O & M Manual

.
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 & SD 23.07.2010 AA 23.07.2010 USU 23.07.2010 0
PREPARED BY
CHECKED BY
APPROVED BY
REVISION DESC. / REMARK
Operation & Maintenance Manual
Contents
Volume 1 Boiler Description ....................................................................................................1 Section A................................................................................................................................2 1 Design Specication of WHRB ....................................................................................2 2 Flue Gas Data ............................................................................................................2 3 Technical Specication ................................................................................................3 3.1 Flue gas Velocity prole: (for design case) ..........................................................3 3.2 Flue gas Temperature prole:(For Design case)...................................................3 3.3 Water / Steam Temperature prole: (For Design case) ........................................3 3.4 Flue gas Pressure drop prole: (for design case) .................................................4 4 MOC And Specication 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
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 Dos and Donts......................................................................................................... 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
ii
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 Denition 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 Specications .............................................................................. 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 Specications ............................................................................................................. 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
iv
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 Reex 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 Section Section Section Section A B C D E
Volume 1 Boiler Description
Section A
Topics Covered in this Chapter Design Specication of WHRB Flue Gas Data Technical Specication MOC And Specication 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
Design Specication 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 Boiler Rating [MCR] Steam Pressure at Main Steam Stop Valve Outlet from minimum Load upto MCR Steam Temperature at the Main Steam Stop valve at MCR Main Steam Temperature Control range at the Main Steam Stop Valve Outlet (@ 950 deg C Inlet Flue Gas Temp) Maximum allowable working pressure Hydraulic Test Pressure Design Pressure Boiler Performance Testing Procedure DESIGN CODE UNIT TPH Kg/cm2 Deg C VALUE 20 66 4855
% MCR
60 100
Kg/cm2 Kg/cm2 Kg/cm2
75 112.5 75 ASME PTC 4.4 Energy Balance ASME SECTION-1
Flue Gas Data

VALUE 52,935 950
PARAMETERS Boiler Rating [MCR] Nm3/Hr ( Per Boiler) Inlet Temperature C
Section A
PARAMETERS Outlet Temperature C Flue Gas Composition (% V/V):CO2 H2 O N2 O2 SO2 Dust Loading
VALUE 180 5
4.45 6.2 75.79 13.45 100 ppm 100 m g/Nm3
Technical Specication
3.1 Flue gas Velocity prole: (for design case)

Sr No. 1 2 3 4 Component Radiation cavity Superheater Evaporator Economiser Velocity, m/s 8 12 to 15 10 to 11 8 to 9
3.2 Flue gas Temperature prole:(For Design case)

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

Sr 1 2 3 Component Radiation chamber inlet / outlet Pre Evaporator cum Support Tube (Pass 1) inlet / outlet Superheater II (Pass 1) inlet / outlet Deg C 285 / 285 285 / 285 328 / 485
Section A
Sr 4 5 6 7 8 9
Component Superheater 1A (Pass 1) inlet / outlet Superheater 1B (Pass 1) inlet / outlet Evaporator I (Pass 1) inlet / outlet Evaporator II (Pass 2) inlet / outlet Inlet of Economiser Outlet of Economiser
Deg C 368 / 428 285 / 368 285 / 285 285 / 285 120 258
3.4 Flue gas Pressure drop prole: (for design case)

Sr No. 1 2 3 4 Component (at outlet) Radiation cavity +Bends+Screen Superheater Evaporator Economiser Pressure mmWC -5 -30 -85 -165
MOC And Specication of Euqipments
4.1 Steam Drum

Sr No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Design code Design pressure Design temperature Hydrotest pressure Length Inner diameter Thickness Material of construction Quantity per boiler Corrosion allowance Internals Quantity of safety valves Capacity of each safety valve Set pressure of rst safety valve Set pressure of second safety valve Value IBR 1950 with its latest amendments 75 kg/cm g 291 C 112.5 kg/cm g 4000 mm 1375 mm 50 mm SA 516 Gr 70 / Equiv. 1 no. As per IBR Demister pad 2 nos. 7500 kg/hr 74.5 Kg/cm g 75 kg/cm g
4.2 Superheater- II
Sr No. 1 2 Description Design code Design pressure Value IBR 1950 with its latest amendments 75 kg/cm g
Section A
Sr No. 3
Description Design temperature SH II Support Coils
Value
529 C 319 C 490 C 112.5 kg/cm g Horizontal 86.18 m Bare OD 38.1mm x 4.06 mm thk As per IBR SA 213 T22 HFS SA 210 Gr A1 5000 kg/hr 71 kg/cmg
4 5 6 7 8 9 10 11 12 13 14
Design temperature of headers Hydrotest pressure Type Heat transfer area(Thermal) Type of tubes Tube outer diameter Tube thickness MOC of tubes MOC of Support Coils Safety valve relieving capacity Safety valve set pressure
4.3 Superheater IA / IB / Support Coils

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

Sr No. 1 2 3 4 5 6 Description Design code Design pressure Design temperature of coils Design temperature of headers Hydrotest pressure Type Heat transfer area (thermal Area) A) Convection Panel (Pass 1) 7 B) Pre Evaporator cum Support Tube C) Evaporator I (Pass 1) D) Evaporator II (Pass 2) 8 9 10 11 12 13 14 15 16 17 Type of tubes Tube outer diameter Tube thickness MOC of tubes MOC of Water wall tubes Tube OD of water wall tubes Tube thickness of water wall tubes MOC of headers Header outer diameter Header thickness 190.05 m 7.182 m 258.54 m 206.832 m Bare OD 38.1 mm x 3.66 mm thk As per IBR SA 210 GR A1 SA 210 GR A1 HFS OD 63.5 mm x 4.06 thk mm As per IBR SA 106 Gr B OD 219.1mm x 18.26 mm thk As per IBR Value IBR 1950 with its latest amendments 75 kg/cm g 319C 316 C 112.5 kg/cm g Horizontal
4.5 Economiser
Sr No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Design code Design pressure Design temperature of coils Design temperature of headers Hydrotest pressure Type Heat transfer area Type of tubes Tube outer diameter Tube thickness MOC of tubes MOC of headers Value IBR 1950 with its latest amendments 75 kg/cm g 269 C 258 C 112.5 kg/cm g Horizontal 827.33 m Bare OD 38.1 mm x 3.66 mm thk As per IBR SA 210 GR A1 SA 106 Gr B
Section A
Sr No. 13 14
Description Header outer diameter mm Header thickness mm
Value OD 114.3 mm x 13.49 mm thk As per IBR
4.6 Attemperator
Sr No. 1 2 3 4 5 6 7 8 Description Type Nos Location Water Flow at MCR (kg/h) MOC of headers Header outer diameter mm Header thickness mm Desidn Temperature Value Spray type Attemperator One Between SH I & SH II Later SA 335 P11 OD 219.1 mm x 12.7 mm thk x 5000mm long As per IBR 428 deg C
4.7 Insulation
Sr No. 1 2 3 4 Description Type Density Cladding Skin Temperature Value Mineral wool mattress 100 Kg/M3 up to 400 Deg C 120 Kg/M3 above 400 Deg C Aluminum sheet of 24 SWG 30 Deg C above ambient temp.
4.8 Blow Down Tank

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

Parameters Voltage Units V Value 415 +/- 10%
For LT motors (UPTO AND INCLUDING 200 KW)
Section A
Parameters Frequency Type Voltage Frequency Type For Field Transmitters Voltage Frequency Type
Units Hz
Value 50 +/- 5% AC, 3 Phase, 4 wire
For Instrumentation (eld switches, Level gauge illumination, solenoid valves etc.) V Hz 110 50 Single Phase, 2 wire V Hz 24 NA DC
5.2 Cooling Water

Parameters Supply Pressure Supply Temperature Quality Duty Quantity (for BFP pump) Quantity (for Sample cooler) Kg/Hr Kg/Hr Unit Kg/cm2(g) Deg C Value 34 @ Battery Limit Ambient @ Battery Limit Clear & colourless BFP Pump cooling & Sample cooler 1000 (Normal) , 1200 (Maximum) 600 (Normal) , 720 (Maximum)
5.3 DM Water
Parameters Supply Pressure Supply Temperature Flow Unit KSC (g) Deg C Kg/Hr Value 5 @ Battery Limit Ambient @ Battery Limit 1200 (Normal) , 15000 (Maximum)
5.4 Instrument Air

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

Parameters Pressure Temperature Quanlity Unit Kg/cm2(g) Deg c Kg/hr Value 4.0 (Normal) , 9.0 (Maximum) 185 5000 (Normal)
Section A
5.6 Chemicals for Dosing

HP Dosing LP Dosing Tri sodium phosphate Hydrazine
ID Fans
Sr No. 1 2 2 3 4 5 6 7 8 9 10 11 12 13 Description Type of fan Quantity Drive Coupling Rated head Rated capacity MOC of casing MOC of impeller MOC of shaft Fan speed Cooling water requirement Type of ow control Type of isolation Type of Lubrication Value Centrifugal 02 nos Electric motor Resilient type coupling 410 mmWC 31.6 m3/sec IS 2062 Gr A (MS) SAILMA 350 EN 8 980 rpm Not required. By variable frequency control & Pneumatic operated multi louver damper. Not required Grease (Servo Gem; EP2)
Deaerator
Valve 48 m3/hr (Max) 27 m3 16 m3 1.76 bar(g) 120 C (case 1) & 130 C (case 2) 3.0 Kg/cm2(g) 200 C ASME SECT. VIII DIV Edition 2004, ADDENDA 2006 (WITH U STAMPING)
Description Deaeration capacity Storage tank Capacity (Full) Storage tank capacity Operating pressure Operating temperature Design pressure Design temperature Design & Construction code
HP/ LP Dosing System
Make : Metapow Industries Sr No. 1 Description Major parts Value Storage tank 1 no, Stirrer 1 no., Dosing pumps 2 nos. Storage tank Details
Section A
Sr No. 1 2 3 4 1 2 3 4 5 6 7 1 2
Description Size of storage tank Tank capacity MOC of tank MOC of chemical basket Pump make Pump capacity (HP/LP) Pump type Operating Pressure (HP/LP) Safety Relief Valve Set Pressure (HP/LP) Type of Lubrication / Quantity Motor Details Type of operation Motor Details
Value 600 mm x 800 mm x 5 mm 150 liters IS 2062 MSRL; Rubber lined 3mm SS 304 Dosing pump Details VK Pumps / Equiv. 0 6 LPH Reciprocating Plunger type 76 kg/cm2 / 6.35 kg/cm2 102 kg/cm2 / 8 kg/cm2 ISO VG 460 / 0.8 liters Crompton Greaves Stirrer details Motorised 0.5 HP / 1000 RPM (HP); 750 RPM (LP)
Boiler Feed Pump

UNIT VALUE KSB PUMPS LTD. HAD 65/15 NO RPM m3/hr M C 3 (2W/1 SB) FEED WATER 2900 26 960 130 Gear type Spacer Coupling (Make - Rathi) OIL kW/RPM SERVO SYSTEM / ENKLO- 46 160 /2985 (Make Siemens)
DESCRIPTION MAKE Type & Size Quantity Fluid Pump Speed Capacity Design Head Fluid Temp Coupling Type Lubrication Motor
10 Soot Blower
Sr No. Description Long Retractable soot blower Super heater & Evaporator Zone Saturated 20 Rotary soot blower
1 2 3
Location Steam temperature deg c : Steam pressure kg/cm2(g)
Economizer Zone
Section A
10
Sr No. 4 5
Description Source of Steam Drive
Long Retractable soot blower Motorised
Rotary soot blower
Saturated steam from Steam Drum
11 Gauge Glass
Drum level Gauge Description Make Tag No. Type Location Operating pressure. Hydrotest pressure C/c distance Visibility Range Operating temp. Blow Down Level Gauge Description Make Tag No. Type Location Working pressure. C/c distance Visibility range Operating temp. Details Chemtrol Samil 11 LG 601 Tubular Level Gauge Assly Blow Down Tank 5 kg/cm2 (g) 500 mm 360 mm 200 C (Saturated) Normal Operating Details HI TECH SYSTEM & SERVICES LTD 11 LG 143/ 11 LG 144 & 12 LG 143/ 12 LG 144 Bi Colour Duco Gauge Steam drum 69 kg/cm2 (g) 112.5 kg/cm2 (g) 750 mm 314 mm 5 Ports 285 C Normal Operating
12 Safety Valve
DESCRIPTION APPLICATION TYPE MAKE TAG NO SIZE ORIFICE SETPRESSUR. OPERATING TEMP. Kg/cm2 DEG.C 74.5 285 75 285 71 485 UNIT DRUM #1 SPRING LOADED ANDERSON GREENWOOD CROSBY 11-PSV-001 11-PSV-002 11-PSV-003 DRUM #2 SH
Section A
11
DESCRIPTION APPLICATION RELIEVING CAPACITY QUANTITY FLUID
UNIT TPH -
DRUM #1 8000 1 Sat Steam
DRUM #2 8000 1 Sat Steam
SH 6000 1 Sup Steam
13 Safety Relief Valve

DESCRIPTION / APPLICATION TYPE MAKE SIZE ORIFICE SET PRESSURE Model Relieving Capacity Rated / Requried QUANTITY Kg/hr UNIT Kg/Sq.cm Details SPRING LOADED TYCO SANMAR LTD 2.5 X JX 4.0 23 JOSHE35-C-IBR-SPL 10595/8000 1 / BLR
14 EMR Valve
DESCRIPTION / APPLICATION TYPE MAKE SIZE ORIFICE SET PRESSURE Model Relieving Capacity Rated / Requried Kg/hr UNIT Kg/Sq.cm Details SPRING LOADED TYCO SANMAR LTD 2.5 X 4.0 100 HPV-ST-68W-IBR 20611/2750
Section A
12
15 Gauge Glass
Drum level Gauge Description Make Tag No. Type Location Operating pressure. Rating pressure Hydrotest pressure C/c distance Visibility Range Operating temp. Blow Down Level Gauge Description Make Tag No. Type Location Working pressure. C/c distance Visibility range Operating temp. Details Levcon Instruments LI 35001 Tubular Level Gauge Assly Blow Down 10 kg/cm2 (g) 1000+/-1 860 mm 200 C (Saturated) Normal Operating Details HI-TECH SYSTEMS & SERVICES LTD. LI34101 and LI-34102 Bi-Colour duco Level Gauge Assly Steam drum 101.0 kg/cm2 (g) 210 Bar 315 kg/cm2 (g) 750 mm 314 mm 5 Ports 311 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
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 Rating Steam Pressure Steam Temperature 20 TPH 66 kg/cm2 485+/- 5 Deg C
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 WHRBs 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 ow 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 nal 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.
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 eld 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 nal control element to control the process variables. Position transmitters allow the monitoring of the controlling element position. Closed control loops are congured 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
Section B
14
Control philosophy of these loops is described in the document submitted separately.
rest of boilers 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 prexed with 10 for common items. 11 & 12 for WHRB 1 & 2 respectively
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
15
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 owing from the feed water main to convert it to HP steam of 66 Kg/cm(g) at a temperature of 485 C (5C). The components in the serial order of water ow 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 ows in a direction counter to the water / steam ow 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.
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 ushed with inner wall of the vapour tanks dished end and embedded inside the water level of storage tank to facilitate the feed water ow 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 ow direction by a hood tted at the top, thus facilitates the steam ow 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 xed on the ring header to spray the water into ne 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 ows 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 xed on the ring header to spray the water into ne 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
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 efciency 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
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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 xed 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.
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 ow 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 ow/ intake to deaerator or malfunctioning of pressure control loop. Temperature Gauge A temperature gauge [10-TE 107] is xed 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 ow 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 orice and a globe Valve in parallel with it. Through the Air vent, Steam and dissolved gases are vent out
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to the atmosphere. The Valve shall be throttled to minimize the outow of Steam. N20 is also one connection provided for air vent without orice. 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 ow. 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 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 Vendors manual is to be referred for more details on operation and maintenance.
Feed water pumps 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 lter. 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 ow 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 ow through the circulation line. Non-return valve to prevent the back ow. 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 ow required through the pump, when the ow to boiler is low. This minimum circulation ow 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 stufng 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.
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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/cm and a temperature of 120C. There is one feed control station, which is in service when the WHRB is operational. 100% Flow control FCV-137 The 100% ow control valve FCV-137 is capable of feeding the WHRB when the steam ow 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 ow 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 ow transmitters provide feed ow 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.
The valve 11-FCV-137 is positioned by the ow 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 ow from WHRB and the current feed water ow, 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 ow 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 ow 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 ow signal it receives from ow 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 ow, feed ow & the feed control valve position can be monitored. The three element control adopted for the 100% ow control valves FCV-137 takes into account the drum level, steam ow and feed water ow for positioning the control valve as well as it takes only drum level for its operation at low load.
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 ows up wards. Economizer is provided with air vent and drains. ECO is hung from the top by two guide supports
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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.
(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 ow 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
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 tted 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 tted 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 owing through the evaporator panels, by absorbing heat from the coke oven exhaust gas, the hot water gets converted to water / steam mixture and ows 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 ows tangentially through the Diemeister pad installed in the steam drum. In this tangential ow, 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.
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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 reect 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 tted 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.
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 ring system, closure of steam valves etc., two spring loaded safety valves have been tted on the drum. On increase of steam pressure beyond a predetermined 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
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may be referred for a full understanding of the safety valves.
3.5 Evaporator
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 y off of sound absorbing materials during operation of silencer at high ow rates The process uid 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 operational care is needed except opening the drain plug provided in the drain line, once in three months to drain the line.
EVAPORATOR Figure 1
3.4 Air Vent

An air vent on the drum to vent out air during initial boiler lling, before start up and during start up. During start up, the air vents are closed at a drum pressure of 2 Kg/cm (g) and when copious steam is passing. The air vents are opened after shut down of the boiler when the boiler pressure falls to 2 kg/cm2.
The Evaporators convert hot boiler water received from the Drum through down comer pipes into a steam water mixture, by absorption of heat from the Coke oven exhaust gas. The steam water mixture is led back to the drum from the evaporators through riser pipes. There are two sections Evaporator 1 & Evaporator II. of Evaporators,
The Evaporators are hung from the top headers in the ue path, on two guide supports and one anchor support with provision for thermal expansion downward & in the sides. Hot water ow 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 ows through the two down comer pipes to down comer header.
From the down comer header, the hot water ows to the lower headers, and then through Evaporation panel tubes, to the Evaporation panel top headers. During its passage through
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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, ows in the steam drum. In the steam drum, the steam water mixture ows through the separators where water & steam are separated and saturated steam ows to the Superheaters. Seperated water mixes with boiler water to ow through the Evaporator panels again.
An inter-stage attemperator is provided in the superheater to maintain the nal 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 xed at the entrance to the restricted venturi section. The sleeve is held in position rmly 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.
3.6 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 nal steam outlet at 4855C. 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.
3.9 Super Heater II

Superheater II receives the steam from bottom header of Superheater I. From the top header of the SH II, steam ows through the panel tubes to the bottom header of the same panel, absorbing heat. Then the steam ows 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/cm.
3.7 Super Heater I

Saturated steam from the drum ows to the rst super heater top header of Superheater I. From the top header of the SH l, steam ows through the panel tubes to the bottom header of the same panel, absorbing heat. Then the steam ows 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/cm.
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 ow 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.
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 410C.
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Drain valves DSW-VG-112/113, these drain valves are opened to drain the line for maintenance. Pneumatically operated ow control valve 11-TCV-153. The ow 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 owing 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.
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 ow transmitter 11-FT-157. The ow transmitter reading, after steam pressure & temperature compensation is used for the following, Steam ow reading. (11-FI 157) Steam ow compensation for feed ow, 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 ow, steam ow instruments.
Main Steam Piping 5
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/cm, 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 ow for the superheaters. STEAM LINE DRAIN The steam line drain consists of the following valves manually operated MSS-VG-101/102/108/109. These
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 rst 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
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differences of temperature between steam and water surfaces of the drum. Such a difference can set up thermal stresses, which are not desirable, and an alarm sounds at DCS. To minimize the thermal stresses, the operator must restrict the ring rate when starting the WHRB by modulating the diverter damper. Boiler water temperature rise rate must not be above 56 0C per hour till operating pressure is reached. SWELLING During WHRB startup, as the Boiler water temperature reaches 90C, there is an increase of water level caused by increase in the volume of hot water. Such swelling, if not controlled, can cause a High Level trip. To avoid this, initial lling is normally restricted to low level (say 100 to 150 mm) and the smart Operator anticipates a swell and uses the IBD to drain and control the level. Do not operate the WHRB with safety valves gagged. Passing safety valves must be attended during the next planned shut down. Super Heaters & Attemporator Super heaters must be drained after shut down and cooling of the boiler. They must also be kept open before a cold start up till 2 - 3 kg/cm2 pressure is built up. During hot light ups they are opened for a few minutes. Soot blowing of Super Heaters may be done once a shift to keep their surfaces clean, it liquid fuels are burnt. Super heat steam temperatures at exit of Super Heater- 1, Super Heater 2 main steam temperatures must be monitored to see there is no excessive heat pick up. Compare these gures with predicted performance values. High steam temperatures may mean high metal temperatures. General Boiler water can be drained after a shut down only after depressurizing to 2 kg/sq. cm and after cooling to 80 C Draining of Boiler water must preferably done through the blow down tank. If a tube failure is detected, it is advisable to plan for an early shut down. It may be possible to quickly repair the failed tube and return to service. If the shut down is in-ordinately delayed, there are possibilities of larger secondary damages, which may prolong the shut down, required for repairs.
Manually operated valves must be closed hand tight only. Use of levers on hand wheels is not desired.
5.1 Steam and Water System Technical Performance Data

WHRB HEATING SURFACES ECO Modules (Pass 2) Evaporator I & II Superheater I & II - 827.33 m - 662.6 m - 200.45 m
WHRB Design Pressure : Maximum working pressure - 75.0 kg / cm2 (g) Set pressure and capacity of safety valves Tag No 11-PSV-001 (Drum) 11-PSV-002 (Drum) 11-PSV-003 (MS Line) Drum Level Gauge Normal Water Level High Level Alarm Low Level Alarm Low Level Trip Drum Axis (0 mm) 50 % 65% 35% 25% Set Pressure kg / sq. cm (g) 74.5 75 71 Capacity (Kg/Hr) 7500 7500 5000
6
AIM
Boiler Blowdown System
This chapter describes the WHRB blow down system for safe draining of high pressure / High temperature steam and water from the boiler using the blow down tank. System Description The P & ID of the steam and water system shows the various drains from the WHRB, SH steam line and the soot blower system. Large quantities of steam or high pressure / temperature water are not to be drained through open canals for the following reasons: a) Such draining will cause splashing of high volumes of steam, which can be a nuisance by
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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. No. 1. Source Continuous blow down Emergency blow down Valve Nos
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 depending on quality of baler water Occasional during high levels in drum, during start up
CBD-104
291C
2.
EBD-102
Upto 291C
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 uid 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
6.2 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.
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 uid 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
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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 ow 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 ow also ensures that these lines do not get chocked for want of adequate ow. 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 owing through tubes and the cooling water in the outer shell, with the specic 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).
Two dosing pumps (with one stand by) DM Water source for preparation of the phosphate solution as well as for ushing
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 ow 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 tted 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:
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.
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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 tted before the common discharge line. A safety relief valve has also been tted 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 rectied). 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 veried 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 lled with phosphate solution. The pump is started by switching on
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 ushed with water to keep them clean in the following manner. A (ushing) 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 ushes 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 dosing pump when the HP tank is dry or lled with water or the dosing solution. The operation of the stirrer can lead to failure of stirrer (misalignment of the stirrer). HP not dry the
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7.5 Water And Steam Quality Control And Monitoring

AIM This chapter describes the standards for the boiler feed water and boiler water for corrosion and scale PARAMETER pH at 25C Total hardness as CACO3 Chlorides as NACL Silica as SIO2 Total Iron as FE Copper as CU Dissolved Oxygen Sodium Sulphate Residual Hydrazine Organic matter Oil Total dissolved solids Conductivity at 25C after cation exchanger and CO2 removal Total CO2 Sodium + Potassium
free operation of the WHRB and for obtaining pure steam. Methods of control of boiler water are also explained. Suggested quality of boiler feed water (and attemperator water) fed to the WHRB is given in following table: Max. permissible value 8.5-9.5 Nil Not traceable <0.02ppm < 0.01 ppm < 0.003ppm < 0.007cc/lit Not traceable Traces Nil Nil < 0.1 PPM < 0.15 micro siemens per cm Nil Not traceable
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Note 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 .
Following TABLE gives the Boiler Water Quality to be maintained in the Drum.
PARAMETER Conductivity at 25C after neutralization. pH value at 25C Silica as SiO2 Sodium Phosphate as PO4 p value 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 : Continuous blow control to restrict the contaminants to prescribed levels suggested for Boiler water ( Table 9 ) 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.
MAX permissible < 50 micro siemens/cm 9.5 to 10.2 <1.2 mg/kg 2 to 6 mg/kg < 0.1 m Val/kg
7.6 Maintaining Quality of Steam

Good Quality steam is obtained if the following requirements are met: Proper assembly of bafes, demister pad in the steam drum as per erection instructions (checked before commissioning of the Boiler) Boiler feed water as per norms as suggested above. (monitor the feed water conductivity & PH analysers) Control of Boiler water quality as suggested above. Monitor the saturation steam & main steam conductivity
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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, bafes 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.
the WHRB through an expansion bellow. The following are the instruments in the ue gas system. Exhaust gas from the Sponge iron kiln enters the WHRB through an expansion bellow. The following are the instruments in the ue 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.
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.
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)
Flue Gas System
This chapter describes the sponge iron kiln exhaust ow 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
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The oven exhaust gas after ECO is exhausted through the Stack. The stack is a hollow cylindrical structure (Customer scope) Aviation warning lights are tted at two elevations on the stack. Sampling probes for measurement of CO, NO2 & SO2 are xed at two suitable elevations on the Stack. There are ve platforms providing access to the aviation lights, sample probes and ease of repainting the Stack. The platforms are accessible from the ground by ladders. On the top 20metres of the Stack, helical wind breakers are built around the outer shell, to provide stability to the Stack against wind forces.
Soot Blower System
9.1 Soot Blower

AIM Soot blowers, 09 in number, have been provided for SH II, SH I, Evaporators and Economisers. A PLC based local control panel for operation and control of these soot blowers are provided. Vendor manuals of the soot blowers and the local control panel have been included in Volume VIII of this manual, which may be referred for details of their construction and mode of operation. This chapter explains steam supply to the soot blowers and deals with the need for soot blowing, factors determining the optimum frequency and care to be taken during its operation. 9.1.1System Description Operating environment of Soot blowers

The anticipated performance gures both steam / water and gas side has been given in following section. The operator shall familiarize himself with these gures. Elaborate instrumentation has been provided to measure 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 gures 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 Number Position Angle of rotation 9.1.2Steam Supply Steam supply required for soot blowing is taken from the steam drum, which is at a pressure of 66 LRSB Between SH II & I 0-360 LRSB Between
LRSB & RSB Between Evap I & II 0-180
RSB Between Evap II & Eco modules 0-360
SH I & Evap I 0-360
kg/cm. Pressure controller 11-PSV-147 exists on the steam supply line to maintain pressure. The Long retract soot blowers remain fully retracted to their parking position when not
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in use. The steam admission to the LRSB is automatically established as soon as the LRSB enters the ue gas path. Cleaning operation, by jetting steam from the LRSB takes place both during its advancing and retracting cycles. The steam ow through the lance also serves to cool the lance tube from the excessive heat of the ue 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 denite sequence in the line of ue gas ow, 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 specied 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 benets 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 difcult. Unabsorbed heat from Evaporators and Economizers will increase the ue gas exit temperature from WHRB higher than design, reducing the thermal efciency. Effectiveness of each soot blowing can be studied by noting down the following performance parameters before and after soot blowing.
Flue gas temperature across super heaters, Evaporators, Economizers. Feed water / steam temperature pick up across super heaters, Evaporators, Economizers. Spray water ow through de-super heater Effective soot blowing increases the heat pick up. De-super heater spray water ow 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 ow is above 50% MCR. Soot blowing at lesser loads may disturb the ue gas regime. The rst soot blowing after the WHRB start up is done as soon as 50% MCR steam ow 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 satised 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
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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 satised. 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)
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 satised. 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 rst 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 satised 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
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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
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 signicance. Testing of these interlocks & protections is to be done before the rst 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
10 Boiler Protection & Interlock

AIM This chapter lists out various protections and interlocks provided in the WHRB. Sr. No 1 2 3 Location Steam drum Steam drum Superheater Valve No 11-PSV-001 11-PSV-002 11-PSV-003
Set pr kg/cm 74.5 75 71
Blow down tons/hour 7500 5000
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.
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

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.
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In Three element control O/P of 11 LIC-142B goes to the summation block where the steam ow 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 ow 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 ow 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 ow is measured using transmitter 11FT-137 which receives DP from ow nozzle 11FE-137, the square rooting to be done at DCS side and is used as process variable for Feed water ow controller 11- FIC-137. The output of 11- FIC-137 is used to control the feed water control valve 11- FCV-137. Steam ow is measured using a steam ow transmitter 11 FT-157 connected to ow nozzle; the steam ow transmitter shall be square rooted at DCS side. Pressure and temperature compensation of steam ow 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 ow = Indicated steam ow *[ 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.
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 ow 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 congured as shown in the control schematic. Trends, Totalizers, indicators and alarms shall be congured in the DCS as indicated the Control Schematic drawing. Totaliser 11 FIQ-137, 11 FIQ-157 to be congured in DCS. Following are trip interlocks on Drum level Low Low a) ID fan trip b) Open ue gas process stack inlet damper (11-DI-004) c) Close ue 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 xed 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.
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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 congured 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 nal steam is controlled by attemperation i.e. by spraying feed water into the steam after the primary super heater. 11 TIC-153 receives nal steam temperature as the process value from 11 TT-153. The temperature controller shall have 485 C set point for the nal 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 congured 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 congured 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
with a xed 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 congured 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 congured 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
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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 Dos and Donts WHRB Log Sheet Emergency Procedures Alarms and Interlocks Troubleshooting Chart Water Quality Recommendations Safety In WHRB House
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 ow and pressure of instrument air and cooling water is as per requirement.
Section Overview
This section describes the start up, shut down procedures of the WHRB. WHRB operation & safety are also described here.
Operation Procedure
3.1 Feed Water Supply

Primarily before allowing the ue 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 specied in the latest Thermax P Diagram. (Drg. No. D12-0WH-09484). Refer concerned chapter for recommended water chemistry.
(Please refer the P & I Diagram for Waste Heat Recovery Boiler Drg No.- D12-1WH-6203P for the valve references described in this section)
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 oating 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 eld 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 ow
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 lling. It is also advisable to trace feed water piping from
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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.
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 ow and ue gas ow 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.
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 lling. It is desirable to ll the boiler with de-aerated feed water. Filling with hot water is permissible provided water is added slowly and ow does not exceed capacity of de-aerating heater. Strains set up in the waste heat recovery boiler from hot water lling are minor compared to strains induced from heating cold water rapidly. When lling 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 ue 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 lled with water, the ue gas may be taken into the boiler. The ue gas
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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.
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 denite ow 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 denite steam ow is obtained through the superheater tubes. It is essential that steam should ow 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 ue gas ow 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 nal superheater outlet header drain and startup vent. Do not close startup vent completely until steam ow 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.
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 ow through a superheater and at a rate sufcient to absorb and carry away the heat surrounding the superheater. The rate of steam ow 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 400C 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
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10. 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.
Note NOTE:IT IS ADVISED TO AVOID FREQUENT STARTUP AND STOPPAGE, AS THIS WILL LEAD TO THERMAL CYCLIC LOADING OF THE BOILER AND PREMATURE FAILURES
Figure 2
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4.2
Hot Startup Procedure
1. Restarting the boiler after banked condition again requires controlled ue gas ow 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.
2. Boiler Trip on interlock protection emergency shutdown by the Operator.
or
If the shut down is only for few hours, it is not recommended to cool the bed material. If the shut down is for few days, it is recommended to cool the bed material.
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 ue gas ow rate in line with decreasing steam ow. 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 70C before draining.) 10. Open the manhole when the ue gas temperature is below 50 Deg. C.
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 ue gas for a period of 30 minutes. Keep a close watch on the superheater outlet steam temperature (TT-153). Adjust attemperator water ow (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 ue gas ow and increase the steam drum pressure (PT-145) as per the pressure rising curve. Adjust the ue 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.
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.
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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
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/cm, drum air vents can be closed SD-VG-119, SD-VL-120 When the steam pressure builds up to 2 kg/cm . 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 owing 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
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 ue gas temp at boiler inlet drops below 400 deg C the boiler can be hot boxed up.
Paralleling WHRB To The Plant steam Mains
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 90C, 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).
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
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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 ow established FCV-137 can be taken in auto mode. Observe the feed control station. When steam ow exceeds 25%, full load control station comes into service (based on operator selection)
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 airow 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.
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.
Dos and Donts
DOS 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, insulated ducts must be properly
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.
10. Servicing of equipments should be done as per the manufacturers schedule 11. Maintain proper operation log sheets regularly
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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 ange joints 16. Operate the blowdown recommendation valves as per
DONTS 1. Dont bypass any instruments and safety interlocks 2. Dont use raw water as WHRB feedwater 3. Dont operate operation limits the WHRB beyond the
4. Dont leave the furnace door open while the WHRB is in operation 5. Dont mix up different lubricants 6. Dont alter the equipment maintenance schedule 7. Dont leave the instrument control panel unattended 8. Dont 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 rst followed by gas. Ensure always-proper air to fuel ratio corresponding to load.
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 ue gas temperature at economizer outlet as recommended 20. Use genuine spares 21. WHRB surroundings and equipments must be properly illuminated
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WHRB Log Sheet
It is suggested to record the WHRB parameters during startup and normal operation. Observed abnormalities (if any) recorded can be used for analysis, troubleshooting and maintenance purposes. Log sheet to be lled once in every hour by the operating staff. Feed water, WHRB water qualities are also to be noted once in four hours. SL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PARAMETER Turbine load ID fan speed DRUM LEVEL MAIN STEAM PRESSURE MAIN STEAM TEP STEAM FLOW FEED WATERFLOW ATTEMPERATOR I WATER FLOW STEAM FLOW TOTALISER FEED WATER FLOW TOTALISER ATTEMPERATOR I FLOW TOTALISER FEED WATER PRESSURE AT CONTROL STATION INLET FEED WATER TEMP.AT ECO . INLET FEED WATER TEMP.AT ECO. OUTLET STEAM TEP AT SH I INLET STEAM TEP AT SH I OUT LET STEAM TEP AT SH II INLET STEAM TEP AT SH II OUT LET FLUE GAS TEP. AT BOILER INLET FLUE GAS TEMP. AT SH I INLET
Total gas consumption and steam production of a day to be noted. Logbook should furnish the details about WHRB trips with reasons and time. WHRB running hours. WHRB shut down details (forced or planned, outage hours, jobs carried out, etc.,) Sample log sheet is enclosed.
UNIT MW % MmWC Bar G DEG C TPH TPH TPH MT MT MT Bar G DEG C DEG C DEG C DEG C DEG C DEG C DEG C DEG C DEG C
Time
FLUE GAS TEMP. AT EVAPORATOR INLET FLUE GAS TEMP. AFTER EVAPORATOR DEG C FLUE GAS TEMP. AFTER ECO FLUE GAS PRESSURE AT BOILER INLET FLUE GAS PR. AFTER ECO
DEG C mmWC mmWC
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SL NO 26
PARAMETER FEED WATER ANALYSIS: PH CONDUCTIVITY TDS SILICA HARDNESS OXYGEN
UNIT
Time
27
DRUM WATER ANALYSIS: PH TDS ALKALINITY AS CaCO3 SILICA PHOSPHATE AS PO4 SULPHITE AS SO3
OPERATOR NAME:
SIGNATURE: DATE:
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10 Emergency Procedures
This Section Describes Causes of Emergency and Action on .
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
10.1 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 uctuations that might occur with extraordinary changes in load, appropriate action should be taken at once to trip the fuel. Any decision to continue to operate, even if only for a short time at a reduced rating would have to be made by someone in authority who is thoroughly familiar with the circumstances that led to the emergency and positively certain that the water level can be restored immediately without damaging the boiler. In the absence of such a decision Stop the ID fan and open the stack cap Shut off steam ow 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 ow to boiler gradually to normal water level. (Do not hurry up which may lead to sudden quenching and tube leak) if pressure part damage is suspected 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
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 nd the cause of tube failures before operation is resumed.
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11 Alarms and Interlocks

ALARM LIST FOR WHRB BOILER Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Tag No. PAH 105 PAL 105 LAH 102 LAHH 102 LAL 102 LALL 102 LAH 142 LAHH 142 LAL 142 Service Deaerator Pressure Deaerator Pressure Deaerator level Deaerator level Deaerator level Deaerator level Steam drum level Steam drum level Steam drum level Steam drum level Alarm HIGH LOW HIGH HIGH HIGH LOW LOW LOW High HIGH HIGH Low Alarm value 2 kg/cm.2 (g) 1.5 kg/cm.2 (g) 60% 75% 40% 30% 100 mmWC 200 mmWC -100mmWC from NWL -250 mmWC from NWL Open Bypass duct damper Trip ID Fan Close Boiler inlet damper & simultaneously open by pass duct damper. 480C 500C 40 mmWC BFWP TRIP Interlock Details
10.
LALL 142
Very Low
11.
ID 160A/B
ID fan motor
Trip
12. 13. 14.
TAL 153 TAH 153 PAH 178
Super Heater steam temp. Super Heater steam temp. ID Fan discharge FG pressure ID Fan discharge FG pressure FG pr. at boiler inlet FG pr. at boiler inlet Soot blower Pressure
Low High HIGH
15. 16. 17. 18.
PAL 178 PAL 160 PAH 160 PAL 147
LOW Low High Low
30 mmWC -70 mmWC -10 mmWC 15 kg/cm.2 (g)
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Sr. No. 19. 20. 21.
Tag No. PAH 147 DPH 118 DPHH 118
Service Soot blower pressure DP across BFWP strainer DP across BFWP strainer
Alarm High High High high
Alarm value 23 kg/cm.2 (g) 0.1 kg/cm.2 (g) 0.15 kg/cm.2 (g)
Interlock Details
BFWP trip
Note Interlock is indicated in BOLD All the values mentioned are preliminary may undergo revision at time of commissioning if required.
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12 Troubleshooting Chart
Indication Probable Source Probable Cause Repair method & Preventive Measures Remove boiler from service at rst convenient time. Hydrostatic test to be done to locate leak. Repair by welding or splicing as indicated and as approved by insurance or State Inspection. Determine cause of failure and correct it. Operation at normal loads should put chemical back in solution. Substantial leak from tube/tubes. Over-heating The same as above Remove boiler from the line immediately. Inspect or determine whether tube splicing or wholesale tube replacement is necessary. Check for bafe leaks in steam drum when out of service, or boiler water contamination. Check of degasied steam sample will indicate if CO2 or NH3 is high
Tube Leak Unable to maintain boiler water concentration Slight leakage from pitting or cracking of tube .
Hideout Sound of steam blowing in furnace or seeing visible steam from the stack. Steam explosion in furnace followed by inability to maintain water level.
Tube leak
Tube rupture
Failure of tube from low water, tube blockage or erosion of exterior metal surface.
High conductivity
Solids carry over in the steam or high CO2 or NH3 in boiler water
High boiler water concentrations, excessive water level uctuation drum bafe leakage or deposits on scrubbers High boiler concentrations, extreme load swings, varying supply pressure or control loop adjustment
Excessive water level uctuation
Water load or control conditions
Correct condition leading to the problem
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Indication
Probable Source
Probable Cause
Repair method & Preventive Measures Severity of bowing will determine extent of tube replacement. Internal scale will call for internal cleaning. If low water is indicated a thorough inspection for drum damage and tube seat leakage must be made. Take steps to prevent recurrence or low water condition Repair by retubing or welding in tube section or by heating and driving back blister depending upon insurance carrier or State Inspectors approval. Clean internally by turbining or acid cleaning. Depth and extent of pitting determines need and extent of tube replacement. Extensive drum pitting can be welded but is subject to approval by either the manufacturer & insurance carrier or State. Source of oxygen must be located and eliminated
Bowed water wall generating tubes
Overheating
Internal deposit or low water. Usually internal deposits result in tubes bowing away from the furnace & low water /starve results bowing toward the furnace.
Tube blisters
Localized overheating
Internal deposit
Internal pitting sharp edged and covered with barnacles in drum or tubes.
Corrosion
Oxygen in Boiler water
Internal loss of metal not sharply dened and accompanied by black iron oxide (Fe 3 O4 )
Corrosion
Overheating resulting in breakdown of water into H & O2 Cause is usually from sludge letdown or pluggage.
Individual inspection will determine extent or replacement, internal cleaning and correction of water conditions are required
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Indication
Probable Source
Probable Cause
Repair method & 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 differential expansion with adjacent tubes. Proper external cleaning can prevent out of service corrosion. Locate and eliminate source of moisture. If dew point is from in -service corrosion, take steps to raise metal temperature When accessible and with insurance or State approval, the cracks can be ground out and welded, otherwise splice in section or replace tube. Locate & eliminate source of expansion difculty by inspection or hot to cold expansion measurements. Using tube spacers can stop vibration. Where accessible and with insurance or State approval pad weld or splice in a tube section. Eliminate channeling of steam from soot blowers or use tube shields Extent of metal loss will determine extent of tube or tube section replacement. Inspection or a thermocouple installation will determine cause of overheating
External pitting
Corrosion
From corrosive ash deposit and moisture either from dew point or external source such as leaking soot blowing tube.
Tube cracking
Mechanical stress or a combination of stress corrosion or tube variation.
Interference with expansion or differential expansion with adjacent parts to give mechanical stress or this stress plus corrosion attack. Vibration set up by turbulent gas ow characteristics over tubes.
External metal loss. Highly polished area
Erosion
Mechanical abrasion from soot blower action.
External metal loss. Oxidized re scale area.
Overheating
Prolonged or repeated overheating.
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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. NOTE PARAMETER pH at 25C Total hardness as CACO3 Chlorides as NACL Silica as SIO2 Total Iron as FE Copper as CU Dissolved Oxygen Sodium Sulphate Residual Hydrazine Organic matter Oil Total dissolved solids Conductivity at 25C after cation exchanger and CO2 removal Total CO2 Sodium + Potassium NOTE 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 PARAMETER Conductivity at 25C after neutralization. pH value at 25C Silica as SiO2 Sodium Phosphate as PO4 p value
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: FEEDWATER MAX. permissible value 8.5-9.5 Nil Not traceable <0.02ppm < 0.01 ppm < 0.003ppm < 0.007cc/lit Not traceable Traces Nil Nil < 0.1 PPM < 0.15 micro siemens per cm Nil Not traceable 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. DRUM WATER MAX permissible < 50 micro siemens/cm 9.5 to 10.2 <1.2 mg/kg 2 to 6 mg/kg < 0.1 m Val/kg
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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.
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 anges in drum or pipeline, ensure that the drum/line has been isolated and drained. Do not use toxic uids like CTC for cleaning in a conned 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.
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
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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 Specications General Principle Of Weld Repairs Water Chemistry
Maintenance can be classied 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.
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
Preventive Maintenance
The objective of the preventive maintenance program is to obtain trouble free service from the component till the next maintenance. Vendor manuals for various equipments suggest inspection periods, checks to be done and recommended spares. The true objective of the maintenance program can only be realized, if a master plan of maintenance of all the components is prepared as per vendor instructions. Full benets of maintenance can be obtained only if proper parts are used. Mandatory spare part list covers most of the spares required. It may be found that in the rst two years of operation due to variations of site conditions, some additional spares not included are also required. Action has to be initiated to procure such spares. Some equipment have 100% reserve standby units. (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 rst three years of the boiler operation. It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are either too much or too less. Based on site experience, the frequencies and work schedules can be modied. A
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.
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scientic 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.
A scientic method of preparation of the preventive maintenance schedule is to make them condition based. In condition based maintenance, the equipment and components of the plant are inspected daily, weekly, monthly etc. as per suggested schedule by the local operators and the deteriorating conditions if any observed are reported. Suggested inspection program is given in this chapter. Based on operator reports of such inspection, maintenance works are planned for the next available planned shutdown. Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the equipment condition.
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 ange joint, if necessary.
Conditioned Based Maintenance
The schedule of daily, weekly and monthly inspections given in the following pages do not require a boiler shutdown and in fact can only be done when the boiler is in service. Three and six monthly inspections are done utilizing an available planned shutdown approximately in the specied time period. Objective of these inspections is to ensure that: 1. The components are in trouble free condition. 2. To carry out any minor repairs or adjustments which can be done with the boiler in service. 3. To plan for repair of such items, which cannot be attended when the boiler is in service, during the next available shutdown. 4. To collect a database to determine optimum service life of the systems and components before maintenance if required. The schedule can be expanded, curtailed or modied based on experience in the rst two years of operation.
3.2 Preventive Maintenance Program for Spares

It may be found that in the rst two years of operation due to variations of site conditions, some additional spares are also required. Action has to initiate to procure such spares. The prepared master plan for maintenance should be periodically reviewed during the rst three years of the boiler operation. It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are either too much or too less. Based on site experience, the frequencies and work schedules can be modied
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,
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which require maintenance work for correction, have been included. EQUIPMENT Local level gauges on steam drum CHECK Check illumination is proper. Leaking valve glands. leaking ports Blurred level WORK TO BE DONE Replace fused bulbs. Isolate level gauge and tighten leaking glands. Replace leaking ports. Steam wash mica as suggested by vendor (not to be done too frequently) Comparison of levels indicated by local level gauge with that of remote level indicators in the control room Traces of water, oil spots on boiler oor, buck stay beams, boiler cladding etc. Compare the levels after verifying there are no leaks from valves, glands etc. of the level gauge and indicators. Report discrepancies. Such spots are indicative of valve leaks, instrument tapping leaks etc., Trace the source of leak. If there are serious discrepancies calibration of the remote level indicators has to be planned immediately. Maintenance to be planned to eliminate the source either immediately or during next planned shut down (depending on the source and quantity of leak) and accessibility for maintenance. Top up if required (immediately) If leakage through oil seals, gaskets drain plugs etc. are noticed plan for maintenance during next planned shutdown. Check bearing temperatures . Check for Vibration Levels If higher than normal bearing temperatures are noticed check for cause proper oil level, correct grade and quality of oil or grease, abnormal sound or vibration. If bearing temperatures are very high, start the reserve equipment ( if avl.) and plan for a maintenance checks . If vibrations are above the satisfactory limits. Check for mechanical looseness and start the reserve equipment ( if avl.) and plan for a maintenance check.
Lubricating oil levels of Fans, & feed pumps bearings, dosing pump gear box etc.
Check adequacy of oil level.
Fans, BFW pumps dozing pumps
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EQUIPMENT Drum and super safety valves. heater
CHECK Check for passing of safety valves (noise or wisp of steam through silencer)
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.
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)
Oil and moisture in the instrument air is likely to clog the positioners of pneumatic controllers / solenoids and make their operation sluggish or unreliable. Open drain valves of air receivers for short time to drain condensate if any. If these measures not successful, inform Maintenance group. are the
Steam or water leakages from valves and from ange joints
Loose valve gland Loosened bolts of ange joint and / or failed gasket.
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.
Boiler cladding, air duct or ue gas duct.
Check for hot spots
Hot spots may be due to leakage of ue gas or hot air. Source of leakage has to be located after selective removal of insulation (to be planned for the next planned shutdown)
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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 oor, buck stays or casings 7. Check for valve & gland leakages. 8. Check for air / gas leakages from ducts and ue. 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 eld 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, ow of air, suction damper opening, (Capacity of the FD Fan) pressure (seal air blowers, HP dosing pump) By monthly recording of data, establish a data base for deciding the overhaul time of the equipment. An overhaul once in two or three years may be adequate. Database will help in deciding the time frame. Sharp increase in vibration levels bearing temperatures or sound levels may call of early scheduling of overhauls. By monthly recording of data, establish a database for deciding the overhaul time of the equipment. An overhaul once in two or three years may be adequate. Database will help in deciding the time frame. Sharp increase in vibration levels bearing temperatures or sound levels may call of early scheduling of overhauls. If necessary do the adjustments. Clean with normal water
BFW pumps
Check for coupling alignment between motor and pump. Check the impeller is not rubbing with pump body. Check operation of NRV at pump discharge.
Safety valve operation Feed water internals tank /
Increase the boiler pressure and check the operation of valves. Deposits of foreign particles
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Dosing system
Cleanliness of dosing tank, operation of pressure relief valve, lubrication oil level in pump. Choking of impulse tubes Liquid level in manometer Close the steam out let valve and gas by pass damper. Open blow down valve and check for level switch very low alarm.
Clean dosing tank with normal water, Adjust relief valve ,if required Fill lubrication oil , if required Clean impulse tube with air Keep liquid level at zero If switch or alarm is not working, do the rectication work.
D P Manometer Level switch for steam drum water level very low
4.4 Checks Every Six Months

During a planned shut down of the boiler, the following checks can be done. EQUIPMENT Boiler safety interlocks, start permissive, boiler trip protection. CHECK Coinciding with a planned shut down of boiler, carry out the checks to identify malfunctioning or sluggish pressure, temperature switches, solenoid operated valves, positioners, proximity switches, actuators etc., WORK TO BE DONE Plan for maintenance or re-calibration of defective items if any noticed, during the shut down period.
4.5 Checks Every Year

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

COMPONENT NAME 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 INSPECTION REQD FOR
Pipe in steam drum
Tightness Holes orientation Corrosion / Pitting
Continuous blow down Pipe in steam Drum
Plugging Tightness Hole orientation Corrosion / pitting
Furnace tubes (water side)
Corrosion Scale Pitting Metal reduction
Furnace tubes (gas side)
Corrosion Build up Blisters Sagging Over heating Fly ash erosion Sealing Supports Cracks Expansion clearance
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COMPONENT NAME
INSPECTION REQD FOR Steam impingement Refractory status Insulation Erosion
Inbed evaporator coils re side
Erosion Corrosion Build up Blisters Sagging Over heating Sealing Cracks Steam impingement Refractory status
Super heater if provided. (steam side)
Corrosion Erosion Scale Pitting Metal reduction Flare cracking Deposits
Super heaters if provided. (gas side)
Corrosion Build up Sagging Over heating Fly ash erosion Sealing Supports Cracks Exp clearance Steam impingement Refractory status Insulation
Economiser (water side)
Corrosion Scale Pitting
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COMPONENT NAME Economiser (gas side) Corrosion Build up Blisters Sagging
INSPECTION REQD FOR
Over heating Fly ash erosion Sealing Supports Cracks Expansion clearance Steam impingement Tightness of access Doors Refractory Looseness Missing pieces Erosion Sealing burner throat Refractory Flame impingement on refractory Refractory holding arrangements. Bafe tile status 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
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COMPONENT NAME Dampers
INSPECTION REQD FOR 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
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COMPONENT NAME Water level gauges Leaks Visibility
INSPECTION REQD FOR Cleanliness
Illumination Reectors 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
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COMPONENT NAME Remote level gauges Leaks Visibility
INSPECTION REQD FOR Cleanliness
Illumination Gauge cocks status Internal deposits Insulation Dosing pumps Power cylinders Liquid status (if any) As per manuals As per manuals
Boiler Annual Maintenance and Overhaul
5.2 Shutdown and Cooling the Boiler

1. Shutdown the boiler in a planned manner. 2. Dont force cool the boiler. 3. Open all access and inspection doors.
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).
5.3 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 tted over temporary stand to force air through the drum. 3. From the time the drum manholes are opened till they are closed after inspection, the area around the drum must be cordoned to restrict entry only to specically authorized personnel. 4. The names of persons who are entering the drum for inspection, along with tools they carry must be entered in a register. Persons coming out of the drum after inspection should be asked to account for the material they carried into the drum. This precaution is to prevent accidental dropping of foreign material through the water wall tubes, which may block water circulation through them and can cause tube failures. 5. Carry out a preliminary inspection of the drum to check for deposits on the water side of the drum.
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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6. Using nylon brushes, the deposits (which are normally soft) are cleaned, collected on trays and disposed off outside the drum. Washing down the deposits to the boiler tubes is not recommended. 7. In case of excessive deposits, the chemist is asked to analyze the nature of the deposits. Incase of excessive deposits, a review of phosphate concentrations (higher than 10ppm) and boiler water quality control ( high conductivity ?) may be made to reduce the deposit in the next year of operation. After cleaning the following examinations can be made. 1. Examine the boiler drum metal for scale, pitting, corrosion and metal wastage. (Drum thickness is measured at a few selected spots using ultrasonic instruments and compared to design thickness). 2. Inspect fastenings of the bafes, cyclones, and demisters to see that they are intact, without corrosion pitting or holes. Eroded or corroded drum internals can be patched by welding. No welding however is permitted on the drum metal. The cyclones and demisters can be examined in position. They need not be dismantled. Reasonable water tightness of the bafes and cyclones are to be ensured. 3. Examine that feed water pipe is intact with ange connections tight and discharge exit correctly oriented. 4. Examine that the continuous blow down pipe and dosing pipes is not plugged or corroded 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.
2. Evidence of pitting / erosion / corrosion on tube outer surfaces (exposed to the ue gas path) 3. Evidence of overheating (bulging of tubes, blue color of tubes, blisters, disturbed vertical alignment of panels)
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.
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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Reduce carry over of water with steam, which is the cause of deposition on super heater/turbine blades, leading to the expensive failures. To maintain peak boiler efciency by keeping complete boiler water system clean. In order to meet above objectives, it is necessary to maintain certain chemical conditions in boiler, condense and feed water systems. A brief review of important factors is given in this section to assist those taking charges of new boiler equipment. It is not possible to cover the subject fully, there fore, it is recommended that the care and control of water quality be entrusted to water treatment specialist. 2. NEED FOR WATER TREATMENT A. CORROSSIVE CONTROL Water is corrosive to boiler metal. Typically corrosion due to water will reduce thickness of tube @ 1 mm/year. Thus the life and safety of boiler entirely depends on the rate of corrosion of boiler metal. In order to protect boiler from corrosion, pre-treatment is done to remove excessive corrosion ions like chloride, sulphate etc. However, further chemical conditioning is required to protect boiler and auxiliary systems from corrosion. Tri sodium phosphate, caustic, ammonia and amines are used as corrosion inhibitors. These chemicals form a protective lm over metal surface and reduce corrosion. It is necessary to maintain prescribed concentration of these chemicals in boiler water systems continuously. B. OXYGEN CORROSION INHIBITOR: Oxygen is present in dissolved form in water. At high temperature, oxygen reacts with metal to cause pitting corrosion. Thus prevention of oxygen lead to pin holes in economizer, steam drums and steam tubes. Most of the oxygen is removed externally by deaerator and preheating of feed water. However, traces of residual oxygen must be removed by chemical conditioning. Sodium sulte, hydrazine and amines are recommended for oxygen removal. These chemicals react with residual oxygen making it inactive and protect metal against pitting corrosion. Catalyzed oxygen scavengers are used for quick reaction. C. SCALE / DEPOSIT CONTROL: Raw water contains dissolved solids, hardness salts and suspended matters.
External treatment is used to remove such impurities. Clarication - To remove suspended matters. Filtration - To remove residual turbidity Softening - To remove hardness salts Dealkaliser - To remove hardness salts and excessive alkalinity Demineralization - To remove residual salts and silica Mixed bed - To remove residual salts and silica from DM water. A combination of above equipments are used to remove undesirable impurities in raw water. SCALE CONTROL Hardness salts in feed water cause formation in boiler. Under temperature and pressure inside the boiler and due to concentration, hardness salts precipitate in tubes as calcium carbonate, calcium sulphate and Ca/Mg silicate scales. External treatment like softening, demineralization or de-alkalisation removes most of the hardness salts from boiler feed water. However, malfunctioning of this equipment, occasional bypassing of the softener/DM plant or contamination of condensate or feed water with raw water often led to ingress of hardness in the boiler. All hardness salt precipitate inside boiler leading to hard scale formation on tubes. Such scale has lower conductivity causing increase in metal temperature, leading to bursting of tubes in extreme conditions. Therefore, inspire of elaborate external treatment, internal chemical conditioning is always recommended as additional safety. Following chemical methods are used for internal treatment. PHOSPHATE CONDITIONING Trisodium phosphate is commonly used. Hardness salts react with trisodium phosphate to form calcium phosphate precipitate. This precipitate above pH of 9.5 colloidal in nature and therefore do not allow for form hard scale of carbonate and silicates. The precipitated hardness salts are then removed through blow down as sludge and boiler tubes are kept scale free. Trisodium phosphate, apart from acting as hardness conditioning agent, also is a
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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.
ammonia cyclohexylamine and lming amine is recommended. E. TURBINE / SUPERHEATER DEPOSITION CONTROL: The solids in boiler feed water get concentrated in boiler. The concentration of solids in boiler is decided blowdown and feed water quality. The carryover of boiler water with steam depends on; Mechanical Factors: Boiler load - Higher the load, lower is the steam purity Water level in boiler - Higher the water level in drum, lower is steam purity. Load Variation - Sudden increase in load reduce steam purity for short time. Separation efciency - Higher efciency, better is steam purity. Chemical Factors:
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
TDS - Higher TDS in boiler, lower is steam purity. Total Alkalinity - Higher alkalinity as % of TDS lower is steam purity Organics - Higher the organic contamination, lower is steam purity. Foaming - Higher the foaming character of water, Lower is steam purity. The water carried over with steam due to above reasons is exactly similar in quality to blow-down or boiler water. In superheater or in turbines, water evaporates, leaving dissolved and suspended matter as scales or deposits. Thus severity of scaling and fouling of superheater and turbine depends on boiler water quality and steam purity. Maintaining boiler water quality as per norms and maximum steam purity is the only way to prevent deposition due to carryover of water with steam. Antifoam agents help to some extend to improve steam purity in case of excessive in boiler. F. SILICA DEPOSIT CONTROL: Silica is volatile under high temperature and pressure inside boiler. In turbines, the evaporated silica precipitates during pressure and temperature reduction and form hard scales. Maximum allowable concentration of silica depends on water analysis. Experts best decide the maximum permissible concentration after striding the operating parameters.
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G. CONDENSATE CORROSION CONTROL: The carbon dioxide is present in boiler feed water in dissolved and combined from as carbonate. Under boiler pressure and temperature it is liberated and carried over with steam as CO2 gas. This gas re dissolves in steam condensate to form carbonic acid. CO2 + H2O = H2CO3 H. MAINTENANCE OF PEAK EFFICIENCY: Corrosion, scaling, fouling carryover and condensate corrosion can cause unscheduled shutdown, accidents and deterioration of system efciency.Therefore for trouble free operation and maintenance peak operation efciency, a combination of various internal chemical treatments is essential along with a good control over boiler water quality. Maintaining boiler water quality by using commodity chemicals likes TSP, Hydrazine, and Sodium sulte. However, it is recommended that the care and control of water chemistry be entrusted to specialist.
6.1 Denition of Water Quality

Some cleaning procedures, hydrostatic testing and storage require water of higher quality than others. For the purpose of economy and convenience the lowest water quality consistent with requirements is specied in these various procedures. The terms that identify the different water qualities along with their denitions are list below: Station service water - Water normally used for drinking, re protection, etc. Softened water - Filtered, sodium zeolite softened water with total hardness less than 1 ppm. Two- bed demineralised water - Water then has been passed through cation and anion ion exchanges in series. Mixed bed demineralised water - Water that has been passed through a mixed bed demineraliser. Water from an evaporator is considered to be of equal quality. Treated demineralised water - Mixed bed demineralised water that has 200 ppm of hydrazine and enough ammonia added to give nal concentration of 10 ppm (or a pH of 10.0). In this procedure, condensate is considered to be treated demineralised water.
Boiler Preservation Procedure
INTRODUCTION Both the gas and waterside of a boiler should be protected against corrosion during out of service periods. It is known that many of the corrosion problems of boiler and auxiliary equipment have their inception during storage. Rusting of tube surfaces, as indicated by the formation of the red hematite (Fe2O3), not only cause a roughened tube surface but also results in attack of parent metal. The advantages of efcient feedwater and boiler water treatment during operation may be lost if the same diligence is not applied to protect heat. Transfer surfaces during idle periods. Protection from corrosion during storage becomes vitally important considering the number of times during the life of a boiler when it and its auxiliary equipment are idle. To minimize the possibility of corrosion, boiler to be placed into storage must be carefully prepared for the idle period and closely watched during the outage. There are two methods available for storing the unit dry storage and wet storage. Although the wet storage procedures is preferred such factors as availability of good quality water, ambient weather conditions, length of storage period, auxiliary supply of heat, etc may dictate that the dry storage procedure is more practical.
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 ring. Secure the boiler and when the pressure decays to 1.3 kg/cm2G, immediately drain the boiler and headers under air. As soon as possible, open the drums to allow air to circulate for drying of all internal surfaces. This step is included for a unit that has been in service and is to be placed into storage. For a unit that has never been in service, start with Step 2.
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2. If the unit is full of water and cold, drain the unit under air. All non-drainable boiler tubes should be blown with compressed air. If an external source of heat is available such as a steam coil air heater, portable heaters, etc., operate these heaters to assist in drying the internal boiler surfaces. Install trays (of non-porous construction and capable of passing through the drum manhole) containing the moisture absorbent (silica gel is preferred) into the drums. Insert the trays into the drum being certain that none of the absorbent comes into contact with the metal surface of the drum. To insure against an overow of corrosive liquid after the moisture has been absorbed, the trays should not be more than full of dry absorbent. The amount of absorbent can vary but the recommended minimum is one Kg of absorbent per 1000 Kg per hour steam ow capacity of the unit. 3. Open the isolation valve for nitrogen connection, on the steam drum, close all other vents and drains and pressurize the 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.
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 lled with deaerated, Demineralised water treated with 200 ppm hydrazine (N2H4) for oxygen removal and sufcient 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-ll method. The blend-ll method consists of blending the chemicals with the demineralised water at a continuous rate such that a uniform mixture is entering the boiler. Simply introducing the chemicals through the drum after establishing water level will not insure adequate dispersion of chemicals to all internal surfaces, unless sufcient heat is delivered to the furnace (i.e. ring the boiler) to induce natural circulation throughout the boiler. 3. Fill the unit with the treated demineralised water to the normal centerline of the steam drum. Stop lling further. 4. Back-ll the with treated Demineralised water until a rise in steam drum level is noted. Continue lling until water exits from the steam drum vents. After lling,
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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.
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 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, sufcient chemicals should be added through the chemical feed line, to establish the proper levels recommended. Samples of the treated water can be taken at the continuous blowdown line or any suitable drain connection. No unit should be stored wet when there is any possibility of a temperature drop to the freezing point unless sufcient heat can be provided to the
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, ash dries most of the moisture present on the tube surfaces. As the pressure parts remain dry, corrosion is prevented. This
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method of preservation however is not effective for move than a week.
6.6 Alkaline Water Dozed With Hyderzine

If a WHRB has to be preserved for long periods (two months or more) an effective method of preservation is to ll the WHRB, Super Heater and economizer with water treated with ammonia to a pH of 10.5 and dozed with 200 PPM or more hydrazine. This water is completely lled in the water and steam space of the WHRB and a pressure of 5 kg/cm2 (g) is maintained in the drum by a pump. This method is effective but requires additional equipment such as a tank, and a pump with a connection to one of the drain headers. All the possible methods of preservation of a shut down WHRB, the nitrogen blanketing method is simple and suitable for the type of preservation, which may be ordinarily required.
6.7 Preservation of Extra Surfaces of Pressure Parts of WHRB During Long shutdown
During WHRB shut downs exceeding a few days, the external surfaces of the pressure parts of especially in a chemical plant environment, may come under corrosive attacks by moisture, SO2, SO3 vapors etc. Keeping inspection doors tightly closed (when no inspection is being planned) may minimise such corrosion. Water lancing with hot water or mild alkaline water once a month may wash out the corrosive components from the external surfaces of the pressure parts. (See maintenance volume)
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6.8 Boiler Lay Up Procedures

TYPE OF SHUTDOWN SHORT OUTAGES 4 DAYS OR LESS. UNIT NOT DRAINED 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. LONG OUTAGES MORE THAN 15 DAYS - UNIT IS DRAINED. Dry storage of boiler with nitrogen alone is preferred procedure. Nitrogen cap of 0.3 to 0.6 kg/cm2G to be maintained on the steam drum. Installed silica gel tray in the steam drum to soak moisture if any present in the drum atmosphere. 5. Operate quick shutoff valves frequently (Twice a week) 6. Ensure that O2 analyzer is powered up and reference air supply is given when ue gas is present. 7. Check operation of Ignition Transformer once in 2 weeks if burners are provided. 8. Check operation of Flame Scanners & Flame Ampliers once in 2 weeks if burners are provided.
SHORT OUTAGES 4 DAYS OR LESS. UNIT IS DRAINED
LONG OUTAGES LONGER THAN 4 DAYS UPTO 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
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 specied and indicated on a drawing. Vulnerable locations are usually chosen. On request, the Field Engineering Department of TL can establish such a program. Each document should have the following minimum vital information. Tube thickness measurements at the selected locations are made and recorded after water
d. Ensure no dust/water accumulates on the rotating equipment.
6.10 Preservation of Instruments

1. Cover all eld instruments with plastic sheets 2. Power up the panel instruments and check the operation 3. Keep the control room dust and moisture free 4. Operate control valves, power cylinders once a week and check operation.
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washing and drying, during the rst annual overhaul. The base value is the design thickness of the tubes. Subsequent measurements are made at the same locations, every alternate year. The tube thickness survey provides useful data on corrosion / erosion rates and can alert the owner when serious loss of thickness is noticed. Details with sketches and drawings will give more clarity for analysis Date of inspection Tube no / Coil no. Inner coil / Outer coil details Location. RHS / LHS Clock position. Reference points. Thickness including decimals. Visual observations Condition of studs.
It is recommended that every effort be made to nd the cause of tube failures before operation is resumed. It should be ensured that, whenever a spool piece is inserted in the failed zone, the weld joint needs to be of proper weld quality. Free from excess weld penetration to avoid any obstruction in the water / steam mixture ow inside the tube. Excess weld penetration can cause internal tube erosion and results in tube failures. It is suggested to have all the joints are x-rayed and interpreted by qualied / experienced radiographer.
7.1 Tube Failure Investigation / Analysis Method

Investigation / analysis methodology is listed as follows, which needs to be followed to nd the actual root cause of the problems. Please ll up the enlcosed form duly lled and the same may be sent to Thermax along with tube sample for analysis.
Tube Failures
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 identied, the leaks may be repaired by replacing the failed tube or by splicing in a new section of tube, conrming to IBR code.
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 specic failure, the principal stages that comprise the investigation & analysis of a failure are: 1. Collection of background & selection of samples 2. Preliminary examination of the failed part(visual examination & record keeping) 3. Nondestructive testing 4. Mechanical testing (including hardness & toughness testing)
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.
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5. Selection, identication, preservation, and/or cleaning of all specimens. 6. Macroscopic examination and analysis(fracture surfaces, secondary cracks, & other surface phenomena) 7. Microscopic examination and analysis 8. Selection & preparation of metallographic sections 9. Examination and analysis of metallographic sections
The failed pressure part tube should not be hammered, any mechanical impact should be avoided. 3. Inspect the failed tube and record all ndings on the same as well as its adjacent tubes. Carry out dimensional measurement of failed tube and affected adjacent tubes. 4. Number mark the failed tube for its location, ue gas ow, steam ow with oil paint. After completion of inspection, recording and photography, cut the failed tube and affected adjacent tube, if any, with the help of HACKSAW only. Gas cutting of the tubes should be avoided as much as possible. The failed tube, keeping the failed portion in middle should be cut for total length of minimum 350 mm. Immediately after cutting the tube sample both the ends should be covered with plastic caps. While doing this the internal or external scale of tube should not fall down. 5. The failed tube samples nicely packed in plastic bag / wooden case accompanying duly lled format with water chemistry of boiler log sheets should be sent to H.O Pune.
Collection of Background Operating Data

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

1. Study the boiler log sheet & water chemistry record prior to tube failure and after tube failure. Preserve the copies of these log sheets. Record, if any abnormality noticed, such as mal operation, malfunction, very high or low temp. / loads, uctuating loads, sudden increase in load or temp., poor water chemistry, start up vent crack open / close etc. etc. (if possible collect and send the water samples, internal scale from drum & tubes, external scale samples). 2. After entering in boiler and before proceeding to tube failure location inspect & record the condition of boiler and pressure parts without disturbing the evidence i.e. distortion of pressure parts/coils, bulging of pressure parts, scaling / lump formation on pressure parts, blockage of ue gas path, other / secondary failures etc. etc. In such case taking photographs will help in great extent in analyzing of the tube failure, boiler problem.
Removal of Failed Tube Sample

1. The tube sample should be cut with a hacksaw blade. Gas cutting should be avoided. 2. The sample should be cut approx. 8-10 inches above & below the affected area. 3. & elevation should be marked on the tube sample. 4. The direction of the uid ow should be marked on the tube sample. 5. Immediately after cutting the tube sample both the ends should be covered with plastic caps. While doing this the internal or external scale of tube should not fall down. The failed tube sample nicely packed in plastic bag / wooden case accompanying duly lled format as given below with water chemistry of boiler log sheets should be sent to H.O for metallurgical investigations.
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7.2 Tube Thickness Survey Data Collection Format

(FURNACE / BOILER BANK / ECONOMISER TUBES) BOILER NUMBER : DATE OF INSPECTION : COIL NO CLOCK POSITION TUBE THICKNESS STUD LENGTH VISUAL OBSERVATIONS UNIT NO : CUSTOMER :
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 FAX : WEB SITE : EMAIL : 020 66126464 020 27479048 http://www.thermaxindia.com Yashwant1@thermaxindia.com Uumale@thermaxindia.com DEAR CUSTOMER, WE WANT TO HEAR FROM YOU, WE STRIVE TO CONTINUOUSLY IMPROVE THE QUALITY AND PERFORMANCE OF OUR PRODUCTS. WE WOULD LIKE TO HEAR FROM YOU, SHOULD YOU EXPERIENCE PROBLEMS WITH OUR EQUIPMENT OR SHOULD YOU WANT TO 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.)
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CUSTOMER FEEDBACK FORM 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 1. 2. PROBLEM DETAILS OBSERVATIONS
CUSTOMER DETAILS:
CORRECTIVE ACTIONS TAKEN
COMMENTS / RECOMMENDATIONS
OTHER INFORMATION: EXPECTATIONS FROM TBW : REPLY AWAITED / SERVICE ENGINEER VISIT : SIGNATURE & DATE
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Welding Procedure Specications
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 specication of the materials and shapes adopted by Thermax can be obtained on request. The welding procedure distinguishes between welding of thin and thick material. The welding process specication denes the following for each category of welding. Edge preparation (angle, shape) Joint preparation (cleaning, gap) and tagging Joint pre-inspection before welding Pre-heat of the weld joint, if any required (method of pre-heating, temperature method of checking temperature) Root weld (gas welding, TIG or Arc, size of electrode, type of electrode) Radiographic inspection of root weld if required Subsequent runs of welding (TIG, Arc or other methods, size of electrode, type of electrode, number of runs) Post weld heat treatment if any required (temperature, rate of increase of temperature, method of increasing temperature, holding time, rate of cooling) Radio graphic examination of the weld joint, indicating defects if any to be corrected Correction of weld defects Final acceptance of the weld joint The WPS indicates compatible categories of materials that can be welded. The WPS also lays down the type of electrode to be used for each
category of welding. As the electrode deposits materials, the composition of the electrode must be compatible with the material welded and add strength. The coating of the electrode also must meet specic requirements. The WPS must be used not only during fabrication of the boiler, but also when any repair or maintenance works are to be done. Thermax has WPS to cover every welding job connected with fabrication of the boiler in the factory and erection of the boiler at site, conforming to IBR requirements. The Field Engineering Department of Thermax will be glad to provide a WPS for any site repair weld jobs required for maintenance.
8.1 Window Patch Welding

PURPOSE The purpose of the window patching method is to allow the welding of tubes that could not otherwise be welded because of limited access to part of the tube diameter. This procedure is restricted to that use. PREPARATION 1. The area to be patched shall be cleaned to bare metal. 2. The patch shall be made from tube material of same type, diameter and thickness, as the tube being welded 3. The area of the tube to be removed shall be carefully marked out as close as possible to contour of the patch. The tube section may then be removed using an oxyacetylene gas cutting torch or by mechanical means 4. The weld preparation shall be made as per the Figure #1. The t up of the patch weld gap shall be 2.4 0.8 mm Welding 1. A welder qualied to the requirements of ASME shall make the tube and patch welds in accordance with an approved weld procedure. 2. The root pass shall be done with GTAW process. The weld may then be completed with either SMAW or GTAW process. Some acceptable weld procedure specications are listed in Table below TESTING All the tube and patch welding shall be subject to close visual inspection and 100% radiography
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in accordance with the requirements of ASME section V. The standard for accepting /rejecting is specied in ASME section I Base Material P1 TO P1 P3 TO P3 P3 TO P3 P4 TO P4 P5 TO P5 P8 TO P8 Carbon Steel To Carbon Steel Carbon Moly To Carbon Moly Cr Moly To Cr Moly 1-1/4 Cr TO 1-1/4 Cr 2-1/4 Cr 1 Moly To 2-1/4 Cr 1 Moly Stainless To Stainless
Completed welds are subject to hydrostatic test
Filler Metal ER 70S.2 ER80S.B2 ER80S.B2 ER80S.B2 ER90S.B3 ER308 E7018 E7018A1 E8018B2L E8018B2L E9018B3L ER308-16
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 difcult to obtain accurate cuts on furnace tubes especially those in welded furnace walls. However, it is worth to spend extra time to get the existing tube ends squared and correctly chamfered and to cut the replacement tube to the correct length. Poor t-up increase the possibility of an unsuccessful weld. 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 solidies. A butt weld in the tube will shorten the total tube length about 1.6 mm.
Figure 3
General Principle Of Weld Repairs
8. Use a clamp or guide lug to hold one end of the replacement tube alignment while the rst weld is made. Do not tack weld both end of the replacement tubes particularly if the existing tubes are rigidly supported 9. As a general rule, rst complete the welds at the lower end of the replacement tube. Do not start welding the upper end of the replacement tube until both the replacement and the existing tubes have cooled to ambient temperature. WELD REPAIR OF SMALL CRACKS IN TUBE In the interest of saving time and cost, it is better to weld small cracks rather than replace a length of the tube.The crack must be ground out to form an acceptable welding groove. The groove should continue well beyond the ends of the crack. Inert gas arc or oxy acetylene process must make the rst pass of the weld. Note 1. This type of the repairs entails some risk. Internal deposits. Particularly copper, may exist under the crack which will result in
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 rst pass of the weld must be made with inert gas-arc or oxy acetylene. The weld passes may be completed by either process, or by a manual metal arc. 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
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damaging the parent and/or weld metal causing failure in a short period of time. 2. Over-heating the tube may have caused the longitudinal crack. In this case, the tube has swollen and the weld thickness reduced. In the modern welded wall construction, it is difcult to accurately measure the tube diameter or circumference to detect the minor swelling. If visual indicates swelling and reduction of wall thickness at the crack, a complete replacement of the damaged tube length is the best solution. 3. A circumferential crack indicates a failure due to excessive stress applied by expansion restriction, bending or fatigue; welding can repair such cracks. However, unless the cause of failure is diagnosed and corrected, another similar failure could occur at or near the original crack. 4. Also the tube cannot be cleaned from inside and there is always a possibility internal deposits will contaminate the weld.
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 denite hole must be punched or drilled in the tube to prevent a possible dangerous buildup of pressure between the tube plugs. 4. A expanded tube leaking at the seat should be removed from its seat and a. a new tube rolled in b. a new short stub rolled in and plugged c. the tube end seal welded to the shell or, if the drum shell is internally counter bored, a cylindrical plug must be installed and seal welded to the drum shell.
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 rst pass of the weld. Note 1. This type of the repairs entails some risk. Internal deposits. Particularly copper, may exist under the crack which will result in damaging the parent and/or weld metal causing failure in a short period of time. 2. Over-heating the tube may have caused the longitudinal crack. In this case, the tube has swollen and the weld thickness reduced. In the modern welded wall construction, it is difcult to accurately measure the tube diameter or circumference to detect the minor swelling. If visual indicates swelling and reduction of wall thickness at the crack, a complete replacement of the damaged tube length is the best solution. 3. A circumferential crack indicates a failure due to excessive stress applied by expansion restriction, bending or fatigue; welding can repair such cracks. However, unless the cause of failure is diagnosed and corrected,
Note: Point. (a) is the preferred x with Point. (c) the least preferred. 5. Seal welding of tube ends, tapered plugs, or cylindrical plugs to the shell should be done in such a manner as to minimize the heating of adjacent tube seats, which may become loose. It is essential that the welding process should be as per standard procedure for carbon steel shells and tubes to be followed very closely to ensure success. Deviations from these parameters will normally result
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in unsatisfactory connections. The major welding parameters for shells or tubes other than carbon steel may be obtained from qualied welding procedures. Ensure that welders are qualied in accordance with ASME Section IX and local provincial requirements. They must also ensure that the welding is done to the applicable qualied weld procedure.It also to be ensured that the proposed repair has been approved by the Boiler Inspection Branch of the local jurisdiction. 6. Machined tube stubs and plugs are used where the old tube can be removed from its seat without seat damage and for new construction that is drilled for future addition of tubes. The rolled-in tube stub extends into the shell and a solid plug is installed and seal welded to the stub. These stubs and plugs are standardized to have only one tube stub and one plug for each standard tube hole. 7. Before rolling stubs in, they should be cleaned inside and outside with a wire brush, abrasive paper, or a liquid cleaner until the metal is free of all foreign substances. In general, stubs do not require cleaning beyond the removal of dirt, rust, scale or foreign material.The stub seat (tube hole) should be similarly cleaned. If a liquid solvent is used to clean either the stub and/or tube hole, care must be taken to dry the metal completely. Liquid trapped between the stub and its seat prevents contact of the two metal surfaces. 8. Before the expanding tool is inserted, the inside of the stub should be lubricated with a suitable compound. The compound selected should be water soluble to facilitate cleanup. The rolling process should not be rushed since heat generated during rolling is detrimental to the strength of the rolled joint. The tube stub is properly expanded when the wall thickness in the seat is reduced by 6 to 10 percent for generating tubes and 10 to 14 percent for other boiler tubes. The tube stub wall reduction for thin shells should be less than that for thicker shells. This is to prevent over rolling which could cause adjacent tube seats to leak. Since the stub wall itself cannot be measured after it is rolled in its seat, the only alternative is to calculate the increase in the stub ID that is necessary to prove that the wall has in fact been reduced by the required percentage. This depends upon the tube seat ID (hole diameter), tube stub OD, the clearance between these two and also the stub wall. An example of this conversion for
a 2 " OD by 0.150-inch wall tube stub for a 10% wall reduction is as follows Measure Hold Dia = Measure Stub OD = Measure Stub ID = Clearance = 2.531 -2.500 0.031 Clearance 2.200 0.031 2,231 Stub ID @ Contact Stub ID @ Contact = 10% of 0.150 x 2 = 2,231 0.030 2.261 Stub ID after expanding 9. Plug all internal counter bored holes in the eld with the cylindrical plug when the tube is still in the seat. Some counter bores may be shallow enough that the tube ends are exposed sufciently to permit seal welding to a tapered plug. 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 specic plug size desired. 11. Tapered plugs are used to plug existing tubes where it is not practical to remove the tube from its seat and there is no internal counter bore. These plugs must be tailor made for each tube diameter and tube wall thickness. Figure 08 shows the details of this tapered plug and give instructions for a plug to t tube diameters from 1-3/4" through 4 " OD and any wall thickness. Figure 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 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.
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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 gures are met. If those conditions cannot be satised, tube replacement is recommended. In these two gures, the pressure is on the internal end of the plug and the external strength weld restrains the plug. 15. Plugged tubes that are below the horizontal centerline of the shell will not drain. Therefore, after chemical cleaning it is necessary that the plug to be removed and the stub swabbed out to remove the chemicals in these stubs. The plug can then be welded back in or in some cases it will have been destroyed in the removal process and anew one will have to be installed. Care must be taken in the plug removal process to not damage or thin the tube stubs wall.
damage to the tube seats. If the tube seat is damaged, it may be impossible to ever roll another tube in and make a tight seal. Gouging of the tube seat could also affect the ligaments between tube holes and integrity of the shell. Tubes can be removed from their seats without seat damage if the following procedures are carefully followed. With lightgage tubes, it is often possible to cold crimp the tube end to loosen it in its seat, then drive or "jack" the tube out. 2. When the tubes are too heavy for cold crimping, the two-stage heating method may be used. Heat is applied to the inside of the tube end with a torch. Heat is rst applied for a short period - not long enough for it to be transferred to the tube sheet. When the tube end cools, the joint will have loosened enough so that the second heat will not be transferred readily to the tube sheet. The tube end can then be heated sufciently for crimping and the tube can be pushed out of its seat. If neither of these methods is applicable, the following methods may be employed. 3. To remove light tube tubs, it is advisable to cut grooves about 3/4 inch apart with a round nose chisel. When the tongue (the metal between the two grooves) is knocked free, the tube can be collapsed and removed. 4. To remove heavy gage tubes, the type of grooving tool shown in gure 12 is used to prepare the tongues without damage to the tube seat. It is used with a pneumatic hammer, but it is necessary that the tool be suited to the tube thickness so that it will cut the grooves as deep as possible and yet leave a minimum thickness of metal over the tube seat. In very heavy gage tubes, a third groove is often cut, as nearly opposite the tongue as possible, so that less heavy pounding will be required to collapse the stub. These latter two methods require that the are on the end of the tube be crimped straight before starting, to cut the grooves for collapsing the tube. Of course, the seal weld around the end of any tube must be ground or machined off before attempting to cut the grooves for collapsing the tube. This must be done carefully to prevent damage to the drum shell.
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 qualied 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
9.6 Plugging of Tubes Drawings

Attached gures 04 to 12
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Tapered plug application for shallow internal CTRB Tube end must be exposed sufciently for seal welding. Figure 4
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Figure 5
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Figure 6
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Figure 7
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Figure 8
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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.
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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 O.D tube Plug of SA 181 Gr 70 material preferred Sa 105 is also accepted
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Figure 12
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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 classied as given below 1. Un dissolved and suspended solid materials. 2. Dissolved salts and minerals. 3. Dissolved gases. 4. Other materials (a soil, acid) either in mixed and unmixed forms.
D) IRON: Most common soluble iron in water is ferrous bicarbonate. The water containing ferrous bicarbonate deposits becomes yellowish and reddish sediment of ferric hydroxide if exposed to air. Majority of ground surface water contains less than 5 ppm but 0.3 ppm, can create trouble in the feed water system by soft scale formation and accelerating the corrosion. E) MANGANESE: It also occurs in similar form as iron and it is also equally troublesome. F) SILICA: Most natural water contains silica ranging from 1 to 100 ppm. Its presence is highly objectionable as it forms very hard scale in boilers and forms insoluble deposits on turbine blades. In modern high-pressure boilers its presence is reduced as low as 10-50 ppm. G) MICROBIOLOGICAL GROWTHS: Various growths occur in surface water (lake and river). The microorganisms include diatons, molds, bacterial slimes, algae; manganese and sulfate reducing bacteria and many others. These can cause coating on heat exchanger and clog the ow passages and reduce the heat transfer rates. H) COLOR: Surface waters from swampy areas become highly colored due to decaying vegetation. Color of feed water is objectionable as it causes foaming in boilers and may interfere by chlorinating of absorption by activated carbon.
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 ltration. Their presence is undesirable because heating or evaporation produces hard stony scale deposits on the heating surface and clog uid system. Both are objectionable as they cause damage to the boiler system. A standard of measurement of hardness is taken as being the amount of calcium carbonate (CaCO3) in the water and is referred to in part per million (ppm) or grains per gallon (grain/gallon) X 17.1 = ppm. B) SODIUM AND POTASSIUM SALTS: These are extremely soluble in water and do not deposit unless highly concentrated. Their presence is troublesome as they are alkaline in nature and accelerate the corrosion. C) CHLORIDES: Majority of the chloride corrosive action of water. causes increased
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 classied as temporary and permanent hardness. The temporary hardness is caused by the bicarbonates of calcium and magnesium and can be removed by boiling. The boiling converts the soluble bicarbonates into less soluble carbonates, which can be removed by simple blow-down method. The presence of chlorides, sulfates and nitrates of calcium
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cause the permanent hardness of the water and magnesium and they cannot be removed just by boiling because they form a hard scale on heating surfaces.
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.
number denoting the degree of acidity or alkalinity of a substance. It does not indicate the quantity of acid or alkali in a solution as found by ltration method. It is derived by measuring the amount of hydrogen ion (H+) in grams per liter of solution. The greater the amount of hydrogen ions present in solution its acid reaction becomes stronger. Therefore, pure water is being neutral solution, any solution producing more hydrogen ion than pure water will be acidic and degree is governed by difference and other solution producing less hydrogen ions than pure water will be alkaline and the degree is also governed by the difference. THE ROLE OF pH IN CORROSION: The role of pH in corrosion of metals is extremely important. The corrosion rate of iron in the absence of oxygen is proportional to pH up to a value of 9.6. At this point, hydrogen gas formation and dissolving of iron practically stops. This is the came pH produced by a saturated solution of ferrous hydroxide Fe (OH) 2. The Oxygen in the water unites with ferrous hydroxide to form ferric hydroxide. This reaction lowers pH of the solution and levels to stimulate corrosion. Alkalinity adjustment and lm formation are closely related. The pH value of feed water should be maintained greater than 9.6 to reduce the corrosion effects caused by the reason mentioned above. The required alkalinity of feed water is adjusted by adding soda ash caustic soda or trisodium phosphate. The calcium hardness, alkalinity and pH are inter-related variables in scale control. Calcium carbonate is one of the most troublesome deposits responsible for scale formation.
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 bafe separators generally remove it. The effects of all the impurities present in the water are the scale formation on the different parts of the boiler system and corrosion. The scale formation reduces the heat transfer rates and clogs the ow passage and endangers the life of the equipment by increasing the temp above the safe limit. The corrosion phenomenon reduces the life of the plant rapidly. Therefore it is absolutely necessary to reduce the impurities below a safe limit for the proper working of the power plant.
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 ows into the Boiler for continuos generation of Steam. With conversion of water into steam in Boiler, solids are left behind to concentrate the remaining water. The scale formation tendency increases with the increase in temperature of feed water. Because, the solubility of some salts (as calcium sulphite) decreases with the increase in feed water temperature. Calcium sulphite has solubility
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
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of 3200 ppm. at 15 Deg. C and it reduces to 55 ppm. at 230 Deg. C and 27 ppm. At 320 Deg. C. Scale formation takes place mainly due to salts of calcium and magnesium. Sometimes, it is cemented into a hard mass by Silica. Among all, calcium is the principal offender and particularly, Calcium sulphate, magnesium sulphate and other Chlorides are sufciently soluble in water and are not much troublesome. Sodium salts are highly soluble in water and are non-scale forming. The scale formation takes place mainly in feed water piping and Boiler Tubes. Its rst effect on the piping system is to choke the ow of water by reducing the ow area and increases the pressure required to maintain the water delivery. Another effect of scale formation is to reduce the transfer of heat form the hot gases to water. Real dangers of the scale formation exist in radiant heat zone where boiler tubes are directly exposed to the combustion. The scale formation retards the ow of heat and metal temperature increases. Even a thin layer of scale in high heat zone can over-heat the metal enough to rupture the tubes. The metal tubes weakened due to over-heating yield to pressure providing a protrusion known as bag. Such bag provides a pocket for the accumulation of sludge and scale, which eventually causes failure. The over-heating of metal causes layer of metal to separate and form a blister. 2. CORROSION The corrosion is eating away process of boiler metal. It causes deterioration & failure of the equipment, eventually this cause for major repairs or expensive shut -downs or replacements. The corrosion of boilers, economizers, feed water heaters & piping is caused by an acid or low PH in addition to the presence of dissolved oxygen & carbon dioxide in the boiler feed water. The presence of oxygen is mostly responsible for corrosion among all other factors. The permissible limit of oxygen content varies with the acidity of water. Generally it should not should exceed 0.5 cc per liter .O2 generally enters into closed system through make up condenser leakage and condensate pump packing. CO2 is next to O2, which is responsible for corrosion. The CO2 comes out of bicarbonates on heating and combines with water to form weak acids known as carbonic acid. This acid slowly reacts with iron and other metals to form their bicarbonates. The newly formed bicarbonates of metals decompose by heat once more and CO2 is again liberated. This gas again unites with water
to form carbonic acid and the cycle is repeated. Adding alkali solution to neutralize acids in water and raise the PH value can minimize the corrosion. The effect of CO2 is minimized by the addition of ammonia or neutralizing the amines in water. This is necessary because CO2 lowers the PH of the boiler feed water and dissolved solids to leave the boiler. The priming is a violent discharge of water with steam from the boiler. It can be compared to the pumping of water that frequently accompanies rapid heating in a open vessel. In priming the water level in the boiler undergoes rapid and great changes and there are violent discharges of bursting bubbles. Therefore sludge of boiler water is thrown over with the steam. The priming is caused due to improper boiler design, improper method of ring, overloading, sudden load changing or a combination of these factors. The priming effect is reduced by installing steam purier, lowering water level in the boiler and maintains constant load on boilers. The foaming is the formation of small and stable bubbles throughout the boiler water. The high percentage of dissolved solids, excessive alkalinity and presence of oil in water are responsible for foaming. Boiler water solids are also carried over in the moisture mixed with steam even when there is no indication of either priming or foaming. This is known as carry-over. The carry-over of boiler water solids is partly a mechanical and partly a chemical problem. The amount of suspended solids and alkalinity in the boiler water is also important in addition to other reasons like boiler design, high water level, and overloading and uctuating loads on boiler. 3. CAUSTIC EMBRITTLEMENT The caustic embrittlement is the weakening of boiler Steel as a result of inner crystalline cracks. This is caused by long exposure of boiler steel to combination of stress and highly alkaline water. The course of embrittlement takes place under following condition: a) When boiler water contains free hydroxide, alkalinity and some silica. It has been always found that the feed water was high in sodium bicarbonate, which broke down into sodium carbonate in the boiler and partially hydralized as shown by the following reaction in case of embrittlement.
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Na2CO3 + HOH = CO2 + 2 NaOH b) Slow leakage of boiler water through a joint or seam. c) Boiler metal is highly stressed at the point of leakage. This may be caused by faulty design and expansion etc. The prevention of caustic embrittlement consists of reducing the causticity or adding inhibiting
agents to the feed water. The most practical method of preventing caustic embrittlement is to regulate the chemical composition of the boiler water. The obvious solution to embrittlement is to eliminate all free NaOH from feed water by addition of Phosphates.
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Section E
Topics Covered in this Chapter Lubrication Schedule
Lubrication Schedule
This section holds the Lubrication Schedule for the Waste Heat Recovery Boiler on Coke Oven Lubrication Schedule
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Volume 2 Drawings
Chapters Covered in this Part List of Drawings
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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
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Volume 3 Drawings
Chapters Covered in this Part E & I Specications
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E & I Specications
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
Specication for MOV Valve Actuator
Section 08
8.1 Electrical Load List 8.2 Power & Control Cable Schedule
Section 09
Specication 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 Specication for Transmitters & Analysers 12.2 Specication for Gauges & Switches
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101
12.3 Specication for Valves & Actuators 12.4 Specication for Sensors 12.5 Specication for Actuators
Section 13
13.1. ARC Valve Specication 13.2. CBD Valve Specication 13.3. EBD Valve Specication
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
Volume 4 Vendor Manuals

Chapters Covered in this Part Section Section Section Section Section Section Section Section Section Section 01 02 03 04 05 06 07 08 09 10
103
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
104
I to P Converter ABB_Manual
Section 08
8.1 Flow Nozzle Starmech Controls
Manual for Flow Nozzle Data Sheets of Orice Plate Boiler 1 Data Sheets of Orice 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
105

Chapters Covered in this Part Section Section Section Section Section 01 02 03 04 05
106
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
107
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
108

Chapters Covered in this Part Section Section Section Section Section Section Section Section Section Section 01 02 03 04 05 06 07 08 09 10
109
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 Specication 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
Reex Level Gauge Chemtrols
O & M Manual Reex Level Gauge Chemtrols_Manual Drawings & Datasheet Reex Level Gauge - Chemtrol_Drawing
110
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
111
112
Index
100% Feed Controller ................................... 19 Dry Storage Preservation .............................. 71 During Black - Out Procedure Condition ......... 43
A
Air Vent ........................................................ 22 Alarms and Interlocks ................................... 49 Alarms And Interlocks ................................... 35 Annual Maintenance Check Sheet ................. 62 Attemperator .............................................7, 23 Automatic Control ......................................... 35
E
Economiser .................................................... 6 Economizer .................................................. 19 Effects of Impurities ...................................... 94 Electrical power .............................................. 7 Emergency Procedures................................. 48 Emergency Shutdown Procedure................... 43 EMR Valve ................................................... 12 Evaporator ................................................... 22 Evaporator / Convection Bank Tubes ............... 6 Expansion Joints .......................................... 68
B
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
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 prole: (for design case)............................................................ 4 Flue Gas System .......................................... 31 Flue gas Temperature prole : ( For Design case)............................................................ 3 Flue gas Velocity prole: (for design case) ......... 3 Forced Cooling ............................................. 44 Furnace and Boiler Tubes ............................. 81
C
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
G
Gauge Glass ........................................... 11, 13 General Principle Of Weld Repairs................. 81
H
High Water Level .......................................... 48 Hot Startup Procedure .................................. 42 HP Dosing System........................................ 27 HP/LP Dosing System..................................... 9
D
Daily Checks ................................................ 57 Daily Maintenance ........................................ 60 Deaerator..................................................9, 16 Deaerator Steam ............................................ 8 Dissolved Gases .......................................... 94 Dissolved Salts and Minerals......................... 93 DM Water....................................................... 8 Dos and Donts ............................................ 44 Drum Inspection ........................................... 67 Drum Level Control....................................... 21 Drum Safety Valve ........................................ 21
I
ID Fans .......................................................... 9 Inspection after Cooling ................................ 67 Inspection of Screen, Primary & Secondary Superheaters, Evaporators I/II & Economiser ................................................ 68 Instrument Air................................................. 8
113
Insulation ....................................................... 7 Insulation and Cladding................................. 68
Replacement of Tube Section........................ 84
L
Low Water Level........................................... 48
S
Safety In WHRB House................................. 55 Safety Relief Valve........................................ 12 Safety Valve ..................................................11 Section Overview.....................................38, 56 Shutdown and Cooling the Boiler ................... 67 Silencer ....................................................... 22 Soot Blower.............................................10, 32 Soot Blower System ..................................... 32 SOOT BLOWING SEQUENCE...................... 34 Steam and Water System Technical Performance Data....................................... 25 Steam Drum ..............................................4, 20 Steam Supply............................................... 32 Steam Temperature Control Loop .................. 23 Super Heater................................................ 23 Super Heater I .............................................. 23 Super Heater II ............................................. 23 Superheater IA / IB / Support Coils .................. 5 Superheater- II ............................................... 4 System Description............................ 3132, 44
M
Main Steam Piping........................................ 24 Maintaining Quality of Steam ......................... 30 Mixing Tank .................................................. 27 MOC And Specication of Euqipments ............. 4 Monthly Checks............................................ 60
N
Natural Cooling............................................. 44 Normal Shutdown Procedure......................... 42
O
Operation and Control................................... 33 Operation Procedure..................................... 38 Operational Control............................ 24, 3132 Operator Action Required during Boiler Cold Start up .............................................. 43 Other Drains................................................. 26 Other Equipment .......................................... 68 Other Materials............................................. 94
T
TECHNICAL SPECIFICATIONS ...................... 3 Tube Failure ................................................. 48 Tube Failures ............................................... 76 Tube Thickness Survey................................. 75 Tube Thickness Survey Data Collection Format ....................................................... 78
P
Paralleling WHRB To The Plant steam Mains ......................................................... 43 pH Value of the Water and its Importance......... 94 Phosphate Dosing Pump............................... 27 Planning Before Overhaul ............................. 67 Plugging Tubes in Drums & Headers.............. 82 Pre-requisites to Be Attended Before Start up: ............................................................. 38 Preparation of 5% Phosphate Solution in the tank ...................................................... 27 Preservation of Instruments........................... 75 Preservation of Rotating Equipments ............. 75 Preventive Maintenance................................ 56 Preventive Maintenance Program for Spares ....................................................... 57 Preventive Maintenance Program for Valve.......................................................... 57
U
Undissolved and Suspended Solid Materials .................................................... 93 Utilities........................................................... 7
V
Valve Settings:.............................................. 38
W
Water / Steam Temperature prole: (For Design case) ................................................ 3 Water And Steam Quality Control And Monitoring .................................................. 29 Water And Steam System ............................. 16 Water Chemistry ........................................... 93 Water Quality Recommendations................... 54 Weld Repair Of Small Cracks in Tube ............ 82 Welding Procedure Specications (WPS) ........................................................ 80
R
Recommended Maintenance Practices .......... 56 Removing Tubes from Drums, Headers & Tube Plates ................................................ 84
114
Wet Storage Preservation ............................. 72 WHRB Log Sheet ......................................... 46
Window Patch Welding ................................. 80
115

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OPERATION & MAINTENANCE MANUAL

THERMAX POWER A/C BHATIA ENERGY & STEELS LTD

THERMAX PROJECT NO.: PL 0501 02

THERMAX LIMITED BOILER & HEATER GROUP PUNE, INDIA

REVISION DESC. / REMARK

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

Volume 1 Boiler Description

Volume 1 Boiler Description

Operation & Maintenance Manual

Design Specication of WHRB

Kg/cm2 Kg/cm2 Kg/cm2

75 112.5 75 ASME PTC 4.4 Energy Balance ASME SECTION-1

Flue Gas Data

PARAMETERS Boiler Rating [MCR] Nm3/Hr ( Per Boiler) Inlet Temperature C

Operation & Maintenance Manual

4.45 6.2 75.79 13.45 100 ppm 100 m g/Nm3

3.1 Flue gas Velocity prole: (for design case)

3.2 Flue gas Temperature prole:(For Design case)

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

Operation & Maintenance Manual

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

MOC And Specication of Euqipments

4.1 Steam Drum

Operation & Maintenance Manual

Description Design temperature SH II Support Coils

4.3 Superheater IA / IB / Support Coils

Operation & Maintenance Manual

4.4 Evaporator / Convection Bank Tubes

Operation & Maintenance Manual

Description Header outer diameter mm Header thickness mm

Value OD 114.3 mm x 13.49 mm thk As per IBR

4.8 Blow Down Tank

5.1 Electrical power

For LT motors (UPTO AND INCLUDING 200 KW)

Operation & Maintenance Manual

Value 50 +/- 5% AC, 3 Phase, 4 wire

5.2 Cooling Water

5.4 Instrument Air

5.5 Deaerator Steam

Operation & Maintenance Manual

5.6 Chemicals for Dosing

HP/ LP Dosing System

Operation & Maintenance Manual

Boiler Feed Pump

Location Steam temperature deg c : Steam pressure kg/cm2(g)

Operation & Maintenance Manual

Description Source of Steam Drive

Long Retractable soot blower Motorised

Rotary soot blower

Saturated steam from Steam Drum

Operation & Maintenance Manual

DESCRIPTION APPLICATION RELIEVING CAPACITY QUANTITY FLUID

DRUM #1 8000 1 Sat Steam

DRUM #2 8000 1 Sat Steam

SH 6000 1 Sup Steam

13 Safety Relief Valve

O & M Manual

O & M Manual