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GREENESOL POWER SYSTEMS (P) LIMITED
DETAILED ENGINEERING FOR 130 TPH BOILER AT A/C. M/s.MADRAS SUGARS LIMITED
BOILER COMMISSIONING MANUAL
APRIL 2011
DOCUMENT NO.: 4-10003-DOC-0913

PREPARED BY R.S CHECKED BY S.M APPROVED BY J.G.E
M/s.Greenesol Power Systems (P) Ltd. Habib Towers, Plot No.59, 1st Avenue, 100 ft. Road, Ashok Nagar, Chennai 600 083. Kind Attn.: Mr. K N Ramani E-mail:Keyenar2201@gmail.com Tel: 044-24711179, 80, 99
GREENESOL POWER SYSTEMS (P) LIMITED DETAILED ENGINEERING FOR 130 TPH BOILER A/C. M/S.MADRAS SUGARS LIMITED
1. BRIEF DESCRIPTION OF BOILER: 130 TPH Bagasse /coal fired, balanced draft, natural circulation, single drum travelling grate Boiler.
2. PURPOSE: The purpose of this manual is to outline the sequence to be followed while carrying out commissioning of Bagasse /coal fired Boiler and associated auxiliaries at the site.
3. SCOPE: The following commissioning procedure shall be followed after completion of boiler erection & hydro testing activities at site.
AVANT-GARDE
PROCEDURE FOR GAS LEAKAGE TEST Ensure that mechanical erection of boiler and ducting up to chimney is completed. Ensure Trial run of fan is completed Check the completion of sealing system and all weld joints and flange joints in ducting exposed to test Close the discharge damper of ID to chimney. Run FD fan and keep open all the dampers in the air and flue gas path. Keep the air pressure and running time as approved by design. Detect leakage by soap solution /smoke test Vital point for leakage 1. Manhole doors 2. Peephole doors 3. Duct joints 4. Fan flanges 5. Pent house 6. Air heaters Note the leakage and number them for rectification and record.
AVANT-GARDE
PROCEDURE FOR AIR LEAKAGE TEST Close all the dampers in the wind box Run the FD fan and open all the dampers excluding the dampers in the wind box. Keep air pressure and running time as approved by design. Detect leakage by soap solution /smoke test Vital point for leakage Air heaters Duct joints Weld joints Note the leakage and number them for rectification and record.
AVANT-GARDE
PREPARING BOILER FOR LIGHT UP Ensure mechanical erection is completed Remove all loose construction material around the boiler also cut off temporary supports, construction platforms not envisaged in the drawings. Ensure that sufficient wooden logs at the required sizes are available for initial light up of boiler. Mark all the valves in the boiler by tag number and identification plates All pipe lines to be identified such as 1. Feed water line from feed pump 2. Line to economiser 3. Drain line 4. Attemprator spray water line etc On all equipment mark prominently the lubricant to be used Inspect the water walls, superheaters, economisers, air heater, ducts, pent house and look for the following foreign materials 1. Wooden planks 2. Manila ropes 3. Plat forms 4. Bamboo and 5. Left over refractory material Remove all the foreign materials Retractable soot blowers must be in withdrawn position Ensure that Trail run of all axillaries are completed Ensure that Boiler instrumentation is ready Ensure that Trail run of fuel feeding system is completed Ensure that Refractory work is completed
AVANT-GARDE
Ensure that DM water, flush water system, cooling water is available Ensure that sufficient lighting is available Ensure that chemical lab is functioning Ensure that Inter lock is tested. Ensure that drum level signaling and instrumentation is operational Ensure that an arrangement for expansion measurement is ready.
AVANT-GARDE
PROCEDURE FOR REFRACTORY DRY-OUT
OBJECTIVE The objective of this procedure is to ensure proper drying, curing of refractory applied on furnace and other components.
The castable refractory usually undergoes considerable chemical changes, during initial heating. Controlled heating, through these reactions ensures maximum strength. While heating there must be free air flow over the system to ensure removal of moisture.
PRE-REQUISITES In order to commence refractory dry out, the following pre requisites /inputs have to be ensured.
Ensure the availability of adequate feed water, adequate wooden logs to the required sizes, Draft system and instruments required for the Boiler firing.
Fill the drum with the specified quality feed water 50mm below the normal water level since the water level in gauge will raise as heat is absorbed.
Ensure the availability of adequate qualified boiler operating staff/operators.
PROCEDURE
Refractory baking/dry out cycle requires very slow and controlled heating of recovery as recommended by the refractory manufactures. Please refer typical heating schedule for refractory baking which are as follows. Thermal stresses will be produced if heating rate is too rapid.
AVANT-GARDE
Longer period of low temperature drying causes more even heat distribution resulting better refractory dry out.
Place the fire wood on the grate and light up the unit with wood to dry out the refractory slowly.
Ensure that rate of heating is maintained at the rate of 25c per hour
Raise the temperature of flue gas at boiler outlet to 100c hold the temperature to 10 hours at 100c for soaking refractory castables. If the temperature falls increase the firing rate and maintain the required temperature.
Then raise the flue gas temperature at boiler outlet to 250c and hold it 6 hours for soaking refractory castables.
Again raise flue gas temperature at boiler outlet to 350c and hold it for 10 hours for soaking refractory castables.
Once the fire is extinguished the boiler may be allowed to cool down naturally keeping FD, ID & SA fans off. Fan auxiliary dampers should be in fully closed condition. A thorough examination is to be made to check refractory condition after boiler is cooled down. Minor cracks (up to 3mm) are to be filled with castable refractory.
NOTE Keep open all the vent lines on the boiler drum, top super heater headers 100 % through out the refractory dry out period.
Maintain normal water level in the drum through out the period by draining through CBD/IBD and if required water can be fed to maintain the drum level.
AVANT-GARDE
PROCEDURE FOR ALKALI BOIL OUT OBJECTIVE The purpose of alkali boil out is to remove the deposits like oil, grease, mill scale etc from boiler internals, which was resulting out of manufacturing, fabrication and erection. Such deposits in the boiler tube walls will restrict heat transfer and will result in failure due to overheating. PRE-REQUISITES In order to commence alkali boil out of the boiler, the following pre requisites /inputs have to be ensured. Ensure the Mechanical completion of boiler including auxiliaries and piping. Ensure the completion of hydraulic test activities and refractory dry out. Ensure the readiness of electrical and instrumentation controls. Ensure that adequate illumination is available in and around boiler house. Ensure that electrical power is available for motorized valves and gauge glass illuminator. Ensure the availability of DM water through boiler feed pumps. Ensure the readiness of sample collection system. Ensure the availability of required chemicals for the alkali boil out. Ensure that the boiler is fully ready for light up with thermal expansion provisions. Ensure the availability of lab facilities to test the water. (PH and oil deduction) Ensure the readiness of chemical dosing system. Ensure that all the debris is removed from Boiler.
AVANT-GARDE
Ensure that the drum internals are removed from steam drum and match marking is given. Ensure that all the access doors in the boiler are closed.
Ensure the availability of the following. 1. 2. 3. 4. 5. 6. 7. 8. 9. Good working drum level gauge glass with illuminator assembly. Boiler drum pressure gauge. Safety /relief valves with gags or hydrostatic plugs are removed. CBD, IBD and all drain valves in good working conditions. Water level control and associated alarms Cooling water piping and air piping Furnace pressure gauge Temperature indications for flue gas feed water and steam line. Ensure that during alkali boil out, transmitters connected to steam drum and steam piping is isolated to avoid any damages to transmitters due to alkali. 10. Ensure that blow down and drain connections are terminated to safe location. 11. 12. Ensure that feed water pump operates satisfactorily. Ensure that all dampers are in good working condition and OPEN CLOSE, positions are marked correctly.
AVANT-GARDE
PROCEDURE FOR 1st STAGE BOIL OUT (At 20 kg/cm(g) pressure) 1. Fill the specified quality feed water 50mm below the steam drum manhole rim. 2. Exact quantity of chemicals (280 Kg 0f Tri sodium phosphate
Na3PO412H2O, 280Kg of Caustic soda, and 70 Kg of Detergent) is to be carried in dry form up to the drum level platform. The chemicals are to be dissolved in DM water externally in a container near the drum manhole in batches. The concentrated solutions so prepared are to be poured in to the drum through the manholes. When entire quantity of chemical has been dissolved and poured in to the drum. Close the manhole and fill the drum to the normal level. 3. 4. Increase slowly the heat input to boiler to raise pressure. At a pressure of approximately 30 psi (2.1 kg/cm (g)) a good flow of steam from air release valves will be noticed. Up on seeing this close the air release valve. 5. 6. Continue increasing the pressure to 20 kg/cm(g) . Maintain pressure at 20 kg/cm(g) for a period of 16 hours. This will ensure rapid circulation of water through boiler. 7. Give blow down at every 2 hours interval from water wall drains for one minute each, 8. Extinguish the fire and blow down boiler manifolds individually giving blow down for a period of 2-3 minutes each. 9. Allow boiler to cool down naturally when pressure comes to 2.5 kg/cm with manifolds closed; blow down steam drum until water level falls below gauge glass. 10. Following this entire boiler can be blown down as quickly as possible using all manifold and drum blow down and drains. This way evacuate the water before any dirt or oil has time to settle down. Note: When blowing down through all drains and blow downs by
simultaneously, due regard must be exercised for the capacity of the blow down system.
10
AVANT-GARDE
11. 12.
When pressure falls to 30 psi (2.1 kg/cm) open air release valves. With blow down and drain valves still open flush through drums, Manifolds, and tubes with high pressure clean water to wash out any remaining sediment.
PROCEDURE FOR 2ndSTAGE BOIL OUT
Fill the specified quality feed water 50mm below the steam drum manhole rim.
Exact
quantity
of
chemicals
(280
Kg
0f
Tri
sodium
phosphate
Na3PO412H2O, 280 Kg of Caustic soda, and 70 Kg of Detergent) is to be carried in dry form up to the drum level platform. The chemicals are to be dissolved in DM water externally in a container near the drum manhole in batches. The concentrated solutions so prepared are to be poured in to the drum through the manholes. When entire quantity of chemical has been dissolved and poured in to the drum. Close the manhole and fill the drum to the normal level. BOILER LIGHT UP After ensuring the above, light up the boiler and raise the boiler pressure slowly to monitor the thermal expansion of pressure parts. Ensure the normal water level in drum is maintained through out boil out operation. BOIL OUT PRESSURE & DURATION At a pressure of approximately 30 psi (2.1 kg/cm(g)) a good flow of steam from air release valves will be noticed. Up on seeing this close the air release valve. Raise the boiler pressure to 40kg/cm(g) and carry out boil out operation by maintaining this pressure for a period of 16 hours .This will ensure rapid
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AVANT-GARDE
circulation of water through boiler. The pressure is to be maintained by controlling the fuel firing and modulation of the start up vent. During this process normal drum level is to be ensured.
BLOW DOWN
Operate IBD for 10 seconds every one hour. Blow down through low point drains by opening the valves ,one by one but one at a time for one minute interval each mean while ensure the drum level.
Blow down the water wall drains every two hours for one minute. Blow down the system at an interval of every 2 hours & Allow drum pressure to rise up to 40 kg/cm (g) and ensure the drum level to normal. After every blow down operation collect drum water sample and analyze for phosphate and oil content .Replenish phosphate concentration through HP dosing system as and when the residual value goes less than half of the concentration maintained at the start of the process.
Continue the boil out operation till the oil content in the sample collected does show less than whichever is later 5ppm or till the eight blow downs are completed
COMPLETION OF BOIL OUT
When analysis confirms the oil presence in the samples is equal to or less than 5 ppm the boil out operations treated as completed.
For confirmation it is suggested to collect 3 samples within 5 minutes of each other and check the consistency of the results.
POST BOIL OUT OPERATION
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AVANT-GARDE
Operate each blow down and drain valve successively for a few seconds to discharge any accumulated sludge. Repeat several times meanwhile maintain drum level.
Allow the boiler to cool down naturally .When the drum pressure comes to 2 kg/cm (g) open the all air release valves. When the drum pressure drops to atmospheric, drain the boiler by opening all valves on drain headers. Fill the boiler up to the drum to the required level and back flush the super heaters into the drum till the sample collected from super heater off take tube mouth in the drum shows a low conductivity and high clarity.
BOILER RINSING After completion of Alkali boil out and boiler is considerably cooled, flush the boiler with DM water till the system is free from alkali solution .i.e. Ph value of effluent should be equal to that the DM water used for flushing
FINAL INSPECTION After draining the boiler cut the inspection caps in headers to inspect for any sediment, cleaning and flushing. After boiler has cooled down completely, open all manhole doors and remove all manifold inspection caps to inspect the internal surfaces. Re-weld the end caps on headers as per recommended procedures and carry out necessary NDT and stress reliving as applicable. Accumulated dirt and sludge should be scrapped out in drum, manifolds and tubes washed through high pressure clean water. Examine all heating surfaces and gas passes of boiler for excessive soot deposits resulting from low firing rates employed in Boil out. Clean manually the soot deposits. Check all refractory for any cracks.
13
AVANT-GARDE
Check for any ash accumulation in any area. Check that expansion joints are set correctly and that expansion clearances are adequate.
NOTE Boiler water contains chemicals, which are hazardous for human safety and hence safe disposal is necessary.
Procedure for passivation of Boiler
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AVANT-GARDE
Objective
Passivation is the treatment applied to the cleaned steel parts to produce a continuous, coherent and corrosion resistant layer of magnetite on the surface. A combination of hydrazine and ammonia is used to form a magnetite layer.
Procedure
After completion of 2 stage alkali boil out flush the generating section pressure parts by fill and dump method. This should be done number of times to rid -off all iron oxide loose debris in the system. Ensure that drum internals are in position After completion of fill and dump method fill the Boiler with DM water and add required quantities of hydrazine hydrate and ammonia to get hydrazine content of 200 ppm and PH of 10.(Hydrazine hydrate 26 Kgs with 2.5Kgs of Ammonia liquid) Light up the boiler and raise the pressure to 40 kg/cm as per O&M instructions. Continue Boil out for 20 hours and collect the samples at every one hour and analyze the hydrazine content and PH. During this period add chemicals whenever necessary to maintain hydrazine content and PH value of 200 ppm and 10 respectively. Ensure the positive flow through super heaters for effective passivation of super heaters. After 20 hours of operation at 40 kg/cm, the Boiler should be drained hot after cooling to 1-2 kg/cm.
All the bottom drains should be opened while draining.
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AVANT-GARDE
Open the drum vent when drum pressure reaches to 2 kg/cm Now the boiler is ready for steam blowing.
Note:
Ensure that no solid chemicals are added in to the drum during steam blowing
STEAM BLOWING PROCEDURE
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AVANT-GARDE
PURPOSE The purposes of steam blowing is to descale and remove foreign materials from steam pipe lines leading to turbine in order to avoid damage to turbine blades in the course of normal operation. PRINCIPLE Steam blowing is carried out by PUFFING method to 1. Dislodge rust/scales from pipe work by thermal shocks 2. High momentum of expanding steam in the pipe work purges out the loosened materials REQUIREMENTS Temporary pipes and temporary valves used for steam blowing must be equal to the maximum sizes of permanent pipes
Sharp elbows, bends and tees are to be avoided in temporary piping as these contribute to increased pressure loss during steam blowing conditions
Temporary discharge piping should be well supported to with stand reacting forces during blowing
The steam must be exhausted to atmosphere out side the turbine hall
The area should be cordoned off and notice should be displayed prominently
For thermal expansion of the pipe, proper allowances must be given. First steam blow is given at a lower mass flow of steam and the pipe lines is to be surveyed for proper expansion and supports
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AVANT-GARDE
Ensure that all permanent hangers of various pipe lines including main steam line is erected as per drawing and the values set accordingly to the design values also ensure that locking of hangers are removed
Ensure that ID, FD, SA Fans and Boiler feed pumps are available for operation
Ensure that Burning fuel and fire light up arrangement is completed
Ensure that feed water with dosing chemicals is available
Ensure that remote operation of start up valve, stop valve and by pass valve is possible
Ensure that drum level indication is available
Ensure that flow nozzles, control valves, non return valve flaps are not erected before steam blowing. Spool pieces may be erected at its places where ever applicable
Ensure that hydraulic test of pressure part/pipe lines are completed
Ensure that insulation of temporary and permanent piping is completed as per schedule before starting the steam blowing
STEAM BLOWING Increase the boiler pressure gradually to 40 kg/ cm(g). Maintain drum level to 55% of gauge glass and then open main steam valve fully and maintain the fuel firing rate to keep the pressure to 40 kg/ cm(g)
Continue steam blowing till the pressure comes down to 20 kg/ cm(g)
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AVANT-GARDE
Keep a constant watch on drum level
Maintain at least 3 hours time gap between the consecutive blows
After 2-3 blows place the Aluminum target plate in its pre determined location (place the target plate at the nearest possible final user point) and inspect the target plate.
Repeat the blowing operation till the target plate is found clear
COMPLETION CRITERIA Indications for the result of steam blowing are the number of pitting / impression found on the target plate. The highest velocity of steam is in center of pipe and hence judgment should be made at this area. It is recommended to place the target plate after completing few blows in each stage
The result of blowing operation can be judged by the absolute number of pitting / impression on target plate central zone
ACCEPTANCE CRITERIA The piping is considered clean if there are not more than 5 (five) pitting less than 1 mm dia in central zone area and shall not have any deformed edge. Besides this there shall be no pitting in the rim zone.
ERECTION OF FLOW NOZZLE
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AVANT-GARDE
After completion of steam blowing cut the required length on Main steam piping at the elevation and location where flow nozzles to be provided.
After grinding the gas cutting edges, do the Dye penetrant tests on gas cut edges of the main steam pipe to identify surface defects if any.
Ensure the edge preparations are as per the drawing and check with templates.
Ensure the orientation of flow nozzles as per drawing.
Ensure the root gap is maintained properly while making fit up of flow nozzle with main steam piping.
Ensure proper pre heating as per WPS.
Ensure root run is being done by TIG welding and subsequent run by SMAW. Extreme care should be taken during welding and inside main steam pipe should be free from foreign materials.
After completion of root run. Check the root welding by Dye Penetrant test.
NDT & Stress reliving shall be carried out as per IBR.
Ensure weld cleats are grounded smoothly.
Complete the drain/vent piping and instrument tapping of flow nozzle as per drawing.
Ensure all temporary supports are removed after providing permanent supports to Main steam piping.
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AVANT-GARDE
PROCEDURE FOR SAFETY VALVE SETTING OBJECTIVE The objective of this procedure to outline the procedures involved in setting the safety valves to the designed set pressures before allowing the boiler to go for commercial steaming.
DEFINITION OF TERMS SET PRESSURE This is the pressure at which the valve begins to lift from the valve seat.
This pressure is set sufficiently above the normal working pressure of the boiler in order to avoid unnecessary simmering such as induced by normal fluctuations in steam pressure when boiler on load.
FULL LIFT PRESSURE This pressure at which the valve reaches its fully open position
CLOSING PRESSURE Closing pressure is the pressure at which the valve reseats.
BLOW DOWN The blow down is the difference between the set pressure and the closing pressure expressed as a percentage of set pressure.
Blow down % = set pressure closing pressure ----------------------------------------Set pressure
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AVANT-GARDE
PREPARATION Fill the boiler to the gauge glass water level.
Fit the calibrated pressure gauge to test connection on steam drum.
Close the boiler main steam stop valve.
Open the super heater drain valve.
Keep the gags ready; fit the gags once the pressure reaches to 60 % of normal working pressure.
Open all air release valves.
Close the I.D fan dampers and start the I.D fan, when fan is up to the speed open damper to maintain draft.
Close the F.D fan dampers and start the F.D fan, when fan is up to the speed open damper.
Light up the Boiler and adjust the air flow.
Slowly raise the pressure at about 2 kg/cm (g) and ensure the air is released through air release valves, and then the air release valves may be closed.
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AVANT-GARDE
SETTING THE VALUES This operation involves increasing and decreasing the heat input to the boiler to raise and lower the steam pressure. The set pressure and closing pressure of each valve is checked and adjusted in turn from the highest pressure valve first to the lowest pressure last.
Steam flow through super heater must be maintained and controlled at an adequate rate by manipulation of super heater drain/vent.
Raise steam pressure slowly to set pressure for the first valve.
When sound of escaping steam is heard note the pressure reading on calibrated gauge .Note the pressure when the full lift point is reached
Allow the pressure to fall and note the pressure at which the valve closes.
If the noted pressures are not as specified by design, then adjustments must be made and process of checking repeated until correct reading is obtained.
During the test a close watch must be kept on drum water level, as steam will be lost at each lift of the safety valves as well as continuous discharge through super heater drain/vent. Control the feed to compensate these losses.
Repeat the test for each valve in descending order of set pressures. The valve which was set already should be left un gagged.
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AVANT-GARDE

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GREENESOL POWER SYSTEMS (P) LIMITED

BOILER COMMISSIONING MANUAL

DOCUMENT NO.: 4-10003-DOC-0913

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

PROCEDURE FOR REFRACTORY DRY-OUT

Ensure the availability of adequate qualified boiler operating staff/operators.

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

PROCEDURE FOR 2ndSTAGE BOIL OUT

BOILER COMMISSIONING MANUAL

COMPLETION OF BOIL OUT

POST BOIL OUT OPERATION

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

Procedure for passivation of Boiler

BOILER COMMISSIONING MANUAL

All the bottom drains should be opened while draining.

BOILER COMMISSIONING MANUAL

STEAM BLOWING PROCEDURE

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

Ensure that Burning fuel and fire light up arrangement is completed

Ensure that feed water with dosing chemicals is available

Ensure that drum level indication is available

Ensure that hydraulic test of pressure part/pipe lines are completed

BOILER COMMISSIONING MANUAL

Keep a constant watch on drum level

Maintain at least 3 hours time gap between the consecutive blows

ERECTION OF FLOW NOZZLE

BOILER COMMISSIONING MANUAL

Ensure the orientation of flow nozzles as per drawing.

Ensure proper pre heating as per WPS.

NDT & Stress reliving shall be carried out as per IBR.

Ensure weld cleats are grounded smoothly.

BOILER COMMISSIONING MANUAL

Blow down % = set pressure closing pressure ----------------------------------------Set pressure

BOILER COMMISSIONING MANUAL

PREPARATION Fill the boiler to the gauge glass water level.

Fit the calibrated pressure gauge to test connection on steam drum.

Close the boiler main steam stop valve.

Open the super heater drain valve.

Open all air release valves.

Light up the Boiler and adjust the air flow.

BOILER COMMISSIONING MANUAL

BOILER COMMISSIONING MANUAL

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