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Boiler Details
Boiler make : Thermax
Type : IRCFBC (U-Beam)
Capacity : 165 TPH
working press : 109 kg/cm2
Working Temp : 540 ± 5 oC
Eco inlet Temp : 200 oC
Heating surface
area : 8332 sq.cm
IR-CFBC:
(Internal recirculation circulating fluidized bed combustion)
 Startup of a cold Boiler :

Boiler start-up can be termed as cold start-up when there is no pressure or when
pressure is less than 2 Kg/cm2 (g) in the steam drum.
In a cold start up, possibilities of some inspection or maintenance works have
been done is presumed. A walk down check is required

Prior to startup:

➢ Ensure that all work permits have been returned, safety tags are removed and permission
from respective departments is available.

➢ Inspect the Boiler before startup & ensure that startup checklist was completed.

➢ All equipment's trial to be taken.

➢ All interlocks to be cross checked.

Boiler startup sequence:
➢Walk-down checks
➢Valve lineup
➢Damper lineup
➢System lineup
➢Filling of water in Boiler
➢Bed material filling
➢Cold startup of Boiler
Equipment startup sequence:

➢A.C.W Pump ➢S.A Fan

➢Compressor ➢Burners
➢C.H.P ➢B.F.P
➢L.D.O Pump ➢Coal D.C.F
➢A.H.P ➢M.D.C
➢I.D Fan ➢E.S.P
➢P.A Fan ➢B.A.C
 PREPARATION BEFORE LIGHT UP:
1. Ensure Bed Material of size ≤ 0.5mm size is charged into the boiler furnace to a
static bed height of 650 mm above Bubble cap.( WB drain to be in close condition)
2. Ensure that DM tank level was healthy and fill water in drum through initial filling
line of economizer up to 30-40 % of level. ( header drains should be in close
condition )
3. Ensure that Deareator level was healthy ( 65-70 % ) with DMWTP in ready for
service.
4. Ensure that LDO tank level was healthy ( above 50 % ) with pump ready for
service.
5. Ensure industrial LPG gas cylinder along with respective regulator & hose pipe are
available.
6. ACW pump in running with above 3 kg/cm2 discharge press.
7. Inst compressor running with air pressure at receiver tank should be maintained
minimum at 5 kg/cm2.
8. Ensure bunker level is healthy min 50 % .
 Boiler light up:
➢ Start ESP rapping, hopper heater, insulator heater, purge air blower before 2 hrs of
boiler start up.

➢ Start AHP 1hr before boiler start up.

➢ Start LDO pump & keep in recirculation with 1200 kg/cm2 oil flow.
➢ Start ID fans as per fan start up procedure & maintain furnace press at -1 to -3
mmwc initially with manual damper control at minimum speed.

➢ Once ID Fan has started , PA Fan can be started after satisfying start up permissive.
➢ Start PA fans as per fan start up procedure with initially APH bypass path in service
& main damper close.

➢ Increase APH outlet press manually above 1250 mmwc, after attaining desired
pressure ( i.e. above 1250 mmwc) keep both fans in auto mode. Keep observation on
draft ,if ID fans regulating suction dampers were fully opened then control draft by
varying fan speed.
➢Increase flow gradually with wind box pressure maintained such that fluidization of
bed material occurs & uniformly spread around the furnace. The air flow at which
minimum fluidization occurs is noted down for future reference.

➢Open wind box damper( dampers should be > 11%) & increase flow to 25-30 TPH
which will give permission for start furnace purge. Purging time will be 5min which
displays in DCS.

➢ After furnace purge completion start SA fans as per fan start up procedure with
Initially bypass path of APH in service.

➢ Increase SA air pressure up to 800 mmwc by varying fan speed manually , after
attaining desired press keep fans in auto mode & maintain 23-25TPH of air flow to
burners by varying burner common isolation damper.

➢ Check whether burner pre-interlocks were healthy if so, Start Burner purging.
Purging time will be 5min which displays in DCS.
➢ After burner purge completion reduce SA to burner air flow to 18 TPH by
maintaining draft and check whether burner main interlocks, inst air press, LPG gas
press, atomizing air press were healthy if so , give Start command to middle
Burner.

➢ Once burner start control the oil flow 1000 - 1200kg/cm . Maintain furnace draft and
2

sufficient air flow according to oil flow (1kg oil needs 17-18 kg of air).

➢ As furnace temp reaches 200-250 C raise oil flow to 1200kg/cm and start second
o 2

burner & maintain the furnace pressure around -3 to –5 mmwc and normal water
level in Drum.

➢ Number off Burner can be taken into service as per requirement.

➢ Whenever the steam drum pressure reaches about 2kg/cm , close the steam drum
2

vent valve & maintain startup vent 100 % open.

➢ Once drum pressure reaches to 5 kg/cm close the super heaters header vents &
2

maintain stop valve before & after drains 10 % open and raise steam pressure
slowly as per startup curve.
Cold startup press raising curve:
➢Monitor and maintain the steam drum metal differential temperature at 25°C by
modulating the firing rate and water flow rate.

➢Once all burner through , maintain PA air flow 40 TPH so as to avoid over heating of
bed material & raise bed temp up to 450 °C.

➢Mean while keep observation on drum level and make through BFP & feed control
station.

➢Prior to start Coal feeding ensure seal air to the Coal feeder & Coal rod gates are
open and maintain the required pressure (≈ 550-600 mmwc).

➢Start one of the Drag Chain feeders with minimum speed and admit the fuel into
the furnace. Observe the bed temperature carefully, if there is no change in the bed
temperature after admitting the Solid Fuel discontinue the Solid fuel feeding and
increase the bed temperature to 500 0C by burners and then admit coal again.

➢Monitor the bed temperature raise closely, whenever the bed temperature reaches
550 0C, Start the second feeder at minimum speed.

➢During coal admit closely watch o2 & bed temp to avoid bed clinker formation.
➢ Once bed temp shoot up control bed temp by adjusting oil flow & coal.
➢ At 650 C cutoff one burner by maintaining bed temp with coal & raise PA air flow
0

according to o2. At 750 0C of bed temp cutoff all burners.

➢ After all burners get cutoff maintain burner air duct press above 50 mmwc of mid
DP if it is not showing properly maintain 400 mmwc for partial load & 550 mmwc for
full load.

➢ Mean while make through Ash recycle system air-slide fluidising air 1100 mmwc &
pushing air 700 mmwc.

➢ Raise bed temp up to 850 -890 0C by adjusting coal & air flow up to 80TPH with wind
box press above 1100 mmwc.

➢ If the Bed temperature continue to increase even after regulating coal feeding
Start MDC RAV at min speed & maintain bed temp.
STEAM LINE CHARGING :
➢Open all main steam line drain valve partially and drain condensate to avoid hammering of
pipe line.
➢Once the boiler press reaches as per startup curve, open MSSV by-pass valve in inching mode
and warm up main steam line at 40 kg/cm2.
➢Once 110ata Temp reaches 280- 300 0C open MSSV fully & maintain main steam press 85 to 90
kg/cm2 by adjusting coal.

➢After SYNC boiler with TG, slowly close startup vent according to steam flow & maintain
steam press 108 kg/cm2.
➢ Once steam flow reaches 55 TPH startup vent can be closed fully.
➢On confirming steady stream flow, switchover the drum level controllers into auto control
mode.

ESP CHARGING

➢ESP shall be charged after attaining the required flue gas temperature.
➢Required ESP I/L flue gas temp can be adjusted by adjusting PA ,SA APH main
damper.
➢Once rated temp reach, charge ESP transformers as mentioned in manual.
Thanks….