1

BABCOCK BOILER
UAN WEST 1 TO 6
Operation Manual

Prepared By Ashek Ullah

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Table of Contents

A. BOILER 1 TO 6 :

1. TECHNICAL DATA

2. START UP PROCEDURE
i. COLD
ii. WARM
iii. HOT

3. FIRING SYSTEM

i. NATURAL GAS
ii. CRUDE OIL

4. SHUT DOWN PROCEDURES

i. NORMAL
ii. EMERGENCY SHUT DOWN

5. OPERATION OF SOOT BLOWING SYS.

6. INTER LOCKS

7. ALARMS & PROTECTIONS

8. ISOLATION BOILER MAJOR AUXILIARY EQUIPMENTS

i. BOILER FEED WATER PUMPS

ii. BOILER F.D. FANS
iii. COOLING AIR FANS
iv. LP GAS REDUCING STATIONS
v. CRUDE OIL TRANSFER PUMPS
vi. BURNER CRUDE OIL PUMPS
vii. BOILER GAS / CRUDE OIL BURNER
viii. BOILER FW CONTROL VALVES
ix. DEAERATOR STEAM REDUCING STATION
x. SH ATTAMPERATER SPRAY WATER
xi. BOILER WASTE DRAIN PUMS.
xii. MAJOR OVERHOLING
xiii. BOILER TUBE LEAK
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A - 1.BOILER TECHNICAL DATA:

(For individual unit only)

BOILER (1 – 6) TECHNICAL DATA:

DESIGN DATA OPERATING DATA PRESENT DATA
A. BOILER - :
Max. Continuous loading = 365 t /h
Min. stable loading = 73 t / h
Design pressure = 86,4 bar
Drum pressure = 80,8 bar
0
Super Heater Outlet temp .=490 C
Super heater Outlet press = 66.7 bar
0
Feed water Inlet temp. = 140 C
B) FIRING EQUIPMENTS -:
Note- it is possible to operate the Boiler either with N. Gas or Crude oil or N. Gas and Crude oil during the same
time : but not in same burner.
1. Natural Gas Burner -:
Type of Burner =6 multi speed lances
Number of Burner= 9 nos.
Design net calorific values -:
a) 10450 K.cal / Nm3
b) 11000 K. cal / Nm3
Cap. Of burner Nozzle 3083 Nm3 / h
Min. Gas press. Before burner 0.05 bar
Max. Gas press. Before burner 1 . 2 bar
Turn down ratio of burner 1 to 4
2. Type of Burner = Swirl parallel flow
Type of Nozzle = 15 / 10 YELN 385243 100
Number of Burners 9 nos.
Design net calorific value= 9989 K. cal/ kg
Cap. of burner Nozzle =3253 kg / h
Min. Crude oil flow before burner= 5.0 bar
Max. Crude oil flow before burner= 16.0 bar
at 100 % load = 1 %
Excess Air ( O2 )
at 50 % load = 1 %
at 20 % load = 3 ,4 %
Turn down ratio of burners = 1 to 4
Note- to be able to start the boiler from cold with crude oil burner 7, 8 & 9 with atomizing Air.
Atomizing air press. before burner = 6.0 bar
Auto. steam press. outlet Red. station 13.5 bar
o
Auto steam temp. before burner 225 C
3. Ignition burner -:
Type = High voltage ignito. Drug. 400 - 43 Ex / D - 2L 400
NO. of Burner 9 nos.
4. LP Gas Station - :
Inlet Press. 6 to 8 bar
Out Let press. 4.0 bar
Capacity of each station 30 ,00 Nm3
Number of Station 2 nos.
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C. Pumps & Fans

1. Boiler Feed water Pump: - Flow 200 m3 / h
(RL111A1,RL12A1 & RL13A1) Nor. Head 1120 m WC
Req. Power 803 kW
Speed 2980 r.p.m.
NO. of Pump 3 nos.
Max. Amps. 120 A
2. Clean drain pump (RU11A1 & RU12A1) Flow 270 t / h
Nor. Head 110 m WC
Req. Power 104.85 kW
Speed 1450 r.p.m.
Max. Amps. 240 A
NO. of Pump 2 nos.
3. Service water pump ( VG Flow 70 m3 / h
Nor. Head 49.6 m WC
Req. Power 14.86 kW
Speed 2900 r.p.m.
NO. of pump 2 nos.
4. Make up water pump ( UA Flow 100 t / h
Nor. Head 50 m WC
Speed 2900 r.p.m.
NO. of pump 3 nos.
5. Waste drain pump ( RT Flow 90 to 110 t / h
Nor. Head 8 to 10 m WC
Speed 1450 r.p.m.
NO. of pump 2 nos.
6. Waste drain pit over flow pump ( ?

7. Crude oil burner pump (NM21A1 & Flow 36.9 m3 / h

NM22A1) Nor. Head 18.3 bar
Req. Power 47 kW
Speed 2960 r.p.m.
NO. of Pump 2 nos.
8. FD Fan (NG11A & NG12A1) 62 Nm3 /sec
Flow
(223700 Nm3 / h)
Nor. Head 827 m WC
Req. Power 578 kW
Speed 1490 r.p.m.
NO. of Fan 2 nos.
Max. Amps. 80 A
9. Cooling Air Fan ( NK51A1 & NK52A1) Flow 1073 Nm3 / h
Nor. Head 106.5 m WC
Req. Power 25 kW
Speed 2965 r.p.m.
NO. of fan 2 nos.
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A – 2, BOILER START UP: -

According to the boiler temperature, distinguish three start- up modes: -

i. Cold Start : it may be classified either boiler evaporator & superheater temperature as
environment level or start up after periodical inspection or overhauling.

ii. Warm Start : after down time of 24 hours, the boiler pressure of approx. 10 bars and
evaporator & superheater temperature approx. 180 oC.

iii. Hot Start : after a downtime of 8 hours, the boiler pressure approx. 40 bars and
evaporator & superheater temperature approx. 300 oC. If necessary, boiler will be re-fed as
low water level. The FW temperature amounts to approx. 100 o C.

2 – 1. a. PREPARATION TO START UP: -

Before start up the boiler check that the following items are fulfilled: -

i.All maintenance or inspection works at boiler or auxiliaries has to be completed and all work
permits must be cancelled.
ii. Combustion chamber, flue gas passes and flue gas ducts are cleaned and all manholes are
closed.
iii. Boiler drum cleaned and both manholes are properly tied. Level indicators are cleaned.
iv. The soot blowers should be in their retracted position.
v. All auxiliaries of the unit must be ready for operation e.g. all oil levels at pumps, motors and
gears are checked and topped up.
vi. All dampers, vanes etc. are greased.
vii. All safety instructions have to be checked about proper and exact functioning e.g. safety &
relief valves.
viii. All by pass valves in regulating loops should be closed and all regulating valves checked
about proper working conditions.
ix. All chemical analysis has to be in working order, cation filters are regenerated etc.
x. The isolating valves of all indications or transmitters impulse line must be open.
xi. All electric breakers should be in working place.
xii. The T.V. cameras for boiler furnace and drum level indication are ready for service but the
furnace camera kept in operation before 1st burner fire.( N / A )
xiii. Check waste water drain pumps and grease pots are filled
xiv. Check service water pumps; related water basin & over head tank.
xv. Check instrument air compressors , dryers & reserve tank.
xvi. Check service air compressors & reserve tank.
xvii. Check emergency diesel air compressors.
xviii. Check make up water pumps
xix. Check instrument air supplied all consumers.
xx. Power supplied to burners cubicle HB1-4 switch ON.
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2 – 1. . PREPARATION TO START UP: -
a. CONDITION OF THE MOTERIZE VALVE

Circuit breakers of the motorized valve Valve position

FW Stop valve - 1 RL41G201 Working position Closed
FW Stop valve - 2 RL42G201 Working position Closed
FW Stop valve - 3 RL43G201 Working position Opened
FW Control valve - 1 RL41G401 Working position Closed
FW Control valve - 2 RL42G401 Working position Closed
FW by pass valve - 3 RL43G401 Working position Closed
FW inter Connection valve RL70G201 Working position Closed
Main FW stop valve to boiler NA 1G201 Rack out Closed
Start up stop valve NA70G201 Working position opened
Start up Control valve NA70G401 Working position Opened 50 %
Attamp. spray water valve - 1 NA51G401 Working position Closed
Attamp. spray water valve - 2 NA52G401 Working position Closed
Drum drain valve NC15G401 Working position Closed
NC
SH - 1 drain valve Working position opened
33G401
NC
SH - 2 drain valve Working position opened
40G401
NC
SH - 3 drain valve Working position opened
49G401
Boiler HP steam stop valve & by
NA49G201 Working position Closed
pass valve
Boiler blow down valve RZ16G401 Working position Closed
Spray water inter connection valve RL73G401 Working position Closed
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b. CONDITION OF THE HAND OPERATED VALVE

HAND OPERATED & MOTOR OPERATED VALVE POSITION Remarks

Supporting tube outlet header drain
NC 33 G 1 Open
valve ( SH – 1)
Super Heater - 2 drain valve NC 40 G1 Open
HP steam line SH – 3 outlet drain valve NC 49 G 1 open
NC 23 G11 upto
Evaporator drain valves NC23 G 71
Open
Evaporator header drain valves NC 91 G 81 / 82 Closed
Economizer drain valves NC 6 G 1 / G2 Closed
Boiler drum drain valve NC 15 G 1 Closed
Saturated steam header vent valve NC 28 G1 / G2 2 turns open
Economizer inlet vent valves NC 2 G1 / G2 2 turns open
Attamp. - 1 vent valve NC 38 G 1 / G 2 2 turns open
Superheater – 3 vent valve NC 46 G 1 / G 2 2 turns open
Feed water supply line to Distiller valve RL 80 G 1 Closed
RL 72 G 1 Closed
RL 73 G 1 Closed
RL 53 G 1 Closed
Isolating valves of Spray water control RL 53 G1 Closed
valves NA 54 G1 Closed
NA 55 G1 / G2 Closed
NA 56 G1 Closed
NA 56 G2 Closed
Isolating valves of Spray water control NA 51 G1 / G2 Open
valves NA56 G1 / G2 Open
RL- 70 G1 Open slowly , after
Vent FW line up to FW control station RL - 30 G8 venting over, valves
RL - 40G7 closed
FW Stop valve ( by pass station) RL 43 G201 Open fully
Open stepwise upto
FW control valve ( by pass station) RL43G401
15 %
Vent FW line before Eco. 1 inlet ( direct
RL 60 G5 / G6 Open partially.
vent)
Boiler filling valves at ‘0’ meter level NC 1 G1/ G2 Open slowly
Control FW flow through control valve RL 43 G401 Flow approx. 30 t / h
Watch FW tank level Maintain normal level.
after venting
Watch economizer venting NC 2 G1 / 2 completed closed
vent valves
When low level alarm disappeared ( > 100 mm)
Watch boiler drum level locally & TCR
closed RL43 G401 & filling valves NC1 G1 / 2
NC 23 G11 up-to
Closed evaporator drain valves NC23 G 71
Closed
FW Stop valve ( by pass station) RL 43 G201 Closed fully
FW control valve ( by pass station) RL43G401 Closed fully
Elec. CB rack in &
FW main stop valve to boiler NC 1G201
open
Fill up the boiler drum up to > HH RL 43 G201 Open full
Open stepwise up to
RL 43G401
15 %
Open the boiler drain valve kept operation level ( - 200 mm)
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A – 2. 2. BOILER FEED WATER TANK FILLING UP : -

2.2.1 Inform Lab. boiler start up program ,

& prepared to fill the boiler feed water tank up to normal level ~ 2.6 m:-

Before filling the FW tank, check the following valves are in their correct position or not.
• drain valve of FW tank closed,
• vent valve of deaerator 1 turn opened.
• over flow valve must be closed & Selection in ‘AUTO’ position.
• all isolating valves of level transmitters etc. must be opened.

It may fill FW tank either with the direct make up water filling valve (UA2G201) or with turbine
condensate pumps if the condensate water conductivity as usable condition.

2 – 2. 1. FEED WATER PUMP START UP: -

After FW tank level filled: - 

2.3. Prepared to start any one FW pumps ( RL 11, 12 & 13A1): -

i. FW pumps suction, lubricating oil & gland sealing water filters should be cleaned & installed.
ii. Checked all filters ∆P
iii. pump & suction filter drain valves closed
iv. Suction filters & sealing water filters properly vented.
v. Pumps suction side manual valves (RL11, 12,13G1) are fully opened.
vi. Isolating valves of all pressure switches & pressure transmitters opened.
vii. Pumps discharge by pass manual valves (RL21G2/G3, 22G2/G3, 23G2/G3) Closed.
viii. Pumps motorize discharge isolating valves (RL 21, 22 & 23G201) Closed.
ix. Pumps balancing water isolating valves (RL24, 26,28G2) opened.
x. Pumps minimum flow manual isolating valves (RL25, 27,29G2) opened.
xi. Sealing water isolating valve open.
xii. Oil levels in the lube oil tanks are normal.
xiii. Lub. Oil pumps oil discharge line isolating valve opened.
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xiv. A/C & D/C Lube oil pumps, FW pumps & discharge valves Elec. Circuit breakers are in working
position.

xv. Start a / c lube oil pump from TCR

xvi. Check lube oil pressure & flow each for bearing.
xvii. Lube oil coolers cooling service water isolating valves opened & check cooling water flow through
the lube oil coolers.
xviii. EM push buttons of the FW pumps released.
xix. FW pumps Selector switch in TCR.
xx. Start one of the FW pumps, watch amp. meter
xxi. FW pump discharge by pass valve (RL21G2/3, 22G2/3, and 23G 2/3 gradually open; wait for pressure
equalization ~ 130 bars.
xxii. Pumps discharge valves (RL21, 22 & 23G201) open step by step.
xxiii. Pumps discharge by pass valves (RL21G2/G3, 22G2/G3, 23G2/ G3) closed.
xxiv. Start one of the reserve pump’s a/c lube oil pump & Select the FW pump in ‘AUTO’.
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A - 2. 3. PREPARE TO FILL UP BOILER: -

PRE – CONDITIONS: ONE FW PUMP INSERVICE & THE FOLLOWING MOTORIZED VALVES C.V ARE IN
WORKING POSITION.

1. FW stop valves 1, 2 & 3 ( RL41,42 & 43G201).

2. FW control valves RL41, 42 & 43G401.
3. Start up stop valve NA70G201
4. Start up Control valve NA70G401
5. Spray water Valve (attempt.)NO.1 & NO.2 NA51 & 52G401
6. Drum drain valve NC15G401
7. SH NO. 1,2 & 3 drain valves NC33/40G401,NC49G401.
8. HP steam stop valve of boiler and by pass valve
9. Boiler blow down valve RZ16G201.
10. Spray water valves RL72, 73G401.
• Open slowly vent valves RL70G1 & RL30G8 in the FW control station, if water continuously
flowing out, close vent valves.
11. open fully FW stop valve RL43G201
12. Open step wise FW control valve RL43G401~ 15 %
13. Open FW vent line valves RL60G5 & G6.
• before economizer NO.1 , when water continuously flowing out, close vent valves.
14. Open stepwise boiler filling valves NC1G1 & G2
15. Control FW flow approx. 30 t / h through RL43G401.
16. Watch FW tank level, maintain its normal level by feed valve.
• Check economizer vent valve NC2G1 & G2, if water continuously flowing out, close vent valves.
17. watch boiler drum level indicator, when low level signal disappeared, ( - 100 mm) *
• some times it was observed that, drum filled upto HH level for hydraulic test & later drain
excess water .
• closed FW line valve RL43G401
• Close filling valve NC1G1 & G2
18. Close evaporator drain valves , NC23G11 to NC23G72
19. Boiler FW main stop valve RL60G201 C.B. rack in & open
20. Maintain drum level - 200 mm; open RL43G201 fully & throttle FW flow approx. 30 t / h through valve
RL43G401.
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BOILER FILLING UP FLOW DIAGRAM

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A – 2. 4. Cold Start-up of the Boiler

I. by NATURAL GAS -:

Conditions:-

• boiler filled starting level ( - 200 mm)

• Main Gas Red. Station in operation ( HP Gas .Red. station)
• One Condensate pump in service.
• One Feed Water pump in service.

1. Check all manholes on boiler and air ducts are closed.

2. Check instrument air supplied to all consumers.
3. power supplied to burners cubicle HB1-4 switch ON.
4. HP Gas Red. Station outlet press. ~ 7.00 bar.
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LP GAS RED. STATION

5. Open inlet valve of both LP gas red. station NN2G1 & NN7G1.
6. Closed valve in nitrogen and vent lines.
7. Fill LP gas red. Station and waiting for press. equalization ~ 6.0 bar,
• by opening the by pass valve NN3G4 and NN8G4.
8. Open natural gas quick closing valve (NN8G401, NN3G401) by pressing the hand levers.
• An switch ON the Stop valve
9. Check proper function of LP gas red. Station valves.
• by opening the vent valve ( NN5G1, NN10G1) pressure drop,
• and watch press. after red. Station valve at ~ 3.9 bar and 4.0 bars respectively;
• then close the vent valves.
10. Open outlet valve of LP gas red. Station (NN3G1, NN8G1).
11. Check the position of natural gas control valve (NN20G401.
• It must be close position.
12. Open the natural gas relief valve, NN34G801 from TCR desk.
13. Circuit breakers of Cooling air fans working position.
• and EM. Push button released & Select Switches in TCR position.
14. Check all cooling air valves to photo cell are opened.
15. Start one of the cooling air fan. NK51A1 or NK52A1 from TCR desk.
• cool Air press. Low signal ‘ disappear ‘
nd
16. Select 2 Cooling air Fan NK52A1 to ‘AUTO’ position.
17. Tripped the running fan by pressing EM. Push button from local , Sel. ‘Auto’ stand by will take place
18. Release EM. Push button & Sel. he Fan NO. in AUTO position ;
nd st
• Press EM button of the 2 running fan, after tripped 1 one will take place.

19. Prepare the FD Fan NO.1 & NO.2.

Check the oil level.

Check the function of the fans dampers and vanes.

put circuit breakers in working position.

Make sure that, hand operated dampers in the air ducts are opened.

Released EM. Push buttons of the both Fans.

Sel. Switch of both Fans in TCR position.

20. Start of the FD fans from TCR desk on ‘AUTO’ program or ‘MAN’ Selection for purging.

21. Purging Program: -

(Time Setting 160 Seconds & rate of air volume 2950 m3 / min or 177,000 m3 / hr.)

[ Boiler purging means, clear the boiler furnace & down stream flue gas paths upto chimney inlet by a sufficient volume
of air to get rid ( make free) of undesirable elements in order to safe guard the equipment against any explosion]

PRECONDITIONS:-

Connecting the interlock setting of the boiler main protection & firing interlocks systems established.
• i. Emergency push buttons released.
• ii. Control air pressure > min.
• iii. Boiler release existing means that the following interlocks are fulfilled .
a) Furnace pressure < min.
b) Drum level between < HH & > LL
c) Fuel air ratio < HH
d) F.D. Fan 1 or 2 in operation.
e) All oil quick closing valves are closed.
f) All natural quick closing valves are closed.
g) No purge program existing or any burner in service.
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Press push button “ Preventing ON’

Air dumpers of all burners will open.
22. when all burner dampers are in open position ;

start to open FD Fan vane
3

and bring the air flow to ~ 200,000 nm / h.

signal “Preventing running ' appears.

after 160 seconds signal ‘Preventing finish ‘will appears &
“ Ready for ignition” period will start . TIME SETTING 10 minutes.
3

reducing the air flow by closing FD fan vane to 15 %; with air flow of approx. 45,000 nm / h,

and burners ‘Ready for Ignition ‘signal will appears at each of the nine burners.

25. Open the natural gas Main Stop valve.

Open natural gas isolating valves infront each burners.

and check gas press. before burners must be at ~ 0.11 to 0.15 bars.

23. Starting the first burner from bottom row with natural gas burner.

PRECONDITIONS: -

To get “Burner Ready” signal the following interlocks have to be fulfilled:

a. Boiler Release existing when the below conditions ‘a to g’ are fulfilled.

i. Furnace pressure < min.
ii. Drum level between < HH & > LL
iii. Fuel air ratio < HH
iv. F.D. Fan 1 or 2 in operation.
v. All oil quick closing valves are closed.
vi. All natural quick closing valves are closed.
vii. No purge program existing or any burner in service.

b. Boiler air purge terminated.

3
c. Ignition air flow > min ( 45,000 Nm / h )either one burner in operation ( min. air flow signal is taken from
FD Fan vane position)
b. Gas regulating valve in close position.
c. One flare in operation.
d. Burner natural gas pressure before burner, > min.min. ( 0.02 bar) [ NN18P2]
e. Burner natural gas pressure before burner < max. max. ( 0.3 bar) [ NN18P4]
f. Gas relief valve open.
g. Photocell is not picking up any stray light.

wait until “Flame ‘signal appears;

observe the air damper is moving to open position,

then close natural gas relief valve from TCR.

[Note: - incase of some disturbance:

• air dampers of all burners open automatically;
• and purging has to be repeated, by increasing the air flow to ~ 200,000 Nm 3 / h.]
3
27. Increase air flow to > 45,000 Nm / h, ( FD fan guide vane must be > 18 % open)

start burner No.9.
• after flam appeared
• Check the stability and brightness of the flame by the flame intensity indicator and TV
combustion monitor screen, also locally through furnace side glass.
3 nd

Increase the combustion air flow to 50,000 Nm / h. in preparation to start 2 burner.
3

Start burner No. 7, observe the firing sequence, gas flow will be double i.e. 2200 Nm / h.
3
Immediately increase air flow upto 50,000 Nm / h.

and gas pressure by opening the gas control valve.
nd
• In case fails to start 2 burner or any other one, wait for at least 5 min. before making further
attempts to start the burner & continuously observe the flame in side the combustion
chamber.
• Observe the 02 flue gas in recorder.
 15
• Watch all figure ( drum metal , super heaters temperature, flow and pressure rate;
28. When the drum pressure reached  2 ~ 3 bars;
• Close the vent valves of super heaters and drum.
• Increase the press. & temp. of the boiler by corresponding controlling air flow and gas press.
gas flow respectively the number of burners in operation.
Note:
• While fire rate increase, always increase air flow first before increasing gas.
• While decrease firing rate, gas flow reduce first later air flow reduce.
3 3
• During start up time maintain 20Nm of air flow for each 1Nm of natural gas.
• Firing rate will be increase when steam temp. tends to be steady.
• During start up stage always maintain continuous feed water flow through economizer coils.
o
• Watch waste drain basin level & temperature should not exceed > 60 C.

o
29. When SH NO.1 steam out let temperature app. ~ 300 C press. about 5 bar,
• Then close step by step throttle all Super heaters drain valves according their metal
temperature.
• Keep an eye super heaters multi point metal temperature.
• After 30 min.
3
30. Increase the combustion air flow to 70,000 Nm / h also increase N.G. pressure to 0.7 bars, gas flow
approx. 4,000 Nm3 / h.
3 3
31. After 40 min. increase air flow 80, 00 Nm / h & gas press. to 0.8 bar (gas flow around 4300Nm /h).
32. 3 rd burner ‘8’ start : -
rd
• before start 3 burner, prepare the attemperators station for service to maintain required
temperature.( drain valves close , isolating valves opened & properly vented).
3
33. Air flow increase to 90,000Nm / h, adjust gas pressure to 0.6 bars, corresponding gas flow about 5,000
Nm3 / h.
• The fire rate must be kept in a limit, press. not more than & press. 1.5 bars / min.
o
• The super heater metal temp. normal increasing rate 5 C / min,

34. When boiler outlet steam press. reach 10 bar :-

Start heating up the HP line RA-1 by gradually opening motorize by pass valve NA50G201.

As required, open by pass valves to Turbine (RA2G202) & Distiller (RA4G2) also deaerator

When press. Equalized.

Start opening HP steam main valve NA49G201 and close by pass valve RA50G201.
• As soon as steam consumption increase steam pressure tends to come down.

Gradually close start up control valve NA70G401 & observe boiler load not be < 72 t / h at any
time.

Firing rate increase according steam consumption (turbine & distiller).
35. Start opening the FW tank HP Red. Station.( isolating valves are opened)
• and spray water control valves for heating up FW tank.( isolating valves are opened)
• monitor continuously for the proper fuel – air ratio,
• when gas pressure reaches 0.9 bar put one more gas burner in service.
36. when drum press. reach 30 ~ 35 bars :-

as require, start turbine Hogging Ejector.

to start falling up vacuum in condenser,

main steam valve to turbine RA2G201 slowly open;

open steam valve RH32G1 to deaerator.

37. when boiler steam pressure about  40 bar

• adjust FW flow to 50 ~ 70 t / h.
• increase press. and temp. and steam flow to turbine and distiller as required.
38. when boiler load reached 80 t / h.
• Change-over the FW control valve, by pass RL43G401 to  main control RL41G401 or
RL42G401.

Open FW controller stop valve behind the main control valve;
• Open main Control valve slowly and close the by pass valve; observe FW flow & drum level.
 16

39. when boiler load reach approx. 100 t / h;

o
• bring boiler steam parameters to 50 bars and temp. 420 C,
• Proceed to put into AUTOMATIC CONTROL LOOP of the boiler as per following sequence:

FFED WATER CONTROL LOOP

COMBUSTION CONTROL LOOP ( FUEL)

COMBUSTION CONTROL LOOP ( AIR)

BOILER LOAD CONTROL LOOP

SPRAY WATER CONTROL LOOP

• FW and combustion control valves to ‘AUTO ‘(Gas, contr. valve & FD Fan vane).
40. when boiler load reach approx. 180 t / h,
nd

start the 2 FW pump.
3
41. when air flow reach approx. 170,000 Nm / h ,
nd

start the 2 FD Fan;
nd

then open 2 FD fan vane until, both fans are equalized,
nd

select the 2 FD Fan vane control to automatic position
42. Bring steam parameters of boiler up to operating values;
o
• press. 65 bars & temp. 490 C,
• by increasing the number of burners firing respectively with load.
 17

A – 3.2. COLD START UP OF THE BOILER

II. BY CRUDE OIL WITH ATOMIZING AIR & ATOMIZING STEAM: -

CONDITIONS: -
i. At least one crude tank filled.
ii. One crude oil transfer pump running.
iii. one transfer pump selected to ‘AUTO’ start
iv. one service air compressor running
v. Boiler filled up to normal starting level.
vi. condensate pump running for mechanical sealing of the FW pump
vii. One feed water pump running.

1. Open hand isolating vale OUS 70G1 from service air main ring line to boiler.
2. Open hand isolating valve OUS70 G2 service air to atomizing air.
 indication ‘Atomizing air pressure Low signal disappears.
3. Bring anti – vibration rings into oil position on burner 7, 8 & 9.
4. Preparations before start of the 1st burner

i. All manholes on the boiler and air ducts closed.

ii. Instrument air connected to all consumers.
iii. Power supply to the burner cubicles switch ON
iv. Circuit breakers of cooling air fan (NK51, NK52A1) working position.
v. Both cooling air fans emergency push buttons released.
vi. All cooling air valves to the fotocell are open.
vii. Start one cooling air fan
 Cooling air pressure Low signal disappears
viii. Check cooling air fans performance one by one.
ix. Both FD fans Circuit breakers in working position & Selector switches are TCR position.
x. Dampers & vanes circuit breakers are in working position.

5. Circuit breakers of crude oil booster pumps (NM21A1 & NM22A1) are working position.
6. One oil filter in normal position, other one cleaned & properly filled.
7. Open suction, discharge and minimum flow valves at each pump : -
(NM1G1,NM21G1,NM22G1NM23G1,NM24G1,NM25G1,NM26G1, NM34G1,NM34G2)
8. open hand valves ( NM27G1 & NM27G2) before & after relief valve
9. Close by pass valve (NM27G1) of the pressure relief valve.
10. Close crude oil control valve ( NM32G401
11. Open controller’s hand isolating valves (NM32G1 & NM32G2).
12. Close crude oil by pass valve (NM33G1).
13. Open hand isolating valve (NM31G1 & NM31G2) before & after crude oil start up valve.
14. Open crude oil flow meter isolating valves (NM34G1 & NM34G2).
15. Close by pass valve (NM35G1) of crude oil flow meter.
16. Close hand isolating valves (NM41G1 – 49G1) before each burner.
17. Close oil return valve (NM51G801).
18. Through by pass valve (NM52G1) throttled oil flow approx. 6 t / h.
19. open 2 turn by pass valve (NM92G1) of the atomizing steam trap.
20. open atomizing steam control station outlet valve (NM62G4).
21. close by pass valve (NM63G1 & G2) of the atomizing steam control valve
22. open 2 turn by pass valve (NM94G1) of the atomizing steam trap.
23. open slowly to 100 % isolating valve (NM62G1) infront reducing station.
 watch pressure & temperature.
O
 temperature after reducing station approx. 200 C.
 open fully atomizing steam control station inlet & outlet valves (NM62G1 & G2 )
 pressure approx. 13.5 bars.
24. Open steam trap isolating valves (NM91G1 & G3).
 18
25. close atomizing steam trap by pass valves (NM92G1 & NM94G1).
26. Start crude oil booster pump ( NM21A1 or NM22A1) : -
 Release EM. Push buttons both pumps (BM21& 22A1).
 Selections are in TCR.
 Start one pump  deliver pressure approx. 23 bars.
 Both pumps performance test will be carry out one by one.
 Physically check that all oil & atomizing steam hoses are properly connected.
 Open hand isolating valves at each burner.
 After opening the atomizing steam hand isolating valves on burner 7, 8 , & 9 ‘Atomizing medium
Low ‘ signal must disappear.
 Close by pass valve to oil return, watch oil flow will be 0 t / h.
 Watch oil pressure before oil QCV of burner, approx. ~ 6.0 bar.

27. Both FD fans dampers & vanes check function by opening & closing.
i. Both FD fans oil level check.
ii. Open all hand operated dampers (NG30, 31,40,41,50 & 51G1) in the air ducks.
iii. EM push buttons released.
iv. Start one of the FD Fan from TCR on AUTO program

 Select ‘AUTO’ program > Press release button & ON button of the fan > when running up
time of the starting FD Fan is over > damper will open automatically.
v. Press push button ‘ Preventing ON’
 air dampers of the all burners will open, if they are not yet open.
vi. When above air dampers are open position 
 open air vane and check air flow.
3
 Air flow > 200,000 Nm / h.
 Signal ‘Preventing Running’ appears.
 After 160 seconds signal ‘Preventing Finish’ will appear.
28. Air flow approx. 55,000 Nm3 / h.:
Start oil burner 8 from TCR and wait until the flame signal appears and damper is moving in the open
position.
29. Watch all figures (drum level, feed water tank level, temperature, flow, pressure, also feed water flow
through economizer.
30. when drum pressure reaches 2.5 to 3 bar - close vent valves of the drum & super heater.
31. increase air flow to 65,000 Nm3 / h.:
3
Start oil burner NO.7, after start burner NO.7,  increase air flow to 80,000 Nm / h.
32. Start burner NO.9, After the signal flame appears and the air damper open stop burner NO.8.
3
 After stopping burner NO.8, reduce air flow to 65,000 Nm / h.
33. When drum pressure 10 – 15 bar start heating up steam lines.
34. Watch atomizing steam pressure & temperature before burner 7, 8 & 9.
35. Burner atomizing medium change over from air to atomizing steam : -
When atomizing steam pressure is higher than atomizing air pressure the non-return valves in
atomizing lines will be closed automatically by the atomizing steam pressure and the change over
period starts.
Closing all atomizing air valves starts within 10 minutes time delay. After the 10 minutes the
atomizing air valves will be closed automatically and the signal ‘Atomizing steam press Low Low ‘
disappears.

36. Start other burners and & watch all parameters , increase pressure and temperature of boiler by
correspondingly controlling oil flow and air flow respectively the number of burners in operation.

Working sequences of the oil system: -

After pressing ‘ON ‘ button start the burner the “Ready “ signal disappearing oil lance will be inserted air
damper is moving into ignition position. When the oil lance is inserted the atomizing steam valve is opening for heat
up the oil lance and pushes the accumulated condensate out of the atomizing steam system. When the pre-purging
or pre-heat time is over and the air damper is in ignition position the power for the electric igniter is switch on and
the igniter starts move into the operation position. After igniter established the safety ignition time starts ( 5 second)
and the oil valve opens if the following criterias are fulfilled : -
 19
i. air damper ignition position.
ii. Oil operation released
iii. No order ‘OFF’ appeared
iv. Air flow > min.
v. Atomizing steam valve open
vi. Oil lance inserted.

The fuel air mixture will ignite on the sparks of the igniter and fotocell must pick up the flame within the safety ignition time.
If this done, then the signal “Flame” will appear and the air damper is moving into operation.
After the expiry of the safety ignition time the igniter is retracted and the power switched off. If the fotocell is not picking up
the flame within the safety time the oil quick closing valve will close again and the signal oil burner distur-bance and oil
burner purge will be appearing.
The oil lance will be retracted.
The burner ‘OFF’ or disturbance signal has to be cancelled by pressing the burner ‘OFF’ push button.
3
Is no other gas or oil burner in operation the automatic furnace purge will start as soon as air flow is above 200,000 n m /
h.
When the preventing of the boiler is finished the burner may be re-started or steam purge. If you want to start oil burner,
press oil ‘ON’ button, if you want to steam purge the burner press the ‘OFF’ button.

STEAM PURGE SEQUENCE OF AN OIL BURNER: -

Steam purge with igniter

• May be oil valve opened & photocell did not pickup the flame, with pressing the ‘OFF’ push button the steam
purge can be started 
• The signal ‘purge of lance ‘ is indicating that the steam purge is taking place.
• The air damper is moving into ignition position and the power for the ignition will be ON when the photocell
criterias are fulfilled:
i. Stem purge release exists
ii. Steam purge memory is set.
iii. No flame is existing
iv. Oil valve is closed
v. No burner in ‘ON’ or ‘OFF’ program
vi. When the push button ‘ burner off’ was pressed
vii. When the return signal of the open position of atomizing steam and purge steam is there, the first purge
program starts. The oil which was remaining in the oil lance will be blown out and ignited at the sparking
igniter. When the time for the 1 purge program is over the air damper is closing, the igniter retracting, the
power for igniter switch off.
• Is no burner in operation, the boiler has to be air purged before ignite the next burner.
• If the preventing finished, the signal ‘Ready’ for ignition is appearing & required criterias are fulfilled.
• if the second steam purge will not be interrupted with give a new ‘ON’ signal, the steam purge valve stays open
until also the time of second purge will be over.

Steam purge with out igniter: -

• If one oil burner will be switched off during normal operation by pressing the ‘OFF’ push button, the atomizing
steam valve is closing the steam purge valve will open too and till remaining oil is burnt with the existing flame.
20
 21
A – 3. 1. Boiler 1 to 6 FIRING SYSTEM CHANGE OVER

I. NATURAL GAS TO CRUDE OIL

Conditions:

at least one crude oil tank is filled.

one transfer pump is running

and one transfer pump selected to ‘AUTO’ position.

Crude oil line properly vented & an oil flow 5 to 10 t / h is circulating each boiler ( which
prevent that wax or other part of the oil can settle in the pipe & choke the strainers and
oil gun nozzles.

All valves should be in their normal operation condition.

All oil lances installed in the retracted position and atomizing steam hoses are
connected.

The nitrogen buffer system has to be filled with nitrogen, during normal operation the
pressure should be > 21 bars.

Preparation of crude oil sys. -

1. circuit breaker of the booster pump in working position;

NM21A1 - crude oil booster pump No.1

NM22A1 - crude oil booster pump No.2
2. one filter in normal and other stand by one cleaned & filled (NM1B10).
3. open the following suction, discharge & minimum flow valves of both crude oil booster pumps:
NM1G1 NM3G1 NM25G1
NM21G1 NM13G2 NM2G1
NM22G1 NM23G1 NM24G1

4. Hand valve before and after press. relief valves, NM27G1 – open, NM27G2 – open,

by pass valve of pressure relief valve NM28G1 – closed.
5. crude oil control valve NM32G401 open; and hand isolating valve NM32G2 open.

Crude oil control valve, by pass valve NM33G1 - close.
6. Hand operated isolating valve before and after the crude oil start-up valve NM31G1 and
NM31G2 – open.
7. crude oil flow meter before and after isolating valve NM34G1 and NM34G2 – open.

by pass valve NM35G1 of the flow meter – close.
8. Hand isolating valve before each burner NM41 to NM49G1 – close.
9. oil return pneumatic valve NM51G801 – close.

by pass valve NM52G1 to oil return –: throttle crude oil flow approx. 6 t / h.
10. by pass valve of steam trap of atomizing steam valve NM92G1 – open 2 turns.
11. Hand operated isolating valves before and after steam trap NM91G1 & G3 – open.
12. Atomizing steam control station outlet valve NM62G4 - open.
13. By pass valve of atomizing steam control valve NM63G1 & G2 – close.

by pass valve of the steam trap NM94G1 open 2 turns

isolating valve NM62G1, in front Red. Station –– open slowly to full.

isolating valve NM62G2 before Red. Station – open slowly.

and watch pressure and temp.
14. Temperature reaches after Red. Station approx. ~ 200 o C.

stepwise open valve NM62G2 fully and watch press. approx. 13.5 bar.
15. by pass valve of steam trap of atomizing Red. Station drain valve NM94 & 92G1 – close.

and watch temp. after Red. Station approx. 245 o C.
16. Release EM. Push buttons of both crude oil booster pumps.
 22

Select booster pumps NM21, NM22A1 in the TCR position.
17. start one of the booster pumps from TCR.

and watch the crude oil control valve approx. 23 .00 bar.
18. Select stand by crude oil booster pump to ‘AUTO’, and check ‘AUTO’ start up.

trip the running pump by EM. push button.

stand by pump start automatically.
19. Repeat the same other crude oil booster pump.
20. make sure that, all oil and atomizing steam hoses are connected,

and open the oil hand isolating valve in front of each burner.
21. close by pass valve to oil return valve.

and watch oil flow, 0.0 t / h.

watch press. before oil quick stop valve of burners approx. 6 ~ 7 bar.
Note: -Start-up oil pressure is 7.0 bars.
 23
A – 3. 1. BOILER FIRING SYSTEM CHANGE OVER

II. CRUDE OIL TO NATURAL GAS

Conditions: - :
 Boiler load 200 t / h, with 9 burners in operation.
 HP Gas Red. Station in service.
 LP Gas Red. Station in service.

1. Set flue gas 02 % vol. to 3 %.

• by increasing the fuel / air ratio set point, in TCR Desk.
2. check LP gas Red. Station, if already in operation.
3. open the main gas stop valve NN17G801.
• and gas relief valve from TCR desk
4. open full the gas hand operated isolating valve in front of the burners.
5. check natural gas press. before the burners, 0.11 ~ 0.15 bar.
6. stop crude oil burner NO. 7 by pressing ‘OFF ‘push button in TCR desk.

after steam purge of the burner has taken placed- :

and oil lance retracted,-

start gas burner NO. 7 , when ‘ FLAME’

signal appears , -

Close the natural gas relief valve.

And increase the gas pressure to approx. 0.7 bars, by opening the gas control valve
manually.
Note: boiler combustion and load control remain in ‘AUTO’ mode.

7. stop crude oil burner NO. 9 , after purge time over & oil lance retracted :-

start gas burner NO. 9 , when ‘ FLAME’ signal appears,

increase the gas press. to approx. 0.6 bar ~ 0.7 bar, by opening gas control valve.
8. stop oil burner NO. 8, after purge time over & oil lance retracted :-

start gas burner NO. 8, when ‘FLAME’ signal appears, increase gas press.

Kept Natural gas Contr. Valve ‘AUTO’
9. stop oil burner NO. 5, after purge time over & oil lace retracted :-

start gas burner NO. 5, when ‘FLAME’ signal appears, increase gas press.

repeat the steps for next all other burners.
10. when the oil control valve NN32G401 has reach 20% opening position,-

change the control valve from ‘AUTO’ to ‘MANUAL’ position.
11. stop the next oil burner, after purging time over & oil lance retracted:-.
 start the gas burner
12. when last oil burner remain in service, -
 close the oil control valve manually,
 and keep one oil burner on oil start – up valve; -
 and keep one oil burner on oil start – up valve; -
 watch the gas press. , not more than 1.0 bar.
13. stop the last oil burner ;-

when purge time over and oil lance retracted , -

the firing is completely changed to gas firing.
14. change 1st the position of stand by oil pump , which in ‘AUTO’ to ‘ Manual’ selection,-
 then stop the crude oil running pump.
15. open the oil return valve.
16. close the atomizing steam valve.
17. close the hand isolating oil valves before each burner.
 24

A – 3. 2. BOILER HOT START UP: -

CONDITIONS: -
I. The boiler pressure is approx. 40 bar
II. All unit auxiliaries still are in service

1. Prepare to start feed water pump after fulfilled pre-conditions.

• if the feed water temperature is 100 0C and FW tank pressure less, fed make up water to
FW tank to get the feed water temperature down or take steam through inter-connection
steam line from other unit  before that arrange spray water for reducing stations.
2. Pressurized feed water line, if it was already pressure less upto boiler main feed water valve
NA01 GG201.
3. Prepare the natural gas system as cold start up process.
4. Start FD Fan with auto program
5. Start feeding the boiler until drum level reach – 200 mm.
6. Open hand isolating valves of drain & super heater drains.
7. open the motorized valve some steps until steam is coming out of the drains , watch the
change of the flowing noise.
8. When steam is coming, close motorized valves again, approx. after 2 to 5 minutes.
9. The feeding through the economizer is important because , steam bubbles get out of the
economizer. Therefore feed with a flow of about 50 t/ h for at least about 10 mins.
10. If drum level higher than – 200 mm, it will be equalized by using after the start of the 1st burner
the drum drain valve.
11. When the boiler furnace is air purged , drum level at start up position , start – up stop valve
open .
12. Hand isolating valve before burner open
13. Burner ready for ignition signal appeared , then boiler is ready to start the 1st burner
14. After burner fired, open start up regulating valve approx. 15 %.
15. Open super heater drain valves 10 steps.
16. When the temperature is approx. 300 o C close the drain of 2nd super heater completely.
17. And the drain of the 3rd one to 5 steps .
18. Watch the temperature of the feed water after economizer 3 outlet. Keep the temperature
below the saturated steam temperature.
19. Regulate the feed water flow accordingly.
20. As soon as the steam temperature respectively the super heaters metal temperature.
21. Start the 2nd burner.
22. This means 7 & 9 in service and NO.8 out of service.
23. Further procedure are same as cold start up .
 25
A - 3.3. BOILER WARM START UP:
 26
A – 4. 1. BOILER NORMAL SHUT DOWN PRCEDURES: -

1. Reduce the boiler load by reducing turbine or distiller to minimum.

keep turbine load on 25 MW,

then either start shut down distiller or transfers to other available unit.

after shut down distiller, close following valves :
• RA04G1, HP steam valve to distiller.
• RL80G1 , spray water valve to distiller
• RM90G201, return condensate water valve from distiller to FW tank.
2. Inform Lab. About boiler shut down program.
3. when boiler load reduced to approx.~ 100 t / h,
Change all boiler close loop ‘AUTO’ control to manual mode.
• FW control valve RL41 / 42 G401.
• Fuel gas control valve.
• Boiler (load) Master control.
• FD fan 1 & 2 vane control.
• Stop one FW pump.
4. when boiler load reduce to < 90 t / h,

change FW main controller to by pass control valve,

check the gas pressure,

stop some burner, if needed,

to keep 0.5 bar gas press. by reducing the firing rate, ( at 3 burners remain in
service),

keep air flow at 90,000 nm 3 /h.
5. when attempt. Spray water valve have reached to 5 % opening position,

change the control valves to manual position.

6. when boiler load reduce further 70 ~ 80 t / h:

start opening the start up regulating valve approx. 25 %.

And keep FW flow about 50 ~ 70 t / h through economizer.
7. when turbine load ~ 5 MW,

trip the turbine,

the quick transformer will work in the moment, when the generator breaker is open.

Open direct drain valve of the steam strainer, before turbine Q.C.valve
(RA2G10&G11).
8. when 3 burners are remain in service ( 7,8 & 9) ,

reducing the firing rate stepwise by closing the natural gas regulating valve until the
:-

start up regulating valve will take over at 0.15 bar gauge pressure.
9. close continuous blow down valve to increase boiler drum level up to + 200 mm.
10. stop burner NO.9.

and close the natural gas regulating valve,

as by pass regulating valve taking over,( which is capable of taking 2 burners in
service),

keep burners 7 & 8 in operation,

and adjust the air flow to 75,000 Nm 3 / h.
11. open by pass valve of the boiler HP steam

and close HP steam valve of the boiler.
12. Stop the last two burners 7 & 8 one by one ,

which close in parallel the main natural gas stop valve.

Then open the gas relief valve.
 27

13. when boiler drum level in + 200 mm,

close the FW controller by pass valve, RL43G401.
14. stop the remaining FW pump.

then close the HP by pass valve of the boiler.
15. close make up water valve to condenser.
16. Change the cold. condenser level control valve RM30G401 and RM35G410 to manual; and
close both valves.
17. wait up to Shaft turning gear start.
18. stop the running condensate pump
19. start purging the boiler furnace :

by increasing the air flow to ~ 200,000 nm 3 / h,

by opening the FD fans vane control for approx. 3 min.

as purge finish signal appears.
20. stop the FD fan one by one,

by closing the vanes and air dampers respectively, and stop the motor.

Keep cooling air fan in service, until boiler is cold.
21. close the boiler main natural gas valve.
22. close all the hand isolating valves in front of the burners.
23. close the gas auto shut off valves of each LP gas Red. stations from local :
• by opening the hand lever.
24. close hand operated isolating valves of the sample points at SH and drum drains.
25. when boiler press. drop to 10 bar :

open the drum and SH drains.

26. when boiler press. drop to 2. 5 – 3.0 bar :

open the drum and SH vents.
 28
A - 4. 2. BOILER EMERGENCY SHUT DOWN:
 29

A – 5. BOILER SOOT – BLOWE SYTEM: -

. Preparation to start –up: -

Check which to be carried out prior to operation of the soot blowers.

i. drain by pass valve NV41G1 open
o
ii. contact thermometer set point 200 C
iii. the following sealing & cooling air valves must be open at all soot blowers 
NV61G1, NV71G1, NV62G1, NV72G1, NV63G1, NV73G1, NV69G1, NV74G1, NV65G1, NV75G1,
NV66G1, NV67G1.

SOOT BLOWER 7 TO 10
NV53G1, NV54G1, NV55G1, NV56G1

iv. Steam hand isolating valves should be open at each soot-blower

NV21G1 to NV26g1 & NV31G1 to NV34G1
v. all soot blowers have to be in their retracted position, if not pull them into the retraced position with
the hand lever.
[indication in TCR – panel ‘OFF’ when the control voltage is switched ‘ON’ and the soot blowers are
pre-select.]
vi. impulse lines of pressure switch NV1P3 & NV1P and pressure indication must be open.
vii. The safety valve should not be blocked
viii. Steam pressure > 40 bar.
ix. Main switch of the cubicle HC 01 is switch ON

b. OPERATION OF THE SOOT BLOWER SYSTEM: -

The following criterias have to be fulfilled either Manual or Automatic operation : -

i. control voltage switch ON ( key switch at soot blower panel in TCR)

ii. drain valve ( NV4G201) closed
iii. main hand isolating valve ( NV1G1) closed.
iv. Motorized isolating valve ( NV1G201) closed.
 30
v. All soot blowers in their retracted position
vi. All soot blowers are pre-selected to operate in the correct sequence.
vii. No fault indication appeared of soot blowers 1 - 9 & main valve or drain valve.
viii. When the boiler is in operation the key switch in the control cubicle has to be selected to the position ‘
with pressure’
• If during the ‘COLD’ boiler the function of the soot blower system has to be tested the key switch
has to be selected to the position ‘ without pressure’.

a. AUTOMATIC OPERATION OF THE SOOT BLOWERS:

[ all remote control operating switches are arranged in TCR Cont. Panel, from where Selection
‘AUTO’ /’ MAN’ / LOCAL’ & Operation will be carry out]
Sequence of the operation: - 
ix. Open the drain valve manually from TCR Contr. Panel
x. Open main valve main valve from TCR Contr. Panel
xi. Open the main isolating valve , for heating up the line.
xii. Cancelled the ‘PRESSURE LOW’ indication by pressing the button.
o
• If the temperature is above 200 C the drain valve is close automatically.

xiii. Close main valve manually.

xiv. When closed indication appeared of the main valve 
xv. Pre- select ‘ AUTOMATIC ( Soot blower panel)
xvi. Press Automatic Start button.
xvii. Main drain valve will open
(Flush light during the operation, steady light , when the valves are in open position)
xviii. When open signal appeared, open main hand isolating valve NV1G1 slowly to heat up the steam
lines.
xix. When the steam pressure is > 8 bars , the signal ‘Pressure Low in TCR can be cancelled by pressing
the ‘Alarm OFF’ push button.
xx. The steam lines automatic vent valves ( NV1G4 & NV3G1) are closing in the moment , when the line
pressure is > 0.5 bar.
xxi. When the steam temperature is > 200 oC the drain valve is closing automatically ( warm up time is
app.1 hr.)
xxii. When drain valve closing indication appeared, the soot blowers are starting according to sequence 7
10 & 1  6.
xxiii. Flushing signal ‘ON’ is appearing during inserting and retracting.
xxiv. When soot blower is back in the retracted position the signal ‘ON’ & ‘OFF’ is appearing.
xxv. When the last soot blower has reached again the retracted position the signal ‘END’ appears and
main steam valve closes automatically.
xxvi. With operating the push button ‘END’ signal ‘END’ and ‘START’ and ‘ON’ will be cancelled at each
blower.
xxvii. The drain valve kept closed.
xxviii. The soot blower system is ready to be started again.
xxix. After completed of the soot blower, close again the hand operated isolating valve NV1G1.
xxx. When soot blowing line is nearly 1 bar the vent valves NV1G4 & NV1G3 open automatically.

b. MANUAL OPERATION OF THE SOOT BLOWERS:

FROM TCR SELECTION

SOOT BLOWERS SELECTION FROM TCR,

Sequence of the operation procedures: - 
i. Open the drain valve by pressing the push button ‘OPEN’ in TCR
ii. When drain valve opened full,
iii. Open main steam valve also .
iv. Open steam hand isolating valve , heat up the steam line.
v. Cancelled ‘PRESSURE LOW” signal
vi. If the temperature is > 200 oC , the drain valve closing automatically.
st
vii. When drain valve closed, start 1 shoot blower manually with pressing the push button ‘ON’.
nd st
viii. The 2 blower should only be started after the 1 one has reached its retraced position.
ix. By this way complete other
 31

c. MANUAL OPERATION OF THE SOOT BLOWERS:

FROM LOCAL SELECTION

Select soot blowers in LOCAL , now it is able to operate the system from Locally by ‘ON ‘ button
• during local operation it is not possible to open the drain valve from TCR.
• When last soot blower has been operated the main steam valve can be closed from TCR , close push
button.
• After close the manual hand isolating valve

OPERATION STEAM PARAMETERS SETTING

MINIMUM STAEM PRESSURE----------- = 8 BAR.

o
MINIMUM STAEM TEMPERATURE---- = 200 C.
SAFETY VALVE OPENING PRESS.-----= 40 BAR
STAEM PRESS. AFTER REG. VALVE -= 20 BAR.
BLOWING PRESSURE-------------------- = 10 BAR.
ALARM STEAM PRESS. > HIGH --------= 30 BAR
 32
A - 6. BOILER PRESSER SWITCHES & INTERLOCKS: -
a. PRESSURE & LIMIT SWITCHES: -
TRIPPING
AK NO. EQUIPMENT REMARKS
VALUES
NG11A2 FD Fan 1 Vane Position 12%
NG12A2 FD Fan 2 Vane Position 12%
NR01P02 Furnace press. 400 mm WC
NA16L03 Drum Level Low Low - 320 mm WC
NA16L03 Drum Level High High + 320 mm
NN17F01
NM01F01
UE80P1 Control Air press. L L 3,5 bar
NK6P1 Cooling air press. 20 m. bar
NN37P1 Gas press. Torch 3 , 5 bar
NN35P1 Gas press. Torch 3 , 5 bar
NN16P03 Gas press. After LP Red. Station 3 , 0 bar
NN18P2 Burner N. Gas Press. 20 m bar
NN18P3 Start Gas press. High 0 , 3 bar
NN14P4 Burner N. Gas press. Low 0, 2 bar
US90P4 Auto. Air press. Low 4 , 0 bar
NM67P2 Auto. Steam press. Low 8 , 0 bar
NM77P3 Auto. Medium press. 4 , 0 bar
NM78P3 Auto. Medium press. 4 , 0 bar
NM79P3 Auto. Medium press. 4 , 0 bar
NM21P01 Crude oil press. before pump 1 , 5 bar
NM22P01 Crude oil press. before pump 1 , 5 bar
NM27G401 Crude oil Relief valve 23 , 0 bar Opening Set value
NM31G401 Starting oil Reg. Valve 5. 0 bar Opening Set value
NM19G401 Starting oil Reg. Valve 0 , 10 bar
NN3G401 LP Gas Reg. valve 4 , 0 bar
NN8G401 LP Gas Reg. valve 3 , 9 bar
NN3G401 LP Gas Quick closing valve 5 , 1 bar
NN8G401 LP Gas Quick closing valve 5 , 1 bar
NN6G101 LP Gas Red. Station safety valve 4 , 5 bar
NN11G101 LP Gas Red. Station safety valve 4 , 5 bar

b. TIME SETTINGS: -

Air purge time of Boiler Furnace & with min. air flow
160 sec. Remarks
Fuel Gas press. 200,000 N m3 / h
Ready for ignition period 10 mins.
Opening time of oil burner QCV 2 sec.
Opening time of gas burner QCV 1.5 , 2 sec
Purge time of gas burner QC v/v 30 sec.
Safety time gas burner 3 sec.
Safety time of oil burner 5 sec.
First stage burner oil purge 60 sec. Alarm Setting
2nd stage burner oil purge 90 sec.
Safety time photo Photocell 1 sec.
Closing time ( time ) QCV gas 1 sec.
Closing time QCV crude oil 1 sec.
Time delay NM21P01 3 sec.
Time delay NM22P01 3 sec.
Time delay NM16l03 ( Boiler Drum) 1 sec.
Time delay Fuel / Air ratio 10 sec.
 33
A. - 7. : BOILER ALARMS & PROTECTIONS: -

a. FLOW MEASUREMENTS:

AK NO. DESCRIPTION ALARM INTERLOCKING / PROT.

NG11G401 Position of Comb. Air fan damper 18 %
NG12G401 Position of Comb. Air fan damper 18 %
NG20F01 combustion air flow S = 2000, 000 Nm3 / h
RL11F01 lube oil flow FW P/P NO.1 L = 40 l/min L = 40 l/min
RL12F01 lube oil flow FW P/P NO.2 L = 40 l/min L = 40 l/min
RL13F01 lube oil flow FW P/P NO.3 L = 40 l/min L = 40 l/min
RL11F02 sealing water flow FW P/P NO.1 L=7,5 l / min L=7,5 l / min
RL12F02 sealing water flow FW P/P NO.2 L=7,5 l / min L=7,5 l / min
RL13F02 sealing water flow FW P/P NO.3 L=7,5 l / min L=7,5 l / min
RL11F03 sealing water flow FW P/P NO.1 L=7,5 l / min L=7,5 l / min
RL12F03 sealing water flow FW P/P NO.2 L=7,5 l / min L=7,5 l / min
RL13F03 sealing water flow FW P/P NO.3 L=7,5 l / min L=7,5 l / min

b. LEVEL MEASUREMENTS: -

HH = +320 mm Z = HH = +320 mm
NA16L03 Boiler drum level
LL = - 320 mm Z = LL = - 320 mm
H = + 100 mm
NA16 L01 Boiler drum level
L = - 100 mm
RH03 L01 HH =2940 mm Z = HH =2940 mm
RH03 L05 Feed water tank level LL = 700 mm Z = LL = 700 mm
RH03 L06 LL = 700 mm Z = LL = 700 mm
RH03 L07 LL = 700 mm Z = LL = 700 mm
H = 2800 mm
RH03 L08 Feed water tank level
L = 25OO MM
H = 13. 5 m. S = 10 m
RM33 L02 Cold cond. storage tank level
L = 10 , 0 m. Z = 1 , 0 m.
S = 1380 mm
RT01 L01 Waste drain basin level S = 1960 mm
Z = 2160 mm
RT01 L01 Grease switch 300 sec. time delay
H = 1800 mm
RU01 L01 Clean drain tank level
L = 1350 mm
RU01 L02 Clean drain tank level S = 1920 mm
RU01 L03 Clean drain tank level S = 1650 mm
RU01 L04 Clean drain tank level Z = 1420 mm
H = 1700 mm
VF10,30 & 50 L01 Service water Basin unit (1 - 2 )
L = 1100 mm Z = 900 mm
VF17, 37 & 57 L01 Service water elevated tank L L = 2900 mm
RZ16L01 Continuous blow down flash vessel- L H = 130 mm
 34

c. PRESSURE MEASUREMENTS: -

NA16 P02 Boiler drum press. HH = 84 , 8 bar

H = 82 , 8 bar
Z=73,7 bar
NA49 P01 Boiler outlet press.
Z=69,0 bar
H = 70, 0 bar
NA49 P03 Boiler outlet press.
L = 62, 0 bar
NG20 P01 Combustion air press. L = 10.0 mbar
NK01 P01 Cooling air press. L = 20.0 m bar
NM06 P06 Fuel oil filter ∆P H = 0, 4 bar
NM02 P01 Fuel oil before fuel oil pump L = 2 , 0 bar
NM04 P02 Fuel oil after control valve LL = 3 , 0 bar S = 3 , 0 bar
H = 18 ,0 bar
NM04 P03 Fuel oil after control valve
L = 6 , 0 bar
NM21 P01 Fuel oil before pump NO.1 LL = 1 , 5 bar Z = 1 , 5 bar S = 2.0 BAR
NM22 P01 Fuel oil before pump NO.2 LL = 1 , 5 bar Z = 1 , 5 bar S = 2.0 BAR
NM67 P02 Atomizer steam after cont. V / V LL = 8 , 0 bar Z = 8 , 0 bar
NM67 P03 Atomizer steam after cont. V / V L = 10 , 5 bar
NM77 P03 Atomizer medium before burner-7 L = 4 , 0 bar Z = 4 , 0 bar
NM78 P03 Atomizer medium before burner-8 L = 4 , 0 bar Z = 4 , 0 bar
NM79 P03 Atomizer medium before burner-9 L = 4 , 0 bar Z = 4 , 0 bar
NN02 P01 Natural gas ∆ P. filter Red.stin-1 H = 0 , 68 bar
NN07 P01 Natural gas ∆ P. filter Red.stin-2 H = 0 , 68 bar
NN16 P03 Natural gas press. after Red. station LL = 3 , 0 bar Z = 3 , 0 bar
NN18 P02 Burner N. gas press. after control valve LL = 0,02 bar Z = 0,02 bar
NN18 P03 Burner starting N. gas press. after cont. V. Z = 0 ,3 bar
NN18 P04 N. gas press. after contr. Valve HH = 2 .0 bar Z = 2 .0 bar
NN18 P05 burner starting N. gas press. after c.v HH = 0, 3 bar
H = 1 , 6 bar
NN18 P06 burner starting N. gas press. after c.v
L = 0 , 3 bar
NN35 P01 Ignition gas press. for torch equipment -1 L = 3 , 5 bar Z = 3 , 5 bar
NN37 P01 Ignition gas press. for torch equipment -2 L = 3 , 5 bar Z= 3 , 5 bar
NR01 P01 Flue gas press. H =34 ,2 mbar
NR01 P02 Flue gas press. HH=39,2 mbar Z =39,2 mbar
H = 30,0 bar
NV01 P03 Steam press. before soot blower
L = 8 , 0 bar Z = 8 , 0 bar
H = 3 , 0 bar
RH03 P03 Deaerator steam press.
L = 2 , 3 bar
RL11 P02 Boiler FW P/P NO. 1 suc. Filter ∆ P H = 0 , 25 bar
RL11 P05 FW P/P NO. 1 LUB.OIL Filter ∆ P H = 0.294 BAR
RL12 P02 Boiler FW P/P NO. 2 suc. Filter ∆ P H = 0 , 25 bar
RL12 P05 FW P/P NO. 2 LUB.OIL Filter ∆ P H = 0.294 BAR
RL13 P02 Boiler FW P/P NO. 3 suc. Filter ∆ P H = 0 , 25 bar
RL13 P05 FW P/P NO. 3 LUB.OIL Filter ∆ P H = 0.294 BAR
RL21P03 FW P -1, press. Between NRV & stop valve L= 70 BAR L= 70 BAR
RL22P03 FW P -2, press. Between NRV & stop valve L= 70 BAR L= 70 BAR
RL23P03 FW P -3, press. Between NRV & stop valve L= 70 BAR L= 70 BAR
US90P01 Atomizer air pressure L = 8.0 bar Z = 8. 0 bar
OVF
20,40 & Service water line pressure L = 3.2 bar S = 3.2 bar
60P01
 35
d. CHEMICAL MEASUREMENTS: -
NA29Q01 Saturated steam conductivity H = 0.5 µs / cm
NA49Q01 Sup. heated steam boiler outlet H = 0.5 µs / cm
NC16Q01 Drum water conductivity H = 50 µs / cm
NR01Q01 Flue gas C0 H = 0.05 µs / cm
NR01Q02 Flue gas 02 H=3%
RL01Q01 Feed water 02 H = 0.5 µg / l
RL01Q02 Feed water pH H = 9.5
L = 8.5
RL01Q03 Feed water conductivity H = 0.5 µs / cm
RM30Q01 Main condensate H = 0.5 µs / cm
RM90Q01 Cond. From desalination plant H = 0.5 µs / cm
RU01Q01 Clean drain conductivity H = 1.0 µs / cm

e. TEMPERATURE MEASUREMENTS: -

NG11T03 FD fan – 1, motor Winding Temp. H = 125 O C

NG12T01 FD fan – 2, motor Winding Temp. H = 125 O C
NG12T02 FD Fan 2, motor Winding Temp. H = 125 O C
NG12T03 FD Fan 2, motor Winding Temp. H = 125 O C
NM04T01 Fuel oil Temp. H= 50 O C
NV04T01 Condensate after Soot blower S = 200 O C
O
RA02T01 Live steam Temp. before turbine H = 497 C
L= 475 O C
Boiler drum Dif. Temperature H = ∆T 20O C
O Z = HH = 509 O C , turbine trip
RA02T02 Live steam Temp. before turbine HH = 509 C
Del time 20 min.
RH30T02 EXTR.-3 Temp. , to FW tank H = 300 O C Z = 85 O C
RL11T03 FW Pump – 1, HP Bearing Temp H = 75 O C Z = 85 O C
RL12T03 FW Pump – 2, HP Bearing Temp H = 75 O C Z = 85 O C
RL13T03 FW Pump – 3, HP Bearing Temp H = 75 O C Z = 85 O C
RL11T04 FW Pump – 1, LP Bearing Temp H = 75 O C Z = 85 O C
RL12T04 FW Pump – 2, LP Bearing Temp H = 75 O C Z = 85 O C
RL13T04 FW Pump – 3, LP Bearing Temp H = 75 O C Z = 85 O C
RL11T05 FW Pump – 1, Thrust Bearing Temp H = 75 O C Z = 85 O C
RL12T04 FW Pump – 2, Thrust Bearing Temp H = 75 O C Z = 85 O C
RL13T04 FW Pump – 3, Thrust Bearing Temp H = 75 O C Z = 85 O C
RL11T07 FWP – 1, MOTOR WINDING Temp. H = 125 O C
RL11T08 FWP – 1, MOTOR WINDING Temp. H = 125 O C
RL11T09 FWP – 1, MOTOR WINDING Temp. H = 125 O C
RL12T07 FWP – 2, MOTOR WINDING Temp. H = 125 O C
RL12T08 FWP – 2, MOTOR WINDING Temp. H = 125 O C
RL12T09 FWP – 2, MOTOR WINDING Temp. H = 125 O C
RL13T07 FWP – 3, MOTOR WINDING Temp. H = 125 O C
RL13T08 FWP – 3, MOTOR WINDING Temp. H = 125 O C
RL13T09 FWP – 3, MOTOR WINDING Temp. H = 125 O C
OVF20,40 & O O
Service water Temp. H = 46 C Z = 46 C
60T01

f. FUEL / AIR RATIO & TRANSMITTER FAULT: -

Fuel / air Ratio: HH = 1: 0.8 = 1. 25

H = 1: 0.9 = 1. 11
L = 1 : 1.15 = 0.8696
Transmitter fault adjustment SET to ± 10 %
Minimum Load for automatic operation 100 t / h = 27.5 %
 36
A - 8. ISOLATION OF BOILER MAJOR AUXILLIARY EQUIPMENTS.

8.I. Boiler Feed water Pump.

1. Stop the pump and emergency push button pressed in or put in SWG position in TCR.
2. The 6.0 K.V. circuit breaker is racked out or in test position and the space heater MCB is switch off & tagged.
3. Discharge motorized valve and bypass manual valve are closed, 380 volt C.B. rack out and valves are chain
locked.
4. Suction manual valve closed and chain locked and strainer drain & vent valves are open.
5. Sealing water line valve to pump is closed.
6. Balancing line valve is closed and chain locked.
7. Minimum flow line valve is closed and chain locked.
8. AC / DC lube oil pumps are stopped and C.B's. are rack out or in SWG position in TCR, their EPB are pushed
in.
9. Open the pump body drain valve.
10. All instrument attachment to the pump are to be removed by IMD.

NOTE: If motor is not overhaul, space heater should be on.

Boiler Feed water Pump Motor.

1. The Pump is stop and 6 K.V. C.B. is racked out and earthed.
2. AC / DC lube oil pump is off, E.P.B. is pushed in and put in SWG position in TCR.
3. Space heater MCB is switch off and tag.
4. Pump and motor to be decoupled by MMD
5. Lube oil line to motor to be removed by MMD.
6. All instrument attachment to motor to be removed by IMD.

8.2 . Force Draft Fan.

1. Stop the fan and emergency push button is pressed in or put in SWG position in TCR.
2. 6.0 K.V. circuit breaker is racked out or in test position and the space heater MCB is switch off & tagged.
3. F.D. fan air damper and vane are in closed position and their 380 volts circuit breakers racked out.

8.3. Cooling Air Fans.

1. Stop the fan and emergency push button pressed in or put in SWG position in TCR.
2. 380 volts circuit breaker is racked out or in test position and the space heater MCB switch is off & tagged.

8.4. Burner Crude Oil Pumps.

1. Stop the pump and pressed in the emergency push button or put in SWG position in TCR.
2. 380 volts circuit breaker racked out or in test position and space heater MCB switch off & tag.
3. Suction and discharge manual valves are closed and chain locked.
4. Open the pump drain and vent.

8.5. Burner Crude Oil Strainers/Filters.

1. The strainer/filter is in standby position.

2. Its vent and drain are open.
 37
8.6 . Boiler F.W. Control Valves.

1. The feed water control valve to be isolated is in standby position.

2. Both isolating valves (inlet and outlet) are closed and chain locked.
3. Outlet isolating valve 380 volts motor, circuit breaker is racked out or in test position.
4. Drain valve before the control valve must be opened.

8.7. Deaerator Steam Reducing Station.

1. The deaerator steam reducing station to be isolated is in standby position.

2. Both isolating valves (inlet and outlet) are closed and chain locked.
3. The pressure and temperature controllers 380 volts motors circuit breakers are racked out or in test position.
4. Drain and vent valve before the control valve must be opened.
5. Spray water manual isolating valve is closed.

8.8. Superheater Attemperators Spray water.

1. The superheater attemperators spray water to be isolated is in by-pass position (by-pass valve is open).
2. Both isolating valves (inlet and outlet) are closed and chain locked.
3. The spray water control valve 380 volts motor circuit breaker is racked out or in test position.
4. Drain valve after the control valve must be opened.

8.9. Boiler Waste Drain Pump.

1. Stop the pump and pressed in the emergency push button or put in SWG position in TCR.
2. Its 380 volts circuit breaker is racked out or in test position and the space heater MCB is switch off & tagged.
3. The Discharge manual valves is closed and chain locked.

BOILER OVERHAULING ISOLATION PROCEDURE:

O
1. Boiler is shut down, drained and vented. Boiler temperature is 50 C
2. All feedwater pumps are out of service. Isolated according to the above isolation procedure.
3. Both F.D. fans are out of service. Isolated according to the above isolation procedure.
4. LP Gas reducing stations 1 and 2 are out of service, isolated and purge by Nitrogen gas.
5. The cooling air fans are out of service and isolated according to procedure stated above.
6. Fuel oil pumps are out of service and isolated.
7. The H.P. steam valve and its by-pass are closed, chain locked and their motors C.B’s. are switch off.
8. The H.P. steam interconnection valve and its by-pass are closed, chain locked and their motors C.B’s. are
switch off.
9. F.W. interconnection valve and its by-pass are closed, chain locked and their motors C.B’s. are switch off.
10. Make-up water valve to feed water tank is closed, chain locked and their motors C.B’s. are switch off.
 38

A - 10. Boiler abnormal operation & Trouble –shooting: -

TROUBLE SHOOTING

Process plants operate maximum days of the month to cover the overall costs. The remaining days of the
month operate to make profit. If the process is down for some days, then the company cannot cover the costs
and no profit has been made. So, respective persons must quickly and successfully solve any problems that
occur. Sometimes the problems occur during startup, sometimes just after a maintenance turn-around, and
sometimes unexpectedly during usual operation.
A trouble – shooting problem is one sometimes occurs that is unexpected to such an extent that it is perceived
that some corrective action may be needed. The trouble occurs somewhere in a system that consists of various
pieces of interacting equipment run by the people. The corrective action requires may be:

• to initiate emergency shut- down procedures.

• to forget the situation : it will eventually correct itself,
• to return the situation to ‘safe-park’ and identify and correct the cause and try to prevent a
reoccurrence,
• to identify and correct the cause while the process continues to operate under current conditions.

Now a days widely use and familiar with the word ‘trouble shooting’.

WHAT IS THE TROUBLE SHOOTING ?

Trouble shooting is the process used to diagnose the fault safely & efficiently, decide on corrective action and
prevent the fault from reoccurring.

Characteristics of a Trouble – Shooting Problem:

The problems share four common characteristics: the problems differ in their seriousness and when they occur.
This problems share mainly the following four characteristics: a) exhibit symptoms of deviations from the
expected, b) have tight time constraints, c) are constrained by the physical plant layout & d) involve people.

a) exhibit symptoms of deviations from the expected: the symptoms may suggest fault on the plant or they
might be caused by trouble upstream or downstream. The symptoms may be false and misleading
because they result from faulty instrument or incorrect sampling. These kinds of symptoms might not
reflect the real problem.
b) the tight time constraints related to safety and economics. The symptoms indicative of a potential
explosion or major leak in the system. We should initiate immediate shut-down and emergency
procedure.
c) The process configuration constrains a trouble shooter. The process is fabricated in a given way. The
valves, lines and instruments are in fixed locations. We may want to measure or sample, but no easy
way is available We have to work within the existing process system.
d) sometimes the cause of the problem is people. Someone may not have followed the expected
procedure and was unwilling to admit error. Someone may open the bypass valve in the belief that ‘the
process operates better that way’. The alarm may have turn OFF. The orifice plate may have been put
in backwards.

When emergencies arise, due to logical, physical or fault causes, analyze and identify the causes, decide on
the most applicable action, and proceed quickly. It is essential that an operator know the plant thoroughly to
handle emergencies. Proper knowledge of the plant not only will make it possible to act wisely but also will give
the operator the necessary confidence. Learn what constitutes safe practices and how they are applied to plant.
Do not shut down unless it is absolutely necessary, but do not hesitate to shut down rather than resort to unsafe
practices. When emergencies of this nature arise, quick and decisive action is important, and a through
knowledge of the plant and a pre-considered line of action are essential. Study the various means available
sources and utilize them in proper way.
“When any problem arises, it might be some causes and several solutions in our hand, which one perfect and
applicable it is depending on experience & broad knowledge regarding the subject.”
 39
In the processing plant several problems & difficulties are arising, all of them are not possible to add due to our
limitation; only some of them difficulties and their causes show bellows: -

Plant difficulties encountered in operation:

A. Oil firing
A summary of the difficulties that may encountered in operating oil fired plant are as follows:-
1. Failure of the oil to flow to the pumps due to inactive venting of the tank.
2. Clogged strainers caused by sludge deposits in the tank
3. Failure of pumps to operate due to air leaks in the suction line.
4. Vapor formation in the pump suction line as a result of too high temp. in tank.
5. Oil too heavy to flow to the pumps because of insufficient heating
6. Faulty atomizing caused by:
a. too low an oil temperature.
b. carbon formation on burner trips.
c. worn burner trips
d. too low oil pressure.
e. insufficient steam or air.

7. Smoke, poor combustion, and flames striking furnace walls caused by:
a. faulty atomization of oil.
b. incorrect adjustment of air supply.
c. automatic control not functioning properly.
8. Fire hazard and unsightly appearance caused by leaks in the pump discharge line.

B. Boiler water level:

Thought should be given to the procedure to be followed if difficulty is experienced in maintaining the water
level in the boiler. Small oil / gas fired boilers equipped for automatic operation have low water fuel-cutoff
devices. In the event of low water, the fuel valve automatically closed and the water level restored. However,
industrial and utility plant shutdown must be avoided if at all possible. Alarms are provided, but in the event of
high or low water, the operator must decide on the action to be taken.
When the water level in the drum drops below the minimum required as specified by the boiler designer, stop
the fuel and air supplies.
 Priming & foaming are caused by boiler water high in solids, high capacities, high water level, or a
combination of these. Foaming is serious, since it makes it difficult to determine the water level. Priming can
result in a mixture of steam and water in steam lines, causing water hammer, which may result in rupture of
the piping system. When this trouble develops, reduce the capacity and blow the boiler down through the
surface blow off, if one is provided; otherwise, use the main blow off. If the priming becomes so serious that
the water level can no longer be detected, close the steam valve long enough to determine the correct level.
Blow down the gauge glass and water column to make sure the water level indicated is correct. If conditions
do not return to normal, take the boiler out of service.

C. Boiler tube failure:

Stop the fuel feed and proceed to reduce combustion. Maintain water level unless this affects the feed water
supply. This is a matter that requires instant decision on the part of operator, and the correct action depends on
the size of the leak and available reserve supply of water. The pressure should be reduce as quickly as possible
to prevent the blow of water and steam from cutting other tubes. Except for the fact that tube failures cause
boiler outage, they are not considered serious.
Operating a boiler with tube leak, escaping water or steam that can cut other tubes by impingement and
cause a chain reaction of tube failures. With the loss of water or steam, a tube failure can change boiler
circulation and possible cause overheating in the circuits, which can lead to further failures.
Small leak can be detected at times by loss of water from the system, by the loss of chemicals from a drum
type boiler or by noise that is created by the leak.

Damage of boiler tubes are normally recognized by the following signs:

a. Pressure increase in combustion chamber.
b. Increase of difference between water & steam flow.
c. Changing in flue gas temperature without changing load.
 40
d. Blowing noise in the boiler.
e. Steam at chimney exit.
If above reason appeared, shut down the boiler normal way. If serious leaking, stop boiler by pressing
emergency button.

D. Incase of more then one burner tripping, put muster control immediately on Hand Control.
Reduce load according to still available burner load.

8 burner up to 100 % load approx. = 360 t/h

6 burner up to 70 % load approx. = 240 t/h
3 burner up to 30 % loads approx. = 120 t/h.

When trouble is over, change Hand control to AUTO.

E. If all burners are tripped, turbine will trip due to inter lock. If inter lock is not operating, trip turbine with
emergency button.
F. Break down of oil / air ratio control or gas/air ratio control. Change master control to Hand. Change oil / air
ratio respectively gas /air ratio (air flow & fuel flow) keep the plant running. Keep sufficient air by observing 02.
4. Break down temperature control, change immediately from AUTO to Hand ( manual position) if temperature
dropping too far ,quickly trip the turbine.
Abnormally low steam temperatures may also produce by:
b. Insufficient excess air.
c. Higher then design feed water temperature.
d. Excessive moisture carries over from the boiler.
e. A fouled super heater externally & internally.
f. Leaking spray water valves.
g. Poorly adjusted control equipment.

On the other hand following conditions can produce steam temperature abnormally high:

a. dirty furnace
b. Too much excess air
c. Lower than design feed water temperature.
d. Irregular ignition or delayed combustion.
e. Poorly adjust control equipments.
If temperature exceeds maximum allowed value reduce burner load immediately.

G. Failure of the fuel supply: - low capacity, too much primary/ combustion air and disturbance from blowing
soot may result in loss of ignition when fuel is burned in suspension. If the equipment is supplied with a flame
detector the fuel feed will be shut off automatically.
H. Safety valve leak: - even pressure lower than for which it is set, try to free it by operating the lift levers. If this
fails to stop the leak, the valve must be repaired or replaced. Never attempt to stop a leaking safety valve by
blocking or fighting the spring.
I. Gauge glass breaks: -shut off the flow of steam and water. While the gauge glass is out of service, check the
water level by using the try cock. Before inserting the new gauge glass, blow out the connections to make sure
that no broken pieces remain in the fitting, and check the glass and gasket for the correct length and size. Pull
up the packing slowly and not to tightly to avoid breaking the glass. When the new glass is in position, open the
top or steam valve first and allow the drain valve to remain open. This permits steam to circulate through the
glass, gradually heating the entire surface to a uniform temperature. Then partly open the lower valve. After the
water has reached the normal level, open the lower valve. After the water has reached the normal level, open
both valves all the way. When the lower valve is first opened, the glass is subjected to a vibration in temperature
that may result in breakage.
 41
BURNER NOT FIRE

Possible Causes:

1. Pilot not burning.

2. Main gas valve solenoid coil burned out.
3. Water level too low or no water in sight glass.
4. Honeywell operating pressure switch defective.
5. Broken wire in burner circuit.
6. Loose or broken probe in water column.
7. Scale build-up on probe and/or water column.

Corrective Action:

1. Check the gas supply.

2. Replace solenoid coil.
3. Replace gas valve.
4. Replace operating pressure switch.
5. Check wiring for loose or broken connection.

BURNER NOT SHUT OFF

Possible Causes:

1. Pressure switches not operating.

2. Faulty operating mechanism on gas valve.
3. Broken wire in burner circuit (shorted to ground).

Corrective Action:

1. Replace pressure switch.

2. Replace gas valve.
3. Check for electrical short circuit and repair.

PILOT BURNER NOT BURNING OR NOT STAY LITGHT

Possible Causes:

1. Pilot burner orifice plugged or dirty.

2. Ignition wire burnt or shorting out.
3. Igniter lance cracked or broken.
4. Igniter lance misaligned.
5. Ignition module defective.
6. Pilot solenoid valve not opening.
7. Pilot regulator plugged or broken.

Corrective Action:

1. Clean pilot burner orifice.

2. Replace igniter.
3. Replace pilot safety relay.
4. Re-align igniter to the center of the pilot assembly.
5. Replace ignition module.
6. Replace pilot solenoid valve.
7. Clean or replace pilot regulator.
 42
PRE-IGNITION OR POOR LIGHT OFF

Possible Causes:

1. Pilot in wrong location in relation to main burner. 2.

Dirty main burner orifices.

Corrective Action:

1. Clean pilot burner and orifice without enlarging.

2. Locate pilot burner so that top of burner is 1/2” above and 1/2” to the side of main burner.
3. Clean burner caps with drill bit. Consult factory for proper drill bit size. Caution: be careful to avoid any
increases in orifice size.
4. Adjust barometric damper in stack. Check for collapsed stack or restriction in stack.

PUMP NOT PERFORMING PROPERLY

Possible Causes:

1. No water being supplied to suction side of pump.

2. Plugged strainer screen.
3. Check valves worn or leaking.
4. Pump leaking at shaft.
5. Pump out of adjustment.
6. Air lock.
7. Vapor lock.

Corrective Action:

1. Clean lines connecting float tank to water jacket on 9.5, 10 & 15 HP models.
2. Remove and clean pump intake strainer screen. Clean lines from water jacket to pump.
3. Repair or replace check valves.
4. Replace shaft seal and “O” ring in pump.
5. Adjust pump impeller.
6. With pump running, carefully loosen hex nut on angle check valve to bleed air from system. Tighten hex
nut when water starts escaping.
7. If vapor lock is caused by leaking check valves, replace check valves. If vapor lock is caused by too
high a temperature in the return tank, check all steam traps for proper operation and repair as required.

PUMP MOTOR WILL NOT RUN

Possible Causes:

1. Starter relay defective.

2. Broken electrical connection.
3. Motor burned out.
4. Inter lock block to start the pump

Corrective Action:

1. Replace starter relay.

2. Release the pump from inter lock blocking
3. Check wiring for loose or broken connection.
4. Repair or replace motor.
 43
POOR BOILER PERFORMANCE (Low steam pressure or slow recovery)

Possible Causes:

1. Low water condition in boiler.

2. Insufficient fuel supply to burners.
3. Defective operating pressure switch.
4. Calcium deposits, (boiler scale) in water tube assembly.
5. Soot formation on water tube assembly.

Corrective Action:

1. Clean burners.
2. Replace operating pressure switch.
3. De-scale boiler or replace plugged water tube assembly.
4. Remove soot from tubes by means of soot blowers.
5. Improper fuel air ration.
6. Fuel oil / gas caloric values are poor for improper combustion.

SIGHT GLASS GASKETS LEAK

Possible Causes:

1. Gaskets deteriorated.
2. Fittings improperly aligned.

Corrective Action:

1. Boiler shut down and allow cooling down.

2. Replace gaskets.
3. Loosen nuts, carefully align sight glass fittings and tighten nuts.