BOILER OPERATION

COLD START UP

This means a normal start up of for a new unit or a unit that has been shut for a long time to allow complete cooling of all metal parts
BOILER INSPECTION

Before firing a boiler the complete boiler should be inspected. The furnace should be inspected and cleaned both internally and externally. Any structure pipelines that might restrict normal expansion of the unit should be cleaned. General cleanliness to be adhered to All vent valves on the boiler (economiser, drum, superheater) are to be opened before filling up the boiler. In most of the cases separate filling lines are provided. Filling is done through the header drains provided in evaporating section. Economiser coils also be filled thro its drain or thro the main feed line All the time of filling operations gauge glass must be brought on line .As the boiler is filled up water will start raising in the drum and appear in the gauge glass. Filling is continued till it rises up to recommended operating level. The quality of feed water and its temp are quite important. If the feed water temperature is high, the utmost care should be taken to avoid temperature strains or shocks by slow feeding. Here boiler temperature is relative to the boiler metal temperature. In general the temperature of feed water should not differ more than 50 deg Cfrom drum metal temperature at the time of filling
Lighting Up

The following steps are to be ensured prior to light up. 1 All foreign materials have been removed from pressure parts 2 All personnel cleared and access door closed 3 Interlocks and protections checked 4 Elements of retractable soot blowers fully retracted from the gas side 5 Individual fuel valves at burner closed 6 All boiler fittings (damper valves) in working condition Check for the conditions 1 All drain valves on boiler water walls should be closed

2 Blowdown valves (CBD, EBD) to be closed 3 Boiler filling and superheater filling valves should be closed 4 Steam supply valves to soot blowers to be closed 5 Main steam stop valves to be closed 6 Desuperheater valves including bypass to be closed 7 Feed regulating valves to be closed The following valves to be opened 1 Drum vents 2 Superheater drains and vent valves 3 Main steam line drain 4 Water level gauge glass to be in service Equipment mentioned below should be ready for service 1 Air heater 2 Induced draft fan 3 F.D.fan 4 Igniter fan 5 Seal air fan 6 Scanner fan 7 Primary air fan 8 Milling systems 9 Boiler feed pump 10 All drives for dampers and valves 11 All instruments and controls In addition to this burner position, connection and valve positions to be checked Purging the furnace It has been recognised that the boiler is prone for explosions under the following conditions 1 During start up when the combustion can be improper or when a boiler which has tripped and when in the furnace combustible fuel due to previous operation are present which during light up can explode 2 Condition, which can cause explosion, is present such as fuel rich furnace atmosphere All modern boilers at the time of light up provided with a purging sequence, which aims at preventing the explosions. The aim of any purge sequence is the following

1 To get ride of any remnant fuel in suspension from the previous firing in the furnace 2 To replace at least three times the atmosphere present in the boiler with fresh air 3 To provide an air rich atmosphere during light up These are achieved by providing the sequence as follows This takes place when a predominant airflow, which can be 30 % minimum to as much as 100% depending on the design is, established thro the furnace. The impulse is usually from airflow The purges to start some other conditions like the following are to be satisfied 1 Normal furnace vacuum 2 Drum water level normal 3 All fuel valves closed 4 All attemperator valves closed
PURGE COMPLETE

Maintaining the previous conditions for a fixed predetermined time, the time usually vary from 5 to 15 minutes signifies the purge complete. A variable timer is usually be available for adjustment Often the operation engineer has a temptation to shorten this time. While guidelines can be issued as to what is the right purge period if the engineer remembers, what the purge aims at, he will not be tempted to cut down the time without justification
REPURGE

In some boilers we have another safe guard where even after the purge completion if the boiler is not lit within, say 5 minutes we may have to go thro purge cyclic operation again. In boilers where such provision does not exist before relighting the boiler after an unsuccessful attempt furnace purging is done .It must be remembered that after a purge or during the purge if any condition established to start the purge disappears, one has to start purge sequence again After furnace purging the boiler is lighted up. Eventhough we have purged the boiler previously it is not out of explosion danger .The national fire

prevention association (NFPA) of USA has established a min of 30% air flow for all condition of operation less than 30%MCR .We have adopted the principle to ensure a rich mixture during initial light up. Temptation to reduce the airflow to less than 30% resisted. It should be borne in mind that thro 30% airflow need not necessarily come through the burner, which is being lighted but can be spread among other burners as well. Wherever igniters are provided for oil burner igniter must put into service. when igniters are proven warm up oil burners must be lit. The light up sequence of igniters warm-up guns and load carrying oil guns and coal combustion will be dealt later. We shall establish some general principles connected with light up. To quickly bring the boiler to its rated parameters or to condition where the turbine can be rolled or synchronised will be the aim of every operator. Quick pressure raising may bring about unequal thermal expansion, overheating of the tubes etc. Our aim to quick start must take into these factors Permissive rate of pressure raising The permissible rate of pressure raise based on the saturated temperature rise in the boiler .The max. permissible rate for a natural circulation boiler is given 100 deg C per. hour. It will be seen for our conditions this rate is rarely achieved. This 100deg C raise is again subjected to following limitations. 1 Whether we are able to establish a flow thro the SH. A definite flow get established when the turbogenerator is rolled or synchronised or venting is maintained thro startup valve 2 Temp of flue gas before the SH must not exceed 540deg C .In some boilers we will find that a provision of travelling furnace probe is available to monitor this temp where such provision does not exist the temperature has to be incorporated from available instrument readings 3 The drum metal temperature differential between any two points in the drum should not exceed 50 deg C. Where drum metal is of carbon steel this may not be significant and some time no provision may exist for measuring this temperature. The operator should understand that the permissible rate of saturated steam temp rise of 100deg C per hour should be interpreted with restrictions imposed by the factors stated above. In the initial firing it will be seen that superheater metal does not have protection. While flue gas

transmits heat tom the superheater tubes till such time the flow is established thro the SH, no withdrawal of heat takes place. Also in the initial period of operation water remains in the superheater tubes may restrict the steam flow. This condensed water should be drained from the SH loops using the drain provided. Operation of start up vent also ensures to get ride of the condensate from the SH tubes. In addition to SH are provided with metal temp points. Monitoring of SH temp with instrument gives us an idea of temperature difference between the tubes. . Abnormal differences in metal temperature can only be corrected by intense draining and slowing down firing rate. While lighting up a new boiler another retraint to firing is to ensure uniform expansion of water wall headers. Normally once this has been checked during initial periods of operation of the boiler in subsequent star ups this factor is not very significant unless some repair works have been done
VALVE OPERATION

SH drains remain open at start up and are initially closed as soon as steady steam comes out thro drains when boiler pressure is 3 to 5 KSC. It is good practice to reopen drain valves on the SH s say for 5 minutes at intervals of every 30 minutes till the boiler is connected to the turbine or comes on steady load Attemperator headers also to be drained similarly. Till such time boiler connected to the turbine a load on the boiler is to be established to ensure cooling of the SH. This load is very essential to protect the SH. The load can be provided a) Full opening of the SH drains. Which perhaps is the only possible load when the boiler pressure is low. This SH draining also helps to get ride of condensate in SH loop as it forms the shortest discharge path b) B) Start up vent where available. It will be noticed that the steam from the drum has to overcome the initial resistance of SH as well as condensate loops The start up vent will be useful only when the boiler pressure builds up to atleast 10 atm. Till then we must rely on drains. The capacity of the startup vent is again reduced by silencers provided if any. Start up vent can be either provided at SH outlet or at the main SH outlet or at the main steam outlet just before turbine stop valve. Using the latter is a preferred method since we can warm up the main steam line of the process.

C) Where HP/LP bypass is provided The system can provide the initial load with the added advantage of noise and saving in water which can be recovered from the condenser .We must remember that LP/HP by pass can be brought into play only after building up pressure to about 10 to 15 atm. And raising vacuum in the condenser. Till such time one must depend on the drains of the SH and main steam line The boiler engineer should understand that raising boiler pressure by throttling drain, startup vents or bypass is risky if it is going to deprive the SH from cooling
WATER LEVEL

Checking of water level is very essential since the boiler has only a very little water in reserve for evaporation. At a lower pressure a liberal Blowdown of the G/g may be given to clear any foreign material that may be present .The gauge glass should be blowdown several times at low pressure while warming up a new boiler (During normal operation blowdown must be minimum to protect the gauge glass)
NOTE

* Only direct gauge glass to be relied upon during initial startup of a boiler. Water level always should be kept within the visible range. (Recommended range) in the gauge glass The following precautions are to be taken as far as the direct level gauge glass is concerned 1 Water level should always be in normal position or zero position 2 Due to the temperature differential between the water in the g/g and water inside the drum at lower pressures the level indicated in the g/g will correspond to a lower than normal actual level in the drum 3) Adjustment of water level should be gradual 4) When the steam demand is fluctuating the water level would go up and high water may lead to carryover 5) When the unit is in normal operation remote water level can be relied upon with the routine check up of direct water level g/g(once in a shift) At any instant only a very little reserve of water is present in a boiler for evaporation. In a regular operation at any load we manage by maintaining constant amount of steam we are taking out of the boiler. Water level can fall or shoot up due to any one of the following reasons 1 Feed pump tripping 2 Failure of feed regulating valve/feed station valve

3 Water wall drain valve leakage 4 Water wall bursting 5 Wrong indications of the g/g or other instruments Water level change is quite drastic under the following conditions 1 Sudden increase of firing rate (swelling) 2 sudden decrease of firing rate (cooling) 3 When a safety valve opens 4 Sudden load fluctuation 5 When blowing down the boiler
BOWING DOWN A GAUGE GLASS

The following procedure should be adapted for blowing down gauge glass This is to prevent the g/g from thermal shocks cause by incorrect blowing down A) Close the upper gauge cock and open the drain valve of gauge. This will allow the water to drain and clear bottom parts B) Close the drain cock. This will result in water to rise in gauge glass body. After this drain should be opened. This process of opening and closing of the drain valve should be repeated for several times. This process clear and clean the water side port of gauge glass For cleaning the upper port the following procedure to be adapted 3) Empty the gauge glass by shutting down both the upper and lower valves and by opening the drain valve 4) Now open the upper gauge valve steam drains thro the port 5) Repeat this by opening and closing the steam side cock for two to three times 6) Open steam side and waterside cocks and closes the drain to bring the gauge glass back in service
NOTES

1 Micas are exposed to severe thermal shocks by the boiler pressure and frequent blow downs 2 Any leaks noted must be attended immediately. Leak in waterside will result in lower than actual level being shown in the gauge glass. Similarly leak from the steam side will result in higher than actual reading
SUPERHEATED STEAM

Effect of variables in SH temp 1 By feed water injection (attemperation) 2 By using top rows of burners 3 By burner tilt ( as applied to tilting tangential burners) 4 By pass recirculation With a constant load abnormally high Super Heat is caused by 1 Too high excess air 2 Too slow feed water temperature 3 Slagged up furnace 4 Secondary combustion 5 Improper operation of automatic steam temp indicating and controlling equipment With a constant load low SH temp is caused by 1 Too low excess air 2 Too high feed water pump 3 Excessive external deposits on SH 4 Excessive moisture carry over from drum 5 Passing Attemperator valves
SOOT BLOWING

Blowing of soot is important for keeping the heat transfer high. This should be done as and when there is indication of soot build up. By regular logging the exit and other temperature soot blowing programs can be made out. Care should be taken not to operate soot blowers on a cold boiler. Fire should not be extinguished while blowing The factors to be watched during the boiler operation Furnace Vacuum This should be maintained to provide a negative atmosphere -2 to 5 mm of water column at the top of the furnace. The value given must be increased if the tapping point of the instrument is not on the top of the furnace but located at the convenient point elsewhere. A good proof of adherence to this rule can be verified by the absence of the ash accumulator in the pent house Water level Immediately cut off firing if water level is not visible in the gauge glass (Low water level may result in the water wall tube failure). Overfilled boiler which can be sensed by the rapid fall of steam temp will result in the damaged turbine SH and main steam line.

Superheater Temperature Effects of the SH temperature have been indicated .The control of super heat can be achieved either by attemperation or by burner tilt. If the super heat temperature control is important but also the control of the temperature after convection SH platens etc If we remember that each section of SH is designed for a specific temp pick up and which are much lower than the final superheat temperature the need for controlling the interstage temp will be apparent Operating either the interstage superheater or the final stage SH at values above the designed limits even if they do not cause a failure immediately, will cause accelerated failures due to CREEP later. This is usually referred to as the Time Temperature deformation relationship of material strength
COMBUSTION AND EXCESS AIR CONTROL

Combustion adjustments are vital importance. Mechanic of combustion has been discussed earlier. The operation engineer should aim at the following Stable flame Excess air control Flame should not sweep or hit the boiler tubes Absence of slag In coal burners flame should be away from the burners to avoid distortion The combustion adjustment forms the most critical duty in boiler operation. For good adjustments the operation engineer should know not only the properties of fuel but also the capabilities of the equipment available with him for combustion The combustion control requires special skills, which are required by experience. Some general points can however be mentioned which by themselves would not be sufficient 1 Flame stability has to be achieved even if it is to be done at the cost of other parameters such as excess air, load limitation, cleanings oil burner etc. Combustion as we know is a process where fuel and air combine at the right temperatures. Correct mixing of air with fuel in practical terms mean ensuring the right windbox pressure ensuring the velocity of the secondary and primary air and also fuel air .For this purpose in a tangential fired boiler we have the following

Total air regulation The output control of the FD fans ensures total quantity of air to be supplied for combustion .It must borne in mind even when the FD fan delivers the required quantity combustion may not be proper if air is not distributed where is required. The distribution is done as described below Primary air flow In coal fired boilers working on direct systems, primary air is the drying medium of the coal and carrying medium .The primary air usually forms 18 to 25% of total air The Fuel Air The fuel air in coal fired boiler and in the oil-fired boiler is the air around the burner nozzle. The fuel air determines the ignition point of the fuel. It will be seen during light up that a flame can be lit readily when the fuel air is throttled to a minimum. Once the fuel is lit, the fuel air can be opened to control the flame shape and ignition point. The fuel air usually varied in the proportion to the fuel loading in a nozzle. As an illustration it may be said that when coal feeder is at min speed, in the nozzles served by the feeder the fuel air dampers may be at 30 % opening. Corresponding to the min speed of the feeder the fuel air damper will open at 100%. the figure mentioned in the example are for illustration only and actual positions are to be determined by the trials at site
THE AUXILLIARY AIR (SECONDARY AIR)

Dampers, which are either above or below the fuel nozzles, are regulated to obtain the furnace to wind box differential or in other words for windbox pressure in general ensures equitable distribution of air thorough various dampers than a low wind box pressure. From the explanations given above it will be seen that burner air dampers do not control the quantity of air distributed but their velocity. The quantity control we may repeat is done by FD air fan output A good combustion should ensure a clear furnace at the hopper. If the furnace appears dark at the lower zone increasing the quantity of air thro the lower most nozzles would help. The top air nozzle helps to control NO2 emission. If the control of the NO2 emission is important then we may increase the air flow thro the top nozzle even if it would mean excess air The explanation given for various adjustments of dampers is applicable to a coal or fired (tilting tangential burners). In tangential firing we should

remember that we have no burners as such and merely fuel nozzles .The furnace itself serves as a burner. Advantages of tangential firing can be realised only when the burners are fired firewise in pairs of two, diametrically opposite Wind box differential pressure is specified in operation manual. These are predicted values and we are free to chose one, which gives stable combustion
EXCESS AIR

Operating the boiler at less than required percentage of excess air would result in the following 1 Improper combustion 2 slaging 3 Inadequate superheat 4 Risk of explosion It is undesirable to operate the boiler under inadequate air condition. On the other hand high excess air would mean 1 High convection superheat 2 Possibilities of ash erosion in SH and economiser coils 3 Poor thermal efficiency Where burner designs do not match with the fuel to be burnt perhaps high excess air operation would be inevitable. Slagging condition can be some times are controlled by only high air operation Considering all these factors the correct excess air has to be chosen Flame hitting the tubes If a burner flame directly impinges on a water tube the combustion will not be complete and will lead to deposits on tube. The tube also under such conditions will be overheated and fail. In making an assessment we must distinguish between a direct impingement of the flame, which is a harmful and casual sweeping of the flame, which is not dangerous. The methods employed to avoid flame impingement as follows 1 Proper adjustment of the fuel air and secondary air 2 In an oil burner determining the position of the burner tip with respect to the diffuser and also changing the shape and size of the diffuser 3 Sometimes using an oil tip with a wider angle spay

SLAG

Can be caused by the following 1 Inadequate air 2 Unequal distribution of air to various corners 3 Ash fusion temp low (Fe2O3,CaO,& Na2O) and Na2O are mainly responsible for low ash softening temperature 4 Improper grinding at tube welding
AIR HEATER FIRES

Air heater fires are usually indicated by an unusual increase in temperature. There are two types of air heaters, rotary and tubular. Emergency measures are in case of fire in different for rotary and tubular heaters .We discuss rotary first and then tubular air heaters Rotary air heaters fires As soon as unusual increase of gas or air temperature is noted, check the air heater for fire If the unit is a pressurised unit or has only one air heater trip the boiler and proceed to fight the fire as indicated in steps 1 to 4 as below If the unit has two or more air heater decrease the load and isolate the burning heater, being sure to close the dampers on air side of the heater. Proceed to fight the fire as bellow. 1 Open the deluge fire fighting system. If this is not provided start the wash water and cleaning device being sure to open drain valves to dispose of the water 2 Connect a fire hose open the access door and direct the water to the fire location 3 If the fire is on one location on the rotor try to stop the rotor at a position where the full impact of the fire hose will be more effective 4 If the fire is general leave the rotor turning as long as it will turn. Use large amount of water to cool the air heater metal 5 If there any danger of water pick up air flowing through the air heater still in operation trip the unit or shut it down in an orderly manner Do not use foam or chemicals or steam, as they are ineffective on this type fire. Corrective action after the heater has fully cooled out is to inspect the air heater thoroughly and replace any components affected by the fire

TUBULAR AIR HEATER

As soon as unusual increase of gas or air temperature is noted check the air heater for fire .If the fire is located proceed as follows 1 Trip the unit 2 Close all fan and duct dampers on the air side 3 Connect a fire hose, open all drain valves and direct the fire hose steam at he fire Corrective action after the heater has fully cooled to inspect the heater thoroughly and replace any component affected by the fire This type of emergency can be practically eliminated if proper precaution in furnace operation is taken. The key to prevention of air heater fires is clean combustion in the furnace. This clean combustion can be accomplished by being particularly careful during cold starts and light load operation Some of the things to watch are 1 Keeping the fuel oil at proper temperature 2 If steam administration is being used having adequate steam for proper steam oil differential pressure 3 If available, steam should be slightly superheated 4 Setting dampers or burner vanes for proper flame shape or stable ignition point 5 Use of igniters during cold starts and light load operation

Compiled by B.P.Sadanand