OPERATION & MAINTENANCE MANUAL

for

KHARTOUM NORTH POWER STATION-

PHASE III (2×100MW) PROJECT

BOILER PART
Volume 02

Volume Name: Maintenance of oil fired Boiler

Document No. KNPS-OM0205

Version 0

Page 0 of 27
Page 1 of 27
 National Electricity Corporation Volume 02
(NEC), Sudan Oil Fired Boiler

Table of content

1 INSPECTION OF BOILER.......................................................................................................................................1

1.1 INSPECTION ROUTE.............................................................................................................................................1

1.2 CONTENTS OF INSPECTION ITEMS......................................................................................................................1
1.3 INSPECTION FREQUENCY.....................................................................................................................................1

2 PERIODIC OPERATION OF BOILER...................................................................................................................1

2.1 BOILER BLOWDOWN............................................................................................................................................1

3 SAFEGUARD OF BOILER SHUTDOWN.............................................................................................................3

3.1 PRINCIPLES OF BOILER MAINTENANCE..............................................................................................................3

3.2 MAINTENANCE METHODS....................................................................................................................................3

4 LIST OF SPARE PARTS..........................................................................................................................................4

5 SPECIAL TOOLS LIST.............................................................................................................................................4

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 National Electricity Corporation Volume 02
(NEC), Sudan Oil Fired Boiler

1 INSPECTION OF BOILER
1.1 Inspection route
1.2 Contents of inspection items
1.3 Inspection frequency

2 PERIODIC OPERATION OF BOILER

2.1 Boiler blowdown
2.1.1 Periodic blowdown
1) Periodic blowndown of boiler should be carried out according to the chemical
requirements.
2) Generally, do not carry out these three items at the same time: periodic
blowdown,boiler emergency discharge water, and deaerator emergency
discharge water.
3) Boiler periodic blowdown should be carried out under stable operation working
condition, and not coincide with soot blowing and etc.
4) At the beginning of blowdown, water impact should be avoided. Once there is
water crushing, close the blowdown valve. After the water impact disappears,
open the blowdown valve.
5) While adopting manual blowdown, every blowdown point of downcomer and
water wall lower header
6) If there are abnormal conditions, accidents or malfunctions of blowdown
system, stop blowdown at once.
2.1.2 Continuous blowdown
1) Confirm the condition of putting continuous blowdown flash tank into operation
2) During normal operation, the amount of continuous blowdown should be
adjusted by chemical personnel in light of chemical requirements.
2.2 Putting boiler sleeve water level meter into operation and flushing it
2.2.1 Putting the water level meter into operation
For the sake of the safety of boiler and operators, we hope that operators operate
strictly according to the instruction and its guidance so as to avoid any accidents
and extend the using time of water level meter.
1) Heat the water level meter
A Close all valves
B Slightly open blowdown valve
C Slightly open steam valve second stop 1/4 week to let steam enter into
water level meter and then expel out from blowdown valve. Heat the water
level meter for almost 40 minutes when the ambient temperature is 20 ℃.
2) Lead hot water and steam into water level meter and confirm the water level.
A Close blowdown valve
B Slightly open water valve 1/4 round, and lead hot water into water level

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meter continuously
C Slightly open steam valve second stop 1/4 round, and lead steam into
water level meter.
Attention: do not open the water valve and steam valve too wide and too
quick, otherwise safety ball will act and it will block the steam and water
passage: if the safety ball has acted yet, firstly close all valves and then
open them slowly.
D Open all steam valves and water valves
E Carefully watch the water level: boiler water begins to enter into the water
level meter and make the water level rise gradually until the water level
does not change. However, the water level should have slight wave to show
that water and steam pipelines are smooth and operates normally.
F Turn back 1/4 round of steam valve primary stop, water valve primary stop,
heating valve and water-reducing valve in order to avoid valve rod and
backseat stick together.
G Check if no crack in glass and isinglass, no leakage in pressure cover and
valve is normal
2.2.2 Purpose of flushing water level meter
All water level meter must indicate correctly. Local water level meter, electric
connecting point water level meter and water level transformer should indicate the
same data. Check it on site during every duty. The water level high and low
instruments of boiler sleeve and alarm should be reliable and verified periodically.
Under normal condition, the liquid level of local water level meter should indicate
within the range of boiler sleeve normal water level ±50mm with slight wave. The
water level is clear and visible with well illumination.
To avoid blurring or liquid surface stagnation of local water level meter which will
affect the safe operation of boiler, water level meter should be flushed periodically.
At least flush the local water level meter every ten days.
2.2.3 Process of flushing local water level meter
Slightly open water discharge valve. If the liquid surface can flow it is normal,
otherwise it is the false water level.
When local water level meter does not indicate clearly, wash it immediately. If the
indication data of the two local water level meter are different, judge which one has
malfunction in time. Close steam side valve or water side valve, and open water
discharge valve.
2.2.4 Noticeable items on operation and flushing of water level meter
A The job of putting water level meter into operation should be .
B Be cautious of putting water level meter into operation and flushing and then
out of operation in hot state. Do not face up rightly in front of water level meter.
Once having found any leakage, parallel off the water level meter immediately.
C Avoid the impact of external cold wind and water on water level meter during the
operation.

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D I f there are serious leakage or blowing up with water level meter during
operation, carry on paralleling off and wear protective mask and glove under
others’ supervision.

3 SAFEGUARD OF BOILER SHUTDOWN

3.1 Principles of boiler maintenance
After shutdown of boiler, carefully handle with anti-corrosion no matter when it is in
standby state or maintenance state.
1) Operation equipments as short-term standby, pressure vessels need no
maintenance, and ready for startup at any time.
2) During the overhaul, minor repair or over ten days standing-by,
We generally adopt “with pressure discharge water, waste heat drying” to
maintain.
3) If the operation equipments turn into standby for over one month, maintain
them with hydrazine and ammonium solution. Like the pressure vessels which
is tight, maintain it by means of nitrogen filling.
4) Cold boiler cannot turn into dry standby. If there is no other choice, must ignite
and raise the pressure to 30% of rated pressure and then decrease the
pressure, maintain it by means of waste heat drying method.
3.2 Maintenance methods
3.2.1 Heating and pressurizing method
1) After boiler shutdown, strictly close every drainage valve, sampling valve and
steam discharging valve of boiler. Keep the boiler pressure over0.3MPa, close
the inlet and outlet damper of forced draft fan, reduce the thermal loss of
furnace and seal boiler to keep boiler pressure at 0.3MPa.
2) During the maintenance of boiler, assay the main steam by sampling every
duty, analyze oxygen content of boiler water every day, analyze iron content
every day (dissolved oxygen≯≯14μg/l, iron content≯≯30μg/l).
3） When the water quality id not qualified, dealing with it at once. While the
dissolved oxygen is not qualified, open air stop and ignite until it is qualified,
then close air stop and stop heating.
4) Discharge water of boiler bottom when iron content in boiler water is not
qualified; prevent air from entering system during water exchanging.
5) Keep water level of boiler sleeve within the normal water level+100mm all the
time.
3.2.2 Waste heat drying method
1) After boiler shutdown, reduce the pressure by means of expelling steam and
control the pressure reducing speed.

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2) When pressure decreases to 0.5MPa, open all blowdown valve, drainage

valve, feed water pipes and water discharge stop to release water. When the
pressure decreases to 0.2MPa-0.5MPa, open all the upper air stops. Release
water quickly to avoid steam condensate in super heater. While releasing
water, strictly supervise every point wall temperature of boiler sleeve. The
temperature difference between any two points cannot be more than 40 ℃. Dry
out the heating surface by means of boiler waste heat. During drying out, take
sampling every one hour from steam, water sampling stop, and air stop to
measure the temperature. When moisture is less than 70% or equals to the
ambient relative moisture, close all water discharge stops and air expelling
stops. If the boiler temperature reduces to 105 ℃ and air temperature has not
achieved the standards, ignite boiler again and dry it out.
3.2.3 Diamine and Ammonia Solution Method
1) Diamine consistence is 150 － 200mg/l, use ammonia to adjust the PH value
above 10.
2) Discharge all boiler water before chemical dosing. Isolate the other boiler
instruments guiding pipes except air stop, dosing stop and water level meter
connecting pipes.
3) Add diamine and ammonia into feed water system by ammonia-adding pump to
achieve the standards mentioned above. At the same time, check every water
discharge stop is strict or not.
4) Take sampling and assay diamine and PH value every three days. While it is
lower than the standard, make up diamine and ammonia solution for inside of
boiler by high pressure dosing pump.
5) Relief some protective liquid before equipments startup, keep the water quality
standard of operation condition.
3.2.4 Combined Application of Nitrogen Filling and Diamine
1) Dosing with diamine and ammonia solution methods, keep boiler sleeve at
normal water level.
2) Keep water side diamine at 150－200mg/l an PH value above 10.
3) Connect nitrogen tank with air side well. Check every air stops and blowdown
stops. Open nitrogen tank outlet stop in all closed state and open boiler
nitrogen-filling valve to fill nitrogen into the boiler.
4) Keep nitrogen pressure 0.3-0.5MPa. Nitrogen solution consistence is above
95%. Assay boiler water and ammonia every week and control them in eligible
range.

4 LIST OF SPARE PARTS

5 SPECIAL TOOLS LIST

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