&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

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                                        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

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                                       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.

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                          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

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 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

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 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

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 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

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 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

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 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

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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

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 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

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 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

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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

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                             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

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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

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  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

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  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=^=

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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

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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

-------
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

-------
                              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

-------
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:^^=^^^=^=

-------
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

-------
   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

-------
FIRETUBE BOILER
   Boiler Operator Training
                            Slide 2 - 4

-------
    WATERTUBE BOILER
  Drum
 Wsterwall
 Tubes
Oowncomer
 Windbox
                                      Slide 2 - 5
          Boiler Operator Training

-------
CONVECTION PASS COMPONENTS
              Superheaters
              Reheater
              Economizer
              Air Heater
                                      Slide 2 - 6
           Boiler Operator Training HBSBsnBBa=srsses=====ssssan=]^

-------
NATURAL CIRCULATION IN A BOILER
                  Steam Out
             Fecdwater
                  Downcomer
                  (Not Heated)
                            Hent from
                            Combustion
                           Riser
                           (Heated)
                 Waterwall
                  Header
                                            Slide 2 - 7
               Boiler Operator Training

-------
WATER-SIDE COMPONENTS
          Feedwater pump
          Waterwalls
          Drum
          Downcomers
          Risers
                                    Slide 2 - 8
        Boiler Operator Training •Ba^EnsEE=a=^^=s=a=m3:scasss=aBs

-------
STEAM-SIDE COMPONENTS
        Steam Drum
        Superheater
        Desuperheater
        Reheater
        Safety Valves
        Boiler Operator Training
                                   Slide 2-9

-------
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

-------
DEMINERALIZATION TECHNIQUES
              Evaporation
              Membrane Treatments
              Reverse Osmosis
              Ion Exchange
                                        Slide 2-13
            Boiler Operator Training •••cBmi™«B8^s=^^^=3=^=^B^s:^

-------
                        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

-------
                              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

-------
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

-------
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^^^^^

-------
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^^^^

-------
COMBUSTION PROCESS COMPONENTS
               Fuel
               Primary Air
               Secondary Air
               Combustion Chamber
               Burners
               Fans
                                        Slide 3-3
              Boiler Operator Training

-------
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

-------
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

-------
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

-------
                   TYPICAL FAN DESIGNS3
Two-stage Axial Fan
Straight-Blade Centrifugal Fan
                                                       Slide 3-7
                        Boiler Operator Training

-------
HEAT TRANSFER MODES
          Radiation
          Conduction
          Convection
                                     Slide 3-8
       Boiler Operator Training m^ssBBssRaBssEs=sss=s^asEE=

-------
             COMBUSTION GAS CIRCUIT
          Drum
Fuel
                                           Flue Gas
                                           Treatment
                                                 ID Fan
                      Boiler Operator Training
                                                      Slide 3-9

-------
                       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

-------
                              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

-------
 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^^^^^^^^^^^^

-------
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                   —

-------
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

-------
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


-------
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

-------
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

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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                    •

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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 ^==^====

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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==!^====

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        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                    	

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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

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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

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    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                       ~~

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            BASIC MODES OF HEAT TRANSFER
                     Conduction
                     Convection
II                    Radiation
                                                Slide 5-15
                         Boiler Operator Training                ==

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HEAT TRANSFER PARAMETERS

     Heat Transfer Area
     Temperature Difference
     Conductivity
     Diflfusivity
     Velocity and Turbulence
     Relative Positions
                                      Slide 5 -16
             Boiler Operator Training :===^====Z=====Z=Z======:

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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

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                            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

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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

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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

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COMBUSTION DEPENDENT AIR POLLUTANTS
   Products of Incomplete Combustion (PIC)
      Paniculate
      Carbon Monoxide
      Volatile Organic Compounds (VOC)
   Nitrogen Oxides
                                     Slide 6- 3
                Boiler Operator Training

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  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

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GAS CONCENTRATIONS
 Mole Fractions
  Parts Per Million (ppm)
                           Slide 6 • 5
      Boiler Operator Training es=SBSBS5S=es^=^=E

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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

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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

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         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

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     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

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  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!

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GAS CONCENTRATIONS AT STANDARD DILUTION

              or
              or
3% O2, dry
0% O2, dry
12% CO,, dry
                 Boiler Operator Training
                                    Slide 6-11

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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=^========

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 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

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    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

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  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

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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

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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

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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 •••••••••••••••••••••••••

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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

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 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

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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

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      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

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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

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  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

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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

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     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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I   Radiation k»* in pc^nt of gross heal input (American Boiler Manufacturers Assoc.aiion)
                                                                                   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


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 o   o
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O

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^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 *
                     ne|QOjQQ|Qf^QQ|QqQQ|oqQO|Q
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 ——————————

-------
                             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

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Presentation Outline (Continued):
                    17.3  Electrical Power Equipment
                          A. Motors
                          B. Generators
                          C. Transformers
                          D. Other Equipment

                    17.4  Instruments and Meters
                                 17-2

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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

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STEADY DC AND OSCILLATING AC ELECTRON FLOW
                  Boiler Operator Training
                                         Slide 17-3

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    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^=======:=^=

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VOLTAGE OSC
1 fVr
I.Ur
0.8-
0.6

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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

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            OHM's LAW
VOLTAGE-CURRENT RELATIONSHIP

     Voltage = Current x Resistance

             V = IxR
               = V/R
                                   Slide 17-7

            Boiler Operator Training  =s==^^^^^=^^^=

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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

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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==^=^^^=^^=^^=

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GRAPHICAL RELATIONSHIP OF POWER
                            P = Power (watts)
                            I = Amperage (amps)
                            V = Voltage (volts)
          P=Ix V
= P/V
                 Boiler Operator Training
                                            Slide 17- 10

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    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===^^^^^^=

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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                   "

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TRANSFORMER WINDING SCHEMATIC
                Coils

                440V
                 1
                           T
220V
 i
           Primary Coil -*
             Secondary Coil

               Step-down Transformer
                Boiler Operator Training
                                            Slide 17-14

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SCHEMATIC OF 3-PHASE ELECTRIC CURRENT
                  v!7  K j
                 Oscillation, Degrees
                  Boiler Operator Training
                                          Slide 17-15

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   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=:==^==^^=^^^^=

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                             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

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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

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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 .

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STEAM GENERATOR EQUIPMENT & FLOW SCHEMATIC2
                    -t>
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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                 —

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STEAM CONDENSER SCHEMATIC
                    -Exhaust Steam Inlet
                         Condenser
                         Tubes     /- Cooling Water
                                 / OLrtlet
                                     Baffle
                                    Cooling Water
                                    Inlet
                Boiler Operator Training
                                               Slide 18- 4

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       AC GENERATOR1
Frame
Rotor
    Fan
                                   Stator
                                 Slip Rings
                               Stator Leads
             Boiler Operator Training
                                           Slide 18- 5

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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

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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

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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                 —

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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

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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^^^

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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

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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^^^^^^^^^=

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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=

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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

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Presentation Outline (Continued):
                     21.5  Secondary Pollutants
                           A. Photochemical Oxidant
                           B. Acid Deposition

                     21.6  Hazardous Pollutants
                           A. Metals
                           B. Organics
                                   21-2

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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

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           AIR QUALITY OVERVIEW
       Atmospheric Interactions
         Pollutant
         Emissions
        Sources
Y7////////////////////////////////////////W^
                         Boiler Operator Training

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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

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             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

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                  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

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               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

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        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

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    FORMATION OF PHOTOCHEMICAL OXIDANT
   Nitrogen Oxide
                        Sunlight
Reactive Hydrocarbons
Photochemical
Oxidant
                      Boiler Operator Training

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              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

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          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

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              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

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                            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

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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

-------
     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=:

-------
        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...... .

-------
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 =^==^=^=^^^=^^^=

-------
                            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  -

-------
CLASSIFICATION OF CEMS
       In-Situ
       Extractive
                                   Slide 23 - 2
         Boiler Operator Training                    "

-------
IN-SITU CEM SYSTEMS
                       Readout
              Analyzer
            and Detector
       Stack
                                        Slide 23 - 3
         Boiler Operator Training

-------
       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

-------
           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^^^=^=

-------
ANALYTICAL TECHNIQUES
       Spectroscopic
       Luminescence
       Electrochemical
       Paramagnetism
                                   Slide 23 - 8
          Boiler Operator Training                  ZZI

-------
BASIC SPECTROSCOPIC INSTRUMENTATION
   Light Wavelength
  Source  Selector
Sample
Vessel
                  Signal Processor/
                     Readout
                                              Slide 23 - 9
                   Boiler Operator Training

-------
                  NDIR ANALYZER
Infrared
Source
          Beam
         Chopper
                              Sample
                              Exhaust
                                                    Sensor
                        Sample  Cell

                       Reference Cell
                                                          Slide 23 - 10
                         Boiler Operator Training

-------
   GAS FILTER CORRELATION ANALYZER
 Light
Source
 Blower
 Beam
Alternator
                                    Neutral Filter
                                               Detector
                          Gas-Correlation
                              Cell
                                        Electronics
                                                    Slide 23 - 11
                     Boiler Operator Training

-------
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

-------
CHEMILUMINESCENCE ANALYZER
      I
              Flow Control  Sample In
              O3 Generator I
                    Photomultlpller
                      Tube
               Sample
               Exhaust
                               Signal
              Boiler Operator Training
                                           Slide 23-14

-------
           POLAROGRAPHIC ANALYZER
Thin-Film
Membrane
                                Sensing
                                Electrode
                                 Counter
                                Electrode
                                                Signal Processor/
                                                   Readout
                                                       Slide 23- 15
                         Boiler Operator Training

-------
      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

-------
      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

-------
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  ==^=^^=^==^=

-------
         THERMAL SENSING SYSTEMS
A thermal-sensing

  velocity probe
   A hot-wire

anemometry sensor
            Slide 23 - 20
                   Boiler Operator Training

-------
ACOUSTIC VELOCIMETRY
  — (---}
  2cosa MA  tg /
        Boiler Operator Training
                                   Slide 23-21

-------
       SINGLE PASS TRANSMISSOMETER
     Collimaiing
       tens
         \
Light
source
  Collima ting
    lens
                   ACROSS-STACK
                                            Detector
Rotary blower
                                                Slide 23 - 22
                    Boiler Operator Training

-------
        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

-------
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  "

-------
  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                        =

-------
PARTICULATE CONTROL DEVICES
            Cyclone




            Electrostatic Precipitator




            Fabric Filter




            Wet Scrubber




            Side Stream Separator
                                          Slide 24 - 3





              Boiler Operator Training —-—————	

-------
CYCLONE APPLICATION
   Low Capture Efficiency




   Poor Fine Particle Capture




   Simple Operation and Maintenance




   High Temperature Application
                                      Slide 24- 4




        Boiler Operator Training  "

-------
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

-------
 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

-------
          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                       ==

-------
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

-------
       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=

-------
   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^^=^^=

-------
         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

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TWO-STAGE, CONTINUOUS NEUTRALIZATION SYSTEM
          Neutralizing
          chemical
pH controller
         Influent
         Neutralized
         effluent
                                                      Slide 28 - 9
                         Boiler Operator Training

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                            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

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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                        ""

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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

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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  .

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      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

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   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

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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

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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 .                ~~~

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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

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                             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  -.

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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

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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                         ""

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WASTE TREATMENT METHODS
         Dewatering
         Stabilizing
         Fixating
                                    Slide 30- 8
           Boiler Operator Training                  *"""

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DEWATERING METHODS
        Settling Ponds
        Dewatering Bins
        Thickeners
        Cyclones
        Centrifuges
        Vacuum Filters
                                        Slide 30- 9
          Bni ler Operator Training                      "*"

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  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

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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

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    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                        "~

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    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

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        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

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        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

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      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

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      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

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 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 .                      —'

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      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

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 STABILIZATION
•   Addition of Dry Solids
•   Increase Shear Strength
•   Lower Permeability
•   Lower Volume
•   Can Be Rewetted
                                      Slide 30 - 20
       Boiler Operator Training                      ~

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      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. •

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     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

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                           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

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 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

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 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

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 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

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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

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 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

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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

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                          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

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 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

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 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

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  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

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 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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