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BOILER START UP OPERATION SHORTCUT

STEP 1 Preparation
1) Manpower and Schedule
2) Readiness of equipment before start up.
3) Boiler Island/Utilities Building Motorized and
Pneumatic Valves/Dampers Stroke Testing
4) Boiler and EP manholes box up, sealed & fully tighten
5) Boiler Manual Isolation Valves Checking
6) DCS checking of all Motorized and Pneumatic
Valves/Dampers
STEP 2 Electrostatic Precipitator Auxiliaries Started Four
(4) hours before Boiler Start Up
1) Air Heater (706HX01)
2) Purge Air Fan (706FN01)
3) DE and CE Rapping Motors
STEP 3 Steam Drum Water Filling
1) Target level: 26 percent (- 127 mm )
2) Amine Dosing Pump Stroke is 55 percent
STEP 4 Boiler Draft Fan Started
1) 701PV105 - 35 percent open
2) 701HV136 and 701HV137 - fully close
3) Furnace Pressure Control-Hydraulic Coupling
4) Staging Air Motorized Valves Opening
4.1) Lower -701HV180ABCDEF - 10 percent
4.2) Upper - 701HV180GHIJKL - 60 percent
5) Start Induced Draft Fan (701FN03)
6) Start Fluidizing Air Blower (701BW01A or B)
7) Start Secondary Air Fan (701FN02)
8) Start Primary Air Fan (701FN01)
9) Furnace Control (Hydraulic) put in AUTO
STEP 5 Furnace Purging
1) Start Furnace Purging
STEP 6 Sand Injection to Furnace
STEP 7 Start Up Burners Ignition
1) 701PV145 - 64 percent open
2) 701HV147 - fully close
3) 701FV152AB - fully open
4) 701FV189AB - 16 percent open
5) Start one SUB
6) Temperature gradients becomes stable
STEP 8 Boiler Pressure Raising
1) Target Pressure - 6 MPaG
2) Target Temperature 400 C
3) Reduce SUBs Return Flow Control Valve
4) Increase SUBs Air Flow Control Valve
5) Control Steam Drum Level thru 701HV136/701HV137
6) AUTO Deaerator Storage Tank Level Control
Valve (701LV118) and SV is 65. 2 percent
7) AUTO Steam Drum Level Control Valve (701LV135)
8) At Steam Drum Pressure of 200 KPaG, fully close
manual vent isolation valves

9) At Steam Drum Pressure of 500 KPaG, conduct furnace


STEP 9 Deaerator System in Service
1) 701-V-028 - 20 percent open
2) 701-V-065 - 20 percent open
3) LOCAL 711HV099 - 5 percent open
4) Target Pressure: 0.65 ~ 0.70 MPaG
5) Target Temperature: 120 C
6) After item 4 & 5 attained, fully open 701-V-028, fully
close 701-V-065 and fully open 711HV099, switch to
STEP 10 Electrostatic Precipitators Hoppers Heat up
1) Close steam trap isolation valves
2) Open bypass isolation valve of steam trap
3) Fully close 701-V-972
4) Fully open 701-V-973
5) 50 percent open bypass 701-V-974
6) 20 percent open drain 701-V-975
7) 20 percent open of 701-V-314
8) Line already purge and condensate is minimal,
8.1) Online steam trap and close bypass
8.2) fully open 701-V-972
8.3) fully close bypass 701-V-974
8.4) fully close drain 701-V-975
STEP 11 Steam Turbine Rolling or Turning
1) Target Pressure is attained: 6.0 MPaG
STEP 12 Coal Feeding to Boiler Furnace
1) Target Lower Bed Temperature is attained
of 450 C ( 701TI170L )
2) Intermittent local start of Coal Feeder starting
by one at a time: 30 sec., 1 min. and 5 min.
3) Lower Bed Temperature (701TI170L) reaches to 500 C
4) Continuous running of Coal Feeder B
5) Lower Bed Temperature ( 701TI170L ) is 550 C
6) Continuous running of Coal Feeder A or C
7) Lower Bed Temperature (701TI170L ) is 600 C
8) Continue mix firing until 701TI170L is 650 C
9) If 701TI170L is 650 C ( ideal temperature for coal firing
), stop SUB one at a time
10) One ( 1 ) tph of diesel is Two ( 2 ) tph of coal
11) Put in AUTO each Coal Feeder for Coal MasterControl
12) Adjust Primary Air Flow rate from 85 to 120 KNm3/hr
13) Adjust Secondary Air Flow rate from 120 to 60
STEP 13 Electrostatic Precipitator Transformers put in
service
1) Target ESP inlet temperature (701TI165AB)
120 C
2) Service ESP Transformer 1, 2, 3 and 4
STEP 14 Power Transfer from DEG to STG
1) 1 MW per minute transfer
2) Adjust 701PV105 opening
STEP 15 Fly Ash Handling System put in service
STEP 16 Limestone Injection System Start

STEP 17 1st and 2nd Stage Desuperheater Service


1) MSF 63.6 tph or 20 percent MCR
2.1) For 1st Stage Desuperheater:
2.1.1) Permission is YES of 701KV131
2.1.2) AUTO mode of 701TIC103
2.1.3) REMOTE mode of 701TIC102
2.1.4) manually open 701KV131
2.1.5) AUTO mode of 701KV131
2.2) For 2nd Stage Desuperheater:
2.2.1) Permission is YES of 701KV132
2.2.2) AUTO mode of 701TIC105
2.2.3) REMOTE mode of 701TIC104
2.2.4) manually open 701KV132
STEP 18 Boiler Sampling Rack in Service
STEP 19 AUTO-Standby Mode of Standby Equipment
1) 712CP01A or B in AUTO - HOT START ENABLE
2) 701PU01A or B in REMOTE - AUTO
3) 701PU02A or B or C in REMOTE - AUTO
4) 701BW01A or B in REMOTE AUTO
STEP 20 Parallel of 701PU02AB or AC or BC
1) If MSF 130 tph
2) For Desuperheater use also
STEP 21 Sand Injection to Furnace
1) Furnace Bed Differential Pressure Target is 14~14.5
KPaG.
STEP 22 HPH and LPH in service
STEP 23 1 Element to 3 Element of Steam Drum Level
Control
1) If MSF 50 tph
2) 1 Element Control ( 701LIC1E ) in AUTO
3) REMOTE mode of 701FIC129
4) AUTO mode of 701LIC3E
5) At Drum Control Mode, switch 1E to 3E
6) AUTO mode of 701PV105
STEP 24 Coal Master Control in AUTO
1) If MSF is 150 tph or TG output is 50 percent of its
rated capacity
2) Confirm SUB Flow Valve in Fully close position
(701KV151A1/A2/B1/B2)
3) REMOTE mode of 701FIC181
4) REMOTE mode of 701FIC183
5) AUTO mode of IDF Hydraulic Coupling
6) Coal Feeder Control in AUTO mode
7) AUTO mode 701BW01A or B suction control damper
(701FV191A or B)
8) After all above condition is confirm, set Coal Master
STEP 25 Boiler Master Control in AUTO
1) Confirm the following:
1.1) If MSF is 150 tph or TG output is 50 percent of its
rated capacity

1.2) Confirm SUB Flow Valve in Fully close position


( 701KV151A1/A2/B1/B2 )
1.3) REMOTE mode of 701FIC181
1.4) REMOTE mode of 701FIC183
1.5) AUTO mode of IDF Hydraulic Coupling
1.6) Coal Feeder Control in AUTO mode
1.7) AUTO mode 701BW01A or B suction control
damper ( 701FV191A or B )
1.8) After all above condition is confirm, set Coal Master
Control to AUTO mode.
1.9) Fully close 701PV105 and in AUTO.
2) Switch the Boiler Master (701HICBM) in AUTO mode
STEP 26 Normal Boiler Operation
1) Monitor the following parameters.
1.1) Steam Drum Pressure
1.2) Main Steam Pressure
1.3) Main Steam Flow
1.4) Steam Drum Level
1.5) Furnace Temperature
1.6) Total Air Flow
1.7) Coal Feedrate
1.8) Furnace Pressure
1.9) Furnace Upper Differential Pressure
1.2.1) Among others
2) Adjust the Secondary Staging Air Motorized Valves:
2.1) 10 percent open for rear wall - lower
2.2) 10 percent open for rear wall - upper
2.3) 25 percent open for front wall - lower
2.4) 14 percent open for front wall - upper
3) Bottom Ash Removal after SUBs shutdown
4) Sand Injection to Furnace after bottom ash removal
5) Monitoring of Boiler Parameters and normalize the
operation.
6) Conduct water analysis and make adjustment of the
Boiler Dosing Stroke.
SUMMARY
STEP 1 Preparation
STEP 2 Electrostatic Precipitator Auxiliaries Started Four (4) hours
before Boiler Start Up
STEP 3 Steam Drum Water Filling
STEP 4 Boiler Draft Fan Started
STEP 5 Furnace Purging
STEP 6 Sand Injection to Furnace
STEP 7 Start Up Burners Ignition
STEP 8 Boiler Pressure Raising
STEP 9 Deaerator System in Service
STEP 10 Electrostatic Precipitators Hoppers Heat up
STEP 11 Steam Turbine Rolling or Turning
STEP 12 Coal Feeding to Boiler Furnace
STEP 13 Electrostatic Precipitator Transformers put in service
STEP 14 Power Transfer from DEG to STG
STEP 15 Fly Ash Handling System put in service
STEP 16 Limestone Injection System Start
STEP 17 1st and 2nd Stage Desuperheater Service
STEP 18 Boiler Sampling Rack in Service
STEP 19 AUTO-Standby Mode of Standby Equipment
STEP 20 Parallel of 701PU02AB or AC or BC
STEP 21 Sand Injection to Furnace
STEP 22 HPH and LPH in service
STEP 23 1 Element to 3 Element of Steam Drum Level Control
STEP 24 Coal Master Control in AUTO
STEP 25 Boiler Master Control in AUTO
STEP 26 Normal Boiler Operation