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Boiler Operating Procedure PDF
Boiler Operating Procedure PDF
1.Procedure for Checking, draining and putting back into operation of the
boiler gauge glass:
Responsibility : Operator
¾ Prior to check the gauge glass the control room Panel engineer shall be informed
about the activity.
¾ The firing floor operator shall wear all PPE ( Face shield and hand gloves) .
¾ Switch on the light back side of the gauge glass.
¾ Check and confirm the water level in the gauge glass.
¾ Isolate the gauge glass from water side by closing the isolation valves.
¾ Isolate the gauge glass from steam side by closing the isolation valves.
¾ Open the drain valve slowly and observe water level drop in the gauge glass.
¾ Flush the gauge glass and drain by crack opening of steam side isolating valve for
two to three minutes then close the steam side isolating valve.
¾ Carry out the same flushing from water side also.
¾ Close the drain valve.
¾ Slowly open water side and steam side valves to take the gauge glass into
operation and confirm back for water level.
¾ Report back to control room Panel engineer for the activity completion.
Collect Feed water, drum water, drum steam, and main steam samples once a
shift and send them to Central Lab. Monitor their quality parameters against the
below mentioned targets and give blow down, if the drum water quality is beyond
the target.
pH Conductivity Silica
(µ mhos) (ppm)
-----------------------------------------------
-----
Feed Water 7.2 to 9.2 <2 <0.05
Drum Water 7.5 to 10.5 <200 <5.00
Drum Steam 7.5 to 9.5 <5 <0.05
Main Steam 7.5 to 9.5 <2 <0.05
Ensure that minimum five bed temperatures are between 650 – 950 deg.C.
Ensure that the oxygen level in the flue gas is maintained between 3 – 5 % in
stable load conditions above 65% MCR for efficient operation when the bed
condition is healthy.
Check both the drum gauge glasses level once a shift and blow down once in
each shift.
Cross check and ensure that the control panel readings and the Yarway
level, Gauge glass level and transmitter level indicator are same at least
once a shift.
5.EMERGENCY OPERATIONS
Responsibility : Operator
Inform to the shift in-charge and other boiler operators, if any
tube failure occurs and drum level is not maintaining and carry
out the following activities :
Stop coal feeding
Close the range valve and stop valve
Draw steam from other boilers, if required, and reduce the load on TGs
accordingly.
Follow the stopping procedure.
Boiler light up
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 900 Mm of WC.
Start the FD and maintain bed pressure 150 – 250 mmwc.
Start the LD oil pump and maintain the oil pressure between 6.0 – 8.0
kg/cm.sq.
Keep the oil burners in position and flush out the diesel and atomising PA air
lines.
Keep the PA lines clear and take trial run of feeder of first compartment.
Light up the all the four burners.
Increase the FD air flow upto 470 MM of WC and drop to 350 of MM of WC
and allow 5-10 minutes to ignite charcoal and mix the bed by varying air flow.
Initally the top bed temperature raise and at the time of mixing temperature
drops and bottom temperature raises at the time of mixing.
When power cut occurs during start up after mixing it is not possible to
access how much charcoal is burnt out.It is advised to cool throughly and
drain the bed material and do fresh light up.
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.
Take out the oil burners
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.
Open Pilot valve of the Stop valve when the steam pressure reaches 60 - 70
kg/cm.sq. and temperature reaches between 400 to 450 deg.C.
Open Stop valve when the steam pressure reaches 65 - 75 kg/cm.sq. and
temperature reaches between 400 to 450 deg.C. and close the Pilot valve.
Open Range valve when the steam pressure reaches 75-88kg/cm.sq. and
temperature reaches between 475 to 500 deg.C.
Charge the ESP fields and start the ash handling system.
6.COMPARTMENTAL TRANSFER
Responsibility :
• Keep the PA damper of static compartment in open condition.
• Raise the air flow fludising compartment to 120 % MCR and fuel rate to be
increased to maintain bed temperature to 900 DEG C.
• Now open the compartment (FD)air damper of the adjacent compartment which
is to be activated.
• Allow heat transfer from the Hot bed to cold bed until the bed temperature of
operating bed drops to 750 Deg C.
• Slump the new compartment by closing FD Air Damper.
• Follow the process until the new compartment reaches 600 DEG C.
• Start coal feeding to the new compartment.
• If By mistake the operating compartment temperature drops below 600 DEG C it
becomes necessary to raise the temperature by using charcoal if it is First
compartment.
7. COMPARTMENT SLUMPING
Responsibility :
• IF two compartments are in operation any compartment can be slumped.
• IF three compartments are in operation one first and second compartment to be
shut.
• Bring down the fuel rate to minimum and switch of the feeder.
• Wait till the bottom temperature reaches 850 DEG C.
• Close the Fludising air ( FD damper).
• When Fludising air through a compartment is cut off the other compartments air
will increase.
• Adjust the Air flow by regulating FD air suction damper.
• Ensure that slumped bed Bleed of damper is in open condition.
• Reduce the fuel feeding rate and slowly empty before switching off feeders.
• Open the manual doors at the drag chain feeders to kill the vaccum created by
PA fan to avoid carry over of coal by gravity.
• Maintain the same air flow to cool bed faster.
• Isolate main steam stop valve.
• Open air vent to reduce the steam pressure if steam is not drawn out.
• If it is not necessary to enter the boiler for maintenance slow rate of pressure
and temperature decay is desirable. Switch of fans when bed has cooled down to
500 DEG C.
• If it is desirable to accelerate cooling process in order to permit for maintenance
fans should be continued to run at the same flow rate until temperature reaches
100 DEG C.
• Maintain normal water level.
• After bed temperature reaches 100 DEG C open boiler blown down valve and
drain water if the boiler water temperature reaches only 90 DEG C. ( To be done
only incase to attend any maintenance jobs on pressure part side).
• In case to attend fludising nozzles or distrubuter plate jobs drain bed material.
Responsibility :
• Further load can be reduced by reducing fluidising air flow not to the extent of
defluidisation of bed.
• In Such above cases air flow through PA lines should never be reduced.
• Bed height to be maintained around 450-550 MM of WC .
• Make up of bed material once in a week around 5 MT.
• Ingress of foreign material to be removed this may lead line choke which is
indicated by Drop in Bed temperatures for the same load and by PA line DP
switches.
• Maintain flue gas oxygen 3% to 5 % for better results.
• Continous blown down (CBD)to be kept constant after fine tunning. Only
Intermedite Blow down (IBD) to be operated depending upon Lab (Conductivity
,silica & TDS levels)report.
• Observe bed ash color for visual inspection of unburnt.
• Too much variation of furnace drop to be immediately informed to shift incharge
as it is an Sypmtom of Pressure part leakage.
• 10 Deg C Drop in ESP inlet temperature at constant load should be informed is
an indication of FD air leakage in at Air Preheater.
• Safety valves to be inspected at the drip pan for any passing of valves as passing
may lead to damage of safety valve seat.
• Hissing sounds to be observed and informed on frequent rounds which is also a
sypmtom of pressure part leakage.
• Gauge glass draining to be carried out periodically for better visibilty .
• Field pressure gauges,temperature gauges and local level transmitters to be
cross checked during every shift and any deviation to be informed.
2.PA FAN
• ID fan should be in operation.
• PA fan drive end and non drive bearing temperatures should be below 115 Deg C.
• PA fan Motor winding temperatures should be below 135 Deg C.
3.FD FAN
• PA should be in operation.
• Furnace draught should be below +25 MM of WC.
• FD fan drive end and non drive bearing temperatures should be below 115 Deg C.
• FD fan Motor winding temperatures should be below 135 Deg C.
5.COAL FEEDER
• FD fan should be in operation
• FD damper to individual compartment to be in open condition.
• If in auto mode bed temperature should be Between 700 -1000 Deg C.