Fulton 10E Boiler Basic Maintenance Training Handout

Kursus Amali Makmal Loji berlangsung dari 21 Apr hingga 23 Apr 2014 yang lepas. Saya di minta untuk memberikan sedikit penerangan tentang selenggaraan asas yang dijalankan. Di bawah ialah nota ringkas yang saya hasilkan bagi membantu dalam memberi penerangan.

FULTON 10E BOILER

STARTING BOILER

1.       Open Main Stop Valve ( MSV )

2.       Open all valves in the water feedline

3.       Open water column isolation valves

4.       Open water gauge valves

5.       Close the boiler water column and water gauge blow down valves

6.       Switch on the feed water pump motor

*pump will continue to operate until the water reaches the correct level in the boiler. Part of the safety feature, please ensure the feedpump automatically turn on when water level hit below the low water electrode.  This can be done by draining the water column.

STARTING BURNER

1.       Open all the stop valves in the fuel line

2.       Ensure that fuel is available in the secondary fuel tank

3.       Ensure that the boiler has filled with water at the correct level

4.       Press the green start button at the control panel

*the blower motor and fuel pump will start and after a delay of approximately 15 seconds, the burner will fire.

SAFETY FEATURES CHECKING

1.       During  operation,  check that the pipe at the water feedpump outlet is not too hot. Too hot indicates that the check valves may be faulty and this can cause damage to water feedpump.

2.       Visually check that there are no sign of leakage at pipings and fittings ( fuel, steam and water )

3.       Visually check that there are no sign of leakage at hand holes location

4.       Manually press the relief lever of the safety valve to ensure good working condition

5.       Testing water level electrods, THIS TO BE CARRY OUT AT LOW OR NO PRESSURE ;

a)      Blowdown water column, ensure the feedpump is automatically engage when water level reach the low water electrods

b)      With the burner operating, open the blowdown valves.  When the water level drops below the long electrod in the boiler, the burner should shut off.

DAILY OPERATION ( RECOMMENDED )

If the boiler is not being operated consistently on daily basis, carry out following operations daily

1.       Each morning, start the boiler and generate not more than 5 PSIG of steam

2.       Open the boiler blow-off valves for approximately 10 seconds, then close the valves

3.       Open the water column and gauge blow-off valves for approximately 10 seconds, then close the valves

4.       Perform test on the water gauge ;

*before performing this test, please check ;

- Safety glass is installed

- Use proper PPE ( Personal Protective Equipment )

- Nobody nearby the hot water and steam outlet

- DO NOT perform test at high pressure

- Normal position of the cocks are correct

- Water level at middle of the glass

        Then carry out testing as follows ;

a)      Close steam cock, close water cock, open drain cock

b)      Open steam cock, close water cock, steam is released

c)       Close steam cock, open water cock, water is released

d)      Close drain cock, open steam and water cock, actual water level is shown in the gauge

WATER TREATMENT

The purpose of boiler water treatment is to protect the boiler and steam system against corrosion and scale formation and help maintain steam purity and quality.

Without the right boiler feed water treatment, a steam-raising plant will suffer from scale formation and corrosion. At best, this increases energy costs and can lead to poor quality steam, reduced efficiency, shorter plant life and an operation which is unreliable. At worst, it can lead to catastrophic failure and loss of life.

BASIC FEEDWATER CONDITION CHECKING

1.       pH level : method of checking using pH meter or pH incator strips ( control at 9-11 )

2.       Sample appearance ( visual )

3.       Total Dissolved Solid (TDS) : method of checking using TDS meter ( <1000mg/l )

FURTHER ANALYSIS

1.       Hardness of water ( presence of dissolved minerals in water )

2.       Chloride content ( high cocentration can act corrosively on metals )

3.       Tannin content ( oxigen scavenger )

4.       Silica/phosphate content

CHEMICAL S USED IN WATER TREATMENT

1.       Sodium sulphite – oxigen scavenger

2.       Phosphate – reduce scaling

3.       Sodium hydroxide –alcalinity booster

4.       Sodium carbonate – sludge conditioner ( prevent accumulation of sludge )

PREPARING BOILER FOR SCHEDULED INSPECTION BY DOSH ( EVERY 15 MONTHS )

a) Remove water column, water gauge, electrodes

b) Remove feed water tube, check valves

c) Remove blowdown tube, valves

d) Open handholes

e) Remove safety valves

f) Remove burner unit

g) Perform necessary maintenance and cleaning

h) Prepare all for inspection

References ;

1.       FULTON 10E Oil Fired Operation, Installation & Maintenance Manual

2.       Water Treatment for Steam Raising Plant, www.fulton.co.uk

3.       Boiler Maintenance & Water Treatment, www.parkerboiler.com

Prepared by,

Rosedi bin Che Rose