BOILER OPERATION

COLD START UP

This means a normal start up of for a new unit or a unit that has been shut
for a long time to allow complete cooling of all metal parts

BOILER INSPECTION

Before firing a boiler the complete boiler should be inspected. The furnace
should be inspected and cleaned both internally and externally. Any
structure pipelines that might restrict normal expansion of the unit should
be cleaned. General cleanliness to be adhered to
All vent valves on the boiler (economiser, drum, superheater) are to be
opened before filling up the boiler. In most of the cases separate filling
lines are provided. Filling is done through the header drains provided in
evaporating section. Economiser coils also be filled thro’ its drain or thro’
the main feed line
All the time of filling operations gauge glass must be brought on line .As the
boiler is filled up water will start raising in the drum and appear in the gauge
glass. Filling is continued till it rises up to recommended operating level. The
quality of feed water and its temp are quite important. If the feed water
temperature is high, the utmost care should be taken to avoid temperature
strains or shocks by slow feeding. Here boiler temperature is relative to the
boiler metal temperature. In general the temperature of feed water should
not differ more than 50 deg Cfrom drum metal temperature at the time of
filling

Lighting Up

The following steps are to be ensured prior to light up.

1 All foreign materials have been removed from pressure parts
2 All personnel cleared and access door closed
3 Interlocks and protections checked
4 Elements of retractable soot blowers fully retracted from the gas side
5 Individual fuel valves at burner closed
6 All boiler fittings (damper valves) in working condition
Check for the conditions
1 All drain valves on boiler water walls should be closed

SeminarsTopics.com
2 Blowdown valves (CBD, EBD) to be closed
3 Boiler filling and superheater filling valves should be closed
4 Steam supply valves to soot blowers to be closed
5 Main steam stop valves to be closed
6 Desuperheater valves including bypass to be closed
7 Feed regulating valves to be closed
The following valves to be opened
1 Drum vents
2 Superheater drains and vent valves
3 Main steam line drain
4 Water level gauge glass to be in service
Equipment mentioned below should be ready for service
1 Air heater
2 Induced draft fan
3 F.D.fan
4 Igniter fan
5 Seal air fan
6 Scanner fan
7 Primary air fan
8 Milling systems
9 Boiler feed pump
10 All drives for dampers and valves
11 All instruments and controls
In addition to this burner position, connection and valve positions to be
checked
Purging the furnace
It has been recognised that the boiler is prone for explosions under the
following conditions
1 During start up when the combustion can be improper or when a boiler
which has tripped and when in the furnace combustible fuel due to previous
operation are present which during light up can explode
2 Condition, which can cause explosion, is present such as fuel rich furnace
atmosphere

All modern boilers at the time of light up provided with a purging sequence,
which aims at preventing the explosions. The aim of any purge sequence is
the following

SeminarsTopics.com
1 To get ride of any remnant fuel in suspension from the previous firing in
the furnace
2 To replace at least three times the atmosphere present in the boiler with
fresh air
3 To provide an air rich atmosphere during light up

These are achieved by providing the sequence as follows

This takes place when a predominant airflow, which can be 30 % minimum to
as much as 100% depending on the design is, established thro’ the furnace.
The impulse is usually from airflow
The purges to start some other conditions like the following are
to be satisfied
1 Normal furnace vacuum
2 Drum water level normal
3 All fuel valves closed
4 All attemperator valves closed

PURGE COMPLETE

Maintaining the previous conditions for a fixed predetermined time, the time
usually vary from 5 to 15 minutes signifies the purge complete. A variable
timer is usually be available for adjustment
Often the operation engineer has a temptation to shorten this time. While
guidelines can be issued as to what is the right purge period if the engineer
remembers, what the purge aims at, he will not be tempted to cut down the
time without justification

REPURGE

In some boilers we have another safe guard where even after the purge
completion if the boiler is not lit within, say 5 minutes we may have to go
thro’ purge cyclic operation again. In boilers where such provision does not
exist before relighting the boiler after an unsuccessful attempt furnace
purging is done .It must be remembered that after a purge or during the
purge if any condition established to start the purge disappears, one has to
start purge sequence again
After furnace purging the boiler is lighted up. Eventhough we have purged
the boiler previously it is not out of explosion danger .The national fire

SeminarsTopics.com
 prevention association (NFPA) of USA has established a min of 30% air flow
for all condition of operation less than 30%MCR .We have adopted the
principle to ensure a rich mixture during initial light up. Temptation to
reduce the airflow to less than 30% resisted. It should be borne in mind
that thro’ 30% airflow need not necessarily come through the burner, which
is being lighted but can be spread among other burners as well.
Wherever igniters are provided for oil burner igniter must put into service.
when igniters are proven warm up oil burners must be lit. The light up
sequence of igniters’ warm-up guns and load carrying oil guns and coal
combustion will be dealt later.
We shall establish some general principles connected with light up. To
quickly bring the boiler to its rated parameters or to condition where the
turbine can be rolled or synchronised will be the aim of every operator.
Quick pressure raising may bring about unequal thermal expansion,
overheating of the tubes etc. Our aim to quick start must take into these
factors

Permissive rate of pressure raising

The permissible rate of pressure raise based on the saturated temperature
rise in the boiler .The max. permissible rate for a natural circulation boiler is
given 100 deg C per. hour. It will be seen for our conditions this rate is
rarely achieved. This 100deg C raise is again subjected to following
limitations.
1 Whether we are able to establish a flow thro the SH. A definite flow get
established when the turbogenerator is rolled or synchronised or venting is
maintained thro ’startup valve
2 Temp of flue gas before the SH must not exceed 540deg C .In some
boilers we will find that a provision of travelling furnace probe is available to
monitor this temp where such provision does not exist the temperature has
to be incorporated from available instrument readings
3 The drum metal temperature differential between any two points in the
drum should not exceed 50 deg C. Where drum metal is of carbon steel this
may not be significant and some time no provision may exist for measuring
this temperature.
The operator should understand that the permissible rate of saturated
steam temp rise of 100deg C per hour should be interpreted with
restrictions imposed by the factors stated above. In the initial firing it will
be seen that superheater metal does not have protection. While flue gas

SeminarsTopics.com
transmits heat tom the superheater tubes till such time the flow is
established thro’ the SH, no withdrawal of heat takes place.
Also in the initial period of operation water remains in the superheater
tubes may restrict the steam flow. This condensed water should be drained
from the SH loops using the drain provided. Operation of start up vent also
ensures to get ride of the condensate from the SH tubes. In addition to SH
are provided with metal temp points. Monitoring of SH temp with instrument
gives us an idea of temperature difference between the tubes. . Abnormal
differences in metal temperature can only be corrected by intense draining
and slowing down firing rate.
While lighting up a new boiler another retraint to firing is to ensure uniform
expansion of water wall headers. Normally once this has been checked during
initial periods of operation of the boiler in subsequent star ups this factor is
not very significant unless some repair works have been done

VALVE OPERATION
SH drains remain open at start up and are initially closed as soon as steady
steam comes out thro’ drains when boiler pressure is 3 to 5 KSC.
It is good practice to reopen drain valves on the SH s say for 5 minutes at
intervals of every 30 minutes till the boiler is connected to the turbine or
comes on steady load
Attemperator headers also to be drained similarly. Till such time boiler
connected to the turbine a load on the boiler is to be established to ensure
cooling of the SH. This load is very essential to protect the SH. The load can
be provided
a) Full opening of the SH drains. Which perhaps is the only possible load
when the boiler pressure is low. This SH draining also helps to get ride of
condensate in SH loop as it forms the shortest discharge path
b) B) Start up vent where available. It will be noticed that the steam from
the drum has to overcome the initial resistance of SH as well as
condensate loops
The start up vent will be useful only when the boiler pressure builds up to
atleast 10 atm. Till then we must rely on drains. The capacity of the startup
vent is again reduced by silencers provided if any. Start up vent can be
either provided at SH outlet or at the main SH outlet or at the main steam
outlet just before turbine stop valve.
Using the latter is a preferred method since we can warm up the main steam
line of the process.

SeminarsTopics.com
C) Where HP/LP bypass is provided
The system can provide the initial load with the added advantage of noise
and saving in water which can be recovered from the condenser .We must
remember that LP/HP by pass can be brought into play only after building up
pressure to about 10 to 15 atm. And raising vacuum in the condenser. Till
such time one must depend on the drains of the SH and main steam line
The boiler engineer should understand that raising boiler pressure by
throttling drain, startup vents or bypass is risky if it is going to deprive the
SH from cooling

WATER LEVEL
Checking of water level is very essential since the boiler has only a very
little water in reserve for evaporation. At a lower pressure a liberal
Blowdown of the G/g may be given to clear any foreign material that may be
present .The gauge glass should be blowdown several times at low pressure
while warming up a new boiler (During normal operation blowdown must be
minimum to protect the gauge glass)
NOTE
* Only direct gauge glass to be relied upon during initial startup of a boiler.
Water level always should be kept within the visible range. (Recommended
range) in the gauge glass
 The following precautions are to be taken as far as the direct level gauge
glass is concerned
1 Water level should always be in normal position or zero position
2 Due to the temperature differential between the water in the g/g and
water inside the drum at lower pressures the level indicated in the g/g will
correspond to a lower than normal actual level in the drum
3) Adjustment of water level should be gradual
4) When the steam demand is fluctuating the water level would go up and
high water may lead to carryover
5) When the unit is in normal operation remote water level can be relied upon
with the routine check up of direct water level g/g(once in a shift)
At any instant only a very little reserve of water is present in a boiler for
evaporation. In a regular operation at any load we manage by maintaining
constant amount of steam we are taking out of the boiler.
Water level can fall or shoot up due to any one of the following reasons

1 Feed pump tripping

2 Failure of feed regulating valve/feed station valve

SeminarsTopics.com
3 Water wall drain valve leakage
4 Water wall bursting
5 Wrong indications of the g/g or other instruments

Water level change is quite drastic under the following conditions

1 Sudden increase of firing rate (swelling)
2 sudden decrease of firing rate (cooling)
3 When a safety valve opens
4 Sudden load fluctuation
5 When blowing down the boiler

BOWING DOWN A GAUGE GLASS

The following procedure should be adapted for blowing down gauge glass
This is to prevent the g/g from thermal shocks cause by incorrect blowing
down
A) Close the upper gauge cock and open the drain valve of gauge. This will
allow the water to drain and clear bottom parts
B) Close the drain cock. This will result in water to rise in gauge glass body.
After this drain should be opened. This process of opening and closing of
the drain valve should be repeated for several times. This process clear
and clean the water side port of gauge glass
For cleaning the upper port the following procedure to be adapted
3) Empty the gauge glass by shutting down both the upper and lower valves
and by opening the drain valve
4) Now open the upper gauge valve steam drains thro’ the port
5) Repeat this by opening and closing the steam side cock for two to three
times
6) Open steam side and waterside cocks and closes the drain to bring the
gauge glass back in service
NOTES
1 Micas are exposed to severe thermal shocks by the boiler pressure and
frequent blow downs
2 Any leaks noted must be attended immediately. Leak in waterside will
result in lower than actual level being shown in the gauge glass. Similarly
leak from the steam side will result in higher than actual reading

SUPERHEATED STEAM

SeminarsTopics.com
Effect of variables in SH temp
1 By feed water injection (attemperation)
2 By using top rows of burners
3 By burner tilt ( as applied to tilting tangential burners)
4 By pass recirculation
With a constant load abnormally high Super Heat is caused by
1 Too high excess air
2 Too slow feed water temperature
3 Slagged up furnace
4 Secondary combustion
5 Improper operation of automatic steam temp indicating and controlling
equipment
With a constant load low SH temp is caused by
1 Too low excess air
2 Too high feed water pump
3 Excessive external deposits on SH
4 Excessive moisture carry over from drum
5 Passing Attemperator valves

SOOT BLOWING
Blowing of soot is important for keeping the heat transfer high. This should
be done as and when there is indication of soot build up. By regular logging
the exit and other temperature soot blowing programs can be made out. Care
should be taken not to operate soot blowers on a cold boiler. Fire should not
be extinguished while blowing

The factors to be watched during the boiler operation

Furnace Vacuum
This should be maintained to provide a negative atmosphere -2 to –5 mm of
water column at the top of the furnace. The value given must be increased if
the tapping point of the instrument is not on the top of the furnace but
located at the convenient point elsewhere. A good proof of adherence to this
rule can be verified by the absence of the ash accumulator in the pent house
Water level
Immediately cut off firing if water level is not visible in the gauge glass (Low
water level may result in the water wall tube failure). Overfilled boiler which
can be sensed by the rapid fall of steam temp will result in the damaged
turbine SH and main steam line.

SeminarsTopics.com
Superheater Temperature

Effects of the SH temperature have been indicated .The control of super

heat can be achieved either by attemperation or by burner tilt. If the super
heat temperature control is important but also the control of the
temperature after convection SH platens etc
If we remember that each section of SH is designed for a specific temp
pick up and which are much lower than the final superheat temperature the
need for controlling the interstage temp will be apparent
Operating either the interstage superheater or the final stage SH at values
above the designed limits even if they do not cause a failure immediately,
will cause accelerated failures due to CREEP later. This is usually referred
to as the Time –Temperature – deformation relationship of material
strength
COMBUSTION AND EXCESS AIR CONTROL
Combustion adjustments are vital importance. Mechanic of combustion has
been discussed earlier. The operation engineer should aim at the following
Stable flame
Excess air control
Flame should not sweep or hit the boiler tubes
Absence of slag
In coal burners flame should be away from the burners to avoid distortion

The combustion adjustment forms the most critical duty in boiler operation.
For good adjustments the operation engineer should know not only the
properties of fuel but also the capabilities of the equipment available with
him for combustion
The combustion control requires special skills, which are required by
experience. Some general points can however be mentioned which by
themselves would not be sufficient

1 Flame stability has to be achieved even if it is to be done at the cost of

other parameters such as excess air, load limitation, cleanings oil burner etc.
Combustion as we know is a process where fuel and air combine at the right
temperatures. Correct mixing of air with fuel in practical terms mean
ensuring the right windbox pressure ensuring the velocity of the secondary
and primary air and also fuel air .For this purpose in a tangential fired boiler
we have the following

SeminarsTopics.com
Total air regulation
The output control of the FD fans ensures total quantity of air to be
supplied for combustion .It must borne in mind even when the FD fan
delivers the required quantity combustion may not be proper if air is not
distributed where is required. The distribution is done as described below
Primary air flow
In coal fired boilers working on direct systems, primary air is the drying
medium of the coal and carrying medium .The primary air usually forms 18 to
25% of total air
The Fuel Air
The fuel air in coal fired boiler and in the oil-fired boiler is the air around
the burner nozzle. The fuel air determines the ignition point of the fuel. It
will be seen during light up that a flame can be lit readily when the fuel air is
throttled to a minimum. Once the fuel is lit, the fuel air can be opened to
control the flame shape and ignition point. The fuel air usually varied in the
proportion to the fuel loading in a nozzle. As an illustration it may be said
that when coal feeder is at min speed, in the nozzles served by the feeder
the fuel air dampers may be at 30 % opening. Corresponding to the min
speed of the feeder the fuel air damper will open at 100%. the figure
mentioned in the example are for illustration only and actual positions are to
be determined by the trials at site

THE AUXILLIARY AIR (SECONDARY AIR)

Dampers, which are either above or below the fuel nozzles, are regulated to
obtain the furnace to wind box differential or in other words for windbox
pressure in general ensures equitable distribution of air thorough various
dampers than a low wind box pressure. From the explanations given above it
will be seen that burner air dampers do not control the quantity of air
distributed but their velocity. The quantity control we may repeat is done by
FD air fan output

A good combustion should ensure a clear furnace at the hopper. If the

furnace appears dark at the lower zone increasing the quantity of air thro’
the lower most nozzles would help. The top air nozzle helps to control NO2
emission. If the control of the NO2 emission is important then we may
increase the air flow thro’ the top nozzle even if it would mean excess air
The explanation given for various adjustments of dampers is applicable to a
coal or fired (tilting tangential burners). In tangential firing we should

SeminarsTopics.com
remember that we have no burners as such and merely fuel nozzles .The
furnace itself serves as a burner.
Advantages of tangential firing can be realised only when the burners are
fired firewise in pairs of two, diametrically opposite
Wind box differential pressure is specified in operation manual. These are
predicted values and we are free to chose one, which gives stable
combustion

EXCESS AIR

Operating the boiler at less than required percentage of excess air would
result in the following
1 Improper combustion
2 slaging
3 Inadequate superheat
4 Risk of explosion
It is undesirable to operate the boiler under inadequate air condition. On the
other hand high excess air would mean
1 High convection superheat
2 Possibilities of ash erosion in SH and economiser coils
3 Poor thermal efficiency

Where burner designs do not match with the fuel to be burnt perhaps high
excess air operation would be inevitable. Slagging condition can be some
times are controlled by only high air operation
Considering all these factors the correct excess air has to be chosen

Flame hitting the tubes

If a burner flame directly impinges on a water tube the combustion will not
be complete and will lead to deposits on tube. The tube also under such
conditions will be overheated and fail. In making an assessment we must
distinguish between a direct impingement of the flame, which is a harmful
and casual sweeping of the flame, which is not dangerous.
The methods employed to avoid flame impingement as follows
1 Proper adjustment of the fuel air and secondary air
2 In an oil burner determining the position of the burner tip with respect
to the diffuser and also changing the shape and size of the diffuser
3 Sometimes using an oil tip with a wider angle spay

SeminarsTopics.com
SLAG

Can be caused by the following

1 Inadequate air
2 Unequal distribution of air to various corners
3 Ash fusion temp low (Fe2O3,CaO,& Na2O) and Na2O are mainly
responsible for low ash softening temperature
4 Improper grinding at tube welding

AIR HEATER FIRES

Air heater fires are usually indicated by an unusual increase in temperature.

There are two types of air heaters, rotary and tubular. Emergency measures
are in case of fire in different for rotary and tubular heaters .We discuss
rotary first and then tubular air heaters

Rotary air heaters fires

As soon as unusual increase of gas or air temperature is noted, check the air
heater for fire
If the unit is a pressurised unit or has only one air heater trip the boiler and
proceed to fight the fire as indicated in steps 1 to 4 as below
If the unit has two or more air heater decrease the load and isolate the
burning heater, being sure to close the dampers on air side of the heater.
Proceed to fight the fire as bellow.
1 Open the deluge fire fighting system. If this is not provided start the
wash water and cleaning device being sure to open drain valves to dispose
of the water
2 Connect a fire hose open the access door and direct the water to the fire
location
3 If the fire is on one location on the rotor try to stop the rotor at a
position where the full impact of the fire hose will be more effective
4 If the fire is general leave the rotor turning as long as it will turn. Use
large amount of water to cool the air heater metal
5 If there any danger of water pick up air flowing through the air heater
still in operation trip the unit or shut it down in an orderly manner

Do not use foam or chemicals or steam, as they are ineffective on this type
fire. Corrective action after the heater has fully cooled out is to inspect the
air heater thoroughly and replace any components affected by the fire

SeminarsTopics.com
TUBULAR AIR HEATER

As soon as unusual increase of gas or air temperature is noted check the air
heater for fire .If the fire is located proceed as follows
1 Trip the unit
2 Close all fan and duct dampers on the air side
3 Connect a fire hose, open all drain valves and direct the fire hose steam
at he fire

Corrective action after the heater has fully cooled to inspect the heater
thoroughly and replace any component affected by the fire

This type of emergency can be practically eliminated if proper precaution in

furnace operation is taken. The key to prevention of air heater fires is clean
combustion in the furnace. This clean combustion can be accomplished by
being particularly careful during cold starts and light load operation

Some of the things to watch are

1 Keeping the fuel oil at proper temperature
2 If steam administration is being used having adequate steam for proper
steam oil differential pressure
3 If available, steam should be slightly superheated
4 Setting dampers or burner vanes for proper flame shape or stable
ignition point
5 Use of igniters during cold starts and light load operation

SeminarsTopics.com
SeminarsTopics.com