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.
 OPERATION & MAINTENANCE

MANUAL

FOR 2 X 20TPH

WASTE HEAT RECOVERY BOILER ON COKE OVEN

SUPPLIED TO

THERMAX POWER A/C BHATIA ENERGY

& STEELS LTD

GUMMIDIPOONDI, TAMILNADU

THERMAX PROJECT NO.: PL 0501 – 02

THERMAX LIMITED
BOILER & HEATER GROUP
PUNE, INDIA
PSK & 23.07.2010 AA 23.07.2010 USU 23.07.2010 0
SD

PREPARED BY CHECKED BY APPROVED BY REVISION

DESC. /
REMARK
 Operation & Maintenance Manual

Contents
Volume 1 — Boiler Description ....................................................................................................1
Section A................................................................................................................................2
1 Design SpeciÞcation of WHRB ....................................................................................2
2 Flue Gas Data ............................................................................................................2
3 Technical SpeciÞcation ................................................................................................3
3.1 Flue gas Velocity proÞle: (for design case) ..........................................................3
3.2 Flue gas Temperature proÞle:(For Design case)...................................................3
3.3 Water / Steam Temperature proÞle: (For Design case) ........................................3
3.4 Flue gas Pressure drop proÞle: (for design case) .................................................4
4 MOC And SpeciÞcation of Euqipments .........................................................................4
4.1 Steam Drum ......................................................................................................4
4.2 Superheater- II ..................................................................................................4
4.3 Superheater IA / IB / Support Coils .....................................................................5
4.4 Evaporator / Convection Bank Tubes ..................................................................6
4.5 Economiser .......................................................................................................6
4.6 Attemperator .....................................................................................................7
4.7 Insulation ..........................................................................................................7
4.8 Blow Down Tank ................................................................................................7
5 Utilities .......................................................................................................................7
5.1 Electrical power .................................................................................................7
5.2 Cooling Water....................................................................................................8
5.3 DM Water..........................................................................................................8
5.4 Instrument Air....................................................................................................8
5.5 Deaerator Steam ...............................................................................................8
5.6 Chemicals for Dosing .........................................................................................9
6 ID Fans ......................................................................................................................9
7 Deaerator ...................................................................................................................9
8 HP/ LP Dosing System ................................................................................................9
9 Boiler Feed Pump ..................................................................................................... 10
10 Soot Blower ............................................................................................................ 10
11 Gauge Glass ........................................................................................................... 11
12 Safety Valve............................................................................................................ 11
13 Safety Relief Valve .................................................................................................. 12
14 EMR Valve.............................................................................................................. 12
15 Gauge Glass........................................................................................................... 13
Section B.............................................................................................................................. 14
1 Section Overview ...................................................................................................... 14
2 Water And Steam System.......................................................................................... 16
2.1 Component Description.................................................................................... 16
3 Boiler Pressure Part Description................................................................................. 19
3.1 Economizer ..................................................................................................... 19
3.2 Steam Drum .................................................................................................... 20
3.3 Silencer .......................................................................................................... 22
3.4 Air Vent ........................................................................................................... 22
3.5 Evaporator ...................................................................................................... 22
3.6 Super Heater .................................................................................................. 23
3.7 Super Heater I ................................................................................................. 23
3.8 Attemperator ................................................................................................... 23
3.9 Super Heater II ................................................................................................ 23
3.10 Steam Temperature Control Loop ................................................................... 23
4 Main Steam Piping .................................................................................................... 24
5 Operational Control .................................................................................................. 24
5.1 Steam and Water System Technical Performance Data ...................................... 25

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6 Boiler Blowdown System ........................................................................................... 25

6.1 Other Drains.................................................................................................... 26
6.2 Continuous Blow Down Control ........................................................................ 26
7 Chemical Dosing & Sampling System......................................................................... 27
7.1 HP Dosing System........................................................................................... 27
7.2 Mixing Tank ..................................................................................................... 27
7.3 Preparation of 5% Phosphate Solution in the tank.............................................. 27
7.4 Phosphate Dosing Pump.................................................................................. 27
7.5 Water And Steam Quality Control And Monitoring .............................................. 29
7.6 Maintaining Quality of Steam ............................................................................ 30
7.7 Operational Control.......................................................................................... 31
8 Flue Gas System ...................................................................................................... 31
8.1 System Description .......................................................................................... 31
8.2 Operational Control.......................................................................................... 32
9 Soot Blower System .................................................................................................. 32
9.1 Soot Blower..................................................................................................... 32
10 Boiler Protection & Interlock ..................................................................................... 35
10.1 Alarms And Interlocks .................................................................................... 35
10.2 Operational Control........................................................................................ 35
10.3 Automatic Control .......................................................................................... 35
Section C ............................................................................................................................. 38
1 Section Overview ...................................................................................................... 38
2 Operation Procedure ................................................................................................. 38
3 Pre-requisites to Be Attended Before Start up ............................................................. 38
3.1 Feed Water Supply .......................................................................................... 38
3.2 Valve Settings ................................................................................................. 38
3.3 Filling With Water............................................................................................. 39
3.4 Heating Up ...................................................................................................... 39
4 Boiler Start Up .......................................................................................................... 40
4.1 Cold Start Up Procedure .................................................................................. 40
4.2 Hot Startup Procedure .................................................................................... 42
5 Boiler Shutdown........................................................................................................ 42
5.1 Normal Shutdown Procedure............................................................................ 42
5.2 Emergency Shutdown Procedure...................................................................... 43
5.3 During Black - Out Procedure Condition ............................................................ 43
5.4 Operator Action Required During Boiler Cold Start up ........................................ 43
6 Paralleling WHRB To The Plant steam Mains .............................................................. 43
7 Cooling of Shutdown WHRB & Its Preservation ........................................................... 44
7.1 System Description .......................................................................................... 44
7.2 Natural Cooling................................................................................................ 44
7.3 Forced Cooling ................................................................................................ 44
8 Do’s and Dont’s......................................................................................................... 44
9 WHRB Log Sheet...................................................................................................... 46
10 Emergency Procedures ........................................................................................... 48
10.1 Low Water Level ............................................................................................ 48
10.2 High Water Level ........................................................................................... 48
10.3 Tube Failure .................................................................................................. 48
11 Alarms and Interlocks .............................................................................................. 49
12 Troubleshooting Chart ............................................................................................. 51
13 Water Quality Recommendations ............................................................................. 54
14 Safety In WHRB House ........................................................................................... 55
Section D ............................................................................................................................. 56
1 Section Overview ...................................................................................................... 56
2 Recommended Maintenance Practices....................................................................... 56
3 Preventive Maintenance ............................................................................................ 56

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3.1 Preventive Maintenance Program for Valve ....................................................... 57

3.2 Preventive Maintenance Program for Spares..................................................... 57
4 Conditioned Based Maintenance................................................................................ 57
4.1 Daily Checks ................................................................................................... 57
4.2 Daily Maintenance ........................................................................................... 60
4.3 Monthly Checks ............................................................................................... 60
4.4 Checks Every Six Months................................................................................. 61
4.5 Checks Every Year .......................................................................................... 61
4.6 Annual Maintenance Check Sheet .................................................................... 62
5 Boiler Annual Maintenance and Overhaul ................................................................... 67
5.1 Planning Before Overhaul ................................................................................ 67
5.2 Shutdown and Cooling the Boiler ...................................................................... 67
5.3 Inspection after Cooling.................................................................................... 67
5.4 Drum Inspection .............................................................................................. 67
5.5 Inspection of Screen, Primary & Secondary Superheaters, Evaporators I/II &
Economiser................................................................................................ 68
5.6 Expansion Joints ............................................................................................. 68
5.7 Insulation and Cladding.................................................................................... 68
5.8 Other Equipment ............................................................................................. 68
5.9 Feed & Boiler Water Conditioning ..................................................................... 68
6 Boiler Preservation Procedure.................................................................................... 71
6.1 DeÞnition of Water Quality ................................................................................ 71
6.2 Dry Storage Preservation ................................................................................. 71
6.3 Wet Storage Preservation ................................................................................ 72
6.4 Nitrogen Blanket .............................................................................................. 73
6.5 Hot Draining .................................................................................................... 73
6.6 Alkaline Water Dozed With Hyderzine ............................................................... 74
6.7 Preservation of Extra Surfaces of Pressure Parts of WHRB During Long
shutdown ................................................................................................... 74
6.8 Boiler Lay Up Procedures................................................................................. 75
6.9 Preservation of Rotating Equipments ................................................................ 75
6.10 Preservation of Instruments ............................................................................ 75
6.11 Tube Thickness Survey .................................................................................. 75
7 Tube Failures............................................................................................................ 76
7.1 Tube Failure Investigation / Analysis Method ..................................................... 76
7.2 Tube Thickness Survey Data Collection – Format .............................................. 78
7.3 Failure Reporting Formats ................................................................................ 78
8 Welding Procedure SpeciÞcations .............................................................................. 80
8.1 Window Patch Welding .................................................................................... 80
9 General Principle Of Weld Repairs ............................................................................. 81
9.1 Furnace and Boiler Tubes ................................................................................ 81
9.2 Weld Repair Of Small Cracks in Tube ............................................................... 82
9.3 Plugging Tubes in Drums & Headers................................................................. 82
9.4 Replacement of Tube Section........................................................................... 84
9.5 Removing Tubes from Drums, Headers & Tube Plates ....................................... 84
9.6 Plugging of Tubes Drawings ............................................................................. 84
10 Water Chemistry ..................................................................................................... 93
10.1 Undissolved and Suspended Solid Materials ................................................... 93
10.2 Dissolved Salts and Minerals .......................................................................... 93
10.3 Dissolved Gases............................................................................................ 94
10.4 Other Materials .............................................................................................. 94
10.5 pH Value of the Water and its Importance ........................................................ 94
10.6 Effects of Impurities ....................................................................................... 94
Section E.............................................................................................................................. 97
1 Lubrication Schedule ................................................................................................. 97

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Volume 2 — Drawings................................................................................................................ 98
List of Drawings .................................................................................................................... 99
Volume 3 — Drawings.............................................................................................................. 100
E & I SpeciÞcations ............................................................................................................. 101
Section 01 ................................................................................................................... 101
Section 02 ................................................................................................................... 101
Section 03 ................................................................................................................... 101
Section 04 ................................................................................................................... 101
Section 05 ................................................................................................................... 101
Section 06 ................................................................................................................... 101
Section 07 ................................................................................................................... 101
Section 08 ................................................................................................................... 101
Section 09 ................................................................................................................... 101
Section 10 ................................................................................................................... 101
Section 11.................................................................................................................... 101
Section 12 ................................................................................................................... 101
Section 13 ................................................................................................................... 102
Section 14 ................................................................................................................... 102
Section 15 ................................................................................................................... 102
Volume 4 — Vendor Manuals ................................................................................................... 103
Section 01 .......................................................................................................................... 104
Pressure Transmitter — Emerson.................................................................................. 104
Section 02 .......................................................................................................................... 104
Temperature Transmitter — Emerson ............................................................................ 104
Section 03 .......................................................................................................................... 104
Pressure Switch — Switzer Instruments......................................................................... 104
Section 04 .......................................................................................................................... 104
4.1 Pressure Gauge — Gauges Bourdon ....................................................................... 104
4.2 Temperature Gauge — Goa Instruments .................................................................. 104
Section 05 .......................................................................................................................... 104
Power Cylinder — Keltron ............................................................................................ 104
Section 06 .......................................................................................................................... 104
Loop Power Indicator — Switzer Instruments ................................................................. 104
Section 07 .......................................................................................................................... 104
I to P Converter — ABB ................................................................................................ 104
Section 08 .......................................................................................................................... 105
8.1 Flow Nozzle — Starmech Controls........................................................................... 105
8.2 Thermocouple — Thermal Instruments..................................................................... 105
Section 09 .......................................................................................................................... 105
Control Valves— MIL .................................................................................................... 105
Section 10 .......................................................................................................................... 105
Motorised Valve Actuator— Auma India Ltd.................................................................... 105
Volume 5 — Vendor Manuals ................................................................................................... 106
Section 01 .......................................................................................................................... 107
ID Fan - Flakt Woods.................................................................................................... 107
Section 02 .......................................................................................................................... 107
BFW Pump — KSB Pumps .......................................................................................... 107
Section 03 .......................................................................................................................... 107
LP / H.P Dosing System - Metapow Industries................................................................ 107
Section 04 .......................................................................................................................... 107
4.1 Long Retractable Soot Blower - R.R. Techno ............................................................ 107
4.2 Rotary Soot Blower - Sitson India Ltd. ...................................................................... 108
Section 05 .......................................................................................................................... 108
5.1 Motors— Siemens .................................................................................................. 108

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5.2 ARC Valve — Schroedahl........................................................................................ 108

Volume 6 — Vendor Manuals ................................................................................................... 109
Section 01 .......................................................................................................................... 110
Safety Valve – Tyco Sanmar ......................................................................................... 110
Section 02 .......................................................................................................................... 110
Safety Relief Valves — Tyco Sanmar............................................................................. 110
Section 03 .......................................................................................................................... 110
Drum Level Gauge — Hitech......................................................................................... 110
Section 04 .......................................................................................................................... 110
Level Gauge (Tubular ) – Chemtrol ............................................................................... 110
Section 05 .......................................................................................................................... 110
Reßex Level Gauge — Chemtrols.................................................................................. 110
Section 06 .......................................................................................................................... 111
Process Valve — KSB ................................................................................................. 111
Section 07 .......................................................................................................................... 111
Process Valve — Xomox Sanmar .................................................................................. 111
Section 08 .......................................................................................................................... 111
Blow Down Valve — Levcon Instruments ....................................................................... 111
Section 09 .......................................................................................................................... 111
9.1 Spring Hanger Support — Techno Industries ............................................................ 111
9.2 Hanger Support – Pipe Support ............................................................................... 111
Section 10 .......................................................................................................................... 111
Damper - United Technomech Engineers Pvt. Ltd. ......................................................... 111
Index.................................................................................................................................. 113

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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 1

 Operation & Maintenance Manual

Section A

Topics Covered in this Chapter

♦ Design SpeciÞcation of WHRB
♦ Flue Gas Data
♦ Technical SpeciÞcation
♦ MOC And SpeciÞcation of Euqipments
♦ Utilities
♦ ID Fans
♦ Deaerator
♦ HP/ LP Dosing System
♦ Boiler Feed Pump
♦ Soot Blower
♦ Gauge Glass
♦ Safety Valve
♦ Safety Relief Valve
♦ EMR Valve
♦ Gauge Glass

1 Design Specification of WHRB

NUMBER & TYPE OF BOILER
Two nos. 20-TPH, Water tube, Natural Circulation, Single-Drum Coke Oven WHR Boiler. Bottom
Supported Pressure parts
PARAMETERS UNIT VALUE
Boiler Rating [MCR] TPH 20
Steam Pressure at Main Steam
Stop Valve Outlet from minimum Kg/cm2 66
Load upto MCR
Steam Temperature at the Main
Deg C 485±5
Steam Stop valve at MCR
Main Steam Temperature
Control range at the Main
% MCR 60 – 100
Steam Stop Valve Outlet (@
950 deg C Inlet Flue Gas Temp)
Maximum allowable working
Kg/cm2 75
pressure
Hydraulic Test Pressure Kg/cm2 112.5
Design Pressure Kg/cm2 75
Boiler Performance Testing
ASME PTC 4.4 Energy Balance
Procedure
DESIGN CODE ASME SECTION-1

2 Flue Gas Data

PARAMETERS VALUE

Boiler Rating [MCR] Nm3/Hr ( Per Boiler) 52,935

Inlet Temperature °C 950

Section A 2
 Operation & Maintenance Manual

PARAMETERS VALUE

Outlet Temperature °C 180 ± 5

Flue Gas Composition (% V/V):-

CO2 4.45
H2 O 6.2
N2 75.79
O2 13.45
SO2 100 ppm
Dust Loading 100 m g/Nm3

3 Technical Specification
3.1 Flue gas Velocity profile: (for design case)

Sr
Component Velocity, m/s
No.
1 Radiation cavity 8
2 Superheater 12 to 15
3 Evaporator 10 to 11
4 Economiser 8 to 9

3.2 Flue gas Temperature profile:(For Design case)

Sr
Component Deg C
No.
1 Radiation chamber inlet / outlet 950 / 878
Pre Evaporator cum Support Tube
2 878 / 849
(Pass 1) inlet / outlet
3 Superheater II (Pass 1) inlet / outlet 849 / 723
4 Superheater 1A (Pass 1) inlet / outlet 723 / 669
5 Superheater 1B (Pass 1) inlet / outlet 669 / 590
6 Evaporator I (Pass 1) inlet / outlet 590 / 390
7 Evaporator II (Pass 2) inlet / outlet 390 / 336
8 Inlet of Economiser 336
9 Outlet of Economiser 180

3.3 Water / Steam Temperature profile: (For Design case)

Sr Component Deg C
1 Radiation chamber inlet / outlet 285 / 285
Pre Evaporator cum Support Tube
2 285 / 285
(Pass 1) inlet / outlet
3 Superheater II (Pass 1) inlet / outlet 328 / 485

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Sr Component Deg C
4 Superheater 1A (Pass 1) inlet / outlet 368 / 428
5 Superheater 1B (Pass 1) inlet / outlet 285 / 368
6 Evaporator I (Pass 1) inlet / outlet 285 / 285
7 Evaporator II (Pass 2) inlet / outlet 285 / 285
8 Inlet of Economiser 120
9 Outlet of Economiser 258

3.4 Flue gas Pressure drop profile: (for design case)

Sr
Component (at outlet) Pressure mmWC
No.
1 Radiation cavity +Bends+Screen -5
2 Superheater -30
3 Evaporator -85
4 Economiser -165

4 MOC And Specification of Euqipments

4.1 Steam Drum
Sr
Description Value
No.
1 Design code IBR 1950 with its latest amendments
2 Design pressure 75 kg/cm² g
3 Design temperature 291 °C
4 Hydrotest pressure 112.5 kg/cm² g
5 Length 4000 mm
6 Inner diameter 1375 mm
7 Thickness 50 mm
8 Material of construction SA 516 Gr 70 / Equiv.
9 Quantity per boiler 1 no.
10 Corrosion allowance As per IBR
11 Internals Demister pad
12 Quantity of safety valves 2 nos.
13 Capacity of each safety valve 7500 kg/hr
14 Set pressure of Þrst safety valve 74.5 Kg/cm² g
15 Set pressure of second safety valve 75 kg/cm² g

4.2 Superheater- II
Sr
Description Value
No.
1 Design code IBR 1950 with its latest amendments
2 Design pressure 75 kg/cm² g

Section A 4
 Operation & Maintenance Manual

Sr
Description Value
No.
3 Design temperature
SH II 529 °C
Support Coils 319 °C
4 Design temperature of headers 490 °C
5 Hydrotest pressure 112.5 kg/cm² g
6 Type Horizontal
7 Heat transfer area(Thermal) 86.18 m²
8 Type of tubes Bare
9 Tube outer diameter OD 38.1mm x 4.06 mm thk
10 Tube thickness As per IBR
11 MOC of tubes SA 213 T22 HFS
12 MOC of Support Coils SA 210 Gr A1
13 Safety valve relieving capacity 5000 kg/hr
14 Safety valve set pressure 71 kg/cm²g

4.3 Superheater IA / IB / Support Coils

Sr
Description Value
No.
1 Design code IBR 1950 with its latest amendments
2 Design pressure 75 kg/cm² g
Design temperature of SH IA 467 °C
Design temperature of SH IB 407 °C
3 Design temperature of support coils 319 °C
4 Design temperature of headers
SH IB Inlet Header 291 °C
SH IA Outlet Header 428 °C
SH II Inlet Header 428 °C
SH II Outlet Header 490 °C
5 Hydrotest pressure 112.5 kg/cm² g
6 Type Horizontal
7 Heat transfer area(Thermal) 43.09 m² + 71.187 m²
8 Type of tubes Bare
9 Tube outer diameter OD 38.1 mm x 4.06 mm thk
10 Tube thickness As per IBR
11 MOC of SH IA tubes SA 213 Gr T11 HFS
MOC of SH IB / support coils tubes SA 210 T22 Gr A1 HFS
12 MOC of headers SA 335 P11
13 Header outer diameter OD 168.3 mm x 14.27 mm thk

Section A 5
 Operation & Maintenance Manual

4.4 Evaporator / Convection Bank Tubes

Sr
Description Value
No.
1 Design code IBR 1950 with its latest amendments
2 Design pressure 75 kg/cm² g
3 Design temperature of coils 319°C
4 Design temperature of headers 316 °C
5 Hydrotest pressure 112.5 kg/cm² g
6 Type Horizontal
Heat transfer area (thermal Area)
A) Convection Panel (Pass 1) 190.05 m²
7 B) Pre Evaporator cum Support Tube 7.182 m²
C) Evaporator I (Pass 1) 258.54 m²
D) Evaporator II (Pass 2) 206.832 m²
8 Type of tubes Bare
9 Tube outer diameter OD 38.1 mm x 3.66 mm thk
10 Tube thickness As per IBR
11 MOC of tubes SA 210 GR A1
12 MOC of Water wall tubes SA 210 GR A1 HFS
13 Tube OD of water wall tubes OD 63.5 mm x 4.06 thk mm
14 Tube thickness of water wall tubes As per IBR
15 MOC of headers SA 106 Gr B
16 Header outer diameter OD 219.1mm x 18.26 mm thk
17 Header thickness As per IBR

4.5 Economiser

Sr No. Description Value

1 Design code IBR 1950 with its latest amendments
2 Design pressure 75 kg/cm² g
3 Design temperature of coils 269 °C
4 Design temperature of headers 258 °C
5 Hydrotest pressure 112.5 kg/cm² g
6 Type Horizontal
7 Heat transfer area 827.33 m²
8 Type of tubes Bare
9 Tube outer diameter OD 38.1 mm x 3‘.66 mm thk
10 Tube thickness As per IBR
11 MOC of tubes SA 210 GR A1
12 MOC of headers SA 106 Gr B

Section A 6
 Operation & Maintenance Manual

Sr No. Description Value

13 Header outer diameter mm OD 114.3 mm x 13.49 mm thk
14 Header thickness mm As per IBR

4.6 Attemperator
Sr No. Description Value
1 Type Spray type Attemperator
2 Nos One
3 Location Between SH I & SH II
4 Water Flow at MCR (kg/h) Later
5 MOC of headers SA 335 P11
6 Header outer diameter mm OD 219.1 mm x 12.7 mm thk x 5000mm long
7 Header thickness mm As per IBR
8 Desidn Temperature 428 deg C

4.7 Insulation
Sr No. Description Value
1 Type Mineral wool mattress
100 Kg/M3 up to 400 Deg C
2 Density
120 Kg/M3 above 400 Deg C
3 Cladding Aluminum sheet of 24 SWG
4 Skin Temperature 30 Deg C above ambient temp.

4.8 Blow Down Tank

Sr. Description Value
1 Design code IBR 1950 with its latest amendments
2 Design pressure 3.5 kg/cm² g
3 Design Metal Temperature 150 °C
4 Hydrotest pressure 5.25 kg/cm² g
5 Shell Hight 1500 mm
6 Shell ID 960 mm
7 Shell thickness 10 mm
8 Type of ends Dished
9 Material of construction SA 516 Gr. 70

5 Utilities
5.1 Electrical power
Parameters Units Value
For LT motors (UPTO AND INCLUDING 200 KW)
Voltage V 415 +/- 10%

Section A 7
 Operation & Maintenance Manual

Parameters Units Value

Frequency Hz 50 +/- 5%
Type AC, 3 Phase, 4 wire
For Instrumentation (field switches, Level gauge illumination, solenoid valves etc.)
Voltage V 110
Frequency Hz 50
Type Single Phase, 2 wire
For Field Transmitters
Voltage V 24
Frequency Hz NA
Type DC

5.2 Cooling Water

Parameters Unit Value
Supply Pressure Kg/cm2(g) 3–4 @ Battery Limit
Supply Temperature Deg C Ambient @ Battery Limit
Quality Clear & colourless
Duty BFP Pump cooling & Sample cooler
Quantity (for BFP pump) Kg/Hr 1000 (Normal) , 1200 (Maximum)
Quantity (for Sample cooler) Kg/Hr 600 (Normal) , 720 (Maximum)

5.3 DM Water
Parameters Unit Value
Supply Pressure KSC (g) 5 @ Battery Limit
Supply Temperature Deg C Ambient @ Battery Limit
Flow Kg/Hr 1200 (Normal) , 15000 (Maximum)

5.4 Instrument Air

Parameters Unit Value
Pressure Kg/cm2(g) 5– 6
Dew point Deg c -40
Temperature Deg c Ambient
Quality — Oil & moisture free
Quantity scfm 50 (continuous) & 25 (Intermittent)

5.5 Deaerator Steam

Parameters Unit Value
Pressure Kg/cm2(g) 4.0 (Normal) , 9.0 (Maximum)
Temperature Deg c 185
Quanlity Kg/hr 5000 (Normal)

Section A 8
 Operation & Maintenance Manual

5.6 Chemicals for Dosing

HP Dosing Tri sodium phosphate
LP Dosing Hydrazine

6 ID Fans
Sr
Description Value
No.
1 Type of fan Centrifugal
2 Quantity 02 nos
2 Drive Electric motor
3 Coupling Resilient type coupling
4 Rated head 410 mmWC
5 Rated capacity 31.6 m3/sec
6 MOC of casing IS 2062 Gr A (MS)
7 MOC of impeller SAILMA 350
8 MOC of shaft EN 8
9 Fan speed 980 rpm
10 Cooling water requirement Not required.
By variable frequency control & Pneumatic
11 Type of ßow control
operated multi louver damper.
12 Type of isolation Not required
13 Type of Lubrication Grease (Servo Gem; EP2)

7 Deaerator
Description Valve
Deaeration capacity 48 m3/hr (Max)
Storage tank Capacity (Full) 27 m3
Storage tank capacity 16 m3
Operating pressure 1.76 bar(g)
Operating temperature 120° C (case 1) & 130 ° C (case 2)
Design pressure 3.0 Kg/cm2(g)
Design temperature 200 ° C
ASME SECT. VIII DIV Edition 2004, ADDENDA
Design & Construction code
2006 (WITH ‘U’ STAMPING)

8 HP/ LP Dosing System

Make : Metapow Industries
Sr No. Description Value
Storage tank – 1 no, Stirrer – 1 no., Dosing
1 Major parts
pumps – 2 nos.
Storage tank Details

Section A 9
 Operation & Maintenance Manual

Sr No. Description Value

1 Size of storage tank 600 mm x 800 mm x 5 mm
2 Tank capacity 150 liters
3 MOC of tank IS 2062 MSRL; Rubber lined 3mm
4 MOC of chemical basket SS 304
Dosing pump Details
1 Pump make VK Pumps / Equiv.
2 Pump capacity (HP/LP) 0– 6 LPH
3 Pump type Reciprocating Plunger type
4 Operating Pressure (HP/LP) 76 kg/cm2 / 6.35 kg/cm2
5 Safety Relief Valve Set Pressure (HP/LP) 102 kg/cm2 / 8 kg/cm2
6 Type of Lubrication / Quantity ISO VG 460 / 0.8 liters
7 Motor Details Crompton Greaves
Stirrer details
1 Type of operation Motorised
2 Motor Details 0.5 HP / 1000 RPM (HP); 750 RPM (LP)

9 Boiler Feed Pump

DESCRIPTION UNIT VALUE
MAKE KSB PUMPS LTD.
Type & Size HAD 65/15
Quantity NO 3 (2W/1 SB)
Fluid FEED WATER
Pump Speed RPM 2900
Capacity m3/hr 26
Design Head M 960
Fluid Temp °C 130
Gear type Spacer Coupling
Coupling Type (Make - Rathi)
Lubrication OIL SERVO SYSTEM / ENKLO- 46
Motor kW/RPM 160 /2985 (Make – Siemens)

10 Soot Blower
Long Retractable soot
Sr No. Description Rotary soot blower
blower

Super heater & Evaporator

1 Location Economizer Zone
Zone
2 Steam temperature deg c : Saturated
3 Steam pressure kg/cm2(g) 20

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 Operation & Maintenance Manual

Long Retractable soot

Sr No. Description Rotary soot blower
blower
4 Source of Steam Saturated steam from Steam Drum
5 Drive Motorised

11 Gauge Glass
Drum level Gauge
Description Details

Make HI TECH SYSTEM & SERVICES LTD

11– LG – 143/ 11– LG – 144 & 12– LG – 143/ 12–
Tag No. LG – 144
Type Bi Colour Duco Gauge
Location Steam drum
Operating pressure. 69 kg/cm2 (g)
Hydrotest pressure 112.5 kg/cm2 (g)
C/c distance 750 mm
Visibility Range 314 mm 5 Ports
Operating temp. 285 °C Normal Operating

Blow Down Level Gauge

Description Details
Make Chemtrol Samil
Tag No. 11– LG– 601
Type Tubular Level Gauge Assly
Location Blow Down Tank
Working pressure. 5 kg/cm2 (g)
C/c distance 500 mm
Visibility range 360 mm
Operating temp. 200 °C (Saturated) Normal Operating

12 Safety Valve

DESCRIPTION
UNIT DRUM #1 DRUM #2 SH
APPLICATION

TYPE - SPRING LOADED

MAKE ANDERSON GREENWOOD CROSBY
TAG NO - 11-PSV-001 11-PSV-002 11-PSV-003

SIZE ORIFICE -

SETPRESSUR. Kg/cm2 74.5 75 71

OPERATING
DEG.C 285 285 485
TEMP.

Section A 11
 Operation & Maintenance Manual

DESCRIPTION
UNIT DRUM #1 DRUM #2 SH
APPLICATION

RELIEVING
TPH 8000 8000 6000
CAPACITY
QUANTITY - 1 1 1
FLUID - Sat Steam Sat Steam Sup Steam

13 Safety Relief Valve

DESCRIPTION /
UNIT Details
APPLICATION

TYPE - SPRING LOADED

MAKE - TYCO SANMAR LTD

SIZE ORIFICE - 2.5 X JX 4.0

SET PRESSURE Kg/Sq.cm 23
Model JOS–H–E—35-C-IBR-SPL
Relieving Capacity Rated
Kg/hr 10595/8000
/ Requried
QUANTITY 1 / BLR

14 EMR Valve

DESCRIPTION /
UNIT Details
APPLICATION

TYPE - SPRING LOADED

MAKE - TYCO SANMAR LTD

SIZE ORIFICE - 2.5 X 4.0

SET PRESSURE Kg/Sq.cm 100
Model HPV-ST-68W-IBR
Relieving Capacity Rated
Kg/hr 20611/2750
/ Requried

Section A 12
 Operation & Maintenance Manual

15 Gauge Glass

Drum level Gauge

Description Details

Make HI-TECH SYSTEMS & SERVICES LTD.

Tag No. LI–34101 and LI-34102
Type Bi-Colour duco Level Gauge Assly
Location Steam drum
Operating pressure. 101.0 kg/cm2 (g)
Rating pressure 210 Bar
Hydrotest pressure 315 kg/cm2 (g)
C/c distance 750 mm
Visibility Range 314 mm 5 Ports
Operating temp. 311 °C (Saturated) Normal Operating

Blow Down Level Gauge

Description Details
Make Levcon Instruments
Tag No. LI —35001
Type Tubular Level Gauge Assly
Location Blow Down
Working pressure. 10 kg/cm2 (g)
C/c distance 1000+/-1
Visibility range 860 mm
Operating temp. 200 °C (Saturated) Normal Operating

Section A 13

Section B
Topics Covered in this Chapter
♦ Section Overview
♦ Water And Steam System
♦ Boiler Pressure Part Description
♦ Main Steam Piping
♦ Operational Control
♦ Boiler Blowdown System
♦ Chemical Dosing & Sampling System
♦ Flue Gas System
♦ Soot Blower System
♦ Boiler Protection & Interlock
1 Section Overview
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 Operation and Maintenance manual of
THERMAX LTD (B & H Group) in Subsequent
volumes, provide useful information, guidelines
and data required for the safe operation and
maintenance of the two WHRB’s supplied to
M/s Bhatia Energy & Steels Ltd AT Getanamalli
Tehsil, Gummudipondi, Tamilnadu. Contents of
each of the volumes have been listed else where
in these manuals. It is expected that the Bhatia
Energy & Steels Ltd Engineers and Operators
will familiarize themselves with these data before
operating the boilers.
The WHRB is designed to extract maximum
recoverable heat from the exhaust gas of the
coke oven. For this purpose the exhaust gas ßow
from the oven is arranged in a direction counter
to the water/ steam circuit of WHRB. The exhaust
gas from the coke oven enters the super-heaters.
From the Super-heaters, the exhaust gases travel
through the HP boiler evaporator and economiser
modules before exhausted to the atmosphere by
the stack.
To achieve better controllability of Þnal steam
temperature on varying loads, two stage
super-heater is envisaged with an inter stage
spray type attemperator.
The steam drum placed above the evaporator
serves as a balancing vessel for water and steam.
Section B
Operation & Maintenance Manual
It receives feed-water from the Economiser and
maintains positive water supply to the evaporator
modules. Drum receives the mixture of steam and
water from the evaporator modules by the heat
transfer. After separating water from the steam
/ water mixture at drum, the saturated steam is
supplied to the super-heaters.
Economisers installed behind the evaporator
modules serve to preheat the feed-water fed to
the steam drum recovering heat energy from the
exhaust gas.
General Capacity
The main parameters of the boiler are
Maximum Continuous 20 TPH
Rating
Steam Pressure 66 kg/cm2
Steam Temperature 485+/- 5 Deg C
Generation capacity of the WHRB at the base load
is 20 TPH at super-heater outlet pressure of 66
kg/cm2(g) and temperature of 485+/- 5 ° C.
General description of WHRB
instrumentation
The latest generation of the Þeld instruments
is used to facilitate monitoring and control of
the process variables, generating alarms and
trips. Differential pressure Transmitters for the
measurement of process variables like Pressure,
drum Level and Flow are used. Thermocouples
with transmitters are used for the measurement
of temperature. Control valves with position
transmitter and proximity switches form a part
of control system and act as the Þnal control
element to control the process variables. Position
transmitters allow the monitoring of the controlling
element position. Closed control loops are
conÞgured in DCS (by customer).
Process switches and transmitters monitor the
process variables and generate alarms and safe
shutdown of WHRB.
Control Loops:
Following closed loop controls are provided for the
WHRB operation:
• Drum level Control
• Steam temperature Control
• Furnace Pressure Control
• Soot Blower Pressure Control
• De-aerator Level and Pressure Control
14

Control philosophy of these loops is described in
the document submitted separately.
Referance Drawings:
• D12-0WH-09484 - P & ID for Waste Heat
recovery Boiler – Refer latest revision.
This O & M manual shall be for applicable for both
the 02 boilers. The description in the manual of
the instrument and valve tag no. is dealt with
typically one boiler. However the tag no. for the
Section B
Operation & Maintenance Manual
rest of boiler’s instrument and valves shall be as
per the following nomenclature.
Refer the P & I diagram for the tagging procedure.
Instrument Tagging Procedure.
Tag numbers of Instruments, motorized valves,
pneumatic control valves, safety valves, manual
valves, & drives to be preÞxed with 10 for
common items. 11 & 12 for WHRB 1 & 2
respectively
15

2 Water And Steam System
AIM
The water and steam system covered in this
chapter describes the components of the WHRB
which transfer heat from the exhaust gas of the
Coke oven to the feed water ßowing from the
feed water main to convert it to HP steam of 66
Kg/cm²(g) at a temperature of 485 °C (±5°C). The
components in the serial order of water ßow of
path are,
• Deaerator
• Boiler Feed Water Station
• Boiler Feed Control Station
• Integral Economizers
• Evaporators I & II
• Superheater I
• Attemperator
• Superheater II
The exhaust gas from the Oven ßows in a
direction counter to the water / steam ßow path,
with the hottest gas entering across Superheater
II, followed by all the components mentioned
above in reverse order. The exhaust gas,
after transferring all its recoverable heat to
the Superheaters, Evaporators & Economizers
exhausted to the atmosphere through the Stack.
2.1 Component Description
2.1.1Deaerator
PURPOSE OF DEAERATION
Deaeration removes the corrosive gases such as
dissolved oxygen and free carbon dioxide from
the boiler feed water. This ensures protection
of the feed water lines, steam lines, boiler tubes
and other pressure parts of the boiler against
corrosion and pitting, saves costly boiler re-tubing
and expensive plant shutdowns. Further as the
temperature of feed water is raised from ambient
to Deaerator operating temperature of 120 0C
or 130 0C [which corresponds to the operating
pressure of 1.76 kg /cm2 (g)] and then fed to
boilers through feed pumps, the overall boiler
thermal efÞciency also increases.
Heating the feed water with steam does
deaeration. Vigorously scrubbing the water
with this steam removes the last traces of
non-condensable gases and brings down well
below the recommended level in feed water.
CONSTRUCTION FEATURE
Section B
Operation & Maintenance Manual
The Deaerator supplied is of Thermal -
Mechanical Deaerator in which DM water/
makeup feed water is heated to its boiling
temperature at the operating pressure by steam.
At boiling point all the dissolved gases such as
Oxygen, Carbon Dioxide, Etc. are liberated as
solubility of gases decreases with increase in
temperature. The mechanical scrubbing between
water and heating steam ensures release of the
dissolved gases.
Deaerator is of spray and trays type, consists of a
storage tank and a vapour tank. Water is sprayed
from the top of the vapour tank by spray nozzles
on set of multi level trays below it. Steam is fed
from the supply pipe to the distribution headers
inside the storage tank below the water level.
Partial scrubbing of the steam and water takes
place in the storage tank water and the rest is
taking place in the vapour tank with the incoming
water spray.
Vapour tank is mounted upon the storage
tank. Both the tanks are connected with
steam connection Nozzle at the middle. This
interconnection nozzle of 1000 OD is ßushed with
inner wall of the vapour tank’s dished end and
embedded inside the water level of storage tank
to facilitate the feed water ßow from vapour tank to
the storage tank. Interconnection accommodates
concentrically the steam balancing connection
assembly. This steam connection is projected
inside the vapour tank and masked from the water
ßow direction by a hood Þtted at the top, thus
facilitates the steam ßow from storage tank to
vapour tank.
DM water enters to the vapour tank through
the topside nozzle N18 to the distribution ring
header. Five spray nozzles are Þxed on the
ring header to spray the water into Þne particles
covering the entire cross section of the tank so
that easy and complete scrubbing with steam
is possible. Perforated stainless steel trays at
six levels are placed inside the vapour tank to
provide enough delay time to scrub the feed
water with the upcoming steam. Feed water from
vapour tank ßows into the storage tank through
the interconnection pipe.
Condensate enters to the vapour tank through the
topside nozzle N23 to the distribution ring header.
Nozzles are Þxed on the ring header to spray the
water into Þne particles covering the entire cross
section of the tank so that easy and complete
scrubbing with steam is possible.
Heating Steam is supplied through the supply pipe
(Nozzle N10) to the steam distribution headers
kept inside the storage tank well below the water
16

level. Two steam distribution headers connected
to the supply pipe are lied at the bottom and along
the length of the storage tank. These headers are
perforated pipes to distribute the steam along the
entire length of the storage tank water space.
Steam rises from the bottom of Storage
Tank, heating the water and rises through
the interconnection pipe into the Vapor Tank.
Perforated Trays inside the Vapor tank increase
the residence time of water and Heating Steam.
Oxygen, Carbon dioxide and other dissolved
gases are vented out along with Vent Steam
through the nozzle N13.
The dissolved Oxygen level in the feed water
by mechanical deaeration can be brought to
0.02 to 0.03 ppm. If required the residual
dissolved Oxygen can be further scavenged
by the reaction with chemicals such as sodium
sulphite (catalyzed or un-catalyzed) or Hydrazine.
By chemical scavenging the dissolved Oxygen
level can be brought down to as low as 0.007
ppm. Chemical may be dosed in the storage
section of the deaerator through a header. Nozzle
N4 is provided for this and can be utilised. The
dosing of the particular chemicals is done in
predetermined quantity and concentration. A
sample cooler provided in the feed water outlet
piping is used to collect the sample for analysis
of water.
Storage tank is supported by saddle supports.
One of the saddles is Þxed and the other is sliding
one to take care of thermal expansion. PTFE
sheets are provided under the sliding saddle for
free movement of saddle. Platforms and ladders
are provided for tanks and condenser for O & M
feasibility.
THE ACCESSORIES AND THE MOUNTINGS
Deaerator Level Control
The desired normal water level (NWL), which is
maintained through a level control valve [10-LCV
102] of DM water line & condensate return line.
Level in the storage tank is monitored remotely
by the level transmitter [10-LT 102 A & B ]. Two
nozzles (N11 A/B) at this elevation are provided
for LT connection at distance of 301 mm above
and 1392 mm below the NWL.
A Feed back control loop with the electronic
controller [10-LIC 102] is provided for automatic
level control. Process variable signal for the level
controller is transmitted by the [10-LT 102 A & B
]. Set point of the level controller is to be kept at
’0’ mmWC, which corresponds, to NWL.
Section B
Operation & Maintenance Manual
Apart from this remote level indication direct level
gauge glass [10-LG 103 & 104] are provided to
cover the height between very low level and upto
over ßow level. These level gauge are mounted
on a water column connected to the Nozzles N10
A/B
Over Flow Shut Off Valve
[10-XV 109] shut off valve is provided to drain
the excess water from deaerator if level increases
beyond recommended value. Connection N6 is
assigned for that.
Pressure Control
The deaerator operating pressure of 1.76
kg/cm2(g) is maintained by the pressure control
loop, which contains the pressure control valves
[10-PCV 105] in the steam line, a pressure
transmitter [10-PT 105] mounted on the storage
tank nozzle N12 and an electronic pressure
indicating controller [10-PIC 105] in the control
room. Set point for the pressure controller shall
be kept at 1.76 kg/cm2 (g).
Pressure Relief Valve (10-PSV 005)
A Nozzle N17 is provided at the top of vapour
tank to mount a relief valve. Relief valve would
relieve the steam at the design set pressure of 3
bar(g), when there is excessive pressure build-up
inside the vessels (system) incase of sudden
reduction of water out ßow/ intake to deaerator or
malfunctioning of pressure control loop.
Temperature Gauge
A temperature gauge [10-TE 107] is Þxed on to the
storage tank nozzle (N14).
Vacuum Breaker
A Vacuum Breaker assembly consists of Non
Return Valves directed towards vapor Tank from
atmosphere mounted on the Nozzle N18. This is
to prevent Deaerator from operating at vacuum or
negative Pressure. Vacuum condition inside the
Deaerator would mean that the Deaerator is not
being supplied with enough Steam with respect to
the water ßow leading to condensation of heating
Steam. In case the Deaerator happens to go
under vacuum, atmospheric air will rush through
these Non Return Valves breaking the vacuum.
Air vent
Air vent is provided (nozzle N2) on topside of the
vapour tank. Air vent is provided with an oriÞce
and a globe Valve in parallel with it. Through the
Air vent, Steam and dissolved gases are vent out
17

to the atmosphere. The Valve shall be throttled to
minimize the outßow of Steam. N20 is also one
connection provided for air vent without oriÞce.
Other Connections
Feed water outlet nozzle N3 is provided. Water
outlet piping going to the boiler feed water pumps
suction header.
A drain nozzle (N4) for draining the storage tank.
Pegging steam connection (Nozzle N22): A
perforated pipe connected to the nozzle is laid
along the length of the storage tank below the
water level. Admitting steam in a small quantity
through pegging line and heating the water to
a temperature upto 80 Deg C before admitting
the main steam in large quantity will reduce the
possible hammering.
Steam connection N5 is provided for admitting the
LP steam for heating the deaerator after initial
warm up.
Nozzle N16(A to F) are provided for recirculation
line from the boiler feed water pumps.
A Manhole is provided each for storage and
vapour tank.
A sample cooler is provided in the water outlet of
deaerator for the analysis of the water sample.
Sample cooler is a coil & shell heat exchanger,
sample water is passing through the coil and
cooling water through the shell. Needle valves
are provided at the inlet and outlet respectively to
regulate the sample ßow.
Condensate return line is provided at connection
N21
Balancing leak off line from feed pumps are
provided at connections N19 (A to F) .
REFERENCE DRAWINGS
P & I Diagram for Deaerator,FWP & dosing - D12
-1WH-59879 Rev 3
P & I Diagram for WHRB - D12 -0WH-09484 Rev
4 required through the pump, when the ßow to boiler
Assly of Deaerator - W21-1WH-63955 Rev0
2.1.2Boiler Feed Water Pumps
Deaerated water from the deaerator is delivered
to the boiler by means of boiler feed pumps.
There are three motor driven feed water pumps
available. One pump is a standby pump. The
Feed water pumps are of Multistage Centrifugal
type. The Vendor’s manual is to be referred for
more details on operation and maintenance.
Section B
Operation & Maintenance Manual
Feed water pump’s associated system
Suction piping
Common suction header for both the pumps
is connected from the deaerator outlet piping,
providing necessary suction to the pump.
Individual pump is provided with isolation valves
[LFW-VG-117 / 118 / 119] and a suction Þlter.
Filter prevents foreign particle entry into the pump.
Pressure gauge installed at the pump inlet to
indicate the available suction head while the pump
is running. Differential pressure transmitters
helps to monitor the condition of strainer. If
the dP of suction strainer increases beyond the
recommended value, then the feed pumps gets
signal for trip
Balancing piping
Pump is provided with a balancing line, which is
connected to suction line of pump.
Minimum circulation piping
The minimum circulation piping is provided with
individual pump. This ensures that during the
operation of the pump there will always be a
minimum ßow across the pump even when there
is no discharge into the boiler.
An auto re-circulation valve is provided on
individual pump discharge line for the above
purpose
Throttle valve – for controlling the ßow through the
circulation line.
Non-return valve – to prevent the back ßow.
Discharge Piping
Discharge of each pump is connected to the
common discharge header, which supplies feed
water to the boiler. A pressure gauge [10-PG
124 / 125 / 126] & transmitter [10-PT136 / 137
/ 138] are installed on the discharge header for
observing the discharge pressure.
Auto re-circulation valve (ARC) installed at the
pump discharge maintains the minimum ßow
is low. This minimum circulation ßow is taken
through a line connected back to the deaerator
storage tank with a NRV [LFW-VC-131/134/137]
and a globe valve [LFW-VC 130/133/136].
Cooling Water Piping
Feed Pump Gland cooling arrangement is
provided for stufÞng boxes + lift off devices at DE
and NDE side. The cooling water is fed through
plant cooling water system. Refer the pump
vendor drawing for details.
18

Note
Vendor manual for pumps to be referred
for more operation and maintenance
details.
2.1.3Feed Control Station
WHRB, when it is in service, must be kept
continuously supplied with feed water to maintain
near normal level in the drum. Feed water is
obtained at battery limit (at the inlet of feed water
control station) from the feed water pump at a
pressure of 70.5 Kg/cm² and a temperature of
120ºC. There is one feed control station, which is
in service when the WHRB is operational.
• 100% Flow control FCV-137
The 100% ßow control valve FCV-137 is capable
of feeding the WHRB when the steam ßow from
WHRB is from initial stage.
HFW-VL-124 is by pass for 100% FCV.
The following are installed in the common inlet line
from the Plant feed main to the feed regulation
station
• Pressure indicator 11-PG-136 to indicate feed
water pressure
• Tap off for Attemporater spray water
with manually operated Isolating valve
[DSW-VG-101]
• Flow nozzle 11-FE-137 with impulse
connections to ßow transmitter 11-FT-137
• A temperature Element 11-TE-138 for
indicating temperature of inlet feed water to the
DCS indication.
• Pressure indicator 11-PG-139 to indicate feed
water pressure at economiser header inlet
The ßow transmitters provide feed ßow signal to
the feed Indicating controller 11-FIC-137 (which
will be described later).
2.1.4100% Feed Controller 11-FCV-137
Manually operated valve HFW-VG-121 is the
inlet isolating valve. HFW-VG-127 is the outlet
isolating valve which normally remains open.
Drain valves at upstream and downstream of
11-FCV 137 are used for draining only when
the line is isolated for inspection/maintenance of
valve 11-FCV 137.
Valve 11-FCV-137 is a full load feed regulating
valve for maintaining drum water level and is
pneumatically operated by a spring opposed
diaphragm actuator. The valve opens full on
loss of control air and has no manual over ride.
Section B
Operation & Maintenance Manual
The valve 11-FCV-137 is positioned by the ßow
indicating controller 11-FIC-137.
11-FIC-137 is a three element controller, which
takes into account not only the drum level, but also
the steam ßow from WHRB and the current feed
water ßow, to correctly position the feed regulating
valve FCV-137.
The drum level signal, compensated for drum
pressure, is received in controller11-LIC-142.
A linearised steam ßow signal, compensated
for steam pressure and temperature is also
received in 11-FIC-137. The drum level which is
a measured variable signal, is computed with the
anticipatory signal of steam ßow in 11-FI-137 and
a resultant error signal is fed to feed indicating
controller 11-FIC-137. 11-FIC-137 compares
the level error signal with the feed ßow signal
it receives from ßow transmitters 11-FI-157 &
11-FI-137 and computes a control current signal
based on its set point (usually normal level). The
valve position is transmitted to the DCS. On the
DCS, current drum level, steam ßow, feed ßow &
the feed control valve position can be monitored.
The three element control adopted for the 100%
ßow control valves FCV-137 takes into account
the drum level, steam ßow and feed water ßow for
positioning the control valve as well as it takes only
drum level for its operation at low load.
3 Boiler Pressure Part Description
This boiler is a Single-drum, natural circulation,
top supported, and membrane wall construction.
Various pressure parts are grouped as follows:
1. Economiser
2. Steam drum
3. Silencer
4. Air Vent
5. Evaporator
6. Super heater
7. Attemperator
8. Steam Temperature Control
3.1 Economizer
The Economizer located on the last stages of the
exhaust gas path of the WHRB.
Feed water from the feed regulating station,
enters the Bottom header of the ECO ßows up
wards.
Economizer is provided with air vent and drains.
ECO is hung from the top by two guide supports
19

and anchor support with provision for downward
thermal expansion.
The drain valves are used for draining the ECO
tubes when the WHRB is not in service, if required
for maintenance.
Feed water, after picking up heat from the
Economizer, enters the Drum through t
Economizer outlet pipe. Temperature Indication
/ Recording Instruments 11-TE-138 / 141 are
meant for indicating feed water temperatures
before and after Economizer respectively. There
are pressure gauges 11-PG-139 / 140 at inlet and
outlet header of economiser to monitor the feed
water pressure.
3.2 Steam Drum
The Steam Drum is a long (4000mm approx.) all
welded cylindrical vessel made of SA-516 Grade
70 material. The steam drum is supported by
the main down comers and the down comers
are placed on the WHRB structure over beams.
The sliding arrangement permits a limited shift
due to thermal expansion. The drum is insulated
by lightly resin bonded mineral wool mats. Two
manholes, at either end of the drum, provide
access to the drum. The drum is closed tight
at either end cover plates bolted against the
manhole rim by two holding bars. A gasket is Þtted
between the cover plate and the mating machined
surfaces in the dished ends. The cover plates
swing inside, for convenience during opening.
Steam Drum is Þtted with several components
to perform important functions, which are listed
below:
(a) Steam Drum receives feed water from
the Economizer outlet through feed pipes and
distributes the feed water along the length of the
drum by a perforated pipe 80NB to maintain a near
constant level (Normal water level) for continuous
supply to the evaporator. (to be described further
later) through down comer pipes. While ßowing
through the evaporator panels, by absorbing heat
from the coke oven exhaust gas, the hot water
gets converted to water / steam mixture and ßows
back to the Drum through riser tubes.
(b) Steam drum receives the water – steam
mixture from the evaporator panels through the
riser tubes, the water – steam mixture ßows
tangentially through the Diemeister pad installed
in the steam drum. In this tangential ßow, water,
which is heavier, is separated from steam and
trickle down to mix with the water in the steam
drum. Saturated dry steam collects at the top of
the drum and distributed to the Superheater I.
Section B
Operation & Maintenance Manual
(c)Conditioning of Boiler Water
Due to continuous evaporation of boiler water in
the drum, minor impurities present in the feed
water, concentrate to high impermissible levels
in the boiler water. Rise in hardness of water
(conductivity), content of chlorides, silica etc.,
have to be kept to a minimum to prevent scale
formation or deposits, in the evaporator tubes and
drum.
Sample of Boiler water is collected from the
continuous blow down line through a sample
cooler. If the analysis indicate high conductivity,
(chlorides, silica) etc., small pre-determined
amount of water is continuously drained from
the steam drum through the continuous Blow
down valve CBD-104 with a needle valve for
controlling the ßow to reduce their concentration
to permissible levels in the steam drum.
Tri-Sodium phosphate is dosed into steam in the
boiler drum to maintain a phosphate concentration
and a pH. The Phosphate has the capacity to
convert hardness producing insoluble calcium/
magnesium salts to soluble sodium salts, which
are drained through the blow down. A typical
reaction can be as follows.
3 CaSO4 + 2 Na3 PO4 →Ca3 (PO4)2↓ + 3Na2
SO4.
The dozed phosphate also provides desired
alkalinity to the boiler water. An alkaline pH
minimizes the possibilities of corrosion.
The following facilities have been provided in the
steam Drum for the above operations:
(d) Emergency Blow Down (EBD)
During WHRB startup situations arise resulting
in high drum water levels. As high drum water
levels are not permissible provision has been
made for quickly draining some water from the
boiler drum under this condition. The EBD line,
drawn from the entire length of the drum consists
of a manually operated inlet isolating valve
EBD-VG-101, a manual operated parallel slide
emergency blow down valve EBD-102, The EBD
line drains to the blow down tank. The isolating
valves are normally kept closed and are opened
only when emergency blow down has to be done.
Ensure that the EBD should be close to Blow
Down tank so that the operator can easily operate
the valve during emergency.
(e) Level Gauges, Level Indicators, Level
Transmitters
As maintaining normal water level in the steam
drum is one of the important parameters to be
20

monitored and controlled, elaborate provisions
for level instrumentation has been made on
the Steam Drum. Brief mention of these
instrumentation will be made in this section.
(f)Continuous Blow Down Line
To enable the water drained from the drum to
reßect the true composition of Boiler water, a
perforated pipe 25NB is laid along the water space
of the drum and connected to the CBD line to
the Blow down tank. There is one isolating valve
CBD-VG-101,a needle valve CBD-104. The valve
for Boiler water continuous Blow down (CBD) is
positioned to drain continuously a pre-calculated
quantity.
(g)Sampling Line
The CBD line provided to the sample cooler
through two isolating valves CBD-VG-102 &
CBD-VL-103.
(h)HP (Phosphate) Dozing Line
Dosing of phosphate to the Boiler water is to be
done in a manner that it quickly mixes with the
whole of Boiler water. To enable this, a perforated
pipe, 25 NB has been laid along the length of the
drum and connected to the HP dosing line through
a non-return valve HPC-VC-117 and an isolating
valve HPC-VG-118.
(i)Level Gauges (11-LG 143 / 144)
The Level Gauges is of multi-port type. The top of
the gauge glass is connected to the steam side
of the drum through two isolating valves. The
bottom portion of the gauge glass is connected to
the water side of the drum through two isolating
valves. Care is taken to ensure that the center line
of the center port coincides with the center line of
the drum which is the required normal water level.
Twin drain valves are Þtted to each gauge. The
drains normally remain shut when the gauge is in
service with steam side and water side isolating
valves open.
The level gauges are simple direct reading
instruments and serve for quick and accurate
reading of the drum level. During the start up of
WHRB, level gauges may be the only instruments
which can be relied upon as other instruments
may not be accurate. The level gauges are also
used to verify the readings of other instruments.
The level gauges being located at the drum
level are not convenient for regular operation of
the Boiler. The level gauges however must be
maintained in service as IBR requires that atleast
one of the level gauges must be in service to
operate the WHRB.
Section B
Operation & Maintenance Manual
3.2.1 Drum Level Control
Control of water Level in the steam relies on the
following Instruments.
Level Transmitters and indicators 11-LI- 142A /
142B.
WHRB ID fan trip has been envisaged on Drum
level very Low conditions. To avoid a false trip
from malfunction of any one instrument, two out
of the above three instruments must vote for a trip
action.
The level transmitters provide drum level signal to
the single element and three element controllers.
The above level instruments are connected to the
steam drum, steam and water space through twin
isolating valves. The reading of the steam drum
water level by the above instruments are sensitive
to the drum pressure.
Transmitter 11-PT-145 (through twin isolating
valves) mounted on the steam drum, provide
a pressure compensation signal to the level
transmitters, so that their signals represent true
level neutralizing variations due to pressure
changes. They also provide steam drum pressure
signal to DCS.
11-PG-146 is a local instrument indicating Drum
pressure at the drum elevation.
3.2.2 Drum Safety Valve
To protect the boiler and personnel against
consequences of abnormal pressure increases
caused by sudden load decrease, malfunction
of Þring system, closure of steam valves etc.,
two spring loaded safety valves have been Þtted
on the drum. On increase of steam pressure
beyond a pre- determined set value, the safety
valve opens automatically to relieve steam from
the drum to the atmosphere. The safety valve
closes when the steam pressure falls by around
4% of the set value. IBR prescribes norms for
installation, care and testing of the safety valves,
which are mandatory. Safety valve, 11-PSV-001
and 11-PSV-002 along with the 11-PSV-003 have
the capacity, as per IBR, to relieve steam from
the WHRB in such a manner that pressure rise
above 103% of the working pressure is prevented
on any condition.
As the spring loaded safety valves result in high
noise levels when they open, the exhaust of the
safety valves are connected through a silencer to
substantially reduce the noise level.
Installation, adjustment and maintenance
instructions for safety valves are enclosed which
21
 Operation & Maintenance Manual

may be referred for a full understanding of the 3.5 Evaporator

safety valves.

3.3 Silencer

Mention was made that the exhaust of various

safety valves, steam dump & startup valves are
exhausted through Silencers. The Silencers are
acoustically & mechanically designed to attenuate
the large noise made during operation of these
valves
The silencers are made out of suitable casing in
which the sound absorbing materials are packed
in a certain pattern & wrapped by scrim cloth and
wire mesh to avoid ‘ßy off’ of sound absorbing
materials during operation of silencer at high ßow
rates
The process ßuid enters the annular space
between the sound absorbing materials packing
where the sound energy is absorbed throughout
the length of the silencer.
The Silencers are mounted on separate structures
on top of the WHRB and the exhaust pipes from
the valves are connected to the silencers.
As the silencer contain no moving parts, no EVAPORATOR
operational care is needed except opening the Figure 1
drain plug provided in the drain line, once in three The Evaporators convert hot boiler water received
months to drain the line. from the Drum through down comer pipes into
a steam water mixture, by absorption of heat
3.4 Air Vent from the Coke oven exhaust gas. The steam
water mixture is led back to the drum from the
An air vent on the drum to vent out air during initial evaporators through riser pipes.
boiler Þlling, before start up and during start up.
During start up, the air vents are closed at a drum There are two sections of Evaporators,
pressure of 2 Kg/cm² (g) and when copious steam Evaporator 1 & Evaporator II.
is passing. The air vents are opened after shut The Evaporators are hung from the top headers
down of the boiler when the boiler pressure falls in the ßue path, on two guide supports and
to 2 kg/cm2. one anchor support with provision for thermal
expansion downward & in the sides.
Hot water ßow to the evaporators from the drum
and steam / water mixture to the drum from the
Evaporators through risers. A down comer header
of the Evaporator spans all the Evaporator panels.
The top headers of the panel are connected to
the drum by riser tubes .The circulation through
Evaporator panels takes place as follows
• Heated Boiler water from the drum ßows
through the two down comer pipes to down
comer header.
• From the down comer header, the hot water
ßows to the lower headers, and then through
Evaporation panel tubes, to the Evaporation
panel top headers. During its passage through

Section B 22

the Evaporation panel tubes, the hot water
absorbs heat from the exhaust gas of the coke
oven and gets converted to a water/steam
mixture. This circulation is assisted by the
higher density of water in the down comer
compared to the lower density of water / steam
mixture in evaporator and riser tubes
• The water / steam mixture from the top headers
of the Evaporation panel, ßows in the steam
drum.
• In the steam drum, the steam water mixture
ßows through the separators where water &
steam are separated and saturated steam
ßows to the Superheaters. Seperated water
mixes with boiler water to ßow through the
Evaporator panels again.
3.6 Super Heater
Superheating of saturated steam from drum
is done in two stages in Superheater I & in
Superheater II. Between Superheater I & II, an
attemperator is located to control the temperature
of Þnal steam outlet at 485°±5°C.
Superheaters are made of modules, each
consisting of a top header and a bottom header,
with tubes between the headers. Superheater
modules are hung from their top headers with
provision for thermal expansion down wards & in
the sides.
3.7 Super Heater I
Saturated steam from the drum ßows to the Þrst
super heater top header of Superheater I. From
the top header of the SH l, steam ßows through
the panel tubes to the bottom header of the same
panel, absorbing heat. Then the steam ßows
through the super heater II.
Super Heater I top header (being the top most
point) is provided with Air vents (HPS-VL-106 &
HPS-VG 105). The interconnecting pipes of the
Superheater and lower headers (Lowest point),
are provided with two drains (HPS-VG-107/108).
These drains are operated manually. The air
vents & drains are opened before light up of the
boiler. They are closed at a drum pressure of 2
To 5 Kg/cm².
3.8 Attemperator
The function of the attemperator is to control the
temperature of HHS steam at Superheater I outlet
and Super heater II inlet to 410°C.
Section B
Operation & Maintenance Manual
An inter-stage attemperator is provided in
the superheater to maintain the Þnal steam
temperature. Spraying a controlled quantity of
feed water into the superheated steam lowers its
temperature as it looses some heat in evaporating
the sprayed water.
The attemperator is a header, which
accommodates an inner sleeve shaped like a
venturi. A spray nozzle is Þxed at the entrance
to the restricted venturi section. The sleeve
is held in position Þrmly by the locating pins
welded to the header at the steam entry side.
The sleeve is free to expand at the steam exit
side. Water is sprayed through the spray nozzle.
The steam passes through the venturi picks up
the spray, which completes the evaporation and
thoroughly mixes the steam. The connection of
the inlet to the spray nozzle embodies a thermal
sleeve construction to protect the steam line from
temperature differential between the spray water
and the steam. A drain connection is provided at
the exit of the attemperator.
3.9 Super Heater II
Superheater II receives the steam from bottom
header of Superheater I. From the top header of
the SH II, steam ßows through the panel tubes to
the bottom header of the same panel, absorbing
heat. Then the steam ßows into main steam line.
Super Heater II top header (being the top most
point) is provided with Air vents (HPS-VL-110 &
HPS-VG 109). The interconnecting pipes of the
Superheater and lower headers (Lowest point),
are provided with two drains (MSS-VG-101/102).
These drains are operated manually. The air
vents & drains are opened before light up of the
boiler. They are closed at a drum pressure of 2
To 5 Kg/cm².
3.10 Steam Temperature Control Loop
Attemperator spray control is designed to maintain
the steam temperature at 485 deg C. As the heat
pickup in the superheater increases with load, the
spray water requirement increases with load.
The spray water line for the Attemperator, spray
water is obtained from the Boiler Feed water main,
before the ßow transmitter 11-FE 137. The spray
water line consists of the following.
An manually operated isolation valve
DSW-VG-101. The isolation valve needs to be
opened when attemperator is to be taken into
service.
23

Drain valves DSW-VG-112/113, these drain
valves are opened to drain the line for
maintenance.
Pneumatically operated ßow control valve
11-TCV-153. The ßow control valve is
provided with inlet/outlet Isolating valves
DSW-VG-102/108. The inlet/out Isolating
valves remain normally open. The drain
valves DSW-VG-103/104/106/107 which remain
normally closed. These drain valves are opened
after closing inlet/outlet Isolating valves, when
control valve is to be taken for maintenance.
The spray water line connects to the spray
nozzle of the attemperator through a non return
valve DSW-VC-111. Pressure gauge 11-PI-159,
indicates pressure of the spray water ßowing to
the nozzle.
Temperature Indicators 11-TE-151 & 11-TE 152
provides steam temperature indication before and
after the attemperator to judge the effectiveness of
attemperation.
4 Main Steam Piping
The SH steam line connecting the top header of
Superheater II to the plant steam main.
This line incorporates the following.
• ELECTRICALLY OPERATED SH STEAM
STOP VALVE 11-MV 302 This valve Isolates
the WHRB from the plant / Common steam
header. This valve is provided with an
electrically operated, integral by pass valve
11-MV 303.
• SAFETY VALVE 11-PSV-003 This is a spring
loaded, valve set at 71 Kg/cm², pressure to
protect the boiler against over pressures. The
safety valve is similar to Drum safety valves
described earlier. The exhaust of the safety
valve is piped to a silencer to reduce the noise
levels when the safety valve is operating. The
silencer is mounted on a separate structure on
top of the WHRB.
• START UP VENT VALVE 11-PCV 154 is an
pneumatically operated regulating start up vent
valve. 11-MV 301 is an electrically operated
Isolating valve preceding 11-PCV 154. The
outlet of the start up vent valve is exhausted to
atmosphere through a silencer. The start up
vent valve is to be kept open while start up. If
provides initial steam ßow for the superheaters.
• STEAM LINE DRAIN The steam line drain
consists of the following valves manually
operated MSS-VG-101/102/108/109. These
Section B
Operation & Maintenance Manual
valves are kept opened during start up upto 5
kg/cm2 pressure.
• FLOW NOZZLE Flow nozzle 11-FE-157 is
installed on the steam line to provide impulse
to upstream & down stream pressure readings
to steam ßow transmitter 11-FT-157. The ßow
transmitter reading, after steam pressure &
temperature compensation is used for the
following,
– Steam ßow reading. (11-FI 157)
– Steam ßow compensation for feed ßow,
steam temperature controllers
• SH STEAM TEMPERATURE INPUT
Temperature transmitter 11-TE 153 provide the
steam temperature input for the following
– Temperature Indicating controller 11-TIC-153
which provides steam temperature High &
low alarms and also controls positioning
of the attemperator spray control valve as
described earlier.
– Temperature compensation signal to the feed
ßow, steam ßow instruments.
5 Operational Control
This section explains the major operational control
points described in this chapter.
Steam Drum
• Maintain Feed water, Boiler water quality, and
phosphate concentration.
• Maintain water level in the drum within
permissible low and high levels. The protection
system envisages boiler trip at very high and
very low levels, which should not be by passed.
• Maintain drum level gauge glasses LI 3401 &
PI 34102 in good working condition. Operators
may verify the readings of level transmitters
with the readings of the drum level gauge
glasses once a day.
• Drain superheaters thoroughly during startup.
• THERMAL STRESSES IN DRUM DURING
START UP AND SHUT DOWN Steam Drum
is a large cylindrical shell. Before light up of a
boiler, the inner and outer surfaces of the drum
are at the same temperature. When boiler
is lighted up, the inner surface gets heated
up Þrst by the water (and then by steam) and
transmits heat to the outer surface of drum.
The heat transfer is by conduction and is a bit
slow. For short time after light up, there can be
24
 Operation & Maintenance Manual

differences of temperature between steam and • Manually operated valves must be closed hand
water surfaces of the drum. Such a difference tight only. Use of levers on hand wheels is not
can set up thermal stresses, which are not desired.
desirable, and an alarm sounds at DCS. To
minimize the thermal stresses, the operator 5.1 Steam and Water System
must restrict the Þring rate when starting the Technical Performance Data
WHRB by modulating the diverter damper.
Boiler water temperature rise rate must not be WHRB HEATING SURFACES
above 56 0C per hour till operating pressure
is reached. ECO Modules (Pass 2) - 827.33 m²

• SWELLING During WHRB startup, as the Evaporator I & II - 662.6 m²

Boiler water temperature reaches 90°C, Superheater I & II - 200.45 m²
there is an increase of water level caused by
increase in the volume of hot water. Such WHRB Design Pressure : Maximum working
swelling, if not controlled, can cause a High pressure - 75.0 kg / cm2 (g)
Level trip. To avoid this, initial Þlling is normally
restricted to low level (say – 100 to 150 mm) Set pressure and capacity of safety valves
and the smart Operator anticipates a swell and Set Pressure
uses the IBD to drain and control the level. Capacity
Tag No kg / sq. cm
(Kg/Hr)
• Do not operate the WHRB with safety valves (g)
gagged. Passing safety valves must be 11-PSV-001
attended during the next planned shut down. 74.5 7500
(Drum)

Super Heaters & Attemporator 11-PSV-002

75 7500
(Drum)
• Super heaters must be drained after shut down
and cooling of the boiler. They must also be 11-PSV-003
71 5000
kept open before a cold start up till 2 - 3 kg/cm2 (MS Line)
pressure is built up. During hot light ups they
are opened for a few minutes. Drum Level Gauge
Drum Axis (‘0’ mm)
• Soot blowing of Super Heaters may be done Normal Water Level
– 50 %
once a shift to keep their surfaces clean, it
liquid fuels are burnt. High Level Alarm 65%
Low Level Alarm 35%
• Super heat steam temperatures at exit of
Super Heater- 1, Super Heater 2 main steam Low Level Trip 25%
temperatures must be monitored to see there
is no excessive heat pick up. Compare these
Þgures with predicted performance values. 6 Boiler Blowdown System
High steam temperatures may mean high
metal temperatures. AIM

This chapter describes the WHRB blow down

General system for safe draining of high pressure / High
temperature steam and water from the boiler
• Boiler water can be drained after a shut down
using the blow down tank.
only after depressurizing to 2 kg/sq. cm and
after cooling to 80 °C
System Description
• Draining of Boiler water must preferably done
through the blow down tank. The P & ID of the steam and water system shows
the various drains from the WHRB, SH steam line
• If a tube failure is detected, it is advisable to
and the soot blower system. Large quantities of
plan for an early shut down. It may be possible
steam or high pressure / temperature water are
to quickly repair the failed tube and return
not to be drained through open canals for the
to service. If the shut down is in-ordinately
following reasons:
delayed, there are possibilities of larger
secondary damages, which may prolong the a) Such draining will cause splashing of high
shut down, required for repairs. volumes of steam, which can be a nuisance by

Section B 25

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.
Sr.
Source Valve Nos
No.
Continuous blow
1. CBD-104
down
Emergency blow
2. EBD-102
down
The drains indicated above table are connected
to the blow down tank. The blow down tank
is capable of separating steam from the drain
water. The drains are connected tangentially in
the upper half of the drum, to direct the drain ßuid
circumferentially around the inner wall of the tank,
to aid separation of steam and water by their
differences in densities. A vent line of the tank is
connected to Deaerator.
Level of water is maintained by a control valve
11-FCV-137 through level controller 11-LIC-142
6.1 Other Drains
The drains indicated above table are connected
to the blow down tank. The blow down tank
is capable of separating steam from the drain
water. The drains are connected tangentially in
the upper half of the drum, to direct the drain ßuid
circumferentially around the inner wall of the tank,
to aid separation of steam and water by their
differences in densities. A vent line of the tank is
provided open to atmosphere.
It can be seen that drains have been provided in
the feed water line and the attemperator spray
water lines connected to the drain canal. As
these drains are either for operation to drain these
lines after an isolation or for short time during
charging, their connections to the open canal is
not expected to pose a problem.
• 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
Section B
Operation & Maintenance Manual
d) Low-pressure steam, which can be recovered,
if required, is wasted.
HIGH PRESSURE / HIGH TEMPERATURE
STEAM AND WATER DRAINS
Temp of drain °C Frequency of usage
Continuous, quantity
291°C depending on quality
of baler water
Occasional during
Upto 291°C high levels in drum,
during start up
6.2 Continuous Blow Down Control
CBD control involves the following operations
• Obtaining a sample of boiler water from the
steam drum.
• Analyzing the sample for conductivity,
hardness, NaCL, Silica, Fe, etc., and working
out a rate of draining of boiler water to maintain
the concentrations as suggested in Boiler
water.
• Manually positioning the CBD valve is to be
decided depending on the sample analysis
• Repeating the sampling, analysis and
repositioning the CBD valve after certain
interval is necessary to maintain the required
Boiler water quality. This system of manual
control requires the services of a sampler, a
chemist and a laboratory round the clock.
The arrangements provided for CBD control is:
• A perforated pipe, laid along the water space
in the steam drum connects through a stub to
the continuous blow down line.
• CBD line from drum connects to the blow down
tank.
• A tap off from the CBD line is taken to the
sample cooler for continuous analysis of boiler
water conductivity and also for a grab sample
Sampling of CBD / Boiler water is done in one
of the sample coolers of the sampling package.
This package provides analysis of the following
samples to provide a comprehensive information
of quality of steam and water of WHRB.
• Samples of saturated steam from Top saturated
steam header of WHRB.
26

• Samples of main steam from Steam header
of WHRB.
• Samples of boiler water (CBD) from the steam
drum of WHRB.
• Samples of feed water.
While all the samples above are analyzed for
conductivity by separate analyzers, the CBD
sample and the feed water samples are analyzed
in addition for pH also. A brief description of the
salient features of the sample cooler of the CBD
analyser is given. Care of other sample coolers
is identical. CBD-104 is normally kept open to
maintain small continuous ßow of boiler water to
the blow down tank. This is required to ensure
the sample at any time to the sample cooler is
truly representative of the sample being analysed.
This continuous ßow also ensures that these lines
do not get chocked for want of adequate ßow.
Valves CBD-VG-102 & CBD-VL-103 are isolating
valves to the sample cooler which remains open.
The sample cooler is a tube and shell type heat
exchanger with the boiler water ßowing through
tubes and the cooling water in the outer shell, with
the speciÞc purpose of sampling. Cooling water
is provided from the plant fresh water (DM water
circuit) in a closed loop.
Tri-sodium phosphate dosing to Boiler water to
maintain its phosphate content at 2 to 6 PPM. The
tri-sodium phosphate at the suggested levels,
maintains the alkalinity of the boiler water (pH 9.5
to 10.2) and also converts the harmful, insoluble
calcium and magnesium salts which forms the
residual hardness of boiler water, to benign
soluble, sodium salts, in the form of a soft sludge,
to be drained by the CBD. Phosphate dosing,
prevents corrosion of the water washed parts of
the steam drum and the evaporator tubes, by
adjusting the speed or the stroke of the pump
provided as described below. Excess as well as
reduced phosphate levels in Boiler water should
be avoided. (The phosphate dosing is also some
times called as "HP dosing" as the pump used
develops high pressure to dose against the boiler
drum pressure).
7 Chemical Dosing & Sampling
System
7.1 HP Dosing System
The equipment, which are of stainless steel,
provided for phosphate dosing (“HP dosing”), are
shown in P & I diagram and consists of
• A mixing tank for preparation of 5% tri-sodium
solution.
Section B
Operation & Maintenance Manual
• Two dosing pumps (with one stand by)
• DM Water source for preparation of the
phosphate solution as well as for ßushing
7.2 Mixing Tank
The Mixing tank is a stainless steel covered
cylindrical vessel of 150 litres capacity; with a
level indicating gauge glass (11-LI-701), DM
water inlet line (with a manual isolating valve)
HPC-VL-101, an over ßow drain line, a tank drain
line with a manual isolating valve HPC-VB-121, a
basket for placing required quantity of tri-sodium
phosphate powder for preparation of the solution.
A solution inlet connection to the pumps with
a manual isolating valves HPC-VB-105/106. A
motor operated stirrer is also Þtted for preparation
of chemical solutions.
The level of the mixing tank is monitored by level
switch (11-LSL-701). Availability of a minimum
level is a required permissive condition for starting
or continued service of a dosing pump.
7.3 Preparation of 5% Phosphate
Solution in the tank
• Tank drain valve HPC-VB-121 is closed.
• Gauge glass inlet cocks are opened and its
drain is closed.
• The lid of the tank is opened, and a calculated
quantity of phosphate to prepare 150 litres of
solution is placed in the basket and lid closed.
• The water inlet valve HPC-VL-101 is opened
to admit water (from the DM water line). The
level gauge is watched and when the level in
the tank is nearly full, the water inlet valve is
closed.
• The stirrer is placed in service for 30 minutes
by operating its switch in the local panel.
Availability of a minimum level is a precondition
for starting and running of the stirrer.
7.4 Phosphate Dosing Pump
Two phosphate dosing pumps are provided, out
of which one is in service at a time, and the other
is a standby. The pumps are plunger operated
reciprocating, positive displacement type. The
stroke of the plunger can be altered. The motor is
provided with a variable frequency drive through
a gear box for continuous speed control. The
vendor manual of the pump and gearbox is to be
provided for full information on construction and
parts detail.
Each pump is connected to a common discharge
line with the following valve arrangement:
27

• An inlet valve with a "Y" strainer at the pump
inlet. Y strainer traps dirt or other solid particles
in its basket. The Y strainer is to be cleaned
once a month, after stopping the pump and
closing its inlet and outlet isolating valves.
• On the discharge side of the pump, a pressure
gauge and an outlet isolating valve is Þtted
before the common discharge line. A safety
relief valve has also been Þtted on the
discharge line to relieve any over pressures in
case of closure of valves on the discharge line.
The outlet of the relief valve is returned to the
mixing tank. The relief valve must be tested for
its operation at the set pressure atleast once
a year. The pump must not be operated with
the relief valve continuously operating. (cause
of relief valve operation must be found and
rectiÞed).
• The common discharge line is connected to
the HP dosing line of the steam drum through
an NRV and an isolating valve1. The isolating
valve is veriÞed open before boiler light up and
normally remains open all the time. Phosphate
dosing is through a perforated pipe along the
full length of the water space in the drum.
Availability of a minimum level in the mixing
tank is a pre condition for starting or running of
the dosing pumps. Out of the two pumps, one
pump is selected for service and the other is in
reserve (DCS macro, Local panel). The pumps
are interlocked such that when a working pump
trips, the reserve pump starts automatically.
A phosphate pump is placed immediately in
service after the WHRB start up in the following
manner:
• Boiler water sample is analyzed and phosphate
content is determined.
• The pump is prepared by opening the outlet
valve from the mixing tank, opening the inlet
and the two outlet valves of the pump. Two
minutes are allowed after opening the inlet
valve for the pump to get Þlled with phosphate
solution. The pump is started by switching on
Section B
Operation & Maintenance Manual
the motor. The pressure gauge is observed. It
should show a reading, higher than the steam
drum pressure. An accumulator on the pump
discharge line dampens the pulsations which
otherwise would be there as this is a positive
displacement reciprocating pump.
• Any abnormal noise from the pump, motor
or gearbox is noted. The safety relief valve
should not also be operating. If there are no
abnormalities the pump is allowed to run.
• Every four hours, the phosphate content in the
boiler water is checked by laboratory sample
analysis and also by the pH meter. The pump
speed stroke is increased or decreased to
maintain the phosphate content within 8 to 10
PPMS by continuous pump operation.
• The phosphate solution level is observed in the
mixing tank by the gauge glass. If the level
falls to 25% of the gauge glass level, additional
solution is prepared as stated above.
FLUSHING THE PHOSPHATE PUMP AND
THE LINES WITH WATER DURING LONG
STOPPAGE OF THE WHRB:
If the WHRB is to be stopped for more than a few
days for servicing or maintenance, the phosphate
pumps and the line are ßushed with water to keep
them clean in the following manner.
A (ßushing) line is connected from the tank
solution preparation DM waterline to the inlet line
of the pumps . The pump which was in service
earlier is run, for about 30 minutes to one hour.
DM Water ßushes the phosphate solution from
the pump and the lines to the steam drum and
cleans them. The pump is stopped. The outlet
valve from the mixing tank, is not opened till the
boiler is again lighted and a phosphate pump is
required in service. At that time the isolating valve
on the DM line is closed.
NOTE:Do not operated the Stirrer of the HP
dosing pump when the HP tank is dry or not
Þlled with water or the dosing solution. The dry
operation of the stirrer can lead to failure of the
stirrer (misalignment of the stirrer).
28
 Operation & Maintenance Manual

7.5 Water And Steam Quality Control free operation of the WHRB and for obtaining pure
And Monitoring steam. Methods of control of boiler water are also
explained.
AIM
Suggested quality of boiler feed water (and
This chapter describes the standards for the boiler attemperator water) fed to the WHRB is given in
feed water and boiler water for corrosion and scale following table:
PARAMETER Max. permissible value
pH at 25°C 8.5-9.5
Total hardness as CACO3 Nil
Chlorides as NACL Not traceable
Silica as SIO2 <0.02ppm
Total Iron as FE < 0.01 ppm
Copper as CU < 0.003ppm
Dissolved Oxygen < 0.007cc/lit
Sodium Sulphate Not traceable
Residual Hydrazine Traces
Organic matter Nil
Oil Nil
Total dissolved solids < 0.1 PPM
Conductivity at 25°C after cation exchanger and
< 0.15 micro siemens per cm
CO2 removal
Total CO2 Nil
Sodium + Potassium Not traceable

Section B 29
 Operation & Maintenance Manual

Note Following TABLE gives the Boiler Water Quality to

be maintained in the Drum.
• Alkaline levels of feed water minimizes
corrosion of steel
• Chlorides, Silica, Iron, Copper, Organic
matter etc., present in the feed water
concentrate further in Boiler water.
Their higher concentration calls for
increased blow down (CBD) of boiler
water causing loss of useful heat
• Silica in boiler water vaporizes to SiO2
and escapes through steam
• Copper present in water, deposits on
the inner surfaces of evaporator tubes
and is harmful
• Chlorides in boiler water depress
the pH level and renders boiler water
acidic and may cause accelerated
corrosion.
• Oxygen in boiler water promotes
corrosion of boiler tubes
• Oil present in feed water deposit
on tubes and interferes with heat
transfer. Considering all these factors,
maximum permissible values for
contaminants in feed water have been
suggested in Table - 8 .
PARAMETER MAX permissible
Conductivity at 25°C after neutralization. < 50 micro siemens/cm
pH value at 25°C 9.5 to 10.2
Silica as SiO2 <1.2 mg/kg
Sodium Phosphate as PO4 2 to 6 mg/kg
“p” value < 0.1 m Val/kg

Minor permissible contaminants present in the 7.6 Maintaining Quality of Steam

WHRB feed water concentrate to high levels in
boiler water due to continuous evaporation in the Good Quality steam is obtained if the following
steam drum - evaporator circuits. Two controls requirements are met:
are exercised on Boiler water to avoid corrosion
• Proper assembly of bafßes, demister pad in
of WHRB tubes and the drum water - washed
the steam drum as per erection instructions
surfaces. The controls are :
(checked before commissioning of the Boiler)
• Continuous blow control to restrict the
• Boiler feed water as per norms as suggested
contaminants to prescribed levels suggested
above. (monitor the feed water conductivity &
for Boiler water ( Table – 9 )
PH analysers)
• Tri-sodium phosphate dozing to convert
• Control of Boiler water quality as suggested
the hardness producing insoluble calcium,
above.
magnesium salts to soluble sodium salts which
can be drained by CBD and to maintain the • Monitor the saturation steam & main steam
alkalinity levels of boiler water. conductivity

Section B 30

• Increase of saturation steam conductivity may
be a warning for check of drum internals or
maintaining high water levels in steam drum.
It should be understood that if the quality of Boiler
feed water deteriorates, the steam quality is
directly affected as the attemperator spray water
is by boiler feed water..
After several years of service, during a boiler
over haul, bafßes and demister are checked for
damage or erosion holes, which may bypass
steam from the separation devices. Steam which
bypasses the separation devices carry with it
moisture, with its salt contaminants to steam.
Higher than permissible levels of Silica in boiler
water will result in Silica carry over in steam.
7.7 Operational Control
• The water chemistry for determining low
levels of impurities in water calls for special
instruments, special analytical procedures and
an experienced chemist. These should be
available from the time of commissioning the
boiler.
• In a chemical process plant, in spite of the best
available demineralization facilities the boiler
feed water may occasionally get contaminated
by return condenses from the system. A
procedure to systematically check the return
condensates (particularly for contamination by
Fe, Chlorides and Oil) must be established and
contaminated condensates must be discarded.
• pH & Conductivity meters must be calibrated
once a month.
• Phosphate dosing must be adjusted for
continuous operation.
8 Flue Gas System
This chapter describes the sponge iron kiln
exhaust ßow through the WHRB, insulation and
casing of WHRB and the Stack, various sealing
air connections are also indicated..
8.1 System Description
The steam drum & WHRB pressure part panels
are supported on column structures. Insulation
& steel casing is applied enclosing the panels
to provide a gas tight passage for the exhaust
gas from the Sponge iron kiln. WHRB panels &
drum are supported on structures. The panels
are covered fully with insulation and aluminums
cladding. The insulation is held by strips and
the screws as shown in the respective drawing.
Exhaust gas from the Sponge iron kiln enters
Section B
Operation & Maintenance Manual
the WHRB through an expansion bellow. The
following are the instruments in the ßue gas
system.
Exhaust gas from the Sponge iron kiln enters
the WHRB through an expansion bellow. The
following are the instruments in the ßue gas
system.
BEFORE SUPER HEATER:
• Flue gas pressure at DCS, from pressure
transmitter 11-PT-160.
• Temperature transmitters 11-TE-162 &
11-TE-164 for remote indication in DCS.
• These temperature transmitters measure the
temperature of exhaust gas. This is provided
to safeguard the Superheater II, Superheater
I, Evaporator panels.
• Pressure transmitter for remote indication
11-DG-161/163
AFTER SH II
• Temperature indication at DCS 11-TE-165.
(An increase in pressure drop for the same inlet
conditions or drop in heat pickup may suggest
fouling of SH II panels and a need for soot blowing)
AFTER SH I
• Temperature indication at DCS 11-TI-167
• Local pressure indication 11-DG-166
AFTER EVAPORATOR I
• At DCS 11-TE-168 the instruments are for
measuring the heat pickup in Evaporator I and
to institute soot blowing if fouling is suspected
in Evaporator panels.
• Local pressure gauge 11-DG-169 for
measuring draft.
AFTER EVAPORATOR II
• At DCS 11-TE-170 the instruments are for
measuring the heat pickup in Evaporator I and
to institute soot blowing if fouling is suspected
in Evaporator panels.
• Local pressure gauge 11-DG-171 for
measuring draft.
AFTER ECONOMISER
• AT DCS : Temperature indicator 11-TE-172 to
measure the heat pickup in Economizer and to
evaluate fouling if any on Economizer panels.
• Local pressure gauge 11-DG-171 for
measuring draft
STACK (CHIMNEY)
31
 Operation & Maintenance Manual

The oven exhaust gas after ECO is exhausted 9 Soot Blower System
through the Stack. The stack is a hollow
cylindrical structure (Customer scope) 9.1 Soot Blower
Aviation warning lights are Þtted at two elevations
AIM
on the stack. Sampling probes for measurement
of CO, NO2 & SO2 are Þxed at two suitable Soot blowers, 09 in number, have been provided
elevations on the Stack. There are Þve platforms for SH II, SH I, Evaporators and Economisers.
providing access to the aviation lights, sample A PLC based local control panel for operation
probes and ease of repainting the Stack. The and control of these soot blowers are provided.
platforms are accessible from the ground by Vendor manuals of the soot blowers and the local
ladders. On the top 20metres of the Stack, helical control panel have been included in Volume VIII
wind breakers are built around the outer shell, to of this manual, which may be referred for details
provide stability to the Stack against wind forces. of their construction and mode of operation. This
chapter explains steam supply to the soot blowers
8.2 Operational Control and deals with the need for soot blowing, factors
determining the optimum frequency and care to
• The anticipated performance Þgures both be taken during its operation.
steam / water and gas side has been given
in following section. The operator shall
9.1.1System Description
familiarize himself with these Þgures. Elaborate
instrumentation has been provided to measure Operating environment of Soot blowers
each of these factors. Alarms also have
been provided to alert the operator in case of
deviations for several of these readings
• Operator attention is needed particularly for
the following - Kiln Exhaust Gas inlet pressure
and temperature - Gas side pressure and
temperature drop, Steam/Water side heat pick
up across pressure parts like,
– SH II
– SH I
– Evaporator Panels
– ECO
Evaluating these Þgures the operator should
decide the need for soot blowing. (Or other
checks during a shut down).
– Levels of CO, NOX, SOX emissions must
be monitored and any abnormalities must be
reported to the shift in charge
– Healthiness of aviation warning lamps are to
be check periodically
Soot Blower
LRSB LRSB LRSB & RSB RSB
Number
Between Between Between Between
Position Evap II & Eco
SH II & I SH I & Evap I Evap I & II
modules
Angle of rotation° 0-360° 0-360° 0-180° 0-360°

9.1.2Steam Supply kg/cm². Pressure controller 11-PSV-147 exists on

the steam supply line to maintain pressure.
Steam supply required for soot blowing is taken
from the steam drum, which is at a pressure of 66 The Long retract soot blowers remain fully
retracted to their parking position when not

Section B 32

in use. The steam admission to the LRSB is
automatically established as soon as the LRSB
enters the ßue gas path. Cleaning operation, by
jetting steam from the LRSB takes place both
during its advancing and retracting cycles. The
steam ßow through the lance also serves to cool
the lance tube from the excessive heat of the ßue
gas. For this reason, the LRSB should never be
advanced, When an WHRB is in service, without
steam, if an LRSB is being operated, occasionally
it may happen that it gets stuck in the extended
position due to overload. ("Blower Mechanical
Jamming", Soot blower motor overload" Travel
time exceeded alarms on panel). When this
happens, steam from the lance nozzles will be
jetting against the same position on the tube
panels which may cause on erosion of those
tubes leading to a possible tube failure at a later
date. To avoid such steam cutting of the tubes,
the operator must declutch and manually retract
the soot blower immediately using the hand
cranks provided (see soot blower vendor manual).
("Travel time exceeded alarm"). Steam must not
be closed to the LRSB till it is fully retracted for
cooling requirement. Special care is needed for
retraction of soot blowers 1 to 3 which work in
possible high temperature zone which will get
damaged without cooling steam.
Soot blowers are operated in a deÞnite sequence
in the line of ßue gas ßow, starting from SH II
through SH I, Evaporators, Economizer. When
a soot blower is operated, say from SH II, the
soot dislodged from it is likely to resettle on
any of the subsequent heating surfaces (SH I,
Evap II, II, ECO modules) etc. When the soot
blowing is done in the speciÞed sequence, all the
soot, including those which resettle are cleared.
Resettlement of soot however will be more
pronounced on cooler heating surfaces (ECO) for
instance.
Frequency of soot blowing : When the
WHRB are on line, once in a day may be
considered. An optimum frequency can only be
established by carefully studying the beneÞts
of soot blowing or excessive fouling caused by
inadequate soot blowing. When the WHRB is
in continuous service, a fouled super heater will
make attaining the design steam temperature
difÞcult. Unabsorbed heat from Evaporators
and Economizers will increase the ßue gas exit
temperature from WHRB higher than design,
reducing the thermal efÞciency. Effectiveness of
each soot blowing can be studied by noting down
the following performance parameters before and
after soot blowing.
Section B
Operation & Maintenance Manual
• Flue gas temperature across super heaters,
Evaporators, Economizers.
• Feed water / steam temperature pick up across
super heaters, Evaporators, Economizers.
• Spray water ßow through de-super heater
Effective soot blowing increases the heat pick
up. De-super heater spray water ßow may
increase.
It can also happen that there is no change after
a soot blowing. From a careful study of these
parameters, an optimum soot blowing program
can be established related to the fuel.
An effective soot blowing can only be done when
the WHRB steam ßow is above 50% MCR. Soot
blowing at lesser loads may disturb the ßue gas
regime. The Þrst soot blowing after the WHRB
start up is done as soon as 50% MCR steam ßow
is established on the WHRB. Similarly when a shut
down is planned on the WHRB for inspection or
maintenance, the last operation before reducing
the load below 50% MCR should be a soot blowing
so that the panel tubes remain clean during the
shut down without harmful effects of corrosion.
9.1.3Operation and Control
The operation & control is described by a write-up
on sequential soot blowing operation
9.1.4Pre Interlocks
Soot blowing operation can be selected either in
Auto mode from PLC or manual mode by using
selector (soft) switch available in PLC. In auto
mode following interlocks need to be satisÞed for
starting the operation.
• All soot blowers in rest position, feedback
taken from individual S.B. Limit switches
• SB Steam isolation valve open and drain valve
closed
With these, Soot Blowing in Auto Lamp will glow.
Auto sequence can be started from PLC by giving
start command with following conditions in healthy
state
• SB in Auto selected (a knob is provided in the
control room which can select the SB in Auto
or Manual mode, to continue the sequence of
the SB, Auto mode needs to be selected)
• SB sequence reset PB not operated
With this, auto sequence ON lamp will glow and
sequence continues on sheet 3 for drain valve
33

open logic. Reset P.B. is used for resetting
before restarting the sequence and resetting the
mechanical fault condition
DRAIN VALVE OPERATION (OPEN)
Drain Valve to be kept open before starting the
soot blowing cycle for LRSB and RSB. This
ensures removal of condensate accumulated
inside the piping.
The removal of condensate is important because
the water if injected during soot blowing operation
will result in water hammering effect, erosion of
soot blower lance, erosion of tube surface and
more temperature gradient than required at that
zone causing thermal stresses.
S.B. STEAM ISOLATION VALVE OPEN
Ensure that the inlet isolation valve MPS-VG-101
is in open condition. The upstream and
downstream valves of soot blower pressure
control station should be in open condition.
DRAIN VALVE OPERATION (CLOSE)
Close the drain valves of LRSB and RSB
steam piping after ensuring complete removal of
condensate.
However it is advisable to kee the drain valves
crack open during the entire soot blower cycle
completion for continuous removal of condensate
and maintaining the required steam temperature
9.1.5 SOOT BLOWING SEQUENCE
SB-1 (RETRACTABLE)
Sequence continues from SB -1 forwarding
sequence starts with a time delay of 5 secs with
following satisÞed.
• Sequence continued to SB 2 condition
unhealthy. This ensures that there is no repeat
operation of S.B.1 after completion of its one
cycle
• SB1 is pre-selected (if not pre-selected
operation of SB1 is skipped and sequence
continues to SB 2 or next pre-selected S.B)
• Forward position limit switch is not operated
• Retract P.B. is not operated
• SB Steam isolation valve is opened
• DV is closed
• Steam temperature is achieved
• SB 1 is not retracting
• SB 1 fault (overload) is not operated (contact
from MCC)
Section B
Operation & Maintenance Manual
Positive feedback of forwarding contactor in MCC
is taken for SB1 forwarding lamp indication.
As soon as the S.B.1 forward position L.S.
is operated in forwarding operation of SB
-1, forwarding command shall break & SB1
forwarding shall stop. Also if any of the above
mentioned condition goes unhealthy state
forwarding shall stop. Simultaneously Retracting
command shall start retracting operation with
following conditions satisÞed.
• Fault (overload) not operated
• S.B 1 is not forwarding
• S.B 1 rest position limit switch is not operated
In retracting operation when SB1 hits the rest
position limit its retracting stop pulse command
stops the retraction. Sequence is continued to
next pre selected soot blower.
Manual operation of SB1 forwarding is possible
from Local P.B. when manual mode is selected
from PLC (which is Auto mode de selected).
Manual operation of retracting is possible from
local P.B. in both auto and manual mode. It
is also ensured that if any of the soot blowers
is somewhere in mid position when the power
supply is switched ON, the SB shall Þrst retract
and comes to its rest position irrespective of
Auto/Manual mode.
Positive feedback of retracting contractor in MCC
is taken for SB 1 retraction and lamp indication
SEQUENCE COMPLETE
With the sequence continued from SB Steam
isolation valve close logic and following condition
satisÞed sequence completes an respective lamp
glows
1. All soot blowers in rest position .
2. SB Steam isolation valve close
Sequence complete signal is used as pre
interlocks.
MECHANICAL FAULT
In case, any of the soot blowers remains in
operation for more than 300 sec. Which is an
abnormal condition in operation, mechanical fault
alarm is generated. This condition shall occur
because of mechanical failure of soot blower.
Corrective action can be taken on the same
ELECTRICAL FAULT
In case Retractable soot blower trips on overload,
indication Lamp shall glow. One common
overload for all retractable soot blowers is
34

provided as at a time only one soot blower is in
operation.
GENERAL NOTES
• Open, close on commands going to actuators
and MCC are isolated potential free contacts
of relays.
• Actuators shall receive only open or close
command from PLC other necessary
interlocking of switch gears for open close
operation is done inside the actuator integral
starter
10 Boiler Protection & Interlock
AIM
This chapter lists out various protections and
interlocks provided in the WHRB.
Sr.
Location Valve No
No
1 Steam drum 11-PSV-001
2 Steam drum 11-PSV-002
3 Superheater 11-PSV-003
10.1 Alarms And Interlocks
Interlocks provided for various systems ensure
safe and sequential operation at any point of
operation which includes start up, shut down and
emergency conditions. Kindly refer the Section-C
for the detailed description of the Alarms &
Interlocks Description.
10.2 Operational Control
The interlocks are to be tested before
commissioning. Repeat tests are advised once a
year. Any malfunction noted during operation has
to be attended early.
10.3 Automatic Control
AIM
To describe the automatic controls provided for
operation of the WHRB.
Steam Temperature Control
The steam temperature control has following
function:
To position the spray water control valve such a
manner that S.H. steam temperature at outlet of
SH II is controlled at 540 Deg C.
Section B
Operation & Maintenance Manual
As the system protections and interlocks have
been described in the preceding chapters along
with the description of equipment, a listing of
these protections will only be made with brief
notes on their signiÞcance. Testing of these
interlocks & protections is to be done before the
Þrst start up of WHRB and at suitable intervals
subsequently.
Safety Valve on Steam Drum & Superheater
To protect the boiler safety valves have been
provided with set points and blow down capacities
as indicated below
Set pr kg/cm² Blow down tons/hour
74.5
7500
75
71 5000
The control acts on spray control valve, which is a
pneumatically operated control valve, positioned
by positioner.
Drum Level Control
It includes:
• Single Element Control
• Three Element Control
SINGLE ELEMENT CONTROL After density
compensation the drum level signal is used
for indication, control and generation of, Low
alarm, and High alarm.Input goes as PV to the
single element Controller 11 LIC-142A. Out put
of this controller is feed to the level control valve
11-FCV-137. Single element controller should
be used up to 30% load of the boiler. Above
that select three element control to maintain and
control the Drum level with respective to boiler
load.
In case of bad PV both control should go to
Manual mode automatically. And alarm should be
generated.
PV tracking and SP tracking should be provided
to this controller for Auto/ Manual bump-less
transfer.
THREE ELEMENT CONTROL
35

In Three element control O/P of 11 LIC-142B
goes to the summation block where the steam
ßow signal (0-100%) is added to 11 LIC-142B
output. Action of 11 LIC-142B controller is
reverse. The output of summation block is
used as a remote set point for the feed water
ßow controller 11 FIC-137. Remote set point
calculation is given below.
Remote SP for Water Flow Controller (11-FCV
137) = Drum Level Controller (11-LIC 142B) O/P
in % + (Steam ßow signal (11-FT-157) in % * Gain)
+ (Bias in %)
On Bad value of PV, the controller 11-FCV -137
shall be automatically switched to manual mode.
• If (11-FCV 137) is put in manual mode, then
(11-LIC 142B) is to be forced to manual mode.
• SP tracking shall be provided for (11-LIC 142A
& B) in manual mode.
• (11-LIC 600A & B) SP shall track its PV in
manual mode and shall have its local setpoint.
Water ßow is measured using transmitter 11-
FT-137 which receives DP from ßow nozzle 11-
FE-137, the square rooting to be done at DCS
side and is used as process variable for Feed
water ßow controller 11- FIC-137. The output
of 11- FIC-137 is used to control the feed water
control valve 11- FCV-137.
Steam ßow is measured using a steam ßow
transmitter 11 FT-157 connected to ßow nozzle;
the steam ßow transmitter shall be square rooted
at DCS side.
Pressure and temperature compensation of
steam ßow is carried out to take care of errors
arising due to density variation of steam, when
boiler is operating at conditions different from
design conditions.
Comp. Steam ßow = Indicated steam ßow *[
Square Root ({ (P1+1.033) * (T2+273) } / {
(P2+1.033) * (T1+273) } ]
where
P1- Measured pressure signal (Kg/Cm2)
T1- Measured temperature signal in deg C.
P2- Design pressure (Kg/Cm2)
T2- Design Temp of steam, in deg C
[P2 = 66Kg/cm2 absolute & T2 = 485+5 Deg C]
11 LIC-142A Controller action should be direct i.e.
Controller output will increase if PV increases.
Section B
Operation & Maintenance Manual
The action of the 11 LIC-142B (Three Element
controller) is Reverse i.e. out put of the controller
will decrease if the PV increases.
The action of 11 FIC-137 controller shall be direct
action i.e. as the Feed water ßow goes above set
point; the 11-FCV-137 should close (i.e. the 4-20
mA output should increase).
(11 FIC 137) shall have only two modes of
operation. 1. Manual mode 2.Cascade mode
(11 LIC 142A & 11-LIC-142B shall have only two
modes of operation namely. 1. Manual mode 2.
Auto mode
SP shall track its PV in manual mode and shall
have its local setpoint.
Indications and alarms to be conÞgured as shown
in the control schematic. Trends, Totalizers,
indicators and alarms shall be conÞgured in the
DCS as indicated the Control Schematic drawing.
Totaliser 11 FIQ-137, 11 FIQ-157 to be conÞgured
in DCS.
Following are trip interlocks on Drum level Low
Low
• a) ID fan trip
• b) Open ßue gas process stack inlet damper
(11-DI-004)
• c) Close ßue gas damper to boiler inlet
(11-DI-003)
• d) Close damper in recirculation line
(11-DI-005)
FURNACE PRESSURE CONTROL
The furnace pressure is measured using pressure
transmitter 11 PT 160. This is used as a process
variable (PV) and is then compared with a Þxed
set point in the Proportional-Integral controller 11
PIC-160. The resultant control signal actuates the
damper actuator of the ID fan or VFD of ID fan
motor.
ID fan actuator close limit switch 11 ZSC-160 is
taken to DCS as start-up interlock to start ID fan
motor when started in Bypass damper mode. This
is to ensure that the motor starts under no load
condition.
• Action of controller 11 PIC-160 is Direct. The
action of the PID can be changed at site
depending on linkage
• HIC-160A and HIC-160B shall have Auto/
Manual selection.
36

• On Selection of VFD mode damper of same
fan should not go to Auto mode
• Furnace presses Low & high alarms are
generated from 11 PIC-160. • Trends,
indications and alarms shall be conÞgured in
the DCS.
Note
• The ID fan not running signal is taken
from drive logic to close the ID fan
damper when ID fan not running.
• When furnace pressure is controlling
through VFD mode then ID fan damper
will be 100 % open & controlling is
through VFD
• When furnace is controlling through
damper then ID fan motor is in full
speed & controlling is through Damper.
STEAM TEMPERATURE CONTROL
The temperature of Þnal steam is controlled by
attemperation i.e. by spraying feed water into the
steam after the primary super heater.
11 TIC-153 receives Þnal steam temperature
as the process value from 11 TT-153. The
temperature controller shall have 485 °C set point
for the Þnal steam temperature. The out put of the
TIC will be given to the Attemperator temperature
control valve 11 TCV-153. The controller shall
have Reverse action. The controller shall have
PV tracking for manual to auto bump less transfer.
• Steam Temperature Low,High and High High
alarms are to be conÞgured from 11 TIC-153
• The action of the Steam Temp. Controller 11
TIC-153 is Reverse
• The actuator of Steam Temp. Control valve: 11
TCV-153 is air to close type.
• Fail safe action is Stay put /Tends to Open.
• Trends, indications and alarms shall be
conÞgured in the DCS.
SOOT BLOWER PRESSURE CONTROL
The soot blower pressure is measured using
pressure transmitter 11 PT 147. This is used as
a process variable (PV) and is then compared
Section B
Operation & Maintenance Manual
with a Þxed set point in the Proportional-Integral
controller 11 PIC-147. The resultant control signal
actuates soot blower control valve 11-PCV-147.
• Soot blower pressure Low & High alarms are
to be conÞgured from 11 PIC-147
• The action of the soot blower pressure.
Controller 11 PIC-147 is Reverse.
• Fail safe action is close.
• Trends, indications and alarms shall be
conÞgured in the DCS.
DEAEARATOR PRESSURE & LEVEL
CONTROL
Pressure transmitters 11-PT-105 measures the
deaerator pressure & fed to the 11-PIC-105 for
Deaerator Pressure Controller as a PV . The
output of 11-PIC 105 acts on the deaerator
Pressure Control Valve 11-PCV-105. The
controller shall have Reverse action. The
controller shall have PV tracking for manual to
auto bumpless transfer.
• The action of the Deaerator Pressure Controller
shall be reverse.
• Action of DA Pressure control valve 11-PCV
-105 is air to open type.
• Fail safe action is air fail to close.
Deaerator pressure High & Low alarms are
generated from 11-PIC 105 signal.
Level transmitter 11-LT-102A & 11-LT-102B
measures the deaerator level.The output of these
given to 11-LY-102 1002 block .The output of
11-LY-102 fed to the 11-LIC-102 as the PV for
Deaerator Level controller. The output of 11-LIC
102 acts on the Deaerator Level control Valve
11-LCV-102. The controller shall have direct
action. The controller shall have PV tracking for
manual to auto bumpless transfer.
• The action of the DA Level Controller shall be
direct.
• Action of DA Level control valve LCV-002 is
air to close type.
• Fail safe action is open on air fail..
Deaerator Level High & Low alarms are generated
from LIC 102
37

Section C
Topics Covered in this Chapter
♦ Section Overview
♦ Operation Procedure
♦ Pre-requisites to Be Attended Before Start up
♦ Boiler Start Up
♦ Boiler Shutdown
♦ Paralleling WHRB To The Plant steam Mains
♦ Cooling of Shutdown WHRB & Its Preservation
♦ Do’s and Dont’s
♦ WHRB Log Sheet
♦ Emergency Procedures
♦ Alarms and Interlocks
♦ Troubleshooting Chart
♦ Water Quality Recommendations
♦ Safety In WHRB House
1 Section Overview
This section describes the start up, shut down
procedures of the WHRB. WHRB operation &
safety are also described here.
2 Operation Procedure
(Please refer the P & I Diagram for Waste Heat
Recovery Boiler Drg No.- D12-1WH-6203P for the
valve references described in this section)
3 Pre-requisites to Be Attended
Before Start up
• All pre-commissioning activities like Refractory
Dry Out, Alkali Boil Out, pressure test of the
complete system, Safety Valve ßoating check
and steam blowing of pipe lines should have
been completed prior to start up of boiler for
continuous operation
• All instruments should be taken on line and
checked for proper functioning. Switch on
power supply to MCC and control panel.
Ensure all the safety interlocks are in operation
and functioning. Necessary personal protection
equipment and Þeld safety gear should be kept
in place.
• Provide all manholes and hand-holes with
proper gaskets. Use sealant for proper holding
of gaskets.
• Flush all piping like feed water piping, drain
lines, CBD / EBD piping etc with water to
ensure no clogging in pipelines.
• Open isolation valves for level transmitters &
level gauge for steam drum. Run the feed
water pump with minimum opening of ßow
Section C
Operation & Maintenance Manual
control valve. Fill the system with fresh boiler
feed water up to common below normal
water level. Close the manual valve at pump
discharge and stop the pump.
• Check system for any leaks or mal-functioning
equipment.
• Reduce the water level by operating blow-down
valve and check the operation of level low
alarms from transmitter are functioning
properly. Also check readings on level
transmitter and level gauges are matching.
• Keep water level 2 inches below the normal
operating level.
• Adjust valves for boiler operation according to
VALVE SETTINGS.
• Ensure all retractable soot blowers are in rest
positions.
• Check electrical and pneumatic motorised
operation of valves and dampers
• Ensure ßow and pressure of instrument air and
cooling water is as per requirement.
3.1 Feed Water Supply
Primarily before allowing the ßue gases to the
Waste Heat Boiler, a thorough check should be
made of all feed water supply equipment to insure
a continuous and adequate supply of treated and
de-aerated feed water to the boiler. The feed
water quality should be maintained as speciÞed
in the latest Thermax P Diagram. (Drg. No.
D12-0WH-09484). Refer concerned chapter for
recommended water chemistry.
3.2 Valve Settings
Make an inspection of the unit noting the position
of all valves. All valves on blow-down lines,
water wall panel drains, Instrument drains
should be closed. Take level control loop for
De-aerator tank on auto mode and maintain
Normal Operating Level in the tank. Line up the
boiler feed water pump and takes the stand-by
pump on auto-change over mode (if applicable).
Keep all the respective manual valves in the
feed water piping in open position. Initially,
feed water should be introduced to boiler by
“MANUAL MODE” operation of the feed water
control valve FCV 137 or manually operating the
globe valve HFW-VL-124 on feed water control
valve bypass. Keep economizer vent valves
HFW-VL-136,HFW-VG-135 on the outlet header
in fully opened position to remove all air pockets.
Vent on the steam drum SD-VG-119,SD-VL-120
should be opened fully during boiler water Þlling.
It is also advisable to trace feed water piping from
38

supply to boiler insuring that proper valves are
opened or closed as the case may be.
3.2.1See the following valves are closed
positively
• Feed water regulating valves are closed and
are in manual control.
• All blow-down and drain valves on boiler and
water walls
• Soot blower steam supply valve
• Main steam stop valve
• Attemperator control and bypass valves
• Drain valves for instruments.
3.2.2Open the following valves:
• All steam drum vents
(SD-VG-119,SD-VL-120),Puppy header
vent(HPS-VG- 101,HPS-VL-102)
• All instrument and control connection to the
boiler
• Superheater header vents
HPS-VL-106/110,HPS-VG-105/109, drains
HPS-VG-107/108, MSS-VG-101/102, startup
vent MV-301,PCV-154, and main steam line
drains MSS-VG-108/109.
3.3 Filling With Water
Fill the boiler to about 2 inches below normal
water level on the level gauge, thus allowing
room for expansion of water with heating and
pressure rise. Only boiler quality feed water
should be used for Þlling. It is desirable to Þll
the boiler with de-aerated feed water. Filling
with hot water is permissible provided water
is added slowly and ßow does not exceed
capacity of de-aerating heater. Strains set up in
the waste heat recovery boiler from hot water
Þlling are minor compared to strains induced
from heating cold water rapidly. When Þlling
with water, drum vent(SD-VG-119,SD-VL-120)
should be opened to permit escape of
steam or air. The super-heater header drain
valves(HPS-VG-107/108,MSS-VG-101/102) are
all kept open for removal of condensate (i.e. soon
after taking the ßue gas in to the boiler). All the
respective valves on the startup vent piping are
to be kept open.
3.4 Heating Up
Once the boiler has been Þlled with water, the ßue
gas may be taken into the boiler. The ßue gas
Section C
Operation & Maintenance Manual
temperature and the steam drum pressure is to
be controlled as mentioned in the Start-up curve
attached. Annexure – I.
1. Minimum 1/3rd of steam generation to
be vented to assist natural circulation of
boiler and to control superheated steam
temperature. At any point of time during
startup the superheater steam temperature
should not exceed the temperature mentioned
in the curve. By Adjusting the Attemperator
water ßow and ßue gas ßow this can be
achieved.
Note
• CLOSE ALL THE SUPERHEATER
DRAIN VALVES WHEN THE
HEADERS ARE FREE OF
CONDENSATE
• CLOSE DRUM VENTS
(SD-VG-119,SD-VL-120) AS
PRESSURE REACHES TO 3
KG/CM2
• CLOSE PUPPY HEADER
VENT Puppy header
vent(HPS-VG-101,HPS-VL-102)
AND SUPERHEATER VENTS
HPS-VL-106/110,HPS-VG-105/109
AS PRESSURE REACHES TO 5
KG/CM2.
2. As the steam pressure reaches 60% of
operating pressure open the bypass of
main steam stop valve(MV-303) gradually
and allow heating up of steam piping
approximately for 30-45 min. This will help
draining of condensate through the steam
trap bypass line and attaining operating
temperature of piping. After attaining the
required temperature & pressure gradually
open the main steam stop valve MV-302
and close the startup vent valve PCV-154,
bypass of main steam stop valve MV-302.
After achieving the above, opens the stop
valve fully. All steam traps should be lined
up and the by pass valve to be closed and
check periodically for proper removal of
condensate..
3. During all the above steps, maintain normal
water level in the steam drum. Initially, the
controls should be on manual mode only
and once the steam supply to the process
is started, change the controls in auto mode
and monitor continuously.
39

4 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.
4.1 Cold Start Up Procedure
1. In general, superheaters are located in areas
of high temperatures and as a result, the
danger of oxidizing or burning the superheater
tubes always exists. Thus, like it is important
to maintain the water in the boiler, it is equally
important to maintain steam ßow through a
superheater and at a rate sufÞcient to absorb
and carry away the heat surrounding the
superheater. The rate of steam ßow must
compensate for the rate of heat input to the
superheater. It is not only true during periods
of normal operation but also during startup
and shutdown periods. Bearing these in
mind, the following procedure is described for
cold start up.
2. Flue gas temperature at boiler inlet to
be kept below 400°C until the steam
circulation in the superheater is established.
Prior to placing a superheater in
service, the superheater headers drains
HPS-VG-107/108, MSS-VG-101/102, vents
HPS-VL-106/110,HPS-VG-105/109 and
drum vents (SD-VG-119,SD-VL-120), Puppy
Section C
Operation & Maintenance Manual
header vents (HPS-VG-101,HPS-VL-102)
should be opened to clear all water,
condensate and entrained air. These vents
and drains, should all remain open until the
steam pressure reaches about 4 to 5 Kg/cm2
G and a deÞnite ßow of steam through the
superheater have been noted. At this time,
the steam drum vents should be closed.
3. It is necessary to leave the superheater drain
and vent open until the unit is on line and
a deÞnite steam ßow is obtained through
the superheater tubes. It is essential that
steam should ßow through the superheater
at all times when it is subjected to high gas
temperature.
4. Please follow the pressure rising curve for
determining the rate of increasing the steam
drum pressure.
5. Gradually reduce the water level in the drum
during warming up period to normal water
level by blowing down the boiler as required
to maintain the water level in the gauge glass.
This is to drain the water level swelling during
heating up.
6. While the boiler is heating up make frequent
checks of the boiler expansion movements. In
case of any abnormalities, stop ßue gas ßow
and carry out remedial action.
7. Check the boiler water concentration and
constituents as frequently as required to
maintain proper boiler water concentration by
blow down.
8. As the drum pressure increases,
progressively throttle the final
superheater outlet header drain and
startup vent. Do not close startup vent
completely until steam flow through the
main steam line is established.
9. As the steam pressure reaches 60% of
operating pressure open the bypass of
main steam stop valve(MV-303) gradually
and allow heating up of steam piping
approximately for 30-45 min. This will help
draining of condensate through the steam
trap bypass line and attaining operating
temperature of piping. After attaining the
required temperature & pressure gradually
open the main steam stop valve MV-302
and close the startup vent valve PCV-154,
bypass of main steam stop valve MV-302.
After achieving the above, opens the stop
valve fully. All steam traps should be lined up
and the by pass valve to be closed and check
periodically for proper removal of condensate.
40
 Operation & Maintenance Manual

10. During all the above steps, maintain normal Note

water level in the steam drum. Initially, the
NOTE:IT IS ADVISED TO AVOID
controls should be on manual mode only
FREQUENT STARTUP AND
and once the steam supply to the process
STOPPAGE, AS THIS WILL LEAD
is started, change the controls in auto mode
TO THERMAL CYCLIC LOADING
and monitor continuously.
OF THE BOILER AND PREMATURE
FAILURES

Figure 2

Section C 41

4.2 Hot Startup Procedure
1. Restarting the boiler after banked condition
again requires controlled ßue gas ßow rate
so as to prevent the superheater from
overheating. This procedure is applicable
for starting of boiler after a short stop. The
conditions should apply:
2. Drum pressure must be > or equal to 45
Kg/cm2.
3. Drum water level should be at normal water
level.
4. The main steam stop valve MV 302 will be in
closed condition. Open the start up vent valve
PCV 154 to minimum venting and monitor
superheater outlet steam temperature (TT
153).
5. Admit approximately 10% of the ßue gas for
a period of 30 minutes. Keep a close watch
on the superheater outlet steam temperature
(TT-153). Adjust attemperator water ßow
(TCV 153) and start-up vent valve(PCV 154)
as required
6. Open SH drain valves (MSS-VG-108/109) &
removes condensate and open bypass for
main steam stop valve (MV-103)and warm up
the steam line leading to turbine.
7. Now gradually increase the ßue gas ßow and
increase the steam drum pressure (PT-145)
as per the pressure rising curve. Adjust the
ßue gas quantity and / or start-up vent valve
(PCV-154) opening as required.
8. As the steam pressure reaches operating
parameter, open main steam stop valve
(MV-302) & charge steam to turbine.
Gradually close the start up vent (PCV-154)
and bypass for main steam stop valve
(MV-303).
9. Take all the controls on auto mode and check
for stable operation.
Note
IT IS ADVISED TO AVOID
FREQUENT STARTUP AND
STOPPAGE, AS THIS WILL LEAD
TO THERMAL CYCLIC LOADING
OF THE BOILER AND PREMATURE
FAILURES.
5 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.
Section C
Operation & Maintenance Manual
2. Boiler Trip on interlock protection or
emergency shutdown by the Operator.
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.
5.1 Normal Shutdown Procedure
The following procedure for 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. Gradually reduce the load on the unit reducing
the ßue gas ßow rate in line with decreasing
steam ßow. Allow the pressure drop with the
reduction in load to accelerate cooling. Steam
temperature control may be left on automatic
until the point is reached where better control
can be obtained on manual.
2. Open the start up vent (PCV-154) gradually
and close the main steam stop valve
(MV-302).
3. Open the By pass duct damper (DI-004)
and stop I. D fan. Close the boiler inlet duct
isolation damper (DI-003) and damper at ID
Fan outlet (HV-179A/B).
4. Reduce the boiler pressure. As the boiler
pressure drops below 5 Kg/cm2, open steam
drum vent (SD-VG-119, SD-VL-129).
5. Immediately after the boiler is off line, wide
open the superheater vents (HPS-VG-105/09,
HPS-VL-106/10) and drains
(HPS-VG-107/8,MSS-VG-101/2),Puppy
Header Vent (HPS-VG-101/2), main steam
line drain (MSS-VG-108/9) .
6. After the boiler is completely depressurized,
then the cooling process can be initiated
in order to permit entry into the unit for
maintenance, proceed as follows : Purge the
unit ,Cool the unit by opens all the manhole &
Maintain water level at normal.
7. Stop chemical dosing pumps
8. During long shut down of the boiler, Feed
water pump can be shut down only after
stabilizing drum level.
9. If the boiler is to be emptied the boiler water
temperature should be reduced to at least
70°C before draining.)
10. Open the manhole when the ßue gas
temperature is below 50 Deg. C.
42

5.2 Emergency Shutdown Procedure
1. Open the By pass duct damper (DI-004)
and close the damper at boiler inlet (DI-003)
and ID fan outlet damper(HV-179A/B) and
regulating damper DM-001.
2. Open the start up vent PCV-154 gradually and
close the main steam stop valve MV-302.
3. Follow pt. No. 4 to 10 of normal shut down
procedure
5.3 During Black - Out Procedure
Condition
• During the Black out condition
• Open the by pass duct damper DI-004 and
close the damper at boiler inlet (DI-003) & ID
Fan out let (HV-179A/B), regulating damper
(DM-001).
• Ensure that ID fan inlet controlling damper is in
fail-safe position i.e., close condition.
• Close the MSSV (MV-302) and open the
startup vent (PCV-154) to minimum position
just for protecting the superheater (ensure
to avoid overshooting of main steam temp
(TT-153).
• The BFP should start with in 3-min with the
help of emergency power supply and manually
maintain the water level in the steam drum.
• Emergency power supply has to be provided to
the MSSV, Startup vent, inlet hot gas damper,
ID Fan discharge damper and by pass duct
damper. The steam drum pressure and the
level has to be manually maintained.
• Once ßue gas temp at boiler inlet drops below
400 deg C the boiler can be hot boxed up.
5.4 Operator Action Required During
Boiler Cold Start up
• Ensuring permissible rate of heat input to
WHRB during start up
• Operator can also check the local exhaust gas
and temperature indications
• Monitor the water level in the drum (LY-142). As
the temperature reaches about 90°C, a huge
swelling of water level in the drum takes place.
The operator anticipates this and controls the
level by opening the EBD valve (EBD-102).
• Initially, a careful assessment of water level in
the drum is made by checking the local level
gauges (LG-143/44).
Section C
Operation & Maintenance Manual
• Observe the air vent on drum. Air gets expelled
and steady steam starts coming out of the air
vents
• Observe drum pressure (PT-145) at DCS as
also local pressure gauge PG-146
• When drum pressure shows 2kg/cm², drum air
vents can be closed SD-VG-119, SD-VL-120
• When the steam pressure builds up to 2 kg/cm²
. super heater drain valves are to be closed
(HPS-VG-107/8,MSS-VG-101/2)
• When the swelling phase of drum water level is
over and the level shows a decreasing trend,
the 25% feed control can be taken into service
by opening isolating valves .it can be positioned
as required manually to maintain drum level
• Ensure CBD, feed water and super heated
steam samples are ßowing to the coolers and
the pH, conductivity meters are in operation.
Verify pH and conductivity are within permissive
values.
• Allow the WHRB steam pressure and
temperature to build up to rated temperature
and pressure by suitably adjusting ID fan
speed.
• When steady feeding is established through
the feed control valve, the same can be taken
on auto mode, by switching into automode.
If sluggish, continue manual operation of for
some more time before trying again.
• • Monitor the steam drum water level
(LT-142A/B).
• Monitor the parameters, which can cause a
WHRB trip
6 Paralleling WHRB To The Plant
steam Mains
Paralleling WHRB to the steam mains of the plant
is an important operation to be carefully done
without affecting the temperature of steam in the
plant. The pre requisites for this operation are:
• Building the steam pressure in WHRB to a
pressure (PT-156) slightly more than plant
steam pressure.
• With the build up of required steam pressure
and temperature in WHRB, the main steam
stop valve (MV-302) can be opened
• Initiate an open command for MSSV With the
opening of valve , WHRB is ready for supply
of steam to the plant.
• Slowly Increase ID fan speed
43

• Reduce the opening of the start up vent
valve (PCV-154) to about 15%. This valve
can be completely closed later (once
boiler is connected to plant completely.) •
Desuperheater TCV-153 can be taken in
service if SH II outlet temperature TT-153 is
exceeding rated value.
• Observe steam temperatures after SHII TT-153
• Observe the feed control station. When steam
ßow established FCV-137 can be taken in auto
mode.
• Observe the feed control station. When
steam ßow exceeds 25%, full load control
station comes into service (based on operator
selection)
7 Cooling of Shutdown WHRB &
Its Preservation
This chapter describes the methods of cooling a
shut down WHRB and the steps to be taken to
preserve the WHRB to minimize corrosion.
7.1 System Description
WHRB after shut down has to be cooled carefully.
Permissible cooling rate of the WHRB is only half
the permissible rate of heating. If the cooling
rate is accelerated, thermal stresses develop in
the thick components such as the steam drum,
Economiser, Evaporator, Super Heater headers,
Attemperator etc.,
A WHRB is shut down either for keeping it in
reserve as a stand by unit or for maintenance
and inspection. The purpose of the shut down
determines the method of cooling to be adopted.
7.2 Natural Cooling
The WHRB after a shut down is allowed to cool
slowly in a ‘boxed up condition’. The following
valves are also closed.
• HP dosing to Drum HPC-VG-118
• CBD from Drum CBD-104
• Sample line to WHRB water sample cooler
• Sample line to saturated steam sample cooler
& SH steams sample coolers
The WHRB cools slowly, loosing its heat by
radiation to the environment. Till the steam drum
pressure drops to 2 kg/cm2 (g), permissible
water level is maintained in the drum (+150mm
to – 250mm) by intermittent feeding. After
the steam drum pressure falls below 2 kg/cm2
(g) maintaining water level in the drum is not
essential.
Section C
Operation & Maintenance Manual
When the steam drum pressure is less than
2 kg/cm2 (g), the access doors in the WHRB
are kept open to create a natural draft through
the WHRB to the chimney. WHRB cools to an
accessible level in about three-four days.
7.3 Forced Cooling
If the WHRB has to be made available for
inspection or repair and the shut down time has
to be reduced to a minimum, forced cooling of the
WHRB is done.
After the shut down of the WHRB, the HP dosing,
CBD, IBD and sample cooler valves are closed
as for natural cooling. Water level in the drum is
also maintained between permissible levels till the
steam drum pressure falls to 2kg/ cm2 (g).
For 8 hours after the shut down, the WHRB is
allowed to cool naturally in the boxed up condition.
After 8 hours, access doors on WHRB are opened
to allow airßow through the WHRB to the stack.
The de-pressurization of steam in the WHRB is
also speeded up by controlled opening of the start
up valve PCV-154.
However forced cooling is not done unless
absolutely essential.
8 Do’s and Dont’s
DO’S
1. Maintain all instruments and interlocks in good
working condition.
2. All equipment interlocks should always be in
line
3. Maintain normal water level in steam drum
4. Maintain water quality as per the
recommended limits. A table showing the
DM water & drum water quality is included at
the end of this section
5. Pressure raising from cold start must be done
as per the cold start up curve
6. All the duct joints must be leak proof
7. Use proper lubricant and maintain
the schedule as recommended by the
manufacturers
8. Operate the WHRB within the recommended
operation limits
9. WHRB, piping, ducts must be properly
insulated
10. Servicing of equipments should be done as
per the manufacturer’s schedule
11. Maintain proper operation log sheets regularly
44

12. Maintain the instrument air free from moisture
and oily matters and the pressure as
recommended
13. Carry out regular cleaning of direct water level
gauge glasses of WHRB drum
14. Use proper valve gland packing to avoid
leakage
15. Use proper gaskets for ßange joints
16. Operate the blowdown valves as per
recommendation
17. In case of power failure close the steam stop
valve
18. If the water level goes up above the limits
operate the emergency blowdown valve
immediately and maintain the water level to
normal
19. Maintain the feedwater temperature at
economizer inlet and ßue gas temperature at
economizer outlet as recommended
20. Use genuine spares
21. WHRB surroundings and equipments must be
properly illuminated
Section C
Operation & Maintenance Manual
DONT’S
1. Don’t bypass any instruments and safety
interlocks
2. Don’t use raw water as WHRB feedwater
3. Don’t operate the WHRB beyond the
operation limits
4. Don’t leave the furnace door open while the
WHRB is in operation
5. Don’t mix up different lubricants
6. Don’t alter the equipment maintenance
schedule
7. Don’t leave the instrument control panel
unattended
8. Don’t allow unauthorized persons to operate
the WHRB and associated equipments
9. If WHRB is running under combustion control
manual mode, then while increasing load
air should be increased Þrst followed by
gas. Ensure always-proper air to fuel ratio
corresponding to load.
45
 Operation & Maintenance Manual

9 WHRB Log Sheet • Total gas consumption and steam production

of a day to be noted.
• It is suggested to record the WHRB parameters
during startup and normal operation. Observed • Logbook should furnish the details about
abnormalities (if any) recorded can be used • WHRB trips with reasons and time.
for analysis, troubleshooting and maintenance
purposes. • WHRB running hours.
• Log sheet to be Þlled once in every hour by the • WHRB shut down details (forced or planned,
operating staff. outage hours, jobs carried out, etc.,)
• Feed water, WHRB water qualities are also to • Sample log sheet is enclosed.
be noted once in four hours.
SL
NO PARAMETER UNIT Time
1 Turbine load MW
2 ID fan speed %
3 DRUM LEVEL MmWC
4 MAIN STEAM PRESSURE Bar G
5 MAIN STEAM TEP DEG C
6 STEAM FLOW TPH
7 FEED WATERFLOW TPH
8 ATTEMPERATOR I WATER FLOW TPH
9 STEAM FLOW TOTALISER MT
10 FEED WATER FLOW TOTALISER MT
11 ATTEMPERATOR I FLOW TOTALISER MT
FEED WATER PRESSURE AT CONTROL
12 STATION INLET Bar G
13 FEED WATER TEMP.AT ECO . INLET DEG C
14 FEED WATER TEMP.AT ECO. OUTLET DEG C
15 STEAM TEP AT SH I INLET DEG C
16 STEAM TEP AT SH I OUT LET DEG C
17 STEAM TEP AT SH II INLET DEG C
18 STEAM TEP AT SH II OUT LET DEG C
19 FLUE GAS TEP. AT BOILER INLET DEG C
20 FLUE GAS TEMP. AT SH I INLET DEG C
21 FLUE GAS TEMP. AT EVAPORATOR INLET DEG C
FLUE GAS TEMP. AFTER EVAPORATOR DEG
22 C
23 FLUE GAS TEMP. AFTER ECO DEG C
24 FLUE GAS PRESSURE AT BOILER INLET mmWC
25 FLUE GAS PR. AFTER ECO mmWC

Section C 46
 Operation & Maintenance Manual

SL
NO PARAMETER UNIT Time
26 FEED WATER ANALYSIS:
PH
CONDUCTIVITY
TDS
SILICA
HARDNESS
OXYGEN
27 DRUM WATER ANALYSIS:
PH
TDS
ALKALINITY AS CaCO3
SILICA
PHOSPHATE AS PO4
SULPHITE AS SO3

OPERATOR NAME: SIGNATURE: DATE:

Section C 47

10 Emergency Procedures
This Section Describes Causes of Emergency and
Action on .
10.1 Low Water Level
10.1.1Causes
• Feed water control system failure.
• BFP failure 3
• Tube leak
10.1.2Action
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
ßuctuations 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
• Stop the ID fan and open the stack cap
• Shut off steam ßow
Simultaneously, if feed water has become
available and the operator is assured that no
pressure part has been damaged
• Take the feed water control system into manual
mode.
• Allow the water ßow 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
• Reduce the steam pressure gradually
• Open the drum air vent when the pressure
drops below 2 kg/cm2
• Cool the boiler so as to examine the extent of
damage
• Drain the boiler after cooling
• If any tube rupture and bulging is observed
rectify the same
• After the repairs conduct Hydrotest
Section C
Operation & Maintenance Manual
• Determine the cause of low water
10.2 High Water Level
10.2.1Causes
CAUSES
• Feed water control malfunction
• Operator error
• Instrument air supply failure
• Foaming
10.2.2Action
• Take the drum level control loop into manual
mode
• Reduce the water level immediately by
operating the emergency blow down to
maintain the drum level
• Reduce the steam discharge rate, if necessary
• Start the stand by compressor if required
10.3 Tube Failure
Operating the boiler with a known tube leak is not
recommended. Steam or water escaping from
a small leak at pressure 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, boiler casing can get
damaged.
Small leaks can sometime be detected by the loss
of water in the cycle or system. A loss of boiler
water chemicals or by the noise made by the leak.
If a leak is suspected the boiler should be shut
down as soon as possible by following the normal
shutdown procedure.
After the exact location of the leak or leaks is
located, the leaks may be repaired by replacing
the failed tube or by splicing in a new section of
tube, conforming to relevant ASME code.
An investigation of the 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 lab analysis.It is recommended
that every effort be made to Þnd the cause of tube
failures before operation is resumed.
48
 Operation & Maintenance Manual

11 Alarms and Interlocks

ALARM LIST FOR WHRB BOILER

Interlock
Sr. No. Tag No. Service Alarm Alarm value
Details
Deaerator
1. PAH 105 HIGH 2 kg/cm.2 (g)
Pressure
Deaerator
2. PAL 105 LOW 1.5 kg/cm.2 (g)
Pressure
Deaerator
3. LAH 102 HIGH 60%
level
Deaerator
4. LAHH 102 HIGH HIGH 75%
level
Deaerator
5. LAL 102 LOW 40%
level
Deaerator
6. LALL 102 LOW LOW 30% BFWP TRIP
level
Steam drum
7. LAH 142 High 100 mmWC
level
Steam drum
8. LAHH 142 HIGH HIGH 200 mmWC
level
Steam drum -100mmWC
9. LAL 142 Low
level from NWL
Open Bypass
Steam drum -250 mmWC duct damper
10. LALL 142 Very Low
level from NWL
Trip ID Fan
Close Boiler
inlet damper &
11. ID 160A/B ID fan motor Trip simultaneously
open by pass
duct damper.
Super Heater
12. TAL 153 Low 480°C
steam temp.
Super Heater
13. TAH 153 High 500°C
steam temp.
ID Fan
14. PAH 178 discharge FG HIGH 40 mmWC
pressure
ID Fan
15. PAL 178 discharge FG LOW 30 mmWC
pressure
FG pr. at boiler
16. PAL 160 Low -70 mmWC
inlet
FG pr. at boiler
17. PAH 160 High -10 mmWC
inlet
Soot blower
18. PAL 147 Low 15 kg/cm.2 (g)
Pressure

Section C 49
 Operation & Maintenance Manual

Interlock
Sr. No. Tag No. Service Alarm Alarm value
Details
Soot blower
19. PAH 147 High 23 kg/cm.2 (g)
pressure
DP across
20. DPH 118 High 0.1 kg/cm.2 (g)
BFWP strainer
DP across 0.15 kg/cm.2
21. DPHH 118 High high BFWP trip
BFWP strainer (g)

Note
• Interlock is indicated in BOLD
• All the values mentioned are preliminary may undergo revision at time of commissioning if
required.

Section C 50
 Operation & Maintenance Manual

12 Troubleshooting Chart

Repair method &

Indication Probable Source Probable Cause
Preventive Measures
Remove boiler from
service at Þrst
convenient time.
Hydrostatic test to
be done to locate leak.
Repair by welding or
Tube Leak
splicing as indicated
Unable to maintain Slight leakage from and as approved by
boiler water pitting or cracking of insurance or State
concentration tube . Inspection. Determine
cause of failure and
correct it.
Operation at normal
loads should put
Hideout
chemical back in
solution.
Sound of steam
Substantial leak
blowing in furnace
Tube leak from tube/tubes. The same as above
or seeing visible steam
Over-heating
from the stack.
Remove boiler from
the line immediately.
Steam explosion in Failure of tube from low
Inspect or determine
furnace followed by water, tube blockage
Tube rupture whether tube splicing
inability to maintain or erosion of exterior
or wholesale tube
water level. metal surface.
replacement is
necessary.
Check for bafße leaks
High boiler water in steam drum when
concentrations, out of service, or boiler
Solids carry over in the
excessive water level water contamination.
High conductivity steam or high CO2 or
ßuctuation drum bafße Check of degasiÞed
NH3 in boiler water
leakage or deposits on steam sample will
scrubbers indicate if CO2 or NH3
is high
High boiler
concentrations,
Excessive water level Water load or control extreme load swings, Correct condition
ßuctuation conditions varying supply leading to the problem
pressure or control
loop adjustment

Section C 51
 Operation & Maintenance Manual

Repair method &

Indication Probable Source Probable Cause
Preventive Measures
Severity of bowing
will determine extent
of tube replacement.
Internal deposit or low
Internal scale will call
water. Usually internal
for internal cleaning. If
deposits result in tubes
Bowed water wall low water is indicated a
Overheating bowing away from the
generating tubes thorough inspection for
furnace & low water
drum damage and tube
/starve results bowing
seat leakage must be
toward the furnace.
made. Take steps to
prevent recurrence or
low water condition
Repair by retubing
or welding in tube
section or by heating
and driving back
blister depending
Tube blisters Localized overheating Internal deposit
upon insurance carrier
or State Inspector’s
approval. Clean
internally by turbining
or acid cleaning.
Depth and extent of
pitting determines
need and extent of
tube replacement.
Extensive drum pitting
Internal pitting sharp can be welded but is
edged and covered subject to approval by
Corrosion Oxygen in Boiler water
with barnacles in drum either the manufacturer
or tubes. & insurance carrier or
State.
Source of oxygen
must be located and
eliminated
Internal loss of metal
Overheating resulting Individual inspection
not sharply deÞned and
in breakdown of water will determine extent or
accompanied by black
into H & O2 replacement, internal
iron oxide Corrosion
cleaning and correction
Cause is usually from of water conditions are
(Fe 3 O4 ) sludge letdown or required
pluggage.

Section C 52
 Operation & Maintenance Manual

Repair method &

Indication Probable Source Probable Cause
Preventive Measures
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
From corrosive ash
differential expansion
deposit and moisture
with adjacent tubes.
either from dew point
External pitting Corrosion
or external source such Proper external
as leaking soot blowing cleaning can prevent
tube. out of service
corrosion.
Locate and eliminate
source of moisture. If
dew point is from in
-service corrosion, take
steps to raise metal
temperature
When accessible and
with insurance or State
Interference with approval, the cracks
expansion or can be ground out
differential expansion and welded, otherwise
with adjacent parts splice in section or
Mechanical stress
to give mechanical replace tube. Locate
or a combination of
Tube cracking stress or this stress & eliminate source of
stress corrosion or tube
plus corrosion attack. expansion difÞculty
variation.
Vibration set up by by inspection or hot
turbulent gas ßow to cold expansion
characteristics over measurements.
tubes.
Using tube spacers can
stop vibration.
Where accessible and
with insurance or State
approval pad weld or
Mechanical abrasion
External metal loss. splice in a tube section.
Erosion from soot blower
Highly polished area Eliminate channeling
action.
of steam from soot
blowers or use tube
shields
Extent of metal
loss will determine
extent of tube or tube
External metal loss. section replacement.
Prolonged or repeated
Oxidized Þre scale Overheating Inspection or a
overheating.
area. thermocouple
installation will
determine cause of
overheating

Section C 53
 Operation & Maintenance Manual

13 Water Quality Recommendations
AIM
This chapter describes the standards for the boiler
feed water and boiler water for corrosion and scale
free operation of the WHRB and for obtaining pure
steam. Methods of control of boiler water are also
explained.
This chapter must be read in conjunction with the
following vendor manuals.
• HP dosing system -
• Steam and Water analysis system
Suggested quality of boiler feed water (and
attemperator water) fed to the WHRB is given in
following table:

NOTE FEEDWATER

PARAMETER MAX. permissible value

pH at 25°C 8.5-9.5
Total hardness as CACO3 Nil
Chlorides as NACL Not traceable
Silica as SIO2 <0.02ppm
Total Iron as FE < 0.01 ppm
Copper as CU < 0.003ppm
Dissolved Oxygen < 0.007cc/lit
Sodium Sulphate Not traceable
Residual Hydrazine Traces
Organic matter Nil
Oil Nil
Total dissolved solids < 0.1 PPM
Conductivity at 25°C after cation exchanger and
< 0.15 micro siemens per cm
CO2 removal
Total CO2 Nil
Sodium + Potassium Not traceable

NOTE • Copper present in water, deposits on the inner

• Alkaline levels of feed water minimizes
corrosion of steel
• Chlorides, Silica, Iron, Copper, Organic
matter etc., present in the feed water
concentrate further in Boiler water. Their higher
concentration calls for increased blow down
(CBD) of boiler water causing loss of useful
heat
• Silica in boiler water vaporizes to SiO2 and
escapes through steam
surfaces of evaporator tubes and is harmful
• Chlorides in boiler water depress the pH level
and renders boiler water acidic and may cause
accelerated corrosion.
• Oxygen in boiler water promotes corrosion of
boiler tubes
• Oil present in feed water deposit on tubes and
interferes with heat transfer.
DRUM WATER

PARAMETER MAX permissible

Conductivity at 25°C after neutralization. < 50 micro siemens/cm
pH value at 25°C 9.5 to 10.2
Silica as SiO2 <1.2 mg/kg
Sodium Phosphate as PO4 2 to 6 mg/kg
“p” value < 0.1 m Val/kg

Section C 54

Minor permissible contaminants present in the
WHRB feed water concentrate to high levels in
boiler water due to continuous evaporation in the
steam drum - evaporator circuits. Two controls
are exercised on Boiler water to avoid corrosion
of WHRB tubes and the drum water - washed
surfaces. The controls are:
• Tri-sodium phosphate dozing to convert
the hardness producing insoluble calcium,
magnesium salts to soluble sodium salts which
can be drained by CBD and to maintain the
alkalinity levels of boiler water. The controls
are described below.
NOTE The drum water quality should
be continuously monitored and suitable
adjustment in blowdown to be made to
maintain the drum water as per above
recommendations.
14 Safety In WHRB House
• It is expected that BHATIA ENERGY & STEEL
LTD will evolve a comprehensive safety
code for all operations in the plant. A few
suggestions are listed below which can form
part of the plant safety code for the WHRB.
• Hazards of High pressure, high temperature
steam, water must be recognized by the WHRB
operation and maintenance staff.
• Fire extinguishing equipment should always be
available around WHRB
Section C
Operation & Maintenance Manual
• Do not attempt to open the observation ports
in a working WHRB without observing proper
safety procedure.
• For personal safety in handling hot valves,
piping, oil guns etc. wear protective gloves
while working around the WHRB.
• Never enter drums, ducts, furnace etc., until
the WHRB has been shut down and cooled.
• When you need illumination for inspection,
only use low voltage extension cords with low
voltage bulbs with the cords properly earthed.
The power supply be from an earth leak circuit
breaker (ELCB)
• Do not open or enter rotating equipment such
as fans, unless it has been isolated and tagged
from power supply and the rotating equipment
has come to a complete stop.
• Before removing manholes or ßanges in drum
or pipeline, ensure that the drum/line has been
isolated and drained.
• Do not use toxic ßuids like CTC for cleaning in
a conÞned space without adequate ventilation.
• Install and strictly follow a system of permits
and tagging for any maintenance or inspection
work to be done by any person in the WHRB
house.
• Operators trained in Fire Fighting, First AID,
handling electric shocks etc may save lives
and property in an Emergency.
55

Section D
Topics Covered in this Chapter
♦ Section Overview
♦ Recommended Maintenance Practices
♦ Preventive Maintenance
♦ Conditioned Based Maintenance
♦ Boiler Annual Maintenance and Overhaul
♦ Boiler Preservation Procedure
♦ Tube Failures
♦ Welding Procedure SpeciÞcations
♦ General Principle Of Weld Repairs
♦ Water Chemistry
1 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 Recommended Maintenance
Practices
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.
Section D
Operation & Maintenance Manual
Maintenance can be classiÞed as -
• 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.
3 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 beneÞts 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 Þrst 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. (Feed water 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 Þrst 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 modiÞed. A
56

scientiÞc method of preparation of the preventive
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.
3.1 Preventive 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 ßange joint, if necessary.
3.2 Preventive Maintenance Program
for Spares
It may be found that in the Þrst 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 Þrst 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 modiÞed
Section D
Operation & Maintenance Manual
A scientiÞc 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.
4 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
speciÞed 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
modiÞed based on experience in the Þrst two
years of operation.
4.1 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,
57

which require maintenance work for correction,
have been included.
EQUIPMENT
Local level gauges on steam
drum
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 ßoor, buck stay beams,
boiler cladding etc.
Lubricating oil levels of Fans,
& feed pumps bearings,
dosing pump gear box etc.
Fans, BFW pumps dozing
pumps
Section D
CHECK
• Check illumination is proper.
• Leaking valve glands.
• leaking ports
• Blurred level
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.
Check adequacy of oil level.
• Check bearing temperatures .
• Check for Vibration Levels
Operation & Maintenance Manual
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)
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.
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.
58

EQUIPMENT CHECK
Drum and super heater Check for passing of safety
safety valves. valves (noise or wisp of steam
through silencer)
Purity of instrument air 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)
Steam or water leakages • Loose valve gland
from valves and from ßange
• Loosened bolts of ßange joint
joints
and / or failed gasket.
Boiler cladding, air duct or Check for hot spots
ßue gas duct.
Section D
Operation & Maintenance Manual
WORK TO BE DONE
• 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.
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 are
not successful, inform the
Maintenance group.
• 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.
Hot spots may be due to leakage
of ßue gas or hot air. Source of
leakage has to be located after
selective removal of insulation (to
be planned for the next planned
shutdown)
59
 Operation & Maintenance Manual

4.2 Daily Maintenance

Maintenance Check List During Operation

1. Check the correctness of water level in the control desk with direct level glass.
2. Check the level indicators for proper illumination.
3. Check for unusual noises for steam / water leakage.
4. Check for unusual noises for from pumps.
5. Check for vibration in rotary equipments.
6. Check for unusual traces of water on ßoor, buck stays or casings
7. Check for valve & gland leakages.
8. Check for air / gas leakages from ducts and ßue.
9. Check for hot spots, bulging etc. on casings, ducts etc.
10. Check the positions of dampers and cleanliness
11. Check for safety valve steam leakages.
12. Check the bearings for lubrication and cooling water systems.
13. Check all alarm annunciation with respect to set points.
14. Check for water, oil along with instrument air
15. Check the Þeld instruments for its proper indications.
16. Check the stack for any unusual smoke conditions.

4.3 Monthly Checks

Fans, Dosing pumps, With the vibration analyser record
vibration, sound levels and
measure bearing temperature Note
the pressure, ßow 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.

BFW pumps Check for coupling alignment By monthly recording of data,

between motor and pump. Check
the impeller is not rubbing with
pump body. Check operation of
NRV at pump discharge.
Safety valve operation Increase the boiler pressure and
check the operation of valves.
Feed water tank / Deposits of foreign particles
internals
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

Section D 60

Dosing system Cleanliness of dosing tank,
operation of pressure relief valve,
lubrication oil level in pump.
D P Manometer Choking of impulse tubes Liquid
level in manometer
Level switch for steam Close the steam out let valve and
drum water level very low gas by pass damper. Open blow
down valve and check for level
switch very low alarm.
4.4 Checks Every Six Months
During a planned shut down of the boiler, the
following checks can be done.
EQUIPMENT CHECK
Boiler safety interlocks, Coinciding with a planned
start permissive, boiler trip shut down of boiler, carry
protection. out the checks to identify
malfunctioning or sluggish
pressure, temperature switches,
solenoid operated valves,
positioners, proximity switches,
actuators etc.,
4.5 Checks Every Year
(See also jobs listed under Boiler overhaul)
EQUIPMENT CHECK
Pressure temperature, Flow Utilizing the boiler annual shut
level, differential pressure down for overhaul, recalibrate all
controllers pressure, temperature, ßow, level
and d/p controllers as per vendor
manuals
Pressure gauges, Recalibrate, Verify functioning of
temperature gauges, pressure/temperature switches
Pressure/temperature as per design
Switches
Positioners, actuators 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
Section D
Operation & Maintenance Manual
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 rectiÞcation work.
WORK TO BE DONE
Plan for maintenance or
re-calibration of defective items if
any noticed, during the shut down
period.
WORK TO BE DONE
Carry out any maintenance
replacement or adjustment
needed to secure initial calibration
values as per commissioning
records
Repairs or adjustments as
necessary
Repairs or adjustments as
necessary as per vendor manuals
to obtain performance as per
commissioning records. Verify
functioning of proximity switches
where provided. Clean Þlters of
air regulators. Check functioning
of air regulators. Verify tightness
of air connections.
61
 Operation & Maintenance Manual

4.6 Annual Maintenance Check Sheet

COMPONENT NAME INSPECTION REQD FOR

Drums (water side ) • Corrosion
• Scale / deposits
• Pitting
• Metal reduction
• Manhole seat
• Process / instrument tappings
• Internal cleanliness
Feed water pipe in steam drum. • Plugging
• Tightness
• Holes orientation
• Corrosion
• Piping
Chemical dosing • Plugging

Pipe in steam drum • Tightness

• Holes orientation
• Corrosion / Pitting
Continuous blow down • Plugging
Pipe in steam Drum • Tightness
• Hole orientation
• Corrosion / pitting
Furnace tubes • Corrosion
(water side) • Scale
• Pitting
• Metal reduction
Furnace tubes • Corrosion
(gas side) • Build up
• Blisters
• Sagging
• Over heating
• Fly ash erosion
• Sealing
• Supports
• Cracks
• Expansion clearance

Section D 62
 Operation & Maintenance Manual

COMPONENT NAME INSPECTION REQD FOR

• Steam impingement
• Refractory status
• Insulation
• Erosion
Inbed evaporator coils • Erosion
– Þre side • Corrosion
• Build up
• Blisters
• Sagging
• Over heating
• Sealing
• Cracks
• Steam impingement
• Refractory status
Super heater if provided. • Corrosion
(steam side) • Erosion
• Scale
• Pitting
• Metal reduction
• Flare cracking
• Deposits
Super heaters if provided. • Corrosion
(gas side) • Build up
• Sagging
• Over heating
• Fly ash erosion
• Sealing
• Supports
• Cracks
• Exp clearance
• Steam impingement
• Refractory status
• Insulation
Economiser • Corrosion
(water side) • Scale
• Pitting

Section D 63
 Operation & Maintenance Manual

COMPONENT NAME INSPECTION REQD FOR

Economiser • Corrosion
(gas side) • 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.
• Bafße tile status
• Corrosion
• Erosion
• Leakages
• 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

Section D 64
 Operation & Maintenance Manual

COMPONENT NAME INSPECTION REQD FOR

Dampers • Blades rigidity
• Open/ close positions
• Expansion clearance condition of blades
• Erosion of blades
• Bearing freeness
• Lubrications
• Damper linkages
• Interlock mechanisms.
Convection pass • 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

Section D 65
 Operation & Maintenance Manual

COMPONENT NAME INSPECTION REQD FOR

Water level gauges • Cleanliness
• Leaks
• Visibility
• Illumination
• Reßectors
• Mirrors
• Gauge cocks status
• Expansion clearance
• 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

Section D 66

COMPONENT NAME
Remote level gauges
Dosing pumps
Power cylinders
5 Boiler Annual Maintenance and
Overhaul
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).
5.1 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 Ltd. is also
available for carrying out annual overhauls
and inspections.
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Operation & Maintenance Manual
INSPECTION REQD FOR
• Cleanliness
• Leaks
• Visibility
• Illumination
• Gauge cocks status
• Internal deposits
• Insulation
• Liquid status (if any)
As per manuals
As per manuals
5.2 Shutdown and Cooling the Boiler
1. Shutdown the boiler in a planned manner.
2. Don’t force cool the boiler.
3. Open all access and inspection doors.
5.3 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.
5.4 Drum Inspection
1. Open the access doors at either side of the
drum.
2. Allow the drum to ventilate for about 8 hours.
If necessary a fan cooler can be Þtted 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 speciÞcally 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.
67

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 bafßes, 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 bafßes and cyclones are to be ensured.
3. Examine that feed water pipe is intact with
ßange connections tight and discharge exit
correctly oriented.
4. Examine that the continuous blow down pipe
and dosing pipes is not plugged or corroded
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.
5.5 Inspection of Screen, Primary
& Secondary Superheaters,
Evaporators 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
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Operation & Maintenance Manual
2. Evidence of pitting / erosion / corrosion on
tube outer surfaces (exposed to the ßue gas
path)
3. Evidence of overheating (bulging of tubes,
blue color of tubes, blisters, disturbed vertical
alignment of panels)
5.6 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.
5.7 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.
5.8 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
5.9 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.
68

• 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 efÞciency 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 Þlm 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 sulÞte, 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.
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Operation & Maintenance Manual
External treatment is used to remove such
impurities.
• ClariÞcation - 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
69

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
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Operation & Maintenance Manual
ammonia cyclohexylamine and Þlming 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 efÞciency - Higher efÞciency, 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. Expert’s best decide
the maximum permissible concentration after
striding the operating parameters.
70

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
efÞciency.Therefore for trouble free operation
and maintenance peak operation efÞciency,
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 sulÞte. However, it is recommended
that the care and control of water chemistry be
entrusted to specialist.
6 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 efÞcient 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.
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Operation & Maintenance Manual
6.1 Definition 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 speciÞed in these various
procedures. The terms that identify the different
water qualities along with their deÞnitions are list
below: Station service water - Water normally
used for drinking, Þre 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
Þnal concentration of 10 ppm (or a pH of 10.0).
In this procedure, condensate is considered to be
treated demineralised water.
6.2 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 Þring.
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.
71

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 overßow of corrosive liquid
after the moisture has been absorbed, the
trays should not be more than ½ full of dry
absorbent. The amount of absorbent can
vary but the recommended minimum is one
Kg of absorbent per 1000 Kg per hour steam
ßow 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
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.
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Operation & Maintenance Manual
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.
6.3 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 Þlled with deaerated,
Demineralised water treated with 200 ppm
hydrazine (N2H4) for oxygen removal and
sufÞcient ammonia (NH3) in order to attain
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-Þll method. The
blend-Þll 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
sufÞcient heat is delivered to the furnace (i.e.
Þring 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 Þlling further.
4. Back-Þll the with treated Demineralised
water until a rise in steam drum level is
noted. Continue Þlling until water exits
from the steam drum vents. After Þlling,
72

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%.
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.
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, sufÞcient
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 sufÞcient heat can be provided to the
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Operation & Maintenance Manual
unit to eliminate the danger of water freezing and
subsequent damage to pressure parts.
6.4 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.
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 %
6.5 Hot Draining
If the WHRB 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 WHRB can be preserved by hot
draining
The shut down WHRB 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 WHRB
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, ßash dries most of the moisture
present on the tube surfaces. As the pressure
parts remain dry, corrosion is prevented. This
73
 Operation & Maintenance Manual

method of preservation however is not effective 6.7 Preservation of Extra Surfaces of

for move than a week. Pressure Parts of WHRB During
Long shutdown
6.6 Alkaline Water Dozed With
Hyderzine During WHRB shut downs exceeding a few days,
the external surfaces of the pressure parts of
If a WHRB has to be preserved for long periods especially in a chemical plant environment, may
(two months or more) an effective method of come under corrosive attacks by moisture, SO2,
preservation is to Þll the WHRB, Super Heater SO3 vapors etc.
and economizer with water treated with ammonia
to a pH of 10.5 and dozed with 200 PPM or more Keeping inspection doors tightly closed (when no
hydrazine. inspection is being planned) may minimise such
corrosion.
This water is completely Þlled in the water and
steam space of the WHRB and a pressure of 5 Water lancing with hot water or mild alkaline
kg/cm2 (g) is maintained in the drum by a pump. water once a month may wash out the corrosive
components from the external surfaces of the
This method is effective but requires additional
pressure parts. (See maintenance volume)
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 WHRB, the nitrogen blanketing method is
simple and suitable for the type of preservation,
which may be ordinarily required.

Section D 74

6.8 Boiler Lay Up Procedures
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.
6.9 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
d. Ensure no dust/water accumulates on the
rotating equipment.
6.10 Preservation of Instruments
1. Cover all Þeld 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.
Section D
Operation & Maintenance Manual
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.
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. Operate quick shutoff valves frequently
(Twice a week)
6. Ensure that O2 analyzer is powered up and
reference air supply is given when ßue gas is
present.
7. Check operation of Ignition Transformer once
in 2 weeks if burners are provided.
8. Check operation of Flame Scanners & Flame
AmpliÞers once in 2 weeks if burners are
provided.
6.11 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 speciÞed 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
75

washing and drying, during the Þrst 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.
7 Tube Failures
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
down as soon as possible by following normal shut
down procedures (If situation permits).
After the exact locations of the leak or leaks are
identiÞed, the leaks may be repaired by replacing
the failed tube or by splicing in a new section of
tube, conÞrming 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.
Section D
Operation & Maintenance Manual
• It is recommended that every effort be made to
Þnd 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
ßow 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 qualiÞed / experienced
radiographer.
7.1 Tube Failure Investigation /
Analysis Method
Investigation / analysis methodology is listed as
follows, which needs to be followed to Þnd the
actual root cause of the problems.
Please fill up the enlcosed form duly filled and
the same may be sent to Thermax along with
tube sample for analysis.
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
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 speciÞc 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)
76

5. Selection, identiÞcation, 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
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.
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, ßuctuating 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).
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 ßue 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.
Section D
Operation & Maintenance Manual
The failed pressure part tube should not be
hammered, any mechanical impact should be
avoided.
3. Inspect the failed tube and record all Þndings
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,
ßue gas ßow, steam ßow 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
Þlled format with water chemistry of boiler log
sheets should be sent to H.O Pune.
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 ßuid ßow 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 Þlled
format as given below with water chemistry
of boiler log sheets should be sent to H.O for
metallurgical investigations.
77
 Operation & Maintenance Manual

7.2 Tube Thickness Survey Data

Collection – Format

(FURNACE / BOILER BANK / ECONOMISER UNIT NO :

TUBES)
CUSTOMER :
BOILER NUMBER :
DATE OF INSPECTION :

COIL NO CLOCK TUBE STUD LENGTH VISUAL

POSITION THICKNESS OBSERVATIONS

DATA COLLECTION BY

NAME & SIGNATURE

7.3 Failure Reporting Formats

THERMAX LIMITED
ENERGY BUILDING, D1 BLOCK, MIDC, R.D AGA ROAD,
CHINCHWAD, PUNE – 411 019 - INDIA
TELEPHONE 020 – 66126464
FAX : 020 – 27479048
WEB SITE : http://www.thermaxindia.com
EMAIL : 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 SUGGEST 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.)

Section D 78
 Operation & Maintenance Manual

CUSTOMER FEEDBACK FORM CUSTOMER DETAILS:

COMPANY NAME
COMMUNICATION ADDRESS

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 PROBLEM OBSERVATIONS CORRECTIVE COMMENTS /
DETAILS ACTIONS TAKEN RECOMMENDATIONS
1.

2.

OTHER INFORMATION:

EXPECTATIONS FROM TBW :

REPLY AWAITED / SERVICE ENGINEER VISIT :

SIGNATURE & DATE

Section D 79

8 Welding Procedure
Specifications
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.
A speciÞcation 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 speciÞcation deÞnes 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
Section D
Operation & Maintenance Manual
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 speciÞc 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
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 Þt up of the patch weld gap
shall be 2.4 ±0.8 mm
Welding
1. A welder qualiÞed 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 speciÞcations are
listed in Table below
TESTING
All the tube and patch welding shall be subject
to close visual inspection and 100% radiography
80

in accordance with the requirements of ASME
section V. The standard for accepting /rejecting is
speciÞed in ASME section I
Base Material
P1 TO P1 Carbon Steel To Carbon Steel
P3 TO P3 Carbon ½ Moly To Carbon ½ Moly
P3 TO P3 ½ Cr ½ Moly To ½ Cr ½ Moly
P4 TO P4 1-1/4 Cr TO 1-1/4 Cr
P5 TO P5 2-1/4 Cr 1 Moly To 2-1/4 Cr 1 Moly
P8 TO P8 Stainless To Stainless
Figure 3
9 General Principle Of Weld
Repairs
9.1 Furnace and Boiler Tubes
1. 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.
2. Backing rings must not to be used in welding
heat absorbing tubes carrying water or
mixture of steam and water.
3. If a backing ring is not used, the Þrst 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.
4. Pre heat or post heat is not required for
welding carbon steel furnace or boiler tubes.
5. Prior to welding, clean the tube ends to bright
metal inside and outside for at least 40 mm
Section D
Operation & Maintenance Manual
• Completed welds are subject to hydrostatic test
Filler Metal
ER 70S.2 E7018
ER80S.B2 E7018A1
ER80S.B2 E8018B2L
ER80S.B2 E8018B2L
ER90S.B3 E9018B3L
ER308 ER308-16
from the weld area. Remove all deposits of
oxide, boiler water salts and slag to avoid gas
or slag inclusions in the weld.
6. Fit-up of the weld joints is important. It is
difÞcult 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 Þt-up increase the possibility of an
unsuccessful weld.
7. 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 solidiÞes. A butt weld in the tube will
shorten the total tube length about 1.6 mm.
8. Use a clamp or guide lug to hold one end
of the replacement tube alignment while the
Þrst weld is made. Do not tack weld both
end of the replacement tubes particularly if the
existing tubes are rigidly supported
9. As a general rule, Þrst 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
Þrst 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
81

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 difÞcult 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.
9.2 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
Þrst 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 difÞcult 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,
Section D
Operation & Maintenance Manual
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.
9.3 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.
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 deÞnite
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 Þx 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
82

in unsatisfactory connections. The major
welding parameters for shells or tubes
other than carbon steel may be obtained
from qualiÞed welding procedures. Ensure
that welders are qualiÞed in accordance
with ASME Section IX and local provincial
requirements. They must also ensure that
the welding is done to the applicable qualiÞed
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
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
Section D
Operation & Maintenance Manual
a 2 ½" OD by 0.150-inch wall tube stub for a
10% wall reduction is as follows
Measure Hold Dia 2.531
=
Measure Stub OD -2.500
=
0.031 Clearance
2.200
Measure Stub ID =
Clearance = 0.031
2,231 Stub ID @
Contact
Stub ID @ Contact 2,231
=
10% of 0.150 x 2 = 0.030
2.261 Stub ID after
expanding
9. Plug all internal counter bored holes in the
Þeld 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 sufÞciently to permit seal welding to
a tapered plug. 9.6 See Figure 04, page
84. 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
04 and 12. It may be necessary to machine
the tube ends back in order to provide a seat
for the cylindrical plug installation. See Figure
05 and Figure 06.
10. Figure 07 shows the details of this cylindrical
plug and gives instruction for the speciÞc 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.
Figure 08 shows the details of this tapered
plug and give instructions for a plug to Þt
tube diameters from 1-3/4" through 4 ½" OD
and any wall thickness. Figure 09 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
¾ 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.
83

13. Figure 10 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 Figure
11 & Figure 12 where external access is
available and the conditions shown on the
Þgures are met. If those conditions cannot be
satisÞed, tube replacement is recommended.
In these two Þgures, 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
one will have to be installed. Care must be
taken in the plug removal process to not
damage or thin the tube stubs wall.
9.4 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 qualiÞed Welding Procedures.
9.5 Removing Tubes from Drums,
Headers & Tube Plates
1. The removal of tubes from their tube seats
must be done very carefully to prevent
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Operation & Maintenance Manual
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 light-
gage tubes, it is often possible to cold crimp
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 Þrst 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 sufÞciently 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 Þgure 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 ßare 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.
9.6 Plugging of Tubes Drawings
Attached Þgures 04 to 12
84
 Operation & Maintenance Manual

Tapered plug application for shallow internal CTR’B Tube end must be exposed sufficiently for seal welding.
Figure 4

Section D 85
 Operation & Maintenance Manual

Figure 5

Section D 86
 Operation & Maintenance Manual

Figure 6

Section D 87
 Operation & Maintenance Manual

Figure 7

Section D 88
 Operation & Maintenance Manual

Figure 8

Section D 89
 Operation & Maintenance Manual

Figure 9

Figure 10

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.

Section D 90
 Operation & Maintenance Manual

Figure 11

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 ½’ O.D tube
• Plug of SA 181 Gr 70 material preferred
• Sa 105 is also accepted

Section D 91
 Operation & Maintenance Manual

Figure 12

Section D 92

10 Water Chemistry
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
classiÞed 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.
10.1 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 Þltration. Their presence
is undesirable because heating or evaporation
produces hard stony scale deposits on the
heating surface and clog ßuid 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 causes increased
corrosive action of water.
Section D
Operation & Maintenance Manual
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 ßow 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.
10.2 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 classiÞed 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
93

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.
10.3 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.
10.4 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 bafße 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 ßow 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.
10.5 pH Value of the Water and its
Importance
The pH value of the feed water plays very
important controlling the corrosion. pH is a
Section D
Operation & Maintenance Manual
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 Þltration
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 Þlm 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.
10.6 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 ßows 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
94

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 sufÞciently 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 Þrst effect on
the piping system is to choke the ßow of water by
reducing the ßow 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 ßow
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
Section D
Operation & Maintenance Manual
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 Þring, overloading,
sudden load changing or a combination of these
factors. The priming effect is reduced by installing
steam puriÞer, 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
ßuctuating 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.
95
 Operation & Maintenance Manual

Na2CO3 + HOH = CO2 + 2 NaOH agents to the feed water. The most practical
method of preventing caustic embrittlement is to
b) Slow leakage of boiler water through a joint or
regulate the chemical composition of the boiler
seam.
water. The obvious solution to embrittlement is
c) Boiler metal is highly stressed at the point of to eliminate all free NaOH from feed water by
leakage. This may be caused by faulty design and addition of Phosphates.
expansion etc.
The prevention of caustic embrittlement consists
of reducing the causticity or adding inhibiting

Section D 96
 Operation & Maintenance Manual

Section E

Topics Covered in this Chapter

♦ Lubrication Schedule

1 Lubrication Schedule

This section holds the Lubrication Schedule for the Waste Heat Recovery Boiler on Coke Oven
Lubrication Schedule

Section E 97
 Operation & Maintenance Manual

Volume 2 — Drawings

Chapters Covered in this Part

♦ List of Drawings

Volume 2 — Drawings 98
 Operation & Maintenance Manual

List of Drawings
COMMON DRAWINGS FOR BOILER 1 & 2 WHRB
01. P & ID for Waste Heat Boiler (Coke Oven Plant)_D12-0WH-09484_4
02. P & ID for Deaerator & Pumping Ststion_D12-1WH-59879_3
03. Refractory for Boiler_R11-1WH-67044_0
DRAWINGS FOR BOILER NO. 1 ( PL 0501 )
04. G.A. of Boiler No.1_D11-0WH-09485_3
05. Pressure Part Assembly_D11-1WH-66536_1
06. Steam Drum_ P21-1WH-60701_0
07. Steam Drum Internals (Part I)_P21-1WH-60845_0
08. Steam Drum Internals (Part -II)_P21-1WH-60846_0
09. Steam Drum Internal Attachments_P21-1WH-60847_0
10. Detail of Superheater Coil 1A & 1B_PA1-1WH-59631_1
11. Detail of Superheater Coil II_PA2-1WH-59632_1
12. Assembly of Deaerator_W21-1WH-63955_1
DRAWINGS FOR BOILER NO. 2 ( PL 0502 )
13. General Arrangement of Boiler No..2_D11-0WH-09451_3
14..Pressure Part Assembly_D11-1WH-66537_1
15. Steam Drum_P21-1WH-61431_1
16. Steam Drum Internals (Part -I )_P21-1WH-61520_0
17. Steam Drum Internal (Part - II)_P21-1WH-61521_0
18. Detail of Superheater Coil IA & 1B_PA1-1WH-60871_1
19. Detail of Superheater Coil -II_PA2-1WH-60872_1

Volume 2 — Drawings 99
 Operation & Maintenance Manual

Volume 3 — Drawings

Chapters Covered in this Part

♦ E & I SpeciÞcations

Volume 3 — Drawings 100

 Operation & Maintenance Manual

E & I Specifications
Section 01
Instruments Hook Up Diagram

Section 02
2.1 Control Schematic Diagram
2.2 Control Narration

Section 03
DCS Input Output List

Section 04
Soot Blower Input Output List

Section 05
Logic Diagram for Drives

Section 06
Electrical System Required For Motor Selection

Section 07
SpeciÞcation for MOV Valve Actuator

Section 08
8.1 Electrical Load List
8.2 Power & Control Cable Schedule

Section 09
SpeciÞcation for PLC Based SB Panel

Section 10
10.1 Electrical Motor Selection for ID Fan Motor
10.2 Electrical Motor Selection for BFW Pump Motor

Section 11
11.1 Instruments Cable Schedule for Boiler 1
11.2 Instruments Cable Schedule for Boiler 2

Section 12
12.1 SpeciÞcation for Transmitters & Analysers
12.2 SpeciÞcation for Gauges & Switches

Volume 3 — Drawings 101

 Operation & Maintenance Manual

12.3 SpeciÞcation for Valves & Actuators

12.4 SpeciÞcation for Sensors
12.5 SpeciÞcation for Actuators

Section 13

13.1. ARC Valve SpeciÞcation

13.2. CBD Valve SpeciÞcation
13.3. EBD Valve SpeciÞcation

Section 14

14.1 Process Valve Schedule for Boiler 1

14.2 Process Valve Schedule for Boiler 2

Section 15

Soot Blower Panel wiring Diagram Expert Inst

Volume 3 — Drawings 102

 Operation & Maintenance Manual

Volume 4 — Vendor Manuals

Chapters Covered in this Part

♦ Section 01
♦ Section 02
♦ Section 03
♦ Section 04
♦ Section 05
♦ Section 06
♦ Section 07
♦ Section 08
♦ Section 09
♦ Section 10

Volume 4 — Vendor Manuals 103

 Operation & Maintenance Manual

Section 01
Pressure Transmitter — Emerson
O & M Manual
PRESSURE TRANSMITTERS (MODEL 3051)

Section 02
Temperature Transmitter — Emerson
O & M Manual
TEMPERATURE TRANSMITTERS (MODEL 644HA)

Section 03
Pressure Switch — Switzer Instruments
O & M Manual
Pressure Switch Manual

Section 04
4.1 Pressure Gauge — Gauges Bourdon
O & M Manual
Pressure Gauge Manual

4.2 Temperature Gauge — Goa Instruments

O & M Manual
Temperature Gauge Manual

Section 05
Power Cylinder — Keltron
O & M Manual
Damper Actuator - Keltron Manual

Section 06
Loop Power Indicator — Switzer Instruments
O & M Manual
Loop Power Indicator Manual Model (K5105 )

Section 07
I to P Converter — ABB
O & M Manual

Volume 4 — Vendor Manuals 104

 Operation & Maintenance Manual

I to P Converter — ABB_Manual

Section 08
8.1 Flow Nozzle — Starmech Controls

Manual for Flow Nozzle

Data Sheets of OriÞce Plate Boiler 1
Data Sheets of OriÞce Plate Boiler 2

8.2 Thermocouple — Thermal Instruments

Data Sheets

Section 09
Control Valves— MIL

O & M Manual
MIL 41000 HEAVY DUTY BALANCED CAGE GUIDED CONTROL VALVES - MANUAL
MIL 21000 HEAVY DUTY BALANCED CAGE GUIDED CONTROL VALVES - MANUAL
MIL 37 –38 SPRING DIAPHRAGM PNEUMATIC ACTUATOR - MANUAL
8013 Valve Positioner Manual
400 L Positional Transmitter
496 Rotary Electric Switch
776 Air Lock Valve
Solenoid Valve Rotex
Data Sheet & Drawings
Control Valve Data Sheets

Section 10
Motorised Valve Actuator— Auma India Ltd.

Manual
Actuator Manual
MOV G. A. Drawings

Volume 4 — Vendor Manuals 105

 Operation & Maintenance Manual

Volume 5 — Vendor Manuals

Chapters Covered in this Part

♦ Section 01
♦ Section 02
♦ Section 03
♦ Section 04
♦ Section 05

Volume 5 — Vendor Manuals 106

 Operation & Maintenance Manual

Section 01
ID Fan - Flakt Woods
O & M Manual
Fan - Flakt_Manual
Drawings
General Arrangement Drawing of ID Fan

Section 02
BFW Pump — KSB Pumps
O & M Manual
Cover Page
Index of Manual
HDA Manual
Technical Appendix Sheets
Pump Data Sheets
Proposed Performance Curve
Drawings
1. General Arrangement Drawing for Pump
2. Cross Section Drawing for Pump
3. List of Components
4. P&I Diagram for Pump
5. P&I Diagram Part List

Section 03
LP / H.P Dosing System - Metapow Industries
O & M Manual
Dosing System Manual
Drawings
L.P. Dosing System Drawing
H.P. Dosing System Drawing

Section 04
4.1 Long Retractable Soot Blower - R.R. Techno
O & M Manual
LR Soot Blower Manual
Drawings
1. General Arrangement Drawing for LRSB for Boiler 1

Volume 5 — Vendor Manuals 107

 Operation & Maintenance Manual

4.2 Rotary Soot Blower - Sitson India Ltd.

O & M Manual
Rotary Soot Blower Manual
Drawings
1. General Arrangement Drawing for RSB for Boiler 1
2. General Arrangement Drawing for RSB for Boiler 2

Section 05
5.1 Motors— Siemens

Manual
Motor Manual
Data Sheets
Data Sheets for ID Fan Motor
Data Sheets for BFW Pump

5.2 ARC Valve — Schroedahl

Manual
ARC Valve Manual
Data Sheets
Data Sheets for ARC Valve

Volume 5 — Vendor Manuals 108

 Operation & Maintenance Manual

Volume 6 — Vendor Manuals

Chapters Covered in this Part

♦ Section 01
♦ Section 02
♦ Section 03
♦ Section 04
♦ Section 05
♦ Section 06
♦ Section 07
♦ Section 08
♦ Section 09
♦ Section 10

Volume 6 — Vendor Manuals 109

 Operation & Maintenance Manual

Section 01
Safety Valve – Tyco Sanmar
O & M Manual
HCI Model Manual
Drawing & Data sheet
Safety Valve Datasheet
Safety Valve Drawing

Section 02
Safety Relief Valves — Tyco Sanmar
O & M Manual
SAFETY VALVES (JOS — JLT Manual)
Data Sheet & Drawings
SpeciÞcation Sheets
Drawings

Section 03
Drum Level Gauge — Hitech
O & M Manual
Drum Level Gauge Manual
Drawings & Datasheet
Drum Level Gauge Drawings

Section 04
Level Gauge (Tubular ) – Chemtrol
O & M Manual
Tubular Level Gauge Manual
Drawings
Tubular Level Gauge Drawing

Section 05
Reflex Level Gauge — Chemtrols
O & M Manual
Reßex Level Gauge — Chemtrols_Manual
Drawings & Datasheet
Reßex Level Gauge - Chemtrol_Drawing

Volume 6 — Vendor Manuals 110

 Operation & Maintenance Manual

Section 06
Process Valve — KSB
O & M Manual
Process Valve Manual

Section 07
Process Valve — Xomox Sanmar
O & M Manual
Process Valve Manual

Section 08
Blow Down Valve — Levcon Instruments
O & M Manual
Blow Down Valve Manual

Section 09
9.1 Spring Hanger Support — Techno Industries
O & M Manual
Spring Hanger supports Manual
Support Drawing

9.2 Hanger Support – Pipe Support

O & M Manual
Hanger supports Manual
Support Drawing

Section 10
Damper - United Technomech Engineers Pvt. Ltd.
O & M Manual
Manual Guillotion Damper Manual
Pneumatic Guillotion Damper Manual
Pneumatic Operated Multilouvre Damper Manual
Drawings
Manual Guillotion Damper Drawing
Pneumatic Guillotion Damper Drawing
Pneumatic Operated Multilouvre Damper Drawing

Volume 6 — Vendor Manuals 111

 Operation & Maintenance Manual

Volume 6 — Vendor Manuals 112


Index
100% Feed Controller ................................... 19
A
Air Vent ........................................................ 22
Alarms and Interlocks ................................... 49
Alarms And Interlocks ................................... 35
Annual Maintenance Check Sheet ................. 62
Attemperator .............................................7, 23
Automatic Control ......................................... 35
B Evaporator ................................................... 22
Blow Down Tank ............................................. 7
Boiler Annual Maintenance and
Overhaul .................................................... 67
Boiler Blowdown System ............................... 25
Boiler Feed Pump ......................................... 10
Boiler Feed Water Pumps ............................. 18
Boiler Lay Up Procedures.............................. 75
Boiler Preservation Procedure ....................... 71
Boiler Pressure Part Description .................... 19
Boiler Protection & Interlock .......................... 35
Boiler Shutdown ........................................... 42
Boiler Start Up .............................................. 40
C Flue gas Temperature proÞle : ( For Design
Checks Every Six Months.............................. 61
Checks Every Year ....................................... 61
Chemical Dosing & Sampling System ............ 27
Chemicals for Dosing ...................................... 9
Cold Start Up Procedure ............................... 40
Component Description................................. 16
Conditioned Based Maintenance ................... 57
Continuous Blow Down Control ..................... 26
Cooling of Shutdown WHRB & Its
Preservation ............................................... 44
Cooling Water................................................. 8
D Hot Startup Procedure .................................. 42
Daily Checks ................................................ 57
Daily Maintenance ........................................ 60
Deaerator..................................................9, 16
Deaerator Steam ............................................ 8
Dissolved Gases .......................................... 94
Dissolved Salts and Minerals......................... 93
DM Water....................................................... 8
Do’s and Dont’s ............................................ 44
Drum Inspection ........................................... 67
Drum Level Control....................................... 21
Drum Safety Valve ........................................ 21
Operation & Maintenance Manual
Dry Storage Preservation .............................. 71
During Black - Out Procedure Condition ......... 43
E
Economiser .................................................... 6
Economizer .................................................. 19
Effects of Impurities ...................................... 94
Electrical power .............................................. 7
Emergency Procedures................................. 48
Emergency Shutdown Procedure................... 43
EMR Valve ................................................... 12
Evaporator / Convection Bank Tubes ............... 6
Expansion Joints .......................................... 68
F
Failure Reporting Formats............................. 78
Feed & Boiler Water Conditioning .................. 68
Feed Water Control Station ........................... 19
Feed Water Supply ....................................... 38
Filling With Water.......................................... 39
Flue Gas Data ................................................ 2
Flue gas Pressure drop proÞle: (for design
case)............................................................ 4
Flue Gas System .......................................... 31
case)............................................................ 3
Flue gas Velocity proÞle: (for design case) ......... 3
Forced Cooling ............................................. 44
Furnace and Boiler Tubes ............................. 81
G
Gauge Glass ........................................... 11, 13
General Principle Of Weld Repairs................. 81
H
High Water Level .......................................... 48
HP Dosing System........................................ 27
HP/LP Dosing System..................................... 9
I
ID Fans .......................................................... 9
Inspection after Cooling ................................ 67
Inspection of Screen, Primary & Secondary
Superheaters, Evaporators I/II &
Economiser ................................................ 68
Instrument Air................................................. 8
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Insulation ....................................................... 7 Replacement of Tube Section........................ 84

Insulation and Cladding................................. 68
S
L Safety In WHRB House................................. 55
Low Water Level........................................... 48 Safety Relief Valve........................................ 12
Safety Valve ..................................................11
Section Overview.....................................38, 56
M Shutdown and Cooling the Boiler ................... 67
Main Steam Piping........................................ 24 Silencer ....................................................... 22
Maintaining Quality of Steam ......................... 30 Soot Blower.............................................10, 32
Mixing Tank .................................................. 27 Soot Blower System ..................................... 32
MOC And SpeciÞcation of Euqipments ............. 4 SOOT BLOWING SEQUENCE...................... 34
Monthly Checks............................................ 60 Steam and Water System Technical
Performance Data....................................... 25
Steam Drum ..............................................4, 20
N Steam Supply............................................... 32
Natural Cooling............................................. 44 Steam Temperature Control Loop .................. 23
Normal Shutdown Procedure......................... 42 Super Heater................................................ 23
Super Heater I .............................................. 23
Super Heater II ............................................. 23
O Superheater IA / IB / Support Coils .................. 5
Operation and Control................................... 33 Superheater- II ............................................... 4
Operation Procedure..................................... 38 System Description............................ 31–32, 44
Operational Control............................ 24, 31–32
Operator Action Required during Boiler
Cold Start up .............................................. 43 T
Other Drains................................................. 26 TECHNICAL SPECIFICATIONS ...................... 3
Other Equipment .......................................... 68 Tube Failure ................................................. 48
Other Materials............................................. 94 Tube Failures ............................................... 76
Tube Thickness Survey................................. 75
Tube Thickness Survey Data Collection –
P Format ....................................................... 78
Paralleling WHRB To The Plant steam
Mains ......................................................... 43
pH Value of the Water and its Importance......... 94 U
Phosphate Dosing Pump............................... 27 Undissolved and Suspended Solid
Planning Before Overhaul ............................. 67 Materials .................................................... 93
Plugging Tubes in Drums & Headers.............. 82 Utilities........................................................... 7
Pre-requisites to Be Attended Before Start
up: ............................................................. 38
Preparation of 5% Phosphate Solution in V
the tank ...................................................... 27 Valve Settings:.............................................. 38
Preservation of Instruments........................... 75
Preservation of Rotating Equipments ............. 75
Preventive Maintenance................................ 56 W
Preventive Maintenance Program for Water / Steam Temperature proÞle: (For
Spares ....................................................... 57 Design case) ................................................ 3
Preventive Maintenance Program for Water And Steam Quality Control And
Valve.......................................................... 57 Monitoring .................................................. 29
Water And Steam System ............................. 16
Water Chemistry ........................................... 93
R Water Quality Recommendations................... 54
Recommended Maintenance Practices .......... 56 Weld Repair Of Small Cracks in Tube ............ 82
Removing Tubes from Drums, Headers & Welding Procedure SpeciÞcations
Tube Plates ................................................ 84 (WPS) ........................................................ 80

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Wet Storage Preservation ............................. 72 Window Patch Welding ................................. 80

WHRB Log Sheet ......................................... 46

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