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o & M Manual Sheet 1 of 50
OPERATION MANUAL
&
MAINTENANCE INSTRUCTIONS.
PROJECT: 8108 PREPARED

PSR CHECKED/APPROVED AN.W
0& M Manual Sheet 2 of 50
OPERATION & MAINTENANCE MANUAL

FOR WASTE HEAT RECOVERY BOILERS
PROJECT · WASTE HEAT RECOVERY BOILERS

FOR MSW INCINERATORS
CLIENT ·· ATTS INC, 12000 Lineoln Orive West,

302 Marlton,
NJ 08053, USA.
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ORDER NO. ·· P.O.No.1481 dtd.27.1 0.1 O
W.O NO. · 8108
IISSUE NR. : I 1 29.01.2011
I THERMAL SYSTEMS (HYDERABAD) PVT.LTO.,

¡~ PLOT NO. 1, APUROOPA TOWNSHIP,
JEEOIMETLA, HYDERABAD - 500 055,
INDIA.
Tel. Nr. 0091 - 40 - 23091801

Fax Nr. 0091 - 40 - 23097433
Email info@thermalindia.com
PROJECT-8108 I WHR System for A TTS Inc. U S A.

TABLE OF CONTENTS PAGE Nr.
1.1 Steam Production System 5
1.1.1 Purpose 6
1.1.2 Description & Technical data 6-7
1.1.3 Commissioning I Start - up

a) Refractory Dry - out 10
b) Alkali Soil - out 13
e) Steam blowing 17
~ 1.1.4 Normaloperation 19
1.1.5 Shut down 23
1.1.5.1 Short term shut down 23
1.1.5.2 Shut down tor extended period 24
1.1.6 Trouble shooting 27
1.1.7 General Maintenance Instructions 28
1.1.8 In operation Inspection and Maintenance 33

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-
1.2 F eed Water System 34
1.2.1 Description 35
1.2.2 Start - up 36
~
1.2.3 Normal operation 37
1.2.4 Shut down 38
1.2.4.1 Short term shut down 38
1.2.4.2 Shut down for extended period 38
1.2.5 Trouble shooting 39
PROJECT-B108/ WHR System for ATTS Inc. U S A.

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1.3 Sampling Test 41 --
1.3.1 Purpose 41
1.3.2 General Notes 41
1.3.3 Analysis of Feed Water 41
1.3.4 Analysis of Boiler water 41
1.3.5 Analysis of steam 42
1.3.6 Analysis of Demin water 42
1.3.7 Sampling procedure 42
1.3.8 Dosing systems 43
1.4 Personnel safety 48
1.5 Reference drawings. 50
_. _.
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PROJECT-8108 I WHR Systemfor ATTS Inc. U S A.

CHAPTER 1.1
STEAM PRODUCTION SYSTEM
PROJECT -8108 I WHR System for ATTS Inc. U S A.

1.1 STEAM PRODUCTION SYSTEM
1.1.1 Purpose
To recover the energy from the hot gases coming out from the MSW incinerator.
Gasification of MSW is an environmentally and user friendly process which releases huge
quantity of flue gases at high temperature. Heat is recovered from the flue gases for
steam generation.
1.1.2 Description
The steam production system consists of two nos.of horizontal single pass, tire tube,
natural circulation Waste Heat Boiler with a separate Steam Orum connected with
Downcomers and Risers. This two boilers are attached in two lines of MSW incinerators.
The Waste Heat Boiler is mounted horizontally on a fixed saddle of the Gas Inlet Channel
and sliding saddles allowing it to expand freely, to avoid thermal stress.
Manhole provides access into the Waste Heat Boiler for inspection and cleaning.
Adequate numbers of hand holes are also provided for inspection of tubes. Tube sheets
are lined with 76 WT refractory castable lining. Front tube sheet have been provided with
Zirconium silicate ferrules .
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The hot gases coming out of incinerator at +1000 oC re cooled down to +450 oC by
transferring heat to the water in the Waste Heat- oiler & generated steam is utilized for
power generation
The Steam Drum is fitted with a Demister pad. Steam and water separation takes place in
the Steam Drum mounted above the Waste Heat Boilers by natural circulation.
Boiler feed water enters the drum at 14 kg/cm2.g & 100 oC.
7000 kg I hr saturated steam produced from steam drum is at a pressure of approx.10.34

bar (g) & at + 185.4 oC.
Provision of 5tart up steam has been given to heat up boiler water during initial 5tart up ..
Blow down Tank is provided to release the blow down water Le. thrQugh IBO & CBO
valves and finally to drains after mixing with cooling water.

Technical data - waste heat boilers :
1. GAS SIDE DATA (at 100 % Plant Load)
WHB#1 & 2
Gas pressure, boiler inlet + 280 MMWC
Gas Volume flow rate 19285 NM3/hr
Gas inlet Temperature + 1000 oC
~ Gas outlet Temperature + 450 oC
Flue Gas composition
H20 -Vol % 17.37

N2 - Vol % 68.18
02 - Vol % 4.22
C02 - Vol % 10.22
802 - Vol % 0.01
HCI - Vol % 0.00
Dust/
Particulate
Matler ppm
.. - 100
Gas Side Pressure drop across WHB - mmWC 200
2. WATER I STEAM SI DE DATA (At 100 % Plant Load)
Operating pressure 10.34 bar.g
Operating temperature + 185 oC
Design pressure 13.73 bar.g
Hydro- test pressure 20.59 bar.g
Steam output (Total) 7000 kg.1 hr

5 Heating surface area (Effective) 174 M2
6. Safety Valves: Capacity Set Pressure
1. Steam Drum PSV-1 4500 kg/hr 13.73 bar g.
2. Steam Drum PSV-2 4500 kg/hr 14.14 bar 9
7. MATERIAL OF CONSTRUCTION
A. WH BOILERS, STEAM DRUM, R I O PIPING:
1. Boiler shell, dished ends, Orum, Tube

Sheet, Wear plates for saddles, Channel,
Collar and Lifting lugs, Reinforcement pads SA 516 gr.70
2. Plain Tubes 00 60.3 x 4.06 WT (MIN) SA 210 gr. A1
3. Stay Tubes 00 60.3 X 6.35 WT (MIN) SA 210 gr. A1

-, '.
3. Pipes for Nozzles, Risers & Oown comers SA 106 gr. 8
4. Flanges & SW Fittings SA105
5. Butt Welded Fittings SA 234 gr. WPB
6. Oemister Pad with Grid SS 304
7. Chemical feed pipe SA 312 TP 304
8. Studs 1 Bolts & Nuts (External) SA 193 gr. B71 SA 194 gr. 2H
9. Studs 1 Bolts & Nuts (Internal) SA 193 gr. B81 SA 194 gr. 8.
10. 12. Gaskets SS 304, SPWO, GraphiteFilled

With inner & outer ring
11. Refractory Anchors AISI310
12. Tube Ferrules Zirconium Silicate

GAS INLET CHANNEL:
Plates for Shell, Lap Flanges SA 516 gr.70
GAS OUTLET CHANNEL:
Plates fior Shells, Dished Ends, Fabricated

Nozzles, Lap Flanges, Wear Plates for
Saddles, Reinforcement (RF) Pads. SA 210 TP 304
Saddles I S 2062 gr. A / B
Pipes for Nozzles SA 312 TP 304, Welded
WNRF Flanges SA 182 gr. F304
Gaskets SS304, SPWD, Graphite Filled

With inner & outer ring
Studs I Bolts, Nuts SA 193 gr.B8/ SA 194 gr.B
PROJECT-8108 I WHR System for ATTS Inc. U S A.

1.1.3 Cornrnissioning I Start- up:
a) Refractory Dry-out :
General
The refractory dry out is part of the commissioning activities. if the boiler is lined with
refractory. After completion of the refractory work it must be properly cured and subjected
to gradual dry out process. In the absence of proper drying out process. cracks occur on
the refractory surface.
Proper attention should be given during initial heating up of castables. as they have
considerably lower permeability when compared to brick. It is more difficult for the water
to pass through the casta bies and escape as the refractory is heated more rapidly. So
due to this. high-pressure steam is developed inside and this ruptures the lining.
Rapid heating also causes the hot face to dry ang heat up while the rest of castables are
still comparatively coo/. This will lead to expansion of hot face and hence develops a
crack on cold face.
Curing:
AII refractory & insulating castables are hydraulic setting type and need the presence of
moisture for setting process, so it is necessary to ensure that the castables do not dry out
to exposure to ambient conditions or due to heat produced within the mass. It should not
be al/owed to dry during first 24 hours after it has been placed.
Preparation for refractorv dry out:

Before programming for the refractory dry out procedure. the following have to be
ensured.
PROJECT-8108 I WHR System tor ATTS Inc. U S A.

3.1 Boiler erection should have been completed with all assemblies, valves, tittings and
necessary instrumentation.
3.2 Boiler auxiliaries such as fans, Pumps should have been trial taken.
3.3 The water level gauge at steam drum should be made ready for regular operation.
3.4 Supply of adequate fuel and de-mineralised water prior to starting the operation.
3.5 It is preferable to mass flush the major pipelines before commencing the operation.
~
3.6 Refractory & Insulation work should be completed. AII scaffolding, temporary
supports, debris arising out of refractory work (such as bricks, slag wool, stubs, wire
mesh) should be cleared off.
3.7 Provision should be made for permanent lighting facilities at all operating floor
levels.
3.8 Availability of adequate trained personnel shall be ensured. Since the drum level will
be on manual control. adequate lighting shall be provided at steam drum. Personnel
shal/ be planned tor manning the drum level manual/y.
3.9 Suitable tire fighting equipment (such as C02 or foam type fire extinguishers, sand
buckets etc) shall be made available at suitable convenient locations and persons·
working in the area shall be conversant with their usage.
3.10 The drum internal shall be dismantled if wire mesh or corrugated plates have been
titted and which are likely to accumulate deposits.
3.11 Al! spring supports shall be Joaded and temporary locking arrangements if any, are
to be removed.

3.12 Boiler expansion guides shall be in place.
3.13 Boiler expansion movement pointers should have been erected.
Refractorv drv out procedure:
4.1 The boiler shall be filled with treated water. The drum air vent I main steam line air
vent I Main Steam line drain shall be kept open. During the course of slow firing, the
steam pressure in the boiler steam drum will increase. When the drum pressure
reaches 2-kg/cm 2 g, the drum vent shall be closed.
4.2 At first stage. the firing is done very slowly. The refractory is heated to 105 deg C only.
At this temperature the refractory is to be soaked for 48 hrs. This permits the gradual
release of water from the castable refr~ctory.. Sasically the longer duration is .
recommended here as the castable refractory done at various places attains the
temperature very gradually.
4.3 Further, the rate of rise of temperature should not exceed 50°C/hr up to a temperature
level of 500°C, soak the castable for 6 - 8 hours and later, rate of rise in temperature
may be increased at arate of 100°C/hr, till temperature is reached to max. design
temperature ( Le.+1200 oC ). Heating up from 500 deg C onwards can be done when
the burner is put ;nto operation.
4.4 After soaking the refractory at this temperature for mino 4 hours, cooling to be st~rted
at the rate of 50 deg.C per hour by gradual reduction of fuel till we achieve 250 deg.C,
& then switch off the burner and allow it for natural cooling. Once refractory is cooled,
it should be inspected for any cracks etc.
NOTE: The aboye procedure is to be used when no additional information from the
refractory manufacturer is available. If the refractory manufacturer has different
stages of dry-out procedures that of listed aboye, then the refractory
manufacturer's dry-out procedure is to be followed.
PROJECT -8108 I WHR System for ATTS Ine. U S A.

Refractory dry out would take 72 hours approximately. The boiler water shall be drained
once the boiler is cooled below 50 deg C. The boiler shall be put in to dry or wet
preservation as per the preservation procedure if further delay is there for Boiler start up
The boil-out procedure can be combined with the process of drying out of the refractory
Iining, The heat input (flue gas flow rate) should be operated for two (2) to three (3) days
at an extremely low rate, to warm the setting gradually- raising the pressure to about one-
fifth of normal operating pressure or 2.0 kg/cm 2 whichever is lesser.
b) Alkali Bail - out
1. Purpose:
This document is to give a general clarification on the method of degreasing I cleaning a

steam generator of any random size or type.
The basic reason for an alkali boil-out of a boiler is to remove water and alkali-soluble
compounds from the waterside surfaces óf the unit. These compounds may include
lubricants used in the erection of the boiler and in sorne instances protective coatings
applied to prevent atmaspheric rusting following shop fabrication. Lubricants normally
used in fabrication are water-soluble and are easily r~moved by the boil ~ut.
Sand, loose mili scale and corrosion products, which can forrn in the unit after the
hydrostatic test, are removed in the blow down performed throughout the duration of the
boil-out.
2. Procedure:
a. Check on availability
Ensure that the Waste Heat Boiler - Steam Drum system is ready for commissioning. It
is essential that the following support systems are available for use during Alkali BoH-out.
PROJECT-8108 I WHR System tor A ns Inc. U S A.

(1 ) Deaerator
(2) Feed water pumps
(3) Blow down Tank
(4) Drainage system
(5) Cooling water system
(6) Feed water system
(7) Instrument air system
(8) Plant iIIumination & Operating staff
r b. Preparations:
This step is mainly to be taken to conduct an Alkali boíl out, which is not harmful to either
the personnel or the equipment. It should be realized that in most cases this is the first
time the system is put into operation.
c. Alkali Soil-out procedure:
To be able to estimate the effect of the boil out, it is necessary to have a reference of the
unit conditions before starting the cleaning of thé internal pressure parts. Spedal
attention is to be given to the extent of dust and all products, as also leftovers from field
construction are to be removed. If the amount of dust is considerable, it is best to rinse
the Waste Heat Boiler first with clean water, during which the drains and blow down lines
can easily get blocked. This can be avoided by keeping all drain valves open so that
water with a low concentration of dl:Jst is flushed. While rinsing the steam-generating unit,
all systems can also be tested.
As rinsing is completed, the Waste Heat Boiler and Steam Drum shall be filled with
Dematerialized water up to the level just below the Steam Drum manhole, after which the
boíl out additives can be introduced into the water. The type of additives and the
proportions in which they are to be added are as follows.
Preparation of Chemical solution:
Commercial Tri-sodium phosphate has P0 4 content of 200/0. 0.5 kg of Na3P04 has to be

added to per each cubic meter of water hold up. In case the tri-sodium phosphate has
another P04 Concentration, the mass of chemicals should be changed accordingly.
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The Heat Recovery Boiler system has water volume of 13.0 M3 up to NWL of
steam drum
Hence 6.5 kgs of industrial grade tri-sodium phosphate Na3P04 shall be dissolved in DM
water having pH value above 8.5.
Plastic container, which is clear from oil traces and any other foreign matter, shall be
used tor preparation of chemical solution.
Potable water or DM water with pH value above 8.5 shall be added into the container.
Then, add the chemicals according to the container capacity. Mix thoroughly by using
wooden stick free from any foreign matters.
Clean plastic buckets shall be used for transferring water I chemicals into the container.
The person working with chemicals shall wear Rubber gloves, aooron & face shield
as Safety measures.
~ 1) Prepared solution should be transferred to the HP dosing tank. Inject solution of

chemicals through HP Dosing pump.
2) Close the Isolation valves of Level switches, Level transmitters, Floor L.G. and start-up
Vent valve.
3) Start the furnace start up burner.
4) Vent the steam for 5 minutes and then close the Air vent on Steam Drum and raise the
press to 1.0 bar (g).
Take sample Nr.1 of water and do hardness (T.D.S) testing and oil & grease content.'
5) Increase furnace firing till the pressure reaches 2.0 bar (g) and keep for 8 hours, give
blow downs for 3-5 minutes.
6) Increase the furnace firing and bring the boiler pressure to 4 bar (g).
Take sample #2 of water and check hardness (T.D.S) & oi! and grease content.
7) Maintain the press @ 4 - 5 bar (g) and continue furnace firing , and take sample Nr.3, 4 &
5 ... for hardness (T.D.S) & oi! and grease testing @ intervals of 2 hour after blow downs.
If due to the required blow down, the chemical concentrations have decreased to less
than one-half of the original value, then additional chemicals should be added to re- .
establish the original value. This can be done by preparing the chemical solution in HP
Dosing Tank and pumping to Steam Drum.
I
8) If the hardness (T.D.S) of sample Nr.~&main same & oi! and grease content in the
blow down water comes down below 5 ppm desired cleaning is achieved , hence stop
I
the boil-out operation.

Otherwise, continue the boíl-out till the hardness (T.D.S) of further samples remains
constant.
9) Open the Blow-down valve of Waste Heat Boiler and bring down the pressure to 1.0 bar
(g). Now open the Air vent valve on Steam Drum, Drain the Waste Heat Boiler
completely.
10) Now to wash the Waste Heat Boiler, el ose the Blow down valves and tíll the Waste Heat
Boiler with teed water from Deaerator approximately 100°C temp. Wait for 30 minutes.
11) Open the Blow-down valves of Waste Heat Boiler and Drain valve on down comers tor
proper flushing. Repeat the process 5-6 times. Now open the isolation vales and drain
valves of Level switches, Floor L.G. to flush out.
12) After completely draining, open the manhole cover on steam drum, check the internal
surface of the steam drum, scrap & collect sludge at the bottom surface if any. Inspect
the headers & other internals for cleanliness. Check that all nozzles are clean.
Fix the Steam Drum internals Le., Demister pads.
Install & weld the flow orifices I nozzles.
& Make the boiler ready for operation.
NOTES
1) Keep record of the hardness (T.D.S) & testing results.

2) During steam injection, steam gets condensed + as it gets hotter & water expands.
Hence level of water in steam drum raises.
3) Water Level: Please maintain the level water in Steam Drum as shown below:
Top
r'. Within this level
Bottom
LG at Drum level

e) Steam Blow- out:
1. Introduction
Mili scale and other materials enter in the pressure parts of the boiler and pipe line during
manufacture, storage & erection. It is required to remove al! such foreign materials out of
the system so that Turbine receives pure steam. It is proposed to adopt steam blowing to
achieve this requirement.
There is auxiliary steam line, which supplies steam to Deaerator and process plants.
Al! these lines will be steam blown.
11. Principie of Steam Blow-out:
The steam lines will be subjected to a thermal shock repeatedly. The boiler parameters
will be raised and fuI! steam flow at near rated parameters will be achieved and boiler and
steam lines will be blown for 5 - 10 minutes. The blowing will be repeated once in 2
hours, thus subjecting the boiler & piping to__alte~~a.tively heating & cooling, resulting in a
thermal shock. Mili scale and other materials sticking to the surface will get disintegrate
& fall down which will be flushed out of the system by on rushing steam during
subsequent blowing. Normal water level in steam drum will be maintained using feed
water pump.
Preparation
0
1) Disconnect and rotate the flanged elbow of turbine by 180
2) Connect temporary piping, Temporary steam blowing valve and Target plate assembly .
3) Provide supports for temporary piping (If required additional supports may be provided
based on site condition). Free end to be properly re- enforced.
PROJECT -8108 I WHR System tor ATTS Ine. U S A.

a) Method of Blowing
1) The permanent MS stop valve will be kept full open. Dedicated Valve for steam blowing
will remain closed.
2) Keep all drains & vents (Bypass line of steam traps) full open.
3) Raise the boiler pressure & temperature to 7 - 8 bar (g) and +160 oC using start up vent.
4) Close the start up vent and open temporary steam blowing valve fully.
r' 5) Blow the line for 3 to 5 minutes or till the steam pressure comes down to 4 bar (g).
r-- 6) Close the temporary valve. Open the start up vent valve and slowly build up boiler
pressure to 7 - 8 bar (g) & +160 oC.
7) Give next blow after 2 hours.
8) The Target plate need not be kept for first few blows. Afterwards install target plate for
alternate blows.
9) Remove & lnspect the Target plate after steam blowout. The extent of indentation will
decide whether to continue further steam blow out or not. J
10) Repeat the above steps till completion of successful steam blow out.
, \
~). Maximum of 6 to 8 blows can be given in a day.-

-- --------~ ,
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12) After successful completion of steam blow out, the temporary lines may be dismantled.
~ The permanent line should be restored.
~ NOTE:
1) AII flow nozzles & control valves will be removed during steam blowing and spool pieces
will be erected.
2) Watch and maintain drum normal water level throughout steam blowing. Normal water
level is Center line of Steam Drum.
PROJECT -8108 I WHR System tor ATTS Inc. U S A.

1.1.4 Normal operation:
Boiler Start up Procedure:
Ensure al! the drain valves in water side are in e/osed condition.
Open the Vent valves on steam drum.
Fill the WHB # 1 & WHB # 2 and Steam Orum with Feed water up to normal water level by
using BFW pump. Maintain the water level in the Steam Orum at NWL by operating the
Feed water pump discharge valve. Normal water level is center line of the Steam Orum.
~ The starting of the boiler is to be done by admitting the hot gas in a gradual manner in ea eh
~ line with the help of ID fan & its regulating damper. The Iight up is to be done keeping a
minimum draft in the furnace.
The Isolation valve for start-up vent valve shall be opened before starting the heat source, to
vent out the steam, till the rated pressure and temperature achieved.
Slower rise in pressure is acceptable when heat source is ON.
Ouring this period, the generated steam will be vented by regulating start-up vent valve.
Once the rated pressure is reached, the start-up vent valve is to be fully closed (After
ensuring use of steam in the process.
The Boiler is provided with inter locks and protections for safe and reliable operation under
any circumstances these should not be by passed.
Blowdown
r"
~ Intermittent blow down to Waste Heat Boiler at the period during the day when the steam
"demand is lowest. When blowing down the Waste heat Boiler, first fully open the
isolation I shut off valve wide & then open the IBO valve about % open and leave it in
that position until the water is lowered about % in. (13 mm) in the level gauge, then open
the blow-down wide until the blowing down is completed.
After the blowing down is completed, close the IBO valve and then the isolation I shut off
valve. . .
Blow down should be done at least once per shift of 8 hrs.
A continuous blow down valve is fixed to the steam Drum to control the concentration of
solids within prescribed limits.
A safe maximum water concentration can best be maintained by adjusting the continuous
blow down frequently on the basis of water analysis.
PROJECT-B108/ WHR System tor ATTS Ine. U S A.

ii) Safety Valves :
The devices which prevent pressure from exceeding the maximum allowable operating
pressure shall be cheeked, once in three (3) month~ by popping with hand lever for a short
time of 5 to 10 seconds.
Safety valves shall be tested in conjunction with the mandatory inspeetion by raising the
boiler pressure to the set popping pressure of the respective valves, as marked on the
name plate.
In general, the testing should be done at the time the steam generation system is being
shut down for the inspection.
EVERY DAY INSPECTION:
The operator when making his rounds must inspect I check all the parts of the plant and
particularly the following, for proper functioning.
a) Level Gauges
b) Pressure Gauges
e) Safety valves
d) Level switches
e) Level transmitters-
If any irregularity or leaking areas are found on the water or steam pipes, they must be
reported at once and repaired without delay in order to avoid bigger. repairs and break
down of the plant.
During normal operation special attention must be paid to the following.,
Water Level
~
Be certain of the water level at all times. Automatic level control device and low level
~ alarms should be considered solely as operating aids and should not be relied upon
entirely. Water levels indicated by LG & LT should be compared with LG once per shift.
Important differences in level indications should be promptly investigated and reconciled.
The level gauge LG accuracies should be checked by blowing down the gauge and
noting the promptness with which the water level is restored. Close the isolation valve,
open the drain & vent, close the drain and vent, open the isolation valves to check the
functioning of the L.G and levels indicated.
Blow down the Level Gauge glass eaeh shift to be sure the gauge eonneetions are c1ear.
Do not be misled by a dirt mark in the glass, which may look like the surface of water.
Do not allow steam to leak from the gauge glass as it will show a false water level.
Normal water level of Steam drum is Center line of Steam Drum
PROJECT-B108/ WHR System tor ATTS (ne. U S A.

CALCULATION OF BLOWDOWN:
The formula given below may be used to estimate the blow down quantity.
E is the evaporation rate (in 1000 kg/h)
S is the solids content of feed water (ppm)
V is the water content of Waste Heat Boiler
C is the maximum permitted concentration of solids in Waste Heat Boiler water

(ppm)
"
~ C1
B
is the concentration of solids in Waste Heat Boiler water on completion of
intermittent Blow-down (in g/m 3 )
is the actual intermittent or continuous blow-down rate as percentage of

evaporation rateo
BA is the average (intermittent) blow down rate as percentage of evaporation rateo
d is the duration of intermitlent blow-down operation (in h)
t is the interval between completion of one blow-down operation andcompletion of

next (in h) .
Q is the quantity of the Waste Heat Bóíler water discharge during each intermittent
3
blow-down operation (in m )
For continuous blow-down C 1 = C.B A and d = t. The formula linking these variables is as
follows.
S =Conductivity in IJs I cm x 0.7 =0.2 x 0.7 =0.14

C =Conductivity in IJs I cm x 0.7 =50 x 0.7 =35
(a) Continuous blow-down
S
B = 100
C-s
In present case 'B' is determined as follows:
100 x 0.14
.. B = ----------- = 0.400/0
35 - 0.14
PROJECT-B108/ WHR System for ATTS Ine. U S A.

Continuous blow down quantity = 7000 x 004 =28.0 kg/h

100
(b) Intermittent blow-down
100 tSV
8 =
d (eV - 0.5 SE (t-d) - VS)
In present case IBO is determined as follows:
t =8 hrs l e ~ 150 ppm
S ~ 0.073 ppm V =13 m3.

E =7.000 TPH d = 0.05 hr.
100 x 8 x 0.073 x 13
.. B=
0.05 (150 x 13 - 0.5 x 0.073 x 7.0 (8 - 0.05) -13 x 0.073)
= 7.906 %
Intermittent Blow-down quantity per 8 hours =553.42 kg.

EtSV
el = --------------------------------
ev - 0.5 SE (t - d) - VS
SE el
el =e - (t - d) ------ BA = 100 -----
v tE
These formulas are based on steady load conditions ,and on the assumption that priming
and carryover conditions are absent or negligible. It is also assumed that the feed water
treatment is such that all the dissolved solids in the feed water remain in solution in the
Gas cooler & Flash vessel and do not precipitate as scale or sludge. They may be
applied only when the solids content of the feed water is reasonably constant and is
measurable by analysis of sample.
Note: The valve of el e 1 & S are observed values on the sample collected & analysed
in Laboratory.

1.1.5 Shut down
The unit can be taken out of service for many reasons based on the required duration" of
shutdown; the shutdown is classified into two.
Short term shutdown

Shutdown for extended period
1.1.5.1 Short..term shutdown
If the system require shutdown for minor repairs I rectification work which can be
completed within few hours before Waste Heat Boiler pressure drops to 5 bar.g, the
following procedure shall be followed.
Open the start.. up vent valve alternately if possible dump the steam to Auxiliary
condenser or dump condenser through PROS valve.
Stop passing hot gas through Waste Heat Boiler.
As soon as the pressure commences to drop, shut the main steam stop valve and feed
supply.
Keep a continuous watch on steam drum level indicator LG & LT as pressure drops. The
water level must not sink below the low water level.
The level can be maintained by feeding water by F.W Pumps (PU 003 (W) as per normal
operating procedure.
Re-start the hot flue gas supply, as soon as !~e d:f~ct I repair work is completed.
Open the main steam valve.
PROJECT-B10B/ WHR System for ATTS Ine. U S A.

1.1.5.2 Shutdown for extended period
This practice should be followed with care to ensure that any expansions that have
occurred while the Waste Heat Boiler & Steam Drum is in operation should be returned to
normal as gradually as possible.
The following is suggested method.
Open the start-up vent valve.
Shut off flue37

gas supply to the Waste Heat Boiler.
Continue air flow through the system in order to purge the gasses. The purge operation
may continue from 24 - 48 hours with air flow rate between 35- 50% of normal flow rateo
As soon as the pressure commences to drop, shut main stop valve and feed supply.
Close all dampers on gas ducts.
It is recommended that the Steam Drum pressure is allowed to fall as slowly as possible
by allowing the Waste Heat Boiler to cool naturally.
When the pressure has been reduced to 2.0 bar (g) open the vent valve on the Steam
Drum to prevent any possibility of vacuum developing due to steam condensation.
When the Waste ,Heat Boiler pressure is 1.0 bar, the Waste Heat Boiler & Steam Drum
can be emptied by means of the blow down valves. Draining at 1.0 bar will help
evaporation of any left out water in the Boiler.
r Corrosion can start as soon as the Waste Heat Boiler & Steam Drum is emptied and the
attack will be especially severe if pools of water are left in the Waste Heat Boiler.

a) During the idle period, the Waste Heat Soiler & Steam Drum may be preserved as
fo 11 ows
i) Drv Storage:
This procedure may be preferable for steam generating unit out of service for extended
periods of time or in locations where freezing -temperatures may be expected during
stand-by.
The unit should be thoroughly dried, since any moisture left on the metal surface would
cause corrosion to occur on long standing. After drying, precautions should be taken to
preclude entry of moisture in any form steam lines, feed lines or airo
For this purpose, moisture absorbing material, such, as quicklime at the rate,of 2 lb per
30 cU.ft. (1.1 kg/m 3 ) or Silica Gel at the rate of 5 lb per 30 cU.ft (2.7 kg/m 3) of volume, may
be placed on trays inside the Waste Heat Boiler + Steam Drum to absorb moisture from
the airo The manholes should then be closed and all connections on the unit should be
tightly blanked. The effectiveness of the materials for such purposes and need for their
renewal may be determined through regular internal inspections.
ii) Wet Storage:
The method is not generally employed for unit, which may be subjected to freezing
temperatures. Severa' alternative procedures have been employed.
For a short storage period, condensate or feed water containing approximately 200 ppm
of Hydrazine may be used.
Procedure
Complete Waste Heat Boiler from feed control station outlet to main steam fine stop valve
will be filled up with Oemin water with 200 ppm hydrazine concentration.
Total volume of the flooded surface is 15.7 m3 •
1) Boiler will be emptied to remove any residual water I condensate.
2) Al! Air vents will be kept open, Drains will be kept closed.
3) Demin water will be filled up in Deaerator feed tank
4) 200 ppm of Hydrazine wiIJ be pumped through LP Oosing system.

5) Feed pump will be run for 20 to 30 minutes on recirculation mode to ensure thorough
mixing of Hydrazine.
6) Slowly this water will be pumped to WHRB through feed control station.
7) Al! the air vents will be closed one by one after removal of airo
8) Boiler feed pump will continue to run till the whole WHRB pressure comes to 5 bar (g).
9) Boiler feed pump will be stopped and system will be left as it is at this 5 bar (g) pressure.
10) Whenever the system pressure falls below 2 bar (g) feed pump will be started and
pressure will be brought to 5 bar (g).
11) Take out boiler water sample once in 3 days and measure hydrazine ppm.
12) Whenever the Hydrazine level falls below 50 ppm, concentration will be brought upto 200
ppm.
13) Whenever WHRB is required to be restarted bring down the system pressure and drain
whole boiler.
14) No further cleaning is required. Boiler can be filled upto normal water level and normal
start up procedure can be followed.
.. PROJÉCT-B108/ WHR System tor ATTS Inc. U S A.

i!i TV:'i1~¡¡;¡'Jl'¡fHtt;~I ji
•.• z. <.J.•'
:;'t;\~:~';.~~J t~>~·: ((~J ¿fit¡, :?.

O & M Manual Sheet 27 of 50
1.1.6 Trouble Shooting :
O~eration Failure Reasons Solutions
Steam Orum level falls 1 Blockage in the feed 1

rapidly Bypass the LCV on
system
FW fine by opening
bypass valve and
2 Leakage through check for level raise
sorne tubes
Steam Orum water 1 Malfunctioning of LT 1 Check proper

level is too high & L1C functioning of LT & L1C
Rapid I lasting
1 Sudden increase in 1
reduction in steam Reduce steam output
steam demand
drum pressure
Adjust gas-by-pass
2 Imbalance between 2 damper to attain
heat input and output balance between heat
input and output.
Increase the steam
demando Oump steam
Sharp increase in 1 Sudden decrease in 1 through PROS to
steam drum pressure steam demand Auxiliary or dump
condenseroropen
start up vent.
Adjust gas-by-pass
2 Imbalance between 2 damper to attain
heat input and output balance between heat
input and output.
Check the functioning
Steam temperature is 1 1
Malfunctioning of TV of TV and adjust more
too high
steam to bypass
Steam temperature is 1 Malfunctioning of TV 1 Check the functioning

too low control valve ofTV.
2 Water carryover in 2 Check the saturated

steam steam quality
_. -
PROJECT-B1081 WHR System for ATTS Inc. U S A.

1.1.7 General Maintenance Instructions
a) Shutdown inspection and maintenance·
The Waste Heat Boiler should be given an internal and externa I inspection at intervals as
are mutually considered necessary by the responsible engineer and the Authorized
Inspector and subject to approval, where necessary,·of the governmentál authority having
jurisdiction. These inspection intervals are usually at least once each year. It is
advisable to have the plant inspector accompany the Authorized Inspector for these
inspections.
The plant inspector should make available for the benefit of the Authorized Inspector all
'pertinent data on the steam-generating unit as to design, dimensions, age, particulars as
to defects previously noted, and modifications or repairs affected.
A record of each inspection should be kept in uniform manner so that any change of
conditions can be definitely noted and compared, especially with -reference to the
thickness of scale, corrosion. erosion, cracks. and other un usual conditions both
internally and externally.
b) Preparation for Inspection
i) Hot Gas supply to the Waste Heat Boiler shall be shut off.
ii) The Waste Heat Boiler & Steam Drum and setting must be cooled sufficiently to prevent
the baking of deposits that may be present on the heating surface. It is recommended
that the Waste Heat Boiler & Steam Drum be drained while there is still sufficient heat
present to dry out the interior of the unit when ventilated by opening manhole and hand
hole covers.
iii) The water surfaces of Waste Heat Boiler, Steam Drum and tu bes should preferably be
not cleaned. unless otherwise agreed, until afier the Authorized Inspector has had a
chance to observe the condition.
iv) The inspector should enter the Steam Drum & Waste Heat Boiler to make a personal
examination of conditions, but before entering they should first make sure that the
Vessels have been properly ventilated.
v) The external inspection will not require any particular preparation other than giving the
inspector convenient access to the generating unit and its connections.
vi) An external inspection by the Authorized Inspector should comprise the examination of
the unit, its appurtenances, and connections while the unit is in service. It is a form of
examination made primarily to observe operation and maintenance practices.
PROJECT-B108 J WHR System for ATTS Inc. U S A.

c) Inspection of Internal surfaces and parts:
i) The internal inspection of Waste Heat Boiler and Steam Drum by the Authorized
Inspector should include the examination of the physical structure with a view to
determining its adequacy in service. The inspection shal/ cover the condition of the entire
steam generating unit , which includes al/ interconnecting pressurized units with their
fittings , as well as steam, blow off, and water connections with their fittings , and valves.
The inspection shall particularly include a re-examination of defects and repairs made
previously and as evidenced by previous inspection reports.
ii) After Waste Heat Boiler and Steam Drum tubes , and other pressure parts have been
examined for deposits and scale, all these surfaces should be thoroughly c/eaned
internal/y, if required , either by washing, by mechanical means, or by chemical methods ,
to provide a clean metal surface for inspection by the Authorized Inspector. Where
chemical cleaning is used the pressure parts should be thoroughly flushed to remove all
residual chemica/s. During chemical cleaning of boiler interna/s, venting must be
provided for the system and necessary safety precautions taken.
iii) It is not necessary to remove insulation material, masonry, or fixed parts of the unit
unless defects or deterioration are suspected. Where there is moisture or vapour
showing through the covering , the covering should be removed at once and a complete
investigation made.
iv) Scale, Oil etc., The inspector should examine all surfaces of the exposed metal inside to
observe any action caused by treatment, sca/e solvents, oil or other substances which
may have entered the Waste Heat Boiler & Steam Drum. Any evidence of oil should be
noted carefully as a small amount is dangerous and immediate steps should be taken to
prevent the entrance of any more oil into the Waste Heat Boiler & Steam Drum. Oil or
scale on plates subject to furnace heat will result in bulging or rupture of tubes.
v) Corrosion, Grooving: Corrosion a/ong or immediately adjacent to a seam is more serious

than a similar amount of corrosion in the salid plate away from the seams. Grooving and
cracks along longitudinal seams are especial/y significant as they are likely to occur when
the material is highly stressed.
Vi) Careful examination of the interior of the unit should be made for cracks, pitting,
corrosion , erosion, scale and thin places in the drums. The upper half of Steam Drum in
the steam space should be examined particularly for signs of grease, oi! or similar
deposits.
Manholes and other openings: The manhole's nozzles and other openings should be
examined internally as well as externally to see that they are not crackedor deformed.
vii) Wherever possible, observation as to the integriW of the joint. AII openings to external
attachments, such as connections to a low water cutoff and openings to safety relief
valves, should be examined to see if they are free from obstructions.

viii) Fire surfaces - Bulging, Blistering , Leaks: Particülar attention should be given to the plate
or tube surfaces exposed to fire. The inspector should observe whether any part of
Waste Heat Boiler has become deformed during operation by bu/ging or blistering. /f
bu/ges or blisters are of such size as wou/d serious/y weaken the plate or tube , and
especially when water is leaking from such a defect, the unit should be discontinued from
service until the defective part or parts have received proper repairs. Carefulobservation
should be made to detect leakage from any part of the Waste Heat Boiler structure ,
particular/y in the vicinity of seams and tube ends.
ix) The blow down connections should be examined carefully for corrosion and weakness
where they are connected to the Waste Heat Boiler. Blow Down piping should be
supported externally, if necessary, in such a manner that it will drain properly and will not
impose excessive stress on the Waste Heat Boiler connection while either cold or hot and
blowing.
x) Examination should be made of the steam, feed , and blow off connections to see that
they are clear and in good working condition.
xi) Ca refu I examination should be made of the safety valve or valves, their connections to
the Waste Heat Boiler, outlet piping , drains and supports. AII openings should be free
and c/ear. The valves should be tested in accordance with the instructions given tor the
particular plant.
xii) The interior of the tubes should be examined for scale and depo'sits and also the space
between the tubes made visible by lowering a small light between them for the purpose of
making sure that there is no restriction of the circulation.
xiii) Tube Defects: Tubes may deteriorate at the ends toward the fire, and they should be
carefully tapped with a light hammer on their outer surface to ascertain if there has been
a serious reduction in thickness. They should be reached as far as possible either
through the hand ho/es, or inspected at the ends. The surface of tubes should be
examined to detect bulges or cracks or evidence of defective welds. A leak from a tube
may cause serious corrosive action n a number of tubes in its immediate vicinity.
d) Inspection of external surfaces and parts :
i) The inspectors should examine the Waste Heat Boiler for alignment, noting whether or
not there has been any settling, loss of level or plumb, or abnormal movement as
evidenced by displacement of steam drum or other pressure parts. They should see that
provision is made for expansion and contraction of Waste Heat Boiler and setting, that
externa I clearances for Waste Heat Boiler expansion are unobstructed , and that all
supports are in proper condition to carry loads imposed on them. Permanent reference
marks or indicators on Steam Drum and headers are recommended to enable rechecking
their position (both hot and cold). The plant iAspector should verify that the proper
expansion movement occurs as the unit is returned to service after an outage.
PROJECT-8108 I WHR System for ATTS (ne. U S A.

ii) Examination should be made for evidence of corrosion of the exterior of Waste Heat
Boiler and Steam Drum and a check made for leaks from stacks, valvesar pipes.
iii) An examination of the condition of the main steam header and its connections to the
Steam Drum should be made to ascertain that it is properly supported, that due
allowance is made tor expansion and contraction without exerting excessive stress of
strain or the pressure parts of the unit, and that the non return and stop valves are in
good working condition
iv) Connections and Fittings: AII piping should be examined tor leaks; if any are found, it
should be determined whether they are the result of excess strains due to expansion or
contraction or other causes. The general arrangement of the piping. in regard to the
provisions for expansion and drainage, as well as adequate support at the proper points,
should be carefully noted.
v) Safety Valves: As the safety valve is the most important safety device on the unit, it
should be inspected with the utmost care.
There should be no accumulation of rust, scale or other foreign substances in the body of
the valve which will intertere with its free operation. The valve should not leak under
operating conditions. The opening pressure and freedom of operation of the valve should
be tested preferably by opening with the try-Iever in accordance with procedure. The
inspector also to check the drain in safety valve discharge pipe is free from any
obstruction.
If the inspector deems it is necessary, the discharge connection should be removed in

order to determine the freedom of discharge form a safety relief valve.
vi) Appliances: Appliances, such as gauge glasses, gauge cocks, water columns, water-
level controls, high and low-water alarms or cutoffs, blow offs, and feed valves, and on-
return valves should be examined and tested at regular intervals such as during external
inspection or as required by Authorized Inspectors or government codes. Steam Drum
pressure gauges and master gauges should be compared with a properly calibrated test
gauge.
Replace all gaskets of flanged connections that have been broken, with new gaskets.
Pressure Gauge (PI) Test the Steam Drum pressure gauge with a calibrated test gauge.
Test the gauge and blowout connections for obstructions causing choking of the gauge
connections.
Keep the gauge well lighted and the dials and glass covers elean, and maintained tight
and unbroken.
PROJECT -8108/ WHR System for ATTS Inc. U S A.

Level Gauges (LGs); Inspect &c/ean the connections between the Steam Orum and Level
Gauges. Level Gauges should be well lighted and c/ean. Replace with clean glass when
fouled, scored, or broken following the gauge manufacturer's instructions for
replacement.
Feed Water Regulator (L/C I LV): The feed water regu/ator must be maintained in good
working condition. Follow the manufacturer's recommendations for servicing.
Safety valves; Safety valves should be tested by raising the Steam Drum pressure to that
of the respective values. In general, the testing should be done at the time the unit is
being shut down for inspection. This can be accomplished while operating at a low
output and throttling the stop valve until the lowest-set the valve relieves. Normal
pressure should then be restored by slowly opening the stop va/ve. The valve which is
relieved may then be gagged and the procedure repeated until the other valve has been
checked.
A hydraulic device may be used to assist in testing safety valves. This device eliminates
the need for raising Steam Orum pressure above normal and prevents va/ve seat
damage during testing periods.
IBO and CBO valves: Examine the blow down valves when the Waste Heat Boiler and
Steam Orum is washed out and at times of internal inspection. Maintain the pipe, fittings,
and insulation between the blow down valve and the Waste Heat Boiler & Steam Orum in
good condition. If the discharge end of the blow down fine is visible, watch it for the
purpose of detecting leaky blow off valves. A hot blow down line downstream of the
valves will sometimes indicate leakage. Examine piping to determine if adequate
c/earance exists for movement due to boiler and pipe expansiono If blow down val ves
and pipe are exposed to freezing temperatures, protect with electric heating cable or
small steam pipe buried in insulation.
Instruments and Controls: Indicating and recording devices and instruments, such as
steam or feed water flow transmitters, thermometers and draft or pressure gauges should
be wherever possible are given preliminary checks before each start-up.
Protective controls, such as burner trip due to low water level should be tested
frequently and overhauled regularly so that they will be maintained in good
operating condition.
PROJECT-8108 I WHR System for ATTS Ine. U S A.

Steam Drum Internals: Check the primary steam baffles and mesh box at the weld
attachment to the shell to see that all weld joints are sound and that there are no signs· of
leaking or steam bypass. See that the mesh pads are properly installed in the mesh box.
The edge of the pads should be compressed against the mesh box and each other, with
no gaps to allow for steam bypass. Check the pads to see they are not plugged with
deposits. Over a period of several yeas replacement may be necessary.
1.1.8 In-operation inspection and maintenance :
An external inspection by the Authorized Inspector should comprise the examination of

the unit, its appurtenances, and connections while the Waste Heat Boiler is in service. It
is a form of examination made primarily to observe operation and maintenance practices.
Al! appliances should be examined and tested at regular intervals.
Check boiler steam pressure gauges frequently with other gauges in the same system
and test when there is any question of accuracy.
Water Level and Gauge: Test by blowing down the water level gauge noting the
promptness of the water's return.
Safety valve : If it is desired to hand-lift to test the safety valve operation or to blow out
deposits, raise the lift lever to the full-open position, then release to allow the valve to
snap closed as it would have if opened automatically. Do not open the safety valve with
the hand-lifting gear when the steam pressure is less than 75% of the normal popping
pressure.
When a safety valve fails to operate at the set popping pressure, do not attempt to free it
by striking the body or other parts of the valve. The valve may be opened with the lifting
lever and allowed to close, after which the pressure of the Steam Drum should be raised
to the set pressure for which the valve is set to popo If the valve does not then pop, the
set pressure to be adjusted and again safety valve tested.
Care should be exercised to prevent the accumulation of scale, dirt, or other foreign
matter between the coils of the safety valve springs. The springs should be inspected
and a cleaning program established to be sure accumulation does not impede operation
of the valves.
Keep the drains in the safety valve body and discharge pipes open.
Blow down valve: If the discharge end of the bt9V1( down line is visible, watch it for the
purpose of detecting leaky blow down valves. A hot blow down line downstream of the
valves will sometimes indicate leakage.

CHAPTER - 1.2
FEED WATER SYSTEM
PROJECT-8108 I WHR System for A TTS Ine. U S A.

1.2 Feed Water System
1.2.1 Description
The feed water system consists of the following:
Deaerator and Feed Water tank

Motor driven F.W. pump (PU 003 (w) & PU 011 (standby)
FW flow control unit
a) De-aerator and Feed Water Tank
The function of de-aerator is to remove dissolved gases (C02,02) &to heat the
feed water to steam generating unit. The de-aerator consists of a pressure vessel
in which water and steam are vigorously mixed as they travel through the
scrubber unit.
The Feed water is sto red in the tank afier de-aeration.
b) Motor driven FW Pump (PU 003 (wl& PU 011 (standbyl
The feed water from the FW Tank is fed to the Steam drum by motor driven pump,
during initial startup & stand-by conditions.
c) FW Flow Control Unit
The control valve (LlC) on the feed water line regulates the feed water flow to the
(Steam drum), based on the water level in the Steam drum and export steam flow.
I
The Control valve is actuated by instrument air and receives signals from Level
transmitters on Steam drum.
So, steady & continuous water flow to the system is ensured.
PROJECT -8108 I WHR System for ATTS Inc. US A.

1.2.2 Start - UP
Deaerator - Start-up
Flush out all pipe lines and tank with water until there is no indication of foreign matter or
rust. Spray valves should be free of all sea le and debris.
Ensure all the valves are closed.
Open the vent valve fully
Open the isolation valves of level gauges
Open the isolation valves of pressure gauges, pressure transmitters, level switches and
steam pressure control valve.
FiII the tank with water upto 50%, of the tank level and close the valve.
Open the valve (lV) and start flow of inlet water and slowly increase flow rateo
Open the valve (PV) on start up steam line and slowly admit steam into deaerator. A
rumble may occur but this is to be expected beca use of the cold tank. Check pressure
Indicator on deaerator to be absolutely certain that positive steam pressure is maintained
within the deaerator. As the storage compartment fills and some temperature rise is
noted on the storage water thermometer reduce the vent valve setting to above 25% to
500/0 of open.
After storage water level is reached, and over the next hour or so, the vent valve can
gradually be reduced. There should also be a rise in the water temperature of the
storage unit. As the temperature increases, the vent valve should be throttled further
until the visible steam plume is reduced to several feet in length.
As the water approaches the operating level, increase the steam flow, by throttling the
valve.
As the water reaches the operating level, check the operation of Control Valve on water
inlet line to Deaerator by opening the valves and closing the valve.
When a considerable volume of steam is venting from the vent valve, throttle back on the
vent valve until a 3 to 5 foot (914 to 1524 mm) plume of vapor issues from the vent.
PROJECT-B108/ WHR System for ATIS Inc. U S A.

The correct vent valve opening can only be determined by oxygen tests on the effluent
water.
Bring the control valve on condensate make up line and control valve on LP steam, on
line.
Monitor water temperature until saturation is achieved. When this óccurs, the unit is
ready for service.
FW CIRCUIT - START-UP
Ensure all the valves are closed
Open the suction valves to allow the water to feed water pump suction.
Open the following on FW line to steam drum
By pass valve for LCV on FW line
Pump start-up
Open the shut off valve in the minimum flow line.
Check the discharge valve is closed and suction valve is open.
Check cooling water supply to pump is ON.
Switch on the pump (motor).
Slowly open the discharge valve to obtain the required pressure & flow rate after the
pump has reached full speed.
Check the pressure on feed water line.

Once the pump is started & water flow is established.
1.2.3 Normal Operation:
During normal operation, please ensure that the de-aerator is fed with the derived
quantity of make-up water.
This also to be noted that the deaerator has to be operated at normal operating level.
Operating the de-aerator at excessively high operating level may result in water being
carried at high velocity into the de-aerator internals, with consequent damage during
swings in operating pressure.

Please ensure the water temp & pressure at inlel and O/L of all heat bodies, are as
specified.
The control valve on FW line regulates the feed water flow to the Steam drum with regard
to the water level in the Steam drum
As the flow regulation is automatic, no manual control is involved unless a failure in the
control valve operation
It is advisable; the operator checks the tollowing to ensure the proper function of system,
while he makes rounds.
Instrument air line to FT for any leakage in joints.
AIIPI&TI for any leakage I malfunction
~ 1.2.4 Shut down:
Feed water system shut down can be taken up only along with other system. However,
the pump can be brought to shutdown tor maintaining pumps, during operation.
1.2.4.1 Short-term shut down:
Normally one boiler feed pump will be in service and the second pump will be in stand by
condition.
If any abnormal conditions like high bearing temperature, abnormal sound, vibration etc,
immediately the pump should be stopped. Clase suction & discharge valves and attend
to the problem.
Before stopping the running pump, start the stand by pump and maintain boilers drum
leve/.
In case of shutdown ot boiler for short time, the feed pump can continue to run in re-
circulation mode.
As and when the boiler drum level goes down, the feeding can be commenced through
feed control valve bypass line.
Feed pump can be stopped if drum level is normal and no more feeding to boiler is
required.
1.2.4.2 Shutdown tor extended period:
If the boiler is shutdown for a longer period, both the feed pump can be stopped.
Close the discharge, suction & recirculation valves.
Clase the cooling water supply to feed pumps.

1.5.5 Trouble Shooting:
Deaerator
OPERATION FAILURE REASONS SOLUTIONS
Poor Oxygen removal Vent valve opening may be Throttle the valve
Insufficient. for proper opening.
Fluctuating operating Vent valve opening .may be Throttle the valve and
pressure. more. Set the correct opening
r"
Less storage water Vent valve opening may be Throttle the valve for
temperature. more. Proper opening.
Inadequate steam supply Check the steam flow

Check the function of
CV on Steam Line.
Vibration & Hammering Too low steam supply Ensure for adequate
Steam supply.
Blockage within the Steam Check & Clear the

Passages. Steam Passages.
Too high feed water LP steam quantity may be Check for quantity of
Temp. in FW Tank on higher side. steam .
.
~
Too high water level Malfunctioning of LT & LV Check for proper
in FWTank on Cond. & make-up line functioning of LT &
LV
Too low water level Malfunctioning of LT & LV Check for proper

in FWTank on Cond. & make-up line functioning of LT & LV.
.- -
Cond. and make-up water Check the condensate
Pump may not be feeding Pump.
Make-up water
PROJECT-B108/ WHR System for AITS Ine. US A.

CHAPTER -1.3
SAMPLING TEST
PROJECT-8108 I WHR System for Ans Inc. U S A.

o & M Manual Sheet 41 of50
1.3 Sampling & Testing:
1.3.1 Purpose:
To determine the controlling effect of the conditioning process (dosirJg) and the blow
down, a sample of feed water, WHBs water, steam '& condensate water to be analysed
periodically. The specified value for analysis report is given below:
1.3.2 General Notes:
The standards specified below have been determined by the German VGB Committee for
"Wasserchemic in Warmekraftwerken" (Water chemistry in thermal power stations) and
been approved by the Fachverband Dampfkessel - Behalleitungasbau e.V (FDBR)
(Committee for "Steam Boiler, - Vessel - and piping Construction") as well as the
Technischen Uberwachungs - Vereine eVo (VdTUV) (Technical SurveY,Authorities).
The regulations are based on scientific principies and experience made during
operational practice. They guarantee the best possible protection against the corrosion of
all parts connected with the water circulation. Parts in contact with water and steam shall
remain free from deposits so that the generation of clean steam is possible.
1.3.3 Feed Water Analysis:
Total hardness (max) PPM : NIL

pH val ue at 25C -- : 9.0 - 9.4
Oxygen (max) PPM : 0.02
Iron (max) PPM : ~0.02
Copper (max) PPM : ~ 0.003
Silica as Si02 (max) PPM : ~0.02
~ Oil (max) PPM : Nil

Conductivity at 25C I-lS/Cm : < 0.20*
1.3.4 Boiler water Analysis:
pH value : 9.5 -10.5

Silica as Si02 (max) PPM :~4
Total dissolved solids (max) PPM : ~ 150

\
Conductivity IJS/Cm : < 50*

Residual phosphate (max) PPM -, :.~ 6 - 10 \,
* Measuring of conductivity "downstream of strongly acidic sampling cation
exchanger.
PROJECT-B108/ WHR System for ATIS Ine. U S A.

1.3.5 Steam Analysis: .- -
SH Steam Saturated Steam

pH Value 8.5 - 9 8.5- 9
Conductivity @25OC IJs/cm ~0.20 ::: 0.20
Silica as Si02 PPM ~ 0.020 ~ 0.020
Totallron as Fe PPM ~ 0.020 ~ 0.020
Total Copper as Cu PPM ~ 0.003 ::: 0.003
Na PPM ~ 0.010 ~ 0.010
~ 1.3.6 Demin water Analysis :
1. Conductivity : IJs I cm 0.2

2. Silica (Si02) PPM 0.02
3. Total Hardness as (CaC0 3 ) : (mvall kg) < 0.02
4. pH value 7.0
5. Totallron content :PPM < 0.02
6. Total Copper content : PPM < 0.003
7. Oil NIL
1.3.7 Procedures for taking samples through sample cooler:
Open the shut off valve on sampling line.

f"
Open the cooling water inlet valve gradually and allow the cooling water to flow through
the sample cooler.
Increase the flow gradually.
Stabilize the flow at a value higher (say 10 - 15 %) than what is required as per the
specification sheet.
Check whether the cooling water ¡nlet temperatur: i~ as specified.
Open the sample isolation valve gradually 9nd let the steam I sample flow through the
coil.
PROJECT-8108 I WHR System for ATTS Ine. U S A.

Before increasing sample flow rate, just feel the down stream sample line. Temperature
should not exceed 40 - 45°C.
Increase the sample flow rate to the specified value gradually, all the while IIfeeling IIthe
temperature of the exit line. Allow some time for equilibrium to be established (Say 15 -
20 minutes) for safe temperature to be obtained.
Gradually reduce the cooling water flow rate to the specified value and IIfeel" the sample
outlet temperature.
After sampling, shut off the sample shut off valves and sample isolation valves.
Then shut off the cooling water IIL valves.
Frequency of Boiler water sampling is once in 8 hours.
Dosing System:
LP Dosing
Hydrozine (N 2 H4), a neutralizing amine based reagent, after dissolving in the mixing tank,
will be injected into De-aerator to scavenge the last traces of dissolved oxygen in feed
water and to increase the pH value of feed water.
HP Dosing:
Oirect treatment of boiler water is used 1) to prevent scale formations caused by

hardness constituents, and 2) to provide pH control to prevent corrosion. Treatment that
is incorrect or inadequate in either respect can lead to tube failures and result in
unscheduled outages.
In this WHRB, boiler water is treated with trisodium phosphate dosing (Na3P04)". Use of
Trisodium phosphate controls the beiler water pH (9.5 - 10.2) and precipitates the
calcium and magnesium compounds as a flocculent sludge, so that they can be removed
in the boiler blow down rather than being deposited on heat transfer surfaces.
Periodic boiler water sample (once in 8 hours) is taken and pH, total dissolved solids &
free phosphate content is measured. Phosphate content of upto 15 ppm (max.) as free
P04 can be maintained in Drum water.
The continuous blow down quantity is adjusted such that total dissolved solids do not
exceed 150 ppm. Blow down quantity from WHRB will be increased or decreased based
en this value.

c) HP / LP Oosing calculation:
Steam Generation rate net = 7000 kgs / hr
TOS in feed water = 10 ppm

TOS permitted in boiler water = 150 ppm
Oxygen in feed water = 0.02 ppm
Residual phosphate level in boiler water = 15 ppm
Concentration of phosphate solution = 0.3 gm/100 mi
Residual Hydrazine in feed water = 0.02 ppm
Concentration of hydrazine
d) HP Chemical Oosing calculation:

Chemical Oosed in HP Oosing system =Trisodium phosphate
Maximum steam generation capacity of boiler =7000 kg/hr
TOS in feed water =10 ppm
TOS permitted in Boiler water = 150 ppm
10
Percentage blow down = 100 x ------------ = 7.1430/0
(150 - 10)
Actual blow down rate = 7000 x 7.143/100 kg/hr

= 500.01 kg/hr
Recommended phosphate ppm in boiler water = 15 ppm
Loss of phosphate in blow down water = 15 x 500.01/1000 gm/hr
= 7.5 gm/hr
Concentration of phosphate solution = 0.3 gm /100 mi
Rate of dosing =100 x 7.5 /0.3 mllhr = 2500 mllhr
Trisodium phosphate consumption per day = 7.5 x 24/1000
__ _;=.0.18 kg / day, say 0.2 kg / day

e) LP Chemical Dosing (Hydrazine) calculation

Chemical Dosed : Hydrazine
Maximum steam generation capacity of Boiler = 7000 kgs/hr
Oxygen in feed water =0.02 ppm
Required oxygen level in feed water =0.007 ppm
Oxygen to be removed = 0.02 - 0.007 = 0.013 ppm
Hydrazine required (two times) =2 x 0.013 ppm =0.026 ppm
Residual Hydrazine to be kept =0.02 pm
Total hydrazine required =0.026 + 0.02 = 0.046 ppm

Total hydrazine required in kg/kg of evaporation =0.046 x 0.000001 kg/kg
= 0.000000046.kg/kg
Hydrazine required per hour = 7000 x 0.000000046 kg/hr
= 0.000322 kg/hr
Concentration of Hydrazine solution =600/0
Hydrazine to be dosed @600/0 concentration = 0.000322 x 100 1 60 kg/hr
=0.000536 x 24 =0.013 kg/day
f) Consumption of Chemical per day

1) Hydrazine for LP Dosing in Deaerator = 0.013 k~
2) Concentration of Hydrazine in Dosing Tank = 60%

3) Residual hydrazine level in feed water = 0.02 ppm
r' 4) Trisodium phosphate (Na3P04) for HP Dosing in Drum = 0.2 kg/day
5) Concentration of phosphate solution = 0.3 gm 1100 mi
0.3
6) For 200 liter tank capacity = 200 x ----- x 1000 = 600 gm
100
-" '':: 0.6 kg for 200 liters of water
7) Residual Na3Po4 in Drum water =15 ppm

Fault finding I Correction:
Operation Failure Reasons Solutions

Steam drum level falls Blockage in the feed Bypass the control valve
rapidly. system F.W.Line, by opening by
pass valve and closing
isolation valve of control
valve. Á:;,~ _"=,,,
Steam drum water Malfunctioning of Level Check proper functioning

level is too high - Transmitter of Level Transmitter.
Rapid,lasting Sudden ¡ncrease in steam Reduce steam output.
reduction in Steam demand
drumpressure
Sharp ¡ncrease in Sudden decrease in steam Increase the steam
steam drums pressure. demand .. demand or dump steam
through PRDS to Auxiliary
condenser I Dump
condenser.
Deaerator
Operation Failure Reasons Solutions
Poor Oxygen removal Vent valve opening may be Throttle the valve for
Insufficient. proper opening.
Fluctuating operating Vent valve opening may be ThroUle the valve and set
pressure. more. the correct opening.
Less storage water Vent valve opening may be Throttle the valve for
tem peratu re. more. Inadequate steam proper opening. Check the
supply. steam flow. Check the
functioning of CV on
Steam Line.
Vibration & Hammering Too low steam supply Ensure for adequate steam
Blockage within the Steam supply Check & Clear the
Passages. Steam Passages.
Too high feed water LP steam quantity may be Check for quantity of
Temp. in FW Tank on higher side. steam
Too high water level in Malfunctioning of LT & CV Check for proper
FWTank on Cond. & make-up line functioning of LT & CV
Too low water level in Malfunctioning of LT & CV Check for proper

FWTank on Cond. & make-up line functioning of LT & CV.
Cond. and make-up water Check the condensate
pump may not be feeding makes up water pump.
water.

2.2.3 Change out time for major assemblies:
Steam Separator for Steam Drum 24,000 hrs 2 Hrs
Elements for Economisers 32,000 hrs 8 Hrs

CHAPTER -1.4
PERSONNELSAFETY

B) Do not stand directly in front of open ports or doots, especially wheri they are being
opened. Furnace pulsations caused by firing conditions, or tube failure can blow hat
furnace gases out of open doors.
C) Do not use open-ended pipes for roding observation ports on furnace walls. Hot gases
can be discharged through the open-ended pipe directly onto its handler. The pipe can
also become excessively hot.
O) Never enter a vessel, especially a boiler drum, until all steam and water valves, including
drum and blow down valves, have been closed and locked/tagged. It is possible for
steam and hot water to back up through drain and blow down piping, especially when
more than one boiler or vessel is connected to the same drain or blow down tank.
E) Do not enter a confined space until it has cooled, purged of combustible and dangerous
gases, and properly ventilated with precautions taken to keep the entrance open. Station
aman at the entrance, notify a responsible person, or run an extension cord through the
entrance.
F) Use low-voltage extension cords, or cords with properly connected grounds. Bulbs on
extension cords and flashlights should be explosion-proof.
~ G) Never open or enter rotating equipment until it has come to a complete stop and its circuit
breaker is locked open. Some types of rotating equipment can be set into motion with
very little force. This type should be locked with brake or other suitable device to prevent
rotation.
H) For handling Boiler chemicals, the person should use personal protective equipments like
Hand gloves, safety goggles or face shields, aprons gum boots etc.
PROJECT -8108 I WHR System for ATTS lnc. U S A.

Personnel Safety
Operating instructions usually deal primarily with the protection of equipment. Rules and
devices for personnel protection are also essential. The do's and don'ts listed here are based
on actual operating experience, and point out some personnel safety problems.
A) When viewing flames or furnace conditions, always wear tinted goggles or a tintécfstíield
to protect the eyes from harmfullight rays.
r" B) Do not stand directly in front of open ports or doors, especially when they are being
opened. Furnace pulsations caused by firing conditions, or tube failure can blow hot
furnace gases out of open doors.
C) Do not use open-ended pipes for roding observation ports on furnace walls. Hot gases
can be discharged through the opef1-~nded pipe directly onto its handler. The pipe can
also ~ecome excessively hot.
O) Never enter a vessel, especially a boiler drum, until all steam and water valves, including
drum and blow down valves, have been closed and locked/tagged. It is possible tor
steam and hot water to back up through drain and blow down piping, especially when
more than one boiler or vessel is connected to the same drain or blow down tank.
E) Do not enter a confined space until it has cooled, purged of combustible and dangerous
gases, and properly ventilated with precautions taken to keep the entrance open. Station
aman at the entrance, notify a responsible person, or run an extension cord through the
entrance.
F) Use low-voltage extension cords, or cords with properly connected grounds. Bulbs on
extension cords and flashlights should be explosion-proof.
G) Never open or enter rotating equipment until it has come to a complete stop and its circuit
breaker is locked open. Some types of rotating equipment can be set into motion with
very IiUle force. This type should be locked with brake or other suitable device to prevent
rotation.
H) For handling Boiler chemicals, the person should use personal protective equipments like
Hand gloves, safety goggles or face shields, aprons gum boots etc.

'. '.'
1.5 LIST OF REFERENCE DRAWINGS:
SI.
Drawing Nr Title
No ,
1 8108.01.00.10.004 Rev.A P & ID for Waste Heat Boiler
2. 8108.01.03.00.001 Rev.8 GA ofW.H.Boiler.1

Sheet 1 of 2
3. 8108.01.03.00.001 Rev.8 GA of W.H.80iler.1
~ Sheet 2 of 2
4. 8108.02.03.00.001 Rev.8 GA ofW.H.80iler.2
Sheet 1 of 2
8108.02.03.00.001 Rev.8 GA ofW.H.Boiler.2
Sheet 2 of 2

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i a sopesa PLANTA RSU SA " SAN ANDRESS,

PROJECT: 8108 PREPARED

OPERATION & MAINTENANCE MANUAL

PROJECT · WASTE HEAT RECOVERY BOILERS

CLIENT ·· ATTS INC, 12000 Lineoln Orive West,

ORDER NO. ·· P.O.No.1481 dtd.27.1 0.1 O

W.O NO. · 8108

IISSUE NR. : I 1 29.01.2011

I THERMAL SYSTEMS (HYDERABAD) PVT.LTO.,

Tel. Nr. 0091 - 40 - 23091801

PROJECT-8108 I WHR System for A TTS Inc. U S A.

TABLE OF CONTENTS PAGE Nr.

1.1 Steam Production System 5

1.1.2 Description & Technical data 6-7

1.1.3 Commissioning I Start - up

1.1.5 Shut down 23

1.1.5.1 Short term shut down 23

1.1.5.2 Shut down tor extended period 24

1.1.6 Trouble shooting 27

1.1.7 General Maintenance Instructions 28

1.1.8 In operation Inspection and Maintenance 33

1.2.4 Shut down 38

1.2.4.1 Short term shut down 38

1.2.4.2 Shut down for extended period 38

1.2.5 Trouble shooting 39

PROJECT-B108/ WHR System for ATTS Inc. U S A.

,·.:rj(\~ dí t~:: ((~:) ~i;ir~ j_

1.3 Sampling Test 41 --

1.3.2 General Notes 41

1.3.3 Analysis of Feed Water 41

1.3.4 Analysis of Boiler water 41

1.3.5 Analysis of steam 42

1.3.6 Analysis of Demin water 42

1.3.7 Sampling procedure 42

1.3.8 Dosing systems 43

1.4 Personnel safety 48

1.5 Reference drawings. 50

PROJECT-8108 I WHR Systemfor ATTS Inc. U S A.

STEAM PRODUCTION SYSTEM

PROJECT -8108 I WHR System for ATTS Inc. U S A.

1.1 STEAM PRODUCTION SYSTEM

7000 kg I hr saturated steam produced from steam drum is at a pressure of approx.10.34

PROJECT-8108 I WHR System for A TTS Inc. U S A.

Technical data - waste heat boilers :

1. GAS SIDE DATA (at 100 % Plant Load)

Gas pressure, boiler inlet + 280 MMWC

Gas Volume flow rate 19285 NM3/hr

Gas inlet Temperature + 1000 oC

~ Gas outlet Temperature + 450 oC

Flue Gas composition

H20 -Vol % 17.37

Gas Side Pressure drop across WHB - mmWC 200

2. WATER I STEAM SI DE DATA (At 100 % Plant Load)

Operating pressure 10.34 bar.g

Operating temperature + 185 oC

Design pressure 13.73 bar.g

Hydro- test pressure 20.59 bar.g

Steam output (Total) 7000 kg.1 hr