Académique Documents
Professionnel Documents
Culture Documents
PUNE, INDIA.
Section A
Page i
Evaporation capacity
Super heater steam outlet pressure
Super heater steam outlet temp.
Steam temperature control range
Feed water Eco inlet temperature
Design metal temperatures
Steam drum, water drum, riser, saturated supply tubes,
downcomer and furnace panels
Economizer coil
Economizer header: Top / Bottom
Attemperator 1 header
Attemperator 2 header
Primary Super heater 1 header : Inlet / Outlet
Primary Super heater 2 header : Inlet / Outlet
Secondary Super heater header1: Inlet / Outlet
Primary SH coil : I to J / J to K / E to F / F to G /G to H
Secondary SH coil : A to B / B to C / C to D /
Section A
I.B.R.
102 Kgf/cm2(g)
153 Kgf/cm2(g)
100% Bagasse /80 %
Imported /65 % Indian
coal
125 TPH
87 Kgf/cm2(g)
515 5 C
60 100 % MCR ( for Bagasse
only)
165C
C
339.5
285
285 /165
476
492
338/436
383/492
450 / 520
450 / 412/512/486/433
492/542/559
2467.5 m2
2568.5 m2
5036 m2
Page 1
MATERIAL DATA
S.N.
1.
2.
3.
4.
5.
DESCRIPTION
STEAM DRUM
DISHED END
WATER DRUM
DISHED END
FURNACE HEADERS:
FRONT PANEL BOTTOM HEADER
REAR PANEL BOTTOM HEADER
LH & RH SIDE WALL BOTTOM
HEADERS
L.H & RH SIDE WALL TOP
HEADERS
6.
CONVECTION BANK
7.
8.
FURNACE TUBES
RISER TUBES
ASSLY. OF PRI SH 1 COILS
LEG 1 TO 3
LEG 4 TO 5
LEG 6 TO 14
9.
LEG 1 TO 3
LEG 4 TO 9
LEG 10 TO 14
10.
11.
11.
12.
13.
14.
15.
16.
Section A
1375
1375
960
960
SIZE
ID X 100 THK
ID X 80 THK
ID X 63 THK
ID X 63 THK
SA
SA
SA
SA
MATERIAL
516 GR 70
516 GR 70
516 GR 70
516 GR 70
273.1 OD X 35 THK
219.1 OD X 23.01THK
SA 106 GR B
SA 106 GR B
219.1 OD X 23.01THK
SA 106 GR B
219.1 OD X 23.01THK
SA 106 GR B
OD
OD
OD
OD
OD
OD
X
X
X
X
X
X
4.06 THK
4.06 THK
4.5 THK
5.0 THK
4.06THK
4.06THK
SA 210 GR A1
SA 210 GR A1
SA 210 GR A1
SA
SA
SA
SA
SA
SA
213
213
210
213
213
210
T 11
T 11
Gr A1
T 22
T 11
Gr A1
SA 213 T22
SA 213 T22
SA 213 T22
SA
SA
SA
SA
SA
SA
SA
SA
SA
SA
SA
SA 106 Gr B
SA 106 Gr B
106
335
106
335
335
335
335
335
335
106
210
Gr B
P 11
GR B
P 22
P 22
P 22
P 11
P 22
P 22
Gr B
GR A1
Page 2
UTILITIES
SNO.
1
PARAMETERS
Feed water :
TDS (Max)
Oil (Max)
Total Suspended solids (Max)
Silica (Max)
Turbidity
Total Hardness
PH value at 25 Deg. C
Oxygen (Max)
Iron (Max)
Copper (Max)
Drum water
Quality
Total Hardness (Max)
PH value at 25 Deg. C
Silica (Max)
TDS (Max)
Residual Hydrazine (Max)
Residual Phosphate (Max) as PO4
Oil (Max)
Electric Power
LT Electric supply (For all motors)
LT supply Voltage
Frequency
Phase
Total combined variation
Electric power for instruments
Frequency
Volts
Phase
Cooling water for sample coolers
Quality
pH Valve
Supply / return Temperature
Supply / return Pressure
Instrument air
Pressure
Quality
Dew point
Environment
Section A
UNIT
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
VALUE
0.1
Nil
Nil
< 0.02
Nil
Nil
8.5 9.5
0.007
0.01
0.005
Pure
Nil
10.2 10.7
1.33
100
0.02
15 to 30
Nil
V
Hz
415 +/- 6 %
50 +/- 5%
3 PH
10 %
Hz
V
50
230 AC / 24 DC
1
Soft
7.5-8.5
Deg C
Kg/cm2(g)
35 / 45
3/2
Kg/cm2(g)
5
Clean, oil & moisture free
-40
Non corrosive, Hot, humid and
dusty
Page 3
SR.
NO.
7
8
9
10
PARAMETERS
Site conditions
Site location
Temperatures
For Mechanical design
For Performance
For Electrical design
Relative Humidity
For Performance
Maximum
Minimum
Rainfall (Annual Average)
Altitude above MSL
Wind velocity
Basic seismic co-efficient
Design Basis
No. of Boilers
Type of installation
Section A
UNIT
VALUE
C
0
C
0
C
0
C
%
%
%
%
mm
mts
45
30
50
69
90
46
250
150
As per IS 875 part 3
As per IS 1893 Zone IV,part 1
IBR 1950 with latest amendments.
Ones
Outdoor.
Page 4
FUEL SPECIFICATIONS
FUEL:
1. FUEL B: BAGASSE
2. FUEL C: IMPORTED COAL
3. FUEL D: INDIAN COAL
ULTIMATE ANALYSIS
FUEL B
FUEL C
FUEL D
MOISTURE
50.00
10
8.3
ASH
1.50
14.36
39.90
CARBON
HYDROGEN
SULPHER
%
%
%
23.50
3.40
0.00
62.14
4.73
0.96
40.00
2.8
0.38
NITROGEN
0.00
1.01
0.60
OXYGEN
TOTAL
%
%
21.55
100.00
6.80
100.00
8.02
100.00
Kcal/Kg
2270
6300
3800
GCV
SIZING:
For Bagasse
As received
Section A
Page 5
AUXILIARIES
FAN
MAKE: FLAKTWOODS,
SR.
NO.
DESCRIPTION
1.
Fan model
HABB-7-180-244-06-6-8
HABB-7-125-163-041-1
HABB-7-80-17002-1-1
2.
KF-107016 a
KF-107017 b
KF-107018 c
3.
Flow
45 kg/s
32.97 kg/s
4.
Static pressure
13.19 kg/s
675
mmwc
outlet
200 Deg. C
60 Deg.C
250 Deg.C
185 Deg. C
50 Deg. C
205 Deg. C
0.7240 Kg/m3
1.054 Kg/m3
0.7160 Kg/m3
3800 Kg-m 2
1631 Kg-m 2
640 Kg-m 2
735
965
1480
5.
6.
7.
8.
9.
Design
temperature
Operating
temperature
Gas density @
operating temp.
GD2 Value
Fan speed
( RPM)
ID FAN
FD FAN
SA FAN
at
10.
Lubrication
GREASE,Servogem:EP2
GREASE Servoge EP 2
11.
12.
Lub .interval
Fan Bearing
1400 hr.
1400 hr.
GREASE
servogem, EP 2
1400 hr.
22228 EK / C3
Brg. HousingSNA 528
22228 EK / C3
Brg. HousingSNA 528
22220 EK (SKF) +
H320 + SNA520 +
FRB 12/180P
22220 EK (SKF) +
H320 + SNA520
22224 CK (SKF) +
H3124 + FRB
14/215P ,SNA 524
22224 EK (SKF) +
H3124 + SNA 524
MAKE : SIEMENS
220 KW / 8 Pole
HC 22 BHI MAKE
RESILLIENT COUPLING
MAKE : SIEMENS
96 KW/ 4 Pole
HC 17 BHI MAKE
RESILLIENT
COUPLING
MAKE : SIEMENS
143 KW/ 4 Pole
HC 17 BHI MAKE
RESILLIENT
COUPLING
Fixed end
Free end
13.
Motor Rating KW
/ Pole
Coupling
14.
Section A
Page 6
UNIT
NO
RPM
m3/hr
M
C
OIL
kW/RPM
TRANSFER PUMP
DESCRIPTION
MAKE
TYPE & SIZE
QUANTITY
RATED FLOW
RATED HEAD
NOMINAL/ EFF. SPEED
COUPLING MAKE
TYPE & SIZE
LUBRICATION
MOTOR
Section A
UNIT
NO
m3/hr
M
RPM
OIL
Make/kW
Page 7
Unit
No.
Capacity
RPM of Rotor
Kg/Hr
RPM
MAKE
Material Handled
Material Size
Bulk Density
Vane filling Efficiency
Motor Rating
Rotor Speed
Design Temperature
Section A
KW/RPM
RPM
0
C
Remark
2
RAV-01, RAV-02
Design
Maximum
1717
400
3.5
3.5
ROSMIC INDIA ENGINEERING
CORPORATION
Hot ash of bagasse ash + coal ash
100% below 500 micron, fines
400 Kg/m3 - For volume calculation
800 Kg/m3 - For Power
65%
1.5 / 9.5
3.5
300 Max
Page 8
TRAVAGRATE
TRAVAGRATE
Number of grate
Shaft center to center distance
Grate width
Number of bearings/shaft
Number of links/chain assembly
Number of chain assembly
Anchor bearing location
Grate castings 298 mm/Grate bar assly.
Grate castings 229 mm/Grate bar assly
Skid shoe /Grate bar assly.
Fabricated grate ba / Grate
Lubrication
Grate shaft bearings
Frequency
HYDRAULIC DRIVE
Model
Cylinder stoke length (available)
Cylinder stoke length (required)
Hydraulic oil
Dual Grate
6100 mm
8640 mm
04 Nos.
94 Nos.
08 Nos.
Second from drive end
22 Nos.
08 Nos.
16 Nos.
94 Nos.
POLY- ISOBUTENE (PIB128)
Twice in 8 Hrs.(110 grams/bearings/day)
HD III
196 mm
134 mm
ENKLO 46/68 OR SERVOSYSTEM 46/57 OR
BHARAT HYDROL 68
Oil quantity
200 ltr
Drive motor
5
HP
Relief valve set pressure
29 kg/cm2
REFERENCE DRAWINGS
Travagrate assembly with hydraulic drive
Hydraulic drive assembly for RH unit ( model HD-III)
Hydraulic drive assembly for LH unit ( model HD-III)
S1-12-0858
0LB-03604
0LB-03605
25 ltr/min
2
55 kg/cm (MAX).
75 0C
60 0C
3 kg/cm2
35 TO 40 0C
2000 Kg/hr
40 T0 45 0C
40 kg/cm2
4 kg/cm2
Page 9
CYCLO TRANSMISSION
Double stage foot mounted geared motor
SP 2-4 (M)
5 hp/3.7kW
493:1
1440 rpm
2.9 rpm
LUBRICATION
QUANTITY
Section A
Page 10
DESCRIPTION
1.
SB numbers
2.
Travel in mm
3.
Dead travel in mm
4.
Quantity
5.
Location
6.
7.
8.
9.
10.
Blowing pressure
Kg/cm2(g)
Blowing angle
Degrees
Steam
consumption/cyc
in kg
Nozzle size(mm)
Blowing
time/Blower(min)
Section A
Retractable SB
SB 01,02,03 &
04
4500
SB 05 to 12
SB 13 & 14
SB 15 to
18
-
375
1 Each
1 Each.
1 Each.
1Each
PSH
Convection bank
Economiser
10.5
10.5
10.5
10.5
360
360
180
360
620
424
82
328
19
3.37
0.8
0.4
0.4
Secondary SH
Page 11
DOSING SYSTEM
Make: METAPOW INDUSTRIES
SN
1.
2.
3.
4.
5.
6.
7.
DESCRIPTION
TANK
SIZE
VOLUME
MATERIAL
PUMP CAPACITY
PRESSURE ( MAX )
PUMP MAKE / MODEL
TYPE
NO OF PUMPS
MOTOR
MOTORISED AGITATOR
9.
10.
LUBRICATION
8.
Section A
LP DOSING
HP DOSING
6 kg/cm2 (g)
Page 12
LEVEL GAUGES
DEAERATOR
A) GENERAL
a) Location of LG
b) Quantity
c) Type & Mounting
d) Installation
e) C to C distance from top & bottom
connections of LG
f) Visible Length (Min)
g) Tag No.
B) DESIGN PARAMETERS
a) Design Pressure
b) Hydraulic Test Pressure
c) Design Temperature
C) END CONNECTIONS
Size / Type
D) OTHER REQUIREMENT
a) Design code
b) Isolation Valves
c) Vent / Drain Connection with valve
Deaerator Tank
3 No.
Tubular (Vertical)
Outdoor
1000 mm
860 mm
LG 05, LG 06, LG 07
3 Kg/cm2 (g)
4.5 Kg/cm2 (g)
150 0C
25 NB / SW
Non IBR
Offset screwed bonnet
Vent plug/needle valve
CBD TANK
A) GENERAL
a) Location of LG
b) Quantity
c) Type & Mounting
d) Installation
e) C to C distance from top & bottom
connections of LG
f) Visible Length (Min)
g) Tag No.
B) DESIGN PARAMETERS
a) Design Pressure
b) Hydraulic Test Pressure
c) Design Temperature
C) END CONNECTIONS
Size / Type
D) OTHER REQUIREMENT
a) Design code
b) Isolation Valves
c) Vent / Drain Connection with valve
CBD Tank
1 No.
Tubular (Vertical)
Outdoor
500 mm
360 mm
LG 003
3 Kg/cm2 (g)
4.5 Kg/cm2 (g)
150 0C
25 NB / SW
IBR
Offset screwed bonnet
Vent plug/needle valve
IBD TANK
A) GENERAL
a) Location of LG
b) Quantity
c) Type & Mounting
d) Installation
e) C to C distance from top & bottom
connections of LG
f) Visible Length (Min)
g) Tag No.
B) DESIGN PARAMETERS
a) Design Pressure
b) Hydraulic Test Pressure
c) Design Temperature
C) END CONNECTIONS
Size / Type
D) OTHER REQUIREMENT
a) Design code
b) Isolation Valves
c) Vent / Drain Connection with valve
Section A
IBD Tank
1 No.
Tubular (Vertical)
Outdoor
500 mm
360 mm
LG 004
1.5 Kg/cm2 (g)
3 Kg/cm2 (g)
150 0C
25 NB / SW
Non IBR
Offset screwed bonnet
Vent plug/needle valve
Page 14
ESP
Make
Quantity
Model
G.A. Drawing No.
Thermax limiited.
1 No.
SC-25-16-33-(3+1 X 10.625)-2.4P
7E521-145-10 Rev. 02
DESIGN DATA
SR.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
DESIGN PARAMETER
Design Gas Volume
Temperature (Operating)
Max. Inlet Dust Loading(wet
basis)
Outlet Emission From ESP
Moisture in Gas
Unburnt Carbon in Fly Ash
Collection area
Specific collection Rates
No. of Gas Passages
Velocity through ESP
Treatment Time
No. of Fields in Series
Migration velocity
Design Pressure
Flange to Flange Pressure Drop
Section A
387000
150
80%
IPORTED
COAL
194400
140
65%
INDIAN
COAL
163800
140
4.5
26
UNIT
100%
BAGASSE
am3/h
C
Gm/ Nm3
Mg/ Nm3
% w/w
% v/v
m2
m2/m3/sec
No.
m/sec
s
No.
cm/sec
mmWC
mmWG
150
150
150
26.82
9.83
10.03
30-40
45-60
20-30
4886.1
4886.1
4886.1
45.45
90.48
107.39
25
25
25
1.05
0.53
0.45
9.2
18.4
21.8
3 Mechanical & 3 Electrical
8.11
4.39
4.8
+ / - 250
25 30
Page 15
SAFETY VALVE
MAKE: TYCO SANMAR LIMITED
SL
NO
LOCATION/
TAG NUMBER
01
02
03
MODEL / SIZE
HCI-R-56W-IBR-SPL
2.5 x k2 x 6
HCI-R-56W-IBR-SPL
2.5 x k2 x 6
HCI-68-W-IBR
2 x J2 x 4
SET
PRESSURE
RELIEVING
CAPACITY
RATED/REQD.
102 kg/cm2( g)
79580/55000 kg/hr
103 kg/cm2( g)
80352/55000 kg/hr
94 kg/cm2( g)
32864/27500 kg/hr
LOCATION/
TAG NUMBER
STEAM TO DEAERATOR
(PSV 010)
Section A
MODEL / SIZE
JOS-H-E-45-C-IBR-SPL
2.0 x H x 3.0
JOS-H-E-15-C-IBR
2.0 x J x 3.0
JOS-H-E-15-C-IBRSPL.
3.0 x K x 4.0
JOS-H-E-15-C-IBR8.0 x T x10
JOS-H-E-15-C-IBR
6.0 x Q x 8.0
SET
PRESSURE
RELIEVING
CAPACITY
RATED/REQD.
50 kg/cm2(g)
2.5 kg/cm2(g )
2227/1600 kg/hr
1.2 kg/cm2(g )
2.0 kg/cm2(g )
3.5 kg/cm2(g )
Page 16
Section B
Page i
GENERAL ARRANGEMENT
BOILER PRESSURE PART DESCRIPTION
This boiler is a Bi-drum, natural circulation, top supported, and membrane wall construction.
Various pressure parts are grouped as follows:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Steam drum.
Water drum
Down comer Tubes.
Furnace membrane water walls
Riser Tubes
Saturated steam supply tubes
Super heater
Convection bank
Economizer
STEAM DRUM
(Refer Drg no : P21-OTB-06564)
Steam drum (1375 I.D. X 10500 mm long.) is a all welded cylindrical vessel made of SA
516 Gr.70 material. The cylindrical portion of the vessel is made of 100-mm thick plates and
the two Torispherical dish ends are 80 mm. thick. Two elliptical manholes at either end of the
drum provide access inside the drum. These manholes are closed tight at either end by 63-mm
thick plates, bolted against the manhole rim by two holding bars. A gasket is fitted between the
cover plate and the mating machined surfaces in the end shield. The cover plate swing inside
the drum, for convenience during opening.
Steam drum is supported from the super structure of the boiler through 4 nos. U slings (2 at
LHS & 2 at RHS of the shell) and rocker washers.
Steam drum is fitted with several components to perform important functions, which are listed
below:
Direct water level gauge LG 001 & 002 that shows the water level inside the steam drum.
DWLG`S are provided at both ends of the drum.
Two nos. Level transmitters are provided LT 703A & 703B which transmit the actual water
level to the remote indicators i.e. at control room and provide drum level signal to the drum
level controller.
Drum safety valves PSV 001 & 002 which protects the boiler and the personnel against the
consequences of abnormal pressure increase because of sudden load decrease, mal
functioning of firing system, steam stop valve etc.
Remote level gauge RLG 778C: this gauge is mounted at the firing floor, so as the firing
floor attendant can view the drum level.
H.P dosing connection: To dose phosphate in to the steam drum to maintain the boiler
water quality.
Section B
Page 1
Continuous blow down (CBD): To drain the boiler water during operation to maintain the
water concentration. Also the water sample is taken from this blow down. It is connected to
the IBD tank through CBD tank.
Two air vent with isolation valves DM 032, 033 & DM 037, 038 that will be closed at 2
Kg/cm2 (g) during pressure rising and open at 2 kg/cm2 (g) during cooling.
Local Pressure gauge 703 B shows the drum pressure near steam drum, and gauge PG
703 A is mounted at the firing floor.
A pressure transmitter PT 708 is provided to view the drum pressure in the control room.
N2 filling connection with isolation valves DM 034.
Section B
Page 2
WATER DRUM
(Refer Drg no. P31-0TB 06565)
Water drum is a (960 I.D x 9950 long.) all welded cylindrical vessel made of SA 516 Gr. 70
material. The cylindrical portion of the vessel is made of 63 mm. thick plates and the two semi
ellipsoidal dish ends are 63 mm thick. Two elliptical manholes at either end of the drum provide
access to the drum. These manholes are closed tight at either end by 63 thick plates, bolted
against the manhole rim by two holding bars. A gasket 1.5 mm thick is fitted between the cover
plate and the end shield. The cover plate swing inside the drum for convenience during opening.
Water drum is fitted with intermittent blow down connection (IBD) with isolation valve IBD
001,002 & 003 (connected to IBD tank) through which the water can be removed during
emergency situations like high water level and high concentration situation occurs.
Total 18 no, 101.6DX 5.6 thk stubs are provided for downcomer supply pipes.5 no at the
either ends of the drum for sidewall and front wall. For rear wall, 8 no stubs are provided
lengthwise.
Rear wall is terminated in to the water drum by expanding tube ends. Baffle plates form a
separate closed section so those two rows of bank tubes will serve as risers solely for rear wall
tubes. Baffle plates are full welded at corners so as to avoid any mixing of water in mud drum &
saturated steam in rear wall tubes.
DOWN COMER TUBES
(Refer Drg no. P73-1TB 33454 & 27480)
Down comer tubes are of 101 OD x 5.6 thk, which supplies water to furnace wall headers from
water drum.
Seven down comer tubes (DC 1 TO DC 7) i.e. Seven pipes from water drum are connected to
front header.
Ten down comer tubes (DC 8 to 12 & DC 21 to 25) i.e. from waterdurum is connected to side
wall bottom header.
Eight down comer tubes /stand pipe (DC 13 to DC 20 ) from water drum are connected to rear
Water wall header.
FURNACE
Furnace is the part of the boiler where the chemical energy in the fuel is converted into thermal
energy by absorbing the heat produced through combustion of fuel. The furnace is designed for
efficient and complete combustion, with due consideration to the factors that effect, combustion
efficiency like fuel residence time inside the furnace, temperature and the turbulence required
for complete mixing of fuel and air.
Section B
Page 3
Section B
Page 4
RISER TUBES
(Refer Drg no. P71-2TB - 27019)
The purpose of these tubes is to carry the saturated steam from side wall panels to steam
drum. Sidewall panels are connected to steam drum through 18nos. 101.6 O.D x 5.6 thick riser
tubes (8 from either sidewall).
SATURATED STEAM SUPPLY TUBES
(Refer Drg no. P72-3TB - 16255)
The purpose of these tubes is to carry the saturated steam coming out from the steam drum to
the primary super heater inlet. They are 8 (101.6 OD x 5.6 Thick) in number provided from the
top of steam drum.
SUPERHEATER
(Refer Drg no. PA1-1TB 33477)
Super-heaters are provided to raise the steam temperature above the saturation temperature by
absorbing heat from the flue gas. By increasing the temperature of the steam, the useful energy
that can be recovered increases, thereby increasing efficiency of the cycle also. Superheated
steam also eliminates the formation of condensate in steam piping which is harmful to the
turbine blades and pipelines.
From the drum steam flows to primary super heater 1 inlet header (200 NB x SCH 120)
through 8 nos. 101.6 O.D x 5.6 thick supply tubes. From the primary super heater1inlet header
steam flows to primary super heater1outlet header through 50.8 OD x 4.06 thick coils. From
the primary super heater 2 inlet header steam flows to primary super heater2 outlet header
through 50.8 OD x 4.06 /5.0 thick coils.
Primary Super heater 2 outlet header is connected to Secondary Super heater inlet header
through attemperator. Secondary inlet and outlet headers are connected through 38.1 OD X
4.06/5.0/7.11 thick coils. Superheated steam is then taken out from Sec SH outlet header
through main steam piping.
Following connection is attached to primary S.H. inlet header:
25 N.B. sampling line with two valves Tag No. SAM-007 and SAM-008 ,which is used to
take saturated steam sample.
Temperature elemnt TE 708 for remote indication.
Section B
Page 5
Following are the connections attached to Inlet & Outlet pipes of spary type
Attemperator 1 & 2:
25 N.B. air vent with one valve Tag No. SH-009 which is used during hydro-test to vent the
air.
A 25 NB N2 filling connection before attemperator with isolation valves SH-008
Thermocouple (TE-725A ) at I/L TE 725B at O/L for attemperator 1 and TE 725C at
I/L and TE 725D at O/L of attemperator 2 is provided for remote temp. indication.
Attemperator 1 outlet is connected to attemperator 2 inlet through 273.1 OD pipe with SS
liner and attemperator 2 outlet is connected to secondary SH inlet header through 250 OD
X SCH 100pipe with SS liner inside.
88.9 OD connection for soot blower steam with isolation valves SB-001(Motorised).
Following connection is attached to secondary super heater inlet & outlet header:
TE 725 D for remote indication on secondary super heater I/L header.
For local indication of pressure pressure gauge PG 733Bon SSH I/L header.
PG 732 A & PG 732B (Firing Floor) for local indication on SSH O/L header.
Safet valve PSV-003is mounted on SSH O/L header.
CONVECTION BANK
(Refer Drg no. P61-1TB 30365 & P61-2TB 26195)
The name itself indicates that heat transfer in this area is by convection mode. This is a Bi-drum
boiler, the steam drum (Top drum) and the water drum (mud drum) is connected by a set of
tubes called convection bank tubes.
Convection bank tubes are constructed with 23 rows of 63.5 O.D X 4.06 thick tubes and 2 rows
of 76.2 OD x 4.06 THK. Both ends of the tubes are swaged to 50.8 OD and are terminated at
water / steam drum, and the ends are fixed to drums by expansion of the tubes.
2 nos. motorized rotary soot blowers SB 9 &11 on R.H. side & 2 nos. motorized rotary soot
blowers SB 10 & 12 on L.H. side are provided to clean the external deposits on convection bank
tubes.
Bank sides were covered with refractory tiles followed with insulation and outer MS casing. Also
the tubes are strengthened by buck stay arrangement at one elevations.
ECONOMISER
(Refer Drg no PL1-2TB-26280/01)
The function of an Economiser in a steam-generating unit is to absorb heat from flue gases &
add this as a sensible heat to the feed water, before the water enters to the steam drum.
Section B
Page 6
Provision of this additional heating surface, increases the efficiency of the steam-generating unit
and saving in fuel consumption is achieved. Economiser is located in between boiler bank outlet
and Air Pre-heater.
Economiser assembly is constructed with 51 rows of 38.1 O.D x 4.06 thick tubes, in Three
banks and two headers. Both the ends of the coil were terminated to the top and bottom
headers by welding.
Feed water flows from the bottom header to the top headers through these coils. Heated water
flows out from the top header to steam drum through the connecting pipe.
Economiser is provided with, 6 nos. motorised soot blowers SB13 to SB18 to clean the external
deposits.
Economiser top header is provided with the following attachments:
25 NB air vent with two valves (Tag No. EC-001 and EC-002) which will be kept open
during initial filling to remove the air trapped between the coil. Closed after free flow of
water from the vent.
25 NB drain connection with three valves (Tag no. EC-005, 006, & 007) and terminated to
furnace drain header. Which will be kept closed during normal operation and to be operated
to drain the assembly during shut down.
25 NB drain connection with three valves (Tag no. EC-008, 009 & 010) and terminated to
furnace drain header, which will be kept closed during normal operation and to be operated
to drain the assembly during shut down.
Feed water piping from Economiser to steam drum is provided with the following
attachments:
Pressure gauge (Tag no. PG-730) with twin isolation valves (Tag no. EC-003 and EC004).
Local Temperature gauge Tag no. TG-002.
Thermocouple TE 717C for feed water temperature outlet of economiser at control room
panel.
Section B
Page 7
Feed water tank is of 150 M3 At normal water storage capacity, made of steel plates and
supported on a steel structure. Following are the attachments welded to the storage tank:
Feed water tank is provided with baffle type cascade condenser to avoid splashing of
condensate from sugar plant.
Direct water level indicators (LG-, 008 & 009,010), which shows the water level in the
storage tank.
Low-level switch (LAL 720) with isolation valve (FWT 013 & FWT 014).
High-level switch (LAH 720) with isolation valve (FWT 015 & FWT 016).
212.70 OD X 6.35 THK Deaerator Over flow connection.
273.1 OD X 6.35 THK tank outlet piping with isolation valve (FWT-019)
168.3 OD X 7.11 THK inlet connection from DM makeup water.
168.3 OD X 7.11 THK inlet connection from exhaust condensate.
Feed water transfer pumps minimum flow water piping 60.3 OD X 3.91 THK is connected
to the storage tank with isolation valves & NRV (FWT-30,FWT-31 & FWT-32,FWT-33).
114.3 OD X 6.02 THK tank drain piping to open drain.
88.9 OD X 5.49 THK tank drain to trench with isolation valve (FWT-18).
Section B
Page 8
Transfer pumps outlet is connected to the 273.1 OD X 6.35 THK common discharge
header, through Non Return Valves (FWT 28 & FWT 29) and with manual isolation valves
(FWT 34 & FWT 35). Pump is provided with a minimum flow line, connected backs to the
feed water storage tank with NRV and isolation valves (FWT 30 , FWT 31 & FWT 32 ,FWT
33). Pressure gauges (PG 721 A & PG 721 B) are provided at both the pump outlets
before the NRV.
From the common discharge header, water flows to the deaerator through the deaerator level
control station. (Ref. Deaerator level control for details of control station)
From the DM water to feed water storage tank piping a 88.9 OD x 5.49 THK tapping is taken
for filling the boiler during start-up. From the 88.9 OD x 5.49 THK piping 1 x 48.3 OD X 3.68
THK tapping is taken for HP & LP dosing system.
DEAERATOR
The following is the general description, its principle of operation, accessories, mountings,
controls etc. of the Deaerator.
PURPOSE OF DEAERATION
Deaeration removes corrosive gases such as dissolved oxygen and free carbon dioxide from the
boiler feed water by heating feed water to the operating temperature by steam, and vigorously
scrubbing the water with this steam, so that the last traces of non-condensable gases are
removed from the feed water. This ensures protection of the feed water lines, economizer coils,
steam lines, boiler tubes and other pressure parts of the boiler against corrosion and pitting,
saves costly boiler re-tubing and expensive plant shutdowns. Further as the temperature of feed
water is raised to deaerator design temperature and then fed to boiler, the overall boiler
efficiency also boosts up.
CHEMICAL DOSING IN THE DEAERATOR
To ensure the total removal of the traces of dissolved oxygen, scavenging chemicals such as
sodium sulfite (catalyzed or un-catalyzed) or Hydrazine is carried out in the storage section of
the deaerator. The dosing of the particular chemicals should dose in predetermined quantity and
concentration.
CONTROLS, MOUNTINGS AND ACCESSORIES
DEAERATOR LEVEL CONTROL
The level of the water in the storage tank is maintained at normal operating limit, The storage
tank receives water from Feed water storage tank.
DEAERATOR PRESSURE CONTROL
Steam from following sources is available to the deaerator.
Section B
Page 9
RELIEF VALVE
A relief valve (Tag No. PSV-007) is mounted on the deaerator vapor tank to relieve the steam,
when there is excessive pressure build-up inside the vessel.
VACUUM BREAKER
The vacuum breaker assembly, a 88.9 ODX5.49 THK line with non return valve (Tag No. DA-18)
is mounted on the vapour tank, to prevent deaerator from going to vacuum. Incase, when the
deaerator happens to go under vacuum, this NRV will open and atmospheric air will be sucked
in, thus the vacuum will be broken. A vacuum condition inside the deaerator would mean that
the deaerator is not being supplied with enough steam with respect to the water flow or sudden
stop of steam supply to the deaearaor.
AIR VENT
A 60.3 OD X 5.54 THK air vent with isolation valve (DA-56) is provided on the vapour tank,
through which the evaporated gases from the Deaerator vented out during initial charging until
the operating / set pressure is reached.
Section B
Page 10
LEVEL TRANSMITTER
A level transmitters (LT 701) is provided with isolation valves. These transmitter are used to
maintain the deaertor water level reliably
PRESSURE INDICATOR
A Local Pressure gauge (Tag No. PG-724) with isolation valve, to read the steam pressure inside
vessel is provided. A pressure transmitters (PT 707 A) are provided with isolation valves to
control the Pressure Control Valve according to the pressure set point given.
OUTLET CONNECTIONS
114.3 OD drain piping with a isolation valve Tag No. DA-036 that is connected to overflow
line from deaerator to feed wtaer storage tank.
273.1 OD X 6.35 THK Feed pump inlet header piping with an isolation valve Tag No. DA-037.
A temperature elemnt TE 702 is mounted on the line to measure the deaerator outlet water
temperature.
INLET CONNECTIONS
25 NB chemical dosing piping with isolation valves Tag No. DA 050 and NRV Tag No. DA 049
3 x 60.3 OD piping from feed water pump balancing leak off line, with the isolation and nonreturn vales Tag No. BFW-02,05,08 and BFW-03,06,09 respectively.
3 x 88.9 OD minimum flow line from the feed water pumps with the isolation and non-return
vales Tag No. and FW-016, 018, 020 and BFW- 017,019 ,021
250 NB steam piping with pegging steam.
Condensate from CEP discharge 150 NB.
100 NB flash steam from CBD tank.
Section B
Page 11
2. FEED PUMP:
Three motor driven pumps of 60% capacity are provided. Two are working while other one is
standby. These KSB make pumps are a multistage pump .
3. COOLING WATER SYSTEM:
To protect the pump glands from overheating cooling water system is provided. Cooling chamber
is provided itself on the pump and Cooling water inlet, outlet piping will be connected through
isolation valves. Cooling water exit is terminated to the nearest cooling water outlet piping.
4. MINIMUM FLOW AND BALANCING LEAK OFF LINE:
During start of the pump discharge valve is kept closed to minimise the starting current of the
feed pump drive. If certain amount of flow through the pump is not allowed in this period results
in heat generation and hence pump ceasing. Therefore minimum flow line is provided through
Auto re-circulation valve. Initially discharge port of the valve will be closed by a spring and
minimum flow line port will be open. After attaining the full speed, pressure generated by the
pump is sufficient to open the discharge port. Minimum flow line port gets closed as the stems of
both the valves are interconnected. Minimum flow line is routed back to the deaerator with
isolation valve and a NRV. Balancing line is provided to balance the thrust towards suction side
of the pump. As there is a large difference between suction and discharge pressures, pump shaft
tends to move towards suction side. Two discs; balancing and counterbalancing are provided in
the mechanism at the discharge end of the pump. There is a small gap between rotating balancing disc and stationary - counterbalancing disc. High-pressure water tends to pass
through this gap. Pressure drop in the gap results in opposite thrust on the disc. Low-pressure
water that comes out of the gap is taken out of the pump through balancing leak off line.
Balancing line is also routed back to the deaerator. Balancing leak off line is provided with a
pressure indicator (Tag no. PG- 726 A, 726 B, 726 C. )
5. DISCHARGE PIPING:
All four pumps are separately connected to the common discharge header with auto recirculation cum NRV valves and isolation valves. Pump discharge piping is provided with a
pressure gauge (Tag no. PG-741 A, 741 B, 741 C). Also to start other pump in auto incase
the pump discharge pressure goes low pressure has been provided. From the common discharge
header two tappings have been taken, one goes to boiler and other goes to PRDS. In the line
which is going to boiler pressure gauge(Tag no. PG 722 E) for local indication and presssure
trnasmitter (Tag no. PT 722 ) for remote indication has been provided.
Section B
Page 12
Start up vent:
Start up vent, with motorised control valve (SH-021) and manual isolation valve (SH-020)
is used to vent the steam to atmosphere during boiler start up, as the l main steam stop
valve & by-pass valve (Tag no. SH-027 & SH-028) remains closed till the boiler reaches
the operating pressure. This also protects the SH coils from over heating during start up. To
reduce the noise level from the steam venting to atmosphere, a silencer is provided to
the start up vent line.
250 NB main steam stop valve Tag No. SH-027, along with a bypass/equalising valve Tag
No. SH 028. Both the valves are motorised valves.
Section B
Page 13
Thermocouple (Tag No. TE-727) is provided for main steam temperature control loop and
for local indicaton temperature gauge (Tag. No. 727) is provided.
Drain connection with twin valves SH-034 & SH-035 before the main steam stop valve.
Drain is terminated to S.H common drain header.
Drain connection with twin valve SH-036 & SH-037 manual operated after the main steam
stop valve. NRV (Tag. No. SH-038) is provided in the line for avoiding the steam charging
before opening the MSSV.Drain is terminated to S.H common drain header.
250 NB Non Return Valve Tag No .SH- 029 is located after the main steam stop valve.
Steam flow-measuring device, i.e. flow nozzle Tag No. FE-704 along with flow transmitter
Tag no. FT-704 with impulse piping and isolation valves (Tag No. SH-30 to 33)
Section B
Page 14
SOURCE
Continuous Blow
down from Drum
Intermittent Blow
down
NRV CBD-005
NRV IBD-003
TEMP. OF
DRAIN 0C
FREQUENCY OF USAGE
316
Continuous (depending on
quality of Boiler water)
316
~ 60
Saturated steam
sample cooler.
~ 70
~ 70
~280
SB-031,032,034,035,037
Furnace drain
header
Feed water Sample
SB 031,033,036
NRV SH-038
EC-005 TO 010,
FD-001 TO 018,IBD 004
Varying
from
70 to 280
~70 - 150
~ 70
NRV IBD-005
SAM-003 & 004
The drains indicated in the above Table are connected to the existing intermittent blow down
(IBD) tank except CBD water and various samples. CBD tank is connected to IBD tank while
samples to the nearest drain trench.
Following connections are connected to the IBD tank.
A gauge glass LG-004 with isolation valves IBD-014 & 015 has been fitted on the tank to
verify water level in the tank.
Tank is provided with a 100 NB drain pipe with a valve (Tag no. IBD-018) for flushing
purpose.
IBD tank outlet piping is connected to CBD tank with NRV ( Tag no.-IBD 019)
It can be seen from the P&I drg. that various connections with separate NRV connected to
IBD tank through common header are, the furnace drain header outlet (Tag no IBD-005),
Section B
Page 15
the super heater drain header out let (Tag no IBD-008), CBD line directly (Tag no CBD010), IBD piping (Tag no IBD-003).
Section B
Page 16
Ambient air from FD & SA fans passes through respective compartments of pass-I & II of APH
to absorbs sensible heat from flue gases. Hot primary air is then connected to plenum hopper
below Travagrate from rear side bottom & hot secondary air to SA duct to furnace at various
levels. To avoid cold end corrosion 6 rows of corten steel are provided at air inlet of pass-I.
Air pre heater is a non-mixing type heat exchanger in which flue gases pass through the tubes
and air out side the tubes. Flues enter in air heater from top of pass-II, turn at bottom, enter in
to pass-I & leave the air heater from top of pass-I. APH is provided with common hopper for
Following are the attachments of flue gas inlet duct to APH:
Section B
Page 17
To minimise the forces due to possible movement of the discharge ducts on the fan, as well as
to isolate fan vibrations being passed on to the duct, the fans are connected to the discharge
duct through bellow type expansion joints.
The fan outlet duct is connected to APH & from APH outlet, SA duct five nos. branch ductings
are tapped at boiler front side and four at the rear. SA duct is having bypass to APH to control
flue gas temperature at furnace outlet & SH steam. Detail of the branch ducts are as explained
below:
Boiler front side:
Upper duct nozzles are located at +11851 mm elevation, having 7 nozzles of 60.3 O.D
pipe inclined downward. Ducting is provided with common damper to adjust the air pressure.
Upper Middle duct nozzles are located at +10855 mm elevation, with 7 nozzles of 60.3
O.D pipe inclined downward. Ducting is provided with common damper to adjust the air
pressure
Pneumatic spreader (At elevation +9100): Secondary air duct is connected to all the
three pneumatic spreaders through 5 isolation dampers and 5 rotating dampers driven by
a cyclo geared motor. Common ducting is provided before dampers.
Travagrate top panel duct nozzles are provided .Main purpose of these nozzles is to cool
the front plate.
Boiler Rear side:
Upper duct nozzles are located at +11851 mm elevation, having 7 nozzles of 60.3 O.D
pipe positioned inclined downward. Ducting is provided with common damper to adjust the
air pressure.
Middle Upper duct nozzles are located at +10855 mm elevation, having 7 nozzles of
60.3 O.D pipe positioned horizontally. Ducting is provided with common damper to adjust the
air pressure.
Middle lower duct nozzles are located at +9905 mm elevation, having 12nozzles of 60.3
O.D pipe positioned horizontally. Ducting is provided with common damper to adjust the air
pressure.
Lower duct nozzles are located at +8529 mm elevation, having 18 nozzles of 60.3 O.D
pipe positioned horizontally. Ducting is provided with common damper to adjust the air
pressure.
FLUE GAS SYSTEM
Flue gas from the furnace passes through S.H coils, Convection bank tubes, Economiser coils,
Air Pre-heater tubes and ESP to I.D Fans. From the I.D fan gas is blown through chimney to
atmosphere.
System description:
The combustion products of gases exits from the furnace and passed to S.H zone. Furnace is
provided with the following attachments in the flue path.
Furnace pressure transmitter, Tag no PT-714 with isolation valve Tag no GAS-001 to
measure the furnace pressure.
Section B
Page 18
Pressure switches, Tag no. PSHH-702 & PSLL-703 with isolation valves Tag no. GAS-002
& 004 to indicate the furnace pressure, high and low at control room.
One no temperature elemnt Tag no. TE- 732 is provided.
From the furnace, flue gases pass through the super heater zone. First it enters to secondary
S.H and then to primary S.H coil assembly. From the super heater zone the gases further passes
through the convection bank tubes and enters to economiser assembly.
A Pressure transmitter PT-750 with isolation valve Tag no. GAS-005 for remote indication in
panel, thermocouple Tag no TE-733 is provided to measure the gas pressure and temperature
at economiser inlet.
From the economiser the flues pass to air pre heater assembly. Pressure transmitter PT-715
with isolation valve Tag no. GAS-007 for remote indication in panel, Thermocouple/ Draft gauge
for remote indication in panel, Local temperature gauge TG-014 and probe connection to
measure the O2 % by O2 Analyzer-Tag no AT-722 in the gas are provided.
Further the gas from APH outlet pass through the ESP and to I.D fans. From the fans it is
discharged to atmosphere through the chimney.
A Pressure transmitter PT-716 with isolation valve Tag no. GAS-008 for remote indication in
panel, thermocouple Tag no TE-735 & draft gauge are provided to measure the gas pressure
and temperature at ESP inlet.
A thermocouple Tag no TE-736 is provided to measure the gas temperature and pressure at
ESP outlet.
Boiler is provided with 2 x 60 %. I.D fans A & B driven by electric motor. The fan is driven by
variable frequency drive. Fan inlet dampers are operated on input signals of furnace pressure
transmitter (Tag no. PIC-714) through a pneumatic power cylinder (Tag no. PV-714A &
714B) to maintain the required furnace draft. Also two manual field operated dampers (Tag no
GD-002 & 004) are provided at each fan outlet duct. To minimise the force due to possible
movement of the discharge duct on the fan, as well as to isolate fan vibrations being passed on
to the duct, the fans are connected to the duct through bellows type expansion joints.
I.D. fan outlet ducts are connected separately to chimney.
Section B
Page 19
Section B
Page 20
Section B
Page 21
5. GRATE ACCESS is provided by a grate removal door. Design is such that any grate section
can be replaced without taking
the stoker out of service .simply remove a single bolt,
nut
and washer and slide the grate off the grate bar (carrier bar)
6. GRATE SUPPORT within the furnace is provided by a series of skids and skid rails, each
constructed of chill hardened cast iron for maximum life.
7. FRONT AND REAR SHAFT carry the grate chains on hardened sprockets. Bearings and
sprockets are strategically located along the shafts for maximum load - bearing efficiency.
8. A FORCED LUBRICATION SYSTEM for the drive and idle shafts is mounted outside on the
stoker frame for each access.
9. GRATE ALARM SYSTEM, built into the rear end of the grate assembly, is designed so that
any foreign material or obstruction in the grates will come in contact with the pull cord wire,
which trips drive motor and immediately stop the grate. And it is indicated in the
annunciation panel in the control room to alert the operator.
10. THE GRATE CHAIN are forged steel thereby eliminating breakage and grate shutdown.
11. FRONT AIR SEAL reduce air by-passing to the ash discharge end. These front seals are
constructed for long service and to maintain continuous close sealing contact.
12. UNDER-GRATE ACCESS DOORS located on each side of the stoker frame provide
inspection of and access to grate catenary.
13. HEAVY DUTY GEARED COUPLING connecting hydraulic drive and main drive shaft.
HYDRAULIC DRIVE
The Hydraulic Drive is a powerful and effective self-contained unit in a single heavy requiring no
external piping or equipment. It is constructed of heavy-duty casting and high strength steel
parts. To control the speed of Travagrate hydraulic drive is equipped with flow control valve,
flow directional valve, and pressure relief valve.
The capacity of the flow control valve and hydraulic system as such that the rotation of drive
shaft can be adjusted in terms of grate speed up to - 45' per hour.
Pressure relief valve is factory tested and set at 28 Kg/Cm2 (g) pressure and should never be
tempered with to increase the pressure. Heavy-duty geared coupling connects the hydraulic
driveshaft and drive shaft of the Travagrate.
OIL COOLERS
With pneumatic spreader and agro waste fuel, the combustion is at the combination of bed and
suspension. Since the combustion is in split mode there will be very little ash generation on the
grate bed, hence travagrate needs to be operated at a very low speed.
Section B
Page 22
While operating the hydraulic drive at slow speed, lot of oil will be directed to sump through the
pressure relief valve, which increases the temperature of the oil due to churning. Oil cooler is
provided to maintain the oil temperature to the safe limit.
From the pressure relief valve, oil is pass to a tubular heat exchanger, through a three-way valve
and is returned to the drive sump. If the temperature is within the limit, oil can be returned to
sump directly (bypassing the cooler) by changing the oil flow direction through the three-way
valve.
Section B
Page 23
Section B
Page 24
one NRV, a pressure gauge and isolation valve is provided. One relief valve to maintain the
pressure in the system is given. In HP dosing, relief valve set pressure is to be adjusted by
closing the main isolation valve in the discharge line.
Discharge of the relief valve is connected to the tank. Pressure gauge is provided with a Snubber
and a Diaphragm, snubber helps to dampen the fluctuating pressure and diaphragm avoids direct
contact of chemicals and the gauge internals. One drain after the pressure gauge is used to
release pressure while adjusting the relief valve setting, also it can be used to check the flow.
According to the system, discharge line of the H.P dosing is connected to Steam Drum. Supports
at required elevations are given. All the piping in the system is to withstand corrosive chemical
solution.
FLUSHING LINE:
In the system, the chemical mixing water line is connected to the pump suction line also, called
as flushing line. This is provided to clear the line whenever there is no need for dosing.
Whenever the dosing is stopped, always there is a chemically concentrate water is stagnant
inside the piping. If this liquid is not evacuated, it may tend to solidify and settle inside the
piping, which will create a problem for free flow of chemical whenever the dosing is re-started.
Whenever the dosing is stopped, first close the mixing tank outlet valve and open the flushing
line valve, operate the pump for 2 hrs. In this process, the chemically concentrated water is
replaced with the clear water; thus choking of piping can be avoided.
Section B
Page 25
OPERATION .................................................................................................................. 3
OPERATOR'S RESPONSIBILITY .................................................................................... 3
PERSONNEL SAFETY ..................................................................................................... 4
START UP PROCEDURE ................................................................................................. 5
INPUTS ...................................................................................................................................... 5
WALKDOWN CHECKS ................................................................................................................ 5
SYSTEM LINE UP ....................................................................................................................... 5
WATER FILLING............................................................................................................ 8
LIGHT-UP...................................................................................................................... 9
BAGASSE FIRING .................................................................................................................... 10
PRESSURE RISING...................................................................................................... 13
PRESSURE RISING CURVE .......................................................................................... 15
SUPER HEATER COIL PROTECTION DURING PRESSURE RISING ............................... 16
OPERATION ................................................................................................................ 16
FUELS DISTRIBUTION............................................................................................................. 16
GRATE SPEED .......................................................................................................................... 16
COMBUSTION AIR ................................................................................................................... 17
SECONDARY AIR PRESSURE SETTING .................................................................................... 17
TRAVAGRATE .............................................................................................................. 20
OPERATION ............................................................................................................................. 20
SPEED CONTROL ..................................................................................................................... 20
ESP.............................................................................................................................. 21
STEAM TEMPERATURE CONTROL................................................................................ 21
CHEMICAL DOSING SYSTEM ....................................................................................... 21
BLOW-DOWN SYSTEM ................................................................................................ 22
INTERMITTENT BLOW-DOWN (IBD)....................................................................................... 22
CONTINUOS BLOW-DOWN (CBD) ........................................................................................... 22
Section C
Page i
DEAERATOR ................................................................................................................ 24
START UP................................................................................................................................. 24
OPERATION ............................................................................................................................. 24
SHUTTING DOWN.................................................................................................................... 25
Section C
Page ii
OPERATION
This section describes the startup and shutdown procedures of the boiler along with the
operation, troubleshooting and safety points.
Procedures explained in this section apply for start up of a boiler already commissioned.
Commissioning a new boiler call for several additional requirements, which are not explained
here.
It is assumed that the boiler operators are fully familiar with the design and construction
feature described in section A.
It is assumed that operators are trained in operation of similar Travagrate boilers and have
been licensed to operate boilers by the concerned authorities.
The owner is encouraged to evolve standard operating procedures (SOP) based on the
framework and recommendations that are explained in the subsections below. The SOPs have
to be well understood by the utility managers and operators for safe and reliable operation.
OPERATOR'S RESPONSIBILITY
Boiler operator is responsible not only for the successful operation of the boiler and its related
equipment, but also for the safety of all personnel involved. The operator must be aware of any
operating conditions affecting the boiler or related equipment. Should be able to recognize
hazardous conditions and to act properly to avoid injury.
Even though operating procedures are normally given for each piece of equipment, a complete
knowledge of all components their design, purpose, limitations and relationship with other
components is must for the operators.
Section C
Page 3
PERSONNEL SAFETY
Operating instructions usually deal primarily with the protection of equipment. Rules and devices
for personnel protection are also essential. The items listed here are based on actual operating
experience and point out some personnel safety considerations.
1. When viewing flames or furnace conditions always wear tinted goggles or a tinted shield to
protect the eyes from harmful light intensity and flying ash or slag particles.
2. Do not stand in front of open ports or doors, especially when they are being opened. Furnace
pulsations caused by firing conditions, soot blower operation, or tube failure can blow hot
furnace gases out of open doors, even on suction-fired units. Aspirating air is used on
inspection doors and ports of pressure-fired units to prevent the escape of hot furnace gases.
The aspirating jets can become blocked, or the aspirating air supply can fail. In some cases,
the entire observation port or door can be covered with slag, causing the aspirating air to
blast slag and ash out into the boiler room.
3. Do not use open ended pipes for rodding observation ports or slag on furnace walls. Hot
gases can be discharged through the open ended pipe directly onto its handler. The pipe can
also become excessively hot.
4. When handling any type of rod or probe in the furnace especially in coal-fired furnaces be
prepared for falling slag striking the rod or probe. The fulcrum action can inflict severe
injuries.
5. Be prepared for slag leaks. Iron oxides in coal can be reduced to molten iron or iron sulfides
in a reducing atmosphere in the furnace resulting from combustion with insufficient air. This
molten iron can wash away refractory, seals and tube and leak out onto equipment or
personnel.
6. Never enter a vessel, especially a boiler drum, until all stem and water valves, including drain
and blow down valves, have been closed and locked or tagged. It is possible for steam and
hot water to back up through drain and blow down piping, especially when more than one
boiler or vessel is connected to the same drain or blow down tank.
7. Be prepared for hot water in drums and headers when removing manhole plates and manhole
covers.
8. Do not enter a confined space until it has been cooled, purged of combustible and dangerous
gases and properly ventilated with precautions taken to keep the entrance open. Station a
worker at the entrance, notify a responsible person, or run an extension cord through the
entrance.
9. Be prepared for falling slag and dust when entering the boiler setting or ash pit.
10. Use low voltage extension cords, or cords with ground fault interrupters. Bulbs on extension
cords and flashlights should be explosion proof.
11. Never step into flyash. It can be cold on the surface yet remain hot and smoldering
underneath for weeks.
12. Never use toxic or volatile fluids in confined spaces.
13. Never open or enter rotating equipment until it has come to a complete stop and its circuit
breaker is locked open. Some types of rotating equipment can be set into motion with very
little force. This type should be locked with a brake or other suitable device to prevent
rotation.
Section C
Page 4
14. Always secure the drive mechanism of dampers, gates and doors before passing through
them.
START UP PROCEDURE
Prior to start the boiler, following input requirements to be satisfied.
INPUTS
Inputs required for startup are as follows:
Fuel
Feed water.
Uninterrupted electric power supply for auxiliary equipments.
Lighting for equipments, walk ways and field instruments.
Instrument air.
Plant air.
Cooling water.
Lubricant for the rotary equipments.
Chemical for feed and boiler water treatment.
Readiness of drainage and ash disposal system.
Fire fighting system.
WALKDOWN CHECKS
Verify that the Nitrogen capping is removed and the unit is purged properly so as it is safe for
man entry for inspection.
Steam and water drums are clean and manholes are closed properly.
Verify that the furnace S.H and convection bank are clear
Verify that all access and inspection doors of furnace are tightly closed.
Verify that the air duct to furnace and flue up to stack is clear and the manhole doors closed
properly.
Ensure the walkways are clear with out any obstruction.
SYSTEM LINE UP
A. Process valve position during start-up
Following valves to be kept in open position:
Air vent on steam drum.
Start-up vent at S.H. steam outlet.
Air vent on economiser outlet header
Instrument air connections to all the instruments.
Isolation valve for drum level gauge
Steam and water system pressure gauges/transmitters
Section C
Page 5
Section C
Page 6
Control panel/DCS
Control valves
Motorized valves
All the field and panel instruments.
Damper actuators
Sensors
F. ESP
Switch on the ash handling system one hour prior to light up.
Open the isolation gate above the RAV and switch on the rotary airlock valves.
Incase of pneumatic evacuation, open the isolation gate above the vessel.
Switch on the rapping mechanism one-hour before the light up.
Switch on the hopper and insulator heater four hours prior to light up.
Check and ensure all the safety interlocks are tested prior to startup.
G.
Others
Verify all the soot blowers are in rest position.
Ensure the test gags of safety valves are removed.
Verify all the safety interlocks are working as per the desired logic/values.
Ensure the availability of cooling water/seal air to the system.
Section C
Page 7
H. Cold start-up:
During cold startup at most care to be taken to ensure trouble free start-up and smooth operation
of the boiler plant.
After completing the above pre start checks, ensure all the manholes in furnace, flues and
ducting are closed and locked properly, except the wood-firing door.
Fill-up the fuel-bunker/silo with specified fuel.
Open the cooling water to boiler feed water pump, sample coolers and hydraulic drive oil
cooler.
Fill up boiler with feed water, 50 mm below normal water level.
WATER FILLING
Caution: Feed water should be confirm to the specification.
Prior to fill the water, keep the following valves in open position:
Air vent at economiser outlet header
Air vent on steam drum
Start up vent
Economiser drain
Keep the following valves in closed position:
Furnace drain header outlet
Furnace bottom headers drain
Water drum drain/blowdown
CBD piping
H.P Dosing piping
Steam sampling line
Main steam isolation and by-pass valve
Attemperator spray water isolation
Feed water control valve isolation
Steam to soot blower
Start the feed water transfer pump and admit the water through the filling line.
OR
Start the feed water pump as per the pump start up procedure, open the feed water flow control
station by-pass valve gradually and feed the water to the boiler through the regular system. Feed
water flow to be controlled in such a way that the electrical load on the pump motor is with in the
operating limit also the pump outlet pressure is maintained. In this case keep the economiser
drain in closed position wile line up the valves for water filling.
Whenever the water flow from the economiser vent is free from air, close the vent valve.
Continue water filling till the level in steam drum reaches 50mm below the normal operating limit
and stop the pump.
Section C
Page 8
LIGHT-UP
Stack around 200Kgs of firewood on the travagrate, light up the wood by kerosene soaked torch
from out side the furnace through the wood firing door. (Firewood should be of small size- 2" x
500 mm long, without nail or packing metal strips, which may damage grate components).
Maintain low and moderate fire initially and do not operate the fans at this stage, which may
increase the furnace temperature rapidly.
Whenever the fire is well spread over the grate, start the I.D fan as per the Fan start up
procedure. Continue the firing with the I.D fan in operation, at one stage the temperature will be
stagnant, then start the F.D fan and increase the rate of fuel feeding.
Maintain furnace pressure between (-) 2 to (-) 5 mmwc by adjusting the fan speed or fan
suction damper opening.
Close the drum vent valve whenever the pressure reaches to 2kg/cm2 (g). Do not close the
start up vent.
Whenever the drum pressure reaches 5kg/cm2 (g), stop the firing and reduce the boiler
pressure to 2kg/cm2 (g), quickly operate the I.B.D. and furnace bottom header drain valves,
individually for 1min. In this operation, the sediments from the pressure part internals if any, may
be removed. It also helps to reconfirm the drain pipe/valves are clear with out any
obstruction/blockages. Maintain drum water level while doing the above operation.
After completion of hot draining operation re start the firing and increase the pressure.
Open the continuous blow down valve (CBD) around 25% at this stage.
At times, it may be require poking the fire during start up. Care should be taken while poking by
ensuring sufficient negative draft inside the furnace.
Section C
Page 9
BAGASSE FIRING
Whenever the boiler is ready for bagasse firing, start the S.A fan as per the fan startup procedure
and maintain 200 to 300mmwc pressure at the pneumatic spreader air ducting. Then start the
air-modulating damper.
Keep the pneumatic spreader trajectory plate in horizontal position.
Bagasse should be loose with moisture <50 %, and free from foreign materials like steel, stone,
bricks, binding wire and wood etc. Presence of foreign material may jam the fuel feeders and
damage the Travagrate grate and fuel feeder components. Start the bagasse carrier and fill up
the silo.
Prior to start the bagasse feeder, ensure the furnace temperature is adequate for the combustion
of bagasse, otherwise there will be un-burnt in the flue gas, which may create problem of choking
the cinder re-firing system, APH tubes and ESP hoppers. Hence it is recommended to start the
feeders whenever the furnace temperature is achieved >500 C.
Whenever the required furnace temperature is achieved, start the screw feeders and run at
minimum speed then start the twin drum feeder one by one and run at minimum speed, however
it may require to operate the feeders intermittently depends on furnace conditions. Watch the
furnace for fuel throw/spreading pattern and combustion. If the fuel is falling close to the front
plate, increase the SA pressure at the spreader duct. Initially there will be heaps in the furnace,
during such conditions, stop the feeder of the section where the fuel pile up on the travagrate
and wait for the heaps to burn. Pocking may also require in such condition to disturb the heap for
quick burning. Feeder can be started once the heaps are cleared.
While viewing the furnace utmost care to be taken, as in the event of fuel feeding
interruption there will be a possibility of furnace puffing. View the furnace condition
through the peep hole in the access door at the travagrate front panel, it also advised
to use safety goggle while viewing to avoid accident.
During start-up, there will be mouth feeding and un-burnt in the bottom ash, due to low furnace
temperature, which will be gradually reduced when the furnace temperature/load is increased.
Furnace pressure is to be maintained between (-) 2 to (-) 5 mmwc, if the furnace pressure is
too negative fine bagasse particles will either fire close to S.H. zone or fly as unburned. Firing at
free board is to be avoided for the protection of S.H. coils from over heating.
Section C
Page 10
Section C
Page 11
While starting coal firing care should be taken that, initially the green coal bed thickness should
not be increased more than 50 mm at any location. Also the fire should start close to the rear
wall (50 to 75mm), if the fire moves away from the rear wall it will cause fire slippage and we
have to do the start up almost fresh. Operate the Travagrate intermittently at lower speed to
maintain the above. It is also required charging of wood chips, kerosene soaked cotton waste and
jerking of bed with poking rod, to assist for establishing the coal fire through out the grate.
Increase the coal feed rate progressively along with the under-great and over fire air.
Once the fire is well spread and across the grate area, run the coal feeders and Travagrate
continuously.
Maintain furnace pressure between -2 to -5 mmWC through the furnace pressure controller
Start-up with coal:
In this method,
Start the ID fan, Prior to start the fan, and keep the suction damper 100% close, through the
furnace pressure controller and switch on the fan
Then start the FD fan by keeping the fan suction damper close fully through the damper
controller and Keep the FD fan suction damper in closed position.
Operate the I.D fan suction damper to maintain the furnace pressure to 3 to -5 mmWC through
the controller.
Switch on the coal spreaders and drag chain feeders (DCF), operate the DCF at the lowest speed
through the speed controller and spray a thin layer (40-mm) of coal over the grate. Stop the DCF
but keep the spreaders in running.
Cover the coal, sprayed over the grate surface with wood chips and cotton waste and spray
kerosene over the coal and wood chips. Light up the fuel bed from the wood-firing door with the
kerosene soaked torch.
As the fire begins to build up start the DCF and feed light shower of coal to the furnace
intermittently. Do not feed the fuel continuously at this stage also do not operate Travagrate.
When the fires intensity has increased sufficiently and a layer of ash begins to form on the grate
surface, open the F.D fan suction damper and supply required amount of air to the plenum. Also
start the hydraulic drive and operate at the lowest speed through the oil flow controller mounted
on the hydraulic drive.
At this time the secondary air fan to be started can be started by keeping the suction damper
fully closed through the fan suction damper operating controller and maintain the fan discharge
pressure at pressure (200 mmWC) by adjusting the fan suction damper.
Section C
Page 12
While starting coal firing care should be taken that, initially the green coal bed thickness should
not be increased more than 50 mm at any location. Also the fire should start close to the rear
wall (50 to 75mm), if the fire moves away from the rear wall it will cause fire slippage and we
have to do the start up almost fresh. Operate the grate intermittently at lower speed to maintain
the above. It is also required charging of wood chips, kerosene soaked cotton waste and jerking
of bed with poking rod, to assist for establishing the coal fire through out the grate.
Increase the coal feed rate progressively along with the under-great and over fire air.
Once the fire is well spread and across the grate area, run the coal feeders and Travagrate
continuously. Also close the wood-charging door once the continuous coal feeding is initiated.
Maintain furnace pressure between - 2 to - 5 mmWC through the furnace pressure controller and
switch over the controller into auto mode immediately after the continuous coal firing is
established.
PRESSURE RISING
Close the drum vent valve when the pressure reaches to 2-kg/cm2 (g). Keep the start up vent
and SSH drain valves in open position.
As the pressure increases, carefully watch the pressure part for free expansion/movements.
Increase the boiler pressure as per the cold start up curve, rate of firing is to be varied as per the
requirement, at times it may require to stop the feeders, but ensure that the feeding is not
discontinued for a long time so as to maintain the furnace temperature.
During pressure raising, keep the drum water level controller in manual or single element control
mode, however furnace pressure control can be switched over to auto mode.
Whenever the boiler pressure reaches close to the operating range make preparation for charging
the main steam piping viz. opening the drain valves in the steam line. Open the by-pass valve of
the main steam stop valve (MSSV) to warm up the steam line. Whenever the steam line is warm
and condensate (if any) is removed, open the main steam stop valve (MSSV). Close the MSSV bypass valve after the stop valve is opened fully.
On confirming steady steam flow, take the drum level controller in to automatic control mode. It
is advisable to keep a watch on the performance of the controller whenever it is put in to
automatic control mode at least for one hour. If the steam flow varies more than 20% better to
keep it in manual mode till steady steam flow is ensured.
Start up vent to be closed once the steam flow from the boiler is above 30% and the demand is
steady with out any disturbance.
Section C
Page 13
As the steam flow demand increases, required quantity of the fuel and airflow to be increased to
maintain the boiler outlet steam pressure. During initial firing and load up to 60%MCR, both the
fuel and airflow to be controlled manually through the respective controller.
Whenever the steam flow from the boiler is increased more than 60% of MCR switch over the
fuel flow controller in to auto mode along with the main steam pressure controller. Initially the
airflow to be controlled manually for a period of two hrs, after taking the steam pressure
controller into auto mode. On confirmation of satisfactory working of controller switch over the air
flow controller into automatic control mode along with the O2 trimming controller
While loading the boiler care to be taken that the feed and boiler water parameters to
be brought to the recommended limit before increasing the load beyond 50% of the
MCR.
Section C
Page 14
Pressurising Curve
100.0
325
90.0
300
275
80.0
250
70.0
175
50.0
150
40.0
125
30.0
100
75
20.0
50
10.0
25
0
0
50
100
150
200
250
300
0.0
350
Time in min
Saturated Steam Temperature
Section C
Drum Pressure
Page 15
60.0
200
Pressure (kg/cm g)
225
OPERATION
Fuels distribution
During first few days of operation, adjustment of Travagrate speed and spreader air pressure
may require to bring the firing system to its fullest efficiency.
For fuel spreading adjustment, system is provided with trajectory plate, air pressure control
dampers along with air modulating dampers.
Position of trajectory plate and air pressures setting depends on the fuel quality and firing
conditions. To throw the fuel towards the rear wall, trajectory plate is to be kept horizontal and
the air pressure to be adjusted so as the fuel spreading is beyond the grate centerline. Larger
particle and high moisture fuels require high pressure air for spreading, however the air pressure
to be reduced if the fuel is with low moisture and small size fiber.
During start up, there will be mouth feeding of fuel close to the front wall, as the furnace
temperature will be less during this period. Hence the fuel falling close to the front wall burning
will be slow and looks like mouth feeding, this pile will be burnt and cleared as the boiler load
increases, at times it may require to assist the fire by manual poking to clear the pile.
GRATE SPEED
Oil flow control valve located at the front of the hydraulic drive unit controls speed of the grate.
By tuning the control knob, counter clockwise from 0 setting, the speed can be increased from 0
to 13.7mtrs/ hour maximum,
Section C
Page 16
Quantity of fuel burnt and ash content of the fuel being fired determine the speed of the grate.
Travagrate under high loads, burning fuel with a high ash content will require an accelerated
grate speed to keep the ash bed level at an optimum height. Travagrate under lower loads,
burning fuel with low ash content will require slow grate speed.
Operator should adjust the drive speed accordingly, any adjustments should not be radical or
made in rapid succession. The time between changing a setting and the effects could be several
hours.
COMBUSTION AIR
For the complete combustion of fuel being fired, air is fed into the furnace from various sections.
Primary air from FD fan through the Air per heater (APH), helps the combustion of fuel on the
grate. Air flow to be adjusted according to the quantity of fuel feeding and bed ash thickness.
The exact quantity of air requirements can be adjusted as per the excess air from the O2
measurement in flue gas and furnace conditions.
During start-up Air Pre Heater (APH) is by-passed from airside, to avoid gas condensation
because low gas temperature and tube corrosion. To maintain the APH tube metal temp. airflow
through the APH is to controlled by adjusting the dampers provided in the F.D fan to APH and
APH by-pass ducts. These dampers are to be adjusted to maintain the gas temperature at APH
outlet at 140C.
Over fire from SA fan is fed to furnace at various elevations, provides turbulence, which
thoroughly mixes with volatile gases and fine fuels, thus assuring complete combustion. Dampers
at the individual elevation ducts are to be adjusted to maintain the required air pressure to create
good penetration into the furnace and vigorous air turbulence above the grate.
Cinder re-firing system is also connected with the secondary air system and the required air
pressure (250 to 350mmwc) to be maintained all the time i.e. after stabilising the coal firing and
prior to run the coal feeding continuously. It is also required to keep the system clean and
through always to ensure re-injection of cinder from flue gas.
SECONDARY AIR PRESSURE SETTING
Whenever the plant is stabilised and boiler loaded is around 60% MCR, adjust the secondary air
pressure at various levels, as per the enclosed chart and record the same for future reference.
Note that the air pressure at pneumatic spreader inlet is to adjusted according to the quality of
bagasse viz. moisture and fibber size. Spreading of bagasse depends on the pressure at the
spreader inlet and the position of trajectory plate. During plant commissioning the quality of
bagasse varies frequently, under such condition there is always a possibility of chute jamming
and mouth feeding of bagasse happens. To overcome such situations it is advisable to keep little
high pressure at pneumatic spreader inlet.
Section C
Page 17
250 to 350mmwc
250 to 350mmwc
250 to 350mmwc
TO CINDER
RECOVERY
SYSTEM
150 to 300mmwc
200 to 250mmwc
200 to 250mmwc
100-125mmwc
150 to 175mmwc
O/L PRESSURE =
mmWC
S.A
FAN
Section C
Page 18
Boiler front
TOP DUCT
200 to 250mmwc
TOP DUCT
200 to 250mmwc
CINDER FIRING
300 to 350mmwc
LOWER DUCT
100 to 150mmwc
FINE THROW NOZZLE
200 to 400mmwc
Pressure to be adjusted at site depends upon the fuel quality. When the fines are more in the
fuel, fine through air nozzle pressure is to be increased to throw the fuel far from front plate.
Pressure provided is for reference only, actual setting will be carried out at site depends on the
performance of fuel throw and firing performance.
Section C
Page 19
TRAVAGRATE
Operation
In stoker firing, part of the fuel is burned in suspension and remaining on the grate. Fuel is
sprayed across the furnace by the series of fuel feeders with a uniform spreading action,
permitting suspension burning of the fine particles during travel. The larger pieces fall on the
grate for combustion, forming a thin fast burning fuel bed. This method of firing fuel provides for
extreme load fluctuation as ignition is almost instantaneous on increase of firing rate and the thin
fuel bed can be burned out rapidly when required. Specifically designed air - metering grates for
under grate air, over fire air system, to reduce carbon loss. Combustion controls are furnished to
coordinate fuel and air supply with load demand. The traveling grate has an extraordinary ability
to burn any type of fuel with a wide range of burning characteristics with no limit on the ash
content. An over fire air system is provided for successful suspension burning. This air mixes
with the furnace gases and creates the turbulence required to complete combustion. To
compensate for variation of the ash content in the fuel, the grate speed can be adjusted up to
13.7mtrs/ hour. The ash is continuously discharged over the front end of the grate into an ash
hopper.
Travagrate is extremely sensitive to load fluctuations since ignition is almost instantaneous on
increase of firing rate and burn out of the thin fuel bed can be rapidly effected when desired. The
grates employ the basic design concepts of high resistance with air metering to avoid blowholes
through the thin bagasse pith bed. With pneumatic distribution feeding, fresh bagasse pith is
distributed uniformly over the surface of the burning fuel bed. It is ignited from the fire bed
beneath and burns upward. Thus the grates are always protected from high temperature by a
layer of ash.
Control of both the quantity and the distribution of combustion air are important and are
generally done with the help of the damper at the fan inlet or by varying the speed.
Speed control
To control the speed of the grate, it is equipped with a flow control valve, which is located at the
front of the drive. Turning its control knob anti clock wise increase the quantity of fluid flowing
into the cylinder, thus making the piston travel at the faster rate. Increasing the rate of piston
travel in turn increases speed of the grate. Turning the control knob clockwise will decrease the
oil-flow and speed of the grate
Capacity of the flow control valve and hydraulic system is such that the rotation of the drive shaft
can be adjusted up to 45 foot per hour. The speed at which the drive should operate will depend
on the amount of fuel being burned and its ash content.
Section C
Page 20
ESP
Following care to be taken in ESP operation.
Monitor the gas inlet temperature during start up and low load operation, as the ESP to be
charged once the gas temperature is increased above 125C.
During start up, ESP to be charged 4hrs after the flue gas temperature is reached 125C,
this is to avoid mild explosions due to the presence of CO in flue gas, as CO generation is
common during start up because of transient conditions.
If the boiler operation is not stable, it is advised to switch off the transformer, but keep the
heater and rapping mechanism in operation.
It is recommended to switch off the ESP Transformer, if the ESP ash handling system is not in
service.
Ensure proper functioning of insulator heater, presence of moisture can cause cracking of
Insulator.
Check and confirm the healthiness safety interlocks.
Monitor the ESP gas outlet temperature.
Verify the normal operation of purge air fan and cleanliness of the suction filter.
Section C
Page 21
BLOW-DOWN SYSTEM
Dissolved and suspended solids entering into the boiler through feed water system remain in the
boiler, as steam is generated continuously. During steaming process the solids retain the boiler
which increase the concentration of boiler water gradually. There is a limit for the concentration
level of solids in the boiler water depends on the operating pressure, exceeding the limit of Total
Dissolved Solids (TDS) may produce undesirable foaming and carryover.
To control the concentration limit, part of the water is to be drained off, and replaced with fresh
water keeps the TDS level under control.
Blow down rate is determined by the TDS of the boiler water, blow-down may be controlled
either intermittently (IBD) or continuously (CBD).
Intermittent Blow-down (IBD)
Through this system blow-down is carried out intermittently to control the water concentration,
whenever the drum level increase above the safe limit, to control the level water can be drained
though this system.
IBD is tapped from water drum
Section C
Page 22
AIR PRE-HEATER
Air pre heater provided is of tubular type and the purpose is to recover a portion of the sensible
heat from flue gases thereby improving combustion efficiency. The arrangement consists of tubes
set vertically in a surrounding ductwork. The ends of the tubes are expanded into the supporting
tube sheets. The flue gas passes through the tubes while the incoming air for heating passes
from the out side of the tubes.
SOURCES OF TROUBLES AND PREVENTION
Fouling
Tubular heater elements are susceptible to fouling due to fly ash accumulation, particularly at the
air inlet to the heater and near the exit of gas from Air Pre Heater.
Dust build up on the gas side of the tubes can be detected by observing the following conditions.
Increased draft loss across the heater.
Increased gas temperature leaving the heater.
Decreased air temperature at the APH outlet can often be prevented or minimized.
Fouling can be prevented or minimized by proper operation of firing equipment and maintaining
APH tube metal temperature above the gas dew point limit. To minimise the dust deposit, APH is
provided with air By-pass arrangement. As there will be gas condensation inside the tubes, during
boiler start up due to low back-end gas temperature. Hence during start up the by pass damper
to be kept open 100% open and the inlet damper to be kept closed. Opening of these dampers
to be adjusted in such a way to maintain the gas outlet of APH at 140C
Corrosion
When fly ash deposited in the gas path of cold end tubes, they often form a hard bonded material
that acts as insulation. This insulation lowers the tube metal temperature until it approaches the
incoming air temperature. This temperature is usually below the dew point of the flue gas, acid
constituents within the ash, which become corrosive in the presence of moisture. Conditions
causing corrosion can be minimized by keeping the tube surface free of deposits through proper
combustion and by maintaining safe flue gas temp. i.e. 145C at APH exit.
Fires
Tubular air-heater can be damaged or go out of shape by fires occurring in the gas passes.
Generally these fires are caused by the deposition of large quantities of unburned combustible
materials within tubes and on the tube sheets. Unbound fly ash may be deposited on the tube
surface during initial start up and on abrupt changes of firing rate, may ignite this deposits
leading to damage of the tubes.
Section C
Page 23
APH fire is indicated by a very rapid increase in temperature of gas or air flowing from the APH. If
this occurs, following steps should be taken.
Discontinue firing immediately.
Shut down all fans & dampers.
Floor area of fire with CO2 or suitable fire extinguisher.
Ensuring complete combustion of fuel can prevent APH fires.
DEAERATOR
START UP
It is recommended to charge the steam to the deaerator as soon the LP steam is made available,
if the steam charging is done at boiler load conditions may cause thermal shock and water
hammering due to imbalance in steam and water flow till the stabilisation of deaerator.
Procedure for placing the deaerator in to service is as below:
OPERATION
During the normal operation, vent valve (DA-056) should be closed as the required volume of
steam will be vented out through the by-pass line with orifice. Also the pegging line isolation
valve is kept in closed position whenever the deaerator pressure is stable. It also recommended
to monitor the steam supply pressure and deaerator operating pressure to maintain required
outlet water temperature.
Section C
Page 24
SHUTTING DOWN
To isolate the deaerator from service;
SOOT BLOWER
Soot blower operation is depend on fuel type, steam flow, steam temperature and boiler
arrangement. In general, frequency of cleaning may be determined by observing flue gas exit
temperatures raised from the boiler, economiser, air heaters, draft loss across the flue gas system
and steam outlet temperature. It may be more economical on the other hand to operate soot
blowers as required rather than to adopt a fixed blowing schedule.
This boiler is provided with, 4 nos. motorised long retractable and 14 nos. of motorised multi-jet
rotary soot blowers.
Superheater Zone
Super heater & B.B zone 4 (SB- 05, 06, 07 & 08)
Economiser Zone
6 (SB- 13 TO 18)
Soot blowing system is provided with a manual start up arrangement. Hence, during start up and
normal/ operation, the soot blower control should be kept off or in manual mode along with the
steam pressure control. Soot blower panel to be switched on and put into auto timer operation
mode along with the steam pressure controller in auto mode, during soot blowing. It is
recommended to operate soot blowers, whenever the steam flow from the boiler crosses 60%.
While operating the soot blower, Prior to start up, furnace draft should be increased considerably
to ensure sufficient draft to carry soot through the boiler. Secondly, open soot blower steam
piping drain valve and steam trap valves. Keep the steam pressure control valve in auto mode
and open the main steam valve & keep the drain open till all the condensed water is removed
from the piping. Once the steam temperature reaches to the specified limit operate the blowers
as per the order specified. On completion of blowing cycle main valve to be closed and the drain
valve to be kept open to remove the condensate. Also the furnace pressure control to be made
normal.
Section C
Page 25
Section C
Page 26
Description
STEAM
Evaporation
Steam Temperature @ Boiler Outlet
Drum operating pressure
Steam Pressure @ Boiler Outlet
Primary SH Steam Inlet
Sec. SH inlet
Sec. SH outlet
FEED WATER
Eco inlet pressure
Eco outlet pressure
Eco inlet temperature
Eco outlet temperature
FLUE GAS
Flue Gas Temp. Leaving Furnace
Flue Gas Temp. Leaving
Superheater Section
Flue Gas Temp. Leaving Convection
Section
Flue Gas Temp. Leaving Economizer
Flue Gas at APH Out let
Temperature
Flue gas at furnace outlet
Flue gas at Boiler outlet
Flue gas at Economiser outlet
Flue gas at APH outlet
Flue gas at ESP outlet
Flue gas at I.D. inlet
AIR
APH inlet
APH outlet
FD Fan outlet
APH outlet
Under grate
SA Fan outlet
O2
Section C
unit
TPH
o
C
Kg/Cm2
Kg/Cm2
o
C
o
C
o
C
Kg/Cm2
Kg/Cm2
o
C
o
C
o
mmwc
mmwc
mmwc
mmwc
mmwc
mmwc
o
C
C
mmwc
mmwc
mmwc
mmwc
%
o
Page 27
Clean the internals before closing the manholes of pressure parts furnace and ducting.
All the control and isolation dampers must be in smooth operating condition.
Maintain hydraulic drive oil pump pressure as per the recommended set pressure.
Pressure raising from cold start must be done as per the cold start up curve.
Boiler, Piping, Ducts, Feed water and Oil tank must be properly insulated.
Maintain the instrument air free from moisture and oil matters and the pressure as
recommended.
In case of power failure close the steam stop valve and stop the fire immediately.
Section C
Page 28
SA Fan
Section C
Page 29
DONTS
Dont throw big size wooden logs inside the furnace for slow firing.
Dont increase the set pressure of the TRAVAGRATE hydraulic oil pressure beyond the
recommended limit.
Dont allow super heater steam temp. to go beyond the designed limits.
Dont operate the furnace wall header drain valves while the Boiler is in operation.
Dont leave the furnace door open while the boiler is in operation.
Dont by pass compressed air, dryer, if any problem attend to it at the earliest.
Avoid continuous operation of boiler at low loads (low back-end temperature) to protect
Economiser, ESP and Air Pre-Heater corrosion.
Do not dose chemicals into the boiler in batch wise, they should be done on a continuous
basis.
Do not open any of the ESP manholes, while the I.D. Fans in operation.
Section C
Page 30
OPEN
During boiler filling.
Main
steam
stop valve.
After
ensuring
100%
removal of condensate from
the steam piping.
Also
ensure the pipeline is
heated up to the working
temperature.
Open for emergency drum
level control and for sludge
removal.
Open for draining the boiler
after
killing
the
fire
completely.
Adjust the opening to
maintain the TDS of the
boiler water.
Open
before
and
completion of blowing cycle.
IBD valve
Water
drains.
wall
CBD valve
Soot
blower
steam line drain
valve.
Section C
CLOSE
After ensuring free water flow from
the vent.
When the drum pressure
reaches to 2 kg/cm2 during start
up.
Page 31
Make note of any leaky valves and prepare maintenance schedule to repair them.
Check to see that proper water level is being shown by the direct water level gauge. Check
for water or steam leaks from ports or drain connections, which will cause a false water level
in the gauge glass. Inspect the glass for discoloration or fouling.
While doing routine operation of soot blowing, inspect for condensate, steam and leaks
from the soot blowers.
Section C
Page 32
Page 33
All ash must be removed completely from the boiler and hopper and the boiler
temperature must be below 50c before personal are allowed to enter for maintenance or
inspection.
Shut down all the auxiliary equipment at this time.
system, make-up system, ash removal systems, etc.
Section C
Page 34
Section C
Page 35
3. Equipment lineup
Section C
Fuel
Feed water.
Uninterrupted electric power supply
for auxiliary equipments.
Lighting for equipments, walk ways
and field instruments.
Instrument air.
Plant air.
Cooling water.
Lubricant for the rotary equipments.
Chemical for feed and boiler water
treatment.
Readiness of drainage and ash
disposal system.
Fire fighting system.
Nitrogen capping is removed and the
unit is purged properly so as it is safe
for man entry for inspection.
Steam and water drums manholes
are closed properly.
furnace S.H and convection bank are
clear and all access / inspection
doors are tightly closed.
air duct to furnace and flue up to
stack is clear and the manhole doors
closed properly.
walkways are clear with out any
obstruction.
Page 36
Equipment lineup
Section C
Page 37
Equipment lineup
ESP
Switch on the ash handling system
one hour prior to light up.
Open the isolation gate above the
RAV and switch on the rotary airlock
valves.
Incase of pneumatic evacuation,
open the isolation gate above the
vessel.
Switch on the rapping mechanism
one-hour before the light up.
Switch on the hopper and insulator
heater four hours prior to light up.
Safety interlocks are tested prior to
startup.
Section C
Page 38
3. Equipment lineup
4. Water filling
Others
Verify all the soot blowers are in rest
position.
Ensure the test gags of safety valves
are removed.
Verify all the safety interlocks are
working
as
per
the
desired
logic/values.
Ensure the availability of cooling
water/seal air to the system.
Switch on the RAV below ash
hoppers and ash conveyors.
Valves to be kept in open position:
Air vent at economiser outlet header
Air vent on steam drum
Start up vent
Economiser inlet header drain
Section C
Page 39
or
Section C
Page 40
4. Startup
Start ID Fan
Start FD Fan
Start SA Fan
Section C
Page 41
5. Pressure rising
Section C
Page 42
Section C
Page 43
Section D
Page i
WATER CHEMISTRY
INTRODUCTION
The natural water contains solid, liquid and gaseous impurities and therefore, this
cannot be used for the generation of steam in the boilers. The impurities present in the
water should be removed before its use for steam generation. The necessity for
reducing the corrosive nature and quantity of dissolved and suspended solids in feed
water has become increasingly important with the advent of high pressure, critical and
supercritical boilers.
The impurities present in the feed water are classified as given below
1.
2.
3.
4.
Section D
Page 1
D) IRON :
Most common soluble iron in water is ferrous bicarbonate. The water containing ferrous
bicarbonate deposits becomes yellowish and reddish sediment of ferric hydroxide if exposed to air.
Majority of ground surface water contains less than 5 ppm but 0.3 ppm, can create trouble in the
feed water system by soft scale formation and accelerating the corrosion.
E) MANGANESE:
It also occurs in similar form as iron and it is also equally troublesome.
F)
SILICA:
Most natural water contains silica ranging from 1 to 100 ppm. Its presence is highly
objectionable as it forms very hard scale in boilers and forms insoluble deposits on
turbine blades. In modern high-pressure boilers its presence is reduced as low as 10-50
ppm.
G) MICROBIOLOGICAL GROWTHS:
Various growths occur in surface water (lake and river). The microorganisms include
diatons, molds, bacterial slimes, algae; manganese and sulfate reducing bacteria and
many others. These can cause coating on heat exchanger and clog the flow passages
and reduce the heat transfer rates.
H) COLOUR:
Surface waters from swampy areas become highly colored due to decaying vegetation. Color of
feed water is objectionable as it causes foaming in boilers and may interfere by chlorinating of
absorption by activated carbon.
Section D
Page 2
DISSOLVED GASES
A) OXYGEN:
It is present in surface water in dissolved form with variable percentage depending upon the water
temperature and other solid contents in water. Its presence is highly objectionable, as it is corrosive
to iron, zinc, brass and other metals. It causes corrosion and pitting of water lines, boilers and heat
exchangers. Its effect is further accelerated at high temperature.
B) CARBON DIOXIDE:
The river water contains 50 ppm & well water contains 2-50 ppm of CO2. It also helps to accelerate
the corrosive action of oxygen.
The other gases are H2S, CH4, N2 and many others but their percentage are negligible Therefore
their effects are not discussed here.
OTHER MATERIALS
A] FREE MINERAL ACID:
Usually present as sulfuric or hydrochloric acid and causes corrosion. The presence is required by
neutralization with alkalis.
B] OIL:
Generally the lubricating oil is carried with steam into the condenser & thorough the feed system to
the boiler. It causes sludge, scale & foaming in boilers. Strainers and baffle separators generally
remove it.
The effects of all the impurities present in the water are the scale formation on the different parts of
the boiler system and corrosion. The scale formation reduces the heat transfer rates and clogs the
flow passage and endangers the life of the equipment by increasing the temp above the safe limit.
The corrosion phenomenon reduces the life of the plant rapidly. Therefore it is absolutely necessary
to reduce the impurities below a safe limit for the proper working of the power plant.
Section D
Page 3
This reaction
Alkalinity adjustment and film formation are closely related. The pH value of feed water
should be maintained greater than 9.6 to reduce the corrosion effects caused by the
reason mentioned above. The required alkalinity of feed water is adjusted by adding
soda ash caustic soda or trisodium phosphate. The calcium hardness, alkalinity and pH
are inter-related variables in scale control. Calcium carbonate is one of the most
troublesome deposits responsible for scale formation.
EFFECTS OF IMPURITIES
The major troubles caused by the feeding of water of undesirable quality are scale formation,
corrosion, foaming, caustic embrittlement, carry-over and priming. The details described below: SCALE FORMATION
Feed water containing a group of impurities in dissolved and suspended form flows into the Boiler
for continuos generation of Steam. With conversion of water into steam in Boiler, solids are left
behind to concentrate the remaining water. The scale formation tendency increases with the
increase in temperature of feed water. Because, the solubility of some salts (as calcium sulphite)
decreases with the increase in feed water temperature. Calcium sulphite has solubility of 3200 ppm.
at 15 Deg. C and it reduces to 55 ppm. at 230 Deg. C and 27 ppm. At 320 Deg. C.
Scale formation takes place mainly due to salts of calcium and magnesium. Sometimes, it is
cemented into a hard mass by Silica. Among all, calcium is the principal offender and particularly,
Section D
Page 4
Calcium sulphate, magnesium sulphate and other Chlorides are sufficiently soluble in water and are
not much troublesome. Sodium salts are highly soluble in water and are non-scale forming.
The scale formation takes place mainly in feed water piping and Boiler Tubes. Its first effect on the
piping system is to choke the flow of water by reducing the flow area and increases the pressure
required to maintain the water delivery. Another effect of scale formation is to reduce the transfer
of heat form the hot gases to water. Real dangers of the scale formation exist in radiant heat zone
where boiler tubes are directly exposed to the combustion. The scale formation retards the flow of
heat and metal temperature increases. Even a thin layer of scale in high heat zone can over-heat
the metal enough to rupture the tubes. The metal tubes weakened due to over-heating yield to
pressure providing a protrusion known as bag. Such bag provides a pocket for the accumulation of
sludge and scale, which eventually causes failure. The over-heating of metal causes layer of metal
to separate and form a blister.
CORROSION
The corrosion is eating away process of boiler metal. It causes deterioration & failure of the
equipment, eventually this cause for major repairs or expensive shut -downs or replacements.
The corrosion of boilers, economizers, feed water heaters & piping is caused by an acid or low PH in
addition to the presence of dissolved oxygen & carbon dioxide in the boiler feed water. The
presence of oxygen is mostly responsible for corrosion among all other factors. The permissible limit
of oxygen content varies with the acidity of water. Generally it should not exceed 0.5 cc per liter
.O2 generally enters into closed system through make up condenser leakage and condensate pump
packing.
CO2 is next to O2, which is responsible for corrosion. The CO2 comes out of bicarbonates on heating
and combines with water to form weak acids known as carbonic acid. This acid slowly reacts with
iron and other metals to form their bicarbonates. The newly formed bicarbonates of metals
decompose by heat once more and CO2 is again liberated. This gas again unites with water to form
carbonic acid and the cycle is repeated. Adding alkali solution to neutralize acids in water and raise
the PH value can minimize the corrosion. The effect of CO2 is minimized by the addition of ammonia
or neutralizing the amines in water. This is necessary because CO2 lowers the PH of the boiler feed
water and dissolved solids to leave the boiler.
The priming is a violent discharge of water with steam from the boiler. It can be compared to the
pumping of water that frequently accompanies rapid heating in a open vessel. In priming the water
level in the boiler undergoes rapid and great changes and there are violent discharges of bursting
bubbles. Therefore sludge of boiler water is thrown over with the steam.
The priming is caused due to improper boiler design, improper method of firing, overloading,
sudden load changing or a combination of these factors. The priming effect is reduced by installing
steam purifier, lowering water level in the boiler and maintains constant load on boilers.
Section D
Page 5
The foaming is the formation of small and stable bubbles throughout the boiler water. The high
percentage of dissolved solids, excessive alkalinity and presence of oil in water are responsible for
foaming.
Boiler water solids are also carried over in the moisture mixed with steam even when there is no
indication of either priming or foaming. This is known as carry-over. The carry-over of boiler
water solids is partly a mechanical and partly a chemical problem. The amount of suspended solids
and alkalinity in the boiler water is also important in addition to other reasons like boiler design,
high water level, and overloading and fluctuating loads on boiler.
CAUSTIC EMBRITTLEMENT
The caustic embrittlement is the weakening of boiler Steel as a result of inner crystalline cracks.
This is caused by long exposure of boiler steel to combination of stress and highly alkaline water.
The course of embrittlement takes place under following condition:
a) When boiler water contains free hydroxide, alkalinity and some silica. It has been always found
that the feed water was high in sodium bicarbonate, which broke down into sodium carbonate in
the boiler and partially hydralized as shown by the following reaction in case of embrittlement.
Na2CO3
+ HOH
= CO2
+ 2 NaOH
Section D
Page 6
Section D
Page 7
Table 1
Boiler Pressure
Kgs/Cm2
00-20
20-40
40-60
Above 60
pH
10.5
10.5
09.5
08.5
11.5
11.5
10.5
9.5
0 -20
20-40
40-60
Above 60
30-40
20-30
5-10
---
0.1 - 0.2
0.1 0.2
0.1 - 0.2
0.1 - 0.2
Clarification
- To remove suspended matters.
Filtration
- To remove residual turbidity
Softening
- To remove hardness salts
Dealkaliser
- To remove hardness salts and excessive alkalinity
Demineralization
- To remove residual salts and silica
Mixed bed
- To remove residual salts and silica from DM water.
combination of above equipment can be used to remove undesirable impurities in raw water.
Section D
Page 8
SCALE CONTROL
Hardness salts in feed water cause formation in boiler. Under temperature and pressure inside the
boiler and due to concentration, hardness salts precipitate in tubes as calcium carbonate, calcium
sulphate and Ca/Mg silicate scales.
External treatment like softening, demineralization or de-alkalization removes most of
the hardness salts from boiler feed water. However, malfunctioning of this equipment,
occasional bypassing of the softener/DM plant or contamination of condensate or feed
water with raw water often led to ingress of hardness in the boiler.
All hardness salt precipitate inside boiler leading to hard scale formation on tubes. Such scale has
lower conductivity causing increase in metal temperature, leading to bursting of tubes in extreme
conditions.
Therefore, inspire of elaborate external treatment, internal chemical conditioning is always
recommended as additional safety. Following chemical methods are used for internal treatment.
PHOSPHATE CONDITIONING
Trisodium phosphate is commonly used. Hardness salts react with trisodium phosphate to form
calcium phosphate precipitate. This precipitate above pH of 9.5 colloidal in nature and therefore do
not allow to form hard scale of carbonate and silicates. The precipitated hardness salts are then
removed through blow down as sludge and boiler tubes are kept scale free.
Trisodium phosphate, apart from acting as hardness conditioning agent, also is a good corrosion
inhibitor. The recommended concentration in boiler water is given in Table -1
Note 1: TSP will act as hardness conditioner, only when boiler pH is above 9.5, below 9.5 pH TSP
may cause hard scale formation of Ca3 (PO)2. Therefore, coordinated or congruent phosphate
treatment is recommended. The water treatment experts can advise you right treatment after
studying your water quality and operation conditions.
Thermax Chemicals can provide services for arriving at right chemical treatment for your boiler.
Chelant- Polymer treatment:
Hardness scales do not precipitate in presence of chelant like NTA/EDTA. The chelant treatment is
recommended when hardness ingress in boiler is experienced regularly.
Caution: Excessive chelant dosing cause corrosion of boiler. Hence balanced chelant program as
recommended by experts should be used.
Section D
Page 9
Organic polymer conditioners are used to prevent hardness scales. Such organic polymer disperse
scale forming compounds like CaCO3 & Ca(PO4)2 in colloidal form facilitating their removal through
blow down. Polymer and copolymer of acrylic, methacrylic, styrene maleic acrylics are commonly
used. Most of the polymers are proprietary in nature and therefore dosage is best recommended by
manufacturer.
FOULING CONTROL
Suspended matter, oil/grease /oxygen & iron salts commonly cause fouling inside the boiler. Most of
the suspended matter and iron salts are removed by external treatment. However due to mfg. of
these equipment, contamination through condensate and concentration in boiler cause fouling of
boiler tubes.
Similar to hardness scales, such foulants are poor conductor of heat. Thus fouling causes
overheating of tubes.
Fouling can best be avoided by maintaining quality of feed water as per norms. In case of upsets or
occasional contamination, polymeric disersent help to prevent fouling due to turbidity and organic
matter. Iron is picked up mostly in condensate system due to corrosion of condensate line. In such
case, condensate corrosion inhibitor like ammonia cyclohexylamine and filming amine is
recommended.
TURBINE / SUPERHEATER DEPOSITION CONTROL
The solids in boiler feed water get concentrated in boiler. The concentration of solids in boiler is
decided blowdown and feed water quality. The carryover of boiler water with steam depends on;
Mechanical Factors:
Boiler load
- Higher the load, lower is the steam purity
Water level in boiler
- Higher the water level in drum, lower is steam purity.
Load Variation
- Sudden increase in load reduce steam purity for short time.
Separation efficiency - Higher efficiency, better is steam purity.
Chemical Factors:
TDS
Total Alkalinity
Organics
Foaming
The water carried over with steam due to above reasons is exactly similar in quality to blow-down or
boiler water. In superheater or in turbines, water evaporates, leaving dissolved and suspended
matter as scales or deposits.
Section D
Page 10
Thus severity of scaling and fouling of superheater and turbine depends on boiler water quality and
steam purity.
Maintaining boiler water quality as per norms and maximum steam purity is the only way to prevent
deposition due to carryover of water with steam. Antifoam agents help to some extend to improve
steam purity in case of excessive in boiler.
SILICA DEPOSIT CONTROL
Silica is volatile under high temperature and pressure inside boiler. In turbines, the evaporated
silica precipitates during pressure and temperature reduction and form hard scales.
One way to control silica deposition is by maintaining silica concentrate within the limit as
recommended in Table-3
Table - 3
Max silica in boiler water as SiO2 *
150
40
15
2.45
Boiler Pressure
0-20
20-40
40-60
Above 60
* Maximum allowable concentration of silica depends on water analysis. Expert's best decide the
maximum permissible concentration after striding the operating parameters.
CONDENSATE CORROSION CONTROL
The carbon dioxide is present in boiler feed water in dissolved and combined from as carbonate.
Under boiler pressure and temperature it is liberated and carried over with steam as CO2 gas. This
gas redissolves in steam condensate to form carbonic acid.
CO2 + H2O
= H2CO3
The carbonic acid is highly corrosive to condensate lines and steam using equipment cause in failure
of such equipment. The corrosion products are carried with condensate as iron and copper salts in
the boiler causing severe fouling and copper induced corrosion.
Ammonia, cyclohexyl amine, filming amine is commonly used in neutrally carbonic acid and prevents
condensate corrosion. The dose and dosing point depends on boiler system and is best
recommended by experts after system study. Table 4 gives recommended condensate quality to
prevent condensate corrosion.
Section D
Page 11
Table 4
Pressure/Parameters
pH
Hardness(max) as
CaCO3
Iron + Copper
TDS
0-20
8 - 8.5
20-40
8 - 8.5
30-60
8 - 8.5
>60
8.5 - 9.5
0.2
ND
ND
0.15
8.0
0.05
4.0
0.03
1.0
0.015
0.1
S.N
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Section D
BOILER
WATER
0
10.2 10.7
------------1.33
0
NIL
100
0
0
0.02
15-30
Page 12
Section E
Page i
Section E
Page 1
LTD
PUNE, INDIA.
PROJECT NO-PB0751
PREVENTIVE MAINTENANCE
The objective of the preventive maintenance program is to obtain trouble free service
from the component till the next maintenance.
Vendor manuals enclosed in the respective volumes suggest the inspection periods,
checks to be done and recommended spares to be changed. The true objective of the
maintenance program can only be realized if a detailed plan of maintenance of all the
components is prepared as per vendor instructions.
Full benefits of maintenance can be obtained only if proper genuine parts are used.
PREVENTIVE MAINTENANCE PROGRAM FOR FANS
Equipment such as a fan is said to be under preventive maintenance, when it is stopped
after some period of operation &,
The expansion joints at the discharge end are checked to see that they are not
compressed or expanded.
Damages if any to the bellows are corrected by patch up. Discharge duct supports are
checked and adjusted to their design value.
The suction damper bearings/ bushings are checked for wear and repaired or replaced
as necessary. The travel of the damper is checked and corrected where required.
The end shields of the drive motor are opened.
The stator-rotor spaces are cleaned blowing a jet of warm air.
The bearings are cleaned and re-lubricated.
The insulation resistance of the stator coils is measure and compared to their
previous values.
The end shields are assembled,
The motor coupling is aligned to the fan coupling.
Trial run of the fan is taken.
Section E
Page 2
LTD
PUNE, INDIA.
PROJECT NO-PB0751
Dismantle the bonnet, clean the trim and valve seat, lapping them if necessary.
Cleaning the valve stem and re-lubrication of the operating threads.
Renewing the bonnet joint, and assembling the trim on the valve seat.
Renewing the gland packing.
Renewing the valve flange joint, if necessary.
The prepared master plan for maintenance should be periodically reviewed during the
first three years of the boiler operation.
It may be found that due to varying site conditions, the frequencies and quantum of
work scheduled as per vendor manuals are either too much or too less. Based on site
experience, the frequencies and work schedules can be modified.
A scientific method of preparation of the preventive maintenance schedule is to make
them condition based.
Section E
Page 3
LTD
PUNE, INDIA.
PROJECT NO-PB0751
In condition based maintenance, the equipment and components of the plant are
inspected daily, weekly, monthly etc. as per suggested schedule by the local operators
and the deteriorating conditions if any observed are reported. Suggested inspection
program is given in this chapter. Based on operator reports of such inspection,
maintenance works are planned for the next available planned shutdown. Mandatory
inspections prescribed by the vendors are also taken care of, irrespective of the
equipment condition.
Section E
Page 4
LTD
PUNE, INDIA.
PROJECT NO-PB0751
To carry out any minor repairs or adjustments which can be done with the boiler in
service.
To plan for repair of such items, which cannot be attended when the boiler is in
service, during the next available shutdown.
The schedule can be expanded, curtailed or modified based on experience in the first
two years of operation.
Section E
Page 5
LTD
PUNE, INDIA.
PROJECT NO-PB0751
DAILY CHECKS
To be done once a day by the operator as a routine job. Checks are to be done in each
shift by the local operators. Only those operational checks, which require maintenance
work for correction, have been included.
EQUIPMENT
CHECK
Local level gauges Check
illumination
is
on steam drum
proper.
Leaking
valve
glands,
leaking ports
Blurred level
2
Comparison of levels
indicated by local
level gauge with
that of remote level
indicators in the
control room
Traces of water, oil
spots on boiler floor,
buck-stay
beams,
boiler cladding etc.
Hydraulic drive
WORK TO BE DONE
Replace fused bulbs.
Isolate local level gauges and
tighten leaking glands. Replace
leaking ports.
Steam wash mica as suggested
by vendor. (not to be done too
frequently)
If
there
are
serious
discrepancies calibration of the
remote level indicators has to be
planned immediately.
Maintenance to be planned to
eliminate the source either
immediately or during next
planned shut down (depending
on the source and quantity of
leak) and accessibility for
maintenance.
Lubricating oil levels Check adequacy of oil level Top up if required (immediately)
of Fans, & feed
If leakage through oil seals,
pumps
bearings,
gaskets drain plugs etc. is
dosing pump gear
noticed plan for maintenance
box etc.
during next planned shutdown.
Oil level in
Check adequacy of oil Top up if required (immediately)
Travagrate hydraulic level.
Check for leakage.
drive
Section E
Page 6
LTD
PUNE, INDIA.
dosing pumps
PROJECT NO-PB0751
temperatures
10
11
Section E
their
proper
Page 7
LTD
PUNE, INDIA.
PROJECT NO-PB0751
MONTHLY CHECKS
Fans,
dosing
pumps,
BFW
pumps
Section E
Page 8
LTD
PUNE, INDIA.
PROJECT NO-PB0751
ANNUAL OVERHAUL
PLANNING BEFORE OVERHAUL
-
Prepare a list of jobs to be done during the overhaul based on earlier inspection
reports and the jobs listed below.
Ensure availability of spares required for the proposed jobs.
Ensure tools, tackles, scaffolding materials required for the job.
Ensure availability of manpower required for the job (Own sources, contract labour
etc) services of TBW are also available for carrying out annual overhauls and
inspections.
1. STEAM DRUM
Operational Checks:
Check for steam and water leaks from connections and fittings to the drum.
Prior to Annual Shutdown:
Check drums pressure gauges, safety valves water level gauges for accuracy &
reliability.
Annually:
Clean out any debris that has accumulated inside the drum. Remove any scale and
sediment.
Section E
Page 9
LTD
PUNE, INDIA.
PROJECT NO-PB0751
Check for and clean any scale or sludge in the following areas:
Primary scrubber elements
Feed water line
Continuous blow-down line
Chemical feed line
Connections
Connections
Connections
Connections
to
to
to
to
blow-down
water columns and level gauges.
pressure gauges
transmitters
Inspect the drum internals to ensure that joints in the following areas are tight:
If chemical cleaning has been performed, inspect for proper fit of internals.
Ensure all flanges and corrugated plate sections are seated properly.
Match marks all adjusted internals for future removal and reinstallation.
Inspect and replace manhole gaskets if damaged or deteriorated.
Check for evidence of corrosion on the exterior of the drum.
Removes all drum internals and inspect for wear corrosion & erosion.
Section E
Page 10
LTD
PUNE, INDIA.
PROJECT NO-PB0751
2. HEADERS
Annually:
Visually inspect headers for any cracks.
Inspect header caps/flange joints for signs of leaks or cracking.
Internal deposits or plugging
Every Five Years:
Check headers for the following:
Corrosion
Inspect for cracking of welds in the areas listed below using non-destructive testing
method.
Tube to header welds.
Header shell between tubes (ligaments).
Nozzle to header welds.
Thermo-wells.
Lug and hanger connections.
Hand-hole fittings.
Longitudinal and circumferential welds.
Drain connections.
Cracking in safety valve opening.
3. FURNACE
Operational Checks:
If possible, inspect the slagging condition of furnace walls through ports. Use extreme
caution when doing so. Always wear tinted goggles or shield to protect eyes
from harmful light rays, slag or ash particles. Do not stand directly in front of
open ports.
Walk around the exterior and observe for any hot spots or gas leaks.
Prior to Annual Shutdown:
Check for gas leaks at observation ports, as well as manhole and access doors.
Note or mark any such areas in which leakage is occurring (for ease of location during
shutdown).
Annually:
Inspect the tube surfaces for signs of leaking, corrosion, overheating (blistering and
bulging), warping, misalignment, pitting, or cracking.
Section E
Page 11
LTD
PUNE, INDIA.
PROJECT NO-PB0751
Inspect all wall tubes in the vicinity of soot-blowers for erosion. Pad-welded and
correct position of blower nozzle in relation to eroded wall tubes if any.
Inspect furnace side wall at junction of furnace and convection pass for cracking
due to differential expansion.
Inspect furnace rear wall to arch junction for casing leaks.
Ensure baffles are in place and healthy condition.
Inspect for cracking of membrane bar at field panel splits.
Check the condition of all refractory.
Locate any deposits of ash or slag not removed by soot blowing, which may effect
heat transfer or block gas passage through the unit. Such deposits may indicate a
problem with operation or blowing pressure of soot-blowers.
Clean and reset manholes. Inspect condition of gaskets.
Inspect the condition of seal around doors and openings.
Inspect the inner surfaces of furnace wall tubes for deposits and scale.
Every 5 years:
Take random ultrasonic tube thickness measurements in critical locations, such as:
At furnace rear wall headers.
Lower furnace wall tubes.
Around soot-blower wall openings.
Around burner openings.
In furnace corners.
Section E
Page 12
LTD
PUNE, INDIA.
PROJECT NO-PB0751
4. SUPERHEATER
Annually:
Externally inspect tubes for signs of:
If internal deposits are suspected, tube sections should be removed for inspection,
the cause determined and corrected prior to returning to service.
Inspect support system.
Check attachment to tube welds for cracking or wear.
Inspect the condition of superheater seals where the tubes penetrate the furnace
roof.
5. ECONOMISER
Operational Checks:
Listen for any unusual noise around the economiser section, which may be indicative
of an economiser leak (i.e. hissing).
Inspect hoppers to make sure they are emptying properly.
Prior to Annual Shutdown:
Perform soot blowing in the vicinity of economiser tubing.
Annually:
Visually inspect economiser to locate any deposits not removed by soot blowing that
may interfere with heat transfer or block gas paths. The presence of such deposits is
an indication that operation and blowing pressure of soot-blowers should be
checked.
Section E
Page 13
LTD
PUNE, INDIA.
PROJECT NO-PB0751
If pitting has been found in the steam drum, take economiser tube samples and
inspect them internally for pitting.
If internal deposits are suspected, tube sections should be removed for inspection,
the cause determined and corrected prior to returning to service.
Inspect support system. Check for erosion around spacer bars and lugs.
Check attachment to tube welds for cracking or wear.
Inspect economiser hopper trusses and gusset plates for erosion and corrosion
damage.
6. PENTHOUSE
Operational Checks: Visually inspects for gas leaks.
Prior to Annual Shutdown:
Externally inspect penthouse area for any gas leaks and mark or make note of their
location for ease of finding during shutdown.
Annually:
Inspect for cracks or tears of penthouse corners and bottom plate.
Inspect for corrosion around corners, attachments to furnace and behind insulation.
Replace access door gaskets.
Inspect all support systems (hanger rods) for corrosion or other damage.
Inspect condition of penthouse and piping insulation.
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Inspect for damaged or missing refractory around furnace roof, screen and
superheater penetrations, steam drum and baffle plates.
Inspect penthouse casing for gas leaks or air infiltration.
Inspect condition of roof to wall seals.
Inspect condition of any roof penetration seals (i.e. superheater).
7. PLENUM HOPPER
Operational Checks:
Inspect for air leaks around the plenum hopper.
Inspect for signs of overheating that may indicate hot gas re-circulation within the
plenum hopper.
Monitor the plenum hopper for excessive vibration or possible fluctuations.
Investigate the source of the problem immediately.
Review the pressure drop between the plenum hopper and furnace regularly.
Changes in this pressure for a given load condition may indicate flow restriction
problems within the plenum hopper.
Annually:
Inspect plenum hopper for accumulated build up of bagasse pith / ash.
Inspect all internal baffles, tie-bars and trusses to ensure they are in good condition.
Inspect for bowed tie-bars and trusses caused by overheating or over pressure.
Excess tension, slackness or deflection of these components should be reviewed for
potential expansion problems.
Check to ensure that the register louvers are cleans and free to move. Lubricate all
moving parts with a high temperature anti-seize compound.
Inspect plenum hopper corners and expansion joints for signs of cracking or tears.
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Gas tightness
Disengagement or misalignment of support hangers and supporting rods
Tightness of the mounting hardware
Corrosion and erosion on inner surfaces
Excessive deposits of dust and ash
glands
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Any sticking
operation of
Tightness of shutoff dampers
PROJECT NO-PB0751
9. SUPPORTS
Prior to Annual Shutdown:
Inspect external areas of boiler for damaged support equipment. By taking a walk
around piping systems, an indication of support and supported equipment condition can
be obtained. This will aid in the formation of a shutdown maintenance schedule.
Annually:
Inspect boiler for alignment, noting any abnormal movement.
Check condition of header guides and supports to ensure alignment yet permit
expansion of tubes without excessive strain.
Check that main steam piping and connected equipment are properly aligned and
have proper clearance for expansion.
Inspect for signs of support failure such as insulation damage and changes in scale
readings on flexible type supports.
On spring type hangers, check for broken springs. Measure and record spring
lengths.
Inspect support system of tubes compression supports, compression support burnback, support lug failure, and lower tube sag.
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Check piping supports and hangers for disengagement or misalignment. Verify each
hanger is carrying load.
Inspect hanger rods for tightness.
Check for corrosion of hanger components, including tube spacers and support
saddles. If corrosion is found, apply a rust inhibitor.
Look for broken or cracked hanger rods, pins, lugs, ties or saddles. Tighten any
loose nuts.
For constant support hangers, inspect levers and remove any fly ash deposits found.
Re-pack with grease.
Inspect drum and down-comer hydraulic shock arrestors for damage. Check the fluid
level and look for fluid leakage.
Every 2 Years:
Inspect buck-stays for straightness and their attachment to furnace walls.
Every 5 Years:
Perform visual and magnetic particle inspection of support ties, saddles and attachment
welds.
10. REFRACTORY AND INSULATION
Operational Checks:
Inspect around all air and gas passages for possible air or gas leaks.
Inspect around the boiler casing for gas leaks or hot spots.
Annually:
Inspect the condition of the refractory around spreader throats and surrounding wall
area. Repair or replace as necessary.
Inspect the condition of refractories on furnace walls, front plate and around corner
sections. Visually check if cracks have formed and if the cracks have crossed one
another enough to cause a section to fall off.
Inspect the refractory in the ash hoppers for damage.
Inspect the condition of the refractory around access doors and observation ports.
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Annually:
Clean internal parts. There should be no accumulation of rust, scale or other foreign
substances, which will interfere with their free operation.
Clean exterior of fly ash, bagasse, dust, etc.
Recondition valve seats (laps).
REFER MANUFACTURERS MANUAL FOR DETAIL
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Roller orientation.
Distorted or bent trip fork
Sheared trip fork stop pin
Proper lubrication of rollers, trip linkage
And pillow blocks.
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Check condition of the feed tube and valve stem packing. Replace if hard and dry.
Add more packing rings to the feed tube gland as necessary. Do not over tighten.
Check puppet valves condition. If the valve shows signs of leakage, re-lap and
inspect internals for corrosion or damage.
Ensure the valve spring, spring retainer, yoke and trigger are intact, and that the
portion of the trigger that makes contact with the valve stem does not show
excessive wear.
Inspect for the following on the cam and trigger :
Excessive wear
Distorted valve trigger, restricting opening of the valve.
Proper engagement and depression of the valve lift pin (located on the large gear
wheel) is intact and making contact with gear on the valve trigger when the trigger
rides off the cam.
Lubricate the following areas :
Worm gear housing
Worm thrust bearings
REFER MANUFACTURER,S MANUAL FOR DETAIL
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16. FANS
Operational Checks:
Inspect bearing lubrication and check for proper oil level.
If ring-oiled, check for free revolution and adequately distributed oil.
Check bearing temperatures. If hot, determine cause and remedy the situation. Oil
temperature should not exceed 82 degrees Celsius (180 degrees Fahrenheit). White
metal temperature should not exceed 88 degrees C (190 degrees F).
Ensure a flow of water is getting to the bearings and that the water out temperature
is not excessively warm.
Ensure that the seals are intact and functional.
Feel and inspect for vibration.
Listen for unusual motor or fan noises.
Look for any loose material, which may get sucked into the fan.
Visually inspect bearing seals.
Lubricate drive assembly linkages.
Prior to Annual Shutdown:
Take vibration readings.
Check control room records of fan for :
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Annually:
FAN HOUSING
INLET CONE
Check for signs of wear or corrosion
Damage
Check clearance and fit up and ensure it is correct
ROTOR WHEEL
Check for signs of corrosion
Check for abrasive wears on blades.
Check that the wheel is completely clean, and that the blades and the shroud are
Free of any build up.
Check that the wheel is tight on the shaft
Check that the shaft is straight
Check for mechanical damage indicating an object has entered the wheel during
operation
Visually inspect for weld cracks, if in doubt, perform a liquid dye penetrate test
ROLLER BEARINGS
Drain bearings, take oil sample
Disassemble, clean and check clearance between rollers and the inside diameter of
the bearing outer ring.
Inspect the oil seals.
Check bearing gaps in housing.
Inspect rollers for flat spots.
Check bearing hold-down bolts for tightness
Clean top and bottom half of bearing housing split line
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COUPLING
Clean and inspect for internal wear.
Renew all worn sealing devices.
Renew all lubricants.
Re-torque all bolts.
Check for proper gap setting.
Check alignment and realign if required.
DRIVE MOTOR AND BELTS
SHAFT SEALS
Disassemble and check for wear.
Inspect rotor shaft for wear in seal area.
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17. TRAVAGRATE
Travagrate is the heart of Boiler firing equipment. Hence it is essential that it to be
maintained as per the following instruction, to ensure 100% availability during
operation.
OPERATIONAL CHECKS:
Check the hydraulic drive oil pressure, it should not be more than 28 Kg/cm2.
Maintain the oil level in the drive unit.
Lubricate the grate bearings once in a shift (once in 8 Hrs) with the specified
lubricant.
Check the tightness of the drive coupling.
Check the working of alarm system once in week.
Ensure all the moving parts of the hydraulic drive are lubricated.
Ensure the pressure gauges on the hydraulic drive is indicting properly.
Check for any oil leakage from the fittings and piping.
Ensure, drive inspection window glass is properly fastened, so as to avoid dust entry
to sump.
Keep the drive unit clean from dust and fine fuel/ash particles.
DURING SHORT SHUT DOWN FOLLOWING INSPECTION CAN BE CARRIED
OUT:
Prior to entering the furnace ensure it is sufficiently cool and free from ash.
Check the grate lock pins are in place and ensure its tightness.
Check the grate catenary, for any damaged components and loose fasteners.
Replace the damaged side and rear seal refractory if any.
Check for any burn out middle/side seal casting and replace if any.
Check the hydraulic drive oil filter for cleanliness. If the filter unit is defective replace
the same.
ANNUAL MAINTENANCE:
Prior to dismantling, check the distance between the catenary bottom to top frame.
If the distance is increased by 100 mm remove one chain link. Refer the erection
protocol for initial reading.
Check the chain for hole oblong if the hole size is increased by more than 2mm,
replace the chain link.
Check the alignment of the travagrate frame, shaft and coupling alignment.
Clean the grease piping.
Clean the bearing and refill with new grease.
Replace the defective bearing if any.
Replace damaged grate bars and grate castings if any.
Replace the worn out skid shoe/rail.
Replace worn out/deformed coking plate.
Check the side seal for looseness & damage. Replace the damaged casings and tight
the loose fasteners.
Check the floating seal for alignment and expansion clearance.
Repair the defective side and rear refractory castings, if any.
Replace the hydraulic drive oil once in six months.
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CAUTION
PROTECT THE GRATE COMPONENTS FROM MOISTURE AND RUST DURING
OFF-SEASON AND IDEAL PERIOD OF THE BOILER.
RAINWATER CAN ENTER THE FURNACE THROUGH THE RETURN BAGASSE
CARRIER OPENINGS. THIS HAS TO BE AVOIDED; OTHERWISE IT WILL
DAMAGE THE FRONT PLATE REFRACTORY AND GRATE COMPONENTS.
NEVER KEEP THE GRATE UN OPERATED FOR LONG PERIOD OF TIME DURING
OFF-SEASON, THIS MAY LEADS TO CHAIN RUSTING AND JAMMING OF THE
GRATE MOVEMENT.
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TUBE FAILURES
Operating a boiler with a known tube leak is not recommended. Steam or water
escaping from a small leak can cut other tubes by impingement and set up a chain
reaction of tube failures. Large leaks can be dangerous. The boiler water may be lost,
the ignition may be lost, and the boiler casing may be damaged.
Small leaks can some times be detected by the loss of water in the cycle or system, a
loss in boiler water chemicals or by the noise made by the leak. If a leak is suspected
the boiler should be shut down as soon as possible by following normal shut down
procedures (If situation permits).
After the exact locations of the leak or leaks are identified, the leaks may be repaired by
replacing the failed tube or by splicing in a new section of tube, confirming to IBR code.
CAUTION:
WARNING;
EXCESS WELD PENETRATION EVEN CAUSE INTERNAL TUBE EROSION AND RESULTS IN
TUBE FAILURES.
INTERNAL OBSTRUCTION (in water / steam mixture side) WILL AGGREVATE THE
CAUSTIC GOUGING PROCESS AND LEADS TO TUBE FAILURES.
An investigation of tube failure is very important so that the condition causing the tube
failure can be eliminated and future failures can be prevented. This investigation should
include a careful visual inspection of the failed tube and in some cases a laboratory
analysis.
It is recommended that every effort be made to find the cause of tube failures before
operation is resumed.
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6. The failed tube sample nicely packed in plastic bag / wooden case accompanying
duly filled format as given below with water chemistry of boiler log sheets should be
sent to TBW H.O for metallurgical investigations .
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DATE:
Section E
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(Please mark)
2. DIMENSIONAL MEASUREMENT
4. HARDNESS TESTING
Section E
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D.M.
Water
Condensate
F.W. to
Boiler
Drum
water
pH
TDS PPM
Conductivity m/s
SiO2 - PPM
Fe2O3 - PPM
CHLORIDES AS CL PPM
M-ALKALITY OF CaCO3 PPM
P-ALKALITY AS CaCO3 PPM
HYDRAZINE OR SO3 PPM
(The above are the minimum required data. More are welcome)
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Section E
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FIGURE 1
Section E
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TABLE #1
WPS NO
Section E
BASE MATERIAL
P1 TO
CARBON STEEL TO CARBON
P1
STEEL
P3 TO
CARBON MOLY TO CARBON
P3
MOLY
P3 TO
CR MOLY TO CR
P3
MOLY
P4 TO
1-1/4 CR TO 1-1/4 CR
P4
P5 TO
2-1/4 CR 1 MOLY TO
P5
2-1/4 CR 1 MOLY
P8 TO
STAINLESS TO STAINLESS
P8
FILLER METAL
ER 70S.2
E7018
ER80S.B2
E7018A1
ER80S.B2
E8018B2L
ER80S.B2
E8018B2L
ER90S.B3
E9018B3L
ER308
ER308-16
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Section E
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Note:
I. This type of the repairs entails some risk. Internal deposits. Particularly copper,
may exist under the crack which will result in damaging the parent and/or weld
metal causing failure in a short period of time.
II. Over-heating the tube may have caused the longitudinal crack. In this case, the
tube has swollen and the weld thickness reduced. In the modern welded wall
construction, it is difficult to accurately measure the tube diameter or
circumference to detect the minor swelling. If visual indicates swelling and
reduction of wall thickness at the crack, a complete replacement of the damaged
tube length is the best solution.
III. A circumferential crack indicates a failure due to excessive stress applied by
expansion restriction, bending or fatigue; such cracks can be repaired by
welding. However, unless the cause of failure is diagnosed and corrected,
another similar failure could occur at or near the original crack.
IV. Also the tube cannot be cleaned from inside and there is always a possibility
internal deposits will contaminate the weld.
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RE EXPAND
AREA.
6 THIS
M.M SEAL
WELD
INSIDE
OF
NOTE:
1. Clean and dry area to be seal welded.
2. Use E 7015, E 7016 or E 7018 welding electrodes.
3. Seal weld to be made in three passes.
4. SA 515 and SA 516 drum material required pre heating up to 200 F
5. Re expand the tube seat after seal welding as shown
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DRY STORAGE
When it is known that a boiler is to be idle for a considerable length of time and that a
brief period will be allowed for preparation to return it to service, the dry storage
method is recommended. In this method the unit is emptied, thoroughly cleaned
internally and externally dried, and then closed up tight to exclude both moisture and
air. Trays of lime, silica gel, or other moisture absorbent may be placed in the drums to
draw off the moisture in the air trapped by the closing up of the boiler.
The following general procedure is recommended when placing a unit into dry storage.
1.
Fire the boiler according to the normal start-up procedure and establish 50 psig
drum pressure. Secure the boiler and when the pressure decays to 20 psig,
immediately drain the boiler and headers under air. As soon as possible, open
the drums to allow air to circulate for drying of all internal surfaces.
This step is included for a unit that has been in service and is to be placed into
storage. For a unit that has never been in service, start with Step 2.
2.
If the unit is full of water and cold, drain the unit under air. All non-drainable
boiler tubes and superheater tubes should be blown with compressed air. If an
external source of heat is available such as a steam coil air heater, portable
heaters, etc., operate these heaters to assist in drying the internal boiler
surfaces.
Install trays (of non-porous construction and capable of passing through the
drum man way) containing the moisture absorbent (silica gel is preferred) into
the drums. Insert the trays into the drum being certain that none of the
absorbent comes into contact with the metal surface of the drum. To insure
against an overflow of corrosive liquid after the moisture has been absorbed, the
trays should not be more than full of dry absorbent. The amount of absorbent
can vary but the recommended minimum is one pound of absorbent per 1000
pounds per hour steam flow capacity of the unit.
3.
Attach a source of nitrogen to the steam drum vent, close all other vents and
drains and pressurize the boiler to 10 to 15 psig with nitrogen. The amount of
nitrogen required will vary according to the volume of the unit.
4.
With the boiler and superheater pressurized, alternately open all boiler drains
(including superheater) to purge air from the unit until pressure decays to zero.
It may be necessary to repeat this process several times to reduce the amount of
oxygen left in the unit to a minimum.
5.
The unit should now be stored under 5 to 10 psig nitrogen pressure maintained
at the steam drum. To maintain the nitrogen pressure, all connections and valves
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WET STORAGE
The advantage of employing the wet storage procedure is that the unit is stored
completely wet with the recommended levels of chemicals to eliminate a wet-dry
interface where possible corrosion can occur. It is suggested that volatile chemicals be
used to avoid increasing the level of dissolved solids in the water to be used for storage.
In preparing a unit for wet storage, the following procedure is recommended.
1.
The unit should be filled with deaerated, de-mineralized water treated with 200
ppm hydrazine (N2 H4 ) for oxygen removal and sufficient ammonia (NH3)in order
to attain a pH of 10 (for de-mineralized water, this will require approximately 10
ppm ammonia).
2.
3.
Fill the unit with the treated de-mineralized water to the normal centerline of the
steam drum. Stop fill.
4.
Back fill the superheated with treated de-mineralized water until a rise in steam
drum level is noted. Continue filling until water exits from the steam drum vents.
After filling, all connections should be blanked or tightly closed.
If storage continues into winter, ambient temperatures below the freezing point
of water create a real hazard to the boiler pressure parts and it will be necessary
to provide a means of keeping the unit warm to avoid damage.
6.
At some later date when the unit is to be placed into service, the boiler can be
drained to normal start-up water level and placed into operation.
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7.
PROJECT NO-PB0751
8.
9.
No unit should be stored wet when there is any possibility of a temperature drop
to the freezing point unless sufficient heat can be provided to the unit to
eliminate the danger of water freezing and subsequent damage to pressure
parts.
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NITROGEN BLANKET
Nitrogen should be introduced through a T fitting or one vent (or drain) at each of the
following locations:
1.
2.
Drum vents.
Superheater outlet header connection.
The T fitting is to be installed between the pipe (or header) and the vent (or drain)
valve. The nitrogen inlet to the T should include a stop valve identical to the vent (or
drain) valve. The stop valve and T fitting should be a permanent addition to the
location listed.
The nitrogen required to seal the drainable components may be supplied from a
permanent nitrogen system or portable tanks located near the vent elevations. Due to
differences in plant layout, the owner should choose his own method of piping the
nitrogen, either from their permanent system or from portable tanks, to the vent (or
drain) locations listed.
CAUTION : THE UNIT SHOULD BE PROPERLY TAGGED AND THE APPROPRIATE
WARNING SIGNS ATTACHED NOTING THAT THE BOILER IS IS STORED UNDER
NITROGEN PRESSURE AND THAT COMPLETE EXHAUSTION OF THE NITROGEN MUST
OCCUR BEFORE ANYONE ENTERS THE DRUM. BEFORE ENTERING DRUMS TEST TO
PROVE THAT THE OXYGEN CONCENTRATION IS AT LEAST 19.5 percent.
PROTECTION OF EXTERNAL SURFACES
Gas side corrosion of an idle boiler can cause considerable damage, especially to the ash
hoppers, expansion joints, dampers, boiler casing, fuel burning equipment, baffles, and
flues and ducts.
Flue dust, ash, slag, or cinders from sulphur bearing fuels contain sulphuric acid. When
moisture is added, a dilute acid is formed which is very corrosive. In preparing the boiler
for storage these accumulations must be removed by either blowing with air lances,
washing with water, scraping, or brushing. In most cases the deposits cannot be
completely removed by mechanical means & must, therefore, be neutralized with
alkaline water. The alkaline flush should be continued until the water leaving the boiler
is completely neutralized. Litmus paper may be used to determine the acidity of the
wash leaving the boiler.
After the flushing operation has been completed, the boiler should be filled with treated
water and fired with a low sulphur fuel to completely dry the setting. During the storage
period it may be necessary to use auxiliary heaters and blowers to maintain the metal
temperature above the dew point. These auxiliary heaters and blowers are also
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necessary to prevent freezing when the wet storage method is used and the
temperature is likely to fail below freezing.
In areas with extremely corrosive atmosphere, all machined surfaces on fuel burning
equipment should be protected with a preservative coating.
Throughout the storage period, particular attention must be given to make sure that no
fuel leakage occurs. It is, therefore, recommended that all oil and gas connections to
burners be disconnected.
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1.
2.
3.
4.
5.
A Final Note
A good rule to follow when deciding whether or not to water wash is, A partial water
wash is worse than no water wash at all.
Section E
Page 55
Section F
Page i
INDICATION
PROBABLE CAUSE
PROBABLE SOLUTION
1.
2.
3.
Excessive
water
level fluctuations
4.
Low S.H.
Temp.
steam
5.
6.
Furnace
unsteady.
Section F
temp.
Control
bagasse
feeding and excess air
Ensure start up vent and
S.H. drains are kept open
fully.
Secondary combustion of Adjust secondary
bagasse near S.H. zone.
air setting.
Furnace tubes are dirty
Clean the tubes
Uneven fuel feeding.
Adjust the fuel feeder
variation.
Inconsistent fuel quality.
Maintain quality of the
fuel.
Page 1
7.
7.
High conductivity
in steam
High
temp.
flue
gas
8.
9.
10.
11.
12.
13.
14.
15.
Section F
Page 2
16.
17.
Section F
Page 3
Shut off all steam flow & water flow from the boiler.
Simultaneously, if feed water has become available and the operator is assured that no
pressure parts have been damaged,
Take the feed water control system into manual mode.
Allow the water flow to boiler gradually to normal water level. (Do not hurry up
which may lead for sudden quenching and tube leak.)
If pressure parts damage is suspected,
b. Depends upon the circumstances run the I.D. & F.D. Fans and allow very less air
to furnace to cool the boiler so as to examine the extent of damage.
Open the drum vents when the pressure drops below 2 kg/cm2.
Section F
Page 4
Drain the boiler when the drum metal temperature is 90C following normal draining
procedures.
Section F
Page 5
Operator error.
Foaming
Action
Reduce the water level immediately by operating the intermittent blows down to
maintain the drum level.
Section F
Page 6
Tube rupture.
Action
1. Take the furnace draft and airflow controls system into manual mode and maintains
the furnace pressure.
2. Never increase fuel/auxiliary fuel/air flow suddenly.
3. In case of tube failure take the boiler out of service immediately.
Section F
Page 7
Action
1. Immediately open the startup vent valve and reduce the S.H. steam temperature to
safe limits.
2. Avoid sudden fuel flow into the furnace.
3. Avoid sudden load fluctuations on the boiler which leads for uncontrolled fuel feed
into the furnace.
4. Avoid secondary combustion in the superheater zone by adjusting the secondary
airflow.
5. Check the excess air levels and control the primary airflow by observing the O2/CO2
levels in the flue gas.
6. Keep the water wall tubes clean by monitoring the combustion.
Section F
Page 8
2.
With the mixture of unburned fuel with air in explosive proportions and the
application of heat sufficient enough to raise the temperature of the mixture to
ignition point.
Action
1.
2.
3.
Section F
Page 9
BOILER IMPLOSIONS
Causes
Too negative furnace draft due to failure of furnace pressure control system.
Action
In case of sudden fuel trip take the draft control system into manual mode and
maintain the furnace pressure.
Section F
Page 10