M/s.

GLAXO SMITHKLINE
CE T HA R V ESSEL S L I MI T ED CONSUMER HEALTH CARE LTD.
1 X 20 TPH FBC BOILER (BI074)

TABLE OF CONTENTS

SL. NO. DESCRIPTION PAGE NO.

I. GENERAL

CONTRACT DATA SHEET 003

GENERAL DESCRIPTION OF BOILER 004

TECHNICAL WRITE-UP FOR BOILER COMPONENTS 008

PRINCIPLE OF FLUIDISED BED COMBUSTION 029

WATER QUALITY REQUIREMENT 033

METHOD OF WATER ANALYSIS 045

BOILER OPERATING INSTRUCTIONS 066

PROCEDURE FOR HYDROSTATIC TESTING 107

PROCEDURE FOR SLOW FIRING 110

PROCEDURE FOR ALKALI BOILOUT 113

PROCEDURE FOR STEAM BLOWING 117

OPERATION ON LOW LOADS 121

TROUBLE SHOOTING CHART 123

DO’S AND DONT’S 131

INSPECTION AND MAINTENANCE SCHEDULE 134

PRESERVATION OF BOILER 139

CHEMICAL REQUIREMENT 143

II. SCHEDULE

VALVES 146

LUBRICATION 163
GENERAL
 CONTRACT DATA SHEET

CUSTOMER M/S. GLAXO SMITHKLINE CONSUMER HEALTH CARE LIMITED.

LOCATION NABHA, PUNJAB.

BOILER TYPE BI-DRUM WATER TUBE BOILER (FBC)

CAPACITY 20 TPH

PRESSURE 10.8 Ksc (g)

TEMPERATURE SATURATED

FUEL FIRING INDIAN COAL

FEEDER TYPE POCKET FEEDER

TYPE OF FIRING FLUIDISED BED COMBUSTION

FURNACE BED SIZE 3900 X 2400 mm

EXPANDED BED HEIGHT 682 mm

HEAT INPUT (Kcal/hr) 13454665

HEATING SURFACE AREA (M²)

BANK TUBE ASSY. 225.00

HEATING WATER WALL ASSY. 151.88

SURFACE BED COIL ASSY. 62.71

INTEGRAL ECONOMISER ASSY. 177.00

TOTAL 616.65

SIZE SET RELIEVING

LOCATION QTY. (NB) / PRESSURE CAPACITY END CONN.

(Nos) ORIFICE (Kg/cm²) OF VALVE

(Kg/hr)

STEAM 2 80 / 100 I) 11.75 i) 12,497 FLANGED

DRUM ‘L’ ii) 12.00 ii) 12,741 ANSI B16.5

SAFETY 300# / 150#

VALVE DEAERATOR 1 50 / 80 3.00 1778 FLANGED

‘J’ ANSI B16.5

300# / 150#
GENERAL DESCRIPTION OF BOILER
 GENERAL DESCRIPTION OF BOILER

The "CETHAR FLUIDIX" is a fluidised bed boiler with the following features.

a) Compartmentalised combustion chamber.

b) Under bed fuel feeding system.

c) Bi-drum water tube type.

The boiler is designed for INDIAN COAL as main fuel with capacity of 20 TPH

at MCR. The outlet steam parameters are 10.8 Ksc(g) pressure and

SATURATED steam temperature.

CETHAR has designed, manufactured and supplied a BI-Drum water tube

boiler with natural circulation and with bottom support arrangement. The boiler

consisting of steam drum, mud drum, water wall panels, bank tubes, bed coils,

Economiser, Air heater, Inter connecting pipings, air and gas ductings, fuel

feeding system, supporting structure with platforms and staircases etc.

AIR SYSTEM:

This system starts with FD fan to supply the required combustion air and

impart energy for fluidisation. FD fan is a centrifugal type, direct coupled fan.

Ambient air from fan outlet is heated in air heater and heated air is distributed

evenly to combustion chamber through compartmentalised air box. A part of

combustion air is tapped from air heater outlet and further pressurised by a PA

fan for pneumatic fuel feeding. PA fan is also of centrifugal type, direct

coupled fan. Air flow is measured using aerofoil meter.

COMBUSTION CHAMBER:

The distributor plate is the heart of FBC system. It is made up of carbon steel

base plate with air nozzles to distribute the fluidising air from air box uniformly

over the entire bed. Bed coils are immersed in the bed to maintain the bed

temperature of 850-900°C by absorbing the heat through them. Sufficient

free board volume is available above the bed to ensure complete

combustion of fuel.

FUEL AND ASH HANDLING SYSTEM:

The fuel from bunker is fed pneumatically into the bed by pocket feeder and

mixing nozzles located below the bunker. The speed of fuel flow can be

adjusted from the control panel.

The ash generated is collected at bed, bank, Economiser, air heater and

ESP. The ash collected at the bed zone is cooled through bed ash coolers

sieved through vibratory screen and disposed manually. The ash collected at

bank, Economiser/Airheater and Electrostatic Precipitator (ESP) shall

transported pneumatically to the ash silo with Dense Phase Ash Handling

system.

FLUE GAS SYSTEM:

The hot flue gas generated from the combustion chamber is cooled by,

passing through waterwall, bank tubes, Economiser, air heater and ESP.

Balance draft is maintained by FD and ID fans. Flue gas is passed through a

high efficiency ESP before lifting it to the atmosphere through the chimney.
WATER AND STEAM CIRCUIT:

The feed water at 105°C is fed to the boiler feed pump where it is pressurised

to the required pressure. The feed water from feed pump is fed to the

economizer. The purpose of economizer is to preheat the boiler feed water

before it enters the steam drum and to recover some heat from the flue gas

having the boiler. From economizer the feed water is fed to steam drum. From

steam drum the water passes through the bank tubes to mud drum. While

passing through the bank tubes the water is heated up by the flue gas passing

over the tubes. The hot water enters into the bed coils, through downcomers

and further heated up. The steam water mixture then rises through the water

wall panel tubes and enters into the steam drum through riser tubes.
TECHNICAL WRITE-UP FOR
BOILER COMPONENTS
TECHNICAL WRITE UP FOR THE BOILER COMPONENTS

FLUIDISED BED COMBUSTION .

FLUDISED BED

When air or gas is passed through an inert material such as sand supported on a
fine mesh or grid, the air initially will seek a path of least resistance and pass
upward through the sand. With further increase in velocity, the air bubbles through
the bed and the particles attain a state of high turbulence. Under such conditions,
the bed assumes the appearance of a fluid and exhibits the properties associated
with a fluid and hence the name 'Fluidised Bed'

MECHANISM OF FLUDISED BED COMBUSTION

If the inert material , in a fluidised state, is heated to the ignition temperature of the
fuel and the fuel is injected continuously in to the bed, the fuel will burn rapidly and
the bed attains a uniform temperature due to effective mixing. This in short is
fluidised bed combustion.

While it is essential that temperature of bed should be atleast equal to ignition

temperature of fuel and it should never to be allowed to approach ash fusion
temperature to avoid the melting of ash. This is achieved by extracting heat from
the bed through heat transfer tubes immersed in the bed.

If the velocity is too low, fluidisation will not occur and if the gas velocity becomes
to high, the particles will be entrained in the gas stream and lost. Hence to sustain
stable operation of the bed, it must be ensured that gas velocity is maintained
between minimum fluidisation velocity and particle entrainment velocity.

Almost, all Atmospheric Bubbling Fluidised Bed Combustion Boilers (AFBC) use the
bed evaporator (Bed coil) tubes as the mode of extracting heat from the bed to
maintain the bed temperature.

The Boiler components are categorised as Pressure and Non – Pressure Parts as
mentioned below.
1.0 BOILER PRESSURE PARTS

The complete system of boiler pressure parts covers

- Steam drum / Mud drum.

- Bank tubes
- Water wall system.
- Bed tube sections.
- Economiser.

Together with all required headers, integral piping, interconnecting

piping and supports.

The complete system of pressure parts tubing, piping and headers will
be of ERW or seamless construction as applicable.

1.1 STEAM DRUM / MUD DRUM

The steam drum / mud drum shall be of fusion welded construction.

Liberally sized with high efficiency of internals. The drums will be
provided with 2 nos. manhole doors, to open inwards. Steam drum is
provided with screen box separators with screen type dryers as
drum internals.

Suitable nozzles with flanges of adequate thickness will be provided in

the drum to mount the valves and fittings. Provision for blow down will
be given in the mud drum. Liberally sized down comers and risers are
provided.

The thickness on the drum is arrived based on the requirements

as specified under IBR 1950 with latest amendments. The drums are
provided with ellipsoidal dished ends.
1.2 BANK TUBES

The bank tubes are of ERW. Tubes connecting to the drums shall enter
readily on both ends of the bank tubes are expanded into the steam
and mud drums. The bank tubes are designed with multi pass
arrangement and the average flue gas velocity is kept at optimum,
considering the life of bank tubes.

1.3 FURNACE - WATER WALL SYSTEM

The furnace is of natural circulation, balanced draft design

suitable for firing the fuels specified. The complete furnace section,
including the fluid bed and water wall section are fabricated with
welded wall type panel construction. Necessary supporting /
suspension systems are provided for the complete system - for free
expansion of components when unit is in operation.

1.4 BED COIL SECTION

The bed is provided with three nos. of compartments with individual

air control system for reliable and continuous operation of Fluidised
bed steam generator at continuous MCR load.

Water circulation in the bed tubes is kept optimum to ensure longer tube
life. Access door are provided at suitable elevation on any sides of the
bed on the walls, for easy access to the bed section, for any inspection
and maintenance.
1.5 ECONOMISER

The purpose of economiser is to preheat the boiler feed water before it

enters the steam drum and to recover some heat from the flue gas
leaving the boiler.

The inlet and outlet headers are positioned horizontally. It is fed with
feed water by a pipe from the feed water control station. There are 15
parallel paths of Economiser coils connecting the inlet header to the
outlet header. The economiser coils are horizontally arranged and are
split into two banks with a gap of 950 mm in between them. The
economiser coils are suspended from the economiser casing top
frame through lugs and pins. There is a link connecting the economiser
outlet header to the drum.

The feed water flow is upward through the economiser, that is, in
counterflow to the hot flue gases. Most efficient heat transfer is hereby
accomplished.

MAINTENANCE

Before starting up the boiler, the economiser should be inspected

externally and if necessary cleaned. Especially if the installation is
new, accumulation of erection materials is not unusual. Large debris
should be removed manually followed by washing the economiser with
water.

It should be ensured that after water washing, the water droplets

from economiser surface are removed by running the FD and ID fans
which otherwise will lead to corrosion. The external inspection of the
economiser can be made whenever an opportunity is provided or the
draft loss through economiser is more than usual, or the heat pick up in
the economiser is less than normal.
2.0 NON - PRESSURE PARTS.

2.1 BUNKER AND FUEL FEEDING SYSTEM

Boiler is equipped with fluid bed combustor consisting of complete

system of fuel transportation from the bunker to the fluidized bed.

Bunker is sized with proper valley angle for the better flowability of the
fuel. The bunker bottom portion is divided into six no. of hoppers
corresponding to the number of compartment in the Air box. The outlet
of each bunker is connected with pocket feeders. From Pocket feeder
to the mixing nozzle the fuel will be taken by dividing chutes, and it will
be sent into the furnace using high pressure air from Primary air fan.
Feeder units will be so spaced and arranged that, individual units are
well accessible for inspection, repair and maintenance as required.

2.2 FUEL DISTRIBUTING SYSTEM

The Primary fuels from the feeding points will be pneumatically

transported through IS 1239 fuel feed pipes to the fluidised bed.
Forced air flow to each of the bed compartments can independently
controlled by suitable means. A Pneumatically operated damper is
provided in the air ducting to each bed section. There are 12 nos. of
feeding points and are located in the bed for uniform fuel distribution.

Fluidised Bed Proper: The Fluidised Bed system will be of the proven
design capable of continuous reliable operation and firing the fuel
specified with wide turndown range. The nozzle design will permit
effective fluidisation at lower loads with shutting down of some
compartments. Fluidising nozzles will have suitably sized stem portion
extending from the bed plate to the furnace side. Besides the design
and arrangement of fuel feeding, air supply to the bed, their controls,
will ensure achieving complete combustion efficiency, avoiding
problems of slagging and clinker formation.
 The design and arrangement of the bed sections are such that it will
be possible to isolate any bed section from fuel feed side, and
primary air feed side, as and when required for operational
requirements.

The bed air nozzles are of MS + SS material and shall be fixed on to

the bed plate by threading from the bottom side.

3.0 TUBULAR AIR HEATERS

Air heater of multitubular recuperative type is provided at the

downstream of bank tubes with gas flow through the tubes and air
flow over the tubes.

The air heater tubes are of mild steel construction. The air heater is
complete with all casing, supporting structures, ducting systems etc.

4.0 FANS - DRAUGHT SYSTEM

The boiler is equipped with each one no. of 100% MCR FD fan, ID fan
and PA fan.

The fans supplied are complete with coupling, base plates etc. All
control vanes/dampers are provided with complete and connecting
mechanism etc., All the Fan impellers are dynamically balanced.
Forced draft fan are provided with grease lubrication.

5.0 DUCTING SYSTEM

All ducts are of Mild steel suitably stiffened and reinforced on the
outside and designed to withstand the pressures encountered.
 The ducting system is complete with all required expansion joints,
mating flanges, dampers, supports, access doors, platforms,
insulation etc. All ducts are of welded construction.

6.0 REFRACTORY, INSULATION, CLADDING

All other piping, air ducts, flue ducts, etc., are provided with insulating
system of adequate thickness.

7.0 BOILER STRUCTURES

The boiler is provided with all required base frame, steel work of
sufficient height, with required foundation bolts, etc. The steel
supporting structure for boiler, bank tubes and airheater are from the
firing floor, which is RCC.

The required structural columns, frame work for the ducting and
piping, equipment, stair cases up to boiler drum level, are provided
with stairs and walkways. The steam drum ends are provided with
independent local platform.

In addition, pipe supports, duct supports, etc., are provided for the
complete system.

8.0 AIR SYSTEM

The air from the Forced draught fan will pass through Airheater to
Air box. The combustion air will assist the combustion as well as the
fluidisation. In the proposed under bed feeding system a small
quantity of air which is tapped from the combustion air, will be
boosted by a primary air fan and will be used to transport the fuel
pneumatically to the furnace.
9.0 BED MATERIAL FEEDING SYSTEM.

One number of Bed Material Bunker (Mild Steel) having suitable storage

volume with supports and feeding chute is provided for feeding the Bed

material into the Bed. Bunker outlet chute will have the Pocket Feeder.

10.0 ELECTROSTATIC PRECPITATOR

Electrostatic Precipitator is the most effective method for removal of

solid particles from the flue gases. The Electrostatic Precipitator

basically consists of a large steel chamber and the electrodes. High

voltage DC supply is applied between the emitting electrode and the

collecting electrode. The emitting electrode is connected to the

negative terminal. The collecting electrode is connected to the

positive terminal and earthed. When flue gases pass through the

chamber, because of the high DC voltage applied across the emitting

and the collecting electrodes, the solid particles get ionised and are

attracted to the collecting electrode Ash drops down in the hoppers,

which is then removed and disposed off.

The dust concentration in the flue gas is reduced to the requirement by

use of the electrostatic precipitator placed after the air heater. The

outlet duct of the electrostatic precipitator connected to the inlets of

the ID fans. ID fans are provided with power cylinder operated

regulation dampers and power cylinder operated discharge dampers.

 EQUIPMENTS

1.0 DEAERATOR CUM STORAGE TANK

2.0 DOSING SYSTEM

LP DOSING

3.0 BLOW DOWN TANK

4.0 START UP OIL FIRING SYSTEM

5.0 BED ASH DRAIN SYSTEM

1.0 DEAERATOR CUM STORAGE TANK

INTRODUCTION

The deaerator is placed before boiler feed pump in the feed water cycle to

remove the dissolved corrosive gases from the feed water, which goes to the

boiler. The oxygen is reduced Carbon Di-Oxide is reduced to untraceable

limits, in the condensate leaving deaerator.

It is a direct intimate contact type heat exchanger and is located before

suction side of boiler feed pump in thermal cycle. The steam is drawn to

heat the condensate that, is broken into fine droplets for effective heat and

mass transfer of non-condensable gases.

The deaerator consists of vertical deaerating chamber called header and

horizontal feed storage tank.

The condensate and make up water enters the deaerating chamber and is

sprayed by spray valves. The sprayed water falls through tray stack for heat

and mass transfer. The condensate is divided into fine droplets and comes

in contact with the steam resulting in release of non condensate gases which

are carried by the steam moving upwards.

The condensate after leaving deaerating header enters into feed storage

tank from where it goes out to boiler feed pumps. Steam enters the feed

storage tank and then goes into deaerating header where it gets condensed,

some steam along with non condensate gases goes of the equipment.

PRINCIPLE

When the liquid reaches its saturation temperature corresponding to

pressure or in short. When it starts boiling the partial pressure of gases tend

to become zero. Once the partial pressure gags disappears the gas

molecules are free to be liberated and effective mass transfer of gas

molecules takes place by scrubbing the liquid containing the dissolved gases

continuously with a counter-current flow of steam more rapid removal and

lower gas concentrations result when the liquid is sprayed in thin films and

droplets and then violently scrubbed by the incoming steam.

Corrosion in boiler cycles is caused by the presence of non-condensable

gases such as oxygen and Carbon Di-Oxide and by a low PH value. The
PH of water can be raised chemically, but the gases in the cycle must be

mechanically removed. Today’s employment of higher pressure cycles has

resulted in an even greater need to protect expensive components in the

feed cycle from corrosion. Indeed, a boiler would deteriorate rapidly by the

ravages of corrosion, where deaeration of the feed water is incomplete. It is

in the lower pressure same that the system experiences maximum air

leakage, providing a continuous ingress of oxygen and Carbon Di-Oxide.

The condenser and Shell side of low pressure feed water heaters are

typically under vacuum at full and partial load operations. These and other

sources such as expansion joints, welds, piping connections, gauges

glasses, valve steam packing pump seals and supplemented tanks for

continuous make-up contribute to the problem. Moreover, this region of the

cycle is also burdened by additional carbon di-oxide that results from

alkalinity breakdown in the make up water which is a very substantial flow in

industrial units.

DEAERATOR STORAGE TANK

The shell of storage tank is fabricated from boiler quality steel plates. The

ends are closed with dished head ends. Various connections like condensate

outlet, steam inlet, make up water inlet, drain outlet, pressure relief valve,

temperature gauges, level gauges are provided.

DEFECTS AND REMEDIES IN DEAERATORS

DEFECTS REASON REMEDY

The oxygen content in Temperature of water Reduce the supply of low
deaerator increase more supplied into deaerator is temperature water.
than 10 micrograms / liter too low (even if water is
and free CO2 appears in oxygen free)
the deaerated water. Deaerator is over loaded. Reduce deaerator load
Heating steam superheat Increase steam super
insufficient. heat if possible.
The insufficient exhaust Increase the exhaust by
from deaerator. opening the valve more.
clogged deaerator. Clean perforations in
deaerator trays.
Deaerator trays bent or Fix deaerator trays.
broken.
Hydraulic hammering in Thermal over loading of Check the quantity and
the deaerator column. the deaerator due to low temperature of
temp. of steams or huge condensate entering the
incoming condensate column. Check the
supply working of LP heaters.
Repair in the deaerator. Stop the block and repair
the deaerator.
Hydraulic hammering in Condensation of the Do not allow the degree
the water and steam steam in the steam line of heating of water in the
supply lines. due to the low quantity column to be less than
of heating steam coming 5°C.
to the deaerators.
Pressure reduction in Reduction of the heating Change the supply of
deaerators. steam pressure steam to the external
source.
 DEFECTS REASON REMEDY
Pressure reduction in Improper working of the
deaerators. pressure regulators.
a. Jamming of the valve in a. Try to move the valve.
the closed position.
b. Repairs in the automatic b. Change to remote or
circuits. hand regulation or
pressure.

Improper connections of Check the scheme of

heating steam lines in the heating steam pipeline.
scheme.
Huge supply of cold water to Increase in cold water
the column. supply must be done
slowly.
Increase of pressure The pressure regulators are Change to remove or
in deaerators and not functioning properly (The hand control or change to
the safety valve start valves are jammed in open feeding steam from
blowing. position. The automatic circuits external source.
are not functioning unregulated
opening of the valves)
Reduction of the The level regulator is not The level regulator must be
level in deaerator functioning properly (the changed either to remove
storage tank. valves jamming or improper or hand regulation. If the
automatic circuits) valve jammed, start
supplying the make up
water direct from the
condenser reserve in the
deaerator.
Reduction of topping of make The supply from reserve
up water into the block cycle. condensate tank. Inform the
water treatment plant about
insufficient supply of make
up water.
Huge leakage of steam and Check full closing of drains
water from the cycle. of accumulation tanks.
 DEFECTS REASON REMEDY

Increase in the Improper working of the Change either to remote

deaerator storage tank level regulator (valves or hand control

level. jammed in open position

improper working of

automatics. Huge

unregulated flow from the

regulating valves.

Water throw out from Thermal over loading of the Reduce the deaerator

the deaerator. deaerator. loading by increasing the

temperature and reduce

the quantity of entering

condensate into deaerator.

Too much opening of the Reduce the exhaust to the

valve in the deaerator normal valve.

exhaust.
2.0 DOSING SYSTEM

The main purpose of dosing system is to clean the water by adding

chemicals. Normally dosing can be divided into two types following as

2.1 LP DOSING

In LP dosing system, Hydrazine (N2H4) is dosed to feed water at the inlet

of feed pumps (or) inlet of feed water tank to scavenge the last traces of

dissolved oxygen in feed water.

To ensure proper dosing, a residual concentration of Hydrazine (0.02

ppm) is usually maintained in the boiler water. The correct treatment

level may vary depending on operating conditions like water

characteristics and boiler pressure.

DESCRIPTION

DM water or condensate is mixed with concentrated Hydrazine using

motorised agitator in mixing tank and stored at storage tank

prepared chemical is dosed to feed water using reciprocating pump.

The flow of reciprocating pump can be varied by adjusting the stroke of

the plunger through a scaled knob. At the pump discharge a

pressure gauge is provided to read the pump discharge pressure. One

no. of pressure relieving valve is provided to safeguard the pump against

high pressure. Necessary isolation valves are provided to isolate the

pump.
 PROCEDURE

When the boiler is under normal operation, chemical is dosed at a

particular rate and feed water sample is analysed for residual hydrazine.

Based on analysis, increase or decrease the dosing rate to get the required

residual hydrazine in the feed water. Once the required residual

hydrazine is obtained note the stroke and chemical concentration (Ratio

of water / concentrated N2H4) which should not be varied unless there is

any change in the feed water quality.

HANDLING AND STORAGE:

1. Avoid contact with skin and eyes.

2. Solution if prepared, should be made in a covered tank. Since the

solution can absorb oxygen from the atmosphere, not more than

one day requirement should be prepared at a time.

3.0. BLOW DOWN TANK

One no. Blow Down tank will be provided for the continuous and

intermittent blow down. The boiler Continuous Blow down line will be

connected to common Continuous Blow Down tank and drains from other

systems will be connected to the Common Intermittent Blow Down Tank.

The Intermittent Blow Down tank outlet and continuous blow down tank

outlet will be left to the drain system. Required supports, drain valves

and necessary piping, etc., have been provided for the tanks. Continuous

blow down tank is a IBR approved pressure part and is used for flash steam

recovery. The recovered flash steam will be used in deaerator.

4.0 START UP OIL FIRING SYSTEM

START UP PROCEDURE:

As this boiler is having start up oil burner system separately to make the start

up very convenient.

The total Qty. of charcoal requirement will be approximately 12 - 15% of the

qty. of bed material in the start up compartment. As the charcoal addition is

done during fluidising condition, the fluidisation will get affected due to the

additional weight of charcoal. The drag force required to fluidise the new

bed material & charcoal mixture will be more. Hence increasing of air flow

by observing the bed condition is a must during charcoal charging. Keeping

unnecessarily more air (or) more PA header pressure may throw the

charcoal to the adjacent compartment which will lead to localised

clinker formation in the compartment border due to static burning. During this

cold fluidisation study and charcoal charging, the burner combustion air

should be kept in open condition to avoid chocking of burner lines.

Start the oil pump and allow the oil to circulate through the return oil line

for some time, throttle the oil return line value to increase the oil pressure

Now start the burner one by one as per following procedure.

1. Keep minimum oil and minimum atomising air open.

2. Ignite the burner by swab through the ignition hole.

3. Increase the oil flow and atomising air flow.

4. Observe the flame length and colour. It should be yellowish violet.

This is to be achieved by proper adjustment of atomising and combustion

air.

In case if flame cut off occurs during start up, immediately that particular

burner oil to be stopped and burner light up to be done as per procedure

explained above.

All the charcoal which are in fluidised state will get ignited by burner flame. Keep

this condition for 10 minutes to allow all the charcoal to get fire. Now

decrease the fluidising air flow little bit to avoid rapid burning of charcoal. Keep

this condition for 2 to 5 minutes. Slowly all the bed material will get red hot during

this period closely watching of bed condition is a must to avoid quenching of fire

in bed and delaying of temp. pick up due to excess air. Now all the bed

temperature will increase fastly , once it reaches 600°C set MCR air

flow, for I compartment stop oil pump and start fuel feeder.

Set optimum feeding and ensure coal catches fire in the start up

compartment. Now the bed temperature to be maintained between 850 -

900° C by regulating feeders RPM.

5.0 BED ASH DRAIN SYSTEM

This boiler is having three compartments and each compartment is

having one no. of ash drain point. . The ash drain pipe has been
connected to the bed ash cooler, Where the bed ash of 900°C will be
cooled to 175°C. Each ash drain pipe will be connected with separate
ash coolers and each ash cooler will be having separate ash discharge
points and these ash discharge points will be connected to Screw
Conveyor.

The bed ash cooler is same as like of FBC system. The atmospheric air
has been tapped at the outlet of F.D. fan and fed through the air
nozzles provided in the ash cooler, where the air and bed ash will be
mixed and get cooled. The cooled ash has to be collected through the
Screw Conveyor and it can be conveyed to another Screw Conveyor and
then to the Recycling Bucket Elevator through a Vibratory Screen. The
hot air from the ash coolers have been connected through ducts to
Air heater flue gas outlet. In case of ash cooler maintenance / failure,
the ash can be removed manually through the bottom of ash drain pipe
gate arrangement.

Power cylinder operated shutoff dampers are provided at the air inlet of
ash coolers. These dampers can be operated from the PLC panel
either manually or automatically. To accomplish the above, individual
pressure switches are provided in each air box compartments so that
whenever the air box pressure is getting increased due to the buildup
of bed ash materials, an alarm will be generated to indicate the
operator to perform the task manually. The same can be operated
automatically considering the programs done in the PLC according to
the logics provided.
The sequence of cooling of bed ash should be such that ash in

alternate compartment is cooled repeatedly. The operation sequence is

decided in such a way that only one compartment can be operated at a

time.

Air inlet in the bed ash coolers is controlled by the power cylinders

whose operating time is decided and set in the PLC. The compartment

damper (ie. ash cooler air inlet damper) will be opened only for a pre-

set time.

When the time is elapsed the adjacent compartments damper will be

opened. The compartment not in operation shall not be considered in

the sequence of operation.

The timing sequence (ie. one cooler to other) can be 5 minutes

(maximum) and it should be decided during commissioning of the cooler.

Please note that the complete operation depends on ash being

generated in the furnace. Normally these coolers operation will be

intermittent only.
 PRINCIPLE OF
FLUIDISED BED COMBUSTION
 FLUIDISED BED COMBUSTION

FLUIDISED BED

When air or gas is passed through an inert bed of solid particles such as sand
supported on a fine mesh or grid, the air initially will seek a path of least resistance and
pass upward through the sand. With further increase in the velocity, the air bubbes
through the bed and the particles attain a state of high turblence. Under such
conditions, the bed assumes the appearance of a fluid and exhibits the properties
associated with a fluid and hence the name “Fluidised Bed”.

MECHANISM OF FLUIDISED BED COMBUSTION

If the sand, in a fluidized state, is heated to the ignition temperature of the fuel
and the fuel is injected continuously into the bed, the fuel will burn rapidly and the
bed attains a uniform temperature due to effective mixing. This, in short is fluidized
bed combustion.

While it is essential that temperature of bed should be atleast equal to ignition

temperature of fuel and it should never be allowed to approach ash fusion
temperature (1050°C TO 1150°C) to avoid melting of ash. This is achieved by
extracting heat from the bed by conductive and convective heat transfer through
tubes immersed in the bed.

If velocity is too low, fluidization will not occur and if the gas velocity becomes too
high, the particles will be entrained in the gas stream and lost. Hence to sustain
stable operation of the bed, it must be ensured that gas velocity is maintained
between minimum fluidization velocity and particle entrainment velocity.

ADVANTAGES OF FBC BOILERS

1. Considerable reduction in boiler size is possible due to high heat transfer

rate over a small heat transfer area immersed in the bed.

2. Low combustion temperature of the order of 750°C - 900°C facilities burning

of coal with low ash fusion temperature, prevents NOx formation, reduces
high temperature corrosion and erosion, and minimises accumulation of
harmful deposits due to low volatilization of alkali components.
3. High sulphur coals can be burnt efficiency without much generation of Sox
by feeding limisestone continuously with the fuel.

4. The unit can be designed to burn a variety of fuels including low grade coals like
floatation slimes and washery rejects without much sacrifice in operation
efficiency, because only about 1% by wt. of carbon content in the bed can
sustain the fluidized bed combustion.

5. High turbulence of the bed facilities quick start-up and shut down.

6. Full automation of start-up and operation using simple reliable equipment is

possible.

7. Inherent high thermal storage characteristics can easily absorb fluctuations in

fuel feed rate.

8. There is reduced possibility of formation of local hot spots on heat transfer

surfaces.

9. Though having comparatively low efficiency, fluidized bed coal fired boilers offer
the following distinct advantages over pulverized coal fired boilers, especially
when using low rank coals:-

i) High thermal inertia helps to overcome the problems of flame stability.

It eliminates the necessity of supplementary oil firing to prevent
extinction of flame when moisture and ash content of coal are high.

ii) The formation of sticky deposits on the fire side of the tubes because of
lowering of ash fusion temperature by sodium components in ash is
avoided due to low bed temperature.

iii) Lower coal crushing cost due to higher particle size.

10. Efficiency of 80% and above can be achieved.

WATER QUALITY REQUIREMENT
 WATER QUALITY REQUIREMENT FOR BI-DRUM BOILERS

FEED WATER:

DRUM OPERATING PRESSURE (Kg/cm² (g) UPTO 20

HARDNESS ppm max. 1.0

pH AT 25°C --- --- 8.8 - 9.2

OXYGEN ppm max. 0.02

TOTAL IRON ppm max. 0.05

TOTAL COPPER ppm max. 0.01

SiO2 ppm max. 1.0

CONDUCTIVITY AT 25°C µs/cm max. 10.0

HYDRAZINE RESIDUAL ppm ---- ---

BOILER WATER

DRUM OPERATING PRESSURE (Kg/cm² (g) UPTO 20

pH AT 25°C --- --- 10.0 – 10.5

PHOSPHATE RESIDUAL ppm --- 20 – 40

TOTAL DISSOLVED SOLIDS ppm max. 2000

SPECIFIC ELECTRICAL CONDUCTIVITY AT 25°C µs/cm max. 4000

SILICA ppm max. 25.0

SODIUM SULPHATE AS NA2 SO3 ppm -- 20 – 40

 WATER TREATMENT

I. SOURCES OF WATER:
Water can be generally classified as:

a. Surface water.
b. Ground water

a. SURFACE WATER
Surface water comes from streams, ponds, lakes and reservoirs.

b. GROUND WATER
Ground water comes from wells, mines and springs.

II. IMPURITIES IN WATER:

Impurities in water can be classified into:

a) Suspended solids.
b) Dissolved solids.
c) Dissolved gases.

a) SUSPENDED SOLIDS :
Clay, silt, Organic matter and micro organisms.

b) DISSOLVED SOLIDS.

Calcium Salts Calcium carbonate, calcium bicarbonate, calcium

sulphate, calcium chloride and calcium nitrate.
Magnesium salts Magnesium carbonate, Magnesium bicarbonate,
Magnesium sulphate, Magnesium chloride and
Magnesium nitrate.
Sodium salts Sodium carbonate, Sodium bicarbonate, Sodium
sulphate, Sodium chloride and Sodium nitrate.

Miscellaneous :
Dissolved solids : Silica, Iron, Aluminium & Manganese.

Hardness forming salts:

Hardness is only due to calcium and magnesium salts.
Carbonate Hardness : (Temporary hardness)

- Calcium Bicarbonate
- magnesium Bicarbonate

Non-carbonate Hardness : (Permanent hardness)

- Calcium sulphate
- Calcium chloride
- Calcium Nitrate
- Magnesium sulphate
- Magnesium chloride
- Magnesium Nitrate

Silica : Presence of silica in water also gives rise to hard deposits which are as
bed as scales.

Alkalinity :

Alkalinity is due to presence of

- Bicarbonates
- Carbonates
- Hydroxides

‘M’ Alkalinity represents Total Alkalinity.

‘P’ Alkalinity represents Partial Alkalinity.

Total Hardness : H
Total Alkalinity : M

a) When H>M Both carbonate and non-carbonate hardness are present

H-M Non carbonate hardness (NCH)

b) When H=M Only carbonate hardness is present.

c) When M>H Only carbonate hardness is present.

M-H Sodium bicarbonate.
 c) DISSOLVED GASES :

Oxygen, Carbon-di-oxide and Hydrogen sulphide.

III. EFFECTS OF IMPURITIES:

A. DISSOLVED SOLIDS AND SUSPENDED SOLIDS:

They give rise to scaling and deposition in a given system. They also accelerate
corrosion.

B. ORGANIC MATTER:

This has a greater effect on scale deposition than on corrosion. However, the
effect of micro organisms on both deposition and corrosion can be major and
must not be overlooked.

C. DISSOLVED GASES:

They invariably influence the corrosion rate.

IV. TREATMENT:

Water is purified by

- External treatment
- Internal treatment.

EXTERNAL TREATMENT:

- Clarifiers : For precipitating colloids and setting suspended matter.

- Filtration : To remove suspended matter.
- Remove of hardness : Cold Lime soda process.
Hot Lime soda process.
Ion Exchange process.
- Removal of dissolved : Determineralization by Ion Exchange process.
Solids Desalination.
Electrodialysis.
Reverse Osmosis.
 INTERNAL TREATMENT:

A. For Boiler Water Treatment:

Water is internally conditioned by the use of chemicals. Chemicals are added

to water for the following purposes.

1. Internal softening.
2. Oxygen scavenging.
3. Alkalinity Building.
4. Sludge conditioning.
5. Anti foaming.

1. INTERNAL SOFTENING:

The residual hardness in the feed water should be treated to bring it down to zero.
If allowed to concentrate, scales would begin to form. Hardness is taken care of
by providing a phosphate treatment. The principle behind it is as follows:

Calcium is allowed to react with phosphate and is converted into calcium

phosphate which is easily removed by blow down. Phosphate reserves of 30
ppm to 40 ppm is provided in the boiler water.

2. OXYGEN SCAVENGING

Corrosion would be rampant if oxygen in feed water is not removed. This can
affect the pre-boiler, boiler and condensate line sections. The removal of
oxygen therefore is a must.

The concentration of oxygen is dependent on temperatures. Oxygen content is

lesser at higher temperatures. Oxygen in water is removed by addition of
sodium sulphite. Sodium sulphite reacts with oxygen to form sodium sulphite.
We should necessarily provide reserves of sulphite (around 30 ppm) for
exigencies. Catalysed sulphite should be used.

Hydrazine hydrate can also be used for removal of oxygen. But the speed of
reaction is much lesser with hydrazine. Further, it is toxic in nature. However,
hydrazine is effective in reducing oxides of copper and iron and is more
effective in preventing deposition of corrosion products in feed lines, etc.
Hydrazine also helps in removing old corrosion products from boiler internals
and helps to maintain a uniform Fe3O4 layer on internal boiler surfaces.
Reserves of 0.1 to 0.2 ppm of hydrazine should be maintained.
3. ALKALINITY:

Alkalinity is necessary for the following reasons :

a. To prevent Magnesium to Magnesium Hydroxide sludge which is easily

removed by blow down. If Magnesium is allowed to react with phosphate
Magnesium phosphate, a thick slimy sludge will be formed, which is as bad
as a scale. Therefore OH alkalinity is provided whereby Magnesium
preferably reacts with it to form Magnesium hydroxide.

b. To minimize solubility of iron.

c. It keeps silica in solution. i.e, it reacts with silica and forms a complex
silicate compound which will remain in solution and will precipitate.

NOTE : Excess alkalinity should be avoided as it will give rise to

caustic embrittlement.

4. SLUDGE CONDITIONING:

Sludge conditioning is a must and must be provided in boiler water. The

sludge that is formed should be kept in suspension so that it is removed
easily during blow down. If the sludge is not conditioned, it would deposit on
the tubes and drums. This will serve as nuclear for scale formation.
Sludge conditioning can be achieved by the use of chemical sludge
conditioners.

5. ANTIFOAMING:

Foaming is said to occur when the steam space in the boiler is partially
filled with unbroken steam bubbles. Foaming is caused by impurities in the
water preventing the free escape of steam as it rises to the surface or by
and oily scum on the surface on the water. This surface scum may be
caused by oil, organic matter or any suspended matter in the water.

Remedy :

1. To provide an anti foaming agent.

2. Provide enough blow down to avoid excessive concentration of salts.
3. Treatment and filtration of the water to remove solid impurities.
Priming :

Priming is carrying over of water slugs with the steam. The causes are the same as
that of foaming. But it may occur even with perfectly pure feed water itself.

a. The steam space is too small.

b. If the boiler is operated way above its normal capacity.
c. If the water level is carried too high.

Remedy :

1. To avoid priming, all main stop valves on boilers and steam lines should be
opened very slowly and water in the boiler should not be carried above its
normal level.

2. Boiler design should be corrected to increase the steam space.

Summary :

01. Internal Softening Provide phosphate treatment to take care of

residual hardness.
(Provide 20-40 ppm of phosphate reserves)
Avoid high PO4
02. Oxygen Scavenging Introduce an oxygen scavenger like catalysed
sodium sulphite to remove completely dissolved
oxygen. Provide 20-30 ppm of sulphite reserves.
03. Alkalinity Provide 200 ppm of OH Alkalinity in boiler water.
04. Sludge conditioning Sludge should be conditioned with the help of a
sludge conditioner.
05. Antifoam Antifoam should be incorporated in the chemical
treatment to take care of foaming.
06. Suspended Solids Guard against mud, silt, oil, process contaminants,
etc. Provide filteration for raw water if necessary.
07. Blow down Control blow down properly to keep sludge
accumulation under control and to avoid excessive
TDS concentration.
CONVERSION TABLE FOR SPECIFIC CONDUCTANCE TO TDS AT 25°C (11°F)

uS TDS uS TDS uS TDS

5 3 300 188 2200 1485

10 6 350 218 2400 1647

15 8 400 251 2600 1795

20 11 450 284 2800 1950

25 14 500 320 3000 2085

30 17 550 347 3200 2200

35 20 600 376 3400 2395

40 23 650 402 3600 2530

50 26 700 428 3800 2685

60 35 750 462 4000 2855

70 40 800 495 4200 3010

80 47 850 530 4400 3180

90 53 900 564 4600 3335

100 59 960 623 4800 3505

110 64 1000 660 5000 3675

170 104 1300 858 8000 6115

180 110 1400 923 8500 6600

190 116 1500 975 9000 7045

200 121 1600 1000 9500 7525

220 136 1700 1145 10000 7857

240 148 1800 1195 12000 9850

260 160 1900 1205 14000 11805

280 173 2000 1315 16000 11900

BASED ON CONDUCTANCE OF SODIUM SULPHATE SOLUTIONS

 OXYGEN CONTENT AT VARIOUS TEMPERATURES

Oxygen Oxygen
Temperature Temperature content Temperature Temperature content
°F °C ppm °F °C ppm

135 57.2 4.9 185 85.0 2.4

145 62.8 4.4 190 87.8 2.0

155 68.3 3.9 ----- ----- -----

165 73.9 3.6 200 93.3 1.1

175 79.4 3.0 205 96.1 0.7

180 82.2 2.6 210 98.9 0.3

Deaerator
pressure Temperature °F
Psi
212 205 197 188 178 164 148 133 118
0
218 212 204 195 186 175 162 149 134
2
227 221 215 208 200 191 180 169 159
5
237 227 221 215 208 200 190 181 170
7
239 235 230 224 218 211 204 196 185
10
Max. Oxygen 0 0.7 1.4 2.2 2.9 3.6 4.3 5.0 5.7
content (ppm)
WATER TREATMENT SUPPLIER ADDRESS’S

M/S. ANCO INDIA CHEMICALS (P) LTD,

PLOT NO. 1/1A, U.R. NAGAR EXTENSION,
JAWAHARLAL NEHRU ROAD,
ANNA NAGAR WEST EXTENSION,
CHENNAI – 600 101.

M/S. AQUA CONTROLS & SYSTEMS

2/33, D-TYPE SIDCO NAGAR,
VILLIVAKKAM,
CHENNAI – 600 049.

M/S. EFFIMAX ENGINEERS,

PLOT NO. : 5107, IST FLOOR,
12TH MAIN ROAD,
ANNA NAGAR,
CHENNAI – 600 040.

M/S. ION EXCHANGE (INDIA) LTD,

‘ION HOUSE’,
42, B.N. REDDY ROAD,
T. NAGAR,
CHENNAI – 600 017.

M/S. SURAJ CLEAR WATER SYSTEMS,

12, IIIRD STREET,
THIRUMURTHY NAGAR,
NUNGAMBAKKAM,
CHENNAI – 600 034.
METHOD OF WATER ANALYSIS
 METHODS OF WATER ANALYSIS

CONTENTS

1. SAMPLE COLLECTION - PRECAUTIONS

2. USE OF INSTRUMENTS – GENERAL INSTRUCTIONS.

3. DETERMINATION OF HARDNESS

4. DETERMINATION OF P & M ALKALINITY

5. DETERMINATION OF SULPHITE

6. DETERMINATION OF DISSOLVED OXYGEN MORE THAN 0.1 PPM

7. DETERMINATION OF TOTAL DISSOLVED SOLIDS.

8. DETERMINATION OF OIL

9. DETERMINATION OF pH

10. DETERMINATION OF TOTAL SILICA

11. DETERMINATION OF ORTHOPHOSPHATE

 METHODS OF WATER ANALYSIS

SAMPLE COLLECTION - PRECAUTIONS

Proper sampling procedure is equally important as the actual investigation to ensure

reliable measurements.

As a matter of principle, water for testing should be sampled by the actual person
responsible for the examination or atleast by someone familiar with the plant and
suitably instructed.

Sampling lines are to be kept continuously flowing. Sampling and cooling water lines
should be free from choking and sampling lines to be purged for about 30 minutes
everyday as a routine and whenever choking is suspected. To avoid contamination of
cooled samples, they are to be collected in dust-free atmosphere. Cooling water
contamination of samples is to be prevented. The sampling rate should be of not less
than 25 kg/hr and sample temperature shall not exceed about 40°C. The container
used for collecting samples should be made of polythene or polyethylene. Before
collecting samples, rinse the container atleast 3 times. After collecting the samples,
rinse the stopper and tightly close the container.

USE OF INSTRUMENTS - GENERAL INSTRUCTIONS

SPECTROPHOTOMETER

The following instructions shall be followed to ensure the accuracy of spectrometric

determinations.

1. The spectrophotometer used for colorimetric determinations is to be calibrated

atleast once in six months.

2. The temperatures of both sample solution and calibration solution shall be

nearly equal to each other. (Preferably within the range 20°C to 25°C). To
obtain this temperature, the sample shall be externally cooled with ice.
 3. Same optical cell is to be used for calibration and measurement.

4. For the determination of the various constituents, individual graphs are to be

prepared with standard solutions.

5. The straight line portion of the curve which represents linearity only is to be
used.

6. Solutions of higher concentrations are to be diluted suitably so that the

concentrations can be measured within the linear portion of the graph.

7. Supplier’s other operation instructions shall also be followed.

OTHER INSTRUMENTS

The general operating instructions supplied along with instruments shall be followed.

DETERMINATION OF HARDNESS

I. INTRODUCTION

1. TOTAL HARDNESS

Calcium and magnesium ions in water are sequestered by the addition of sodium
ethylene diamine tetra acetate. The end point of the reaction is detected by means
of an indicator, chrome-black Tat an optimum pH of 10.0 – 10.4 which has a wine
red colour in the presence of calcium and magnesium and a blue colour when
they are sequestered.

2. CALCIUM HARDNESS

Calcium ions in water are sequestered by addition of EDTA. The end point of the
reaction is detected by means of an indicator, murexide which is dark purple in the
absence of calcium but which with calcium forms a light salmon red complex.
The optimum pH range is about 10.4.
II. PROCEDURE

1. TOTAL HARDNESS

a. Pipette 50 ml of the sample into a white procelin casserole. If

necessary adjust to pH7 – 10 kg using ammonium hydroxide of HCL.

b. Add 0.5 ml of buffer solution and mix by stirring. (The pH of this

solution should be between 10 – 10.2)
c. Add approximately 0.2 gms of dry chrome black T indicator to
produce the required depth of colour. The titration with EDTA should
proceed immediately upon addition of the chrome black T.

d. If hardness is present the solution will turn red. Standard EDTA

solution is added slowly with continuous stirring until the end point is
read which is pure blue colour with no reddish tinge remaining.
Further addition of EDTA will produce no further colour change.

2. CALCIUM HARDNESS

a. Pipette 50 ml of the sample into a white porcelain casserole.

b. Add 2 ml of 4% NaOH solution and stir. (The pH of this solution

should be above 10.4)

c. Add approximately 0.2 gms of calcium (Murexide indicator).

d. Add standard EDTA solution slowly with continuous stirring until the
colour changes from salmon pink to orchid purple.
 CALCULATION

1. Total hardness (as ppm CaCO3) = ml std EDTA soln x 20

2. Calcium hardness (as ppm CaCO3) = ml std EDTA soln x 20
3. Magnesium hardness (as ppm CaCO3) = Total hardness (as ppm CaCO3)
minus calcium hardness (as ppm CaCO3)
III. REAGENTS

1. Standard calcium chloride solution (1 ml equals 1 mg CaCO3)

Dissolve 1.00000 gm of reagent grade calcium carbonate containing less than

0.04% MG (dry at 110°C for one hour) in 10 ml 1:1 Hydrochloric acid, without
spattering, dilute exactly to one litre and transfer to a clean dry glass
stoppered bottle for storage (or use a commercially prepared standard).

2. Buffer solution

350 ml ammonium hydroxide (conc.) + 54 gms ammonium chloride + 20 ml

magnesium complex solutions are mixed and made up to one litre with distilled
water. Magnesium complex solution is prepared as follows. 4.1 gm of MgO
(analar) is mixed with 37.2 gms of EDTA and dissolved in 410 ml of warned
distilled water.
3. Calcium Indicator

Murexide : Grind 0.2 gm ammonium purpurate (murexide) with 100 gms of

sodium chloride to 40 to 50 mesh size.

4. Chrome Black T Indicator

Grind 0.2 gms of chrome black T powder with 80 gms of powered Nacl and store
in a dark chloride bottle.
 5. Standard EDTA solution

Weight 4.0 gms of di sodium di hydrogen EDTA di hydrate and dissolve it in 800
ml water. Adjust to pH 10.5 with 5% NaOH. To standardize, pipette 25 ml of
standard Cacl2 solution (prepared above) and add ammonium hydroxide (1 : 4)
solution to obtain to obtain a pH of 10 to 10.4 add 0.2 gms of chrome-black T
indicator. Titrate with EDTA solution according to the procedure above. This
EDTA solution should be equivalent to more than 1 mg of CaCO3 per ml. Let V =
the volume of standard EDTA solution required to titrate 25 ml of standard
CaCl2 solution. Then 25 ml CaCl2 / V (times volume of EDTA to be diluted) =
volume to which EDTA must be diluted.

Using volumetric pipettes and / or burettes make the required dilution, mix well and
restandardize as a check. The use of a factor is also satisfactory. This
solution should be stored in polyethylene bottles and restandardized monthly.

6. Sodium hydroxide solution (4%)

Dissolve 4.0 gms of NaOH in water and dilute to 100 ml.

IV. GLASS WARES

1. Titration apparatus outfit, consisting of automatic – zeroing 10 ml burette with

reservoir bottle.

2. 50 ml measuring cylinder – 1 No.

3. White porcelain casserole with a glass stirrer.

4. Stop cock lubricant.

DETERMINATION OF P&M ALKALINITY

THEORY OF TEST

This test is based on the determination of the alkaline content of a sample by titration
with a standard acid solution. In this measurement, the end points are taken of
change in the colour of organic indicators phenolphthalein (approx. pH 8.3) and
methyl orange (approx. pH 4.3) represent definite points to which the alkalinity of
the sample has been reduced by the addition of the standard acid solution.

APPARATUS REQUIRED

1 Burette, automatic, 25 ml or ordinary

1 Casserole, porcelain 250 ml
1 Cylinder, graduated, 50 ml
1 Stirring rod, glass.

CHEMICALS REQUIRED

Sulphuric acid, N/50

Phenolphthalein indicator
Methyl orange indicator
Methyl purple indicator

PROCEDURE FOR TEST

Measure a clear 50 ml sample of water in the graduate and transfer to the

casserole. Add 4 or 5 drops of phenolphthalein indicator. If the sample is an
alkaline water, such as usually is the case with the boiler water, it will turn red. If
the sample is a raw or natural water, it usually will remain colourless, Add the
standard N/50 sulphuric acid from the burette drop by drop to the sample in the
casserole, stirring constantly until the point is reached where on drop removes the
last trace of red colour and the sample becomes colourless. Stop and record the total
number of ml to this point as the P reading.
Add 4 drops of methyl orange indicator (if no red colour developes on the addition of
the phenolphthalein indicator to the original sample, the titration may be started with
the methyl orange indicator at this point). Continue adding the acid drop by drop
until one drop changes the colour from a yellow to a salmon-pink. Record the final
burette reading as the M reading. This is a more difficult end point and some practice
may be required. The general tendency is to add too much acid. If too much acid is
added, the sample will change from a salmon-pink to definite red. Record the titration
to P point and the total titration to the M point as the P and M readings respectively.
(Note that the M reading will always be greater then the P reading in as much as the
P reading is included in the M reading.)

CALCULATION OF RESULTS

FORMULA
1000
ppm alkalinity as Ca CO3 = ml N/50 sulphuric acid x --------------
ml sample

Using a 50 ml sample, the phenolphthalein alkalinity in parts per million as CaCO3 is

equal to the ml of N/50 sulphuric acid required for the P reading multiplied by 20. The
methyl orange alkalinity is equal to the ml of N/50 sulphuric acid required for the M
reading multiplied by 20.

LIMITATION OF TEST

It is preferable to express the results of the alkalinity determination in terms of P and

M alkalinity as above. However, results are sometimes calculated in terms of
bicarbonate, carbonate and hydrate on the assumption that titration to the P and point
is equivalent to all the hydrate and one half the carbonate alkalinity and that the
titration to M is equivalent to the total alkalinity. Many factors such as the presence of
phosphate silica, organic and other buffers affect this titration and the calculation of
the form of alkalinity present may be in error. Under normal circumstances in plant
control, expression of results as P and M alkalinity is entirely satisfactory and is to be
preferred from the standpoint of simplicity.
DETERMINATION OF SULPHITE

This method is designed primarily for the routine control of boiler feed waters subject
to sulphite treatment. Reductants like sulphite and certain heavy metal ions react
similarly to sulphite. Copper catalyzes the oxidation of sulphite on exposure to air
especially at warm temperatures.

REAGENTS

Standard Potassium Lodate Titrant

Dissolve 0.566 g KIO3 dried at 120°C and 0.5 g NaHCO3 in distilled water and
dilute to 100 ml. The equivalent of this titrant is 1.0 mg Na2SO3 per 1.00 ml.

Potassium iodide solution 50 g per litre. Dissolve 50 mg of iodate free Kl and 0.5 g of
sodium bicarbonate (NaHCO3) in freshly boiled and cooled water and dilute to one
litre.

Starch indicator.
Hydrochloric Acid 1 + 1

PROCEDURE

Place 10 ml 1 + 1 HCL in a 250 ml flask. Rapidly add 100 ml sample submerging the
pipette tip below the acid surface to minimize air exposure. After adding 1 ml starch
indicator solution and 5 ml Kl solution titrate with standard KlO3 titrant to the first
appearance of a persistent blue colour. Determine the blank titration by carrying 100
ml distilled water through the complete procedure.

SO3 milligrams per litre = (a-b) x 6.35

Na2SO3 milligrams per litre = (a-b) x 10
Where A = milliliters of titration for sample
B = milliliters of titration for blank.
APPARATUS REQUIRED

1. 250 CC Erlenmeyer flask

2. 10 CC pipette (for 1 : 1 HCL)
3. 100 ml pipette (for the sample to be measured)
4. 1 ml pipette (for starch indicator)
5. 5 ml pipette (for Kl solutin)
6. 50 ml burette (for KlO3 titrant)

DETERMINATION OF DISSOLVED OXYGEN IN INDUSTRIAL

WATERS CONTAINING MORE THAN 0.10 PPM

I. SAMPLING

It is important to use air tight connections in all apparatus used for sampling
and testing. When sampling hot water a water cooled coil should be
introduced into the sampling line. A convenient arrangement for sampling
for feed water is shown in the figure. The sample itself should be taken in a
500 ml winkler flask containing a few glass beads, as shown in figure and
water should flow through for atleast 10 minutes before taking the actual
sample so as to displace all traces of air. Care must be taken to see that air
bubbles do not form around the stopper of the winkler flask while sampling.

II. REAGENTS REQUIRED

1. Manganous chloride

Dissolve 400 gm of Manganous chloride (AR) in one litre.

2. Alkaline iodine

Dissolve 600 gm of Potassium Hydroxide and 140 gm of Potassium iodide

in one litre of water.
 3. N / 100 Sodium thiosulphate

Dissolve 2.482 gm of AR sodium thiosulphate (Na2S2O3 5H2O) in water

and make up to one litre. Add about 1 gm of AR sodium carbonate to
preserve the solution.

4. Sulphuric Acid 1 : 1

Add 250 ml of conc. Sulphuric acid to 250 ml of water. Cool and store.

III. PROCEDURE

By means of the funnel fitted to the Winkler’s flask add 2 ml of the

manganous chloride solution and then add 2 ml of the alkaline iodide
solution. Mix allow to stand for 10 minutes and then add 2 ml of 1 : 1 H2SO4.
Take 250 ml of the sample and titrate the liberated iodine with N/100
thiosulphate solution using starch as indicator. Millilitre of N/100 thiosulphate
used for 250 ml sample x 0.224 = ml of oxygen / litre 1 ml of oxygen / litre
= 1.430 mg / litre.

IV. GLASSWARES

1. Winkler’ flask arrangement as shown in the figure.

2. 2 ml pipette.
3. Burette 50 ml – 1 No.
 DETERMINATION OF EVAPORATION (T.D.S.) IGNITION RESIDUES
AND VOLATILE MATTER

a) Evaporation residues at 105°C apparatus required.

1, 200 CC. capacity platinum evaporation dish.

2. 100 CC. 200 CC. pipettes to measure water to be tested.
3. Water bath.
4. Drying over.
5. Dessicator.
6. Ignition furnace.

PROCEDURE

100 CC or possible a greater quantity of the water to be tested (filter if

suspended solids are present – estimate separately suspended solids
content) is evaporated in a platinum dish on a water bath until it is dry after
which it is dried down to constant weight in a drying over at 105°C. It is
weighed after cooling in the dessicator.

b) Determining the ignition residues

The evaporation residue determined at 105°C as described above is ignited

in an ignition furnace at 600 ±25°C until constant weight. Cool in the
dessicator and weigh. Constant weight shall be considered as attained when
the change in weight of the dish plus residue shall be not more than 0.5 mg
between two successive operations involving heating, cooling in a
dessicator and weighing.

c) Determining the volatile matter

Record the loss in weight in the previous determination as weight of volatile

dissolved matter.

CALCULATIONS

Total dissolved solids ppm A/W x 1000

Ignition residue ppm B/W x 1000

(A – B)
Volatile matter ppm ---------- x 1000
W
Where,
A = mg of dissolved matter.
B = mg of ignition residue
(A-B) = mg of volatile matter
W = (CC) weight of sample used.
DETERMINATION OF OIL INDUSTRIAL WATERS CHLOROFORM –
EXTRACTABLE MATTER

THEORY OF TEST

This test determines the substances which are extractable by chloroform and is not
a test specific for oil. Heavy oils, fats and certain other organic compounds will be
measured by the test. Following evaporation to dryness of the chloroform extract,
the residue is weighed.

CHEMICALS REQUIRED

Hydrochloric acid (1 : 9)
Chloroform, redistilled

PROCEDURE FOR TEST

Procedure for collecting the sample – collect approximately 900 ml of sample in a

glass container such as a wide-mouth, 1000 ml Erlenmeyer flask. The sample
should be collected directly in the flask and not transferred from another container.
Glass stoppers or caps covered with aluminum foil should be used. The flask
should be weighed prior to collection of the sample.

Procedure for Determination – Weigh the flask and its contents to the nearest 1
gram and obtain the weight of the sample by difference. Withdraw a few drops of
the sample, determine pH and adjust to between pH 3.0 and 4.0 by hydrochloric
acid (1 : 9).

Add 100 ml of chloroform to the flask and agitate by means of shaking machine or
mechanical stirrer for 15 minutes. After separation, transfer the chloroform layer by
a glass siphon to a 500 ml separate funnel. No lubricant should be used on the
funnel stopcock. Add 50 ml of chloroform to the flask and repeat agitation for 15
minutes. Then transfer this second portion of chloroform to the separate funnel.

Draw off the chloroform layer through a dry, fat-and-oil-free filter paper into a 250 ml
breaker. It there is suspended matter at the interface, leave about 2 ml of the
chloroform layer the funnel. Add 20 ml portion of fresh chloroform directly to the
funnel shake and then withdraw the chloroform, using it as a wash for the filter.
Evaporate the chloroform on a boiling water bath to about 20 ml then transfer
quantitatively to a weighted platinum or silica evaporating dish. If the source of the
water sample was at or above 212°F. Continue evaporation to dryness on the
boiling water bath. If the sample was from a source below 212°F, again reduce
the volume to about 20 ml on the boiling water and then continue evaporation at
room temperature. Weigh until constant weight is obtained.

CALCULATION OF RESULTS

Chloroform – extractable matter ppm =

1000
weight increase of evaporating dish, mg x --------------
ml sample

LIMITATIONS OF TEST

With proper technique, an accuracy of 1.0 ppm or 2% which ever is greater can
be obtained. The method does not determine lighter hydrocarbons which volatilize
under the test conditions. Substances other then oil are included as chloroform
extractable matter. While this procedure is based on ASTM method D1178 -54T,
that method should be consulted if it is desired to conduct the test in exact
conformity to ASTM – standards.

APPRATUS REQUIRED

1. A well-equipped laboratory
2. Wide mouth 1000 ml Erlenmeyer flask.
3. Balance capable of weighing upto 1 kg with an accuracy of ± 1 gm.
4. pH meter.
5. 100 ml measuring cylinder.
6. Shaker or mechanical stirrer.
7. 500 ml separating funnel
8. Glass syphon
9. Oil free filter paper
10. 250 ml beaker.
11. Funnel with filter stand.
12. Water path suitable for heating (thermostat)
13. Platinum or silica evaporation dish.
DETERMINATION OF pH VALVE

INTRODUCTION

As a yard stick for the concentration of hydrogen ions, the pH value gives an
indication of the percentage reaction (alkalinity or acidity) of the water and hence
its aggressivity. The pH value is the negative logarithm to the base 10 of the
hydrogen ion concentration, expressed as gram ions per litre.

The pH value of a given solution depends on the temperature and as a rule it is

quoted for 20°C. At this temperature the pH value ranges from 0 to about 14.
Water with pH=7 has a neutral reaction, while there is an acid reaction at pH<7
and a basic reaction at pH>7.

APPARATUS REQUIRED

1. A pH meter with associated glass and reference electrodes.

2. Buffer table of kwown pH.

ELECTROMETRIC DETERMINATION OF pH VALUE

With the electrometric method, the pH value is determined from the potential
difference between the measuring electrodes immersed in the liquid under test and
a reference electrode of known potential for testing water electrode assemblies
comprising a glass electrodes and a calomel reference electrode are suited.

pH meter is to be operated in accordance with the instruction supplied with it, by

its manufacturer. To ensure accurate measurements, air must be prevented from
getting to the sample, since pH value may be strongly influenced by atmospheric
contaminants.

Where water is very pure and the pH value and electrical conductivity are being
determined simultaneously, make sure that the pH electrodes are inserted AFTER
the conductivity electrodes if the measuring points are connected in series.

ELECTRODE TREATMENT

New glass electrodes and those that have been stored dry shall be conditioned and
maintained as recommended by the manufacturer. If the assembly is in intermittent
use, keep the immersed ends of the electrodes in water between measurements.
For prolonged storage, glass electrodes may be allowed to become dry, but the
junction and filling openings of reference electrodes should be capped to reduce
evaporation.
STANDARDISATION OF ASSEMBLY

Turn on the instruments, allow it to warm up and bring it to electrical balance in

accordance with the manufacturer’s instructions. Wash the glass and reference
electrodes and the sample cap by means of a flowing stream of distilled water from
a wash bottle. Note the temperature of the test solutions and adjust the
temperature dial of the meter to correspond. Select the two reference buffer
solutions, the pHs values of which are close to the anticipated pH of the test
solution. (Buffer solutions can be prepared from the buffer tablets following
manufacturer’s instructions). Warm or cool these reference solutions as necessary
to match within 2°C the temperature of the unknown. Fill the sample cup with the
first reference buffer solution, and immerse the electrodes. Engage the operating
button, turn the range switch if present to the proper position and rotate the
assymmetry potential knob until the reading of the dial corresponds to the known
pH of the reference buffer solution. Repeat the above procedure until two
successive instrument readings are obtained, without changing the setting of the
assymmetry potential knob. Care should be taken to see that the level of the KCI
solution in the reference electrode must always be kept within that of the measured
solution. To reduce the effects of thermal and electrical hysteresis, the
temperature of electrodes, reference buffer solutions and wash water should be
kept as close to that of the unknown sample as possible.

Wash the electrodes and sample cum three times with water. Place the second
reference buffer solutions in the sample cup and measure pH by simply reading the
dial. Do not change the setting of assymmetry potential knob.

The assembly shall be judged to be operated satisfactorily if the pH reading

obtained for the second reference buffer solution agrees with its assigned pH value
with in 0.05 unit. In long series of measurements, supplement initial and final
standardisations by interim checks.

Wash the electrodes by means of a flowing stream from a wash bottle. Place the
water sample in a clean glass beaker. Measure the temperature. Insert the
electrode and measure pH as before.

INSTRUCTIONS

pH meter should be checked for its performance using buffer tablets atleast once a
shift.
DETERMINATIONS OF TOTAL SILICA IN HIGH PURITY WATER

INTRODUCTION

Some boiler stations using ion exchange columns of preboiler water purification
have noticed silica concentrations building up in the units and at the same time a
soluble silica analysis on water coming from the ion exchange column showed no
silica. Analysis for colloidal silica on these same samples showed that the silica
was present as a colloidal particle. This technique has been developed as an
analytical procedure to accurately determine trace concentrations of silica where all
or a part is present in colloidal form. Total silica is determined
spectrophotometrically after solubilization by the pressurized bomb method. (Paar
oxygen bomb).

PROCEDURE

1. Accurately measure 50 ml or a suitable aliquot of the sample into a platinum

cup.

2. Add 1 ml of 0.2 N NaOH and close the cup with a platinum cover.

3. Place the closed cup in a paar oxygen bomb containing 100 ml of deionized
water and completely assemble the bomb.

4. Nitrogen is added to obtain 30 pounds pressure and let out five times to
completely, flush out oxygen in the bomb to prevent bomb corrosion.

5. Pressurize the bomb with nitrogen to 45 psig (maintained for specified

period) and place in an oven at 190°C for 8 hours. The oven should be
placed in a hood since all gaskets in the bomb are made of Teflon.

6. Remove the bomb from the oven, cool and remove the sample from the
platinum cup. Silica is determined spectrophotometerically by using the
applicable high or low range method.

CALCULATION

1. See silica curve for the spectrophotometer used.

2. Colloidal silica (ppm) = Total silica (ppm) - soluble silica (ppm)
APPARATUS REQUIRED

1. 25 ml – Pipette
2. 50 ml – Pipette for suitable aliquot sample.
3. 10 ml – Pipette
4. Platinum cup with cover.
5. Oxygen bomb.
6. 1 ml Pipette (for 0.2 N NaOH solution)
7. 10 ml – Pipette (for deionized water)
8. Nitrogen cylinder with pressure regulator opener etc.
9. AIR OVEN to be capable of giving a temp, of 190°C for 12 hours
continuously.
10. Spectrophotometer at 815 nm.

DETERMINATIONS OF ORTHOPHOSPHATE INDUSTRIAL WATER

ASTM : D515-68
INTRODUCTION

This method is applicable to the routine determination of orthophosphate in the

2 – 25 ppm PO4 range in industrial water and is based on the photometric
measurement of the yellow colour of the molybdo vanadophosphoric acid
produced. The colour intensity is proportional to the orthophosphate concentration
in the sample. Highly coloured water such as tannin treated boiler water and high
concentration of ferric iron interfere thus requiring preliminary treatment to remove
these materials.

PROCEDURE

1. To a 125 ml Erlemeyer flask, using a pipette or volumetric flask, add 50 ml. of

the clear sample or a liquit there of diluted to 50 ml. with deionized water. The
sample must be free of suspended matter to avoid arroneous high results.
Filtration using what man no. 42 filter paper has been found to be satisfactory
in most cases.

2. Add, using a graduate, 25 ml of ammonium vanadomolybdate solution and mix

well by swirling.

3. Allow 10 minutes for colour development and read within 30 minutes on the
spectrophotometer at 400 mm.

4. Reagent blank and atleast two phosphate standards should be run along with
samples.
CALIBRATION AND STANDARDIZATION

1. Prepare a series of standards to cover the range 0-25 mg/litre (ppm) and
prepare calibration curve.

REAGENTS

1. Ammonium vanadomolybdate solution – Dissove 40 grams of ammonium

molybdate – tetrahydrate (NH4)6MO7O244H2O) in 400 ml. of water. Dissolve
1.0 gram of ammonium metavanadate in 300 ml of water and add 200 ml
concentrated nitric acid (SP. GR. 1.42). Add the first solution to the second
solution mix well, and dilute to 1 litre with water in a volumetric flask.

2. Phosphate standard solution (1 ml = 1 mg PO4) – Dissolve 1.433 grams of oven

dried (4 hours at 105°C )C.P. potassium dihydrogen phosphate (KH2PO4) in
water and dilute volumetrically to one litre.

APPARATUS REQUIRED

1. 125 ml Erlenmeyer flask.

2. 50 ml – Pipette
25 ml – Pipette for suitable aliquot sample.
10 ml – Pipette

3. Filter stand with funnel, 42 what man filter paper etc.

4. 25 ml – Pipette (for ammonium vanadomolybdate solution)

5. Spectrophotometer at 40 nm.
BOILER OPERATING INSTRUCTIONS
 BOILER OPERATING INSTRUCTIONS

01. STARTING OF ALL INDIVIDUAL EQUIPMENTS

02. STARTING OF BOILER FEED PUMPS

03. DP STUDY

04. BED MATERIAL, CHARCOAL & KEROSENE REQUIREMENT

05. BOILER LIGHT UP

06. NORMAL OPERATION

07. NORMAL SHUT DOWN TO COLD

08. NORMAL SHUT DOWN TO HOT STAND BY

09. HOT RESTART

STARTING OF ALL INDIVIDUAL
EQUIPMENTS
STARTING OF ALL INDIVIDUAL EQUIPMENT

GENERAL

The boiler is provided with interlocks for safe and reliable operation and none of these
should be bypassed.

The sequence of starting of the equipments is as follows:

* Check water level gauge for water in Drum.

01. Start the ID fan.

02. Start the PA fan.
03. Start the FD fan.
04. Start the Fuel feeders.

Similarly while switching off, reverse sequence must be followed.

The individual equipment can be started through DCS or from Local Push Button
(LPB). Switch on the power supply to the motor control centre (MCC) panel. The
fuses of individual motor controls shall be checked for continuity. Three phase supply
of 415 V / 11000 V 50 Hz with allowable percentage of variation shall be ensured
before switching on the equipment.

STARTING OF BOILER FEED PUMPS

GENERAL

Ensure that the suction valve is open and water is available in the deaerator storage
tank. Also ensure that, the discharge valve or the feed control valve including the
bypass valve is closed. Then start the feed pump. Do not close the suction valve, when
the pump is running. The auto recirculation valve to be opened automatically at the
time of starting the pump and the same will be after crossing the pump min. flow. After
that outlet valve is to be opened immediately. Do not run the feed pumps without suction
filter. During normal running of boiler the pump can be started / stopped with discharge
valve open, since the feed line is under pressurised condition.
DP STUDY
DP STUDY

DP study must be carried out individually for all compartments. In simple terms, DP
study is nothing but finding out the pressure drop across distributor plate at different air
flows. Follow the steps given below.

DP study shall be done separately for each compartment. Hence close the FD, PA
dampers of the compartments which are not being studied.

Switch on ID fan, PA fan and then FD fan. Open the suction damper of FD fan and set 10
mm air flow in Aerofoil meter. Measure the air box pressure and gas plenum pressure (ID
fan damper is to be adjusted to maintain a gas plenum pressure of -5 mmwc at all
conditions).

Suppose,
FD air flow = 10 mmwc across Aerofoil meter
Air box pressure = 75 mmwc
Gas plenum pressure = -5 mmwc
The pressure drop across DP at 10 mm air flow = 75 + 5 mmwc
= 80 mmwc

Thus, the pressure drop across DP can be found out 20, 30, 40, 50, 75, 100 & 125 of air
flow.

* The pressure drop values should be found out for other compartment too.

* The pressure drop values shall be compared. For the same air flow, if there is
a deviation of more than 5 mm between compartments, then it becomes
necessary to check the following.
* The manometer readings may be incorrect. Check for leakage in the pressure
tapping locations or Aero foil meter and air box.

* Check for leakage in the impulse lines to manometer/ Draft indicator.

* Check for leakage between fuel feed pipe and air box.

* Check for broken air nozzles.

* The pressure drop values found in DP study, shall be recorded for

future use. The pressure drop values measured in DP study are used to
find out the bed height when the boiler is in running condition i.e. at a
particular air flow. Also it is used to establish the practical pressure drop
across the aero foil meter at the MCR air flow. If the DP drop is subracted
from the total drop across the bed and DP, then bed height can be arrived at.

The pressure drop values taken shall be recorded on the following tables for future
reference.
DP STUDY READINGS

COMPARTMENT – I

PRESSURE DROP ACROSS DISTRIBUTOR

SL. FD AIR FLOW (MM) GAS PLENUM PLATE (AIR BOX PRESSURE – GAS
NO. PRESSURE (MM) PLENUM PRESSURE)

01

02

03

04

05

06

07

08

COMPARTMENT – II

PRESSURE DROP ACROSS DISTRIBUTOR

SL. FD AIR FLOW (MM) GAS PLENUM PLATE (AIR BOX PRESSURE – GAS
NO. PRESSURE (MM) PLENUM PRESSURE)

01

02

03

04

05

06

07

08
DP STUDY READINGS

COMPARTMENT – III

PRESSURE DROP ACROSS DISTRIBUTOR

SL. FD AIR FLOW (MM) GAS PLENUM PLATE (AIR BOX PRESSURE – GAS
NO. PRESSURE (MM) PLENUM PRESSURE)

01

02

03

04

05

06

07

08

COMPARTMENT – IV

PRESSURE DROP ACROSS DISTRIBUTOR

SL. FD AIR FLOW (MM) GAS PLENUM PLATE (AIR BOX PRESSURE – GAS
NO. PRESSURE (MM) PLENUM PRESSURE)

01

02

03

04

05

06

07

08
BED MATERIAL, CHARCOAL & KEROSENE

REQUIREMENT
BED MATERIAL, CHARCOAL, KEROSENE REQUIREMENT

BED MATERIAL REQUIREMENT:

Quantity of bed material per startup : 4120 Kgs.

Quantity of Bed material to be stocked : 41200 Kgs. (For 10 Startups)

BED MATERIAL SPECIFICATION:

Maximum particle size : 2.36 mm

Particles to pass through sieve No. : 8

Minimum particle size : 0.85 mm

Particles to stay on sieve No. : 20

Particle density : 2000 Kg/m3

Bulk density : 1000 to 1100 Kg/m3

Chemical composition
Alumina : 45% to 35%
Silica : 55% to 65%

Fusion temperature : 1400°C (Min.)

(Bed material shall be from Crushed refractory bricks or from sieved ash).

CHARCOAL REQUIREMENT:

Quantity of charcoal per startup : 155 Kgs.

Quantity of charcoal to be stocked : 1550 Kgs. (For 10 Startups)

CHARCOAL SPECIFICATION:

Charcoal size : 15 to 25 mm LUMPS

Calorific value : 6600 Kcal/Kg.

(Charcoal should be sundried)

KEROSENE:

Quantity of kerosene per startup : 17 Litres.

Quantity of kerosene to be stocked : 170 Litres. (For 10 Startups)

USE OF BED MATERIAL

The bed material plays a vital role in the fluidised bed combustion process. The bed
material is inert and does not undergo any chemical change. The size of the bed
material is so selected to meet the fluidisation requirements. The bed material once
heated serves like an ignitor for the incoming fuel. The normal bed height when
defluidised is maintained in the range of 300 mm to 400 mm. The bed material also acts
as the carrier of heat between the burnt and the heat transfer surface.

PROCUREMENT OF BED MATERIAL

The bed material shall be procured from refractory supplier. Alternatively, the bed
material can be purchased from the user of a coal fired fluidised bed boiler. The ash
drained from the fluidised bed can be screened and used as bed material.

IMPORTANCE OF BED MATERIAL QUALITY AND QUANTITY

1. Before programming for a light up, it is necessary that the recommended quantity
of bed material is procured according to the specifications. The bed material is to
be stocked atleast for 10 start ups.

2. If the bed materials is procured from a refractory supplier, ensure only refractory
bricks are crushed to make bed material. Mix up of insulation bricks is not
allowed.

3. The fusion temperature of the bed material has to be above 1400°C. If the fusion
temperature is lower, clinkering will occur in the bed.

4. It is important that the bed material is procured according to the size

recommended. Oversize particles do not fluidise well and fine powder will fly away.
Also the fine powder puts off charcoal fire while start up. (Because fine bed
material quickly transfer heat to the bed coils).
 5. In a coal fired boiler, the ash produced from coal partly accumulates in the bed
and the same is drained to maintain a constant recommended bed height in the
fluidised bed. This ash drained from the bed can also be screened and the
screened ash can be used as bed material. In an agro fuel fired boiler, the bed
material will not be generated and hence bed material has to be procured for daily
consumption.

6. A coal fired fluidised bed in operation contain good amount of fines and coarse
particles. Which are due to varying coal particle size on crushing. Hence for
every light up (except hot restart) fresh bed material is to be used. This is
essential for a smooth and quick start up.

7. When the bed material is procured from a refractory supplier, the size of the
bed material is to be specified up mentioning the upper sieve no. 8 and lower
sieve no. 20. The material has to pass through sieve no. 8 and to stay on sieve
no. 20.

USE AND IMPORTANCE OF CHARCOAL:

1. Charcoal is required for lighting up of the boiler. A fixed quantity of charcoal is burnt
in the fluidised bed to raise the bed temperature in the start up compartment.
Once the bed temperature is raised further fuel is fed to establish combustion of
fuel in the fluidised bed.

2. Charcoal is selected as the start up fuel, mainly, because of its high heat content ,
rapid burning characteristics and low ignition temperature.

3. Good quality charcoal is a must for easy light up. Ensure charcoal is dry and not
already burnt. Heavier charcoal is an indication of good quality. Tamarind wood
charcoal is the best because it burns for more time and the calorific value is
about 6600 kcal/kg.

4. Charcoal should be dry for rapid burning. Wet charcoal should not be used in
any case. Ensure the charcoal in stock is also dry.
 5. The charcoal should not contain powder or bigger lumps. The charcoal shall be
sized to 15 - 25 mm. Fine charcoal burns easily and does not contribute much for
heating the bed. Bigger lumps would cause clinker formation as the lumps do not
easily fluidise.

BED MATERIAL FILLING:

* The bed material can be filled by entering the furnace. For start up purpose, the
bed height shall be 200 - 225 mm above the air nozzle top level in the start up
compartment.

* The bed material below the nozzle level remains static all the time. This is not to
be counted as the bed height.

* Uniform spreading can be done by admitting fluidising air through the bed. The
air should be sufficient enough to fluidise bed.

* The bed height can be measured physically after putting off the air flow.

* Alternatively the bed height can be found out by pressure drop across the
fluidised bed.

Let us assume,

For 100 mm fluidising air flow the distributor plate pressure drop is found to be 150 mm.

Let gas plenum pressure = -10 mmwc

Let air box pressure drop across the fluidised bed = 484 mmwc

The pressure drop across the fluidized bed and the distributor plate = 491 mmwc
The pressure drop across the distributor plate is 121 mmwc as found in DP study.

The pressure drop across the bed = 491 - 121.

= 270 mmwc

Since the bulk density of the bed material is 1000 kg/m^3, the pressure drop across the
bed in mm is the bed height in mm.

Though the normal operating bed height is 300 - 550 mm, initial bed material filling is
done only upto 200-225 mm. This low bed height reduces the charcoal requirement for
start up purpose. Also low bed height helps in raising the boiler pressure slowly.

In the case of compartmental start up the bed material shall be filled as explained below:

Fill the bed material to a height of 300 mm in all compartments. Fluidise all the
compartments together provided the fan motor amperes are below the limits. If not
possible, fluidise two compartments together for levelling. Then the next compartment
can be fluidised separately. The start up compartment is to be fluidised separately.
When this is done a portion of the bed material spills to the adjacent compartment and
forms a mount along the edge of the compartment. Further bed material is to be added
to the start up compartment so that the bed height of 200 - 225 mm is maintained.
BOILER LIGHT-UP
04. BOILER LIGHT-UP:

The lighting up of the boiler is to be done with the help of charcoal and kerosene. The
light up is to be done only for a single compartment. After stabilising with a single
compartment fire is transferred to other compartments as per the procedure explained
separately.

PREPARATIONS:

01. Inspect the boiler prior to starting and check the following.

- All access doors are closed.

- All personnel cleared.
- All foreign materials are removed from furnace and pressure parts.
- Starting equipment and interlocks are in position.
- Boiler is filled with DM water above the low level limit.

02. Check the following equipments for adequate lubrication and readiness for service.

- Fans and drives.

- Feed pumps and drives.
- Fuel feeders and controllers.

03. Check dry fuel (0-6) mm is available in the bunker, the gates below the bunker
are open and fuel is available at feeder inlet.

04. Check the instrument air is available at the required pressure (of 7 kg/cm2) for
instrumentation and control.

05. Check the following valves in the Boiler drum are closed.

- Feed control valve and its bypass valve.

- Blow down valve.
- Main steam stop valve.
- Drain valves of water level gauge.

06. Check the following valves are kept open.

 - Air vent on top of drum.
- Water level gauge, pressure gauge and level transmitter / isolation valves.
- Valves before and after the feed control valve in the feed line.
- Valves on the feed line connecting to the feed pumps in operation.

07. Check the bed material is filled in the furnace and fluidisation study is
complete.

BOILER FILLING:

Before starting the filling up, keep the vent on the drum open and close the blow down
and drain valves. The filling up is done by running the feed pumps but the rate of flow is
controlled by means of feed control valve. During the filling up check the operation of
blow down valve and drain valves and then close them. The boiler is filled up
completely till water comes through the drum vent and is drained to bring the water level
to low level alarm limit.

FLUIDISATION STUDY:

* During the fluidisation studies, except for large compartments the fuel
transport air need not be introduced as it would disturb the bed.
* Observe the fluidisation of the start up compartment by varying the air flow
gradually. Mark the position of dampers when the bed material begins to
fluidise. In the case of pneumatically operated dampers, note the input signal
"PSI" from the manual loaders.

* The on set fluidisation may also be observed by plotting the bed pressure drop
against the air flow.

* Set the air flow at 5 mm P.

* Measure the air box pressure, P1 mm wc

* Add the gas plenum pressure P2 to P1 (P1+(P2)) is the pressure drop across
the distributor plate and bed.
* Substact P3 mmwc, which is the pressure drop across DP alone which is
measured in DP study. i.e., (P1 + (P2)) - P3 would be the pressure drop across
the bed.
* The pressure drop across the bed is thus obtained for various air flows. The
readings may be plotted in a graph as shown.

* The air flow at which fluidisation starts is noted. This value is to be maintained
for the purpose of mixing at the time of startup.

* Once the fluidisation study is completed, the fans shall be switched off and boiler
shall be taken for light up.

The boiler light up is done using charcoal and kerosene as explained below.

* A fixed quantity of dry charcoal is spread uniformly over the start up compartment.

* A fixed quantity of Kerosene mixed charcoal is spread uniformly over the dry
charcoal layer.

* The fire is initiated using swab.

* Further by proper air flow control, fire can be spread and the heat released by
charcoal is utilised to heat the bed material to a temperature above the ignition
temperature of the fuel.

* In the process of preheating bed material the required fluidisation velocity is

maintained in the bed by suitably opening the FD fan inlet damper.

* Further the fuel feed rate is adjusted to maintain a bed temperature of 800°C to
850°C.

* The charcoal of size below 15 mm shall not be accounted for the above quantity.

* Keep the ID fan damper open at the time of lighting up. This would reduce the
possibility of furnaces puff.

* Initiate the fire bushing number of swabs. Throw the swabs in such a way that
the fire spreads uniformly over the entire furnace. If the spreading of the fire is
non uniform sprinkle some kerosene choked charcoal and throw it to the
locations where fire is not there. Unless the fire is more or less present over the
entire surface, it is advised not to proceed with the light up. Unless the top
layer or charcoal gets ignited, further charcoal would not get ignited.
BED TEMPERATURE AND AIR FLOW CONTROL

The thermocouples are located in such a way that they are well utilised for start up.

The top level bed thermocouple is located at a height to read the temperature just at the
burning charcoal layer. The bottom level thermocouple is located to read the bed material
temperature at a height of 100 mm from nozzle level.

After the introduction of fire, top level thermocouple temperature will go up. It is
very important to increase the air flow gradually in order to increase the top level
temperature to 800°C. At first the ID fan damper opening alone allows some leakage
air. Further opening of FD fan damper will add some more air to increase the bed
temperature. Now close ID fan and FD fan inlet dampers. Start ID fan then FD fan. Open
ID fan and FD fan inlet dampers step by step to increase the top level temperature to
800°C to 850°C. Till this period the bottom level thermocouple would not have
shown increase in temperature. Once the top level temperature reaches 800 - 850°C,
the burning top layer of charcoal shall be mixed with rest of the bed. The mixing is
done by increasing the air flow so as to fluidise the bed. The mixing air flow should not
be higher than that of the air flow established during the fluidisation study. For this
purpose the markings made on damper positions shall be used.If the mixing is done at
higher airflow, the burning charcoal will spill into the adjacent compartment. More than
the loss of charcoal in the start up compartment, the bed height will reduce in start up
compartment. This would lead to defluidisation as the air would tend to bypass at bed
heights lower than 100 mm.

The duration of mixing shall be between 20 - 30 seconds. During the mixing process,
the top level temperature would start reducing. At the same time, bottom level
temperature would begin to rise.

Soon after the mixing is completed the air flow is brought to a minimum. Open the man
hole door and visually ensure through mixing has been done. If top layer charcoal
has not been disturbed at some places, mixing shall be carried out once again.
After ensuring thorough mixing, the air flow shall be brought down to minimum and
then shall be increased in steps. The airflow shall be increased gradually so as to
raise the bed temperature. The airflow shall be brought up at MCR airflow in process of
raising bed temperature above 600°C.

Once the bed temperature shoots above 600°C, the fuel transport lines are to be
dechoked and fuel flow shall be established.

* Switch on the New PA fan.

* Open the fuel transport air dampers of the start up compartment.

* Check the suction at the mixing nozzle. If suction is not available, open the
respective bottom drain gates of fuel pipes to dechoke, if any. After the choking
of fuel feed pipe is cleared close the gates.

* In the case of larger compartments it is advisable to initiate minimum airflow

in fuel pipe lines just before mixing process to avoid choking of the fuel lines.

* Adjust the PA fan suction damper, to maintain the header pressure in between
700 to 900 mm of wc.

Initiate the fuel flow by switching on the fuel feeders. The fuel flow shall be kept
minimum at the beginning. At the time of fuel feed initiation, the charcoal might not
have burnt fully. Hence it is most important to initiate fuel feed gradually.

Excess fuel feed will increase the bed temperature uncontrollably. Though the
bed temperature can be controlled by increasing the air flow, it is advisable to take care at
the time of fuel feed initiation. Stabilise the start up compartment operation with a bed
temperature of 850°C and with the MCR air flow.
* On the waterside watch the drum level. If the level goes down switch on feed
pump and regulate the feed control valve. ON/OFF operation of feed pump
should be avoided to the extent possible. If the feed pump is auto operated,
keep the selector switch in auto mode. Here again regulatethe feed control valve
to avoid frequent start/stop of the pump.

* Close the drum vents at 2 kg/cm² pressure if the boiler is provided with
superheater. This is done so that superheater coils are cooled better by more
steam flow through them. Ensure the vents, start up vents, drains are open
in superheater lines. The condensate in superheater coils and main steam pipe
should have been removed earlier. In the case of non drainable sections of
superheater coils it is possible that condensate leads to water hammer.

* In cases of powercut during start up after the mixing it will not be possible to
access how much charcoal is burnt out. It is advised to cool throughly and drain
the bed material in start up compartment and do a fresh light up.

* However, if the powercut had occurred before mixing one may attempt to light up
as below:

* Sprinkle Kerosene soaked charcoal through man hole evenly over the start up
compartment. The charcoal quantity shall be the same as that for light up.

* Throw swabs and light up.

* Follow the same procedure as discussed in a regular light up.

* If the powercut occurs after mixing and provided the duration is also short, it
may be possible to ligh up.
* Fluidise the bed minimally. Check the bed temperature. If the bed temperature is
more than 400°C add dry charcoal to the bed. The charcoal should be thrown
uniformly over the entire bed. Observe the rise in temperature. If there is no
improvement in bed temperature it is better to cool the bed. Never allow the bed
to be static in this method. If the bed is static, clinker formation will start.

START-UP PARAMETERS:

Bed height : 300 mm from Distributor plate

Bed material size : 0.85 - 2.38 mm.
Before firing Charcoal (Dry) : Kg.
Charcoal kerosene
mixed : Kg.

PA header pressure : mmwc

Before mixing Mixing temperature : 850°C
Mixing air flow : mmwc

Bed temp. before

fuel feed : Min. 600°C
Fluidising airflow : mmwc
After mixing PA header pressure : mmwc
Feeder rpm

COMPARTMENTAL TRANSFER:

The start up with one compartment is recommended for the following reasons.

01. Gradual loading of pressure parts.

02. Reduction of Charcoal for start up.
03. Load variation.
The compartment transfer means activating a static (cold) compartment of the
furnace adjacent to the activated compartment. This is done just by admitting the
fluidising air to the compartment to be activated and mixing the cold material with hot
material of the operating compartment. Before activating a static compartment, the
airflow in the fluidising compartment shall be increased to 120% of the MCR air flow,
and the fuel feed rate shall be correspondingly increased to maintain the bed temperature
at 900°C.

Now open the compartment air damper of the adjacent compartment which is to be
activated. The cold bed material in this compartment would begin to mix up with that
of hot bed material in the operating compartment. The bed temperature in new
compartment would begin to rise.

The bed temperature in operating compartment will begin to drop. Once this temperature
reaches 750°C slump the new compartment by closing the air damper.

The bed temperature of the operating compartment shall be once again brought up to
900°C before another attempt is made.

By following the process of mixing the bed material of the compartment to be

activated with that of the operating compartment, on one or many attempts, the
activation can be completed. The bed temperature of the new compartment shall be
brought to atleast 600°C before fuel feeding is commenced.

The primary air lines in the new compartment shall be opened and the fuel feeding can
be commenced and the bed temperature shall be brought to 800°C with MCR fluidising air
flow condition. Care shall be taken not to drop the temperature of operating
compartment below 600°C in the process of activating adjacent compartment.

If by mistake, the temperature of the operating compartment drops below 600°C, it

becomes necessary to raise the temperature using charcoal. The charcoal should be
sprayed over the entire compartment. Charcoal should be mixed with the bed keeping
the bed minimally fluidised. The charcoal if burns under static condition, the chance of
clinkering is high.
NORMAL OPERATION
05. NORMAL OPERATION

LOAD CONTROL:

The steam generation needs to be matched with that of demand to avoid venting of
steam. If the steam drawn from the boiler is less compared to steam generated then the
pressure would rise and thus resulting in lifting of safety valve. Frequent lifting of safety
valve will damage the safety valve seat. Steam generation can be varied by slumping
compartments or by varying the fluidisation air flow or by varying the bed temperature
or by varying the bed height.

Load variation of 70% to 100% may be obtained by varying the bed temperature. The
bed temperature can be reduced upto 700°C and can be increased to 900°C based on
demand. For this purpose the fuel fed rate needs to be varied. Further turndown is
also possible by reducing the fluidisation airflow but not to the extent of defluidisation of
the bed. In such cases the air flow through primary air lines should never be reduced.
Only the fluidising airflow should be reduced. Further load control is done by slumping
the compartments. The compartments can be slumped only from either ends of the
bed. In case of two compartments any compartment may be slumped. In case of
three compartments only first or third compartment is to be slumped, before the middle
compartment is slumped.

Slumping of the compartment is to be done as explained here. Bring down the fuel
rate to minimum and switch off the feeder. Wait till the bottom bed temperature comes
around 850°C, and then close the fluidising air damper of the compartment. Then close
the fuel transport air line dampers. When the fluidising air through a compartment is
cut off, the air through the other compartments would increase. This air flow shall be
adjusted by throttling inlet damper of FD fan. Further draft in the furnace shall be
adjusted by throtting of ID fan inlet damper.

Reactivation of a compartment shall be done in the following sequence. Open the fuel
transport airline valves first and ensure the required air pressure is available in the PA fan
header. If the line is choked, choke shall be removed by using the drain gates, of the
fuel transport lines. Then open the fluidising air damper and set the FD fan inlet damper
for the required MCR airflow. If the bed temperature is above 600°C fuel feed shall be
initiated and the bed temperature shall be brought to the required operating
temperature.
In case the temperature of the bed is less than 600°C immediately after fluidisation, the
compartment shall be started in the manner explained in the compartment transfer
method. The load control is graphically depicted in figure 2 for the furnace with three
compartments.

During one compartment operation, the bed height can not be increased as the bed
is not contained on one side. This is applicable to some extent to two compartments
operation also maximum variation is possible in all compartments operation as the bed
is totally contained in all four sides by the furnace water wall.

DYNAMICS IN FLUIDISED BED:

The height of the fluidised bed needs to be increased after the activation of all
compartments in order to meet the steam demand. In the case of coal firing, the bed
height automatically increases due to generation of ash from coal burning. The ash
which is retained in the bed, if not drained, will accumulate to an extend that the air flow
through the bed starts coming down below the MCR airflow. The height of bed is not to
be allowed to increase beyond the recommended bed height which is about 300 mm to
400 mm. The bed height is indirectly measured by means of air box pressure as
explained in the earlier sections. Other than the purpose of maintaining required bed
height, the bed drain gates are to be operated for removing higher size particles.
When there are deviations from the specified fuel feed size, ie., minus 6 mm, the higher
size particles would begin to settle down at the air nozzle level. Similarly when agro fuel is
used stones ingress with fuel would lead to setting of stones.

The bed drain is to be operated frequently to drain the higher size particles. If the drain
is not operated frequently the fluidisation will be upset causing clinker formation. In
the case of fuels (Agrowaste) which do not generated bed ash, bed material requires to
be added frequently in order to compensate for loss of bed material by attrition and
subsequent elutriation. Hence sufficient stock of bed material is to be maintained.

ASH REMOVAL:

The ash should be drained from all collection points. Failure to remove the ash will result
in choking of flue gas path.
BOILER TRIPPING DUE TO POWER CUT:

In case of boiler tripping due to power cut or for any other reason, immediately close
the inlet dampers of the FD fan and ID fan. In the event of power availability and if the
boiler is required to be started immediately switch on the fans. Establish the MCR air flow
and start fuel feeding. Otherwise if the boiler is to be boxed up, close the main steam
stop valve. Close the compartment dampers also. The boiler can be restarted as
explained in the further chapters. (Write up on hot restart).

INGRESS OF FOREIGN MATTER IN FUEL:

Ingress of cotton waste, waste cloth, coconut shell, mango seed etc., will block the fuel
flow from the chute into the feeder. This is indicated by the drop in bed temperature
(provided the feed rate of the feeder is not increased).

The above mentioned problems can be eliminated if a screen is provided in the fuel
handling system. Feeder tripping due to foreign material is a great nuisance and at times
it may lead to boiler shut down. In case of coal, it becomes necessary to provide a
magnetic separator to separate out the tramp iron from the coal. This not only protects
the crusher, but also prevents to damage to the feeder.At times it may so happen that the
foreign matter may block the fuel transport line. When there is no airflow in the fuel
transport line, the bed material from the bed enters the fuel feed nozzle and leads to
choking of the line. The choking should be removed by slumping the bed and by opening
the drain gates. Also the foreign matter should be removed from the mixing nozzle
opening the plug of the mixing nozzle.
NORMAL OPERATING PARAMETERS (STABILISED CONDITION)

Air box pressure :

(Drain the bed if the pressure is high) :

Fluidising air flow :

Primary air header pressure :

Bed temperature :

Feeder rpm / vibratory feeder setting :

Furnace gas plenum pressure :

Blowdown every : hrs.

NORMAL SHUT DOWN TO COLD
06. NORMAL SHUT DOWN TO COLD:

Reduce the fuel feed rate and slow the feeders to empty before stopping them. Maintain
the same air flow to cool bed faster. If the steam is not drawn from the boiler, open the
airvent to reduce pressure. If it is not necessary to enter the boiler for maintenance,
slow rate of pressure and temperature decay is desirable switch off the fans after the
bed has cooled down to 500°C. Switching off the fans should be in the order of FD and
ID fans. If it is desirable to accelerate the cooling process in order to permit entry into the
unit for maintenance, the fans could be continued to run at the same flow rate until
temperature reaches 100°C. During the process maintain normal water level in the boiler.
After the bed temperature reached 100°C open the blowdown valve and drain the
boiler. (The boiler water temperature must be reduced atleast 90°C before draining).
Drain the bed material. This can be done by opening the gates below the drain points
collect this bed material, sieve and reuse for subsequent light ups.
NORMAL SHUT DOWN TO HOT STANDBY
07. NORMAL SHUT DOWN TO HOT STAND BY

If the boiler has to be shut for a relatively short period (minimum of 2 hours) follow the
procedure given below.

01. Switch of the fuel feeder, FD, PA & ID fans instantaneously. The PA line dampers
and fluidising air dampers need not be closed. But FD & ID fans dampers must be
closed.

02. Do not reduce the boiler pressure in line with unit load reduction. When the
desired pressure at which the boiler is to be held is reached after the boiler is off
the line, the boiler may be up by closing the main steam valve.

03. Keep the water level in sight in the gauge glass and add make up rate as
required.
HOT RESTART
08. HOT RESTART

After a shut down for a brief period, follow the steps given below to re-start the unit.

01. Open the air vent. Check fluidising air damper and PA damper are "OPEN".

02. Keeping the ID and FD fan dampers in the closed position.

03. Start ID, FD and PA fans in quick succession.

04. Start the fuel feeders with minimum speed.

05. Gradually open ID and FD fan dampers to maintain air flow D.P. of 30 mm and
gas plenum pressure of 10 mm.

06. Increase the speed of fuel feeders and watch the bed temperature.

07. If the bed temperature is slowly increasing then increase fuel feed and air flow in
line with load requirement.

08. If the bed temperature is not increasing, stop the fuel feeders.

09. If the bed temperature is below 600°C throw charcoal through access door, till
temperature reaches 600°C. This has to be carefully done. This may be required
if more than one hour has lapsed after shutting down.

10. If the bed temperature is less than 300°C, cool the bed and start the boiler
following "normal startup from cold" procedure.
 PROCEDURE FOR
HYDROSTATIC TESTING
 PROCEDURE FOR HYDROSTATIC TESTING

The system components have been hydrostatically tested to (1-1/2) times the design
pressure in the factory. However, the complete system, along with all interconnecting
piping should be hydrostatically tested before start-up to comply with code
requirements and to check for leaks that might have resulted during shipping and
handling. The boiler and process lines must be completely vented in order to fill them
with water.

The following is a recommended procedure for hydrostatic testing:

1. Open the steam drum vent valve and close steam outlet valve.

2. The boiler safety valve stubs are plugged with end plates and sent as a dummied
stub. Hence this end plate have to be cut and removed after hydrotest and the
safety valves are to be buttwelded.

3. For subsequent hydro test if any and for every annual hydro testing gag the safety
valves in accordance with safety valve manufacturer's recommendations. In lieu of
gagging, the safety valves may be removed and replaced with test plugs or blind
plates.

4. Isolate pressure switches, gauge glasses or control components which are

not intended to be subjected to a hydrostatic test.

5. Fill the system with treated water in accordance with recommended CVPL's water
quality. The temperature of water used shall not be less than 20°C and greater than
50°C.

6. Once the system is filled and the pressure is approximately 1 kg/cm², close all vents.
The pressure may then be increased gradually to the test pressure requirement of
the local steam boiler inspecting agency. Do not subject any pressure part to more
than 1-1/2 times the design pressure rating of the component.
7. Examine the system for any leaks. If no leaks are visible, hold the system in a
pressurised static condition for a period of 1/2 hour to satisfy the code requirements.

8. After that the pressure shall be reduced to maximum allowable working pressure
and maintained for sufficient time to permit close visual inspection for leakage of
pressure parts.

9. Upon completion of the test, release pressure slowly through a small drain valve.
Then fully open the vents and drains when the pressure drops to 1 Kg/cm2(g).
Particular care must be given to make sure that parts not normally containing water
during operation are drained free of water. The system should be drained fully after
hydrostatic testing to prevent freezing, if the unit is installed in a cold weather area,
and to minimize corrosion of the metal surfaces.

10. If temporary handhole or manhole gaskets were used for the test, they should be
replaced with regular service gaskets before reading the unit for operation. Gaskets
should never be reused. Replace gauge glass if necessary and make sure that the
gauge cocks are open. Remove all blanks or gags from safety valves and install
safety valves, if removed.
PROCEDURE FOR SLOW FIRING
 PROCEDURE FOR SLOW FIRING

REFRACTORY DRY OUT:

After the refractory works are finished, the refractory work must be subjected to proper
curing and initial heating. These two procedures must be strictly carried out. Otherwise,
cracks may occur on the refractory surface. These procedures are explained below.

CURING FOR CASTABLE REFRACTORY:

All the castable are hydraulic setting and need the presence of moisture for setting
process, so it is necessary to ensure that the castable does not dry out to exposure or
due to heat produced within the mass. It should not be allowed to dry during first 24
hours after it has been placed.

Moist condition has to be maintained by covering the castable with wet gunny sacks
or by frequent sprinkling of fine mist of cold water on all exposed surfaces. Sprinkling
should be started after the castable has set partially. It is generally advisable to spray
water on dense castables every 45 minutes for hours.

INITIAL HEATING FOR CASTABLE REFRACTORY:

Proper attention should be given during initial heat up of castables, as they have
considerably lower permeability when compared to brick. It is more difficult for the
water to passthrough the castable and escape as the refractory is heated more rapidly.
So due to this, high pressure steam is developed inside the brick and this ruptures the
lining.

Rapid heating also causes the hot face to dry up and heat up while the rest of castables
is still comparatively cool. This will lead to expansion of hot face and hence develops a
crack on cold face.
SLOW FIRING PROCEDURE :

Following are to be done before slow firing is started:

a) All the coal nozzles and air nozzles must be fully covered with bed materials.

b) No fans should be operated for the heating purpose. Firing should be done only by
natural draught. For this all dampers should be kept open.

c) Sufficient sized fire wood required has to be stocked for the dry out.

The following heat and curing schedule is recommended:

01. Heat gradually up to 110°C and hold at this temperature for six hours.

02. Then raise the temperature at the rate of 10°C per hour up to 550°C and hold at
this temperature for six hours.

03. After this, the furnace can be cooled naturally.

Slow firing can be done by burning sized waste wood in the furnace on the bed
material. The fuel required shall be computed as if the boiler would be operated
to generate 20% MCR load. The sized wood can be fed in the furnace through
the manhole.
PROCEDURE FOR ALKALI BOILOUT
 PROCEDURE FOR ALKALI BOILOUT

1. Check boiler erection work is completed with all assemblies, valves, fittings and
necessary instrumentation.

2. Boiler auxiliaries such as fans, feed pumps should have been trial run and made
ready for operation.

3. Check boiler instrumentation and control panel are ready for regular operation. But
the following instruments are to be isolated for alkali boilout.

I) Flow, pressure and level transmitters.

ii) Pressure switches.

4. Ensure steam drum internals have been fixed in position.

5. Check all the refractory and insulation work are completed.

6. Check all scaffolding, temporary supports, debris are cleared.

7. Ensure slow firing is done as per the slow firing procedure.

8. Check suitable fire fighting equipments such as Co2 or foam type fire
extinguishers, sand buckets, etc, are available at suitable convenient places.

9. Check boiler chemical feeding system is ready for operation.

10. Check sufficient quantity of chemicals are available. Based on the water
volume of the boiler the chemicals required can be estimated. If water volume of
the boiler is Q M^3 each chemicals required will be 4 x Q kgs. The same quantity of
chemicals will be required for each boil out.

11. For alkali boilout sodium carbonate and trisodium phosphate are used.
12. Prepare 20% concentrated solution of the chemicals separately in a
drum and the solution is charged in to the boiler through the nozzles (either
auxiliary steam top nozzle or Air vent nozzle) in to the shell/drum manually by
means of funnel.

13. After the addition of chemicals in to the required quantity, the nozzles are covered
with the cover flange and fill up water to the normal operating level.

14. Light up the boiler and raise the steam pressure is gradually to 5 ata as per
standard operating procedure and maintain the pressure for minimum period of 12
hours.

15. Tighten all glands and flange joints.

16. Raise the firing rate to achieve a boiler loading of nearly of the normal loading rate
of the boiler.

17. Samples to be taken every two hours and analysis is to be carried to determine
the following:

a) Ph value
b) Alkalinity
c) Phosphate
d) Oil
e) Silica

18. Ensure the pre-commissioning activities are carried out as per the commissioning
check list.

19. Ensure the alkali Boilout is carried out in 3 stages and fresh chemicals are
changed before each stage.
20. Ensure the pressure is maintained in the boiler for each stage alkali boilout as
follows:

DURATION

I stage - 5 kg/cm sq. - 12 hours.

II stage - 7 kg/cm sq. - 12 hours.

III stage - 10 kg/cm sq. - 12 hours.

(Ensure the pressure of the boiler is raised gradually for alkali boilout).

21. Each stage of boiling can be terminated when the content of oil in the boiler
water maintains a steady value. However final reading of oil should be less than 5
ppm.

22. After termination of boilout procedure, shut down the boiler and allow the unit to
cool down gradually.

23. Drain the boiler after the drum pressure reaches atmospheric pressure. Water jets
shall be used to clean the headers.

24. After complete draining of boiler, clean the complete unit by filling the water and
drain it for atleast one time.

The handhole pipes of all headers preferably at bottom most point to be cut and
inspected for any foreign materials availability and to be cleaned.

25. After inspection and cleaning reweld the end caps and hydro test the boiler to
working pressure.

26. Now the boiler is ready for steam blowing.

PROCEDURE FOR STEAM BLOWING
 PROCEDURE FOR STEAM BLOWING

STEAM BLOWING

Steam blowing is an established practice for the purpose of physically removing any
substance which remain deposited in the superheater and associated pipe lines. These
substances are mainly scales and loose minerals that might have been entrapped
during manufacture, storage and erection at site.

PRINCIPLE

The principle of steam blowing is to give thermal shock and dislodge the scales.
These scales will be subsequently driven out by the dynamic velocity of the expanding
steam. Before starting the boiler for steam blowing the following points are to be
ensured:

1. Alkali boilout is completed.

2. All the instruments calibration are completed and safety interlocks are in line, except
water level interlock which is to be isolated temporarily.

3. NRV and flow nozzle should not be fitted initially and thermowell in steam line is to
be removed.

4. All the spring hangers in steam line are loaded properly.

5. Temporary steam line is erected and anchored properly for steam blowing.

6. Target plate fixing arrangement to be kept ready.

7. Required target plates are to be machined and kept ready to fix when required.
Target plates shall be of aluminium material.
PROCEDURE :

The method of steam blowing is as below :

1. Operate with one compartment and raise the boiler pressure above 35 kg/cm^2. The
bed temperature shall be maintained at about 800-950°C.

2. Quickly open the main steam stop valve (or the temporary blowing valves if
provided). In order to maintain the flow to atmosphere the main steam stop valve is to
be kept open till the steam pressure drops down close to 16 kg/cm².

3. Slowly reduce the firing rate and slump the boiler. The main steam stop valve
shall be closed when the boiler pressure reaches 16 kg/cm²
.
4. After one hour, the boiler shall be restarted with one compartment and the bed
temperature shall be maintained at about 800 - 950°C'.

The steam blowing shall be once again started when the pressure reaches 35
kg/cm². By the above procedure, the scale adhering to the contours get cracked
due to temperature difference and get removed to subsequent blows.

* SCHEME OF BLOWING

Temporary discharge piping which lead the steam to the atmosphere shall be welded
downstream of main steam line must be properly supported and anchored.

OPERATIONAL PRECAUTIONS

1. Normally the steam blowing operation is the first occasion to fire the unit at
significant rate. The unit must be brought up much slower while all equipments are
checked and expansion movements are monitored closely.
2. During blowing, water level in drum gauge glass may fluctuate very widely.
Feed regulating station must be checked for proper remote operation. Sufficient
quantity of D.M water availability muse be ensured.

3. Flue gas temperature at the inlet of convection superheater must be restricted to

450°C.

4. Temporary discharge piping which should be atleast equal to the diameter of piping to
which it is connected must be well supported to withstand reaction forces during steam
blowing.

5. Discharge piping should be so diverted that personnel and equipments are not
endangered. The area should be cordoned off.

6. After three free blows, target plate can be fixed.

7. Based on target plate condition as recommended by the turbine supplier blow can
be continued or terminated.

8. During blowing sufficient time duration should be given between blows to attain
better thermal shock to discharge the scale and other deposits in pressure parts and
steam line.

9. After clearing the steam blowing, boiler to be stopped and steam line to be cooled
to complete the welding of NRV and flow nozzle and thermowell fixing in main steam
line.

10. Temporary steam line to be removed and permanent line to be connected with TG.

11. After completion of the job, the boiler is ready for safety valve floating.
OPERATION ON LOW LOADS
 OPERATION ON LOW LOADS

The boiler should not be operated at low loads continuously for long time. If the boiler

is run continuously at low loads (<60% MCR load) then due to low quantity of steam

flow through the super heater, the super heater tubes may fail. To protect the super

heater tube from failure, the boiler should be run at higher loads (>60% load) only and

the excess steam over the utilised steam shall be vented continuously through start-up

vent.
TROUBLE SHOOTING CHART
 TROUBLE SHOOTING CHART
DURING START UP

Sl.NO. TROUBLE CAUSES REMEDY

01. Start up failures. Improper Bed material size. Bed material size has to be between 0.85 mm and 2.36 mm.

Improper charcoal size. Charcoal size should be 15-25 mm.

Poor Quality of charcoal. Charcoal shall be dry for good quality.

Insufficient Qty. of charcoal. Qty. of charcoal shall be 20 kg. per m2 area of bed and kerosene
soaked charcoal shall be 10 kg. per m2 area of bed.

Insufficient bed height. Bed height should be 200 mm above the air nozzle.

Excess bed height. Bed height should be 200 mm above the air nozzle.

Improper spreading of charcoal. Uniform spreading of charcoal shall be ensured.

Improper spreading of fire over the Swab fire initiated should be even. If not throw kerosene soaked
top layer of kerosene soaked charcoal at such locations where fire is not present.
charcoal.

Wrong bed temperature indication. Thermocouples are to be checked using swab fire before starting

Improper mixing. Mixing should be done with the predetermined air flow level
(Just above MFC level)
Sl.NO. TROUBLE CAUSES REMEDY

Improper fuel feeding. Fuel is to be fed only after the bed temperature reaches 600°C.

P.A. Line choking. Minimum airflow in fuel transport line is to be maintained till the
start of fuel feed. Before fuel feed, increase airflow to MCR air flow
Dechoking of the lines is possible by opening the line flap damper
fully and by opening the corresponding drain gates in the airbox.

02. Clinker formation High bed temperature over the entire Charcoal Quantity shall be as per recommendations.
during start up bed. This is due to excess charcoal
over the entire (or) due to excess fuel feed before High bed temperature can be reduced by controlling fuel feed and
bed. charcoal combustion is complete. by increasing the air flow.
(or) incomplete mixing.
Give the required mixing air flow.

Warning: Air flow should be slightly more than MCR level.

Otherwise all hot material would go to the adjacent compartment.

Low fluidisation velocity after mixing. Air flow level can be increased. (MCR air flow level)

Wrong temperature indication. Checking the thermocouple with swab fire before starting.

Excess fuel feeding. Fuel feeding should be gradually increased after ensuring that the
fuel is catching fire.

03. Localised Clinker Localised vigorous static burning of Before mixing clinkers may form due to delay in mixing.
Formation charcoal before and after mixing :
After mixing, clinkers form due to inadequate mixing (i.e. less mixing
air flow or less duration of mixing)
After proper mixing, clinkers may form if the air flow is not brought to
MCR level.
Sl.NO. TROUBLE CAUSES REMEDY

DURING COMPARTMENTAL TRANSFER (FROM COLD CONDITION)

01. Fire extinguishing Improper method of activation. The bed temperature of operating compartment drops because of
in operating cold bed material in activated compartment mixing with hot bed
compartments. material of operating compartment.

Attempting for compartment Slump the activated compartment as soon as the bed temperature
transfer in one to two trials. in operating compartment drops below 750°C. Further attempt
should be made only after bringing the bed temperature of the
operating compartment to 900°C with 120% MCR air flow.

02. Clinker formation Insufficient air flow. After compartmental transfer, the air flow should be once again
in Operation brought to MCR condition in operating compartment.
compartment.
Excess fuel feed. After tranferning, the fuel feed rate in operating compartment needs
to be reduced.

03. Bed temperature a. Inadequate air flow for disturbing Increase the airflow momentarily if the fan capacity is available and
not rising in the cold bed material. provided the bed temperature in operating compartment is not low.
activated
compartment. Alternatively, momentarily close the FD damper of the operating
compartment.

Long operation with single compartment results in excess bed

material ash accumulation in the compartment adjacent to the
operating comparment. Drain the bed if necessary.
Sl.NO. TROUBLE CAUSES REMEDY

04. Clinker formation Insufficient air flow static bed This can be avoided by maintaining the bed fluidising before fuel
in activated promotes vigorous burning of fuel at feed. To disturb the clinker formation momentary mixing may be
compartment. several locations and thus clinkers adopted at times.
form.

Excess fuel feed before the bed Fuel should not be fed before bed temperature rises to fuel ignition
temperature rises to fuel ignition temperature (600°C for coal; 300°C for husk) . Sudden bed
temperature. Otherwise, fuel temperature rise could be controlled by increasing the air flow or by
accumulated leads to sudden bed activating the adjacent cold compartment.
temperature rise.

05. Bed temperature Excess fuel feeding when the bed Fuel feeding should be gradually increased, when bed temperature
dropping in temperature around 600°C is 500° - 600°C.
activated quenches the fire.
compartment.
Operating at less air flow condition Air flow should be sufficient. MCR air flow is required.
leads to CO formation and less heat
release and thus bed temperature
remains low.

06. PA line choking

Failure to set fuel transport air flow Minimum air heater pressure of 700 mmwc is required to be set to
before attempting activation. prevent PA line choking. The header pressure should be increased
to MCR condition before fuel feed.
DURING CONTINUOUS OPERATION
01. Bed temperature Insufficient fuel feed rate. Sufficient fuel feed rate is required.
dropping.
Excess fuel Sufficient fuel feed rate is required.

Excess air flow. Sufficient air flow is required (MCR air flow)
Sl.NO. TROUBLE CAUSES REMEDY

Fuel line choking.

- Due to wetness of fuel. Wet fuel should be avoided.

- Due to entry of foreign materials. To avoid the entry of foreign materials a vibratory screen (or)
magnetic separator can be provided in the fuel handling system.

Fuel not being fed from feeder.

- Due to high moisture in the fuel, To avoid this, high moisture fuel should not be used.
fuel would adhere in the pocket
feeders blade, so no fuel would be
fed.

Excess bed height causes less Bed should be drained once in every shift. (Maintain air box
fluidisation. pressure below 425 mm of wc).

Thermocouple is in loose contact. Thermocouple to be corrected.

Bed height is less than 175 mm. Bed height should be increased.

02. High bed More fuel feed rate. Fuel feed rate has to be reduced.
temperature.
Less air flow. Air flow has to be increased slightly (upto MCR air flow level)

Excess feeding of fuel from feeder. Rotor requires replacement.

One of the causes may be, broken
pocket feeder blades. Due to this
more fuel would be fed.
Sl.NO. TROUBLE CAUSES REMEDY

03. Clinker High bed temperature due to excess Decreasing the fuel feed rate (or) air flow may be slightly increased.
formation. fuel feeding.

Low fluidisation velocity. Air flow can be slightly increased.

- leads to static burning at places.

Bigger size fuel. Bigger size fuel could be avoided. So correct size fuel could be used
(Below 6 mm).

Bigger size fuel would burn partially.

So partially burnt fuel would settle in
the bed. Sometimes bed
temperature would shootup
suddenly. This may cause clinker
formation.

Bed draining not done - due to this To avoid this bed should be drained once for every shift. (Maintain
bed height would increase. So, there air box pressure below 425 mm of wc).
would be defluidisation.

Erratic disturbance in fuel feeding. Erentual disturbance fuel feed leads to reduction in bed temperature
- may be due to foreign particles, and thus velocity and the fuel feed is restored if be necessary to
tripping the feeder or choking the increase the air flow momentarily.
mixing nozzle.
Sl.NO. TROUBLE CAUSES REMEDY

04. PA line choking. Foreign material choking the mixing This can be avoided by providing vibratory screen or magnetic
nozzle. seperator in fuel handling system.

05. Backflow of air Fuel line choking due to one of the Choking is to be removed..
thro’ bunker gate. above causes.

06. Back firing. ID fan damper has been opened ID fan damper has to be slightly opened. (maintain furnace pressure
sufficiently. of minimum - 10 mm of wc).

Insufficient air pressure to lift power Sufficient air pressure is to be supplied (pressure 3.5 to 5 kg/cm2 for
cylinder. power cylinder action).

Ash accumulation in hoppers above Ash should be removed periodically.

various drain points.
- This would reduce ID fan suction.

07. Steam production Improper parameters. Proper parameters should be followed.

is less.
DO'S AND DONT'S
 DO’S AND DONT’S

Sl.NO. DO’S DONT’S

01. ECONOMISER Run the boiler with continuous running of the feed Don’t run the boiler with frequent switching ON
pump. & OFF of the feed pump.

02. FEED PUMP Keep the isolation valves at spare feed pump ----
open.

03. LEVEL TRANSMITTER Blow down should be given once, daily for level Don’t stat the boiler, if the liquid level limitter is
transmitter lines. not functioning for high level, low level and trip
level.

04. WATER LEVEL GAUGE Give frequent blow downs of water level gauge to Don’t run the boiler, if the water level gauges
free from blockages at both top and bottom are not showing the same water level.
points.

05. FUEL OVER SIZE Allow 10% of 8 - 10 mm size fuel. Don’t start the boiler if the fuel size is more
than 6 mm ( 8 - 10 mm, over size upto 10%
accepted ).

06. ASH DRAIN POINT During boiler operation check whether there is Don’t open the ash drain gates frequently.
(other than bed drain suction in all the ash drain points.
points)

07. FEED WATER & Analyse the feed water and boiler water daily. Don’t run the boiler if the water quality is not as
BOILER WATER per the specifications given in the manual.
Sl.NO. DO’S DONT’S

08. RELAY SETTING Set the relay in full load amps of the motor. Don’t start the fans before setting the relay
(MOTORS) amps.

09. GAS PLENUM Maintain the gas plenum pressure at minus 5 --------
PRESSURE mmwc.

10. THREE PHASE SUPPLY Check the continuity of fuses. Don’t bypass the fuses with direct wire
connection.

11. CONTINUOUS BACK Ensure that ash chutes and ducts are clean from Don’t run the boiler with continuous back fire.
FIRE ash accumulation.

12. PART LOAD BOILER Change the compartments every shift. Do not run a particular compartment alone
OPERATION continuousl.
INSPECTION AND MAINTENANCE
SCHEDULE
 INSPECTION AND MAINTENANCE SCHEDULE
EQUIPMENT NO. POINTS TO BE CHECKED FREQUENCY REMARKS
FD SYSTEM

FD fans & Motors 1. Check whether motor bearing temperature is Daily One set of motor bearings is to be
normal. kept as spare.

2. Check whether the motor current is normal. Daily (For coupled fans, one set of fan
bearings is to be kept as spare)
3. Check whether the vibration level and sound level is Daily
normal.

Airfoil meter 1. Ensure that the draught connections are not leaky. Weekly.

2. Ensure that the manometer water is clean. Weekly.

Air box draft / mano 1. Ensure that the draft connections are not leaky. Weekly.
meter / Draft gauge
2. Ensure that the manometer water is clean if a Weekly.
manomer is provided.

Air box 1. Ensure that all the nozzles are in good condition. At every shut 50 nozzles are to be maintained
down. as spare.

2. Ensure that the nozzles are free from plugging by At every shut Use compressed air for cleaning.
coal powder. down.

3. Ensure that the nozzles are free from plugging by If furnace Use compressed air for cleaning.
refractory. refractory work
was done.
 EQUIPMENT NO. POINTS TO BE CHECKED FREQUENCY REMARKS

4. Clear the sieved bed material from each Once in three

compartment in the air box. months/in case
of air nozzle
breakage.
ID SYSTEM

ID fan & Motor 1. Check the bearing temperature of the fan and Daily One set of motor and fan bearings
motor is to be maintained as spare.

2. Check whether the motor current is normal. Daily

3. Check whether the vibration and sound level is Daily.

normal.

ID fan impeller 1. Check for erosion / damage. Once in six Keep a spare ID fan impeller
months. expected life 1 year.

PA SYSTEM

PA fan & Motor 1. Check motor bearing temperature. Daily One set of motor and fan bearings
are to be maintained as spare.
2. Check whether the motor current is normal. Daily

3. Check whether the vibration level and sound level Daily.

is normal.

Fuel feed nozzle 1. Inspect the fuel nozzle cap for any damage. Everyshutdown Keep 4 nos. of fuel nozzles as
spare for replacement.
2. Inspect the supporting lugs of coal nozzle cap. Everyshutdown
 EQUIPMENT NO. POINTS TO BE CHECKED FREQUENCY REMARKS
FUEL FEEDING SYSTEM
Feeders & Drive 1. Check the any damage in the feeder due to foreign Weekly
material.

2. Chain lubrication. Weekly

3. Gear box Lubrication oil level. Weekly

4. Change gear box oil, on contamination. Weekly

FEED WATER SYSTEM

Feed pumps 1. Check the operation of spare pump. Daily Refer O & M Manual.

2. Replace the gland packing. If leaking. Keep spare gland packings.

3. Check for abnormal vibration and sound. Daily Keep spare gland packings.

4. Check for suction strainer choking. Daily

Feed water 1. Check for Hardness, pH, O2, oil content and TDS in Daily Compare with recommendation
feed water. given and take corrective
measures.
FURNACE
Bed thermocouple. 1. Ensure that all the thermocouple compensating When 40 m length of compensating
cables are in good condition and the end thermocouple cable is to be kept as spare.
connections are not loose. shows above
1200°C.

2. Replace the thermocouple if burnt. During the Keep 4 nos. of spare bed
immediate thermocouples at stock.
next shut down
 EQUIPMENT NO. POINTS TO BE CHECKED FREQUENCY REMARKS
Refractory wall 1. Repair the cracks in the refractory wall. During the Keep required castable refractory
immediate and binding mortar in stock.
next shut
down.
Water level gauge 1. Check the water level gauge function by giving a Keep spare glasses and washers
blowdown. Every shift. for both water level gauges.
BOILER SYSTEM
Boiler water 1. Check Alkalinity, pH, Residual SO4 residual Every shift Compare with recommendation
phosphate and TDS. given and take corrective actions.

2. Follow blowdown schedule to bring TDS to limits. Every shift

1. Blow the steam through safety valve by hand Every one

Safety valves popping with the lever to avoid seat seizure. month
ASH REMOVAL SYSTEM
Ash hoppers 1. Ensure that ash is being removed and ash flows out Every shift.
freely.

Bed coil headers. 1. Inspect and remove sludge accumulation in the bed Every year.
coil header.

Blowdown the water through header drain valve At every shut

after the fire is put off, but with the boiler under a down.
pressure of min. 5 kg/cm2.

Valves in feed water, 1. Inspect for gland leakages and tighten the gland Weekly.
boiler water systems, nuts.
steam line
2. Replace the gland packings. Every year / on
major leakage
PRESERVATION OF BOILERS
 PRESERVATION OF BOILERS

INTRODUCTION

Atmospheric corrosion of ferric materials proceeds rapidly in the presence of oxygen and
moisture. The oxides produced are objectionable and can be transported to critical heat
transfer areas. Also, through the wall, pit type corrosion can occur. In today’s boilers
with their numerous complex circuits and bends, it is usually impossible to completely dry
a boiler in preparation for storage. Draining all circuits (if drainable) while hot may
temporarily dry the surfaces; however, unless dry air can be continuously circulated
to eliminate all the water vapour from the unit, recondensation will again result in moist
conditions. For this reason, wet lay-up normally offers the most positive method of
protection for components in modern boilers.

LAY-UP METHOD

This method employs filling up the boiler with treated water and keeping the unit
pressurized to 5 Kg /cm²(g) feed pump may be used for this purpose. Water
conforming to recommended specification furnished in earlier section, is to be used
for filling.

However, a better method of preserving of boiler would be to have nitrogen blanketting.

In this method the boiler is filled with water treated for pH and O2 and sealed with
nitrogen at a pressure of 0.35 atg to avoid air ingress.

Figure shows the general arrangement of the rig up required for nitrogen blanketting.
Nitrogen cylinders can be employed for this purpose. The nitrogen supply can be
connected to the drum vent and superheater vent.

WET METHOD

If the boiler is likely to be out of service for more than a few days, but may be needed for
steaming at short notice, all parts, including the economizer and superheater should be
completely filled with correctly conditioned water. Non-drainable superheaters should be
filled only with condensate quality water treated with volatile chemicals such as hydrazine
or ammonia. It is most important that pockets of air are not allowed to remain in the
boiler and that there should be no leakage.

When completely filling the boiler with water, sufficient sodium sulphite or hydrazine
should be added to combine with the dissolved oxygen and leave an excess of 100
mg/ 1 to 200 mg/1 of sodium sulphite as Na2 SO3 or hydrazine as N2H4. In addition,
alkali should be added to ensure that a pH value of 10.0 to 11.5 is maintained.
Distribution of these chemicals throughout the bulk of the water should be ensured
by filling with a premixed solution, by use of a circulating pump or by heating the
boiler when partially filled and then topping up with conditioned water.

It is recommended that the aircock on the drum or shell should be connected to a

surge tank located at a higher level. This compensates for any volumetric change
and ensures a positive pressure thus preventing admission of oxygen to the unit. This
tank should be covered and kept dosed with oxygen scavenger and alkali. Alternatively,
pressure on the system should be maintained by using a small pump.

The oxygen scavenger reserve and the pH value or alkalinity should be checked regularly
and additional treatment chemicals added, as necessary and distributed to maintain
the treatment levels within the recommended range. Any additional water added to
the boiler should contain the appropriate quantities of treatment chemicals.

When required for service the boiler should be drained down to normal working
level before firing. Phosphate or other conditioning reserves should be re-established
as soon as possible.

This method of storage is recommended only if there is no likelihood of frost damage

occuring. Wet storage is not recommended for periods of longer than 2 or 3 months
unless the treated water is circulated regularly in all parts of the boiler including the
economizer and superheater. Wet storage tends to promote condensation of
atmosphere moisture and hence corrosion in the flue gas side. Where this proves
trouble some dry storage is to be preferred.
CHEMICAL REQUIREMENT
 CHEMICAL REQUIREMENT & SPECIFICATION

FOR LP DOSING SYSTEM:

NAME HYDRAZINE

FORMULAE N2H4

COLOR & CRYSTALLINE FORM WHITE, LIQUID

SPECIFIC GRAVITY AT 15°C 1.011

MIN. QUANTITY TO BE STOCKED 3 Kgs / MONTH

(HYDRAZINE SHOULD BE DILUTED TO 60% CONCENTRATION)

FOR ALKALI BOILOUT:

NAME TRI-SODIUM PHOSPHATE SODIUM CARBONATE

FORMULAE Na3PO4 Na2CO3

COLOR & CRYSTALLINE FORM WHITE, POWDER WHITE, POWDER

SPECIFIC GRAVITY AT 17.5°C 2.537 2.533

SOLUBILITY IN 100 PARTS

OF COLD WATER 0°C 4.5 7.1

OF HOT WATER 100°C 77 48.5

QUANTITY 155 Kgs / BOILOUT 155 Kgs / BOILOUT

NO. OF BOILOUT 3 3

NOTE:

THE ABOVE QUANTITY IS TENTATIVE ONLY AND THE SAME SHOULD BE CHECKED AND

ADJUSTED DURING BOILER OPERATION.

IN THE ABOVE QUANTITY INITIAL FILLING IS NOT CONSIDERED, REQUIREMENT FOR THE

SAME IS AS FOLLOWS.

I) HYDRAZINE - 0.25 Kgs.

SCHEDULES
VALVES
LUBRICATION
 LUBRICATION SCHEDULE

BRAND NAME / SPECIFICATION INITIAL FIRST SUBSEQUENT

SL. ITEM MAKE ITEM PARTS PARTS TYPE OF OF LUBRICANT FILLING FILLING FILLING
No. DESCRIPTION QTY. TO BE QTY. LUBRICANT QUANTITY (RUNNING (RUNNING
(Nos) LUBRICATED (Nos) IOCL MAKE HP MAKE (PER ITEM) HOURS) HOURS)

01. FD FAN CVL 1 BEARING 2 GREASE SERVOGEM EP-2 --- 0.51 Kg. 1300 1300

02. ID FAN CVL 1 BEARING 2 GREASE SERVOGEM EP-2 --- 0.50 Kg. 1500 1500

03. PA FAN CVL 1 BEARING 2 GREASE SERVOGEM EP-2 --- 0.30 Kg. 1500 1500
SERVOPRIME-46
04. FEED PUMP GRUNDFOS 2 BEARING 3 OIL ENKLO 46 1.4 Ltrs. 300 8000
(OR)
SERVOSYSTEM-46

05 LP DOSING SWELORE 2 GEAR UNIT 1 OIL SERVO-320 ENKLO-320 0.5 Ltr. 500 2000

PUMP BEARING 2 GREASE SERVOGEM-2 LITHON-2 0.3 Kg. 200 6 MONTHS

06. GEAR BOX ELECON 6 GEAR UNIT 6 OIL SERVOMESH- ENKLO-320 1.5 Ltrs. 250 3000

SP320

07. GEARED IC-BAUER 6 GEAR UNIT 6 OIL SERVOMESH- ENKLO-320 2.7 Ltr. 10,000 2 TO 3

MOTOR SP320 YEARS

BEARING 6 GREASE SERVOGEM-2 LITHON 2 0.3 Kg. 150 ONCE IN A

WEEK

08. MOTORS CROMPTON 14 BEARING 2 GREASE SERVOGEM - 2 LITHON 2 0.2 Kg. 300 1200

IOCL -- INDIAN OIL CORPORATION LTD. HP - HINDUSTAN PETROLEUM