P-3218 Vantaa

Systems training steam boiler

Edition 04.06.2013

Operating personnel training

Introduction

The purpose of this training is to familiarise operating staff with the plant equipment and
how to use it. It is a good idea for staff to visit the plant while the equipment is being
fitted, in order to be able to see where the equipment is located on the plant, especially
the connecting pipelines. Once the insulation has been installed the plant will look quite
different.
Training will cover the following basic topics:
Theoretical classroom training
Practical training at the boiler plant

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Table of Contents

Process
Configuration Vantaa
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance

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Table of contents

Process
Configuration Vantaa
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance

Process

Fundamental of waste incineration steam generators

The following slides are not related to a specific plant.
For simplification, the expression boiler is used for steam generator

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Main Components of Boiler

Principle of Natural Circulation in Evaporators

Main Control Loops

Life steam flow

waste input, combustion air flow (control within Combustion Control System (CCS)

Life steam pressure

turbine inlet valve (control turbine, no control within boiler)

Drum water level

feed water input (control of constant level)

Steam temperature throughput water injection attemperators (control constant steam temperature)

Arrangement of Heating Surfaces (Heat Exchangers)

Example: 2-Pass Horizontal Boiler

Note:
Each heat exchanger may consist of several bundles (banks)
e.g.: Eco = Eco 1.1 + Eco 1.2 + Eco 1.3 + Eco 1.4 + Eco 1.5 + Eco 2
+ Eco 3 , SH 1 = SH 1.1 + SH 1.2
Additional heat exchangers may be installed,
e.g.: evaporator between SH and Eco

Control of Flue Gas Temperature

at Boiler Outlet with preheater (External economiser)
Minimum flue gas temperature may
be required by flue gas cleaning system.
Note: max. flue gas temperature can not be
controlled (results from boiler fouling).

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Control of Flue Gas Temperature

at Boiler Outlet with preheater (External economiser)

Control of Flue Gas Temperature

at Boiler Outlet with Eco-Bypass (1)

Minimum flue gas temperature may

be required by flue gas cleaning system.
Note: max. flue gas temperature can not be
controlled (results from boiler fouling).

Continuous Boiler Blow Down

Steam generation =distillation

impurities are accumulated in
boiler water (evaporators)
Continuous blow down from drum
is adjusted in order to maintain boiler
water qualitiy within acceptable limits.
Typical continuous blow down:
0.5 % of life steam flow

Effect of Boiler Fouling on Flue Gas Temperature

Fouling increases with boiler operation time

Fouling = insulation of boiler tubes
Assuming same flue gas and water/steam temperatures in heat exchanger:
heat flux can be reduced by up to ca. 50 % due to fouling
Due to higher flue gas temperature in case of fouled boiler: heat flux in whole boiler is reduced only by
few % and results in an increase of flue gas temperature at boiler exit of ca. 30 C within 8000 h

Minimizing Corrosion: Final Superheater (SH 4) with Co-Flow

Steam temperature and therefore tube surface temperature is highest in final superheater
Highest risk of corrosion in final superheater (SH3 = SH3.1 + SH3.2)
Co-flow: reduction of corrosion rate, but
reduction of heat flux compared to counter-flow

Table of contents

Process
Configuration Vantaa
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance

Natural circulation boiler

Most common type of boiler (used in industry, combined heat and power stations)
Uneconomical for larger plants (> 500 t/h steam)
Simple evaporator design
Part loads and changes in load are easily possible
Changes in load: require control through injection, variation of live steam temperature
Sensitive to rapid pressure drops (profuse steam generation)
Reduced output of feed water pumps required
Lower feed water quality required (due to blow-down)

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Boiler operating principle

The feed water pump (6) conveys the feed water through the economiser (1) into the
boiler drum (2). The difference in density between the water/steam mixture in the
heated riser pipes (3) and the water in the non-heated downpipes (5) causes a
natural circulation to occur. The saturated steam, which is ultimately superheated in
the superheater (4), accumulates in the top part of the boiler drum (2).
No.

Description

Economiser(pre-heater)

Boiler drum

Evaporators (heated risers)

Superheaters

Non-heated downpipes

Feed water pump

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Boiler plant assembly method

Description of the boiler assembly process:

Pipes with 21.3 to 219.1 mm diameter are welded together
The diaphragm walls are made with longitudinal welding of pipes and steel strips
Method of transporting the parts from the workshop to the site and final assembly.
When the boiler is assembled, further procedures are to be carried out, such as:
Rinsing the boiler
Cleaning the water side of the boiler chemically
Drying the refractory lining
Steam cleaning of superheating surfaces.

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Steam boiler
Technical specifications
Description

Data

Nominal rating (saturated steam)

83 t/h

Live steam nominal pressure

91 bar (a)

Live steam nominal temperature

400 C

Feed water temperature

132 C

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Steam boiler
Size of heating surfaces
Description

KKS-No.

Data

External economiser 1.1

451 m2

J1HAC05 AC011

External economiser 1.2

451 m2

J1HAC05 AC012

External economiser 1.3

451 m2

J1HAC05 AC013

External economiser 1.4

451 m2

J1HAC05 AC014

External economiser 1.5

451 m2

J1HAC05 AC015

Economiser 2L/2R

1438 m2

J1HAC10 AC021
J1HAC10 AC022

Economiser 3L/3R

1438 m2

J1HAC10 AC031
J1HAC10 AC032

Evaporator walls

2063 m2

J1HAD10 AC001

Evaporator 1

214 m2

J1HAD10 AC002

Superheater 1.1L/1.1R

902 m2

J1HAH10 AC111
J1HAH10 AC112

Superheater 1.2L/1.2R

902 m2

J1HAH10 AC121
J1HAH10 AC122

Superheater 2L/2R

867 m2

J1HAH20 AC201
J1HAH20 AC202

Superheater 3.1L/3.1R

366 m2

J1HAH30 AC311
J1HAH30 AC312

Superheater 3.2L/3.2R

523 m2

J1HAH30 AC321
J1HAH30 AC322

Total

7190 m2

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Steam boiler
Volume of the boiler pressure system
Description
Boiler drum
Evaporator 1
Superheater 1.1L/1.1R
Superheater 1.2L/1.2R
Superheater 2L/2R
Superheater 3.1L/3.1R
Superheater 3.2L/3.2R

KKS-No.

Data
22,908 m

J1HAD10 BB001

2,193 m

J1HAD10 AC002

8,528 m
8,528 m
7,118 m
5,762 m
4,104 m

External economiser 1.1

2,435 m

External economiser 1.2

2,325 m

External economiser 1.3

2,325 m

External economiser 1.4

2,325 m

External economiser 1.5

2,435 m

J1HAH10 AC111 J1HAH10 AC112

J1HAH10 AC121 J1HAH10 AC122
J1HAH20 AC201 J1HAH20 AC202
J1HAH30 AC311 J1HAH30 AC312
J1HAH30 AC321 J1HAH30 AC322
J1HAC05 AC011
J1HAC05 AC012
J1HAC05 AC013
J1HAC05 AC014
J1HAC05 AC015

Membran walls - vertical part

35,816 m

J1HAC10 AC021
J1HAC10 AC022
J1HAC10 AC031
J1HAC10 AC032
J1HAD10 AC001

Membran walls-horizontal part

16,547 m

J1HAD10 AC001

Connecting pipings

18,969 m

168,73 m

Economiser 2L/2R
Economiser 3L/3R

Total

13,204 m
13,204 m

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Structure of the boiler

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Structure of the boiler

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Structure of the boiler

The steam is generated with a 5-pass horizontal boiler. This consists
of the vertical 1st to 3rd pass the horizontal 4th pass, and vertical 5th pass
The lower part of the 1st pass forms the furnace. In the grate area, the side walls are
fitted with refractory lining.
The side walls of passes 1 to 4 are designed as evaporator pipes with a gas-tight
diaphragm construction and are connected to the natural circulation system.
The economiser, the evaporator and the superheater are arranged in the horizontal
4th pass. The boiler drum is arranged diagonally at the top, on the boiler.
External vertical convection 5th pass with economiser heating surfaces and
sheet metal casing

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Boiler layout and internal circulation of all fluids

Passes (vertical and horizontal) including associated heating surfaces
are to be indicated as follows:
Superheating surfaces SH 1.1, SH 1.2, SH2, SH3.1, SH 3.2 with internal attemperators
for outlet temperature control
Evaporating surfaces ECO1.1 ECO1.5, ECO2, ECO3
Internal connecting pipelines; feed-water heater drum steam
Superheater 1.1. steam superheaters 1.2 - Attemperator 1 steam superheaters 2 Attemperator 2 steam superheaters 3.1 - steam superheaters and main steam line.
Location of draining and venting points
evaporators
Feed-water heaters Directions of flue gas flow through the boiler are also to be indicated. Flue gases from
domestic waste incineration boilers contain a high amount of ash that should be removed
from heating surfaces by means of mechanical rapping devices.

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Superheater:
final superheater co-flow
2 desuperheaters
Economiser
Evaporator
protection evaporator upstream SH

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Live steam:
Typically
402 C, 41.5 bar

Outlet
economiser:
15 C below
boiling

Inlet economiser:
132 C

Evaporator - Vantaa

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Economiser - Vantaa

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Superheater Vantaa

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External economiser - Vantaa

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Associated components: refractory lining

Reference to the following training of J + G

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Safety equipment and control circuits overview

Installed safety equipment includes:
Safety transmitter of minimum and maximum level in the drum J1 HAD10 CP001,
J1 HAD10 CP002, J1 HAD10 CP003.
Safety valve J1 LBA10 AA510 with control unit J1 HAD10 CG501
Thermometer J1 LBA10 CT002 protection of maximum temperature of
superheated steam
Transmitter J1 LBA10 CP002 maximum steam pressure protection
The purpose of the installed safety equipment is to protect the plant
against deviations from default values.

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Safety equipment and control circuits overview

Control circuits are:
Control of drum level consisting of feed-water control level transmitters, including
water and steam flow meters
Control circuit to protect feed-water from dropping below minimum temperature
Control circuit of steam attemperation
Control circuit to protect against high drum level.
Other operating (auxiliary) systems are:
Chemicals dosing system in order to maintain pH values of steam and water
within default values
System for collecting water from blow-down
Boiler warming system, i.e. maintaining standby condition.

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Fitted equipment overview

Presentation and description of operation of fitted equipment:
Safety valves
Cooling valves including associated attemperators
Valves for continuous water blow-down from the boiler drum
Water and steam quantity measurement measuring orifices
Three-way control valve J1 HAC05 AA020 for protecting feed water against dropping below
minimum temperature,
Water and steam sampling system
System for mechanical cleaning of heating surfaces
Wet cleaning.
Each part of the equipment should be provided
with the relevant suppliers brochure.

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Safety valve

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Safety valve on main steam line

Flow area 2827 mm2

Normal pressure 91 bar (g)
Set pressure in main steam line 1 96 bar(g)
Set pressure in main steam line 2 97 bar(g)
Set pressure in drum 107,0 bar(g)

Pneumatic contol unit

M1 96 barg main steam line

M1 96 barg main steam line
M3 108 barg boiler drum

Instruments
Thermometer J1 LBA10 CT003 protection of maximum temperature of superheated steam
Transmitter J1 LBA10 CP001 maximum steam pressure protection
The purpose of the installed safety equipment is to protect the plant against deviations from
default values.

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Control circuits are

Control of drum level consisting of feed-water control valve, level transmitters including water and
steam flow meters.
The function of the transparent water level indicator J1 HAD10 CL502 is checked as follows:
No
.

Description

KKS-No.

Boiler Drum

J1HAD10 BB001

Shut-off valve boiler drum measurement connection

J1HAD10 AA654

Shut-off valve boiler drum measurement connection

J1HAD10 AA653

Level measurement boiler drum

J1HAD10 CL502

Shut-off valve boiler drum measurement connection

J1HAD10 AA652

Shut-off valve boiler drum measurement connection

J1HAD10 AA651

Shut-off valve measuring instrument drain boiler

J1LCL90 AA830

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Drum level measuring

Bicolour level gauge

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Blow-down expansion tank

level measuring

Blow-down expansion tank

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Cooling valves including associated attemperators

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AUMA actuator

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Water and steam quantity measuring

Orifice plate

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Pneumatic rapping device

The rapping system is an automatically working cleaning device that cleans off the bundle of
pipes of a heating boiler through strikes against especially developed rapping points of the
bundle of pipes. For this a rapping carriage moves between two travelling way supports on
the outer wall of the heating boiler. The rapping carriage is moved via a rubber wheel on the
travelling way by a geared motor. The rapping carriage is guided by curved rollers on ball
bearings. Rams are built into the boiler wall at regular intervals and are situated at the
rapping points of the bundles of pipes. If the rapping carriage reaches a ram an initiator is
occupied by a positioning lug on the ram structural component. The rapping carriage stops
in this position. The occupation of the initiator is a fundamental precondition for the rapping
procedure. A further precondition is that compressed air is pending. These are arranged on
both side walls.
The dirty heating surfaces are caused to vibrate so that the resulting caking falls off.

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Pneumatic rapping device

Rapping device

KKS-No.

Rapping device 1

1 HCE40 AW001

Rapping device 2

1 HCE40 AW002

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Helical Soot Blowers

Long retractable blower
The long retractable blowers consist of a blow pipe and a nozzle head on the
end of the blow pipe. They move in an axial direction past the heating surfaces
to be cleaned. Live steam/MP steam is used as a blowing medium. The rest
position of the lance-type screw blowers is outside of the combustion gas flow.
Scoot blower

KKS-No.

Helical Soot Blowers 1

J1HCB05 AN001

Helical Soot Blowers 2

J1HCB05 AN002

Helical Soot Blowers 3

J1HCB05 AN003

Helical Soot Blowers 4

J1HCB05 AN004

Helical Soot Blowers 5

J1HCB05 AN005

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Helical Soot Blowers

Area of application: Cleaning of heating surface banks.
The blowing tube is installed in the flue gas pass and it and is helically moved
forward and backwards. The helical movement of the blowing tube / lance tube is
effected by chain drive at the soot blower carriage which is driven by a geared
motor. The blowing tube is on its entire length equipped with Venturi nozzles. A
full cleaning effect over the whole blowing distance is ensured due to the conical
expansion of the blowing jets and due to the arrangement of the nozzles.

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Helical Soot Blowers

Soot Blowes - parts

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Three-way control valve

J1 HAC05 AA020

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P&I diagrams
All P&I diagrams and their functions are to be included:
P&I diagram of boiler drum eco
P&I diagram of boiler superheaters
P&I diagram of boiler blow-down
P&I diagram of boiler drains vents
P&I diagram of boiler FG-side 2
P&I diagram of primary air preheater
P&I diagram of external eco & soot blowers

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P&I diagram of boiler drum eco

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P&I diagram of boiler superheaters

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P&I diagram of boiler drains vents

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P&I diagram of boiler blow-down

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P&I diagram of boiler FG-side 2

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P&I diagram of primary air preheater

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P&I diagram of external eco & soot blowers

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Table of contents

Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance

Description and preparation of plant start-up

This section contains a brief description of the plant preparation and start-up, its operation and
shutdown.
Presentation of the preparation for starting up the plant:
Procedures for plant start-up preparations
Initial drum water level
Top up from the start-up pipeline and valve
Warming up the superheated steam pipeline from the main steam valve to the steam
Turbine by using the bypass valve for warming up
Description of work during regular boiler plant operation
Controlled shutdown procedure.
The "Operating instructions manual for boiler plant" should be used to describe the abovementioned procedures, i.e. the most common plant operation scenarios.

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Associated components: scrubbing systems

The problem!

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Example: Shower Cleaning System

On-load boiler water cleaning

Spray nozzle

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Associated components: sampling station

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Table of contents

Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance

Safety

You have probably gone through hundreds of site

inductions and will probably go through hundreds more
The induction is important as all sites are different andhave a wide range of hazards which will
change as the site develops
This site induction is specific to this site and provides you with information on the current hazards of
the site and tells you about the site rules

Signs on Site

Always comply with safety signage

Read the labels on containers before using any substances
Use any safety precautions required

Personal Protective Equipment

Look after your P.P.E. and always wear it when required

Table of contents

Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance

Table of contents

Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance

Most important aspects of maintenance

Input

B3.10 Chap.1.2 Maintenance work plan

B3.10 Chap.1.3 Lubrication schedule and products

Thank you very much

for your attention