{"id":4335,"date":"2020-04-06T10:54:17","date_gmt":"2020-04-06T10:54:17","guid":{"rendered":"http:\/\/www.indira.co.id\/IDMBoiler\/?p=4335"},"modified":"2022-01-27T12:07:28","modified_gmt":"2022-01-27T12:07:28","slug":"boiler-safety-operation-standards","status":"publish","type":"post","link":"https:\/\/www.indira.co.id\/IDMBoiler\/boiler-safety-operation-standards\/","title":{"rendered":"Boiler Safety Operation Standards"},"content":{"rendered":"

INDUSTRIAL SAFETY – Boiler Safety Operation Standards<\/strong><\/b><\/h1>\n

Boiler: A Steam Boiler<\/strong><\/b><\/h3>\n
\"SOP

SOP HWG Boilers<\/p><\/div>\n

Boiler is a closed vessel where the combustion heat is flowed into water to form hot water or steam in the form of work energy.\u00a0Water is a useful and inexpensive medium for transferring heat to a process.\u00a0Hot water or steam at a certain pressure and temperature has an energy value which is then used to transfer heat in the form of heat energy to a process.\u00a0If the water is boiled until it becomes cold, the volume will increase about 1600 times, producing power that resembles explosive gunpowder, so the boiler system is a device that must be managed and maintained very well.<\/p>\n

Boiler Work Process<\/strong><\/b><\/p>\n

The heat energy generated in the boiler system has a value of pressure, temperature, and flow rate that determines the utilization of\u00a0\u00a0steam\u00a0\u00a0to be used.\u00a0Based on these three things the boiler system recognizes the state of\u00a0\u00a0low pressure (low pressure \/ LP)\u00a0, and\u00a0\u00a0high pressure (high pressure \/ HP)\u00a0, with the difference that the utilization of\u00a0steam\u00a0\u00a0coming out of the boiler system is utilized in a process to heat the liquid and run a machine\u00a0\u00a0(commercial and industrial boilers),\u00a0\u00a0or generate electrical energy by converting heat energy into mechanical energy then turning a generator to produce electrical energy\u00a0\u00a0(power boilers).\u00a0However, there is also a combination of the two boiler systems, which utilize high-temperature pressure to generate electricity, then the remaining\u00a0\u00a0steam\u00a0\u00a0from the turbine with a low-pressure state can be utilized in industrial processes with the help of\u00a0\u00a0boiler heat recovery.<\/p>\n

The boiler system consists of a feed water system, a\u00a0steam\u00a0system\u00a0\u00a0, and a fuel system.\u00a0The feed water system provides water to the boiler automatically according to\u00a0steam\u00a0needs\u00a0\u00a0.\u00a0Various taps are provided for maintenance and repair of feed water systems, feed water handling is needed as a form of maintenance to prevent damage to the\u00a0steam\u00a0system\u00a0\u00a0.\u00a0The\u00a0steam\u00a0system\u00a0\u00a0collects and controls\u00a0steam\u00a0production\u00a0\u00a0\u00a0in the boiler.\u00a0Steam is\u00a0flowed through the piping system to the user’s point.\u00a0In the whole system,\u00a0steam\u00a0pressure\u00a0\u00a0regulated using a faucet and monitored with a pressure monitor.\u00a0Fuel systems are all equipment used to provide fuel to produce the heat needed.\u00a0The equipment required in the fuel system depends on the type of fuel used in the system.<\/p>\n

Before explaining the diversity of boilers, it is necessary to know the components of the boiler that support the creation of\u00a0\u00a0steam\u00a0, the following components of the boiler:<\/p>\n

    \n
  1. Furnace<\/li>\n<\/ol>\n

    This component is a place for burning fuel.\u00a0Some parts of the\u00a0\u00a0furnace\u00a0\u00a0include:\u00a0\u00a0refractory\u00a0, fireplace room,\u00a0\u00a0burner\u00a0,\u00a0\u00a0exhaust for flue gas\u00a0,\u00a0\u00a0charge and discharge door\u00a0\u00a0.<\/p>\n

      \n
    1. Steam Drum<\/li>\n<\/ol>\n

      This component is a hot water reservoir and\u00a0steam\u00a0generator\u00a0\u00a0.\u00a0Steam is\u00a0\u00a0still saturated (\u00a0saturated steam\u00a0).<\/p>\n

        \n
      1. Superheater<\/li>\n<\/ol>\n

        This component is a place for drying\u00a0\u00a0steam\u00a0\u00a0and is ready to be sent through the\u00a0\u00a0main steam pipe\u00a0\u00a0and ready to drive a steam turbine or run an industrial process.<\/p>\n

          \n
        1. Air Heater<\/li>\n<\/ol>\n

          This component is a heating chamber that is used to heat the outside air that is absorbed to minimize the humid air that will enter the furnace.<\/p>\n

            \n
          1. Economizer<\/li>\n<\/ol>\n

            This component is a heating chamber that is used to heat water from condensed water from the previous system and new feed water.<\/p>\n

              \n
            1. Safety valve<\/li>\n<\/ol>\n

              This component is a\u00a0steam\u00a0exhaust\u00a0\u00a0\u00a0in the event that the\u00a0steam\u00a0pressure\u00a0\u00a0\u00a0exceeds the boiler’s ability to withstand\u00a0steam\u00a0pressure\u00a0\u00a0.<\/p>\n

                \n
              1. Blowdown valve<\/li>\n<\/ol>\n

                This component is a channel that functions to remove deposits that are inside the\u00a0steam\u00a0pipe\u00a0\u00a0.<\/p>\n

                <\/a>Boiler Classification<\/strong><\/b><\/p>\n

                After knowing the short process, the boiler system, and the components forming the boiler system, it is necessary to know the diversity of the boiler.\u00a0Various forms of boilers have evolved following technological advances and evaluations of previous boiler products that are affected by boiler exhaust gases that affect the environment and\u00a0what kind of\u00a0steam\u00a0products\u00a0will be produced.\u00a0The following classification of boilers that have been developed:<\/p>\n

                Based on the pipe type:<\/strong><\/b><\/p>\n

                  \n
                1. Fire Tube<\/li>\n<\/ol>\n

                  Fire pipe boiler types have the following characteristics: produce low\u00a0steam\u00a0capacity and pressure\u00a0.<\/p>\n

                  How it works: the ignition process occurs in the pipe, then the heat generated is delivered directly into the boiler that contains water.\u00a0The size and construction of the boiler affect the capacity and pressure generated by the boiler.<\/p>\n

                    \n
                  1. Water Tube<\/li>\n<\/ol>\n

                    The type of water pipe boiler has the following characteristics: high\u00a0steam\u00a0capacity and pressure\u00a0.<\/p>\n

                    How it works: the ignition process occurs outside the pipe, then the heat generated heats the pipe filled with water and before the water is conditioned first through an economizer, then the\u00a0steam\u00a0produced first is collected in a\u00a0steam-\u00a0drum.\u00a0Until the pressure and temperature match, through the secondary superheater and\u00a0\u00a0the new primary superheater,\u00a0steam is\u00a0released into the main distribution pipe.\u00a0In a water pipe, running water must be conditioned to minerals or other contents that are dissolved in the water.\u00a0This is the main factor that must be considered for this type.<\/p>\n

                    Table 1.1.\u00a0Boiler advantages and disadvantages based on pipe type.<\/em><\/p>\n\n\n\n\n\n\n\n\n\n\n\n
                    No.<\/td>\nBoiler Type<\/td>\nThe advantage<\/td>\nLoss<\/td>\n<\/tr>\n
                    1<\/td>\nFire Tube<\/td>\nThe installation process is easy and fast, does not require\u00a0\u00a0special\u00a0settings<\/td>\nSteam\u00a0operating pressure is\u00a0\u00a0limited to 18 bar low pressure<\/td>\n<\/tr>\n
                    <\/td>\n<\/td>\nThe initial investment of this boiler is cheap<\/td>\nSteam\u00a0capacity is\u00a0\u00a0\u00a0relatively small (13.5 TPH) when compared to a water tube<\/td>\n<\/tr>\n
                    <\/td>\n<\/td>\nThe shape is more\u00a0compact\u00a0\u00a0and\u00a0\u00a0portable<\/td>\nThe kiln is difficult to reach for cleaning, repair and condition checking.<\/td>\n<\/tr>\n
                    <\/td>\n<\/td>\nDoes not require a large area for 1 HP boiler<\/td>\nThe efficiency value is low, because a lot of heat energy is wasted directly into the stack<\/td>\n<\/tr>\n
                    2<\/td>\nWater Tube<\/td>\nLarge\u00a0steam\u00a0capacity\u00a0\u00a0\u00a0up to 450 TPH<\/td>\nThe construction process is more detailed<\/td>\n<\/tr>\n
                    <\/td>\n<\/td>\nOperating pressure reaches 100 bar<\/td>\nInitial investment is relatively more expensive<\/td>\n<\/tr>\n
                    <\/td>\n<\/td>\nThe efficiency value is relatively higher than the fire tube boiler<\/td>\nThe handling of water entering the boiler needs to be maintained, because it is more sensitive for this system, it needs supporting components for this<\/td>\n<\/tr>\n
                    <\/td>\n<\/td>\nThe furnace is easy to reach for inspection, cleaning and repair.<\/td>\nBeing able to produce greater\u00a0steam\u00a0capacity and pressure\u00a0\u00a0\u00a0, the construction requires a large area<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                    Based on the fuel used:<\/strong><\/b><\/p>\n

                      \n
                    1. Solid Fuel<\/li>\n<\/ol>\n

                      Solid fuel boiler types have the characteristics: the price of combustion raw materials is relatively cheaper compared to boilers that use liquid and electric fuels.\u00a0The efficiency value of this type is better when compared to electric type boilers.<\/p>\n

                      How it works: heating that occurs due to combustion between mixing of solid fuels (coal, baggase, rejected products, municipal waste, wood) with oxygen and heat sources.<\/p>\n

                        \n
                      1. Oil Fuel<\/li>\n<\/ol>\n

                        The type of liquid fuel boiler has the following characteristics: the price of the most expensive combustion raw material compared to all types.\u00a0The efficiency value of this type is better when compared with solid fuel and electricity boilers.<\/p>\n

                        How it works: heating that occurs due to combustion between the mixing of liquid fuels (diesel, IDO, residues, kerosene) with oxygen and heat sources.<\/p>\n

                          \n
                        1. Gaseous Fuel<\/li>\n<\/ol>\n

                          The type of gas fuel boiler has the following characteristics: the price of the combustion raw material is the lowest compared to all types of boilers.\u00a0The efficiency value of this type is better when compared to all types of boilers based on fuel.<\/p>\n

                          How it works: combustion that occurs due to mixing of gas fuel (LNG) with oxygen and heat sources.<\/p>\n

                            \n
                          1. Electric<\/li>\n<\/ol>\n

                            This type of electric boiler has the characteristics: the price of heating raw materials is relatively cheaper compared to boilers that use liquid fuel.\u00a0The efficiency value of this type is lowest when compared with all types of boilers based on fuel.<\/p>\n

                            How it works: heating that occurs due to a source of electricity that supplies a source of heat.<\/p>\n

                            Table 1.2.\u00a0Boiler gains and losses based on fuel.<\/em><\/p>\n\n\n\n\n\n\n\n\n\n\n\n
                            No.<\/td>\nBoiler Type<\/td>\nThe advantage<\/td>\nLoss<\/td>\n<\/tr>\n
                            1<\/td>\nSolid Fuel<\/td>\nRaw materials are easy to get.<\/td>\nResidual combustion is difficult to clean<\/td>\n<\/tr>\n
                            <\/td>\n<\/td>\nCheap construction.<\/td>\nDifficult to get good raw materials.<\/td>\n<\/tr>\n
                            2<\/td>\nOil Fuel<\/td>\nNot much combustion left over and easier to clean.<\/td>\nThe price of the most expensive raw materials.<\/td>\n<\/tr>\n
                            <\/td>\n<\/td>\nThe ingredients are easy to get.<\/td>\nExpensive construction.<\/td>\n<\/tr>\n
                            3<\/td>\nGaseous Fuel<\/td>\nThe cheapest fuel prices.<\/td>\nExpensive construction.<\/td>\n<\/tr>\n
                            <\/td>\n<\/td>\nThe best value is its efficiency.<\/td>\nDifficult to obtain raw materials, there must be a distribution channel.<\/td>\n<\/tr>\n
                            4<\/td>\nElectric<\/td>\nThe easiest maintenance.<\/td>\nThe worst value efficiency.<\/td>\n<\/tr>\n
                            <\/td>\n<\/td>\nEasy construction and easy to get the source.<\/td>\nThe lowest combustion temperature.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                            Based on the use of the boiler:<\/strong><\/b><\/p>\n

                              \n
                            1. Power Boiler<\/li>\n<\/ol>\n

                              This type of\u00a0power boiler\u00a0has characteristics: its main use is as a\u00a0steam\u00a0generator as a power plant, and the remaining\u00a0steam is\u00a0used to run industrial processes.<\/p>\n

                              How it works: the\u00a0steam\u00a0produced by this boiler uses a type of water tube boiler, the resulting\u00a0steam\u00a0has a large pressure and capacity, so it is able to turn\u00a0steam\u00a0turbines and generate electricity from generators.<\/p>\n

                                \n
                              1. Industrial Boiler<\/li>\n<\/ol>\n

                                Industrial boiler\u00a0types\u00a0have characteristics: their main use is as a producer of\u00a0steam\u00a0or hot water for running industrial processes and as an additional heater.<\/p>\n

                                How it works:\u00a0steam\u00a0produced by this boiler can use the type of water tube or fire tube boiler, the resulting\u00a0steam\u00a0has a large capacity and moderate pressure.<\/p>\n

                                  \n
                                1. Commercial Boiler<\/li>\n<\/ol>\n

                                  This type of\u00a0commercial boiler\u00a0has characteristics: its main use is as a producer of\u00a0steam\u00a0or hot water as a heater and in addition to running commercial operations.<\/p>\n

                                  How it works:\u00a0steam\u00a0produced by this boiler can use a type of water tube or fire tube boiler, the resulting\u00a0steam\u00a0has a large capacity and low pressure.<\/p>\n

                                    \n
                                  1. Residential Boiler<\/li>\n<\/ol>\n

                                    This type of\u00a0residential boiler\u00a0has characteristics: its main use is as a producer of\u00a0steam\u00a0or low pressure hot water that is used for housing.<\/p>\n

                                    How it works: the\u00a0steam\u00a0produced by this boiler uses the type of fire tube boiler, the resulting\u00a0steam\u00a0has a low pressure and capacity<\/p>\n

                                      \n
                                    1. Heat Recovery Boiler<\/li>\n<\/ol>\n

                                      The type of\u00a0heat recovery boiler\u00a0has the characteristics: its main use as a producer of\u00a0steam\u00a0from unused hot steam.\u00a0The results of\u00a0this\u00a0steam\u00a0are used to run industrial processes.<\/p>\n

                                      How it works:\u00a0steam\u00a0produced by this boiler uses a type of water tube boiler or fire tube boiler, the resulting\u00a0steam\u00a0has a large pressure and capacity.<\/p>\n

                                      Table 1.3.\u00a0Boiler gains and losses based on utility.<\/em><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n
                                      No.<\/td>\nBoiler Type<\/td>\nThe advantage<\/td>\nLoss<\/td>\n<\/tr>\n
                                      1<\/td>\nPower Boiler<\/td>\nCan produce electricity and the remaining\u00a0\u00a0steam\u00a0can run industrial processes.<\/td>\nInitial construction is relatively expensive.<\/td>\n<\/tr>\n
                                      <\/td>\n<\/td>\nSteam\u00a0\u00a0produced has a high pressure<\/td>\nSafety factors need to be considered.<\/td>\n<\/tr>\n
                                      2<\/td>\nIndustrial Boiler<\/td>\nEasier boiler handling.<\/td>\nSteam\u00a0\u00a0produced has a low pressure.<\/td>\n<\/tr>\n
                                      <\/td>\n<\/td>\nInitial construction is relatively inexpensive.<\/td>\n<\/td>\n<\/tr>\n
                                      3<\/td>\nCommercial Boiler<\/td>\nEasier boiler handling.<\/td>\nSteam\u00a0\u00a0produced has a low pressure.<\/td>\n<\/tr>\n
                                      <\/td>\n<\/td>\nInitial construction is relatively inexpensive.<\/td>\n<\/td>\n<\/tr>\n
                                      4<\/td>\nResidential Boiler<\/td>\nEasier boiler handling.<\/td>\nSteam\u00a0\u00a0produced has a low pressure.<\/td>\n<\/tr>\n
                                      <\/td>\n<\/td>\nInitial construction is relatively inexpensive.<\/td>\n<\/td>\n<\/tr>\n
                                      5<\/td>\nHeat Recovery Boiler<\/td>\nEasier boiler handling.<\/td>\nSteam\u00a0\u00a0produced has a low pressure.<\/td>\n<\/tr>\n
                                      <\/td>\n<\/td>\nInitial construction is relatively inexpensive.<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                                      Based on boiler construction:<\/strong><\/b><\/p>\n

                                        \n
                                      1. Package Boiler<\/li>\n<\/ol>\n

                                        The type of boiler package has characteristics: boiler assembly is carried out at the manufacturing plant, direct delivery in the form of a boiler.<\/p>\n

                                          \n
                                        1. Site Erected Boiler<\/li>\n<\/ol>\n

                                          The type of\u00a0site erected boiler\u00a0has the following characteristics: boiler assembly is carried out at the site where the boiler is to be built, deliveries are carried out per component.<\/p>\n

                                          Table 1.4.\u00a0Boiler gains and losses based on construction.<\/em><\/p>\n\n\n\n\n\n\n\n
                                          No.<\/td>\nBoiler Type<\/td>\nThe advantage<\/td>\nLoss<\/td>\n<\/tr>\n
                                          1<\/td>\nPackage Boiler<\/td>\nEasy shipping.<\/td>\nLimited pressure and work capacity.<\/td>\n<\/tr>\n
                                          <\/td>\n<\/td>\nIt takes a short time to operate after sending.<\/td>\nBoiler components depend on the boiler manufacturer.<\/td>\n<\/tr>\n
                                          2<\/td>\nSite Erected Boiler<\/td>\nWork pressure and capacity can be adjusted according to desire.<\/td>\nDifficult to send, expensive cost.<\/td>\n<\/tr>\n
                                          <\/td>\n<\/td>\nBoiler components can be integrated with other manufacturers.<\/td>\nIt takes quite a long time after the boiler stands, after the shipping process.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                                          Based on boiler working pressure:<\/strong><\/b><\/p>\n

                                            \n
                                          1. Low Pressure Boilers<\/li>\n<\/ol>\n

                                            Low pressure boiler type has characteristics: this type has an\u00a0operating\u00a0steam\u00a0pressure\u00a0of less than 15 psig or produces hot water with pressure below 160 psig or temperature below 250\u00a00<\/sup>\u00a0F<\/p>\n

                                              \n
                                            1. High Pressure Boilers<\/li>\n<\/ol>\n

                                              High pressure boiler type has characteristics: this type has an\u00a0operating\u00a0steam\u00a0pressure\u00a0above 15 psig or produces hot water with pressure above 160 psig or temperatures above 250\u00a00<\/sup>\u00a0F<\/p>\n

                                              Table 1.5.\u00a0Boiler gains and losses based on working pressure.<\/em><\/p>\n\n\n\n\n\n\n\n
                                              No.<\/td>\nBoiler Type<\/td>\nThe advantage<\/td>\nLoss<\/td>\n<\/tr>\n
                                              1<\/td>\nLow Pressure<\/td>\nLow pressure so that the handling is not too complicated<\/td>\nThe resulting pressure is low, it cannot generate electricity.<\/td>\n<\/tr>\n
                                              <\/td>\n<\/td>\nThe area required is not too large, and the construction cost is not more expensive than a\u00a0\u00a0high pressure boiler<\/td>\n<\/td>\n<\/tr>\n
                                              2<\/td>\nHigh Pressure<\/td>\nThe resulting pressure is high so that it can generate electricity and the rest can be recycled to operate industrial processes<\/td>\nHigh pressure so that the handling needs to be considered safety aspects.<\/td>\n<\/tr>\n
                                              <\/td>\n<\/td>\n<\/td>\nThe area required is large and the construction cost is more expensive than a\u00a0\u00a0low pressure boiler<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                                              Based on how to burn fuel:<\/strong><\/b><\/p>\n

                                                \n
                                              1. Stoker Combustion<\/li>\n<\/ol>\n

                                                Stoker combustion\u00a0type\u00a0has the following characteristics: this type utilizes solid fuel to ignite, solid fuel is put into the combustion chamber via\u00a0conveyor\u00a0or manually.\u00a0This type has combustion residue that must be handled in the form of\u00a0bottom ash\u00a0or\u00a0fly ash\u00a0\u00a0which can pollute the environment.<\/p>\n

                                                  \n
                                                1. Pulverized Coal<\/li>\n<\/ol>\n

                                                  How it works: this process destroys coal with a ball mill or roller mill so that coal has a size of less than 1 mm.\u00a0then this powdered coal is sprayed into the combustion chamber.<\/p>\n

                                                    \n
                                                  1. Fluidized Coal<\/li>\n<\/ol>\n

                                                    How it works: this process destroys coal with a crusher, so that coal has a size of less than 2 mm.\u00a0In this process combustion is carried out in a layer of sand, coal will immediately burn if it hits the sand.<\/p>\n

                                                      \n
                                                    1. Firing Combustion<\/li>\n<\/ol>\n

                                                      Firing\u00a0type\u00a0has characteristics: this type utilizes liquid, solid, and gas fuels to do combustion, heating which occurs more evenly.<\/p>\n

                                                      How it works: liquid fuel used as\u00a0preliminary firing fuel is\u00a0put into the combustion chamber through an\u00a0oil gun\u00a0.\u00a0After reaching the appropriate temperature, combustion is taken over by\u00a0coal nozzle\u00a0or\u00a0gas nozzle\u00a0.<\/p>\n

                                                      \u00a0Table 1.6.\u00a0Boiler gains and losses based on combustion.<\/em><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n
                                                      No.<\/td>\nBoiler Type<\/td>\nThe advantage<\/td>\nLoss<\/td>\n<\/tr>\n
                                                      1<\/td>\nStoker Combustion<\/td>\nThe construction is relatively simple.<\/td>\nMore waste is produced by combustion<\/td>\n<\/tr>\n
                                                      <\/td>\n<\/td>\n<\/td>\nThe resulting heat is less even if there are no supporting components.<\/td>\n<\/tr>\n
                                                      <\/td>\n<\/td>\n<\/td>\nRelatively low efficiency<\/td>\n<\/tr>\n
                                                      2<\/td>\nPulverized<\/td>\nRelatively high efficiency<\/td>\nThe construction is complicated and requires expensive investment funds.<\/td>\n<\/tr>\n
                                                      <\/td>\n<\/td>\nThe combustion process is more evenly distributed in the furnace.<\/td>\n<\/td>\n<\/tr>\n
                                                      3<\/td>\nFluidized Bed<\/td>\nRelatively high efficiency<\/td>\nThe construction is complicated and requires expensive investment funds.<\/td>\n<\/tr>\n
                                                      <\/td>\n<\/td>\nThe combustion temperature does not reach 1000\u00a0\u00a00<\/sup>\u00a0C so it does not cause NO\u00a0X<\/sub><\/td>\n<\/td>\n<\/tr>\n
                                                      4<\/td>\nFiring<\/td>\nLess waste produced by combustion<\/td>\nConstruction is relatively complicated, it needs a\u00a0\u00a0nozzle.<\/td>\n<\/tr>\n
                                                      <\/td>\n<\/td>\nThe heat is produced more evenly<\/td>\n<\/td>\n<\/tr>\n
                                                      <\/td>\n<\/td>\nRelatively better efficiency<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                                                      Based on the boiler constituent material:<\/strong><\/b><\/p>\n

                                                        \n
                                                      1. Steel<\/li>\n<\/ol>\n

                                                        The type of boiler made of\u00a0steel\u00a0has characteristics: the main raw material for boilers is made using\u00a0steel\u00a0in the\u00a0steam\u00a0area\u00a0.<\/p>\n

                                                          \n
                                                        1. Cast Iron<\/li>\n<\/ol>\n

                                                          The type of boiler made from\u00a0cast iron\u00a0has the following characteristics: the main raw material of the boiler is made using cast iron\u00a0in the\u00a0steam\u00a0area\u00a0.<\/p>\n

                                                          Table 1.7.\u00a0Boiler gains and losses based on material.<\/em><\/p>\n\n\n\n\n\n\n\n
                                                          No.<\/td>\nBoiler Type<\/td>\nThe advantage<\/td>\nLoss<\/td>\n<\/tr>\n
                                                          1<\/td>\nSteel<\/td>\nStrong and durable.<\/td>\nCost is relatively expensive.<\/td>\n<\/tr>\n
                                                          <\/td>\n<\/td>\nSteam\u00a0can be used\u00a0\u00a0for high pressure.<\/td>\nMore complicated construction.<\/td>\n<\/tr>\n
                                                          2<\/td>\nCast Iron<\/td>\nThe cost is relatively cheap.<\/td>\nVulnerable and easily damaged.<\/td>\n<\/tr>\n
                                                          <\/td>\n<\/td>\nSimpler construction.<\/td>\nCould be loaded with\u00a0\u00a0steam\u00a0\u00a0for a limited pressure.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                                                          Boiler safety<\/strong><\/b><\/p>\n

                                                          600 MW PLTU boiler<\/p>\n

                                                          Boiler Protection \/ Safety Function<\/strong><\/b><\/p>\n

                                                          Boiler safety is intended to maintain and avoid more serious interference with the boiler and its supporting tools, which results in a decrease in boiler capability, or damage to equipment.<\/p>\n

                                                          <\/a>Basic principles<\/strong><\/b><\/em><\/p>\n

                                                          The basis of boiler protection and its auxiliary equipment is that the safety device must be able to guarantee the continuity\u00a0of the boiler’s steam production service.<\/p>\n

                                                          Protection<\/strong><\/b><\/em><\/p>\n

                                                          <\/a>A boiler needs safety to maintain the reliability of operation in a long period of time.\u00a0This boiler safety system in general will describe the safety of the boiler from corrosion, overheating and thermal stress that is caused during the process of startup, normal operation and shutdown.<\/p>\n

                                                          Boiler vent must be opened during the filling process so that air in the boiler tube can be removed, the aim is to reduce the possibility of corrosion due to oxidation of air trapped in the boiler tube other than air.\u00a0It also can cause cavitation and water hammer.\u00a0Before operating the boiler must be rinsed (purge) from the used gas that accumulates in the combustion chamber is important because the waste gas from the combustion that is not wasted will form a hot gas that can cause an explosion in the room at the boiler ignitor startup because during this period many combustible possibilities occur and explosive due to frequent ignitor ignition failures and unstable binding conditions.<\/p>\n

                                                          Boiler areas that require special attention include:<\/p>\n

                                                          <\/a>Economizer<\/strong><\/b><\/p>\n

                                                          Feedwater is not always added when raising the boiler pressure because the water in the boiler always circulates naturally.\u00a0But without the presence of feedwater in the filling water will not flow to the economizer.\u00a0Economizer is secured from the formation of feedwater evaporation in the tube, because the steam trapped inside can cause water hammer, thermal shock and can cause fluctuations in drum level control.\u00a0To safeguard this problem there needs to be a continuous flow of circulation from the economizer inlet header to one of the downcomers.\u00a0This valve must be opened when the boiler is experiencing interference with feedwater flow control, the aim is to avoid the evaporation process in the economizer tube due to the cessation of natural circulation.\u00a0Economizer is subject to both internal and external corrosion.\u00a0Internal corrosion can be prevented by maintaining PH feedwater between 8 and 9 by chemical injection.\u00a0External corrosion can be caused by the occurrence of condensation between the low temperature of the feedwater and the high temperature of the combustion gases that pass through the economizer.\u00a0Overcoming this problem by keeping the economizer in an area far from the dew point, this case must be avoided during the startup process and after the unit is loaded.<\/p>\n

                                                          <\/a>Furnace<\/strong><\/b><\/p>\n

                                                          Furnace is a part that requires serious attention.\u00a0Because it deals with the problem of vapor pressure and steam temperature and combustion chamber temperatures are very high.\u00a0Factors of concern are:<\/p>\n

                                                          –
                                                          \nBoiler\u00a0operating pressure\u00a0Boilers must not operate above their working pressure and never exceed their design pressure.
                                                          \n– Balance balance firing operation
                                                          \nThis relates to the heat generated by combustion of the combustion chamber in the case of imbalance firing, which will cause disruption of the natural circulation process and interference with the tube due to overheating.<\/p>\n

                                                          <\/a>Steam Drum<\/strong><\/b><\/p>\n

                                                          During normal operating conditions pressure on the drum and drum level and water quality must always be controlled.\u00a0The surface of the steam drum is very high, so at startup and shutdown the temperature difference in this area must be considered, namely the difference between the top and bottom should be as small as possible in this case it is important to maintain the occurrence of thermal stress on the steam drum.<\/p>\n

                                                          Limitations that must be considered include:
                                                          \n– When there is a change in the phases of water and steam in the steam drum.
                                                          \n– The difference between top and bottom does not exceed the maximum setpoint of 50 0C for startup and 100 0C for shutdown.<\/p>\n

                                                          <\/a>Superheater<\/strong><\/b><\/p>\n

                                                          Superheater located in an area where heat transfer by convection induction attracts quite serious attention because it is related to the condition of the steam temperature and the safety temperature of the metal tube. overheating due to disrupted production and vapor flow while the combustion gas stream passing through the high induction convection area.<\/p>\n

                                                          Superheater safety limits include:
                                                          \n– Main steam temperature must always be controlled
                                                          \n– Combustion conditions must be balanced firing \/ adjusted according to its formation
                                                          \n– Thermocouple superheater exit must be monitored
                                                          \n– Gas temperature superheater entry area must be limited during startup to normal operating unit conditions.<\/p>\n

                                                          <\/a>Boiler Safety Mode Operation<\/strong><\/b><\/p>\n

                                                          <\/a>Safety Directly<\/strong><\/b><\/p>\n

                                                            \n
                                                          1. \u00a0Safety Valve<\/li>\n<\/ol>\n

                                                            Before the boiler is declared ready for operation, the safety valve must be checked and if necessary reset in accordance with the working area.\u00a0This procedure is very important considering that after the boiler firing will produce pressure.\u00a0This vapor pressure can determine that the safety valve serves as a safety against the occurrence of excess vapor pressure produced by the boiler.<\/p>\n

                                                              \n
                                                            1. \u00a0Relief Valve<\/li>\n<\/ol>\n

                                                              Relief valve can be classified as a safety as well as a safety valve, but this relief valve serves as a limiting or maximum pressure safety in the liquid work area.\u00a0The use of relief valve is placed in the following areas:
                                                              \n– Header reheat \/ HP bypass spray water
                                                              \n– Header auxiliary steam spray
                                                              \n– Ignitor oil level header
                                                              \n– Heavy fuel oil level header<\/p>\n

                                                              <\/a>Indirectly Security<\/strong><\/b><\/p>\n

                                                                \n
                                                              1. \u00a0Pneumatic Valve<\/li>\n<\/ol>\n

                                                                The pneumatic valve as well as the safety valve serves as a safety for over steam pressure on the boiler only equipped with a pressure sensor which is conveyed through an electronic signal to the electro mechanical to open the pilot valve.<\/p>\n

                                                                  \n
                                                                1. Safety Boiler Drum Level<\/li>\n<\/ol>\n

                                                                  Serves to control the level of water level on the boiler drum as a safety for the occurrence of “high level drum boiler trip” and “low level drum boiler boiler”.
                                                                  \nThe reason for securing a “high level drum trip boiler” is to secure the boiler drum from carrying over in the drum which will result in deposits in the superheater area and turbine blade.\u00a0Deposits will inhibit the heat transfer of the superheater which results in overheating of the superheater tube and the turbine blade will cause unbalance and vibration of the turbine.
                                                                  \nWhile the condition of “low level drum trip boiler” can cause disruption of natural circulation which will result in overheating in the steam drum and steam production is inhibited.<\/p>\n

                                                                    \n
                                                                  1. Safety of the Boiler Furnace<\/li>\n<\/ol>\n

                                                                    Serves to control the pressure of the combustion chamber \/ boiler as a safety for the occurrence of:
                                                                    \n– Furnace pressure & gt;\u00a0max
                                                                    \n– Furnace draft & gt;\u00a0max
                                                                    \nIn connection with the type of boiler with a balance draft design where the design pressure allowed is -10mmWg, this is to ensure the stability of the combustion process.\u00a0Transportation of coal fuel to the combustion chamber and the process of removing coal ash from inside the combustion chamber to a dust catcher etc.\u00a0If the security limits are exceeded and distorted, the above process will be disrupted.Things that must be maintained to avoid the above conditions are by:
                                                                    \n1) Check the water seal through level on the bottom hopper boiler must be in a position above the normal level.\u00a0Check LCV and bypass valve water supply.
                                                                    \n2) Check the boiler manhole condition before the boiler startup must be in a closed condition including desorvation door.
                                                                    \n3) The water level at the SDCC boiler bottom is normal.<\/p>\n

                                                                      \n
                                                                    1. Main Steam Temperature Boiler Safety<\/li>\n<\/ol>\n

                                                                      Its function is to control the high temperature of the main steam coming out of the second level superheater as a safety for the main steam temperature to exceed the allowable design limit.
                                                                      \nThis security is intended to avoid the occurrence of thermal stress in a first level turbine due to the temperature difference that is too high between the temperature of the main vapor entering with the metal temperature at the turbine blade.\u00a0In addition to avoiding material fatigue in superheater tubes due to steam temperatures that exceed the maximum capacity of superheater tubes.<\/p>\n

                                                                        \n
                                                                      1. Safety of Total Air Flow<\/li>\n<\/ol>\n

                                                                        Serves to secure the total amount of air entering the windbox \/ combustion chamber during the boiler purification process.\u00a0At the time of boiler startup and normal operation must meet the total flow amount greater than the minimum (& gt; 30% when the boiler purge).
                                                                        \nAt the time of flushing the boiler we expect all the combustion gases that have accumulated in the combustion chamber and exhaust gases to be pushed \/ released by air in the amount of & gt; 30% or about 600 tons \/ hour to be discharged into the outside air at least gases remaining clean combustion within 3 minutes (design) then safeguarding at startup and normal operation Toral air plays a role as combustion air so that when the total combustion air is at least 30% then the amount of ratio between air and fuel will not we are absolutely certain that we are worried about repeated ignition failures and one of the causes of combusable in flue gas.<\/p>\n

                                                                          \n
                                                                        1. Safeguarding the Air Pressure Header Instrument<\/li>\n<\/ol>\n

                                                                          Instrument air is a major requirement in the pneumatic power control system.\u00a0The instrument air supply must be properly maintained and very special considering that the source of power for all turbine boiler controls and its assistants lies in the continuous reliability of the instrument air supply and its working pressure.
                                                                          \nConsidering the virtue and function of the instrument air as a source of power for all turbine boiler controls and assist equipment, if air pressure drops below its working point, this will cause all pneumatic control functions to cease and will cripple the operation of the boiler and turbine.<\/p>\n

                                                                          Anticipate when an instrument low pressure alarm occurs, including:
                                                                          \n– Immediately open the SAC backup valve to the instrument air header.
                                                                          \n– Immediately check the condition of the instrument air compressor and its supply process.
                                                                          \n– Localize the possibility of instrument air leakage on all lines.
                                                                          \n– Localize the possibility of an open air drain \/ vent valve.<\/p>\n

                                                                            \n
                                                                          1. Security Pressure Cool Scanner<\/li>\n<\/ol>\n

                                                                            Its function is to secure the cooling system on the flame sensor scanner.\u00a0The importance of flame detection in a boiler to ensure the existence of combustion, so that there will be no buildup of fuel due to failure of ignition.\u00a0The flame detector is secured from the heat of the combustion chamber by providing cooling in the form of pressurized air seals on the entire surface of the fire detector.<\/p>\n

                                                                            The disruption of this cooling system will result in a melting point on the flame detector because there is direct contact between the device and the heat of the fire detected in the damage.\u00a0The fire detector \/ scanner will signal the burners that are operating for the trip so that the boiler will trip.<\/p>\n

                                                                            If a low pressure alarm blower discharge flame scanner occurs, do the following:
                                                                            \n– Check the standby auto start scanner’s blower select in the auto position.
                                                                            \n– Check the air filter \/ filter blower inlet may be dirty.
                                                                            \n– Check for possible leaks in the joint line.<\/p>\n

                                                                            <\/a>Examples of Operating Limits<\/strong><\/b><\/p>\n

                                                                              \n
                                                                            1. \u00a0Drum Level
                                                                              \nHigh Alarm : 50 mm ; Low Alarm : -50 mm
                                                                              \nHigh Trip : 250 mm\u00a0 ; Low Trip : -250 mm
                                                                              \n2.\u00a0\u00a0 \u00a0Temperature Main Steam &amp; Reheat Steam
                                                                              \nHigh Alarm : 550 oC ;\u00a0 High Trip : 570 oC (delay 60 second)
                                                                              \n560 oC (delay 600 second)\u00a0 ; 550 oC (delay 6000 second)
                                                                              \n3.\u00a0\u00a0 \u00a0Furnace Pressure
                                                                              \nHigh Alarm : 50 mmWg\u00a0 ; Low Alarm : -50 mmWg
                                                                              \nFurnace Draft High Trip : 225 mmWg ; Furnace Pressure Low : -225 mmWg
                                                                              \n4.\u00a0\u00a0 \u00a0 Boiler Safety Valve Main Drum
                                                                              \nRV 39 : 3011 psi , RV 40 : 2975 psi , RV 41 : 3047 psi, RV 42 : 3064 psi , RV 43 : 2993 psi , RV 44 : 3029 psi
                                                                              \nSecondary Superheater Outlet Header \/ Main Steam ; SV 13 : 195 kg\/cm2, SV 14 : 196 kg\/cm2, SV 15 : 197 kg\/cm2
                                                                              \nReheat Outlet Header \/ Hot Reheat ; SV 92 : 57 kg\/cm2, SV 102 : 57 kg\/cm2 (SV=safety valve)<\/li>\n<\/ol>\n

                                                                              <\/a>Water Quality<\/strong><\/b><\/p>\n

                                                                              water that enters the boiler is always conditioned (mineral free water) so that it does not damage the material \/ pipes of the boiler iron, so the quality is always controlled, and each time a water sample is taken and injected with chemicals where the pH, conductivity, chlorine, phosphate, silica maintained within the allowable value.\u00a0and if there is poor quality, it must be removed (blow down) and replaced with new water (make up).<\/p>\n

                                                                              Salt\u00a0water quality\u00a0: & lt;\u00a020 usings;\u00a0PH: 9.2 – 9.5 \/ Silica: & lt 0.0185 ppm \/ PO4: 0.3 – 3 ppm \/ Cl-: & lt;\u00a00.5 ppm<\/p>\n

                                                                              <\/a>Efficiency:<\/p>\n

                                                                              so that the boiler works economically and efficiently in addition to the type of coal used, the combustion process is optimized to achieve perfect combustion.\u00a0which boiler operator plays an important role to control, including the composition of fuel and combustion air, oxygen analyzer, chimney, sootblowing, etc. are always monitored.<\/p>\n

                                                                              <\/a>Reliable<\/p>\n

                                                                              \u00a0auxiliary equipment on the boiler installed more than one (a pair or more), aiming that if one of these aids occurs interference then it will not be to stop the boiler but the stand-by will be the way to back it up.\u00a0so that steam production remains available even if not with maximum generator loading.<\/p>\n

                                                                              The following picture is one type of boiler<\/p>\n

                                                                              <\/a>Boiler and Problems<\/strong><\/b><\/p>\n

                                                                              <\/a>Failure Tubes (leaked)<\/strong><\/b><\/p>\n

                                                                              \u00a0The cause<\/p>\n