Would like to share a story of a steam boiler at my work place with the details as below.
Capacity : 27mt/hr
ASWP : 24 bar
Working pressure : 21 bar
Fuel : palm fibre and shell.
Issue of concern : black smoke exceed 15minutes per 24 hrs.
Root cause :
A. high boiler steam flow during processing, (25-27mt/hr)
B. Fuel feed into boiler furnace only drop at front side of furnace and require boilerman to push it further at this moment black smoke will occur at boiler chimney.
Corrective action
1. High boiler steam flow.
A. Fine tune on sterilizer program by reducing opening of make up valve.
B. Close sterilizer inlet valve during 1st and 2nd peak blow off.
C. Repair leak steam traps at kernel silos, steam main line and engine room.
D. Replace BPV surplus valve metal seat to reduce steam wastage.
Result.
Steam flow able to reduce to 22mt/hr
2. Fuel distributions
A. Dismantle fuel feed duckting and mudalating damper duckting, check on Mudalating damper impeller and ensure all are parallel.
B. Repair fuel feel duckting m.s damper. Reduce gap between and smothen the adjustment mechanism.
C. Clear all solidify fuel stuck at cast iron chute.
Result
A. Fuels able to be distributed evenly in furnace.
Final result.
A. Black smoke emission is averaging 5-6 minutes / 24 hours.
