Bhatia Gummidipoondi WHRSG O&m Manual Final

ENMAS GB POWER SYSTEMS PROJECTS LIMITED
Chennai 600 018 INDIA
OPERATION AND MAINTENANCE MANUAL

CUSTOMER: BHATIA COKE & ENERGY LTD GUMMIDIPOONDI, TAMILNADU PROJECT CODE : IB002A & IB004A 2 x 26.4 TPH/71 kg/cm/4905 C WHR BOILER.
FOREWORD
TO
INSTRUCTIONS
These recommendations and instructions have been written as a direction to the starting up and operation of the 2 X 26.4 TPH Waste Heat Recovery Boiler supplied to M/s. BHATIA COKE & ENERGY LIMITED, GUMMIDIPOONDI, TAMILNADU.
The recommendations and instructions are for the guidance of competent and responsible engineers having knowledge of standard operational procedure and routine maintenance of boiler plant.
It is appreciated that conditions on individual plant may require minor modifications to the instructions, but major changes should not be made without prior consultation with the boiler manufacturer.
BOILER OPERATION & MAINTENANCE MANUAL
Page.No.1


Important Instruction to End User

The instruction provided in this manual are Standard practices on boiler maintenance as per manufacturer / consultants years of experience in the field of Pressure and Process equipment operation and maintenance. It is highly recommended for the end user to ensure the operation team is familiar & qualified to operate Waste Heat Recovery Steam Generator as per the instructions of Original Equipment Manufacturer [EGBPSPL] for operations & maintenance of the system. The Operational parameter will vary drastically, if the recommended input parameter is not maintained.
Quality
of
Feed
Water
and
Boiler
water
should
be
maintained
as
per
the
recommendation to avoid the failure in pressure parts.
Hot Flue Gas (COFG) Quality & Quantity should be within the Manufacture recommended range.
Over-Loading of Equipments is not recommended at any point of time.
Utility inputs from End user should be within the recommendation.
EGBPSPL here by confirm that the user is responsible for the cause and failure of boiler unit due to violation of recommendation given at the Project stage.
ENMAS GB POWER SYSTEMS PROJECTS LIMITED, CHENNAI INDIA.
Page.No.2


VOLUME - I
BOILER OPERATIONS
CONTENTS
CHAPTER No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
DESCRIPTION INTRODUCTION AND SCOPE GENERAL & TECHNICAL INFORMATION DESCRIPTION OF BOILER PLANT DESIGN DATA FOR BOILER PERFORMANCE BOILER PLANT SAFETY AND PROTECTION FEED AND BOILER WATER BOILER OPERATIONS SHUT DOWN, TUBE FAILURES, TROUBLE SHOOTING BOILER MAINTENANCE ANNEXURE
PAGE No 4 18 22 49 54 61 96 184 201 223
Page.No.3


CHAPTER 1
INTRODUCTION AND SCOPE
Page.No.4


CHAPTER 1
INTRODUCTION AND SCOPE
CONTENTS
SL.NO. a. b. c. d. e. f. g.
DESCRIPTION Radiant Chamber Steam Drum Water Wall Panel Super Heaters Supports & Hangers Buck Stays Economizer
PAGE NO 8 8 8 9 9 9 10
Page.No.5


CHAPTER 1 INTRODUCTION AND SCOPE

The boiler supplied for this contract is of WHRB (Waste Heat Recovery Boiler) which is located at downstream of Coke Oven to recover waste heat from the Oven exhaust. The salient features of the boiler are as described below:-
The boiler is of Water tube, natural circulation, bottom supported, single drum, all welded type pressure part design, negative/suction draft waste heat recovery steam generator type. The boiler allows unrestricted and uniform upward expansion ensuring better leak tightness and low thermal stress for pressure parts over prolonged periods.
The boiler has enclosure of radiant chamber surrounded by water cooled walls to ensure better optimum recovery of heat from the hot flue gas from coke oven exhaust.
The supporting structure consists of the main columns, their foundation, the framework for the boiler and the built-in auxiliarys supports and the section girders for bracing the structure. The calculations of the column strength takes into account an earthquake resistant factor.
The gallery supports outside and over the main structure consisting of a sectional girder frame properly spaced and braced, for the safe working at different levels as well as to approach highest elevation in the boiler, for the operation and maintenance of the boiler.
Hot flue gases, from the Coke oven exhaust is supplied normally at 900 to 950 C which is considered for sizing the boiler pressure parts. The Hot flue gas shall be supplied at
approximately 0.0 m elevation with a flange to connect the hot flue gas duct to the boiler. The duct cross section considered is approximately 2.875 x 1.555 (ID) m. The flue gas is routed through refractory lined hot flue duct to the boiler.
1 No.
Hydraulic Operated Guillotine is placed in the hot
water flue
cooled to
damper the boiler
of and
bottom 1 No.
supported Hydraulic
arrangement
gas
Page.No.6


Operated Guillotine water cooled damper of the bottom supported arrangement is placed in the cold flue gas connecting the ID fan and existing process stack, with the guillotine operating in vertical direction. Provision for drying chamber with manual damper/valve is provided in the flue gas duct from ID fan outlet and process stack inlet before the Hydraulic Operated Guillotine water cooled damper.
The WHRB units have been designed and arranged in 2 vertical passes with the hot flue gases received in the first pass horizontally into the Screen tubes of the Water wall radiant chamber, and then flows vertically upwards through the Primary Super heater, Secondary Super heater and Evaporator coil assemblies; cross over to the second pass Economizer section and flows vertically downwards.
All the heating surfaces of Primary Super heater, Secondary Super heater, and Economizer are arranged horizontally; and the Evaporator coils are arranged with a slight slope to the horizontal.
The Vertical sections are of the self supporting type; and are of bottom supported design And will be rested on the supporting steel work of boiler, the high temperature water wall section.; and the Economizer section at a higher level. Ash collection
hoppers are provided below radiant chamber and economiser sections.
The steam drum is located at the front side of boiler, above the top Water wall headers and is supported on 2 No. Large sized down comer pipes which is mounted on a slide bearing arrangement on the structure for thermal movement of down comer when boiler is heated up with waste heat gases.
The boiler is provider with proper circulation system consisting of bottom water wall headers, top water wall headers, relief and supply tubes. Circulation system of boiler provides appropriately sized system with unheated down comers, which avoids formation of De-nucleate boiling at all operating conditions.
Page.No.7


All required structural steel, platforms & stairs, piping & duct supports; Weather Rain protection roof covering arrangement over each boiler are provided. Flue Economizer outlet will be drawn by an ID fan and delivered to Process stack. gas from
A brief pressure part description of boiler is as follows:
a. Radiant Chamber
The primary purpose of the radiant chamber is to provide a gas tight enclosure for complete absorption of heat source from coke oven flue gas to the water walls.
b. Steam Drum
The boiler is provided with sufficiently sized steam drum which houses baffles, cyclones and scrubbers to remove water particles from saturated steam before it enters super heater coils. Steam drum is also provided with necessary nozzles for mountings, feed water and chemical injection. Steam drum is also provided with manhole entries on either side with door and bull dog clamp arrangement for its closure. Necessary air vent and pressure tapings were provided as per the requirements.
c. Water Wall Panel
The Water wall section provided essentially covers all 4 sides of the Inlet Radiant chamber to enclose Primary and Secondary Super heater sections and the Evaporator section. All four sides of water wall is membrane wall construction having bottom and top headers, which are connected by supply pipes and risers tubes respectively. The entire water walls are robust in construction with gas tight conditions. The water wall is also provided with dilution duct arrangement along with necessary damper to control the gas temperature entering the radiant chamber.
Page.No.8


d. Super Heaters
The Super heater consists of Primary and Secondary Super heater sections located in the radiant chamber. The secondary super heater is located just above the primary super heater coil arrangement.
The Primary SH and Secondary SH had been arranged as counter and parallel flow type and fully drainable type. The Primary super heater coil assemblies; and the Secondary super heater coil assemblies are horizontal, in-line tube arrangement, with the main inlet and outlet headers located outside the Water wall enclosure.
The
PSH
&
SSH
heat recovery surfaces
are
placed
inside
welded
water
wall
enclosures; suspended through Evaporative hanger tubes from the top side of Water wall section; and is free to expand upwards, along with the hanger tubes.
e. Supports & Hangers
The boiler is bottom supported construction with free upward movement. The entire boiler is supported from external steel work. The heaviest girders are formed as a support framework below the bottom side wall headers and down comer. All the pressure parts of the boiler and integral piping are supported from this frame work with sling rod construction.
f. Buck Stays
The buck stays are provided around the radiant chamber wall to ensure the structural rigidity when there is a pressure increase or decrease inside the radiant chamber due to mal-operation of draft system. The buck stays are acting likes a stiffener to the boiler
enclosure. Buck stay also guides the boiler thermal expansion.
Page.No.9


g. Economizer
Boiler is provided with huge economizer sections in the 2nd pass of the gas to recover the heat from hot flue gas coming out of evaporator section. Bottom side of the economizer is also provided with hopper and slide gate arrangement to remove fly ash coming out of boiler.
The following are the components of major equipments for the boiler:
1. Steam Drum
Steam drum with nozzles and manholes. Steam drums internals with cyclones, baffles, Primary & Secondary separators. Feed distribution sparge flange pipe with thermal sleeve. Chemical distribution pipe. Continuous Blow down Line.
2. Water Walls
Tubes with attachments / fins / Membrane wall. Openings for access doors, inspection doors, Temperature & Pressure instrument tapping Top headers along with stubs and attachments. Bottom headers with stubs and attachments. Structural attachments.
3. Evaporative Boiler Bank System
Evaporative Bank tubes. Bottom Headers. Top Headers.
Page.No.10


4. Primary Super Heater
Inlet header along with stubs and attachments. Outlet header along with stubs and attachments. Lugs and spacers for Coils.
5. Attemperator
Complete Attemperator with spray nozzles, Thermal Sleeve and Venturi.
6. Final Super Heater
Super heater elements. Inlet header along with stubs and attachments. Outlet header along with stubs and attachments. Lugs and spacers for the same.
7. Economizer
Economizer Elements. Inlet header along with stubs and attachments. Outlet header along with stubs and attachments. Lugs and spacers & spectacle plates for the same. Erosion shields. Cassette baffles. Hoppers
Page.No.11


8. Integral Piping
Large bore down-comers with stubbed ends. Supply pipes. Riser pipes. Saturated steam pipe to Primary Super Heater. Link between Primary Super heaters to Attemperator. Link pipe between Attemperator to Secondary Super heater. Main steam flow nozzle. Link pipe between Attemperator tap off point to Attemperator control station inlet. Link pipe between Attemperator control station outlets to inter stage Attemperator. Attemperator water flow orifice. Link pipe between battery limit and feed control station. Link pipe from outlet of Feed Control Station to economizer inlet header. Feed water flow orifice. Link pipe between economizer outlet and steam drum. Start -up vent piping. Link between drum to Blow down Tank. Super heater and boiler drains to drain header. Drain header to Blow down Tank. Intermediate blow down piping. Piping to sample coolers.
9. Low Pressure vessels and piping
Safety Valve exhausts piping. Blow Down tank with drains. Blow Down tank escape / vent piping. Cooling water piping to sample coolers. Temporary piping for steam blowing. HP chemical dosing system. Piping from HP chemical system to drum. BOILER OPERATION & MAINTENANCE MANUAL Page.No.12


10. Piping supports
Supports for Main Steam piping. Supports for Feed Water control station to Economizer inlet. Supports for Economizer to Drum Piping Supports for risers piping Supports for Saturated Steam Line piping Supports for Supply Line piping Supports for Down comer Supports for start-up vent piping. Supports for safety valve escape piping. Supports for BD tank escape piping. Supports for Primary Super Heater to Attemperator piping. Supports for Attemperator to Secondary Super Heater piping. Supports for Attemperator spray water line piping. Supports for all drain piping. Supports for risers. Supports for supply pipes.
11. Casing, Flue Gas Ducting System
1. Refractory lined hot flue gas duct from coke oven exhaust to inlet radiant chamber. 2. Flue gas from boiler exit to economizer. 3. Economizer casing. 4. Flue gas duct from economizer to existing common flue gas duct. 5. Duct from common flue gas duct to ID inlet. 6. ID discharge duct to stack. 7. All expansion joints. 8. Necessary supports. 9. Measurement tapping on ducts. 10. Necessary fasteners.
Page.No.13


12. Structural
Total boiler structure along with main columns, bracing, tie beams, & ceiling structure.
13. Galleries and Ladders
Galleries, platform, stairs. Hand rails and guard plats.
14. Hot Structures
Buck Stays and Tie Bars. Stand Off Plates. Corner connections. Earthquake restrains. Boiler thermal anchors and ties. Arch support beams, channels and structures. Economizers hot support beams.
15. Supports and hangers.
Necessary guide for steam drum along with saddles. Necessary slide bearings for water wall along with saddles. Necessary supports for final / primary super heaters along with saddles / lugs.
16. Miscellaneous Structures
Structures for handling equipment. Run way beams.
Page.No.14


17. Castings
Access door with mounting plate. Inspection door with mounting plate.
18. Dampers and expansion bellows
All Manual dampers as per the P & I drawings. Hot flue gas duct bellows as required.
19. Insulation and Cladding
Complete boiler insulation and cladding. Insulation and cladding for flues and ducts. Insulation and cladding for air integral piping.
20. Refractory
Refractory at radiant hopper region. Refractory at the inlet of flue gas duct. Refractory on doors / openings
21. Pumps
Boiler Feed Pumps. HP Chemical dosing pump.
Page.No.15


22. Valves
Manual and motorized valves as per P & ID. Super heater safety valve. Drum safety valves. Motorized main steam stop valve. All air release valves. All header drain valves. Chemical line valves. Necessary root valves. All control valves as per P & I. 1 x 100% Pneumatic Feed Control Valve. 1 x 30% Pneumatic Feed Control Valve 1 x 100 % manual feed bypass valve.
23. Silencers
Silencer for startup vent. Silencer for main steam line safety valve.
24. Electrical
Local Isolators (only for LT, MOV and dampers). Local Push button stations. Junction Boxes. Inter connecting power and control cabling.
Page.No.16


25. Motors
Motors for ID fans. Motors for Feed pump. Motors for chemical dosing systems / agitators. Motors for all motorized dampers and Valves
26. Instrumentation
Field mounted instruments as shown in P & ID. Local gauge instruments as shown in P & ID. Instrument Cables. Local junction boxes and instrument racks. Instrument cable trays. Instrumentation piping. Instrument air piping.
27. Major Mountings
Drum safety valves Drum level Direct Water Level gauge. Drum Level Remote Water Level Indicator with 4 20 mA DC Output. Drum Level level Transmitter & indicator. Pressure and temperature gauge.
Page.No.17


CHAPTER 2
GENERAL AND TECHNICAL INFORMATION
Page.No.18


CHAPTER 2
GENERAL AND TECHNICAL INFORMATION

CONTENTS
SL.NO. 1. 2.
DESCRIPTION General Information Technical Information 2.1 Boiler 2.2 2.3 2.4 Electrical & Instrumentation Process Steam Instrument Air
PAGE NO 20 20 20 21 21 21
Page.No.19


CHAPTER 2 GENERAL AND TECHNICAL INFORMATION 1. GENERAL INFORMATION

SL.No Description 1. Plant Information 2 X 26.4 TPH Waste Heat Recovery Steam Generator in M/s. BHATIA COKE & ENERGY LTD,Gummidipoondi,Tamilnadu About 15 M (approx) above MSL NH 5 Chennai about 65 KM Gummidipoondi Seismic Zone III (Light to Moderate) 90 % 50C
2. 3. 4. 5. 6. 9. 10. 2. 2.1
Elevation Above Sea Level Road Link Air Port Rail Link Seismic Zone & Co efficient Relative humidity - Design Ambient Temperature
TECHNICAL INFORMATION Boiler
SL. No Description 1. Numbers and type of Boiler 2 off Single drum, Natural circulation, Bottom supported Fully drainable Waste heat recovery Boiler.
SL. No DESCRIPTION 2. 3. 4. 5. 6. 7. Final Super Heater Flow at 100 % BMCR Steam Pressure at Main Steam Stop Valve Outlet (MSSV) Boiler Steam Drum Design Pressure Main Steam Temperature at Super Heater Outlet Boiler Feed Water Inlet Temperature Maximum Flue Gas Temperature at Boiler Outlet
UNITS TPH kg/cm2(g) kg/cm2(g) C C C
VALUES APPROXIMATE 26.4 71 85 4905 140 160
Page.No.20


2.2 Electrical & Instrumentation For all drive motors For Controls Instrumentation Interlocks and Annunciation Voltage Variation Frequency Variation Combined Variation : : : : : : 415V; 50 Hz, 3 Phase 220 V 24V (2 Wire) DC 10% 5% 10%
2.3 Instrument Air Quality Pressure Dew Point Temperature : : : : Oil and Moisture Free 7.0 Kg/cm2 (g) -40C Ambient
2.4 Cooling Water Water inlet Temperature Pressure : : 32C 5 Kg/cm2 (g)
Page.No.21


CHAPTER 3
DESCRIPTION OF BOILER PLANT
Page.No.22


CHAPTER 3
DESCRIPTION OF BOILER PLANT
CONTENTS
SL.NO. a. b. c. d. e. f. g. h. i. J. k. l. m. n. o. p. q. r. s. t. u. v. w. x. y. DESCRIPTION Feed control Station Circulation System & Steam Drum Boiler Water Wall Systems Evaporator Section Super Heater Section Attemperator Unit Economizer Section Boiler Inter Connecting Piping Boiler Internal / Trim Piping Valves & Fittings Non-Pressure Parts Boiler Supporting Structural, Platforms & Stairs Economizer Casing & Supporting Steel Flue Gas Ducting Hot Flue Gas I/L Duct to WHRB Slide Bearings Supports Ash Hoppers Buckstays Refractory Materials, Insulation & Outer Casing Induced Draft Fan Guillotine Dampers Dosing System De-aerator, Feed Storage Tank Boiler Feed Pumps & Drives Soot Blower PAGE NO. 24 25 27 29 30 34 35 36 37 38 40 41 42 42 42 43 43 43 44 45 45 46 47 47 48
Page.No.23


CHAPTER 3 DESCRIPTION OF BOILER PLANT

PRESSURE PARTS BRIEF DESCRIPTION AND DETAILS
The High Pressure Boiler primarily consists of the following Pressure Parts: 1. 2. 3. 4. 5. 6. 7. 8. Feed Control Station Circulation System & Steam Drum (with internals) Water walls system (including the inlet radiant section) Super heaters consisting of Primary and Secondary Sections Attemperator unit Evaporator Sections Economizer Sections All the Boiler Connecting Piping (between Economizer Drum Evaporator; and between Super heater sections etc.): Feed control station to Economizer feed piping; Main Steam piping up to MS stop valve. 9. All the Boiler integral / Trim piping
10. One number BD Tank 11. Valves and Fittings (Steam & Water System)
The Pressure parts design materials and thickness has been conservatively chosen, with required margins over the code requirements for trouble free unit operation. The Access doors are provided on both side of the boiler, to which required access platforms are provided.
The Brief Description and Details of the various Pressure parts are as follows:
a.
Feed Control Station
Feed control station is meant for controlling feed water to boiler. comprises of following: 100 % Pneumatic feed control valve. 30 % Pneumatic feed control valve. BOILER OPERATION & MAINTENANCE MANUAL
The feed water line
Page.No.24


100 % manual by-pass valve. Manual isolation Valves for Control Valve. Drain Valve located before Feed water Regulator valve. Feed check valve and Shut-off Valve. Pressure Gauge Isolation valves. Thermo well box with Thermo well. Feed water sampling valves. Initial filling line valve. Root & Isolation valve for all HP tappings.
b.
Circulation System & Steam Drum

The heated feed water from outlet of Economizer is discharged into the drum, below the Normal Water level, where it gets mixed with hot water in the steam drum. From the drum, the water flows down
through the unheated down comer pipes to the bottom headers of water wall section. The water flows through the heat absorbing walls and gets partly evaporated into steam. The steam water mixture flows to the drum through riser pipes. The internals provided in the steam drum separates steam from the water. The water particles fall down and enter the circulation
system again, while the saturated steam leaves the drum for super heaters.
Figure 1: Circulation System

BOILER OPERATION & MAINTENANCE MANUAL Page.No.25


Boiler is provided with two main down comer which supply water to water wall, evaporator and hanger tubes. Evaporator circuit is provided with four supplies and six risers. Hanger tube is provided with two supplies and two risers. Water wall is provided with bottom and top headers along with down comer and raisers.
Steam Drum
The Boilers are of the single drum type. The steam drum of each WHRB unit is placed
horizontally on the RHS side of the boiler, at an elevation of approx. 33.0 m above ground level. The drum is supported on 2 Nos. Large size vertical down comer pipes.
FIGURE 2: ELEVATION (Steam Drum) (View looking from Rear of Boiler)
The steam drum will be of fusion welded construction, with semi ellipsoidal dished ends with a manhole doors. Cyclone separator type drum internals are provided, for
this high pressure duty to achieve assured steam purity over wide operating conditions. The steam drum is sized sufficiently large to have sufficient water holding between the NWL and Trip level for full load operation.
Page.No.26


The dimensions of the Steam Drum are as below:
Number of Drum / Boiler Drum ID / Raw Plate Thickness Minimum Shell Length Dished Ends Type Material of Drum Plates
mm mm -
One 1220 X 55 3400 Semi Ellipsoidal SA 515/516 Gr 70 or Equal: Carbon Steel Turbo Separators and Screen dryers. One 2 (Two) On 2 Nos. Down Comer pipes 85
Drum Internals 2 Stage Water Holding Capacity (NWL Trip Level) Max at 100% BMCR. Number of Down Comer Pipes Drum Supporting Arrangement Drum Design Pressure
minute kg/cm (g)
Key Drawing: Steam Drum c. : ICAA0200-1-F-03-01-0352
Boiler Water Wall Systems (Including the inlet Radiant Section)
The Water wall section provided essentially covers all 4 sides of the Inlet Radiant chamber, the Primary and Secondary Super heater sections and the Evaporator section as shown in the figure-3. All required bottom and top headers are provided.
The water wall system will be designed for a pressure of 400 mm WC, and required Buck stays and tie bars are provided. Required access doors and soot blower openings etc. are provided in the water wall panels. The entire Water wall will be supported at about ~ 7.0 m level over structural support steel work and is free to expand upwards.
Page.No.27


The dimensions of the Water wall systems are as below:

Description Boiler Width W Depth D CL of WW Top Header [Height] WW Tubes [OD X T] Front & Rear WW Tubes [OD X T] LHS & RHS WW Tubes [OD X T] Roof Tubes Material Tubes WW Tubes [OD X T] Front & Rear WW Tubes [OD X T] LHS & RHS WW Tubes [OD X T] Roof Tubes WW Fins [W X T] Material Fins WW Header OD [Top/Bottom] Hanger Tube Header OD [Inlet/Outlet] Material Header [WW/Hanger] WW Heating Surface Area 3657.6 mm 2349.8 mm 30700 mm Design Values
(50.8 X 4.0) mm
(50.8 X 4.0) mm
(50.8 X 4.0) mm SA 210 Gr A1 76.2 mm
76.2 mm
76.2 mm (25.4 X 6) mm IS 2062 Gr C (219.1/219.1) mm (219.1/219.1) mm SA 106 Gr B/ SA 106 Gr B 440 m
FIGURE 3: ELEVATION
Page.No.28


Key Drawing: Arrangement of Water Wall Panel d. Evaporator Section

The Evaporator heating surfaces consist of a number of Evaporator coil
ICAA0200-1-F-04-01-0939
assemblies, in-line tubes; each element arranged at 9 to the horizontal.
The
coil
assemblies
are
connected
at
the inlet and outlet end by large size headers. are The Evaporator heating surfaces inside the welded coils wall are
arranged
enclosure. The suspended
Evaporator
through
Evaporator hanger
tubes from the top side of the Water wall section; and is free to expand
downwards along with the hanger tubes.
FIGURE 4: ELEVATION (Arrangement of Evaporator Coils with Sling Tubes) (View looking from R.H.S of Boiler)
Page.No.29


The dimensions of the Evaporator Section are as below:
Description Number of V Tube Section
Units =
Design Values One Parallel Flow (With
Type of Flow
Saturated water flowing upwards)
Tube OD X Thk Materials - Tube Materials Header [Inlet & Outlet] On load cleaning System Total Bed Evaporator Coil Heating Surface Provided
mm
= = = =
60.3 X 4.0 SA 106 Gr. B/ SA 210 Gr. A1 SA 106 Gr. B/C Steam soot blower (Rotary Type) 868
Key Drawing Evaporator Coil Assembly e. Super Heater Section : ICAA0200-1-F-04-35-0001
The waste heat recovery boilers is provided with two stage super heater (primary and secondary) and inter stage attemperator to have better control to the final steam temperature. The Primary super heater coil assemblies; and the Secondary super heater
coil assemblies are horizontal, in-line tube arrangement, with the main inlet and outlet headers located outside the Water wall enclosure. The Primary SH and Secondary SH have been designed as counter and parallel flow type and fully drainable type.
Page.No.30


FIGURE 5: ELEVATION (Arrangement of PSH with Sling Tubes) (View looking from RHS of Boiler)
FIGURE 6: ELEVATION (Arrangement of SSH With Sling Tubes) (View looking from RHS of Boiler)
Page.No.31


The PSH & SSH heating surfaces are placed inside welded water wall enclosures; suspended through Evaporative hanger tubes from the top side of Water wall section; and is free to expand down wards, along with the hanger tubes.
FIGURE 7: STEAM FLOW DIAGRAM
Page.No.32


The dimensions of the Super Heater Section are as below:
Sl.No Description Number of 1. Sections/WHRB Location in the gas path 2. (In the direction of gas flow) 3. 3. 4. Type of flow SH tubes OD X Thick Material of SH Tubes (all as required per IBR) SH Headers materials 5. (all as required per IBR) Size / Material of SH 6. Inter connecting pipes (PSH -SSH) Enclosure Side Water 7. wall tubes & Screen tubes [OD X T] 8. WW Headers Material Total heating surface of 9. the Super heaters sections (approx.)
Units -
Primary Super Heater One
Secondary Super Heater One
Rear Side Front Side
mm -
Counter & Parallel Flow 50.8 X 4.0 SA 210Gr.A1 & SA 213Gr.T11 SA 106Gr. B / SA 335 P11
Counter & Parallel Flow 50.8 X 4.0 & 5.0 SA 213 T11 & T22
SA 335 P11 / SA 335 P22
100 NB / SA 335 P11
50.8 X 4.0 50.8 X 4.0
SA 106 Gr. B/C
m2
126
103
Key Drawing: Arrangement of PSH Arrangement of SSH : ICAA0200-1-F-05-01-0149 : ICAA0200-1-F-05-06-0052
Page.No.33


f.
Attemperator Unit
To have a wide range of controlling from 50% to 100 % of MCR steam flow for the final steam temperature an attemperator is located in the connecting piping, between PSH outlet and the SSH inlet connecting pipe.
FIGURE 8: ATTEMPERATOR ASSEMBELY
The dimensions of the De-Super Heater Section are as below:
Number of DSH Type Control of Spray DSH OD Material Control Range
mm -
One Spray Type (Variable Orifice) By Spray Control Valve 114.3 SA 335 P11 50% to 100% of Boiler MCR
Key Drawing: De Super Heater Assembly : ICAA0200-2-F-06-03-0064
Page.No.34


g.
Economizer System
The Economizer heating surfaces are arranged in the second pass of gas flow. The Economizer coil
assemblies consist of horizontally arranged inline tubes, with the inlet and outlet headers located
outside the gas path. The Economizer coil assemblies are supported / suspended over support beams and the coils are free to expand.
The Economizer heating surfaces are enclosed in a steel casing, suitably stiffened and arranged with a structural steel system. Economizer section as a whole is of the self supporting type, and of bottom supported design.
The Economizer is the last stage of heat recovery, placed in the gas path, on the downstream side of the Evaporator surfaces. economizer will be Each bank height of mm the and
approximately 3000
interbank gap will be 700 mm. Necessary soot blowers for periodically cleaning the soot at the economizer sections are provided.
FIGURE 9: ELEVATION (View looking from RHS of Boiler)
Page.No.35


The dimensions of the Economizer Section are as below:
Number of Economizer Sections
One Counter flow (With FW flow
Type
upwards and gas flow downwards
Tube Outer Diameter x Thickness Material of Tubes Header Outer Diameter Header Material and Connecting Pipes Enclosure of Economizer Coil Assembly Total Heating Surface Area Economizer (approx) -
(38.1 x 3.6) mm SA 210 Gr A1 141.3 mm SA 106 Gr B 6 mm Carbon steel plates 1969 m
Key Drawing: Arrangement of Economizer : ICAA0200-1-F-02-01-0043
h.
Boiler Inter connecting piping
1. Economizer Sections & System Feed Pipe Sl.No 1. 2. Description Feed Control station to Economizer inlet Economizer outlet to drum Pipe Size 80 NB 80 NB Material SA 106 Gr B SA 106 Gr B
2. Evaporator Sections / Circulating System Sl.No 1. 2. 3. 4. Description Down comer Pipes -From Drum Supply Pipes DC Pipes to Evaporator & Water Wall Riser Pipes - From Evaporator & WW Top Outlet Connecting Pipes to Drum (Risers) Distribution at Drum end Pipe Size 200 NB 125 NB 125 NB 125 NB Material SA 106 Gr B SA 106 Gr B SA 106 Gr B SA 106 Gr B
Page.No.36


3. Super Heater section (Saturated Steam Pipes) Sl.No Description 1. 2. 3. Saturated Steam Pipe - Drum to PSH Inlet SH Inter Connecting Pipe & DSH Connecting PSH & SSH Main Steam Piping up to MS Stop Valve Pipe Size 100 NB 100 NB 100 NB Material SA 106 Gr B SA 335 P11 SA 335 P11
i.
Boiler Internal / Trim Piping
a)
The complete requirements of boiler integral trim piping will be supplied for each
boiler. This will include the following. Drain piping Vent piping Drum emergency drains / Intermittent Blow down piping Exhaust piping for Safety valves and starting vent Drain header for HP drains Steam / water piping connections for instrument connection De-Super Heater spray water piping Chemical feed piping De SH spray water Pipings Sampling piping to Sample coolers
b)
A Blow down tank (Common for both intermittent blow down and Continuous Blow
Down) will be provided for each WHRB unit. All the drain of super heater and boiler drain lines, IBD, CBD are terminated at a common header collecting water / condensate from the mentioned sources are connected to the BD tank. The BD tank is provided with a vent piping to atmosphere at safe elevation. The condensate drain is passing through a siphon into the blow down pit. The condensate drain is passing through a siphon into the blow down pit.
Page.No.37


j.
Valves and fittings (Steam & Water System)
The Steam Generator are equipped with all required Valves and fittings for safe and efficient unit operation as part of the Boiler Integral pressure part system. The details, arrangement and location of Valves and fittings are shown in the P&IDs enclosed in Volume II (Mechanical Drawings).
For the ready reference, we had enclosed herewith the list of major valves and fittings.
LIST OF MAJOR LARGE SIZE VALVES AND FITTINGS (Refer P&ID Steam and Water system also for details) Sl.No Service / Description A BOILER SYSTEM Feed Control valve(100% 1 capacity) Feed Control valve(30% 2 capacity) for low load operation Bypass Feed Control valve 3 (100% capacity) Isolation valves for the 4 100% capacity valve Isolating valves for the 30% 5 6 7 capacity valve Feed stop valve Feed check valve NB 50 (On NB 80 feed line) NB 25/32 (On NB 40 feed line) NB 80 Hand 1 Pneumatic 1 Pneumatic At feed control station FEED WATER NB Operation No. provided Remarks
At feed control station At feed control station At feed control station At feed control station Eco inlet Eco inlet
NB 80
Hand
NB 40 NB 80 NB 100
2 1 1
Hand Hand Auto
Page.No.38


Flow Nozzle
NB 80
Inlet of feed control station
Sl.No Service / Description B DRUM SYSTEM Drum Safety valves (Without 1 2 silencers) Direct water level gauges Electronic water level 3 indicator unit (with local & remote indication) EVAPORATION
NB
No. provided
Operation
Remarks
NB 25 NB 25
Auto spring 2 2 loaded -
Steam Drum Steam Drum
NB 25
Steam Drum
Blow down valve 4 CBD
Hand NB 25 1 (Angle Type) NB 25 NB 25 1 1 Hand Hand In CBD Line In IBD Line In CBD Line
5 6.
Blow down valve isolation Drum emergency drain valve Drum emergency drain
7. C
isolation valve SUPERHEATED SYSTEM STEAM
NB 25
Hand
In IBD Line
Super heater safety valve with silencer
NB 25
Auto spring MS Line at FSH 1 loaded Hand outlet
Start up vent valves (30% capacity) with silencer
NB 50
Page.No.39


Isolating valve to start up vent valve
NB 50
Hand
Main steam stop valve (with integral MO bypass)
NB 100 NB 100 NB 100
1 1 1
Motor Auto -
5 6 D 1 2
Main steam check valve Main steam flow nozzle DESH SPRAY WATER Flow orifice Spray water control valve
NB 15 NB 15
Pneumatic
Spray water line Spray water
control station
Standby Spray water Motor Operated valve
NB 15
Hand
Isolating
valves for
Spray NB 15 2 Hand
Control valve and Regulating valve
k.
Non-Pressure parts
The main Non Pressure parts of the each WHRB units, essentially consist of the following:
Boiler supporting structurals and connected steel work; Platforms; Stairways; Supports for Boiler Connecting Piping and Ducting, etc.
Economizer Casing and Supporting steel work. Hoppers (below the vertical gas passes). Flue ducting from outlet of Evaporator and inlet of Economizer; Flue ducting at Eco outlet side, from the outlet of Economizer to inlet of ID fan; and ID fan to stack (with the required supporting steel)
Hot flue gas inlet duct (at inlet of Radiant Boiler section) with supporting steel, as required.
Page.No.40


Structural support steel for Boiler roof and sides covering (weather protection). Buck stays (for the Water wall enclosure section). Other miscellaneous supports; Structural steel for ID fan and motor handling arrangement.
The Structural steel supporting steel system will include all the main and auxiliary columns, beams and bracings, Duct and piping supports, equipments, support
structures, etc. as required.
The
brief
description
and
details
of
the
various
non
pressure
parts
will
be
as
follows:
The brief description and details of the various non pressure parts are as follows:
l. Boiler Supporting Structural, Platforms & Stairs
The complete Boiler Pressure parts in 2 vertical sections, and the Drum & Piping etc. will be supported from bottom side, on the structural steel work (at approx. 7.0 m elevation).
The complete structural system will be of the Welded Construction. The Steam drum is provided with flooring all around, for access to the manhole doors, various valves and fittings etc.
The Platforms and stairs have been provided on one side of the boiler (giving approach to the Access doors, valves and fittings, etc.).
Slope of stairways will be between 40-45:
Ladders are provided only wherever
required. The Slope of the stairways will be preferably 41. A Stairways arrangement up to drum level has been provided, as per the GA drawings. The Width of Stairways and platform is 750 mm and will be as per ENMAS standards. Hand railing design and arrangement will be as per ENMAS standards. Handrails made out of 34.2 and 27.3 OD pipes. Floor grating and stair (step) treads will be about 25 mm thickness open type, as per ENMAS standards.
Page.No.41


The supporting steel for boiler roof covering materials.
Notes
Please refer to GA drawings of boiler for general details of the arrangement of the supporting structurals, platform and
stairs, etc.
m. Economizer Casing & Supporting Steel
Complete Structural steel for the Economizer section, with platforms is provided. Economizer casing are fabricated of 6 mm thick Carbon steel plates, suitably stiffened.
The Economizer sections are provided in separate gas passes, with separate ash hoppers. The Structural supporting steel materials and manufacture will be as that of main Boiler supporting steel. This arrangement is to facilitate O & M even under adverse operating conditions.
n.
Flue Gas Ducting

Flue gas duct work connecting Evaporator and Economizer section (min. 6 mm thick.) will be supplied including required expansion joint.
The complete flue gas ducting from Eco outlet, up to stack will be fabricated with min. 5 mm thick Carbon steel plates and suitably stiffened. Flue ducting will be of rectangular cross section, with suitable stiffeners. This duct will be laid out as shown in the GA drawing enclosed in Volume II (Mechanical Drawing).
All
required
metallic
non-metallic
type
expansion
joints
and
dampers
as
required per design, will be provided for the gas ducting. Required steel supports for this flue ducting are provided. The supporting steel materials and manufacture will be as that of main boiler steel work.
Page.No.42


o.
Hot Flue Gas Inlet Duct to WHRB
A small length of Hot flue gas duct is provided at inlet to the SH section and the same will be fabricated with 5 mm thickness, carbon steel, suitably stiffened. This duct will be lined with suitable 2 layer high temperature refractory materials on the inside, applied over SS anchors; This duct will be supported over the boiler structural steel work.
The flue gases from stacks is to be tapped off at
0.0 m elevation through the
T off connection from the existing hot flue gas duct to stack. At the inlet of hot flue gas duct to boiler 100 % leak proof guillotine damper is provided.
p.
Slide Bearings Supports
The Water wall enclosure and Down Comer pipes are supported at the bottom side on structural base at approx. 7.0 m elevation. To ensure free thermal expansion at
each of the support locations special slide bearings were provided and mounted over the supporting structural frame.
q.
Ash Hoppers
In order to collect fly ash from the hot flue gas from the coke oven a hopper is provided both below radiant section and economiser section which is made out of 6 mm thick Carbon steel plates. The outlet of the hoppers will be of approx. size 400 x 400; and will be kept closed by slide gates. The slide gates shall be opened to remove fly ash as and when required.
r.
Buckstays
The hot inlet flue gas passes water wall enclosure section will be provided with a system of Buckstays and Tie bars, at various levels, to withstand any unusual variations in gas pressure in the boiler. Buck stays are designed for a internal gas pressure of 400 mmWC and are allowing free thermal Expansion of pressure parts.
Page.No.43


Key Drawing: Arrangement of Buck stay s. : ICAA0200-0-F-04-28-0035
Refractory Materials, Insulation & Outer Casing
1.
Refractory
The hot flue gas inlet duct will be lined with suitable high temperature refractory material: SS anchors will be welded to the inlet duct for holding the refractory in its position.
The ash hoppers of (the Water wall section) below Radiant section will be refractory lined over SS anchors welded to the hoppers, as required.
also
All access doors, peep hole doors provided on the radiant chamber will be refractory lined to with stand the high temperature.
The refractory materials which are to be used in the hot flue inlet gas duct are as given below: SL.NO. Location Refractory Material Hot face will be ACC:WHYT HEAT a) Hot Flue Gas inlet duct from existing coke oven exhaust to radiant chamber. 1. C = 200 mm (thick) And Cold face will be calcium silicate block = 50 mm (thick) Stainless steel SS 310 b) Anchors Stud / Anchors will be welded to carbon steel duct.
2.
Insulation
Boiler is provided with lightly bonded insulating mattress and cladding over all hot surfaces to prevent heat burn to personnel as well as to reduce the radiation losses while boiler is in operation.
Page.No.44


Similarly all integral and process pipes are provided with required thickness of insulation and cladding material.
t.
Induced Draft Fan
The boiler is having 2 x 85 % MCR capacity Induced Draft Fans to suck hot flue gas from the coke oven exhaust duct which passes through all pressure parts located in the downstream of inlet guillotine damper located at inlet hot flue gas duct. ID fan also discharges the low temperature flue gas to stack after heat is recovered by various section of WHR boiler. The
ID fans were designed in such a way that at MCR flow the suction pressure will be maintained at -33mmWC at the inlet to the WHR Boiler.
1. 2. 3. 4.
No. of Fans / WHRB Type Drive Control of Fan
2 (Two) both in operation. Backward curved, Over hung; Plate bladed design, Variable speed operation Motor driven Multi Loure dampers in suction ducts, of the fan; with pneumatic actuator / VFD
Sl.No 1. 2. 3.
Particulars/Fans Flow Temperature Suction Pressure
Units
100% MCR Load (2 Fan Operation)
m/Sec 14.99 C 160
mmWC -420
u.
Guillotine Dampers
Two Number water cooled guillotine dampers one at the hot flue gas inlet and another at ID discharge duct to stack were provided for each WHR boiler to ensure 100 % sealing.
1.
Number provided/WHRB
2 No.
(one
in
each
hot
flue gas
Page.No.45


duct, connected from tap of point to boiler and the other in the cold flue gas duct to process stack ) Water cooled disc - Refractory lined 2. Type = on casing and on Disc, at the gas
flow section Gas side isolation of Coke oven flue 3. Duty / Service = gases at WHR Boiler inlet - 100% open/close Arrangement / damper blade opening / location Gas flow to damper - Normal (100%MCR) Design temperature Operating pressure Dust loading in COFG mg/Nm
3
Vertical shaft with horizontal Gas = Flow - Damper supported at the
4.
bottom (on structural base) = = = = = = 63000 Nm3/hr at 950C Hot
5. 6. 7. 8. 9. 10.
Flue Gas duct to boiler inlet 1000C -33 mmWC 150 (max) 98% Hydraulic
Sealing efficiency (on cross sectional area basis) Method of operation
v.
Dosing Systems
HP Dosing Units
Boiler is provided with a High pressure chemical dosing unit which consists of SS tank for mixing motorized agitator and 2X100% capacity Hydrazine Dosing pumps simplex, reciprocating plunger type positive displacement pump along with necessary valves and fittings.
Page.No.46


w. De-aerator, Feed Storage Tank (Common for Two WHRB Unit)
1.
De-aerator
The boiler is provided with common De-aerator along with Feed Storage Tank to scavenge oxygen from the DM water before feed water is fed into the boiler. The Deaerator is spray cum tray type with SS trays located in the Deaerator tower which is mounted on the feed storage tank. The Deaerator is complete with all the connected piping (Auxiliary steam, Condensate & DM Water) Valves and Fittings as required. Spray nozzles and Trays of Deaerator are of Stainless steel. The De-aerator has been sized considering boiler operation 2 X 26.4 TPH.
2.
Feed Storage Tank

One Horizontal, Cylindrical 2 No. Saddle supports; 2400 mm x 5000 mm 12 min
Number of Unit Type / Orientation Supports arrangement & Location Size approx.: ID x Shell Length Capacity of water holding (as specified) (between NWL and Trip) Operating pressure and temperature
2.7 kg/cm (g); 140 C
The Feed Water Storage Tank is complete, with all the connected piping, valves and fittings.
x.
Boiler Feed Pumps & Drives
The High pressure feed pump located below the Deaerator supplies water to WHR Boiler. Feed pumps are motor driven and provided with minimum circulation mechanical valve (ARC) to ensure that minimum quantity of water is always circulated through the feed pump to prevent over heating of pump internals and thereby failure of internal components. No. of Feed pumps provided (2 operating + 2 stand-by) Type 4 x 100% Both Motor driven Multistage, Centrifugal, Horizontal axis, Constant speed, direct motor driven BOILER OPERATION & MAINTENANCE MANUAL Page.No.47


Parameters of pump (Each)
4 X 100 % MCR 1. 2. 3. 4. 5. 6. 7. Volume of Flow Feed Water Temperature Density of Water Delivery Pressure Feed Pump Suction Pressure Speed Power required at Pump Shaft TPH C kg/m kg/cm (g) kg/cm (g) RPM KW 27.19 140 926.13 91.5 2.7 2980 160 TB 29.9 140 926.13 95.97 2.7
y.
Soot Blower
Boiler is provided with soot blower to remove soot deposition on the pressure parts during running of the WHRB unit. Two long retractable soot blowers one each to clean primary and secondary super heaters. Similarly 6 Nos. of rotary type soot blowers were located at the economizer zone. Necessary PRV station for reducing the steam pressure to require steam blowing pressure through soot blower along with Program logic controller to take care of sequential logic control for soot blower operation is provided. Soot blowing shall be always carried out only above 60% of MCR load of the boiler to avoid metal temperature increase during steam blowing operation from the soot blower.
Page.No.48


CHAPTER 4
DESIGN DATA FOR BOILER PERFORMANCE
Page.No.49


CHAPTER 4
DESIGN DATA FOR BOILER PERFORMANCE
CONTENTS
SL.NO. 4.1 4.2
DESCRIPTION Design Data Waste Gas 4.2.1 Predicted Hot Flue Gas (approx. values) 4.2.2 Ambient Conditions 4.2.3 Properties of COFG
PAGE NO 51 51 51 51 52 52
4.3
Predicted Performance Details
Page.No.50


CHAPTER 4 DESIGN DATA FOR BOILER PERFORMANCE 4.1 Design Data

SL.No 1. Description Number and type of boiler Remarks 2off Single drum, Natural circulation, Balanced draft Waste Heat Recovery Steam Generator Unit.
SL.No 2. 3. 4. 5. 6. 7. 8. 9. 10.
Desciption Final Super Heater Flow at 100 % BMCR per WHRB Unit Steam Pressure at Main Steam Stop Valve Outlet (MSSV) Boiler Steam Drum Design Pressure Main Steam Temperature at Super Heater Outlet Main Steam Temperature Control Range. Feed Water Temperature at Economizer I/L Maximum Flue Gas Temperature leaving economizer to ID Fan and to stack Quantity of COFG & temperature required at inlet of each WHRB Dust Concentration in Hot Flue Gas
Units TPH kg/cm (g) kg/cm (g) C % BMCR C C Nm/hr & C mg/Nm
Values 26.4 71 kg/cm (g) 85 490+5 50 to 100 140 160 63,000 950 150
4.2 Waste gas

4.2.1 The predicted approximate hot flue gas requirement are given below Sl.No 1. 2. Description 100% MCR Load Condition 50% MCR Load Condition Unit Nm/hr Nm/hr Values 63,000 31,500
4.2.2 Ambient Conditions (For Performance Design of Boiler) are given below Sl.No 1. 2. Description Temperature Relative Humidity Unit C % Values 50 90
Page.No.51


The Proposed Waste gas analysis for the boiler are given below 4.2.3 Properties of COFG Sl.No 1. 2. 3. 4. 5. 6. 7. 8. Constituents Nitrogen Sulphur Di-Oxide Carbon Di-Oxide Oxygen Water Vapour Total COFG Flow rate per WHRB Unit Inlet temperature of COFG per WHRB Symbols N2 SO2 CO2 O2 H2O Unit % Vol. % Vol. % Vol. % Vol. % Vol. % Vol. Nm/hr C Values 68.65 00.05 04.10 13.70 13.50 100.00 63,000 950
4.3 Predicted Performance Details as per Technical Specification

The following is the Predicted Performance of the each WHRB unit and Auxiliaries, based on the Basic Design Parameters and Data, detailed in the specification as follows:
Boiler Parameters Proportionate steam generation SH steam pressure at outlet of MS stop valve SH steam temperature at outlet of MS stop valve Feed water temperature entering Economizer Temp of Hot inlet flue gases at entry to each WHB Hot inlet flue gases at entry to each WHB Gas Temperature COFG entering Inlet screen tubes of Radiant section Entering Primary Super heater Entering Secondary Super heater Entering Evaporator section Entering Economizer section Entering ID Fan Entering Stack
Units TPH kg/cm2(g) C C C Nm/hr
100% MCRMaxi. Flue Gas Flow 26.4 71 4905C 140 950 63000
C C C C C C
950 834 716 644 349 160
Page.No.52


Water & Steam Temperature Feed inlet of Economizer Feed outlet of Economizer Drum operating (Saturated - Entering Pry. SH section) Steam leaving Pry. SH Steam entering Sec. SH Steam leaving Sec. SH Spray water quantity Flue Gas Pressure Radiant Chamber Super Heater O/L Evaporator O/L Economizer O/L ID Fan I/L ID Fan O/L
Notes
C C C C C C kg/hr
140 277 289 415 402 490 5 363
mmWC mmWC mmWC mmWC mmWC mmWC
-59 -76 -112 -312 -337 +25
These are all the above values for information purpose only.
Page.No.53


CHAPTER 5
BOILER PLANT SAFETY AND PROTECTION
Page.No.54


CHAPTER - 5
BOILER PLANT SAFETY AND PROTECTION
CONTENTS
SL.NO a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u.
DESCRIPTION General Requirements Safety Precautions Radiant Chamber Inspection Maintenance Work Steam & Water Source Isolation Residual Pressure (or) Vacuum Safety Measures for Internal Inspection and during Start-Up Residual Heat Hot dust and/or Noxious / inflammable gas Flue Gas Leakage and Firefighting equipment Burning / welding within Boiler interior Deviation from Recommended Procedures Maintenance Equipment Work Permits Dampness Steam & Water at Elevated Pressure & Temperature Mechanical Equipments Flue Gases HP and LP dosing Chemicals Noise Protective Materials and Clothing
PAGE NO 56 56 56 56 57 57 57 57 58 58 58 58 59 59 59 59 60 60 60 60 60
Page.No.55


CHAPTER 5 BOILER PLANT SAFETY a. General Requirements
In the interest of safety of all personnel who are operating the unit, the compliance with the instructions on the boiler plant safety should be effected by or under the supervision of responsible, competent and properly trained personnel familiar with the operating and maintenance procedures relevant to this type of plant.
It should be clearly under stood that for plant of this complexity; it is not practicable to anticipate all the possible circumstances, which may arise during the operating life of the plant.
b.
Safety Precautions
To ensure that the boiler and its auxiliaries operated efficiently and reliably as possible, the periodic maintenance of all Equipments and auxiliaries should be done. Procedures recommended by the various manufacturers for preventive and corrective maintenance should be implemented to obtain the maximum plant utilization and safety.
c.
Radiant Chamber Inspection
When opening the radiant chamber inspection door to view hot flue gas, dark glasses should be worn and care should be taken to stand to one side to guard against a chamber disturbance. Never open a radiant chamber inspection door to view the flue gas without the prior knowledge of the boiler operator.
d.
Maintenance work
Before commencing any maintenance work on the boiler unit or auxiliaries particularly those items connected to an electrical power supply the Equipment must be completely
Page.No.56


isolated, both mechanically and electrically, in accordance with current Safety Regulations laid down for the plant.
e.
Steam and Water Source Isolation
Prior to opening up a boiler for inspection, cleaning, or maintenance, the boiler must be cool, and extreme care must be taken to prevent steam or hot water entering the unit from systems that may be under pressure from other sources. This includes steam and feed piping, drains and blow down lines, which can be connected to systems in use, and it is imperative therefore to avoid serious accidents that the boiler is completely isolated from any steam and water sources by locked shut off valves and blanking if required.
f.
Residual Pressure or Vacuum
In necessity demands, opening up any pressure part on a hot boiler, a check must be made to ensure that there is no residual pressure, or a vacuum, by means of the releasing the air by opening the vent provided on the pressure parts, pressure gauge readings are not to be taken for granted under these circumstances.
g.
Safety Measures For Internal Inspection & During Start Up
When inspecting the boiler unit internally, protective clothing goggles and gloves, footwear, and helmet must be worn before entering any enclosed internal space. A hand held inspection lamp of the twenty four volt (24 volt) type or a torch should be taken inside for checking. Before going for internal inspection of radiant chamber or other enclosed space, there must be another person posted outside at the inspection / access door monitoring the movements of the operator inside so that, if necessary, external assistance may be sought for due to any emergency situation.
h.
Residual Heat
Before entering the radiant chamber or gas passages to carry out an inspection, maintenance, or water washing, the amount of residual heat must be carefully considered. BOILER OPERATION & MAINTENANCE MANUAL Page.No.57


i.
Hot Dust and / or Noxious / Inflammable gas
Accumulations of dust / flue gas contaminant particles can retain high temperatures inside for extended periods and on contact with water can generate sufficient steam to injure any unprotected person in the immediate vicinity. The effect is accentuated in a confined space. Precautions must therefore be taken to avoid scalding of operators and adequate ventilation must be ensured to guard against the possible presence of noxious or inflammable gas.
j.
Flue Gas Leakage and Fire Fighting Equipment
Firing galleries should be kept clean. Any flue gas leaks should be immediately arrested. All precautions should be taken to avoid boiler front fires and the firefighting equipment must be maintained in good order as prescribed by the manufacturer. The Fire Extinguisher should be appropriate for Class of Fire.
k.
Burning / Welding within Boiler Interior
Any burning or welding work to be carried out within the boiler interior, the space must be adequately ventilated, and suitable firefighting equipment must be available, together with a bucket of water for cooling any dismantled part. Staging complying with the Factory Acts must also be used in those places inaccessible to the radiant chamber assess equipment. Skill Worker has to attend the work, to avoid damage of pressure parts.
l.
The
Deviation from Recommended Procedure

maintenance instructions must be followed as closely as possible, although
circumstances can arise which may necessitate a deviation from the recommended procedure. In any instance where doubt can exist that will involve risk to personnel, the decision must rest with a responsible engineer who must examine every aspect of the particular case before giving a decision whether or not to proceed with the work in question.
Page.No.58


m. Maintenance Equipment
Generally however, full use must be made of the maintenance equipment provided access doors, walkways, and ladders, runway beams hoists, and cable reeling drums rather than improvising for the sake of expediency.
n.
Work Permits
Where doubt exists concerning the safety of mechanical or electrical plant, then the station Safety Regulations are to be followed, complete isolation of all mechanical and electrical equipment in accordance with the Permit to work system - must be obtained by the responsible Engineer before the work is commenced. Guards on rotating machinery, belt drives etc., must be refitted before plant is re- commissioned after maintenance.
o.
Dampness
Certain equipment, although located within the plant building, can be subject to dampness or condensation. Cubicles housing electrical or other control equipment, if located in a cold draft position, are particularly vulnerable to this condition. Therefore, precautions must be taken against dampness occurring. Cubicle doors must be closed and locked to prevent
them being inadvertently left open. Electric heaters can be installed or, if in short supply, carbon filament lamps may be used.
p.
Steam and Water at Elevated Pressures & Temperatures
Saturated steam is generated in the boilers. This is visible. However, extreme care should be taken when trying to locate it. Sampling of steam and water must be carried out with care, Gloves and face masks must be worn.
Page.No.59


q.
Mechanical Equipment
Moving machinery can always be dangerous, should be treated with respect. It should be ensured that guards are in place on all operating machinery.
r.
Flue Gases
Flue gases have very low oxygen content and will cause asphyxiation if breathed even for a short time. Usually flue gas will at a temperature of above 100 C, so it is dangerous for the persons who working near to the flue gas leakages or passing from the radiant chamber zone.
s.
HP&LP
Dosing
Chemicals
Water treatment chemicals used in H. P. and L. P. dosing are both irritants and toxic if ingested. Gloves and eye protection must be worn when handling these chemicals.
t.
Noise
Noise can permanently damage the hearing ability. Hence, care should be taken for ear protection at all times when in the plant.
u.
Protective Materials and Clothing
Table below indicates the name of the protective materials and clothing that may be used for protection of the operating and maintenance personnel. SL. No. 1 2 3 4 5 6 7 Safety Boots Overalls Hard Hat Goggles or Face mask Dust Mask Safety Gloves (leather and PVC) Ear Plugs Description Protection Foot Protection Body Protection Head Protection Face and Eye Protection Lung Protection Hand Protection Hearing Protection
Page.No.60


CHAPTER 6
FEED AND BOILER WATER
Page.No.61


CHAPTER - 6
FEED AND BOILER WATER
CONTENTS
SL.NO. 6.1 6.2 6.3 6.4 6.5
DESCRIPTION WATER CONDITIONING DE AERATION ALKALINITY CAUSTIC SODA, AMMONIA, AMINES SUPPLEMENTARY WATER TREATMENT SIGNIFICANT SALT SOLUTIONS PROPERTIES
PAGE NO. 63 71 76 80 90
Page.No.62


6.1 - WATER CONDITIONING
Page.No.63


6.1 - WATER CONDITIONING

CONTENTS SL.NO. a. b. c. d. e. f. g. h. i. j. DESCRIPTION General Raw Water and chemical Dosing Water and Steam sampling Hardness Phosphate Conditioning Boiler Water Quality Feed Water Quality Phosphate Dosing Phosphate Hide- Out Co-ordinate Phosphate pH Control Congruent control PAGE NO. 65 65 66 66 66 67 68 68 68 69
Page.No.64


6.1 - WATER CONDITIONING a. General
The generated steam in the boiler is supplied to the plant for its various requirements as well as to the auxiliaries. There are many water treatment specialists, whose services are available to boiler users. Unless the installation has adequate water testing facilities and personnel skilled in the interpretation of the results, it is recommended that the care and control of water be entrusted to such specialists.
The development of highly Pressure water tube boilers has resulted in the need for close control of feed and boiler water quality. The successful use of such boilers has been so dependent upon the proper water conditioning that added impetus has, in turn, been given to water treatment and to the necessity for accuracy in its control. While it is beyond the scope of these instructions to cover the subject fully, the following is submitted as a brief review of some of the outstanding factors, in order to assist those taking charge of new boiler equipment.
In order to minimize deposits, scale formation, and corrosion, in the Pressure parts. Boiler Feed water and Boiler water should be treated with chemical to maintain the Water quality. In the feed line, feed heaters, economizers, and prime movers, it is necessary to maintain chemical conditions in the boiler water by injecting treatment chemicals. Dosing of chemical can be done by injecting chemicals in feed water after de-aerator and H.P Dosing system for dosing chemical directly into the Steam Drum.
b.
Raw water and Chemical Dosing
The selection of the chemical depends on the type of the water treatment. Raw water gets de-mineralized in the DM plant and then passes through the de-aerator to get de-gasified. The DM water is dosed with chemicals to attain proper alkalinity and de-aeration and finally fed to boiler by boiler feed pump. To maintain the contents and property of water under control, HP dosing to drum is often used. Periodic sampling and testing of water from
Page.No.65


different parts of the boiler is conducted for record and control purpose.
Oxygen scavenger should be injected to eliminate dissolved oxygen even if the feed water is de-aerated mechanically. The amount of the chemical must be determined on the basis of the quality of feed water actually used, the load and the chemical analysis of the boiler water.
For the injection of the chemical by the chemical dosing pump, most adequate quantity shall be determined by adjusting the pump stroke considering the content. Chemicals should be injected continuously during boiler operation so as to avoid erratic boiler water conditions.
c.
Water and Steam Sampling
Samples are drawn from feed water, Drum water, saturated steam, superheated steam and turbine inlet steam for measurement of pH, conductivity. In addition to that, Dissolved oxygen analyzer is provided for feed water. These samples are passed through SWAS panels where all sample coolers, Roto meters, Pressure and temperature relieving valve are provided for protection of analyzing instrument.
d.
Hardness Phosphate Conditioning
Internal deposits of calcium and magnesium salts, and iron oxides will be minimized provided the maximum concentrations of hardness salts and iron given in table for Feed Water Conditions are not exceeded.
e.
Boiler Water Quality

: : : : 100 ppm (Max) 200 S/cm (Max) 15 25 ppm 9.8 10.2 ppm
Total dissolved solids Specific electrical conductivity at 25C Phosphate residual pH at 25C
Page.No.66


f.
Feed Water Quality

: : : : : : : : : Colorless and Clear 0.5 S/cm 8.8 9.2 0.007 ppm (Max) Nil 0.01 0.02 0.02 ppm(Max) 0.01 ppm (Max) 0.01 ppm (Max)
Appearance Specific Electrical Conductivity at 25C (after CO2 removal) pH at 25C Oxygen Hardness, Oil,Per Manganate, CO2,etc Hydrazine residual Silica Total Iron Total Copper
It is necessary to maintain a phosphate reserve in the boiler water to guard against scale formation on the internal heating surface of the boiler This type of scale formation results either from residual hardness in the softened feed water or contamination of steam condense from the plant due to cooling water infiltration. To resist this phenomenon, phosphates of sodium are dosed to the steam drum.
The
phosphates
usually
employed
are
tri-sodium
phosphate,
di-sodium
hydrogen
phosphate, and monosodium di-hydrogen phosphate or sodium poly phosphates. The choice of phosphate depends on the alkalinity of the feed water, which in many instances is determined by the preliminary softening treatment of the make-up water. Acid phosphate e.g., mono sodium di hydrogen phosphate is used when it is desired to reduce the alkalinity in the boiler water, whereas tri sodium phosphate is used when an increase in boiler water alkalinity is desired. Mainly tri sodium phosphate is dosed.
In the water, phosphates react with calcium and magnesium salts to form insoluble calcium and magnesium phosphates, which are precipitated as sludge.
The maximum concentration of hardness (in the feed water) that can be tolerated is indicated in 6.1d. Greater quantities may lead to loss of phosphate reserves and to the
formation of scale on tubes at areas of high heat input, which may result in tube
Page.No.67


overheating and failure. Hardness should be absent from feed water to boilers operating in pressure ranges above 42.12 kg /cm. The small phosphate reserve normally
recommended is not intended to deal with more than slight contamination arising from condenser leakage, evaporator priming or other unforeseen irregularities.
g.
Phosphate Dosing
The recommended method of introducing phosphate is by means of a high-pressure pump injecting direct to the drum. This avoids precipitating hardness sludge in feed lines or Economizer.
h.
Phosphate Hide Out
A phenomenon associated with high-pressure plant is that known as Phosphate hide out where the phosphate concentration apparently disappears or is reduced at full load, and reappears on reducing load. The advice of a water treatment specialist should be sought. Phosphate conditioning is not recommended for boilers of 64 kg / cm and above which exhibit hide out.
i.
Coordinated Phosphate - pH Control
Based on earlier work by eminent chemists and demonstrated by others that, adjustment of the boiler water chemistry to assure that phosphate alkali balances approximate the stoichiometric hydrolysis of tri-sodium phosphate will prevent caustic corrosion.
This system, which is called coordinated phosphate pH control, depends on the feed of mixtures of orthophosphate or a mixture of caustic and disodium phosphate to control pH in otherwise un-buffered water. Monosodium, disodium and tri-sodium phosphates can accomplish this purpose as a result of their ability to hydrolyze to (H2 PO4)-, (H P O4)
2
and (PO4)3, and to establish an equilibrium among these forms, in conjunction with (O H)-1 concentration or, by interference, the pH. BOILER OPERATION & MAINTENANCE MANUAL Page.No.68


The reactions of concern are as follows: (PO4)-3 (HPO4)-2 (H2PO4)-1 + + + H2O H2O H2O = = = (HPO4)-2 (H2PO4)-1 3H+ + + + (OH)-1 (OH)-1 (PO4)-3 + (OH)-1
In water containing a low concentration of dissolved solids other than sodium phosphate, the equilibrium between the various forms of the phosphate ion can be utilized to control the acidity or alkalinity of the whole system. The ratio of one phosphate to the other can be controlled to produce any desired sodium to phosphate (Na / PO4) ratio. If all the
phosphate is present in the tri sodium form, the (Na / PO4) ratio is obviously 3.0. At or just below this level, there will be no free hydroxide present. The term free sodium
hydroxide or free caustic defines the amount of sodium hydroxide in solution in excess of that derived from the hydrolysis of tri sodium phosphate according to the following equation. Na
3
PO
Na
HPO
Na O H
The relationship between (P O4)3 concentration and pH at 25 C for a pure Na3PO4 solution. This curve is the basis for the system of co-coordinated phosphate pH control. Phosphate is usually controlled at 5 10 ppm to avoid carryover at the higher pressure and 15 25 ppm in the 42 84 kg/cm range.
j.
Congruent Control
Originally, it was thought that adjustment to assure that phosphate pH co ordinates followed the tri sodium phosphate hydrolysis curve would eliminate free caustic. Cases of caustic corrosion continued to occur, however, in boilers in which the chemistry had been adjusted following this principle. Various explanations have been advanced, the most probable being that the solids which precipitate from a super saturated Na3PO4 solution are not pure tri sodium phosphate, i.e., that as a result of the concentrating effect at the tube surface, both tri sodium and disodium phosphate deposit on the tube, leaving an excess of sodium hydroxide in the supernatant liquid. The exact composition of the precipitating phosphate depends on temperature, but has a Na / PO4 ratio in the range of
Page.No.69


2.85 to 2.6 for pressure from 84 to 211 kg / cm. A ratio of 2.6 is considered safe for all drum type boilers.
The temporary deposition of usually water soluble chemicals during normal operation is referred to as hideout . When the steaming rate is appreciably reduced, or the boiler taken off line, the deposited chemicals re-dissolve in the boiler water. Although a number of substances exhibit this phenomenon, sodium phosphate is of most interest in boiler operation. At temperatures above 117C, tri sodium phosphate exhibits a retrograde solubility. It is this property that makes hideout possible Phosphate hideout is also undesirable because it may raise tube wall temperatures and cause failures similar to those brought about by other deposits.
Phosphate precipitation and the formation of free caustic can also occur if boiler water is totally evaporated in the steam blanketed area or is highly concentrated within or under a porous surface deposit.
Congruent control, used when phosphate hideout may occur, is similar to coordinated phosphate pH control, except that the Na / PO4 ratio is intentionally controlled at a specific value, usually 2.6 to 2.8 rather than just below 3.0. The concept of maintaining a specific ratio at 2.6 assures that no concentrated caustic solution can be formed in the event of phosphate precipitation.
In this situation, the sodium and phosphate will invariably leave the solution in such proportions that the remaining solution has a Na / PO4 ratio lower than the original ratio, therefore without free hydroxide or caustic.
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6.2 - DEAERATION
Page.No.71


6.2 - DEAERATION
CONTENTS SL.NO. a. b. c. d. e. f. g. h. i. j. k. DESCRIPTION Introduction Thermal De Aeration Chemical De Aeration Use of Sodium Sulphite Use of Catalyzed form of Sodium Sulphite Sodium sulphite injection point Use of Hydrazine Ammonia from excess Hydrazine Hydrazine Reserve Health Regulation Injection Chemicals PAGE NO. 73 73 74 74 74 74 74 75 75 75 75
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6.2 - DEAERATION
a.
Introduction
Dissolved gases are normally present in feed water, being present in the make up water or due to condensate coming into contact with the atmosphere {in open feed tanks, for
example}. The principal gases are oxygen and carbon dioxide, the presence of which can cause corrosion of the feed system, boiler or condensate system. It is, therefore, advisable to reduce the concentration of dissolved gases in the feed water to the lowest practicable value.
b.
Thermal De-Aeration
In order to reduce the gas content of the feed water, it is normal practice to employ an independent de-aerating plant in which the gases are removed from solution by steam heating either under pressure or under vacuum, and are then ejected to atmosphere. The need for the installation of a mechanical / thermal de-aerator is dependent upon various factors, such as plant loading, percentage condensate return etc. Generally speaking, however, plant with a high evaporation rate, irrespective of boiler pressure, should be provided with full flow mechanical de-aeration.
The dissolved oxygen content of the water leaving the de-aerator should be as low as possible Oxygen in the feed water and / or the iron oxide produced by its reaction with feed pipe work and economizer become particularly damaging in the higher pressure ranges and de-aeration to the highest attainable degree then becomes essential, requiring a guaranteed performance of the order 0.007 ppm oxygen maximum. It is important that regular testing be carried out to check the efficiency of physical de-aeration. A slight unbalance in temperature / vacuum in a vacuum type de-aerator can result in high oxygen figures and an oxygen recorder in the de-aerator discharge line is recommended.
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c.
Chemical De-Aeration
The trace quantities of dissolved oxygen remaining after mechanical de-aeration should be removed by chemical treatment. In those cases where a de-aerator is not fitted, full oxygen removal by chemical treatment should be employed.
d.
Use of Sodium Sulphite
Sodium sulphite is widely used as an oxygen scavenger and has been found satisfactory at pressures up to about 70 kg /sq. cm. Above this pressure there is uncertainty as to its stability, but available information suggests that in general it is satisfactory for pressures up to 95 kg /sq. cm. where alkalinity due to sodium salts is maintained consistently in the boiler water. The preferred method of application is to dose the feed water continuously to maintain the concentration in the boiler water within a specific range.
e.
Use of Catalyzed Form of Sodium Sulphite
Where corrosion in the feed system is experienced, the use of a catalyzed form of sodium sulphite is an advantage. The effect of the catalyst is to speed up the oxygen sulphite reaction, so that it is completed well before the feed water reaches the boiler, thus giving a greater degree of protection to feed lines and economizer.
f.
Sodium Sulphite Injection Point
Sodium sulphite is a solid and this is charged in the feed water system.
g.
Use of Hydrazine
Hydrazine (N2H4) is a liquid and does not increase the dissolved solid contents in the boiler water. This is recommended for boilers operating above 42 kg / sq. cm and is widely used as the oxygen scavenger. Hydrazine is very volatile and it is difficult to maintain a useful
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concentration in the boiler water; this demands that the reaction with oxygen be largely effected in the feed system. Therefore, hydrazine should be injected at the furthest possible point in the feed system remote from the boiler before feed pump.
h.
Ammonia from Excess Hydrazine
Apart from scavenging of oxygen, the ammonia produced by decomposition of excess hydrazine adds to the alkalinity of feed water and can provide suitable alkaline conditions in the steam and in the condensate system. Provided the excess is controlled to avoid undue rise in the ammonia in the steam, there is little danger of copper corrosion in the condensing plant but good de-aeration is essential.
i.
Hydrazine Reserve
Hydrazine is a volatile chemical, and hence the possible reserves, which can be maintained in the boiler water, decrease generally as the temperature and pressure rise. Since the possible reserve also depends on the individual boiler characteristics, some variation can be found. The important point is to keep whatever reserve proves practical without excessive chemical consumption. A reserve of about 0.05-ppm is maintained.
j.
Health Regulation
Hydrazine is not normally permitted by health regulations where the steam comes into contact with foodstuff.
k.
Injecting Chemicals
A low-pressure pump is recommended for injecting chemicals for feed water alkalinity control and oxygen scavenging. This pump should have a provision to adjust the injection rate.
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6.3 - ALKALINITY CAUSTIC SODA, AMMONIA, AMINES
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6.3 - ALKALINITY CAUSTIC SODA, AMMONIA, AMINES

CONTENTS SL.NO. a. b. c. d. DESCRIPTION Alkalinity Maintained by Caustic Soda and Ammonia Caustic Soda Concentration Amines Volatile Treatment PAGE NO. 78 78 79 79
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6.3 - ALKALINITY CAUSTIC SODA, AMMONIA, AMINES a. Alkalinity Maintained by Caustic Soda and Ammonia
Whatever the operating pressure, the feed and boiler water should be alkaline to safeguard against corrosion not only in the boiler itself but in the feed lines, feed heaters and economizers.
The chemicals used for this purpose are either non-volatile, e.g. caustic soda, or volatile e.g. ammonia, cyclo-hexylamine. For all pressures, the addition of non-volatile alkali
depends upon such factors as residual alkalinity of the make-up water, the percentage of make-up, and the amount of alkali required in the boiler water.
When the makeup is distilled or de-mineralized, this alkalinity should be provided by continuous feed line dosing with caustic soda or a volatile amine e.g. cyclo-hexylamine In the pressure range over 53 kg / sq. cm. On load corrosion presents an important risk and so boiler water alkalinity (and consequently feed water alkalinity) is adjusted to optimize the circumstances of the individual installation.
b.
Caustic Soda Concentration
The caustic soda concentration in the boiler water becomes of increasing importance in the higher-pressure range. A high caustic soda concentration may allow very high localized concentrations at the steam / water / metal interface and cause continuous growth of thick magnetite at the surface which accelerates the reaction further and which temperature changes may cause to crack and thus allow further corrosion.
The mechanisms of such corrosion can be quite complicated they are not fully understood but experience has shown that reducing the boiler water concentration of caustic soda can reduce corrosion; however, inadequate caustic soda concentration where the water salts are largely chlorides can be just as damaging.
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Thus where it is desired to reduce the risk of caustic attack by reducing the caustic concentration, it is necessary to limit the boiler water concentration of dissolved solids as well, particularly where chlorides form an important proportion. Caustic soda is mainly added to maintain the boiler water reserve, the alkalinity being taken care of mainly by ammonia or cyclo-hexamine.
These observations concerning caustic soda apply to a limited extent to sodium phosphate and partly explain the reduced concentrations recommended elsewhere for the highpressure ranges.
c.
Amines
Condensate lines may be protected from corrosion by the use of a filming amine, preferably injected into the steam main. A typical filming amine is Octadecylamine.
d.
Volatile Treatment
The ultimate internal treatment to prevent free hydroxide or caustic alkalinity is the system called volatile treatment, or zero solids treatment. The sodium is eliminated from the feed water by evaporation and/or demineralization of the make up water and full flow, mixed bed demineralization of return condensate. No chemical containing sodium is added for internal treatment. The chemicals used are all volatile materials: ammonia and/or morphine or cyclo-hexylamine for p H control, and hydrazine or catalyzed hydrazine as an oxygen scavenger and corrosion inhibitor.
Such treatment is limited to very high-pressure boilers. It is the only system possible for once through or mono tube boilers and most manufacturers of PWR type nuclear reactors favour its use in the secondary steam generating loop to overcome unique crevice corrosion problems. It is occasionally employed in drum type boilers operating at 197 kg / cm2 and above but provides less safety and corrosion resistance against a temporary disturbance, particularly which of a condenser leak, than does the phosphate pH treatment system. In actual operation, most systems using volatile chemistry provide a phosphate feeding facility for emergency use during a period when feed water is contaminated with dissolved salts.
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6.4 - SUPPLEMENTARY WATER TREATMENT
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6.4 - SUPPLEMENTARY WATER TREATMENT

CONTENTS SL.NO. a. b. c. d. e. f. g. h. i. j. k. l. m. n. DESCRIPTION General Chelants Polymer Sludge Conditioning Anti Foams Oils Organic Matter and Suspended Solids in Feed Water Iron Copper and Nickel in Feed Water Silica and Aluminum in Feed Water Concentration of Dissolved Solids Carry Over, Steam Purity Turbine Deposits due to Silica Intermittent Blow Down / I. B. D. Continuous Blow Down / C. B. D. Water Sampling Measurements of Steam Purity Recommendations on boiler water, its sampling & Testing PAGE NO. 82 82 82 82 83 83 83 84 84 85 86 86 86 87
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6.4 - SUPPLEMENTARY WATER TREATMENT a. General
There are commercially available numerous water treatment chemicals to supplement or in some cases to replace the conventional treatments described previously.
Notes on some of these chemicals follow, but it is strongly advised that before using any of these treatments the services of specialist water Treatment Company should be sought.
b.
Chelants
By their chemical nature cheating agents such as the tetra sodium salt of ethylene-diamine tetra-acetic acid (Na4 EDTA) form soluble complex salts with calcium, magnesium, soluble iron and soluble copper. Particulate iron e.g. corrosion products brought into the boiler by condensate corrosion will not be chelated, at the pH level in the boiler water.
Chelant treatments require a high standard of control and the absence of oxygen from the feed and boiler water, following chemical scavenging, via a stainless steel injection fitting.
c.
Polymer Sludge Conditioning
Polymer sludge conditioning is normally used with phosphate conditioning, the purpose being to render the phosphate sludge less adherent. Polymers are also used in conjunction with chelants affording benefits in certain applications. In these cases the control of residual concentrations in boiler water is less critical than where chelants are used alone.
d.
Anti-Foams
Numerous proprietary anti-foams are available. They are used to reduce foaming (for example of highly alkaline boiler water) thus reducing carry-over.
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e.
Oils, Organic Matter and Suspended Solids in Feed Water
Oil contamination in boiler feed water can cause tube failures by two mechanisms. A layer of oil on the inside surface of the tube can have the same effect as other scales, causing the tube to overheat. The second mechanism is that oil tends to make phosphate sludge coalesce; again causing a scale to form on the parts of the tubes subject to higher fluxes, leading to eventual tube failure. Organic matter in the boiler breaks down which giving rise to corrosive agents such as carbon dioxide and organic acids.
Suspended solids in the boiler can promote priming and carry-over. Suspended solids can also bake onto evaporating surfaces again causing tube overheating and subsequent failure.
Oil, organic matter and suspended solids can also lead to foaming and consequently, carryover of solids.
f.
Iron, Copper and Nickel in Feed Water
Above 42 kg / cm 2, iron, copper and nickel produced by corrosion in the feed system, or iron produced more directly by corrosion in the boiler circuit, are often associated with particularly damaging corrosion mechanisms such as hydrogen embrittlement and every effort should therefore be made to minimize pick up in the condensate system. Suggested limit is 0.01 ppm at higher pressures .If values exceed this limit and / or immobile deposits in drums, headers etc. are encountered, advice should be sought from a water treatment specialist.
g.
Silica and Aluminum in Feed Water
The hazard of silica is mainly that it is a constituent of some of the most undesirable scales formed in tubes in the water circuit, notably for their very low conductivities. An eggshell scale thickness can cause tube failure. It is very difficult to remove these scales either mechanically or chemically. It is recommended that caustic soda concentration in the boiler water be maintained at 150 200 ppm above the silica concentration. In order to suppress
Page.No.83


the tendency for silica to react with calcium, iron or magnesium etc. in the formation of such scales.
The presence of aluminum, together with silica in the feed and boiler water can often give rise to analcite (hydrated silicate of aluminum and sodium) type scales, resulting in tube failures. It is, therefore, important to eliminate aluminum entirely from the feed water.
Where aluminum salts are used for coagulation of the raw water, strict control of the process is essential to prevent the transference of either soluble or suspended aluminum salts to the feed system.
h.
Concentration of Dissolved Solids Carryover, Steam Purity
The concentration of solids in the feed dictates the rate of blow down of boiler water and / or the boiler water concentration. Boiler water concentrations must be maintained below the values at, which contamination of the steam becomes important, in order to avoid carryover and the accompanying dangers of deposits in the main steam valves and prime movers.
The occurrence of carryover is influenced by a number of factors other than the concentration of salts in the boiler water, such as fluctuations in water level and load, incorrectly refitted drum internals, and the presence of oil, grease and other foam inducing materials in the feed water.
Operational experience will be the best guide as to the maximum concentration of suspended solids, dissolved solids and alkalinity which can be tolerated without giving rise to carryover. It is advised to adopt lower values of suspended solids to reduce carryover and the risk of corrosion.
i.
Turbine Deposits due to Silica
All the salts normally found in boiler water are volatile in steam to some degree, insignificant at the boiler pressures under consideration except for silica which becomes
Page.No.84


important above 42 kg / cm2 silica in steam tends to condense and deposit in medium and low pressure stages of turbines. It is generally believed that such deposition should remain within acceptable limits provided silica in steam does not exceed 0.02 ppm as SiO2. For this, it is necessary to limit the silica concentration in the boiler water .
The boiler water concentrations should be regarded as maximum and lower concentrations may be preferred since less deposition would be expected on the turbine. The recommended silica content as given is 0 mg / l or ppm. Silica in the feed water thus should be limited to 0.02 ppm SiO2.
Where blow down, given to reduce the concentration of dissolved solids, does not reduce the boiler silica content, extra blow down must be carried out to achieve this, if turbine fouling is to be avoided.
j.
Intermittent Blow down / IBD
Reduction of boiler water concentration of suspended solids, dissolved solids or blowing down effects silica. Blowing down should never be done via economizer and water wall drains when on load. Intermittent blow down / IBD / main blow down line is drawn from the water drum for the above purpose. To carry out blow down through the IBD line, first open the stop valve near the water drum, and then open the stop valve distant the water drum. After blow down, close the stop valve distant the water drum first and then close the stop valve near the water drum. Close the valves tight and ascertain no leakage. Normally not more than 25 mm in the gauge glass should be blown at one blow down.
For sludge removal, short and sharp bursts are most effective. It is recommended that during normal service the isolating valves on IBD line for control of suspended solids, dissolved solids or silica concentration or for lowering the water level in the steam drum should be padlocked open and that drains from radiant chamber water wall bottom headers should be padlocked shut since operation of these latter valves at full load may disturb circulation and cause very severe damage.
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The virtual exclusion of hardness salts in the feed water for high pressure boilers eliminates the production of a hardness sludge but it is none the less prudent to operate the blow down from the lower drum regularly everyday to reduce dissolved iron concentration and blowing down is therefore solely for concentration control as it becomes necessary. Deposits that normally occur are iron oxide and copper these may be partially removed, as opportunity arises, by emptying the boiler at 7 kg/cm2.with economizer and radiant chamber front wall bottom header drain wide open.
k.
Continuous Blow down / CBD
Continuous blow down offers a means of economic control of the water concentrations, total dissolved solids or other impurities according to the standard practice.
This blow down is extracted at the discharge from cyclone separators within the drum, at which points the boiler water is at its maximum concentration. In case that any chemical is used to treat the boiler water in the drum, the amount of the chemicals shall be considered as a part of the total dissolved solids in feed water.
Sometimes the amount of blow down must be determined by some content of boiler water other than the above total dissolved solids.
l.
Water Sampling
Water sample coolers are provided for boiler water and for the saturated steam. The boiler water sampling line is drawn from continuous blow down CBD line while the saturated steam sampling line is drawn from the main steam line before the steam flow meter connecting lines. Cooling water inlet and outlet headers are connected to steam and boiler water sample coolers.
m. Measurements of Steam Purity

Among the methods available for measuring steam purity are flame photometries,
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conductivity of condensed steam, evaporation of condensate to dryness and sodium ion electrode techniques.
Sodium flame photometry is capable of indicating concentrations of less than 0.03 ppm sodium. Conductivity of a degassed sample should normally be of the order of 2 micro-mhos or less. Evaporation to dryness normally indicates 0.5 to 1.0 ppm. It has been reported that the sodium specification electrode is not reliable below 0.002-ppm sodium, due to ammonia interference. The sodium ion electrode is, however, the most commercially useful and accurate method for the determination of steam purity
Sodium flame photometry and sodium ion electrodes indicate only sodium, not silica or gases derived from organic matter in the feed water, CO2, ammonia, hydrazine etc., which tend to flash off . in the drum and pass to the plant . These gases may not be completely
removed in a de gasser and often give rise to a higher conductivity than would be expected by sodium analysis. Evaporation to dryness may indicate (for example) iron which may
form a scum on the surface of the water in the drum and be carried direct to the steam line, being indicated neither by sodium flame photometry nor by conductivity
There is no absolute measure of impurities in steam suitable for simple correlation against a rate of turbine fouling but the foregoing methods offer a fairly high degree of surety against excessive, uncontrolled deposition.
n.
Recommendations on Boiler Water, its Sampling & Testing
BOILER FEED WATER LIMITS
SL. No DESCRIPTION 1. pH (copper alloy pre- boiler system) Conductivity
LIMIT 8.8 9.2 Less than 0.5 micros mhos/cm
TESTING FREQUENCY Twice a shift manually
2.
Twice a shift - Manually
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3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Dissolved oxygen Total silica Residual hydrazine Total Iron Total copper Total hardness Chlorides Permanganate Number (Organics) Total CO2 Oil and grease
Less than 0.007 ppm Less than 0.02 ppm 0.01 0.02 ppm Less than 0.01 ppm Less than 0.01 ppm BDL BDL BDL BDL BDL
Once a day manually (Indigo carmine method) Once a shift manually Once a shift - Manually Once a day manually Once a day manually Once a shift Manually Once a shift Manually Once a day manually Once a day - manually Once a week - Manually
BOILER WATER LIMITS

SL. No DESCRIPTION 1. 2. PH Conductivity LIMIT 9.8 10.2 Less than 200.0 micro mhos / cm Less than 100 ppm TESTING FREQUENCY Twice a shift manually Twice a shift manually
3. 4. 5. 6. 7.
TDS Residual phosphate 2P-M ( P for P Alkalinity and M for M Alkalinity Total Hardness Chlorides (Mercury Thio cyanate method)
15- 25 ppm Nil BDL BDL
Once a shift - manually Twice a shift manually Once a shift manually Once a shift manually
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SATURATED STEAM AND MAIN STEAM
Sl.No 1. 2. 3. 4. 5. 6.
Description Conductivity (Before Cation) Ammonia Total Silica Total Hardness(TG Condensate)
Limit Less than 3.0 micro mhos / cm Less than 0.3 ppm Less than 0.02 ppm BDL
Testing Frequency Twice a shift Manually Once a Shift Manually Once a Shift Manually Once a Shift Manually Once a Shift Manually Once a Week - Manually
Chlorides (TG Condensate) BDL Sodium (Saturated Steam) Less than 20 ppb
CBD line must be kept open continuously.
Any deviation from the above said parameters should be taken seriously and boiler must be shut in case of any deviation to prevent permanent damage to the equipment.
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6.5 - SIGNIFICANT SALT SOLUTIONS PROPERTIES
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6.5 - SIGNIFICANT SALT SOLUTIONS PROPERTIES

CONTENTS SL.NO. a. b. c. d. e. f. DESCRIPTION Basic Chemistry PAGE NO. 92 92 93 93 93 95
Measurement Units Hardness Caustic, Carbonate and Bi-Carbonate Alkalinity Titration with Acids Equivalent Mineral Acidity E. M. A.
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6.5 - SIGNIFICANT SALT SOLUTIONS PROPERTIES a. Basic Chemistry
Raw water comprises rainwater that has dissolved mineral matter from strata through which it has passed. These mineral salts are almost completely dissociated in solution and effectively the raw water contains mainly calcium, magnesium, sodium and potassium cations and bicarbonate, carbonate, chloride, sulphate and nitrate anions. Softening processes often convert bicarbonate to carbonate and introduce the hydroxide anion.
Sodium and potassium salts are highly soluble but some calcium and magnesium salts are less soluble and may easily be precipitated e.g. calcium carbonate, magnesium hydroxide. Calcium sulphate has a particularly undesirable characteristic in that its solubility decreases with increasing temperature so that whilst it remains in solution i.e. dissociated as calcium and sulphate ions, in the bulk of boiler water, it may be precipitated by high temperature at the steam / water / tube surface interface and form a scale. Raw waters contain other mineral and organic matter normally not of direct importance to boiler operation but often affecting softening processes.
b.
Measurement Units
Concentrations are usually expressed in ppm i.e. parts solute per million parts solution by weight; this is the same as mg / liter .
Oxygen has traditionally been expressed in
cc / liter i.e. ml / liter at standard for Feed Water
temperature and pressure but the attached recommendation in Table 6d
Conditions follow current trend and are in ppm. For oxygen, 1 ppm = 0.7cc / liter.
Alkalinity and Hardness concentrations are normally expressed in ppm as Ca C O
3.
The
3
obsolescent degrees (British) may still be encountered -.10 = 1 grain Ca C O gallon = 14.3 ppm as Ca C O
3.
per
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A term common in Continental Europe is m Val / liter , this is the same as ppm , equivalent per million or the number of equivalents per million or the number of equivalent weights solute per million parts weight of solution. 1 m val / liter = 1 p pm = 50 ppm as Ca C O 3.
The term pH is used to express the acidity or alkalinity of aqueous solutions due to Ionization. The acidity or alkalinity is a function of the hydrogen ion concentration which may be measured electrometrically or calorimetrically. A solution is acid if the pH value is below 7, alkaline if the pH value is between 7 and 14 and neutral if the pH value is exactly 7.
c.
Hardness
The hardness of water is the calcium and magnesium content and it is usual to express concentrations of hardness in terms of the chemically equivalent concentration of calcium carbonate (irrespective of whether it is hardness due to magnesium or whether carbonate in fact is present). Thus raw water may have a total hardness of 80 ppm as Ca C O calcium hardness may be 60 ppm as Ca C O magnesium hardness expressed as Ca CO 3.
3 3,
of which
and the remainder, 20 ppm, is the
d.
Caustic, Carbonate and Bicarbonate Alkalinity
Hydroxide, carbonate and bicarbonate are alkaline and may be measured by titration against an acid. The term alkaline is used for these anions or for the salts they form. Bicarbonate and hydroxide cannot (generally) co exists but react to form carbonates with the evolution of CO2. Caustic alkalinity, carbonate alkalinity and bicarbonate alkalinity refers respectively to the concentration of hydroxide, carbonate & bicarbonate. Concentrations are expressed in terms of the chemically equivalent concentration of Ca CO
3.
e.
Titration with Acid
Titration with acid to pH 9.3, corresponding to the end-point of phenolphthalein, neutralizes
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hydroxide (if present) and half the carbonate. Titration to pH 4.5, corresponding to the end point of methyl orange neutralizes the remaining carbonate and bicarbonate (if present). i.e., titration to pH 4.5 neutralizes the total alkalinity. By titration with acid using phenolphthalein as indicator and in the presence of barium chloride, only the caustic soda is neutralized; this test is employed where phosphate is present.
The following relations as given in Table below apply where P, M, and P (Ba Cl respectively the alkalinities measured as above, in ppm. P, M AND P (BACL 2) RELATIONSHIP.
2)
are
Titration P = Nil 2P < M 2P = M 2P >M P=M P>P(Ba Cl 2) P(Ba Cl2)= Nil
Hydroxide Nil Nil Nil 2P-M P P(Ba Cl 2) Nil
Carbonate Nil 2P 2P 2 (M-P) Nil 2{P-P(Ba Cl 2)} 2P
Bicarbonate M M-2P Nil Nil Nil Nil M-2P
Total Alkalinity M M M M M 2PP(BaCl2) M
Alkaline hardness (approximating to the traditional temporary hardness) refers to the calcium and magnesium hardness that may theoretically be associated with alkalinity i.e. carbonate, or hydroxide anions. The remaining non alkaline (permanent) hardness,
if present, is the calcium and magnesium hardness associated with non alkaline anions, sulphate, chloride and nitrate.
Thus where water has a total hardness of 80 ppm as Ca C O
and its total alkalinity is 50

3 and
ppm Ca C O 3, it may be said to have an alkaline hardness of 50 ppm as Ca C O alkaline hardness of 30 ppm as Ca C O
3.
a non
If the total hardness were 80 ppm but the total
alkalinity were 100 ppm, then the alkaline hardness would be 80 ppm and there is said to be no non- alkaline hardness (the remaining 20 ppm alkalinity being associated with sodium and / or potassium) Hardness and alkalinity concentrations are insufficient by themselves to fully describe the mineral matter of a water since they alone give no indication of sodium,
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potassium, sulphate, chloride and nitrate concentrations.
f.
Equivalent Mineral Acidity E. M. A.
The term E. M. A. equivalent mineral acidity, is often used to express the total of the sulphate, chloride and nitrate concentrations, again as .C a C O
3
Calcium carbonate and
magnesium hydroxide are relatively insoluble at the temperature of boiler water and the maintenance of a concentration of free sodium carbonate in the water of a boiler may be enough to precipitate sufficient calcium (as a free flowing sludge of calcium carbonate). and so prevent the formation of calcium sulphate on the steam producing tube.
Unfortunately Surfaces sodium carbonate breaks down at high temperature so that at 14 kg / cm 2, for example, about 90 % of the carbonate may be broken down to the hydroxide and carbon dioxide (which passes off with the steam) and it becomes impossible to maintain the necessary 300 ppm carbonate without unacceptably high hydroxide concentrations (by priming and carryover considerations).
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CHAPTER 7
BOILER OPERATION
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CHAPTER - 7
BOILER OPERATION
CONTENTS
SL.NO. DESCRIPTION
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 FILLING WATER IN ECONOMIZER AND BOILER HYDRAULIC TEST PROCEDURE REFRACTORY DRY-OUT & ALKALI BOIL-OUT STEAM BLOWING PROCEDURE SAFETY VALVE SETTING PROCEDURE BOILER START-UP INCLUDING PRE-COMMISSIONING CHECKS & COLD START-UP PROCEDURE BOILER PRESERVATION PROCEDURE RAISING PRESSURE BOILER STEAM LOADING NORMAL STEAMING
PAGE NO.
98 105 112 126 135 148 159 164 170 174
Page.No.97


7.1 - FILLING WATER IN ECONOMIZER AND BOILER
Page.No.98



CONTENTS SL.NO.
a. b. c. d. e. f.
DESCRIPTION
Feed Water Feed Water piping Economizer Boiler and Mountings Drum gauge glasses Water filling into boiler i) Valves has to be in Open position before Water Filling ii) Valves has to be in Close position before Water Filling iii) Valves has to be in Close position after Water Filling
PAGE NO.
100 100 100 101 102 102 102 103 103 104
g.
Steam drum water level
Page.No.99


a.
Feed Water
for service, care should be taken to use only properly
When the boiler is filled initially
treated and de-aerated water, so that correct / recommended water quality shall be maintained right from the initial filling to avoid internal pressure parts related problems such as scaling, corrosion etc in long run. Please also refer to recommended feed water quality.
b.
Feed Water Piping
Make sure that the feed water pipe line is clean. If required, drain valve in the pipe line and economizer inlet header drains shall be kept open to flush the line prior to filling of steam drum. Close the inlet and outlet isolation valve of the control valves, and open 100 % bypass valve of the feed water control station. Close all feed water line drain valves one by one after ensuring feed line is sufficiently flushed and cleaned. Prior to flushing of feed line close the root valves of the measuring instruments to avoid dirt/ foreign matters going in to the instrument capsules.
c.
Economizer
Open the Economizer air vent valves. Open economizer inlet stop valve. Open the drain valve for short period and close the drain valves once water clarity is equal to feed water clarity. Make sure that there is no foreign matter in the gas path of the economizer enclosure. When a flow of water has been established through the economizer air vent, close the air vent valve.
Water should be gradually taken into the boiler through feed control station and ensures the water filling is carried out in controlled manner. As water filling occurs gradually, air will completely vent out & chance of sudden pressure rising will be avoided. BOILER OPERATION & MAINTENANCE MANUAL Page.No.100


Once boiler filled with water up to main steam stop valve, pressure shall be raised gradually in controlled manner up to the hydraulic test pressure. At prescribed hydro test pressure to be maintained for 30 min and inspect the boiler thoroughly for leakage. Hydraulic test is carried out as described elsewhere in case of a new boiler or after major maintenance job of the boiler pressure parts. After hydraulic test, water level in the steam drum is brought down to 50mm below NWL (Normal Water Level).
In case the hydraulic test is not required, bypass above and close the feed water flow control valve, when steam drum water level reaches 50mm under NWL (Normal Water Level)
Stop the boiler feed water pump if it is not necessary after ensuring the safe water level for the operation.
a) Do not over tighten the valves by applying excessive leverage as it may lead to permanent damage of valve & its seat b) Do not fill super heaters by filling the drum. Always prefer heaters. d. Boiler and Mountings back filling from of super being heaters carried to into avoid super
contaminants
drum
Clean the steam drum manually after temporarily closing the down comer opening and clean the steam drum to ensure all foreign particles are removed.
Check if drum internals are fixed tightly and are arranged as per drawing. We should also ensure that all internals are in good shape without damage. Replace damaged gaskets of drum manhole with new one. Confirm the tightness of manhole door.
Page.No.101


Notes
Dont
apply
any
grease
on
the
gasket;
it
will
contaminate the boiler water. e. Drum Gauge Glasses
Make sure that the drum Gauge glasses are in good working condition. It is most essential for safe operation of the boiler to keep the drum direct water level gauge glass is kept in working condition during operation. One should not relay only on automatic control which is based on electronic or annunciation system. It is recommended always to maintain adequate lighting around the gauge glass for easy observation of level. It is recommended to flush the drum gauge glasses once in a day and check the proper functioning of the same.
f.
Water Filling into Boiler
The procedure for initial filling of boiler with water is described as below,
i)

Valves has to be in Open position before Water Filling

Feed water line drain valves Feed Control Station, Control Valve Before & After drain valves Economizer inlet stop valve Economizer header air vent valves Economizer drain valves Steam drum air vent valve All Drum gauge glass root & isolation valve Drum blow down valves Bottom blow down valves Water wall header drain valves Raiser air vent valves Super heater air vent valves Main steam line air vent valve Main steam line drain valve BOILER OPERATION & MAINTENANCE MANUAL Page.No.102


Blow down Tank drain valve Blow down Tank level Gauge root valves Start-up vent valve
ii) Valves has to be in closed position before Water Filling

Main steam stop valve. Main steam stop valve bypass valve. Drum pressure gauge root valve Drum pressure transmitter root valve Level transmitter root valves Main steam flow / pressure transmitter root valves Main steam pressure Gauge root valves Feed water flow transmitter root valves
iii) Valves which are to be closed after Water Filling

Close the feed water line drain valves after feed water pipe line is flushed. Close the feed water line vent valves when the water overflows. Close the Economizer drain valve, after ensuring water drained sufficiently and Economizer coils are flushed fully. Close the Economizer air vent, once water overflows through the vent. Close the Bottom blow off valves, after sufficient flushing. Close the Water Wall header drain valve as water starts coming out. All Drum water level gauge drain valves are to be closed after water flows through the drains. Close the boiler blow down valve when feed water flows out from blow down tank drain valve. Close the Raiser air vents, after water overflows through the vents.. Close the drum air vent valve, after drum is filled with water and overflow through the drum vent. Close the Super heater air vent, after the super heater coil is filled with water. Close the Main steams air vent, after ensuring that water filled up to main steam line. Close the Chemical feed valve.
Page.No.103


Close DWLI & RWLI isolation Valve Feed water flow control valve Feed water flow control bypass valve Feed water flow control valve isolating valves Boiler steam drum sampling valve
g.
Steam Drum Water Level

Monitor the steam drum water level Arrangement for inter-communication between the operators at drum level and firing floor is to be made.
Test the level transmitter for low water level trip at 200 mm. from center line of steam drum which is considered as 0 mm (Normal water Level). and confirm if the trip position is correct. High and low alarms are set at +100 mm and -100mm from the Normal water level. Keep the water level normally within 50 mm from the normal level (Drum center line) during operation of boiler.
Check that the difference in readings between the transparent type level gauge and controller indicator and match the same to avoid any deviation between the two. Before starting the boiler maintain the water level in between Low Low level and Low level of the boiler so that during initial firing water will not swell and carried over to super heater coils. We can also check the functioning of low level setting for alarm when the water swells and cross the set limit of -100mm from the normal water level.
If hot water is used to fill the boiler and economizer, extreme care must be taken by slowly raising the water level after proper venting so that no pressure developed due to flash steam in side the boiler unit. To avoid excessive thermal stress to the pressure parts it is recommended that the difference of temperature of the feed water and drum should not exceed more than 28C.
Check the water level gauge and water column by opening all valves attached at least once a day periodically.
Page.No.104


7.2 - HYDRAULIC TEST PROCEDURE
Page.No.105


7.2 - HYDRAULIC TEST PROCEDURE

CONTENT SL.NO. a. b. c. d. e. f. g. DESCRIPTION Introduction. Preparation for Hydraulic Test. Applicable Code and Test Pressure. Pressuring and Inspection Procedure. Monitoring of Test Conditions. Acceptance Criteria. Post Hydraulic Test. PAGE NO. 107 107 108 108 109 110 110
Page.No.106


7.2 - HYDRAULIC TEST a. Introduction
The hydraulic test is carried out after erection and after repair of the boiler and economizer pressure parts to ascertain that there is no leakage.
b.
Preparation for Hydraulic Test

Ascertain that no tool or foreign materials is left in the boiler and economizer Close the steam drum manhole door tightly. Clean up the radiant chamber, if found fouled. Install and connect the temporary equipment and piping. Isolate the parts of the boiler and economizer which is not designed durable under the test pressure.
Replace the safety valve with a blind cover/ hydro plug. Inspect the pressure gauges as well as the leading pipe, whether the pipe is clear from choking.
Check the connection of the pressure gauges and open the root valves fully. Downstream piping of the control valve should be flushed sufficiently before operating the control valve.
Close all the other valves mounted on the boiler and economizer except the air vent valves. Close fully and tightly all the valves for the instruments and transmitters to prevent damage.
Ensure sufficient quantity of DM Water (approx. water holding capacity 40 m3) is required for carrying out one hydraulic test. It is advisable to maintain D.M water for 3 fills.
Notes
For New boiler or for the boiler, which is under shut for long period, the boiler has to flush sufficiently, to avoid sludge formation inside the pressure parts.
Page.No.107


c.
Applicable Code and Test Pressure

Applicable code IBR 1950
i)
Test Pressure for the boiler
Design Pressure / Maximum allowable working pressure for boiler, radiant chamber and screen tubes is 88 kg/cm2 (g), Hence Hydraulic test pressure is 132 kg/cm2 (g).
ii) Test Water and Pressure Gauge

DM water shall be used for hydraulic test. The water temperature shall be not less than 21.1 C and having the pH value around 9 to be used for hydraulic test, 150 ppm of hydrazine shall be maintained in the boiler.
The range of the pressure gauge shall be about two times of the maximum test pressure but not less than 1.5 times for that pressure. Test pressure gauge shall have been calibrated within six months.
Fill up the boiler and economizer with DM water. During water filling work, all air vent valves shall be left open in order to relieve the remaining air inside boiler and economizer.
Air vent valves shall be tightly closed, after confirming water flow through the vents.
d. i)
Pressuring and Inspection Procedure Pressuring and preliminary inspection
The pressure shall be raised at a rate of less than 3.5 bar per minute and shall be maintained at about 1/4, 2/4 and 3/4 of the test pressure for 5 to 10 minutes to make sure that no leakage is observed.
Page.No.108


ii) Maximum pressure test

After raising the pressure to of the test pressure and checking that there is no leakage, the pressure is raised to the test pressure .The pressure shall be under proper control at all times. This test pressure shall be maintained for a sufficient period (10-15 minutes).The closed visual inspection for leakage is not required during this step.
Under any circumstances test pressure should not go above

!
6% of test pressure i.e. above of 106% is not advisable. It is highly recommended that only authorized personnel are allowed to inspect while on hydraulic test. Please ensure zero disturbances and the site should halt their erection while on pressure buildup.
iii) Reducing the test pressure and close visual inspection

The pressure shall be gradually reduced to the maximum allowable working pressure and shall be maintained for minimum 30 minutes while pressure parts are inspected.
The metal temperature shall not exceed 48.8 C during the close visual inspection. After this inspection, the pressure shall be gradually reduced.
e.
Monitoring of test condition
Temperature of atmosphere, water and metal shall be monitored. Test pressure shall be monitored by pressure gauges.
Inspection method: Leakage, crack and deformation shall be checked by visual inspection.
Page.No.109


f.
Acceptance criteria
Following condition (s) shall be not permitted
1. Leakage 2. Crack 3. Deformation
Notes
Leakage at temporary seals, which are installed for the purpose of conducting the hydraulic test and which will be replaced or removed later, may be permitted unless the leakage exceeds the capacity to maintain the test pressure for the required amount of time.
g.
Post hydraulic test
When the hydraulic test is finished, drain the water completely by opening the bottom blow off valves and open the air vent valves on the steam line so as not to decrease the pressure below atmospheric pressure. Reset the safety valves and others in the normal conditions.
Page.No.110


Annexure-I PRESSURE TEST REPORT REPORT NO. DATE Type of Test System Code of Standard Isometric Drawing No. Total No. of Field Joints Design Pressure Test Pressure Holding Time : : : : : : : : : : IBR 1950 CUSTOMER SITE Hydraulic : :
Identification No. of Pressure Gauge: The leak test has been carried out as per above parameters and entire system has been checked physically and no oozing / leakage observed from the system / parts under test. Remarks:
System is released for further activity including Painting/Insulation. Test Conducted By Witnessed By Date Signature : : : : EGBPSPL BCEL
EGBPSPL
BCEL
Page.No.111


7.3 - REFRACTORY DRY-OUT & ALKALI BOILOUT PROCEDURE
Page.No.112


7.3 - REFRACTORY DRY-OUT & ALKALI BOIL-OUT PROCEDURE

CONTENT SL.NO. a. b. c. d. e. f. g. h. i. j. k. DESCRIPTION General Chemicals Economizer Admission of Coke Oven gas into the boiler Sequence of drying and boil-out Checking of mountings and gauges during boil-out Procedure for determination of Oil and Grease in boiler water samples during Alkali Boil-Out Post boil-out inspection Replacement of gauge glass parts Refractory inspection Passivation PAGE NO. 114 114 115 115 117 118 120 122 122 122 123
Page.No.113


7.3 - REFRACTORY DRY-OUT & ALKALI BOIL-OUT PROCEDURE a. General
When the boiler is new or after extensive repair to the pressure parts, residual oil or grease remained inside the pressure parts must be removed by alkali boiled out.
During the initial boiling out process, or after major repairs are done to refractory materials, the drying out shall be carried out to dry the refractory bricks and castables. When the refractory bricks and castables are new, the drying out must not be started within 24 hours after the completion of the refractory work.
Before proceeding with alkali boiling out of boiler, ensure internals of steam drum is cleaned manually for oil or other foreign materials to avoid chocking of pressure parts leading to poor circulation and possible tube failure.
b.
Chemicals
The pressure parts should be boiled out with a dilute solution of Tri-sodium phosphate (Na3 PO4) and caustic soda (NaOH) to remove grease and loose mill scale from the internal surfaces. Suggested quantities of these chemicals which are to be added to the boiler water are given below in kilograms based on the water holding capacity of the boiler (approximately 40 Tonnes)
Crystalline tri-sodium Phosphate Caustic Soda flakes
Na3 PO4, 12 H2O NaOH
175 kgs. 20 kgs.
Crystalline form of tri-sodium phosphate is preferred as it dissolves more easily in water than the anhydrous form.
Open the boiler steam drum manhole door. See that there is about 150 mm depth of water in the drum. Dissolve the chemical in a plastic tank with hot water and filter the solution to
Page.No.114


avoid un-dissolved salt entering the drum. Transfer the solution manually when the water temperature in the drum is approximately 70 C with care through steam drum manhole while slowly feeding the drum with water. This procedure will ensure that the solution is thoroughly distributed. If the solution were poured into an empty boiler drum, the whole quantity would disappear into the nearest boiler down comer.
Dissolve 50 kilograms of Tri-sodium phosphate solution to inject same through chemical dosing pump if required during boil-out stage to maintain the boiler water chemical concentration more than 50 % of the initial concentration. After closing the drum manhole door, add water to bring the water level into the gauge glasses.
c.
Economizer
Economizer, during the boiling out procedure, should be handled in the same manner as during the starting-up period; i.e. the procedure and precautions for the operation of the air cocks, drains, feed valves, etc., called for in the starting-up instructions, should apply during boiling out period.
d.
Admission of Coke Oven gas into the boiler
Before admitting the hot flue gas into the WHR Boiler, it is recommended as earlier mentioned that the following precautions should be taken
Remove all structural timber from the radiant chamber and gas passages, especially from locations where the gas temperature may reach the point at which wood will burn or glow. The glowing member may be the cause for explosive gases which can accumulate inside the gas path of boiler leading to undesired explosion.
Keep the Drum internals in loose condition inside the steam drum prior to the start-up chemical boil-out.
Ensure the entire thermal expansion measurement indicator is provided. Check that all blow-down and drain valves for its effectiveness. Make sure that the drum gauge glasses are in good working order. Make sure that the inlet guillotine damper provided on the coke oven gas inlet duct to
Page.No.115


WHR Boiler is functioning properly and ensure full close and open is achievable for the guillotine damper. Make sure that the unit is filled with water and chemicals in accordance with the foregoing instructions. Before letting coke oven gas into the boiler ensure startup vent and drum vents are kept open. Gradually open inlet guillotine damper after opening both suction and discharge dampers of Induced draft fan is kept at full open condition. Open dilution damper to required level to maintain desired gas temperature at the radiant chamber. After two to three hours time start the ID fan and run the ID fan at its minimum RPM to suck additional gas into the WHR Boiler. Manipulate the speed of the ID fan to required gas through the boiler so that the steam saturation temperature rising rate within 1C per minute. This limitation should be duly kept under consideration during all the three days of boiling out period. Precaution should be taken against the spall and crack of refractory caused by intense flue gas flow. After the start to chemical boil out activity, it is important to admit the hot flue gas continuously at the minimum rates consistent with the boiling out process as per the alkali boil out curve in annexure A.
Notes
The drying out and boiling out periods may give rise to hazards fumes unless very great care is taken to observe the safety rules. In particular, experienced operators
only should handle the chemical boil out operation and it is recommended that they should have adequate training and opportunity to become familiar with the new equipment
before start of chemical boil out.
Page.No.116


e.
Sequence of Drying and Alkali Boil-Out (Ref: standard boil-out
curve provided at the end of this chapter 7.2)

The drying and alkali boiling out should be completed only after satisfactorily results are obtained. The maximum boiling out pressure shall be 50 % of the normal working pressure specified for the boiler.
If required, the main steam range may be warmed through during this period. Steam traps on steam range drains should be by-passed and drain valves frequently opened wide to blow out sediment. At first, the hot flue gas flow into boiler should be gradually increased so that the pressure gradually raised to have proper drying out of the refractories. The water level gauges should be kept clean by blowing them through as soon as sufficient pressure is available.
On the 1st day morning the refractory dry-out shall be carried out. During this process the steam pressure is maintained below 8-bar (g) for a considerable period till the refractories are dried out. On the 2nd day morning, the boiler shall be started for alkali boil-out. During the alkali boilout, when the boiler pressure is raised to 30 % of normal working pressure for boiling-out and also when full pressure is being raised for the first time, all pressure parts should be kept under observation to confirm free thermal expansion of pressure parts as per the thermal expansion drawing. Maintain the boiling of chemicals for 8 hours duration before closing the inlet guillotine damper at hot flue gas inlet duct for blow downs. Operate the blow down valves at the end of boiling period in quick succession to remove accumulated sludge after taking the thermal expansion measurements of the pressure parts. Blow down water samples are to be drawn from all blow downs and allow the boiler to cool naturally during night hours.
On the 3rd day morning, the boiler pressure will be gradually increased to 50 % of its working pressure and continue the chemical boiling for 8 hours. At the end of 8th hour close the inlet guillotine damper in the hot flue gas duct and the entire blow downs are to be
Page.No.117


operated in quick succession to blow off sediments after taking the thermal expansion reading of pressure parts. Blow down water samples are to be drawn from all blow downs. The above procedure is once again repeated till satisfactory results are obtained in the analysis of blow down water. The boiling out is carried out during day time till oil tracers are obtained below 4 ppm for two consecutive blow-down samples.
f.
1.
Checking of Mountings and Gauges during boiling-out

As soon as steam is heard blowing from the air cocks, the steam pressure gauge connection should be checked for possible choke by closing the shut off cock on the gauge and opening the drain valve. As soon as the line is clear, the drain valve should be closed and the gauge cock is to be opened. With increase in boiler pressure, the action of the gauge needle should be watched to make sure that the gauge itself is functioning properly.
2.
If the steam pressure gauges shall be hooked up in line once the steam is jetting out of the air vents.
3.
Make a careful inspection of drum manhole joints and hot tighten if necessary. Inspect the complete boiler for gas and steam leaks.
4.
After closing the hot flue gas entry to boiler the water level in the gauge glass is raised to the upper limit of the range and the boiler sediments are allowed to settle over night.
5.
During the boiling out period all dampers should be operated to ensure that they are free to move throughout the full extent of their travel under hot conditions.
6.
The procedure of raising the pressure and allowing the pressure to fall greatly assists the removal of mill scale from the internal surfaces of the pressure parts.
7.
Before pressure is raised open each boiler blow down valve, and wall drain for a few seconds to get rid of any accumulated sludge, and add feed water to restore the water level to normal. Use the toppingup line or the direct feed line to the steam drum, if fitted, to avoid removing boiling out chemical from the economizer.
8.
At the end of the alkali boil-out, when the boiler pressure drops down to 7 kg/cm2 (g) during cooling down, the boiler is hot drained through radiant chamber front wall bottom header drain valve and the economizer drains. The drum air release valve is opened at 2 kg/cm2 (g).
Page.No.118


9.
Close the blow down valves and refill the boiler with D.M water once the drum metal temperature is approximately 70 C. Multiple rinses with DM water is advocated after the boiler is hot drained to reduce the pH of drum water less than 9.5 and to obtain clear blow down water.
10.
As the boiler water used for boiling out is of high alkaline, special care must be taken for the selection of the place where the water is finally drained.
Notes
Water
holding
capacity
is
40
Tonnes
(approx)
up
to
normal water level. Tri Sodium Phosphate requirement for the Alkali Boil out shall be 175 Kg (Minimum). At any time of Alkali Boil out pressure should not rise above 50 % of the working pressure or 45 kg/cm2 (g). TSP concentration shall not be below 50% of the original concentration. If Succession Oil traces test result shows less than 4 ppm, boiled out can be stopped and boiler flushing & rinsing can be started. The results shall be reported in mg/l (ppm). Results to be achieved after Rinsing: Conductivity Phosphate Iron PH <5 S/cm <25ppm <5 ppm 9.5(or)equal to the DM water quality Oil Turbidity <2 ppm <1 ppm.
After reaching the above results and the rinsing can be declared as completed and will be permitted for water wall bottom header & down comer drain stub cutting and drum cleaning activities. BOILER OPERATION & MAINTENANCE MANUAL Page.No.119


g.
Procedure for determination of Oil and Grease in boiler water samples during Alkali Boil-Out
The following procedure is in close accordance with ASTM D 1178 and accuracy of this method is 1 ppm. We are giving below a standard oil testing method carried out for water. The various equipments required for testing has to be arranged by clients in advance for their laboratory to carry out the test during chemical boil-out.
Collection of samples
Samples shall be collected through individual drains through all bottom headers and a composite sample shall be prepared and used for analysis of oil and grease. The sample shall be collected in a thoroughly cleaned Stainless steel / Plastic Bucket.
List of equipments
500 / 250 ml glass separating funnel 500/250 ml glass measuring cylinder 25 ml glass measuring cylinder Glass funnel 100 ml glass beaker Desiccators pH meter Chemical Balance (0.1-mg accuracy) Air Oven
List of chemicals
Chloroform AR Sodium Sulphate Anhydrous AR 1:4 Sulphuric Acid AR / Concentrated Hydro Chloric Acid AR Universal Indicator Solution GF / A filter paper (Pore size 1.6 micron) No. 1 filter paper BOILER OPERATION & MAINTENANCE MANUAL Page.No.120


Procedure
Composite sample collected shall be filtered through GF / A filter paper. The clarity of the filtered water shall be as good as DM water. 500 / 250 ml of composite filtered sample shall be taken for analysis and 10 ml of 1:4 Sulphuric Acid / hydrochloric acid shall be added to the above sample to make the solution distinctly acidic. This shall be ensured by testing a fraction of the sample either with pH meter or with universal indicator solution. 25 ml of Chloroform shall be added to the separating funnel and shaken well (care shall be taken that no grease or oil is applied on the stopcock or the stopper of the separating funnel). The separated chloroform layer at the bottom of the separating funnel shall be allowed to pass through Anhydrous Sodium Sulphate taken in no.1 filter paper in a glass funnel and filtered chloroform shall be collected in a pre-weighed 100 ml glass beaker.
The addition of chloroform to the sample, shaking it well and filtering it through anhydrous sodium sulphate shall be made at least twice and all the filtered chloroform shall be collected in the same pre-weighed beaker. Finally Sodium Sulphate is given to wash 25 ml of fresh chloroform and this will also be collected in the same beaker. The glass beaker to the chloroform shall be kept in a water bath and shall be allowed to evaporate completely. This beaker shall than be kept inside an air oven at 105 C and allowed it to cool in desiccator and weighed.
The above experiment shall be carried out with the DM water, the results shall be taken as a blank, and this shall be subtracted from the sample.
Notes
If Succession Oil trace test result shows less than 4 ppm, Boiled out can be stopped and Boiler flushing & rinsing can be started. The results shall be reported in mg/l (ppm).
After attaining the satisfactory results the chemical boil-out can be declared as completed
Page.No.121


and will be permitted for water wall bottom header & down comer drain stub cutting and drum cleaning activities.
h.
Post Boil-out Inspection
Remove sufficient hand hole caps to permit an internal inspection to be made. The caps removed for inspection should be marked. Scrap out loose mill scale and sludge, and wash the headers internally with a water jet. Finally all blow down and drain valves should be washed through and operated to make sure they are clear. Make an internal inspection, as far as possible to form an opinion as to the advisability of washing or brushing through the tubes. A second boil out is rarely necessary, but should be undertaken if there is doubt about the cleanliness of the heating surfaces.
Open the drum manhole door to permit inspection and washing. Fit the drum internals such as cyclone, scrubbers, baffle plates, feed pipe, chemical feed pipe etc., and prepare the safety valves for testing and setting. The drum internal fittings should be inspected carefully. Necessary care being taken to see that the joints between the individual fittings and the drum are tight at all locations. The pressure parts may then be boxed up and filled with suitable water for carrying out passivation.
i.
Replacement of Gauge Glass Parts
Gauge glasses may become dirty during the chemical boil out. Before the boiler goes into service, these should be dismantled and cleaned. The mica sheet on flat glasses shall be replaced, if necessary before re-assembling the gauge glass.
j.
Refractory inspection
Before going into the gas passage for inspection, sufficient ventilation is essential to avoid the danger due to the combustible or harmful gas.
After drying out, go into the gas passage, and inspect the refractory for a proper dry
Page.No.122


condition, any crack and excessive contraction. Normally, small crack is no problem for operation. But if excessive cracks are found, put the ceramic fiber into the crack. Clean up the gas passage after the inspection. Be certain that no cloth or foreign material remain inside.
k.
Passivation
This operation is carried out prior to steam blowing after fixing of drum internals. LP dosing tank shall thoroughly be cleaned and kept ready for normal operation.
Hydrazine shall be pumped through economizer and taken into steam drum as well as super heaters and circulation established through all vents in Economizer, Steam Drum and main steam header. Hydrazine concentration shall be maintained (100 200) ppm and pH between (10 - 10.5) with the help of Ammonia. After establishing necessary concentration of Hydrazine and pH, circulation shall be stopped and steam drum drained to normal water level. Boiler shall be fired slowly, pressure raised to 2 kg/cm2, and then the Steam Drum vent is closed. The pH is maintained at (10 10.5) & Hydrazine level is maintained (100200) ppm throughout the complete passivation operation.
Using the start up vent, above pressure shall be maintained by letting the hot flue gas into the WHR boiler for a period of 8 hours. If the pH or Hydrazine level decrease, the above values it shall be maintained by using with ammonia solution & hydrazine, pumped through LP dozing system. Boiler shall be allowed to cool naturally after the above operation. The Boiler is now ready for steam blowing operation. During steam blowing operation chemistry of feed water, boiler water and steam shall be maintained with the help of Hydrazine and Ammonia. Feed Water pH shall be maintained between 8.8 and 9.2, boiler water pH shall be maintained between 9.8 and 10.2 & steam pH shall be maintained between 8.8 and 9.0.
With this operation, internals of the boiler would have been passivated. If necessary, drum manhole shall be opened and inspected for jet-black coating of magnetic oxide (Fe3O4).
To confirm the magnetic oxide coating, after opening the drum manhole, coating from the
Page.No.123


accessible area shall be scrapped and tested with magnet wrapped with paper. coating is magnetic, entire scrapped material shall be attracted towards magnet.
If the
Dosage avoided
of
Tri-Sodium drum
Phosphate shall
through be
HP
dosing at
system the
shall
be
and
level
maintained
lowest
level
possible.
Now the boiler is ready for Steam blowing & Safety valve settings.
Page.No.124


ANNEXURE-A
Page.No.125


7.4 - STEAM BLOWING PROCEDURE
Page.No.126


7.4 - STEAM BLOWING PROCEDURE

CONTENTS SL.NO. a. b. c. d. e. DESCRIPTION Introduction. Requirement of Temporary Steam Line for Blowing. Procedure for Blowing. Steam Blowing Completion Criteria. Precautions. PAGE NO. 128 128 129 130 131
Page.No.127


7.4 - BLOWING OUT STEAM LINES a. Introduction
When a boiler and its associated steam piping have been erected, there is a possibility that debris, such as welding beads and dirt may have been left in the tubes and piping. In addition, these parts may have an internal coating of oxide or mill scale, which will flake off during initial temperature changes. Failure to remove the debris results in increased erosion, turbine blade damage and rapid deterioration of turbine efficiency.
To avoid any hazard of such material causing obstruction or damage to machinery, it is recommended that arrangements be made to blow the piping systems to atmosphere before the final connections are made and steam is passed to the plant. This blowing through is done with steam, which is exhausted through adequate sized, open-ended low-pressure temporary piping. The steam blowing operation cleans the system and provides the steam of requisite purity for the plant.
This low-pressure temporary piping must be connected as near as possible to the terminal point of the section of the system being purged. In some cases an appropriate valve cover may be removed and the temporary piping led off the valve chest. The run should be as short as possible consistent with steams discharging freely to atmosphere without causing danger to personnel or damage to structure and equipment. If a basket type strainer is installed in the steam piping it must be removed prior to steam blowing and subsequently replaced. The precautions listed below must be strictly observed.
b.
Requirement of Temporary Steam Line for Blowing
The diameter of temporary discharge piping shall not be less than the diameter of the respective line to be steam blown. The spool pieces should have an opening equal to the diameter of the respective temporary pipeline the temporary discharge piping and supports shall be capable to withstand steam-blowing parameters.
Page.No.128


c.
Procedure for Blowing
There are two alternative procedures for blowing out the steam lines to the plant.
One is to raise pressure in the boiler to just below the permissible pressure in the temporary atmospheric discharge piping, gradually open the boiler stop valve while increasing the firing rate to maintain pressure during the blow, then gradually close the stop valve whilst reducing the firing rate. This procedure has the advantage that the blowing period may be as long as is necessary to clean the steam piping thoroughly.
Usually the waste steam discharged to atmosphere will be dark in color when blowing starts, and will become clear as foreign matter is removed from the system. Several successive blows should be made with an adequate cooling period between each, as the associated temperature changes will assist in loosening mill scale.
The alternative procedure is the puffing method. The boiler is raised to around 40 kg / cm2 (g) or 50 % of working pressure of the boiler (whichever is low). Hot flue gas inlet guillotine damper is closed along with ID fan before starting the steam blowing.
Ensure that the drum water level is at the lowest port. Open the boiler stop valve quickly. Water level in the drum swings upward. The level may even go beyond visible limit. Permit the boiler pressure to drop about 10.5 to 14 kg/cm2. The change in steam saturation temperature is kept less than 42 C then quickly closes the stop valve.
This method has the advantage, that the sudden change in steam pressure produces a sudden change in saturated steam temperature causing a thermal shock which helps to loosen the adhered scale from the inside of tubes and piping. The steam expands quickly through the system as the pressure drops.
The scales are removed while steam expanding through the pressure parts. However, all the pressure parts, including the drum are subject to thermal shock. To prevent excessive stresses and differential expansions, the change in saturation temperature should not exceed 42C. For ensuring thorough cleaning, a number of successive blows
Page.No.129


must be made due to the limited blowing period permitted by the allowable pressure reduction. For both procedures, experienced observation can determine when sufficient lowing
through has been effected. Clean metal target plates are rigidly secured in the path of the discharging steam at a suitable distance from the pipe end.
These are placed in position for evaluation of debris carryover along with the steam after the initial few blows when the steam is visibly clean. After each blow the target plates are inspected for any pitting by the debris.
Target plate assembly is located in the temporary exhaust pipe and placed nearest to the permanent pipe work. Availability of sufficient number of target plates is to be ensured. Stainless steel plates having mirror finish shall be used in final blows.
In preceding blows target plates of aluminum shall be used. Further blows are given until they indicate that no debris remains in the piping. It is a standard practice to limit the number of blows to 6 to 8 per day at an interval of 2 hours between 2 consecutive blows and with an overnight cooling.
A complete record of the events and observations are to be maintained.
d.
Steam Blowing Completion Criteria
Steam blowing can be declared complete only after ensuring cleanliness of target plates mounted in the temporary exhaust pipe. As already mentioned, for evaluating the cleanliness and termination point of the steam blowing, aluminum target plates is to be used initially. For the final stages, target plates of stainless steel having mirror finish are to be used.
The highest velocity of steam being at the center of pipe, the effectiveness of steam blowing is judged by the absolute pitting on the target plate in the central zone i.e. the area covered by three quarter of the pipe diameter.
Page.No.130


The piping is considered clean if there are not more than five pitting on the target plate central zone and the edges are not deformed. Besides, there should be no pitting in the rim zone i.e. the area other than the central zone. This should be achieved in three consecutive plates.
After attaining steam purity during steam blowing operation system is ready for giving steam for turbine rolling. During initial period of steam being taken to turbine rolling, the chemistry of feed water, drum water and steam shall be maintained with the help of Hydrazine and Ammonia.
Afterwards, drum water chemistry shall be maintained with Tri Sodium Phosphate (HP Dosing) and feed water pH shall be maintained with Hydrazine and if necessary, feed water chemistry shall be adjusted with the help of dosage of Ammonia.
Firing shall be killed and drum pressure shall be allowed to drop to 5 kg/cm2 and boiler shall be hot drained and all the vents shall be opened.
e.
Precautions
To prevent excessive strain on pressure parts and danger to personnel, the following precautions must be strictly observed.
The securing arrangements of permanent piping must be complete, or adequate temporary bracing installed. For thermal expansion of pipes, proper allowance must be given. First test steam blow should be given at lower pressure and the temporary piping should be surveyed for proper expansion and supports.
The temporary low pressure piping exhausting to atmosphere will be subject to strong reaction forces during the blow and must be adequately secured. The exhaust can be diverted at an angle of 30 from horizontal to reduce reaction force on temporary support.
During the blowing period steam and debris will be coming forth from the discharge pipe at
Page.No.131


high velocity and the location and direction of this must be carefully considered in terms of safety. The steam must be exhausted to the atmosphere outside the boiler house and so directed that personnel and equipment are not damaged or endangered. The area should be cordoned off and warning / safety notices displayed prominently.
Since it is necessary to have a high steam velocity through the system being cleaned during the blowing period, the temporary piping exhausting to atmosphere must generous size so that it will not significantly restrict the flow. be of
The boiler pressure used for blowing out the lines must not exceed the design pressure of the low pressure temporary piping and fittings used during the blowing period. The temporary piping should have minimum 1 in 100 slopes towards exhaust for removal of condensate and should be well supported. This should have proper provision for thermal
expansion. During pressure raising and blowing, all NRV internals, control valves and flow nozzles, orifice plates if any in the blow circuits are to be removed and spool provided. pieces to be
An adequate reserve of feed / DM water must be kept readily available to replace the blowing losses.
Water level in the boiler must be carefully watched and kept under proper control at all times particularly as feed heaters may not be in commission Special care must be taken to prevent priming and carry over. If the water level drops below the bottom of the gauge glass, there is a possibility of quenching the hot drum with cold feed water when regaining level, and causing excessive thermal stresses.
The temperature of the water entering the steam drum should be monitored at all times. It is recommended that the differential between water leaving economizer and drum shell temperature shall not exceed 20 C.
1.
All the permanent pipelines and temporary pipelines passing through working area should be insulated before the blowing.
Page.No.132


2.
All permanent hangers and supports for various lines are to be erected and set for proper values as per design figures. All locks and restraints are to be removed from pipelines.
3.
Provision should be made for tightening of flanges of holding plates. Spare gaskets for flanges are to be kept ready.
arrangements for target
4.
In addition to usual light up instruments, provision is to be made for monitoring / recording pressure and temperature at outlet of boiler and before temporary exhaust.
5.
The area around the exhaust point should be cordoned off. For warning sound, prior to blow, siren or PA system can be utilized.
6.
Effective communication and lighting system should be ensured at the vulnerable areas.
7.
Boiler should be ready in all respects including 1. 2. 3. 4. 5. Interlocks protections, alarm annunciation & instruments. Chemical dosing system. Insulation of radiant chamber and flue gas ducts. Fire Fighting System as per designed scheme COFG inlet duct.
Chemical cleaning of the pressure parts internals should be complete prior to steam blowing.
Page.No.133


Annexure 1 (Steam Blowing Arrangement)
Page.No.134


7.5 - SAFETY VALVE SETTING PROCEDURE
Page.No.135


7.5 - SAFETY VALVE SETTING PROCEDURE

CONTENTS SL.NO. a. b. c. d. e. f. g. h. i. j. DESCRIPTION Introduction Blow Off Testing of Drum & Super Heater Safety Valves Safety Valve during Hydrostatic Testing of Boiler Floating of Valve Field Setting Safety Valve Precaution Accessory Equipment Safety Valve External View Safety Valve Cross Sectional View Hydro Test Plug & Gag of Safety Valve PAGE NO. 137 137 138 139 140 143 144 145 146 147
Page.No.136


7.5 - SAFETY VALVES SETTING a. Introduction
Three numbers safety valves are provided in this boiler, steam drum (2 No) & Main steam (1 No), summation of three having a relieving capacity of 100 % of the peak load steam generation.
During the inspection of the boiler after boiling out, the safety valve escape pipes must be inspected to confirm that they are led to safe points of discharge and are properly secured, and that the safety valve drains are clear. Also see that the expansion chambers have the correct clearance, so that when the pressure parts are hot they do not foul the safety valve exhaust pipes.
Before the boiler is put into service, after the pressure parts of a new boiler have been boiled out. I.e. ready for steaming, the safety valves should be floated with the main steam stop valve closed, to make sure that the valves lift and close satisfactorily at the specified pressures.
b.
Blow Off Testing of Drum & Superheater Safety Valves (Reference Data)
Safety valves are installed over the drum & super heater for the operation of WHR Boiler with the following operating parameters. Evaporative capacity of boiler (100%MCR) Steam Drum design Pressure Steam Drum design Temperature : : : 26.4 88 302 TPH kg/cm2 (g) C
TECHNICAL PARAMETERS Sl. Description No . 1 Type Make: 2 Quantity
Unit
No.
Drum Safety Valve Super heater Safety Valve I II Full Lift spring loaded TYCO SANMAR 1 1 1
Page.No.137


3 Fluid 4 Set Pressure 5 Operating Pressure 6 Operating Temperature 7 Over Pressure (max.) 8 Blow down (max.) 9 Outlet 10 Flange Type 11 Sizing Basis 12 Inspection & Certification 13 Design Code 14 Location kg/cm (g) kg/cm (g) C % %
Saturated Steam 87 80.2 293.8 (Saturated) 88
Superheated Steam 76 71.3 4905
2.5 - 5 5-8 Flanged to ANSI B 16.5 Raised Face IBR IBR IBR / ASME Outdoor
Safety Valves are devices that protect the steam and water circuits against accidental over- pressurization. An overpressure condition can occur in one of two ways
1. 2. A gradual increase in pressure due to improper operation or malfunctioning equipment. A sudden and rapid increase in pressure caused by an immediate loss / reduction of steam flow.
c.
1.
Safety Valve during Hydrostatic Testing of Boiler

Before conducting the hydrostatic testing, it is necessary to install the O-ring and backup ring or Blank Flanges. These components are separately dispatched during the supply of Safety Valve.
2.
Observations should be made at the start of the hydro-test that there is no leakage from Safety Valve when pressure is applied. If leakage is evident, pressure to be made is zero, and the O-ring should be checked for any damage or improper fitment.
3.
On completion of hydrostatic test, the plugs must be removed and safety valve is reassembled.
Page.No.138


4.
Hydrostatic testing at pressure above the valve set-pressure using a gag is not recommended.
5.
The O-ring and backup ring materials are suitable for a temperature of 232 C (and to 260 C for a short period of time), hence the boiling out operation can be performed to a saturated steam pressure corresponding to that temperature. So if it is planned to install the Safety Valves in position after completion of Chemical Boil-out operation, same can be done confirming the O-ring quality with referring to the suppliers manual.
d.
Floating of Valve
1.
The field testing should involve a check of the proper functioning of the valves as to correct opening pressure, correct blow down, proper mechanical operation without chatter and clean closure without leakage.
2.
These valves are set to have a clean popping action and to reseat tightly. Boiler safety valve blow off test is conducted with the unit kept preferably in desynchronized / isolated condition. Calibrated test gauge will be fixed to monitor the pressure of the Boiler during popping and reseating of the Valve.
3.
For testing of safety vale, the Boiler is to be started in normal operating sequence or to be desynchronized from load as the condition may be.
4.
Positions of the adjusting rings should not be disturbed unless problem faced against the Factory Set positions
Notes
This procedure for Safety Valve testing should be referred along with specific Instruction manual
supplied by Valve Manufacturer.
Page.No.139


e.
Field Setting
1.
Set Pressure Adjustment
Check the following before raising the boiler pressure

Set pressure of the Safety Valve can be checked using the steam pressure of the boiler as follows: 1. Set Pressure testing by this method will establish the popping pressure as well as reseat pressure (i.e., blow down). 2. Prior to Safety Valve testing, calibrated pressure gage should be fitted in the steam drum and Super heater. 3. Outlet piping should be anchored as per drawing sufficiently to avoid any vibration during floating of Safety Valve. 4. 5. 6. 7. Set Screw should be locked into the body and locked with wire. The tapped holes for drains in body should be connected to a drain. Lifting Gear should be securely fastened on the valve. Communication arrangement should be ready between Control Room and the Safety Valve area.
All safety valves of the boiler (Drum & Super heater) except the valve which is to be popped should be gagged. System Pressure should be 70% of valve set pressure before gagging. This is to prevent added loads from being applied to the spindle due to thermal expansion.
Gagging must be done with care not to overload the spindle since considerable damage may occur to the valve spindle, seat and other internals. However, a minimum force to be applied to ensure that the valve will not open.
If a new valve is to be gagged for any reason, the valve is to be popped manually beforehand through operating lever and kept in lifted condition for a minute so that any welding
Page.No.140


slags,
dust,
etc.
get
removed.
After
manual
lifting,
the
valve is allowed to seat suddenly to make a sharp closing without chattering.
Boiler pressure is now increased. The pressure indicated on the pressure gauge is to be recorded when the valve open, heating rate is
pops open. After the valve pops
to be reduced in the boiler and pressure reduced until the valve closes. The Start-Up Vent can be operated to reduce the steam pressure of the boiler. The closing pressure is to be noted and recorded.
If in raising the boiler pressure, the valve doesnt open within 3% overpressure, the heating-rate is to be reduced in the boiler and the attached rope connected with drop lever is to be pulled to open the valve.
If
the
valve
operation
is
in
compliance
with
the
points
mentioned above, we can proceed to trial with next Safety Valve.
If the valve pops before set pressure is reached or it does not pop at set pressure, the following steps for adjusting the set pressure to be followed:
Remove the forked lever and cap assembly. Loosen the locknut for adjusting bolt. To increase the popping pressure- Adjusting Bolt to be tightened clockwise. To decrease the popping pressure- Adjusting Bolt to be rotated counter clockwise. After each adjustment, the locknut should be securely tightened to prevent loosening of the bolt, and lifting gear reinstalled.
The adjusting bolt should never be turned when the boiler pressure is near the set pressure of that valve. Adjustments
Page.No.141


should never be made until the pressure is 10-20% below the actual popping pressure of the valve. This protection is to be adopted for safety as well as avoiding possible damage of internal parts.
2.
Guide Ring and Nozzle Ring Adjustment
The guide ring and nozzle ring location are determined at the factory and their locations are stamped on the valve bonnet where the cap is seated. However, if the desired blow down is not obtained, it will be necessary to adjust the rings.
Never make any ring adjustment with boiler under pressure without gagging the specific valve.
Care should be taken to use only sufficient torque on the gag to hold the valve closed. Over gagging may damage the valve internal.
3.
Guide Ring Adjustment
The guide ring (10) is the principal blow down control ring in the valve. To change the guide ring position, remove the guide ring set screw (11) from the body (1A). Insert a screwdriver or similar tool and engage one of the notches (these can be seen through the set screw hole). The guide ring can then be turned to the right or left as desired.
Turning the guide ring clockwise decreases blow down. The guide ring should never be turned more than five notches either way without retesting the valve. After each
adjustment always replace, tighten and lock wire the set screw being careful that its point engages a notch.
Page.No.142


4.
Nozzle Ring Adjustment
The nozzle ring (3) is necessary in obtaining the pop action of the valve. This ring setting is carefully determined by factory test and normally does not need any further adjustment after installation. However, in case the guide ring (10) adjustment does not give the described operating characteristics under all conditions of operation, the nozzle ring may be adjusted to control the valve-operation for very fine adjustment.
The nozzle ring is adjusted by removing the nozzle ring set screw (4) from the valve body (1A). Moving the ring to the right (counterclockwise) results in a strong pop action and will increase blow down. Moving the ring to the left (clockwise) lowers the ring and decreases the blow down. Warn or simmer may result if lowered too far.
The range of adjustment of this ring is limited and it should not be moved more than one notch at a time from its pre-set position. The valve performance should be checked after each adjustment. After each adjustment, always refix, tighten and lock wire the set screw, being careful that its point engages a notch. Whenever, ring adjustments are changed, a record should be kept of the number of notches and the direction in which the ring was moved. This will make it possible to return to the original setting in case of error. After the valve has been adjusted to open and close at the desired pressures, make sure the adjusting bolt locknut and the set screws are installed properly and tightened. If different locations are obtained from testing, re-stamp the valve bonnet with the new ring settings. Install the cap, forked lever and lever making sure there is a 1/16 inch (1.59 mm) clearance between the spindle nut and forked lever.
f.
1.
Safety Valve Precautions

When steam safety valves are subjected to an excessively high water level, the valve can be expected to have a long blow down that ring position will be unable to correct. It is recommended that the cause of high water level be corrected so valves may function correctly at the ordered condition.
2.
Nobody should go near the discharge side of safety valve.
Page.No.143


3.
The safety valve body drain must be piped to a safe area. If left open, steam will escape and present a burn hazard to personnel near the valve.
4. 5.
The safety valve must be gagged before making ring adjustments. When pulling hand-lever for inspection purposes, a rope should be attached to the handle of sufficient length (minimum 20-30 long) to protect the operator from escaping steam, dust, fly ash, etc.
6.
There should be proper communication system between Drum Level, Control Room and Burner Floor for smooth control during testing of Safety Valves.
g.
Accessory Equipment
The valve has been supplied with one hydro test plug and one gag for use as per requirement. For adjustment Of lower & upper rings, screwdriver will be used. For adjusting the compression screw, a suitable- size Spanner can be used.
Page.No.144


h.
Safety Valve- External view
Page.No.145


i.
Safety Valve- Cross sectional view
Page.No.146


j.
Hydro test plug and Gag for Safety Valve
Page.No.147


7.6 - BOILER START-UP INCLUDING PRECOMMISSIONING CHECKS & COLD START-UP PROCEDURE
Page.No.148


7.6 - BOILER START-UP INCLUDING PRE-COMMISSIONING CHECKS & COLD START-UP PROCEDURE
CONTENTS SL.NO a. b. c. d. e. f. g. h. i. j. k. l. DESCRIPTION Introduction Safety Interlocks & Alarm Utilities Checking of Radiant Chamber & Flue Gas Passages, Access Doors Pressure Gauges on the Steam Drum Induced Draft Fan Instrument & Plant Air Heat input into the Boiler Main Fuel Trip Condition Auxiliary Equipment Prior to Initial Operation Operational Procedure 151 151 152 152 152 153 153 153 154 PAGE NO. 150 150 150
Page.No.149


7.6 BOILER START-UP INCLUDING PRE-COMMISSIONING CHECKS & COLD START-UP PROCEDURE a. Introduction
Basic rules must be followed in the operation of boilers and secondary equipment. The operators should familiarize themselves with characteristics of this particular installation. Emergency conditions, resulting in unnecessary shutdowns and repairs, can be avoided by a proper working knowledge and attention on the part of the operator.
b.
Safety Interlocks and Alarms
After loop checking of all control wiring, all Safety Interlocks and alarms are to be checked one by one by simulation to verify the correctness of software provided in the DCS. Similarly all alarms connected to the annociators to be verified by forcing the condition for alarm and checked for its correctness.
Do
!
not
by
pass
any
safety
interlocks
protections
without proper understanding as it may cause damage to the equipment & injury to personnel.
c.
Utilities
Instrument Air. Electric Power. De-mineralized Water. Cooling Water. Service Air. Lubricant Oil / Grease. Availability of sufficient quantity of COFG. Chemicals for boiler water and boiler feed water treatment.
Checks prior to start up following utilities are available.
Page.No.150


Ensure quality of utilities mentioned above is as prescribed in the contract so that it is available readily for use. Check that all blow down and drain valves are working properly.
d.
Checking Of Radiant Chamber & Flue Gas Passages, Access Doors
Remove all scaffolding materials used during erection from radiant chamber, air & flue gas ducts before boxing up of the boiler. Remove all unwanted materials welded with pressure parts/ casings which will be a hindrance to free thermal expansion of pressure parts. Remove all temporary support inside and outside of the duct casing which is used in the erection.
Ensure cleanliness of all slide supports and its bearing for free thermal expansion when the boiler units temperature is raised gradually during initial firing. Check boiler, economizer, expansion joints and their supports and confirm that thermal expansion during operation will not be restrained.
Open and close all the covers for cleaning, and confirm they are in good order. All access doors on boiler, duct work and auxiliaries are closed.
Ascertain that the safety valve is free from drain or accumulated rainwater. Confirm that stoppers or cover plates used for hydraulic test have been removed.Confirm that each position of the valves, such as feed water, steam, and drain valves is in good condition to operate freely.
Make sure that man or foreign matters are cleared from the duct and manhole in the duct is in close condition and Inspect the expansion joint of the duct. Open the root valves of the all measuring instruments.
e.
Pressure Gauges on the Steam Drum
Ensure pipe after root valve of pressure gauge is clean and all valves are in good working condition. During the initial operation of the boiler, the pressure indication of local pressure gauge is very important parameter for safe operation of the boiler. BOILER OPERATION & MAINTENANCE MANUAL Page.No.151


Calibrate the pressure gauge with the standard pressure gauge periodically to make sure that the indication shown is correct.
f.
1.
Induced Draft Fan

Check that the fan erection and alignment are in accordance with instruction manual issued by the manufacturer.
2.
Make sure that any foreign materials such as papers; waste cloths etc. are not blocking the suction area of ID fan.
3. 4. 5.
Confirm that the lubrication is done as per instruction. Inspect the Inlet Guide Vane and its actuator unit. Inspect the inside of the fan casing through the manhole door in the fan casing, and then close the manhole door & ensure it is airtight.
6. 7. 8.
Ensure that Electric supply is available for the Draft Fan Motors. The Inlet Guide Vanes of the Draft fan are shut. Turn the fan and its drive motor and observe right rotating direction and smooth moving.
9.
Inspect the Fan discharge & Suction expansion joint of the duct.
Notes
For further details, refer to Instruction manual of induced draft fan .
g.
Instrument & Plant Air
Confirm the instrument air and plant air with adequate pressure is supplied. Check the zero indication of pressure gauge when no pressure is applied. Observe that the stop valves for pressure gauge and pressure transmitters are fully opened.
h.
1.
Heat input into the boiler

Hot flue gases, from the Coke oven hot stack section will be supplied normally at 900 C; and 950C at MCR Temperature conditions, to each of the WHRB unit.
2.
The flue gas is routed through refractory lined hot flue duct to the boiler. BOILER OPERATION & MAINTENANCE MANUAL Page.No.152


i.
Main Fuel Trip Conditions (MFT)
The following signals are conditions of MFT by which the boiler trip is caused. MFT is initiated by manually activating the Emergency push button provided in the instrument panel or through DCS. MFT is an event resulting in the instantaneous shutting off the Boiler a. b. c. d. e. f. g. h. MFT P. B. (Local) pressed. MFT P. B. (DCS) pressed. No ID fan running. COFG Inlet Duct pressure High High. COFG Inlet Duct pressure Low- Low Drum level Low Low. Drum level High High. Instrument Air Pressure Low.
j.
Auxiliary Equipment
Ensure all auxiliary equipments lined up for operation prior to allowing the flow of hot flue gas to the boiler.
All control systems have been powered up checked out and is available for service. All instrumentation and associated mechanical equipment have been checked out and are available for service.
k.
-
Prior to initial operation

Inspect, or walk-down, the unit prior to starting. Before any start-up of unit, the first job an operator does is to walk down the boiler from the top to the ground floor, and check that each piece of equipment is ready for operation.
Check that all of the access doors are properly closed. Of course, if an access door is found open, we must be absolutely sure that no one is inside before closing and sealing the door.
All maintenance work has been completed and the equipment released for service. All areas must be free of debris that will hinder expansion. BOILER OPERATION & MAINTENANCE MANUAL Page.No.153


All unauthorized personnel are clear. If opened, steam drum internals should be inspected to ensure that the internals are installed according to the contract drawings. Baffle joints and cyclone flanges must be tight.
All access door and dilution damper are closed. Starting equipment and interlocks are cleared. All instrument valves should be lined up for service. Drum level gauge glasses should be clean and visible. All sample line valves should be closed. All chemical feed valves should be closed. All drain valves should be closed. All alarms and interlocks are functional. All pressure and temperature measuring devices are calibrated. Open and close the drain valves of the Drum water level gauges to ensure that they are reading correctly.
Check the safety valves to see that the gags have been removed, the lifting levers have been replaced and the valves are not fouled or hung up.
l. i.
Operational Procedure- Initial Filling Introduction
This section describes the recommended procedure for filling an empty boiler with water. If the unit is hot, filling with cold water should be done slowly to avoid severe temperature strains. Also, since deposits of solids in a superheater can cause corrosion or inhibit heat transfer, introduction of solids by carryover of boiler water from the drum during filling, hydrostatic testing, or chemical cleaning, must be avoided. Please refer chapter 7.1 for further details.
Page.No.154


ii.
Start-up from Cold
This section describes the recommended procedure for starting the Boiler from cold condition with no pressure in the boiler sections.
The De-superheater spray water control valve is in AUTO. Open the de-superheater spray-water control isolating valves.
Open the Superheater Drain valves. Open the Superheater and Drum Vents. Prior to start-up, reset the water level set-points in the feedwater control system to ensure that the water levels in the Drums and Storage tank are just above the low water alarm points.
Use judiciously the down comer drain valves as necessary to reduce the water level. Superheater Vent Valves must be opened to ensure a positive flow of steam which will reduce the thermal expansion stresses during warm-up.
Before starting the ID fan, a free flow path must be established through the boiler. This is necessary because an ID fan is capable of developing a vacuum in the radiant chamber that is greater than that of what water walls can withstand. Be very careful to maintain the radiant chamber draft within safe limits at all times, and be especially careful whenever starting a fan. With the free air flow path established, prepare to start the ID fan. Ensure that the feedwater pumps are running and all feed system valves are lined up.
Allow the hot flue gas from coke Oven gas outlet duct to flow into the WHR boiler. Monitor the radiant chamber inlet gas temperature. The temperature of the hot waste flue gas into the boiler must be monitored during start-up. This temperature must be controlled during initial start-up by adjusting the air dilution damper provided on the radiant chamber so that the metal temperature of Superheater zone is in safe limit till there is a continuous steam flow through the Superheater.
The other point to be monitored when bringing the boiler up to pressure and temperature, the increase in drum pressure should be limited to a corresponding saturation temperature increase of 1C per minute. This limitation is needed to protect
Page.No.155


the thick metal of the steam drum shell from temperature stresses during start-up. However, during warm and hot start-up of boiler, faster rate of heating is acceptable. Maintaining the proper water level in the steam drum is extremely important. The water gauges should show the water level at about the centre line of the gauge. If the water level is too high, water and chemical carry-over to the superheater can occur. To lower the water level, use the blowdown. During the warm-up period, the boiler steel expands rapidly. During expansion, all corners of the radiant chamber should move uniformly. The boiler also expands outward, but not nearly as much as vertically. Keep a close watch on boiler expansion during the warm-up period. If signs of unequal expansion are noticed, check for possible obstructions to rectify it. While the steam generator is being brought up to pressure All cold steam piping should be gradually heated and drained of condensate. Ensure that all steam piping downstream of the boiler piping is drained prior to admitting steam. When measurable steam-flow is established (2kg/cm Steam pressure), the
superheater Vent Valve should now be closed. As the pressure continues to increase, the drain valves on the final super heater outlet header can be throttled, but should not be closed fully. There must always be a sufficient flow through the superheater elements to prevent overheating. Once the boiler pressure and temperature requirements have been reached for Turbine-requirement, the same can be allowed for entry into Turbine. Main-steam piping drains which were opened during warming up can now be gradually throttled and finally closed once continuous steam flow into Turbine is established. When the unit is on continuous steam-flow greater than 30%, all remaining vents/drains can be closed and the feed water controller can be put in AUTO. The spray water system should be ready now controlling the final superheater outlet temperature and once stabled, can be put on AUTO.
Page.No.156


iii.
Shutdown of the WHRB
This section describes the recommended procedure for securing the WHRB in order to drain the unit prior to performing maintenance.
Reduce the steam-generation by gradually controlling the hot flue gas entry into boiler. Shutdown hot flue gas entry to Boiler. The ID fans can continue to operate for a few minutes for purging the radiant chamber and then shutting the fans.
The de-superheater isolating valves should be closed. It is a good practice to recheck the expansion movements during cool down period to make sure that all parts of the boiler return to their cold position.
When the drum pressure falls to 2 kg / cm, open the Drum and Super heater Vent Valves.
When the drum pressure has dropped to 1 kg/ cm, open the Superheater Drain valves.
The Boiler can be drained, if required for doing any maintenance-work when it is completely cooled.
Page.No.157


ANNEXURE-1 (Cold Start-Up Curve)
Page.No.158


7.7 - BOILER PRESERVATION PROCEDURE
Page.No.159


7.7 - BOILER PRESERVATION PROCEDURE

CONTENTS SL.NO. a. b. c. d. e. DESCRIPTION Storage of Boilers. Protection of External Surfaces. Ancillary Equipment. Protection of Boiler Internal Surfaces. Summary of Storage Procedures. PAGE NO. 161 161 161 162 163
Page.No.160


7.7 - BOILER PRESERVATION PROCEDURE a. Storage of Boiler
Boilers can be stored in DRY or WET method. For the present WHRB unit, we recommend wet storage method.
Boilers have been successfully stored over long periods using the wet storage method; however, the requirements for control are such that continuous checks must be carried out.
The necessary facilities for preparing the boilers for, and keeping them in storage must be taken into consideration before firing and auxiliary equipment are dismantled for overhaul.
b.
Protection of External Surfaces
Whether units are dry or wet stored, the following procedure is recommended in preparing boiler external surfaces for storage.
The external and internal surfaces of all pressure parts and other metallic surfaces should be completely cleaned for Inspection and Cleaning.
The safety valve escape piping should be removed or closed off so that no rain water can enter if the boiler will be kept out of service for a long duration.
It is important to keep the boiler casings in good condition. All access doors must be carefully replaced and joints remade, if necessary to ensure air tightness. Where cooling or scavenging air is supplied to boiler casing attachments, i.e. radiant chamber sight doors, soot blower wall boxes etc. these must be checked to see that the air lines are clear and isolated.
c.
Ancillary Equipment
It is also important that all rotating ancillary equipment is kept well lubricated and rotated on a planned cyclic basis.
Page.No.161


d.
Protection of Boiler Internal Surfaces (Wet Storage)
If the boiler is to remain out of service for more than a few days, but less than two months, wet storage may be the most convenient method of protection. Wet storage is particularly useful in cases where the boiler is on standby and must be available for immediate use. Long term wet storage is possible, but the risk of corrosion requires that suitable precautions (described below) must be taken.
The boiler should be filled through the economizer to normal working level. The feed water should be dosed with sufficient hydrazine to react with all the dissolved oxygen and provide a surplus of 300 mg/l. Enough volatile alkali should be added to raise the pH to the range 9.5 - 10.5. The water used for topping up should be dosed in the same way as the feed water described above. The boiler water should be dosed further if necessary to maintain the levels of hydrazine and pH. The super heaters should be back filled from the drain points / filling lines with same quality of feed water. When the super heater is full, the boiler drum can be topped up.
Filling operations should be done in a way that prevents the formation of air pockets. (Corrosion is particularly active at an air-water interface). Obviously, boiler leakage must be avoided in order to prevent air pocket formation. A useful safety measure, which must be used during long storage periods, is to connect the drum air-cock to a surge tank (500 liters capacity, say) located 3 or 4 meters above the drum. This will compensate for any volume changes due to temperature and ensure a positive pressure which will prevent admission of oxygen. This tank should be kept covered and dosed with oxygen scavenger and alkali. Alternatively, the pressure on the system can be maintained between 8 to 10 kg/cm2 (g) at a drum level by the fill in pump. When pressure comes down below 2 kg/cm2 (g) it can be boosted up by starting pump again. Third alternative is to connect all drain points to a
common nitrogen header. The N2 pressure to be maintained at 4 kg/cm2(g) an automatic system can be designed which will allow pressurized nitrogen to enter the top most point when water level falls due to system leakage.
Boiler connections should be periodically checked for tightness and frequent boiler water
Page.No.162


samples taken for analysis. When the hydrazine level or the pH falls, further dosing should be carried out to compensate.
The possibility of corrosion must not be underestimated. No boiler should be held in wet storage for an extended period without emptying for periodic inspection.
e. Table - Summary of Storage Procedures

Procedure Period of Application. Required Plant Modifications. Wet Storage Indefinite Pumps and pipe-work to allow circulation of the storage solution. Fitting of header tanks on air-cocks. Additional sampling points Plant to be filled to air-cocks with storage solution of correct composition. Nitrogen Capping 4 - Weeks Installation for nitrogen storage and distribution. Additional pipe-work for nitrogen Inject nitrogen in such a way that air ingress is minimized. Nitrogen flushing may be necessary to maintain low oxygen levels. As for nitrogen storage.
Special Conditions of Applications.
Monitoring Requirement.
Returning to Service.
Regular monitoring of storage solution composition once or twice every 7 days maintain pH, NH3, N2, H4, and CI within prescribed specification. Reinstate plant item as required with demineralised and deaerated water with correct chemical dosing. Ensure that Nitrogen disposal from the plant is safely dispersed. Return to service. Drain ensure safe disposal of storage solution. Reinstate plant item. Flush with demineralised water. As required refill demineralised and deaerated water with correct chemical dosing.
Return to service. Isolate nitrogen injection equipment as necessary return to service ensuring that nitrogen displaced from plant is safely disposed.
Page.No.163


7.8 - RAISING PRESSURE
Page.No.164


7.8 - RAISING PRESSURE

CONTENTS SL.NO. a. b. c. d. e. f. g. DESCRIPTION Preliminary Checks Admission for COFG into the Boiler Check the items before Start-Up Use of Drains Testing of Gauge Glass General Check-up Water Level PAGE NO. 166 166 167 167 168 168 169
Page.No.165


7.8 - RAISING PRESSURE a. Preliminary Checks
Before commencing to raise pressure in a boiler, make sure that all auxiliary equipment is in working order and test the controls. The steam drum water level for boiler tripping is set at 200 mm. Water is taken in the steam drum just above this level. Test the water level by opening and closing the drain cocks. The cause of any sluggish movement of the water should be investigated.
Open the air cocks and drains connected to the steam line before the main steam stop valve MSSV. Operate all dampers and set them in the correct position. Remove any combustible material in contact with steam pipes or ducts, as later it may ignite and cause trouble.
Test feed lines and make sure that the economizer is full by feeding some water into the boiler via the economizer to raise the water level in the gauge glass by about 10 mm.
After wards close only the regulating valve so that water is readily available. See that the valve admitting feed direct to the drum is closed and that the automatic feed valve is in the fully open position and ready for setting. Before the boiler goes into operation when there is continuous flow of water through the economizer, water should be taken intermittently through the economizer to avoid overheating of its tubes during pressure raising, alkali boil out or setting of safety valves etc.
See that access doors on the boiler are closed and that steam and water valves and pressure gauge cocks are workable and correctly set. Run the fan and check the inlet guillotine valve operation to admit hot flue gas into the boiler..
b.
Admission of coke Oven Flue Gas into boiler
Admit hot waste flue gas gradually to maintain an increase in saturation temperature, not more than 67 C per hour.
Page.No.166


Follow allowable pressure raising rate by manually regulating guillotine damper opening at the inlet of hot flue gas entry to WHRB as well as manipulating the RPM of I D Fan and adjust opening of main steam vent valve in order to keep the limitations, i.e., maximum temperature raising rate is 67C / hr. by supervising the steam pressure raising.
c.
Check especially the following items during start up period

Inlet Hot Flue Gas temperature Steam Drum water level. Drum Pressure to calculate the saturation temperature. Thermal expansion of boiler pressure parts..
Open boiler blow down valve and control the blow down flow rate to be about 1 % of steam flow by controlling continuous blow line valve. Open the Main Steam Stop Valve MSSV slightly, but not as much as causing leakage in order to prevent the valve from sticking due to thermal expansion.
When drum pressure reaches about 2 kg / cm2 (g). Close the following valves 1. 2. Drum, Raiser, Super heater air vents. Water column vent valves.
But leave main steam line air vent valves and drain valves open. Before the pressure has reached 2 kg / cm2, re-tighten handhold caps, steam drum and water drum man doors which have been removed for inspection purposes.
d.
Use of Drains
The boiler outlet steam line drain must be kept open during the whole pressure-raising period to ensure a flow of steam through the steam line.
Page.No.167


e.
Testing Gauge Glasses
Thoroughly test each water gauge, by the following method. Partially open the drain valve for half a minute to allow the glass and fitting to reach the maximum temperature gradually without thermal shock, then open the drain valve wide. Opening the drain valve suddenly may cause the glass to fracture.
Test the steam connection by closing the water valve and allowing steam to escape through the gauge glass to the drain until satisfied that the steam connection is clear. Open the water valve.
Test the water connection by closing the steam valve and allowing water to escape to drain until satisfied that the water connection is clear. Open the steam valve.
Close the drain valve, when the water should return promptly to its true level in the gauge glass. Any sluggishness in the movement of the water may indicate that the steam
connection or the water connection is partially choked and the level may be false.
The operating engineer should satisfy himself that each boiler operator fully understands how to test the water gauge.
Notes
For Detail refer Instruction Manual of DWLI General Check Up
f.
Confirm that all newly made hand hole cap joints and manhole door joints have been fully tightened, and keep all joints under observation during the pressure raising period. When pressure is being raised, the expansion of water may make it necessary to blow out some water to prevent the water level from rising above the gauge glasses.
It will be found advantageous to put the Remote level indicator into service, while pressure raised, so that it will be ready for use, and the boiler feeding with hot flue gas (COFG) can be seen and controlled from the concrete floor, when the boiler commences to deliver
Page.No.168


steam. It must be remembered that the most reliable indication of the water level is obtained from the direct water level gauge glass. The Remote water level indicator should be checked against this when commissioned. Drum Normal Water Level (NWL) has to be mark. The high and low level water alarm should be put into commission in accordance with the commissioning instructions and should be checked by raising and lowering the water level. High and Low water level has to be assign with reference to the NWL.
g.
Water Level
As the pressure builds up, the water level in the boiler gauge glass will rise due to the expansion of the heated water. When water level rises higher than the upper range i.e., + 100 mm in the water level gauge, blow off the boiler water by opening the continuous blow line valve. The water level can be kept within the range of the gauge, preferably near the normal water level i.e. 0 mm which coincides with the steam drum centre line.
Open the feed water flow control valve isolating valves. With the rise of steam pressure, supply the feed water by opening feed water flow control valve to supplement the exhaust steam lost through air vent valve, drain valve and steam vent valve by adjusting feed water flow control valve. The intermittent feeding of water will also prevent the overheating of the economizer tubes.
Extreme care must be taken that the level is not abnormally high when the boiler is cut in, as there would be danger of the water being carried over into the steam line.
The main steam stop valve should be opened gradually. Otherwise, such action of water carrying over to steam line would cause undue temperature strains in the steam line and possibly damage the steam driven equipment. As a precautionary measure the water level should never be allowed to rise to the extreme top of the glass during the starting up period, and the boiler should be blown down to half glass shortly before line pressure is reached.
Page.No.169


7.9 - BOILER STEAM LOADING
Page.No.170


7.9 - BOILER STEAM LOADING

CONTENTS SL.NO. a. b. c. d. DESCRIPTION For New Plant Range Already Under Pressure Feed Water Control Steam Loading PAGE NO. 172 172 173 173
Page.No.171


7.9 - BOILER STEAM LOADING a. For New Plant
When the boiler pressure reaches 90% of the rated pressure, open the main steam stop valves bypass, and warm-up the Main steam line. The range drains should be opened, with the steam traps by passed to drain the steam line of condensate, and to create a flow of steam.
Special care must be taken to prevent water hammer caused by condensate accumulated in the steam pipe when steam is supplied to the cold steam pipe. Confirm that the piping from the boiler outlet to main steam stop valve MSSV and the steam piping after this valve is warmed up and the condensate drained out completely from the piping.
After warming up is completed, close main steam line vent valve and all drain valves provided on the main steam pipe as slowly as possible and confirm that the steam is surely flowing through the steam piping. Raise the boiler pressure to the rated pressure. Just before working pressure is reached, open the main steam stop valve fully.
On a new plant, the steam traps should be bypassed for a longer period to avoid choking with mill scale.
While opening the By-pass valve for warming-up the line, boiler pressure will drop, so firing shall be to increase to compensate the pressure drop and to raise the boiler pressure to rated pressure.
b.
Range Already Under Pressure
If the range is already up to pressure, obtained from another source, the main steam stop valve and bypass should be kept closed until the boiler pressure is nearly equal to the range pressure. The main steam stop valve bypass is opened. When the pressure in the range and boiler are equal, the main steam stop valve is opened.
Page.No.172


c.
Feed Water Control
The boiler water level should be below half gauge glass so that priming will be avoided if there is a sudden flow of steam caused by a large steam demand.
A reliable assistant should be stationed at the feed regulating valve to be solely responsible for feeding water into the boiler and maintaining the water level until the high and low water alarm is tested and the automatic feed regulator is in service; then responsibility for
feeding the unit may be taken over by the boiler operator. This precaution is particularly necessary in starting up a new boiler, as the operators may be unacquainted with the plant and various other duties may claim their attention at this time.
Commence feeding a steady flow of water to the boiler immediately as the water level begins to fall. Avoid intermittent feeding which may cause undesirable temperature changes in the economizer.
Test the high and low water alarm by raising and lowering the boiler water level, and record the levels at which the alarm operates.
d.
Steam Loading
When the boiler goes on load, the rate of hot flue gas flow into the WHRB should be adjusted to maintain pressure and meet the steam demand without lifting the safety valves.
It is advisable to steam a new unit on light load for a period to prove its reliability and to allow the operators to become familiar with the controls. Full use should be made of this period to ensure that the instruments are working satisfactorily and to try out all steam consumer services.
Page.No.173


7.10 - NORMAL STEAMING
Page.No.174


7.10 - NORMAL STEAMING

CONTENTS SL.NO. a. b. c. d. e. f. DESCRIPTION Standard Operating Condition Gauge glasses and Water Columns Chemical Treatment and Blow Down Dampers Thermal Expansion and Expansion Joint Walk Down Check List during Operation PAGE NO. 176 177 179 180 180 181
Page.No.175


7.10 - NORMAL a. Standard Operating Condition
STEAMING
The main steam flow is measured by the steam flow meter; the boiler load is increased by rising the hot flue gas flow rate through the boiler.
When the boiler commences full load steaming, the operating engineer should check the performance and establish standard operating conditions that can be used as a guide to safe and economical everyday operation. The temperatures and drafts should be accurately
measured over a period of several hours to ascertain whether or not they are reasonably in accordance with the anticipated figures.
The Steam Generation T / Hr Vs. Anticipated hot flue gas Consumption Nm3/ Hr and the Steam Generation T / Hr Vs Anticipated Various Temperatures of Steam, Feed Water and Flue Gas can be checked with the figures as given in the Anticipated Performance Data.
Minor discrepancies are of little consequence provided that the final gas temperature upon which the efficiency of the boiler largely depends, does not materially exceed the anticipated figure. If the final gas temperature or the draft loss through the boiler is found to be materially higher than anticipated, the cause should be found and corrected.
Operation of rapid load change is not recommended. Excessive rapid load may cause fluctuation of steam pressure or that of water level. An Orsat apparatus should be used to check the CO2 content of the flue gases at the boiler outlet and economizer outlet. A drop of more than 2 % between the boiler outlet and economizer outlet indicates excessive infiltration of air into the economizer or into the flue duct in between the boiler and economizer. Steps should be taken to stop this infiltration. Great care is sometimes
necessary to avoid false CO2 readings from the boiler outlet and the economizer outlet caused by stratification of the flue gases.
Page.No.176


At any point of time do not increase the boiler-steaming load beyond the MCR heat input of the boiler.
Do not operate the boiler with drum level below low low trip level.
Do not operate water wall header and down comer drains when hot flue gas is flowing inside the WHRB.
If the draft loss through the boiler increases noticeably while the boiler is in service, an inspection of the flue gas passes should be made at the first opportunity, to locate and remove any deposits from the flue gas passages. Quick drop of main steam temperature is often the indication of carry over. In this case, reduce the boiler load and investigate the reason of the quick drop in order to prevent further trouble with the main steam line and others.
The cause may be an excessive rise of drum water level, rapid load change, excessively high salt content of boiler water or contamination of oil into boiler.
b.
Gauge Glasses and Water Columns
In general, water columns should be blown down once every eight hours, as described in for testing gauge glasses and the manner in which the water leaves and returns in the gauge glass should be observed. If the section of the water in the glass is sluggish, then the gauge glass should be blown sufficiently to clear any obstruction and to satisfy the operator that all is correct.
Unless the operator believes that the action of the water in the gauge glass requires fully wide open gauge glass blowing, it is considered unnecessary to suffer the high maintenance on the glass, mica and fittings resulting from testing the gauge glass with the drain wide open. Normally, the drain valve is cracked open during testing.
Gauge glasses should be kept clean. Leakage at the gauge glass connection will cause rapid
Page.No.177


deterioration and may cause a false level in the gauge glass. The glass should be well illuminated under all conditions.
When the high pressure flat type gauge glass is dismantled, particular attention should be given to the mica sheets. As long as these are not allowed to wear through, the glass should remain serviceable, but the mica bundle should be entirely replaced if the cleaning there of requires peeling off so many sheets that the resulting bundle will be less than standard thickness.
Checking of water level gauges and water columns are necessary in case of After replacing of the glass. Particular constant indication of the water level, which may mean the blockage of connection pipe. Priming and carry-over in the steam drum.
In case of sudden increase of the boiler load, which tends to raise the water temporarily, do not reduce the feed water flow. If the feed water flow rate is reduced in this case, the water level may fall below the range of water level gauges when sudden decrease of load takes place.
Special care is necessary when any doubtful trace of oil contamination is observed in the water level gauges or in the continuous blow down water. If the existence of oil in the boiler water is observed, shut down the boiler at once and exhaust the oil. If the amount of oil or grease is much, soda boiling is to be carried out again. After eliminating the source of oil, put the boiler into operation again.
In case of the water level is not in sight of the level gauge, blow off the water column or water level gauge to check whether the water level is above or below the range of the level gauge and adjust the water level to the normal level.
i.
Breakage of Glass
When the glass is broken, close the isolating valve as soon as possible. Take the broken glass very carefully and blow off small particles of glass by slightly opening the isolating valves with the drain valves open.
Page.No.178


ii.
Replacing of Glass
It is advised that steam and water valves for the replaced water level gauge should be opened very slowly to prevent breakage or crack of the glass due to thermal shock. Steam and water shall be supplied into the gauge in the following manner.
Warm up the glass by slightly opening the steam valve and the drain valve. Close the drain valve after slightly opening the water valve. Gradually open the steam and water valves to full open. In order not to damage the glass of the level gauge, uniform and gradual tightening of all the bolts is essential. High and low water alarm should be tested at least once a week by raising and lowering the boiler water level. The external alarm should be blown through only as stated in the makers instructions.
c.
Chemical Treatment and Blow down
Chemical treatment of the feed water, conditioning of the boiler water, and regulation of the boiler water concentration, should be placed on upon a routine basis immediately a new boiler goes into service.
In many plants, the amount of frequency of blowing down is ordinarily determined from a chemical analysis of the water from the boiler. Where such analyses are not made, the boiler should be blown down at least once every twenty four hours, the amount of blow down depending upon the class of feed water and the amount of steam generated.
In regular operation, economizer and water cooled radiant chamber walls, should never be blown down, in the ordinary sense, while the unit is in active steaming service. Blow down valves on this type of equipment are provided to serve only as drain valves and should be padlocked while the boiler is in service.
If the water level in the gauge glass cannot be seen by the person operating the blow down valves, an assistant should be so stationed that he can observe the level, and signal the completion of desired amount of the blow down.
Page.No.179


Under no circumstances should water walls be blown down with the boiler in service. Any such blow down must only be carried out with the boiler under bank condition.
If feed water and drum water quality parameters show

!
deviation from the specified parameters and immediate steps to be taken to find out the probable reason for it and suitable corrective action to be taken. Shut the boiler immediately if the deviation is more than 10 % than specified to prevent damage to boiler pressure parts.
d.
Dampers
It is essential that dampers are moved from their set position at least once every seven days, not only during boiler outages but also during prolonged operating periods. This will ensure that damper spindles do not become seized in their bearings.
e.
Thermal Expansion and Expansion Joint
Ascertain the thermal expansion of the boiler supports. Restriction of free thermal expansion by abnormal or temporary materials may cause excessive thermal stresses.
Do not exert excessive thermal stress on the boiler by

!
frequent sudden
starting loading /
and
stopping
of
the
boiler The
or
by
pressure
fluctuations.
drum
pressure raising and lowering should be done strictly at a saturation temperature rate of 1.2C per minute only to avoid thermal shock to the boiler.
Page.No.180


f.

Walk down Check List during Operation (Boiler)

Check for unusual noises. This may be from steam or water leakage. Check for steam or water leaks from valves, connections and fittings. Check for unusual traces of water on floor. Check for flue leakage in the boiler casing and ducting. Walk around the radiant chamber exterior and observe for any hot spots or gas leaks. Check positions of fan suction damper and check for obstruction. Check for passing from safety valves at normal operating pressure. Check to see that proper water level is being shown by the direct water level gauge. Check for water or steam leak from ports or drain connections, which will cause a false water level in the gauge glass. Inspect the glass for discoloration fouling. or
Check for any obstruction for thermal expansion.
i.
Dos and Don'ts for Boiler Operation
Dos
Maintain all instruments in good working condition. All equipment interlocks should always be in line. Maintain normal water level in steam drum. Maintain water quality as per the recommended limits. Fan dampers must be in smooth operating condition. Pressure raising from cold start must be done as per the cold start up curve. All the duct joints must be leak proof. Use proper lubricant and maintain the schedule as recommended by the
manufacturers. Operate the boiler within the recommended operation limits. Boiler, piping, ducts must be properly insulated. Servicing of equipments should be done as per the manufacturers schedule. Maintain proper operation log sheets regularly. Maintain the instrument air free from moisture and oily matters and the pressure as recommended.
Page.No.181


Carry out regular cleaning of direct water level gauge glasses of Boiler drum. Use proper valve gland packing to avoid leakage. Use proper gaskets for flange joints. Operate the blow down valves as per recommendation. In case of power failure close the steam stop valve. If the water level goes up above the limits operate the Emergency blow down valve immediately and maintain the water level to normal.
Maintain the feed water temperature at economizer inlet and flue gas temperature at economizer outlet as recommended.
Use genuine spares. Boiler surroundings and equipments must be properly illuminated.
Donts
Dont by pass any instruments and safety interlocks. Dont use raw water as boiler feed water. Dont operate the boiler beyond the operation limits. Dont leave the radiant chamber door open while the boiler is in operation. Dont mix up different lubricants. Dont alter the equipment maintenance schedule. Dont leave the control panel unattended. Dont allow unauthorized persons to operate the boiler and associated
equipments. Do not dose chemicals into the boiler in batch wise, they should be done on a continuous basis.
ii.
Operational Precautions for Safety
Operating the boiler with low feed water temperature will result in corrosion of economizer coils. The raising and lowering of steam parameters should be restricted to the value given in the starting diagram. Exceeding these values will result in reduced fatigue life of pressure parts. In case of tube failure, which can be identified by hearing the noise in the boiler gallery and
Page.No.182


increase in draft pressure, flue gas and steam temperature, and the boiler should be shutdown at the earliest by regular procedure for maintenance work. Otherwise large number of tubes may fail due to steam erosion and impingement.
Boiler salt in the wet steam will accelerate corrosion. Always use de-aerated de-mineralized water for boiler feeding. Carryover of salt in steam occurs either due to mechanical or vapour carryover from steam drum.
Efficient drum internals can only reduce mechanical carry over. Silica is always carried over in vaporous form. Continuous monitoring of sodium and silica in boiler water and steam is desirable. Before operating a boiler, ensure complete knowledge of water chemistry. Whenever boiler is started after a shutdown of more than 3 days, check all safety interlocks before boiler start up for proper functioning.
The steam drum should normally be filled up to the point when water is showing in the bottom part of the gauge glass. This is to allow for the swell on heating and to reduce any blowing down resulting from this cause to a minimum. Once the boiler is boxed up, the water level in the steam drum must be raised to the very top of the drum. Filling the drum like this will prevent excessive temperature differentials along the drum wall. The water is then shut-off and the boiler is allowed to cool.
While raising pressure on boilers, continuous firing is recommended, since intermittent firing may result in re-condensation in the tube loops.
Page.No.183


CHAPTER 8
SHUT DOWN, TUBE FAILURES, TROUBLE SHOOTING & PROBLEMS
Page.No.184


CHAPTER 8
SHUT DOWN, TUBE FAILURES, TROUBLE SHOOTING & PROBLEMS
CONTENTS SL.NO. 8.1 8.2 8.3 DESCRIPTION Boiler Shutting Down Tube Failures Trouble Shooting & Problems PAGE NO. 186 190 195
Page.No.185


8.1 BOILER SHUTTING DOWN
Page.No.186


8.1 BOILERSHUTTING DOWN

CONTENTS SL.NO. a. b. DESCRIPTION Emergency Shut Down Steps for Boiler Safety after Emergency Shut Down PAGE NO. 188 189
Page.No.187


8.1 BOILER SHUTTING DOWN a. Emergency shut down
The conditions of emergency shut down and possible causes are listed below.
EMERGENCY SHUT DOWN POSSIBLE CAUSES SL. NO. EMERGENCY SHUT DOWN 1. 2. MFT push button depressed on Control room or Local push button Loss of ID fans Motor or turbine trip/stop POSSIBLE CAUSES
COFG Inlet duct pressure high-high
Quick load change Trouble of draft system Trouble in feed water control system
4.
Steam drum level low low
Quick load increase Tube failure
5.
Instrument air pressure low -low
Trouble in air supply system
Operators shall activate the manual trip switch immediately to protect the boiler when abnormal condition, such as drum level very low low / high high, COFG inlet duct pressure very low low / high high occurred, if interlock is failed to operate automatically.
Notes
The detail start-up procedure is elaborated in Chapter # 7
Page.No.188


b.
Steps for Boiler Safety after Emergency Shut Down
Operators shall take the following steps for safety of the boiler immediately after an emergency shutdown has happened.
Close the following valves

Close fully the inlet guillotine damper in the hot flue gas inlet duct. Change control system from auto to manual Open the main steam vent valves slightly so as not to reduce the drum pressure quickly Close main steam stop valve at the boiler outlet If ID fans are running, keep them running for 5 minutes to purge the radiant chamber. Keep the drum water at normal level even after the boiler trip Close economizer inlet stop valve Close boiler water blow down valve, main steam sampling valve and chemical feed valve.
Page.No.189


8.2 - TUBE FAILURES
Page.No.190


8.2 - TUBE FAILURES

CONTENTS SL.NO. a. b. c. d. e. f. g. DESCRIPTION Introduction Leakage Detection Inlet Flue Gas Damper Control and Feed Water Flow Inspection Investigation Repair of the leakage Recommendation PAGE NO. 192 192 192 193 193 194 194
Page.No.191


8.2 - TUBE FAILURES a. Introduction
Operating a boiler with a known tube leak is not recommended. If even slight leakage is observed during operation, investigate the reason and repair at the next shut down of the boiler. Steam or water escaping from a small leak can cut other tubes by impingement and set up a chain reaction of tube failures.
If a considerable amount of leakage is observed shut down the boiler and repair as soon as possible. Large leaks can be dangerous. The boiler water may be lost, and the boiler casing may be damaged.
b.
Leakage Detection
Small leakage can sometimes be detected by the loss of water in the cycle or system, 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 normal-operating procedures will permit.
c.
Inlet Flue Gas Damper Control and Feed Water Flow
In case of boiler tube failure shut down the boiler and keeps the forced draft fan running. Unless further troubles are expected, continue feed water supply until the refractory bricks are cooled down so that they may not be damaged due to overheating.
Several factors are involved in taking the decision to continue the flow of feed water. In general the feed water flow should be continued as long as the temperature of the hot flue gas passing through the flue path is hot enough to damage the unit.
It may be necessary to continue thus the flow of feed water even though the steam drum water level cannot be maintained. The thermal shock resulting from feeding relative cold feed water to an empty steam drum should be considered. Sudden increase of feed water supply may cause sudden cooling of the pressure parts near the internal pipe of feed water, BOILER OPERATION & MAINTENANCE MANUAL Page.No.192


which may result in excessive thermal stress on the part, leakage at the joint or cracks thermal shock is minimized if the feed water passing through economizer is hot and it mixes with the existing boiler water in the steam drum.
Considering much steam demand, it may not be possible to stop the boiler immediately. The operating engineer has to take the decision as the leakage can gradually develop. But in cases where the steam drum water level cannot be maintained, shut off the COFG inlet duct and shut off completely any output of steam from the boiler by closing the main steam stop valve.
d.
Inspection
After the unit has been cooled, make a thorough inspection for evidence of overheating and for incipient cracks, especially in headers and the steam drum. All indicated repairs should be made and should be approved by the authorized inspector.
e.
Investigation
An investigation of the tube failure is very important so that the conditions 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.
Background information leading up to the tube failure should be reviewed. This information should include the location of the failure, the length of time the unit has been in operation, load conditions, start up and shutdown conditions and feed water treatment.
Page.No.193


f.
Repair of the leakage
After the exact location of the leak or leaks are located and proper inspection and investigations are carried out, the leaks may be repaired by replacing the failed tube or by installing a section of tube if this meets the approval of the authorized inspector.
g.
Recommendation
It is recommendation that every effort be made to find the cause of tube failures. Before operation is resumed and necessary corrected measures should be taken for avoiding such problems in the future.
Page.No.194


8.3 - TROUBLE SHOOTING AND PROBLEMS
Page.No.195


8.3 - TROUBLE SHOOTING AND PROBLEMS

CONTENTS SL.NO. 1. 2. 3. 4. 5. 6. DESCRIPTION Abnormal Rise in Steam pressure Abnormal drop in Main Steam Pressure Abnormal Rise in Steam Drum Level Abnormal Drop in Steam Drum Level Gauge Glass Level Trouble Trouble for Feed Water Control System PAGE NO. 197 197 198 198 199 200
Page.No.196


8.3 - TROUBLE SHOOTINGS AND PROBLEMS 1. a) Abnormal Rise in Main Steam Pressure Quick Load Down
Steam distribution system and boiler ACC system will automatically control the Steam pressure in case sudden drop in steam demand occurs. If they dont follow the variation, change over the master controller to manual operation and bring down the inlet COFG rate.
b)
Trouble of master Controller
Change over master controller from auto to manual operation and adjust the main steam pressure manually. If not possible, change over ACC system of boiler from master controller by changing over to manual control, or shut down the boiler.
2.
a.
Abnormal Drop in Main Steam Pressure

Quick Load Up due to large amount of Leakage in main steam pipes
In case of trouble for steam distribution system, take pertinent measure such as change over control system in trouble from auto to manual etc.
b.
Trouble of Master Controller
Change over master controller from auto to manual operation and adjust the main steam pressure manually. If not possible, disconnect ACC system of boiler from by changing over to hand control, or shut down the boiler. master controller
Page.No.197


c.
Trouble in inlet guillotine damper
Check the availability of waste gas from coke Oven as well as operation of guillotine damper. If the dampers are not functioning then close the hot flue gas entry to WHRB and attend to the same.
3. a.
Abnormal rise in Steam Drum Level Trouble in Feed water Control System
Change over the feed water controller to manual and bring down feed water flow rate and open continuous blow down valve if necessary.
b.
Quick Load Increase
As this is a passing response, if all instruments are in good condition, water level will be suitably controlled and restored gradually. If water level fluctuation is too large and there is a danger to shut down boiler by safeguard system, check the controller for proper set values of P & I actions, readjust it if necessary.
c.
Trouble in Feed water Control Valve
Change over to another control valve. For trouble shooting for the value, refer to vendors manual.
Notes
For trouble shooting for individual Equipments, refer to vendors manual.
4.
Abnormal Drop in Steam Drum Level
Change over the feed water controller to manual, bring up feed water flow rate and close continuous blow down valve if necessary.
Page.No.198


a.
Quick Load Decrease
As this is a passing response, if all instruments are in good condition, water level will be suitably controlled and restored gradually. If water level fluctuation is too large and there is a danger shut down boiler by safeguard system. Check the controller for proper set values of P & I actions, readjust it if necessary.
b.
Trouble in Feed Water control Valve
Change over to another control valve. For trouble shooting for the valve, refer to vendors manual.
c.
Tube failure
If drum level goes down suddenly and feed water flow increases quickly, tube failure may occur. If simultaneously steam pressure decreases suddenly, immediately push shut down button.
If steam pressure is not much fluctuated bring down boiler load smoothly and shut down the boiler.
Feed water should be supplied continuously through and after shut down, cool down the boiler gradually.
Notes
For tube repairing procedure, refer to Tube Repair Procedure. In part No.9.4 of chapter 9.
5.
Gauge Glass Level Trouble

Leakage from Gauge Glass Exchange gland and seat packing or glass
High Temperature of Feed Water - Check de-aerator pressure
Page.No.199


6.
Trouble for Feed Water Control System
Change over the feed water controller to manual and bring down feed water flow rate and open continuous blow down valve if necessary.
Notes
For trouble
shooting
for
individual
equipments,
refer to vendors manual.
Page.No.200


CHAPTER 9
BOILER MAINTENANCE
Page.No.201


CHAPTER 9 BOILER MAINTENANCE CONTENTS

SL.NO. 9.1 9.2 9.3 9.4 DESCRIPTION Routine maintenance Tube Repair Refractories Inspection and Cleaning PAGE NO. 203 208 212 217
Page.No.202


9.1 - ROUTINE MAINTENANCE
Page.No.203


9.1 - ROUTINE MAINTENANCE

CONTENTS SL.NO. a. b. c. d. e. DESCRIPTION Periodic Inspection for Safety Valves Periodic Inspection for Valves and Actuators Valve Operation Sealing Function Some Typical Problems PAGE NO. 205 205 205 206 206
Page.No.204


9.1 - ROUTINE MAINTENANCE a. Periodic Inspection for Safety Valves
The periodic inspection for the safety valve shall be made to the following items.
Confirmation of the set pressure. Seat leakage test (Check the safety valve for any leakage when applying ninety per cent of the set pressure).Confirmation of working of the safety valve.
In case any leakage or something unusual is found, disassemble and inspect the safety valve in accordance with the guidelines as given in the supplier s manuals.
b.
Periodic Inspection for Valves and Actuators
Again, for valves and actuators, periodic inspection (at least twice a week, depending on the service conditions) should be carried out for the following items
c.
Valve Operation
Open and Close Operation Check if actuated valves can be fully opened and closed following ON - OFF control of actuators. Ensure that the valve opening or closing degree is adequately maintained in correct response to the signal pressure or signal currency accessories. of actuators and their
Noiseless and Vibration Free Operation. If an abnormal noise is detected, air passage through the actuators and their piping or fluid travel through the valve bore might have been disturbed by dust particles or other foreign objects.
Find the source of the noise and perform an appropriate maintenance.
Page.No.205


d.
Sealing Function
i) External leakage
Apply soap solution over sealing areas of valves, actuators and air piping joints. External leak detection is a cause for replacement of O rings, Gaskets or packing rings.
ii) Internal leakage

Check at the air exhaust port of the solenoid valve or at the air supply port of the actuator to ensure that the air pressure is satisfactorily sealed within the actuator. Internal leak detection is a cause for replacement of O rings of the actuator.
iii) Firmly tightened bolting

Bolts and nuts used to assemble valves, actuators and accessories should be periodically re tighten, because they are inherently apt to loosen during operation Many pieces of O rings are used for sealing actuators critical areas. O rings are subject to repeated frictions with moving parts such as pistons, which reduce life of O-rings, the expendables. A periodic replacement of O rings is needed.
e.
Some Typical Problems
The following are also to be noted.
Ensure periodically tightness of valve glands and / or replacing of gland
packing rings.
Where the line temperature excessively varies contacts of valve and pipe flanges may get loose and cause leakage through joint gaskets. When leakage is detected, re tighten flange bolting or replace flange gaskets.
Valve bodies may be frozen up and damaged in winter times. Drain the water from valves or adequately insulate valves in advance when freeze is forecast. BOILER OPERATION & MAINTENANCE MANUAL Page.No.206


Disturbance of air travel through the air piping may result in an abnormal noise. Take an appropriate action to maintain the piping and joints where such an abnormal noise is detected. An abnormal noise may be also resulted from disturbance of valve closing
Function caused by galling between valve seats and foreign objects. Replace damaged seats immediately. An excessive vibration of valves may cause external fluid leakage from valves or malfunction of actuators. Provide appropriate supports to pipes and actuators.
Page.No.207


9.2 - TUBE REPAIR
Page.No.208


9.2 - TUBE REPAIR

CONTENTS SL.NO. a. DESCRIPTION Economizer Tubes PAGE NO. 210
Page.No.209


9.2 - TUBE REPAIR a. Economizer Tubes
i.
Emergency Repair
Blind Plug Method

In case that spare tubes or time is not available, damaged tubes may be sealed by hammering blind plugs and seal welded for emergency. Blind plugs shall be hammered and then seal welded.
Procedure
Blind plug shall be hammered and seal welded so as to secure tightness. Hydraulic test should be conducted to confirmed that there is no leakage.
Blind plug shall be hammered straight to tube. Surface

Notes
of blind plug and tube inner surface should be rubbed by sand paper or vinyl grinder. ii. Permanent Repair
The permanent repair method is either to renew the whole tube or to repair only the damaged part of the tube by welding. In order to renew a failed tube, it may be necessary to renew not only the failed tube but also some adjacent sound tubes depending on the location of the failed tubes.
Therefore, if only a small portion of a tube is damaged, the latter method may be applied. Economizer tubes shall be removed after removing cage panel. Remove the outer casing, insulation and insulating support. Cut off the tubes to be removed at a point of about 30mm away from original welded seam. Cut off the welded portion by gas and / or grinder. BOILER OPERATION & MAINTENANCE MANUAL Page.No.210


Extract the tubes where the tube extraction places are provided. For new tubes, the length and welding end shall be adjusted and prepared previously before inserting them. For the stub tubes remained with header and 180 bend tubes, the welding end shall be prepared.
Insert the new tubes and adjust their tube welding ends (new tube, stub tube and180 bend tube). Join the tubes by TIG ARC welding carefully, referring to the original drawing. After completion of welding, remove any material and ensure the completion of repairs by hydraulic pressure test.
Restoration shall be done in a reverse order against removal procedure for such as inner casing, insulating support, insulation, outer casing etc. After completion of inner casing, ensure the completion of repairs by airtight test.
Page.No.211


9.3 - REFRACTORIES
Page.No.212


9.3 - REFRACTORIES
CONTENTS SL.NO. a. b. c. d. DESCRIPTION Refractory Definition Refractory Application in Boiler Refractories Properties Refractories Failure and Repair PAGE NO. 214 214 214 215
Page.No.213


9.3 - REFRACTORIES a. Refractory Definition
Since early days the boilers and radiant chamber walls were made of special bricks. These special bricks could withstand more temperature than the ordinary bricks. These bricks were made of special clays, which are known, as fire clays. These are known as firebricks.
The products made from fire clay are now known as refractories, from the word refractory, which means difficult to fuse and from the word refractoriness, which means capacity to resist high temperature. The refractories have high fusion point.
b.
Refractory Application in Boiler
The refractory are applied in the hot flue gas inlet duct and radiant chamber hopper of WHR boiler for protection of MS plate material. Similarly the entire seal box are filled with
refractory to reduce the air ingress into the boiler. All manhole and Peep holes located on the radiant chamber is backed up with refractory to protect the same.
c.
Refractories Properties
The hot flue gas duct or radiant chamber of refractory construction is as nearly gas tight as possible. This should be having sufficient mechanical strength. Again there should be flexibility to permit movement of the wall with boiler thermal expansion and contraction.
The cast able refractories are stable at high temperatures. Materials used for the cast able refractories can be repeatedly heated and cooled without disintegration from the base of the refractory cast able. The refractories should be always kept dry.
Sudden change of radiant chamber temperature must be prevented with sufficient care. If water is splashed on hot refractory materials, the refractory materials will be damaged. BOILER OPERATION & MAINTENANCE MANUAL Page.No.214


Therefore, leakage of the boiler water wall must be repaired as soon as possible.
Refractory materials may also be damaged by the supply of cold air into the hot radiant chamber. Therefore, do not open the radiant chamber to the atmosphere and do not continue post purge of the WHR boiler more than the pre-set time (5 minutes) after boiler shut down.
The spalling of refractory materials means cracks and falling off of the materials, which may occur in case of small loose space for thermal expansion and sudden change of temperature.
The refractory materials must be examined for the loose space for thermal expansion as well as cracks and holes on the surface.
The repair must be in accordance with the repair procedure as described further below. On the application of castables and refractorys, it is advisable to consult a professional. Cast ables must be left covered with plates at least for 24 hours before the start of drying out. Repair cracks or erosion on the refractory bricks by using plastics and / or mortar.
Any cast able which was manufactured more than six months before must not be used.
d.
Refractories Failure and Repair
Typical refractory failures are spalling, slogging and erosion. Spalling tends to be caused by rapid temperature fluctuation or poor allowance of expansion. The refractory is always exposed to the high temperature gases and gets corroded little by little from the surface, but the rate of corrosion is influenced by inlet hot flue gas conditions.
As cast able and plastic refractory which have been manufactured more than six months ago are not good for use, it is recommended to have much spare refractory. All castables should be dry mixed in a clean container before adding the water as prescribed by the manufacturer. Where metal tubes penetrate into or through the cast able or whenever the
Page.No.215


cast able is anchored with metal anchors, provision should be made for expansion of the metal within the cast able.
When all work has been completed, and all safety precautions have been complied with, a slow fire (wood if possible) should be started. This drying up or baking period will permit the moisture to escape without building up captive steam in packets through the lining. It is advantageous to maintain this fire for 18 to 24 hours if possible. The temperature should be gradually increased until the water is evaporated.
Patching or minor repairs to the radiant chamber or boiler refractory should be made as soon as discovered. This procedure will prevent serious damage to the refractories and other boiler parts.
Page.No.216


9.4 - INSPECTION AND CLEANING
Page.No.217



CONTENTS SL.NO. a. b. c. d. DESCRIPTION Internal Inspection External Inspection Dry Storage Wet Storage PAGE NO. 219 220 221 222
Page.No.218


a.
Internal Inspection
A boiler unit should be taken out of service periodically for routine inspection and Cleaning. The interval between these outages is to be determined by experience with the conditions of operation, water, hot flue gas temperature and statutory requirements Prior to entering the boiler for inspection and cleaning, particular care must be taken to guard against the possibility of steam or hot water entering the unit through open drains or blow down valves connected with similar parts of other units under pressure at the time, or through the careless opening of any steam or feed valve to the unit. (Serious and sometimes fatal cases of scalding have resulted from neglect of steam or water by double shut off, or the removal of a section of the piping.
The pressure parts should be examined internally for signs of scale, corrosion or other potential sources of trouble directly attributable to water conditions. Obviously, the finding of these conditions should be reported to those responsible, so that the problem of water treatment may receive proper and immediate attention.
The control of the purity of feed water and boiler water is necessary to keep the boiler clean internally at the same time; steps should be taken to remove the deposits before the unit is returned to service. When scale deposits, internal cleaning is required. This can be accomplished by the use of water or air driven turbine cleaners or by chemical cleaning.
Scale tends to deposit especially on the radiant chamber wall tube due to high heat load. When soft scale deposits, cleaning up with a wire brush and water washing may be effective.
When hard scale deposits, cleaning up with a tube cleaner is necessary after drying. If perfect cleaning is required, acid cleaning should be carried out. Any pitting or other corrosion should be scraped and cleaned with a wire brush until the metal is perfectly clean. BOILER OPERATION & MAINTENANCE MANUAL Page.No.219


Any leakage from an expanded joint should be stopped by re-expanding, but repeated expanding usually proves ineffective and new material will then be required.
The internal inspection should also include the physical conditions to make sure that all parts and accessories are in place as designed and can function as intended.
This phase covers such items as feed connections, steam separators, safety valves, drains, blow down and other fittings for taking steam or water to, through and from the complete unit, particular care should be taken to see that the connections to the water column gauge glass and steam pressure gauge are in good condition and unobstructed, and that these fittings are in a condition satisfactory for the purpose intended. Check that thermal sleeves, where fitted are correctly positioned.
b.
External Inspection
For the external cleaning of tubes during shut down, open the manhole covers and access doors and take off accumulated soot mechanically. The external surfaces should be inspected for signs of overheating, leakage. Corrosion, erosion and any other condition which will impair the safety of the pressure parts. The inspection should also cover the condition of all supports and hangers, gas baffles, and safety appliances. Repairs should be made from the standpoint of safety as well as to ensure continuity of service.
Such cleaning should be done as is necessary to supplement the cleaning devices provided and used during the operation of the unit this cleaning can be accomplished by brushing, scraping, air lancing, water washing, steam soaking or any other means demanded by the conditions or permitted by access. Washing can be carried out by first soaking the deposits in a solution of soda ash, the strength depending on the percentage sulfur in the deposits, with a wetting agent.
The surfaces should then be washed down. The best time for water or steam washing of external heating surface is just before the unit is put back in service, so that the heating up of the unit will thoroughly dry the water out of all the crevices, pockets, or other places
Page.No.220


where it may have collected and may cause corrosion if allowed to remain. If water or steam washing is done at some other time during an outage the unit should be immediately fired sufficiently to dry it thoroughly.
It should be noted that the boiler should not be left idle for a period of a few days before water washing, or deposits will absorb atmospheric moisture and cause corrosion. The washing should therefore be carried out as soon as the boiler has cooled and, immediately following, the boiler should be fired for a short period to dry out the tubes and setting. The inspection should also include the COFG inlet duct, especially those parts, which are not accessible, when the unit is in service.
Repairs or replacements should be made to permit proper functioning of the equipment, as well as to reduce the possibility of interruption during subsequent operation.
c.
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. Moisture absorbent like silica gel in pockets on a tray should be placed in the drums to draw off the moisture in the air trapped by the closing up of the boiler. Particular care must be taken to prevent water, steam or air leakage in to the unit.
Periodic inspections should be made to insure that no corrosive action is taking place, and that these items, the absorbent should be replenished as required. The same general method of preparing the boiler for out of service periods should be followed for the super heater and economizer.
If extent of shut is known before shutting the unit the boiler, while cooling down boiler shall be got drained at 2 kg /cm2 (g) with drum vent in open. Once the boiler is cooled down the drum vent shall be kept crack open.
Page.No.221


d.
Wet Storage
Although dry storage is preferred, a wet method is acceptable if a boiler must be kept on emergency stand by or the time frame before restart is short. The wet storage is not recommended where the ambient temperature drop below freezing temperature.
For wet storage, the boiler should be inspected, cleaned if necessary, and filled to the full level with de aerated feed water. Maintain the pH of water above 10.0 by addition of hydrazine to 200 PPM and NH3 solution.
With the drum and super heater vents open, heat should be applied top boil the water for one hour. Completely fill the unit, including super heater, with de aerated water. All vents and drains should be tightly closed and inspected for leakage. After filling the boiler completely, nitrogen tank at 0.35 kg /cm2 (g), should be connected to the steam drum vent. This supply will compensate for volumetric changes due to temperature variations.
The boiler water should be tested regularly each week with treatment being added as necessary to maintain minimum treatment levels and when chemicals are added, the boiler water should be circulated by starting a circulating pump with suction connected to the bottom headers and discharge to top most vent and running for one hour.
Where a chelant treatment program is in effect, high additions of chelant are not recommended. Simply filling the boiler with feed water containing normal chelant concentrations is satisfactory. High pressure boilers requiring short (2 to 3 days) outages can be protected with nitrogen or inert gases under a pressurized system. A slightly positive nitrogen pressure should be maintained after the boiler has been filled to normal operating condition.
Page.No.222


CHAPTER 10
ANNEXURE
Page.No.223


Symbols used in the manual
Warning Electrical Caution Operation Notes
!
Notes
Page.No.224

Bhatia Gummidipoondi WHRSG O&m Manual Final

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ENMAS GB POWER SYSTEMS PROJECTS LIMITED

Chennai 600 018 INDIA

OPERATION AND MAINTENANCE MANUAL

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

Important Instruction to End User

recommendation to avoid the failure in pressure parts.

Over-Loading of Equipments is not recommended at any point of time.

Utility inputs from End user should be within the recommendation.

ENMAS GB POWER SYSTEMS PROJECTS LIMITED, CHENNAI INDIA.

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

PAGE No 4 18 22 49 54 61 96 184 201 223

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

CHAPTER 1 INTRODUCTION AND SCOPE

Hydraulic Operated Guillotine is placed in the hot

damper the boiler

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

hoppers are provided below radiant chamber and economiser sections.

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

A brief pressure part description of boiler is as follows:

c. Water Wall Panel

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

heat recovery surfaces

e. Supports & Hangers

enclosure. Buck stay also guides the boiler thermal expansion.

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

3. Evaporative Boiler Bank System

Evaporative Bank tubes. Bottom Headers. Top Headers.

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

4. Primary Super Heater

Complete Attemperator with spray nozzles, Thermal Sleeve and Venturi.

6. Final Super Heater

BOILER OPERATION & MAINTENANCE MANUAL

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

9. Low Pressure vessels and piping

ENMAS GB POWER SYSTEMS PROJECTS LIMITED

OPERATION AND MAINTENANCE MANUAL

10. Piping supports

11. Casing, Flue Gas Ducting System

BOILER OPERATION & MAINTENANCE MANUAL