Boiler

Special Operations
Hydro Test
Safety valve Floating
Forced Cooling
Wet Preservation

Hydro Test

Drum metal temp should be less than 80C.

Ensure SH coils metal temperatures are <50C.
Furnace temp should be less than 50C.
Close boiler main stop valve[MSV] and its bypass MOV.
Physically check &ensure tight closure of the MSV at
local.
Open fully all the drain valves in the MST line after the
MSV.
Open fully all the drain valves in the SSB line after the
control station to avoid water entry into RAH-hoppers
thro SSB.

Isolate the power supply for MSV and its bypass

MOV.
IDs and FD Fans should be in stopped condition.
Ensure locking of the spring supports in MST line
&SH-III o/l header.
Ensure the Gag on the SVs and tight close the HOV
before the ERV.
Keep open the manholes at 44ML and at 15 ML and
some manholes in coil areas.
Provide focus lights at 44ML & at 15ML for furnace
inspection.
Making through the dummy on the filling line.

Using fill pump fill the WW, Eco, Drum, and

SHs contour.
Ensure opening of the vent valves at the
headers [5 nos of WW+4 nos of SH 2&3] and
at the vent station [2for SH3; 2for SH2; 2for
eco & 1for WW].
In case the water temp is higher [say 60~70C]
continue venting at that section alone.
Make simulations in the logic for opening &
closing of SH spray valves [both block & any
one line] that will be used for pressure raising.

Pressurize up to 5 bar using fill pump and close

all the HOV & MOV vent valves including SH
3 startup vent.
Close the HOV &put back the dummy on
filling line and before starting the BFP.
Start BFP and using SH Attemperation line or
low load line-Eco by pass line pressurize the
contour using feed pump scoop.
Advantage of using SH spray line is that we
can get the measure of water flow during Pr
raising but simulation is to be done for opening
the valve.

During contour filling and pressurizing, check

the MSV after valve drains for any water
flow; and ensure that there is No Flow of
water to turbine side.
Rate of Pr rise is 2bar/min up to 50bar.
Inspect the boiler contour for any leaks.
Continue Pr raising up to 100bar at the same
rate and inspect again.
Start second BFP.
Thereafter Pr rise is 1bar/min up to 170 bar in
drum.

Offer the boiler for DCIB inspection.

In case of delay in the arraival of DCIB; keep
the drum pr at 120 bar and use the feed pumps
alternately to maintain the pr in the system.
Hold the pressure for hour using both
BFPs.
Depressurize the boiler by using BFP scoop at
the same rate of pr raise.
At 50 bar inspect ABGs and coils & Record
the leaks.
At 50 bar C&I will do flushing of impulse
lines of SWAS.

Close all valves in the feed manifold and also in

the spray station.
Stop the BFPs.
Open CBD line and release the pressure @
2bar/min upto 0 bar.
Open SH & Drum start up vents, drains before
MSV.
Drain the MS line, SHs and partly the Drum [up
to working level]
Remove all simulations & the gags in SVs
Unlocking of the spring supports in MST line
&SH-III o/l header.
Avail supply for MSV and its bypass MOV.

In case of puncture note down

the location of puncture and
drain that particular section
only.

Safety valve Floating

SV floating is done preferably before unit
synchronization.
SV floating is done after every SV servicing
or after attending to valve passing.
SV floating if done actually will subject all
the system parts to high Pr.

REQUIREMENT OF SAFETY VALVE

Proper functioning
- Opening at correct set pressure
- Correct blow down
- Proper mechanical operation &
Clean closure without leakage.

The set pr of the four SVs are as follows.

Keep in hand the previous values and details
like make no, seat area etc
Drum Valve 101 located at left front side
opens at 178 Ksc [measurement not in bar].
Drum Valve 102 located at left rear side
opens at 179 Ksc [measurement not in bar].
Drum Valve 103 located at right side opens at
180 Ksc [measurement not in bar].
SH Valve 104 located at SH-III outlet header
on the left- front side opens at 168 Ksc
[measurement not in bar].

CHATTERINGRapid opening and closing of the valve is

known as chattering.
CAUSES
- Insufficient blow down
- More back pressure due to under size
discharge piping
- Insufficient steam flow to the valve
- lifting with water

SIMMERING
The valve is just about to open and has indefinite
contact.
It is an audible sound caused by the
vibration of air molecules around the seat.
BLOWDOWN:
Opening pre Closing pre
---------------------------Opening pressure

X 100

Valve should be set with in 1% of set

pressure
Valve should be hand popped at
75 to 80% of set pressure
GAGGING
Arresting the stem mechanically from
lifting.
- Do not gag in cold condition
- Gag at 80% of low set value
pressure.

At local it is preferable to mount precision

gauges. If one valve is to be floated all the other
valves are to be gagged.
By actual float we can know the Opening, Closing
Pr and we can compute the Blow down.
It is always advisable to use oil burners for actual
float test.
Drum level surges will take place and hence level
simulations have to be done to avoid boiler trip.

ATTENTION!!
-

Do not stand near Discharge pipe of

the Safety Valve

- Test and achieve within minimum

number of pops.
- Bring Blow down between 3 and 5 %

In TREVI test SV floating shall be done after

synchronization preferably in full opr Pr.
Instead if TREVI test is done the system pr is the
steady opr pr but the external force is given to the
valve spindle for opening the valve.
The applied hydraulic cylinder pr will pull the
valve stem upwards against the spring force.
We can know only the Opening pr but not the
Closing Pr and so we cannot compute the Blow
down.

No need of oil burners.

No need for gagging the SVs.
Drum level surges will not take
place.
Some agencies give valve lift
plotting graph.

Forced Cooling
AFTER BOILER IS TRIPPED DO NOT CLOSE
STOP VALVE.
HP BY PASS & LP BY PASS WILL COME INTO
SERVICE ON AUTO.
CARRY OUT BOILER PURGE.
FEED THE BOILER USING BFP UPTO +400MM.
MAINTAIN 400T/HR AIR FLOW INITIALLY.
STOP BOTH CGR FANS.

USING PR SET POINT OF THE BY PASS VALVE

GRADUALLY REDUCE BOILER DRUM PRESSURE.
DRUM INNER TOP/BOTTOM TEMP SHOULD NOT
EXCEED 25C.
IN CASE OF INCREASING TREND REDUCE AIR FLOW.
STOPPING FD FAN IS TO BE CONSIDERED IF MANY
POINTS HAVE DELTA T AND RESTARTING AFTER
NORMALISATION.
CHECKING THE CLINKER FALLING AT LOCAL,
GRADUALLY STEP UP AIR FLOWTO UPTO 700T/HR.
4 HRS AFTER BOILER TRIP, START BOTH GR FANS.

FEED THE BOILER USING BOILER FEED PUMP

WHENEVER - LEVEL GOES OUT OF RANGE.
ONCE THE BY PASS IS CLOSED SHUT THE BOILER
STOP VALVE.
OPEN SH VENTS AT 6 BAR DRUM PR.
OPEN DRUM VENTS AT 3 BAR PR.
HOT DRAIN THE DRUM, ECO, WW AT 140C.
FANS TO BE KEPT IN SERVICE TILL RH, SH TUBE
TEMP IS AROUND 60C
SLAG BATH CAN BE DRAINED AFTER 24 HOURS

FURNACE MANHOLE DOORS CAN BE

OPENED AFTER 24 HOURS
ONE FD FAN CAN BE STOPPED WHEN SLAG
BATHWATER IS DRAINED
SECOND FD FAN, ONE ID FAN CAN BE
STOPPED AFTER 36 HOURS AFTER BOILER
TRIP
SECOND ID FAN TO BE STOPPED /KEPT IN
SERVICE IN CONSULTATION WITH BOILER
MTCE DIVISION.

WET PRESERVATION
Boiler water drained fully @ room temp.
One CST was isolated. i.e DM Water line
valve from WCTP was closed.
CST inter connection valve was closed.

Liquid hydrazine [N2H4] was added from the top

of the tank
200 PPM hydrazine solution prepared in the CST
by starting fill pump and recirculating water.
Some amount of liquid Ammonia was added to
improve PH value in this solution.

All boiler drains were closed tightly.

Using down comer drain lines fill pump was
started and chemical filled upto Drum
working level i.e +300 mm
All vents were closed to box-up the SH coils in
lieu of N2 capping.
Nothing was done to preserve the RH coils.

Periodically, say once a week, check solution

concentration in water.
If the solution concentration decreses,
chemical dept will add more chemical solution
after draining some water.