O & M Manual For Boiler

.
OPERATION & MAINTENANCE MANUAL

FOR 1 X 41TPH 100% INDIAN COAL FIRED
ATMOSPHERIC FLUIDISED BED COMBUSTION BOILER
SUPPLIED TO
HARE KRISHNA METALLICS LIMITED

KOPAL, KARNAKATA
THERMAX PROJECT NO.: PD 0161
THERMAX LIMITED BOILER & HEATER GROUP PUNE, INDIA

0 REV SSC 03.12.2008 AA 05.12.2008 USU 08.12.2008 0 REVISION DESC. / REMARK
PREPARED BY
CHECKED BY
APPROVED BY
Operation & Maintenance Manual
Contents
Volume 1 Boiler Description ....................................................................................................1 Section A................................................................................................................................2 1 Design Specications of Steam Generator ....................................................................3 2 Design Code...............................................................................................................3 3 Material Specications Pressure Parts .....................................................................3 4 Heating Surface Area ..................................................................................................5 5 Fuel ...........................................................................................................................5 6 Fuel Analysis (% By Wt.) .............................................................................................5 6.1 Ultimate Analysis ...............................................................................................5 6.2 Fuel size ...........................................................................................................5 7 Bed Material ...............................................................................................................6 7.1 Bed Material Specications - Crushed Refractory ................................................6 8 Continuous Blowdown .................................................................................................6 9 Intermittent Blowdown .................................................................................................6 10 Feed Water Recommended Quality ............................................................................6 11 Boiler Water Recommended Quality ...........................................................................7 12 Utilities .....................................................................................................................7 12.1 Electrical Power...............................................................................................7 12.2 Cooling Water..................................................................................................7 12.3 Instrument Air ..................................................................................................8 12.4 Service Air.......................................................................................................8 13 Chemicals for Dosing ................................................................................................8 14 Site Condition ...........................................................................................................8 15 Fans.........................................................................................................................8 16 HP Dozing System ....................................................................................................9 17 Rotary Feeders ....................................................................................................... 10 17.1 Capacity Chart............................................................................................... 10 18 Gauge Glass........................................................................................................... 11 18.1 Drum Level Gauge......................................................................................... 11 18.2 Blow Dowm Tank Level Gauge ....................................................................... 11 19 Safety Valves .......................................................................................................... 11 20 Temperature Prole ................................................................................................ 13 20.1 Gas Temperature ........................................................................................... 13 20.2 Water Temperature ........................................................................................ 13 20.3 Air Temperature ............................................................................................. 13 21 Flue Gas Pressure Prole ........................................................................................ 13 22 Process Flow Diagram............................................................................................. 13 Section B ............................................................................................................................. 14 1 Section Overview ...................................................................................................... 15 2 Feed Water System................................................................................................... 16 2.1 Feed Water Control Station .............................................................................. 16 2.2 Attemperation Control Station........................................................................... 17 3 Boiler Pressure Part Description................................................................................. 17 3.1 Economizer ..................................................................................................... 17 3.2 Steam Drum .................................................................................................... 17 3.3 Water Drum..................................................................................................... 18 3.4 Down Comer Tubes ......................................................................................... 18 3.5 Furnace .......................................................................................................... 19 3.6 Inbed Evaporator ............................................................................................. 20 3.7 Riser Tubes..................................................................................................... 20 3.8 Super Heater................................................................................................... 20 3.9 Attemperator ................................................................................................... 20 3.10 Convection Bank ........................................................................................... 21
Main Steam Piping .................................................................................................... 21 Boiler Blow Down System .......................................................................................... 21 5.1 Drain Lines...................................................................................................... 22 5.2 CBD Drain....................................................................................................... 22 5.3 IBD Drain ........................................................................................................ 22 5.4 Other Drains.................................................................................................... 23 5.5 Blow down Tank .............................................................................................. 23 6 Air and Gas System .................................................................................................. 24 6.1 System Description: ......................................................................................... 24 6.2 FD Fan ........................................................................................................... 24 6.3 Air Pre Heater ................................................................................................. 24 6.4 PA Fan............................................................................................................ 25 6.5 Air Ducts ......................................................................................................... 25 7 Flue Gas System ...................................................................................................... 27 7.1 System Description .......................................................................................... 27 7.2 Electrostatic Precipitator (ESP)......................................................................... 27 7.3 ID Fan............................................................................................................. 27 8 Fuel Feeding & Firing System .................................................................................... 28 8.1 Fuel Bunker..................................................................................................... 28 8.2 Rotary Feeders................................................................................................ 28 8.3 Fuel Mix Nozzles ............................................................................................. 29 8.4 Combustor ..................................................................................................... 29 8.5 Bed Drain System............................................................................................ 30 8.6 Ash Drain ........................................................................................................ 30 9 Chemical Dosing & Sampling System......................................................................... 30 9.1 HP Dosing System........................................................................................... 30 9.2 Description of Dosing System Skid HP)............................................................. 30 9.3 Sampling System............................................................................................. 31 Section C ............................................................................................................................. 32 1 Boiler Start Up .......................................................................................................... 32 1.1 Start-up of a Cold Boiler ................................................................................... 32 1.2 Procedure For Normal Operation ...................................................................... 36 2 Operational Control ................................................................................................... 39 2.1 Load Operation................................................................................................ 39 2.2 Bed Level Control ............................................................................................ 40 2.3 Bed Ash Alkali Control ..................................................................................... 40 2.4 Adequate Bed Temperature.............................................................................. 41 2.5 Fuel and Bed Material Sieve Analysis as per the Designed Conditions ................ 41 3 Balance of Plant Start Up (Boiler) ............................................................................... 42 3.1 Deaerator Charging ......................................................................................... 42 3.2 Air Pre Heater ................................................................................................. 43 4 Part Load Operation By Bed Slumping ....................................................................... 43 4.1 Bed Slumping Procedures ................................................................................ 43 4.2 Slumped Bed to Active Bed .............................................................................. 43 5 Warm / Hot Start Up .................................................................................................. 44 5.1 Case-I (Bed Ash Temperature > 600C) ............................................................ 44 5.2 Case-II (Bed Ash Temperature < 600C) ........................................................... 44 6 Boiler Shutdown........................................................................................................ 45 6.1 Planned Shut Down ........................................................................................ 45 6.2 Boiler Emergency Trip...................................................................................... 45 7 Dos and Donts......................................................................................................... 47 8 Controls.................................................................................................................... 48 9 Troubleshooting Chart ............................................................................................... 49 10 Walkdown Checklist during Operation....................................................................... 52 11 Boiler Safety ........................................................................................................... 53
4 5
ii
11.1 Emergency Procedures .................................................................................. 53 12 Operational Precautions for Safety ........................................................................... 55 Section-D ............................................................................................................................. 59 1 Section Overview ...................................................................................................... 59 2 Recommended Maintenance Practice ........................................................................ 59 2.1 Preventive Maintenance................................................................................... 59 3 Conditioned Based Maintenance................................................................................ 60 3.1 Daily Checks ................................................................................................... 60 3.2 Daily Maintenance ........................................................................................... 62 3.3 Weekly Checks................................................................................................ 63 3.4 Monthly Checks ............................................................................................... 63 3.5 Checks Every Six Months................................................................................. 64 3.6 Checks Every Year .......................................................................................... 64 3.7 Annual Maintenance Check Sheet .................................................................... 65 4 Boiler Annual Maintenance and Overhaul ................................................................... 72 4.1 Planning Before Overhaul ................................................................................ 72 4.2 Shutdown and Cooling the Boiler ...................................................................... 72 4.3 Inspection after Cooling.................................................................................... 72 4.4 Drum Inspection .............................................................................................. 72 4.5 Inspection of Screen, Primary & Secondary Superheater, Evaporator I/ II & Economiser................................................................................................ 73 4.6 Expansion Joints ............................................................................................. 73 4.7 Insulation and Cladding.................................................................................... 73 4.8 Other Equipment ............................................................................................. 73 4.9 Feed & Boiler Water Conditioning ..................................................................... 73 4.10 Fans ............................................................................................................. 75 4.11 Safety Valves, Start Up Vent Valves And Other Isolating Valves ........................ 76 5 Boiler Preservation Procedure.................................................................................... 77 5.1 Denitions OF Water Quality ............................................................................ 77 5.2 Dry Storage Preservation ................................................................................. 77 5.3 Wet Storage Preservation ................................................................................ 78 5.4 Nitrogen Blanket .............................................................................................. 79 5.5 Hot Draining .................................................................................................... 79 5.6 Alkaline Water Dozed With Hyderzine ............................................................... 79 5.7 Preservation Of External Surfaces Of Pressure Parts During Long Shut Down......................................................................................................... 80 5.8 Boiler Lay Up Procedures................................................................................. 80 5.9 Preservation of Rotating Equipments ................................................................ 80 5.10 Preservation of Instruments ............................................................................ 80 5.11 Tube Thickness Survey .................................................................................. 81 6 Tube Failures............................................................................................................ 81 6.1 Tube Failure Investigation / Analysis Method ..................................................... 81 6.2 Tube Thickness Survey Data Collection Format .............................................. 84 6.3 Failure Reporting Formats ................................................................................ 85 7 Water Chemistry ....................................................................................................... 87 7.1 Undissolved and Suspended Solid Materials ..................................................... 87 7.2 Dissolved Salts and Minerals............................................................................ 87 7.3 Dissolved Gases.............................................................................................. 88 7.4 Other Materials................................................................................................ 88 7.5 pH Value of the Water and its Importance.......................................................... 88 7.6 Effects of Impurities ......................................................................................... 88 7.7 Feed & Boiler Water Conditioning ..................................................................... 90 8 Welding Procedure Specications (WPS) ................................................................... 92 8.1 Window Patch Welding .................................................................................... 93 8.2 General Principle of Weld Repairs .................................................................... 94
iii
8.3 Weld Repair of Small Cracks in Tube ................................................................ 98 8.4 Plugging Tubes in Drums & Headers................................................................. 98 8.5 Replacement of Tube Section......................................................................... 100 8.6 Removing Tubes from Drums, Headers & Tube Plates ..................................... 100 8.7 Attached gures 13 to 21 ............................................................................... 101 Section E............................................................................................................................ 110 Volume 2 Drawings.............................................................................................................. 111 List of Drawings .................................................................................................................. 112 Volume 3 E & I Specications.............................................................................................. 113 Section 01 .......................................................................................................................... 114 Section 02 .......................................................................................................................... 114 Section 03 .......................................................................................................................... 114 Section 04 .......................................................................................................................... 114 Section 05 .......................................................................................................................... 114 Section 06 .......................................................................................................................... 114 Section 07 .......................................................................................................................... 114 Section 08 .......................................................................................................................... 114 Section 09 .......................................................................................................................... 114 Section 10 .......................................................................................................................... 115 Volume 4 Vendor Manuals ................................................................................................... 116 Section 01 .......................................................................................................................... 117 Fan TLT Engineering ................................................................................................ 117 Section 02 .......................................................................................................................... 117 H.P / LP. Dosing System - NM Enterprises ..................................................................... 117 Section 03 .......................................................................................................................... 117 Level Gauge Hi Tech Systems (Tyco) ........................................................................ 117 Section 04 .......................................................................................................................... 117 Level Gauge Chemtrol.............................................................................................. 117 Section 05 .......................................................................................................................... 117 Tight Shout off Damper Virgo ..................................................................................... 117 Section 06 .......................................................................................................................... 118 Kniff Gate Valve Orbinox .......................................................................................... 118 Section 07 .......................................................................................................................... 118 Process Valve KSB ................................................................................................. 118 Section 08 .......................................................................................................................... 118 Safety Valves Tyco Sanmar ...................................................................................... 118 Section 09 .......................................................................................................................... 118 Motors Siemens........................................................................................................ 118 Section 10 .......................................................................................................................... 118 Rotary Feeder - Nova Bulk............................................................................................ 118 Volume 5 Vendor Manuals ................................................................................................... 119 Section 01 .......................................................................................................................... 120 Pressure Transmitter Emerson.................................................................................. 120 Section 02 .......................................................................................................................... 120 Temperature Transmitter Emerson ............................................................................ 120 Section 03 .......................................................................................................................... 120 I/P Converter ABB..................................................................................................... 120 Section 04 .......................................................................................................................... 120 Pressure Switch Switzer ........................................................................................... 120 Section 05 .......................................................................................................................... 120 5.1 Orice Plate General Instruments ......................................................................... 120 5.2 Thermocouple General Instruments ..................................................................... 120 Section 06 .......................................................................................................................... 120 Pressure Gauge Gages Bourdon .............................................................................. 120
iv
Section 07 .......................................................................................................................... 120 Local Indicator Nishko ............................................................................................... 120 Section 08 .......................................................................................................................... 121 Control Valves MIL .................................................................................................... 121 Section 09 .......................................................................................................................... 121 Power Cylinder Keltron.............................................................................................. 121 Section 10 .......................................................................................................................... 121 ACVFD Drives ABB.................................................................................................. 121 Index.................................................................................................................................. 123
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Volume 1 Boiler Description

Chapters Covered in this Part Section A Section B Section C Section-D Section E
Volume 1 Boiler Description
Section A
Topics Covered in this Chapter Design Specications of Steam Generator Design Code Material Specications Pressure Parts Heating Surface Area Fuel Fuel Analysis (% By Wt.) Bed Material Continuous Blowdown Intermittent Blowdown Feed Water Recommended Quality Boiler Water Recommended Quality Utilities Chemicals for Dosing Site Condition Fans HP Dozing System Rotary Feeders Gauge Glass Safety Valves Temperature Prole Flue Gas Pressure Prole Process Flow Diagram
Section A
Number and Type of Boiler 1 no. AFBC, Bi Drum, outdoor, water tube, natural circulation, balance draft, Under-bed ring system, Bottom Supported with RCC construction..
Design Specications of Steam Generator
Parameters
Unit
Value
Boiler Rating [MCR] Steam Pressure at Main Steam Stop Valve Outlet from minimum Load upto MCR Steam Temperature at the Main Steam Stop valve at MCR Main Steam Temperature Control range at the Main Steam Stop Valve Outlet. Feed Water Temperature at Economiser Inlet / Spray water temp Flue Gas Temperature at APH Outlet Main Fuel Start Up Fuel for Coal Fuel Zizing Boiler Performance Testing Procedure
TPH Kg/cm2(g)
41 66
Deg C
490+/- 5
% MCR
60 100
Deg C
130
Deg C
160 Indian Coal Charcoal Sprayed with diesel fuel. 100 % Indian coal < 6mm , 30%(max) <1mm ASME PTC 4.1 Indirect addreviated heat loss method on GCV Basis
Design Code
: As per IBR
Boiler & Economiser / Pressure Parts
Material Specications Pressure Parts

Description Steam Drum Details Shell Dished End (SEMI-ELIPSOIDAL) Shell Water Drum Riser Dished End (SEMI-ELIPSOIDAL) Tube Size In Mm 4540 X 1000 X 70 Thk 1375 I.D. X 70Thk 3173 X 2500 X 50 Thk 960 I.D. X 50 Thk 101.60 O.D. x 5.74 Thk. SA 516 Gr.70 Material
SA 516 Gr.70 SA 516 Gr.70 SA 210 Gr A1
Section A
Description
Details Top Header Bottom Header Panel Tubes Bend Tube Top Header Bottom Header Panel Tubes Opening Tubes Top Header Bottom Header Panel Tubes Opening Tubes Top Header Bottom Header Panel Tubes Opening Tubes DC1-DC11 Reducer
Size In Mm 200 NB X SCH 160 200 NB X SCH 160 63.5 O.D x 4.06 Thk 63.5 O.D x 4.06 Thk 200 NB X SCH 160 200 NB X SCH 160 63.5 O.D x 4.06 Thk 63.5 O.D x 4.06 Thk 200 NB X SCH 160 200 NB X SCH 160 63.5 O.D x 4.06 Thk 63.5 O.D x 4.06 Thk 200 NB X SCH 160 200 NB X SCH 160 63.5 O.D x 4.06 Thk 63.5 O.D x 4.06 Thk 100 x Sch 80 200 x 100Nb x Sch 80 168.3 O.D x 10.97 Thk 100 x Sch 80 63.5 O.D x 4.0 Thk 44.5O.D x 4.06 Thk
Material SA 106 Gr B SA 106 Gr B SA 210 Gr A1 SA 210 Gr A1 SA 106 Gr B SA 106 Gr B SA 210 Gr A1 SA 210 Gr A1 SA 106 Gr B SA 106 Gr B SA 210 Gr A1 SA 210 Gr A1 SA 106 Gr B SA 106 Gr B SA 210 Gr A1 SA 210 Gr A1 SA 106 Gr B SA 234 WPB SA 106 Gr B SA 234 WPB SA 210 Gr A1 SA 210 Gr A1 SA 210 Gr A1 SA 213 Gr T11 SA 213 Gr T22 SA 106 Gr B SA 213 T22 SA 106 Gr B SA 106 Gr B SA 106 Gr B SA 210 Gr A1 SA 106 Gr B SA 210 Gr A1 SA 106 Gr B SA 210 Gr A1
RH Panel
Front Panel
LH Panel
Rear Panel
Down comers
Pipe 90 Elbow Tube Stub
Super Heaters (CSH & RSH)
Coils
44.5O.D x 4.06 Thk 44.5O.D x 4.06 Thk 44.5O.D x 4.06 Thk
Pipe Super Heaters (CSH & RSH) Tube Pipe Pipe Attemperator Inbed Coils Inbed Header Economiser Boiler bank Header Tube Header Tube Top & Bottom headers Tube
219.1 O.D x 18.26 Thk 44.5O.D x 4.06 Thk 88.9 O.D x 7.62Thk 88.9 O.D x 7.62Thk 219.1 O.D X 18.26 thk 50.8 O.D X 6.35 Thk. 200 O.D x Sch 120 38.1 O.D x 3.66 Thk 168.3 O.D x 14.27 Thk 50.8 O.D x 4.06 Thk
Section A
Heating Surface Area

Zone Boiler Bank Zone Water wall Zone Super Heater Zone Inbed coils Economiser Total Heating Surface Unit Sq.Mtr Sq.Mtr Sq.Mtr Sq.Mtr Sq.Mtr Sq.Mtr Value 354.0 242.1 688.0 81.6 566.0 1931.7
Fuel
Fuel Type Main Fuels Start up Fuel Indian Coal Charcoal sprayed with Diesel fuel. Fuel Name
Fuel Analysis (% By Wt.)
6.1 Ultimate Analysis

Composition Hydrogen Carbon Nitrogen. Oxygen. Moisture Ash Sulphur Caloric Value (GCV) Unit % Wt % Wt % Wt % Wt % Wt % Wt % Wt Kcal/kg Indian Coal 2.30 37.1 0.70 6.60 8.00 45.0 0.30 3500 Char 0.42 40.30 0.17 2.84 3.21 52.68 0.38 3200
6.2 Fuel size

Indian Coal 100 % Up to 30 % (Max.) Char 100 % Up to 30 % (Max.) Coal: - Non caking type. We have consider standard analysis for India Coal & Char available It is recommended that the fuels be stored in covered yards to prevent choking and bridging of fuel storage and feeding system due to surface moisture. All the Fuels should be free from chlorine. Predicted Thermal efciency on 70% Indian Coal, + 30 % Char ( Mixing by weight Basis) Firing Shall be 83 +/- 1% : : < 3mm < 1mm : : < 6 mm < 1mm
Section A
Bed Material
: : : : 60 Metric Tonnes (Approx.) 0.8 mm to 2.36 mm (100 %) 10001100 AL2O3 % 35 to 45 SiO2 % 55 to 65
Required Per start Up Lump Size Bluk Density Chemical Composition
7.1 Bed Material Specications - Crushed Refractory

Material refractory Bulk Density Temperature SIZE Shape Chemical Composition SIO2 AL2O3 FEO TIO2 MNO CAO MGO P2O5 NA2O K2O : : : : : : : : : : : : : : : Sieved natural sand/Crushed 1200 1400 Kg/m3 >1300 deg C 0.7 to 2 (for sand) Fusion Sub Angular / Spherical. Percentage limits 5060 37-40 , Min 30% required <2.0 1.67 Traces 0.54 0.23 0.08 0.22 0.45
Continuous Blowdown
Max Normal : : 3 %/ Hr 1 %/ Hr
Intermittent Blowdown
Once in 8 Hours : 6%
10 Feed Water Recommended Quality

Parameters General Appearance Total Hardness as CaCO3 ppm Unit Value Clear & Colorless Nil
Section A
Parameters Total Fe Total Cu Total O2 Oil & Organic. pH Value at 25 Deg C Total Dissolved Solids Silica as SIO2 Hyderzine residual
Unit ppm ppm ppm ppm ppm ppm ppm
Value <0.01 <0.003 <0.007 Nil. 8.5 9.5 0.1 <0.02 0.02 0.04
11 Boiler Water Recommended Quality

Parameters pH at 25 deg C Phosphates PO4 Total Alkalinity Sodium Sulphite Oil & Organic p value Silica as SiO2 Unit ppm ppm ppm ppm mval/kg Ppm Value 9.5 10.2 2- 6 4 max. Nil Nil 0.1 2
12 Utilities
12.1 Electrical Power
Parameters Voltage Frequency Type Voltage Frequency Type For Field Transmitters Voltage Frequency Type V Hz 24 NA DC V Hz Units V Hz Value 415 +/- 10% 50 +/- 5% AC, 3 Phase, 4 WIRE 110 50 AC, 1 Phase, 2 Wire,
For LT motors (UPTO AND INCLUDING 160 KW)
For Instrumentation (eld switches, Level gauge illumination, solenoid valves etc.)
12.2 Cooling Water

Parameters Supply Pressure Unit Kg/cm2(g) Value 34
Section A
Parameters Supply Temperature Quality Duty
Unit Deg C
Value Ambient SOFT & Chlorine free Sample Cooling.
12.3 Instrument Air

Parameters Pressure Dew point Temperature Unit Kg/cm2(g) Deg C Deg C Value 67 -40 Ambient
12.4 Service Air

Parameters Pressure Temperature Quality Duty Unit Kg/cm2(g) Deg C Value 7 Ambient Dry & Oil Free General purpose
13 Chemicals for Dosing

HP Dosing LP Dosing Tri sodium phosphate Hydrazine
14 Site Condition
Site Location Ambient Temperature Performance Maximum Minimum Electrical Design Relative Humidity Altitude Seismic coefcient 36 C 45 C 20 C 60 C 60% 890 m above MSL As per IS 1893, Part 1,2002, Zone-2 Kopal, Karnataka
15 Fans
FD fan Duty conditions Make Model Unit Test Block Conditions TLT Engineering 2218 / 758 ID Fan Test Block Conditions TLT Engineering 16378B 982 PA Fan Test Block Conditions TLT Engineering 3166256
Section A
FD fan Duty conditions Quantity Nature of medium Air /Gas density Volume Gas Temperature at Fan Inlet Absorbed Power / Rated Fan Power Differential static head Fan Speed Static Pressure Kg/N M3 Kg/hr Deg C KW mmWc Rpm mmWC Unit Nos. Test Block Conditions 1 Clean Air 1.29 77486 45 250 860 1480 8437 22220 EK/C3 Free/Fixed Bearing Housing SNH-520 22220 EK/C3 SNH-520 Bearing Lubrication Motor Servogem; EP-2 250 KW 4 Pole Siemens Make Flexible Resilient Coupling Model / Make Size 212A Wellman MakeI
ID Fan Test Block Conditions 1 Flue Gas 1.31 86970 150 90 200 980 1962 222216 EK/C3 SNH-516 222211 EK/C3 SNH-511 Servogem; EP-2 90 KW 6Pole Siemens Make Flexible Resilient Size 212A Wellman MakeI
PA Fan Test Block Conditions 2 Clean Air 1.29 15300 45 50 760 2920 2920 222176 EK/C3 LOE-217 222174 EK/C3 LOE-214 Servogem; EP-2 55 KW 2Pole Siemens Make Flexible Resilient Size 212A Wellman MakeI
16 HP Dozing System
Make : N M Enterprises Drg no : NMEDS-HP-21 Rev -1 Description Pumps Make Model Type Flow Discharge Pressure Relief Valve Set Pressure Motor for Dosing Pumps Metachem Pump MC 2 Reciprocating Plunger 10 LPH by Stroke Adjustment 86 kg/cm2 g 110 kg/cm2 g HP
Section A
Description Make Type Rating Motor for agitator Make Type Rating Storage Working Volume Fluid To Be Handled.
HP Crompton/Siemens 0.5HP, 1500 RPM, TEFC-IP55, 50 Deg C amb. ,415 V, 50 Hz 0.5 HP / 1500 rpm N M Enterprises AG 2 Model, Motorised propeller type 750 rpm (material SS 304) 0.5 HP / 1500 rpm 300 litres Tri sodium phosphate.
17 Rotary Feeders
Make - Nova Bulk Handlers (P) Ltd. Refer G.A for Drag Chain Feeder. Drg No : Nova /48/ 0708. 2 sheets Description Type Capacity Material Used Location Length Of Feeder Rotary Feeder Horizontal See Table Below Indian Coal l At Bunker Outlet 781mm 2.2 KW with Variable Frequency Drive. Geared Motor (2 HP , 4 Pole Frame) 3 HP , 4 Pole Frame size- 100L; Make :Siemens Chain Sprocket; Head & Tail Type of Drive Rotor Size Simples 1.25 pitch (Reduction 1:2.53) Simplex 1.25 pitch Motorised With VFD Drive Dia 208 mm X 625 MM LG
17.1 Capacity Chart

Indian Coal Capicity Speed Through Loading Capicity Per Unit time per Revelation Char Capicity Unit Kg/hr RPM % Kg/hr/reve 0.00234 Unit Kg/hr Design 2100 100% MCR 1750 50% MCR 875 Min 438 Design 3840 7.2 95 100% MCR 3200 6.0 50% MCR 1600 3.0 Min 800 1.5
Section A
10
Char Speed Through Loading Capicity Per Unit time per Revelation
Unit RPM % Kg/hr/reve
Design 3.14 95 0.00234
100% MCR 2.62
50% MCR 1.31
Min 0.65
18 Gauge Glass
18.1 Drum Level Gauge
Description Make Tag No. Type Location Operating Pressure Design Pressure Hydrotest Pressure C/C Distance Visibility Range Operating Temp. Details HI- TECH SYSTEMS AND SERVICES LTD. LG-600A & LG-600B Bicolor Port type Steam drum 72.7 kg/cm2 (g) 78.8 kg/cm2 (g) 315 BAR 800 mm 403 mm 289 Deg C (Saturated) Normal Operating
18.2 Blow Dowm Tank Level Gauge

Description Make Tag No. Type Location Operating Pressure C/C Distance Visibility Range Operating Temp. Details Chemtrol Samils (I) Pvt Ltd. LG-550 Tubular Level Gauge Blow Down Tank 05 kg/cm2 (g) 500 mm 360mm 200 Deg C (Saturated) Normal Operating
19 Safety Valves
Description Application Type Make Size Orice Set Pressure Kscg 1.5/ H/3.0 78.8 Unit Drum LHS Drum RHS Spring Loaded Tyco Sanmar Ltd 1.5/ H/3.0 80.0 1.5/H /3.0 71.8 SH
Section A
11
Description Application Tag No Model Rated Capacity Quantity
Unit
Drum LHS B7 HC56 W-IBR-SPL
Drum RHS B8 HC56 W-IBR-SPL 19313 1 / BLR
SH S4 HCA58 W-IBR-SPL 13892 1 / BLR
Kg/Hr
19027 1 / BLR
Section A
12
20 Temperature Prole
20.1 Gas Temperature
At the outlet of furnace At the outlet of bank tubes At the outlet of economiser At the outlet of air-preheater At the outlet of ESP : : : : : 875 Deg C. 445 Deg C. 250Deg C. 160Deg C. 160Deg C.
20.2 Water Temperature

Condensate from process Process return Make up water inlet of FW Pumps the inlet of economiser At the outlet of economiser : : : : : : 47 Deg C. 100 Deg C. 32 Deg C. 130 Deg C. 130 Deg C. 216Deg C.
20.3 Air Temperature

t the inlet of air heater At the outlet of air heater : : 45 Deg C. 150 Deg C.
21 Flue Gas Pressure Prole

Furnace After Boiler Bank After Economiser After Air Heater After ESP At ID Fan Inlet At ID Fan Out let : : : : : : : 5 40 80 110 135 135 +5
22 Process Flow Diagram

Process Flow Diagram
Section A
13
Section B
Topics Covered in this Chapter Section Overview Feed Water System Boiler Pressure Part Description Main Steam Piping Boiler Blow Down System Air and Gas System Flue Gas System Fuel Feeding & Firing System Chemical Dosing & Sampling System
Section B
14
Section Overview
GENERAL DESCRIPTION The main parameters of the boiler are Maximum Continuous Rating Steam Pressure Steam Temperature Fuel Fired 41TPH 66 kg/cm2 490+/- 5 Deg C Indian Coal and Char
This section gives a brief overview of the boiler and its associated systems. The description of the various systems that form part of the boiler package is also included. The aim of this section is to make the reader familiar with the boiler package components before introducing the operation and maintenance sections.. Brief Overview The boiler package supplied by Thermax Ltd, Pune, India and has been designed for 41 TPH steam generation, 66 kg/cm2 (g) pressure, 490 +/- 5 deg C Super Heated Steam output designed for ring with 100% Indian Coal and secondary fuel 70% Indian Coal + 30% Char. This boiler is AFBC, Bi-Drum, outdoor, natural circulation, Water tube, uidised bed combustion, Underbed Fuel Feeding System, balance draft, Bottom Supported with Steel construction & Hopper Bottom design. Fuel Combustion will be in an Atmospheric Bed Combustor (AFBC) xed at the Boiler bottom. Fuel is stored in Bunker. Rotary feeders are connected at the bottom of hoppers (below the bunker). The fuel is fed by these feeders to under-bed fuel feeding system and transported to the furnace for ring in the bed. As a complete unit the boiler plant is equipped with the following circuits. Feed water and steam system. Pressure parts circuit. Boiler Steam circuit. Boiler Blow down circuit. Sample coolers. Chemical dosing system Combustor Combustion Air Fuel handling storage & Fuel feeding system Flue gas circuit Refractory and insulation. Electrical and Instrumentatio Chimney
The boiler has been designed to conrm to Indian Boiler Regulations (IBR) The boiler is divided into a combustion zone i.e. furnace and non-combustion zone i.e. economiser, air heater etc. The furnace sides, front and rear are of membrane panel construction providing a gas tight sealing. For all the four water wall bottom headers, water is fed through supply pipes from water drum. The sidewall, front wall and rear wall panel tubes top headers are connected to the steam drum through risers. The front wall panel tubes form the roof of the furnace. Feed water is pumped by feed water pumps from deaerator to economiser through feed water control station. The feed water from economiser outlet is then led to the steam drum. Steam is generated in the furnace membrane wall tubes. The resulting water-steam mixture from the riser tubes of membrane panel returns to the steam drum where the separation of steam from water takes place. The saturated steam is led through the supply pipes to the PSH inlet header. From the PSH inlet header steam passes through the coils to PSH O/l header, then steam is led to Attemperator and then to the Sec SH inlet header and passed through coils to the Sec SH outlet header. Finally from the Sec SH outlet header steam is passed to the main steam line to Turbine. Combustion of the fuel takes place in the furnace bed where the fuel is spread with the help of the fuel feeding screw feeders over the Bedplate. Combustion air is sucked from the plant environment by the motor driven FD fan and combustion air is passed through specially designed air nozzles which are welded in distributor plate or Bed plate. Secondary Air arrangement is done to: Suppress the unburnt fuel materials from escaping the combustion zone.
Section B
15
Maintains the super heater temperature by controlled combustion. Balanced draft conditions inside the furnace suitable for combustion is being maintained by I.D fan. Air pre-heater, ESP and nally into the stack by ID fan. The starting, stopping and safe shut down of boiler are done by manual intervention systematically and sequentially through DCS control system from control room. Details of equipments, their brief operational and maintenance features are elaborated in the subsequent sub-sections and chapters of this manual.
kept closed. This drain is to be opened only to drain the line when control valve has to be opened for inspection/maintenance. Following instruments are provided at the inlet of feed water control station: Flow nozzle FE-500 with ow transmitter FT-500 is provided for total feed water ow measurement. Flow transmitter transmits the water ow signal to ow indicating controller at control panel. A 25 NB pipe tapping with W33 valve for the SH desuperheater. Control valve is operated through the Flow indicating controller (FIC-600). Input signals are given to FIC-600 by Level indicating controller (LIC-600), steam ow transmitter (FT-604) and feed water ow transmitter (FT-500). Ref. three element control for detail operation of drum level controller. From the control station feed water ows to economiser inlet header (bottom) through an 100 NB non return valve (W-24). Thermocouple TG-501 is located before the Eco. inlet header to measure the feed water temperature prior to Eco. Pressure gauge PG-501 is provided with isolation valves (W15 & W16)to measure the FW pressure at Eco. inlet. From the economiser bottom header, water ows to the outlet (top) header through coils. Heated water ows from Eco. top header to steam drum, through feed water Eco. outlet piping. . 2.1.1 Single & Three-element control 1. Drum level control is the single most important process control for any steam generator. The simplest of the control loops involve measuring the drum level and comparing with a xed set point. A control signal to operate the control valve will be calculated based on the deviation between the set point and the process variable. This calculated signal would be a function of the loop conguration parameters. The simplicity of the loop is its advantage at low loads and constant loads. However, at higher loads and with load swings, this loop fails to control the process parameter. This has necessitated the introduction of two more elements (process parameters) into the control loop. The additional elements that are measured are steam ow & water ow. In the three-element drum level control, drum level is maintained as a function of the drum level and the steam ow. The control signal is a suitable summation of these two elements. This variable is compared to the measured water ow
Feed Water System
(Ref. P & I Diagram D12-1PD-6499P, R-2) Feed water system consists of the following: 1. Feed water control station.
2.1 Feed Water Control Station

When the boiler is in service, feed water must be continuously supplied to maintain near- normal water level in the steam drum. It is unsafe to operate the boiler at lower water levels. Feed water control station regulates the water ow to the steam drum to maintain the steady & required water level Feed water control station consists of the following: Feed water control station consists of one welded type ow control valve of 100 % capacity (FCV-500), which is pneumatically actuated by a spring opposed diaphragm actuator The 100 % FCV is provided with isolation valve W12 & W12 at upstream and downstream respectively, whereas W12 is manual valve. There are two bypass valves one is 100% bypass manual globe valve & another is FCV-500B 30% bypass pneumatic control valve, W13 is isolation valve of 30% bypass valve having manual isolation valve W13 & W13. Whereas W17 is 100% manual bypass valve. These main isolation valves are normally kept closed before the main valve is opened during pump start-up. The bypass valve should also be closed during pump start-up. The bypass is used only if the control valve is out of service. Drain valves W-14 is provided after the 100% control valve. Theses drain valves are normally
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and a suitable control signal is generated which is used to drive the 100% control valve. The major advantage of the loop is its ability to maintain drum level during load swings, variations & throw conditions that are certain to occur during the operating regime of any steam generator. Though this loop is advantageous from an operation point of view, it is recommended to use this loop at loads > 30%, as the single element control loop is optimised for low load conditions with its control valve sizing & parameter tuning
Provision of this additional heating surface, increases the efciency of the steam-generating unit and saving in fuel consumption is achieved. Economiser is located in between boiler bank outlet and Air Pre-heater. A continuous loop tube Economiser assembly is constructed with rows of 38.1 O.D x 3.66 thick tubes, and two headers. Both the ends of the coil were terminated to the top and bottom headers by welding. Feed water ows from the bottom header to the top headers through these coils. Heated water ows out from the top header to steam drum through the connecting pipe. The economiser is fully drainable by the drain valves W-26 located on the inlet header. Economiser top header is provided with the following attachments: 25 NB air vent with two valves (Tag No. W 28 which will be kept open during initial lling to remove the air trapped between the coil. Closed after free ow of water from the vent. Pressure indicator PG-502 with twin isolation valve W 27. Thermocouple (TE-502) is provided for panel mounted temperature indicator. Pressure gauge(PG-502) is provided for Local Indication.
2.2 Attemperation Control Station

A tapping 25 NB from Feed Water line is provided, to supply spray water for Attemperator. This line is provided with a manual isolation valve W-33 & NRV W37. A temperature control valve TCV-604 with isolation valves W-34 is provided. A by-pass manual valve W-35 is provided. This line connects to Attemperator through a NRV W-36.
Boiler Pressure Part Description
This boiler is AFBC design, BI-Drum, outdoor, natural circulation, Water tube, uidised bed combustion, Underbed Fuel Feeding System, balance draft, Bottom Supported with STEEL construction & Hopper Bottom design. Various pressure parts are grouped as follows: 1. Economiser 2. Steam drum 3. Water drum 4. Down comer Tubes 5. Furnace 6. RH & LH Inbed Evaporator 7. Furnace membrane water walls 8. Riser Tubes 9. Saturated steam supply tubes 10. Super heater 11. Attemperator 12. Boiler bank
3.2 Steam Drum

(Refer Drg no: P21-1PD-43823, Rev-1) Steam drum (1375 ID X 70-mm thk.) is a welded cylindrical vessel made of SA 516 Gr.70 material. The cylindrical portion of the vessel is made of 70-mm thick plates and the two Torispherical dish ends are 70mm. thick. Two elliptical manholes at either end of the drum provide access inside the drum. These manholes are closed tight at either end by 70-mm thick plates, bolted against the manhole rim by two holding bars. A gasket is tted between the cover plate and the mating machined surfaces in the end shield. The cover plate swing inside the drum, for convenience during opening. Steam drum is supported by saddle supports on the super structure of the boiler. Steam drum is tted with several components to perform important functions, which are listed below: Direct water level gauge LG 600A & LG 600B that shows the water level inside the steam
3.1 Economizer
Refer Drg no: PL4-1PD-45132, R-0 Function of an Economiser in a steam-generating unit is to absorb heat from ue gases & add this as a sensible heat to the feed water, before the water enters to the steam drum.
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drum. DWLGS are provided at both ends of the drum. Two nos. Level transmitters are provided LT 600A B C which transmit the actual water level to the remote indicators i.e. at control room and provide drum level signal to the drum level controller Drum safety valves B 7 & B 8 which protects the boiler and the personnel against the consequences of abnormal pressure increase because of sudden load decrease, malfunctioning of ring system, steam stop valve etc. Level indicator LI 600: this gauge is mounted at the ring oor, so as the ring oor attendant can view the drum level. H.P dosing connection: To dose phosphate in to the steam drum to maintain the boiler water quality. Continuous blow down (CBD): To drain the boiler water during operation to maintain the water concentration. Also the water sample is taken from this blow down. It is connected to the common IBD tank directly as well as through CBD tank. Two air vent with isolation valves B 6 that will be closed at 2 Kg/cm2 (g) during pressure rising and open at 2 kg/cm2 (g) during cooling. Local Pressure gauge PG 600A with isolation B9 & B9 shows the drum pressure near steam drum and PG-600B with isolation B11 & B11 at operator oor. One pressure transmitter PT-600 is given to three element drum level control compensation. 3.2.1 Steam Drum Internals (Refer Drg. no. P21-1PD-41824, R-0) Steam drum internals are provided to supply moisture free steam to S.H coils. Steam drum receives water/steam mixture from the water wall panels through the raiser tubes in the bafes of the boiler drum. In this steam/water mixture, high-density water is separated from steam and trickle down to mix with water in the drum. Steam raises upward to ow through the demister pads and nally moisture free saturated steam goes out of the steam drum. Feed water pipe 1 No. 100 NB perforated pipe with holes is installed in the drum with holes positioned at 7 & 7 O clock position while looking from RH Side (i.e. towards boiler front). This will
ensure the uniform distribution of feed water in the entire length of the steam drum. Pipe is made in two pieces for installation ease and provided with anged joint. Continuous blow down pipe (CBD) 1 no 25NB perforated pipe with 6-7 holes is installed in the drum with holes at 6 O clock position. CBD pipe is provided to drain the boiler water to maintain the boiler water concentration at the specied limit. Pipe is made in two pieces for installation ease and provided with a drain hole to drain the water during shut down. HP dosing pipe 1 no 25NB perforated pipe with 6-4 holes is installed in the drum with holes at 12 Oclock position. As the pipe is of perforated type the chemical is uniformly distributed across the length of the drum. Chemical dosing at steam drum is, to maintain boiler water concentration as per the specied limit. Pipe is made in two pieces for installation ease and provided with a drain hole to drain the water during shut down.
3.3 Water Drum

(Refer Drg no: P21-1PD-43928, Rev-1) Water drum is a shell welded cylindrical vessel made of SA 516 Gr.70 material I.D. 960 and 50 mm thick. The cylindrical portion of the vessel is made of 50mm thick plates and the two semi-ellipsoidal dish ends. Two elliptical manholes at either end of the drum to provide access to the drum. A gasket is tted between the cover plate and the end shield. The cover plate swing inside the drum for convenience during opening. There is also arrangement of blow-off bafe with clamp arrangement inside the water drum.. Water drum is tted with intermittent blow down connection (IBD) of size 40 NB with isolation valves (D3 & IBD Valve D4) through which the water can be removed during emergency situations like high water level and high concentration situation.
3.4 Down Comer Tubes

(Refer Drg no. P73-1PD-46307, R- 1) Down comer tubes are of 323.9 O D x 33.3 THK size, which supplies water to furnace wall & convection bank headers from steam drum.
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There are two main down comers from water drum which supplies water to all bottom headers these have O.D 323.9 and 33.32 thk. And material is SA 106 Gr. B. Two branch supply pipes are taken from these downcomers to supply water to bottom headers. Supply pipes are taken for RHS and LSH evaporator panel bottom header each had been provided. And supply pipes are taken for front wall bottom header & for rear wall bottom header each.
shape under the expansion conditions. Front wall tubes are supported through rod slings with rocker washer from the super structure. Front wall bottom header is provided with a 25 N.B. drain connection, which normally remains closed during operation of the boiler. It is to be used to drain the boiler during shut down and start-up.. 3.5.2 Rear Wall (Refer Drg no. P45-1PD 45012)
3.5 Furnace
Furnace is the part of the boiler where the chemical energy in the fuel is converted into thermal energy by absorbing the heat produced through combustion of fuel. The furnace is designed for efcient and complete combustion, with due consideration to the factors that effect, combustion efciency like fuel residence time inside the furnace, temperature and the turbulence required for complete mixing of fuel and air.. Following are the distinct advantages of the furnace design: Heat transfer is facilitated inside the furnace in addition to combustion Practically no maintenance for refractory is required in case of membrane wall furnace Due to heat transfer inside the furnace, higher loading is possible, as part of heat generated, is already absorbed by the furnace tubes leaving the ue gas temperature out of furnace within acceptable limits into super heater zone. Furnace is constructed with shop fabricated membrane (water wall) construction. It comprises of Front panel, Rear panel, L.H panel and R.H panel. Furnace is 7380 mm long x 5040 mm wide. 3.5.1 Front Wall (Refer Drg no. P42-1PD 45013, R-1) Front wall is formed with front header (200NB x SCH 160) and 63.5 O.D x 4.06 Thick tubes. One end is connected to the bottom header and the other end is terminated to the top header. Front wall tubes receive water from steam drum through supply pipes. To strengthen the wall tubes, Buckstays beams are provided all around the furnace. The buck stay beams are supported on cleats from the water wall panels and exibly interconnected at the corners. The buck stay beams help to retain the furnace shape within permissible deviations of furnace pressure. Corner end connecting links maintain furnace
Rear wall is formed with rear bottom header (200 NB x SCH 160 THK) and 63.5 OD x 4.06 thick tubes (One end is welded to the bottom header and the other end is terminated to the top header. Rear wall tubes receive water from steam drum through supply pipes. To strengthen the wall tubes buck stay beams have been provided. Rear wall tubes are supported through rod slings with rocker washer from the super structure. Rear wall bottom header is provided with a 25 N.B. drain connection, which normally remain closed during operation of the boiler. It is to be used to drain the boiler during shut down and start-up. 3.5.3 R.H & L.H Side Wall (Refer Drg no. P43-1PD-45215 , R-1) P41-1PD45213 &
L.H & R.H Side wall is formed with Inbed evaporator top header & sidewall panel top headers (200 NB x SCH 160) and 63.5 O.D x 4.06 thick tubes. Both ends of tubes are terminated at bottom and top headers. Sidewall panels are connected to steam drum through riser tubes from either sidewall . Both the wall assemblies are supported through sling rods with rocker washers from the super structure of the boiler. To strengthen the wall tubes buckstay beams have been provided. Sidewall headers are provided with a 25 N.B. drain connection, which normally remain closed during operation of the boiler. It is to be used to drain the boiler during shut down and start-up. Some of the tubes of the LHS wall are specially bent to accommodate one burner at front of the boiler for boiler 2, RHS for boiler 1. A large furnace volume has been provided to obtain complete combustion of fuel, full radiant heat transfer to the water wall panels to ensure that there is no ame radiation in the second pass and only hot ue gas ows to the second pass. Interlaced Secondary air nozzles are provided at single elevation on LHS & RHS wall. Membrane wall construction of the furnace and the second pass provided a totally gas
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sealed enclosure suitable for balanced draft operation. Adequate number of access doors (which normally remain tightly closed) have been provided in the furnace and in the second pass for inspection of observation of the bed/Flame and for addition bed material during regular operation.
Superheated steam also eliminates the formation of condensate in steam piping which is harmful to the turbine blades and pipelines. There are two stages of superheater in this boiler. They are SH-1 & 2. From the steam drum dry saturated steam enters the SH-1 i.e. 1st stage inlet header (O.D 219.1 x 18.26) through saturated steam supply tubes. From the 1st stage inlet header, steam ows to 1st stage outlet header through 44.45 O.D x 4.06 Thk coils. SH-1 is installed vertically above the goose neck zone with adequate supports. The SH headers are supported through saddle supports. 1st stage outlet header is connected to SH-2 i.e.2nd stage inlet header with Attemperator. From the 2nd stage inlet header, steam ows to 2nd outlet header through 44.5 OD x 4.06 thick coils. 150 NB Steam outlet line is taken from the 2nd stage outlet header of Superheater SH-2. Following connection is attached to primary S.H. Inlet header: 15NB sampling line with isolation valve S-17, which is used to take saturated steam sample. A 25 NB air vent with twin isolation valves S-1 & S-1 is provided for the PSH I/L header.
3.6 Inbed Evaporator

(Drg No. PD1-1PD-45751, R-1)
Figure 1 Inbed Evaporator
In-bed coils (50.8 OD x 6.35 THK Tubes) are provided inside the furnace. Water mixture enters the in bed evaporator bottom header through down comers from steam drum (D1 to D4) and the steam water mixture exits through in bed evaporator top header and then through water wall panel tubes to water wall top headers. Both R.H & L.H Inbed Evaporator bottom headers receive water from the steam drum through supply pipes. Inbed evaporator outer and Inner coils bottom loops are provided with round studs at an angle of 120 deg to reduce direct impingement of particles on the bare tubes and to avoid erosion. Phoscast 90 XR Refractory has been applied over the bends for reducing the erosion and extend the life of the coils.
3.9 Attemperator
(Refer Drg no. PB1-1PD-42672, R-0) Attemperator is provided in between the two stages of superheater in this boiler. From the PSH outlet steam enters the Attemperator made of 219.1 OD x 12.7 thk SA 335 P11 material. Function of Attemperator is to control the nal temperature of the steam to a pre-determined value by spraying required quantity of feed water. Inner SS sleeve is provided to shield the header from thermal stresses due to temperature variations. The inner shield is rmly held at one end by location pins welded on to header and is free to expand at the other end. Flanged joints on to the header hold the spray nozzle. The Spray nozzle at the blind end rests on a guide to with stand the force of the steam. Water is sprayed along the steam ow direction. Spray water for attemperation is taken from feed water line branch after ow nozzle, through spray water control station. Following are the connections attached to Inlet & Outlet pipes of Spray type Attemperator:
3.7 Riser Tubes

(Refer Drg no. P71-1PD-41465, R-1) Purpose of these tubes is to carry the saturated steam from front, rear & sidewall panels to steam drum. Sidewall panels are connected to steam drum through 101.6 ODx5.74 Thk riser tubes. Front wall top header is connected to steam drum through 4 nos. 150 NB x SCH 8 riser tubes and rear wall top header is connected through 10nos. 101.6 O.D x 5.6 THK riser tubes. Convection Bank top headers are connected through 14 nos. 101.6 O.D x 5.6 THK riser tubes (6 from each top header).
3.8 Super Heater

(Refer Drg no. PA1-1PD-45809, R-1/ PA2-2PD-41254, R-1 / PA3-1PD-45937 R-1) Super-heaters are provided to raise the steam temperature above the saturation temperature by absorbing heat from the ue gas. By increasing the temperature of the steam, the useful energy that can be recovered increases, thereby increasing efciency of the cycle also.
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Thermocouple (TE-601) is provided on inlet pipe for panel mounted temperature indicator (TI-601). Thermocouple (TE 602) is provided at the outlet of the Attemperator header for panel mounted temperature indicator (TI-602) . After Attemperator steam enters the secondary super-heater inlet header.
of pressure at panel, for steam density correction and for pressure indicating PI 404 for Steam ow compensation. Start up vent: Start up vent, with pneumatic control valve (S3) and manual isolation valve (S2) is used to vent the steam to atmosphere during boiler start up, as the main steam stop valve & by-pass valve remains closed till the boiler reaches the operating pressure. This also protects the SH coils from over heating during start up. To reduce the noise level from the steam venting to atmosphere, a silencer is provided to the start up vent line. If there is any interruptions in steam ow due to sudden turbine trip / load cut by the end users, start up vent valve to be opened immediately to maintain boiler pressure else safety valve will blow. Drain connection with twin valves S8 & S8 before the main steam stop valve. Drain is terminated to Blow down tank. 150 NB Main Steam Stop Valve (MSSV) S-9 (M 131 ), along with a integral bypass/equalising valve S -10 (S 9 ). Both the valves are motorised valves and bypass Valve S 10is manual operated Valve. During regular operation of the boiler, MSSV is kept fully open supplying steam from the boiler to the plant. Integral bypass valve is opened during the start up of the boiler for initial warming of the main steam line before opening the MSSV. A 15 NB line with twin isolation valves (S12 & S12) is taken from Main steam line for Sample cooler. A NRV (S13) is provided before the stop valve to prevent back ow of the steam from the plant to the boiler. Steam ow-measuring device, i.e. ow nozzle (FE-606) along with ow transmitter Tag no. FT-606 with impulse piping and isolation alves (Tag No. S-11)
3.10 Convection Bank

(Refer Drg no. P61-2PD-40326, R-1) The name itself indicates that heat transfer in this area is by convection mode. This is a Bi-drum boiler, the steam drum (Top drum) and the water drum (mud drum) is connected by a set of tubes called convection bank tubes. Convection bank tubes are constructed of 50.8 O.D x 4.06 thk. Both ends of the tubes are terminated at water / steam drum, and the ends are xed to drums by expansion of the tubes. Bank sides were covered with refractory tiles followed with insulation and outer MS casing. Also the tubes are strengthened by buck stay arrangement at one elevations. An Ash hopper has been provided below convection bank to collect y ash, which is disposed to Ash Handling System (AHS).
Main Steam Piping
Super heated steam from IBSH outlet header is connected to common steam distribution header by the main steam piping. Main steam piping is of 150 N.B. pipe with the following attachments: Safety valve S 4 is provided on steam line. To reduce the noise level from the steam venting to atmosphere, a silencer is provided to the safety valve exhaust line. Pressure Gauge (PG-604) with twin isolation valves (S5 & S5) for indication of main steam pressure.. Thermocouple (TE-604) is provided for main steam temperature control loop. Temperature indicator (TI 604) is provided for local temperature indication in the operating oor and for temperature indicating controller (TIC 604) for steam ow compensation Pressure Transmitter (PT-604) with twin isolation valves (S7 & S7) for remote indication
5
Aim
Boiler Blow Down System
This chapter describes the Boiler Blow down system for safe draining of high pressure and temperature steam and water from the boiler using the Blow down tank.
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System Description P & I Diagram (D12-1PD-6499P, R 21) (Steam and Water system) show the various drains from the boiler, main steam lines, etc. A common drain system has been provided for both he boilers. Large quantities of steam of high pressure / temperature water are not drained through open canals for the following reasons: a) Such draining will cause splashing of high volumes of steam, which can be a nuisance by the noise it creates, and also it affects the visibility around the draining area. b) High temperatures of these drains can cause scalding injuries to workmen who may come in contact with it. c) The force and temperature of these drains will erode the linings of the drain canals. d) Low-pressure steam, which can be recovered, if required, is wasted.
LH In-bed evaporator bottom header RH In-bed evaporator bottom header Economiser header drains Eco I/L header Drain header has following A 50 NB -thk drain line for draining Furnace Drain Header to nearest trench. An 50 NB thk initial lling line with W -26 and isolation valve W-26. The water is supplied from DM water transfer pump. Drain line is connected to IBD tank with an isolation valve W - 40 5.1.2 SH Drain Line Following drains (All 25 NB) are connected to the SH drain header ). Main steam line drain before and after main steam stop valve. Main steam line drain before main steam stop valve has 25 NB drain line with isolation valve (S-8) this line is connected to the BD tank.
5.1 Drain Lines

A 50 NB Common drain line is provided which is connected to the Blowdown tank with an isolation valve W40. Two drain lines from sidewall panel headers are connected to this common drain line. Also Economiser drain is connected with same line. A 50 NB initial lling with isolation valve and NRV DW 16 & DW 17 is connected to the common drain line. 5.1.1 Furnace Drain Line A furnace drain header 50 NB is provided as a common collection point for the drains from various points of the boiler. The following drains (All 25 NB ) of the boiler are connected to the Furnace drain header. All water wall drains fromSOURCE Continuous Blow down from Drum Intermittent Blow down from Drum VALVE TAG NOS.
5.2 CBD Drain

A CBD is tapped from STEAM drum, A 25 NB line for continuous blow down (CBD) is connected to the blow down tank. A CBD valve (D-2) is provided on CBD line. Isolation valve (D-1) is provided.
5.3 IBD Drain

IBD is tapped from WATER drum with a 40 NB pipeline with isolation valve (D-3) and IBD VALVE (D-4). Intermittent blow down (IBD) which is connected to the blow down tank. Table shown below is a summary of such drains with tag nos High Pressure / High Temperature Steam And Water Drains TEMP. OF DRAIN C 306 FREQUENCY OF USAGE Continuous (depending on quality of Boiler water) During high levels in drum and during boiler draining.
D1 isolation, D-2 CBD VALVE.
D-3 isolation, D-4 IBD VALVE.
306
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SOURCE S.H. & Main steam drain Furnace & Economiser drains
VALVE TAG NOS. FOR M.S. LINE isolation valves S-8 For ECO drains isolation valves are W-26, and for furnace W.W isolation valves are W-39.
TEMP. OF DRAIN C Varying from 70 to 520 ~70 - 150
FREQUENCY OF USAGE Draining of condensate during start-up and after a shut down. During boiler start-up and shutdown.
Drains indicated in the above Table are connected to the common intermittent blow down (IBD) tank except CBD drain and various samples. CBD tank is connected to IBD tank while samples to the nearest drain trench.
5.4 Other Drains

Other drains of the boiler are open drains and are connected to the nearest trench within the boiler area. The drains are All level control station drain All pressure control station drain Steam drum level indicator. Steam drum safety valve drains Sample cooler sample let off drain
of the tank, such that the drain uid is directed circumferentially around the inner wall of the tank. Tangential ow of the drain uid into the tank separates steam from the water. Steam rises to the top of the tank and water collects at its lower portion. A vent is provided at the top of the tank. Following connections are connected to the common BD tank. A Level gauge glass LG-550 with isolation valves D6 & D6 has been tted on the tank to verify water level in the tank. Tank is provided with a 50 NB drain pipe with a valve (Tag no. D-7) for ushing purpose. Connections from CBD line, from IBD line, from Drain line, and from MS Drain line. An air vent to atmosphere.
5.5 Blow down Tank

Blow down tank is a pressure vessel capable of separating steam from the drained hot water. This drain is connected tangentially in the upper half
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Air and Gas System
( P & I DIAGRAM D12-1PD-6500P, R- 2) Air System This chapter describes supply of primary and secondary air to the boiler. The components that form part of air system are FD Fan Air Pre-Heater (APH) Air ducts Combustion air to Windbox Secondary Air OR Over re air. Secondary Air For Air Spray Nozzle
the required fan output pressure and ow. The VFD receives input signal from furnace pressure indicating controller (HZ 200). Fan Discharge Duct 1. To minimise the force due to possible movement of the discharge duct on the fan, as well as to isolate fan vibrations being passed on to the duct, the fan is connected to the discharge duct through bellows type expansion joint (1no) Test pockets temp. gauge and pressure gauge is provided on outlet duct. A Draft Gauge (DG 200) is provided with an isolation valve (A1) at the outlet duct. Fan outlet is connected to air pre-heater (APH) through a ducting. Aerofoil An Airfoil to measure the airow is provided (AFM 200). The airow is measured by the principle of pressure drop across the element being proportional to the airow passing across it. Flow transmitter (FT-200) gives input to a controller (FIC-200), which also get inputs from combustion control and ultimately it controls suction air by power cylinder. Please refer Vendor Manual for safe Operation & Maintenance of FD fans.
6.1 System Description: 6.2 FD Fan

Figure 2 FD Bearing
Each Boiler is provided with 1x 100 %. F.D fans driven by electric motor to supply main combustion air to the furnace and various other equipment. FD fan is of centrifugal type, with radial, backward curved blades. FD Fan Suction Side FD fan is provided with a suction duct with silencer for cold combustion air from the plant environment. The details are elaborated below in the component wise description. FD Fan Suction Duct Bird Screen & Silencer At the inlet of the FD fan suction duct rain cowl with bird screen is provided. An absorption type silencer is installed to attenuate the noise. FD Fan Suction Damper Suction damper (inlet guide vane) control has been tted on the suction of the FD fan. FD fan sucks air from environment through the suction duct and inlet damper. The percentage opening of the inlet damper (guide vane) regulates the capacity of the fan to meet the combustion air and other requirements of the boiler. Fan inlet damper gets input signal from pressure indicating controller (HZ 200). A pneumatic actuator (HY 200) is provided to operate the damper. The actuator is provided with limit switches (ZSC 0/C 200) for 0% & 100% positions, which are used as safety interlocks for fan start permissive. VFD is provided. In VFD mode, the inlet damper is kept full open and the motor speed is varied to get
6.3 Air Pre Heater

Reference drg no: A32 - 1PD - 44980 R 0 Air heater provided is of tubular type and the purpose is to recover a portion of the sensible heat from ue gases by all incoming combustion air, thereby improving combustion efciency. The hot ue gas passes through the tubes to heat air while the air from F.D fans passes from out side of the tubes for heating. APH is single ue gas pass and double air pass. APH is assembled on a steel structure enclosed with a 4-mm thick steel casing. Bottom Tube sheet is plate 3495 X 2035 X 16 THK. and the Top Tube sheet is 3495 X 2035 X 12 THK , Middle Tube sheet is 3495 X 1851 X 10 THK. APH tubes are 63.5 mm OD X 2.34-mm thk. Every tube is expanded in top and bottom sheet. Bafe plates are provided to support and strengthen APH tubes between top and bottom tube sheets. To avoid cold end corrosion some rows of CORTEN STEEL are provided. APH is a non-mixing type heat exchanger in which ue gases pass through the tubes and air out side the tubes. Flues enter in APH from bottom of APH-I, enter in to APH-II & leave from top of
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APH-II. APH is provided with common hopper for APH-II & APH-I. Due to change in direction and sudden pressure drop in APH hopper, y ash gets collected in the hopper. Hot air duct from Bed Ash Cooler is connected to APH hopper. Ambient air from FD passes through APH to absorbs sensible heat from ue gases. A manually Operator damper is provided at the inlet of APH. Access doors are provided in connecting ducting for inspection of air heater tubes. Hot primary air is then connected to Windbox Compartments below Combustor (Bedplate) from bottom & hot secondary air to SA duct to furnace. Following are the attachments to APH inlet duct: Aerofoil AFM-200 for total air ow measurement. Pressure Indicator ( Draft Gauge) DG-200 with isolation valve A1 for remote indication in panel. Following are the attachments to APH outlet duct: Pressure Indicator ( Draft Gauge) PG-202 with isolation valve A-3 for remote indication in panel. One temperature element TE-201 and its indication TI-201 is provided in DCS. Thermocouple TE-201 for remote indication TI-201 in panel. APH can be bypassed partially so as to maintain the back end temperature, to maintain the ue gas exit temp out of air heater above sulphur dew point temperature. To facilitate this, an interconnecting duct with buttery damper (HCV-400A) in between APH inlet and outlet duct is provided. A tapping is taken from the APH O/l (Hot air) going to the suction of PA fan for Fuel Feeding System. Combustion Air from APH is passed to the Windbox. From Windbox, which is divided into 5 nos. compartments, hot primary air passes across the Bedplate in to the furnace.
A pneumatically operated inlet guide vane damper is provided at PA fan inlet, to maintain the required pressure at the fan outlet. The actuator is provided with limit switches for 0% positions, which are used as safety interlocks for fan start permissive. Tight shut-off dampers are provided at the upstream & downstream of PA fan, to isolate fans in case of maintenance. A pressure Indicator ( Draft Gauge DG-300 with Isolation Valve (A6 ) is provided at common outlet duct for indicating the Primary Air pressure to fuel feeding system. To minimise the forces due to possible movement of the discharge ducts on the fan, as well as to isolate fan vibrations being passed on to the duct, the fans are connected to the discharge duct through bellow type expansion joints.
6.5 Air Ducts

6.5.1 Combustion Air To Windbox Hot air duct after APH terminates to 3 compartments in the windbox through branch ducts. The main duct is branched into 6ducts and connected to each compartment through pneumatically operated dampers. Start up 1st, 2nd, & 3rd compartments are provided with manually operated dampers. Pressure Indicators PI-6Nos. with isolation valves A5 & Draught gauges DG-101 A/B, 102 A/B, 103 A/B with isolation valve A5 for each compartment are provided for pressure indication.. 6.5.2 Secondary Air (Over Fire Air) System A SA Header-1, 2, 3 & 4 with rows of spray nozzles provided on RHS & LHS wall respectively. Header 1 & 2 are at 7.8-m elevation & header 3 & 4 are at 7.1 m elevation. Secondary air ducts from nal APH outlet is taken and branched to air spreading nozzle & connected to Header-1 & 2 mounted on sidewall. High-pressure Secondary Over Fire inject air into the furnace through the spray nozzles mounted in the Header-1 & 2 which is to help for complete combustion of fuel. Boiler RHS sidewall nozzles are located at +7825 mm & +7150 mm elevation above C/L of IB Evaporator bottom header on Header-1, having 30 nozzles of 33.4 O.D x 2.87 thk pipe inclined horizontally. Ducting is provided with damper at inlet of Header to adjust the air pressure. Boiler LHS sidewall nozzles are located at +7825 mm & +7150 mm elevation above C/L of IB Evaporator bottom header on Header-2, having
6.4 PA Fan
Each Boiler is provided with 2x 100 %. PA fans driven by electric motor to deliver high-pressure air, which is used for transportation of fuel to the Combustor. The suction for the PA fan is taken after APH second pass.
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30 nozzles of 33.4 O.D x 2.87 thk pipe inclined horizontally. Ducting is provided with damper at the inlet of Header to adjust the air pressure. A pressure pocket and test pocket is provided each on LH and RH OFA headers. 6.5.3 Secondary Air Duct To Air spreading nozzle A Secondary air tapping is taken from APH fan outlet duct. One main branch is taken from the APH outlet duct, which is further divided into two sub-branches, One branch is connected to the HEADERS 1 & 2 on both sides and other branch is connected to the HEADERS 3 & 4. And one
another branch is connected to Air spreading nozzle, which is used for Fuel spreading inside the furnace. Manual dampers are provided at inlet of air spreading nozzle on both LHS & RHS. Boiler RHS & LHS Air spreading nozzles are located at 733-mm & 1408-mm distance from C/L of IB Evaporator bottom header. This spreading nozzle consists of Holes & Openings. Sufcient Ducting supports are provided at suitable locations to strengthen the branch ducts. Sufcient Expansion Bellows had been provided at suitable locations in air ducts to take care of thermal expansion.
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Flue Gas System
Temperature Indicators Flue gas temperature at Air-heater outlet Flue gas temperature at ID fan inlet (TE-109) (TI-110)
Flue gas from the furnace passes through S.H coils, Convection bank tubes, Economiser coils, Air Pre-heater tubes and ESP to I.D Fans. From the I.D fan gas is blown through chimney to atmosphere..
7.1 System Description

Combustion products of gases exits from the furnace and passed to S.H zone. Furnace is provided with the following attachments in the ue path. Furnace pressure transmitters, PT-100 with isolation valves FG- 1 and Pressure Indicator PIC100 are provided to Measure Furnace Pressure Furnace pressure high and low alarm / trip (PAHH-100 & PAH-100, PALL-100 & PAL-100) are also generated from above transmitters. A Temperature Elements 3 no (TE-102 A B C ) at the top of the furnace. Temperature Element (Tag no. TE-100) with temperature indicator TI-100 at the topside for the measurement of the uegas temperature at the inlet of the super heater stage -II. From furnace, ue gases pass through the super heater zone, enters to SSH and then to PSH coil assembly. From the super heater zone the gases further passes through the convection bank tubes and enters to economiser assembly.. From the economiser the ues pass to air pre heater assembly. Further the gas from APH outlet pass through the ESP and to I.D fans. From the fans it is discharged to atmosphere through the chimney. Following instruments are provided in ue gas pathTemperature Indicators Bed temperature for each compartment Flue gas temperature at boiler bank inlet Flue gas temperature at economiser inlet Flue gas temperature at economiser outlet Local temperature indicator after APH (TE-102 A B C) (TE-100) (TE-106) (TE-107) (TI-109)
Pressure Indicators ( Draft Gauge) Flue gas pressure at Economiser inlet Flue gas pressure at Economiser outlet Flue gas pressure at Air-heater outlet Flue gas pressure at ID fan inlet O2 Analyser A probe connection to measure the O2 % by O2 Analyser Tag no AP is provided in ID Fan Inlet duct. (DG-106) (DG-107) (DG-108)
(DG-109)
7.2 Electrostatic Precipitator (ESP)

ESP in Customer scope. The dust particles in the ue gas are collected here in ESP and clean gas is let into the stack through ID fan. Refer O & M manual of ESP vendor manual for safe Operation & Maintenance.
7.3 ID Fan
Figure 3 ID Fan
Boiler is provided with 1x 100 %. I.D fans. ID fan is driven by variable frequency drive. ID fan is of centrifugal type, with radial, backward curved blades and driven by electrical motor. The percentage opening of the inlet damper OR the motor speed regulates the furnace pressure. Fan inlet dampers are operated on input signals of furnace pressure indicating controller (Tag no. PZ 100) through a pneumatic actuator (Tag no. PY-100) to maintain the required furnace draft. The actuator is provided with limit switches. (ZS-100 & 100 O/C) for 0% & 100% positions, which are used as safety interlocks for fan start permissive. In VFD mode, the inlet damper is kept full open and the motor speed is varied to get the
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required furnace Draught. The VFD receives input signal from furnace pressure indicating controller (PIC-100). Also two manual eld operated dampers are provided at fan inlet & outlet duct. Pressure Gauge DG-109 are provided on individual ID fan inlet duct for remote indication. To minimise the force due to possible movement of the discharge duct on the fan, as well as to isolate fan vibrations being passed on to the duct, the fans are connected to the duct through bellows type expansion joints. ID fan outlet ducts are connected to chimney.
Description
Details Indian Coal: mm, 100%< 6
30% (max) < 1 mm. Fuel Size Char: 100%< 3 mm 30% (max) < 1mm. Iron particles < 0.5% by wt. Coal: Non caking type. Feeders Type and Size Horizontal , Dia 208 mm x 625mm Long.
Fuel Feeding & Firing System

System DRG no
8.1 Fuel Bunker

From the fuel processing plant the fuel enters the fuel bunker of different capacities as mentioned above, through belt conveyors. Fuel is stored in separate bunker and fed through feeders to a chute above Rotary Feeders and then fed to boiler through under bed feed system. A manually operated isolating sliding gate is provided at the bottom of bunker, before fuel enters chute above Rotary feeders. By isolating this gate maintenance job can be taken up in the respective feeder. A rod type gate is also provided before fuel enters Rotary feeders. By inserting or withdrawing required nos. of rod, the fuel feed quantity can be controlled.
(Refer Fuel Feeding F591PD-46483, R-0) Aim
Fuel feeding system is of UNDERBED FEED type and the fuel is burnt in an ATMOSPHERIC FLUIDISED BED COMBUSTOR. Fuel is fed through fuel feed ROTARY FEEDERS with the help of VFD driven motors into a hot uid bed where the combustion takes place. This sub-section describes the handling, storage and feeding system of fuel to the Boiler. Fuel feeding system comprises the following: Fuel bunker Rod Gate below bunker Fuel distribution chutes Fuel mixing nozzles Primary Air line for PA headers & mixing nozzle Secondary air line for combustion Rotary Feeders for Coal Rotary feeder for Coal and Char Component Description Description Bunker Capacity Fuel Feeding Type Details 110 Cu M for Coal 110 Cu M for Char/Coal Under Bed Feeding
8.2 Rotary Feeders

There are 3nos. of ROTARY FEEDER provided below Indian Coal bunker. Provided each on LHS & RHS below the Surge hopper (Inlet Chutes). These Rotary feeders are Motor driven coupled with Gearbox and the speed is controlled by VF drives and these three stage reduction gearboxes. Fuel control can be achieved by varying the speed of the feeder. Fuel from feeder discharge is conveyed to Combustor with the help of air spreading nozzle. Also provided 3 local control switchboard. There are 3nos. of ROTARY FEEDER provided below Coal and char bunker. Each on LHS & RHS below the Surge hopper (Inlet chutes). Fuel enters through these chutes from bunker. These Rotary feeders are Motor driven and the speed is controlled by VF drives and through double stage reduction gearboxes. Fuel control can be
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achieved by varying the speed of the feeder. Fuel from feeder discharge is conveyed to Combustor with the help of air spreading nozzle. Fuel Distribution Chutes Fuel from the fuel drop chute is fed into the MIXING NOZZLE provided below the fuel drop chute, where fuel and air mixes for conveying the fuel pneumatically to the Combustor.
Ash drain-pipe per compartment is provided to the Combustor, at suitable locations. Bed drainpipe from the Combustor is provided with a hand operated sliding gate to drain the ash. 8.4.3 Bed Thermocouples There are 6 bed thermocouples having 35 mm of holes. 2 thermocouples for each compartment for indication of the bed temperatures. Details of bed thermocouplesTemperature Indicators 1st Compartment (Start-up Compartment) 2nd Compartment TE-101 A, TE-102 A TE-101B & TE-102E 3rd Compartment TE-101C & TE-102C The above temperature element gives input to Temperature controller TIC-101 A to C which provides Temperature High & Low Alarms Indicators (3 nos. each provided, Tag nos. 101 A to C) 8.4.4 Refractory FIRE BRICKS (IS:6) Layer is applied on the Combustor on the both side wall upto certain height (4013 mm from centre line of IB Evaporator top header) to avoid erosion on the sidewall. CASTABLE WHITEHEAT-K is applied on boiler front and rear panel. Also Air supply pipes are provided with Tile 600x150x150Thk, side skew block and whytheat-K applied after winding 10-dia rope. This arrangement is for sealing for all the six air supply pipes. 8.4.5 Sealing Boiler Pressure Parts are top supported having downward & sideways expansion. Windbox/ Combustor is bottom supported having sideways expansion. Since water walls, which are part of furnace & Combustor have expansion in opposite direction, an arrangement of sealing water walls & Combustor has been provided, so as to construct an airtight furnace suitable for balanced draught operation, without any hot air/ue gas leakage. 8.4.1Start Up Firing System Light up of boiler is done by charcoal/wood coal assisted ring. The detailed light up procedure is described in Sec. C (cold light up of boiler).
8.3 Fuel Mix Nozzles

Air from the PA fan enters the mixing nozzle and creates the suction to allow the fuel to enter the mix nozzle for conveying to Combustor. In the mixing nozzle fuel and air mixes and enters the fuel-conveying pipe. Total 9 nos. mixing Nozzles are provided. PA lines from respective PA headers, for nozzles is provided with manual buttery type damper (125 NB) Below the fuel mixing nozzle there is a drain provided to clean the mix nozzle in case of any foreign materials / big size particles accumulation.
8.4
Combustor
The combustor is the zone where the ring of the fuel takes place. The combustor of this boiler is of unique design. The combustor is divided into three compartments. Combustion air distribution pipes Air nozzles (Bubble caps) Bed drain pipes. Bed thermocouples 8.4.1 Combustor Air distribution pipes There are 6 combustor air supply pipes mounted in the combustor. All compartments are equipped with two pipes each. The uidising air nozzles are mounted on these combustor pipes. 8.4.2 Air Nozzle Fluidising nozzles are mounted on the combustion air supply pipes. Stainless steel uidising nozzles are specially designed to prevent in bed spouts and inbed coils erosion. Besides, the nozzles shall permit effective uidisation at lower loads with shutting down of some compartments. 8.4.3 Bed Drain Pipes To maintain bed level and to drain out bed ash / shale / stones etc from the uid bed Combustor,
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8.5 Bed Drain System

To maintain bed level and to drain out bed ash / shale / stones etc from the uid bed Combustor, Manual ash drainpipe per compartment is provided to the Combustor with slide gate, at suitable locations..
One mixing water connection, one drain, one over ow connection with isolation valves, one motorised agitator for proper mixing of the solution and a perforated screen at the inlet to avoid foreign material entry. Two pumps with motors are mounted on the base frame. One pump is operating while another is stand by. Pump suction line is tapped of from the bottom of the tank. It is connected to the pump through an isolation valve and a strainer. A direct connection of the DM water is given in between strainer and isolation valve for ushing of the discharge piping & strainer. Pumps are high precision positive displacement type, in which feeding volume can be controlled. In the discharge line a pulsation dampener is given to dampen intermittent discharge from the pump. After that one NRV, a pressure gauge and isolation valve is provided. One relief valve to maintain the pressure in the system is given. (Please refer Vendor Manual for relief valve set pressure) Discharge of the relief valve is connected back to the tank. Pressure gauge is provided with a Snubber and a Diaphragm, snubber helps to dampen the uctuating pressure and diaphragm avoids direct contact of chemicals and the gauge internals. One drain provided after the pressure gauge is used to release pressure while adjusting the relief valve setting. Also it can be used to check the ow. According to the system, discharge line of the H.P dosing is connected to Steam Drum & discharge line of the LP dosing is connected to the Deaerator. Supports at required elevations are given. All the piping in the system is to withstand corrosive chemical solution. Flushing Line In the system, the chemical mixing water line is connected to the pump suction line also, called as ushing line. This is provided to clear the line whenever there is no need for dosing. Whenever the dosing is stopped, always there is a chemically concentrate water is stagnant inside the piping. If this liquid is not evacuated, it may tend to solidify and settle inside the piping, which will create a problem for free ow of chemical whenever the dosing is re-started. Whenever the dosing is stopped, rst close the mixing tank outlet valve and open the ushing line valve, operate the pump for 2 hrs. In this process,
8.6 Ash Drain

During the boiler operation ash is generated in the Combustor. Fine ash goes along with the ue gas, which will be collected in the ESP, and the coarse particles remain in the bed and gradually increase the bed level. Bed ash quantity depends upon the ash content in the fuel, foreign materials like stones and shells etc. Since bed height needs to be maintained for trouble free operation, it is necessary to drain the excess material to maintain the desired level.
Chemical Dosing & Sampling System
Chemical dosing system consists of chemical dosing tank with two pumps with motorised agitator interconnecting piping, valves and mountings. The complete assembly is mounted on the skid. Chemical dosing system are required to maintain feed & boiler water quality at desirable levels.
9.1 HP Dosing System

During the boiler operation the impurities in the boiler water keep on getting concentrated. If the boiler feed water is hard the concentration of such chemicals may cause formation & deposition of scales on boiler heat transfer surfaces, which is dangerous. The chemicals dosed, react and form insoluble compounds, which prevent scale formation and aid in removal of existing scales. The quantity of such chemicals should to be calculated and depending on the analysis of boiler water.
9.2 Description of Dosing System Skid HP)

Total system is mounted on a Base frame. Chemical-mixing tank made of M.S. with rubber lined of H.P. = 700 DIA X 950 LONG700 HT. X 5 THK. (300 ltrs) is provided, where the chemical is mixed with water for 8/24 hrs dosing. Following are the attachments of the tank - A level gauge,
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the chemically concentrated water is replaced with the clear water; thus choking of piping can be avoided. Please refer Vendor manuals for technical data & safe Operation and Maintenance of dosing system.
The sample coolers are simple shell and coil type heat exchangers. In these sample coolers, the sample is passed through the coils while the cooling media is passed around the coils on the shell side. Individual sample coolers are provided with isolation valves on the cooling water inlet & cooling water return lines. The cooling water is provided from the plant via the terminal point at pressure of 3.5 Kg/cm2 (g) & temp. 33 Deg C. The supply & return line is provided with isolation valves
9.3 Sampling System

Sampling system consisting of sample cooler and the cooling water sub-system for providing steams & waters samples suitable for SWAS system. Sample Coolers There are three sample coolers provided on the boiler for the Feed water sample, Drum water sample and Superheated Steam sample.
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Section C
Topics Covered in this Chapter Boiler Start Up Operational Control Balance of Plant Start Up (Boiler) Part Load Operation By Bed Slumping Warm / Hot Start Up Boiler Shutdown Dos and Donts Controls Troubleshooting Chart Walkdown Checklist during Operation Boiler Safety Operational Precautions for Safety Section Overview This section describes the start-up and shutdown procedures of the boiler. Note The procedures explained in this section apply for start up of a boiler already commissioned. Commissioning a new boiler call for several additional requirements, which are not explained here. The procedures explained in this section apply for start up of a boiler already commissioned. Commissioning a new boiler call for several additional requirements, which are not explained here. It is assumed that operators are trained in operation of similar AFBC boilers and have been licensed to operate boilers by the concerned authorities. The owner is encouraged to evolve standard operating procedures (SOP) based on the framework and recommendations that are explained in the subsections below. The SOPs have to be well understood by the utility managers and operators for safe and reliable operation. Operators Responsibility The boiler operator is responsible not only for the smooth operation of the boiler and its related equipment, but also for the safety of all the personnel involved. The operator must be aware of any operating conditions affecting the boiler or related equipment. Should be able to recognise hazardous conditions and to act properly to avoid injury. Even though operating procedures are normally given for each piece of equipment, a complete
knowledge of all components their design, purpose, limitations and relationship with other components is must for the operators.
Boiler Start Up
This chapter describes the boiler start up and shut down procedures as applicable for the following boiler conditions: 1. Start up of a cold boiler 2. Start up of a warm / Hot boiler 3. Boiler shut down NOTE Procedures explained in this chapter apply for start up of the boiler already commissioned. Commissioning a new boiler calls for several additional requirements. It is assumed that operators are fully familiar with the design and construction features described in the earlier section. It is assumed that Operators are trained in operation of similar type of boilers and have been licensed to operate boilers by the State Boiler Authority. Owner is encouraged to evolve standard operating procedures (SOP) based on the framework and recommendations that are explained in the subsections below. The SOPs have to be well understood by operating personnel for safe and reliable operation.
1.1 Start-up of a Cold Boiler

1. Boiler start-up can be termed as cold start-up when there is no pressure or when pressure is less than 2-bar (g) in the steam drum. 2. In a cold start up, possibilities of some inspection or maintenance works having been done is presumed. A walk down check is required and the boiler and its auxiliaries are to be prepared meticulously for a start up from the DCS of the control room. Before a walk down check ensure that all work permits have been returned, safety tags are removed and maintenance permission for boiler start up is available. 1.1.1 Walkdown Checks Using powerful torches or low voltage inspection lamps, inspect the furnace, other generating sections, auxiliaries, ue and air ducting of the boiler and ensure the following: BOILER
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1. Furnace, Super heater and convection bank area are clear, all maintenance personnel have been removed and no scaffolding or inspection devices have been left inside. 2. Furnace oor, water wall and convection tubes are clean and there is no evidence of any water drips, slag or any other deposits. 3. Steam drum is clean and manholes are closed properly. 4. Conrm the evaporator and furnace wall drain valves are in closed position. 5. Verify the in-bed super heater supports are intact and in its rest position 6. Verify that all access doors, inspection doors of furnace and wind box are tightly closed. 7. Verify that all peepholes have been tightly closed and sealing/ cooling air connections are intact and the air valves are open. 8. Verify that the air duct, windbox, economiser, air pre-heater, dust collecting equipments and ue gas ducts are clear and that all maintenance personnel have been withdrawn. Ensure that the manhole doors closed properly. 9. Verify that the safety valves are not gagged. 10. Verify that the illuminators of local level gauges are ON. Inlet valves from steam and waterside is open and their drain valves are closed. Verify whether the Nitrogen purging valves are open (connected to the steam drum and main steam piping). If they are open, they have to be closed just before boiler light up, when air vents are opened.
5. Verify that the drains and vents of standpipes provided for level transmitters, indicator & gauges are closed. WATER DRUM 1. Close the IBD line isolation valve(D-3 ) and the IBD valve (D-4). ID, FD & PA FANS 1. Check that the fan inspection doors are closed. 2. Ensure that the bearing lubrication is done properly. 3. Check that the coupling and guards are installed properly. 4. Check that the manual isolation dampers at inlet and out of the fan are kept closed. 5. Ensure that the control damper actuator is properly xed to the operating lever and air supply is open to actuator and I/P Converter. DEAERATOR (DEAERATOR IS NOT IN THE SCOPE OF SUPPLY, YET FOLLOWING ARE THE CHECKS TO BE DONE PRIOR TO START UP OF THE BOILER) 1. Conrm the tank is clean and the manholes are closed. 2. Close the tank drain valve 3. Keep the vapour tank vent valve open 4. Keep the chemical dosing valve open 5. Conrm the pegging steam valve) kept closed. 6. Conrm the isolation valves to the level gauges are in open position. 7. Conrm the isolation valves to the gauges and transmitters are in open position. 8. Conrm the isolation valve to the steam to deaerator in close position. 9. Fill up the tank with feed water to the operating level. BOILER FEED WATER PUMPS (NOT IN THE SCOPE OF SUPPLY, YET FOLLOWING ARE THE CHECKS TO BE DONE PRIOR TO THE START UP OF THE BOILER) 1. Verify the bearing lubrication is done properly. 2. Check that the coupling and guards are installed properly. 3. Ensure that the suction strainers are cleaned and secured in its place.
11.
ECONOMIZER 1. Verify the internal is clean and all the manholes are closed with proper sealing 2. Keep the air vent on the outlet header open. 3. Ensure that the drain valves of top and bottom headers are kept closed STEAM DRUM 1. Ensure that the drum vent valves (B 6) are kept open 2. Open the CBD line isolation valve (D 1)and keep close the CBD valve(D-2) . 3. Open the HP dosing line isolation valve (HP13) 4. Conrm that the isolation valves to the direct level gauges are kept in open position.
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4. Check that the manual isolation valves at pump suction, minimum re-circulation and balancing lines are kept in open position and the discharge valves are close position. 5. Check that the cooling water supply is available. FEEDWATER AND SPRAY WATER LINE 1. Select the drum level and feed water ow controllers( LCV-120)in manual mode and close the control valves (FCV-500B ) also close the bypass motorized control valve 100 % W-17. and 30% FCV500B 2. Open the isolation valves of 40 % control valve. 3. Select steam temperature controller TIC 604 in manual mode with 0% output 4. Close the manual isolation valves of the spray water control valve (W34 & W34) for Attemperator, along with the bypass valve (W35). SAMPLE SYSTEM 1. All the sample lines isolation valves to be closed. Sample coolers can be taken into service once the boiler is pressurised. 2. Ensure a slight bleeding through the sample line as the boiler is pressurized to 2 bar to avoid choking of the line and the cooler coil. COMBUSTOR & AIR SUPPLY PIPES 1. Verify the bubble caps holes are clear without any blockages. 2. Verify the furnace seals are intact. 3. Verify the furnace seals are intact. 4. Verify the wall refractory is intact without any spalling/damage. 5. Verify the in-bed coil refractory is intact. 6. Coal feed nozzles are in good condition. 7. Verify the elevation of bed thermocouples. 8. Verify the seal air to the bed thermocouples are isolated. 9. Ensure the Combustor supporting structure is free for expansion without any obstruction. 10. Ensure the Combustor supporting structure is free for expansion without any obstruction. 11. Conrm the open closing operation of compartment dampers and keep the dampers in close position. 12. Verify the windbox pressure transmitter isolation vales are in open position.
ROTARY FEEDER 1. Verify the bearing lubrication is done properly. 2. Conrm the tightness of the drive chain. 3. Conrm the tightness of the feeder chain. 4. Open the slide and rod gate above the feeder and admit the coal to the feeder. 5. Conrm the outlet chutes are clear with out any blockages. UNDER BED FIRING SYSTEM 1. Pa nozzle bolts tightness to be checked. 2. Pa line/duct leakage to be checked. 3. Pa line blockages to be checked. 4. Dampers proper operation to be checked. 5. Verify the open/close operation of the compartment PA damper and keep the damper in close position. 6. Verify the individual pipe isolation vales are in open position. APH 1. Ensure the soundness of the tube rolling joints. 2. Verify tube ends are clean without erosion. 3. Verify the tubes are clear with out any blockages. 4. Verify the tubes are in good condition with out damage. 5. Conrm the manholes are properly closed with seal rope. 6. Ensure that Inlet damper to APH is kept closed. 7. Ensure that APH by-pass damper is kept fully open during start-up. ESP 1. Switch on the insulator and hopper heaters 4hrs prior to boiler light up. 2. Switch on the rapper mechanism 2hrs prior to light up. 3. Switch on the ash handling system below the hopper prior to coal ring. GENERAL 1. Ensure that the battery limit valves are open and the inputs are available. 2. Instrument air and Service air. 3. Availability of sufcient quantity of feed water. 4. Power up the feeders at MCC.
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5. Pilot gas [LPG] up to terminal point isolation valve. 6. LDO tank is lled with sufcient quantity. 7. LDO pump is ready for operation. 8. Ensure cooling water supply to the various equipments. 9. Coal bunker is lled up with specied coal. 10. Lime stone bunker is lled with limestone. 11. Availability of initial lling and makeup bed material. 12. Availability of chemical for feed and boiler water treatment. 13. Availability of lubricants for normal operation. 14. Ash handling system is ready for normal operation. 1.1.2 System Line Up PRELIMINARY REQUIREMENTS 1. Power supply: Ensure that the power supply is switched ON and available for all the feeders in MCC and for all panels. 2. Operating station -is ensured for readiness and emergency push buttons are released, if activated. 3. As instrument air is necessary for the operation of most of the valves and actuators, charge the instrument air header, the branch lines and instruments supply lines elsewhere. Root valves of all Instruments (Pressure gauges, Pressure transmitters, DP transmitters, Level gauges, etc.,) must be kept open and their drains if any are to be kept closed. They are not separately listed. 4. Ensure that all the eld instruments are lined up mechanically / electronically. 1.1.3 Filling of Water in the Boiler Following are the guideline to ll the boiler: It is recommended to use the lling line for initial water lling of the boiler. Prior to start the pump; 1. Open the furnace front wall, rear wall and evaporator header drain valves. 2. Open the economiser bottom header drain and top header vent valves (W-26 & W-28 respectively) 3. Close the Furnace drain header outlet valve W-39, to IBD tank. 4. Open the drum vent valve B-6
1. Start the feed water pump as per the start up procedure. On conrming the pump start-up, open the lling line isolation valve gradually. Valve to be opened in such a way that the load on the pump motor is with in the operating limit. Since there is no backpressure from the boiler side at this stage, pump outlet pressure also to be maintained by manipulating the valve opening. 2. Close the economiser air vent, on conrming the free ow of water from the vent outlet. Continue the lling, till the water level in steam drum reaches to 50mm below the normal operating limit. Stop the pump after lling and close the drain valves at furnace bottom headers, economiser bottom header and water lling line isolation valves & open the furnace drain header isolation valve.
While lling the water care should be taken to maintain the metal temperature above 21C to avoid brittle fracture. Hence, the water temperature must be maintained to meet this requirement. 1.1.4 Bed Material Filling 1. Bed material size and chemical property must be maintained strictly as per the specication for smooth start up and efcient operation. It also necessary to conrm the material must be dry with out moisture. 2. Shift the bed material to the feeding platform. 3. Start the ID fan as per fan start-up procedure. 4. Adjust the furnace pressure to 2mmWc. 5. Start FD fan as per fan start-up procedure. 6. Open all the compartment windbox dampers 7. Isolation dampers to over re air and PA lines shall be kept closed 8. Open FD fan suction damper or increase the fan speed and maintain the windbox pressure 100 125mmWC. 9. Maintain furnace pressure 2mmWc. 10. Note down the windbox pressure of individual compartments. 11. Bed material may be lled manually through openings provided on the sidewall wall panels for view port cum bed material lling opening. 12. Bed material lling should be done in batches, it should not be in one stretch as it will cause
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accumulation of material at the drop point and restrict the uidisation of bed material at this location. 13. Bed material shall be lled up-to 275 to 300mm heights above the bubble cap top, which is to be veried physically. 14. Prior to conrm the bed height, it is recommended to uidise the compartments thoroughly to spread the material uniformly. It may require uidising the compartments one by one with higher windbox pressure so as to distribute the bed materials evenly across the combustor. 15. On conrming the uniform distribution of bed material, it is a must to study the minimum uidisation windbox pressure. Record the minimum uidisation windbox pressure and airow for the start-up compartment as the same is a guiding parameter during coal ring. 16. After conrming the minimum uidisation windbox pressure, start-up compartment (only) bed height to be increased to 450mm above the bubble cap by adding additional bed material.
3. After completion of uidisation check. Feed dry charcoal uniformly over entire (start up compartment) bed, afterwards feed charcoal mixed with kerosene into the bed and spread it evenly across the complete start up (over dry charcoal). Ignite the charcoal by throwing a burning cotton waste 4. After ensuring re over the entire bed, start ID, FD fans, increase the air ow gradually to bring the charcoal to red hot condition by this top level bed material will start getting heated up. After achieving the above condition mixing of the bed should be carried (such that all the burning charcoal get mixed up with the bed material) by using the damper markings established during uidisation check. After 2- 3 minutes reduce the airow to minimum (i.e.; minimum bubbling). All the burning charcoal will disappear for a little while as they get covered with the bed material. Within a short period, the whole surface again will start glowing due to charcoal burning, carefully observe bed temperature raise and correspondingly increase the air ow to raise the temperature more than 600 degrees. If required, add charcoal to the bed for raising the bed temperature. Once the bed temperature of 600 Deg C is achieved, then the fuel feeding can be started by keeping slow speed. After ensuring ring of the fuel in the furnace, The speed of feeder to be adjusted such that the bed temperature is maintained at around 700-850 Deg C. Once we start feeding the fuel, the FD fan inlet damper is opened more and bed material to be added so that the plenum pressure is around 500 - 550 mmwc. 5. The fuel feeding to the combustor will be maintained so as to match with the steam demand. In case the load on the boiler is less, then the fuel feeding shall be reduced along with reduction in combustion air ( by reducing the FD fan damper). The FD fan air should not be reduced below 70%(approx) of that required at MCR. In case of further reduction in fuel feed, there will be drop in the bed temperature. If the bed temperature drops below around 600 Deg C, then the bed level may be drained suitably to reduce the inbed heat absorption and thus maintain the bed temperature. In case the load on the combustor is more, then the rate of fuel feeding will be increased along with increase in combustion air ow. If this result in increase in bed temperature, then by adding
1.2 Procedure For Normal Operation

1. Check and assure that there is sufcient storage of fuels in the bunker and normal water level in the drum. Clean the bed and the nozzle holes prior to bed material charging, Fill BED MATERIAL of specied size in the combustor about 250 mm from the distributor plate top. Start the FD fan and open the fan damper gradually to level the sand bed. Check the uidization uniformity by observing the at surface of the sand bed. If any non-uniformity is noticed, the same should be rectied by clearing the sand around the location & checking for any heavier stone or metallic particle and blockage of nozzle holes. Any external material or blocked hole should be cleared and further uidizing trial should be taken. 2. After completion of uidisation check for all the compartments, close the second compartment and check the uidisation as earlier for start up compartment. While doing the same, mark or note the damper opening where minimum uidisation (bubbling) will occur and mark the damper where mixing of the bed will occur and stop the fans.
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bed material, which will result in more inbed area immersion, the bed temperature can be brought under control.. 6. The High and Low set points for the bed temperature should be set at 900 and 650 Deg C. respectively. During start-up, the Low temperature set point can be set below ambient temperature and after start-up, re-set again at 650 Deg C. 7. During start up it is advisable to go with the specied fuel and after complete stabilisation of the boiler with recommended bed height, combination fuels can be started. Ultimate care to be taken to avoid higher bed temperature than recommended, 2 The following are the predicted normal operating parameters for the start up. Bed temperature (Deg C) : 800-850 Fluidizing air pressure (mmwc) : 550-575 1. Close the drum vent valve when the pressure reaches to 2 kg/cm2(g). Do not close the start up vent and drain valve on the S.H steam out let header. 2. Crack open the CBD valve to avoid blockage of CBD pipe holes and sample cooler coil. 3. As the pressure increases, carefully watch the pressure part for free expansion/movements 4. At times it will be required to poke the re during start up. Care should be taken while poking by ensuring sufcient negative draft inside the furnace 5. While viewing the furnace utmost care to be taken, because if any interruption in fuel feeding occurs, there is always a possibility of furnace pufng. Use safety goggle and wear cotton cloths and view through peep holes provided to avoid accident. 6. Furnace pressure is to be maintained between 2 to 5 MMWC, if the furnace
pressure is too negative all the ne fuel particles will either re close to S.H. zone or y as un-burnt. Firing at free board is to be avoided for the protection of S.H. coils from overheating.. 1. Increase the boiler pressure as per the cold start up curve, to have a control on the pressure raise, rate of ring is to be varied as per the requirement. 2. At times feeder may have to be stopped, but ensure that feeding is not discontinued for a long time so that the bed temperature will be maintained. 3. Once the boiler reaches close to the operating pressure make preparation for charging the main steam and other distribution lines viz. opening the drain valves. 4. First open the main steam valve by-pass valve to warm up the Main steam line also to equalise the pressure at the in/out let of the Main steam stop Valve (MSSV). 5. When ever the steam line is warm and condensate (if any) is removed, open the main steam stop valve slowly. Fast opening may cause sudden increase in drum level and water carry over to S.H coils. 6. Close the M.S.S.V by-pass valve fully after the stop valve is opened fully. 7. Keep the start-up vent valve open till the steady ow of steam is ensured from the end users. Also put the drum level controller in to automatic control mode after ensuring steady steam ow. 8. It is advisable to keep a watch on the performance of the controller whenever it is put in to automatic control mode at least for one hour. If the steam ow varies more than 20% better to keep it in manual mode till steady steam ow is ensured. At this stage it is helpful if the furnace draft control is taken to auto mode.
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Cold Pressure Raising Curve
Figure 4
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Operational Control
2.1 Load Operation
necessary to raise the start-up compartment temperature with the help of start up burner if necessary. 8. Above procedure to be followed for the activation of the remaining compartments. Note
While loading the boiler care to be taken that the feed and boiler water parameters to be brought to the recommended limit before increasing the load beyond 50% of the MCR. To meet the steam ow demand, following parameters are to be maintained to achieve the desired output; 2.1.1 Number of Compartments in Active Condition Depends on the load requirement number off compartments to be activated. Compartment activation may be as per the following procedure; COMPARTMENT TRANSFER 1. Compartment transfer means, activating a static (cold) compartment of the Combustor adjacent to the activated compartment. This is done by admitting the uidising air to the compartment to be activated and mixing the cold bed material with hot bed material of the activated / operating compartment. 2. Before activating a static compartment, fuel ow shall be increased to the active compartment to avoid drastic drop in bed temperature of the operating bed during mixing. 3. Increase the active bed temp around 875C and increase the airow sufcient to maintain the active compartment windbox pressure while opening the bed to be activated 4. While mixing the cold bed with hot material, the bed temperature starts rising gradually, however the bed temp of the operating compartment may drop. Mixing shall be continued till the drop of 50C in the operating compartment and close the cold compartment damper. 5. Mixing to be continued, once the active compartment bed temperature increase to 875 C. 6. Whenever the cold bed temperature rise to 450C, start the fuel feeding and stabilise the compartment with coal ring. 7. In case if the temperature of the operating compartment drops below 700C, it
After every compartment transfer stabilize the active compartments to the required parameters i.e bed temperature and wind box pressure. 2.1.2 Fuel Feed Lines Cleaning Moist coal, foreign materials and bigger size fuel may choke fuel feed lines. This may results in bed temperature drop. Following are the guidelines during such situations: 1. Ensure that PA air available with sufcient pressure at the fuel feed line. 2. To identify the line thoroughness, carefully drain the vertical portion of the feed line. Once cold bed material is drained, hot particles ow out along with a jet of air. This indicates that the fuel feed line is clear. 3. If the air is not coming out of the line this indicates that the horizontal line is choked which needs isolation of air line and fuel feeding. Whenever the fuel feeder is stopped, fuel ow needs to be increased to other compartments. 4. To ensure the feed line cleanliness open the drain plug of coal feed mixing nozzle, open the P.A. air. Place your hand below the drain plug. If there is a good suction of air, it indicates that the path is clear. If there is positive pressure, it indicates that the line is choked ahead of the nozzle. 5. Check any foreign particles/bigger size coal above the mixing nozzle, if any, clear the same. 6. Dismantle or poke the lines through poking holes and choking should be cleared. 7. Pass air through the line to ensure the line cleanliness and put the feed line into service. 2.1.3 Adequate Bed Levels with Desired Bed Chemistry If the load demand is very low and may be for few hours, it is suggested to go for low bed level operation by reducing the bed level. So as to keep more number off compartments in service. This will help is accumulation of ash over the idle bed and cause trouble during activation.
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During low bed level operation some of the inbed tubes surface will be exposed from the active bed, thus reducing the steam generation. NOTE: 1. Bed level should not be less than 350mm during boiler operation. 2. During low bed level operation, the bed temperature may be high and possibility of high bed temperature uctuation even for small upset in process changes, which is to be taken care suitably. 3. While increasing the boiler load it is suggested to increase the bed level to the required level of around 450-500mm. During low bed level operation if the boiler trips necessary quick care to be taken to re start the unit as there is a high possibilities of faster bed cooling and furnace blackout situation may happen.
for high bed ash accumulation. Apart from sizing, ash content in the fuel also reects the ash accumulation levels in the bed. 6. Along with fuel stones/shales also enters the furnace which accumulates in the furnace bottom, and increase the bed bulk density and warrants increase in wind box pressure to maintain required air ow to the compartment. During higher bed bulk density situations, bed draining to be done frequently to remove the accumulated stones/shells to maintain the bed bulk density to the desired limit maximum of 1250Kg/m3 to avoid de-uidisation and clinker formation. Also fresh bed material to be added to maintain the required bed height during bed draining. 7. Restrict shales/slates and stones entering with coal before fed to the crusher/bunker. Adequate arrangement to be made for picking up these foreign particles in the conveying system suitably. This is to avoid packing of bed and air-lancing, which shall lead to greater erosion of bed coils. 2.2.1 How low performance? bed level affects
2.2 Bed Level Control

1. During boiler operation, portion of ash generated will be accumulated in the bed and should be drained at regular intervals to maintain required bed level & bed bulk density (1250Kg/m3) for effective uidisation and good combustion to meet the required steam demand. 2. Pressure drop across the bed will increase with the accumulation of bed ash. This will reect on increase in windbox pressure. Gradual increase in wind box pressure (without increasing the FD ow) indicates the accumulation of bed ash. Consequently, quantity of air ow through the bed, wind box pressure may have to be maintained at higher level at the expense of high pressure drop. This in turn will increase the power consumption of FD fan. 3. In case if the bed bulk density increase more than 1250Kg/m3, it also reect in higher windbox pressure for the air the required airow. 4. If the bed height is too low, boiler load cannot be increased to the rated capacity. At this condition sieved bed material as per the size specied may be used as a bed make up material to maintain the bed level to the requirement. 5. Rate of bed ash accumulation depends on ash in fuel and size distribution. With higher percentage of nes in the fuel, ash accumulation in the bed will be less. Coal with very less percentage of nes contributes
1. Coil exposure and leads to low loads 2. Elutriation & high unburnt carbon in y ash. 3. Low bed level leads to high bed temperature uctuations 4. Low bed level leads to high excess air as this is required to keep the bed under controlled temperatures.
2.3 Bed Ash Alkali Control

Bed chemistry needs to be monitored as the fuel bound alkalies like Fe2O3, Na2O, K2O etc may cause fouling of heat transfer sections and result in low heat pick-up and loss in efciency. Following are the guideline for the bed chemistry control: 1. Regular analysis of bed ash for Fe2O3, Na2O, K2O, Sieve analysis, bulk density etc. 2. Minimise the concentration of fouling alkali constituents by frequent bed draining. Analyse bed ash for following parameters and decide on draining rate. a. Iron Oxide : <4 % b. Na2O + K2O : <4% c. Bed material agglomerate which is in small egg shape 4 mm:<10%
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d. In case of high alkali content in the fuel, bed-draining cycle should be strictly adhered to maintain the limits, this is to avoid agglomeration of bed.
2.4 Adequate Bed Temperature

Bed temperature is a function of Operating load No of active compartments Bed height Bed bulk density Bed material chemical composition Excess air Moisture in fuel. 2.4.1 Low Bed Temperature Operation 1. Bed temperature varies depends on the bed level, quality of fuel & boiler load. Fuel and air should be adjusted to get the required bed temperatures depends upon the load. Apart from varying fuel feed rate, air ow and bed level, boiler load also can be controlled by slumping and activating compartments. While operating with more compartments, for lower load conditions, the bed temperature may be operated at less than the MCR values. However number off compartment requirement may be decided in such a way that the bed temperature should not drop below 750 Deg C for safe / trouble free continuous operation. 2. Also the bed temperature should be controlled to suit the fuel being red, as it may leads to clinker formation if it is exceed. 3. Along with the rise in boiler load, fuel feed rate with combustion air also increased to maintain the steam pressure. With the additional fuel ring the bed temperature rise subsequently. During operation if the required bed level is not maintained, it may leads to high bed temperature situations and leads to clinker formation. Hence it is a must to maintain proper bed level to control the bed temperature. 4. Bed material also plays an important role to maintain this parameter, if the bed material bulk density is more than the desired limit, it will warrant higher windbox pressure to lift the material. If sufcient pressure is not available, bed may not uidise properly and leads to clinker formation. If the windbox pressure is increased more than the limit, it will erode the inbed coils and may fail prematurely.
5. Similarly, if the bed material chemical property is not as per the design recommendations, the bed temperature may uctuate during fuel feed upset conditions. If the alumina content in the bed material is lower than the limit, bed may not retain the heat during interruption in fuel feeding, also when ever the unit is trips, the bed temperature drops quickly and cause trouble for hot start-up. 6. Also if excess air is pumped into the bed, it will cool the bed and warrant additional fuel to maintain the bed temperature. Hence there should be a balance between the air to fuel ratio along with the bed height. 7. Whenever the moisture in the fuel increase, bed temperature drops equally as additional heat energy is required to evaporate the moisture in the fuel. Similarly, if the moisture is less than the design value bed temperature increase for the same steam ow conditions. High moisture fuel require increase in PA pressure also, it may also leads to the erosion of bed coils.
2.5 Fuel and Bed Material Sieve Analysis as per the Designed Conditions
FUEL Quality of fuel plays an important role in the availability and efciency of the boiler. Hence it is essential to maintain the fuel as per the design limits. Following are the major factors are to be monitored during operation Fuel sieve analysis Fuel moisture Shales and stones Alkalis in fuel GCV Ash BED MATERIAL As explained in the previous chapters, bed material is an important element hence it is mandatory to maintain the quality of bed material to improve the availability and efciency of the boiler. Following are the major factors are to be monitored during operation Sieve Analysis Chemical Analysis
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Bulk Density Shape Fusion Temperature Ensure bed material bulk density is always between 1000 - 1100 kg/m3. . Whenever the boiler is to be shutdown, it is recommended to stabilise the boiler operation with coal ring prior to slump the bed
Cross check with the level indication available at control room through the level transmitter . Stop the water supply to the deaerator when normal water level has reached. 5. In the mean time charge the steam up to the pressure control valve to warm up the line and keep the steam readily available for charging into deaerator. Once, water level has attained NWL, then slowly admit the steam into deaerator through the pegging steam line. It will take minutes or one or two hours to heat the water with pegging steam. Whenever the water temperature reaches 60 to 70 0C, deaerator is ready for charging the steam through main supply line. 6. Try to maintain a low water level before admitting the steam through the main supply line. Level may be maintained well above the very low level and below the centreline of the tank. Due to direct scrubbing of steam with warm or cold water there may be little hammering or vibration in the storage tank. By keeping the low Water level the quantity of the water in the storage tank will be less and less steam will be required initially to heat it. Thus vibration or hammering can be reduced while pressurising the deaerator. Keeping low water level will have to be done manually watching the level in the direct level gauge and by maintaining the water intake manually, as the Level Transmitter will be out off its range. 7. Start charging the steam gradually by opening the Pressure control valve, water will be heated up and steam will start coming out of the vent. Whenever the steam vapour start ows increase the steam ow (slowly) and maintained the pressure as per the desired value. 8. Along with steam, increase water ow simultaneously but gradually. Objective is to maintain Normal Water Level and to increase deaerator pressure up to the required value. Once there is considerable rise in temperature, admitting of steam in more quantity will not cause hammering in the deaerator. 9. Water and steam intake should be synchronised so that at no point of time deaerator pressure shall go beyond the pressure above the desired limit and to vacuum pressure. More steam ow will lead to increase in deaerator pressure and less steam ow than the requirement for the water
Balance of Plant Start Up (Boiler)
ASH HANDLING: Fly ash handling system shall be started one hour prior to coal ring. ESP Rapping mechanism should be started one hour prior to start the ring. Hopper and insulation heater should be switched on 4hrs prior to charge the ESP. 4hrs. after attaining the required ue gas temperature at ESP inlet, the ESP shall be charged. However in case of disturbance in normal operation of the boiler, it is advised to switch off the transformer.
3.1 Deaerator Charging

The procedure for placing the deaerator in service is outlined below: 1. It always recommended that the deaerator have to be taken in line as soon as the LP steam is made available or at lower loads. It would be easier to control the parameters and there wont be any hurry in stabilizing the system. It is also recommended to take deaerator in operation, as the boiler is started and steaming out, so that the risk of corrosion and pitting will be minimised. 2. Open the vent valve at the vapour tank to atmosphere. 3. Line up all the instruments on deaerator system. 4. Fill the deaerator slowly through the makeup water inlet connection by opening the deaerator level control valve. Watch the water level in the level gauges and ensure that the gauges are indicating the correct water level.
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ow will lead to condensing of steam and will result into reduction in deaerator pressure, even to vacuum pressure. 10. As the deaerator pressure increases the water temperature will start increasing. If the water outow from deaerator is faster, then the temperature rise will be faster.
may require to slump one or more beds depend upon the situation.
4.1 Bed Slumping Procedures

While slumping the bed, following procedures may be followed1. Reduce coal feeding gradually and stop the feeder of the compartment to be slumped. 2. Observe the dropping trend of bed temperature, whenever the temperature drops steadily stop the airow to the compartment by closing the compartment damper. 3. Maintain air ow through the PA lines to clear the lines. 4. Due to slumping of the bed, FD outlet pressure may increase, which is to be controlled to maintain the required air ow and wind box pressure for the active compartments. 5. Adjust / increase the fuel ow to the active compartments to meet the steam demand. Maintain the bed temperature and should not increase more than 950C, or less than 750C during boiler operation depending on the design condition. 6. After ensuring the coal feed lines are clear, PA air to coal feed lines may be closed, depends on the requirement. 7. Number of beds to be slumped can be decided by the operating staff based on the steam requirement. 8.
11. Once the level and pressure are reached the set values the controllers can be put into auto. Temperature will reach automatically to the operating value. 12. Flash steam if any from the boiler system can now be admitted into deaerator. 13. The vent valve on the vapour tank can be throttled to optimise the venting steam ow. 14. In the event of taking the deaerator into line, if abnormal hammering or vacuum situation is created, stop admitting the steam and repeat the whole charging process once again.
3.2 Air Pre Heater

1. When the boiler backend ue gas temperature increase above 160C, APH to be taken in line. Opening of APH inlet & bypass damper to be adjusted in such a way to maintain the gas outlet of APH at 1640C. 2. APH Tubular heater elements are susceptible to fouling due to y ash accumulation, particularly at the air inlet to the heater and near the exit of gas from Air Pre Heater; corrosion due to condensation of the ue gas, acid constituents within the ash, which become corrosive in the presence of moisture; & re occurring in the gas path by the deposition of large quantities of unburned combustible materials within tubes and on the tube sheets. Above conditions can be minimised by keeping the tube surface free of deposits through proper combustion and by maintaining safe ue gas temp. i.e. 160C at APH exit. FLY ASH SILO UNLOADING Unloading dampers shall be kept ready and y ash silo shall be evacuated once in four hours. The frequency of evacuation shall be determined as per site conditions.
Part Load Operation By Bed Slumping
Accumulation of y ash may lead to problems like clinker formation and sudden drop in bed temperature. While slumping the bed it is mandatory to activate the compartment intermittently to avoid accumulation of ash over the idle bed. It also suggested to drain the bed intermittently to remove the collection of y ash settled over the bed.
Though it is better to operate the boiler with all the compartments in service, at times for some reason due to sudden drop in steam demand, it
4.2 Slumped Bed to Active Bed

While converting the slumped bed in to active bed the following procedures may be followed:
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1. While converting the slumped bed in to active bed the following procedures may be followed: 2. Open gradually the slumped bed wind box damper for few minutes to uidise the beds, by observing the furnace pressure. 3. Observe the bed temperature, and while mixing the bed temperature will rise in the slumped bed and the bed temp will drop in the adjacent active bed, fuel ow needs to be increased to the active bed, to maintain the bed temperatures within safe limits, above 750 deg.c. 4. Meanwhile allow air to the coal feed P.A. lines and clear the vertical line of the coal feed line and keep ready the fuel feed system to inject coal to the compartment. 5. Open / close the wind box damper of slumped bed and increase the bed temperature more than 600 deg. C. and allow steady air ow to the bed. 6. At this point fuel ow to the new bed to be initiated, which will increase the bed temperature in the new bed. 7. Coal ow / air ow to be adjusted to get the required bed temperature / steam ow and other operating parameters. N.B.: 1. It is advised to slump the extreme bed instead of middle bed. 2. It is preferred to keep the start up bed always in service and not recommend for slumping.
4. Start the ID Fan, FD Fan and PA Fan as per fan start-up procedure. 5. Load the ID fan to maintain furnace pressure, load the FD and PA fans with pressure of 600 and 1300 mmWC at the fan outlet respectively. 6. Open the PA compartment dampers and clear the PA lines of the start-up compartment. 7. Once PA lines are cleared in the start up compartment, start the fuel feeder without delay otherwise bed may cool down rapidly. 8. Open the windbox damper such that the bed is just bubbling, ensure that uidisation is uniform and satisfactory. 9. Gradually increase the fuel and airow, observing the rise in bed temperature. 10. Adjust the airow and fuel ow to stabilise the start up bed temperature. 11. Proceed with compartment transfer procedures mentioned earlier according to steam demand. 12. Take feed water control and furnace draft on auto mode. 13. Charge the ESP if the ue gas temperature is OK. 14. Put the boiler into Auto mode.
5.2 Case-II (Bed Ash Temperature < 600C)

AFTER BOILER TRIP IF THE BED TEMPERATURE IS LESS THAN 600 C or BOILER BEING OUT OF SERVICE FOR MORE THAN 8 HOURS, FOLLOWING SEQUENCE MAY BE FOLLOWED TO BRING BACK THE BOILER INTO SERVICE. 1. Open the start up vent valve to 30%, normalise drum level 2. Close all the Compartments air dampers, Fan suction dampers and PA fan Compartment dampers. 3. Bring back the fuel feeders to the minimum speed setting. 4. Start the ID Fan, FD Fan and PA Fan as per fan start-up procedure. Load the ID fan to maintain furnace pressure, load the FD and PA fans with pressure of 600 and 1300 mmWC at the fan outlet respectively. 5. Load the ID fan to maintain furnace pressure, load the FD and PA fans with pressure
Warm / Hot Start Up
5.1 Case-I (Bed Ash Temperature > 600C)

AFTER BOILER TRIPPING IF THE BED TEMPERATURE IS ABOVE 600 C OR WITHIN 8 HOURS OF HOT BOXING UP OF BOILER. FOLLOWING SEQUENCE MAY BE FOLLOWED TO BRING BACK THE BOILER INTO SERVICE. 1. Open the start up vent valve 30%, normalise drum level. 2. Close all the Compartments air dampers, Fan suction dampers and PA fan Compartment dampers. 3. Bring back the fuel feeders to the minimum speed setting.
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of 600 and 1300 mmWC at the fan outlet respectively. 6. If the bed level is too high drain the bed and bring down the bed height to the required level. 7. Start the start up oil burner as per burner light up procedures. 8. Repeat the cold start-up procedures mentioned earlier and stabilise the boiler with coal ring.
11. Verify the IBD valve is closed. 12. Allow the boiler to cool naturally 13. Whenever the steam drum pressure drops to 2-kg/cm2 (g), open the steam drum vent and the start-up vent. 14. If the unit is to be shut for a short period, no personnel should be admitted to the boiler. If the operating personnel need to enter the unit, the boiler, economiser, air heater hoppers, and the ash collection equipment hoppers (ESP) must be emptied of any solids and the enclosure temperature cooled below 50 15. All solids must be removed completely from the boiler and the boiler temperature must be below 50 deg C before personal are allowed to enter for maintenance or inspection. a) Use airow to uidise the bed. b) Start the bed draining system 16. After the bed material ow from the bed drain has stopped, a layer of dead bed material will remain in the bed. 17. The bed material temperature must be less than 50 dec Cor less before any attempt to enter into the boiler. After the unit has cooled to a safe temperature below 50 deg C, shut the FD and ID fans, then evacuate the remaining bed material from the furnace. 18. Shut down all the auxiliary equipment at this time. This will include the feed water system, make-up system, bed drain ash removal systems etc
Boiler Shutdown
Boiler shut down can be of two types: 1. Planned Shutdown, where the operator gets advance notice and adequate time to shut down the boiler in an orderly manner. 2. Boiler Trip on interlock protection emergency shutdown by the Operator. or
If the shut down is only for few hours, it is not recommended to cool the bed material. If the shut down is for few days, it is recommended to cool the bed material.
6.1 Planned Shut Down

The following procedure for Planned or Normal shutdown is based on the assumption that the unit is operating at full load on automatic control and the unit should be brought to zero pressure and cool the boiler completely 1. Reduce the boiler load gradually according to the process requirement. , 2. Stop the fuel feeders one by one and slump the compartments as per slumping procedure. 3. Whenever the load demand reduced below 30%MCR stop the ring, close the main steam stop valve and open the start up vent valve to maintain at least 10% MCR steam ow. Continue the bed uidisation and reduce the bed temperature below 250 Deg C prior to stop the fans .
6.2 Boiler Emergency Trip

Boiler may trip either by safety interlock or due to a power failure or by an emergency trip command by the operator causing the I.D Fan to stop and abruptly stopping the ring. Under such emergency trip conditions the operator action is 1. Protect the boiler 2. Investigate the cause of trip and if possible to eliminate the cause 3. If the cause is eliminated, restart the boiler 4. If the cause cannot be eliminated immediately, continue the shutdown till the problem is attended to safe and reliable operation. 6.2.1 Boiler Protection after a Trip
4. Stop the steam supply to the deaerator. 5. Stop phosphate dosing. 6. Close the CBD valve. 7. Close the sample lines 8. Stop the FD fan and close the suction damper. 9. Stop the ID Fan. 10. Maintain normal water level.
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1.
Close main steam stop valve immediately
2. Continue to feed the water ow, if the water level requires to be maintained 3. Check that fuel feeders are stopped. 6.2.2 Boiler Shutdown during sudden Tube Failure 1. In case of a sudden tube rupture followed by a severe loss of drum water level, it is advised immediately to stop the burners / fuel feeders, and also isolate the steam & feedwater system. This is to avoid undue thermal stresses on pressure parts. The
drum vent & start up vent have to be opened whenever the pressure falls to 2kg/cm2 (g). Extent of the damage is to be ascertained after cooling the boiler completely. 2. In case of a tube failure and if the water level could be maintained though the re is not lost, it is recommended to stop the boiler immediately to avoid major damage to the pressure parts. 3. The impingement of steam & water from a leaking tube on adjacent tubes can cause additional failure of tubes. In such cases, the normal planned shutdown procedure is immediately implemented.
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Dos and Donts
15. Boiler surroundings and equipment must be properly illuminated. 16. Cleared the bed material immediately to make room for emergency. 17. Use genuine spares. DONTS 1. Dont by pass any instruments and safety interlocks. 2. Dont run the Boiler pressurized condition. with furnace in
DOS 1. Maintain all instruments and interlocks in good working condition. 2. Maintain the instrument air free from moisture and oily matters and the pressure as recommended. 3. .All dampers must be in smooth operating condition. 4. Maintain fuel as per the recommendation 1. . 5. Use the bed material as per the specication. 6. Maintain bed chemistry as per the design limits. 7. Maintain feed and boiler water as per the design limits. 8. Use proper lubricants as per the manufacturer recommendation. 9. Clean all Ash hoppers, feed water and transfer pump suction strainers, Oil gun regularly. 10. Operate the boiler within the recommended operating limits and Maintain proper operation log sheets regularly. 11. Operation & Servicing of individual equipment should be done as per the manufacturers schedule. 12. Carry out regular cleaning of Direct water level gauge glass on Feed water tank, Deaerator and Boiler drum. 13. Keep the stand by auxiliaries ready for operation. 14. Chemical dosing recommendation. systems as per
3. Dont throttle the feed water pump balancing leak off valve while the pump is in operation. 4. Dont operate the furnace wall header drain valves while the Boiler is in operation. 5. Dont leave the furnace door open while the boiler is in operation. 6. Do not open the furnace manhole without the permission from control room. 7. Do not reuse the drained bed material. 8. Do not operate the boiler with clinker. 9. Dont leave the Instrument Control Panel unattended. 10. Dont allow unauthorized persons to operate the boiler and associated equipment. 11. Avoid continuous operation of boiler at low loads (low back end temperature) to protect economizer and air preheater corrosion. 12. Do not dose chemicals into the boiler in batch wise, they should be done on a continuous basis. 13. Do not slump the in-between compartments, it must be from the last compartment. 14. Do not slump the start-up compartment.
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Controls
FURNACE PRESSURE CONTROL: 1. Operate Furnace pressure in auto mode with (2 to -5) mmWC as set point. Can be switched over to auto mode after the stabilisation of coal ring in start-up compartment. During bed activation and slumping control may be taken into manual mode as the air and gas ow may vary drastically during these operation. DRUM LEVEL 1. During start-up level can be maintained in auto mode with single element control,
till the boiler is connected to steady load. Whenever the steam ow is increased more than 30% MCR control can be switched over to three-element control mode. O2 CONTROL: 1. Whenever the boiler load increase above 60% and the operation is stable, O2 control can be taken into service. However close observation may be required as any upset condition like heavy bed, moist fuel and uctuating steam demand, it will be difcult to maintain the O2 as per the predicted values. Please refer Volume-3 , Section-6 for detailed Control Schematic drawings and write-up.
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Troubleshooting Chart
This section to be used for solving problems arising during operation. 1. Indication: Unable to maintain boiler water concentration Check the probable source Tube Leak or Hideout Probable Cause: Check Slight leakage from pitting or cracking of tube or tube seat leak. The repair method and preventive measures involves the following Remove boiler from service at rst convenient time. Hydrostatic test to be done to locate leak. Repair by welding or splicing as indicated and as approved by insurance or State Inspection. Determine cause of failure and correct it. Operation at normal loads should put chemical back in solution. 2. Indication: Sound of steam blowing in furnace or seeing visible steam from the stack. Check the probable source Tube Leak Probable Cause: Substantial leak from tube/tubes. Over-heating as from scale or tube seat leakage. Repair method and preventive measure The same as above plus tubes re-rolling. 3. Indication: Steam explosion in furnace followed by inability to maintain water level. Check the probable source Tube rupture Probable Cause: Failure of tube from low water, tube blockage or erosion of exterior metal surface.
Repair method and preventive measure Remove boiler from the line immediately. Inspect or determine whether tube splicing or wholesale tube replacement is necessary. 4. Indication: High conductivity. Check the probable source Solids carry over in the steam or high CO2 or NH3 in boiler water. Probable Cause: High boiler water concentrations, excessive water level uctuation drum bafe leakage or deposits on scrubbers. Repair method and preventive measure Check for bafe leaks in steam drum when out of service, or boiler water contamination. Check of degasied steam sample will indicate if CO2 or NH3 is high. 5. Indication: High gas temperature. Check the probable source High excess air. Probable Cause: Improper control / adjustment of airow. Repair method and preventive measure Check excess air at furnace boiler outlet, and correct airow if required. 6. Indication: Excessive water level uctuation. Check the probable source Water load or control conditions Probable Cause:High boiler concentrations, extreme load swings, varying supply pressure or control loop adjustment. Repair method and preventive measure Correct condition leading to the problem. 7. Indication: tubes Bowed water wall generating
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Check the probable source Overheating Probable Cause: Internal deposit or low water. Usually internal deposits result in tubes bowing away from the furnace & low water /starve results bowing toward the furnace. Repair method and preventive measure Severity of bowing will determine extent of tube replacement. Internal scale will call for internal cleaning. If low water is indicated a thorough inspection for drum damage and tube seat leakage must be made. Take steps to prevent recurrence or low water condition. 8. Indication: Tube blisters Check the probable source Localised overheating Probable Cause: Internal deposit. Repair method and preventive measure Repair by re-tubing or welding in tube section or by heating and driving back blister depending upon insurance carrier or State Inspectors approval. Clean internally by turbining or acid cleaning. 9. Indication: Internal pitting sharp edged and covered with barnacles in drum or tubes. Check the probable source Corrosion Probable Cause: Oxygen in Boiler water. Repair method and preventive measure Depth and extent of pitting determines need and extent of tube replacement. Extensive drum pitting can be welded but is subject to approval by either the manufacturer & insurance carrier or State. Source of oxygen must be located and eliminated.
10. Indication: Internal loss of metal not sharply dened and accompanied by black iron oxide (Fe 3 O4 ). Check the probable source Corrosion Probable Cause: Overheating resulting in breakdown of water into H & O2 Cause is usually from sludge letdown or pluggage. Repair method and preventive measure Individual inspection will determine extent or replacement, internal cleaning and correction of water conditions are required. 11. Indication: External pitting. Check the probable source Corrosion Probable Cause: From corrosive ash deposit and moisture either from dew point or external source such as leaking soot blowing tube. Repair method and preventive measure Extent of repair must be determined by individual inspection. In emergency tubes out of high heat zone can be plugged, being sure they are cut to vent and to prevent differential expansion with adjacent tubes. Proper external cleaning can prevent out of service corrosion. Locate and eliminate source of moisture. If dew point is from inservice corrosion, take steps to raise metal temperature. 12. Indication: Tube cracking Check the probable source Mechanical stress or a combination of stress corrosion or tube variation. Probable Cause: Interference with expansion or differential expansion with adjacent parts to give mechanical stress or this stress plus corrosion attack. Vibration set up by turbulent gas ow characteristics over tubes.
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Repair method and preventive measure When accessible and with insurance or State approval, the cracks can be ground out and welded, otherwise splice in section or replace tube. Locate & eliminate source of expansion difculty by inspection or hot to cold expansion measurements. Using tube spacers can stop vibration. 13. Indication: External metal loss. polished area Check the probable source Erosion Probable Cause: Mechanical abrasion from soot blower action. Repair method and preventive measure Where accessible and with insurance or State approval pad weld or splice in a tube section. Eliminate channeling of steam from soot blowers or use tube shields. Using tube spacers can stop vibration. Highly
14. Indication: External metal loss. Oxidised re scale area. Check the probable source Overheating Probable Cause: Prolonged or repeated overheating. Repair method and preventive measure Extent of metal loss will determine extent of tube or tube section replacement. Inspection or a thermocouple installation will determine cause of overheating. Using tube spacers can stop vibration.
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10 Walkdown Checklist during Operation

1. Check for unusual noises from steam / water leakages. 2. Check for unusual traces of water on oor, buck stay or leakage from casing joints. 3. Check for oil Spills around burner 4. Look for valve and gland leakage. 5. Discoloration, hot spots and bulging etc. on casing, ducts and hoppers 6. Check for steam and water leaks from connections and ttings to the drum. 7. Watch the furnace for any clinker formation. If possible inspect the slogging condition of furnace walls and super heater coils (if provided) through the observation ports. 8. Walk around the furnace exterior and observe for any hot spots or gas leaks. 9. Listen for any unusual noise around economiser which may indicate economiser leak (i.e. hissing noise)
10. Inspect penthouse for gas leakages. 11. Inspect windbox corners welded joints for any air leakage. 12. Inspect all ash hoppers to make sure they are being emptied properly. 13. Check around all air/ue ducts for signs of leakage. 14. Check position of fan and eld dampers. 15. Check for any gas leakages from refractory sealing. 16. Check for leakages from safety valves at normal operating pressure. Also note the safety valve blow off and shut off pressure. Check that the drain lines and drip pans are not plugged. 17. Make note of any leaky valves and prepare maintenance schedule to repair them. 18. Check to see that proper water level is being shown by the direct water level gauge. Check for water or steam leaks from ports or drain connections, which will cause a false water level in the gauge glass. Inspect the glass for discoloration or fouling.
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11 Boiler Safety
11.1 Emergency Procedures
Low Water Level Causes 1. Feedwater control system failure. 2. BFP failure 3. Tube leak Action Compare control room indication with gauge glass level. If the water level falls out of sight due to momentary failure of water supply system, due to negligence of the operator, due to momentary uctuations that might occur with extraordinary changes in load, appropriate action should be taken at once to trip the fuel. Any decision to continue to operate, even if only for a short time at a reduced rating would have to be made by someone in authority who is thoroughly familiar with the circumstances that led to the emergency and positively certain that the water level can be restored immediately without damaging the boiler. In the absence of such a decision 1. Stop the fuel feeders and Fans immediately. Shut off the main steam stop valve . Simultaneously, if feedwater has become available and the operator is assured that no pressure part has been damaged 1. Take the feedwater control system into manual mode 2. Allow the water ow to boiler gradually to normal water level. (Do not hurry up which may lead to sudden quenching and tube leak) if pressure part damage is suspected 3. Reduce the steam pressure gradually 4. Open the drum air vent when the pressure drops below 2 kg/cm2 5. Cool the boiler so as to examine the extent of damage 6. Drain the boiler after cooling 7. If any tube rupture and bulging is observed rectify the same 8. If any tube leakage were observed ,rectify / repair the leaking tubes and after the repairs conduct hydrotest 9. Determine the cause of low water High Water Level Causes
1. Feedwater control malfunction 2. Operator error 3. Instrument air supply failure 4. Foaming Action 1. Take the drum level control loop into manual mode 2. Reduce the water level immediately by operating the intermittent blow down to maintain the drum level 3. Reduce the necessary steam discharge rate, if
4. Start the stand by compressor if required Furnace Pufng & Back Firing Causes 1. Uncontrolled feeding of fuel into the furnace 2. Sudden increase in FD fan air 3. Tube rupture 4. Foaming Action 1. Take airow control system into manual mode and maintain the furnace pressure 2. Never increase fuel / air ow suddenly. Always increase air rst then fuel / oil / gas while taking boiler on load 3. In case of tube failure take the boiler out of service immediately 4. Keep the water wall tubes clean by monitoring the combustion conditions. Boiler Explosion Causes 1. Accumulation of fuel in the furnace due to incomplete combustion 2. Loss of ignition 3. Fuel oil valve leakages 4. Frequent unsuccessful startups 5. In-sufcient purging of furnace With the mixture of unburned fuel with air in explosive proportions and the application of heat sufcient enough to raise the temperature of the mixture to ignition point. Action 1. Trip the ID Fan immediately 2. Analyse the reasons for explosion and rectify the system
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3. Evacuate or clean the furnace to the possible extend Conditions for Boiler Restart after Furnace Explosion After a case of furnace/ boiler explosion, the restart of the boiler has to be carried out only after a thorough and detailed investigation & understanding of the cause of explosion. Following necessary actions have to be completed to prevent the repeat incidence of explosion and before restart of the boiler. Find out the root cause for the explosion and rectify the same. 1. Inspect the furnace for any signs of bulging or damage to the tubes.
2. Inspect the furnace refractory for damages 3. Inspect the air and ue ducts for any signs of damage 4. Inspect the expansion bellows in the air and ue ducts for damages 5. Inspect the economizer casing for damages 6. Assess the damage if any and rectify the same. 7. Carry out the hydro test of the boiler. In the event of a failure of the hydro test, identify the tubes that have failed and proceed to rectify the same as explained in the maintenance section.
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12 Operational Precautions for Safety

Introduction
The handling and burning of any fuel is potentially hazardous. Some fuels ignite more readily than others. Safe handling and operation demands knowledge of the characteristics of the fuel and careful observance of necessary precautions. 1. Operating the boiler with low feed water temperature along with high excess air will result in exceeding metal temperature. There should be no hesitation to bring down the load on the boiler if this temperature cannot be brought under control by other means. 2. In the case of tube failure which can be identied by hearing the noise in the boiler gallery and cross checked by difference in steam and water ow, gas and steam temperature, the boiler should be shut-down at the earliest by regular procedure for maintenance work. Otherwise large number of tubes may fail due to steam erosion and impingement. 3. Entry of wet steam into superheater and rst row or after desuperheaters will result in removal of oxide lm due to thermal shock. Boiler salt in the steam will accelerate corrosion. Austenitic steel is the worst affected due to stress corrosion in this case. Hence temperature after the desuperheater should be maintained well above the saturation point in the case of direct spray type. 4. Boiler washing (when the unit is shut down) can be done effectively by using hot water. Immediately after washing, the surfaces should be dried. 5. Always use deaerated, de-mineralised water for boiler feeding with the recommended feed water quality. 6. Feedwater temperature must also be maintained at the highest level possible either with the help of feedwater heaters or heating the water in the feed tank. Low feedwater temperature obtained during low load operation will result in external corrosion of economiser. 7. The economiser circulation system if provided should be kept in service when there is re in the boiler with no feed ow. 8. Steaming in economiser is harmful to economiser unless otherwise it is designed as steaming type and hence steaming should be
prevented by keeping a watch on economiser outlet water temperature. 9. Carryover of salts in steam occur either due to mechanical or vapour carry over from steam drum. Efcient drum internals can only reduce mechanical carry over. Silica is always carried over in vaporous form. Continuous monitoring of sodium and silica in steam is desirable. 10. Before operating a boiler, ensure complete knowledge of water chemistry. 11. Whenever boiler is started after a shutdown of more than 3 days, check all safety interlocks before boiler start up for proper functioning. 12. Superheater drain valve should be operated as per recommendations. 13. The steam drum should normally be lled upto the point when water is showing in the bottom part of the gauge glass. This is to allow for the swell on heating and to reduce any blowing down resulting from this cause to a minimum. 14. Firing should be maintained having regard to the instructions for protection of superheater, which will limit the maximum gas temperature in the superheater zone. 15. Once the boiler is boxed up, the water level in the steam drum must be raised to the very top of the drum. Filling the drum like this will prevent excessive temperature differentials along the drum wall. The water is then shut-off and the boiler is allowed to cool. 16. When staring from cold, the drains on both the inlet and outlet superheater boxes should be wide open (if applicable) 17. While raising pressure on boilers, a technique of continuous ring should be developed if possible, since intermittent ring may result in recondensation in the tube loops. 18. Where spray type attemperator are tted, it is very important that control of steam or superheater tube metal temperature is not attempted by the use of the spray during pressure raising. This can lead to the entry of spray water into the secondary superheater tube loops. 19. Ensure the availability of fuel / bed material / recycle ash in the bunkers. 20. Never allow oil or gas to accumulate anywhere, other than in a tank or lines which form a part of a fuel supply system.
21. Purge the furnace completely before introducing any light or spark. On a multiple burner unit, burners may be ignited without a purge if one or more in service already.
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22. Have a lighted torch or spark producing device in operation before introducing any fuel into furnace. 23. 24. Maintain a positive airow through the burners into the furnace and up the stack. Maintain adequate oil pressure and temperature for atomisation & also adequate steam or air pressure in case of steam or air atomisers.
over in vaporous form. Continuous monitoring of sodium and silica in steam is desirable. 29. Before operating a boiler, ensure complete knowledge of water chemistry. 30. The threaded portion of the burner tip should be covered with a non-hardening high temperature lubricating compound. This facilitates easier subsequent removal. (Please refer burner manual) 31. Lapped burner tips must be kept in a plastic container to prevent damage for atomising steam with internally mixing type steam atomisers. 32. Whenever boiler is started after a shutdown of more than 3 days, check all safety interlocks before boiler start up for proper functioning.
25. Ensure operation staff alerts to all abnormal conditions. To observe the above rules, automatic control instruction may include :a. Purge interlocks e.g. requiring a specied minimum airow for a specic time period sufcient to purge the setting before the fuel trip valve can be opened. b. Flame Detector: Each burner should have its own ame detector connected to an alarm and interlocked to shut-off the fuel to the burner, it serves upon ame failure. c. Closed position switches for burner shut-off valves, requiring that all shut-off valves be closed to permit opening the fuel trip valve.
Proper Handling of Access Door

1. Never open an access door while the unit is operating. 2. Any access door can have large amount of material built up behind it even after the bed has been drained. This material will fall out when the door is opened. Bed material can stay hot for many days even after boiler shutdown. 3. Open the door slowly and always stand to the side of the opening. 4. Look at the cavities through the door before entering into the boiler. have sufciently bright light available at all times when personnel are in the furnace and or in convection pass.
d. Shut-off of fuel on failure of draft fan (s). e. Shut-off of fuel in the event of low fuel pressure and low atomising steam or air pressure, and low instrument air pressure. f. Shut-off of fuel in gas red units in event of excessive fuel gas pressure.
g. Shut off of fuel in the event of electric power failure. 26. The raising and lowering of steam parameters should be restricted to the value given in the starting diagram. Exceeding these values will result in reduced fatigue life of pressure parts. 27. Entry of wet steam into superheater and rst row or after de-superheaters will result in removal of oxide lm due to thermal shock. Boiler salt in the steam will accelerate corrosion. Austenitic steel is the worst affected due to stress corrosion in this case. Hence temperature after the de-superheater should be maintained well above the saturation point in the case of direct spray type. 28. Carryover of salts in steam occur either due to mechanical or vapour carryover from steam drum. Efcient drum internals can only reduce mechanical carry over. Silica is always carried
Proper Handling of Thermocouples

1. Repair or changing of thermocouple / thermowells during boiler operation is absolutely prohibited, particularly in the positive pressure zone of the boiler. However if the need arises, always recall that the furnace is pressurised and that the thermowell may be an open path to the pressurised furnace. slowly and carefully disconnect the thermocouple from the well 2. If you encounter resistance in removing the thermocouple, it is an indication that the thermowell has eroded and is packed with ash and bed material. abort the attempt to replace the thermocouple and refasten it until the boiler is off the line and cooled. 3. If no resistance is encountered then carefully remove the faulty thermocouple and replace it. 4. Never look into the thermowell opening.
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Handling of Secondary Air Ports

1. The hand-operated dampers in the secondary air nozzles will be very hot. 2. While handling the dampers / ports protective gloves should be worn and enough attention to be given.
2. Always use a full-face mask with tinted glass. 3. Do not stand directly in front of open ports or doors especially when they are opened. 4. Use sealing air when opening the doors / observation ports. 5. Use ear protection devices, whenever it is necessary. 6. Wear protective gloves when working around the boiler. 7. Do not use open-ended pipes for rotting observation doors or ports. 8. Never enter drums, ducts etc. until all the steam and water valves including the drain and blow down values have been closed to check and tagged. 9. Do not enter a conned space until it has been cooled below 30 C and property ventilated. 10. Completely drain the solids from the bed, hoppers etc. while entering. 11. Always use low voltage extension cords and light bulbs with properly connected ground. 12. Never open or enter the rotating equipment until it has come to a complete stop and circuit broken i.e. open 13. When entries the furnace ducts etc. prepared for falling. be
Handling of Solid Piles

1. Always be cautious of piles of bed material. 2. The surface of piled material may be cool in the surface while just below the surface still may be very hot. 3. Bed material in a pile can stay hot for several days.
Handling of Furnace Observation Doors
Ports
and
1. Ports and observation doors are open to the positive pressure in the furnace. 2. Never stand directly in front of the ports. 3. Do not leave the poking rod in the furnace for long. It will heat up quickly making the rod hot to handle and hazardous when it is removed from port. 4. Never look directly into the port or stand directly in front of the open port. If there is a pressure pulse in the furnace, hot bed material can suddenly and unexpectedly spurt out. 5. Never use anything that may burn or melt, such as plastic or rubber, to temporarily blow the port. 6. Properly dispose of all combustible material from the port area. If any hot material blows out from the boiler it presents a potential re hazard. 7. Be sure aspirating air is on before you open the port door. If the air is not on, a stream of hot furnace gas, ash and bed media will blow out of the boiler. Open the port cap slowly. 8. When inserting a probe in the port, stand as far back as you can. Due to pressure some bed material can blow out. 9. When extracting the probe, again stand well back. 10. Never leave the port unattended ever for short time while working.
14. Never step into y ash or bed material. It can be cold on the surface yet remain hot and smoulder underneath for extended period of time. Always secure the drive mechanism of dampers, gates and doors before passing through them. 15. Watch for hot water in drum and headers when removing manhole and manhole covers. 16. Never use toxic uids like CTC in conned spaces without adequate ventilation. 17. Never direct an air or water stream into an accumulation of y ash in a conned area. If the y ash is smouldering the asatation could result in an explosion.
Safety Tips
1. All scaffolding materials are removed and cleaned. 2. Check any observation for expansion and dampers operations. 3. Ensure that all inspection doors, access doors and openings are closed and pad locked as required.
Safety Precautions
1. Do not attempt to open the boiler doors or observation ports without observing the proper safety procedure.
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4. Disconnect and isolate the nitrogen purge if it was used during the outage.
5. Open the steam drum vents and the vents.
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Section-D
Topics Covered in this Chapter Section Overview Recommended Maintenance Practice Conditioned Based Maintenance Boiler Annual Maintenance and Overhaul Boiler Preservation Procedure Tube Failures Water Chemistry Welding Procedure Specications (WPS)
Preventive maintenance mostly condition based Annual Boiler overhauls to clean and inspect pressure parts. The shutdown period of the overhaul is also utilized to attend to systems and parts which cannot be attended during short shutdowns or when the boiler is in operation The vendor manuals of the fans, motors, control valves with their positioners and actuators, instruments and controls, power cylinders etc., prescribe certain minimum maintenance requirements which are to be carried out in one of the above two maintenance categories. It is suggested to maintain a defect register in the control room to register all the items, which need maintenance.
Section Overview
This section describes the various maintenance practices, overhauling and preservation techniques. Also discussed are failures and repair techniques.
This section covers the following

RECOMMENDED MAINTENANCE PRACTICES PREVENTIVE MAINTENANCE PROGRAM CONDITION BASED MAINTENANCE Maintenance check list for daily, weekly, Monthly and Annual inspection SHUTDOWN AND COOLING THE BOILER INSPECTION AFTER COOLING PRESSURE PART & EQUIPMENT CHECKS BOILER PRESERVATION TUBE THICKNESS SURVEY WELDING PROCEDURE SPECIFICATIONS TUBE FAILURE INVESTIGATION PLUGGING TUBES REPAIRED AND NOT PLUGGING TUBES REPLACEMENT OF SECTIONS OF TUBES
2.1 Preventive Maintenance

The objective of the preventive maintenance program is to obtain trouble free service from the component till the next maintenance. Vendor manuals for various equipments suggest inspection periods, checks to be done and recommended spares. The true objective of the maintenance program can only be realized, if a master plan of maintenance of all the components is prepared as per vendor instructions. Full benets of maintenance can be obtained only if proper parts are used. Mandatory spare part list covers most of the spares required. It may be found that in the rst two years of operation due to variations of site conditions, some additional spares not included are also required. Action has to be initiated to procure such spares. Some equipment have 100% reserve standby units. (Feedwater pumps etc.). Maintenance of such equipments can be organized even when the boiler is in service, although some minimum risk is involved. Equipment such as igniters, scanners have replacement spares which can be utilized when the working equipment are to be maintained without affecting the boiler operation. The prepared master plan for maintenance should be periodically reviewed during the rst three years of the boiler operation. It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are either too much or too less. Based on site experience, the frequencies and work schedules can be modied. A scientic method of preparation of the preventive
Recommended Maintenance Practice
Systematic maintenance is essential to keep the boiler and its auxiliaries in good condition and to obtain reliable operation of the boiler with high availability and plant load factor. Effective maintenance aims at timely inspection of parts to repair or replace defective components and to prevent their failure when the boiler is in service. Maintenance can be classied as -
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maintenance schedules is to make them condition based. In condition based maintenance, the equipment and components of the plant are inspected daily, weekly monthly etc., as per a suggested schedule by the local operators and deteriorating conditions if any observed are reported. Suggested inspection program is given in this section. Based on operator reports of such inspection, maintenance works are planned for the next available planned shut down. Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the equipment condition. 2.1.1Preventive Maintenance Program for Valve A preventive maintenance program for valves once in two years can be done with one or more of the following works: Dismantle the bonnet, clean the trim and valve seat, lapping them if necessary. Cleaning the valve stem and re-lubrication of the operating threads Renewing the bonnet joint, and assembling the trim on the valve seat Renewing the gland packing Renewing the valve ange joint, if necessary. 2.1.2Preventive Maintenance Program for Spares It may be found that in the rst two years of operation due to variations of site conditions, some additional spares are also required. Action has to initiate to procure such spares. The prepared master plan for maintenance should be periodically reviewed during the rst three years of the boiler operation. It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are either too much or too less. Based on site experience, the frequencies and work schedules can be modied. A scientic method of preparation of the preventive maintenance schedule is to make them condition based.
In condition based maintenance, the equipment and components of the plant are inspected daily, weekly, monthly etc. as per suggested schedule by the local operators and the deteriorating conditions if any observed are reported. Suggested inspection program is given in this chapter. Based on operator reports of such inspection, maintenance works are planned for the next available planned shutdown. Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the equipment condition.
Conditioned Based Maintenance
The schedule of daily, weekly and monthly inspections given in the following pages do not require a boiler shutdown and in fact can only be done when the boiler is in service. Three and six monthly inspections are done utilizing an available planned shutdown approximately in the specied time period. Objective of these inspections is to ensure that: 1. The components are in trouble free condition. 2. To carry out any minor repairs or adjustments which can be done with the boiler in service. 3. To plan for repair of such items, which cannot be attended when the boiler is in service, during the next available shutdown. 4. To collect a database to determine optimum service life of the systems and components before maintenance if required. The schedule can be expanded, curtailed or modied based on experience in the rst two years of operation.
3.1 Daily Checks

To be done once a day by the local operator during his walkdown checks. Such walkdown checks are to be encouraged to be done in each shift by the local operators. Only those operational checks, which require maintenance work for correction, have been included.
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EQUIPMENT Local level gauges on steam drum
CHECK Check illumination is proper. Leaking valve glands. leaking ports Blurred level
WORK TO BE DONE Replace fused bulbs. Isolate level gauge and tighten leaking glands. Replace leaking ports. Steam wash mica as suggested by vendor (not to be done too frequently)
Comparison of levels indicated by local level gauge with that of remote level indicators in the control room Traces of water, oil spots on boiler oor, buck stay beams, boiler cladding etc.
Compare the levels after verifying there are no leaks from valves, glands etc. of the level gauge and indicators. Report discrepancies. Such spots are indicative of valve leaks, instrument tapping leaks etc., Trace the source of leak.
If there are serious discrepancies calibration of the remote level indicators has to be planned immediately. Maintenance to be planned to eliminate the source either immediately or during next planned shut down (depending on the source and quantity of leak) and accessibility for maintenance. Top up if required (immediately) If leakage through oil seals, gaskets drain plugs etc. are noticed plan for maintenance during next planned shutdown.
Lubricating oil levels of Fans, & feed pumps bearings, dosing pump gear box etc.
Check adequacy of oil level.
Fans, BFW pumps dozing pumps
Check bearing temperatures . Check for Vibration Levels
If higher than normal bearing temperatures are noticed check for cause proper oil level, correct grade and quality of oil or grease, abnormal sound or vibration. If bearing temperatures are very high, start the reserve equipment ( if avl.) and plan for a maintenance checks . If vibrations are above the satisfactory limits. Check for mechanical looseness and start the reserve equipment ( if avl.) and plan for a maintenance check.
Drum and super safety valves.
heater
Check for passing of safety valves (noise or wisp of steam through silencer)
Hand pop the affected safety valve one or two times to clear any dirt sticking to the valve seats Lightly tap on the stem of the safety valves. If these measures do not succeed, if request for check of the safety valve during next planned shutdown.
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EQUIPMENT Purity of instrument air
CHECK Check by visual observation that the instrument air is oil and moisture free. (Oil and moisture content can also be checked by laboratory examination as per standards)
WORK TO BE DONE Oil and moisture in the instrument air is likely to clog the positioners of pneumatic controllers / solenoids and make their operation sluggish or unreliable. Open drain valves of air receivers for short time to drain condensate if any. If these measures not successful, inform Maintenance group. are the
Fan suction damper linkages and their power cylinders
Check for their proper operation
Sluggish operation of fan suction damper may be due to stuck linkage, stuck damper, faulty power cylinder and faulty positioner. Sluggish operation of air register dampers may be due to stuck air register vanes, faulty power cylinders and faulty positioner. Check for possible cause. Maintenance works have to be planned. Tighten the gland nuts. If the leakage not getting arrested, plan for maintenance during shut down. Tighten the bolts. If the gasket failed then plan for the maintenance during shut down.
Steam or water leakages from valves and from ange joints
Loose valve gland Loosened bolts of ange joint and / or failed gasket.
Boiler cladding, air duct or ue gas duct.
Check for hot spots
Hot spots may be due to leakage of ue gas or hot air. Source of leakage has to be located after selective removal of insulation (to be planned for the next planned shutdown)
3.2 Daily Maintenance
5. Check for unusual noises for steam / water leakage.
Maintenance Operation
Check
List
During
6. Check for unusual noises for from fans / pumps. 7. Check for vibration in rotary equipments. 8. Check for unusual traces of water on oor, buck stays or casings 9. Check for valve & gland leakages. 10. Check for air / gas leakages from ducts and ue. 11. Check for any coal / dust / ash leakages from chutes and hoppers
1. Check the correctness of water level in the control desk with direct level glass. 2. Check the illumination. level indicators for proper
3. Check the combustor for proper uidization through peep holes 4. Drain the bed and check for unusual combustibles in the bottom ash.
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12. Check for hot spots, bulging etc. on casings, ducts etc. 13. Check the cleanliness positions of dampers and
17. Check all alarm annunciation with respect to set points. 18. Check for water, oil along with instrument air 19. Check the eld instruments for its proper indications. 20. Check the stack for any unusual smoke conditions.
14. Check for safety valve steam leakages. 15. Check the bearings for lubrication and cooling water systems. 16. Check the fan damper linkages for lubrication and cleanliness. Igniters
3.3 Weekly Checks

Remove the spark device, clean and check spark gap. Check insulation resistance of the spark device. Check healthiness of the HT transformer. Check BMS sequence for energizing HT transformer and opening of block valve
At Least once a week each ignitor must be tested for its performance by manual command from BMS local panel. If an ignitor fails to light up on command the Ignitor requires be servicing and keeping in working condition.
3.4 Monthly Checks

Fans, Dosing pumps, With the vibration analyser record vibration, sound levels and measure bearing temperature Note the pressure, ow of air, suction damper opening, (Capacity of the FD Fan) pressure (seal air blowers, HP dosing pump) By monthly recording of data, establish a data base for deciding the overhaul time of the equipment. An overhaul once in two or three years may be adequate. Database will help in deciding the time frame. Sharp increase in vibration levels bearing temperatures or sound levels may call of early scheduling of overhauls. By monthly recording of data, establish a database for deciding the overhaul time of the equipment. An overhaul once in two or three years may be adequate. Database will help in deciding the time frame. Sharp increase in vibration levels bearing temperatures or sound levels may call of early scheduling of overhauls. If necessary do the adjustments. Clean with normal water
BFW pumps
Check for coupling alignment between motor and pump. Check the impeller is not rubbing with pump body. Check operation of NRV at pump discharge.
Safety valve operation Feed water tank / internals
Increase the boiler pressure and check the operation of valves. Deposits of foreign particles
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Dosing system
Cleanliness of dosing tank, operation of pressure relief valve, lubrication oil level in pump. Choking of impulse tubes Liquid level in manometer Close the steam out let valve and gas by pass damper. Open blow down valve and check for level switch very low alarm.
Clean dosing tank with normal water, Adjust relief valve ,if required Fill lubrication oil , if required Clean impulse tube with air Keep liquid level at zero If switch or alarm is not working, do the rectication work.
D P Manometer Level switch for steam drum water level very low
3.5 Checks Every Six Months

During a planned shut down of the boiler, the following checks can be done. EQUIPMENT Boiler safety interlocks, start permissive, boiler trip protection. CHECK Coinciding with a planned shut down of boiler, carry out the checks to identify malfunctioning or sluggish pressure, temperature switches, solenoid operated valves, positioners, proximity switches, actuators etc., Visual check that there are no loose bricks, spalling or cracks WORK TO BE DONE Plan for maintenance or re-calibration of defective items if any noticed, during the shut down period.
Combustor / refractory work.
Burner
If any abnormalities are seen repair works to be planned during next available shut down
3.6 Checks Every Year

(See also jobs listed under Boiler overhaul) EQUIPMENT Pressure temperature, Flow level, differential pressure controllers CHECK Utilizing the boiler annual shut down for overhaul, recalibrate all pressure, temperature, ow, level and d/p controllers as per vendor manuals Recalibrate, Verify functioning of pressure/temperature switches as per design Verify functioning of positioners and actuators by feeding current inputs to positioners and measuring the air pressure output of the positioners and opening closing of actuators WORK TO BE DONE Carry out any maintenance replacement or adjustment needed to secure initial calibration values as per commissioning records Repairs or necessary adjustments as
Pressure gauges, temperature gauges, Pressure/temperature Switches Positioners, actuators
Repairs or adjustments as necessary as per vendor manuals to obtain performance as per Verify commissioning records. functioning of proximity switches where provided. Clean lters of air regulators. Check functioning of air regulators. Verify tightness of air connections.
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3.7 Annual Maintenance Check Sheet

COMPONENT NAME Drums (water side ) Corrosion Scale / deposits Pitting Metal reduction Manhole seat Process / instrument tappings Internal cleanliness Steam purier Assly in steam Drum Corrosion Deposits Erosion Tightness Pittings Sealings Bafes Feed water pipe in steam drum. Plugging Tightness Holes orientation Corrosion Piping Chemical dosing Plugging INSPECTION REQD FOR
Pipe in steam drum
Tightness Holes orientation Corrosion / Pitting
Continuous blow down Pipe in steam Drum
Plugging Tightness Hole orientation Corrosion / pitting
Furnace tubes (water side)
Corrosion Scale Pitting Metal reduction
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COMPONENT NAME Furnace tubes (gas side) Corrosion Build up Blisters Sagging
INSPECTION REQD FOR
Over heating Fly ash erosion Sealing Supports Cracks Expansion clearance Steam impingement Refractory status Insulation Erosion Inbed evaporator coils re side Erosion Corrosion Build up Blisters Sagging Over heating Sealing Cracks Steam impingement Refractory status Super heater if provided. (steam side) Corrosion Erosion Scale Pitting Metal reduction Flare cracking Deposits
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COMPONENT NAME Super heaters if provided. (gas side) Corrosion Build up Sagging
INSPECTION REQD FOR
Over heating Fly ash erosion Sealing Supports Cracks Exp clearance Steam impingement Refractory status Insulation Economiser (water side) Economiser (gas side) Corrosion Scale Pitting Corrosion Build up Blisters Sagging Over heating Fly ash erosion Sealing Supports Cracks Expansion clearance Steam impingement Tightness of access Doors Refractory Looseness Missing pieces Erosion Sealing burner throat Refractory Flame impingement on refractory Refractory holding arrangements. Bafe tile status
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COMPONENT NAME Corrosion Erosion Leakages
INSPECTION REQD FOR
Clearance between Rotor and casing Damper operating Mechanisms Bearings conditions Bearings clearances Lubrication argt. Cooling water argt. Fly ash deposits Shaft seals conditions Coupling alignment Air preheater Cooling discs. Gas side plugging/Sealings Gas side cleanliness Air side cleanliness Gas side corrosion Air side sealing Drive mechanisms ( if any) Soot blower status (if any) Dampers Blades rigidity Open/ close positions Expansion clearance condition of blades Erosion of blades Bearing freeness Lubrications Damper linkages Interlock mechanisms.
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COMPONENT NAME Convection pass
INSPECTION REQD FOR Erosion and material accumulation. Signs of gas channeling. Water walls for erosion patterns. Economiser support beams for erosion. Lower water wall headers for erosion / cracks. Seal at economiser and superheater piping penetration. All penetration for erosion. Superheater supports Furnace rear wall Riser roof For penetrations Sealing and cracks. Walls for erosion at the top of the tube / refractory interface. Roof refractory for erosion or damage. Erosion coupons and pins for the Refractory thinning. Refractory on furnace rear wall outlet header for erosion or damage. Thermocouples and pressure taps for erosion / corrosion. Pressure taps for plugs
All penetration for sealing and erosion. All penetration and plates for warpage or damage. Casing Bent Bulging Gas leakages Access door tightness Corrosion Erosion Water level gauges Cleanliness Leaks Visibility Illumination Reectors Mirrors Gauge cocks status Expansion clearance
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COMPONENT NAME
INSPECTION REQD FOR Internal deposits Insulation High/low water alarms/tripping
Valves
Erosion Corrosion Leakages Spindle movement Handle rigidity Drive mechanisms Lubrications
Safety valves
Valve nozzle conditions Disc seat conditions Corrosion of internals Pitting Cracks Valve spring status Spring stiffness Corrosion of spring
Silencer status
Spring stiffness Drain line status Drain line rigidity Discharge pipe rigidity Expansion clearances Valve settings
Remote level gauges
Cleanliness Leaks Visibility Illumination Gauge cocks status Internal deposits Insulation Liquid status (if any)
Fuel mix nozzles in the pA line
Erosion Alignment Sealing
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COMPONENT NAME Fuel feed nozzles in the combustor Erosion
INSPECTION REQD FOR Divertor ring condition Alignment Sealing
Feed water pumps Dosing pumps Power cylinders Deaerator
As per manuals As per manuals As per manuals Feed pipe/dosing pipe status Spray nozzles status Sediments Corrosion
Combustor
Missing nozzles Erosion Plugging
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Boiler Annual Maintenance and Overhaul
2. Allow the drum to ventilate for about 8 hours. If necessary a fan cooler can be tted over temporary stand to force air through the drum. 3. From the time the drum manholes are opened till they are closed after inspection, the area around the drum must be cordoned to restrict entry only to specically authorized personnel. 4. The names of persons who are entering the drum for inspection, along with tools they carry must be entered in a register. Persons coming out of the drum after inspection should be asked to account for the material they carried into the drum. This precaution is to prevent accidental dropping of foreign material through the water wall tubes, which may block water circulation through them and can cause tube failures. 5. Carry out a preliminary inspection of the drum to check for deposits on the water side of the drum. 6. Using nylon brushes, the deposits (which are normally soft) are cleaned, collected on trays and disposed off outside the drum. Washing down the deposits to the boiler tubes is not recommended. 7. In case of excessive deposits, the chemist is asked to analyze the nature of the deposits. Incase of excessive deposits, a review of phosphate concentrations (higher than 10ppm) and boiler water quality control ( high conductivity ?) may be made to reduce the deposit in the next year of operation. After cleaning the following examinations can be made. 1. Examine the boiler drum metal for scale, pitting, corrosion and metal wastage. (Drum thickness is measured at a few selected spots using ultrasonic instruments and compared to design thickness). 2. Inspect fastenings of the bafes, cyclones, and demisters to see that they are intact, without corrosion pitting or holes. Eroded or corroded drum internals can be patched by welding. No welding however is permitted on the drum metal. The cyclones and demisters can be examined in position. They need not be dismantled. Reasonable water tightness of the bafes and cyclones are to be ensured. 3. Examine that feed water pipe is intact with ange connections tight and discharge exit correctly oriented. 4. Examine that the continuous blow down pipe and dosing pipes is not plugged or corroded
In addition to the check and inspections listed under preventive maintenance, the boiler requires an annual shut down of about 10 to 15 days for cleaning, inspection ad overhaul of boiler pressure parts. The shut down period is restricted to a minimum by deploying adequate resources. If required, Field Engineering department of Thermax Ltd. can assist the customer in carrying out the boiler overhaul. The annual shutdown is utilized for cleaning and inspection of the pressure parts and to collect data on the wear pattern of boiler, superheater and economizer pressure parts. The shutdown opportunity is also utilized for overhaul of safety valves, regulating and isolating valves and components, which can not be attended when the boiler is in service. (The valve overhauls need not be done every year).
4.1 Planning Before Overhaul

1. Prepare a list of jobs to be done during the overhaul based on earlier inspection reports and the jobs listed below. 2. Ensure availability of spares required for the proposed jobs. 3. Ensure tools, tackles, scaffolding materials required for the job. 4. Ensure availability of manpower required for the job (Own sources, contract labour etc) services of Thermax is also available for carrying out annual overhauls and inspections.
4.2 Shutdown and Cooling the Boiler

1. Shutdown the boiler in a planned manner. 2. Dont force cool the boiler. 3. Open all access and inspection doors.
4.3 Inspection after Cooling

1. Carry out a preliminary inspection after cooling to check cleanliness and sign of deposition on water wall panels and needs any cleaning.
4.4 Drum Inspection

1. Open the access doors at either side of the drum.
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their supports are normal, their holes have been correctly oriented. 5. Examine that there are no cracks in the stub welding s of the drum. After the inspection, clean the manhole seats and provide new gaskets. Sometimes the boiler inspector may like to inspect the steam drum. After this inspection and after verifying that all men and material have been removed from the drum, close the manholes and bolt them tight.
4.9 Feed & Boiler Water Conditioning

1. INTRODUCTION The successful use of boiler is dependent on proper water conditioning and treatment. The quality of water must have accurate for trouble free operation of boiler. The water as available to industry is not suitable for boiler use. A complete pre-treatment and internal chemical treatment is necessary to make raw water suitable for boiler feed. The objective of the water treatment is: Eliminate scaling - deposition in boiler which cause tube over heating leading to accidents. Control corrosion of boiler system, which cause failure of boiler tubes, leading to unscheduled shutdowns. Reduce carry over of water with steam, which is the cause of deposition on super heater/turbine blades, leading to the expensive failures. To maintain peak boiler efciency by keeping complete boiler water system clean. In order to meet above objectives, it is necessary to maintain certain chemical conditions in boiler, condense and feed water systems. A brief review of important factors is given in this section to assist those taking charges of new boiler equipment. It is not possible to cover the subject fully, there fore, it is recommended that the care and control of water quality be entrusted to water treatment specialist. 2. NEED FOR WATER TREATMENT A. CORROSSIVE CONTROL Water is corrosive to boiler metal. Typically corrosion due to water will reduce thickness of tube @ 1 mm/year. Thus the life and safety of boiler entirely depends on the rate of corrosion of boiler metal. In order to protect boiler from corrosion, pre-treatment is done to remove excessive corrosion ions like chloride, sulphate etc. However, further chemical conditioning is required to protect boiler and auxiliary systems from corrosion. Tri sodium phosphate, caustic, ammonia and amines are used as corrosion inhibitors. These chemicals form a protective lm over metal surface and reduce corrosion. It is necessary to maintain prescribed concentration of these chemicals in boiler water systems continuously. B. OXYGEN CORROSION INHIBITOR: Oxygen is present in dissolved form in water. At high temperature, oxygen reacts with metal
4.5 Inspection of Screen, Primary & Secondary Superheater, Evaporator I/ II & Economiser
Check the above mentioned sections for any 1. Suspicion of abnormalities. If yes, consult M/s THERMAX LTD or a metallurgist for necessary advice 2. Evidence of pitting / erosion / corrosion on tube outer surfaces (exposed to the ue gas path) 3. Evidence of overheating (bulging of tubes, blue color of tubes, blisters, disturbed vertical alignment of panels) 4.
4.6 Expansion Joints

Examine the expansion joints. Eroded / corroded parts can be patched by welding. When severe erosion is noticed (after several years of service) the expansion joints are to be replaced. Collapse or stretching of the expansion joints is usually due to forces exerted by the connecting ducts. Readjustment of duct supports will solve the problem and will assist the expansion joints to regain their original dimensions.
4.7 Insulation and Cladding

1. Verify insulation as per drawings and correct wherever necessary. 2. Inspect cladding for damages due pitting, hotspots, dislocation etc. Repaired as necessary.
4.8 Other Equipment

Overhaul of fans, pumps, fuel feeders, control valves, actuators etc., is scheduled as per vendor instructions and condition monitoring described under preventive maintenance
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to cause pitting corrosion. Thus prevention of oxygen lead to pin holes in economizer, steam drums and steam tubes. Most of the oxygen is removed externally by deaerator and preheating of feed water. However, traces of residual oxygen must be removed by chemical conditioning. Sodium sulte, hydrazine and amines are recommended for oxygen removal. These chemicals react with residual oxygen making it inactive and protect metal against pitting corrosion. Catalyzed oxygen scavengers are used for quick reaction. C. SCALE / DEPOSIT CONTROL: Raw water contains dissolved solids, hardness salts and suspended matters. External treatment is used to remove such impurities. Clarication - To remove suspended matters. Filtration - To remove residual turbidity Softening - To remove hardness salts Dealkaliser - To remove hardness salts and excessive alkalinity Demineralization - To remove residual salts and silica Mixed bed - To remove residual salts and silica from DM water. A combination of above equipments are used to remove undesirable impurities in raw water. SCALE CONTROL Hardness salts in feed water cause formation in boiler. Under temperature and pressure inside the boiler and due to concentration, hardness salts precipitate in tubes as calcium carbonate, calcium sulphate and Ca/Mg silicate scales. External treatment like softening, demineralization or de-alkalisation removes most of the hardness salts from boiler feed water. However, malfunctioning of this equipment, occasional bypassing of the softener/DM plant or contamination of condensate or feed water with raw water often led to ingress of hardness in the boiler. All hardness salt precipitate inside boiler leading to hard scale formation on tubes. Such scale has lower conductivity causing increase in metal temperature, leading to bursting of tubes in extreme conditions.
Therefore, inspire of elaborate external treatment, internal chemical conditioning is always recommended as additional safety. Following chemical methods are used for internal treatment. PHOSPHATE CONDITIONING Trisodium phosphate is commonly used. Hardness salts react with trisodium phosphate to form calcium phosphate precipitate. This precipitate above pH of 9.5 colloidal in nature and therefore do not allow for form hard scale of carbonate and silicates. The precipitated hardness salts are then removed through blow down as sludge and boiler tubes are kept scale free. Trisodium phosphate, apart from acting as hardness conditioning agent, also is a good corrosion inhibitor. The recommended concentration in boiler water is given in Table -1 Note 1 : TSP will act as hardness conditioner, only when boiler pH is above 9.5 . Below 9.5 pH TSP may cause hard scale formation of Ca3 (PO)2. Therefore, coordinated or congruent phosphate treatment is recommended. The water treatment experts can advise you right treatment after studying your water quality and operation conditions. Thermax Chemicals can provide services for arriving at right chemical treatment for your boiler. Chelant- Polymer treatment: Hardness scales do not precipitate in presence of chelant like NTA/EDTA The chelant treatment is recommended when hardness ingress in boiler is experienced regularly.
Excessive chelant dosing cause corrosion of boiler Hence balanced chelant program as recommended by experts should be used. Organic polymer conditioners are used to prevent hardness scales. Such organic polymer disperse scale forming compounds like CaCO3 & Ca(PO4)2 in colloidal form facilitating their removal through blow down. Polymer and copolymer of acrylic, methacrylic, styrene maleic acrylics are commonly used. Most of the polymers are proprietary in nature and therefore dosage is best recommended by manufacturer. D. FOULING CONTROL
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Suspended matter, oil/grease /oxygen & iron salts commonly cause fouling inside the boiler. Most of the suspended matter and iron salts are removed by external treatment. However due to mfg. of these equipment, contamination through condensate and concentration in boiler cause fouling of boiler tubes. Similar to hardness scales, such foulants are poor conductor of heat. Thus fouling causes overheating of tubes. Fouling can best be avoided by maintaining quality of feed water as per norms. In case of upsets or occasional contamination, polymeric disersent help to prevent fouling due to turbidity and organic matter. Iron is picked up mostly in condensate system due to corrosion of condensate line. In such case, condensate corrosion inhibitor like ammonia cyclohexylamine and lming amine is recommended. E. TURBINE / SUPERHEATER DEPOSITION CONTROL: The solids in boiler feed water get concentrated in boiler. The concentration of solids in boiler is decided blowdown and feed water quality. The carryover of boiler water with steam depends on; Mechanical Factors: Boiler load - Higher the load, lower is the steam purity Water level in boiler - Higher the water level in drum, lower is steam purity. Load Variation - Sudden increase in load reduce steam purity for short time. Separation efciency - Higher efciency, better is steam purity. Chemical Factors: TDS - Higher TDS in boiler, lower is steam purity. Total Alkalinity - Higher alkalinity as % of TDS lower is steam purity Organics - Higher the organic contamination, lower is steam purity. Foaming - Higher the foaming character of water, Lower is steam purity. The water carried over with steam due to above reasons is exactly similar in quality to blow-down or boiler water. In superheater or in turbines, water evaporates, leaving dissolved and suspended matter as scales or deposits.
Thus severity of scaling and fouling of superheater and turbine depends on boiler water quality and steam purity. Maintaining boiler water quality as per norms and maximum steam purity is the only way to prevent deposition due to carryover of water with steam. Antifoam agents help to some extend to improve steam purity in case of excessive in boiler. F. SILICA DEPOSIT CONTROL: Silica is volatile under high temperature and pressure inside boiler. In turbines, the evaporated silica precipitates during pressure and temperature reduction and form hard scales. Maximum allowable concentration of silica depends on water analysis. Experts best decide the maximum permissible concentration after striding the operating parameters. G. CONDENSATE CORROSION CONTROL: The carbon dioxide is present in boiler feed water in dissolved and combined from as carbonate. Under boiler pressure and temperature it is liberated and carried over with steam as CO2 gas. This gas re dissolves in steam condensate to form carbonic acid. CO2 + H2O = H2CO3 H. MAINTENANCE OF PEAK EFFICIENCY: Corrosion, scaling, fouling carryover and condensate corrosion can cause unscheduled shutdown, accidents and deterioration of system efciency.Therefore for trouble free operation and maintenance peak operation efciency, a combination of various internal chemical treatments is essential along with a good control over boiler water quality. Maintaining boiler water quality by using commodity chemicals likes TSP, Hydrazine, and Sodium sulte. However, it is recommended that the care and control of water chemistry be entrusted to specialist.
4.10 Fans
Equipment such as a fan is said to be under preventive maintenance, when it is stopped after some period of operation. 1. De-coupled from its drive, 2. Bearing housing oil (for oil lubrication) is drained,
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3. Top cover of the housing is opened and a visual examination of the bearing is done. 4. The access door of the impeller housing is opened and the impeller blades are cleaned and examined for wear. 5. Defective or worn parts noticed are repaired or replaced. 6. Oil seals O rings if any, are replaced. 7. The tightness of the bolts and nuts, which x the fan casing to the foundation, are checked with a torque wrench. 8. The fan bearing housing cover is assembled and recommended lubricant is lled to the correct level. 9. The expansion joints at the discharge end are checked to see that they are not compressed or expanded 10. Damages if any to the bellows are corrected by patch up. Discharge duct supports are checked and adjusted to their design value. 11. The suction damper bearings / bushings are checked for wear and repaired or replaced as necessary. The travel of the damper is checked and corrected where required. 12. The end shields of the drive motor are opened. 13. The stator-rotor spaces are cleaned blowing a jet of warm air. 14. The bearings are cleaned and re-lubricated. 15. The insulation resistance of the stator coils is measure and compared to their previous values. 16. The end shields are assembled.
17. The motor coupling is aligned to the fan coupling. 18. Trial run of the fan is taken. 19. Bearing vibrations, temperatures, noise levels are measured and compared to previous values. 20. Adjustment if any required (alignment, bearing clearances etc.) are done. 21. The maintenance exercise is successful, if the observed values are better than the values before the shutdown. 22. Another variant of the maintenance can be disassembling the fan to its components level, taking out the bearing, impeller etc. 23. Checking the trueness of the shaft, checking bearings etc. before re-assembly. 24. In the drive motor also, the rotor is taken out and the rotor and stator coils are examined for tightness. 25. The coils are cleaned by air blowing and re varnished.
4.11 Safety Valves, Start Up Vent Valves And Other Isolating Valves
These valves require regular overhauls, normally once in three years even if condition reports do not indicate any abnormality. Earlier overhauls can be scheduled if condition reports warrant. Overhauls of the valves can be staggered after the rst two years of operation in a manner that certain number of valves are overhauled every year. Overhauls of the valves are as per their vendor manuals enclosed.
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Boiler Preservation Procedure
INTRODUCTION Both the gas and waterside of a boiler should be protected against corrosion during out of service periods. It is known that many of the corrosion problems of boiler and auxiliary equipment have their inception during storage. Rusting of tube surfaces, as indicated by the formation of the red hematite (Fe2O3), not only cause a roughened tube surface but also results in attack of parent metal. The advantages of efcient feedwater and boiler water treatment during operation may be lost if the same diligence is not applied to protect heat. Transfer surfaces during idle periods. Protection from corrosion during storage becomes vitally important considering the number of times during the life of a boiler when it and its auxiliary equipment are idle. To minimize the possibility of corrosion, boiler to be placed into storage must be carefully prepared for the idle period and closely watched during the outage. There are two methods available for storing the unit dry storage and wet storage. Although the wet storage procedures is preferred such factors as availability of good quality water, ambient weather conditions, length of storage period, auxiliary supply of heat, etc may dictate that the dry storage procedure is more practical.
nal concentration of 10 ppm (or a pH of 10.0). In this procedure, condensate is considered to be treated demineralised water.
5.2 Dry Storage Preservation

When it is known that a boiler is to be idle for a considerable length of time and that a brief period will be allowed for preparation to return it to service, the dry storage method is recommended. In this method the unit is emptied, thoroughly cleaned internally and externally dried, and then closed up tight to exclude both moisture and air. Trays of lime, silica gel, or other moisture absorbent may be placed in the drums to draw off the moisture in the air trapped by the closing up of the boiler. The following general procedure is recommended when placing a unit into dry storage. 1. Fire the boiler according to the normal start-up procedure and establish upto 3.5-kg/cm2G-drum pressure. Stop ring. Secure the boiler and when the pressure decays to 1.3 kg/cm2G, immediately drain the boiler and headers under air. As soon as possible, open the drums to allow air to circulate for drying of all internal surfaces. This step is included for a unit that has been in service and is to be placed into storage. For a unit that has never been in service, start with Step 2. 2. If the unit is full of water and cold, drain the unit under air. All non-drainable boiler tubes should be blown with compressed air. If an external source of heat is available such as a steam coil air heater, portable heaters, etc., operate these heaters to assist in drying the internal boiler surfaces. Install trays (of non-porous construction and capable of passing through the drum manhole) containing the moisture absorbent (silica gel is preferred) into the drums. Insert the trays into the drum being certain that none of the absorbent comes into contact with the metal surface of the drum. To insure against an overow of corrosive liquid after the moisture has been absorbed, the trays should not be more than full of dry absorbent. The amount of absorbent can vary but the recommended minimum is one pound of absorbent per 1000 pounds per hour steam ow capacity of the unit. 3. Open the isolation valve for nitrogen connection, on the steam drum, close all other vents and drains and pressurize the
5.1 Denitions OF Water Quality

Some cleaning procedures, hydrostatic testing and storage require water of higher quality than others. For the purpose of economy and convenience the lowest water quality consistent with requirements is specied in these various procedures. The terms that identify the different water qualities along with their denitions are list below: Station service water - Water normally used for drinking, re protection, etc. Softened water - Filtered, sodium zeolite softened water with total hardness less than 1 ppm. Two- bed demineralised water - Water then has been passed through cation and anion ion exchanges in series. Mixed bed demineralised water - Water that has been passed through a mixed bed demineraliser. Water from an evaporator is considered to be of equal quality. Treated demineralised water - Mixed bed demineralised water that has 200 ppm of hydrazine and enough ammonia added to give
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boiler to 0.3 to 0.6 kg/cm2G with nitrogen. The amount of nitrogen required will vary according to the volume of the unit. 4. With the boiler pressurized, alternately open all boiler drains to purge air from the unit until pressure decays to zero. It may be necessary to repeat this process several times to reduce the amount of oxygen left in the unit to a minimum. The unit should now be stored under 0.3 to 0.6-kg/cm2G nitrogen pressure maintained at the steam drum. To maintain the nitrogen pressure, all connections and valves should be blanked or tightly closed. Check gas pressure daily to ensure protection. We would recommend that periodic inspection of the unit be performed every 3 months to assure that no corrosive action is taking place and to replenish the absorbent as required. Since air will enter the unit during this inspection, it will be necessary to repeat Steps 3 & 4 to expel the air.
a pH of 10 (for demineralised water, this will require approximately 10 ppm ammonia). 2. We strongly recommend pre-mixing of the chemicals with the water to insure a uniform mixture entering the boiler. This can be accomplished by the blend-ll method. The blend-ll method consists of blending the chemicals with the demineralised water at a continuous rate such that a uniform mixture is entering the boiler. Simply introducing the chemicals through the drum after establishing water level will not insure adequate dispersion of chemicals to all internal surfaces, unless sufcient heat is delivered to the furnace (i.e. ring the boiler) to induce natural circulation throughout the boiler. 3. Fill the unit with the treated demineralised water to the normal centerline of the steam drum. Stop lling further. 4. Back-ll the with treated Demineralised water until a rise in steam drum level is noted. Continue lling until water exits from the steam drum vents. After lling, all connections should be blanked or tightly closed. 5. A source of low-pressure nitrogen should be connected at the steam drum to maintain 0.3 to 0.6 Bar G to prevent air from entering the unit during the storage period.
The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under nitrogen pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum. Before entering drums test to prove that the oxygen concentration is at least 19.5%. The above procedure is intended to include the economizer.
5.3 Wet Storage Preservation

The advantage of employing the wet storage procedure is that the unit is stored completely wet with the recommended levels of chemicals to eliminate a wet-dry interface where possible corrosion can occur. It is suggested that volatile chemicals be used to avoid increasing the level of dissolved solids in the water to be used for storage. In preparing a unit for wet storage, the following procedure is recommended. 1. The unit should be lled with deaerated, Demineralised water treated with 200 ppm hydrazine (N2H4) for oxygen removal and sufcient ammonia (NH3) in order to attain
The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under nitrogen pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum. Before entering drums test to prove that the oxygen concentration is at least 19.5%. If storage continues into winter, ambient temperatures below the freezing point of water create a real hazard to the boiler pressure parts and it will be necessary to provide a means of keeping the unit warm to avoid damage. At some later date when the unit is to be placed into service, the boiler can be drained to normal start-up water level and placed into operation. In some cases, an expansion tank or surge tank (such as a 55-gallon drum) above the steam drum elevation may be required to accommodate volume changes due to temperature changes.
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This tank is equipped with a tight cover and sight glass and contains properly treated water. The tank should be connected to an available opening, such as a vent line at the top of the steam drum in order to create a hydrostatic head. This tank will provide a ready, visual check of water level or in leakage during lay up. A source of low-pressure nitrogen should be connected to the surge tank to maintain 0.3 to 0.6 Bar G to prevent air from entering the unit during the storage period. The treated demineralised water should be analyzed weekly, and when necessary, sufcient chemicals should be added through the chemical feed line, to establish the proper levels recommended. Samples of the treated water can be taken at the continuous blowdown line or any suitable drain connection. No unit should be stored wet when there is any possibility of a temperature drop to the freezing point unless sufcient heat can be provided to the unit to eliminate the danger of water freezing and subsequent damage to pressure parts.
5.5 Hot Draining

If the AFBC shut down is for a short period of less than seven days and during that period maintenance work on pressure parts have to be undertaken, the AFBC can be preserved by hot draining The shut down AFBC is allowed to depressurize upto 2kg/cm2 (g) pressure on the drum. Water level is maintained upto prescribed levels till that time. When the steam drum pressure drops to 1.5 kg/cm2 (g), the air vents of the steam drum, Super heaters, economizer are opened and the AFBC is drained through the economizer, evaporator (or only the sections required) by opening the required drain valves. When all the water is drained, the residual heat of the water wall, economizer, Super Heater and steam drum, ash dries most of the moisture present on the tube surfaces. As the pressure parts remain dry, corrosion is prevented. This method of preservation however is not effective for move than a week.
5.4 Nitrogen Blanket

Nitrogen can be introduced at the following locations 1. Through the steam drum 2. Through the main steam line The nitrogen required to seal the drainable components may be supplied from a permanent nitrogen system or portable tanks located near the vent elevations. Due to differences in plant layout, the owner should choose his own method of piping the nitrogen, either from their permanent system or from portable tanks, to the vent (or drain) locations listed.
5.6 Alkaline Water Dozed With Hyderzine

If a AFBC has to be preserved for long periods (two months or more) an effective method of preservation is to ll the AFBC, Super Heater and economizer with water treated with ammonia to a pH of 10.5 and dozed with 200 PPM or more hydrazine. This water is completely lled in the water and steam space of the AFBC and a pressure of 5 kg/cm2 (g) is maintained in the drum by a pump. This method is effective but requires additional equipment such as a tank, and a pump with a connection to one of the drain headers. All the possible methods of preservation of a shut down AFBC , the nitrogen blanketing method is simple and suitable for the type of preservation, which may be ordinarily required.
The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under nitrogen pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum. Before entering drums test to prove that the oxygen concentration is at least 19.5 %
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5.7 Preservation Of External Surfaces Of Pressure Parts During Long Shut Down
During AFBC shut downs exceeding a few days, the external surfaces of the pressure parts of especially in a chemical plant environment, may come under corrosive attacks by moisture, SO2, SO3 vapors etc.
Keeping inspection doors tightly closed (when no inspection is being planned) may minimise such corrosion. Water lancing with hot water or mild alkaline water once a month may wash out the corrosive components from the external surfaces of the pressure parts. (See maintenance volume)
5.8 Boiler Lay Up Procedures

PROCEDURE Maintain the same hydrazine and ammonia concentration as present during normal operation. Establish 0.3 to 0.6 kg/cm2G nitrogen cap on the steam drum Drain and open only those sections require repair. Isolate remainder of the unit under 0.3 to 0.6 BarG nitrogen pressure where possible. Maintain the same nitrogen and ammonia concentration for water remaining in the cycle Fill the boiler with Polish water having 200 ppm of hydrazine and 10 ppm of ammonia to maintain pH 10. Establish nitrogen cap of 0.3 to 0.6 kg/cm2G over the steam drum.
TYPE OF SHUTDOWN SHORT OUTAGES 4 DAYS OR LESS. UNIT NOT DRAINED
SHORT OUTAGES 4 DAYS OR LESS. UNIT IS DRAINED
LONG OUTAGES LONGER THAN 4 DAYS UPTO 15 DAYS. UNIT IS DRAINED
LONG OUTAGES MORE THAN 15 DAYS - UNIT IS DRAINED.
Dry storage of boiler with nitrogen alone is preferred procedure. Nitrogen cap of 0.3 to 0.6 kg/cm2G to be maintained on the steam drum. Installed silica gel tray in the steam drum to soak moisture if any present in the drum atmosphere.
5.9 Preservation of Rotating Equipments

1. Put the rotating equipment in service once in every 48 hours or atleast once in a week 2. If the equipment is going to be under long shutdown a. Fill bearing block full of oil to preserve the bearing and rotate the Fan/Pump Shaft by 90o once in every 48 hours ( If bearing housing is oil lubricated) b. Rotate the fan / pump shaft by 900 once in 48 hours ( for bearing housings with grease ) c. Cover the bearing block & uncovered portion of shaft with plastic sheets to prevent dust/water ingress
5.10 Preservation of Instruments

1. Cover all eld instruments with plastic sheets 2. Power up the panel instruments and check the operation 3. Keep the control room dust and moisture free 4. Operate control valves, power cylinders once a week and check operation. 5. Operate quick shutoff valves frequently (Twice a week) 6. Ensure that O2 analyzer is powered up and reference air supply is given when ue gas is present. 7. Check operation of Ignition Transformer once in 2 weeks if burners are provided. 8. Check operation of Flame Scanners & Flame Ampliers once in 2 weeks if burners are provided.
d. Ensure no dust/water accumulates on the rotating equipment.
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5.11 Tube Thickness Survey

The following checks relate only to external erosion / corrosion of the tubes and that too qualitatively. To make a quantitative assessment of wastage of tubes (both internal and external) a tube thickness survey using ultrasonic tube thickness gauges is recommended. For a useful tube thickness survey program, measurement locations on inbed evaporators, Furnace water wall, superheaters and economizer tubes must be specied and indicated on a drawing. Vulnerable locations are usually chosen. On request, the Field Engineering Department of TL can establish such a program. Each document should have the following minimum vital information. Tube thickness measurements at the selected locations are made and recorded after water washing and drying, during the rst annual overhaul. The base value is the design thickness of the tubes. Subsequent measurements are made at the same locations, every alternate year. The tube thickness survey provides useful data on corrosion / erosion rates and can alert the owner when serious loss of thickness is noticed. Details with sketches and drawings will give more clarity for analysis Date of inspection Tube no / Coil no. Inner coil / Outer coil details Location. RHS / LHS Clock position. Reference points. Thickness including decimals. Visual observations Condition of studs.
down as soon as possible by following normal shut down procedures (If situation permits). After the exact locations of the leak or leaks are identied, the leaks may be repaired by replacing the failed tube or by splicing in a new section of tube, conrming to IBR code.
An investigation of tube failure is very important so that the condition causing the tube failure can be eliminated and future failures can be prevented. This investigation should include a careful visual inspection of the failed tube and in some cases a laboratory analysis. It is recommended that every effort be made to nd the cause of tube failures before operation is resumed. It should be ensured that, whenever a spool piece is inserted in the failed zone, the weld joint needs to be of proper weld quality. Free from excess weld penetration to avoid any obstruction in the water / steam mixture ow inside the tube. Excess weld penetration can cause internal tube erosion and results in tube failures. It is suggested to have all the joints are x-rayed and interpreted by qualied / experienced radiographer.
6.1 Tube Failure Investigation / Analysis Method

Investigation / analysis methodology is listed as follows, which needs to be followed to nd the actual root cause of the problems. Please ll up the enlcosed form duly lled and the same may be sent to Thermax along with tube sample for analysis.
Tube Failures
Objectives of Failure Investigation

Boiler tube failures are the largest cause of forced outages experienced by a utility. To avoid or minimize outages and the associated economic penalties, it is important to identify the mechanism and root cause of tube failures. Informed visual inspection is often adequate for this purpose, however failure analysis involving detailed metallurgical investigation is necessary. Tube failures may be due to overheating, corrosion, erosion, fatigue, hydrogen damage etc. A failure investigation and subsequent analysis should
Operating a boiler with a known tube leak is not recommended. Steam or water escaping from a small leak can cut other tubes by impingement and set up a chain reaction of tube failures. Large leaks can be dangerous. The boiler water may be lost, the ignition may be lost, and the boiler casing may be damaged. Small leaks can some times be detected by the loss of water in the cycle or system, a loss in boiler water chemicals or by the noise made by the leak. If a leak is suspected the boiler should be shut
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determine the primary cause of a failure, and based on determination, corrective action should be initiated that will prevent similar failures.
Stages of Failure Analysis

Although the sequence is subject to variation, depending upon the nature of a specic failure, the principal stages that comprise the investigation & analysis of a failure are: 1. Collection of background & selection of samples 2. Preliminary examination of the failed part(visual examination & record keeping) 3. Nondestructive testing 4. Mechanical testing (including hardness & toughness testing) 5. Selection, identication, preservation, and/or cleaning of all specimens. 6. Macroscopic examination and analysis(fracture surfaces, secondary cracks, & other surface phenomena) 7. Microscopic examination and analysis 8. Selection & preparation of metallographic sections 9. Examination and analysis of metallographic sections
2. After entering in boiler and before proceeding to tube failure location inspect & record the condition of boiler and pressure parts without disturbing the evidence i.e. distortion of pressure parts/coils, bulging of pressure parts, scaling / lump formation on pressure parts, blockage of ue gas path, other / secondary failures etc. etc. In such case taking photographs will help in great extent in analyzing of the tube failure, boiler problem. The failed pressure part tube should not be hammered, any mechanical impact should be avoided. 3. Inspect the failed tube and record all ndings on the same as well as its adjacent tubes. Carry out dimensional measurement of failed tube and affected adjacent tubes. 4. Number mark the failed tube for its location, ue gas ow, steam ow with oil paint. After completion of inspection, recording and photography, cut the failed tube and affected adjacent tube, if any, with the help of HACKSAW only. Gas cutting of the tubes should be avoided as much as possible. The failed tube, keeping the failed portion in middle should be cut for total length of minimum 350 mm. Immediately after cutting the tube sample both the ends should be covered with plastic caps. While doing this the internal or external scale of tube should not fall down. 5. The failed tube samples nicely packed in plastic bag / wooden case accompanying duly lled format with water chemistry of boiler log sheets should be sent to H.O Pune.
Collection of Background Operating Data

Boiler operating data just before & at the time of a tube failure is very important as it will give information of the service conditions faced by the tube at the time of failure. This operating data should also be co-related with the past operation data & abnormalities if any should be taken care off. Water chemistry analysis, fuel analysis should also form an important part of this data. This data & the metallurgical analysis will help us in true sense to arrive at the exact cause of a tube failure.
Removal of Failed Tube Sample

1. The tube sample should be cut with a hacksaw blade. Gas cutting should be avoided. 2. The sample should be cut approx. 8-10 inches above & below the affected area. 3. & elevation should be marked on the tube sample. 4. The direction of the uid ow should be marked on the tube sample. 5. Immediately after cutting the tube sample both the ends should be covered with plastic caps. While doing this the internal or external scale of tube should not fall down. The failed tube sample nicely packed in plastic bag / wooden case accompanying duly lled format as given below with water chemistry
Investigation of Tube Failure in a Boiler

1. Study the boiler log sheet & water chemistry record prior to tube failure and after tube failure. Preserve the copies of these log sheets. Record, if any abnormality noticed, such as mal operation, malfunction, very high or low temp. / loads, uctuating loads, sudden increase in load or temp., poor water chemistry, start up vent crack open / close etc. etc. (if possible collect and send the water samples, internal scale from drum & tubes, external scale samples).
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of boiler log sheets should be sent to H.O for metallurgical investigations.
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6.2 Tube Thickness Survey Data Collection Format

(FURNACE / BOILER BANK / ECONOMISER TUBES) CUSTOMER : BOILER NUMBER : UNIT NO : DATE OF INSPECTION : COIL NO CLOCK POSITION TUBE THICKNESS STUD LENGTH VISUAL OBSERVATIONS
DATA COLLECTION BY
NAME & SIGNATURE
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6.3 Failure Reporting Formats

THERMAX LIMITED ENERGY BUILDING, D1 BLOCK, MIDC, R.D AGA ROAD, CHINCHWAD, PUNE 411 019 - INDIA TELEPHONE FAX : WEB SITE : EMAIL : 020 66126464 020 27479048 http://www.thermaxindia.com Yashwant1@thermaxindia.com Uumale@thermaxindia.com DEAR CUSTOMER, WE WANT TO HEAR FROM YOU, WE STRIVE TO CONTINUOUSLY IMPROVE THE QUALITY AND PERFORMANCE OF OUR PRODUCTS. WE WOULD LIKE TO HEAR FROM YOU, SHOULD YOU EXPERIENCE PROBLEMS WITH OUR EQUIPMENT OR SHOULD YOU WANT TO SUGESST IMPROVEMENTS, JUST FILL IN THE INFORMATION NEEDED AT THE ENCLOSED FORMAT AND FAX / POST IT TO OUR CUSTOMER SERVICE DEPARTMENT TO THE ABOVE MENTIONED ADDRESS. KINDLY USE ADDITIONAL SHEETS IF REQUIRED. PLEASE PROVIDE ADEQUATE INFORMATION / DRAWINGS REFERENCE / LOG SHEET READINGS ETC FOR PROPER ANALYSIS & FEED BACK WE WILL GLADLY REVIEW YOUR SUGGESTIONS AND REPLY TO YOU WITH IN A REASONABLE TIME. WE ARE AT YOUR SERVICES ALWAYS,
U.S. UMALE DY GENERAL MANAGER (FIELD ENGG.)
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CUSTOMER FEEDBACK FORM COMPANY NAME COMMUNICATION ADDRESS
CUSTOMER DETAILS:
TELEPHONE NUMBER FAX NUMBER E-MAIL ADDRESS CONTACT PERSON OTHER DETAILS (IF ANY) BOILER DETAILS BOILER NUMBER : DATE OF COMMISSIONING; BOILER CAPACITY MCR STEAM PRESSURE STEAM TEMPERATURE FUEL FIRED EQUIPMENT DETAILS S.N 1. 2. PROBLEM DETAILS OBSERVATIONS CORRECTIVE ACTIONS TAKEN COMMENTS / RECOMMENDATIONS
OTHER INFORMATION: EXPECTATIONS FROM TBW : REPLY AWAITED / SERVICE ENGINEER VISIT :
SIGNATURE & DATE
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Water Chemistry
D) IRON: Most common soluble iron in water is ferrous bicarbonate. The water containing ferrous bicarbonate deposits becomes yellowish and reddish sediment of ferric hydroxide if exposed to air. Majority of ground surface water contains less than 5 ppm but 0.3 ppm, can create trouble in the feed water system by soft scale formation and accelerating the corrosion. E) MANGANESE: It also occurs in similar form as iron and it is also equally troublesome. F) SILICA: Most natural water contains silica ranging from 1 to 100 ppm. Its presence is highly objectionable as it forms very hard scale in boilers and forms insoluble deposits on turbine blades. In modern high-pressure boilers its presence is reduced as low as 10-50 ppm. G) MICROBIOLOGICAL GROWTHS: Various growths occur in surface water (lake and river). The microorganisms include diatons, molds, bacterial slimes, algae; manganese and sulfate reducing bacteria and many others. These can cause coating on heat exchanger and clog the ow passages and reduce the heat transfer rates. H) COLOR: Surface waters from swampy areas become highly colored due to decaying vegetation. Color of feed water is objectionable as it causes foaming in boilers and may interfere by chlorinating of absorption by activated carbon.
INTRODUCTION The natural water contains solid, liquid and gaseous impurities and therefore, this cannot be used for the generation of steam in the boilers. The impurities present in the water should be removed before its use for steam generation. The necessity for reducing the corrosive nature and quantity of dissolved and suspended solids in feed water has become increasingly important with the advent of high pressure, critical and supercritical boilers. The impurities present in the feed water are classied as given below 1. Un dissolved and suspended solid materials. 2. Dissolved salts and minerals. 3. Dissolved gases. 4. Other materials (a soil, acid) either in mixed and unmixed forms.
7.1 Undissolved and Suspended Solid Materials

A) TURBIDITY AND SEDIMENT: Turbidity in the water is suspended insoluble matter including coarse particles (mud, sediment sand etc,) that settle rapidly. Amounts ranges from almost zero in most ground waters and 60,000 ppm. in muddy and turbulent river water. The turbidity of feed water should not exceed 5 ppm. These materials can be removed by settling coagulation and ltration. Their presence is undesirable because heating or evaporation produces hard stony scale deposits on the heating surface and clog uid system. Both are objectionable as they cause damage to the boiler system. A standard of measurement of hardness is taken as being the amount of calcium carbonate (CaCO3) in the water and is referred to in part per million (ppm) or grains per gallon (grain/gallon) X 17.1 = ppm. B) SODIUM AND POTASSIUM SALTS: These are extremely soluble in water and do not deposit unless highly concentrated. Their presence is troublesome as they are alkaline in nature and accelerate the corrosion. C) CHLORIDES: Majority of the chloride corrosive action of water. causes increased
7.2 Dissolved Salts and Minerals

A) CALCIUM AND MAGNESIUM SALTS: The calcium and magnesium salts present in the water in the form of carbonates, bicarbonates, sulfates and chlorides. The presence of these salts is recognized by the hardness of the water (hardness of water is tested by soap test). The hardness of water is classied as temporary and permanent hardness. The temporary hardness is caused by the bicarbonates of calcium and magnesium and can be removed by boiling. The boiling converts the soluble bicarbonates into less soluble carbonates, which can be removed by simple blow-down method. The presence of chlorides, sulfates and nitrates of calcium
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cause the permanent hardness of the water and magnesium and they cannot be removed just by boiling because they form a hard scale on heating surfaces.
7.3 Dissolved Gases

A) OXYGEN: It presents in surface water in dissolved form with variable percentage depending upon the water temperature and other solid contents in water. Its presence is highly objectionable, as it is corrosive to iron, zinc, brass and other metals. It causes corrosion and pitting of water lines, boilers and heat exchangers. Its effect is further accelerated at high temperature. B) CARBON DIOXIDE: The river water contains 50 ppm & well water contains 2-50 ppm of CO2. It also helps to accelerate the corrosive action of oxygen. The other gases are H2S, CH4, N2 and many others but their percentage are negligible Therefore their effects are not discussed here.
number denoting the degree of acidity or alkalinity of a substance. It does not indicate the quantity of acid or alkali in a solution as found by ltration method. It is derived by measuring the amount of hydrogen ion (H+) in grams per liter of solution. The greater the amount of hydrogen ions present in solution its acid reaction becomes stronger. Therefore, pure water is being neutral solution, any solution producing more hydrogen ion than pure water will be acidic and degree is governed by difference and other solution producing less hydrogen ions than pure water will be alkaline and the degree is also governed by the difference. THE ROLE OF pH IN CORROSION: The role of pH in corrosion of metals is extremely important. The corrosion rate of iron in the absence of oxygen is proportional to pH up to a value of 9.6. At this point, hydrogen gas formation and dissolving of iron practically stops. This is the came pH produced by a saturated solution of ferrous hydroxide Fe (OH) 2. The Oxygen in the water unites with ferrous hydroxide to form ferric hydroxide. This reaction lowers pH of the solution and levels to stimulate corrosion. Alkalinity adjustment and lm formation are closely related. The pH value of feed water should be maintained greater than 9.6 to reduce the corrosion effects caused by the reason mentioned above. The required alkalinity of feed water is adjusted by adding soda ash caustic soda or trisodium phosphate. The calcium hardness, alkalinity and pH are inter-related variables in scale control. Calcium carbonate is one of the most troublesome deposits responsible for scale formation.
7.4 Other Materials

A) FREE MINERAL ACID: Usually present as sulfuric or hydrochloric acid and causes corrosion. The presence is required by neutralization with alkalis. B) OIL: Generally the lubricating oil is carried with steam into the condenser & thorough the feed system to the boiler. It causes sludge, scale & foaming in boilers. Strainers and bafe separators generally remove it. The effects of all the impurities present in the water are the scale formation on the different parts of the boiler system and corrosion. The scale formation reduces the heat transfer rates and clogs the ow passage and endangers the life of the equipment by increasing the temp above the safe limit. The corrosion phenomenon reduces the life of the plant rapidly. Therefore it is absolutely necessary to reduce the impurities below a safe limit for the proper working of the power plant.
7.6 Effects of Impurities

The major troubles caused by the feeding of water of undesirable quality are scale formation, corrosion, foaming, caustic embrittlement, carry-over and priming. The details described below: 1. SCALE FORMATION Feed water containing a group of impurities in dissolved and suspended form ows into the Boiler for continuos generation of Steam. With conversion of water into steam in Boiler, solids are left behind to concentrate the remaining water. The scale formation tendency increases with the increase in temperature of feed water. Because, the solubility of some salts (as calcium sulphite) decreases with the increase in feed water temperature. Calcium sulphite has solubility
7.5 pH Value of the Water and its Importance

The pH value of the feed water plays very important controlling the corrosion. pH is a
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of 3200 ppm. at 15 Deg. C and it reduces to 55 ppm. at 230 Deg. C and 27 ppm. At 320 Deg. C. Scale formation takes place mainly due to salts of calcium and magnesium. Sometimes, it is cemented into a hard mass by Silica. Among all, calcium is the principal offender and particularly, Calcium sulphate, magnesium sulphate and other Chlorides are sufciently soluble in water and are not much troublesome. Sodium salts are highly soluble in water and are non-scale forming. The scale formation takes place mainly in feed water piping and Boiler Tubes. Its rst effect on the piping system is to choke the ow of water by reducing the ow area and increases the pressure required to maintain the water delivery. Another effect of scale formation is to reduce the transfer of heat form the hot gases to water. Real dangers of the scale formation exist in radiant heat zone where boiler tubes are directly exposed to the combustion. The scale formation retards the ow of heat and metal temperature increases. Even a thin layer of scale in high heat zone can over-heat the metal enough to rupture the tubes. The metal tubes weakened due to over-heating yield to pressure providing a protrusion known as bag. Such bag provides a pocket for the accumulation of sludge and scale, which eventually causes failure. The over-heating of metal causes layer of metal to separate and form a blister. 2. CORROSION The corrosion is eating away process of boiler metal. It causes deterioration & failure of the equipment, eventually this cause for major repairs or expensive shut -downs or replacements. The corrosion of boilers, economizers, feed water heaters & piping is caused by an acid or low PH in addition to the presence of dissolved oxygen & carbon dioxide in the boiler feed water. The presence of oxygen is mostly responsible for corrosion among all other factors. The permissible limit of oxygen content varies with the acidity of water. Generally it should not should exceed 0.5 cc per liter .O2 generally enters into closed system through make up condenser leakage and condensate pump packing. CO2 is next to O2, which is responsible for corrosion. The CO2 comes out of bicarbonates on heating and combines with water to form weak acids known as carbonic acid. This acid slowly reacts with iron and other metals to form their bicarbonates. The newly formed bicarbonates of metals decompose by heat once more and CO2 is again liberated. This gas again unites with water
to form carbonic acid and the cycle is repeated. Adding alkali solution to neutralize acids in water and raise the PH value can minimize the corrosion. The effect of CO2 is minimized by the addition of ammonia or neutralizing the amines in water. This is necessary because CO2 lowers the PH of the boiler feed water and dissolved solids to leave the boiler. The priming is a violent discharge of water with steam from the boiler. It can be compared to the pumping of water that frequently accompanies rapid heating in a open vessel. In priming the water level in the boiler undergoes rapid and great changes and there are violent discharges of bursting bubbles. Therefore sludge of boiler water is thrown over with the steam. The priming is caused due to improper boiler design, improper method of ring, overloading, sudden load changing or a combination of these factors. The priming effect is reduced by installing steam purier, lowering water level in the boiler and maintains constant load on boilers. The foaming is the formation of small and stable bubbles throughout the boiler water. The high percentage of dissolved solids, excessive alkalinity and presence of oil in water are responsible for foaming. Boiler water solids are also carried over in the moisture mixed with steam even when there is no indication of either priming or foaming. This is known as carry-over. The carry-over of boiler water solids is partly a mechanical and partly a chemical problem. The amount of suspended solids and alkalinity in the boiler water is also important in addition to other reasons like boiler design, high water level, and overloading and uctuating loads on boiler. 3. CAUSTIC EMBRITTLEMENT The caustic embrittlement is the weakening of boiler Steel as a result of inner crystalline cracks. This is caused by long exposure of boiler steel to combination of stress and highly alkaline water. The course of embrittlement takes place under following condition: a) When boiler water contains free hydroxide, alkalinity and some silica. It has been always found that the feed water was high in sodium bicarbonate, which broke down into sodium carbonate in the boiler and partially hydralized as shown by the following reaction in case of embrittlement.
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Na2CO3 + HOH = CO2 + 2 NaOH b) Slow leakage of boiler water through a joint or seam. c) Boiler metal is highly stressed at the point of leakage. This may be caused by faulty design and expansion etc. The prevention of caustic embrittlement consists of reducing the causticity or adding inhibiting agents to the feed water. The most practical method of preventing caustic embrittlement is to regulate the chemical composition of the boiler water. The obvious solution to embrittlement is to eliminate all free NaOH from feed water by addition of Phosphates.
boiler entirely depends on the rate of corrosion of boiler metal. In order to protect boiler from corrosion, pre-treatment is done to remove excessive corrosion ions like chloride, sulphate etc. However, further chemical conditioning is required to protect boiler and auxiliary systems from corrosion. Tri sodium phosphate, caustic, ammonia and amines are used as corrosion inhibitors. These chemicals form a protective lm over metal surface and reduce corrosion. It is necessary to maintain prescribed concentration of these chemicals in boiler water systems continuously. B. OXYGEN CORROSION INHIBITOR: Oxygen is present in dissolved form in water. At high temperature, oxygen reacts with metal to cause pitting corrosion. Thus prevention of oxygen lead to pin holes in economizer, steam drums and steam tubes. Most of the oxygen is removed externally by deaerator and preheating of feed water. However, traces of residual oxygen must be removed by chemical conditioning. Sodium sulte, hydrazine and amines are recommended for oxygen removal. These chemicals react with residual oxygen making it inactive and protect metal against pitting corrosion. Catalyzed oxygen scavengers are used for quick reaction. C. SCALE / DEPOSIT CONTROL: Raw water contains dissolved solids, hardness salts and suspended matters. External treatment is used to remove such impurities. Clarication - To remove suspended matters. Filtration - To remove residual turbidity Softening - To remove hardness salts Dealkaliser - To remove hardness salts and excessive alkalinity Demineralization - To remove residual salts and silica Mixed bed - To remove residual salts and silica from DM water. A combination of above equipments are used to remove undesirable impurities in raw water. SCALE CONTROL Hardness salts in feed water cause formation in boiler. Under temperature and pressure inside the boiler and due to concentration, hardness salts
7.7 Feed & Boiler Water Conditioning

1. INTRODUCTION The successful use of boiler is dependent on proper water conditioning and treatment. The quality of water must have accurate for trouble free operation of boiler. The water as available to industry is not suitable for boiler use. A complete pre-treatment and internal chemical treatment is necessary to make raw water suitable for boiler feed. The objective of the water treatment is: Eliminate scaling - deposition in boiler which cause tube over heating leading to accidents. Control corrosion of boiler system, which cause failure of boiler tubes, leading to unscheduled shutdowns. Reduce carry over of water with steam, which is the cause of deposition on super heater/turbine blades, leading to the expensive failures. To maintain peak boiler efciency by keeping complete boiler water system clean. In order to meet above objectives, it is necessary to maintain certain chemical conditions in boiler, condense and feed water systems. A brief review of important factors is given in this section to assist those taking charges of new boiler equipment. It is not possible to cover the subject fully, there fore, it is recommended that the care and control of water quality be entrusted to water treatment specialist. 2. NEED FOR WATER TREATMENT A. CORROSSIVE CONTROL Water is corrosive to boiler metal. Typically corrosion due to water will reduce thickness of tube @ 1 mm/year. Thus the life and safety of
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precipitate in tubes as calcium carbonate, calcium sulphate and Ca/Mg silicate scales. External treatment like softening, demineralization or de-alkalisation removes most of the hardness salts from boiler feed water. However, malfunctioning of this equipment, occasional bypassing of the softener/DM plant or contamination of condensate or feed water with raw water often led to ingress of hardness in the boiler. All hardness salt precipitate inside boiler leading to hard scale formation on tubes. Such scale has lower conductivity causing increase in metal temperature, leading to bursting of tubes in extreme conditions. Therefore, inspire of elaborate external treatment, internal chemical conditioning is always recommended as additional safety. Following chemical methods are used for internal treatment. PHOSPHATE CONDITIONING Trisodium phosphate is commonly used. Hardness salts react with trisodium phosphate to form calcium phosphate precipitate. This precipitate above pH of 9.5 colloidal in nature and therefore do not allow for form hard scale of carbonate and silicates. The precipitated hardness salts are then removed through blow down as sludge and boiler tubes are kept scale free. Trisodium phosphate, apart from acting as hardness conditioning agent, also is a good corrosion inhibitor. The recommended concentration in boiler water is given in Table -1 Note 1 : TSP will act as hardness conditioner, only when boiler pH is above 9.5 . Below 9.5 pH TSP may cause hard scale formation of Ca3 (PO)2. Therefore, coordinated or congruent phosphate treatment is recommended. The water treatment experts can advise you right treatment after studying your water quality and operation conditions. Thermax Chemicals can provide services for arriving at right chemical treatment for your boiler. Chelant- Polymer treatment: Hardness scales do not precipitate in presence of chelant like NTA/EDTA The chelant treatment is recommended when hardness ingress in boiler is experienced regularly. Excessive chelant dosing cause corrosion of boiler Hence balanced chelant program as recommended by experts should be used. Organic polymer conditioners are used to prevent hardness scales. Such organic polymer disperse scale forming compounds like CaCO3 & Ca(PO4)2 in colloidal form facilitating their removal through blow down. Polymer and copolymer of acrylic, methacrylic, styrene maleic acrylics are commonly used. Most of the polymers are proprietary in nature and therefore dosage is best recommended by manufacturer. D. FOULING CONTROL Suspended matter, oil/grease /oxygen & iron salts commonly cause fouling inside the boiler. Most of the suspended matter and iron salts are removed by external treatment. However due to mfg. of these equipment, contamination through condensate and concentration in boiler cause fouling of boiler tubes. Similar to hardness scales, such foulants are poor conductor of heat. Thus fouling causes overheating of tubes. Fouling can best be avoided by maintaining quality of feed water as per norms. In case of upsets or occasional contamination, polymeric disersent help to prevent fouling due to turbidity and organic matter. Iron is picked up mostly in condensate system due to corrosion of condensate line. In such case, condensate corrosion inhibitor like ammonia cyclohexylamine and lming amine is recommended. E. TURBINE / SUPERHEATER DEPOSITION CONTROL: The solids in boiler feed water get concentrated in boiler. The concentration of solids in boiler is decided blowdown and feed water quality. The carryover of boiler water with steam depends on; Mechanical Factors: Boiler load - Higher the load, lower is the steam purity Water level in boiler - Higher the water level in drum, lower is steam purity.
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Load Variation - Sudden increase in load reduce steam purity for short time. Separation efciency - Higher efciency, better is steam purity. Chemical Factors: TDS - Higher TDS in boiler, lower is steam purity. Total Alkalinity - Higher alkalinity as % of TDS lower is steam purity Organics - Higher the organic contamination, lower is steam purity. Foaming - Higher the foaming character of water, Lower is steam purity. The water carried over with steam due to above reasons is exactly similar in quality to blow-down or boiler water. In superheater or in turbines, water evaporates, leaving dissolved and suspended matter as scales or deposits. Thus severity of scaling and fouling of superheater and turbine depends on boiler water quality and steam purity. Maintaining boiler water quality as per norms and maximum steam purity is the only way to prevent deposition due to carryover of water with steam. Antifoam agents help to some extend to improve steam purity in case of excessive in boiler.
F. SILICA DEPOSIT CONTROL: Silica is volatile under high temperature and pressure inside boiler. In turbines, the evaporated silica precipitates during pressure and temperature reduction and form hard scales. Maximum allowable concentration of silica depends on water analysis. Experts best decide the maximum permissible concentration after striding the operating parameters. G. CONDENSATE CORROSION CONTROL: The carbon dioxide is present in boiler feed water in dissolved and combined from as carbonate. Under boiler pressure and temperature it is liberated and carried over with steam as CO2 gas. This gas re dissolves in steam condensate to form carbonic acid. CO2 + H2O = H2CO3 H. MAINTENANCE OF PEAK EFFICIENCY: Corrosion, scaling, fouling carryover and condensate corrosion can cause unscheduled shutdown, accidents and deterioration of system efciency.Therefore for trouble free operation and maintenance peak operation efciency, a combination of various internal chemical treatments is essential along with a good control over boiler water quality. Maintaining boiler water quality by using commodity chemicals likes TSP, Hydrazine, and Sodium sulte. However, it is recommended that the care and control of water chemistry be entrusted to specialist.
Welding Procedure Specications (WPS)
The pressure part of the boiler is made of several types of steel of varying thickness. Welding is the basic technique used in the fabrication of the boiler. The joints produced by welding should have strength not less than that of the parent metal. In the weld joint, the parent metals should fuse together, without cracks, blowholes, slag inclusions or defects of any kind. The weld joint apart from proving its mechanical strength in tension must also be able to resist bending without cracking. Such requirements can only be met if the welding process used is strictly controlled. ASME (and other organizations) classify materials into categories (P1 P2, P3, ... P9) as per carbon content and alloying metals (chromium, Nickel, Molybdenum etc.) and specify the procedure to be used for welding materials of the same category or one category with another category.
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A specication of the materials and shapes adopted by Thermax can be obtained on request. The welding procedure distinguishes between welding of thin and thick material. The welding process specication denes the following for each category of welding. Edge preparation (angle, shape) Joint preparation (cleaning, gap) and tagging Joint pre-inspection before welding Pre-heat of the weld joint, if any required (method of pre-heating, temperature method of checking temperature) Root weld (gas welding, TIG or Arc, size of electrode, type of electrode) Radiographic inspection of root weld if required Subsequent runs of welding (TIG, Arc or other methods, size of electrode, type of electrode, number of runs) Post weld heat treatment if any required (temperature, rate of increase of temperature, method of increasing temperature, holding time, rate of cooling) Radio graphic examination of the weld joint, indicating defects if any to be corrected Correction of weld defects Final acceptance of the weld joint The WPS indicates compatible categories of materials that can be welded. The WPS also lays down the type of electrode to be used for each category of welding. As the electrode deposits materials, the composition of the electrode must be compatible with the material welded and add strength. The coating of the electrode also must meet specic requirements. The WPS must be used not only during fabrication of the boiler, but also when any repair or maintenance works are to be done. Thermax has WPS to cover every welding job connected with fabrication of the boiler in the factory and erection of the boiler at site, conforming to IBR requirements. The Field Engineering Department Base Material P1 TO P1 P3 TO P3 P3 TO P3 P4 TO P4 P5 TO P5 P8 TO P8 Carbon Steel To Carbon Steel Carbon Moly To Carbon Moly Cr Moly To Cr Moly 1-1/4 Cr TO 1-1/4 Cr 2-1/4 Cr 1 Moly To 2-1/4 Cr 1 Moly Stainless To Stainless
of Thermax will be glad to provide a WPS for any site repair weld jobs required for maintenance.
8.1 Window Patch Welding

PURPOSE The purpose of the window patching method is to allow the welding of tubes that could not otherwise be welded because of limited access to part of the tube diameter. This procedure is restricted to that use. PREPARATION 1. The area to be patched shall be cleaned to bare metal. 2. The patch shall be made from tube material of same type, diameter and thickness, as the tube being welded 3. The area of the tube to be removed shall be carefully marked out as close as possible to contour of the patch. The tube section may then be removed using an oxyacetylene gas cutting torch or by mechanical means 4. The weld preparation shall be made as per the Figure #1. The t up of the patch weld gap shall be 2.4 0.8 mm Welding 1. A welder qualied to the requirements of ASME shall make the tube and patch welds in accordance with an approved weld procedure. 2. The root pass shall be done with GTAW process. The weld may then be completed with either SMAW or GTAW process. Some acceptable weld procedure specications are listed in Table below TESTING All the tube and patch welding shall be subject to close visual inspection and 100% radiography in accordance with the requirements of ASME section V. The standard for accepting /rejecting is specied in ASME section I Completed welds are subject to hydrostatic test Filler Metal ER 70S.2 ER80S.B2 ER80S.B2 ER80S.B2 ER90S.B3 ER308 E7018 E7018A1 E8018B2L E8018B2L E9018B3L ER308-16
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Figure 5
8.2 General Principle of Weld Repairs

FURNACE AND BOILER TUBES The minimum replacement tube length should be not less than 150 mm. A damaged tube should be cut at least 75 mm each side of the defective area. Backing rings must not to be used in welding heat absorbing tubes carrying water or mixture of steam and water. If a backing ring is not used, the rst pass of the weld must be made with inert gas-arc or oxy acetylene. The weld passes may be completed by either process, or by a manual metal arc. Pre heat or post heat is not required for welding carbon steel furnace or boiler tubes. Prior to welding, clean the tube ends to bright metal inside and outside for at least 40 mm from the weld area. Remove all deposits of oxide, boiler water salts and slag to avoid gas or slag inclusions in the weld. Fit-up of the weld joints is important. It is difcult to obtain accurate cuts on furnace tubes especially those in welded furnace walls. However, it is worth to spend extra time to get the existing tube ends squared and correctly chamfered and to cut the replacement tube to the correct length. Poor t-up increase the possibility of an unsuccessful weld. Allow for shrink in the welding, remember, the weld metal and parent metal are melted in the welding process and the molten metal shrinks as it solidies. A butt weld in the tube will shorten the total tube length about 1.6 mm. Use a clamp or guide lug to hold one end of the replacement tube alignment while the rst weld is made. Do not tack weld both end of the replacement tubes particularly if the existing tubes are rigidly supported As a general rule, rst complete the welds at the lower end of the replacement tube. Do not start welding the upper end of the replacement tube until both the replacement and the existing tubes have cooled to ambient temperature. WELD REPAIR OF SMALL CRACKS IN TUBE In the interest of saving time and cost, it is better to weld small cracks rather than replace a length of the tube. The crack must be ground out to form
an acceptable welding groove. The groove should continue well beyond the ends of the crack. Inert gas arc or oxy acetylene process must make the rst pass of the weld. Note This type of the repairs entails some risk. Internal deposits. Particularly copper, may exist under the crack which will result in damaging the parent and/or weld metal causing failure in a short period of time. Over-heating the tube may have caused the longitudinal crack. In this case, the tube has swollen and the weld thickness reduced. In the modern welded wall construction, it is difcult to accurately measure the tube diameter or circumference to detect the minor swelling. If visual indicates swelling and reduction of wall thickness at the crack, a complete replacement of the damaged tube length is the best solution. A circumferential crack indicates a failure due to excessive stress applied by expansion restriction, bending or fatigue; welding can repair such cracks. However, unless the cause of failure is diagnosed and corrected, another similar failure could occur at or near the original crack. Also the tube cannot be cleaned from inside and there is always a possibility internal deposits will contaminate the weld. PLUGGING TUBES IN DRUMS & HEADERS Often after a tube failure, it is desirable to plug the failed tube in the drum or header shell so the boiler may be returned to service with the least possible delay. It is recommended that the failed tube be replaced whenever possible in lieu of plugging. If the leak is remote from the tube seats and accessible, the faulty section of the tube should be cut out and replaced rather than plugging. Water wall tubes (space tube) should be replaced if possible and plugged only as a last resort. The plugged tube must be free to expand and distort with respect to the adjacent tubes. Membrane tubes must be repaired and not plugged. When tubes are plugged, the old tube should be removed from the boiler setting since it probably
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will burn off due to lack of cooling and could become displaced and obstruct gas lanes, foul up soot blowers, be dangerous to personnel after shutdown, and etc. If the tube is not removed from the setting, a denite hole must be punched or drilled in the tube to prevent a possible dangerous buildup of pressure between the tube plugs. A expanded tube leaking at the seat should be removed from its seat and 1. a new tube rolled in, 2. a new short stub rolled in and plugged, 3. the tube end seal welded to the shell or, if the drum shell is internally counter bored, a cylindrical plug must be installed and seal welded to the drum shell. Note No. (1) is the preferred x with No. (3) the least preferred. Seal welding of tube ends, tapered plugs, or cylindrical plugs to the shell should be done in such a manner as to minimize the heating of adjacent tube seats, which may become loose. It is essential that the welding process should be as per standard procedure for carbon steel shells and tubes to be followed very closely to ensure success. Deviations from these parameters will normally result in unsatisfactory connections. The major welding parameters for shells or tubes other than carbon steel may be obtained from qualied welding procedures. Ensure that welders are qualied in accordance with ASME Section IX and local provincial requirements. They must also ensure that the welding is done to the applicable qualied weld procedure. It also to be ensured that the proposed repair has been approved by the Boiler Inspection Branch of the local jurisdiction. Machined tube stubs and plugs are used where the old tube can be removed from its seat without seat damage and for new construction that is drilled for future addition of tubes. The rolled-in tube stub extends into the shell and a solid plug is installed and seal welded to the stub. These stubs and plugs are standardized to have only one tube stub and one plug for each standard tube hole. Before rolling stubs in, they should be cleaned inside and outside with a wire brush, abrasive paper, or a liquid cleaner until the metal is free of all foreign substances. In general, stubs do not
require cleaning beyond the removal of dirt, rust, scale or foreign material. The stub seat (tube hole) should be similarly cleaned. If a liquid solvent is used to clean either the stub and/or tube hole, care must be taken to dry the metal completely. Liquid trapped between the stub and its seat prevents contact of the two metal surfaces. Before the expanding tool is inserted, the inside of the stub should be lubricated with a suitable compound. The compound selected should be water soluble to facilitate cleanup. The rolling process should not be rushed since heat generated during rolling is detrimental to the strength of the rolled joint. The tube stub is properly expanded when the wall thickness in the seat is reduced by 6 to 10 percent for generating tubes and 10 to 14 percent for other boiler tubes. The tube stub wall reduction for thin shells should be less than that for thicker shells. This is to prevent over rolling which could cause adjacent tube seats to leak. Since the stub wall itself cannot be measured after it is rolled in its seat, the only alternative is to calculate the increase in the stub ID that is necessary to prove that the wall has in fact been reduced by the required percentage. This depends upon the tube seat ID (hole diameter), tube stub OD, the clearance between these two and also the stub wall. An example of this conversion for a 2 " OD by 0.150-inch wall tube stub for a 10% wall reduction is as follows Measure = Hold Dia Measure = Stub OD Measure = Stub ID Clearance = Stub ID @ Contact 10% of 0.150 x 2 = 2.531 2.500 / 0.031 Clearance 2.200 0.031 / 2,231 Stub ID @ Contact 2.231
0.030 / 2.261 Stub ID after expanding
Plug all internal counter bored holes in the eld with the cylindrical plug when the tube is still in the seat. Some counter bores may be shallow enough that the tube ends are exposed sufciently to permit seal welding to a tapered plug. See Figure 2. If the tube seat is leaking, then the tube must either be seal welded to the drum shell or the
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counter bore can be plugged with the cylindrical plug and seal welded per Figures 3 and 4. It may be necessary to machine the tube ends back in order to provide a seat for the cylindrical plug installation. See Figures 3 and 4. Figure 5 shows the details of this cylindrical plug and gives instruction for the specic plug size desired. Tapered plugs are used to plug existing tubes where it is not practical to remove the tube from its seat and there is no internal counter bore. These plugs must be tailor made for each tube diameter and tube wall thickness. Figure 6 shows the details of this tapered plug and give instructions for a plug to t tube diameters from 1-3/4" through 4 " OD and any wall thickness. Figure 7 shows the arrangement of the tapered plug seal welded to the tube. The plugs and seal welds described above are designed for the boiler pressure to be on the head (seal weld side) of the plug only. The inch diameter by 1/8-inch thick button weld on the plug is to eliminate leakage through the piping which can occur at the center of some bar stock. Figure 8 shows a tube seal welded to the shell. This arrangement may be used when the tube seat is leaking and it is not practical to replace or remove the tube and use a rolled stub and plug. Economizer headers and superheater headers may be plugged as shown in Figure 9 & 10 where external access is available and the conditions shown on the gures are met. If those conditions cannot be satised, tube replacement is recommended. In these two gures, the pressure is on the internal end of the plug and the external strength weld restrains the plug. Plugged tubes that are below the horizontal centerline of the shell will not drain. Therefore, after chemical cleaning it is necessary that the plug to be removed and the stub swabbed out to remove the chemicals in these stubs. The plug can then be welded back in or in some cases it will have been destroyed in the removal process and anew one will have to be installed. Care must be taken in the plug removal process to not damage or thin the tube stubs wall. REPLACEMENT OF SECTIONS OF TUBES Experienced personnel must do the replacement of a section of failed tube. The length of the replaced section should be a minimum of 12 inches. Usual practice is to cut out the defective section with an oxyacetylene torch, but it is
preferable to use a saw or wafer disc. Care must be taken to prevent slag from entering the tube. The ends are prepared for welding by grinding or with special tools. The root pass of the joint should be deposited with the gas tungsten arc process. A 3/32-inch diameter shielded metal arc-welding electrode is recommended for the remainder of the joint. The welding parameters for tubes may be obtained from qualied Welding Procedures. REMOVING TUBES FROM DRUMS, HEADERS & TUBE PLATES The removal of tubes from their tube seats must be done very carefully to prevent damage to the tube seats. If the tube seat is damaged, it may be impossible to ever roll another tube in and make a tight seal. Gouging of the tube seat could also affect the ligaments between tube holes and integrity of the shell. Tubes can be removed from their seats without seat damage if the following procedures are carefully followed. With lightgage tubes, it is often possible to cold crimp the tube end to loosen it in its seat, then drive or "jack" the tube out. When the tubes are too heavy for cold crimping, the two-stage heating method may be used. Heat is applied to the inside of the tube end with a torch. Heat is rst applied for a short period - not long enough for it to be transferred to the tube sheet. When the tube end cools, the joint will have loosened enough so that the second heat will not be transferred readily to the tube sheet. The tube end can then be heated sufciently for crimping and the tube can be pushed out of its seat. If neither of these methods is applicable, the following methods may be employed. To remove light tube tubs, it is advisable to cut grooves about 3/4 inch apart with a round nose chisel. When the tongue (the metal between the two grooves) is knocked free, the tube can be collapsed and removed. To remove heavy gage tubes, the type of grooving tool shown in gure 12 is used to prepare the tongues without damage to the tube seat. It is used with a pneumatic hammer, but it is necessary that the tool be suited to the tube thickness so that it will cut the grooves as deep as possible and yet leave a minimum thickness of metal over the tube seat. In very heavy gage tubes, a third groove is often cut, as nearly opposite the tongue as possible, so that less heavy pounding will be required to collapse the stub. These latter two methods require that the are on the end of the
Section-D
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tube be crimped straight before starting, to cut the grooves for collapsing the tube. Of course, the seal weld around the end of any tube must be ground or machined off before attempting to cut
the grooves for collapsing the tube. This must be done carefully to prevent damage to the drum shell.
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8.3 Weld Repair of Small Cracks in Tube

In the interest of saving time and cost, it is better to weld small cracks rather than replace a length of the tube.The crack must be ground out to form an acceptable welding groove. The groove should continue well beyond the ends of the crack. Inert gas arc or oxy acetylene process must make the rst pass of the weld. Note 1. This type of the repairs entails some risk. Internal deposits. Particularly copper, may exist under the crack which will result in damaging the parent and/or weld metal causing failure in a short period of time. 2. Over-heating the tube may have caused the longitudinal crack. In this case, the tube has swollen and the weld thickness reduced. In the modern welded wall construction, it is difcult to accurately measure the tube diameter or circumference to detect the minor swelling. If visual indicates swelling and reduction of wall thickness at the crack, a complete replacement of the damaged tube length is the best solution. 3. A circumferential crack indicates a failure due to excessive stress applied by expansion restriction, bending or fatigue; welding can repair such cracks. However, unless the cause of failure is diagnosed and corrected, another similar failure could occur at or near the original crack. 4. Also the tube cannot be cleaned from inside and there is always a possibility internal deposits will contaminate the weld.
3. When tubes are plugged, the old tube should be removed from the boiler setting since it probably will burn off due to lack of cooling and could become displaced and obstruct gas lanes, foul up soot blowers, be dangerous to personnel after shutdown, and etc. If the tube is not removed from the setting, a denite hole must be punched or drilled in the tube to prevent a possible dangerous buildup of pressure between the tube plugs. 4. A expanded tube leaking at the seat should be removed from its seat and a. a new tube rolled in b. a new short stub rolled in and plugged c. the tube end seal welded to the shell or, if the drum shell is internally counter bored, a cylindrical plug must be installed and seal welded to the drum shell.
Note: Point. (a) is the preferred x with Point. (c) the least preferred. 5. Seal welding of tube ends, tapered plugs, or cylindrical plugs to the shell should be done in such a manner as to minimize the heating of adjacent tube seats, which may become loose. It is essential that the welding process should be as per standard procedure for carbon steel shells and tubes to be followed very closely to ensure success. Deviations from these parameters will normally result in unsatisfactory connections. The major welding parameters for shells or tubes other than carbon steel may be obtained from qualied welding procedures. Ensure that welders are qualied in accordance with ASME Section IX and local provincial requirements. They must also ensure that the welding is done to the applicable qualied weld procedure.It also to be ensured that the proposed repair has been approved by the Boiler Inspection Branch of the local jurisdiction. 6. Machined tube stubs and plugs are used where the old tube can be removed from its seat without seat damage and for new construction that is drilled for future addition of tubes. The rolled-in tube stub extends into the shell and a solid plug is installed and seal welded to the stub. These stubs and plugs are standardized to have only one tube stub and one plug for each standard tube hole. 7. Before rolling stubs in, they should be cleaned inside and outside with a wire brush, abrasive paper, or a liquid cleaner until the metal is free of all foreign substances. In general, stubs
8.4 Plugging Tubes in Drums & Headers

1. Often after a tube failure, it is desirable to plug the failed tube in the drum or header shell so the boiler may be returned to service with the least possible delay. It is recommended that the failed tube be replaced whenever possible in lieu of plugging. If the leak is remote from the tube seats and accessible, the faulty section of the tube should be cut out and replaced rather than plugging. 2. Water wall tubes (space tube) should be replaced if possible and plugged only as a last resort. The plugged tube must be free to expand and distort with respect to the adjacent tubes. Membrane tubes must be repaired and not plugged.
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do not require cleaning beyond the removal of dirt, rust, scale or foreign material.The stub seat (tube hole) should be similarly cleaned. If a liquid solvent is used to clean either the stub and/or tube hole, care must be taken to dry the metal completely. Liquid trapped between the stub and its seat prevents contact of the two metal surfaces. 8. Before the expanding tool is inserted, the inside of the stub should be lubricated with a suitable compound. The compound selected should be water soluble to facilitate cleanup. The rolling process should not be rushed since heat generated during rolling is detrimental to the strength of the rolled joint. The tube stub is properly expanded when the wall thickness in the seat is reduced by 6 to 10 percent for generating tubes and 10 to 14 percent for other boiler tubes. The tube stub wall reduction for thin shells should be less than that for thicker shells. This is to prevent over rolling which could cause adjacent tube seats to leak. Since the stub wall itself cannot be measured after it is rolled in its seat, the only alternative is to calculate the increase in the stub ID that is necessary to prove that the wall has in fact been reduced by the required percentage. This depends upon the tube seat ID (hole diameter), tube stub OD, the clearance between these two and also the stub wall. An example of this conversion for a 2 " OD by 0.150-inch wall tube stub for a 10% wall reduction is as follows Measure Hold Dia = Measure Stub OD = Measure Stub ID = Clearance = 2.531 -2.500 0.031 Clearance 2.200 0.031 2,231 Stub ID @ Contact Stub ID @ Contact = 10% of 0.150 x 2 = 2,231 0.030 2.261 Stub ID after expanding 9. Plug all internal counter bored holes in the eld with the cylindrical plug when the tube is still in the seat. Some counter bores may be shallow enough that the tube ends are exposed sufciently to permit seal welding to
a tapered plug. 8.7 See Figure 13, page 101. If the tube seat is leaking, then the tube must either be seal welded to the drum shell or the counter bore can be plugged with the cylindrical plug and seal welded per Figures 14 and 15. It may be necessary to machine the tube ends back in order to provide a seat for the cylindrical plug installation. See 8.7 Figure 14, page 101 and 8.7 Figure 15, page 101. 10. 8.7 Figure 16, page 101 shows the details of this cylindrical plug and gives instruction for the specic plug size desired. 11. Tapered plugs are used to plug existing tubes where it is not practical to remove the tube from its seat and there is no internal counter bore. These plugs must be tailor made for each tube diameter and tube wall thickness. 8.7 Figure 17, page 101 shows the details of this tapered plug and give instructions for a plug to t tube diameters from 1-3/4" through 4 " OD and any wall thickness. 8.7 Figure 18, page 101 shows the arrangement of the tapered plug seal welded to the tube. 12. The plugs and seal welds described above are designed for the boiler pressure to be on the head (seal weld side) of the plug only. The inch diameter by 1/8-inch thick button weld on the plug is to eliminate leakage through the piping which can occur at the center of some bar stock. 13. 8.7 Figure 19, page 101 shows a tube seal welded to the shell. This arrangement may be used when the tube seat is leaking and it is not practical to replace or remove the tube and use a rolled stub and plug. 14. Economizer headers and superheater headers may be plugged as shown in 8.7 Figure 20, page 101 & 8.7 Figure 21, page 101 where external access is available and the conditions shown on the gures are met. If those conditions cannot be satised, tube replacement is recommended. In these two gures, the pressure is on the internal end of the plug and the external strength weld restrains the plug. 15. Plugged tubes that are below the horizontal centerline of the shell will not drain. Therefore, after chemical cleaning it is necessary that the plug to be removed and the stub swabbed out to remove the chemicals in these stubs. The plug can then be welded back in or in some cases it will have been destroyed in the removal process and anew
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one will have to be installed. Care must be taken in the plug removal process to not damage or thin the tube stubs wall.
the tube end to loosen it in its seat, then drive or "jack" the tube out. 2. When the tubes are too heavy for cold crimping, the two-stage heating method may be used. Heat is applied to the inside of the tube end with a torch. Heat is rst applied for a short period - not long enough for it to be transferred to the tube sheet. When the tube end cools, the joint will have loosened enough so that the second heat will not be transferred readily to the tube sheet. The tube end can then be heated sufciently for crimping and the tube can be pushed out of its seat. If neither of these methods is applicable, the following methods may be employed. 3. To remove light tube tubs, it is advisable to cut grooves about 3/4 inch apart with a round nose chisel. When the tongue (the metal between the two grooves) is knocked free, the tube can be collapsed and removed. 4. To remove heavy gage tubes, the type of grooving tool shown in gure 12 is used to prepare the tongues without damage to the tube seat. It is used with a pneumatic hammer, but it is necessary that the tool be suited to the tube thickness so that it will cut the grooves as deep as possible and yet leave a minimum thickness of metal over the tube seat. In very heavy gage tubes, a third groove is often cut, as nearly opposite the tongue as possible, so that less heavy pounding will be required to collapse the stub. These latter two methods require that the are on the end of the tube be crimped straight before starting, to cut the grooves for collapsing the tube. Of course, the seal weld around the end of any tube must be ground or machined off before attempting to cut the grooves for collapsing the tube. This must be done carefully to prevent damage to the drum shell.
8.5 Replacement of Tube Section

Experienced personnel must do the replacement of a section of failed tube. 1. The length of the replaced section should be a minimum of 12 inches Usual practice is to cut out the defective section with an oxyacetylene torch, but it is preferable to use a hack saw or wafer disc. Care must be taken to prevent slag from entering the tube. The ends are prepared for welding by grinding or with special tools 2. The root pass of the joint should be deposited with the gas tungsten arc process. A 3/32 - inch diameter shielded metal arc-welding electrode is recommended for the remainder of the joint. The welding parameters for tubes may be obtained from qualied Welding Procedures.
8.6 Removing Tubes from Drums, Headers & Tube Plates

1. The removal of tubes from their tube seats must be done very carefully to prevent damage to the tube seats. If the tube seat is damaged, it may be impossible to ever roll another tube in and make a tight seal. Gouging of the tube seat could also affect the ligaments between tube holes and integrity of the shell. Tubes can be removed from their seats without seat damage if the following procedures are carefully followed. With lightgage tubes, it is often possible to cold crimp
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8.7 Attached gures 13 to 21
Tapered plug application for shallow internal CTRB Tube end must be exposed sufciently for seal welding. Figure 6
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101
Figure 7
Section-D
102
Figure 8
Section-D
103
Figure 9
Section-D
104
Figure 10
Section-D
105
Figure 11
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Figure 12 Notes: T1 is the greater of 1.25 x Nominal tube wall or 3/16 Plug Head O.D = nominal Tube I.d 3/32 Plug length is 1 up thru 3 O.D tube over 3 O.D Tube use 2 Length Plug of SA 181 Gr70 preferrred SA 105 is acceptable.
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Figure 13 Notes: T1 is the greater of 1.25 x nominal wall or 3/16 Plug diameter = Nominal tube I.D 3/32 Plug length is 1 up thru 4 O.D tube Plug of SA 181 Gr 70 material preferred Sa 105 is also accepted
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Figure 14
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109
Section E
This section holds the Lubrication Schedule and Spare Part List for the AFBC Single Drum Bed Plate Boiler. Lubrication Schedule Lubrication Schedule Spare Part List Spare Part List for AFBC Boiler
Section E
110
Volume 2 Drawings
Chapters Covered in this Part List of Drawings
Volume 2 Drawings
111
List of Drawings
01 G.A. OF Boiler _D11-0PD-07967_3 02 Foundation Plan & Loading Data_D11-1PD-44268_4 03 Boiler Auxillary Foundation Data_D11-1PD-47979_3 04 Pressure Part Assembly _D11-1PD-43038_1 05 Thermal Expansion Diagram_D11-1PD-49076_0 06 P & I D for Steam & Water _D12-1PD-6499P_2 07 P & I D for Fuel Air & Flue Gas System_D12-1PD-6500P_2 08 Fuel Feed Chute Assly_F28-1PD-48091_0 09 Fuel Feed Chute Details_F28-1PD-48092_0 10 Underbed Fuel Feeding System Layout & Details _F59-1PD-46483_0 11 Steam Drum _P21-1PD-43823_1 12 Steam Drum Internal Assly & Details_P21-1PD-43824_0 13 Internal & External Attachment of Steam Drum _P21-3PD-18383_0 14 Water Drum _P31-1PD-43928_1 15 Internal & External Attachment of Water Drum_P31-2PD-40150_0 16 Primary Super Heater Coil _PA1-1PD-45809_1 17 Secondary Super Heater Coil_PA22PD41254_1 18 Economiser Assly _PL4-1PD-45132_0 19 Integrated Economiser Module I, II & III _PL4-2PD-40868_1 20 GA OF Furnace Refractory_R11-1PD-47758_0
Volume 2 Drawings
112
Volume 3 E & I Specications

Chapters Covered in this Part Section Section Section Section Section Section Section Section Section Section 01 02 03 04 05 06 07 08 09 10
113
Section 01
Electrical System Required for Motor Selection
Section 02
2.1 Electrical Motor Selection For FD Fan 2.2 Electrical Motor Selection For PA Fan 2.3 Electrical Motor Selection For ID Fan
Section 03
Instruments Hook Up Diagram
Section 04
Instruments Loop Diagram
Section 05
5.1 Logic Diagram For Drives 5.2 Control Schematic Write up
Section 06
6.1 DCS IO List 6.2 Alarm & Set Point List
Section 07
7.1 Specication for Motorised Actuator 7.2 Instruments Cable & JB Cable Schedule 7.3 Specication For Junction Box
Section 08
8.1 Instruments Specication for Transmitters & Analysers 8.2 Instruments Specication for Gauges & Switches 8.3 Instruments Specication for Valve & Actuator 8.4 Instruments Specication for Sensors
Section 09
9.1 Specication for CBD Valve 9.2 Specication for IBD Valve 9.3 Valve Schedule 9.4 Valve Schedule Add
114
Section 10
ACVFD Panel Wiring Diagram
115
Volume 4 Vendor Manuals

116
Section 01
Fan TLT Engineering
O & M Manual ID_FD_PA FAN Drawings 1. GA DRG FOR FD FAN 2. GA DRG FOR ID FAN 3. GA DRG FOR PA FAN
Section 02
H.P / LP. Dosing System - NM Enterprises
O & M Manual HP Dosing System Manual Drawings 1. H.P. Dosing System Drawing
Section 03
Level Gauge Hi Tech Systems (Tyco)
O & M Manual LEVEL GAUGE MANUAL Drawings LEVEL GAUGE DRAWINGS
Section 04
Level Gauge Chemtrol
O & M Manual LEVEL GAUGE MANUAL Drawings LEVEL GAUGE DRAWINGS
Section 05
Tight Shout off Damper Virgo
Manual Manual
117
Section 06
Kniff Gate Valve Orbinox
O & M Manual Kniff Gate Valve
Section 07
Process Valve KSB
O & M Manual Process Valve
Section 08
Safety Valves Tyco Sanmar
O & M Manual SAFETY VALVES (HC-HCA Manual) Data Sheet a Specication Sheets Drawings Drawings
Section 09
Motors Siemens
Manual Motor Manual Data Sheets
Section 10
Rotary Feeder - Nova Bulk
O & M Manual Rotary Feeder Manual Drawings 1. Rotary Feeder GA Sheet 1 2. Rotary Feeder GA Sheet 2
118

119
Section 01
Pressure Transmitter Emerson
O & M Manual PRESSURE TRANSMITTERS (MODEL 3051)
Section 02
Temperature Transmitter Emerson
O & M Manual TEMPERATURE TRANSMITTERS (MODEL 644H)
Section 03
I/P Converter ABB
O & M Manual I/P Converter ABB
Section 04
Pressure Switch Switzer
O & M Manual Pressure Switch Manual
Section 05
5.1 Orice Plate General Instruments
Calculations & Drawings
5.2 Thermocouple General Instruments

Data Sheets
Section 06
Pressure Gauge Gages Bourdon
O & M Manual Pressure Gauge Manual
Section 07
Local Indicator Nishko
Manual Process Indicator Nichko
120
Section 08
Control Valves MIL
O & M Manual MIL 21000 SINGLE PORTED TOP GUIDED CONTROL VALVES - MIL_MANUAL MIL 41000 HEAVY DUTY BALANCED CAGE GUIDED CONTROL VALVES - MIL_MANUAL MIL37 38 SPRING DIAPHRAGM PNEUMATIC ACTUATOR - MIL_MANUAL MIL 776 Air Lock Valve MANUAL 8013 Electro pneumatic Valve Positioner - MIL_MANUAL 400 L Electric Position Transmitter- MIL_MANUAL Data Sheet and Curves CONTROL VALVE DATA SHEET
Section 09
Power Cylinder Keltron
Manual Manual
Section 10
ACVFD Drives ABB
Manual ACS 550 ACVFD Drives ABB Manual
121
122
Index
A
Adequate Bed Temperature........................... 41 Air and Gas System ...................................... 24 Air Ducts ...................................................... 25 Air Pre Heater .........................................24, 43 AirTemperature............................................. 13 Annual Maintenance Check Sheet ................. 65 Ash Drain ..................................................... 30 Attemperation Control Station........................ 17 Attemperator ................................................ 20 Daily Maintenance ........................................ 62 Deaerator Charging ...................................... 42 Deaerator Level Gauge ..................................11 Description of Dosing System Skid ................ 30 Design Code .................................................. 3 Design Specications...................................... 2 Dissolved Gases .......................................... 88 Dissolved Salts and Minerals......................... 87 Dos and Donts ............................................ 47 Down Comer Tubes ...................................... 18 Drain Header................................................ 22 Drum Inspection ........................................... 72 Drum Level ...................................................11 Dry Storage Preservation .............................. 77
B
Balance of Plant Start Up .............................. 42 Bed Ash Alkali Control .................................. 40 Bed Drain System......................................... 30 Bed Level Control ......................................... 40 Bed Material................................................... 6 Bed Slumping Procedures............................. 43 Blowdown Tank ............................................ 23 Boiler Annual Maintenance and Overhaul .................................................... 72 Boiler Blowdown System ............................... 21 Boiler Emergency Trip................................... 45 Boiler Lay Up Procedures.............................. 80 Boiler Preservation Procedure ....................... 77 Boiler Pressure Part Description .................... 17 Boiler Shutdown ........................................... 45 Boiler Start Up .............................................. 32 Boiler Water Recommended Quality ................ 7
E
Economizer .................................................. 17 Effects of Impurities ...................................... 88 Electrical Power.............................................. 7 Electrostatic Precipitator................................ 27 Emergency Procedures................................. 53 Expansion Joints .......................................... 73
F
Failure Reporting Formats............................. 85 Fans .........................................................8, 75 FD Fan ........................................................ 24 Feed & Boiler Water Conditioning .............73, 90 Feed Water Control Station ........................... 16 Feed Water Recommended Quality ................. 6 Feed Water System ...................................... 16 Flue Gas System .......................................... 27 Fuel ............................................................... 5 Fuel Analysis.................................................. 5 Fuel and Bed Material Sieve Analysis as per the Designed Conditions........................ 41 Fuel Bunker.................................................. 28 Fuel Feeding & Firing System........................ 28 Fuel Mix Nozzles .......................................... 29 Fuel Size........................................................ 5 Furnace ....................................................... 19
C
Capacity Chart ............................................. 10 Case- II (Bed Ash Temperature < 600C)......... 44 Case- II (Bed Ash Temperature > 600C)......... 44 CBD Drain.................................................... 22 Checks Every Six Months.............................. 64 Checks Every Year ....................................... 64 Chemical Dosing & Sampling System ............ 30 Chemicals for Dosing ...................................... 8 Combustor ................................................... 29 Conditioned Based Maintenance ................... 60 Continuous Blowdown..................................... 6 Controls ....................................................... 48 Convection Bank .......................................... 21 Cooling Water................................................. 7 Crushed Refractory......................................... 6
G
Gas Temperature.......................................... 13 Gauge Glass .................................................11 General Principle of Weld Repairs ................. 94
D
Daily Checks ................................................ 60
H
Heating Surface Area...................................... 5
123
HP Dosing System........................................ 30 HP Dozing System.......................................... 9
Procedure For Normal Operation ................... 36
R I
IBD Drain ..................................................... 22 ID Fan ......................................................... 27 Inbed Coil .................................................... 20 Inspection after Cooling ................................ 72 Inspection of Screen, Primary & Secondary Superheater, Evaporator I/ II & Economiser ................................................ 73 Instrument Air................................................. 8 Insulation and Cladding................................. 73 Intermittent Blowdown..................................... 6 Recommended Maintenance Practice ............ 59 Removing Tubes from Drums, Headers & Tube Plates .............................................. 100 Replacement of Tube Section...................... 100 Riser Tubes.................................................. 20 Rotary Feeders........................................10, 28
S
Safety Valves ................................................11 Safety Valves, Start Up Vent Valves And Other Isolating Valves ................................. 76 Sampling System.......................................... 31 Section Overview.......................................... 59 Service Air ..................................................... 8 Shutdown and Cooling the Boiler ................... 72 Site Condition................................................. 8 Slumped Bed to Active Bed ........................... 43 Start Up Firing System .................................. 29 Start-up of a Cold Boiler ................................ 32 Steam Drum ............................................1718 System Description..................................24, 27
L
Load Operation............................................. 39
M
Main Steam Piping........................................ 21 Material Specications .................................... 3 Monthly Checks............................................ 63
O
Operation Control ......................................... 39 Operational Precautions for Safety................. 55 Other Drains................................................. 23 Other Equipment .......................................... 73 Other Materials............................................. 88
T
Temperature Prole ...................................... 13 Tube Failures ............................................... 81 Tube Thickness Survey................................. 81 Tube Thickness Survey Data Collection Format ....................................................... 84
P
PA Fan......................................................... 25 Part Load Operation By Bed Slumping ........... 43 pH Value of the Water and its Importance......... 88 Planned Shut Down ...................................... 45 Planning Before Overhaul ............................. 72 Plugging Tubes in Drums & Headers.............. 98 Preservation of Instruments........................... 80 Preservation of Rotating Equipments ............. 80 Pressure Parts ............................................... 3 Preventive Maintenance................................ 59 Preventive Maintenance Program for Spares ....................................................... 60 Preventive Maintenance Program for Valve.......................................................... 60 Primary Super Heater ................................... 20
U
Ultimate Analysis ............................................ 5 Undissolved and Suspended Solid Materials .................................................... 87 Utilities........................................................... 7
W
Walkdown Checklist during Operation ............ 52 Water Chemistry ........................................... 87 Water Temperature ....................................... 13 Weekly Checks............................................. 63 Weld Repair Of Small Cracks in Tube ............ 98 Welding Procedure Specications.................. 92 Wet Storage Preservation ............................. 78 Window Patch Welding ................................. 93
124
SUPER HEATED STEAM TO TURBINE 41000 Kg/hr 66 Kg/cm2 (g) O 490 +5 C
38410 Kg/hr 74 Kg/cm2 (g) O 130 C
FROM FEED PUMP

FEED WATER 41410 kg/hr 76 kg/cm2 (g) O 130 C
SPRAY WATER FLOW 3000 Kg/hr 74 Kg/cm2 (g) O 130 C
FD FAN
60526 kg/hr
38410 Kg/hr 73.5 Kg/cm2 (g) O 216 C 65610 kg/hr -5 mmwg BOILER + SUPER HEATER HEAT TRANSFER ELEMENTS CONTINUOUS BLOW DOWN 410 kg/hr 72.5 kg/cm2 (g) O 290 C SEC. AIR FLUE GAS
O 445 C -40 mmwg
+726 mmwg
45
65610 kg/hr 250 OC -80 mmwg FLUE GAS
AIR PREHEATER
65610 kg/hr 160 OC -105 mmwg FLUE GAS CO2 % BY VOL WET: CO2 % BY VOL DRY: O2 % BY VOL WET: O2 % BY VOL DRY: 12.8 14.53 4.31 4.89
65610 kg/hr
O 160 C -135 mmwg
FLUE GAS
ECONOMISER
ESP
FLUE GAS
ID FAN
65610 kg/hr 160

O C +5 mmwg
BOILER
COMBUSTOR 150 C +650 mmwg 6053 kg/hr

O
SUPERHETAER STEAM TEMPERATURE AFTER 1

ST
STAGE SUPERHEATER:BEFORE SPRAY AFTER SPRAY
FD AIR
COAL 9600 kg/hr
: :
O 439 C
O 366 C
60526 kg/hr O 150 C +650 mmwg 10200 kg/hr O 150 C +1400 mmwg
PA FAN
FUEL : TYPE OF FIRING : LOAD : G.C.V : % MOISTURE :MADE DATE CHKD.BY DATE APP.BY DATE PRODUCT :- BDF - 410 - 41TPH / 66 kg/cm2 g / 490 deg C CLIENT :TITLE :POWER A/C. HAREKRISHNA METALLIKS
COAL UNDERBED 100 % 3500 kcal/kg 8 % PD0161 07.12.07 07.12.07 JRV 07.12.07 JRV
GN ALT. NO
SYMBOL
SERVICE STEAM LINE FUEL LINE AIR LINE WATER LINE FLUE GAS
ALT. NO.
ALTERATION
OC NO:
SCALE NTS DESIGNED CHECKED APPROVED
PROCESS FLOW DIAGRAM FOR COAL
THERMAX LIMITED
CHINCHWAD PUNE -411019 BOILER AND HEATER GROUP
DRG.NO. / PART NO.
PD0161 0033
( SHEET 1 OF 2)
SUPER HEATED STEAM TO TURBINE 41000 Kg/hr 66 Kg/cm2 (g) O 490 + 5 C
38310 Kg/hr 74 Kg/cm2 (g) O 130 C
FROM FEED PUMP

FEED WATER 41410 kg/hr 76 kg/cm2 (g) O 130 C
SPRAY WATER FLOW 3100 Kg/hr 74 Kg/cm2 (g) O 130 C
FD FAN
64572 kg/hr 69240 kg/hr 255 OC -95 mmwg FLUE GAS
38310 Kg/hr 73.5 Kg/cm2 (g) O 218 C 69240 kg/hr -5 mmwg BOILER + SUPER HEATER HEAT TRANSFER ELEMENTS CONTINUOUS BLOW DOWN 410 kg/hr 72.5 kg/cm2 (g) O 290 C SEC. AIR FLUE GAS
O 445 C -50 mmwg
+800 mmwg
45
AIR PREHEATER
69240 kg/hr 160 OC -125 mmwg FLUE GAS CO2 % BY VOL WET: CO2 % BY VOL DRY: O2 % BY VOL WET: O2 % BY VOL DRY: 13.75 15.22 4.38 4.85
69240 kg/hr
O 160 C -155 mmwg
FLUE GAS
ECONOMISER
ESP
FLUE GAS
ID FAN
69240 kg/hr 160

O C +5 mmwg
BOILER
COMBUSTOR 6457 kg/hr 715 mmwg

O
SUPERHETAER STEAM TEMPERATURE AFTER 1

ST
150
STAGE SUPERHEATER:BEFORE SPRAY AFTER SPRAY
50%COAL
5250 kg/hr
: :
O 445 C
359 C
50%CHAR
5250 kg/hr
FD AIR
64572 kg/hr O 150 C 715 mmwg
10200 kg/hr O 150 C +1410 mmwg
PA FAN
FUEL:- 50%COAL + 50%CHAR TYPE OF FIRING : - UNDERBED LOAD : - 100 % G.C.V : - 3350 kcal/kg % MOISTURE :- 5.61 %
APP.BY DATE PRODUCT :- BDF - 410 - 41TPH / 66 kg/cm2 g / 490 deg C CLIENT :TITLE :-
SYMBOL
SERVICE STEAM LINE FUEL LINE AIR LINE WATER LINE FLUE GAS
ALT. NO.
ALTERATION
MADE DATE
CHKD.BY DATE
POWER A/C. HAREKRISHNA METALLIKS
OC NO:
SCALE NTS DESIGNED CHECKED APPROVED
PROCESS FLOW DIAGRAM FOR 50%COAL + 50%CHAR
PD0161 07.12.07 07.12.07 JRV 07.12.07 JRV

GN ALT. NO
THERMAX LIMITED
CHINCHWAD PUNE -411019 BOILER AND HEATER GROUP
DRG.NO. / PART NO.
PD0161 0033
(SHEET 2 OF 2)

O & M Manual For Boiler

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OPERATION & MAINTENANCE MANUAL

ATMOSPHERIC FLUIDISED BED COMBUSTION BOILER

HARE KRISHNA METALLICS LIMITED

THERMAX PROJECT NO.: PD 0161

THERMAX LIMITED BOILER & HEATER GROUP PUNE, INDIA

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Volume 1 Boiler Description

Volume 1 Boiler Description

Operation & Maintenance Manual

Operation & Maintenance Manual

Design Specications of Steam Generator

Boiler & Economiser / Pressure Parts

Material Specications Pressure Parts

SA 516 Gr.70 SA 516 Gr.70 SA 210 Gr A1

Operation & Maintenance Manual

Pipe 90 Elbow Tube Stub

Super Heaters (CSH & RSH)

44.5O.D x 4.06 Thk 44.5O.D x 4.06 Thk 44.5O.D x 4.06 Thk

Operation & Maintenance Manual

Heating Surface Area

Fuel Analysis (% By Wt.)

6.1 Ultimate Analysis

6.2 Fuel size

Operation & Maintenance Manual

Required Per start Up Lump Size Bluk Density Chemical Composition

7.1 Bed Material Specications - Crushed Refractory

10 Feed Water Recommended Quality

Operation & Maintenance Manual

Unit ppm ppm ppm ppm ppm ppm ppm

11 Boiler Water Recommended Quality

For LT motors (UPTO AND INCLUDING 160 KW)

12.2 Cooling Water

Operation & Maintenance Manual

Parameters Supply Temperature Quality Duty

Value Ambient SOFT & Chlorine free Sample Cooling.

12.3 Instrument Air

12.4 Service Air

13 Chemicals for Dosing

Operation & Maintenance Manual

Operation & Maintenance Manual

17.1 Capacity Chart

Operation & Maintenance Manual

Unit RPM % Kg/hr/reve

Design 3.14 95 0.00234

100% MCR 2.62

50% MCR 1.31

18.2 Blow Dowm Tank Level Gauge

Operation & Maintenance Manual

Description Application Tag No Model Rated Capacity Quantity

Drum LHS B7 HC56 W-IBR-SPL

Drum RHS B8 HC56 W-IBR-SPL 19313 1 / BLR

SH S4 HCA58 W-IBR-SPL 13892 1 / BLR

Operation & Maintenance Manual

20.2 Water Temperature

20.3 Air Temperature

21 Flue Gas Pressure Prole