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

Plant OPS

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

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

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

Math & Physics Mercury Manometers

Math & Physics

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

Math & Physics http://home.earthlink.net/~mmc1919/venturi.html

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

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

Math and Physics

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.

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

Math & Physics

Math and Physics

Math & Physics

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.

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

Math & Physics

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

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

PSIG = PSIA + 14.7 Math & Physics

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

Air Compressors

Air Compressors Intercooler cool the stage air

Air Compressors High temperature is necessary

Air Compressors

Gauges

Gauges Siphon loop

Gauges

Gauges One is required

Gauges

Softeners Convert Calcium and Magnesium to Sodium. Ion exchange process

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

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

Pumps

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

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

Pumps

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

Pumps

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.

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

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

Valves

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

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

Valves You need to know what a Maxim Valve is.

Valves What does a safety Valve do?

Valves How is a Relief valve rated?

Valves What is an Automatic non-return valve.

Valves Main steam lines should be valves

Valves How should an accumulation test be done?

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.

Valves How can valves be attached to boilers?

Valves What is an accumulation test

Valves How do you test a safety valve

Valves What is the most important fitting on a boiler?

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

Induced draft fan

Draft

Boilers

Boilers Boiler light-off procedures

Boilers

Know boiler start sequence Boilers

Boilers

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

Boilers Know the components of a water wall system

Boilers Discuss startup procedures

Boilers Which is more dangerous a fire or water tube boiler

Boilers Which boiler is most likely to explode

Boilers

Define low pressure Boilers

Locate the vent Boilers

Identify the fire side of a boiler Boilers

Boilers Discuss boiler inspection procedures

Boilers

Boilers How do we measure boiler capacity

Boiler Accessories How do thermocouples work?

Boiler Accessories

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

Boiler Accessories How hot can the blowdown be entering the sewer

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

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

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

Boiler Accessories

Boiler Accessories What are the start of shift procedures

Boiler Accessories

Boiler Accessories What accessories improve boiler efficiency

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

Boiler Accessories

Pre heater troubleshooting

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

Boiler Accessories

Boiler Accessories Where does an open feed water heater sit?

Boiler Accessories

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.

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

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

Boiler Accessories Where is a single element feedwater regulator located?

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.

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

Boiler Water Treatment What causes boiler corrosion?

Boiler Water Treatment TDS 2000 to 35000

Boiler Water Treatment What causes corrosion

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

Boiler Water Treatment

Boiler Water Treatment What is a good boiler PH

Boiler Water Treatment What should the condensate PH be?

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

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

Boiler Water Treatment What would a faulty DA tank cause?

Boiler Water Treatment What do Sulphites do?

Boiler Water Treatment When should you blowdown a boiler

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.

Boiler Combustion What controls combustion air?

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

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).

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.

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

Boiler Combustion What causes furnace explosions

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

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

Misc Oil gets thinner as it gets hotter.

Misc Oil gets thicker when cold

Misc Gear pumps pump fuel oil to the burners

Misc Glass thermometers have limited range.

Misc What effects fuel storage

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

Misc How often should a motor be lubricated

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