CILEGON COMBINED CYCLE POWER PLANT

AUXILIARY BOILER PLN PROJECT

MITSUBISHI HEAVY INDUSTRIES LTD.

Training Program
Auxiliary Boiler 12 Ton/Hr , 12 Barg
By. PT Basuki Pratama Engineering

Items of Training
I.
II.
III.
IV.
V.
VI.

Preface
Utilizing Equipments
System Description
Operation Sequence
Maintenance
Boiler Operation Water Treatment

PREFACE

What is that Steam Boiler BHS-12000-LO ?

II. Utilizing Equipments

1 Unit Steam Boiler BHS-12000-LO (10QHA01AC101)

Capacity

: 12 Ton/Hr , 12 Barg

Design / Operating Pressure

Efficiency
Type of Fuel
Max Fuel Consumption @ Full load

: 12 Barg / 9 Barg
: 89 % (min)
: Diesel Oil
: 812 Kg/Hr

1 Unit Diesel Oil Burner (10QHH01AV101)

Brand / Type

: OILON / KP-700 M-II

Capacity (max)
Driving Motor
Control
Regulation

: 812 Kg/Hr
: 26 KW
: Fully Automatic
: Fully Automatic

1 Unit Superheater (10QLB11AC001)

Steam Capacity
Steam Temperature
Operating Pressure
Design Pressure / Temp.
Test Pressure

: 10,000 Kg/Hr
: 260 oC
: 8 Barg
: 12 Barg / 300 oC
: 18 Barg

2 Units Feed Water Pump (10QLA11AP101/102)

Conveying Capacity
Delivery Head
Motor Capacity

: 12,000 Liter/Hr
: 132 M
: 11 KW

1 Unit Feed Water Tank w/Deaerator

(10QLA11AC101 / 10QLA11BB101)
Operating Pressure
Design Pressure
FWT Capacity
Deaerator Capacity
FWT Dimension
Deaerator Dimension

: 0.13 Barg
: 1 Barg
: 12,000 Ltr
: 12 M3/Hr
: Dia 1900 x 4200 S/S
: Dia 650 x 1400 S/S

1 Unit Chimney (10QHN01BV101)

Dimension
Accessories

: Dia 785 X 20,000 Height

: - Insulation & Cladding up to 2 M Height
- Free Standing

1 Unit Blow Down Tank (10QHF01BB001)

Dimension
Design Pressure / Temperature
Operating Pressure
c/w

: Dia 600 x 1,200 S/S

: 1 Barg / 120 oC
: Atmospheric
: Vent Head & Silincer

1 Unit Daily Fuel Tank (10QHH01BB101)

Capacity
Dimension
Design Pressure
Operating Pressure

: 25,000 Liter
: Dia 2500 x 5000 S/S
: Atmospheric
: Atmospheric

3 Units Sample Cooler

(10QUA03AC001 ; AC002 ; AC003)
Dimension
Material
Cooling Water Inlet Valve
Hot Water Inlet Valve

: Dia 100 x 300 Height

: SUS 304
: 3/8
: DN6 PN40

1 Unit FWT Dosing Device (10QLF11AP201)

Diaphragm pump type

: Pulsatron LPD3S2-365

Max. Capacity
Working Pressure
Voltage
C/W Storage Tank
Tank Contents
Material
C/W Mixer
Type
Motor Rating

: 1.9 Ltr/Hr
: 17 Barg
: 230VAC 50 Hz / 0.5A 1 Phase
: 650 Liter
: Polyethylene
: MIX6/2 EMEC
: 110 W

1 Unit Boiler Dosing Device (10QLF11AP201)

Diaphragm pump type

: Pulsatron LPF4S2-365

Max. Capacity
Working Pressure
Voltage
C/W Storage Tank
Tank Contents
Material
C/W Mixer
Type
Motor Rating

: 3.2 Ltr/Hr
: 17 Barg
: 230VAC 50 Hz / 0.5A 1 Phase
: 650 Liter
: Polyethylene
: MIX6/2 EMEC
: 110 W

III. System Description

Process Flow Diagram

Piping & Instrumentation Diagram

10QHH01BB101
DAILY FUEL TANK

10QHF01BB001
BLOW DOWN TANK

10QLB11AC001
SUPERHEATER

10QLB11BB901
CONDENSATE POT

10QUA03AC001,10QUA03AC002
10QUA03AC003
SAMPLE COOLER

10QHH01AV101
DIESEL OIL BURNER

10QHA01AC101
STEAM BOILER BHS-12000-LO

10QLA11AP101/102
FEED WATER PUMP

10QHN01BV101
CHIMNEY

10QLA11AC101&10QLA11BB101
FEED WATER TANK WITH DEAERATOR

10QLA11BB901
CONDENSATE POT

10QLF11AP201
FWT DOSING DEVICE

10QLF11AP101
BOILER DOSING DEVICE

10

Front Control Panel

Inside Control Panel

11

Feed Water System

Logic Diagram
Feed Water Tank
FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

BY PASS LEVEL
INDICATOR
10QLA11CL01QN
LIS 144

L5

FIELD OUTPUT

DRY RUN
FEED PUMP

H10

WATER LEVEL REACH

THE ELECTRODE = CLOSED

AUDIBLE
ALARM
BS

NAND
DISTURBANCE

L4

WATER LEVEL REACH

THE ELECTRODE = CLOSED

NAND
HW ALARM
FW TANK

H11
L1

WATER HIGH

F.W. PUMP 1 & 2

Off
10QLA11 AP001
10QLA11 AP002

BS

DISTURBANCE

NAND

L2

AUDIBLE
ALARM

HIGH LEVEL REGULATION

SOLENOID VALVE #1
ON

NAND

WATER INLET VALVE 1

AUTO/OFF/MANUAL

L13

S7

AND

1
AUTO
OR

SOLENOID VALVE 1
OPEN
10QLA11 AA002
FCV 159

S
R

MANUAL

SOLENOID VALVE 1
WILL CLOSE WHEN
LEVEL REACH L2

OFF

L3

L4

MIDDLE LEVEL REGULATION

LOW LEVEL REGULATION

NAND

SOLENOID VALVE #2
NAND

ON

WATER INLET VALVE 2

AUTO/OFF/MANUAL

S8

L14
AND

2
AUTO
OR
MANUAL

S
R

SOLENOID VALVE 2
OPEN
10QLA11 AA007
FCV 161
SOLENOID VALVE 2
WILL CLOSE WHEN
LEVEL REACH L3

OFF

12

Feed Water Tank

L1

Instrument

By-pass level indicator 5 switch (LIS 144) :

Used for control level feed water tank and level indicator

Solenoid valve 1 (FCV 159) and Solenoid valve 2 (FCV 161) :

Valve water inlet feed water tank

Pressure switch (PSL145) :

Used for monitoring of pressure in water tank.

L2

L3

System Description
Water inlet valve can operate manually and automatically with selector switch
water tank valve in control panel. Auto status, valve operate depend on level
switch. If water level :

Above L1; valve1 & valve2 close, alarm FWT high, digital input FWT on, and
disturbance indicator FWT high ON.

Above L2; valve1 & valve2 close.

Above L3; valve1 open & valve2 close

Below L4; valve1 & valve2 open

Below L5; valve1 & valve2 open, alarm FWT low, FWP off, digital input FWT
low, disturbance indicator FWT ON.

L4
Pressure switch
L5

By-pass level
indicator

If pressure feed water tank below setting (set=0.1 bar), pressure switch signal
to digital input feed water tank pressure to low

Solenoid valve

Logic Diagram
Dosing System

FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

Solenoid Valve
Service Water Inlet
FCV 159
DOSING PUMP 2
AUTO/OFF/MANUAL

S2

DOSING PUMP 2
ON

FCV 161

L2

OR
AND

AUTO
OR
MANUAL

S
R

DOSING PUMP 2
START
10QLF11 AP201
HV 177

OFF

13

Feed Water Tank Dosing Pump

Instrument

Dosing pump :
Supply hydrazine and amine from feed water tank
dosing to feed water tank

Mixer pump :
Mix hydrazine and amine in feed water tank dosing
System Description
Dosing device can operate manually and
automatically with selector switch dosing pump2 in
control panel. Auto status, dosing device operate
depend on solenoid valve1 water inlet feed water
tank.

Dosing pump

Mixer

Fuel Oil System

14

Logic Diagram
Daily Fuel Tank
FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

BY PASS LEVEL
INDICATOR
10QHH01

L1

L2

FIELD OUTPUT

OIL LEVEL
HIGH
OIL HIGH

L16

HIGH LEVEL REGULATION

AND

OIL LEVEL

L3

LOW LEVEL REGULATION

LOW

L17

L4

INTERLOCK
TO BURNER
(OFF BURNER)

OIL LOW

VALVE OIL INLET

ON

OIL INLET VALVE

AUTO/OFF/MANUAL

S9

L15

AND

LCV 239
AUTO
OR
MANUAL

S
R

10QHH01
AA002
SOLENOID VALVE
OIL INLET

OFF

Daily Fuel Tank Level

L1
L2

Instrument

By-pass level indicator (LI 215) with 5 switch (LT 218) :

Used for control level fuel oil and level indicator
Solenoid valve (LCV 239) :
Valve fuel oil inlet daily fuel tank

L3

L4
L5

System Description
Fuel oil inlet valve can operate manually and automatically with selector switch oil
inlet valve in control panel. Auto status, valve operation depends on level switch. If
oil level :

Above L1; valve close, digital input fuel oil tank level high on, and indicator oil to
high on.

Above L2; valve close

Above L3; valve open

Below L4; valve open, indicator oil to low on, alarm oil tank to low, burner off
(manual ON)

Below L5; valve open, digital input fuel oil tank level to low on

By-pass level
indicator

Solenoid valve

15

Oil Measurement
Instrument

Oil flow meter (FQI 190) :

Used for measuring oil flow daily fuel tank to boiler

Oil totalizer :
Display water totalizer in control panel

Oil flow rate :

Display water flow in control panel

Recorder :
Record oil flow in control panel.

Recorder

System Description
Flow meter signal to oil totalizer, oil flow rate, oil flow recorder, and
auxiliary analog output (4-20mA) fuel firing rate (terminal X3 74;75).

Flow rate

Totalizer

Steam Outlet & Start-up Line

16

Saturated Steam Temperature

Instrument

Temperature sensor PT 100 ( TE 221) :

Measuring saturated steam temperature

Temperature display (TI 141) :

Display saturated steam temperature in control panel

System Description
Temperature sensor signal to temperature display for saturated steam
temperature.

Sensor PT 100

Temperature Display

Logic Diagram
Blow out
FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

S12

SELECTOR
OPEN

OFF
10QLB11
AA903
SERVO MOTOR

CLOSE
BLOW OUT
10QLB11AA903
10QLB11
CF01

FT
137
FT 137 BUILT IN
PRESS. TRANSMITTER
FOR TEMP.
COMPENSATION

BLOW OUT

I
SET POINT=2 Bar

Press. After
Super Heater

START
PID CONTROL
Controller Burner

17

Steam Flow Meter and Blow Out Steam

Instrument

Steam flow meter (FT 137) :

Used for measuring steam from boiler

Steam display and controller (FC139) :

Display steam flow in control panel

Valve blow out (FCV 224) :

Valve for steam start up

Steam display
and controller

System Description
Flow meter signal to steam totalizer, steam display controller, and steam
flow recorder in control panel. Blow out valve can operate manually and
automatically with selector switch blow out in control panel. Auto status,
valve open (blow out steam) if pressure super heater not reach (set = 2
bar) and burner not OK.

Actuator valve

Valve

Logic Diagram
Super Heater

FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

TEMPERATURE SUPER HEATER

REGULATION
10QLB11 CT09QN
10QLB11
CT14QP

P
TE
211

260C

I
D
SET POINT

10QLB11
CP01QB

PT
207

> 7.7 barg

PRESSURE

> 960 kg/hr

FLOW

10QLB11
CF01

FT
137

10QLB11
AA008
SERVO MOTOR
SUPER HEATER FLAP

18

Super heater

Instrument

Temperature sensor PT 100 ( TE 211) :

Measuring super heater temperature steam

Temperature display and controller (TIC 213;TI 210) :

Display temperature super heater steam in control panel
and control damper super heater

Actuator damper super heater :

Damper for control temperature super heater steam

Actuator damper
super heater

Sensor PT 100

System Description
Temperature sensor signal to temperature super heater display in control panel
and auxiliary analog output (4-20mA) super heater steam temperature (terminal
X3 76;77).
Damper operate regulation if flow steam reach 960 kg/h and pressure > 7.7 bar.
If temperature 280C digital input super heater temp. high on.
If temperature 300C disturbance indicator super heater temp. to high on

Temperature steam display

and controller

Main Steam Valve

Instrument

Pressure Transmitter :
Pressure Transmitter are used to measure pressures in liquids
and gases. The pressure is converted into an electrical signal

Pressure super heater display and controller :

Display Pressure super heater steam in control panel
and control damper burner

Actuator steam out :

Actuator for control valve saturated steam out

Valve saturated steam out :

Valve for saturated steam out

Pressure Transmitter

Pressure super heater steam

display and controller

System Description
Valve saturated steam out operate with selector switch main
steam valve in control panel ( open-close valve ).
if pressure reach 8 bar in pressure display control panel operator
can operate this switch.

Valve
Actuator steam out

19

Blow Down Tank & Drain System

Logic Diagram
Blow Down Tank
FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

TEMPERATURE CONTROL
10QHF01
TIC231
10QHF01
CT01

TE
232

Temperature Controller will Open/Close

ON

TEMPERATURE HIGH

Solenoid Valve automatically at set point value

Below Set Point = Logic 0

OFF

Above Set Point = Logic 1

SET POINT= 50 C
SET POINT

BLOWDOWN TANK
ON

S3
BLOWDOWN TANK
AUTO/OFF/MANUAL

L3
AND

AUTO
OR
MANUAL

10QHG01
AA002

SOLENOID VALVE
COOLING WATER IN
OPEN

OFF

20

Blow Down Tank

Instrument

Temperature sensor PT 100 ( TE 232) :

Measuring blow down tank temperature

Temperature controller (TIC 231) :

Control for blow down tank temperature

Solenoid valve (TCV 233) :

Valve service water inlet blow down tank
Temperature controller

System Description
Service water inlet valve can operate manually and automatically
with selector switch blow down tank valve in control panel. Auto status, valve
operation depends on setting temperature (set = 50C). If temperature over
setting valve open and conversely.
if temperature increase (>60C), digital input blow down tank discharge
temperature high on.

Sensor PT 100

Solenoid valve

Steam Boiler System

21

Steam Boiler System

1. Bottom Blow Down

Instrument

Blow down controller (PRS-7b) :

Generates a control pulse which, after the preset blow down
interval, operates the three way solenoid valve.
Three way solenoid Valve :
Solenoid for control valve intermittent blow down
Valve intermittent blow down (BDV 115) :
Intermittent blow down valve boiler
Sightglass (FG123) :
Visual supervision of condensate conditions in heat
exchangers and flow conditions pipelines. It clearly indicates
loss of live steam, banking up of condensate or the presence
of air.

System Description
Controller turn actuates the rapid action blow down valve by
means of compressed air and closes it again at end of the
pulse (blow down) duration. The blow down intervals can be
adjusted.

Schematic layout

Three way solenoid valve

And strainer

Sightglass

Logic Diagram
Surface Blow Down

FIELD INPUTS

CONTROL SWITCHES

10QHA01
CT01QP

CE
124
ELECTRODE
CONDUCTANCE

SWITCH
DESALTING ON/OFF

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

DESALTING
REGULATOR AND
CONDUCTIVITY
LIMITER
LKER 1
OPERATION
10QHA01
BT001

10QHA01
AA005
SERVO MOTOR
DESALTING VALVE

22

Steam Boiler System

2. Surface Blow Down

Instrument

Conductivity Electrode (CE 124) :

Monitoring of condensate return to boiler to detect water any
penetration of acid, alkalis etc.
Continuous blow down controller (LRR 1-5b) :
Automatically controlled continuous blow down to reduce blow
down wastage and increase operating safety.
Control Valve (CCV 122) :
Motorized control valves for continuous blow down system of
steam boiler.

Conductivity
electrode

System Description
Surface blow down can operate manually and automatically with
selector switch blow down valve in control panel.
Automatic system work depends on value setting. If condensate
boiler over setting value, valve open and operate conversely

Logic Diagram
Boiler Water Level Control
FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

HIGH WATER
LEVEL
10QHA01
CL05QN

L7

LEHH
103
HIGH WATER
ELECTRODE
10QHA01
CL04QN

AUDIBLE
ALARM
BS

HIGH & LOW WATER

LEVEL CONTROL
NRS 1-2b

LOW WATER
LEVEL

L6
10QHA01

LELL
104
ELECTRODE
10QHA01
CL07QN

OFF Burner (Auto ON)

CONTINUOUS
WATER LEVEL
CONTROL
NRR 2-2e

LT
106
CONTINUOUS WATER
LEVEL PROBE

10QHA01
AA026

MOTORIZED VAVE
SERVO MOTOR
10QHA01
CL08QN

10QHA01
AA026

AND

AND

Feed Water Pump

Control

ZS
SWITCH OFF DELAY
MIN. POSITION SWITCH
SERVO DRIVE

EXTRA LOW
WATER LEVEL

10QHA01
CL06QN

LELL
105
ELECTRODE

L8
WATER LEVEL
CONTROL
NRS 1-7b

AUDIBLE
ALARM
BS

BOILER
10QHA01

OFF Burner (Manual ON)

23

Steam Boiler System

3. Boiler Water Level Control
Instrument

Level electrode (LELL 104; LEHH 103) :

Signaling of level conductive (Low level alarm, high level alarm).

Level electrode (LELL 105) :

Signaling of level conductive (Extra low level alarm).

Level Probe (LT 106) :

Level probe for modulating level control boiler.

Level Switch (NRS 1-2b) :

Control for low level and high level boiler

Level Switch (NRS 1-7b) :

Control for extra low level boiler

Level controller (NRR 2-2e) :

Control valve for feed (fill) or drain (discharge) for modulating level
boiler

Actuator Valve (LCV 184) :

Motorized control valve modulating level boiler.

Lamp indicator (LI 107) :

Indicator for dangerous level water in boiler.

boiler level :
Indicator level boiler in control panel

Steam Boiler System

System Description

Control valve

Sensor

Controller

LT 106

NRR 22e

Valve
LCV 184

Valve open regulation depend on monitoring probe

LT 106 in boiler.
If low level (LELL 104 ) reach, burner auto interlock, lamp indicator water
level low and Digital input boiler water level low on.
If high level (LEHH 103) reach feed water pump interlock, lamp water
level high on, Digital input boiler water level high on and alarm high level
boiler.
If extra low level (LELL 105) reach, lamp water level extra low on, digital
input boiler water level to low on, alarm extra low level boiler, and extra
low level indicator in panel.

Actuator valve

Indicator lamp

Valve

Level boiler

24

Steam Boiler System

4. Pressure Switch and Pressure Limiter
Instrument

Pressure switch regulation (PSHL 110) and Pressure switch limiter

(PSHH 111) :
Used for controlling and monitoring of pressure in steam boiler.
System Description

If pressure boiler over pressure switch regulation setting (9.5 bar); burner interlock
(auto operate), pressure high indicator panel on, display fault in panel, and digital
input steam pressure high on.

If pressure boiler over pressure switch limiter setting (10 bar); burner interlock
(manual operate), pressure high indicator panel on, digital input steam pressure to
high on

Pressure switch

Pressure limiter

Logic Diagram
Operation Burner
FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

AUTOMATIC
BURNER
CONTROLLER
LAL 2.25

BURNER START/
FAILURE RESET
10QHA01
CP03QN

PSHL
110

FIELD OUTPUT

BURNER
ON

L21

10QHH01
DPOO1
* MANUAL RESET ON
PRESSURE SWITCH
AND
DISTURBANCES

PRESSURE BOILER
NOT HIGH

10QHH01
AV101

WATER LEVEL
EXTRA LOW

BLOWER MOTOR

OIL LEVEL LOW

10QHH01
AV101

AND

WATER LEVEL LOW

S13

COMPOUND REGULATOR
SERVO MOTOR
START PID

BURNER CONTROL

CONTROLLER
AUTO

DECREASE

1. Control Blow Out

2. Pressure saturated
steam control
OR

S
10QHH01
AV101

OIL PUMP MOTOR

STEADY

INCREASE

OFF

10QHH01
AV101

10QHH01
CR001

FLAME SENSOR

IGNITION TRANSFORMER

FLAME INTENSITY

25

Logic Diagram
Control Damper Burner

FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

PRESSURE CONTROLLER BURNER

10QHH01
AV101
10QLB11
CP01QB

PT
207
PRESSURE
TRANSMITTER

D
SET POINT= 8.5 Bar
SET POINT

10QHA01
AV101
COMPOUND REGULATOR
SERVO MOTOR

COMPOUND
REGULATOR
POSITION

Burner controller

START CONTROLLER

START
PID CONTROL
CONTROLLER IN MANUAL MODE
OPEN/STOP/CLOSED

REF. SH. NO. 33

SWITCH S13

Control blow Out

Steam Boiler System

5. Burner
Instrument

Automatic burner controller :

Used to control Burner of steam boiler.

Light oil Burner

Burner Controller

System Description

Burner operate with push button (start / stop burner).

Damper burner can operate manually and automatically with selector
damper switch in control panel.

Burner off if one of this condition happens : Boiler pressure too high,
boiler extra low, and oil low level and must start again.

Operating burner control with automatic burner controller.

Time sequence diagram shows burner operation system

Regulation burner depends on pressure saturated steam

Burner

26

Time Sequence Diagram

Boiler Dosing Pump

FIELDINPUTS

CONTROL SWITCHES

L OGI C

FWP1
DOSINGPUMP1
AUTO/OFF/MANUAL

S1

LAMPINDICATORS(LCP)

DOSINGPUMP1
ON

FWP2

L1

OR
AND

AUTO
OR
MANUAL

FIELDOUTPUT

S
R

DOSINGPUMP1
START
10QLF11 AP101
HV177

OFF

27

Boiler Dosing Pump

Instrument

Dosing pump :
Supply phosphate from boiler dosing to feed water
tank

Mixer pump :
Mix phosphate in boiler dosing

Dosing pump

System Description
Dosing device can operate manually and
automatically with selector switch dosing pump2 in
control panel. Auto status, dosing device operation
depends on solenoid valve1 water inlet feed water
tank.

Mixer

Logic Diagram
Feed Water Pump Operation
FIELD INPUTS

CONTROL SWITCHES

LOGIC

LAMP INDICATORS (LCP)

FIELD OUTPUT

F.W PUMP 1
OPERATION

S5
SELECTOR FEED WATER
AUTO/OFF/MANUAL

L9
F.W. PUMP 1

AND

AND

AND

OR

OR

F.W. PUMP 1
10QLA11 AP101

AND

AUTO

MANUAL

OFF

S6
SELECTOR FEED WATER
PUMP1/OFF/ PUMP2
OR

F.W PUMP 2
OPERATION

PUMP 1

L10
F.W. PUMP 2

PUMP 2
OR

AND
OR

OFF

4
F.W. PUMP 2
10QLA11 AP102

DEAERATOR
LEVEL NOT LOW
BOILER
LEVEL NOT HIGH

AND

AND
AND

AND
PUMP 1 TRIP

PUMP 2 TRIP

28

Feed Water Pump

Instrument

Feed water pump (130) :

Pump from feed water tank to boiler

Pressure Indicator (PI 131) :

Indicate pressure in line feed water pump
System Description
There has two feed water pump operate interlock.
Each feed water pump can operate manually and automatically with selector
feed water pump in control panel.
In auto status, pump operation depends on high level boiler, and feed water
tank level low.
If a pump trips, trip pump indicator in control panel on, display feed water
pump trip in control panel, digital input feed water pump trip on.
pressure gauge shows pressure in line of feed water pump

Feed Water Pump

Pressure Indicator

Flue Gas Temperature

Instrument

Temperature sensor PT 100 ( TE 140) :

Measuring flue gas temperature

Temperature display (TI 141) :

Displaying flue gas temperature in control panel

System Description
Temperature sensor signal to temperature display for flue gas
temperature.

Sensor PT 100

Temperature Display

29

Feed Water Measurement

Instrument

Feed water flow meter (FQI 175) :

Used for measuring water flow from feed water tank to boiler

Water totalizer :
Display water totalizer in control panel

Water flow rate :

Display water flow in control panel

Recorder :
Record water flow in control panel.

Recorder

System Description
Flow meter signal to water totalizer, water flow rate, and water flow
recorder.

Totalizer

Flow rate

IV. Operation Sequence

30

Control Panel

1. Operate Main Switch (Q0) to ON position

View Voltage (R-S; R-T; S-T; =380 Volt) in KWH meter
2. Pull Emergency Switch (ES)
View lamp Power On (L0) operate
3. All Breaker in ON position (inside control panel)
- Feed water pump 1 (-Q1)
- Feed water pump 2 (-Q2)
- Burner Fan (-Q3)
- Oil pump (-Q4)
- Dosing pump boiler (-Q5)
- Dosing pump feed water tank (-Q6)
- Socket 220 volt (-Q7)
- Transformer for heater (-Q8)
4. Operate feed water tank
- Selector switch water tank valve 1(-S7) in auto position
- Selector switch water tank valve 2(-S8) in auto position
feed water valve 1 and valve 2 indicator ON, feed water valve 1 and valve 2 will off when level
water tank reach high level
5. Operate dosing pump 2 (dosing boiler)
- Selector switch dosing pump 2 in auto position
6. Operate oil inlet valve
- Selector switch oil inlet valve in auto position
7. Operate feed water pump
Wait after feed water tank level high
- Selector switch operational pump in auto position
- Selector switch feed water pump in position pump1 or pump2

31

8. Operate dosing pump 1(dosing feed water tank)

- selector switch dosing pump 1in auto position
9. Operate blow down tank
- selector switch blow down tank valve in auto position
10. Check alarm and disturbance indicator
No sound/indicator alarm and disturbance indicator no fault.
Alarm
1. Emergency switch
2. High level boiler
3. Boiler extra low level
4. Pressure to high
5. Burner fail
6. Fuel oil tank to low
7. Feed water tank high
8. Feed water tank low

Disturbance indicator
1. Emergency switch
2. High water level
3. Burner Disturbance
4. Extra low level
5. Over load F.W.P 1
6. Over load F.W.P 2
7. Over load burner
8. Steam pressure high
9. S.H steam temperature to high
10. Feed water tank low
11. Feed water tank high

11. Operate boiler

- push start burner
12. Operate blow out
- selector switch blow out in auto position
13. Operate main steam
- if pressure reach 8 bar in display pressure and temperature reach 260 C in control
panel, selector switch main steam can operate in open position.

V. Maintenance

32

Operating Log Book

A. Records of daily checks and servicing operations as well as other checks must be
kept in an operating log book and signed daily by the responsible boilerman
(operating personnel). In the case of some installation, this operating log book may
be demanded as a prerequisite for the operating permit. Recurring test carried out
by the technically competent person must also be entered in this operating log
book. The forms appended to these operating instruction should be used for this
purpose. When using boilers with superheaters, the operator must enter details of
the hot steam temperature at brief intervals (at least every 30 minutes) in a
separate sheet, along with details of the date and time, if no use has been made of
a hot steam temperature control and if the superheater is installed in the are of high
exhaust gas temperature. Here damage may occur if operation is not carried out
conscientiously.
B. The boilermans superior must convince himself at least weekly of proper operation
and servicing of the steam boiler installation and must note this on the rear of the
sheet in the operating log book along with his signature and the date

Daily Checks and Servicing

A.

Prior to start up of the installation and when each shift commences, the operating personnel (boilerman) must convince themselves of
the installations proper operating condition.

B.

The function of the water level limiters must be checked daily and at the start of each shift, unless they are self monitoring,i.e. specialdesign, devices. External devices must be blown out
Temperature and pressure limiters need not be checked daily. The intervals for these units depend on their nature-refer to weekly
checks and servicing.
The time intervals for checking safety valves must be agreed by the operator and technical expert considering the service life of the
sealing faces, daily checking is not recommended.
Blowing out
Water level indicators and external feed water controllers and limiters must be blown out, attention being paid to the necessary
operating sequence for shut-off and blown out valves.
Checks of all fire systems
f.1. Keep the fire chamber free from residues and coke sediment
f.2. Smoke-free combustion
f.3. Correct oil temperature when using heavy fuel oil
f.4. Suitable oil pressure
Checks to be carried out when using heavy fuel oil
g.1. Gas pressure
Water analysis
Refer to the operating log book and the water directives
Note
Pay attention to the operating instructions issued by the supplier of the water treatment plant. Devices or checking the feed water
generally do not suffice for checking the boiler water. Please enquire in cases of doubt.
Boiler blow down
Check sealing points and lock them and, if necessary, retighten them and renew the packings
Important note
If controllers are rendered inactive by malfunction, the installation must be observed continuously if its operation is continued. If safety
devices should fail, please inform our Customer Service and, if necessary, shut down the installation and inform the installer for the
installation of BASUKI representative in your area, or directly to us (refer to our contact address & phone/fax numbers)

C.
D.
E.
F.

G.
H.

I.
J.
K.

33

Weekly Checking and Servicing

A. Maximum water level ensuring facility in the case of hot steam boilers.
B. Safety temperature limiters need only be checked on special circumstances
C. Pressure limiters if they are not preceded by safety valves of a special design
devices.
D. If necessary, temperature and pressure controllers are tested by pressing the bypassing push button
E. Seals, locks and packings
F. Shaft bearing (noise and heat development)
G. Stand by feed pumps and oil pumps etc. must be started-up briefly/valves must be
switched over.
H. Firing parts, flame monitors

Semi-annual Checks
Controllers and safety devices must be serviced and
checked by a technically competent person after every
period of 6 months. We recommend our customer
service for this purpose.

34

Operating Logbook for Aux. Steam Boiler

Operating Logbook for Aux. Steam Boiler

35

Operating Instruction for Aux. Steam Boiler

VI. Boiler Operation Water Treatment

36

Phosphate Dosing System Line

Hydrazine & Amine Dosing System Line

Feed Water Sample Line

37

Blow Down System Line & Boiler Sample Line

Origin of the Problem

The water quality control system required
shall be controlled by hydrazine & neutralizing
amine which supplied by chemical dosing
system consist of injection pumps, dosing
tanks & motorized agitator

Source of corrosion :
Dissolved gas: oxygen,
carbon dioxide, and ammonia.
Oxygen is the most aggressive.
Cause pitting corrosion

Make-up water introduces soluble oxygen.

The condensate return system contains soluble
oxygen

38

Boiler Waterside Corrosion

Contributors: dissolved oxygen, acid

or caustic in the water and a high
temperature. Cause severe pitting,
gouging and embrittlement
FAILURE

Water will rapidly corrode mild steel;

as the temperature increases, the
reaction accelerates.

Reaction :

Anode : Fe Fe2+ + 2e-

Cathode: 1/2O2 + H2O + 2e- 2OH-

Overall: Fe + 1/2O2 + H2O Fe (OH)2

Waterside Deposition
Boiler deposits result from hardness salts, metallic oxides, silica and a number
of other feed water contaminants that can enter the system.
Minimizing the adverse impact of these contaminants is the role of the boiler
water treatment program.
Even the best controlled systems occasionally have upsets that cause
excessive amounts of contamination to pass into the boiler. Some examples
would be:

Excess leakage from an ion exchange system

Contamination from leakage into condensate systems
Inadequate steam condensate protection programs resulting in high levels of
corrosion products returning to the boiler

An internal boiler water treatment program must be forgiving enough to handle

not only normal operating conditions but periodic upsets as well.

39

Mechanism of Deposition

Reaction:
10Ca2+ + 6PO43- + 2OH- 3Ca3(PO4)2Ca(OH)2 Calcium hydroxyapatite
3Mg2- + 2SiO32- + 2OH- + H2O 2MgSiO3Mg(OH)2H2O Serpentine

More deposit will decrease Boiler

efficiency and subject to overheating

A Partial List of Boiler Deposits

Name

Formula

Acmite

Na2OFe2O34SiO2

Analcite

Na2OAl2O34SiO22H2O

Anhydrite

CaSO4

Aragonite

CaCO3

Brucite

Mg(OH)2

Calcite

CaCO3

Cancrin

4Na2OCaO4Al2O32CO29SiO23H2O

Hematite

Fe2O3

Hydroxyapatite

Ca10(OH)2(PO4)6

Magnetite

Fe3O4

Noselite

4Na2O3Al2O36SiO2SO4

Pectolite

Na2O4CaO6SiO2H2O

Alpha-Quartz

SiO2

Serpentine

3MgO2SiO22H2O

Thenardite

Na2SO4

Wallastonite

CaSiO3

Xonotlite

5CaO5SiO2H2O

40

Embrittlement

Caustic embrittlement or
intercrystalline cracking

Undetectable during operating

conditions

Catastrophic results
Causes:
1. Leakage of boiler water
2. Concentrated caustic soda occurs from the concentrated boiler
water.
3. There is high metal stress in the area of caustic concentration and
leakage.

External Treatment

To improve the quality of this source prior to its use

as boiler feed water, including reducing contaminants.

Applied to water prepared for use as boiler feed water, refers to the
chemical and mechanical treatment of the water source.

External treatment normally includes: Clarification, Filtration, Softening,

Dealkalization, Demineralization, Deaeration, Heating

Internal Treatment

To minimize impurities after the best and most appropriate external

treatment of the water source, boiler feed water (including return
condensate)

41

Steam Plant Operation- Feed Water Preparation

Deaerate the feedwater

By using a deaerator and adding oxygen scavengers (Hydrazine) in the
feed water tank.

Minimize hardness
Ex : Calcium and Magnesium, migratory iron, migratory copper, colloidal
silica, consistent with boiler design and operation parameters.

Minimize corrosive gases

Ex : Dissolved oxygen and dissolved carbon dioxide
The deposition of these metallic oxides in the boiler is frequently more
troublesome than the actual damage caused by the corrosion.

Deaeration (Mechanical and Chemical)

Mechanical and chemical deaeration is an integral part of modern boiler

water protection and control.

Objectives :
To remove oxygen, carbon dioxide and other non-condensable gases
from feed water
To heat the incoming makeup water and return condensate to an optimum
temperature
Minimizing solubility of the undesirable gases
Providing the highest temperature water for injection to the boiler, from
ambient temperature to 103 C to prevent boiler from thermal shock

42

Deaeration (Mechanical and Chemical)

Designed to minimize
saturated dissolved O2
content in the supplied
de-mineralized water
and to achieve a suitable
O2 content fed to the
boiler

Saturated steam (1243 kg/hr, temperature 105-180 C, pressure 9 bar (g) )

The dissolved oxygen leaving the deaerator will be 7 ppb to protect auxiliary
boiler system from corrosion with residual hydrazine approximate 0.1 ppm.

Deaerating Heater Troubleshooting Guide

Symptom

Remedy
1. Insufficient venting-increase vent rate by opening the manually operated air vent valve.

Excessive oxygen content in

deaerator effluent

2. Check steam pressure reducing valve. Check valve for free operation, and see that
control line is connected to the connection provided in the deaerator.
3. Check water and, if possible, steam flow rates vs. design. Trays or scrubber and inlet
valves are designed for specific flow ranges.

Temperature in storage tank does

not correspond within 3 C of
saturation temperature of the
steam

1. Improper spray from spray nozzle. Check nozzle for sediment or deposit on seat or
broken spring.
2. Excessive free air due to leaking stuffing boxes on pumps upstream of deaerator that
have negative suction head. Repair stuffing box or seal with deaerated water.
1. Trays collapsed-possibly from interrupted steam supply or sudden supply of cold water
causing a vacuum.

Excessive consumption of
oxygen scavenger

2. Condensate may be too hot. Water entering the deaerating heater must usually be
cooled if the temperature is within 20 F of saturation temperature of the steam.
Check the design specification to determine what inlet water temperature was originally
intended.
1. Improper operation of inlet control valve. Adjust as necessary.
2. Check faulty operation of steam pressure reducing valve.

High or low water level

Low pressure

3. Check relief valves on the deaerator and in the main steam supply system for proper
operation.
1. Check for improper operation of steam pressure reducing valve.

43

The Effect of pH On Corrosion Rate

Effect of pH on the Corrosion Rate of
Steel. Water Chemistry Upsets Result in
Decrease or Increase of pH of Boiler
Water, Resulting in Tube Deposits or
5
7 Corrosion.
4
3

9
10

11

12

14

approximate pH

Relative Corrosion Rate

The slowest corrosion

rate In Boiler Water are in
9.5 - 11
3650

365 36.5
3.6
0.36
ppm HCl

40
4
0.4

400

4 000

40 000

200 000

ppm NaOH

Mineral Carryover
Definition:
Carryover is generally considered to be any
contaminant that leaves a boiler steam drum with
the steam.
Causes:
Mechanical Factor: Priming (sudden pressure
while load rises)
Chemical Factor: Foaming (by alkalinity, organic
and synthetics contaminant), Selective vaporous
carryover
Effects:
1.
Deposition in regulators and valving
2.
Deposition in superheaters
3.
Deposition in control valves and turbines
4.
Process contamination

44

Carbon dioxide Corrosion

Source:
Alkalinity in feed water
HCO3
CO3 heat CO2
Air in- leakage
Organic material
Characteristics:
Reaction:
CO2 + H2O H2CO3
H2CO3 H+ + HCO3

Cause pH drop and grooving on metal surface

Caustic Corrosion
Characteristics :

Often occurs in High Pressure Boiler

Localized corrosion

Contributed by deposit accumulation (Iron,

copper, etc)

Boiler operation excess maximum capacity

Massive load fluctuation

Reactions :

Fe2O3 + 2NaOH 2NaFeO2 + H2O

FeO + 2NaOH Na2FeO2 + H2O

Fe +2NaOH + 2H2O 2NaFeO2 + H2O

45

Internal Boiler Water Treatment

Use internal conventional program :

Hydrazine
Magnetite build up
N2H4 + 6Fe2O3 4Fe3O4 + N2 + H2O

Phosphate, An anti-scale agent

3Ca(HCO3)2 + 2Na3PO4 Ca3(PO4)2 + 3Na2CO3 + 3CO2
Sludge
Thermally unstable
Corrosive volatile gas

10Ca2+ + 6PO43- + 2OH- 3Ca3+(PO4)2Ca(OH)2 [Calcium hydroxyapatite]

3Mg2- + 2SiO32- + 2OH- + H2O 2MgSiO3Mg(OH)2H2O [Serpentine]

Neutralizing Amine, Removing acid

NH3 + CO2 + H2O NH4+ + HCO3R-NH2 + CO2 + H2O R-NH3+ + HCO3R-ONH + CO2 + H2O R-ONH2+ + HCO3-

Corrosion Control Programs

The basic approach to chemical treatment of condensate systems is through the use
of Hydrazine, Phosphate Program, Neutralizing Amine, combinations of both amines
and hydrazine.

REAKSI HYDRAZINE

Oxygen scavenging,
N2H4 + O2 N2 + 2 H2O

Stochiometric reaction,
dosage of 35 % solution 8.6 ppm/1 ppm residual
oxygen

Poisonous,
LD50 rating class 5 toxin 82 mg/kg

Magnetite build up,

N2H4 + 6Fe2O3 4Fe3O4 + N2 + H2O

46

Neutralizing Amines
Function:
To neutralize the carbon dioxide and then provide small
additional amounts to buffer the pH to 8.5 or 9.5.

Neutralizing carbonic acid

NH3 + CO2 + H2O NH4+ + HCO3R-NH2 + CO2 + H2O R-NH3++ HCO3R-ONH + CO2 + H2O R-ONH2+ + HCO3-

WATER SPECIMENT

Boiler and feed water must be

checked daily. At least the boiler
water should be sampled by
means of a sample cooler. If
there is a possibility of feed water
hardness, it is also necessary to
check the hardness of the feed
water everyday.

47

QUALITY WATER PARAMETER

1. Demin Water Outlet
Spec. conductivity : < 1.0 uscm
Silica:
: < 0.02 ppm SiO2
pH:
: 6.5 ~ 7.5
Sodium:
: < 0.005 ppm Na
Iron
: 0.02 ppm Fe

2. Boiler Feed Water

Spec. conductivity : < 5.0 us/cm at 25 deg.C
Silica
: < 0.02 ppm SiO2
pH
: 8.5 ~ 9.5
Hydrazine
: < 0.2 ppm N2H4
Iron
: <0.02 ppm Fe

3. Boiler Water
Spec. Conductivity:
Silica
:
pH
:
Phosphate
:

< 150.0 us/cm at 25 deg.C

< 2 ppm SiO2
9.5 ~ 10.5
3.0 ~ 10. ppm PO4

4. Steam
Spec. Conductivity: < 5.0 us/cm at 25 deg.C
Silica
: < 0.02 ppm SiO2
pH
: 8.5 ~ 9.5
Iron
: <0.02 ppm Fe

Blow down Definition

Every steam generator must be blow down periodically (recommended every two
hours, at least every one shift). The quantity of blow down water depends on the
degree of thickening. If no desalting fitting is provided, blowing down simultaneously
extracts salt from the boiler
Function:
To maintain the solids content of the boiler water within prescribed limits
Basic Calculation

% Blow down :
Concentration of dissolved solids in Feed water =
Concentration of dissolved solids in blowdown
Quantity of blow down/Feed water

% Make up :
Concentration of dissolved solids in Feed water =
Concentration of dissolved solids in Make-up water
Quantity of makeup/ Feed water

48

Blow down in Action

CR = 1/%blowdown x 100 =
Concentration dissolved solids of blowdown
Concentration dissolved solids of Feed water
Feed water = Make up + Condensate
Feed water = Boiler Capacity + Blow down

Do open blow down if the quality of water excess limit :

Demin Water
Spec. conductivity : > 10 uscm
Silica:
: > 0.02 ppm SiO2
pH:
: <6.5 or > 8

Boiler Water
Spec. conductivity : > 150 uscm
Silica:
: > 2 ppm SiO2
pH:
: > 10.5

WATER SIDE CONSERVATION

Purpose
The greatest danger to steam boilers is today the uncontrolled absorption of atmospheric oxygen
by the boiler water during shut down periods.
Oxygen has a corrosive effect particularly during start-up, but also during shut down periods.

Method
1. Wet conservation binds the oxygen of the water held in the boiler.
oxygen binding agents are: Hydrazine & Sodium sulphite
2.

Dry conservation ensures that no moisture remains in the boiler effectively preventing
corrosion of the steel

49

HYDRAZINE WET CONSERVATION PROCEDURE

1 g (atmospheric) oxygen in the water is bound by 1 g hydrazine (N2H4) = 7
g commercial, approx. 24% hydrazine hydrate (N2H4.H2O)
The additionally required hydrazine excess is shown in the table:
Hydrazine excess based on the
length of the rest period

Boilers with alkalinization and

fully demineralized feed
water
50 h (weekend)
1 month
longer
Boilers with alkalinization and
only softened feed water
irrespective of time

N2H4

N2H4.H2O 24%

g/m3

g/m3

20 - 30
50 100
100- 350
150 - 450

140-210
350 700
700 - 2000
1000 - 3000

HYDRAZINE WET CONSERVATION PROCEDURE

a, In glass vessels, pure hydrazine reacts only above 60C with oxygen dissolved in water.
the Fe3O4 of the protective layer is an excellent catalyst.
b. Wet conservation the pH-value of the hydrazine-containing solution should be 10 or
higher.
c. To prevent varying oxygen concentration and therefore the creation of air entrainment
elements, the steam boiler must be completely filled with hydrazine-containing boiler water.
d. All gate and screwdown stop valves must be closed completely after filling the boiler with
hydrazine-containing boiler water and kept closed during the conservation treatment.
e. If within the shut down period the hydrazine concentration must be topped up.
Circulate the boiler water to ensure through mixing.
f. When the boiler is restarted, the water level is reduced to normal provided that higher N2H4
contents in the initial steam are acceptable.

50

SODIUM SULPHITE WET CONSERVATION

PROCEDURE
1 g (atmospheric) oxygen in the water is bound by 9 g commercial, approx.
92% moisture-free, sodium sulphite (Na2SO3)
The additionally necessary sodium sulphite excess is shown in the table:
Sodium sulphite excess based on the length of the
shut down period
Boiler with alkalinization and fully demineralized feed
water 50 h (week end)
1 month
longer
Boiler with alkalinization and only softened feed water
independent of time

Na2SO3 92%
g /m3
200-300
450 900
900 - 3000
1500 - 5000

SODIUM SULPHITE WET CONSERVATION

PROCEDURE
a. Powdered sodium sulphite must be dissolved in warm feed water at 30-40C before
filling it into boiler. (Per 1 kg sodium sulphite 5 liters water).
b. In the case of wet conservation the pH value of the sodium sulphite containing solution
should be at 10 or higher. Apart from caustic soda and phosphate, as present in the boiler
water and sufficient for alkalinization, an extra addition of ammonia may also be successful
c. To exclude different oxygen content and therefore the formation of the air entrainment
elements, the steam boiler must be completely filled with sodium sulphite containing boiler
water. In superheaters or feed water preheater the sodium sulphite containing.
d. All gate and screw down stop valves must be closed after the boiler has been filled with
sodium sulphite containing boiler water and kept closed during the conservation treatment.
d. If within the shutdown period the sodium sulphite excess drops below 500 g/m3, the sodium
sulphite concentration must be topped up.
e. Before restarting the boiler, the boiler water condition must be adjusted to the specified values
(pH-value, sodium sulphite content)

51

Test Procedure Wet Conservation

Purpose
Testing for excess of oxygen binding agent in the case if wet conservation
i.

Hydrazine measurement
Hydrazine forms in an acid solution with p-dimethylaminobenzaldehyde, depending on
concentration, a yellow to red colored quinoid compound for color comparison

Reagents
Sulphuric 2% p-dimethylaminobenzaldehyde solution Colour comparison ampoules
(Both available from Farbenfabriken Bayer AG, Leverkusen, Germany, or their agents)

Test Procedure Wet Conservation

Procedure
1. The water sample to be tested for hydrazine content must first be cooled to < 40C
(sampling is best carried out with a cooling agreement). The boiler water may first have to
be filtered.
2. 5 ml of this water sample is filled up to the first calibration mark into the empty ampoule, 5
ml hydrazine reagent is filled in to reach the second calibration mark, and then shaken
twice. The test liquid will turn yellow. Now the reference ampoule or color comparison
sheet nearest to this color shade is determined. The value shown on this ampoule or the
sheet indicates the hydrazine (N2H4) content in kg/l of the water sample.
3. If the test liquid shows yellow color shades which are not covered by the comparison
scale, the N2H4 content is situated above 1 mg/l. These values, too, can be determined
more accurately by first diluting 1 ml of the water to be tested with 99 ml cold tap water,
mixing 5 ml of this diluted water with 5 ml reagent and comparing against the color scale.
The value found must then depending on the dilution used be multiplied by 100.
4. The reagent must always be stored in a dark and cool place. Storage life approximately 1
year (see use-by date printed on the label). The effectiveness of the reagent solution can
be verified at any time by mixing 5 ml tap water with 5 ml reagent, after which there must
be, no coloration exceeding the zero value of the color scale.

52

Test Procedure Wet Conservation

ii. Sulphite measurement
The process is intended to provide a simple check of the addition of sodium sulphite
necessary to bind the oxygen in the boiler water
In an acid solution, iodine oxidizes sulphite to sulphate and is then itself reduced to iodide.
Excess iodine produces a blue coloration in combination with starch solution. Nitrites,
sulphides and larger quantities of organic substances have an interfering effect (KMnO4
consumption over 60 mg/l)

Reagents
Phosphoric acid D.1.14 (25%)
0.01 standard iodine solution (Store in a cool place in a brown bottle)
Starch solution, approx. 1%

Instruments
300 ml Erlenmeyer flask
10 ml graduated pipette
20 ml burette, 0.1 ml graduation

Test Procedure Wet Conservation

Procedure
1. 100 ml of the sample, cooled to room temperature and filtered clear is filled into a 300
ml Erlenmeyer flask and acidified with 3 ml phosphoric acid (reagent a)
2. After that, add approx. 0.5 to 1 ml of the starch solution (reagent c)
3. Using a burette, 0.01 standard iodine solutions (reagent b) is now added until the
sample turns blue.
4. 1 ml 0.01 standard iodine solution corresponds when using 100 ml sample solution to
approx. 6.3 mg/l sodium sulphite (Na2SO3)

Quick test
Small test sticks can be used for a quick determination of the sulphite content (e.g.
Sulphite Test made by Fa.Merck)

53

Alkaline Boiling Out Procedure

Purpose
Alkaline boiling is carried out to removal of oils, fat and silica in newly installed
boilers, and drying the heat insulating material of boilers.

Applicable Item
Auxiliary Boiler BHS-12000-LO

Measurement Equipment & Safety Equipment

Balance
Hand Pump
Rubber gloves
Masker
pH meter

: 1 unit
: 1 unit
: 4 pair
: 4 pair
: 1 unit

Alkaline Boiling Out Procedure

Consumable Material
Sodium hydroxide
Sodium Phosphate
Sodium Sulfite

100 kg
200 kg
60 kg

Application
1.

Mixing of the Chemical

Fill the demineralized water to the Feed Water Tank approximate of volume (6 m3)

Prepare 7.2 kg Sodium Sulfite, 24 kg Sodium Phosphate & Sodium Hydroxide 12 kg

Fill the phosphate dosing tank with 500 liter Demineralized Water.

Slowly through the 1.2 kg Sodium Sulfite, 4 kg Sodium Phosphate and 2 kg of

sodium hydroxide to the phosphate tank than turn on the mixer approximate 15
minutes. Measured the pH

Transfer the mixing solution to Feed Water Tank by Hand Transfer pump. Measured
the pH of the solution in the feed water tank. The pH of the feed water tank < 11.5
but higher than 10.5

54

Alkaline Boiling Out Procedure

Repeat point b to point e for six times.

Open the valves on feed water line to full fill the solution at feed water line the
solution to the boiler.

Turn on The feed water pump to transfer the solution to the boiler

Now the solution in the boiler will be approximate of volume of the Boiler.

Repeat point a to h until the boiler is full of the solution.

2. Closed all the valves attached in the boiler

3. Turn on the burner and heating the boiler until the temperature of mixing
solution is 140 C 145 C or boiler pressure 2.5 bar(g) 3 bar(g). The rate
of the heating of the boiler must not exceed about 50 C per hour by
adjusting the burner combustion rate.
4. Maintain the temperature 140 C 145 C or boiler pressure 2.5 bar(g) 3 bar(g) for 4
hours than cool down the boiler by ambient temperature. The cooling rate must not
exceed 50 C per hour.

Alkaline Boiling Out Procedure

5.

While maintain the temperature or pressure, prepare the solution as per point

6.

After the boiler temperature is about 70 C than slowly drained the solution
up to solution level of the boiler while take the solution sample for
analyzing than feeding the new solution to the boiler. The concentration of
the cleaning agents while draining & feeding must not fall below of the
initial level.

7.

After the boiler water have been drained approximate the volume of the
boiler, or the Feed Water Tank have transfer the solution approximate 12 m3,
than closed the drained valve, repeat the point j to full fill the boiler with the
solution again.

8.
9.

Repeat the point 2 point 8 for 2 times.

Drain out all the water in the boiler and make a new solution to the Feed Water
tank same as point 1 but the pH < 9.5 but not less than 8.5. than full fill the boiler
with this solution. If the boiler ready to run the water level of this solution shall
be at the normal level.

55

THE END

56