BOILER HOUSE OPERATING INSTRUCTIONS

1.Procedure for Checking, draining and putting back into operation of the
boiler gauge glass:
Responsibility : Operator
¾ Prior to check the gauge glass the control room Panel engineer shall be informed
about the activity.
¾ The firing floor operator shall wear all PPE ( Face shield and hand gloves) .
¾ Switch on the light back side of the gauge glass.
¾ Check and confirm the water level in the gauge glass.
¾ Isolate the gauge glass from water side by closing the isolation valves.
¾ Isolate the gauge glass from steam side by closing the isolation valves.
¾ Open the drain valve slowly and observe water level drop in the gauge glass.
¾ Flush the gauge glass and drain by crack opening of steam side isolating valve for
two to three minutes then close the steam side isolating valve.
¾ Carry out the same flushing from water side also.
¾ Close the drain valve.
¾ Slowly open water side and steam side valves to take the gauge glass into
operation and confirm back for water level.
¾ Report back to control room Panel engineer for the activity completion.

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1. Procedure for inspection of furnace condition, sampling of coal

from coal feeders.
Responsibility : Operator
¾ Prior to check the furnace and collecting the coal sample from feeder the control
room panel engineer will be informed about the activity.
¾ The control room Pannel engineer shall maintain the furnace draft between –3 to
–5 mmwc and permit the activity.
¾ The operator shall wear all PPE (Face shield, hand gloves) and open the furnace
peephole for confirming the negative draft.
¾ When there is no backfiring is observed, the operator shall check the furnace
condition through peephole.
¾ For collecting the coal sample the operator shall ensure the above conditions then
collect coal from the feeder mouth.
¾ When the above activities are completed inform the control room panel engineer
for normalization of furnace pressure.
¾ Control room Pannel engineer shall reduce the furnace draft to normal value.

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3. Procedure for hydraulic testing of the boiler:

Responsibility : Operator
¾ Prior to conducting the hydraulic test for the boiler ensure that all safety valves
are gagged.
¾ Keep open the drum air vents, main line air vents.
¾ Ensure that all drains of the boiler are closed.
¾ Ensure that the main steam stop valve is closed and open the drain between stop
valve and range valve.
¾ Ensure that gauge glasses, drum level transmitters and Yarway level indicator are
isolated.
¾ Close the feed check valve.
¾ Ensure that all pressure parts are properly illuminated for facilitating the
inspection.
¾ Start filling the boiler with cold water from the line provided at the economizer
inlet header.
¾ Once the boiler is filled with water the water from vents can be observed.
¾ Close all vents when the boiler pressure reaches 3.0 kg/cm2 and no air bubble
from vents.
¾ Close the clod water isolating valve.
¾ Start the boiler feed water pump.
¾ Keep the Spray control valve 15% opened.
¾ Keep feed control isolation valve crack open.
¾ Establish the feed water flow to the minimum so that the pressure raise in the
boiler shall be 1kg/cm2/minute. To achieve this the boiler Spray control valve can
be adjusted suitably.
¾ Raise the boiler pressure to 1.5 times of maximum drum working pressure slowly
and steadily.
¾ Keep the boiler pressure at hydro test pressure for 3 minutes.
¾ Slowly drop the pressure to drum normal working pressure with Main line vent
¾ Thoroughly inspect the boiler pressure parts i.e furnace, superheaters,
economiser and wind box for any leakage or water sweating.
¾ Once the inspection is completed inform the leakages if any to the engineer in-
charge.
¾ Slowly drop the pressure at the rate of 1.5 kg/cm2/minute .
¾ Once the pressure drops to < 10 kg/cm2 stop the boiler feed water pump.
¾ Once the pressure drops to 3.0 kg/cm2 open the drum, main line vents, bed
superheater drains.
¾ Remove the safety valve gags.
¾ Keep the drum water level to normal working level to make the boiler for start
up.
¾ Dose hydrogen hydrate in drum water and maintain 0.2 ppm.

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4. OPERATIONS DURING RUNNING :

Responsibility : Operator
ƒ Float the main line safety valve once in a week.
ƒ Collect coal sample twice a shift and send the composite sample to Central Lab
once a day during the early shift to measure GCV and total moisture.
ƒ Collect Fly Ash sample at Economiser, AIR preheater,ESP’S twice a shift send the
composite sample to Central Lab once a day during the early shift to measure the
unburnt carbon.
ƒ Monitor the quality parameters against the following targets on monthly average
basis. Fly Ash Unburnt Carbon (UBC) less than 6 %
Thermal Efficiency above 85%
(with moisture correction)

ƒ Collect Feed water, drum water, drum steam, and main steam samples once a
shift and send them to Central Lab. Monitor their quality parameters against the
 below mentioned targets and give blow down, if the drum water quality is beyond
the target.
pH Conductivity Silica
(µ mhos) (ppm)
-----------------------------------------------
-----
Feed Water 7.2 to 9.2 <2 <0.05
Drum Water 7.5 to 10.5 <200 <5.00
Drum Steam 7.5 to 9.5 <5 <0.05
Main Steam 7.5 to 9.5 <2 <0.05
ƒ Ensure that minimum five bed temperatures are between 650 – 950 deg.C.
Ensure that the oxygen level in the flue gas is maintained between 3 – 5 % in
stable load conditions above 65% MCR for efficient operation when the bed
condition is healthy.
ƒ Check both the drum gauge glasses level once a shift and blow down once in
each shift.
ƒ Cross check and ensure that the control panel readings and the Yarway
level, Gauge glass level and transmitter level indicator are same at least
once a shift.

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5.EMERGENCY OPERATIONS
Responsibility : Operator
Inform to the shift in-charge and other boiler operators, if any
tube failure occurs and drum level is not maintaining and carry
out the following activities :
ƒ Stop coal feeding
ƒ Close the range valve and stop valve
ƒ Draw steam from other boilers, if required, and reduce the load on TGs
accordingly.
ƒ Follow the stopping procedure.

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 6. BOILER LIGHT UP PROCEDURE
Responsibility : Operator
Requirements of Bed material,Charcoal & Diesel.
Bed material
• Maximum Particle size : 2.36 MM
• Particles to pass through sieve No : 8
• Minmum particle size : 0.85 MM
• Partcles to stay on sieve No : 20
• Particle density : 2000 Kg/M3
• Bulk density : 1000 to 1100 Kg/M3
• Chemical composition : Alumina 45% to 35%
Silica 55% to 65%
• Fusion temperature : 1400 Deg C
• Qty required for start up : 19.89 MT
Charcoal
• Size : 15-25 MM Lumps
• Calorific value : 6600 Kcal/Kg
• Qty required for start up : 440 Kgs
Diesel
• Qty required for start up : 50-150 Ltrs

Preparation before light up

ƒ Bed material to be filled and level of defluidised bed should be 300 MM of WC.
And first compartment to 225 MM of WC for reduction of charcoal and diesel
consumption.
ƒ Fill the water and keep the drum level 30-40%.Irrescpective of drum level 30-
40% take water into drum through economiser initial fill up line and drain
excess quantity to avoid any starvation of economiser if yet all economiser is
in emptied before light up by any mistake.
ƒ Ensure CBD and IBD valves are in operation by operating once.
ƒ Inspect the boiler before start and check the following
1. All access doors are closed.
2.All personel cleared.
3.All foreign materials are removed from furnance and pressure parts.
4.All equipment trial to be taken.
5.All interlocks to be cross checked.
ƒ Check the following equipments for adequate lubrication.
1.Fans and drives.
2.Feed pump and drives.
3.Fuel feeders and controllers.
4. LDO pump.
ƒ Check for dry fuel(0-6 MM) is available in bunker and gates below bunker are
open and fuel is available at feeder inlet.
ƒ Check instrument air pressure is available at the required pressure ( of 7
Kg/sqcm) for instuement and control.
ƒ Check the following valves in boiler are in closed condition.
1. Feed control valve and its bypass valve.
2. Blow down valve.
3. Main steam stop and pilot valve.
4. Drain valves of water level gauge.
ƒ Check the following valves are kept in open condition.
1. Drum and main line vent.
2. Water level gauge,pressure gauge and level transmitter/all primary
isolation valves.
3. Valves before and after feed control valve in feed line.
4. Valves on feed line connecting to feed pumps operation.
5. Start up vent valve.
6. Bed super heater drains.
ƒ Check the bed material and fludisation study is being done.
1. Set the air flow to 5 MM of wc P.
 2. Measure air box pressure (P1) MM of wc
3. Add gas plenum pressure P2( Furnace draught) to P1.(P2+P1) is the
pressure drop across distributar plate and bed.
4. Subtract P3 MM of wc which is the pressure across DP alone which is
already measured in DP study.i.e ((P1+P2)-P3) would be pressure drop
across bed.
5. The pressure drop across bed is obtained for various air flow.
6. The air flow at which fludisation starts is noted and will be maintained at
the time of mixing.
7. Once fludisation study is completed boiler is ready for light up.

Boiler light up
ƒ A fixed quantity of dry charcoal (400 Kgs i.e 20 Kg.per M3 area of bed)is
spread uniformly over the start up compartment.
ƒ A fixed quantity of diesel wetted Charcoal ( 40 Kgs) is spread uniformly over
the compartment.
ƒ Start ID Fan and maintain furnace draught of -3 to -5 MM of wc.
ƒ Start PA Fan and Maintain header pressure of 900 Mm of WC.
ƒ Start the FD and maintain bed pressure 150 – 250 mmwc.
ƒ Start the LD oil pump and maintain the oil pressure between 6.0 – 8.0
kg/cm.sq.
ƒ Keep the oil burners in position and flush out the diesel and atomising PA air
lines.
ƒ Keep the PA lines clear and take trial run of feeder of first compartment.
ƒ Light up the all the four burners.
ƒ Increase the FD air flow upto 470 MM of WC and drop to 350 of MM of WC
and allow 5-10 minutes to ignite charcoal and mix the bed by varying air flow.
ƒ Initally the top bed temperature raise and at the time of mixing temperature
drops and bottom temperature raises at the time of mixing.
ƒ When power cut occurs during start up after mixing it is not possible to
access how much charcoal is burnt out.It is advised to cool throughly and
drain the bed material and do fresh light up.
ƒ When the bed temperatures reaches 450-600 Deg C start the drag chain coal
feeder.
ƒ After stabilisation of bed temperatures stop the burners and LDO pumps.
ƒ Take out the oil burners
ƒ Close all air vents when the drum pressure reaches between 2 to 3 kg/cm.sq.
ƒ Close the bed superheater drains.
ƒ Ensure feed water flow through economiser at the time of light up to avoid
steaming of economiser.
ƒ Maintain drum level.
ƒ Open Pilot valve of the Stop valve when the steam pressure reaches 60 - 70
kg/cm.sq. and temperature reaches between 400 to 450 deg.C.
 ƒ Open Stop valve when the steam pressure reaches 65 - 75 kg/cm.sq. and
temperature reaches between 400 to 450 deg.C. and close the Pilot valve.
ƒ Open Range valve when the steam pressure reaches 75-88kg/cm.sq. and
temperature reaches between 475 to 500 deg.C.
ƒ Charge the ESP fields and start the ash handling system.

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6.COMPARTMENTAL TRANSFER
Responsibility :
• Keep the PA damper of static compartment in open condition.
• Raise the air flow fludising compartment to 120 % MCR and fuel rate to be
increased to maintain bed temperature to 900 DEG C.
• Now open the compartment (FD)air damper of the adjacent compartment which
is to be activated.
• Allow heat transfer from the Hot bed to cold bed until the bed temperature of
operating bed drops to 750 Deg C.
• Slump the new compartment by closing FD Air Damper.
• Follow the process until the new compartment reaches 600 DEG C.
• Start coal feeding to the new compartment.
• If By mistake the operating compartment temperature drops below 600 DEG C it
becomes necessary to raise the temperature by using charcoal if it is First
compartment.

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7. COMPARTMENT SLUMPING
Responsibility :
• IF two compartments are in operation any compartment can be slumped.
• IF three compartments are in operation one first and second compartment to be
shut.
• Bring down the fuel rate to minimum and switch of the feeder.
• Wait till the bottom temperature reaches 850 DEG C.
• Close the Fludising air ( FD damper).
• When Fludising air through a compartment is cut off the other compartments air
will increase.
• Adjust the Air flow by regulating FD air suction damper.
• Ensure that slumped bed Bleed of damper is in open condition.

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8. BOILER TRIPPING DUE TO POWER CUT

Responsibility :
• In case of power failure shut off inlet dampers of FD fan and ID fan.
• In the event of immediate availabilty of power boiler can be started immediately
by switching on fans.
• Clear off PA lines for any jamming.
• Establish MCR air flow and start feeding.
• In case of Boiler stoppage.Close the boiler stop valve and maintain drum level.

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9. NORMAL SHUT DOWN TO COLD

Responsibility :

• Reduce the fuel feeding rate and slowly empty before switching off feeders.

• Open the manual doors at the drag chain feeders to kill the vaccum created by
PA fan to avoid carry over of coal by gravity.
• Maintain the same air flow to cool bed faster.
• Isolate main steam stop valve.
• Open air vent to reduce the steam pressure if steam is not drawn out.
• If it is not necessary to enter the boiler for maintenance slow rate of pressure
and temperature decay is desirable. Switch of fans when bed has cooled down to
500 DEG C.
• If it is desirable to accelerate cooling process in order to permit for maintenance
fans should be continued to run at the same flow rate until temperature reaches
100 DEG C.
• Maintain normal water level.
• After bed temperature reaches 100 DEG C open boiler blown down valve and
drain water if the boiler water temperature reaches only 90 DEG C. ( To be done
only incase to attend any maintenance jobs on pressure part side).
• In case to attend fludising nozzles or distrubuter plate jobs drain bed material.

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10. NORMAL SHUT DOWN TO HOT STAND BY

Responsibility :
• If the boiler is required for shut for short period (Minimum 2 Hours) only.
• Switch of the fuel feeder,FD,PA& ID fans instantaneously.
• The PA dampers and FD dampers remain in open condition.
• Close FD and ID dampers must be closed.
• Close the main steam stop valve and keep the vents in closed condition to
sustain steam pressure and temperature.
• Maintain the water level in the drum.

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11. HOT RESTART

Responsibility :
• Open the air vent Ensure FD damper and PA damper for open condition.
• Keep the FD and ID fan dampers in close condition.
• Start ID,PA and FD fans in quick succession.
• Start the fuel feeders with minimum speed.
• Gradually open ID and FD fan dampers to maintain air flow D.P of 30 MM and
plenum chamber 10 MM.
• Increase the speed of fuel feeders and watch the bed temperatures.
• As the bed temperatures increases slowly increase the air flow and fuel feed rate
as per load requirement.
• If bed temperature fails to raise stop the fuel feeders.
• If the bed temperature is below 600 DEG C throw charcoal and raise the
temperature.
• If th bed temperature falls below 300 DEG C cool the bed and start the boiler
following “ normal startup from cold “ procedure.

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12. CONTROL LOOPS

Responsibility :
a.Drum level Control
• Purpose is to maintain constant water level in the drum
• For single element control drum level is directly taken and feed control valve
regulates according to it.
• For Three element control the three parameters are
1. Drum Level
2. Steam flow
3. Feed water flow
Drum level has 3 level transmitters 2/3 three logic is being followed and
Level signal is density compensated by drum pressure signal.
Steam flow has 2 flow transmitters and flow is compensated by steam pressure
and temperature.
Feed water flow has 2 flow transmitters and any one being considered.
• Up to 30% of boiler load drum level to be controlled by single element and above
30% by three element control.
b. Combustion control
• Purpose is to ensure air flow into the furnance is proportional to the total amount
of fuel entering the furnace at any instant.
• Combustion control divided into two parts
1. Air flow control ( Auto Mode).
• Air flow control to be taken in auto when all compartments are in service
atleast once.
• Atleast two compartments should be in operation.
• Cross check the air flow Vs steam flow curve.
 • Observe for alarms when air flow reaches maximum and minimum valves.
2. Fuel flow control ( Auto Mode).
• Main steam pressure and bed temperatures are considered for fuel flow
control.
• Out of two bed temperatures average is considered and erratic signal( like
bed temperature less than 600 Deg c, Open circuit of thermocouple and
temperature difference of more than 50 deg C)are not considered.
• The fuel feeder trips if bed temperature reaches high 950 Deg C and starts
when temperature drops 750 Deg C.
• Irrespective of steam pressure fuel feeding increases when bed
temperature falls less than 800 Deg C.

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 13. NORMAL OPERATION

Responsibility :

• Steam generation can be varies by slumping compartments or by varying the bed

temperature or by varying bed height or by varying fluidisng air flow.
• Load variation of 70% to 100 % may be obtained by varying bed temperature.
• Bed temperatures can be reduced upto 700 Deg C and can be increased upto 900
Deg C based on demand.

• Further load can be reduced by reducing fluidising air flow not to the extent of
defluidisation of bed.
• In Such above cases air flow through PA lines should never be reduced.
• Bed height to be maintained around 450-550 MM of WC .
• Make up of bed material once in a week around 5 MT.
• Ingress of foreign material to be removed this may lead line choke which is
indicated by Drop in Bed temperatures for the same load and by PA line DP
switches.
• Maintain flue gas oxygen 3% to 5 % for better results.
• Continous blown down (CBD)to be kept constant after fine tunning. Only
Intermedite Blow down (IBD) to be operated depending upon Lab (Conductivity
,silica & TDS levels)report.
• Observe bed ash color for visual inspection of unburnt.
• Too much variation of furnace drop to be immediately informed to shift incharge
as it is an Sypmtom of Pressure part leakage.
• 10 Deg C Drop in ESP inlet temperature at constant load should be informed is
an indication of FD air leakage in at Air Preheater.
• Safety valves to be inspected at the drip pan for any passing of valves as passing
may lead to damage of safety valve seat.
• Hissing sounds to be observed and informed on frequent rounds which is also a
sypmtom of pressure part leakage.
• Gauge glass draining to be carried out periodically for better visibilty .
• Field pressure gauges,temperature gauges and local level transmitters to be
cross checked during every shift and any deviation to be informed.

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 14. INTER LOCKS/ START PERMISSIVES
1.ID FAN
• To start ID fan Drum level should be between 22%to 88% .
• ID fan suction damper should be in close condition.
• ID fan drive end and non drive bearing temperatures should be below 115 Deg C.
• ID fan Motor winding temperatures should be below 135 Deg C.

2.PA FAN
• ID fan should be in operation.
• PA fan drive end and non drive bearing temperatures should be below 115 Deg C.
• PA fan Motor winding temperatures should be below 135 Deg C.

3.FD FAN
• PA should be in operation.
• Furnace draught should be below +25 MM of WC.
• FD fan drive end and non drive bearing temperatures should be below 115 Deg C.
• FD fan Motor winding temperatures should be below 135 Deg C.

4.FD COMPARTMENTAL DAMPERS

• PA Damper to individual damper compartment to be in open condition
• When FD damper of individual compartment is in open condition Compartment
Bleed off damper should be in close condition and vice versa.

5.COAL FEEDER
• FD fan should be in operation
• FD damper to individual compartment to be in open condition.
• If in auto mode bed temperature should be Between 700 -1000 Deg C.

6.BOILER FEED PUMP

• Deaerator level should be greater than 30%.
• Feed pump drive and non drive temperatures should be below 115 Deg C.
• Feed pump motor winding temperature should be below135 Deg C.
• Boiler feed pump suction DP should be less than 1600 MM WC.

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 14. TRIPPINGS

Source of Tripping Alarm Trip Value Tripping Victim

• Drum level low 33% 22% ID fan

High 77% 88% ID fan

• Furnace draught High +10 MMWC +24.5 MMWC FD fan

Low -24.5 MMWC - -

• BFP Bearing Temp 90 Deg C 115 Deg C Feed pump

Winding Temp 110 Deg C 135 Deg C Feed pump
Suction DP 1300 MMWC 1600 MMWC Feed pump
Deaerator Level - 30 % Feed pump

• FD Bearing Temp 90 Deg C 115 Deg C FD fan

Winding Temp 110 Deg C 135 Deg C FD fan
PA Trips - - FD fan
Furnace draught - +24.5 MMWC FD fan

• PA Bearing Temp 90 Deg C 115 Deg C PA fan

Winding Temp 110 Deg C 135 Deg C PA fan
ID Trips - - PA fan

• ID Bearing Temp 90 Deg C 115 Deg C ID fan

Winding Temp 110 Deg C 135 Deg C ID fan
Boiler drum level Low - 22% ID fan
High - 88% ID fan

• Coal Feeder FD fan - FD fan trip Fuel Feeder

PA damper - Closes Fuel Feeder
FD damper - Closes Fuel Feeder

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