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*** DOCUMENTS OF OPERATION ***

BOILER, OIL THERMAL HEATER CHAIN GRATE


I/ PROCESS OF ALKALINE, CLEANING
II/ PROCESS OF DRY-OUT
III/ HANDBOOK GUIDE OPERATION
IV/ CALCULATION OF EFFICIENCY
V/ COMMENT AND EVALUATION

Prepare: Bui Pham Thien Van


Present: Bui Pham Thien Van
Company: Martech boiler Co, LTD
Documents circulated internally
I/ PROCESS OF ALKALINE, CLEANING

1/ Scope of Application :
- Only for boiler
2/ Purpose:
In order to clean the welding slag, iron, dust, grease during the construction of the boiler.
Create a protective layer into metal that limits chemical corrosion to occur.
3/ Process of alkaline:
- Refer to Martech standard
- Refer to external subcontractors
4/ Request:
- Calculate the boiler’s volume.
- Provide protective equipment for working with chemicals.
- Strictly monitor and control the process of alkaline in accordance with the given process.
- Record the phenomenon, the steps of alkaline process according to reality.
- After completing the process of alkaline process, save the record.
DRY-OUT PROCESS FOR BOILER
II/ PROCESS OF DRY-OUT

450
450
450
500

400
400
400

400
400
450

350
350
350

350
350
400

300
300
300

300
300
350

Temperature (`C)
1/ Scope of application:

250
250
250

250
250
300

- Boiler.

200
200
200

200
200
250

150
150
150

150
150
200
- Oil thermal heater.

100
100

100
100
150
2/ Purpose: 100

- Drying brick, mortar, insulation in furnace. 50

- Heating, stabilizing metal lattice after fabrication. 0

102
104
106
108
110
112
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
6

96
12
18
24
30
36
42
48
54
60
66
72
78
84
90
3/ Dry-out process: Time (h)
- Refer to Martech standard boiler dry-out process.
- Refer to Martech standard oil thermal heater dry-out process. DRY-OUT PROCESS FOR OIL
4/ Request: THERMAL HEATER

275
275
275
300
- Do not use rice husk to perform dry-out.

250
250
250
250
225
225
225
225
- Record the boiler parameters during the boiler dry-out process. 250

200
200
200
- Record the oil thermal heater parameters during the oil heating

Temperature (`C)

175
175
175
200

150
150
150
process.

125
125
125
150
- After finish the dry-out process, check the entire boiler system.

100
100
100
100

75
75
Make sure the combustion chamber doesn't have any abnormalities. If

50
yes, fix repair. 50

25
0

102
108
114
120
126
132
138
144
150
156
162
168
174
0
6

18

36
12

24
30

42
48
54
60
66
72
78
84
90
96
Time (h)
III/ HANDBOOK GUIDE OPERATION
Scope of Application :
- Boiler.
- Oil thermal heater.

1/ INSTRUCTION OF CHAIN GRATE BOILER


- Check boiler before operation.
- Start-up, operate the boiler.
- Valve operation rules.
- Stop boiler.
- Some notes when operating the boiler.
- Operating water tank with degassing.
- Operating water supply pump from tank to steam drum.
- Boiler maintenance.
2/ INSTRUCTION OF THERMAL OIL HEATER CHAIN
GRATE
- Check oil thermal heater before operating.
- Start-up, operate the oil thermal heater.
- Operating procedures.
- Stop the oil thermal heater.
- Some notes when operating the oil thermal heater.
- Oil thermal heater maintenance.
IV/ CALCULATION OF EFFICIENCY
Scope of application:
- Boiler
- Oil thermal heater

1/ BOILER EFICIENCY
a/ Formula:
𝐺. (𝐼𝒔 − 𝐼𝒘 )
𝜂= . 100%
𝑀. 𝑄𝒏𝒆𝒕

- Where: + G: Total steam flow (kg/h)


+ Is: Steam enthalpy at working pressure (Kcal/kg).
+ Iw: Water enthalpy at working temperature (Kcal/kg).
+ Qnet: Net calorific value of fuel (Kcal/kg).
+ M: Fuel consumption (Kg/h)
b/ Documents:
- Minutes of testing oil furnace acceptance capacity.
- Excel performance spreadsheet.
IV/ CALCULATION OF EFFICIENCY

2/ EFFICIENCY OF THERMAL OIL HEATER:


a/ Formula:
𝐺. (𝐼𝒐𝒖𝒕 − 𝐼𝒊𝒏 )
𝜂= . 100%
𝑀. 𝑄𝑛𝒆𝒕

- Where: + G: Total oil flow (kg/h) or (m3/h)


+ Iout: Enthalpy of outlet oil (Kcal/kg).
+ Iin: Enthalpy of inlet oil (Kcal/kg).
+ Qnet: Net calorifc value in ARB (Kcal/kg).
+ M: fuel consumption (Kg/h)
b/ Document:
- Minutes of testing oil furnace acceptance capacity.
- Excel performance spreadsheet.
V/ COMMENT AND EVALUATION
A/ BOILER
1/ Evaluate actual performance compared to calculation
2/ Evaluate temperature of insulation
3/ Evaluate of fire regime in combustion chamber
4/ Evaluate water level fluctuation in steam drum, vibration of water circulation downcomer, raiser.
5/ Evaluate the wind temperature, smoke temperature in each region compared to the design
6/ Evaluate some fan, conveyor, screw, load bucket, water pump, heat sensor, pressure sensor, temperature meter,
pressure meter ...
7/ Boiler parameters: depending on the furnace, there are different parameters. During operating boiler, it is
necessary to record the parameters in order to have a basis for evaluating the boiler.
B/ OIL THERMAL HEATER
1/ The evaluation criteria are almost like the boiler
2/ Oil thermal heater parameters: depending on the thermal oil heater, there are different parameters. During
operating thermal oil heater, it is necessary to record the parameters in order to have a basis for evaluating the
thermal oil heater
VI/ INCIDENTS AND RESOLUTION
A/ INCIDENTS & RESOLTION CHAIN GRATE BOILER
1 / Leak water in the combustion chamber
2 / Water pump is insufficient capacity, flow, running 2 pumps
3 / Water level fluctuates strongly, often indicate L, LL
4 / There is a strong noise, shaking water economizer’s pipe
5 / Water level of water tank is strongly fluctuated when there is circulating water from economizer
6 / 3-way valve of the supply water to the evaporator is a bit lacking, and the water returns the sink is much
7 / Condensate from the factory to the tank directly connected to the tank without going through Cyclone on the
tank, causing the water level to fluctuate strongly
8 / Cavitation in water pump - NPSH is not enough
9 / Pneumatic control valve is damaged due to incorrect air pressure adjustment
10 / The hammer vibrates too loudly, there is a strange noise when vibrating
11 / Water Pump is not enough
12 / Black flue gas, dust out of the chimney
13 / The steam from the Ventury rolled out of the chimney, the exhaust fan is worn out
14 / The temperature inlet the bag filter is too high or too low
15 / Fire in combustion chamber is not good, burning arc shape on chain grate
16 / Oxygen concentration is too high or too low
17 / Overload devices, yellow warning lights
18 / Light-emitting overheating indicator light
19 / Control problems
20 / Level signal alarm of steam drum does not work
VI/ INCIDENTS AND RESOLUTION
B/ INCIDENTS & RESOLTION CHAIN GRATE THERMAL OIL HEATER
1/ Oil flow is not enough for production
2/ Oil temperature is higher than 100oC
3/ Oil pump cold start-up at temperature < 70oC, overloaded motor
4/ Some incidents causes shutdown the thermal oil heater refer to “CHAIN GRATE THERMAL OIL HEATER
OPERATION HANDBOOK ’
THE END!
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