104 Questions
EASY Why is it important to carefully prepare a boiler for startup?
To avoid costly downtime later on
What determines the boiler preparation procedures in a large plant?
The role the steam system plays in the plant
Why do boiler preparation procedures vary depending on the reason for shutdown?
To accommodate the length of time the boiler was shut down
What is assumed about the safety systems and devices on the boiler?
They were verified as operational during the commissioning period
What is the focus of this chapter?
Common operational tasks for boiler plants being brought online
What is required before bringing a boiler online?
A valid inspection certificate
What is one of the tasks involved in preparing a boiler for startup?
Operating boiler plant auxiliaries
What prior knowledge is recommended to understand the tasks in this chapter?
Prior knowledge of boilers, fuels, valves, pumps, and basic instrumentation
What is the first step in checking the feedwater system?
Check all the valves in the water line from the source and manually verify that they are open.
What is the purpose of a deaerator in a boiler plant?
To remove air from the feedwater system.
What should be checked in the fuel oil system before starting a boiler?
The entire fuel train from the supply tank to the burner.
What is the purpose of a gas train?
To supply natural gas to the burner.
What should be checked in the natural gas system before starting a boiler?
Each valve in the gas train, from the service entrance to the burner.
Why is it important to check the pressure drop across the fuel filter?
To ensure the correct delivery pressure range is achieved.
What should be verified in the feedwater pre-treatment equipment?
All equipment, including ion exchangers, water softeners, filters, and clarifiers, are in service and functional.
Why is it important to check the oil level in the fuel oil tank?
To verify that the tank has a sufficient level to meet the needs of the plant.
What should be checked in the boiler feedwater pumps before starting a boiler?
The operating parameters, including oil level, temperature, and vibrations.
Why is it important to ensure the boiler water level is within range?
To verify that the boiler is ready for service.
What should be done if the fuel filter has an excessive pressure drop?
Service the fuel filter
Why is it important to confirm fuel oil flow is within range?
To ensure oil is flowing
What is included in the typical equipment inspection?
All equipment including fuel heaters and pressure control valves
What should be done if leaks are found during the walk down of the fuel oil supply system?
Stop and isolate the fuel supply pumps
Why is it important to check the combustion air openings to the outdoors?
To ensure an adequate supply of air is available
What should be checked before starting the draft fan?
The lubrication system for the fan bearings and motors
What should be done if the combustion air flow is blocked by frost?
Clean the screens at the outside air entrance
Why is it important to check the furnace pressure after starting the draft fan?
To adjust the furnace pressure into range if necessary
MEDIUM What should be done if there is no pressure drop across the fuel filter?
Verify fuel oil flow is within range
What should be checked during the walk down of the fuel oil supply system?
Fuel supply system components, including valves and heaters
What should be done if leaks are found during the walk down of the fuel oil supply system?
Stop and isolate the fuel supply pumps, lockout, tagout, and drain the affected parts of the fuel supply system
What should be checked before starting the draft fan?
The lubrication system, air dampers, and combustion air openings
Why is it important to ensure the combustion air openings to the outdoors are unobstructed?
To ensure adequate air supply for combustion
What is the primary purpose of checking the feedwater system before starting a boiler?
To confirm the readiness of the feedwater system
What should be done if frost blocks the combustion air flow?
Clean the screens and ensure they are frost-free
During the startup ignition sequence, which valve must be opened?
Main gas cock
What should be checked after starting the draft fan?
The furnace pressure, and adjust into range if necessary
Why is it important to inspect each piece of equipment for expected operation?
To ensure the boiler starts safely and efficiently
What is the correct sequence for checking the natural gas system?
Starting from the gas train to the burner
What is the purpose of the deaerator in a boiler plant?
To remove air from the feedwater
What should be checked during a walk-down of the fuel oil supply system?
The entire system from the fuel tank to the burner
Why is it important to check the boiler water level?
To ensure proper steam production
What should be checked in the fuel oil system before starting a boiler?
The entire system from the fuel tank to the burner
What is the purpose of the gas train?
To supply natural gas to the burner
Why is it important to verify the fuel oil flow rate?
To ensure proper combustion
What should be checked in the boiler feedwater pumps before starting a boiler?
The operating parameters, including oil level, temperature, and vibrations
What is a key consideration when preparing a boiler for startup?
The role the steam system plays in the plant
What should be verified as operational during the commissioning period?
All safety systems and devices on the boiler
What is assumed about the boiler before preparing it for startup?
The boiler has a valid inspection certificate
What is the main focus of this chapter?
Common operational tasks performed on boiler plants being brought online
What should be checked for leaks before preparing a boiler for startup?
The boiler, external piping, and fittings
What type of boilers does this chapter focus on?
New boilers or those that have undergone extensive maintenance work
What prior knowledge is helpful in understanding the tasks in this chapter?
Boilers, fuels, valves, pumps, and basic instrumentation
What is a potential consequence of inadequate boiler preparation?
Costly downtime
What is the primary reason for carefully preparing a boiler for startup?
To prevent costly downtime later on
What determines the scope of boiler preparation procedures?
The role of the steam system in the plant
What is the primary concern when preparing a newly constructed boiler for startup?
All of the above
HARD What is the main focus of this chapter?
Common operational tasks for boiler startup
What is assumed about the boiler before preparing it for startup?
All safety systems and devices are operational
What is the purpose of checking the boiler feedwater system before startup?
To reduce the risk of boiler failure
What is the primary concern when preparing a boiler that has undergone extensive maintenance?
All of the above, plus additional steps
Why is it important to ensure the boiler and steam system are prepared and started before other process units in a large plant?
To provide energy supply to other process units
What is the primary reason for checking the fuel oil flow rate?
To prevent excessive pressure drop across the fuel filter
What is the consequence of not checking the combustion air openings to the outdoors?
Insufficient air supply to the boiler
What is the purpose of inspecting each piece of equipment for expected operation?
To identify faulty equipment
What should be done if an excessive pressure drop is found across the fuel filter?
Service the fuel filter to restore proper flow
What is the primary focus of the walk-down inspection of the fuel oil supply system?
Checking for leaks and repairing them
What should be done if the draft fan is not operating correctly?
Check the lubrication system for the fan bearings and motors
What is the consequence of not checking the furnace pressure after starting the draft fan?
Furnace pressure may not be within range
What should be done if the combustion air flow is blocked by frost?
Clear the frost blockage to restore air flow
What is the purpose of checking the boiler water level before starting a boiler plant?
To confirm the feedwater pumps are operating within range
What is the primary purpose of the deaerator in a boiler plant?
To remove oxygen from the feedwater system
What should be verified during the walk-down of the fuel oil supply system?
That the fuel oil tank is at the correct level and all valves are in the correct position
What is the purpose of the gas train in a natural gas system?
To provide a safe and reliable ignition source for the burner
Why is it important to check the combustion air openings to the outdoors?
To ensure the combustion air flow is not blocked by frost or other obstructions
What should be checked before starting the fuel oil pump?
The fuel oil tank level and valve positions
Why is it important to verify the feedwater pre-treatment equipment is in service and functional?
To remove impurities from the feedwater system and prevent corrosion
What should be done if leaks are found during the walk-down of the fuel oil supply system?
Shut down the system and repair the leaks
Why is it important to check the fuel oil flow rate before starting a boiler?
To confirm the fuel oil supply system is functioning correctly
What is the purpose of the main gas cock in a natural gas system?
To isolate the gas supply to the boiler
Match the boiler startup preparations with their corresponding purposes:
Checking the fuel oil system = To ensure proper fuel delivery Inspecting the boiler feedwater pumps = To guarantee proper water supply Verifying the fuel oil flow rate = To prevent overheating Checking the combustion air openings = To ensure proper ventilation
Match the boiler components with their corresponding checks:
Fuel oil tank = Oil level Feedwater pre-treatment equipment = Proper operation Fuel filter = Pressure drop Boiler water level = Within range
Match the boiler startup procedures with their corresponding goals:
Checking for leaks = To prevent system damage Verifying safety systems = To ensure operational safety Inspecting the boiler = To identify potential issues Starting the draft fan = To provide combustion air
Match the boiler components with their corresponding purposes:
Deaerator = To remove dissolved gases Gas train = To regulate gas flow Draft fan = To provide combustion air Safety valves = To prevent overpressure
Match the boiler startup considerations with their corresponding importance:
Proper fuel delivery = To prevent overheating Proper ventilation = To prevent explosion Proper water supply = To prevent scaling Proper safety system operation = To prevent accidents
Match the boiler components with their corresponding checks:
Fuel oil system = For leaks Feedwater system = For proper treatment Combustion air openings = For blockages Boiler = For proper insulation
Match the boiler startup procedures with their corresponding timings:
Verifying safety systems = During commissioning period Inspecting the boiler = Before startup Checking the fuel oil system = Before startup Starting the draft fan = During startup
Match the boiler components with their corresponding importance:
Safety valves = Critical for safety Fuel oil pumps = Critical for operation Draft fan = Critical for combustion Deaerator = Optional for efficiency
Match the following components with their functions in the fuel oil system:
Fuel filters = Remove impurities from fuel oil Fuel supply pumps = Supply fuel oil to the boiler Fuel heaters = Heat heavy fuel oils Pressure control valves = Regulate fuel oil pressure
Match the following actions with the correct step in preparing a boiler for startup:
Check the lubrication system for the fan bearings and motors = Before starting the draft fan Inspect each piece of equipment for expected operation = During the walk-down of the fuel oil supply system Verify fuel oil flow is within range = During the inspection of the fuel oil system Confirm combustion air openings to the outdoors are unobstructed = Before starting the draft fan
Match the following items with their purposes in the combustion air system:
Screens at the outside air entrance = Prevent debris from entering the boiler Combustion air dampers = Regulate combustion air flow Frost-protected combustion air openings = Prevent frost buildup Air intake openings = Draw in combustion air
Match the following components with their purposes in the fuel oil system:
Fuel recirculation valves = Recirculate excess fuel oil Fuel supply valves = Control fuel oil flow Pressure control valves = Regulate fuel oil pressure Fuel supply pumps = Supply fuel oil to the boiler
Match the following actions with the correct response to a problem in the fuel oil system:
Excessive pressure drop across the fuel filter = Service the fuel filter No pressure drop across the fuel filter = Check for oil flow Leaks found in the fuel oil supply system = Stop and isolate the fuel supply pumps Low fuel oil flow rate = Verify fuel oil flow is within range
Match the following components with their maintenance checks:
Draft fan = Check for vibration and unusual noises Fuel oil pumps = Check for leaks and proper operation Fuel filters = Check for excessive pressure drop Combustion air dampers = Check for proper operation and interlock with the burner system
Match the following steps with the correct sequence in preparing a boiler for startup:
Walk down the fuel oil supply system = After verifying fuel oil flow and pressure Check the lubrication system for the fan bearings and motors = Before starting the draft fan Inspect each piece of equipment for expected operation = During the walk-down of the fuel oil supply system Verify fuel oil flow is within range = After checking the fuel oil supply system
Match the following components with their purposes in the boiler system:
Draft fan = Supply combustion air to the boiler Fuel oil pumps = Supply fuel oil to the boiler Combustion air dampers = Regulate combustion air flow Fuel heaters = Heat heavy fuel oils
Match the following components of a boiler plant with their description:
Deaerator = Removes air and other gases from the feedwater Fuel oil pump = Supplies fuel oil to the burner Feedwater pre-treatment equipment = Removes impurities from the feedwater Gas train = System of valves and devices that regulate the flow of natural gas to the burner
Match the following components of a boiler plant with their function:
Ion exchangers = Remove impurities from the feedwater Bleed valves = Allow for the safe release of gas Water softeners = Remove minerals from the feedwater Limit switches = Shut off the fuel supply in case of an emergency
Match the following components of a boiler plant with their location:
Fuel oil tank = Tank farm or pipeline Boiler feedwater pumps = Boiler room Gas service entrance = Outdoor area Condensate return tank = Feedwater system
Match the following components of a boiler plant with their purpose:
Fuel filter = Removes impurities from the fuel oil Pilot gas manual isolation valve = Allows for the safe ignition of the main burner Main burner manual isolation valve = Allows for the safe shutdown of the main burner Boiler isolating valve = Isolates the boiler from the rest of the system
Match the following components of a boiler plant with their function:
Emergency isolation valve = Shuts off the fuel supply in case of an emergency Relief valves = Allow for the safe release of pressure Manual valves = Control the flow of fuel or gas Safety shut-off valves = Shut off the fuel supply in case of an emergency
Match the following components of a boiler plant with their purpose:
Fuel oil system = Supplies fuel oil to the burner Feedwater system = Supplies water to the boiler Combustion air system = Supplies air to the furnace Boiler water level = Indicates the level of water in the boiler
Match the following components of a boiler plant with their function:
Fuel pump = Supplies fuel oil to the burner Draft fan = Supplies air to the furnace Feedwater pumps = Supplies water to the boiler Boiler feedwater = Supplies water to the boiler
Match the following components of a boiler plant with their purpose:
Raw water tank = Stores untreated water Treated water tank = Stores treated water Makeup water tank = Stores additional water for the boiler Condensate return tank = Stores returned condensate
Match the following components of a boiler plant with their function:
Clarifiers = Remove impurities from the feedwater Filters = Remove impurities from the feedwater Ion exchangers = Remove impurities from the feedwater Water softeners = Remove minerals from the feedwater
Match the following components of a boiler plant with their purpose:
Pilot burner test firing valve = Allows for the safe ignition of the pilot burner Main burner test firing valve = Allows for the safe ignition of the main burner Pilot gas manual isolation valve = Allows for the safe shutdown of the pilot burner Boiler isolating valve = Isolates the boiler from the rest of the system
Study Notes
Boiler Preparation
- Boiler preparation is a step-by-step process that varies depending on the reason for shutdown and the role of the steam system in the plant.
Auxiliaries Preparation
- Feedwater system must be checked and prepared before starting a boiler plant.
- Fuel system must be checked and prepared before starting a boiler plant.
- Combustion air system must be checked and prepared before starting a boiler plant.
Feedwater System Preparation
- Check all valves in the water line from the source and manually verify they are open.
- Ensure bypass valves around automatic control valves are closed.
- Ensure feedwater pre-treatment equipment is in service and functional.
- Confirm raw and treated water tanks are at their proper levels.
- Ensure deaerator level is at set point, and corresponding valves are positioned for service.
- Verify boiler feedwater pumps are in service, and operating parameters are within range.
- Confirm boiler water level is within range.
Fuel System Preparation
- Verify all necessary valves in the main and pilot fuel supply systems are open.
- Verify correct temperature and pressure for fuel oil or natural gas.
- Ensure main gas cock and other related valves are in their proper positions to initiate startup ignition sequence.
- Check natural gas lines, starting at each burner, and verify the position of each valve in the train.
- Check the emergency isolation valve, boiler isolating valve, main burner manual isolation valve, and pilot gas manual isolation valve.
Fuel Oil System Preparation
- Perform a comprehensive tour of the oil storage and delivery system from the supply oil tank to the burner.
- Verify the fuel tank has a sufficient level to meet the needs of the plant.
- Check that all valves are in the correct startup position.
- Start the fuel oil system.
- Check pressure drop across the fuel filter and fuel oil flow.
- Confirm fuel oil supply pressure is within range.
- Reset low oil pressure, low oil temperature, and low atomizing media pressure cut-off switches.
- Inspect each piece of equipment for expected operation.
- Walk down the fuel oil supply system to check for leaks.
Combustion Air System Preparation
- Check for adequate lubricant in the fan bearings.
- Check the belt for cracks or fraying and replace as necessary.
- Stroke the air dampers to ensure they are free to move their full range.
- Ensure adequate supply of air is available.
- Verify combustion air openings to the outdoors are unobstructed.
- Ensure screens at the outside air entrance are clean and not covered with frost.
- Check dampers are secured in the fully open position and interlocked with the burner system.
- Start the draft fan and check furnace pressure, and adjust into range if necessary.
- Check for vibration in the motor and bearings, and listen for unusual noises.
Boiler Preparation
- Boiler preparation is a step-by-step process that varies depending on the reason for shutdown and the role of the steam system in the plant.
Auxiliaries Preparation
- Feedwater system must be checked and prepared before starting a boiler plant.
- Fuel system must be checked and prepared before starting a boiler plant.
- Combustion air system must be checked and prepared before starting a boiler plant.
Feedwater System Preparation
- Check all valves in the water line from the source and manually verify they are open.
- Ensure bypass valves around automatic control valves are closed.
- Ensure feedwater pre-treatment equipment is in service and functional.
- Confirm raw and treated water tanks are at their proper levels.
- Ensure deaerator level is at set point, and corresponding valves are positioned for service.
- Verify boiler feedwater pumps are in service, and operating parameters are within range.
- Confirm boiler water level is within range.
Fuel System Preparation
- Verify all necessary valves in the main and pilot fuel supply systems are open.
- Verify correct temperature and pressure for fuel oil or natural gas.
- Ensure main gas cock and other related valves are in their proper positions to initiate startup ignition sequence.
- Check natural gas lines, starting at each burner, and verify the position of each valve in the train.
- Check the emergency isolation valve, boiler isolating valve, main burner manual isolation valve, and pilot gas manual isolation valve.
Fuel Oil System Preparation
- Perform a comprehensive tour of the oil storage and delivery system from the supply oil tank to the burner.
- Verify the fuel tank has a sufficient level to meet the needs of the plant.
- Check that all valves are in the correct startup position.
- Start the fuel oil system.
- Check pressure drop across the fuel filter and fuel oil flow.
- Confirm fuel oil supply pressure is within range.
- Reset low oil pressure, low oil temperature, and low atomizing media pressure cut-off switches.
- Inspect each piece of equipment for expected operation.
- Walk down the fuel oil supply system to check for leaks.
Combustion Air System Preparation
- Check for adequate lubricant in the fan bearings.
- Check the belt for cracks or fraying and replace as necessary.
- Stroke the air dampers to ensure they are free to move their full range.
- Ensure adequate supply of air is available.
- Verify combustion air openings to the outdoors are unobstructed.
- Ensure screens at the outside air entrance are clean and not covered with frost.
- Check dampers are secured in the fully open position and interlocked with the burner system.
- Start the draft fan and check furnace pressure, and adjust into range if necessary.
- Check for vibration in the motor and bearings, and listen for unusual noises.
Boiler Preparation
- Boiler preparation is a step-by-step process that varies depending on the reason for shutdown and the role of the steam system in the plant.
Auxiliaries Preparation
- Feedwater system must be checked and prepared before starting a boiler plant.
- Fuel system must be checked and prepared before starting a boiler plant.
- Combustion air system must be checked and prepared before starting a boiler plant.
Feedwater System Preparation
- Check all valves in the water line from the source and manually verify they are open.
- Ensure bypass valves around automatic control valves are closed.
- Ensure feedwater pre-treatment equipment is in service and functional.
- Confirm raw and treated water tanks are at their proper levels.
- Ensure deaerator level is at set point, and corresponding valves are positioned for service.
- Verify boiler feedwater pumps are in service, and operating parameters are within range.
- Confirm boiler water level is within range.
Fuel System Preparation
- Verify all necessary valves in the main and pilot fuel supply systems are open.
- Verify correct temperature and pressure for fuel oil or natural gas.
- Ensure main gas cock and other related valves are in their proper positions to initiate startup ignition sequence.
- Check natural gas lines, starting at each burner, and verify the position of each valve in the train.
- Check the emergency isolation valve, boiler isolating valve, main burner manual isolation valve, and pilot gas manual isolation valve.
Fuel Oil System Preparation
- Perform a comprehensive tour of the oil storage and delivery system from the supply oil tank to the burner.
- Verify the fuel tank has a sufficient level to meet the needs of the plant.
- Check that all valves are in the correct startup position.
- Start the fuel oil system.
- Check pressure drop across the fuel filter and fuel oil flow.
- Confirm fuel oil supply pressure is within range.
- Reset low oil pressure, low oil temperature, and low atomizing media pressure cut-off switches.
- Inspect each piece of equipment for expected operation.
- Walk down the fuel oil supply system to check for leaks.
Combustion Air System Preparation
- Check for adequate lubricant in the fan bearings.
- Check the belt for cracks or fraying and replace as necessary.
- Stroke the air dampers to ensure they are free to move their full range.
- Ensure adequate supply of air is available.
- Verify combustion air openings to the outdoors are unobstructed.
- Ensure screens at the outside air entrance are clean and not covered with frost.
- Check dampers are secured in the fully open position and interlocked with the burner system.
- Start the draft fan and check furnace pressure, and adjust into range if necessary.
- Check for vibration in the motor and bearings, and listen for unusual noises.
Boiler Preparation
- Boiler preparation is a step-by-step process that varies depending on the reason for shutdown and the role of the steam system in the plant.
Auxiliaries Preparation
- Feedwater system must be checked and prepared before starting a boiler plant.
- Fuel system must be checked and prepared before starting a boiler plant.
- Combustion air system must be checked and prepared before starting a boiler plant.
Feedwater System Preparation
- Check all valves in the water line from the source and manually verify they are open.
- Ensure bypass valves around automatic control valves are closed.
- Ensure feedwater pre-treatment equipment is in service and functional.
- Confirm raw and treated water tanks are at their proper levels.
- Ensure deaerator level is at set point, and corresponding valves are positioned for service.
- Verify boiler feedwater pumps are in service, and operating parameters are within range.
- Confirm boiler water level is within range.
Fuel System Preparation
- Verify all necessary valves in the main and pilot fuel supply systems are open.
- Verify correct temperature and pressure for fuel oil or natural gas.
- Ensure main gas cock and other related valves are in their proper positions to initiate startup ignition sequence.
- Check natural gas lines, starting at each burner, and verify the position of each valve in the train.
- Check the emergency isolation valve, boiler isolating valve, main burner manual isolation valve, and pilot gas manual isolation valve.
Fuel Oil System Preparation
- Perform a comprehensive tour of the oil storage and delivery system from the supply oil tank to the burner.
- Verify the fuel tank has a sufficient level to meet the needs of the plant.
- Check that all valves are in the correct startup position.
- Start the fuel oil system.
- Check pressure drop across the fuel filter and fuel oil flow.
- Confirm fuel oil supply pressure is within range.
- Reset low oil pressure, low oil temperature, and low atomizing media pressure cut-off switches.
- Inspect each piece of equipment for expected operation.
- Walk down the fuel oil supply system to check for leaks.
Combustion Air System Preparation
- Check for adequate lubricant in the fan bearings.
- Check the belt for cracks or fraying and replace as necessary.
- Stroke the air dampers to ensure they are free to move their full range.
- Ensure adequate supply of air is available.
- Verify combustion air openings to the outdoors are unobstructed.
- Ensure screens at the outside air entrance are clean and not covered with frost.
- Check dampers are secured in the fully open position and interlocked with the burner system.
- Start the draft fan and check furnace pressure, and adjust into range if necessary.
- Check for vibration in the motor and bearings, and listen for unusual noises.
Learn about the step-by-step process of preparing a boiler for startup, including the importance of proper preparation and its impact on other process units in a large plant. Understand the role of the steam system in a plant and how it affects other processes.
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