Nash

NANDIPUR 425MW CCPP AUXILIARY BOILER& FUEL OIL OPERATION MANUAL
1
Abbreviation
Abbreviation Full Title
HSFO High Sulphur Furnace Oil
HSD High Speed Diesel
DCS Distributed Control System
PLC Programmable Logic Controller
LED Light Emitting Diode
2
Preface
This manual is edited on the basis of provisions and relevant drawings

from manufacturer and design institute, only for auxiliary boiler and fuel oil
system operation of Pakistan Nandipur 425MW Combined Cycle Power
Plant. With the progress of the project, the manual will be supplemented and
improved.
Reference Drawing
FUEL OIL SYSTEM

FO-01-J1802-01GENERAL ARRANGEMENT OF FUEL OIL AREA-1
FO-04-J1803-01HSD OIL UNLOADING EQUIPMENT&PIPE SYSTEM
FO-05 J1803-02HSFO UNLOADING EQUIPMENT&PIPE SYSTEM-1
FO-06 J1803-02HSFO UNLOADING EQUIPMENT&PIPE SYSTEM-2
FO-07 J1804-01HSD OIL EQUIPMENTS AND PIPES IN FUEL OIL PUMP
HOUSE SYSTEM
FO-08 J1804-02HSFO EQUIPMENTS AND PIPES IN FUEL OIL PUMP
HOUSE SYSTEM
FO-09 J1805-01FLOW DIAGRAM OF OIL PIPE SYSTEM IN HSFO
STORAGE AREA
FO-10 J1805-10 FOAM FIRE-FIGHTING PIPE IN DFO STORAGE
AREA
FO-11-J1805-13FLOW DIAGRAM OF OIL PIPE SYSTEM HSD OIL
STORAGE AREA
FO-12-J1813-01FLASH TANK AND PIPES WATER TANK IN STORAG1
FO-13-J1813-01 FLASH TANK AND PIPES WATER TANK IN
STORAG2
FO-14-HSFO TREATMENT SYSTEM1
3
FO-14-HSFO TREATMENT SYSTEM2
AUXILIARY BOILER SYSTEM
AB-00-GENERAL DRAWING OF BOILER

AB-01-BOILER BODY
AB-02-STEAM OF BOILER SYSTEM DRAWING
AB-03-P&ID OF STEAM AND WATER-1
AB-03-P&ID OF STEAM AND WATER-2
AB-04-SMOKE&AIR SYSTEM
AB-05-P&ID OF OIL SYSTEM
AB-06-BOILER WIRING DIAGRAM-1
4
5
Content
Abbreviation ............................................................................................. 2
1Auxiliary Boiler Specification ............................................................... 1

1.1System Summary ........................................................................................... 1
1.2Auxiliary Boiler Specification ....................................................................... 1
1.2.1 Boiler Main Designed Parameters ....................................................... 1
1.2.2 Fuel Oil Characteristic ......................................................................... 3
1.2.3 Steam Water Quality Standard ............................................................. 4
1.3 Thermodynamic Calculation for Parts of the Boiler ..................................... 5
1.4Boiler Flue Gas Resistance Parameters ......................................................... 5
1.5 Strength Calculation List of Boiler ............................................................... 6
1.6 Combustion Devices Specification ............................................................... 6
1.7Feeding Water System and Specification ....................................................... 7
1.7.1 Water Pump Main Technical Parameters ............................................. 7
1.7.2 Main Technical Parameters of Auxiliary Boiler Blowdown Vessel .... 7
1.8Air Fan Specification ..................................................................................... 7
1.9 Deoxidation System Specification ................................................................ 8
1.9.1 Deaerator Specification ........................................................................ 8
1.9.2Deoxidation Water Pump Specification ................................................ 8
1.10 Steam Muffler Specification ....................................................................... 9
1.11Expander Specification ................................................................................ 9
1.12 Sampling Cooler........................................................................................ 10
2 Conditions and Tests before Starting the Boiler ............................. 10
2.1Check-up Before Starting the Boiler............................................................ 10
2.1.1 Check-up inside Combustion Chamber and Gas Duct ...................... 10
2.1.2Check-up of Steam-water System ....................................................... 10
2.1.3Check-up of Running Machine ................................................................. 11
2.1.4 Check-up of Oil System before Boiler .............................................. 11
2.1.5 Check-up of Pressure Meter and Operation Panel ............................. 11
2.1.6 Check-up of Expansion Indicator ...................................................... 11
2.1.7 Check-up of Site Lighting .................................................................. 12
2.2Feeding Water System .................................................................................. 12
2.2.1Check-up before Starting Feeding Water Pump ................................. 12
6
2.2.2Putting Feeding Water Pump into Operation ...................................... 12
2.2.3Normal Operation and Maintenance of Feeding Water Pump ............ 13
2.3 Hydraulic Test ............................................................................................. 13
2.3.1 Purpose of Hydraulic Test .................................................................. 13
2.3.2 Requirement of Boiler Hydraulic Test ............................................... 13
2.3.3Process of Boiler Hydraulic Test ........................................................ 13
2.3.4 Notes for Boiler Hydraulic Test ......................................................... 14
2.3.5 Conditions of Boiler over Pressure Hydraulic Test ........................... 15
2.4 Trial Operation of Running Machine .......................................................... 15
2.4.1 Purpose of Trial Operation of Running Machine .............................. 15
2.4.2 Regulations of Trial Operation of Running Machine ........................ 15
2.4.3Running Machine Trial Operation Qualified Standards ..................... 16
2.4.4 Conditions of Machine Emergancy Stop ........................................... 16
2.5 Running Machine Interlock and Start-stop Test ......................................... 16
2.6 Safety Valve Setting Test............................................................................. 17
2.6.1 Setting Test Conditions of Safety Valve ............................................ 17
2.6.2 Regulation Standard and Setting Values of Safety Valve .................. 17
2.6.3 Safety Valve Regulation Process and Notes ...................................... 17
2.7 Boiler Air Leakage Test .............................................................................. 18
2.8 Boiler Dry-off.............................................................................................. 18
2.8.1Preparation before Boiler Dry-off ....................................................... 18
2.8.2Boiler Dry-off...................................................................................... 18
2.8.3Temperature Control during Boiler Dry-off ....................................... 18
2.8.4 Qualified Standards of Boiler Dry-off ............................................... 19
2.9 Boiling Boiler .............................................................................................. 19
2.9.1Preparation before Boiling Boiler ....................................................... 20
2.9.2 Boiling Methods and Requirements................................................... 20
2.9.3Boiling Time and Pressure Requirements ........................................... 20
2.9.4 Sampling and Analysis ....................................................................... 20
2.9.5 Decreasing Pressure for Blowing Down ............................................ 20
2.9.6 Water Changing and Cleaning ........................................................... 20
2.9.7 Qualified Standards of Boiling .......................................................... 21
2.9.8Notes for Boiling ................................................................................. 21
3 Start of the Boiler Unit ....................................................................... 21
3.1Basic Working Principle of Boiler ............................................................... 21
3.1.1 Basic Construction ............................................................................. 21
3.1.2Basic Control Principle ....................................................................... 22
3.1.3Fuel Flow Process ............................................................................... 22
3.1.4 Water Vapor Process........................................................................... 23
7
3.2 Preparation before Starting the Boiler ........................................................ 24
3.3 Notes to Operation ...................................................................................... 25
3.4 Operation Method for Boiler....................................................................... 27
3.4.1 Entering the Operation ....................................................................... 28
3.4.2 Operation Graph ................................................................................. 28
3.4.3 Main Menu Functions ........................................................................ 30
4 Supervision and Regulation during Boiler Operation .................... 32
4.1Main Task of Boiler Operation Regulation .................................................. 32
4.2Main Parameters and Range of Boiler Operation Regulation ..................... 33
4.3Boiler Water Level Regulation..................................................................... 33
4.4 Steam Pressure and Steam Temperature Regulation .................................. 33
4.5Boiler Blowing Down .................................................................................. 34
4.6 Boiler Soot Blow ......................................................................................... 35
5 Stop of Auxiliary Boiler ...................................................................... 35
5.1Boiler Normal Stop ...................................................................................... 35
5.1.1Operation Process of Stopping Boiler ................................................ 35
5.1.2 Cooling Process after Stopping Boiler ............................................... 36
5.1.3 Boiler Water Discharging ................................................................... 36
5.2 Operation Process of Emergency Stop........................................................ 36
5.3 Maintaining after Boiler Stop ..................................................................... 37
5.4 Heating to dry .............................................................................................. 37
6 Operating Procedures of Burner ....................................................... 38
6.1 Overview ..................................................................................................... 38
6.2 Burner Device Specifications...................................................................... 39
6.3 Burner Operation......................................................................................... 41
6.3.1Burner Operating Principle ................................................................. 41
6.3.2The Operation of Programmer for Burner .......................................... 42
6.4Fuel Oil Cycle .............................................................................................. 44
6.5 Burner Adjustment ...................................................................................... 44
6.5.1Oil Mass Adjustment ........................................................................... 44
6.5.2 Combustion Air Adjustment, Regulating Cam .................................. 46
6.5.3 Burner Maintenance ........................................................................... 46
6.5.4 Burner Failure Status and Program .................................................... 46
8
7 Boiler Water System ........................................................................... 49

7.1Summary ...................................................................................................... 49
7.2Requirements to Feed and Boiler Water ...................................................... 50
7.3Management of Water Treatment and Dosing Equipment ........................... 50
7.3.1 Inspection of Water Treatment Equipment ........................................ 50
7.3.2 Inspection of Dosing Equipment ....................................................... 51
7.4 Dosing ......................................................................................................... 51
8 Combustion System ............................................................................ 52
8.1Summary ...................................................................................................... 52
8.2 HSFO Pump ................................................................................................ 52
8.2.1 General ............................................................................................... 52
8.2.2 Oil Pump Specification ...................................................................... 53
8.3Oil Tank Specification.................................................................................. 53
8.4 Heavy Oil Pump Operating Principle ......................................................... 54
8.5 Structure and Function ................................................................................ 54
8.6 Pump Operation Method ............................................................................. 55
8.7 Safety Valve................................................................................................. 55
8.7.1Safety Valve Adjustment ..................................................................... 55
8.7.2Safety Valve Discharge Value ............................................................. 56
9 Boiler Accident Handling ................................................................... 57
9.1Boiler Emergency Stop ................................................................................ 57
9.1.1Conditions of the Boiler Emergency Stop .......................................... 57
9.1.2 The Conditions of Boiler Manual Stop .............................................. 58
9.2Boiler Full Water .......................................................................................... 58
9.2.1Phenomenon ........................................................................................ 58
9.2.2Reason ................................................................................................. 58
9.2.3Treatment ............................................................................................ 58
9.3 Boiler Water Shortage ................................................................................. 59
9.3.1Phenomenon ........................................................................................ 59
9.3.2Reason ................................................................................................. 59
9.3.3Treatment ............................................................................................ 59
9.3.4 Operation of full water and decreasing water .................................... 60
9.4 Drum Water Level Indicator Damage ......................................................... 60
9.4.1Phenomenon ........................................................................................ 60
9
9.4.2Reason ................................................................................................. 60
9.4.3Treatment ............................................................................................ 61
9.5 Steam-Water Priming Accident ................................................................... 61
9.5.1Phenomenon ........................................................................................ 61
9.5.2Reason ................................................................................................. 61
9.5.3Treatment ............................................................................................ 61
9.6 Boiler Cooling Water Wall Damage............................................................ 62
9.6.1Phenomenon ........................................................................................ 62
9.6.2 Reason ................................................................................................ 62
9.6.3 Treatment............................................................................................ 62
9.7 Economizer Pipe Damage ........................................................................... 63
9.7.1Phenomenon ........................................................................................ 63
9.7.2Reason ................................................................................................. 63
9.7.3Treatment ............................................................................................ 63
9.8 Superheater Pipe Damage ........................................................................... 63
9.8.1Phenomenon ........................................................................................ 63
9.8.2Reason ................................................................................................. 63
9.8.3Treatment ............................................................................................ 64
9.9 Steam Pipe and Feeding Water Pipe Damage ............................................. 64
9.9.1Phenomenon ........................................................................................ 64
9.9.2Reason ................................................................................................. 64
9.9.3Treatment for feeding water pipe damage .......................................... 65
9.9.4Treatment for steam pipe water damage ............................................. 65
9.10 Boiler Pipe Water Impact .......................................................................... 65
9.10.1Phenomenon ...................................................................................... 65
9.10.2Reason ............................................................................................... 65
9.10.3Treatment .......................................................................................... 66
9.11Load Sharp Decrease.................................................................................. 66
9.11.1Phenomenon ...................................................................................... 66
9.11.2Reason ............................................................................................... 66
9.11.3Treatment........................................................................................... 66
9.12 Flue Secondary Combustion at Boiler Tail Section .................................. 67
9.12.1Phenomenon ...................................................................................... 67
9.12.2Reason ............................................................................................... 67
9.12.3Treatment .......................................................................................... 67
9.13 Oil Leakage and Firing of Fuel Oil System .............................................. 67
9.13.1Phenomenon ...................................................................................... 67
9.13.2Reason ............................................................................................... 67
9.13.3 Treatment.......................................................................................... 68
9.14 Air Fan Failure .......................................................................................... 68
10
9.14.1Phenomenon ...................................................................................... 68
9.14.2Reason ............................................................................................... 68
9.14.3Treatment .......................................................................................... 68
9.15 Feeding Water Pump Failure ..................................................................... 69
9.15.1Phenomenon ...................................................................................... 69
9.15.2Reason ............................................................................................... 69
9.15.3Treatment .......................................................................................... 70
9.15.4 Interlock Condition of Pump ........................................................... 70
9.15.5 Manual Switch Conditions of Pump ................................................ 70
9.16 I&C Supply Power Vanishing ................................................................... 71
9.16.1Phenomenon ...................................................................................... 71
9.16.2Reason ............................................................................................... 71
9.16.3Treatment .......................................................................................... 71
10 GT Fuel Oil System........................................................................... 72
10.1 HSFO System ............................................................................................ 72
10.1.1 Equipment Specification .................................................................. 72
10.1.2Trap Flash Tank ................................................................................. 73
10.1.3 Oil Storage Tank and Heater ............................................................ 75
10.1.4 Heavy Oil Unloading ....................................................................... 77
10.1.5 Operation of HSFO Unloading Pump .............................................. 78
10.1.6 Heavy Oil Delivery Processes ......................................................... 79
10.1.7 The General of HSFO Treatment ..................................................... 80
10.1.8 The Operation of HSFO Treatment Plant ........................................ 98
10.1.9 Waste Oil Processing...................................................................... 101
10.1.10 Steam Process .............................................................................. 101
10.2 Light Oil System (HSD) ......................................................................... 103
10.2.1 Equipment Specification ................................................................ 103
10.2.2 Light Oil Unloading Process .......................................................... 106
10.2.3 HSD Unloading Pump Specification ............................................. 106
10.2.4 Light Oil Delivery Process............................................................. 107
10.2.5 Waste Oil Processing...................................................................... 107
10.2.6 Steam Process ................................................................................ 107
10.3 Fuel Oil Sample....................................................................................... 108
10.3.1 Meaning of Specification Tests ...................................................... 108
10.3.2 Fuel Analysis Data Requirements .................................................. 114
11
1Auxiliary Boiler Specification

1.1System Summary
Pakistan Nandipur 425MW combined cycle power plant project has three
WNS20-1.0/200-YZ boilers (two in use and one standby) produced by Jiangsu
Shuangliang Boiler Co., Ltd., whose rated evaporation is 20t/ h, rated steam
pressure is 1.0Mpa and steam temperature is 200 ℃. They are aimed to meet the
steam required under start-up of power plant and normal running circumstance.
The boiler fuel adopts both heavy oil and light oil. Boiler start-up adopts light
diesel oil (HSD). The fuel used under normal running circumstance is heavy oil
(HSFO) or light diesel oil.
Start-up boiler room is arranged within 34m ×21m (centerline) range. Start-up
boiler room is divided into two parts: one part consists of start-up boiler, blower,
sampling cooler, other devices, control room and oil pump room; the other part
consists of dosing device, condensed water de-ironing device, water feed pump,
periodic blowdown flash tank, continuous blowdown flash tank, deaerator and
other devices; deaerator should be mounted at a high position -- 7.2m high from
the ground; chimneys and sewage cooling pool should be arranged outdoor.
Main steam pipes, water feed pipes and fuel pipes adopt low overhead layout
over the ground. Sewage pipes and drainage pipes adopt overhead layout over
trenches.
1.2Auxiliary Boiler Specification
1.2.1 Boiler Main Designed Parameters
No Unit /Item Data

1 Boiler type WNS20-1.0/350-YZ
2 Rated steam output 20t/h
3 Rated steam pressure 1.0 MPa
4 Rated steam temperature 194℃
5 Design efficiency 90.6%
Rated Inlet water
6 20℃ 105℃
temperature
7 Fuel Diesel Fuel Heavy Oil
8 Fuel combustion 1177kg/h 1225kg/h
9 Combustion mode Micro-positive pressure
Automatic ratio
10 Adjust mode
combustion adjustment
11 Boiler net weight 52.8t
1
No Unit /Item Data
12 Water capacity 32t
13 Truckrying size 8050 X 3750 X 3960 mm
14 Boiler size 10670 X 5100 X 4856 mm
Regulating Fully auto.
15 Fully auto proportional
method step
Gas Dispersed
Mechanical atomization
Diesel oil
with return oil
Heavy fuel oil Mechanical atomization
Atomizati ＜𝟔𝟎# with return oil
16
on method
Heavy fuel Rotating cup atomization
oil𝟔𝟎# ~𝟐𝟎𝟎# or steam atomization
Heavy fuel oil
Rotating cup atomization
＞𝟐𝟎𝟎#
17 Control system Fully auto PLC
Oil consumption under
18 rated operating conditions
(t / h)
Light oil consumption
19 under rated operating
conditions (t / h)
20 Number of burners 1
21 Chimney height 15m
22 Chimney outlet diameter 1.0m,wall thickness 8mm
Steam drum working
23 1.1MPa
pressure
Minimum boiler operating
24 25%
load
Superheated steam
25 temperature deviation 350±20℃
range
26 Ensured efficiency 90%
27 Designed efficiency 90.6%
Note:
a. Fully automatic control is used for all types of boilers, where the rotating
cup burner is used.
b. It is prohibited to use oil with high volatility, such as gasoline and low grade
2
diesel oil.
c. Gas should be used with heating value and supply pressure, which should
meet the requirements of contract.
d. Additive should be used and boiler should be checked periodically for
corrosion to be protected from low temperature corrosion, when the heavy fuel
oil with high content of sulfur is applied.
1.2.2 Fuel Oil Characteristic
Furnance Oil (HSFO) Specification
TEST UNITS LIMITS TEST METHODS
Acid Number, Strong mgKOH/g Max. Nil ASTM D 664/D-974
Ash %W Max. 0.10 ASTM D 482/IP-4/75
Calorific Value, Gross BTU/Lb Min. 18200 ASTM D-240

Truckbon Residue,
%W Max. 12.0 ASTM D 189
Conradson
Flash point, PMcc Deg. C Min. 66 ASTM D 93
IP 228 or ASTM D
Potassium + sodium Ppm Max. 50
2788
Pour Point Deg. C Max. 50 ASTM D 97
Relative Density @
Deg. F Max. 0.9800 ASTM D 1298
60/60
ASTM D 473
Sediment %W Max. 0.15
or IP - 53
ASTM D 1552 or 2622
Sulphur %W Max. 3.5
or 4294
ASTM D 1548 or IP
Vanadium Ppm Max. 60
288
ASTM D 1548 or IP
Calcium Ppm Max. 10
288
Max.180
Viscosity, Kinematic Summer ASTM D 445 or IP
cst
@50 Deg. C Max.125 71/75
Winter
Water %V Max. 0.50 ASTM D 95
Inlet oil pressure： 2~3bar
Inlet oil temperature： 60~70℃
Max consumption： 2.7t/h
3
TEST UNITS LIMITS TEST METHODS

Inlet head pipe： D159×5
Head pipe of combustor: D133×5
High Speed Diesel (HSD) Oil Specification
TEST UNITS LIMITS Test Methods
Max.
Ash %Wt
0.01
Truckbon Residue, Conradson %Wt Max. 0.1
Pour Point Deg. C Max. -6
Cloud Point Deg. C Max. +5
Colour ASTM - Max. 2.5
Corrosion, copper strip 3h＠100℃ - Max. No.1
Centane Number/Centane Index - Min.45
Flash point, PMcc Deg. C Min. 66
Min.0.820
Relative Density @ 60/60℉
Max.0.870
Sediment %Wt Max. 0.01
Sulphur %W Max. 1.0
Min. 1.6
Viscosity, Kinematic @37.8℃ cst
Max. 5.5
Water %Vol Max. 0.10
Calorific Value Gross BTU/lb 18500 43.031MJ/Kg
Inlet oil temperature： normal
Max consumption： 2.6t/h
Inlet head pipe： D57×3.5
Head pipe of combutor: D133×5
1.2.3 Steam Water Quality Standard
Item Unit Feed water Boiler water
Suspended solids mg/L ≤5
Total hardness mmol/L ≤0.03
Total alkalinity mmol/L 6～24
pH（25℃） ≥7 10～12
Dissolved oxygen mg/L ≤0.1
Dissolved soilds mg/L <3500
SO32- mg/l mg/L 10～30
PO43- mg/l mg/L 10～30
Relative alkalinity <0.2
4
（free NaOH/dissolved
soilds）
Oil content mg/L ≤2
Note :
a. The basic elements for hardness mmol/L is C（1/2Ca2+、1/2Mg2+）。
b. The basic elements for alkalinity mmol/L is C（OH-、HCO3-、1/2CO32-）。
c. The deaerator should be provided, if the boiler capacity is more than 6t/h , or
deaeration measures should be taken in case of corrosion, if the boiler capacity
is less than 6t/h.
1.3 Thermodynamic Calculation for Parts of the Boiler
Super Convection Convection
Item Symbol Unit Furnace Chamber
heater Tube bank2 Tube bank3
Inlet gas
θ' ℃ 1979 1406.8 465.3 1312 413.6
temperature
Outlet gas
θ" ℃ 1406.8 1312 413.6 465.3 228.2
temperature
Inlet
working t' ℃ 188.9 188.9 188.9 188.9 188.9
tempreature
Outlet
working t" ℃ 188.9 188.9 203.2 188.9 188.9
tempreature
Flue gas
Wy m/s / / 9.6 30.2 23.5
flow speed
Heat
transferring k W/m2.℃ / / / 48.8 68.5
coefficient
Hot area S m2 19 10.1 11.5 231.6 188.2
Heat
Q kJ/kg 13521.4 2149.5 993.9 18007.8 363
absorption
warmpress F ℃ / / 235.6 603.9 106.2
Flow
V m/s 23
velocity
1.4Boiler Flue Gas Resistance Parameters
Item Unit Data
Boiler gas (air) resistance (except for Pa 2203.635
5
burner)
Flue gas amount（140℃） m3 /kg 1.288
Air amount（25℃） m3 /kg 10.729
1.5 Strength Calculation List of Boiler
Item Sign Unit Value
Rated evaporation capacity D t/h 20
Basic
Rated working perssure pe MPa 1
Parameter
Out let steam temperature tj ℃ 200
Rated pressure pe MPa 1.0
Steam resistance △ pz MPa 0.1
Working pressure p1 MPa 1.1
fluid column pressure △ psz MPa 0.0
additional pressure △p MPa 0.0
Cylindrical
shell Accounting pressure p MPa 1.1
Material Q245R
Accounting medium
tb ℃ 189.0
temperature
Accounting wall temperature tbi ℃ 250.0
Basic allowable stress [σ]j MPa 125.0
1.6 Combustion Devices Specification
Name. Item Unit Data
Boiler outline dimension
mm 10670 X 5100 X 4856
(including flat roof)
Furnace capacity m3 12.517
Total furnace heated area m2 19
Furnace Furnace designed pressure Pa
Furnace explosion-proof
Pa
pressure
Burner type, arrangement
type
Type - RP-1600 ME
Burner Number - 1
Manufacturer Oilon company
Stack Outer diameter mm Φ1016
6
Height mm 15000
1.7Feeding Water System and Specification
1.7.1 Water Pump Main Technical Parameters
No. Name Item Data
Type CRCM20-14
Feeding Water Flow 22m3 /h
1
Pump Head 1600 mH2 O
Motor power 15KW
Type KQL80-160-7.5-2
Supply Water Flow 50m3 /h
2
Pump Head 32mH2 O
Motor power 7.5KW
1.7.2 Main Technical Parameters of Auxiliary Boiler Blowdown Vessel
No. Name Item Data
Type DN800
Work pressure 1.0MPa
Continuous Work
1
blowdown vessel temperature
Volume V=1.5m3
Working Medium Water /Steam
Type DN1500
Working pressure 1.0MPa
regularly Work
2
blowdown vessel temperature
Volume V=3.5m3
Working medium Water /Steam
1.8Air Fan Specification
No. Item Unit Data
1 Brand -- Oilon complement
2 Model -- GMB20
3 Motor Rating -- 75KW2PABB
4 Flow Nm3/h 25920
5 Static Pressure mbar 70
6 Speed rpm 2900
7 Noise Level dB(A) 88dB(A)  3dB(A)
8 Driven Type -- direct connection
9 Weight kg 1000 kg
7
1.9 Deoxidation System Specification
1.9.1 Deaerator Specification
Item Data Item Data
Max work pressure 0.02 MPa Work temperature ≤104℃
Designed pressure 0.08MPa Designed temperature 250℃
Medium Water/ Steam Roated inlet pressure 40t/h
Nozzle inlet water
~0.15MPa volume 25m3
pressure
welded joint Head
0.7￠ 2.0 mm
coefficient corrosion deoxygenize
Main pressure allowance
Q235-B feed tank 1.5 mm
componentmaterial
1.9.2Deoxidation Water Pump Specification
Capacity Head Speed Power NPSHr Weight
Type
𝐦𝟑 /𝐡 L/s （m）（r/min）（KW）（m）（kg）
31.3 8.7 11
KQL
44.7 12.5 10 2690 2.2 3 54
80/90-2.2/2
53.6 14.9 8
35 9.72 13.8
KQL
50 13.9 12.5 2960 3 3 63
80/100-3/2
60 16.7 10
31.3 8.7 17.5
KQL
45 12.5 16 2960 4 3 79
80/110-4/2
54 15 13.6
KQL 35 9.72 22
80/125-5.5/ 50 13.9 20 2960 5.5 3 105
2 60 16.7 17
KQL 30.3 8.4 26
80/140-5.5/ 43.3 12 24 2960 5.5 3 105
2 52 14.4 21
KQL 32.7 9.1 30.6
80/150-7.5/ 46.7 13 28 2960 7.5 3 112
2 56 15.6 24
Deoxidation Water Pump Size Table：
𝐋𝟎 m a c 𝐋𝟏 𝐛𝟏 𝐛𝟐 x
Type DN
mm
8
80/90-2.2/2 80 490 245 145 30 430 120 290 110
80/100-3/2 80 490 245 145 30 465 125 295 110
80/100-4/2 80 490 245 145 30 490 125 315 100
80/125-5.5/2 80 490 245 145 30 555 185 400 110
80/140-5.5/2 80 490 245 145 30 555 185 400 110
80/150-7.5/2 80 490 245 145 30 555 185 400 110
80/160-7.5/2 80 490 245 145 30 555 185 400 110
1.10 Steam Muffler Specification
No. Item Data
1 Type HZDXS-II/125-/100/1.6
2 Diameter ∅478
3 Steam exhaust 20t/h
4 Designed temperature 260℃
5 Designed pressure 1.6MPa
6 Roated steam temperature 200℃
7 Roated steam pressure 1.0MPa
Mufflers at levels Ⅰand Ⅱare
made of stainless steel
Material explanation
Mufflers at the remaining four
levels and rain-hats are Q235-B
1.11Expander Specification
Item Data Item Data
PeriodicBlowdown Expander
Max work pressure 0.15MPa Work temperature <250℃
Designed
Designed pressure 0.20MPa 250℃
temperature
medium Sewer/Steam volume 3.53m3
welded joint
1.0/0.85 corrosion allowance 1.0mm
coefficient
Main pressure
Typr 1 Q235-8
componentmaterial
ContinuousBlowdown Expander
Max work pressure 0.25MPa Work temperature ≤250℃
Designed
Designed pressure 1.0MPa 250℃
temperature
medium Sewer/Steam volume 1.5m3
welded joint
1.0/0.85 corrosion allowance 1.0mm
coefficient
Type 1 Main pressure Q235-B,20II
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componentmaterial
1.12 Sampling Cooler
Item Unit shell side monitor
Working pressure MPa 1.0 ATM
Design Temperature MPa 1.1 ATM
Working
℃ - -
Temperature
Design Temperature ℃ 250 400
medium - water Water steam
Heat transfer area m2 0.407
Vassel weight kg 86
Equipment number FBC10023
2 Conditions and Tests before Starting the Boiler

2.1Check-up Before Starting the Boiler
All the maintenance work inside the boiler should be completed after boiler
maintenance and maintenance personnel have evacuated; the operators check the
equipments completely with the cooperation of maintenance personnel.
2.1.1 Check-up inside Combustion Chamber and Gas Duct
a.There are no working personnel, foreign materials and forgotten tools in
combustion chamber and gas duct, the pipe wall is clean; all the manholes are closed
after check.
b. All the air valves, damper switches are agile; the remote indication positions
comply with actual positions. The transferring devices are in fine condition
c. All the measuring instruments and meters and controlling device accessories
are complete.
d. All the platforms, ladders are complete without barriers; lighting is sufficient.
All temporary measures for maintenance have already been recovered.
e. Oil gun outline is complete; the position is right without block.
f. All the insulation and supports are complete and fix, the expansion indicators
are clear with right indication.
2.1.2Check-up of Steam-water System
a. All the steam-water valves are complete and agile with right and complete
signs and medium flow direction sign is right.
b. Motorized valve remote control device is in fine condition and remote
indications comply with actual condition.
c. Remote control water indicator is in fine working condition. Local level
indicator mica is clear and transparent with right scale and sufficient light, the
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protection cover is complete and the indicator is in operation.
d. All parts of drum and super heater safety valves are complete without block
by foreign material.
e. The indication positions of motorized valves and regulation valves comply
with actual positions.
2.1.3Check-up of Running Machine
a. There is no foreign material around running machine and lighting is
sufficient.
b. Oil is clean with oil level at 1/2, there is no oil leakage.
c. Cooling water flow smoothly and water amount is sufficient.
d. Protection cover and earth wire is fine, the anchor bolts are fixed.
e. All running machine emergency button are complete.
f. Turn the turning gears after check-up and there should be no friction, bump
and block inside.
2.1.4 Check-up of Oil System before Boiler
a. Oil pressure is at 2.5MPa, and oil temperature is normal.
b. Soot blowing pressure is within 0.5MPa～0.8MPa.
c. Oil gun is smooth without steam and oil leakage.
d. Oil gun ignition device is complete and in standby.
2.1.5 Check-up of Pressure Meter and Operation Panel
a. All the panels of instrumental meters and pressure meters are clear; the drum
and superheater pressure meters and FDF & IDF ampere meters are complete and
in fine condition.
b. All the pointers of meters are at zero position.
c. All the pressure meters are calibrated and qualified with calibration sign.
d. The signals of operation panel, operation switches and transferring switches
are complete and in fine condition.
e. The meters should be clean with all signs, right names of clear writing and
are in fastness.
f. Indicator lights are with covers, colors of which are right.
g. Emergency horn is with alarm bell, which is in fine condition.
2.1.6 Check-up of Expansion Indicator
a. Figure plate is welded on boiler framework or beam or pole; finger is
vertically welded on expansion elements.
b. Scale on finger plate is right and clear.
c. Finger can not be blocked and should be vertical with plate surface. The
distance between indicator and plate surface is 3～5mm.
d. When the boiler is cold state, the finger should be on the benchmark point of
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“0” on the finger plate.
2.1.7 Check-up of Site Lighting
a. All the bulbs for lighting at all parts of the boiler should be complete and
ladders & platforms should be with sufficient brightness.
b. The lighting at drum water level indicator, drum, superheater headers and
local pressure meters should be sufficient.
c. Emergency light power supply is reliable.
d. Lighting in operation room is sufficient and with gentle ray.
2.2Feeding Water System
2.2.1Check-up before Starting Feeding Water Pump
a. After maintenance of feeding water pump, work permit ticket should be
completed and taken back; there is nothing influencing putting into operation.
The site is clean with no foreign material and all the signs are complete and
right.
b. All the valve positions are right.
c. All the meters are complete and local indication comply with remote indication;
protection and alarm are in operation.
d. Water level in feeding water tank is normal; inform chemical personnel to
make up water when water is qualified.
e. Turn the shaft coupler manually and there should be no block, bump and
friction.
f. The shaft coupler cover is complete and fixed. Bearing oil level is normal and
the oil is qualified.
g. Bearing sealing cooling water is smooth with sufficient water amount.
h. Anchor bolts are fixed.
i. Motor insulation is qualified and its shell earth wire is fixed, junction box is
tightly connected. There is no damage to the air fan. Local emergency buttons
are complete and with no damage.
j. When feeding water pump motor is energized, the green light on control panel
is on.
k. Feeding water by feeding water pump is completed.
2.2.2Putting Feeding Water Pump into Operation
a. Open the inlet valve and re-circulating valve of feeding water pump and close
outlet valve of the feeding water pump.
b. Press the “On” button to start feeding water pump.
c.When current returns to the position of empty load, check the water pump and
motor and make sure that there is no abnormal sound, the outlet pressure is
normal, vibration does not exceed 0.06mm and bearing temperature does not
exceed 80℃.
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2.2.3Normal Operation and Maintenance of Feeding Water Pump
a. The current does not exceed rated value.
b. Bearing temperature does not exceed 75℃.
c. Bearing vibration does not exceed 0.05mm.
d. Motor temperature rise does not exceed 60℃.
e. Bearing oil quality and oil level are normal.
f. Running machine runs evenly without any abnormal sounds, intermittent
friction noise and clash.
g. Outlet pressure of feeding water pump is normal.
h. Cooling water is smooth with sufficient water amount.
i. Safety fences are complete; anchor bolt and earth wire are fixed.
j. All the drive switches, emergency buttons are complete; they can not be
operated casually to avoid operation by mistake.
k. The standby pump is in fine standby and all the outlet and inlet valves are
open.
2.3 Hydraulic Test
2.3.1 Purpose of Hydraulic Test
Hydraulic test must be done for boiler pressure bearing parts after installation
or maintenance to check up the tightness of heated surfaces, steam-water pipes
and valves and to ensure safe, stable and reliable operation of the boiler.
2.3.2 Requirement of Boiler Hydraulic Test
a. Hydraulic test must be done to the boiler after maintenance to check up the
tightness of the pressure bearing parts.
b. Before water pressure test, pipeline support & and suspending frames are
overloaded, protection measures should be done. Check the support & and
suspending frames after hydraulic test.
c. Boiler hydraulic pressure test is 1.226MPa.
d. The standard of qualified hydraulic test is that pressure has no change or
obvious decrease, there is no water leakage or wetness at surface at pressure
bearing parts and there is no residual distortion of pressure bearing elements
after stopping feeding water and under condition that feeding water valve has
been closed for 5 minutes.
e. Feeding water pump is at standby. Feeding water to the feeding water tank,
and water levels are normal.
f. After hydraulic test is qualified, the speed for releasing pressure does not
0.3MPa/min.
2.3.3Process of Boiler Hydraulic Test
a. Put the drum water level indicator and pressure meters into operation.
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b. Open the drum water level indicator and primary valve of pressure meter.
c Close outlet main steam valve of superheater and close all the drainage
valves, water discharging valves and blow down valves of the boiler.
d. Press and fix the safety valve of drum and superheater, remove water level
protection and check that all the valves are in the position for hydraulic test.
e. Water is analyzed to be qualified and the water temperature keeps within
20～30℃. Start the feeding water pump to feed water slowly and close the air
valve when it sees water.
f. Start feeding water pump and increase pressure with regulation valve of
feeding water pipelines.
g. The speed of pressure rise does not exceed 0.3MPa/min.
h. When pressure is increased to 10% of working pressure, stop increasing
pressure for check; if there is no leakage, continue to increase pressure and; if
there is serious leakage, stop increasing pressure and continue to increase after
leakage point has been cleaned.
i. When the pressure is increased to 80% of working pressure, stop increasing
pressure for checking the tightness of inlet water valve; if there is no problem,
continue to increase pressure, speed of which should not exceed 0.2MPa/min.
j. When the pressure is increased to 1.87MPa, stop increasing pressure, close
feeding water valve and stop the feeding water pump for 5 minutes, record the
pressure drop value and check it completely.
k. After hydraulic test is qualified, open the sampling valve for releasing
pressure; the pressure drop does not exceed 0.3MPa/min.
l. The pressure is drop to zero (0), open the air valve and drainage valve and
discharge water according to requirements.
2.3.4 Notes for Boiler Hydraulic Test
a. Before feeding water, test the steam venting valve and emergency water
discharging valve.
b. At least three pressure meters are in operation and right.
c. Special personnel should be at site for guiding and organizing maintenance and
operation before hydraulic test.
d. Special personnel should be in charge of increasing pressure during hydraulic
test to avoid over pressure. Pressure on drum local pressure meter should be
prevailed, special personnel should be arranged to supervise the local pressure
meter. When the pressure is close to test pressure, pressure increasing speed
should slow down to avoid over pressure. The person between local and remote
should keep in contact, when the difference between local and remote indication
is big, pressure increasing should be stopped immediately and continue after
I&C personnel checking and confirming.
e. Periodic blow down valve can be measure of releasing pressure to avoid over
pressure during hydraulic test.
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f. Pressure increasing and decreasing should be even and stable, pressure
increasing speed should be strictly limited to avoid exceeding regulated
pressure. Regulation inlet water amount should be slow and even to avoid water
concussion.
g. After hydraulic test, the test results and problem found during check should be
recorded in related notebook.
2.3.5 Conditions of Boiler over Pressure Hydraulic Test
a. For boiler in operation, hydraulic test should be done once for every six years
periodically.
b. Newly built boiler or transferred boiler.
c. Boiler that has been stopped for more than one year before putting into
operation.
d. Boiler that its cooling water wall pipes have been dismantled and changed
above 50%.
e. Except for pipes of heated surfaces, hydraulic test should be done after welding
of boiler pressure bearing parts or large area repair by welding.
f. When all the pipes of superheater or economizer are dismantled and changed.
g. After drum, the superheater headers or cooling water wall headers have been
changed.
h. After concave and protruding locations of main parts of boiler (e.g. drum,
superheater header, cooling water wall header) have been repaired.
i. When over pressure hydraulic test is required according to the actual condition
of the equipments.
2.4 Trial Operation of Running Machine
2.4.1 Purpose of Trial Operation of Running Machine
a. Check that whether the installation and maintenance quality of running
machine comply with the standards or not.
b. Validate the reliability of running machine.
c. Close drive power supply and control power supply.
d. Turn the switch of power cabinet to ‘manual’ for single machine trial operation,
turn the switch to ‘automatic’ after making sure that single machine has no fault.
If the single machine is in fault or can not operate normally, turn the switch to
‘stop’ and clean the fault as soon as possible.
2.4.2 Regulations of Trial Operation of Running Machine
a. Motor should have trial operation separately before connecting to mechanical
part to check the reliability of turning direction and emergency button. New
motor trial operation should be no less than 8 hours and no less than 2 hours
for motor after complete maintenance.
b. Shaft coupler protection cover should be complete and fixed. Turn the shaft
coupler and make sure that there is no block, bump and friction.
c. For the first start, when the running machine reaches to full speed, stop the
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machine with emergency button and watch the bearing and turning parts to
make sure that there is no friction and other abnormal conditions, then start it
normally.
d. After normal start, increase the load gradually after the current is normal until
the current reaches to rated value.
e. Check whether there is friction or other abnormal sound inside the bearing
with listening needle; if there is any abnormal sound needed, the reason should
be found out and clean it as soon as possible.
f. Continuous running time for running machine: new motor trial operation
should be no less than 8 hours and no less than 2 hours for motor after
complete maintenance.
2.4.3Running Machine Trial Operation Qualified Standards
a. The machine runs evenly, there is no abnormal sound, intermittent friction
and clash at bearing and running parts.
b.Bearing working temperature is normal, motor bearing working temperature
does not exceed 80℃, sliding bearing of running machine temperature does
not exceed 70℃ and rolling bearing temperature does not exceed 80℃.
c. Bearing vibration complies with following standards:
a) Above 1500r/min, not exceeding 0.05mm; under 1500r/min, not
exceeding 00850mm;
b) Above 1000r/min, not exceeding 0.10mm; above 750r/min, not exceeding
0.12mm;
c) String bearing is not more than 2～4mm.
d. There is no oil leakage and water leakage.
2.4.4 Conditions of Machine Emergancy Stop
a. Endanger human beings safety.
b. Motor is on fire and smoke.
c.Vibration, string bearing exceed regulations which may damage the equipment.
d. Rotor is in friction with stator, which may damage the equipment.
e. Bearing temperature is increasing sharply, which may damage the equipment.
2.5 Running Machine Interlock and Start-stop Test
a. Interlock device test and local emergency button test should be done before
every ignition for newly built boiler or boiler after complete & small
maintenance.
b. Start IDF, FDF, FWP, stop the running machines with emergency button, the
running machine stop immediately.
c. Running machine interlock devices test
a) Start IDF, FDF and put interlock device into operation, stop IDF and stop
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FDF by interlock.
b) Start one feeding water pump and put interlock into operation, stop the
running feeding water pump and start the feeding water pump in standby
with interlock. Test the other feeding water pump with same method.
2.6 Safety Valve Setting Test
2.6.1 Setting Test Conditions of Safety Valve
For the safety of boiler equipments, safety valve setting test should be done if
any of the following occurs:
a. Newly built boiler or boiler after complete maintenance;
b. After maintenance of safety valve;
c. Safety valve doesn’t act when steam pressure goes beyond limitation.
2.6.2 Regulation Standard and Setting Values of Safety Valve
Drum #1, #2 working safety valve actuated pressure: 1.47×1.06=1.558MPa
Drum #1, #2 working safety valve reseating pressure: 1.449～1.496MPa
Superheater outlet header safety valve actuated pressure: 1.27×1.04=1.32MPa
Superheater outlet header safety valve reseating pressure: 1.228～1.267MPa
2.6.3 Safety Valve Regulation Process and Notes

a. Safety valve regulation should be guided and organized by special person; the
maintenance and operation team make the scheme together which is then
informed to the operators.
b. When everything is ready, close the steam exhaust valve, ignite the boiler and
increase pressure for regulating safety valve.
c. During safety valve regulation, control the combustion and increase &
decrease the pressure according to requirements, special personnel should be
designated to operate the steam exhaust valve for regulating steam pressure.
d. Safety valve regulation should be done one by one from high pressure to low
pressure and from drum safety valve to superheater safety valve.
e. When safety valve acts, water level and steam temperature changing should be
nearly supervised and regulated timely.
f. When drum pressure increases to 80% of rated pressure of the boiler, regulate
combustion and stabilize pressure; compare the error of pressure meters
between local and control room, the values on local meters should be
prevailed. The commanders and operators should know fairly well and use
pressure meters with precision above 0.5 when it is necessary.
g. Seat starting pressure and reseating pressure should be recorded after
regulation of safety valve; if the safety valve regulation is not qualified, the
boiler is not allowed to bring in system or operate.
h. During safety valve calibration, if there is any abnormal conditions, calibration
should be stopped immediately.
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i. During boiler operation, seat starting pressure of safety valve can not be
increased randomly or press safety valve to death with tensioning device.
2.7 Boiler Air Leakage Test
Boiler air leakage test adopts negative pressure method.Boiler air leakage test
process.
a. Close all the inlet dampers of the FDF and all the manholes.
b. Start IDF and regulate IDF damper to keep furnace negative pressure at 500Pa.
c. Ignite torch or candle and check the boiler wall and flue. If flame is sucked into
wall or flue and air duct, it proves that there is air leakage, mark it and treat it
after the test.
2.8 Boiler Dry-off
Boiler dry-off should be done for newly built boiler and boiler stopped for more
than 3 months.
2.8.1Preparation before Boiler Dry-off
Prepare boiler dry-off scheme and curve and disclose technical issues to the
joining personnel and make the records of boiler dry-off well. Temperature
detection points and sampling points should be arranged on the boiler wall and,
thermometers and sampling tools should be prepared.
2.8.2Boiler Dry-off
The boiler adopts flame dry-off method, among which prophase is dry-off
with small fire and anaphase is dry-off with 15% load of the burners.
2.8.2.1Prophase of Boiler Dry-off (Small Fire)
Firstly start the regulation valve before IDF to 1/5 to1/6, ignite burner with
small fire and regulate the flame according to temperature rise and keep the
furnace with minute negative pressure; the flue gas flows slowly. Then increase
the flame gradually according to the displayed detection points and flue gas
temperature at back of superheater should be taken as monitoring regulation
values.
2.8.2.2Anaphase Boiler Dry-off (12.5% Load of the Burners)
When the small can not increase the temperature after superheater (generally
2～3 days), fuel amount should be increased for boiler dry-off and IDF & FDF
should be started to increase air amount and enhance burning to increase flue gas
temperature continuously.
2.8.3Temperature Control during Boiler Dry-off
During boiler dry-off, temperature should be controlled strictly. The speed of
temperature rise has a direct effect to boiler dry-off result. Generally, method of
measuring flue gas temperature after superheater is adopted to control fuel
feeding amount and IDF air amount.
Temperature rise for the first day should not exceed 50℃ and 30℃ per day
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for the following days; temperature rise should not exceed 10℃ per hour. During
anaphase of boiler dry-off, flue gas temperature should not exceed 220℃, the
lasting time for boiler dry-off within the range of highest temperature should be
no less than 24 hours. If the boiler wall is very wet, temperature rise speed should
be decreased properly.
Control burning flame. Burning should be even during boiler dry-off and
temperature readings should be recorded on schedule. Expansion conditions of
the boiler body and boiler wall should be watched, treat it as soon as possible if
any abnormity occurs.
Discharge the water vapor in time. Upper valve for check should be open to
timely discharge water vapor produced during boiler dry-off. When boiler wall
temperature is too high, temperature rise speed should slow down and ventilation
should be enhanced to make the moisture vaporize timely and discharge
smoothly.
The time for boiler dry-off is generally 5-7 days and is decided by boiler wall
actual condition and local weather conditions.
2.8.4 Qualified Standards of Boiler Dry-off
There should be no distortion or racks for boiler wall after dry-off and there
should be no defects (such as collapse and drop) for the concrete.It is deemed as
qualified if any of the following standards is reached:
a.Boiler wall slurry sampling method: Take 50g ash slurry from ‘T’cross of
firebrick at middle & low position of boiler wall at superheater location, if its
water content is less than 2.5%, it is deemed as to be qualified.
b.Temperature measuring method: Temperature detection point should be set at
joint between boiler wall firebrick and heat insulation layer of the superheater,
when the temperature reaches to 50℃ and keeps for 48 hours, it is deemed as
to be qualified.
c. During boiler dry-off with temperature measuring method, temperature
detection points should be watched and recorded, and temperature rise curve
should be prepared and stored in boiler technical files.
2.9 Boiling Boiler
Purpose of boiling boiler: Clean the oil pollutions and rust on boiler inner
heated surface to ensure qualified boiler water. Boiling boiler is done after boiler
dry-off.
NaOH and Na3PO4.12H2O are adopted for boiling boiler with dosing amount
of 2～3 kg per ton boiler water, which confects 20% equal liquor and fill in the
boiler. Chemicals are not allowed to fill into the boiler directly.
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2.9.1Preparation before Boiling Boiler
a. Preparation of personnel and apparatus and tools
After personnel for boiling boiler are confirmed, their duties should be
clarified and they main should be informed the points of boiling boiler. Before
boiling, rubber gloves, protection glasses, masks should be prepared. There
should be with clean water, first aid medicines and gauze for emergency.
b. Preparation of chemicals
150kg NaOH and 200kg Na3PO4.12H2O should be prepared, and 65kg
NaOH and 85kg Na3PO4.12H2O are dissolved with 400kgwater, which
confects liquor with concentration of 20%.
2.9.2 Boiling Methods and Requirements
At anaphase of boiler dry-off, when the water content of red brick slurry of
boiler wall decreases to be less 10% or outside temperature of superheater
firebrick reaches to 50℃, boiler boiling an be started.
Chemical dosing to boiler: when boiler is at lowest water level, fill in the
confected liquor with concentration of 20% through drum dosing pipelines at one
time.
2.9.3Boiling Time and Pressure Requirements
a. The pressure is increased to 0.3～0.4MPa after dosing, which should be kept
for 4 hours, and boiler boiling should be done for 12 hours under such
pressure. All the manholes, hand holes and valves should be fixed tightly.
b. Continue to heat until the pressure reaches to 0.8MPa, boil the boiler for 12
hours and watch the boiler operation condition.
c. Boil the boiler for 12 hour under pressure of 1.2MPa; if any problem occurs,
treat it after pressure decreased.
d. When the pressure decreases to 0.3～0.4MPa, fill water and keep the pressure
and boil boiler for 4 hours.
2.9.4 Sampling and Analysis
Boiler water sampling test should be done continuously during boiling boiler;
supplement chemicals timely if alkalinity is lower than 45mg. equivalence/liter.
2.9.5 Decreasing Pressure for Blowing Down
If blowing down is necessary during boiler boiling, pressure should be
decreased.
2.9.6 Water Changing and Cleaning
After boiler boiling, alkaline water should be discharged and sediments inside
drum and headers should be cleaned; valves ever contacted with chemicals inside
boiler should be flushed. Blowing down valve should be checked with no block.
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2.9.7 Qualified Standards of Boiling
There is no oil pollution inside drum and headers.After rubbing out attached
matters, there should be no rust spot on metal surfaces.
2.9.8Notes for Boiling
a. During boiler boiling, boiler should keep at height water level to ensure parts
to be cleaned are immersed in cleaning liquor. Meanwhile, chemical liquor is
not allowed to enter into superheater. Cleaning of superheater and main
steam pipes should be done at the same time. If chemical liquor stays too
long in superheater, it can bring serious corrosion.
b. At anaphase of boiler boiling, the pressure has reached to 75% of working
pressure, all the changing and expansion of all parts should be paid attention,
especially pipes of heated surfaces, expansion joints, suspending &
supporting frames, boiler wall, boiler drum and header contacting parts
should be checked truckefully.
c. During boiling boiler, pressure bearing elements, seals of pipelines, air ducts
should be checked from time to time.
d. During boiling boiler, blowing down should be done symmetrically between
front and rear, left and right.
e. After boiler boiling, all the pipeline systems should be purged and flushed.
3 Start of the Boiler Unit

3.1Basic Working Principle of Boiler
3.1.1 Basic Construction
Shuangliang fully automatic WNS type boiler is a horizontal three pass fire
tube boiler with wet back. All the boilers of this type have the similar
construction with section, shown by following diagram.
(1)Burner (2)Ladder (3)Control panel (4)Base (5)Manual blow-down

(6)Water pump (7)Anti-explosion door (8)Rear smoke box (9)Smoke outlet
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(10)Back combustion chamber (11)Flue gas tube of second pass (12)Flue gas
tube of third pass (13)Shell pass (14)Continuous blow down (15)Secondary
steam outlet (16)Safety valve (17)Main steam outlet (18)Display and
control unit for water level (19)Front smoke box (20)Wave-form furnace
(21)Insulation for boiler casing
3.1.2Basic Control Principle
Shuangliang WNS type steam boiler is provided with control panel, which
incorporates the control and supervising means, such as PLC (programmable
logic controller), touch screen, program controller, water level controller, and
load controller (it is absent for boiler with stage regulated flame).
The water level controller is used to control the water level in the normal limits
by the stage or proportional control of feed water.
Program controller is applied to control the fuel combustion by control and
supervising the burner.
Load controller is used to adjust the combustion by the steam pressure signal,
which is transmitted to the program controller of burner. For boiler with stage
controlled combustion, flame is controlled by program controller, which signal is
fed from PLC.
All above-mentioned signals from control elements are fed to the PLC, which
analyses and determines the received signals. All control elements function
simultaneously the supervising function, and transfer the treated signals to the
touch screen, which will display the operation conditions of boiler, and control
the boiler by the touch screen,
Touch screen is a display to show the current conditions of boiler, and also the
screen to control the operation of boiler.
3.1.3Fuel Flow Process
a. Gas fired boiler. Combustible gas is fed to the burner through the valve train
adjusting the pressure, mixed with pressurized air in the burner head, and
fired in the combustion chamber with ignition by the high voltage spark.
b. Diesel oil fired boiler. Fuel oil is pumped to the burner, mechanically
atomization, and fired in the combustion chamber with ignition by high
voltage spark.
c. Heavy fuel fired boiler. It is more complicated for this type of fuel to be
supplied, atomized and started to ignite.
3.1.3.1Heating of heavy fuel oil
For transporting the heavy fuel oil and its full combustion, it should be heated
and line warmed to reduce the viscosity, which is large during normal
temperature, and to improve the flow ability.
Heavy fuel oil is heated normally by steam or electricity, and/or two means
simultaneously: electric heating is only for starting, and steam heating is used for
normal operation. Heavy fuel oil can be heated only by steam, if steam is
available in the starting stage. For steam heating system, in addition to fuel tank
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and daily oil tank, which are equipped with electric heating elements, the pipeline
also warmed by steam. In addition to that, before entering the burner, an
additional steam heater is provided. For starting with electric heating, in addition
to the daily oil tank, which is equipped with electric heating elements, sometimes
an additional electric heater is provided before the entering the burner.
3.1.3.2 Starting of Boiler
For starting heavy fuel oil fired boiler, in the same house additional diesel oil
or gas fired boiler is provided to generate steam, which is used to heat the heavy
fuel oil for starting the boiler. The above mentioned boiler can be avoided, if the
starting steam is available.
For house with only a heavy fuel oil fired boiler is provided, the boiler will be
equipped with two system of fuel oil supply, the diesel oil and heavy fuel oil
systems. The boiler is started with diesel oil to generate steam, which is enough to
heating the heavy fuel oil. Then the boiler is transferred from firing with diesel to
heavy fuel oil, which meets the conditions of combustion. For shutdown the
boiler, it will be transferred from combustion with heavy fuel oil to with diesel oil.
Boiler can incorporate both electric and steam heating measures, while for
starting the boiler, heavy fuel oil is heated by electric means to the temperature,
under which the fuel can flow and be ignited. The boiler is transferred to the
steam heating, if it is adequate for heating the fuel. After the boiler shutdown, the
fuel supply piping of boiler should be purged by steam.
3.1.3.3 Atomization Method
For heavy fuel oil fired boilers different atomization methods can be used for
sorts of fuel. For Shuangliang WNS boilers, mechanical atomization is used for
fuel oil #60 and less, rotating cup or steam atomization is used for fuels # 60-200,
and rotating cut atomization for fuel more than #200.
3.1.3.4 Ignition Type
Heavy fuel oil fired boiler is usually provided with heavy fuel oil combustion
system and additional ignition system with diesel oil, as the heavy fuel oil is
difficult to be ignited. In the mean time, Shuangliang boiler is equipped with
heavy fuel oil system and additional gas ignition system.
For boiler with oil and gas firing, the burner is a combination of oil burner and
gas burner. But the oil/gas burner can be used only oil or gas, and cannot be
operated with oil and gas simultaneously. The mechanism of combustion is
similar to the above mentioned.
Heat produced during combustion is transmitted to water in boiler shell
outside the furnace mainly by radiation and to water in the second and third
passes from high temperature flue gas by convection. Flue gas, given up heat, is
discharged outside through chimney.
3.1.4 Water Vapor Process
Softened feed water (or deaerated feed water in some cases) is pumped into
boiler shell from upwards. Water in the boiler forms two symmetric turns in
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relation to the central line as the heating surface of boiler is arranged
symmetrically, and natural circulation of water is formed because of the weight
difference of water. Boiler feed water is heated and raised to form vapor-water
mixture, from which vapor flows to the main steam piping through steam water
separator, and becomes saturated at the outlet valve in the main steam piping.
The water level in the boiler is controlled automatically. For boiler with
capacity of 4t/h and more, the water level is controlled by combined means:
proportional and multi-stage type. The proportional control is used normally, and
multi-stage type control is used only for emergency, when the proportional
control is failed. For multi-stage type control of feed water, a by-pass valve
should be opened, while the electric feed water regulating valve should be closed.
For boiler with capacity of less than 4t/h, only the multi-stage type regulating is
applied.
Schema of water circulation is shown in following Figure.
3.2 Preparation before Starting the Boiler

Before the starting of boiler, the following items should be follow:
a. Check the gauges and instrument for correct work.
b. Check the pressure controllers on the water and steam piping, fuel pressure and
temperature controllers on the fuel piping for set values.
c. Before starting, the water and oil pumps should be vented to ensure that they
rotate without cavitation and burning of pumps.
d. Check the gas pressure. Inspect the gas piping for leakage. Boiler can be put
into operation only after the boiler had been leak tested with satisfactory
results.
d. Check oil tank for oil in it, and ensure that the piping is leak free and without
clogging.
e. Ensure that there is enough fuel for ignition of heavy fuel oil.
f. Before operation the heavy fuel oil should be heated.
g. Before operation reset the programmable controller for burner.
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h. Check the tank with soft water, and open feed water valve, confirming
presence of water in the tank.
i. Check the feed water to meet the specification.
j. Check the water softener for its correct work.
k. Check the dosing unit for its correct work.
l. Check the chemical tank with chemicals in it.
m. Check the absence of any abnormal in the boiler house.
3.3 Notes to Operation
a At any time, when the combustible gas alarm unit gives alarm, it is forbidden to
start the boiler or make spark. Stop the boiler and check it, if the boiler is
operating during such conditions.
b Do not repeat ignitions many times, if the boiler cannot be ignited or abrupt
cutout of flame during operation of boiler.
c Stop the boiler and analyze the cause, if the trouble occurs during operation of
boiler. Contact the Shuangliang Co., if it cannot be solved by yourself.
Note: The normal standby conditions and shutdown of boiler due to trouble
should be differentiated.
d Observe the fans, water and oil pumps for their normal stable work and without
abnormal noise and vibration. stop operation of boiler and check cause, if
trouble occurs.
e Observe the oil and gas pressure gauges for their correct readings and without
deviation from normal values. Stop the boiler, check for leak, and analyses the
cause.
f Observe the steam and feed water pressure gauges for their correct readings and
without deviation from normal values. Stop and analyze the cause, if the
pressure is abnormal. The main steam valve should be opened slowly, when the
pressure in the boiler is increased to 0.4-0.5MPa.
g Observe the water level in the boiler for its normal value and without great
variation. Stop boiler and analyze the cause, if the water level is changed
considerably.
h For boiler with heavy oil as fuel attention should be paid to the following:
a) The oil types used should be as close as possible, otherwise, the burner set values
should be adjusted, if new oil is different from that of used one.
b) Oil pressure and temperature set values should be kept unchanged, the
temperature of oil preheater in the piping can be changed according to the type of
oil used.
c) For heavy fuel oil fired boiler house, the electric oil heater is just used for starting
ignition, or temporary application, and cannot be used as constant heating means.
d) In the boiler house the heavy fuel oil tank can be installed with oil temperature
not higher than 90℃, and heating temperature of oil in the heavy fuel oil storage
25
tank should be 5℃ less than boiling temperature under local atmosphere, and 10℃
less than flash point of oil. The lower temperature from above two values should
be taken as reference.
e) Oil in the tank should be stored not more than 85% of its volume.
f) The steam pressure should be 0.6-1MPa, when steam is used to purge the heavy
fuel oil piping.
g) For boilers manufactured in our Company, the gun type burners are used. While
the heavy fuel oil is #200 or less, the viscosity to the nozzle is 15-20cst, oil inlet
pressure to the oil pump is 0.06-0.6MPa. Also the steam atomized burners are
used with steam pressure of 0.6MPa (for oil less than 200# rotary cap type
burners also can be used.); The rotary cap burners are used for oil with viscosity
more than 200#, while the viscosity of oil before entering the burner should be
less than 45 cst at temperature about 120℃ and pressure of 0.2.-0.35MPa.
Note: cst is an unit of kinetic viscosity, 1cst=1mm2/s. At certain temperature, kinetic
viscosity Vt can be changed to conditioned viscosityE by the formula:
Vt=7.31E-6.31/E in unit mm2/s.

h) Boiler can be ignited by LPG or LNG with pressure of 400-1500mmH2O.
i) Water quality should be analyzed periodically to keep it in the good limits. Boiler
should be drained periodically, with blowdown of constant quantity of water to
meet the requirements.
j) Blowdown of boiler water should be done only under light load and under severe
control.
k) Blowdown should be stopped, if water hammer, or piping vibration, or other
conditions to impair the normal operation of boiler occurs.
l) Two or more boilers are not blown simultaneously, when two or more boilers are
connected into common drain piping.
i Observe the combustion to ensure the optimum conditions of firing with the
satisfactory ratio of fuel to air. Following criteria are listed for reference:
a) For oil fired boilers:
Black flame. Black smoke from chimney means insufficient air. For that, air
flap should be opened additionally.
Orange flame. Orange flame fills all the volume of furnace, smoke is
colorless and transparent, means the full combustion.
White flame. White flame with sparks at front and white smoke from chimney
means too big quantity of air in combustion, the air flap should be closed
additionally.
b) For gas fired boiler:
Red-yellow flame and black smoke from chimney means air is too small.
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Flame with central red-yellow tint and blue periphery fills all the volume of
furnace, smoke is colorless and transparent, means the full combustion.
Flame with distinguished blue, and white smoke from chimney, means too big
air ratio.
For setting the data, such as flap opening, gas pressure, and so on, see report of
starting and commissioning of boiler.
j Stop boiler immediately by cutout the electric power supply in the following
conditions:
a) Programmable logic controller (PLC) is failed to communicate, as the following
conditions occur:
Time displayed on the touch screen did not change.
Touch screen displays the same graph and is not changed by pressing
the key. No effect by pressing any location at the touch screen.
All operating parts of boiler stop their operation without any
indication of trouble. Or all the parts stop operation, exclude the
combustion system is working, and no indication of trouble.
b) No feed water owing to the failure of water pump or feed water system.
c) The water level in the boiler is lower than the lowest visible limit of water gauge.
d) Water level is decreasing though the water is added continuously.
e) All the pressure gauges and safety valves located on the steam space are failed to
work.
f) Damage of elements of boiler tends to endanger the personnel safety.
3.4 Operation Method for Boiler
Shuangliang boiler is the fully automatic intelligent boiler with touch screen as
man-machine interface. It is easy to be operated with the following functions:
a. Display in real time. Display the operation flow curve, operation data, troubles
and troubleshooting.
b. Starting and commissioning. Starting the boiler in single steps or for operating
commissioning.
c. Protected by password. To be protected from intervention by unauthorized
person.
d. Automatic start or stop. Set the automatic start/stop operation time of boiler.
e. Automatic changing over of screen. To change-over operation graph
automatically, if no operation of touch screen in the predetermined interval of
time.
f. Record of operation history. Record the troubles information and main operation
history actually.
Note: The digits displayed on the following graphs of touch screen for
Shuangliang boiler are just examples, not the set values from the manufacturer,
and even these graphs are subject to change without notice also.
Operation procedures for touch screen are as follows:
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3.4.1 Entering the Operation
a. Connect power supply to the touch screen, and display the graph
“Welcome”, as shown in Fig. 1.
b. Display the graph “Notes” of Fig. 2 with time lag of several seconds.
If press the key NO in this graph, then it is not possible to enter the operation
graph, as shown in Fig.3.
If press the key YES in this graph, then display the graph “Enter the
password”, as shown in Fig 4.
c. Enter the correct password in the Fig.4, then entering the operation
graph.
Entered password should be confirmed, or the input will be without effect.
Key Delete is used to delete the input, but only one symbol by one pressing.
Key Clearing is used to clear all the inputs by one pressing.
Note: Password “1234”is set in Shuangliang, but can be changed by
customer.
Fig.1 Fig.2
3.4.2 Operation Graph
Input the correct password and confirm it, then enter the operation graph,
which can be used to operate the boiler. Operation graph will be changed in
relation to the used fuel in the following manner:
The main function keys are similar in the operation graph, no matter which
type of fuel is selected. They are described as follows:
Fig 3 Fig 4
The operation graph displays the operation data schematically in dynamic
conditions, such as steam pressure, flame size, operation conditions of fan, oil
pump (or gas flap) and water pump, and recent conditions of boiler. The graph
permits to control the operation of boiler. The light flashes at the left side indicate
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the operation condition of boiler.
a Press the key START, and boiler enters the fully automatic operation conditions.
Note: Shuangliang WNS boiler equipped with control panel, where the
programmable controller is installed. The boiler can be started only when the
controller is at the position “START”.
b Press the key STOP, and boiler will stop its operation automatically.
Fig 5 Fig 6 Fig 7

c Press the key PROTECTION, and boiler will enter the condition of to be
protected. It means, that the boiler will not be operated with pressing any key by
unauthorized person, unless the correct releasing password is entered.
d Press the key MAIN MENU, the graph of main menu will be displayed .Show in
Fig8.
Fig 8 Fig 9 Fig 10

e Troubles experienced in Shuangliang boilers and their causes are stored in the
control system. When trouble occurs, it will be sprung out with the possible
causes to guide the operator, stop the operation of boiler and gives alarm by bell
rings.
Note: In any case when trouble occurs, it will shutdown the boiler with
alarm, but normal stop will take place without alarm.
As a trouble, the abnormal cutout of flame in the diesel oil fired boiler is
described as follows:
Press lightly the key Clearing or HELP, alarm will silent.
Press the key Maintain guide in Fig 8, it will be sprung out with main
causes for trouble, as shown in Fig. 9 and Fig 10.
Press the key Menu, then display the graph of Fig 8. .
Note: For trouble of burner, see the trouble location display on the
programmable controller.
When the trouble is corrected in accordance with the information of cause
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by pressing the key in Fig 9 or Fig 10, then display the operation graph. Press
the key lightly, boiler will be put into operation automatically.
Note: The trouble should be corrected manually, and press the reset
button on the program controller (this is for diesel oil and gas operated
boilers, no manual intervention is needed for heavy fuel oil fired boiler), then
to start boiler operation.
f F. Shuangliang boiler is provided with the function of standby, as indicated by
Fig. 9 or Fig 10.Boiler will stop operation, when pressure in boiler is over the
highest set value. This is a normal condition, when no alarm will be given and
indication about overpressure will display. Boiler will re-start, when the pressure
drops to the lower limit without manual intervention.G. Graph on the touch
screen will be changed to the operation graph, if no operation of graph in the set
time interval during normal operation of boiler.
3.4.3 Main Menu Functions
Fig 11 Fig 12 Fig 13

Press the key MAIN MENU, touch screen will display the graph of main
menu, which will be a little different in relation to selected fuel.
This graph is needed, when fuel is changed from one type to the other by
pressing the suitable key on then screen. Close the valve on the original fuel
supply line at the same time.
Fig 14 Fig 15
For implementing this function, you should select YES (either YES or NO
can be set), and provide for that function with some hardware, such as MODEM
connected with PLC, and direct dial telephone set, connected with that
MODEM.
The WNS type boiler is provided with this function to prevent the damage of
boiler from inadequately expanded packaging due to quick rising the
temperature of boiler. PREHEATING BOILER can be implemented by pressing
the key MANUAL CONTROL or SYSTEM CONTROL.
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If the SYSTEM CONTROL is chosen, then boiler will be ignited and
warmed in accordance with the preset program, and cannot be controlled
manually, and keys ▲ and ▼ will be not effective.
If MANUAL CONTROL is chosen, then operation of boiler will be
controlled manually. It is recommended to use this preheating procedure. The
keys ▲ and ▼ represent the increasing and decreasing the flap opening and
the big and small fire respectively.
Fig 16 Fig 17……………Fig 18

a Press the key System time adjustment, it will display the graph shown in Fig. 16.
a) If customer wants to set time of the boiler, then he can select Stop for SETUP,
and set the date and time.
For time setting, press the key HOUR, set the required hour by the digit keyboard
in the right side, then press the key CONFIRM. For setting the minutes, the
procedure is similar: press the key MINUTE, enter the digits by the keyboard on
the right side, and CONFIRM it.
For setting the rest days in a week, the procedure is take Monday as digit 1,
Tuesday as 2, and so on for other days. Saturday will 6 and Sunday will 7.
You can set the rest days as 6 and 7, if you are rest in these days, or you can left
blank, then all these days are not rest, or you can only set one day as rest, and left
the other days blank.
b) You can for the key DOES BOILER OPERATE IN REST DAY choose YES or
NO. You can choose YES, if you want the boiler operate in rest day.
c) Or you can choose NO for this key, then all the keys for setting will lose function.
d) Press key Clearing, all set values will be cleared.
e) Press the key HELP(), it will display the graph shown in Fig.17.
Note: Time should be corrected, if the “system current time” not meet
the actual time (with accuracy to minute).
f) The correct procedure is as follows: Input the correct digit of time in the frame
before the year, and press CONFIRM, then correct year is obtained. Correct the
month, day, hour, minute and second in the similar way as for year, and then you
get the correct system time.
g) Press the key Clearing, then all the input digits will be cleared.
h) Press the key MENU, then the screen will return to the graph of main menu.
i) Press the key MENU, then the screen will return to the graph of main menu.
Fig 18
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j) In the Fig.19, if you press the key PAGE DOWN, then the next page of table
records (Fig. 20) will be displayed.
k) In the Fig. 20, if you press the key PAGE UP, then the fore page of table records
(Fig. 19) will be displayed.
l) If the customer wants to change the password, then you input the new password
(maximum 4 digits, and minimum 1 digit). First press the lower key CONFIRM,
and then press the upper key CONFIRM,. Then repeat all the process of changing
password again.
Note: Place the zero “0” in the first position, this digit zero is not effective, for
instance, the 0123 and 123 is equivalent.
m) Input the new password, and press the key CONFIRM. If the new password
repeats the password, which already input, then it will display the graph shown in
the MENU. If the new password is wrong, The customer is required to repeat all
the process of correct password in the right way.
n) The customer can operate the boiler without password, if four digits “0” are
entered.
Fig19 Fig 20 Fig21

Note: In addition to the above-mentioned functions, Shuangliang boilers can be
parallel operated, commissioned in single steps or in operation mode. All these
functions should be realized with the help of Shuangliang Service engineer, and not
changed by customer.
4 Supervision and Regulation during Boiler Operation

4.1Main Task of Boiler Operation Regulation
a. Keep boiler vapor within a rated range, overload operation is not allowed.
Operation with decreasing pressure or exhausting steam can be done for low
load requirement of steam users.
b. Keep a stable steam temperature and steam pressure.
c. Regulate water level in time and feed water evenly to keep a normal water
level.
d. Ensure safe operation of the boiler unit.
e. Keep a good combustion to improve boiler efficiency.
f. Ensure a qualified steam supplying.
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4.2Main Parameters and Range of Boiler Operation Regulation
a. Boiler evaporation amount：20t/h；
b.Superheater steam pressure：1.226MPa；
c.Superheater steam temperature：200℃；

d. Drum water level:
e. Furnace negative pressure：
f. Make-up water tank water level：0±800mm；
g. Superheater flue gas inlet wall temperature: 465.319℃
h. Superheater flue gas outlet wall temperature: 413.533℃

4.3Boiler Water Level Regulation
a. Supervise feeding water pressure; the drum pressure should be higher than
0.5MPa, otherwise feeding water pressure should be increased.
b. During normal operation, drum water level should be kept within 0±50mm.
c. Pay attention to steam water flow difference and basically keep steam flow and
water flow in balance. Regulate water level with emergency drainage valve
when water level is abnormally increasing.
d. When water level changes a lot, regulation should be done to solve it; if the
water level recovers, decrease the regulation amount and basically keep steam
flow and water flow in balance.
e. Supervise water level automation, if any abnormity occurs, change automation
to manual operation immediately. Water level should be regulated manually
under accident state or when load is unstable.
f. Indications of drum local water level indicator and remote water level indicator
should be compared periodically. If the indications are not the same, the
rightness of drum water level should be validated. If the local water level
indicator is not right, I&C personnel should be informed to clean it as soon as
possible.
4.4 Steam Pressure and Steam Temperature Regulation
a. During operation, regulate boiler evaporation according to the requirements of
steam users.
b. Boiler steam temperature and steam pressure should be kept relatively stable
for measuring normal parameters of supplying steam.
c. Steam temperature adopts spray attemperator regulation, put attemperator
water into operation and regulate attemperator water regulation valve to
ensure steam temperature within a permit range. Attemperator regulation
33
valve can also be regulated manually.
d. During operation, regulate boiler steam pressure and steam temperature
according to load and keep superheater steam pressure at 1.226MPa and main
steam temperature within 350±20℃. The temperature of attemperator and
depressor should be controlled within regulated range.
e. Attemperator water amount should be used reasonably and attemperator flow
should keep in stable. Regulate attemperator water amount according to steam
temperature changing, great increase and decrease is strictly prohibited.
f. Both steam temperature regulation and wall temperature control with
attemperator should be considered to prevent pipe wall of superheater from
operating with over temperature.
g. If there is any steam acute changing, reasons should be found out and regulate
it as soon as possible.
h. When steam temperature rising is out of control, drum pressure should be
decreased properly.
i. During operation, steam pressure and steam temperature should be supervised
according to indication conditions of all meters to avoid over temperature and
over pressure due to failures of meters.
j. Forecasted regulation should be done well to ensure steam temperature not
exceeding regulations.
4.5Boiler Blowing Down
a. During boiler operation, continuous blowing down should be done to make the
boiler qualified. Blowing down amount should be decided according to
analyzing value of boiler water. Boiler operation personnel should be
informed by chemical operation personnel to operate the continuous blowing
down valve.
b. In order to supplement insufficiency of continuous blowing down and
eliminate sediment inside the boiler, periodic blowing down should be done to
water drum and all the headers.
c. During normal operation, periodic blowing down should be done at latter night
shift; blowing down of headers should be done as soon as possible to avoid
affecting water circulation.
d. Periodic blowing down should be done in sequence of circulating loop;
blowing down should not be done to a second circulating loop at the same
time.
e. During periodic blowing down, water level should be increased to highest
water level; water level changing should be supervised during blowing down.
It should be ensured that water level does not decrease to be lower than lowest
water level.
f. During blowing down, blowing down pipelines should be preheated slowly to
avoid water impact. If there is abnormity, blowing down should be stopped
immediately and continued after defects cleaned.
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4.6 Boiler Soot Blow
a. Chief operator should be informed before soot blowing, which only can be
done after chief operator’s approval.
b. Soot blowing should be done in turn according to flue gas flow direction.
c. Boiler combustion should keep stable during soot blowing and proper negative
pressure should be added to avoid gas spewing to outside.
d. To contact with maintenance personnel for defect cleaning if any soot blower is
in fault during soot blowing; and steam source can not be stopped at this time
to avoid burning of soot blowers.
e. After automatic opening of soot blower steam valve, check whether this is
steam entering into soot blower or not immediately, if there is no steam; exit to
avoid burning the soot blowers.
f. No open of watch holes for watching combustion is allowed during soot
blowing.
g. If there is damage of soot blowing device or accident in boiler, soot blowing
should be stopped immediately.
5 Stop of Auxiliary Boiler

5.1Boiler Normal Stop
a. Boiler unit can only be stopped after receiving shift manager’s formal notice
that clarifies the time and mode of stopping the unit (stop for maintenance,
stop for standby); the operators on duty should prepare for stopping unit.
b. A complete check should be done to the boiler equipments before stopping the
unit; defects that found should be recorded well.
c. Before stopping the boiler, drum mica water level indicator should be
compared to prove the rightness and reliability of the low position water level
indicator.
d. A complete soot blow should be done to the boiler.
e. Blowing down should be done to cooling water wall header and economizer
header to ensure smooth of water discharging pipes and emptying boiler water
after boiler stopped.
5.1.1Operation Process of Stopping Boiler
a. Decrease oil inlet amount and control steam pressure speed; decrease boiler
load properly and decrease air inlet amount relatively.
b. Cut off feeding water automation and keep drum water level by manual
regulation and close all the check valves of attemperator water.
c. Close regulation valve and inlet oil & oil returning valves; the boiler
extinguishes.
d. After 4 minutes of ventilation, close air valve of burners and dampers of IDF
gradually, stop FDF. 45 seconds after stopping FDF, then stop IDF and close
all the air valves and dampers.
35
e. After 1 minute, the system recovers automatically.
f. When steam flow is at zero, close main steam valve, open superheater drainage
valve and cool the superheater. Close blowing down valve & sampling valve
and close dosing valve.
g. After stopping steam supplying, continue to feed water to boiler and stop when
water level is at maximum level of +50mm; stop the feeding water pump and
close feeding water valve, open re-circulating valve of economizer and keep
the water level.
h. When boiler steam pressure is higher than 0MPa, boiler equipments should be
supervised continuously.
5.1.2 Cooling Process after Stopping Boiler
a. Within 4～6 hours after stopping the boiler, close all the manholes, flue and air
duct dampers to avoid acute cooling of the boiler.
b. After 4～6 hours, open the flue damper and feed water & discharge water once
respectively if it is necessary.
c. After 8～10 hours, feed water & discharge water once again. If cooling speeds
up, IDF can be started, increase water feeding & water discharging times,
otherwise IDF is not allowed to start for cooling.
5.1.3 Boiler Water Discharging
a.When steam pressure decreases to 0.1MPa, open air valve; water can be
discharged when water temperature is under 100℃.
b.If hot boiler water discharging is adopted and when steam pressure decreases
within 0.3～0.5MPa, discharging water with pressure is adopted. Surplus heat
of the boiler is used for drying the boiler pipes to achieve aim of dry antisepsis.
5.2 Operation Process of Emergency Stop
a. Close oil gun stop valve.
b. Maintain drum water level; close all stop valves of attemperator water.
c.After 5～10min of ventilation, stop IDF & FDF and close its inlet damper.
d. If the boiler stops due to ‘four pipes’ explosion, IDF may keep in operation and
stop the IDF after steam are completely exhausted.
e. If there is re-combustion in flue, IDF & FDF should be immediately stopped at
the same time, all the flue dampers and air duct dampers should closed.
f. Stop chemical dosing, close boiler main steam valve, open superheater
drainage valve or vent steam exhausting valve.
g. After stopping steam supplying, open re-circulating valve of economizer
36
(except for boiler serious water shortage, pipe explosion of cooling water wall
and economizer).
h. Except for accident of serious water shortage, generally water should be fed to
boiler continuously to maintain normal water level.
i. Report to shift manager after accident, and records should be taken.
j. During boiler emergency stop, supervision and regulation of steam pressure
and water level should be strictly paid attention. During boiler emergency stop,
load of boiler in failure should be decreased rapidly. Steam pressure must not
be too high; if steam pressure increases suddenly, there might be false water
level. Feeding water should be regulated rightly and timely to keep normal
water level.
5.3 Maintaining after Boiler Stop
Item 197 of “Procedure of safety inspection for steam boilers” requires, that
the corrosion protection measures should be taken for boiler during its shutdown
period.
As all know, the corrosion of boiler water and steam system is even severe
than that of boiler during operation, and will impair the operation life and leads to
potential risk of unsafe operation. So the corrosion protection measures should be
taken for boiler, which will stop operation for long time.
In addition to the measures taken by th user for the water and stream systems
outside the boiler, the following means should be performed for the boiler itself:
5.4 Heating to dry
In case of shutdown of boiler operation, drain water from boiler, and open its
bleeding, when boiler water temperature is decreased to 100-120℃. When water
is drained, boiler itself will be heated to dry, and close all the valves connected to
the atmosphere, when the boiler is cold down and no repair work will be done for
the boiler.
This method is suitable to the boiler, which will stop operation a short
period(within a week0 or for maintenance.
a. Charging of Nitrogen
When the boiler is shutdown, it will be drained and charged with nitrogen with
purity of better than 99% in its shell side. Boiler is charged with nitrogen to its
pressure higher than 0.05MPa, while all water and steam valves should be kept
closed and sealed against leakage. The nitrogen pressure in water and steam
systems should be maintained and periodically checked for leakage of nitrogen
from boiler.
The nitrogen pressure should be maintained by additional charging of nitrogen.
This method can be used for boiler shutdown for rather long period (more than 3
months) or protection of boiler from icing for the freezing zone. The nitrogen
will be discharged to atmosphere, when the boiler is required to be start for
operation again.
b. Keeping of Desiccants
37
When the boiler is shutdown and drained in the hot condition to dry the boiler
by the rest of heat of boiler. When the boiler is cold, put the desiccants (such as
anhydrous calcium chloride, silica gel, quicklime and etc in the rate of 1-3kg/m3
of boiler volume) in small packages into the boiler through inspection holes of
boiler. The packages should be distributed in the internal space of boiler, and van
be taken out , when the boiler is required to start again. During this period all the
connections to the outside should be closed, and the packages should be checked
periodically (for instance every month), and renewed.
This method can be used for boiler shutdown for rather long period (more than
3 months) or protection of boiler from icing for the freezing zone. The packages
with desiccants will be taken out from the boiler, which will be washed out, when
the boiler is required to start operation again.
c. Keeping the Feed Water Pressure
When the boiler is shutdown, charge the fully deaerated feed water into the
boiler, close all the valves on the water side to protect it from ingress of air.
During this period the water side pressure should be maintained more than
0.3MPa by the feed water pump, and water will be changed, if the oxygen
content is more than satisfactory. This method is suitable for application for the
shutdown period within 1 month. It can be used within 3 months, if the water is
added by sodium sulfite in the rate to keep residue of 5-10mg/L sodium sulfite in
water.
The measures for protecting the boiler from freezing should be taken, when
this method is used in freezing zone.
d. Gas Phase Corrosion Inhibitor
Gas phase corrosion inhibitor includes inorganic ammoniums and organic
amines, such as ammonium biphosphate, urotopine, ammonium benzolformate,
truckbonate cyclic ethylamine and etc. The application of gas phase inhibitors is
similar as that of desiccants. Water is drained from boiler at hot condition to dry
the boiler. The inhibitor will put into the boiler in bags to be distributed in
different locations in the boiler space in the rate of 50-100g/m3. The packages
should be taken out for starting the boiler operation. During this period the boiler
is kept in closed conditions.
This ensures the closed conditions effect for about 3 months, if the sealing is
tight. The method can be used for boiler shutdown for rather long period or
protection of boiler from icing for the freezing zone. The packages will be taken
out from the boiler, which will be washed out, when the boiler is required to start
operation again.
6 Operating Procedures of Burner

6.1 Overview
Oilon RP-1600 ME is a fully automatic and adjustable heavy oil burner which
can burn heavy fuel or temporarily burn light fuel. The burner is suitable for fuel
oil (heavy fuel oil), its viscosity can reach 250 mm ²/ s (cSt) (+50 °C) at largest,
38
and can reach 650 mm ²/ s (cSt) (+50 °C) at largest when burning on the burner
with electromagnetic field. The fuel (heavy) feed into the burner should be
filtered before entering the pressurizing pump, and the filter may be max300m.
The burner’s minimum inlet pressure is 2200 kPa (22 bar). When heavy oil burns,
the atomization pressure is 2500 - 3000 kPa. (25 - 30 bar). The atomizing
temperature of oil must be set to ensure the viscosity of the oil in the nozzle
reaches the maximum 16 mm ²/ s (cSt). The preheater on the pressurizing device
makes the oil temperature rises to atomization temperature. Oil temperature is
controlled by an electronic controller.
The maximum adjustment ratio is 1:2, 5 (100% - 40%). Air and fuel ratio are
controlled by servo motor and complex regulator according to load requirements.
Control voltage is at 230 V -15% / +10%, 50 Hz, 1-phase, supply voltage is at 400
V, 50 Hz, 3-phase
Burning and flame monitoring are automatic. During burner operation, the
ambient temperature is 0 ... +40 C.
When burning heavy oil, the solenoid valve and the nozzle valve’s function is
guaranteed by incubator, which keeps the device at desired temperature. The fan
can be placed in a separate room, so that the noise will not affect the burner
operation. At temporary situation, the burner can burn light fuel, and the viscosity
is 4 - 12 mm ²/ s (cSt) (+20 °C).
Note: When burning light fuel, the preheater must be closed.
6.2 Burner Device Specifications
Burner model: RP 1600ME (voltage subject to Chinese standards, otherwise
the price will change)
Number of burners used by each boiler: one
Single burner maximum output power: 16.5MW
Burner arrangement: arranged at boiler front wall or top
Model: RP-1600 MEFuel: heavy fuel
Design specifications and
1 EN230
manufacturing standards
2 Model RP-1600 ME
3 Output power KW 3900-15500
4 Manufacturing plant Finland Oilon
Heavy oil, below
5 Suitable fuel
250cst/50℃
Suitable fuel heavy oil flow range Kg /
6 350-1400
h
7 Combustion efficiency 99.9%
8 Adjustment method Ratio adjustment
9 Turndown ratio 1: 3
10 Structure type Split nonunion fan
39
Noise (Host, at 1 meter position
11 82
without silencer) dB (A)
12 Burner body weight Kg 650
13 Emissions
Ringelman emittance ＜1
14 The main components
Name of
Name of plant
Name Name plant and place
and place of origin
of origin
Programmable L&S Programmable L&S
controller Germany controller Germany
L&S L&S
Air damper Air damper
Germany Germany
L&S L&S
Flame detector Flame detector
Germany Germany
Ignition SIEMENS Ignition SIEMENS
transformer Germany transformer Germany
Complex OILON OILON
Complex regulator
regulator Finland Finland
Heavy oil Heavy oil
CAL
temperature CAL Germany temperature
Germany
controller controller
Heavy oil gun and Heavy oil gun and
OILON OILON
choke choke
Heavy oil main LUCIFER Heavy oil main LUCIFER
solenoid valve America solenoid valve America
OILON OILON
Ignition device Ignition device
Finland Finland
Heavy oil flow OILON Heavy oil flow OILON
control valve Finland control valve Finland
Heavy oil back oil Heavy oil back oil
OILON OILON
pressure protection pressure protection
Finland Finland
switch switch
Oil pressure Oil pressure gauge
OILON OILON
gauge and oil and oil temperature
Finland Finland
temperature gauge gauge
OILON OILON
Oil check valve Oil check valve
Finland Finland
Air pressure DUNGS Air pressure DUNGS
protection switch Germany protection switch Germany
40
6.3 Burner Operation
6.3.1Burner Operating Principle
See figure No. C-397C
At fuel pass phase, solenoid valve (18) is closed, while solenoid valve (19) and
(6) are open. During this period, the fuel does not flow through the entire control
circuit but just reaches the head of the nozzle. The nozzle has been filled full with
fuel at pre-fuel-pass phase. Thermostat (5) controls the fuel temperature to make
it lower than atomization temperature by about 20 ℃. The fuel returns to the
pump through pressure regulator and the check valve (11).
After fuel pass finishes (when LPG burner is used), the solenoid valve (21)
opens, flame is ignited on the auxiliary burner, solenoid valve (18) opens the
solenoid valve (6) closes, and then oil pressure begins to function on nozzle
control circuit. The pressure acts on the connecting piston, so that the spring with
needle previously at close position releases, the nozzle supply conduit opens, and
in the pressure regulator, the return oil is at ignition position.
At full load, the atomization pressure is 2500 - 3000 kPa. (25 - 30 bar). The
spray needle completely disengages, and at this moment, the oil pressure in
control circuit is about 1800 kPa (18 bar), the return oil pressure in regulator (2) is
800 - 1000 kPa (8 - 10 bar) at ignition position and 1000 - 1200 kPa (10 - 12 bar)
at partial load. Return oil pressure depends on the position of oil pressure
regulator.
For safety reasons, mount a throttle piston on control circuit solenoid valve
(18), on which there is a ø1, 5 mm hole.
The piston can reduce the direct impact of strong oil flow on spring load piston.
If the burner is turned off, the solenoid valve (18) is closed, the solenoid valve (6)
is open, the control oil pressure is discharged, and the spray needle locks the oil in
the nozzle.
Note! When burning light fuel, the atomization pressure is about 2500 kPa (25
bar).
Figure No. C-397C
41
6.3.2The Operation of Programmer for Burner
6.3.2.1 Check the following items before initial start-up：

a Connected properly (motor turns right)
b Supply pipe valve opens
c Oil tank is filled with oil
d Regulating and control devices are set correctly
e Boiler room is adequately ventilative
f Boilers and devices are under working conditions
g Burner pump is ventilative
h Adequate oil pressure and temperature
6.3.2.2 Operation Process
In the control panel of Shuangliang WNS type boiler a control programmer is
installed to control and monitor the burner for automatic operation of
42
combustion.
Control programmer integrated with reset pushbutton, display window and
failure indicator (not lit, when no failure occurs). Rotating indicating disk
displays the condition of burner during the combustion process through the
display window. Control programmer makes the failure indicator lit and alarm,
rotating indicating disk stopped at the position, where the failure occurs, and cut
the oil supply immediately, when failure occurs. Correct the cause of failure
manually, press the reset pushbutton, the rotating indicating disk turns to position
a, and failure indicator goes out, then press the start pushbutton on the touch
panel to start the boiler.
When the failure occurs, in addition to the failure indicator, the touch panel
displays the failure information simultaneously. Use the spring out menu to study
the cause of failure. For more information see the operation instruction of burner.
Note: If the cause of failure is not corrected, control programmer cannot be
reset, and the boiler cannot be started. When the boiler cannot be started due to
some failure, open the control panel to check the flashing of failure indicator of
control programmer, and not to repeat the starting of boiler. Press the reset
pushbutton not longer than 10 sec. It is to be noted, that for heavy fuel oil system
no matter the failure occurs or not, no manual operation is needed.
The positions, indicated by the rotating indicating disk, show the conditions of
burner and the failure. The positions mean:
a Program start position, normal shutdown position, return to the program start
position, when the cause of failure is corrected.
a-b Process of programmed starting of burner.
b-b’ The program free operation zone from starting to automatic shutdown,
including some time for adjusting the load.
b’ The operation position of program.
b(b’)-a Repeat purging process after normal shutdown of boiler.
43
6.4Fuel Oil Cycle
6.5 Burner Adjustment

6.5.1Oil Mass Adjustment
Servo motor (2) controls the oil mass regulator (5), so that the return oil is
adjusted according to the load demand.
At partial load, oil mass regulator (5) opens, the oil mass in the valve is
maximum, and the return oil pressure and nozzle load are enough. At full load,
regulator (5) is closed, the oil mass in the valve is minimum, the pressure is
maximum, and regulating cam (4) adjusts air flow to make it matches the fuel
amount (see "combustion air adjustment, regulating cam")
Note! Adjustment must be checked in accordance with exhaust gas analysis.
44
1. Air damper
2. Servo motor;
3. Regulating lever,
air;
4. Regulating cam,
air;
5. pump regulator;
5.1. Measuring unit;
5.2 shaft;
A. Select shaft;
B. Arc shaft;
C. air
1 Regulating 10 Steam. Hexagonal

cam; screw (tightening
2 Regulating regulation);
guide rail; 11 Steam hexagonal
3 Spring guide screw;
rail; 12 Hexagonal screw
4 Tightening (tightening regulation);
device; 13 Steam hexagonal
5 Spring strip; screw;
6 Regulating 14 Hexagonal nut;
screw; 15 Tightening nut;
7 Regulating 16 Washer;
screw; 17 Spring;
8 Regulating 18 Spring pad
screw;
9 Regulating
screw;
45
6.5.2 Combustion Air Adjustment, Regulating Cam
Throttle damper opening is controlled by the deformation of regulating cam
spring. The deformation may be adjusted by adjusting guide rail and adjusting
screws. The force of spring on throttle damper is transmitted by adjusting lever
to pass by. Regulating cam controls air flow to make it matches the fuel amount.
As for spring installation, check every point of regulating cam at partial load
and full load according to exhaust gas analysis.
Loosen screws 10 and 12 to adjust, and then fasten the screws.
6.5.3 Burner Maintenance
To ensure reliable operation, clean the ignition electrode and check electrode
installation. Flame detectors should be kept clean. If necessary, clean the filter. If
the nozzles are worn or damaged, replace them. Clean the burner to prevent
moisture and suspended impurities, and keep the burner clean. Check the
combustion characteristics periodically according to exhaust gas data. Burner
should be inspected by special person at least once a year.
Keep boiler room clean and keep the door closed. Ensure there is enough
water (pressure) in the heating system. Periodically scrub blast furnaces and flues.
Periodically check whether the smoke baffle is adjusted correctly. Prevent water
splashing onto the burner. When necessary, clean the oil tank at least once every
four to five years.
Boiler room air freshener should be open. According to the local requirements,
check the safety devices of heaters and burners. Check whether the boiler and its
devices are under normal working conditions.
6.5.4 Burner Failure Status and Program
To resume operation when there is a failure, firstly check the following:
1) Check the power supply situation (control and power supply voltage).
2) Check to make sure the regulating and control devices are installed
correctly.
3) Whether safety devices are under normal running state
4) Whether does the burner get oil supply Whether is the oil valve open
Whether there is oil in the tank
If none of the foregoing items is the cause to the failure, check every
functional element of the burner. If the control device is at locked position (signal
light is on), reset it. When the master program has run to the start position, the
burner starts to work. Observe burner functional elements. Check the mark as it
suggests the possible types of failure. Measuring instrument can also be used to
identify failures. Attached figure.
No. Equipment Note Possible cause Corrections
Blower Main circuit Find the cause
motor / malfunction and correct
1 Motor
pump motor Motor overload is Check the
can not start slightly open installation,
46
work Fuse blown correct and reset
Motor contactor failure Reinstall or
Control circuit failure replace
Servo motor cam Replace
installed incorrectly or Find the cause
motor failure and correct,
check the control
device to replace
the control
device
Correct, replace
the servo motor
Servo motor can not
Blower
reach full load position
motor starts
of damper Replace
work and
2 Start failure - Servo motor failure Correct
remains at
- Cam installed Check and repair
pre-scavengi
incorrectly
ng phase
- Damper blocked
Pressure difference
Blower
switch installed Check and adjust
motor starts
incorrectly if necessary
to work, but
Impulse pressure Clean hoses /
Air pressure is locked
3 difference switch tube is tubes
is too low during or
not clean Replace
after
Pressure switch failure Clean
pre-scavengi
Fan is not clean Reload
ng
Motor rotation error
Fans begin
to work, but Servo motor can not
the program reach full load position
remains at of damper
pre-scavengi - Servo motor failure
Replace
ng phase - Cam installed
Correct
Fans begin incorrectly
Ignition Adjust according
4 to work Ignition electrodes are
failure to instructions
There is not clean or damaged
Replace
control and the insulation is
Replace
voltage from broken
control Ignition electrodes are
device to distant from each other
ignition Ignition cable damaged
transformer,
47
so the
ignition fails
and locks
after a short
time
Oil pump pressure is too
low, and the pump can
not be pressurized to
Fans start to
adequate Adjust, repair or
working,
Oil pump motor rotation replace
ignite and
is incorrect Reload
lock after a
Nozzle is clogged or Clean or replace
short time.
5 Flameless damaged Replace
Ignition
Solenoid valve failure Regulate LPG
nozzle can
Control circuit failure solenoid valve
not feed oil
The liquefied solenoid Replace
LPG
valve opening degree is defective parts
shortage
not adequate
- Solenoid valve failure
- Coil cable damaged
Fans start to Solenoid valve failure
working, - Solenoid valve failure
Replace
ignite and or coil cable damage
The main defective parts
lock after a - Control device failure
flame can Repair, clean or
6 short time Nozzle valve failure
not be replace
Nozzle can Booster pump or device
formed Replace
not feed oil failure
Reload motor
Oil pressure Booster motor rotation
is too low is incorrect
Incorrect burner
Flame
adjustment
forms, and
Dirty filters
when the Adjust
Nozzle clogging
burner runs Clean
Oil temperature is too
Flame to full load, Replace
low:
7 forms and it locks and Repair or replace
- Oil preheating unit
locks then restarts Check and adjust
non-movement or power
Flame the oil inlet
shortage.
forms, then temperature
- Low (lower) limit
close and
temperature is set
restart
incorrectly
Oil flows Oil flows Nozzle valve leak Clean, repair or
8
into the into the Solenoid valve failure replace
48
combustion boiler too Replace
chamber early
Flame detector position
is unreasonable
Flame detectors are not Move to the
clean correct position
Flame is too weak Clean
Flame detector Check the
Blower
malfunction adjustment of the
motor starts
Flame Control device failure burner
to work,
9 detector Flame detector Replace
flame forms,
malfunction malfunction Replace
and then
Control device failure Replace
locks.
Serious oil stain and Replace
truckbon in the burner Clean and adjust
head Replace
Flame detector failure or Replace
aging
Control device failure
The distance between
Replace if
atomization device and
necessary
nozzle is incorrect
Atomizer
Gas regulator or
burnout Adjust correctly
atomization device is
Serious oil Adjust
10 Burner head incorrect
stain and Increase air feed
Boiler room ventilation
truckbon Replace the
is inadequate
inside appropriate
Nozzle size or model is
nozzle
incorrect
Replace
Nozzle damaged
7 Boiler Water System

7.1Summary
For feed water of small type boiler the city water or well water is used. This
kind of water has the impurities, which leads to form scale, corrosion and water
truckry-over with steam, even impairs the operation efficiency, working life or
explosion of boiler. So, the management of water quality is a very important point
in the operation of boiler.
In order to prevent the effects of malfunction of water treatment facility,
GB1576-1996 “Water quality for low pressure boilers” formulates the clear
requirements to the water treatment method, the quality of feed and boiler water,
which should be realized in the practice by the boiler user.
49
Shuangliang WNS boiler requires the feed water be treated chemically outside
the boiler, and also by the dosing additives in boiler additionally. In addition to
that, dissolved oxygen and truckbon dioxide will corrode the boiler wall surface
both chemically and electrical-chemically. So for improving the life cycle of big
type boiler, the deaerator (especially for removing the oxygen) should be
provided.
For boiler equipped with the water treatment and dosing facilities, the
installation, operation and maintenance of facilities is illustrated in the instruction
manuals.
7.2Requirements to Feed and Boiler Water
The requirements to the feed water quality of Shuangliang WNS type boiler
are listed in the following table in accordance with GB1576-1996 “Water quality
for low pressure boilers” on the basis of chemical treatment outside the boiler:
Boiler
Item Unit Feed water
water
Suspended solids mg/L ≤5
Total hardness mmol/L ≤0.03
Total alkalinity mmol/L 6-24
pH *(25℃) ≥7 10-12
Dissoved oxygen mg/L ≤0.1
Dissolved solids mg/L <3500
SO32 mg/L 10-30
PO43 mg/L 10-30
Relativ alkalinity
(Free NaOH/dissolved <0.2
solids)
Oil content mg/L ≤2
Note:
a. The basic elements for hardness mmol/L is C(1/2 Ca 2+,1/2 Mg2+)
b. The basic elements for alkalinity mmol/L is C(OH-,HCO--, Co32)
c. The deaerator should be provided, if the boiler capacity is more than 6t/h , or
deaeration measures should be taken in case of corrosion, if the boiler capacity is
less than 6t/h.
7.3Management of Water Treatment and Dosing Equipment
For users selected the water treatment and dosing equipment from the supply
of Shuangliang Comapany, the following items should be checked truckefully
before the daily operation of boiler. Or the appropriate instructions should be
followed, if they use the equipment supplied by other companies.
7.3.1 Inspection of Water Treatment Equipment
a. Ensure the proper operation of water treatment equipment.
b. Check the soft water to meet the requirements.
c. Ensure the presence of salt in the salt vessel.
50
d. Ensure the passage of raw water through the water treatment equipment.
7.3.2 Inspection of Dosing Equipment
a. Ensure the interlocking of dosing pump with the water pump.
b. Ensure the enough chemicals in the dosing vessel, and fresh water be added
to prevent the air into the dosing pump, if the chemicals is not enough.
c. Ensure that air is removed from the dosing pump, and the suction head not
clogged.
Equipment specifications of chemical dosing system
No. Item Data
1 Type JY-1-3XJX-40/1.6
2 Metering pump type JX-50/4.0 3set
3 Metering pump power 0.37KW X3
4 Agitator power 1.1KW
Equipment specifications of add ammonia device
No. Item data
1 Type JY-1.0-3XJXB-50/1.0
2 Metering pump type JX-50/1.0 2set
3 Metering pump power 0.37KW X2
4 Agitator type GJ-2 1set
5 Agitator power 1.1KW
7.4 Dosing
The dosing liquor with chemical additives for Shuangliang boiler is yellowish
homogeneous liquid to prevent the new type of boilers from formation of scale
and protect boiler from corrosion.
The dosing amount: 0.04L (about 50g) dosing liquor per 1 ton of feed water.
The method of application: The dosing liquor is diluted by softened water when
mixed together. Then the mixed liquid is added to the dosing vessel, and pumped
into the boiler through dosing pump.
The dosing liquor is used in the following rate (the 20% of continuous
blowdown is taken into consideration):
Diluted
Dosing Diluted
Nominal Dilution liquid
liquor liquid
capacity,t/h rate required,
required, L/h required, L/h
L/24h
2 0.096 10:1 1.056 25.344
3 0.144 10:1 1.584 38.016
4 0.192 10:1 2.112 5.0688
6 0.288 10:1 3.168 760.32
8 0.384 5:1 2.304 55.296
10 0.48 5:1 2.88 69.12
51
8 Combustion System
8.1Summary
This chapter focuses on heavy oil pump and heaters. Heavy oil pump uses
YCB series arc gear pump, heater group model is PKYR1 ... 6. Heavy oil pump
and heaters heat and pressurize the fuel whose maximum viscosity is 650mm2 /s,
+50 ℃ before it enters the burner. Fuel should be filtered before entering the
pumps; the maximum allowable aperture of the filter is 400um; before fuel enters
pumps, the positive pressure 3-5ar is required. The parameters of other heavy oil
pumps, heaters and heavy oil filters PKYR5 are as shown below:
No. Item Place of origin Value Quantity Note
Heavy oil ALLWEILER
1 SPF40R46 1
pump Germany
(two groups
Electric 8×6KW standby,
2 OILON Finland 1
heater 400V 50Hz actually use
6X6 kW)
Heavy oil
3 OILON Finland 1
filter
Oil pressure
4 OILON Finland 25-30bar 1
regulator
Valves and
5 OILON Finland 1
fittings
Heavy oil
high and low
6 OILON Finland 1
temperature
protection
5.5kw
Oil pump
7 OILON Finland 400V 50Hz 1
motor
3000rpm
Oil
8 temperature OILON Finland PT100 1
sensor
Oil pressure
9 OILON Finland 1
gauge
8.2 HSFO Pump
8.2.1 General
YCB series arc gear pump is a kind of external gearing arc gear with latest
structure, and it is jointly produced by Shanghai Jiaotong University Department of
52
Mechanical Engineering Hydraulic Laboratory and our plant. The gear in the arc
gear pump has the gear shape formed with advanced arc plus other curves, so the
pump has excellent operating characteristics. Compared with traditional 2CY
involute gear pumps, the pump has such strengths as: small pressure fluctuations,
low noise, high efficiency, long life, etc. It is a kind of new energy-saving pump.
Arc wheel pump is suitable for the delivery of all kinds of lubricating oil fluid in
petroleum, chemical, shipbuilding, machinery manufacturing and other industries.
The temperature of petroleum, heavy oil, industrial light oil and other liquid should
not exceed 701 ℃, and the viscosity should be 5 ~ 1500cSt (centistokes). The pump
is not suitable for the delivery of oil that contains hard particles and debris or fiber
material. It is also not suitable for the delivery of highly volatile and low idle point
fuel, such as: gasoline, benzene, etc.
Standard pump has safety valve which can also be removed according to user
requirement.
Standard pump is mounted on the common chassis of cast iron or on the
common chassis made with welded steel, after flexible coupler is directly
connected to three-phase step motor.
Arc gear pump is installed horizontally or vertically, and can be designed into
other ways according to user requirements to adapt to different environments
8.2.2 Oil Pump Specification
No. Item Data
1 Type SPF40R46
2 Roated power 5.5KW
3 Working flow 4420kg/h
4 Head 25bar
5 Oil pump outlet flow 12mm2 /s
6 Outlet pressure 25bar
8.3Oil Tank Specification
No. Name Item Data
Design Pressure Normal
Working pressure nornal
Availably volume V=3m3
1 Heavy oil tank Steam heatng area S=2m2

electrical heating
5KW
power
Heating medium Heavy oil
mode of heating Electric/Steam
Design Pressure Normal
2 Light diesel oil Highest work
Normal
pressure
53
Design Temp. 80℃
Max /Minwork
50℃
temp.
Volum V=1m3
Net Weight 590kg
8.4 Heavy Oil Pump Operating Principle
Figure 1 illustrates the operating principle of gear pump. A pair of meshing arc
gears installed inside the casing, the front and rear covers of the gears are sealed,
the gears divide the inner part of the casing into two non-communicating cavities
A and B, and there are two holes on the casing to connect cavities A and B. When
the gear rotates in the direction shown in the figure, a pair of teeth in cavity A will
disengage, so that the volume of the cavity increases and forms partial vacuum,
and then the oil in the oil tank flows into cavity A through oil pipe and casing
under the action of the external atmospheric pressure. This cavity is oil suction
cavity. The oil intake into the teeth of cavity A rotate with the gear in sealed space
and flow into cavity A along the inner wall of the casing. Between the teeth filled
with oil in cavity B, the teeth meshing makes the volume of this cavity gradually
decreases and squeezes oil out of the teeth. This cavity is oil squeezing cavity.
When the teeth rotate continuously, cavities A and B will continue to intake oil
and discharge oil. This is the operating principle of gear pump.
8.5 Structure and Function
Figure 1. Gear pump operating

principle
1. rear cover; 2 gasket; 3 bearing housing; 4 bearing

seat;
5 driven shaft; 6 gear; 7 drive shaft;8 front cover; 9
flexible graphite; 10 gland; 11 pump; 12 safety valve;
Figure 2. Arc gear pump structure
diagram
This series pump has simple and compact structure. Separate pump and valve.
Easy to use and maintain. The main parts are made of high quality steel, through
54
precision manufacturing, so are reliable.
The oil pump has good self-suction characteristic, therefore does not need to
fill oil before opening the pump.
The oil pump is automatically lubricated by the fed oil, therefore there is
additional lubricant.
Pump: a pair of gears and four bearing seats are installed in the two holes on
the two parallel planes of pump 2. Installed above are safety valves. Front cover
and rear cover should be mounted. The flange on both sides is for connection use
by the user. Flange dimension should conform to AISO and DIN general use pipe
flange (Metric) dimension, and meet the foreign trade standard CBM flange
dimension of China State Shipbuilding Co., Ltd. Gears and shafts: gears adopt
helical gears, and combine with shaft to form shaft gear. Bearing seat and shaft
bushing (sliding bearing): bearing and shaft bushing assembled into a whole and
then mounted into the pump to support gear running.
Gasket: Gaskets will be placed on the surface between pump and front and
rear covers, to increase plane adhesiveness,
8.6 Pump Operation Method
Before initial operation of the pump, do check whether the piping system is
installed well, and make sure all valves on the inlet and outlet pipes are open.
Rotate the coupler manually, and check whether there is any abnormality. When
the pump is started, firstly short press the switch. Confirm the direction of
rotation, and after confirming there is no abnormality, press down the switch to
make the pump run. If the oil pump runs normally, gradually reduce the opening
of the control valve on oil discharge pipe, so as to regulate the desired pressure,
but the regulated pressure should not be more than the discharge pressure as
specified in the technical specifications. During continuous running of the oil
pump, observe the discharge pressure in the oil pump, and check whether the
shaft seal and vibration are normal.
8.7 Safety Valve
The safety valve of this series pump is installed as a separate unit on the pump.
If the user does not need a safety valve, we can provide special cover 29 to be
installed at safety valve position, as shown in Figure 3. The operating principle of
safety valve lies in controlling the start and close of oil pump with spring force.
The role of safety valve is that, when oil discharge pressure is too high and
exceeds the specified pressure of oil pump, or when there is a failure in oil
discharge pipe and the oil discharge pipe valve is closed, the safety valve will
open automatically, and the delivered oil will flow to the oil suction cavity
partially or totally, so as to avoid possible accidents. But safety valve should not
be used as flow control valve for a long time.
8.7.1Safety Valve Adjustment
In standard case, the total reflux pressure of safety valve is 1.5 times the rated
pressure. If you need low pressure, please adjust according to the following
method (see Figure 3)
55
Unscrew the cap nut and loosen the adjusting nut.
Counterclockwise rotate the adjustment screw, and gradually close the control
valve on discharge pipe, so see whether the back-discharge pressure is the desired
pressure. If it fails to reach the requirement after one adjustment, please adjust
several times.
(Note: after the back-discharge pressure is reduced, the pump will work under
rated discharge pressure and the oil pump flow will reduce. In addition, when
regulating the safety valve, it is only allowed to instantly close all control valves.)
After the adjustment, fasten the adjusting nut, then fasten the cap nut.
Safety valve shutdown is very simple: just cut off motor power. After pump
shutdown, close the control valve on discharge pipe.
8.7.2Safety Valve Discharge Value

No. Item Symbol Unit Value
1 Rated evaporation of boiler D Kg/h 20000
2 Rated pressure of boiler Pe Mpa 1

3 Degree of superheat Tg ℃ 50
Steam pressure P1 Mpa 1.1
Pressure correction factor Kp - 1
Drum Superheat correction factor Kg - 1
4 safety Hematocrit correction factor K - 1
valve A48Y-16
Safety valve model C DN100
PN1.6
56
Number of valves n 2
Safety valve runner diameter D1 mm 65
Safety valve runner area A1 mm2 6637
Safety valve theory emissions E1 Kg/h 19058
Steam pressure P2 Mpa 1
Pressure correction factor Kp 1
Superheat correction factor Kg 0.94
Hematocrit correction factor K 0.94
Superheat A48Y-16
5 steam Safety valve model C DN80
outlet PN1.6
Number of valves N 1
Safety valve runner diameter D2 mm 50
Safety valve runner area A2 mm2 1963
Safety valve theory emissions E2 Kg/h 4851
6 Total emissions E Kg/h 23909
9 Boiler Accident Handling

9.1Boiler Emergency Stop
9.1.1Conditions of the Boiler Emergency Stop
a. Fire extinguishing in boiler furnace.
b. Boiler water level is lower than lowest visible water level of water level
indicator.
c. Boiler water level is higher than highest water level of water level indicator and
can not been seen after water discharging.
d. All the water level indicators are damaged.
e. There is pipe explosion (including water pipelines, economizer pipes or
cooling water wall pipes) in boiler and it can not keep normal water level.
f. Main steam pipes are blown up, which is dangerous to human beings and
equipments.
g. There is explosion in furnace or flue, which makes the equipment seriously
damaged.
h. All the power supplies of I&C instruments are intermitted and can not be
recovered in time; the operators has no way to operate.
i. There is secondary combustion at flue of tail section and exhausting gas
temperature is increasing abnormally.
j. Safety valve does not actuate when the pressure exceeds actuated value.
k. Introduced air fan (IDF) or forced draft air fan (FDF) trips.
l. There is fire alarm in boiler house, which directly affects the safety operation of
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the boiler.
9.1.2 The Conditions of Boiler Manual Stop
a. There is leakage at cooling water wall pipes, superheater pipes, economizer
pipes and attemperator pipes due to different reasons, but the boiler can keep
running.
b. Metal wall temperature of heated surface or boiler main steam temperature
exceeds permit value, but it can not recover even after regulation by parties.
c. Boiler feeding water, boiler water or steam quality is seriously lower than
standard, and it can not recover even after regulation by parties.
d. Boiler brick in combustion chamber drops or the insulation part of drum,
headers and pipes contacting with gas drops.
e. There is serious defect at IDF and FDF, which can not be clean without
stopping the boiler and may result in serious equipment damage.
f. Operation power supply is intermitted and can not be recovered for a long
time.
9.2Boiler Full Water
9.2.1Phenomenon
a. All the water level indicators are higher than normal water level and with
positive values.
b. Water level high alarm signal is sent out.
c. Feeding water flow is abnormal and bigger than steam flow.
d. Salt content in steam is increasing.
e. Main steam temperature is decreasing when the boiler water is seriously full
and there is water impact inside the steam pipes.
9.2.2Reason
a. Feeding water automation is in failure and feeding water regulation device is
in failure.
b. The indications of water level indicator, steam flow or feeding water flow is
wrong, which makes the operators wrongly operate by wrong judge.
c. Boiler load increases too fast and there are fake water level.
d. Feeding water pressure increases suddenly.
e.High & low water level alarming device is in failure, which does not alarm or
alarm by mistake.
f. The operators did not supervise the water level inadequately or regulated
untimely or operated by mistake.
9.2.3Treatment
a. When water level high is found, compare steam, water flow and all the water
level indicators to prove its veracity of indication.
b. When water level high is proved, feeding water automation should be stopped
and partly close feeding water valve to decrease feeding water amount.
58
c. If the water level continues to rise, emergency drainage valve should be
opened.
d. If the water level increases due to boiler load sharp increase, load increasing
should be reprieved.
e. If boiler full water is +100mm, the boiler should be stopped in emergency and
then close feeding water valve and open re-circulating valve of economizer
and report it to the shift manager.
f. Fully open the emergency water discharging valve to stop attemperator.
g. When drum water level decreases to normal level, close the emergency water
discharging valve and keep a normal level, and then open the drainage valve
of the superheater and ask the shift manager for ignition after drainage water
are completely discharged.
9.3 Boiler Water Shortage
9.3.1Phenomenon
a. All the water level indicators’ indications are lower than normal level and
indicate to negative direction.
b. Alarm signal of water level low is sent.
c. Feeding water amount is abnormal and less than steam flow. (It is in reverse
when the boiler has pipe explosion.)
d. Superheating steam rises when attemperator water is seriously decreased.
9.3.2Reason
a. Feeding water automatic regulation is in failure and feeding water regulation
device is in failure.
b. The indications of water level indicator, feeding water flow and steam flow
indication are wrong, which makes the operators wrongly operate by
mistake.
c. Boiler load decrease sharply or feeding water pressure drops.
d. Boiler blowing down pipelines, valves leak or blowing down amount is too
big.
e. Feeding water pipelines, cooling water wall, economizer and blowing down
system have serious leakage or pipe explosion.
f. The operators did not supervise the water level inadequately or regulated
untimely or operated by mistake.
9.3.3Treatment
a. When water level low is found, compare steam, water flow and all the water
level indicators to prove its veracity of indication.
b. When water level low is proved, feeding water automation should be stopped
and open the feeding water regulation valve bigger to increase feeding water
amount.
c. If feeding water regulation valve is failure, feeding water bypass valve should
be open bigger and feed water to boiler.
59
d. If blowing down is under process, blowing down should be stopped
immediately and check whether there is serious leakage at blowing down
system or heated surfaces or not.
e. If feeding water pressure is low, increase feeding water pressure or decrease
drum pressure properly.
f. If the drum water level is lower than -100mm, the boiler should be stopped
urgently; report the shift manager to fill water to the boiler, restart the boiler
after drum water level is recovered.
g. If drum level is lower than drum lowest visible level, check the water after
boiler stops, if water level can be increased, enhance to feed water and restart
the unit; if there is no indication on water level indicator, feeding water is not
allowed, ask the general engineer whether to feed water and ignite after
clarifying the reasons.
h. Close feeding water valve, stop attemperator; close blowing down valve and
steam-water sampling valve.
9.3.4 Operation of full water and decreasing water
9.3.4.1 Full water method
a. Close primary valve and secondary valve at water side.
b. Close secondary valve at steam side and then open it in half.
c. Open the water discharging valve slowly, check whether there is water
indication or not. If there is water level indication, it shows the boiler is in
slight full water; if there is no water level indication, it shows the boiler is in
serious water shortage.
9.3.4.2Decreasing water method
a. Close primary & secondary valves at steam side.
b. Close secondary valve at water side and then open it in half. Open the water
discharging valve and flush the water pipes.
c. Close the water discharging valve, check whether there is water indication or
not. If there is water level indication, it shows the boiler is in slight
decreasing water; if there is no water level indication, it shows the boiler is
seriously decreasing water.
d. Put the water level indicator into operation after water level check.
9.4 Drum Water Level Indicator Damage
9.4.1Phenomenon
a. There is steam and water spray.
b. There is big noise.
9.4.2Reason
a. The mica temperature of water level indicator changes greatly.
b. The mica thickness of water level indicator is insufficient, which has a low
pressure bearing.
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c. Pressure bearing surface is not flat or its strength is insufficient.
d. Flushing water level indicator is operated improperly.
9.4.3Treatment
a. When drum level indicator is damaged, it should be disconnected
immediately. Close water valve and steam valve and open water discharging
valve.
b. When one of the drum water level indicators is damaged, the other should be
used for supervising drum water level; contact the maintenance and repair
the damaged water level indicator as soon as possible.
c. If both of the local water level indicators are damaged but its low water level
indicator is right, the boiler can continue running for 2 hours, but boiler load
should be stable and feeding water flow and steam flow should be in balance.
Repair the drum local water indicator as soon as possible.
d. If both of the drum local water level indicators are damaged, and the low
water level indicator is unreliable, the boiler should be stopped immediately.
e. If all the low water level indicators are in failure, the boiler should be stopped
immediately and urgently.
9.5 Steam-Water Priming Accident
9.5.1Phenomenon
a. Salt content of steam and boiler water are increasing.
b. Drum water level fluctuates acutely, and water level can not be seen when it
is serious.
c. Superheater steam temperature decrease acutely.
d. When it is serious, there is water impact in steam pipes and there is steam
emitting from the flange.
9.5.2Reason
a. Boiler water is unqualified with high salt content and high alkalinity and too
much suspending matters.
b. Boiler water supervision is not strict or chemicals are invalid.
c. Blow down has not been done according to regulations.
d. Boiler load fluctuates excessively.
e. Boiler runs with severe overload.
9.5.3Treatment
a. Decrease boiler load and keep the load stable.
b. Fully open the periodic blowing down valve and increase blowing down
times; stop chemical dosing.
c. Open the drainage valves of superheater and steam pipes for water drainage.
d. Keep the drum water level lower than normal water level.
e. Inform steam users to decrease steam consumption.
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f. Inform analyzers to take samples to analyze and take measures to improve
boiler water quality.
g. Flush the water level indicator once after defects are cleaned.
h. Recover unit normal operation after water levels are normal.
9.6 Boiler Cooling Water Wall Damage
9.6.1Phenomenon
a. There is slight leakage and steam spray noise; there is obvious noise when
pipe explosion occurs.
b. Drum water level decreases rapidly, steam pressure and feeding water
pressure decreases.
c. Feeding water flow is abnormally higher than steam flow.
d. Combustion chamber changes to be in positive pressure, and there is gas and
steam spraying out from boiler.
e. Exhausting temperature decreases, which cause extinguishing.
9.6.2 Reason
a. Feeding water is unqualified and boiler water is often unqualified, analyzing
supervision is not strict, blowing down is done not according to regulations
that makes dirty in pipes and corrosion leading pipe explosion.
b. During maintenance or installation, pipes are blocked by foreign materials,
which causes bad water circulating and overheat of pipe walls and produces
swellings and crackles.
c. Pipes are installed improperly, manufacturing has defects, materials are
unqualified or welding quality is not good.
d. Ignition mode is not right, which makes drum or headers heated unevenly,
expansion points producing too high stress and makes expansion points
loosen and crack.
e. Boiler design and manufacturing is not good, flame declines or blowing down
is too much, which makes boiler load too low and destroys water circulation.
9.6.3 Treatment
a. If there is leakage at cooling water wall and the drum water level can keep,
the boiler can be in operation for a short time.
b. If the cooling water wall pipes explode and normal water level can not be
maintained, stop the boiler and report to the shift manager immediately.
c. IDF keeps running after the boiler stops, and it will be stopped after all the
steam has been exhausted.
d. Close all the blowing down valves after boiler stops, if the water level can be
maintained, feed water to the boiler; if there is water leakage and water level
can not be maintained, feeding water should be stopped and the boiler should
be sealed.
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9.7 Economizer Pipe Damage
9.7.1Phenomenon
a. Feeding water flow is abnormally higher than steam flow, and drum water
level decreases when it is serious.
b. Exhausting gas temperature decreases.
c. Flue gas resistance increases and IDF current increases.
d. There is water leakage at flue of economizer with noise when it is serious.
9.7.2Reason
a. The inner part erodes and outer part wears and tears because of unqualified
boiler water.
b. Material is unqualified, manufacturing, welding have defects and make
crackles.
c. Feeding water is uneven, which makes economizer impacted.
9.7.3Treatment
a. Increase boiler feeding water and keep normal drum water level, report to
shife manager to decide stop time for maintenance as soon as possible.
b. Economizer pipes explode, which can not maintain a normal water level; stop
the boiler immediately.
d. Maintain drum water level and close all the water discharging valves,
blowing down valves, sampling valves and close re-circulating valve of
economizer. If there is leakage and water level can not be maintained,
feeding water should be stopped immediately.
e. Strictly close all the air valves after boiler stops, keep the furnace at
minimum negative pressure (no steam is spraying out).
9.8 Superheater Pipe Damage
9.8.1Phenomenon
a. Feeding water flow is abnormally lower than steam flow.
b. Steam pressure decreases when it is seriously damaged.
c. Negative pressure in combustion chamber abnormally decreases or changes
to positive pressure. There is steam and smoke leakage at un-tight places.
d. Superheater steam temperature is changing; and there is noise near
superheater.
e. IDF current increases.
9.8.2Reason
a. Analyzing supervision is not strict; steam water separator structure is not
good or has defects, which makes steam unqualified. There is dirty forming
in superheater pipes, which causes pipe walls overheated.
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b. Combustion is not normal and flame declines or extends to superheater and
boiler wall is coking slag, which makes superheater temperature increases.
c. Steam flow fluctuates greatly, which makes steam quality unqualified.
Coking slag in pipes of superheater causes temperature rise of pipe walls.
d. Pipes often get overheated due to untimely regulation by the operators; pipe
material has squirming expansion after years.
e. Attemperator water amount is too much or there is leakage at water pipe of
attemperator, which makes water block at elbow of superheater and causes
part overheated.
f. During ignition and pressure increasing, superheater steam ventilation amount
is insufficient that causes overheating.
g. Superheater structure is arranged unreasonably, which causes over
temperature of pipe walls.
h. Superheater is installed improperly, manufacturing has defects, material is
unqualified or welding is not good.
i. Superheater is blocked by foreign material or pipe outer wall is abraded by
flying ash.
9.8.3Treatment
a. When the superheater pipe leakage is not serious, it can maintain a short time
operation. It should be reported to the shift manager to decide boiler stop
time for maintenance as soon as possible.
b. Boiler should be stopped immediately when superheater is in serious pipe
explosion.
9.9 Steam Pipe and Feeding Water Pipe Damage
9.9.1Phenomenon
a. There is noise when pipelines have slight leakage and insulation layer is wet
or leaks steam or water.
b. There is obvious noise when pipeline explode and steam & water is spraying
out.
c. Steam or feeding water flow is changing abnormally. If explosion part is
before orifice plate, the flow indication decreases; if it is after orifice plate,
the flow indication increases.
d. Steam pressure or feeding water pressure decreases.
9.9.2Reason
a. Steam pipe heating is insufficient and heavy water impact is produced.
b. Feeding water system operation is not normal, pressure or flow fluctuates
greatly, which produces water impact and vibration.
c. Pipes are improperly installed, manufacturing has defects, material is
unqualified or welding quality is not good.
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d. The supporting & suspending frames of the pipes are wrongly installed,
which affects pipes free expansion.
e. Steam pipes run with over temperature; squirming expansion exceeds
standard or operation time is too long; or metal strength decreases.
f. Feeding water is not good or pipe outside catches water, which makes inside
and outside corrosion of the pipe walls.
g. Feeding water pipe part flush
9.9.3Treatment for feeding water pipe damage
a. If the feeding water pipe has slight leakage and it can main boiler feeding
water, it can keep operation for a short time. It should be reported to the shift
manager to decide the time of stopping the boiler for maintenance as soon as
possible.
b. The boiler should be stopped immediately if there is pipeline explosion and it
can not maintain drum water level for operation.
9.9.4Treatment for steam pipe water damage
a. If there is slight leakage at steam pipeline or headers, the pressure &
maintenance can be decreased for a short time operation. It should be
reported to the shift manager to decide the time of stopping the boiler for
maintenance as soon as possible.
b. The boiler should be stopped if there is boiler steam pipeline explosion which
threaten safety of human beings and equipments.
9.10 Boiler Pipe Water Impact
9.10.1Phenomenon
a. When there is water impact at feeding water pipeline, feeding water pressure
vibrates; when there is water impact at steam head pipes, steam head pipe
pressure meter vibrates.
b. There is water clash in pipelines and the pipeline vibrates when it is serious.
9.10.2Reason
a. Feeding water pressure and temperature change acutely.
b. When water enters into feeding water pipes and economizers, which shows
that air has not been completely discharged or feeding water flow is too
much.
c. Attemperator water amount is too small, which makes feeding water boil
away.
d. Feeding water flow to the cold boiler is too big; feeding water temperature is
too high.
e. During boiler ignition and pressure rise, steam pipeline heating is not
sufficient and drainage water has not been discharged completely.
f. The temperature in main steam pipe suddenly decreases greatly or steam in it
is with water.
65
9.10.3Treatment
a. When there is water impact in feeding water pipelines, feeding water valve
can be partly closed and heat source may be cut off.
b. When there is water impact in attemperator, its inlet valve can be partly
closed and then opened slowly. If the defect can not be cleaned, weaken the
combustion and stop the attemperator temporarily and check whether the
feeding water temperature is too low or not.
c. If there is water impact in steam pipelines due to steam temperature sudden
decrease, attemperator water valve should be closed or water level should be
decreased to raise steam temperature.
d. After water impact in steam pipelines is cleaned, check the supporting and
suspending frame conditions and clean the defects as soon as possible.
9.11Load Sharp Decrease
9.11.1Phenomenon
a. Boiler steam pressure increases sharply.
b. Steam flow decreases.
c. Drum water level decreases and then increases; feeding water amount
decreases when automatic feeding water is in operation.
d. Drum and superheater safety valves actuate.
9.11.2Reason
a. Steam consumption for auxiliary steam users decreases suddenly or stops.
b. Air supplying valve of superheater outlet is closed by mistake.
9.11.3Treatment
a. Decrease FDF inlet dampers and IDF air correspondingly and keep the
negative pressure of the furnace.
b. Keep the drum level normal and change automation to manual for the feeding
water regulation if it is necessary.
c. Open the drainage valve of superheater or steam exhaust valve properly to
release pressure according to load decreasing speed and steam pressure
increasing speed to avoid actuation of the safety valve.
d. Decrease inlet oil amount to the furnace.
e. Partly close or stop the attemperator according to steam temperature changing
of the superheater.
f. If the safety valve actuates, check the tightness of the safety valve after the
working pressure is recovered.
g. Report to the shift manager.
h. The load should be increased slowly to avoid too fast load increasing and
steam pressure drop.
66
9.12 Flue Secondary Combustion at Boiler Tail Section
9.12.1Phenomenon
a. Gas temperature in flue is increasing abnormally.
b. Flue negative pressure fluctuates sharply.
c. Parameter such as feeding water temperature is increasing abnormally.
d. There is smoke or spark from un-tight places of the flue and black smoke
emits from the stack.
e. Explosion-proof valve blow up when secondary combustion is serious.
9.12.2Reason
a. Combustion regulation is improper, air amount is insufficient or oil gun
atomization is not good, which makes the unburned combustible
accumulated at tail section heated surfaces or in flue.
b. During starting and stop, furnace temperature is too low; part of the fuel oil is
unburned and accumulated in tail flue.
9.12.3Treatment
a. When flue gas temperature at tail flue is increasing abnormally, find out the
reason and enhance combustion regulation.
b. When secondary combustion is confirmed, the boiler should be stopped
immediately urgently; IDF & FDF should be stopped.
c. Close all the air valves, dampers to isolate air.
d. Enhance water feeding and water discharging.
e. After flue gas temperatures decrease obviously at all sections, check and
make sure that there is no fire in all parts of the flue, clean the deposited
combustible matters. Start the IDF for ventilation for 10～20min, check it
completely and confirm there is no damage to the equipments, report to the
shift manager and ignite for starting the boiler.
9.13 Oil Leakage and Firing of Fuel Oil System
9.13.1Phenomenon
a. Fuel oil system oil pressure decreases.
b. There are oil spray and fire at leaking points.
c. When oil leakage is serious, boiler combustion is unstable or fire
extinguishing occurs.
9.13.2Reason
a. There is oil leakage at oil pipelines during operation.
b. Parts of oil pipeline valves, instrumental meters are in aging and with oil
leakage.
c. There is leakage at flare connection of oil gun, the material of oil gun is
unqulified with insufficient intension.
67
d. Air valve or oil discharging valve of fuel oil system is opened by mistake.
9.13.3 Treatment
a. If oil pressure decrease is found, check the oil system immediately and
locally to make sure whether there is oil leakage or not and ask whether there
is operation or not at boiler and fuel oil system. And report it to the shift
manager immediately.
b. If there is oil leakage in oil system, measures should be taken immediately
for isolation; if it can not be isolated, inform the oil station to stop the oil
pump and stop the boiler urgently. Inform the maintenance to treat the
leaking points immediately.
c. During treatment, if there is a fire, manpower should be organized for fire
fighting and inform the fire department for fire fighting.
d. Recover the oil system for running after defects are cleaned; ask for the shift
manager to restart the boiler.
9.14 Air Fan Failure
9.14.1Phenomenon
a. The finger of current meter swing excessively.
b. Inlet & outlet air pressure of air fan changes.
c. There is abnormal sound (friction or impact) at air fan.
d. Air fan has a high vibration.
e. Bearing temperature is too high.
9.14.2Reason
a. Impeller blade is abraded that makes rotor in unbalance; air fan and
foundation are in resonance.
b. Gas is with water that makes impeller blade corrosive and accumulated with
ash.
c. The anchor bolts of air fan and motor loose and it is gets loose between
impeller blades and shaft.
d. Lubricate oil quality is not good, oil amount is insufficient and cooling water
is too small, which makes bearing abraded.
e. The manufacturing and maintenance of bearing and rotor are not qualified.
9.14.3Treatment
9.14.3.1 Boiler Should be Stopped Immediately and Stop All the Air Fans If any of the
Following Conditions Occurs
a. There is strong vibration, impact and friction in the air fan.
b. Bearing temperatures of motor and air fan are abnormally increasing, which
exceeds permit limitation and have no effect after treatment.
c. Motor temperature exceeds limitation.
d. Air fan must be stopped if electric equipments are in failure.
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e. Motor or air fan has serious defects, which threatens safety of human beings
and equipments.
f. Fire accident happens, which threatens safety of the equipments.
g. Life accident happens which can only be rescued by stopping air fan.
9.14.3.2If the vibration, friction or impact of the air fan will not cause damage to the
equipment, it can continue to operate by decreasing air fan load properly.
Check the operation conditions from time to time and find out the reason and
clean it as soon as possible. If air fan fault is still in failure after the above
treatment and getting worse, the boiler should be stopped and the air fan
should also be stopped.
9.14.3.3When air fan bearing temperature is increasing, oil amount, oil quality and
cooling water amount should be checked and adding cooling water amount,
adding oil or changing oil can be done if it is necessary. If the bearing
temperature is still increasing and exceeds permit limitation after the above
treatment, the boiler should be stopped and the air fan should also be stopped.
9.14.3.4If the air fan bearing smokes, stop the air fan and cut off the power supply. The
bearing should be turned after stopping to avoid bearing distortion.
9.14.3.5When the motor or electric equipments are in failure, if it will be restarted,
notice and approval should be obtained from electric working personnel.
9.15 Feeding Water Pump Failure
9.15.1Phenomenon
a. Water pump does not pump, outlet pressure meter indication decreases and its
finger swing acutely.
b. Water pump does not suck, inlet vacuum meter indication increases.
c. Pressure meter has pressure but pump does not sop up.
d. Current decreases; pump body gets hot and has noise.
e. Flow is lower than designed requirement.
f. There is noise inside the pump and it does not sop up.
g. Water pump vibrates or bearing is overheated.
h. Sealing stuff at both sides of water pump has steam leakage.
9.15.2Reason
a. Water filled into water pump is insufficient, water pipe and instrumental meters
have air leakage.
b. Low valve is not open or blocked; resistance of suck pipe is too big; suction
height is too high.
c. Resistance of water outlet pipe is too big; running direction is wrong; impeller
blade is blocked; water pump running speed is not enough.
d. Water pump is blocked, sealing rings are abraded too much and running speed
is insufficient.
e. Cover of stuffing is too tight; impeller blade is abraded; water pump water
supplying amount increases.
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f. Flow is too big; the resistance of water suction pipe is too big; there is air
leakage at water suction location; temperature of liquid for sending and
sucking is too high.
g. Bearing lacks oil or axes are not the same.
h. Water tank level is too low.
i. Output of feeding water pump is too small and the re-circulating is not open.
j. Inlet filter is blocked.
k. Inlet valve of the feeding water pump is closed by mistake.
9.15.3Treatment
a. Fill water into water pump, tight or stop the air leakage.
b. Correct or change low valve or change suction pipe to decrease water suck
height.
c. Check the motor, shorten outlet water pipe, clean impeller blade and pipes and
change the sealing rings, which are to increase running speed.
d. Loose stuffing cover, change the impeller blade and increase resistance of
outlet water pipe to decrease flow.
e. Adding oil or cleaning bearing body, make the centers of water pump and
motor to be on the same line.
f. Increase make up water amount.
g. Open the re-circulating valve.
h. Clean the filter after stop.
i. Inlet valve of feeding water pump is fully open.
9.15.4 Interlock Condition of Pump
a. Any bearing temperature of water pump or motor is increasing to be more than
80℃ or bearing is on fire.
b. Water pump motor has acute vibration and metal grating.
c. Current is increasing abnormally or exceeds rated value.
d. Motor is on fire.
e. Boil away is produced by feeding water pump, and it can not be recovered even
outlet pressure is decreased.
f. It threatens safety of human beings or equipments.
9.15.5 Manual Switch Conditions of Pump
a. There is burning smell inside the motor.
b. Stuffing at both sides is overheated, which has no effect after regulating
cooling water.
c. Sealing stuff has steam leakage or is throwing water heavily.
d. Vibration of any bearing exceeds 0.05mm.
e. Water has entered into motor.
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9.16 I&C Supply Power Vanishing
9.16.1Phenomenon
a. All the automatic regulations are in failure and can not be operated remotely.
b. All the digital plates don’t shine and the bells do not sound.
c. All the recording meters, electric indication meters and electric connection
points are at zero.
9.16.2Reason
I&C power supply switch protection trips or artificial operation by mistake.
9.16.3Treatment
a. Report to the shift manager and stabilize load to maintain boiler operation.
b. Change the electric power to standby power and recover power supply.
c. If it can not be recovered in a short time, the boiler should be stopped for
treatment.
d. Designate personnel to supervise water level.
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10 GT Fuel Oil System

10.1 HSFO System
10.1.1 Equipment Specification
Tabe-1
Furnance Oil (HSFO) Specification
TEST
TEST UNITS LIMITS
METHODS
Acid Number, Strong mgKOH/g Max. Nil ASTM D 664/D-974
Max. ASTM D
Ash %W
0.10 482/IP-4/75
Min.
Calorific Value, Gross BTU/Lb ASTM D-240
18200
Truckbon Residue, Max.
%W ASTM D 189
Conradson 10.0
Flash point, PMcc Deg. C Min. 66 ASTM D 93
IP 228 or ASTM D
Potassium + sodium Ppm Max. 50
2788
Pour Point Deg. C Max. 50 ASTM D 97
Relative Density @ Max.
Deg. F ASTM D 1298
60/60 0.9800
Max. ASTM D 473
Sediment %W
0.15 or IP - 53
ASTM D 1552 or
Sulphur %W Max. 3.5
2622 or 4294
ASTM D 1548 or
Vanadium Ppm Max. 60
IP 288
ASTM D 1548 or
Calcium Ppm Max. 10
IP 288
Max.180
Viscosity, Kinematic Summer ASTM D 445 or IP
cst
@50 Deg. C Max.125 71/75
Winter
Max.
Water %V ASTM D 95
0.50
Inlet oil temperasure： 60~70℃
Largest fuel oil consumption： 2.7t/h
Inlet pipe size： D159×5
Fuel oil supply pipe size: D133×5
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Tabe-2
Duplex strainer of HSFOpre-pump
Type 500FWSL-40/1.0-B
Diameter DN500
Medium HSFO
Pressure 1.0MPa
Flow 600m/h^3
Filter fineness 40mesh
Main parts materials Shell and the flange:truckbon steel
Mesh and orifice plate: stainless
steel
Remark 2
HSFO underground oil
V=300m3
poolVolume
Treated HSFO Tank
V=10000m3
Untreated HSFO Tank
V=10000m3
Heavy Fuel Oil Treatment Plant
Q=120m3 /h
HSFO Suction Heater
Q=120m3 /h 50°To 65°
Heater
Q=41m3 /h 65°To 135°
Oil Filter
Q=10m3 /h head 6bar
Heavy Oil Forwarding Skid
Q=37.6m3 /h p=13 bar
Tabe-3 HSFO supply pump of auxiliary boiler

Pump Type SNH120R42E15W21
Motor Type YB100L1
Motor Output 2.2kw
Flow
6m3 /h
Pressure 1.0mpa
Speed 1450rpm
Coupling B1104-12/11-19B
Base Plant 273 8006 081
10.1.2Trap Flash Tank

Trap flash tank expands the volume and reduces the pressure of the water in
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the pressure drain pipe, to separate water and steam, and then lead steam into the
heat exchanger or steam deaerator to make full use of its heat. The water is led to
the water drain tank and delivered to water feed system periodically, mainly for
reducing the pressure. If the high pressure steam directly enters the condenser, it
may lead to condenser overpressure. The trap flash tank can reduce pressure and
avoid overpressure. In addition, there is a temperature reducer inside to reduce
the temperature.
Mechanical (free ball float, lever float, inverted bucket) steam trap is closed
and opened according to buoyancy principle. It can automatically identify steam
and water, and is usually used for the recovery and recycling of the water drained
after continuous and large flow drainage. Lever float steam trap and inverted
bucket steam trap have complex structure. Free ball float steam trap has simple
structure, with no steam leakage, and is generally used for drain of pipeline or
devices;
Thermal power type (disc type, impulse type) steam trap makes use of
aerodynamics and start and close the valve by the pressure drop as a result of
steam shift. It is suitable for places with small flow, large pressure difference and
no high continuity requirement. It has simple structure, with impulse leakage, so
generally used for drain of pipelines.
Trap flash tank is composed of casing, multiple inlet pipes and steam-water
separator. If necessary, it can be equipped with manual hole and cooling water
pipe, to facilitate equipment maintenance and safe running.
Commissioning: heavy oil heater should slowly warm the oil to normal
temperature and flow while slowing feeding steam.Relevant Parameters in the
following table：
Type Outside Class
Volume
25m3
Working Pressure 0.12mPa
Design Pressure 0.8mPa
Working Pressure 160℃
Design Temperature 200℃
Medium Water , Saturation, Steam
Fluid Characteristic non-lethal&non-flammability
Main Pressure Parts Materials Q245R
Corrosion Allowance 1.0mm
Joint Efficiency 1.0mm
Whole Capacity
25m3
Open Pressure of SV 0.6mPa
Flow Metering Equipment
Q=37.6m3 /h
74
10.1.3 Oil Storage Tank and Heater
75
a. Steam properties
b. Heavy Fuel Oil Heat Exchanger
76
Heavy Fuel Oil Heat Exchanger is a kind of thermal equipment which heat up
the heavy fuel oil to certain temperature with once heat source and vapour.
c. Attention when Operating
Commissioning
heavy oil heater should slowly warm the oil to normal temperature and flow
while slowing feeding steam.
Out of operation :when the Heavy Feul Oil Heat Exchanger is out of
operation,the steam should be stopped slowly,at the same time shut off the oil
inlet slowly untill all the valves were closed. It is strictly prohibitted to close the
valve and oil pump on the fuel oil side firstly so as to avoid the concretion of the
fuel oil.
The tank was struictly probibitted to operate under super pressure and super
temperature
Any repair and fastening shall not be done when there is pressure inside the
tank
1 Ultrasonic flow meter LDC
Q=5m3 /h
2
Q=200m3 /h
3
Q=37.6m3 /h
10.1.4 Heavy Oil Unloading

Heavy oil comes from the truck oil tanker oil guide, flows into underground
receiving oil pit, then flows into the front duplex strainer of heavy oil unloading
pump to heavy oil unloading pump, and then into four standby tanks.
Check-up before oil unloading:
a. Check to make sure the valve OENA20AA200 is closed.
b. Check to make sure the front duplex strainer OENA10AT001 of heavy oil
unloading pump is in open state.
c. Check to make sure each bypass Normally Closed Globe Valve of the filter
is in closed state.
d. Check to make sure OENA23AA001 and OENA24AA001 are in open state.
e. Check to make sure duplex strainer Check Valve is in closed state.
f. Check to make sure OENA10A001 and OENA10A002 are in open state.
g. Check to make sure OENA23AA200 and OENA24AA200 are in open state.
h. Check to make sure Motor Operated Control Valve OENA23AA101 and
OENA24AA101 are in open state.
i. Check to make sure pipeline sewage valves are in closed state.
j. Check to make sure valves OENB11AA101, OENB21AA101,
OENB31AA101 and OENB41AA101 are in open state.
77
k. Check to make sure valves OENB01AC004, OENB01AC003,
OENB01AC002 and OENA01AC001 are in closed state.
l. Check to make sure valves OENB12AA101, OENB22AA101,
OENB32AA101 and OENB42AA101 are in closed state.
m. Check the opening and closing of oil processing unit valve.
10.1.5 Operation of HSFO Unloading Pump
10.1.5.1Equipment Specifications
Pump Type W8.4Zk
Motor Type YB315L
Weight 3510kg
Motor Output 200kw
Flow 600m^3/h
Pressure 0.6mpa
Speed 1450rpm
Base/Hitch DZ2250.0920.315
Coupling HRC280 FF 80/60
Sheild HZQ00.165.320
Foundation Bolt M24X400
10.1.5.2 Preparations for Initial Start-up
——Check all the connections for correct implement and operation. Test
leaking and pressure and clean all pipelines, valves and filter to make sure the
impurity cleaned.
——Check and make sure pump shaft revolve freely, if have any jam and
abrasion, must be settled. Pumps have been tested before leaving factory, but
there is adverse infects during transportation.
——Check and make sure the reaction force of the pipeline connections of
pump’s suction and outer sides on pump are not over the permitted value.
——Check and make sure whether the connection bolts are fastness and
reliable.
——Check whether the power is switched on.
——Check whether the gear casting and the oil position of front cover attain
the position of oil mark position. Above 5mm the middle level when the pump is
still is the correct oil level.
——Check whether all valves and control equipment and supervise meters are
work correctly.
——Inspect the veer.
——The pump with heater must be operated by hand when the temperature
achieves the certain temperature. Steam, hot water or hot oil can be the heat
truckrier. Select the pressure of heat truckrier in the range of 0.2—1.0MPa
78
according to the material of pump. The injecting and discharge hole of heat
truckrier are on the pump, refer to the unit installation drawing or pump outline
drawing.
NOTE: The differential temperature between delivered medium and heat
truckrier should as small as possible to avoid leading stress.
NOTE: If the pump has double mechanical seal, there must have seal off
liquid system. The pressure of seal off liquid system should be above the suction
pressure 0.1～0.2MPa. Run seal off liquid system first before operating the main
pump.
The pump with seal off liquid refers to the requirement of seal off liquid.
10.1.5.3 Start-up
The sequence of starting up pump: entirely open the inlet and outlet valves; fill
thedelivery medium into pump; spot move the motor to observe the veer; then
startingup the pump.
NOTE: Forbidden to run the pump when the inlet and outlet valve are closed.
Shut off the pump and relative equipment if no capacity output after initial
start-up, and restart several minutes later, if still no capacity output, check the
pump and relative equipment, see “Operating Faults Causes and Remedies”.
After the checking and remedying, restart the pump according to the fore steps.
10.1.5.4 Stop
Shut off the switch of units, shut off the valve fixing on the inlet and outlet
pipeline nearestthe pump, separate the pump and pipeline. Shut off the seal off
liquid system after cooling; shut off the heater if has. If the pump stops for a long
time, please protect the pump according to “transportation, Claims for
compensation and storage”.
10.1.6 Heavy Oil Delivery Processes
Deliver fuel from ROAD TANKER to the underground oil tank, and control
the switch of the control valve OENA20AA200 in the oil tank so as to control the
flow of heavy oil. The heavy oil delivered from the oil tank will firstly flow into
the standby oil tank. When the turbine is running, the heavy oil in the standby oil
tank flows through pre-heater to oil processing unit. Part of the oil will flow into
the four front oil tanks and be used for unit running. Another part of oil will flow
from oil processing unit back to standby oil tank. The heavy oil that flows into the
four front oil tanks will firstly be warmed partially to 65 ℃, and then will flow
into two pipelines: one is heavy oil pre-set oil feed module, and then flow into
turbine heavy oil feed pump, and then flow out of the oil feed pump and flow into
the heavy oil heater. At this moment, the oil temperature will rise to 135 ℃. The
heavy oil flows out of the heater and will then pass through a three-way valve,
where part of the heavy oil will flow back to front oil tank and start next oil
79
circulating. The remaining heavy oil will pass flow measuring device. The fuel
will enter the turbine if there is no problem. The other pipeline is front duplex
strainer of auxiliary boiler heavy oil pump -- auxiliary boiler heavy oil pump -
flow measuring device - auxiliary boiler.
10.1.7 The General of HSFO Treatment
10.1.7.1 HSFO System Design
The Power Plant Nandipur 425MW CCPP designed to operate using High Sulphur
Furnace Oil (HSFO) as main fuel.
When operating with high viscosity / heavy fuel oil as fuel, high temperature
corrosion can occur within the gas turbine, this is attributed to the presence of minor
quantities of heavy metal contaminants within the fuel such as Sodium and
Potassium.
These impurities form low melting point ash compounds that condense on
metallic surfaces within the hot gas path of the turbine. The accumulation of these
deposits on hot alloy surfaces will result in high temperature corrosion and
ultimately component failure.
Mainly these contaminants originate from sea/salt water contamination of the
crude oil and become more concentrated during subsequent processing at the
refinery; others are introduced during transportation or storage, typically through
contamination with sea water.
The anticipated levels of contamination of the HSFO fuel provided for use at the
Nandipur 425MW CCPP Power Plant exceed the acceptable limits stipulated for
the gas turbine. Consequently, a Fuel Oil Treatment Plant is required to reduce the
level of Sodium and Potassium salts within the fuel to within acceptable limits.
10.1.7.2Descrption
a. Scope of the HSFO Treatment System
The High Sulphur Furnace Oil Treatment Plant is consisting of:
- one (1) Transfer Pump, Heat Recovery and Demulsifier Dosing Skid
- four (4) High Sulphur Furnace Oil Treatment Skids
- one (1) Water Booster Pump Skid
- one (1) Water Accumulator (for water booster pump skid, loose supply)
- one (1) Common Control Cabinet for fuel oil treatment plant
- one (1) Operator Work Station with monitor, key-board and track-ball
b. Duty Operation
The Fuel Oil Treatment Plant must only be used for the application and
operating parameters as
described as follows:
Each deviation from the described application and parameters can cause
equipment and
personal damage.
80
Westfalia Separator is not liable for damages caused by deviations of the duly
operation,
specified application and operation parameters.
Westfalia Separator is not liable for damages caused by inadmissible alterations
at the
separators, skid installations and controls.
Treatment of heavy fuel oil by means of
Application
two-stage centrifugal separator washing system
Fuel oil to be processed
High Sulphur Furnace Oil (HSFO) / Heavy
Kind of fuel oil
Fuel Oil (HFO)
max. 180 cSt @ 50°C Summer
viscosity
max. 120 cSt @ 50°C Winter
Density max. 0,980 g/ml @ 15,6°C (@ 60°F)
flashpoint > 66°C
Water content at plant
min. 0,2% by vol., max. 1,5% by vol.
inlet
Sediment content at plant
max. 0,025 % by vol.
inlet
Sodium+Potassium
max. 50 ppm Na + K
content
Any contents of aphaltenes must be stable and
Asphaltene content of soluble
HSFO/HFO within the HSFO/HFO at separating
temperature (98°C).
The fuel oil / fuel oil blend must be stable
and compatible and must meet as minimum the
HSFO/HFO quality requirements
and recommendations as per ISO 8217
and CIMAC-Number 11 & 25
HSFO temperature at
60°C
plant inlet
HSFO pressure atplant
gravity flooded, max. 1,5 bar g
inlet
98°C
(in worst case up to 110°C if the performance
cannot be
achieved at 98°C due to bad HSFO qualities.
HSFO Separating
A slightly increased wear/aging on the bowl
Temperature
gaskets and
sludge pump stators at separating temperatures
above 98°C
separating temperatures is possible.)
Treated HSFO Outlet up to 3,0 bar g
81
Pressure
Treated HSFO Outlet 79°C with heat recovery at 60°C inlet
Temperature: temperature
in total: 93 m³/h (@ 98°C) with three (3)
HSFO Treatment
HSFO Treatment Skid’s in operation,
Capacity:
per HSFO Treatment Skid: 31 m³/h (@ 98°C).
Waste Water Outlet
up to 3,0 bar g
Pressure:
Sludge Outlet Pressure: up to 3,0 bar g
Operation 3-phase 400V +5% (+10% short) - PEN / 50Hz
Voltage/Infeed: +2% (+5%short)
Control Voltage: 230V AC
Pilot Solenoid Valve
24V DC
Operation Voltage:
boiler feed water with additives or
Wash/Operating Water:
boiler condensate is not permitted
54 to 107 mg/dm³CaCO3 (3 – 6°dH german
Hardness as CaCO3:
hardness)
pH-value 6,5 - 7,5
Chloride ions: max. 100 mg/dm³
Na+K content: max. 50 mg/dm³
Suspensed matter: max. 50 mg/dm³
Particle size: max. 50 μm
Feed pressure at plant inlet gravity flooded / max. 1,5 bar g
Feed temperature: >0°C / ambient
Required feed capacity: min. 9,5 m³/h
normal 4 – 6%, max. 10% of actual HSFO
Wash Water Addition: treatment capacity,
depends on actual HSFO quality
Wash Water Consumption normal 3,7 – 5,6 m³/h, max. 9,3 m³/h
Wash Water Temperature heated-up to HSFO separating temperature
Operating Water approx. 0,2 m³/h
Consumption at one (1) bowl cleaning cycle every one (1) hour
Heating Medium: Steam
Temperature 180°C , max. 200°C
Pressure 8 – 9 bar abs
approx. 5000 kg/h without heat recovery
Consumption
approx. 3400 kg/h with heat recovery
Air supply: Compressed/Service Air
Pressure 5 - 10 bar g
Consumption average ~ 2 Nm³/h
usual 50 - 250 ppm of demulsifier of actual
Demulsifier Addition for
treatment capacity,
HSFO Treatment:
depends on actual HSFO quality and selected
82
demulsifier.
Which demulsifier brand/type has to be used for
the
HSFO treatment has to be decided by the
operator based on
trial tests with regard to:
- the demulsifier must be oil soluble,
- the demulsifier must be compatible with the
actual HSFO,
- the demulsifier must be fast acting,
- the demulsifier must demulsify sufficiently
- sufficient de-watering efficiency of the HSFO
treatment,
- sufficient de-salting efficiency of the HSFO
treatment,
The demulsifier selection may have also an
influence on the
oil/emulsion content of the waste water
discharge.
GEA Westfalia Separator made good experiences
with the
demulsifier brands/types:
- Turbotect - “EP 343“,
- Baker Petrolite - “TRETOLITE* DMO80035”,
- Lucent Oil – “Emulsion Treatment 171”.
The demulsifier dosing pumps are sized for a
dosing ratio
of up to 404 ppm.
Adjustments, Set Points acc. to Adjustment & Set Point List and the
and individual
further Technical Details: manuals of aggregates and components
c. Design
Design ambient
Indoor , FOTP Building: >0°C up to +50°C
temperature of skids:
Design ambient
Indoor, Control Room up to +35°C
temperature of control:
Design code: PED 97/23 EC, AD-2000
Steam and condensate pipes: 10 bar g / 200°C
HSFO and wash water pipes: 10 bar g / 120°C
Mechanical design:
Cold fresh water pipes: 16 bar g / 50°C
Demulsifier pipes: 10 bar g / 50°C
Air pipes: 10 bar g / 50°C
Protection class of Instruments, junction boxes
skid mounted and valve actuators: conventional, IP55 / IP65
83
electrical equipment: Electric motors for pumps
separators and mixers: EExdeIIBT3, IP54 /
IP55
d. Performance Request
Performance request for HSFO Treatment:
Reduction of Sodium (Na) and Potassium (K):
The content of salts, sodium (Na) and Potassium (K) (as water soluble chlorides
NaCl + KCl, resulting
from sea/salt water contamination) has to be reduced at a treatment capacity of
31 m³/h (@ 98°C) per
HSFO treatment skid
from Na content and K to Na + K content downstream of
content upstream of the HSFO the HSFO Treatment Plant
Treatment Plant
< 50 ppm Na + K < 0,5 ppm Na + K
provided that
- the HSFO is separable and does not contain chemical wastes as for example
caustic
soda (NaOH, KOH) or waste oil,
- the content of Na and K as NaCl and KCl (resulting from sea/salt water
contamination) is
totally dissolved in the free water content of min 2000 ppm of the untreated
HSFO,
- the water content of the untreated HSFO is pH-neutral (pH 6,5 – 7,5) , not
bounded into the
HSFO,.not emulsified in the HSFO, and not dissolved in the HSFO,
- the free water content is sufficient reductable by means of centrifugal
separation.
Measuring Method:
Average value of several samples,
analysed by Rotating Disc Electrode – Atomic Emmission Spectrometer
(RDE-AES).
10.1.7.3Function
a. Transfer Pump, Heat Recovery & Demulsifier Dosing Skid
The untreated heavy fuel oil is stored within the main storage tanks and will be
transferred by the“Transfer Pump, Heat Recovery & Demulsifier Dosing Skid” to
the inlets of the “HSFO Treatment Skids”.For pump protection one (1) duplex
basket strainer is installed upstream of the transfer pumps. One of the strainer
chamber is for operation and the other for standby and cleaning works. The strainer
condition is supervised by a differential pressure indicator/switch (set 0,3 bar).
Downstream of the duplex basket strainer demulsifier will be added to the fuel
84
oil by means of a piston dosing pump in order to prevent an emulsion built up
during the treatment process. As dosing pumps two (2) piston dosing pumps, one
for operation and one as stand-by are installed. The dosing pump capacity is
frequency converter and the Pump motor frequency depends on the No. of HSFO
Treatment Skids in operation:
one (1) HSFO Treatment Skid in operation => 17 Hz => max. dosing pump
capacity 12,5 l/h
two (2) HSFO Treatment Skids in operation => 34 Hz => max. dosing pump
capacity 25,1 l/h
three (3) HSFO Treatment Skids in operation => 51 Hz => max. dosing pump
capacity 37,6 l/h
(three (3) + Stand-By HSFO Treatment Skid in operation => 68 Hz => max.
dosing pump capacity 50,1 l/h)
The required demulsifier dosing ratio has to be determined by trial tests and
depends on
- the quality of the HSFO,
- the selected demulsifier type,and has to be adjusted by means of the manual
stroke adjustment (0-20mm) of the dosing pump to the maximum possible
de-watering efficiency of the HSFO treatment skid’s. The de-watering of the HSFO
treatment has to be determined by the Water-in-Oil-Test-Kit.
A demulsifier storage tank of 1 m³volume is installed on the skid for storage
demulsifier for approx. 2 days operation (at usual dosage ratio of up to 250 ppm).
The common dosing pump discharge line is equipped with a pressure switch (PAL)
and the storage tank is equipped with a low level switch (LAL). In case of a dosing
pump failure the stand-by dosing pump starts automatically. In the event of low
level (LAL) of the demulsifier storage an alarm is initiated. The operator has then
to refill the storage tank by means of the delivered hand barrel pump.
As transfer pumps, two (2) screw spindle pumps are installed, one for operation
and one as stand-by.The pre-selected transfer pump starts automatically once the
fist HSFO treatment skid preselected for operation and in its start-up sequence.
Downstream of each transfer pump a pressure switch (PAL) for supervision of the
HSFO flow is installed. The stand-by pump starts automatically in case of a pump
failure.
The Untreated HSFO coming from the transfer pumps is transferred through one
(1) plate type heat exchanger for heat recovery.The plate heat exchanger recovers
the heat from the treated fuel oil in order to pre-heat the untreated
fuel oil during the treatment process. The plate heat exchanger is capable for the
total treatment capacity of three (3) HSFO Treatment Skids and is sized to reduce
outlet temperature of the treated HSFO from 98°C down to 79°C at 60°C HSFO
inlet temperature. In order to maintain a constant feed pressure (set 4,0 bar) to the
HSFO Treatment Skids, a spring loaded over flow valve is installed in a
recirculation line back to the to the suction line of the transfer pumps. The
over-capacity of the transfer pumps is re-circulated back into pump suction line.
85
b. HSFO Treatment Skids
The untreated HSFO coming from Transfer Pump, Heat Recovery & Demulsifier
Dosing Skid is split into three (3) streams, one for each HSFO Treatment Skid in
operation. The treatment process within each HSFO Treatment Skid is identical,
the function description is for one Treatment Skid, but is applicable for all skids. In
order to achieve the required treatment temperature of 98°C, the fuel oil is first
heated in a Steam/HSFO tube type heat exchanger, the oil temperature being
regulated by the temperature control loop and the motor-actuated steam control
valve. Downstream of the HSFO heater a volumetric ultrasonic type flow indicator
and a throttling valve are installed. The fuel oil flow will be throttled by means of
the throttle valve to the specified HSFO treatment capacity.
The wash water separated from the second separator stage is added to the HSFO
upstream of the firststage mixer. The fuel oil is thoroughly mixed with the water in
a multi-stage mixer. Salt waters dispersed with the fuel oil will be extracted into the
added water.
Down stream of the mixer the HSFO temperature is monitored by TAL and
TAH.
The oil/water mixture flows via the 3-way feed valve to the centrifugal separator
of the first (1st) washing stage. The solids are spun out due to the high centrifugal
force, the dissolved salts together with the wash water, are simultaneously
separated out.
The salt content in the fuel oil is substantially reduced and contaminants such as
sand, rust and cat fines are removed from the oil.
Fresh water, which is heated up to 95-98°C by means of an steam/water tube
type heat exchanger with temperature control loop and motor-actuated steam
control valve, is added to the purified oil upstream of the second-stage mixer. After
intensive mixing, the oil/water mixture is sent via the 3-way feed valve
to the centrifugal separator of the second (2nd) stage, where further purification and
desalting takes place.
The required wash water addition has to be determined by trial tests and depends
on
- the quality of the HSFO,
- the sodium and potassium content of the untreated HSFO,
- the specified sodium and potassium content in the treated HSFO,
- the water quality.
In the treated/clean oil discharge line, water in oil sensor is fitted. This sensor is
used for continuous monitoring of the water content. If the specified limit is
exceeded, the oil is fed back to the untreated storage tank via a 3-way discharge
valve.
The treated/clean HSFO discharges from the HSFO treatment skids into to the
treated oil tank via the heat exchanger of the “Transfer Pump, Heat Recovery &
Demulsifier Dosing Skid”.
86
The separated solids/sludge’s are ejected time depended from the separator bowl
into the sludge collecting channel underneath the separators. The sludge collecting
channel is drained level controlled and during each bowl-ejection cycle by means
of eccentric worm pumps (one in operation, one as standby) to the oily sludge
discharge.
Each separator is equipped with monitoring equipment for
- separator vibration, NSH / NAHH
- bowl speed, SE
- ejection monitoring, IAL
- motor temperature, TAH
- HSFO discharge pressure high / low, PAH / PAL
- waste water discharge pressure high, PAH
c. Water Booster Pump Skid
The pressure of the water which is required for wash water and operating water
for the separators needs to be increased by a pressure booster pump skid.
As water booster pumps, two (2) inline centrifugal are installed, one for
operation and one for peakload/stand-by. Downstream of each booster pump a
pressure switch (PAL) for pump supervision is installed. The stand-by pump starts
automatically in case of a pump failure.
The common discharge line is equipped with two pressure switches with
adjustable hysteresis, one switch is adjusted at 7/8 bar for Start/Stop the
pre-selected operation pump, and one switch is adjusted at 6,5/7,5 bar for
Start/Stop the pre-selected stand-by pump.In the main water line downstream of the
water booster pump skid a diaphragm water accumulator is installed in order
reduce the start/stop intervals of the pumps, and to buffer and pressurize the
required operating water volume for the bowl ejection-cycles of the separators.
d.Controls
The common control cabinet for fuel oil treatment plant is designed for
installation inside of an air conditioned control room. All control logics and control
loops for the operation and supervision of the fuel oil treatment process are
managed within this control cabinet which is equipped with a PLC and all
required motor starters and circuit breakers. Emergency stop push buttons are
installed inside the skids and one is installed at the control for emergency stop of
the complete system. The emergency stop circuits for the emergency stop buttons
and separator vibration switches NAHH are hard wired executed and will not be
influenced by PLC failures.
The process status and function as well all alarms and failures of the treatment
plant are visualized at the Operator Work Station, equipped with monitor,
key-board and track-ball. The Operator Work Station is designed for installation
inside an air conditioned control room.
10.1.7.4Technical Data’s For Main Equiment
a.Transfer Pump, Heat Recovery & Demulsifier Dosing Skid
87
Suction Strainer:
KKS No.: 01EPN01AT001/AT002
No. of: one (1)
Kind: Duplex basket strainer
Manufacturer: FILTREX
Type: DFSU-726/S-200
Size: DN 200
Connection: DIN EN Flange, DN200, PN16
Design Pressure: 10 bar g
Design Temperature: 100°C
Body material: mild carbon steel, welded construction
Degree of filtration 0,25 mm absolute
Pressure loss: < 0,1 bar (clean)
Diff. pressure indicator: contact setting Δp = 0,3 bar
Transfer Pump:
KKS No.: 01EPN11/21AP001
No. of: two (2) in operation, one (1) as stand-by
Kind: Screw spindle type, vertical type
Manufacturer: Leistritz
Type: L3NG-125/200-ASOKII-G
Suction connection: DIN EN Flange, DN250, PN16
Pressure connection: DIN EN Flange, DN250, PN16
Capacity: 120 m³/h @ 180 cSt / 117 m³/h @ 50 cSt
Speed: 1450 1/min
Differential pressure: 6,0 bar
Power consumption: 31,4 kW @ 180 cSt / 27,4 kW @ 50 cSt
NPSH-required: 5 mWC @ 180 cSt / 4,1 mWC @ 50 cSt
Pump body material: ductile iron EN-GJS-400 (GGG-40)
Spindle material steel, 16MnCrS5
Motor: 400V, 50 Hz, 50,6 kW, 1450 1/min, IEC size 225 / V1,
InsCl. F, space heater 230V, protection EExde…/IP54
Demulsifier Dosing Pump:

KKS No: 01EPN09AP001/AP002
No. of: two (2), one (1) in operation, one (1) as stand-by
Kind: Piston type
Manufacturer: BRAN+LUEBBE
Type: NOVADOS E-P31
88
Stroke adjustment (manual): 0 – 20 mm stroke length (depend on required
dosing ratio)
Motor Speed adjustment: 1:4 , by frequency converter 17/34/51/68 Hz
(depends on FOTP skids in operation)
Capacity at max stroke length: 12,5 l/h @ 17 Hz converter frequency
25,1 l/h @ 34 Hz converter frequency
37,6 l/h @ 51 Hz converter frequency
50,2 l /h @ 68 Hz converter frequency
Piston diameter / stroke length: ∅ 20 mm / max. 20 mm
Pressure at suction side: flooded suction
Pressure at press. side: max. 10 bar g
Body material: S.S. 1.4571
Piston material: S.S. 1.4571
Motor: 400 V, 50 Hz (17 – 51 Hz), 0,55 kW, 1400 1/min @ 50 Hz,
Ins. Cl. F, PTC thermistor, protection EExdeIICT4 / IP55
Demulsifier Tank:
KKS No: 01EHR09BB001
No. of: one (1)
Manufacturer: Behle
Volume: 1 m³
Design pressure: Atmospheric
Material: S.S. 1,4301
Heat Exchanger (for HSFO Heat Recovery):

KKS No: 01EPN01AH001
No. of: one (1)
Kind: Plate type
Manufacturer: GEA Ecoflex
Type: NT150L B-10
No. off plates: 229
Exchange surface: 186 m²
Plate material: AISI 316
Plate thickness: 0,5 mm
Frame material: mild carbon steel, S235-JRG2
Gasket material: NBR, glue less
Design pressure: 10 bar
Design temperature: 120°C
Connection size: DN150, PN10
89
Heat transfer: 933 kW
Medium: cold side: untreated HSFO warm side: treated HSFO
Mass flow: cold side: 113.600 kg/h warm side: 86.020 kg/h
Volume flow: cold side: 120,5 kg/h warm side: 92,4 m³/h
Inlet temperature: cold side: 64,6°C warm side: 98°C
Outlet temperature: cold side: 79°C warm side: 79°C
Pressure drop: cold side: 0,99 bar warm side: 0,44bar
b. HSFO Treatment Skid’s (typical for HSFO treatment skid 1)
HSFO Treatment Skid 1: KKS No.: 02 EPN ….
Heat Exchanger, HSFO Heater:
KKS No.: 02EPN01AH001
No. of: one (1)
Kind: Tube type heat exchanger, vertical,
Manufacturer: Prang
Type: WT-16-27-1
Material shell: Mild carbon steel, St35.8
Material tubes: Mild carbon steel, St37.4
Material tube plates: Mild carbon steel, P265GH
No. of streams (tube side): one (1)
Heat transfer: 621,7 kW
Medium shell / tube side: shell side: HSFO tube side: Steaml
Flow shell/tube side: shell side: 31 m³/h tube side: 1.062 kg/h
Inlet temperature: shell side: 60°C tube side: 152°C
Outlet temperature: shell side: 98°C tube side: 152°C
Pressure drop: shell side: 0,81 bar
Design pressure Temperature: 10 bar g / 200°C
Connections: DIN EN Flange
shell side: DN80 PN16 tube side: DN80 / DN50 PN16
Exchange surface: 16 m³
Design code: PED 97/23/EC , TÜV-Inspection
Heat Exchanger, Wash Water Heater:

KKS No.: 02EPN03AH001
No. of: one (1)
Kind: Tube type heat exchanger, vertical,
Manufacturer: Prang
90
Type: WT-2,5-15-4
Material shell: Mild carbon steel, St35.8
Material tubes: 1.4571 / 316TI
Material tube plates: 1.4571 / 316Ti
No. of streams (tube side): two (2)
Heat transfer: 336 kW
Medium shell / tube side: shell side: Staem tube side: Wash Water
Flow shell/tube side: shell side: 574 kg/h tube side: 3,1 m³/h
Inlet temperature: shell side: 152°C tube side: 5°C
Outlet temperature: shell side: 152°C tube side: 98°C
Pressure drop: tube side: 0,16 bar
Design pressure/temperature: 10 bar g / 200°C
Connection: DIN EN Flange
shell side: DN50 / DN25 PN16 tube side: DN25 PN16
Exchange surface: 2,5 m³
Design code: PED 97/23/EC , TÜV-Inspection
HFO Main Flow Indicator/Meter:

KKS No.: 02EPN01CF001
No. of: one (1) per
Kind: Ultrasonic type, three channel
Manufacturer: Krohne
Type: UFM 3030 K
Connection / Size: DIN EN Flange DN80, PN40
Body material: 1.4404 / 316L
Range: 0 – 40 m³/h
Accuracy: < + 0,5% of measuring value @ velocity 0,5 – 20 m/s
Power supply: 24 V DC
Output: 4 – 20 mA = 0 – 40 m³/h
Local indication: 0 – 40 m³/h
Protection: IP 67
Wash Water Flow Indicator:

KKS No.: 02EPN03CF501
No. of: one (1)
Kind: Variable area flow indicator
Manufacturer: Krohne
Type: H250 RR M9
Connection / Size: DIN Flange DN 25, PN 40
91
Body material: 1.4404 / 316L
Range / local indication: 400 – 4000 dm³/h Water @ 25°C
Accuracy: class 1,6
Multi Stage Mixer:

KKS No.: 02EPN11/21AM001
No. of: two (2) , one (1) in 1st and one (1) in 2nd process stage
Kind: Multi stage mixer
Manufacturer: Prema-Service
Type: VA-1200-A055-7,5kW
Net volume: ~ 2,63 m³
No. of mixing stages / agitators: five (5)
Agitator diameter: ∅ 500 mm
Vessel material: mild carbon steel, St35.8 / HII / C22.8
Design pressure: 4 bar g
Design temperature: 120°C
Design code: PED97/23EC / AD2000 , TÜV
Gear motor: 400V, 50 Hz, 7,5 kW, Ins.-Cl. F, IP55, space heater 230 V
protection EExdeIICT4 / IP55
HFO Separator:
KKS No.: 02EPN11/21AT001
No. of: two (2) , one (1) in 1st and one (1) in 2nd process stage
Kind: Centrifugal separator
Manufacturer: Westfalia Separator Systems GmbH
Type: OSE80-01-037/80 (self cleaning type)
Separating capacity, per separator: up to 31 m³/h HSFO/HFO, plus up to 10%
wash water addition
Operation mode: purifier, 2-stage series operation
Kind of bowl e-jection: total ejection (total de-sludging)
Bowl speed: 6800 1/min
Electric motor: 400 V, 50 Hz, 37 kW, 1470 1/min, IEC size 225S / V1
Ins.-Cl. F, space heater 230V, PTC-thermistors
protection EExdeIICT4 / IP55
Sludge Pump:
KKS No: 02EPN06AP001/AP002
No. of: two (2), one (1) in operation, one (1) as stand-by
Kind: Eccentric worm type
92
Manufacturer: Allweiler
Type: AEB1E50-IE/011P01M-113P5846
Capacity: 2 m³/h
Speed: ~ 329 1/min
Pressure at suction side: - 0,1 bar g
Pressure at discharge side: 3 bar g
Pump body material: EN GJL-250 (GG-25, grey cast iron)
Stator, material / temp. range: Perbunan, temp. range 76 – 105°C
Rotor material 1.2436
Gear motor: 400V, 50 Hz, 0,75 kW, 1450 1/min,IEC size 80, Ins.-Cl. F
Protection EExdeIICT4 / IP55
Sludge Collecting Channel:

KKS No: 02EPN06B001
No. of: one (1)
Size: square tube 400x400x10, length 9050 mm
integrated part of foundation frame
Design Pressure: atmospheric,
Material: Mild carbon steel R-St52.3
Storage vol. between LSH / LSL: approx.: 170 dm³,
the sludge collecting channel will be frequently emptied at
each separator bowl ejection or when the level LSH is
reached in order to avoid sediment accumulations.
c.Water Booster Pump Skid
Water Booster Pump:
KKS No.: 06EPN13/23AP001
No. of: two (2), one (1) in operation, one (1) for peak-load / stand-by
Kind: Multistage inline centrifugal type, vertical
Manufacturer: Apollo
Type: KIVR-50/7-540/GN
Capacity: 15 m³/h @ 85 mWC
Speed: 2900 1/min
Feed press. 0,1 – 6 bar g
Motor: 400V, 50 Hz, 9,2 kW, 2850 1/min, Ins.-Cl. F
Protection EExdeIICT4 / IP54
Water Accumulator (loose supply)

KKS No.: 06EPN03BB001
No. of: one (1)
93
Kind: Diaphragm type
Manufacturer: Reflex
Type: DT 2000
Nom. Volume: 2 m³
Usable volume, max.: 1,8 m
Diaphragm pre-load: 4 bar g
Design Pressure / Temperature: 16 bar g / 70°C
Connection: 2 x DIN EN Flange, DN80, PN16
Design code: PED 97/23 EC
10.1.7.5 Adjustments and Set Point
a. Transfer Pump, Heat Recovery & Demulsifier Dosing Skid
KKS No.: Setting point of
Description Remarks
01EPN .. ..... Instrument
Safety valve,
01EPN01 AA003 suction filter 5,0 bar g fixed
(thermal relief)
Safety valve,
01EPN11 AA002
transfer pump 5,0 bar g fixed
01EPN21 AA002
(thermal relief)
Safety valve, heat
01EPN01 AA005
exchanger 10,0 bar g fixed
01EPN02 AA002
(thermal relief)
01EPN01 AA009 Overflow valve 4,0 bar g
Differential
01EPN01 CP001 pressure switch, DPAH: 0,3 bar fixed
suction filter
Pressure switch,
01EPN11 CP001
transfer pump PAH: 3,0 bar
01EPN21 CP001
discharge
Relief valve, dosing
pump
01EPN09 AA009 10,0 bar g fixed
(pump
protection)
Pressure retain
01EPN09 AA010 2,0 bar g fixed
valve
depends on
Dosing ratio:
01EPN09 AP002 Demulsifier HFO quality
~ 50 to 250
01EPN09 AP003 dosing pump and selected
ppm
demulsifier
Pressure switch,
01EPN09 CP001 dosing pump PAL: 1,5 bar
discharge
94
Level switch, LAL: ~ 150 mm
01EPN09 CL001 fixed
demulsifer tank from bottom
01EPN01 CT002
01EPN01 CT003
01EPN01 CT004 Electric trace TS: 55°C
01EPN01 CT005 heating TAH: 150°C
01EPN11 CT001
01EPN21 CT001
b. HSFO Treatment Skid’s, typical for HSFO Treatment Skid 1
Description
HSFO Treatment
KKS No.: Skid 1
02EPN .. ..... HSFO Treatment
Setting point of
03EPN .. ..... Skid 2 Remarks
Instrument
04EPN .. ..... HSFO Treatment
05EPN .. ..... Skid 3
HSFO Treatment
Skid
Safety valve, HSFO
02EPN01 AA006
lines 10 bar g fixed
02EPN22 AA003
(thermal relief)
02EPN11 AA001 Safety valve,
4,0 bar g fixed
02EPN21 AA001 Mixer
Safety valve, water
02EPN03 AA010 heater 6,0 bar g fixed
(thermal relief)
HSFO main feed
02EPN01 AA004
throttle valve/Main 31,00 m³/h
/02EPN01 CF001
flow indicator
Throttle valve, 1st CAUTION !
stage same feed pressure throttle valve
02EPN11 AA003 separator feed at re-circulation and should be
/02EPN11 CP501 pressure / separation mode, opened as
separator feed press < 3 bar g much as
gauge 1st stage possible!
Throttle valve, 2nd CAUTION !
stage same feed pressure throttle valve
02EPN21 AA003 separator feed at re-circulation and should be
/02EPN21 CP501 pressure / separation mode, opened as
separator feed press < 3 bar g much as
gauge 2nd stage possible!
HSFO discharge
02EPN11 AA006
throttle valve, of 1st 3,0 bar g
/02EPN11 CP502
stage separator /
95
discharge pressure
gauge
HSFO discharge
throttle valve, of
02EPN22 AA002
2nd stage separator 3,0 bar g
/02EPN22 CP501
/ discharge pressure
gauge
Wash water
02EPN03 AA002
pressure reducer 3,5 bar g
/02EPN03 CP501
/pressure gauge
Wash water throttle
4 – 6% (max. 10%) Depends on
02EPN03 AA007 valve
of actual fuel oil fuel oil
/02EPN03 CF501 Wash water flow
flow quality
indicator
Operating water at open
pressure operating
02EPN13 AA001
reducer, 1st stage 2,5 bar g water
/02EPN13 CP501
separator / pressure solenoid
gauge valve
Operating water at open
pressure operating
02EPN23 AA001
reducer, 2nd stage 2,5 bar g water
/02EPN23 CP501
separator / pressure solenoid
gauge valve
Compressed air
02EPN04 AA002 pressure
5.0 bar g
/02EPN04 CP501 reducer / pressure
gauge
Pressure switch,
02EPN01 CP001 upstream 1st stage PAH : 3,5 bar g
Mixer
Pressure switch,
02EPN11 CP001 HSFO outlet 1st PAL : 2,5 bar g
stage Separator
Pressure switch,
02EPN11 CP002 HSFO outlet PAH : 4,5 bar g
1st stage Separator
Pressure switch,
02EPN22 CP001 HSFO outlet PAL : 2,5 bar g
2nd stage Separator
Pressure switch,
02EPN22 CP002 HSFO outlet PAH : 4,5 bar g
2nd stage Separator
02EPN15 CP001 Pressure switch, PAH : 3,5 bar g
96
Waste Water Outlet
1st stage Separator
Pressure switch,
02EPN25 CP001 Waste Water Outlet PAH : 3,5 bar g
2nd stage Separator
Temperature adjustment at
02EPN01 CT001
control, (TC) : 98°C FOTP
(TC)
HSFO heater control
adjustment at
02EPN01 CT001 Temperature alarm, (TAH) : 108°C
FOTP
(TAHL) HSFO heater (TAL) : 88°C
control
adjustment at
02EPN11 CT001 Temperature alarm, (TAH) : 108°C
FOTP
(TAHL) 1st stage mixer (TAL) : 88°C
control
adjustment at
02EPN21 CT001 Temperature alarm,
(TAL) : 88°C FOTP
(TAL) 2nd stage mixer
control
Temperature adjustment at
02EPN03 CT001
control, (TC) : 98°C FOTP
(TC)
Water heater control
Temperature
control,
02EPN06 CT502 TC : 50°C
sludge collecting
channel
Vibration switch, NSH ...: 4,5 mm/s
02EPN11 CY001 fixed
1st stage Separator NAHH : 7,0 mm /s
Vibration switch, NSH ...: 4,5 mm/s
02EPN21 CY001 fixed
2nd stage Separator NAHH : 7,0 mm /s
Water sensor,
adjustment at
02EPN22 CQ001 HSFO QAH : 0,5%
FOTP control
discharge
Level switch LSL,
LSL : 80 mm
02EPN06 CL001 Sludge collecting fixed
from bottom
channel
Level switch LSH,
LSH : 130 mm
02EPN06 CL002 Sludge collecting fixed
from bottom
channel
Level switch
LAHH, LAHH : 280 mm
02EPN06 CL003 fixed
Sludge collecting from bottom
channel
02EPN01 CT002
Electric trace TS: 55°C
02EPN11 CT003
heating TAH: 150°C
02EPN21 CT003
97
02EPN06 CT001
c.Water Booster Pump Skid, Water Accumulator
Description
KKS No.: Setting point of
Water Booster Remarks
06EPN ..3. ..... Instrument
Pump Skid
Start / Stop
Pressure switch
pre-selected
water pump PSL: 7 bar g
06EPN03 CP001 operational
discharge line PSH: 8 bar g
water
PSHL
booster pump
Start / Stop
Pressure switch
stand-by/peak-lo
water pump PSL: 6,5 bar g
06EPN03 CP002 ad
discharge line PSH: 7,5 bar g
water booster
PSHL
pump
Pressure switch
06EPN13 CP001
pump PAL: 5,5bar g
06EPN23 CP002
discharge
Diaphragm water Diaphragm
06EPN03 BB001
accumulator pre-load: 4,0 bar g
10.1.8 The Operation of HSFO Treatment Plant
10.1.8.1 Before Commissioning And Start-up
The pipes installed by the customer must be checked by overpressure and for
tightness.
Check that the operating media are available as specified in the data sheet.
All electrical connections must be installed in accordance with the standard
applicable regulations and standards.
The grounding connection for the frame can be seen on the installation
drawing.
The electric trace heating and insulation must be completely installed at the
interconnectingpipe header on site. The installation has been done in accordance
with the instructions, givenin the manual for the common pipe header
installation.
Before assembling the bowl of the separator, the direction of rotation of the
spindle must bechecked (clockwise when looked at from above).
The separator bowl must be mounted in accordance with the instructions in the
separatormanual. All screws of the hood, the bowl and pipes must be tight.
A leakage test must have been truckried out:
Hydrostatic tests: Should only be conducted on all site fabricated pipe work
Leak test: Leak test on skid with 1 bar, test medium should be nitrogen or air
It must be ensured that the exhaust air system which serves to vent the sludge
channels connects every treatment skids vent individually to its deflector cap,
98
located outside of thebuilding. It is not allowed to lead the sludge channel vents
into one commonventilation line.
The deflector caps belong to customers scope of supply.
In accordance to the Block Diagram, one steam trap and 3 globe valves have to
be installed inthe steam piping on site. These belong to customers scope of
supply.
10.1.8.2Before Initial Start-up
a. Switch on the main switch of the control cabinet before the piping is filled
withHSFO.The electric pipe trace heating is only in operation in case that the
main switch is ON !
b. Check if all sample, drain and vent cocks are closed.
c. Check that no insulation material has been removed from piping and valves
in order tosecure that the electric trace heating can keep constant pipe
temperature.
d. Prepare all aggregates according the corresponding operation manuals.
e. Check the adjustment of the instruments acc. to the instrument setting list
inside the DataSheet & Function Description and the individual manuals of
aggregates and components
f. Fill-up and de-aerate the main fuel oil feed and discharge pipes with fuel oil.
g. Fill up and de-aerate properly the fuel oil suction strainer, the transfer pumps
and heatrecovery plate heat exchanger with fuel oil
h. Secure that the drain and vent valves in closed position and protected against
improperopening in order to avoid accidentally opening during operation.
i. Fill up and de-aerate the service water pipes with demin. water and de-aerate
the watersupply pumps properly.
j. Prepare the separators and select the regulating ring according to the
corresponding gf1installation manual
k. Fill in demusifier into the demulisfier storage tank of the transfer pump skid
and pre-adjustthe dosing pump stroke adjustments to expected stroke length.
l. Pre-fill the sludge collecting channels of the treatment skid with water up to a
level of 100mm from bottom.
10.1.8.3 Start-up
a. Check if all sample and vent cocks are closed
b. Check that all instrument valves are open and the vent ports of the
instrument valves are closed.
c. Check if all manual operated service shut-off valves and throttle valves are
open.
d. Check that the separators and aggregates are prepared for start-up acc. to
thecorresponding instruction manuals.
e. Check the pre-adjustment of the instruments acc. to the setting list in the
Data Sheet & Function Description
99
f. Switch on the power supply at the control cabinet the „Main switch“ (Q1or
Q2), wait until the Operator Touch panel is completely started and shows the
process overview page.
g. Use the mouse and the keyboard to enter the page of the HSFO Treatment
Plant. From this page and its sub-pages the whole treatment plant can be
controlled and operated.
h. At first all depending drives for operation have to pre-selected that means
the relevant sludge pump, transfer pump and dosing pump for operation has to be
pre-selected to “pump 1 or 2” and then set the relevant drives to AUTO-Mode.
i. Pre-select the Water Booster pump which shall be operated as basic load.
Therefore please touch the button “Wtr. booster pumps” and select the pump. The
other pump will be for peak load and stand-by.
j. Pre-select 3 HSFO Treatment skids in the AUTO-Mode section for
automatic start up. One HSFO-Treatment plant is normally for stand by and has
to be pre-selected to “OFF”
k. Select now the Wash Water Addition, because wash water addition is
necessary for the separation process. If this function is selected, it is valid for all
selected separators.
l. Pre-select/check now the separation time for all separators by touching first
the field below “Separating time”. Please select there the time as mentioned in the
Timer Setting List.
m. If all selections are done, the system is ready for process start. To start the
process, please touch the button “Process Start“.The system will start up
automatically with the pre-selected HSFO Treatment skids. Afterthe rated speed
of the separators is reached, the separators will pass a closing programfor each
bowl. Then the pre-selected transfer pump starts. As soon as the temperature
ofthe fuel oil and the wash water has reached the preselected temperatures, the
treatmentsystem will go automatically into separation-process.
n. Now check and if required, re-adjust the fuel oil feed capacity at the main
feed throttle valve of each treatment skid to 31 m³/h per separator, and fix the
valve position by screwing the limit screw into centre of the hand wheel.
o. Check and if required, re-adjust the fuel oil discharge pressure of each
separator at the throttle valve in the separators discharge line to 3,0 bar and fix the
valve position by screwing the limit screw into the centre of the hand wheel.
p. Check and adjust the press. control valve for wash water to 3,5 bar g.
q. Check and adjust the press. control valves of each separators operating water
to 2,5 bar g at open solenoid valve for operating water.
w. Check and adjust the press. control valves for compressed air to 5 bar g.
10.1.8.4 Shut-down
Shut-Down
At normal operation condition it is not allowed to stop the HSFO treatment
plant by the
100
switches
“Emergency Stop” and “Main Switch”
Push the button “Emergency Stop” only in case of emergency!
Shut-Down by “Process Stop”
Stop the Light Fuel oil separation program of the skid by touching the button
“Process Stop” atthe control.
The HSFO transfer pump will be stopped and the wash water valve will close
after treatmentskids main shutoff valves and all separator 3-way feed valves are
closed. The separators willtruckry out a bowl ejection cycle and the separator
motors will be stopped.
Attention
Before maintenance works or after shut-down of a separator, the throttle
valves in the
feed and discharge pipe of this separator have to be closed.
The HSFO feed- and discharge hoses at the stopped separator have to be
drained
immediately after shut-down by the sample/drain ball valves.
This is necessary to avoid that the fuel cools down and blocks the
hoses!Further Notes and instructions for start-up, operation, shut-down and
maintenance are given inthe start and stop instructions of the individual manuals
of the separator and individual plantcomponents.
10.1.9 Waste Oil Processing
Part of the waste oil comes from the oil stain left in eight oil tanks, and part
comes from the oil stain produced by oil processing device as well as the oil stain
produced by duplex strainer and the residues left in all components and valves.
The waste oil flows into waste oil pool and then flows into oil sewerage system
under the function of waste oil delivery pump.
Water Oil Pit
Q=41m3
Dirty Oil Delivery Pump
Q=10m3 /h head 5bar
10.1.10 Steam Process

In the whole process of heavy oil delivery, the main heating manner is steam
heating. The steam comes from the auxiliary boiler and F6181S-J1801-02. The
first part of steam is for warming the heavy oil before the heavy oil flows into
underground oil tank; the second part is for keeping the oil temperature of heavy
oil that flows out of underground oil pool, before it flows into standby oil tank;
the third part is for heating the heavy oil that flows into standby oil tank inlet pipe
and outlet pipe; the fourth part is for heating the heavy oil in working oil tank
inlet and outlet pipes; the fifth part is for heating heavy oil feed pump outlet pipe;
the sixth part is for heating of heavy oil rear heater; the seventh part is for heating
101
of oil processing device. In all figures below: flow direction is from left to right
according to the table.
Tabe-1
OENT21AA OENT21AA OENB303AC
008 009 001
OENT10AA OENT20AA OENT21AA OENT21AA OENB303AC
001 001 005 006 002
OENT21AA OENT21AA OENB303AC
002 003 003
Tabe-2
OENT10AA001 OENR01BB001
Tabe-3
Double-Filter For HSOF Oil Transfer Pump To
Auxiliary Boiler
OENT22AA00
OENT10A OENT21A 2~7
A001 A001 OENT23A OENT22A OENT22AA00
A001 A001 8~11
OENT22AA00
12~15
Tabe-4
OENT34AA001
OENT10AA001 OENT30AA001 OENT33AA001

OENT32AA001
OENT31AA001
Tabe-5
Wash the ground
OENT10AA001 OENT71AA422
OENT62AA020~001
Tabe-6
HSOF unloading pump/ Duplex
OENT10AA001 OENT60AA001 strainer before HSOF unloading
pump
Tabe-7
OENT54AA001
OENT53AA001
OENT10AA001 OENT50AA001
OENT52AA001
OENT51AA001
102
10.2 Light Oil System (HSD)
10.2.1 Equipment Specification
Tabe-1
High Speed Diesel (HSD) Oil Specification
UNIT TEST
TEST LIMITS
S METHODS
Ash %Wt Max. 0.01
Truckbon Residue, Conradson %Wt Max. 0.1
Pour Point Deg. C Max. -6
Cloud Point Deg. C Max. +5
Colour ASTM - Max. 2.5
Corrosion, copper strip
- Max. No.1
3h＠100℃
Centane Number/Centane
- Min.45
Index
Flash point, PMcc Deg. C Min. 66
Min.0.820
Relative Density @ 60/60℉
Max.0.870
Sediment %Wt Max. 0.01
Sulphur %W Max. 1.0
Min. 1.6
Viscosity, Kinematic @37.8℃ cst
Max. 5.5
Water %Vol Max. 0.10
Calorific Value Gross BTU/lb 18500 43.031MJ/Kg
Inlet oil temperasure： Normal temperature
Largest fuel oil consumption： 2.6t/h
Inlet pipe size： D57×5
Fuel oil supply pipe size: D133×5
Tabe-2
Underground Receiving Oil Pit V=100m3
HSD Oil Tank V=10000m3

Double-Filter For HSD Oil Unloading Pump
Diameter DN20
Medium High Speed Diesel
Pressure 1.0MPa
103
Flow
200m3 /h
Main parts materials Shell and the flange:truckbon steel
Mesh and orifice plate: stainless
steel
Tabe-3
Double-Filter For HSD Oil Transfer Pump To Diesel Generator
Flow
Q=6m3 /h
Pressure 1.0MPa
Tabe-4
HSD Oil Transfer Pump To Diesel Generator
Type SNH120R46E6.7W21
Motor Type Y100L
Motor Output 3kw
Flow
5.8m3 /h
Pressure 1.0MPa
Speed 1450rpm
Weight 123KG
Coupling HRC110 FF28/28
Base Plant bolt M16X300
Base Plate/Frame 273 8003 006
Transition plate/Shield HZP 150.75.90
Tabe-5 Y-strainer
Type-1
Type 50FWSL-60/1.0-B1
Diameter DN50
Pressure 1.0MPa
Flow
5m3 /h
Type-2
Type 50FWSL-60/1.0-B2
Diameter DN50
104
Pressure 1.0MPa
Flow
6m3 /h
Type-3
Diameter DN65
Pressure 1.0MPa
Flow
6m3 /h
Tabe-6
Double-Filter For HSD Oil Transfer Pump To Auxiliary Boiler
Type 50FWSL-0/1.0-B
Flow
5m3/ h
Pressure 1.0MPa
Tabe-7
HSD Oil Transfer Pump To Auxiliary Boiler
Pump Type SNH120R42E6.7W21
Motor Type Y91L
Motor Output 1.5kw
Flow
5m3 /h
Pressure 0.5MPa
Speed 1450rpm
Weight 103KG
Coupling HRC110 FF24/28
Base Plant/Frame 273 8003 006
Transition plate/Shield HZP 150.75.90
Base Plant bolt M16X300
Tabe-8
1 Ultrasonic flow meter LDC
Q=5m3 /h
2
Q=200m3 /h
105
3
Q=37.6m3 /h
10.2.2 Light Oil Unloading Process

Light oil firstly flows from car oil tanker into light oil underground unloading
pool - front duplex strainer of light oil unloading pump - light oil unloading pump
- motor operation control valve - flow measuring device - light oil tank.
Check-up before oil unloading:
a. Check to make sure valves OEGA11AA004, OEGA11AA003, OEGA11AA002
and OEGA11AA001 are in open state
b. Check to make sure valve OEGA10BB001 is in closed state
c. Check to make sure the front duplex strainer OEGA10AT001 of light oil
unloading pump is in open state
d. Check to make sure valves OEGA31AA001 and OEGA32AA001 are in open
state
e. Check to make sure light oil fee pumps OEGA10AP001 and OEGA10AO002
are in open state
f. Check to make sure valves OEGA31AA002 and OEGA32AA002 are in open
state
g. Check to make sure valves OEGA31AA101 and OEGA32AA101 are in open
state
h. Check to make sure flow detector left and right valves OEGA40AA00A and
OEGA40AA002 are in open state
i. Check to make sure valves OEGB10AA101 and OEGB11AA101 are in open
state
j. Check to make sure valves OEGB20AA001 and OEGB21AA001 are in closed
state
k. After light oil unloading preparation, open valve OEGA10BB001, light oil will
flow into oil tank and all return pipes are open.
10.2.3 HSD Unloading Pump Specification
HSD Oil Unloading Pump
Pump type VS-250MB-75
Motor Output 75kw
Flow 200m3 /h
Pressure 0.6MPa
Coupling weight 40kg
Accessories weight 40kg
Speed 1450rpm
106
10.2.4 Light Oil Delivery Process
Light oil firstly flows from ROAD TANKER to the underground oil unloading
pool, then to front duplex strainer of light oil unloading pump, light oil unloading
pump and flow measuring device, and then into two oil tanks. The light oil that
flows out of oil tanks will be divided into three parts: the first part flows
according to such process: the duplex strainer of diesel generator light oil feed
pump -- diesel generator light oil feed pump -- HSD Oil Emergency Diesel
Generator/Diesel Engine Driven Fire Fighting Pump; the second part flows
according to such process: the duplex strainer of auxiliary boiler light oil feed
pump -- auxiliary boiler light oil feed pump -- flow measuring device -- Auxiliary
Boilers; the third part flows according to such process: Y Type Oil-Filter –
turbine oil feed pump HSD Forwarding Pump -- Oil-Filter -- flow meter –
turbine.
10.2.5 Waste Oil Processing
The main source of light oil stain is oil tank and its branch pipes and valves.
The waste oil produced will all flow into waste oil tank and will flow into Oil
Discharge System under the function of waste oil pump.
Water Oil Pit
Q=40m3
Oil Filter
Q=10m3 /h P=6bar
Dirty Oil Delivery Pump
Q=10m3 /h P=5bar
10.2.6 Steam Process

The heating of light oil mainly comes from Auxiliary Steam System (Refer to
auxiliary boiler system), to heat the inlet and outlet of light oil tank. Before
steam enters valve OEGT32AA001, the steam pipelines will begin to divide:
Path for the first part (flow direction from left to right):
OEGT32AA202/OEGT32AA002~3
OEGT32AA001 OEGT32AA201 OEGT32AA004~5

OEGT32AA006~7
OEGT32AA015~18
Another part will heat light oil inlet and outlet pipes. Before steam enters
OEGT31AA001, the steam pipelines begin to divide again:
Path for the first part (flow direction from left to right):
OEGT31AA001
OEGT31AA015~18
107
10.3 Fuel Oil Sample
10.3.1 Meaning of Specification Tests
Chemical tests are specified because slag-forming substances present in oil
ash can cause turbine corrosion and deposits, and the presence of sulfur can
result in corrosion of heat recovery equipment in the turbine exhaust. Certain
physical tests are specified because they influence the operation of the gas
turbine fuel handling, fuel treatment and combustion systems.
10.3.1.1Ash and Trace Metal Contaminants
Ash-forming materials may be present in a fuel as oil-soluble
organometallic compounds, as watersoluble salts in water dispersed in the fuel,
or as solid foreign contaminants. The most common ashforming elements
which can be present in fuels are aluminum, calcium, iron, magnesium, nickel,
potassium, sodium, silicon and vanadium. Ash-forming materials are present
to varying degrees in crude oils depending on their geographical source. They
are concentrated in the residual fractions during the refining process, leaving
the light distillates contaminant-free; however, ash-forming materials may be
introduced later by contamination with salt-bearing water or with other
petroleum products during transportation and storage.
Gas turbine operating experience has shown that some of the ash-forming
substances that may be present in the fuel can lead to corrosion and deposit
problems. These problems are most acute with residual and crude oils which
contain larger quantities of the troublesome substances. Corrosion can result
from vanadium, sodium, potassium or lead. These elements as well as calcium
(and others such as magnesium, manganese, iron, silicon and aluminum) can
cause ash deposits which are difficult to remove. Calcium can act as an
effective inhibitor for vanadium corrosion, but its deposition tendencies have
precluded its use.
In light distillate fuels, the total ash content is usually very small, and trace
metal contamination is essentially a sodium (salt) problem. There are also
usually traces of lead and calcium and smaller traces of potassium and
vanadium. It is advantageous to purchase fuel within the specified
contaminant limits and to maintain this quality during transportation, handling
and storage. On-site desalting by contaminated water removal or by fuel
washing of distillate fuels with relatively high sodium levels is required to
keep corrosion of the hot gas path and the fuel system components, such as
flow dividers and fuel pumps, at a very minimum level.
Crudes and contaminated distillates almost without exception have high
enough salt levels, or the risk of significant salt levels, that they require
desalting. The vanadium levels may also be significant and require the
addition of a magnesium-base inhibitor to establish a ratio of 3 parts of
magnesium to 1part of vanadium by weight.
108
Residual fuels have the highest ash and trace metal contaminant levels
usually necessitating complete fuel pretreatment: desalting and vanadium
inhibition by a magnesium-based additive (3:1 Mg: V ratio as above). Due to
the less favorable physical properties of residual fuels, it is not possible to
reduce the sodium consistently to the low levels obtainable in light crudes and
distillates. The higher sodium levels in treated residual fuels result in
controlled corrosion and deposit accumulation with some increase in
maintenance. Calcium levels may be high in some residual fuels, but they may
be appreciably lowered by the fuel treatment. Nickel, which is not removed by
fuel treatment, may also be high in certain residual fuels and is somewhat
beneficial in that it tends to neutralize vanadium corrosion in much the manner
of magnesium. Residual fuels contain harmless aluminum, iron and silica as
components of suspended solids (dirt). A significant portion of these
suspended particles is removed either in the fuel washing or by fuel filtration.
10.3.1.2Sulfur
Sulfur occurs in fuels as combustible organic compounds yielding sulfur
oxides on combustion.
These combine with any traces of sodium or potassium present to form
alkali sulfates; a principal source of hot corrosion. The sulfur level in a fuel
cannot be lowered enough by refining to avoid the formation of alkali sulfates;
they must be controlled by limiting the sodium and potassium levels in the fuel.
Gas turbine installations utilizing exhaust heat recovery equipment could
have metal temperatures below the dewpoint of sulfuric acid, and in these cases
it is necessary to know the sulfur level in the fuel to avoid acid corrosion of
heat transfer surfaces. The maximum allowable sulfur to avoid sulfuric acid
condensation will depend on the specific heat recovery equipment used. For
fuels exceeding this maximum level, the operating temperature of the heat
recovery equipment could be changed accordingly to avoid condensation of
acid products.
The sulfur level of liquid fuels is regulated in many localities as a means of
controlling the emission of sulfur oxides in the exhaust gases.
Crude oils burned directly as fuels may also contain active sulfur in the
form of hydrogen sulfide or mercaptans. These substances, especially in the
presence of water, may cause corrosion to fuel system components. For this
reason, the water content of such fuels should be kept as low as possible.
10.3.1.3 Nitrogen
Fuel-bound nitrogen in petroleum fuels comes largely from organo-nitrogen
compounds present in the original crude oil. In some distillate fuels, fuel-bound
nitrogen may also come from additives such as stabilizers.
This chemically bound nitrogen in the fuel will contribute to the total nitrogen
oxide pollutant in the exhaust gases, adding to the nitrogen oxides from the direct
combination of atmospheric nitrogen and oxygen in the gas turbine combustion
reaction. The particular combustion system and operating conditions will affect the
109
total nitrogen oxide production from both atmospheric and fuel-bound
nitrogen.
10.3.1.4Hydrogen
The percent combined hydrogen in a hydrocarbon fuel is a critical factor in
controlling stack smoke levels. In general, the higher the hydrogen content in a
liquid fuel the lower the smoke level will be. As an example: paraffinic
hydrocarbons with high hydrogen contents (14-15%) have much less tendency to
smoke than do aromatic hydrocarbons which can have 10% or less hydrogen.
Hydrogen is usually determined by an accurate measurement of the amount of
water produced in the controlled combustion of a weighed amount of fuel.
10.3.1.5Carbon Residue
Carbon residue is measured as the residue remaining when a fuel sample is
completely distilled in a standard apparatus. To obtain measurable residue with
light distillates, the fuel is first distilled to remove 90% (ASTM Method D 86) by
volume, and then the carbon residue is determined on the 10% Residuum or 10%
Bottoms. One effect of a high carbon residue is carbon formation near the fuel
nozzle. To control this, air atomization is used in the combustion of all but the
lightest fuels, high pressure air being required for the heaviest fuels.
10.3.1.6Water and Sediment
Water and sediment in a fuel oil tend to cause fouling of the fuel handling
facilities and the gas turbine fuel system. Accordingly they should be kept at as
low a value as practicable and always within the maximum values shown in this
specification.
The sediment in fuel can be gums, resins, asphaltic materials, carbon, scale,
sand or mud. It is mainly a problem in residual fuels. Very few distillate fuels
leave the refinery with more than 0.05% water and sediment. However, poor
handling practices can unnecessarily raise this level, and once an oil becomes
contaminated it may not be feasible to restore its original cleanliness, such as the
case of lead or vanadium contamination. ASTM D 2709 is the preferred test for
distillate fuels; ASTM D 1796 is preferred for the heavier fuels.
Gas turbines are normally equipped with high capacity filters. Since there are
practical limits to the efficiency of filtration systems, a fraction of the solids
entering the filter remains in the oil and can be an important factor in fuel system
component life. Since the design of the filters is dependent on the fuel type,
Consult GE Energy for specific details of the filter sizes.
Fuel storage tanks should be designed with floating suctions that are equipped
with low level bottom limits to insure that the suction is always some distance
from the bottom to avoid the water and sediment that collects there. The operator
should drain the bottom of the tank periodically to reduce the accumulation and
the risk of contamination. Automatic water drainage systems are preferred.
110
10.3.1.7 Filterable Dirt
Filterable dirt is essentially the suspended solid particulate matter in a distillate
fuel which can cause fuel filter maintenance problems. It is measured as the
weight of solids held on a low porosity filter during the filtration of a given
volume of fuel. The filterable dirt level of distillate fuels generally does not
exceed 10mg per 100ml of the fuel. Higher levels than 10mg per l00ml may result
in shorter filter lives and are not recommended.
10.3.1.8 Viscosity
The viscosity of fuel is a measure of its resistance to flow. It is important in the
fuel auxiliary equipment since it determines pumping temperature, atomizing
temperature and oil pump pressure.
In order to obtain proper operation of the gas turbine, the maximum viscosity
at the fuel nozzles must not exceed 10 centistokes for pressure atomizing or
low-pressure air-atomization fuel systems, and 20 centistokes for high-pressure
air-atomizing systems. When these limits are exceeded, poor ignition
characteristics, smoking, unsatisfactory combustor exit temperature distribution,
lowered combustion efficiency or formation of carbon may occur. In most cases,
fuel heating must be employed to insure that these viscosity limits at the fuel
nozzle are met under all ambient conditions. In all cases the fuel at initial light-off
must be at or below 10 cSt viscosity.
Minimum viscosity limits are imposed to safeguard the high pressure fuel
pump, which depends on the lubricating qualities of the fuel for satisfactory
operation. It should be noted that naphtha fuel can have a minimum viscosity as
low as 0.5 cSt at 100°F (37.8°C).
Special pumps may be required for viscosities below 1.8 cSt at 100°F.
10.3.1.9Pour Point and Cold Filter Plugging Point
The pour point of a fuel is the temperature at which it will barely flow under
standard conditions, and it is significant in connection with fuels that may require
heating to make them pumpable and with fuels fed to a pump by gravity flow.
Petroleum oils when cooled may change to a plastic state as a result of partial
separation of wax (wax pour) or by congealing of hydrocarbons (viscous pour)
comprising the oil.
A waxy fuel must be maintained at a high enough temperature to ensure that
all of the wax is in solution to prevent wax crystals from clogging filters and lines.
For distillates, wax separation can usually be avoided by heating the fuel to at
least 20-30°F (11-17°C) above the pour point.
Waxy crude oils used as fuels may require even higher temperature
differentials. Each type of waxy fuel must be evaluated individually for minimum
wax solution temperature.
111
In cold climatic areas, determination of the lowest temperature at which a fuel
will give trouble-freeflow, can also be determined by Cold Filter Plugging Point
(CFPP) test per ASTM D 6371. There is no limit set for CFPP but the fuel
temperature should be kept at least 5-10°F above the CFPP.
10.3.1.10 Fuel Gravity
The specific gravity (relative density) is not a critical property of gas turbine
fuels. Within a given fuel type it can indicate the chemical composition of the
hydrocarbons. As an example, a distillate with a low specific gravity will be
largely paraffinic whereas a high specific gravity will be more aromatic. The latter
would have a greater tendency to smoke with other factors being equal.
Gravity can have an economic significance where the fuel is purchased by
volume since the total heat units will decrease with decreasing specific gravity.
Residual fuels requiring washing will be more difficult to wash if the specific
gravity approaches that of water.
In the petroleum industry it is customary to use API gravity instead of specific
gravity for convenience since the API system eliminates the small decimal
difference between fuel samples encountered in the use of specific gravity. It is
always referenced to 60°F (15.6°C).
Some typical examples are:

Table . API Gravity Scale Values
Specific Degrees
Gravity API
Water 1.00 10.0
Kerosense 0.78-0.83 50-39
No. 0.82-0.86 41-33
2Distillate
Crudes and 0.80-0.92 45-22
Blends
Residual 0.92-1.05 22-3
Oils
10.3.1.11 Distillation
The heavy duty gas turbine is not sensitive to the distillation characteristics of
the fuel per se.
Extremely volatile fuels such as naphthas require the use of a start-up fuel
112
(light distillate) due to the low temperature at which they vaporize, giving the
possibility of combustible vapors in the fuel lines.
Very high end-point fuels, approximately 1000°F (538°C), can have excessive
traces of vanadium which have distilled over. For this reason pure distillate
usually would havea maximum end point specification. (This is also prevented by
setting a maximum vanadium level.)
10.3.1.12 Flash Point
The flash point of a fuel is the temperature at which fuel vapors will flash
when ignited by an external flame.
The flash point is regulated for safety in fuel handling and storage. By itself it
is not critical to turbine operation although it can affect the requirements for
auxiliary equipment such as motors, relays,heaters, etc.
Minimum permissible flash points are regulated by local, state or federal laws.
Explosion-proofing of equipment may be required by local, state or federal
regulations or other applicable codes when the flash point is below a minimum
permissible value.
10.3.1.13 Thermal Stability
The thermal stability of anoil is a measure of its ability to resist breaking down
when heated to form deposits of resins and sludge. This can occur in the fuel
nozzle area and in fuel heaters especially if the heater surface is far hotter than the
surrounding oil. This polymerization to form deposits is a time-temperature
phenomenon, accelerated by high temperatures, long exposure times and contact
with air. Methods other than the ASTM D 1661 should be proposed to GE Energy
where this older method is not readily available.
Thermal stability is most critical for high viscosity residual fuels which require
high temperatures to meet fuel atomization viscosity requirements. The maximum
allowable temperature specified is 275°F (135°C).
10.3.1.13Compatibility
Mixing certain residual type fuels with dissimilar residual fuels or diluting
residual type fuels withcertain distillates may result in the formation of tarry
precipitates. The precipitation may occur immediately after mixing or may take
some time to develop. Heating for prolonged periods of time will generally
accelerate the separation.
This tarry residue can accumulate in the bottom of tanks and can settle out in
fuel lines and on filters.
When the separation of residue occurs, it is usually in those residual fuels
which have a heavy asphaltene fraction present as a colloidal metastable gel, fuels
that generally have had an intensive heating history during refining. The nature of
113
a solvent used for dilution (blending) is also important; paraffinic (low specific
gravity) distillates are more apt to cause precipitation than aromatic (high specific
gravity) distillates.
One method of testing for compatibility is to make a 50-50 mixture of two oils
and then subjecting the mixture to a thermal stability test. A simple screening test
is ASTM D 4740, " Standard Test Method for Cleanliness and Compatibility of
Residual Fuels by Spot Test."
ASTM Specifications do not specify this property, again because it has not
been the practice of the oil suppliers to make this test. These specifications do not
call for the test on the light distillate oils because it is very rare that they encounter
compatibility difficulties with one another. However, for the heavier oils, it is
necessary to start up and shut down the gas turbine on a light distillate oil;
therefore, it is advisable to test the compatibility of the heavy oil/distillate
mixture.
10.3.1.14 Cetane Number
Cetane number is an index of the burning quality of fuel in a diesel engine. It is
specified only when the turbine fuel is also used in a diesel starting engine.
Cetane number is most accurately measured in a special test engine, but a
reasonably accurate value can be obtained from a correlation between the specific
gravity and the 50% distillation point.
10.3.2 Fuel Analysis Data Requirements
To evaluate a liquid fuel for gas turbine application certain physical and
chemical data are required. Basic specification requirements are given in Table 2.
Certain other data are needed for engineering purposes. Table is a list of
required data. Following is pertinent information on some of the analytical tests.
10.3.2.1 Sampling
Since analyses of small traces of metals are involved, and since some tests use
small amounts of sample, it is very important that the fuel sample is uniform and
representative of the fuel as received by the user or shipped by the supplier. If the
fuel is taken from a container, it should be thoroughly mixed mechanically before
sampling. For sampling from storage tanks, refer to ASTM Standard Methods for
Sampling Petroleum Products, D 4057 and D 4177.
The sample for analysis should be stored preferably in plastic or plastic-lined
metal containers. Avoid metal cans with soldered seams and containers with seals
(rubber) that can disintegrate and contaminate the fuel. The container should only
be about two-thirds full so that it may be well shaken before taking analytical
samples. Heavy residual fuels should be in wide-mouth containers.
10.3.2.2 Heat of Combustion (Heating Value or Calorific Value)
The heat of combustion measured is the Gross Heat of Combustion, where the
114
water produced is condensed. SI units are MJ/kg (multiply by .002326 for
BTU/lb.) Gross Heat of Combustion is also known as the Higher Heating Value or
Gross Calorific Value. ASTM D 4809 and D 240 are methods for this
determination. The Net Heat of Combustion (Lower Heating Value or Net
Calorific Value) is calculated from the Gross Heat and an accurate value for
percent hydrogen in the fuel. (ASTM D 1405 is an estimation method for Net
Heat of Combustion that is based on aniline point and density but is limited to the
very light fuels.)
10.3.2.3 Viscosity
Viscosities at two temperatures are needed for a viscosity-temperature
relationship for the fuel; the two temperatures normally being 100°F (37.8°C) and
210 F (98.9°C). If the pour point is between 70°F (21°C) and 90°F (32°C), the
lower temperature should be 122°F (50.0°C). For pour points between 90°F (32°C)
and 120°F (49°C), the lower temperature should be 150°F (65.6°C).
10.3.2.4 Trace Metal Analysis
Trace metal contaminant levels are usually measured by spectrometric
methods such as atomic absorption, flame emission or a spark source
spectrometry. The first two methods use a solvent diluted fuel sample while the
latter operates directly on the original fuel. In any case, the reference standards
must match the fuel properties as closely as possible. For achieving better
detection limits on trace metals, Graphite Furnace Atomic Absorption (GFAA) or
Inductively Coupled Plasma-Mass Spectroscopy techniques are recommended.
For very accurate analyses of vanadium and lead, it is better to ash the fuel and
run the spectrometric analysis on an aqueous solution of the treated ash. In the
ashing procedure, special care must be taken not to lose these elements.
10.3.2.5 Wax Content and Wax Melting Point
Crude oils and heavy true distillates should be tested to determine the
minimum fuel temperature required to keep all of the wax in solution.
One approach is to remove the wax from the fuel and then to determine its
melting point, which represents the maximum solution temperature. There is no
standard method for wax separation, but there are several laboratory procedures
which are satisfactory. They all involve dilution of the fuel with a poor wax
solvent and then chilling to 0°F (-18°C) or lower to separate the wax crystals
which are filtered out at low temperature.
For light distillate fuels, ASTM D 2500 Cloud Point or ASTM D3117 Wax
Appearance Point may be used
115
116

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NANDIPUR 425MW CCPP AUXILIARY BOILER& FUEL OIL OPERATION MANUAL

Abbreviation Full Title

HSFO High Sulphur Furnace Oil

HSD High Speed Diesel

DCS Distributed Control System

PLC Programmable Logic Controller

LED Light Emitting Diode

This manual is edited on the basis of provisions and relevant drawings

FUEL OIL SYSTEM

AB-00-GENERAL DRAWING OF BOILER

1Auxiliary Boiler Specification ............................................................... 1

7 Boiler Water System ........................................................................... 49

1Auxiliary Boiler Specification

No Unit /Item Data

Ash %W Max. 0.10 ASTM D 482/IP-4/75

Calorific Value, Gross BTU/Lb Min. 18200 ASTM D-240

TEST UNITS LIMITS TEST METHODS

a. The basic elements for hardness mmol/L is C（1/2Ca2+、1/2Mg2+）。

b. The basic elements for alkalinity mmol/L is C（OH-、HCO3-、1/2CO32-）。

Deoxidation Water Pump Size Table：

2 Conditions and Tests before Starting the Boiler

2.6.3 Safety Valve Regulation Process and Notes

3 Start of the Boiler Unit

(1)Burner (2)Ladder (3)Control panel (4)Base (5)Manual blow-down

3.2 Preparation before Starting the Boiler

Vt=7.31E-6.31/E in unit mm2/s.

Fig 5 Fig 6 Fig 7

Fig 8 Fig 9 Fig 10

Fig 11 Fig 12 Fig 13

Fig 16 Fig 17……………Fig 18

Fig19 Fig 20 Fig21

4 Supervision and Regulation during Boiler Operation

b.Superheater steam pressure：1.226MPa；

c.Superheater steam temperature：200℃；

f. Make-up water tank water level：0±800mm；

g. Superheater flue gas inlet wall temperature: 465.319℃

h. Superheater flue gas outlet wall temperature: 413.533℃

5 Stop of Auxiliary Boiler

6 Operating Procedures of Burner

6.3.2The Operation of Programmer for Burner

6.3.2.1 Check the following items before initial start-up：

6.5 Burner Adjustment

1 Regulating 10 Steam. Hexagonal

7 Boiler Water System

1 Heavy oil tank Steam heatng area S=2m2

Figure 1. Gear pump operating

1. rear cover; 2 gasket; 3 bearing housing; 4 bearing

8.7.2Safety Valve Discharge Value

2 Rated pressure of boiler Pe Mpa 1

9 Boiler Accident Handling

10 GT Fuel Oil System

Tabe-3 HSFO supply pump of auxiliary boiler

10.1.2Trap Flash Tank

b. Heavy Fuel Oil Heat Exchanger

10.1.4 Heavy Oil Unloading

Demulsifier Dosing Pump:

Heat Exchanger (for HSFO Heat Recovery):

Heat Exchanger, Wash Water Heater:

HFO Main Flow Indicator/Meter:

Wash Water Flow Indicator:

Multi Stage Mixer:

Sludge Collecting Channel:

Water Accumulator (loose supply)