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Answer : a-(ii),b-(iv),c(iii),d(iii),e(ii),f(iv),g(iv),h(i),i(ii)&j(iv).

Q.1(B) : Explain in brief importance of the following terms :---

(a) Sugar test in boiler water.
(b) Mounting and Accessories related to boiler.
© ‘U’ seal for thermal deaerator.
(d) Boiler steam test.
(e) Flue gas analysis.

Answer :
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(a) Sugar test in boiler water.
A small amount of sugar in condensate(boiler feed water) can damage boilers. At
temperatures sugar breaks down into acids, causing foam, corrosion and deposit(scale)
inside the boiler tubes. This damages the boiler and its accessories considerably. In
serious cases, the boiler must be shut down for corrective action.
Inline instruments such as conductivity meter or flame photometer are installed in the
feed water line and can detect even a trace of sugar in the boiler’s feed water. Boiler
feed water is tested for sugar in the laboratory hourly, and even more frequently when a
trace of sugar is detected. Even with the best prevention measures, sugar does
sometimes get into feed water. When sugar is in the condensate , small doses of caustic
soda can be added into the feed water to neutralized its acidity.

Sugar usually get to condensate because of the following reasons:---

1. Leak in heating tubes.
2. High juice level in evaporators.
3. Aggressive boiling in evaporators.
4. Foaming in evaporators.

(b) Mounting and Accessories related to boiler.

© ‘U’ seal for thermal deaerator :---

U seal in thermal deaerator is the provision which is given into the deaerator to hold/
sustain the pressure during pressurized condition. It is just a level of water column build
up through level filling by water into the thin tube. Up to the desired pressure in dearator
,its sustain and U loop seal to hold the deaerator pressure. Above the desired pressure
seal becoming break it means water thrown outside the seal. This kind of provision are
very reliable and safe for thermal deaerator. Most of the lower capacities of plant using
this kind of U seal.

(d) Boiler steam test :--

A newly registered boiler to issue renewal certificate steam test to be done in presence
of boiler inspector. At the time of test safety valve shall be left free and capable of being
adjusted to approval of working pressure. After the adjustment of valve to be corrected
blowing pressure the boiler shall be trial at full steam and firing with the feed water
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shutoff and the stop valve shall be closed, during which time the inspector shall be note
the accumulation of pressure and other details of the test as well as loading and
adjustment of safety valve. All the safety valve blow down to be about 5% of working
pressure.

A steam test is primarily intended for the purpose of ascertaining of actual test whether the
safety valve are sufficient to reliever boilers effectively of excess steam and whether they
operate at the time when maximum working pressure is reached. Inspector should always
send to owner due notice of the date fixed for the steam test.

(e) Flue gas analysis :----

Flue gas analysis is used both for efficiency and emissions purposes. The instruments
used for analysis can be inexpensive small hand-held devices that produce reasonable
accuracy, to larger permanently installed units that are capable of producing lab quality
results on a continuous basis. The type of flue gas analysis performed and the
equipment required will be determined by:

 is the primary need for efficiency, environmental regulation or both

 will analysis be spot-checked on a periodic basis or is continuous monitoring
required
 what gases/emissions must be monitored
 what accuracy is required

The combustion process inputs are fuel and air. Therefore, the components of flue gas
are primarily made up of compounds of oxygen, nitrogen, hydrogen and carbon. The
components that are of interest because they effect efficiency are primarily oxygen (O)
and carbon (C). The components that are of interest from an environmental perspective
are nitrous-oxides (NOx), carbon-dioxide (CO2), carbon-monoxide (CO) and sulfur-
dioxide (SO2) - if the fuel source is oil or coal.

Q.2(a) What are the advantages of forced circulation over natural circulation.

Answer :

Advantages of Forced circulation over natural circulation :----

1. Steam generation rate is higher for same physical dimensions and weight,
2. Greater capacity to meet load variation,
3. Quicker start-up from cold,
4. Lower scaling problem due to high circulation velocity,
5. More uniform heating of all parts reduces the danger of overheating and thermal
stresses
6. Smaller tube diameter and hence lighter tubes and
7. Greater freedom in arrangement of furnace, boiler component and tube layout.

Q.2(b) List out limitations of Bimetallic thermostatic steam traps and write steps
involved in steam trap management.

Answer :

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Limitations of Bimetallic-thermostatic steam traps :

• Although less susceptible than the inverted bucket trap, the float type trap can be
damaged by severe freezing and the body should be well lagged, and / or implemented
with a small supplementary thermostatic drain trap, if it is to be fitted in an exposed
position.
• As with all mechanical type traps, different internals are required to allow operation
over varying pressure ranges. Traps operating on higher differential pressures have
smaller orifices to balance the bouyancy of the float.

Steps involved in steam trap management.

Steam traps have play a very important role in steam distribution systems. The service
performed by steam traps is primarily to discharge condensate. Normally a steam trap
can be easily and quickly selected by considering only the average operating conditions.
However, an exact analysis of these conditions will give the proper data necessary for
selecting the type and size for greater savings and proper plant operation. After the
careful selection of the steam trap, it must be properly installed, tested, periodically
inspected, cleaned and maintained to keep it operating efficiently. Traps need cleaning
periodically. A simple way to prevent dirt from entering is to drop a short length of pipe
vertically below the supply to the trap (called a dirt leg) which can be cleaned easily and
frequently. Traps can be seriously damaged by scale or pipe comings in lines.
A good practice is to install strainers ahead of the traps which should be inspected and
cleaned frequently. Traps are subject to severe wear if steam blows through
continuously. They should be inspected for worn valve parts or a change in operating
conditions. When a steam trap fails to discharge, inspect the heating system and be
certain that all units are drained with separate traps, thus guarding against short
circuiting, loss of energy, and reduction of operating efficiency. Traps operating under
high pressure or superheated steam are often insulated in a manner similar to adjacent
pipe lines. In such instances, they shall be fitted with dirt pockets, test valves, and
drains. Steam traps installed in areas exposed to climatic conditions will lose heat if not
insulated and may freeze unless adequately protected. Discharge lines should be short
and self draining and traps should be fitted with a drain tapping and valves. Steam traps
handling large volumes of air require more frequent inspection and proper venting for
efficient operation. Vents shall be used to avoid air binding and ensure positive drainage.
Gauge glasses shall be kept in proper repair, for they indicate whether or not the trap is
working. Periodic cleaning and gauge glass replacement shall be considered as a high
priority in the maintenance of steam traps. All steam traps require protection from
corrosion to prevent unnecessary deterioration. All valves, joints, and gaskets should be
kept tight to avoid steam leakage and ultimate energy losses.
For continuous and efficient operation. steam traps require periodic inspection and
maintenance for purposes of eliminating foreign matter and obstructions in supply and
discharge lines. Each steam trap at an assigned work station should be inspected as
specified by the preventive maintenance program.

Q.2© What is the basic difference between sub-critical and supercritical boilers?
List out merits of supercritical boilers as compared to sub-critical boiler.

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Answer : Difference between sub-critical and supercritical boilers :--

DESCRIPTION SUPERCRITICAL SUB-CRITICAL

Circulation Ratio 1 Once-thru=1

Assisted Circulation=3-4
Natural circulation= 7-8

Feed Water Flow Control -Water to Fuel Ratio Three Element Control
(7:1) -Feed Water Flow
-OHDR(22-35 OC) -MS Flow
-Load Demand -Drum Level

Latent Heat Addition Nil Heat addition more

Sp. Enthalpy Low More

Sp. Coal consumption Low High
Air flow, Dry flu gas loss Low High
Coal & Ash handling Low High
Pollution Low High
Aux. Power Consumption Low More
Overall Efficiency High (40-42%) Low (36-37%)
Total heating surface area Low (for 660MW : 84439m2) High (for 500MW : 71582m2)
Reqd
Tube diameter Low High
Material / Infrastructure Low High
(Tonnage) 7502 MT 9200 MT
Start up Time Less More
Blow down loss Nil More
Water Consumption Less More

Merits of Super Critical Boiler over Sub Critical Boiler:

a) The heat transfer rate is very high. (Typically, the heat transfer co-efficient in
subcritical boiler is 400 kcal/m2.hr.C while that in super-critical boiler is 50000
kcal/m2.hr.C).
b) By using super critical boiler, steam efficiency of power plant can be as high as about
40 to 42%.
c) Due to absence of steam-water mixture (no two-phase effect), there is very less
erosion and corrosion.
d) The overall operation is very easy.
e) The turbo generator connected to super critical boiler can easily attain peak-loads.

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Q.2(d) A close circular tank is to be installed in a boiler house as a feed water
tank. Diameter and height of tank are 2.1m and 6m respectively. Find water
holding capacity of the tank. Also find the cost for insulating the tank including
top with insulation thickness of 50mm. Assume insulation cost Rs. 145/m2.

Solution :
=π.r2.L
Volume of the circular tank
=3.14x1.05x1.05x6
=20.7711m3 (Holding capacity of tank)
Tank insulation area =Tank vertical face area+ Tank top face area.
=π.r.L + π.r2
=(3.14x1.10x6.05)+(3.14x1.10x1.10)
=20.8967+3.7994 =24.6961m2
Insulation Cost=24.6961x145= Rs. 3581/-

Q.3(a) Enlist tips to improve steam plant efficiency.

Answer : In many industries, steam plants now provide a crucial energy source,
delivering reliable high-quality steam for the production process.However, rising gas
prices and a need to reduce CO2 emissions has led to an increasing focus on the
efficiency of steam plants.

While there are many ways to improve efficiency they often involve considerable
investment (e.g., the wholesale change of steam traps), so before embarking on any
large capital project, it is worth taking a closer look at the system itself by following these
five steps to improve steam plant efficiency.

Step 1: Do a Steam Trap Survey

Step 2: Understand the Value of Condensate

Step 3: Insulate your Steam System

Step 4: Look for Steam Leaks

Step 5: Start Steam Metering

Q.3(b) What are the comparative advantage and dis-advantages of fire tube and
water tube boiler?

Answer :
The advantages of water tube boiler over the fire tube boiler are:
a) Furnace and pressure parts are more easily accessible for cleaning, inspection and
repairs,
b) Comparatively, water tube boilers can operate at high steam and superheat
temperature,
c) Start up and bringing to full load is faster compared to fire tube boilers,
d) Fairly long path of flue gas flow coming in contact with a larger area of heat transfer
and as a result better efficiency of operation,
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e) Due to fairly large heat transfer surface and flue gas retention time more effective
transfer of heat by radiation, conduction and convection takes place, giving more
flexibility in operation,
f) Fairly non-complicated construction which does not pose great problems of thermal
expansion of individual components,
g) Pressure parts are not subjected to undue thermal stress,
h) Provides ease of adopting better efficient fuel firing system,
i) Boiler can respond well for sudden load variations and
j) Boiler is safe to operate and maintain and less prone for serious accidents compared
to fire tube boilers.

The disadvantages of water-tube boilers are,

a) Water chemistry poses a big problem. Comparatively pure non corrosive, non-scale
forming water is necessary for use as feed water,
b) Necessity of keeping better feed water control to avoid low water level operation,
which may otherwise result in tube failure due to starvation,
c) Initial cost of installation and gestation period are more due to complicated water
circulation system.

Note: Firetube boiler is usually preferred where the steam pressure required is less
than about 30 kg/cm2(g) and steaming rate is lesser than 30 t/hr. Above this limits,
watertube boilers are more economical.
In power plants, normally, high pressure water-tube type boilers are used, where
capacity rages from 30 to 650 t/hr, having pressure & temperature upto 160
kg/cm2(g) and 540 0C respectively.

Q.3© Why are water tube boiler most frequently used for waste heat recovery?

Answer:
Reasons are as following :
1. They can work successfully at higher pressures.
2. Since water is circulated in the tube-side, which can be readily cleaned, Water tube
WHBs are not so susceptible to damage from poor feed water quality.
3. Better capacity to withstand the shock due to fluctuation of gas temperature.
4. The furnace wall can be adequately cooled by applying water-wall tubes. This
imparts a long life to the refractory lined WHB interior wall.
5. The slagging and erosion problems can be minimized by varying the tube size and
spacing.
6. Dust particles may be recovered.
7. Lends itself to a more economic arrangement.

Q.3(d) Find the volume of 1 Kg of steam at a pressure of 14kg/cm2(g), in each of

the following case:--
(i) When steam is dry saturated.
(ii) When steam is wet having a dryness fraction of 0.9.
(iii) When steam is superheated, the degree of superheat being 40*C.

Solution :
(i) From steam table (Table No.-2, Saturated pressure table)
Volume of dry saturated steam at 15kg/cm2(abs) v=vg=0.13167m3/kg
(ii) Volume of wet steam at 15kg/cm2(abs) v=x.vg=0.9x0.13167=0.118503m3/kg
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(iii) From steam table (Table No.-3, Specific volume of superheated steam)
Saturation temperature at 15kg/cm2(abs) is 198.3*C
Degree of superheat is 40*C
Temperature of the superheated steam=198.3+40=238.3*C
Volume of superheated steam at 15kg/cm2(abs) & 238.3*C =0.147492 m3/kg

Q. 4(a) Write important parameters to monitor of running boilers and what affects
fuel bill?

Answer :
Following important parameters to be monitor in any running AFBC Boiler :
1. Drum level has to be maintained 50%.
2. Desired Main steam temperature & pressure to be maintained at final super
heater outlet.
3. Furnace draft has to be maintained about -5mmwc.
4. O2 % in flue gas has to be maintained between 3.5% at higher load & 6% at
lower load.
5. ESP inlet temperature has to maintained between 130 to 150*C.
6. Economizer feed water inlet temperature has to be maintained as per
manufacturer recommendations.
7. Economizer feed water outlet temperature has to maintained below
corresponding saturation temperature of boiler working pressure.
8. Plenum pressure, PA header pressure & bed height to be maintained as per
manufacturer recommendations.
9. Running bed temperature has to be maintained between 850 to 925*C.
10. Bunker level has to maintained as max as possible.

Following factors are affecting fuel bill in AFBC Boiler :

1. LOI in fly ash.
2. Blow down from boiler.
3. O2 % in flue gas.
4. Fluidization condition of bed.
5. Radiation heat loss form boiler.
6. Moisture content in fuel.

Q.4(b) Explain effects of impurities on Boiler components.

Answer : Without proper treatment of feed water and boiler water, deposits and scale
may form by one or a combination of the following mechanisms :-
1. Precipitation of relatively insoluble feed water hardness compounds either in the
pre-boiler and/or the boiler.
2. Improper selection or inadequate control of chemical sludge conditioners and
dispersants.
3. Super-saturation and crystallization of relatively soluble dissolved solids at the
heat transfer surfaces.
4. Increasing the concentration of suspended solids in the boiler water due to
inadequate blow down.
5. Accumulation of iron and copper oxides from corrosion by-products entering the
boiler from the pre-boiler system or transported with the return condensate.
6. Oil or process contamination can adhere to boiler surfaces or increase
adherence of boiler solids.
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Q.4© What are the causes, effects and control of following losses :-
1. Boiler on-off loss.
2. Blow down loss.
3. Stack loss.

Answer :

SN Name of Causes Effects Control

the loss
1 Boiler on-off 1. Corrosion/Eros 1. Failure of tubes 1. Operate boiler at
loss ion 2. Tripping of boiler recommended
2. Malfunction parameters by
manufacturer
2. Avoid frequent manual
operation.
2 Blow down Removal of impurities Reduction MCR loading Automation in blow down of
loss from boiler water of boiler boiler water.
3 Stack loss Higher excess air Higher heat loss from Keep O2 in flue gas in specific
boiler i.e. reducing boiler range.
efficiency

Q.4(d) The following data was obtaining during a test on two boilers working
under similar conditions, except that the draught in the first boiler was produced
by an induced draught fan and in the second fan by a forced draught fan:-
Air supplied/kg of fuel burnt: 19kg
Density of air under given conditions: 1.205kg/m3
Density of flue gases at the specific temp 0.769kg/m3
Combustion rate 150kg of fuel/hr
Fan draught produced in each case 75mmwc
Efficiency of fan in both cases 50%
Calculate Brake Horsepower of fan in each case.

Solution :

BHP = Q x SP / (6356 x Fan Eff.)

Where
• BHP = Break Horsepower
• Q = Air flow rate in CFM
• SP = Static pressure in-WG

Calculation of BHP in 1st Case (ID Fan) Calculation of BHP in 2nd Case (FD Fan)

Flow rate of flue gas ‘Q”= Flow rate of air ‘Q”=

=150x20=3000kg/hr=50kg/min=50x0.769m3/min =150x19=2850kg/hr=47.5kg/min=47.5x1.205
=38.45m3/min=38.45x35.31CFM m3/min=57.2375m3/min=57.2375x35.31CFM
=1357.67CFM =2021.056CFM

Brake horsepower(BHP) of ID fan= Brake horsepower(BHP) of FD fan=

=1357.67x75/(6356x0.50) =2021.056x75/(6356x0.50)
=101825.25/3178=32.04HP =151579.2/3178=47.69HP

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Q.5(a) What are classifications of pulverized coal burner and oil burners?
(Only classification).

Answer :

Types of pulverized coal burners :

1. Long Flame Burner (U-Flame Burner):- In this burner air and coal mixture travels a
considerable distance thus providing sufficient time for complete combustion .
2. Short Flame Burner (Turbulent Burner):- The burner is fitted in the furnace will and
the flame enters the furnace horizontally.
3. Tangential Burner:- In this system one burner is fitted attach corner of the furnace.
The inclination of the burner is so made that the flame produced are tangential to an
imaginary circle at the centre.
4. Cyclone Burner :- This burner uses crushed coal intend of pulverised coal. Its
advantages are as follows :
(i) It saves the cost of pulverisation because of a crusher needs less power than a
pulveriser.
(ii) Problem of fly ash is reduced. Ash produced is in the molten form and due to
inclination of furnace it flows to an appropriate disposal system.

Types of Oil Burners :

The various types of burners are :
a) Pressure jet burners
b) Air pressure burners
c) Steam atomizing burners : i) Inter mix type burner ii) External mix type burner
d) Rotary cup burners
e) Modern sonic burners

Q.5(b) Write formula to calculate chimney draught produced in mm of water

column and what are the main factors which determine the amount of boiler
draught necessary?

Answer :
h = 353 H [1/Ta – (w + 1) / w.T] mmWC
Where :-
w = Weight of air required in kg for burning 1 kg of fuel.
T = Average absolute temperature of gas passing through chimney in deg. K
Ta = Absolute temperature of air outside the chimney in deg. K
h =Furnace Draught in mm of water.
H = Height of chimney in meters
w + 1 = Weight of the flue gas produced in kg per kg of fuel burnt.

Following factors are necessary for determining the boiler draught :

1. Height of chimney.
2. SO2 emission rate.
3. SPM(Suspended particulate matter).
4. Type of fuel combustion in boiler.
5. Type of draught to be used.

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Q.5© Draw a schematic diagram of Mechanical ash handling system and
enumerate the requirements of a good ash handling system.

Answer :
Mechanical ash handling system:-- In below mention figure shows a mechanical ash
handling system. In this system ash cooled by water seal falls on the belt conveyor and
is carried out continuously to the bunker. The ash is then removed to the dumping site
from the ash bunker with the help of trucks.

Requirements of a good ash handling system :--

Q.5(d) During the test of an oil fired water tube boiler, the following data was
obtained:-
Steam pressure 16kg/cm2(ab)
Weight of water evaporated 283kg/min
Boiler feed water temp 76*C
Quality of steam 99%
Weight of fuel burnt 22.45kg/min
Calculate –
(a) Actual evaporation per kg of fuel oil
(b) Factor of equivalent evaporation
(c) Equivalent evaporation from and at 100*C
(d) Boiler horsepower

Solution :
(a) Evaporation rate ‘Mact”=283/22.45=12.61 kg of steam/kg of fuel oil
(b) Specific enthalpy of steam under the operating condition Kcal/kg ‘H’
=Total enthalpy of steam at 16kg/cm2(abs) [from steam table]
=hf+x.hg

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=205.28+0.99x667.55
=866.15 Kcal/kg
Factor of equivalent evaporation ‘F” =(H-Hwt)/539=(866.15-76)/539=1.47
© Equivalent evaporation from and at 100*C =MactxF
=12.61x[(866.15-100)/539]
=12.61x1.421=17.92
(d) Meq =Mactx[(H-Hfw)/539]
=(283x60/1000)x[(866.15-76)/539]
=16.98x1.47=24.9606TPH
One Boiler HP is the capacity to evaporate 15.653 kg of feed water per hour at 100*C
into dry saturated steam at 100*C.
Boiler HP = Meq/15.653=24.9606/15.653=1.595HP

Q.6 : Write short notes on(any four) :-

(a) Best practices for condensate removal on steam lines.
(b) Two element drum level control.
© Types of boiler furnaces used in bagassed fired boilers in sugar industry.
(d) Boiler safety.
(e) Boil out procedure for cleaning new water tube boiler.

Answer :
(a) Best practices for condensate removal on steam lines:---

A steam trap should be installed immediately before pressure reducing valves /

control valves to prevent condensate from pooling when the valve is closed. The
trap also helps reduce erosion of the valve seat from condensate. Similarly, traps
are also generally installed between two pressure reducing valves in a series
installation to remove condensate trapped between the valves during operation
or shut-off. A steam trap should be installed in front of valves closed for long
periods of time to help eliminate the pooling of condensate which could otherwise
be propelled at high speed down the pipeline when the manual valve is opened.
Similarly, a steam trap is needed at the end of a pipe run (end of main) to help
drain the system for safe and effective operation. A steam trap should be set at
the bottom of vertical piping sections because dis-entrained condensate can
accumulate there due to gravity and directional changes.

If piping support (e.g. pipe hangers) is set too largely apart, the piping can deflect under
its own weight. This type of problem can cause condensate to pool at unwanted
locations even if piping is set at a slight inclination, so it is important to both:
1. Set piping support at appropriate intervals.
2. Set piping at a slope of no less than 1 in 100.

Efficient removal of condensate requires at least the following:

1. Carefully choosing steam trap locations
2. Providing proper support and inclining the steam piping
3. Configuring drip legs to allow for the smooth removal of condensate
4. Properly removing air and condensate at end-of-lines

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(b) Two element drum level control :-
This uses a control loop that provides regulation of feedwater flow in response to
changes in steam flow, with a second control loop correcting the feedwater flow to
ensure the correct drum water level. The steam flow control signal anticipates load
changes and begins control action in the proper direction before the drum-level
control loop acts in response to the drum water level. The drum-level measurement
corrects for any imbalance between the drum water level and its set point and
provides the necessary adjustment to cope with the “swell and shrink” characteristics
of the boiler.

( c ) Types of boiler furnaces used in bagasse fired boilers in sugar industry:

1. Fixed bed type furnace

2. Stoker-firing system (firing on grate) type furnace
3. Fluidized beds (bubble, circulating) type furnace
4. Cyclone type furnace

( d ) Boiler safety :To ensure that the boiler plant and auxiliaries operate as efficiently
and reliably as possible, the regular planned maintenance of all plant items and
associated equipment is essential. Procedures recommended by the various
manufacturers – both for preventive and corrective maintenance should be implemented
– to obtain the maximum plant utilization and safety.
Apart from above we should take care about following point
1. Furnace Inspection
2. Maintenance Work
3. Steam and Water Source Isolation
4. Residual Pressure or Vacuum
5. Safety Measures for Internal Inspection and during Start –up
6. Residual heat
7. Hot dust and / or Noxious / Inflammable gas
8. Fuel oil Leakage and Fire Fighting Equipment
9. Burning / Welding within Boiler Interior

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MH BOE-2014 Paper-1 Solution
10. Deviation from Recommended Procedures
11. Maintenance Equipment
12. Work Permits
13. Dampness
14. Safety Hazards
15. Steam & Water at Elevated Pressure & Temperature
16. Mechanical Equipment
17. Flue gases
18. HP and LP Dosing Chemicals
19. Noise
20. Protective Materials and Clothing

(e) Boil out procedure for cleaning new water tube boiler:---

1. As the steam drum pressure reaches at 50% of working pressure the alkali boil out (
internal cleaning of Boiler ) commences. Hold the temperature and the pressure for 8
hours. Take sample from CBD once in 2 hours.
2. The effectiveness of Alkali boil out will be identified by change in phosphate ppm and
Oil and Fe2O3 content from the initial value.
After alkali boil out is completed, generally the boiler is stopped and depressurised to
commence flushing. But in this case, since refractory dry out activity is also carried out
along with boil out, it is advised to go for an extended boil out so that the refractory dry
out activity can be completed.
3. Now the flue gas temperature can be brought down by reducing the firing rate.
4. Rate of reduction in flue gas inlet temperature to Boiler will be at the rate of 50
Deg C / Hr. When the flue gas temperature drops to 250 Deg C, stop ID Fan and
adjust the stack cap to maintain Kiln pressure below ABC as 3 to 5 mmWC. At
this time online flushing can be carried out by opening the CBD, IBD. Pressure
can be reduced to 10 kg / cm2.
5. At the above pressure take a blow down from the bottom header valves one by
one for not more than 10 seconds per drain valve.
While this is being done it must always be ensured that the drum level does not fall
below the normal working level and the water level is always visible in the level gauge.

6. Gradually increase the opening of the start up vent valve, to relieve the steam
drum pressure to 5 kg / cm2.
7. Constantly watch the flue gas temperature at Boiler inlet. In case the temperature
shoots up beyond 250 Deg C, stop draining and investigate to take remedial
action.
8. Fully open the steam drum vent gradually when the drum pressure falls to 2 kg
/cm2. Take sample from CBD piping and analyse for pH, conductivity,
phosphates, oil contents and Fe2O3.
9. Open CBD valve and drain water to blow down tank. Dilute the blow down tank
content with water and divert the solution to a pre-determined safe location.
10. After draining the content from the steam drum, start draining from evaporator
module and bottom headers respectively. Also drain from support tube bottom
header and water wall bottom headers subsequently. Close all the drain valves.
11. After the Boiler cools down, fill in the water into the Boiler up to the drum Normal
water level and flush.
12. Repeat this operation a few times till the quality of boiler water and the feed water
are very close.
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“IBCS is the Premier BOE Coaching Services in India, where dream convert into reality in very short
duration”