Boiler Start up and Shutdown

Plant Status       Plant is in normal operation but one boiler is in shut down position for some maintenance job Boiler is empty at ambient pressure and temperature Before start-up the boiler we took a general round for check up the following’s HP/LP Drums and Economizers drains should be closed position HP/LP super heaters drain valves should be open position HP Drum vent valve be open position .

 HP/LP super heater outlet steam stop valve’s should be open position  Condensate Pre-heater inlet isolating valve should be close position  HP Economizer inlet valve be close position  HP/LP bypass system valves are in normal position .

.LP Drum Filling  Two Condensate pumps are already in operation and standby pumps are in auto position  Confirm that pre heater and deaerator inlet shut off valve’s be open position  Slowly open the condensate pre heater inlet manual valve and regulate the minimum flow  Check any hammering in the pipeline if there is no any hammering slowly increase the flow after 5 minutes and wait for filling the LP Economizer.

 As Water coming from the LP Economizer vent valves close the vent valves and full open the condensate pre heater inlet valve.  Inform control room operator for filling LP drum flow controlling by LP feed water level control valve at slow flow rate and wait for water appearing in LP Drum  As the water level reach to 50% put the feed water level control valve auto position and drum level set point at 50% .

& Drum      Before start up the BFP check its bearing cooling water be in normal operation Pump suction and discharge be in open position Pump warm up line valve in open position Check any discrepancy from DCS and pump is reset position Start the BFP and open HP Economizer inlet valve slowly and regulate the minimum flow and check any hammering in feed water pipe line .Filling of HP Econo.

increase the flow after 5 minutes and wait for filling HP Economizer  As water coming from HP Economizer Vent valves close the vent valves and full open the HP Economizer inlet valve  Inform control room operator that filling of HP Economizer is completed and you can start filling of HP drum through flow controlling by HP feed water Level control valve at slow flow rate. Any hammering in the pipe line can damage the pipe line bends or valve seat  If there is no any hammering. .

8 bar .  Now boiler filling is completed  Put the HP boiler start up valve pressure set point 3 bar and Hp bypass valve pressure set point 7 bar  LP boiler start valve pressure set point 1. As the HP Drum level filled up to 50% put the feed water level control valve to auto position and HP drum level set point 50%.5 bar and LP bypass valve pressure set point 2.

       Start and synchronize GT load 5 MW GT trip & motors reset then reset boiler trip Check boiler start up permissive are ok Check any common alarm on Diverter box panel and reset it. Keep the GT load at 5 MW and let the boiler to warm up at slow rate . Start chemical dozing system. Give the command GT Combine cycle mode diverter box will be start opening.

 .  Increase the GT load slowly controlling steam temperature not increase more than 10 oF / minute . As the HP drum pressure at 2 bar close the Hp drum vent valve and HP super heater drain valves. because rapid start-up and shutdown of boiler will cause heavy stresses produced due to rapid expansion of tube metal which cause to leak or burst of boiler tube joints.

close the LP super heater drain valves and as the LP bypass system comes in service.5 bar for close it. . increase LP boiler start up valve pressure set point to 4.8 bar. Increase step by step GT load and wait for matching of boiler pressure and temperature with the other two boilers  As the pressure of LP drum reach to 1.

 As the HP steam Pressure and Temperature matched with other two boilers connect the HP boiler to HP main steam header by slowly opening HP steam stop valve and slowly increase the HP bypass valve pressure set point to 40 bar for close it  As the LP steam pressure and temperature matched with other two boilers connect it with LP main steam header by opening LP steam outlet stop valve .

. Close the LP steam line drain valves  Rapid start-up of boiler will cause over stressing and uneven expansion of parts of boiler and increase the danger of tube joints leak.

Close the HP/LP main steam header control valves. As the GT load reduce to 5 MW. . Close the diverter box. Stop the chemical dozing system. Maintain the drum level up to 60% and stop the BFP.Boiler Shutdown      Reduce the load on GT gradually and observe drum level during load reduction.

 As the HP drum pressure down to 2 bars.  Let the boiler to cool down at a rate which will avoid damage from high temperature differentials. open the drum went valve to avoid vacuum creating inside the drum . Close the pre heater and deaerator inlet shut off valves.

 If need to drain the boiler wait for pressure completely released and temperature is < 95oC  Fast cool down the boiler metal will cause uneven contraction .

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