UNIT START UP

BOILER FILLING AND

COLD FLUSHING
Prepared By: Umair Ahmed

1
 TABLE OF CONTENTS
1. OVERVIEW

2. OPERATIONAL DRAINS AND VENTS

3. MAINTAINING WATER LEVEL IN

LEVELLING VESSEL
4. CONTROLLING LEVEL IN FLASH TANK

5. START OF BCP

6. FLOWCHART OF COLD FLUSHING

PROCESS
 BOILER FILL UP
There are 3 lines into Economizer

• 2 Controlling lines 2*30% BMCR.

• 1 Main line 1*100% BMCR

• Normally control lines are used in Boiler filling and start-up

1.The economizer inlet is controlled in such a way to maintain following

parameters:
Flow= 100 ~200t/h via CV. (Note: No need to use balancing valves in the
start).

2.Economizer inlet control valve position is maintained between 15 to 20% in

the start and then control the inlet economizer flow to 200t/h via CV by
observing hammering and vibration of boiler.

3.Pressure before economizer inlet valve =80~90 bar

Temperature of feedwater =100~120C
 OPERATIONAL DRAINS AND VENTS

After that we must confirm that all the following vents on the boiler
side are operated:
1. Economizer and Evaporator vents are opened.(Closed after
visual inspection from local site)
2. Levelling vessel vents are opened.
3. Superheater side vents and drains are opened.
4. Reheater side vents and drains are Opened.
5. Water side drains to flash tank are closed.
6. Water side Intermediate headers drain between economizer and
evaporator to condensate storage tank are closed. (Note: Water
Side drains can be left slightly open to help cold flushing
proceed at faster speed if Fe>1000ppm).
OPERATIONAL DRAINS AND VENTS
 MAINTAINING WATER LEVEL IN LEVELING VESSEL

Maintain the water level of levelling vessel around 16~25 meter.

Duration of boiler water filling should be at least 2 hours (for
level vessel filling up 16m to 25m).
 When the temperature of levelling vessel is increased to around
80~90C, we can assume that the boiler is filled up to levelling
vessel.
LEVEL LIMIT CONTROL OF LEVELLING VESSEL

CONTROLLED
BY
FEEDWATER
FLOW
CONTROLLING OF WATER LEVEL IN FLASH TANK
Hydraulic station of control valves is started from local site and
maintain pressure of oil 14MPa (Note: Can only be operated from local).
Isolation inlet overflow valves to flash tank is manually opened and
control valves are put in auto mode. These Hydraulic actuator control
valves help in controlling water level in levelling vessel.
Water is drained to drain pit from condensate storage tank during cold
washing and its level is controlled by putting condensate storage tank
drain valve in auto mode and LOCK mode is ON
Drain valve is opened when condensate storage tank level reaches up
to the level of 2700mm (i.e., 90% HMAX6)and closed when the level is
lower than 2400mm (i.e., 80% LMAX4).
HYDRAULIC ACTUATORS OF FLASH TANK
 START OF BCP
Before BCP is started recirculation valve of the pump is opened and Auto-
closed(AUTO/LK MODE ON) when the flow is 180t/h. Following
Parameters are maintained during operation of BCP.

1.Differential pressure of 14~18 bar.

2.Outlet flow = 300~400 t/h.

3. Cooling water to BCP At start >12.5m^3/ ,Normal operation> 24m^3/h

4. BCP normal operating current should be maintained at 87 A.

5. Out flow of BCP and MBFP is maintained to control the main

evaporator flow to approximately 600 t/h.
SCHEMATIC
COLD WASHING
Water will be drain out in pit during the cold washing . If the Fe content is very high,
water wall drains can be slightly left open. When the Fe content at the condensate tank
outlet is less than 1000ppm cold washing can be considered done.

HOT WASHING
 After Cold flushing is finished, Boiler can be ignited for hot flushing.

Water will be drain out in hot washing till Fe content is above 100ppm. Below
100ppm it can flow back in the condenser thorough drain pumps.
COLD WASHING
Water will be drain out in pit during the cold washing . If the Fe content is very high,
water wall drains can be slightly left open. When the Fe content at the condensate tank
outlet is less than 1000ppm cold washing can be considered done.

HOT WASHING
 After Cold flushing is finished, Boiler can be ignited for hot flushing.

Water will be drain out in hot washing till Fe content is above 100ppm. Below
100ppm it can flow back in the condenser thorough drain pumps.
 FLOW CHART OF COLD FLUSHING PROCESS

BCP