Q&A (54-90) Part-4

IBCI (Indian Best Coaching Institute)
Boiler Engineering-Q&A
Q54.How does the boiler feed water temperature affect the super heated steam temperature?
Answer : Following factors affecting in the said case :
1. The mean temperature of heat addition is decreasing which in fact is the temperature at which
the heat is added.
2. The time which is taken to flash into steam at the constant pressure is more, which results
increment in the circulation ratio a bit.
3. The retention time of fluid is increased, resulting in more heat gain in a given time.
4. As Feed Water temperature is less so we need to fire more amount of coal, resulting more flue
gas which ultimately have an increased heat flux for tube area so steam temperature is high.
Q55.Why does silica slippage in the treated water of dmplant occur?

Answer :
If the SAC exhausts before the SBA then there will be a rise in
conductivity
Sodium slips from SAC unit before silica slips from SBA unit
Can safely use conductivity as indication of exhaustion to initiate
regeneration
But what happens as the anion resin ages or becomes fouled?
Plant is no longer cation limited
The SBA exhausts before the SAC and there will be a slight fall in
conductivity followed by a sharp rise in conductivity
By which time silica will already be slipping.
Q56.Which safety valve should blow first, the super heater safety valve or drum safety valve? And
why?
Answer : Super heater safety valve should blow first because lower setting to be done of super heater
safety valve to avoid any starvation in super heater tubes. Starvation of super heater tubes means the
overheating of super heater tubes during the absence of steam flow through super heater tubes. To avoid
such kind of incident it has been recommended as per IBR norms that super heater safety valve setting to
be lower in any case with respect to drum safety valve.
Q57.How does excess gas volume affect the performance of esp?what are the reasons for excess
gas volume?
Answer : Significant variations in oxygen may indicate large swings in the gas flow rate that may
decrease ESP performance and indicate the need to routinely determine ESP gas volume. Low SCA
values, high velocities, short gas treatment times (5 seconds or less), and much higher oxygen levels at
nearly full load conditions are indicators that excess flue gas flow rate may be causing decreased ESP
performance.
Q58.What do you understand by the term cluster porosity? How it can be eliminated?
Answer :
Cluster porosity has pores grouped locally with irregular distribution, deriving frequently from faulty
start or stop of welding arc, or from arc blow. Cluster porosity can be eliminated by deriving smooth
operation of welding by regular distribution of fusion metal and through proper starting and stoppages
of welding arc.
Q59.Write short notes on LTSH,DPSH and PSH related to 500MW power plant.
Answer : 500MW super heater is in three stages composed of
LTSH=Low temperature super heater
DPSH=Divisional Panel super heater
PSH=Platen super heater
The PSH is located on horizontal gas path, above furnace real arch tubes and consists of 47.63mm ID
assemblies spaced on 762 cntres. Total heat surface area is 1458sq mtr.
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The DPSH is located between front wall and pendant platen section. It is composed of 6front and 6 rear
panel assemblies made from 44.5mm OD tubes. Total heat surface area is 1362sq mtr.
The LTSH is located in the second pass above economizer, consist of 116 assemblies of 51OD tubes
spaced on 152.4mm centres across the width of furnace. Total heating surface area is 9620sq mtr.
Q60.Principal types of pulveriser used in power plant? Explain working principle of bowl mill. List
any three factors affect the performance of the mill with reasons?
Answer :Regarding pulveriser please refer Soft copy Part-E(PDF Power Plant Engineering )Book page
No-178 to 184.Regarding Mill firing please refer Part-B page no-20(Hard copy).
Q61.convert
160delta f to--------------delta0c
8N/mm2 to---------------Mpa
40 Hp to ------------------Kcal
650mmwc to -----------Kg/cm2
Answer :
160delta f =71 delta0c
8N/mm2 =0.81Mpa
40 Hp =25648Kcal
650mmwc=0.88Kg/cm2
Q.62 What is Scale Formation ?

Answer : Scale formations in boilers are responsible for lost efficiency, increased maintenance and
operating costs not to mention lost revenue due to outages and downtime. Most scale formations in
boilers can be traced to the presence of hardness in the make-up water. This hardness reacts in the high
temperatures environment within the boiler to form and insoluble scale. This insoluble scale coats the
heat transfer surfaces, acting as an insulator to impede heat transfer.
Hardness isn't the only cause if scale formation in boilers, other impurities such as iron, silica, copper, oil,
etc. are often found in samples of boiler scale. In fact, it is rare to find scale which isn't the result of
several of these impurities.
Normally pre-softening the water before feeding it to the boiler is the first step in eliminating scale
formations. Even when the make-up is soft, there is still a need for chemical scale inhibitors inside the
boiler. With proper treatment the problems of lost efficiency, tube damage and lost production can be
avoided or greatly reduced. Proper treatment requires the right balance of chemical treatment and
control.
Q.63 How do I stop Scale Formation from happening ?

Answer : The first and foremost aspect of stopping scale formation is to have a good idea of the make-
up water that is feeding your system. If you aren't sure, have a certified laboratory complete a fully
analysis on this water so you can make an informed decision on what exactly the potential problems you
may encounter.
After determining these specific aspects of your make-up water then your water treatment expert can
guide you through a program that fits your situation.
Just a few items that may be of concern when putting together a good water treatment program for your
boiler. A complete program will include sludge build-up, pH levels, oxygen removal, condensate
treatment, and alkalinity levels.
Q.64 What is corrosion ?

Answer : Corrosion in boilers can almost always be traced to one or both of two problems. The most
common cause is dissolved oxygen entering the system via the feed-water. The oxygen causes very
localized corrosion to occur in the form of pitting. The pits are small but deep pinpoint holes which
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eventually can penetrate tube walls and cause their failure. Another common cause of corrosion in boiler
systems is low pH within the boiler. This reduced pH may result from carbon dioxide infiltration or form
contamination by other chemicals.
Oxygen corrosion is normally controlled by driving the oxygen from the feed-water in a deaerating heater
or by chemically removing it with an oxygen scavenger such as sodium sulfite.
There are many contaminates which can infiltrate a boiler system and cause low pH levels to develop.
Manufacturing wastes such as sugar or acids from plating operations which can be returned to the boiler
with condensate can be a source of problems because they concentrate in the boiler. Oxygen can
infiltrate the boiler system at virtually any point. When dissolved, oxygen is present in boiler feed water
attach on feed lines, pumps and economizers can be expected. The severity of the attach depends upon
the concentration of the oxygen and the temperature of the water.
Q.65 How do I stop Corrosion ?

Answer : You can use a deaerator which is defined as a piece of equipment which heats water with
steam to insure essentially complete removal of dissolved gases. There are several types of deaerator
available, each having its own advantages and disadvantages.
Internal treatment for dissolved oxygen corrosion is normally accomplished by the addition of sodium
sulfite. Most oxygen scavengers contain a catalyst which speeds the reaction of the sulfite with the
oxygen. In systems equipped with a deaerator the sulfite should be fed to the storage tank of the
deaerator or to either the suction or pressure side of the feed water pump. In systems which do not have
a deaerator, the sulfite can be fed at almost any point in the feed water system, including the condensate
tank.
Internal treatment for carbon dioxide is normally accomplished by the use of a volatile amine. "Amine"
refers to any of a number of chemicals derived from ammonia. There are two major groups of amines in
practice as water treatment chemicals today. There are normally referred to as "neutralizing amines" or
"filming amines" depending upon whether they neutralize the acid formed by carbon dioxide or form a
protective film on the metal.
Filming amines do not neutralize the carbonic acid which forms in condensate systems. Instead, they
form a film on the metal which is non-wettable, or impervious to water. this protective film prevents the
corrosive impurities from contacting the metal.
Neutralizing amines function by increasing the pH of the condensate. Normally they are fed at such a
rate that the pH of the condensate is maintained slightly above 7.0. Satisfactory reduction of carbon
dioxide corrosion is possible with the use of a neutralizing amine. it is necessary to supplement this type
of condensate protection with an oxygen scavenger to remove dissolved oxygen.
Whether condensate corrosion is controlled by chemical treatment or a combination of mechanical and
chemical methods, it is important that careful checks and testing be incorporated as a part of the
treatment program. No treatment can be better than the way in which it is applied. Consult a water
treatment expert to get you started on the right foot.
Q.66 Why all the concern about Condensate Treatment and Monitoring ?
Answer : You Condensate is very important to your facilities overall operation, ignoring this unseen
component will soon cause failures costing bottom-line dollars. Therefore, condensate must be treated
with the proper chemistry. Treating your plants steam condensate is critical for several reason, but
these are the most important two reasons:
1. To insure the integrity of your equipment.
2. To keep the amount of condensate corrosion minerals that are returned to the boiler's
makeup water in check.
Corrosion in your steam lines occurs when the carbonic acid builds up and begins to breakdown the
metallic surfaces throughout the system. When the Carbonic acid is allowed to build, localized attacks
occur due to the simple increase in CO2, which is the breakdown product of carbonate alkalinity in the
boiler, condensing with water to form H2CO3. This results in the "pitting" of condensate piping, which
usually shows up by visual leaks at threaded junctions. Oxygen pitting occurs as steam condenses and
the vacuum created pulls air into the system. Due to the localized nature of oxygen pitting, it can cause

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relatively quick failure in a condensate system.
The most common method of dealing with this problem is through the use of neutralizing amines. These
chemicals, better known as morpholine and cyclohexylamine, neutralize the carbon acid, and increase
the pH of the condensate. Corrosion of mixed metallurgy condensate systems is minimized when the pH
is maintained between 8.8 and 9.0. Due to high alkalinity in boiler makeup water elevating the pH to this
level may not be economical. In this case the pH should be maintained at 8.3 or higher, or a filming amine
applied.
A filming amine, such as octyldecylamine, provides a non-wettable protective barrier against both
carbonic acid and oxygen. When utilizing a filming amine, the pH is usually maintained between 6.5 and
7.5, so a neutralizing amine may still be required.
In order to minimize oxygen pitting one can utilize a filming amine as previously mentioned, or a volatile
oxygen scavenger such as DEHA (diethylhydroxyamine.) DEHA provides better results as it scavenges
oxygen and passivates or coats the condensate system, making it less susceptible to corrosion.
Depending on the treatment method chosen, condensate monitoring can vary. In all cases the following
tests should be performed.
1. Soluble and insoluble iron levels.
2. pH levels at various points in your steam condensate system. It is extremely important that pH
measurements be made on cooled samples. If the sample is taken hot, carbon dioxide will gas off, which
results in artificially high pH measurements.
If a filming amine is utilized, the residual should be measured. The same is true if DEHA is used as
an oxygen scavenger. In the latter case, a residual of 100 to 150 ppb is usually targeted. Note that
this may take time (as much as 6 months) since much of the DEHA will be consumed passivating
the system.
Q.67 How do I to Prevent the Most Common Boiler Problems ?
Answer : A regular inspection schedule is critical and should cover four areas: boiler,
burner, controls, and system.
Preventive maintenance is the most widely used means of minimizing common problems in
boilers. Unfortunately, most maintenance programs do not properly address the needs of the
boiler and its related systems. Statistics indicate about two-thirds of all boiler failures and nearly
all unscheduled shutdowns are caused by poor maintenance and operation. Regardless of
boiler design, application, or size, the basic maintenance criteria remain the same.
1.Maintaining the Boiler

There are eight primary areas of the boiler itself that should he examined or inspected regularly.
(i) Water level. The most important maintenance inspection is to check the boiler water level daily.
Insufficient water causes pressure vessel damage or failure. At a minimum, steel in the pressure
vessel could overheat. The condition could change the pressure withholding capabilities of the
vessel, necessitating vessel repair or replacement. More seriously, a low water level could damage
the equipment or building. or even cause personal injury.
(ii) Boiler blow down. Steam boilers should be blown down daily to maintain recommended dissolved
solids levels and to remove sludge and sediment. Hot water boilers generally take on no makeup
water and, therefore do not need to be blown down.As the boiler takes on makeup water the solids
concentration builds up. Solids accumulate in either dissolved or suspended form. Unless they are
controlled dissolved solids promote carryover of water with the steam causing water hammer and
damaging piping, valves, or other equipment. Carryover also raises the moisture content in the steam,
affecting proper operation of equipment that uses steam.
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(iii) Suspended solids, which cause sludge or sediment in the boiler, must be removed because they
affect the heat transfer capabilities of the pressure vessel. Sludge buildup leads to problems ranging
from poor fuel-to-steam efficiency to pressure vessel damage.
(iv) Water column blow down. Water columns on steam boilers should be blown down once each shift
or at a minimum once a day. This action keeps the column and piping connections clean and free of
sediment or sludge. The water column also must he kept clean to ensure the water level in the gauge
glass accurately represents the water level in the boiler. The gauge glass and tricocks connected to
the water column are the only means of visually verifying boiler water level.
The low-water cutoff should be checked once a week by shutting off the feed water pump and
letting the water evaporate under normal steam conditions at low fire. The gauge glass should he
observed and marked at the exact point at which the low water cutoff shuts down the boiler. The
test verifies operation of the low-water cutoff under operating conditions. The low-water cutoff also
should the removed and cleaned every six months.
(V) Water treatment. Proper water treatment prolongs boiler life and ensure safe and reliable operation.
Treatment programs are designed around the quality and quantity of raw water makeup and system
design. They should be directed by a qualified water management consultant. Flue gas temperature.
Flue gas temperature is a good indicator of boiler efficiency changes. The temperature should be
recorded regularly and compared to those of a clean boiler under the same operating conditions.
Accurately determining the affect on efficiency requires that the firing rate and operating pressure be
the same. A rise in flue gas temperature usually indicates dirt on the fireside of the boiler or scale on the
waterside. As a rule of thumb a 40-deg F rise in temperature reduces boiler efficiency 1% The cost
of fireside cleaning should be compared to those of lower operating efficiencies to determine the
minimum temperature rise at which the fireside should be cleaned. Other factors also affect flue gas
temperature. For example, a rise in stack temperature may indicate a baffle or seal in one of the
boiler's passes has failed.
(Vi) Waterside and fireside surfaces. Waterside and fireside surfaces should be inspected and cleaned
annually. A visual inspection provides an early warning that the vessel needs repair or water
treatment or that combustion needs adjustment. Inspecting and cleaning water-column connections
should receive special attention. Soot in the breeching is a fire hazard and can cause severe
combustion-related problems.
(vii) Safety valves. Safety valves are the most important safety devices on the boiler They are the last
lineof defense for protecting the pressure vessel from overpressure. Once a year. operating pressure
should be tested by bringing the relief valve to its setting. Valves should pop and reseat according to
the valve stamping.
(viii) Refractory. Refractory protects steel not in direct contact with the water from overheating. It also
helps maintain proper burner flame patterns and performance. If the boiler remains on all the time,
refractory should be inspected twice a year. If the boiler cycles more frequently or is turned on and
off daily, refractory should be inspected more often.Heating and cooling refractory a lot shortens its life
considerably. It cracks and eventually fails. Hot spots on the steel that the refractory protects indicate
refractory or gasket failure. If a hot spot is found, the cause should be determined and repaired
immediately to prevent the steel from failing.
2. Maintaining the Burner

Although burners vary by design, application, fuel, regulations, and insurance requirements, the same
basic maintenance criteria must be addressed. Burner maintenance generally focuses on safety.
efficiency, and reliability. Adjustments should be made only by a trained service technician using the
proper instrumentation and tools.

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(i) Combustion. Poor combustion is unsafe and costly. Changes in combustion air temperature and
barometric pressure, for example, impact burner performance (see table). Low excess air levels
result in incomplete combustion, sooting, and wasted fuel. High excess air levels raise stack
temperatures and reduce boiler efficiency. Maintaining steady excess air levels with an oxygen trim
system helps ensure optimum efficiency at all times.
Visually inspecting combustion is the easiest way to detect changes that affect safety and efficiency.
Changes in flame shape, color, and sound are among early indicators of potential
combustion-related problems. Changes may be due to:
1.Large fluctuations in ambient temperatures
2. Changes in fuel temperature, pressure, heating value, or viscosity
3. Linkage movement dirty or worn nozzle
4. Dirty or distorted diffuser dirty fan
5. Dirt on the boiler fireside
6. Furnace refractory damage.
Visual combustion inspection should be compared to flame characteristics observed at similar firing
rates with efficient combustion. However, combustion efficiency is verifiable only with a flue gas
analyzer. Even if a flame appears to be good, it should be checked with an analyzer and adjusted
once a month.
(ii) Fuel and air linkage. Changes in fuel and air linkage affect the combustion fuel-to-air ratio. Flame
failure or a hazardous fuel rich condition may result. Proper linkage settings should be physically
marked or pinned together. Linkage should be checked for positioning, tightness, and binding. Any
noticeable changes should be remedied immediately.
(iii) Oil pressure and temperature. Pressure and temperature directly affect the ability of oil to properly
atomize and burn completely and efficiently. Changes promote flame failure, fuel-rich combustion,
sooting, oil buildup in the furnace, and visible stack emissions. Causes include a dirty strainer, worn
pump, faulty relief valve, or movement in linkage or pressure-regulating valve set point. Oil
temperature changes typically are caused by a dirty heat exchanger or a misadjusted or defective
temperature control.
(iv) Gas pressure. Gas pressure is critical to proper burner operation and efficient combustion. Irregular
pressure leads to flame failure or high amounts of carbon monoxide. It may even cause over or
under firing, affecting the boiler's ability to carry the load. Gas pressure should be constant at steady
loads, and should not oscillate during firing rate changes.
Usually, pressure varies between low and high fire. Therefore, readings should be compared to
those taken at equivalent firing rates to determine if adjustments are needed or a problem exists.
Gas pressure irregularities are typically caused by fluctuations in supply pressure to the boiler
regulator or a dirty or defective boiler gas pressure regulator.
(v) Atomizing media pressure. When oil is burned, an atomizing medium, either air or steam, is needed
for proper, efficient combustion. Changes in atomizing media pressure cause sooting, oil buildup in
the furnace, or flame failure. Changes result from a regulator or air compressor problem or a dirty
oil nozzle.
(vi) Fuel valve closing. If a fuel valve leaks, after burn may occur when the burner is turned off, or raw
fuel could leak into a hot boiler and cause an explosion. When the burner is turned off, the flame
should extinguish immediately. Prolonged burning is a hazard and demands immediate action.
3. Maintaining the Controls

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Controls are often used to protect the boiler against unsafe operation. Flame safeguard, operating,
limit, and safety interlock controls are among the most common. Of course, controls only protect
the boiler if they are maintained and adjusted properly.
(i) Flame safeguard control. Also called the primary control or the programmer, the flame safeguard
control ensures safe light-off, operation, and shutdown of the burner. The control regulates purging
the boiler of all gases prior to trial for ignition. It also verifies that there is no flame in the boiler prior
to lightoff, and checks for a pilot before allowing the main flame to light. The control provides proof
that the main flame has ignited before releasing the boiler to the run (modulation) mode. Most
importantly it does not allow any action to occur if operating controls, limits, or safety interlocks are
open.
In addition, this control initiates a post purge upon shutdown to remove all gases from the boiler.
And it often provides a means for detecting a problem elsewhere in the system. Although the flame
safeguard is designed for fail-safe operation and is quite reliable, a faulty device can be catastrophic
and should not be ignored.
(ii) Operating and limit controls. These controls tell the boiler at what temperature and pressure to
operate. Proper settings minimize boiler cycling, maintain proper limits for efficient system operation,
and ensure the boiler shuts down when predetermined limits are reached.
Improperly set operating controls cause the burner to operate erratically and stress the pressure
vessel. All these controls should be checked weekly. The scale of the control for temperature or
pressure settings should not be relied upon. Settings should be verified with the actual operating
temperatures and pressures on the boiler gauges.
(iii) Safety and interlock controls. Safety and interlock controls vary with state, local, and federal codes
and insurance requirements. They must be operational at all times. Among the consequences of
inoperable safety interlocks are personal injury, equipment or property damage, and liability for
losses or damages. All interlocks should be checked weekly for proper operation. A defective
control should be replaced immediately. A control should never be bypassed to make a boiler run.
(iv) Indicating lights and alarms. Indicating lights and alarms are part of the control circuit. They alert
the operator to specific boiler conditions. Unfortunately, they are often neglected and do not provide
the intended information. Many control circuits have test buttons to verify proper operation. Circuits
that do not should be checked by simulating conditions that activate a light or alarm.
4. Maintaining the System

All too often, when a boiler problem occurs, the system is overlooked. The emphasis falls on the
equipment and not the equipment's function in the overall system. An effective maintenance program
must be based on an understanding of the entire system and the function of each piece of equipment.
Only an understanding of the system provides the means for preventing the causes of system-related
problems and reducing the time spent on the symptoms.
(i) Operating conditions. Operating parameters of the boiler room system should be recorded daily.
The data provide a means for evaluating boiler operation trends that affect efficiency, downtime, and
maintenance planning. The following data should be recorded.
(ii) Feed water pressure/temperature. Changes in feed water pressure affect the system's ability to
maintain proper boiler water levels. A pressure drop may be caused by a leaky check valve on a
standby pump or a worn pump impeller. Changes in feed water temperature are indicative of a
problem in the deaerator, potential pump seal damage, loss in efficiency, dirty economizer, dirty
blow down heat recovery exchanger, or excessive or insufficient condensate returns.
(iii) Boiler water supply/return temperatures. On hot water systems, supply and return temperatures to
the boiler are a means for evaluating the system's effect on the boiler and vice versa. The desired
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operating temperature set point and temperature differential across the boiler should be evaluated
against the system design to determine if a potential problem exists. High temperature differentials
caused by excessive load or a control malfunction could cause thermal shock and subsequently
pressure vessel damage.
(iv) Makeup water use. Records of the amount of makeup water used help determine the presence of
leaks or losses in the system. They also assist in developing a more effective chemical treatment
program. Excessive water use indicates a change in system operation and, therefore, a change in
efficiency.
(v) Steam pressure. Steam pressure operating set points usually are based on system design and type
of steam use. Pressure changes are typically caused by problems with control settings, burner
operation, boiler efficiency, or, most commonly, changes in steam demand.
(v) Leaks, noise, vibration, and unusual conditions. Checking for leaks, noise, vibration, and the like is
a cost-effective way to detect system operational changes. For example, a small leak is repaired by
tightening connections. By the time a leak becomes large, sealing surfaces usually are worn and
major repairs are needed.
A More In-depth Look

A maintenance program must focus on prevention to be an effective tool. Whether the maintenance
program is motivated by safety, cost, reliable operation, or all of these, it is the best means of
preventing common, boiler-related problems.
Automatic low-high water control equipment must be serviced on a daily basis when the boiler is in
operation. A high frequency of boiler failures is the result of low water, and can be attributed to a careless
boiler operator. A procedure must be established at your school to regularly clean the glass gauge
column by "blowing down" the column at the start of the school day, during non-peak operating periods,
and at the conclusion of the school day or shift. This ensures ability to determine the level of water in the
boiler.
Low Water
A major reason for damages incurred to low pressure steam boilers is the low water within the boiler. If
the condition of low water exists it can seriously weaken the structural members of the boiler, and result in
needless inconvenience and cost. Low pressure boilers can be protected by installing an automatic water
level control device.
Steam boilers are usually equipped with automatic water level control devices. It must be noted, however,
that most failures occur due to low water on boilers equipped with automatic control devices. The water
control device will activate water supply or feed water pumps to introduce water at the proper level,
interrupt the gas chain and ignition process when the water reaches the lowest permissible level, or
perform both functions depending on design and interlocking systems. No matter how automatic a water
control device may be, it is unable to operate properly if sediment scale and sludge are allowed to
accumulate in the float chamber.
Accumulations of matter will obstruct and interfere with the proper operation of the float device, if not
properly maintained. To ensure for the reliability of the device, procedures must be established in your
daily preventive maintenance program to allow "blow-down" the float chamber at least once a day. Simply
open the drain for 3 to 5 seconds making certain that the water drain piping is properly connected to a
discharge line in accordance with local Codes. This brief drainage process will remove loose sediment
deposits, and at the same time, test the operation of the water level control device. If the water level
control device does not function properly it must be inspected, repaired and retested to guarantee proper
operation.
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Low Water Cutoff - Tests and Maintenance

There are two very effective tests for low water controls on steam boilers. The first is the quick drain. or
blow down test, which should be performed at a time other than a peak steam generating period. As the
water is drained from the column the firing sequence is interrupted, the low water alarm signal activates
and the boiler operation shuts down.
The second, and more costly method is the slow-drain test. By opening the blow down valves the water
level can be checked to determine the water level in the column, the gauge glass, and the boiler. The
boiler should shut down while you determine the level in the gauge glass.
As a safety precaution, the low water float chamber of hot water boilers should be tested daily, at the
beginning of the shift, at the end of the shift, and once during non-peak firing periods. Time of tests and
the boiler controls tested should be recorded on your Boiler Room Log.
Annually, or as required, a thorough inspection of all low water control parts shall be performed. The
annual inspection should include opening and cleaning the water chamber.
Feed Water Pumps

Old, worn and obsolete feed water pumps are sometimes overlooked as potential problems. A centrifugal
pump may have worn seal rings that allow the water to chum between the suction and discharge
openings.
An indicator of the latter problem is low pressure discharge. Also, by comparing the time it takes to raise
the boiler water level to a predetermined level or the time to empty the condensate tank to the time it
formerly required, it is possible to determine if a pump is operating properly. Also, a pump that operates
quietly does not mean it is functioning properly.
Overpressure
Safe operation of a boiler is dependent on a vital accessory, the safety valve. Failure to test the safety
valve on a regular basis or to open it manually periodically can result in heavy accumulations of scale,
deposits of sediment or sludge near the valve. These conditions can cause the safety valve spring to
solidify or the disc to seal, ultimately rendering the safety valve inoperative. A constantly simmering safety
valve is a danger sign and must not be neglected. Your preventive maintenance program includes the
documentation and inspection of the safety valve. A daily test must be performed when the boiler is in
operation Simply raise the hand operating lever quickly to its limit and allow it to snap closed. Any
tendency of a sticking, binding or leaking of the safety valve must be corrected immediately.
Steam trap -Care and Maintenance
Q.68 What are the steam trap care, maintenance & troubleshooting ?
Answer : Steam Traps
Care and Maintenance
Steam traps have play a very important role in steam distribution systems. The service performed by
steam traps is primarily to discharge condensate. Normally a steam trap can be easily and quickly
selected by considering only the average operating conditions. However, an exact analysis of these
conditions will give the proper data necessary for selecting the type and size for greater savings and
proper plant operation. After the careful selection of the steam trap, it must be properly installed, tested,
periodically inspected, cleaned and maintained to keep it operating efficiently.
Traps need cleaning periodically. A simple way to prevent dirt from entering is to drop a short length of
pipe vertically below the supply to the trap (called a dirt leg) which can be cleaned easily and frequently.
Traps can be seriously damaged by scale or pipe comings in lines. A good practice is to install strainers
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ahead of the traps which should be inspected and cleaned frequently.
Traps are subject to severe wear if steam blows through continuously. They should be inspected for worn
valve parts or a change in operating conditions.
When a steam trap fails to discharge, inspect the heating system and be certain that all units are drained
with separate traps, thus guarding against short circuiting, loss of energy, and reduction of operating
efficiency.
Traps operating under high pressure or superheated steam are often insulated in a manner similar to
adjacent pipe lines. In such instances, they shall be fitted with dirt pockets, test valves, and drains.
Steam traps installed in areas exposed to climatic conditions will lose heat if not insulated and may freeze
unless adequately protected. Discharge lines should be short and self draining and traps should be fitted
with a drain tapping and valves.
Steam traps handling large volumes of air require more frequent inspection and proper venting for
efficient operation. Vents shall be used to avoid air binding and ensure positive drainage. Gauge glasses
shall be kept in proper repair, for they indicate whether or not the trap is working. Periodic cleaning and
gauge glass replacement shall be considered as a high priority in the maintenance of steam traps.
All steam traps require protection from corrosion to prevent unnecessary deterioration. All valves, joints,
and gaskets should be kept tight to avoid steam leakage and ultimate energy losses. For continuous and
efficient operation. steam traps require periodic inspection and maintenance for purposes of eliminating
foreign matter and obstructions in supply and discharge lines. Each steam trap at an assigned work
station should be inspected as specified by the preventive maintenance program.
Troubleshooting
It is important to inspect the operation of steam traps frequently. There are many conditions under which
traps may fail to operate property. The following are some of the most common reasons for trap failures:
1. Condensate does not flow into the trap:

A. Obstruction in line to trap inlet.
B. Valves leading to trap are closed.
C. Bypass open or leaking.
D. Trap may be air bound.
E. Insufficient pressure to blow condensate through orifice.
F. Improper installation of trap.
G. Accumulation of foreign matter within the trap.
H. Trap held closed by defective mechanism.
I. Strainer may be blocked.
2. Condensate fails to drain from trap.

A. Discharge valve may be closed.
B. Trap may not be large enough to handle condensate.
C. Pressure may be too low to blow the condensate through.
D. Improper installation for draining.
E. Check valve may not be holding.
F. Obstruction in return line or the line may simply be too small.
3. Trap does not shut off.

A. Trap is too small for the condensate load.
B. Trap held open by defective mechanism,
C. Overload due to excessive boiler foaming or priming.
duration
D. Submerged steam coils leaking.
E. Differential pressure exceeds design of trap.
F. Scale or foreign matter lodged in orifice.
4. Steam blows through trap.

A. Valve mechanism does not close due to wear or defective valve.
B. Mechanism is held open by foreign matter.
C. Trap has not been properly primed or reprimed after clean-out or blow-off.
D. Bypass is open or leaking.
E. Excessive pressure for design of trap.
Q.69: How to improve poor boiler steam-fuel ratio and increase boiler efficiency?
Answer: For occasional low efficiency --- clean the burner tips and fuel oil pumps filters, check for
viscosity of fuel oil, burner tip holes and atomizing steam pressure. For continuously low efficiency -check
flame color & if the color of the flame is not bright golden yellow, combustion is poor. If stack temperature
is high, there is soot deposition in the boiler. Stop the boiler and carry out cleaning of the boiler. Check
water side deposition/ scale formation. If scale formation is observed, plan for cleaning the boiler with
appropriate method. Evaluate for installation of economizer and soot blowing frequency.
Q.70: Soot deposition in my boiler is heavy. How to reduce soot formation and deposition?
Answer: The reasons for heavy soot deposition are normally due to:
1. Poor quality of fuel with higher ash content metals, high insolubility and hence ensure good quality of
fuel.
2. Poor combustion; improve the combustion by checking Atomizing Steam pressure by cleaning burner
tip and fuel oil system filters and checking viscosity near burner tip.
3. Avoid mixing of different types of fuels.
Q.71 : Blow down losses are heavy, how to reduce blow down rate?
Answer:
1. Monitor boiler water treatment. All volatile treatment is better than conventional treatment if there is
techno-economic feasibility.
2. Check water treatment process for seepage of Chloride, Silica, etc. Check TSP quality for Chloride
content.
3. Fine control of CBD with increased frequency of Blow Down water will help in saving of energy & boiler
water.
Q.72: There is corrosion problem in the pressure parts on F.W. circuit, how to overcome the
problem?
Answer:
1. Check proper deaeration in the Deaerator. D.O.(Dissolved oxygen) should be less than 7 PPB.
duration
2. Maintain pH more than 9 in the CBD water.
3. Closely monitor TSP level in the CBD water.
4. Check feasibility of changeover of BFW treatment to AVT.
5. Verify for proper selection of oxygen scavenger if used.
Q.73: In my boiler, Burner tip choking is frequently ,How to solve it?
Answer:
To avoid frequent Burner tip choking, check for - poor fuel quality, improper fuel temperature/ viscosity at
Burner tip, high ash content in the fuel and passing of sludge particles through filter. Check for filter mesh
size.
Q.74: Chimney emits blackish smoke frequently, how to ensure proper stack emission?
Answer:
Blackish smoke for chimney indicates poor combustion or inadequate combustion air, take necessary
action to improve combustion and adjust fuel-air ratio. If ID and FD dampers are not free, the operation
will be sluggish and result in poor combustion during load variation. Rouse the damper.
Q75. How to laying boiler foundations?
Answer:
Digging the foundations for a wall is a physically demanding job that could take a couple of days, but it's
worth doing properly. The success of your wall will depend on the quality of your footings, so make sure
you get off to a good start.
You will need following terms to lay the foundation of boiler :---
Spade
Four pegs
String
Enough cement and ballast to make your concrete (for foundations, your concrete should be 1
part cement to 5 parts ballast)
Step-1 : Setting out :
For small walls your footings need to be 150 millimetres deep by 300 millimetres wide. However if you're
building a wall over a metre high, you'll need to check how big your footings should be.
Once you know how big your footings need to be, mark out the width and length of the trench with pegs
and string.
Step-2 : Digging the hole :

duration
Grab a spade and get digging. Try and cut out any tree roots you encounter and keep an eye out for
drains.
Step-3 : Filling the concrete :
Drive stakes into the trench at one metre intervals, with the depth of footing you're after marked on their
tops. Check them with a spirit level and then start to pour the concrete. Leave it to dry for a day and it's
ready to build on.
Q76. What are the steps or modifications to be done for conversion of oil fired boiler to fbc
boilers?
Answer:
Retrofitting of Boiler from one type to another type :

Every boiler is designed to burn a particular type of fuel and, conversely, the selected fuel type is an
important factor in the design of boilers. The major effects of fuel type on boiler design are the following:
- Furnace size
- Design, amount and location of heating surfaces (superheater, reheater, economizer etc.)
- Equipment to prepare and burn fuel
- Type and size of heat recovery equipment
- Flue gas treatment, ash handling and particulate control equipment.
Changes to be considerable according to all above facts.
For example i.e. conversion of oil to fbc boiler.

Following major changes has to be done.
1. Equipment to prepare burn i.e. oil burner will replaced by coal feeders/drag chain feeders/rotary
feeders.
2. Coal Bunker has to be provided along with coal handling plant
3. Ash handling system has to be provided.
4. Wind box provision has to be made.
5. DP Plate, coal nozzle & air nozzle provision has to be made.
6. Auxiliaries capacities has to be reviewed
Q77. What is the post weld heat treatment?
Answer : Post weld heat treatment is designed to return a metal as near as possible to its prefabrication
state of yield, ultimate tensile and ductility.The rate of temperature rise, holding time at temperature and
rate of cooling are vitally important. For this reason, furnace thermocouples must measure metal
temperature, not furnace atmospheric temperature.Heat treatment of any type must be a planned,
systematic action. Poorly performed heat treatment can result in far more harm to material than any good
which may result.Test coupons must be subjected to the identical conditions as the vessel or part in order
to obtain meaningful tensile and toughness (Charpy) test results.
Q78. What is the Dolachar ?
Answer : Dolachar is the non-magnetic reject material more offend form during the production of Sponge
iron (oxidation process of iron ore). Dolachar having very low GCV about 800 to 1200 Kcal/kg and having
very high content of ash. It may uses as fuel in few FBC boilers with adequately blended with coal about
3500 to 4500 kcal/kg of fuel. Dolachar having low VM which is demerits of this fuel. It is an alternative fuel
substitution of FBC boiler & cost wise economical to utilizing in such kind of boiler. Some medium and
small scale industry widely using thing fuel to sustainable growth of their organization. As a energy
security point of view it is recommended to use as max as possible.
duration
Q79. What is the Low water and high water causality ?
Answer : Low water is occurring starvation of boiler tube i.e. failure and weakening of boiler water tubes
& Higher water level is harmful for super heater tubes as well at for Turbine blades as a pitting effect on
blades. To avoid these causality lower and higher drum low tripping protection are provided all the water
tube boilers.
Q.80: WHAT ARE THE CODE RULES FOR RANGE OF PRESSURE SETTINGS FOR TWO OR MORE SYS ON A
HP STEAM BOILER?
Answer : Kindly study Part-E(7.Boiler Room Guide book).
Q.81: WHAT ARE THE DIFFERENT TYPES OF THE SAFETY RELIEF VALVE?
Answer :
The ASME / ANSI PTC25.3 standards applicable to the USA define the following generic terms:
Pressure relief valve - A spring-loaded pressure relief valve which is designed to open to relieve
excess pressure and to reclose and prevent the further flow of fluid after normal conditions have
been restored. It is characterised by a rapid-opening 'pop' action or by opening in a manner
generally proportional to the increase in pressure over the opening pressure. It may be used for
either compressible or incompressible fluids, depending on design, adjustment, or application.
This is a general term, which includes safety valves, relief valves and safety relief valves.
1. Safety valve - A pressure relief valve actuated by inlet static pressure and characterised
by rapid opening or pop action. Safety valves are primarily used with compressible gases
and in particular for steam and air services. However, they can also be used for process
type applications where they may be needed to protect the plant or to prevent spoilage of
the product being processed.
2. Relief valve - A pressure relief device actuated by inlet static pressure having a gradual
lift generally proportional to the increase in pressure over opening pressure. Relief valves
are commonly used in liquid systems, especially for lower capacities and thermal
expansion duty. They can also be used on pumped systems as pressure overspill
devices.
3. Safety relief valve - A pressure relief valve characterised by rapid opening or pop action,
or by opening in proportion to the increase in pressure over the opening pressure,
depending on the application, and which may be used either for liquid or compressible
fluid.
Q.82: WHERE & WHY ARE SELF LOCKING DOOR LATCHES REQUIRED ON FIRING DOORS?
Answer : A water tube boiler shall have the firing doors of the inward opening type, unless such doors
are provided with substantial and effective latching or fastening devices or are otherwise so constructed
as to prevent closed doors from being blown open by pressure on the furnace side. These latches or
fastenings shall be of the positive, self-locking type. Friction contacts, latches, and bolts actuated by
springs shall not be used. The foregoing requirements for latches or fastenings shall not apply to coal
openings on downdraft or similar furnaces. All other doors, except explosion doors, not used in the firing
of the boiler may be provided with bolts or fastenings in lieu of self-locking latching devices. Explosion
doors, if used and located in the setting walls within seven feet of the firing floor or operating platform,
shall be provided with substantial deflectors to divert the blast.
duration
Q.83: WHAT IS THE PURPOSE OF PRESSURE REDUCING OR PRESSURE REGULATING VALVE?WHERE
MIGHT YOU FIND ONE?
Answer : The purpose of a pressure regulating valve is to stop the flow of liquid or steam to a portion of a
closed circuit system. The valve protects a part of a system from higher pressure.
Following are the application area of PRV in a power station :
1. Auxiliary steam for gland sealing for turbine.

2. Auxiliary steam for SJE/Hogger.
3. Pegging steam for dearators.
4. Heating of Heavy furnace oil.
5. Atomization for oil burner.
6. Soot blowing operation of boiler.
7. For process use etc.
Q.84: WHY IS A DRAIN REQUIRED IN A WATER COLUMNN & WHY SHOULD IT BE ATLEAST 3/4 INCH
DIAMETER?
Answer : A drain required in a water column because a drain is needed to remove sendiment which
might block the lower connection and thus cause a false water level indicate.
The drain should be of at least inch in drain so that it does not easily become obstructed with
sendiments.
Q.85: WHAT IS THE PROTECTIVE COATING USED FOR IN A BOILER?
Answer : Magnetide layer is the protective layer in water tube boiler which is formed during the alkali
blowout (commissioning) of any water tube boiler. It is protecting from corrosion of internal surface of
boiler tubes which may lead to leakage/failure of tubes.
Q.86: WHAT WOULD HAPPEN IF A BAFFLE BROKE DOWN?
Answer : Baffle is used to uniformly distribution of Flame (Oil fired boiler) or Flue gas (Coal fired boiler).
Incase of break down of baffle distribution of flame/gas will be disturbed which may lead to erosion of
tubes.
Q.87 :WHAT ARE THE USUAL % OF EXCESS AIR IN BURNING THE VARIOUS COMMON FUELS IN
BOILERS?
Answer : To ensure complete combustion of the fuel used, combustion chambers are supplied with excess air.
Excess air increase the amount of oxygen and the probability of combustion of all fuel.
when fuel and oxygen in the air are in perfectly balance - the combustion is said to be stoichiometric
The combustion efficiency will increase with increased excess air, until the heat loss in the excess air is larger
than than the heat provided by more efficient combustion.

duration
Typical excess air to achieve highest efficiency for different fuels are
5 - 10% for natural gas

5 - 20% for fuel oil
15 - 60% for coal
Q.88: WHEN DOES A BOILER BECOME A HIGH TEMPERATURE HOT WATER (HTHW) UNIT?
Answer : HTWH(High temp hot water) is a kind of explosion of a conventional boiler that was caused by
low water level in the boiler. The massive destruction caused is an example of what can happen due to
explosion with conventional designs that are not properly maintained.
Q.89: IN WHAT MANNER IS THE QUALITY OF A WELD CHECKED?
Answer : Methods of weld testing and analysis are used to assure the quality and correctness of the weld
after it is completed. This term generally refers to testing and analysis focused on the quality and strength
of the weld, but may refer to technological actions to check for the presence, position and extent of welds.
These are divided into destructive and non-destructive methods. A few examples of destructive
testing include macro tech testing, fillet-weld break tests, transverse tension tests, and guided bend
tests. Other destructive methods include acid tech testing, back bend testing, tensile strength break
testing, nick break testing, and free bend testing.
Non-destructive methods include fluorescent penetrate tests, magna flux tests, eddy current
(electromagnetic) tests, hydrostatic testing, tests using magnetic particles, X-rays and gamma ray based
methods and acoustic emission techniques. Other methods include ferrite and hardness testing.
Q.90: WHAT IS THE MAIN DIFFERENCE IN THE PURPOSE AND FUNCTION OF A DEARATOR & AN OPEN
FEED WATER HEATER?
Answer : Kindly study Part-E(13.Deaerator pdf file).

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IBCI (Indian Best Coaching Institute)

Q55.Why does silica slippage in the treated water of dmplant occur?

Q.62 What is Scale Formation ?

Q.63 How do I stop Scale Formation from happening ?

Q.64 What is corrosion ?

Q.65 How do I stop Corrosion ?

website link: http://mithileshkhudawal.wix.com/boeindia

Q.67 How do I to Prevent the Most Common Boiler Problems ?

1.Maintaining the Boiler

2. Maintaining the Burner

website link: http://mithileshkhudawal.wix.com/boeindia

3. Maintaining the Controls

4. Maintaining the System

A More In-depth Look

Low Water Cutoff - Tests and Maintenance

Feed Water Pumps

Steam trap -Care and Maintenance

1. Condensate does not flow into the trap:

2. Condensate fails to drain from trap.

3. Trap does not shut off.

4. Steam blows through trap.

3. Avoid mixing of different types of fuels.

3. Closely monitor TSP level in the CBD water.

4. Check feasibility of changeover of BFW treatment to AVT.

5. Verify for proper selection of oxygen scavenger if used.

Q.73: In my boiler, Burner tip choking is frequently ,How to solve it?

Q75. How to laying boiler foundations?

website link: http://mithileshkhudawal.wix.com/boeindia

Retrofitting of Boiler from one type to another type :

For example i.e. conversion of oil to fbc boiler.

Q77. What is the post weld heat treatment?

Q78. What is the Dolachar ?

Answer : Kindly study Part-E(7.Boiler Room Guide book).

Following are the application area of PRV in a power station :

1. Auxiliary steam for gland sealing for turbine.

Q.85: WHAT IS THE PROTECTIVE COATING USED FOR IN A BOILER?

Q.86: WHAT WOULD HAPPEN IF A BAFFLE BROKE DOWN?

website link: http://mithileshkhudawal.wix.com/boeindia

5 - 10% for natural gas

Q.89: IN WHAT MANNER IS THE QUALITY OF A WELD CHECKED?

Answer : Kindly study Part-E(13.Deaerator pdf file).

website link: http://mithileshkhudawal.wix.com/boeindia

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