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Boiler Lightup SOP

1. The document outlines the standard operating procedure for lighting up a boiler, including completing checks, starting auxiliary equipment, and gradually starting fans and burners. 2. It describes starting the induced draft, primary air, and secondary air fans in sequence while maintaining furnace pressure, and adjusting the fans to stabilize operation. 3. The procedure then covers starting the oil burners one by one to heat the furnace, initiating coal firing once target temperatures are reached, and synchronizing the boiler online once pressure and temperature match the running boiler.

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Sudipta Das
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622 views

Boiler Lightup SOP

1. The document outlines the standard operating procedure for lighting up a boiler, including completing checks, starting auxiliary equipment, and gradually starting fans and burners. 2. It describes starting the induced draft, primary air, and secondary air fans in sequence while maintaining furnace pressure, and adjusting the fans to stabilize operation. 3. The procedure then covers starting the oil burners one by one to heat the furnace, initiating coal firing once target temperatures are reached, and synchronizing the boiler online once pressure and temperature match the running boiler.

Uploaded by

Sudipta Das
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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BNK POWER SOLUTION RSPL SITE DWARKA GUJARAT

Boiler Light-Up Standard Operating Procedure.


1. Ensure that all walks down checks, valve and damper line up, system line up, water
fillings, bubble cap test, and bed material fillings are completed & boiler safety
interlock are tested and in operation.
2. After Ensuring, Boiler cold startup checklist -Desk and field side must be signed by shift
Inchrge, before cold startup of boiler.
3. ESP hopper & Supporting heaters should be started 3-4 hours before cold startup of
boiler.
4. LDO pump should be started 2 hours before startup and should run in recirculation.
A- Start-up sequence of ID, PA & SA fan:
• ID fan should start first followed by PA& then SA fan, keep boiler drum level up
to 45%
• Before start of ID Fan Check damper positions
• Guillotine damper at ID inlet Closed
• Control damper at ID inlet Closed
• Guillotine damper at ID Outlet Closed

Check that starts permissive is available.

• Start the ID fan from DCS (VFD 10%)


• Observe motor current reading
• Open discharge damper and inlet damper
• Adjust fan speed through VFD to maintain negative furnace draft (-5mmwc)
I. To start PA fan, ID fan should run for 2 min., Ensure shut off damper at PA outlet duct –
close.
II. Ensure PA APH Bypass Damper is open condition
III. Check that start permissive is available
IV. Start PA fan with VFD 10 % & Open shut off damper at PA outlet.
V. Observe motor current and vibration reading
VI. Adjust fan speed through VFD
VII. Ensure CO vent is Forced closed and bed ash cooler to APH Damper force open
VIII. Maintain furnace draft (-5mmwc)
IX. Verify Bed ash cooler to APH (UV-1041) shut off valve open automatically through logic
X. PA air flow to wind box to be adjusted by wind box damper
XI. To start SA fan, PA fan should run for 3 min. SA fan shut off outlet damper – close
XII. SA to APH bypass damper must be in open condition.
XIII. Check that start permissive available
XIV. Start SA fan with 10% VFD.
XV. Observe motor current reading
XVI. Immediate after SA fan start up, PA air to MDC slider will open automatically.
XVII. Adjust fan speed through VFD to maintain negative furnace draft (-5mmwc).
XVIII. Stabilize all the fans and furnace pressure for normal operation.
B- Burner Startup:
• Check Opening and closing combustion damper for all burners are smooth
BNK POWER SOLUTION RSPL SITE DWARKA GUJARAT

• Verify Colling air to flame scanner are available


• Verify operation of LDO flow control valve opening and closing.
• Start oil pump and maintain rated oil pressure (8-9 kg/cm2) at main fuel trip valve
inlet
• Before starting the Burner, Pre interlock, main interlock & oil firing permissive to be
satisfied.

C- Furnace Purging:
• Whenever Pre interlock satisfied, the system ids ready for purging & is indicated by
glow of lamp. “PURGE READY TO START”
• For purging maintain PA air flow greater than 75TPH & SA air flow 95 TPH by
adjusting fan speed /damper opening.
• Initiate the purge start from DCS “Purge in progress” will appear, after present time I,
e. 5 minutes, purge complete indication will appear.
• After completion of purging wind box air sleeve damper moves to start up position
• Normalize PA & SA flow for burner start up.
D- Oil Firing:
• Check permissive available for start the oil burners.
• Open main fuel shut off valve (UV-1070) & set oil, oil flow control valve (FCV-1078) to
35-40 % observing pressure 7-8kg/cm2.
• Burner ready to start indication will appear.
• Initiate burner start command to burner -1, oil gun of burner goes to insert position
(firing position)
• Burner atomizing air valve opens
• Ignitor goes to insert position & igniter is energized for spark generation; igniter will
be in energized condition for 15 seconds.
• Burner -1 shut off valve will open & oil recirculation valve will continue to remain
close.
• Main flame will be established & “Burner On” indication will be generated.
• Stabilize burner operation & adjust oil firing rate (650-900 kg/Hr./ burner).
BNK POWER SOLUTION RSPL SITE DWARKA GUJARAT

• Follow up the boiler cold startup curve as below

• Second burner will be taken service after Drum skin temperature reaches 90 Degree.
• Number of burners can be decided as per requirement.
• Increase oil pressure by increasing oil flow.
• Whenever steam drum pressure reaches 2kg/cm2 close steam drum vent valve
followed by super heaters wing wall.
• Whenever pressure reaches to 3kg/cm2 close super heater drain valve, wing walls
drain valve & enclose panel drains.
• Initial Start vent should be 100 open condition. Close as per requirement during
synchronizing the boiler.
E- Coal Firing
• Whenever bed temperature reaches around 550’C-600’C initiate coal firing.
• Prior to start fuel feeder, ensure seal air to coal feeders & coal feed pipe are open
maintain required pressure greater than 500mmwc.
• Start DCF -01 with minimum RPM & coal flow 1.5-2.2 TPH
• Whenever bed temperature reaches 750’C start second DCF.
• Whenever bed temperature reaches 800’C switch off over bed burner one by one
gradually.
• Inform Electrical deportment for ESP Field Charging After ESP inlet point Reaches 120
degree.
• Main steam line pressure reaches 20 bar open the MMSV bypass MOV for equalizing
the pressure.

Note: If any other boiler is in running condition, then raise the pressure and
temperature up to running boiler pressure and Temperature then-

Firstly, Open MMSV, once MMSV fully open then equalize with PR-07 header and Line up
slowly.

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