auxilary boiler basuki inc]

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CILEGON COMBINED CYCLE POWER PLANTAUXILIARY BOILER – PLN PROJECT

MITSUBISHI HEAVY INDUSTRIES LTD.

Training ProgramAuxiliary Boiler 12 Ton/Hr , 12 BargBy. PT Basuki Pratama Engineering

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Items of Training

I. PrefaceII. Utilizing EquipmentsIII. System DescriptionIV. Operation SequenceV. Maintenance VI. Boiler Operation Water Treatment

P R E F A C E

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What is that Steam Boiler BHS-12000-LO ?

II. Utilizing Equipments

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1 Unit Steam Boiler BHS-12000-LO (10QHA01AC101)Capacity : 12 Ton/Hr , 12 BargDesign / Operating Pressure : 12 Barg / 9 BargEfficiency : 89 % (min)Type of Fuel : Diesel OilMax Fuel Consumption @ Full load : 812 Kg/Hr

1 Unit Diesel Oil Burner (10QHH01AV101)Brand / Type : OILON / KP-700 M-IICapacity (max) : 812 Kg/HrDriving Motor : 26 KWControl : Fully – AutomaticRegulation : Fully – Automatic

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1 Unit Superheater (10QLB11AC001)Steam Capacity : 10,000 Kg/HrSteam Temperature : 260 oCOperating Pressure : 8 BargDesign Pressure / Temp. : 12 Barg / 300 oCTest Pressure : 18 Barg

2 Units Feed Water Pump (10QLA11AP101/102)Conveying Capacity : 12,000 Liter/HrDelivery Head : 132 M Motor Capacity : 11 KW

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1 Unit Feed Water Tank w/Deaerator(10QLA11AC101 / 10QLA11BB101)Operating Pressure : 0.13 BargDesign Pressure : 1 BargFWT Capacity : 12,000 LtrDeaerator Capacity : 12 M3/Hr FWT Dimension : Dia 1900 x 4200 S/SDeaerator Dimension : Dia 650 x 1400 S/S

1 Unit Chimney (10QHN01BV101)Dimension : Dia 785 X 20,000 HeightAccessories : - Insulation & Cladding up to 2 M Height

- Free Standing

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1 Unit Blow Down Tank (10QHF01BB001)Dimension : Dia 600 x 1,200 S/SDesign Pressure / Temperature : 1 Barg / 120 oCOperating Pressure : Atmosphericc/w : Vent Head & Silincer

1 Unit Daily Fuel Tank (10QHH01BB101)Capacity : 25,000 LiterDimension : Dia 2500 x 5000 S/SDesign Pressure : AtmosphericOperating Pressure : Atmospheric

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3 Units Sample Cooler(10QUA03AC001 ; AC002 ; AC003)

Dimension : Dia 100 x 300 HeightMaterial : SUS 304Cooling Water Inlet Valve : 3/8”Hot Water Inlet Valve : DN6 – PN40

1 Unit FWT Dosing Device (10QLF11AP201)

Diaphragm pump type : Pulsatron – LPD3S2-365

Max. Capacity : 1.9 Ltr/HrWorking Pressure : 17 BargVoltage : 230VAC 50 Hz / 0.5A 1 PhaseC/W Storage Tank

Tank Contents : 650 LiterMaterial : Polyethylene

C/W MixerType : MIX6/2 “EMEC”Motor Rating : 110 W

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1 Unit Boiler Dosing Device (10QLF11AP201)

Diaphragm pump type : Pulsatron – LPF4S2-365

Max. Capacity : 3.2 Ltr/HrWorking Pressure : 17 BargVoltage : 230VAC 50 Hz / 0.5A 1 PhaseC/W Storage Tank

Tank Contents : 650 LiterMaterial : Polyethylene

C/W MixerType : MIX6/2 “EMEC”Motor Rating : 110 W

III. System Description

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Process Flow Diagram

Piping & Instrumentation Diagram

10QLF11AP101BOILER DOSING DEVICE

10QUA03AC001,10QUA03AC002 10QHN01BV101CHIMNEYFEED WATER PUMP

10QLA11AP101/102DAILY FUEL TANK

10QHH01BB101 10QLA11AC101&10QLA11BB101FEED WATER TANK WITH DEAERATOR

10QHA01AC101STEAM BOILER BHS-12000-LO

10QHH01AV101DIESEL OIL BURNER10QUA03AC003

SAMPLE COOLER

10QLB11BB901CONDENSATE POT

10QLB11AC001SUPERHEATER

10QHF01BB001BLOW DOWN TANK CONDENSATE POT

10QLA11BB901 10QLF11AP201FWT DOSING DEVICE

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Front Control Panel

Inside Control Panel

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Feed Water System

Logic Diagram Feed Water Tank

1

R

L13

SOLENOID VALVE #1ON

OPEN10QLA11 AA002

NAND

NAND

MANUAL

AUTO

OFF

WATER INLET VALVE 2AUTO/OFF/MANUAL

S8

OR S

R

L14

SOLENOID VALVE #2ON

OPEN10QLA11 AA007

2

FCV 159

FCV 161

S

AND

AND

10QLA11CL01QN

BY PASS LEVELINDICATOR

L4

L3

L2

L1WATER HIGH

HIGH LEVEL REGULATION

MIDDLE LEVEL REGULATION

LOW LEVEL REGULATION

NAND

NAND

WATER LEVEL REACHTHE ELECTRODE = CLOSED

L4

WATER LEVEL REACHTHE ELECTRODE = CLOSED

L5ALARM

AUDIBLE

FEED PUMPDRY RUN

H10

10QLA11 AP002

Off10QLA11 AP001

SOLENOID VALVE 1

SOLENOID VALVE 2

LIS 144

F.W. PUMP 1 & 2

H11

HW ALARMFW TANK

AUDIBLEALARM

DISTURBANCE

DISTURBANCE

BS

BS

WILL CLOSE WHENLEVEL REACH L3

SOLENOID VALVE 2

SOLENOID VALVE 1

LEVEL REACH L2WILL CLOSE WHEN

FIELD INPUTS CONTROL SWITCHES L O G I C LAMP INDICATORS (LCP) FIELD OUTPUT

NAND

NAND

MANUAL

AUTO

OFF

WATER INLET VALVE 1AUTO/OFF/MANUAL

S7

OR

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Feed Water Tank

InstrumentBy-pass level indicator 5 switch (LIS 144) :Used for control level feed water tank and level indicatorSolenoid valve 1 (FCV 159) and Solenoid valve 2 (FCV 161) :Valve water inlet feed water tankPressure switch (PSL145) :Used for monitoring of pressure in water tank.

System DescriptionWater inlet valve can operate manually and automatically with selector switch water tank valve in control panel. Auto status, valve operate depend on level switch. If water level :Above L1; valve1 & valve2 close, alarm FWT high, digital input FWT on, and disturbance indicator FWT high ON.Above L2; valve1 & valve2 close.Above L3; valve1 open & valve2 closeBelow L4; valve1 & valve2 openBelow L5; valve1 & valve2 open, alarm FWT low, FWP off, digital input FWT low, disturbance indicator FWT ON.

If pressure feed water tank below setting (set=0.1 bar), pressure switch signal to digital input feed water tank pressure to low

Solenoid valve

Pressure switch

L1

L3

L5

L4

L2

By-pass levelindicator

Logic Diagram Dosing System

DOSING PUMP 2

AND

HV 177

12

10QLF11 AP201START

ONDOSING PUMP 2

L2

R

SOR

ORS2

AUTO/OFF/MANUALDOSING PUMP 2

OFF

AUTO

MANUAL


FCV 159FCV 161

Service Water InletSolenoid Valve

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Feed Water Tank Dosing Pump

InstrumentDosing pump :Supply hydrazine and amine from feed water tank dosing to feed water tankMixer pump :Mix hydrazine and amine in feed water tank dosing

System Description Dosing device can operate manually and automatically with selector switch dosing pump2 in control panel. Auto status, dosing device operate depend on solenoid valve1 water inlet feed water tank. Dosing pump

Mixer

Fuel Oil System

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Logic Diagram Daily Fuel Tank

OIL HIGH

HIGH LEVEL REGULATION

LOW LEVEL REGULATION

OIL LOW

INTERLOCKTO BURNER

10QHH01

LCV 239

R

SOR

AUTO/OFF/MANUALOIL INLET VALVE

OFF

AUTO

MANUAL

S9 AND

INDICATORBY PASS LEVEL

FIELD OUTPUTLAMP INDICATORS (LCP)L O G I CCONTROL SWITCHESFIELD INPUTS

(OFF BURNER)

AA00210QHH01

SOLENOID VALVEOIL INLET

HIGHOIL LEVEL

L16

L15

VALVE OIL INLET ON

LOW

OIL LEVEL

L17

AND

L1

L2

L3

L4

Daily Fuel Tank Level

Instrument

By-pass level indicator (LI 215) with 5 switch (LT 218) :Used for control level fuel oil and level indicatorSolenoid valve (LCV 239) :Valve fuel oil inlet daily fuel tank

System DescriptionFuel oil inlet valve can operate manually and automatically with selector switch oil inlet valve in control panel. Auto status, valve operation depends on level switch. If oil level :Above L1; valve close, digital input fuel oil tank level high on, and indicator oil to high on.Above L2; valve closeAbove L3; valve open Below L4; valve open, indicator oil to low on, alarm oil tank to low, burner off (manual ON)Below L5; valve open, digital input fuel oil tank level to low on

Solenoid valve

L1

L3

L5

L4

L2

By-pass levelindicator

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Oil Measurement

InstrumentOil flow meter (FQI 190) :Used for measuring oil flow daily fuel tank to boiler Oil totalizer :Display water totalizer in control panelOil flow rate :Display water flow in control panelRecorder :Record oil flow in control panel.

System DescriptionFlow meter signal to oil totalizer, oil flow rate, oil flow recorder, and auxiliary analog output (4-20mA) fuel firing rate (terminal X3 74;75).

Totalizer

Recorder

Flow rate

Steam Outlet & Start-up Line

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Saturated Steam Temperature

InstrumentTemperature sensor PT 100 ( TE 221) :Measuring saturated steam temperatureTemperature display (TI 141) :Display saturated steam temperature in control panel

System Description Temperature sensor signal to temperature display for saturated steam temperature. Sensor PT 100

Temperature Display

Logic Diagram Blow out

FOR TEMP.COMPENSATION

PRESS. TRANSMITTERFT 137 BUILT IN SET POINT=2 Bar

S12

CLOSE

OFF

OPEN

CF0110QLB11

137

PID CONTROLSTART

10QLB11AA903

10QLB11AA903

Controller Burner

P

I

D

FT

SELECTOR

BLOW OUT

SERVO MOTORBLOW OUT


Press. After Super Heater

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Steam Flow Meter and Blow Out Steam

Instrument Steam flow meter (FT 137) :Used for measuring steam from boilerSteam display and controller (FC139) :Display steam flow in control panelValve blow out (FCV 224) :Valve for steam start up

System DescriptionFlow meter signal to steam totalizer, steam display controller, and steam flow recorder in control panel. Blow out valve can operate manually and automatically with selector switch blow out in control panel. Auto status, valve open (blow out steam) if pressure super heater not reach (set = 2 bar) and burner not OK.

Steam displayand controller

Actuator valve Valve

Logic Diagram Super Heater


260ºC

> 960 kg/hr

> 7.7 barg

FT137

10QLB11CF01

CT14QP10QLB11

211

207

10QLB11CP01QB

AA008

PRESSURE

10QLB11

10QLB11 CT09QNREGULATION

SUPER HEATER FLAPSERVO MOTOR

TEMPERATURE SUPER HEATER

SET POINT

TE

D

I

P

FLOW

PT

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Super heater

InstrumentTemperature sensor PT 100 ( TE 211) :Measuring super heater temperature steamTemperature display and controller (TIC 213;TI 210) :Display temperature super heater steam in control paneland control damper super heaterActuator damper super heater :Damper for control temperature super heater steam

System DescriptionTemperature sensor signal to temperature super heater display in control panel and auxiliary analog output (4-20mA) super heater steam temperature (terminal X3 76;77).Damper operate regulation if flow steam reach 960 kg/h and pressure > 7.7 bar.If temperature 280°C digital input super heater temp. high on.If temperature 300°C disturbance indicator super heater temp. to high on

Actuator damper super heater

Sensor PT 100

Temperature steam display and controller

Main Steam Valve

InstrumentPressure Transmitter :Pressure Transmitter are used to measure pressures in liquids and gases. The pressure is converted into an electrical signalPressure super heater display and controller :Display Pressure super heater steam in control paneland control damper burner Actuator steam out :Actuator for control valve saturated steam out Valve saturated steam out :Valve for saturated steam out

System DescriptionValve saturated steam out operate with selector switch main steam valve in control panel ( open-close valve ). if pressure reach 8 bar in pressure display control panel operator can operate this switch.

Valve

Actuator steam out

Pressure TransmitterPressure super heater steam

display and controller

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Blow Down Tank & Drain System

Logic Diagram Blow Down Tank

OPEN

Below Set Point = Logic 0Above Set Point = Logic 1

TEMPERATURE CONTROL

SET POINT

TE

OFF

ONCT0110QHF01

MANUAL

AUTO

OFF

TEMPERATURE HIGH

BLOWDOWN TANKAUTO/OFF/MANUAL

S3

OR S

R

L3

BLOWDOWN TANKON

COOLING WATER INSOLENOID VALVE

10QHF01TIC231

232

10QHG01AA002

SET POINT= 50 C

AND

Temperature Controller will Open/CloseSolenoid Valve automatically at set point value


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Blow Down Tank

InstrumentTemperature sensor PT 100 ( TE 232) :Measuring blow down tank temperatureTemperature controller (TIC 231) :Control for blow down tank temperatureSolenoid valve (TCV 233) :Valve service water inlet blow down tank

System Description Service water inlet valve can operate manually and automaticallywith selector switch blow down tank valve in control panel. Auto status, valve operation depends on setting temperature (set = 50°C). If temperature over setting valve open and conversely.if temperature increase (>60°C), digital input blow down tank discharge temperature high on.

Sensor PT 100

Temperature controller

Solenoid valve

Steam Boiler System

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Steam Boiler System

1. Bottom Blow Down

InstrumentBlow down controller (PRS-7b) : Generates a control pulse which, after the preset blow down interval, operates the three way solenoid valve.Three way solenoid Valve :Solenoid for control valve intermittent blow down Valve intermittent blow down (BDV 115) :Intermittent blow down valve boilerSightglass (FG123) :Visual supervision of condensate conditions in heat exchangers and flow conditions pipelines. It clearly indicates loss of live steam, banking up of condensate or the presence of air.

System DescriptionController turn actuates the rapid action blow down valve by means of compressed air and closes it again at end of the pulse (blow down) duration. The blow down intervals can be adjusted.

Schematic layout

Three way solenoid valveAnd strainer

Sightglass

Logic DiagramSurface Blow Down


124CE

CONDUCTANCE10QHA01

SWITCHDESALTING ON/OFF

SERVO MOTORDESALTING VALVE

LKER 1LIMITER

OPERATION

BT00110QHA01

CONDUCTIVITYREGULATOR ANDDESALTING

ELECTRODE

CT01QP10QHA01

AA005

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Steam Boiler System

2. Surface Blow Down

InstrumentConductivity Electrode (CE 124) :Monitoring of condensate return to boiler to detect water any penetration of acid, alkalis etc.Continuous blow down controller (LRR 1-5b) :Automatically controlled continuous blow down to reduce blow down wastage and increase operating safety.Control Valve (CCV 122) :Motorized control valves for continuous blow down system of steam boiler.

System Description Surface blow down can operate manually and automatically with selector switch blow down valve in control panel.Automatic system work depends on value setting. If condensate boiler over setting value, valve open and operate conversely

Conductivity electrode

Logic DiagramBoiler Water Level Control

OFF Burner (Auto ON)

OFF Burner (Manual ON)

AUDIBLEALARM

BS

L8

EXTRA LOWWATER LEVEL

LEVELLOW WATER

L6

AUDIBLEALARM

BS

L7

HIGH WATERLEVEL

BOILER

NRS 1-2b

LELL104

105

106

103

ELECTRODE

CL04QN10QHA01

10QHA01CL06QN

ELECTRODE

LELL WATER LEVEL CONTROLNRS 1-7b

10QHA01

MOTORIZED VAVESERVO MOTOR

AA02610QHA01

Feed Water PumpAND

SERVO DRIVEMIN. POSITION SWITCH

10QHA01AA026

SWITCH OFF DELAY

ZS

AND

A

CL08QN10QHA01

NRR 2-2eCONTROLWATER LEVEL CONTINUOUSLT

CONTINUOUS WATER

CL07QN10QHA01

LEVEL PROBE

10QHA01

LEVEL CONTROLHIGH & LOW WATER

ELECTRODE

10QHA01CL05QN

HIGH WATER

LEHH


Control

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Steam Boiler System

3. Boiler Water Level Control

InstrumentLevel electrode (LELL 104; LEHH 103) :Signaling of level conductive (Low level alarm, high level alarm).Level electrode (LELL 105) :Signaling of level conductive (Extra low level alarm).Level Probe (LT 106) :Level probe for modulating level control boiler.Level Switch (NRS 1-2b) :Control for low level and high level boilerLevel Switch (NRS 1-7b) :Control for extra low level boilerLevel controller (NRR 2-2e) :Control valve for feed (fill) or drain (discharge) for modulating level boilerActuator Valve (LCV 184) :Motorized control valve modulating level boiler.Lamp indicator (LI 107) :Indicator for dangerous level water in boiler.boiler level :Indicator level boiler in control panel

Steam Boiler System

System DescriptionControl valve

Valve open regulation depend on monitoring probeLT 106 in boiler.If low level (LELL 104 ) reach, burner auto interlock, lamp indicator water level low and Digital input boiler water level low on.If high level (LEHH 103) reach feed water pump interlock, lamp water level high on, Digital input boiler water level high on and alarm high level boiler.If extra low level (LELL 105) reach, lamp water level extra low on, digital input boiler water level to low on, alarm extra low level boiler, and extra low level indicator in panel.

LT 106 NRR 2-2e

LCV 184

Sensor Controller Valve

Actuator valve

Indicator lamp

Valve

Level boiler

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Steam Boiler System

4. Pressure Switch and Pressure Limiter

InstrumentPressure switch regulation (PSHL 110) and Pressure switch limiter (PSHH 111) :Used for controlling and monitoring of pressure in steam boiler.

System DescriptionIf pressure boiler over pressure switch regulation setting (9.5 bar); burner interlock (auto operate), pressure high indicator panel on, display fault in panel, and digital input steam pressure high on.If pressure boiler over pressure switch limiter setting (10 bar); burner interlock (manual operate), pressure high indicator panel on, digital input steam pressure to high on

Pressure switch

Pressure limiter

Logic DiagramOperation Burner

10QHH01AV101

OIL PUMP MOTOR

PRESSURE SWITCH* MANUAL RESET ON

WATER LEVEL LOW

OIL LEVEL LOW

WATER LEVELEXTRA LOW

L21

BURNERON

AND

AND

S

R

OR

110

OFFAV101

10QHH01

10QHH01AV101

10QHH01DPOO1

LAL 2.25CONTROLLER

AUTOMATICBURNER

FLAME INTENSITY

10QHH01

FLAME SENSOR

CR001 IGNITION TRANSFORMER

SERVO MOTORCOMPOUND REGULATOR

BLOWER MOTOR

AV10110QHH01

DISTURBANCES

CP03QN

NOT HIGHPRESSURE BOILER

10QHA01

PSHL

BU

RN

ER

CO

NTR

OL

S13

INCREASE

STEADY

DECREASE

AUTO

BURNER START/FAILURE RESET


CONTROLLERSTART PID

1. Control Blow Out2. Pressure saturated

steam control

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Logic DiagramControl Damper Burner

SET POINT= 8.5 Bar

Control blow Out

207

REGULATOR

PID CONTROLSTART

TRANSMITTER

10QHA01AV101

OPEN/STOP/CLOSEDCONTROLLER IN MANUAL MODE

SWITCH S13REF. SH. NO. 33

START CONTROLLER

SERVO MOTORCOMPOUND REGULATOR

A

T

AV101

SET POINT

PT

PRESSURE D

I

P

COMPOUND

10QHH01PRESSURE CONTROLLER BURNER

CP01QB10QLB11

POSITION


Burner controller

Steam Boiler System

5. Burner

InstrumentAutomatic burner controller :Used to control Burner of steam boiler.Light oil Burner

System DescriptionBurner operate with push button (start / stop burner).Damper burner can operate manually and automatically with selector damper switch in control panel.Burner off if one of this condition happens : Boiler pressure too high, boiler extra low, and oil low level and must start again.Operating burner control with automatic burner controller.Time sequence diagram shows burner operation systemRegulation burner depends on pressure saturated steam

Burner Controller

Burner

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Time Sequence Diagram

Boiler Dosing Pump

DOSING PUMP 1

AND

HV 177

34

10QLF11 AP101START

ONDOSING PUMP 1

L1

R

SOR

ORS1

AUTO/OFF/MANUALDOSING PUMP 1

OFF

AUTO

MANUAL


FWP 1FWP 2

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Boiler Dosing Pump

InstrumentDosing pump :Supply phosphate from boiler dosing to feed water tankMixer pump :Mix phosphate in boiler dosing

System Description Dosing device can operate manually and automatically with selector switch dosing pump2 in control panel. Auto status, dosing device operation depends on solenoid valve1 water inlet feed water tank.

Dosing pump

Mixer

Logic DiagramFeed Water Pump Operation

OR

ANDAND

AND

OR

OR

S

R

S

R

L9

F.W PUMP 1OPERATION

L10

F.W PUMP 2OPERATION

10QLA11 AP101F.W. PUMP 1

10QLA11 AP102F.W. PUMP 2

F.W. PUMP 2

F.W. PUMP 1

PUMP 2 TRIP

PUMP 1 TRIP

DEAERATOR

OR

3

4

S5

MANUAL

AUTO

OFF

SELECTOR FEED WATERAUTO/OFF/MANUAL

S6

PUMP 2

PUMP 1

OFF

SELECTOR FEED WATERPUMP1/OFF/ PUMP2

OR

AND

AND

BOILERLEVEL NOT HIGH


AND

AND

AND

AND

LEVEL NOT LOW

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Feed Water Pump

InstrumentFeed water pump (130) :Pump from feed water tank to boiler Pressure Indicator (PI 131) :Indicate pressure in line feed water pump

System Description There has two feed water pump operate interlock.Each feed water pump can operate manually and automatically with selector feed water pump in control panel. In auto status, pump operation depends on high level boiler, and feed water tank level low.If a pump trips, trip pump indicator in control panel on, display feed water pump trip in control panel, digital input feed water pump trip on.pressure gauge shows pressure in line of feed water pump

Feed Water Pump

Pressure Indicator

Flue Gas Temperature

InstrumentTemperature sensor PT 100 ( TE 140) :Measuring flue gas temperatureTemperature display (TI 141) :Displaying flue gas temperature in control panel

System Description Temperature sensor signal to temperature display for flue gas temperature. Sensor PT 100

Temperature Display

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Feed Water Measurement

InstrumentFeed water flow meter (FQI 175) :Used for measuring water flow from feed water tank to boilerWater totalizer :Display water totalizer in control panelWater flow rate :Display water flow in control panelRecorder :Record water flow in control panel.

System DescriptionFlow meter signal to water totalizer, water flow rate, and water flow recorder.

TotalizerFlow rate

Recorder

IV. Operation Sequence

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Control Panel

1. Operate Main Switch (Q0) to ON positionView Voltage (R-S; R-T; S-T; =380 Volt) in KWH meter

2. Pull Emergency Switch (ES)View lamp Power On (L0) operate

3. All Breaker in ON position (inside control panel) - Feed water pump 1 (-Q1)- Feed water pump 2 (-Q2)- Burner Fan (-Q3)- Oil pump (-Q4)- Dosing pump boiler (-Q5)- Dosing pump feed water tank (-Q6)- Socket 220 volt (-Q7)- Transformer for heater (-Q8)

4. Operate feed water tank - Selector switch water tank valve 1(-S7) in auto position- Selector switch water tank valve 2(-S8) in auto position

feed water valve 1 and valve 2 indicator ON, feed water valve 1 and valve 2 will off when level water tank reach high level

5. Operate dosing pump 2 (dosing boiler) - Selector switch dosing pump 2 in auto position

6. Operate oil inlet valve - Selector switch oil inlet valve in auto position

7. Operate feed water pump Wait after feed water tank level high

- Selector switch operational pump in auto position - Selector switch feed water pump in position pump1 or pump2

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8. Operate dosing pump 1(dosing feed water tank) - selector switch dosing pump 1in auto position

9. Operate blow down tank - selector switch blow down tank valve in auto position

10. Check alarm and disturbance indicatorNo sound/indicator alarm and disturbance indicator no fault.

11. Operate boiler - push start burner

12. Operate blow out - selector switch blow out in auto position

13. Operate main steam - if pressure reach 8 bar in display pressure and temperature reach 260 °C in control panel, selector switch main steam can operate in open position.

1. Emergency switch2. High water level3. Burner Disturbance4. Extra low level5. Over load F.W.P 16. Over load F.W.P 27. Over load burner8. Steam pressure high9. S.H steam temperature to high10. Feed water tank low 11. Feed water tank high

1. Emergency switch2. High level boiler3. Boiler extra low level4. Pressure to high5. Burner fail 6. Fuel oil tank to low7. Feed water tank high8. Feed water tank low

Disturbance indicatorAlarm

V. Maintenance

33

Operating Log Book

A. Records of daily checks and servicing operations as well as other checks must be kept in an operating log book and signed daily by the responsible boilerman(operating personnel). In the case of some installation, this operating log book may be demanded as a prerequisite for the operating permit. Recurring test carried out by the technically competent person must also be entered in this operating log book. The forms appended to these operating instruction should be used for this purpose. When using boilers with superheaters, the operator must enter details of the hot steam temperature at brief intervals (at least every 30 minutes) in a separate sheet, along with details of the date and time, if no use has been made of a hot steam temperature control and if the superheater is installed in the are of high exhaust gas temperature. Here damage may occur if operation is not carried out conscientiously.

B. The boilerman’s superior must convince himself at least weekly of proper operation and servicing of the steam boiler installation and must note this on the rear of the sheet in the operating log book along with his signature and the date

Daily Checks and Servicing

A. Prior to start up of the installation and when each shift commences, the operating personnel (boilerman) must convince themselves of the installation’s proper operating condition.

B. The function of the water level limiters must be checked daily and at the start of each shift, unless they are self monitoring,i.e. special-design, devices. External devices must be blown out

C. Temperature and pressure limiters need not be checked daily. The intervals for these units depend on their nature-refer to weekly checks and servicing.

D. The time intervals for checking safety valves must be agreed by the operator and technical expert considering the service life of the sealing faces, daily checking is not recommended.

E. Blowing out Water level indicators and external feed water controllers and limiters must be blown out, attention being paid to the necessaryoperating sequence for shut-off and blown out valves.

F. Checks of all fire systemsf.1. Keep the fire chamber free from residues and coke sedimentf.2. Smoke-free combustionf.3. Correct oil temperature – when using heavy fuel oilf.4. Suitable oil pressure

G. Checks to be carried out when using heavy fuel oilg.1. Gas pressure

H. Water analysisRefer to the operating log book and the water directivesNotePay attention to the operating instructions issued by the supplier of the water treatment plant. Devices or checking the feed water generally do not suffice for checking the boiler water. Please enquire in cases of doubt.

I. Boiler blow downJ. Check sealing points and lock them and, if necessary, retighten them and renew the packingsK. Important note

If controllers are rendered inactive by malfunction, the installation must be observed continuously if its operation is continued. If safety devices should fail, please inform our Customer Service and, if necessary, shut down the installation and inform the installer for the installation of BASUKI representative in your area, or directly to us (refer to our contact address & phone/fax numbers)

34

Weekly Checking and Servicing

A. Maximum water level ensuring facility in the case of hot steam boilers.

B. Safety temperature limiters need only be checked on special circumstancesC. Pressure limiters if they are not preceded by safety valves of a special design

devices.D. If necessary, temperature and pressure controllers are tested by pressing the by-

passing push buttonE. Seals, locks and packingsF. Shaft bearing (noise and heat development)G. Stand by feed pumps and oil pumps etc. must be started-up briefly/valves must be

switched over.H. Firing parts, flame monitors

Semi-annual Checks

Controllers and safety devices must be serviced and checked by a technically competent person after every

period of 6 months. We recommend our customer service for this purpose.

35

Operating Logbook for Aux. Steam Boiler

Operating Logbook for Aux. Steam Boiler

36

Operating Instruction for Aux. Steam Boiler

VI. Boiler Operation Water Treatment

37

Phosphate Dosing System Line

Hydrazine & Amine Dosing System Line Feed Water Sample Line

38

Blow Down System Line & Boiler Sample Line

Origin of the Problem

Source of corrosion :Dissolved gas: oxygen, carbon dioxide, and ammonia. Oxygen is the most aggressive.Cause pitting corrosion

• Make-up water introduces soluble oxygen.• The condensate return system contains soluble

oxygen

The water quality control system required shall be controlled by hydrazine & neutralizing amine which supplied by chemical dosing system consist of injection pumps, dosing tanks & motorized agitator

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Boiler Waterside Corrosion

Contributors: dissolved oxygen, acid or caustic in the water and a high temperature. Cause severe pitting, gouging and embrittlementFAILURE

Water will rapidly corrode mild steel; as the temperature increases, the reaction accelerates.

Reaction :

Anode : Fe Fe2+ + 2e-

Cathode: 1/2O2 + H2O + 2e- 2OH-

Overall: Fe + 1/2O2 + H2O Fe (OH)2

Boiler deposits result from hardness salts, metallic oxides, silica and a number of other feed water contaminants that can enter the system. Minimizing the adverse impact of these contaminants is the role of the boiler water treatment program.

Even the best controlled systems occasionally have upsets that cause excessive amounts of contamination to pass into the boiler. Some examples would be:

• Excess leakage from an ion exchange system• Contamination from leakage into condensate systems• Inadequate steam condensate protection programs resulting in high levels of

corrosion products returning to the boiler

An internal boiler water treatment program must be forgiving enough to handle not only normal operating conditions but periodic upsets as well.

Waterside Deposition

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Mechanism of Deposition

“More deposit will decrease Boiler

efficiency and subject to overheating”

• Reaction:10Ca2+ + 6PO43- + 2OH- 3Ca3(PO4)2·Ca(OH)2 Calcium hydroxyapatite

3Mg2- + 2SiO32- + 2OH- + H2O 2MgSiO3Mg(OH)2H2O Serpentine

A Partial List of Boiler Deposits

5CaO·5SiO2·H2OXonotlite

CaSiO3Wallastonite

Na2SO4Thenardite

3MgO·2SiO2·2H2OSerpentine

SiO2Alpha-Quartz

Na2O·4CaO·6SiO2·H2OPectolite

4Na2O·3Al2O3·6SiO2·SO4Noselite

Fe3O4Magnetite

Ca10(OH)2(PO4)6Hydroxyapatite

Fe2O3Hematite

4Na2O·CaO·4Al2O3·2CO2·9SiO2·3H2OCancrin

CaCO3Calcite

Mg(OH)2Brucite

CaCO3Aragonite

CaSO4Anhydrite

Na2O·Al2O3·4SiO2·2H2OAnalcite

Na2O·Fe2O3·4SiO2Acmite

FormulaName

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Embrittlement

Caustic embrittlement or intercrystalline cracking

Undetectable during operating conditions

Catastrophic results

Causes:1. Leakage of boiler water 2. Concentrated caustic soda occurs from the concentrated boiler

water.3. There is high metal stress in the area of caustic concentration and

leakage.

External TreatmentTo improve the quality of this source prior to its use as boiler feed water, including reducing contaminants.

Applied to water prepared for use as boiler feed water, refers to the chemical and mechanical treatment of the water source.

External treatment normally includes: Clarification, Filtration, Softening, Dealkalization, Demineralization, Deaeration, Heating

Internal Treatment

To minimize impurities after the best and most appropriate external treatment of the water source, boiler feed water (including return condensate)

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Steam Plant Operation- Feed Water Preparation

Deaerate the feedwaterBy using a deaerator and adding oxygen scavengers (Hydrazine) in the feed water tank.

Minimize hardnessEx : Calcium and Magnesium, migratory iron, migratory copper, colloidal silica, consistent with boiler design and operation parameters.

Minimize corrosive gasesEx : Dissolved oxygen and dissolved carbon dioxideThe deposition of these metallic oxides in the boiler is frequently more troublesome than the actual damage caused by the corrosion.

Deaeration (Mechanical and Chemical)

Mechanical and chemical deaeration is an integral part of modern boiler water protection and control.

Objectives :

• To remove oxygen, carbon dioxide and other non-condensable gases from feed water

• To heat the incoming makeup water and return condensate to an optimum temperature

• Minimizing solubility of the undesirable gases

• Providing the highest temperature water for injection to the boiler, from ambient temperature to 103 ºC to prevent boiler from thermal shock

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Saturated steam (1243 kg/hr, temperature 105-180 ºC, pressure 9 bar (g) )The dissolved oxygen leaving the deaerator will be ± 7 ppb to protect auxiliary boiler system from corrosion with residual hydrazine approximate 0.1 ppm.

Deaeration (Mechanical and Chemical)

• Designed to minimize saturated dissolved O2content in the supplied de-mineralized water and to achieve a suitable O2 content fed to the boiler

Deaerating Heater Troubleshooting Guide

1. Check for improper operation of steam pressure reducing valve.Low pressure

3. Check relief valves on the deaerator and in the main steam supply system for proper operation.

2. Check faulty operation of steam pressure reducing valve.

1. Improper operation of inlet control valve. Adjust as necessary.

High or low water level

2. Condensate may be too hot. Water entering the deaerating heater must usually be cooled if the temperature is within 20 º F of saturation temperature of the steam. Check the design specification to determine what inlet water temperature was originallyintended.

1. Trays collapsed-possibly from interrupted steam supply or sudden supply of cold water causing a vacuum.

Excessive consumption of oxygen scavenger

2. Excessive free air due to leaking stuffing boxes on pumps upstream of deaerator that have negative suction head. Repair stuffing box or seal with deaerated water.

1. Improper spray from spray nozzle. Check nozzle for sediment or deposit on seat or broken spring.

Temperature in storage tank does not correspond within 3 º C of saturation temperature of the steam

3. Check water and, if possible, steam flow rates vs. design. Trays or scrubber and inlet valves are designed for specific flow ranges.

2. Check steam pressure reducing valve. Check valve for free operation, and see that control line is connected to the connection provided in the deaerator.

1. Insufficient venting-increase vent rate by opening the manually operated air vent valve.

Excessive oxygen content in deaerator effluent

RemedySymptom

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Effect of pH on the Corrosion Rate of Steel. Water Chemistry Upsets Result in

Decrease or Increase of pH of Boiler Water, Resulting in Tube Deposits or

Corrosion.

Rel

ativ

e C

orro

sion

Rat

e

ppm HCl ppm NaOH

40.4

3650 365 36.5 200 00040 0004 0004000 403.60.36

approximate pH141211102 6345 7

9

The Effect of pH On Corrosion Rate

The slowest corrosion rate In Boiler Water are in

9.5 - 11

Mineral Carryover

Effects:1. Deposition in regulators and valving2. Deposition in superheaters3. Deposition in control valves and turbines4. Process contamination

Definition:Carryover is generally considered to be any contaminant that leaves a boiler steam drum with the steam.

Causes:Mechanical Factor: Priming (sudden pressure while load rises)Chemical Factor: Foaming (by alkalinity, organic and synthetics contaminant), Selective vaporous carryover

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Characteristics:Reaction:CO2 + H2O H2CO3

H2CO3 H+ + HCO3-

Cause pH drop and grooving on metal surface

Carbon dioxide CorrosionSource:

Alkalinity in feed waterHCO3

CO3 heat CO2

Air in- leakageOrganic material

Caustic Corrosion

Characteristics :Often occurs in High Pressure BoilerLocalized corrosionContributed by deposit accumulation (Iron, copper, etc)Boiler operation excess maximum capacityMassive load fluctuation

Reactions :Fe2O3 + 2NaOH 2NaFeO2 + H2OFeO + 2NaOH Na2FeO2 + H2OFe +2NaOH + 2H2O 2NaFeO2 + H2O

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Internal Boiler Water Treatment

10Ca2+ + 6PO43- + 2OH- 3Ca3+(PO4)2·Ca(OH)2 [Calcium hydroxyapatite]

3Mg2- + 2SiO32- + 2OH- + H2O 2MgSiO3Mg(OH)2H2O [Serpentine]

Use internal conventional program : • Hydrazine

Magnetite build upN2H4 + 6Fe2O3 4Fe3O4 + N2 + H2O

• Phosphate, An anti-scale agent 3Ca(HCO3)2 + 2Na3PO4 Ca3(PO4)2 + 3Na2CO3 + 3CO2

Thermally unstableCorrosive volatile gas

Sludge

• Neutralizing Amine, Removing acid NH3 + CO2 + H2O NH4+ + HCO3-

R-NH2 + CO2 + H2O R-NH3+ + HCO3-

R-ONH + CO2 + H2O R-ONH2+ + HCO3-

Corrosion Control Programs

The basic approach to chemical treatment of condensate systems is through the use of Hydrazine, Phosphate Program, Neutralizing Amine, combinations of both amines and hydrazine.

REAKSI HYDRAZINEOxygen scavenging,N2H4 + O2 N2 + 2 H2O

Stochiometric reaction,dosage of 35 % solution – 8.6 ppm/1 ppm residual oxygen

Poisonous, LD50 rating – class 5 toxin – 82 mg/kg

Magnetite build up,N2H4 + 6Fe2O3 4Fe3O4 + N2 + H2O

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Function: To neutralize the carbon dioxide and then provide small additional amounts to buffer the pH to 8.5 or 9.5.

Neutralizing Amines

Neutralizing carbonic acidNH3 + CO2 + H2O NH4+ + HCO3-

R-NH2 + CO2 + H2O R-NH3++ HCO3-

R-ONH + CO2 + H2O R-ONH2+ + HCO3-

WATER SPECIMENT

• Boiler and feed water must be checked daily. At least the boiler water should be sampled by means of a sample cooler. If there is a possibility of feed water hardness, it is also necessary to check the hardness of the feed water everyday.

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Spec. conductivity : < 1.0 uscmSilica: : < 0.02 ppm SiO2pH: : 6.5 ~ 7.5Sodium: : < 0.005 ppm NaIron : 0.02 ppm Fe

1. Demin Water Outlet

QUALITY WATER PARAMETER

Spec. conductivity : < 5.0 us/cm at 25 deg.CSilica : < 0.02 ppm SiO2pH : 8.5 ~ 9.5Hydrazine : < 0.2 ppm N2H4Iron : <0.02 ppm Fe

2. Boiler Feed Water

Spec. Conductivity: < 150.0 us/cm at 25 deg.CSilica : < 2 ppm SiO2pH : 9.5 ~ 10.5Phosphate : 3.0 ~ 10. ppm PO4

3. Boiler Water

Spec. Conductivity: < 5.0 us/cm at 25 deg.CSilica : < 0.02 ppm SiO2pH : 8.5 ~ 9.5Iron : <0.02 ppm Fe

4. Steam

Blow down Definition

Function:To maintain the solids content of the boiler water within prescribed limits

Basic Calculation % Blow down : Concentration of dissolved solids in Feed water =Concentration of dissolved solids in blowdownQuantity of blow down/Feed water% Make up : Concentration of dissolved solids in Feed water =Concentration of dissolved solids in Make-up water Quantity of make–up/ Feed water

Every steam generator must be blow down periodically (recommended every two hours, at least every one shift). The quantity of blow down water depends on the degree of thickening. If no desalting fitting is provided, blowing down simultaneously extracts salt from the boiler

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CR = 1/%blowdown x 100 =

Concentration dissolved solids of blowdownConcentration dissolved solids of Feed water

Feed water = Make up + CondensateFeed water = Boiler Capacity + Blow down

• Do open blow down if the quality of water excess limit : Demin Water Boiler Water

Blow down in Action

Spec. conductivity : > 10 uscmSilica: : > 0.02 ppm SiO2pH: : <6.5 or > 8

Spec. conductivity : > 150 uscmSilica: : > 2 ppm SiO2pH: : > 10.5

WATER SIDE CONSERVATIONPurpose

The greatest danger to steam boilers is today the uncontrolled absorption of atmospheric oxygen by the boiler water during shut down periods.

Oxygen has a corrosive effect – particularly during start-up, but also during shut down periods.

Method

1. Wet conservation binds the oxygen of the water held in the boiler. oxygen binding agents are: Hydrazine & Sodium sulphite

2. Dry conservation ensures that no moisture remains in the boiler effectively preventing corrosion of the steel

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HYDRAZINE WET CONSERVATION PROCEDURE1 g (atmospheric) oxygen in the water is bound by 1 g hydrazine (N2H4) = 7 g commercial, approx. 24% hydrazine hydrate (N2H4.H2O)

1000 - 3000150 - 450Boilers with alkalinization and only softened feed water irrespective of time

140-210350 – 700700 - 2000

20 - 3050 – 100100- 350

≤ 50 h (weekend)1 monthlonger

Boilers with alkalinization and fully demineralized feed water

g/m3g/m3

N2H4.H2O 24%N2H4Hydrazine excess based on the length of the rest period

The additionally required hydrazine excess is shown in the table:

HYDRAZINE WET CONSERVATION PROCEDUREa, In glass vessels, pure hydrazine reacts only above 60°C with oxygen dissolved in water.

the Fe3O4 of the protective layer is an excellent catalyst.

b. Wet conservation the pH-value of the hydrazine-containing solution should be 10 or higher.

c. To prevent varying oxygen concentration and therefore the creation of air entrainment elements, the steam boiler must be completely filled with hydrazine-containing boiler water.

d. All gate – and screwdown stop valves must be closed completely after filling the boiler withhydrazine-containing boiler water and kept closed during the conservation treatment.

e. If within the shut down period the hydrazine concentration must be topped up. Circulate the boiler water to ensure through mixing.

f. When the boiler is restarted, the water level is reduced to normal provided that higher N2H4contents in the initial steam are acceptable.

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SODIUM SULPHITE WET CONSERVATION PROCEDURE

1 g (atmospheric) oxygen in the water is bound by 9 g commercial, approx. 92% moisture-free, sodium sulphite (Na2SO3)

The additionally necessary sodium sulphite excess is shown in the table:

1500 - 5000Boiler with alkalinization and only softened feed water independent of time

g /m3200-300450 – 900900 - 3000

Boiler with alkalinization and fully demineralized feed water ≤50 h (week end)1 monthlonger

Na2SO3 92%Sodium sulphite excess based on the length of the shut down period

SODIUM SULPHITE WET CONSERVATION PROCEDURE

a. Powdered sodium sulphite must be dissolved in warm feed water at 30-40°C before filling it into boiler. (Per 1 kg sodium sulphite 5 liters water).

b. In the case of wet conservation the pH value of the sodium sulphite – containing solution should be at 10 or higher. Apart from caustic soda and phosphate, as present in the boiler water and sufficient for alkalinization, an extra addition of ammonia may also be successful

c. To exclude different oxygen content and therefore the formation of the air entrainment elements, the steam boiler must be completely filled with sodium sulphite containing boiler water. In superheaters or feed water preheater the sodium sulphite containing.

d. All gate and screw down stop valves must be closed after the boiler has been filled with sodium sulphite containing boiler water and kept closed during the conservation treatment.

d. If within the shutdown period the sodium sulphite excess drops below 500 g/m3, the sodium sulphite concentration must be topped up.

e. Before restarting the boiler, the boiler water condition must be adjusted to the specified values (pH-value, sodium sulphite content)

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Test Procedure Wet Conservation

Testing for excess of oxygen binding agent in the case if wet conservation

• Purpose

i. Hydrazine measurement

Hydrazine forms in an acid solution with p-dimethylaminobenzaldehyde, depending on concentration, a yellow to red colored quinoid compound for color comparison

• Reagents

Sulphuric 2% p-dimethylaminobenzaldehyde solution Colour comparison ampoules (Both available from Farbenfabriken Bayer AG, Leverkusen, Germany, or their agents)

• Procedure

1. The water sample to be tested for hydrazine content must first be cooled to < 40°C (sampling is best carried out with a cooling agreement). The boiler water may first have to be filtered.

2. 5 ml of this water sample is filled up to the first calibration mark into the empty ampoule, 5 ml hydrazine reagent is filled in to reach the second calibration mark, and then shaken twice. The test liquid will turn yellow. Now the reference ampoule or color comparison sheet nearest to this color shade is determined. The value shown on this ampoule or the sheet indicates the hydrazine (N2H4) content in kg/l of the water sample.

3. If the test liquid shows yellow color shades which are not covered by the comparison scale, the N2H4 – content is situated above 1 mg/l. These values, too, can be determined more accurately by first diluting 1 ml of the water to be tested with 99 ml cold tap water, mixing 5 ml of this diluted water with 5 ml reagent and comparing against the color scale. The value found must then depending on the dilution used – be multiplied by 100.

4. The reagent must always be stored in a dark and cool place. Storage life approximately 1 year (see use-by date printed on the label). The effectiveness of the reagent solution can be verified at any time by mixing 5 ml tap water with 5 ml reagent, after which there must be, no coloration exceeding the zero value of the color scale.


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ii. Sulphite measurement

The process is intended to provide a simple check of the addition of sodium sulphitenecessary to bind the oxygen in the boiler water

In an acid solution, iodine oxidizes sulphite to sulphate and is then itself reduced to iodide. Excess iodine produces a blue coloration in combination with starch solution. Nitrites, sulphides and larger quantities of organic substances have an interfering effect (KMnO4 –consumption over 60 mg/l)

• Reagents

Phosphoric acid D.1.14 (25%)0.01 standard iodine solution (Store in a cool place in a brown bottle)Starch solution, approx. 1%

• Instruments300 ml Erlenmeyer flask10 ml graduated pipette20 ml burette, 0.1 ml graduation


• Procedure

1. 100 ml of the sample, cooled to room temperature and filtered clear is filled into a 300 ml Erlenmeyer flask and acidified with 3 ml phosphoric acid (reagent a)

2. After that, add approx. 0.5 to 1 ml of the starch solution (reagent c)

3. Using a burette, 0.01 standard iodine solutions (reagent b) is now added until the sample turns blue.

4. 1 ml 0.01 standard iodine solution corresponds when using 100 ml sample solution to approx. 6.3 mg/l sodium sulphite (Na2SO3)

Quick testSmall test sticks can be used for a quick determination of the sulphite content (e.g. Sulphite Test made by Fa.Merck)


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Alkaline Boiling Out Procedure

Alkaline boiling is carried out to removal of oils, fat and silica in newly installed boilers, and drying the heat insulating material of boilers.

• Purpose

• Applicable ItemAuxiliary Boiler BHS-12000-LO

• Measurement Equipment & Safety Equipment

Balance : 1 unitHand Pump : 1 unitRubber gloves : 4 pairMasker : 4 pairpH meter : 1 unit

Sodium hydroxide 100 kgSodium Phosphate 200 kgSodium Sulfite 60 kg

• Consumable Material

1. Mixing of the Chemical

• Fill the demineralized water to the Feed Water Tank approximate ½ of volume (6 m3)

• Prepare 7.2 kg Sodium Sulfite, 24 kg Sodium Phosphate & Sodium Hydroxide 12 kg

• Fill the phosphate dosing tank with 500 liter Demineralized Water.

• Slowly through the 1.2 kg Sodium Sulfite, 4 kg Sodium Phosphate and 2 kg of sodium hydroxide to the phosphate tank than turn on the mixer approximate 15 minutes. Measured the pH

• Transfer the mixing solution to Feed Water Tank by Hand Transfer pump. Measured the pH of the solution in the feed water tank. The pH of the feed water tank < 11.5 but higher than 10.5

• Application


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• Turn on The feed water pump to transfer the solution to the boiler

• Now the solution in the boiler will be approximate ½ of volume of the Boiler.

• Open the valves on feed water line to full fill the solution at feed water line the solution to the boiler.

• Repeat point a to h until the boiler is full of the solution.

• Repeat point b to point e for six times.

2. Closed all the valves attached in the boiler

3. Turn on the burner and heating the boiler until the temperature of mixing solution is 140 °C – 145 °C or boiler pressure 2.5 bar(g) – 3 bar(g). The rate of the heating of the boiler must not exceed about 50 °C per hour by adjusting the burner combustion rate.

4. Maintain the temperature 140 °C – 145 °C or boiler pressure 2.5 bar(g) – 3 bar(g) for 4 hours than cool down the boiler by ambient temperature. The cooling rate must not exceed 50 °C per hour.


5. While maintain the temperature or pressure, prepare the solution as per point

6. After the boiler temperature is about 70 °C than slowly drained the solution up to ¾ solution level of the boiler while take the solution sample foranalyzing than feeding the new solution to the boiler. The concentration of the cleaning agents while draining & feeding must not fall below ½ of the initial level.

7. After the boiler water have been drained approximate ¾ the volume of the boiler, or the Feed Water Tank have transfer the solution approximate 12 m3, than closed the drained valve, repeat the point j to full fill the boiler with the solution again.

8. Repeat the point 2 – point 8 for 2 times.

9. Drain out all the water in the boiler and make a new solution to the Feed Water tank same as point 1 but the pH < 9.5 but not less than 8.5. than full fill the boiler with this solution. If the boiler ready to run the water level of this solution shall be at the normal level.


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THE END

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