P-3218 VantaaSystems training steam boiler
Operating personnel trainingEdition 04.06.2013
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Introduction
The purpose of this training is to familiarise operating staff with the plant equipment and how to use it. It is a good idea for staff to visit the plant while the equipment is being fitted, in order to be able to see where the equipment is located on the plant, especially the connecting pipelines. Once the insulation has been installed the plant will look quite different.
Training will cover the following basic topics:
Theoretical classroom training
Practical training at the boiler plant
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Table of Contents
Process
Configuration Vantaa
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance
Table of contents
Process
Configuration Vantaa
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance
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Process
Fundamental of waste incineration steam generators
The following slides are not related to a specific plant.
For simplification, the expression „boiler“ is used for „steam generator“
Main Components of Boiler
Principle of Natural Circulation in Evaporators
saturated steam to superheaters
water from eco(below boiling temperature)
downcomer(not heated)
risers = evaporators(heat exchanger tubes)
heat input
saturated steam
boiling water
steam drum
Circulation caused by difference in density in risers and downcomers
Steam content in risers: at inlet: 0 % (water at boiling temperature) at outlet: ca. 5 mass -% (> 50 volume-%)
circ
ulat
ion
Main Control Loops
Life steam flow → waste input, combustion air flow (control within Combustion Control System (CCS)
Life steam pressure → turbine inlet valve (control turbine, no control within boiler)
Drum water level → feed water input (control of constant level)
Steam temperature → throughput water injection attemperators (control constant steam temperature)
Arrangement of Heating Surfaces (Heat Exchangers)Example: 2-Pass Horizontal Boiler
superheated steam
feed water
steam
water
SH 1SH 3 SH 2 Eco
saturated steam
Ev
ap
ora
tor
Evaporator(membrane walls)
Note:• Each heat exchanger may consist of several bundles (banks) e.g.: Eco = Eco 1.1 + Eco 1.2 + Eco 1.3 + Eco 1.4 + Eco 1.5 + Eco 2
+ Eco 3 , SH 1 = SH 1.1 + SH 1.2
• Additional heat exchangers may be installed, e.g.: evaporator between SH and Eco
Control of Flue Gas Temperatureat Boiler Outlet with preheater (External economiser)
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Minimum flue gas temperature maybe required by flue gas cleaning system.
Note: max. flue gas temperature can not be controlled (results from boiler fouling).
Control of Flue Gas Temperatureat Boiler Outlet with preheater (External economiser)
Control of Flue Gas Temperatureat Boiler Outlet with Eco-Bypass (1)
3-way valve
eco
no
mis
er
flue gas
T FG out
steam drum
bypass
Minimum flue gas temperature maybe required by flue gas cleaning system.
Note: max. flue gas temperature can not be controlled (results from boiler fouling).
Continuous Boiler Blow Down
Steam generation =„distillation“
→ impurities are accumulated in boiler water (evaporators)
Continuous blow down from drumis adjusted in order to maintain boiler water qualitiy within acceptable limits.
Typical continuous blow down:0.5 % of life steam flow
steamconductivity < 0.2 μS/cm
feed water from ecoconductivity 0.2 < μS/cm << 50(downstream chemical dosing)
circulating boiler water (evaporators)conductivity < 50 μS/cm
blow down valve
expansion vessel
steam vent
drain
steam drum
Effect of Boiler Fouling on Flue Gas Temperature
Flue Gas Temperature in Clean and Fouled Boiler
100
200
300
400
500
600
700
800
900
1000
1100
1200
flue gas path (-)
flu
e g
as
te
mp
era
ture
(°C
)
economiserssuperheaters
radiationpasses
190
163
fouled
clean
inlet boiler exit boiler
• Fouling increases with boiler operation time
• Fouling = „insulation“ of boiler tubes
• Assuming same flue gas and water/steam temperatures in heat exchanger:
heat flux can be reduced by up to ca. 50 % due to fouling
• Due to higher flue gas temperature in case of fouled boiler: heat flux in whole boiler is reduced only by few % and results in an increase of flue gas temperature at boiler exit of ca. 30 °C within 8000 h
Minimizing Corrosion: Final Superheater (SH 4) with Co-Flow
• Steam temperature and therefore tube surface temperature is highest in final superheater• Highest risk of corrosion in final superheater (SH3 = SH3.1 + SH3.2)• Co-flow: reduction of corrosion rate, but
reduction of heat flux compared to counter-flow
Final Superheater with Co-Flow
300
350
400
450
500
550
600
650
700
Ste
am
- a
nd
Flu
e G
as
Tem
per
atu
re (
°C)
flue gas flow diection
steam flow direction
steam temperature
flue gas temperatureavoid combinationof high flue gas and high steam temperature
inlet outlet
Table of contents
Process
Configuration Vantaa
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance
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Natural circulation boiler
Most common type of boiler (used in industry, combined heat and power stations)
Uneconomical for larger plants (> 500 t/h steam)
Simple evaporator design
Part loads and changes in load are easily possible
Changes in load: require control through injection, variation of live steam temperature
Sensitive to rapid pressure drops (profuse steam generation)
Reduced output of feed water pumps required
Lower feed water quality required (due to blow-down)
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Boiler operating principle
The feed water pump (6) conveys the feed water through the economiser (1) into the boiler drum (2). The difference in density between the water/steam mixture in the heated riser pipes (3) and the water in the non-heated downpipes (5) causes a natural circulation to occur. The saturated steam, which is ultimately superheated in the superheater (4), accumulates in the top part of the boiler drum (2).
No. Description
1 Economiser(pre-heater)
2 Boiler drum
3 Evaporators (heated risers)
4 Superheaters
5 Non-heated downpipes
6 Feed water pump
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Boiler plant assembly method
Description of the boiler assembly process:
Pipes with 21.3 to 219.1 mm diameter are welded together
The diaphragm walls are made with longitudinal welding of pipes and steel strips
Method of transporting the parts from the workshop to the site and final assembly.
When the boiler is assembled, further procedures are to be carried out, such as:
Rinsing the boiler
Cleaning the water side of the boiler chemically
Drying the refractory lining
Steam cleaning of superheating surfaces.
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Steam boiler
Description Data
Nominal rating (saturated steam) 83 t/h
Live steam nominal pressure 91 bar (a)
Live steam nominal temperature 400 °C
Feed water temperature 132 °C
• Technical specifications
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Steam boiler
• Size of heating surfacesDescription Data KKS-No.
External economiser 1.1 451 m2 J1HAC05 AC011
External economiser 1.2 451 m2 J1HAC05 AC012
External economiser 1.3 451 m2 J1HAC05 AC013
External economiser 1.4 451 m2 J1HAC05 AC014
External economiser 1.5 451 m2 J1HAC05 AC015
Economiser 2L/2R 1438 m2 J1HAC10 AC021J1HAC10 AC022
Economiser 3L/3R 1438 m2 J1HAC10 AC031J1HAC10 AC032
Evaporator walls 2063 m2 J1HAD10 AC001
Evaporator 1 214 m2 J1HAD10 AC002
Superheater 1.1L/1.1R 902 m2 J1HAH10 AC111 J1HAH10 AC112
Superheater 1.2L/1.2R 902 m2 J1HAH10 AC121 J1HAH10 AC122
Superheater 2L/2R 867 m2 J1HAH20 AC201 J1HAH20 AC202
Superheater 3.1L/3.1R 366 m2 J1HAH30 AC311 J1HAH30 AC312
Superheater 3.2L/3.2R 523 m2 J1HAH30 AC321 J1HAH30 AC322
Total 7190 m2 -
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• Volume of the boiler pressure system
Steam boiler
Description Data KKS-No.
Boiler drum 22,908 m³ J1HAD10 BB001
Evaporator 1 2,193 m³ J1HAD10 AC002
Superheater 1.1L/1.1R8,528 m³
J1HAH10 AC111 J1HAH10 AC112
Superheater 1.2L/1.2R8,528 m³
J1HAH10 AC121 J1HAH10 AC122
Superheater 2L/2R7,118 m³
J1HAH20 AC201 J1HAH20 AC202
Superheater 3.1L/3.1R5,762 m³
J1HAH30 AC311 J1HAH30 AC312
Superheater 3.2L/3.2R4,104 m³
J1HAH30 AC321 J1HAH30 AC322
External economiser 1.1 2,435 m³J1HAC05 AC011
External economiser 1.2 2,325 m³J1HAC05 AC012
External economiser 1.3 2,325 m³J1HAC05 AC013
External economiser 1.4 2,325 m³J1HAC05 AC014
External economiser 1.5 2,435 m³J1HAC05 AC015
Economiser 2L/2R13,204 m³
J1HAC10 AC021J1HAC10 AC022
Economiser 3L/3R13,204 m³
J1HAC10 AC031J1HAC10 AC032
Membran walls - vertical part 35,816 m³ J1HAD10 AC001
Membran walls-horizontal part 16,547 m³ J1HAD10 AC001
Connecting pipings 18,969 m³ -
Total 168,73 m³ -
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Structure of the boiler
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Structure of the boiler
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Structure of the boiler
The steam is generated with a 5-pass horizontal boiler. This consists of the vertical 1st to 3rd pass the horizontal 4th pass, and vertical 5th pass
The lower part of the 1st pass forms the furnace. In the grate area, the side walls are fitted with refractory lining.
The side walls of passes 1 to 4 are designed as evaporator pipes with a gas-tight diaphragm construction and are connected to the natural circulation system.
The economiser, the evaporator and the superheater are arranged in the horizontal 4th pass. The boiler drum is arranged diagonally at the top, on the boiler.
External vertical convection 5th pass with economiser heating surfaces and
sheet metal casing
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Boiler layout and internal circulation of all fluids
Passes (vertical and horizontal) including associated heating surfaces
are to be indicated as follows:
Superheating surfaces SH 1.1, SH 1.2, SH2, SH3.1, SH 3.2 with internal attemperators for outlet temperature control
Evaporating surfaces ECO1.1 – ECO1.5, ECO2, ECO3
Internal connecting pipelines; feed-water heater – drum – steam
Superheater 1.1. – steam superheaters 1.2 - Attemperator 1 – steam superheaters 2 - Attemperator 2 – steam superheaters 3.1 - steam superheaters and main steam line.
Location of draining and venting points
– evaporators
Feed-water heaters -
Directions of flue gas flow through the boiler are also to be indicated. Flue gases from domestic waste incineration boilers contain a high amount of ash that should be removed from heating surfaces by means of mechanical rapping devices.
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Superheater: final superheater co-flow 2 desuperheatersEconomiserEvaporator protection evaporator upstream SH
Inlet economiser:≥ 132 °C
Outlet economiser:≥ 15 °C belowboiling
Live steam:Typically402 °C, 41.5 bar
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Evaporator - Vantaa
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Economiser - Vantaa
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Superheater – Vantaa
External economiser - Vantaa
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Associated components: refractory lining
Reference to the following training of J + G
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Safety equipment and control circuits overview
Installed safety equipment includes:
Safety transmitter of minimum and maximum level in the drum J1 HAD10 CP001, J1 HAD10 CP002, J1 HAD10 CP003.
Safety valve J1 LBA10 AA510 with control unit J1 HAD10 CG501
Thermometer J1 LBA10 CT002 – protection of maximum temperature of superheated steam
Transmitter J1 LBA10 CP002 – maximum steam pressure protection
The purpose of the installed safety equipment is to protect the plantagainst deviations from default values.
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Safety equipment and control circuits overview
Control circuits are:
Control of drum level consisting of feed-water control level transmitters, including water and steam flow meters
Control circuit to protect feed-water from dropping below minimum temperature
Control circuit of steam attemperation
Control circuit to protect against high drum level.
Other operating (auxiliary) systems are:
Chemicals dosing system in order to maintain pH values of steam and water within default values
System for collecting water from blow-down
Boiler warming system, i.e. maintaining standby condition.
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Presentation and description of operation of fitted equipment:
Safety valves
Cooling valves including associated attemperators
Valves for continuous water blow-down from the boiler drum
Water and steam quantity measurement – measuring orifices
Three-way control valve J1 HAC05 AA020 for protecting feed water against dropping below minimum temperature,
Water and steam sampling system
System for mechanical cleaning of heating surfaces
Wet cleaning.
Each part of the equipment should be provided
with the relevant suppliers’ brochure.
Fitted equipment overview
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Safety valve
Safety valve on main steam line
Flow area – 2827 mm2
Normal pressure – 91 bar (g)
Set pressure in main steam line 1 96 bar(g)
Set pressure in main steam line 2 97 bar(g)
Set pressure in drum 107,0 bar(g)
Pneumatic contol unit
M1 – 96 barg – main steam line
M1 – 96 barg – main steam line
M3 – 108 barg – boiler drum
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Instruments
Thermometer J1 LBA10 CT003 – protection of maximum temperature of superheated steam
Transmitter J1 LBA10 CP001 – maximum steam pressure protection
The purpose of the installed safety equipment is to protect the plant against deviations from default values.
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Control circuits are
Control of drum level consisting of feed-water control valve, level transmitters including water and
steam flow meters.
The function of the transparent water level indicator J1 HAD10 CL502 is checked as follows:
No.
Description KKS-No.
1 Boiler Drum J1HAD10 BB001
2 Shut-off valve boiler drum measurement connection J1HAD10 AA654
3 Shut-off valve boiler drum measurement connection J1HAD10 AA653
4 Level measurement boiler drum J1HAD10 CL502
5 Shut-off valve boiler drum measurement connection J1HAD10 AA652
6 Shut-off valve boiler drum measurement connection J1HAD10 AA651
7 Shut-off valve measuring instrument drain boiler J1LCL90 AA830
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Drum level measuring
Bicolour level gauge
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Blow-down expansion tank level measuring
Blow-down expansion tank
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Cooling valves including associated attemperators
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AUMA actuator
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Water and steam quantity measuring
Orifice plate
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Pneumatic rapping device
The rapping system is an automatically working cleaning device that cleans off the bundle of pipes of a heating boiler through strikes against especially developed rapping points of the bundle of pipes. For this a rapping carriage moves between two travelling way supports on the outer wall of the heating boiler. The rapping carriage is moved via a rubber wheel on the travelling way by a geared motor. The rapping carriage is guided by curved rollers on ball bearings. Rams are built into the boiler wall at regular intervals and are situated at the rapping points of the bundles of pipes. If the rapping carriage reaches a ram an initiator is occupied by a positioning lug on the ram structural component. The rapping carriage stops in this position. The occupation of the initiator is a fundamental precondition for the rapping procedure. A further precondition is that compressed air is pending. These are arranged on both side walls.The dirty heating surfaces are caused to vibrate so that the resulting caking falls off.
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Pneumatic rapping device
Rapping device KKS-No.
Rapping device 1 1 HCE40 AW001
Rapping device 2 1 HCE40 AW002
Helical Soot Blowers
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Long retractable blower The long retractable blowers consist of a blow pipe and a nozzle head on theend of the blow pipe. They move in an axial direction past the heating surfacesto be cleaned. Live steam/MP steam is used as a blowing medium. The restposition of the lance-type screw blowers is outside of the combustion gas flow.
Scoot blower KKS-No.
Helical Soot Blowers 1 J1HCB05 AN001
Helical Soot Blowers 2 J1HCB05 AN002
Helical Soot Blowers 3 J1HCB05 AN003
Helical Soot Blowers 4 J1HCB05 AN004
Helical Soot Blowers 5 J1HCB05 AN005
Helical Soot Blowers
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Area of application: Cleaning of heating surface banks.The blowing tube is installed in the flue gas pass and it and is helically moved forward and backwards. The helical movement of the blowing tube / lance tube is effected by chain drive at the soot blower carriage which is driven by a geared motor. The blowing tube is on its entire length equipped with Venturi nozzles. A full cleaning effect over the whole blowing distance is ensured due to the conical expansion of the blowing jets and due to the arrangement of the nozzles.
Helical Soot Blowers
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Soot Blowes - parts
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Three-way control valve J1 HAC05 AA020
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P&I diagrams
All P&I diagrams and their functions are to be included:
P&I diagram of boiler drum eco
P&I diagram of boiler superheaters
P&I diagram of boiler blow-down
P&I diagram of boiler drains vents
P&I diagram of boiler FG-side 2
P&I diagram of primary air preheater
P&I diagram of external eco & soot blowers
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P&I diagram of boiler drum eco
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P&I diagram of boiler superheaters
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P&I diagram of boiler drains vents
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P&I diagram of boiler blow-down
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P&I diagram of boiler FG-side 2
P&I diagram of primary air preheater
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P&I diagram of external eco & soot blowers
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Table of contents
Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance
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Description and preparation of plant start-up
This section contains a brief description of the plant preparation and start-up, its operation and shutdown.
Presentation of the preparation for starting up the plant:
Procedures for plant start-up preparations
Initial drum water level
Top up from the start-up pipeline and valve
Warming up the superheated steam pipeline from the main steam valve to the steam
Turbine by using the bypass valve for warming up
Description of work during regular boiler plant operation
Controlled shutdown procedure.
The "Operating instructions manual for boiler plant" should be used to describe the above-mentioned procedures, i.e. the most common plant operation scenarios.
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Associated components: scrubbing systems
The problem!
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Example: Shower Cleaning SystemOn-load boiler water cleaning
Spray nozzle
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Associated components: sampling station
Table of contents
Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance
Safety
You have probably gone through hundreds of site
inductions and will probably go through hundreds more
The induction is important as all sites are different andhave a wide range of hazards which will
change as the site develops
This site induction is specific to this site and provides you with information on the current hazards of
the site and tells you about the site rules
Signs on Site
Always comply with safety signage
Read the labels on containers before using any substances
Use any safety precautions required
Personal Protective Equipment
Look after your P.P.E. and always wear it when required
Table of contents
Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance
Table of contents
Process
Structure
I&CO functions
Plant operation
Safety at work
Fault rectification
Maintenance
Most important aspects of maintenance
InputB3.10 Chap.1.2 Maintenance work planB3.10 Chap.1.3 Lubrication schedule and products
Thank you very muchfor your attention
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