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Safety Valve Floating

Safety valve data

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Amitava Pal
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219 views

Safety Valve Floating

Safety valve data

Uploaded by

Amitava Pal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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By: Dhruv Garg

Engineer/Boiler
PS-TS
OBJECTIVE

The objective is to test the safety valves by


actually floating in the real conditions and ensure
that safety valves lift and set at recommended
values, whenever the operating pressure in the
pipelines shoots above its set pressure.
Types of Safety Valves used in Boiler
 Mechanical Spring Loaded Safety Valves

Work in fully auto condition without operator


control, whenever operating pressure in the line
shoots above the set pressure of the valve.

 Electro-matic Relief Valves (ERV)

Work in partially auto & partially at control of


operator, whenever operating pressure in the line
shoots above the set pressure of the valve.
SAFETY VALVES – LOCATION

Main Safety Valves are placed at Four locations in


the Boiler:

1. Drum
2. Main Steam Line
3. Cold Reheat Line
4. Hot Reheat Line
SAFETY VALVE – DATA SHEET (500MW)
Location Line Type Make No. Set Pr. Kg/cm2 g

Safety Valve 1750 WB 2 204.0, 206.0


(Mech. Type)
Drum Safety Valve 1740 WB BHEL 4 208.1, 208.1, 210.1,
(Mech. Type) 210.1
Super- Safety Valve 1740 WD BHEL 2 186.6, 186.6
heater (Mech. Type)
outlet Electromatic 1538 VX - 184.7, 184.7,184.7,
SAFETY (Main Relief Valve 10W BHEL 5 183.6, 183.6
VALVES Steam Line) (ERV)

Re-heater Safety Valve


Inlet (Mech. Type) 1786 WB BHEL 4 52.4, 52.4, 54.0, 54.0
(CRH)
Safety Valve 1786 WD BHEL 4 49.4, 49.4, 50.9, 50.9
Re-heater (Mech. Type)
Outlet ERV 1525 VX BHEL 4 48.9, 48.9, 48.4, 48.4
(HRH)
Activities Prior to the
Safety Valve Floating
1. Pre-Commissioning activities of the boiler, such as
a) Acid cleaning completed
b) Steam Blowing completed

2. Drip pan arrangement, its drain, body drain,


exhaust pipe, all the supports, and silencer of all
safety valves are erected & welded properly as per
recommended drawing.

3. HP/LP Bypass system commissioned and available


for operation from control room.
Activities Prior to the
Safety Valve Floating
4. Calibrated pressure gauges of required range
and Least count are mounted in Drum / SH
outlet location.

5. Expansion Trams for the measurement of boiler


expansion are erected at identified locations of
different elevations.
COMMISSIONING PROCEDURE
1. Start up procedure given in Boiler O & M manual to
be adopted for the start up of the boiler.

2. Boiler lighted up and pressure gradually raised to


around 30-40 kg/cm2

3. Cut in HP and LP Bypass System after charging


Main Steam Line and establish gradual steam
dumping operation.

4. Gradually increase firing rate through LFO/HFO


burners and at the same time, by regulating HP
Bypass system, raise the boiler pressure. During
this, pressure in CRH-RH-HRH are kept at lower
value of around 5-10 kg/cm2 by regulating LPBP
system.
COMMISSIONING PROCEDURE
5. Two Nos. of Drum Safety valves are to set at the
highest pressure of 210.1 kg/cm2 and therefore,
the pressure of the boiler is gradually raised to
that value.

6. While raising the pressure, boiler expansion


readings are taken at selected drum pressure
values, preferably at 50 kg/cm2, 100 kg/cm2
and 150 kg/cm2.

7. When the drum pressure reaches around 100


kg/cm2, gags are put to all drum and SH safety
valves except the valve to be floated and they
are hand tightened.
COMMISSIONING PROCEDURE
8. When the pressure reaches around 180-190 kg/cm2,
the safety valves is warmed up by manual popping
and for this, the popping arrangement provided is
made use off through rope. Once or twice the
manual popping done to clear the safety valves path
and also to warm up the valve.

9. Raise the Drum Pressure by gradually closing the


HPBP valves and float the valve. Note down the
pressure at which the safety valve floated –
Immediately after the valve floated, open HPBP
valves and reduce the Drum pressure fastly. If
required, firing rate also can be reduced. Note down
the pressure at which the safety valve resets.
COMMISSIONING PROCEDURE
10. Verify the set pressure, reset pressure and
percentage of blow down with the data sheet. The
valve to be refloated again after effecting the required
adjustments for set pressure and blow down.
(Refer O & M Manual for Safety Valve for safety valve
adjustments) till the safety valves are set as per data
sheet.
Maximum % of Blow Down is 5 %

11. The other safety valves in Drum and SH outlet


sections are floated on similar method as explained
above.

Note: Adjustment in the settings of the safety valve


requires high degree of expertise and it is better to call
an expert from Trichy
COMMISSIONING PROCEDURE
12. For floating safety valves in CRH and HRH lines,
LPBP valves are used in conjunction with HPBP
valves for pressure raising and lowering.
Floating of the valve, adjustments to be made
are all same as explained above.

13. While floating the safety valves of lower set


values, it is preferable to gag those safety
valves with higher set pressure and for which
setting already completed. This is mainly
intended to avoid simultaneous floating of more
than one valve while setting one valve.
COMMISSIONING PROCEDURE
14. During safety valve floating, exhaust pipes,
silencer, drip pans, drain lines are observed and
if any abnormality found, the same attended.

15. After completing the pressure setting of all


valves, all the gags of the safety valve are
removed and kept safely for any future use.
THANK YOU

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