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Boiler Startup Recommendations

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Boiler Startup Courtesy of Rentech Boilers


Suggested Start-Up
It must be recognized that all boilers and auxiliary equipment require operator attention during start up. Special
care must be exercised in the manipulation of feedwater and fuel systems to protect against damaging the unit
and to insure personnel safety.
Check and close the manual blow-off valves, the continuous blowdown valves, the gage cocks and the water
column and gage glass drain valves. Open the drum vent valve, the water column shutoff valves (if provided),
the gage glass shutoff valves and the steam pressure gauge valve.
The unit should be slowly filled with properly treated feedwater using the level control valve bypass valve.
The filling rate depends on the temperature of the feedwater. The feedwater should be as close as possible to
the metal temperature to prevent excessive temperature stresses that could cause tube leakage. The minimum
recommended feedwater temperature is 70F. Fill slowly and vent fully to prevent any pressure buildup from
the flashing of warm feedwater. The level should be set and manually maintained at just below the normal
water level so that there is room for expansion when water is heated. Blowdown the gauge glass and observe
the return of liquid to insure that the glass is clear and functioning properly.
When the unit is filled and the level is stabilized, start the purge cycle of the combustion controls as specified
by the combustion equipment manufacturer. Allow adequate time to completely purge the entire boiler, duct
work, etc.
The drum vent valve should be initially open to vent generated steam while purging air from the system. Close
the steam drum vent at 15 psig. (Refer to table entitled "Summary of valve positions").
The start-up rate of the boiler is limited by the following items:
1. Allowable heat up rate of refractory, to achieve acceptable refractory life.
2. Elimination of temperature stress that could cause leaking tube joints.
3. If sulfur or HCl is present in normal fuel effluent, start the heating process on clean fuel until the dewpoint is
passed.
During this period of operation, carefully observe that all components function properly. Be prepared to shut
the unit down should a lack of proper operation become evident. Visually observe combustion conditions for
proof that gauges, meters, and other instrumentation are properly reporting operating conditions.
Maintain the normal water levels at all times. The level can be maintained by hand feeding or by blowing
down as necessary. Too high a level will render the separators ineffective and cause water carryover in the
steam, while too low a level will allow possible overheating of pressure parts. If the water level is not visible,
firing should have been stopped automatically and the reason for the low water determined. The feedwater
control valve should be cut in when the operating pressure is obtained and then the bypass valve should be
closed.
If the unit is tied into a main steam line with other units and there is pressure downstream of the not-return
valve, then the system must be brought up to slightly above that operating pressure. The steam stop valve can
then be opened to permit flow through the non-return valve. Re-check inspection openings, fittings and piping
connections for leaks, tighten as required to insure proper gasket seating. Always maintain proper water
treatment as recommended by the Owner's water consultant.
back to Banks Engineering Boiler page

http://www.banksengineering.com/blrstart.htm

7/28/2009

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