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This document provides guidance on daily inspection practices for AFBC boilers. Key areas to check include water quality, the fuel feeding system, air heaters, the furnace, and ensuring proper functioning of valves, pumps, and instruments. Regular inspections of components like fans, feeders, dampers and checking parameters like temperatures and pressures are important to identify any issues and ensure safe boiler operation. Addressing issues like leaks, abnormal readings or component wear before they become problems is emphasized.
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power plant daily routine part for operation engineer.
This document provides guidance on daily inspection practices for AFBC boilers. Key areas to check include water quality, the fuel feeding system, air heaters, the furnace, and ensuring proper functioning of valves, pumps, and instruments. Regular inspections of components like fans, feeders, dampers and checking parameters like temperatures and pressures are important to identify any issues and ensure safe boiler operation. Addressing issues like leaks, abnormal readings or component wear before they become problems is emphasized.
This document provides guidance on daily inspection practices for AFBC boilers. Key areas to check include water quality, the fuel feeding system, air heaters, the furnace, and ensuring proper functioning of valves, pumps, and instruments. Regular inspections of components like fans, feeders, dampers and checking parameters like temperatures and pressures are important to identify any issues and ensure safe boiler operation. Addressing issues like leaks, abnormal readings or component wear before they become problems is emphasized.
Daily inspection aspects of Daily inspection aspects of AFBC boilers AFBC boilers Check for deviations in Feedwater & boiler water quality. Check the condensate return conductivity is normal. Check condensate pH does not deviate from 8 to 8.5. If the condensate pH is likely to be upset plan for a separate storage tank. Look for iron oxide contamination in condensate return. In case of deviation take remedial action. Check the DM water tank water pH is 8 to 8.5. WATER QUALITY WATER QUALITY Check saturated steam conductivity remains normal as before. Check raw water turbidity due to rain and modify the back washing cycle of filters. Check appropriate PO4 levels are maintained as per the boiler operating procedure. When there is a possibility of boiler stoppages, give blow down at all bottom most drains. Do not practice intermittent blow down as it upsets the chemical concentrations. WATER QUALITY WATER QUALITY Blow down water shall not be reddish / whitish. Reddish implies corroding boiler. Whitish water shows excess chemical dosage. Ensure minimum hydrazine levels are maintained as per water quality recommendations. Whenever feedwater pH becomes lower than 7, trip the boiler and safeguard the boiler from low hydrogen damage. WATER QUALITY WATER QUALITY Check the temperatures of FD fan Plummer blocks are normal. If abnormal, record in logbook for change during shut down. Keep the FD fan Plummer blocks clear from dust accumulations. Every shift the dust shall be cleared off the Plummer block. FD SYSTEM FD SYSTEM Check the fan inlet wire screen is free from blockage. The wire screen gets blocked due to rope, waste paper, etc. Check motor body temperature is normal. If overheating is observed notify electrical personnel. FD SYSTEM FD SYSTEM Check the power cylinder is free from dust accumulations. FD FAN POWER CYLINDER FD FAN POWER CYLINDER Check the air heater gas outlet temperature and air outlet temperatures are normal. Use these values to identify airheater tube failures. Check O2 values before & after APH on gas side. If there is increase in O2 after APH, the APH needs inspection. AIRHEATER AIRHEATER Check the Airbox is free from bed material. The compartment drain valve shall be operated with FD fan on. Check bed temperature thermowell cooling air is 0.1 kg/cm2. Check compartment air operated power cylinders are in normal working condition. AIRBOX AIRBOX Clean up the fuel feeders. Check the feeder motor body temperature is normal. Check the oil level is geared motor is normal. If any leakage is observed the seals shall be changed. Check the feeder bearing temperature is normal. Measure and record the feeder motor current. Compare the present reading with earlier reading. FUEL FEEDING SYSTEM FUEL FEEDING SYSTEM Check the chain & sprockets of the feeder are free from dust. Chain shall be lubricated with light oil. Check the VFDs of fuel feeders are not overheated. Check the VFD is free from dust. Dust shall be removed using hand blower. Check the fuel is of right size. FUEL FEEDING SYSTEM FUEL FEEDING SYSTEM Check bunker top inspection doors are in closed condition. Otherwise foreign material could go inside. Check the feeder rpms are normal. If there is large variation there should a reason such increase in moisture content / ash % / Lower GCV. Otherwise check for accumulations in feeder. FUEL FEEDING SYSTEM FUEL FEEDING SYSTEM Check the damper openings are not disturbed. Ensure the secondary air pressures are set as per load requirement. Check the manometers / draft gauges indicating the pressure settings are in proper working condition. SECONDARY AIR SYSTEM SECONDARY AIR SYSTEM Check the damper openings are not disturbed. Ensure the air pressure is normal. Check the PA fan header pressure is normal. Check the PA fan current is normal. PA fan current increases when the mixing nozzle is worn out. PRIMARY AIR SYSTEM Check the thermocouples are working. If not working, replace the thermocouples. Order for spare thermocouples. Check Airbox pressure and air flow are normal. Check the bed height is normal and is at least 300 mmWC to avoid static burning and thus clinker formation. Check compensating cables of thermocouples are free from possible damage, from hot bed material. FURNACE FURNACE Check the bed material is free from stones, clinker. Bed material as required for one charge shall be kept on stock. Always maintain a constant bed height. Before draining bed material charge the same quantity in the furnace. Drain the bed by opening the drain gate partly but never fully. This is to ensure that the bigger size particles are removed effectively. Never keep any compartment under slumped condition for long. It could lead to caustic gouging in bed coil. FURNACE FURNACE Check for abnormal bed temperatures in any compartment. It implies clinker has formed in the bed. It is advisable to drain the bed and replace to remove clinker pieces. If not, the boiler has to be shut to clean the bed. Running with clinkered bed leads to localized bed coil erosion. Cross check the O2 % with orsat apparatus once in a week. FURNACE FURNACE Check the glands of valves in the Deaerator & feed water storage tank are free from leakages. In the level station, check the signal connections of I/P transmitter & positioner are proper. In the pressure control station, check the signal connections of I/P transmitter & positioner are proper. Look for damage in insulation. Repair the damaged insulation. DEAERATOR DEAERATOR Check the local level gauge levels are tallying with the panel indication. Observe the steam plume & adjust if required. Use initial heating line to boost up the deaerator outlet water temperature in case it is too low. DEAERATOR DEAERATOR Check the current taken by the feed pump is normal. Check the lubrication to bearings is normal. Change over to stand by pump every month to ensure the next pump is operational. Do this on fixed dates. Check cooling water flow is adequate and temperature is normal. Operate the drain of the suction strainer of the feed pump. FEED WATER SYSTEM FEED WATER SYSTEM Check the continuous blow down is open. Operate the drain valves of bed coil headers whenever the beds are slumped. This is to remove the sludge / suspended matter that may settle down in the headers over a period of operation. The blow down shall be given when the boiler is still under pressure. Check the remote drum level indication is matching with local direct water level gauges. BOILER SYSTEM BOILER SYSTEM Check the water level gauge is working satisfactorily. Remote level indications can be verified only with direct water level gauge. If water is running down the gauge glass check for suspended impurities in boiler water. Use antifoaming chemicals to control. BOILER SYSTEM BOILER SYSTEM Make sure safety valve exhaust pipe is not blocked by foreign material such as dead birds. SAFETY VALVE SAFETY VALVE Check the spray control valve opening is not abnormal. SUPERHEATER SYSTEM SUPERHEATER SYSTEM Check the ESP field current is normal. Check all heaters are functioning. DUST COLLECTION SYSTEM DUST COLLECTION SYSTEM FUEL HANDLING SYSTEM FUEL HANDLING SYSTEM Check crusher hammer condition & replace on time schedule. Worn out hammers produce oversize particles and increase recycling load to screen. Check oversize chute is not overflowing and mixing up with right size fuel. Use coarser coal during monsoon times. Check conveyor belt condition periodically to avoid major shut down. Check and remove the screen blinding by ropes, stones etc. Replace the screen if found damaged. Check the ash is being discharged from all ash points. Check the LOI in the ash remains normal. Check the dense phase vessels are evacuating ash from hoppers above. Abnormal ash accumulations can damage the boiler. ASH HANDLING SYSTEM ASH HANDLING SYSTEM Flush condensing pots occasionally to clear the dirt trapped. Isolate the transmitters while flushing. INSTRUMENTS & CONTROL INSTRUMENTS & CONTROL If any control valve is hunting set right the PID values. Make sure the combustion control does not raise the feeder rpm abnormally. INSTRUMENTS & CONTROL INSTRUMENTS & CONTROL