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#BoilerManual #OptimizingCombustion #Section9 #Page18

Questions for optimizing combustion

1. What is the definition of combustion?

2. What are the Three T's of Combustion?

........ 1. __________________________________

........ 2. __________________________________

........ 3. __________________________________

3. What is the difference between complete combustion and perfect combustion?

4. Name three areas of controllable heat loss in the boiler.

........ 1. __________________________________

........ 2. __________________________________

........ 3. __________________________________

5. Explain how the cyclone furnace works?

6. Name five requirements necessary for slag tap furnaces.

........ 1. __________________________________

........ 2. __________________________________

........ 3. __________________________________

........ 4. __________________________________

........ 5. __________________________________

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#BoilerManual #OptimizingCombustion #Section9 #Page18

Questions for optimizing combustion

1. What is the definition of combustion?

2. What are the Three T's of Combustion?

........ 1. __________________________________

........ 2. __________________________________

........ 3. __________________________________

3. What is the difference between complete combustion and perfect combustion?

4. Name three areas of controllable heat loss in the boiler.

........ 1. __________________________________

........ 2. __________________________________

........ 3. __________________________________

5. Explain how the cyclone furnace works?

6. Name five requirements necessary for slag tap furnaces.

........ 1. __________________________________

........ 2. __________________________________

........ 3. __________________________________

........ 4. __________________________________

........ 5. __________________________________

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#BoilerManual #Ramping #Section8 #Page18

As the ramp progresses, flow through the SSH is increased and flow to the flashtank is decreased. With the decreased flow to the flashtank, flow is also reduced to the FW heaters and the DA so feedwater temperature will decrease. When flashtank pressure has decayed sufficiently, the heaters and DA will go on extraction steam and the FW temperature will begin to increase by the end of the ramp. The flashtank is kept warm by an interconnection with the deaerator via the 236 valve. Flashtank pressure will float with DA pressure.

EXAMPLE OF A RAMP WITH INCORRECT PRE-RAMP CONDITIONS

The following discussion will indicate the importance of stabilizing the system prior to the initiation of the ramp. The ramp in our example was initiated immediately after the initial opening of the 201 valve for the

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Alt = Labeled Fig. 8 Temperatures during the ramp. It's a chart where only the x axis and the lines for the 201 and 200 are identical to the previous charts. The y axis is marked Degrees F and is arbitrarily incremented in different but ascending spots as 380, 655, 710, 925, 950 and 1000. The corresponding lines drawn from those are, in ascending order, Feedwater temp., Convection pass outlet temperature, PSH outlet temperature, SSH outlet temperature and Gas temperature. Where each of those lines cross the x axis points of B, C, D and E are drawn with vertical dashed lines.

#BoilerManual #Ramping #Section8 #Page18

As the ramp progresses, flow through the SSH is increased and flow to the flashtank is decreased. With the decreased flow to the flashtank, flow is also reduced to the FW heaters and the DA so feedwater temperature will decrease. When flashtank pressure has decayed sufficiently, the heaters and DA will go on extraction steam and the FW temperature will begin to increase by the end of the ramp. The flashtank is kept warm by an interconnection with the deaerator via the 236 valve. Flashtank pressure will float with DA pressure.

EXAMPLE OF A RAMP WITH INCORRECT PRE-RAMP CONDITIONS

The following discussion will indicate the importance of stabilizing the system prior to the initiation of the ramp. The ramp in our example was initiated immediately after the initial opening of the 201 valve for the

------------------------------------------------- 18 ------------------------------------------------------
Alt = Labeled Fig. 8 Temperatures during the ramp. It's a chart where only the x axis and the lines for the 201 and 200 are identical to the previous charts. The y axis is marked Degrees F and is arbitrarily incremented in different but ascending spots as 380, 655, 710, 925, 950 and 1000. The corresponding lines drawn from those are, in ascending order, Feedwater temp., Convection pass outlet temperature, PSH outlet temperature, SSH outlet temperature and Gas temperature. Where each of those lines cross the x axis points of B, C, D and E are drawn with vertical dashed lines.

#BoilerManual #BypassSystem #Section7 #Page18

Flashtank level will be established when the temperature of the fluid reaches 298 F. Valve 241 drains to the condenser and maintains flashtank level about -3" below centerline. This valve modulates between wide open at +1" and fully closed at -7". Flow and firing continues to increase flashtank pressure. Flow and firing continues to increase flashtank pressure. When flashtank pressure reaches 120 psi and a level has been established, the steam line block valve, 242, will open. At this point the deaerator steam pegging valve, 231, will control deaerator pressure at 42 psi. With the deaerator pegged at 42 psi by flashtank steam all flashtank drain flow is diverted to the condenser for polishing and water cleanup.

Flow and firing continues as before. When the fluid temperature at the boiler outlet reaches 300 F the boiler pressure is increased on a controlled ramp to 2550 psi. Pressure is controlled by the PSH bypass valve, 202. The SSH bypass valve, 207, will open to a minimum position and control the fluid temperature to 700 F at the PSH outlet. Before exceeding a fluid temperature of 550 F at the PSH bypass, 202, the feedwater iron content should not exceed 100 ppb.

When the flashtank pressure reaches 300 pis the low pressure stop valve, 205, will open to permit approximately 2% of full load steam to flow to the SSH for steam line warming. Since it is a stop check valve, it will close when the superheater pressure is higher than flashtank pressure. Minimum flow through the SSH is established using the turbine stop valve above seat drain, steam to boiler feed pump drains, and the main steam line drain valve, MS-2. After the steam line is warmed, flashtank pressure will continue to rise to its setpoint pressure which is determined by turbine throttle set point and controlled, first by steam control valves to the heaters, and second by the flashtank overpressure control valve which sends excess steam to the condenser.

The high pressure heater steam control valve, 220, is permitted to open when flashtank pressure reaches its setpoint (500 psi). Steam is discharged from flashtank to the "G" high pressure heaters for heat

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#BoilerManual #BypassSystem #Section7 #Page18

Flashtank level will be established when the temperature of the fluid reaches 298 F. Valve 241 drains to the condenser and maintains flashtank level about -3" below centerline. This valve modulates between wide open at +1" and fully closed at -7". Flow and firing continues to increase flashtank pressure. Flow and firing continues to increase flashtank pressure. When flashtank pressure reaches 120 psi and a level has been established, the steam line block valve, 242, will open. At this point the deaerator steam pegging valve, 231, will control deaerator pressure at 42 psi. With the deaerator pegged at 42 psi by flashtank steam all flashtank drain flow is diverted to the condenser for polishing and water cleanup.

Flow and firing continues as before. When the fluid temperature at the boiler outlet reaches 300 F the boiler pressure is increased on a controlled ramp to 2550 psi. Pressure is controlled by the PSH bypass valve, 202. The SSH bypass valve, 207, will open to a minimum position and control the fluid temperature to 700 F at the PSH outlet. Before exceeding a fluid temperature of 550 F at the PSH bypass, 202, the feedwater iron content should not exceed 100 ppb.

When the flashtank pressure reaches 300 pis the low pressure stop valve, 205, will open to permit approximately 2% of full load steam to flow to the SSH for steam line warming. Since it is a stop check valve, it will close when the superheater pressure is higher than flashtank pressure. Minimum flow through the SSH is established using the turbine stop valve above seat drain, steam to boiler feed pump drains, and the main steam line drain valve, MS-2. After the steam line is warmed, flashtank pressure will continue to rise to its setpoint pressure which is determined by turbine throttle set point and controlled, first by steam control valves to the heaters, and second by the flashtank overpressure control valve which sends excess steam to the condenser.

The high pressure heater steam control valve, 220, is permitted to open when flashtank pressure reaches its setpoint (500 psi). Steam is discharged from flashtank to the "G" high pressure heaters for heat

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#BoilerManual #CycloneOperation #Section6 #Page18

temperature. The primary/tertiary air shutoff damper will go to fully open at a windbox temperature greater than 300 F.

A Maintained lighter may only be initiated when the cyclone is off management. In order to start a maintained lighter when the cyclone is on management, the operator must take the cyclone off management, start the lighter via Lighter Start push button, and transfer the cyclone back on management. The Lighter Start pushbutton will backlight red.

If a cyclone stop is commanded by the computer while the cyclone is On Management and Maintained lighter is in service, the lighter is shutdown along with the cyclone.

To reset a lighter trip, depress the Lighter Stop pushbutton. It will backlight green when the stop command has been memorized.

The Lighter Trouble indicator will flash amber when a lighter trouble alarm is present. The pushbutton, when depressed, acknowledges the alarm and changes the flashing alarm to a steady indication.

CYCLONE COAL MONITOR

If a cyclone remains in a start or stop sequence for longer than one minute, sequence monitoring will be required. At the end of one minute if the cyclone is started but not successfully lit, or stopped and not successfully shutdown, the cyclone will be tripped.

Monitoring of the cyclone begins when the feeder starts. If when the feeder starts the following permissives are not met, the cyclone will trip.

* Feeder pressurized
* Feeder outlet valve opened.
* Feeder inlet valve opened.

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#BoilerManual #CycloneOperation #Section6 #Page18

temperature. The primary/tertiary air shutoff damper will go to fully open at a windbox temperature greater than 300 F.

A Maintained lighter may only be initiated when the cyclone is off management. In order to start a maintained lighter when the cyclone is on management, the operator must take the cyclone off management, start the lighter via Lighter Start push button, and transfer the cyclone back on management. The Lighter Start pushbutton will backlight red.

If a cyclone stop is commanded by the computer while the cyclone is On Management and Maintained lighter is in service, the lighter is shutdown along with the cyclone.

To reset a lighter trip, depress the Lighter Stop pushbutton. It will backlight green when the stop command has been memorized.

The Lighter Trouble indicator will flash amber when a lighter trouble alarm is present. The pushbutton, when depressed, acknowledges the alarm and changes the flashing alarm to a steady indication.

CYCLONE COAL MONITOR

If a cyclone remains in a start or stop sequence for longer than one minute, sequence monitoring will be required. At the end of one minute if the cyclone is started but not successfully lit, or stopped and not successfully shutdown, the cyclone will be tripped.

Monitoring of the cyclone begins when the feeder starts. If when the feeder starts the following permissives are not met, the cyclone will trip.

* Feeder pressurized
* Feeder outlet valve opened.
* Feeder inlet valve opened.

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#BoilerManual #CycloneDescription #Section5 #Page18

Questions for cyclone description

1. What force occurs in cyclonic action which is responsible for throwing coal particles into the slag layer?

2. Where does combustion actually occur? In the radial burner, or the main barrel of the cyclone?

3. What is the purpose of tertiary air?

4. Which air supply is the main source of oxygen for combustion in the cyclone furnace?

5. What three requirements does the cyclone meet for complete and efficient coal combustion?

............ 1. ______________________________________

............ 2. ______________________________________

............ 3. ______________________________________

6. Under which of the following operating conditions is poor slag tapping likely to occur?

............ A. Low loads - all cyclones fired.
............ B. Low loads - few cyclones fired.
............ C. High loads - all cyclones fired.
............ D. Coal sizing limitations exceeded.

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#BoilerManual #CycloneDescription #Section5 #Page18

Questions for cyclone description

1. What force occurs in cyclonic action which is responsible for throwing coal particles into the slag layer?

2. Where does combustion actually occur? In the radial burner, or the main barrel of the cyclone?

3. What is the purpose of tertiary air?

4. Which air supply is the main source of oxygen for combustion in the cyclone furnace?

5. What three requirements does the cyclone meet for complete and efficient coal combustion?

............ 1. ______________________________________

............ 2. ______________________________________

............ 3. ______________________________________

6. Under which of the following operating conditions is poor slag tapping likely to occur?

............ A. Low loads - all cyclones fired.
............ B. Low loads - few cyclones fired.
............ C. High loads - all cyclones fired.
............ D. Coal sizing limitations exceeded.

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#BoilerManual #Lighters #Section4 #Page18

POSSIBLE OPERATING PROBLEMS

The following are possible operating problems and their causes:

Lighter will not extend or retract.

a) Interlocks not satisfied.
b) Insufficient air pressure to cylinder.
c) Mechanical binding of lighter.
d) Broken or worn piston rings {Mechanics didn't rebuild those--C&I did}
e) Malfunctioning lighter controls.

Lighter extends and retracts too slowly.

a) Flow control valves open excessively.
b) Leak in cylinder's exhaust connection.

No ignition spark.

a) Electrode spark gap too large.
b) Electrical connection broken.
c) Dirty electrode insulators.
d) Electrode grounded.

Lighter flame too small.

a) Dirty or plugged sprayer plate.
b) Oil pressure below 150 psi.
c) Dirty or plugged oil strainer.

This concludes our discussion on the Mark IV Oil Lighters. You should now have a functional understanding of the various operating modes of the lighter as well as a familiarization with the correct operating checks and adjustments which ensure proper lighter operation.

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#BoilerManual #Lighters #Section4 #Page18

POSSIBLE OPERATING PROBLEMS

The following are possible operating problems and their causes:

Lighter will not extend or retract.

a) Interlocks not satisfied.
b) Insufficient air pressure to cylinder.
c) Mechanical binding of lighter.
d) Broken or worn piston rings {Mechanics didn't rebuild those--C&I did}
e) Malfunctioning lighter controls.

Lighter extends and retracts too slowly.

a) Flow control valves open excessively.
b) Leak in cylinder's exhaust connection.

No ignition spark.

a) Electrode spark gap too large.
b) Electrical connection broken.
c) Dirty electrode insulators.
d) Electrode grounded.

Lighter flame too small.

a) Dirty or plugged sprayer plate.
b) Oil pressure below 150 psi.
c) Dirty or plugged oil strainer.

This concludes our discussion on the Mark IV Oil Lighters. You should now have a functional understanding of the various operating modes of the lighter as well as a familiarization with the correct operating checks and adjustments which ensure proper lighter operation.

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#BoilerManual #AirAndGasFlow #Section3 #Page18

To illustrate this, consider the following example while referring to Figure 13. In order to maintain a secondary air flow of 300,000 lb/hr with a secondary air temperature of 500 F, the differential across the bellmouth (cyclone air flow measuring device) should be 8.4". In order to maintain the same air flow with an increase of air temperature to 700 F, it now requires an increased air flow differential of 10" at the bellmouth.

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Alt = A large graph labeled Fig. 13 Effect of density on air flow. The y axis is labeled "Bellmouth air-flow differential--(inches of water), and increments sequentially. The x axis is labeled "Scondary air flow (1000 lb/hr)" and increments from 0 to 500 every 50 units with only the 100s lines marked as such.
Definition of "bellmouth" can be found here: en.wikipedia.org/wiki/Bell_mou…

#BoilerManual #AirAndGasFlow #Section3 #Page18

To illustrate this, consider the following example while referring to Figure 13. In order to maintain a secondary air flow of 300,000 lb/hr with a secondary air temperature of 500 F, the differential across the bellmouth (cyclone air flow measuring device) should be 8.4". In order to maintain the same air flow with an increase of air temperature to 700 F, it now requires an increased air flow differential of 10" at the bellmouth.

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Alt = A large graph labeled Fig. 13 Effect of density on air flow. The y axis is labeled "Bellmouth air-flow differential--(inches of water), and increments sequentially. The x axis is labeled "Scondary air flow (1000 lb/hr)" and increments from 0 to 500 every 50 units with only the 100s lines marked as such.
Definition of "bellmouth" can be found here: en.wikipedia.org/wiki/Bell_mou…

#BoilerManual #FluidCirculation #Section2 #Page18

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Alt = Labeled Fig 16 Cyclone flow schematic. The image is displayed on the page sideways with the top of it along the left edge and the bottom aligned with the right. The top edge label reads "From cyclone supply downcomers (rear walls)" referring to a solid line across the top as a pipe. Arrows descend from this line to each of 7 oblongs labeled, in descending order, B7 thru B1, representing cyclone positions. Similarly along the bottom are 7 oblongs labeled, in descending order, A7 thru A1 representing another row of cyclone positions but A6, A4, and A2 are also marked "U". A note at the bottom left: "U - Upper Cyclones". Between the two rows are 3 circles aligned top down with the middle circle being larger than the other two, labeled "Cyclone discharge mix bottle", and then an arrow pointing away from that labeled "To furnace walls".

#BoilerManual #FluidCirculation #Section2 #Page18

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Alt = Labeled Fig 16 Cyclone flow schematic. The image is displayed on the page sideways with the top of it along the left edge and the bottom aligned with the right. The top edge label reads "From cyclone supply downcomers (rear walls)" referring to a solid line across the top as a pipe. Arrows descend from this line to each of 7 oblongs labeled, in descending order, B7 thru B1, representing cyclone positions. Similarly along the bottom are 7 oblongs labeled, in descending order, A7 thru A1 representing another row of cyclone positions but A6, A4, and A2 are also marked "U". A note at the bottom left: "U - Upper Cyclones". Between the two rows are 3 circles aligned top down with the middle circle being larger than the other two, labeled "Cyclone discharge mix bottle", and then an arrow pointing away from that labeled "To furnace walls".

@Su_G #BoilerManual #UnitDescription #Section1 #Page18

COMBUSTION & HEAT TRANSFER

A boiler requires a source of heat at a sufficient temperature level to produce steam. At Baldwin, coal is the fuel utilized for the generation of steam and it is burned directly for this purpose in the cyclones and boiler furnace.

Combustion may be defined as the rapid chemical combination of oxygen with the combustible elements of fuel. There are just three combustible chemical elements of significance - carbon, hydrogen and sulfur. Sulfur is of minor significance as a heat source, but it can be of major significance in corrosion and environmental considerations.

The objective of good combustion is to release all of the heat while minimizing losses from combustion imperfections and superfluous air.

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@Su_G #BoilerManual #UnitDescription #Section1 #Page18

COMBUSTION & HEAT TRANSFER

A boiler requires a source of heat at a sufficient temperature level to produce steam. At Baldwin, coal is the fuel utilized for the generation of steam and it is burned directly for this purpose in the cyclones and boiler furnace.

Combustion may be defined as the rapid chemical combination of oxygen with the combustible elements of fuel. There are just three combustible chemical elements of significance - carbon, hydrogen and sulfur. Sulfur is of minor significance as a heat source, but it can be of major significance in corrosion and environmental considerations.

The objective of good combustion is to release all of the heat while minimizing losses from combustion imperfections and superfluous air.

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