DESIGN DATA: (Reference from data sheet)

Make: Thermax PC/oil fired boiler

Capacity: 750TPH
Design Pr.: 111 kg/cm2
Design Temp.: 540

0
C
Hydro test Pr.: 202 kg/cm2

OPERATING PROCEDURE:

Sr.
No.
ACTIVITY
RESPONSIBILITY
SIC DE FE
PRE- START CHECKS:
1. Confirm no any permit to work (PTW) is pending on boiler.
2. Ensure availability of DM water, LDO, HFO with conformation from utility
department.


3. Ensure that deaerator is lineup & also BFP is available.
4. Ensure main steam line & drum safety valve not gagged.(PSV001-001A-
002-002A-003)

5. Ensure that all transmitters & instrument are healthy.
6. Ensure that power supply is available for all motorized operated valves.
7. Ensure that no safety protection is by pass.
8. Ensure that feed water is lineup up to FRS station.
100% FCV FV1805 close.
100% FCV upstream MOV1804 close.
100%FCV downstream isolation valve open.
100%FCV bypass FV1807 close.
100%FCV bypass upstream MOV1806 close.
100%FCV bypass downstream isolation valve open.
30%FCV FV1803 open.
30%FCV upstream MOV1802 open.
30%FCV bypass downstream isolation valve open.



9. Ensure that Attemperation is lineup.
Attemperator main isolation valve is open.
Attemperator CV close.(TV 28112823 2825B 2825A)
Attemperator CV upstream MOV close. (MOV 1822 1824 1828
1826)
Attemperator CV downstream isolation valve open.
Attemperator CV bypass MOV close. (MOV 1822A 1824A 1828A
1826A)
Attemperator CV bypass MOV upstream isolation valve open.


10. Ensure LDO is lineup.
Igniter oil line master fuel trip valve XV3902 open.
Upstream & downstream isolation valve of flow transmitter FT3901
open.
Isolation valves at all burner open.
Shutoff valves at all burner close.


11. Ensure HFO is lineup.
Oil flow control valve FV 3903A 3903B close.
Manual isolation valve at Upstream & downstream of FCV open.
Oil flow pressure reducing valve PV3904 close.
Oil flow master fuel trip valve XV3902 close.
Upstream & downstream isolation valve of flow transmitter FT3902
open.
Oil return line shut off valve XV3905 & other manual isolation valve
open.
Oil ring header return line Control valve FV3904A open.
Wash oil return line isolation valve close.
Steam tracing is lineup.


12. Ensure that atomizing steam is lineup.
Ensure that DP CV PV2907D close.
Ensure that DP CV PV2907C close.
Ensure that DP CV PV2907A open.(auto)
Ensure that all manual isolation valve open and shutoff valve close.


13. Secondary air lineup.
Ensure that FD fan A O/L damper close.(MOV4909)
Ensure that FD fan B O/L damper close.(MOV4910)
Ensure that RAPH A inlet damper open. (MOV4911)
Ensure that RAPH B inlet damper open. (MOV4913)
Ensure that RAPH A outlet damper open. (MOV4912)
Ensure that RAPH B outlet damper open. (MOV4914)


14. Primary air lineup.
Ensure that PA fan A I/L damper close.(MOV4919)
Ensure that PA fan B I/L damper close.(MOV4920)



15. Flue gas path lineup.
Ensure that RAPH A inlet damper open. (MOV5907)
Ensure that RAPH B inlet damper open. (MOV5908)
Ensure that ID fan A I/L damper open.(MOV5901)
Ensure that ID fan B I/L damper open.(MOV5904)
Ensure that ID fan A O/L damper close.(MOV5903)
Ensure that ID fan B O/L damper close.(MOV5906)


16. Ensure that down comer 1 to economizer R/C line MOV open.(MOV1809)
17. Ensure that drum vent valve open. (MOV2831 MOV2832).
18. Ensure that CBD (MOV1811) and EBD (MOV1814) valve close. And its
isolation valve open. (CB022 & MOV1813).


19. HP dosing isolation valve open.
20. Ensure that drain valve (HS009) of SH drain Header (Carbon Steel)to IBD
tank open. Filling valve close.


21. Ensure that drain valve (HS030) of SH drain Header (Alloy Steel) to IBD tank
open. Filling valve close.


22. Open the Roof inlet header drain valve (HS035 & MOV2861) (to SH Drain
Header (carbon steel)).


23. Open the HCPFW-B header drain valve (HS186 & MOV2864) (to SH Drain
Header (carbon steel)).


24. Open the HCPRW-B header drain valve (HS188 & MOV2863) (to SH Drain
Header (carbon steel)).


25. Open the HCPRH-B & PCPRH-B header drain valve (HS104 & MOV2862) (to SH
Drain Header (carbon steel)).


26. Open the HCPLH-B & PCPLH-B header drain valve (HS184 & MOV2865) (to SH
Drain Header (carbon steel)).


27. Open Primary Super heater inlet header drain valve (HS182 & MOV2866) (to SH
Drain Header (carbon steel)).


28. Open Platen Super heater inlet header drain valve (HS172 & MOV2871) (to SH
Drain Header (carbon steel)).


29. Open Primary Super heater outlet header drain valve (HS180 & MOV2867) (to
SH Drain Header (alloy steel)).


30. Open Secondary Super heater inlet header drain valve (HS168 & MOV2873) (to
SH Drain Header (alloy steel)).


31. Open Secondary Super heater inlet header drain valve (HS170 & MOV2872) (to
SH Drain Header (alloy steel)).


32. Open Secondary Super heater outlet header drain valve (HS166 & MOV2874)
(to SH Drain Header (alloy steel)).


33. Close the roof inlet header vent valve (MOV2833).
34. Close the primary Super heater inlet vent valve (MOV2834) and outlet
header vent valve (MOV2835)


35. Close the Attemperator-1A vent valve (MOV2836) and 1B header vent
valve (MOV2837).


36. Close the Platen super heater outlet header vent valve (MOV2839).

37. Open Main steam line drain before MSSV (HS163 & MOV2875) (to SH Drain
Header (alloy steel))


38. Open Main steam line drain After MSSV (HS162 & MOV2876) (to SH Drain
Header (alloy steel)).


39. Close the MSSV and Its bypass valve (HS138 & HS138A) (MOV
2851/2851A).


40. Open the Startup vent valve (MOV2852 & HV2854) and Pressure control
vent valve (MOV2856 )& PV2858 close &in auto).



POST- START CHECKS:


1. Start water filling through water filling connection (Water filling will be
stared through Down comer drain manifold)
While filling the boiler only use high quality & demineralised water.


2. Keep vigilance and allow water to fill in steam drum up to NWL.
3. After gating NWL (30%) in drum stop filling line isolation valve & down
comer drain isolation valve.


4. Give start command to RAPH.(as per SOP)
Ensure that all parameters are healthy.



5. Give start command to igniter air & scanner cooling air fan. (as per SOP)
Ensure that all parameters are healthy.



6. Give start command to ID fan.(as per SOP)
Ensure that all parameters are healthy.
Furnace draft Maintained at -5 to -10 MMWC



7. Give start command to FD fan.(as per SOP)
Ensure that all parameters are healthy.
Furnace draft Maintained at -5 to -10 MMWC



8. Gradually increase the air flow up to 30% with respect to Furnace draft.
9. Boiler Purge.
To purge the boiler following permissive should be satisfied
Both PA fan stopped.
Total boiler air flow at purge rate (30%)
One FD & ID fan running.
All igniter group SSVs closed.
Igniter header SSV closed.
All oil burner SSVs closed.
Oil header SSV close.
All coal feeders stopped.
All pulverizer swing valve stop.
All air registered damper at light-off position.
No MFT trip condition present.
Once these permissive have been established a purge timer will start to




accumulate time 420sec.
10. After purge completion reset MFT puss button.
11. Open atomizing air CV (PV4902).
12. Open igniter oil header SSV.
13. Igniter group starting.
Following permissive must be satisfied.
Burner group ASD at light off position.
Igniter group oil SSV closed.
Igniter group atom. Air SOV closed.
Igniter group trip reset.
After all permissive have been met igniter start indication generated.
Give start command to igniter.
After start command following sequences will proceed
automatically.
Open atom. Air SOV.
Open oil SSV.(3sec time delay)
(7sec delay time failed to open & close for all SSV SOV)



14. Check healthiness of flame.
15. Start other igniter group as per temp. Controlling rising curve.
16. If required more igniter groups can be taken in to line to match pressure
rising curve.



17. Maintain water level with opening 30% FWCV.
18. HFO burner starting.
Following permissive must be satisfied to starting the burner on HFO.
Burner group ASD at light off position.
Burner oil SSV closed.
Burner atom. Steam SOV closed.
Boiler oil header SSV open.
Oil burner trip reset.
Oil burner gun retracted.
Oil burner firing selected.
Igniter group ready to start or in service.
After all permissive have been met burner start indication generated.
1. Give start command to burner.
2. After start command following sequences will proceed
automatically.
3. Burner oil gun insert.
4. PC piping cooling air valve open.
5. Open atom. Steam SOV.
6. Open oil SSV.
7. Oil burner successfully lit.
8. ASD at firing position.



19. Close drum vent @ 2 kg/cm
2
(1:45 hours after first igniter startup) start up

vent to modulate to match the pressure rising curve. (Start up vent to be
maintained minimum 40% till flow established through main header)
20. Ensure that steam flow is established from super heater (Flue gas
temperature and skin metal temperature monitoring to be started
on continuous Basis once igniter groups are placed in service.
Once the all the water /condensate from SH is drained fully &
proper steam flow is established then only the gas temperature
can be increased above 538 Deg C. SH metal temperature reaching
42DegC above saturation temperature give indicates that SH is
drained fully.
Once this phenomenon is notice start increasing furnace
temperature by increasing fuel firing to suit start up curve. During
start up / normal operation SH Metal temperature should not cross
the design metal temperature of tube.)



21. Open IBD valve for flushing.(to avoid chocking of line)
22. At 5 kg/cm
2
close all 13 drain valve.


23. Ensure that pressure rising is as per curve.
1. Boiler Pressure should not be more than 4kg/cm2 (2hours after
first igniter startup)
2. Boiler Pressure should not be more than 7 kg/cm2(2:15hours after
first igniter startup)
3. Boiler Pressure should not be more than 9 kg/cm2(2:30hours after
first igniter startup)
4. Boiler Pressure should not be more than 12 kg/cm2(2:45hours
after first igniter startup)
5. Boiler Pressure should not be more than 15 kg/cm2(3:00hours
after first igniter startup)



24. At 15 kg/cm
2
Start charging VHP Header up to STG-1 & 2 MSSV(charge
header by opening bypass valve after charging open MSSV)



25. If required more oil burner & igniter groups can be taken in to line to
match pressure rising curve.



26. Ensure that pressure rising is as per curve.
1. Boiler Pressure should not be more than 23kg/cm2 (3:15hours
after first igniter startup)
2. Boiler Pressure should not be more than 30kg/cm2 (3:30hours
after first igniter startup)
3. Boiler Pressure should not be more than 38kg/cm2 (3:45hours
after first igniter startup)
4. Boiler Pressure should not be more than 48kg/cm2 (4:00hours
after first igniter startup)
5. Increase boiler load up to 260 TPH ( Ramp rate should be less than
20 TPH / 5 Min)
6. Boiler Pressure should not be more than 60kg/cm2 (4:15hours




after first igniter startup)
7. Boiler Pressure should not be more than 75kg/cm2 (4:30hours
after first igniter startup)
27. Boiler Pressure should not be more than 90kg/cm2 (4:45hours after first
igniter startup)
Boiler Pressure should not be more than 110kg/cm2 (5:00hours after first
igniter startup) (300min 111 kg/cm
2
540
o
C)



28. Coal mill start up.
After achieving required temperature and pressure start first pulveriser as
per SOP
Following permissive must be satisfied.
Boiler firing permissive satisfied.
Pulverizer group not tripped.
Pulverizer equipment permissive satisfied.
Coal feeder equipment permissive satisfied.
Associated igniter group ready or in service.
All burner PC pipes isolation valves are open.




Boiler Cold Start Up

> Ensure Boiler Readiness for Light Up
> Start the ID Fan as per start up Procedure
> Start the FD Fan as per start up Procedure
> Start Both RAPH as per start up Procedure
> Establish Air Flow between 30% to 40% of TAF
> Insulator, Hopper Htr & Rapping system of ESP
> Start Boiler Purging

0:00
> Start of First Igniter Group from lower Elevation (Prefrd)
0:10
> Start Second Group of Igniter
0:25
> Start of Third Igniter Group
1:30
> Start Pressure Rising in Boiler.
1:45
> Boiler Pressure. should not be more than 2 kg/cm2
2:00
> Boiler Pressure. should not be more than 4kg/cm2
2:15
> Boiler Pressure. should not be more than 7 kg/cm2
2:30
> Boiler Pressure. should not be more than 9 kg/cm2
2:45
> Boiler Pressure. should not be more than 12 kg/cm2
3:00
> Boiler Pressure. should not be more than 15 kg/cm2
3:05
> Start charging VHP Header up to STG-1 MSSV
3:15
> Boiler Pressure. should not be more than 23 kg/cm2
3:30
> Boiler Pressure. should not be more than 30 kg/cm2
3:45
> Boiler Pressure. should not be more than 38 kg/cm2
3:50
> Start Turbine Preheating with opening of MSSV - Bypass
valve and opening warm up vent valve
4:00
Boiler Pressure should not be more than 48 kg/cm2
4:00
Increase Blr load to 260 TPH (20 TPH / 5 Min Ramp rate)
by operating let-down station and maintain
steam Temp between 400 deg. C to 500 deg.C
4:15
Boiler Pr. should not be more than 60 kg/cm2
4:30
Boiler Pr. should not be more than 75 kg/cm2
4:35
Start Turbine Rolling.
4:45
Boiler Pr. should not be more than 95 kg/cm2
5:00
Boiler Pr. should not be more than 110 kg/cm2
5:05
Turbine @ FSNL, ready for synchronization.
5:15
Synchronize Turbine & Increase MW based on MS Temp.
5:30
Start First Pulveriser, Increase Boiler Loading up to 260
to 300 TPH within approximately 1.5 hr duration
& stabilise Mill Operation
7:00
Start 2nd Mill, Increase Blr Loading up to 350 to 400 Tph
within approximately 1 hr 15 mins. duration & stabilise
mill Operation, Cut One-bY-One FO Burner.
8:15
Start Third Pulveriser, & Increase Boiler Loading from to
400 TPH to 750 TPH as per plant requirement but ramp
rate should not be more than 50 TPH / 15 mins.