Standard operating procedure in Operation&

maintenance
 Introduction
J K Savani
Assistant Director of Boiler -Vadodara
Qualification
BE - Mech,
PGDBM , MBA ( Operation Management)
Energy Manager certified by BEE
Experience :
Total 10 years of Boiler Operation ,Commissioning &
Maintenance which includes

500 MW Power Boiler commission/ Maintenance

200 MW & 75 MW Boiler operation & maintenance
 BEST OPERATING
PRACTICES OF BOILERS

3
 What is BEST operation of
Boilers ?
• BEST operation of Boiler means boiler
should run without any trouble with
designed parameters and optimum
efficiency .

• What to do to achieve?
 General Boiler Operation
• Basic operating principles still apply
-- Rated parameter must achieve
• Combustion safety
– Before firing no lingering combustible material
– Purge is essential – 25% of max air flow
– Once combustion established air/fuel ratio tuning
– proper steam / water cooling are essential

• General Environmental norms

– CO2 NOx & SOx are to be optimised

 Operation
• Regular Log of All Parameters, hourly, daily,
weekly, fortnightly, monthly and annually.
• All operating limits are to be checked and
simulated periodically.
• Operating instructions are to be followed strictly
as per supplier’s recommendations.
• Regular checking of water treatment procedure,
analysis of Boiler water and Steam.
• Proper Communication system to be adopted
to avoid any wrong interpretation.
 Communication
• Direct Communication.
• Writeup instructions.
• Use of Walky-Talky for proper and fast
communications.
• Each Operational activity done during shift
will be written in I/c Shift Book.
 Training
• The training for all operating staff must be appropriate for
the equipment they will operate.
• The level of competence and training must be review
when a system is modified or changed.
• The training is delivered by people who have appropriate
knowledge on assessment skill on their specific boilers
and equipments.
• Trainers have enough industrial experience to put the
information in the right context and knowledge for the
working environment in which the trainee is expected to
work.
• Latest technological tools to be used for appropriate
required training at shop floor and simulators.

Example: Safety valve

Typical operator walk down check list
 Look for valve & valve packing leak
 Hotspots on casing / ductwork or vapor leak
 Open all inspection door & check for slag accumulation
 Listen for tube leak
 Check for unusual noises, overheating & adequate
lubrication on all motors
 Look for leaks in gage glasses & water columns
 Check that no soot blowers are stuck & no leak
 Tilting tangential for uniformity in all corners
 Check secondary air damper setting
 At firing floor check for fuel leak – coal, oil & gas
 Check all vertical coal pipe for plugging or over heating
 Inspect ash pit for bridging
 Check level of water in ash hopper& bottom seal trough
 Key operation functions
 Burner adjustments
◦ Fuel air ratio
◦ Carbon burn out,
◦ Pollutant optimization
 Excess air adjustments, Oxygen mapping
 Fuel conditions
◦ liquid fuel -Pressure & temperature
◦ Solid fuel-Particle size & primary air
 Feed water & boiler water conditioning
 Soot blower operation
 Primary air to secondary air ratio
 Wind-box settings
 Boiler Operation
• Marginal difference in operation
based on type of boiler
– Natural circulation
– Once through
– Fluidized bed
• Bubbling bed
• Circulating
• Pressurized
– Chemical recovery
– Stoker fired
There are so many technology available which are helpful
for standard O & M of boiler

Boiler side
 Combustion Optimization
 Identifying Heat transfer surface
fouling
 Improving fuel and water quality
 APH performance But we will discuss
 Insulation survey techniques which
 Effective & timely soot blowing affordable & feasible
 Furnace temperature mapping .
 Reduce specific Oil consumption.
 Clean air flow test
 Boiler air ingress survey
 Minimize loss due to moisture in
Fuel
 Minimize un-burnt Carbon loss
 Minimize RH /SH spray
1.Combustion Optimization

13
Stochiometric Air :When fuel and oxygen in the air are
in perfectly balance - the combustion is said to be
stoichiometric.

Excess Air :To ensure complete

combustion of the fuel used,
combustion chambers are supplied
with excess air.
Excess air increase the amount of
oxygen and the probability of
combustion of all fuel. Which
increse combustion efficiency.
14
 Combustion Optimization
• combustion should be complete
within furnace
i.e All carbon to CO2 ,Hydrogen to H2O
& Sulfur to SO2
• Maintain 3T(Time, Temp, Turbulance)

• Excess Air should be optimum

• Furnace exit temp as per Design
• Maintain residence time 1-2 for complete
combustion
• It minimize SH/RH Sprays
• No Slagging & Clinkering
• Change Primary air to Secondary Air
Ratio in case coal quality change

Example for 500 MW Unit

Case :1 Coal flow :280 T/hr , Total air : 1550 T/hr PA flow: 450 T/hr SA
flow :1100 T/hr
Case : 2 Coal flow :330 T/hr , Total air : 1550 T/hr PA flow: 500 T/hr SA
flow :1050 T/hr
Eexcess air to achieve highest efficiency for
different fuels are
• Power plant boilers normally run about 10 to 20 %
• Fuel Oil Fired boilers may run as low as 5 to 15%.
• Natural gas fired boilers may run as low as 5 to 10%
• Pulverized coalfired boilers may run with 15 to 20%
• Gas turbines run very lean with up to 300%

16
Analyais
1.Oxygen(%O2)
2.Carbon dioxide (CO2)
Both are important indication
of the combustion efficiency.

17
Theoretical Maximum Co2 for various fuels
Sr.No. Fuel Maximum CO2 %
1. Bitominious Coal 18.6
2. Coke 19.7
3. Anthracite 19.5
4. Lignite 19.0-19.5
5. Peat 19.5-20.1
6. Fuel Oil 15.3
7. Natural Gas 11.8

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2.Furnace temperature mapping – by IR
gun

Why this is happen ?

•Reasons: Furnace temp at peep holes
 High Furnace Temp at various locations using an
 Dirty Water wall optical pyrometer or infra red
 Fire ball is shifted guns can help diagnose
 Not optimize shoot combustion related problems
blowing / LRSB and evaluate the impact of
 Coal quality is changed changes in coal quality
 3.Reduction of Air Ingress in Boiler
• In old unit - maximum
potential improvement
area for fuel optimization.

Location :
• Boiler gas duct
• Pent Huse , Goose neck
Peep hope , Man hole ,
Check point : 0.5 or
less Oxygen %
should rise from
Furnace to Eco out
let

Effect:
• reduce the need for
secondary air
• The temp drops in flue
gas
• Better heat transfer
• In complete combustion
• High loading of ID fan
 THE PARAMETERS REQUIRED TO BE
MAINTAINED STRICTLY IN AFBC BOILER FOR
EFFICIENT OPERATION

1. Bed Height / F.D. Air Pressure

2. Primary Air Pressure

3. Bed Temperature / Furnace Temperature

4. Fuel Size

5. Bed Material Size & Specifications

6. Air & Fuel Ratio 21

 1. BED HEIGHT / FD AIR PRESSURE
• Static height for AFBC boiler is to be maintained
250 to 300 mm during initial light up of boiler.
• Expand bed height for AFBC boiler is to be
maintained 500 to 600 mmwc.
• FD air discharge pressure is to be maintained 600
to 650mmwc
• Windbox or airbox pressure is to be maintained
500 to 600mmwc
NOTE :- High W.B. pressure increases the erosion of
bed coils & low W.B. stops fluidization.

22
 2. PRIMARY AIR PRESSURE
• P.A. fan air header pressure for AFBC boiler is to
be maintained 1000 to 1150 mmwc.

• Diff. of Primary Air Pressure & F.D. Wind Box

pressure is to be maintained approximately 500mmwc.

Note :- High P.A. Pressure increases the high bed

coil erosion and carryover.
Low P.A.pressure cause the blockage of P.A.
lines and puffing in boiler and also chances
of clinkerisation.

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3. BED TEMP. / FURNACE TEMPERATURE

• Depends upon the type of fuel & firing method.

• For (Indian Coal) bed temp. in FBC/AFBC/CFBC is

to be maintained 850 Deg.C to 900 Deg.C.

• For Imported Coal bed temp. in FBC/AFBC/CFBC

is to be maintained bed 875 Deg. C to 925 Deg.C.

• For lignite bed temp. in FBC/AFBC/CFBC is to be

maintained 800 C to 850 C.

• For Petcock bed temp. in FBC/AFBC/CFBC is to be

maintained 875 C to 950 C. 24
• For Rice husk and other Bio-mass fuel bed
temp. in FBC/AFBC/CFBC is to be maintained
850 C 900 C.

• For Stoker firing furnace temperature is to be

maintained 1100 C to 1200 C.

• For Pulverized Fuel firing furnace temperature

is to be maintained 1100 C to 1300 C.

• For oil & gas fuel firing furnace temp.is to be

maintained 1100 to 1500 C.

25
 4.FUEL SIZE
When firing with Indian/Imported coal following
sizes are to be strictly maintained as it will affect
on performance and efficiency of boiler.
• For FBC / AFBC / CFBC Boiler.
Size : 0 to 8 mm,
less then 1mm not allowed more then 20%
Distribution : 1 to 5mm – 70%
5 to 8mm – 20%
0 to 1mm – 10%
Note : Lower the size of coal higher the unburnt
in fly ash. Higher the size of coal higher the
erosion of bed coils and blockage of fuel air pipe
& clinkerization in Boiler.

26
• For Stoker fired Boiler

Size : 5 to 25mm ,
less then 5mm not allowed more then 5%

Distribution : 5mm to 15mm – 25 %

15mm to 25mm – 75%
0 to 5mm – 05%

Note: Lower the size of coal higher unburnt in

flyash & carryover through Boiler.

27
• For Pulverized Fired Boiler.

Raw Coal Feeder Inlet – 0 to 25mm( higher size

will be effected by pulverizer (Pulverizer Inlet)
performance and more rejection )

Pulverized Coal Size – 200 mesh powder

Size Distribution : 150 – 200 - 60%

100 – 150 - 30%
75 - 100 - 10%

Note: Higher the size of pulverized coal below 100

mesh results unburnt in bottom ash.
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5. BED MATERIAL SIZE & SPECIFICATIONS

Bed Material Size :-

Size:0.85mm o 2.36mm (not below 0.85mm)

Distribution : 0.85 mm to 1.0mm –10%

1.0 mm to 1.5mm – 50%
1.5 to 2.36 mm – 40%

Note: Higher the size of bed material cause higher

erosion of bed coils & lower size cause wastage
through ash from boiler.

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Bed Material Specifications :
Crushed Fire Bricks Castable IS8 grade Bricks or River Silica
Sand

Fusion Temperature : 1300 Deg. C.

Shape : Spherical Angular
Bulk Density : 1050 Kg/m3
Silica (SiO2) : 68 %
Al203 : 28 %
Fe203 : 1.05%
PiO2 : 1.67%
MnO : Trace
CaO : 0.54%
MgO : 0.23%
P2O5 : 0.08%
A2O : 0.22%
K2O : 0.45%
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 6. AIR & FUEL RATIO
• Theoretical Air For Combustion :-

Theoretical Air Required = 4.31 {8/3 C (H-O/8)+S} gram/gm

of Fuel

• Excess Air :-

To understand the basics of Efficient Boiler Operation, the

combustion process must be understood. Stable combustion
conditions requires the right amounts of fuels and oxygen. The
combustion products are heat energy, carbon dioxide, water vapor,
nitrogen, and other gases (excluding oxygen). In theory there is a
specific amount of oxygen needed to completely burn a given
amount of fuel. In practice, burning conditions are never ideal.

Therefore, more air than ideal must be supplied to burn all fuel
completely. The amount of air more than the theoretical
requirement is referred to as excess air. 31
Theoretical Maximum Co2 for various fuels
Sr.No. Fuel Maximum CO2 %
1. Bitominious Coal 18.6
2. Coke 19.7
3. Anthracite 19.5
4. Lignite 19.0-19.5
5. Peat 19.5-20.1
6. Fuel Oil 15.3
7. Natural Gas 11.8

Theoretical Air x Theoretical CO2 = Actual Air x Actual CO2

32
Best Maintenance
Practices
 Role of senior Officers :
Stage : Maintenance
• Insist for maintenance and proper working
conditions of …..
– Soot blowers
– All boiler tube and flue gas temp measuring devices
• During AOH/COH Insist for…..
– thorough examination and testings indicating condition of
boiler tubes
– Implementing all possible recommendations for prevention of
BTF
– Quality contractors and quality weld joints
• Insist (rather than avoid) for RLA exercise at
recommended intervals
 Stage : Attending Tube Failure
• Insist for …..
 Collect all maximum possible information of
tubes in as failed condition
 Cutting failed tubes without damaging failure
features and keeping all required
identification necessary for failure analysis.
 Confirmation about identification and
rectification of secondarily damaged tubes.
 Replacement only after verification of
chemical analysis and tube thickness
 Quality of weld joints
 Stage : Failure Analysis
• Develop In-house failure analysis team or
engage competent external failure analysis
agency.

• Understand …..
findings of failure analysis
Identified root cause
Identified preventive measures
 Improvements for Reduced Tube
Failure

• Errosion:
Lower flue gas velocity over tube banks-CAVT
Erosion shields / cassette baffles
Erosion allowance for leading tubes
• Corrosion: Water chemistry
• Over heating : Combustion
Effects of Bad water Quality
 NEW APPROACH FOR BOILER O & M
and TROUBLE SHOOTING

(1) Boiler Tube Leakages Detection.

(2) SWAS system-Water chemistry
(3) Smart soot blowing
 PRESENT TECHNIQUES TO
IDENTIFY BTL

(1)Manual By Operator Visibility and Sound

Difference

(2)By Operation Parameters Change

( Pressure /Temp. Flow etc.)
 Boiler Tube Leakage Detection
Benefits of the early detection of tube leaks
• Increased Personal Safety.
• Early Warning
• prevent expensive secondary damage.
• An increase in boiler availability of just one day will
more than cover the cost of a leak detection system.
• To prevent explosion in case of Chemical reactors or
chemical process.
• Approx 6 to10% down time hours of any boiler due to
tube leakages can be reduced.
 NEW APPROACHES

(1)Sound Detection Techniques.

(2)Thermography Techniques
(1)Sound Detection Techniques.
1)Sound Detection Techniques
 2)Thermography Techniques
Thermal Imaging for Furnace and Boiler
Inspection :-
Small problems with industrial furnaces
and boilers can quickly become expensive
problems. See through the flames with
Thermal Image Cameras to quickly and
safely inspect your facility.
Furnace Tube Inspection By Thermal Image Camera
Furnace Tube Inspection By Thermal Image
Boiler Operational
Safety
DM Plan operation
Bed Material Handling
Bed Material Handling
Bed Material Handling
General Boiler Operation
General Boiler Operation
General Boiler Operation
 General Boiler Operation

Inside Water Inside Water

Temp. is above Temp. is Below
100 0 C 50 0 C
General Boiler Operation
General Boiler Operation
As per IBR 1950, regulation 396,
safety of person inside the Boiler
(A) Boiler effective disconnection is must
 General Boiler Operation
As per IBR 1950, regulation 396,
safety of person inside the Boiler
(B) Electrical Light used Inside Boiler should be 24 V or less &
(C.) If any electrical Equipment is used it should have proper earthling.
 General Boiler Operation

Lockout / Tagout
General Boiler Operation
 Case Study
• 670 T/hr boiler, natural circulation and with tangential firing
system
• The furnace size is 1386 x10592 mm
• 6 bowl mills, with five mills catering to full load of boiler
• Designed for an excess air operation of 20%
• The design coal proximate analysis.
• Fixed carbon : 25.0%
• Volatile matter : 20.0%
• Moisture : 15.0%
• Ash : 40.0%
• Grindability index : 80 HGI
• High heating value : 3200 kcal/kg
 Case Study (Cont)
• The Proximate Analysis, Ultimate Analysis & Coal Ash Analysis Of
The 6 Samples Of Coal Fired During Trials

TRIAL NUMBER 1 2 3 4 5 6 7

PROXIMATE ANNALYSIS
MOISTURE % 6.08 7.06 7.02 6.86 8.37 6.54 7.1
VOLATILE MATTER % 21.14 22.14 22.05 21.85 22.04 20.93 21.14
ASH % 46.7 41.35 41.78 41.87 40.58 46.13 44
FIXED CARBON % 26.08 29.47 29.15 29.42 29.01 26.4 27.76
HHV Kcal/Kg 3086 3402 3396 3367 3416 3098 3172
ULTIMATE ANNALYSIS
CARBON % 33.65 37.86 37.17 37.28 37.69 34.05 35.43
HYDROGEN % 2.23 2.55 2.53 2.52 2.51 2.3 2.46
SULPHUR % 0.51 0.5 0.55 0.5 0.5 0.54 0.58
NITROGEN % 0.95 0.89 1.05 0.9 0.95 1.02 1.07
OXYGEN % 5.01 5.05 5.52 5.39 4.89 4.64 4.76

ASH ANALYSIS
SiO2 % 61.8 61 62.1 59.6 60.8 61.4 60.8
Fe2O3 % 17.2 16.9 17.4 14 15.9 15.2 13.7
TiO2 % 0.7 0.9 0.9 0.8 0.8 0.7 0.7
Al2O3 % 8.6 9 8.1 10.7 9.8 10 9.6
CaO % 7.6 7.9 7.5 10.6 8 7.8 9.7
MgO % 3.4 3.7 3.2 3.3 3.9 4.1 4.8
Na2O % 0.1 0.2 0.1 0.2 0.1 0.2 0.1
K2O % 0.3 0.3 0.2 0.4 0.3 0.3 0.3
 Case Study (Cont)
The Flame Temperatures Taken During All The Six Trials

ELVATION TRIAL 1 TRIAL 2 TRIAL 3 TRIAL 4 TRIAL 5 TRIAL 6 TRIAL 7

METER TEMPERATURE IN DEGREE CENTIGRADE

14.2 800 815 850 780 813 823 825 NOTE: THE TRIALS WERE CARRIED OUT IN

17.1 1066 1086 1108 1073 1076 1054 1009 THE 670 T/Hr BOILER AT LOADS THAT

20.4 1120 1110 1150 1150 1175 1155 1070 WAS TO BE MAINTAINED BY THE TURBINE

23.2 1217 1213 1211 1263 1250 1225 1140

26 1180 1240 1210 1291 1275 1255 1215

29 1246 1254 1267 1291 1250 1235 1275

32.4 1211 1261 1251 1266 1232 1220 1282

35.7 1192 1243 1229 1212 1181 1195 1246

41.9 1172 1163 1148 1100 1117 1115 1210

44.5 1170 1150 1125 1025 1065 1055

 Case Study (Cont)
The Details Of The Winbox Auxiliary Air Dampers Setting

FF FF AT 10% OPEN FF OPEN AT 80%

F
EF ALL FUEL AIR ALL FUEL AIR ALL FUEL AIR ALL FUEL AIR
E DAMPER AT 5% OPEN DAMPER AT 5% OPEN DAMPER AT 5% OPEN DAMPER AT 5% OPEN
DE
D ALL AUX. AIR DAMPER
CD AT 30% OPEN AUX. AIR DAMPER AUX. AIR DAMPER AUX. AIR DAMPER
C GRADUALY REDUCED GRADUALLY OPENED GRADUALLY OPENED
BC FROM 60% AT AA FROM 10% AT AA FROM 10 % AT AA
B TO 12% AT FF TO 50% AT FF TO 50% AT EF
AB
A AA AT 60% OPEN
AA

TRIALS TRIAL 1 TRIAL 2 TRIAL 3 & TRIAL 4 TRIAL 5 & TRIAL 6

MILS IN ABDEF ABDEF ABDEF (3) B C D E F (5)

OPERATION ABCDE (4) A B C E F (6)

BOILER LOAD 496 T/Hr 496 T/Hr 480 T/Hr & 596 T/Hr 608 T/Hr & 604 T/Hr

SH SPARY 70 T/Hr 75 T/Hr 85 T/Hr & 60 T/Hr 75 T/Hr & 77T/Hr

RH SPARY 21 T/Hr 21 T/Hr 21 T/Hr & NIL T/Hr NIL T/Hr

 Case Study (Cont)
The Flame Temperature Profile

TRIAL 1 TRIAL 2 TRIAL 3

50
50
50
40
40
40
30
30 30

20 20
20
10 10
10

0 0 0
0 500 1000 1500 0 500 1000 1500 0 500 1000 1500

TRIAL 4 TRIAL 5 TRIAL 6

50 50 50
40 40 40
30 30 30
20 20 20
10 10 10

0 0 0
0 500 1000 1500 0 500 1000 1500 0 500 1000 1500

PARAMETER IN THE X- AXIS IS FLAME TEMPERATURE IN DEGREE CELSIUS

PARAMETER IN THE Y- AXIS IS BOILER PEEP HOLE ELEVATION FROM WHERE THE TEMPERATURE IS MEASURED

FIGURE:4
 Conclusion
• The combustion behaviour of Indian coals can very widely
hence combustion optimisation is a must for Indian boilers
• It can be concluded from the flame temperature study that
for low reactive coals the air distribution plays a very
important roll
• The height at which the maximum quantity of the
hydrocarbon to be burnt will depend upon the reactivity,
the petrographic characteristic and the burning profile of
the coal being fired
• Understanding the type of coal being fired and
correspondingly making proper operational adjustments /
modification will help in combustion optimisation and
reduction of unburned carbon in bottom ash / fly ash.
• The Indian high ash coals are found to give large variation
in properties due to its virtue of formation which also
affects the carbon loss in the boiler and needs a regular
watch and tuning of the operational regime
FURNACE EXPLOSION
(A) CAUSE :-
1. Accumulation of unburnt fuel during lit up / start up of
boiler.
2. Improper burning.
3. Inadequate air.
4. Secondary combustion.
(B) EFFECT :-
1. Furnace explosion can cause extensive damage.
(C) ACTION :-
1. Always purge the boiler with 40% full load air for about
five minutes. No cut short in purging allowed.
2. Adjust fuel air ratio.
71
OVERVIEW OF UTILITY BOILER
OVERVIEW OF UTILITY BOILER
PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
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PHOTOGRAPHS OF BOILER
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PHOTOGRAPHS OF BOILER
AFTER EXPLOSION
PHOTOGRAPHS OF BOILER
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PHOTOGRAPHS OF BOILER
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PHOTOGRAPHS OF BOILER
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PHOTOGRAPHS OF BOILER
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PHOTOGRAPHS OF BOILER
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