Manual Caldera PDF

JNO - HD
INSTRUCTION MANUAL
TABLE OF CONTENTS
1. SAFETY INSTRUCTIONS ......................................................................................................................... 4
1.1. GENERAL SAFETY INSTRUCTIONS .................................................................................................................. 4
1.2. SAFETY DURING LOADING, MOVING AND UNLOADING...................................................................................... 5
1.3. SAFETY DURING ERECTION .......................................................................................................................... 5
1.4. SAFETY DURING MAINTENANCE ................................................................................................................... 6
1.4.1. General ......................................................................................................................................... 6
1.4.2. Health Risks................................................................................................................................... 6
1.4.3. After Maintenance ........................................................................................................................ 7
1.5. OPERATIONAL SAFETY MEASURES ................................................................................................................ 7
2. FUNCTIONAL DESCRIPTION................................................................................................................... 8
2.1. PURPOSE ................................................................................................................................................. 9
2.2. RADIATION SECTION ................................................................................................................................ 10
2.3. THE CONVECTION CHAMBER ..................................................................................................................... 13
2.4. THE ECONOMISER ................................................................................................................................... 18
2.5. THE SUPER HEATER (OPTIONAL) ................................................................................................................ 19
2.6. CLEANING SYSTEM (OPTIONAL) .................................................................................................................. 20
3. STEAM GENERATION .......................................................................................................................... 21
4. GENERAL REMARKS IN CONNECTION WITH STEAM ............................................................................ 22
4.1. GENERAL ............................................................................................................................................... 22
4.2. DEFINITION ............................................................................................................................................ 23
4.3. THE FEED-WATER AND BOILER WATER OF STEAM BOILERS ............................................................................. 23
4.4. CORROSION CONTROL IN BOILER INSTALLATIONS ........................................................................................... 24
4.4.1. General ....................................................................................................................................... 24
4.4.2. Corrosion ..................................................................................................................................... 24
4.4.3. Thermal/Physical Degassing ....................................................................................................... 24
4.4.4. Chemical Degassing .................................................................................................................... 24
4.4.5. Removal of Salts ......................................................................................................................... 24
5. REQUIREMENTS FOR THE QUALITY OF THE BOILER WATER ................................................................ 25
6. PREPARATION FOR START-UP ............................................................................................................. 31
6.1. OPENING AND CLOSING OF VALVES............................................................................................................. 31
6.2. FILLING THE DEGASSER ............................................................................................................................. 31
6.3. FILLING OF THE GRATE COOLING ................................................................................................................ 32
6.4. FILLING THE BOILER ................................................................................................................................. 32
6.5. STARTING THE CONTROL SYSTEM ............................................................................................................... 33
6.6. START-UP OF THE WATER PURIFICATION SYSTEM (OPTIONAL) ......................................................................... 34
6.7. START-UP OF THE ELECTRICAL FILTER (OPTIONAL) ......................................................................................... 34
7. START-UP OF THE BOILER FROM COLD STATE ..................................................................................... 35
7.1. CONVEYING FUEL TO THE GRATE ................................................................................................................ 35
7.2. VENTILATION PROCEDURE......................................................................................................................... 36
7.3. STARTING THE FIRE ................................................................................................................................. 36
7.4. HEATING THE WATER............................................................................................................................... 38
7.5. START-UP OF TURBINE AND CONDENSER (OPTIONAL)..................................................................................... 39
7.6. BOILING OUT AND BLOWING DOWN THE BOILER........................................................................................... 39
8. START-UP OF THE BOILER FROM A HEATED STATE ............................................................................. 40
8.1. CONTROL LOOP FAILURE (CONTROL CIRCUIT OF)............................................................................................ 40
8.2. SAFETY LOOP FAILURE .............................................................................................................................. 40
8.3. FLUE GAS FAN FAILURE ............................................................................................................................ 40
IM JNO Rev.2 ENG – dd. 20150402 - CDE Page 2 / 59

9. SHUTTING DOWN THE STEAM BOILER ................................................................................................ 41
9.1. BASIC SHUT-DOWN ................................................................................................................................. 41
9.2. TEMPORARY SHUT-DOWN ........................................................................................................................ 42
9.2.1. Boiler Goes into Alarm ................................................................................................................ 42
9.2.2. Emergency Stop Shut-Down........................................................................................................ 43
9.2.3. Power Cuts .................................................................................................................................. 43
10. PROCESS MONITORING .................................................................................................................... 44
10.1. WATER LEVEL CONTROL ......................................................................................................................... 44
10.2. FLUSH CONTROL ................................................................................................................................... 44
10.3. SUPERHEATED STEAM – TEMPERATURE CONTROLE (OPTIONAL)..................................................................... 45
10.4. UNDER PRESSURE ADJUSTMENT............................................................................................................... 45
10.5. CAPACITY ADJUSTMENT .......................................................................................................................... 46
10.5.1. Primary Air Control ................................................................................................................... 46
10.5.2. Secondary Air Control ............................................................................................................... 46
10.6. OXYGEN REGULATION AND CONTROL OF FLOW OF FUEL ............................................................................... 47
10.7. REGULATION OF THE GRATE SPEED .......................................................................................................... 47
10.8. FLUE GAS RECIRCULATION (OPTIONAL) ...................................................................................................... 48
10.8.1. Adjustment of the Recirculation to the Primary Air Zones ........................................................ 48
10.8.2. Adjustment of the Recirculation through the Grate ................................................................. 48
11. EVALUATION OF THE COMBUSTION PROCESS .................................................................................. 49
12. MAINTENANCE ................................................................................................................................. 51
12.1. MAINTENANCE TABLE ............................................................................................................................ 51
12.2. CLEANING THE WATER SECTION ............................................................................................................... 53
12.3. CLEANING THE FLUE GAS SECTION ............................................................................................................ 53
12.4. REPAIRS TO FIREPROOF MATERIAL............................................................................................................ 54
12.4.1. Use ............................................................................................................................................ 54
12.4.2. Preparation of the Fireproof Material ...................................................................................... 54
12.5. EMPTY THE ASH BINS ............................................................................................................................. 54
12.6. LAYING UP THE INSTALLATION WHEN OUT OF SERVICE ................................................................................. 55
12.6.1. Wet Lay-Up ............................................................................................................................... 55
12.6.2. Dry Lay-Up ................................................................................................................................ 55
13. TROUBLESHOOTING ......................................................................................................................... 56
14. SPARE PARTS .................................................................................................................................... 58
15. LIST OF SERVICE CENTERS OF VYNCKE............................................................................................... 59

1. SAFETY INSTRUCTIONS
These safety requirements are to be thoroughly studied before starting up the system.
The meaning of the safety icons and of the warning signs must be familiar to everyone who is
present in the vicinity of the system.
All operational and safety requirements must be handed over to the operators of the system.
Besides the safety instructions in this manual, all safety and prevention regulations prescribed
by law must be complied with.
1.1. General Safety Instructions

ATTENTION: The equipment must not be used except as described in this manual. The company
Vyncke accepts no liability for any damage incurred by incorrect use.
The JNO1 is constructed to provide the highest levels of reliability and uses up-to-date state-of-
the-art technology. If the JNO is used incorrectly or is operated by untrained staff, risks of death
or injury to the user or material damage may arise.
The JNO may only be operated if it is in good technical condition.
Defects of the JNO that could lead to further damage or safety risks must be repaired immediately.
The JNO may not be used in an environment where there is a danger of explosion. For more
information on ATEX compliance, we refer you to the official European website
http://ec.europa.eu/enterprise/atex/index_en.htm.
ATTENTION:
In the space inside the JNO an explosive environment may arise. This space
may be regarded as internally safe provided the instructions in this manual
are strictly adhered to.
All process-related specifications and possible sources of ignition have been taken into account
during the risk assessment of this Vyncke assembly.
The company Vyncke is not responsible for the consequences of the application or insertion of
external ignition sources, prior modification of the fuel, or human handling of the fuel which
could cause an explosion (smouldering particles, smoking, welding, grinding, non-contractual
fuel, etc.).
The JNO, as described in this manual, is designed to be integrated into the assembly of the Vyncke
installation, as described in the contract. It is strictly prohibited to start this machine before the
assembly of the Vyncke installation, into which it is integrated, has been declared to be in
conformity with the Machinery Directive 2006/42/EC.
1 Jumbo New Design (Jumbo Nieuw Ontwerp)

1.2. Safety during Loading, Moving and Unloading
The appliances must be suspended using the specific lifting gear (lifting lugs) provided. Only these
provisions have been calculated to bear the load.
The lifting device must be strong enough to move the apparatus. Information about the weight
can be found in the relevant technical data sheet and on the appliance itself or on its packaging.
After the appliance has been offloaded from the transport vehicle, it must be placed on a stable
base so that it cannot fall over unexpectedly.
Everything must be done with the care necessary in order not to cause damage to the device.
Therefore, to the extent possible, the apparatus should be handled in its (original) packaging.
It is advisable to carefully inspect the goods after unloading for damage arising from careless
transport. Any damage must be reported immediately to the transport company and to Vyncke
so that a claim may be made under the transport insurance.
1.3. Safety during Erection

The installation is a “stand alone” installation. This means that once the several parts of the
machine have been installed, they must not be moved. Because erection is a delicate activity, it is
only to be carried out under the supervision of Vyncke or its appointed installer.
It is forbidden to carry out any erection or dismantling of the installation without the express
approval of Vyncke NV.
Figure 1: Lifting the JNO convection part

1.4. Safety during Maintenance
1.4.1. General
A priority before inspection of the boiler is, that the heat generation has been switched off and
that the grate has continued to move until completely empty.
Only approved qualified staff may enter the JNO and only once the feed and ash removal systems
have been completely shut down.
During maintenance, it is mandatory to shut down the JNO and disable the switch so that it cannot
inadvertently be restarted during maintenance. Hang up the below “UNDER MAINTENANCE”
warning sign.
DANGER
UNDER
MAINTENANCE
Provisions must be made for adequate lighting during maintenance. When descending into the
boiler and in the flue gas channels, only appropriate and approved electrical equipment may be
used.
1.4.2. Health Risks

1. The authorised staff must wear protective clothing. The legal personal protective equipment
(dust goggles, dust mask, safety gloves and overalls) must be made available to staff by the
safety supervisor. Furthermore, the safety supervisor must check on compliance with the
safety requirements and operating procedures described.
2. The boiler must be thoroughly ventilated prior to being accessed (see also VENTILATION
PROCEDURE). It is also obligatory that the above protection measures be employed during
maintenance inside the combustion chamber. Dangerous substances and gases may be
present.
3. To remove the ashes from the ash removal area or to perform other maintenance work to the
boiler, it is mandatory to use the aforementioned protective measures.
4. Looking through the inspection hatches during operation or shortly after the shut-down of the
installation always entails danger. Looking through the inspection hatches should be avoided
as much as possible. One must always consider that dangerous hot swirling particles could
escape the installation via these inspection hatches. For this reason, the necessary safety
provisions must be made (exit routes, clothing, etc.). If the fuel assumes bridge formations,
this can even cause a significant risk of possible collapse of a fuel bridge.

5. When cleaning the boiler, boiler scale, sludge, fly ash and soot2 must be removed in a safe
manner. When doing this, special attention should be paid to the use of corrosive, intoxicating,
poisonous and highly flammable gases.
1.4.3. After Maintenance

1. Following maintenance, the seals must be thoroughly closed to prevent dangerous hot
swirling particles (dust and air). In addition, spurious air can reduce the efficiency of the boiler.
2. After maintenance, all tools and extraneous objects must be removed from the JNO before
restarting. Extraneous metal objects can serve as an ignition source for explosion if subject to
friction.
3. Precautions must be taken to avoid staff being trapped in the boiler. Accidental activation of
the installation must be prevented.
Signs such as “DANGER – STAFF INSIDE THE BOILER” are useful.
Before the boiler is restarted, one must check and make sure that there is no-one still present
in the boiler.
1.5. Operational Safety Measures

Inspection of the installation during operation is not permitted. If it is necessary to inspect a part
of the material, that part must be isolated from the rest of the installation.
2 When doing this, it is prohibited to use sharp tools so that the boiler walls will not be damaged.

2. FUNCTIONAL DESCRIPTION
Pictures of the JNO

2
1
1
4 2
Figure 2: The JNO installation
No. Description
1 Radiation section
2 Convection section
3 Economiser
4 Super heater (optional)
2.1. Purpose
The combustion of the fuel on the grate changes the combustion air coming from outside into
energy-rich flue gases. These flue gases return the energy thus obtained to the water in the water
screens of the radiation section and around the fire tubes of the convection section.
Continuous heating of the water causes steam bubbles, which are separated naturally from the
hot water in the convection section.
The steam leaves the boiler through the exhaust opening of the convection section.
Beyond the convection section, an economiser has been positioned. The purpose of this bundle
of pipes is to further cool down the flue gases using cold feed-water. The economiser ensures a
higher efficiency for the installation.

2.2. Radiation Section
Two or more banks of water pipes divide the radiation section into various chambers or passages.
The radiation section consists of a combustion chamber or furnace and a gas burn-out section:
the post-combustion chamber.
a. Combustion Chamber
The fuel is inserted at the top of the grate. The introduced fuel pushes the fuel which is present
along so that it is slowly preheated and the gasification takes place more quickly. The gas arising
as a result mixes above the fuel bed with the air already present (and additional extra air) and is
ignited by the high temperatures. In this phase, approximately 70% of the energy from the fuel is
converted, without significant volumetric reduction.
Because the dosing bunker still continues to feed, the fuel falls evenly down onto the grate. The
speed of the fuel for each burn-out zone is regulated by the speed of the pushing grates and the
amount of combustion air.
At the end of the grate, the fuel is completely burned into ash.
The heat, which is released from the fuel, is transferred by means of radiation into the water in
the banks of water pipes.
Optionally, a pilot igniter based on oil or natural gas can be provided for the automatic ignition of
the boiler.
b. Post-Combustion Chamber
After the gasification, combustion is continued and completed in the post-combustion chamber,
by adding secondary air.
No. Description
1 Secondary air openings
8 2 Inspection doors
Combustion chamber or
3
4 furnace
5 6
First pass or post-combustion
4
chamber
2
1 5 Second pass
Third pass (optional with
6
3 superheaters)
7 Provision for ash removal screw
7 8 Support points
Fly ash that is dragged along with the flue gases

and which would settle in the radiation section
can optionally be removed by the use of a water-
cooled screw.

c. Fireproof Concrete
To obtain optimal combustion, high temperatures in the furnace are required. That’s why the
combustion chamber is covered with refractory concrete.
Because of that fireproof casing, the temperature in the furnace is retained for a certain time
which allows the furnace to restart automatically even after a relatively long stop (up to a several
hours3).
This fireproof layer in turn is protected all around by the water-cooled screen. The thickness of
the lining is chosen so that the wall temperature always remains far below the ash fusion
temperature.
To sufficiently limit the temperature of the boiler’s outside wall,4 the boiler is further encased
with a layer of insulation and a finishing plate.
3 This value depends on the type of fuel, the feeding system, the type and capacity of the boiler, ambient heat, ...
4 The temperature on brief touch may not exceed 65°C in order not to injure humans and animals. (source: EN - 563)

For certain parts, it is technically impossible to apply insulation and protection5 against burns.
It is the job of the operator’s safety officer to provide the necessary instructions, warnings, and
personal protective equipment for this.
An inspection door in the rear wall above the combustion grate offers easy access to the furnace
and grate. For access to the empty passes, an inspection door is located in the third pass of the
radiation section. A large inspection window in the rear wall of the combustion chamber allows
optimal optical checking of the combustion process.
d. Combustion Air
The JNO boiler has a compact and simple air management which can be subdivided into two
phases, namely the primary and the secondary air.
The primary air serves mainly for the gasification and the fuel burn-out on the combustion grate.
This air is directed through or over the fuel by the primary air fan by way of openings in the moving
grate elements of the combustion grate.
The secondary air ensures a full burn-out of the combustion gases and is blown by the secondary
air fan into the post-combustion chamber. The amount of air is regulated by a control valve with
servomotor and frequency control on the fan.
e. Flue Gas Recirculation (Optional)

Flue gas recirculation serves to limit the combustion temperature, as well as to reduce the NOx
values. The recirculated gases are extracted just prior to reaching the chimney so that only
purified flue gas is returned to the combustion chamber. The flue gas recirculation takes place by
means of a separate recirculation fan.
f. PSS Injection Openings (Optional)

The PSS6 feed system has been specially designed to burn up fine-grained fuel. The fuel is
conveyed pneumatically from a dosing silo with an accurately calculated air quantity to the
combustion chamber. The fuel and the transport/combustion air are injected with high speed into
the combustion chamber. As a result of the high temperature in the combustion chamber, the
dust ignites automatically. The length of time that the particles remain in the combustion zone is
artificially extended by the whirling movement to ensure a sufficient burn-out.
The PSS feed system consists of a transport fan that blows the dust along with the primary air
directly into the boiler’s combustion chamber. A non-return valve is placed in the injection pipe
to prevent any backfire of flames from the combustion chamber. In addition to the transporting
air, secondary and tertiary air is also supplied via the injection openings.
5 The temperature on brief touch may not exceed 65°C in order not to injure humans and animals. (source: EN - 563)
6 PSS=Pneumatisch Stook Systeem or Pneumatic Dust Injection System

2.3. The Convection Chamber
Pictures of the convection part.

The convection section is a single or multi-pass fire tube boiler. Externally, the welded cylindrical
hull is equipped with the necessary connection points for accessories, pipes, etc. Internally, a
bundle of steel fire tubes is welded onto the front and the back. At the back of the boiler is the
reversal chamber. A solid chassis supports the boiler and its accessories.
The boiler hull is surrounded by a layer of insulation to both limit heat loss and enhance safety.
The insulation is finished with an aluminium protection.
A convection section with a horizontal pipe bundle ensures a rapid cooling of the combustion
gases by convection. The large volume of water and the large evaporation surface ensure a quick
response when a high steam output is required. Moreover, optimal dryness of the steam is
obtained by means of the internally installed steam dryer.
The optimal combustion and adjusted speed of the flue gases limit pollution and erosion of the
fire tubes to a strict minimum. Owing to the specific nature of the fuel, if necessary, a cleansing
system is installed that cleans the fire tubes using compressed air “shock blasts”. As a result, the
need for manual intervention for the cleaning of the fire tubes is reduced to a minimum.
Since the connection between the radiation chamber and the convection chamber is not capable
of being closed off, the steam process is fully integrated and all safety measures for the radiation-
convection assembly are provided on the convection chamber.

Principle drawing
The convection part can also be called ‘steam vessel’.
Side view and Cross-section of JNO single-pass convection part.

No. Description No. Description
1. Upper steam inlet: steam, created 2. Lower steam/water inlet: steam and
in the tubes of the radiation part of water, created in the tubes of the
the JNO is lead inside the steam radiation part of the JNO is lead inside
section of the vessel the water section of the steam vessel
3. Flue gas entrance: flue gases, 4. Manometer: used to measure the

created by the incineration pressure inside the steam vessel
process, are lead into the fire tubes
of the steam vessel through this
opening
5. Pressure switch: used to relieve 6. Water level alarms: give alarm if the
excess pressure of the steam water level inside the steam vessel is too
vessel high or too low
7. Water level indicators: measure 8. Safety valves (2): will open when the
the water level inside the vessel pressure in the vessel is too high
9. Steam exhaust: lets out the steam 10. Upper inspection opening: manhole that
generated in the vessel to be lead can be opened for maintenance and/or
to consumers in the installation or inspection purposes (possibility to enter
to be lead to the super heater the vessel)
11. Fire tubes: tubes through which 12. Water level: level of water inside the
the hot flue gases are lead, serving vessel (during normal operation)
as a heat exchanger for the water
present in the vessel
13. Three way valve: water, coming 14. Water preheater inlet: lets in the water
from the demineralization to the preheater
installation of the plant can be lead
in two directions: one directly to
the economizer and one to a
preheater
15. Water preheater: tube bundle 16. Outlet feed water: lets out the preheated
inside the steam vessel (under water and leads it further to the
water level) used to preheat the economizer
feed water before it is send to the
economizer
17. Steam area: steam bubbles, 18. Water area: the lower part of the vessel
emerging from the heated water holds the water in which steam is
form steam generated
19. Flue gas chamber: changes the 20. Dewatering culvert: drain that can be
flow of the flue gases to be lead used to remove excess water
onto the economizer

21. Water feed inlet: water, preheated 22. Down comers: allow the natural internal
and coming from the economizer, water circulation and leads colder water
is lead into the water section of the of the steam vessel back to the furnace
steam vessel
23. Down comer water: is lead to the 24. Conductivity control: controls the
tubes of the radiation chamber to conductivity of the water present in the
be further heated vessel
25. Front shock blast system: valves, 26. Rear shock blast system: 26 valves,
installed on both sides of the installed on the rear side of the flue gas
vessel, create a sonic shock to chamber, create a sonic shock that
remove the ash sticking to the removes the ashes from the inside of the
tube-sheet and obstructing the fire tubes
inlet of the fire tubes

2.4. The Economiser
The economiser or pre-heater is a component with

which the feed-water is heated using flue gases,
before it enters the boiler.
The economiser consists of one or more tube

bundles and is located in a steel-plated enclosure.
The economiser is the last heating element on the
flue gas side of the boiler.
The economiser is fed with feed-water from the

degasser at a minimum of 105°C. The temperature
of the water rises through heat absorption from the
hot flue gases. The pre-heated water goes to the
convection chamber via the outlet collector and a
non-closable riser.
The flue gas inlet is connected to the convection

outlet. The flue gases give off their heat to the feed-
water that flows through the tube bundles of the
economiser. The flue gases that leave the
economiser exiting through the flue gas outlet are
sent by the flue gas fan to the flue.

2.5. The Super Heater (Optional)

A super heater produces superheated steam.
The location of the super heaters depends on the required temperature of the superheated steam
as well as the type of fuel. The bundle is located before the convection for high steam
temperatures, and behind the convection for lower steam temperatures.
The saturated steam, coming from the convection chamber, is sent through the tube bundle,
causing this steam to become superheated.
The super heater typically consists of two pipe bundles. For regulating the steam temperature, an
injection cooler is placed between both bundles, which atomises water coming from the feed-
water circuit into the connecting tube.
The outlet of the super heater is provided with the necessary safety equipment.
2.6. Cleaning System (optional)

The cleaning of the boiler’s fire tubes and the pipe plate is done by means of a pneumatic cleaning
system. The cleaning is done by a short burst of compressed air. The frequency of cleaning is set
during commissioning.
The cleaning of the super heater and the economiser takes place by means of an automatic soot-
blasting system that works with superheated steam or compressed air. An automatic valve is
integrated into each of the soot blasters. A rotating soot blaster is installed among each set of
pipe bundles.

3. STEAM GENERATION
Cold feed-water is introduced into the steam drum where, because of the higher density of cold
water, it descends through the down-pipes or down-comers in the direction of the furnace. At
the same time, the heated water moves upwards from the furnace through the risers or the
membrane walls of the radiation chamber.
Heating of the water is obtained through the combustion in the furnace. The heat is exchanged
with the water in the membrane wall of the boiler.
Because the water evaporates in the steam drum, the boiler must be supplied with new feed-
water in order to maintain the water level in the steam drum.

4. GENERAL REMARKS IN CONNECTION WITH STEAM
4.1. General
Whenever steam comes into contact with the skin or whenever it is inhaled, it causes very
severe burns. Rehabilitation can take years. The reason for this is that steam possesses a heat
capacity 4000 times greater than water. So be aware of this risk whenever maintenance works
are to be carried out.
At atmospheric pressure (0 bar g), water boils at 100 °C, and 419 kJ of energy are needed to heat
1 kg of water at 0 °C to the boiling point of 100 °C. This fact has given rise to the specific heat
capacity cp of water (4 186 kJ*kg-1*K-1).
When the temperature of the water rises because energy is added, and the water is nearing its
boiling point, then a number of molecules obtain sufficient kinetic energy to reach speeds that
allow them the chance to escape the liquid to above the water surface, to then fall back.
Further heating causes an even greater excitation and the number of molecules with enough
energy rises. At the moment that the water achieves boiling temperature, steam bubbles form in
the liquid. These rise and reach the water surface.
Considering the molecular structure of liquids and gases, it is logical that the density of steam is
much lower than that of water because the steam molecules are much further removed from
each other. The space immediately above the water surface is thus filled with less dense steam
molecules.
At the moment that the number of molecules leaving the liquid exceeds the number that fall back
by precipitation, the water will evaporate spontaneously. At that moment, the liquid has reached
its boiling point or its saturation temperature.
If the pressure remains constant and heat continues to be added, then the temperature does not
increase further but the water continues to form saturated steam. If the pressure rises, then the
temperature does increase and a new saturation temperature is created.
The relationship between the saturation temperature and pressure is the steam saturation curve:
Steam saturation curve

4.2. Definition
In engineering, steam refers to evaporated water. It is a pure, completely invisible gas (not fog).
Pure steam (unmixed with air, but in equilibrium with liquid water) has a temperature of around
100 °C at standard atmospheric pressure and occupies approximately 1600 times the volume of
liquid water. Steam can, of course, be much hotter than the boiling point of water. Such steam is
called superheated steam.
4.3. The Feed-Water and Boiler Water of Steam Boilers

Proper treatment of feed-water and boiler water can prevent a great -deal of damage to the boiler
and all appliances of the water, steam and condensation circuit. Damage to the installation can
be caused by:
1. Hard feed-water. The presence of lime, inter alia, results in a reduced heat transfer and
less effective cooling of the heat exchanging components.
2. Rusting or oxidation of the metal caused by the presence of oxygen in the feed-water,
with corrosion of the boiler (primarily of the fire tubes) and risk of damage by boiler leaks
as a result.
3. Excessive content of aggressive gases. These gases which are absorbed in the water, e.g.
oxygen and free carboxylic acids, can, especially if present together, cause significant
corrosion.
4. Excessive oil content in the feed-water. An oil deposit on the superheated boiler parts
greatly reduces the heat transfer.
5. Excessive salinity of the boiler water. Consequence: the quiet and dry evaporation under
normal circumstances becomes very turbulent.
6. The steam also carries water particles along with it. As a result, salt deposits form in the
steam pipes, steam machines, taps, and other accessories, with the risk of seizure through
silting up. In short order, the complete steam installation is polluted. Excessive salinity of
the boiler water is extremely dangerous for the super heaters.
7. To reduce these risks, strict conditions for the boiler water and the feed-water are
mandatory. Chemical purification is the easiest method. For larger installations, thermal
degassing is recommended in preference to removing the aggressive oxygen with
scavengers.

4.4. Corrosion Control in Boiler Installations
4.4.1. General
Damage in boiler installations and heating installations is caused mainly by the oxygen that is
dissolved in the water, by free carbon dioxide and by boiler scale formed because of the hardness
of the water.
4.4.2. Corrosion
Every form of corrosion is a chemical attack on the metal surface. In the presence of oxygen, the
points of corrosion (also called cells) of ordinary metals change into pits and holes. This is called
“pitting” and is a typical sign of oxygen corrosion. Free carbon dioxide, like any other acid,
corrodes the entire surface of the metal. If the water contains large quantities of oxygen and free
carbon dioxide, a very great deal of damage will be caused.
The rust brown colour of boiler water, caused by the formation of iron components, is easy to
spot and is a sure indication of the presence of corrosion. Because of this, the water must be kept
free of dissolved oxygen and free carbon dioxide by means of thermal and chemical degassing.
4.4.3. Thermal/Physical Degassing

The solubility of oxygen in water depends on the temperature, whereby the solubility decreases
as the temperature rises. This principle is often used in boiler installations to remove oxygen and
free carbon dioxide from the water. The water is uniformly divided as a spray in the degassing
tower which is mounted above a closed drum. The water is brought to boiling point at a pressure
slightly above atmospheric pressure by a counter flow of steam. This process is known as thermal
degassing of water.
The gases expelled from the water, such as oxygen and free carbon dioxide escape with the vapour
through the degassing tower. At a temperature above 100 °C, the treated water contains no more
than 0.1 mg/kg of oxygen and less than 1 mg*kg-1 of free carbon dioxide.
4.4.4. Chemical Degassing

See information from the supplier.
4.4.5. Removal of Salts

Flushing is by definition the removal of a small part of the concentrated boiler water so as not to
exceed the maximum quantity of dissolved and suspended solids in the system.
The concentration (salt quantity, °Bé on the Beaumé hydrometer scale) and the alkalinity (pH
value) in the boiler must be maintained in accordance with the guideline values given by the
manufacturer. The boiler water must be desalinated whenever the boiler water has a cloudy
appearance caused by occurrence of precipitated iron oxides, salts and other suspended solids.
As long as the boiler contains these suspended solids, it is necessary to perform desalination.

5. REQUIREMENTS FOR THE QUALITY OF THE BOILER WATER
The values for the maximum permitted concentration of impurities and the values for the
maximum and minimum concentration of chemical reagent, added to minimise corrosion, sludge
formation and deposits, must be in accordance with the following tables 5.1 to 5.3 and figures 5.1
to 5.5 from the EN12952-12:2003 standard.

.

6. PREPARATION FOR START-UP
6.1. Opening and Closing of Valves
Verify that all valves/taps are in the correct position:
If present, before the start-up of the boiler the following equipment must be “closed”:
1. Flush valves of the radiation chamber;
2. Flush valves of the condensate tank;
3. Flush valves of the buffer tank with degasser;
4. Flush valves of the grate cooling;
5. Valves in steam pipes to consumers (main steam pipe, steam-based air pre-heaters, soot
blower, degasser, …)
6. Valve to injection cooler.
If present, the following equipment must be “open”:
1. Valves for manometers, pressure transmitters and pressure control;
2. Bleed valves;
3. Valves for level detection and transmitter valves on the steam drum;
4. Flush valve of the convection chamber;
5. Valves in the water pipes to the boiler (economiser), the condensate tank, the degasser,
the grate cooling, water-based air pre-heaters, etc.;
6. Valves in front of and behind the feed pumps;
7. Valve for the expansion tank;
8. Valves in the secondary circuit;
9. Valves in the circuit of the emergency cooling battery;
10. Valves in the primary circuit of heat exchangers;
11. Valves in the oil or gas pipes of the burners present.
The safety valves of the entire system must be on standby.
Check the following on the flue gas side:
1. There are no longer any persons present in the boiler, the buffer tank, the degasser, and
the combustion chamber;
2. There are no tools or other apparatus in the boiler or feed-water circuit;
3. Cleaning and inspection hatches are closed;
6.2. Filling the Degasser

The degassing drum should be flushed and must be filled with demineralised water. During filling,
the drum must be checked for any leaks. A check must be made as to whether the start-stop level
of the pump is functioning correctly. The alarm signalling must be tested. This includes the
following alarms:

1. Stopping of the water feeding pump and the pump for grate cooling – hardware contacts
required
2. Low level alarm
3. High level alarm
6.3. Filling of the Grate Cooling

The grate cooling system must be taken into use and filled when the temperature in the
combustion chamber is below 60 °C. This is necessary to avoid thermal shock. There is no problem
whatsoever with this during the initial start-up of the installation. When the valves are correctly
set, the cooling system can be filled manually. It is only necessary to check the system for leaks.
The necessary feed-water for the grate cooling circuit is softened by means of a water treatment
installation and pumped through the pipes by the mains water system pressure. Filling, refilling
and pressure preservation of the grate cooling circuit takes place by means of the expansion
system.
When filling, both right and left venting valves must be closed at the highest point of the grate as
soon as water flows from the valves. Following on from this, the desired system pressure is set via
the expansion system.
6.4. Filling the Boiler

The boiler must be filled when the temperature in the furnace is below 60 °C to avoid thermal
shock. The temperature of the feed-water should normally be equal to the temperature of the
boiler wall. Filling the boiler with cold feed-water is not permitted if the temperature in the boiler
is higher than 100 °C. When the difference in temperature between the boiler tubes and the boiler
exceeds 20 °C then the boiler must be filled very slowly and carefully. The boiler must be filled
under manual (“Hand”) control. The following matters should be checked and done in advance:
1. Water level control – “Hand”
2. Control valve on feed-water with electrical drive in position “O”
3. Valves in the correct position
Filling the system can start when there is sufficient water present in the drum of the degasser,
this means that the water level in the drum is at least 100 mm above the minimum water level.
The selected pump must be turned on manually. The control valve must be opened slowly until
the flow of the feed-water is about 5 m³/hr. The flow can be checked by viewing it on the display
panel.
The boiler must be filled with this feed-water until the level in the drum exceeds the minimum,
this means when the “water shortage” alarm stops. If water escapes from the bleed valve, then
the bleed valve should be closed (the pump can then be stopped). When the water has reached a
level higher than the minimum, the control valve on the feed-water should be closed and the
pump stopped.

6.5. Starting the Control System
- Switch on the
main switch.
- After waiting a
few seconds, keep
the Reset button on
the control panel
depressed for at
least 5 seconds.
- After waiting a
few seconds, once
again keep the Reset
button depressed
for at least 5
seconds.
- The boiler is
ready to start up.
Figure 3: Control cabinet
NO. DESCRIPTION
1 RESET button and ON/OFF switch
2 Main switch
3 On and off switches for installed components
4 Touch panel (optional)

6.6. Start-Up of the Water Purification System (optional)
The water purification system is to be started up in accordance with the manufacturer’s user
manual. The control for the water purification is located on the device itself, and it is operated
from there. On the display panel, a collective fault alarm as well as fault alarms from the
conduction control and hardness control will follow.
The water purification and the ionised water purification systems must be in operation and the
reservoir containing the supply of ionised water and fresh water must be at least 50% full, before
starting up the boiler.
6.7. Start-Up of the Electrical Filter (optional)

The electrical filter is to be started up in accordance with the electrical filter manufacturer’s user
manual. Switching the filter on and off is done from the control panel of the electrical filters. On
the display panel a collective fault alarm as well as a fault alarm from the high-voltage control will
follow.
Insulator heating and ancillary heating for the dust-collecting screw must be in operation
approximately 5 hours before start-up of the boiler installation.

7. START-UP OF THE BOILER FROM COLD STATE
Start-up when the boiler is fully extinguished and no fuel nor any smouldering fuel is present.
The start-up of a cold boiler must be done manually and be continuously monitored by the
operator. Several steps must be completed before the boiler is started up:
7.1. Conveying Fuel to the Grate
DESCRIPTION OF POINT TO BE CHECKED CHECK
Introduce fuel into the dosing bunker by switching on the feed system to the
1 dosing bunker on the control panel.
2 Start the ventilation procedure (see chapter 7.2).
3 Choose the touch panel option “Fill”.
4 Verify that there are no alarms.
5 Switch on the flue gas fan.
Switch on the dosing system to the boiler: the fuel is now introduced into the
6 boiler.
7 Switch on the cooling pump for the grate.
Switch on the hydraulic group for the grate (including the cooling pump and
cooling fan) to evenly distribute the fuel onto the grate. Stop when the fuel has
8 reached the end of the second zone. The initial fuel bed must be a layer 100-
200 mm thick. Ensure that the layer of fuel on the grate is not too thick. That
would make combustion difficult.
9 Switch off the dosing system.
You have 10 minutes to convey the fuel to the grate before beginning the
10
following procedure “Start the fire”.
The feed system can work in 3 modes:

- “Fill” Mode = filling of the grate
The fuel supply to the dosing bunker is active. The fuel must then be manually introduced
onto the grate.
- “Normal” Mode = normal operation during combustion
The fuel supply to the boiler and the air supply are activated. The fuel supply to the dosing
funnel is active.
- “Emptying” Mode = emptying the grate
The fuel supply to the dosing bunker is shut down. The fuel supply to the boiler and the
air supply are still active to allow the boiler to empty.

7.2. Ventilation Procedure
In certain situations, before starting up the boiler, the complete flue gas circuit must be ventilated.
This is to remove dangerous and explosive gases from the boiler.
The ventilation procedure can be started by pressing the “Start venting” button.
Note: the ventilation procedure can only be started if the fans are turned on and if no main alarms
are being reported.
The ventilation procedure starts automatically and goes through the following steps sequentially:
1. Close air valves

2. Start primary and secondary fans
3. Open the air valves
4. Boiler is ventilated for a pre-set time
5. Primary and secondary fans fall silent
6. Air valves return to starting position
7. On the screen, the message “VENTING IS OK” appears
7.3. Starting The Fire

If there is a pilot igniter present, the start-up can happen simply by using this igniter. As soon as
combustion on the grate is running by itself, the pilot igniter must be switched off and shielded.
If auxiliary fuel ignition is provided for emission control, no solid fuel should be placed on the grate
for ignition until a sufficiently high temperature has been reached in the post-combustion
chamber (850 °C).

After a successful ignition, the fire door must be immediately closed and
locked. The operator must keep an eye on the development of the flames on
the grate through the inspection window. As soon as the flames are burning
over the full width of the grate, the following sections of equipment must be
switched on:
1. Primary air fan
1 2. Secondary air fan
3. Grate drive – grate movement
4. Fuel supply for the grate combustion
5. If applicable, the electrical filter must be started up according to the
manufacturer’s user manual, i.e. with full power of the high-voltage
installation.
As soon as the grate transport and the grate movement are in operation, the
2 fuel is slowly shifted in the direction of the burn-out zone of the grate. The
capacity of the installation can now be increased manually.
If applicable, the recirculation fan is switched on if the temperature in the post-
combustion chamber exceeds a predetermined value. During the start-up
3 procedure, the setting of the separate recirculation quantities automatically
follows the boiler capacity by way of the recirculation valves.
The combustion should be started up slowly. The prescribed temperature

4
gradients for the heating of the fireproof casing must be complied with.

The boiler itself must also be started up slowly. As soon as the combustion is in
stable operation, the boiler will be brought up to temperature using a start-up
5 programme. As soon as the boiler pressure exceeds 5 bars and the post-
combustion chamber temperature exceeds 700 °C, the boiler can be switched
into a capacity-dependent start-up mode.
The boiler is now running at a limited 40% capacity until the furnace has
reached a temperature of 400 °C.
Ramping: when the boiler is no longer running at limited capacity, the capacity
will increase by 1%, e.g. every 30 seconds (depending on the settings under
ramping on the start-up screen).
6
This is to prevent the boiler from going straight to the desired operating
pressure and rising to 100% capacity in a few minutes. If you increase the
pressure in small steps, then the boiler is gently regulated upwards, and you
avoid the scenario where you have too low a pressure in the boiler and a high
temperature in the furnace or in the superheater.
When the combustion is in full operation, it can:
7 1. Work with automatic combustion control

2. Work with grate combustion + injection combustion
Optional:
If the steam outlet is connected to a turbine:
At start-up from standstill, it is recommended that the maximum capacity be
limited to 60% and when the turbine in taken into operation, increase it
manually by 10%!
1. Pay attention to the temperature of the superheated steam exiting the

8
super heater and avoid exceeding the maximum steam temperature, see
the technical data.
2. If the temperature nonetheless rises, ensure a greater flow rate through
the super heater by blowing off steam using the bypass over the turbine
or by opening the valve of the soot-blower pre-heaters
3. Shut the boiler down for a brief time
4. When the pressure and a superheated steam temperature is reached in
the boiler, proceed to starting up the turbine

7.4. Heating the Water
During the start-up procedure, constant monitoring of the boiler water level and pressure is
necessary because of the expansion of the boiler water volume caused by heating the boiler. The
boiler water level must be kept below the high water alarm level by manual release of boiler water.
When releasing the water, pay attention that the water level remains above the low water level.
The boiler must be heated slowly, to guarantee a uniform heating of all boiler parts. The bleed valve
on the convection chamber must be closed at a boiler pressure greater than 1.5 bar. Before the start-
up procedure, the following measures must be taken:
1 Water pump “on”
2 Optional: Condensate pump “on”, in case of a bypass over the turbine
3 Optional: Open the valve in the steam pipe to the feed-water tank.
Optional: Temperature control of the superheated steam must be switched to

4 manual. The control valve on the flue gas side bypass to the super heater must
be opened!
The pneumatic soot-blasting system for the convection chamber must be

5 switched on
The boiler feed pump is switched on as soon as a constant decrease in steam is

6 to be expected, at a steam pressure greater than 1.5 bar. The feed pump is
turned on when the feed-water control valve is closed.
The water level control is switched to “automatic” if the boiler feed pump is in
7 operation.
Optional: At a boiler pressure greater than 1.5 bar the high pressure valve for
8 steam to the turbine and pressure reducing station must be opened.
Optional: The amount of steam sent to the pressure reducing station (through
9 bypass or exhaust pipe) is set manually in such a way that adequate cooling of
the super heater is guaranteed.
10 The flush control must be set to automatic.
11 Optional: The superheated steam temperature control must be set to automatic.
Optional: The boiler installation is brought to operating pressure using the

12 automatic start-up program as soon as the pressure reducing station is in
operation.

7.5. Start-Up of Turbine and Condenser (optional)
The turbine is taken into operation in accordance with the instructions in the turbine
manufacturer’s user manual.
7.6. Boiling Out and Blowing Down the Boiler

If required for the steam quality, after the boiler has been shut down for a prolonged period (more
than 3 months), it is necessary to boil it out and blow it down to remove rust and other
contaminated particles in the steam pipe. Contact Vyncke to carry out the boiling out and blowing
down procedure to full satisfaction.

8. START-UP OF THE BOILER FROM A HEATED STATE
Start-up when the boiler has been set to ‘OFF’ for a certain period of time, but where there is still
smouldering fuel present.
8.1. Control Loop Failure (control circuit of)

If the control loop has failed (e.g. if the boiler reaches the pressure), the boiler will automatically
restart. No actions are necessary in such a case.
8.2. Safety Loop Failure

If the safety loop has failed, the alarm messages will be showing on the display panel. Check what
has gone into alarm state, solve the problem using the “Alarm list” section, and reset the boiler
by keeping the Reset button on the control panel depressed for a few seconds. The boiler
automatically restarts.
Automatic start-up of the boiler includes the following sequence:
1. Starting the secondary fan
2. Starting the primary fan
3. Starting the dosing system
Note: the dosing system can only be started up if the feed sequence has already been switched
on.
8.3. Flue Gas Fan Failure

If the flue gas fan has failed, the boiler will go into alarm state and will also fail. Check what has
gone wrong with the fan and solve the problem. Carry out the procedure below.

The display panel shows the message that the VENTING procedure no longer
1 meets the requirements. Start the ventilation procedure as described in the
“Ventilation” chapter.
If the temperature in the furnace is still high enough, it is possible to restart the
boiler using the “Normal” automatic mode. Verify that the combustion is again
running optimally.
2
If the temperature in the furnace is too cold to automatically ignite again, you
will have to restart the boiler using the manual “Fill” mode, as described in
“Starting up a cold boiler”.

9. SHUTTING DOWN THE STEAM BOILER
9.1. Basic Shut-Down
The steam boiler is a modulating installation. That means that the boiler itself will automatically
start and stop depending on the energy consumption. If there is no single appliance running, that
would not necessarily mean that the installation is shut down. It is also possible that it is
temporarily out of action because too little energy in the circuit is being consumed.
The manual procedure for basic shut-down of the boiler is desirable if the boiler is going to be
inactive for more than 12 hours.
In the following paragraphs, the word shut-down shall mean long-term deactivation of the
installation. That can happen, amongst other reasons, to allow for interim maintenance or
because there is no demand for energy (e.g. in the summer).
Switch the boiler into the manual “Emptying” mode. The fuel supply to the
1 dosing bunker will automatically be shut down.
2 Let the boiler burn empty.
3 If the boiler is completely burnt out, it can be switched off at the control panel.
Afterwards the flue gas fan can be switched off and all other parts of the
4 installation.
Once the boiler is fully cooled down to less than 100 °C, and all ashes have
5 been removed from the boiler, the ash removal system may be switched off
and the circulation pump for the grate can be shut down.
The boiler is now off, but the circuit and the furnace may still continue to be
hot for a long time. The fuel bed burns downward very slowly, and is covered
with a layer of ash that insulates and keeps the fuel mass glowing for a very
long time. So take great care to check the temperature and take sufficient
measures not to get burnt.

9.2. Temporary Shut-Down
In the case of a temporary shut-down, such as for mechanical maintenance where the shut-down
does not exceed 12 hours, it is not necessary to empty the dosing system and the grate.
9.2.1. Boiler Goes into Alarm

A main alarm shut-down is caused by a fault or a blockage in the control system. The operator
must investigate and solve the cause of the alarm. To this end, the alerts are displayed on the
display panel. The operator acknowledges the alarm by pressing the Reset button. This means
that the problem has been resolved and that the boiler can be automatically restarted.
On activation of one of the safety components, the following alerts may be distinguished:
If the safety circuit has failed, check what has gone into alarm state, resolve the problem using
the “Alarm list” section, and reset the boiler by keeping the Reset button on the control panel or
on the display panel depressed for a few seconds. The boiler automatically restarts.
Automatic start-up of the boiler includes the following sequence:
1. Starting the secondary fan
2. Starting the primary fan
3. Starting the dosing system
Note: the dosing system can only be started up if the feed sequence has already been switched
on.
On activation of one of the safety components, the following alerts may be distinguished:
a. Major Alarm
A major alarm causes the combustion to be switched off. It is visually and audibly reported via the
control panel and the display panel. With that alarm, the following components are switched off:
- Feed system
- Combustion air fans
- Grate movement
The other modules remain in operation to preserve the safety of the installation.
b. Minor Alarm
A minor alarm causes the switching off of the part where something has gone wrong. The alarm
is visually and audibly reported via the control panel and the display panel. The modules in the
same sequence as the failed component will also be switched off. The other modules remain in
operation to preserve the safety of the installation.
c. Warning
This is an optical and acoustic “alarm” that does not switch off any component. The operators
decide what has to be done.

9.2.2. Emergency Stop Shut-Down
If the emergency stop push button is pressed, this shuts down the entire boiler with the exception
of the extinguishing system. That remains in operation to ensure the safety of the installation.
After the hazardous state has been lifted, the stoker in charge decides whether the installation is
to be restarted or fundamentally shut down.
9.2.3. Power Cuts

In the event of a power cut, those components of the boiler installation which are essential for
safety are kept operational by emergency power. The electrical control has two power supplies:
- Operational net – 400 V
- Emergency power net – 400 V
In addition to the emergency power net, a UPS is provided. In case of a power cut, the switch from
normal operation to emergency power follows automatically. The following installation
components are put on emergency power:
- Electrical control, including PLC (Power Line Communication)
- Display panel
- Fire extinguishers
- Control valves; these valves are closed in the event of a power cut
- Cooling pumps (only partial power for minimum circulation)
Dangerous situations cannot arise as a consequence of power cuts. Immediately after the failure
of the separate installation components, the combustion is stopped.

10. PROCESS MONITORING
The process of the boiler is monitored by the following measurement and control systems:
10.1. Water Level Control

The water level in the drum can always be checked visually using the gauges available. To ensure
that the level indicated on the gauge corresponds to the level in the steam drum, the gauges
should be flushed.
The water level in the drum is monitored by a continuous measurement of the level driving the
modulating feed valve.
To avoid the boiler boiling dry, there are several controls provided. Two independent low water
alarms measure the level and put the boiler into alarm state if the water drops below this level.
The feed pump still remains operational in this case.
There is a high water alarm to protect the boiler from overfilling.
The feed pump runs continuously and will only be stopped if the high water alarm level in the
boiler is reached. To provide a minimum continuous flow through the pump, a return pipe from
the modulating supply valve to the feed-water tank is provided.
The adjustment of the water level is done by a PID (Proportional Integral Derivative) controller (in
the PLC), and regulates the amount of feed-water, depending on the water level in the steam
boiler. Optionally, a three point control is provided, where the flows of feed-water and steam are
continuously monitored to obtain a more accurate adjustment of the feed-water flow and the
water level.
10.2. Flush Control

The flush control works while the feed pumps are running, and regulates the conductivity of the
boiler water. The adjustment consists of:
- Conductivity electrode
- Flush regulator, built into the electricity cabinet
- Automatic flush valve
The regulation of the conductivity does not affect the normal operation of the controls of the
boiler installation. If the boiler installation is inactive, this regulating valve is closed.

10.3. Superheated Steam – Temperature Controle (Optional)
The superheated steam temperature exiting the super heater is constantly measured. The signal
from the temperature measurement unit is used to control an injection cooler. This is installed
amongst the pipe bundles and injects cool water so as to obtain the correct steam temperature
at the output of the super heater.
The outlet of the super heater is provided with the necessary safety equipment.
The display panel shows the following
- Superheated steam temperature on exiting the super heater
- Superheated steam temperature on exiting the cooler
- Steam temperature on entering the super heater
- The status of the actuator at the regulating valve/injection cooler
Switching the controller from “manual” to “automatic” is done at the display panel. During the
fine tuning of the boiler, this adjustment is set to “automatic” mode. On starting up the
installation, the regulator is set to “manual” mode. Details of start-up are described separately.
For low temperature super heaters, as an alternative, a flue gas side bypass is provided for the
adjustment of the steam temperature.
10.4. Under Pressure Adjustment

The flue gas fan ensures that the flue gases from the boiler are transported to the stack. It also
ensures that the furnace is always subjected to under pressure so that the flame stays in the
boiler. The boiler door may not be opened if either the flue gas fan and/or the air fan is running.
There is thus absolute certainty that there will never be propagation of the flame outside the
boiler. To view the flame during combustion, one or more protected viewing windows are
mounted on the boiler.
The under pressure in the furnace is measured continuously. The measured value is displayed on
the display panel. The adjustment of the under pressure in the furnace is a function of the
measured pressure in the furnace. A PID controller (in the PLC) controls the under pressure in the
furnace. The output signal of this controller is linked to the frequency control of the flue gas fan.
In the process control, the under pressure adjustment can be done under “automatic operation”
or “manually”. During the operation of the installation, the regulator is always set to “automatic”.
On the process controller, the following values can be visualised:
1. Under pressure in the furnace
2. Feedback on the rotational speed of the flue gas fan

10.5. Capacity Adjustment
The capacity is regulated by a PID controller (in the PLC). This capacity adjustment regulates the
installation as a function of the heat uptake.
The capacity adjustment of the installation can be both “manual” and “automatic”. The “manual”
mode of operation is used for the start-up of the installation and for adjustment of the installation.
The amount of combustion air, the fuel supply and the regulation of the grate speed is mainly
governed by the setting for the boiler capacity.
The capacity of the installation can be regulated on the basis of the steam pressure in the boiler
or on the basis of the steam flow exiting the super heaters.
The controller calculates the value of the necessary capacity based on the difference between the
current value and the desired value.
The necessary amount of combustion air, the grate speed and the amount of fuel are set according
to the calculated capacity.
10.5.1. Primary Air Control

The system for air distribution for each grate zone consists in all cases of a valve with a servo
motor and a positional feedback device.
The desired value is separately programmed into the PLC for each grate zone.
The signal from the positional feedback device is compared with the value set, and then the servo
motor regulates the valve to the desired position.
This desired value is pre-set by the commissioning engineer and is done for each zone and each
capacity individually.
Optionally, a flow rate meter is provided for each grate zone. In this case, it is not the status of
the valve but a fixed flow rate which is set for each capacity, and the air valves are driven as a
function of the desired flow.
10.5.2. Secondary Air Control

The system for the secondary air distribution consists of valves with a servo motor and a positional
feedback device. The speed of the fan is likewise adjusted to the capacity.
The desired values are pre-set (into the PLC) for each capacity by the commissioning engineer.
Here too, the signal from the positional feedback device is compared with the value set, and then
the servo motor regulates the valve to the desired position.

10.6. Oxygen Regulation and Control of Flow of Fuel
The desired capacity (calculated from the difference between the desired and the actual process
value, such as steam pressure) drives the supply of air and fuel. These values (set by the
commissioning engineer) provide in theory for optimum combustion. However, in practice, there
are many factors that influence combustion (read oxygen content) and disrupt it (moisture and
calorific value of the fuel, type of fuel, fuel size, etc.) as a result of which it is necessary to adjust
the ratio between air and fuel according to the actual situation
We do this on the basis of the effectively measured oxygen (an oxygen sensor measures the
volume percentage of oxygen present in the flue gases). The oxygen content is generally between
7 % vol. and 9 % vol.
The fuel flow is regulated by a PID controller (in the PLC) in order to get back optimal combustion
(correct ratio of oxygen to fuel).
10.7. Regulation Of The Grate Speed

The regulation of the grate speed takes place as a function of the output signal from the capacity
regulator.
The speeds of the cylinders in the combustion zones are set by means of a proportional valve set
as a function of the capacity. The speed of the cylinder of the last ash removal zone is set at a
fixed value at start-up of the installation.
The feedback from the position of the hydraulic cylinder and the time needed for the ongoing
movement can be called up by the process control.

10.8. Flue Gas Recirculation (optional)
10.8.1. Adjustment of the Recirculation to the Primary Air Zones
The supply of the recirculation air to the primary air zones is assigned as a percentage of the
primary air quantities for zones 1 and 2.
Each of the two zones is equipped with a control valve with a servo motor. The positional feedback
takes place via the potentiometer on the servo motor. Each valve has a position regulator. The
controllers programmed in the PLC operate independently of the guide signal from the “guide
adjustment for primary air”.
The valve positions are displayed on the display panel. The minimum and maximum positions of
the regulator valves, as well as the properties of each separate control circuit are adjusted in the
context of the commissioning.
10.8.2. Adjustment of the Recirculation through the Grate

The recirculation quantity is continuously measured, compensating for pressure and temperature.
On the display panel, there appears:
 Recirculation quantity in Nm³/hr
 Recirculation temperature
The regulation of the recirculation quantity then follows, linked to the capacity signal from the
flow rate controller and also depending on the recirculation amount as measured by recirculation
amount regulator programmed in the PLC. The regulator can work “manually” or “automatically”.
When starting up the installation, the regulator is set to “manual”. During normal operation of
the combustion chamber, the regulator is set to “automatic”.
The output signal of the controller is fed to the servo motor of the control valve. The position of
the valve is reported on the display panel.

11. EVALUATION OF THE COMBUSTION PROCESS
The combustion process of solid fuels is a fairly complex process. A certain amount of experience
is necessary to monitor and evaluate such a combustion process. It is therefore absolutely
advisable that the operator has gained sufficient experience during the period of commissioning
and has taken notes of important information.
If the boiler can operate under correct conditions and if the parameters are set correctly, then it
is possible that the combustion can proceed in a controlled way so as to deliver the desired
capacity, to achieve good emission values, to minimise alarms, to obtain a good burn-out, etc.
Good combustion means:
- The height of the fire is about 1 to 2 m
- The fire burns over 80 % of the grate width
- The fire burns over 50 % - 80 % of the grate length
Note:
The help methods that follow can give the operator sufficient information about how the
combustion should actually take place. Extreme situations can be dangerous and must be
immediately recognised by the operator.
The best observation of the combustion can take place by looking at the fire
through the observation windows. You can see immediately whether there is
too much or too little fuel on the grate.
Too much fuel in comparison with the intake of combustion air or too little
combustion air in comparison with the amount of fuel.
1
Features:
1. There is a thick layer of fuel on the grate
2. Unburned fuel ends up in the ash removal area
Check the O2 regulation which influences the amount of feeding and check the
capacity regulation which sets the air dampers of the combustion air.
Too little fuel on the grate. The fuel layer on the grate is thin and has already
burned out at a very early stage. This is the reverse situation of above, the same
2 actions are required as above.
Contact Vyncke Customer Service Department if no failure can be found.
The fuel is too wet. There is a lot of fuel divided over the grate, but combustion
has only taken place in the final zones of the grate. The operator must
3
immediately adapt the settings of the boiler to the properties of the fuel. If
necessary, contact Vyncke.
Poor air distribution over the grate or incorrect speed of the grate as a result
4 of which the fuel does not burn evenly. Check if no grate chariot is blocked or
if there is no failure with the hydraulic grate drive system.

Uneven combustion. The seat of the fire is located on only one side of the grate.
5
Check if there is no bridging happening in the grate feeding system.
Fusion of the ash to the side wall of the combustion chamber (‘slag formation’).
Verify that the fuel meets the pre-set parameters. Clinkers are formed by
6
cooling down of melted ashes. Melting of ash happens at high temperature.
Check for too thick fuel layers in which the air cannot go through.
Uneven temperature of the flue gases indicates intermittent, uncontrolled

7
combustion. Check the function of the feeding system (bridging).
The emission values give good insight into the combustion. Excessive CO
8
emissions indicate incomplete combustion.

12. MAINTENANCE
Incomplete and incorrect maintenance activities can constitute a safety risk.
Maintenance activities may only be carried out by authorised personnel.
12.1. Maintenance Table

12.2. Cleaning the Water Section
1 Shut the boiler down
2 Open the inspection apertures.
3 Clean the boiler with a high pressure cleaning device.
4 Close the inspection apertures again.
12.3. Cleaning the Flue Gas Section

Amongst other things, the efficiency of the boiler depends on the extent of pollution in the flue
gas section of the boiler. Soot and carbon deposits interfere with heat transfer. It is thus
appropriate to thoroughly clean the fire tubes at least once every 6 months. Rising chimney
temperatures indicate a dirty boiler. In that case, the cleaning needs to be carried out sooner.
FURNACE
1 1. Crawl into the furnace and check the inner wall of the boiler.
2. Check the concrete and repair where necessary according to the instructions
under “repairing concrete”.
FIRE TUBES
1. Open the upper and lower inspection lids on the reversal chambers.
2. Ensure that the sealing cord is not damaged. Replace it if necessary.
3. Clean the pipes with a steel brush. You must push this brush completely
2 through before pulling it back. Perform this movement several times until
you encounter almost no resistance any longer. The soot can then be
removed on both sides.
4. Clean the chimney outlet.
5. Carefully close all lids.
CHIMNEY
3
1. It is also advisable to clean the chimney annually.

12.4. Repairs to Fireproof Material
12.4.1. Use
With the installation, two bags (each 25 kg) containing fireproof material are supplied for
performing small repairs. The manner of preparation can be found in the next paragraph.
The concrete in question is ideal for small repairs, considering that it can be applied with a trowel
to the damaged layer.
12.4.2. Preparation of the Fireproof Material

The areas to which the concrete is applied must be well cleaned. These surfaces must never be
moistened.
The concrete is mixed in the proportions of 6.5 to 9 litres of water per 50 kg. The exact amount is
indicated on the packaging.
Intensive mixing is necessary. That can be done with a trowel or a concrete mixer. The application
of the concrete is best done with a trowel in several layers of 10 to 15 mm thickness.
After about 30 minutes, the concrete may already be exposed to heat. The temperature increase
may be between 30°C and 80°C per hour.
The concrete can be stored in frost-free and dry premises for up to 8 months. Contact Vyncke if
you need more concrete.
12.5. Empty the Ash Bins

Emptying the ash bins needs to be done according to the legal health, safety and environmental
regulations in the relevant country. The staff must realise that they are dealing with hot and thus
dangerous materials. Therefore, the following are general rules:
1 Try to avoid direct contact with the ash bins as much as possible.
Allow the ash bins to cool down sufficiently in a place where the dangers of
2 physical burn injuries are made clearly apparent to passers-by.
When emptying the ash bins, take into account possible unburned particles in
3 the ashes: these can cause a flash fire when mixed with air. Therefore, never
empty the bins against the wind!

12.6. Laying Up the Installation when Out of Service
12.6.1. Wet Lay-Up
1 Switch off the installation as prescribed.
2 Allow the fuel to burn out completely on the grates.
Once all the fuel is burnt out, open all doors for ventilation and further cooling.
3 There is still a large amount of heat in the combustion chamber: therefore take
adequate safety measures.
Once all the fuel is burnt out, open all doors for ventilation and further cooling.
4 There is still a large amount of heat in the combustion chamber: therefore take
adequate safety measures.
12.6.2. Dry Lay-Up
1 Follow the “Wet lay-up” procedure.
2 Close the tap between the boiler and the pipes to the consumers.
Open all taps to let the water out of the boiler and convection section.
Depending on the local area, the manner of discharge (into a sewer, into
3 surface water, etc.), the chemical composition of the water, etc., there are legal
conditions (e.g. maximum temperature of the water) relating to the discharge
of water. Contact your environmental coordinator for information about this.
4 Clean all components.
5 Allow the installation to dry out by uncovering all access openings.
Apply preservatives such as silica gel to the installation to prevent rust formation
6 and to avoid oxidative corrosion.
This should be repeated several times to refresh the preservatives, depending

7 on the period of shut-down and the environmental conditions.
It is in your interests to make it known in several places that, from a certain

8 date, the boiler will be in dry lay-up.
If the shutdown is for longer than 3 months, it is appropriate to keep the boiler in dry lay-up.

13. TROUBLESHOOTING
DESCRIPTION POSSIBLE CAUSE SOLUTION
Furnace temperature too Too little fuel on the grate Check all previous equipment
low in the feed system for
blockages
Polluted flue gas tubes Clean the flue gas tubes
Too little primary air Change the position of the

primary air valves
Black smoke Too much fuel on the grate Reduce the flow of fuel
Polluted flue gases Check the requirements and

settings of the filter
Too little secondary O2 measuring equipment not

combustion air working
Change the position of the

secondary air valves and/or
the frequency of the
secondary fan
Gray smoke Too little secondary Change the position of the

combustion air secondary air valves and/or
the frequency of the
secondary fan
O2 measuring equipment not

working
The ashes are not uniform in Too much fuel on the grate Reduce the flow of fuel
colour, the fuel is not burnt
out completely
Too little water uptake by the Change the settings to the

customer desired capacity
Speed of the fuel on the Change the settings for the

grate too high grate speed
Too little primary combustion Change the position of the

air primary air valves

DESCRIPTION POSSIBLE CAUSE SOLUTION
Matter remains stuck to the Contaminated water pipes Clean the water pipes,
concrete walls contact Vyncke if necessary
Too little oxygen O2 measuring equipment not

working
The fuel composition has Check the fuel composition

changed and change the boiler
settings if necessary to the
desired capacity
The grate has cooling Check the equipment for

problems reducing the heat uptake
from the grate
Problems with the feed pump
Poor water quality Flushing the boiler. Contact

your water treatment
supplier if the problem does
not restore itself
Speed of the fuel on the Change the settings for the

grate too high grate speed
Too much/too little primary Change the position of the

air in the furnace primary air valves
Too little flue gas Change the position of the

recirculation flue gas recirculation valves
and/or the frequency of the
flue gas recirculation fan

14. SPARE PARTS
Because the spare parts are project related the spare parts list can be found in the section headed
“Spare parts list”

15. LIST OF SERVICE CENTERS OF VYNCKE
VYNCKE N.V. (Global Headquarters) VYNCKE Thailand
Gentsesteenweg 224 GTB Building, 7th floor, 335/39
B - 8530 Harelbeke Srinakarin Road, Nongborn, Pravej
Belgium Bangkok 10250
Tel: + 32 56 730 630 THAILAND
Fax: + 32 56 704 160 Tel : + 66 2 366 04 22
mail@vyncke.com Fax : + 66 2 366 04 21
☒  G.M.T. + 1
24 /7
☐ mail@vyncke.com
 G.M.T. + 6
VYNCKE S.R.O. VYNCKE LTDA.

Příborská 288 R. Acylino Francisco Medeiros 605A,
Cz – 73942 Frýdek-Místek-Chlebovice CEP: 94010 - 972 D. IND., RS,
Czech Republic Gravataí
BRASIL
Tel : +420 553 829 951 Tel: + 55 51 3470 1302
☐ Fax : +420 553 829 970 Fax: + 55 51 3439 3044
mail@vyncke.com
 G.M.T. + 1
☐ mail@vyncke.com
 G.M.T. - 3
VYNCKE SDN. BHD. VYNCKE DEUTSCHLAND

C-17-07, Level 7, Block C, 3 Two square, Albstrasse 10
2 Jalan 19/1, 46300 Petaling Jaya D – 73765 Neuhausen
Selangor Darul Ehsan Deutschland
Malaysia
Tel : + 603 7952 9000 Tel : + 49 715 895 63371
Fax : + 603 7954 1409 Fax : + 49 711 601 3814
☐ mail@vyncke.com
 G.M.T. +8
☐ mail@vyncke.com
 G.M.T. + 1
VYNCKE LTD.
15, JianPu Road, (Cross Susheng Road)
Suzhou Industrial Park
215126 Suzhou
China
☐ Tel : + 86 51 2676 31008
Fax : + 86 51 2628 20009
mail@vyncke.com
 G.M.T. + 7
CDE IM JNO Rev1 ENG dd 2-4-'15

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JNO - HD

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1.1. General Safety Instructions

1 Jumbo New Design (Jumbo Nieuw Ontwerp)

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1.3. Safety during Erection

Figure 1: Lifting the JNO convection part

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1.4.2. Health Risks

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1.4.3. After Maintenance

1.5. Operational Safety Measures

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Figure 2: The JNO installation

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Fly ash that is dragged along with the flue gases

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e. Flue Gas Recirculation (Optional)

f. PSS Injection Openings (Optional)

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Pictures of the convection part.

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Side view and Cross-section of JNO single-pass convection part.

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3. Flue gas entrance: flue gases, 4. Manometer: used to measure the

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No. Description No. Description

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The economiser or pre-heater is a component with

The economiser consists of one or more tube

The economiser is fed with feed-water from the

The flue gas inlet is connected to the convection

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2.6. Cleaning System (optional)

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Steam saturation curve

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4.3. The Feed-Water and Boiler Water of Steam Boilers

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4.4.3. Thermal/Physical Degassing

4.4.4. Chemical Degassing

4.4.5. Removal of Salts

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6.2. Filling the Degasser

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6.3. Filling of the Grate Cooling

6.4. Filling the Boiler

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Figure 3: Control cabinet

1 RESET button and ON/OFF switch

3 On and off switches for installed components

4 Touch panel (optional)

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6.7. Start-Up of the Electrical Filter (optional)

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