. Before starting the warming-up of the auxiliary equipments, make sure the
whole feed system is filled with water and no air is left behind in this piping.
6. Ensure that no cold water pocket exist in line by draining them completely.
5.3 Start up the Deaerator
Make sure that all the valves are aligned as described in Startup chapter of
this O &M manual.
The start up of deaerator can be preceded as follow:
8.1. The air vent mounted at the top of deaerator is open through valve with Tag
# 546.
8.2. Make sure sufficient level of water is available in the mix water tank.
8.3. Start Mix water pump by pushing it’s On /Off button as per instruction of pump
manual.
8.4. Start supply of mix water to Deaerator system by gradually opening of pump
discharge valve MOV- 100/101/102 with minimum flow not less than 42 TPH.
8.5. Now start filling the Feed water tank/deaerator by slight opening the mix water
level control valve bypass (Client scope).
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8.6. Bring the level to the slightly higher than LWL. If already filled then keep it as
low as possible.
8.7. Now the warming-up of the feed water tank/deaerator can be started. This is
done by controlling the bypass valve PCV-500 A bypass in the steam supply
line. This should be done very slowly in order to minimize the hammering.
8.8. Now slowly bring the deaerator temperature to the operating value of 105 °C.
8.9. When the required temperature is achieved, the pressure control valve
PCV-501 A can be put in auto control by closing its bypass valve.
8.10. Bring water level slowly to NWL for utilization in Boiler. By opening the level
control valve LCV-(Client scope) partly.
8.11. When the required water level is achieved then the level control valve LCV-Client
scope can be put in automatic control.
5.3.1 Items required special attention
1. Do not put the Demin water into deaerator without having ascertained that there is
no air left in the supply piping and that the piping is only filled with Demin water.
2. Do not heat up the deaerator at a lower pace than indicated above.
3. Never start-up the deaerator at a higher staring level than NWL
5.4 Shut down of the deaerator
When deaerator is to be brought down from on-line service for short time, do
the following steps.
• The water level should be maintained at normal of the gauge glasses.

• Make sure that mix water level control valve and pressure control valve are
in close position, if not manually closed.
• The Temperature should be maintained at operating conditions as long as
possible.
• Close the mix water pumps if the duration of shut down is longer.
For long shut down of deaerator see the preservation procedure.
______________________________________________________________________________

_______________________________________________________________
5.5 Start up and shut down of sample coolers
Make sure that all the valves are aligned as described in Startup chapter of
boiler O&M manual.
When new sample line is being taken into service, flow steam and
condensates through it for 24 hours before samples are collected. Before a
sampling period blow steam through sample lines to remove any impurities
deposited in it. Adjust the desired sample flow rate and flow the sample at this
rate for 1 hour before conductivity measurement.
For taking sample first open the vent valve of steam samples till a clear, free
of rust, clear sample is available, now close vent valve and open sample valve
for some time, when clear, transparent sample is available at ambient
condition, you can take sample. For liquid sample, bleed samples till you get
the free of rust, clear sample. Now take the sample and close the sample valve.
Make sure that the sample is at ambient temperature while you take sample.
Note:
If a sample is taken to laboratory for analysis which has temperature lower

than ambient temperature; Do not open the sample bottle immediately as it will
flash steam and will provide wrong analysis. The right procedure is to bring the
sample to laboratory temperature and then open the sample bottle for
performing its analysis.
6. AUXILIARY EQUIPMENTS INSPECTION AND MAINTENNACE
We refer you to the Boiler Inspection procedure in O&M manual as a guide for
inspection and maintenance of auxiliary equipments.
______________________________________________________________________________

_______________________________________________________________
7. PRESERVATION PROCEDURE
7.1. Dry preservation
This method may be used for preserving of deaerator taken out of service for a
longer period of time say 1 month.
The Demin water, steam and boiler feed water/blow down coming to deaerator
is put out of service. When the pressure has fallen sufficiently the deaerator
will be drained completely, after which the manhole covers are removed. The
whole of the deaerator is cleaned and possible corrosion is removed properly.
Safety valve, stop valves, etc. are properly checked and as far as necessary
provided with acid-free grease.
If the deaerator has been installed in a boiler house, which is sufficiently dry
(relative humidity < 60 %), the manhole covers can be omitted so that some
ventilation through the deaerator is possible to keep it properly dry. If it is not
quite certain that the deaerator can be kept dry, or if the Deaerator has been
installed in the open, boxes containing silica gel have to place in the water
space. A quantity of about 0.03 kg per m3 of contents of the deaerator is
sufficient.
The boxes have to be of wood or enameled iron and must not leak. They are
to be filled for about ¾. In this case the manhole covers must be fitted and
firmly tightened.
Note:
Preservation method does not provide a complete protection. Therefore it is

necessary to check from time to time whether the deaerator remains dry and
no rust is formed.
______________________________________________________________________________

_______________________________________________________________
7.2. Entering auxiliary equipments
The following safety measures must be taken before attempting to open

access cover.
i) Vessel entry permit must be issued including all necessary information.

ii) All external services outlet streams and inlet streams etc must be safely
and visibly closed.
iii) Electricity must be isolated from all auxiliary equipments (where applicable).
iv) Post DANGER notices at all isolators and access points saying
WORKERS IN auxiliary equipments.
v) Open auxiliary equipments vent to release any pressure.
vi) Drain auxiliary equipments through drain valve.
vii) Open all access covers and allow auxiliary equipments to ventilate.
viii) It is essential to have an operator standing by, outside the auxiliary
equipments.
Depending upon condition of unit it is advantageous to hose down inside while

it is still warm. Any further cleaning may be done with wire brush as required.
After this, it should be thoroughly washed with water prior to refilling and close
the man hole using new joints.
8. SAFETY REQUIREMENTS
8.1 General safety
− It is a requirement by law that a manufacturer and or supplier of equipment

ensures that the equipment manufactured is at such a standard so as to be
operated and maintained in safely.
− It is also a requirement by law and suitable for intended function that the
purchaser and user of the equipment, ensures that the installation,
commissioning, operation and maintenance of said equipment is carried out
by competent persons.
______________________________________________________________________________

_______________________________________________________________
− Where the competency of the person is in doubt then appropriate training
shall be provided or obtained.
− It is also a requirement by law that the operator and maintenance persons
ensure that they are adequately trained to carry out their responsibility on
the said equipment and that they are given suitable training where required.
− It is also a requirement by law that the operations and maintenance
departments act in a safe manner and take due care of their own and others
safety during the execution of their duties.
8.2 Pre-requisite for the safe operation of the auxiliaries equipments:
− The auxiliary equipments shall be housed in an adequately ventilated space.

− Suitable fire fighting equipment shall be situated in the building.
− The area around the deaerator should be kept clean and free of all debris
− Do not leave control panels and junction box door covers open during
“power on” and operation. If it is necessary to do so for fault diagnosis and
rectification, then suitable notices should be posted around the area
indicating same and the work should only be conducted by personnel
suitably qualified by training and expertise, ensuring that the doors and
cover are replaced as soon as possible.
− Ensure that all hot pipes are suitably insulated.
− A set of practices and procedures should be developed for any maintenance
work to be carried out, and should include permit to work control procedures.
8.3 Safety practices and procedures:
• For auxiliary equipment operators
In the event of the failure:

− The unit is to be shut downed completely.
− Notices are to be posted indicating that unit is not to be restarted
− Notify maintenance personnel of problem
• In the event of fire

______________________________________________________________________________

_______________________________________________________________
− Switch off all electrical supplies (Where Applicable).

− Notify the appropriate fire authority within the company. Learn and use fire
extinguishing devices in case of emergency.
− Shut off all ventilation systems.
• General house keeping
− Ensure that all water leaks are stopped and the spillage is cleaned away
and that any leaks have been rectified.
− Ensure that no debris exists around the deaerator and any associated
equipment.
− Ensure that the space is adequately ventilated at all times.
− Monitor at regular intervals the operational functions of the unit.
− Be aware of the water treatment plant and chemicals used.
− Observe safety precautions at all times
.
• For maintenance operations
− Use a permit to work procedure. This ensures that all necessary persons
are notified and that appropriate precautions are in place.
− Always ensure that electrical supplies are isolated and are locked off with
notice of name and department.
− Post notices around indicating work taking place.
• Routine maintenance work
− Obtain permit to work as appropriate to the type of work being undertaken.

− Switch and lock off all appropriate supplies such as Heating Steam, Soft
Water, Steam Condensates and Electricity.
− Post notices to indicate work being undertaken and associated hazards.
______________________________________________________________________________

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DESCON ENGINEERING LIMITED

Title : OPERATING AND MAINTENANCE MANUAL

Client : United Sugar Mills Limited

02-12-13 00 First issue MZI KA FB

DM.12227-000-B91-800 Operating and Maintenance Manual Page 1 of 1

Client : United Sugar Mills Limited

Designer : Descon Engineering Limited

Manufacturer : Descon Engineering Limited

Document No. : DM.12227-000-B91-810

Date : 02 Dec 2013

Title : OPERATING AND MAINTENANCE MANUAL

Client : United Sugar Mills Limited

DM.12227-000-B91-820 Introduction Descon Engineering Limited Page 1 of 5

1.1 General Instructions ………………………………………………… 3

DM.12227-000-B91-820 Introduction Descon Engineering Limited Page 2 of 5

1.1 General Instructions

The Instruction Manual describes the operation and maintenance of the

1.2 Technical Service

If you do call for consultation, please have available:

1. All DESCON prints, electrical and/or mechanical, that relates to your

DM.12227-000-B91-820 Introduction Descon Engineering Limited Page 3 of 5

To facilitate scheduling of our Service Engineers, we require a minimum of two

1.3 Correspondence Address

Technical Service Section- Operations Boilers Department

DM.12227-000-B91-820 Introduction Descon Engineering Limited Page 4 of 5

1.4 Office Address

Descon Engineering Limited

1.5 Design Approval

Before a new boiler installation is permitted to be commissioned, it shall be

DM.12227-000-B91-820 Introduction Descon Engineering Limited Page 5 of 5

Title : OPERATING AND MAINTENANCE MANUAL

Introduction to Direct Fired

Client : United Sugar Mills Limited

DM.12227-000-B91-830 Introduction to Direct Fired Boiler Page 1 of 20

1. Introduction direct fired boiler……………………………………………………... 3

3. Process description of the direct fired boiler…………………..………………. 6

3.1 General description……………………………………………..…………………..... 6

4 Construction of the direct fired boiler………………………………….............. 11

4.1 General …………….……………………………………………..…………………..... 11

DM.12227-000-B91-830 Introduction to Direct Fired Boiler Page 2 of 20

1. INTRODUCTION DIRECT FIRED BOILER

The boiler is equipped with the following main sections / parts:

- Boiler parts comprises of:

• Water cooled membrane Wall furnace

- Deaerator system for Boiler comprises of

• Deaerator storage vessel

DM.12227-000-B91-830 Introduction to Direct Fired Boiler Page 3 of 20

- Bagasse firing system for boiler comprises of:

DM.12227-000-B91-830 Introduction to Direct Fired Boiler Page 4 of 20

− Combustion air/flue gas system for boiler comprising of:

DM.12227-000-B91-830 Introduction to Direct Fired Boiler Page 5 of 20

- Chemical dosing system including pumps, vessel, electric mixer etc.

- Steam/water sampling system comprising of Six (6) sample coolers.

- Local instrumentation comprising of instrument block valves, flow measuring

- Insulation for all hot components

3. PROCESS DESCRIPTION OF THE DIRECT FIRED BOILER

3.1 General description

DM.12227-000-B91-830 Introduction to Direct Fired Boiler Page 6 of 20