Boiler Components and Equipment
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Questions and Answers

What type of air preheater is mentioned in the text?

  • Gas Recirc Air Preheater
  • Scanner Air Preheater
  • Steam Coil Air Preheater (correct)
  • Forced Draft Air Preheater

    • Which document provides information on Safety Valves?

  • MV Vol 10 Part 5 Sec 3
  • DO Vol 5 Part 5 Sec 1
  • MV Vol 5 Part 4 Sec 1 (correct)
  • I2B-000120-1E8418

    • What is the purpose of a Sootblower?

  • To increase combustion efficiency
  • To reduce steam production
  • To clean soot from the boiler (correct)
  • To increase airflow in the boiler

    • Which system is responsible for circulating water in the boiler?

    <p>Boiler Circulation Pump System</p> Signup and view all the answers

    What type of fans are mentioned in the text?

    <p>All of the above</p> Signup and view all the answers

    What is the purpose of the Steam Coil Airheater?

    <p>To heat air before it enters the boiler</p> Signup and view all the answers

    Which document provides information on Sootblowers?

    <p>MV Vol 16 Part 5 Sec</p> Signup and view all the answers

    What is the purpose of the Combustion and Flue Gas System?

    <p>To mix air and gas in the boiler</p> Signup and view all the answers

    Which system is responsible for starting up the boiler?

    <p>High Pressure Startup and Warmup System</p> Signup and view all the answers

    What type of system is the Scanner Air System?

    <p>Scanner Air System</p> Signup and view all the answers

    What is the primary consideration for soot-blower selection in a boiler?

    <p>Boiler configuration and probable dirtying characteristics of the oil ash</p> Signup and view all the answers

    Which of the following is not a boiler auxiliary equipment?

    <p>Feed-water pumps</p> Signup and view all the answers

    What is the primary function of air heaters in a boiler?

    <p>To heat the air and gas flows</p> Signup and view all the answers

    What is the purpose of soot-blowers in a boiler?

    <p>To clean the boiler surfaces</p> Signup and view all the answers

    What is the primary consideration for air-heater sizing in a boiler?

    <p>Air and gas flows and temperatures</p> Signup and view all the answers

    Which of the following is a boiler auxiliary equipment?

    <p>Pumps within the boiler circuit</p> Signup and view all the answers

    What is the primary function of pumps within the boiler circuit?

    <p>To circulate boiler water</p> Signup and view all the answers

    Why is it important to consider the boiler configuration and oil ash characteristics in soot-blower selection?

    <p>To determine the appropriate soot-blower type and size</p> Signup and view all the answers

    What is the recommended duration for supplying station air to high-pressure nozzles after soot blowing?

    <p>5 minutes</p> Signup and view all the answers

    When should off-load high-pressure water washing be conducted?

    <p>Only when required to reduce gas side pressure drop to within acceptable operating limits</p> Signup and view all the answers

    What is the recommended increase in gas side pressure differential that warrants high-pressure water washing?

    <p>50% over the design value</p> Signup and view all the answers

    Why should high-pressure water washing of the heating elements be done only when necessary?

    <p>To prevent damage to the heating elements due to high pressure and subsequent surface oxidation</p> Signup and view all the answers

    When can the air preheater be water washed?

    <p>After the boiler has been shut down and the preheater has been vacuumed clean of ash and debris</p> Signup and view all the answers

    What is the recommended timeframe for completing the washing, drying, and inspection process of the air preheater?

    <p>24 – 48 hours</p> Signup and view all the answers

    Why is it important to vacuum clean the air preheater before water washing?

    <p>To remove loose particles and ash</p> Signup and view all the answers

    What is a safety precaution that should be taken when inspecting the air preheater?

    <p>DO NOT ENTER THE AIRHEATER while the rotor is turning or without proper permits</p> Signup and view all the answers

    What is the percentage of steam generation at the point where the warmkeeping system line valve control is set to 60?

    <p>35%</p> Signup and view all the answers

    At what percentage of steam generation is the warmkeeping system control typically engaged?

    <p>20%</p> Signup and view all the answers

    What is the primary function of the circulation line management system in a boiler?

    <p>To circulate water through the boiler</p> Signup and view all the answers

    In which boiler operating mode is the warmkeeping system typically engaged?

    <p>Standby mode</p> Signup and view all the answers

    What is the purpose of the line valve control in the warmkeeping system?

    <p>To control the warmkeeping system</p> Signup and view all the answers

    At what point does the steam generation percentage reach 70%?

    <p>When the warmkeeping system line valve control is set to 60</p> Signup and view all the answers

    What is the primary consideration for managing circulation line valves in a boiler?

    <p>Water circulation rate</p> Signup and view all the answers

    In which boiler operating mode is the warmkeeping system typically disengaged?

    <p>Startup mode</p> Signup and view all the answers

    What is the primary purpose of the remote demand feature in the boiler system?

    <p>To ensure a delta setpoint between HHV and actual values</p> Signup and view all the answers

    What happens to the flow rate when no burner is in service?

    <p>It zeros to prevent unnecessary fuel consumption</p> Signup and view all the answers

    What is the effect of restricting the valve demand on the boiler system?

    <p>It limits the number of burners in service</p> Signup and view all the answers

    What is the primary purpose of the delta setpoint in the boiler system?

    <p>To ensure a consistent fuel-to-air ratio</p> Signup and view all the answers

    What happens when the HHV setpoint is not met?

    <p>The fuel-to-air ratio is adjusted</p> Signup and view all the answers

    What is the purpose of the controller in the boiler system?

    <p>To manage the number of burners in service</p> Signup and view all the answers

    What is the effect of having multiple burners in service on the valve demand?

    <p>It increases the valve demand</p> Signup and view all the answers

    What is the primary purpose of the return flow feature in the boiler system?

    <p>To prevent low-pressure nuisance trips</p> Signup and view all the answers

    What is the primary function of the ID & FD fan blade pitch control?

    <p>To regulate combustion air flow</p> Signup and view all the answers

    What is the purpose of the SH & RH spraywater control valves?

    <p>To control steam temperature</p> Signup and view all the answers

    What is the function of the redundant pressure transmitters in the FAN CONTROL system?

    <p>To provide backup pressure measurement</p> Signup and view all the answers

    What is the purpose of the furnace pressure control mimic (ID FAN CONTROL)?

    <p>To maintain furnace pressure</p> Signup and view all the answers

    What type of system is used to control combustion air and flue gas in the boiler?

    <p>Auctioneered median-select system</p> Signup and view all the answers

    What is the purpose of the windbox air dampers?

    <p>To regulate combustion air flow</p> Signup and view all the answers

    What is the function of the gas recirculation dampers?

    <p>To recirculate gas for emission control</p> Signup and view all the answers

    What is the purpose of the startup system control valves?

    <p>To control startup system operation</p> Signup and view all the answers

    According to NFPA-85-2015, what is the minimum ignition energy required for a Class 1 Igniter?

    <p>10% of full load burner fuel input</p> Signup and view all the answers

    What is the primary characteristic of a Class 2 Igniter?

    <p>Operates under low load or certain adverse operating conditions</p> Signup and view all the answers

    What is the typical capacity range of a Class 3 Igniter?

    <p>4% to 10% of full load burner fuel input</p> Signup and view all the answers

    What is a Class 3 Special Igniter capable of?

    <p>Directly igniting the main burner fuel</p> Signup and view all the answers

    What is the primary function of an igniter in a combustion system?

    <p>To provide sufficient ignition energy under any burner light-off or operating conditions</p> Signup and view all the answers

    According to NFPA-85-2015, what is the purpose of an igniter in a combustion system?

    <p>To provide sufficient ignition energy to raise any credible combination of burner inputs</p> Signup and view all the answers

    What is the tilt range of the nozzles in the Twin Fireball burner arrangement?

    <p>+/- 30°</p> Signup and view all the answers

    How many Main WB Assemblies are vertically stacked in the Twin Fireball burner arrangement?

    <p>Eight (8)</p> Signup and view all the answers

    What is the function of the Auto Tilt System in the FGR Elevations?

    <p>+/- 30° CC-OFA thru UFA tilt control</p> Signup and view all the answers

    What type of system is the Spinner Vane Stabilized Oil Elevation?

    <p>HEA system</p> Signup and view all the answers

    How many NG Elevations are there in the Twin Fireball burner arrangement?

    <p>Three (3)</p> Signup and view all the answers

    What type of Ignitor & Flame Scanner system is used in the NG Elevations?

    <p>Twin Ignitor system</p> Signup and view all the answers

    What is the primary function of the High Energy Arc (HEA) Retractable Ignitor?

    <p>To light off the main fuel directly without a separate pilot ignitor</p> Signup and view all the answers

    What is the stroke length of the pneumatic cylinder in the HEA Retractable Ignitor?

    <p>8 inches</p> Signup and view all the answers

    What is the purpose of the solenoid in the HEA Retractable Ignitor?

    <p>To retract the ignitor on loss of power</p> Signup and view all the answers

    What is the typical insertion length of the HEA Rod Assembly into the wet spray?

    <p>7 inches</p> Signup and view all the answers

    What is the purpose of the advance and retract limit switches in the HEA Retractable Ignitor?

    <p>To limit the advance and retract motion of the ignitor</p> Signup and view all the answers

    What is the typical application of the High Energy Arc (HEA) Retractable Ignitor?

    <p>Lightoff of oil guns</p> Signup and view all the answers

    What is the primary function of the NFPA Class 1 Ignitor?

    <p>To support ignition under any burner light-off or operating conditions</p> Signup and view all the answers

    What is the firing rate of the NG Pipe Ignitor?

    <p>24 MBTU/Hr</p> Signup and view all the answers

    What is the purpose of the Compartment Ignitor Proven Vote?

    <p>To prove both ignitors in the compartment are in service via IFM Flame Rod</p> Signup and view all the answers

    What is the heat input required for the main gas operation?

    <p>10% Compartment Heat Input</p> Signup and view all the answers

    What is the purpose of the Air Inlet in the Yanbu LIMELIGHTTM 3” NG Pipe Ignitors?

    <p>To provide combustion air to the burner</p> Signup and view all the answers

    What is the primary function of the Ignitor Assembly?

    <p>To provide ignition energy to the burner</p> Signup and view all the answers

    What is the purpose of the Twin 3-inch NG Pipe 12 MBTU/Hr Ignitors?

    <p>To provide ignition energy to the burner</p> Signup and view all the answers

    What is the total fuel heat input of the NG Compartment?

    <p>6,087 MBTU/Hr</p> Signup and view all the answers

    What is the purpose of the Main Gas Operation?

    <p>To require 3 of 4 Compartment Ignitor Votes at Elevation</p> Signup and view all the answers

    What is the percentage of Compartment Heat Input required for the Main Gas Operation?

    <p>10% Compartment Heat Input</p> Signup and view all the answers

    Study Notes

    Boiler Auxiliaries

    • Boiler auxiliaries include air preheaters, soot blowers, safety valves, fans, and boiler circulation pumps.
    • These components are essential to the operation of the boiler and represent a significant portion of the overall steam-generator investment.

    Air Preheaters

    • Air preheaters are sized based on air and gas flows and temperatures, as well as allowable static pressure losses.
    • Steam coil air preheaters require a manual for operation.
    • Air preheaters can be water washed, but only when necessary, with the air preheater out of service, and after the boiler has been shut down and vacuumed clean.

    Soot Blowers

    • Soot blowers are selected based on the boiler configuration and probable dirtying characteristics of the oil ash.
    • Soot blower systems include half retract and full retract soot blowers.

    Fans

    • Fans are used in the boiler auxiliary system, including forced draft air fans and gas recirculation fans.

    Safety Valves

    • Safety valves are used in the boiler system, including electromatic relief valves.

    Boiler Circulation Pumps

    • Boiler circulation pumps are used to circulate water within the boiler circuit.

    Operation and Maintenance

    • Station air must be supplied to the high-pressure nozzles for 5 minutes after soot blowing.
    • High-pressure water washing should be conducted only when required to reduce the gas side pressure drop to within acceptable operating limits.
    • Off-load high-pressure water washing should be conducted only when required.
    • The air preheater should be inspected through the observation ports during and after washing.

    References

    • Multiple manuals and P&ID diagrams are referenced for specific equipment and systems.

    Boiler Controls Training

    • Warmkeeping System Line Valve Control prevents low pressure nuisance trips and zeros flow if no burner is in service.
    • Remote demand comes in with delta setpoint to actual, restricted by the number of burners in service.

    Controlled Equipment - Unit

    • ID & FD FAN BLADE PITCH CONTROL is part of the CLC controlled equipment.
    • FUEL CONTROL VALVES, BOILER FEEDWATER DEMAND, SH & RH SPRAYWATER CONTROL VALVES, STARTUP SYSTEM CONTROL VALVES, WINDBOX AIR DAMPERS, WINDBOX TILTS, GAS RECIRCULATION DAMPERS, and STEAM COIL CONTROL VALVES are also part of the CLC controlled equipment.

    Fan Control

    • Redundant pressure transmitters are used in fan control.

    Combustion Air and Flue Gas Overview

    • Combustion air and flue gas overview is a crucial part of boiler controls training.

    Combustion Air and Flue Gas Train A

    • Specific training is provided for combustion air and flue gas Train A.

    Furnace Pressure Control Mimic (ID FAN CONTROL)

    • Furnace pressure control mimic is used in ID FAN CONTROL.

    Furnace Pressure / ID FAN CONTROL

    • Furnace pressure control is crucial for ID FAN CONTROL.

    NFPA 85 - Furnace Pressure Control Functional Requirements

    • Block A shows the requirements for three furnace pressure transmitters arranged in an auctioneered median-select system, each on a separate pressure sensing tap, as per NFPA 85.

    NFPA 85 Igniter Types

    • Class 1 Igniter: Provides sufficient ignition energy (over 10% of full load burner input) to ignite fuel input under any burner light-off or operating conditions.
    • Class 2 Igniter: Provides ignition energy (4-10% of full load burner fuel input) under prescribed light-off conditions and supports ignition under low load or adverse operating conditions.
    • Class 3 Igniter: A small igniter that ignites fuel input to the burner under prescribed light-off conditions, with a capacity not exceeding 4% of the full load burner fuel input.
    • Class 3 Special Igniter: A high energy electrical igniter capable of directly igniting the main burner fuel.

    High Energy Arc (HEA) Retractable Ignitor

    • Defined as a Class 3 Special Ignitor per NFPA 85.
    • Capable of directly igniting the main burner fuel without a separate pilot ignitor.
    • Standard GE practice for light-off of oil guns since the 1980s.
    • Features an 8” stroke pneumatic cylinder, solenoid (retracts on loss of power), and advance and retract limit switches.

    HEA Rod Assembly

    • Comprises a guide tube and an HEA spark rod (Champion).
    • The HEA spark rod is part of the HEA rod assembly.

    HEA Insertion Target

    • The HEA insertion target has an 8” stroke and inserts 7” into the spray.

    Yanbu III Key Features

    • Twin Fireball - Eight (8) Main WB Assemblies – Vertically Stacked Nozzles with +/- 30° Tilt Range.
    • Future NG Elevation - Top End Air.
    • 4 Spinner Vane Stabilized Oil Elevations / HEA & Flame Scanner.
    • 3 NG Elevations / Twin Ignitor & Flame Scanner.
    • Auto Tilt System +/- 30° CC-OFA thru UFA.
    • CC-OFA +/- 20° Yaw.
    • Top / BTM End Air.
    • UFA Elevation.
    • FGR Elevations +/- 30° Manual Tilt.

    Corner Firing - Twin Fireball / One Burner - Control

    • Features a corner firing arrangement.

    Gas Firing System

    • Yanbu firing system orientation is used for gas firing.
    • Air flow control and distribution are crucial for proper air distribution.

    Ignitor Assembly

    • Components of the LimelightTM NG Pipe Ignitor include Spark Wiring, DFI Wiring Connection, Air Inlet, Dust Cap, Camlock Coupling, and ¼” NPT Gas Pressure Tap.

    Gas Supply and Pressure

    • NG Supply Pressure should be set to 2.8 psig for 12 BTU/hr.
    • Air Pressure should be set to 3 in wc dp with lower furnace static pressure.
    • NG Pressure can be adjusted via Valve Train Manual Globe Valve.
    • Air Pressure can be adjusted via Butterfly Valve.

    Scanner Cooling Air/Ignitor Air

    • A pressure control damper is used to maintain a constant differential pressure between the Scanner Cooling/Ignitor Air Header and the Furnace.
    • The ignition system may also be sized to provide sufficient heat input for warming of the unit.

    NG Compartment – Pipe Ignitor

    • NFPA Class 1 Ignitor is used to ignite the fuel input through the burner and to support ignition under any burner light-off or operating conditions.
    • The ignitor provides sufficient ignition energy, typically in excess of 10% of full load burner input, at its associated burner to raise any credible combination of burner inputs of both fuel and air above the minimum ignition temperature.

    NG Pipe Ignitor – 2 x 12 MBTU/Hr

    • Class I Ignitor provides 10% Heat Input.
    • NG Total Fuel Heat Input is 6,087 MBTU/Hr BMCR.
    • Ignitor Firing Rate is 24 MBTU/Hr.
    • Compartment Ignitor Proven Vote requires proving both ignitors in the compartment are in-service via IFM Flame Rod.
    • Main Gas Operation requires 3 of 4 Compartment Ignitor Votes at Elevation - per Furnace Cell.

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    Description

    This quiz covers various components and equipment used in boilers, including air preheaters, soot blowers, safety valves, fans, and boiler circulation pumps. Test your knowledge of these essential systems.

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