A m1050 - 00 Boiler Start Up Procedure

0 FIRST ISSUE 13-06-2019
REV. DESCRIPTION DATE
DATE DEPARTMENT NAME SIGNATURE

ISSUED 13-06-2019 C&C Madè.P
CHECKED 13-06-2019 C&C Gornati P.
APPROVED 13-06-2019 C&C Canton S.
RELEASED 13-06-2019 PE Torretta L.
UPPER EGYPT ELECTRICITY PRODUCTION

COMPANY
ASSIUT SUPERCRITICAL POWER PLANT
1 x 650 MW STEAM POWER STATION
BOILER START-UP PROCEDURE
JOB NO. DOCUMENT NO. REV.

POWER GENERATION ENGINEERING AND
SERVICES COMPANY
10077
PROJECT CLIENT
ASSIUT SUPERCRITICAL POWER STATION POWER GENERATION ENGINEERING AND

1X650 MW GAS/OIL FIRED BOILER SERVICES COMPANY
JOB NO. DEPARTMENT DOC TYPE
3064 VC C&C
BOILER START-UP PROCEDURE

AC Boilers S.p.A. reserves all rights on this document that can not be
reproduced in any part without its written consent
DOCUMENT NO. REVISION SHEET OF
30641-A-M1050 0 1 88
Informazioni strettamente riservate di proprietà di AC BOILERS S.p.A. - Da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential information, property of AC BOILERS S.p.A. - Not to be used for any purpose other than that for which it is supplied.
Titolo Identificativo Rev. Pagina di
Title Document no. Rev. Page of
BOILER START-UP PROCEDURE 30641-A-M1050 0 2 88
INDEX
ABBREVIATIONS AND ACRONYMS 4
1. REFERENCE DOCUMENTS 5
1.1 BOILER P&IDS 6

1.2 BOILER PROCESS FUNCTIONAL DESCRIPTIONS 8
1.3 BOILER LOGIC DIAGRAM & DESCRIPTIONS 9
1.4 BOP P&ID (PGESCO) 10
2. SCOPE 12
3. BOILER & EQUIPMENT MAIN CHARACTERISTICS 13
4. FOREWORD 14
5. START-UP MODES 15
6. BOILER WATER & STEAM SYSTEM 17
6.1 COLD START-UP MODE 18

6.1.1 CONSTRAINTS 18
6.1.2 START-UP PROCEDURE 20
6.2 WARM START-UP MODE 28
6.3 HOT & VERY HOT START-UP MODE 33
6.4 BOILER OPERATION 38
6.4.1 LOAD RAMP 38
6.4.2 WET / DRY MODE TRANSFER 38
6.4.3 NORMAL OPERATION 39
6.5 BOILER SHUT-DOWN 40
6.5.1 SHUT-DOWN AT BENSON LOAD 40
6.5.2 SHUT-DOWN AND COOLING 40
6.6 EMERGENCY OPERATION 42
6.6.1 LOAD RUN BACK 42
6.6.2 LOAD REJECTION 42
6.6.3 HOUSE LOAD OPERATION 43
6.6.4 ELECTRIC BLACK-OUT 44
AC BOILERS S.p.A. si riserva tutti i diritti su questo documento che non può essere riprodotto neppure parzialmente senza la sua autorizzazione scritta
AC BOILERS S.p.A. reserves all rights on this document that cannot be reproduced in any part without its written consent
7. BOILER AIR & FLUE GASES SYSTEM 45
7.1 INITIAL CONDITIONS 46

7.1.1 NATURAL DRAFT 46
7.1.2 WAITING TIME FOR PURGE 46
7.1.3 FURNACE PURGE 46
7.2 START-UP PROCEDURE 48
7.2.1 AIR & GAS LINE 48
7.2.2 REGENERATIVE AIR HEATER 50
7.2.3 FORCED DRAFT FAN 53
7.2.4 GAS RECIRCULATION FAN 56
7.2.5 STEAM COIL AIR PRE-HEATER START-UP 57
7.3 AUXILIARY AIR FAN START-UP PROCEDURE 59
7.3.1 SOOTBLOWERS SEALING AIR FANS 59
7.3.2 BURNERS AND FLAME SCANNERS COOLING AIR FANS 59
7.4 DAMPERS SEALING SYSTEM 61
8. BOILER FUELS & BURNERS SYSTEM 63
8.1 INITIAL CONDITIONS 64

8.2 IGNITORS 65
8.2.1 NATURAL GAS IGNITORS 65
8.2.2 SOLAR OIL IGNITORS 67
8.2.3 IGNITOR TRIP 68
8.3 BURNERS 70
8.3.1 NATURAL GAS BURNERS 70
8.3.2 SOLAR OIL BURNERS 73
8.3.3 FUEL OIL BURNERS 76
8.3.4 BURNERS IGNITION SEQUENCE 82
8.3.5 BURNERS AUTOMATIC IGNITION / SHUT-DOWN OPERATION 83
8.3.6 BURNERS TRIP 84
8.4 AIR REGISTER SETTING 85
8.4.1 BURNERS AIR REGISTER SETTING AND ALIGNMENT 85
8.4.2 OVERFIRING AIR SETTING AND ALIGNMENT 85
9. SOOTBLOWERS SYSTEM 86
9.1 START-UP PROCEDURE 87

9.2 SOOTBLOWERS TRIP 88
ABBREVIATIONS AND ACRONYMS
ACB AC BOILERS
AVT (O) ALL VOLATILE OXIDIZING
AVT (R) ALL VOLATILE REDUCING
BCP BOILER CIRCULATION PUMP
BFWP BOILER FEED WATER PUMP
BMCR BOILER MAXIMUM CONTINUOUS RATE
BOP BALANCE OF PLANT
CCCW CLOSE CIRCUIT COOLING WATER
FDF FORCED DRAFT FAN
LCS LEAKAGE CONTROL SYSTEM
MBL MINIMUM BENSON LOAD
MCR MAXIMUM CONTINUOUS RATE
MFT MASTER FUEL TRIP
OT OXYGENATED TREATMENT
RAH REGENERATIVE AIR HEATER
VWO VALVE WIDE OPEN
FAH FLAY ASH HANDLING SYSTEM
1. REFERENCE DOCUMENTS
General Note
Notice:
Changes from previous revision are highlighted in yellow.
1.1 BOILER P&IDs
Boiler W&S system - Eco and Furnace P&ID

30641-G-G0100 / 10077-9-V05-MBPV-00076
Boiler W&S system - SH P&ID

30641-G-G0101sh. 1 & 2 / 10077-9-V05-MBPV-00077
Boiler W&S system - RH P&ID

30641-G-G0102 / 10077-9-V05-MBPV-00078
Boiler Start-up system P&ID

30641-G-G0105 sh. 1 & 2 / 10077-9-V05-MBPV-00081
Boiler Blowdown system P&ID

30641-G-G0103/ 10077-9-V05-MBPV-00079
Steam sootblowers system P&ID

30641-G-G0104 / 10077-9-V05-MBPV-00080
A&G System - Combustion air P&ID

30641-G-G0110 sh. 1 & 2 / 10077-9-V05-MBPV-00082
A&G System - Flue gases P&ID

30641-G-G0111/ 10077-9-V05-MBPV-00083
A&G System – Furnace & Convective passage P&ID

30641-G-G0112 / 10077-9-V05-MBPV-00084
Forced draft fans P&ID

30641-G-G0130/ 10077-9-V05-MBPV-00091
Recirculation gas fans P&ID

30641-G-G0131 / 10077-9-V05-MBPV-00092
Regenerative air heater Lube oil & Washing system P&ID

30641-G-G0134 / 10077-9-V05-MBPV-00093
Sealing and Cooling air P&ID

30641-G-G0113/ 10077- 9-V05-MBPV-00085
Steam coil air heater system P&ID

30641-G-G0136 / 10077-9-V05-MBPV-00095
Boiler fuel Firing System – Mazout oil – solar oil distribution P&ID
30641-G-G0122 / 10077-9-V05-MBPV-00088
Boiler fuel Firing System – Mazout oil - Solar oil supply system P&ID
30641-G-G0120 / 10077-9-V05-MBPV-00086
Firing System –Oil distribution system P&ID

30641-G-G0122 / 10077-9-V05-MBPV-00088
Firing System – Typical burner system P&ID

30641-G-G0123 / 10077-9-V05-MBPV-00089
Firing System – Mazout oil additive system P&ID

30641-G-G0144 / 10077-9-V05-MBPV-00099
Boiler close cooling water system P&ID

30641-G-G0140 / 10077-9-V05-MBPV-00096
Instrument air distribution system P&ID

30641-G-G0141/ 10077-9-V05-MBPV-00097
Service air distribution system P&ID

30641-G-G0142 / 10077-9-V05-MBPV-00098
Boiler sampling system P&ID

30641-G-G0145 / 10077-9-V05-MBPV-00100
Fly ash handling system P&ID

30641-D-E5600 / 10077-9-V05-MGHF-00007
Fly ash handling system P&ID – auxiliary fluid

30641-D-E5601 / 10077-9-V05-MGHF-00059
1.2 BOILER PROCESS FUNCTIONAL DESCRIPTIONS
Boiler W&S system – Functional description

30641-G-G0200 / 10077-9-V05-MBPV-00377
Steam sootblowers system – Functional description

30641-G-G0203 / 10077-9-V05-MBPV-00380
A&G System – Functional description

30641-G-G0201 / 10077-9-V05-MBPV-00378
Fuels Firing System – Functional description

30641-G-G0202/ 10077-9-V05-MBPV-00379
Boiler feed water and steam chemistry

30641-A-M1004 / 10077-9-V05-MBPV-00001
Boiler lay-up procedure

30641-A-M1010 / 10077--9-V05-MBPV-00424
Boiler start-up curves

30641-A-M1000 / 10077--9-V05-MBPV-00165
1.3 BOILER LOGIC DIAGRAM & DESCRIPTIONS
DCS Typical command logic description

30641-G-G2138 / 10077-9-V05-MBPV-00491
BMS Typical command logic description

30641-G-G2139 / 10077-9-V05-MBPV-00321
BMS Logic descripition

30641-G-G2121 / 10077-9-V05-MBPV-00319
Boiler Protection System – Logic Diagram

30641-G-G2120/ 10077-9-V05-MBPV-00318
Boiler Steam & Water – control & automation logic diagram

30641-G-G2102 / 10077-9-V05-MBPV-00340
Boiler Air & Flue gases – Control Logic Diagram

30641-G-G2103 / 10077-9-V05-MBPV-00290
Boiler Fuel System Control – Logic Diagram

30641-G-G2123/ 10077-9-V05-MBPV-00341
Boiler Management System – Logic Diagram

30641-G-G2101 / 10077-9-V05-MBPV-00317
Sootblowers Automation System – Logic Diagram

30641-G-G2105 / 10077-9-V05-MBPV-00322
Boiler Protection System – Logic Description

30641-G-G1120 / 10077-9-V05-MBPV-00318
Boiler Steam & Water – Logic Description

30641-G-G2122/ 10077-9-V05-MBPV-00279
Boiler Air & Flue gases System – Logic Description

30641-G-G2123 / 10077-9-V05-MBPV-00280
Burners Management System – Logic Description

30641-G-G2121 / 10077-9-V05-MBPV-00319
Sootblowers Automation System – Logic Description

30641-G-G2125 / 10077- 9-V05-MBPV-00320
1.4 BOP P&ID (PGESCo)
Piping & Instrumentation Diagram fire protection system

10077-9-M6-PF-00001/00002/00003/00004/00005
Piping & Instrumentation Diagram condensate transfer system

10077-9-M6-SC-00001
Piping & Instrumentation Diagram service water system

10077-9-M6-WS-00002
Piping & Instrumentation Diagram waste water system

10077-9-M6-XW-00001/00002/00003
Piping & Instrumentation Diagram main steam system hp steam& hp bypass

10077-9-M6-AB-00001/00002
Piping & Instrumentation Diagram main steam system crh system

10077-9-M6-AB-00003/00004
Piping & Instrumentation Diagram main steam system hrh & lp bypass
10077-9-M6-AB-00005
Piping & Instrumentation Diagram main steam system

10077-9-M6-AB-00006
Piping & Instrumentation Diagram feed water system start-up system

10077-9-M6-AE-00001
Piping & Instrumentation Diagram feed water system

10077-9-M6-AE-00002
Piping & Instrumentation Diagram feed water system main boiler feed pumps
10077-9-M6-AE-00003
Piping & Instrumentation Diagram feed water system

10077-9-M6-AE-00004
Piping & Instrumentation Diagram extraction steam

10077-9-M6-AF-00001/00002/00003/00004/00005/00006/00007/00008/00009/00010
Piping & Instrumentation Diagram auxiliary steam system

10077-9-M6-SA-00001/00002/00003
Piping & Instrumentation Diagram condensate system

10077-9-M6-AD-00001/00002/00003/00004
Piping & Instrumentation Diagram boiler blowdown system

10077-9-M6-BM-00001
Piping & Instrumentation Diagram fuel oil system

10077-9-M6-FO-00001/00002
Piping & Instrumentation Diagram solar oil system

10077-9-M6-FOI-00001
Piping & Instrumentation Diagram service gas system

10077-9-M6-PG-00001/00002/00003
Piping & Instrumentation Diagram compressed air system ( instrument air )

10077-9-M6-PI-00001
Piping & Instrumentation Diagram compressed air system service area

10077-9-M6-PI-00002
Piping & Instrumentation Diagram reboiler system

10077-9-M6-SB-00001/00002
Piping & Instrumentation Diagram symbols & legends

10077-9-M6-GOO-00001/00002/00003/00004/00005
Piping & Instrumentation Diagram closed cooling water system

10077-9-M6-WB-00001/0002/00003
Piping & Instrumentation Diagram closed cooling water system

10077-9-M6-WB-00001
Piping & Instrumentation Diagram compressed air system

10077-9-M6-PI-00001/0002
Piping & Instrumentation Diagram demineralized water system
10077-9-M6-WD-00001
Piping & Instrumentation Diagram water analysis system

10077-9-M6-JA-00001
Piping & Instrumentation Diagram fuel gas system

10077-9-M6-FG-00001
2. SCOPE
This document describes guidelines and chronological sequence of actions (on complete systems or single
equipment) to be performed for boiler start-up or shut-down under different conditions (cold, warm, hot
start-up and shut-down).
Under abnormal operating conditions, operators are required to follow the written and/or verbal procedures
provided each time by the plant managers.
The start-up and shut-down of single equipment is described in the relevant “Operating manual” while
start-up and shut-down of the whole system is described in the relevant “System design specification”.
Note:
These operating instructions are based on plant design documentation and have to be improved with plant
commissioning and operation experience, especially as far as the timing actions is concerned.
3. BOILER & EQUIPMENT MAIN CHARACTERISTICS
Here below the reference of operating data for boiler and main equipment.
Please refer to the last revision available.
BOILER
Boiler technical data sheet

30641-B-A1001 / 10077-9-V05-MBPV-00002
EQUIPMENT
FD Fan data sheet

30641-D-E2200 / 10077-9-V05-MBPV-00386
GR Fan data sheet

30641-D-E2210 / 10077-9-V05-MBPV-00314
Sootblower data sheet

30641-D-E1200 / 10077-9-V05-MBPV-00473
Boiler circulating pump data sheet

30641-D-E8124 / 10077-9-V05-MBPV-00342
Burner data sheet

30641-F-F0008 / 10077-9-V05-MBPV-00157
Ash handling system data sheet

30641-D-E5500 / 10077-9-V05-MHGF-00001
4. FOREWORD
The following document is the recommended start up procedure issued by AC Boilers in order to define
as much as possible the boiler and steam turbine coordination during plant start-up of Assiut Power Plant
- 1 x 650 MW gas/oil pressure fired boiler; the boiler is once-through type, supercritical Benson type which
is designed for sliding pressure operation.
5. START-UP MODES
Start-up modes are defined mainly by the boiler and the steam turbine warm up requirements depending
upon the initial relevant metals temperature.
Based on that the following cases can be identified:
 Cold start: time from shut down > 48 hours

boiler depressurised
separator vessel temperature < 175 °C
 Warm start: time from shut down between 48 and 8 hours

boiler residual pressure < 50 barg
separator vessel temperature within 175 °C and 255 °C
 Hot start: time from shut down < 8 hours

boiler residual pressure > 50 barg
separator vessel temperature > 255 °C
During start-up the separator vessels saturation temperature change rate shall not exceed the limit of 5
°C/min.
The suggested preliminary boiler gradient values, to be finalized during commissioning, are:
 Cold: up to 70 barg ~ 0.75 bar/min

from 70 to 130 barg ~ 2.75 bar/min
(2 °C/min on separator temperature)
 Warm: up to 70 barg ~ 1.25 bar/min

 Hot: up to 70 barg ~ 1.5 bar/min

The maximum allowable boiler load changing rates are as follows:
 Cold: up to 40% ~ 2 %/min

from 40 to 100% ~ 2 %/min
 Warm: up to 40% ~ 4 %/min

from 40 to 100% ~ 5 %/min
 Hott: up to 40% ~ 5 %/min

from 40 to 100% ~ 6 %/min
6. BOILER WATER & STEAM SYSTEM
6.1 COLD START-UP MODE
6.1.1 CONSTRAINTS
6.1.1.1 BOILER CONSTRAINTS
Due to process peculiarities in the once-through type boiler, impurities contained in boiler feed water will
form scale that adhere inside heat transfer surfaces and/or will be carried to steam turbine, the first can
lead to overheating and failure of boiler tubes while the second can cause deposit on steam turbine blades.
Because of that, once-through boiler requires more severe and stringent water quality control than natural
circulation subcritical boiler; therefore at burner light off feed water cationic conductivity shall be less than
0.60 S/cm or better.
To minimize and/or to prevent corrosion and deposits in the water and steam circuit, the most appropriate
chemical conditioning has to be applied to feed water; moreover because of higher operating temperature
and pressure, compared to subcritical boiler, to minimize the corrosion, the water purity shall be higher.
Basically there are three feed water treatment that can be applied, choice depends primarily on water and
steam cycle materials, on the desired buffering capacity against contaminations and the capability to
maintain the water purity:
 reducing all volatile treatment:
AVT(R), by using ammonia and a reducing agent;
 oxidizing all volatile treatment:
AVT(O), by using ammonia without reducing agent;
 oxygenated water treatment:
OT, oxygen and ammonia are added to feed water.
Use of AVT (R) feed water treatment favours the growth of internal magnetite layer and thus increases
water side pressure drop.
Use of AVT(O) and OT feed water treatment minimizes inner protective iron oxide film build-up on the
furnace walls tubes and thus the frequency of chemical cleaning and the increase of water side pressure
drop.
AVT(O) treatment has to be adopted during normal start up / shut-down / preservation period while OT
has to be applied during normal operation.
Action
Parameter Unit AVT (O) AVT (R) OT
Level
N 9.2 ÷ 9.6 9.0 ÷ 9.3 8.0 ÷ 8.5
AL1 < 9.2 / > 9.6 < 9.0 / > 9.3 < 8.0 / > 8.5
pH -
AL2 - - -
AL3 - - -
N ≤ 0.2 ≤ 0.2 ≤ 0.15
AL1 ≤ 0.4 ≤ 0.4 ≤ 0.3
Cationic conductivity μS/cm
AL2 ≤ 0.8 ≤ 0.8 ≤ 0.6
AL3 > 0.8 > 0.8 > 0.6
N < 10 ≤5 30 ÷ 150
AL1 > 10 ≤ 10 -
Oxygen (O2) μg/kg
AL2 - ≤ 20 -
AL3 - > 20 -
N ≤ 10 ≤ 10 ≤ 10
AL1 > 10 > 10 > 10
Silica (SiO2) μg/kg
AL2 - - -
AL3 - - -
N ≤2 ≤2 ≤2
AL1 >2 >2 >2
Iron (Fe) μg/kg
AL2 - - -
AL3 - - -
N ≤3 ≤3 ≤2
AL1 ≤6 ≤6 ≤4
Sodium (Na) μg/kg
AL2 ≤ 12 ≤ 12 ≤8
AL3 > 12 > 12 >8
N, AL1, AL2 and AL3 define respectively Normal, Action Level 1, Action Level 2 and Action Level 3 values
for each parameter.
For base load units, the relevant cumulative hours per year for each action level are:
Action Level 1 2 weeks (336 hours)
Action Level 2 2 days (48 hours)
Action Level 3 8 hours
Permissives for Benson mode:

Cationic conductivity (S/cm) ≤ 0,15
Oxygen (ppb) < 10
Silica (ppb) < 20
Permissive for Oxygenated Treatment:
Oxygen injection can be started when feed water cationic conductivity is 0,15 μS/cm or lower.
Vice versa, if feed water when cationic conductivity is over 0,3 μS/cm, oxygen injection shall be stopped
to avoid increasing of corrosion problems.
In case of feed water sodium content over 50 ppb or cationic conductivity > 1 μS/cm shall be foreseen
immediate shutdown.
Separator temperature and load changing rate shall not exceed the limits stated at paragraph 5.
6.1.1.2 STEAM TURBINE CONSTRAINTS
The minimum requirements of steam inlet conditions for steam turbine rolling are:
 pressure:
HRH 11 barg
SH 130 barg
 temperature:
HRH 350 °C
SH 380 °C
6.1.1.3 OVERALL CONSTRAINTS
The most stringent constrain among all power plant components will become the restriction for any
allowable variation.
Particularly for load changing rate will be:
 up to 40% 2 %/min;
 from 40 to 100% 2 %/min.
6.1.2 START-UP PROCEDURE
6.1.2.1 BOILER FILLING
Following boiler shut down and long term outage, boiler water sections (e.g. economiser, evaporator, etc.)
shall be filled, if these sections have been maintained filled with preservation water, before water filling,
the preservation water has to be discharged to waste drain pit through atmospheric flash tank (BM MT
100) and drain receiver tank (BM MT 101) during boiler clean-up phase.
Boiler filling is performed as follows:

 open the motor operated valve located at economizer inlet (AE HV 701), close the related bypass
valve (AE HV 702);
 set ready condensate extraction pumps and related valves;
 feed deaerator by the CEP, deaerator is pressurized (approx. 5 ÷ 6 bara) by means of auxiliary
steam, however advise with BOP start-up procedure;
 set ready boiler feed water pumps and related valves;
 set ready feed water chemical dosing system;
 open the motor operated vent valves located at economizer outlet (AA HV 731) and furnace outlet
manifold (AA HV 732);
 fill up the boiler by the start-up BFWP, electrically driven, however advise with BOP start-up
procedure;
 set the feed water flow at 25 kg/s (approx. 5%) of nominal boiler feed water flow;
 start feed water chemical dosing system to achieve the required limits:
pH (-) ≥ 9,8
cationic conductivity (S/cm) ≤1
oxygen (ppb) < 20
iron (ppb) < 50
 open all motor operated valves related to start-up system, i.e. boiler circulating pump discharge
and warming (AA HV 743/744), sub-cooling (AE HV 741) and overflow line warming (AA HV 745)
and open partially the BCP discharge control valve (AA FCV 554);
 when the water storage tank (AA MT 101) level achieves the predetermined level (approx. 13500
mm), stop the water filling and close all the vent valves and above mentioned isolation and control
valves.
6.1.2.2 BOILER CLEAN-UP
Following boiler filling the boiler cold clean-up phase continues as follows:
 increase feed water flow, set the flow at 120 kg/s (approx. 20%) of nominal boiler feed water flow;
 discharge excess water from water storage tank to atmospheric flash tank through related
overflow line, i.e. check locked open the manual shut-off valve (AA PV 119/120) and release to
auto the level control valves (AA LCV 547 A/B) controlling water storage tank level (overflow);
 check the water quality at water storage tank outlet, and when cationic conductivity is less than
0,6 μS/cm, the boiler is ready for heat-up;
 from atmospheric flash tank, condensate is discharged to drain receiver tank and then:
 either directly to waste drain pit (blow-down sump) via tank overflow pipe;
 or to condenser through the condensate transfer pumps (BM MP 101 A or B) according to
condenser and condensate polishing system availability;
 this phase lasts until the water quality at water storage tank outlet will come within the range as
specified at paragraph 6.1.1.1 for burners light-off.
The expected duration has to be evaluated taking care of both procedures, i.e. boiler filling and clean-up.
The duration varies according to boiler initial status and feed water quality; the worst case is following a
wet lay-up, because the whole water volume also has to be changed up to comply with the above water
quality requirement, in such case procedures can last approximately 2 ÷ 2,5 hours (e.g. one hour and half
up to two hours for filling and half hour to one hour for clean-up).
6.1.2.3 BOILER WATER CIRCULATION
Once filling and clean-up phases are completed, the forced circulation through start-up circuit starts;
therefore operator shall proceed as follows:
 check BCP circulator has been properly flushed and filled;
 if any, open manual valves on CCCW to the filling cooler (AA ME 001) inlet/outlet (WB PV
101/102) setting the proper flow, then open manual valves (AE PV 125, AA PV 127/143) on filling
water line and control the flow (max 2 l/min) through the manual needle valve (AAPV126), check
water temperature downstream the cooler is within the limit (approx. 30 ÷ 40 °C), if the
temperature rises increase the CCCW flow to BCP filling cooler in order to avoid BCP motor
windings dangerous situation (e.g. insulation degrading), as the BCP circulator is filled close the
manual valves (AA PV 127/143);
 open isolation and check open manual valve on CCCW to the BCP motor cooler (AA ME 002)
inlet/outlet (WB HV 701/702 and WB PV 103/104 respectively) setting the proper flow;
 check that manual valve on BCP suction (AA PV 114) and BCP minimum flow line (AA PV 116)
are locked open;
 start the BCP (AA MP 001);

 as BCP runs the sub-cooling motor operated valve (AE HV 741) automatically opens and the BCP
and overflow line warming motor operated valves (AA HV 744/745) automatically close;
 open the BCP discharge shut-off valve (AA HV 743);
 BCP discharge minimum flow control valve (AA FCV 541) controls BCP minimum flow to avoid
BCP abnormal operating condition;
 BCP discharge flow control valve (AA FCV 554) controls boiler circulation flow according to water
storage tank level;
During furnace purge phase and up to the first burner ignition the feed water flow is settled at the
minimum approx. 25 kg/s (split as approx. 17,5 kg/s feed water to eco and approx. 7,5 kg/s as sub-
cooling water to BCP) preventing the economiser from steaming, this excess water from water storage
tank is discharged to atmospheric flash tank via the overflow control valves (AA LCV 547 A/ B).
The control system regulates the required minimum water flow to the evaporator (approx. 175,8 kg/s
i.e. maximum forced circulation flow, by BCP, plus the above minimum feed water flow, by BFWP) up
to evaporation starting. Then the boiler water is circulated and discharged until the water quality
becomes within the values mentioned at paragraph 6.1.1.1 for the first burner light-up.
If water quality becomes worse, the water circulation flow via BCP is reduced by manual operation and
consequently the feed water from BFWP increases; to maintain the water level into the storage tank,
the excess water discharged to atmospheric flash tank through overflow lines will increase too.
6.1.2.4 BURNER LIGHT-OFF, HEAT UP AND PRESSURISING
When the above phases are complete and the feed water quality satisfy the mentioned conditions at
paragraph 6.1.1.1 for firing (feed water cationic conductivity less than 0.6 S/cm or lower), checked
separator vessels temperature is not higher than approx. 175 °C (i.e. approx 9 bar) the cold start-up
procedures can proceed and the first burner is light off, with either solar oil or natural gas, according to
the proper sequence, see paragraph 8.3.
Operations on boiler W&S system are as follows:
 check manual valves (AA PV 511/512/513/514) upstream boiler drain valves are locked open;
 open partially boiler drain positioning valves (AA HV 733/734/735/736), according to water
storage tank pressure preliminary set is as follows:
up to 15 barg: fully open;
from 15 and up to 50 barg: approx. 40% open;
then increasing the pressure above mentioned value drain valves close.
 open main steam valves (AA HV 737/738);
 open drains valves on main steam and HP bypass lines, however advise with BOP start-up
procedure;
 open drains valves on reheat steam and LP bypass lines, however advise with BOP start-up
procedure;
 check manual valves (AA PV 119/120) upstream water storage tank overflow level control
valve are locked open;
 check manual valves (AE PV 106/112/114/116/118) on spray water to superheaters DSH are
open;
 check that fuel and burners systems, either solar oil or natural gas, are ready to be started;
 check that combustion air flow is settled at a purge rate (approx. 30 % MCR flow), see
paragraph 7.1.3;
 check that HP and LP bypass valves are set in the right position;
 feed water flow under control and settled as per above paragraph 6.1.2.3;
 BCP running and circulated water flow settled as per above paragraph 6.1.2.3, BCP minimum
flow and storage tank level control switched on auto;
 storage tank overflow level control switched on auto;
 condenser vacuum established;
 light-off the burners, see paragraph 8;
In this phase combustion has to be controlled in order to meet the most severe of the following limits:
 flue gas temperature at furnace outlet should not be higher than the superheater and reheater
design temperature. Due to the fact that during warm up and pressurization the steam flow
available for cooling is limited (heat is mainly used to heat and pressurize the boiler);
 main and reheat steam temperature not higher than the values allowed for steam turbine
rolling;
 temperature changing rate not higher than the above mentioned limits (the temperature
changing rate at the separators is controlled by means of the pressure set of the HP by-pass
system).
As the evaporation starts the water storage tank level becomes high because of boiler water volume
increase (swelling), the excess water from the water storage tank, that cannot be circulated by BCP, is
discharged to atmospheric flash tank, through the two overflow control valves (AA LCV 547 A/B).
The water storage tank level control is based on three different level bands:
 the lowest (main) one: regular start-up operation circulating water through BCP and related
flow control valve;
 the intermediate one: dumping excess water through the first overflow level control valve;
 the upper one: dumping excess water through the second overflow level control valve;
To avoid unwanted water loss the overflow level control valves opening position is also characterised
as function of storage tank pressure, again as the storage tank pressure increases at approx. 135 barg
the overflow level control valves are forced to close position.
The medium discharged through overflow control valves enters the atmospheric flash tank, due to
different operating conditions, it flashes, the flashed steam is vented to atmosphere and the remained
saturated water is dumped to drain receiver tank where, through the condensate transfer pumps (BM
MP 101 A or B), is carried to condenser.
During boiler heat-up the water storage tank swelling effect achieves its peak, the operating condensate
transfer pump is not able to discharge all the incoming water to the condenser, therefore as drain
receiver tank level increases up to high level value the stand-by condensate transfer pump
automatically starts, thus the two condensate pumps discharge the excess water to the condenser,
once the level comes back to the normal value, the stand-by condensate pump automatically stops and
only one pump remains in operation.
Because the once-through Benson boiler does not need of continuous blow-down, in regular operation
above once-through load, due to water shortage, the condensate transfer pumps works as on-off type
according to drain receiver tank level. Drain receiver tank is also equipped with overflow pipe that in
emergency condition will flow-rate the condensate, after cooling, to the waste drain pit (blow-down
sump).
As steam starts to be generated from the separator vessel, the HP and LP bypass systems control will
be switched in automatic operation mode; therefore the HP and LP bypass system plays an important
role in the main steam pressure control as follows.
HP bypass valves will be placed in automatic mode controlling the main steam pressure from initial
minimum pressure approx. 12 barg up to approx. 130 barg (i.e. steam turbine start, however advise
with steam turbine start-up procedure), in order to maintain the prescribed pressurization rate (i.e.
separator vessels saturation temperature as per paragraph 5), then the hot reheated steam flows to the
LP bypass valves preliminary manually open to about 20% travel while the associated spray control
valves in automatic. When the pressure upstream LP bypass valves reach approx. 8 barg, the pressure
control will be placed in automatic controlling the HRH steam pressure at approx. 11 barg;
During start-up and at low load operation, i.e. forced circulation mode, the water flow to the evaporator
is maintained constant and controlled to the above mentioned minimum flow, see paragraph 6.1.2.3.
Heating up the boiler, as the evaporation increases, the water storage tank level decreases and
consequently also the water circulation flow via BCP, therefore, to maintain constant the minimum water
flow to evaporator, i.e. economiser inlet, the BFWP flow increases.
This phase lasts approximately 3 hours and half.

At the end of the heat up and pressurization phase the boiler is at the following conditions:
 boiler mode: in water circulation;
 firing rate: approx. 15%;
 main steam pressure: approx. 130 barg, controlled by HP bypass valves;
 hot reheat steam pressure: approx. 11 barg, controlled by the LP bypass valves;
 estimated main steam flow: approx. 85 kg/s;
 reheat steam flow: approximately the same as main steam flow;
 main steam temperature: approx. 380 °C;
 cold reheat steam temperature: approx. 290 °C;
 hot reheat steam temperature: approx. 350 °C;
The conditions for steam turbine warming and rolling are established; however advise with steam
turbine start-up procedures.
After steam turbine synchronization and when switchover of pressure control from HP and LP bypass
valves to steam turbine is complete, HP and LP bypass valves are forced to fully closed position, and
their control is shifted to override control adding a predetermined bias to the steam pressure set point
that will be removed allowing HP and LP bypass valves quick opening when steam turbine trip or house
load or load rejection or run-back occur, however advise with steam turbine start-up procedure and/or
unit coordinator control philosophy.
6.1.2.5 BOILER HOT CLEAN UP
During a boiler cold start-up it might be required an additional hot clean-up phase to improve water
quality at economizer inlet up to the required satisfactory values as follows:
Cationic conductivity: < 0,20 μS/cm at 25°C
Therefore when the boiler water temperature at the separator vessels achieves approx.. 190 °C (i.e.
approx. 11,5 barg) stop boiler heating and pressurizing, if any reduce the firing rate in order to maintain
pressure and temperature in the separator vessels approximately constant and start the hot clean-up
procedure to achieve the above mentioned values, it can last 0,5 ÷ 1 hour depending on water
characteristic.
If water quality at the water storage tank outlet becomes worse, stop the heating up phase and keep
fluid temperature constant until water quality improves again; if water quality does not improve also
after stop of boiler heating up phase, reduce circulation flow by manual operation until water quality
improves again, then continues boiler heat up and pressurizing phases.
6.1.2.6 BCP TRIP
BCP trips whenever any of the following conditions occurs:

 BCP motor trip, i.e. electrical overload;
 BCP motor cavity temperature very high, i.e. higher than 65 °C;
 water storage tank level very low, i.e. lower than 100 mmwg;
 BCP total flow very low, i.e. lower than 210 kg/s;
6.2 WARM START-UP MODE
6.2.1 CONSTRAINTS
At burner light off feed water cationic conductivity at boiler inlet shall be less than 0,60 μS/cm.
The feed water chemical conditioning will be AVT(O) and then switched on OT as soon the permissive
for oxygen dosing are met (cationic conductivity 0,15 μS/cm or better).
 pressure:
HRH 11 barg
SH 130 barg
 temperature:
HRH 370 °C
SH 400 °C
Particularly for load changing, rates will be:
 up to 40%: 4 %/min;
 from 40 to 100%: 5 %/min.
Established the water storage tank required level, boiler is in forced circulation mode (i.e. BCP in
service), as soon as the feed water quality satisfy the mentioned conditions at paragraph 6.2.1.1,
checked separator vessels temperature is between 175 °C and 255 °C (i.e. up to approx. 43 bar) the
warm start-up procedures can proceed and the first burner is light off, with either solar oil or natural gas,
according to the proper sequence, see paragraph 8.3.
Operations on boiler W&S system are as follows:
 up to 15 barg: fully open;
 from 15 and up to 50 barg: approx. 40% open;
then increasing the pressure above mentioned value drain valves close.
 check that main steam valves (AA HV 737/738) are open, otherwise main steam pipes shall
be heated and pressurized through their bypass valves (AA HV 739/740), as per the next
step;
 if any, open drains valves on main steam and HP bypass lines, however advise with BOP
start-up procedure;
 if any, open drains valves on reheat steam and LP bypass lines, however advise with BOP
start-up procedure;
open;
 check that combustion air flow is settled at a purge rate (approx. 30% MCR flow), see
paragraph 7.1.3;
rolling;
system).
flow control valve;
saturated water, via the tank overflow line, is dumped to drain receiver tank where, through the
condensate transfer pumps (BM MP 101 A or MP 101 B), is carried to condenser.
sump).
 As steam starts flowing toward superheater outlet, main steam pipes can be heated and
pressurized as follows:
procedure;
 open main steam bypass shut-off valves (AA HV 739/740);
 when the equalize condition are achieved, i.e. differential pressure and temperature across
main valves are within the limits, < ±1,5 bar and < ±10 °C respectively, open main steam shut-
off valve (AA HV 737/738) and close related bypass shut-off valves (AA HV 739/740);
 the HP and LP bypass systems control will be switched in automatic operation mode therefore
the HP and LP bypass system plays an important role in the main steam pressure control
from starting pressure value up to approx. 130 barg (i.e. steam turbine start, however advise
with steam turbine start-up procedure), in order to maintain the prescribed pressurization rate
(i.e. separator vessels saturation temperature as per paragraph 5), then the hot reheated
steam flows to the LP bypass valves preliminary manually open to about 20% travel while the
associated spray control valves in automatic. When the pressure upstream LP bypass valves
reach approx. 8 barg, the pressure control will be placed in automatic controlling the HRH
steam pressure at approx. 11 barg;
is maintained constant and controlled to the above mentioned (approx. 175,8 kg/s) minimum flow.
consequently also the water circulated flow via BCP, therefore, to maintain constant the total minimum
water flow to economiser inlet, the BFWP flow increases.
This phase lasts approximately 1 hour; at the end of the heat up and pressurization phase the boiler is
at the following conditions:
The conditions for steam turbine start-up are established; however advise with steam turbine start-up
procedures.
load or load rejection occur, however advise with steam turbine start-up procedure and/or unit
coordinator control philosophy.
6.3 HOT & VERY HOT START-UP MODE
6.3.1 CONSTRAINTS
At burner light off feed water cationic conductivity at boiler inlet shall be less than 0,60 μS/cm.
The feed water chemical conditioning will be AVT(O) and then switched on OT as soon the permissive
for oxygen dosing are met (cationic conductivity 0,15 μS/cm or lower).
 pressure:
HRH 11 barg
SH 130 barg
 temperature:
HRH 500 °C
SH 520 °C
Particularly for load changing rate will be:
 up to 40%: 5 %/min;
 from 40 to 100%: 6 %/min.
Established the water storage tank required level, boiler is in forced circulation mode (i.e. BCP in
service), as soon as the feed water quality satisfies the mentioned conditions at paragraph 6.3.1.1,
checked separator vessels temperature is higher than 255 °C (i.e. higher than approx. 43 bar) the hot
start-up procedures can proceed and the first burner is light off, with either solar oil or natural gas,
according to the proper sequence, see paragraph 8.3.
Operations on boiler water and steam system are as follows:
 from initial pressure up to 120 barg: approx. 30% opening;
then increasing the pressure above mentioned value drain valves close;
 check that main steam valves (AA HV 737/738) are open, otherwise main steam pipes shall
be heated and pressurized through their bypass valves (AA HV 739/740), as per the next step;
 if any, open drains valves on main steam and HP bypass lines, however advise with BOP start-
up procedure;
 if any, open drains valves on reheat steam and LP bypass lines, however advise with BOP
start-up procedure;
open;
 check that combustion air flow is settled at a purge rate (approx. 30% MCR flow), see
paragraph 7.1.3;

rolling;
system).
flow control valve;
saturated water, via the tank overflow line, is dumped to drain receiver tank where, through the
condensate transfer pumps (BM MP 101 A or B), is carried to condenser.
sump).
As steam starts flowing toward superheater outlet, main steam pipes can be heated and pressurized
as follows:
procedure;
 open main steam bypass shut-off valves (AA HV 739/740);
 when the equalize condition are achieved, i.e. differential pressure and temperature across
main valves are within the limits, < ±1,5 bar and < ±10 °C respectively, open main steam shut-
off valve (AA HV 737/738) and close related bypass shut-off valves (AA HV 739/740);
 the HP and LP bypass systems control will be switched in automatic operation mode; therefore
the HP and LP bypass system plays an important role in the main steam pressure control from
starting pressure value up to approx. 130 barg in order to maintain the prescribed
pressurization rate (i.e. separator vessels saturation temperature as per paragraph 5), then
the hot reheated steam flows to the LP bypass valves preliminary manually open to about 20%
travel while the associated spray control valves in automatic. When the pressure upstream LP
bypass valves reach approx. 8 barg, the pressure control will be placed in automatic controlling
the HRH steam pressure at approx. 11 barg;
is maintained constant and controlled to the above mentioned (approx. 175,8 kg/s) minimum flow.
consequently also the water recirculation flow through BCP, therefore, to maintain constant the total
minimum water flow to economiser inlet, the BFWP flow increases.
This phase lasts approximately 20 minutes for hot start-up and less than 10 minutes for very hot start-
up; at the end of the warm up and pressurization phase the boiler is at the following conditions:

The conditions for steam turbine start-up are established; however advise with steam turbine start-up
procedures.
load or load rejection occur, however advise with steam turbine start-up procedure and/or unit
coordinator control philosophy.
6.4 BOILER OPERATION
6.4.1 LOAD RAMP
Completed the boiler heat-up and pressurising phase, the boiler load is increased step by step up to
approx. 33% MCR (Minimum Benson Load), load changing rate shall be within the maximum allowable
values as per paragraph 5.
If burners are selected on oil firing, when firing rate demand increases above 20% MCR operator shall
ignite mazout oil burners gradually replacing solar oil burners, see paragraph 8.3.2.3, while fuel
changing is not mandatory if burners are selected on natural gas firing.
6.4.2 WET / DRY MODE TRANSFER
When boiler load achieved approx. 30% MCR, steam at the separator vessels is in dry condition,
therefore the water storage level drops to minimum and consequently the water circulation flow control
valve (AA FCV 554) closes and, as the fuel flow increases at approx. 35%, the BCP is automatically
stopped, boiler starts to operate in “once-through mode” and the enthalpy control overcomes the
minimum feed water flow to evaporator control.
As the BCP is off, to prevent thermal shock due to hot water flow, the isolation valves on warming lines,
branched off from economiser outlet, to BCP and to water storage tank overflow pipes (AA HV 744 and
HV 745 respectively) automatically open to keep them warmed to be ready to start for eventual sudden
load reduction below once through load.
The warm water flows back to water storage tank and most of it becomes steam and flows to separator
vessels and superheater, the possible residual water into the water storage tank, through relief shut-off
valve (AA HV 742) is discharged to 2nd stage superheater spray water lines, the valve automatically
opens as BCP is off and at least one warming valve opened.
For Benson mode the water chemistry permissives are as follows:

 cationic conductivity: ≤ 0,15 μS/cm at 25°C
 oxygen ≤ 10 μg/kg
 silica < 20 μg/kg
Boiler load around wet/dry mode transfer, i.e. between approx. 28% ÷ 33% MCR, is in unstable
condition, therefore continuous boiler steady state at this load is not recommendable and it should be
avoided.
Slightly above MBL, e.g. approx. 35% MCR, the boiler is working at stable operating range hence
normal operation can start and the boiler-steam turbine coordinated mode can be applied.
6.4.3 NORMAL OPERATION
Up to approx. 35% MCR boiler operates at constant pressure then up to BMCR, i.e. 105% = VWO,
boiler operates in sliding pressure.
During boiler start-up the feed water recommended chemical conditioning is the AVT(O) treatment and
water quality shall comply with the following:
 cationic conductivity ≤ 0,2 μS/cm at 25 °C
 pH: 9,2 ÷ 9,6
 oxygen < 10 μg/kg
 silica ≤ 10 μg/kg
 iron ≤ 2 μg/kg
 sodium ≤ 3 μg/kg
During normal operation, the chemical conditioning has to be switched to the OT treatment and water
quality shall comply with the following:
 cationic conductivity ≤ 0,15 μS/cm at 25 °C
 pH: 8,0 ÷ 8,5
 oxygen 80 μg/kg
 silica ≤ 10 μg/kg
 iron ≤ 2 μg/kg
 sodium ≤ 2 μg/kg
6.5 BOILER SHUT-DOWN
6.5.1 SHUT-DOWN AT BENSON LOAD
When a shut-down is planned for short period it is suggested to stop the boiler keeping as much as
possible the main steam pressure close to the condition of steam turbine restart, i.e. approx. 130 bara.
In such case if feed water chemical conditioning is still switched on OT mode, just a couple of hours
before of unit parallel off it is recommended to switch the feed water chemical conditioning to AVT(O)
mode.
Then the basic steps are as follows:

 decrease unit load, i.e. boiler steam production and steam turbine load;
 reduce the number of operating burners complying with unit load;
 achieved Benson load, i.e. approx. 35% MCR and feed water flow of approx. 175,8 kg/s, shut
down steam turbine;
 HP and LP bypass system is release to auto mode modulating to control main steam pressure
at 130 barg;
 trip the boiler and remained burners in service by means of emergency trip push button, i.e.
Master Fuels Trip (MFT).
6.5.2 SHUT-DOWN AND COOLING
When an outage is planned for long period, e.g. scheduled equipment maintenance, the unit is usually
required to be cooled-down and boiler depressurised as much as possible, steps are as follows:
 decrease unit load, i.e. boiler steam production and steam turbine load;
 reduce the number of operating burners complying with unit load;
 just below MBL, i.e. approx. 30% MCR and feed water flow of approx. 175,8 kg/s, start the
BCP and switch the boiler operation mode to “boiler forced circulation” mode
 as BCP starts, warming (AA HV 744/745) and relief shut-off (AA HV 742) valves close;
 reduce further unit load to approx. 15% MCR and switch main steam pressure control on HP
and LP bypass system;
 at unit load of approx. 5 ÷ 10% MCR stop electric generator and trip steam turbine, however
advise with steam turbine shut-down procedures;
 stop the remained burners and trip the boiler;

 if any, stop air fans too.
6.6 EMERGENCY OPERATION
6.6.1 LOAD RUN BACK
When run-back occurs for any cause (e.g. one FDF or one BFWP trip) but steam turbine and electric
generator remain regularly in service, a sudden boiler demand down to approx. 50% MCR is performed,
however advise with steam turbine start-up procedure and/or unit coordinator control philosophy. Then
the basic steps are as follows:
 fuels flow is suddenly cut to approx. 50% MCR and consequently air flow too;
 HP and LP bypass system is release to auto mode, if any modulating to control main steam
pressure down to approx. 150 bara;
 if any, the number of operating burners is automatically reduced to comply with approx. 50%
MCR load.
6.6.2 LOAD REJECTION
From boiler point of view, following a steam turbine and/or electric generator trip, when possible, a
sudden boiler load reduction to a load compatible with HP and LP steam bypass maximum capacity is
the suggested operation; to comply with the whole plant operation philosophy the behaviour will be as
follows:
The load rejection can be initiated by two different scenarios:

 electric generator breaker opens but steam turbine remains in service;
 steam turbine trip;
boiler load is reduced to Benson load, depending on the load at the time of the event the behaviour is
little bit different, as follows:
1) load higher than 50% MCR:

 suddenly reduce boiler load to 50% MCR by cutting fuels flow, contemporaneously the
pressure will reduce in sliding pressure with a maximum ramp rate of approx. 10 – 12 bar per
minute;
 stabilize boiler load at 50% MCR for approx. 15 minutes;
 reduce further to Benson load (approx. 35% MCR) with a load ramp rate of approx. 2% per
minute while pressure will follow the sliding pressure curve until main steam pressure falls
down to approx. 130 bara;
2) load at 50% MCR or lower:

 reduce to Benson load (approx. 35% MCR) with a load ramp rate of approx. 2% per minute
following sliding pressure curve until main steam pressure falls down to approx. 130 bara;
 HP and LP bypass system suddenly open to reduce the boiler trip possibility, then it is release
to auto mode, if any modulating to control main steam pressure down to approx. 150 bara and
then to the final approx. 130 bara; however advise with steam turbine start-up procedure and/or
unit coordinator control philosophy;
In the above transient condition, if main steam pressure exceeds the predetermined value, the foreseen
remotely power operated safety valves (AA PRV 911/912) located on steam lines at separator vessels
outlet will open automatically to prevent superheater spring safety valves lifting, while, if reheated steam
pressure exceeds the predetermined value, the reheated steam spring safety valves located on
reheater inlet/outlet will lift.
6.6.3 HOUSE LOAD OPERATION
In the event of unit disconnection from the grid due to events external to the power plant, while electric
generator breaker remains closed, the unit shall remain in service on the auxiliary load, approx. 3%
MCR, i.e. house load operation.
The behaviour will be as follows:
 steam turbine is suddenly transferred to house load, i.e. approx. 3% MCR, however advise
with steam turbine start-up procedure;
 boiler load is reduced to Benson load, depending on the load at the time of the event the
behaviour is little bit different, as follows:
1) load higher than 50% MCR:

 suddenly reduce boiler load to 50% MCR by cutting fuels flow, contemporaneously the
pressure will reduce in sliding pressure with a maximum ramp rate of approx. 10 – 12 bar per
minute;
 stabilize boiler load at 50% MCR for approx. 15 minutes;
 reduce further to Benson load (approx. 35% MCR) with a load ramp rate of approx. 2% per
minute while pressure will follow the sliding pressure curve until main steam pressure falls
down to approx. 130 bara;
2) load at 50% MCR or lower:

 reduce to Benson load (approx. 35% MCR) with a load ramp rate of approx. 2% per minute
following sliding pressure curve until main steam pressure falls down to approx. 130 bara;
 HP and LP bypass system suddenly open to reduce the boiler trip possibility, then it is release
to auto mode, if any modulating to control main steam pressure down to approx. 150 bara and
then to the final approx. 130 bara; however advise with steam turbine start-up procedure and/or
unit coordinator control philosophy;
6.6.4 ELECTRIC BLACK-OUT
The electric black-out can generate a dangerous situation for BCP motor windings insulation because
of abnormal heat transfer from BCP to motor due to cooling water (CCCW) lack. Therefore the BCP
motor cooling shall always be guaranteed in worst case too until the pump/motor temperature drops
within the acceptable value (approx. 60 °C).
Operator can start the emergency cooling pump commanding step by step the related equipment
(pump, valves, etc.) or satisfied the following permissive:
 CCCW system out of service;
 BCP running or BCP motor cavities temperature > 50°C;
 the selected emergency cooling pump (SC MP 101 A or B) automatically starts and
consequently cooling water valves are positioned as follows:
 as one emergency cooling water pumps is running the valves on condensate cooling circuit
(SC HV 701/702, respectively at BCP cooler inlet and outlet) open;
 as one emergency cooling water pumps is running the BCP main cooling circuit (CCCW) is
automatically isolated by closing the actuated valves (WB HV 701/702, respectively at BCP
cooler inlet and outlet);
in such condition the condensate emergency cooling water is drained to drain receiver tank.
If condensate cooling water does not flow properly within due time, operator has to check/open manual
valves at pumps suction/discharge (SC PV 101/103 and SC PV 104/106) are open.
7. BOILER AIR & FLUE GASES SYSTEM
7.1 INITIAL CONDITIONS
7.1.1 NATURAL DRAFT
Following a MFT due to both FDF trip, all control and shut-off dampers in the air and flue gases passage
up to the stack are fully open to create as much natural draft as possible to ventilate the unit, i.e. furnace,
ducts and dry electrostatic precipitator.
This condition called “Natural draft” shall be maintained for not less than 15 minutes, at the end of period
some dampers can be properly closed to allow immediately starting of related RAH and FDF to increase
air flow up to 30÷40% of full load mass flow, i.e. air flow rate shall not be less than 25% of full load mass
flow, in order to perform the regular furnace purge (see paragraph 7.1.3).
7.1.2 WAITING TIME FOR PURGE
Following a MFT due to combustion air flow very low, i.e. lower than 25% of full load mass flow, the
control system forbids to change the air flow and the boiler purge cannot be performed.
This condition called “Waiting time for purge” shall be maintained for not less than 5 minutes, the air
flow will be maintained at the existing flow rate and at the expiring period air flow will be increased up
to the purge flow rate, i.e. approx. 30÷40% of full load mass flow, to perform the furnace purge.
7.1.3 FURNACE PURGE
Following a MFT, operating fans are maintained in service, if the MFT is not due to combustion air
malfunction (i.e. both FDF trip or combustion air flow very low, see above paragraphs 7.1.1 and 7.1.2),
the air flow will be slowly set at the purge flow rate, i.e. approx. 30÷ 40% of full load mass flow, to
perform the furnace purge for not less than 5 minutes.
Before any fuel firing following a MFT a satisfactory furnace purge must be completed, when all
hereinafter permissive are satisfied as well as the combustion air flow, the furnace purge automatically
starts and it is performed in two phases.
Purge permissive to be satisfied are as follows:
 all fuel trip valves closed (i.e. solar oil and natural gas to ignitor, solar oil and fuel oil and natural
gas to burners);
 all header vent valves closed (i.e. front and rear ignitor and burners natural gas vent header
valves
 all ignitors solar oil valves closed;
 all ignitors natural gas valves closed;
 all burners solar oil valves closed;
 all burners valves closed or fuel oil burners rows trip valves closed;
 all burners natural gas valves closed;
 at least twenty burners air registers open;
 no boiler trip condition present;
 no flame detected;
 water storage tank level adequate;
 at least one air/flue gas line in service;
 at least one RG fan running for purge;
 no natural draft required;
 no waiting time for purge required;
When all the above "purge permissive" are satisfied, the combustion air rate is set at 30% of full load
mass flow rate, once the air rate is at 30% the furnace purge sequence automatically starts and furnace
purge is performed as follows:
 the first phase provides to purge combustion air ducts, furnace and flue gases ducts up to the
chimney without involving the flue gases recirculation system, this phase lasts not less than 2
minutes;
 when the first phase is complete the second phase starts providing the flue gases recirculation
system purging too, this phase lasts not less than 3 minutes.
At the time expiring, the furnace purge sequence is complete.

If, during the purge time, any of the purge permissive would disappear, as well as the 30% air rate falls
down, then the purge phase is interrupted and a new furnace purge has to be carried out.
7.2 START-UP PROCEDURE
7.2.1 AIR & GAS LINE
7.2.1.1 AIR & GAS LINE START-UP
After checking that:

 natural draft has been completed, see paragraph 7.1.1;
 waiting time for purging not required, see paragraph 7.1.2;
 at least one air and flue gases path open, it means that not only dampers related to equipment,
i.e. regenerative air heater and forced draft fan, are fully open, but at least a minimum number
of burners shut-off air registers and OFA dampers too.
Steps to provide one air and flue gas stream equipment in service are as follows:
 start the RAH as per paragraph 7.2.2.1;
 start the FDF as per paragraph 7.2.3.1;
 start the GRF as per paragraph 7.2.4.1;
 start the SCAPH as per paragraph 7.2.5;
The air and flue gases line is considered regularly in service when all the following conditions occur:
 RAH in service;
 FDF in service;
The regular recommended operation is with both air and flue gases lines in service at low load too, i.e.
two FDF – two RAH – two SCAPH – two GRF, however operation with one main equipment out of
service is also allowed, in such condition the maximum recommendable/achievable boiler load is
approx. 60% MCR.
7.2.1.2 AIR & GAS LINE SHUT-DOWN

 waiting time for purge is not required;
Steps to provide one air and flue gas stream equipment in service are as follows:
 stop the GRF as per paragraph 7.2.4.2;
 stop the FDF as per paragraph 7.2.3.2;
 start the RAH as per paragraph 7.2.2.2;
 force the auxiliary steam to SCAPH (RAH cold end control) control valve in manual and close
position.
7.2.2 REGENERATIVE AIR HEATER
7.2.2.1 REGENERATIVE AIR HEATER START-UP

 all manual valves on RAH bearings lube oil system are open;
 manual valve on CCCW to lube oil cooler (AP ME 153) inlet/outlet (WB PV 119/121
respectively) are open and cooling water flow properly set, i.e. not less than 0,25 kg/s;
 RAH lube oil temperature adequate, i.e. not less than 30 °C otherwise start lube oil tank electric
heater (FL ME 104) to achieve the minimum requirement;
 RAH properly selected for operation, i.e. main electric motor switched on regular speed, i.e. 1
rpm;
Operator can start RAH commanding step by step the related equipment (lube oil pump, motor,
dampers, etc.) or automatically through the sequence as follows:
 start RAH selected lube oil pump (FL MP 151 A or 151 B) to feed properly RAH guide and
support bearings, i.e. oil flow not less than 0,15 kg/s to each bearing and oil pressure not less
than 2,5 barg;
 start RAH main electric motor;
 open RAH dampers, i.e. outlet air (AP HV 704 A, by-pass air (AP HV 703 A), inlet flue gases
(FU HV 701 A, outlet flue gases (FU HV 702 A), DESP A bypass (FU HV 706 A), DESP A inlet
(FU HV 708 A) and DESP A outlet (FU HV 707 A);
At start-up, if combustion air temperature at RAH outlet is below approx. 180 °C, the air by-pass damper
(APHV703A) opens, when air achieves the mentioned value or the load increases up to approx. 20%
MCR, the damper automatically closes.
The RAH is considered regularly in service when all the following conditions occur:
 RAH main electric motor on;
 RAH outlet air damper open OR air bypass damper open;
 RAH inlet and outlet flue gases damper open;
7.2.2.2 REGENERATIVE AIR HEATER SHUT-DOWN

 natural draft not required;
 related FDF off;
Operator can stop RAH commanding step by step the related equipment (lube oil pump, motor,
 close RAH dampers, i.e. outlet air (AP HV 704 A, by-pass air (AP HV 703 A), inlet flue gases
(FU HV 701 A, outlet flue gases (FU HV 702 A), command are effective only if the RAH is not
the last in service; that means, according to NFPA rules, the last RAH will be stopped with all
dampers open to perform the natural draft, see paragraph 7.1.1;
 stop RAH main electric motor, command is memorised and it becomes effective after several
hours (approx. 72 hours) when the RAH has been cooled;
 stop RAH selected lube oil pump (FL MP 151 A or 151 B);
7.2.2.3 REGENERATIVE AIR HEATER TRIP
RAH main motor trips whenever any of the following conditions occurs:
 RAH rotation not detected with main motor running and regular speed selected, i.e. speed
lower than 1 rpm;
 RAH main electric motor trip, i.e. electrical overload;
 RAH support bearing high temperature, i.e. higher than 85 °C, 2 minutes time delayed;
 RAH guide bearing high temperature, i.e. higher than 85 °C, 2 minutes time delayed;
If both RAH are in service, trip of one of them causes:

 shut-down of related FDF;
 closing of the related shut-off dampers on both air and flue gases side, if it is not the last RAH
in service;
 run-back of the boiler at 60% of MCR;
Trip of both RAH causes trip of both FDF and consequently Master Fuel Trip and opening of all the
dampers installed on air and flue gases circuit to perform the natural draft (see paragraph 7.1.1).
7.2.2.4 REGENERATIVE AIR HEATER LEAKAGE CONTROL SYSTEM
To minimize leakage path each RAH is equipped with its own “Leakage control system” that, during
RAH operation, automatically drives the top sector plates, i.e. RAH hot end side, adjusting and reducing
the gap between seals and sealing plate.
As RAH is running, operator from control room can enable the LCS that through the proprietary control
system moves the sector plates to the proper position toward the rotor.
The LCS gap control is based on two systems:
 primary system: through a gap sensor measures the deflection of the rotor at cold end and
then proportionally adjusted the sector plates position;
 secondary system: in case of failure of primary one, the secondary system control is based on
hot and cold end differential temperature that adjusts the sector plates distance accordingly;
7.2.3 FORCED DRAFT FAN
7.2.3.1 FORCED DRAFT FAN START-UP
Before starting the FDF associated to the running RAH, it shall be checked that, according to NFPA
requirements, air flow path open is maintained, this means to check/open dampers of the RAH and FDF
of other line.
 all manual valves on FDF and motor bearings lube oil system are open;
 all manual valves on FDF control oil system are open;
 manual valve on CCCW to lube oil cooler (FL ME 131 A or FL ME 131 B) inlet/outlet (WB PV
135/353/354 and WB PV 136/349 respectively) are open and cooling water flow properly set,
i.e. not less than 0,5 kg/s;
 manual valve on CCCW to control oil cooler (FL ME 114) inlet/outlet (WB PV 119/121
respectively) are open and cooling water flow properly set, i.e. not less than 0,5 kg/s;
 FDF lube oil temperature adequate, i.e. not less than 25 °C otherwise start lube oil tank electric
heater (FL ME 150 A) to achieve the minimum requirement;
 FDF control oil temperature adequate, i.e. not less than 25 °C otherwise start lube oil tank
electric heater (FL ME 140 A) to achieve the minimum requirement;
 related RAH properly in service OR other air and flue gases line in service;
Operator can start FDF commanding step by step the related equipment (lube and control oil pump,
motor, dampers, etc.) or automatically through the sequence as follows:
 if the other air and flue gases line is not already in service open all control and shut-off dampers
on this line and overfiring air too to provide the open path;
 start FDF selected lube oil pump (FL MP 111 A or 111 B) to feed properly FDF and motor DE
and NDE bearings, i.e. oil flow not less than 1,8 l/min to each FDF bearing and not less than
5,4 and 4,9 l/min to motor DE and NDE bearing respectively and oil pressure not less than 1,5
barg;
 start FDF selected control oil pump (FL MP 112 A or 112 B) to feed properly FDF inlet control
blades actuator, i.e. oil pressure not less than 30 barg;
 close FDF dampers, i.e. outlet (AP HV 701 A) and inlet control blades (AP FCV 514 A);
 start FDF motor;
 open FDF dampers, i.e. outlet (AP HV 714 A) and balancing duct (AP HV 702 A);
 release the FDF control in automatic mode, i.e. inlet control blades (AP FCV 514 A) and OFA
control dampers (AP FCV 518 A) and penthouse control damper (CA PCV 501), the OFA
throats positioning dampers (AP HV 705 A/B to HV 710 A/B and AP HV 715 A/B to HV 720
A/B) open based on boiler load function.
The FDF is considered regularly in service when all the following conditions occur:
 FDF motor on;
 FDF outlet damper open;
7.2.3.2 FORCED DRAFT FAN SHUT-DOWN

Operator can stop FDF commanding step by step the related equipment (lube and control oil pump,
motor, dampers, etc.) or automatically through the sequence as follows:
 close the FDF inlet control blade (AP FCV 514 A), command is effective only if the FD fan is
not the last in service; that means, according to NFPA rules, the last FD fan will be stopped
with damper open;
 close FDF discharge damper, i.e. outlet (AP HV 701 A), as per control blade it is effective only
if the FDF is not the last;
 stop FDF motor;
 stop FDF selected lube oil pump (FL MP 111 A or 111 B) and selected control oil pump (FL
MP 112 A or 112 B);
Therefore, as above mentioned the last FDF is stopped with the discharge damper opened and the inlet
control blades, to avoid excessive furnace pressure transients, is smoothly transferred to full open
position to perform the natural draft, see paragraph 7.1.1.
7.2.3.3 FORCED DRAFT FAN TRIP
FDF trips whenever any of the following conditions occurs:

 FDF motor trip, i.e. electrical overload;
 FDF DE bearing temperature very high, i.e. higher than 105 °C;
 FDF NDE bearing temperature very high, i.e. higher than 105 °C;
 FDF bearing vibration very high, i.e. higher than 7,1 mm/s;
 FDF in stall condition, i.e. differential pressure across fan higher than 5 mbar and blade angle
not less than 42 degree, time delayed;
 furnace pressure very-very high, i.e. higher than 73,6 mbarg, only running fans will be tripped;
 implosion protection enabled, it means all fuels off and furnace purge completed and furnace
pressure very high, i.e. higher than 66 mbarg, only running fans will be tripped;
 FDF local emergency stop push-button activated;
 temperature inside related RAH very high, i.e. fire detected;
 related RAH main electric motor not in service;
If both FDF are in service, trip of one of them causes:

 closing of the related control and shut-off dampers, if it is not the last FDF in service;
 closing of the related RAH shut-off dampers on both air and flue gases side;
 run-back of the boiler at 60% of MCR.
Trip of both FDF causes the MFT and the opening of all the dampers installed on air and flue gases
circuit to perform the natural draft (see paragraph 7.1.1).
7.2.4 GAS RECIRCULATION FAN
7.2.4.1 GAS RECIRCULATION FAN START-UP

 all manual valves on GRF bearings lube oil system are open;
 manual valve on CCCW to lube oil cooler (FL ME 123 A or FL ME 123 B) inlet/outlet (WB PV
105/107 respectively) are open and cooling water flow properly set, i.e. not less than 0,8 kg/s;
 GRF lube oil temperature adequate, i.e. not less than 20 °C otherwise start lube oil tank electric
heater (FL ME 741 A) to achieve the minimum requirement;
 at least one RAH and related FDF properly in service OR other air and flue gases line in
service;
Operator can start GRF commanding step by step the related equipment (lube oil pump, motor,
 start GRF selected lube oil pump (FL MP 121 A or 121 B) to feed properly GRF DE and NDE
bearings;
 close GRF dampers, i.e. inlet (FU HV 703 A) and outlet (FU HV 704 A and HV 705 A) and inlet
control vane (FU TCV 597 A);
 start GRF motor, as GRF motor is running the turning gear motor (FU MA 001/002) is stopped;
 open GRF dampers, i.e. inlet (FU HV 703 A) and outlet (FU HV 704 A and HV 705 A);
 close GRF sealing air dampers, i.e. inlet and outlet (CA HV 806 A and CA HV 807 A);
 release the GRF control in automatic mode, i.e. inlet control vane (FU TCV 597 A).
The GRF is considered regularly in service when all the following conditions occur:
 GRF motor on;
 GRF inlet damper open;
 GRF outlet dampers open;
7.2.4.2 GAS RECIRCULATION FAN SHUT-DOWN

Operator can stop GRF commanding step by step the related equipment (lube oil pump, motor,
 close the GRF inlet control vane (FU TCV 597 A);
 close GRF shut-off dampers, i.e. inlet (FU HV 703 A) and outlet (FU HV 704 A and HV 705 A);
 stop GRF motor, as GRF motor is off the turning gear motor (FU MA 001/002) starts;
 stop GRF selected lube oil pump (FL MP 121 A or 121 B), command is memorised and it
becomes effective only when both GRF motor, i.e. main and turning gear, are off and the fan
bearings temperature is lower than 40 °C;
 as GRF main motor is off open GRF sealing air dampers (CA HV 806 A and CA HV 807 A fan
inlet and outlet respectively);
7.2.4.3 GAS RECIRCULATION FAN TRIP
GRF trips whenever any of the following conditions occurs:

 GRF motor trip, i.e. electrical overload;
 GRF DE bearing temperature very high, i.e. higher than 85 °C;
 GRF NDE bearing temperature very high, i.e. higher than 85 °C;
 GRF bearing vibration very high, i.e. higher than 9 mm/s;
 GRF local emergency stop push-button activated;
 both FDF’s off.
If both GRF are in service, trip of one of them causes:

 closing of the related control and shut-off dampers, if it is not the last GRF in service;
 following emission values check, operator has to decide either boiler load reduction or shut-
down.
7.2.5 STEAM COIL AIR PRE-HEATER START-UP
At boiler start-up and low load operation, i.e. up to approx. 20% MCR, with either solar oil or natural gas
firing, SCAPH are required in service, increasing the load, i.e. above approx. MBL, with natural gas
firing SCAPH are no more required in service while they are still required in service with fuel oil firing.
As per above clarification, when SCAPH is required in service, after checking that:
 auxiliary steam manual valve at battery limit (SA PV 131) and manual valves
upstream/downstream (SA PV 101/102) auxiliary steam control valves (SA TCV 508 A) are
open;
 manual valves at condensate pumps suction/discharge (SA PV 111/113 and/or SA PV 121/123
respectively) are open;
 manual valves upstream/downstream (SA PV 127/128) condensate tank level control valve
(SA LCV 503) are open;
 manual valve on CCCW to SCAPH condensate pumps seal inlet/outlet (WB PV 147/151 and
WB PV 148/152 respectively) are open and cooling water flow properly set, i.e. not less than
10 l/minute.
Operator can provide in service the SCAPH commanding step by step the related equipment
(condensate pump, valves, etc.) as follows:
 open condensate valve to flash tank (SA HV 702) and close that one to deaerator (SA HV
701);
 release the RAH cold end control in automatic mode, i.e. auxiliary steam flow control valve (SA
TCV 508 A);
 release the SCAPH condensate tank level in automatic mode, i.e. condensate level control
valve (SA LCV 503);
 as soon as tank level achieves a required level start the selected condensate pump (SA MP
101 A or 101 B) to maintain the level within the limit;
 as the boiler load increase up to approx. 30% MCR, switch the condensate discharge to
deaerator opening valve (SA HV 701) and closing that one to flash tank (SA HV 702).
Condensate pump trips whenever any of the following conditions occurs:

 pump motor trip, i.e. electrical overload;
 condensate pump cooling water flow very low, i.e. lower than 10 l/min;
 condensate tank level very low, i.e. lower than - 1100 mmwg.
7.3 AUXILIARY AIR FAN START-UP PROCEDURE
Boiler is equipped with auxiliary air fans for two different duties as follows:
 2 x 100% sootblowers sealing air fans;
 3 x 50% natural gas burners;
 2 x 100% flame scanners cooling air fans
Before any fuel firing auxiliary air fans are to be properly in service, i.e. at least one sealing air fan and
at least two cooling air fans.
7.3.1 SOOTBLOWERS SEALING AIR FANS

 manual damper on sootblowers sealing air fans suction (CA PV 111/112) are open.
Operator carries out in service the selected sealing air fan (CA MA 001 A or CA MA 001 B) commanding
step by step the related equipment (motor, damper, etc.) as follows:
 start the sealing air fan motor (CA MA 001 A);
 open related discharge damper (CA HV 761 A).
Pressure transmitter is installed on sealing air fan discharge circuit controlling the stand-by fan logic.
7.3.2 BURNERS AND FLAME SCANNERS COOLING AIR FANS
Heavier operating condition occurs when all thirty-two burners natural gas nozzles are to be cooled, i.e.
idle burners or burners firing oil (solar oil or fuel oil), therefore at boiler start before any fuels firing two
cooling air fans shall be in operation (all burners idle) with vane control nearly fully opened supplying
the required amount of cooling air to all natural gas burners nozzle and flame scanners.
As the number of natural gas burners in service increases, i.e. greater or equal to seventeen natural
gas burners in service, one of the two cooling air fans in service automatically stops, the second fan
automatically starts again as the number of natural gas burners decreases below seventeen.
The most favourable operation is when no cooling air is required to natural gas burners nozzles, i.e. all
thirty-two burners are firing natural gas, in such condition only one cooling air fan is required in operation
supplying the minimum amount of cooling air to flame scanners and burners equipment (e.g. oil gun,
view port, etc.) only.

 manual damper on burners and flame scanners cooling air fans suction (CA PV 101/102/103)
are open;
Operator carries out in service at least two selected cooling air fans (CA MA 002 A and/or CA MA 002
B and/or CA MA 002 C) commanding step by step the related equipment (motor, damper, etc.) as
follows:
 start the cooling air fan motor (CA MA 002 A);
 open related discharge damper (CA HV 751);
 release to auto cooling air fans discharge pressure control, i.e. suction damper (CA PCV 561
A);
 start the second cooling air fan motor (CA MA 002 B or CA MA 002 C);
 open related discharge damper (CA HV 752 or CA HV 753);
 release to auto cooling air fans discharge pressure control, i.e. suction damper (CA PCV 561
B or CA PCV 561 C);
Pressure transmitters are installed on cooling air fans discharge circuit controlling the stand-by fan logic
and trip function, low cooling air pressure causes MFT.
7.4 DAMPERS SEALING SYSTEM
Where required to improve air and flue gases main dampers tightness, some of them is equipped with
dedicated sealing system; hereinafter is listed dampers equipped with such sealing system:
Main damper
Sealing air fan Sealing air damper
SERVICE TAG
CA MA 011 A
AP HV 703 A CA HV 811
CA MA 011 B
RGFAN inlet damper
CA MA 012 A
AP HV 703 B CA HV 812
CA MA 012 B
CA MA 013 A
AP HV 704 A CA HV 813
CA MA 013 B
RGFAN outlet damper
CA MA 014 A
AP HV 704 B CA HV 816
CA MA 014 B
FU HV 701 A CA MA 017 CA HV 804

RAH flue gases inlet damper
FU HV 701 B CA MA 018 CA HV 814
FU HV 702 A CA MA 019 CA HV 805

RAH flue gases outlet damper
FU HV 702 B CA MA 020 CA HV 815
The sealing system is carried out in service automatically as soon as the related main damper closes
and boiler is in service, i.e. at least one burner in service, as follows:
 start the related sealing air fan motor;
 open the related discharge sealing air damper.
Vice versa as soon as the main damper leaves the closed position, the related sealing air system stops:
 close the related discharge sealing air damper;
 stop the related sealing air fan motor.
Above operations can also be carried out step by step by the operator.
When all the following conditions occur, operator is warned the related sealing air system is in service:
 related sealing fan motor running;
 related sealing air shut-off damper open;
 related sealing air pressure adequate.
If main damper is closed and related sealing air system in not properly service, an alarm warns operator
that damper tightness is jeopardised.
8. BOILER FUELS & BURNERS SYSTEM

The boiler is equipped with thirty-two burners, arranged in four rows of four burners each installed on
the front (16) and rear (16) furnace walls.
Burners system is sized to enable boiler continually operation at BMCR load; steam temperature control
and emissions are maintained with all burners in service, such requirements is also satisfied with one
or two opposite burners out of service for short-term maintenance. Burner ignition is singularly
commanded.
All burners are arranged for either fuel oil or natural gas firing, i.e. fuels firing combination on same
burner is forbidden. Burners 2nd row is also arranged for solar oil (solar oil) firing, i.e. start-up fuel when
natural gas is not available. Each burner is equipped with its own dual firing ignitor, either solar oil or
natural gas.
Boiler heating and loading phase up to approx. 20% is achieved by means of either solar oil or natural
gas firing, increasing boiler load solar oil firing shall be switched on fuel oil, no load restriction firing
natural gas.
8.1 INITIAL CONDITIONS
Before starting any burners, the operator has to check/fill the boiler, see paragraph 6.1.2.1, and then
check/start the following equipment:
 at least one boiler feed water pump in service, advise with BOP start-up procedure;
 boiler on water circulation mode, see paragraph 6.1.2.3;
 at least one air & flue gases line in service, see paragraph 7.2.1;
 at least two cooling air fan in service, see paragraph 7.3.2;
 at least one sealing air fan in service, see paragraph 7.3.1;
satisfied above conditions, the combustion air flow increases up to approx. 30% MCR to perform the
furnace purge, as per above paragraph 7.1.3, once the furnace purge is complete, fuel firing can be
carried out as per following paragraphs:
 natural gas firing, see paragraph 8.3.1.2;
 solar oil firing, see paragraph 8.3.2.2;
 mazout oil firing, see paragraph 8.3.3.4;
8.2 IGNITORS
Following a MFT or related fuel trip, before any ignitors and/or burners ignition, a satisfactory leak test
has to be performed on both ignitors and burners.
8.2.1 NATURAL GAS IGNITORS
Just before natural gas firing natural gas reducing station and filter separator are required in service
delivering natural gas to the boiler; however advise with BOP start-up procedure.
8.2.1.1 NATURAL GAS IGNITORS LEAK TEST
Satisfied the following permissive:

 all ignitors natural gas valves closed;
 no trip conditions existing.
Ignitor leak test proceeds as follows:

 check manual valve on natural gas pipe at battery limit (FG PV 111) is open;
 check manual valve on ignitors natural gas main header (FG PV 101) is open;
 partially open ignitors pressure control valve (FG PCV 520) pressurising the line up to ignitors
natural gas main trip valve (FG HV 701);
 open ignitors natural gas main trip shut-off valve (FG HV 701) and ignitors natural gas front
and rear wall headers vent shut-off valves (FG HV 702 and 703);
 after approx. 2 minutes close ignitors natural gas front and rear wall headers vent shut-off
valves (FG HV 702 and 703);
 maintaining closed all ignitors natural gas shut-off valves, open partially ignitors natural gas
pressure control valve (FG PCV 520) to control ignitors pressure;
 pressurize natural gas pipes up to single ignitor shut-off valves;
 close main trip shut-off valve, memorizing the pressure value;
 after two minutes approx., if pressure value is within the established range (i.e. approx. ± 3%)
leak test is satisfactory completed and enables ignitors ignition, vice versa if leak test fails
ignitors start-up is forbidden until leak is repaired and satisfactory leak test carried out again;
8.2.1.2 NATURAL GAS IGNITORS IGNITION / SHUT-DOWN
Just before ignition operator has to select the fuel for each igniter (either natural gas or solar oil),
operator can select the fuel, i.e. selection allowed, when all the following conditions are satisfied:
 related igniter all fuels shut-off valves closed, i.e. both natural gas and solar oil ;
 igniter not in lighting;
 igniter purge not required;
 igniter gun retracted.
After fuel selection and following satisfactory leak test as per paragraph 8.2.1.1 and satisfied the
following permissive:
 natural gas pressure not low;
 natural gas pressure not high;
 ignitor being started not in trip condition, see paragraph 8.2.3;
 related burner not in trip condition, see paragraph 8.3.4.
Ignitor ignition proceeds as follows:

 check manual valve on natural gas and primary air of each ignitor (e.g. FG PV 131 C and CA
PV 131 C) are open;
 open ignitors natural gas main trip shut-off valve (FG HV 701); at this time natural gas is
available up to ignitors shut-off valves, therefore when burner ignition sequence or operator
command requires the ignitor ignition, the related ignition sequence will be as follows:
 ignitors natural gas pressure control valve (FG PCV 520) opens automatically in order to
maintain the required set pressure value;
 advance ignitor gun (FG HY 112 C);
 open ignitor primary air shut-off valve (CA HV 711 C);
 open ignitor natural gas shut-off valve assembly (main valves FG HV 711/712 C open and
vent valve FG HV 713 C closes);
 energize ignitor spark transformer for 10 seconds;
 if flame is detected within 15 seconds of natural gas valve open, ignitor is lighted-on.
When the burner sequence requires out of service the ignitor, the related ignitor shut-down is as follows:
 close ignitor natural gas and primary air shut-off valves;

 withdraw ignitor gun.
8.2.2 SOLAR OIL IGNITORS
Just before solar oil firing at least one solar oil forwarding pump (FOI MP 001 A or B) is required in
service conveying solar oil to the boiler; solar oil shall be properly pressure controlled, by means of
related control valve on return line to tanks, however advise with BOP start-up procedure.
8.2.2.1 SOLAR OIL IGNITORS LEAK TEST

 all ignitors solar oil valves closed;
Ignitor leak test proceeds as follows:

 check manual valve on ignitors solar oil main header (FOI PV 101) is open;
 partially open ignitors pressure control valve (FOI PCV 511) pressurising the line up to ignitors
solar oil main trip valve (FOI HV 701);
 open ignitors solar oil main trip shut-off valve (FOI HV 701);
 maintaining closed all ignitors solar oil shut-off valves, open partially ignitors solar oil pressure
control valve (FOI PCV 511) to control ignitors pressure;
 pressurize solar oil pipes up to single ignitor shut-off valves;
leak test is satisfactory completed and enables ignitors ignition, vice versa if leak test fails
ignitors start-up is forbidden until leak is repaired and satisfactory leak test carried out again;
8.2.2.2 SOLAR OIL IGNITORS IGNITION / SHUT-DOWN
Just before ignition operator has to select the fuel for each igniter (either natural gas or solar oil),
operator can select the fuel, i.e. selection allowed, when all the following conditions are satisfied:
 related igniter all fuels shut-off valves closed, i.e. both natural gas and solar oil ;
 igniter not in lighting;

 igniter purge not required;
 igniter gun retracted.
 solar oil pressure not low;
 ignitor being started not in trip condition, see paragraph 8.2.3;
 related burner not in trip condition, see paragraph 8.3.4.
Ignitor ignition proceeds as follows:

 check manual valve on solar oil , primary and scavenging air of each ignitor (e.g. FOI PV 131
C, CA PV 131 C and PA PV 131 C) are open;
 open ignitors solar oil main trip shut-off valve (FOI HV 701); at this time solar oil is available
up to ignitors shut-off valves, therefore when burner ignition sequence or operator command
requires the ignitor ignition, the related ignition sequence will be as follows:
 ignitors solar oil pressure control valve (FOI PCV 511) opens automatically in order to
 advance ignitor gun (FG HY 112 C);
 open ignitor primary air shut-off valve (CA HV 711 C);
 open ignitor solar oil shut-off valve (FOI HV 711 C);
 energize ignitor spark transformer for 10 seconds;
 if flame is detected within 15 seconds of solar oil valve open, ignitor is lighted-on.
When the burner sequence requires out of service the ignitor, the related ignitor shut-down is as follows:
 open ignitor scavenging air shut-off valve (PA HV 711 C);
 close ignitor solar oil and primary air shut-off valves;
 after 60 sec close ignitor scavenging air shut-off valve;
 withdraw ignitor gun.
8.2.3 IGNITOR TRIP
Whenever any of the following conditions occurs, ignitor trips:
 loss of flame;
 fuel valve open failure;
 local trip push-button activated;
 gun failure;
 combustion air valve failure;
 loss of power supply;
 I/O module failure.
As one of the first two conditions occurs two scenarios are possible:
 ignitor in service on natural gas: sudden trip;
 ignitor in service on solar oil: shut-down sequence automatically starts to perform the ignitor
purge if ignitor has not already been purged.
Following a MFT and/or a ignitor trip due to causes different of the above first two, the ignitor purge is
inhibited, therefore, after furnace purge and/or trip causes clearing, operator has the possibility to start
the related ignitor shut-down sequence to perform the ignitor purge.
8.3 BURNERS
Following a MFT or related fuel trip, before any ignitors and/or burners ignition, a satisfactory leak test
has to be performed on both ignitors and burners.
8.3.1 NATURAL GAS BURNERS
Just before natural gas firing natural gas reducing station and filter separator are required in service
delivering natural gas to the boiler; however advise with BOP start-up procedure.
8.3.1.1 NATURAL GAS BURNERS LEAK TEST

 all burners natural gas valves closed;
 natural gas pressure upstream main trip shut-off valve (FG HV 801) higher than minimum (> 2
barg);
Burner leak test proceeds as follows:

 check manual valve on natural gas pipe at battery limit (FG PV 111) is open;
 check manual valves on burners natural gas main header upstream/downstream control valves
(FG PV 112/113 and/or FG PV 114/115 and/or FG PV 116/117 respectively) are open;
 partially open (approx. 5%) burners pressure control valve (FG PCV 503) pressurising the line
up to burners natural gas main trip valve (FG HV 701);
 open burners natural gas main trip shut-off valve (FG HV 801) and burners natural gas front
and rear wall headers vent pressure control valves (FG PCV 525 and PCV 526);
 maintaining closed all burners natural gas shut-off valves, partially open burners start-up flow
control valve (FG FCV 505 C) to control burners pressure;
 after approx. 2 minutes close burners natural gas front and rear wall headers vent pressure
control valves (FG PCV 525 and PCV 526);
 pressurize natural gas pipes up to single burner shut-off valves;
leak test is satisfactory completed and enables burners ignition, vice versa if leak test fails
burners start-up is forbidden until leak is repaired and satisfactory leak test carried out again.
8.3.1.2 NATURAL GAS BURNER IGNITION / SHUT-DOWN
Just before ignition operator has to select the fuel for each burner (either natural gas or fuel oil or solar
oil, last one for 2nd row burner only), operator can select the fuel, i.e. selection allowed, when all the
following conditions are satisfied:
 related burner all fuels shut-off valves closed, i.e. both natural gas and fuel oil and solar oil,
last one for 2nd row burner only;
 burner not in lighting;
 burner purge not required;
 burner gun retracted.
 natural gas pressure not low;
 natural gas pressure not high;
 burner being started not in trip condition, see paragraph 8.3.4.
Proceed as follows:
 open burners natural gas main trip shut-off valve (FG HV 801);
 as natural gas main trip valve opens the natural gas pressure control is switched on auto and
the valve (FG PCV 503) opens automatically (approx. 5%) in order to maintain the required set
pressure value;
 as natural gas main trip valve opens the natural gas flow control is switched on auto and
cascade control and the start-up flow control valve (FG FCV 505 C) opens automatically
(approx. 5%) in order to maintain the required set flow value.
At this time natural gas is available up to burners shut-off valves.
Burners ignition the hereinafter sequence refers to one burner; it shall be repeated for the required
number of burners to be provided in service, when burner ignition is required, proceed as follows:
 check manual valve on natural gas and cooling air of each burner (e.g. FG PV 132 C and CA
PV 134 C) are open;
 check manual valve on cooling air of each burner (e.g. CA PV 135 C) is set properly;
 the burner air register (AP HV 143 C), if not already closed, closes as soon as related burner
ignition sequence starts;
 start ignitor (FG MU 112 C) as per paragraph 8.2.1.2 or 8.2.2.2 according to ignitor selected
fuel;
 command to open the burner natural gas shut-off valve assembly (main valves FG HV 811/812
C open and vent valve FG HV 813 C closes), it will be effective as soon as the burner cooling
air shut-off valve close;
 as soon as the natural gas shut-off valve is commanded to open, the burner cooling air shut-
off valve assembly (main valves CA HV 712/713 C close and vent valve CA HV 714 C opens)
closes;
 the burner air register (AP HV 143 C) opens as soon as related fuel valve is not closed;
 if flame is detected within 5 seconds of natural gas valve open, burner is lighted-on.
 after 30 seconds that fuel valve has been open shut-down ignitor (FG MU 112 C) as per
paragraph 8.2.1.2 or 8.2.2.2 according to ignitor selected fuel.
Burner shut-down when the burner is required out of service the sequence is as follows:
 close burner natural gas shut-off valve assembly (main valves FG HV 811/812 C close and
vent valve FG HV 813 C opens) and open burner cooling air shut-off valve assembly (main
valves CA HV 712/713 C open and vent valve CA HV 714 C closes);
 the burner air register (AP HV 143 C) closes as soon as related fuel valve is closed.
When the last natural gas burner has been shut-down, i.e. all burners natural gas shut-off valves are
closed, also natural gas main trip shut-off valve (FG HV 801) closes.
8.3.1.3 NATURAL GAS BURNERS FUEL CONTROL
As the first burner natural gas shut-off valve opens the natural gas pressure control valve (FG PCV
503) and natural gas start-up flow (30%) control valve (FG FCV 505 C) previous fixed position demand
(approx. 5%) is removed and they are released to auto satisfying the natural gas demand.
In this phase the fuel input is controlled and limited by means of retractable thermo-probe inserted into
the furnace in order to satisfy the furnace flue gases required temperature, not higher than 500 °C;
based on that operator can gradually increase the number of burners in service and firing rate up to
achieve approx. 15% natural gas flow rate in order to meet the above mentioned limits. At this load, if
not already retracted by operator, thermo-probes will be automatically retracted and boiler firing rate
demand (generated by unit coordinator) will take over of fuel demand.
As the natural gas flow increases up to approx. 20% (6,5 kg/s), the selected natural gas main control
valve (FG FCV 505 A or FG FCV 505 B or both) opens and the start-up control valve (FG FCV 505 C)
smoothly closes, as the natural gas flow increases more up to approx. 30% (10 kg/s), independently of
main control valve selection, both the natural gas main control valves are required in service equally
sharing the flow.
During load reduction, as the natural gas flow drops below approx. 25% (8,5 kg/s) only one natural gas
main control valve may be required in service, as the natural gas flow decreases more down to approx.
15% (5 kg/s), the start-up control valve opens and the main control valves smoothly close.
8.3.2 SOLAR OIL BURNERS
Just before solar oil firing at least one solar oil forwarding pump (FOI MP 001 A or MP 001 B) is required
in service conveying solar oil to the boiler; solar oil shall be properly pressure controlled, by means of
related control valve on return line to tanks, however advise with BOP start-up procedure.
8.3.2.1 SOLAR OIL BURNERS LEAK TEST

 all burners solar oil valves closed;
 solar oil pressure upstream main trip shut-off valve (FOI HV 801) higher than minimum (> 10
barg);
 check manual valves on burners solar oil main header upstream/downstream filter (FOI PV
121/122 respectively) are open;
 check manual valves on burners solar oil main header upstream/downstream control valve
(FOI PV 124/125 respectively) are open;
 open burners solar oil main trip shut-off valve (FOI HV 801);
 maintaining closed all burners solar oil shut-off valves, open partially (approx. 5%) burners
solar oil flow control valve (FOI FCV 505) to control burners pressure;
 pressurize solar oil pipes up to single burner shut-off valves;
8.3.2.2 SOLAR OIL BURNER IGNITION / SHUT-DOWN
 related burner all fuels shut-off valves closed, i.e. both natural gas and fuel oil and solar oil ,
last one for 2nd row burner only ;
 solar oil pressure not low;
 atomising air pressure not low;
Proceed as follows:
 open burners solar oil main trip shut-off valve (FOI HV 801);
 as solar oil main trip valve opens the solar oil flow control is switched on auto and cascade
control and the control valve (FOI FCV 505) opens automatically (approx. 5%) in order to
maintain the required set flow value.
At this time solar oil is available up to burners shut-off valves.
 check burner gun is clamped (FG MU 111 C - ZS);
 check manual valve on solar oil and service air of each burner (e.g. FOI PV 171 C and PA PV
135 C) are open;
 check manual valve on natural gas nozzle cooling air of each burner (e.g. CA PV 134 C) is
open and that one on cooling air of each burner (e.g. CA PV 135 C) is set properly;
 check burner cooling air shut-off valve assembly is opened (i.e. main valves CA HV 712/713
C open and vent valve CA HV 714 C close);
fuel;
 advance burner oil gun (FG MU 111 C);
 open burner atomizing air shut-off valve (PA HV 811 C);
 open burner solar oil shut-off valve (FOI HV 811 C);
 if flame is detected within 5 seconds of solar oil valve open, burner is lighted-on.
Burner shut-down when the burner is required out of service the sequence is as follows:
fuel;
 close burner solar oil shut-off valve (FOI HV 811 C);
 the burner air register (AP HV 143 C) closes as soon as related fuel valve is closed;
 open burner scavenging air shut-off valve (PA HV 812 C);
 after 30 seconds that scavenging air valve has been open shut-down ignitor (FG MU 112 C)
as per paragraph 8.2.1.2 or 8.2.2.2 according to ignitor selected fuel;
 after 180 seconds that burner scavenging air shut-off valve has been open close it (PA HV 812
C) and atomizing air valve (PA HV 811 C);
 withdraw burner oil gun.
When the last solar oil burner has been shut-down, i.e. all burners solar oil shut-off valves are closed,
also solar oil main trip shut-off valve (FOI HV 801) closes, then operator, according to plant needs
and/or solar oil availability, has to choose among the following possibilities:
 solar oil system out of service: in such case operator has to stop the solar oil forwarding pump;
 restart the boiler: the solar oil forwarding pump is recommended to be in service on minimum
pressure control circuit;
8.3.2.3 SOLAR OIL BURNERS FUEL CONTROL
As the first burner solar oil shut-off valve opens the solar oil flow control valve (FOI FCV 505) previous
fixed position demand (approx. 5%) is removed and it is released to auto satisfying the solar oil demand.
In this phase the fuel input is controlled and limited by means of retractable thermo-probe inserted into
the furnace in order to satisfy the furnace flue gases required temperature, not higher than 500 °C;
based on that operator can gradually increase the number of burners in service and firing rate up to
achieve approx. 15% solar oil flow rate in order to meet the above mentioned limits. At this load, if not
already retracted by operator, thermo-probes will be automatically retracted and boiler firing rate
demand (generated by unit coordinator) will take over of fuel demand.
The maximum achievable load firing solar oil is approx. 20% MCR, and then next burners to start have
to be switched on mazout oil firing, at that time for fuel switchover, it is recommended to freeze the
boiler load, so the operator can ignite gradually an equivalent number of fuel oil burners and increasing
the fuel oil flow rate the system (fuel master control) automatically provides to reduce solar oil flow rate
proportionally.
8.3.3 FUEL OIL BURNERS
8.3.3.1 FUEL OIL SYSTEM HEATING ELECTRICAL TRACING
The electrical tracing system has the duty to heat and to prevent from sluggish oozing the mazout oil
inside pipes and equipment (i.e. filter, valves) from boiler battery limit up to the burners.
To achieve above requirement the fuel oil inside the pipes is maintained above minimum required
temperature (i.e. approx. 36 °C) taking care of pipes insulation too; as soon as fuel oil is delivered at
boiler battery limit feeding the oil heaters, operator has to switch-on the electrical tracing system, and
then fuel oil temperature is controlled (on-off) from the above mentioned minimum up to approx. 60 °C.
As soon as reboiler steam is available feeding selected oil heaters, see paragraph 8.3.3.2, the fuel oil
temperature downstream oil heater increase and the electrical tracing of related circuit automatically
switches-off.
8.3.3.2 FUEL OIL PUMPS
Independently of fuel oil firing requirement or just before fuel oil firing at least one fuel oil supply pump
(FO MP 001 A/B/C) can be required in service conveying fuel oil to the boiler; fuel oil shall be properly
heated, by means of fuel oil pump suction heater, and pressure controlled, by means of related control
valve on return line to tanks, however advise with BOP start-up procedure.
As soon as the fuel oil is available at boiler battery limit it can be heated circulating it through short
recirculation line as follows:
 check manual valves at oil heater inlet/outlet (FO PV 131/133 or FO PV 132/134 respectively)
are open;
 check manual valves upstream/downstream filter (FO PV 135/136 respectively) on fuel oil inlet
header are open;
 open burners fuel oil short recirculation valve (FO HV 802), it means fuel oil main trip shut-off
valve (FO HV 801) closes;
 if any, open manual valve (FO PV 431 or FO PV 432) venting air from fuel oil heater A or B
respectively;
 check manual valves on reboiler steam to oil heater upstream/downstream control valve (SB
PV 101/102 and/or SB PV 111/112 respectively) are open;
 check manual valves to condensate collection tank (SB PV 501/502 and/or SB PV 511/512)
are open;
 selected fuel oil temperature control valve (SB TCV 504 A or 504 B) opens automatically in
order to heat fuel oil up to the required set temperature value;
At that time fuel oil is circulating in boiler area up to fuel oil main trip shut-off valve and it is heated up
to the settled temperature.
As the boiler load will increase more than 50% MCR a second fuel oil pump is required in service.
8.3.3.3 FUEL OIL BURNERS LEAK TEST

 all burners fuel oil valves closed;
 fuel oil pressure upstream main trip shut-off valve (FO HV 801) higher than minimum (> 10
barg);

if fuel oil manual valves have been maintained in the position set as per paragraph 8.3.3.2, skip the
following first three bullets, otherwise proceeds as follows:
 check manual valves at oil heater inlet/outlet (FO PV 131/133 or FO PV 132/134 respectively)
are open;
 check manual valves on burners fuel oil main header upstream/downstream filter (FO PV
 if any, open manual valve (FO PV 431 or FO PV 432) venting air from fuel oil heater A or B
respectively;
 check manual valves on burners solar oil main header upstream/downstream control valve
(FOI PV 141/142 respectively) are open;
 check manual valves on upstream/downstream burners fuel oil return flow meter (FO PV
 check manual valves on all fuel oil row headers (FO PV 149/151/153/155/157/159/161/163)
are open;
 open burners fuel oil return shut-off valve (FO HV 803);
 open all fuel oil row headers shut-off valve (FO HV 810 A to FO HV 810 H);
 open burners fuel oil main trip shut-off valve (FO HV 801);
 maintaining closed all burners fuel oil shut-off valves, open partially (approx. 5%) burners fuel
oil flow control valve (FO FCV 509) to control burners pressure;
 after approx. 2 minutes close burners fuel oil return shut-off valve (FO HV 803);
 pressurize fuel oil pipes up to single burner shut-off valves;
8.3.3.4 FUEL OIL BURNER IGNITION / SHUT-DOWN
 related burner all fuels shut-off valves closed, i.e. both natural gas and fuel oil and solar oil ,
last one for 2nd row burner only;
 fuel oil temperature adequate (approx. 105 °C);
 combustion air temperature adequate (approx. 150 °C);
 fuel oil pressure not low;
 atomising steam pressure not low;
If fuel oil manual valves have been maintained in the position set as per paragraph 8.3.3.2, skip the
following first three bullets, otherwise proceed as follows:
 check manual valves on reboiler steam to oil heater upstream/downstream control valve (SB
PV 101/102 and/or SB PV 111/112 respectively) are open;
 check manual valves to condensate collection tank (SB PV 501/502 and/or SB PV 511/512)
are open;
 selected fuel oil temperature control valve (SB TCV 504 A or 504 B) opens automatically in
order to heat fuel oil up to the required set temperature value;
 check manual valves on auxiliary steam at battery limit (SA PV 131) is open;
 check manual valves on auxiliary steam upstream/downstream control valve (AT PV 101/102
respectively) are open;
 check manual valves on atomising steam drain lines (AT PV 501/502 – AT PV 504/505 – AT
PV 511/512 – AT PV 515/516 – AT PV 521/522 – AT PV 525/526– AT PV 531/532 – AT PV
535/536 – AT PV 541/542 – AT PV 545/546) are open;
 open atomising steam main shut-off valve (AT HV 801);
 burners atomising steam pressure control valve (AT PCV 501) opens automatically in order to
 open burners fuel oil main trip shut-off valve (FO HV 801);
 open burners fuel oil return shut-off valve (FO HV 803);
 open all fuel oil row headers shut-off valve (FO HV 810 A to FO HV 810 H);
 as fuel oil main trip valve opens the fuel oil flow control is switched on auto and cascade control
and the control valve (FO FCV 509) opens automatically (approx. 5%) in order to maintain the
required set flow value.
Fuel oil is circulated flowing back to the tank until it achieves the temperature adequate (approx. 105
°C) for firing, at this time fuel oil is available up to burners shut-off valves.
 check burner gun is clamped (FG MU 111 C - ZS);
 check manual valve on fuel oil and atomising/scavenging steam of each burner (e.g. FO PV
171 C and AT PV 141 C) are open;
 check manual valve on natural gas nozzle cooling air of each burner (e.g. CA PV 134 C) is
open and that one on cooling air of each burner (e.g. CA PV 135 C) is set properly;
 check burner cooling air shut-off valve assembly is opened (i.e. main valves CA HV 712/713
C open and vent valve CA HV 714 C close);
fuel;
 advance burner oil gun (FG MU 111 C);

 open burner atomizing steam shut-off valve (AT HV 811 C);
 open burner fuel oil shut-off valve (FO HV 811 C);
 if flame is detected within 5 seconds of fuel oil valve open, burner is lighted-on.
When at least four fuel oil burners are in service the fuel oil return shut-off valve (FO HV 803)
automatically closes.
Burner shut-down when the burner is required out of service, the sequence is as follows:
fuel;
 close burner fuel oil shut-off valve (FO HV 811 C);
 the burner air register (AP HV 143 C) closes as soon as related fuel valve is closed;
 open burner scavenging steam shut-off valve (AT HV 812 C);
 after 30 seconds that scavenging steam valve has been open shut-down ignitor (FG MU 112
C) as per paragraph 8.2.1.2 or 8.2.2.2 according to ignitor selected fuel;
 after 180 seconds that burner scavenging steam shut-off valve has been open close it (AT HV
821 C) and atomizing steam valve (AT HV 811C);
 withdraw burner oil gun.
When the last fuel oil burner has been shut-down, i.e. all burners fuel oil shut-off valves are closed, also
fuel oil main trip shut-off valve (FO HV 801) closes and the short recirculation valve (FO HV 802) opens;
then operator, according to plant needs and/or fuel oil availability, has to choose among the following
possibilities:
 fuel oil system out of service: in such case operator has to stop feeding of the reboiler steam
to oil heater and to stop the fuel oil pump;
 restart the boiler: the fuel oil supplying pump is recommended to be in service on return line
through the short recirculation valve (FO HV 802);
 restart the boiler: following a boiler trip if all the following permissive are satisfied:
 boiler trip;
 all burners fuel oil valve (e.g. FO HV 811 C) proven closed or fuel oil burners rows trip
valves (e.g. FO HV 810 C) proven closed.
Operator can command the fuel oil emergency recirculation opening fuel oil main trip shut-off valve
(FO HV 801) and long recirculation fuel oil return shut-off valve (FO HV 803) maintaining fuel oil
supplying pump is in service and heating up fuel oil up to the burners shut-off valve.
The fuel oil emergency recirculation demand is reset when any of the following conditions occurs:
 fuel oil main trip shut-off valve (FO HV 801) no more command to open;
 on operator demand;
 boiler no trip, i.e. furnace purge is completed.
8.3.3.5 FUEL OIL BURNERS FUEL CONTROL
As the first burner fuel oil shut-off valve opens the fuel oil flow control valve (FO FCV 509) previous
fixed position demand (approx. 5%) is removed and it is released to auto satisfying the fuel oil demand.
Until solar oil switchover to fuel oil is complete, fuel oil flow variation has to be controlled by the operator,
i.e. control station on auto and internal set-point, as fuel oil increases solar oil decreases.
Therefore the operator can gradually increase the number of burners in service and firing rate up to
achieve approx. 15 ÷ 20% fuel oil flow rate in order to meet the above mentioned solar oil conditions.
As the switchover is complete fuel oil control can be switched on auto and cascade control and boiler
firing rate demand (generated by unit coordinator) will take over of fuel demand.
At first fuel oil burner ignition, operator has to start the fuel oil additive system, i.e. one dosing pump FA
MP 505 A or 505 B, switching the control in auto, the fuel oil additive flow is injected proportionally to
fuel oil flow.
8.3.4 BURNERS IGNITION SEQUENCE
The preliminary suggested burners ignition pattern according to the elevation, that will be
confirmed/updated after site combustion optimization tuning, is starting from second row as follows:
C -> D -> A -> B -> E -> F -> G -> H
On the same row is preferable to lit up first the central burners proceeding from front to rear in opposite
scheme, then passing to the lateral burners according to the following example:
AB or AC -> BB or BC -> AC or AB -> BC or BB -> AA or AD -> BA or BD -> AD or AA -> BD or BA
The above natural gas firing pattern is still admitted for oil firing, starting firing solar oil on second row
(burners elevations C and D only), then increasing the boiler load, i.e. above approx. 20% MCR, other
burners will be ignited with fuel oil, consequently the solar oil burners load will be automatically reduced
but solar oil burner shut-down shall be commanded by operator.
Take care that symmetrical burners pattern, referring to the boiler vertical centreline, is always the
preferred one.
Burners shut-down pattern is the reverse one.
Operator is warned of abnormal firing pattern, i.e. when number of burners in service per wall is
unbalanced more than four.
8.3.4.1 NATURAL GAS/FUEL OIL SWITCH OVER AND MIXED FIRING BURNERS PATTERN
Natural gas to fuel oil switch over or vice versa shall be executed when the relevant permissives are
satisfied, taking care to keep preferably the fuel oil burners in the lowest elevation available.
8.3.5 BURNERS AUTOMATIC IGNITION / SHUT-DOWN OPERATION
Up to four burners ignition/shut-down is commanded by the operator.

When at least four burners, firing same fuel, are proven in service, next burners can be ignited
commanded by the operator or automatically according to boiler load demand, i.e. fuel pressure.
Burners automatic ignition/shut-down is foreseen for main fuels only, i.e. natural gas and fuel oil.
Once switched on auto mode, next fuel oil (natural gas) burner automatically ignites when the following
conditions occur:
 at least four fuel oil (natural gas) burners in operation;
 fuel oil (natural gas) pressure higher than maximum;
 fuel oil (natural gas) pressure not lower than minimum;
 fuel oil (natural gas) control valve in auto.
Once switched on auto mode, next fuel oil (natural gas) burner automatically stops when the following
conditions occur:
 at least five burners in operation with fuel oil (natural gas);
 fuel oil (natural gas) pressure not higher than maximum;
 fuel oil (natural gas) pressure lower than minimum;
 fuel oil (natural gas) control valve in auto.
8.3.6 BURNERS TRIP
Whenever any of the following conditions occurs, burner trips:

 loss of flame;
 fuel valves opening failure;
 air register opening failure;
 atomizing valve anomaly;
 cooling air valve anomaly;
 fuel valve position incongruence (i.e. open and closed status simultaneously);
 gun not clamped or gun failure;
 local trip push button activated;
 purging valve anomaly;
 loss of power supply;
 I/O module failure.
As one of the first five conditions occurs two scenarios are possible:
 burner in service on natural gas: sudden trip;
 burner in service on oil (fuel oil or solar oil ): shut-down sequence automatically starts to
perform the burner purge if burner has not already been purged.
Following a MFT and/or a burner trip due to causes different of the above first five, the burner purge is
inhibited, therefore, after furnace purge and/or trip causes clearing, operator has the possibility to start
the related burner shut-down sequence to perform the burner purge.
8.4 AIR REGISTER SETTING
8.4.1 BURNERS AIR REGISTER SETTING AND ALIGNMENT
Before any burner ignition air register shall be local manually settled, the preliminary suggested
settlement that will be confirmed/updated after site “combustion optimization” tuning, is as follows:
 general air damper sleeve: fully open;
 secondary air damper: 75% opening;
 secondary air swirler: 40° angle.
After a natural draft and/or after furnace purge completion, only the register of the burner to be light off
will be kept open while the other will be kept closed.
8.4.2 OVERFIRING AIR SETTING AND ALIGNMENT
Before any burner ignition OFA injectors shall be local manually settled, the preliminary suggested
settlement that will be confirmed/updated after site “combustion optimization” tuning, is as follows:
 tilting (vertical): 0° angle;
 yawing (horizontal): -5° , -10° , -15° (5° , 10° , 15°) angle, respectively for 1 to 3
(negative angle) and 4 to 6 (positive angle) nozzles central – intermediate – side injector.
OFA dampers preliminary suggested settlement that will be confirmed/updated after site “combustion
optimization” tuning, is as follows:
 upper damper:
up to 40% BMCR minimum opening (approx. 10%) for cooling duty;
from 40% function of load up to 60% fully open;
 lower damper:
up to 40% BMCR minimum opening (approx. 10%) for cooling duty;
from 40% function of load up to 60% fully open;
9. SOOTBLOWERS SYSTEM
The boiler is equipped with thirty-six steam sootblowers arranged as follows:

 24 full retractable sootblowers (SS AT 503 A/B to SS AT 514 A/B) installed on boiler walls in
between the banks;
 8 half retractable sootblowers (SS AT 501 A/B to SS AT 502 A/B and SS AT 517 A/B to SS AT
518 A/B) installed on boiler walls in between the banks;
 4 sootblowers (SS AT 515 A / 515 B to SS AT 516 A / 516 B) two for each RAH installed at
RAH flue gases inlet (hot side) and outlet (cold side).
9.1 START-UP PROCEDURE
As the boiler start, before any fuels firing, at least one sootblowers sealing air fan shall be in operation,
see paragraph 7.3.1, to ensure sootblowers wall-box sealing, in order to prevent flue gases leakage,
and sootblowers lance tube scavenging.
Before any sootblower operation, steam proper condition shall be achieved, therefore operator has to
proceed as follows:
 check that manual valve on steam feeding line at secondary superheater outlet (AA PV 131) is
open;
 check manual valves upstream/downstream (SS PV 101/103 and/or SS PV 102/014) steam
pressure control valves (SS PCV 502 A and SS PCV 502 B respectively) are open;
 check manual valves upstream/downstream (SS PV 511/512 and SS PV 521/522 and SS PV
531/532) steam traps are open;
 open the sootblowing system motor operated (SS HV 801), as the valve is commanded to open
the drain motor operated valve (SS HV 802/803/804) are also commanded to open;
 the selected steam pressure control valve (SS PCV 502 A or SS PCV 502 B) opens at approx.
10% to perform sootblowing lines heating;
 as the drain temperature achieves the required value (approx. 285 ÷ 290 °C), the related drain
motor operated valve (SS HV 802/803/804) is commanded to close;
 as all the drain lines achieve the required temperature (approx. 285 ÷ 290 °C) the pressure control
valve is release to auto controlling the pressure at the set value (approx. 24 ÷ 25 barg).
As the start-up conditions are satisfied operator has to select the sootblowers operation mode:
 Auto: all sootblowers as per sequence;
 Manual: each sootblower is individually remote commanded;
 Local: each sootblower is individually local commanded.
The sootblowers operation shall be preliminary set at least once per shift, then if cleaning is not sufficient
the sootblowing frequency can be increased according heat exchange banks fouling and/or pressure
drop, last one for RAH only.
9.2 SOOTBLOWERS TRIP
Whenever any of the following conditions occurs, sootblowers trip:

 emergency trip command;
 sootblowers steam low pressure;
 sootblowers steam low flow;
 sootblower electric motor trip, i.e. electrical overload;
 loss of steam sootblowers side heating.

A m1050 - 00 Boiler Start Up Procedure

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A m1050 - 00 Boiler Start Up Procedure

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0 FIRST ISSUE 13-06-2019

REV. DESCRIPTION DATE

DATE DEPARTMENT NAME SIGNATURE

UPPER EGYPT ELECTRICITY PRODUCTION

1 x 650 MW STEAM POWER STATION

BOILER START-UP PROCEDURE

JOB NO. DOCUMENT NO. REV.

ASSIUT SUPERCRITICAL POWER STATION POWER GENERATION ENGINEERING AND

BOILER START-UP PROCEDURE

DOCUMENT NO. REVISION SHEET OF

BOILER START-UP PROCEDURE 30641-A-M1050 0 2 88

ABBREVIATIONS AND ACRONYMS 4

1.1 BOILER P&IDS 6

3. BOILER & EQUIPMENT MAIN CHARACTERISTICS 13

6. BOILER WATER & STEAM SYSTEM 17

6.1 COLD START-UP MODE 18

BOILER START-UP PROCEDURE 30641-A-M1050 0 3 88

7. BOILER AIR & FLUE GASES SYSTEM 45

7.1 INITIAL CONDITIONS 46

8. BOILER FUELS & BURNERS SYSTEM 63

8.1 INITIAL CONDITIONS 64

9.1 START-UP PROCEDURE 87

BOILER START-UP PROCEDURE 30641-A-M1050 0 4 88

ABBREVIATIONS AND ACRONYMS

BOILER START-UP PROCEDURE 30641-A-M1050 0 5 88

BOILER START-UP PROCEDURE 30641-A-M1050 0 6 88

1.1 BOILER P&IDs

Boiler W&S system - Eco and Furnace P&ID

Boiler W&S system - SH P&ID

Boiler W&S system - RH P&ID

Boiler Start-up system P&ID

Boiler Blowdown system P&ID

Steam sootblowers system P&ID

A&G System - Combustion air P&ID

A&G System - Flue gases P&ID

A&G System – Furnace & Convective passage P&ID

Forced draft fans P&ID

Recirculation gas fans P&ID

Regenerative air heater Lube oil & Washing system P&ID

Sealing and Cooling air P&ID

Steam coil air heater system P&ID

BOILER START-UP PROCEDURE 30641-A-M1050 0 7 88

Firing System –Oil distribution system P&ID

Firing System – Typical burner system P&ID

Firing System – Mazout oil additive system P&ID

Boiler close cooling water system P&ID

Instrument air distribution system P&ID

Service air distribution system P&ID

Boiler sampling system P&ID

Fly ash handling system P&ID

Fly ash handling system P&ID – auxiliary fluid

BOILER START-UP PROCEDURE 30641-A-M1050 0 8 88

1.2 BOILER PROCESS FUNCTIONAL DESCRIPTIONS

Boiler W&S system – Functional description

Steam sootblowers system – Functional description

A&G System – Functional description

Fuels Firing System – Functional description

Boiler feed water and steam chemistry

Boiler lay-up procedure

Boiler start-up curves

BOILER START-UP PROCEDURE 30641-A-M1050 0 9 88

1.3 BOILER LOGIC DIAGRAM & DESCRIPTIONS