ISGEC JOHN THOMPSON

PRESENTATION ON

SHISHIR SAXENA
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ISGEC JOHN THOMPSON

TOPICS COVERED

STAGES OF COMMISSIONING

PRE START CHECKS

EFFICIENCY CALCULATION

TIPS ON EFFICIENT OPERATION

EMERGENCIES & TROUBLE SHOOTING

ISGEC JOHN THOMPSON

COMMISSIONING STAGES

ISGEC JOHN THOMPSON

COMMISSIONING & STABLIZATION STAGES

1- Mechanical
Erection
Completion

11-PG Test

2- Hydro test

3. Duct Leak
test

10-Commercial
steaming

STEPS OF
COMMISSIONING

9-Steam
Blowing

4-Motor Trial

5-Trial run of
rotating
equipment

8-Safety Valve
Floating
7-Alkali
boil out

6-Refractory
Dry Out

ISGEC JOHN THOMPSON

HYDRAULIC TEST
WHY ??
To check the strength of all welding carried out as well as parts
strength.
CARE TO BE TAKEN
Boiler should be in cold condition.
Water used must be as near as possible at the temperature of the boiler
pressure parts temperature & difference should not be more then 50 deg.
Maintain boiler water pH between 8.5 to 10.5 & hydrazine to approximately
150 ppm.
Boiler must be hydro tested to 1.5 Times design pressure only for first time
test after completion of erection as per Regulation requirement.

ISGEC JOHN THOMPSON

LEAK TEST OF DUCT AND OTHER AREAS

WHY
To ensure no Flue gas or Air leakage. This also reflects completion of welding
done on non pressure parts
IF NOT DONE:
Leakages during operation, loss in efficiency, Load restriction
CARE TO BE TAKEN
Take leak test of all ducting preferably with smoke.
Take enough care for Air pre-heater Leak test
Roof sealing to be carefully examined.
Mark the leak area for attending it later.
Carry out repair with good engineering practice

ISGEC JOHN THOMPSON

NO LOAD/LOAD TRIAL OF MOTORS & AUXILIARIES

WHY
To ensure smooth working of Motors, Auxiliaries
CARE TO BE TAKEN
Proper Electrical connection to motors.
All necessary Electrical protection in place.
Motor No Load trial for 4-8 hrs
Final alignment of motor with rotating equipment
Load trial with Rotating equipment for 8 hrs.
Measure Vibration.
Watch Bearing temperature.

ISGEC JOHN THOMPSON

REFRACTORY DRY OUT / SLOW FIRING

WHY
Controlled & Slow heating of refractory to remove moisture within it. Pressure
parts are also heated up for the first time in controlled manner
IF NOT DONE:
Cracking or separation of refractory may occur. Pressure parts may face
thermal shocks
CARE TO BE TAKEN
In deciding initial heating temperature and its duration the following factors
should be considered:
Estimated moisture content of walls and refractory.
Thickness of walls and refractory.
The distance from heat source.
Strict follow up of Drying curve
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ISGEC JOHN THOMPSON

CHMICAL / ALKALI BOIL OUT

WHY ??
To remove oil, grease and other foreign particle
IF NOT DONE THEN ??
Oil, Grease has very low heat transfer coefficient, if not removed they
can hindrance in local heat transfer thus tube failure may occur.
CARE TO BE TAKEN :

Chemicals used must never be introduced in solid form but must first be
dissolved in water and introduced in to the boiler system.

Alkali boil out is carried in Two stages : Atmospheric boil out at low pressure
for pre cleaning followed by pressure boil out at 75% of working pressure of
40 kg/cm2 whichever is less.

The solution is formulated by dissolving the following proportionate

quantities for Atmospheric boil out.
0.05% Na2PO4.7H2O (500 PPM disodium phosphate)
0.1% Na3PO4.12H2O (1000 PPM trisodium phosphate)
Surfactant (Washing powder) 10 to 20 PPM to reduce surface tension

ISGEC JOHN THOMPSON

CHMICAL / ALKALI BOIL OUT

The atmospheric boil out is carried for 12 hours giving blowdowns from all
header and drum drains every two hours.

The solution is formulated by dissolving the following proportionate

quantities for pressure boil out.
0.05% Na2PO4.7H2O (500 PPM disodium phosphate)
0.05% Na3PO4.12H2O (500 PPM trisodium phosphate)
Surfactant (Washing powder) 10 to 20 PPM to reduce surface tension
Boiler water samples are obtained from CBD and analysed for alkalinity,
phosphate content, dissolved silica and oil content.
Repeat every 2 hours till the oil level in the sample falls below 5 PPM.

Pressure boil out is declared complete when oil level in sample falls below 5
ppm or after a minimum of 12 hours.
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ISGEC JOHN THOMPSON

SAFETY VALVE FLOATING

WHY ??
TO CHECK WORKABILITY WITH STEAM AT HIGHEST PRESSURES OF SAFTEY
VALVES PROVIDED ON BOILER
Set Pressure
This is the pressure at which the valve begins to lift from the valve seat.
Full lift pressure
This is the pressure at which the valve reaches its fully open position.
Closing Pressure
Closing pressure is the pressure at which the valve reseats.
Blow down %
The blow down is the difference between the set pressure and the closing
pressure expressed as a percentage of the set pressure e.g.
Blow down % = Set pressure-Closing pressure x100
Set pressure
And is usually in order of 2 to 4 .
Sequence of setting :
Drum 1- Drum 2 - Superheater

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ISGEC JOHN THOMPSON

STEAM BLOWING
WHY
To descale and remove foreign materials from steam pipes leading to turbine
IF NOT DONE THEN:
Damage to turbine blades from such material in the course of normal operation.
PRINCIPLE
STEAM BLOWING IS CARRIED OUT BY PUFFING METHOD TO:
Dislodge rust/scales from pipe work by thermal shocks.
High momentum of expanding steam in the pipe work purges out the loosened
material.
It is required to create a higher momentum during steam blowing than
possible during operation of the unit. This is applicable for all steam piping
leading to turbine.
Care to be taken to terminate the discharge to a safer place
Steam blowing completion criteria to be discussed & decided as per the
application of steam

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ISGEC JOHN THOMPSON

PRE START CHECKS

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ISGEC JOHN THOMPSON

COMMERCIAL STEAMING
PRE-START CHECK
1.. Filling the boiler
If hot water is used the boiler, care should be exercised to feed slowly to
avoid severe temperature strains.
Make sure that all drains are closed prior to filling the boiler and that the
unit is adequately vented during filling procedure.
Fill until water is visible in the gauge glass. The steam drum vent should
remain open during the filing operation and during initial firing.
It shall not be closed until all the air is vented from the unit and an
appreciable quantity of steam is issuing therefore.
The unit may be considering free of air when the drum pressure reaches 2
kg per cm sq.
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ISGEC JOHN THOMPSON

2..

Super heater Drains/ Vents

The super heater should be drained prior to lighting off through lines free from
back pressure.
The super heater drain should be closed, the super heater outlet vent which
must remain open to assure a flow of steam in order to protect the super-heater
elements from overheating until the boiler has gone on the line and is carrying
load.
The vent valve may be throttle some what when the boiler pressure becomes
sufficient to assure considerable flow through the super heater.

3.. Steam Gauge

The steam pressure gauges should be checked as soon as sufficient pressure is
available.
Blow out the connecting piping then check the action of the gauge needle to be
sure that it is functioning.
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ISGEC JOHN THOMPSON

4.. Water Gauge

Check & Flush the water gauge if reqd
5.. Water Level
Water level is to be maintained 50% level of gauge glass.
During normal operation, the water level in the gauge glass should be observed
periodically even though the boiler is equipped with a reliable feed water
regulator or remote water level indicator.
Never shutoff the feed water supply to a steaming boiler completely, not even
for only a short period of time.

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ISGEC JOHN THOMPSON

6.. Warming up Steam Lines
While the boiler is being brought up to pressure, provision should be made for
gradually heating and adequately draining all cold steam piping. If the main
steam line is cold, it is generally advisable to raise pressure on the line from
the beginning by opening all valves.
7.. Gas Temperature
The stack gas temperature will rise with an increasing load and fall with a
decreasing load..
If the gas temperature is above normal, look for
a. High excess air.
b. Fouled Firesides
c. Secondary combustion

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ISGEC JOHN THOMPSON

8.. Steam Temperature
The steam temperature varies with the load, raising as the load decreases.
With constant load, abnormally high superheat steam temperature may be
caused by :
a. Too high excess air.
b. Too low feed water temperature
c. Secondary Combustion
d. Improper operation of automatic steam temperature indicating and
control equipment.
Super heater steam temperature below normal for the load may be caused by
a. Too low excess air
b. Too high feed water temperature
c. Excessive moisture carry over from the boiler
d. Excessive external deposits on super heater tubes
e. Improper operation of automatic steam temperature
indicating and control equipment

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ISGEC JOHN THOMPSON

9.. Blow Downs
The data on blow downs should be recorded. Their frequency and duration are
best determined from a chemical analysis of the boiler water.
The use of the boiler bottom blow-off valves should be restricted to periods of
moderate steaming rates and preferably very low combustion rate.
The bottom blow down should always be used to free a boiler of sediment
when the boiler is being cut out.
Never make the blow down long enough to loose sight of the water in the gage
glass.
Check the valves for leaks occasionally
A continuous blow down line offers the best means for controlling the
concentration of soluble salts in the boiler water, because, it maintains a
relatively constant concentration
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ISGEC JOHN THOMPSON

10.. Soot Blowers
Soot blower should be operated as often as necessary, to keep the external
heating surfaces clean. Watching the gas temperature to the stack may have an
indication of the need for blowing soot.
Never use soot blowers on a cold boiler.
It is good practice to blow soot just before taking the boiler out of service.
Be sure that the combustion rate is high enough when blowing soot so that the
fires are not extinguished.
Open the drain valve and let the steam blow freely long enough to heat the lines
thoroughly before operating the soot blowers.
The soot blower piping should be drained before each use to prevent damage to
the soot blower elements by slugs of water.

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ISGEC JOHN THOMPSON

EFFECTIVE START UP

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ISGEC JOHN THOMPSON

EFFECTIVE START UP

RAISE THE PRESSURE AS PER THE COLD START-UP CURVE.

KEEP THE START-UP VENT IN OPEN CONDITION, TILL STEADY FLOW OF

STEAM IS ENSURED.

PRIOR TO ADMIT FUEL, ENSURE THE BED TEMPERATURE IS ADEQUATE

FOR IGNITION (350-400C)

MAINTAIN S.H STEAM TEMPERATURE WITH IN THE LIMIT

CONTROLLING THE FIRING & START-UP VENT VALVE OPENING.

DO NOT INCREASE THE STEAM FLOW > 50% TILL THE WATER QUALITY IS

BY

UNDER CONTROL.

MAKE SURE THAT ALL THE ASH HANDLING SYSTEM IS RUNNING RIGHT
FROM THE BEGINNING

MAKE SURE THAT UNBURNT & ASH ARE CONTINUOUSLY DISCHARGED

FROM HOPPER, IF REQUIRED LITTLE HAMMERING OF HOPPER MAY BE
DONE.
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ISGEC JOHN THOMPSON

EFFICIENCY CALCULATION

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ISGEC JOHN THOMPSON

Boiler Efficiency Measurement Procedures

(B) BY IN DIRECT METHOD ( ID) : [100 (Sum of losses)]

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ISGEC JOHN THOMPSON

Calculation for theoretical air required for combustion

C + O2 -----
12 32
1
2.67
C
2.67C

CO2
44
3.667
3.667 C

C = Carbon per kg fuel

S + O2 ---- SO2
32 32
64
1
1
2
S
S
2S

S = Sulphur per kg fuel

2H2 + O2 ---- 2H2O

4
32
36
1
8
9
H
8H
9H

H = Hydrogen per kg fuel

Theoretical O2 required = 2.67C + S + 8H O

Since Air contain 23% O2 by weight
Theoretical Air required
=
(2.67C + S + 8H O)/0.23
=
11.61C + 4.35S 34.78(H-O/8)

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ISGEC JOHN THOMPSON

Excess Air = O2 / (21 O2) x 100%

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ISGEC JOHN THOMPSON

The data collected are

for
a
boiler
using
bagasse as the fuel.
Find out the boiler
efficiency by indirect
method.

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ISGEC JOHN THOMPSON

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ISGEC JOHN THOMPSON

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ISGEC JOHN THOMPSON

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ISGEC JOHN THOMPSON

m = mass of dry flue gas

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ISGEC JOHN THOMPSON

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ISGEC JOHN THOMPSON

AAS = Actual Air Supplied = Theoretical Air + Excess Air

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ISGEC JOHN THOMPSON

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ISGEC JOHN THOMPSON

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ISGEC JOHN THOMPSON

TIPS FOR EFFICIENT

OPERATION OF BOILER

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ISGEC JOHN THOMPSON

EFFICIENT OPERATION

FACTORS
BOILER

AFFECTING

PERFORMANCE

Gas temperature leaving air heater

Excess air / O2 at Eco. outlet

Unburnt carbon in ash

Air leakage into furnace

Feed water and Boiler water quality

Deaerator in service

OF

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ISGEC JOHN THOMPSON

EFFICIENT OPERATION
GAS TEMPERATURE LEAVING AIR HEATER

While designing boiler gas temperature leaving air heater is

optimally selected to give optimum boiler efficiency.

Increase in gas temperature of 20C will reduce the boiler

efficiency by about 1%.

Gas temperature may increase due to

*

Fouling of heat transfer surfaces

Choking of air heater tubes

Higher excess air operation

Incomplete combustion of fuel

Design gas temperature leaving air heater is 150C

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ISGEC JOHN THOMPSON

EFFICIENT OPERATION
EXCESS AIR

For completing the combustion of any fuel required air/oxygen has to

be supplied which is called stoichiometric air

In boiler to ensure completion of combustion additional air more than

stoichiometric requirement is supplied which is called excess air

Recommended excess air is ~ 20%

Increase in excess air more than recommended would reduce boiler

efficiency

Increase in 5% excess air would reduce the boiler efficiency by 0.2%

Higher excess air also increase power consumption of FD and ID fan

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ISGEC JOHN THOMPSON

EFFICIENT OPERATION

UNBURNT CARBON

In boiler design every attempt is made ensure 100% combustion of

fuel or carbon

But practically it is difficult to achieve this

Small portion of carbon gets entrapped in ash and get carried away
from furnace

Flue gas also carries small portion carbon monoxide

Boiler design considers such unburnt loss in design stage itself.

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ISGEC JOHN THOMPSON

EFFICIENT OPERATION

UNBURNT CARBON

Any reduction in unburnt loss during operation will help to improve the
boiler efficiency and saving in fuel

It is necessary to regularly monitor unburnt loss to get better

performance

Unburnt can be reduced by proper tuning of combustion parameters like

excess air, distribution of secondary air & primary air by actual field
test.

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ISGEC JOHN THOMPSON

EFFICIENT OPERATION

AIR LEAKAGE INTO FURNACE

To get good performance of boiler all air shall be supplied

through fans and air heater

In

practice

as

boiler

operates

at

negative

pressure

considerable air leaks into furnace through duct joints,

access doors, instrument opening etc.

Such ingress of air into boiler makes

Air heater ineffective

Starves the fuel of oxygen

Increases dry gas loss, reduces boiler efficiency

Hence to get good performance of boiler keep watch on such

leakage, keep all openings properly closed.

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ISGEC JOHN THOMPSON

TIPS FOR EFFICIENT OPERATION OF THE BOILER:

Operation of the boiler with higher excess air than recommended

means, higher dry gas loss and lower efficiency and higher power
consumption. Hence, it recommended to operate the boiler at
indicated values.

Keep the gas temperature leaving closer to predicted value indicated.

Higher the gas temperature, lower would be the efficiency.

Adjust the secondary air to get lower unburnt in ash. Reduction in

unburnt will improve the boiler efficiency.

Prevent any leakage in furnace, ducting etc. Ingress of air into the
furnace will reduce efficiency and increase power consumption.

Always ensure minimum 30% MCR flow through superheater

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ISGEC JOHN THOMPSON

EMERGENCIES
&
TROUBLE SHOOTING

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

In principle the immediate objective in an emergency situation will be to
reduce or cease production of steam and to relieve existing steam
pressure so as to reduce boiler pressure.

LOSS OF DRAUGHT
If the forced draught is lost for any reason i.e. power or mechanical
failure the combustion efficiency will be lost resulting in heavy smoke
from stack.
In this event the boiler must be shut down until full draught conditions
are restored. If an I.D. Fan is provided it may be possible to operate on
this solely under reduced boiler load

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

POWER FAILURE
Loss of electric power to auxiliaries can have very serious consequences
If turbine driven standby feed and circulating pumps are provided switch
over to these immediately.
Place the boiler immediately under manual control.
Reset all electrical controls to stop position to avoid overloading motors
when re-starting.

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

COLLAPSE OF REFRACTORY
An appreciable fall of internal Refractory may not only interfere with the
gas flow through the boiler, but could also cause serious mechanical
damage to heating elements.
Careful examination should therefore be made of adjacent heating
surfaces at the earliest opportunity.
Rebuild the refractory and dry out slowly before returning into service.

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

LOW STEAM DRUM WATER LEVEL
CAUSES.
Feed water controller/control valve malfunction.
Boiler feed water pump failure.
Abnormal increase in steam load on the boiler.
Boiler pressure parts failure.
Operator negligence.
ACTIONS
If level is below normal and still above the very low-low, step should be
taken to maintain the level by correcting the above mentioned causes.

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

LOW - LOW STEAM DRUM WATER LEVEL

In case boiler level falls below low-low level it will trip on auto. In case it
does not trip following action has to be taken to avoid water starvation in
pressure parts of the boiler.
Shut off the fuel supply to extinguish the fire in furnace as quickly as
possible.
Close the CBD line.
Shut off the steam being discharged from the unit by closing the
header isolation valves.
Feed water supply to the boiler is to be restored after identifying and
rectifying the problem.
The make up of water to steam drum can be done as soon as problem is
rectified, if some water is available in steam drum.
In case no water is available in the drum, water should not be taken until the
temperature of pressure parts reduces to safe level.

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

HIGH STEAM DRUM WATER LEVEL
CAUSES
* Feed water controller/control valve malfunction.
* Decrease of boiler steam load.
* Foaming due to impurities in boiler water, high solid content etc.
EFFECT:
Abnormally high water level should be avoided as it may lead to carry
over and damage of super heater coils, turbine blade erosion and
turbine blade scale coating.
ACTIONS
* Reduce the drum water level immediately by opening the intermittent
blow (IBD) and continuous blow down (CBD) line valves.
* Place the feed water controller on manual mode.
* If drum level increases to high-high point, boiler will trip on auto mode.
If it does not trip, trip manually.

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

BOILER PRESSURE PARTS FAILURE
INDICATIONS
The difference between steam flow and feed water flow has increased
Fluctuation in furnace pressure
Increase/decrease in super heater steam temperature.
Decrease in flue gas temperature
CORRECTIVE ACTIONS
Operator has to take corrective actions depending upon the type and
zone of tube failure as explained.
Tube repair is to be carried out by authorize skill fitter & welder.
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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

EXCESSIVE SUPERHEATER TEMPERATURE
CAUSES
Attemperator control valve malfunction.
Jamming of Strainer in attemperator feed water line.
Jamming of NRV in its closed position.

Isolation valves along the attemperator are kept closed.

Super heater tube leakage.

Excessive Fuel firing rate.

Drum level low

ACTIONS
Check the attemperator water flow.
Reduce fuel-firing rate.
Check the water level in the drum.
Decrease the temperature of combustion air.
Increase consumption of steam from boiler , if necessary by opening the
startup vent valve Causes for the failure of super heater temperature
control are.

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

DRUM SAFETY VALVE POPPED
CAUSES
Excessive fuel firing rate.
Sudden decrease in steam load.
Faulty setting of safety valve

ACTIONS
Reduce fuel-firing rate.
Open the start up vent.
Observe the steam flow of the super heater . If there is no flow , trip the
boiler.
Maintain the steam drum level.

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ISGEC JOHN THOMPSON

EMERGENCIES & TROUBLE SHOOTING

SUPERHEATER SAFETY VALVE POPPED.
CAUSES
Excessive fuel firing rate .
Sudden decrease in steam demand.
Faulty setting of safety valve .
ACTIONS
Reduce fuel firing rate.
Open the start up event vent if required .
Maintain the steam pressure & if does not reset at preset pressure reduce
the pressure further to enable for adjustment of safety valve setting.

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ISGEC JOHN THOMPSON

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