Boiler Start Up Procedures 2i4w6u

S. P. Thermal Systems Inc. 4504 Green Meadow Blvd. Beamsville, Ontario L0R 1B5, Canada

FROM: Stephen Foster Ph 905 563 8651 Fax 905 563 6234 Cell: 416 876 0684 Email: [email protected] Web Page: www.spthermal.homestead.com

PRODUCTS AND SERVICES Agents: For: Group Simoneau (Low Water Volume Boilers), Hurst Boiler, Jacklyn Industry Water Treatment Chemicals and Management Services. Supplier: New and Used Boilers, Steam - Hot Water & Thermal Fluid, Pumps, Blow down Tanks, Water Softeners, Water Polishers, R.O, Automatic Blowdown Controllers, Chemical Pumps, Chemical Equip, Safety Valves, Feed Water Tanks, Deaerators, Lead Lag Controllers Specialty: Low Water Volume Boilers – Fire Tube & Tubeless Boilers - Water Treatment Consulting – Energy Management Services

BOILER START - UP PROCEDURES & CHECK LIST ROUTINE BOILER OPERATIONAL CHECKS ENERGY TIPS RECOMMENDED SPARE PARTS LIST Dear Customer: We thank you for purchasing a boiler from us. The following are some helpful information that can save you time and money. These suggestions are based on personal experience and should only be used in conjunction with the “Boiler Supplier manual recommendations”, which must be fully followed at all times. PRIOR TO START UP The Boiler Stack weight must be ed off the boiler, at all times. The stack must be designed to float upwards with expansion. ‰ All Steam, Condensate and feed water piping must be designed taking into consideration expected expansion. ‰ The Installing contractor, must have the proper approvals to install boilers, and have the necessary piping procedures approved by TSSA. Without this, your boiler installation might be rejected by TSSA during inspection. ‰ Check to see if all Gas valves are vented to the outside as per Local Gas code. The openings in the roof must be sealed off as per local Gas code. Gas regulator must be screened. Gas line to have dirt pocket meeting code. ‰ Check to see if all Gas lines are painted or marked as per Local Gas Code ‰ Check to see if the Local TSSA Officer & Gas Company has inspected the installation prior to Start up. ‰ Check the Air in and Air out is adequate meeting Local Gas Code. The Air in should be ducted to 18” above the Floor level. The air out should have a minimum of 10% opening of the air in. This should be installed at the highest point in the boiler room. Follow Code Can / CGA B 149.1 ‰ Check the Stack installed meets Local Code requirements for type and for height out of roof. S.P. Thermal Systems Inc. Page 1 Agents for Group Simoneau Boiler – Hurst Boiler – Water Treatment Chemicals and Services Ph 905 563 8651 Fax 905 563 6234 E-Mail [email protected] ‰

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If other equipment is in the Boiler room, such as Air compressors make sure the air In / Out satisfy all the equipment requirements. The Temperature of the boiler room should have ventilation, to keep the temperature < 95 F in room. Review boiler room requirements for an independent heater to be installed encase the boilers all failed. The heater must be big enough to prevent the room from freezing. The blowdown drains on the boilers should be a Clay Tile construction to prevent the drains collapsing due to the heat from the boiler blowdowns. When using a single stack on multiple boilers use a barometric damper on each stack. Also if you have very high existing stacks use a barometric damper. Consult with the damper supplier for more details. Low Volume Boilers should always have Softeners and a Polisher sized and installed correctly for the system expected usage and for the water quality in the area. Check to see if you have softener salt on site prior to start up Check to see you have boiler chemicals and control equipment installed, to control the chemicals. A good procedure is to install a temporary by steam line off the steam boiler, vented through the roof with a shut off valve. This is used in case there is not a sufficient load on high fire, to keep the boiler on High fire, during commissioning of the boiler. All steam piping, condensate piping, boiler down comer tubes, steam drum and steam headers are to be insulated. This will save Energy and also make the boiler safer to operate. The Ministry of Environment air and noise approval is a requirement. This application must be submitted and is the responsibility of the equipment owner to have this approval done prior to start up. An Automatic Blowdown controller should be installed to control boiler solids. All Steam boilers that are hooked up to one or more boilers, require having a steam check valve installed on each boiler steam outlet. This is a TSSA requirement. Review complete installation to determine if all equipment is installed correctly

START UP / COMMISSIONING THE BOILER o The procedure for start up is shown in the manual. The Commissioning Engineer must follow the proper Refractory curing during start up as outlined in the manual. o The Commissioning Engineer must be qualified to Commission the Boiler and Burner and have the necessary tickets to work on the system. o The boiler on start up from Cold should always be put on manual firing and warmed up on low fire before going on to automatic firing. This procedure is normal on all operating boilers. o The Feed water Pumps supplied has a bleed line at the side of the pumps. All pumps must be bleed prior to start up. Failure to do this will damage the seals. The Pumps must never run dry or they will fail. o The Pump motor must be checked for correct motor rotation. o Fuel, Water, Electrical and all Vent hook ups must be reviewed and corrected prior to start up. o The burner Fan Blower Motor must be checked for correct motor rotation. o The door at the back of boiler should be opened and the refractory inspected prior to start up and after commissioning, for cracks. This is done by carefully opening the door at the back of the boiler. The Refractory is to be replaced in the same manner after completing the inspection. Any cracks found must be repaired. Tighten the door securely. o The wires in the burner control should be checked to make sure they are secure and tight prior to start up.

S.P. Thermal Systems Inc. Page 2 Agents for Group Simoneau Boiler – Hurst Boiler – Water Treatment Chemicals and Services Ph 905 563 8651 Fax 905 563 6234 E-Mail [email protected]

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Check the Hand hole / Man Hole covers to ensure they are secure. Also, retighten them after the boiler has warmed up. Check the Safety Valves settings on the boiler to make sure they match the desired operating pressure. The Boiler Pressure switches must be set no higher than 10% less than the safety. Check that the Main Steam valve is CLOSED before firing the boiler. Fill the Boiler with soft water. Make sure to BLEED the air from the boiler by OPENING a valve on the column or by the Pressure switch at the Front of the boiler, while filling with water. Close valve when the air is removed. The Curing of the refractory takes 5 hours +. Please follow the Boiler manual procedure. In the period of curing the refractory, a boil out chemical treatment should be added to the boiler. This is usually an alkaline product containing caustic. The chemical can be added by taking off one of the safety valves and pouring it into the top of the boiler. This must only be done when water is in the boiler, prior to start up. The safety valve should then be replaced. Use protective equipment such as gloves, goggles etc. These products can burn the skin. Have water available in case of a spill. Apply water immediately to the area and seek medical attention. During the boiler warm up, vent any air further from the boiler by opening the highest valve at the front of the boiler. Close valve when the air is eliminated. When the boiler has reached a few pounds below the header pressure, SLOWLY open the Main Steam valve at the top of the boiler. Care must be taken to make sure the steam is not going to places where people are still working on the system lines. After the refractory has finished curing the boiler should be cooled slightly and the water drained from the boiler. The hand hole cover on the steam drum and one in the bottom of the drum should be opened for inspection. A water hose should be used to wash out the boiler. The front column probes for controlling the Water levels should have the valves opened and drained. After washing out the boiler the hand hole covers and gaskets should be replaced and fresh soft water added to the boiler. Care must be taken not to drop the hand hole covers into boiler. During the refractory Curing, blowdown all boiler Water Control columns frequently to keep the probes clean. Also Blowdown the boiler Gauge Glass column. Any condensate that is dirty should be diverted to drain until clear. If this is not done, you will run the risk of fouling the water probe controls. If this is to happen, the probes in the two columns on the front of the boiler and the probe at the back of the boiler will have to be cleaned. When cleaning the probes make sure to wire back the probes correctly, otherwise you will have electrical problems. After Curing the refractory the boiler should be commissioned by a qualified person familiar with the Burner. The commissioning engineer should use a Gas analyser to set up the burner on High fire, Medium fire and at Low fire. The values expected to achieve is 3 - 6 % as O2 throughout this range. The boiler Fuel input should be checked to determine if you are achieving maximum input to boiler. Over- firing of boiler will void all manufacturers warranties. Boilers that are not sized correctly & operate under Over - Firing condition will fail early . During the commissioning, the engineer will need to set up the gas input pressure correctly to prevent the gas pressure switches going off on Low pressure or High pressure. These switches also have reset buttons. The gas regulator provided would have the correct spring for the pressure that the boiler was ordered with. If the boiler was to trip on High / Low gas you will need to reset it. The Pressure switches on the boiler will require setting, based on the pressure the boiler is going to be operating at. There is an Operating pressure switch, which controls the modulation of the boiler, a Shut off High Pressure switch which shuts off the boiler when this pressure is reached and a High water level switch which will shut off the boiler if this is exceeded.

S.P. Thermal Systems Inc. Page 3 Agents for Group Simoneau Boiler – Hurst Boiler – Water Treatment Chemicals and Services Ph 905 563 8651 Fax 905 563 6234 E-Mail [email protected]

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These switches also have resets, which will restart the boiler when the limits are made, for what they are set. All these reset switches should be shown, when training the Operators in the boiler checks and operation. The Relay, (Honeywell / Fire-Eye), which controls the boiler also has a reset button if one of the limits were locked out. In the event of 2 - 3 resets, the fault should be found and corrected. It is a good policy to have a fault Module for this relay. It can be supplied as an extra if not included in the purchase of the boiler. A proof of Air check should be done. This will require the blower motor terminals being removed, and starting the boilers. If a fault shows up then this is working properly. The boiler should be manually blowdown frequently in the first week of operation, to remove any further sludge that is in the new boiler. The Automatic Blowdown Control if supplied should be set up based on the recommendations of your Water Treatment specialist or manufacturer guidelines. The Chemical Control to the boilers should be maintained based on your Water Treatment specialist. Failure to maintain adequate levels could result in Tube failure. Boiler Warranty does not cover Water Treatment Failures We recommend daily water tests to be done and the control limits provided by your Water Treatment specialist to be followed. All daily tests results and blowdown, should be recorded in a log book. In all applications, we recommend that the Feed water to the boilers be of “ZERO” hardness. This can be accomplished using a Duplex Softener and then a Single unit Polisher on the make up supply. Hardness tests should be done daily on Softener / Polisher / Feed water Tank Start - Up Report must be filled in and Faxed backed to S.P. Thermal Systems 905 563 6234

START UP COMMON PROBLEMS In the period just after commissioning the boiler, the boiler might require slight adjustments. One of the common problems is dirty water fouling the probes, as discussed above. Also the pump strainers or the Feed water check valve might not be seating properly due to dirt. These are the normal conditions that might occur if Low water problems occur. Wrong pump rotation also will cause Low water conditions. The correct pump NPSH is required to operate the pump efficiently. Certain pumps also may require a certain discharge pressure to achieve maximum efficiency. High water can be a cause of water entering the boiler through the pump, when the boiler shuts off for extended periods of time. This usually happens when the boiler cools off, creating a vacuum. This can be prevented, by installing a vacuum a breaker at the highest point on the piping that holds the Pressure controls at the front of the boiler. Chemical pumps should also be adjusted as required. DAILY ROUTINE MAINTENANCE Minimum daily hardness tests must be done on the softener, Polisher and at the Feed water Tank. “Zero” hardness is the target and anything outside of this target must be immediately corrected as otherwise you will have a scale build up in the boiler which will result in tube failure. ‰ The Oxygen scavenger should be maintained at the level set by your Water Treatment specialist. Values set in the control limits must be maintained to achieve the best protection for the boiler at all times. (When boiler is on or off line.) ‰ The Automatic blowdown control should be set to activate blowdown based on the control limits recommended by your Water Treatment specialist. Normally the control limit is 4000 mmhos max based on most waters. This could vary based on water quality. The timer to activate the automatic blowdown is normally set at 1 hour. The duration timer is usually set at around 10 seconds to allow sufficient time for the probe to check the water. The probe must be installed on the boiler as shown in the manual provided with the Automatic Blowdown Controller. Another common mistake is installing the probe in the wrong position. There is a mark on the base of the probe, which should line up with the pipe. This probe needs to be flushed daily as shown in the manual of the Automatic Controller. S.P. Thermal Systems Inc. Page 4 Agents for Group Simoneau Boiler – Hurst Boiler – Water Treatment Chemicals and Services Ph 905 563 8651 Fax 905 563 6234 E-Mail [email protected] ‰

All daily water tests and blowdown should be recorded as a requirement of TSSA, in a Logbook. The boiler must always start when cold, on (Low Fire), before going to automatic control firing. If this is not done the refractory will have a short life. ‰ Manual bottom blowdown of the boiler is normally 2 - 3 slow bursts of 3 seconds each, per day. ‰ The two Front columns & Gauge Glass should be blowndown daily while the boiler is running. This is to make sure that the Low water trips are functioning properly. Do one at a time. ‰ All Blowdown Water is sent to a Blowdown tank on high-pressure boilers. These are boilers operating above 15 psig. The Cold water for cooling the blowdown tank needs to be adjusted to maintain the temperature going to the sewer. This varies based on regulations, (120 - 140 F). ‰ If the boiler cannot be blowndown manually during weekends, then based on regulations, the Automatic Blowdown controls might be sufficient. Check stipulations with the TSSA officer. ‰ Daily, the Water softeners and the Polisher should be checked for salt. The salt level should be maintained at a minimum of 3/4 full at all times. ‰ The Safety Valves should be tested regularly, as a requirement of your Insurance Company. ‰ All leaks should be repaired immediately. ‰ In the event the boiler is not operating for long periods, please review with your Water Treatment specialist, the best way to maintain the boiler off line. (Chemical values to maintain) ‰ Feed water tank temperature must be checked and controlled at 180 – 190 F to prevent Thermal Shock. Thermal shock could damage the boiler tubes, resulting in boiler failure. SIX MONTHS OPERATION ‰ Every 6 months the boiler combustion should be checked to make sure that you are achieving maximum combustion efficiency. Keeping the combustion correct will save in Fuel. ‰ The Inlet air blower burner damper should be cleaned and any dirt in the burner removed. ‰ The burner should also be checked to see if all parts are ok in the burner. ‰ Probes for controlling the boiler water level should be checked and cleaned. There are 3 sets of probes. Two are in the front columns on the boiler and one set at the back of the boiler. ‰ Check Boiler Water Gauge Glass and seals. If leaking replace. Replace protector shield. ‰ ‰

TWELVE MONTHS OPERATION I. The boiler should be inspected every 12 months by your Insurance inspector. This is the normal procedure. This inspection will require that the hand holes be opened. The boiler should then be washed out in preparation for inspection. II. After the inspection the gaskets on the hand hole covers must be replaced with new ones III. The boiler combustion should be checked to make sure that you are achieving maximum efficiency. Keeping the combustion correct will save in Fuel. IV. The burner should also be checked to see if all parts are ok. Clean the damper blades also. V. Probes in the boiler for controlling the water level should be checked and cleaned. There are 3 sets of probes. Two are in the front columns on the boiler and one set at the back of the boiler. VI. Check Boiler Water Gauge Glass and seals. If leaking replace. Replace protector shield. VII. Feed Water check valve should be checked and replaced if required. VIII. Safety Valves should be checked and replaced if leaking. IX. Feed water pumps should be checked and seals replaced if required. Bleed pumps after. X. Water probe control in the Feed tank should be checked, cleaned and repaired if required XI. The “Probe” & Solenoid valves on the Automatic Blowdown Control and the Steam Temperature controller in the Feed water Tank, should be checked and replaced if required. Also clean Needle valve and Strainer, which is installed just after the Blowdown Probe. XII. Check all Boiler blowdown valves for leaks, and replace if necessary. XIII. Gauge Glass protector on boiler should be checked and replaced if required.

S.P. Thermal Systems Inc. Page 5 Agents for Group Simoneau Boiler – Hurst Boiler – Water Treatment Chemicals and Services Ph 905 563 8651 Fax 905 563 6234 E-Mail [email protected]

ENERGY SAVING TIPS TO CONSIDER, TO MAINTAIN AN EFFICIENT BOILER SYSTEM Below are Energy Savings guidelines, which should be followed to achieve maximum efficiency. The cost of Fuel today makes it important that all measures are taken to reduce Energy Loss. • Make sure the Burner Combustion set up is done correctly for maximum Efficiency. • Insulate all areas that are hot. Example: Feed water tank, Steam Lines, Condensate lines, Steam Headers. • The Boiler Steam Drum and the Down Comer Tube at the front and the back of boiler should be insulated. • The Boiler manual blowdown and automatic blowdown controller should be set to achieve control values specified by your Water Treatment specialist. • Regular Burner Combustion checks should be done on the boiler, about every 6 months. • All steam leaks should be repaired immediately. • All Steam Traps should be monitored frequently and fixed when leaking. • The Feed Water Tank should be monitored to maintain between 180 – 190 F temperature. (If higher check traps for leaking or adjust steam heater) • Monitor water make up to make sure you are returning as much of condensate as possible. Loss of condensate water will mean higher energy, water & chemical cost. • Repair any insulation that has been removed or damaged. • Shut off steam going to areas that are not requiring steam any longer. • Reduce steam pressure if possible, to the limits that are safe to operate the boiler. • Make sure your water softener is always producing soft water. Remove boiler scale. • Run Boilers sized to load. Oversized boilers have higher Radiation & Purge losses. • Reduce Wet Steam by controlling Boiler blowdown effectively.

RECOMMENDED SPARE PARTS FOR MOST BOILERS • Burner ignition electrodes • Honeywell Flame scanner (Mini-Peeper) • Fan Blower Wheel • Blower Motor • Hand Hole Gaskets • Gauge Glass “O” Rings • Gas Pilot regulator • Pilot Gas solenoid valve • Burner Diff (Spinner) • Honeywell Relay RM 7840 L 1018 or similar. Check unit on boiler. • Automatic Blowdown Probe • On Boilers with motorized Feed Water valves we recommend keeping a spare valve and actuator. • Feed Water Pump if a spare is not hooked up and piped in line. Please note all these parts are normally readily available. However, in critical production conditions where time is important, we recommend that the above items should be kept in stock. S.P. Thermal Systems Inc. Page 6 Agents for Group Simoneau Boiler – Hurst Boiler – Water Treatment Chemicals and Services Ph 905 563 8651 Fax 905 563 6234 E-Mail [email protected]

Always have a reliable Boiler Mechanic Service Company assigned to your plant, encase you have, to have work done on your equipment in an emergency.

SEASONAL BOILER OPERATIONS RECOMMENDED PROCEDURE o

The Boiler Main Gas and fuel valves should be closed at the time boilers are shut down.

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Boiler systems that are shutdown for any long periods should have the condensate drained.

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The Boiler tubes should be drained of water, flushed and inspected. All the hand holes should be left open for air to circulate and keep the tubes dry. Customer should periodically inspect boilers to make sure adequate air circulation is occurring, to prevent moisture in the air not causing surface corrosion.

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Any water dripping into the boilers should be immediately stopped, and the valves or source repaired.

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All boiler control probes should be cleaned, hand hole gaskets replaced, gauge glass seals replaced, gauge glass and valves replaced if required, automatic blowdown probes cleaned, check valves inspected and replaced if required, safety valves inspected and tested if required, blower motor and fan inspected and cleaned.

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All valves should be repaired and traps and strainers inspected prior to start up through out the steam system.

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The Feed Water System should have the Feed Tank cleaned out, suction strainers cleaned, float control inspected, steam heater controls inspected and repaired.

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Feed Water Pumps should be checked for seal leaks. On start up the Feed Water pumps must be bleed to prevent damage to the seals.

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A complete Combustion test and set up is recommended on start up for the new season.

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On re - start up of boilers, the condensate water should be diverted until the condensate shows clean.

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Softener and Polisher salt levels should be checked and filled up. All water purification system should be checked for proper operation

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Chemicals pumps and chemical system should be checked for proper functional of system.

S.P. Thermal Systems Inc. Page 7 Agents for Group Simoneau Boiler – Hurst Boiler – Water Treatment Chemicals and Services Ph 905 563 8651 Fax 905 563 6234 E-Mail [email protected]