STANDARD OPERATING PROCEDURE

BOILER COLD START UP

Preparations:--

(A) Inspect the boiler prior to starting and particularly check the following.

 All foreign material have been removed from pressure parts & from inside the furnace.

 Cold fluidization checks are to be made & recorded and it shall be ensure that the air nozzles in the
distributor plates are clean.

 All Access doors closed

 Starting equipment and interlocks in position.

 The boiler is filled with treated water up to normal through initial filling pump.

(B) Check the following equipment for adequate lubrication

 Fans & drives.

 Feed Pump & drives.

 Feeders & Drives.

 All Drives valves & dampers.

(C ) It is presumed that crushed fuel (0- 6 mm) is stored in crushed fuel bunker

and available for firing.

 100 Bags of Charcoal available.

 Bed Material Bunker is full of New Bed Material.

 At lest 50 L Diesel should be available.

 Put all automatic control equipment on manual control & see that control equipmentare ready

for service.

 Trials of all the equipment should be done according to the checklist.

(D) Following Valves are to be kept closed.

 Feed Regulating valve & its By pass Valves

 Spray Control Valves & Its By Pass

 Main Steam Stop Valve.

 All Blow down & Drain Valves & air vent valves specified here

- Valves on drain line on feed line to Economizer.

- Valves on air vent line at Economizer I/L & O/L

- Valves on the CBD line

- Valves on the emergency drain line

- Valves on the water wall lower header drain line.

- Valves on SH header & Main steam line drains

- Valves on sampling lines

- Drain valves on water level gauges & level transmitters.

(E) The following valves are to be kept open.

- Drum Vent valves & saturation steam line vent valves.

- Water level gauges level transmitter isolation valves

- Main steam line vent valves

- Startup vent valves, vent on the SH header & other vent valves on MS line

Procedure For Cold Startup: ---

(A) Bed Material filling

- Check the size of bed material ( It should be 0.85 mm to 2.36 mm ) Ensure closing of the
fuel feed vertical drain line and Bed drain pipe Take the bed material in the furnace to the required
level ( Up to just above nozzle height in all the compartment.

(B) Fluidization checking

-Fluidize all the compartments by opening wind box dampers. Once the bed fluidization is satisfied, then
take 300 mm of bed height in all compartments (While checking the fluidization use Helmet, goggles and
dust mask for personal protection).

(c) Preparation of First compartment for light up

. Make boundary in first compartment by taking max. Fluidization and stop the fans. Then spread crushed
charcoal in first compartments (40 bags dry and 10 bags mixed with diesel).

(D) Burner light up

-Fuel oil pressure OK ( It should be 5 kg/cm2 )Drum level normal,ID fan running, PA fan running,
Furnace pressure should be between -1 to -2 mmWC
-Start the ID fan and maintain draft -1mmWC then start PA fan and take PA Header pr. Max. Then
lightup the burners and start FD fan (all FD dampers should be closed) then load the FD damper . As
charcoal catched fire load 1st compt. Damper and raise w/b

(E) Taking first and second compartments in line.

-As first compt. temp raise above 900 deg. Increase the FD air flow and coal feeding (about 5 % in first
comt.) and open PA damper of second compt. And then open first comt. FD damper to 100 % and then
open second compt. FD damper (but w/b of both comp

(F) Closing air vents and drains.

-At 5 Kg/Cm2 pressure close all air vents of boiler.• At 15.0 Kg/Cm2 pressure closes all the Super heater
drains.

(G) Bituminous Fuel feeding in all comp

-Simultaneously take other compartments into service & raise the pressure & temperatures of steam.

(H) Feed water circuit control

-Closely monitor the drum level and maintain normal drum level through manual operation of feed control
valve and CBD.Start up vent keep open as per drum level can maintain.

(I) Taking boiler in range

-After achieving required pressure ( 85 kg/cm2) & temperature (above 480*C) take the boiler into
range.First crack open MS header isolation valve (to back charge the MS line ) and open drains of MS
line, as superheated steam starts coming from drains then Opens the MSSV.

(J) ESP charging

-Charge the ESP if the flue gas temperature is more than 120 deg c

BOILER HOT START UP

Procedure For Hot Startup

After Boiler Trips or emergency shutdown it can be hot started.

 Ensure that during outage boiler is totally boxed up.

 Close Main Steam Stop Valve

 Close Main Steam Stop Valve.
 Boiler Drum level is maintained & Close all Feed Water line valves.
 Close CBD & IBD isolation valves.
 Close the startup vent valve.
 Close all the dampers of all the drives.
 Start I.D Fan open and then inlet damper.
 Start PA fan. Open O/l damper, & IGV 10% respectively.
 Start F.D fan. Open outlet damper, open IGV 15%.
 Open PA Damper and than F.A damper-1, simultaneously start coal firing.
 RPM of coal feeders to be kept same as at the time of tripping.
 After sudden increase in bed temperatures, it will gradually start decreasing and stabilize at 650
degC.

 As first compt. temp raise above 900 deg. Increase the FD air flow and coal feeding (about 5 % in
first comt.) and open PA damper of second compt. And then open first comt. FD damper to 100 %
and then open second compt. FD damper (but w/b of both comp

 -After achieving required pressure ( 85 kg/cm2) & temperature (above 480*C) take the boiler into
range.First crack open MS header isolation valve (to back charge the MS line ) and open drains of
MS line, as superheated steam starts coming from drains then Opens the MSSV.