BOILER OPERATING PROCEDURE

PRE START UP ACTIVITIES

COLD START UP

WARM/ HOT STRAT UP

BOILER SHUT DOWN

CONTROL SCHEMATICS

SUPPLEMENTARY FIRING

PRE START INSPECTION

Furnace and flue path are clean and scaffolding material removed
Ensure access doors of flue path are closed
Steam and LP drums are clean and manholes are closed properly
Check and ensure that the safety valves are not gagged
Ensure the nitrogen capping valves are isolated
Fuel gas line is de-spaded and flexible hoses are connected
Ensure the Flame Scanners are aligned and fitted rigidly
Ensure sealing/ cooling air valves are open for the peepholes & flame scanners

PRE START INSPECTION - DEAERATOR

Ensure the water spray nozzles are tightly screwed in its place
Ensure perforated plates are in place
Ensure the cleanliness of the tank internal

Equipments are boxed up and lubricated (Aux fans, Dosing system,etc...

Ensure that all field instruments are in good working condition and lined up

PRE REQUISITES

FEED WATER

DIVERTOR DAMPER READINESS

POWER FOR EQUIPMENTS

INSTRUMENT AIR

READINESS OF FIELD INSTRUMENTS

DCS READINESS

READINESS OF DRAIN/ BLOW DOWN SYSTEM

READINESS OF AUX AIR FANS

GT OPERATION

CHEMICALS FOR HP & LP DOSING

FIRING SYSTEM & FUEL GAS READINESS

WATER FILLING
STEAM DRUM VENT
DEAERATOR VENT
VALVES TO BE OPEN

START UP VENT
SUPER HEATER DRAINS
MUWH TO BYPASS MODE
ALL THE DRAINS OF EVAPORATOR,
ECONOMISER & DEAERATOR

EBD & CBD

MAIN STEAM STOP VALVE

VALVES TO BE CLOSE

SPRAY WATER TO ATTEMPERATOR

DRAIN VALVES TO IBD TANK
SAMPLE LINES

WATER FILLING
ENSURE ADEQUATE FEED WATER QUANTITY
START FILLING THE EVAPORATOR, ECONOMISER AND
DEAERATOR THROUGH BACK FILLING
FILL STEAM DRUM & LP DRUM UPTO - 75 MM FROM
NWL
CLOSE THE HEADER DRAIN VALVES AND LINEUP FEED
WATER SYSTEM
KEEP READY THE CONDENSATE / MAKE UP WATER PUMP
KEEP READY THE BOILER FEED WATER PUMP

COLD START UP
AUX AIR FANS
Air for flame stabilization
Combustion purposes
Cooling of burner components
Two fans - one auto stand by
Switches:
ON - AUTO - OFF
Start one of the aux air fan and line up
the air system to burners

SAFETY INTERLOCKS
HP Steam Drum level not very low
HP Steam Drum level not very high
Deaerator level not very low
Auxiliary air pressure not very low
Furnace pressure not high
Emergency Stop is not operated
Steam pressure not very high

Boiler interlocks
Gas turbine running
Divertor is open to boiler
Instrument air pressure not low
Fuel Gas pressure not high
Fuel Gas pressure not low

BOILER INTERLOCKS
BMS

BURNER INTERLOCKS
BURNER TRIP INTERLOCKS

Main Flame failure

Igniter flame failure
Ignition time expired

Burner trip interlocks

Main Flame failure
Igniter flame failure
Flue gas temp very High
Sec super heater metal temp very High
Deaerator level not High

COLD START UP
Water filling done
GT is running at considerable load
Auxiliary Air fan is running
Boiler safety interlocks are satisfied
Now DD shall be opened
Throttle the DD opening - slow heating of the pressure part
Cold start up pressurizing curve

Objective is to reach minimum operating parameters

Drum swelling

COLD START UP
MODULATE THE DD ACCORDING TO THE PRESSURIZATION CURVE
KEEP THE DRUM UP VENT OPEN TILL STEADY STEAM FLOW IS
ESTABLISHED
CLOSE THE SUPERHEATER DRAINS AT 2 BAR PRESSURE
KEEP THE START UP VENT OPEN AND MODULATE AS REQUIRED
MAINTAIN THE DRUM LEVEL AND SELECT INTO TO 1E MODE
KEEP DEAERATOR VENT FULL OPEN AND MAINTAIN LEVEL
KEEP THE MUWH IN BYPASS MODE
START PHOSPHATE DOSING TO STEAM DRUM
START OXYGEN SCAVENGER DOSING TO LP DRUM

COLD STRAT UP
BEFORE CHARGING THE MAIN STEAM LINE, OPEN THE DRAINS
& TRAP STATIONS IN LINE TO STEAM TURBINE
OPEN THE MSSV BY-PASS / PRESSURE EQUALISING VALVE
OPEN THE MAIN STEAM VALVE ONCE THE STEAM LINE IS WARM
AND PRESSURE IS EQUALIZED
CLOSE THE START UP VENT GRADUALLY
OPEN THE DIVERTOR DAMPER AS THE HRSG IS LOADED
SWITCH OVER TO THREE ELEMENT CONTROL ONCE THE
STEAM FLOW IS > 25% MCR
TAKE THE STEAM TEMPERATURE CONTROL INTO AUTO MODE
TAKE THE DEAERATOR PRESSURE & MUWH OUTLET TEMP
CONTROL INTO AUTO MODE ONCE THE DEAERATOR IS
STABILISED

WARM / HOT STARTUP

Restart of the boiler above a steam pressure of 20 TO 40 bar is termed
as a warm startup.
Restarting a boiler immediately after a trip, when the boiler is still at
near about operating pressure - termed as a hot restart
In a warm start / hot restart, as the boiler was in service till the trip
out, the required valve line up will be available and can be quickly
checked by visual inspection
Following are the steps involved in the hot startup:
Normalize the steam drum level by modulating the feed water flow
control valve
Open the start up vent valve

Open the divertor damper after achieving the necessary Safety interlocks
Follow the Warm / Hot start up pressurisation curve
Follow the remaining start up procedure as explained for cold start up

WALK DOWN CHECK LIST

Unusual noises, may be from steam or water leakages
Steam or water leaks from valves, connections and fittings
Flue gas leakage from boiler casing
Passing from safety valves at normal operating pressure.
Clear & bright flame and clear stack
Fuel gas leaks
Proper water level is being shown by the direct water level gauges

BOILER SHUTDOWN
PLANNED SHUTDOWN:
Sequence of
shutdown:

activities

to

be

followed

during

planned

Stop the duct burners after reducing the firing rate to

minimum
Reduce the boiler load gradually, at steam flow below 25%
switch the drum level control to single element
Take the deaerator pressure control into manual mode and
open the vent valve fully

Close the MSSV

Close the divertor damper

Stop the phosphate & oxygen scavenger dosing

Close the CBD valve

Maintain the drum level

BOILER SHUTDOWN

Verify the EBD valve is closed

Allow the boiler to cool naturally

Auxiliary air fan is continued

temperature falls below 100 0C

till

the

furnace

If the boiler shut down is for more than 8 hours, fuel gas
supply has to be isolated
When the steam drum pressure drops to 2 bar, open the
steam drum and the startup vent. Also, open the super
heater drains
If the shut down is for longer period, keep the boiler
under preservation

CONTROL SCHEMATICS
CONTROL LOOPS:
HP boiler drum level control
LP Drum level control
Deaerator pressure control
HP steam temperature control
Make up water heater outlet temp control
Combustion control