NORMAL BOILER COLD START-UP OPERATION

“Timely Regulating HGG (FCV) Flow Control Valve during

Light Diesel to Coal Fuel Transition”
Objective:
This document is to standardize the approach by timely regulating the fuel oil flow control
valve (FCV) to reduce the Light Diesel Oil (LDO) consumption during normal cold start-up
boiler operation. It’s also serves as a guide of the new Control Operator (CO), especially
during diesel fuel and coal fuel transition operation.

Action Plan:
Regulating the Hot Gas Generator (HGG) oil Flow Control Valve (FCV) Timely during the
transition from diesel fuel to coal fuel sprinkling and to continue coal fuel operation.

1. Make sure that the LDO pump is already running before you perform the boiler furnace purge,
so that the Plant Operator (PO) have a time to check the fuel oil line if no possible leakages at
the flanges nearby HGG area. After the first HGG is already fired, either in automatic sequence
or in manual operation. Adjust the fuel oil FCV by manually regulating the pressure not less
than 4Ksc and also the atomizing air pressure should maintain above 4Ksc.
Note: the HGG fuel oil pressure switch LL trip at <4ksc.
2. Expect that the furnace bed temperature sudden increase of furnace ambient temp from 40°C to
200°C after first HGG fired. - See figure 1.

3. Manually regulate the fuel oil flow according to the furnace bed temp ramp rate, around 1.1°C
per minute.

4. After 1 hour of first HGG firing, start the second HGG manually. Then, if it’s already running
in good condition stopped the first fired HGG, in this manner it will equalized the heat
distribution into the furnace bed. Regulate the running HGG fuel oil FCV to maintain the ramp
rate of 1.1°C per minute, more or less from around 200°C going up to 266°C gradually.

5. After another 1 hour of second HGG firing, Re-start the first HGG manually, then if it’s
already running in good condition. Regulate both HGG fuel oil FCV and continue maintain the
ramp rate of 1.1°C per minute, from around 266°C going up to 500°C gradually for more than
5 Hours.

6. If the furnace bed temp reach at 500°C slowly introduce the coal fuel at sprinkling mode
alternately start and stop, from CF-B then check if the coal fuel was burned by seeing the eco
inlet oxygen slightly going down and furnace temp slightly increase. Do the start and stop
operation also at CF-A and CF-C. If you notice the furnace bed temp started to increase,
regulate both HGG fuel oil FCV insure that the same ramp rate of bed temp was observe. Until
you can decide to continuously operate the 1 or 2 coal feeder by your choice then continue also
to regulate both HGG fuel oil FCV to minimum just make sure that the individual pressure
reference of both HGG will not go less than 4Ksc to ensure that the HGG will not trip due to
fuel oil pressure switch LL.

7. If the furnace bed temp reached more than 650°C average, decide to stop 1 of the HGG
manually. Make sure that the remaining HGG is continued running even in minimum fuel oil
flow with respect to tripping pressure.

8. If the furnace bed temp reached more than 750°C average, provided that the bed temp is
increasing, stop the remaining HGG. Now both HGG are already stop then regulate the Coal
Fuel to maintain the bed temp. with respect to Main Steam Pressure (MSP). If the Electro
Static Precipitator (ESP) inlet temp. reached around 120°C start ESP field’s transformer. Then
 also, if the burning of coal fuel is stable and the bed temp is also stable at more than 800°C
average, don’t forget to stop the LDO pump.

Conclusion:
By doing this, during normal cold boiler start-up we can reduce the LDO fuel consumption as
per previous start up reference we used only less than 7000Kg. Approximately we can save at
least less 1000Kg of fuel oil during normal cold start-up boiler operation.