. we ANT | “LOAD ANTICIPATED PARAMETERS, D PERFORMANCE Le MCR _* STEAM & WATER PR. AT 101 % MCR | PAGE NO. C-5/1OM THERMAX BABCOCK & WILCOX LTD REV-1 20.05.96 O&M MANUAL BOILER OPERATION WALK DOWN CHECK LIST DURING OPERATION ¢ Check for unusual noises from steam/water leakages. © Check for unusual traces of water on floor, buck stay or leakage from casing joints. © Check for oil Spills around burner /OPH unit CiF CEROVWDED) © Look for valve and gland leakages. ¢ Discoloration, hot spots and bulging etc. on casing, ducts and hoppers. * Check for steam and water leaks from connections and fittings to the drum. © Watch the furnace for any clinker formation and for any abnormality. e Walk around the furnace exterior and observe for any hot spots or gas leaks. * Listen for any unusual noise around economiser which may indicate economiser leak (i.e. hissing noise) + Inspect windbox for any air leakage. © Check around all air/flue ducts for signs of leakage * Check position of fan and field dampers. © Check for any gas leakages from refractory sealing. * Check for leakages from safety valves at normal operating pressure. Also note the safety valve blow off and shut off pressure. Check that the drain lines and drip pans are not plugged. PAGE NO. C -6/1om REV-1 2005.96 THERMAX BABCOCK & WILCOX LTD O&M MANUAL BOILER OPERATION WALK DOWN CHECK LIST DURING OPERATION © Make note of any leaky valves and prepare maintenance schedule to repair them. © Check to see that proper water level is being shown by the direct water level gauge. Check for water or steam leaks from ports or drain connections which will cause a false water level in the gauge glass. Inspect the glass for discoloration or fouling. © While doing routine operation of soot blowing, inspect for condensate, steam and leaks from the soot blowers. ° FANS: Inspect bearing lubrication and check for proper oil/ grease level If ring - oiled, check for free revolution and adequately distributed oil. Check bearing temperature . If hot determine cause and rectify the cause Ensure continuous water flow to water cooled bearings if provided. Listen for any unusual noises in the fan... Feel and inspect for vibration. Inspect bearing seals. Check for any abnormality in couplings. e MOTORS: - Check for unusual noises and inspect for vibrations. - Check for winding temperatures, bearing temperatures. - Check current and voltage. PAGE NO. C- 6/2OM THERMAX BABCOCK & WILCOX LTD REV-1 20.05.96 O&M MANUAL BOILER OPERATION DO’S AND DONT ‘S FOR BOILERS DO'S 1. Clean the internals before closing the man holes of pressure parts furnace and ducting. 2. Maintain all instruments in good working condition. 3, All equipment interlocks should be always in 4. Maintain normal water level in Feed water tank, Deaerator tank and 5. Maintain water quality as per the recommended limits. 6. All dampers must be in smooth operating condition. 7. Pressure raising from cold start must be done as per the cold start up curve. 8. All the duct joints must be leak proof. 9. Use proper lubricants recommended by the manufacturer regularly. 10.Start_ the equipment as per sequence i.e. start Compressor, Feed water pump, FD Fan as per the procedures. 11.Carry out regular soot blowing for boiler and economiser 12.Regularly clean feed water and Transfer pump suction strainers. 13.Operate the boiler within the recommended operation limits. PAGE NO. C-7/1OM THERMAX BABCOCK & WILCOX LTD REV-1 O&M MANUAL BOILER OPERATION ’S AND DON’TS FOR __ BOILER (Continued) 14.Boiler, Piping, Ducts, Feed water and Oil tank must be properly insulated. 15.Servicing of equipments should be done as per the manufacturer’s schedule. 16.Maintain proper operation log sheets regularly. 17.Maintain the instrument air free from moisture and oily matters and the pressure as recommended. 18.Camy out regular cleaning of Direct water level gauge glass on Feed water tank, Deaerator tank and Boiler drum. 19.Use proper valve gland packing to avoid leakage. 20.Use proper gaskets for flange joints. 21.Regularly maintain Refractory construction. 22.Keep the OPH unit clean and ready for operation at any time. 23.Clean the Oil gun regularly. 24,Retract the Gun whenever not in service.(Manually)(If any) 25.Operate the blowdown valves as per recommendation. 26.Boiler surroundings and equipments must be properly illuminated. 27.In case of power failure close the steam stop valve and stop the fire immediately. PAGE NO C-7/2om THERMAX BABCOCK & WILCOX LTD REV-1 O&M MANUAL BOILER OPERATION DO’S AND DON’TS FOR __ BOTLER (Continued) 28.If the water level goes up above the limits operate the intermittent blowdown valve immediately and maintain the water level to normal. 29.Use genuine spares. 30.Before starting these equipments ensure the following. 31.COMPRESSOR (IF APPLICABLE) © Check oil level © Check cooling water flow to Air cooler. © Ensure that Compressor discharge valve is in open condition. 32.FEED WATER PUMPS Ensure proper water level in the Deaerator tank Open suction valve fully. Open recirculating valve fully. Open balancing line valve fully. Close the discharge valve fully. Ensure cooling water supply to stuffing box (If provided ). Cheek lubricating oil level coc eee 33.FD FAN e ID Fan in running condition * Close suction damper * Check lubrication PAGE NO. C-7/3om. THERMAX BABCOCK & WILCOX LTD REV-1 O&M MANUAL BOILER OPERATION 10’S AND DON’TS FOR BOILER (Continued) 34.In case of traces contamination in the condensate being found in boiler feed water, give heavy blow downs once every hour.Use DM water and avoid using condensate until contamination are eliminated. 35.Change over to stand by pumps / compressors periodically. 36.Provide alarm indicating fuel handling plant Stoppage in the boiler control room and fuel handling plant. cee PAGE NO. C-7/4om REV-1 2005.96 THERMAX BABCOCK & WILCOX LTD O&M MANUAL BOILER OPERATION DO’S AND DON'TS Fi BOILER DON’TS 01. Don’t by pass any instruments and safety interlocks. 02. Don’t use raw water as Boiler feed water. 03. Don’t start any fan with suction damper in open condition. 05. Don’t start any Pump with the delivery valve in open condition. 06. Don’t throttle the feed water pump balancing leakoff valve while the pump is in operation. 08. Don’t operate the furnace wall header drain valves while the Boiler is in operation. 09. Don’t operate the boiler beyond the operation limits. 10. Don’t leave the furnace door open while the boiler is in Operation. 11. Don’t mix up different lubricants. 12. Don’t by pass compressed’ air dryer, if any problem attend to it at the earliest. 14. Don’t alter the equipment maintenance schedule. 15. Don’t leave the Instrument Control Panel unattended. 16. Don’t allow unauthorised Persons to operate the boiler and associated equipments. 17. Avoid continuous operation of boiler at low loads (low back end temperature) to protect economiser and air preheater corrosion. 18. Do not dose chemicals into the boiler in batch wise, they should be done on a continuous basis. PAGE NO. C-7/5RECOMMENDED MAINTENANCE PRACTICES Systematic maintenance is essential to keep the Boiler and its auxiliaries in good condition to obtain reliable operation of the boiler with high availability and plant load factor. Effective maintenance aims at timely inspection of parts to repair or replace defective components and to prevent their failure when the boiler is in service. Maintenance can be classified as a) Preventive maintenance -- mostly condition based b) Annual Boiler over haul to clean and inspect pressure parts and to comply with IBR requirements. The shut down period of the overhaul is also utilised to attend to systems and parts which cannot be attended during short shut downs or when the boiler is in operation. ‘The vendor manuals of the FD Fans, Drive Turbine, Motors, Scanner Cooling Air Blowers, Control Valves with their positioners and actuators, isolating valves, instruments and controls, conductivity, pH, oxygen , CO, SO, analysers, power cylinders etc., prescribe certain minimum maintenance Tequirements which are carried out in one of the above two maintenance categories : PAGE NO. C- 9/1PREVENTIVE MAINTENANCE (INTRODUCTION) ‘An equipment such as a fan is said to be under preventive maintenance, when it is stopped say after some period of operation, de-coupled from its drive, bearing housing oil is drained, top cover of the housing is opened and a visual examination of the bearing is done. The access door of the impeller housing is opened and the impeller blades are cleaned and examined for wear. Defective or worn parts noticed are repaired or replaced. Oil seals ‘O” rings if any, are replaced. The tightness of the bolts and nuts which fix the fan casing to the foundation are checked with a torque wrench. The fan bearing housing cover is assembled and recommended lubricant is filled to the correct level. The expansion joints at the discharge end are checked to see that they are not compressed or expanded. Damages if any to the bellows, are corrected by patch up. Discharge duct supports are checked and adjusted to their design value. ‘The suction damper bearings / bushings are checked for wear and repaired or replaced as necessary. The travel of the damper is checked and corrected where required. The end shields of the drive motor are opened. The stator-rotor spaces are cleaned blowing a jet of warm air. The bearings are cleaned and re-lubricated. ‘The insulation resistance of the stator coils are measured and compared to their previous values. The end shields are assembled. The motor coupling is aligned to the fan coupling. Trial run of the fan is taken. Bearing vibrations, temperatures, noise levels are measured and compared to previous values. Adjustments if any required (alignment, bearing clearances etc.,) are done. The maintenance exercise is successful, if the observed values are better than the values before the shut down. Another variant of the maintenance can be disassembling the fan to its components level, taking out the bearings, impeller etc., checking the trueness of the shaft, checking bearings etc., before re-assembly. In the drive motor also, the rotor is taken out and the rotor and stator coils are examined for tightness. The coils are cleaned by air blowing and revarnished. PAGE NO. C- 9/2A preventive maintenance programme for valves once in two years can be done with one or more of the following works. Disassembling the bonnet, cleaning the trim and valve seat, lapping them if necessary - Cleaning the valve stem and re-lubrication of the operating threads. - Renewing valve seat @ the bonnet joint, and assembling the trim on the - Renewing the gland packing. - Renewing the valve flange joint, if necessary Maintenance for the pneumatic actuators call for disassembly and checking the integrity of the diaphragm, verifying the air tightness of the diaphragm chamber etc.. Calibration of the flow, pressure, temperature transmitters, conductivity. pH, oxygen, CO, NOX. SO, analysers to the values indicated in their data sheets also come under the preventive maintenance programme. Proximity switches, limit switches require to be tested for their correct operation. Ignitors. spark device. IFM and UV flame monitoring devices oil guns require periodical cleaning and check as per the vendor manuals. the objective of the preventive maintenance programme is to obtain trouble ¢ service trom the component till the next maintenance. Vendor manuals enclosed in this volume suggest the inspection periods, checks to be done and recommended spares to be changed. The true objective of the maintenance programme can only be realised, if a master plan of maintenance of all the components is prepared as per vendor instructions Full benefits of maintenance can be obtained only if proper parts are used Mandatory spare part list given in section C of this volume covers most of he spares required. It may be found that in the first two years of operation due to variations of site conditions, some additional spares not included in section C ure also required. Action has to be initiated to procure such spares PAGE NO. C- 9/3Some equipment have 100% reserve standby units. (two FD Fane blowers, two feed control stations, control valves with manual by pass arrangement etc.). Maintenance of such equipment can be organised even when the boiler is in service, although some minimum risk is involved, equipment such as oil guns, ignitors, scanners have replacement spares which can be utilised when the working equipment are to be maintained without affecting the boiler operation. The prepared master plan for maintenance should be periodically reviewed during the first three years of the boiler operation. It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are either too much or too less. Based on site experience, the frequencies and work schedules can be modified. A scientific method of preparation of the preventive maintenance schedules is to make them condition based. In condition based maintenance, the equipment and components of the plant are inspected daily, weekly monthly etc., as per a suggested schedule by the local operators and deteriorating conditions if any observed are reported. Suggested inspection Programme is given in this Chapter. Based on operator Teports of such inspection, maintenance works are planned for the next available planned shut down. Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the equipment condition. PAGE NO. C- 9/4SCHEDULE OF INSPECTIONS FOR CONDITION BASED ed The schedule of daily, weekly and monthly inspections given in the following Pages do not require a boiler shut down and in fact can only be done when the boiler is in service. Three and six monthly inspections are done utilising an available planned shut down approximately in the specified time period. Objective of these inspections are to ensure that - the components are in trouble free condition. - to carry out any minor repairs or adjustments which can be done with the boiler in service. - to plan for repair of such items, which cannot be attended when the boiler is in service, during the next available shut down. - to collect a data base to determine optimum service life of the systems and components before maintenance is required. The schedule can be expanded, curtailed or modified based on experience in the first two years of operation. DAILY CHECKS To be done once a day by the local operator during his walk down. Checks are also encouraged to be done in each shift by the local operators. Only those operational checks which require maintenance work for correction have been included. EQUIPMENT CHECK WORK TO BE DONE 1. Local level gauges | Check illumination is __ | Replace fused bulbs on steam drum proper Isolate local level Leaking valve glands, | gauge and tighten Leaking ports leaking glands. Replace Blurred level leaking ports. Steam wash mica as suggested by vendor (Not to be done too frequently) PAGE NO. C - 9/5a 2. Comparison of Compare the levels If there are serious levels indicated by after verifying there are | discrepancies, local level gauge no leaks from valves, | calibration of the with that of remote glands etc., of the level | remote level indicators level indicators in the | gauge and indicators _| has to be planned control room. Report discrepancies. | immediately 3. Traces of water, Such spots are Maintenance to be oil spots on boiler indicative of valve planned to eliminate the floor, buck stay leaks, Instrument source either oO beams, boiler cladding | tapping leaks, boiler _| immediately or during etc. tube leaks etc., Trace | next planned shut down the source of leak. (depending on the source and quantity of leak) and accessibility for maintenance.) 4, Lubricating Oil Check adequacy of oil | Top up if required levels of FD fan level (immediately) bearing, drive turbine Lub Oil tank, seal air If leakage through oil blower bearings, HP seals, gaskets drain dozing pump gear box plugs etc., are noticed, 7 etc: plan for maintenance CWiicHeVer TS) during next planned (ApriicaBie shut down. PAGE NO. C- 9/65. FD fan, Drive turbine, seal air blowers, Dosing pumps CNHICHEVER i) APPUCABLE, Check bearing temperatures If higher than normal bearing temperatures are noticed check for cause- proper oil level, correct grade and quality of oil, abnormal sound or vibration. If bearing temperatures are very high, start the reserve equipment and plan for a maintenance check, 6. Drum and super heater safety valves, Dump valve WIcHEVER is ) we APPLICABLE) Check for passing of safety valves (noise or wisp of steam through silencer) Hand pop the affected safety valve one or two times to clear any dirt sticking to the valve seats (Remote operation for PV- 602) Lightly tap on the stem of the safety valves. If these measures do not succeed, if request for check of the safety valve during next planned shut down. 7. Purity of Instrument air Check by visual observation that the instrument air is oil and moisture free (Oil and moisture content can also be checked by laboratory examination as per standards) Oil and moisture in the instrument air is likely to clog the positioners of pneumatic controllers ‘solenoids and make their operation sluggish or unreliable. Open drain valves of air receivers for short time to drain condensate if any. If these measures are not successful, inform: the Maintenance Group. PAGE NO. C- 9/78. FD Fan suction damper linkages, Air Register linkages and their power cylinders Check for their proper operation ‘Sluggish operation of f suction damper may be due to stuck linkage, stuck damper, faulty power cylinder, and faulty positioner. Sluggish operation of air register dampers may be due to stuck air register vanes, faulty power cylinders and faulty positioner. Check for possible cause. Maintenance works have to be planned. 9. Boiler cladding, air duct or flue gas duct Check for hot spots Hot spots may be due to leakage of flue gas or hot air. Source of leakage has to be located after selective removal of insulation (to be planned for the next planned shut down) WEEKLY CHECKS Ignitors If guns are in service continuously, at least once a week each ignitor must be tested for its performance by manual command, from BMS local -Check healthiness of the panel. If'an ignitor | HT transformer fails to light up on —_| - Check BMS sequence command the ignitor | for energizing HT requires to be transformer and opening serviced and kept in| of ‘block valve’ and working condition. __| closing of ‘bleed’ valve. ~ Remove the spark device, clean and check spark gap - Check insulation resistance of the spark- device PAGE NO. C- 9/8- Check healthiness of flame rod and its amplifier - A periodic maintenance schedule for the above works based on observations can be established so that ignitor is readily available when required MONTHLY CHECKS FD Fans, seal air blowers, HP dosing pumps HICHEVER ES APPLICABLE, With a vibration analyser record vibration, sound levels and measure bearing temperature. Note the Pressure, flow of air , suction damper opening , (Capacity of the FD Fan ) pressure (seal air blowers, HP dosing pump) By monthly recording of data, establish a data base. for deciding the overhaul time of the equipment. An overhaul once in two or three years may be adequate Database will help in deciding the time frame. Sharp increase in vibration levels bearing temperatures or sound levels may call for early scheduling of overhauls. Fuel Oil Guns Fire eye flame scanner Once a month, utilising low load periods, Oil guns may be taken out one by one and cleaned Follow vendor instruction check and service Replace gaskets with new ones after cleaning. Observe for enlargement of nozzle tipholes Ensure availability of spares PAGE NO. C- 9/9CHECKS EVERY THREE MONTHS Boiler Pre-interlock, | Coinciding with a Plan for maintenance or purge interlock, oil _| planned shut down of | recalibration of defective permissive, Boiler | boiler, carry out the _| items if any noticed, during trip protections checks to identify the shut down period. malfunctioning or sluggish pressure, temperature switches, solenoid operated valves, positioners, proximity switches,actuators etc., CHECKS EVERY SIX MONTHS During a planned shut down of the boiler, the following checks can be done. Bumers refractory ] Visual check that Ifany abnormalities are work, there are no loose seen repair works to be bricks, spalling or —_| planned during next cracks available shut down Airregister vanes | Check for uniform | Visual check for uniform opening and closing of | opening and closing, Force the vanes by operating | required should not exceed the shaft. 70 to 120 kg. Higher force Check also by a spring | indicates possible rubs. To balance the force be corrected during an required for its available shut down. operation. Es U.V. Scanner Clean U.V. Scanner Replace scanner cell if components cell and check its output is suspect. Adjust output as per vendor | amplifier flame relay if, manual. Check its Tequired. amplifier and flame relay PAGE NO. C- 9/10CHECKS EVERY YEAR (See also jobs listed under Boiler overhaul) Pressure temperature,Flow level d/p controllers Utilising the boiler | Carry out any maintenance annual shut down for | replacement or adjustment overhaul, recalibrate | needed to secure initial all pressure, calirbration values as per temperature, flow, commissioning records. level and d/p controllers as per vendor manuals Pressure gauges, Recalibrate, Verify | Repairs or adjustments as temperature gauges, | functioning of necessary Pressure/temperature | pressure/temperature switches switches as per design Positioners, actuators | Verify functioning of | Repairs or adjustments as positioners and necessary as per vendor actuators by feeding | manuals to obtain current inputs to performance as per positioners and commissioning records. measuring the air Verify functioning of pressure output of the | proximity switches where positioner and opening | provided . Clean filters of closing of actuators | air regulators. Check functioning of air regulators. Verify tightness of air connections Burners Clean and inspect ‘Change Atomiser/spray burner components plates if their ports are enlarged or distorted. PAGE NO. C- 9/11BOILER ANNUAL MAINTENANCE AND OVERHAUL In addition to the check and inspections listed under preventive maintenance. the boiler requires an annual shut down of about 15 to 20 days for cleaning. inspection ad overhaul of boiler pressure parts. IBR requirements are also met during this shut down. The shut down period is restricted to a minimum by deploying adequate resources. The Field ngineering department of TBW can assist the customer in carrying out the boiler overhaul. The annual shut down is utilised for cleaning and inspection of the pressure parts and to collect data on the wear pattern of boiler, super heater and economiser pressure parts. The shut down opportunity is also utilised for of safety valves, regulating and isolating valves and components which can not be attended when. thé boiler is in service. (The valve overhauls need not be done every year as explained later). ANNUAL OVERHAUL I PLANNING BEFORE OVERHAUL Prepare a list of jobs to be done during the overhaul based on earlier inspection reports and the jobs listed below. - Ensure availab’ ry of spares required for the proposed jobs - Ensure tools. tackles, scaffolding materials required for the job - Ensure availability of man power required for the job (Own sources, contract labour etc.) Services of TBW is also available for carrying out annual overhauls and inspecti SHUT DOWN AND COOLING THE BOILER Shut down the boiler in a planned manner . Force cool the boiler. Open al access and inspection doors. PAGE NO. C- 9/12INSPECTION AFTER COOLING Carry out a preliminary inspection after cooling to determine the following Extent of soot deposits on water wall panels and the need for water wash. Slag deposits, oil spray present may be noted. Soot deposits if any on super heaters, Economiser II, Economiser I A, I B, flue duct (Effectiveness of soot blowing). Determine the need for a water wash. PREPARATIONS FOR A WATER WASH ‘Small scaffolding may be needed in the furnace for effective water washing and subsequent inspection. Water jetting nozzles have to be arranged for jetting water at low pressure (about 5 kg/cm? (g)). High pressure jets are not usually needed. The burner openings including the refractories, Instrument tappings, peep holes etc., are covered inside the furnace by sticking thick polythene sheets over them so that water spray does not damage them or allow the spray water to penetrate to the insulation material. The first effluents of a water wash may be highly acidic. Efforts to neutralize them in the drain canal may be made if required. Persons carrying out water spray cleaning should wear goggles, boiler suit, gum boots, gloves etc., for personal protection, The furnace to be illuminated by suitable flood lights protected for water spray. WATER WASHING All the furnace drain pockets are kept open. Periodically during water washing the drain pockets must be checked to see they are not blocked by soot. Water washing commences from the top surfaces of water walls. Normally the low pressure water jets will be able to clear the soot deposits. Any stubborn deposit which are resistant, can be sprayed with water, allowed to soak for 30 minutes and a repeated spray will usually dislodge the soot. PAGE NO. C- 9/136 cooling DRUM INSPECTION (This work can be done independent of water washing, after the boiler) - Open the access doors at either end of the drum. - Allow the drum to ventilate for about 8 hours. If necessary two fan coolers can be fitted over temporary stands to force air through the drum. : ~ From the time the drum manholes are opened till they are closed after inspection; the area around the drum must be cordoned to restrict entry only to specifically authorized personnel - The names of persons who are entering the drum for inspection, along with tools they carry must be entered in a register. Persons coming out of the drum after inspection should be asked to account for the material they carried into the drum. This precaution is to prevent accidental dropping of foreign material through the water wall tubes, which may block water circulation through them and can cause tube failures. - Carry out a preliminary inspection of the drum to check for deposits on the water side of the drum. ~ Using nylon brushes, the deposits (which are normally soft) are cleaned, collected on trays and disposed off outside the drum. Washing down the deposits to the boiler tubes is not ecommended PAGE NO. C- 9/14- The chemist is asked to analyse the nature of the . case of excessive deposits, a review of phosphate concentrations (higher than 10 ppm) and boiler water quality control (high conductivity?) may be made to reduce the deposits in the next year of operation. - After cleaning the following examinations are made. * Examine the boiler drum metal for scale, pitting , corrosion and metal wastage. (Drum thickness is measured at a few selected spots using ultrasonic instruments and compared to design thickness) * Inspect fastenings of the Baffles, cyclones, demisters to see that they are intact, without corrosion pitting or holes. Eroded or corroded drum internals can be patched by welding. No welding however is permitted on the Drum metal, The cyclones and demisters can be examined in position. They need not be dismantled. Reasonable water tightness of the baffles and cyclones are to be ensured. * Examine that feed water pipe is intact with flange connections tight and discharge exit correctly oriented. Examine that the continuous blow down pipe is not plugged or corroded, their supports are normal, their holes have been correctly oriented. Examine that there are no cracks in the stub weldings of the drum. - After the inspection, clean the manhole seats and provide new gaskets. Sometimes the boiler inspector may like to inspect the steam drum. After this inspection and after verifying that all men and material have been removed from the drum, close the manholes and bolt them tight. * * INSPECTIONS IN THE FURNACE - Check the water wall tube panels in the furnace for * Evidence of pitting / erosion / corrosion on tube outer surfaces (exposed to the furnace) PAGE NO. C - 9/1516. 18. 19, SAFETY VALVES, START UP VENT VALVES AND OTHER ISOLATING VALVES These valves require regular overhauls, normally once in three years even if condition reports do not indicate any abnormality Earlier overhauls can be scheduled if condition reports warrant. Overhauls of the valves can be staggered after the first two years of operation in a manner that certain number of valves are overhauled every year. Overhauls of the valves are as per their vendor manuals enclosed. EXPANSION JOINTS (AFTER FD FAN, COMBUSTION AIR DUCT, FLUE GAS DUCT ETC.) Examine the expansion joints. Eroded / corroded parts can be patched by welding. When severe erosion is noticed (after seve years of servie) the expansion joints are to be replaced. Collapse or stretching of the expansion joints are usually due to forces exerted by the connecting ducts. Readjustment of duct supports will solve the problem and will assist the expansion joints to regain thei original dimensions INSULATION Verify sulation as per drawings and correct where necessary CLADDING Inspect cladding for damages due pitting, hotspots, dislocation etc. Repaire as necessary. OTHER EQUIPMENT Overhaul of FD fans, Seal Air blowers, HP dosing pumps, Valves, Actuators ect., are scheduled as per vendor instructions and condition monitoring described under preventive maintenance. PAGE NO. C - 9/18LIGHT UP OF THE BOILER AFTER MAINTENANCE Al OVERHAUL The pressure raising rate during the first light up after the overhaul should be slower than usual giving time for check of equipment and comonents. Valve flange joints and glands must be checked fo! absence of leaks and can be re-tightened where necessary when the boiler pressure is less than 5 Kg/em?. Each burner performance has to be verified and its axial position corrected if required. Performance of the safety valves of the boilers must be verified by floating them. The boiler inspector may like to witness the safety valve floating. The boiler expansions must be varified during pressure raising ( as described under commissioning, Vol III ) A Boiler overhaul is considered successful if it enables another twelve months of trouble free boiler operation. PAGE NO. C - 9/19WELDING PROCESS SPECIFICATIONS (WPS) The pressure parts of the boiler is made of several types of steel (Low carbon Steel, medium alloy steels) of varying thickness from 4.6 mm to 75 mm. Welding is the basic technique used in the fabrication of the boiler. The joints produced by welding should have a strength not less than that of the parent metal. In the weld joint, the’parent metals should fuse together, without cracks, blow holes, slag inclusions or defects of any kind. The weld joint apart from proving its mechanical strength in tension, must also be able to resist bending without cracking. Such requirements can only be met if the welding process used is strictly controlled. TBR. ASME ( and other organisations) classify materials into categories (P Ps . P3.... Py) as per carbon content and alloying metals (chromium, Nickel Molybdenum etc.) and specify the procedure to be used for welding materials of the same category or one category with another category. A specification of the materials and shapes adopted by TBW is enclosed. The welding procedure distinguishes between welding of thin and thick material. The welding process specification defines the following for each category of welding. = Edge preparation (angle, shape) . Joint preparation (cleaning, gap) and tagging - Joint pre-inspection before welding ~ Pre-heat of the weld joint, if any required (method of pre- heating, temperature method of checking temperature) ~ Root weld (gas welding, Tig or Are, size of electrode, type of electrode) ~ Radiographic inspection of root weld if required - Subsequent runs of welding (Tig, Are or other methods, size of electrode, type of electrode, number of runs) ~ Post weld heat treatment if any required (temperature, rate of nerease of temperature, method of increasing temperature. holding time, rate of cooling) ~ Radio graphic examination of the weld joint, indicating defects if any to be corrected. - Correction of weld defects - Final acceptance of the weld joint. PAGE NO. C- 9/24The WPS indicates compatible categories of materials that can be welded. ‘The WPS also lays down the type of electrode to be used for each category of welding. As the clectrode deposits materials, the composition of the electrode must be compatible with.the' material welded and add strength The coating of the electrode also must meet specific requirements. he WPS must be used not only during fabrication of the boiler, but also when any repair or maintenance works are to be done. TBW has WPS to cover every welding job connected with fabrication of the boiler in the factory and erection of the boiler at site, conforming to IBR requirements. The Field Engineering Department of TBW will be glad to provide 2 WPS for any site repair weld jobs required for maintenance. PAGE NO. C - 9/252.2.1_TBW STANDARD MATER] USED IN WPS CARBON STEEL (CS) - “P1” MATERIAL! MATERIAL CLASSIFICATION | PRODUCT FORM SA 36 PLATE | SA 36 PLATE SA 106 Gr. A PIPE SA 106 Gr. B PIPE SA 106 Gr. C PIPE SA 192 HFS TUBE (SEAM LESS) SA 515 Gr. Al | TUBE (SEAM LESS) SA 515 Gr. 60 PLATE SA 515 Gr. 60 PLATE SA 515 Gr. 70 PLATE [SA 515 Gr. 70 PLATE | SA 105 FORGING (FLANGE) | SA 105 FORGING (FLANGE) | 1S 2062, PLATE AIS PLATE/BAR [AT a PLATE/BAR | BS 3059 Pt. 1 ERW TUBE (ERW) | [BS 3059 Pt. 2 TUBE (ERW) | [SA 216 WCA CASTING | [SA 216 WCA CASTING | SA 216 WCA CASTING SA 178 Gr. A TUBE (ERW) | 23 [SA178Gr.C TUBE (ERW) | ___24__[SA179 TUBE (SEAM LESS) | [35 [SA234 WPB PIPE FITTING | [26 | SA 234 WPC PIPE FITTING | [37 [SA 210Gr AT TUBE | PAGE NO. C - 9/26"MATERIALS [SR.NO. | MATERIAL CLASSIFICATION | PRODUCT FORM 0 SA 302 Gr. A PLATE 02 [SA 302 Gr. B PLATE {03 [SA302Gr.C PLATE 04 |SA335 Gr PI PIPE [05 [SA335Gr. P2 PIPE 06 [SA 334 WPI PIPE / FITTINGS (07 [SA313 Gr. T2 TUBE (SEAM LESS) | 108 SA 387 Gr. 2 CLT PLATE 09 [SA387Gr.2CL2 PLATE i 10 | SA 182Gr. FI FORGING | SA 182 Gr. F2 FORGING. SA 204 Gr, A’ PLATE i 13 | SA 204 Gr. B PLATE | 14 [$A 204Gr.C PLATE | 15 |15Mo3 PIPE / TUBE | PAGE NO. C - 9/27ALLOY STEEL (AS) - “P4” MATERIALS SR.NO. | MATERIAL CLASSIFICATION | PRODUCT FORM | [01 [SA182Gr FIT FORGING 02 |SA182Gr.F FORGING i (03 [SA 182Gr.F FORGING | 04 [SA 182 Gr. F 12 FORGING | | FORGING 06 [SA213Gr TH TUBE (SEAM LESS) SA 213 Gr. T 12 TUBE (SEAMLESS) | [SA 234 WP IT PIPE / FITTINGS [SA 234 WP 12 PIPE / FITTINGS SA335 Gr. PIT PIPE | SA335 Gr. PID PIPE | SA217 WC4 CASTING | [SA 217 Gr. WC5 CASTING | SA 217 Gr. WC6 CASTING | [SA 387Gr. 11 CLI PLATE | [SA 387 Gr. 11 CL2 PLATE | SA 387 Gr. 12 CLI PLATE | PLATE | 13 Cr. Mo. 44 CASTING | ALLOY STEEL (AS) - “P5” MATERIALS MATERIAL CLASSIFICATION | PRODUCT FORM SA 182 Gr. F.22 | FORGING SA 213 Gr 721 | TUBE (SEAM LESS) SA 213 Gr. 722 TUBE (SEAM LESS) SA 234 WP 22 PIPE / FORGING SA 335 Gr. P21 PIPE SA 335 Gr. P22 PIPE i 07 SA 217Gr. WC 9 CASTING | | 08 10 Cr. Mo. 9 CASTING PAGE NO. C - 9/28ALLOY STEEL (SS) - “P8” MATERIALS SR. NO. MATERIAL CLASSIFICATION PRODUCT FORM SA 240 Gr. TP 302 PLATE SA 240 Gr. TP 304 PLATE _ | SA 240 Gr. TP 304 H PLATE SA 240 Gr. TP 304L PLATE i SA 240 Gr. TP 309 Cb PLATE | | SA 240 Gr. TP 309 S PLATE | SA 240 Gr. TP 310 Cb PLATE | L SA 240 Gr. TP 310S PLATE | SA 249 Gr. TP 309) WELDED TUBE SA 249 Gr. TP 310 WELDED TUBE | SA 167 Gr. TP 304 WELDED TUBE | SA 213 Gr. TP 304 TUBE (SEAM LESS) Ie SA 213 Gr. TP 316 | TUBE (SEAM LESS) SA 213 Gr. TP 321 TUBE (SEAM LESS) [SA 213 Gr. TP 347 TUBE (SEAM LESS) ! | SA 312 Gr. TP 316 TUBE (SEAM LESS L & WELDED) 7 SA 312 Gr. TP 321 TUBE (SEAM LESS & WELDED) | 18 | SA 312 Gr. TP 347 TUBE (SEAM LESS. & WELDED) 19 _SA 240 Gr. TP 316. PLATE 20 TUBE PAGE NO. C - 9/29om REV-1 20.05.96 THERMAX BABCOCK & WILCOX LTD O&M MANUAL BOILER OPERATION FEED AND BOILER WATER CHEMISTRY In order to minimise deposits, scale formation and corrosion, not only in the boiler but also in the feed lines, feed heaters, economiser and superheaters, it is necessary to maintain certain chemical conditions and to inject treatment chemicals into the feed system and into the steam drum of the boiler. The following notes give recommended feed and boiler conditions and explain the uses of the conditioning chemicals. L HARD} |S-PHOSPHATE CONDITIONING It is necessary to maintain a phosphate reserve the boiler water to guard against scale formation on the internal heating surfaces of the boiler. In the boiler, all the phosphates are present in the trisodium form and react with calcium & magnesium phosphate, which are precipitated as sludge. Phosphate is preferably to be dosed directly into the drum to avoid precipitating hardness sludge in feed lines or economiser. DEAERATION Dissolved gases are normally present in the feed water. The principal of them are oxygen and carbon dioxide, the presence of which can cause corrosion of the feed system, boiler or condensate system. Therefore, it is necessary to reduce the concentration of dissolved gases in the feed water to the lowest practicable value. The oxygen is removed by mechanical/chemical deaeration in the deaerator. The dissolved 02 content of water leaving the deaerator should be as low as possible, to reduce its reactions on the feed pipe work and economiser which are prominent in the higher pressure range operation. Traces of O2 that remain in water after mechanical deaeration are removed by chemical treatment, Hydrazine is widely used for chemically scavenging this dissolved oxygen. PAGE NO C-10/1om REV-1 200596 FEED AND BOILER WATER CHEMISTRY w THERMAX BABCOCK & WILCOX LTD O&M MANUAL BOILER OPERATION Hydrazine (N2H/4) is liquid and does not increase the dissolved solid content in the boiler water. As hydrazine is volatile and it is difficult to maintain its concentration in the boiler water, it is important that its reaction with oxygen is effected in the feed system. Hydrazine is therefore injected at the furthest possible point in the feed system remote from boiler ( i.e. at deaerator outlet). The ammonia produced by decomposition of excess hydrazine provides a suitable alkaline condition in steam. Feed water alkalinity, with almost complete removal of dissolved oxygen is maintained in the range of pH 8.5 to 9.5. Traces of hydrazine are to be maintained in boiler water. SILICA IN FEED WATER Silica is a constituent of some of the most undesirable scales formed in tubes in the water circuit. They have very low heat conductivity, so low that a thin layer of scale deposit may cause a tube failure. These scales are very difficult to remove mechanically or chemically. Silica in steam tends to come out of solution at high pressures. Generally speaking the deposits formed due to this silica should be acceptable in quantity, provided silica in steam does not exceed 0.02 PPM as Sio2. For this, it is necessary to control the SiO2 in feed water as specified in the attached specification sheet. SiO2 in boiler water can be controlled by giving blowdown from the drum where the silica coming out of solution due to pressure in the drum is readily available for expulsion from the system. This blowdown is done through a special blowdown line provided with valves for controlling the rate of blowdown. PAGE NO C-10/2om THERMAX BABCOCK & WILCOX LTD REV-1 20.05.96 O&M MANUAL BOILER OPERATION TUBE FAILURES Operating a boiler with a known tube leak is not recommended. Steam or water escaping from a small leak can cut other tubes by impingement and set up a chain reaction of tube failures. Large leaks can be dangerous. The boiler water may be lost, the ignition may be lost, and the boiler casing may be damaged. Small leaks can some times be detected by the loss of water in the cycle or system, a loss in boiler water chemicals or by the noise made by the leak. If a leak is suspected the boiler should be shut down as soon as possible by following normal shut down procedures (If possible). After the exact location of the leak or leaks are located, the leaks may be repaired by replacing the failed tube or by splicing in a new section of tube, confirming to [BR code. An investigation of tube failure is very important so that the condition causing the tube failure can be eliminated and future failures can be prevented. This investigation should include a carefull visual inspection of the failed tube and in some cases a laboratory analysis. It is recommended that every effort be made to find the cause of tube failures before operation is resumed. see PAGE NO. C-om THERMAX BABCOCK & WILCOX LTD. REV-0 09:03:96 O&M MANUAL BOILER OPERATION EQUIPMENT CHEMICAL DOSING During boiler operation the specified feed water and boiler water quality to be maintained. To maintain the water quality chemicals should be used. LP dosing is to be done to deaerator to remove the traces of dissolved oxygen from feed water after mechanical deaeration. HP dosing is to be done in steam drum to maintain the boiler water PH and to maintain the other parameters like phosphate. Chemical dosing system are described as follows : Chemical dosing system consist of chemical dosing tank with motorised or manual agitator / chemical dosing pumps with motor, interconnecting piping, valves and mountings. The complete assembly is mounted ona skid. Chemical dosing system are required to maintain water quality at desirable levels. L.P. Dosing system Sodium sulphite (catalised or uncatalised) or hydrazine is used for oxygen removal from boiler feed water. The major amount of oxygen is removed in dearator. The remaining traces of oxygen are removed by reacting with sodium sulphite or hydrazine. Some excess quantities of oygen scavengers are normally used to ensure absence of oxygen.Removal of oxygen from boiler feed water is essential as presence of oxygen may cause corrosion and pitting of feed water lines or condensate lines, boiler tubes and other pressure parts resulting in retubing or other expensive plant shut downs. HLP.Dosing system_: During the boiler operation the chemicals in the boiler keep on getting concentrated. If the boiler feed water is hard the concentration of such chemicals may cause deposition of scales on boiler heat transfer surface. This can be dangerous. To soften the boiler water or for removal of other chemicals which may be harmful dosing of chemicals is required. The chemicals dosed would react and form products which do not form hard, harmful scales. The quantity of such chemicals have to be calculated and would vary depending on the analysis of boiler water. N.B. : PLEASE REFER CHEMICAL DOSING PUMPS / SYSTEMS MANUALS FOR MORE DETAILS PAGE NO. C- 12/1