Auxiliary Boiler Training Manual RA

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TRAINING MANUAL
FOR
AUXILIARY BOILER
GULF SRC POWER PLANT PROJECT
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1. GENERAL DESCRIPTION
▪ GENERAL PROCESS DESCRIPTIONS
▪ KEY SPECIFICATION
▪ RATED CAPACITY
▪ COMBUSTION
2. HEAT & MASS BALANCE
▪ HEAT & MASS BALANCE DIAGRAM
▪ UTILITY CONSUMPTION
3. AUTOMATIC CONTROL & SAFETY DEVICE
▪ SUPERHEATED STEAM OUTLET PROCESS CONTROL
▪ ACC ( AUTOMATIC COMBUSTION CONTROL )
▪ DEAERATOR CONTROL & FEEDWATER CONTROL
▪ BLOWDOWN CONTROL
▪ STEAM TEMPERATURE CONTROL
▪ ESD ( Emergency Shut Down ) FOR BOILER SHUTDOWN
▪ START-UP PERMISSIVE CONDITION
▪ PURGE PERMISSIVE CONDITION
▪ SYSTEM CONFIGURATION
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4. OPERATING PROCEDURES
▪ CONTAINER ROOM CONTROL PANEL
▪ STEP GUIDE FOR AUTO START UP
▪ STEP GUIDE FOR SCHEDULED SHUTDOWN
▪ BMS FLOW CHART(START SEQUENCE)
▪ BMS FLOW CHART(STOP SEQUENCE)
▪ INSPECTION & PREPARATION
▪ COLD START UP CURVE
▪ WARM START UP CURVE
▪ HOT START UP CURVE
5. STEAM PURITY & BOILER WATER QUALITY

▪ FEEDWATER, BOILER WATER AND STEAM QUALITY
▪ CHEMICAL DOSING SYSTEM
▪ SAMPLING SYSTEM
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6. TROUBLE SHOOTING
7. MAINTENANCE
▪ WATER WALL TUBE REPLACEMENT
▪ PLUGGING OF TUBE
▪ DAILY MAINTENANCE PROGRAM
▪ WEEKLY MAINTENANCE PROGRAM
▪ MONTHLY MAINTENANCE PROGRAM
▪ SEMI ANNUAL MAINTENANCE PROGRAM
▪ YEARS MAINTENANCE PROGRAM
▪ TEN YEARS MAINTENANCE PROGRAM
8. PRESERVATION PROCEDURE
▪ PRESERVATION METHODS
✓ Wet Preservation
✓ Inert Preservation
✓ Preservation with Silica Gel
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8. PRESERVATION PROCEDURE
▪ PRESERVATION METHODS
✓ Wet Preservation
✓ Inert Preservation
✓ Preservation with Silica Gel
▪ PRESERVATION METHOD SELECTING

▪ SHUTDOWN PRESERVATION SELECTING CHART
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1.GENERAL DESCRIPTIONS
➢ General Process Descriptions
The purpose of auxiliary boiler is to supply the superheated steam required for Steam
Turbine Gland Sealing to attain vacuum in condenser during Start-up. In order to cater
this requirement, the auxiliary boiler is designed to produce 6.6 ton/hr, 320 degC of
superheated steam at tie-in point .
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➢ Key Specification
1. Type of boiler : Single Drum, Water tube ( Natural Circulation )
2. Location : Outdoor
3. Number of Boiler : One(1) set
4. Design Code of boiler : ASME Sec I
5. Steam Capacity
❑ At tie-in : 6,6 t/h (SH Steam)
❑ Including internal consumption : 7,2 t/h (Sat. Steam)
6. Outlet Steam Temperature : 320 °C
7. Outlet Steam Pressure
❑ Design : 1.3 Mpa(g)
❑ Operating : 0.687 Mpa(g)
8. Feed-water temperature : 105 °C ( Deaerator Outlet )
9. Draft System : 2 x %100 Forced Draft Fan
10. Firing System
❑ Main fuel : Light oil( LHV of Fuel oil: 43,106 kj / kg)
❑ Ignition fuel : Prophane gas
11. Turndown ratio : 1/6
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➢ Rated Capacity
❑ Steam Flow Rate : 6,6 t/h ( at tie-in point )

❑ Steam Operating Pressure : 0.687 Mpa(g) ( at tie-in point )
❑ Steam Temperature : 320 °C ( at tie-in point)
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➢ Combustion
Combustion is combination of fuel with oxygen in the air as fastly.
C + O2 CO2 + 7,830 kcal/kg carbon
2H2 +O2 2H2O + 28,890 kcal/kg hydrogen
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➢ Combustion
The oxygen in the air, flame source and fuel are required for combustion.
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➢ Combustion
There are two type of combustion as full combustion and incomplete combustion.
❑ All combustible components of the fuel are completely burned at full combustion.
❑ The combustion products at incomplete combustion contains unburned fuels or

components as C,H2, CO and OH. The actual reason of incomplete combustion is
insufficient oxygen. But This is not only reason.
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➢ Heat&Mass Balance Diagram
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➢ Utility Consumption
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➢ SUPERHEATED STEAM OUTLET PROCESS CONTROL
The main steam control valve-PCV (90QLB20AA704) is used to heat the steam line and isolate the steam outlet from
auxiliary boiler to the system. The monitoring of the control valve position and controlling of the valve are
performed via the PLC.
When the boiler starts up;

- The minimum fire position is kept when the drum pressure is from 0 kPa to 150 kPa.
- When the drum pressure is 150 kPa or less, the main steam control valve-PCV (90QLB20AA704) and
the start-up vent valve-FCV (90QLB20AA703) are opened to the specified opening value which is not fully closed. (eg
5%)
- When the drum pressure is 150kPa or higher, the burner output is controlled by PI control for the set value of drum
pressure.
- The set value of drum pressure increases gradually with increasing drum pressure (for example, the drum pressure
set value is determined by drum pressure + 20kPa.)
- When the drum pressure is 150 kPa or higher, PCV controls the flow rate so that the steam flow rate is 2.0t / h.
- When the drum pressure is 150 kPa or higher, FCV controls the flow rate in order to ensure the minimum
steam flow of 1.65t /h or more.
- After the drum pressure reaches the specified pressure, PCV is fully (100 %) opened after the signal from the DCS
turns ON.
- FCV continues to control the flow rate to ensure the minimum flow rate even after the drum pressure
reaches the specified pressure.
- In addition, FCV controls the superheated steam pressure so that it does not exceed the set value.(eg 900kPa)
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➢ SUPERHEATED STEAM OUTLET PROCESS CONTROL
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➢ ACC ( AUTOMATIC COMBUSTION CONTROL)
The purpose of ACC is to regulate the firing rate of the burner for the required boiler drum pressure. This control
system maintains the drum pressure at the preset value by regulating firing rate in order to compensate for
variations of load.
The burner is controlled by Autoflame Combustion Management System - MM Mk8 (BMS). This controller has a
pre-installed settings and temporary operation data, it has also password protection. This device is
commissioned at the site by an authorized and experienced staff only, according to the instructions given in the
Autoflame manuals.
The main loops of ACC are given in the following;
1) ACC - The Start Sequence
In order to start the firing sequence, the ‘Start’ button (B101) on the panel front is pressed.
-Burner motor starts.
-Selected FD fan starts.
-Fuel-oil pump selected as first starts.
- Purge starts and continues till the end of purge time (e.g 40 seconds). Position of the primary and secondary
air damper and speed of the fan are 100% during purge time.
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➢ ACC ( AUTOMATIC COMBUSTION CONTROL)
- After purge is finished, primary and secondary air damper position are adjusted to minimum fire position and
fuel valve is at minimum fire position and speed of the fan is also at the minimum fire speed.
Ignition process is done according to the following sequence.
•BMS sends energy to ignition transformer (90QHH01AV201) to create a spark on pilot line.
•BMS sends energy to the pilot's valves (90QHH02AA004&005) to let propane gas flow towards the burner.
•The pilot flame is checked by the flame sensors (90QHH01CR001-90QHH01CR002).
•If the pilot flame is steady and adequate, BMS opens the main fuel valve (90QHH01AA702) to generate main
flame.
•After the generation of main flame, the pilot line and ignition transformer are de-energized.
•The burner keeps the boiler at the required (set) pressure value with PID control depending on the superheated
steam pressure.
When the boiler trips or manually stopped, the burner can be restarted without any time delay as long as there
is no continuing trip condition.
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➢ ACC (AUTOMATIC COMBUSTION CONTROL)
2) ACC - The Stop Sequence
While the burner is in service, the ‘Stop’ button (B102) is pressed on panel front to initiate stop
sequence as given in the following.
- BMS proceeds to the minimum fire rate. Primary and secondary air dampers move to the minimum
fire position, and fuel valve moves to the minimum fire position and also the speed of the fan goes to
the minimum fire speed
- As the minimum fire position is reached, main fuel valves are de-energized (closed).
- Post purge starts and continues till the end of post purge time (e.g 40 seconds). Position of the
primary and secondary air damper and speed of the are at the 100% during post purge time.
- After post purge is finished ,primary and secondary air damper position are at the minimum fire
position and speed of the fan is also at the minimum fire speed.
- Burner motor is stopped
- Selected FD fan is stopped.
- Running FO pump is stopped
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3) ACC – Fuel Oil Flow Control
The fuel oil control valve adjusts the fuel oil flow to the burner and the fuel servo motor of the valve is
controlled by the BMS, allowing the fuel ratio to be adjusted very precisely. The valve is combined with servo
motor and potentiometer. The valve potentiometer provides 'position feedback'.
The PID control in BMS continuously monitors the real and required drum pressure value, and in order to
achieve the required (set) drum pressure value, the right amount of fuel is adjusted by BMS using the fuel
control valve.
The control valve (and combined servo motor) positions are the points on the “fuel-air curve” which is
formed during the commissioning of the burner. The sample “fuel-air curve” is given below.
The above sample “fuel-air curve” is formed to determine the right amount of fuel and air which are required
in the full operating range of the burner.
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4) ACC - Oxygen in Flue-Gas Control
O2 analyzer (90QHN01CQ101) is provided to measure residential oxygen in flue gas. The

measured O2 value is used by BMS for oxygen trim control, to compensate the fuel/air flow
ratio.
In order to obtain the required (pre-set) value of O₂ in the flue gas, the measured O₂ from
oxygen analyzer (AT_90QHN01CQ101) is compared with the required O₂ value at each load.
According to the difference between the real and required (pre-set) value, the airflow amount
is adjusted by BMS to obtain the required O2 value by either increasing or decreasing the
actual airflow (by adjusting the secondary air damper).
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➢ ACC (AUTOMATIC COMBUSTION CONTROL) BMS- Control Logic Diagram
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➢ DEAERATOR CONTROL & FEEDWATER TANK CONTROL
Deaerator (90QLA11AC101) is used for the removal of oxygen and other dissolved gases from
feed water. In particular, dissolved oxygen in boiler waters will cause serious corrosion damage in
steam system by attaching to the walls of metal piping and other metallic equipment.
FEED WATER TANK LEVEL CONTROL
The control valve is located to demine water line (90GHC20BR001). This valve is used to control
the water level of the feedwater tank. The valve operates proportionally by taking the level
information from the level transmitter (90QLA11CL101) on the feedwater tank.
The control valve is combined with a pneumatic actuator and a positioner. The valve positioner
provides 'position feedback'.
DEAERATOR PRESSURE CONTROL
The control valve is located to the deaerator saturated steam pressure reducing line
(90QLB20BR005).
The valve is used to control deaerator steam pressure. The valve operates proportionally by taking the
pressure information from the pressure transmitter (90QLA11CP101) on the deaerator.
The control valve is combined with a pneumatic actuator and a positioner. The valve positioner
provides 'position feedback'.
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➢ DEAERATOR CONTROL & FEEDWATER TANK CONTROL
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FEEDWATER CONTROL
This system controls feed water flow rate in order to maintain the drum water at the preset level during the
boiler load change.
This control system is of three (3) element type, comprising steam flow element, feed water flow element
and drum level element, in order to prevent water level fluctuation due to the swell and shrink
characteristics during boiler load change.
The valve is located on the boiler feed water line(90QLA11BR108).
This valve(90QLA11AA711) is used to control the feed water flow. The control of this valve operates
proportionally with 3 elements control by the,
❑ level transmitter on the drum (90QHA01CL101),
❑ feed water flowmeter (90QLA11CF101),
❑ steam flowmeter (90QLB20CF101).
The control valve is combined with a pneumatic actuator and a positioner. The valve positioner provides
'position feedback'.
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FEEDWATER CONTROL
The main steam flow from flow transmitter (FT_90QLB20CF101) compensating output from
level controller is fed to the multiplying unit. If some deviation occurs by load variable, the
output signal of multiplying unit is changed. The output signal of multiplying unit is fed to feed
flow water controller.
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FEEDWATER CONTROL
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➢ BLOWDOWN CONTROL
CONTINUOUS BLOWDOWN CONTROL
Surface blowdown removes dissolved solids that accumulate near the boiler liquid surface
and is often a continuous process.
Boiler water conductivity value (as 4-20 mA signals) from conductivity electrode
(90QMA20CQ101) to PLC is continuously monitored. According to the conductivity value, the
continuous blowdown valve (90QMA20AA701) is controlled via PLC.
INTERMITTENT BLOWDOWN CONTROL
There are two controls for Intermittent (Bottom) Blowdown Control. One is that when the boiler
water level is too high, the bottom blowdown valve is opened till the desired water level is
reached. Another is that the valve opens to dispose sludge sediment at the bottom of the boiler
(bottom collectors) at the time interval set on the PLC.
▪ Boiler Bottom Blowdown Valve On/Off (90QMA20AA701)
The opening period of the valve is determined according to the chemical analysis of the water
in the boiler. In general, the valve is operated by PLC during startup by sequentially setting the
valve to open and close.
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BLOWDOWN OUTLET LINE CONTROL
The temperature transmitter (90QMA20CT101) on the blowdown outlet line

(90QMA20BR902) continuously reads the water temperature. According to the water
temperature set value, blowdown temperature control valve (90GHA20AA711) is opened and
service water is taken into the line to lower to the set value before draining it.
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➢ STEAM TEMPERATURE CONTROL
The system is controlled by desuperheater control valve (90QLA11AA712)

and temperature transmitter (90QLB120CT104) on the second stage of
superheater outlet line (90QLB20BR004). This desuperheater spray water
control system is maintaining the 320 °C of the Auxiliary boiler terminal
point. Desuperheater control valve will run with PID control automatically
and the superheated steam temperature is kept at the terminal point
according to the set value (320 °C).
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➢ STEAM TEMPERATURE CONTROL
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➢ ESD ( Emergency Shut Down ) FOR BOILER SHUTDOWN
SET POINT
DESCRIPTION RANGE OPERATING
LL HH
DRUM WATER LEVEL < LL % _ 11 _
DRUM STEAM PRESSURE > HH kPag _ _ 1170
SH STEAM TEMPERATURE > HH ◦C 320 340
FUEL-OIL PRESSURE < LL kPag _ 200 _
SECONDARY AIR PRESSURE < LL kPag _ 0.75 _
PRIMARY AIR PRESSURE < LL kPag 0.3 _
BURNER COVER NO CLOSED _ CLOSED NOT CLOSED
BURNER MOTOR NOT RUNNING _ RUNNING NOT RUNNING
NO FAN RUNNING _ RUNNING NOT RUNNING
AIR / GAS PATCH NOT OPEN _ OPEN NOT OPEN
FLAME FAILURE _ ON FAIL OFF
EMG STOP ACTIVE _ NOT ACTIVE ACTIVE
PLC TRIP _ NOT TRIP TRIP
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➢ START-UP PERMISSIVE CONDITION
SET POINT
LL HH
IGNITION FLAME FAILURE _ ON FAIL OFF
➢ PURGE PERMISSIVE CONDITION
SET POINT
LL HH
SECONDARY AIR PRESSURE < LL kPag _ 0.75 _
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➢ SYSTEM CONFIGURATION
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4. OPERATING PROCEDURE
➢ CONTAINER ROOM CONTROL PANEL
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➢ CONTAINER ROOM CONTROL PANEL
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➢ STEP GUIDE FOR AUTO START UP
NO OPERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION
BMS PANEL
1 Check Emergency Stop Button Release it if required.

(B105) on panel front.
BMS PANEL HMI DISPLAY
Select one of the FD fans via selector Selected FD fan and damper icons turn Selected FD fan damper is
2
switch (S00) on panel front. ''RED'' on HMI. automatically opened.
HMI DISPLAY HMI DISPLAY
3 Open flue gas damper via OPEN Flue gas damper icon turns ''RED'' on Flue gas damper opened.
button on HMI screen. HMI.
BMS & PLC PANEL HMI display and lamp light on BMS
panel
Select “Boiler Front” page on HMI
and check there’s no TRIP condition. -TRIP conditions not active ''GREEN''on
4 If there’s a TRIP status press RESET HMI and “BURNER TRIP” lamp light off
button (B104) on the BMS panel to on the BMS panel.
clear it.
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NO OERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION
BMS PANEL
Select LOCAL position via selector

5 switch (S102) on panel front
BMS PANEL BMS-HMI display and lamp light on

BMS and MCC panel
Press START button (B101) on
panel front to start firing sequence. Observe the firing sequence on BMS-
6 HMI defined as the flowing steps.
Motor status values can be monitored
either by MCC lamps or on the HMI.
HMI DISPLAY
Burner motor icon turns ''RED'' on HMI. Burner motor is started.
HMI DISPLAY
Selected FD fan turns ''RED'' on HMI. Selected FD Fan is started.
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HMI DISPLAY
6 Continue Selected Fuel-Oil pump turns ''RED'' on Selected Fuel-Oil pump is started.
HMI.
HMI DISPLAY Purge starts and continues till the

end of purge time. Position of the
-Purging icon turns ''RED'' on HMI. Primary and Secondary Air
-Primary and Secondary Air Damper Damper and speed of the fan
position ''%100'' should be 100% during purge
-Speed of the fan ''100%'' time. Purge time (ie.40 seconds).
HMI DISPLAY After purge is finished. Primary
and Secondary Air Damper
-Primary and Secondary Air Damper position should be at minimum
position(eg %9) fire position (eg.9%) and fuel
-Fuel valve position (eg 9%) valve should be in minimum fire
-Speed of the fan (eg 50%) position (eg 9%) and speed of the
fan should also be in minimum
fire speed (eg.50%)
HMI DISPLAY
Ignition transformer icon turns ''RED'' on Ignition Transformer is energized.

HMI.
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HMI DISPLAY
Continue 3 seconds after, Pilot Valves
6 Pilot Valves icons turn ''RED'' on HMI. are opened.
HMI DISPLAY
3 seconds after, Main Fuel
Main Fuel Valves icons turn ''RED'' Valves are opened.
on HMI.
HMI DISPLAY
10 seconds after it’s
Ignition transformer icon turns energized, Ignition
''WHITE'' on HMI. Transformer is deenergized.
HMI DISPLAY
On proving of the main flame
-Pilot Valves icons turn ''WHITE'' on for 5 seconds, pilot valves are
HMI. closed and Main Fuel Valves
-Main Fuel Valves icons still ''RED'' remain open.
on HMI.
BMS PANEL HMI display and lamp light on BMS
panel
Burner is in service now. Check
7 BMS-HMI and “Burner Running” -Burner icon turns ''RED'' on HMI.
lamp (H05) on panel front. -''BURNER RUNING'' lamp lights on
''RED'' on the BMS panel.
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➢ STEP GUIDE FOR SCHEDULED SHUTDOWN
BMS PANEL BMS-HMI display and lamp light on BMS

and MCC panel
STOP button (B102) on panel front to
1 stop sequence. Observe the stop sequence on BMS-HMI BMS proceeds to the minimum fire
defined as the flowing steps. Motor status rate.
values can be monitored either by MCC
lamps or on the HMI.
HMI DISPLAY Primary and Secondary Air

Damper position should be at
-Primary and Secondary Air Damper minimum fire position (eg.9%) and
position (eg 9%) fuel valve should be in minimum
-Fuel valve position (eg 9%) fire position (eg.9%) and speed of
-Speed of the fan (eg 50%) the fan should also be in minimum
fire speed (eg.50%)
HMI DISPLAY
As the minimum fire position is
Main Fuel Valves icons turn ''GREEN'' on reached, Main Fuel Valves are
HMI. closed.
HMI DISPLAY
Post purge starts and continues till
the end of post purge time (ie.40
-Post Purging icon turns ''RED'' on HMI.
seconds). Position of the Primary
-Primary and Secondary Air Damper
and Secondary Air Damper and
position ''%100''
speed of the fan should be 100%
-Speed of the fan ''100%''
during post purge time.
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➢ STEP GUIDE FOR SCHEDULED SHUTDOWN
HMI DISPLAY
After post purge is finished
Primary and Secondary Air
-Primary and Secondary Air Damper
Damper position should be at
position (eg 9%)
1 Continue minimum fire position (eg.9%)
-Fuel valve position (eg 9%)
and speed of the fan should also
-Speed of the fan (eg 50%)
be in minimum fire speed
(eg.50%)
HMI DISPLAY
Burner motor is stopped.
Burner motor icon turns ''GREEN'' on
HMI.
HMI DISPLAY
Selected FD fan turns ''GREEN'' on Running FD Fan is stopped.

HMI.
HMI DISPLAY
Running FO pump is stopped.
Burner motor icon turns ''RED'' on HMI.
BMS PANEL HMI display and lamp light on BMS

panel
Burner is in stop now. Check BMS-
2
HMI and “Burner Running” lamp -Burner icon turns ''GREEN'' on HMI.
(H05) on panel front. -''BURNER RUNING'' lamp lights off on
the BMS panel.
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➢ BMS FLOW CHART (START SEQUENCE)
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➢ BMS FLOW CHART (STOP SEQUENCE)
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➢ Inspection & Preparation
ITEM OPERATION
-Close 90GHC20AA005 Bypass valve
Demiwater Line -Open 90GHC20AA012 (DW for chemical dosing system)
-Open other manual valves
-Close all bypass, drain and vent valves

Feedwater Line + -Open all ınstrument shut-off valves
Desuperheater Cooling -Open manuel valves(90QLA11AA106 and 90QLA11AA111) on pump
Water Line min.flow line
-Open manuel valve(90QLA11AA120) on feedwater sampling line
-Open other manual valves
Deaerator+Feedwater -Open deaerator vent valve(90QLA11AA902)

Tank -Close drain bypass valve(90QLA11AA916)
-Open drain valve(90QLA11AA908)
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ITEM OPERATION
-Open all ınstrument and level gauges/instruments shut-off valves
-Close Condensate line bypass valves(90QLB20AA903, 90QLB20AA926)
-Open condensate line valves
-Close main steam valve(90QLB20AA704)
-Open manual valve on start up line(90QLB20AA919)
Steam Line -Close start up vent control valve(90QLB20AA703)
-Close safety valve steam line drain valves and start up line drain
valves(90QLB20AA925, 90QLB20AA928, 90QLB20AA927,
90QLB20AA924)
-Open manuel valve on sampling line(90QLB20AA006)
-Close bypass valves
-Close drain valves
Instrument Air Line -Open all shut off valve before control valve
-Open main shut off valve(90QFB20AA021)
-Adjust pressure regulator(90QFB20AA029) as pressure after regulator is
600kPa(g)
-Open all ınstrument and level gauges shut-off valves
Gauge + Instruments -Close level gauge/instrument drain and vent valves
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ITEM OPERATION
-Open manual vent valve(90QLB20AA915)
-Close control valve on vent line(90QLB20AA702)
-Close bypass valve on continous blowdown line (90QMA20AA111)
Boiler -Open all manuel valves on continous blowdown line
-Close continous blowdown collector drain valve(90QMA20AA904)
-Open all manuel valves on intermittent blowdown line
Superheater -Open manuel valves on superheater drain line,
-Close manuel valves on superheater drain bypass line,
Service Water Line -Close bypass valve,
-Close drain valves,
-Open other manuel valves,
Fuel Lines -Close drain valves

-Open other all manuel valves on fuel lines(fuel pumps suction line, fuel
pumps discharge line, fuel recirculation line,fuel tank fuel feed line)
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ITEM OPERATION
Prophane Line -Open manuel valve(90QHH02AA006) before safety valve
-Open other all manuel valves
Exhaust System -Close economiser exhaust drain valve(this valve is opened at start up
time for a short time and then closed)
Sampling System -Open main shut off valve on service water line
-Close Other all manuel valves
Chemical Dosing Unit -Close drain valves

-Open other all manuel valves inside unit and dosing lines
Potable Water Line -Open shut off valve(needle valve, 90GKB20AA201) on potable water line
for eye shower
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➢ Cold Start-Up Curve
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➢ Warm Start-Up Curve
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➢ Hot Start-Up Curve
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➢ Feedwater, Boiler Water and Steam Quality
Feed water quality should be as mentioned table below.
Feedwater
Item Unit Value Standard
Free conductivity(25°C) µS/cm <0.2 EN12952-12
Silica(SiO2) ppm <0.02 EN12952-12
Sodium+Potassium (Na + K) ppm <0.01 EN12952-12
Dissolved oxygen(before chemical addition) ppm <0.007 ABMA

Total iron(Fe) ppm ≤ 0.1 ABMA
Total copper (Cu) ppm ≤ 0.05 ABMA
Total hardness ppm ≤ 0.3 ABMA
pH(25°C) 8.3 - 10 ABMA
Not
ABMA
Chemicals for preboiler system protection specified
Nonvolatile TOC ppm <1 ABMA
Oil ppm <1 ABMA
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Boiler water quality should be as mentioned table below.
Boiler Water
Direct conductivity(25°C) µS/cm Max. 1500 EN12952-12
pH(25°C) 10-11 EN12952-12
Phosphate(PO4) ppm 5-10 EN12952-12
Silica (SiO2) ppm ≤ 150 ABMA
Total alkalinity (CaCo3) ppm <350 ABMA

Not
ABMA
Free OH alkalinity specified
Specific conductance(25°C without
µS/cm 5400-1100 ABMA
neutralization)
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Steam quality should be as mentioned table below.
Steam
Total dissolved solids ppm 0.2-1 ABMA
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5.STEAM PURITY & BOILER WATER QUALITY
➢ Chemical Dosing System
The purpose of chemical dosing system is :

• To minimize corrosion at water side of boiler
• To extend of boiler life
❑ The chemicals to be used at boiler are :
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5.STEAM PURITY & BOILER WATER QUALITY
➢ Sampling System
The main objective of the sampling skid are:

• To Ensure water conditioning stability in the water vapour circuit and stability of the
auxiliary boiler.
• To Detect the accidental introduction of pollutants.
• To Detect a possible corrosion in the auxiliary boiler.
Sampling points are :
Medium Sampling Point Manuel On-line
Analysis Analysis
Feedwater Suction line of Yes No
feedwater pumps
Boiler water Continous blowdown Yes No
valve
Superheated Main steam line at Yes No
Steam outlet of superheater
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6.TROUBLE SHOOTING
Equipment Case/Problem Reason Influence Solution Method
Boiler could lack water and so

Feedwater Pump breakdown Check pumps and armatures
pressure parts may be damaged.

Drum level instrument breakdown Check Level instrument

Rapid load increase Decrease the boiler load
Check if manual valves located

Shut-off valve opening position on Boiler could lack water and so
on feedwater line are in open
feedwater line pressure parts may be damaged.
position.
Low Level - Low-
BOILER Boiler could lack water and so
Low Level Alarm Filter clogging on line Clean filters
Kontrol vanası kontrol
edilmelidir. Esntrüman
Boiler could lack water and so havasının varlığı ve basıncı
Feedwater control valve breakdown
pressure parts may be damaged. kontrol edilmelidir. / Check
Control valve and instrument
air existance and pressure.
Drum water fluctuations take
place because of rapid load
Fluctuating at drum water change. This problem be
overcome after load
normalization
1/15/2020 67
6.TROUBLE SHOOTING
General: If level not decrease,

this decrease must be
- - maintained by openning
intermittent or continuous
blowdown valve
Water carry over with steam could
Feedwater Pump breakdown form and so steam quality may Check pumps and armatures
decrease.
Water carry over with steam could
Drum level instrument breakdown form and so steam quality may Check Level instrument
decrease.
High Level - Water carry over with steam could
BOILER High-High Level Rapid load decrease form and so steam quality may Increase the boiler load.
Alarm decrease.
Water carry over with steam could Check Control valve and
Feedwater control valve breakdown form and so steam quality may instrument air existance and
decrease. pressure.
Drum water fluctuations take
Water carry over with steam could place because of rapid load
Fluctuating at drum water form and so steam quality may change. This problem be
decrease. overcome after load
normalization
Water carry over with steam could Boiler must be heated in a
Rapid rising of heating rate form and so steam quality may controlled way, rapid heating
decrease. must be avoided
1/15/2020 68
6.TROUBLE SHOOTING
Boiler must be stopped.

Pressure must be decreased by
opening vent valve. Water in
- - boiler must be discharged slowly
by opening drain valve. After
boiler cooling, damaged tube
must be detected and repaired.
Tube overheating and puncturing
Check Level instruments and
could occur. Boiler efficiency
feedwater system considering
Water lack at tubes decreases. So, rapid decrease at
boiler working without water
steam load may be seen. Exhaust
Water wall tubes - possibility
temperature increase to normal
Evaporator tubes Tube overheating and puncturing
BOILER problems, over- could occur. Boiler efficiency
heating at wall Drum level instrument breakdown decreases. So, rapid decrease at Check Level instrument
tubes steam load may be seen. Exhaust
Chemical cleaning could be
Clogged tube, abraded tube decreases. So, rapid decrease at
performed
Chemical cleaning could be
Fouling at tubes decreases. So, rapid decrease at
done in case of fouling
1/15/2020 69
6.TROUBLE SHOOTING
General: If boiler pressure

- - increases in uncontrolled way, it
must be stopped manually
Drum water level may fluctuate. Boiler

Rapid decrease at loading/steam will automatically stop in case of high
Decrease boiler load slowly
Rapid pressure flowrate pressure alarm. Safety valve will be
BOILER
rise active in case pressure still increase.
Drum water level may fluctuate. Boiler Boiler must be stopped manually
will automatically stop in case of high and burner must be controlled. If
Burner fault(flow control valve fault)
pressure alarm. Safety valve will be required, burner must be
active in case pressure still increase. repaired.
Fouling, clogging and corrosion at Chemical cleaning must be

Tubes could be clogged in time.
tubes performed.
Low steam Drumda zamanla delinmeler meydana Kimyasal yıkama yapılmalıdır. /

quantity - Low Fouling at drum gelebilir. / Drum could be clogged in Chemical cleaning must be
BOILER time. performed.
steam pressure
and temperature
Check burner, fuel control valve,
Low fuel flowrate -
fresh air damper and fan
1/15/2020 70
6.TROUBLE SHOOTING
Apply controlled heating to

Problem could occur at the
Problem at boiler. Repair the damaged
BOILER Uncontrolled elongation at boiler connection points between equipment
stoppers (saddle) stoppers and problems occured
attached to boiler and compensator
at connection points.
Boiler steam quantity and Stop the boiler, open the vent
temperature decreases. If any valve and maintain pressure
Weld crack
personel in close area, he/she may value is 0. If required, discharge
suffer. water in boiler.
Steam-water
BOILER
leakage
Boiler steam quantity and Stop the boiler, open the vent
temperature decreases. If any valve and maintain pressure
Gasket problem
personel in near area, he/she may value is 0. If required, discharge
suffer. water in boiler.
1/15/2020 71
6.TROUBLE SHOOTING
Low feedwater temperature and Change the tube if problem level
flowrate values are obtained at is serious. For other issues,
Corrosion-
economiser outlet. Boiler efficiency perform the chemical cleaning.
ECONOMISER puncture at heat Fouling-Clogging at tubes
and steam generation decreases. Check the feedwater quality.
transfer tubes
Exhaust with moisture removes stack. Don't supply water not
Exhaust temperature decreases appropriate as per standards.
Stop the boiler and change the

Further expansion or shrinking acc. to Exhaust leaks. Steam quantity
compensator. Choose the
design criteria decreases.
proper compensator.
EXPANSION JOINT Tearing

Stop the boiler and change the
Exhaust leaks. Steam quantity compensator. Mount the
Installation fault
decreases. compensator axially and without
connection problem.
Stop the boiler and repair

Insulation material problem in duct Shell heats
Heating up at insulation
FLUE GAS DUCT
shell Exhaust leaks. Steam quantity Stop the boiler and repair the
Leakage at flue gas duct
decreases. flue gas duct
Stop the boiler. Check the

High or low fluid flowrate occurs. control valve and if instrument
Boiler water level increase or air pressure supplied to valve is
INSTRUMENTS and Pneumatic control decrease seriously. Rapid boiler proper. Check also if filter before
On-off problem
ARMATURES valves pressure change is observed. Water control valve is clean. Check
level in drum fluctuates. Drum level manual valve position before
measurement fault is observed. and after control valve. Be sure
that instrument air is dry.
1/15/2020 72
7.MAINTENANCE
➢ Water Wall Tube Replacement
1) Remove the boiler insulation materials around damaged tube.
2) Cut the damaged section of tube(Cutted area should cover area which is distance of
50 mm from each side of damaged section)
3) Remove the cutted part
4) Cut the new tube,
5) Prepare the Butt welding end to new tube and the tubes where new tube will be
placed(butt welding angle is 60°)
6) Put the new tube to place of removed part
7) Perform the butt welding
8) Perform 100%RT + PT
9) Perform hydrostatic test
1/15/2020 73
7.MAINTENANCE
➢ Plugging of Tube
• The plugging method of tube can not be performed to this boiler due to which is with
one drum.
• We recommend that the damage tube should be replaced with new tube.
1/15/2020 74
7.MAINTENANCE
➢ Daily Maintenance Program
Equipment Name Equipment Part Main Check Point Checking Method Checking Description Action
Buhar-Su Sızıntısı /
KAZAN / BOILER Dram / Steam Drum Steam-Water Görsel / Visual - Tamir / Repair
Leakage
İzolasyondaki
Genleşmeler -
KAZAN / BOILER Dram / Steam Drum Hatalar / Görsel / Visual - Tamir / Repair
Expansions-Faults
On The Insulation
Buhar-Su Sızıntısı /
Duvar Su Boruları /
KAZAN / BOILER Steam-Water Görsel / Visual - Tamir / Repair
Water Wall Tubes
Leakage
Görsel + Koklama +
Duvar Su Boruları / Egzoz Sızıntısı /
KAZAN / BOILER Ölçümsel / Visual + - Tamir / Repair
Water Wall Tubes Exhaust Leakage
Sniff + Measurable
İzolasyondaki
Genleşmeler -
Duvar Su Boruları /
KAZAN / BOILER Hatalar / Görsel / Visual - Tamir / Repair
Water Wall Tubes
Expansions-Faults
On The Insulation
Gözetleme Camı / Cam Temizliği /
KAZAN / BOILER Görsel / Visual - Cam temizlenir. / Glass is cleaned
View Glass Glass Cleaning
Soğutma havası vanası açılır ve hava
Gözetleme Camı / Soğutma Sistemi / gelip gelmediği kontrol edilir. / Cooling
KAZAN / BOILER Elle / Manual Tamir / Repair
View Glass Cooling System air valve is opened and it is checked
whether air comes.
Anormal Ses İşitsel + Elle +
Tum Gövde / All ,Vibrasyon / Ölçümsel / Audial +
KAZAN / BOILER - Tamir / Repair
Casing Abnormal Noise , Manual +
Vibration Measurable
1/15/2020 75
7.MAINTENANCE

KIZDIRICI / ,Vibrasyon / Ölçümsel / Audial +
Gövde / Casing - Tamir / Repair
SUPERHEATER Abnormal Noise , Manual +
Görsel + Koklama +
KIZDIRICI / Egzoz Sızıntısı /
Gövde / Casing Ölçümsel / Visual + - Tamir / Repair
SUPERHEATER Exhaust Leakage
Sniff + Measurable
İzolasyondaki
Genleşmeler -
KIZDIRICI /
Gövde / Casing Hatalar / Görsel / Visual - Tamir / Repair
SUPERHEATER
Expansions-Faults
On The Insulation
EKONOMİZER / ,Vibrasyon / Ölçümsel / Audial +
ECONOMISER Abnormal Noise , Manual +
Görsel + Koklama +
EKONOMİZER / Egzoz Sızıntısı /
ECONOMISER Exhaust Leakage
Sniff + Measurable
İzolasyondaki
Genleşmeler -
EKONOMİZER /
Gövde / Casing Hatalar / Görsel / Visual - Tamir / Repair
ECONOMISER
Expansions-Faults
On The Insulation
1/15/2020 76
7.MAINTENANCE
EGZOZ KANALI
KOMPANSATORL
Görsel + Koklama +
ER / Egzoz Sızıntısı /
COMPENSATORS Exhaust leakage
Sniff + Measurable
OF EXHAUST
DUCT
EGZOZ KANALI
KOMPANSATORL Anormal Ses İşitsel + Elle +
ER / ,Vibrasyon / Ölçümsel / Audial +
COMPENSATORS Abnormal Noise , Manual +
OF EXHAUST Vibration Measurable
DUCT
DUMAN Görsel + Koklama +

Egzoz Sızıntısı /
KANALLARI / Gövde / Casing Ölçümsel / Visual + - Tamir / Repair
Exhaust leakage
EXHAUST DUCTS Sniff + Measurable
İzolasyondaki
DUMAN Genleşmeler -
KANALLARI / Gövde / Casing Hatalar / Görsel / Visual - Tamir / Repair
EXHAUST DUCTS Expansions-Faults
On The Insulation
DUMAN
,Vibrasyon / Ölçümsel / Audial +
KANALLARI / Gövde / Casing - Tamir / Repair
Abnormal Noise , Manual +
EXHAUST DUCTS
1/15/2020 77
7.MAINTENANCE
Anormal Ses /
FAN / FAN Gövde / Casing İşitsel / Audial - Tamir / Repair
Abnormal Noise
Vibrasyon, Sıcaklık ,
Rulmanlar, Yataklar / Görsel + Ölçümsel / Rulman değiştirilir / Change the
FAN / FAN Kirlilik / Vibration, -
Bearings, Seats Visual + Measurable bearing
Temperature, Fouling
EGZOZ KLAPELERİ Anormal Ses İşitsel + Elle +
/ EXHAUST Gövde / Casing ,Vibrasyon / Abnormal Ölçümsel / Audial + - Tamir / Repair
DAMPERS Noise , Vibration Manual + Measurable
Seviye göstergesinde sıvı olup olmadığı
kontrol edilir. Seviye göstergesinde
okunan sıvı seviyesi değeri ile scada
CAMLI SEVİYE Görsel + Uygun
ekran üzerinde okunan değerin aynı olup
GÖSTERGELERİ / Seviye Camı / Level Enstrümanlar & Visual
Seviye / Level olmadığı kontrol edilir. / It is checked Tamir / Repair
LEVEL GAUGES Glass + Appropriate
whether there is water inside level gauge
WITH GLASS Instruments
and also whether it is the same that water
level value read from level gauge and
from screen.
CAMLI SEVİYE
GÖSTERGELERİ / Seviye Camı / Level Cam Temizliği / Glass Gösterge camları temizlenir. / Gauge
Görsel / Visual -
LEVEL GAUGES Glass Cleaning glasses are cleaned
WITH GLASS
EMNİYET
Emniyet vanası tedarikçiye gönderilir /
VANALARI / Gövde / Casing Sızıntı / Leakage Görsel / Visual -
The safety valve is sent to supplier.
SAFETY VALVES
TÜM VANA VE
ENSTRÜMANLAR / Tamir veya Değiştirme / Repair or
Gövde / Casing Sızıntı / Leakage Görsel / Visual -
ALL VALVES AND Changing
INSTRUMENTS
1/15/2020 78
7.MAINTENANCE
➢ Weekly Maintenance Program
Yağ Miktarı, Kirlilik /

Rulmanlar, Yataklar / Yağ eklenir veya değiştirilir / Oil
FAN / FAN Oil Quantity, Görsel / Visual -
Bearings, Seats is added or changed.
Fouling
EGZOZ
Yağ Miktarı, Kirlilik /
KLAPELERİ / Rulmanlar, Yataklar / Yağ eklenir veya değiştirilir / Oil
Oil Quantity, Görsel / Visual -
EXHAUST Bearings, Seats is added or changed.
Fouling
DAMPERS
Seviye göstergesinin ekipmanla
olan alt bağlantı vanası kapatılır.
Seviye göstergesinin drain
vanası açılır ve göstergedeki sıvı
drain edilir. Sonra ekipman
bağlantı vanaları kontrollü bir
şekilde açılır. Göstergeden
okunan seviye değeri PLC den
CAMLI SEVİYE
Gösterge İçi Kirlilik / okunan ile kıyaslanır. / The
GÖSTERGELERİ Gösterge İçi / Inside
Gauge Inner Part Görsel / Visual - Bottom Connection Valves
/ LEVEL GAUGES of Gauge
Fouling between level gauge and
WITH GLASS
equipment are closed. Drain
valve of level gauge is opened
and liquid in gauge is drained.
Then, equipment connection
valves are opened under control.
The readed level value on the
gauge is compared with readed
value onto PLC.
1/15/2020 79
7.MAINTENANCE
➢ Monthly Maintenance Program
Tüm Bağlantı
Gevşeklik / Mekanik /
FAN / FAN Civataları / All - Civatalar sıkılır / Bolts are tightened
Loosening Mechanical
Connection Bolts
Deformasyon / Milin değiştirilmesi / Changing of
FAN / FAN Mil / Shaft Görsel / Visual -
Deformation Shaft
Korozyonun temizlenmesi ve
Görsel + NDE Test +
korozyon koruyucu malzeme
Kalınlık Kontrolü /
FAN / FAN Mil / Shaft Korozyon / Corrosion - sürülmesi / Cleaning of corrosion
Visual + NDE Test +
and applying of material preventing
Thickness Checking
from corrosion.
ENSTRÜMAN
HAVA
Enstrüman Havası / Kimyasal Analiz /
BORULANDIRMAS Kuruluk / Dryness - Tamir / Repair
Instrument Air Chemical Analysis
I / INSTRUMENT
AIR PIPING
1/15/2020 80
7.MAINTENANCE
➢ Semi Annual Maintenance Program
Boruların Egzoz
Tarafında Kirlenme- Görsel + Kalınlık
KIZDIRICI / Su Isıtma Boruları / Heat İlgili boru değiştirilir veya temizlenir. /
İslenme / Fouling- Kontrolü / Visual + -
SUPERHEATER Transfer Tubes Related tubes are changed or cleaned
Sooting at Exhaust Thickness Checking
Side of Tubes
Dış Yüzeyde Erozyon,
Korozyon, Görsel + NDE Test +
İlgili boru değiştirilir veya tamir edilir. /
KIZDIRICI / Su Isıtma Boruları / Heat Deformasyon / Kalınlık Kontrolü /
- Related tubes are changed or
SUPERHEATER Transfer Tubes Erosion, Corrosion , Visual + NDE Test +
repaired.
Deformation of Outer Thickness Checking
Surface
Boruların Egzoz
Tarafında Kirlenme- Görsel + Kalınlık
EKONOMİZER / Su Isıtma Boruları / Heat İlgili boru değiştirilir veya temizlenir. /
İslenme / Fouling- Kontrolü / Visual + -
ECONOMISER Transfer Tubes Related tubes are changed or cleaned
Sooting at Exhaust Thickness Checking
Side of Tubes
İlgili boru değiştirilir veya tamir edilir. /
EKONOMİZER / Su Isıtma Boruları / Heat Deformasyon / Kalınlık Kontrolü /
- Related tubes are changed or
ECONOMISER Transfer Tubes Erosion, Corrosion , Visual + NDE Test +
repaired.
Surface
BLÖF TANKI /
İç Kısım / Inner Part Kirlenme / Fouling Görsel / Visual - Temizlik / Cleaning
BLOWDOWN TANK
Klapede istenilen açıklık oranı ile
EGZOZ KLAPELERİ Kanatların Açıklık Oran
Görsel + Ölçümsel / meydana gelen açıklık oranı kıyaslanır ve Kanatlar ayarlanır. / The flaps are
/ EXHAUST Kanatlar / Flaps / Opening Rates of
Visual + Measurable kontrol edilir. / The opening rates wanted adjusted.
DAMPERS Flapsı
and occured are compared and checked.
1/15/2020 81
7.MAINTENANCE
➢ Semi Annual Maintenance Program
Pressure value read from pressure
gauge is checked with another
pressure gauge ensuring safety
measurement. Pressure gauge
BASINÇ
connection valves is closed,
GÖSTERGELERİ / Kalibrasyon / Ölçümsel / Basınç göstergesi kalibre edilir. /
Gövde / Casing calibrated pressure gauge is
PRESSURE Calibration Measurable Pressure gauge is calibrated
connected to cock and valve of this
GAUGES
part is opened. Then, valve at the
other pressure gauge and two
pressure values read from these 2
gauge are compared.
1/15/2020 82
7.MAINTENANCE
➢ Years Maintenance Program
Boru üzerinde kireçlenme olup olmadığı

kontrol edilmeli, kireçlenmenin olduğu
yerden su-buhar sızıyor demektir. / It
KIZDIRICI / Isıtma Boruları / Heat Buhar-Su Sızıntısı / İlgili boru değiştirilir veya tamir edilir. /
Görsel / Visual should be checked whether there is furring
SUPERHEATER Transfer Tubes Steam-Water Leakage Related tubes are changed or repaired.
on the pipe. If having, ıt means that have
water/steam leakage at the location with
furring
Isıtma Boruları ve
KIZDIRICI / Kollektorler / Heat Ölçümsel / İlgili boru değiştirilir / Related tube is
Kalınlık / Thickness -
SUPERHEATER Transfer Tubes and Measurable changed
Collectors
Boru üzerinde kireçlenme olup olmadığı
kontrol edilmeli, kireçlenmenin olduğu
yerden su-buhar sızıyor demektir. / It
EKONOMİZER / Su Isıtma Boruları / Heat Buhar-Su Sızıntısı / İlgili boru değiştirilir veya tamir edilir. /
Görsel / Visual should be checked whether there is furring
ECONOMISER Transfer Tubes Steam-Water Leakage Related tubes are changed or repaired.
on the pipe. If having, ıt means that have
water/steam leakage at the location with
furring
Su Isıtma Boruları ve
EKONOMİZER / Kollektorler / Heat Ölçümsel / İlgili boru değiştirilir / Related tube is
Kalınlık / Thickness -
ECONOMISER Transfer Tubes and Measurable changed
Collectors
EGZOZ KANALI
Gövdede, uzamalardan meydana gelen Kompansatör değiştirilir veya tamir
KOMPANSATORLER Hiza Kontrolü / Görsel + Ölçümsel /
Gövde / Casing çarpıklık kontrol edilir. / Distortion caused edilir. / Compensator is changed or
/ COMPENSATORS Alignment Visual + Measurable
by Casing elongation is checked. repaired
OF EXHAUST DUCT
İç Yüzeyde Erozyon,
Korozyon,
DUMAN KANALLARI Refrakter tamir edilir veya değiştirilir /
Refrakter / Refractory Deformasyon / Erosion, Görsel / Visual -
/ EXHAUST DUCTS Refractory is repaired or changed.
Corrosion , Deformation
of Inner Surface
1/15/2020 83
7.MAINTENANCE
➢ Years Maintenance Program

Deformasyon / Kalınlık Kontrolü / Tamir edilir veya mil değiştirilir /
FAN / FAN Kanatlar / Flaps -
Erosion, Corrosion , Visual + NDE Test + Repaired or the shaft is changed.
Surface
Ekipman basıncı , emniyet vanası set
basıncına yükseltilir, bu basınçta emniyet
vanasının açtığı ve buharın-suyun deşarj
EMNİYET
Açma Kontrolü / Görsel ve Mekanik / olduğu gözlemlenir / The equipment Emniyet vanası tedarikçiye gönderilir /
VANALARI / Gövde / Casing
Opening Control Visual anc Mechan pressure is increased to safety valve set The safety valve is sent to supplier.
SAFETY VALVES
pressure and ıt observed that the safety
valve is opened at this pressure and the
steam-water is discharged.
Presostat tekrardan ayarlanır ve
Ekipman basıncı , set basıncına presostatın uygun şekilde çalıştığı ,
yükseltilir, bu basınçta sistemin durduğu kazan basıncı set basıncına
PRESOSTAT / Set Basıncı / Set kontrol edilir. / The equipment pressure is yükseltilerek kontrol edilir /
Gövde / Casing Mekanik / Mechanical
PRESSURESTAT Pressure increased to set pressure and ıt is Pressurestat is adjusted again and
checked that the equipment is stopped at checked as ıt is worked properly by the
this pressure boiler pressure is increased to set
pressure.
TUM BORULAR /
Civatalar / Bolt Gevşeklik / Loosening Mekanik / Mechanical - Civatalar sıkılır / Bolts are tightened
ALL PIPES
1/15/2020 84
7.MAINTENANCE
➢ Ten Years Maintenance Program
Boru-Kollektör
Kollektörler / Görsel + NDE Test /
KAZAN / BOILER Kaynakları / Tube- - Tamir / Repair
Collectors Visual + NDE Test
Header Welds
Boru-Kollektör
KIZDIRICI / Kollektörler / Görsel + NDE Test /
Kaynakları / Tube- - Tamir / Repair
SUPERHEATER Collectors Visual + NDE Test
Header Welds
Boru-Kollektör
EKONOMİZER / Kollektörler / Görsel + NDE Test /
Kaynakları / Tube- - Tamir / Repair
ECONOMISER Collectors Visual + NDE Test
Header Welds
1/15/2020 85
8.PRESERVATION PROCEDURE
➢ Preservation Methods
Preservation methods are;
• Wet Preservation
• Inert Preservation
• Preservation with Silica Gel
1/15/2020 86
Wet Preservation
• Water level is stayed at normal operating case

• Remaining spaces is filled with nitrogen
Inert Preservation
• All water is drained

• The system is filled with nitrogen
Preservation with Silica Gel
• The silica gel is putted inside to equipment

• The silica gels are changed periodically comply with supplier recommendations.
1/15/2020 87
➢ Preservation Method Selecting
FOR SHUT DOWN
FOR TRANSPORTATION FOR SITE STORAGE
> 1 week < 1 week
INERT
INERT PRESERVATION IS INERT PRESERVATION IS WET PRESERVATION IS
BOILER PRESERVATION IS
APPLIED APPLIED APPLIED
APPLIED
INERT
ECONOMISER PRESERVATION IS
APPLIED
INERT
SUPERHEATER PRESERVATION IS
APPLIED
BLOWDOWN TANK - - - -
INERT
FEEDWATER TANK & INERT PRESERVATION IS INERT PRESERVATION IS WET PRESERVATION IS
PRESERVATION IS
DEAERATOR APPLIED APPLIED APPLIED
APPLIED
FUEL TANK - - - -
PUMPS - - - -
FANS - - - -
CHEMICAL DOSING SYSTEM - - - -

PRESERVATION
PRESERVATION WITH PRESERVATION WITH SILICA
ELECTRIC BOARD WITH SILICA GEL IS -
SILICA GEL IS APPLIED GEL IS APPLIED
APPLIED
1/15/2020 88
➢ Shutdown Preservation Selecting Chart
1/15/2020 89

Auxiliary Boiler Training Manual RA

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1/15/2020 1

5. STEAM PURITY & BOILER WATER QUALITY

✓ Preservation with Silica Gel

✓ Preservation with Silica Gel

▪ PRESERVATION METHOD SELECTING

❑ Steam Flow Rate : 6,6 t/h ( at tie-in point )

Combustion is combination of fuel with oxygen in the air as fastly.

C + O2 CO2 + 7,830 kcal/kg carbon

2H2 +O2 2H2O + 28,890 kcal/kg hydrogen

❑ The combustion products at incomplete combustion contains unburned fuels or

When the boiler starts up;

1) ACC - The Start Sequence

4) ACC - Oxygen in Flue-Gas Control

O2 analyzer (90QHN01CQ101) is provided to measure residential oxygen in flue gas. The

FEED WATER TANK LEVEL CONTROL

DEAERATOR PRESSURE CONTROL

The valve is located on the boiler feed water line(90QLA11BR108).

❑ level transmitter on the drum (90QHA01CL101),

❑ feed water flowmeter (90QLA11CF101),

❑ steam flowmeter (90QLB20CF101).

CONTINUOUS BLOWDOWN CONTROL

INTERMITTENT BLOWDOWN CONTROL

BLOWDOWN OUTLET LINE CONTROL

The temperature transmitter (90QMA20CT101) on the blowdown outlet line

The system is controlled by desuperheater control valve (90QLA11AA712)

DRUM WATER LEVEL < LL % _ 11 _

DRUM STEAM PRESSURE > HH kPag _ _ 1170

SH STEAM TEMPERATURE > HH ◦C 320 340

FUEL-OIL PRESSURE < LL kPag _ 200 _

SECONDARY AIR PRESSURE < LL kPag _ 0.75 _

PRIMARY AIR PRESSURE < LL kPag 0.3 _

BURNER COVER NO CLOSED _ CLOSED NOT CLOSED

BURNER MOTOR NOT RUNNING _ RUNNING NOT RUNNING

NO FAN RUNNING _ RUNNING NOT RUNNING

AIR / GAS PATCH NOT OPEN _ OPEN NOT OPEN

FLAME FAILURE _ ON FAIL OFF

EMG STOP ACTIVE _ NOT ACTIVE ACTIVE

PLC TRIP _ NOT TRIP TRIP

IGNITION FLAME FAILURE _ ON FAIL OFF

➢ PURGE PERMISSIVE CONDITION

SECONDARY AIR PRESSURE < LL kPag _ 0.75 _

NO OPERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION

1 Check Emergency Stop Button Release it if required.

BMS PANEL HMI DISPLAY

HMI DISPLAY HMI DISPLAY

NO OERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION

Select LOCAL position via selector

BMS PANEL BMS-HMI display and lamp light on

Burner motor icon turns ''RED'' on HMI. Burner motor is started.

Selected FD fan turns ''RED'' on HMI. Selected FD Fan is started.

NO OERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION

HMI DISPLAY Purge starts and continues till the

Ignition transformer icon turns ''RED'' on Ignition Transformer is energized.

NO OERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION

NO OERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION

BMS PANEL BMS-HMI display and lamp light on BMS

HMI DISPLAY Primary and Secondary Air

NO OERATION ACTION INTERLOCK FUNCTION MECHANICAL FUNCTION

Selected FD fan turns ''GREEN'' on Running FD Fan is stopped.

BMS PANEL HMI display and lamp light on BMS

-Close all bypass, drain and vent valves

Deaerator+Feedwater -Open deaerator vent valve(90QLA11AA902)

Fuel Lines -Close drain valves