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Boiler PDF
Boiler PDF
Boiler PDF
BOILER
A. Boiler
B. Steam boiler
C. Supercritical boiler
D. Once-through boiler
E. Steam Generator
4. What is combustion?
A). Using steam or air under pressure to break the oil into droplets.
B). By forcing oil under pressure through a nozzle
C). By tearing an oil film into droplets by centrifugal force.
Heating value of fuel is the heat liberated by the complete and rapid
burning of a fuel per unit weight or volume of the fuel.
A). Control of air supply for proper ratio of all and fuel.
B). Thorough mixing of fuel and air to attain good combustion.
C). Temperature of combustion, have proper pre-heat temperature to
Maintain combustion.
Insufficient air supplied to the fuel will result in a longer and smoky
flame. The flue gas will have unburned fuel such as carbon particles
or carbon monoxide, thus less heat will be given off by the
combustion process.
Burning should always be with excess air to ensure that all the fuel is
properly burned and thus attain better efficiency in heat release. This
also reduces smoke formation and soot deposits which now-a-days,
with stricter Pollution Laws are important.
13. What indicators will show the relative quantity of air being
supplied to the furnace?
14. How does the forced draft fan differ from an Induced draft
fan?
16. How does the Air pre-heater increase the boiler efficiency?
The APH recovers high exit gas temperature and heats the incoming
combustion air. A 35 to 40 ◦ F drop in gas exit temperature raises
boiler efficiency about 1%.Pre-heated air speed-up combustion at all
load and 300◦ F combustion air save fuel as much as 5%.
21. Why are baffles used to gas passages of water tube boiler?
A). Radiant Type Super heater which mainly absorb radiated heat
from the furnace.
B). Convection type super heater which absorb heat from the flue gas
passing through it.
Economizers are waste heat recovery devices that heats incoming feed
water by exit flue gases.
Classifications of economizers are,
A). Horizontal and vertical tubes according to the direction of flue
gas Flow with respect to the tubes in the bank
B). Parallel or counter flow with regard to the relative direction of
gas and water flow.
C). Streaming or non-streaming according to the thermal
performance.
D). Return bend or continuous tube type.
E). Plain tube on extended surface (finned type) according to the
detail of design and the form of heating surface.
In soot blower between half and full load we can establish enough
draft to carry the soot out of the stack while maintaining complete
combustion.
Soot- blowing at low load, fire may be blown out. Soot blowing at
full load it may not possible to increase air supply thus soot
blowing is not effective
29. Why should water wall headers not be blow down while the
boiler is under load?
If blow down, the boiler normal circulation will be upset and will
result to over heating, bulging and rapture of the tubes.
30. Why is down comer placed outside the boiler casing?
32. How would you manage the drum level when lighting off a
cold boiler and also when cutting out a boiler that has been in
service?
Before lighting a boiler have the water level about one (1) inch from
the bottom of gauge glass. As the boiler heats water expands and the
drum level reaches half the glass or over by the time the boiler is
ready to cut-in. When the fires are extinguished, bring water level to
at least half the gauge glass. Heat stored in the furnace generates
steam for sometime. During this time water in the glass drops, so
that it is necessary to feed the boiler from time to time.
Purpose of the Hydrostatic test is to see that all welds, joints and the
connection are tight Hydrostatic test are conducted:-
a. When boiler is newly constructed.
b. When repairs are made on a boiler.
c. When the exact source of leakage or defect in some parts of
the boiler is to be determined.
48. What is the purpose of the free blow and where it is tapped in
the boiler?
49. After a new boiler has been completed, what are the steps to
be followed before it is finally placed in operation?
Boiling out
Boiling out with chemically treated water to remove any oil or other
Deposits accumulated in the pressure parts during fabrication and
erection.
- Safety valve setting.
- Initial operation at moderate load.
- Placing on line in normal high duty operation or normal rated
capacity.
50. During load rising, what are the conditions should be observed?
Safety controls are those that limit energy input and thus shut down the
equipment when
Unsafe conditions develop. They are.
A. pressure or temperature limits
B. low water level/pressure
C. fuel failures safeguard system
D. automatic ignition controls
E. air and fuel pressure interlock control
F. feed water regulating controls
53.Why is the safety valve considered as one of the most important boiler
accessory?
It prevents the boiler pressure from going above a predetermined pressure by
allowing excess pressure to escape into the atmosphere when the set point is
reached. This guards against a possible explosion from excessive pressure.
55. What is the difference between a relief valve and a safety valve?
A relief valve is used primarily for liquid service and is an automatic relieving
device actuated by the static pressure upstream of the valve. A safety valve is
used for gas or vapours service and is an automatic relieving device, actuated
by static pressure upstream of the valve and which opens with a full pop
action once the upstream pressure activates the valve.
54.Explain the term safety valve blow down/blow back and the
requirements for its setting.
Blow down or blow back is the difference between the opening and closing
pressure of the safety valve. If a safety valve is set to open at 250 psi and
reset at 243 psi, then the blow back or blow down is 7 psi. Blow-down must
not be more than 4% and not less than 2% of the set pressure.
57. Explain why super heater safety valves are set at a lower pressure
than the drum safety valve.
Supper heater safety valves are set at a lower pressure than the drum
safety valves to ensure steam flow through the super heater at all times.
If the drum safety valve blows first, the super heater tubes will be starved
which may lead to possible overheating.
A. Means of lowering the drum level in cases of too high water level.
B. permits removal of precipitated sediments.
C. Controls the concentration of suspended solids in the boiler. The solids
would settle on metal parts, reducing heat transfer and causing metal
overheat where the scale is located. Rupturing of tubes shells and tubes
sheet may occur.
59.What precaution must be observed when starting boilers equipped
with non-drainable Super heaters?
61. What are the causes of tubes failure in water tube boilers?
A. Solid deposits
B. Low water level condition
C. Corrosion
D. Slugging of gas passages
E. High concentration of heat in some areas
F. Stress Corrosion
G. Flame impingement
H. Poor circulation
I. Steam cutting by soot blowers which are improperly located or in
poor condition.
62. Why are instruments and knowledge of the required operating
parameters important for properly operating a steam generator?
Use of instruments and knowledge of the required operating parameters are
important responsibilities of an operator. Instruments indicate the conditions
in the boiler, thus, any variations from the design or stipulated conditions
serve as a warning of impending danger or inefficient operation. Thus,
necessary adjustment on corrective/ remedial measures can be instituted to
attain desired results.
72. In a boiler bi-color gauge, explain how steam and water are
indicated as red and green, respectively.
The operation of a bi-color gauge glass is based upon the principle of
refraction. When light passes through a denser medium, as water,
light is bent obliquely towards the green colored strip. Light bent less
when passing through a less dense medium as air or steam and
towards the red colored strip.
73.Why should the Boiler Tripping Interlock (BTI) be in service
whenever the unit is on the line?
74. List the condition that will actuate Boiler Tripping Interlock
(BTI).
Conditions that will actuate BTI are:
A. Economizer inlet temperature pressure drops to 2480 psi.
B. Feed water flow lower than 85% of 1/3 maximum continuous
rating (MCR).
C. High Furnace pressure.
D. Tripping of both forced Draft Fan (FDF).
E. Closure of two turbine main stop valve.
F. Closure of boiler main stop valve.