BOILER STARTUP

PROCEDURE:
1. PREPARATIONS BEFORE LIGHT UP-

All the reduction gears should be flushed with oil & filled
with correct grade of lubricant up to the recommended
level. Please over filling should be avoided because it
causes oil churning and resulting in over heating and
leakage. Dipsticks/ sight glass are provided to facilitate
checking of oil level.
Once the initial lubrication has been taken properly and
stoker equipment has been inspected and tested , the
next step is to prepare for lighting up. It is presumed that
treated water is taken in the boiler upto normal level.
Ensure commissioning of all auxiliary equipments &
instruments has been carried out satisfactorily.
Check & ensure all interlocks & protection systems are
working properly.
Maintain at least 60% MCR airflow through boiler for 5
min. before lighting up,to purge any combustible gases
from boiler. Check the healthiness of all fans.
Ensure availability of fuel at plate gate valve/ rack &
pinion gate of each spreader. All dampers in the main air
duct shoul be opened. Start the feeding to spreader
slowly. The fuel leaving the plate gate valve/rack & pinion
gate will fall on spreader through drum feeders and
spread into the furnace. By adjusting the spreader air
pressure & angle of deflector plate ,spread of fuel can be
made uniform.
Check furnace & examin the lateral distribution of fuel on
the grate to confirm that it is uniform. After completing
this activity clean the furnace by removing all fuel from
grate bed.

2. LIGHTING UP FROM COLD CONDITION-

Maintain water level at 40% of gauge glass in the steam

drum.
Open all air vent & main steam line,superheater line all
drain valves.
Check & close all blow down valves.
Check operation of start of vent valve.

 Check air compressor & instrument air pressure

available.
Start ash handling system & hoppers RAV to avoid
chocking and jamming of ash hoppers.
Properly lay down kindling( i.e wood & waste oil rags) on
to the entire grate surface.
Open all inlet & outlet dampers of all fans and riddling
hopper dampers are open.
Set fire to the start up wood & waste oil/cloth.
The natural draught through the grate will cause
combustion progressively to spread over the bulk of the
fuel area.
As soon as the fuel is well ignited,slight adjustments to
air supply may be necessary to maintain satisfactory
combustion.
The I.D fan must be started first then F.D fan,it will
prevent the pressurization of the chamber.
Close I.D fan dampers and start I.D fan at minimum
speed .Open the damper & increase speed as required to
maintain required air flow observing the fire in the
furnace. Maintain the suction in the combustion chamber
of -2mmwc to -10mmwc.
Close F.D fan dampers & start F.D fan. Open the damper
and increase speed as required to maintain required air
flow observing the fire in the furnace.
Keep a close watch in the fire inside the furnace, furnace
condition & furnace temperature rise.
Adjust I.D fan to give a suction of -5mmwc in combustion
chamber.
Close S.A fan dampers & start S.A fan. Open the damper
and increase speed as required to maintain air flow.
Maintain at least 380 mmwc pressure at spreader
header.
Keep a constant watch on furnace condition in close
coordination with field.
Start fuel feeding system when the furnace temperature
reaches greater then 250C.
If there is black smoke from the stack then reduce fuel
quantity or increase air , until the stack gas is clear.
At a steam pressure of about 30 psig (2.1 kg/cm2.g.)
steam will be seen to issue freely from the air release
valves. These can now be shut.

 Maintain water level at 40% of gauge glass.

Superheater steam temperature must be monitored until
pressure is raised and flow is established through super
heater.
Steam will now be passing through super heater tubes
and through open drain valves & start up vent valve.
This flow of steam can be controlled to a level sufficient
to prevent over heating of the super heater tubes by
manipulation of drain valve & start up vent valve.
No mention has so far been made about using the
secondary fan for the supply of combustion air through
the secondary air nozzle. Experience will show the
extent to which this has to be used either at all ratings
or only at some, and not at others. If the chimney gas
can be kept reasonably clear in color without the use of
the secondary air at any particular rating there is then
no need to use it at that rating at all. To facilitate
adjustment of secondary air for over fire air(OFA)nozzle
at different elevation dampers are provided in the
ducting. Adjust these to obtain the best operating
condition of the boiler.
Start chemical dosing system & maintain required boiler
water chemistry.
Charge the deaerator, HP heater, SCAPH, and must be
taken in line as soon as possible after light up of the
boiler to avoid air pre heater chocking & other effects
such as back end corrosion.
Keep a constant watch on all auxillary equipment, record
the temperature of bearings associated with fans and
pumps.
Start the ESP as soon as flue gas temperature raises
about 120 deg C at ESP inlet.

3. LIGHTING UP FROM HOT CONDITION-

If the boiler has been on standby under pressure and is

required back in service. Boiler is considered in hot condition
if all the conditions are as follows achieved: Boiler main steam line pressure at the time of restarting
or taken in service should be greater then 40% of its
working pressure.
Furnace pressure should not be less then 400 deg C. if
furnace temperature comes below then 400 deg C then
immediately put/ throw firewood compeletly dip with

diesel inside the furnace to maintain the furnace

temperature.
Further fuel feeding system will be started only when
furnace temperature is more then 250 deg C maintained
with fire wood.
STARTING PROCEDURE Maintain water level at 40% of gauge class in the
steam drum.
Open all drain valves of main steam line & super
heater line.
Start ash handling system & hoppers RAV to avoid
chocking & jamming of ash hoppers.
Follow the boiler light up procedure as started above.
PUTTING THE BOILER ON LOAD When pressure is raised and boiler is ready to accept
load the main steam line must first be warmed
through.
Open steam main drain valve & all steam drain valve
up to end user to remove any condensate.
Open boiler main steam stop valve equalizer/ bypass
and warm main steam line.
When main steam line is warm, close drain valves and
slowly equalize the pressure on both side of stop valve
through bypass valve if provided.
Open stop valve fully when pressure on both sides is
equal.
As load is taken feed water must be introduced to
maintain normal working level and fuel input must be
controlled to maintain constant pressure and balance
the steam output.
When a steady flow of steam is established ,the super
heater drain valve can be shut. Ensure 30% steam
flow through super heater elements by either process
demand or by startup vent valve opening.
When conditions are stabilized the feed water control
loop can be put into service. Check that this is
maintaining water level at normal working level.
Put all boiler controls in automatic mode once the
boiler load exceeds 60% MCR.

 As soon as the unit is under load travelling grate

should be started. The speed of travelling grate should
be controlled so that unburnt %age in ash before
discharge/leaving the grate is minimum and grate
surface should be free from any heap/uneven
distribution.
The speed of travelling grate has an influence on
longitudinal fuel distribution. Increased speed of stoker
have a tendency to draw fuel away from the rear wall
and vice versa. Accordingly, it may be necessary to
slightly adjustment of deflector plate angle & spreader
air nozzle angle with changes in grate speed.