Math & Physics. Complete combustion requires an Air-FuelRatio of 14.7 to 1 for combustion.

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1 Plant OPS

2 Math & Physics Complete combustion requires an Air-FuelRatio of 14.7 to 1 for combustion.

3 Math & Physics Increasing oxygen levels by 9 to 15% improves boiler efficiency.

4 Math & Physics Draft is the flow of air or gases of combustion caused by a difference in pressure between two points.

5 Math & Physics Mercury Manometers

6 Math & Physics

7 Math & Physics

8 Math & Physics

9 Math & Physics

10 Math & Physics

11 Math & Physics A 100 ft. length of steel pipe will expand approximately one inch in length for every 100 degrees of temperature rise

12 Math & Physics

13 Math & Physics A column of water weighs.433 pounds per square inch per foot of rise.

14 Math & Physics Water boils at approximately 212 deg. F. at atmospheric pressure. At approximately 53 PSIG water boils at 300 deg. F

15 Math and Physics

16 Math & Physics Combustion of a fuel produces heat and gases of combustion. A combustion control is a control that regulates fuel, air, air-to-fuel ratio, and removal of gases of combustion.

17 Math and Physics We measure feed water quality Cooling tower water. Softened water. Temperatures. Pressures Vibration.

18 Math & Physics

19 Math and Physics

20 Math & Physics

21 Math & Physics

22 Math & Physics

23 Math & Physics There are several measures of purity, depending on available insturmentation. Color - the more color the less pure the water. Turbidity - the cloudier the water the less pure the water. Conductivity - the higher the conductivity the less pure the water. ph - the further you get above or below ph of 7, the less pure the water.

24 Math & Physics Specific heat capacity is the amount of heat required to change temperature of a given quantity of a substance by one degree. The specific heat of alcohol is.58 water is 1

25 Math & Physics

26 Math & Physics How many BTU s will it take to raise 6 pounds of 20 deg.f ice to 145 deg. F. water

27 Math & Physics How many BTU s to convert 5 # of steam at 400 deg.f to 5 # of ice at 10 deg.f

28 PSIG = PSIA Math & Physics

29 Math & Physics Rise of temperature causes expansion of gases if pressure stays the same

30 Air Compressors

31 Air Compressors

32 Air Compressors Intercooler cool the stage air

33 Air Compressors High temperature is necessary

34 Air Compressors

35 Gauges

36 Gauges Siphon loop

37 Gauges

38 Gauges

39 Gauges

40 Gauges

41 Gauges One is required

42 Gauges

43 Softeners Convert Calcium and Magnesium to Sodium. Ion exchange process

44 Water Softeners An ion exchange process Allowing the zeolite to adsorb calcium and magnesium and replace The calcium hardness with sodium hardness

45 Softeners Regeneration process involves: Backwash to fluf or reposition the zeolite and remove debris Brine rinse to replace the magnesium and calcium. Rinse to remove excess brine

46 Pumps

47 Pumps

48 Pumps

49 Pumps

50 Used for: Boiler Feed Tower recirculation Cooling tower Hot water loop Chilled water loop Potable water Pumps

51 Centrifugal pumps convert centripetal force into pressure and flow in the volute. Pumps

52 Pumps

53 Pumps Volute ei Scroll housing Vanes Impellor Seal ring Seal Assembly Bearing assembly

54 Pumps

55 Pumps

56 Pumps

57 Pumps

58 Pumps

59 Pumps

60 Pumps

61 Valves When multiple pressure relief valves are used, one valve shall be set at or below the Maximum Allowable Working Pressure, MAWP, and the remaining valve(s) may be set up to 5% over the MAWP. When sizing for multiple valve applications, the total required area is calculated on an overpressure of 16% or 4 psi, whichever is greater.

62 Valves Must be set at MAWP or lower Used a huddling chamber to increase opening speed and allow the valve to stay open longer Must be welded flanged or threaded

63 Valves Globe and gate valves are used in a boiler feed system but gate valves are used for isolation.

64 Valves

65 Valves

66 Valves Must be tested monthly manually with the boiler at 75% of its working pressure

67 Valves Cannot allow the boiler to exceed 6% of its MAWP

68 Valves You need to know what a Maxim Valve is.

69 Valves What does a safety Valve do?

70 Valves How is a Relief valve rated?

71 Valves What is an Automatic non-return valve.

72 Valves Main steam lines should be valves

73 Valves How should an accumulation test be done?

74 Valves Try cocks are necessary on large boilers if the boiler only has one gauge glass. Three try cocks are necessary to correctly test a boiler Try cocks are not reliable with pressures over 250 psig.

75 Valves How can valves be attached to boilers?

76 Valves What is an accumulation test

77 Valves How do you test a safety valve

78 Valves What is the most important fitting on a boiler?

79 Valves These must be on a safety valve nameplate Manufacturers name and trademark Design and type number Size of valve in inches and seat diameter Popping pressure in psig Blowdown in pounds per square inch Capacity in pounds per hour Lift of the valve in inches Year built or code mark ASME symbol Serial number

80 Induced draft fan

81 Draft

82 Draft

83 Draft

84 Draft

85

86 Draft

87 Draft

88 Boilers

89 Boilers

90 Boilers

91 Boilers Boiler light-off procedures

92 Boilers

93 Know boiler start sequence Boilers

94 Boilers

95 Boilers What is the percentage of excess air necessary for efficient combustion

96 Boilers Know the components of a water wall system

97 Boilers Discuss startup procedures

98 Boilers Which is more dangerous a fire or water tube boiler

99 Boilers Which boiler is most likely to explode

100 Boilers

101 Define low pressure Boilers

102 Locate the vent Boilers

103 Identify the fire side of a boiler Boilers

104 Boilers Discuss boiler inspection procedures

105 Boilers

106 Boilers How do we measure boiler capacity

107 Boiler Accessories How do thermocouples work?

108 Boiler Accessories

109 Boiler Accessories From the firebox into the boiler is the correct direction for a fusible plug

110 Boiler Accessories How hot can the blowdown be entering the sewer

111 Boiler Accessories Scanners can be IR, UV or ION. They provide what proofs.

112 Boiler Accessories You should test the low water cutoff each shift.

113 Boiler Accessories Rotary cup atomizers use centrifugal force and air to atomize fuel Pressure atomizing uses high pressure oil with a restrictor at the tip Steam atomization mixes steam and fuel before the tip Air injection is at the tip

114 Boiler Accessories

115 Boiler Accessories

116 Boiler Accessories What are the start of shift procedures

117 Boiler Accessories

118 Boiler Accessories

119 Boiler Accessories

120 Boiler Accessories

121 Boiler Accessories What accessories improve boiler efficiency

122 Boiler Accessories What are the differences between fire tube and water tube boiler fittings

123 Boiler Accessories

124 Boiler Accessories

125 Boiler Accessories

126 Boiler Accessories

127

128 Pre heater troubleshooting

129 Boiler Accessories How do you know the water level in a boiler

130 Boiler Accessories

131 Boiler Accessories

132 Boiler Accessories Where does an open feed water heater sit?

133 Boiler Accessories

134 Boiler Accessories So under higher operating conditions drum level control is to be done by considering the following three parameters 1. Drum Level (The only parameter considered in Single element control) 2. Feedwater flow (Input to drum) 3. Steam flow (Drum output). These are the THREE ELEMENTS used in drum level control.

135 Boiler Accessories a two-element system which only looks at level and feedwater flow.

136 Boiler Accessories FEEDWATER REGULATOR Control water level in the feed water heater and boiler

137 Boiler Accessories Where is a single element feedwater regulator located?

138 Boiler Accessories In a single-element strategy, one device measuring instantaneous drum level provides a control signal to a feedwater regulator (Figure 2). Used in both on/off and modulating modes, this strategy is practical only for smaller boilers with moderate load changes because level phasing can lead to over- or underfilling.

139 Boiler Water Treatment When is the best time to take your TDS reading?

140 Boiler Water Treatment What causes boiler corrosion?

141 Boiler Water Treatment TDS 2000 to 35000

142 Boiler Water Treatment What causes corrosion

143 Boiler Water Treatment Same as the last one but condensate lines.

144 Boiler Water Treatment

145 Boiler Water Treatment

146

147 Boiler Water Treatment What is a good boiler PH

148 Boiler Water Treatment What should the condensate PH be?

149 Boiler Water Treatment What is mechanical treatment: 1. Clarification 2. Filtration 3. Softening 4. Dealkalization 5. Demineralization 6. Deaeration 7. Heating

150 Boiler Water Treatment 1. Clarification 2. Filtration 3. Softening 4. Dealkalization 5. Demineralization 6. Deaeration 7. Heating Reduce oxygen

151 Boiler Water Treatment What would a faulty DA tank cause?

152 Boiler Water Treatment What do Sulphites do?

153 Boiler Water Treatment When should you blowdown a boiler

154 Boiler Water Treatment Priming As the water level is raised the volume of the steam space is decreased, the speed of the steam across the surface is increased drawing foam and water droplets towards the steam outlet. A sudden increase in steam demand can cause a slug of boiler water to enter the steam outlet. This is known as priming. Operation of the boiler below its design pressure will also produce a similar effect.

155 Boiler Combustion What controls combustion air?

156 Boiler Combustion A=ASH B=BOILS C=ELECTRICAL D=METALS

157 Boiler Combustion A boiler's excess air supply provides for safe operation above stoichiometric conditions. A typical burner is usually set up with 10-20% excess air (2-4% O2).

158 Boiler Combustion Gas analysis apparatus in which various gases are absorbed selectively (volumetric basis) by passing them through a series of preselected solvents. Is an Orsat Analyzer.

159 Boiler Combustion Complete combustion can be characterized by clear exhaust gases and no soot.

160 Boiler Combustion What causes furnace explosions

161 Boiler Combustion The air used in the combustion process is classified into three types: Primary = controls rate of combustion Secondary = controls combustion efficiency Excess = more than is needed to burn fuel

162 Misc If a tube ruptures: Secure the fuel Isolate the boiler Shut-off the feed water When the boiler has cooled shut off the fans

163 Misc Oil gets thinner as it gets hotter.

164 Misc Oil gets thicker when cold

165 Misc Gear pumps pump fuel oil to the burners

166 Misc Glass thermometers have limited range.

167 Misc What effects fuel storage

168 Misc Fire extinguishers are identified by the product they are designed to be the most effective with: A = Ash B = Boiling C = Electrical D = Metal

169 Misc How often should a motor be lubricated

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172 Thank You