Page 92 - Boiler_Operators_Handbook,_Second_Edition

Boiler Plant Operations 77

service pumps, motors, and bearings when firing load. When indicated, sample and test boiler flue
oil, fuel gas supply pressure, fuel tank levels, and gases to evaluate firing conditions then adjust fuel
look for signs of leakage. to air ratio accordingly.

• Draw representative samples of boiler water and • Provide escort for visitors, inspectors and contrac-
test the water for partial alkalinity, total alkalin- tors. Note work being performed by contractors
ity, phosphate residual, sulfite residual, chlorides, and service providers, inspect their work where
iron, total dissolved solids, and other concentra- required. Receive shipments of fuel oil, water
tions as dictated by the water treatment supplier. treatment chemicals, maintenance parts and other
Draw representative samples of condensate and materials. Document all visitors, contractors, de-
test for hardness, pH, iron, total dissolved solids, liveries, etc., in the log.
and other concentrations as dictated by the water
treatment supplier. Draw multiple samples of con- In addition to the daily activities described above,
densate and test when necessary to isolate hard- perform weekly activities including: Inspect air inlet
ness leakage. Draw representative samples of the louvers and screens for blockage, clean as necessary. Re-
boiler feedwater to test for pH, chlorides, total dis- store full levels to all lubricating oil reservoirs in pumps,
solved solids, and other concentrations as dictated blowers, fans, air compressors, etc., using the required
by the water treatment supplier. Draw samples of lubricant. Check salt elutriation conditions and adjust
raw water and test for hardness and total dissolved brine feed accordingly. Draw representative samples of
solids. Draw samples of softened makeup water the boiler feedwater and test for dissolved oxygen. Take
and test for hardness, repeating frequently near direct level readings and check for water incursion in
ends of softener runs to detect breakthroughs. fuel oil storage tanks. Perform bottom blowoff of operat-
ing boilers (this activity normally requires the presence
• Record, in the boiler plant log, many of the lev- of two operators).
els, pressures and temperatures described above, In addition to the foregoing, perform monthly ac-
maintenance activities described below, unusual tivities including: Lift test safety valves on all operating
activities and events, and observations of condi- steam boilers. Conduct slow drain test of low water cut-
tions that are precursors to failures. Record water, offs. Test flame detectors. Check along all fuel gas piping
fuel and steam flow meter readings. Calculate and elements with leak tester. Check fuel gas regulator vents
record evaporation rate and fuel consumption per to detect diaphragm leaks, vent valve vents to detect
degree day then evaluate the results to identify leaking vent valves. Inspect all piping in plant for loss
changes or upsets in system operation and qual- or dislodging of insulation. Inspect stack cleanout for
ity of control adjustments. Calculate percentage of accumulation of debris, clean as required. Changing and
returns and compare with history to detect system cleaning of filters is usually performed on a monthly
leaks and upsets. basis but each one is staggered to provide a level load of
work as much as possible.
• Perform normal operating activities including: Annually the operators should prepare each boiler
Test the low water cutoffs on each operating boiler for the internal annual inspection by the National Board
each shift for three shift operation and at least Commissioned Inspector. During that process the opera-
twice each day. Calculate effect of changes in raw tors should inspect the boiler internals on the water side
water hardness on softener capacity and adjust to assess their performance in maintaining water quality
softener regeneration rates accordingly. Adjust the and on the fire side to detect any soot accumulation, re-
continuous blowdown rates at operating boilers fractory damage or dislodging, seal damage or loss, and
to maintain dissolved solids concentrations, iron, other problems that might change the heat transfer rates
alkalinity, or whatever is the controlling factor. Ad- in the boiler. At least two people are needed for inspec-
just the chemical feed pump rates to restore normal tions to satisfy confined space requirements.
water chemistry for each concentration. Clean fuel Biannual, five-year, and ten-year inspection and
oil filters when firing oil. Operate boiler soot blow- maintenance cycles need to be considered as well. Pro-
ers as required. Adjust firing rate controls to main- grams for greasing motors and driven equipment can be
tain normal operating pressures and/or cycling scheduled in a manner that spreads this work out rather
controls to maximize cycle time according to the than doing it all at once.