BOILER

HYD TEST / LIGHTUP &

TROUBLESHOOTING
BOILER HYDRAULIC TEST

AUXILLARIES / SYSTEMS REQUIRED

• D M WATER SYSTEM
• G S WATER SYSTEM
• INSTRUMENT AIR SYSTEM
• ONE ELP, ONE BFP, FEED LINE
CHARGED
• BOILER MAINT CLEARANCE
• INSTRUMENTATION
• VOLUME OF WATER REQUIRED DURING
HYDRAULICTEST
• Boiler Drum 37.2 m3
• Water Wall 126.30
• SH 97.18 m3
• RH 48.10 m3
• Economiser 25.17 m3
• Piping 12.05 m3
• TOTAL 346.00 m3 (i.e. @ 4.5 UDT)
 BOILER HYDRAULIC TEST

• Ensure locking of pipe line hangers & safety valves gagging from BM.
• UDT / FST is filled , Open DM 1,2 or bottom ring header valves
• feed line is charged & drains / vents are closed.
• FW-26,its iso valves , eco I/L valve E-2 is open.
• BFP suction pressure / discharge pressure low - bypassed.
• EBD & CBD & their iso valves - closed.
• water wall bottom ring header drains - closed
• SH drains -closed, drum ,SH,eco vents - open .
• soot blowing iso valve - close , soot blowing line drains - open.
• Ensure MS-11,12 hand tightened.& after drains are open.
• Ensure PRDS valves - closed & drains are open.
• PRDS spray iso valves - closed.
• sample cooler v/v at PRDS - closed
• Chemical dozing valves at PRDS level- closed.
• R-17, R-18,19 - closed.
• (A) Ensure following Turbine side valves are CLOSED/OPENED
– MS line drains along with inspection drains - opened.
– HP bypass spray, BD isolating valve is closed inspection drains
open.
– MS-1,2,3,4,5,6 - closed & drains between MSV & ESV - open.
– MS-7,8 - closed & after drains open
– HP/LP bypass drains to UFT - open.
– CRH/HRH drains to UFT along with inspection drains - open.
– HPT/IPT transfer pipe drains along with inspection drains - open.
– CR-3,4 - closed, CR-5,6 along with inspection drains - open.
– HPT/IPT casing drains - open.
– HPT/IPT rotor heating valves AS-42,43,44 - closed, inspection
drains are open
 – HPT/IPT flange & stud heating valves As-16,17,18,19,20,21 -
closed.
– Observe condenser level & UDT levels

• STARTING
• Start ELP.
• Close economizer & drum vents after sufficient water flowing.
• Close SH vents, start up vents after sufficient water venting out.
• Drum pressure increased to 20 kg/cm2
• Checking by BM, stop ELP
• Start BFP & raise the pressure to 50 kg/cm2.
• After clearance from BM raise the pressure gradually up to desired
pressure . Hold it for some time & then stop the BFP.
• Observe pressure drop rate, observe drains at the IBD tank to confirm
that there is no water is coming out due to passing of valves.
• Reduce the pressure to 50 kg/cm2
• At @ 4 kg/cm2 pressure, open all Boiler vents & SH drain valves.
• Reduce drum level to normal operating level
• Ensure the pipe line hangers are removed & safety valves are
normalized by BM.
• Normalise the system at Boiler & Turbine side.
 BOILER LIGHT UP

• PRECHECKS:-
• Ensure that relevant permits are cleared
• Ensure that all HT/LT bus ,board, are normalised
• Ensure all required systems are available.
• Ensure ID/FD fans are available.
• Ensure seal trough is charged and over flow is maintained
• Fill up bottom ash hoppers and obtained overflow.
• Check ESP path’s safety diaphragm doors are open.
• Check GD-6, GD-7,GD-8&GD-9 are open.
• Check ESP manhole doors are closed properly.
• Check oil level in rectifier transformers.
• Put ESP rapping mechanism & hoppers heater in service.
• Make support and shaft insulator’s ‘ON’ at least four hours in advance
before Boiler light up.
• Test charging of all ESP fields to be done. Take the trials of clinker
grinders.
• Ensure FSSS is in service ID/FD fan’s IGV trails are taken.
• Ensure instrumentation is available and showing correct value
• Ensure Drum both guage glasses along with lighting bulbs are
available.
• Ensure communication is available between Working Staff at drum
level, firing floor & PCR.
• Check that CBD isolating valves are open.
• Ensure phosphate dozing pumps are available and their suction /
discharge valves are open.
• Spray valve E-13 - closed and ensure the trials of all spray station
valves are taken.
• ENSURE FOLLOWING VALVE POSITION:-
• Check the valves position of MS-11 & MS-12
• All soot blowers are at their home position. Soot blowers lines
isolating valve - closed.
• Boiler vents ( Economiser, Drum, R/H, S/H start up vents ) are open.
• Super heater drains - open.
• Boiler filling by ELP, DM-1, DM-2 valves - open.
• Feed stations all isolating valves - open. Trial of control valve is taken.
• Economiser recirculation valves - open.
• Economiser inlet valve E-2 - open.
• Oil detectors inside the Air heater inlet duct are placed. Cooling water
is provided to them.
• Air heater rotors inspection door glasses are cleaned and sufficient
lighting is provided.
• Ensure trial of wind box, auxillary air dampers is taken.
• Ensure trial of burner tilt is taken & keep it at horizontal position.
• Ensure all oil guns especially AB elevations oil guns (which are first
required) for L.D.O. firing are cleaned and fitted properly with
clampings.
• Ensure all flame scanners are cleaned and inserted in position.
• Make AB elevation through at Firing Floor for L.D.O. firing. Put
selectors switch on ‘REMOTE’.
• See that automising air pressure (service air) is @ 5.5 kg/cm2 at
automising station at firing floor.
• Start L.D.O. pump and put it on recirculation. See that isolating valves
of LDO trip valve are open.
• Charge PRDS (16 Ata heater) from neighboring unit and open SCAPH
valve for Air-heater soot Blower’s operation.
• Drum level transmitters isolating valves. All pressure guages root
valves, sampling valves are open.
• STARTING :-
• Start Boiler filling through ELP up to normal operating level i.e. 3 ports (@
2.5 to 3 UDT) and then stop the pump.
• Start both air heaters one by one by following operational procedure and
confirm that LOP’s are in service.
• Start one air cycle or both as may be the case. Adjust furnace draft
• Observe total air flow, maintained it slightly more than 30%
• Start Scanner fan See that the scanner air fans discharge pressure is @ 400
mmwc.
• Check furnace is purged satisfactorily as per the FSSS logic scheme by a five
minute timer in purge cycle. After appearing ‘purge ready’ lamp on CD-2.
Push ‘purge start’ push button and ‘purge in progress’ lamp appears. Same will
be ‘off’ after five minutes and purge complete will appear.
• Check that Boiler trip command (Red push button) is resetted.
• Open LDO trip valve, LDO pressure is to be maintained @ 7 to 8 kg/cm2 by
adjusting the recirculation valve at firing floor.
• See that LDO selection is done on the Control Desk.
• Give command to either 1-3 to 2-4 LDO oil gun. Start push button. Watch
selected guns are ‘ON and flame is OK. i.e.bright and large. Confirm the
position from LOCAL.
• NORMAL OPERATION AND OBSERVATIONS :-
• Watch furnace draft. Check that Auxiliary air dampers are in modulation or
adjusted with manual command.
• Inform to chemist about the ‘Boiler Light up’ and take clearance from him.
• Start Air heater soot blowing one by one.
• Observe chimney emission smoke from time to time.
• Watch for any oil traces on air detector probes from time to time, also observe
the inspection glasses of Air heater rotors for any flame inside.
• Observe for any oil coming in bottom ash overflow and inform to PCR
accordingly.
• Monitor flue gas and air temperature on recorders which should have
increasing trend, also watch super heater and reheater metal temperatures
accordingly.
• Control drum level and same is to be counter checked from operator at drum
level, who is kept there to monitor drum gauge glasses.
• At @ 3.00 kg/cm2 drum pressure or at economiser feed water out let
temperature of @ 130c, close all Boiler vents except start up vents, which are
kept crack open.
• Close superheater drains except SH-14 header drains which are to be kept
crack open.
• Follow the Chemists programme for giving @ 10 kg/cm2 or 20 kg/cm2 blow
down. Before giving blow down fire is to be killed and Boiler is to be lighted
up after the blow is over.
• For Boiler blow-down at ring header, five water wall headers i.e. platen water
wall, LHS water wall, RHS water wall, front water wall and rear water wall,
are provided with two isolating valves on each drain 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 second each and close them.
• Close master drain.
• Close first isolating valves.
• Put FO on recirculation well in advance and see that oil temperature at firing
floor maintained @ 90c.
• Boiler is lighted up with FO (instead of LDO) after 20kg/cm2 blow down is
over.
• Start BFP for giving make up to the drum or maintaining the drum level.
• Close the Economiser recirculation valves.
• After blow down Boiler is to be relighted up with FO oil gun’s.
• IMPORTANT INSTRUCTIONS:-
• take periodic round aorund the Boiler area and check for oil leakages, flue gas
leakages, steam leakages and report to Control Room.
• Check the oil detectors placed at Air heater inlet duct for oil traces during
Boiler light up.
• Ensure the compressed air for Air heaters air motor is available.
• Check that while changing over from LDO to FO flue gas temperature is
above 200c inside Boiler.
• Boiler Blow-Down is to be given after killing fire.
BOILER TROUBLESHOOTING

• One or both Airheater tripped

• One or both ID Fans tripped
• One or both FD Fans tripped
• One or both PA Fans tripped
• One of the Coal Mills tripped
• One or both Seal Air Fans tripped
• One or both LOP’s tripped
• One or both F O Pumps tripped
• Boiler tripped
• Furnace draft not maintaining
• MS / RH temp not maintaining
• Boiler clinker formation
• ESP field undervoltage
•
THANKS
 REHEATER HYD TEST

• PRECHECK
• Ensure UDT & FST is filled DM water & chemicals.
• Ensure ELP is available & its discharge line is connected to CRH drain
valve near UFT & other modification work is carried out, so as to fill
DM water in RH circuit from CRH line.
• Ensure one BFP is available & charged
– Ensure feed line is charged.
– Feed stations all valves are closed to arrest the entry of water
towards economizer side.
– DM-1,2 valves are closed.
• Ensure SH spray valve E-13,RH spray valve R-17,18,19 are available
for service & kept closed. Ensure RH attemperator station drain valve
is closed.
• Ensure SH spray valves (LHS / RHS) S-27,28 are closed.
• Ensure HP/LP bypass spray blow down isolating valve is closed.
• Ensure PRDS spray isolating valve FW-76 & its bypass valve is
closed.
• Bypass BFP main pump ‘suction pressure low’ & ‘discharge pressure
low’ & ‘FST level high to ELP trip’ tripping protections.
• Check :-
– Both IVs to be dummied.
– Ensure CRH,HRH & MS lines hangers are locked by TM.
– Ensure RH vents are open.
– Ensure HPH-6 steam extraction valve ES-4 is closed, drain valve
after ES-4 is open to atmosphere. (i.e. ES-18 & inspection drains
are open.)
– ES-4 line drain before ES-4 which is connected to drain before ES-
1 (HPH-7 FCNRV) is blocked. This dummy shall be removed after
concluding RH hydraulic test.
– Ensure CRH drains after HP by pass station HPH drains are
closed.
– Ensure CR-5,6 are open along with inspection drains.
– Ensure CR-3.4 are closed.
– Ensure LP by pass station valve is closed & drain before LP
bypass is also closed
– Ensure MS-7,8 along with HP bypass are closed. Drains before
MS-7,8 & before bypass are open.
– Ensure MS-1,2,3,4,5,6 are closed, drains between MSV & ESV
are open.
– Ensure MS line drains along with inspection drains are open.
– Ensure ES-6,7 are closed. Its line drain valve is open.
– Ensure HPT/IPT transfer pipe drains along with inspection drains
are open.
– Ensure HPT/IPT casing drains are open
– Condenser level & UDT levels to be watched during the process of
water filling to ensure NO passing of valves.
• STARTING
• Start ELP for RH filling.
• Check for any water leakage at Turbine side, especially at IVs
dummies.
• Close RH vents after sufficient water vented out.
• Ensure RH pressure is raised to 20 kg/cm2.
• If no leakage, stop ELP, Close discharge valve.
• Start BFP & put it on recirculation. Raise the discharge pressure to 50
kg/cm2.
• Open E-13, R-17 & then R-18,19., Watch the RH pressure is raised @
35 kg/cm2.
• Check for leakages., Stop BFP. Depressurize the line.
• Open RH vents & drains of CRH & HRH lines.
• Ensure complete draining of RH circuit.
• Ensure CRH/HRH/MS lines hangers support released by BM
THANKS