BOILER LIGHT UP PROCEDURE

CCCW PUMP, ACW Pump & PHE should be in service.

CEP should be in service, condensate system charged up to Deaerator

D/A flushing will continue through Blow Down tank until feed water quality of Fe < 500 PPb is achieved. (Initial
Flushing)

Charge Steam to Deaerator and maintain its Water Temp at 80 0C

Take the water through FRS (30%) to Economizer & Furnace wall & fill the Separator tank up to 6~9m. Water
should not enter the Super Heater.

Open Eco. & Bottom ring header drains & flush for 30 min.

Open intermediate header drain & flush for 30 min.

Open Valve 361 or 361A & dump the water to Condenser CW return line. (Cold Flushing)

When water quality of Fe<500 PPb is achieved at separator outlet sampling point then open 361A valve & dump
the water to Condenser Hotwell.

10

Take BCP on line (Start the pump, give two bump start in 10 sec. for removing air pockets). Before starting ensure
proper BCP purging & filling has been done. Maintain feed flow > 630 TPH by controlling BCP Discharge CV.

11

Maintain Separator level by controlling FRS 30% valve & by 361 Dumping Valve.

12

Normalize Air & Flue path of boiler.

13

Confirm seal trough & Bottom ash hopper is filled.

14

Take both ID & FD Fans in service & maintain furnace pr. -500 to -1000 Pa. & wind box DP of 0.3 Kpa.

15

Set the SADC at 60% open position.

16

Set the purge air flow (700 to 800 TPH)

17

Start purge (5 min. purge time). Remember no MFT condition should persists.

18

After purge MFT will reset automatically.

19

Reset OFT & Do the oil leak test. If oil leak test is successful then proceed to the next steps.

20

First Open LORV and then open LOTV. After that open LOCV gradually & maintain oil pr. around 0.15 Mpa.

21

Charge the HFO Short Recirculation Line.

22

Ensure Aux. steam is Charged (from Aux. Boiler) & APH Soot blowing system is ready to operate. (Aux. Steam
pr.> 1 mpa. & temp. >2000C) Later while sufficient pr. & temp. of Main Steam is achieved then we should charge
APH soot blowing system from platen O/L.

23

Through the Auxiliary Steam start Deaerator Pegging.

24

Before going to light up start APH Soot blowing.

25

Charge HFO Heaters, Tank heating system, Steam tracing lines & maintain HFO tank temp to 700C & Heater O/L
temp to 1250C & HFO temp at firing floor should be around 100 to 1050C.

26

After achieving water quality of Fe < 200Ppb we can go for Boiler Light up.

27

Before Boiler light up, Boiler O/L MS SVs should be in open condition. All drains in MS, CRH, HRH lines should be
in open condition.

28

First Take BC-1 oil gun and ensure flame stability

29

After 20-30 min. take BC-3 oil gun.

Page 1 of 2

30

After 20-30 min. take BC-2 oil gun.

31

After 20-30 min. take BC-4 oil gun.

32

The temp. rise rate of furnace metal should be 10C/ min. upto 1000C & After that 1.5 to 20C/ min and the Pr. raising
rate should not be more than 0.12 Mpa/min.

33

At 0.2 Mpa separator pr. close all vents of separator.

34

Continue blow down through 361 & 361A (Hot blow down) at water temp. 180-2100C.

35

Completion criteria of Hot flushing is Fe< 50 PPB.

36

Take CPU on line when water quality of Fe< 500 Ppb is achieved at the time of HOT Flushing.

37

Charge Turbine gland steam from APRDS which can be charged from Aux. boiler or from other unit.

38

Start vacuum pump & raise the condenser vacuum -90kpa. (Turbine should be on barring).

39

At 0.3 to 0.4 Mpa close super heater vents & Drains except second pass bottom header drains.

40

Remember the temp at Flue Gas O/L should always be < 5380C.

41

Take AB tier oil guns one by one considering metal temp rising rate criteria.

42

If required control the oil pr. or retract oil gun. (Monitor furnace pr. & Separator Level while taking or retracting
oil guns).

43

Note boiler expansion in every hour.

44

Check line supports, leakages & any other abnormalities.

45

Raise the steam pr. up to 8.7 to 8.9 Mpa & temp to 3500C. This criteria is required for Turbine cold rolling.

46

Take PA Fan in Service and start Seal Air fan.

47

When Boiler >20% & APH O/L Air temp reaches > 1700C then we can take Coal Mill 1B or 1A.

48

Before taking mill in service we have to take 7 to 8 nos. oil guns for flame stability.

49

Before taking mill in service HP-LP Bypass should be taken in line, otherwise MFT occurs at RH Protection.

50

Monitor furnace pr. while taking Coal Mill in service.

51

SH & RH temp controller should be ready to operate when needed.

52

When first Mill loading will be >80% then take the second mill on line.

53
54

When second Mill loading will be >80% then take the third Coal Mill on line & the same process for next three
mills also.
After 4th Mill is taken & Load>200MW remove Oil Guns & Charge ESP. APH Soot blowing can be stopped once Oil
Guns are removed.

55

At 30 to 35% load when we cannot maintain separator level, throttle the BCP O/L CV & raise Feed flow. Maintain
the Eco. I/L feed flow > 700TPH. Then set the BCP O/L CV<20% & BCP Flow to 100TPH and then Stop the BCP

56

After wet to dry changeover maintain over heat degree (degree of sup. Heat at separator O/L) 20-300C.

Page 2 of 2