Dwadsad

PT. POSCO E&C INDONESIA-PT.
KE
BLOCK NO. DWG. NO.
NO. A DATE 2012. 09. 20 REVISIONS & DESCRIPTION FIRST ISSUE
CLASS NO. I01-110-EZ610-10300

Drawn J.H.CHO Checked S.M.GO Reviewed Approved
W.J.CHOI C.H.CHONG
OPERATION & MAINTENANCE MANUAL
File No : POSCO Engineering & Construction DOCUMENT STATUS 1. Work may proceed. Contractor may proceed with fabrication or construction in accordance with specification. 2. Revise and resubmit. Contractor may proceed in accordance with specification based on making revisions as noted and resumit. 3. Revise and resubmit(work may not proceed). Revise as noted and resubmit. Hold fabrication/ construction. 4. For information only M. Resubmit. Not acceptable for microfilm or reproductions. Otherwise considered status 1 and work may proceed. NOTE. Permission to proceed does not constitue acceptance or approval of design data, calculations, analysis, test methods or materials developed or selected by the supplier and does not relieve the supplier from full compliance with contractural obligations. REVIEW DATE : . .
FOR APPROVAL
UNIT TOTAL QUANTITY PERUN TOTAL WEIGHT(KG) SCALE NONE A4
NO.
DESCRIPTION
MAT'(KS)
REMARK'S
PROJECTION NONE DIMENSION NONE
PT KRAKATAU POSCO POWER

SIZE
REF. DWG. NO.
TITLE
Indonesia ISM Power Plant
EQUIPMENT MAKER DWG. NO.
DRAWN POSCO E&C SIGNATURE DATE
CHECKED
REVIEWED
APPROVED
DRAWN
CHECKED S.M.GO 12.9.20
REVIEWED W.J.CHOI 12.9.20
APPROVED C.H.CHONG 12.9.20
PROJECT DWG No.
BHI
I01-110-EZ61010300
J.H.CHO 12.9.20
POSCO POWER DWG No.
INDONESIA ISM POWER PLANT

STEAM GENERATOR & AUXILLIARIES TABLE OF CONTENTS Paragraph Number List of Figures List of Attachments SECTION 1 1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.4.1 1.3.4.2 1.3.4.3 1.3.4.4 1.3.5 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.5 1.6 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6 1.6.7 1.6.8 1.6.9 1.6.10 1.6.11 1.6.12 DESCRIPTION GENERAL BOILER SYSTEM Water and Steam Flow Air and Gas Flow Fuel and Firing Equipment Steam Temperature Regulation
DATE REV. NO. DOC. NO. I01-110-EZ61010300
2012-09-20 A PAGE i
Title
Page iv v
1-1 1-2 1-2 1-2 1-3 1-3 1-4 1-4 1-4 1-5 1-6 1-6 1-6 1-6 1-7 1-7 1-7 1-7 1-7 1-7 1-8 1-8 1-8 1-8 1-9 1-9 1-9 1-9 1-9 1-9 1-10 1-10 1-10 1-11 1-11 1-11 1-11
STEAM GENERATOR PRESSURE PARTS COMPONENTS Economizer Steam Drum Furnace Superheaters Stringer Tubes, Roof and Heat Recovery Area (HRA) Rear Wall Primary Superheater Secondary Superheater Finishing Superheater Reheater BOILER PIPING SYSTEM HP Steam and Reheat Steam Boiler Feedwater Boiler Economizer Recirculation Boiler Drain, Vent and Blowdown Sampling and Chemical Dosing Utilities REFRACTORY, THERMAL, ACOUSTIC INSULATION & LAGGING AUXILIARY EQUIPMENT Fuel Burning Equipment Fans Motors Gas Air Heater Sootblowers Dampers Safety Valves Valves CCTV Systems Steam Drum Level Indicating System Instrumentation Miscellaneous BHI CO. LTD

STEAM GENERATOR & AUXILLIARIES
2012-09-20 A PAGE ii
SECTION 2 2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.6 2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.8 2.9
SAFETY PRECAUTIONS AND PREPARATION FOR OPERATION SAFETY PRECAUTIONS HYDROSTATIC TESTS DRYING OUT REFRACTORY BOILING OUT General Preparation for Boiling Out Recommended Chemicals for Boiling Out Boiling Out Procedure CHEMICAL CLEANING OF ECO. & STEAM GENERATING CIRCUITS General Determining the Extent of Chemical Cleaning Solvent Systems General Cleaning Operations OPERATIONAL CHEMICAL CLEANING OF SH & RH FEEDWATER AND BOILER WATER TREATMENT General Corrosion Scale Formation Water Treatment for the Prevention of Carryover Points to Consider with Respect to Feedwater Limits During Start-Up Operations MAXIMUM RECOMMENDED DRUM PRESSURE DROP DURING STEAM BLOWS SETTING OF SAFETY VALVES 2-1 2-2 2-4 2-5 2-5 2-5 2-7 2-7 2-8 2-8 2-8 2-8 2-9 2-9 2-9 2-9 2-11 2-12 2-12 2-12 2-13 2-13
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SECTION 3 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.3.8 3.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.6 3.7 3.7.1 3.7.2 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 3.9 3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5
OPERATIONS AND MAINTENANCE GENERAL PRECAUTIONS COLD AND WARM START-UP PROCEDURE Preparation Prior to Start-Up Purging the Unit Fuel Safety Preparation for Light-Off Combination Burners Firing Methods Light-Off (HFO Heavy Oil Firing 100% Basis) Light-Off BFG exclusive Firing (BFG Firing 90% + Stabilizing COG 10%) Light-Off Combination Firing (BFG Firing 90% + Stabilizing HFO 10%) Raising Pressure and Loading Turbine HOT START-UP (LESS THAN 6 HOUR SHUT-DOWN) OF STEAM GENERATOR NORMAL OPERATION Firing Fuel Switching Water Chemistry and Steam Purity Acoustic Cleaning System for Boiler and Steam Soot blowing for Gas Air Heater Steam Attemperation NORMAL SHUTDOWN LOAD REJECTION Fast Cut Back (FCB) Burner Action from BMS ERV (Electromagnetic Relief Valve) EMERGENCIES Tube Failures Gradual Loss of Water Sudden Loss of Water Loss of Combustion Safety Interlocks Burner Safety MAINTENANCE SPECIAL AIR HEATER INSTRUCTIONS Preparation Before Light-Off Precautions Against Air Heater Fires Air Heater Washing Instructions Emergency Action Stationary Washing Equipment 3-1 3-1 3-3 3-3 3-8 3-10 3-11 3-12 3-13 3-15 3-18 3-22 3-25 3-28 3-28 3-28 3-29 3-30 3-31 3-31 3-33 3-33 3-33 3-33 3-33 3-33 3-33 3-33 3-34 3-34 3-34 3-36 3-36 3-37 3-37 3-38 3-39
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LIST OF FIGURES FIGURE NO. SECTION 1 1-1 1-2 1-3 1-4 SECTION 2 2-1 2-2 2-3 2-4 SECTION 3 3-1 3-2 3-3 3-4 DRAWINGS P&ID Diagrams I01-110-ER103-01010 I01-110-ER103-01011 I01-110-ER103-01020 I01-110-ER103-01030 I01-110-ER103-01035 I01-110-ER103-01040 I01-110-ER103-01050 I01-110-ER103-01060 I01-110-ER103-01070 I01-110-ER103-01080 I01-110-ER103-01090 I01-110-ER103-01100 I01-110-ER103-01110 I01-110-ER103-01120 I01-110-ER103-01130 I01-110-ER103-01140 I01-110-ER103-01160 I01-110-ER103-01170 I01-110-ER103-01180 I01-110-ER103-01190 I01-110-ER103-01200 I01-110-ER103-01210 I01-110-ER103-01220 I01-110-ER103-01230 I01-110-ER103-01240 I01-110-ER103-01250 Title
Performance Data Steam and Water Flow Air and Gas Flow Steam Drum Internals
Recommended Boiling Out Pressures for Different Design Pressures Vaporous Carryover Response Surface of Trisodium Phosphate Maximum Silica Concentration in Boiler Water to Limit Silica in Steam to 20 PPB Maximum Recommended Drum Pressure Drop During Steam Blows
Cold Start-Up Curve Warm Start-Up Curve Hot Start-Up Curve Saturation Temperature at Various Reheat Inlet Pressures
LEGEND & SYMBOL 1/2 LEGEND & SYMBOL 2/2 STEAM & WATER SYSTEM 1/3 STEAM & WATER SYSTEM 2/3 STEAM & WATER SYSTEM 3/3 AIR & FLUE GAS SYSTEM GAH DETAIL FD FAN DETAIL ID FAN DETAIL GI FAN DETAIL FRESH WATER & CLEAR WATER & CCW FLOW DIAGRAM BLOWDOWN SYSTEM STEAM AIR HEATER SYSTEM SOOT BLOWER SYSTEM CONTROL AIR FLOW DIAGRAM SEAL AIR FLOW DIAGRAM FUEL & BURNER SYSTEM 1/10 FUEL & BURNER SYSTEM 2/10 FUEL & BURNER SYSTEM 3/10 FUEL & BURNER SYSTEM 4/10 FUEL & BURNER SYSTEM 5/10 FUEL & BURNER SYSTEM 6/10 FUEL & BURNER SYSTEM 7/10 FUEL & BURNER SYSTEM 8/10 FUEL & BURNER SYSTEM 9/10 FUEL & BURNER SYSTEM 10/10

2012-09-20 A PAGE v
LIST OF ATTACHMENT ATTACHMENT NO. ATTACHMENT - 1 ATTACHMENT - 2 ATTACHMENT - 3 ATTACHMENT - 4 ATTACHMENT - 5 ATTACHMENT - 6 ATTACHMENT - 7 ATTACHMENT - 8 ATTACHMENT - 9 ATTACHMENT - 10 ATTACHMENT - 11 ATTACHMENT - 12 Title Fuel Burning Equipment Fans Motors Gas Air Heaters Sootblowers Dampers Safety Valves Valves C.C.T.V. Systems Steam Drum Level Indicating Instrumentations Miscellaneous

2012-09-20 A PAGE 1-1
SECTION I DESCRIPTION 1.1 GENERAL The single stage reheat steam generator is a natural circulation unit designed to fire BFG (Blast Furnace Gas) as main fuel and together with COG (Coke Oven Gas) LDG (Basic Oxygen Furnace Gas) and heavy Oil as auxiliary or stabilizing fuel continuously in a balanced draft furnace. The unit is designed to deliver as much as 360,000 Kg/ Hr high pressure (128.5 Barg, 541 C) steam at Boiler Maximum Continuous Rated (BMCR) load. Combustion air is furnished by a forced draft (FD) fan system. The unit also includes a flue gas recirculation (FGR) system. The FGR system reduces the formation of Nitrogen Oxide (NOx) emissions by reducing burner flame temperatures. In addition, the unit is equipped to vary portions of the FGR flow as a means to control reheat temperatures. The steam generator consists of water wall furnace, horizontal bank convection superheaters (primary, secondary and final superheater), a horizontal bank convection reheater and horizontal economizer banks. Combustion is accomplished in the lower portion of the furnace, where heat is absorbed by the furnace front, rear and side water wall tube circuits. The water wall circuits are gas-tight panels of welded fin tube construction and are able to contain and direct the flow of flue gases through the unit. About half way up the unit, the rear water wall pitches away from the rear wall into the center of the furnace, after which it continues vertically upward to the roof. As the rear water wall tube circuit approaches the roof, the furnace wall changes, from a closed surface, to rows of open, staggered tubes, which allow flue gas to pass and move through the horizontal bank convection reheater tubes, then to a Heat Recovery Area (HRA) partition. The HRA partition links the up-flow and down-flow sections of the unit. In addition to the water wall circuits mentioned above, the unit includes the following tube circuits: 1) HRA Roof and Rear Wall linked to the HRA Side Walls. 2) Horizontal and Vertical Hanging Tubes Primary superheater and Economizer Banks are situated in the convective HRA section of the unit. The Secondary Superheater,Final Superheater and horizontal - vertical hanging tube sections are within the radiant furnace. Final superheater steam temperature is controlled by spray water attemperators. Final reheat steam temperature is controlled by varying the flow of flue gas recirculation. Other major components include GAH (Gas Air Heater, Steam air pre-heater, steam drum, air/gas movement equipment (including FD, GI and ID Fans) to stack. Figure 1-1 contains a sectional side view of the steam generator and Summary Performance Sheets which tabulate physical and operational data for this unit for several load conditions. Descriptions of the operating components of the steam generator are given below. Installation, operation and maintenance instructions for auxiliary equipment manufactured by others and supplied by BHI are contained in subsequent parts of this manual. Piping and Instrumentation Diagrams (P&ID's) are provided at the end of this volume and are referred to, as necessary, in the following descriptions. They are identified in the preceding list of illustrations.
NOTE
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DRAWINGS ARE TYPICALLY NUMBERED AS I01-110-ER10301020, 01030, ETC. FROM THIS POINT ON, REFERENCES IN TEXT WILL BE SHORTENED TO -01020, -01030, ETC. 1.2 BOILER SYSTEM 1.2.1 WATER AND STEAM FLOW Figure 1-2 and Drawings 01020, -01030 and -01035 show in a diagram the flow paths of water and steam through the unit. Feedwater is introduced into the unit in the economizer inlet header. It flows through the economizer section and from each end of the outlet header through external pipes to each end of the steam drum. The feedwater enters the drum and is distributed internally along the drum length by perforated feed pipes. Water from the drum is supplied to the furnace waterwalls through external downcomer pipes. Feeder tubes from the bottom of the downcomer pipes distribute water to the furnace front, rear and side waterwall lower headers. Steam is generated as the water flows up through the furnace walls and is heated. The steam/water mixture leaves the waterwalls, and discharges through riser tubes into the steam drum where the steam and water are separated. The separated steam leaves through the top of the steam drum and passes through the HRA partition transfer pipe to the hanging tubes. The hanging tubes are also used to support the final and secondary superheater. The steam is superheated as it flows next through the roof transfer pipes HRA rear wall, HRA Rear - Side wall common header and rises through HRA side walls to primary superheater, secondary superheater and through the final superheater, ready as feed to the HP turbine stage. A reheater section is provided to increase the temperature of steam received from the turbine high pressure (HP) stage. Reheat steam is normally fed to the IP turbine stage. Drawing 01035 shows this circuit in more detail. A motorized globe valve economizer recirculating system is installed connecting two downcomers, and a check valve one on each side of the unit, to drain connections on the economizer inlet header. During startup, when there is no feedwater flow to the drum, the motorized globe valves are opened to allow economizer water to naturally circulate to the drum, thus promoting flow in an otherwise stagnant flow circuit. The hot economizer water is replaced with colder water from the downcomers. In addition, a motorized globe valve water filling system is installed to compensate water and system losses and to maintain steam drum water level during startup. It also functions as a makeup water system for boiler water treatment. Water spray apparatus (attemperators) for controlling steam temperature is provided in the supply pipe carrying steam from the primary superheater to the secondary superheater and in supply pipe connecting the secondary superheater to the final superheater. The unit is equipped with a startup and load rejection system with motorized globe valve and Electromagnetic relief valve respectively (See Drawing 01030). 1.2.2 AIR AND GAS FLOW Figure 1-3 and Drawing -01040 show in a diagram the air and gas flow paths through the unit. Air is delivered by a forced draft fan through a steam air heater to the air side of a gas - air heater. Heating elements, which rotate continuously through the gas and air sides of the air heater, absorb heat from the hot flue gas in the gas side, rotate to the air side and heat the incoming air. The heated air flows to a gas/air mixing box. Here, the air is mixed with recirculated flue gas delivered by the GI fans. This gas mixture is distribution to the burner windboxes. After entering the windboxes, the air/gas mixture then enters the furnace through control dampers on the burner assemblies.
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The hot gas produced by the burning of fuel travels upward through the furnace giving up heat to the furnace waterwalls. In its upward path, beyond the furnace, the gas flows across the tubes of the hanging tubes, secondary superheater and final superheater. The gas then flows to the steam generator giving up heat to the roof tubes, to the screen formed by the furnace rear waterwall tubes, Reheater and to the HRA partition wall tubes located in the first convection pass. The gas turns into the rear pass (second convection pass) flows downward across the primary superheater and the economizer and exits the HRA. A portion of the gas is withdrawn by the flue gas recirculation fan and the remainder flows through the gas side of the Gas Air heater to the stack, where it is discharged to the atmosphere. The Gas Injection (GI) fan takes gas for recirculation from the horizontal flue immediately downstream of the economizer. Gas then flows to the Reheater Temperature Control Damper and enters the rear wall beneath the hopper throat via slots between the tubes. This gas is used for controlling reheat steam temperature as a first option another option is to control the Reheater (RH) Pass and Primary Superheater (PSH) dampers installed in the Furnace and HRA respectively. Both options are required to make reheat temperatures at higher turndown ratios. A portion of this gas is then branched into the combustion air ducts for each windbox to control Nitrogen Oxide (NOx). The recirculated gas and combustion air mixture is injected into the burners thereby cooling the peak flame temperature. The mixing box consists of a plenum with tubes extending across the interior. These tubes have holes along their length. As air enters the box on the outside of the tubes, gas enters the tubes and is sparged into the air via these holes. 1.2.3 FUEL AND FIRING EQUIPMENT The combination burners are designed to fire BFG, COG, LDG, and Heavy Oil fuels. Nine (9) burners are arranged in (3) levels and (3) rows located at the steam generator front, the lower (3) burners are designed to fire BFG and LDG as main fuel, middle (3) burners to fire BFG, LDG and Heavy Oil and upper (3) burners to fire BFG, COG and Heavy oil. All burners have sub fuel firing COG and Heavy Oil. The combination low- NOX type burners are designed to be able to maintain the specific evaporation and high combustion efficiency with wide range of automatic control. Firing case are, Case-1: Heavy oil (100%) basis, Case-2: BFG exclusive firing, BFG (90%) + stabilizing fuel (10%) and Case-3: BFG, COG and LDG mixed firing with heavy oil. Ignition fuel is COG. Each supply gas piping are installed with seal pots to remove water contained in gas and contributed towards reducing dust and other contaminants. Description of the steam generator combustion system refers to section 4 of this O&M manual. 1.2.4 STEAM TEMPERATURE REGULATION Steam temperatures from superheaters are controlled by water spray attemperators (desuperheaters) from primary and secondary superheater transfer pipe to the finishing superheater. Reheat outlet temperatures will be controlled by dampers, which vary the amount of recirculated flue gas admitted to the bottom of the furnace to the hopper throat. As loads decrease, an increasing proportion of gas recirculation will be required to make reheat temperatures. Although gas recirculation generally decreases unit flue gas temperatures, these heat transfer debits are small compared to the higher convection rates of heat transfer attained by increased gas flow through the unit. Therefore, as more gas is re-circulated, higher reheat temperatures will be obtained. However, if loads or other conditions are changing rapidly, a back-up means of control may be required. Therefore, as a secondary control of the reheat steam temperature, will be controlled by increasing or
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reducing the flue gases flowing over the second pass section or HRA. Superheater and Reheater gas bias dampers at the bottom of the HRA flue gas passage are used to control the flow. The second pass of the boiler is divided in to two parallel paths up the economizer. The SH gas bias damper kept in the largest opening, so that closing of this damper will divert flue gas to the smaller RH gas bias damper opening where the reheater surface is. This increases the pickup in the reheater steam and thus the outlet temperature of the reheater is increased. Reducing the flow by opening the damper in the other parallel path will reduce the flue gas flow through the reheater section and thus reduce the reheater steam outlet temperature. The desuperheaters are located as described in Paragraph 1.2; there are two (2) stations per boiler at both the secondary superheater inlets and finishing superheater inlets. Each desuperheater assembly is equipped with a stainless steel thermal liner and spray water nozzle(s) 2% Cr. 1% Mo (F-22). Discs (target plates) are installed just upstream of water nozzles on both the roof circuit and finishing superheater desuperheaters. Thermal liners are provided within desuperheater assemblies at the spray points to protect the piping from thermal shock. The steam is cooled as the spray water is mixed with the steam and evaporated in the liner zones. Droplets of water, which occasionally may not vaporize immediately, could impinge on the assembly's ID. The liner precludes impingement and thermal shock to the pressure part. The quantity of water nozzles that are provided in each desuperheater assembly will satisfy water capacity or biased control under the variety of steam generator loads expected. Each spray station at the inlet secondary superheater and finishing superheater spray station have (1) water nozzle. The disc assemblies located at the inlet to the finishing superheater desuperheaters enhance the low pressure area at the nozzle's exit, thereby providing the capability of increased flow within the desuperheaters. The amount of spray water is controlled to provide the required final steam temperature. During operation of the steam generator, the dampers on the recirculated flue gas being injected to the hopper throat regulate the gas flow over the reheater providing control of the final reheat steam temperature and bias dampers in the HRA gas pass. The spray water flow at the inlets to the secondary and finishing superheaters in then automatically adjusted to control the final superheater steam temperature. 1.3 STEAM GENERATOR PRESSURE PARTS COMPONENTS 1.3.1 ECONOMIZER The economizer is composed of horizontal finned surface (50.8mm OD) tubes and a single ended inlet and a double ended outlet header. It contains (15 ) loops of (1) loop-in-loop finned tube, (59) number of sections wide, arranged in (3) banks. Feedwater enters the economizer through the inlet header, flow through the elements and leaves through both ends of the outlet header. The heated feedwater then flows through external pipes to each end of the steam drum. Water flow in the economizer is counter to the direction of gas flow. 1.3.2 STEAM DRUM The steam drum is located at the top and arranged across the front of the steam generator. The steam drum serves as a water reservoir for the steam generating circuits. The drum contains steam separating equipment and internal piping for distribution of chemicals to the water, for distribution of feedwater and for blowdown of the water to reduce solids concentration. Two spring loaded safety valves are installed on the boiler drum to provide part of the overpressure relief capacity for the boiler. Refer to section 1.3.6 Safety Valve Setting.
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Figure 1-4 shows the arrangement of the steam drum internal components. The (1524 mm) diameter drum is (9944.1 mm) straight length and has internals as noted, Steam Separators Driers Feed Pipe Horizontal, In-line; 78 total separators, 39 each side. Integral Chevron, Non-drainable. 28 driers total. Two (2), one (1) at each end of drum; splits internally into four (4) perforated pipes, beneath the girth baffle, two (2) fed from each end. One (1) single outlet perforated, tee'd from centerline of drum. One (1) single inlet perforated, tee'd from centerline of drum. Three (3) pipes, equidistant across the bottom of the drum
Blowdown Pipe Chemical Feed Pipe Downcomer Pipes
An internal circumferential (girth) baffle extending almost the full length of the shell forms an annulus along the bottom half of the steam drum. The steam-water mixture from the furnace waterwall risers and a portion of incoming feedwater enters the drum in this annulus and then passes through the Horizontal steam separators. The separated steam flows out of the openings on the outboard sides of the separators and into the Chevron driers. The first stage of separation of steam from the water is accomplished in the horizontal separators. The steam-water mixture enters the inlet riser and flows upward. As the mixture follows the curved contour of the separator, the heavier water particles are forced outside, discharging through the primary and secondary water outlet and then through the mist eliminator wire mesh into the bottom of the drum. The mist eliminator dissipates the discharging velocity and allows entrained steam to escape. The separated steam flows out of the opening on the outboard sides of the separators and into the chevron driers. The final separation of moisture in the steam is accomplished as the steam comes into contact with the W-shaped chevron elements forming the chevron drier assemblies. Steam enters the driers at a low velocity and makes several abrupt changes of direction of flow. This causes the entrained moisture to adhere to the large surface area presented by the chevrons. The water film then drains by gravity to the lower part of the drum. The separated steam flows into the dry box and leaves the drum through the steam tubes at the top. The water separated from the steam falls to the water space of the drum and flows through the vortex eliminators to downcomer pipes. The downcomer pipes carry the water to the bottom of the unit for distribution to the furnace waterwalls. The remaining portion of incoming feedwater, outside the girth baffle, flows directly into the downcomers. 1.3.3 FURNACE Steam is generated in the waterwalls forming the furnace of the steam generator. The walls are formed by panels of welded fin tubes. The front, rear and side walls enclose the combustion chamber in the lower part of the furnace. The bottom of the furnace is hopper shaped, formed by the front and rear walls. The center space is open for discharge of ash. The waterwalls of the furnace are of MONO-WALL construction (gas tight panels of welded fin tubes). The furnace rear wall is arranged in two different vertical planes, connected by a sloped section. The rear wall shape controls how flue gas passes through the unit. Flue gas flows toward the front wall and rises through the up-flow pass. At the top of the furnace, the rear wall fins terminate and the tube spacing is increased, to form a screen, across which the gas enters the reheater horizontal bank tubes and through the HRA partition wall, down flow to the convection pass of the HRA. The furnace side walls continue pass the top and the HRA partition divides the Furnace to form the radiant furnace.
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The front wall contains (3) horizontal rows of burners each row has (3) burners, comprising a total of (9) burners. The furnace front wall and rear wall are each comprised of (118) tubes and each side wall is comprised of (100) tubes. The waterwall tubes are (63.5 mm OD). The front and rear furnace walls each have one (273 mm OD) lower inlet header and each sidewall has three (3) (273 mm OD) lower inlet headers. The rear wall has one upper outlet header, and the front wall has one upper outlet header. Each side wall has 3 upper outlet headers. Three (457 mm OD) downcomer pipes from the steam drum carry water to feeder pipes which supply the lower headers of the four furnace walls. The water is heated as it flows upward in the waterwalls and steam is generated. From the top of the furnace walls, the steam-water mixture flows through outlet headers and riser tubes into the steam drum for separation. The separated water is recirculated in the furnace after mixing with feedwater. 1.3.4 SUPERHEATERS The steam generated in the furnace leaves the drum as dry saturated steam. It is then superheated in several sections described below. 1.3.4.1 HRA (Heat Recovery Area) and Hanging Tubes Steam from the drum flows down through the (273.0 mm OD) HRA partition roof inlet header down to the open staggered screen wall tubes (63.5 mm OD, 59 tubes) out through the HRA partition outlet header (273.0 mm OD). The steam from the HRA partition header transfer pipe connected to the hanger Tubes inlet header (273.0 mm OD), pass through the horizontal (45 mm OD), (29) sections wide, (116 Tubes), single loop of (4) loop in loop hanger tubes then up through the up flow hanging tubes (45 mm OD), through an unheated outlet tubes (45 mm OD) and out through the a collecting outlet header (273.0 mm OD). Roof steam feeder pipes (168.3 mm OD, 6 pipes) from the hanger tube collecting header are connected to the HRA roof - rear wall inlet header (273.0 mm OD) steam down through the HRA rear wall tubes (50.8 mm OD, 118 tubes) that forms the steam generator roof which includes the furnace and HRA convection area. The steam from HRA roof-rear walls tubes are collected in a common header (273.0 mm OD) with the HRA side walls (50.8 mm OD, 98 tubes, 49 tubes each side) this is to efficiently distribute dry saturated steam pass around the HRA convection area. Steam then exits through the HRA side wall outlet header (273 mm OD). The heat recovery area (HRA) rear wall, the roof and side walls are formed of MONO-WALL construction. The extension of the rear wall of the furnace and HRA rear wall form a vertical gas pass (second convection pass) containing the primary superheater and economizer. Hot gas flows through this gas pass on its way to the stack. 1.3.4.2 Primary Superheater Steam from the HRA side wall tubes enters the (273 mm OD) primary superheater inlet header and flows through the vertical inlet leg and then through the horizontal tube sections in an upward direction. The steam then flows through the vertical outlet up and out of the (355.6 mm OD) outlet header. From the outlet header, the steam flows through spray attemperators to the secondary superheater inlet header. The primary superheater is located above the economizer in the rear side of the second convection pass or HRA area. Vertical heated inlet leg tubes (45 mm OD 234 tubes) connect the inlet header with 117 sections of horizontal elements
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comprising 5 loops of 2 loop-in-loop tubes (45 mm OD). The vertical outlet leg comprises 58 sections of 4 loop-in-loop tubes (45.0 mm OD) and connects the unheated outlet tubes to the outlet header. 1.3.4.3 Secondary Superheater The secondary superheater is located near directly above the horizontal portion of the hanger tubes section. It consists of 29 sections wide suspended from the vertical hanger tubes and arranged across the width of the furnace. Each superheater section consists of 2 loops of 6 loop-in-loop tubes. All loops contain (45 mm OD) tubes. Steam enters the secondary superheater via both ends of one (1) (323.8 mm OD) inlet header from the spray piping connected to the primary superheater outlet header. It flows through the secondary superheater elements to the (406.4 mm OD) outlet header and then enters the finishing superheater. 1.3.4.4 Finishing Superheater The finishing superheater is located near the top of the furnace directly above the secondary superheater section. It consists of 29 sections suspended from the hanger vertical tubes and arranged across the width of the furnace. Each superheater section consists of 2 loops of 6 loop-in-loop tubes. All loops contain (45 mm OD) tubes. Steam enters the finishing superheater via one (1) (323.8 mm OD) inlet header from the spray piping connected to the secondary superheater outlet header. It flows through the finishing superheater elements to the (406.4 mm OD) outlet header and then leaves the steam generator through one end of the header. 1.3.5 REHEATER The reheater is located in the end, flow gas pass of the furnace. The reheater consists of a lower inlet header, vertical inlet tubes (50.8 mm OD), 117 sections, 4 loops of 3 loop-inloop arranged in two (2) banks of horizontal elements, and an outlet header on top. Steam from the turbine enters the reheater through one end of a (508 mm OD) inlet header at the bottom of the tube section, flows upward through the elements and leaves through one end of a (559 mm OD) outlet header. 1.4 BOILER PIPING SYSTEM 1.4.1 HP STEAM AND REHEAT STEAM The HP (High Pressure) steam piping system is designed to convey and pass through steam 360,000 Kg/Hr MCR high pressure steam 128.5 Barg, 541.0 C to the HP steam turbine. The piping nominal size is DN 300A, 323.8 OD, thickness SCH. 140, and material A335 P91, in accordance with the piping material specification. The RH (Reheat) steam piping system is designed to convey and pass through steam 280,868 Kg/Hr MCR reheat steam 37.2 Barg, 541.0 C to LP steam turbine. The piping nominal size is DN 500A, 508.0 OD, thickness SCH. 100, and material A335 P22, in accordance with the piping material specification. 1.4.2 BOILER FEEDWATER The (BFW) Boiler Feedwater piping system is designed to convey and pass through feedwater to the economizer inlet header at a rate of 310,938 Kg/Hr MCR, 146.4 Barg, 249.0 C. The system includes spray attemperator water at the secondary superheater inlet at a rate of 40,062 Kg/Hr MCR, 152.6 Barg, 249.0 C and at the final superheater inlet at a
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rate of 9,000 Kg/Hr MCR, 153.3 Barg, 249.0 C. The Piping system is in accordance with the piping material specification. 1.4.3 BFW piping economizer Inlet (DN 250A, 273.0 OD, SCH. 160, and material A106 B) st BFW to 1 Attemperator (DN 80A, 88.9 OD, SCH. 160, and material A106 B) BFW to 2nd Attemperator (DN 65A, 73.0 OD, SCH. 160, and material A106 B)
BOILER RECIRCULATION (DOWNCOMER TO ECONOMIZER INLET) A valve controlled economizer recirculating system is installed connecting (2) downcomer, to the economizer inlet header. During startup, before feedwater flow is established, the motorized globe valve is opened to allow economizer water to naturally circulate to the drum, thus promoting flow in an otherwise stagnant flow circuit. The hot economizer water is replaced with colder water from the downcomers.
1.4.4
BOILER DRAIN, VENT, BLOWDOWN AND BLOWOFF The boiler drain, vent and blowdown are piped to the blowdown tank, open drain, or vented to the atmosphere, each major point location are as follows, a) b) c) d) e) f) g) h) Steam Drum Drum Level Gauge Furnace and HRA walls Main Feed water piping Economizer Inlet Primary, Secondary and Final Superheaters Main steam piping And, other miscellaneous location maintenance purpose.
A blowdown and mass blowoff system is provided to maintain boiler water condition consistent with the required water quality it consist of a blowdown tank and a piping system. Blowdown system is combined by blow down tank and flash tank, the flash tank supply condensate steam to Daerator. This blowdown system is not operated continuously; conductivity of boiler water in the steam drum is checked in sampling cooler system automatically. When conductivity value is higher than limit set point value, alarm is run, operator open drain valve properly by remote devise. Blowdown from the steam drum removes non-adherent sludge and maintain proper water alkalinity. Mass Blowoff system is added as required it is intended for frequent short blows to optimize removal of suspended solids and promotes operating economy. It is used also when Water level in drum will rise due to swelling of water in the waterwall system and drum and to reduce water level. The drum mass blow-off valve should be used as required. 1.4.5 SAMPLING AND CHEMICAL DOSING The steam generator is placed with proper sampling points to observe boiler water condition. It is connected by piping and valves connected to a sampling unit. Scheduled regular laboratory test of samples are recommended. Other than the sampling locations, chemical dosing pipe links are also installed in proper locations in the steam generator this is to enable boiler water treatments if so necessary and required. Sampling points are located in, a) Main Feedwater Piping b) Steam Drum (Blowdown Water Piping) c) Saturated Steam and Superheated steam piping Chemical Dosing is located at the steam drum 1.4.6 UTILITIES
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Air and water utilities are in place for the steam generator consumption for controls, cleaning, cooling and instrumentation. Utilities placed are, a) Control Air supply for pneumatic instruments, controls and drives b) Cooling water supply and return is used to maintain controlled temperature of auxiliary equipment rotating parts c) Fresh water for seal pot and blowdown tank d) Clear Water for Gas Air Heater e) Seal Sir from FDF outlet duct The boiler piping system are all in accordance with the piping material specification issued by Posco Power Document No:. 380-EP242-001, the specification is intended to cover basic requirements of piping system for Indonesia Integrated Steel Mill Power Project designed by POSCO Engineering and Construction (POSCO E&C), relevant code and standards are also described in the specification. 1.5 REFRACTORY, THERMAL INSULATION, ACOUSTIC INSULATION AND LAGGING For main boiler parts, ducting, piping and auxiliary equipment, in all cases where the surface temperature is expected to exceed 55.4, in conditions where the ambient temperature is 30.4 and wind velocity 0.5 m/second, to ensure the safety of personnel and to prevent heat loss insulation is applied. Insulation thickness is determined by consideration of the internal temperature and the difference between the insulation surface temperature and the ambient temperature. Acoustic protection will be applied to those equipment and piping which will produce a sound level greater than 110dBa during normal operation. Boiler Gas / Air ducts are insulated with mineral wool with aluminum sheet lagging. Boiler roof will be made of metal sheet plate and furnace and HRA outer wall tubes are placed with an outer casing in between are filled with mineral wool insulation. Pipes are insulated with Perlite with aluminum sheet lagging. Concave tube formation inside the furnace and HRA are formed with refractory to prevent deterioration under high temperature. 1.6 AUXILIARY EQUIPMENT The equipment listed below has been supplied by BHI Co., Ltd., for use in operation of the steam generator for one (1) unit only. The manufacturers' instructions for the installation, operation, and maintenance of this equipment are contained in subsequent appendices of this manual which are identified by tabs (Attachment 1, Attachment 2, etc.); the following paragraph lists the equipment suppliers and summarizes the quantity of equipment supplied per unit. 1.6.1 Fuel Burning Equipment (Attachment - 1) Nine (9) combination burners with all accessories furnished by KET Co., Ltd 1.6.2 Fans (Attachment - 2) Fans with all accessories furnished by Tongyang/ Plant, a) One (1) Forced Draft air Fans (01HLB01AN101) b) One (1) Induced Draft Fan (01HNC01AN101) c) One (1) Gas Injection Fans (01HNF01AN101) 1.6.3 Motors (Attachment - 3) Boiler fan electric motors furnished by Hyundai,
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1.6.4
a) One (1) forced draft air fan motors, Squirrel Cage (Frame No. HRQ3 453-48E, TEAAC, 850 KW, 1490 RPM, 4 POLES) b) One (1) induced draft air fan motors, Squirrel Cage (Frame No. HRQ3 567-68E, TEAAC, 2100 KW, 994 RPM, 6 POLES) c) One (1) gas injection fan motors, Squirrel Cage (Frame No. HLE5 401-68E, TEFC, 430 KW, 993 RPM, 6 POLES) Gas Air Heaters (Attachment - 4) GAH (01HLD01AC101) furnished by Robot Engineering Co., Ltd. One (1) Gas Air-Heater GAH size and description 227.5-RZVI-1215 Element Code: Hot layer Height (mm) HZ 915, Cold layer Height (mm) HZ 300
1.6.5
Sootblowers (Attachment - 5) Sootblowers (01HCA01AT101~AT116) furnished by Hanyang Semitech Inc, Korea Sixteen (16) Model DC-75 Acoustic Horn, 75 Hz, 147dB Sootblowers
1.6.6
Dampers (Attachment - 6) 1.6.6.1 Burner and OAP Control Damper in common frame a) Secondary Air to Burners Control Dampers (01HLA05AA981~AA983) furnished by HSGHI Co., Ltd. Korea Three (3) Louver/ 3000mm x 1400mm Control Damper & Three (3) Double acting Actuator w/ Smart Positioner. b) Secondary Air to OAP Control Dampers (01HLA05AA984) furnished by HSGHI Co., Ltd. Korea One (1) Louver/ 3000mm x 500mm Control Damper & Double acting Actuator w/ Smart Positioner. GI to Windbox Shut-off Damper in common frame GI to windbox Shut-off Dampers (01HNA01AA982~AA984) furnished by HSGHI Co., Ltd. Korea Three (3) Louver/ 1250mm x 500mm Shut-off Damper & Three (3) Double acting Actuator w/ Limit Switch. 1.6.6.3 GI to Hopper Control Damper GI to Hopper Control Dampers (01HNA01AA981) furnished by HSGHI Co., Ltd. Korea One (1) Louver/ 2800mm x 2000mm Shut-off Damper & Double acting Actuator w/ Smart Positioner 1.6.6.4 Superheater and Reheater Outlet Pass Bias Dampers
1.6.6.2
1.6.7
a) Superheater Outlet Pass Bias Control Dampers (01HLZ03AA981) furnished by HSGHI Co., Ltd. Korea One (1) Louver/ 9807mm x 2400mm Control Damper & Double acting Electro hydraulic actuator modulating controller b) Reheater Outlet Pass Bias Control Dampers (01HLZ03AA982) furnished by HSGHI Co., Ltd. Korea One (1) Louver/ 9807mm x 1703mm Control Damper & Double acting Electro hydraulic actuator modulating controller Safety Valves (Attachment - 7) Various safety valves furnished by Dresser Industries
BHI CO. LTD

STEAM GENERATOR & AUXILLIARIES 1.6.8 Valves (Attachment - 8) 1.6.8.1 Manual Valves
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(Refer to Doc. No. I01-110-EP442-10300 Manual Valve List for individual tag # and descriptions) Various Manual Globe, Gate, Check & ball Valve furnished by Samshin Limited 1.6.8.2 Control Valves For Steam and Water a) Spray Desuperheater Control Valve furnished by Copes-Vulcan (Refer to Doc. No. I01-110-EM136-10100 Control Valve individual tag # and descriptions) b) Various control valves furnished by CCI (Refer to Doc. No. I01-110-EJ44510400 Control Valve individual tag # and descriptions) For Fuel and Burner Fuel and Burner Control Valve (Refer to Doc. No. I01-131-EJ445-40200 Control Valve individual tag # and descriptions) 1.6.8.3 Motor Operated Valves a) Economizer Recirculation MOVs furnished by Shilla Valves Corp. (Refer to Doc. No. I01-110-EJ442-10100 MOV List for individual tag # and descriptions) b) Various MOVs furnished by Shilla Valves Corp. (Refer to Doc. No. I01-110EJ442-10100 MOV List for individual tag # and descriptions) Shut-off Valves Fuel and burner shut-off valves furnished by Machinery Technology Solutions Co., Ltd. (Refer to Doc. No. I01-1-EJ460-41000 for individual tag # and descriptions) 1.6.9 C.C.T.V. Systems (Attachment - 9) One (1) Furnace T.V. system furnished by Lenox which includes the following: Wallbox, Furnace Camera, Video Monitors, Air Filtration System, Cables. 1.6.10 Steam Drum Level Indicating (Attachment - 10) One (1) Multi-port Glass Type Level Gauge (Model DCG-3) Tag # 01HAG01CL502 furnished by Dae Ryun Co., Ltd Korea. b) One (1) Remote Steam Drum Level Indicating System Hydrastep Model Tag # 01HAG01CL501 furnished by Solatron c) Two (2) Level Transmitters differential pressure type Tag # 01HAG01CL102 furnished by _____ 1.6.11 Instrumentations (Attachment - 11) For Boiler Part (Steam and Water) a) b) c) d) e) f) g) h) i) Various Flow Element furnished by _____ Various Flow Transmitter furnished by _____ Various Pressure Gauge furnished by _____ Various Pressure Transmitter furnished by _____ Various Pressure Test Point furnished by _____ Various Differential Pressure Transmitter furnished by _____ Various Temperature Gauge furnished by _____ Various Temperature Element furnished by _____ Various Temperature Transmitter furnished by _____
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1.6.8.4
a)

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j) Various Temperature Test Thermowell furnished by _____ For Fuel and Burner a) Various Pressure Transmitter furnished by _____ b) Various PD Flow Meter furnished by _____ c) Various Pressure Switch furnished by _____ d) Various Temperature Switch furnished by _____ a) Various Pressure Gauge furnished by _____ b) Various Temperature Detector furnished by _____ c) Various Temperature Gauge furnished by _____ 1.6.12 Miscellaneous (Attachment - 12) a) b) c) d) Steam Coil Air Heater furnished by _____ Steam tracing Manifolds furnished by _____ Boiler Tube leak Detector furnished by _____ Seal Pots furnished by _____
BHI CO. LTD

STEAM GENERATOR & AUXILLIARIES STEAM GENERATOR DATA FIGURE 1-1 KOREA CO. LTD
2012-09-20 0 PAGE FIGURE 1-1
CLIENT: LOCATION: NO. OF UNITS: TYPE: P.T. Krakatau Steel Works Bantan Province, Cilegon City Indonesia 2 CONTRACT NO: ---
DESIGN PRESS: FINAL STEAM TEMP: CAPACITY:
151.7 barg 541 C 360 T/H
Natural Circulation, Reheat, Outdoor Type
BHI CO. LTD

STEAM GENERATOR & AUXILLIARIES STEAM GENERATOR DATA FIGURE 1-2 WATER AND STEAM FLOW
2012-09-20 0 PAGE FIGURE 1-2
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STEAM GENERATOR DATA FIGURE 1-3 AIR AND GAS FLOW
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STEAM GENERATOR DATA FIGURE 1-4 STEAM DRUM INTERNAL COMPONENTS
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SECTION 2 SAFETY PRECAUTIONS AND PREPARATION FOR OPERATION 2.1 SAFETY PRECAUTIONS The following instructions are some of the general precautions which apply when placing a steam generator into operation. They are intended to supplement the experience and judgment of those in charge of operation and cannot cover all precautions which should be observed. The manufacturer has complied with all of the ASME and other applicable codes pertaining to the construction of the unit. A newly erected unit, prior to being placed into operation, must be carefully inspected to assure that all component parts are properly assembled. It is the Purchaser's responsibility to see that the unit has been inspected and approved by his insurance inspector and, if required, inspected and approved by the State and/or Municipal Inspectors. All auxiliary equipment must be in first class operating condition and suitable for operation at design specifications and should be operated in accordance with Manufacturer and BHI Co. Ltd., recommendations and instructions. When preparing a new unit for service, see that the following is accomplished as required: a) The gage glasses must be checked and installed in accordance with the drawings prior to preliminary operation. When the water level in the drum is lowered below the lowest visible point of the gage glass, all water should drain out of the glass. Any time a repair or change is made to the gage glass, this should be checked. b) Blowdown lines from water column and gage glasses must be properly piped and drain valves closed. The gage glasses must be properly illuminated and clearly visible to the operator from the operating floor or control panel. c) All drain and blowdown lines must be readily accessible and properly piped to a blowdown tank, or other safe location, so as not to endanger plant operators at any time. Drain valves of multiple boilers should not be connected together. d) If valves are located between the drum and water column, they must be of the rising stem type and locked in the full open position. e) Information from each steam pressure gage must be visible to the operator from the operating floor and gages must be correctly installed with intermediate line valves open. f) All safety valve gags must be removed and valves in proper operating condition. Discharge stacks, pipes, vents and drains should be arranged and supported in accordance with the safety valve manufacturer's recommendations.
g) Drum internals must be properly installed in accordance with drawings to assure that there will not be any steam by-passing the internals. h) All necessary test connections must be installed. i) j) All fans and blowers shall have been operated. Lubrication systems shall be operable. Equipment shall be balanced and operate within vibration tolerances. All dampers, operators and actuators shall have been subjected to internal and external inspection and it has been confirmed that dampers actually move to the positions called for by the controls.
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k) All remotely operated valves and slide gates shall have been operated and limit switches checked to ensure that proper installation has been accomplished. l) If supplied, all conveyors shall have been operated to substantiate readiness.
m) All critical flow elements shall be calibrated. n) All critical thermocouples and pressure transmitters shall be checked for proper connections and to ensure that they are operable. Calibrations shall be completed. o) All flues, ducts, pipes, chutes or conduits through which air, gas, water, steam or solids flow shall be connected securely; check to ensure that proper flow paths have been maintained. p) All expansion joints shall be inspected to ensure that proper connections have been made and that any members utilized for shipping and installation only are removed. q) If supplied, the baghouse shall be checked to verify that all bags are installed properly and that the cleaning system is operating. r) All electrical connections shall be inspected to ensure that they have been properly installed and that all insulation is in good condition. In addition to the above, the following items should be thoroughly checked each time a steam generator is placed into operation. s) All necessary operating instruments, both permanent and temporary, must be installed, operating properly and correctly calibrated. t) All areas must be sufficiently illuminated.
u) No hazardous walkways, ladders or stairways should be used. Provide substantial walkways and platforms where needed. v) Air and gas passages must be free from obstruction and the unit capable of being thoroughly purged by the circulation of air through the unit. w) The source of feedwater to the steam generator and makeup water to the cycle must be sufficient and constant once the unit is in operation. x) A sufficient and constant fuel supply should be available. y) All access and observation doors must be closed after it is confirmed that no personnel are inside the unit.
z) Manway openings must be closed and properly made up. When it is assured that the above precautions are fully understood and have been complied with, then, and only then, should subsequent operations such as hydrostatic pressure testing, alkaline boilout and chemical cleaning be initiated. 2.2 HYDROSTATIC TESTS Every steam generating unit must be subjected to a hydrostatic test when erection of the pressure parts is completed. A hydrostatic test shall also be made upon the completion of each general overhaul or repair affecting any pressure part of the unit, or at other times when it is desirable to inspect for leaks. All sections of the unit to be hydrostatically tested should be filled with demineralized or condensate quality water containing 10 ppm of ammonia and 200 ppm of hydrazine. This should produce a solution pH (at 25C) of 10.0. This water must contain less than 100 parts per billion (ppb) chloride ion. The superheater should be filled first to overflow into the boiler drum (as applicable). Then the economizer and waterwalls can be filled through normal fill connections. If the unit is to be placed into service within a short time using the test water, the treatment may be as for normal operation and the unit should be filled with demineralized or condensate quality water for the test.
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Insurance company regulations, also ASME, state, county, municipal or other codes and inspection requirements, typically specify that the unit shall be subjected to hydrostatic test pressure of one and one-half times the design pressure. This is the initial hydrostatic test to be applied upon completion of erection of a new installation and prior to operation of the unit. After a unit has been initially operated and repairs or revisions are made to pressure parts, or it is found desirable to check the unit for possible leaks, it is recommended that the unit be tested for leaks at operating or design pressure. Before applying a hydrostatic test on a unit, make a thorough internal and external inspection to be absolutely sure that: a) All foreign material and tools have been removed. b) No personnel are inside the unit. c) Pressure gages have been correctly calibrated by dead weight test and are connected properly with intermediate line valves open. d) All safety valves are blanked or gagged if the hydrostatic test pressure is near to or will exceed the lifting pressure of any safety valve; all power actuated relief valves are valved out of service. e) Any part not designed to withstand the hydrostatic test pressure is properly isolated or blanked off from such pressure. Telltale drains should be left open outside the boundaries of the hydrostatic test to check for isolation valve leaks. f) All steam circuit spring hangers are pinned in a fixed position.
g) All valves operate freely and seat properly. When the foregoing have been carefully checked : h) Close all manholes. i) Close stop and check valves, all drain and blowdown valves and valves to any gages or other integral equipment not designed to withstand the hydrostatic test pressure. IT IS IMPERATIVE THAT ALL SAFETY PRECAUTIONS AND VALVE PROCEDURES BE ADHERED TO STRICTLY AND WITHOUT EXCEPTION. j) Open vents on the highest points of each component part of the unit. TAGGING
k) Be sure that the water will not freeze during test and that non-drainable portions of the unit will be freeze protected following the hydrostatic test. NEVER PUT A HYDROSTATIC TEST OF MORE THAN DESIGN PRESSURE ON A UNIT THAT IS AT OR NEAR OPERATING TEMPERATURE. l) Check that only authorized personnel are in the vicinity of the unit to be tested. All personnel should remain a minimum of twenty (20) feet away from any pressure parts during the test.
Start filling the unit with water, which should be relatively close in temperature to that of the pressure parts, so that the temperature of drum metal and water is a minimum of 21C before applying a hydrostatic test pressure. All other pressure parts must be at a temperature of not less than 21C.
CAUTION WHENEVER HYDROSTATIC TEST PRESSURE IS IN EXCESS OF 78.6 Bar, THE MINIMUM DRUM METAL AND WATER TEMPERATURE OF 21C MUST BE OBSERVED TO INSURE THAT HYDROSTATIC TESTING IS PERFORMED ABOVE THE BRITTLE TO DUCTILE TRANSITION TEMPERATURE FOR THE METAL.
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Hydrostatic test temperature requirements can be achieved by any of the following methods: a) IF THE STEAM GENERATOR FUEL BURNING SYSTEM IS NOT FUNCTIONING (AS MAY BE THE CASE FOR INITIAL HYDROSTATIC TESTING), ANY ONE OF THE FOLLOWING METHODS (1), (2), OR (3) IS RECOMMENDED: 1) Fill and circulate with water, heated from an external source, to obtain the recommended test temperature. Measure drum temperature by drum insert type thermocouples. 2) If available from another source (another unit at jobsite), connect a saturated steam supply to drum blowdown or chemical feed line to heat water and drum shell. Start out with drum at normal operating level and add water after recommended temperature is reached. Go slightly beyond actual temperature 5 to 10F (2.8 to 5.6C) so that the addition of makeup water does not lower temperature below that recommended. 3) Use small oil and/or gas burners aimed through doors or resting on the furnace bottom to raise the temperature to that recommended. b) IF THE STEAM GENERATOR FUEL START-UP OR LIGHT-OFF SYSTEM IS FUNCTIONING, THE FOLLOWING METHOD IS RECOMMENDED. 1) After filling unit to normal water level, fire to raise drum temperature to 2.8 to 5.6C above that recommended. Extinguish fires and continue to fill unit. Inspect drains and manways for leaks as the unit fills. Close the high point vents when water issues from them. Raise pressure to the intended figure slowly to avoid shock. The recommended rate of pressure increase should not exceed (3.43 bar) per minute. The unit must be maintained at full hydrostatic pressure test level for duration of time that satisfies qualified inspectors. If hydrostatic test was applied at pressure above design pressure, reduce pressure slowly and thoroughly inspect unit for leaks only at operating or design pressure. When inspection is completed, release pressure slowly and open vents and drains. All drainable portions of the unit not intended to contain water during operation must be drained. If temporary manway gaskets were used during initial hydrostatic tests, they are to be replaced with proper gaskets before refilling unit for operation. Remove blanks or gags from safety valves and pins from spring hangers after test has been completed and pressure has been reduced below design pressure. NOTE SPRING SETTING SHOULD BE VERIFIED IN BOTH COLD AND HOT MODES 2.3 DRYING OUT REFRACTORY The MONO-WALL panels used in the furnace design of these units have all but eliminated use of refractory settings. However, some areas of the unit, particularly at burner throats, access doors and penetrations, are formed of castable or plastic refractory which requires the slow application of controlled heat to remove moisture from these materials and cause them to attain their permanent "set" without cracking. This should be accomplished in conjunction with the "boiling out" operation described below.
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It is preferable that drying out is done at moderate temperature over an extended period. Rapid heating will cause unequal drying and may cause cracks in the refractory.
2.4 BOILING OUT 2.4.1 General Boiling out is the process of chemical cleaning for the removal of oil and grease, and the solvent usually consists of a strong aqueous alkaline solution. Oils and greases previously introduced for the purpose of providing protection during the storage of tubes and other pressure parts for extended periods of time must be removed prior to unit operation. The presence of even very thin films of oil or grease or their decomposition products on the boiler heating surfaces will seriously retard heat transfer. The resultant increase in metal temperature may be sufficient to cause overheating and blistering of boiler tubes, and ultimate failure at high loads. During the boiling out process, the gage glass may become badly discolored and permanently etched. BHI Co., Ltd suggests that the customer have, on hand at the jobsite, replacement kits for all gage glasses. The inoperable gage glass should be restored to its original condition after boiling out and chemical cleaning, and before the next filling of the unit with treated demineralized or condensate quality water. Where a feedwater consultant has been retained, it is recommended that his advice on chemical dosages be obtained. However, where this service has not been solicited, the use of one of the several proven procedures listed herein is suggested. The chemicals should be dissolved in water before being added to the boiler and should never be added to the boiler in solid form. In handling caustic materials, care should be exercised to avoid contact with the eyes, skin or clothing. When mixing this material, it is recommended that goggles, rubber gloves and cotton clothing be employed. The chemical cleaning solutions should not be added to the boiler through the regular chemical feed system since these high concentrations may plug the chemical feed piping and valves. Chemical solutions should always be added by means of an external blend/fill pumping system. 2.4.2 Preparation for Boiling Out Prior to boiling out a steam generator, the items previously outlined under "Safety Precautions" and "Drying Out" should be consulted and followed. Generally, "drying out" and "boiling out" are combined as one continuous operation. CAUTION BEFORE FILLING THE UNIT WITH CHEMICAL CLEANING SOLUTIONS, THE SUPERHEATER MUST BE BACKFILLED WITH DEMINERALIZED OR CONDENSATE QUALITY WATER CONTAINING LESS THAN 100 PPB CHLORIDE ION. CARE MUST BE TAKEN BY ALL PERSONNEL TO AVOID CONTACT WITH THE CLEANING CHEMICALS. ONLY ABSOLUTELY NECESSARY PERSONNEL SHOULD BE PRESENT IN THE CHEMICAL PREPARATION AND MIXING AREA. REPORT ANY LEAKAGE OR SPILLS OF CLEANING CHEMICALS TO THE CLEANING SUPERVISOR AND THE SHIFT SUPERVISOR IMMEDIATELY.
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SPECIAL CARE MUST BE TAKEN TO PREVENT CONTAMINATION OF THE SUPERHEATER WITH ANY OF THE CLEANING CHEMICALS. PRECAUTIONS INCLUDE KEEPING DRUM LEVEL WITHIN LIMITS AT ALL TIMES AND CAREFUL REVIEW OF VALVE POSITIONS AT EACH STEP OF THE PROCESS. IF DRUM LEVEL CONTROL IS LOST AT ANY TIME DURING THE PROCESS, REPORT THIS IMMEDIATELY TO THE CLEANING SUPERVISOR AND THE SHIFT SUPERVISOR. BEFORE ADDING CHEMICALS, VALVE OUT BOILER INSTRUMENT CONNECTIONS. THESE CONNECTIONS SHOULD BE FLUSHED FOLLOWING THE CHEMICAL CLEANING OPERATION/PROCEDURE. SINCE THE DRUM LEVEL TRIPS WILL NOT BE OPERATIONAL DURING CHEMICAL CLEANING, IT WILL BE THE RESPONSIBILITY OF THE OPERATOR TO MAINTAIN DRUM LEVEL BETWEEN THE PRESCRIBED LIMITS. ONCE WATER LEVEL IS VISIBLE IN THE GAGE GLASS, DRUM LEVEL MUST BE WATCHED CLOSELY TO AVOID OVERFILLING. IT IS IMPERATIVE THAT NO CHEMICAL SOLUTION OVERFLOW FROM THE DRUM INTO THE SUPERHEATER CIRCUITS OF THE BOILER. A careful cleaning and inspection of the interior and exterior surface of the boiler and auxiliaries should be made for the purpose of removing all scrap metal, borings, wood, tools, rags and other miscellaneous materials. It is very important that these materials be removed before boiling out, otherwise foreign material in the interior boiler sections is likely to interfere with the operation of blowdown valves and future operation of the boiler. It is considered undesirable to attempt to set safety valves when the boiler contains water of high chemical concentration such as that used for boiling out purposes. The safety valves should be set when the boiler contains water of approximately normal concentration for steam generation. The boiler should be filled to normal water level (NWL). The unit should be filled through the feed pipe normally used during operation. Water should be supplied from the condenser hot well or condensate storage tank, through the condensate pump, boiler feed pump, and connecting piping through the extraction heaters, to the economizer through the main feedwater pipe, through the economizer and into the boiler drum. If this filling procedure is followed, it will flush all the piping and auxiliaries ahead of the boiler, and eliminate fouling of the boiler surfaces with contaminants after the boiler has been properly cleaned. Flushing the feedwater supply system also reduces the quantity of silica found in boiler water during the initial period of operation. All superheater drains and vents and boiler steam drum vents should be opened wide after filling the boiler. Close all access and observation doors. Check the firing equipment and the feedwater system to be sure they are in correct operating condition. Pressure gages, correctly calibrated, should be mounted in locations readily visible to the operator. One (1) pressure gage should be located at the boiler steam drum and another located at the firing aisle, each indicating "steam drum pressure". Where gas fuel is to be used, the burner valves should be checked so that they are closed before opening the main gas valve. When using oil for boiling out, the oil piping should first
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be checked for leaks. Fans should be operated for several hours during which time they should be checked for excessive vibration, hot bearings and stability. Fan dampers should be checked for tight closure and full opening over their required range of travel. Fan linkages should be checked to assure that all cotter pins are inserted in linkages and the fan linkage is free of any "lost motion" (excessive motion).
2.4.3
Recommended Chemicals for Boiling Out Strong alkaline detergent solutions are commonly used for boiling out a unit since these agents possess the ability to saponify the oils and greases and form a soap compound that is easily removed by high pressure blowdown during the boiling out process. For the most effective removal of oil from boiler metal surfaces, it is recommended that a "wetting agent" be incorporated in the boiling out mixture. These agents increase the "wetting power" of the water by reducing the surface tension and therefore reduce the adherent characteristics of oils and greases to a minimum. The combination of a "wetting agent" along with the regular boiling out chemicals will therefore break down the oil-sludge bond and aid in the removal of oil and grease from the metal surfaces. There are wide variations in the composition of boiling out chemicals which can be employed. Alkaline formulations based on the use of trisodium phosphate, disodium phosphate and a small amount of detergent (wetting agent) are recommended. A suggested formulation for preoperational boilout of a unit is as follows: 0.6 wt. % trisodium phosphate, 0.067 wt. % disodium phosphate, 0.0135 wt. % sodium sulfite, 0.012 wt. % detergent (wetting agent)
2.4.4
Boiling Out Procedure The boiler should be lit off in accordance with the start-up procedure contained in the Operation and Maintenance section of this manual. Fire at minimum capacity until steam issues forcibly from the steam drum vent. At this time, close the drum vent and all superheater vents and drains. Slowly raise the pressure on the unit. Figure 2-1 shows the proper boiling out pressure to be used based upon the design pressure of the unit. The specified pressure for boiling out is necessary to provide complete circulation throughout the unit and develop boiling out water temperatures sufficient for complete removal of greases and oils present on the metal surfaces. During the boilout phase, the drum water level must be maintained at NWL. Condensate and boiler feed pumps must be ready for operation for delivery of make-up water to the boiler by injection into the superheater spray station, thus backflushing into the boiler drum. After the prescribed boiler steam drum pressure has been obtained, this pressure should be maintained for at least twenty-four (24) hours. Every six (6) hours, either extinguish the fires or reduce the firing rate to the minimum that will maintain a definite furnace draft. If fires are extinguished, the furnace must be purged for the next firing. Start blowing down each of the blow-off lines. Regulate the rate of blow-off from each valve to complete the blowdown. A complete blowdown has been achieved when water level has been lowered to the lowest port of the gage glass. Refill the boiler to normal operating steam drum level by backflushing the superheater and begin firing again. Repeat the above procedure every six (6) hours until all signs of oil have disappeared from a cooled boiler water sample.
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After each blowdown period, a cooled sample should be checked for pH and phosphate concentration. The times of each blowdown, valve cycles and chemistry data should be recorded on a blowdown data sheet. After the boiling out period, when the boiler has been cooled and drained, the steam drum should be inspected and any sediment removed by hand. If the quantity warrants, inspect headers. Where inspection nipples are not provided on headers, inspection may be accomplished by cutting a feeder or riser tube at the stub and bending the tube out of the way. If any foreign material is found in a header, it can be removed by hand or flushed with a high pressure water hose, In addition to checking for sediment, inspection should assure that the metal internal surfaces are free from oil adherence. After the drum and headers have all been cleaned and inspected, the unit can be closed. New manway gaskets should be installed on the drum and any inspection nipple caps or tubes cut for cleaning and inspection should be replaced. The Cautionary Notes concerning maximum chloride content in the water must be observed (see Paragraph 2.4.2); the unit should be filled with either demineralized water or condensate and subjected to a hydrostatic test pressure approximately that of normal operating pressure. The unit should then be drained to normal operating drum level. 2.5 CHEMICAL CLEANING OF ECONOMIZER AND STEAM GENERATING CIRCUITS 2.5.1 General Preoperational chemical cleaning of high pressure steam generators is standard industry practice. The implementation of a preoperational cleaning will provide for highest reliability and efficiency after the units are placed into service. Additionally, a cleaning performed prior to initial operation for the purpose of removing mill scale provides the base upon which a thin, uniform protective coating of iron oxide can develop during operation. An easier startup with respect to overall cycle chemistry will additionally be a primary benefit by removal of unwanted contaminants during the cleaning procedure. The need for removal of operational deposits will vary considerably depending on the type of feedwater used and the history of condenser leakage or make-up system problems. Because of the wide variety of materials that make up operational deposits, removal may be much more complex than the removal of mill scale. No steam generator can operate dependably if the heat transfer surfaces are fouled. 2.5.2 Determining the Extent of Chemical Cleaning The determination of scope and methodology of a preoperational cleaning will depend on how much oxidation of all cycle components can be expected to take place during construction. Factors influencing this are storage procedures and environmental conditions at the plant site. Deposits formed during operation can be varied and complex and maximum tolerable amounts are difficult to establish. Tube samples should be removed from the unit on an annual or biannual basis and the deposit weight measured. Generally speaking, without reference to the specific deposit composition, a unit with 25 to 40 mg/cm2 of deposit on the hot side of the furnace tube should be considered dirty enough for chemical cleaning at the next maintenance outage. 2.5.3 Solvent Systems Solvent selection is made on the basis of two primary considerations. The first is compatibility with the materials of construction and the second is the suitability for removal of the deposits. The two are not independent of each other since dissolution of deposit material
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by the solvent may create corrosive conditions for a tube material that would not be attacked by the solvent in the absence of the deposits. Mineral acids such as hydrochloric or hydrofluoric acid are commonly used as the solvent base for mill scale removal. Solution strength will depend on the deposit analysis, weight and structure. Proper inhibition is necessary to prevent acid attack of base metal. Organic acids, singly or in mixture, and in combination with various other materials are also used as solvents. While they generally are less aggressive than the mineral acids, proper inhibition and preliminary testing remain a necessity. In addition, because of the lesser dissolving capacity of the organic materials, some means of circulation within the unit may be required to insure against local depletion of the solvent before the deposits are completely dissolved. 2.5.4 General Cleaning Operations Chemical cleaning of a steam generator should never be attempted by inexperienced personnel. There is danger of extensive damage should operations deteriorate or improper materials/chemicals be used. Careful planning is required to assure that the specified chemical conditions are attained, that conditions hazardous to life and property do not occur and that disposal of the spent materials will comply with local, state, provincial and federal laws. After backfilling the superheater (see Cautionary Note, Paragraph 2.4.2), the unit may be filled with condensate or demineralized water and fired at a low rate to obtain required metal temperatures. Using drum thermocouples, and temporary thermocouples if necessary, monitor unit temperature to assure that there are no areas above the limits for the solvent system and inhibitor used. The limits must be specified by the solvent system supplier. The unit is then blend-filled with a solvent solution previously checked for proper inhibition. CAUTION NEVER FIRE THE UNIT WHEN IT CONTAINS ACID AS INHIBITOR BREAKDOWN MAY OCCUR. While the solvent is in the unit, the acid strength, iron concentration, temperatures and any condition or constituent necessary for control of the particular solvent system should be monitored on a regular basis. When the cleaning is complete, as indicated by the leveling of the iron concentration, additional condensate is then pumped into the superheater to expel/purge any water that may have absorbed solvent fumes. The solvent is then drained from the unit under a nitrogen blanket. The unit may be filled and drained one or more times to rinse any residual solvent from the unit. The rinse may contain an iron complexing agent to prevent precipitation of iron on the cleaned surfaces. All rinse/drain cycles should be done under nitrogen. When the rinsing is complete, the unit is filled with an alkaline solution to neutralize any residual solvent and passivate the surfaces to prevent after-rusting. The alkaline solution may be heated prior to filling the unit or the unit may be fired to attain the desired temperature. Upon completion of the passivation, the unit may be drained for inspection and removal of any temporary piping. Nitrogen is not required at this time. The overview presented above is condensed. Detailed procedures would be required for proper execution of a chemical cleaning operation.
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Although different aqueous chemical formulations may be employed during various sequential steps of an overall cleaning procedure, the cautionary notes presented in Paragraph 2.4.2 must always be followed. 2.6 OPERATIONAL CHEMICAL CLEANING OF SUPERHEATERS AND REHEATERS Because of the complexity and variability of superheater and reheater circuitry, BHI Co., Ltd should be consulted for recommendations in each specific instance where an operational chemical cleaning of a superheater or reheater may be contemplated. 2.7 FEEDWATER AND BOILER WATER TREATMENT 2.7.1 General The treatment of feedwater and conditioning of boiler water are beyond the control of the BHI Co., Ltd. Therefore, the Company shall not be held responsible for damage due to the presence of oil, grease, scale or deposits on the internal surfaces of the equipment; or for damage resulting from foaming caused by chemical conditions of the water; or for damage resulting from corrosion of any form, cause or nature. The Corporation shall not be responsible for carryover resulting from the presence of oil, grease or other contaminating material. The treatment of feedwater is a highly specialized field and should be placed in the hands of properly qualified individuals or consultants. As such, the following information is intended only as a general guide to the operators of steam generating units. The recommended limits given in the following table represent generally accepted values dictated by years of experience. RECOMMENDED MAXIMUM LIMITS FOR FEEDWATER ENTERING BOILER.
0 301 450 20.8 31.0 451 600 31.1 41.4 601 750 41.4 51.7 751 900 51.8 62.0 901 1000 62.1 68.9 1001 1800 69.0 124.1 1801 2350 124.2 162.0 2351 2600 162.1 179.3 2601 2900 179.3 199.9
Drum Op. gauge Press
psi 300 0 bar 20.7
Total Hardness CaCO3, PPM Organics, PPM pH Oxygen, PPM Silica, PPM Iron, PPM Copper, PPM .04 -.05 .03 .8 - .5 .02 .01 8.0 - 9.6
0*
0 8.8 - 9.2 non ferrous tubes in heaters; 9.2 - 9.6 steel tubes in heaters. .005 .5 - .25 .01 .005 .02
BHI CO. LTD

STEAM GENERATOR & AUXILLIARIES Hydrazine PPM as N2H4
2012-09-20 A PAGE 2 - 11
--
.02
* It is recommended that the hardness in the feedwater be reduced to zero (not detectable).
Even where the hardness in feedwater has been reduced to zero, a phosphate residual should be maintained in the boiler to prevent the formation of scale.
The total dissolved solids (TDS), total alkalinity and suspended solids in the boiler water should not exceed the values given below for the corresponding full load operating drum pressure. Analysis of the various constituents in feedwater or boiler water should be carried out by employing the standard methods given in the current edition of Section 11 of the Annual Book of ASTM Standards. Deposit accumulations in tubes will impair heat transfer and may result in overheating. Corrosion of the tube metal may also result or the formation of scale may occur due to the high concentration of boiler water chemicals at the deposit-to-metal interface.
RECOMMENDED MAXIMUM LIMITS FOR BOILER WATER Drum Press. PSIG Drum Press. barg Total Suspended Alkalinity, PPM Solids, PPM (max.) (max.) 700 600 500 200 150 125 N/A N/A N/A N/A 15 10 8 3 2 1 1 N/A N/A N/A
TDS, PPM (max.) 3500 3000 2500 1000 750 625 100 50 25 15
0 301 451 601 751 901 1001 1801 2351 2601
300 450 600 750 900 1000 1800 2350 2600 2900
0 20.8 31.1 41.4 51.8 62.1 69.0 124.2 162.1 179.3
20.7 31.0 41.4 51.7 62.0 68.9 124.1 162.0 179.3 199.9
Whenever possible, the waterside of the steam generator should be inspected and, if deposition in the tubes appears excessive, a sample should be submitted to a feedwater consultant for analysis. The consultant may then be able to suggest a change in water treatment to render the deposition less adherent, or to reduce the amount of corrosion products entering the steam generator. A steam generator should be treated for the prevention of corrosion, scale formation and foaming that results in carryover. Chemicals required for boiler water treatment should be added continuously rather than by "shot-feed" and the chemical feed connection provided in the steam drum should be used for this purpose. 2.7.2 Corrosion The subject of boiler corrosion can be divided into two parts, the corrosion due to oxygen and the corrosion due to pH, whether the latter be low or high. To prevent corrosion due to oxygen, it is customary to employ external deaerators which typically have a guarantee of 0.005 ppm. In some cases where separate deaerators are not
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installed, a surface condenser with an air-removal section is used. The use of a reducing agent or oxygen scavenger is not universal but varies with plant design and the overall treatment philosophy. Where an oxygen scavenger such as sulfite is used, it is usually injected directly into the deaerator storage tank or feed pump suction. Since a definite reaction time is required, injection ahead of the boiler affords more positive protection to the boiler and economizer. It is recommended that this chemical be added continually and, in high pressure boilers, the sulfite residual should not exceed 8-10 ppm with 5 ppm being a satisfactory excess. Where higher residuals are experienced, sulfite may break down with the liberation of acid-forming gases which will contribute to corrosion in the preboiler system and turbine. Use of sulfite should be limited to boilers operating at less than 124.1 barg. When hydrazine or any other oxygen scavenger not forming solid reaction products is used, it may be introduced into the system at various points in the lower pressure sections of the condensate system. No residuals are maintained in the boiler as it is fed in proportion to the oxygen level in the feedwater and measured at the deaerator outlet or economizer inlet. In order to prevent corrosion in the boiler and to maintain stable protective iron oxide films, the pH (at 25 C) of the boiler water should be maintained above 9. This is usually done through the addition of sodium phosphates. If deposits form on the tube surfaces, chemicals such as caustic may concentrate under them to a corrosive level. When this occurs, the protective film of iron oxide is removed and corrosion may proceed at a very rapid rate. Where phosphate is used for alkalinity control (coordinated phosphate-pH control method), no excess caustic can occur. In high pressure boilers, a satisfactory boiler water treatment regimen may be obtained by operating with a sodium-to-phosphate ratio of < 2.6. For a phosphate range of 2-6 ppm, the corresponding pH values will be about 9.1 to 9.6. These conditions can be controlled by feeding various forms of sodium phosphate and by blowdown. For units operating without phosphate, the pH of the boiler water will be approximately that of the condensate and feedwater. For units where ammonia is used to control the pH of the condensate, this will be in the range of 8.8 to 9.6 (at 25 C) depending on the materials of construction of the low pressure components. Accumulation of corrosion products in boilers presents a serious problem and much effort has been directed to the elimination of these materials, a major portion of which is carried into the boiler with the feedwater. By controlling the condensate pH as indicated above and by minimizing ingress of air and cooling water to the cycle, corrosion product transport can be kept to low levels. 2.7.3 Scale Formation For the prevention of scale formation in high pressure boilers, the feedwater hardness should be reduced to zero (not detectable). Where make-up is evaporated or where demineralizers are used to provide the make-up, this can be readily achieved and the hardness may increase above zero only at times when condenser leakage occurs. However, to provide protection against the formation of calcium and magnesium scales, supplementary boiler water treatment is required. To enable or facilitate the removal of calcium hardness, phosphate in various forms is widely used. Where proper alkalinity is maintained, this results in the formation of a fluid non-adherent sludge which can usually be removed by continuous blowdown. The magnesium is usually removed as either magnesium hydroxide or magnesium silicate, both of which are non-adherent. 2.7.4 Water Treatment for the Prevention of Carryover Carryover can generally be divided into two parts, namely: (1) constituents which are mechanically entrained by the steam from the boiler water and (2) constituents which are volatile. Except at the highest pressures (see Figure 2-2), the mechanically entrained
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constituents form a major portion of the total carryover of solids from the boiler. Total carryover can be maintained within required limits by keeping the boiler water total solids concentration within the values specified in the table in Paragraph 2.7.1 as a function of operating pressure, by the elimination of oily matter and organic substances and by the control of alkalinity. Silica, a volatile material, is particularly troublesome in the turbine where it condenses on the blades to reduce the passageway clearances; this decreases both the turbine capacity and efficiency. The accepted practice for reducing silica carryover is to control its concentration in the boiler water by optimum makeup and feedwater quality control and by blowdown. Approximate values to be maintained in the boiler water to give 0.02 ppm in steam can be obtained from Figure 2-3. 2.7.5 Points to Consider with Respect to Feedwater Limits During Start-up Operations 1) Preboiler system flushing must be carried out at a flow of 25% MCR minimum, and discarded through the deaerator storage vessel blowdown line. If suspended solids "hang up" in this vessel, an internal perforated pipe blowdown line should be installed along the length of the storage vessel, located slightly above the vessel bottom. 2) During the refractory cure period, iron concentration values may be higher or lower than the specified limit. Since this is a short-term operation, deviations from recommended limits are allowable provided that the necessary calculations are performed to ensure that significant iron oxide levels/amounts will not deposit within the boiler at temperature >550F (288C). (This is the approximate bulk boiler water temperature region where iron oxide species will "plate out", or precipitate, on boiler tubing). 3) Values of pH and O2 in the feedwater, measured at the economizer inlet, must be maintained within recommended limits. Deviations from recommended values will increase corrosion rates and result in a further increase of iron oxide products entering the boiler. In particular, residual hydrazine (N2H4) values must be controlled in the 10-20 ppb range: Little or no hydrazine (N2H4) residual detected implies that Oxygen scavenging does not exist. Too much hydrazine residual (>500 ppb) will increase corrosion rates of preboiler ferritic surfaces - thus adding to the iron oxide burden entering the boiler.
Since deaeration must be accomplished early in the start-up sequence, auxiliary steam must be available for deaeration requirements. Properly designed deaerators are very good at removing dissolved oxygen from incoming feedwater. Given rapid flow transient conditions however, such as that experienced during start-up and steam-blow operations, a deaerator can also function as a very good aerator. This will occur if sufficient steam head pressure conditions are not maintained. Thus - the deaerator must be supplied with adequate auxiliary steam to be continuously pegged at (0.70-1.03 bar), T-SAT. 4) Upon initial steam-to-turbine operations, it is to be considered normal to observe "spikes" of iron oxide levels as flows increase toward design values in the preboiler system. Judicious use of deaerator blowdown and drum mass blowdown will assist in purging the system of this corrosion product introduction. Adequate deaeration and pH control will assure that all feedwater chemistry limits will be achieved. 2.8 MAXIMUM RECOMMENDED DRUM PRESSURE DROP DURING STEAM BLOWS
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When raising pressure in the steam drum to use steam blows to clear debris from the superheater/reheater steam lines, it is recommended that the drum pressure drop during these steam blows be kept within the guidelines established by Figure 2-4. Following these guidelines ensures that the inside surface metal temperature of the drum will not change by more than 80F (44C) during an individual steam blow. This procedure is recommended to prevent steam drum metal overstressing. 2.9 SETTING OF SAFETY VALVES The safety valves installed in the boiler, relieves pressure in excess of the safe working pressure of the boiler. Special care should be exercised in setting of safety valves. Refer to Table 2.1 Boiler Safety Valves Description. The table shows the safety valves installed on the boiler pressure part components and their set pressures. Refer to vendor standard specification and literatures in the document attachments. The spring loaded type safety valve operates when the steam entering the inlet of the valve exerts a force which overcomes the spring pressure that holds the valve disk against the seat. When this occurs, the disk is lifted from the valve seat, exposing a larger area of the disk to the steam pressure and the valve pops open. The final action of the disk is so rapid that the valve pops closed. Once the valve is closed, it does not operate again until there is another over pressure. The electromagnetic safety valve can be operated from the control room. Each valve has an inlet isolating motorized valve. The electromagnetic relief valve is an extra safety valve to give added lifting capacity in the event of the main valves fail to lift or the operator wants to relieve pressure on the boiler prior to reaching the valve lifting pressure.
Table1.1 Safety Valves Location Qtty Tag No. Size in. (mm) 2.5" x 6" (73.0 x 168.3) 3" x 6" (88.9 x 168.3) 2.5" x 6" (73.0 x 168.3) 2.5" x 4" (73.0 x 114.3) 3" x 6" (88.9 x 168.3) 4" x 6" (114.3 x 168.3) 4" x 6" (114.3 x 168.3) 4" x 6" (114.3 x 168.3) Model No. 1737B 1737B 1737B 3537W 1747D 1765D 1765D 1765D Set Pressure PSIG (Barg) 2,200 (151.7) 2,265 (156.2) 1,977 (136.6) 1,938 (133.6) 653 (45.0) 703 (48.5) 693 (47.8) 683 (47.1) Relieving Capacity Lb/Hr (Kg/Hr) 275,638 (125,027) 374,748 (169,983) 184,164 (83,535) 82,363 (37,359) 93,166 (42,259) 205,003 (92,988) 201,245 (91,283) 199,987 (90,395)
Drum Drum SHO ERV RHO RHI RHI RHI
1 1 1 1 1 1 1 1
01HAG01AA201 01HAG01AA202 01LBA01AA201 01LBA01AA701 01LBB01AA201 01LBC01AA201 01LBC01AA202 01LBC01AA203
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BAR
BAR
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220.2
206.8 193.1 BAR 179.3
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BHI CO. LTD 20 40 60 80

2012-09-20 A PAGE 2 - 18
10 (18)
20
30
40 BAR
50
60
70
BHI CO. LTD

STEAM GENERATOR & AUXILLIARIES SECTION 3 OPERATION AND MAINTENANCE 3.1 GENERAL
2012-09-20 A PAGE 3-1
a) The operator should be thoroughly familiar with the function and controls of the steam generator components and auxiliary equipment before operating the unit. The information given in this section is not intended to be a detailed procedure for operation of the steam generator, but is meant to serve as a guide together with the instructions of the auxiliary equipment manufacturers and with knowledge derived from initial unit operation. b) The operator should be aware of the limitations imposed on the various parts of the boiler and its auxiliaries and be alert to the actual operating conditions during start-up. 3.2 PRECAUTIONS a) Since the unit operates under positive air pressure, no doors or inspection openings should be opened until it is proven that aspirating air is turned on and available at that opening. Head and body should not be in direct line of opening until it is certain nothing will exit that opening. In addition, protective clothing, including face, head and hands, should be worn when opening any area for any reason. b) All high and low furnace pressure safety interlocks should be checked for proper values and correct switching action and should be in service before starting fans. c) All safety valves are set by the manufacturer but should be rechecked under actual operating conditions as the unit is being brought up to pressure during initial operation. If a safety valve does not lift at the pressure stamped on its nameplate or reseat properly, the valve should be readjusted. In some localities, it is required that only certain authorized personnel may change or adjust safety valve settings or that changes in safety valve settings be witnessed by authorized personnel. Consult governmental and insurance requirements before changing the setting of any safety valve. On the higher pressure sections of the boiler (i.e. drum and superheat), the safety valve relieving pressure exceeds 82.74 barg. At these pressures, it is recommended that safety valve settings be checked and adjusted by the valve manufacturer service engineer prior to initial operation. A hydraulic or pneumatic test device is recommended, if approved by the inspecting authority. This device eliminates the need for raising boiler pressure above normal and minimizes the possibility of valve seat damage during testing. d) Care should be exercised to insure that proper fuel-air ratio for combustion is maintained. The Performance Data following Figure 1-1 indicates the minimum excess air requirements. Operation with less than the minimum expected excess air can be detrimental from the standpoint of good combustion and safe operation of the unit. e) Do not light any burner from an adjoining burner at any time or under any circumstances. The igniter should always be used for lighting the main fuel burners. f) Should it be necessary to operate at low capacity, burners should be taken out of service rather than each burner operated at low loads. At low capacity operation, it is most important that burner operation be watched closely to insure stable combustion conditions during this period. Periodic checking of flame scanner signal strength is required to ensure proper combustion especially at low loads.
g) For purposes of monitoring start-up conditions and load ramping transients during the life of the boiler, permanent-type thermocouples are installed at the outlet ends of the finishing superheater, primary superheater, hanger tubes and reheater; three thermocouples are installed in the rear waterwall riser tubes, two (2) thermocouples are installed on the steam drum. All rear waterwall
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riser tube and drum thermocouples are installed in the unheated zone. These thermocouples are to be used as an aid in determining acceptable firing rates during start-up and load ramping. Thermocouples are installed in the following components: the finishing superheater has 9; the primary superheater has 10; the hanger tubes outlet has 10; the reheater has 9. All these thermocouples are located in the unheated tube outlet sections. Since these thermocouples are located in a zone where flue gas does not sweep over the tubes, the temperature obtained will approximate the steam temperature. h) The unit can be operated up to the steam temperature limits indicated in the table below. To protect the equipment, the operator should correct any condition which has caused an alarm to sound. Section Hanging Tubes Primary Superheater Secondary Superheater Finishing Superheater Reheater Location of Temperature Measurement Tube outlet ends, Unheated zone Tube outlet ends, unheated zone Tube outlet ends, unheated zone Tube outlet ends, unheated zone Tube outlet ends, unheated zone Alarm Limitation Steam Temp. C 399 C 549 C 537 C 602 C 611 C
i)
To prevent plugging, rusting, oxidation and faulty operation of equipment, service air used on the Steam Generator for operational purposes, whether for sealing, aspirating, or atomizing, should be free of dirt, oil and water. BHI recommends that CO analysis equipment be permanently installed, and that CO emissions be monitored continuously during operation of the steam generator.
j)
k) It is strongly recommended that the reliability of all drum level indicators be checked at least once a shift. This would include all gage glasses, remote level indicators and level recorders. A water level indicator connection that is being used to control water level should not be blown down until the control is switched to another water level controller or feedwater control is put on manual. The drum level gages are connected to the drum level averaging system which should negate major differences in drum level readings on opposite ends of the drum. NOTE DIFFERENCES IN READINGS WILL REQUIRE AN INVESTIGATION OF AVERAGING SYSTEM l) On commonly operated valves, such as superheater drains and vents, only the end valves should be closed. The root valve should only be closed for end valve maintenance or downstream line maintenance. Both valves on waterwall wall drains can be left closed. In all cases, end valves should be closed before closing root valves and opened only after opening the root valve in order to minimize potential root valve seat damage. 3.3 COLD AND WARM START-UP PROCEDURE
BHI CO., LTD

STEAM GENERATOR & AUXILLIARIES NOTE
2012-09-20 A PAGE 3-3
IF THE BOILER HAS BEEN SHUT-DOWN BETWEEN 24 ~ 60 HOURS, THEN A WARM START-UP PROCEDURE SHALL APPLY. IF THE SHUT-DOWN OCCURRED MORE THAN 60 HOURS EARLIER, THEN COLD START-UP PROCEDURES SHALL APPLY. IF THE BOILER IS A NEW UNIT BEING PREPARED FOR INITIAL SERVICE, INSTRUCTIONS IN SECTION 2 OF THIS MANUAL SHALL BE OBSERVED AND COLD START-UP PROCEDURE SHALL BE CAREFULLY NOTED. The operating sequence recommended insuring a safe and proper start-up is given below. Modifications may be necessary as subsequent operating experience dictates, including test and commissioning as required. Follow the manufacturer's instructions for operating auxiliary equipment. 3.3.1 Preparation Prior to Start-Up
NOTE IN ADDITION TO THE ITEMS LISTED BELOW, ALL AUXILIARY EQUIPMENT SHOULD BE MADE READY FOR OPERATION; REFER TO MANUFACTURERS INSTRUCTIONS AS NECESSARY. a. Make sure that test gags are removed from all safety valves. b. Check availability of utility services, power, ignition and main fuel, and suitably treated feedwater. c. Check operation of all valves and dampers. Check that control equipment functions properly.
d. Check the igniters and burner auxiliaries assuring that all are operable and that associated valves are in their proper open or closed positions and that the fuel supply will be adequate. Check that atomizing mediums are available, as necessary, for the igniters and burners. e. Check availability of thermocouples in representative locations to measure tube metal temperature distribution across the superheaters in the unheated zones near the outlet headers. Check availability of thermocouples to measure steam drum metal temperature. For initial operation, the following thermocouples are required to measure saturated water temperature: three (3) on the furnace rear wall screens. These are used to establish a suitable start-up rate. f. Close all access doors and observation ports after it is ascertained that no one is inside the unit.
g. All instruments are in proper operating condition isolation valves for Pressure instrumentation except test gauges has to be opened. h. Place the steam generator main valves, vent and drain valves in the following initial positions including steam instrumentations (Refer to Drawing -1020, -1030 and -1035 for valve locations):
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Tag No. 01 01 01 01 01 LAB LAB LAB LAB LAB 51 51 51 51 51 AA AA AA AA AA 810 101 007 401 402
Valve Description Main Feed Water Stop Valve Main Feed Water Control Valve Main Feed Water Isolation Valve Main Feed Water Drain Valve (** First open to drain then close during operation) Steam Drum Saturated Steam transfer pipe (Roof Vent Isolation Valve) Steam Drum Saturated Steam transfer pipe (Roof Vent End MOV) Drum Nitrogen Isolation valve Drum Steam Press Indicator Isolation Valves (01HAG01CP501) Drum Steam Press Indicator Transmitter Isolation Valves (01HAG01CP101, 102, 103)
Valve Position Note Operation MOV AOV Manual Manual Close Close Open Open
(**)
01 QJA 01 01 QJA 01 01 HAG 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 QJA HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG HAG LFN LFN LFN 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 00 00 00
AA 002 AA 003 AA 805 AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA 001 305 306 301 302 303 304 327 328 307 308 309 310 315 316 317 318 311 312 313 314 319 320 321 322 323 324 325 326 401 402 403 404 405 406 001 002 201
Manual MOV Manual Manual Manual
Open Open Close Open Open (1)
Drum Level Indicator Shut-off valves (01HAG01CL501, 502)
Manual
Open
Drum Level Indicator Transmitter Shutoff valves (01HAG01CL102, 103, 104)
Manual
Open
Drum Level Indicator (01HAG01CL501, 502) water column drain
Manual
Close
Drum Chemical Feed Isolation Valves Drum Chemical Feed Check Valve
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Manual Manual
Open Open

STEAM GENERATOR & AUXILLIARIES Tag No. 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 HAG HAG HAG HAG HAG HAG QUA QUA HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD HAD 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA 002 804 802 001 803 801 001 002 403 404 405 406 415 416 421 422 401 402 411 412 413 414 407 408 423 424 425 426 409 410 417 418 419 420 Valve Description
2012-09-20 A PAGE 3-5
Valve Position Note Operation Manual MOV MOV Manual MOV MOV Manual Manual Open Open Close Open Open Close Close Close
Drum Mass Blow-Off (Shut -off Valve) Drum Mass Blow-Off (Root Valve) Drum Mass Blow-Off (End Valve) Drum Blowdown (Shut-off Valve) Drum Blowdown (Root Valve) Drum Blowdown (End Valve) Drum Water Sampling Isolation valves Furnace Lower Front Wall and Rear Wall Header Drain
(2)
(2)
Furnace Lower Side Wall Header Drain (Right Side & Left Side)
Manual
Close
Downcomer Drains
Manual
Close
01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 02 01 QUA 01
AA 401 Hanger Tubes Inlet Pipes Drain (Right Side & Left Side) Isolation Valve AA 801 Hanger Tubes Inlet Pipes Drain (Right Side & Left Side) End Valve AA 501 Hanger Tubes Outlet Transfer Pipes AA 502 Vent Isolation Valves AA 402 Furnace Roof Outlet Pipes Drain (Right Side & Left Side) Isolation Valve AA 803 Furnace Roof Outlet Pipes Drain (Right Side & Left Side) End Valve AA 404 Primary SH Inlet Header Drain (Right Side & Left Side) Isolation Valve AA 803 Primary SH Inlet Header Drain (Right Side & Left Side) End Valve AA 003 Steam Drum Saturated Steam Transfer
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Manual MOV Manual Manual MOV Manual MOV Manual
Open Open Open Open Open Open Open Close (1) (1) (1) (1)

STEAM GENERATOR & AUXILLIARIES Tag No. 01 QUA 01 01 01 01 01 01 01 HAH HAH HAH HAH HAH HAH 02 02 02 02 02 02 Valve Description AA 004 Pipes Sampling AA AA AA AA AA AA 501 502 301 302 303 304
2012-09-20 A PAGE 3-6
Valve Position Note Operation
Primary SH Outlet Pipes Vent Isolation Valves Primary SH Outlet Press. Indicator Transmitter Isolation Valves Secondary SH Inlet Header Press. Test Gauge Isolation Valves
Manual Manual Manual Manual MOV Manual Manual Manual Manual MOV Manual Manual Manual MOV Manual ERV Manual Manual MOV Manual Manual MOV Manual Manual MOV Manual Manual Manual Manual
Open Open Close Open Open Open Close Close Open Open Open Close Open Close Open Close Open Open Open Open Open Open Open Open Open Close Open Close Close
(1)
(3)
01 HAH 03 01 HAH 03 01 01 01 01 01 01 01 HAH HAH HAH HAH HAH HAH HAH 03 03 03 03 03 03 04
01 HAH 04 01 01 01 01 01 LAB LAB LBA LBA LBA 04 04 01 01 01
01 LBA 01 01 LBA 01 01 LBA 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 LBA LBA HAC HAC HAC HAC HAC HAC HAJ HAJ LBC LBC LBB LBB QJA QJA LBB 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01 01
AA 401 Secondary SH Inlet Pipes Drain Isolation Valve AA 801 Secondary SH Inlet Pipes Drain End Valve AA 501 Secondary SH Outlet Pipes Vent AA 502 Isolation Valves AA 301 Secondary SH Outlet Header Press. AA 302 Test gauge Isolation Valves AA 303 Final SH Inlet Header Press. Test AA 304 Gauge Isolation Valves AA 801 Final SH Inlet Header Drain Isolation Valve AA 801 Final SH Inlet Header Drain End Valve AA 501 Final SH Outlet Pipes Vent Isolation AA 502 Valves AA 301 Final SH Outlet Header Press. Test AA 302 gauge Isolation Valves AA 001 Main Steam Start-Up Vent Shut off Valve AA 801 Main Steam Start-Up Vent End Valve AA 004 Main Steam ERV Valve Root Valve AA 701 Main Steam ERV Valve PCV AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA 002 003 001 801 201 002 802 202 801 801 301 302 501 502 201 001 301 Main Steam ERV Valve Press. controller Isolation Valve Economizer Recirc. #1 Root Valve Economizer Recirc. #1 End Valve Economizer Recirc. #1 Check Valve Economizer Recirc. #2 Root Valve Economizer Recirc. #2 End Valve Economizer Recirc. #2 Check Valve RH Inlet Pipes Drain Root Valve RH Inlet Pipes Drain End Valve RH Inlet Header Press. Test Gauge Isolation Valve RH Outlet Pipes Vent Isolation Valve RH N2 Gas Connection isolation Valve RH outlet Header Press. Test Gauge
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(1) (1) (3) (3)
(1) (1) (3)
(4) (5)
(1)
(1)
(3)

STEAM GENERATOR & AUXILLIARIES Tag No. 01 LBB 01 Valve Description AA 302 Isolation Valve NOTES
2012-09-20 A PAGE 3-7
Valve Position Note Operation
(1) TO BE CLOSED DURING PRESSURE RISING CONDITION FOR SAFETY: OPEN UNTIL A STEADY STEAM FLOW OF AT LEAST 10% OF THE RATED BOILER EVAPORATION IS ESTABLISHED. (2) BLOWDOWN TO MAINTAIN DRUM WATER QUALITY AND MASS BLOWOFF TO BE OPENED AS REQUIRED OPTIMIZING SUSPENDED SOLIDS REMOVAL AND OPERATING ECONOMY, FREQUENT SHORT BLOWS ARE PREFERRED TO INFREQUENT LENGTHY BLOWS. (3) THESE VALVES MAY OPTIONALLY BE SET OPEN IF FULL FUNCTIONING INSTRUMENT CAPABILITY IS DESIRED. (4) START UP VENT VALVE IS OPEN ONLY DURING START-UP. OPEN UNTIL A STEADY STEAM FLOW OF AT LEAST 10% OF THE RATED BOILER EVAPORATION IS ESTABLISHED. CLOSE START-UP VENT DURING BOILER LOAD UP AND PRESSURE RISING CONDITION. (5) ERV VALVE IS DESIGNED TO PROVIDE AUTOMATIC OR MANUAL OVERPRESSURE PROTECTION AND FUNCTION TO PROTECT MECHANICAL SAFETY VALVES OF PERMANENT DAMAGE. The initial open position of the drain valves will drain the Hanging Tubes circuit headers, the primary and finishing superheater headers, and heat recovery area roof and rear walls. These sections must be drained so that subsequent flow of steam will not be blocked by water or condensate. In addition, all isolation valves including drain valves in the 1 stage and 2 stage inlet spray control attemperators should be open and the control and block valves should be closed. Tag No. 01 LAE 01 01 LAE 01 01 01 01 01 01 01 01 LAE LAE LAE LAE LAE LAE LAE 01 01 01 01 01 01 01
st st nd
Valve Description AA 005 1 stage Attemperator Isolation Gate Valve nd AA 003 2 stage Attemperator Isolation Gate Valve st AA 405 1 stage Attemperator Drain Valves AA 406 nd AA 405 2 stage Attemperator Drain Valves AA 406 st AA 801 1 stage Attemperator Block Valve nd AA 802 2 stage Attemperator Block Valve st AA 101 1 stage Attemperator Control Valve
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Valve Position Note Operation Manual Manual Manual Manual MOV MOV Control Open Open Open Open Close Close Close

STEAM GENERATOR & AUXILLIARIES Tag No. 01 LAE 01 i. j. k. l.
nd
2012-09-20 A PAGE 3-8
Valve Description AA 102 2 stage Attemperator Control Valve
Valve Position Note Operation Control Close
Check that the remote water level indicators and steam drum pressure gages are operating. Check that lubricating and cooling systems for all drive units are as specified by the manufacturer. See that cooling water is available as necessary. Check that all pressure and draft gages are calibrated and functioning properly. Check all safety interlocks for proper operation.
m. Fill the unit by admitting water to the economizer inlet header using water from the regular feedwater source or filling water from boiler filling water system. As a vent issues water during filling, that vent must be closed. The temperature of the water should not be more than 167C above or below the temperature of the pressure parts. Fill the unit until water in the steam drum is just visible in the bottom of the gage glass. Operate the water column and gage glass blowdown valves to assure that water returns promptly in the gage glass when valves are closed. n. Initial position of all dampers in the air ducts and gas flues as indicated below. Refer to Drawing -01040 and Figure 1-4 for locations of the dampers. DAMPER DESCRIPTION FD Fan Vanes GI Fan Inlet Damper GI Fan Outlet Damper R.H Gas Damper GI to Burners Shutoff Dampers (Low, Mid, Upp) Secondary Air Dampers to Burners/ OAP TAG NO. 01HLA01AA101 01HNA01AA101 01HNA01AA102 01HNA01AA102 01HNA01AA982 01HNA01AA983 01HNA01AA984 01HLA05AA981 01HLA05AA982 01HLA05AA983 01HLA05AA984 01HLA05AA006 01HLA05AA007 01HLA05AA008 01HNA04AA101 01HLA07AA101 01HLZ03AA981 01HLZ03AA982 CONTROL SHUT-OFF MANUAL Close Close Open
50% (Open Purge Position)
Close Close Close Open Open Open Open 30% Open 30% Open 30% Open Close Open Open Open
Over fire dampers (OAP)
ID Fan Inlet Damper ID Fan Outlet Damper RH HRA Bias Dampers SH HRA Bias Dampers
m) Blow out any air flow instrument connections. o. The following operating sequence is recommended to insure a safe and proper start-up. Modifications may be necessary as subsequent operating experience dictates. Follow the manufacturer's instructions for operating auxiliary equipment. 3.3.2 Purging the Unit Purging must be carried out immediately prior to each start and prior to starting, after an unsuccessful starting attempt.
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2012-09-20 A PAGE 3-9
NOTE REFER TO THE DCS OPERATING MANUAL (SUPPLIED BY OTHERS) FOR A COMPREHENSIVE SUMMARY OF ALL PERMISSIVES WHICH APPLY. The purging operation has been programmed into the DCS and is initiated from the control room. In order for the DCS to commence purging, the following boiler permissives (and possibly other system permissives) must be satisfied: ID fans on. FD fan running. GI fans on. Gas Air heater running. All Heavy oil and gas trip valves closed. All burner valves closed. Cooling air pressure adequate. All flame scanners show No flame. At least 85% of burner air register are open. Total air flow greater than 25%. No boiler trip conditions met. Accordingly, the following purge procedure is recommended. CAUTION THE FOLLOWING PROCEDURE PROVIDES FOR A CLEAR AIR FLOW PATH FROM THE FD FAN INLET TO THE STACK DURING START-UP OF EACH FAN TO PREVENT POSITIVE PRESSURE DAMAGE TO THE FURNACE AND DUCTWORK a. Make sure all flue and duct dampers are in the positions specified in Para. 3.3.1, step n. b. Start the gas air heater. c. Open all burner air register.
d. Follow the following sequence to start ID Fan. 1. Open and change the setting of the ID Fan inlet damper gradually to keep furnace draft about -10mmAq. 2. Check that all the ID fan permissives including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Open path established, and ID Fan not running, and No trip conditions present for this fan
3. Start ID Fan, following the manufacturers instructions, and the steps below. 4. Ensure that all the following recommended boiler permissives are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissive which apply: No trip conditions present for this fan ID Fan running, and ID Fan inlet vane not closed, and ID Fan outlet damper open.
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2012-09-20 A PAGE 3 - 10
5. Regulate ID Fan Damper opening paying attention to furnace draft. e. Follow the following sequence to start FD Fan. 1. Open the inlet control vanes of Fan 2. Check that all the FD fan permissives including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Open path established, and FD Fan not running, and No trip conditions present for this fan
3. Start FD Fan, following the manufacturers instructions, and the steps below. 4. Initiate a FD Fan Start sequence through the DCS. 5. Set Fan to 15% BMCR air flow. 6. Ensure that all the following recommended boiler permissives are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissive which apply: No trip conditions present for this fan FD Fan running, and FD Fan inlet vane not closed, and FD Fan outlet damper open.
7. Upon DCS release of the FD Fan to inlet vane control, adjust fan speeds and flow set points to attain about 30% BMCR air flow. f. Follow the following sequence to start GI Fan. Note that the DCS system will auto switch GI fan onto turning gear whenever fuel is being fired. After the purge is completed, it is within the operators discretion to manually shut down GI Fan under certain operating conditions. If such action is taken, the DCS is programmed to automatically switch on the turning gear motor, and close the fan inlet vanes and outlet damper. 1. Check GI fan permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Furnace pressure within limit, and FD Fan running, and No trip conditions present for this fan. Start GI Fan, following the
2. Initiate a GI fan start command through the DCS. manufacturers instructions.
3. With all conditions satisfied, the DCS system will auto-start Fan. Set the Reheat Control Damper to 50% Open. g. With at least 25% air flow established, check that the rest of the purge permissives outlined at the start of this section are satisfied. h. Command the DCS to initiate the purge sequence. This will begin programmed auto purge operation. Total purge time 5 minutes. Blows air via the FD fans through the unit for 5 minutes. After Auto purge is complete, GI fan may be shut down and damper setting will revert to dampers positions specified in Para. 3.3.1, step n. 3.3.3 Fuel Safety
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2012-09-20 A PAGE 3 - 11
Fuel safety operation will reset automatically after purge is complete. All Main shut off valve, 1. Ignition Gas Main shut off Valve 2. Stabilizer COG Main shut off valve 3. Stabilizer H-Oil Main shut off valve 4. BFG Main shut off valve 5. H-Oil Main shut off valve 6. LDG Main shut off valve 7. COG Main shut off valve Operator manual option is also included in the setting. After Purge is complete all Main shut off valve will automatically revert to firing position, Following all the conditions in the DCS operating manual (by others). 3.3.4 Preparation for Light-Off After purging, the igniters and burners are placed into service in accordance with the following sequence. See the manufacturer's instructions for proper operation of the igniters. a. Ensure that the gas air heaters remain running. b. Continue air flow of not less than 25% of full load air flow. Check that the DCS system has placed GI Fans on turning gear. Once a fan is started as part of the purge sequence, and is subsequently shutdown by operator manual action, the DCS system should have automatically left that fan on turning gear. Check that all burner secondary air register are open. c. Refer to manufacturer's instructions and to Paragraph 3.10 for requirements of boiler acoustic horn cleaner and gas air heater soot blowing.
d. Check that igniters and burners are operable and ready for operation. If an igniter or burner is inoperable, the fuel shut off valve for the igniter or burner should be maintained in its closed position. NOTE FIGURE 3-1 IS A COLD START-UP CURVE AND FIGURE 3-2 IS A WARM START-UP CURVE. REFER TO THESE CURVES AS NECESSARY. e. Turbine roll and synchronization will be affected utilizing the HP bypass system which diverts steam from the HP turbine to the reheater for feed to the IP turbine stage. Prior to turbine roll and synchronization, reheat steam shall be further bypassed from the reheater to the condenser, via the LP bypass (By Others). Position the high pressure (HP) bypass system as follows: 1. Set the HP bypass control valve to 3-5% open. 2. Put the HP control valve and bypass spray system on AUTO. After light-off, the HP bypass control valve modulates to hold main steam pressure constant, but not until the main steam pressure increases to about 4 bar. Cracking open the bypass valve permits steam to pass to the reheat system while pressures are building, yet remain below 4 bar. f. Check that both economizer recirculation shut-off valves are open.
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STEAM GENERATOR & AUXILLIARIES Tag No. 01 01 01 01 01 01 HAC 01 HAC 01 HAC 01 HAC 01 HAC 01 HAC 01 Valve Description
DATE REV. NO. DOC. NO. I01-110-EZ61010300 Valve Operation Manual MOV Manual Manual MOV Manual
2012-09-20 A PAGE 3 - 12
Position Open Open Open Open Open Open
AA 001 Economizer Recirc. #1 Root Valve AA 801 Economizer Recirc. #1 End Valve AA 201 Economizer Recirc. #1 Check Valve AA 002 Economizer Recirc. #2 Root Valve AA 802 Economizer Recirc. #2 End Valve AA 202 Economizer Recirc. #2 Check Valve
Close fully and then open turn the following drain valves: Tag No. 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 02 01 HAH 03 01 HAH 03 01 HAH 04 01 HAH 04 Valve Description AA 401 Hanger Tubes Inlet Pipes Drain (Right Side & Left Side) Root Valve AA 801 Hanger Tubes Inlet Pipes Drain (Right Side & Left Side) End Valve AA 402 Furnace Roof Outlet Pipes Drain (RS & LS) Isolation Valve AA 803 Furnace Roof Outlet Pipes Drain (RS & LS) End Valve AA 404 Primary SH Inlet Header Drain (Right Side & Left Side) Isolation Valve AA 803 Primary SH Inlet Header Drain (Right Side & Left Side) End Valve nd AA 401 2 ry SH Inlet Pipes Drain Isolation Valve nd AA 801 2 ry SH Inlet Pipes Drain End Valve AA 801 Final SH Inlet Header Drain Isolation Valve AA 801 Final SH Inlet Header Drain End Valve Valve Operation Manual MOV Manual MOV Manual MOV Manual MOV Manual MOV Position Open turn Open Open turn Open Open turn Open Open turn Open Open turn Open
Close (completely) the reheater inlet header drain valves. Tag No. 01 HAJ 01 01 HAJ 01 Valve Description AA 801 RH Inlet Pipes Drain Isolation Valve AA 801 RH Inlet Pipes Drain End Valve CAUTION MAKE SURE THAT WATER CANNOT ACCUMULATE IN THE REHEATER AND REHEATER PIPING PRIOR TO AND AFTER TURBINE ROLL. TAKE ALL NECESSARY PRECAUTIONS TO PREVENT WATER FROM ENTERING TURBINE. 3.3.5 Combination Burners Firing Methods
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Valve Operation Manual MOV
Position Close Close

2012-09-20 A PAGE 3 - 13
The boiler is designed to fire the following fuels in the combination burners, a. HFO Heavy Fuel Oil (100%) basis - All burners are capable of firing the heavy oil. The boiler is able to reach full load on this fuel. b. BFG (Blast Furnace Gas) exclusive firing; BFG (90%) + Stabilizing fuel (10%) - BFG Exclusive firing means that the boiler is fired with BFG 90% plus COG 10% as main and auxiliary fuel. c. Stabilizing fuels are 1) COG, and 2) SHFO (Stabilizing Heavy Fuel Oil)
d. BFG, COG and LDG mixed firing with HFO e. Pilot Fuel: Propane Gas and COG. Boiler shall be fired by BFG as main fuel and fired by COG, LDG, and Heavy oil as auxiliary fuel together with BFG. When BFG is firing, COG for stabilized fuel will be fired 10% heat capacity.
3.3.6
Light Off (HFO Heavy Fuel Oil Firing 100% Basis) The following details the burner light-off procedure for a cold start-up on 100% HFO when no gas is available. Under these conditions, the middle row of burners is fired off first. All controls for the burners are executed through the DCS. a. Check that the feedwater pump, valves and controls are appropriately set up and initialized to deliver feedwater to the boiler during light off. b. Determine at what stage of the light off sequence, it is appropriate to switch to automatic feedwater control. Place the feedwater system on automatic (i.e. drum level) control, at the selected stage of operation. c. Check scanner cooling air is available.
d. Check that there is an adequate source of steam for atomizing and purging oil burners gun. e. Check burner gun for proper tips or sprayer plates and place gun in proper position. Refer to the burner operating manual (by others). f. Check individual burner and igniter Shutoff valve closed.
g. Check main fuel control valve closed. h. Check atomizing steam header has been blown free of condensate and header steam trap is functioning. i. Initiate the DCS sequence to open the main shutoff valve and recirculation valve to circulate heated oil through the main fuel control valve and the burner header. Ensure that all of the HFO open permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: All burner HFO individual shutoff valves are closed. No boiler trip condition exists. No trip condition are present (i.e. none of the following are true). The HFO close push button in the DCS is pressed The HFO trip push button (hard wired to control room) is pressed A boiler trip condition exists An HFO main shutoff valve open failure has occurred
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2012-09-20 A PAGE 3 - 14
j.
Any one of the HFO burner valves is open and the oil pressure in the common line is low low. Initiate Purge command referring to section 3.3.2.
1. Open main damper(s) to purge position. 2. Open all registers to purge position. 3. Start purge timer and purge. k. Open atomizing steam individual burner shutoff valve to be lighted. Blow free of condensate and confirm atomizing pressure has been established. l. Immediately proceed with light-off cycle after completion of purge. If airflow rate drops below purge rate re-purge before initiating light-off cycle. m. Initiate igniter Light-off Maintain purge airflow rate. Check igniter safety shutoff valve permissive Ignition fuel pressure adequate. Adjust register of burner to be lighted to light off position, if necessary. Energize igniter for first burner. Open igniter safety shutoff valve, prove flame within 10 seconds. If flame not proved, safety shut-off valve for this igniter should close and spark should be deenergized. 7. If ignition flame is not established, determine cause and make necessary corrections. Burner register should open to purge position for at least 1 minute before repeating the cycle, until igniter flame is proven. n. After igniter flame is proven, adjust register of burner to be lighted to light-off position, if necessary. o. Verify igniter flame is present, then commence main burner light off. p. Commencing with one of the MIDDLE row burners, issue a HFO burner start sequence. Ensure that all of the HFO burner start sequence permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Atomizing steam to oil differential pressure is not low low Scanner cooling air manifold pressure is adequate. (i.e. not low low). HFO pressure is adequate. HFO Main shutoff valve is opened No failure has occurred in the HFO logic. HFO temperature is adequate. No boiler trip present. HFO relay reset. The individual burner shut off valve to be started is closed. The HFO gun is in the retract position. Permission to light HFO gun has been given. Scanner cooling air pressure is adequate. The burner to be list shows no flame OR, HFO shutdown condition does not exist. (i.e. none of the following are true). The emergency stop button (Local) pushed for the burner being lit.
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1. 2. 3. 4. 5. 6.

2012-09-20 A PAGE 3 - 15
An HFO Main shutoff valve failure occurs A boiler trip occurs The HFO valve of the burner being lit fails. The HFO gun for the burner being lit fails. The scanner for the burner being lit failed to detect a flame. A HFO stop command is given from the DCS for the burner being lit. Assuming all permissives are satisfied, the DCS will respond as follows (additional permissives apply as the following steps are executed): 1. Opens air registers. 2. HFO gun is advanced. 3. Atomizing steam valve opens. q. Burner individual shut off valve is opened and burner lights off using igniter flame. r. s. t. Repeat this lighting sequence for the remaining burners. During the light-off, it may be necessary to close the air slides of those burners not in service to maintain sufficient combustion air at 30% air flow. As burners are placed in operation, check that the firing rate does not exceed the following start-up limitations:
3.3.7
1. To protect the drum from undue thermal stress, the temperature differential between top and bottom of the drum should not exceed 117C. 2. To protect the superheater, gas temperature at nearby furnace probes should not exceed 538C until an adequate flow of cooling steam is established in all superheater and/or reheater tube elements (turbine synchronization). Light off BFG exclusive Firing (BFG Firing 90% + Stabilizing COG 10%) a. Check that the feedwater pump, valves and controls are appropriately set up and initialized to deliver feedwater to the boiler during light off. b. Determine at what stage of the light off sequence, it is appropriate to switch to automatic feedwater control. Place the feedwater system on automatic (i.e. drum level) control, at the selected stage of operation. c. Firing stabilizing COG (Coke Oven Gas) 10% 1. Issue a DCS command to open the COG main shutoff valve. Ensure that all of the main BFG open permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: No boiler trip condition exists All the gas burner valves are closed The main shut off valve is closed No MFT Trip condition exists The Emergency trip push button is pressed (hard-wired in control room). A boiler trip condition occurs. A Main fuel shutoff valve open failure occurs (i.e. valve open limit switch fails to show valve open in required period). The gas pressure is the common line is low low while any individual gas burner valve is open The gas pressure in the common line is high high while any individual gas burner valve is open.
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STEAM GENERATOR & AUXILLIARIES 2. Initiate Purge command referring to section 3.3.2. 3. 4. 5. Open main damper(s) to purge position. Open all registers to purge position.
2012-09-20 A PAGE 3 - 16
Start purge timer and purge. Immediately proceed with light-off cycle after completion of purge. If airflow rate drops below purge rate re-purge before initiating light-off cycle. Initiate igniter Light-off Maintain purge airflow rate. Check igniter safety shutoff valve permissive Ignition fuel pressure adequate. Adjust register of burner to be lighted to light off position, if necessary. Energize igniter for first burner. Open igniter safety shutoff valve, prove flame within 10 seconds. If flame not proved, safety shut-off valve for this igniter should close and spark should be deenergized.
6. 7. 8.
If ignition flame is not established, determine cause and make necessary corrections. Burner register should open to purge position for at least 1 minute before repeating the cycle, until igniter flame is proven. After igniter flame is proven, adjust register of burner to be lighted to light-off position, if necessary. Verify igniter flame is present, then commence stabilizing burner light off. Open the main flow control valve at least 5 ~ 10% for low fire start condition and is capable of supplying gas to the first 3 lower burners to be lit, at relatively low firing rates. The DCS is programmed to auto-switch control over to the main flow control valve by sensing pressure drops within the burner distribution system, as firing rates are increased. Commencing with one of the lower row burners, issue a stabilizing COG burner start sequence (i.e. requests DCS to open an individual gas burner shut-off/vent valve combination). Ensure that all of the stabilizing COG start sequence permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: No boiler trip present Trip relay reset Shut off valve closed for burner to be started Gas header vent valve closed Permission to light off all gas burners Scanner cooling air pressure adequate Burner to be lit shows no flame No shut down condition exists for gas burner to be started (i.e. none of the following are true) The local emergency stop button pressed Stabilizing COG trip valve failure Boiler tripped
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9.

2012-09-20 A PAGE 3 - 17
Gas burner valve failure Gas burner flame failure Gas burner stop command from the DCS 10. Assuming all permissives are satisfied the DCS will respond as follows: Opens burner air registry. Individual gas burner shut-off valve will open (i.e. the upstream and downstream burner shut-off solenoid valves will open, and the burners vent solenoid valve will close).
Successful light-off will be indicated by gas burner in service condition or else the burner shut-off valves will trip, and the trip condition will need to be analyzed and reset before another light-off attempt can be made. 11. Immediately commence BFG firing after Stabilizing COG light off condition is achieved. 12. Repeat the preceding step until lower three (3) burners are successfully lighted, 13. During the light-off, it may be necessary to close the burner air slides of those burners not in service to maintain sufficient combustion air at 30% air flow. d. Firing BFG (Blast Furnace Gas) 90% 1. Issue a DCS command to open the BFG main shutoff valve. Ensure that all of the main BFG open permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: No boiler trip condition exists All the gas burner valves are closed The main shut off valve is closed No trip valve trip condition exists (i.e. none of the following is true)
2.
The BFG close push button in the DCS is pressed. The BFG trip push button is pressed (hard-wired in control room). A boiler trip condition occurs. A BFG Main shutoff valve open failure occurs (i.e. valve open limit switch fails to show valve open in required period). The gas pressure is the common line is low low while any individual gas burner shutoff valve is open The gas pressure in the common line is high high while any individual gas burner valve is open. Close the main flow control valve. The DCS is programmed to auto-switch control over to the main flow control valve by sensing pressure drops within the burner distribution system, as firing rates are increased. Fire the burner placed into service firing stabilizing COG, referring to 3.3.7 d. Alternately after achieving BFG light off commence firing stabilizing COG on the next middle burners until achieving BFG and stabilizing COG light off for all burners or as necessary. Preferably, warm the unit and raise pressure using the lowest row of burners. Place the lowest row of 3 burners into operation initially. When flame conditions have stabilized and combustion is satisfactory, light-off the next higher row. Commencing with one of the lower row burners, issue a select BFG fuel gas burner start sequence (i.e. requests DCS to open an individual gas burner shut-off/vent
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3.
4.
5.

2012-09-20 A PAGE 3 - 18
valve combination). Ensure that all of the gas burner start sequence permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: No boiler trip present MFT relay reset Shut off valve closed for burner to be started Gas header vent valve closed Permission to light off all combination burners Scanner cooling air pressure adequate Burner to be lit shows no flame No shut down condition exists for combination burner to be started (i.e. none of the following are true) The local emergency stop button pressed Main Shutoff valve failure Boiler tripped Gas burner valve failure Gas burner flame failure Gas burner stop command from the DCS Assuming all permissives are satisfied the DCS will respond as follows: 6. 7. 8. Adjust registry of burner to be lighted to light off position if necessary. Ignition shutoff valve is opened and ignition 3.3.7.d.12 lights off using spark igniter plus heat generated by stabilizing COG firing. Individual gas burner shut-off valve will open (i.e. the upstream and downstream burner shut-off solenoid valves will open, and the burners vent solenoid valve will close). Successful light-off will be indicated or else the burner shut-off valves will trip, and the trip condition will need to be analyzed and reset before another light-off attempt can be made.
9.
10. Repeat the preceding step until all burners are successfully lighted. a. During the light-off, it may be necessary to close the burner air registry of those burners not in service to maintain sufficient combustion air at 30% air flow. b. As burners are placed in operation, check that the firing rate does not exceed the following start-up limitations: 1. Once steam generation begins, makeup feedwater flow will begin automatically. To protect the drum from undue thermal stress, the temperature differential between top and bottom of the drum should not exceed 117C. To protect the superheater and reheater tubes, gas temperature nearby furnace probes should not exceed 538C until an adequate flow of cooling steam is established in all superheater and/or reheater tube elements (turbine synchronization).
2.
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STEAM GENERATOR & AUXILLIARIES 3.3.8
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Light off Combination firing (BFG Firing 90% + Stabilizing HFO 10%) The following details the burner light-off procedure for a cold start-up on 90% BFG + 10% stabilizing fuel (10% SHFO). Under these conditions, the lower row of burners is fired off first. All controls for the burners are executed through the DCS. c. Check that the feedwater pump, valves and controls are appropriately set up and initialized to deliver feedwater to the boiler during light off.
d. Determine at what stage of the light off sequence, it is appropriate to switch to automatic feedwater control. Place the feedwater system on automatic (i.e. drum level) control, at the selected stage of operation. e. Commence firing following sequence below, f. Initiate firing sequence Stabilizing HFO (Stabilizing Heavy Fuel Oil) 10% capacity. 1. 2. 3. 4. 5. 6. 7. Check scanner cooling air is available. Check that there is an adequate source of steam for atomizing and purging oil burners. Check burner gun for proper tips or sprayer plates and place gun in proper position. Refer to the burner operating manual (by others). Check individual burner and igniter Shutoff valve closed. Check main fuel control valve closed. Check atomizing steam header has been blown free of condensate and header steam trap is functioning. Initiate the DCS sequence to open the shutoff valve and recirculation valve to circulate heated oil through the stabilizing Heavy oil fuel control valve and burner header. The main heavy oil control and recirculation valve is closed. Ensure that all of the stabilizing Heavy oil open permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: All burner individual Stabilizing HFO shutoff valves are closed. No boiler trip condition exists.
8.
No trip condition are present (i.e. none of the following are true). The Stabilizing HFO close push button in the DCS is pressed The Stabilizing HFO trip push button (hard wired to control room) is pressed A boiler trip condition exists An Stabilizing HFO oil main shutoff valve open failure has occurred Any one of the Stabilizing HFO burner individual shutoff valves is open and the oil pressure in the common line is low low. Initiate Purge command referring to section 3.3.2. Open main damper(s) to purge position. Open all registers to purge position.
9.
Start purge timer and purge. Verify stabilizing atomizing steam individual burner shutoff valve to be lighted. Blow free of condensate and confirm atomizing pressure has been established.
10. Immediately proceed with light-off cycle after completion of purge.
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11. If airflow rate drops below purge rate re-purge before initiating light-off cycle. 12. Initiate igniter Light-off Maintain purge airflow rate. Check igniter safety shutoff valve permissive Ignition fuel pressure adequate. Adjust register of burner to be lighted to light off position, if necessary. Energize igniter for first burner. Open igniter safety shutoff valve, prove flame within 10 seconds. If flame not proved, safety shut-off valve for this igniter should close and spark should be deenergized.
If ignition flame is not established, determine cause and make necessary corrections. Burner register should open to purge position for at least 1 minute before repeating the cycle, until igniter flame is proven. 13. After igniter flame is proven, adjust register of burner to be lighted to light-off position, if necessary. 14. Verify igniter flame is present, then commence stabilizing burner light off. 15. Commencing with one of the lower row burners, issue a Stabilizing HFO burner start sequence. Ensure that all of the Stabilizing HFO burner start sequence permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Stabilizing Atomizing steam to oil differential pressure is not low low Scanner cooling air manifold pressure is adequate. (i.e. not low low). Heavy oil pressure is adequate. Stabilizing HFO Main shutoff valve is opened No failure has occurred in the Heavy oil logic. Heavy oil temperature is adequate. No boiler trip present. Heavy Oil relay reset. The individual burner shut off valve to be started is closed. The Stabilizing HFO gun is in the retract position. Permission to light Stabilizing HFO gun has been given. Scanner cooling air pressure is adequate. The burner to be list shows no flame OR, Heavy oil shutdown condition does not exist. (i.e. none of the following are true). The emergency stop button (Local) pushed for the burner being lit. An Stabilizing HFO Main shutoff valve failure occurs A boiler trip occurs The Stabilizing HFO individual shutoff valve of the burner being lit fails. The Stabilizing HFO gun for the burner being lit fails. The scanner for the burner being lit failed to detect a flame. A Heavy oil stop command is given from the DCS for the burner being lit. Opens air registers.
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STEAM GENERATOR & AUXILLIARIES Stabilizing HFO gun is advanced.
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Stabilizing Atomizing steam valve opens. 16. Burner Stabilizing HFO individual shut off valve is opened and burner lights off using igniter flame. 17. Immediately commence BFG firing after Stabilizing HFO light off condition is achieved. 18. Repeat step n above for each of Three (3) lower row burners. g. Firing BFG (Blast Furnace Gas) 90% 1. Issue a DCS command to open the BFG main shutoff valve. Ensure that all of the main BFG open permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: No boiler trip condition exists All the gas burner valves are closed The main shut off valve is closed
2.
No trip valve trip condition exists (i.e. none of the following is true) The BFG close push button in the DCS is pressed. The BFG trip push button is pressed (hard-wired in control room). A boiler trip condition occurs. A BFG Main shutoff valve open failure occurs (i.e. valve open limit switch fails to show valve open in required period). The gas pressure in the common line is low low while any individual gas burner shutoff valve is open The gas pressure in the common line is high high while any individual gas burner valve is open. Close the main flow control valve. The DCS is programmed to auto-switch control over to the main flow control valve by sensing pressure drops within the burner distribution system, as firing rates are increased. Fire the burner placed into service firing Stabilizing HFO, referring to 3.3.7 d. Alternately after achieving BFG light off commence firing SHFO on the next middle burners until achieving BFG and Stabilizing HFO light off for all burners or as necessary. Preferably, warm the unit and raise pressure using the lowest row of burners. Place the lowest row of 3 burners into operation initially. When flame conditions have stabilized and combustion is satisfactory, light-off the next higher row. Commencing with one of the lower row burners, issue a select BFG fuel gas burner start sequence (i.e. requests DCS to open an individual gas burner shut-off/vent valve combination). Ensure that all of the gas burner start sequence permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: No boiler trip present MFT relay reset Shut off valve closed for burner to be started Gas header vent valve closed Permission to light off all combination burners
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3.
4.
5.

STEAM GENERATOR & AUXILLIARIES Scanner cooling air pressure adequate Burner to be lit shows no flame
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No shut down condition exists for combination burner to be started (i.e. none of the following are true) The local emergency stop button pressed Main Shutoff valve failure Boiler tripped Gas burner valve failure, Gas burner flame failure Gas burner stop command from the DCS Assuming all permissives are satisfied the DCS will respond as follows: 6. 7. 8. Adjust registry of burner to be lighted to light off position if necessary. Ignition shutoff valve is opened and ignition 3.3.7.d.12 lights off using spark igniter plus heat generated by Stabilizing HFO oil firing. Individual gas burner shut-off valve will open (i.e. the upstream and downstream burner shut-off solenoid valves will open, and the burners vent solenoid valve will close). Successful light-off will be indicated or else the burner shut-off valves will trip, and the trip condition will need to be analyzed and reset before another light-off attempt can be made.
9.
10. Repeat the preceding step until all burners are successfully lighted. h. During the light-off, it may be necessary to close the burner air registry of those burners not in service to maintain sufficient combustion air at 30% air flow. i. As burners are placed in operation, check that the firing rate does not exceed the following start-up limitations: 1. Once steam generation begins, makeup feedwater flow will begin automatically. To protect the drum from undue thermal stress, the temperature differential between top and bottom of the drum should not exceed 117C. 2. To protect the superheater and reheater tubes, gas temperature nearby furnace probes should not exceed 538C until an adequate flow of cooling steam is established in all superheater and/or reheater tube elements (turbine synchronization). 3.3.9 Raising Pressure and Loading Turbine The following start-up steps need to be coordinated with burner light off procedures outlined in Sections 3.3.5, 3.3.6. and 3.3.7. a. When drum pressure reaches 1.72 barg and a strong blow of steam issues from the vents, close the following vent valves. Tag No. 01 QJA 01 01 QJA 01 01 HAG 01 01 HAH 02 01 HAH 02 Valve Description AA 002 Steam Drum Saturated Steam transfer AA 003 pipe (Roof Vent Isolation Valve) AA 805 Steam Drum Saturated Steam transfer pipe (Roof Vent End MOV) AA 501 Primary SH Outlet Pipes Vent Isolation AA 502 Valves
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Valve Operation Manual MOV Manual
Position Open Close Open

STEAM GENERATOR & AUXILLIARIES Tag No. 01 01 01 01 01 01 HAH HAH LAB LAB LBB LBB 03 03 04 04 01 01 AA AA AA AA AA AA 501 502 501 502 501 502 Valve Description
DATE REV. NO. DOC. NO. I01-110-EZ61010300 Valve Operation Manual Manual Manual
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Position Close Close Close
Secondary SH Outlet Pipes Vent Isolation Valves Final SH Outlet Pipes Vent Isolation Valves RH Outlet Pipes Vent Isolation Valve
Close completely the following drain valves: Tag No. 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 01 01 HAH 02 01 HAH 03 01 HAH 03 01 HAH 04 01 HAH 04 Valve Description AA 401 Hanger Tubes Inlet Pipes Drain (Right Side & Left Side) Isolation Valve AA 801 Hanger Tubes Inlet Pipes Drain (Right Side & Left Side) End Valve AA 402 Furnace Roof Outlet Pipes Drain (Right Side & Left Side) Isolation Valve AA 803 Furnace Roof Outlet Pipes Drain (Right Side & Left Side) End Valve AA 404 Primary SH Inlet Header Drain (Right Side & Left Side) Isolation Valve AA 803 Primary SH Inlet Header Drain (Right Side & Left Side) End Valve AA 401 Secondary SH Inlet Pipes Drain Isolation Valve AA 801 Secondary SH Inlet Pipes Drain End Valve AA 801 Final SH Inlet Header Drain Isolation Valve AA 801 Final SH Inlet Header Drain End Valve Valve Operation Manual MOV Manual MOV Manual MOV Manual MOV Manual MOV Position Open Close Open Close Open Close Open Close Open Close
b. Pulse open start-up vent to maintain a constant pressure rising up to 7 barg. Tag No. 01 LAB 01 01 LAB 01 Valve Description AA 001 Main Steam Start-Up Vent Shut off Valve AA 801 Main Steam Start-Up Vent End Valve Valve Operation Manual MOV Position Open Pulsed Open (Do not open quickly)
c.
If the boiler water silica content is above the recommended limit, the unit should be blown down using the drum blowdown valve until the recommended limit is reached. (See Figure 2-3.) blowdown is designed for 5 % of MCR steam flow although normal blowdown shall not exceed 0.5%. Tag No. Valve Description AA 803 Drum Blowdown (Root Valve) AA 801 Drum Blowdown (End Valve) Valve Operation MOV MOV Position Open (Operate as required)
01 HAG 01 01 HAG 01
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STEAM GENERATOR & AUXILLIARIES d. Maintain visible water level in the gage glass.
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Water level in drum will rise due to swelling of water in the waterwall system and drum. To reduce water level, the drum mass blow-off valve should be used as required. Tag No. 01 HAG 01 01 HAG 01 01 HAG 01 Valve Description AA 002 Drum Mass Blow-Off (Shut -off Valve) AA 804 Drum Mass Blow-Off (Root Valve) AA 802 Drum Mass Blow-Off (End Valve) Valve Operation Manual MOV MOV Position Open Open (Operate as required) Normally Closed
e. During pressure rising, the startup vent valve can be pulsed closed to assist in stabilizing a constant pressure rise until reaching steam generator pressure at 34.5 barg. Tag No. 01 LAB 01 01 LAB 01 f. Valve Description AA 001 Main Steam Start-Up Vent Shut off Valve AA 801 Main Steam Start-Up Vent End Valve (Confirm pressure when closing) Valve Operation Manual MOV Position Open Pulsed to Close
If the vent and/or drain valves in the main steam pipe to the turbine are open, the finishing superheater inlet header drain valves may be throttled to clear away water from the final superheater or throttle start-up vent at the same time to maintain pressure rising. Tag No. Valve Description AA 801 Final SH Inlet Header Drain Isolation Valve AA 801 Final SH Inlet Header Drain End Valve Valve Operation Manual MOV Position Open Throttle Control to close
01 HAH 04 01 HAH 04
g. At the appropriate pressure about 50 barg, start taking gland seal steam and establish vacuum in the condenser. h. Steam produced upon start-up is routed through the HP/LP bypass to the drain system. Check that HP bypass system (by others) is set up and initialized in accordance with section 3.3.4, step e. Check that the LP bypass system (by others) is properly initialized and functioning. i. j. k. Increase firing by placing additional burners into service following the procedures of sections 3.3.5 or 3.3.6 or 3.3.7 to increase the quality and flow of boiler steam production. Confirm close position of reheater inlet drain valves and superheater inlet drain valve. When the proper steam pressure and temperature are available, start admitting steam to the turbine in accordance with the turbine manufacturers instructions. Warm, roll and synchronize the turbine, typically by admitting reheat steam through the IP turbine stage, adjusting the turbine bypass system as required. Increase firing rate to 13-16% MCR heat input by placing additional burners in service while raising reheater outlet pressure by gradually closing off the LP bypass system (by others). With the HP bypass control valves on AUTO, increase the superheater outlet pressure setpoint without exceeding maximum load ramping rates.
l.
m. When superheater steam conditions meet the turbine manufacturers requirements, begin admitting superheater steam to the turbines HP stage. Re-direct steam flow from the HP/LP bypass system(s) to both turbine stages.
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n. Place additional burners into service as required to supply the steam demand of the turbine. When all burners are in service, increase steam production by increasing firing rate. o. After constant feedwater flow through the economizer is being maintained, close the economizer recirculation shut-off valves. Tag No. 01 01 01 01 01 01 HAC 01 HAC 01 HAC 01 HAC 01 HAC 01 HAC 01 Valve Description Valve Operation Manual MOV Manual Manual MOV Manual Position Close Close Close Close Close Close
AA 001 Economizer Recirc. #1 Root Valve AA 801 Economizer Recirc. #1 End Valve AA 201 Economizer Recirc. #1 Check Valve AA 002 Economizer Recirc. #2 Root Valve AA 802 Economizer Recirc. #2 End Valve AA 202 Economizer Recirc. #2 Check Valve
p. Required final steam temperature should be maintained during start-up by using the following: 1. For HP steam, use the first stage desuperheaters. It is important that the temperature of the steam leaving the first stage spray headers be not less than 11C above saturation temperature. 2. For reheat steam, use the reheater pass outlet temperature control damper, when steam flow has been established through the reheater. q. When conditions permit, insure that drum level, steam and reheat temperature, and air flow are on automatic control. r. s. t. When load, steam pressure and temperature have been normalized, insure that steam generator is on full automatic control. Increase load as required. When approaching full load, the rate of load increase should be adjusted, as necessary, to avoid overriding full load conditions.
3.4 HOT START-UP (LESS THAN 6 HOUR SHUT-DOWN) OF STEAM GENERATOR The unit can be shut down for short periods of time and held in the hot or bottled-up condition. When the steam generator is shut down, and the unit has been properly purged, all valves are closed and all dampers are closed so that a minimum amount of heat is lost. No fire is maintained or introduced into the furnace; therefore, the pressure in the steam drum will decrease together with the temperatures at the superheater and reheater outlets. BHI does not recommend bottling-up the unit, when heavy oil is being fired, if operation prior to the shutdown was such that unburned oil or carbon may have been deposited on the baskets of the gas air heater. These deposits would result from extended periods of firing heavy oil burners in a cold furnace at low loads, or other conditions which could result in deposits being formed from oil vapors condensing or unburned carbon depositing in the air heater. Particular care should be taken when load is raised on the unit after an extended period of operation at low loads. When the only fuel fired in the boiler is gas, these concerns are greatly diminished. For oil firing, before bottling-up the flue gas side, the Gas Air Heater baskets should be carefully inspected. If an oil film or heavy carbon deposit is present, DO NOT BOTTLE UP the unit. Using proper procedures, water wash and dry the air heater. Continue to rotate the Gas Air Heater until the inlet gas temperature decays below 121C.
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2012-09-20 A PAGE 3 - 26
If inspection reveals no oil or carbon deposits on the Gas Air Heater baskets and the air heaters have been cleaned by thorough soot blowing prior to shut-down, the unit may be bottled-up. The Gas Air Heater rotation should be continued until the flue gas inlet temperature decays below 121C at which time, it may be stopped if desired. The Gas Air heater air and gas side temperatures should be monitored frequently, and logged, even after shutdown, to detect any temperature rise which might indicate a fire developing in the air heater. Refer to special Gas Air Heater instructions at the end of this section and to vendor's instructions for water washing instructions. To start up the steam generator from a bottled-up condition, proceed as follows: a. Prepare main fuel systems for operation. For start-up on 100% heavy oil (100% HFO), check heavy oil is at the proper temperature and viscosity. Check all igniters and ignition fuel function ability. b. Purge the steam generator as per Section 3.3.2. Steps of the purge sequence are repeated in Steps c. through j. below. As noted previously, in order for the DCS to commence purging, the following recommended boiler permissives (and possibly other DCS system permissives) must be satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: c. ID fan running. FD fan running. Gas Air heater running. Oil and gas trip valves closed. All burner valves closed. Scanner cooling air pressure adequate. All flame scanners show No flame. At least 85% of burner air register are open. Total air flow greater than 25%. No boiler trip conditions met. GI fans on.
Make sure all flue and duct dampers are in the positions specified in Paragraph 3.3.1, step n.
d. Start the gas air heater. e. Open all burner air registry f. Follow the following sequence to start ID Fan. 1. Open and change the setting of ID Fan inlet damper gradually to keep furnace draft about ( - 10 mmAq). 2. Check that all the ID fan permissives including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Open path established, and ID Fan not running, and No trip conditions present for this fan
3. Start ID Fan, following the manufacturers instructions, and the steps below.
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2012-09-20 A PAGE 3 - 27
4. Ensure that all the following recommended boiler permissives are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissive which apply: No trip conditions present for this fan ID Fan running, and ID Fan inlet vane not closed, and ID Fan outlet damper open.
5. Regulate ID Fan Damper opening paying attention to furnace draft. g. Follow the following sequence to start FD Fan. 1. Open the inlet control vanes of Fan 2. Check that all the FD fan permissives including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Open path established, and FD Fan not running, and No trip conditions present for this fan
3. Start FD Fan, following the manufacturers instructions, and the steps below. 4. Initiate a FD Fan Start sequence through the DCS. 5. Set Fan to 15% BMCR air flow. 6. Ensure that all the following recommended boiler permissives are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissive which apply: No trip conditions present for this fan FD Fan running, and FD Fan inlet vane not closed, and FD Fan outlet damper open.
7. Upon DCS release of the FD Fan to inlet vane control, adjust fan speeds and flow set points to attain about 30% BMCR air flow. h. Follow the following sequence to start GI Fan. Note that the DCS system will auto switch any idle GI fan onto turning gear whenever fuel is being fired. After the purge is completed, it is within the operators discretion to manually shut down GI Fan under certain operating conditions. If such action is taken, the DCS is programmed to automatically switch on the turning gear motor, and close the fan inlet vanes and outlet damper. 1. Check GI fan permissives, including the following recommended boiler permissives, are satisfied. Refer to the DCS operating manual (by others) for a comprehensive list of all permissives which apply: Furnace pressure within limit, and FD Fan running, and No trip conditions present for this fan. 2. Initiate a GI fan start command through the DCS. Start GI Fan, following the manufacturers instructions. 3. With all conditions satisfied, the DCS system will auto-start Fan. Set the Reheat Control Damper to 50% Open. i. With at least 25% air flow established, check that the rest of the purge permissives outlined at the start of this section are satisfied.
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STEAM GENERATOR & AUXILLIARIES j.
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Command the DCS to initiate the purge sequence. This will begin programmed auto purge operation. Total purge time 5 minutes. Blows air via the FD fans through the unit for 5 minutes. After Auto purge is complete, GI fan may be shut down and damper setting will revert to dampers positions specified in Para. 3.3.1, step n.
k. l.
Refer to manufacturer's instructions and to Paragraph 3.10 for Air Horn Acoustic Cleaners for boiler and soot blowing requirements of the gas air heater. Check that igniters and burners are operable and ready for operation. If an igniter or burner is inoperable, the fuel shut-off valve for the igniter or burner should be maintained in its closed position. NOTE FIGURE 3-3 IS A HOT START-UP CURVE. REFER TO THIS CURVE AS NECESSARY.
m. Position the high pressure (HP) bypass system as follows: 1. Set the HP bypass control valve to 3-5% open. 2. Put the HP control valve and bypass spray system on AUTO. n. After light-off, the HP bypass control valve modulates to hold main steam pressure constant, but not until the main steam pressure increases to about 4 bar. Cracking open the bypass valve permits steam to pass to the reheat system while pressures are building, yet remain below 4 bar. o. Follow the manufacturers instructions to properly set up and test the operation of the LP turbine bypass system. p. Start burners in accordance with Sections 3.3.5 or 3.3.6 or 3.3.7 depending upon fuel type. CAUTION ONCE STEAM GENERATION BEGINS, MAKEUP FEEDWATER FLOW WILL BEGIN AUTOMATICALLY. MONITOR AND KEEP NORMAL TEMPERATURES OF TOP AND BOTTOM OF DRUM. q. Steam flow should be immediate. Check water level in the steam drum. If necessary, make adjustments to bring water level to normal level. r. s. As the HP/LP bypass system begins to open and steam flows through the reheater, the reheat outlet temperature control should be placed on AUTO At approximately 10% steam flow and steam outlet temperatures suitable for admission to the turbine, roll and synchronize the turbine per turbine manufacturer instructions. Steam flow at synchronization should be about 10% and rising. Continue hot restart by following steps of cold start commencing with Paragraph 3.3.9, Step k.
t.
3.5 NORMAL OPERATION 3.5.1 Firing a. Check the fires periodically to be certain that there is no heavy flame impingement on any of the burner heating surfaces. b. Change burner register as required to improve flame conditions. Only 2 positions are possible fully open or fully closed.
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STEAM GENERATOR & AUXILLIARIES c.
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It is desirable to keep as many burners in service as the boiler load will permit. Should the load be decreased below the stable minimum output for burners in operation, additional burners should be removed from service. At low capacity operation, it is important that burner operation be watched closely to insure stable combustion conditions during this period. The sequence of removing burners from service should be such as to maintain a uniform distribution of heat release across the furnace. When firing heavy oil, if there is evidence of instability due to some abnormal condition of operation or fuel quality, it may be desirable to switch off the heavy oil, and to re-start the burner with BFG or LDG and Gas stabilizers. Stop fuel flow to burners to be removed from operation by closing the individual burner shut-off valves.
3.5.2
Fuel Switching Individual burners of the boiler can be switched from gas to oil firing and vice versa during normal operations. Excess air and flue gas re-circulation rates may also need to be adjusted. Burners should be switched starting with the lowest row and working up. A full row on one wall should be done first then the next upper row. During a fuel change, it recommended that at least some of the boiler control functions be switched over to manual control (i.e. superheat temperature control, reheat temperature control, excess oxygen content). Note also that it is necessary to provide a signal to the DCS of the fuel type being fired in order to drive a number of DCS control functions. The operator has the flexibility to change the fuel type within the DCS at any time. For the case where it is desired to convert all of the boilers burners, it is recommended that the DCS fuel type be changed when all of the burners have been converted from the old to the new fuel. It may be possible and desirable to change these procedures as additional unit operating experience is acquired. The following procedures apply:
a. Fuel Switch - Oil to Gas 1. Close the gas header vent valve. Open the main gas trip valve, and open flow control valve. The vent valve will close automatically when the trip valve is commanded to open. 2. Select a burner. Shut off the oil flame on this burner. Automatically, the ignitor and ignition fuel will be put into firing position and the oil gun purged. Note: Burners should be converted one at a time to minimize fluctuations in heat input and other parameters. The other oil burners will automatically increase their heat input to maintain load. 3. Initiate gas firing on this burner. The controls will automatically place the spark ignitor in service to light off ignition gas and then open the individual burners shut off valve. 4. Follow items 2 and 3 for the rest of the burners. 5. When the last oil burner has been removed from service, decrease the excess air to that required for gas (3%), close the main oil flow control valve. GI fans will adjust as required to furnace pressure. b. Fuel Switch Gas to Oil The following fuel switch sequence, from Gas to Heavy oil, assumes a hot, online boiler to start with. Under these conditions, stabilizing oil firing is not required.
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1. Increase excess air to that required for heavy oil (10%). 2. Open the Heavy oil fuel trip valve. Open the heavy oils flow control valve 10 ~ 15%. 3. Select a burner. Shut off the gas flame on this burner. Note: Burners should be converted one at a time to minimize fluctuations in heat input and other parameters. The other gas burners will automatically increase their heat input to maintain load. 4. Initiate oil firing on this burner. The controls will automatically start the atomizing steam, place the spark igniter in service and light off ignition fuel, and open the individual burners shut off valve. 5. Follow items 3 and 4 for the rest of the burners. 6. The GI fans will adjust as required to furnace pressure. 7. When the last gas burner has been removed, close the gas headers trip valve and open the vent line. 3.5.3 Water Chemistry and Steam Purity a. Assure that the desired water solids concentration and chemistry are maintained. Improper boiler water chemistry can lead to fouling or corrosion of internal surfaces, reducing the efficiency of the unit and possibly resulting in overheating of tubes leading to tube failure. b. It is preferable that oxygen content of feedwater not exceed 0.007 cc per liter and the PH of the feedwater be maintained above 8.6. c. Assure that moisture carryover from the drum is within permissible limits. Operation of the unit in excess of design conditions can result in moisture carryover to the superheater. For operation within design conditions, the steam separation equipment will keep solids carryover within acceptable limits. Moisture carried over can include solids and other impurities which may deposit on internal tube surfaces causing overheating and possible tube failure.
d. If solids carryover is being caused by excessive boiler water solids concentration, this may be controlled by adjustment of the steam drum blowdown valve. An increase in blowdown rates can be accomplished by using the steam drum mass blow-off valve. To avoid overfiring, this valve should only be used when the steam generator is operating at loads below 75% of full load. CAUTION BECAUSE OF THE SIZE OF THE MASS BLOW-OFF VALVE, IT SHOULD NOT BE OPENED RAPIDLY. SINCE USE OF THE MASS BLOW-OFF VALVE WILL INCREASE HEAT INPUT TO THE UNIT FOR A GIVEN OUTPUT, THE PRIMARY SUPERHEATER OUTLET TEMPERATURE SHOULD BE MONITORED. e. The frequency of blowdown is best determined by the conditions existing on each installation. CAUTION DRAIN VALVES ON THE ECONOMIZER INLET HEADER AND ON THE LOWER WATERWALL HEADERS SHOULD NOT BE USED FOR
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BLOWDOWN PURPOSES WHEN THE UNIT IS IN OPERATION. 3.5.4 Acoustic Cleaning System for Boiler and Soot Blowing for Air Heater All external surfaces of tubes and elements must be kept reasonably free of deposits if full capacity and efficiency are to be maintained. Acoustic Cleaning for Boiler and Steam Soot blowing for Gas Air Heater should be used as often as necessary to accomplish this. CAUTION ACOUSTIC CLEANING SYSTEM EMITS INTENSE SOUND WAVES AND MAY CAUSE PAIN, BODILY INJURY, OR PERMANENT HEARING LOSS. a. Acoustic Cleaning System for Boiler The following cleaning procedures apply to Heavy oil firing: After the unit is placed in service, operate the Acoustic Cleaning System to remove any deposits which may be present. Cleaning should always be done on the pre-established schedule basis regardless of the operating load. By principle the acoustic cleaning is to prevent build up on the tubes from occurring and therefore acoustic horn cleaning cycle should be initiated immediately upon start up of the system. 1. Cleaning cycle operations are considered a part of the boiler operations and require frequent monitoring to achieve optimum cleaning. Optimum cleaning can be defined as the condition of the heat transfer surface that promotes the most efficient operation of the boiler/auxiliary equipment. Variations in fuel and/or unit load may dictate the need for a change in the soot blower pattern. In addition to monitoring boiler performance, routine inspections of the soot blowing equipment and boiler pressure parts should be made. 2. The following items should be reviewed prior to start-up for optimum acoustic cleaning sequence Refer to manufacturer's instructions for exact settings. 2.1 Air Piping Proper airflow to the acoustic horn is critical to sounding. 2.2 Air Pressure check the air pressure before and during sounding of the Horns. Ideally the air pressure will be in the middle of the range of manufacturers stated air pressure requirements. 2.3 Verify operation Listen to each acoustic horn as it operates to make sure that each is sounding properly. You should hear a definite foghorn tone and may even feel some resonation in your feet or body when the acoustic cleaner sounds. 2.4 Verify sounding sequence The horns are not sounded continuously. They are typically cycled on and off A typical acoustic cleaning cycle for boilers is 10 seconds on every 10 minutes cycle, exposure 8 - minutes/ 8 hr shift or 0.133 hr / shift. This on time can be adjusted to clean the reheater or economizer more or clean the reheater or economizer less, as deemed necessary in actual conditions. Cycles may need to be adjusted based on loading and operational needs. b. Steam Soot Blowing for Air Heater Proper operation of thermal drain valves (For steam sootblowing of Air Heater). The result of improper operation of the thermal drain or trap Gas Air Heater walls may
BHI CO., LTD

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erosion occur within the first several feet of blower travel that is caused by water droplets entrained in the steam being propelled against the Gas Air Heater wall surface. 1. Checks of the settings of individual blower blowing pressures. (This can usually be done at each blower's poppet utilizing a test gage when the blower is in service.) Refer to manufacturer's instructions for exact settings. 2. During unit down time, visually inspect the furnace convection passes for ash accumulations. 3. Gas Air heater air and gas side pressure loss. Typically, when the soot blowing system is first commissioned, the aforementioned boiler parameters are monitored and an optimized soot blowing sequence is adapted. Periodic monitoring of the system is recommended. 3.5.5 Spray Attemperation Do not desuperheat the steam leaving the first stage spray headers to less than 11C above saturation temperature. 3.6 NORMAL SHUTDOWN a. As the load is reduced below approximately 35% of boiler rated capacity or recirculated flue gas is no longer required, shut down any excess fan capacity. Be sure to leave the FD fan, and GI fan operating at all times. Check that the DCS has placed idle flue gas recirculation GI fans on turning gear and close the inlet vanes and outlet dampers. b. If the unit has not been cleaned since its last oil firing, blow soot before reducing load and taking unit out of service. c. Reduce the firing rate to the minimum for stable operation.
d. During shutting down, do not exceed a maximum temperature difference of 117C between top and bottom of the drum. e. Control, as necessary, the superheater outlet temperature by regulating the spray attemperator water flow. Close the water shut-off valves when attemperation is no longer required. The shutoff valve closes automatically whenever the control valve is <5% open. f. Check and maintain drum level at normal.
g. Discontinue feeding fuel to the burners to be removed from service in the reverse order of the start-up procedure specified in Paragraph 3.3. h. Adjust air flow as necessary to maintain excess air requirements. i. As the load is reduced below approximately 10 percent of rated boiler capacity, remove the turbine generator from service (refer to turbine manufacturer instructions) and open the end and root superheater outlet header drain valves. The drain end valves may subsequently require throttling to regulate the rates of cooling of the unit but should never be fully closed during this period as long as burners are in service. After the fires have been extinguished, leave the forced draft and other fans in operation with burner sleeves and fan dampers in their last set position for at least five minutes to purge the gas passes of combustibles. If the unit is to be held in a "bottled up" condition, shut down the fans after purging the unit in order to minimize heat losses. When the drum pressure has fallen below the lowest relief valve setting in the superheater circuit, and there is insufficient residual heat remaining in the unit to pop the safety valves, close the superheater outlet header drain valves. The drain and vent valves should remain closed when not firing the unit.
j.
k.
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Before firing a unit to maintain and/or raise steam pressure, the finishing superheater outlet header drain valves must be opened. Keep the drains open during firing and keep the feedwater supply system in operation as long as steam is being taken from the unit. Maintain drum water level visible near normal level indication on the gage glass when firing. BHI does not recommend bottling-up the unit when heavy oil was previously fired, if operation prior to the shut down was such that unburned oil or carbon may have been deposited on the baskets of the air heater. These deposits would result from extended periods of oil main burners in a cold furnace at low loads, or other conditions which could result in deposits being formed from oil vapors condensing or unburned carbon depositing in the air heater. Particular care should be taken when load is raised on the unit after an extended period of operation at low loads. For oil firing, before bottling-up the gas side, the Gas Air Heater baskets should be carefully inspected. If an oil film or heavy carbon deposit is present, DO NOT BOTTLE UP the unit. Using proper procedures, water wash and dry the air heater. Continue to rotate the Gas Air Heater until the inlet gas temperature decays below 121C. If inspection reveals no oil or carbon deposit on the Gas Air Heater baskets, the unit may be bottled-up. The Gas Air Heater air and gas side temperatures should be monitored frequently, and logged, even after shutdown, to detect any temperature rise which might indicate a fire developing in the Gas Air heater. Refer to special Gas Air heater instructions at the end of this section and to vendor's instructions for water washing instructions. l. If it is desired to remove all pressure from the unit, the superheater outlet header drain valves may be regulated along with other superheater drain valves to decrease drum pressure at the desired rate. After purging the unit, the fans (i.e. FD fan, GI fan) may be used for cooling. Cool the unit as uniformly as possible. The residual heat in the setting and the boiler components will continue to generate steam for considerable time. During this period, the boiler water level should be maintained near the upper limit of gage glass visibility. While the unit is cooling, the finishing superheater drain valves may be regulated, as required, to decrease the drum pressure in accordance with the allowable cooling rates. m. Keep the Gas Air Heater operating until inlet gas temperatures are lowered to below 121C. Then the Gas Air Heater may be shut down if desired. n. If the unit is to be drained, open all vents and drains when the drum pressure has decreased to approximately 1.0 barg. Temperature of the boiler water should not exceed 121C when the unit is drained. Draining the unit when there is still a small amount of pressure on the unit is preferred as the residual heat will assist in drying the internal surfaces. o. Superheater header drain and vent valves should remain open during short outages. p. Refer to Section 3.9 for corrosion prevention of internal boiler pressure parts during outages. 3.7 LOAD REJECTION 3.7.1 Fast Cut Back (FCB) Burner Action from BMS FCB represents a demand on reducing the firing rate of the boiler. FCB status is maintained if one of two conditions occurs a. FCB Time 180 second elapse b. FCB reset condition complete
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During FCB mode, Main burner shall extinguish in 10 seconds interval. Refer to the Operation and system description in the DCS by others for FCB burner extinguishing sequence. 3.7.2 ERV (Electromagnetic Relief Valve) The 10% MCR 01LBA01AA701power relief vent at the superheater outlet may open upon an increase in throttle pressure in excess over normal operating pressure. During load rejection the reheater tubes must be protected. Observe the metal temperature alarm limits listed in Paragraph 3.2.i. 3.8 EMERGENCIES 3.8.1 Tube Failures In case of waterwall tube failure, the burner fires should be extinguished. Stop feedwater flow to the boiler. Open hopper drains under furnace and air heater. Allow the fans to operate with dampers open to purge and to assist in cooling the boiler so that expeditious repairs may be made. Operate the ash removal systems, if possible, to remove ash before it gets wet. 3.8.2 Gradual Loss of Water If at anytime it is impossible to maintain normal drum level, the load on the unit should be reduced and the cause of the difficulty corrected. If it is impossible to maintain normal drum level at the reduced rating, then the unit must be taken out of service until the trouble is remedied. An appreciable decrease in drum level from the normal position can seriously affect the circulating rate, thus causing overheating and tube failures. 3.8.3 Sudden Loss of Water If the cause is known and immediately correctable, readmit feedwater to the drum. The temperature of the water should not be more than 167C above or below the temperature of the pressure parts. If the cause of loss of water level is not known and immediately correctable, extinguish the fires immediately and follow the procedure as outlined above for failures. 3.8.4 Loss of Combustion If all fires have been lost, cut off flow of fuel to burners and igniters. Do not increase air flow immediately after a main fuel trip. The unit must be purged as for normal start-up before attempting to light-off again. 3.8.5 Safety Interlocks Fans and drives are interlocked to start in a particular sequence. Loss of service of particular equipment will then trip all equipment following it in sequence but will not interfere with equipment ahead of it in sequence. Loss of flame, loss of forced draft fans, or loss of all fuel should initiate a master fuel trip. Do not increase air flow immediately after a master fuel trip. The unit must be purged as for a normal start-up before relighting the igniters or burners. 3.8.6 Burner Safety Fuel leaks to the burner deck or windbox shall be corrected immediately following discovery. Check mating flanges and connecting points in all fuel lines regularly. To avoid fire hazards, the total burner area should be maintained in an extremely clean condition. Any fuel that may have leaked should be cleaned up immediately. 3.9 MAINTENANCE
BHI CO., LTD

STEAM GENERATOR & AUXILLIARIES CAUTION
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BEFORE ENTERING A UNIT FOR ANY REASON, USE A DETECTING DEVICE (SNIFFER) TO DETERMINE THE PRESENCE OF ANY HARMFUL SUBSTANCES. a. Provision should be made for nitrogen protection of idle boilers by connecting a rack of cylinders containing nitrogen through a regulating valve to all high points on the boiler and superheater. Wet Layup/Preservation During the unit shutdown/storage period, the boiler should be filled to Normal Water Level (NWL) with either demineralized water treated for normal operation or with water treated for wet layup. If the storage period is estimated to be less than seven (7) calendar days, then the unit should be filled with demineralized water at a pH of 9.2 9.6 with ammonia, with sufficient Hydrazine to counteract any residual dissolved oxygen. If the storage period is anticipated or planned to be greater than seven (7) calendar days, then the unit should be drained and refilled with demineralized water containing 200 ppm Hydrazine adjusted to a pH of 10.0 with ammonia. A nitrogen cap (overpressure of 5 - 10 psig) (0.34 - 0.69 barg) throughout the steam generator pressure parts boundary should be introduced and maintained for the duration of the standby period. During cold seasons, the boiler must be protected against freezing conditions. This can be achieved by any of the following methods: 1. If available from another source (another unit at jobsite), connect a saturated steam supply to drum blowdown or chemical feed line to heat water and drum shell. Water temperature may be maintained above the freezing point by this method, although chemical balance control may be more difficult because of steam introduction/dilution. 2. Use small oil and/or gas burners aimed through doors or resting on the furnace bottom to raise the temperature of the water within the unit and to maintain it above the freezing point. Dry Layup/Preservation All equipment is to be preserved for an extended period of time. Preservation of both the air/gas side and the steam/water side of the boiler will be by dehumidified air flow. Most materials, particularly ferrous metals, are subject to corrosion by oxidation with the atmosphere. Every substance eventually changes from one form to another as a result of chemical reactions. Many of these reactions, particularly those which depend upon oxygen, are catalyzed and accelerated by moisture. Ferrous metals, such as iron and steel, are well known for their corrosion and corrosion product formation in the presence of moisture. In corrosion prevention applications, the controlled (protected) space is maintained at a specific relative humidity (RH) such that the metals in the controlled space cannot absorb moisture from the surrounding atmosphere. Thus, boiler components are also protected from corrosion. As a general rule, rust and other oxidizing type corrosion reactions will not occur if the relative humidity in the controlled area is maintained at or below 30% RH. Materials or components residing in this atmosphere need not be coated with oil or other surface protecting materials, and can thus be kept in ready-to-use condition. Boiler-Air/Gas Side 1. Seal all observation and access doors. 2. Seal the flues between the fans and the stack. Provide an atmospheric air entrance to the base of the stack between the seal and the stack. This is to prevent air flow through the units as a result of the stack effect.
BHI CO., LTD

STEAM GENERATOR & AUXILLIARIES 3. Seal all fan inlets.
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4. Introduce dehumidified air to all flues, ducts and boiler gas passes. Run the air dryer until all gas side volumes are dry, and then once a month or as required to maintain a dry condition. (A relative humidity of 30% or less must be maintained). Boiler-Steam/Water Side This area can most easily be preserved in conjunction with the turbine-condenser and deaeratorfeedwater systems if they are also to be preserved with dehumidified air. If air is fed to the above mentioned systems it can be allowed to flow to the boiler through the economizer and superheater and out to atmosphere through the various vents an drains. Non-drainable superheater components will require initial water removal by a combination of low heat and vacuum to permit subsequent air flow through the superheater. Safety valves may be left in place with the spring compression released. Again, run the air dryer until all gas side volumes are dry, and then once a month or as required to maintain a dry condition. (A relative humidity of 30% or less must be maintained). Nitrogen Preservation As an alternate to either the wet layup an dry layup procedures, the following method can also be employed for the boiler-steam/water side. 1. Fill the unit with demineralized water containing 200 ppm hydrazine adjusted to a pH of 10.0 with ammonia. As much of the internal pressure parts should be filled with this solution as possible-similar to a hydrostatic pressure test. 2. Drain the treated solution under a nitrogen cap (overpressure of 5-10 psig) (0.34 0.69 barg), and store with a same nitrogen overpressure for the shutdown duration. It is important for the above procedure to be effective that the aqueous solution being drained has been treated adequately with hydrazine and ammonia. This will insure that any potential remaining liquid will not be corrosive to internal pressure parts of the boiler. CAUTION NITROGEN SHOULD NOT BE USED UNTIL ALL INTERNAL BOILER WORK IS COMPLETED. BEFORE ALLOWING PERSONNEL ENTRY INTO ENCLOSED AREAS BOUNDED BY OR ADJACENT TO A NITROGEN-CAPPED BOILER, ADEQUATE SAFETY MEASURES, SUCH AS GAS SAMPLING, PURGING AND PROPER VENTILATION, MUST BE FOLLOWED. b. When the unit is shut down for repairs, it should never be entered until it has been determined that all fuel shut-off valves and dampers are locked in closed position. Should there be some question about their tightness, it is recommended that the fuel lines be blanked off. c. Only approved safety types of lights and flashlights should be used when inspecting and working in the unit.
d. During outages, the pressure containing parts and internal surfaces should be inspected when possible. Unusual signs of wear or accumulations should be investigated and the causes corrected. e. Where Acoustic Horn Cleaners are furnished, the alignment should be checked. instruction manual (by others). f. When gasketed closures are opened for access, the used gaskets should be replaced.
BHI CO., LTD
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g. If hard external deposits are found on economizer elements, it is generally due to operation for extended periods with the gas temperature in the region below the dew point. Removal of such hard deposits usually requires a washing operation or sand or shot blasting. h. The burner throat refractory should be maintained in good condition since the flame shape is materially affected by the shape of the burner throat. i. j. During overhaul periods, all burners should dampers checked for ease of operation. be carefully inspected for any damage and all
Repair all leaks as soon as possible. Leaks which are allowed to persist can cause further damage due to water or steam cutting. Repairs should not be attempted on parts which are subject to pressure. Repairs to pressure parts should be accomplished when all pressure has been removed. Combustion control equipment and other control equipment, such as feedwater regulators and steam temperature controllers, should be kept in optimum adjustment at all times. Efficient and safe operation depends upon the proper functioning of this equipment.
k.
3.10 SPECIAL GAS AIR HEATER INSTRUCTIONS LIQUID PETROLEUM FUELS NOTE THIS SECTION APPLIES WHENEVER HEAVY OIL HAS BEEN PREVIOUSLY FIRED WITHIN THE UNIT. THE FOLLOWING ITEMS ARE MORE CONSERVATIVE IN NATURE AND GO BEYOND, WITHOUT DILUTING, THE CORRESPONDING AIR PREHEATER COMPANY INSTRUCTIONS LOCATED AS SPECIFIED IN THE INDEX TO THIS MANUAL. REFER TO GAS AIR PREHEATER INSTRUCTIONS FOR OTHER OPERATING AND CLEANING INSTRUCTIONS. 3.10.1 Preparation Before Light-Off a. Basketed chambers of the Gas Air preheater revolve in an atmosphere below the dew point of combustion gases during initial start-up. The gases can carry particulate matter and oily soot into the baskets where they may accumulate and ignite spontaneously. Bring the steam coil air heater(s) into service and use the air preheater air bypass system as soon as possible to raise the gas air heater cold end temperature. b. Continuous soot blowing is required during light-off of liquid fuels, up until minimum stable load on the main fuel is reached. During this time, soot blowing may be accomplished with auxiliary steam. c. Observation ports on the air preheater are to be accessible for frequent inspection of the baskets.
d. The thermocouples that indicate the air inlet, air outlet, gas inlet and/or gas outlet temperatures of each Gas Air preheater should be connected to a suitable recorder; confirm that the thermocouples and recorder are operating. e. Insure availability for a water supply to each Gas Air preheater deluge system. Water control valves must be accessible for rapid opening. If a deluge system is not installed, water washing of the Gas Air Heater should be provided by other similar means, either through the Gas Air Heater manufacturer standard water washing nozzles or a fixed manifold system with high pressure nozzles directed towards the Gas Air preheater. Drains are to be provided to remove the deluge or wash water. See Gas Air preheater company operating instructions for this contract for required water pressure and water flow.
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STEAM GENERATOR & AUXILLIARIES f.
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Fire hoses for fighting Gas Air Heater fires should be made ready for emergency use.
3.10.2 Precautions Against Gas Air Heater Fires a. Do not stop the Gas Air heater until the temperature of gas to the Gas Air Heater decays to 121C. b. If an inspection of the Gas Air heater reveals a thin coating of raw oil (shiny and/or oily) or black soot (greasy to the feel), Gas Air heater washing should commence immediately. NOTE CAREFUL BURNER ADJUSTMENT AND CONTROL IS PARTICULARLY IMPORTANT DURING PERIODS OF OPERATION WITH A RELATIVELY COLD FURNACE. THIS WILL MINIMIZE DEPOSITS IN THE GAS AIR HEATER. A HELPFUL TOOL TO JUDGE OIL AND SOOT CARRYOVER IS TO USE ONE OR MORE METAL TARGET PLATES INSERTED IN THE GAS PATH AHEAD OF THE AIR HEATER(S) DURING START-UP AND LOW LOAD OPERATION. THESE TARGET PLATES CAN BE WITHDRAWN AND INSPECTED AT FREQUENT INTERVALS AND THE OIL OR SOOT DEPOSITED ON THEM CAN BE USED AS AN INDICATOR OF BURNER PERFORMANCE AS WELL AS PROVIDING AN INDICATION OF HOW MUCH COMBUSTIBLES MAY BE DEPOSITING IN THE AIR HEATER(S). c. Physical inspection should be done each time a Gas Air Heater is removed from service and made available for entry.
d. Refer to Gas Air Heater manufacturer's cleaning instructions for Gas Air heater cleaning procedure. 3.10.3 Gas Air Heater Washing Instructions After Prolonged Firing Using Low Pressure Washing Devices and Plain Water a. Water washing to decrease the hazard of a Gas Air Heater fire will require two (2) hours minimum. b. Water washing to remove ash and/or other materials from the basketed sections will require 12 hours minimum. c. See air preheater company operating instructions for this contract for required water pressure and water flow.
d. It is recommended that the air heaters be water washed after each occasion where oil firing has been used under the following conditions: 1. A water wash is to be performed before raising load above 25% if oil igniters, auxiliary oil guns or main oil burners have been in operation for a period of three (3) days or more under cold furnace conditions (i.e. less than 15% load). 2. The Gas Air Heater should not be operated for more than one (1) week at loads continuously less than 25%, when firing main oil burners or oil igniters, without water washing at least once a week.
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e. If the material plugging the Gas Air Heater cannot be dissolved or dislodged by normal water washing, high velocity jet nozzles may be necessary. This service may be procured from various "specialist" firms in this field or by installing a high pressure washing device supplied by the air preheater company. f. Thoroughly dry the Gas Air Heater immediately following water washing (see Paragraph 3.10.5, steps d and e).
3.10.4 Emergency Action a. Stoppage of Rotation Because of Binding WARNING STOPPAGE OF ROTATION CAN BE CAUSED BY A FIRE IN THE AIR HEATER. IF DUCT IS NOT UNDER POSITIVE PRESSURE, CAUTIOUSLY OPEN A DOOR IN THE GAS INLET OF THE AIR HEATER. FIRE RESISTANT PROTECTIVE CLOTHING, GLOVES AND A FACE SHIELD SHOULD BE WORN DURING THIS INSPECTION. IF THERE IS NO INDICATION OF A FIRE, CONTINUE TO ADMIT AMBIENT AIR THROUGH THE OPEN DOOR, AND OTHERS IF AVAILABLE, TO COOL THE GAS AIR HEATER SUFFICIENTLY TO MAKE ROTATION POSSIBLE. THE AIR MOTOR IS MORE POWERFUL FOR TURNING THE GAS AIR HEATER ROTOR THAN THE ELECTRIC MOTOR. IF FIRE IS DETECTED IN THE GAS AIR HEATER WHEN THE DOOR IS OPENED, IMMEDIATELY FOLLOW THE INSTRUCTIONS 3.10.4-b GAS AIR HEATER FIRE PROTECTION. b. Gas Air Heater Fire Protection CAUTION AN GAS AIR HEATER FIRE STARTS AS A SOOT AND/OR OIL DEPOSIT FIRE. IF IT IS NOT EXTINGUISHED IMMEDIATELY, THE METAL PARTS, PARTICULARLY THE BASKETS, IGNITE. AS A METAL FIRE, IT CANNOT BE EXTINGUISHED BY SMOTHERING. AT THIS STAGE, IT MUST BE EXTINGUISHED BY WATER QUENCHING TO REDUCE THE TEMPERATURE OF THE BURNING METAL BELOW THE IGNITION TEMPERATURE. THIS IS BEST ACCOMPLISHED BY APPLYING LARGE QUANTITIES OF WATER. FOR THIS PURPOSE, THE GAS AIR HEATER MUST HAVE AN ADEQUATE WATER SUPPLY AVAILABLE FOR CONNECTION TO THE INTERNAL DELUGE SYSTEM, IF PROVIDED, OR TO LOCAL FIRE NOZZLES. THE CONNECTIONS SHOULD BE OF THE QUICK-CONNECT TYPE AND ARE IN ADDITION TO THE GAS AIR HEATER WATER WASH SYSTEM. PROVISIONS FOR DRAINAGE OF THESE LARGE QUANTITIES OF WATER MUST BE MADE AT
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SUITABLE LOCATIONS IN THE CONNECTING FLUES AND DUCTS. ALL DRAINS MUST BE OPEN BEFORE ALLOWING WATER TO ENTER THE AIR HEATER. THIS SYSTEM SHOULD BE BROUGHT INTO FULL OPERATION AT THE FIRST SIGN OF A GAS AIR HEATER FIRE AS INDICATED BY ABNORMAL AIR OR GAS TEMPERATURES, OBSERVATION, HOT SPOTS OR BY A FIRE DETECTION SYSTEM. (1) ISOLATE THE AIR HEATER (2) OPEN ALL DRAINS (3) ADMIT THE DELUGE WATER CAUTION DRAINS SHOULD BE PROVIDED FOR GAS AIR HEATER HOPPER, FAN HOUSINGS, DUCTS AND ANY OTHER ADJACENT EQUIPMENT THAT COULD BE AFFECTED. 3.10.5 Stationery Washing Equipment The air heaters should be washed in accordance with the following sequence: a. After the boiler is off the line, reduce the speed of the Gas Air Heater rotor to approximately 1/15 rpm by using the air motor drive, throttling the air valve as necessary to reduce the speed (rotor speed can be reduced further to prevent water carryover).
b. For a horizontal shaft air heater, close air and gas side dampers on both the hot and cold ends to eliminate or minimize moisture from backing up through the system. For a vertical shaft air heater, any air and gas side dampers between the Gas Air Heater and the wash water drain must be open to allow the wash water to drain properly. The air and gas side dampers above the vertical shaft Gas Air Heater should be closed to eliminate or minimize moisture from carrying over through the system. c. Wash the Gas Air Heater per manufacturer's instructions. If the Gas Air Heater is not thoroughly water washed, residual deposits may be hygroscopic and would tend to extract water from the air. These deposits could be of a highly corrosive nature and could cause considerable damage.
d. Thoroughly dry the Gas Air Heater after washing. 1. Natural draft can be used to dry the air heater. Cold end dampers on gas side must be open, and to aid the draft, the hot end inspection ports on the gas inlet must be open. 2. For immediate dry-out requirement, the fan can be used, but at a regulated flow, so that flyash is not re-entrained into the air heater. Hot and cold end dampers on both air and gas side must be open. Precaution must be taken to have secondary air flow measurement lines blown clear after a wash before readmitting air flow to the Gas Air Heater that was washed.
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e. Inspect the Gas Air Heater through the cold end ports to insure moisture has evaporated from the surface of the heating elements. If the Gas Air Heater is not thoroughly dried, moisture in the presence of residual deposits may be highly corrosive.
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PT. POSCO E&C INDONESIA-PT.

CLASS NO. I01-110-EZ610-10300

OPERATION & MAINTENANCE MANUAL

PT KRAKATAU POSCO POWER

Indonesia ISM Power Plant

OPERATION & MAINTENANCE MANUAL

EQUIPMENT MAKER DWG. NO.

DRAWN POSCO E&C SIGNATURE DATE

CHECKED S.M.GO 12.9.20

REVIEWED W.J.CHOI 12.9.20

APPROVED C.H.CHONG 12.9.20

PROJECT DWG No.

POSCO POWER DWG No.

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

BHI CO. LTD

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

2012-09-20 A PAGE iii

BHI CO. LTD

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

2012-09-20 A PAGE 1-1

BHI CO. LTD

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

2012-09-20 A PAGE 1-2

BHI CO. LTD

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

2012-09-20 A PAGE 1-3

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

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INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

2012-09-20 A PAGE 1-5

Blowdown Pipe Chemical Feed Pipe Downcomer Pipes

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

2012-09-20 A PAGE 1-6

INDONESIA ISM POWER PLANT

OPERATION & MAINTENANCE MANUAL

DATE REV. NO. DOC. NO. I01-110-EZ61010300

2012-09-20 A PAGE 1-7

BHI CO. LTD