Vickers Hoskins (M) Sdn. Bhd. ( 37739-A) ADDRESS: Lot 6074, Jln. Hj.

Abdul Manan, 42200 Kapar Selangor, Malaysia Tel: ++(603) 33927385 Fax: ++(603) 33927389 www.vickershoskins.com

BOILER OPERATION
CHECKS & STEPS REQUIRED BEFORE, DURING & AFTER OPERATION OF BOILER
1. Check water level in the boiler. Normally half full in the steam drum. 2. Ensure all valves are in good working condition. All valves must be tightly closed except the feedwater valve and blow down stop valve. 3. Ensure that air compressor is in good working condition and the compressor head is filled with oil. 4. Open the air vent valve. If there is superheater both the air vent valve and drain valve must be opened (more care must be taken for the superheater to prevent the tubes from been punctured or distorted). Always check the drain bypass pipe orifice, if blocked clean immediately. 5. Ensure the ID fan and FD fan dampers and fuel door can be opened and closed manually. Open the dampers before starting any burning to allow the gases to flow. 6. Inspect the fire grate, brickwork and air nozzles in the furnace ensuring they are in good condition. Ensure the air lock is not blocked. 7. During burning, the temperature in the furnace must rise slowly and gradually to prevent any cracks in the brickwork. 8. When the steam pressure is at 3 bar, close the air vent valve. 9. Open and close the side headers drain valves two (2) to three (3) times to flush out the dirt and residue. 10. Ensure the instrument and control panel is switched off before switching on the ID fan to prevent burnt out of electronic instruments. The voltage will drop while the ID fan is switch on. 11. Ensure the ID fan damper is fully closed before starting the fan motor. FD fan damper shall also be fully closed before starting fan motor. 12. During manual operation of the ID and FD fans, ensure the furnace draft reading is between 0-50mm Hg. 13. When boiler pressure is at ten (10) bar. a. Manually check gauge glass for leaks and the water level. i. Close steam and water valves and open drain valve. ii. With drain valve opened, open the water valve and listen for water draining out, then close the water valve. iii. With drain valve opened, open the steam valve and listen for steam discharge, then close the steam valve. iv. Now close the drain valve and open both steam and water valves. You will see the correct water level in the gauge glass. b. Check Mobrey control to ensure extra low alarm is working properly. i. Close steam and water valves and open drain valve. ii. When the water in the chamber drained off, the float will sink to the bottom. iii. Now the extra low alarm will sound. Process Value (PV) of Chino should be about 21%. iv. Dirt in the chamber will also be drained off. v. Close the drain valve and then open slowly the water valve. The float will rise up. vi. Now open the steam valve, the Mobrey will show normal water level. vii. While testing extra low water level, all equipments must be switched off except the fuel feeder fan in order to ensure the extra low alarm works.

Vickers Hoskins (M) Sdn. Bhd. ( 37739-A) ADDRESS: Lot 6074, Jln. Hj. Abdul Manan, 42200 Kapar Selangor, Malaysia Tel: ++(603) 33927385 Fax: ++(603) 33927389 www.vickershoskins.com

c.

Open and close the blowdown valve quickly several times continuously for 10 to 15 seconds. If the Total Dissolved Solid (TDS) level is higher than normal, blowdown more frequently.

d. Open and close all side headers drain valves. If the boiler was operated for twenty four (24) hours, open the valve slowly and close when the dirt is discharged. 14. When the boiler pressure reaches fifteen (15) bar, open the main stop valve and ensure all main and turbine drain valves are opened. Once the pressure is at set point, switch the ID fan and FD fan dampers to Auto control. 15. Ensure the electrical pump outlet valve is closed before switching on the pump motor to prevent tripping. When the motor is on, open the outlet valve slowly ensuring that the amp is below the specified amps. Check that the pressure relief pipe orifice is not blocked from time to time. 16. Clean the smoke density sensor every morning. If the smoke reading is higher than normal, clean again. Rightly the reading should be same as the smoke in the chimney. 17. Ensure the fuel in the furnace is evenly spread. Always and each time when opening the firedoor, ensure the FD fan damper is manually closed to prevent back fire. Remove the ash from the ash pit every sixteen (16) operating hours. After the ash has been removed, fill the ash pit with water to the required level. 18. Discharge water in the boiler with the blowdown every hour. Check that the TDS is between 2000 to 2200 ppm. If the TDS value is higher, discharge more frequently to achieve the required value. 19. While opening the Pressure Reducing Valve (PRV) for soot blowing, ensure by opening slowly and intermittently. The pressure shall not exceed 100 psi (Pressure for PRV is 100 psi or 7 bar). Soot blowing should be carried out everyday every six (6) to eight (8) hours. a. Ensure soot blower drain valve is opened and not blocked. b. Ensure the pressure does not exceed 100 psi. c. Ensure the soot blower pipe is not bent. 20. When stopping operation of boiler, ensure water in the boiler is enough. 21. Remove all fuel and ash from the furnace and ash pit. 22. Ensure main steam outlet, PRV, steam pump, feedwater inlet, and blowdown stop valve are closed. 23. After switching off ID fan, open the damper fully to release the air and gases in the furnace. 24. Reduce the boiler pressure as much as possible. Discharge water and dirt from the headers. 25. Before returning home, ensure water in drum is three quarter (3/4) full (level will drop when pressure drop). Turbine Feedwater Pump a. Ensure there is oil in the governor. b. Apply oil to all handle and spring. c. Inspect the trip handle. d. Warm up the turbine everyday. e. Replace turbine oil every three (3) months.

Vickers Hoskins (M) Sdn. Bhd. ( 37739-A) ADDRESS: Lot 6074, Jln. Hj. Abdul Manan, 42200 Kapar Selangor, Malaysia Tel: ++(603) 33927385 Fax: ++(603) 33927389 www.vickershoskins.com

DAILY TASKS. a. Drain air compressor every hour. b. Remove ash in ash pit every sixteen (16) hours. c. Soot blow every six (6) to eight (8) hours. d. Blow down water every hour, if TDS is high blow down more frequently. e. Check power pack oil level and open coolant drain valve when running air compressor. Inspect drain valve regularly. WEEKLY TASKS (MAINTENANCE DAY) a. Clean areas in furnace and ash pit. b. Clear all openings in the furnace. c. Inspect and clean inside of ash hopper. d. Clean ID fan and ash from chimney. e. Dismantle and service ID and FD fan cylinder pistons. f. Apply grease to every valve stem (gear). g. Tidy boiler area. h. Apply grease to turbine and electric feedwater pump. EVERY THREE (3) MONTHLY TASKS. a. Clean boiler tubes area and dust collector. b. Replace air compressor oil. c. Inspect soot blower elements (blow pipes). d. Inspect dust collector cones for puncture. e. Replace water in the pressure gauge pipe. f. Inspect internals of steam drum and re-tighten bolts & nuts. Check that scrubber plates are tight and correct to prevent water carry over. EVERY SIX (6) MONTHLY TASKS. a. Inspect the steam and water drums for dirt and residue.