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Purpose
The purpose of the SOP of “Boiler Cold start-up” is to train and guide operation personnel for optimum and safe
operation of the system.
2. Scope
This SOP defines the lineup, pre checks, permissive, operation procedure, Post startup checks, interlocks &
protections for Boiler cold start up.
: ANN_BCD_E17_OPSOP_01_U_2
: ANN_RKT_E17_OPSOP_01_U_2
: ANN_RKT_E17_OPSOP_01_U_3
: ANN_RKT_E17_OPSOP_01_U_4
6. O & M parameters
No. & Capacity: 1 per unit
15. Abbreviation
8 CBD,IBD,EBD Continuous/intermittent/emergency
ANNEXURE: ANN_BCD_E17_OPSOP_01_U_1,3,4
Reference SOP : E17_OPSOP_01
Applicability to generating unit(s) : U# 1,3,4
6. O & M parameters
No. & Capacity: 1 per unit
Design Code CFBC # 1 CFBC # 3& 4
ID FAN OFF
SA FAN OFF
PA FAN OFF
EMERGENCY TRIP
Temperature Vs Time
Checks during boiler Lit- Up.
1. Reduce steam generation up to 60 TPH by adjusting coal and air flow. And reduce load on TG as per pressure.
2. Maintain steam temperature as per design value 535 C by adjusting attemprator control valve in manual
mode.
3. Maintain drum level by 0-40 % valve.
4. Stop ash recirculation to boiler and divert ash from all fields, APH to main ash silo side.
5. Close gate valve of coal feeder inlet chute and empty both coal feeder. And close attemprator manual
isolation valve.
6. Then send the operator to MSSV floor with valve key.
7. When temperature comes 505 C then close Main steam stop valve. And check it is fully closed or not.
8. Confirm the close limit switch of MSSV. If not confirm, then close the valve manually immediately.
9. All fans kept running condition.
10. Stop one boiler feed pump.
11. Discharge ESP all field.
12. Keep operation of rapping system
13. Operate ash conveying system to Main ash silo side till all hoppers not empty.
14. Open Drum vent valve at Drum pressure comes 3.0 kg/cm2.
15. After complete depressurizing of boiler open both valve of start up vent.
16. When bed temperature comes 70 C then stop the PA, SA fan.
17. Adjust the furnace draft around -15 to -20 MMWC.
18. Drain furnace bed material if there is a requirement related to maintenance.
15. Abbreviation
8 CBD,IBD,EBD Continuous/intermittent/emergency
6. O & M parameters
No. & Capacity: 1 per unit
10. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
11. Ensure power availability of all Equipments
12. All Fans are available.
13. LDO system is available.
14. APH are available.
15. Coal Bunker level is sufficiently maintained.
16. Sand Bunker level should be sufficient in furnace.
17. Sufficient DM water is available.
18. Light up clearance available from all service departments and to be signed by all concerned personal.
19. Main Steam Stop Valve & Its Equalizer is operative.
20. All Motorized & Control Valves are operative.
21. Ensure availability of Bottom ash & Fly ash system.
22. Ensure availability of BFP.
23. Availability of Flue Gas Path.
24. Availability of Air Path.
25. Ensure that Ring Header Drains are closed.
26. Cooling water system of all Boilers related equipment should be charged.
27. Ensure availability of Instrument air to all equipments.
28. Ensure availability of service air.
29. Check availability & healthiness of Oil guns & Igniter system.
30. Ensure drum vents/ SH vents/ RH vents/ Economizer vent/ DSH vent kept in open position.
31. Ensure that all SH drains are open.
32. Ensure all low pressure boilers filling line valves kept closed.
33. Ensure that Main Steam Stop valve & its equalizer are closed.
34. Ensure SH spray control station is isolated.
35. All instrument gauges and impulse lines are charged and functional.
36. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
37. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
38. All sample coolers are charged.
39. Ensure that all safety valve in operative condition.
40. Ensure readiness of EMSV (Manually pilot valve checking)
41. Check the smooth operation of the following dampers, gates and valves before lit up-
42. ID/SA/PA fan inlet damper/ gate
43. ID/SA/PA fan outlet damper/gate
44. HGG should healthy.
45. Feed water control valves.
46. Spray water control valve.
47. All auxiliary and coal air damper
48. Feed check valve.
7.3 Interlocks & Protections ( Boiler Trip Interlock)
Interlocks Protections
ID FAN OFF
FD FAN OFF
PA FAN OFF
EMERGENCY TRIP
FURNANCE PRESSURE VERY HIGH
DRUM PRESSURE
8. Startup sequence
1. Start ID fans, PA fans & FD fans.
2. Maintain furnace draught @ -3 mmwc.
3. Open PA & FD damper of compartments no.1 &4.
4. Set FD air flow @ 50 TPH.
5. Charge Bed material from compt.no.1 & 4.
6. Open PA & FD dampers of compartment no.2 & 4 intermittently to allow fluidisation/bed material flow.
7. Charge Bed material till wind box pre.>450mmwc in all four compartments.(Static Bedht. should be
350mmwc)
8. Check fluidization in all compartments.
9. After satisfactory fluidization & bed ht. achieved close PA & FD dampers of compartments no.2, 3 & 4 .Keep
open only 1st compartment PA & FD damper.
10. Keep open Bleed off v/v of compartments no.2, 3, & 4.
11. Start boiler fill pump & ensure water flow through compt.no.1 DP plate.
12. Set FD air flow through compt.no.1 @ 35-40 TPH.
13. Start pilot burner.
14. Take one main oil burner after ensuring stable flame of pilot burner.
15. Take 2nd main burner in line only after achieving HGG O/L temp.>250c.
16. HGG O/L Temp. Should not increase more than 800c.
17. Clean all PA lines of compt.-1 & increase PA header pressure @ 1200mmwc.
18. Gradually raise bed temperature of compt.1 up to 550 C.
19. Start coal feeding through coal feeder with minimum speed.(@ 20% reference)
20. Check furnace for proper fluidization & sparking of coal/flame of coal in furnace.
21. Adjust coal feeding & raise bed temperature up to 850 C .
22. Give short mixing (@ 2 to3 min.) in compartment no.2 by opening PA & FD dampers to
23. raise bed temperature .At the time of mixing bed temp. of compt.1 dropped sharply.
Note: Do not allow to drop bed temperature below 800C in compartment no.1 at the time of mixing in
compt.2 i.e. closes PA & FD line dampers of compt.2 when bed temp.in compt.1 reaches up to 800C.
24. After @ three to four mixing bed temp. in compt.2 raise upto 600C.
25. Then Keep open PA & FD line dampers of compartment no.2 & charge coal through coal feeders with
minimum speed. Adjust the coal feeding & raise bed temperature upto 850C.
26. Close all steam side vents when drum pressure increase 2 to 3 kg/cm2.Keep start up vent fully open to raise
steam temp.& for circulation of steam flow through tubes.
27. Close steam side drains when drum pressure reaches more than 5kg/cm2.
28. Adjust air flow & coal feeding in compt.1 & 2 to maintain bedtemperature@850C.
29. Stop the burner when bed temperature in both the compartments are healthy.
30. Raise the steam pressure & temperature gradually.
31. When boiler steam pressure reaches upto 58kg/cm2 & steam outlet temp.upto 480C open stopv/v.
32. Close startupventv/v gradually by maintaining steam pressure & temperature.
33. Now boiler in line with another running boiler(CFBC).
34. Increase coal feeding as per requirement to maintain boiler pressure & steam temperature.
35. Give three to four mixings as mention above in 3rd compartment & raise its bed temp. upto 600C.
36. Charge coal with minimum speed in compartment no.3 & raise bed temp. @850C by adjusting air flow(65TPH)
& Coal feeding.
37. Adjust attemperature c/v to maintain steam outlet temperature.
38. Same way compartment no.4 to betaken in service as per steam load demand.
39. Stop the boiler fill pump when HGG O/L temp.<250C.
40. Close HGG augmentation air damper.Start ID fan by checking all start up permissive and purge the boiler.
9. Operation monitoring & control
1. Check the bearing temperature & vibration.
2. Maintain the PA header pressure normal.
3. Maintain bed temperature up to 900 C by.
4. Maintain bed height around 600 mmwc.
1. Reduce steam generation by adjusting coal and air flow. And reduce load on TG as per pressure or taking
load on other boiler.
2. Maintain steam temperature as per design value 485 C by adjusting attemprator control valve in manual
mode.
3. Maintain drum level by main FCS control valve.
4. Then send the operator to MSSV floor with valve key.
5. When temperature comes 475 then close Main steam stop valve. And check it is fully closed or not.
6. Confirm the close limit switch of MSSV. If not confirm, then close the valve manually immediately.
7. All fans kept running condition.
8. Discharge ESP all field.
9. Keep operation of rapping system
10. Operate ash conveying system to Main ash silo side till all hoppers not empty.
11. Open Drum vent valve at Drum pressure comes 3.0 kg/cm2.
12. After complete depressurizing of boiler open both valve of start up vent.
13. When bed temperature comes 70 C then stop the PA, SA fan.
14. Adjust the furnace draft around -05 MMWC.
15. Drain furnace bed material if there is a requirement related to maintenance.
11. Best practices followed (If any): Not Applicable
15. Abbreviation
8 CBD,IBD,EBD Continuous/intermittent/emergency
6. O & M parameters
7. Startup Sequence:
7.1 Physical Checks:
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Light up clearance available from all service departments and PROTOCOL to be signed by all concerned
personal.
3. Ensure healthiness of lube oil system of all equipments.
4. Ensure cooling water system (like ID fan, Static ash cooler, Bad ash cooler etc.) of boiler related equipment is
charged.
5. Ensure availability of Instrument air & service air to all equipments & pressure is greater than 5kg/cm 2.
6. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
7. Ensure all motorized & control valves are available & operative.
8. Ensure all IGV & dampers are available & operative.
9. Ensure all instrument gauges and impulse lines are charged and functional.
10. Ensure all the drives ID, SA & PA Fans are available & electrically normalised.
11. Ensure Coal Bunker level is sufficiently maintained for start-up.
12. Ensure both DCC is available & bunker coal rod gate is in open condition.
13. Ensure both CASF & both BAC is available & electrically normalised.
14. Ensure availability of bottom ash & Fly ash conveying system.
15. Ensure LDO system is available & LDO tank level is sufficient for lit-up.
16. Check availability & healthiness of Oil guns & Igniters system.
17. Ensure ESP rapper is started and ESP hopper heater switched ON before boiler lit-up.
18. Ensure Sufficient DM water is available for boiler start-up.
19. Ensure availability of BFP.
20. Ensure DM water filled up by cold filling line along with N 2H4 & NH3 up to boiler Lit-Up drum level.
21. Ensure power availability of all Equipment
22. Ensure that all safety valve is in operative condition & gagged were in removed.
23. Ensure following valves are in closed condition before cold start up:
24. All feed control station drains, down comer LHS & RHS drains, both Eco-1 & 2 drains, Evaporator drain, Rear
wall drains, side wall drains, attemperation stage-1 & 2 drains,
25. All Feed water station & attemperation station valves (FW # 202, FW-209, FW-210, FW-211, FW # 264, FW #
265, FW # 266, FW # 267, FW # 268, and FW # 269).
26. Main Steam stop valve & its equalizing valve (MS #202 A, MS #202 B).
27. Main steam vent (i.e. 80NB vent).
28. Ensure following valves are in open condition.
29. Steam Drum vent, MS line steam vent & super heater-1 outlet vent.
30. Super heater 1, 2 & 3 drain valves, MS line drain (MS-204 & MS-205), isolation valves of Electrometric safety
valve, Feed water station isolation manual valve (FW #215), attemperation stage-1 & 2 manual valves (FW-
270, FW-271, FW-272 & FW-273,).
31. Open all three manual valve after feed water control valves (FW CV 104-A, 104-B & 104-C)
32. “Primary air” to both siphon manual valve.
33. Both Bad ash cooler’s bottom ash inlet manual valve.
34. Both Cyclone screw feeder ash inlet manual valve.
35. Variable/constant load hanger supports are unlocked.
1st hour 2nd hour 3rd 4th hour 5th hour 6th hour
hour
Temperature at end of hour in degree 100 190 320 450 600 850
Temperature rise rate (deg/min) 1.0 1.5 2.2 2.2 2.5 4.2
Bed
temp
in
˚C
Time in Minutes
12. Exception/ Emergency handling : Refer to Boiler Emergency handling procedure SOP
13. Dos & Don’ts:
DO’s DON’Ts
Check all the permissive. Close the APH bypass damper and gate
when the flue gas temperature <120 o C.
Monitor the expansion of the boiler.
Don’t bypass any protection.
Check for the flame healthiness through the peep hole
when oil gun firing is done.
Scope : This annexure covers the 11,12,14 &15 clauses of SOP E17_OPSOP_01
6. O & M parameters
No. & Capacity: 1 per unit
15. Abbreviation
8 CBD,IBD,EBD Continuous/intermittent/emergency
ANNEXURE: ANN_MUR_E17_OPSOP_01
6. O & M parameters
No. & Capacity: 1 per unit
Design Code Specification
2. Start up interlock
2a. HSD pump running
2b. HSD pressure high
2c. Burner gun atomising pressure lo
2d. HSD pressure Lo
2e. HSD to burner-1 gun shut off valve close condition
2f. HSD to burner-2 gun shut off valve close condition
2g. Scavenging air to Burner-1 valve close condition
2h. Scavenging air to Burner-2 valve close condition
2i. Atomising air to burner-1 shut valve close condition
2j. Atomising air to burner-1 shut valve close condition
2k. BMS start permissive ok
2l. Emergency stop push button not released
2m. Scanner cooling air pressure low
2n. Combustion air pressure low
2o. Instrument air pressure Low
2p. Oil outlet pressure low
2q. Fire control valve at low fire condition
3. Purge permissive
3a. Any burner scavenging not started
3b. Common trip interlock ok
3c. Start up interlock ok
4. Air flow >30% and <40%
5. Burner start permissive
5a. HSD to burner-1 gun shut off valve close condition
5b. HSD to burner-2 gun shut off valve close condition
5c. Scavenging air to Burner-1 valve close position
5d. Scavenging air to Burner-1 valve close position
5e. Purge complete
5f. Flame on
5g. Atomising air to burner gun shut off valve close position
5h. Common trip interlock condition ok for both burner
6. Burner ready to fire
6a. Burner start command
6b. HSD to burner shut off valve close condition
6c. Combustion air damper at low fire position
6d. Burner start permissive
6e. Burner start delay after scavenging
6f. burner running
6g. Burner trip interlock ok
6gi. Burner flame not fail
6gii. Oil inlet pressure Lo Lo
6giii. Oil inlet pressure Hi Hi
6giv. Atomising air pressure Lo Lo
Any SA >9000m3/hr
8. Startup sequence
41. Charge Instrument air & service air to all equipments.
42. Boiler filled up to Normal Drum Level.
43. Start fluid coupling pump with scoop position to zero.
44. Start one ID Fan with scoop position zero and open discharge and suction damper establish furnace draft to -5
mmWC.
45. Start W.S.B. Keeping discharge damper in open position and observe the discharge pressure > 4000 mmwc
and it should not go beyond 5500 mmwc. If wall seal blower discharge pressure goes beyond 5500 mmwc , it
will result in blower vibrations and failure. (If required the vent valve in the wall seal blower to be opened
minimally to keep the pressure below 5500mmwc. Wall seal blower has a safety valve in the discharge piping
at the back side, it is adjusted at 5400 – 5500mmwc. The settings of this safety valve should not be disturbed.
Always keep the exhaust fan in wall seal blower acoustic hood in running condition to provide good
ventilation for the blower and the motor. Incase of any problem with the exhaust fan, the acoustic hood doors
to be kept opened when the blower in running condition.
46. Check return leg fluidization and solid transfer line
47. Check stand blower discharge pressure by taking it in service and keep other in standby mode.
48. Close combustor manhole.
49. Start one SA fan with suction IGV and discharge damper in close condition.
50. Start one PA Fan with suction IGV and discharge dumper in close condition.
51. Start AC Scanner Air Fan
52. Start second ID Fan & PA Fan.
53. Carry out the DP test carrying PA air flow to 90 TPH with maintaining the furnace draft. At air flow of 90 TPH
windbox pressure should be below 700mmWC.
54. Open SA and PA bypass dampers. Open CAD 204 and 205(SA nozzles) 5% and Burner Dampers 206 and 207 up
to 20%.
55. Slowly increase SA Flow by opening discharge damper and suction IGV. Establish 20,000 m³/ hr SA Flow.
Maintain furnace pressure – 5 to –10 mmwc. Keep SA disch Press after A/H around 300 mmwc (1PT 210).
Minimum SA air flow to be maintained through each oil burner is 4000 m³/ hr
56. Slowly increase PA Flow up to 22,000 m³/hr.
57. For oil firing, start Fuel oil ( HSD ) pump keeping suction & discharge valve in fully open position and the oil
pressure will be around 12kg/cm2. Keep oil flow Control Valve 10% open and atomizing air Valve 26% open.
58. Select the oil burner and open the SA damper up to 80% of selected Oil Burner.
59. Check all the boiler safety interlock is in healthy (green) condition.
60. Check the boiler PURGE permissive are satisfied.
61. Start boiler purging. During purging ensure all SADC are opened 100%.
62. After 5 minutes, Purge complete signal will occur. Then bring down the SA damper opening of selected burner
from 80% to 20%. Reduce opening of 2nd Burner Damper from 20% to 15%, Maintain the air flow through
each burner 7-7.5 tph while burner start up.
63. Set furnace Draft at - 15 mmWC. Start the selected burner. Control oil flow at 10 - 13 LPM.
64. Open atomising air PCV 50% and oil PCV 15% and oil presure 5-5.5 kg and take 2nd burner.
The Burner inlet pressure to maintained at 2-2.3 kg/cm2 while start up.
65. For raising Furnace temp strictly follow Boiler Cold start curve for Cold start up curve.
66. Note: The firing rate should be controlled until steam flow through superheater is established.
67. Establish feed water flow through feed control station
68. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
69. 40% FCV to be taken in service & if it can’t be taken in service then only100% FCV can be taken in service.
70. Maintain drum water level at normal level.
NOTE: SH flow to be maintained through start up vent. Drain before Main Steam Stop Valve to be kept opened till
MS-1 does not opened fully.
DO’s DON’Ts
19. Check all the permissive before purging.
20. Monitor the expansion of the boiler.
11. Don’t bypass any protection.
21. Monitor the drum metal rise temperature.
22. Check for the flame healthiness through the peep
hole when oil gun firing is done.
23. Hot flushing through Ring header should be done
very carefully and safely.
24. Always follow the start-up curve provided by
manufacturer.
25. Check for oil leakages during oil firing.
26. Monitor the Drum water/ Steam silica.
15. Abbreviation
8 CBD,IBD Continuous/intermittent
ANNEXURE: ANN_RKT_E17_OPSOP_01_U_1
Reference SOP: E17_OPSOP_01_B#1
6. O & M parameters
No. & Capacity: 1 per unit
Design Code Specification
EMERGENCY TRIP
LOSS OF 110V DC
LOSS OF 24V DC
Interlocks Protections
Atomizing Air pressure Low (3.0 Kg/Cm 2) & Minimum one LOTV close
LONV in open position
Oil pressure Low (3.0 Kg/Cm2) & Minimum one LONV in LOTV close
open position
3 LOTV closed
8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Charge Bottom Oil system at boiler.
4. Bottom Oil pump is in service with short recirculation maintaining header pressure 18 Kg/Cm 2
5. Slowly charge the Boiler Bottom Oil line.
6. Start one ID Fan.
7. Start FD Fans.
8. Start second ID Fan.
9. Maintain total air flow more than 30% & less than 40%.
10. Check the boiler PURGE permissive is satisfied.
11. Start boiler purging for 5 minutes and wait for “purge complete” signal to come.
12. Light up boiler according to the BMS procedure and take two bottom oil guns in service at low flow (0.2 to 0.3
tph) and raise pressure as per the start-up curve.
13. Raise boiler water temperature 110-115°C. Kill fire and drain boiler, if CBD water conductivity is more than 24
micro mhos/cm.
14. Stop the FD Fan.
15. Again fill fresh hot DM water.
16. Start the FD Fan and lit up the boiler keeping furnace draft -5 to -10 mmwc.
17. Give Blow down the unit as required maintaining the drum water level insight in the gauge glass.
Note: The firing rate should be controlled to keep the furnace exit gas temperature below 525 deg C.
18. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
19. Close drum vents at 2Kg/Cm2.
20. Open the CBD valve 100% and regulate it as per requirement.
21. Establish feed water flow through feed control station
22. Start BFP & line up feed water system.
23. Maintain drum water level at normal level.
24. Close all SH drain & vents at 5-8 Kg/Cm 2.
25. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help of
service department (only after Annual Overhauling).
26. Raise the pressure in boiler as per Boiler startup curve.
27. Give boiler hot blow down through bottom ring header after killing the fire at drum pressure 15, 25 and 35
kg/cm2 to control boiler water silica.
28. Charge the main Steam line through boiler stop valve equalizer.
29. Raise the super heater outlet pressure above process header pressure (> 40 Kg/cm2), open motorized stop valve
gradually, keeping in view of Main Steam line Temperature greater than 110 o C.
30. Gradually, open PRDS control Valve. Increase the flow of the bottom oil guns and increase steam load 5 to 10
TPH.
31. Take top two oil guns in service one-by-one and adjust oil flow. Close line drains.
32. Bring 20% steam load on Boiler and close SH drains. Check line temperature. It should not increase above 440°C.
33. Maintain steam temperature 440°C during the above operation.
34. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per requirement.
35. Put ID fan, FD fan on Auto.
36. Check all the running equipments, inspect the furnace and stack. Stack emission should not be black.
37. Start PA fan and bring PA duct pressure to 480 mm WC.
38. Reset MTR and check PA fan.
39. Start purging of bottom coal conduit and wait for ‘AADB OK to release’ signal to come on BMS panel.
40. Release auxiliary air to auto.
41. Remove top oil guns for controlling SH temperature.
42. Open seal air SO damper.
43. Open BSD pair bottom.
44. Keep PA flow control damper at minimum 30%.
45. Start lube and lift pump.
46. Confirm lube oil flow 4.0 LPM before Ball Mill start up.
47. Start Ball Mill.
48. Open PASO.
49. Open hot air damper and bring Ball Mill temperature about 65°C.
50. Watch the SHS temperature increase. It should be 1 to 1.5°C/minute control by opening super heater drain on
reducing oil flow.
51. Charge spray water and bring super heater temperature to normal.
52. When Ball Mill level (low) comes down to 30% start coal feeders and increase coal feeding rate corresponding to
Mill temperature and level.
53. Bring 60% steam load on bottom coal burners and oil guns slowly.
54. Take top two oil guns in service one-by-one and adjust oil flow to control super heater steam temperature.
55. Start purging of top coal conduits and wait for ‘AADT OK to release’ signal to come.
56. Release auxiliary air to auto.
57. Open BSD pair top and increase the steam load gradually to full load. Maintain normal boiler parameters.
58. Put feed water control on auto.
59. Put ESP in service after removal of oil support and 80% steam load.
9. Operation monitoring & control
17. Monitor and maintain Boiler drum level.
18. Monitor and maintain Boiler furnace draft.
19. Monitor and Maintain Boiler main steam pressure and temperature by adjusting coal feed and
attemperator flow.
20. Monitor and maintain excess oxygen levels.
21. Reduce exit flue gas temperature by soot blowing as per SOP.
22. Monitor and maintain Boiler bed level and bed temperature.
23. Monitor and maintain Boiler water and steam parameters within range.
24. Monitor fan and motor bearing temperature.
25. Monitor oil level of Fluid coupling, WSB.
26. Check and report oil leakages, abnormal sound and vibration.
27. Monitor collection of coal sample and coal quality.
28. Monitor Boiler efficiency and report heat loss area.
29. Monitor Boiler instruments and their feedback positions.
30. Monitor Boiler auxiliary loading.
31. Monitor Boiler ash conveying system for normal operation.
32. Log Boiler operating parameters on regular basis.
8 CBD,IBD,EBD Continuous/intermittent/emergency
ANNEXURE: ANN_RKT_E17_OPSOP_01_U_2
Reference SOP: E17_OPSOP_01_B#2
6. O & M parameters
No. & Capacity: 1 per unit
Design Code Specification
EMERGENCY TRIP
LOSS OF 24V DC
3 LOTV closed
8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Start one ID Fan.
4. Start one PA Fan.
5. Start one FD Fans.
6. Start second ID Fan & FD Fan.
7. Start charging bed material by keeping total air flow between 120-125 Cu M / Hr (Keep FD fans inlet damper
on 85% position). After charging bed material, measure the dead bed height and ensure it for 300-325 mm.
8. Check fluidization in all 4 compartments keeping FD air flow between 120-125 Cu M / Hr. And for
compartment -1, check for minimum air required to fluidize the bed. This may be around 40-45 Cu M / Hr.
again fluidized the all compartment for 5 minute.
9. Stop PA & FD fans and keep one ID fan running.
10. Check the Bed-material leakage from DP, inside the wind-box, and attend it, if found.
11. Spray dry charcoal in compartment -1. The quantity may be around 240 Kgs (60 bags). After that charge
Kerosene / HSD mixed charcoal. The quantity may be around 240 Kgs (60bags).
12. Spread charcoal to be ignited by means of fire torches, with sufficient suction, (-) 8 to (-) 10 mmwc.
13. Start PA & FD fan. Maintain PA duct pressure between 1050-1100 mmwc. Throttle Comp-1 CTA line air, up to
70% and ensure 100-120 mmwc differential pressure.
14. Open PAD & FAD of Comp -1. Increase FD air flow to 38 CuM / Hr and wait till bed top temperature starts
increasing.
15. Increase airflow further to 42 Cu M / Hr, so that fired charcoal is mixed evenly into bed and to bring top and
bottom bed temperature even. Wait till bed temperature (top and bottom both evenly) increases near to 550
Deg C. If required, charcoal charging may be continued from outside through manhole.
16. Ensure all feeders are selected on Remote (GUS).
17. Run the coal feeders of Comp-1 and gradually start increasing RPM from 0.10 to 7 RPM, depending upon
temperature variation and furnace physical condition. Stop charging charcoal, when temperature of bed
increases more than 550 deg.C. .
18. If the bed temperature starts increasing rapidly, decrease coal flow suitably and give a kick of FD air (50-55
CuM / Hr). Ensure that the bed temperature should not come down below 550 Deg C and coal feeders are
running at optimum rate to maintain bed temperature.
19. Open the throttled CTA line valve further and maintain CTA line differential pressure between 120-150
mmwc.
20. Boiler pressure should be raised gradually as per BHEL procedure (i.e. 1.5 to 2.0 degree C per minute or as
slow as possible, in case of cold start-up) and keeping bed temperature up to the range of 820-870 Deg C
accordingly.
21. Differential of Drum-metal Temperature (top & bottom, both sides) should not exceed > 50 deg. C, in any
case.
22. Close DRUM vents, when drum pressure is 5.0 KGSC.
23. Raise the pressure in boiler as per Boiler startup curve.
24. Charge the main Steam line through boiler stop valve equalizer.
25. Raise the super heater outlet pressure above process header pressure (> 40 Kg/cm2), open motorized stop
valve gradually, keeping in view of Main Steam line temperature greater than 110 o C. Charge the steam
header by opening MSSV up to interconnection.
26. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling).
27. Raise steam pressure to 1.5 KGSC above header pressure and open interconnection valve.
28. Gradually, open PRDS control Valve & increase steam load 5 to 10 TPH.
29. Raise the boiler pressure till we achieve steam flow on boiler. Close startup vent and super heater drains,
after ensuring continuous steam flow of around 20 TPH. It is essential to note that bed super heater drain
and 20% (minimum) start-up vent is opened, if the boiler load is running less than 10 TPH.
30. To activate Comp-2, increase the bed temperature of Comp-1 in the range of 925-950 Deg C. Activate Comp-
2 and watch the bed temperature of Comp-1. Do not allow Comp-1 bed temperature to come down below
700 Deg C. Accordingly stop Comp-2. Again raise Comp-1 bed temperature and reactivate Comp-2. By this
way, Comp-2 to be activated and to keep both compartment temperatures in the range of 850-870 Deg C. Air
flow may be increased accordingly.
31. After stabilization of two compartments, Comp-3 & Comp-4 are to be activated by following same procedure
as in point- No 30.
32. Give spray water control valve in service and maintain Sup. Heated steam temperature within design limit
(not more than 450 Deg C).
33. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per requirement.
34. Once the boiler is put into steady state operation, feed water control valve & furnace draft control are to be
turned into auto mode.
35. Check all the running equipments, inspect the furnace and stack. Stack emission should not be black.
36. Put ESP in service, when boiler load is 80% of MCR. (i.e. 65 TPH).
37. Monitor SPM of stack and check the rappers and KV of each field.
Important notes:-Use PPE (Gloves, helmet, apron, goggles and dust mask) while startup and operation of
boiler. Maintain SPM of stack less than 150 mg/NM3 after putting ESP in service
38. Use ear plug during steam venting & safety valve settings.
39. If the boiler is lit up in rainy season and feed coal is having high moisture, spread feed coal on the feeder
firing floor, in advance, before startup of the boiler and use this for initial feeding (manually), till two
compartments activation.
40. To ensure skilled manpower at firing floor as well as on control desk.
41. The quality of received charcoal to be recorded. The recommended quality parameters are as under: -
42. Size: -10-15 mm
43. Fines less than 15% (3 mm & below)
44. CV 5500 Kcal/Kg (Min)
45. Ash < 10%
9. Operation monitoring & control
1. Check the bearing temperature & vibration.
2. Permission to start any two coal elevation through FSSS.
3. Maintain the PA header pressure normal.
10. Shutdown Procedure: Refer Shut down SOP
11. Best practices followed (If any):N.A.
DO’s DON’Ts
36. Check all the permissive before purging. 16. Exceed drum metal differential temperature >50 C
37. Monitor the expansion of the boiler. 17. Close steam drain before stop valve before
38. Monitor the drum metal rise temperature. continuous flow of steam.
39. Check for the flame healthiness through the peep
18. Don’t bypass any protection.
hole.
40. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
41. Always follow the start-up curve provided by
manufacturer.
42. Monitor the Drum water/ Steam silica.
15. Abbreviation
8 CBD,IBD,EBD Continuous/intermittent/emergency
EMERGENCY TRIP
LOSS OF 110V DC
LOSS OF 24V DC
Interlocks Protections
Atomizing Air pressure Low (3.0 Kg/Cm 2) & Minimum one LOTV close
LONV in open position
Oil pressure Low (3.0 Kg/Cm2) & Minimum one LONV in LOTV close
open position
3 LOTV closed
8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Start Air pre heaters
4. Charge Bottom Oil system at boiler.
a. Bottom Oil pump is in service with short recirculation maintaining header pressure 18 Kg/Cm 2
b. Slowly charge the Boiler Bottom Oil line.
5. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
6. Start one ID Fan.
7. Start one FD Fans.
8. Start second ID Fan & FD Fan.
9. Maintain total air flow more than 30% & less than 40%.
10. Check the boiler PURGE permissive is satisfied.
11. Start boiler purging. During purging ensure all SADC are opened 100%.
12. After completion of purging push reset SADC.
13. Maintain wind-box DP around 30 mmwc.
a. All Coal elevation- A, B, C, D Fuel air dampers are in auto & closed.
b. All auxiliary air dampers of elevation AB, BC & CD are in modulating, if not then adjust to maintain
the wind box DP as per boiler loading Vs Wind-box DP curve.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
14. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
15. Give Blow down the unit as required maintaining the drum water level insight in the gauge glass.
16. Start APH soot blowing from Steam in every 2 hours interval (up to oil gun in service).
17. Note: The firing rate should be controlled to keep the furnace exit gas temperature below 500 deg C.
18. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
19. Close drum vents at 2Kg/Cm2.
20. Open the CBD valve 100% and regulate it as per requirement.
21. Establish feed water flow through feed control station
a. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
b. 30% FCV to be taken in service & if it can’t be taken in service then only100% FCV can be taken in
service.
22. Maintain drum water level at normal level.
23. Close all SH drain & vents at 5-8 Kg/Cm 2.
24. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with
help of service department (only after Annual Overhauling).
25. Raise the pressure in boiler as per Boiler startup curve.
26. Give boiler hot blow down through bottom ring header after killing the fire at drum pressure 15, 25 and
35 kg/cm2 to control boiler water silica.
27. Charge the main Steam line through boiler stop valve equalizer
28. At 40 Kg/cm2 super heater outlet pressure, open motorized stop valve gradually, keeping in view of Main
Steam line Temperature greater than 110 o C.
29.
a. Raise the super heater outlet pressure above common header pressure or process header pressure if
Turbine is not in service.
b. Open HPT01 & PRDT01 for common header and PRDT-02 for process header for supplying the steam
to the process.
c. Raise the Boiler pressure and temperature till we achieve steam load about 10% of MCR. Close start-
up vent and drains before main Steam stop valve and maintain constant Steam flow on oil firing by
adjusting the steam load on Boiler #1 & 2.
30. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler
water conditions & start TSP dosing as per requirement.
31. For placing the first Pulveriser (A or B) in service, following conditions to be satisfied :
i. Minimum 3 out of 4 oil guns of elevation 'AB' must be in service.
ii. Cooling water of bearings opened.
iii. Coal burner shut off gates opened.
iv. Ensure all classifier vanes are identical.
v. Lubrication pump is running and ensure discharge pressure is > 3 Kg/cm 2.
vi. Coal gate to feeder is open.
vii. Exhauster / Mill discharge valve fully opened and vent valve closed.
viii. Hot air gate and hot air control dampers closed.
32. Ensure pulveriser ready condition on BMS panel / screen is present.
a. Start pulveriser.
b. Open hot air gate and increase the Pulveriser outlet temperature to 70ºC.
c. Start coal feeder at minimum rating. Regulate hot air control damper to maintain the required
temperature. Ensure the ignition of coal has started.
d. Adjust Pulveriser loading keeping current normal.
e. Charge the spray water to maintain super heater outlet temperature 535ºC +0ºC/-5ºC.
f. Place the second Pulveriser in service in a similar manner keeping pressure and temperature
parameters within limits. When the second Pulveriser is proven in service then equalize the feeder
rating of two Pulverisers.
33. Place the third pulveriser in service in a similar manner keeping pressure and temperature parameters
within limits. When the third Pulveriser is proven in service then equalize the feeder rating of all three
Pulverisers.
15. Abbreviation
8 CBD,IBD,EBD Continuous/intermittent/emergency
20. Bottom hopper filled up with water and ensures that water is overflowing.
21. Water charged into seal trough and ensures that water is overflowing.
22. Ensure availability of Mill reject system.
EMERGENCY TRIP
LOSS OF 110V DC
LOSS OF 24V DC
Interlocks Protections
Atomizing Air pressure Low (3.0 Kg/Cm 2) & Minimum one LOTV close
LONV in open position
Oil pressure Low (3.0 Kg/Cm2) & Minimum one LONV in LOTV close
open position
3 PA Fan Tripped
4 LOTV closed
5 All HAG closed
8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Charge Bottom Oil system at boiler.
a. Bottom Oil pump is in service with short recirculation maintaining header pressure 18 Kg/Cm 2
b. Slowly charge the Boiler Bottom Oil line.
4. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
5. Keep the flue gas damper of air pre-heater primary side in fully closed position
6. Keep the flue gas damper of air heater secondary side in open position
7. Start one ID Fan.
8. Start one FD Fans.
9. Start second ID Fan & FD Fan.
10. Maintain total air flow more than 30% & less than 40%.
11. Check the boiler PURGE permissive is satisfied.
12. Start boiler purging. During purging ensure all SADC are opened 100%.
13. After completion of purging push reset SADC.
14. Maintain wind-box DP around 30 mmwc.
a. All Coal elevation- A, B, C, D Fuel air dampers are in auto & closed.
b. All auxiliary air dampers of elevation AB, BC & CD are in modulating, if not then adjust to maintain
the wind box DP as per boiler loading Vs Wind-box DP curve.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
15. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
16. Give Blow down the unit as required maintaining the drum water level insight in the gauge glass.
17. Note: The firing rate should be controlled to keep the furnace exit gas temperature below 500 deg C.
18. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
19. Close drum vents at 2Kg/Cm2.
20. Open the CBD valve 100% and regulate it as per requirement.
21. Establish feed water flow through feed control station
a. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
b. 30% FCV to be taken in service & if it can’t be taken in service then only100% FCV can be taken in
service.
22. Maintain drum water level at normal level.
23. Close all SH drain & vents at 5-8 Kg/Cm 2.
24. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with
help of service department (only after Annual Overhauling).
25. Raise the pressure in boiler as per Boiler startup curve.
26. Give boiler hot blow down through bottom ring header after killing the fire at drum pressure 15, 25 and
35 kg/cm2 to control boiler water silica. Charge the main Steam line through boiler stop valve equalizer
27. At 40 Kg/cm2 super heater outlet pressure, open motorized stop valve gradually, keeping in view of Main
Steam line Temperature greater than 110 o C.
28.
a. Raise the super heater outlet pressure above common header pressure or process header pressure if
common header is not charged.
b. Open HPT01 & PRDT01 for common header and PRDT-02 for process header for supplying the steam
to the process.
c. Raise the Boiler pressure and temperature till we achieve steam load about 10% of MCR. Close start-
up vent and drains before main Steam stop valve and maintain constant Steam flow on oil firing by
adjusting the steam load on Boiler #1 & 2.
29. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler
water conditions & start TSP dosing as per requirement.
30. For placing the first Pulveriser (A or B) in service, following conditions to be satisfied :
i. Minimum 3 out of 4 oil guns of elevation 'AB' must be in service.
ii. Cooling water of bearings opened.
iii. Coal burner shut off gates opened.
iv. Ensure all classifier vanes are identical.
v. Lubrication pump is running and ensure discharge pressure is > 3 Kg/cm 2.
vi. Coal gate to feeder is open.
vii. Exhauster / Mill discharge valve fully opened and vent valve closed.
viii. Hot air gate and hot air control dampers closed.
31. Before start Mill following activities to be carried out.
32. Start PA fan.
33. Open the flue gas outlet damper of primary air pre-heater and PA fan discharge damper. Maintain header
pressure above 750 mmwc.
34. Start SEAL air fan and maintain header pressure above 1400mmWC.
35. Ensure pulveriser ready condition on BMS panel / screen is present.
a. Start pulveriser.
b. Open hot air gate and increase the Pulveriser outlet temperature to 70ºC.
c. Start coal feeder at minimum rating. Regulate hot air control damper to maintain the required
temperature. Ensure the ignition of coal has started.
d. Adjust Pulveriser loading keeping current normal.
e. Charge the spray water to maintain super heater outlet temperature 535ºC +0ºC/-5ºC.
f. Place the second Pulveriser in service in a similar manner keeping pressure and temperature
parameters within limits. When the second Pulveriser is proven in service then equalize the feeder
rating of two Pulverisers.
36. Place the third pulveriser in service in a similar manner keeping pressure and temperature parameters
within limits. When the third Pulveriser is proven in service then equalize the feeder rating of all three
Pulverisers.
DO’s DON’Ts
50. Check all the permissive before purging. 22. Exceed drum metal differential temperature >50 C
51. Monitor the expansion of the boiler. 23. Close steam drain before stop valve before
52. Monitor the drum metal rise temperature. continuous flow of steam.
53. Check for the flame healthiness through the peep
24. Don’t bypass any protection.
hole.
54. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
55. Always follow the start-up curve provided by
manufacturer.
56. Monitor the Drum water/ Steam silica.
8 CBD,IBD,EBD Continuous/intermittent/emergency
6. O & M parameters
Boiler
1 Type Balanced draft, Dry Balanced draft, Dry Balanced draft, Dry Bottom
Bottom Bi-Drum, Bottom Bi-Drum, Hopper, Bi-Drum, Natural
Natural Circulation Natural Circulation Circ, Tilting Tangential
-firing
6 Design pr. and Temp at 91.4 kg/cm2 and 515 0 C 93kg/cm2 and 530 0 C 96 kg/cm2 and 535 0C
SH outlet
8 Type of APH Tubular, Gas through Tubular, Air through tube Tubular, Gas through tube
tube
1 Type Balanced draft, Dry Balanced draft, Dry Balanced draft, Dry Bottom
Bottom Hopper, Bi- Bottom Hopper, Bi-Drum, Hopper, Bi-Drum, Natural
Drum, Natural Circ, Natural Circ, Tilting Circ, Tilting Tangential
Tilting Tangential Tangential -firing -firing
-firing
6 Design pr. and Temp at 95 kg/cm2 and 530 oC 96 kg/cm2 and 530 oC 96 kg/cm2 and 535oC
SH outlet
Interlocks Protections
37. Atomizing Air pressure Low & Minimum 38. LOTV/ HOTV close
one LONV in open position
39. Oil pressure Low & Minimum one LONV 40. LOTV/ HOTV close
in open position
8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Start both Air preheaters.
4. Charge LDO/ HSD/ HFO/ Bottom Oil system at boiler.
a. LDO/ HSD/ HFO/ Bottom Oil pump is in service with recirculation maintaining header pressure.
b. Slowly charge the Boiler LDO/ HSD/ HFO/ Bottom Oil line.
5. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
6. Start one ID Fan.
7. Start one FD Fans.
8. Start second ID Fan & FD Fan.
9. Maintain total air flow more than 30% & less than 40%.
10. Check the boiler ‘’PURGE’’ permissive are satisfied.
11. Start boiler purging. During purging ensure all SADC are opened 100%.
12. Maintain wind-box DP around 30 to 40 mmwc.
a. All Coal elevation- A, B, C, D, E Fuel air dampers are closed.
b. All auxiliary air dampers of elevation AB, BC, CD & DE are in modulating.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
13. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
14. Start APH soot blowing from Steam in every 2 hours interval (up to oil gun in service) and start the sonic soot
blower.
15. Blow down the unit as required maintaining the drum water level insight in the gauge glass.
16. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
17. Close drum vents at 2Kg/Cm2.
18. Open the CBD valve 100% and regulate it as per requirement.
19. Establish feed water flow through feed control station and start BFP & line up feed water system.
20. Maintain drum water level at normal level.
21. Close all vents at 2 to 3 Kg/Cm2.
22. Close all SH drains 1,2 &3at 10 Kg/Cm 2 and ensure that final SH drain is full open till synchronization.
23. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling)
24. Give boiler hot blow down through bottom ring header drain after killing the fire at drum pressure 10, 20, 30
&40 Kg/Cm2. Further blow downs to be done in view of Drum water/ Steam silica condition.
25. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per chemical department.
26. Open Main Steam equalizer valve at 20 Kg/Cm 2, keeping Turbine side steam line drains in open condition.
27. Open Main Steam Stop Valve at 30 Kg/Cm 2and close Main Steam equalizer valve.
28. Raise the pressure in boiler as per Boiler startup curve and requirement of turbine.
8.1 Checks during boiler Lit- Up.
1. Check for any igniter oil leakages/ seepages.
2. Check oil igniters flame condition and no any oil spillage in the furnace.
3. Check for any oil leakages/ seepages.
4. Check drum metal differential temperatures should not exceed 50 o C.
5. Maintain drum level up to Normal level.
6. Final superheater drain should be open right from the very beginning.
7. Open CBD to maintain continuous flow from economizer.
8. Check that phosphate dozing in boiler drum is done.
9. Check for continuous rotation of oil guns at 15 min time interval.
8 CBD,IBD,EBD Continuous/intermittent/emergency
ANNEXURE: ANN_UAL_E17_OPSOP_01
Reference SOP (SMP) :ANN_UAL_E17_OPSOP_01
Applicability to generating unit(s) : U# 1,2,3
Scope : This annexure covers the 6,7,8,13 clauses of SOP (SMP) E17_OPSOP_01
6. O & M parameters
1 Ensure all permit to work has been cancelled SCE Control room
B ACW System:
Start one compressor, observe for receiver pressure build CRE (opn), Field
3 up engineer
D Other:
Ensure all scanner air filter & HFO filter are clean & SCO & SCE
3 vented (mechanical)
SCO, Boiler
4 Check oil gun are clean Operator& SCE
5 Ensure AC power supply for FSSS & hydra step are normal SCE(electrical)
DM plant
7 Ensure DM plant tank level is normal (80%) operator/SCO
8 Check bottom ash hopper & seal trough filled with water Boiler Operator
Ensure fly & bottom ash handling system are ready & AHP field
10 available operator/SCO
11 Ensure availability of ESP
Ensure drum & S/H, Eco., De- S.H. vents are open & all
14 drains are closed Boiler Operator
17 Check line up for chemical dosing line & sampling line Boiler Operator/SCO
SCE(C&I),SCE(Opn),
A Conditions of furnace purging
SCO WIN
SCE (C & I)
Conditions of boiler MFT, and interlocked actions
B
initiated by MFT WIN/UAIL
Automatic weighing system of each coal feeder has been SCE (C&I)
6
adjusted and tested accurate with correct indication
Furnace gas temperature probes have been adjusted SCE (C & I)
8
and set and tested freely being protruded and retracted
Programmed control system of soot blowing and
9 intermittent blow down has been adjusted statically, and SCE (C & I)
operated correctly and reliably in simulation test
Simulation testing of boiler interlocks and protections
10 has been finished, showing correct in logic and reliable SCE (C & I)
in action
1. Start filling of Boiler by running DM transfer pump & filling up .If de-aerator in service Water can be taken
through starting the BFP’s
2. Stop filling when drum level increases to <= 20 % But not less than 10%.
3. Start-up one IDF A or B side then start the corresponding opposite corner FDF A or B side before that Start
respective ID Fan and FD Fan lube oil system.(Refer to Doc No For FD F & ID F start up )
4. In all fans lube oil system Start one lube oil pump & put other stand by pump in auto (Please ensure cooling
water line in charge condition, lube oil tank level must be <=75%, pressure should be maintained 2.4 bar and
maintained oil level at both bearing side <75%).
5. After starting of one FDF & IDF maintain the air flow around 30% (1,00,000 m³/hr to 1, 20,000 m³/hr) of the
total air flow (4,00,000 m³/hr).Ensure Furnace draft should be maintained between -2 to -5 mmWC.
6. Put the furnace purging for 10-15 min.
7. Start one Scanner air fan & check the pressure should be between 6 to 7 KPa. Put the other stand by fan in
Auto interlock.
8. Start LDO supply pump and put in long recirculation mode, check the oil pressure (10 to15 bars) in Boiler
floor of 12 meter
9. Start all Mill lube oil system after mill lube oil temperature reaches 40-45 deg (Start the heaters to raise the
lube oil temperature to 40-45 deg )
10. After ensuring boiler ignition conditions are satisfied, open main fuel oil valve, get ready to ignite the
furnace
· The lower oil guns should receive priority when applying oil guns.
i. .Operate or change over oil guns depending on firing condition & carefully watch
DO’s DON’Ts
66. Check all the permissive before purging. 30. Exceed drum metal differential temperature >50 C
67. Monitor the expansion of the boiler. 31. Close steam drain before stop valve before
68. Monitor the drum metal rise temperature. continuous flow of steam.
69. Check for the flame healthiness through the peep
32. Don’t bypass any protection.
hole.
70. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
71. Always follow the start-up curve provided by
manufacturer.
72. Monitor the Drum water/ Steam silica.
15. Abbreviation
8 CBD,IBD,EBD Continuous/intermittent/emergency