Cover

English Units

SPM-1500 SUPERHEATED STEAM

BOILER
Operator Training Manual
Version 6.3

Information: 1-800-730-0760 Simtronics Corporation

+1-732-747-0322 P.O. Box 38
1-732-224-0009 Fax Little Silver, NJ 07739-0038
USA

Technical Support: 1-800-730-0760 [email protected]

+1-732-869-6651

Document Revision 6
SPM-1500 Manual Operator

Front Matter

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SPM-1500 SUPERHEATED STEAM BOILER

Contents

Topic See Page

Process Description 4
Process Description, continued 5
Process Flow and Instrumentation Diagrams 7
Instrumentation 8
Instrumentation, continued 9
Normal Operations 11
Normal Operations, continued 12
Pre-Startup 13
Startup 14
Shutdown 18
Emergency Operations 20

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Process Description

Process Flow Warning: Real fired heaters are very dangerous to operate. Explosions, fires and
damaged tubing along with severe injury or even death to personnel can occur
despite following approved operating procedures. Some heaters have minimal trip
logic while others are highly instrumented to protect the heater from damage. In
either case, experience has shown it is still possible to damage a heater from normal
operations. The simulator will not necessarily replicate these scenarios because they
highly depend on the type of heater and the particular fuel type, combustion air
supply system, controls and interlocks. Therefore, operations practiced on the
simulator should not be considered absolutely safe just because there were no
dangerous conditions experienced. The simulator is intended to familiarize the
operator with the basic principles of heat transfer by the combustion of fuel.
Additional safety training on fired heaters is highly recommended in order to master
the principles of safe operation.

Refer to the main process schematic below.

Economizer

Makeup boiler feedwater is preheated in a heat exchanger called an Economizer

before entering the steam drum. The Economizer uses hot combustion gases to
preheat the boiler feed water in order to minimize the amount of heat lost to the
stack.

Steam Drum

Preheated boiler feedwater from the Economizer enters the Steam Drum situated
atop the boiler’s structure. The Steam Drum is a long horizontal vessel and supplies
water to the Downcomers. The Steam Drum also serves to separate the water and
steam entering the vessel from the Risers. Arrays of specially engineered moisture
separators separate saturated steam from the boiler water. The separated steam is
saturated and is routed to the Superheater.

Downcomers

The Downcomers are a string of tubes that pass outside the firebox to supply water
to the Mud Drum by gravity. The water from the Downcomers collects in the Mud
Drum.

Mud Drum

The Mud Drum is a long horizontal vessel that sits at the base of the boiler firebox
and collects water and a small amount of steam from the Downcomers. The Mud
Drum supplies the Risers with water. The Mud Drum also serves to collect, as its
name implies, solids formed in the boiler system. These solids (sediment) will settle
at the bottom of the Mud Drum. Regular purging of water from the Mud Drum
(known as blowdown) helps keep these solids from accumulating. Blowdown also
helps prevent accumulation of undesirable dissolved chemicals that can increase
scaling and corrosion of the boiler’s tubes.

Continued on next page

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Process Description, continued

Risers

The Risers are also a string of tubes that pass through the main volume of the
firebox to produce steam from pickup of heat from hot combustion gases. The string
of tubes is commonly referred to as a waterwall.

The upward flow of fluid in the Risers is induced from a physical phenomenon
commonly referred to as the Thermosiphon Effect or the Bernoulli Effect. This effect
is that lower density fluids will rise in a gravitational field compared to higher density
fluids (e.g. a hot air balloon in cool air). As steam is produced from heat pickup in
the Risers, it lowers the net density of the fluid in the Risers. As the fluid rises higher
in the Risers, it picks up even more heat and more vaporization occurs. This
decreases the fluid’s density even more, resulting in a vigorous upward flow from
the Mud Drum back to the Steam Drum. Thus, the Thermosiphon Effect will cause
the Risers to pull water (and steam) from the Mud Drum which, in turn, receives
water by gravity from the Steam Drum via the Downcomers.

Superheater

Saturated steam is generated in the Risers of the boiler. Saturated steam readily
forms condensate in piping as the steam cools. Therefore, saturated steam needs to
be heated well above its dew point (superheating) to avoid excessive condensation
in the utility piping network the Boiler serves. Superheating also improves the
performance of equipment such as steam turbines.

Before going to the Steam Header, the saturated steam leaves the Steam Drum and
passes through the Superheater where it reenters the firebox of the boiler and is
superheated.

Attemperator

The final temperature of the superheated steam from the boiler is controlled by
injecting a small flow of boiler feedwater into the steam line. A special mixer known
as an Attemperator is used for injecting the boiler water. The boiler water normally
vaporizes completely. This system prevents excessively superheated steam from
reaching the Steam Header. High steam temperatures can damage piping and
equipment that the Steam Header serves.

Steam Header

In addition to the steam produced by the Boiler, two other boilers of similar design
and capacity as the main boiler provide superheated steam to the steam header.
These other boilers are not simulated in detail. Steam users then draw the
superheated steam from the Steam Header.

Continued on next page

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Process Description, continued

Fuel Firing

Fuel and air enter the firebox of the boiler where they are ignited and burned. The
superheater, the downcomers, and risers are heated both by radiant and convective
heat transfer. The hot combustion gases then preheat the boiler feedwater in the
economizer before passing out the stack. The rate of steam generated will depend
on the rate of fuel fired.

Product Three boilers provide approximately 250 KPPH (500 GPM of BFW) of superheated
Specifications steam each to the steam header. The pressure in the steam drum is 735 PSIG. The
saturated steam is then superheated to 761 DEG F. The pressure in the steam
header is maintained at 700 PSIG.

Each boiler requires approximately 12,675 PPH of fuel to accomplish this task. 3,815
MSCFH of air is required to maintain a 25 % excess of air in the boiler, whereby the
stack O2 is maintained at 4.25 VOL %. The stack gases leave the boiler at
approximately 300 DEG F.

Equipment The boiler consists of a firebox where the fuel and air mixture is burned, a radiant
Specifications heat transfer section, and convective heat transfer section, superheater,
downcomers, risers, steam drum, mud drum, economizer, and stack. The boiler
consumes a total of approximately 96 MW of energy. Each boiler operates at
approximately 60% to 75% of its maximum capacity.

In the event of a flame out, and during startup, there is burner logic that requires
that the furnace is purged with air for 60 seconds before the flame can be ignited.

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Process Flow and Instrumentation Diagrams

Superheated
Steam Boiler

Burner Logic

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Instrumentation

Basic Controls Refer to the main process schematic above.

Boiler feed water to the Steam Drum is controlled by flow controller FIC-101. Boiler
feedwater temperature is indicated by TI-101. Boiler feedwater temperature
entering the Steam Drum is indicated by TI-102. Blowdown from the Mud Drum is
controlled by flow controller FIC-103.

Steam Drum pressure is indicated by PI-101, and the superheated steam

temperature is indicated by TI-103 and tempered by TIC-104. Steam Drum level is
indicated by LIC-101. Steam rate is indicated by FI-102. The Boiler may be isolated
from the steam header by HIC-102. An atmospheric vent of superheated steam is
controlled by HIC-103.

Fuel rate to the Boiler is indicated by FI-301 and air to the Boiler is controlled by
FIC-201. The switch “BURNER” acts as both an ignitor and a flame indicator. Fuel
and air temperature are indicated by TI-301 and TI-201 respectively. Stack
temperature is indicated by TI-202 and stack O2 is indicated by AIC-201.

Steam Header pressure is controlled by PIC-501. The steam generated by the other
2 boilers is indicated by FI-401. The percentage of steam generated by the boilers
is indicated by HIC-301 and HIC-401. Steam demand is controlled by FIC-601.

Advanced Refer to the main process schematic above.

Controls
Boiler Master

The boiler master control consists of the steam header pressure controller (PIC-501)
and the firing bias controllers (HIC-301 and HIC-401). The output of the pressure
controller (PIC-501) is multiplied by the setpoint of the bias controllers (HIC-301 and
HIC-401). This signal is the output of the bias controllers (HIC-301 and HIC-401)
which in turn adjusts the fuel valves.

To get maximum firing from the boilers, the setpoints of the bias controllers (HIC-
301 and HIC-401) should be 100%. To change the ratio of firing amongst the
boilers the setpoints of the bias controllers should be changed. To increase the
amount of steam generated by the main boiler, the setpoint of the bias controller for
the other two boilers (HIC-401) should be decreased. To increase the amount of
steam generated by the other two boilers, the setpoint of the main boiler's bias
control (HIC-301) should be decreased. The bias controllers (HIC-301 and HIC-401)
indicate the percentage of total steam that each boiler generates.

Please keep in mind that when you are manipulating the bias controller for the other
two boilers (HIC-401), you are in fact changing the bias for those two boilers
simultaneously. Since all three boilers are of similar design, the ratio of steam
generated by each boiler should be approximately one-third each. However, keep in
mind that under loads vastly different from design, the setpoints of the bias
controllers (HIC-301 and HIC-401) may have to be trimmed to maintain a steam
generation rate of one-third each.

Continued on next page

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Instrumentation, continued

Air Control

The air rate to the boiler is controlled by FIC-201. This controller gets its setpoint
from the fuel rate indicator process variable (FI-301). This process variable is
multiplied by a ratio parameter to maintain a 25% excess of air. This ratio is valid
only for a particular fuel. When the stack oxygen controller is in automatic mode, it
adjusts the ratio of FIC-201 to obtain the desired oxygen content in case the fuel
characteristics change. Note that output and setpoint of AIC-201 are initialized in
manual mode so that the controller does not bump the ratio of FIC-201 when AIC-
201 is placed in automatic mode.

Three-Element boiler Feedwater Control

When steam vapor is generated in the risers of the boiler, some of the volume in the
tubes is displaced by steam bubbles. These steam bubbles have a smaller density
than the boiler feed water. The density of these steam bubbles is also a function of
temperature and pressure. As more and more of these steam bubbles are
generated, the level indicator does not give a true indication of the inventory of
boiler feed water in the system. As steam demand is increased, this effect becomes
increasingly more pronounced, and the level in the steam drum rises rather than
decreases, as one would expect.

This phenomenon is known as "Shrink and Swell". Under these circumstances, a

simple level controller would cut back rather than increase the amount of boiler feed
water to the steam drum. Consequently, a more sophisticated control scheme is
required. This control scheme is known as a Three-Element Boiler Feed Water
Control. Three inputs are used to control the drum level. The three elements are
drum level (LIC-101), feedwater flow (FIC-101), and steam flow (FI-102). When
operating, the steam flow signal acts as a feedforward signal. This permits the
feedwater control valve (FIC-101) to respond to steam flow changes without having
to wait for a change in drum level.

Continued on next page

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Instrumentation, continued

Logic System Refer to the burner logic schematic above.

The Logic system trips off the burners if any of the following conditions occur:
 FIC-201 air flow rate is zero
 FI-301 fuel flow rate is zero
 LIC-101 steam drum level is below its low alarm limit

Similarly, the Logic system allows the burners to start only if all of the following
conditions are met:
 FIC-201 air flow rate is greater than zero
 FIC-201 air purging exceeds 60 seconds
 FI-301 fuel flow rate is greater than zero
 LIC-101 steam drum level exceeds its low alarm limit

Note that fuel cannot be introduced until the air purge is completed. The air purge
timer starts when the fuel flow FI-301 is zero and the air rate FIC-201 is greater
than zero.

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Normal Operations

Normal Design The following table is a list of the normal design conditions (initial condition 1) for
Conditions the SPM-1500 Superheated Steam Boiler Simulation as provided by Simtronics.

Design Output
Tag ID Description Eng Units
Value Percent
AI-301 FUEL GAS GRAVITY 0.556 SP GR
AIC-201 STACK OXYGEN 4.25 WT%O2
BURNER IGNITOR SWITCH FLAME N/A
FI-102 STEAM TO HEADER 249 KPPH
FI-301 FUEL TO BURNER 12,675 PPH
FI-401 STEAM TO HEADER 500 KPPH
FIC-101 BFW FLOW 498 GPM 49.8 %
FIC-103 BLOWDOWN FLOW 0 GPM 0.0 %
FIC-201 AIR TO BURNER 3,815 MSCFH 43.8 %
FIC-601 STEAM DEMAND 750 KPPH 50.0 %
HIC-102 STM FLOW TO HEADR 50.0 % VLV 50.0 %
HIC-103 STEAM VENT VALVE 0.0 % VLV 0.0 %
HIC-301 MAIN BOILER 33.3 %BIAS 50.0 %
HIC-401 OTHER BOILERS 66.7 %BIAS 50.0 %
LI-101 MUD DRUM LEVEL 100.0 % LVL
LIC-101 STEAM DRUM LEVEL 50.0 % LVL 50.0 %
MEGAWATT MAIN BOILER 96.3 MWATT
PI-101 STM DRUM PRESSURE 735 PSIG
PIC-501 HEADER PRESSURE 700 PSIG 50.0 %
TI-101 BFW SUPPLY 220.0 DEG F
TI-102 BFW TO DRUM 400.0 DEG F
TI-103 SUPERHEATED STEAM 761 DEG F
TI-201 AMBIENT AIR TEMP 68.0 DEG F
TI-202 STACK TEMP 300 DEG F
TI-301 FUEL SUPPLY 68.0 DEG F
TIC-104 STEAM ATEMPRATR 750 DEG F 22.4%

Normal Below are the major process variables to be polled.

Production
Monitoring The other process variables should be periodically polled to ensure normal process
operation.

Tag ID Description
AIC-201 STACK O2
BURNER FLAME INDICATOR
FI-102 STEAM FLOW
FI-301 FUEL FLOW
FI-401 STEAM FLOW
FIC-101 BFW FLOW
FIC-201 AIR FLOW
FIC-601 STEAM DEMAND
LIC-101 STEAM DRUM LEVEL
PIC-501 STEAM HEADER PRESSURE

Continued on next page

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Normal Operations, continued

Adjusting To smoothly increase or decrease overall steam production, the steam users' flow
Production controller (FIC-601) setpoint should be gradually adjusted.

To smoothly change steam header pressure, the steam header pressure controller
(PIC-501) setpoint should be gradually adjusted.

To smoothly change the biasing of the three boilers, the setpoints of the bias
controllers (HIC-301 and HIC-401) should be gradually adjusted.

Note that there is a significant lag time between a change in fuel output and a
change in steam production. Therefore, regulation of the Steam Header pressure
(PIC-501) cannot be tightly controlled to its setpoint by adjusting the fuel rate (FI-
301). If large changes in steam demand are made quickly, it may be necessary to
manually adjust the fuel firing by placing PIC-501 and changing its output faster
than the controller would in automatic mode. If manual adjustments to the firing
rate are made, monitor the boiler conditions closely, especially the stack oxygen
content. Do not make fuel rate changes - especially increases - faster than the air-
to-fuel ratio controller FIC-201 will permit so as to keep the oxygen content in a safe
range.

Responding to An instrument in alarm indicates that there is an upset condition in the process. A
Alarms swift response to an alarm can prevent a dangerous condition from occurring.

Responding directly to a key process variable that is in alarm may not always be the
best corrective action. Understanding and observing the relationships of all process
variables can help you troubleshoot the problem and take proper corrective action to
return the process to design conditions.

For example, in the Superheated Steam Boiler, a stack O2 alarm might not
necessarily indicate a problem with the air system, but rather a change in the fuel.

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Pre-Startup

Pre-Startup Pre-startup procedures must be performed before any startup may begin.
Procedure

Normal Pre- All Simtronics process simulations assume that the following normal procedures have
Startup already been completed. However, trainees should be made aware of these
Procedure procedures and any other procedures particular to your process plant.

SPM-1500 Superheated Steam Boiler: Normal Pre-Startup Procedure

 Notify all personnel involved with the startup:
 Shift Supervisors
 Process Engineers
 Control Engineers
 Outside Operators
 Instrument Technicians
 Flush, clean, and purge all lines
 Flush, clean, and purge all equipment
 Pressure test all lines
 Pressure test all equipment
 Check, calibrate, and zero all instruments
 Commission all pumps
 Commission all heat exchangers
 Commission any other process equipment as required

Cold Start Pre- The cold start initial condition provided by Simtronics ensures that the following
Startup procedures have already been completed. However, trainees should be required to
Procedure perform these procedures as a matter of course. You may change the cold start
initial condition provided by Simtronics, to ensure that trainees do in fact perform
these procedures.

SPM-1500 Superheated Steam Boiler: Cold Start Pre-Startup Procedure

 Check position of all block valves (open or closed)
 Check position of all control valves (open or closed)
 Check status of all controllers (manual, automatic, or cascade)
 Check status of all switches (on or off)
 Check status of all pumps (run or stop)
 Check status of any other equipment or instrumentation as required

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Startup

Normal The following is a startup procedure recommended by Simtronics. You may modify
Startup this procedure to more closely reflect your particular process plant startup
Procedure procedures. Refer to Exercise 2 for the expert solution to the startup procedure.
The entire startup should take approximately 2 hours.

Warning: Real fired heaters are very dangerous to operate. Explosions, fires and
damaged tubing along with severe injury or even death to personnel can occur
despite following approved operating procedures. Some heaters have minimal trip
logic while others are highly instrumented to protect the heater from damage. In
either case, experience has shown it is still possible to damage a heater from normal
operations. The simulator will not necessarily replicate these scenarios because they
highly depend on the type of heater and the particular fuel type, combustion air
supply system, controls and interlocks. Therefore, operations practiced on the
simulator should not be considered absolutely safe just because there were no
dangerous conditions experienced. The simulator is intended to familiarize the
operator with the basic principles of heat transfer by the combustion of fuel.
Additional safety training on fired heaters is highly recommended in order to master
the principles of safe operation.

Overview

The following basic steps are used to start up the Superheated Steam Boiler:

 Fill unit with boiler feedwater

 Purge firebox
 Start fuel firing
 Vent steam to atmosphere and pressure up boiler
 Increase firing rate
 Start steam to header and establish full rate operation with one boiler
 Bring other boilers into service

Continued on next page

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Pre-Startup, continued

Check Step Procedure

1 Bring boiler feedwater into the unit by placing FIC-101 into
automatic with a setpoint of 300 GPM. Confirm that the level in
the Mud Drum increases (visible on the process schematic)
followed by filling of the Steam Drum as shown on LIC-101.
2 Start purging the firebox by placing air flow controller FIC-201
into automatic with a setpoint of 2,000 MSCFH. Verify on the
logic schematic that the purge timer is counting up. Also verify
that the steam header pressure controller PIC-501 is in manual
with 0 % output. This ensures that the fuel gas valve is closed.
3 Make sure the steam valve to the Steam Header HIC-102 is
closed.
4 Fully open the steam vent to atmosphere using HIC-103. When
steam is first generated any air or nitrogen in the system will be
vented.
5 Set the output of boiler master controller PIC-501 to 5%. Make
sure the setpoints of HIC-301 and HIC-401 are 0 %. These
setpoints determine how much the output of PIC-501 opens the
fuel gas valves for the main boiler and the two other
supplemental boilers, respectively.
6 Place boiler feedwater flow controller FIC-101 into cascade.
7 Place LIC-101 into automatic with a setpoint of 50 %.
8 As the Steam Drum level approaches 50 %, ensure boiler water
keeps flowing into the economizer coil during startup by adjusting
the output of the blowdown flow controller FIC-103 to 100 %.
9 Verify the purging of the firebox with air is complete. Once the
level in the Steam Drum is above the low alarm setting, start fuel
firing by admitting a small flow of fuel to the burners. The master
controller’s output (PIC-501) should already be 5% per Step 5.
Admit fuel to the firebox by adjusting the setpoint of main boiler
firing hand controller HIC-301 to 100 %. This will open the fuel
gas valve to 5% x 100% / 100% = 5%. Once a flow of fuel gas
is indicated on FI-301 immediately ignite the fuel by setting the
position of the “BURNER” switch from SMOKE to FLAME. Verify
that the switch stays in the FLAME position.

If this light-off fails, set HIC-301’s setpoint to 0 % to stop fuel

flow, purge the firebox, re-admit fuel gas and ignite it. If ignition
fails again, make sure the air flow is not too high. High air flow
will tend to inhibit initial ignition.
10 Monitor outlet temperatures from the Economizer and
Superheater coils for any sign of excessively high temperatures.
Since there is virtually no flow in the Superheater coil, increase
combustion air flow to 4,000 MSCFH to keep coil temperatures
from getting too high as the boiler begins to warm up. Note the
Superheater outlet temperature TI-103 will indicate ambient until
the water is warmed up to its boiling point and steam is pushed
through the Superheater tubes.
11 After 10 minutes of warmup at minimum fuel firing, increase the
output of master controller PIC-501 to 10%. Verify that steam
production is beginning.

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Check Step Procedure

12 After 10 minutes of venting steam, start closing vent valve HIC-
103 to 80% open. Verify the pressure of the Steam Drum as
indicated on PI-101 is increasing.
13 Manually increase firing by adjusting the output of PIC-501 to
15%.
14 Place Attemperator controller TIC-104 into automatic mode with
a setpoint of 750 DEG F.
15 Now that steam generation has started, completely stop
blowdown flow by adjusting the output of FIC-103 to 0%.
16 Continue to gradually increase the Steam Drum pressure by
closing vent HIC-103 to 70 %.
17 Manually increase firing by adjusting the output of PIC-501 to
20%.
18 Place air flow controller FIC-201 into cascade with ratio to fuel
gas flow FI-301. Verify the stack oxygen content AIC-301 does
not fall below 3 VOL %. If it does, place FIC-201 into automatic
and adjust the setpoint manually as fuel flow changes.
19 Continue to gradually increase the Steam Drum pressure by
closing vent HIC-103 to 60 %.
20 After a few minutes, manually increase firing by adjusting the
output of PIC-501 to 25%.
21 Continue to gradually increase the Steam Drum pressure by
closing vent HIC-103 to 50 %.
22 After a few minutes, manually increase firing by adjusting the
output of PIC-501 to 30%.
23 Once the Superheater outlet temperature TI-103 reaches around
450 DEG F, start admitting steam to the Steam Header by
opening HIC-102 to 50%.
24 Fully close the vent to atmosphere by adjusting the output of
HIC-103 to 0 %.
25 As the Steam Header pressure PIC-501 approaches the Steam
Drum pressure PI-101, start taking steam to users by placing
FIC-601 into automatic with a setpoint roughly equal to the
current steam generation rate as indicated on FI-102. This will
minimize the disruption to the pressures in the system.
26 Place the fuel firing into automatic control by placing PIC-501 into
automatic with a setpoint roughly equal to the current Steam
Header pressure to avoid bumping the fuel rate. Gradually
increase the setpoint of PIC-501 to 200 PSIG over 10 minutes.
27 Increase the steam rate to the users by adjusting the setpoint of
FIC-601 to 150 KPPH.
28 Gradually increase the setpoint of PIC-501 to 400 PSIG over 10
minutes.
29 Increase the steam rate to the users by adjusting the setpoint of
FIC-601 to 200 KPPH.
30 After a few minutes, Gradually increase the setpoint of PIC-501
to 600 PSIG over 10 minutes.
31 Increase the steam rate to the users by adjusting the setpoint of
FIC-601 to 250 KPPH. This is the design capacity of one
operating boiler.
32 After a few minutes, increase the setpoint of PIC-501 to its
design pressure of 700 PSIG. Allow the conditions to stabilize and
verify operation. Correct any problems as needed.

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Check Step Procedure

33 Place stack oxygen controller AIC-201 into automatic with a
setpoint of 4.25 VOL %. AIC-201 will now adjust the ratio of air
flow controller FIC-201 to maintain the oxygen level.

Note: the output of AIC-201 is automatically initialized in manual

mode to track the actual ratio of air to fuel and the setpoint
tracks the measurement so that the switch to automatic mode of
operation is bumpless.
34 The other boilers can be brought into service by gradually
increasing the setpoint of HIC-104. Adjustment of the firing of
the other boilers should be done gradually and in conjunction
with an increase in flow to steam users.

Start bringing steam in from the other boilers by increasing the

setpoint of HIC-104 to 10%.
35 Increase the flow of steam to users by gradually adjusting the
setpoint of FIC-601 to 350 KPPH.
36 Over the next 15 minutes, gradually and simultaneously increase
the steam flow to users to 750 KPPH while increasing the
setpoint of HIC-104 to 100%.
37 Verify all pressures, temperatures and flows stabilize at design
conditions. Adjust the operation as necessary.
38 STARTUP COMPLETE

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Shutdown

Normal The following is a shutdown procedure recommended by Simtronics. You may

Shutdown modify this procedure to more closely reflect your particular process plant shutdown
Procedure procedures. Refer to Exercise 1 for the expert solution to the normal shutdown
procedure. The entire shutdown should take approximately 90 minutes.

Overview

The following basic steps are used to perform a normal shutdown of the
Superheated Steam Boiler:

 Reduce steam demand and fuel firing to take the other boilers out of service
 Reduce steam demand and fuel firing on the main boiler
 Put firing into manual control and switch lineup from steam header to
atmospheric vent
 Stop firing, cool and drain unit

Check Step Procedure

1 Take the other boilers out of service over 20 minutes by
gradually reducing the setpoint of steam demand FIC-601 to 350
KPPH. At the same time, reduce the firing of the other two boilers
by gradually reducing the setpoint of HIC-401 to 0%.

This will leave the main boiler in operation at design capacity.

2 Gradually reduce the steam demand to 150 KPPH70 KKG/H over
10 minutes. At the same time, gradually reduce firing by
adjusting the setpoint of HIC-301 to 20%.
3 Once the conditions are reasonably stable, start venting steam to
atmosphere by opening HIC-103 to 10%. This will help keep the
Steam Header pressure from going too high as the user steam
flow is decreased further.
4 Place the air flow controller FIC-201 into automatic mode with a
setpoint of 3,000 MSCFH. This will put an excess amount of air
into the firebox so that combustion temperatures stay on the
cooler side. Cooler temperatures will keep the Superheater from
overheating as firing rates are further reduced.
5 Place stack oxygen controller AIC-201 into manual.
6 Reduce the setpoint of user steam flow controller FIC-601 to 100
KPPH. Also reduce the setpoint of HIC-301 to 10%. This will bring
the boiler to minimum firing conditions.
7 5 minutes later, place PIC-501 into manual mode with an output
of 20%.
8 Over a period of 5 minutes, gradually open the vent to
atmosphere HIC-103 to 100% while gradually closing the steam
valve to the Steam Header HIC-102 to 0%.
9 Depressure the Steam Header by placing FIC-601 into manual
with an output of 20%.
10 Place the Attemperator controller TIC-104 into manual with an
output of 0%.
11 Stop firing of the main boiler by adjusting the output of PIC-501
to 0%. Air will still be flowing to the firebox in order to cool it
down.

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SPM-1500 Manual Operator

Check Step Procedure

12 Stop boiler feedwater by placing FIC-101 into manual with an
output of 0%.
13 Place Steam Drum level controller LIC-101 into manual.
14 Drain water from the system by placing blowdown flow controller
FIC-103 into manual with an output of 100%. Drain the Steam
Drum and the Mud Drum.
15 When the Mud Drum is empty adjust the output of FIC-103 to
0%.
16 Once the Steam Header is depressured, adjust the output of
users’ steam flow controller FIC-601 to 0%.
17 Once the unit is cooled and depressured, stop air to the firebox
by placing FIC-201 into manual with an output of 0%.
18 Verify the unit is completely cool and depressured.
19 SHUTDOWN COMPLETE

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SPM-1500 Manual Operator

Emergency Operations

Emergency All emergencies should be handled quickly. The particular steps taken in an
Operation emergency are specific to the problem at hand. As always, your trainees should
Procedure follow the emergency procedures particular to your process plant. If an emergency
cannot be handled quickly, then an emergency shutdown should be performed.

Emergency The following is an emergency shutdown procedure recommended by Simtronics.

Shutdown You may modify this procedure to more closely reflect your particular process plant
Procedure emergency shutdown procedures. The entire shutdown should take approximately
20 minutes.

Overview

The main steps to follow in an emergency shutdown of the Superheated Steam

Boiler are:

 Immediately stop firing in the main boiler

 Place the air flow controller into automatic with a minimum flow to purge the
firebox
 Close the valve to the Steam Header
 Verify the unit conditions are safe

Check Step Procedure

1 Stop fuel firing in the main boiler by adjusting the setpoint of
HIC-301 to 0%.
2 Immediately place combustion air flow controller FIC-201 into
automatic with a setpoint of 1,000 MSCFH to purge the firebox.
3 Close off steam to the Steam Header by placing HIC-102 into
manual with an output of 0%.
4 Stop the Attemperator by placing TIC-104 into manual with an
output of 0%.
5 Manually vent steam to avoid lifting the safety valve on the
Steam Drum by adjusting the output of HIC-103 to 10%. Steam
will be generated for a few minutes or so because of the residual
heat in the firebox and tubing.
6 After a couple minutes, stop venting steam and close HIC-103
output to 5%. Verify the pressure of the Steam Drum remains
safe.
7 After a few more minutes, close HIC-103 completely by adjusting
its output to 0% once boiling from the residual heat has stopped.
8 Stop the air flow by placing FIC-201 into manual with an output
of 0%. This will keep the boiler warm in case it will be quickly
restarted.
9 Verify conditions of the main boiler are safe. Also, verify that the
other two boilers have enough capacity to satisfy the total steam
demand. If they do not, reduce steam demand accordingly by
adjustment of the setpoint of FIC-601.
10 EMERGENCY SHUTDOWN COMPLETE

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