Installation, Operation and Maintenance of Central Boiler Plants

Transcription

1 PDH-Pro.com Installation, Operation and Maintenance of Central Boiler Plants Course Number: ME PDH: 9 Approved for: AK, AL, AR, GA, IA, IL, IN, KS, KY, MD, ME, MI, MN, MO, MS, MT, NC, ND, NE, NH, NJ, NM, NV, OH, OK, OR, PA, SC, SD, TN, TX, UT, VA, WI, WV, and WY New Jersey Professional Competency Approval #24GP North Carolina Approved Sponsor #S-0695 This document is the course text. You may review this material at your leisure before or after you purchase the course. In order to obtain credit for this course, complete the following steps: 1) Log in to My Account and purchase the course. If you don t have an account, go to New User to create an account. 2) After the course has been purchased, complete the quiz at your convenience. 3) A Certificate of Completion is available once you pass the exam (70% or greater). If a passing grade is not obtained, you may take the quiz as many times as necessary until a passing grade is obtained (up to one year from the purchase date). If you have any questions or technical difficulties, please call (508) or us at admin@pdh-pro.com. Telephone (508) Washington Street, Suite 159, Wellesley, MA

2 TM5650zyxwvutsrqponm TECHNICAL MANUAL C ENTRAL BO ILER PWNTSzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPON 1 Approved for public release; distribution is unlimited HEADQUARTERS, DEPARTMENT OF THE ARMY OCTOBER 1989

3 TM TECHNICAL MANUAL No HEADQUARTERS DEPARTMENT OF THE ARMY CENTRAL BOILER PLANTS CHAPTER 1. Section I. Section II. Section III. CHAPTER 2. Approved for public release; distribution is unlimited. Paragraph GENERAL CONSIDERATIONS Introduction Purpose...l-l l-l Central Boiler Plants...zyx 1-2 l-l Equipment...l Elementary Combustion Principles. Fossil Fuels...zyx Combustion......l Combustion of Coal Combustion of Oil Combustion of Natural Gas Soot and Smoke Flue Gas Analysis and Temperature Combustion Efficiency Boiler Efficiency Central Boiler Plant Efficiency Principles of Steam and Hot Water Generation Basic Principles Heat Transfer DESCRIPTION OF EQUIPMENT Section I. Section II. Section III. Boilers and Heat Exchangers Boiler Classifications Boiler Design Requirements Fabrication Fire Tube Boilers Water Tube Boilers Hot Water Generators Economizers Air Heaters Boiler Accessories and Fittings ASME Requirements Gage Glass, Gage Cocks Water Columns Pressure Gage, Temperature Gage Safety Valves Boiler Outlet Valves Blowoff Valves and Piping Fusible Plugs Sootblowers Fuel- Handling and Combustion Equipment T his Manual Supersedes TM 5-650, dated August 1962 and rescinds TM 5-651, dated December i

4 . Figure No. Title Page 1-4 Combustion of Oil...z Combustion of Coal Combustion Efficiency Motor Elementary Boiler Water Circulation Effects of Soot and Scale on Heat Transfer Tube Expander Flared and Beaded Tubes Scotch Boiler Two, Three, and Four Pass Scotch Boiler Designs Horizontal Return Tubular Boiler Four Drum Water Tube Boiler Refractory Expansion Joints Water Wall Construction Steam Drum Internals Superheater in Two Drum Boiler Package Boiler Configurations D Package Boiler Hot Water Generator Hot Water End Uses Hot Water Distribution Bare Tube Economizer Extended Surface Economizer Cold End Corrosion - Minimum Metal Temperatures Tubular Air Heater Regenerative Air Heater Water Gage Glass Water Column Safety Valve Installation Huddling Chamber Safety Valve Outside Screw and Yoke Gate Valve Non-ReturnValve Slow-Opening Blowdown Valve Set Fire Tube Cleaning System Fixed Position Mechanical Sootblower Underfeed Stoker Power Dump Grate Spreader Stoker Underfeed Spreader Traveling Chain Grate Stoker Vibrating Grate Stoker Fluidized Bed Fire Tube Boiler Coal Handling System Types of Bucket Elevators Weigh Larry Pneumatic Ash Handling System Hydraulic Ash Handling System Steam Atomizer... T Rotary Atomizer Register Burner Low Excess Air Burner Arrangement of Above-Ground Fuel Oil Tank Underground Fuel Oil Storage Tank ii

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6 TM Section IV Section V. Section VI. CHAPTER 3. Section I. Section II. Paragraph Coal Combustion Equipment Coal-Handling Equipment Ash-Handling Equipment Oil-Firing Equipment Oil Storage and Handling Gas-Firing Equipment Liquified Petroleum Gas Controls and Instrumentation Feedwater-Drum Level Controls Combustion Controls Boiler Safety Control Additional Controls and Instrumentation Water Treatment Control Pollution Control Equipment Pollution Regulations Types of Pollutants and Control Methods Mechanical Collectors Fabric Filters Electrostatic Precipitators Wet Scrubbers Auxiliary Equipment... Feedwater Heaters Pumps and Injectors Forced Draft Fans Induced Draft Fans Stacks, Flues, and Ducts Steam Turbines Electric Motors Electrical Equipment Variable Speed Drives Air Compressors Steam Traps Piping Systems Page OPERATION Preliminary Operating Procedures Plant Operation Considerations Standing Operating Procedures Daily and Monthly Boiler Plant Operating Logs Inspection Applicable Codes Basis for Comments Preparation for Startup Starting Fire Warm-up Time Placing a High Pressue Steam Boiler in Service Placing a Hot Water Boiler in Service Operating Adjustments and Procedures Boiler Operation Maintaining Pressure or Temperature Feedwater and Boiler Water Treatment

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8 TM Section II. Paragraph Responsibility Inspection Housekeeping Utilities Inspection and Service Records Tools Spare Parts Special Supplies Scheduled Preventive Maintenance Scheduling and Use of The Information...zy Boilers Economizers Air Heaters Water Columns...i Safety Valves Fusible Plugs...zy Sootblowers Stokers Pulverized Coal Equipment Coal Handling Equipment Ash Handling Equipment Oil Burners Oil Handling Equipment Gas Burners Feedwater Drum Level Controls Combustion Controls Boiler Safety Controls Instrumentation Mechanical Collectors Stacks Zeolite Water Softeners Hot Lime-Soda Softeners Deaerating Heaters and Dearators Pumps Centrifugal Pumps Reciprocating Pumps Steam Injectors Steam Turbine (Non-Condensing) Air Compressors Steam Traps Electric Motors Forced-Draft and Induced-Draft Fans Command Inspections Technical Inspection Major Army Command Inspections Page APPENDIX A. APPENDIX B. REFERENCES...A-1 CHEMICAL ANALYSIS PROCEDURES External Treatment Plants...B-l Boiler Water B-2 Miscellaneous Tests B-3 A-l A-3 A-4 A-10 vi

9 TM APPENDIX C. APPENDIX D. Paragraph HEAT BALANCE CALCULATIONS 100 PSIG Steam Heat Balance...C-l 15 PSIG Steam Heat Balance...C-2 High Temperature Water Heat Balance...C-3 BOILER WATER CALCULATIONS Boiler Blowdown Calculations...D-I Determining Feedwater Requirements...D-2 Determining Makeup Requirements...D-3 Determining Chemical Treatment Requirements... D-4 A-11 A-13 A- I5 A-17 A-17 A-17 A- 19 LIST OF TABLES Table No. l-l l Title Page Classification of Coals Standard Specification for Fuel Oils Fuel Oil Characteristics Combustion Efficiency for Natural Gas Combustion Efficiency for Number 2 Oil... I-19 Combustion Efficiency for Number 6 Oil Combustion Efficiency for Coal, 3.5 Moisture, Bituminous Combustion Efficiency for Coal, 9.0% Moisture, Bituminous Water/ Steam Characteristics Water/ Steam Mixtures Typical Point Source Emission Levels for Various Pollutants Comparison of NOx Reduction Techniques Performance Characteristics of Flue-Gas &sulfurization Systems Performance Characteristics of Particulate Control Devices Characteristics of Mechanical Dust Collectors Removal Efficiencies of Uncontrolled Particulate Emissions from Combustion Process... Permissible Maximum Suction Lits and Minimum Suction Heads in Feet for Various Temperatures and Altitudes... Piping Codes and Standards for Boiler Plants Typical Piping Material Applications Flue Gas Analysis at 25%, 50%, and 100% Load for Natural Gas, No Oil, No. 6 Oil, and Stoker Coal... Common Cations and Anions... Water ph... Guide for Selection of External Treatment Equipment y... Common Sodium Phosphates... Deaerator Temperature Versus Pressure... Lubricating Oils, Greases, and Preservatives... Lubricating Oil and Grease Uses LIST OF FIGURES Figure No. Title Page l-l 100 psig Steam Heat Balance psig Steam Heat Balance High Temperature Water Heat Balance vii

10 Figure No a 2-105b a 2-109b a 2-125b Title Multicyclone Configuration... Cyclone Fractional Efficiency Curve...;... Reverse Flow Baghouse Pulse Jet Baghouse... Weighted Wire Type Electrostatic Precipitator... Wet Approach Venturi Scrubber... Tube and Shell Heat Exchanger... Maintain Proper Slope to Suction Line... Suction Line Installation... Centrifugal Pump... Reciprocating Piston Pump... Two Methods of Providing Lost Motion... Rotary Screw Pump... Rotary Gear Pump... Steam Injector... Forced Draft Fan with Inlet Damper... Typical Outlet Fan Dampers....:.... Fan Curves for Different Inlet Vane Positions... Fan Curve for Fan with Outlet Damper... Single-Stage Impulse Non-Condensing Turbine... Thermostatic Steam Trap... Float and Thermostatic Steam Trap... Disc/ Thermodynamic Steam Trap... Inverted Bucket Steam Trap... Standard Hanger Types for Piping Systems... Sdid Wedge Disc Gate Valve... Single Port Globe Valve... Non-Lubricated Plug Valve... Butterfly Valve... Swing Check Valve... Y-Type Spring Lift Check Valve...d.. Daily Boiler Plant Operating Log... Monthly Boiler Plant Operating Log... Gil viscosity versus Temperature...<...a...?... Smoke Density versus Percent Oxygen... Fuel/Air Ratio Biasing... Boiler Efficiency versus Load Condensate Pipe Corrosion... Boiler Tube Failure Caused by Scale... Superheater Tube Showing Carryover Deposits... Effects of Treatment on Raw Water... Sodium Zedite Softener...Z...!... Hot Process Lime Soda Softener... Hot-Lime Hot-Sodium Zedite Softener... Hydrogen and Sodium Zeolite Softeners Operating in Parallel... Hydrogen Zeolite with Alkaline Neutralization... Degasifier/ Decarbonating Tower... Sodium Zedite-Chloride Ion Exchanger System... Dcmineralizer... Tray Deaerator... Spray Deaerator... Type I Deaerator Installation... Page viii

11 TM Figure No C-l c-2 c-3 D-l D-2 Title Type II Deaerator Installation.... Type III Deaerator Installation... Blowdown System with Flash Tank and Heat Exchanger... Automatic Continuous Blowdown Controls... Conductivity Meter... Boiler Water Treatment Operating Log... Water Cooled Sample Cooler... Condensate Corrosion Tester... Zeolite Softener Water Flows... Effect of Excessive Water Flow Bates... Zeolite Bed Inspection Points... Solubility of Oxygen in Water... Pressure Pot Feeder... Automatic Proportioning Feeder... Chemical Mixing Tank with Chemical Feed Pump... Chemical Feed Pump Plunger/ Diaphragm Type... Eyewash Station... Safety Shower... Wet Storage Method... Record Card Example psig Steam Heat Balance psig Steam Heat Balance... High Temperature Water Heat Balance... Example of Boiler Feedwater, Steam Generation and Blowdown Relationships... Example of Boiler Calculations... Page

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