SOP For Boiler Light Up Checklist

JINDAL INDIA THERMAL POWER LIMITED
DERANG, ANGUL
2 X 600 MW Power Plant
SOP for BOILER CHECKLIST

Issue No: Issue Date: Revision: Revision Date: File no: Page 1 of 9
WORK INSTRUCTIONS
FOR
BOILER CHECKLIST
[JITPL/ SOP / BC]
Prepared by: Reviewed by: Approved by:
Signature: Signature: Signature:

Name: Name: Name:
Designation: Designation: Designation:
DERANG, ANGUL

Amendment Record
Amendment Amendment Nature of Change ACK No.

Date
Rev Page
No. No.

Name: Name: Name:
DERANG, ANGUL

1.0 Purpose:
This Procedure is intended to provide guidance and instructions for carrying out for cold start up
checklist of Boiler.
2.0 Responsibility:
a) All the personnel involved in carrying out /supervising the above activities are required to ensure
implementation of this procedure and may consult any other relevant documents indicated under
Reference section below.
b) In the event of any changes required in the procedure such changes may be requested with Site
in charge who would take appropriate action with approval from respective departmental heads.
3.0 Cold Start up Boiler Checklist:
BOILER SIDE CHECKS

GENERAL
1. No PTW is pending on Boiler Pressure parts/Draught system /ESP /AH system etc.
2. All manhole doors of boiler/FG duct/APH/ESP/Air ducts etc. are closed
3. All materials are removed such as scaffoldings/sky climber etc.
4. Written clearance given by Boiler Maint. Dept. Pressure Parts / PM group /Mill Group /ESP & Ash
Handling Group for start up of boiler.
BOILER DRAINS & VENTS

1. Boiler drum vents are open.
2. N2 capping vents are closed.
3. RH vents are open (During vacuum pulling close).
4. RH Drain at firing floor is open. With manual valve.
5. MS SV before drains are open from LHS/RHS.
6. SH drain header all valves are open along with their manual valves. Common main manual valve
to IBD is open.
7. SH vents along with the start-up vents are open.

Name: Name: Name:
DERANG, ANGUL

8. EBD are lined up.

9. CBD tank is lined up to D/A or IBD Tank, Manual valves are opened accordingly.
10. CBD manual valve below drum floor is in open condition.
11. CBD sample line root valve is open.
12. Boiler drains are closed at “0” Mtr drain station along with their respective manual isolation
valves. Main drain valve to the IBD tank is also closed.
BOILER WATER AND STEAM CKT
1. Boiler is filled with water up to normal drum level ( +/- 50 mm ) with chemicals
2. Filling is to be done by following the standard filling procedure to bring up to the normal level. (add
chemical dosing during boiler filling ). Inform shift chemist for boiler filling.
3. All Spring loaded safety V/Vs are available.
4. If any safety valve not available record it with reason.
5. Both ERV’s isolation V/Vs are open.
6. All expansion indicators are available & the format for expansion measurement available.
7. All sample (Sat. Steam, Feed water, Main Steam) coolers are charged from water side. All root
valves of the mentioned samples are open at different elevations. After light up ensure samples
are coming.
8. At least one DG in line
CC PUMPS & AUXILIARIES
1. Check CC pump breakers are racked in after boiler filling and drum level+200mm.
2. Check One SG DMCW pump is in service.
3. Check CC booster pump power supply is available & both pumps are lined up Keep One pump in
service
4. Line up of LP/HP cooler & purge system is checked. It should be in isolated condition.
5. Emergency make up line to overhead tank is lined up.
6. Check in MMI all alarms /indications.
7. Check all three CC pump discharge valves are open.
ECONOMISER

Name: Name: Name:
DERANG, ANGUL

1. Eco. I/L header Drain valve is closed.

2. Eco recirculation line to Bottom Ring header valve is open.
SH / RH SPRAY SYSTEM
1. SH spray is lined up, RH spray is lined up from respective BFP 's.
2. All manual spray ISO valves are open.
3. All drains /Vents at the station are closed after purging.
4. Air supply to the Block valve and control valves are open.
ID FANS A & B
1. VFD AC system is in service/ VFD room is clean.
2. VFD source breaker is racked in & alarm at VFD room is reset.
3. VFD breaker (Load breaker) racked in.
4. Lub Oil systems are in service (LOP auto changeover is checked).
5. Cooling water system charged for Lub oil coolers & Motor cooler.
6. I/L, O/L gate & IGV operation checked.
7. Outlet gate air blower & valves operation checked.
8. Check the MMI for all permissive are available.
PA/FD Fans A& B

1. All Fan Breakers are racked in.
2. Lub oil pump change over checked, one pump in service.
3. Fan discharge gate is opened.
4. Discharge gate operation is checked & OK.
5. Blade pitch operation checked & is in minimum position. Check links are properly locked
6. Fans are lined up to take start.
SEAL AIR FANS

1. Check PA fan header pressure greater than 750 mmwc.
2. Keeping one fan in manual start other fan.
3. Check the discharge header pressure

Name: Name: Name:
DERANG, ANGUL

2 NOS APH (TRISECTOR)

1. All motor power supplies are available.
2. Air motor lined up and all filters are having oil.
3. Soot blowers are available. Dry Operation of SB checked.
4. All air side dampers are closed/open checking BOTH inlet & outlet.
5. Thermocouples for hotspot detection are OK.
6. Lub oil system in service & GB/SB , oil level OK
7. Oil carry over probe is ready
8. Cooling water system charged for oil carry over probe / Lube oil system
9. Fire Fighting system / APH water washing system are properly isolated.
10. APRDS HT HDR. Charged & Aux steam to APH soot blowing is charged.
LDO & Atomising air SYSTEM

1. Check all isolation valves in oil system are open.
2. Check LDO is charged or while charging check for leakage.
3. Short recirculation is open. Atomising air is charged.
4. Check Drain oil tank level. & available of oil pump.
5. Check the PCV are lined up.
6. Check all drains are closed.
7. Check all return line valves are open.
BURNER SYSTEM/SCANNER AIR FAN

1. Scanner cooling air fan is in service .Note down pr. Check all hoses are connected.
2. Check availability of DC scanner air fan
3. All elevation isolation Valves for guns are open & guns are clamped in position.
4.
All elevation Burner tilt is horizontal.
5. All igniters are in position and fixed to guide pipe.
6. SA air to all igniters is opened.
7. Fire hydrant sprinkler system is charged & deluge V/V is kept on auto.
MILLING SYSTEM
1. Coal Bunkers
1. Ensure CHP is informed about coal bunkering

Name: Name: Name:
DERANG, ANGUL

2. RHS mills are fed first then the LHS mills

3. All Bunker level indications are correctly indicating
4. Status of Bunker outlet gates & their power supply.
5. If feeders PTW are cancelled then all the bunker outlet gates can be kept opened .
2. MILLS
1. Check nos of mills available for operation.
2. Respective HT BKRS are racked in. (6.6KV)
3. Lub Oil system is in service. Oil level & pressure adequate. Changeover of Oil pumps are
checked
4. Cooling water system for gear box oil cooler is lined up.
5. Check mill seal air fans are lined up.
6. Both Seal air fans are available & Power supply normalised. One Seal air fan EPB is kept
pressed to avoid auto start on PA fan starting.
7. Check MDV , Burner isolation gates are open for the available mills
8. CAG/CAD, HAG/HAD are lined up .All Mech. locks are removed.
9. Check in the Pulveriser interlock page the criteria are satisfied.
3. Coal Feeders
1. Check bunker outlet gates are open. Feeder inlet manual gates are open for available
feeders.
2. Seal air valves are ready.
3. Feeder outlet gate air supply charged.
4. Bunkers are filled with coal (Confirm from CHP)
4. MILL REJECT HANDLING SYSTEM

1. Check the service air charged to the air receivers and record its pressure.
2. Check all the gates are lined up properly.
3. Check the PLC system is in service
4. The system is selected in auto mode
ESP PASSES A/B/C/D

1. All 4 passes are charged from FG side. If any pass is isolated record it.
2. All 8 ESP transformers & ESP boards are independently charged.

Name: Name: Name:
DERANG, ANGUL

3. All auxiliaries are in service and all field power supplies are normalised and EC panel isolators are
ON.
 Hopper Heaters are ON. (28 Hrs. Prior to boiler light up)
 Shaft & Support insulator heater are ON (28 Hrs. Prior to boiler light up)
 Purge air blower.
4. Status of VFD /ESP AC plant. ESP control room is clean.
5. ESP Fields if not available record with reason.
BA HOPPER
1. All man hole doors are closed for hoppers and Clinker Grinder.
2. BALP pumps are in service for refractory cooling and seal trough make up.
3. BA Hopper and seal troughs are filled and seal trough is overflowing. No ash settlement is there in
seal trough.
4. BAMCC all sections are charged .All Clinker Grinder power supply is normalised.
5. BA LCP is charged & OK.
6. BAHP common valve is open position
7. Eco system to BAH are lined up.
8. BAH over flow tank to be line up.
FA SYSTEM
1. Check Instrument air is charged from its compressors are in service.
2. Check AHP SWGR is charged independently.
3. Check the vacuum pumps are ready.
4. Check all auxiliaries are available and power supplies are normalized.
5. Keep the system lined up to take start before Boiler Light up
6. Run the system, Clear all hopper mouth & note down hopper empty vacuum.
7. Ensure ESP fluidising blower readiness with its heater. Keep them in service
BOILER ACTIVITIES BEFORE LIGHTUP:
1. Boiler is filled up to normal level with all three CC Pumps in service. CC Booster Pump in service
, Standby BP lined up
2. All Vents in drum (4 nos), SH, RH are open. SH drains are open with final Manual Valve to IBD tank
in open position.

Name: Name: Name:
DERANG, ANGUL

3. Eco recirculation Valve is open till continuous FW flow is established through the Economiser to
Boiler Drum.
4. Check other vent /drain system lined up as per requirement.
5. CBD /EBD system lined up with manual valves open.
6. Both APH‘s are in service. Air Motor Available. Air pressure > 5.5 Ksc. Check All damper status
.Ensure FG Inlet damper power supply is isolated with damper in Open position.
7. Check all 4 passes of ESP are lined up with their auxiliaries in service.
8. Check BA /FA system are ready, BA Hopper/seal trough filled with water. Refractory Cooling
charged. CG Power Supply available.
9. All ID/FD/PA fans are lined up.
10. Start one pair of ID/FD Fans and ensure that other fans are not rotating in reverse,
11. Maintain air flow > 30% (680- 800 T/hr)<40%,
12. Start one scanner fan. Check availability of DC Fan. Note down Pressure.
13. Put SADC control in auto to maintain a fixed furnace to wind box D P,
14. Charge fuel oil station & put the LDO system in long recirculation. Atomising Air lined up.
Atmospheric drains are open in all 4 corners of AB elevation(15 Mins.). Atomising air pr > 6.5 ksc
15. Ensure burner tilt is in horizontal position (in all corners).
16. Ensure all MFT Conditions are Reset in MFT page ( all 3 channels )
17. Ensure all purge conditions are satisfied.
18. Check Boiler is ready for purge has come. Then Purge the Boiler for 5-10 minutes.
19. Put Oil guns on scavenging mode, check for any leakage near the gun connection. Ensure BMD
person’s availability.
20. Boiler stop valves are in closed condition & before stop valve drains (MS 401/402) are open with
manual valves are also in open position. Power supply Normalised for all valves.
21. Check HT PRDS charged, APH soot-blowing steam charged.
22. SH /RH spray station also lined up.

Name: Name: Name:

SOP For Boiler Light Up Checklist

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SOP For Boiler Light Up Checklist

Uploaded by

Copyright:

Available Formats

JINDAL INDIA THERMAL POWER LIMITED

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

Amendment Amendment Nature of Change ACK No.

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

3.0 Cold Start up Boiler Checklist:

BOILER SIDE CHECKS

BOILER DRAINS & VENTS

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

8. EBD are lined up.

BOILER WATER AND STEAM CKT

CC PUMPS & AUXILIARIES

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

1. Eco. I/L header Drain valve is closed.

PA/FD Fans A& B

SEAL AIR FANS

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

2 NOS APH (TRISECTOR)

LDO & Atomising air SYSTEM

BURNER SYSTEM/SCANNER AIR FAN

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

2. RHS mills are fed first then the LHS mills

4. MILL REJECT HANDLING SYSTEM

ESP PASSES A/B/C/D

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

BOILER ACTIVITIES BEFORE LIGHTUP:

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

2 X 600 MW Power Plant

SOP for BOILER CHECKLIST

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:

You might also like