BOILER

Definitions:

General : Boiler is a closed vessel with which with the application of heat, water is
boiled and steam is generated at the atmospheric pressure.

IBR: “Boiler” means any closed vessel exceeding 22.75 litres(five gallons) in capacity
which is used expressly for generating steam under pressure and includes any mounting
or other fitting attached to such vessel, which is wholly or partly under pressure when
steam is shut off.

Types:

Types of fuel used for the operation of boiler are,

1. Solid Fuel.

2. Liquid Fuel.

3. Gaseous Fuel.

Solid Fuel :

o Coal.
o Coke.
o Lignite.
o Wood.
o Agricultural Waste like Bagasse, Rice husk, Coffee husk, Coconut waste etc.
o Biomass( Industrial Waste)
o Pet coke.

Liquid Fuel :

o Petroleum Products.
o Black Liquor.
Gaseous Fuel :

o Natural Gas.
o Blast Furnace Gas.
o Coke Oven Gas.

Combustion

In brief combustion is chemical reaction with the evaluation of heat and light.

Basic combustible elements in any fuels are carbon, Hydrogen and sulphur.
Properties and heat values of different fuels mainly depends on the variation of above
constituents.
Reaction taking place and heat liberated by burning of these basic elements are
below:
Carbon - 8100 k.cal/kg
Hydrogen - 34400 k.cal/kg
Sulphur - 2240 k.cal/kg

Carbon + Oxygen - Carbon Dioxide.

C + O2 - CO2

Hydrogen + Oxygen - Water vapour.

2H2 + O2 - 2H2O

Sulphur + Oxygen - Sulphur Dioxide.

S + O2 - SO2

Complete combustion

When all the constituents of fuel oxidized to their highest state of oxidation is
called complete combustion.

For complete combustion of fuel following are the weight of oxygen:

1. Carbon 1 Kg + 2.66 Kg oxygen = 3.66 kg Carbon dioxide.

2. Hydrogen 1 Kg + 8.0 Kg oxygen = 9.00 kg Water vapour
3. Sulphur 1 Kg + 1.0 Kg oxygen = 2.00 kg Sulphur Dioxide.

We know that atmosphere is a mixture of oxygen, nitrogen and a very small

amount of inert gases. The proportions by weight and volume are:
 Volume Weight
Oxygen 20.9% 23.2%
Nitrogen 79.1% 76.8%

So, suppose that a particular type of fuel contains carbon as the only combustible. So, for
complete combustion of carbon, it will combine with all of the 21% of O2 which the air
contains to form 21% by volume of CO2. 79% of nitrogen will remain unchanged.

Thus if there is no excess air, the analysis of the flue gas by burning this particular flue
will be as follows:

Oxygen 0%
Carbon Dioxide 21%
Nitrogen 79%
Total 100%

If there is 100% excess air, unburnt oxygen equals that burnt to carbon dioxide
and the gas analysis is:

Oxygen 10.5%
Carbon Dioxide 10.5%
Nitrogen 79%
Total 100%

If there is 50% excess air the unburnt oxygen is half that burnt to carbon dioxide,
and the gas analysis is :

Oxygen 7%
Carbon Dioxide 14%
Nitrogen 79%
Total 100%

The elements of a fuel :

The fuel contains Carbon, Hydrogen, Oxygen, Sulphur, Moisture, Ash. In the
following table, the percentage of CO2 & O2 for different fuels with the corresponding
percentage of excess air has been given:

Kind of fuel Ingredients Percent excess air

0 20 40 60 80 100

Anthracite CO2 19.5 16 13.8 12 10.7 9.6

O2
Bituminous CO2 18.6 15.5 13.2 11.5 10.1 9.2
O2 0 3.3 6 8 9.5 10.6

Fuel oil CO2 15.5 12.6 10.6 9.3 8.2 7.4

O2 0 3.7 6.4 8.1 9.6 10.8

Natural gas CO2 12.2 10 8.5 7.5 6.5 5.7

O2 0 4 6.5 8.5 9.9 10.9

A typical flue gas analysis for bituminous coal firing under various conditions is
given below:

Combustion Conditions CO2% O2% CO% %N

Poor 9.0 10.5 0.5 80

Average 12 7.5 0.1 80.4
Good 15 4.0 0.1 80.8

Primary elements of combustion

There are three “T”s in basic combustion.

1. Temperature: is one of the first criteria in the combustion. For any fuel, it is to
be heated to its ignition temperature to start self combustion. Then it start
generating its own heat, so the temperature is most important in combustion of
fuel.

2. Turbulence: is second factor in combustion. For combustion of solid fuel without

turbulence it is very difficult. Normally solid fuel contains ash. Combustion takes
place on the surface of any fuel. After burning a layer of ash deposits on the
surface. For further combustion to continue, the ash layer is to be dislodged
exposing fresh surface for combustion. This can be achieved by creating
turbulence in the combustor.

3. Time: is the last but most important factor. If sufficient time is not allowed for
total combustion, unburnt fuel will be carried out along with flue gas as well as
through ash.
FIRING PROCEDURE :

1. Hand firing
2. Fire thickness : a uniform thickness of 150 to 175mm cube gives the best
result.
3. Mechanical firing
4. Mechanical stoker of W.T.Boilers particle size varies from 6mm to 20mm.
5. Fluidized bed combustion firing : Particle size varies up to 6mm to 10mm.

PRINCIPLES OF FLUIDISATION AND FLUIDISED BED COMBUSTION

COMPARISON OF DIFFERENT FIRING TECHNIQUES

METHOD PARTICLE SECTIONAL EXCESS FLUE VOLUMETRIC

SIZE HEAT AIR % GAS HEAT
LOADING VELOCITY RELEASE 106
106 KCAL/M2H M/S KCAL/M2H

OIL - 2-4 10-15 25-30 0.25-0.88

COAL

PF FIRED 0.01-0.1 1-4 20-25 12-14 0.1-0.25

 STOKER 20-50 1.2-1.9 30-50 12-14 0.22-0.27

FLUIDISED 1.5-3.5 1-3 10-20 12-14 1.5-3.5

BED

Pre Starting Checkups

Refractory Dry Out
Alkali /Acid Boil Out
Passivation
Cold preservation
Safety valve setting
Steam Blowing

Procedure for Alkali Boil Out:

The purpose of alkali boil out is to remove oil, grease, mill scale etc resulting out of
fabrication and erection procedures. Such deposits in the boiler tube walls severely restrict
heat flow through the tube walls causing failures due to overheating.

Prerequisites:
In order to commence alkali boil out of the steam generator, following prerequisites
/ inputs have to be available:
a) Mechanical completion of boiler including auxiliaries and piping
b) Compressed air and uninterrupted power supply for instruments.
c) Adequate illumination in and around the boiler house.
d) Pre – commissioning trials of fans.
e) Electrical power for motorized valves, gauge glass illuminator etc.
f) Demineralised water through boiler feed water pumps.
g) Chemicals required viz Hydrous triosodium phosphate, anhydrous disodium
phosphate and wetting agent.
h) Full readiness for lighting up the boiler and its thermal expansion.
Procedure:
Inspection and Mechanical Cleaning:
a) Make visual check of the entire boiler unit and remove all debris.
b) Remove chevron filters, baffle plates etc from drum internal to ensure proper
flushing of all tubes.
c) After visual checks, close all access to the boiler unit internals
Controls, interlocks and other requirements:
Following minimum controls and requirements are necessary for boiler operation:
a) Drum gauge glass.
b) Boiler pressure gauge.
c) Safety / Relief valves with hydrostatic plugs removed.
d) CBD and all drain valves in good working order.
e) Water level control and associated alarms.
f) Cooling water / air piping.
g) Furnace pressure gauge.
h) Safety interlocks – During alkali boil out, transmitters connected to steam piping
and steam drum will be kept isolated to avoid any damages to transmitters due to
alkalis.

BOILING OUT
Preparation:
Close boiler stop valve, remove NRV internals. In order to evacuate the IBD tank,
leave the tank drain valve open, close valves.
Fill the boiler to normal water level and drain the water completely through
bottom drain by operating them one by one and keeping the header outlet valve fully
open. With this procedure the boiler gets rinsed.
Fill the unit such that the water is visible in second port from bottom of direct
gauge glass (Fill the water through drum feed connections). DM water should be used for
boil out operation. Add some hydrazine to have ½ ppm of hydrazine traces in boiler
water.
Chemicals
Following indicates quantity / Boil out :
1) Hydrous Trisodium Phosphate - 124 Kg.
(Na3PO4.12H2O)
2) Anhydrous Disodium Phosphate - 27 Kg.
(Na2HPO4)
3) Wetting agent (Detergent / Surfactant) - 7 Kg.

Chemicals are to be carried in dry form up to the drum level platform. The
chemicals are to be carried in dry form up to the drum level plat form. The chemicals are
to be dissolved in Dm water externally in a container near the manhole in batches. The
concentrated solution so prepared are to be poured into the drum through the manholes.
When the entire quantity of chemicals has been so dissolved and poured into the drum,
the manholes are to be closed.
Economisers:
The economiser elements are flushed with DM water.
Firing:
Follow these instructions before lighting up the unit.
a) Remove all debris from furnace, air and gas passages.
b) Ensure that blow down and drain connections are terminated to safe location.
c) Ensure that all the dampers are in good working order and “open” “close”
positions are marked correctly.
d) Gauge glasses are in good working order.
e) Ensure that the feed water pumps operate satisfactorily.
f) After ensuring the above, light p the unit and raise the boiler pressure. Ensure
that the maximum temperature of the gases entering the superheater is controlled.
g) Ensure that the feed water pumps operate satisfactorily.
h) After ensuring the above, light up the unit and raise boiler pressure. Ensure that
the maximum temperature of the gases entering the superheater is controlled.
i) Ensure that the normal water level is maintained in the drum through out the boil
out operation.
Duration:
Raise the boiler pressure as per start up procedure. Carry out the boil out
operation by maintaining this pressure for a period of 24 hours. The pressure is to be
maintained by controlling the fuel firing and modulation the start up vent.
Blow down:
After attaining approx. 5 Kg/cm2 drum pressure give blow down to each panel
header drains for 10 sec duration. Ensure water level is restored, allow drum pressure to
raise up to a value which is 50% of operating value or 40 Kg/cm2 whichever is lower.
Ensure that water level in drum is replenished each time. It may be noted here that panel
header drains are not opened once pressure has exceeded 5 kg/cm2.
At the end of 24 hours completion of alkali boil out camphor test is carried out.
Camphor test:
Take a cup of sample water. Drop some camphor on water. Camphor will move of
oil is present in water. If oil is present, the boil out process should be continued further
and camphor test required at every half an hour till desired results are achieved.
Procedures to be followed after chemical boil out:
a) Box up the boiler and allow the unit to cool by natural radiation. When the drum
pressure drops to 5 Kg/cm2, operate the header drains as explained above. When
the drum pressure drops to 3 kg/cm2 open the air vents.
b) When the drum pressure drops to atmospheric, drain the water by opening all
valves on drain headers.
c) Open drum manhole and inspect the drum thoroughly.
d) Flush the drum internals by applying DM water through a hose connected to vent
on boiler feed pump discharge header.
e) Fill fresh DM water through the superheater by connecting a flexible hoses to the
SH start up vent on one end and the BFP discharge header on the other end. DM
water will thus backflow through the SH assemblies and fall into the drum. All
drains on the bottom headers shall be kept open to allow the water from SH and
drum to flow out of the system.
f) Cut all bottom header cleaning stub caps to clean and flush all sediments and
foreign matter in the headers. Check the header internals using hand lamps and
 mirror arrangement. Also charge DM water through attemperator nozzle.
Continue flushing operation until PH of water leaving the boiler is the same as
that of the water entering the boiler. Take 3 samples at 10 minutes interval to
confirm the end points.
g) Reweld cleaning stubcaps. Follow standard procedure for the welding.
h) Reassemble drum internal removed, before starting the boil-out.
i) Close the drum manholes.
j) Take hydrostatic pressure test of the unit up to working pressure, flush water
through impulse piping, connected to drum/ superheater header.

Superheater Elements:
In order to remove any foreign material trapped in S/H Elements, S/H headers,
attemperators as well as main steam pipe steam blowing operation will be carried out
after alkali boil out, and subsequent inspection, boxing up and hydraulic test.

Blowing of the Steam: Steam inlet piping to Turbine to be checked and sufficient
supportings to be provided up to the inlet flange of emergency stop valve. Steam
blowing to be carried at minimum 50% of the working pressure and with superheated
steam minimum quantity flow should be ensured to the extent of 30% of the quantity
flow required for full load of the turbine.

First 8 to 10 blow to be given from 50% pressure to 25% working pressure to be given
without target plate. After this blows, aluminium target plate to be used for assessment
cleanliness of the steam pipeline. For final assessment to ensure cleanliness, the general
practice 3 points / spots to the extent of 1 mm impejement / sq.cm is acceptable as per
International Standard. After successfully blowing operation to the satisfaction of the
Turbine manufacturer, all the external support to the pipe line to be removed and any
deviation, warping, twisting, deformation on the supporting and piping to be rechecked
and confirmed to be in the position as it was before steam blowing operation. Any
deviation on the flange connecting points inlet turbine or Extraction line to be recorded, if
any.