This instruction manual has been prepared to serve as a guide in operating and maintaining the one(1) unit of LP steam boilers for the National Vietnam Gas Company’s Gas Supply Project to be located in Vietnam as below ; It is not intended to cover all possible variations in equipment nor to provide for specific problems which may arise. If additional information be required, the company or its field representatives should be contacted.
Doc No : 09035-62-OPM-VD-MS015-001 OPERATING & MAINTENANCE MANUAL FOR STEAM BOILER Job No : 2009035 Rev No : C1 Page : i REVISION LOG 01 Nov 29, 10 C1 Dec 21, 10 ─ 18, 24 Page Issued for Approval Issued for Construction Doc No : 09035-62-OPM-VD-MS015-001 OPERATING & MAINTENANCE MANUAL FOR STEAM BOILER Job No : 2009035 Rev No : C1 Page TABLE OF CONTENTS OPERATING & MAINTENANCE MANUAL FOR AUXILIARY BOILER PIPING AND INSTRUMENT DIAGRAM MECHANICAL EQUIPMENT OP & MT MANUAL - BURNER - FD FAN - FD FAN (motor) - SAMPLING SYSTEM - SAFETY VAVLE INSTRUMENT OP & MT MANUAL - LEVEL GAUGE - TOUCH PANEL SIMPLE OPERATION MANUAL - CONTROL VALVES - DESUPERHEATER - INSTRUMENTS - PLC & HMI : ii DINH VU POLYESTER PLANT PROJECT STEAM BOILER PACKAGE OPERATING & MAINTENACE MANUAL FOR AUXILIARY BOILER OPERATION & MAINTENACE MANUAL FOR STEAM BOILER IN DIVZ HANOI, VIETNAM Dec 2010 HANKOOK B&TEC Co., Ltd OF CONTENTS INTRODUCTION OPERATING PROCEDURE 2-1 STARTING PROCEDURE 2-1-1 STARTING PREPARATIONS 2-1-2 STARTING (COLD WATER START) 2-1-3 START-UP CURVE 2-1-4 STARTING (HOT WATER START) 2-2 STEAM SENDING 2-2-1 START UP 2-2-2 WARMING UP STEAM LINES 2-2-3 CONNECTING TO PROCESS 2-2-4 AUTOMATIC COMBUSTION CONTROL 2-2-5 LINEAR/SUDDEN LOAD CHANGE 2-3 SHUTDOWN PROCEDURE 2-3-1 SCHEDULED SHUTDOWN 2-3-2 EMERGENCY SHUT DOWN 2-3-3 SHORT-TIME SHUTDOWN 2-4 LOW WATER LEVEL 2-5 TUBE FAILURE 2-6 FURNACE EXPLOSION 2-6-1 CASES OF FURNACE EXPLOSION 2-6-2 PREVENTION OF UNBURNED FUEL ENTERING 2-6-3 TROUBLE OF BURNER 2-6-4 MISFIRE OF THE GAS IGNITOR 2-6-5 POOR BURNING OF THE GAS BURNER 2-6-6 PULSATION OF GAS FLAME 2-6-7 FLAME BRUSHING OF THE FURNACE WALL TUBES 2-6-8 FUEL COMPOSITION OF 2-7 LOSS OF UTILITIES 2-7-1 INSTRUMENT AIR FAILURE 2-7-2 PLANT AIR FAILURE 2-7-3 ELECTRIC POWER FAILURE 2-7-4 COOLING WATER FAILURE 2-8 TABLE OF CAUSE AND EFFECT PRESERVATION 3-1 DRY STORAGE 3-1-1 GENERAL 3-1-2 NITROGEN PURGE 3-1-3 VAPOR CAPSULESS 3-2 WET STORAGE 3-2-1 GENERAL 3-2-2 PROCEDURE INSPECTION 4-1 EXTERNAL INSPECTION OF BOILER 4-2 INTERNAL INSPECTION OF BOILER 4-3 OTHER INSPECTION MAINTENACE 5-1 TUBE REMOVAL AND MAINTENANCE 5-2 TABLE OF MAINTENANCE SERVICES OF INTRODUCTION This instruction manual has been prepared to serve as a guide in operating and maintaining the one(1) unit of LP steam boilers for the National Vietnam Gas Company’s Gas Supply Project to be located in Vietnam as below ; It is not intended to cover all possible variations in equipment nor to provide for specific problems which may arise If additional information be required, the company or its field representatives should be contacted Boiler Specification Type of boiler : Two drum, natural circulation Bottom supported type Number of boiler : One (1) unit Boiler Outlet Steam Flow : 30,000kg/hr (at 100% MCR) Boiler Outlet Steam Temperature : SuperHeated Boiler Outlet Steam Pressure : 26 Bar G Feed Water Temperature : 115 ℃ Draft System : Forced draft system - Ignition : Liquid Propane Gas - Main fuel : Liquid Propane Gas Ambient Temp for Mechanical Design : 23 ℃ Load Change : 10% of load per minutes Firing System OF 31 OPERATING PROCEDURE 2-1 STARTING PROCEDURE 2-1-1 STARTING PREPARATIONS 2-1-1-1 CHECK POINTS (1) Before start-up, the boiler shall be inspected to ensure the following points a All the peep holes and manholes are closed And make sure of no gas leakage b The safety equipment and interlocks are normal position (Not bypass position) c The instrument air, cooling water and other utilities are in service d The feed water equipment and the chemical injection unit are in good order e All shutdown valves (except vent valve) on fuel lines are closed (2) Check that the following valves are closed a Feed water control valves b All blowdown valves and drain valves on the drum, furnace header, and level gauge c Main steam stop valve d All bypass valves for control valve (3) The following valves are opened a Vent valve on the steam line b Feed water stop valve c Root valves and fitting valves for water level gauge d Drain valves for main steam line e Stop valves of all instruments and controlling equipment (4) Check that all the preparation for start-up has been completed and that all the automatic control system (loop) are set at manual position (5) Check that there is sufficient preparation of chemicals for treatment of the boiler feed water and that the chemical injection pumps are ready for use (6) Check that opening of the air register vane and damper are proper position OF 31 2-1-1-2 WATER FILLING Water can be filled in the boiler according to the following procedure (1) Fill water in the boiler by adjusting the BFW control valve Continue to fill water until the drum level rise below -50 ~ -100 mm of steam drum Normal Water Level (NWL) (2) Open the drain valve of water level gauge to check whether level gauge is in order 2-1-2 STARTING (COLD WATER START) WARNING It is necessary to take special attention during boiler cold start-up At start-up, the pressure of steam drum shall be gradually increased according to the start-up curve as shown in para 2-1-3 The boiler shall be filled with demineralized feed water The water level in the steam drum should be –50~-100mm of the normal water level (NWL) Drain valves and vent valve on steam piping and header shall be fully opened at the beginning of pipe warming Drain valves shall be closed after confirming the (UPSTREAM) piping has been sufficiently warmed, no drainage can be seen at the outlet of valves When steam pressure reaches to approx kg/cm2g, vent valve can be closed, and when it reaches to approx kg/cm2g, drain valves can be closed The following step guide are of the procedure for bringing a cold boiler up to normal pressure and temperature OF 31 VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS HMI(FactoryTalk) VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS VIETNAM DINH VU POLYESTER PLANT OPERATION MANUAL-INSTRUMENT PARTS ... 09035-62-OPM-VD-MS015-001 OPERATING & MAINTENANCE MANUAL FOR STEAM BOILER Job No : 2009035 Rev No : C1 Page TABLE OF CONTENTS OPERATING & MAINTENANCE MANUAL FOR AUXILIARY BOILER PIPING AND INSTRUMENT... : ii DINH VU POLYESTER PLANT PROJECT STEAM BOILER PACKAGE OPERATING & MAINTENACE MANUAL FOR AUXILIARY BOILER OPERATION & MAINTENACE MANUAL FOR STEAM BOILER IN DIVZ HANOI, VIETNAM Dec 2010 HANKOOK... 09035-62-OPM-VD-MS015-001 OPERATING & MAINTENANCE MANUAL FOR STEAM BOILER Job No : 2009035 Rev No : C1 Page : i REVISION LOG 01 Nov 29, 10 C1 Dec 21, 10 ─ 18, 24 Page Issued for Approval Issued for Construction