OPERATING MANUAL FOR UB MANUAL

OPERATING MANUAL
FOR
UB MANUAL
DOCUMENT NO.: - PNC/PU/CPP/M/04
INDIAN OIL CORPORATION LTD

PANIPAT NAPHTHA CRACKER PROJECT
CAPTIVE POWER PLANT
PREPARED BY REVIEWED APPROVED BY

BY
Mr V Kamath PUE Mr S L Bangotra, Mr Baljeet Singh,
PUM SPUM
1
PREFACE
This manual contains information on the operation of

CPP Captive power plant at Panipat Naphtha Cracker. The
information has been prepared on the assumption that the
operating personnel have a basic knowledge of power system,
power plant engineering and operation.
It is an essential perquisite for satisfactory operation of

the power plant that the operating personnel are fully familiar
with the design of the power plant and receive thorough
training in operating the unit.
This write up does not replace any manual supplied

by M/S L&T.
It is hoped that user will go through it and will find

it helpful in achieving the safe operation of the Switch
Gear. Suggestions if any for upgrading this manual are always
welcomed and shall be revised accordingly.
S L BANGOTRA
PUM, PNC-CPP
2
UB Operating Manual
Amendment / Updation Record
Sl Amendment Page Page Prepared By Reviewed by Approved by

No date no. revision
no.
1 00 1- Rev-0 Sh. V Kamath Sh. S L Bangotra, Sh. Baljeet Singh,
PUE PUM SPUM
3
UB Operating Manual
Updation/Issue Record
S.No Date of List of recipient Prepared By Reviewed by Approved by

Updation
1 Sh. V Kamath Sh. S L Sh. Baljeet Singh,

PUE Bangotra, PUM SPUM
4
TECHNICAL SPECIFICATIONS OF UTILITY
BOILER
Make - ANSALDO CALDAIE
Capacity - 406.5 TPH

-
-
-
406.5
230 T/hr
SH Steam Pressure - 132 Kg/cm2
SH Stem Temp. - 529 C
Feed Water Temp. at ECO.inlet - 250 C with RLNG firing
236 C with BFO firing
Air quantity - 459.5 T/hr (oil)
- 473.2 T/hr (Gas)
Efficiency at 100 % MCR - 91.6 % (BFO)
85.1 %
(RLNG )
FRONT & REAR WALL FIRED, NATURAL DESIGN PRESSURE : 153

CIRCULATION, PRESSURISED FURNACE,
BOX TYPE,TOP SUPPORTED BOILER Kg/cm2
SH O/LPRESSURE : 132
MAIN BURNERS:
TYPE Low NOx burners (Oil/Gas fired)

MAKE & NOS. ANSALDO CALDIE, 8No.s
CAPACITY (MAX) OF EACH 4500 kg/hr BFO
BURNER 4300 Nm3/hr RLNG
Type of Atomization Constant differential pressure for BFO
Medium of Atomization Steam
FURNACE:
5
TYPE : PRESSURISED FURNACE
Length : 9732.4mm
Width : 7150mm
Depth : 20650mm
SUPERHEATER:
Primary Super heater H.S. AREA : 536m2

Primary super heater O/L H.S.AREA : 727 m2
Final Super heater/ Secondary

H.S. AREA : 426m2
Type :
DESUPERHEATER:
TYPE SPRAY NO. OF STAGES : Two MEDIUM OF SPRAY: FEED WATER
ECONOMISER:
TYPE : PLAIN TUBE TOTAL H.S.: 1626M2

AIR HEATER:
TOTAL M2 MOTOR 11 kW
TYPE : ROTARY H.S.
REGENERATIVE Nos. ONE MAKE
BOILER AUXILIARIES :
6
FLO Dischar
FAN Mak ge DRIV SPEED MOTOR/
TYPE Nos W m
Pressur TEMP TURBINE
S e 3 0
C E RPM Kw
e Static
/sec mm WG
FD 14144Z/12 Motor/ 1440 1700
FAN 86 TLT ONE 139 625Normal 45
Turbin /1620
SOOT BLOWERS:
LOCATION TYPE MAKE NO S. MEDIUM
PRIMARY AND RIZZI

LONG RETRACTABLE
SECONDARY ENERGY 2 STEAM
SOOT BLOWER
SUPER HEATER SPA
PRIMARY RIZZI
LONG RETRACTABLE
SUPERHEATER ENERGY 2 STEAM
SOOT BLOWER
AND ECONOMISER SPA
RIZZI
NON ROTATING LONG
AIR PRE HEATER ENERGY 1 STEAM
RETRACTABLE SOOT BLOWER
SPA
OTHER MOUNTINGS :
Safety Valve of Utility boiler

Set Reliving Reliving Capacity
Description Tag no. pressure temp Rated Required
Kg/Sqcm deg cel (T/hr) (T/hr)
Drum Safety valve-
1 Drum SV1 151.5 343 166.576 160.39
Drum Safety valve-
2 Drum SV2 156 344.25 171.491 165.54
Super heater SV SHSV 141.3 529 139.355 134.596
Power operated SV SH Power SV 138.7 529 64.845 64.229
7
Boiler Operation & Operating
Procedure
General Principles of Boiler operation
FILLING AND VENTING

When filling the boiler, open the boiler vents as noted in the
"Unit Operating Procedures" . Bring the water up to the recommended
operating level in the gauge glass. If hot water (hot relative to the
boiler metal temperatures) is used to fill the boiler, feed slowly to
avoid severe temperature strains on the drums, headers etc., Always
see that the unit is adequately vented and filled until water is visible in
the gauge glass. Necessary vents shall be opened during the filling
operation. The steam drum vent shall not be closed until all the air is
vented from the unit. The drum may be considered free from air when
the drum pressure reaches 2 kg/sq.cm.(g).
2.1.2. STARTING -UP
8
In order that an incorrect firing condition may be detected
promptly, it is important that the instruments used to monitor
operating conditions are in good working order before lighting off.
Draft readings, temperature and pressure readings and a reliable
indication of how much excess air is being used are a prerequisite to
intelligent operation.
Prior to lighting off the unit, the drainable portions (headers,

inlet, outlet and connecting links and piping ) of the super-heater
should be drained through lines free from back pressure and vented at
the outlet. The super heater drains should be closed in accordance with
information given in this manual. The super-heater outlet vent
("starting to atmosphere valve") must remain open to ensure a flow of
steam through the super-heater to protect the elements from
overheating until the unit has gone on the line and is carrying load.
This vent valve may be throttled as the pressure increases, but must
never be closed completely until the boiler is on the line. Refer to 'Unit
Operating Procedures', for specific valve operation. During initial firing,
prior to carrying load, the firing rate must be controlled until the flow
through the super heater is established to avoid overheating of the
super-heater elements.
The time required for bringing a boiler up to temperature and

pressure will depend upon the temperature and pressure at which it is
to operate. During initial start - up of a new boiler the firing rate must
be limited, and increase of firing rate should be relatively slow to allow
inspection of expansion movements and clearances. Subsequent
startups can be done at a faster rate but should not exceed a
saturated steam temperature rise of 55 C per hour. Always make
firing adjustments by hand during this period; never attempt to start
9
up with the combustion control or feed water equipment on
"Automatic".
SHUTTING DOWN
The time required and the procedures to be followed for shutting

down the unit depend on the nature of the shutdown (normal shutdown
to cold, normal shutdown to hot standby, emergency shutdown) and
whether the unit is to be entered for inspection and/or maintenance.
Refer to 'Unit Operating procedures for detailed operating
recommendation.
The anticipated time of the outage should be considered during
the shutting down process in determining the steps to be taken for
laying up the unit or corrosion protection.
Immediately after the unit is off the line and all fires are out,
super-heater drains are opened as required for the desired pressure
reduction. If the unit is shutdown to cold, the drum vents should be
opened when the drum pressure drops to 2 kg/sq cm (g). If pressure
parts inspection or maintenance is required, the water temperature
should be reduced to 90 C before draining the boiler. Fans may be
operated as required to achieve the desired rate of cooling.
During any type of shutdown the cooling rate must not exceed
50 C per hour saturated steam temperature decrease.
WATER LEVEL
Before lighting a fire, the operator should check the water level
in the steam drum by blowing down the water. Column and gauge
glass. Usually slowly cracking the drain valve on the gauges will be
adequate. A liberal blow-down will usually clear the drain valve seats
of any foreign matter that may be present. The gauge glass should be
10
blown down several times at low pressure while warming up a new
boiler. Routine checks of the water level gauge should be made at
least once a shift while a boiler is in operation. (Refer to water gauge
instructions). If the action of the water in the gauge is sluggish when
the drain valve is opened or closed, investigate the cause and correct
the condition immediately. To protect 'the gauge glass, blow downs
should be kept to a minimum, during normal operation.
During normal operation the water level in the gauge glass

should be observed periodically even though the boiler may be
equipped with a reliable feed water regulator and/or remote water
level indicator.
While steaming, the boiler should be protected from rapid

changes in feed water temperature. The feed water flow to the boiler
should correspond fairly closely to the steaming rate and should not
be shut off completely while the boiler is being fired.
The high and low water level trip values are given in BMS
interlocks section "Boiler trips". Unless there is information to the
contrary, the water level should be carried near the centre of the
gauge glass. The gauge glass center line is, normally set to indicate
normal level inside the drum at full pressure conditions. If the unit is
operated at significantly reduced pressure the level indicated at the
gauge glass centre line will correspond to a lower than normal actual
inside the drum, due to difference in temperature between the water
in the glass and the water inside the drum. Any adjustment of the
water level should be gradual. If the water level is too high, carryover
or even priming may occur, especially if the steam demand is large
and rapidly fluctuating. If there is an indication of priming, the water
level should be reduced immediately by blowing down the unit. The
steam rate should be reduced if necessary and feed water control
11
placed on manual. Water condition (alkalinity and solids) should be
investigated immediately. The conditions of the drum internals should
be investigated as soon as an opportunity is afforded. Perhaps the
most serious emergency that may be encountered is low water. As
mentioned in previous paragraph, the water level must be watched
continuously and water gauges should be checked periodically to
ensure proper operation. Protection of water level transmission lines
should be provided to avoid freezing or other damages to these lines.
Do not rely solely on high and low level alarms.
If the water falls out of sight in the water gauge, due to failure of
the feed water supply or neglect of the operator, except in the case of
momentary fluctuations that might occur with extraordinary changes
in load, appropriate action should be taken at once to extinguish the
fire. Any decision to continue to operate, even if only for a short time
at a reduced rating would have to be made by someone in authority,
thoroughly familiar with the circumstances that led to the emergency
and positively be certain that the water level can be restored
immediately without damaging the boiler in the absence of such a
decision,
a) Shut off the fuel supply to extinguish all fires as quickly as
possible. If this is an inadequate measure, appropriate steps should be
taken to 'kill' the fire.
b) Simultaneously if feed water has become available meanwhile

and if the operator is assured that no pressure, parts have been
damaged, the flow of feed water to the boiler should be gradually
reduced (never increased) by manual regulation. The purpose of
handling the feed water in this manner is to avoid quenching pressure
parts with relatively cold water by raising the water level and on the
other hand to avoid exposing additional metal. The feed water
12
regulating valve should be closed completely when the water in the
drum can be maintained at the level desirable for retiring the unit.
c) Maintain a high flow through the unit at first to hasten the cooling
process.
d) If the pressure parts damage is expected reduce the steam pressure
gradually by opening the super-heater outlet drains or drum vents and
as the boiler cools, reduce the air flow materially. Shut down the fans
as soon as the unit is cool enough to enter. Close all the steam outlet
valves when the steam rate approaches zero.
e) Do not empty the boiler until the furnace has cooled enough to
permit a man to enter in it. Determine the cause of low water and
examine the boiler for effects of possible overheating such as leaks and
distortions of pressure parts. Before putting the unit back in service the
boiler should be hydrostatically tested.
WARMING UP AND EXPANSION
while the boiler is being brought up to pressure, provision should

be made for gradually heating and adequately draining all cold steam
piping from the beginning by opening all drain valves and by-passes
(if stop valves are provided).
During initial firing, periodically check the expansion movements
of the boiler and make sure the casing, headers, piping etc., move
freely in respect to the structural steel. Expansion marks should be
installed at suitable locations to facilitate inspection. Periodic checks
should be made during the life of the unit to determine that expansion
movement continues to occur in a normal, uniform manner. All
hangers on the unit and related piping should be checked periodically
for proper setting and functioning.
13
GOING ON THE LINE
If the boiler is to be put on a common steam main that is already

in use, the connecting lead between the boiler and the main header
should be warmed up gradually with a bypass valve or by some
convenient means. Then, if the boiler is equipped with a main steam
stop valve and an automatic non - return valve, gradually open the
stop valve end, while. The boiler pressure is still below the line
pressure, back off the valve stem of the non - return valve enough to
permit automatic operating of the valve when the boiler pressure
becomes equal to the line pressure.
An abnormal increase in draft loss across the gas and / or air

side of an air heater indicates that deposits are Building up. Every
precaution should be taken to keep the gas swept surfaces of the air
heater clean. Water washing equipment and/or other cleaning devices
should be used as necessary to prevent air heater plugging during off
load periods.
If oil is being fired, make certain the fuel is being burned

completely. Watch the temperature of the gas leaving the air heater,
particularly when starting up the unit. A sudden and abnormal increase
in the gas outlet temperature would indicate that a fire has developed.
In this event, the unit should be shut down immediately and steps to
be taken to quench the fire.
The exit gas temperature will rise with increasing load and fall
with decreasing load. If a log is kept of the exit gas temperature, the
operator will soon be able to recognize an abnormally high or low exit
gas temperature. If the exit gas temperature is below normal for the
14
load at which the unit is being operated, look for very low excess air
(very high C02 may be some CO and smoke).
High exit gas temperature may be caused by such conditions as:

High excess air, dirty water walls, secondary combustion, a dirty air
heater and / or a fire in the air heater.
SOOT BLOWERS
Soot blowers should be operated as often as necessary to keep

the external heating surfaces clean. A high economizer exit gas
temperature and / or erratic steam temperature control action may be
an indication of the need for blowing soot. By recording and comparing
this exit gas temperature at various loads and furnace conditions, a
proper soot blowing schedule can be established. It will be found more
difficult to use the soot blower effectively if, during a period of neglect,
a considerable amount of soot deposition is allowed to build up. Never
use soot blowers on a cold boiler. If the boiler is cold there is a chance
of direct impingement of soot blower jets on wall tubes or super-heater
tubes which would result in erosion of tube metal. Always be sure that
the combustion rate is high enough when blowing soot so that the fires
are not extinguished. Refer to soot blower instructions for details.
Note.: The requirement of the steam temperature control

system can be used as an indication of fouling in the furnace
and super-heater since de-super-heater spray water quantity
and gas recirculation (if provided) quantity reflect the changes
in tube surface cleanliness.
With steam soot blowing, proper drainage of the soot blower

piping system is very important in preventing pressure parts erosion.
There should be no water pockets whatever in the piping. A thermal
drain valve is provided at bottom of piping to remove the condensate
periodically when the steam temperature falls below the set point. Let
15
the steam flow freely long enough to heat the lines thoroughly before
operating the soot blowers.
STEAM TEMPERATURE CONTROL
The function of the steam temperature control equipment is to

maintain design super-heater temperatures over the specified control
range.
Steam temperature should never be allowed to exceed the

maximum values shown on the predicted performance especially if
steam temperature control equipment is programmed down to a
boiler rating below the control point. Damage to tubing may result
due to localized overheating, caused by misdistribution of steam flow
at low loads, if the maximum values are exceeded.
With constant load abnormally high superheated steam

temperature may be caused by:
i. Too high excess air.
ii. Too low feed water temperature.
iii. Slagged up furnace (dirty furnace).
iv. Secondary combustion.
v. Improper operation of automatic steam temperature

indicating controlling equipment.
Superheated steam temperature below normal for the load may

be caused by:
i. Too low excess air.
ii. Too high feed water temperature.
iii. Excessive external deposits on super-heater tubes.
iv. Excessive moisture carries over from the boiler drum.
16
v. Improper operation of automatic steam temperature indicating
controlling equipment.
vi. Leaking de super-heater spray water valves.
The superheated steam temperature will drop suddenly and

recover if the boiler is priming. The temperature fluctuations increase
in frequency and severely as the total solids or alkalinity in the boiler
water increases.
Steam temperature control equipment provided for the boiler

includes automatic spray water de superheating system.
Spray Water De super-heaters
The de super-heaters are normally provided to maintain the

design final super-heater steam temperature. De superheated spray
water control is generally a 3 element cascade system, in which final
steam temperature intermediate (De super-heater outlet) steam
temperature and load index (steam flow or air flow measurements) are
applied to achieve proper and fast control actions. The superheated
steam temperature must be maintained at 529 C during continuous
operation. Permissible tolerances are + 5C. However, the temperature
must not be maintained continuously at the upper limit.
The superheated steam temperature is controlled .by feed water

injection into the steam. The de super-heater in which the water
injection takes place is arranged in the pipeline between the individual
parts of the super-heater.
Regulating valves by which the quantity of injection water is

regulated are controlled automatically. In case of emergency, it is
possible to operate these valves manually.
17
The de super-heating station consists of a control valve, stop
valves on either side of the control valve and a by-pass line consisting
of a regulating valve. The stop valves on either side of the control
valve must be open during boiler operation. The by-pass line is always
kept ready for operation and can be operated manually.
The superheated steam temperature controllers require

practically no attendance. But attention is drawn to the fact that the
regulating valves do not seal perfectly when being closed and always
leak a1 little.
SUPERHEATERS
Consideration for protecting the super-heater is a controlling

factor in determining how rapidly a natural circulation unit should be
brought up to pressure. The saturated temperature increase must not
exceed 55 C per hour
during start-ups. The super-heater elements should be heated as
evenly as possible and maximum temperature of the flue gas entering
the first gas toughed super-heater should be controlled during start-
ups.
To assure clearing the super-heater element loops of

condensate, provision must be made for adequate flow of steam
through the super-heater while starting up. Drain and vent valves in
the outlet heaters and / or the main steam line should be opened
before the unit is fired and kept open until the unit is steaming under
load. The start-up vent may be throttled gradually as drum pressure
increases, provided sufficient flow through the super-heater is assured
at all times. When the process draws continuous steam supply, an
adequate steam flow will be assured and the super-heater start-up
vent may be closed.
18
While carrying load, protection in the event of a sudden
interruption of steam flow is provided by the super-heater safety
valves which are set to "pop" before the drum safety valves. If the flow
of steam from the boiler is suddenly stopped, the super-heater safety
valves will open and re-establish the flow. It is imperative that all fuel
be tripped immediately when such interruptions of steam flow occur.
Care must be exercised to avoid carry-over of water and solids to

the super-heaters. Steam samples should be taken at frequent
intervals for the purpose of detecting evidence of carryover. Steam
conductivity recorders are commonly used for this purpose. Sampling
connections are normally provided in the super-heater connecting
tubes, leaving the steam drum. Carry-over may be caused by
abnormal high water level, especially if the steam rate is high. If carry-
over is suspected, steps should be taken immediately to investigate
and eliminate the conditions causing this carryover. If the investigation
indicates that the carry-over is not a result of improper water
condition, the steam internals and the water level control and
indicating equipment should be inspected at the first possible
opportunity.
BLOWDOWN:
The continuous blow down offers the best means for controlling
and maintaining a relatively constant concentration of soluble solids in
the boiler water.
The data on blow down should be recorded. The amount of blow

down is best determined from a chemical analysis of water from the
boiler.
19
Natural circulation boiler is equipped with emergency drain which
may be used for intermittent blow down service at any time. Never use
water wall inlet header drains for blow down while the unit is steaming.
These are for draining only, when the unit is out of service. Unless the
valve manufacturer's recommendations are contrary, open the sealing
valve (next to the boiler) and then the blowing valve (farthest from the
boiler) and close in the reverse order. Never make the blow down long
enough to lose sight of the water in the gauge glass.
All closures on the boiler pressure parts must be opened and
closed gradually so as to prevent pressure shocks, sudden changes of
temperatures and sudden expansion of steam in the boiler. Especially
it is necessary to avoid water shocks which occur when steam comes
into contact with cooler water.
The drain valves provided in water wall header serve only for
draining of the boiler after its shut down and must not be used for
continuous blowing down. Continuous blow down is to take place
always through the blow down valve. A by-pass valve is provided as a
standby for any contingency and is operated manually.
Composition of boiler water must correspond to the prescribed

value. To maintain-these values, it is necessary to take out samples
and test them. For recommended chemical composition of boiler
water and feed water refer to water treatment section.
Quality of steam produced is checked by taking samples of

superheated steam. It is also necessary to take samples of saturated
steam. Thus correct separation of water in the boiler drum can be
checked.
The quality of feed water and boiler water and saturated and
superheated steam must be checked in the laboratory at regular
20
intervals of 3 to 4 times per shift. All samples must be kept open
continuously. It is necessary to blow through the sampling piping
once in a day, in order that the values of the samples correspond to
the actual state. Once a shift it is necessary to check the hardness of
the samples taken to make sure the tightness of the sample coolers.
It is necessary to maintain the quality of boiler water at the required
values by suitably combining blow down and dozing.
After shutting the closure, it is necessary to make sure about

the tightness of the same according to the temperature of the piping.
COMBUSTION CHAMBER
The furnace output must be controlled as follows:
THE MCR OF THE BOILER MUST NOT BE EXCEEDED.
The safety valves should not blow and the steam pressure should
not drop below the normal value during normal operating
conditions.
Maximum steam temperature and the maximum

permissible steam temperature before the de super-heaters
should not be exceeded.
Sudden changes of temperature should not occur in the

combustion chamber.
For good operation of boiler, correct excess air co-efficient as

indicated in the anticipated performance data must be
maintained at the end of the combustion chamber. When there is
insufficient air in the furnace, the steam pressure falls and the
smoke is dark. When there too much air in the furnace,
superheated steam temperature increases and the flame
temperature drops.
Burners which are not in service must be cooled by a flow of

secondary air. The required quantity of air is decided during
operation.
Before peeping into the furnace, it must be ensured that there is
21
no overpressure and if the temperature is more than 1000C, it
is necessary to use dark eye glasses. One should stand in such a
way, that in case of eventual bursting of flame or flue gases it is
possible to turn away from the direction of bursting. When
working at the hopper it is necessary to use protective shields,
dark eye glasses and head protection cover.
TUBE FAILURES
In the event of a failure of one or more water carrying tubes in a

natural circulation boiler, the best method for shutting down the boiler
will be dictated by the size of the failure, the ability to maintain normal
water level in the boiler and the demands for the service of the boiler.
If the failure is such that the water level can be maintained in the
gauge glass by using the normal make-up system and the conditions
require continued operation, the boiler can be kept in-service until it is
more convenient to take it off the line and make the necessary repairs.
As long as the failure does not become one which involvers the loss of
water level in the gauge glass, the boiler should be shut down in the
normal manner, in order that no equipment may be subjected to
sudden temperature changes. If failure is such that the water level can
not be maintained in the gauge glass, then the boiler should be shut
down immediately. After a shut down due to low water, every effort
should be made to keep the water as near normal as possible until the
boiler is cool enough to drain.
A leak in a super-heater element should be investigated at the

earliest possible time, and the unit should be shut down in a normal
manner.
22
An economizer tube leak can be detected by sound and / or
increased makeup water requirements. The leak should be
investigated at the earliest possible time and the unit be shut down in a
normal manner.
Water leaks in the economizer can cause considerable erosion1

damage to the adjacent tubes. Water carried over from an economizer
tube leak may cause plugging of hoppers and air heater.
Any decision to continue operation with known leaks should be

made with the above in mind.
These are recommendations only and are not intended to

supplement the judgment of the operators responsible for the
operation of the equipment. It must be borne in mind that prolonged
operation with leaking tubes may cut other tubes and make major
repair job out of what was a relatively simple and short one, but the
time selected to take the unit off the line is solely the responsibility of
the operators as they are the only ones who know all the
circumstances, the advantages and disadvantages of keeping the unit
on the line.
In case of a leak or tube failure, it does not involve a serious
drain on the feed water supply the water level should be maintained
and the boiler taken out of service in the normal manner, as given
below.
i. Operate the soot blowers if conditions permit.
Ii.Switch the combustion control equipment to manual control

and proceed to reduce the firing rate and air flow in normal
manner.
iii. When all fires are extinguished, continue the air flow through
the unit at a reduced rate to purge all combustible gas, vapor
etc.
23
iv. Regulate feed water to the boiler by hand, maintaining a high
level in the water gauge.
v. When the boiler stops steaming, open the super-heater outlet

drain enough to reduce the saturation temperatures by
approximately 55C per hour. Close the main and auxiliary steam
outlet valves.
vi. When the drum pressure drops to 2 kg/cm 2, open the drum
vent valve and allow the boiler to cool to at least 90C before
draining.
Note: Air flow reduction is accomplished by reducing F.D. fan capacity

(pressurized units). In case of 'tube failure which results in a loss
of feed water so great that the water level could not be
maintained with the feed water supply available, use the method
detailed below:
I. Shut off all fires.
II. Shut off feed water to the boiler.
iii. Reduce the fan capacity and maintain only enough air flow to
carry the escaping gases up the stack. Fans may be left in
service until pressure is off the unit.
iv. After the furnace has cooled enough to permit a man to enter
it, make a thorough inspection of all pressure parts for any
indication of damage.
After the necessary repairs have been made, the boiler should
be hydrostatically tested and the approval of proper authorities
be obtained before putting the unit back in service
FURNACE EXPLOSIONS
Furnace explosions are generally a result of the following conditions:
a. The accumulation of unburned fuel in the furnace due to

incomplete combustion, loss of ignition or fuel valve
leakage.
b. The mixture of this unburned fuel with air in explosive

proportions.
c. The application of sufficient heat to raise the temperature of a

portion of this mixture to the ignition point.
24
Un-burnt fuel may accumulate in the furnace in a number of ways, for
instance:
a. Through leaky main fuel or ignition fuel inlet valves on idle

wind box compartments.
b. If the fires are extinguished and the fuel is not shut off
promptly.
c. If the fuel is not burning as rapidly as it is entering the
furnace.
d. In starting up, if difficulty is experienced in establishing
ignition.
Furnace explosions can be avoided by taking a few precautions such as:
a. During startups maintain a minimum air flow of 30% of full

load air flow to ensure an air rich furnace atmosphere and
prevent accumulation of explosive mixtures.
b. Be sure that the main fuel and ignition fuel inlet valves on
idle fuel
compartments are closed tightly and do not leak. it is
advisable to
remove idle guns from the guide pipes, to avoid dripping.
c. Watch the fires so that the fuel may be shut off without
delay if proper combustion is not maintained. If the fires
are lost, trip all main and ignition fuel immediately. Close
all trip and shut off valves. Purge the furnace for at least 5
minutes after shut down with 30% (minimum) air flow.
d. Clear oil tanks of water and sludge immediately.
e. When a boiler has been idle, purge the furnace before

putting igniters in service. Be sure that the warm up fuel
firing rate is high enough to produce a flame not easily
extinguished.
Never attempt to light an oil or gas nozzle without the

required ignition energy source. Be sure that the oil is
heated and circulated to give the required viscosity at the
nozzles. Do not use heavy oil guns for boiling out, lighting
off and warming up, preferably use light oil.
25
f. Regularly check proper function of interlocks, trips etc prior
to any start-up and periodically during normal operating
periods.
INSPECTION
Whenever the boiler is shutdown, and cool enough to enter

the furnace, make an external inspection of the boiler,
water walls, super-heater, economizer and air-heater. Clean
the firesides where necessary and examine all tubes for
evidence of corrosion, erosion, swelling, warping,
blistering, burning and cracking.
Swelling of super-heater indicates overheating which may

have been caused by bringing the boiler up to pressure too
quickly, failure to vent the super-heater sufficiently while
the boiler is being brought - up to pressure, or scale on the
internal surfaces due to carryover of water from the boiler.
Slight warping is not serious if steps are taken at once to
determine and eliminate the cause.
Check the conditions of the furnace setting and check the

casing and doors for leaks
Before entering the drum, make sure that all valves in

drum connecting piping (feed water, auxiliary steam,
chemical 'feed, blow down drains, sampling, gauge glass
drain, etc.,) are closed tightly and properly tagged so that
they will not be opened inadvertently. Remove the
manhole covers and check the drum internals for
tightness and cleanliness.
Check the drum for corrosion and pitting. Oxygen pitting

is a common form of corrosion that can be found in
boilers, usually in the steam drum above the normal water
level, but is also found in water drums, tubes and headers.
Remove a sufficient amount of and hole caps from each

boiler and water wall header for inspection of the internal
tube surfaces. Wash down the unit to remove any sludge.
Inspect and if necessary clean external heating surface of

the economizer
See that the heating surfaces of the air heater are clean.
26
Corrosion, if present, would appear in the cooler portion of
the heater, particularly where soot and dirt are allowed to
accumulate.
Make a through inspection of the firesides and clean as

required. Check for misalignment of the soot blowers.
Check all boiler instrumentation for cleanliness and proper

operation.
Check fuel burning equipment (nozzles, igniters, oil guns,

linkage, dampers etc.,) for cleanliness and proper
operation. Check where practicable, control valves, relays,
interlocks etc.,
Annual inspection should be complete and include an

internal and external examination of the entire unit.
LAY-UPS
When the unit is shut down for stand-by purposes and draining
of the boiler is not required for maintenance or repairs, the boiler
metals must be protected against corrosion.
PRESSURE GAUGES AND DRAFT GAUGES
The pressure gauges installed on the boiler should be observed

to have a check over the pressure rise above the safety valve opening
allowable and the pressure drop below the minimum allowable
pressure. For checking the pressure gauges in operation in boiler
house there should be at least one check pressure gauge of some
measuring range as prescribed for service pressure gauges.
The readings of the service pressure gauges must be compared

with the readings of the check pressure gauge within the maximum
and minimum limits of pressure once in a year and any deviations
found must be set right.
27
In case the deviation between the service and check pressure
gauges is more than 5% of maximum pressure indicated on the scale
then the service pressure gauge must be replaced by another correct
pressure gauge. Should an immediate replacement of pressure gauge
not possible there must be a correction indicated in the pressure
gauge within the range of maximum and minimum pressure.
SAFETY VALVES
Safety valves must be tested at least once in four months.

Blowing of safety valve during operation is considered as tested. Also
the safety valves must be tested before each planned boiler shut down.
Securing the cone of the safety valve against lifting due to steam
pressure is strictly forbidden.
In case the safety valves blow-up at a lower pressure it is first

necessary to compare the readings of the service pressure gauges with
the check pressure gauge readings. After checking the correctness of
the pressure gauge readings and the incorrect function of the safety
valves, the same must be newly set up, checked and secured.
In case the safety valves blow-up because of exceeding the

maximum of design, it is necessary to bring down the pressure by
reducing the firing, increasing the feeding and steam extraction and
blowing down the boiler.
Blowing up of the safety valves must be recorded in the log

sheet. In the records it must be indicated at which pressure the safety
valves opened and how was the pressure rise.
MISCELLANEOUS
Recommendations of the chemical laboratory must be strictly
28
adhered to.
Correct flow of cooling water, wherever necessary must be
ensured.
At least once a week the standby equipment must be put into
operation.
It is necessary to take care about the tightness of the fuel oil/gas
piping. Any leakage must be rectified in time.
It is necessary to check the insulation and loose insulation must
be irnmediately repaired.
All equipment must be lubricated as per schedule and the
condition of the lubricants must be checked often.
If any leakage is found in pressure parts. Welding, the boiler
must be immediately shut down. The length of shut down period
is determined according to the nature of the defect found.
29
Boiler Starting
Pre- Operational Procedures
G ENERAL :
Before initial firing and prior to each subsequent cold start-up

after maintenance has been done on the unit, ensure that the
following operations have been successfully completed earlier.
a) All repair works are completed.
b) All the manholes and furnace doors should be in closed condition.
c) Operating area is free of all debris
d) Fire water network is to be kept in charged condition
e) Instrument air/Service air pressure to be made normal.
f) Cold filling DM water valve of the boiler is to be kept closed
condition.
g) Ensure boiler safety valves are in de-gagged condition.
h) Ensure no fuel accumulation found inside the furnace.
i) Ensure the steam header drains are kept open condition.
j) Retractable soot blowers are in retracted condition.
k) Ensure that the clearances of wok permits a r e retuned by
concerned
Agencies or by a competent authority of maintenance crew.
l) Combustion chambers and combustion passages are free from
combustion materials and are in good condition.
m) Manholes in boiler drum are in closed tight.
n) The following equipments lubrication supply and cooling water
30
supply to be checked.
i ) FD fans ii) BFP iii ) RAPH
o) All auxiliary equipment is tested and trial run in accordance with
respective instruction manuals.
p) All air and gas passages are tested for air-tightness.
q) All brick settings are dried.
r) Chemical cleaning of boiler is done to remove oil, greases and
foreign
Materials from internal surfaces of pressure parts.
s) Steam blowing of steam lines is done to remove scale and

foreign matter in Steam lines thereby preventing damage to
turbine (if provided) and other equipments.
t) Safety valves on drum and super-heater are set. Popping

pressure and blow downs are adjusted to confirm with design
values.
u) The boiler and economizer are filled to the normal operating level
with properly treated feed water.
2 . Filling up the Boiler and Economiser

a) When filling the unit for service, care should be taken to use
only properly treated and de-aerated water so that conditions
will be in force from the start suitable for the avoidance of
scale, corrosion, and other difficulties caused by improperly
conditioned water.
b) To fill the boiler and economizer, close the following valves:

Feed control valve, isolating valves and bypass.
All blow down valves and drain valves on boiler and water
walls.
31
All drain valves on economizers.
Main steams stop valve and its bypass.
De super-heater control valve, isolating valve and bypass.
c) Open the following valves:

Drum vents.
Water level isolating valves.
Attemperator vents.
Main steam line drains and vents.
d) Isolating valves on the boiler filling header and line can be
connected by a flexible hose only when they are in closed
conditions.
e) By opening these boiler filling valves, the feed line to

economizer is charged with the water. The economizer is filled
first and subsequently the drum and water walls. Boiler drum is
filled until water is seen in the gauge glass. It is preferable to
keep the level low, since after lighting up, the water swells and
the level is likely to rise up.
f) Boiler filling is stopped when the water level approaches the

normal water level in the gauge glass.
g) When filling the boiler, feed slowly especially if the temperature

of water is more than 55'C above the drum shell temperature.
This is to prevent possible temperature strains on the drum shell.
Care should be taken to vent out the air sufficiently so that no
pressure is built up.
32
ANSALDO UTILITY BOILER WATER AND STEAM SYSTEM
The Boiler water and Steam system is capable to provide
superheated steam to the common high pressure steam header. Feed
water from the feed water pumps (by others), is sent to the boiler at
proper characteristics. The feed water flow is regulated by means of
two control valves (one main control valve and one low load control
valve), which control the drum level and super heater steam flow rate
(main control valve is designed for 100% duty, while low load control
valve is designed up to 40% load.
The feed water is delivered to boiler battery limit at the following

condition
Conditio Pressure kg/sq Temperature deg Flow
n cm g cel kg/sec
Operatin 184.1 133 112.917
33
g
Design 225 150 112.917
Water is turned into saturated steam exchanging heat in the

economizer and evaporator sections tubes. And then enters into the
drum where the steam is separated from water and this steam is
superheated and sent to the main steam header at the following
condition.
Conditio Pressure kg/sq Temperature deg Flow
n cm g cel kg/sec
Operatin 131 529 112.917
g
Design 145 544 112.917
NOTE :
The steam super heating system consists of two banks. Considering
the steam flow direction, they are
Primary super heater that will be referenced hereafter as SH-1
Secondary super heater that will be referenced herein after as
SH-2
System equipment
The boiler water and steam system is equipped with
a. one boiler drum
b. control valves, located as follows
No.2 control valves on feed water pneumatically operated and

remotely controlled, main control valve sized for the max load
34
(52-1B-CV-0176A)the low load control valve size for 40% of the
maximum load (52-1B-CV-0176B) for startup duty
No.2 control valves pneumatically operated and remotely
controlled (52-1B-CV-0278, 52-1B-CV-0279, respectively left and
right side) on spray water to superheated steam de superheating
lines(between super heater banks SH-1 and SH-2) each one
equipped with manual upstream shut off valve(52-1B-GV-0204,
52-1B-GV-0202, respectively left and right side), each SH spray
water control valve is equipped with manual shut off valve
downstream it and with manual by pass valve, a common quick
closing shut off valve (52-1B-SOV-0291), pneumatically operated
and remotely controlled is foreseen upstream control valves.
c. Heating exchange surfaces(economizer, boiler walls and super
heater banks)
d. Spring loaded safety valves, located as follows
No.2 on the boiler drum (52-1B-PSV-0101, 52-1B-PSV-0102),
designed to vent approx 160390 kg/h and 165540kg/h of steam
at full lift pressure of approx 151.5 and 156kg/cm2 g
respectively(drum : operating pressure =143kg/cm2 drum design
pressure = 152kg/ cm2 g)
No.1 on superheated steam outlet header (52-1B-PSV-0201),
designed to vent approx 134596 kg/h of steam at full lift pressure
of approx 141.3 kg/cm 2 g
e. Power actuated safety valve, located as follows;
No.1 power actuated valve (52-1b-sov-0290) located on
superheated steam outlet header, designed to vent approx
64229kg/h of steam
Purpose of power actuated safety valve is to reduce spring safety
valve operation, because it is designed for a lower set pressure.
The valve works automatically, based on pressure transmitter
35
according to pressure set. it opens for 138.7 kg/cm2 g and closes
for 134.6kg/cm s g
f. De super heaters located as follows;
No.2, one for each side on the super heated steam pipes
between SH-1 outlet header and SH-2 inlet header
g. Motor operated valves remotely controlled, located as follows.
No.1 isolating valves upstream main feed water control valve
(52-1B-MOV-0180)
No.1 isolating valve upstream low load feed water control
valve(52-1B-MOV-0181)
No.1 feed water isolation valve (52-1B-MOV-0182) at economizer
inlet with integral by pass valve (52-1B-MOV-0183)
No.1 valve (52-1B-MOV-0185)on down comers drain line, used
during startup operations.
No.1 isolating valve in the recirculation line between down comer
and economizer inlet header (52-1B-MOV-0184)
No.1 saturated steam vent valve(52-1B-MOV-0186) used during
start up operations, on saturated steam tubes
No.2 superheated steam vent valve(52-1B-MOV-0281) (52-1B-
MOV-0282) connected in series, used during startup operations,
first one on off type, the second one inching type.
No.2 superheated steam outlet stop valve (52-1B-MOV-0283),
equipped with integral manual by pass valve(52-1B-GV-0207)
No.1 Super heater headers drain valve(52-1B-GV-0280)used
during startup operation
Functional description
36
The boiler water and steam system receives de aerated feed
water from the external de aerated by means of feed water pumps.
The feed water flow is regulated by two control valves.
The low load control valve, sized for 40% of the boiler load,
controls the flow up to 25%(approx) of the maximum value(i.e
during start up)
The full load control valve sized for the fully boiler load, starts to
control the flow from 25%(approx) of the maximum value and
reach the full opening at 75%, over his value the flow is
controlled by feed pumps, having a lapse during which it works
contemporary to the minimum load one.
This allows to cover the fully control range using the more proper
valve and to be safe against flow regulation failure in order to avoid
that low load control valve close before that main control valve has
been open and in regulation.
The boiler can be isolated (water side) by the check valve, used in
order to prevent the back flow of boiler water if the feed water pump
should fail.
From the feed water motorized isolating valve the water passes
through the economizer where it is heated and it is conveyed to the
boiler drum.
The economizer is provided with and includes
- Inlet header
- Banks of horizontal tubes
- Outlet header
- Connecting pipes to the steam drum
The economizer inlet header is also connected to a down comer via

the shut off valve (52-1B-MOV-0184) for a recirculation during start up
phase; the recirculation from the down comer allows a little circulation
in the economizer when it is not still fed.
37
From economizer outlet header, feed water flows to the boiler drum
where it is mixed with the boiler water, then the water flows, by means
of natural circulation, in the water walls tubes(evaporator banks) and
the mixed water and steam turns back into the boiler drum though the
riser tubes.
Centrifugal forces in the drum cyclones are used to separate the
steam from the water and it becomes dry steam.
Then the saturated steam passes through a primary corrugated and
inclined scrubber at the top of the separators. Ultimate steam
separation is obtained after final separation in the secondary scrubber,
located at the top of the steam drum.
The combination of cyclone separators and scrubbers provides the
means to obtain the required steam purity (0.2 micro ohms/cm specific
conductivity in normal operation)
Further connections are provided on the boiler drum for chemical

feed, continuous and intermittent blow-down, safety valves, gauge
glass level indicators, pressure transmitters(one on each side of boiler
drum), level transmitters are connected to hydraulic columns(one on
each side of boiler drum) one remote level indicator (connected to
hydraulic columns)
The saturated steam purity (monitored by a steam sampling) is
achieved by checking the boiler drum water quality. In fact the blow
down sampling analysis indicates the boiler water quality and from the
blow down line a fixed amount of water (quantity established during
commissioning phase according to feed water chemical quality) is
discharged in order to maintain the water salt content at a proper
value (apprx <10micro omh/cm specific conductivity)
When needed, a chemical dosing system provides phosphate
solution to the boiler drum water in order to make the water solids
precipitate (especially as Mg and Ca phosphates)
38
During transients (e.g. during start up) the drum level swelling can
be controlled by opening the motor operated shut off valves(52-1B-
MOV-0185) on emergency blow-off pipe coming from down comers
drain pipe to intermittent blow-down tank for a due period to decrease
the drum level to a safe value. When the drum pressure increases
more than approx 50 bar g opening of the above valves is forbidden.
From the drum, the saturated steam flows to the SH-1(primary

super heater bank) and then after de superheating phase, the
superheated steam enters into the SH-2(secondary super-heater bank)
All the drum the saturated steam flows to the SH-1 (primary super
heater bank) and then after de superheating phase, the superheated
steam enters in to the SH-2 (secondary super-heater bank)
All the super-heaters headers are quipped with suitable drain lines
complete with double drain shut off valves. SH de superheating is
carried out by means of feed water drawn upstream of feed control
station, water enters the de super-heater through the spray nozzles
connected to the steam pipe and it is evaporated and mixed with the
steam.
The boiler is equipped with its own isolation valve (52-1B-MOV-0283)
and related by pass valve installed on main steam pipe.
Moreover, two startup vent lines, located and equipped as follows,
Saturated steam at boiler drum outlet, equipped with shut off
valve, electrically operated and remotely controlled (52-1B-MOV-
0186) designed to vent small amount of steam at nominal
condition.
Main steam at boiler outlet, equipped with double shut off valves,
both electrically operated and remotely controlled (52-1B-MOV-
0281, 52-1B-MOV-0282) designed to vent apprx 30% of steam at
nominal condition.
39
Allow to control the boiler pressure ramp rate during start up
phases.
The safety of the boiler is achieved by means of
Two safety valves located on the steam drum set at 151.5 and
156 kg/sq cm g res.
One on the superheated main steam pipe set at 141.3 kg/sq cm
g, to reduce the operation frequency of the spring loaded safety
valves, one power operated pressure relief valve is provided on
the superheated main steam pipe(52-1B-SOV-0290) set at 138.7
kg/sq cm g.
Boiler preservation is not currently employed but provisions are

installed for nitrogen connection. In case of preservation, the circuits
can be filled with nitrogen by means of inlets (each one equipped with
double shut off manual valve and spectacle blind) located in the upper
points.
The boiler is preferably filled from the bottom through dedicated
lines at low pressure connected to down comers and economizer inlet
header, using existing DM water treated with hydrazine.
The whole boiler can be drained and vented, as necessary; drains
and vents are conveyed to intermittent blow-down tank.
The boiler is also equipped with metal thermocouples. They are
located on the boiler drum, used to check the drum metal top-bottom
differential temperature during pressure changes. On some down
comers and riser pipes, in order to monitor the uniformity of the water
flow to and from water walls tube, on super heater to check tubes skin
temperature
OPERATING MODE
Operating mode of water and steam system are as follows
Startup and normal operation
40
Shut down
Trip
Before the water and steam system startup, some preliminary

operation and checks shall be done and components shall be set ready
for operation as follows
- boiler filled
- boiler bottom drains closed
- feed water pump station and its auxiliary circuits ready
- air and flue gases system in operation
Startup and normal operation

Start up procedure can be as follows
Boiler cold startup sequence, for drum pressure not higher than 2
bar (to be set during commissioning phase)
Boiler warm startup sequence, for drum pressure higher than 2
bar (to be set during commissioning phase) and not higher than
30 bar (to be set during commissioning phase)
Boiler hot and very hot startup sequence, for drum pressure
higher than 30 bar (to be set during commissioning phase)
Cold startup
Cold start up procedure (i.e boiler drum pressure lower than 2 bar g,
set during commissioning phase) related to water and steam system is
as follows:
41
- open boiler drum vent valves (52-1B-MOV-0186) and SH startup
vent valve on SH steam pipe (52-1B-MOV-0281, 52-1B-MOV-282)
- check that continuous blow down needle valve(52-1B-MOV-0380)
is set in the right position and the related manual shut off valve
(52-1B-GL-0308) is open
- check that motorized shutoff valve at economizer inlet (52-1B-
MOV-0182) is fully opened
- open SH drains motor operated valve (52-1B-MOV-0280) all
other drain and vent valves shall be kept closed
- open the economizer recirculation valve (52-1B-MOV-0184)
- drum level (i.e feed water flow) control under operator manual
control, hence low load control valve (52-1B-CV-0176B)
controlled by operator
When the boiler drum pressure reaches 2 bar g approx (set during
commissioning phase)
- close boiler drum vent valve (52-1B-MOV-0186)
When the boiler drum pressure reaches 6 bar g approx (set during
commissioning phase) close SH drains valves, then the steam can be
conveyed to atmosphere towards startup vent valve
- control drum startup pressure acting on SH steam vent valve
(52-1B-MOV-0282) in order to maintain the drum pressure ramp
rate closed to recommended value
- when the steam achieves a condition (P and T close to which one
of main steam header, close start up vent valves on SH steam
header (52-1B-MOV-0281, 52-1B-MOV-0282)
- The economizer recirculation valve (52-1B-MOV-0184) shall be
closed when the boiler is properly fed via feed water pump and
boiler load (i.e steam flow) is greater than appox 10%
Warm Start Up
42
When boiler drum pressure is in between the 2 and 3 bar g (set
during commissioning phase), the start-up procedure are as follows,
-Open start up vent valves on SH steam header (52-1B-MOV-0286,
52-1B-MOV-0282)
- Check that continuous blow-down needle valve (52-1B-MOV-0380)
is set in the right position and the related manual shut off valve (52-
1B-GL-0308) is open.
- Check that the motorized shut off valve at economizer inlet (52-
1B-MOV-0182) is fully opened vent valves
- All other drain and shall be kept closed
- Open the economizer recirculation valve (52-1B-MOV-0184)
- Open the MOV upstream feed water low load control valve (52-1B-
MOV-0181)
- Drum level (i.e. feed after flow) control under operator manual
control, hence low load control valve (52-1B-CV-0176B) controlled
by operator
When the boiler drum pressure reaches 6Kg/sq cm g appox (set
during commissioning phase) the startup procedure will proceed as
per cold startup procedure.
Hot and Very hot startup

It is performed when the shut down time has been less than
10hours and the boiler drum pressure is greater than 30bar g (set
during commissioning phase); in that case turbine warm up phase is
not needed. Hot startup procedure related to water and steam
system is as follows
- Open drains valves on main steam line
- If any, open main steam by pass valve (52-1B-GV-0207), when
the pressure is equalized open main steam valve (52-1B-MOV-
0283)
43
- Check that continuous blow-down needle valve (52-1B-MOV-
0380) is set in the right position and the related manual shut off
valve(52-1B-GL-0308) is set in the right position and the related
manual shut-off valve (52-1B-GL-0308) is open
- Check that the motorized shut off valve at economizer inlet (52-
1B-MOV-0182) is fully opened
- Open the economizer recirculation valve (52-1B-MOV-0184)
- If any, open startup vent valves on SH steam header (52-1B-
MOV-0281, 52-1B-0282) at this time the start up procedure will
proceed as per cold startup procedure.
If necessary during startup procedure, e.g boiler drum swelling
phenomena in emergency condition, the shut off valves from down
comers to intermittent blow-down tank can be opened to control it.
Shut Down
Regular shut down
It is considered a regular shut down when the plant has to be
stopped for a short period. there-fore the boiler shall be bottled with
drum pressure as much higher as possible, near to drum nominal
pressure, in order to reduce the restart time, normal shut down
procedure related to water and steam system are as follows.
- Increase steam pressure up to the boiler maximum allowable
operating value
- Reduce boiler load at minimum, by reducing fuel, air and switch
off some burners
- Switch off all remained burners
- Close main steam shut off valve (52-1B-MOV-0283) and related
by pass
- Check that all drains and vents are closed
Cold shut down
44
It is considered a cold shut down when the plant has to be stopped for
a scheduled maintenance; cold shut down procedure related to water
and steam system is as follows
- Reduce the boiler load
- Open the SH steam vent valves (52-1B-MOV-0281, 52-1B-,PV-
0282)
- Switch off all remained burners
by pass
- Reduce more the boiler load by controlling the ramp rate
opening/using the SH steam vent valves (52-1B-MOV-0283)
- When the drum pressure reaches a value lower than 2 bar g
approx (set during commissioning phase) open drum vent valve,
super heater drains valves.
Emergency shut down

In case of boiler shut down required for internal inspection, in order to
minimize the duration to reach the minimum required conditions for
internal inspection, emergency shut down procedure related to water
and steam system are as follow.
- Switch off all burners
by pass
- Decrease boiler pressure using the startup vent valves
approx (set during commissioning phase) open drum vent valve,
super heater drains valves.
approx (set during commissioning phase), open drum vent valve,
and super heater drains valves.
- Keep drum level at the maximum value
45
- Open the bottom drains manual valves and motor operated
valves on continuous and intermittent blow down when the
pressure reaches 2 bar g approx.
- Flush boiler pipes and tubes with fresh water
Trip
Boiler trip related to water and steam systems are
Drum level very high (LT-0177A/B AND LT-0178 - based on 2 out
of 3 logic) +175mm above NWL (set during commissioning
phases), 15.35 sec time delayed
Drum level very low (LT-0177A/B and LT-0178 based on 2 out of
3 logic) -362.5mm below NWL (set during commissioning phase),
30 sec time delayed
the trip signal will generated a trip condition acting on fuel system,
closing main fuel trip valves.
CONTROL AND AUTOMATION REQUIREMENTS
Main measures on water and steam system are
Feed water flow (FT-0176A/B), temperature compensated (TT-
0176A/B) (based on 1 out of 2 logic) control and supervision
purposes.
Drum level (LT-0177A/B and 0178) (Based on 2 out of 3 logic) trip
and alarm purposes.
Drum level (LT-0177A/B/C) (2 out of 3) density compensated (PT-
0178A/B) (based on 1 out of 2 logic) control and supervision
purposes.
Main steam flow (FT-0276A/B/C), pressure 9PT-0278A/B) and
temperature (TE-0284A/B) compensated (based on 1 out of 2
logic) control and supervision purposes
Super-heater steam SH-2 inlet side A and B temperature (two
separate slave control loops, TE 0278A/B and TE 0279A/B res.
46
each one based on 1 out of 2 logic and TE-0286A/B with temp.
Transmitters for each element on the main steam outlet header
for master control loop of main steam temp. Control and
supervision purposes.
One TE-0285 is provided on the main steam header for steam
temp low interlock with SOV-0202 on the de-super heater spray
water line.
feed water analysis(economizer inlet) (by others)
- Specific conductivity, supervision and alarm purpose
- pH, supervision and alarm purpose
- Dissolved oxygen, supervision and alarm purpose
- Silica, supervision and alarm purpose
Boiler drum analyses (by others)
- Cationic conductivity, supervision and alarm purpose
- Sodium, supervision and alarm purpose
Saturated steam analysis (by others)
Super heater steam analysis (by others)
Additional minor and local measures are provided.
For water and steam system the following main control loops are
foreseen
Drum level control, based on feed forward plus feedback cascade
control loop. Utilizing a basic three elements system(boiler drum
level, main steam flow and feed water flow) acting on drum level
47
control valves, up to 25% on low load valve, above on full load
valve
superheated main steam temperature control, one for each side,
based on feed forward plus feedback cascade control loop,
utilizing the main steam temperature value at boiler outlet
trimmed with the intermediate superheated steam temperature
(i.e super-heater SH-2 inlet) acting on spray water control valves
48
FORCED DRAUGHT FAN
General
The FD fan train unit consists of steam turbine coupled to fan though
gear box on one side and HT motor coupled through fluid coupling to
fan on the other side. HT motor is a stand by arrangement for the FD
fan system.
Quantity 1
Discharge pressure static (mm WG) 625 (normal)
Capacity, Nm3/hr Normal : 395916 Rated : 435508
Pump driver Motor/Steam turbine
Rated BKW 1700
GENERAL ARRANGEMENT OF FD FAN TRAIN

Steam for steam turbine is taken from HP steam header which is
available at the utility boiler terminal point at the condition indicated in
the following table.
HP steam (inlet) condition

Units Normal Max Min
at TP
Kg/cm2
HP Steam Pressure 44 44.75 43
g
o
HP Steam Temperature C 400 410 395
MP steam (outlet) condition

at TP
MP Steam Pressure Kg/cm2 18.8 19 18.2
49
g
o
MP Steam Temperature C 353.3 357 353.3
OPERATIONAL DESCRIPTION
The FD fan unit can be driven either by electric motor or steam
turbine.
At the outset boiler cold start is performed by using the electric motor
until the steam is available so that the steam turbine can be placed in
operation. The HT motor will run the fan through the fluid coupling.
Once the required condition of steam is available the steam turbine will
be put in operation which delivers power through gear box to the fan.
Then the electric motor can be manually stopped and left in standby
for further auto start in case of steam turbine trip or the FD fan reach
the low speed set point. Each side has over running clutch to engage
and disengage the drivers depending on the operation sequence.
Operation of FD fan with electric motor

The HT motor is a DOL start, constant speed motor. The motor is
operated from DCS through manually. The fan speed/air flow is
regulated by inlet damper and fluid coupling according to boiler loads.
The inlet damper is operated by pneumatic cylinder to regulate the air
flow based on the analog signal from DCS. The fluid coupling system is
operated by scoop tube control system to control the speed of the
motor for regulating the air flow based on the analog signal from DCS.
The over running clutch between fluid coupling and the fan will
disengage the fan automatically during the steam turbine operation
once the speeds on both side are same. Before starting of the HT
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motor, the auxiliary oil pump (AOP) shall need to be started for lube oil
supply to FD fan which is an auto start from DCS.
Operation
During cold start up, the inlet damper of the FD fan will be opened
automatically based on the combustion air demand command from the
DCS. The fan air flow will be controlled till 30% of the boiler loads.
Once the boiler load reaches 30%, the fluid coupling will then take over
there by controlling the air flow for the boiler combustion for 30% to
100% loads.
Operation of FD fan with steam turbine

Steam turbine is a variable speed, back pressure and single stage type.
Once the required steam condition is available at the HP steam
terminal point, the ON/OFF solenoid valve (52-1B-SOV-1190) located in
the inlet line of the turbine will be opened manually from remote
through DCS for allowing steam flow in to the turbine. Before this the
ON/OFF motorized valve (52-1B-MOV-1102) located in the turbine lube
oil supply line shall need to be opened manually from DCS, for opening
the trip and throttle valve for steam admission to turbine. The steam
turbine, based on the boiler load conditions and thus quantity, will
deliver the required power to FD fan through gear box. Once the
turbine achieved the operating speed, AOP is auto cut off manually
from DCS and MOP will take over for the lube oil supply for the system.
Auto change over from steam turbine to HT motor (standby)

The steam turbine is envisaged to trip only during the below events,
thereby auto switch over to motor
1. Over speed
2. Bearing temperature rise
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3. Vibration beyond permissive level
4. Lube oil system trip (i.e Turbine trip on low oil pressure)
During the above trips, the following control logic will enable motor to
auto start for safe guarding the turbine.
a. Turbine over speed : The PROTECH will send the trip signal to
open the solenoid valves (SOV-1191 & SOV-1192) for lube oil
bypass thereby closing the throttle valve(ESV-1193) and cut the
steam flow to turbine. At 95% of the allowed over speed, an auto
command from DCS should start the motor before turbine comes
to halt.
b. Bearing temperature rise, high vibration level and lube oil system
pressure low. For these cases, when the set value is beyond the
recommended value, DCS will initiate the tripping sequence.
Before the set value is reached there will be an auto command
from DCS to start the motor simultaneously while turbine is in
operation.
The lube oil supply ON/OFF valve (52-1B-MOV-1102) shall remain open
until the turbine rotor comes to total halt and until the bearing are
cooled. Only when the turbine is planned for long stoppage, MOV 1102
will be closed manually from DCS.
Lubrication system for FD fan train

There is a common lube oil system for FD fan, gear box and steam
turbine. The lube oil system consists of oil reservoir, AC motor driven
auxiliary oil pump(AOP) as a stand by operation and shaft driven main
oil pump (MOP) oil coolers, filters and other accessories. During the
cold start of the boiler, the AOP shall be started first from DCS for
supply of oil to FD fan. When the system is ready for transfer from
motor to turbine, ON/OFF valve (52-1B-MOV-1102) shall be opened for
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supplying lube oil to trip valve, turbine and gear box along with fan.
Once MOP meets the system demand, AOP is remote cut off. At the
time when MOP supply pressure is lower than the set point, the AOP
will be auto cut in form the DCS to augment the supply. Also when the
AOP supply pressure to turbine system is not enough, the turbine will
trip and motor will take over the fan.
FD FAN OPERATION SEQUENCE

Operating mode of fan system is as follows
HT motor Auto start and Manual stop
Steam turbine Manual remote start and Auto stop
General operation of fan

For starting :
1. Check the following before Fan is started :
a. FD fan damper shall be closed
b. Scoop in minimum position
c. Working oil temperature not high
d. Winding temperature is not high
e. Bearing temperature is not high
f. Rotor locked condition not occurred
2. Manual start of the HT motor by means of DCS
3. Turn the local selector near the fan in auto mode
4. Ensure the all steam parameters are adequate
5. Start the lube oil auxiliary pump from DCS before turbine is in
operation for opening the throttle trip and throttle valve
6. Open the solenoid valve in the HP steam line from remote
operation for steam inlet to turbine
7. Once steam turbine is put in operation, the oil main oil pump
(shaft driven) will take over and hence the AOP is stopped by
using DCS
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8. When the steam turbine speed is equal to the motor coupling
speed, the automatic clutch of the motor disengages the motor
coupling.
9. Operator shall stop the motor from remote or from local push
button(ensure the selector switch is in remote mode after
stopping the motor also)
For stopping
1. Turn the local selector near the fan in manual mode.
2. Close the solenoid valve from the remote location for steam cut
off to turbine
3. Open the by pass solenoid valve in the trip and throttle valve
circuit from remote location there by depressurizing the lube oil
supply valve top close and hence steam cut off to turbine.
By HT motor
FD fan electric motor start according to the following steps
1. Closure of FD fan damper from DCS
2. Start the lube oil auxiliary pump from remote location (DCS)
before motor is started.
3. Start the fan electric motor from DCS manually
4. During the steam turbine trips, the DCS will provide the auto
start command for motor to start.
Manual stop Operation

Forced draft fan electric motor stop
1. When the turbine output speed is equal to the fluid coupling
output (relative) speed, the operator shall stop the electric motor
from remote location (DCS) and leave in stand by mode
2. Emergency stop of motor from local hand switch
BY STEAM TURBINE
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a. Manual start operation
Manual start of turbine according to the following steps
a. AOP shall be in ON condition
b. Lube oil pressure shall be adequate
c. Solenoid valve in the HP steam line shall be opened
d. Main steam temperature shall be adequate
e. All the temperatures and vibrations of turbine shall be normal
f. Scoop follow up circuit activated
g. Once the steam turbine is put in operation, the lube oil main oil
pump(shaft driven) will take over and hence the auxiliary oil
pump will be auto cut from DCS.
b. Automatic Stop Operation

Auto stop of steam turbine :
a. Close the ON/OFF solenoid valve from the remote location for
steam cut off to turbine
b. Open the by pass solenoid valve in the trip and throttle valve
circuit from remote location thereby depressurizing the lube oil
supply to close the trip valve and hence steam cut off to turbine.
Note :
a. An electric governor is installed near the steam turbine to control
the speed
b. The manual mode is performed to change from the electric
motor to steam turbine and automatic mode is performed to
change from steam turbine to electric motor.
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FUEL OIL SYSTEM
General
The fuel firing system is capable to provide fuels (either fuel oil
or fuel gas) atomizing steam to burner system.
The oil system also supplies high speed diesel to 4 burners of

bottom elevation of front and rear walls for startup, these burners are
air atomizing.
Start up Fuel Oil System
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The startup fuel oil HSD received from supply system at the following
condition.
Condition Pressure (Kg/sq Temperature deg Flow

cm cel Kg/hr
Operating 15.3 45 3630
(MCR)
Design 24 65 3930
The HSD through related flow control valve, feds the startup
burners system (i.e the 1st row) to bottom elevation of each burner at
the following condition.

cm cel Kg/hr
Operating 3.57 Ambient 1500
(MCR)
Design 3.57 Ambient 150
Blended Fuel Oil system
The Blended Fuel Oil System ( in the following BFO), received
from supply system (from BFO Heater) at the following condition.

cm cel Kg/hr
Operating 18.0 115 31150
(MCR)
Design 24.0 115 31500
The BFO, through the related flow control valve, feds the burners
system to both top and bottom elevation of each burner at the
following condition.

cm cel Kg/hr
Operating 12.24 115 4450
(MCR)
Design 12.24 135 4500
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Fuel Gas System
The fuel gas ( in the following R-LNG), received from supply
system at the following condition.

cm cel Kg/hr
Operating 7.0 90 25305
(MCR)
Design 11.0 105 25900
The R-LNG, through the related flow control valve, feds the
burners system to both top and bottom elevation of each burner at the

cm cel Kg/hr
Operating 0.765 30 3615
(MCR)
Design 0.765 105 3700
Atomizing Steam System
The MP steam, received from Auxiliary steam system at the

cm cel Kg/hr
Operating 17.8 220 2660
(MCR)
Design 20.4 350 3150
Pressure reduced through the related pressure control valve, if
feds the burners system at the following condition.

cm cel Kg/hr
Operating 13.26 220 380
(MCR)
Design 20.4 350 450
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System equipment
Fuels firing system consist of
Feeding system to burners

a) Oil and atomizing / scavenging feeding system to burners consisting of
1. on HSD fuel feeding system main pipe to burners are installed
- HSD flow measuring device (FT0877) orifice coriolis type, common to all HSD
burners; for maintenance purpose the flow meter is equipped with related
upstream, downstream, downstream drain and bypass shut off manual valves.
- HSD main trip valve (SOV-0894), pneumatically operated (remote controlled)
common to all HSD burners
- HSD flow control valve (CV-0877) pneumatically operated (remote controlled)
common to all HSD burners, for maintenance purpose the control valve is
equipped with related upstream, downstream, downstream, downstream drain and
by pass shut off manual valves.
2. On blended fuel oil (BFO) feeding system main pipe to burners are installed.
- Two BFO flow measuring device (FT-0878) on delivery pipe and (FT-0879) on
return pipe mass flow meter coriolis type, common to all BFO burners, for
maintenance purpose the flow meters are equipped with related upstream
downstream block valves, drains at downstream of FT-0878, upstream FT-0879
and by pass shut off manual valves
- BFO main trip valve (SOV-0891), pneumatically operated (remote controlled)
common to all BFO burners.
- BFO short recirculation valve (SOV-0892), pneumatically operated (remote
controlled) this valve is commanded in conjunction with the BFO main trip valve.
i.e. when one opens the other one closes and vice versa
- BFO flow control valve (CV-0878) pneumatically operated (remote controlled) on
delivery pipe, common to all BFO burners, for maintenance purpose the control
valve is equipped with related upstream, downstream, downstream drain and by
pass shut off manual valves
- BFO long recirculation valve (SOV-0893), pneumatically operated (remote
controlled), on delivery pipe common to all BFO burners, for maintenance
purpose the shut off valves is equipped with related upstream, down stream shut
off manual valves and fixed orifice at by-pass.
3. On atomizing/ scavenging system main pipe to burners the following are installed.
- Atomizing steam main shut off valve (SOV-0890), pneumatically operated
(remote controlled), common to all BF oil burners.
- Atomizing steam to burners pressure control valve (CV-0877), pneumatically
operated (remote controlled) for maintenance purpose the control valve is
equipped with related upstream, downstream, downstream drain and by pass shut-
off manual valves.
b. Fuel gas feeding systems to burners.
1. On fuel gas feeding system main pipe to burners the following are installed.
- R-LNG flow measuring devices (FE-0976), orifice type flow meter, common to all
FG burners.
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- R-LNG main trip valve assembly, pneumatically operated (remote controlled),
common to all R-LNG burners, consist of two valves in series (SOV-0990 & SOV-
0991) with vent valve (SOV-0992) in between.
- RLNG flow control valve (CV-0976) pneumatically operated (remote controlled)
common to all R-LNG burners.
- R-LNG vent valves (SOV-0988 & 0989), pneumatically operated control
valves(remote controlled), common to all R-LNG burners. The vent pipes are to be
connected to flare (flare is not in AC scope)
Burners System (6556-EPCC4-PI-P-52-1B-1108, 1109 & 1124)

Burners system consists of
No.08 burners, arranged in two rows each of two burners installed on the furnace
front and rear walls. the burners are sized in such a way to achieve the boiler MCR
load with one burner out of service. Burners are singularly commanded. All burners
are capable of fire R-LNG or BFO/HSD and they are designed to fire all fuels either
individually or in combination in any proportion with in the ACC range. In addition
the bottom row (lower elevation, 4 burners) front and rear wall burners are also
capable to fire HSD for start up duty, any two lower burner shall be used for start up.
Each burner is equipped as follows

Inspection door,
Oil gun advancing and retracting device pneumatically operated (remote
controlled) 52-1B-BSA-2496A for burner 52-1B-B2-001; 52-1B-BSA-2496B for burner
52-1B-BS-002, 52-1B-BSA-2496C for burner 52-1B-BS-003; 52-1B-BSA-2496D for
burner 52-1B-BS-004, 52-1B-BSA-2496E for burner 52-1B-BS-005, 52-1B-BSA-2496F
for burner 52-1B-BS-006, 52-1B-BSA-2496G for the burner 52-B-BS-007; 52-1B-BSA-
2496H for burner 52-1B-BS-008
Air register pneumatically operated (remote controlled)
52-1B-AR-2495A for burner 52-1B-BS-001; 52-1B-AR-2495B for burner 52-1B-BS-002
52-1B-AR-2495C for burner 52-1B-BS-003; 52-1B-AR-2495D for burner 52-1B-BS-004
52-1B-AR-2495E for burner 52-1B-BS-005; 52-1B-AR-2495F for burner 52-1B-BS-006
52-1B-AR-2495G for burner 52-1B-BS-007; 52-1B-AR-2495H for burner 52-1B-
BS-008 One main burner flame scanner for main oil flame and main gas
flame UV/IR type
52-1B-SC-2476A for burner 52-1B-BS-001; 52-1B-SC-2476B for burner 52-1B-BS-002
52-1B-SC-2476C for burner 52-1B-BS-003; 52-1B-SC-2476Dfor burner 52-1B-BS-004
52-1B-SC-2476E for burner 52-1B-BS-005; 52-1B-SC-2476F for burner 52-1B-BS-006
52-1B-SC-2476G for burner 52-1B-BS-007; 52-1B-SC-2476H for burner 52-1B-BS-008
RLNG shut off valve assembly pneumatically operated (remote controlled) valve
assembly consists of two valves in series with vent valve in between with tag ; 52-1B-
SOV-0993A/0994A/0994A for burner 52-1B-BS-001, 52-1B-SOV-0993B/0994B/0995B
for burner 52-1B-BS-002, 52-1B-SOV-0993C/0994C/0995C for burner 52-1B-BS-003,
52-1B-SOV-0993D/0994D/0995D for burner 52-1B-BS-004, 52-1B-SOV-
0993E/0994E/0995E for burner 52-1B-BS-005, 52-1B-SOV-0993F/0994F/0995F for
burner 52-1B-BS-006, 52-1B-SOV-0993G/0994G/0995G for burner 52-11B-BS-007, 52-
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1B-SOV-0993H/0994H/0995H for burner 52-1B-BS-008; for maintenance purpose on
pipe upstream the pneumatic shut off valve, a manual valve is installed.
R-LNG burner cooling air shut off valve assembly pneumatically operated (remote
controlled) valve assembly consists of two valves in series with vent valve in between tag
; 52-1B-SOV-0996A/0997A/0998A for burner 52-1B-BS-001, 52-1B-SOV-
0996B/0997B/0998B for burner 52-1B-BS-002, 52-1B-SOV-0996C/0997C/099C for
burner 52-1B-BS-003, 52-1B-SOV-0996D/0997D/0998D for burner 52-1B-BS-004, 52-
1B-SOV-0996E/0997E/0998E for burner 52-1B-BS-005, 52-1B-SOV-
0996F/0997F/0998F for burner 52-1B-BS-006, 52-1B-SOV-0996G/0997G/0998G for
burner 52-1B-BS-007, 52-1B-SOV-0996H/0997H/0998H for burner 52-1B-BS-008 for
maintenance purpose on pipe upstream the pneumatic shut off valve, a manual valve is
installed.
* HSD shut off valve pneumatically operated (remote controlled) 52-1B-SOV-2493A for
burner 52-1B-BS-001. 52-1B-SOV-2493B for burner 52-1B-BS-002, 52-1B-SOV-2493E
for burner 52-1B-BS-005, 52-1B-SOV-2493F for burner 52-1B-BS-006, for maintenance
Igniters system (6556-EPCC4-PI-P-52-1B-1110)
Igniter system consists of
a) Light Fuel Oil (HSD) and scavenging feeding system to igniters
On light fuel oil (HSD) feeding system main pipe to igniters are installed.
- HSD main trip valve (52-1B-SOV-1090) Pneumatically operated (remote
controlled); common to all HSD igniters.
- HSD pressure control valve(52-1B-CV-1076) Pneumatically operated common to
all HSD igniters; for maintenance purpose the control valve is equipped with
related upstream, downstream, downstream drain and by pass manual valves
b) Light Fuel Oil (HSD) igniters, mechanical atomized, are of class III size
according to NFPA rules(remote singularly controlled) each igniter is equipped as
follows,
*Igniter gun advancing and retracting device pneumatically operated (remote
controlled) 52-1B-IGA-1095A for burner 52-1B-BS-001; 52-1B-BS-1095B for
burner52-1B-BS-002, 52-1B-IGA-1095C for burner 52-1B-BS-003, 52-1B-BS-
1095D for 52-1B-BS-004, 52-1B-IGA-1095E for burner 52-1B-BS-005, 52-1B-BS-
1095F for burner 52-1B-BS-006, 52-1B-BS-1095G, for burner 52-1B-BS-007, 52-1b-
iga-1095H for burner 52-1B-BS-008
* Light fuel oil (HSD) shut off valve pneumatically operated (remote controlled)
52-1B-SOV-1092A for burner 52-1B-BS-001, 52-1B-SOV-1092B for burner 52-1B-
BS-002, 52-1B-SOV-1092C, for burner 52-1B-BS-003, 52-1B-SOV-1092D, for
burner 52-1B-BS-004, 52-1B-SOV-1092E, for burner 52-1B-BS-005, 52-1B-SOV-
1092F, for burner 52-1B-BS-006, 52-1B-SOV-1092G, for burner 52-1B-BS-007, 52-
1B-SOV-1092H , for burner 52-1B-BS-008, for maintenance purpose on pipe
upstream the shut off valve, a manual valve is installed. NRV is installed on pipe
downstream of scavenging shut off valve.
* Scavenging air/ purge air shut off valve pneumatically operated (remote
controlled) 52-1B-SOV-1091A, for burner 52-1B-BS-001, 52-1B-SOV-1091B, for
burner 52-1B-BS-002, 52-1B-SOV-1091C, for burner 52-1B-BS-003, 52-1B-SOV-
1091D, for burner 52-1B-BS-004, 52-1B-SOV-1091E, for burner 52-1B-BS-005, 52-
1B-SOV-1091F, for burner 52-1B-BS-006, 52-1B-SOV-1091G, for purpose on each
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pipe upstream the pneumatic shut off valve, a manual valve is installed. Non return
valve is installed on pipe downstream of shut off valve.
* Atomizing air shut off valve pneumatically operated (remote controlled), 52-1B-
SOV-2494A for burner 52-1B-BS-001, 52-1B-SOV-2494B for burner 52-1B-BS-002,
52-1B-SOV-2494C for burner 52-1B-BS-003, 52-1B-SOV-2494D for burner 52-1B-
BS-004, 52-1B-SOV-2494E for burner 52-1B-BS-005, 52-1B-SOV-2494F for burner
52-1B-BS-006, for maintenance purpose on each pipe upstream the pneumatic shut
off valve, a manual valve is installed. Non return valve is installed on pipe
downstream of shut off valve.
* BFO shut off valve pneumatically operated (remote controlled) 52-1B-SOV-
2490A for burner 52-1B-BS-001, 52-1B-SOV-2490B for burner 52-1B-BS-002, 52-
1B-SOV-2490C for burner 52-1B-BS-003, 52-1B-SOV-2490D for burner 52-1B-BS-
004, 52-1B-SOV-2490E for burner 52-1B-BS-005, 52-1B-SOV-2490F for burner 52-
1B-BS-006, 52-1B-SOV-2490G for burner 52-1B-BS-007, 52-1B-SOV-2490H for
burner 52-1B-BS-008, for maintenance purpose on each pipe upstream the pneumatic
shut off valve, a manual valve is installed. Non return valve is installed on pipe
* Atomizing steam shut off valve pneumatically operated (remote controlled)52-
1B-SOV-2491A for burner 52-1B-BS-001, 52-1B-SOV-2491A for burner 52-1B-BS-
001, 52-1B-SOV-2491A for burner 52-1B-BS-002, 52-1B-SOV-2491B for burner 52-
1B-BS-003, 52-1B-SOV-2491C for burner 52-1B-BS-004, 52-1B-SOV-2491D for
burner 52-1B-BS-005, 52-1B-SOV-2491E for burner 52-1B-BS-006, 52-1B-SOV-
2491F for burner 52-1B-BS-001, 52-1B-SOV-2491G for burner 52-1B-BS-007,
52-1B-SOV-2491H for burner 52-1B-BS-008 for maintenance purpose on each pipe
upstream the pneumatic shut off valve, a manual valve is installed. Non return valve
is installed on pipe downstream of shut off valve.
* Scavenging/Purging shut-off valve pneumatically operated (remote controlled)
52-1B-SOV-2492A for burner 52-1B-BS-001, 52-1B-SOV-2492B, for burner 52-1B-
BS-002, 52-1B-SOV-2492C for burner 52-1B-BS-003, 52-1B-SOV-2492D, for
burner 52-1B-BS-004, 52-1B-SOV-2492E, for burner 52-1B-BS-005, 52-1B-SOV-
2492F, for burner 52-1B-BS-006, 52-1B-SOV-2492G, for burner 52-1B-BS-007, 52-
1B-SOV-2492H, for burner 52-1B-BS-008, Non return valve is installed on each pipe
* One igniter per burner (remote controlled) consisting of the devices as herein
after described burner 52-1B-BS-007, 52-1B-SOV-1091H for burner 52-1B-BS-008
for maintenance purpose on pipe upstream the shut off valve, a manual valve is
installed. Non return valve is installed on pipe downstream of scavenging shut off
valve.
* Combustion / Primary air shut off valve pneumatically operated (remote
controlled) 52-1B-SOV-1093A for burner 52-1B-BS-001, 52-1B-SOV-1093B for
burner 52-1B-BS-002, 52-1B-SOV-1093C for burner 52-1B-BS-003, 52-1B-SOV-
1093D for burner 52-1B-BS-004, 52-1B-SOV-1093E for burner 52-1B-BS-005, 52-
1B-SOV-1093F for burner 52-1B-BS-006, 52-1B-SOV-1093G for burner 52-1B-BS-
007, 52-1B-SOV-1093H for burner 52-1B-BS-008, an fixed type orifice is installed
on pipe in by pass arrangement to each of the shut off valve.
* Flame detector of ionization type.
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Burner font is equipped with fuel oil drains collecting system consisting of
A basin installed each burner to collect fuel oil leakage and drains during
burner maintenance.
A steam traced pipe to collect drains from all basins conveying them to
drain oil pit.
Facility to unplug and blow away incidental oil residual from the above pipes is
provided at one burner level by means of manual valve to inject steam.
The boiler is equipped with eight burners, arranged in two rows of two burners
per row on front and rear wall. Burner ignition is commanded singularly, while fuel flow
control is common to all burners. Burners are sized in such a way to achieve boiler MCR
load firing blended fuel oil (BFO) AND / OR fuel gas(R-LNG).
Bottom elevation of any 2 burner out of 4 burners is also capable to fire light fuel
oil (HSD) for start up duty, hence allowing achieving maximum 10% of boiler MCR
load.
Therefore during cold start up in order to reduce corrosion effect, if the RLNG is
not available boiler is to be heated using HSD burners located at the bottom elevation
If natural gas is not available for boiler start up, it is recommended to start
and warm up the boiler using light oil start up burners due to the fact that
it is more fluid compared to heavy oil and also to reduce air heater
corrosion effect due to acid dew point, and when boiler load achieves 10%
approx. change to heavy oil firing.
HSD flow is controlled by means of control valve 52-1B-CV-0877, common to all

related burners, when the boiler reaches 10% of MCR approx. blended fuel oil burners
can be started and the flow is controlled by means of the control valve 52-1B-CV-0878
common to all related burners.
Mixed combination is allowed when boiler load is greater than 30% of MCR
therefore also RLNG burners can be started and the flow is controlled by means of the
control valve 52-1B-CV-0976, common to all related burners.
OPEATING MODE
Operating mode of fuels and burners system are as follows.
Start up and normal operation
Shut down
Scavenging
Trip
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In case of cold start up after a long term of boiler stop, before starting any
burners, the operator has to check that the boiler drum level is adequate and then starts
following equipments or to check if they are already in service.
Air & flue gases line(i.e regenerative Air heater and F.D fan in service)
At least one boiler feed pump.
After checking that the boiler drum level is adequate, the operator increases the
combustion air flow to burners wind box up to 30% at least, in order to perform the
furnace purge as specified in Air and flue gases system function description (dwg no.
6556-EPCC4-PI-P-52-1B-1106)
Performed the furnace purge, the operator can start fuels, igniters and burner
system through the following operation.
Igniter start up and shut down operation

General procedure to make available HSD to igniters is as follows,
Check the light oil delivery pump is in operation
Open HSD igniters main trip shut off valve (52-1B-SOV-1090) and
perform leak test as follows.
Maintaining closed igniters shut off valves (52-1B-SOV-1092A,1092B,
1092C, 1092D, 1092E, 1092F, 1092G & 1092H)Open partially the HSD
to igniters control valve (52-1B-CV-1076) to control HSD pressure to
igniters.
Open HSD igniters leak test valve (52-1B-SOV-1094)
Pressurize igniters fuel pipe.
Close main trip shut off and leak test valves and memorizing of pressure
valve
After two minutes approx if pressure value is within the established range
leak test is valid and enables opening of main tip shut off valve and
igniters ignition, vice versa if it fails forbids opening of main trip shut off
valve and hence igniter startup until leak test will be repaired and repeated
again.
When HSD igniters leak test has been complete, procedure continues as follows,
Open igniters main trip shut off valves
Open HSD to igniters control valve (52-1B-CV-1076) to control the
header pressure.
At this time HSD is available up to igniters shut off valve, therefore when burners
ignition sequence will require the igniter light on, the related ignition sequence will be as
follows,
Advance the igniter gun(e.g.52-1B-1G-1095A)
Open the igniter HSD shut off valve (52-1B-SOV-1092A)
Open the combustion air shut off valve (52-1B-SOV-1093A)
Energize the ignition transformer for 10 seconds
64
When burner sequence will require to put out of service the igniter, the related
extinguish sequence will be as follows.
Energize the ignition transformer for 10seconds,
Open igniter scavenging air shut off valve (52-1b-SOV-1091A)
Close the igniter HSD and primary air shut off valves
After 60 seconds (to be set during commissioning phase) that scavenging
air shut off valve has been opened, close igniter scavenging shut off vavle.
Retract igniter gun.
Burners start up operation

a. HSD start up burners
Usually this procedure is required to avoid dangerous situation to boiler walls and to
regenerative air heater due to flue gases low temperature it is mandatory to start the
boiler with HSD.
General procedure to make available HSD at burner is as follows,
Check that burners 001, 002, 005 and 006 have been arranged for HSD
firing
Check that pressure upstream HSD main trip valve is adequate (PT-0879)
it means to check that HSD supplying system (e.g. pump) is in operation
Open main trip shut off valve (52-1B-SOV-0894) and perform leak test as
follows.
- Partially open HSD to burners flow control valve (52-1B-CV-0877) maintaining
closed burners shut off valves.
- Open HSD burners leak test valve(52-1B-CV-0877)maintaining closed burners
shut off valves.
- Pressure of fuel pipe
- Closing main trip shut off and leak test valves and memorizing of pressure value.
- After two minutes approximately, if pressure value is within the established range
leak test is valid and enables opening of main trip shut off valve and burner
ignition, vice versa if it fails forbids opening of main trip shut off valve and hence
HSD burner start up until leak test will be repaired and repeated again.
When HSD burners leak test has been complete, procedure continues as follows,
Check that igniters are ready to be operated.
Check that atomizing air pressure is adequate ( not low) (PT-0880A/B/C)
Select one of the above mentioned burner for HSD firing.
Open HSD burners main trip shut off valve (52-1B-SOV-0894)
Open HSD flow control valve(52-1B-CV-0877) at approx, 10% ( to be set
during commissioning phase)
At this time HSD is available up to the burners shut off valve, therefore the operator can
proceed to put in service the burners via the related ignition sequence as follows,
- Start related igniters(say for burner 52-1B-BS-001)
65
- Check / Close burner related air register (52-1B-AR-2495A)
- Advance burner gun (52-1B-BG-2496A)
- Open atomizing air shut off valve (52-1B-SOV-2494A)
- Open HSD burner shut off valve (52-1B-SOV-2493A)
- Open burner related air register (52-1B-AR-2495A)
- After that burner shut off valve (52-1B-SOV-2493A) has been open since 30
seconds and burner is in operation (flame detected)
All above operation are performed by the operator though an automatic sequence.
When the HSD burner is proven. When the HSD burner is proven in service ( flame
detected) the HSD flow control loop will be released to auto mode, and therefore the fuel
control valve will operate according to required boiler load variation.
At that time operator can start the second and next front and rear wall 1 st row HSD
burners. Increasing boiler load up to 10% of MCR maximum.
b. BFO burners
General procedure to make available BFO at burners is as follows.
Check that burners have been arranged for BFO firing.
The first step is to heat the BFO pipe flowing the medium through the
BFO short recirculation valve (52-1B-SOV-0892), the hereinafter
operation can also be performed before furnace purge.
Check that pressure upstream of BFO main trip valve (52-1B-SOV-0891)
is adequate (PT-0881), it means to check that Blended fuel oil supplying
and heating system (i.e pumps and oil heater) are in operation.
Open main trip shut off valve (52-1B-SOV-0891), at the same time short
recirculation valve (52-1B-SOV-0892) will close, and perform leak test as
follows,
- Partially open the BFO flow control valve (52-1B-CV-0878) maintaining closed
burners shut off valves.
- After few second (to be defined) close long recirculation valve (52-1B-SOV-
0893) and the operator should close the manual valve(52-1B-GL-0846) from the
field to perform the leak test.
- Open BFO leak test valve(52-1B-SOV-0895)
- Pressure of fuel pipe
- Closing main trip and leak test shut off valves and memorizing of pressure value.
- After two minutes approx, If pressure value is within the established range leak
test is valid and enables opening of main trip shut off valve and burner ignition,
vice versa if it fails forbids opening of main trip shut off valve and hence BFO
burner start up until leak test will be repaired and repeated again.
When BFO burners leak test has been complete, procedure continues as follows,
Check that igniters are ready to be operated
Check that the atomizing/scavenging steam pressure is adequate (not low)
(PT-0876/C/D/E) as hereinafter described.
the second step is to heat BFO pipe up to the burners shut off valves
flowing the medium through the BFO long recirculation (52-1B-SOV-
0893), installed on BFO return pipe by means of the herein after operation.
66
a. Check that the above operations and furnace purge has been completed.
b. Check/open BFO long recirculation valve(52-1B-SOV-0893), closing of
this valve can be required by the operator or it will automatically close
when at least two(to be defined) BFO burners shut off valve are open and
burners proven in service (i.e. flame detected)
c. Open BFO main trip shut off valve(52-1B-SOV-0891)because main trip
and short recirculation (52-1B-SOV-0892) valves are commanded
simultaneously, opening command of main trip valve will close short
recirculation valve
d. Open BFO flow control valve (52-1B-CV-0878) at approx 10% (to be set
during commissioning phase)
At this time BFO is available up to the burners shut off valve, therefore, when
BFO achieves the right temperature (TE-0876), the operator can proceed to put in service
the first burners via the related ignition sequence as hereinafter explained to avoid
reducing of boiler load, it is recommended beginning to start front and rear wall 2 nd row
BFO burners (52-1B-BS-003, 52-1B-BS-004, 52-1B-BS-007 & 52-1B-BS-008)
maintaining in operation the 1st row HSD burners (52-1B-BS-001 OR 52-1B-BS-002 &
52-1B-BS-005 OR 52-1B-BS-006) Igniting BFO burners, load control will reduce HSD
burners load and then operator has to stop them, changing fuel selection from HSD to
BFO and then, if any to start them again with BFO.
Start related igniter
Check / close burner related air register, Say for burner (52-1B-BS-001
(52-1B-AR-2495A)
Advance burner gun (52-1B-BG-2496A)
Open atomizing steam shut off valve (52-1B-SOV-2491A)
Open BFO burner shut off valve(52-1B-SOV-2490A)
Open burner related air register (52-1B-AR-2495A)
After that burner shut off valve(52-1b-SOV-2490A) has been open since
30 seconds and burner is in operation (flame detected) put out the igniter
when at least one BFO burner is proven in service (flame detected) the BFO flow control
loop will be released to auto mode, and therefore the fuel control valve will operate
according to required boiler load variation.
At that time operator can start the second and next front and rear wall BFO
burners.
Note : It is forbidden to perform a boiler cold start up using BFO, in fact BFO
burners are allowed to start only when boiler drum pressure is greater than 40kg/sq cm g
and combustion air temperature is greater than 220 deg cel
General procedure to make available atomizing steam to BFO burners is as follows

Open steam atomizing main header shut off valve (52-1B-SOV-0890),
performing line heating up
Open partially the atomizing steam pressure control valve (52-1B-CV-
0876) performing line heating up
67
After few minutes release to auto atomizing steam pressure control loop
(i.e pressure control valve 52-1B-CV-0876) in order to maintain the right
atomizing pressure at burners.
c. RLNG burners
General procedure to make available fuel gas at burners is as follows.
- Check that the fuel gas header pressure upstream main trip valve is adequate (PT-
0978)
- Open fuel gas to burners main trip shut off valves(52-1B-SOV-0990/0991) and
perform leak test as follows
Partially open RLNG control valve(52-1B-CV-0976) maintaining closed
burners shut off valves
Open RLNG leak test valve(52-1B-SOV-0999) maintaining closed burners
shut off valves.
Open header vent valves(52-1B-SOV-0988 & 52-1B-SOV-0989)
After few second (to be set during commissioning phase) close RLNG
header vent valve
Pressurize of RLNG circuit and N2 accumulator up to the set value,
achieving the above values.
Closing RLNG main trip shut off valves and leak test shut off valve, hence
the set value will be memorized by the RLNG trapped inside the
accumulator.
After two minutes approx. if pressure value is within the established range
leak test is valid and enables opening of main trip shut off valve and
burner ignition, vice versa if it forbids opening of main trip shut off valve
and hence R-LNG burner start up until leak will be repaired and repeated
again
When R-LNG burners leak test has been complete, procedure continues as follow
Check that igniter is ready to be operated
Select burner for fuel RLNG firing say for 52-1B-BS-001
Open main trip shut off valve(52-1B-SOV-0990 & 52-1B-SOV-0991)
Open RLNG to burners control valve (52-1B-CV-0976) at approx 10%
At this time R-LNG is available up to the burners shut off valve, therefore the operator
can proceed to put in service burner via the related ignition sequence as follows.
- check / close burner related air register (52-1B-AR-2495A)
- Check R-LNG burner shut off valve(52-1B-SOV-0993A/0994A) and close burner
cooling air valve shut off valve(52-1B-SOV-0996A/ 0997A)
- Open burner related air register (52-1B-AR-2495A)
- After that R-LNG burner shut off valve (52-1B-SOV-0996A/0997A) has been
open since 30 seconds and burner is in operation(flame detected), put out the
igniter.
All the above operation are performed by the operator though an automatic sequence.
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When at least one RLNG burner is proven in service the fuel gas flow control loop will
be released in auto mode, and therefore the control valve will operate according to
required boiler load variation.
At that time operator can start the second and next RLNG burners.
BURNER SHUT DOWN OPEATION

During boiler load reduction, burners will be stopped following the opposite
procedure of startup sequence.
a. HSD burners
- General procedure for HSD burners shut down sequence is as follows.
- Open burner scavenging medium shut off valve (52-1B-SOV-2492A)
- Close atomizing air and HSD burner shut off valve (52-1B-SOV-2494A/2493A)
- After then scavenging steam valve has been open since 180 seconds close
scavenging steam shut off valve.
- Close burner air register (52-1B-AR-2495A)
- Retract burner gun (52-1B-BG-2496A)
At this time satisfied that all HSD burners shut off valve are closed, also HSD main trip
shut off valve will close.
b. BFO burners
General procedure for BFO burners shut down sequence is as above explained for HSD
burners, using scavenging/atomizing steam as follows,
Open burner scavenging steam shut off valve(52-1B-SOV-2492A)
Close atomizing steam and BFO burner shut off vavle (52-1B-SOV-
2491A/2490A)
After then scavenging steam valve has been open since 180 seconds close
scavenging steam shut off valve.
Close burner air register (52-1B-AR-2495A)
Retract burner gun (52-1B-BG-2496A)
At this time satisfied that the BFO burners shut off valve are closed, the BFO long
recirculation shut off valve will automatically open to maintain the minimum BFO flow
for heating purpose and consequently burners will be ready to start again. If burners have
not to be started for long period, operator can decide to close also BFO main trip shut off
valve, in that case the BFO short recirculation will automatically open.
c. R-LNG burners
General procedure for R-LNG burners shut down the sequence follows the opposite
operation of start up sequence.
- Close RLNG burner shut off valve (52-1B-SOV-0993A/0994A)
- Open cooling air shut off valve (52-1B-SOV-0996A/0997A)
- Close burner air register (52-1B-AR-2495A)
All above operation are performed by the operator through an automatic sequence.
69
After that the last burner has been stopped and the burners are not to be started for long
period, Operator can decide to close also the R-LNG to burners main trip shut off valve
and open R-LNG header to burners vent valve.
SCAVENGING OPERATION
If burners are operating either HSD or BFO and one or more trips due to any
causes the automatic scavenging sequence cannot be performed, therefore the operator
has to start the dedicated scavenging sequence or to start again the burner.
After check that igniter is ready to be started, general procedure to scavenge the burner is
as follows
Start the ignitor
Advance the burner gun, if any
Open the burner scavenging medium shut off valve
After then scavenging medium shut off valve has been opened since 30
seconds, put out ignitor
After then scavenging medium shut off valve has been opened since
180seconds close it.
Trip
For all fuels main trip valves an emergency closing due to trip causes are
foreseen.
Trips related to burners that suddenly closed the HSD main trip valve (52-1B-SOV-
0894) are
- HSD pressure very low (PT-0880A/0880B/0880C) based on 2 out of 3 logic
- Atomizing air pressure very low (PT-877A/0877B/0877C), based on 2 out of 3
logic
- boiler trip
Trips related to burner that suddenly closed the BFO main trip valve (52-1B-SOV-
0891) are
- BFO pressure very low (PT-0883A/O883B/0883C) based on 2 out of 3 logic
- Atomizing steam pressure very low (PT-0876C / 0876D / 0876E), based on 2 out
of 3 logic
- boiler trip
Trips related to burners that suddenly closed the R-LNG main trip valves (52-1B-
SOV-0990/0991) are
R-LNG pressure is very high (PT-0976C/0976D/0976E), based on 2 out of
3 logic
Furnace / burners R-LNG header differential pressure very low (PDT-
0976A/0976B/0976C) based on 2 out of 3 logic
Boiler trip
Trips related to igniters that suddenly closed the HSD main trip valve (52-1B-
SOV-1090) are
70
HSD pressure very low (PT-1076C / 1076D / 1076E) based on 2 out of 3
logic
boiler trip
ROTARY AIR PREHEATER
71
General
The regenerative air heater consists of
2 No. movable sector plates on the hot end with inboard tracking
2 No. movable sector plates on the cold end with adjusters
2 No. axial seal plates with adjusters
To minimize leakage, maintain the position of air sealing plates
close to rotor radial and axial seals under full load operating condition.
To avoid seals wear, sector plates should be close to rotating sealing as
much as possible. This movement is controlled by the hot end tracking.
The travel of each sector and axial seal plate is limited and
controlled by the various adjusters provided in the casing outside.
Operation
The seal gaps required are determined by a computer program
and the radial and axial seal plates are adjusted to provide these gaps.
By providing finger tabs at selected locations and on attaining full load
on the boiler the seal plates are re- positioned to suit finger tab wear
pattern so that minimum gaps are maintained to control the leakage at
very low loads.
The entire operation is done manually.
72
ROTARY AIR PREHEATER WASHING SYSTEM
a.General
Ansaldo Caldaie recommendation related to the Regenerative air
heater washing system is to wash RAH heat transfer surfaces by
using the low pressure washing procedure.
Service water feeds the booster pump which is common for two
boilers at the following condition.
Conditio Pressure (Kg/sq Temperature deg Flow

n cm cel Kg/hr
Operatin 3 Ambient 33.33
g
Design 10 65
Then the service water pressure is increase up to 6 Kg/sq

cm g through booster pump is injected at both cold and hot end via
dedicated lances until the operation is completed.
b.Fire Fighting System

The system consist of : No.1 Shut off valve (52-1B-GV-1207),
manually operated.
RAH fires are rare, it could occur if improper combustion is taking
place during initial firing of cold furnace or restarting after a hot stand
by. Improper combustion may result in the accumulation of unburned
fuel on RAH surface transported from the furnace during these critical
operations.
When combustible deposits exist on the RAH element, the
ignition point of these deposits may be reached with a subsequent fire.
All RAH terminal temperature has to be checked particularly
during start up phase, an unusual increase in any one of them shall be
investigated immediately.
73
Experience has indicated that an abnormal rise in one or more of
them may reflect an RAH fire. Action taken at this time could reduce or
avoid RAH damage.
Ansaldo Caldaie recommendation related to RAH fire fighting
system is to extinguish incidental RAH fire by using water injected at
air and flue gases hot end via dedicated lances.
This system consists of the pipe connected to service water line
at battery limit at the condition mentioned in the RAH washing at low
pressure.
Functional Description
a. Washing System
Washing of the RAH heat transfer surfaces is necessary when the
deposits are present in RAH heat transfer surfaces and it is not
possible to remove them by soot blowing devices. This is detected
by the draft losses increasing though RAH. Therefore the RAH
washing frequency depends on many variable such as the quality of
fuel burnt, nature and amount of deposits.
RAH washing is performed during outage of the boiler with RAH
rotating at normal operating speed after the RAH heat transfer
surfaces visual inspection to determine the effectiveness of the
washing operation.
Taking into consideration that an incomplete washing is worse
than no washing, take care of the following recommendation.
Operator does not try to cut short the washing time

Make a good inspection to determine when the washing is
complete
Once the RAH heat transfer surfaces washing is started, it shall
be continue until the surfaces are free of deposits. any deposit
74
left on the heat transfer surfaces after washing, when the RAH
returns in service, will become harder making future removal
difficult. if not impossible.
Follow the above recommendation and then the operator has to

proceed as follows
Open the manual valves on service water line (52-1B-GV-1201)
Open manual valves on pump suction (52-1B-GV-1206)
Start the washing pump
Open manual valves on pump discharge (52-1B-GV-1202)
One washing cycle will last approx. in between 16 to 24 hours
depending on how dirty RAH is following washing cycle, RAH has to be
rinsed to remove any remaining deposits.
After RAH washing, if the boiler is required out of the service for
long period, it is recommended to perform the heat transfer surfaces
drying by means of providing the FD fan and steam coil air pre heater
in service. While this operation is not necessary if the boiler is required
to start suddenly after RAH washing.
b. Fire fighting system

At the first evidence of fires, from temperature indication (high
temperature alarm), RAH inspection should be made. If the
temperature continues to rise and / or if fire is visible, the FD fan
should be shut down, check to ensure that all drain lines are open then
water will be admitted to RAH in sufficient quantities to quench the fire.
If it is possible to isolate the area of the fire, stop RAH so that the
water may be directed at the fire. On the other hand, if RAH is burning
in several area, continue to rotate the RAH as long as it will turn to be
sure the water contacts the burning area.
75
If large quantities of water are required to drop the temperature, do
not be conservative. Do not attempt to smother the fire with foam,
chemicals or steam, they are not effective.
Operating mode
Low pressure washing
All the operation has to be done locally and manually under
operator supervision.
From RAH washing local control panel is possible to perform the
following operation.
start / stop RAH motor
start / stop washing motor
The sequence of operation for washing RAH (locally and manually

by field operator) is as follows
start / stop RAH motor
open the related manual isolation valve
start the washing pump
Fire fighting
All the operation has to be done manually under operator
supervision.
After visual checking of fire, RAH bypass damper have to be closed and
then the related fire fighting water shut off valve (52-1B-GV-1207) has
to be open remotely by the operator.
76
CHEMICAL DOSING SYSTEM
General
To prevent scale formation caused by hardness constituents ( Ex. Ca
and Mg) on boiler surfaces, a chemical treatment based on Sodium
Phosphate injection is used, generally this method is recommended. if
any, during startup phase only (however up to a drum pressure not
greater then 60bar app) or during condenser leakage.
The sodium phosphate solution dosing system is capable to inject the
request amount directly into the boiler drum.
System Equipment
Sodium Phosphate dosing system is provided with the following
equipment.
one preparation tank
one service tank
two dosing pumps piston type (52-1B-P-401, 52-1B-P-402), each
designed for 100% duty , used to inject sodium phosphate
Two mixers (52-1B-M-401 & 52-1B-M-402)
relevant manual shut off valves
77
The chemical solution is prepared into a dedicated (preparation)
tank, filling in it with de-mineralized water then via suitable lifting
equipment operator has to raise sodium phosphate bags up to the top
of tank and throw the sodium phosphate compound into service tank
obtaining a diluted solution at a concentration equal at 3%
The chemical solution is homogenized using the mixer located at
the top of tank itself. From preparation tank the tri-sodium phosphate is
transferred to service tank then via dosing pump, sodium phosphate
solution is injected into the boiler drum. To flush the line first operator
has to fill the DM water in preparation tank and remove the PI 0492 &
0493. Then start the plunger pump to remove the scale in the
discharge line of the pump.
Operating mode
Operating mode of Sodium Phosphate dosing system is as follows,
start up and normal operation
shut down operation
trip

In order to prepare sodium phosphate solution, operator has to
fill in preparation tank with de mineralized water and sodium
phosphate compound to achieve the required concentration.
From preparation tank the tri-sodium phosphate is transferred to
service tank. Both tanks are having the provision of mixers to get
homogeneous. The operator can start sodium phosphate dosing
system operation as follows.
though some local operation (e.g. opening shut-off manual valve
(52-1B-GL-0403) at service tank outlet, opening shut off manual
valves (52-1B-GL-0404/0405) on suction and (52-1b-gl-
78
0406/0407) on discharge of dosing pumps, checking that strainer
on suction pump is clean, etc) operator has to make ready to
operate dosing system.
checking that sodium phosphate service tank level is greater
than minimum
starting service tank mixer (52-1B-M-401) for 5 min app
starting dosing pump selected (52-1B-P-401 or 52-1B-P-402)
release to auto the sodium phosphate control
Shut down operation

Shut down operation will be performed following the opposite
operation of start up procedure.
Trip
Sodium phosphate dosing pumps will be tripped when at lease one
of the following condition will occurs.
sodium phosphate service tank level very low
sodium phosphate dosing motor electrical protection (developed
directly inside switchgear)
boiler trip
The second condition or the low low (if any) will cause startup of
stand by pump if selected, while the first and the third condition will
cause sodium phosphate dosing system trip
79
SAMPLING SYSTEM
General
The water and steam sampling system receives samples from
the steam and water system (feed water, boiler water, saturated
steam, SH steam), cools down and perform continuous analysis ( by
others) on them in order to alert operator on bad quality of boiler water
and steam chemistry.
System equipment
The water and steam sample coolers are grouped in a skid and
located in boiler area, each samples line is equipped with
a. sample isolation valve
b. sample cooler
c. cooling water isolation valve
d. sample filter
80
e. thermo safety valves
f. temperature gauge
g. self regulating valve
The water and steam sampling system receives samples from
the steam and water system. All the samples are cooled by the use of
sample cooler that uses general cooling water available in the plant to
cool down the samples. The self regulating valves are used to reduce
the sample pressure after cooling. The self regulating valves are not
only reduces the sample pressure, but also regulates it, irrespective of
upstream pressure fluctuations. This ensures operator safety. These
samples are then sent for analysis.
Operating mode
Because all the operation has to be done locally and manually
under operator supervision, no remote control is foreseen.
AUXILIARY STEAM SYSTEM

General
The auxiliary steam system is capable of meeting the
requirement of steam for auxiliary purposes in boiler area, SCAPH and
FD fan steam turbine.
The auxiliary steam is available at the power block battery limit

at the following conditions.
Steam Unit Norm ma Min Mech. Design

al x
HP steam pressure Kg/sq 44 46 42 50
cm
81
HP steam Deg cel 400 41 390 427
temperature 0
MP steam pressure Kg/sq 18.2 19 17.7 20.4

cm
MP steam Deg cel 310 32 285 350
temperature 0
LP steam pressure Kg/sq 4.5 5.0 4.0 6.5

cm
LP steam Deg cel 225 25 200 288
temeprature 0
The auxiliary steam is utilized for various system as follows :

HP steam - FD fan steam turbine
MP steam - BFO atomization
- Soot blowers
LP steam - SCAPH
- FUEL OIL HEATER
- BFO Tracing
- RLNG Tracing
System Arrangement
The auxiliary steam system is arranged in such a manner, the
safe and steady operation is possible ensuring availability of steam in
the auxiliary steam header( L & T scope) at the required parameters at
all the times.
HP steam
Steam Turbine Drive
The auxiliary steam available as HP steam at power block battery
limit is carried over though isolation valve (52-1B-GV-2301) to the FD
fan steam turbine to drive the turbine and the steam from the turbine
exhaust will be cooled to required MP steam temperature by
82
attemperator (52-1B-CV-1183 REF P & ID 6556-EPCC4-PI-P-52-1B-
1111) and MP steam admitted to MP steam header. The spray water is
taken from pump inter stage and the parameters are
Pd 51 kg/sq cm
Po 46 kg/sq cm
Td 150 deg cel
To -133 deg cel
MP steam
Soot blower
The auxiliary steam available at MP steam header is taken
through isolation valve (& 52-1B-GV-2307) to soot blowers for soot
blowing operation. The soot blower function is described in a dedicated
documents 6556-EPCC4-PI-P-521B-FS-M-3002
BFO atomization
The auxiliary steam available at MP steam header to at power
block battery limit is carried through isolation valve (52-1B-GV-2303)
for the BFO atomization after reducing temperature by attemperator
(52-1B-CV-2376) is available from the power block battery limit that is
bleed from the pump inter stage. The spray water is taken from pump
inter stage and the parameter are
Pd 51 kg/sq cm
Po 46 kg/sq cm
Td 150 deg cel
To -133 deg cel
LP steam
SCAPH
The auxiliary steam available as LP steam is carried through
isolation valve (52-1B-GV-2305) to SCAPH. The steam is used to
83
preheat the air before entering into the air heater during the following
load cases.
a. During 100% BFO firing @ min ambient temp (-0.7deg cel)
b. Startup condition when HSD firing
Suitable vents, drains and steam traps will be provided and condensate
is connected to blow down tank
Fuel oil heater

LP steam is utilized for BFO heating to meet the process
requirement. LP steam is carried though the isolation valve (52-1B-GV-
2308) to fuel oil heater. LP steam requirement is controlled by a control
valve (52-1B-CV-2276) by measuring BFO temperature at heater outlet.
It is a redundant Fuel oil heater (one working + one standby). Each
heater has its own isolation valves (52-1B-GV-2204, 52-1B-GV-2205,52-
1B-GV-2202, 52-1B-GV-2203), drain valves (52-1B-GL-2207, 52-1B-GL-
2211, 52-1B-GL-2210, 52-1B-GL-2212), Vent valves (52-1B-GL-2208 &
52-1B-GL-2209) and safety valves (52-1B-PSV-2201 & 52-1B-PSV-
2202). All drains are connected to drain oil pit except tracing drain
which will be connected to trap drain. High temperature alarm
provided in the downstream of BFO heater.
BFO Tracing
LP steam is utilized for tracing steam for the BFO fuel line to
avoid the heat loss across the surface of fuel pipes and it is taken
through isolation valve (52-1B-GI-2305)
RLNG Tracing
LP steam is utilized for tracing steam for the RLNG fuel line to
avoid the heat loss across the surface of fuel pipes and it is taken
through isolation valve (52-1B-GI-2306)
Operating Mode
84
The auxiliary steam system is arranged in such a manner, the safe
and steady operation is possible to ensure the availability of steam in
the auxiliary steam in the auxiliary steam at the required parameters
at all times.
the auxiliary steam header is connected with the existing system
with an isolation gate valve and charging the auxiliary steam
header with steam from else where (L & T scope)
Preparation of the system
shutdown operations
Preparation system
Before trying to charging the auxiliary steam header with steam the
following shall be checked.
pressure and temperature instruments are available in service
the isolating valves for various incoming and outgoing lines are
kept closed with the drain valves open
the steam trap in the drain line of the unit auxiliary steam
header is taken into service with isolation valves open and
bypass valves in closed position
safety valves are available in service
Charging of auxiliary steam header from during the startup
open the isolation gate valves which are to be charged e.g
SCAPH, with drain and vents kept opened.
charge the auxiliary steam header with steam
watch the pressure and temperature in the header and wait till
the temperature picks up
close the vents as and when pure steam is observed
Shutdown operations
The drain valves which are directed to IBD tank and located in
the steam supply lines shall be kept open when the system is not
85
required, to avoid hammering by collected condensate being blow into
the tank by steam on startup
Control and Instrumentation
Main measures of auxiliary steam systems are
HP steam pressure (52-1B-PI-2390)and temperature(52-1B-TI-
2377)measurement
MP steam pressure(52-1B-PI-2391)and temperature(52-1B-TI-
2378)measurement
BFO atomization steam temperature control station (52-1B-TE-2376A
& 2376B, TT-2376A 7 2376B and 52-1B-CV-2376)
LP steam pressure (52-1B-PI-2392) and temperature (52-1B-TI-2379)
measurement
BFO heater outlet temperature (52-1B-2276A & 52-1B-2276B)
measurement
Spray water pressure(52-1B-PI-2393) and temperature(52-1B-TI-
2390) measurement
86
SOOT BLOWERS
General
The Soot-blowers system is having 4 nos long retractable soot-
blowers for heat exchanging surface cleaning and 1 no. retractable non
rotating soot-blower for air-heater elements cleaning.
Steam for soot blowing is taken from MP steam header which is
available at the utility boiler terminal point at the condition indicated in
the following table.

Kg/cm2
MP Steam Pressure 18.2 19.0 17.7
g
MP Steam o
C 310 320 285
Temperature
System Equipment
The steam soot blowers feeding system consist of
b) Steam line (from the MP steam header available at the terminal
point)
- one main shut off valve (52-1B-GV-2307)
c) Steam Soot blowers :
- Boiler is equipped with 4 long retractable soot blowers (52-
1B-SB-1501/1502/1503/1504)
- Regenerative air heater is equipped with 1 soot blower (52-
1B-SB-1505)
87
- 3 condensate discharge groups(each consisting of
thermocouple, steam trap, filter, manual valves and motor
operated by-pass valve (52-1B-MOV-1580/1581/1581)
Functional Description:
The Soot blowers system takes steam from the MP steam header
available at the terminal point and is conveyed to one soot blower at a
time.
The steam flows through dedicated lines and headers, which
convey the steam to each soot lower. The steam from the soot blowers
nozzle lance strikes the boiler heat exchanging surfaces in order to
remove soot deposit on the tubes, this operation is normally done per
day during boiler operation at a defined lapse of time, established
taking in consideration the tube dirt (contamination)
The blowing tube consists of heat resistant, scale proof steel the
quality of which depends on the flue passes temperature at the place
of installation.
Cooling / purge air is supplied from FD fan for all soot blowers to
avoid the flue gases entering into the lance tube nozzles. Moreover,
the regenerative air heater can be blown, whenever is needed by the
plant operators.
The soot blowers lay out is designed so that the system is
capable to accept future installation of No.4 supplementary soot
lowers, if needed.
During soot blowers system startup operation, the pipes are cold and
they have to be preheated before conveying steam to soot blowers,
hence blowing is forbidden in this condition.
The condensed steam is discharged to the steam trap drain.
OPERATING MODE
Operating mode of soot blowers system is as follows
a. Automatic
88
b. Manual
c. Local
Automatic Mode
In this mode, the operator is available with a complete remote
blowing sequence that provides to start and stop one soot blower at a
time, usually the soot blowing sequence is started once a shift by the
operator.
After selecting one of defined blowing sequence, the sequence steps
are
1. Open the drain motor operated shut off valves ( 52-1B-MOV-
1580/1581/1582)
2. Drain the steam pipes until temperature reaches the proper
value, i.e drain temperature measures have to give the start
permissive.
3. Close the drain motor operated shut off valves (52-1B-MOV-
1580/1581/1582)
4. Start the first soot blower
Manual mode
In this mode, the operator commands manually remote the shut
off motor operated valves and after the permissive are reached he has
to command soot blowers one by one.
The steps are the same as described in automatic mode.
Local Mode
Procedure is the same as Manual mode; only the difference is
that the operation will be commanded locally.
SOOT BLOWERS OF ANSALDO BOILER

RETRACTABLE SOOT BLOWERS OF SUPER HEATER AND
ECONOMIZER ZONE
TOTAL NUMBERS 4
BETWEEN PSH AND SSH 2
BETWEEN ECONOMIZER AND PSH 2
89
WORKING PRESSURE OF STEAM (KG/SQ CM) 17.7, 18.2, 19
DESIGN PRESSURE (KG/SQ CM) 20.4
WORKING TEMPERATURE, DEG CEL 285,310,320
DESIGN TEMPERATURE, DEG CEL 350
STEAM CONSUMPTION PER BLOWER (KG) 294
TOTAL STEAM CONSUMPTION FOR 4 BLOWERS (KG) 1176
GAS DATA
OPERATING TEMPERATURE 720/1183
DESIGN TEMPERATURE 1220
OPERATING PRESSURE, MM OF WATER 244
DESIGN PRESSURE, MM OF WATER 300
RETRACTABLE SOOT BLOWER OF RAH INLET SIDE

TOTAL NUMBERS (RAH inlet side) 1
WORKING PRESSURE OF STEAM (KG/SQ CM) 17.7, 18.2, 19
DESIGN PRESSURE (KG/SQ CM) 20.4
WORKING TEMPERATURE, DEG CEL 285,310,320
DESIGN TEMPERATURE, DEG CEL 350
STEAM CONSUMPTION PER BLOWER (KG) 348
GAS DATA
OPERATING TEMPERATURE 148
DESIGN TEMPERATURE 350
OPERATING PRESSURE, MM OF WATER 25
DESIGN PRESSURE, MM OF WATER 300
90
PREDICTED PARAMETERS OF UB
DESIGN PERFORMANCE (RLNG FIRING)
LOAD (MCR %)
100% 64% 49% 30%
Steam generation, kg/hr 406500 26000 200000
No. of burners in operation 7 7 7
Furnace heat input,

192855
Kcal/m2/hr
Furnace heat absorp.,
228335
Kcal/m3
AMBIENT CONDITIONS :
Ambient temperature, (C) 40 40 40 40
Relative humidity % 60 60 60 60
STEAM & WATER FLOWS, (TPH) :
Main steam flow 406.5 260 200 121.5
Spray water flow 40.65 20 9 1.5
91
FUEL FLOW & EXCESS AIR :
Fuel type
RLNG METHANE
Fuel LHV, kcal/kg

11514
Fuel consumption, Sm3/hr 31390 19855 15460 9365
Excess Air @ burner,% 10 15 18 60
AIR & GAS FLOWS, (TPH) :
Air at FD fan inlet 511.4 346 277.6 235.6
Total air to furnace 473.2 313 246.3 205.3
Total air to wind box 354.9 234.8 184.7 154
Total air to OFA 118.3 78.2 61.5 51.3
Flue gas at APH inlet 498.8 329 258.5 212.9
Flue gas at APH outlet 536.9 361.9 289.8 243.1
STEAM & WATER TEMPERATURES, (C):
Feed water at Economizer

133 133 133 133
inlet
Super heater spray water 133 133 133 133
Water at Economizer outlet 250 232 223 233
Saturation temperature 337 333 332 331
92
Main steam temperature 529 529 529 529
AIR & GAS TEMPERATURE, (C) :
Ambient 40 40 40 40
APH inlet 45 45 45 45
APH air outlet 332 276 252 235
FEGT 1391 1204 1097 885
Flue gas @ APH inlet 382 310 278 256
Flue gas @ APH outlet 140 123 118 90
STEAM & WATER PRESSURES, (Kg/cm2):
Economizer inlet 144.9 136.8 134.4 132.3
Drum 143 136 133.9 132.1
SSH outlet 133.8 132.1 131.7 131.3
MS battery limit 131 131 131 131
AIR & GAS PRESSURES, (mmH2O) :
Fan inlet -50 -23 -15 -11
Fan outlet 625 415 349 285
93
APH air inlet 555 382 327 273
Furnace 241 123 84 51
APH gas inlet 114 60 43 25
APH gas outlet 20 10 8 5
Stack inlet 7 7 7 3
STEAM/WATER SIDE PRESSURE DROPS (kg/cm2) :
Battery limit to Eco. Inlet 6.1 14.2 16.6 18.7
Eco bank + connecting pipes

1.9 0.8 0.5 0.2
up to drum
Drum outlet to SSH bank 8.2 3.5 2 0.7
Attemperator 1 0.4 0.2 0.1
SSH outlet to battery limit 2.8 1.1 0.7 0.3
AIR & GAS DRAFT LOSSES,(mmH2O) :
Fan inlet ( duct +silencer) 50 24 16 9
Ducts & dampers 50 23 15 9
SCAPH 45 21 14 8
APH Air side 74 40 30 15
94
Flow element 15 7 5 3
Burner loss 200 200 200 200
Furnace & convective

97 49 33 21
passage
Ducts & Dampers 50 24 16 9
APH- Flue gas side 94 50 35 20
Total 675 438 364 294
BOILER FLUE GAS VELOCITIES, (mt/s) :
SSH 24.5 14.3 10.5 7.3
PSH outlet bank 26 15 11 7.8
Evaporator screen 27 16 12 8.6
PSH inlet bank 24 14 10 7.7
Economiser 19 11 8 6.3
EFFICIENCY ON GCV BASIS :

LOSSES, (%)
Dry gas loss 3.5 2.935 2.87 -
Moisture loss 10.3 9.922 9.884 -
Radiation loss 0.3 0.344 0.45 -
Unaccounted loss 0.4 0.4 0.4 -
95
Margin 0.4 0.4 0.4 -
TOTAL LOSSES 14.9 14.0 14.0
EFFICIENCY 85.1 86 86 -
DESIGN PERFORMANCE (BFO FIRING)
LOAD (MCR %)
100% 64% 49% 40%
Steam generation, kg/hr 406500 26000 200000
No. of burners in operation 7 7 7
Furnace heat input,

Kcal/m2/hr
Furnace heat absorp.,
Kcal/m3
AMBIENT CONDITIONS :
Ambient temperature, (C) 40 40 40 40
Relative humidity % 60 60 60 60
STEAM & WATER FLOWS, (TPH) :
Main steam flow 406.5 260 200 162.6
Spray water flow 20 5 5 2
FUEL FLOW & EXCESS AIR :
96
Fuel type
BFO
Fuel LHV, kcal/kg 9400
Fuel consumption, TPH 31.19 20.07 15.59 12.71
Excess Air @ burner,% 12 15 40 60
AIR & GAS FLOWS, (TPH) :
Air at FD fan inlet 498.1 335.3 286.6 299.8
Total air to furnace 459.5 303.1 255.8 269.4
Total air to wind box 344.6 227.4 191.9 202
Total air to OFA 114.9 75.7 63.9 67.4
Flue gas at APH inlet 490.4 322.9 271.2 282.1
Flue gas at APH outlet 529 355.1 302 312.5
STEAM & WATER TEMPERATURES, (C):
Feed water at Economiser

133 133 133 133
inlet
Super heater spray water 133 133 133 133
Water at Economiser outlet 236 222 235 239
Saturation temperature 337 333 332 332
Main steam temperature 529 529 529 529
97
AIR & GAS TEMPERATURE, (C) :
Ambient 40 40 40 40
APH inlet 45 45 45 45
FEGT 1342 1164 1075 955
Flue gas @ APH inlet 405 329 320 306
Flue gas @ APH outlet 141 139 138 138
STEAM & WATER PRESSURES, (Kg/cm2):
Economizer inlet 147 138.6 135.9 134.7
Drum 143.3 136.3 134.1 133.1
SSH outlet 133.8 132.1 131.7 131.4
MS battery limit 131 131 131 131
AIR & GAS PRESSURES, (mmH2O) :
Fan inlet -48 -22 -16 -18
Fan outlet 610 385 337 325
APH air inlet 543 355 315 305
98
Furnace 233 106 79 72
APH gas inlet 110 49 37 34
APH gas outlet 19 9 8 7
Stack inlet 7 7 6 4
STEAM/WATER SIDE PRESSURE DROPS (kg/cm2) :
Battery limit to Eco. Inlet 4 12.4 15.1 16.3
Eco bank + connecting pipes

3.6 2.3 1.8 1.6
upto drum
Drum outlet to SSH bank 8.5 3.73 2.19 1.46
Attemperator 1 0.4 0.24 0.16
SSH outlet to battery limit 2.8 1.14 0.68 0.45
AIR & GAS DRAFT LOSSES,(mmH2O) :
Fan inlet ( duct +silencer) 48 22 16 14
Ducts & dampers 48 21 15 14
SCAPH 43 19 14 13
APH Air side 71 32 23 21
Flow element 15 6 5 4
Burner loss 200 200 200 200
99
Furnace & convective passage 94 45 34 32
Ducts & Dampers 48 21 16 14
APH- Flue gas side 92 41 29 27
Total 659 407 352 339
BOILER FLUE GAS VELOCITIES, (m/s) :
SSH 22 13 11.5 10
PSH outlet bank 23.5 14 12.5 11
Evaporator screen 25.5 15 14 12
PSH inlet bank 22.5 13 12 11
Economiser 18 10.5 10 9
EFFICIENCY ON GCV BASIS :

LOSSES, (%)
Dry gas loss 3.8 4 5.1 -
Moisture loss 3.8 3.8 3.8 -
Radiation loss -
0.6 0.7 0.8
Unaccounted loss -
Margin 0.2 0.2 0.2
TOTAL LOSSES 8.4 8.8 9.9
100
EFFICIENCY 91.6 91.2 90.1 -
101

OPERATING MANUAL FOR UB MANUAL

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OPERATING MANUAL

DOCUMENT NO.: - PNC/PU/CPP/M/04

INDIAN OIL CORPORATION LTD

PREPARED BY REVIEWED APPROVED BY

This manual contains information on the operation of

It is an essential perquisite for satisfactory operation of

This write up does not replace any manual supplied

It is hoped that user will go through it and will find

Amendment / Updation Record

Sl Amendment Page Page Prepared By Reviewed by Approved by

S.No Date of List of recipient Prepared By Reviewed by Approved by

1 Sh. V Kamath Sh. S L Sh. Baljeet Singh,

Capacity - 406.5 TPH

FRONT & REAR WALL FIRED, NATURAL DESIGN PRESSURE : 153

TYPE Low NOx burners (Oil/Gas fired)

Primary Super heater H.S. AREA : 536m2

Final Super heater/ Secondary

TYPE SPRAY NO. OF STAGES : Two MEDIUM OF SPRAY: FEED WATER

TYPE : PLAIN TUBE TOTAL H.S.: 1626M2

PRIMARY AND RIZZI

Safety Valve of Utility boiler

General Principles of Boiler operation

FILLING AND VENTING

2.1.2. STARTING -UP

Prior to lighting off the unit, the drainable portions (headers,

The time required for bringing a boiler up to temperature and

The time required and the procedures to be followed for shutting

During normal operation the water level in the gauge glass

While steaming, the boiler should be protected from rapid

b) Simultaneously if feed water has become available meanwhile

WARMING UP AND EXPANSION

while the boiler is being brought up to pressure, provision should

If the boiler is to be put on a common steam main that is already

An abnormal increase in draft loss across the gas and / or air

If oil is being fired, make certain the fuel is being burned

High exit gas temperature may be caused by such conditions as:

Soot blowers should be operated as often as necessary to keep

Note.: The requirement of the steam temperature control

With steam soot blowing, proper drainage of the soot blower

STEAM TEMPERATURE CONTROL

The function of the steam temperature control equipment is to

Steam temperature should never be allowed to exceed the

With constant load abnormally high superheated steam

v. Improper operation of automatic steam temperature

Superheated steam temperature below normal for the load may

The superheated steam temperature will drop suddenly and

Steam temperature control equipment provided for the boiler

Spray Water De super-heaters

The de super-heaters are normally provided to maintain the

The superheated steam temperature is controlled .by feed water

Regulating valves by which the quantity of injection water is

The superheated steam temperature controllers require

Consideration for protecting the super-heater is a controlling

To assure clearing the super-heater element loops of

Care must be exercised to avoid carry-over of water and solids to

The data on blow down should be recorded. The amount of blow

Composition of boiler water must correspond to the prescribed

Quality of steam produced is checked by taking samples of

After shutting the closure, it is necessary to make sure about

The furnace output must be controlled as follows:

THE MCR OF THE BOILER MUST NOT BE EXCEEDED.

Maximum steam temperature and the maximum

Sudden changes of temperature should not occur in the