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#BoilerManual #ProtectingPressureParts #Section10 #Page8

STORAGE PROCEDURES

In the presence of moisture and oxygen, atmospheric corrosion of ferritic materials (tube metals) proceeds rapidly. This not only makes the unit difficult to clean up during initial startup after a layup, but it also results in rough internal tube surfaces, which in turn serve as sites for future operational corrosion and deposition. Since it is impossible to completely dry all circuits, wet layup with treated water normally offers the best method of protection.

Hydrostatic testing and layup should be accomplished with treated demineralized water. Treated demineralized water is defined as water which has been passed through a mixed bed demineralizer system and has ammonia and hydrazine added to give initial concentrations of 10 ppm and 500 ppm respectively. It is not necessary to maintain concentrations at these levels. Protection is still afforded after pH and hydrazine have dropped to lower levels.

In preparation for the storage period, the ammonia and hydrazine should be added in a manner that results in a uniform concentration throughout the system. The hydrazine and ammonia can be added at the condensate header. It is recommended that if the unit is down five days or longer (long term) the unit should be prepared for storage with treated water during downtime.

For contemplated shutdown periods from 1 to 5 days (short term), when circulating to cool down the steam generator, ammonia and hydrazine concentrations should be built up in the system to 100 ppm and 25 ppm respectively. To prevent unnecessary decomposition of hydrazine, the system should be cooled to less than 400 F before adding the hydrazine. These concentrations of chemicals can generally be reached by use of the cycle chemical feed pumps (during the time of adding the ammonia and hydrazine, the demineralizers should be bypassed).

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#BoilerManual #ProtectingPressureParts #Section10 #Page8

STORAGE PROCEDURES

In the presence of moisture and oxygen, atmospheric corrosion of ferritic materials (tube metals) proceeds rapidly. This not only makes the unit difficult to clean up during initial startup after a layup, but it also results in rough internal tube surfaces, which in turn serve as sites for future operational corrosion and deposition. Since it is impossible to completely dry all circuits, wet layup with treated water normally offers the best method of protection.

Hydrostatic testing and layup should be accomplished with treated demineralized water. Treated demineralized water is defined as water which has been passed through a mixed bed demineralizer system and has ammonia and hydrazine added to give initial concentrations of 10 ppm and 500 ppm respectively. It is not necessary to maintain concentrations at these levels. Protection is still afforded after pH and hydrazine have dropped to lower levels.

In preparation for the storage period, the ammonia and hydrazine should be added in a manner that results in a uniform concentration throughout the system. The hydrazine and ammonia can be added at the condensate header. It is recommended that if the unit is down five days or longer (long term) the unit should be prepared for storage with treated water during downtime.

For contemplated shutdown periods from 1 to 5 days (short term), when circulating to cool down the steam generator, ammonia and hydrazine concentrations should be built up in the system to 100 ppm and 25 ppm respectively. To prevent unnecessary decomposition of hydrazine, the system should be cooled to less than 400 F before adding the hydrazine. These concentrations of chemicals can generally be reached by use of the cycle chemical feed pumps (during the time of adding the ammonia and hydrazine, the demineralizers should be bypassed).

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#BoilerManual #OptimizingCombustion #Section9 #Page8

One of the most important attributes of the slag tap furnace is the coating of sticky ash that covers a portion of the furnace walls near the bottom. The sticky surface of molten ash, deliberately maintained in selected high temperature zones, serves to trap other transient particles. The ash, so collected, drains continuously toward the furnace bottom and is removed through the tap holes. The consequent reduction in the quantity of dust and ash leaving the boiler unit has a definite practical value, since it decreases the amount of dust to be handled by collectors and therefore decreases the size and cost of the dust collecting equipment.

SUITABILITY OF COALS

The suitability of coals is dependent on the moisture, ash and volatile contents of the coal together with the chemical composition of the ash. The volatile matter should be higher than 15% on a dry basis, to obtain the required high combustion rate. The ash content should be a minimum of about 6% to provide a proper slag coating in the cyclone and can be as high as 25% on a dry basis. A wide range of moisture content is permissible depending on coal rank, secondary air temperature, and fuel preparation equipment.

One of the two important criteria for coal suitability is the total amount of sulfur compared to the ratio of iron to calcium and magnesium, Figure 2. This comparison gives an indication of the tendency of the coal to form iron and iron sulfide, both of which are very undesirable in the cyclone furnace. Coals with too high a sulfur content and/or a high iron ratio are not considered suitable.

Observations have been made over many years on the formation of iron sulfide (FeS) and the role it plays during corrosion and wastage of cyclone and furnace tubes in coal-fired boilers. {Additionally, the iron pyrite content in slag is FeS2, FYI}

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#BoilerManual #OptimizingCombustion #Section9 #Page8

One of the most important attributes of the slag tap furnace is the coating of sticky ash that covers a portion of the furnace walls near the bottom. The sticky surface of molten ash, deliberately maintained in selected high temperature zones, serves to trap other transient particles. The ash, so collected, drains continuously toward the furnace bottom and is removed through the tap holes. The consequent reduction in the quantity of dust and ash leaving the boiler unit has a definite practical value, since it decreases the amount of dust to be handled by collectors and therefore decreases the size and cost of the dust collecting equipment.

SUITABILITY OF COALS

The suitability of coals is dependent on the moisture, ash and volatile contents of the coal together with the chemical composition of the ash. The volatile matter should be higher than 15% on a dry basis, to obtain the required high combustion rate. The ash content should be a minimum of about 6% to provide a proper slag coating in the cyclone and can be as high as 25% on a dry basis. A wide range of moisture content is permissible depending on coal rank, secondary air temperature, and fuel preparation equipment.

One of the two important criteria for coal suitability is the total amount of sulfur compared to the ratio of iron to calcium and magnesium, Figure 2. This comparison gives an indication of the tendency of the coal to form iron and iron sulfide, both of which are very undesirable in the cyclone furnace. Coals with too high a sulfur content and/or a high iron ratio are not considered suitable.

Observations have been made over many years on the formation of iron sulfide (FeS) and the role it plays during corrosion and wastage of cyclone and furnace tubes in coal-fired boilers. {Additionally, the iron pyrite content in slag is FeS2, FYI}

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#BoilerManual #Ramping #Section8 #Page8

The pressure ramp is an extremely complicated procedure. It relies on the proper operation of numerous valves ond on maintaining the proper firing rate for each steam flow. Steam flow to the turbine is increased to 33% in a relatively short period of time and there is little room for error.

PRE-RAMP CONDITIONS

For the pressure ramp to work properly, it is extremely important that a definite and precise procedure be developed and strictly adhered to for each and every ramp. Conditions prior to initiating the ramp must be the same every time. This point is essential to the success of the ramp and cannot be over-emphasized.

To aid in obtaining stable and consistent pre-ramp conditions, the following guidelines should be observed by the operator immediately prior to initiating each ramp:

* Boiler feed pump - in automatic.

* Feedwater flow - 33% of full load flow (1,400,800 lb/hr).

* Condensate regulator - in automatic.

* Make-up regulator - in automatic.

* Superheater spray valves - reset.

* Primary superheater outlet - fluid temperature should be stable at 700 F.

* Flashtank - should be at 500 psi.

* The turbine valves should be on partial arc and in manual. They should be just below the point where the 201 valves will be opened.

* Bypass system - mode selector switch in startup.

* 202 valve - in automatic.

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#BoilerManual #Ramping #Section8 #Page8

The pressure ramp is an extremely complicated procedure. It relies on the proper operation of numerous valves ond on maintaining the proper firing rate for each steam flow. Steam flow to the turbine is increased to 33% in a relatively short period of time and there is little room for error.

PRE-RAMP CONDITIONS

For the pressure ramp to work properly, it is extremely important that a definite and precise procedure be developed and strictly adhered to for each and every ramp. Conditions prior to initiating the ramp must be the same every time. This point is essential to the success of the ramp and cannot be over-emphasized.

To aid in obtaining stable and consistent pre-ramp conditions, the following guidelines should be observed by the operator immediately prior to initiating each ramp:

* Boiler feed pump - in automatic.

* Feedwater flow - 33% of full load flow (1,400,800 lb/hr).

* Condensate regulator - in automatic.

* Make-up regulator - in automatic.

* Superheater spray valves - reset.

* Primary superheater outlet - fluid temperature should be stable at 700 F.

* Flashtank - should be at 500 psi.

* The turbine valves should be on partial arc and in manual. They should be just below the point where the 201 valves will be opened.

* Bypass system - mode selector switch in startup.

* 202 valve - in automatic.

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#BoilerManual #BypassSystem #Section7 #Page8

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Alt = Labeled Fig. 2 Cold cleanup. The image is sideways with the bottom along the right edge and the top along the left edge. The image is a considerably simplified version of Fig. 1 with the focus on how the Flashtank fits into the system, those pipe lines drawn in heavy lines compared to the others. The details are in the main text.

#BoilerManual #BypassSystem #Section7 #Page8

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Alt = Labeled Fig. 2 Cold cleanup. The image is sideways with the bottom along the right edge and the top along the left edge. The image is a considerably simplified version of Fig. 1 with the focus on how the Flashtank fits into the system, those pipe lines drawn in heavy lines compared to the others. The details are in the main text.

#BoilerManual #CycloneOperation #Section6 #Page8

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Alt = Labeled Fig. 3 Cyclone control station. Similar to Fig. 2 on the previous page, switches and indicator lamps are depicted but in 2 columns of 6 each. Left column is marked Status; right column is marked Control. In the left column, at the top, is indicator marked Test; the indicator under that is laterally divided in half with the top half marked Lighter flame and the bottom half marked Main flame; below that is an indicator marked Lighter ON; the one below that is designated a pushbutton switch, marked Lighter trouble; below that is an indicator marked Cyclone ON, and below that is the last one in the column, designated a pushbutton switch, marked Cyclone trouble.

In the right column, at the top, is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Select and the bottom half marked Management ON; below that is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Select and the bottom half marked Management OFF; below that is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Lighter ready and the bottom half marked Lighter start; the one below that is designated a pushbutton switch, marked Lighter Stop; below that is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Cyclone ready and the bottom half marked Cyclone start; The bottom most indicator is designated to be a pushbutton switch and is marked Cyclone stop.

#BoilerManual #CycloneOperation #Section6 #Page8

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Alt = Labeled Fig. 3 Cyclone control station. Similar to Fig. 2 on the previous page, switches and indicator lamps are depicted but in 2 columns of 6 each. Left column is marked Status; right column is marked Control. In the left column, at the top, is indicator marked Test; the indicator under that is laterally divided in half with the top half marked Lighter flame and the bottom half marked Main flame; below that is an indicator marked Lighter ON; the one below that is designated a pushbutton switch, marked Lighter trouble; below that is an indicator marked Cyclone ON, and below that is the last one in the column, designated a pushbutton switch, marked Cyclone trouble.

In the right column, at the top, is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Select and the bottom half marked Management ON; below that is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Select and the bottom half marked Management OFF; below that is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Lighter ready and the bottom half marked Lighter start; the one below that is designated a pushbutton switch, marked Lighter Stop; below that is an indicator laterally divided in half and designated a pushbutton switch, with the top half marked Cyclone ready and the bottom half marked Cyclone start; The bottom most indicator is designated to be a pushbutton switch and is marked Cyclone stop.

#BoilerManual #CycloneDescription #Section5 #Page8

burner tangentially and imparts a whirling motion to the incoming coal. Secondary air with a velocity of approximately 300 fps {feet per second} is admitted in the same direction, tangentially, at the roof of the cyclone main barrel and imparts a further whirling or centrifugal action to the coal particles. A small amount of air (up to about 6%) is admitted at the center of the burner. This is known as tertiary air, which is primarily used for cooling the burner front.

The combustibles are burned from the fuel at heat release rates of 450,000 to 800,000 Btu/Cu. ft. per hour and gas temperatures exceeding 3000 Fare developed. these temperatures are sufficiently high to melt the ash into a liquid slag, which forms a layer on the walls of the cyclone.

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Alt = Labeled Fig. 6 Cyclone furnace (front view - outside). Very similar to Section 4's Fig. 2 on page 2, but depicts the cyclone frontal view inside of the windbox containment. From top down, then clockwise around the cyclone face are: Windbox enclosure; Crushed coal pipe; Radial burner; Cyclone; Primary-tertiary air duct; Secondary air inlet Secondary air control damper; Lighter.

#BoilerManual #CycloneDescription #Section5 #Page8

burner tangentially and imparts a whirling motion to the incoming coal. Secondary air with a velocity of approximately 300 fps {feet per second} is admitted in the same direction, tangentially, at the roof of the cyclone main barrel and imparts a further whirling or centrifugal action to the coal particles. A small amount of air (up to about 6%) is admitted at the center of the burner. This is known as tertiary air, which is primarily used for cooling the burner front.

The combustibles are burned from the fuel at heat release rates of 450,000 to 800,000 Btu/Cu. ft. per hour and gas temperatures exceeding 3000 Fare developed. these temperatures are sufficiently high to melt the ash into a liquid slag, which forms a layer on the walls of the cyclone.

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Alt = Labeled Fig. 6 Cyclone furnace (front view - outside). Very similar to Section 4's Fig. 2 on page 2, but depicts the cyclone frontal view inside of the windbox containment. From top down, then clockwise around the cyclone face are: Windbox enclosure; Crushed coal pipe; Radial burner; Cyclone; Primary-tertiary air duct; Secondary air inlet Secondary air control damper; Lighter.

#BoilerManual #Lighters #Section4 #Page8

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Alt = Labeled Fig. 4 Oil lighter control schematic. The image is on its side such that the bottom is along the right edge of the page and the top is along its left, and it utilizes the mechanical symbols identified on the previous page. The left section is labeled CONTROL PACKAGE; the section on the right is labeled LIGHTER ASSEMBLY, with the connections between the two shown as solid lines, as are all the other connecting lines, which are complex and better understood in the accompanying section text.

#BoilerManual #Lighters #Section4 #Page8

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Alt = Labeled Fig. 4 Oil lighter control schematic. The image is on its side such that the bottom is along the right edge of the page and the top is along its left, and it utilizes the mechanical symbols identified on the previous page. The left section is labeled CONTROL PACKAGE; the section on the right is labeled LIGHTER ASSEMBLY, with the connections between the two shown as solid lines, as are all the other connecting lines, which are complex and better understood in the accompanying section text.

#BoilerManual #AirAndGasFlow #Section3 #Page8

(Figure 6). Inside this take-off duct, a division wall splits the air flow into two components, primary air and tertiary air.

Primary air, which constitutes 2 - 17% of the total air to the cyclone, enters the burner tangentially and imparts a whirling motion to the incoming coal.

Tertiary air is admitted at the front of the burner and is used for cooling of the burner front. Tertiary air is normally 4 - 6% of the total air to the cyclone.

The primary air and tertiary air dampers are set in a fixed position. The secondary air control dampers (often referred to as velocity dampers) are located in the secondary air inlet port at the top of the cyclone. These dampers control the velocity of the secondary air as it enters the cyclone. The secondary air, constituting 77 - 84% of the total air to the cyclone at

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Alt = Labeled Fig 5 Cyclone burner arrangement. The image is a drawing of how 7 cyclones are located in relation to each other with their coal feed pipes pointed out. They're inside a box marked Windbox with the left side of it marked Sec. air inlet with an arrow pointing rightward toward the box and on the left side, similarly, is marked Sec. air inlet. There is a row of 4 cyclones along the bottom of the box and 3 along the top, and off to the side of the box I added my own notes that the top row was the B Level row and the bottom row was the A Level row. Only the lower left cyclone has a drawing of a box with lighter and duct details overlaid.

#BoilerManual #AirAndGasFlow #Section3 #Page8

(Figure 6). Inside this take-off duct, a division wall splits the air flow into two components, primary air and tertiary air.

Primary air, which constitutes 2 - 17% of the total air to the cyclone, enters the burner tangentially and imparts a whirling motion to the incoming coal.

Tertiary air is admitted at the front of the burner and is used for cooling of the burner front. Tertiary air is normally 4 - 6% of the total air to the cyclone.

The primary air and tertiary air dampers are set in a fixed position. The secondary air control dampers (often referred to as velocity dampers) are located in the secondary air inlet port at the top of the cyclone. These dampers control the velocity of the secondary air as it enters the cyclone. The secondary air, constituting 77 - 84% of the total air to the cyclone at

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Alt = Labeled Fig 5 Cyclone burner arrangement. The image is a drawing of how 7 cyclones are located in relation to each other with their coal feed pipes pointed out. They're inside a box marked Windbox with the left side of it marked Sec. air inlet with an arrow pointing rightward toward the box and on the left side, similarly, is marked Sec. air inlet. There is a row of 4 cyclones along the bottom of the box and 3 along the top, and off to the side of the box I added my own notes that the top row was the B Level row and the bottom row was the A Level row. Only the lower left cyclone has a drawing of a box with lighter and duct details overlaid.

#BoilerManual #FluidCirculation #Section2 #Page8

Figure 8 shows a similar curve for a supercritical UP operating at 3500 psi. Notice that there is no area under the dome where water is converted to steam. Rather fluid temperature is steadily increased in the furnace and superheaters between point B & C.

When water is converted to steam at subcritical pressures (the area under the dome) steam bubbles form. The bubbles are due to the difference in density between water and steam, the lighter steam simply tries to bubble away from the water. The steam bubbles form at the internal tube surface and normally mix with the saturated water in the rest of the tube, carrying heat from the surface to the center, as shown in Figure 9. This is called nucleate boiling.

However, if steam quality and heat input levels are high, these bubbles tend to form a film at the tube surface as shown in Figure 10. This is known as film boiling. The steam does not mix with the water to transfer heat from the tube surface, and the tube metal temperature rises. When film boiling occurs, the tube overheats rapidly and fails. The point at which film boiling begins is known as Departure from Nucleate Boiling (DNB).

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Alt = Figure 8 is labeled Steam generation -- supercritical pressure. The graph is nearly identical to Figure 5 except that there are only points B and C where Point B is near the low left end of the curve labeled 3500 psi where 700 Btu/lb intersects with close-but-not-quite the 700 F line.

#BoilerManual #FluidCirculation #Section2 #Page8

Figure 8 shows a similar curve for a supercritical UP operating at 3500 psi. Notice that there is no area under the dome where water is converted to steam. Rather fluid temperature is steadily increased in the furnace and superheaters between point B & C.

When water is converted to steam at subcritical pressures (the area under the dome) steam bubbles form. The bubbles are due to the difference in density between water and steam, the lighter steam simply tries to bubble away from the water. The steam bubbles form at the internal tube surface and normally mix with the saturated water in the rest of the tube, carrying heat from the surface to the center, as shown in Figure 9. This is called nucleate boiling.

However, if steam quality and heat input levels are high, these bubbles tend to form a film at the tube surface as shown in Figure 10. This is known as film boiling. The steam does not mix with the water to transfer heat from the tube surface, and the tube metal temperature rises. When film boiling occurs, the tube overheats rapidly and fails. The point at which film boiling begins is known as Departure from Nucleate Boiling (DNB).

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Alt = Figure 8 is labeled Steam generation -- supercritical pressure. The graph is nearly identical to Figure 5 except that there are only points B and C where Point B is near the low left end of the curve labeled 3500 psi where 700 Btu/lb intersects with close-but-not-quite the 700 F line.

@Su_G #BoilerManual #UnitDescription #Section1 #Page8

Fuel Flow
Following the diagram in Figure 2, mined coal is delivered to the plant site and stored in a ready pile or in the storage pile. The coal is later reclaimed, sent through a crusher, and placed in the bunkers which are located above the feeders. This crushed coal is dischaged from the feeders to the cyclone coal inlet at a rate dictated by unit load.

Air and Gas Flow

Air and gas flow is the result of the combination of Force Draft (FD) and Induced Draft (ID) creating differential pressures which sustain flow through the boiler system. The FD fans (3) create the positive (above atmosphere) pressure required to force incoming air through the air heater and ducts to the windbox and cyclones. the ID fans (3) are suction fans which create the negative (below atmosphere) pressure necessary to draw the flue gases through the furnace to the stack. The ID fans also maintain the furnace at a slightly negative pressure.

Air from the FD fans is heated in the tubular air heater and distributed to the cyclones in the form of primary, secondary and tertiary air.

Hot flue gases created through combustion in the cyclones is drawn by the ID fans across tube surfaces in the furnace and convection pass. Its heat is transferred to the tube metal and thus to the water or steam in the tubes. This gas then flows past the economizer and exits the boiler. Flue gas exiting the boiler is drawn through the tubular air heater, precipitator, and ID fans and exits to the atmosphere through the stack.

Water and Steam Flow

Following the diagram in Figure 3, feedwater is introduced into the unit

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@Su_G #BoilerManual #UnitDescription #Section1 #Page8

Fuel Flow
Following the diagram in Figure 2, mined coal is delivered to the plant site and stored in a ready pile or in the storage pile. The coal is later reclaimed, sent through a crusher, and placed in the bunkers which are located above the feeders. This crushed coal is dischaged from the feeders to the cyclone coal inlet at a rate dictated by unit load.

Air and Gas Flow

Air and gas flow is the result of the combination of Force Draft (FD) and Induced Draft (ID) creating differential pressures which sustain flow through the boiler system. The FD fans (3) create the positive (above atmosphere) pressure required to force incoming air through the air heater and ducts to the windbox and cyclones. the ID fans (3) are suction fans which create the negative (below atmosphere) pressure necessary to draw the flue gases through the furnace to the stack. The ID fans also maintain the furnace at a slightly negative pressure.

Air from the FD fans is heated in the tubular air heater and distributed to the cyclones in the form of primary, secondary and tertiary air.

Hot flue gases created through combustion in the cyclones is drawn by the ID fans across tube surfaces in the furnace and convection pass. Its heat is transferred to the tube metal and thus to the water or steam in the tubes. This gas then flows past the economizer and exits the boiler. Flue gas exiting the boiler is drawn through the tubular air heater, precipitator, and ID fans and exits to the atmosphere through the stack.

Water and Steam Flow

Following the diagram in Figure 3, feedwater is introduced into the unit

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Lou Marin rezensiert „We shut shit down“ von @[email protected] in den „Libertären Buchseiten“ der @[email protected]:

Bewegung für Klimagerechtigkeit

Ende Gelände und der Zivile Ungehorsam

Das Jahr 2015 war das Jahr des großen Aufbruchs des Anti-Braunkohle-Bündnisses „Ende Gelände“ (im Folgenden: EG), das in den folgenden Jahren mit Massenaktionen zivilen Ungehorsams (im Folgenden: ZU) die Klimagerechtigkeitsbewegung mitgeprägt hat. Es war im Tagebau Garzweiler, wo sich 2015 rund 1.500 Menschen an der ersten großen Kohlebaggerblockade von „Ende Gelände“ beteiligten. Anschließend erhöhten sich die Teilnehmerinnenzahlen, Medienberichte über Kohlegrubenbesetzungen und Blockaden von Kohlezügen sowie des riesigen Abbau-Baggers durch in Weiß gekleidete Aktivistinnen gingen um die Welt. In dem Buch „We Shut Shit Down“ werden Geschichte und Verständnis dieses ZU sowie die verschiedenen Aspekte des Bewegungsbündnisses EG dargestellt. Es geht immer wieder um die Widerstandszentren Garzweiler, Hambacher Forst, Lausitzer Braunkohlerevier, zuletzt Lützerath und deren Aktionscamps. […]

www.graswurzel.net/gwr/wp-content/uploads/2023/10/LibusPDF.pdf#page=8

#EndeGelände #Klimagerechtigkeit #ClimateJustice

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