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BOILER OPERATING PROCEDURE

PRE START UP ACTIVITIES COLD START UP WARM/ HOT STRAT UP

BOILER SHUT DOWN


CONTROL SCHEMATICS SUPPLEMENTARY FIRING

PRE START INSPECTION


Furnace and flue path are clean and scaffolding material removed Ensure access doors of flue path are closed Steam and LP drums are clean and manholes are closed properly Check and ensure that the safety valves are not gagged Ensure the nitrogen capping valves are isolated Fuel gas line is de-spaded and flexible hoses are connected Ensure the Flame Scanners are aligned and fitted rigidly Ensure sealing/ cooling air valves are open for the peepholes & flame scanners

PRE START INSPECTION - DEAERATOR


Ensure the water spray nozzles are tightly screwed in its place Ensure perforated plates are in place Ensure the cleanliness of the tank internal

Equipments are boxed up and lubricated (Aux fans, Dosing system,etc... Ensure that all field instruments are in good working condition and lined up

PRE REQUISITES

FEED WATER DIVERTOR DAMPER READINESS POWER FOR EQUIPMENTS INSTRUMENT AIR READINESS OF FIELD INSTRUMENTS DCS READINESS READINESS OF DRAIN/ BLOW DOWN SYSTEM READINESS OF AUX AIR FANS GT OPERATION CHEMICALS FOR HP & LP DOSING FIRING SYSTEM & FUEL GAS READINESS

WATER FILLING
STEAM DRUM VENT DEAERATOR VENT VALVES TO BE OPEN START UP VENT SUPER HEATER DRAINS MUWH TO BYPASS MODE ALL THE DRAINS OF EVAPORATOR, ECONOMISER & DEAERATOR

EBD & CBD MAIN STEAM STOP VALVE

VALVES TO BE CLOSE

SPRAY WATER TO ATTEMPERATOR


DRAIN VALVES TO IBD TANK SAMPLE LINES

WATER FILLING
ENSURE ADEQUATE FEED WATER QUANTITY START FILLING THE EVAPORATOR, ECONOMISER AND DEAERATOR THROUGH BACK FILLING FILL STEAM DRUM & LP DRUM UPTO - 75 MM FROM NWL CLOSE THE HEADER DRAIN VALVES AND LINEUP FEED WATER SYSTEM KEEP READY THE CONDENSATE / MAKE UP WATER PUMP KEEP READY THE BOILER FEED WATER PUMP

COLD START UP
AUX AIR FANS Air for flame stabilization Combustion purposes Cooling of burner components Two fans - one auto stand by Switches: ON - AUTO - OFF Start one of the aux air fan and line up the air system to burners

SAFETY INTERLOCKS
HP Steam Drum level not very low HP Steam Drum level not very high Deaerator level not very low Auxiliary air pressure not very low Furnace pressure not high Emergency Stop is not operated Steam pressure not very high

Boiler interlocks Gas turbine running Divertor is open to boiler Instrument air pressure not low Fuel Gas pressure not high Fuel Gas pressure not low

BOILER INTERLOCKS BMS BURNER INTERLOCKS BURNER TRIP INTERLOCKS

Main Flame failure Igniter flame failure Ignition time expired

Burner trip interlocks Main Flame failure Igniter flame failure Flue gas temp very High Sec super heater metal temp very High Deaerator level not High

COLD START UP
Water filling done GT is running at considerable load Auxiliary Air fan is running Boiler safety interlocks are satisfied Now DD shall be opened Throttle the DD opening - slow heating of the pressure part Cold start up pressurizing curve

Objective is to reach minimum operating parameters


Drum swelling

COLD START UP
MODULATE THE DD ACCORDING TO THE PRESSURIZATION CURVE KEEP THE DRUM UP VENT OPEN TILL STEADY STEAM FLOW IS ESTABLISHED CLOSE THE SUPERHEATER DRAINS AT 2 BAR PRESSURE KEEP THE START UP VENT OPEN AND MODULATE AS REQUIRED MAINTAIN THE DRUM LEVEL AND SELECT INTO TO 1E MODE KEEP DEAERATOR VENT FULL OPEN AND MAINTAIN LEVEL KEEP THE MUWH IN BYPASS MODE START PHOSPHATE DOSING TO STEAM DRUM START OXYGEN SCAVENGER DOSING TO LP DRUM

COLD STRAT UP
BEFORE CHARGING THE MAIN STEAM LINE, OPEN THE DRAINS & TRAP STATIONS IN LINE TO STEAM TURBINE OPEN THE MSSV BY-PASS / PRESSURE EQUALISING VALVE OPEN THE MAIN STEAM VALVE ONCE THE STEAM LINE IS WARM AND PRESSURE IS EQUALIZED CLOSE THE START UP VENT GRADUALLY OPEN THE DIVERTOR DAMPER AS THE HRSG IS LOADED SWITCH OVER TO THREE ELEMENT CONTROL ONCE THE STEAM FLOW IS > 25% MCR TAKE THE STEAM TEMPERATURE CONTROL INTO AUTO MODE TAKE THE DEAERATOR PRESSURE & MUWH OUTLET TEMP CONTROL INTO AUTO MODE ONCE THE DEAERATOR IS STABILISED

WARM / HOT STARTUP


Restart of the boiler above a steam pressure of 20 TO 40 bar is termed as a warm startup. Restarting a boiler immediately after a trip, when the boiler is still at near about operating pressure - termed as a hot restart In a warm start / hot restart, as the boiler was in service till the trip out, the required valve line up will be available and can be quickly checked by visual inspection Following are the steps involved in the hot startup: Normalize the steam drum level by modulating the feed water flow control valve Open the start up vent valve

Open the divertor damper after achieving the necessary Safety interlocks
Follow the Warm / Hot start up pressurisation curve Follow the remaining start up procedure as explained for cold start up

WALK DOWN CHECK LIST


Unusual noises, may be from steam or water leakages Steam or water leaks from valves, connections and fittings Flue gas leakage from boiler casing Passing from safety valves at normal operating pressure. Clear & bright flame and clear stack Fuel gas leaks Proper water level is being shown by the direct water level gauges

BOILER SHUTDOWN
PLANNED SHUTDOWN: Sequence of shutdown:

activities

to

be

followed

during

planned

Stop the duct burners after reducing the firing rate to minimum
Reduce the boiler load gradually, at steam flow below 25% switch the drum level control to single element Take the deaerator pressure control into manual mode and open the vent valve fully Close the MSSV Close the divertor damper Stop the phosphate & oxygen scavenger dosing Close the CBD valve Maintain the drum level

BOILER SHUTDOWN

Verify the EBD valve is closed Allow the boiler to cool naturally

Auxiliary air fan is continued temperature falls below 100 0C

till

the

furnace

If the boiler shut down is for more than 8 hours, fuel gas supply has to be isolated When the steam drum pressure drops to 2 bar, open the steam drum and the startup vent. Also, open the super heater drains If the shut down is for longer period, keep the boiler under preservation

CONTROL SCHEMATICS
CONTROL LOOPS: HP boiler drum level control LP Drum level control Deaerator pressure control HP steam temperature control Make up water heater outlet temp control Combustion control