PRECHECK BEFORE LIGHT-UP

BOILER FILLING
1. Close all drains except SH header drains.

2. Open all vents (drum, economizer, superheater start up )

3. Open ERVs & Eco. Inlet valve (E2)

4. Open DM-1& 2 (ELP to boiler drum)

5. Check the valve position of MS-11,12 ( Always keep them open unless
otherwise demanded for PRDS / TM-II. Check the hanger position of the
main steam line before & after hydraulic test .These should be released
in normal condition.
6. Ensure main isolating valves of soot blowing line are closed, & drains are
open.All soot blowers are at home position
7. Fill the boiler through low load line up to three ports by ELP( @ 2.5 to 3
UDT). Inform to chemist.
8. All vents including reheaters should be open.

9. S/H drains should be open. Economiser vents should be closed.

10. Bottom header drains should be closed.

11. Oil detectors inside the AH inlet duct are placed. Cooling water is
provided to them.
12. Check that sealing truff is cleaned & fill it with water & ensure the
overflow.
13. Inspect the bottom ash hoppers & fill the hopper till its overflow.
14. Take refractory cooling in service.

Drum Metal temp. Diff.

The boiler drums are filled with water in the bottom & steam in the top,
due to which the cooling & heating rate vary between the top & bottom
.Stress analysis shows that the allowable temp. differentials are based on
tensile strength,drum dia.,wall thickness & pressure. The temp. diff should
not exceeds 50 0C.

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 STARTING OF BOILER LIGHT UP
1 Ensure that trial of wind box,aux. air dampers (AB.CD,EF,BC,DE elevations
is taken AA,FF & all six coal/air dampers are locked at fixed position.
2 Check phosphate dozing valves , CBD isolating valves, Drum level
transmitters isolting valves,all pressure gauge root valve, sampling valves
are open.
3 Start AH,ID & FD
1. Maintain 30 % air flow of total air flow & 12.7 mm WCL furnace
draft.( Air pressure shall not be more than 40 %)
2. Put sy. Air dampers control system on AUTO & check that aux. air
dampers are modulating to maintain 35-40 mm of WCL wind box to
furnace diff pressure.
4 Keep BT horizontal.
5 Start scanner fan.Check scanner fan header pr. is 400 mm of WC
6 Keep EBD open during warm up
7 1. Initiate a furnace purge.
2. Complete furnace purging. Light up the boiler on LDO. Firing rate
should be controlled to keep the furnace exit gas temp below 538 0C.
Incrase the firing rate as required to raise pressure. Take care not to
exceed the furnace exit gas temp limit of 538 0C. To minimize the
possibility to adverse visible stack emission, it is desirable to use the
warm up oil guns to at least 35 ke/cm2 drum pressure & 1770C sy. air
temp. before firing pulverized coal.
3. Fuel air & auxi. Air supply of oil guns :-When oil guns are in service, the
sec. air dampers function as fuel air & operates as per oil pr., when oil
gun are removed out of service, the sec. air dampers starts functioning
as aux. air dampers & it is controlled by wind box pr. controller.
4. Start AH soot blowing one by one.
8 If chimney smoke is black, oil pressure is to be reduced. Oil flame should
be brownish, not blackish.
9 Watch for any oil traces on oil detector probes from time to time, also
observe the inspection glasses of AH rotors for any flame. Observe for
any oil coming in bottom ash overflow.
10 Monitor flue gas,air,SH,RH temp. on recorders.
11 When boiler start steaming, throttle SH vents & drains
12 When drum pressure reaches 3 kg /cm2 or at economizer FW O/L temp. is
@ 1300C .Close drum vents & out let header vent.
13 Close SH DeSH link vent valves.

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14 Close platen SH out let vent valves
15 Throttle following drain valves :-
1. SH drain
2. Radiant roof SH inlet header drain & side steam cooled out let
header drain.
3. Rear header drain.
4. SH SWW front roof inlet header.
( Do not close above drain valves fully before rolling the turbine.)
16 Check the MS line drains are opened (near turbine)
17 Open boiler out let valves(MS 11,12)
18 Throttle start up vent valves to control pressure rise. Do not close them
fully until turbine is under light load or HP/LP by pass system is taken into
service.
19 Before raising a vacuum in the condenser, make sure that all reheater
vents or drains that are open to the atmosphere are closed. Leave drains
or vents connected to HP drain flash tank open until the turbine is carrying
a light load.
20 Bring up the boiler steam parameter to 5 kg/cm 2,195 0C
21 Follow the Chemist programme for giving boiler blow down @ 10 & 20
kg/cm2. Before giving blow don fire is to be killed.
For Boiler blow down at ring header,five WW headers i.e. platen WW,LHS
WW,RHS WW,front WW,rear WW are provided with two isolating valves
on each line.While giving blow down ,first
 Open master drain
 Open first isolating valve of drain line.
 Open second isolating valves one by one for 30 sec. each & then
close them.
 Close master drain
 Close first isolating valve.

BOILER LOADING
1 Put FO on recirculation so that FO temp. is 110 0C at firing floor.
2 Before HO firing, check flue gas temp at APH out let is above 90-100 0C
3 Take SCAPH of FD fan in service. Maintain average cold end temp. above
acid dew point. Charge SCAPH (both), watch air temp. after SCAPH and
flue gas temp at AHs. outlet, they should show rising trend. (At low load
SCAPH should invariably be charged to avoid corrosion & chocking of air
heater elements. Drains of SCAHP should be throttled suitably to get
optimum results.)
4 Before synchronizing the machine, boiler drum pressure is atleast 30
kg/cm2.
5 Close ERV.
6 After blow down boiler is to be relighted on FO oil guns.

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7 Ensure CEP I/S.
8 Charge PRDS preferably from self unit.(cooling water to Sulzer valve
should be available from CEP) Confirm that gland steam/ ejector valves are
closed.(Normal idle time of pump should be 4 to 5 min. when system is in
service & more than 5 min when system is not on AUTO.
9 PRDS spray FW-76. PRDS D&E valves are closed.
10 Check that vacuum is raised in the condenser by the time MS para come to
6 kg/cm2,275 0C.
11 At boiler pressure @ 25 kg/cm2,take HP/LP by pass station I/S.
12 BEFORE STARTING OF BFP
1. Confirm feed line is charged, it’s drains and vents are closed.
2. Feed station isolating valves are open and control valves are closed.
S/H spray valve E-13 is closed. (In some units E-13 is provided with
manually operated bypass valve .For initial charging , bypass valve should be
opened but after the main valve is opened , the bypass valve should be
closed.This is very important because subsequently when boiler trips only
E-13 is closed from PCR & if control valves are passing excessive collection
of water may result in the superheater causing hammering & subsequently
drop in final S/H temp. After boiler has tripped, watch temp. before &
after attemperator. If E-13 does not close, reduce BFP discharge pr. to
minimum. In such case let the drum level drop. After closing E-13 water
can be taken into the drum.)
3. ERVs are closed.(Before starting of BFP for taking water in the
boiler after a light up , it should be ensured that ERVs are closed.
Otherwise if NRVs are passing the relatively cold water may flow
the path of least resistance & enter the boiler water walls
‘bypassing’ the economizer.The present practice of closing of
recirculation valves only after set synchronizing should be stopped.
START BFP
1. Check inspection drains of CRH/ HRH, there should be no flow of
water.
2. After starting of BFP, see that the temp. after S/H attemperator &
HP bypass does not increase.
3. Ensure that CR-3,4 are closed as any passing of spray valves may
cause entry of water into HP turbine.CR-5,6 should be open. Cold
reheat drains should be open.
13 Ensure steam throw off device condensate spray valves are open
14 Close start up vent valves when flow is established through by pass system.
15 Give clearance to start turbine rolling.
16 Boiler parameter are raised to MS pressure & temp.
1. Throttle MS line drain valves
2. Drum level protection I/S
3. Warm up MS lines. CRH,HRH & transfer lines.
4. Check MS parameter of ESV.

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 5. Check MS pipe metal temp. is above 1500C & CR pipe metal above
1000C
6. Check HP transfer pipe metal temp. is above 1000C & IP transfer
pipe metal temp. 1000C
17 HP/LP by pass system is cut out & turbine rolling is started through HPT
for cold/warm rolling.
Close MS lines drains & CRH line drains to condenser
18 TG set syn.(load 10-15 MW)
MS pressure 30 kg/cm2,temp. 350 0C before ESV
19 Maintain ave. cold end temp. at APH out let above acid dew point by
controlling steam flow to SCAPH.
Regulate steam supply control valves & check air temp. before & after
SCAPH, check flue gas temp. after APH.
20 Before increasing drum pressure ensure that silica in water is within
permissible limit at operating pressure.
21 Make SH spray control system ready.
22 Make RH spray control system ready.
23 Close ERV when continuous flow is established through eco.
24 Close:-
1. SH header drain.
2. Radiant SH in let header drain
3. In let header drain
4. Side steam cooled wall out let header drain
5. Steam cooled wall rear header drain .SHS, WWW front roof inlet
header drain
6. Final SH header drain.
25 Pick up 30 MW load
MS pressure 65 kg/cm2,temp. 4300C,RHS temp. 4200C
26 Take main FCV in service.
27 Start coal firing.
1. Keep drum level on lower side just before starting C/M & RCF
2. Mill diff. pressure is less than 250 mm WCL
28 Increase the MS/RH steam para per cold start curve.
29 Maintain SH steam temp. control by spray water.
30 Maintain SH steam temp. control by BT.(RH spray control should be used
as last resort for temp. control.)
31 Start 2nd C/M
32 When load is 70 MW
MS pressure 105kg/cm2,temp. 5000C,HRH temp. 495-5000C
1. Take LPH in service.
2. Drip pump in service
33 At 30 % load furnace to wind box diff. should be 90 mm WCL
34 Start 2nd BFP,CEP

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 ( D/A pressure is increase to 6 kg/cm2)
35 At load 120 MW
MS pressure 120kg/cm2,temp. 5300C,HRH temp. 5250C
36 Put BFP scoop tube on AUTO (Check that 5 kg/cm2 diff. pressure is
maintained by scoop tube position controller.
37 Put main FW CV on AUTO to control drum level.
38 Check that -10 mm WCL furnace draft. Is maintained.
39 SCAPH can be cut out when flue gas out let temp. increases to or if FO is
removed
40 At load 210 MW
1. Drum pressure 145 kg/cm2
2. MS pressure 134 kg/cm2
3. MS temp. 540 0C
4. RH steam pressure 22 kg/cm2
5. RH S temp. 540 0C
6. FW temp. 2450C
41 Check MS temp. low protection trip interlock comes in to service when MS
temp. 5200C( MS temp. out indication will reset)

Hot Restart
A Open wide all SH drains to allow complete draining of SH headers and/ or
elements. After draining close all drains ,except the SH Steam Cooled
Rear Outlet header & side steam cooled wall outlet header drains & start
up vents.(Main steam line vents & drains) Keep the Steam Cooled Wall
header drains slightly crack open until steam is admitted to the turbine.
Keep the start up drains open RH drains & vents are open.Open the DESH
isolating valve.DeSH control valves must be closed
B Light up
C As drum pressure increases progressively, throttle the pendent SH outlet
header drain ( Start up vent) & other start up vents & drains used( main
steam line drain, turbine drains etc.) Sufficient steam flow must be
maintained at all times to assure clearing the SH elements of condensate.
Increase the firing rate as necessary, without exceeding the furnace exit
gas temp. limit. Do not close start up drains completely until steam flow
through the turbine is established. The SH steam Cooled Wall Rear Outlet
Header & the Side Steam Cooled Wall Outlet Header should be closed
immediately after steam is admitted to the turbine.
D Close all RH vents & atmospheric drains before pulling vacuum of condenser
.RH condenser drains may be left open until the turbine is under light load.

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 PLANNED /NORMAL SHUT DOWN TO COLD
1 1)T.G. set on 210 MW with following controls on AUTO :-combustion
control, fuel control, total air control, feed water control, steam temp.
control, furnace draft control
2) Final steam conditions at the time of set withdrawal are
a) MS pressure 90 kg/cm2
b) MS Temp. 465 0 C
c) RH steam temp. 465 0 C
2 For minimising the contraction rate of HP rotor during S/D, supply live
steam
( after heating & blowing down the pipe by opening valve AS-46) to the
second chamber of front sealing by opening valveAS-42,43.Check that
valve AS-47 gets closed under interlock. Temp. of steam supplied to the
2nd sealing chamber should be higher than the metal temp. Of HPT in the
region of governing stage.
3 Gradually reduce load at 3MW/min at rated parameter by SG motor
Carefully monitor turbine conditions & adjust the load,temp.,pressure drop
rate such that HP/LP rotor diff expan. Vibration, eccentricity, shell
diff.erential temp.,turbine cylinder top/ bottom metal temp.,L/R cylinder
flange temp. are within limit.
4 Reduce load to 160 MW
At load @ 160 MW, isolate HPH from steam side by closing ES-3,4,5 &
drain heating steam condensate by opening the drain valve.
5 Maintain D/A & condensate hot well level normal.
6 Reduce load to 150 MW
Approx. parameters at turbine inlet will be :-
a) MS pressure 120 kg/cm2
b) MS Temp. 5200 C
c) RH steam temp. 5200 C
d) Check that D/A steam is C/O from Ex. III to Ex. II through interlock.
7 When the feeder rating on all pulverizers is reduced to 40% of maximum.
W/D upper most mill after taking oil support in EF elevation. Check
furnace to wind box diff. pressure is 90 mm WCL (As the pulverizers are
taken out of service, the sy. Air damper control system should close the
associated wind box dampers & throttle other dampers as required to
compensate for reduction in firing rate.)
8 When load on unit is reduced to 100 MW
Approx. parameters at turbine inlet will be :-
a) MS pressure 112 kg/cm2

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 b) MS Temp. 5100 C
c) RH steam temp. 5100 C
d) Check D/A steam supply is C/O from ext. II to aux.steam header
through interlock.

8 At 90-100 MW load W/D one BFP & one CEP

9 Continue reducing firing rate by withdrawing lower C/Ms & taking oil
support in respective elevation, steam temp. & pressure along with drop in
load.
10 At load 70 MW
Approx. parameters at turbine inlet will be :-
a) MS pressure 105 kg/cm2
b) MS Temp. 4900 C
c) RH steam temp. 4900 C
11 At @ 25-30 MW withdraw LPH from steam side by closing ES-12,13,14.The
drip pump gets trip on interlock when LPH-2 level drops to 200mm ,if not
stop the pump manually.
12 Take drum controller on HAND.
13 Stop one PA fan & adjust header pressure on other.
14 Reduce load to 30 %
Maintain 30 % air flow at all loads below 30%. To avoid firing instability
during this period of high relative air flow, the aux. air dampers at all
elevations should be open & reduce the wind box to furnace diff. pressure
to its lowest setting.
15 At 30 % load, check that sy. air dampers to maintain wind box to furnace
diff. pressure of 30-35 mm WCL
16 Now reduce firing on last mill i.e. lower most & isolate it. Stop PA fan. At
this time all elevation H.O. guns are in service. Check AH cold end average
temp. is above acid dew pt. Charge SCAPH if necessary.
17 At load 40 MW
Take low load feed CV in service & isolate main FCV
18 Switch OFF ESP fields.
19 At 25-30 MW with HO firing C/O auxi supply from UAT to Stn.
20 Reduce load to 5-7 MW
Approx. parameters at turbine inlet will be :-
a) MS pressure 90 kg/cm2
b) MS Temp. 4650 C
c) RH steam temp. 4650 C
21 Charge auxi. steam header from other unit through interconnecting,
isolate auxi PRDS unit.
22 Hand trip turbine, boiler will trip on interlock.
a)ESV & IV should close
b) Set should trip on low forward power, if it fails then it will trip on RPP.

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 (Time for stopping the steam supply to turbine & isolation of generator
should not be more than 4 min.)
23 Check that HP cylinder evacuation valves CR-5,6 on CRH opens & after 1
min get closed.
24 Open IPT front seal valve after tripping of Turbine(if it is closed)
25 MC-53,54 are open (FCNRV) for one minute.
26 Depressurise the reheat lines by partly opening LP bypass valves.
27 Throttle LPH-4 condensate outlet valve as per requirement.
28 Check boiler fire is completely out( See scanner & see through peep hole)
29 Maintain 30 % air flow.
30 Start SOP at 2800 rpm. TG speed.
31 While stopping the turbine, plot the costing down curve of the rotor &
check the eccentricity of TG with dial gauge.
a)Break the vacuum when turbine speed comes to zero. To break vacuum,
cut off the steam supply to main ejector & open the valve CA-6 for vacuum
breaking& or open the valve CA-5 on the line from condenser to the
starting ejector. When TG set on BG, break vacuum ,stop the steam supply
to the sealing by closing by closing the gate valve AS-6.Also close steam
supply to the gland cooler ejector by closing valve AS-9.Also close
valveAS-1,2 & 3 on the pipe line supplying steam to main ejectors.
b) Start BG when TG comes to stand still. When temp. at lower part of
HPT casing at regulating stage drops to 170 0C,BG may be stopped.
c) Check that FC NRV in extraction lines are closed.
32 Check that attemperation SH & RH isolating valves & its bypass valves are
closed( Close isolating valves of SH & RH spray control valves are closed
E-13,R-17,18,19,S-27,28)
33 Open SH start up vent partially & reduce pressure ( Rate of pressure drop
must not exceed the limits specified in the curve to limit saturation temp.
drop rate to less than 83 0C/ hr.)
34 Open RH vents & close CBD valves
35 Close boiler outlet valve MS-11,12
36 Open MS line drains
37 Open CRH & HRH line
38 When the oil temp. at the outlet of bearing drops to 45 0C, stop CW to oil
coolers.
39 Cut off D/A pegging steam supply by closing valve ( Turn on D/A FW
heating steam to maintain FW temp.)
40 Condensate & CW pumps can be stopped when LPT exhaust temp. comes
below 55 0C.Stop CEP. Stop condensate supply to the pump sealing. Stop
CW to IV & ESV servomotor.
41 When max. turbine metal temp. comes down below 200 0C, then & then only
open cylinder, transfer line & remaining steam line drains.
42 If the turbine is to be started before the metal temp. drops to 200 0C,

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 then drain & blow down cocks are only opened during preparation for
restarting.
43 Drain should remain closed if the turbine has been stopped for a period
not exceeding 6 hrs.
44 If turbine has to be shut down for 6-8hrs,take suitable measure so that
the steam parts get cooled to the min.
45 Ensure main spray valve E-13 is closed
46 Maintain water level in Boiler drum up to @ two port.
47 When boiler drum pressure reaches to @ 20 kg/cm 2 stop BFP. Open DM-
1,2 valves for maintaining drum level by ELP.
48 At @ 2 kg/cm2drum pressure,open eco,drum,SH,RH vents & SH header
drains.
49 After tripping of boiler reduce air flow to @ 350 T/hr.Air flow through
furnace shall be controlled to effect the desired cooling rate which can be
controlled by
1) Opening SHH vent
2) Air flow boiler.
50 Do not stop APH till flue gas temp. at APH inlet is less than 205 0C

Various Types Of Boiler Cooling

(A) Forced Cooling After Shut Down
1 Keep air cycle in service& regulate air flow so that at any time saturated
steam temp. drop shall not exceed 83 0C/ hr.
2 Open starting vent valves so as to match rate of cooling but not exceeding
above mentioned limit
3 Bring up the drum level to + 180 mm when it drops to – 180 mm.
4 Open vents & drains of SH at pressure 2-3 kg/ cm 2 (( SH Desup. Link
drains , steam cooled wall header drain , Roof & Rear steam cooled wall
drains)
5 At 1.8 kg/cm2 drum pressure , open drum vents. Stop FD,ID, when flue gas
temp. is reduced to below 2050C & boiler is cooled
6 If require stop AHP( Its LOP should stop when oil temp goes below 40 0C)
7 When boiler water temp. goes below 94 0C, then & then only drain the
boiler.
8 Open Eco. Vents, open low point drain valves from WW low header &
downcommers to WW drain header.
9 Open Eco drain valves in feed line after Eco. in let valve
10 Open WW drain header drain valves

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 Boiler To Be Boxed Up (Normal S/D to Hot S/by)
If it is expected that the unit will be restarted in a very short period of
time , in which turbine metal temp. will not decrease appreciable, it may be
desirable to cool the turbine to below 427 0C by reducing the steam
pressure & temp. while the unit load being reduced. This will reduce the
steam/ turbine metal differential temp. upon restart.
1 Reduce air flow to minimum. It is recommended that after all fires are
extinguished, the ID,FD fans are kept running until the AH gas inlet temp.
has dropped to below 205 0C.
CAUTION & WARNING
If it is known or suspected that combustible deposits are present in the
AH elements, the AH gas inlet temp. must be reduced to 205 0C before
shutting down the FD,ID fans & AH
If rotary AH is provided, it must be thoroughly cleaned to remove any
combustible products before they are S/D
However running an AH with gas inlet temp. above 205 0C & no air flow
through it( i.e. both ID,FD are stopped) will result in seal damage &
subsequent excessive leakage during operation.
2 Close all sy. Air dampers , all flue gas dampers & all auxi air dampers( Wind
box dampers) after the both air cycle are stopped one by one.
3 Bring drum level to +180 mm
4 Open Eco inlet valve & its by pass valves
5 Stop BFP
6 Cut out D/A pegging steam by closing valve.( Turn on FST heating steam.
Maintain FW hot .Maintain Slight pressure in D/A approx. 1.5 ata.)
7 Do not reduce drum pressure in line with unit load reduction. When the
desired pressure at which the boiler is to be held is reached after the
turbine is off the line, the boiler may be bottled up by closing all SH drain
& vents.
8 Close start up vent valves
9 Check SH out let header vents & drains are tightly closed.
10 When APH inlet flue gas temp. reduces to 205 0C APHs may be stopped
11 When SH steam pressure drops down to 3 kg/cm 2 open partially SH vents &
open them fully when pressure drops down to near zero
12 Open drum vents partially when drain pressure comes down & open then
fully when pressure drops down.

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 BOILER START UP
INDEX
Sr.No. HEADING Page
Nos.
1 PRECHECK BEFORE LIGHT-UP 1
BOILER FILLING
2 DRUM METAL TEMP. DIFF. 1
3 STARTING OF BOILER LIGHT UP 2
4 BOILER LOADING 3
BEFORE STARTING OF BFP 4
5 HOT RESTART 6
6 PLANNED /NORMAL SHUT DOWN TO COLD 7-10
7 VARIOUS TYPES OF BOILER COOLING
(A) FORCED COOLING AFTER SHUT
DOWN 10
(B) BOILER TO BE BOXED UP (NORMAL
S/D TO HOT S/BY) 11

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