Requirements of Bed material,Charcoal & Diesel. Bed material    Maximum Particle size Bulk density Chemical composition :0.

85 MM TO 2.36 MM : 1000 to 1100 Kg/M3 : Alumina : Silica   Fusion temperature Qty required for start up Charcoal     Size Calorific value Qty required for start up Diesel Qty required for start up : 20-25 MM Lumps : 6000 6500 Kcal/Kg : 350 400 Kgs (Approx.) : 60 - 100 Ltrs (Approx.) : 1400 Deg C : 25 TO 30 MT (Approx.) 45% to 35% 55% to 65%

Preparation before light up   Check the bed material & char coal are free from moisture. First compartment to 280 MM of WC from DP plate for reduction of charcoal and diesel consumption.   Bed material to be filled and level of defluidised bed should be 350 MM of WC. Fill the water and keep the drum level 30-35%.Irrescpective of drum level 30-35% 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.   Ensure CBD and IBD valves are in operation by operating once. Inspect the boiler before start and check the following 1. Ensure the deaerator water level as normal.

2. Ensure all access doors are closed. 3. Ensure all personel were cleared. 4.Ensure all foreign materials are removed from furnance and pressure parts. 5.Ensure all equipment trial to be taken. 6. All interlocks to be cross checked.  Check the following equipments for adequate lubrication. 1.Fans and drives. 2.Feed pump and drives. 3.Fuel feeders and controllers. 4. LDO pump.  Check for dry fuel(0-6 MM) is available in bunker and gates below bunker are open and fuel is available at feeder inlet.  Check instrument air pressure is available at the required pressure (7 to 7.5 Kg/sqcm) for instuement and control.  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.  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.  Check the bed material and fludisation study is being done. 1. Set the air flow to 5-6 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 procedure  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.    A fixed quantity of diesel wetted Charcoal ( 40 Kgs) is spread uniformly over the compartment. Start ID Fan and maintain furnace draught of -3 to -5 MM of wc. Start PA Fan and Maintain header pressure of 750 to 900 Mm of WC based on bed material fludization.   Start the FD fan and maintain bed pressure 150 250 mmwc. Start the LD oil pump and maintain the oil pressure between 6.0 valve can be opend for maintaining the above pressure)  Ensure all the oil burner nozzles are free from blockage and flush out some diesl through the nozzles. 8.0 kg/cm.sq( Recirculation

   

Charge the atomizing air line and fix the oil gun to the furnace. Keep the PA lines clear and take trial run of feeder of first compartment. Light up all the four burners. Increase the FD air flow gradually to allow proper fludization of bed material & char coal and allow 5-10 minutes to ignite charcoal and mix the bed by varying air flow.

Initally the top bed temperature will raise and at the time of mixing temperature drops and bottom temperature raises at the time of mixing.

     

When the bed temperatures reaches 450-600 Deg C start the drag chain coal feeder. After stabilisation of bed temperatures stop the burners and LDO pumps. Turn off the oil burners and remove from furnace. Close all air vents when the drum pressure reaches between 2 to 3 kg/cm.sq. Close the bed superheater drains. Ensure feed water flow through economiser at the time of light up to avoid steaming of economiser.

 

Maintain drum level at normal recommended level. Open the MSSV bypass valve when the steam pressure reaches 60 - 70 kg/cm.sq. and temperature reaches between 400 to 450 deg.C.

Open the Stop valve when the staem line after MSSV boiler out let reaches the steam pressure 65 75 kg/cm.sq. and temperature reaches between 400 to 450 deg.C. and close the Bypass valve.

Charge the ESP fields when the ESP inlet flue gas temp reaches >120 deg.C and start the ash handling system.

Maintain the steam pressure 85 kg/cm.sq and steam tenperature 515 deg.C and stable the boiler.