&EPA
United States Office of Air Quality
Environmental Protection Planning and Standards
Agency Research Triangle Park NC 27711
Air
EPA-453/B-94-057
September 1994
High Capacity Fossil Fuel
Fired Plant Operator
Training Program
Instructor's Guide
A
-------
EPA-453/B-94-057
HIGH CAPACITY FOSSIL FUEL-FIRED PLANT
OPERATOR TRAINING PROGRAM
INSTRUCTOR'S GUIDE
U. S. Environmental Protection Agency
Industrial Studies Branch/BSD
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
September 30, 1994
-------
NOTICE
This Instructor's Guide is part of a model state training program which addresses the
training needs of high capacity fossil fuel-fired plant (boiler) operators. Included are generic
equipment design features, combustion control relationships, and operating and maintenance
procedures which are designed to be consistent with the purposes of the Clean Air Act
Amendments of 1990.
This training program is not designed to replace the site-specific, on-the-job training
programs which are crucial to proper operation and maintenance of boilers.
Proper operation of combustion equipment is the responsibility of the owner and
operating organization. Therefore, owners of boilers and organizations operating such facilities
will continue to be responsible for employee training in the operation and maintenance of their
specific equipment.
DISCLAIMER
This Instructor's Guide was prepared by the Industrial Studies Branch, Emission
Standards Division, U. S. Environmental Protection Agency (USEPA). It was prepared in
accordance with USEPA Contract Number 68-D1-0117, Work Assignment Number 68.
Any mention of product names does not constitute an endorsement by the U. S.
Environmental Protection Agency.
The U. S. Environmental Protection Agency expressly disclaim any liability for any
personal injuries, death, property damage, or economic loss arising from any actions taken in
reliance upon this Handbook or any training program, seminar, short course, or other
presentation based on this Instructor's Guide.
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AVAILABILITY
This Instructor's Guide and the accompanying Student Handbook are issued by the Office
of Air Quality Planning and Standards of the U.S. Environmental Protection Agency. These
training materials were developed, as required by the Clean Air Act Amendments of 1990, to
assist operators of high capacity fossil fuel-fired plants in becoming certified as may be required
by state regulatory agencies.
Individual copies of this publication are available to state regulatory agencies and other
organizations providing training of operators of high capacity fossil fuel-fired plants. Copies
may be obtained from the Air Pollution Training Institute (APTI), U.S. EPA, MD-17, Research
Triangle Park, NC 27711.
Although this government publication is not copyrighted, it does contain some
copyrighted materials. Permission has been received by the authors to use the copyrighted
material for the original intended purpose as described in the section titled Course Material
Introduction. Any duplication of this material, in whole or in part, may constitute a violation
of the copyright laws, and unauthorized use could result in criminal prosecution and/or civil
liabilities.
The recommended procedure for duplication of the Instuctor's Guide is as follows:
Permission to use this material in total may be obtained from the APTI, provided the
cover sheet is retained in its present form. Permission to use part of this material may also be
obtained from the APTI, provided that the APTI and the authors are properly acknowledged.
-------
TABLE OF CONTENTS
Course Materials Introduction i
Course Preparation Instructions iv
Course Agenda v
Pre-Test
Pre-Test Answer Key
Lesson Plans
1. Introduction 1-1
2. Water and Steam Circuit 2-1
3. Combustion Gas Circuit 3-1
4. Fossil Fuels 4-1
5. Combustion Principles 5-1
6. Air Pollution Fundamentals 6-1
7. Natural Gas Fired Boilers 7-1
8. Oil Fired Boilers 8-1
9. Pulverized Coal Boilers 9-1
10. Stokers 10-1
11. Fluidized Bed Boilers 11-1
12. Gas Turbine with Heat Recovery Steam Generator 12-1
13. Package Boilers 13-1
14. Normal Operation 14-1
15. Automatic Control Systems 15-1
16. Instrumentation: General Measurements 16-1
17. Electrical Theory 17-1
18. Turbine Generator 18-1
19. Preventative Maintenance 19-1
20. Safety 20-1
21. Air Pollutants of Concern 21-1
22. Environmental Regulations 22-1
23. Continuous Emission Monitoring 23-1
24. Particulate Control 24-1
25. Nitrogen Oxides Control 25-1
26. SO, Control 26-1
27. Water Pollution 27-1
28. Wastewater Treatment 28-1
29. Solid Wastes 29-1
30. Solid Waste Management 30-1
Post-Test
Post-Test Answer Key
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COURSE MATERIALS INTRODUCTION
The course materials were developed by the U. S. Environmental Protection
Agency (USEPA) as the model State program for training boiler operators on the
effects their actions have on the air pollution emitted from the boiler. The USEPA
was required to develop a model State training program for high-capacity fossil fuel-
fired plant operators under Title III, Section 129 of the Clean Air Act Amendments of
1990.
The Instructor's Guide and the corresponding Student Handbook make up the
materials for the training program. The course presents the fundamentals of boiler
operation, typical boiler designs, the fundamentals of air, water and solid waste
pollution and the corresponding control technologies.
The Instructor's Guide presents information required by course directors and
instructors, including course preparation instructions, a program agenda, specific
objectives of each chapter, and masters for making overhead projection
transparencies or slides.
The Student Handbook contains the detailed discussion of the course topics
with an outline for the material to be presented at the beginning of each chapter and
a copy of the figures and tables which will be presented by the instructor.
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Training Program Goals
The primary goal of the training program is to provide an adequate level of
understanding to boiler operators of the effects their actions have on the air pollution
emitted from the boiler as well as the proper operation of boilers and the associated
pollution control equipment. Fundamental information is related to general
applications and to the operator's own work experiences. Trainees are encouraged to
comment and ask questions during the training program.
The program was designed to augment, not substitute for, the normal site-
specific, on-the-job and supervised self-study training programs which are provided by
the vendor, owner or operating company.
Training Program Intended Audience
The training program addresses a wide range of boiler sizes and applications.
Specifically, the program addresses gas, oil, and coal fired boilers ranging in size from
10 million BTU per hour heat input up to the large utility boilers. Therefore, boiler
operators of these types of units are the intended audience for this training program.
Other persons who are expected to be trainees in this program include boiler
operating management staff members, technical managers, mechanics and
maintenance personnel, instrument and control technicians, general engineers and
design engineers.
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Course Limitations
Detailed administrative and legal aspects of unit operation are not emphasized
in the program because the regulations under which units operate will vary with
location and time. Operators are urged to obtain specific regulatory information and
permit requirements from the owner/operator organization.
m
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COURSE PREPARATION INSTRUCTIONS
This course requires 4 days for a complete presentation. Planning and
administrating the activities are the responsibilities of the course director. This
includes making provision for activities before and during the course as follows:
1. Making arrangements for scheduling and announcing the course.
2. Recruiting an appropriate group of instructors who have:
a. Knowledge of the design principles and operational aspects of boilers and
specific expertise in their assigned topical area.
b. Knowledge of the job requirements of boiler operators.
c. Relevant practical and operational experience.
d. A positive attitude about environmental management.
3. Briefing of the instructors before the course and providing feed-back during the
course.
4. Maintaining continuity and coordination throughout the course, such as asking
questions and leading discussions with the participants, requesting course
critique, and preparing certificates of course completion.
5. Arrange for the preparation and distribution of the course materials (agenda,
Student Handbook, roster, course critique forms)
6. Provide appropriate lecture materials.
7. Managing and confirming course registration.
8. Arranging for accommodations, including proper classroom size and seating,
projection equipment, and possible provisions for breaks and meals.
IV
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COURSE AGENDA
The course is designed to be a 4-day sequence of learning units in which the
agenda follows the sequence in the Student Handbook. However, the course agenda
can be rearranged to accommodate the special scheduling needs of the speakers. The
following is proposed agenda which follows the outline sequence of the handbook.
AGENDA FOR BOILER OPERATOR TRAINING PROGRAM
Day & Time
DAY1
8:00 - 8:30
8:30 - 9:15
9:15 - 10:00
10:15 - 10:45
10:45 - 11:30
12:30 - 1:45
1:45 - 3:00
3:15 - 4:15
4:15 - 5:00
Subject
Registration
1. Introduction and Pre-Test
2. Water and Steam Circuit
Break
3. Combustion Gas Circuit
4. Fossil Fuels
Lunch
5. Combustion Principles
6. Air Pollution Fundamentals
Break
7. Natural Gas Fired Boilers
8. Oil Fired Boiler
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AGENDA FOR BOILER OPERATOR TRAINING PROGRAM
Dav & Time
DAY 2
8:00 - 8:45
8:45 - 9:30
9:45 - 10:45
10:45 - 11:45
12:45 - 1:15
1:15 - 2:15
2:30 - 3:30
3:30 - 4:00
4:00 - 5:00
Subject
9. Pulverized Coal Boilers
10. Stokers
Break
11. Fluidized-Bed Boilers
12. Gas Turbine with Heat Recovery Steam Generator
Lunch
13. Package Boilers
14. Normal Operation
Break
15. Automatic Control Systems
16. Instrumentation: General Measurements
17. Electrical Theory
VI
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AGENDA FOR BOILER OPERATOR TRAINING PROGRAM
Dav & Time
DAYS
8:00 - 8:45
8:45 - 9:30
9:45 - 10:30
10:30 - 11:45
12:45 - 1:30
1:30 - 2:45
3:00
3:45
3:45
4:30
Subject
18. Turbine Generator
19. Preventative Maintenance
Break
20. Safety
21. Air Pollutants of Concern
Lunch
22. Environmental Regulations
23. Continuous Emission Monitoring
Break
24. Particulate Control
25. Nitrogen Oxides Control
DAY 4
8:00 - 9:00
9:00 - 9:45
10:00 - 10:30
10:30 - 11:00
11:00 - 11:30
12:30 - 2:00
26. SOX Control
27. Water Pollution
Break
28. Wastewater Treatment
29. Solid Wastes
30. Solid Waste Management
Lunch
Post-Test and Course Closure
vu
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BOILER OPERATOR TRAINING
PRE-TEST
Instructions The entire test is to be taken as a closed book test.
Write in your answer or circle the best answer on this sheet
1. Identify which of the following that is not a fossil fuel boiler design
a. fluidized bed
b. watertube
c. stoker
d. firetube
e. carnot
2. The fuel delivery system for a fossil fuel boiler
a. only delivers fuel to the burners
b. prepares fuel for combustion
c. prepares fuel for combustion and transports it to the steam generator
d. transports steam to the steam turbines.
3. The three most common fuels used in steam production are:
a. natural gas, fuel oil and kerosene
b. natural gas, kerosene and wood
c. natural gas, wood and coal
d. natural gas, fuel oil and coal
4. Name three air pollutants of concern generated by fossil fuel fired boilers.
a.
b
c.
5. A boiler is an open vessel in which water is transformed into steam under pressure by the
application of heat.
T
F
6. In a natural draft furnace, the amount of draft, or movement of air, is determined by the
height of the stack, the difference between the inside and outside temperatures, and the
draft losses.
T
F
7 What is the density of a fuel oil at 60 F if its specific gravity is 0.842, given that the
density of water is 8.328 Ib/gal at 60 F and 8.335 Ib/gal at 32 F? Ib/gal
Pre-Test Page 1
-------
8. A lean fuel mixture will produce an oxidizing flame
T
F
9. An HRT boiler is a watertube boiler
T
F
10. In a watertube boiler the pass(es) through the tubes and the pass(es) across
the outside surface of the tubes.
11. Boiler efficiency is defined as the ratio of energy output to energy input expressed as a
percentage.
T
F
12. Fuel oil grades are designated by No for the lightest grade of fuel oil through No.
for the heaviest grade of oil.
a. 1;6
b. 6;1
c. 1;4
d. 2;6
13. Heavy grade fuel oils have low viscosity and a low pour point.
T
F
14. Natural gas combustion can never produce soot or black smoke. Even when operated with
insufficient oxygen or incomplete combustion.
T
F
15. The two general types of stoker boiler are the stoker and the stoker.
a. overfeed, underfeed
b. massfeed, tuyere feed
c. spreader, pulverized coal
d. none of the above.
16. Stoker boilers are uniquely different from pulverized coal burners in that the fuel
particle size is for stokers.
a. smaller
b. much smaller
c. larger
d. much larger
Pre-Test Page 2
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17. Two advantages of fluidized-bed combustion is thar the system can be operated at
low combustion temperatures, and higher heat transfer rates from the fuel to the
watertubes can be achieved
T
F
18. Since gas turbine power is based on mass through-put, the power output of a gas
turbine will decease from the use of water or steam injection for NOX control.
T
F
19. An explosion is usually less disastrous in a firetube boiler than in a watertube
boiler.
T
F
20. O2, SOa, and CO are used to measure the efficiency of the combustion process and
the thermal heat transfer between the hot flue gasses and the steam.
T
F
21. Flame appearance is a good way to adjust the air to the furnace.
T
F
22. A flame scanner is a photo-electric eye connected to the air supply tnp.
T
F
23. An RTD senses temperature by generating a milli-volt output that varies with temperature
T
F
24. Use Ohm's law to determine the current through a device with a resistance of 16
ohms when a voltage of 24 volts is applied. The current would be .
a. 384 amps
b. 0.67 amps
c. 1.50 amps
d. 36 amps
Pre-Test Page 3
-------
25 Using the above information, what is the power consumed by the deuce9
a 36 watts
b. 24 watts
c. 10.67 watts
d. 3 84 wans
26. Transformers are designed to increase or decrease voltage in AC circuits
T
F
27. The boiling temperature of water decreases as pressure decreases.
T
F
28. Critical turbine speed is the optimum speed for low turbine maintenance and long life.
T
F
29. The goal of preventedve maintenance is
a. maximize unit reliability.
b. minimize total operating costs.
c. enhance equipment life.
d. all of the above.
30. Carbon monoxide enters the bloodstream through the lungs in the same manner as oxygen.
T
F
31. MSDSs should only be available to supervisors and managers.
T
F
32. were established by the U. S. Environmental Protection Agency to
establish air quality standards for pollutant species that impact public health and
welfare.
a. SIPs
b. Public health service
c. PSD
d. NAAQS
3 3. Critical factor to determining hazardousness of paniculate matter is (are)
a. particle size.
b. particle type.
c. aerosol concentration.
d all of the above.
Pre-Test Page 4
-------
34 Nitrogen oxides result from the combustion of all fossil fuels
T
F
35 NSPS applies to all fossil fuel boilers in existence in the U. S.
T
F
36. An opacity monitor measures the amount of exhaust gases exiting the stack.
T
F
3 7. Calibration of CEMS analyzers is only performed upon installation.
T
F
3 8. Cyclones are very effective at removing both paniculate matter and sulfur dioxide.
T
F
39. Which of the following is not a paniculate control device?
a. cyclone
b. electrostatic precipitator
c. wet scrubber
d. SCR device
40. Combustion of chemically-bound nitrogen in the fuel can form
a. fuel NOX.
b. thermal NOX.
c. prompt NOX.
d. both "a" and "c"
41. Three techniques to reduce NOx in fossil fuel fired boilers are
a.
b.
c.
42. Utilities are given allowances to emit a certain number of tons of SC>2 in a year and
can also buy additional SC*2 allowances at the Chicago Board of Trade to cover their
actual emissions, or sell their unused allowances.
T
F
Pre-Test Page 5
-------
43 The EPA does not regulate discharges of \\aste water from utilit\ and industrial boilers
T
F
44. Sunlight is an agent available for dechJorination of water and waste water
T
F
45. The air heater flyash hopper in a utility boiler typically collects of the total ash
produced.
a. about 5%
b. 10 to 20%
c. 20 to 40%
d. 50 to 70%
46. High ash fusion temperature will generally indicate low slagging potential.
T
F
47. Contamination of ground water from pollutants released from landfills when rain
water infiltrates the landfill and seeps into the ground water is
a. leaching.
b. sedimentation.
c. settling.
d. desulfurization
48. More than the optimum amount of preventative maintenance will result in
a. a substantially improved unit availability.
b. reduced operating and maintenance costs.
c. increased operating and maintenance costs.
d. the need to overhaul equipment more often.
49. A pH value of 7.0 is an indication that the:
a. water is acidic and potential tube corrosion will be a problem
b. water is basic and watertube erosion will be a problem.
c. water is basic but water tube corrosion problems are probably under control
d. Water is neutral, neither basic of acidic.
50. A properly operating in situ monitor indicates 200 ppm of SC>2 in the flue gas, and
the moisture in the flue gas is known to be 15%. If an extractive instrument which
has an in-line dryer indicated 235 ppm of SO2, then
a the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive analyzer is reading too low.
Pre-Test Page 6
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BOILER OPERATOR TRAINING
PRE-TEST
Answer Ke>
1 Identify which of the following that is not a fossil fuel boiler design
a. fluidized bed
b watertube
c. stoker
d. firetube
e. carnot
2. The fuel delivery system for a fossil fuel boiler
a. only delivers fuel to the burners
b. prepares fuel for combustion
c. prepares fuel for combustion and transports it to the steam generator
d. transports steam to the steam turbines.
3. The three most common fuels used in steam production are:
a. natural gas, fuel oil and kerosene
b. natural gas, kerosene and wood
c. natural gas, wood and coal
d. natural gas, fuel oil and coal
4. Name three air pollutants of concern generated by fossil fuel fired boilers
a. nitrogen oxides carbon monoxide
b. sulfur oxides paniculate matter
c. hydrocarbons
5. A boiler is an open vessel in which water is transformed into steam under pressure by the
application of heat.
False
6. In a natural draft furnace, the amount of draft , or movement of air, is determined by the
height of the stack, the difference between the inside and outside temperatures, and the
draft losses.
True
7. What is the density of a fuel oil at 60 F if its specific gravity is 0.842, given that the
density of water is 8.328 Ib/gal at 60 F and 8.335 Ib/gal at 32 F? 7.01 Ib/gal
8. A lean fuel mixture will produce an oxidizing flame.
True
9. An HRT boiler is a watertube boiler
False
Pre-Test Answers Page 1
-------
10 In a v-atenube boiler the water and steam passfes) through the tubes and the hot
combustion gases pass(es) across the outside surface of the tubes
11. Boiler efficiency is defined as the ratio of energy output to energy input expressed as a
percentage.
True
12. Fuel oil grades are designated by No. for the lightest grade of fuel oil through No
for the heaviest grade of oil.
a. 1; 6
b. 6; 1
c. 1;4
d. 2; 6
13. Heavy grade fuel oils have low viscosity and a low pour point.
False
14. Natural gas combustion can never produce soot or black smoke. Even when operated with
insufficient oxygen or incomplete combustion.
False
15. The two general types of stoker boiler are the stoker and the stoker.
a. overfeed, underfeed
b. massfeed, tuyere feed
c. spreader, pulverized coal
d. none of the above
16. Stoker boilers are uniquely different from pulverized coal burners in that the fuel
particle size is for stokers.
a. smaller
b. much smaller
c. larger
d. much larger
17. Two advantages of fluidized-bed combustion is that the system can be operated at
low combustion temperatures, and higher heat transfer rates from the fuel to the
watertubes can be achieved.
True
18. Since gas turbine power is based on mass through-put, the power output of a gas
turbine will decease from the use of water or steam injection for NOX control.
False
Pre-Test Answers Page 2
-------
19 An explosion is usually less disastrous in a firetube boiler than in a watertube
boiler
False
20. O2, SO2- and CO are used to measure the efficiency of the combustion process and
the thermal heat transfer between the hot flue gasses and the steam.
False
21. Flame appearance is a good way to adjust the air to the furnace.
False
22. A flame scanner is a photo-electric eye connected to the air supply trip.
False
23. An RTD senses temperature by generating a milli-volt output that varies with temperature.
False
24. Use Ohm's law to determine the current through a device with a resistance of 16
ohms when a voltage of 24 volts is applied. The current would be .
a. 384 amps
b. 0.67 amps
c. 1.50 amps
d. 36 amps
25. Using the above information, what is the power consumed by the device9
a. 36 watts
b. 24 watts
c. 10.67 watts
d. 384 watts
26. Transformers are designed to increase or decrease voltage in AC circuits
True
21. The boiling temperature of water decreases as pressure decreases.
True
28. Critical turbine speed is the optimum speed for low turbine maintenance and long life.
False
Pre-Test Answers Page 3
-------
29. The goal of preventative maintenance is
a. maximize unit reliability
b. minimize total operating costs.
c. enhance equipment life
d. all of the above,
30. Carbon monoxide enters the bloodstream through the lungs in the same manner as oxygen.
True
31. MSDSs should only be available to supervisors and managers.
False
32. were established by the U. S. Environmental Protection Agency to
establish air quality standards for pollutant species that impact public health and
welfare.
a. SIPs
b. Public health service
c. PSD
d. NAAQS
3 3. Critical factor to determining hazardousness of paniculate matter is (are)
a. particle size.
b. particle type.
c. aerosol concentration.
d. all of the above.
34. Nitrogen oxides result from the combustion of all fossil fuels.
True
35. NSPS applies to all fossil fuel boilers in existence in the U. S.
False
36. An opacity monitor measures the amount of exhaust gases exiting the stack
False
3 7. Calibration of CEMS analyzers is only performed upon installation.
False
3 8. Cyclones are very effective at removing both participate matter and sulfur dioxide
False
Pre-Test Answers Page 4
-------
39 Which of the following is not a paniculate control device0
a cyclone
b. electrostatic precipitator
c wet scrubber
d. SCR device
40. Combustion of chemically-bound nitrogen in the fuel can form
a. fuel NOX.
b. thermal NO*.
c. prompt NOX.
d. both "a" and "c"
41. Three techniques to reduce NOx in fossil fuel fired boilers are
a. low NOx burners f. flue gas recirculation
b. low excess air operation g. over fire air
c. reduced air preheat h. selective catalytic reduction
d. reburning i. selective non-catalytic reduction
e. burners out of service operation
42. Utilities are given allowances to emit a certain number of tons of SC>2 in a year and
can also buy additional SC>2 allowances at the Chicago Board of Trade to cover their
actual emissions, or sell their unused allowances.
True
43. The EPA does not regulate discharges of waste water from utility and industrial boilers.
False
44. Sunlight is an agent available for dechlorination of water and waste water.
True
45. The air heater flyash hopper in a utility boiler typically collects of the total ash
produced.
a. about 5%
b. 10 to 20%
c. 20 to 40%
d. 50 to 70%
46. High ash fusion temperature will generally indicate low slagging potential.
True
Pre-Test Answers Page 5
-------
47. Contamination of ground water from pollutants released from landfills when rain
water infiltrates the landfill and seeps into the ground water is
a. leaching.
b sedimentation.
c. settling.
d. desulfurization
48. More than the optimum amount of preventative maintenance will result in:
a. a substantially improved unit availability.
b. reduced operating and maintenance costs.
c. increased operating and maintenance costs.
d. the need to overhaul equipment more often.
49. A pH value of 7.0 is an indication that the:
a. water is acidic and potential tube corrosion will be a problem.
b. water is basic and watertube erosion will be a problem.
c. water is basic but water tube corrosion problems are probably under control
d. Water is neutral, neither basic of acidic.
50. A properly operating in situ monitor indicates 200 ppm of SO2 in the flue gas, and
the moisture in the flue gas is known to be 15%. If an extractive instrument which
has an in-line dryer indicated 235 ppm of SO2, then
a the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive analyzer is reading too low.
Pre-Test Answers Page 6
-------
LESSON PLAN
CHAPTER 1. INTRODUCTION
Goal: To give the participant an overview of the objectives of the course and a
general description of issues related to operating a steam generator system.
Objectives:
Upon completion of this unit, an operator should be able to:
1. Describe the basic components of a steam generator system.
2. List the Federal Acts which address emissions standards for a steam
generator system.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What kind of steam generating facilities do you have experience working at?
Do you know what emissions restrictions are imposed on your facility?
What are they?
Presentation Outline:
1.1 Purpose of Course
1.2 Steam Generators
1.3 Regulatory Requirements
1.4 Course Overview
Pre-Test
Pre-Test Answers
1-1
-------
CHAPTER 1. INTRODUCTION
1.4
Purpose of Course
Steam Generators
Regulatory Requirements
A. NAAQS
B. NSPS
C. SIPs
D. NESHAPS
F. Clean Air Act Ammendments
Course Overview
Slide 1-1
Boiler Operator Training
-------
COURSE OBJECTIVES
1. Effects of Operation on Emissions
2. Boiler Operation and Maintenance
3. APCD Operation and Maintenance
4. Auxiliary Systems Operation
Slide I - 2
Boiler Operator Training •BBEBBH^ESSSSESS^SSBEKBBRSSSE
-------
GENERAL SCHEMATIC FOR A
STEAM GENERATOR SYSTEM
Exhaust
APCDs
Fuel
•CP
Fan
Air
Burners
ID Fan
Stack
Flue
Gas
Steam
Generator
Steam.
Process/
Thrbine
Water
Condenser
Feed Pump
Slide 1 - 3
Boiler Operator Training
-------
CLEAN AIR ACT STANDARDS
National Ambient Air Quality Standards (NAAQS)
New Source Performance Standards (NSPS)
State Implementation Plan (SIP)
National Emission Standards for Hazardous Air Pollutants
(NESHAPs)
Slide 1 - 4
Boiler Operator Training •HS33Essssssss=ss=s=s=^=
-------
NATIONAL AMBIENT AIR QUALITY STANDARDS
(NAAQS)
Limit ambient concentration of air pollutants
Concentration limits based on health risk data
Covered Pollutants called "Criteria Pollutants"
Sulfur Oxides (SOx)
Nitrogen Oxides (NOx)
Carbon Monoxide (CO), and
Particulate Matter
Standards apply to geographical areas or basins
Boiler Operator Training
Slide 1 - 5
-------
NEW SOURCE PERFORMANCE STANDARDS
Apply to New Units or Significantly Modified Units
Regulations Established for different Groupings of Pollutant Emission Sources
• Utility Boilers
• Industrial Boilers
• Gas Turbines
Established Stack Emissions Limits for Criteria Pollutants
Limits must be based on Demonstrated Performance of Control Technologies
Slide I - 6
Boiler Operator Training K=EE=S=SE=^S=E=SE=S=
-------
STATE IMPLEMENTATION PLANS (SIPs)
• Plans for Implementing the Requirements of the Clean Air Act
at the State level
• SIPs provide the road map for States to meet NAAQS
• Regulations may apply to New and Existing sources
• Regulations may be More Stringent than NSPS
• SIPs must be reviewed and approved by Federal EPA
Slide I - 7
Boiler Operator Training
-------
Clean Air Act Amendments of 1990 Titles with
Impact on Boiler Operation
Title I: Attainment and Maintenance of NAAQS
Title III: Hazardous Air Pollutants
Title IV: Acid Deposition Control
Slide 1 - 8
Boiler Operator Training iM«^asa:=sEs=s=ssBB^E9^E
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COURSE ORGANIZATION
Introduction
Fundamental Operating Principles
Types of Equipment
Operation and Control Systems
Electrical Theory and Generation
Maintenance and Safety
Air Pollution Regulations and Monitoring
Pollution Control
Slide I - 9
Boiler Operator Training
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LESSON PLAN
CHAPTER 2. WATER AND STEAM CIRCUIT
Goal: To give the participant an overview of the basic designs and operational
issues related to water and steam circuits in boilers.
Objectives:
Upon completion of this unit, an operator should be able to:
1. Describe the process of the transformation of water into steam.
2. Understand the meaning and significance of the various physical qualities
of steam formation, such as sensible heat, latent heat, superheated steam,
and saturated steam.
3. Describe the basic designs of firetube and watertube boilers.
4. Discuss the steam-water circuit in a boiler and the related system
components.
5. Discuss water treatment and properties related to boiler water.
6. Describe the major steam-side components.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What is the difference between firetube and watertube boiler designs?
What is "foaming" in a boiler water circuit?
Presentation Outline:
2.1. Steam Fundamentals
2.2. Boiler Fundamentals
2.3. Water - Steam Circuit
2.4 Water Treatment
2-1
-------
References for Presentation Slides
Slide 2-4 Wilson. Dean R., Boiler Operator's Workbook, American Technical
Publishers, Inc., 1991.
Slide 2-5 Elliott, Thomas C., Standard Handbook ofPowerplant Engineering,
McGraw-Hill Publishing, 1989.
Slide 2-7 Ibid.
2-2
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CHAPTER 2. WATER AND STEAM CIRCUIT
2.1. Steam Fundamentals
2.2. Boiler Fundamentals
2.3. Water - Steam Circuit
A. Circulation
B. Water-Side Components
C. Steam-Side Components
2.4 Water Treatment
A. Mechanical Treatments
B. Chemical Treatments
Slide 2 -1
Boiler Operator Training •BMBMSSSS=S^S:^^=^^^=^=
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TRANSFORMATION OF WATER INTO STEAM
• Sensible Heat Addition
• Heat increases the water temperature
to the Saturation Temperature
Heat added at the Saturation
Temperature produces water vapor
or saturated steam
Pressure increases as more
steam is produced
Pressure is relieved by lid
opening to release the steam
from the kettle
Heat
Additional heat applied to a
closed kettle with saturated steam
produces superheated steam at a
higher temperature and pressure
Superheated
Steam
t
Heat Slide 2 - 2
Boiler Operator Training
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STEAM FUNDAMENTALS
Sensible Heat
Saturation Temperature
Change of Phase
Latent Heat
Saturation Steam
Superheated Steam
Steam Quality
Pressure = [Force -s- Area] (psi)
Atmospheric Pressure (14.7 psi)
Maximum Allowable Working Pressure (MAWP)
Slide2-3
Boiler Operator Training
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FIRETUBE BOILER
Boiler Operator Training
Slide 2 - 4
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WATERTUBE BOILER
Drum
Wsterwall
Tubes
Oowncomer
Windbox
Slide 2 - 5
Boiler Operator Training
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CONVECTION PASS COMPONENTS
Superheaters
Reheater
Economizer
Air Heater
Slide 2 - 6
Boiler Operator Training HBSBsnBBa=srsses=====ssssan=]^
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NATURAL CIRCULATION IN A BOILER
Steam Out
Fecdwater
Downcomer
(Not Heated)
Hent from
Combustion
Riser
(Heated)
Waterwall
Header
Slide 2 - 7
Boiler Operator Training
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WATER-SIDE COMPONENTS
Feedwater pump
Waterwalls
Drum
Downcomers
Risers
Slide 2 - 8
Boiler Operator Training •Ba^EnsEE=a=^^=s=a=m3:scasss=aBs
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STEAM-SIDE COMPONENTS
Steam Drum
Superheater
Desuperheater
Reheater
Safety Valves
Boiler Operator Training
Slide 2-9
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STEAM-SIDE COMPONENTS SCHEMATIC
Steam Drum
Superheater
Desuperheater
Reheater
Slide 2-10
Boiler Operator Training mmuaaa^=sssssssssssssss5sssss=saes=s
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WATER IMPURITIES AND MEASUREMENTS
Dissolved Solids
Dissolved Gases
Suspended Solids
Hardness
pH
Slide 2-11
Boiler Operator Training miasssaes^a=s=s=ssssss=ss=sfsss^
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MECHANICAL WATER TREATMENTS
Technology
Pretreatment
Cooling
Clarification
Filtration
Aeration
Primary Application
Removal of debris
Regulation of water temperature
Removal of large suspended
matter
Removal of remaining suspended
matter
Removal of dissolved iron &
manganese
Stripping of dissolved gases
(C02, H2S)
Devices
Rakes, gates
Cooling tower, canals
Sedimentation tanks,
horizontal clarifier tanks,
vertical clarifiers
Screens, beds of rigid or
granular material
Rotor brush aerators,
aerator towers
Rotor brush aerators,
aerator towers
Demineralization
Removal of remaining dissolved
matter
Flash distillation units,
semipermeable membranes,
reverse osmosis unit,
ion exchange resins
Boiler Operator Training
Slide 2-12
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DEMINERALIZATION TECHNIQUES
Evaporation
Membrane Treatments
Reverse Osmosis
Ion Exchange
Slide 2-13
Boiler Operator Training •••cBmi™«B8^s=^^^=3=^=^B^s:^
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CHEMICAL WATER TREATMENTS
Chemical
Sodium hydroxide (caustic soda)
Sodium carbonate
Sodium phosphate
Sodium aluminate
Chelants
Tanins, starches, lignin
Polymers, copolymers
Sodium sulfite
Hydrazine
Ammonia
Filming amines
Neutralizing amines
Sodium nitrate
Anti-foams
Chlorine
Potassium permanganate
Coagulants
Calcium hydroxide (lime)
Application
Increases pH, precipitates magnesium
Increases pH, precipitates calcium
Precipitates calcium
Precipitates calcium and magnesium
Controls scale by forming heat stable soluble compounds
Prevents water deposits by coating scale to produce a sludge that
does not adhere as readily to pipe surfaces
Disperses sludge, prevents scale, prevents fouling by corrosion products
Prevent O2 corrosion
Prevent O2 corrosion
Adjusts pH
Control return line corrosion by forming protective film on metal surfaces
Controls return line corrosion by adjusting condensate pH
Inhibits caustic embrittlement
Reduces foaming tendency of high solids boiler water
Removal of dissolved gases by oxidation, control of slime and algae
Control of slime and algae
Causes suspended matter to coagulate, used in conjunction with clarification
Adjusts pH
mm Boiler Operator Training •••••••SMI^^M^MBSM^S^
Slide 2-14
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LESSON PLAN
CHAPTERS. COMBUSTION GAS CIRCUIT
Goal: To discuss the combustion process, heat transfer from fossil fuels and
combustion products flowpath for steam generating units.
Objectives:
Upon completion of this unit, an operator should be able to:
1. Describe the basic components of the combustion process in a fossil fuel
boiler.
2. Discuss both forced draft and natural draft in boiler design.
3. Describe the components of a combustion gas circuit in a steam
generating system.
4. Describe the design features of air preheaters and typical fan types.
5. Discuss the modes of heat transfer.
Lesson Time: Approximately 30 minutes.
Suggested Introductory Questions:
Does your facility use a natural draft or forced draft system?
Who can describe the difference between conduction and convection?
Presentation Outline:
3.1 Introduction
3.2 Combustion Process
A. Burner Arrangements
B. Fuel System
C. Primary Air
D. Secondary Air
3.3 Heat Transfer
A. Radiation
B. Conduction
C. Convection
3-1
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Presentation Outline (Continued):
3.4 Combustion Gas Flow Path
A. Furnace
B. Convection Pass
3.5 Flue Gas Treatment
References for Presentation Slides
Sb'de 3-4 Wilson, Dean R., Boiler Operator's Workbook, American Technical
Publishers, Inc., 1991.
Slide 3-5 Ibid.
Slide 3-6 Ibid.
Slide 3-7 Perry, Robert H. and Green, Don, Perry's Chemical Engineers'
Handbook, Sixth Edition,McGraw-Hill Publishing Co., 1984, p. 6-22.
Slide 3-10 Wilson.
3-2
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CHAPTER 3. COMBUSTION GAS CIRCUIT
3.1 Introduction
3.2 Combustion Process
A. Process Components
B. Furnace Draft
3.3 Heat Transfer
A. Radiation
B. Conduction
C. Convection
3.4 Combustion Gas Flow Path
A. Furnace
B. Convection Pass
3.5 Flue Gas Treatment
Slide 3-1
Boiler Operator Training ••BSBHBSBSSS^^SI^MS^S^^^^^
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COMBUSTION GAS CIRCUIT FUNCTIONS
1. Release of heat from the Combustion Process
2. Heat Transfer to Steam-Water Circuit
3. Flue Gas Treatment for Pollution Control
Slide 3-2
Boiler Operator Training •Bi^BBBSsss^=ss=^^aHBE88s^^^^
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COMBUSTION PROCESS COMPONENTS
Fuel
Primary Air
Secondary Air
Combustion Chamber
Burners
Fans
Slide 3-3
Boiler Operator Training
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NATURAL DRAFT FURNACE
STACK
HOT FLUE GASES
OUTLET DAMPER
BOILER DRUM
HEIGHT
VARIES
FURNACE
AIR
FLOW —.
\- INLET DAMPER
AIR ENTERING FURNACE
BREECHING
Boiler Operator Training
Slide 3-4
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FORCED DRAFT FURNACE
STACK
HOT FLUE GASES
OUTLET DAMPER
BOILER DRUM
FURNACE
AIR
FLOW
FORCED DRAFT FAN
INLET DAMPER
AIR ENTERING FURNACE
BREECHING
Boiler Operator Training
Slide 3-5
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BALANCED DRAFT FURNACE
STACK ->
HOT FLUE GASES
INDUCED
DRAFT FAN
OUTLET DAMPER
BOILER DRUM
FURNACE
INLET DAMPER
FORCED DRAFT FAN
AIR ENTERING FURNACE
BREECHING
Boiler Operator Training
Slide 3-6
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TYPICAL FAN DESIGNS3
Two-stage Axial Fan
Straight-Blade Centrifugal Fan
Slide 3-7
Boiler Operator Training
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HEAT TRANSFER MODES
Radiation
Conduction
Convection
Slide 3-8
Boiler Operator Training m^ssBBssRaBssEs=sss=s^asEE=
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COMBUSTION GAS CIRCUIT
Drum
Fuel
Flue Gas
Treatment
ID Fan
Boiler Operator Training
Slide 3-9
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AIR PREHEATERS
FLUE-GAS
OUTLET
SEAL
SECTION
SEGMENTED
WHEEL
FLUE-GAS
INLET
COLO AIR
INLET
HOT AIR
OUTLET
FLUE-GAS
OUTLET
COLD AIR
INLET
BAFFLE
AIR BYPASS
HOT AIR
OUTLET
HOPPER
- TUBES
BAFFLE
FLUE-GAS
INLET
Regenerative
Tubular
Boiler Operator Training
Slide 3-10
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LESSON PLAN
CHAPTER 4. FOSSIL FUELS
Goal: To introduce the participants to the classifications and characteristics of
fossil fuels used in boiler operations.
Objectives:
Upon completion of this unit, an operator should be able to:
1. Identify the three classifications of fossil fuels
2. Discuss the importance of each of the characteristics of gaseous fuels.
3. Understand why fuel analyses are important and why they are needed.
4. Understand the difference between higher heating value and lower heating
value
5. Understand the concept of specific gravity and how it is related to the
various fuel classifications
6. Understand the difference between ultimate and proximate analyses of
coal.
7. Name the four classes of coal and identify the dominant characteristics
8. Calculate fixed carbon and Volatile matter percent on a mineral matter free
basis using a typical coal analysis.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What are some possible problems or consequences that could arise as a result
of switching to a new fuel at your facility?
Presentation Outline:
4.1 Introduction
4.2 Natural Gas
A. Gaseous Fuel Characterization
B. Natural Gas Properties
4-1
-------
Presentation Outline (Continue):
4.3 Fuel Oil
A. Fuel Oil Grades
B. Liquid Fuel Characterization
C. Fuel Oil Properties
4.4 Coal
A. Formation of Coal
B. Classification of Coal
C. Coal Characterization
D. Items of Proximate Analysis
E. Items of Ultimate Analysis
F. Example Coal Analysis
References for Presentation Slides
Slide 4-5 Singer, J. G., Combustion: Fossil Power Systems, 3rd edition,
Combustion Engineering, Inc., 1981.
Slide 4-12 Steam, Its Generation and Use, 40th edition, Babcock and Wilcox
Company, 1992.
4-2
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CHAPTER 4. FOSSIL FUELS
4.1 Introduction
4.2 Natural Gas
A. Gaseous Fuel Characterization
B. Natural Gas Properties
4.3 Fuel Oil
A. Fuel Oil Grades
B. Liquid Fuel Characterization
C. Fuel Oil Properties
4.4 Coal
A. Formation of Coal
B. Classification of Coal
C. Coal Characterization
D. Items of Proximate Analysis
E. Items of Ultimate Analysis
F. Example Coal Analysis
Slide 4 - 1
—^Z^ZZZHI Boiler Operator Training ZZ^HHIIII^^^im^^I^^^^
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FOSSIL FUELS
Natural Fuels
Natural gas
Fuel oils
Coal
Byproduct Fuels
Residual oils
Manufactured Fuels
Coke
Char, tar
Chemical and industrial gases, etc.
Slide 4 - 2
Boiler Operator Training ^^^ZmZZ^^^ZZZ^^^m^^Z^^^^,
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GASEOUS FUEL CHARACTERIZATION
Gas Analysis
Heating Value
Specific Gravity
Direct Weighing Method
Pressure Balance Method
Displacement Balance Method
Slide 4 - 3
Boiler Operator Training I^ZIZ^^^^^^^^^^^^
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NATURAL GAS PROPERTIES
Composition of Natural Gas
Dry and Wet Natural Gas
Sweet and Sour Natural Gas
Heating Value
Specific Gravity
Slide 4 - 4
Boiler Operator Training —
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TYPICAL NATURAL GAS ANALYSES
Constituents (% by volume)
CO,
N,
u c
ni -j^"
CH,
C2H.
i a
C'u
4M10
r n
A
5.50
7.00
77.73
5.56
240
Ar.f V
1 IK
1.IO
Altl*
B
3.51
32.00
0.50
52.54
3.77
222
At.ArAr
<* M
{•ML
Ud*
c
26.2
0.70
59.20
13.9
D
0.17
87.69
.....
10.50
1.64
Density
(Ib/ft3) 0.0562 0.0661 0.0675 0.0712
High Heating Value
Btu/ft3t 1,061 874 849 136
Btu/lb 18,880 13,220 12,580 1,907
* All hydrocarbons heavier than C5H12 are assumed to be C5H12
t If gas is saturated with moisture at 60°F and 30.0 in. Hg, reduced by 1.74%,
Slide 4- 5
Boiler Operator Training Z^Z^ZZZZZZ:^Z!!!^ZZZZ^ZZ
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FUEL OIL GRADES
Distillate Fuel Oils
Fuel Oil No. 1
Fuel Oil No. 2
Residual Oils
Fuel Oil No. 4
Fuel Oil No. 5
Fuel Oil No. 6
Slide 4- 6
Boiler Operator Training Z^HZ^Z^^m^IZZZZIIIIimi
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LIQUID FUEL CHARACTERIZATION
Ultimate Analysis
Specific Gravity
Heating Value
Viscosity
Pour Point
Flash Point, and
Water and Sediment
Slide 4 - 7
Boiler Operator Training ^=Z=znZ^ZHHHmZZZ
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1 TYPICAL ANALYSES AND PROPERTIES OF FUEL OILS*
Grade
Type
Color
API gravity, 60°F
Specific gravity, 60/60°F
Density, Ib/U.S gal, 60°F
Viscos., centistokes, 100°F
Viscos. SSU, 100°F
Viscos., SSF, 122°F
Pour point, °F
Temp, for pumping, °F
Temp, for atomizing, °F
Carbon residue, %
Sulfur, %
Oxygen and nitrogen, %
Hydrogen, %
Carbon, %
Water and sediment, %
Ash, %
Heating Value, Btu/gal
'"Data from Exxon Corporation
No. 1 No. 2 No. 4
Fuel Oil Fuel Oil Fuel Oil
Distillate Distillate Residual
Light Amber Black
40 32 21
0.8251 0.8654 0.9279
6.870 7.206 7.727
1.60 2.68 15.00
31 35 77
Below zero Below zero 10
AtmosphericAtmosphericlS min.
AtmosphericAtmospheric25 min.
Trace Trace 2.5
0.1 0.4-0.7 0.4-1.5
0.2 0.2 0.48
13.2 12.7 11.9
86.5 86.4 86.1
Trace Trace 0.5 max.
Trace Trace 0.02
137,000 141,000 146,000
No. 5
Fuel Oil
Very Light
Residual
Black
17
0.9529
7.935
50.00
232
30
35 min.
130
5.0
2.0 max.
0.70
11.7
85.55
1.0 max.
0.05
148,000
No. 6
Fuel Oil
Light
Residual
Black
12
0.9861
8.212
360.00
170
65
100
300
12.0
2.8 max
0.92
10.5
85.7
2.0 max.
0.08
150,000
Slide 4 - 8
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CALCULATING API GRAVITY FROM SPECIFIC GRAVITY
Given: Sp. Gr. (60/60°F) = 1.000
0API = 141.5/(Sp. Gr. (60/60°F)) -131.5
141.57(1)-131.5
10°
CALCULATING DENSITY FROM SPECIFIC GRAVITY
Given: Sp. Gr. (60°F) of oil = 0.973
Water Density (60°F) = 8.328 Ib/gal
Oil Density (60°F) = 0.973 x 8.328
= 8.099 Ib/gal
Slide 4 - 9
Boiler Operator Training ^^ZZZZZZZZZZZ^I^Z^ZZZZZZZ
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VISCOSITY RANGES FOR FUEL OILS
ASTMStd Viscosity-
T«mp«r«lura) Charts for Liquid
Pttrotoum Products (O341)
SSU * Saybolt Universal Viscosity
100,000
Fuel Oil Composition
Kerosene Straight
Viscosity Distillate , No. 1 Kerosene Plus 5% No 2
Ranges tor Oils No. 2 Straight
Fuel Oils I No 4 Straight and Up to 15% Residuals
Residual f No S Heavy Distillates Plus Up to 40% Residuals
Oils ' No. 6 Up to 100% Residuals
-20 0 20 40 60 80 100 140 200 240 300
Temperature, °F
Boiler Operator Training
Slide 4-10
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1
Clas
I.
1.
2
3
11.
1
2
3
4.
5
III.
1
2
3.
IV
s and Group
Anthracite
Meta- Anthracite
Anthracite 92
Semi-Anthracite1
Bituminous Coals
Low- volatile
Medium- volatile
High- volatile A
High- volatile B
High- volatile C
SubbHuminous
SubbHuminous A coal
SubbHuminous B coal
SubbHuminous C coal
Lignite
Lignite A
Lignite B —
CLASSIFICATION OF COAL BY RANK8
Fixed Carbon Volatile Matter Calorific Value
Limits % Limit,*, % Limits, Btu/lh
(Dry, Mineral- (Dry, Mineral- (Motet", Mineral-
Matter-FreeRasis) Matter-Free Basis) Matter-Free Basis
Equal or Equal or Equal or
Greater Less Greater Uss Greater Less Agglomerating
Than Than Than Than Than Than Character
no 1 Nrwinoolnmprnlinp
VS
98 2
86 92
78 86
69 78
69
8 14
14 22
22 31
1 1
j i
6.300
Boiler Operator Tr
—
14000" Aeelomcr.itinp'
13,000- 14.000
11,500 13,000
10.500 11,500 Agglomerating
10,500 11,500
9.500 10.500 Nonagglomertmg
8.300 9,500
8.300
6.300
Slide 4-11
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PARR FORMULAS2
FC - 0.15S
Dry, mineral-free FC = — \ 100
100-(M+1.08A + 0.55S)
Dry, mineral-free VM = 100 - Dry, mineral-free FC
Btu - SOS
Moist, mineral-free Btu = x 100
100-(1.08A + 0.55S)
APPROXIMATION FORMULAS2
FC
Dry, mineral-free FC = - x 100
100-(M + 1.1A + 0.1S)
Dry, mineral-free VM = 100 - Dry, mineral-free FC
Btu
Moist, mineral-free Btu = - x 100
1 00 -(1.1 A + (US)
Where:
Btu = Heating value per Ib, M = Bed moisture, %
FC = Fixed carbon, % A = ash, %
VM = Volatile matter, % S = Sulfur, %
Slide 4-12
— Boiler Operator Training "
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COAL CHARACTERIZATION
Proximate Analysis
Ultimate Analysis
Bases of Analyses
As-received basis
Dry basis
Dry mineral-matter free basis
Slide 4-13
Boiler Operator Training ^m^ZZ^ZZ^ZZZZZZZZZZ^^^!
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ITEMS OF PROXIMATE ANALYSIS
Moisture
Volatile Matter
Fixed Carbon
Ash
Heating Value
Ash Fusion Temperature
Free Swelling Index
Grindability
Slide 4 - 14
Boiler Operator Training ZZ^ZZZZZZZ^ZZZZZZZZ^ZZZZZZZ
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ULTIMATE ANALYSIS
Carbon
Hydrogen
Nitrogen
Sulfur
Oxygen
Washability
Slide 4-15
Boiler Operator Training —
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EXAMPLE COAL ANALYSES
Coal: Eastern Bituminous
Proximate Analysis (as rec'd) Ultimate Analysis (as rec'd)
Total Moisture 17.80 Moisture 17.80
Volatile Matter 34.04 Carbon 57.76
Fixed Carbon 39.38 Hydrogen 3.99
Ash 8.78 Oxygen 7.51
Nitrogen 1.16
Sulfur 3.00
Ash 8,78
Higher Heating Value 10,406 Btu/lb
Ash Analysis (as rec'd)
SiO2
A12O3
TiO2
Fe2O3
CaO
MgO
Na2O
K2O
P2O5
SO3
50.65
13.91
0.89
18.88
6.26
0.85
1.36
1.52
0.18
5.72
Hardgrove Grindability Index
Ash Fusion Temperatures (°F)
Initial Deform temp.
Softening temp.
Hemispherical temp.
Fluid temp.
Slagging Index
Fouling Index
58
Reducing
1,930
2,000
2,150
2,260
Medium
High
Oxidizing
2,230
2,400
2,480
2,580
Slide 4- 16
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LESSON PLAN
CHAPTER 5. COMBUSTION PRINCIPLES
Goal: To present the participant with the fundamental laws and calculations
for the combustion and heat transfer processes.
Objectives:
After completing this chapter the participant should be able to:
1. Describe the basic elements of the combustion process.
2. Explain the influence of excess air on a combustion system.
3. Understand the concept of the mole, molecular weight.
4. List the fundamental laws governing combustion and understand the
interrelationship between Avogadro's Law and the Ideal Gas Law
through the Mole—Volume relationship.
5. Balance a stoichiometric combustion equation and calculate theoretical
air requirements.
6. Calculate actual air for an excess % air requirement.
7. Describe the difference between conduction, convection and radiation
heat transfer.
8. Be familiar with the concepts of heat transfer.
Lesson Time: Approximately 75 minutes.
Suggested Introductory Questions:
How is the heat context of a fuel released?
How much air creates an excess air condition when burning a given fuel?
5-1
-------
Presentation Outline:
5.1 Basic Combustion Concepts
A. Combustion Processes
B. Composition of Combustion Air
5.2 Air-Fuel Mixture
5.3 Combustion Equations
A. Concept of the Mole
B. Fundamental Laws
C. Balancing Combustion Equations
5.4 Combustion Calculations
A. Molar Evaluation of Combustion
B. Calculating Theoretical Air
C. Calculating Excess Air
D. Calculating Percent Excess Air
5.5 Heat Transfer Fundamentals
A. Basic Modes of Heat Transfer
B. Heat Transfer Parameters
5-2
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CHAPTER 5. COMBUSTION PRINCIPLES
5.1 Basic Combustion Concepts
5.2 Air-Fuel Mixture
5.3 Combustion Equations
5.4 Combustion Calculations
5.5 Heat Transfer Fundamentals
Slide 5 - 1
Boiler Operator Training ==
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SIMPLIFIED COMBUSTION PROCESSES
Reactants
carbon + oxygen
hydrogen + oxygen
sulfur + oxygen
Products
•> carbon dioxide + heat
> water vapor + heat
•> sulfur dioxide + heat
Boiler Operator Training
Slide 5 - 2
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COMPOSITION OF COMBUSTION AIR
Dry Atmospheric Air
Volume % Mol. Wt.
Nitrogen 78.09 28.02
Oxygen 20.95 32.00
Argon 0.93 39.94
Carbon dioxide 0.03 41.01
Slide 5 - 3
Boiler Operator Training ^=
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COMBUSTION TERMS
Excess Oxygen
Excess Air
Stoichiometric
Lean Mixture, Oxidizing Flame
Rich Mixture, Reducing Flame
Oxygen Supply
Time, Turbulent, Temperature
Slide 5 - 4
Boiler Operator Training I=IZIZZ==I=^=I
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CONCEPT OF THE MOLE
A mole always contains the same number of particles
Pound mole (mole) is molecular weight
expressed in pounds.
Example:
1 mole of CO2 weighs 44 Ibs
1 mole of H2O weighs 18 Ibs
Slide 5 - 5
Boiler Operator Training ==
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FUNDAMENTAL LAWS
Conservation of Matter
Conservation of Energy
Law of Combining Weight
Avogadro's Law
Ideal Gas Law
Slide 5 - 6
Boiler Operator Training IZIZIZI^ZIIZZ^^ZZZSIZIIZIIZ:
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IDEAL GAS LAW
This law state that the volume of an ideal gas is directly proportional to its absolute
temperature and inversely proportional to its absolute pressure. The proportionality
constant is the same for one mol of any ideal gas, so this law may be expressed as:
R =
P V P V
1 I ¥ I l 2 2
T T
1 1 2
Where:
R = universal gas constant, 1545 ft Ib/mol R.
V = molar volume, ftVmol
P = absolute pressure, lb/ft2
T = absolute temperature, R = °F + 460
Most gases involved in combustion calculations can be
approximated as ideal gases.
Slide 5 - 7
Boiler Operator Training ==
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COMBUSTION EQUATIONS
Combustibles Reaction
Carbon C + O2 — > CO2
Hydrogen H2 + mO2 — > H2O
Sulfur S + O2 — > SO2
Methane CH4 + 2O2 — > CO2 + H2O
Ethane C2H6 + 7/2O2 — > 2CO2 + 3H2O
Propane CH + 5O — > 3CO + 4HO
38 2 2 2
Slide 5 - 8
Boiler Operator Training •
-------
FORMS OF COMBUSTION EQUATIONS
c + o2 co2
1 molecule C + 1 molecule O2 = 1 molecule CO2
1 mol C +1 mol O2 = 1 mol CO2
121bC + 321bO2 = 441bC02
1 ft3 C(I) +1 ft3 O2 = 1 ft3 CO2
(l) If C were an ideal gas instead of solid, 1 ft3 of C combines with 1 ft3 of
O2toformlft3ofC02.
Slide 5 - 9
Boiler Operator Training ^==^====
-------
BALANCING COMBUSTION EQUATIONS
(unbalanced equation)
C3H, + 02 > C02 + H20
C3H8 + 02 > 3C02 + H20
C3Hg + O2 > 3CO2 + 4H2O
(balanced equation)
C3Hg + 5O2 > 3CO2 + 4H2O
Slide 5 -10
Boiler Operator Training !Z==!^====
-------
MOLE-VOLUME RELATIONSHIP
Because a mole of every ideal gas occupies the same volume, by Avogadro's
law, the mole fraction of a component in a mixture of ideal gases equals the
volume fraction of that component.
Moles of component Volume of component
Total moles Volume of mixture
This is a valuable concept because the volumetric analysis of a gaseous
mixture automatically gives the mole fractions of the components.
Shdc 5-11
Boiler Operator Training
-------
CONVERTING FUEL ANALYSIS FROM
VOLUME BASIS TO MASS BASIS
(1) (2) (3) (4) (5)
Element Moles/ lb/mole lb/ lb/
1 00 moles fuel 1 00 moles fuel lb fuel
C 110.2 12.01 1323.5 0.729
H2 207.5 2.02 419.2 0.231
O2 0.7 32.00 22.4 0.12
N2 1.8 28.01 50.4 0.28
Total 1815.5
(6)
lb/
lOOlbfuel
72.9
23.1
1.2
18
100.0
Slide 5-12
-------
THEORETICAL OXYGEN CALCULATIONS
(i)
Coal
Constit.
C
H
S
o
N
H20
Ash
Total
(2)
%by
wt.
63.50
4.07
1.53
7.46
1.28
15.00
7.16
100.00
(3)
Mole
12
2
32
32
28
18
(4)
wt. Moles
5.30
2.04
0.05
0.23
0.05
0.83
(5) (6)
Comb. Moles theo
Product O2 req.
C02 5.30
H2O 1.02
SO2 0.05
0.23
N2 0.00
H2O 0.00
6.12
Slide 5-13
-------
CALCULATING PERCENT EXCESS AIR
Excess Air, % = K x
21-02
Where:
O2 = Volume percent, dry oxygen in the flue gas
100C + 237H + 37.5S + 9N - 29.6O1
K =
C + 3H + 3/8S - 3/8O'
C = Mass fraction of carbon in the fuel
H = Mass fraction of hydrogen in the fuel
S = Mass fraction of sulfur in the fuel
O1 = Mass fraction of oxygen in the fuel
N = Mass fraction of nitrogen in the fuel
(Note that these mass fractions should be given on a dry weight percent basis;
Ib/lb dry fuel.)
Slide 5 -14
Boi!er Operator Training ~~
-------
BASIC MODES OF HEAT TRANSFER
Conduction
Convection
II Radiation
Slide 5-15
Boiler Operator Training ==
-------
HEAT TRANSFER PARAMETERS
Heat Transfer Area
Temperature Difference
Conductivity
Diflfusivity
Velocity and Turbulence
Relative Positions
Slide 5 -16
Boiler Operator Training :===^====Z=====Z=Z======:
-------
UNITS OF HEAT TRANSFER PARAMETERS
Parameter
Conduction heat flux rate
Conduction heat flux
Thermal Conductivity
Length of heat flow path
Area of heat flow path
Temperature difference
Diffusivity
Specific heat
Density
Film Coefficient
Symbol
k
L
A
AT
English
Btu/hr
Btu/ft2 hr
Btu/ft hr °F
ft
ft2
ftVhr
Btu/lb °F
lb/ft3
Btu/ft2 hr °F
SI
Watts
W/m2
W/mK
m
m2
K
m2/s
J/kgK
kg/m3
W/m2K
Boiler Operator Training
Slide 5-17
-------
LESSON PLAN
CHAPTER 6. Am POLLUTION FUNDAMENTALS
Goal: To introduce the participant to the types and sources of air pollution,
and to familiarize them with the terminology and expose them to
fundamental air pollutant parameters.
Objectives:
Upon completion of this unit the participant should be able to:
1. Identify the type of pollutants causing different colors of smoke.
2. Convert NOx and SO2 ppm concentration to the respective emission
factor.
3. Understand the purpose of converting pollutant emissions levels to 0%
and 3% O2 conditions and be able to correct both gaseous and
particulate emissions to 3% and 0% ©2, and 12% CO2-
4. Understand the meaning of combustion efficiency and be able to
calculate this quantity for carbon.
5. List the possible sources of heat losses for calculation of efficiency from
the heat loss method.
6. Know the difference between heat loss method and heat input-output
method for determining boiler efficiency.
Lesson Time: Approximately 75 minutes.
Suggested Introductory Questions:
What is boiler efficiency?
Does anyone know emissions factors imposed on your facility by the EPA?
Presentation Outline:
6.1 Introduction
6.2 Fuel Dependent Air Pollutants
6.3 Combustion Dependent Air Pollutants
6-1
-------
6.4 Smoke and Particulate
6.5 Gas Concentrations
A. Mole Fractions
B. Parts Per Millions (ppm)
6.6 Emission Factors
A. Converting ppm to Ib/MMBtu
6.7 Correcting Concentrations
A. Correcting to 3% Oxygen
B. Correcting to 0% Oxygen
C. Correcting to 12% Carbon Dioxide
D. Converting [gr/dscf] to [mg/dscm]
6.8 Excess Air Calculations
6.9 Combustion Efficiency Calculation
6.10 Boiler Calculations
A. Methods to Calculate Boiler Efficiency
B. Heat Loss Efficiency
C. Heat Input-Output Efficiency
D. Heat Rates
E. Heat Release Rates
References for Presentation Slides
Slide 6-12 Babcock and Wilcox Company, Steam, Its Generation and Use,
40th Edition, 1992.
Slide 6-13 J.T. Beard, F.A. lachetta, and L.U. Lilleleht, APTI Course 427,
Combustion Evaluation, Student Manual, U.S. Environmental
Protection Agency, EPA-450/2-80/063, February 1980, pp. 5-4 to
5-21.
Slide 6-17 Ibid.
Slide 6-23 Ibid.
Slide 6-10 Codes of Federal Regulations, Protection of Environment 40,
Parts 53 to 60, Office of the Federal Register National Archives
and Records Administration, July 1991, p. 1014.
6-2
-------
CHAPTER 6. AIR POLLUTION FUNDAMENTALS
6.1 Introduction
6.2 Fuel Dependent Air Pollutants
6.3 Combustion Dependent Air Pollutants
6.4 Smoke and Particulate
6.5 Gas Concentrations
6.6 Emission Factors
6.7 Correcting Concentrations
6.8 Combustion Efficiency Calculation
6.9 Excess Air Calculation
6.10 Boiler Efficiency Calculations
Slide 6- 1
Boiler Operator Training
-------
FUEL DEPENDENT AIR POLLUTANTS
Acid Gases
Sulfur Oxides
Nitrogen Oxides (Fuel NOx)
Toxics and Hazardous Materials
Lead
Mercury
Arsenic
Beryllium
Benzene
Radionuclides
Vinyl Chlorides
Carbon Dioxide
Slide 6- 2
Boiler Operator Training
-------
COMBUSTION DEPENDENT AIR POLLUTANTS
Products of Incomplete Combustion (PIC)
Paniculate
Carbon Monoxide
Volatile Organic Compounds (VOC)
Nitrogen Oxides
Slide 6- 3
Boiler Operator Training
-------
SMOKE & PARTICULATE
Black Smoke
Carbon in Particulate
Particulate
Removed by APCDs
White Smoke
Condensed Hydrocarbon Gases
Ammonium Chloride
Water Droplets (Not Smoke)
Blue Smoke
Ammonium Sulfate
Brown Smoke
Nitrogen Oxides
Slide 6- 4
Boiler Operator Training ••^••••••••••••••••••••••^M
-------
GAS CONCENTRATIONS
Mole Fractions
Parts Per Million (ppm)
Slide 6 • 5
Boiler Operator Training es=SBSBS5S=es^=^=E
-------
STOICHIOMETRIC COMBUSTION
+ 1.22 H20 +2.165 O2 +8.14 N2->
1.85 CO, + 3.92 H,O + 8.15 N, + 0.006 SO,
L 2. L 2
Product Wet Gas Dry Gas Dry Gas Dry Gas
Gas Moles Moles Mole Frac. Mole %
CO2 1.85 1.85 0.185 18.49
H20 3.92
N2 8.15 8.15 0.814 81.45
SO2 0.01 0.01 0.001 0.060
Total 13.93 10.01 1.000 100.00
Slide 6 - 6
Boiler Operator Training BBsesssssssBSBSSSSSSSSSSsa
-------
EQUIVALENCE OF GAS CONCENTRATIONS
Mole Fraction x 100 --> Percentage
Mole Fraction x 1,000,000 --> ppm
Percentage x 10,000 -> ppm
Slide 6- 7
Boiler Operator Training
-------
EMISSION FACTORS
Ibs NO /MMBtu =
Ibs of NO2 emitted
Millions Gross Btu Fuel Input
Ibs SO/MMBtu =
Ibs of SO2 emitted
Millions Gross Btu Fuel Input
Slide 6- 8
Boiler Operator Training
-------
CONVERSION OF PPM TO LB/MMBTU
lb NO /MMBtu = 1.19 x 10'7 x F, x NO, (ppm @ 3% O2, dry) x (21/(21-3))
x ax*-
lb SO2/MMbtu = 1.69 x 10'7 x Fd x SO2 (ppm @ 3% O2, dry) x (217(21-3))
Where:
F is the dry F factor of fuel
d J
Slide 6 - 9
Boiler Operator Training
-------
AVERAGE Fd FACTOR FOR VARIOUS FUELS4
Coal:
Anthracite 10,100
Bituminous 9,780
Lignite 9,860
Oil:
(Crude, residual or distillate) 9,190
Gas:
Natural gas 8,710
Propane 8,710
Butane 8,710
Wood: 9,240
Wood Bark: 9,600
Slide 6 - 10
Boiler Operator Training BSSSSBSS^SBSSSSSSSSS!
-------
GAS CONCENTRATIONS AT STANDARD DILUTION
or
or
3% O2, dry
0% O2, dry
12% CO,, dry
Boiler Operator Training
Slide 6-11
-------
EQUATION FOR CORRECTING TO 3% OXYGEN
Assume: COm is the measured dry gas CO
Expressed as a ppm or %
O2m is the measured dry gas O2
Expressed as a percentage
Converting:
CO (@ 3% 02) = C0m x (21 - 3)/(21 - O2m)
= C0mx (18)7(21 -OJ
Slide 6-12
Boiler Operator Training B=^========
-------
EQUATION FOR CORRECTING TO 0% OXYGEN1
Assume:
COm is the measured dry gas CO
Expressed as a ppm or %
O2m is the measured dry gas (X
Expressed as a percentage
2
Converting:
C0(@0%02) = C0mx(21-0)/(21-02m)
= C0mx (21)7(21-02m)
Slide 6-13
Boiler Operator Training
-------
PRODUCT GAS ANALYSIS,
METHANE @ 20% EXCESS AIR
Gas Wet Gas Dry Gas Dry Gas
Moles Moles Mole %
CO2
H2O
1.0
2.0
0.4
9.024
0.001
1.0
0.4
9.024
0.001
9.59
3.84
86.56
0.01
CO
Total 12.425 10.425 100.00
Slide 6 - 14
Boiler Operator Training
-------
EXAMPLE FOR CONVERSION OF GAS
CONCENTRATIONS TO 3% OXYGEN
Let: COm = lOOppm
02m = 3.84% (dry gas)
CO (@ 3% 02) = C0m x (21 - 3)/(21 - O2m)
100 x(l 8)7(21-3.84)
104.9ppm
Slide 6-15
Boiler Operator Training tsssssssssssssss^ssssssss^sssss
-------
EXAMPLES FOR CONVERSION OF
PARTICULATE TO 3% OXYGEN
Let: PMt
o'
2m
= 0.035 gr/dscf (Paniculate Matter)
= 3.84% (Measured Dry Gas O2)
PM (@ 3% 02) = PMm x (21 - 3)/(21 - OJ
= 0.035 x(18)/(21 -3.84)
= 0.037 gr/dscf @ 3% O2
Slide 6 - 16
Boiler Operator Training
-------
EQUATION FOR CORRECTING TO 12% CO2'
Assume:
CO is the Measured Dry Gas CO
m
Expressed as a ppm or %
CO, is the Measured Dry Gas CO,
2m *•
Expressed as a Percentage
Converting:
CO (@ 12% C02) = C0m x (12/CO J
Slide 6- 17
Boiler Operator Training
-------
EXAMPLE CORRECTION TO 12% CO.
A
Let: COm = lOOppm
CO1 = 9.59% (dry gas)
CO (@ 12% CO2) = COm x (12/CO2m)
= lOOx (12/9.59)m
= 125 ppm
Slide 6-18
Boiler Operator Training •••••••••••••••••••••••••
-------
CONVERSION OF [gr/dscf] TO [mg/dscm]
Basic Identities:
1 pound [Ib]
1 gram [g]
1 foot [ft]
1 pound [Ib]
454 grams [g]
1,000 milligrams [mg]
0.3048 meters [m]
7,0000 grains [gr]
For Dry Gases at Standard Conditions:
1 dry standard cubic foot [dscf]
1 dry standard cubic meter [dscm]
1 dscf = 0.0283 dscm
So That:
1 [gr/dscf] =
1 [gr/dscf] x (1 lb/7000 gr) x (454 g/lb)
x (1000 mg/g) x (1 dscf/0.0283 dscm)
Therefore:
1 [gr/dscf] = 2,290 [mg/dscm]
Boiler Operator Training
Slide 6 - 19
-------
EXAMPLE APPLICATION OF THE
CONVERSION FACTOR
Factor: 1 [gr/dscf] = 2,290 [mg/dscm]
Given: 34 [mg/dscm]
Therefore:
34 [mg/dscm] x (1 [gr/dscf]/2,290 [mg/dscm]) = 0.015 [gr/dscf]
Slide 6 - 20
Boiler Operator Training
-------
DETERMINATION OF EXCESS AIR FROM DRY
GAS ANALYSIS1
Assume: CO
CO
O
Therefore:
And:
2m
m
2m
N
2m
EA
Percent Dry Gas CO2
Percent Dry Gas CO
Percent Dry Gas O2
100-(C0
2m
(02m - 0.5 COJ/(.264 NJm - O^ + 0.5 CO,
m)
Slide 6-21
Boiler Operator Training
-------
EXAMPLE DETERMINING EXCESS AIR
Let: CO, = 9.59%
2m
com = 0.01%
(Xm = 3.84%
2m
Therefore: N2m = 100 - (CO2m + CO. + O2m)
100-(9.59+ 0.01 +3.84)
86.56
And: EA = (O2m - 0.5 COm)/(.264 N2m - O2m + 0.5 COJ
EA = (3.84 - 0.005)/(.264 x 86.56 - 3.84 + 0.005)
EA = 0.20 --> 20%
Slide 6 - 22
Boiler Operator Training
-------
EQUATION FOR COMBUSTION EFFICIENCY
(BASED ON CARBON COMBUSTION TO CO2)
C.E.(%) = (100% x C07m) / (C02m + COJ
or
C.E.(%) = 100% x (1 - (CO / (CO. + COJ)
Slide 6 - 23
Boiler Operator Training
-------
EXAMPLE COMBUSTION EFFICIENCY
CALCULATION
Let: CO2m = 9.59 Percent
CO = 0.01 Percent (100 ppm)
C.E.(%) = (100% x C02m)/(C02m + COJ
(100% x 9.59)7(9.59+ 0.01)
99.9%
Slide 6-24
Boiler Operator Training ^^••••^•^••^^^^••••••r
-------
METHODS TO DETERMINE BOILER EFFICIENCY
Heat Loss Method:
TI(%) = 100-Net Heat Losses (%)
Heat Input-Output Method:
Output
Input
Heat absorbed by working fluid(s)
Heat in fuel + Heat credits
xlOO
Slide 6 - 25
Boiler Operator Training asBSBSBSBBSSBBSSSSSSSSSS
-------
HEAT LOSS EFFICIENCY
Net losses =
Loss due to dry gases +
Loss due to moisture in the fuel +
Loss due to hydrogen in fuel +
Loss due to CO in flue gas +
Loss due to unburnt carbon +
Loss due to radiation +
Unaccounted losses
Efficiency = 100 - Net losses
Slide 6 - 26
Boiler Operator Training
-------
HEAT LOSS DUE TO DRY GASES
lb dry gas
HL due to dry gases = x 0.24 (t - ta)
lb fuel fired
Where:
0.24 = Specific heat of gas, Btu/lb °F
t = Temperature of gas leaving unit, °F
t* = Temperature of air entering unit, °F
lb dry gas 11 OX + 8 O9 + 7 (N. + CO) lb C burned
_— = - x + 3/8 S
lb fuel fired 3(CO, + CO) lb fuel fired
CO2,02, N2 and CO are in % by volume of flue gas
S is % 6y weight of sulfur in fuel
Slide 6 - 27
Boiler Operator Training
-------
LOSS DUE TO MOISTURE IN FUEL
H20
HL due moisture in fuel = x (hg - h,)
100
Where:
H2O = % moisture in fuel
h = Enthalpy of vapor at 1 psia and t
h, = Enthalpy of liquid at t
Slide 6-28
Boiler Operator Training
-------
HEAT LOSS DUE TO HYDROGEN IN FUEL
9H2
HL due to H2 in fuel = x (h - h,)
100
Where:
H2 = % of hydrogen in fuel
h = Enthalpy of vapor at Ipsia and
h = Enthalpy of liquid at t
Slide 6 - 29
Boiler Operator Training
-------
HEAT LOSS DUE TO CO IN FLUE GAS
CO IbC
HL due to CO in flue gas = x 10,160 x
CO -i- CO2 Ib fuel
Where:
CO and CO2 are % by volume in flue gas
10,160 is Btu generated burning 1 Ib of CO to CO2
Slide 6-30
Boiler Operator Training BHSBSSSSSSSBSSBSSSSSSS
-------
HEAT LOSS DUE TO UNBURNED CARBON
lb C in ash
HL due to unburned C = x Btu per lb of ash
lb of fuel
Slide 6-31
Boiler Operator Training e^ssssssBSSSSSSSBBSSS
-------
HEAT INPUT-OUTPUT EFFICIENCY
Heat I-O Efficiency = -- — x 100%
C
Where:
W, = Main steam flow, Ib/hr
W2 = Reheat steam flow, Ib/hr
H, = Enthalpy of main steam, Btu/lb
H2 = Enthalpy of reheat steam, Btu/lb
hj = Enthalpy of feed water, Btu/lb
h2 = Enthalpy of steam entering reheater, Btu/lb
C = Total heat input from fuel, Btu/hr
Slide 6-32
Boiler Operator Training BESSsassB8^ess^sss=^s
-------
HEAT RATES
Gross Heat Rate
Net Heat Rate
Boiler Operator Training
Slide 6 - 33
-------
HEAT RATE CALCULATIONS
Gross Heat Rate
Heat input from fuel
Electrical output
Fuel flow x HHV
MW generated
Btu/kWh
Slide 6-34
Boiler Operator Training
-------
EXAMPLE OF HEAT RATE CALCULATIONS
Let: Coal flow
Coal HHV
Gross MW
60,000 Ibs/hr
= 10,540 Btu/lb
= 55 MW
GHR
60,000x10,500 1 MW
x
55
= 11,454 Btu/kWh
1000 kW
Boiler Operator Training
Slide 6 - 35
-------
HEAT RELEASE RATES
Volumetric Heat Release Rate
Burner Zone Heat Release Rate
Slide 6 - 36
Boiler Operator Training B-=s=a===a=a=
-------
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Slide 6 - 37
Boiler Operator Training
-------
1.2
1.0
I °'8
0.6
°4
0.2
0
0 50 100 150 200 250 300 350 400 450
Burner Zone Liberation Rate
(103Btu/Hrft2)
Foeier Wheeler Exrty Cotp
CoMbutioa A Eovirouwnud Syitcim
Figure 6-2. Foster Wheeler boiler NOxcorrelation.
Slide 6 - 38
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 7. NATURAL GAS-FIRED BOILERS
Goal: To familiarize the participant with supply systems and firing equipment
for natural gas fired boilers and typical environmental concerns of these
units.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the key components of the fuel supply system.
2. Identify combustion conditions that produce blue and yellow flames.
3. Describe the design characteristics of the 3 major types of gas fired
burners.
4. Describe the common locations or configurations of natural gas burners
in boilers.
5. Understand that the burner zone heat release is a design consideration
for controlling NOx emissions.
Lesson Time: Approximately 60 minutes.
Suggested Introductory Questions:
What is the cleanest burning fossil fuel? Why?
Presentation Outline:
7.1 Introduction
7.2 Fuel Supply System
7.3 Burner Arrangements
7.4 Boiler Designs Parameters
7.5 Emissions
7-1
-------
References for Presentation Slides
Slide 7-4 North American Combustion Handbook, Second Edition, North
American Manufacturing Company, 1978.
Slide 7-10 Singer, J.G., Combustion: Fossil Power Systems, 3rd Edition,
Combustion Engineering, Inc., 1981.
Slide 7-11 Price, Joyce V., et al., "Low NO* Oil/Gas Burner Retrofits and
Their Effects on Overall Emissions and Boiler Performance,"
May, . 1993 EPA/EPRI Joint Symposium on Stationary
Combustion NOx Control.
Slide 7-12 "Alternative Control Techniques Document - NOx Emissions
from Industrial Commercial/Institutional (ICI) Boilers," U.S.
EPA, EPA-453 / R-94-022, March, 1994.
7-2
-------
CHAPTER 7. NATURAL GAS FIRED BOILERS
7.1 Introduction
7.2 Fuel Supply System
7.3 Burner Arrangements
7.4 Boiler Designs Parameters
7.5 Emissions
Boiler Operator Training
Slide 7 - I
-------
NATURAL GAS FUEL SYSTEM
Pressure regulator
Low gas-pressure switch
High gas-pressure switch
Manual plug shutoff valve
Solenoid Valve
Automatic main gas shut-off valve
Flow control valves
Slide 7 - 2
Boiler Operator Training a^sanasBaeBasssssnaaass^Baraes
-------
NATURAL GAS TRAIN CONFIGURATION
Low air
pressure switch
Automatic air control valve
V«nts above roof
Flexible connection
( Atomizing air
Needle valve
for dampening
N.O.vent
1 valve
y Blocking
shutoff
valve
High Gas
Pr. Sw.
Main high
pressure-
reducing
regulator
Gas/air ratio
regulator
_ Gas
shutoff
valve
Petcock
for leak test
of shutoff valves
Limiting orifices
ihp'""
\
Pilot rero regulator
Pilot solenoid valve
Pilot high pressure
Manual reducing regulator
shutoff valves
burnsr
Boiler Operator Training
Slide 7 - 3
-------
BURNER DESIGNS FOR FLAME STABILITY
Air
PJ
k
G«« —
Air
LEDGE
,/
-------
RING-TYPE GAS BURNER
Section A - A1 Lever for
opening air
registers
o
Gas inlet
Opening
for oil burner
Gas piping
Burner
air registers
Air flow
Windbox
,gas ring
Furnace wall
Boiler Operator Training
Slide 7 - 5
-------
GUN-TYPE GAS BURNER
Air registers
Opening for
oil gun
Burner gun
tip
Gas
openings
Gas Inlet
Windbox
Windbox
casing
Boiler Operator Training
Slide 7 - 6
-------
SPUD-TYPE GAS BURNER
Gas
distribution ring
Center hole for
oil burners ••
Gas
inlet
Windbox casing
Air registers
t
Air flow
Windbox
Boiler Operator Training
Slide 7- 7
-------
WALL MOUNTED BURNER CONFIGURATIONS
Front Wall Firim?
Opposed Wall Firing
Slide 7 - 8
Boiler Operator Training
-------
MULTIPLE BURNER PATTERNS
o
o
o
o
o
o
cv o
"o o
o o
1
1
1
1
1
1
1
V
A.
• • jS
O «1X^^ •!•
O
+
O
o
o
^xO o
c n
D O
c c-
OPPOSED FIRED
CORNER FIRED
Boiler Operator Training
Slide 7 - <>
-------
TANGENTIAL FIRING BURNER LOCATIONS
s
rf Secondary-
jr Air Damper
Primary-Air
m_
Damper
fj Secondary-
S Air Damper
Slide 7 - 10
Boiler Operator Training
-------
FURNACE VOLUME EFFECTS
UNIT
DESIGN
PARAMETER
FURNACE
ELEVATION
(SAMT MWSOT UNIT)
BURNER ZONE
VOLUME
BURNER ZONE
HEAT RELEASE
RATE
NOx @ MCR
GAS FIRING*
~ LOW EXCESS
AIR BURNER
HIGH
HEAT RELEASE RATE
(1 K Bntr Sf»oi«) X Vd* X CVpd,
88,000 BTU/Hr/Ft3
0.55 Lb/MUlion BTU
LOW/MEDrUM
HEAT RELEASE RATE
I M X M,k HRR Vol
53.000 BTU/Hr/Ft3
0 22 Lb/Million BTU
Boiler Operator Training
Slide 7-11
-------
UNCONTROLLED EMISSION DATA FROM
NATURAL GAS-FIRED BOILERS5
Boiler Type and NOx, CO, THC,
Capacity lb/MMBtua lb/MMBtua lb/MMBtua
< 100 MMBtu/hr 0.03 to 0.31 0.0 to 1.45 0.0 to 0.02
> 100 MMBtu/hr 0.04 to 0.45 0.0 to 0.23 0.0 to 0.05
To convert to ppm @ 3% O2, multiply by the following: NOx, 835;
CO, 1,370; THC, 2,400
Slide 7-12
Boiler Operator Training •«^as=s^^sssB^^^=sH^^=ssss=s
-------
LESSON PLAN
CHAPTERS. OIL FIRED BOILERS
Goal: To present the participant with the basic operating systems of oil fired
boilers and familiarize them with specific designs and operating
parameters.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the functions of fuel oil delivery system.
2. Discuss the various attributes of oil gun designs.
3. Understand what components in oil contribute to pollutant emissions.
4. Describe how CO can be reduced if CO emissions are too high.
5. Understand that the color of smoke emitted from the combustion
process gives an indication of what problems may exist in the
combustion process.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What are the advantages and disadvantages to burning oil?
Presentation Outline:
8.1 Introduction
8.2 Fuel Supply System
8.3 Burner Arrangements
8.4 Boiler Designs Parameters
8.5 Emissions
8-1
-------
References for Presentation Slides
Slide 8-3 Wilson, R. Dean, Boiler Operator's Workbook, American
Technical Publishers, Inc., 1991.
Slide 8-4 North American Combustion Handbook, Second Edition, North
American Manufacturing Company, 1978.
Slide 8-5 Wilson, R. Dean.
Slide 8-6 Ibid.
Slide 8-7 Ibid.
Slide 8-8 Ibid.
Slide 8-10 "Alternative Control Techniques Document -- NOX Emissions
from Industrial Commercial/Institutional (ICI) Boilers," Draft
U.S. EPA, July, 199.3.
8-2
-------
CHAPTER 8. OIL FIRED BOILERS
8.1 Introduction
8.2 Fuel Supply System
8.3 Burner Arrangements
8.4 Boiler Design Parameters
8.5 Emissions
Boiler Operator Training
Slide 8 - 1
-------
FUEL OIL SUPPLY SYSTEM COMPONENTS
Fuel Oil Tank
Oil Pressure Regulator with bypass
Oil Heater
Oil Heater Relief Valve
Fuel Oil Strainers
Pump
Pump Discharge Relief Valve
Atomizing Gun
Slide 8 - 2
Boiler Operator Training MI^B^^^^^SX^S^BB^H^HH^S
-------
FUEL OIL TANK AND TANK HEATERS
FILL LINE
VENT LINE
MEASUREMENT WELL CONNECTION
PNEUMERICATOR CONNECTION
RETURN LINE
LOW SUCTION LINE
HIGH SUCTION LINE
TANK
FUEL OIL
OUTLET
FUEL OIL
INLET
CONDENSATE OUTLET
STEAM INLET
SHELL-AND-TUBE
HEATERS
HEATING
ELEMENT
ELECTRIC
TEMPERATURE
ADJUSTING
••> SCREW
Slide 8- 3
Boiler Operator Training
-------
FUEL OIL SYSTEMS PIPING
Gauge
Relief valve
Air bleed + \0
To Other burner /ones
Manual shutoff valva
Check valve Strainer
Drain
Pressure regulator
Strainer
-Air bleed
Limiting valve Burner
Vent
rV
Pump—
\
Drain
• Ground line
Air/Oit ratio regulator
Auto (MR) shutoff valve
-Oil train
.Oil storage tank
Slide 8 - 4
Boiler Operator Training
-------
T-JET STEAM ATOMIZER
FUEL OIL AND
STEAM MIXTURE
SPRAY
Boiler Operator Training
Slide 8 - 5
-------
Y-JET STEAM/AIR ATOMIZER
SECONDARY AIR
SLOTTED
PRIMARY
ATOMIZING AIR
FUEL OIL
TIP
SPRAY
Slide 8 - 6
Boiler Operator Training ^a^eas^s^^a^as^^^sss^^^si^^
-------
ROTARY CUP ATOMIZER
AIR IN
HOLLOW SHAFT
(F UEL TUBF)
ATOMIZED
FUEL OIL
IGNITES
MOTOR
SPINNING
CUP
AIR IN
PRIMARY AIR FAN
Boiler Operator Training
Slide 8 - 7
-------
MECHANICAL ATOMIZER
FUEL OH.
RETURN
TO SUPPLY
TIP
SPRAYER
PLATE
HIGH-PRESSURE
FUEL OIL FLOWS
TO TIP
SPRAY
Boiler Operator Training
Slide 8 - 8
-------
DUAL FUEL BURNER CROSS SECTION
All VOIIilMANOAMMMD
TU( NKIICWTHPlMtK
Boiler Operator Training
Slide 8 - 9
-------
UNCONTROLLED EMISSIONS DATA FOR
OIL-FIRED BOILERS5
Oil Type and NOx CO THC
Boiler Capacity lb/MMBtua lb/MMBtua lb/MMBtua
Residual Oil:
Watertube Units:
lOtolOOMMBtu/hr 0.20 to 0.79 0.0 to 0.11 0.0 to 0.03
> 100 MMBtu/hr 0.31 to 0.60 0.0 to 0.02 0.002 to 0.02
Distillate Oil:
Watertube Units:
10 to 100 MMBtu/hr 0.08 to 0.16 0.0 to 1.18 0.0 to 0.003
>100 MMBtu/hr 0.18 to 0.23 0.0 to 0.84 0.001 to 0.009
•To convert to ppm @ 3% O2, multiply by the following: NOX, 790; CO, 1,300; THC, 2,270
Slide 8-10
•HHHBmHBBaaaBnaaBaBgi Boiler Operator Training B==raessss===sss=s======s==:^=r
-------
LESSON PLAN
CHAPTER 9. PULVERIZED COAL BOILERS.
Goal: To present the participant with the basic operating systems and
functional components of pulverized coal boilers and to familiarize them
with typical emissions characteristics.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the coal characteristics relevant to pulverization.
2. Understand that moisture can cause soft coal to be more difficult to
grind than a hard coal.
3. Describe a basic coal transport system from bunker to burner.
4. Understand the basic differences between various pulverizer air
systems utilized in coal fired boilers.
5. Understand the basic operation of different pulverizer designs.
6. Describe the main attributes of various coal fired furnace firing
configurations.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
Why is coal ground to a fine powder?
Presentation Outline:
9.1 Introduction
9.2 Pulverizing Properties of Coal
A. Grindability
B. Moisture
C. Wear Properties
9.3 Coal Preparation
A. Coal Crushers
B. Coal Feeders
9-1
-------
Presentation Outline (Continued):
9.4 Methods of Pulverizing and Conveying Coal
A. Storage System
B. Direct-Fired System
C. Semi-direct System
D. Source of Heated Air
9.5 Pulverizing Air Systems
A. Indirect Coal-Storage Pulverizing Systems
B. Direct Firing Arrangements
9.6 Types of Pulverizers
A. Ball-Tube Mills
B. Impact Mills
C. Attrition Mills
D. Ring-Roll and Ball-Race Mills
E. Types of Pulverizers for Various Materials
9.7 Pulverized Coal Boilers
A. Wall Fired Boilers
B. Tangentially Fired Boilers
C. Vertically Fired Boilers
D. Cyclone Fired Boilers
9.8 Emissions
References for Presentation Slides
Slide 9-4 Singer, J.G., Combustion: Fossil Power Systems, 3rd Edition,
Combustion Engineering, Inc., 1981.
Slide 9-5 Ibid.
Slide 9-7 Ibid.
Slide 9-8 Ibid.
Slide 9-11 Ibid.
Slide 9-14 Ibid.
Slide 9-16 Ibid.
Slide 9-17 Elliott, C.T., Standard handbook ofPowerplant Engineering,
McGraw-Hill Publishing Company, New York, 1989.
Slide 9-18 Ibid.
9-2
-------
References for Presentation Slides (Continued)
Slide 9-19 Ibid.
Slide 9-20 Singer, J.G.
Slide 9-22 Elliot, C.T.
Slide 9-23 Ibid.
Slide 9-24 Ibid.
Slide 9-25 Ibid.
Slide 9-28 Steam, Its Generation and Use, 40th Edition, Babcock and
Wilcox Company, 1992.
Slide 9-29 Ibid.
Slide 9-30 Ibid.
9-3
-------
CHAPTER 9. PULVERIZED COAL BOILERS
9.1 Introduction
9.2 Pulverizing Properties of Coal
9.3 Coal Preparation
9.4 Methods of Pulverizing and Conveying Coal
9.5 Pulverizing Air Systems
9.6 Types of Pulverizers
9.7 Pulverized Coal Boilers
9.8 Emissions
Slide 9 - 1
Boiler Operator Training
-------
PULVERIZED COAL SYSTEMS
Pulverizing Properties of Coal
Coal Preparation
Methods of Pulverizing and Conveying Coal
Pulverizing Air Systems
Types of Pulverizers
Pulverized Coal Boilers
Slide 9 - 2
BoiIcr Operator Training ZZZ=!!====ZZ=Z==ZZZ!=====z:
-------
PULVERIZING PROPERTIES OF COAL
Grindability
Moisture
Wear Properties
Slide 9 - 3
Boiler Operator Training —
-------
NORTH DAKOTA LIGNITES1
X
0>
o>
I
CCJ
9O
8O
70
6O
5O
4O
3O
O
Moisture Range
in Which
Pulverizing
is Done
Peerless
Mine
Dakota.
Star Mine
Davenport Mine
Kincaid Mine
I
1O
2O 3O 4O
Moisture Content
5O
Slide 9-4
-------
TEMPERATURE OF AIR TO MILL
180°F Leaving Mixture Temperature
17CTF Leaving Mixture Temperature
700
?00
%HiO
Entering - Leaving
2 3
Lbs ol Air Leaving Mill/ Lb ol Co«l
200
i 2 45
Lbs ol Air Leaving Mill / Lb cl Coal
Slide 9 - 5
Boiler Operator Training
-------
COAL PREPARATION
Coal Crushers
Swing-Hammer Crushers
Roll Crushers
Coal Feeders
Belt Feeders
Overshot Feeders
Slide 9 - 6
Boiler Operator Training ——
-------
BRADFORD BREAKER
Casing
Perforated
Plate
Lifter
Slide 9- 7
Boiler Operator Training
-------
SCHEMATIC OF BELT-TYPE GRAVIMETRIC COAL FEEDER
Coal In let
Cleanout Conveyor
Speed Sensor
Demand
Signal
Motor Speed
Controller
Digital
Scale Control
Totalizer
Feedback Signal
Slide 9 - 8
Boiler Operator Training
-------
OVERSHOT ROLL FEEDER
Raw-Coal
Inlet
Hinged
Levelling Gale
Stationary Core
Revolving Blade
Hot-Air Slot
Boiler Operator Training
Slide 9- 9
-------
METHODS OF PULVERIZING AND
CONVEYING COAL
Storage System
Direct-Fired System
Semidirect System
Slide 9- 10
Boiler Operator Training =
-------
STORAGE SYSTEM
Vent
Cyclone Cpltoclo, ^g^ ^^
Raw-Coal
Bunker
Rotary
Motorj valve
Filter
Switching
Valves "
Pulverized-
Transporter Coal
,11 Feeders
S
Motor
Exhauster Fan
Hot Air-
Pulverized-
Coal
Storage
Bunkers
Venturi
Pickups
Hoi Air or Flue Gas
'JJ'gJJ' ToBunwstn
* Botter Furnace
Slide 9-11
Boiler Operator Training
-------
DIRECT-FIRED SYSTEM
Raw-Coal Bunker
To Boiler Furnace
Hot Air
Raw-Coal
Feeder
Motor
_J Exhauster
Pulverizer
Slide 9-12
Boiler Operator Training
-------
SEMIDIRECT SYSTEM
Raw-Coal
Bunker
Raw-Coal
Feeder
To
Boiler
Furnace
Pulverizer
Hot Air
\
Cyclone
Collector
Primary-Air
Fan
Motor
Exhauster
Fan
Slide 9-13
Boiler Operator Training
-------
ALLOWABLE MILL OUTLET TEMPERATURES, °F
System
High-rank, high volatile bituminous
Low-rank, high volatile bituminous
High-rank, low-volatile bituminous
Lignite
Anthracite
Petroleum coke (delayed)
Petroleum coke (fluid)
Storage
130*
130*
135*
110
200
135
200
Direct
170
160
180
110-140
180-200
200
Semi direct
170
160
180
120-140
• • •
180-200
200
* 160°F permissible with inert atmosphere blanketing of storage bin and low oxygen concentration
conveying medium.
Slide 9-14
Boiler Operator Training
-------
PULVERIZING AIR SYSTEMS
Indirect Coal-Storage Pulverizing Systems
Primary Air
Vented Air
Direct-Firing Arrangements
Suction System
Pressure Exhauster System
Cold Primary Air System
Slide 9- IS
Boiler Operator Training =Z==Z===
-------
PULVERIZER TYPES1
Speed Low Medium High
Type Ball-Tube Ring Roll or Impact or
Mill Ball-Race Mill Hammer Mill
Attrition Mill
Slide 9-16
Boiler Operator Training ^^=====:
-------
ARRANGEMENT OF BALL-TUBE MILL
3
Exhauster
Classifier
Raw-Coal Inlet
Boiler Operator Training
Slide 9-17
-------
DIAGRAM OF AN IMPACT MILL
Hot Air
Raw-Co.il
FfM'fler
Feeder
Drive Unit
Pulverized Coal & Air
Exhauster
Whizzer or Fineness
Regulator
Mill Drive
Shaft
Slide 9-18
Boiler Operator Training
-------
DIAGRAM OF BALL-RACE MILL
Stationary Ring
Grinding Ball
Driving Ring
Slide 9-19
Boiler Operator Training
-------
DIAGRAM OF RING-ROLL MILL JOURNAL ASSEMBLY
Grinding
Ring
Main
Vertical
-Shaft
Spring Assembly
Trunnion Shaft
Journal
Slop Bolt
Grinding Roll Assembly
\
Grinding Roll
Slide 9 - 20
Boiler Operator Training
-------
TYPES OF PULVERIZERS FOR VARIOUS MATERIALS'
Type of Material
Low- volatile anthracite
High-volatile anthracite
Coke breeze
Petroleum coke (fluid)
Petroleum coke (delayed)
Low-volatile bituminous coal
Med-volatile bituminous coal
High- volatile A bituminous coal
High-volatile B bituminous coal
High-volatile C bituminous coal
Subbituminous A coal
Subbituminous B coal
Subbituminous C coal
Lignite
Lignite and coal char
Brown coal
Ball- Impact and
Tube Attrition
X
X
X
X
X X
X X
X X
X X
X X
J\ * * *
X
X
... ...
...
...
... A
Ball
Race
• • •
X
• • •
X
X
X
X
X
X
X
X
X
X
X
X
...
Ring
Roll
• • •
X
...
X
X
X
X
X
X
X
X
X
X
X
X
...
Slide 9-21
-------
PULVERIZED-COAL BOILERS
Wall-Fired Boilers
Tangentially-Fired Boilers
Vertically-Fired Boilers
Cyclone-Fired Boilers
Slide 9-22
Boiler Operator Training ZHZI==ZI=ZZZI==
-------
BURNER FOR HORIZONTAL FIRING OF COAL
Ring Dampers
Burner Throat
Coal Nozzle
Coal & Primary Air
Adjustable Air Vanes
Combustion
Zone
Pulverized-Coal
Distribution Vanes
Windbox
Slide 9 - 23
Boiler Operator Training
-------
FLOW PATTERN OF HORIZONTAL (WALL) FIRING
Burner 8
Burner A
Air A
AirB-
AirC
AirO
Fuel A
FuelB
FuelC
FuelD
Burner 0
Burner C
Slide 9 - 24
Boiler Operator Training
-------
TANGENTIAL FIRING PATTERN
Mam Fuel
Nozzle
Secondary-
Air
Dampers
Slide 0 - 25
Boiler Operator Training
-------
ARRANGEMENT OF CORNER WINDBOX
FOR TANGENTIAL FIRING OF COAL3
Wmdbox
Secondary-Air
Dampers
Damper Drive Unit
Coal Nozzle
Secondary-Air
Nozzles
Side Ignitor
Nozzle
Coal Nozzle
Warm-Up Oil Gun
Slide 9 - 26
Boiler Operator Training
-------
BURNER ARRANGEMENT OF VERTICALLY FIRED BOILERS
Arch
Upper Front Wall
000 000 000 OOO O00 000 OOO OOO OOO/OOO
000
OM
.Oil and Secondary Air
Jet Air
Front Wall
Coal and Secondary Air
Slide 9 - 27
Boiler Operator Training
-------
FLOW PATTERN OF VERTICAL FIRING
Upper
Front
(or Rear) v
Wall \
High Pressure
Jet Air
Primary Air and
Pulverized Coal
Secondary Air
Arch
I— Tertiary Air
Admission
"U"-Shaped
Vertical
Pulverized-Coal
Flame
Furnace Enclosure
(Refractory Lined)
Slide 9 - 28
Boiler Operator Training
-------
CYCLONE FURNACE
Coal Deslagging Oil Burner
Crushed Coal Inlet
Tertiary Air
Primary Air
Radial Burner
Main Oil Burner
ReplaceableWear Liners
Secondary Air Gas Burners
Re-entrant Throat
Slag Tap Opening
Slide 9 - 29
Boiler Operator Training
-------
FINAL ARRANGEMENTS USED FOR CYCLONE FURNACES
Screened Furnace
Arrangement
Single Wall
(b)
Open Furnace
Arrangement
Single Wall
(c)
Open Furnace
Arrangement
Double Wail
Slide 9 - 30
Boiler Operator Training
-------
Emissions
COAL FIRED BOILER EMISSIONS
(500 MW Boiler, 2.5 % sulfur, 16% ash)2
Discharge Rate (t/h)
Uncontrolled Controlled Control Equipment
SOx as SO2
NO* as NO,
A if
CO2
Flyash to Air*
Ash to Landfill*
Scrubber Sludge
(Gypsum plus Water)
9.3
2.9
485
22.9
9.1
0
0.9
0.7
485
0.05
32
25
Wet Limestone Scrubber
Low-NO Burners
x
Not Applicable
ESP or Baghouse
Controlled Landfill
Controlled Landfill or
Wallboard Quality Gypsum
* As flyash emissions to the air decline, ash shipped to landfills increases.
Slide 9-31
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 10. STOKERS
Goal: To familiarize the participant with the specific design, operating
systems and characteristics unique to stoker boilers.
Objectives:
Upon completion of this unit an operator should be able to:
1. Point out the unique attributes of a stoker boiler.
2. Describe the different types of stoker designs.
3. Understand the basic differences between different grate designs used in
stoker boilers.
4. Discuss fuel characteristics required by stokers and be familiar with the
basic designs employed in stokers.
5. Describe the function of overfire air in stoker combustion.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
Does anyone know what a tuyere is?
How are the fuel particle sizes different in stoker boilers than in pulverized
coal boilers?
Presentation Outline:
10.1 Introduction
10.2 Types of Stoker
10.3 Underfeed Stokers
A. Side ash Discharge Type
B. Rear Ash Discharge Type
C. Coal Specifications
D. Boiler Furnaces
E. Overfire Air and Combustion Air
10-1
-------
Presentation Outline (Continued):
10.4 Mass Feed Stokers
A. Chain Grate
B. Traveling Grate
C. Water-Cooled Vibrating Grate
D. Fuel Specifications
E. Furjiace Design
F. Overfire Air
10.5 Spreader Stokers
A. Fuel
B. Fuel Burning
C. Fuel Feeders
D. Types of Grates
E. Overfire Air
F. Fly Carbon Reinjection
10.6 Emissions
References for Presentation Slides
Slide 10-8 Steam, Its Generation and Use, 40th Edition, Babcock and
Wilcox Company, 1992.
Slide 10-13 Ibid.
Slide 10-16 Elliot, C.T., Standard handbook ofPowerplant Engineering,
McGraw-Hill Publishing Company, New York, 1989.
Slide 10-17 Ibid.
Slide 10-24 Steam, Its Generation and Use
10-2
-------
CHAPTER 10. STOKERS
10.1 Introduction
10.2 Types of Stoker
10.3 Underfeed Stokers
10.4 Mass Feed Stokers
10.5 Spreader Stokers
10.6 Emissions
Slide 10- I
Boiler Operator Training ^^
-------
COMPONENTS OF A STOKER
Fuel Supply System
Burning Grate
Overfire Air System
Ash Discharge System
Slide 10 - 2
Boiler Operator Training IZZ=Z=Z=ZZZ=Z!Z=ZZ===ZZ=
-------
VIBRATING GRATE STOKER
Fuel Supply
Distribution
Air
Overfire Air Ports
Ash Hopper
Air
Plenum
Slide 10- 3
Boiler Operator Training
-------
TYPES OF STOKER
Underfeed System
Overfeed System
Mass Feed System
Spreader System
Slide 10 - 4
Boiler Operator Training ^==Z==Z=Z=
-------
UNDERFEED STOKERS
Side Ash Discharge Type
Rear Ash Discharge Type
Coal Specifications
Boiler Furnaces
Overfire Air and Combustion Air
Slide 10 - 5
Boiler Operator Training ZZZZZ^T^=!=^^^^^==
-------
SINGLE RETORT UNDERFIRE STOKER WITH
HORIZONTAL FEED, SIDE ASH DISCHARGE
\XXX\\XXXX\\X\\XXXXXXXX
\X\X\X\\X\X\X\\\X\XXX\\
Dumping
Grate Coal
Retort
\XXXXXXXXXXXXXXXXX\XXXX
VXXXXXXXXXXXXXXXXXSXXXX
XXX\VXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXXXXXXX
Air Chamber
End View
Boiler Operator Training
Slide 10 - 6
-------
UNDERFEED STOKER WITH REAR ASH DISCHARGE
Dump Plates
Reciprocating
Extension Grates
Distributing
Pusher Blocks
Coal Hopper -.
Stationary
Air Tuyeres
Feeder
Rams
Slide 10- 7
Boiler Operator Training
-------
TYPICAL UNDERFEED STOKER COAL CHARACTERISTICS
Moisture % vol.
Volatile Matter % vol.
Fixed Carbon % vol.
Ash % vol.
Higher Heating Value Btu/lb
Free Swelling Index
Ash Softening Temp.* °F
Coal Size in
Stationary Grate
OtolO
10 to 40
40 to 50
5 to 10
12,500
5 max
2,500**
1 x 0.25 max
20% through 0.25
with round screen.
Moving Grate
OtolO
30 to 40
40 to 50
5 to 10
12,500
7 max
2,500**
Equal portions: 0.25,
0.25 to 0.5, 0.5 to 1.0.
* The ash softening temperature is the temperature at which the height of a molten globule is equal t
half its width under reducing atmosphere conditions.
** Below 2500°F the moving grate is derated linearly to 70% of its rated capacity at 2300°F ash
fusion temperature. Stationary grates are derated linearly to 70% at 2JOO°F ash fusion temperature
and use steam for temperatures below about 2400°F fusion temperature.
Slide 10 - 8
Boiler Operator Training
-------
MASS FEED STOKERS
Grate Types
Chain Grate
Traveling Grate
Water-Cooled Vibrating Grate
Coal Specifications
Furnace Design
Overfire Air
Slide 10 - 9
Boiler Operator training =
-------
CROSS SECTION OF OVERFEED MASS-BURNING
CHAIN-GRATE STOKER
Coal Hopper
Fuel Feed Gate
Air Zones
U[U U|lJ vJjU *
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Y
¥
Air Zone Seal Plates
Slide 10-10
Boiler Operator Training
-------
CROSS SECTION OF OVERFEED MASS-BURNING
TRAVELING-GRATE STOKER
Overflre
Air Nozzle Q
Coal Hopper
Grate Clips
or Grate Keys
Air Control Dampers
Boiler Operator Training
Slide 10-1
-------
WATER-COOLED, VIBRATING-GRATE STOKER
Coal Hopper
Rear Furnace Arch
3rate Cooling Tubes
Adjustable Ash Dam
Overfire Air
Nozzles
Water-Cooled
Header
Fuel Feed
Gate
Vibrating
Generator
Grate
Support
and Flexing
Member
Slide 10-12
Boiler Operator Training
-------
TYPICAL MASS STOKER COAL CHARACTERISTICS2
Moisture
Volatile Matter
Fixed Carbon
Ash
Higher Heating Value
Free Swelling Index
Ash Softening Temp.*
Coal Size
% vol.
% vol.
% vol.
% vol.
Btu/lb
op
in
See Slide 10-8 for definition.
Chain/Traveling
Grate
OtolO
10 to 40
40 to 50
5 to 10
12,500
5 max
2,500
1 x 0.25 max
20% through 0.25
with round screen.
Water-Cooled
Grate
0 to 10
30 to 40
40 to 50
5 to 10
12,500
7 max
2,500
Equal portions: 0.25,
0.25 to 0.5,0.5 to 1.0.
Slide 10-13
Boiler Operator Training
-------
SPREADER STOKERS
Fuels
Fuel Burning
Fuel Feeders
Types of Grates
Overfire Air
Fly Carbon Reinjection
Slide 10-14
Boiler Operator Training ZZZ=ZZZ=^=Z^^=^Z=Z:
-------
FUEL FEEDERS
Reciprocating Feeder
Chain Feeder
Drum Feeder
Slide 10-15
Boiler Operator Training '
-------
RECIPROCATING COAL FEEDER
Reciprocating
Feed Plate
Coal Hopper
3
Control Shaft
and Linkage
Adjustable
Spill Plate
Air Tuyere
Rotor
Slide 10-16
Boiler Operator Training
-------
CHAIN-TYPE COAL FEEDER3
Chain Feeder
Coal Gate
Rotor
Air Tuyere
Boiler Operator Training
Slide 10-17
-------
TYPES OF GRATES
Stationary and Dumping
Reciprocating
Vibrating
Traveling
Vibrating, Water-Cooled
Slide 10-18
Boiler Operator Training Z^^SI^ZSZSZSZSSZSSSSi:
-------
SPREADER STOKER WITH DUMPING GRATES
Coal Hopper
Fuel Feeder
Over Fire Air Nozzles
Air
- Power Operated
Dumping Grates
Air Chamber
and
Ash Pit
Slide 10-19
Boiler Operator Training
-------
SPREADER STOKER WITH RECIPROCATING GRATES
Coal Hopper^
Over Fire Air Nozzles
Coal Feeder
- Reciprocating Grates
Slide 10-20
Boiler Operator Training
-------
SPREADER STOKER WITH VIBRATING GRATES
Coal Hopper-,
M,
Over Fire Air Nozzles
Coal Feeder
Vibrating or Oscillating Grates
Slide 10-21
Boiler Operator Training
-------
SPREADER STOKER WITH TRAVELING GRATES
Coal Hopper^
Over Fire Air Nozzles
Coat Feeder
Ash
Hopper
Slide 10-22
Boiler Operator Training
-------
SPREADER STOKER WITH WATER-COOLED
VIBRATING GRATES
Over Fire Air Nozzles
Coal Hopper-^
Coal Feeder
Cooling
Water
Inlet
r Cooling
Water
Outlet
Water-Cooled Grate
Eccentric Grate Drive
Sifting Hopper
Slide 10-23
Boiler Operator Training
-------
TYPICAL UNCONTROLLED EMISSIONS FOR
SPREADER-STOKER FIRING2
Bituminous
Subbituminous
Lignite
*% of Heat Input
NOx (as NO2)
Ib/MM Btu
0.35 to 0.50
0.30 to 0.50
0.30 to 0.50
Unburned Carbon Loss*
CO with without
Ib/MM Btu Reinjection Reinfection
0.05 to 0.30 0.5 to 2.0
0.05 to 0.30 0.5 to 1.5
0.10 to 0.30 0.5 to 1.5
3 to 6
3 to 5
3 to 5
Boiler Operator Training
Slide 10-24
-------
LESSON PLAN
CHAPTER 11. FLUIDIZED-BED BOILERS.
Goal: To present the participant with the key benefits of fluidized-bed
boilers and give an overview of the design and operating
characteristics.
Objectives:
Upon completion of this unit an operator should be able to:
1. Describe the 4 different conditions characterizing the interaction
between the bed particles and air flow through the bed.
2. Identify the advantages of fluidized bed combustion over more
conventional combustion systems.
3. Understand the control parameters for operating fluidized bed boilers.
4. Understand the concept of bed-inventory and its importance to heat
release in the operation of a fluidized bed boiler.
Lesson Time: Approximately 60 minutes.
Suggested Introductory Questions:
Can anyone explain what some of the advantages are with fluidized bed
boilers?
What kind of fuels are best for a fluidized bed boiler?
Presentation Outline:
11.1 Introduction
11.2 Typical Fluidized-Bed Conditions
11.3 Fluidized-Bed Combustion Advantages
A. Reduced Emissions
B. Fuel Flexibility
11.4 Atmospheric Pressure Fluidized-Bed Boilers
A Bubbling Bed
B. Circulating Bed
11-1
-------
Presentation Outline (Continued):
11.5 Fluidized-Bed Boiler Furnace Design
A. Design Information
B. Bed Material
C. Pressure Drop
D. Heat Transfer
E. Heat and Material Balance
11.6 Fluidized-Bed Boiler Arrangements
A. Boiler Subsystems
B Auxiliary Equipment
11.7 Operation
A. System Control
B. Bed Temperature Control
C. Bed Material Inventory Control
D. Overfire Air Control
11.8 Emissions
A. Sulfur Dioxide -
B. Nitrogen Oxides
C. Carbon Monoxide and Hydrocarbons
D. Particulate
References for Presentation Slides
Slide 11-3 Steam, Its Generation and Use, 40th Edition, Babcock and
Wilcox Company, 1992.
Slide 11-5 Ibid.
Slide 11-6 Ibid.
Slide 11-7 Ibid.
11-2
-------
CHAPTER 11. FLUIDIZED-BED BOILERS
11.1 Introduction
11.2 Typical Fluidized-Bed Conditions
11.3 Fluidized-Bed Combustion Advantages
11.4 Atmospheric Pressure Fluidized-Bed Boilers
11.5 Fluidized-Bed Boiler Furnace Design
11.6 Fluidized-Bed Boiler Arrangements
11.7 Operation
11.8 Emissions
Slide 11-1
Boiler Operator Training ^^
-------
FLUIDIZED-BED BOILERS
Typical Fluidized-Bed Conditions
Fluidized-Bed Combustion Advantages
Atmospheric Pressure Fluidized-Bed Boilers
Fluidized-Bed Boiler Furnace Design
Fluidized-Bed Boiler Arrangements
Slide 11-2
Boiler Operator Training m^m
-------
TYPICAL FLUIDIZED-BED CONDITIONS
Distributor Plate
(a)
t«
Fixed Bed
(b)
I Air
Minimum
Fluid ization
(O
0 e
. Q-:p
O f>
. ft .•
V--';::-.:":':.a.
k&%
[Air
Bubbling Bed
•j. •
•:.^--:-
I Air
Circulating Bed
Slide 11-3
Boiler Operator Training
-------
FLUIDIZED-BED COMBUSTION ADVANTAGES
Reduced Emissions
SO2
NO
x
Fuel Flexibility
Fuel Ash Properties
Low Btu Fuels
Fuel Preparation
Slide 11-4
Boiler Operator Training ""•"
-------
TYPICAL BUBBLING FLUIDIZED-BED BOILER SCHEMATIC
Secondary
Superheater
Water-Gooled
Walls
Top of Bed
Bubbling
Bed \
Primary Superheater
Economizer
Dust Collector
Superheater and
Boiling Surface
Distributor
Plate Windbox
Slide 11-5
-------
TYPICAL CIRCULATING-BED BOILER SCHEMATIC1
Water-
Cooled
Walls'
Particle
Return
System
Gas
Primary and Secondary
Superheater
U-Beam Particle Collectors
Overfire Air
Supply Ducts
Primary Air
Distributor
Plate
Windbox
Boiler Operator Training
Slide 11-6
-------
FLUIDIZED-BED BOILER FURNACE DESIGN
Design Information
Bed Material
Pressure Loss
Heat Transfer
Slide 11-7
Boiler Operator Training -
-------
FLUIDIZED-BED BOILER ARRANGEMENTS
Boiler Subsystem
Distributor Plate
Overfire Air System
Boiler Furnace
Auxiliary Equipment
Fuel Feed System
Sorbent Feed System
Ash Removal System
Sootblowers
Slide M-8
Boiler Operator Training :=ZZ=ZZ=ZZ==^^=:
-------
OPERATION
System Control
Bed Temperature Control
Bed Material Inventory Control
Overfire Air Control
Slide 11-9
Boiler Operator Training __
-------
AIR FLOW DISTRIBUTION
100
90
80
70
«
.o
£ 50
Z
- 40
-------
FLUIDIZED-BED BOILER EMISSIONS
Sulfur Dioxide
Nitrogen Oxides
Carbon Monoxide and Hydrocarbon
Particulates
Slide 11-11
Boiler Operator Training zzz=Z====
-------
LESSON PLAN
CHAPTER 12. GAS TURBINE WITH A HEAT RECOVERY
STEAM GENERATOR.
Goal: To give the participant a general description of both gas turbine and the
heat recovery steam generators.
Objectives:
Upon completion of this unit an operator should be able to:
1. List the three components comprising the gas turbine.
2. Describe the principle power generation process from combustion in a
gas turbine.
3. Understand that turbine power is directly related to mass throughput
and therefore temperature and pressure ratios of a gas turbine are
major factors influencing the efficiency.
4. Identify the 3 combustor types found in gas turbines.
5. Discuss the different operating cycles used in power generation.
6. Understand the fact that NOX formation in gas turbines is
predominantly thermal NOX and therefore combustion temperatures
are the major factor in controlling NOX emissions
7. Discuss different emission control processes available to G.T. operation.
Lesson Time: Approximately 60 minutes.
Suggested Introductory Questions:
What is cogeneration?
What are the main components of a turbine?
Presentation Outline:
12.1 Introduction
12.2 Gas Turbine Description
12-1
-------
Presentation Outline (Continued):
12.3 Design Classifications
12.4 Operating Cycles and Efficiency
12.5 NOX Formation Mechanisms
12.6 Control Options
12-2
-------
CHAPTER 12. GAS TURBINE WITH A HEAT
RECOVERY STEAM GENERATOR
12.1 Introduction
12.2 Gas Turbine Description
12.3 Design Classifications
12.4 Operating Cycles and Efficiency
12.5 NOV Formation Mechanisms
\
12.6 Control Options
Slide 12- I
Boiler Operator Training 1=^^^=:^^^^^^^^^=^=
-------
GAS TURBINE COMPONENTS
• Compressor
• Combustor
• Turbine
Slide 12-2
Boiler Operator Training ~"
-------
SIMPLIFIED GAS TURBINE SCHEMATIC
Fuel
Air
Combustor
Hot Exhaust Gases
Compressor
Rotary Shaft Power
Turbine
Slide 12-3
Boiler Operator Training
-------
SCHEMATIC OF A TYPICAL SGT COMBUSTOR
Dome
Liner
Fuel Nozzle
Cooling Slot
\
Primary Hole
Intermediate Zone
j \ yv
Air Swirier
Snout
Intermediate Hole
Air Casing
Boiler Operator Training
Slide 12-4
-------
DESIGN CLASSIFICATIONS
Single-Shaft or Dual Shaft
Aero-Derivative or Heavy Duty
Combustor Design
Slide 12- S
Boiler Operator Training :==:^^=z::^^^^=^^^ZZZ=l
-------
SINGLE-SHAFT GAS TURBINE
Fuel
Air
Combustor
Hot Exhaust Gases
Compressor
Load
Slide 12-6
Boiler Operator Training
-------
DOUBLE-SHAFT GAS TURBINE
Fuel
Hot Exhaust Gases
Compressor
High Pressure Turbine
Low Pressure Turbine
Load
Slide 12-7
Boiler Operator Training
-------
EFFECT OF TEMPERATURE AND PRESSURE
ON THERMAL EFFICIENCY
Increasing
Thermal
EfAdancy
Increauig
Pnaauit Ratio
COMBINED CYCLE
SlUPLe CYCLE
Slide 12- X
Boiler O|>erator Training
-------
COMBUSTOR DESIGN
• Annular
• Can-Annular
• Silo
Slide 12-9
Boiler Operator Training ^^=^=^^^^^=^^===:
-------
ANNULAR COMBUSTOR
Flame Tube
H.P. Compressor Outlet
Guide Vanes
Combustion Inner
Casing
Air Spray Fuel
Injector Nozzle
Outer
Casing Nozzle Guide
\ Vanes,
Compressor Casing
Mounting Flange
Casing
Air Holes Mounting Flange
Slide 12- 10
Boiler Operator Training
-------
CAN-ANNULAR COMBUSTOR
Engine Fireseal
Main Fuel
Mainfold
Compressor
Outlet Elbow
Flange Joint
Primary Air
Scoop
Primary Fuel
Manifold
Interconnector
Combustion
Chamber
Air Casing
Drain Tube
Slide 12-11
Boiler Operator Training
-------
SILO COMBUSTOR
Slide 12- 12
Boiler Operator Training
-------
OPERATING CYCLE
• Efficiency
• Simple Cycle
• Regeneration
• Cogeneration
• Combined Cycle
Slide 12-13
Boiler Operator Training :^=^=^^^^^=^=^=^==^=
-------
REGENERATIVE CYCLE GAS TURBINE
Exhaust Gases
Compressed Air
Recuperator
Fuel
Air
t.
£
Hot Exhaust Gases
heated Air
Combustor
Compressor
Turbine
Rotary Shaft Power
Slide 12-14
Boiler Operator Training
-------
EFFECT OF REGENERATIVE CYCLE
ON GT THERMAL EFFICIENCY
I
O 40
-------
STATIONARY GAS TURBINE COGENERATION UNIT
Fuel
Exhaust Gases
t
Heal Recovery
Steam Generator
Sieam
Process
and/or steam
turbine
Compressor Simp,c Cydc Gas Turbjnc Turbine
Rotary Shaft Power
Slide 12-16
Boiler Operator Training
-------
STATIONARY GAS TURBINE
COMBINED CYCLE UNIT
Fuel
Aii
Exhaust GUCJ
1
Meal Recovery
Steam Generator
Combustor
Hoi Exhausi
Gases
Simple Cyck Gaj Turbine Turbine
Steam
Steam
Turbine
Electric Generator
Dearcator and pumping system
H Electric Generator
Boiler Operator Training
Slide 12-17
-------
GAS TURBINE CHARACTERISTICS THAT
DETERMINE NO EMISSIONS
^k
• Combustor Design
• Type of Fuel
• Ambient Conditions
• Operating Cycle
• Output Level
Slide 12-18
Boiler Operator Training .
-------
THERMAL NOX PRODUCTION AS A FUNCTION OF FLAME
TEMPERATURE AND EQUIVALENCE RATIO
4500
4000-
3500
U- 3000
«
,' 2500
200O
1500
1000
500
No. 2 DsoUt* Ol FVJ«|
05
1.0
Equivalence Ratio
MJB.LEAN
-^ *.«.(*>
400
300
-------
TEMPERATURE ON NO
I
O)
s
O
-2
X
f
50
30
20
tu
O 10
z
20
40 60 80
Ambient T«mp«nrtura, d*g. F
Boiler Operator Training
[TY AND
>NNOX
Ktv«Humk3ty *r
, R*«tfv» HumWJty
) 100 120
.F
Slide 12-20
-------
CONTROL OPTIONS
Fuel Switching
Water/Steam Injection
Fuel Emulsion
Combustion Modifications
Selective Catalytic Reduction
Oxidation Catalyst
Slide 12-21
Boiler Operator Training =IS:^=^=^=:^=^^==
-------
COMBUSTION MODIFICATIONS TO LOWER
NO EMISSION RATE
x
Lean Combustion and Reduced Residence Time
Lean Premixed Combustion
Dual-Staged Rich/Lean Combustion
Slide 12-22
Boiler Operator Training """"
-------
LOW NOX STAGING AND NOX CONCENTRATION PROFILE
fUMMT orr«« no.
WNITOM TO »v i OAO
8
NATURAL GAS FUEL
» •» m m ra
% (US TUP8INE LOAD
Boiler Operator Training
-1 100
Slide 12-23
-------
SCR REACTION
NO + NH3 + 1/2 O2 —> N2 + 3/2 H2O
NO2 + 2 NH3 + 1/2 O2 —> 3/2 N2 + 3/2 H2O
Slide 12-24
Boiler Operator Training ""
-------
POSSIBLE LOCATIONS FOR
SCR UNIT IN HRSG
Exhaust
/
X.
"*
<
\ \
Duct Burner Ammonia kSCR
Injection
Grid
Steam ..-
Clean Exhaust
Economizer
Water
Superheater Evaporator SCR Catalyst
ZZH Boiler Operator Training •
Slide 12-25
-------
LESSON PLAN
CHAPTER 13. PACKAGE BOILERS
Goal: To present the participants with common package boiler designs and
their characteristic pollutant emissions.
Objectives:
Upon completion of this unit an operator should be able to:
1. Describe the three types of major package boiler designs.
2. Describe the advantages/disadvantages of a firetube boiler design.
3. Describe three types of firetube boilers.
4. Describe the advantages/disadvantages of a watertube boiler design.
5. Describe three types of watertube boilers.
6. Describe the expected emissions from a package boiler.
Lesson Time: Approximately 30 minutes.
Suggested Introductory Questions:
What is a package boiler?
What applications are best for a package boiler?
Presentation Outline:
13.1 Introduction
13.2 Package Boiler Types
A. Firetube
1. HRT
2. Scotch Marine
3. Firebox
B. Watertube
1. "O" Type
2. "A" Type
3. "D" Type
C. Cast Iron Sectional
13.3 Emissions
13-1
-------
References for Presentation Slides
Slide 13-3 Wilson, R. Dean, Boiler Operator's Workbook, American
Technical Publishers, Inc., 1991.
Slide 13-4 Ibid.
Slide 13-5 Ibid.
Slide 13-6 Ibid.
Slide 13-7 Ibid.
Slide 13-8 Ibid.
Slide 13-9 Ibid.
Slide 13-10 Ibid.
Slide 13-11 "Alternative Control Techniques Document ~ NOx Emissions
from Industrial Commercial/Institutional (ICI) Boilers," U.S.
EPA, EPA-453 / R-94-022, March, 1994.
13-2
-------
CHAPTER 13. PACKAGE BOILERS
13.1 Introduction
13.2 Package Boiler Types
13.3 Emissions
Slide 13-1
Boiler Operator Training —
-------
FIRETUBE BOILER
FIRE
TUBES
COOLED GASES
OF COMBUSTION
//////////////////////
HEAT AND GASES
OF COMBUSTION
Boiler Operator Training
Slide 13-2
-------
HORIZONTAL RETURN TUBULAR BOILER1
FIRE DOOR
BRICK FURNACE
HORIZONTAL SHELL
GRATES
TOP ROW OF
FIRE TUBES
/XXXXXXXXXXXXXXXXXXXftXXX.Lft'/'y
<• .«••* ..« *• » '•>••;.« ..•*•.-,. «_• V»:V- V- '_»:'• i-*.'•;
».. •».-.f V--*. .'•*.-1 }••'••••'
COMBUSTION
SPACE
SUSPENDED
BAFFLE
FIRE BRICK
COMMON BRICK
v'v;-'! CONCRETE
Boiler Operator Training
Slide 13- 3
-------
MULTIPLE PASS FIRETUBE BOILER ARRANGEMENTS
2 pass Dryback
\
3-pass Wetback
3-pass Dryback
4 pass Dryback
Slide 13-4
Boiler Operator Training
-------
FIREBOX BOILER
FURNACE WALL
WATER LEG AREA
BOILER
SHELL
STAYBOLTS
FIRE TUBES
FIRE DOORS
Boiler Operator Training
Slide 13-5
-------
WATERTUBE BOILER
HEAT AND GASES
OF COMBUSTION
Boiler Operator Training
Slide 13-6
-------
WATERTUBE BOILER CONFIGURATIONS
STEAM AND
WATER DRUM
WATER
TUBES
STEAM AND
WATER DRUM
OPEN AREA
FOR COMBUSTION
MUD DRUM\
OPEN AREA
MUD DRUM FOR COMBUSTION
"A" STYLE BOILER
STEAM AND
WATER DRUM
WATER
TUBES
MUD
DRUM
MUD DRUM
WATER
TUBES
OPEN AREA
FOR COMBUSTION'
"0" STYLF BOILER
•D" STYLE BOILER
H Boiler Operator Training
Slide 13-7
-------
STEAM
HEADER
GAUGE
GLASS
DOORS
CAST IRON SECTIONAL BOILER
WATER LEVEL
HEAT AND GASES
OF COMBUSTION
EXTERNAL
MUD DRUM
CAST IRON BASE
Slide 13-8
Boiler Operator Training
-------
PUSH-NIPPLE CAST IRON SECTION
TIE ROD INSERTED
THROUGH EYES PULLS
SECTIONS TOGETHER
PUSH NIPPLE
HOLLOW
CAST IRON
SECTION
STUDS FOR
BETTER HEAT
TRANSFER
PUSH
NIPPLES
EYES FOR
TIE ROD
Boiler Operator Training
Slide 13-9
-------
FIRETUBE BOILER EMISSIONS
NO.
CO
(Ib/MMBtuV (Ib/MMBtul
Natural Gas 0.07 to 0.13 0.0 to 0.784
Distillate
Fuel Oil
Residual
Fuel Oil
0.11 to 0.39 0.0 to 0.014
0.21 to 0.39 0.0 to 0.023
THC
(lb/MMBtii>
0.004 to 0.117
0.012b
0.002 to 0.014
• To convert to ppm @ 3% O2, multiply by the following: NO,, 790; CO 1300; THC, 2270
b Single data point
Slide 13-10
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 14. NORMAL OPERATION
Goal: To present the participants with a general description of boiler operation
and to highlight the most important operating parameters to monitor
and control.
Objectives:
Upon completion of this unit an operator should be able to:
1. Describe conditions required for proper combustion.
2. Describe what fuel supply equipment requires periodic checking and how
often those checks should be made.
3. List potential causes of low drafts in a natural draft furnace.
4. Understand that loss of ignition can lead to explosive conditions and it is
the operators responsibility to prevent this occurrence.
5. Discuss potential problems arising from poor or improper boiler water
treatment. They should also be familiar with the checks and
maintenance procedures for boiler feedwater.
6. Know that if water levels fall below minimum the fuel and air supplies
must be stopped immediately and that adding feed water to a dry hot
boiler will damage the drum materials.
7. Describe proper procedures for correcting high water levels.
8. Understand that high levels of excess O2 result in higher heat loss out of
the stack.
Lesson Time: Approximately 60 minutes.
Suggested Introductory Questions:
What are some of the responsibilities that a boiler operator has while
operating a boiler?
What are some hazards of poor maintenance of boiler safety controls?
14-1
-------
Presentation Outline:
14.1 Introduction
14.2 Maintaining Suitable Combustion Conditions
14.3 Monitoring Combustion
14.4 Maintaining Steam Temperature and Pressure
14.5 Maintaining Suitable Feedwater Conditions
14.6 Monitoring the Steam/Water Circuit
i
14.7 Controlling the Steam Temperature
14.8 Startup Procedures
14.9 Shutdown Procedures
14-2
-------
CHAPTER 14. NORMAL OPERATION
14.1 Introduction
14.2 Maintaining Suitable Combustion Conditions
14.3 Monitoring Combustion
14.4 Maintaining Steam Temperature and Pressure
14.5 Monitoring Suitable Feedwater Conditions
14.6 Monitoring Steam/Water Circuit
14.7 Controlling the Steam Temperature
14.8 Startup Procedures
14.9 Shutdown Procedures
Slide 14- I
= Boiler Operator Training —^———__—
-------
FUEL SUPPLY
Coal
Oil
Gas
Slide 14- 2
Boiler Operator Training ——-
-------
FUEL SUPPLY CHECKLIST
FUEL
Coal
Fuel Oil
Gas
EQUIPMENT
Coal Bunkers
Conveying Equipment
Coal Hopper
Ash Pit
Pulverizer Mills
Storage/Supply Tanks
Duplex Strainers
Burner Tips
Reducing Station or
Booster Compressor
Burner Air Register
Burner Tip
Boiler Casing
ACTION
heck level
heck for wear
Check level
Check level and empty
Visually inspect and
ensure constant supply
of fuel to burners.
Start and end of shift
Dnce a shift
Once an hour
Once a shift / as required
Once an hour
Check level
Switch and clean
Clean and inspect
Ensure proper inlet and
outlet pressure
Inspect and check for
proper operation
Clean and inspect
Inspect for air leaks
FREQUENCY
Start and end of shift
Once a shift / as required
Once a day
Once an hour
Once a shift
Once a day
Once a shift
Slide 14- 3
Boiler Operator Training
-------
COMBUSTION AIR SUPPLY
• Natural Draft
• Mechanical Draft
Balanced
Pressurized Furnace
Slide 14- 4
Boiler Operator Training ---
-------
FLAME APPEARANCE
• Length
• Color
• Shape
• Stability
Slide 14- 5
Boiler Operator Training ——^——————————
-------
COMBUSTION AIR
Flow
Temperature
Pressure
Slide 14- 6
Boiler Operator Training "
-------
FUEL MONITORING PARAMETERS
Fuel Type Pressure Temperature Flow
Solid
Pulv. Coal X
Stoker Coal X
Refuse (Garbage) X
Liquid
Oil XXX
Chem By-Product X XX
Gaseous
Nat. Gas X XX
Gaseous By-Product X XX
Slide 14- 7
Boiler Operator Training ———————^—
-------
FLUE GAS ANALYSIS
C02
CO
NOX
SO.
Slide 14- 8
Boiler Operator Training SUZ^^ZZZ^^^^Z^Z^sn^^^^Z^
-------
Boiler Efficiency Based on Flue Gas Analysis
M
0)
CD
-------
PRESSURE/TEMPERATURE CONTROL
A. Monitor Steam Pressure
B. Maintain Proper Fuel-Air Ratio
C. Monitor Superheater Outlet Temperature
Slide 14-10
Boiler Operator Training I^^S^^^^^S^SZS^^^^SSSZZIS
-------
BOILER WATER PROBLEMS
Deposits or Scale
Waterside Corrosion
Carry-over or Priming
Caustic Embrittlement
Slide 14-11
Boiler Operator Training ————————
-------
MAINTAINING WATER LEVEL
Regular Maintenance/Operation
Low Level Problems
High Level Problems
Slide 14. 12
Boiler Operator Training ——————
-------
SUPERHEAT STEAM
TEMPERATURE CONTROL
Desuperheater
Burner Tilt
Flue Gas Recirculation
Sootblower
Slide 14-13
Boiler Operator Training —————————
-------
STARTUP PROCEDURES
• Pre-startup Inspection
• Establishment of Water Level
• Light-off
• Warm-up
Slide 14 - 14
Boiler Operator Training ^^^^^S^^^^^^^^^^^^^^n:
-------
RECOMMENDED PRE-STARTUP INSPECTION
CHECKLIST
• Pressure Measurement Device Accuracy
• Blowoff Valves Closed and Functional
• Gauge Glass and shut-off valves
• Infrared Detection System
• Main Steam Valve Inspection
• Safety Valves Inspection
• Fans Operational Condition
• Pumps Operational Condition
• Water Conditioning System
Slide 14-15
Boiler Operator Training ——————————
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LESSON PLAN
CHAPTER 15. AUTOMATIC CONTROL SYSTEMS.
Goal: To give the participant a brief overview of automatic control systems as
applied to boiler operation.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the operating principles of different control technologies used in
boilers in the present and past.
2. Describe the basic elements that make up an automatic control system.
3. List the key control parameters needing automatic control (both gas side
and waterside) in typical boiler operations.
4. Discuss the attributes differentiating different control system
configurations and describe advantages and disadvantages of each.
They should also be familiar with typical applications for different types
of control configurations.
5. Discuss the advantages of using microprocessor controls.
Lesson Time: Approximately 60 minutes.
Suggested Introductory Questions:
What types of control systems are used in the facilities that you work in?
Presentation Outline:
15.1 Introduction
15.2 Types of Analog Control Systems
15.3 Types of Digital Control Systems
15.4 Automatic Control System Elements
15.5 Gas-side and Water-side Control Parameters
15.6 Single, Two, & Three Element Controllers
15.7 Microprocessor Based Control Systems
15.8 Control System Applications
15-1
-------
CHAPTER 15. AUTOMATIC CONTROL SYSTEMS
15.1 Introduction
15.2 Types of Analog Control Systems
15.3 Types of Digital Control Systems
15.4 Automatic Control System Elements
15.5 Gas-side and Water-side Control Parameters
15.6 Single, Two, & Three Element Controllers
15.7 Microprocessor Based Control Systems
15.8 Control System Applications
Slide 15-1
Boiler Operator Training "
-------
Types of Analog Control Systems
Mechanical
Hydraulic
Pneumatic
Discrete Electronic Components
Slide IS- 2
Boiler Operator Training =
-------
Types of Digital Control Systems
Straight Mechanical
Hard Wired Interlocks
Relay Systems
Discrete Component Electronic
Microprocessor
Slide 15- 3
Boiler Operator Training
-------
Automatic Analog Control System Elements
Process or Measured Variable
Controller
Hand/Auto Station
Operator Interface
Final Control Element
Slide 15-4
Boiler Operator Training —
-------
Automatic Control System Elements
Process Variable
(Pressure, Temperature,
Level, etc.)
I
Controller
Hand-Auto Station
Operator Interface
(Display of Status and
Valves Plus Operator
Input Devices)
Final Control Element
(Valve, Damper Drive)
Slide IS- 5
Boiler Operator Training
-------
Gas-Side and Water-Side Control Parameters
Steam Pressure
Drum Level (if applicable)
Main Steam Temperature
Reheat Steam Temperature (if applicable)
Furnace Draft (if applicable)
Desired Excess Air
Slide IS- 6
Boiler Operator Training *"
-------
Control System Configuration
Single Element
Two Element Feed Forward
Two Element Cascade
Three Element
Slide 15-7
Boiler Operator Training "
-------
e Element Feedwater Control
Drum Level
Transmitter
Controller
Feedwater
Control Valve
Slide 15- 8
Boiler Operator Training
-------
Two Element Feedwater
Control (Feedforward)
Steam Flow
Transmitter
Drum Level
Transmitter
Controller
Feedwater
Control Valve
Slide 15-9
Boiler Operator Training
-------
Spray Water Attemperator Water Schematic
Attemperator Water
Boiler
Drum
Attemperator Out
Temp, Transmitter
Final Steam
Temp, Transmitter
Spray Water
Attemperator
To
Turbine
Primary
Superheater
\
Secondary
Superheater
Slide 15- 10
Boiler Operator Training
-------
Two Element Steam Temperature Control (Cascade)
Final Steam
Temperature
Transmitter
Steam Temperature
Controller
Attemperator
Controller
1
Attemperator Water
Flow Control
Valve
Attemperator Outlet
Temperature
Transmitter
Slide IS- II
Boiler Operator Training
-------
Three Element Feedwater Control
Steam Flow
Transmitter
Drum Level
Transmitter
Controller
Controller
I
Feedwater
Control Valve
Feedwater Flow
Transmitter
Slide 15-12
Boiler Operator Training
-------
Advantages of Microprocessor Systems
Flexibility
Improved Operator Interface
Reliability
Ability to Incorporate and Integrate Numerous
Systems in a Single Package
Slide 15-13
Boiler Operator Training ""
-------
Control Systems Applications
Boiler Combustion Controls
Boiler Feedwater Controls
Boiler Steam Temperature Controls
Boiler Draft Control
Feedwater Heater Level Controls
Hotwell Level Controls
Deaerator Pressure Controls
Air Heater Cold End Temperature Controls
Numerous Other Applications
Slide 15 -14
Boiler Operator Training ~""
-------
LESSON PLAN
CHAPTER 16. INSTRUMENTATION: GENERAL MEASUREMENTS
Goal: To give the participant a general overview of measurement devices,
instruments and sensors available to boiler operations.
Objectives:
Upon completion of this unit an operator should be able to:
1. Describe the basic devices available for pressure temperature, level and
flow measurement.
Lesson Time: Approximately 30 minutes.
Suggested Introductory Questions:
What are the parameters that need to be measured to monitor the boiler
operation?
Presentation Outline:
16.1 Introduction
16.2 Pressure Measurement
16.3 Temperature Measurement and Equivalence
16.4 Level Measurement
16.5 Flow Measurement
16.6 Weigh Scales
16-1
-------
CHAPTER 16. INSTRUMENTATION:
GENERAL MEASUREMENTS
16.1 Introduction
16.2 Pressure Measurement
16.3 Temperature Measurement and
Equivalences
16.4 Level Measurement
16.5 Flow Measurement
16.6 Weigh Scales
Boiler Operator Training
-------
Pressure Measurement
Pressure Gauges
Manometers
Pressure Transmitters
Draft Gauges
Boiler Operator Training
-------
Temperature Measurement
Human Hand
Liquid Filled Bulb & Tube
Liquid Filled Bulb & Gauge
Thermocouple with Readout Device
Resistance Temperature Detector with Readout Device
Optical Pyrometer
Slide 16- 3
Boiler Operator Training
-------
Level Measurement
Float Type
Sight or Gauge Glass
Level Transmitter
Slide 16-4
Boiler Operator Training
-------
Flow Measurement
Open Channel
Variable Area Meters
Pilot Tube
Differential Pressure
Turbine Meters
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 17. ELECTRICAL THEORY
Goal: To present the participants with the basic principles of electricity to give
the knowledge required for understanding transformers, rectifiers and
electric generators.
Objectives:
Upon completion of this unit an operator should be able to:
1. Understand the concept of AC and DC electrical current.
2. Describe the basic parameters of electricity such as voltage, current,
resistance.
3. Use Ohm's Law and apply it to basic calculations of electrical quantities
such as voltage, current and power.
4. Apply AC power relationships to simple calculations or power.
5. Describe basic fundamental operations of electrical equipment such as
motors, transformers, generators.
6. List commonly used instruments for measuring electrical parameters.
Lesson Time: Approximately 60 minutes.
Suggested Introductory Questions:
Who can explain the difference between AC and DC electrical current?
What is voltage?
Presentation Outline:
17.1 Introduction
17.2 Fundamental Parameters
A. Current
B. Voltage
C. Other Parameters
D. Ohm's Law
E. DC Wattage or Power
F. AC Wattage or Power
17-1
-------
Presentation Outline (Continued):
17.3 Electrical Power Equipment
A. Motors
B. Generators
C. Transformers
D. Other Equipment
17.4 Instruments and Meters
17-2
-------
CHAPTER 17. ELECTRICAL THEORY
17.1 Introduction
17.2 Fundamental Parameters
17.3 Electrical Power Equipment
17.4 Instruments and Meters
Slide 17- I
Boiler Operator Training :zz^=SSSZHIIIIIZ=SI^S^=
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BASIC ELECTRICITY
DC vs. AC Current
Ohms Law
Power
Electrical Phases
Motors and Generators
Transformers
Rectifiers
Slide 17- 2
Boiler Operator Training
-------
STEADY DC AND OSCILLATING AC ELECTRON FLOW
Boiler Operator Training
Slide 17-3
-------
ELECTRICITY - FLUID FLOW ANALOGY
Parameter Electricity Fluids
Flow Rate Electron Flow/Current (amps) Fluid Flow (gpm)
Driving Force Electrical Potential Difference Pressure Difference (psi)
or Voltage (volts)
Slide 17- 4
Boi ler Operator Training ==1^=======:=^=
-------
VOLTAGE OSC
1 fVr
I.Ur
0.8-
0.6
-------
OTHER BASIC ELECTRICAL PARAMETERS
Conductor Material Which Permits Electrons to Flow
Resistance Measures Opposition to Flow
Ohm
Circuit
Unit of Electrical Resistance
Insulator Material with High Resistance
The Path of Electrical Current from a
Source through Various Conductors
and Devices
Slide 17-6
Boiler Operator Training
-------
OHM's LAW
VOLTAGE-CURRENT RELATIONSHIP
Voltage = Current x Resistance
V = IxR
= V/R
Slide 17-7
Boiler Operator Training =s==^^^^^=^^^=
-------
GRAPHICAL RELATIONSHIP OF VOLTAGE
AND CURRENT BY OHM'S LAW
V = Voltage (volts)
I = Amperage (amps)
R = Resistance (ohms)
= IxR
= V/R
R =
Boiler Operator Training
Slide 17-8
-------
DC POWER RELATIONSHIPS
Power = Voltage x Current
P = VxI
P = (I x R) x I
= (I)2xR
or
= (V/R)2xR
= (V)2/R
Slide 17-9
Boiler Operator Training :zz==^=^^^=^^=^^=
-------
GRAPHICAL RELATIONSHIP OF POWER
P = Power (watts)
I = Amperage (amps)
V = Voltage (volts)
P=Ix V
= P/V
Boiler Operator Training
Slide 17- 10
-------
AC POWER RELATIONSHIPS
Power = Voltage x Current x Power Factor
P = V x I x cos 0
P = (I x R) x I x cos 0
P = (I)2 x R x cos 0
or
P = V x (V / R) x cos 0
= (V)2/Rxcos0
Slide 17-11
Boiler Operator Training ==Z===^^^^^^=
-------
AC VOLTAGE AND CURRENT RELATIONSHIPS
(EXAMPLE OF CURRENT LAGGING)
a
o>
DC
Oscillation, Degrees
Slide 17-12
Boiler Operator Training
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AC ELECTRICAL POWER
Apparent Power is Current times Voltage
P = I x V, [KVA]
apparent 7 L J
Power Factor
Power Factor = cos 0 = P/Papparent
Slide 17-13
Boiler Operator Training "
-------
TRANSFORMER WINDING SCHEMATIC
Coils
440V
1
T
220V
i
Primary Coil -*
Secondary Coil
Step-down Transformer
Boiler Operator Training
Slide 17-14
-------
SCHEMATIC OF 3-PHASE ELECTRIC CURRENT
v!7 K j
Oscillation, Degrees
Boiler Operator Training
Slide 17-15
-------
ELECTRICAL POWER EQUIPMENT
COMPONENT
Voltage Regulator
Circuit Breaker
Rectifier
Inverter
FUNCTION
Maintains Constant Voltage from AC Source
Controls the Flow of Electricity
Converts AC Electricity to DC
Converts DC Electricity to AC
Slide 17 -16
Boiler Operator Training
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INSTRUMENTS AND METERS
Voltmeters
Ammeters
Ohmmeters
Synchroscopes
Frequency Meters
Slide 17-17
Boiler Operator Training 1=:==^==^^=^^^^=
-------
LESSON PLAN
CHAPTER 18. TURBINE GENERATOR
Goal: To give the participant a general overview of turbine generator designs
and operation.
Objectives:
Upon completion of this unit an operator should be able to:
1. Identify key components of an AC generator.
2. Describe the components required in a turbine generator and boiler set.
3. Understand the design differences between impulse steam turbines and
reaction steam turbines.
4. Understand the importance at following cold start and shut-down
procedures because of thermal and mechanical stresses on the unit.
5. Describe the use of synchroscope.
6. Discuss potential off-normal operating conditions and the respective
consequences.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
Does anyone know the cold start and shutdown procedures for turbines?
How quickly can you heat up a turbine?
Presentation Outline:
18.1. Introduction
18.2. Steam Turbine Generator Description
18.3. Steam Turbine Designs
18.4. Steam Turbine Generator Operation
18.5. Generator Synchronization With Utility Grid
18.6. Turbine Generator Off-Nominal Conditions
18-1
-------
Jtteterences tor Presentation Slides
Slide 18-2 Wark, Kenneth, Jr., Thermodynamics, Fifth Edition,
McGraw Hill Book Company, New York, 1988, p. 739.
Slide 18-4 Steingrass, Fredrick M. and Frost, Harold J., Stationary
Engineering, American Technical Publishers, Inc.,
Homewood, IL, 1991, pp. 227 - 275.
Slide 18-5 Ibid.
Slide 18-7 Ibid.
Slide 18-8 Ibid.
18-2
-------
CHAPTER 18. TURBINE GENERATOR
18.1 Introduction
18.2 Steam Turbine Generator Description
18.3 Steam Turbine Designs
18.4 Steam Turbine Generator Operation
18.5 Generator Synchronization with Utility Grid
18.6 Turbine Generator Off-Nominal Conditions
Slide 18- 1
Boiler Operator Training .
-------
STEAM GENERATOR EQUIPMENT & FLOW SCHEMATIC2
-t>
-------
TURBINE GENERATOR SYSTEM COMPONENTS
Steam Turbine
Condenser, Hotwell & Air Ejector
Condensate Pump & Heater
Deaerator
Feedwater Pumps & Heaters
Electrical Generator
Slide 18- 3
Boiler Operator Training —
-------
STEAM CONDENSER SCHEMATIC
-Exhaust Steam Inlet
Condenser
Tubes /- Cooling Water
/ OLrtlet
Baffle
Cooling Water
Inlet
Boiler Operator Training
Slide 18- 4
-------
AC GENERATOR1
Frame
Rotor
Fan
Stator
Slip Rings
Stator Leads
Boiler Operator Training
Slide 18- 5
-------
STEAM TURBINE TYPES & FEATURES
TYPES
Impluse Steam Turbine
Reaction Steam Turbine
Impulse-Reaction Steam Turbine
FEATURES
Multiple Stages
Conversion of Thermal Energy
Production of Mechnical Energy
Slide 18- 6
Boiler Operator Training
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IMPULSE TURBINE BLADE CONFIGURATION
& FLOW PARAMETERS1
Fixed Blades
Revolving Blades
Revolving Blades
First-Stage
Nozzle
Initial
Steam Pressure
Second-Stage
Nozzle
Initial
Steam Velocity
Second-Stage
Revovling
Blades
Exit
Steam Pressure
\.
y i x
Exit
Steam Velocity
Time
Slide 18-7
Boiler Operator Training
-------
REACTION TURBINE CONFIGURATION
& FLOW PARAMETERS'
Revolving Blades
Fixed Blades
Fixed Blades
Revolving Blades
Initial
Steam Pressure
Steam Velocity
\\ n/ \
>1K N
Exit
Steam Pressure
Exit
Steam Velocity
Time
Boiler Operator Training
Slide 18- 8
-------
TURBINE GENERATOR OPERATION
Cold Start
Synchronization
Shut-Down
Slide 18 - 9
Boiler Operator Training "
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TURBINE GENERATOR SYNCHRONIZATION
Synchroscope: Phase Angle Meter
Clockwise Rotation
Counterclockwise Rotation
Indicator Pointing Upward
Slide 18-10
Boiler Operator Training —
-------
TURBINE GENERATOR OFF-NORMAL CONDITIONS
Water Induction
Excessive Vibration
High Bearing Temperatures
High-Back Pressure
Speed Control
Slide 18-11
Boiler Operator Training ""
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LESSON PLAN
CHAPTER 19. PREVENTATIVE MAINTENANCE
Goal: To give the participant an overview of the general aspects of
preventative maintenance.
Objectives:
Upon completion of this unit an operator should be able to:
1. Understand that the operator is responsible for safety, protection of
system operations, preventative maintenance, corrective maintenance,
keeping good records and communication.
2. Describe the some potential economic losses that can occur at a boiler.
3. Describe the five features of a maintenance program.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What are some of the goals of preventative maintenance?
Who loses when preventative maintenance is not performed?
Can anyone describe your maintenance programs at your facility?
Presentation Outline:
19.1 Potential Economic Losses
19.2 Features of Preventative Maintenance
19.3 Periodic Inspections
19.4 In-Service Maintenance
19.5 Outage Maintenance Planning
19-1
-------
CHAPTER 19. PREVENTATIVE MAINTENANCE
19.1 Potential Economic Losses
19.2 Features of Preventative Maintenance
19.3 Periodic Inspections
19.4 In-Service Maintenance
19.5 Outage Maintenance Planning
Slide 19- I
Boiler Operator Training ""
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POTENTIAL ECONOMIC LOSSES
1. Cost of Preventive Maintenance
2. Personal Injury
3. Equipment Repair/Replacement
4. Lost Revenue - Equipment Downtime
5. Fines - Regulatory Violations
Slide 19- 2
Boiler Operator Training """""
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OPERATOR RESPONSIBILITIES
1. Safety
2. Production (System Operations)
3. Preventive Maintanance
4. Corrective Maintenance
5. Record Keeping & Communications
Slide 19-
Boiler Operator Training l^ZI^Z^ZSI^IZZ^ZI^^^SS^^^
-------
GOALS OF PREVENTIVE MAINTENANCE
1. Maximize Unit Reliability
2. Minimize Total Operating Costs
3. Enhance Equipment Life
4. Restore Unit Performance
Slide 19- 4
Boiler Operator Training *~"
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FEATURES OF A MAINTENANCE PROGRAM
1. Review Vendor Recommendations
2. Identification of Problems
3. Evaluation of Options
4. Communication & Planning
5. Implementation
Slide 19-
Boiler Operator Training
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IN-SERVICE MAINTENANCE
1. Follow Recommended Procedures
2. Know Special Design Features
3. Know Operational Relationships
Slide 19- 6
Boiler Operator Training Z===Z=Z=ZZZZZZZZZZZZ=ZZ:
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OUTAGE MAINTENANCE
Make & Update an Outage Plan
2. Arrange for Materials/Services
3. Make Detailed Inspections
4. Revise Plans as Necessary
5. Follow Proper Procedures
6. Inspect Upon Conclusion
Slide 19- 7
Boiler Operator Training ZZZS^Z^H^ZZZZZ=^^^^HZ^
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LESSON PLAN
CHAPTER 20. SAFETY
Goal: To give the participant a general description of safety hazards, standard
safety procedures, personnel protection equipment, and consequences of
exposure associated with a steam generating system.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the possible causes and methods of prevention of waterside
explosions on a steam generating system.
2. Discuss the possible causes and method of prevention of gas side
explosions in steam generating systems.
3. Describe the kind of information that can be found on an MSDS sheet.
4. Describe standard industrial safety considerations associated with
working in an industrial environment.
5. List personal protection equipment that may be required to give workers
additional safety.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What kinds of safety procedures do you follow on the job?
Has anyone been close to or personally involved in an accident that could
have been prevented by following simple safety guidelines?
Presentation Outline:
20.1 System Safety Hazards
20.2 Consequences of Exposure to Hazards
20.3 Standard Safety Considerations
20.4 Personnel Protection Equipment
20-1
-------
CHAPTER 20. SAFETY
20.1 System Safety Hazards
20.2 Consequences of Exposure to Hazards
20.3 Standard Safety Considerations
20.4 Personnel Protection Equipment
Slide 20- I
Boiler Operator Training
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SAFETY PROCEDURE ELEMENTS
1. Recognition of Hazards
2. Consequences of Exposures
3. Standard Safety Procedures
4. Personal Protection Equipment
Slide 20- 2
Boiler Operator Training SSSZZI^^^I^^^^^^^^^^^n^^:
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MAJOR HAZARDS OF
STEAM GENERATING SYSTEMS
Water Side Explosions Due to Overheating
and Over Pressure
Gas Side Explosions Due to Explosive Mixtures
Slide 20- 3
Boiler Operator Training """
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OTHER BOILER SYSTEM SAFETY HAZARDS
1. Combustion Gases
2. Noise
3. Observation Hatches
4. Operations in Confined Spaces
5. Boiler Auxiliary Systems
Slide 20- 4
Boiler Operator Training """*
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SYMPTOMS OF ILLNESS
1. Headaches
2. Lightheadedness
3. Dizziness
4. Nausea
5. Loss of Coordination
6. Difficulty in Breathing
7. Chest Pains
8. Exhaustion
Slide 20-
Boiler Operator Training :ZZZ^^ZI:^^^^I^^^^^^^^^=
-------
STANDARD SAFETY CONSIDERATIONS
Exposure to High Pressure Steam
Exposure to Hot Water
Electrical Shock
Exposure to Chemicals
Chemical Mixing
Asbestos Exposure
Noise & Vibration
Exposure to Rotary Equipment
Awkward Access
Movement of Heavy Objects
Fire Hazards
Slide 20- 6
Boiler Operator Training Z^Z^^S^S^^^^^=I^=ZI^Z=
-------
PERSONAL PROTECTION EQUIPMENT
1. Ear Protection
2. Heavy Gloves
3. Hard Hat
4. Respirator
5. Goggles and Safety Glasses
6. Safety Shoes
7. Proper Clothing
8. Back Support
9. Gaseous Concentration Monitors
Slide 20- 7
Boiler Operator Training "
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LESSON PLAN
CHAPTER 21. AIR POLLUTANTS OF CONCERN
Goal: To give the participant an overview of the types and potential health
risk effects of air pollutants.
Objectives:
Upon completion of this unit an operator should be able to:
1. Identify the basic classifications of air pollutants.
2. List the five primary pollutants.
3. Describe the typical form, critical factors, and the health and welfare
effects of the primary pollutants.
4. Understand that the NAAQS represents the maximum levels of
pollutants permitted to exist in the air.
5. Describe the two most common types of secondary pollutants.
6. Describe the formation of secondary pollutants from primary pollutants.
Lesson Time: Approximately 75 minutes.
Suggested Introductory Questions:
Does anyone know what pollutants cause the brown color of smog?
Presentation Outline:
21.1 Introduction
21.2 Air Quality Overview
21.3 National Ambient Air Quality Standards
21.4 Primary Pollutants
A. Particulate
B. Sulfur Dioxide
C. Nitrogen Dioxide
D. Volatile Organics (VOCs)
E. Carbon Monoxide
21-1
-------
Presentation Outline (Continued):
21.5 Secondary Pollutants
A. Photochemical Oxidant
B. Acid Deposition
21.6 Hazardous Pollutants
A. Metals
B. Organics
21-2
-------
CHAPTER 21. AIR POLLUTANTS OF CONCERN
21.1 Introduction
21.2 Air Quality Overview
21.3 National Ambient Air Quality Standards
21.4 Primary Pollutants
21.5 Secondary Pollutants
21.6 Hazardous Pollutants
Boiler Operator Training
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AIR POLLUTANTS OF CONCERN
Primary Pollutants
Particulate Matter
Sulfur Oxides (SO2, SO)
Nitrogen Oxides (NOX, NO2)
Hydrocarbons
Carbon Monoxide
Secondary Pollutants
Photochemical Oxidant (ozone, etc...)
Sulfates
Hazardous Pollutants
Metals (Lead, Mercury, etc...)
Organics (Benzene, Vinyl Chlorides, etc...)
Boiler Operator Training
Slide 21 - 2
-------
AIR QUALITY OVERVIEW
Atmospheric Interactions
Pollutant
Emissions
Sources
Y7////////////////////////////////////////W^
Boiler Operator Training
-------
NATIONAL AMBIENT AIR QUALITY STANDARDS
POLLUTANT
Particulate
Matter (< lOfim)
Sulfur Oxides
Nitrogen Dioxide
Hydrocarbons
(corrected for
methane)
Carbon Monoxide
Ozone
Lead
AVERAGING
TIME
annual mean
24 hour
annual average
24 hour
3 hour
annual average
3 hour
8 hour
1 hour
1 hour
3 month average
PRIMARY
STANDARD
50 ug/m3
150 ug/m3
80 ug/m3
365 ug/m3
100 ug/m3
160 ug/m3
10 mg/m3
40 mg/m3
235 ug/m3
1.5 ug/m3
SECONDARY
STANDARD
50 ug/m3
50 ug/m3
1300 ug/m3
Same
160 ug/m3
Same
Same
Same
Same
Slide 21-4
Boiler Operator Training
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NAAQS OBJECTIVES
Pollutant
Participate
Sulfur Dioxide
Nitrogen Dioxide
Hydrocarbons
Carbon Monoxide
Ozone
Lead
Objective of the Standard
To prevent health effects due to long
term exposure
To prevent pulmonary irritation
(primary) and to prevent odor
(secondary)
To prevent possible risk to public
health and atmospheric discoloration
To reduce photochemical oxidant
formation
To prevent interference with the
capacity to transport oxygen to the
blood
To prevent eye irritation and
respiratory problems and to prevent
damage to vegetation
To prevent lead poisoning
Boiler Operator Training
-------
PARTICULATE MATTER
Typical Form: Solid, Liquid, Aerosol
Critical Factors: Particle Size
Particle Type
Aerosol Concentration
Health Effects: Deposits in Respiratory Passages
Increases Exposure to Toxic Substances
Welfare Effect: Reduces Visibility
Boiler Operator Training
-------
SULFUR OXIDES
Typical Form:
Critical Factor:
Health Effect:
Welfare Effect:
Sulfur Dioxide - Gaseous
Sulfates (SO3, H2SO4) - Liquid
Conversion of SO2 to Sulfates
in the Atmosphere
Causes Broncho constriction,
Especially in Asthmatics
Results in Acid Deposition
Boiler Operator Training
Slide 21-7
-------
NITROGEN OXIDES
Typical Form:
Critical Factor:
Health Effects:
Welfare Effect:
Nitric Oxide (NO) - Gaseous
Nitrogen Dioxide (NO2) - Gaseous
Nitric Acid (HNO3) - Liquid
Conversion of NO to NO2 and to
Nitrates in the Atmosphere
Damages Respiratory Tissues,
Causes Respiratory Symptoms
Results in Atmospheric Discoloration,
Promotes Formation of Photochemical
Oxidant, and Results in Acid Deposition
Slide 21 - 8
Boiler Operator Training
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HYDROCARBONS
Typical Form:
Critical Factor:
Health Effects:
Welfare Effect:
A Wide Range of Organic
Molecules are Possible
Molecule Type
Not Critical at Typical Concentrations
Contributes to Photochemical Oxidant
and Ozone
Boiler Operator Training
-------
CARBON MONOXIDE
Typical Form:
Critical Factor:
Health Effects:
Welfare Effect:
Gas
Concentration
Impairs Oxygen Transport in Blood
Impacts Central Nervous System
None
Slide 21 -10
Boiler Operator Training
-------
FORMATION OF PHOTOCHEMICAL OXIDANT
Nitrogen Oxide
Sunlight
Reactive Hydrocarbons
Photochemical
Oxidant
Boiler Operator Training
-------
OZONE
Typical Form:
Critical Factor:
Health Effects:
Welfare Effect:
Gas
Concentration
Irritates Eyes and Mucous
Membranes.
Causes Respiratory Symptoms and
Lung Damage
Boiler Operator Training
Damages Plants and Materials
-------
ACID DEPOSITION
Sulfuric
Nitric
Sulfur Dioxide
Nitrogen Dioxide
Dry Aerosol
Deposition
\
Precipitation
(Rain, Snow)
Lakes
Vegetation
Boiler Operator Training
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HAZARDOUS METALS
Beryllium
Copper
Mercury
Zinc Oxide
Cadmium
Inorg. Arsenic
Nickel
Lead
Boiler Operator Training
Chromium
Manganese
Zinc
-------
HAZARDOUS ORGANICS
Acrolein
Carbon Tetrachloride
Ethylene Dichloride
Methylene Chloride
Toluene
Vinyl Chloride
Boiler Operator Training
Benzene Benzo(a)pyrene
Chloroform Ethylene Dibromide
HCHO Methyl Bromide
Peroxyacyl Nitrate (PAN) Perchloroethylene
Trichloroethane 1,1,1-Trichloroethane
Xylenes
-------
LESSON PLAN
CHAPTER 22. ENVIRONMENTAL REGULATIONS
Goal: To give the participant an in-depth view of environmental regulations
applicable to steam generating systems.
Objectives:
Upon completion of this unit an operator should be able to:
1. Give a brief description of air pollution regulatory legislation enacted in
recent history.
2. Describe the meaning of the Clean Air Act acronyms, particularly
NAAQS, NSPS, SIP, PSD, and NESHAP.
3. Discuss the Clean Air Act provisions applicable to boiler operations.
4. Discuss the implications of NSPS on boiler operations and understand
that NSPS regulations vary depending on ftiel type.
5. Discuss the requirements related to continuous emissions monitors as
applied to steam generating units.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
How have operations at your facilities been affected recently by
environmental regulations?
Does anyone know what emissions criteria your steam generating units
must meet?
Presentation Outline:
22.1 Regulatory Overview
A. Clean Air Act History
B. Clean Air Terminology
C. Clean Air Act Provisions
22.2 Provisions of the Clean Air Act Relative to Boiler
Operations
22-1
-------
Presentation Outline (Continued):
22.3 New Source Performance Standards
A. Performance Standards for Steam Generators
(>250 MMBtu/hr)
B. Performance Standards for Electric Utility
Steam Generators (>250 MMBtu/hr)
C. Performance Standards for Steam Generators
(>100 MMBtu/hr)
D. Performance Standards for Small Steam
Generators (10-100 MMBtu/hr)
22.4 Additional Standards
A. Acid Rain Program
B. State Implementation Plans
C. National Emission Standards for Hazardous Air
Pollutants
22.5 Permits
A. Title V Overview
B. Permit Program Elements
C. Information Requirements
22-2
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CHAPTER 22. ENVIRONMENTAL REGULATIONS
22.1 Regulatory Overview
22.2 Provisions of the Clean Air Act
Relative to Boiler Operations
22 J New Source Performance Standards
22.4 Additional Standards
22.5 Permits
Slide 22 - I
Boiler Operator Training '
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HISTORY OF THE CLEAN AIR ACT
1881 Smoke control ordinances passed in Chicago and Cincinnati
7955 Federal Air Pollution Control Act enacted to evaluate and assist with air
pollution control
1963 Federal Clean Air Act passed to increase federal government role in
protecting public health and welfare
1965 Motor Vehicle Air Pollution Control Act passed to set emissions
standards for new vehicles
1967 Federal Air Quality Act Enacted to increase air pollution control efforts
1970 Clean Air Act Amendments passed to improve efforts for improving air
quality
7977 Additional Amendments to the Clean Air Act passed to extend deadline
for achieving air quality standards
1990 Clean Air Act Amendments passed to control acid rain, auto emissions,
hazardous pollutants, and to meet the ozone standard nationwide
Slide 22 - 2
^ Boiler Operator Training *^*~
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CLEAN AIR ACT TERMINOLOGY
NAAQS
PSD
NSPS
SIP
NESHAP
National Ambient Air Quality Standards
Prevention of Significant Deterioration
New Source Performance Standards
State Implementation Plans
National Emission Standards for
Hazardous Air Pollutants
Slide 22 • 3
Boiler Operator Training
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CLEAN AIR ACT CONTROL STANDARDS
Criteria Pollutants
LAER Lowest Achievable Emissions Rate
BACT Best Available Control Technology
RACT Reasonably Available Control Technology
Hazardous Air Pollutants
MACT Maximum Available Control Technology
GACT Generally Available Control Technology
Slide 22 - 4
Boiler Operator Training ziz==Z======Z===
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1990 CLEAN AIR ACT TITLES
I. Air Pollution Prevention and Control
II. Emissions Standards for Moving Vehicles
III. Hazardous Air Pollutants
IV. Acid Deposition Control
V. Permits
VI. Stratospheric Ozone Protection
VII. Enforcement
VIII. Miscellaneous Provisions
IX. Clean Air Research
X. Disadvantaged Business Concerns
XI. Clean Air Employment Transition Assistance
Slide 22 - 5
Boiler Operator Training ==^===^=:
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CLEAN AIR ACT PROVISIONS RELATIVE
TO BOILER OPERATIONS
Title I: Air Pollution Prevention and Control
Title III: Hazardous Air Pollutants
Title IV: Acid Deposition Control
Title V: Permits
Slide 22 - 6
Boiler Operator Training ""
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AIR POLLUTANTS COVERED BY CAAA
Title IV Title I Title II Title III
Acid Deposition Nonattainment Mobil Sources Haz. Air Pollutants
Boiler Operator Training
Slide 22 - 7
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NEW SOURCE PERFORMANCE STANDARDS
Apply to New Units or Significantly Modified Units
Regulations Established for Different Groupings of
Pollutants Emission Sources
• Utility Boilers
• Industrial Boilers
• Gas Turbines
Establish Stack Emission Limits for Criteria Pollutants
Limits Must be Based on Demonstrated Performance
of Control Technologies
Establish Monitoring, Recordkeeping, and Reporting
Requirements
Slide 22 - 8
Z=SSSZH=z: Boiler Operator Training —•
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NEW SOURCE PERFORMANCE STANDARDS
Steam Generators with Heat Input > 250 MMBtu/hr
Apply to Units Constructed After 8/17/71
or Significantly Modified Units
Fuel Pollutant Allowable Emissions
Rate (lb/106 Btu)
Coal S02 12
NOX 0.7
Particulate 0.1
Oil SO2 0.8
NOX 0.3
Particulate 0.1
Gas NOX 0.2
Particulate 0.1
Slide 22 - 9
Boiler Operator Training
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CONTINUOUS EMISSIONS MONITORS
Each boiler operator is required to install continuous emissions monitors
for SO2, NOX, and either O2 or CO2 with the following exceptions:
1) Boilers burning gas do not need an SO2 monitor.
2) Boilers burning coal and oil can opt to monitor SO2 by fuel
sampling and analysis, if they do not have a desulfurization
unit.
3) Boilers with NOX emissions which are less than 70 percent of
the standards do not need to install a NOY monitor.
A
4) Boilers not needing SO2 or NOX monitors do not need to
install an O2 or CO2 monitor.
Slide 22-10
Boiler Operator Training ~""
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BOILER OPERATION LOG DATA FOR
NSPS REPORTING
Calendar date
Emission rates (hourly) and/or opacity
Reasons for noncompliance with the emission standards
Description of corrective actions taken.
Ling days for which emission data have not been obtained by an
approvecfmethod
Justification for not obtaining sufficient data
Description of corrective actions taken.
Type of fuel(s) combusted and reference to composition
(i.e. fuel supplier certification)
If a CEMS is used,
• Identification of any times when the pollutant concentration
exceeded the full span of the CEMS.
• Description of any modification to the CEMS that could affect the
ability of the CEMS to comply with Performance Specifications
Results of daily CEMS drift tests
Slide 22 -11
Boiler Operator Training
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NSPS - SULFUR DIOXIDE & PARTICULATE
Electric Utility Steam Generators
with Heat Input > 250 MMBtu/hr
Apply to Units Constructed After 9/18/78
or Significantly Modified Units
Fuel Pollutant
Coal SO2
Particulate
Oil SO2
Particulate
Gas SO2
Particulate
Allowable Emissions
Rate (lb/106 Btu)
1.2
0.6
0.03
0.8
0.2
0.03
0.8
0.2
0.03
Emissions
Reduction
90%
70%
99%
90%
0%
70%
90%
0%
Slide 22-12
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NSPS - NITROGEN OXIDES Electric Utility Steam Generators
with Heat Input > 250 MMBtu/hr
Apply to Units Constructed After 9/18/78 or Significantly Modified Units
Fuel Allowable Emissions Emissions
Rate (lb/10" Btu) Reduction
Gaseous Fuel:
Coal-Derived 0.5 25%
All Other 0.2 25%
Liquid Fuels:
Coal-Derived 0.5 30%
Shale Oil 0.5 30%
All Other 0.3 30%
Solid Fuels
Coal-Derived 0.5 65%
Fuel (25% Coal Refuse) (1) (1)
Fuel (25% Lignite/Slag) 0.8 65%
Fuel (25% Lignite/other) (2) (2)
Subbituminous 0.5 65%
Bituminous 0.6 65%
Anthracite 0.6 65%
All Other 0.6 65%
(1) exempt from the NOX standards and monitoring requirements
(2) fuels in this category are not prorated Slide 22-13
^^^=Z===Z=Z=i: Boiler Operator Training ""
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POTENTIAL COMBUSTION CONCENTRATIONS
Pollutant
Particulate
SO.
NO.
Fuel Type
Solid
Liquid
All
Solid
Liquids
Gaseous
Concentration flb/MMBtu)
7.00
0.17
Based Upon
Fuel Content
2.30
0.72
0.67
Slide 22-14
Boiler Operator Training
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CONTINUOUS EMISSIONS MONITORS
Requirements:
• Install
• Calibrate
• Maintain
Certify
• Record Output
Monitor:
• Opacity
• Sulfur Dioxide
• Nitrogen Oxides
• Oxygen or Carbon Dioxide
Slide 22-15
Boiler Operator Training ^Z==^^^==!^
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SOURCE PERFORMANCE STANDARDS
Steam Generators with Heat Input > 100 MMBtu/hr
Apply to Units Constructed After 6/19/84 or Significantly Modified Units
Fuel
Coal
Oil
Gas
HRR
Pollutant
SO2
NOX:
Spreader Stoker
Mass-Feed Stoker
Pulverized Coal
Fluidized Bed
Particulate
SO2:
Residual
Others
NOX:
HRR < 70,000
HRR > 70,000
Particulate
NOX:
HRR < 70,000
HRR > 70,000
Particulate
= Heat Release Rate in Btu/hr-ft3
B
Allowable Emissions Emissions
Rate (lb/106 Btu) Reduction
1.2 90%
0.6
0.5
0.7
0.6
0.05
0.5 0%
0.8 90%
0.3
0.4
0.10
0.1
0.2
0.10
Slide 22-16
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SOURCE PERFORMANCE STANDARDS
Steam Generators with Heat Input 10-100 MMBtu/hr
Apply to Units Constructed After 6/9/89 or Significantly Modified Units
Fuel Pollutant Allowable Emissions Emissions
Rate (lb/106 Btu) Reduction
Coal SO2 1.2 90%
Particulate 0.05
Oil SO2 0.5
Wood Particulate 0.10
Slide 22-17
Boiler Operator Training """"
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ADDITIONAL STANDARDS
REQUIRING EMISSIONS CONTROLS
Acid Rain Program (Title IV)
-S02
- NO.
X
State Implementation Plans (SIP)
-NOX
- Hydrocarbons
- Particulate
National Emission Standard for
Hazardous Air Pollutants (NESHAP)
- Hazardous Organics
- Metals in Flyash
Slide 22 -18
Boiler Operator Training =Z
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ACID RAIN PROGRAM
Purpose
• Reduce annual SO2 emissions from electric utility power plants by 10 million tons
by the year 2000.
• Reduce NOX emissions from electric utility power plants by 2 million tons.
Sulfur Dioxide Control
Phase 1(1995)
- Emissions limited to 2.5 Ib/MMBtu for plants greater than 100 MW (111 affected
plants).
- SO2 allowance/trading scheme.
Phase II (2000)
- Emission limited to 1.2 Ib/MMBtu for nearly all power plants greater than 25 MW.
- Nationwide cap in utility SO2 emissions at 8.9 million tons per year.
Nitrogen Oxides Control
• Emissions limits to be established by EPA.
• Preliminary limits:
- Tangentially fired boilers = 0.45 Ib/MMBtu.
- Wall-fired boilers = 0.50 Ibs/MMBtu.
• EPA to establish limits for cyclone boilers, wet bottom boilers and boilers equipped
with cell burners.
EPA to revise NSPS.
Slide 22-19
Boiler Operator Training ~
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STATE IMPLEMENTATION PLANS (SIPs)
Plans for Implementing the Requirements of the Clean Air Act at the
State Level
SIPs Provide the Road Map for States to Meet NAAQS
Regulations May Apply to New and Existing Sources
Regulations May Be More Stringent than NSPS
SIPs Must be Reviewed and Approved by Federal EPA
As SIPs are Approved, Boiler Operators will need to Contact State
Regulatory Agencies to Determine Compliance Requirements
Slide 22 -20
Boiler Operator Training ^ZZ=ZZZZ==^^^=Z=:
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TITLE V - PERMITS
Comprehensive Program for Federal Operating Permits
Applies to Significant Sources of Air Pollution:
- Major Sources of Criteria Pollutants
- Sources Regulated by NSPS Provisions
- Sources Subject to NESHAP Rules
States to Develop Operating Permit Program Based upon
EPA Guidelines
EPA to Approve Program Plan
Annual Permit Fees - $25/ton of Pollutant, Except CO
Slide 22-21
Boiler Operator Training "
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STATE PERMIT PROGRAMS
Provisions for Permit Applications and Their Completeness
Requirements for Payment of Fees
Authority to Issue Permits
Provisions for Reopening and Terminating Permits
Provisions to Ensure Operating Flexibility
Permits to Contain Requirements for:
Compliance Certification
- Monitoring Requirements
- Reporting Requirements
Slide 22-22
Boiler Operator Training i...... .
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PERMIT INFORMATION REQUIREMENTS
Location
Type of Source
Owner/Operator Details
Source and Process Description and an
Alternative Operating Scenario
Emissions Inventory Information
Compliance Plan (if needed)
Compliance Certification
Slide 22-23
Boiler Operator Training =^==^=^=^^^=^^^=
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LESSON PLAN
CHAPTER 23. CONTINUOUS EMISSION MONITORING
Goal: To give the participant descriptions of CEMS classifications, CEM
components, analytical methods employed by analyzers, and operating
and maintenance procedures.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the general classifications of CEM systems and describe key
design differences.
2. Describe the major components of a CEMS and their respective
functions.
3. List the kinds of analyzers typically used in utility and industrial boilers.
4. Discuss analytical techniques typically employed in CEM analyzers.
5. Describe the maintenance requirements needed for a CEMS.
Lesson Time: Approximately 75 minutes.
Suggested Introductory Questions:
What kind of CEM analyzers are used at your facility?
Does anyone have first hand knowledge of operating a CEMS and can you
describe your system?
Presentation Outline:
23.1. Statement of Purpose
23.2. General Classifications of CEMS
A. In-situ
B. Extractive
23-1
-------
Presentation Outline (Continued):
23.3. Components of GEMS
A. Probe
B. Sample Transport Line
C. Conditioning System
D. Analyzer and/or Detector
E. Data Acquisition System (DAS)
23.4. Usage of GEMS in Utility/Industrial Boilers
23.5. Analytical Methods
A. Spectroscopic
B. Luminescence
C. Electrochemical
D. Paramagnetism
23.6. Opacity Monitors
A. Single-Pass Transmissometer
B. Double-Pass Transmissometer
23.7. Maintenance and Continuing Operations
A. Calibrations
B. Probe Blockage
C. Condensation
D. Leakage
23-2
-------
CHAPTER 23. CONTINUOUS EMISSION MONITORING
23.1 Statement of Purpose
23.2 General Classifications of CEMS
23.3 Components of CEMS
23.4 Usage of CEMS in Utility/Industrial Boilers
23.5 Analytical Methods
23.6 Opacity Monitors
23.7 Maintenance and Continuing Operations
Slide 23 - I
Boiler Operator Training -
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CLASSIFICATION OF CEMS
In-Situ
Extractive
Slide 23 - 2
Boiler Operator Training "
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IN-SITU CEM SYSTEMS
Readout
Analyzer
and Detector
Stack
Slide 23 - 3
Boiler Operator Training
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EXTRACTIVE CEM SYSTEMS
Heated
Transport
Line
Conditioning
System
Analyzer
and Detector
Readout
Stack Gas
Boiler Operator Training
Slide 23- 4
-------
CLOSE-COUPLED CEM SYSTEMS
Conditioning
System Analyzer
Stack Gas and Detector
Readout
Slide 23 - 5
Boiler Operator Training
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COMPONENTS OF CEMS
Heated
Transport
Llne Conditioning
System
Analyzer
and Detector
Readout
Stack Gas
Boiler Operator Training
Slide 23 - 6
-------
ANALYZERS TYPICALLY USED IN
UTILITY AND INDUSTRIAL BOILERS
Opacity
Oxygen (O2)
Carbon Dioxide (CO2)
Carbon Monoxide (CO)
Nitrogen oxides (NOX)
Sulfur Dioxide (SO2)
Flue-Gas Flow Rate
Slide 23 - 7
Boiler Operator Training =^^^^^=^=S^^^=^=
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ANALYTICAL TECHNIQUES
Spectroscopic
Luminescence
Electrochemical
Paramagnetism
Slide 23 - 8
Boiler Operator Training ZZI
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BASIC SPECTROSCOPIC INSTRUMENTATION
Light Wavelength
Source Selector
Sample
Vessel
Signal Processor/
Readout
Slide 23 - 9
Boiler Operator Training
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NDIR ANALYZER
Infrared
Source
Beam
Chopper
Sample
Exhaust
Sensor
Sample Cell
Reference Cell
Slide 23 - 10
Boiler Operator Training
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GAS FILTER CORRELATION ANALYZER
Light
Source
Blower
Beam
Alternator
Neutral Filter
Detector
Gas-Correlation
Cell
Electronics
Slide 23 - 11
Boiler Operator Training
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DIFFERENTIAL ABSORPTION ANALYZER
Measuring
Phototub*
Sam (transparent Mirror
(Beam Splitter)
Calibration Sample Cell
Filter S02/NOX
Reference
Phototube
Lamp
Recorder
Boiler Operator Training
Slide 23- 12
-------
ULTRAVIOLET FLUORESCENCE ANALYZER
Sample In
Lamp
Detector
Control
9hotomultlpller
Tube
Sample
Exhaust
Slide 23-13
Boiler Operator Training
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CHEMILUMINESCENCE ANALYZER
I
Flow Control Sample In
O3 Generator I
Photomultlpller
Tube
Sample
Exhaust
Signal
Boiler Operator Training
Slide 23-14
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POLAROGRAPHIC ANALYZER
Thin-Film
Membrane
Sensing
Electrode
Counter
Electrode
Signal Processor/
Readout
Slide 23- 15
Boiler Operator Training
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ELECTROCATALYTIC ANALYZER
Sensing
Electrode
Reference
Gas
ounter
I Electrode
Thin-Film
Membrane
Signal Processor/
Readout
Boiler Operator Training
Slide 23-16
-------
PARAMAGNETIC ANALYZER
Signal Processor/
Readout
Slide 23-17
Boiler Operator Training
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FLOW MONITORING TECHNIQUES
Techniques
Instrumentation or Sensor
Differential Pressure Sensing Head Meters, Pitot Tube, Annubar
Fluidic Sensor
Thermal Sensing
Acoustic Velocimetry
HeatedSensor
Ultrasonic Tranducers
Slide 23- 18
Boiler Operator Training
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VELOCITY AND VELOCITY PRESSURE
RELATIONSHIPS
V = K C [(T Ap)/(P M )T
s p p LV s • ' ^ s s7-1
Where: V = velocity of the gas
A
K = constant
P
C = pitot tube calibration coefficient
Ts = absolute temperature of the gas
Ps = absolute pressure of the gas
M = molecular weight of the gas
Slide 23-19
Boiler Operator Training ==^=^^=^==^=
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THERMAL SENSING SYSTEMS
A thermal-sensing
velocity probe
A hot-wire
anemometry sensor
Slide 23 - 20
Boiler Operator Training
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ACOUSTIC VELOCIMETRY
— (---}
2cosa MA tg /
Boiler Operator Training
Slide 23-21
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SINGLE PASS TRANSMISSOMETER
Collimaiing
tens
\
Light
source
Collima ting
lens
ACROSS-STACK
Detector
Rotary blower
Slide 23 - 22
Boiler Operator Training
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DOUBLE-PASS TRANSMISSOMETER
Coltima ting
lens
Light
source
Beam
splitter
Reflecting
mirror
yyiMIIMIIIIIIIIHIIIMIIIIIIMMIIIIIIMIIMMIIIIIIMIIMIIIIMIIIIIIIMIIIIMIIIIHMilMIIIIIUIIMlllliiiiill
* f^^ * • * '
T^r "*""
Detector -
ACROSS-STACK
\
Rotary blower
Boiler Operator Training
Slide 23 - 23
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OPERATION CHECKS
Routine Calibration
Probe Blockage
Condensation
Leakage
Optical Surfaces
Slide 23 - 24
Boiler Operator Training Z=
-------
CEMS MAINTENANCE CHECKLIST
Filter Cleaning
Sample Line Leakage Check
Optical Surface Cleaning
Pump Maintenance
Data Recording Equipment Check
Slide 23 - 25
Boiler Operator Training """
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LESSON PLAN
CHAPTER 24. PARTICULATE CONTROL
Goal: To present the participants with the design, performance, and
operation of some typical particulate control devices used on boilers.
Objectives:
Upon completion of this unit an operator should be able to:
1. List the control devices available for particulate removal from boiler
flue gas emissions.
2. Discuss the operating principles, performance advantages and
disadvantages, and operational characteristics of cyclones, ESPs,
and fabric filter particulate removal systems.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What are mechanical dust collectors? (Cyclones)
What are the advantages and disadvantages of using fabric filters for
particulate removal?
Presentation Outline:
24.1 Control Methods and Typical Arrangement
24.2 Cyclones
A. Design Principles
B. Performance
C. Operator Duties
24.3 Electrostatic Precipitators
A. Design Principles
B. Performance
C. Operator Duties
24.4 Fabric Filters
A. Design Principles
B. Performance
C. Operator Duties
24-1
-------
CHAPTER 24. PARTICULATE CONTROL
24.1 Control Methods and
Typical Arrangement
24.2 Cyclones
24.3 Electrostatic Precipitators
24.4 Fabric Filters
Slide 24 - 1
Boiler Operator Training "
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PARTICULATE CONTROL
Particulate Pollution Sources:
Boilers, Industrial Processes, Mining, Motor
Vehicles, Nature
Particulate Distribution in Boilers:
Bottom Ash, Convective Passes, Air Pollution
Control Device, Stack
Slide 24 - 2
Boiler Operator Training =
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PARTICULATE CONTROL DEVICES
Cyclone
Electrostatic Precipitator
Fabric Filter
Wet Scrubber
Side Stream Separator
Slide 24 - 3
Boiler Operator Training —-—————
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CYCLONE APPLICATION
Low Capture Efficiency
Poor Fine Particle Capture
Simple Operation and Maintenance
High Temperature Application
Slide 24- 4
Boiler Operator Training "
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CYCLONE DESIGN
Vertical Gas Chamber
Axial or Tangential Gas Entry
Swirling Gas Flow
No Moving Parts
Slide 24 - 5
Boiler Operator Training —
-------
Ascending Vortex
Inlet
CYCLONE
Clean Gas Outlet
Cone Apex
Radial Flow
Cone Outlet
Dust
Laden
-O
Clean
Gas Outlet
O-
Path
Of Dust
Tangential
Inlet
Axial Inlet
(Reprinted from "Pollution Engineering Guide to Fine Particulate Control in Air Pollution"
by P. Cherminisoff with permission from Conner Publishing)
Slide 24- 6
Boiler Operator Training
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CYCLONE PERFORMANCE
Capture Efficiency is Dependent on:
• Gas Velocity
• Chamber Diameter
• Particle Size, Density and Composition
Slide 24- 7
Boi ler Operator Training SSS^SS^ZI^^I^^II^^S^^S^^SI
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CYCLONE OPERATION
Pressure Drop and Inlet Gas Temperature are Routinely Monitored,
Inspection and Maintenance Requirement is Minimal.
Life Expectancy is Long.
Slide 24- 8
Boiler Operator Training ==
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ELECTROSTATIC PRECIPITATOR APPLICATION
• High Capture Efficiency
• Lowest Capture Occurs with 0.1 to 1 Micron Particles
• Extensive Monitoring Requirements
• Automatic Controls
• Low Routine Maintenance
Slute 24 - 9
Boiler Operator Training ————•————^—————'~~—"
-------
ELECTROSTATIC PRECIPITATOR
Cover Plate
Top End
Panel
Perforated Gas
Distribution
Plate
Gas Flow
Discharge Electrode
RaPPer ' Insulator
Compartment
Collecting
Plate Rapper
Bottom
End Panel
Side Panel
Electrode
Collecting
Plate
_ Hopper
Baffle
Discharge
Electrode
Weight
Hopper
(Reprinted from 'Pollution Engineering Guide to Fine Paniculate Control in Air Pollution"
by P. Chefminisoff with permission from Conner Publishing)
—————— Boiler Operator Training nz^nzizzz^zzzn:
Slide 24-10
-------
ESP DESIGN CHARACTERISTICS
Basic Physical Characteristics
Number of Fields
Number of Passages per Field
Wire-to-Plate Spacing
Collection Plate Surface Area
Wire (or Rod) Diameter
Aspect Ratio (Length to Height)
Electrical Characteristics
• Maximum Secondary Voltage
• Maximum Secondary Current
• Number of Sparks per Minute
Process Characteristics
Gas Volume Flow Rate
Even Flow Distribution
Particulate Loading
Gas Temperature
Particle Size Distribution
Particle Composition
Particle Resistivity
Slide 24-11
Boiler Operator Training
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ESP PERFORMANCE
Capture Efficiency is Dependent on:
• Specific Collection Area (SCA)
• Operating Voltage
• Particle Characteristics
Particle Size of 0.1 to 1 Micron is Hardest to Capture
Particle Resistivity in the Range of 2 x 10* to 2 x 10"
ohm-cm is Best for Performance
Slide 24-12
Boiler Operator Training SSSZZSS^ZZ^^^^^^sm^^Z^
-------
ESP MONITORING AND MAINTENANCE
Monitoring:
• Inlet Gas Temperature
• Gas Flow Rate
• Electrical Conditions
• Rapper Intensity
• Hopper Ash Level
Maintenance:
• Requires Highly Trained Personnel
• Requires Low Routine Maintenance
• Inspect for Electrode Misalignment, Pitting, Ash Build-Up,
Ash Hardening, Hopper Blockage, Electrode Insulation
Cracks, and Rapper Performance
Slide 24-13
Boi ler Operator Training SSS=^^=3^^^^^^SI^^S=
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FABRIC FILTER APPLICATION
High Capture Efficiency
Capture Efficiency Independent of Particle Characteristics
Frequent Routine Maintenance
Monitoring, Inspection and Maintenance is Simple
Slide 24 - 14
Boiler Operator Training =Z=Z=ZZZZ==Z^^=^^=
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FABRIC FILTER
Exhaust Duct
Fume BlowPipe
Sheet
Atmoshere
Manometer
Induced Flow
Collars
Venturi
Nozzles
Wire Retainers
Filter
Cylinders
Collector
Housing
Inlet
Hopper
Slide 24- 1!S
Boiler Operator Training
-------
PULSE JET
High Pressure Air
Inflates Bag to Dislodge Dust Cake
On-Line Cleaning
Vigorous Cleaning Limits Bag Life
Slide 24- 16
Boiler Operator Training —.. .
-------
REVERSE AIR
• Low Pressure Air
• Contracts Bag to Dislodge Dust Cake
• Off-Line Cleaning Requires Modular Fabric
Filter System
• Low Pressure System Provides Maximum Bag Life
Slide 24-17
Boiler Operator Training ZSZHZII=ZI=^IZ=:^=^^=:
-------
SHAKER
Mechanical Sinusoidal Bag Shaker
Off-Line Cleaning Requires Modular System
High Abrasion to Fabric
Slide 24-18
Boiler Operator Training —
-------
SONIC
Augments Other Cleaning Techniques
Sonic Waves Generates Acceleration and
Dislodges Dust Cake
Slide 24-19
Boiler Operator Training ~""
-------
FABRIC FILTER PROCESS MONITORING
Operation is Monitored by:
• Flue Gas Temperature
• Gas Flow Rate
• Pressure Drop
• Opacity
• CEM
High Pressure can Indicate:
• Binding or Plugging of Filters
• Excessive Gas Flow
• Inadequate Filter Cleaning
Low Pressure can Indicate that Leaks and
Holes Exist Across the Filters
Slide 24 - 20
Boiler Operator Training SUSZ^SSZZ^^^^^^^^^S^^^^^
-------
FABRIC FILTER MAINTENANCE
High Routine Maintenance is Required
Simple Operation, Maintenance and Repair Compared to
Electrostatic Precipitator
Periodic Inspection of Filter Bags for Tears, Holes, Abrasion,
Leaks and Dust Build-Up
Cleaning Cycle Timing, Effectiveness and Equipment
Typical Bag Life is 10 Years but can be Reduced to 2 Years for
Poorly Operated Device
Slide 24-21
Boiler Operator Training SSSSS^^^SS^^^^^^^^SH^^=
-------
LESSON PLAN
CHAPTER 25. NITROGEN OXIDES CONTROL
Goal: To present the participant the formation and control of NOX
emissions.
Objectives:
Upon completion of this unit an operator should be able to:
1. Describe the different oxides of nitrogen and their relative importance
to NOX.
2. Discuss the three sources of NOX formation from the combustion of
fossil fuels.
3. Describe the technologies available for NOX control which employ
combustion modifications.
4. Discuss NOX reduction by stage combustion.
5. Discuss NOX reduction by thermal NOX control.
6. Discuss the SCR and SNCR NOX control processes.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
Can you describe the NOX control strategy / technology used at your
facility?
How important is the fuel type to the NOX control methods used at steam
generating units?
Presentation Outline:
25.1 Nitrogen Oxides Control Overview
A. Sources
B. Species
C. Environmental Concerns
25.2 NOX Formation
25-1
-------
Presentation Outline (Continued):
25.3 Control of NOX Emissions
A. Combustion Modifications
1. Operation
2. Operator Duties
B. Post-Combustion Control
1. Operation
2. Operator Duties
25-2
-------
CHAPTER 25. NITROGEN OXIDES CONTROL
25.1 Overview
25.2 NOV Formation
rt
25.3 Control of NOX Emissions
Boiler Operator Training
-------
SOURCES OF NITROGEN OXIDES
Mobile Combustion Sources
Automobiles, Trucks
Stationary Combustion Sources
Power Plants, Heaters
Natural Combustion Sources
Forest Fires, Volcanos
Non-Combustion Sources
Nitric Acid Manufacturing
Boiler Operator Training
-------
NITROGEN OXIDES
Nitric Oxide (NO)
Nitrogen Dioxide (NO2)
Nitrous Oxide (N2O)
Nitrogen Trioxide (N2O3)
Nitrogen Pentoxide (N2O5)
Boiler Operator Training
-------
ENVIRONMENTAL CONCERNS ABOUT NO
Acid Rain
Damage to Structures
Damage to Water Quality & Fish Life
Sudden Release of Acids
Photochemical Smog
Impairs Human Health, Respiration
Stunts Growth of Vegetation
Oxidizes Materials
Boiler Operator Training
Slide 25- 4
-------
NO FORMATION - FOSSIL FUEL FIRED BOILERS
FUELNOX
Combustion of Chemically-Bound Nitrogen
in the Fuel with Oxygen
THERMAL NOX
High Temperature Reaction of Nitrogen with the
Oxygen and Nitrogen from Air
PROMPT NOX
Oxidation of Fuel Bound Nitrogen under Fuel Rich
Conditions
Boiler Operator Training
-------
IMPACT OF TEMPERATURE AND FUEL NITROGEN
ON NOX EMISSIONS
00
C!
O
• •-*
CO
GO
• l-H
$
O
fc
Nitrogen Content
Flame Temperature
Shapes of curves depend
on excess air level
Fuel Nitrogen Content
Flame Temperature
Boiler Operator Training
Slide 25 - 6
-------
NOY FORMATION REDUCTION TECHNIQUES
1. Decrease Primary Flame Zone Oxygen Level
a. Decrease Overall Oxygen Level
b. Controlled Mixing of Fuel and Air
c. Use of Fuel-Rich Primary Flame Zone
Decrease Time of Exposure at High Temperature
a. Decreased Peak Temperature
Decreased Adiabatic Flame Temperature
Decreased Combustion Intensity
- Increased Flame Cooling
Controlled Mixing of Fuel and Air
Fuel-Rich Primary Flame Zone
d. Decreased Primary Flame Zone Residence Time
Boiler Operator Training
-------
NOX CONTROL TECHNIQUES
Combustion Modifications
Low Excess Air Operation
Burners-Out-of-Service (BOOS) Operation
Overfire Air (OFA)
Reduced Air Preheat
Low NOX Burners (LNB)
Flue Gas Recirculation (FOR)
Reburning
Slide 25 - 8
Boiler Operator Training
-------
NO EMISSIONS AS A FUNCTION OF EXCESS AIR
en
CQ
CO
w
o
o
O
55
NO,
Excess Air (Boiler 02)
Boiler Operator Training
Slide 25- 9
-------
TYPICAL-BURNERS-OUT-OF-SERVICE PATTERNS
FOR FACE FIRED UNITS
o oooo
o ooo o
o o oo o
o o o o o
o o o o o
o oo o o
• O • 00
o» o»o
o o ooo
oo o oo
• o o o •
o • • • o
o oo o o
o oo o o
oo o oo
• •o ••
o o o oo
OOO 00
o • • • o
• o o o*
00*00
o o o o o
% Fuel Flow Terminated
O Burner in Service
Boiler Operator Training
Slide 25 - 10
-------
COMBUSTION ZONE NO. CONTROL
FGR-
CONVECTIVE
RADIANT
FURNACE
BURNER
ZONE
Boiler Operator Training
-------
NOX EMISSIONS AS A FUNCTION OF
AIR PREHEAT TEMPERATURE
0)
OT
a>
•rH
a
w
Oil Fired
Gas Fired
Air Preheat Temperature
Slide 25-12
B Boiler Operator Training
-------
BWE LOW NOX BURNER
Tertiary Secondary
Air
Ignitor Assembly
Boiler Operator Training
-------
NOX EMISSIONS AS A FUNCTION OF % FGR
o
•rH
CO
(A
• I—I
a
w
Percent FGR
• Boiler Operator Trpining
-------
GAS REBURNING CONFIGURATION
Overfire
Air Ports
Burnout
Zone
Returning
Zone
Primary
Combustion
Zone
Slide 25- IS
Boiler Operator Training
-------
OPERATING PARAMETERS TO MONITOR
CO Emissions
O2 Emissions
Superheater Steam Temperature
Reheater Steam Temperature
Boiler Efficiency
Soot/Slag Formation
Boiler Operator Training
-------
NOV CONTROL TECHNIQUES
Post-Combustion
Selective Non-Catalytic Reduction (SNCR)
Selective Catalytic Reduction (SCR)
Boiler Operator Training
-------
POST COMBUSTION NO¥ CONTROL SNCR
A
SECTIONS ^
M. **. *
Reagent
Injection
RADIANT
FURNACE
BURNER
ZONE
Boiler Operator Training
-------
SNCR PERFORMANCE FACTORS
Reagent Selection
Temperature Region: 1,600° - 1,800°F
CO Concentration
Residence Time
Reagent Injection Rate Keyed to NO
Gas Mixing Efficiency
Boiler Operator Training
-------
COMPETING REACTIONS OF AMMONIA
Reduction
4 NH3 + 4 NO + O2
Oxidation (Flue Gas too Hot):
4NH3 + 5O2
No Reaction (Cool Flue Gas, Ammonia Slip):
NH
NH
4N2 + 6HO
4 NO + 6 H2O
Boiler Operator Training
-------
CHEMICAL DECOMPOSITION OF UREA, CO (NHL)
2'2
CO(NH,)
272
NFL + HNCO (Iso-Cyanuric acid)
Boiler Operator Training
-------
SNCR POTENTIAL OPERATIONAL PROBLEMS
Furnace Temperature Variations
Furnace Velocity Variations
NO Increase if T > 2,000 °F
Ammonia Slip - Can React to Form
Ammonium Chloride & White Smoke
Slide 25 - 22
Boiler Operator Training
-------
POST COMBUSTION NO CONTROL SCR
SCR
REACTOR
STACK
PARTICULATE
CONTROL
RADIANT
FURNACE
CEM
N!I3 INJECTION
DISPOSAL /
RECYCLE
Slide 25 - 23
Boiler Operator Training
-------
SCR INJECTION GRID AND CATALYST BED
Exhaust
Gas
Ammonia Lance
NOX
NOX
NOX
NOX
.
© NH3
• NOX
© NH3
NOX
NH3
NOv
NO
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 26. SOXCONTROL
Goal: To give the participant an in-depth discussion of technologies
available for the control of SOX emissions.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the formation of acid rain from SOX emissions.
2. Discuss the fundamental concepts of wet scrubber operation.
3. Describe the advantage and disadvantages of wet scrubbing.
4. Describe the components of a wet scrubber system.
5. Describe the key components of a dry scrubber system.
6. Discuss the concepts of dry scrubber operation and the advantages
and disadvantages of dry scrubbing.
Lesson Time: Approximately 60 minutes.
Suggested Introductory Questions:
What is a flue gas scrubber?
What is the difference between a wet scrubber and dry scrubber?
Presentation Outline:
26.1 Introduction
26.2 Wet Scrubbers
A Operating Fundamentals
B. System Hardware
C. Operation and Maintenance
26.3 Dry Scrubbers
26.4 Furnace Injection
26-1
-------
References for Presentation Slides
Slide 26-5 "Fossil Fuel Fired Industrial Boilers - Background Information
Volume 1", EPA-450/3-82-006a, U.S. Environmental
Protection Agency, March, 1982.
Slide 26-6 Ibid.
26-2
-------
TER 26. SO CONTROL
26.1 Introduction
26.2 Wet Scrubbers
26.3 Dry Scrubbers
26.4 Furnace Injection
Slide 26 -
Boiler Operator Training, ^^Z^^^^^^^^^^^^^^ZZZ
-------
SCHEMATIC OF WET SCRUBBING SPRAY TOWER SYSTEM
Mist-
Eliminators
Cleaned
Tlue Gas
To Stack
Flue Gas From
Dust Collector
Limestone
Slurry Feed
w w^ w ^ ww w w w w w
\vf f yv\y1 yv.ravr ^ '
Wash
Water
/\ /A /\ /\ /\
Absorber
Reaction
Tank
To Slurry
Nozzles
Recycle Liquid
Spent
Solids Disposal
'/////////////////
Slide 26- 2
Boiler Operator Training
-------
WET LIMESTONE SCRUBBER CHEMISTRY
Gaseous SC>2
SO2 (gas) —> SO2 (aqueous)
SO2(aqueous) + H2O —> HSO3'
CaCO3 + H+ —> Ca++ + HCOg'
HSO3" + Ca"1"1" + 1/2H2O —> CaSO3»l/2H2O + H+
or
HSO3" + 1/2O2 + Ca"1"1" + 2H2O —> Gypsum
Slide 26- 3
Boiler Operator Training
-------
IMPACT OF SLURRY pH (ACIDITY)
ON SO2REMOVAL EFFICIENCY1
100
'S 90
o
a
(3 80
O
o
70
60
50
A
A
A
A
A
A
A
l/g=2.5 liters/cubic meter
AP = 4 inches water
Two Stage Absorber
456
Scrubber Effluent pH
8
Slide 26 - 4
Boiler Operator Training
-------
IMPACT OF LIQUID TO GAS RATIO
ON SO2 REMOVAL EFFICIENCY1
100
^ 95
o
I 90
tf
8 85
CO
g 80
I 75
70
AP = 10"
water
AP = 7" water
0
= 5.8to7.1
Single Stage Absorber
10 20 30
Liquid to Gas Ratio (gal/1000 acf)
40
Slide 26- 5
Boiler Operator Training
-------
VENTURI SCRUBBER SCHEMATIC
Gas
Scrubbing
Slurry
Drum Actuator
Liquid Outlet
Scrubbing
Slurry
Movable
Drum
Mist
Eliminator
Slide 26 - 6
Boiler Operator Training
-------
LIMESTONE REAGENT PREPARATION SYSTEM
Dry Limestone
Feed Bin
and Gate
Grinding
Water Supply
P i Weigh Feeder J
X
Hydroclone
Classifier
Overflow
Launder
Underflow
Launder
Limestone
Feed Tank
Main Process
Water
Dilution Water
Mill
Product
Tank
X
Mill
Product
Pump
Slide 26 - 7
Boiler Operator Training
-------
EXAMPLES OF MIST ELIMINATOR PATTERNS
111111
\\\\\\
111111
\\\\\\
Slats
Chevrons
Gas Flow Direction
err
Louvers
S Curves
Slide 26- 8
Boiler Operator Training
-------
WET SCRUBBER INSPECTION CHECKLIST
Equipment
Action
Frequency
Scrubber Module
Agitators
Mist Eliminators
Wash Water Nozzles
Dampers, Fans, Ducts
Limestone Mill
Slurry pump
Slurry pipes
Valves
Thickener
Instrumentation
Visually inspect for scale & corrosion
Inspect for corrosion and erosion
Check bearings and seals.
Check for scale
Monitor pressure
Inspect for corrosion and erosion
Inspect visually, lubricate
Check lining, bearings and seals
Check for deposits and wear
Test functionality, leakage, packing
Check coating for corrosion
Check moving parts for wear
Lubricate motor
Flush slurry lines
Calibrate
Annually
Annually
Based on history
Once per shift
Annually
Each usage
Annually
Annually
Annually
Annually
Annually
Frequently
Daily
Once per shift
Slide 26 - 9
Boiler Operator Training
-------
CONFIGURATION OF DRY SCRUBBING SYSTEM
Stack
Atomizer (Typ) /-Dry Scrubber
Air Heater ---i-
IXI
Baghouse
WWv
ID
Fan
i
Reagent Preparation System
Slide 26 - 10
Boiler Operator Training
-------
DRY FGR SCRUBBER SYSTEM SCHEMATIC
Lime
Silo
Stack
Atomizing Reheat
Air (Optional)
Partlculate
Collector
To Waste
Disposal
Recycle Solids
Slurrylng
Slide 26 - 1 1
Boiler Operator Training
-------
DRY SCRUBBING CHEMICAL REACTIONS
Gaseous SC>2
Slaked Lime - Ca(OH)2
SO2(gas) —> SO2 (aqueous)
SO2(aqueous) + H2O —> HSO3'
HSO3~ + OH~ —> SO3= -i- H2O
Ca(OH)2
2OH~
SO3~ + 1/2H2O —> CaSO3-l/2H2O
Slide 26-12
Boiler Operator Training
-------
EFFECT OF CALCIUM TO SULFUR RATIO
ON SO2 REMOVAL EFFICIENCY
100
~ 80
at
>
o
£
60
40
20
0
o
CO
|
(2
0
1 2
Calcium to Sulfur Ratio
Slide 26-13
Boiler Operator Training
-------
DRY FGD SCRUBBER SYSTEM SCHEMATIC
Humidification
Point
Injection Point
(Lime Sorbent)
Stack
Particular
Collector
Removal of
SorUnt & Fly Aih
Slide 26-14
Boiler Operator Training
-------
FURNACE SORBENT INJECTION
Slide 26-15
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 27. WATER POLLUTION
Goal: To describe to the participants the issues and causes of water
pollution relating to the operation of steam generating systems.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss EPA groupings of wastewater categories.
2. Describe the potential sources of aqueous discharge streams from a
utility boiler.
Lesson Time: Approximately 45 minutes.
Suggested Introductory Questions:
What are some possible causes of water pollution from a steam generating
facility?
Presentation Outline:
27.1 Aqueous Discharge Streams
27.2 Discharge Categories
27-1
-------
CHAPTER 27. WATER POLLUTION
Slide 27- I
Boiler Operator Training ZZZZ==Z=ZZZZ===Z=ZZZZZZI
-------
AQUEOUS DISCHARGES FROM UTILITY BOILERS
Cooling
Tower
Cooling Tower
and Condenser
Slowdown
Turbine
Coal Pile
Boiler
Bottom
Ash
Slowdown Water
Chemical Cleaning
Waste Liquid
Coal Pile
Water Runoff
YYV
FGD
(Scrubber)
Flyash
Water
Settling
Pond
I
FGD Waste
Treatment
and
Dewatering
Stack
FGD
Waste
Water
Slide 27 - 2
Boiler Operator Training
-------
ALLOWABLE CONCENTRATIONS OF POLLUTANTS
Waste Streams and Pollutants
All Discharges
pH (except once through cooling)
PCBs
Low Volume Waste*
Total Suspended Solids
Oil and Grease
Bottom and Flyash Transport Water
Total Suspended Solids
Oil and Grease
Chemical Metal Cleaning Waste
Total Suspended Solids
Oil and Grease
Copper
Iron
Once Through Cooling Water
Total Residual Chlorine
Cooling Tower Slowdown
Free Available Chlorine
Zinc
Chromium
Other 126 Priority Pollutants
Coal Pile Runoff
Total Suspended Solids
Concentration Limits (ing/liter)
Daily
Maximum
6-9
0
100
20
100
20
100
20
1.0
1.0
0.2
0.5
1.0
0.2
0
50
30 Day Rolling
Average
6-9
0
30
15
30
15
30
15
0.2
1.0
0.2
0.0
* Includes: water treatment, evaporator and boiler blowdown,
lab and floor drains, FGD waste water.
ZZZSmnz=ZZZ=: Boiler Operator Training ^^=Z
Slide 27 - 3
-------
SCHEMATIC OF ONCE THROUGH COOLING SYSTEM
Turbine ,
Discharge i
4.
I
' Boiler
1 Feedwater
Boiler Water
Condenser
Cooling Water
Heated
Water
wwwsww^^
Slide 27 - 4
Boiler Operator Training
-------
SCHEMATIC OF A COOLING TOWER
WATER CIRCULATION
Turbine i
Discharge •
*.
Boiler
Feedwater
Boiler Water
Condenser
Cooled
Water
Heated Water
Cooling
Tower
Tower
Slowdown
1 Makeup Water
D
Slide 27- 5
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 28. WASTEWATER TREATMENT
Goal: To describe to the participant the typical methods for wastewater
treatment.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss the methods commonly used for the removal of suspended
solids.
2. Discuss the methods of neutralization of pH and dechlorination of
waste waters.
Lesson Time: Approximately 30 minutes.
Suggested Introductory Questions:
What is the difference between acid and base solutions?
How can you control pH of a solution?
How does a settling basin operate?
Presentation Outline:
28.1. Removal of Suspended Solids
28.2. Neutralization
28.3. Dechlorination
Reference for Presentation Slides
R. A. Corbitt, "Standard Handbook of Environmental Engineering", McGraw
Hill Publishing Company, 1990.
28-1
-------
CHAPTER 28. WASTEWATER TREATMENT
28.1 Removal of Suspended Solids
28.2 Neutralization
28.3 Dechlorination
Slide 28 - 1
Boiler Operator Training ——
-------
CIRCULAR SETTLING BASIN
Peripheral
overflow weir
Sludge
scraper
Skimming scraper
"
Skimming trough
\
Influent
Effluent
Skimmings
removal
Sludge removal
Boiler Operator Training
Slide 28 - 2
-------
HORIZONTAL SETTLING BASIN
Influent
Baffle
Rotary skimmer
troLJ9h v Overflow weir
Effluent
Chain and flight skimmer
and sludge collector
Sludge removal
Slide 28 - 3
Boiler Operator Training ,
-------
BASIN DESIGN PRINCIPLES
1. Inlet Design
Minimize inlet velocities to avoid turbulence
and short circuiting
2. Settling Zone
Provide for calm conditions
3. Sludge Zone
Allow sufficient depth to allow sludge thickening
4. Exit Design
Minimize exit velocities to prevent short circuiting
Slide 28 - 4
Boiler Operator Training , Z^z::^Z^ZII=:^=I==I
-------
STATIC SCREEN SCHEMATIC
(
Triangled
screen
Solids
collector
Influent
Headbox
-* Effluent
Boiler Operator Training
Slide 28 - 5
-------
ROTARY SCREEN SCHEMATIC
Water level
Influent
Spray nozzles
\ Solids
\ collector
Effluent
Boiler Operator Training
Slide 28 - 6
-------
TITRATION CURVE FOR ACIDIC WASTEWATER1
12
10
Q.
0 10 20 30 40
mlofO.INNaOH
Slide 28 - 7
Boiler Operator Training ,
-------
NEUTRALIZATION AGENTS
Chemical Reagent Formula
Neutralization
Requirements,
mgflL*
Basicity
Acidity
Neutralization Factort
Calcium carbonate
Calcium oxide
Calcium hydroxide
Magnesium oxide
Magnesium hydroxide
Dolomitic quicklime
Dolomitic hydrated
lime
Sodium hydroxide
Sodium carbonate
CaCCh
CaO
Ca(OH)2
MgO
Mg(OH)2
[(CaO)o6(MgO)o4l
{[Ca(OH)2lo6
[Mg(OH)2]o4}
NaOH
Na2C03
1.0
0.560
0.740
0.403
0.583
0.497
0.677
0.799
1.059
1.0/0.56=1.786
0.56/0.56=1.000
0.74/0.56=1.321
0.403/0.56 = 0 720
0.583/0.56= 1.041
0.497/0.56 = 0.888
0.677/0.56=1.209
0.799/0.56=1.427
1.059/0.56=1.891
Sulfuric acid
Hydrochloric acid
Nitric acid
H2S04
HCI
HNO3
0.98
0.72
0.63
0.98/0.56=1.750
0.72/0.56=1.285
0.63/0.56=1.125
* The quantity of reagent required to neutralize I mg/L of acidity or alkalinity, expressed an
calcium carbonate.
t Assumes 100 percent purity of all compounds
Slide 28 - 8
Boiler Operator Training
-------
TWO-STAGE, CONTINUOUS NEUTRALIZATION SYSTEM
Neutralizing
chemical
pH controller
Influent
Neutralized
effluent
Slide 28 - 9
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 29. SOLID WASTES
Goal: To present the participant with discussion of solid wastes generated
from a boiler system and the impact of solid waste on water
contamination.
Objectives:
Upon completion of this unit an operator should be able to:
1. Identify fuel ash and flue gas desulfurization wastes as the primary
sources of solid waste from a boiler system.
2. Describe the distribution of ash typically found in an ash producing
boiler system.
3. Discuss ash handling systems commonly used to remove bottom ash
and fly ash.
4. Discuss the importance of ash characteristics and ash testing
methods.
5. Understand the concept of leaching of pollutants from ash into
groundwater.
6. Discuss methods of flue gas desulfurization waste handling and
disposal.
Lesson Time: Approximately 30 minutes.
Suggested Introductory Questions:
How are boiler solid wastes disposed?
Why are the melting characteristics of ash important to boiler design and
ash handling system design?
Presentation Outline:
29.1 Introduction
29.2 Bottom Ash and Fly Ash
29-1
-------
Presentation Outline (Continued):
29.3 Ash Removal and Handling Techniques
A. Bottom Ash Removal and Handling
B. Boiler Back Pass Ash Handling
C. Fly Ash Removal and Handling
29.4 Ash Characterization and Testing
A. Classification of Coal Ash
B. Elemental Analysis
C. Fusion Temperatures
D. Fuel Oil Ash Characteristics
29.5 Flue Gas Desulfurization Wastes
29.6 Handling of FGD Wastes
A. Wet Scrubbing Waste Handling
B. Dry Scrubbing Waste Handling
C. Sorbent Injection Waste Handling
29.7 Groundwater Contamination from Ponds and Landfills
Reference for Presentation Slides
Singer, J. G., Combustion: Fossil Power Systems, 3rd edition,
Combustion Engineering, Inc., 1981.
29-2
-------
CHAPTER 29. SOLID WASTES
29.1 Introduction
29.2 Bottom Ash and Fly Ash
29.3 Ash Removal and Handling Techniques
29.4 Ash Characterization and Testing
29.5 Flue Gas Desulfurization Wastes
29.6 Handling of FGD Wastes
29.7 Groundwater Contamination from
Ponds and Landfills
Slide 29 - I
Boiler Operator Training ""
-------
SOURCE OF SOLID WASTES
Fuel Ash
Flue Gas Desulfurization Waste
Slide 29- 2
Boiler Operator Training S^H^^I=SIIIl=z:=Z=l=H
-------
BOTTOM ASH AND FLY ASH
Source of Ash
Definition of Bottom Ash
Definition of Fly Ash
Slide 29- 3
Boiler Operator Training i
-------
ASH DISTRIBUTION FROM A COAL-FIRED BOILER
Pulverizers
ESP or
Fabric Filter
Bottom Ash Backpass Air Heater Flyash
20 to 40% Ash Flyash 50 to 70%
~ 5%
Stack
Boiler Operator Training
Slide 29 - 4
-------
ASH REMOVAL AND HANDLING
Bottom Ash Removal
Wet Bottom Systems
Dry Bottom Systems
Fly Ash Removal
Vacuum Pneumatic Systems
Pressure Pneumatic Systems
Slide 29 • 5
Boiler Operator Training .
-------
TYPICAL WET BOTTOM ASH SYSTEM
Water-Seal Trough
Overflow Boxes
Access Door
Sluice Gate
Weir Box
Drip Shield
Boiler Seal Plate
Enclosure
Vacuum/Pressure
Relief Assembly
Slope Nozzles
Rear Slope Nozzle
Slide 29 - 6
Boiler Operator Training
-------
SUBMERGED SCRAPER CONVEYOR FOR BOTTOM ASH1
Dewatering Slope
v.»*
-/-•
Water Level
f- Chain \
\
\
Co
,..>
Scraper Flights
Travel Wheels
Dry Return Trough
Transfer
Chute
Clinker
Grinder
Boiler Operator Training
Slide 29- 7
-------
DRY PNEUMATIC VACUUM FLYASH SYSTEM1
Precipitator
or Fabric Filter
Flyash Intakes^A/ V V V
Air Inlet >• T T T Y
Cyclone
Separators N. r>n /
Bag Filter
Mechanical
Exhauster
Discharge
otary Ash Conditioner
Slide 29 - 8
Boiler Operator Training
-------
DRY PNEUMATIC FLY ASH TRANSPORT SYSTEM
USING WATER EXHAUSTERS AS VACUUM PRODUCERS
Air Heater Hoppers
Maintenance ^^ \S Flyash
Gates ^AjJ-i / Intakes
Air Intake
Vent i
Air Separator
Preciprtator
Hoppers
Fluidizing
Air Blowers
Fluidizing
Air Heaters
Maintenance
Gates
Flyash Intakes
Air Intakes
Water Exhausters
I-- High-Pressure Water
To Ash Storage Pond
Slide 29- 9
Boiler Operator Training
-------
DRY PNEUMATIC-PRESSURE FLYASH SYSTEM1
(Alternate Bag Filter H
Vent to Precipitator Inlet
Air Inlet
Vi , ,-JP
Mechanical
Blower or
Compressor
Precipitator
or Fabric Filter
Air-Lock
Feeders
Rotary Ash Conditioner
Boiler Operator Training
Slide 29- 10
-------
VACUUM-TO-PRESSURE DRY PNEUMATIC FLY ASH SYSTEM1
Precipitator
or Fabric Filter
Fly ash Intakes—
Air-Lock Feede
Bag Filter
Primary &
Secondary
Cyclones
V
y^>v Ell
Mechnical (/\J
Blower M M
Surge
Transfer
Tank
Vent
Air Out
Mechanical
Exhauster
{x}-
Flyash
Silo
Spray Alternate:
To Fill Area
Slide 29 - 1 1
Boiler Operator Training
-------
ASH CHARACTERIZATION AND TESTING
Classification of Coal Ash
Elemental Analysis
Fusion Temperatures
Fuel Oil Ash
Slide 29-12
Boiler Operator Training S^SI==ZZ=ZZZ=::=ZZZZZ
-------
EXAMPLE ELEMENTAL ANALYSIS OF COAL ASH
Analysis of ash, % by wt.
S1O2
A120,
TiO.
Fe.
•••••••••••••••••••••••••••••••••••
••• JL« / \J
iTJLliV^
Kn
«V-/ •••••
.
vf««^
i ?7
•••• JL«M /
- -
lVJ.ll.v-/
••••••••••••••••••••*••••••••••••
vf»A /
vF*JLJL
"»vF /
JL Oldl
••••••••••••••••••••••••••••••
Boiler Operator Training
Slide 29-13
-------
INFLUENCE OF TEMPERATURE ON SPECIFIC ASH SHAPES
n
2
IT
3
ST
4
HT
5
FT
1. Cone before heating
2. IT Initial deformation temperature
3. ST Softening temperature (H=W)
4. HT Hemisherical temperature (H=0.5W)
5. FT Fluid temperature
Slide 29 - 14
Boiler Operator Training
-------
FUEL OIL ASH CHARACTERISTICS
Vanadium
Sulfur
Sodium
Slide 29-15
Boiler Operator Training """
-------
FLUE GAS DESULFURIZATION WASTES
Wet Scrubbing
Wet Sludge
Gypsum
Dry Scrubbing
Dry Sludge
Sorbent Injection
Dry Waste
Slide 29 - 16
Boiler Operator Training . ~~~
-------
FGD WASTE HANDLING
Pneumatic Systems
Hydraulic Systems
Pipelines
Conveyors, Aerial Trams
Trucks, Off-Road Vehicles
Railroads
Slide 29-17
Boiler Operator Training .
-------
GROUNDWATER CONTAMINATION
Ground
Leachate
and
Runoff
\
Leaching
Groundwater
Slide 29-18
Boiler Operator Training
-------
LESSON PLAN
CHAPTER 30. SOLID WASTE MANAGEMENT
Goal: To present the participant with the methods of solid waste
management including disposal, treatment, and utilization of solid
wastes from coal burning boiler systems.
Objectives:
Upon completion of this unit an operator should be able to:
1. Discuss wet disposal methods including ponds and reservoirs.
2. Discuss dry disposal methods and landfills.
3. Describe waste treatment methods such as dewatering, stabilizing,
and fixating.
4. Discuss possible utilization of solid wastes from boiler operations.
Lesson Time: Approximately 30 minutes.
Suggested Introductory Questions:
What methods of solid waste disposal does your facility use?
Presentation Outline:
30.1 Introduction
30.2 Disposal Methods
30.3 Wet Disposal — Ponds
A. Pond Configurations
B. Pond Design
30.4 Dry Disposal — Landfills
A. Landfill Configurations
B. Landfill Design
30.5 Treatment Methods
30-1
-------
Presentation Outline (Continue):
30.6 Dewatering
A. Settling Ponds
B. Dewatering Bins
C. Thickeners
D. Cyclones
E. Centrifuges
F. Vacuum Filters
30.7 Stabilization
30.8 Fixation
30.9 Utilization
A. Ash Utilization
B. FGD By-Product Utilization
C. Site Utilization
30-2
-------
CHAPTER 30. SOLID WASTE MANAGEMENT
30.1 Introduction
30.2 Disposal Methods
30.3 Wet Disposal - Ponds
30.4 Dry Disposal - Landfills
30.5 Treatment Methods
30.6 Dewatering
30.7 Stabilization
30.8 Fixation
30.9 Utilization
Slide 30- 1
Boiler Operator Training -.
-------
SOLID WASTE MANAGEMENT
Disposal
Treatment
Utilization
Slide 30- 2
Boiler Operator Training .
-------
DISPOSAL METHODS
Wet Disposal
Ponds or Reservoirs
Dry Disposal
Landfills
Slide 30- 3
Boiler Operator Training SSIZZZSISIIS^SSZ^^S^S
-------
POND CONFIGURATIONS
Diked Disposal Ponds
Incised Disposal Ponds
Sidehill Disposal Ponds
Cross-Valley Disposal Ponds
Slide 30- 4
Boiler Operator Training i
-------
GRAPHICAL ILLUSTRATION OF POND CONFIGURATIONS
Diked pond constructed above grade. Diked pond partially excavated below grade.
An incised disposal pond.
A sidehill disposal pond.
A cross-valley pond configuration.
Slide 30- 5
Boiler Operator Training
-------
LANDFILL CONFIGURATIONS
Heaped Landfill Configuration
Sidehill Landfill Configuration
Valley-Fill Disposal Configuration
Slide 30- 6
Boiler Operator Training i ""
-------
GRAPHICAL ILLUSTRATION OF LANDFILL CONFIGURATIONS
A heaped landfill configuration.
A sidehill landfill.
A valley-fill disposal configuration.
Slide 30- 7
Boiler Operator Training ""
-------
WASTE TREATMENT METHODS
Dewatering
Stabilizing
Fixating
Slide 30- 8
Boiler Operator Training *"""
-------
DEWATERING METHODS
Settling Ponds
Dewatering Bins
Thickeners
Cyclones
Centrifuges
Vacuum Filters
Slide 30- 9
Bni ler Operator Training "*"
-------
SELLING PONDS
Range of Solid Concentrations
lfr-50% FGD Slurry
20-70% Ash
Advantages
Simple Operation
Not Sensitive to Inlet Solid Content
Low Maintenance Costs
High Reliability
Disadvantages
Substantial Land Area
Unpopular with Regulatory Agencies
Solid Removal Difficult
Slide 30-10
Boiler Operator Training IS
-------
DEWATERING BINS
Range of Solid Concentrations
15-25% FGD Slurry
25-75% Ash
Advantages
Reduced Land Area
Relatively Simple Maintenance
Clear Water Produced
Attractive First-Stage Treatment
Disadvantages
Low Slurry Product Solids
Sensitive to Inflow Characteristics
New Technology
Complicated Operation Controls
Slide 30-11
Boiler Operator Training SSSSSSS^^=^^^^^=I
-------
THICKENERS
Range of Solid Concentrations
20-45 %FGD Slurry
Advantages
Reduced Land Area
High Throughput Rates
Established Technology
Disadvantages
Higher Capital Cost
Higher Maintenance Cost
More Complicated Operation
Slide 30-12
Boiler Operator Training "~
-------
A CONVENTIONAL GRAVITY THICKENER
Lift
Indicator
Center Drive
Unit and Lifting
Device
Launder
Drive Motor and
Gear Assembly
Walkway
Feedwell
V-Notch
WeirN.
""* ^~V T~^
High Press Back
Flushing Water Line
Discharge Trench
Underflow
Center Scrapers
Torque and
Rake Arms
Thixo Post
Plow Blades
Boiler Operator Training
Slide 30-13
-------
CYCLONES
Range of Solid Concentrations
35-65% FGD Slurry
Advantages
Low Space Requirements
Relatively Low Cost
Recover high Portion of Large Particles
Low Solid Content in Liquid Fraction
Disadvantages
Do Not Recover Fine Particles
Inefficient with Feeds over 15% Solids
Susceptible to Abrasion and Corrosion
High Liquid Content in Solid Fraction
Slide 30 -14
Boiler Operator Training i
-------
A CYCLONE3
Feed
Feed Inlet
Cross Section
Feed Chamber
Apex Opening
.-^- Overflow
Vortex Finder
Cyclone Diameter
Cone Section
Underflow
Boiler Operator Training
Slide 30-15
-------
CENTRIFUGES
Range of Solid Concentrations
40-65 %FGD Slurry
Advantages
Low Space Requirements
Accept Variation in Inflow
High Product Solid Content
Established Technology
Disadvantages
Do Not Produce Clear Liquid
High Cost
High Maintenance
Subject to Abrasion and Corrosion
Slide 30-16
Boiler Operator Training ZZ
-------
A SOLID-BOWL CENTRIFUGE
Differential Speed
Gear Box
( Rotating
Conveyor
Centrate
Discharge
I
\
Cover
Main Drive Shaft
-»• Feed Pipe
Bearing
Base Not Shown
Sludge Cake
Discharge
\
Slide 30-17
Boiler Operator Training
-------
VACUUM FILTERS
Range of Solid Concentrations
35-65 %FGD Slurry
60-75% Ash
Advantages
Low Space Requirements
High Products Solid Content
Consistent Product Quality
Disadvantages
High Cost
High Maintenance
Complicated Operation
Do Not Produce Clear Liquid
Slide 30-18
Boiler Operator Training . —'
-------
A ROTARY DRUM VACUUM FILTER3
Cloth Caulking
Strips
Automatic Valve
Air and Filtrate
Line
Air Blow-Back Line
Drum
Filtrate Piping
Cake-Scraper
Slurry Agitator
Slurry Feed
Slide 30-19
Boiler Operator Training
-------
STABILIZATION
• Addition of Dry Solids
• Increase Shear Strength
• Lower Permeability
• Lower Volume
• Can Be Rewetted
Slide 30 - 20
Boiler Operator Training ~
-------
FIXATION
Mixing with Alkaline Flyash
Mixing with Lime and Flyash
Mixing with Blast Furnace Slag
Mixing with Portland Cement
Slide 30-21
Boiler Operator Training. •
-------
UTILIZATION
Ash Utilization
Cement Manufacturing
Concrete Materials
Substituted for Sand or Gravel
FGD By-Product Utilization
Agriculture
Metals Recovery
Sulfur Recovery
Gypsum
Site Utilization
Landfill Construction Material
Slide 30 - 22
Boiler Operator Training i
-------
BOILER OPERATOR TRAINING
POST-TEST
Instructions The entire test is to be taken as a closed book test.
Wnte in your answer or circle the best answer on this sheet.
1. Identify which of the following that is not a fossil fuel boiler design.
a. fluid!zed bed
b. watertube
c. stoker
d. firetube
e. camot
2. The fuel delivery system for a fossil fuel boiler
a. only delivers fuel to the burners
b. prepares fuel for combustion
c. prepares fuel for combustion and transports it to the steam generator
d. transports steam to the steam turbines.
3. Name three air pollutants of concern generated by fossil fuel fired boilers.
a.
b.
c.
4. When steam pressure reaches the MAWP, the boiler
a. may burst or explode.
b. steam pressure is at the highest level allowable for safe operation.
c. will produce steam that is too hot.
d. will not produce steam at all.
5. The proper order for the convective pass components in a utility boiler from the
furnace section to the stack is
a. Superheater, reheater, economizer, air heater.
b. Reheater, superheater, air heater, economizer.
c. Superheater, reheater, air heater, economizer.
d. Reheater, superheater, economizer, air heater.
6. Radiant heat transfer predominantly occurs in the of a watertube boiler.
a. reheater
b. convective pass section
c. stack
d. furnace section
7. A rich fuel mixture will produce an oxidizing flame.
T
F
Post-Test Page 1
-------
8. Which of the following is not a balanced combustion equation?
a. lmolC+ lmolO2 > 2 mol CO2
b. 121bC + 321bO2 > 441bCO2"
c. 1 ft3 C + 1 ft3 O2 > 1 ft3 CO2~
d. 1 molecule C + 1 molecule O2 > 1 molecule CO2
9. Correct the concentration measurement of CO at 100 ppm to the standard dilution
rate of 3% excess O2, given the measurement was made with an actual excess O2
concentration of 9%.
10. Which item is not included in a coal proximate analysis.
a. volatile matter.
b. sulfur content.
c. heating value.
d. ash content.
11. What is the density of a fuel oil at 32 F if its specific gravity is 0.742, given that
the density of water is 8.328 Ib/gal at 60 F and 8.335 Ib/gal at 32 F? Ib/gal
12. Which of the following is never a part of the fuel preparation and delivery system
for oil fired boilers?
a. heating
b. steam atomization
c. mechanical atomization
d. pulverization
13. The low gas pressure switch in a natural gas fuel system is also known as a vaporstat
T
F
14. Why are lignite coals which are very soft and anthracite which is very hard, both
very difficult to grind?
15. The two general types of stoker boiler are the stoker and the stoker.
a. overfeed, underfeed
b. massfeed, tuyere feed
c. spreader, pulverized coal
d. none of the above.
16 Natural gas combustion can never produce soot or black smoke. Even when
operated with insufficient oxygen or incomplete combustion.
T
F
Post-Test Page 2
-------
17 CK SCK and CO are used to measure the efficiency of the combustion process and
the thermal heat transfer between the hot flue gasses and the steam
T
F
18. Stoker boilers are uniquely different from pulverized coal burners in that the fuel
particle size is for stokers.
a. smaller
b. much smaller
c. larger
d. much larger
19. A "D" style package boiler is a watertube boiler.
T
F
20. Gas turbines are comprised of three major components. The air is drawn into the
before being mixed with fuel in the . Energy is extracted from
the hot gas stream by the axial flow in the form of shaft horsepower.
21. The primary mechanism for NOx formation in gas turbines is
a. prompt NOX.
b. fuel bound Nitrogen.
c. thermal NOX.
d. none of the above.
22. Use Ohm's law to determine the current through a device with a resistance of 8
ohms when a voltage of 24 volts is applied. The current would be .
a. 3 amps
b. 0.67 amps
c. 1.50 amps
d. 36 amps
23. Using the above information, what is the power consumed by the device?
a. 36 watts
b. 24 watts
c. 10.67 watts
d. 72 watts
24. A two element control system can be configured into either a feed forward type
control system or a cascade type control system.
T
F
Post-Test Page 3
-------
25. Most pressure gauges are of the tube type
a. Bourdon
b. thermo-
c. straight
d. "a" and "c" above.
26. When a restriction such as an orifice, or a venturi is placed in the flow stream in an
enclosed duct or pipeline, the restriction will create a pressure drop in the line that is
linearly proportional to the velocity.
T
F
27. Exposure to low levels of carbon monoxide over an extended period of time is not
as dangerous as exposure to high levels of carbon monoxide for a short period of
time.
T
F
28. During turbine generator start-up the turbine metal temperature will rise to the
temperature of the steam supplied by the boiler. The turbine casing must be
warmed very slowly and carefully to avoid .
a. motoring
b. thermal expansion
c. excessive steam pressure
d. severe thermal stress
29. Critical turbine speed is the optimum speed for low turbine maintenance and long life.
T
F
30. The power factor is
a. the cosine of the phase angle difference between the voltage and current.
b. the ratio of the real power to the apparent power.
c. current times voltage
d. "a" and "b" above.
31. MSDSs should only be available to supervisors and managers.
T
F
3 2. Examples of primary air pollutants are
a. particulate matter, sulfur djoxide and hydrocarbons
b. photochemical oxidants and sulfates
c. hazardous metals and hazardous organics
d all of the above.
Post-Test Page 4
-------
33 Nitrogen oxides result from the combustion of all fossil fuels
T
F
34. Monitoring systems are categorized as either or CEMS according
to the location of the detection device used and the mean by which sample gas is
delivered to the analyzers.
3 5. Two levels of emission controls have been established for hazardous air pollutants.
These are?
a. LAER and BACT
b. RACT and BACT
c. MACTandGACT
d. BACT and GACT
36. Electrostatic precipitators are less efficient at removing fine paniculate than cyclones.
T
F
37. NOX emissions typically decrease as a function of increasing excess combustion air.
T
F
3 8. Which of the following is not a paniculate control device?
a. Cyclone
b. Electrostatic precipitator
c. Wet scrubber
d. SCR device
39. Name three species or parameters typically analyzed in utility and industrial boiler CEMSs.
a. .
b. .
c. .
40. Combustion of chemically-bound nitrogen in the fuel can form
a. Fuel NOX
b. Thermal NOX
c. Prompt NOX
d. Both "a" and "c"
41. Three techniques to reduce NOX in fossil fuel fired boilers are
a.
b.
c.
Post-Test Page 5
-------
42. Two techniques to control SOX emissions are
a .
b. .
43. Suspended solids can be removed from waste water streams by
a. blowdown.
b. agitation.
c. clarification.
d. neutralization.
44. Wet scrubbing technologies use a based scrubbing slurry.
a. limestone
b. ammonia
c. ash
45. Sunlight is an agent available for dechlorination of water and waste water.
T
F
46. A properly operating in situ monitor indicates 150 ppm of SC>2 in the flue gas, and
the moisture in the flue gas is known to be 12%. If and extractive instrument which
has and in-line dryer indicated 190 ppm of SC>2, then
a the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive analyzer is reading too low.
47. Two advantages of fluidized-bed combustion is that the system can be operated at
low combustion temperatures, and higher heat transfer rates from the fuel to the
watertubes can be achieved.
T
F
48. The Clean Air Act
a. allows the states to establish boiler emissions regulations that are
more strict than the federal standards.
b. prohibits the states from having emissions regulations that are more
strict than the federal standard.
c. instructs the USEPA to set boiler emission standards which
correspond to the maximum degree of control possible.
d. does not allow the consideration of economics in the setting of new
source performance standards.
Post-Test Page 6
-------
49 Adding dr\ solids to u, aste slurry to increase the solids content of the product is
a dewatenng
b stabilizing
c. fixating
d. neutralizing
50. High ash fusion temperatures will generally indicate low slagging potential.
T
F
Post-Test Page 7
-------
BOILER OPERATOR TRALMN'G
POST-TEST
Ansner Ke\
1 Identify which of the following that is not a fossil fuel boiler design.
a. fluidizedbed
b. watertube
c. stoker
d. firetube
e. carnot
2. The fuel delivery system for a fossil fuel boiler
a. only delivers fuel to the burners
b. prepares fuel for combustion
c. prepares fuel for combustion and transports it to the steam generator
d. transports steam to the steam turbines.
3. Name three air pollutants of concern generated by fossil fuel fired boilers.
a. nitrogen oxides carbon monoxide
b. sulfur oxides particulate matter
c. hydrocarbons
4. When steam pressure reaches the MAWP, the boiler
a. may burst or explode.
b. steam pressure is at the highest level allowable for safe operation.
c. will produce steam that is too hot.
d. will not produce steam at all.
5. The proper order for the convective pass components in a utility boiler from the
furnace section to the stack is
a. Superheater, reheater, economizer, air heater.
b. Reheater, superheater, air heater, economizer.
c. Superheater, reheater, air heater, economizer.
d. Reheater, superheater, economizer, air heater.
6. Radiant heat transfer predominantly occurs in the of a watertube boiler.
a. reheater
b. convective pass section
c. stack
d. furnace section
7. A rich fuel mixture will produce an oxidizing flame.
False
Post-Test Answers Page 1
-------
8. Which of the following is not a balanced combustion equation9
a. 7 mol C + 1 mol O2 > 2 mol CO?
b. 121bC + 321bO2 > 441bCO2
c. 1 ft3 C + 1 ft3 O2 > 1 ft3 CO2
d. 1 molecule C + 1 molecule O2 > 1 molecule CO2
9. Correct the concentration measurement of CO at 100 ppm to the standard dilution
rate of 3% excess O2, given the measurement was made with an actual excess O2
concentration of 9%. 750 ppm
10. Which item is not included in a coal proximate analysis.
a. volatile matter.
b. sulfur content.
c. heating value.
d. ash content.
11. What is the density of a fuel oil at 32 F if its specific gravity is 0.742, given that
the density of water is 8.328 Ib/gal at 60 F and 8.335 Ib/gal at 32 F? 6.18 Ib/gal
12. Which of the following is never a part of the fuel preparation and deb'very system
for oil fired boilers?
a. heating
b. steam atomization
c. mechanical atomization
d. pulverization
13. The low gas pressure switch in a natural gas fuel system is also known as a vaporstat.
True
14. Why are lignite coals which are very soft and anthracite which is very hard, both
very difficult to erindl Anthracite is difficult to grind because it is very
hard, however lignite typically has a very high moisture content
causing it to have a high tendency for agglomeration and making it
difficult to process through grinding equipment.
15. The two general types of stoker boiler are the stoker and the stoker.
a. overfeed, underfeed
b. massfeed, tuyere feed
c. spreader, pulverized coal
d. none of the above.
16 Natural gas combustion can never produce soot or black smoke. Even when
operated with insufficient oxygen or incomplete combustion.
False
Post-Test Answers Page 2
-------
17 CK SCK and CO are used lo measure the efficiencj of the combustion process and
the thermal heat transfer between the hot flue gasses and the steam
False
18. Stoker boilers are uniquely different from pulverized coal burners in that the fuel
particle size is for stokers.
a. smaller
b. much smaller
c. larger
d. much larger
19. A "D" style package boiler is a watertube boiler.
True
20. Gas turbines are comprised of three major components. The air is drawn into the
compressor before being mixed with fuel in the combustor. Energy is
extracted from the hot gas stream by the axial flow turbine in the form of shaft
horsepower.
21. The primary mechanism for NOx formation in gas turbines is
a. prompt NO*.
b. fuel bound Nitrogen.
c. thermal NOX.
d. none of the above.
22 Use Ohm's law to determine the current through a device with a resistance of 8
ohms when a voltage of 24 volts is applied. The current would be .
a. 3 amps
b. 0.67 amps
c. 1.50 amps
d. 36 amps
23. Using the above information, what is the power consumed by the device?
a. 36 watts
b. 24 watts
c. 10.67 watts
d. 72 watts
24. A two element control system can be configured into either a feed forward type
control system or a cascade type control system.
True
Post-Test Answers Page 3
-------
2 5 Most pressure gauges are of the tube type
a. Bourdon
b. thermo-
c. straight
d. "a" and "c" above
26. When a restriction such as an orifice, or a ventun is placed in the flow stream in an
enclosed duct or pipeline, the restriction will create a pressure drop in the line that is
linearly proportional to the velocity.
False
2 7. Exposure to low levels of carbon monoxide over an extended period of time is not
as dangerous as exposure to high levels of carbon monoxide for a short period of
time. v
False
2 8. During turbine generator start-up the turbine metal temperature will rise to the
temperature of the steam supplied by the boiler. The turbine casing must be
warmed very slowly and carefully to avoid .
a. motoring
b. thermal expansion
c. excessive steam pressure
d. severe thermal stress
29. Critical turbine speed is the optimum speed for low turbine maintenance and long life.
False
30. The power factor is
a. the cosine of the phase angle difference between the voltage and current.
b. the ratio of the real power to the apparent power.
c. current times voltage
d. "a" and "b" above.
31. MSDSs should only be available to supervisors and managers.
False
3 2. Examples of primary air pollutants are
a. paniculate matter, sulfur dioxide and hydrocarbons
b. photochemical oxidants and sulfates
c. hazardous metals and hazardous organics
d all of the above.
33. Nitrogen oxides result from the combustion of all fossil fuels.
True
Post-Test Answers Page 4
-------
34. Monitoring systems are categorized as either in situ or extractive CEMS
according to the location of the detection device used and the mean by which sample
gas is delivered to the analyzers.
35. Two levels of emission controls have been established for hazardous air pollutants.
These are?
a. LAER and BACT
b. RACT and BACT
c. MACT and GACT
d. BACT and GACT
36. Electrostatic precipitators are less efficient at removing fine paniculate than cyclones.
False
31. NOX emissions typically decrease as a function of increasing excess combustion air.
False
3 8. Which of the following is not a paniculate control device?
a. Cyclone
b. Electrostatic precipitator
c. Wet scrubber
d. SCR device
3 9. Name three species or parameters typically analyzed in utility and industrial boiler CEMS s.
a. carbon monoxide. d. oxygen.
b. nitrogen oxides. e. carbon dioxide,
c. sulfur oxides. f. opacity.
40. Combustion of chemically-bound nitrogen in the fuel can form
a. Fuel NOX
b. Thermal NOX
c. Prompt NOX
d. Both "a" and "c"
41. Three techniques to reduce NOX in fossil fuel fired boilers are
a. low NOx burners f. flue gas recirculation
b. low excess air operation g. overfire air
c. reduced air preheat h. selective catalytic reduction
d. reburning i. selective non-catalytic reduction
e. burners out of service operation
42. Two techniques to control SOX emissions are
a. wet scrubbing.
b. dry scrubbing.
c. furnace injection.
Post-Test Answers Page 5
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43. Suspended solids can be removed from waste water streams by
a. blowdown.
b. agitation.
c. clarification.
d. neutralization.
44. Wet scrubbing technologies use a based scrubbing slurry.
a. limestone
b. ammonia
c. ash
45. Sunlight is an agent available for dechlorination of water and waste water.
True
46. A properly operating in situ monitor indicates 150 ppm of 862 in the flue gas, and
the moisture in the flue gas is known to be 12%. If and extractive instrument which
has and in-line dryer indicated 190 ppm of SO2, then
a the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive analyzer is reading too low.
47. Two advantages of fluidized-bed combustion is that the system can be operated at
low combustion temperatures, and higher heat transfer rates from the fuel to the
watertubes can be achieved.
True
48. The Clean Air Act
a. allows the states to establish boiler emissions
regulations that are more strict than the federal
standards.
b. prohibits the states from having emissions regulations that are more
strict than the federal standard.
c. instructs the USEPA to set boiler emission standards which
correspond to the maximum degree of control possible.
d. does not allow the consideration of economics in the setting of new
source performance standards.
49. Adding dry solids to waste slurry to increase the solids content of the product is
a. de watering
b. stabilizing
c. fixating
d. neutralizing
50. High ash fusion temperatures will generally indicate low slagging potential.
True
Post-Test Answers Page 6
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TECHNICAL REPORT DATA
(Please read Instructions on reverse before completing)
REPORT NO.
EPA-453/R-94-057
2.
4. TITLE AND SUBTITLE
High Capacity Fossil Fuel Fired Plant Operator Training
Program - Instructor's Guide
7. AUTHOR(S)
Shirley Pearson, Matt Gardner, Quang Nguyen
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Energy and Environmental Research Corporation
18 Mason
Irvine, California 92718
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, NC 2771 1
15. SUPPLEMENTARY NOTES
James Eddinger, Office of
3. RECIPIENT'S ACCESSION NO.
5. REPORT DATE
September 1994
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-D1-0117
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
Air Quality Planning and Standards
16. ABSTRACT
This Instructor's Guide is part of a model State training program which addresses the training needs
}f high capacity fossil-fuel fired plant (boiler) operators. Included are generic equipment design
features, combustion control relationships, and operating and maintenance procedures which are designed
to be consistent with the purposes of the Clean Air Act Amendments of 1990. This training program is
not designed to replace the site-specific, on-the-job training programs which are crucial to proper
operation and maintenance of boilers.
The Instructor's Guide provides the basic materials for use by the course instructor. It presents the
course description and agenda, course goals, lesson plans, and pretest and post-test materials.
17.
KEY WORDS AND DOCUMENT ANALYSIS
«. DESCRIPTORS
Air Pollution Control Technology
Boilers
High Capacity Fossil Fuel-Fired Plants
Operator Training
18. DISTRIBUTION STATEMENT
Release Limited
b. IDENTIFIERS/OPEN ENDED TERMS
Boilers
Air Pollution Control
Training
19. SECURITY CLASS (Report)
Unclassified
20. SECURITY CLASS (Page)
Unclassified
c. COSATI FieldyOroup
21. NO. OF PAGES
600
22. PRICE
PA Form 2220-1
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