Filosofia Standard Operacion Caldera Thermax

CLIENTE/CLIENT CONTRATISTA PRINCIPAL/MAIN CONTRACTOR
APCC SAN PEDRO BIOENERGY EYRA INTERNACIONAL

APROBADO PARA CONSTRUCCIÓN CON
COMENTARIOS
SELLO O ESTADO DEL DOCUMENTO/DOCUMENT STATUS OR STAMP
SUMINISTRADOR- SUBCONTRATISTA/ Nº REQUISICIÓN/
SUPPLIER-SUBCONTRACTOR: REQUISITION NUMBER:
APROBADO / APPROVED (APR).
Incorporar comentarios y reenviar documento, el

No comments/ Work may proceed.
Nº ORDEN DE TRABAJO O CONTRATO/ ITEM/TAG Nº:
trabajo
REVISADO CON COMENTARIOS. puede
REENVIAR continuar
/ REVIEWED WITH COMMENTS. RESUBMIT (RWC). PURCHASE ORDER OR CONTRACT Nº:
Incorporate comments and resubmit documents, work may proceed.
NOMBRE PROYECTO/PROJECT CODE DESCRIPCIÓN PROYECTO/PROJECT DESCRIPTION
RECHAZADO. VER COMENTARIOS / REJECTED. SEE COMMENTS (REJ). COGENERATION FACILITY

Digitally signed by Alejandro Padilla
Incorporate comments and resubmit documents, work may not proceed. SANPEDRO BIOENERGY IN SAN PEDRO DE MACORIS
Date: 2015.06.16 15:54:20 +02'00'

PARA INFORMACION / FOR INFORMATION. APPROVAL NOT NEEDED (FI).
Nº DOCUMENTO/DOCUMENT Nº:
REV.:
Approval isFecha / Date
not required. Firma / Signature
V-SPB1-CO-0001-PRO-2002 07
Este estado no libera a la Ingeniería de sus compromisos
contractuales.
This status does not release the Supplier from its responsibilities related to the contractual requirements.
Fecha/Date: Firma/Signature: TÍTULO DEL DOCUMENTO/DOCUMENT TITLE:
STANDARD OPERATING PHILOSOPHY
© San Pedro Bio-Energy S.R.L. – Santo Domingo 2012. The information contained in this document is confidential and restricted, and is to be used only for the purposes established in the
document. No modification, exploitation, reproduction, communication to any third party, dissemination or distribution of the whole or any part of the document is permitted without the prior, written
consent of San Pedro Bio-Energy S.R.L. Failure to respond to any request for such consent shall in no way be construed as authorization for use.
ANSWER TO Thermax reply to comments on V-SPB1-CO-0001-PRO-2002_comAITE FROM 6 MAY ARE PENDING

TO BE CLOSE.
THERMAX STANDARD OPERATION PHILOSOPHY FOR TG BOILER
STANDARD OPERATING PROCEDURE
FOR
1 x 140TPH TRAVGRATE BOILER
PROJECT: EYRA INTERNACIONAL

DOMNICAN REPUBLIC
THERMAX JOB NO.: PB 1301
THERMAX
THERMAX LIMITED,
BOILER & HEATER GROUP,
PUNE, INDIA.
Operation Philosophy Page 1

RECORD OF REVISIONS:
REVISION DATE OF SUBMISSION
Revision 00 (Preliminary submission) 17/01/2014
Revision 01 (Commented received from customer dated
16/04/2014
07/04/2014)
Revision 02 (Comment received from customer dated
24/06/2014
22/05/2014)
04/07/2014
27/06/2014)
16/07/2014
09/07/2014)
21/07/2014
17/07/2014)
05/11/2014
29/09/2014)
30/04/2015
03/12/2014)
PREPARED BY REVIEWED BY APPROVED BY

R.Kshirsagar Atul Zade Rex Raj
Asst. Manager- FE.
Deputy Executive HOD- FE. (Solid SBU)
Commissioning
Note: - This is a Computer generated document and hence require no Signature.

INDEX
OPERATION ................................................................................... 5
OPERATOR'S RESPONSIBILITY .................................................................. 5
PERSONNEL SAFETY ...................................................................... 5
START UP PROCEDURE .................................................................. 6
INPUTS .................................................................................................. 6
WALKDOWN CHECKS ............................................................................... 7
SYSTEM LINE UP .............................................................................................7
WATER FILLING ............................................................................. 9

FUEL FIRING................................................................................ 12
BAGASSE FIRING .............................................................................12
COAL FIRING ...................................................................................13
PRESSURE RISING ....................................................................... 14
COLD START UP ........................................................................................14
HOT START UP .........................................................................................16
WARM START UP .......................................................................................17
WARM START UP CURVE ..............................................................................18
OPERATION ................................................................................. 19
FUELS DISTRIBUTION ..................................................................................19
GRATE SPEED ........................................................................................19
COMBUSTION AIR........................................................................ 20
SECONDARY AIR PRESSURE SETTING .......................................................20
SECONDARY AIR PRESSURE SETTING CHART FOR BAGASSE FIRING .............21
TRAVAGRATE ............................................................................... 23
OPERATION .............................................................................................23
SPEED CONTROL .......................................................................................23
ESP .............................................................................................. 23
STEAM TEMPERATURE CONTROL .................................................. 24
CHEMICAL DOSING SYSTEM ........................................................ 24
BLOW-DOWN SYSTEM .................................................................. 24
INTERMITTENT BLOW-DOWN (IBD) ................................................................25
CONTINUOUS BLOW-DOWN (CBD) .................................................................25
AIR PRE-HEATER ......................................................................... 25

SOURCES OF TROUBLES AND PREVENTION ................................. 25

FOULING.................................................................................................25
CORROSION .............................................................................................26
FIRES ....................................................................................................26
DEAERATOR ................................................................................. 26
START UP ...............................................................................................26
OPERATION .............................................................................................27
SHUTTING DOWN ......................................................................................27
SOOT BLOWER ............................................................................. 27
STEAM WATER ANALYSIS SYSTEM (SWAS).................................. 28
SCAPH (STEAM COIL AIR PRE HEATER ) ...................................... 28
WALK DOWN CHECK LIST DURING OPERATION ........................... 29
NORMAL SHUTDOWN PROCEDURE ............................................... 30
SHUT DOWN PROCEDURES - LONG DURATION ...........................................30
SHUTDOWN PROCEDURES - SHORT DURATION ..........................................31
EMERGENCY SHUTDOWN PROCEDURES ...................................... 31
DO’S AND DON’T S FOR BOILER ................................................... 34
DO’S ....................................................................................................34
DON’TS ................................................................................................35

OPERATION
This section describes the startup and shutdown procedures of the boiler along with the
operation, troubleshooting and safety points.
• Procedures explained in this section apply for start up of a boiler already commissioned.
Commissioning a new boiler call for several additional requirements, which are not
explained here.
• It is assumed that the boiler operators are fully familiar with the design and construction
feature.
• It is assumed that operators are trained in operation of similar Travagrate boilers and have
been licensed to operate boilers by the concerned authorities.
• The owner is encouraged to evolve standard operating procedures (SOP) based on the
framework and recommendations that are explained in the subsections below. The SOPs
have to be well understood by the utility managers and operators for safe and reliable
operation.
OPERATOR'S RESPONSIBILITY
Boiler operator is responsible not only for the successful operation of the boiler and its related
equipment, but also for the safety of all personnel involved. The operator must be aware of any
operating conditions affecting the boiler or related equipment. He Should be able to recognize
hazardous conditions and to act properly to avoid injury.
Even though operating procedures are normally given for each piece of equipment, a complete
knowledge of all components their design, purpose, limitations and relationship with other
components is must for the operators.
PERSONNEL SAFETY
Operating instructions usually deal primarily with the protection of equipment. Rules and
devices for personnel protection are also essential. The items listed here are based on actual
operating experience and point out some personnel safety considerations.
1. When viewing flames or furnace conditions always wear tinted goggles or a tinted shield to
protect the eyes from harmful light intensity and flying ash or slag particles.
2. Do not stand in front of open ports or doors, especially when they are being opened.
Furnace pulsations caused by firing conditions, soot blower operation, or tube failure can
blow hot furnace gases out of open doors, even on suction-fired units. Aspirating air is used
on inspection doors and ports of pressure-fired units to prevent the escape of hot furnace
gases. The aspirating jets can become blocked, or the aspirating air supply can fail.
3. In some cases, the entire observation port or door can be covered with slag, causing the
aspirating air to blast slag and ash out into the boiler room.
4. Do not use open ended pipes for rodding observation ports or slag on furnace walls. Hot
gases can be discharged through the open ended pipe directly onto its handler. The pipe
can also become excessively hot.
5. When handling any type of rod or probe in the furnace – especially in coal-fired furnaces –
be prepared for falling slag striking the rod or probe. The fulcrum action can inflict severe

injuries.
6. Be prepared for slag leaks. Iron oxides in coal can be reduced to molten iron or iron
sulphides in a reducing atmosphere in the furnace resulting from combustion with
insufficient air. This molten iron can wash away refractory, seals and tube and leak out onto
equipment or personnel.
7. Never enter a vessel, especially a boiler drum, until all stem and water valves, including
drain and blow down valves, have been closed and locked or tagged. It is possible for steam
and hot water to back up through drain and blow down piping, especially when more than
one boiler or vessel is connected to the same drain or blow down tank.
8. Be prepared for hot water in drums and headers when removing manhole plates and
manhole covers.
9. Do not enter a confined space until it has been cooled, purged of combustible and
dangerous gases and properly ventilated with precautions taken to keep the entrance open.
Station a worker at the entrance, notify a responsible person, or run an extension cord
through the entrance.
10. Be prepared for falling slag and dust when entering the boiler setting or ash pit.
11. Use low voltage extension cords, or cords with ground fault interrupters. Bulbs on extension
cords and flashlights should be explosion proof.
12. Never step into fly ash. It can be cold on the surface yet remain hot and smouldering
underneath for weeks.
13. Never use toxic or volatile fluids in confined spaces.
14. Never open or enter rotating equipment until it has come to a complete stop and its circuit
breaker is locked open. Some types of rotating equipment can be set into motion with very
little force. This type should be locked with a brake or other suitable device to prevent
rotation.
15. Always secure the drive mechanism of dampers, gates and doors before passing through
them.
START UP PROCEDURE
Prior to start the boiler, following input requirements to be satisfied.
INPUTS
Inputs required for startup are as follows:
Fuel
Feed water.
Uninterrupted electric power supply for auxiliary equipment’s.
Lighting for equipment’s, walk ways and field instruments.
Instrument air.
Plant air.
Cooling water.
Lubricant for the rotary equipment’s.
Chemical for feed and boiler water treatment.
Readiness of drainage and ash disposal system.
Fire fighting system.
Burner firing system (for future provision)

WALKDOWN CHECKS
Verify that the Nitrogen capping is removed and the unit is purged properly so as it is safe
for man entry for inspection.
Steam and water drums are clean and manholes are closed properly.
Verify that the furnace S.H and convection bank are clear.
Verify that all access and inspection doors of furnace are tightly closed.
Verify that the air duct to furnace and flue up to stack is clear and the manhole doors closed
properly.
Ensure the walkways are clear with out any obstruction.
SYSTEM LINE UP
A. Process valve position during start-up
Following valves to be kept in open position:

Air vent on steam drum (V-0229 & V-0230).
Feed Water Control isolation valves.(V-0124/0127, V-0128/0131 & V-0132/0133)
Start-up vent at S.H. steam outlet (PCV-1001 & MV-1006).
TCV Bypass valve with isolation valve (TCV-1104B & V-0145/0148)
Drum coil pre-heater isolation valve (V-0150)
H.P Dosing isolation valve (V-0389 )
Instrument air connections to all the instruments.
Isolation valve for drum level gauge (V-0207 to V-0210 & V-0215 to V-0218).
CBD & IBD isolation valves (V-0314/V-0315/V-0317 & V-0328/V-0329/V-0331)
Steam and water system pressure gauges/transmitters.
Eletromagnetic Relief Valve isolation Valve (V-0259)
Following valves are to be kept in closed position:

Main steam stop valve & by-pass valve (MV-1004 & MV-1005).
Air vent on economiser outlet header (V-0161,162 & V-0165,166)
SH header vents (V-0238 & V-0239)
FCV bypass valve (MV-1001)
Furnace drain header drains (V-0185 /0186).
Furnace Drain Header Hydro test line (V-0188)
Furnace drain header to IBD Tank (V-189)
Feed water TCV & TCV isolation valve (TCV-1104A & V-0140/o143)
TCV-1104 Bypass valve (V-0149)
Steam to soot blower root valve. (MV-1007).
Economiser drain (V-0069 to V-0176).
IBD/CBD valve (MV-1011 & MV-1012).
Drum level Gauge drain valves (V-0211, 0212 & V-0219, 0220).
Boiler water sample lines (V-0370 & V-0371).
Spray water line (V-0343).
Water wall panel bottom Header drains (V-0177 to 0184)

B. Field dampers are to be kept open/close as per the following instruction:
Keep the ID fan inlet/outlet damper (PCV-5001/5002 & UV-9021/9022) open.

Keep Close the FD Fan to SCAPH/APH inlet duct damper (TV-9029) and open the
APH by-pass duct damper (TV-9027).
Close the SA Fan to SCAPH/APH inlet duct damper (TV-9030) and open the APH by-
pass duct damper (TV-9028).
Verify the plenum, APH & ESP hopper, ash outlet gates are kept in open position.
Verify the main ash hopper outlet gates are in open position and the by pass chute
gates are in closed position.
Submerged ash conveyor is filled with water so as the ash outlet chutes are immersed in
water.
Open the I.D fan inlet box drain plug during slow firing, due to low heating there is a
possibility of condensation of flue gases, which can be drained through this drain plug.
Open the APH to plenum duct isolation dampers.
Ensure the chimney manhole is kept closed.
C. Verify the readiness of following equipment’s:

♦ I.D., FD, and S.A. fans.
♦ Feed water transfer pump.
♦ Feed water pump.
♦ Travagrate with drive.
♦ Twins drum feeders for Biomass product.
♦ Screw feeders for Biomass product
♦ Drag Chain Feeding for coal feeding.
♦ Fuel handling system.
♦ Ash handling system.
♦ Chemical dosing system.
♦ Soot blowers.
D. Verify the readiness of following instruments:

♦ Control panel/DCS
♦ Control valves
♦ Motorized valves
♦ All the field and panel instruments.
♦ Damper actuators
♦ Sensors
E. Switch over the following controls in manual mode;

Deaerator level and pressure (LIC-7001 & PIC-7002A)
Furnace pressure (PIC-5007)
Drum level (LIC-1001)
Steam Temperature (TIC-1006)
Air flow (HIC-4001 to HIC-4004)

Fuel flow (HIC-6001 , HIC-6007 & HIC-6013)

CBD tank level (LIC-1004).
Soot blower pressure control (PIC-1002)
F. ESP
Verify the internal is clean and all the manholes are closed with proper sealing.
Keep the air vent on outlet header open.
Ensure that the drain valves W26 – 2nos of bottom headers are kept closed.
G. Others
Verify all the soot blowers are in rest position.
Ensure the test gags of safety valves are removed.
Verify all the safety interlocks are working as per the desired logic/values.
Ensure the availability of cooling water/seal air to the system.
WATER FILLING
Caution: Feed water should be confirmed to the specification.
Prior to fill the water keeps the following valves in open position:
Air vent at economiser outlet header (V-0161,0162 & V-0165 , 0166)
Economiser drains (V-0169 to V-0176)
Air vent on steam drum (V-0229 & V-0230)
Start up vent (MV-1006 & PCV-1001)
Initial filling line isolation valve(V-0187)
Following Valve keep in close position

Furnace drain headers drain (V-0185/V-0186)
Furnace Drain Header Drain outlet to IBD tank (V-0189)
N2 filling line (V-231)
Boiler hydro test line (V-0188)
IBD line main and isolation valves (MV-1012 & V-0328/0329/0331)
CBD line main & Isolation Valves (MV-1011 & V-0314/0315/0317)
H.P Dosing valve (V-0389 )
Saturated Steam line SWAS (V- 0368, V-0369)
Superheated Steam line SWAS (V-0366, V-0367 )
Main steam isolation and by-pass valve (MV-1004 & MV-1005)
Feed Water Control station valve (FCV-1001,LCV-1002 & MV-1001)
Attemperator spray water isolation (V-0343)
TCV Bypass Valve (V-0144)
Steam to soot blower (MV-1007)

Start the feed water transfer pump and admit the water through the initial filling line.
OR
If the initial filling line is not ready, in that case fill the water in steam drum through
normal feed water line. The following procedure to be refer.
Start the feed water pump as per the pump start up procedure, open the feed water flow
control station (LCV-1002) valve gradually and feed the water to the boiler through the
regular system. Feed water flow to be controlled in such a way that the electrical load on the
pump motor is within the operating limit also the pump outlet pressure is maintained. In this
case keep the economiser drain in closed position while line up the valves for water
filling.
In above case to fill the water keeps the following valves in open position:
Flow Control Valve & FCV Bypass Valve (LCV-1002 & V-0128/0131)
TCV Bypass Valve (V-0144)
Economiser Isolation Valve (V-0153)
Air vent at economiser outlet header (V-0161,0162 & V-0165 , 0166)
Air vent on steam drum (V-0229 & V-0230)
Start up vent (MV-1006 & PCV-1001)
Following Valve keep in close position

Economiser Drain Valves (V-0169 to V-0176)
Initial filling line isolation valve(V-0187)
Furnace drain headers drain (V-0185/V-0186)
Furnace Drain Header Drain outlet to IBD tank (V-0189)
N2 filling line (V-231)
Boiler hydro test line (V-0188)
IBD line main and isolation valves (MV-1012 & V-0328/0329/0331)
CBD line main & Isolation Valves (MV-1011 & V-0314/0315/0317)
H.P Dosing piping (V-0389 )
Saturated Steam line SWAS (V- 0368, V-0369)
Superheated Steam line SWAS (V-0366, V-0367 )
Main steam isolation and by-pass valve (MV-1004 & MV-1005)
Attemperator spray water isolation (V-0343)
Steam to soot blower (MV-1007)
Whenever the water flow from the economiser vent is free from air, close the vent valve.
Continue water filling till the level in steam drum reaches 50mm below the normal operating
limit and stop the pump.

Note:
An initial starting procedure If temp. difference between the Economizer Module-2 Inlet Gas
and Economizer Module-2 Inlet Water is greater than 38 °C then Economizer Module-2 should
be taken in line and should not be bypassed.
If temp. difference between the Economizer Module-1 Inlet Gas and Economizer Module-1 Inlet
Water is greater than 38 °C then Economizer Module-1 should be taken in line and should not
be bypassed.
dT = Tg1 - Tw1 ≥ 38 0C
dT = Tg2 - T w2 ≥ 38 0C
Tg1= Flue Gas Temperature at Economiser-1 Inlet

Tw1= Feed Water Temperature at Economiser-1 Inlet
Tg2= Flue Gas Temperature at Economiser-2 Inlet
Tw2= Feed Water Temperature at Economiser-2 Inlet
H. Cold start-up:
During cold startup at most care to be taken to ensure trouble free start-up and smooth
operation of the boiler plant.
After completing the above pre start checks, ensure all the manholes in furnace, flues and
ducting are closed and locked properly, except the wood-firing door.
Fill-up the fuel-bunker/silo with specified fuel.
Open the cooling water to boiler feed water pump, sample coolers and hydraulic drive oil
cooler.
Fill up boiler with feed water, 50 mm below normal water level.

FUEL FIRING
BAGASSE FIRING
Stack around 200Kgs of firewood on the travagrate, light up the wood by kerosene soaked
torch from out side the furnace through the wood firing door. (Firewood should be of small
size- 2" x 500 mm long, without nail or packing metal strips, which may damage grate
components).
Maintain low and moderate fire initially and do not operate the fans at this stage, which may
increase the furnace temperature rapidly.
Whenever the fire is well spread over the grate, start the I.D fan as per the Fan start up
procedure. Continue the firing with the I.D fan in operation, at one stage the temperature will
be stagnant, then start the F.D fan and increase the rate of fuel feeding.
Maintain furnace pressure (PT-5001/2/3) between (-) 2 to (-) 5 mmwc by adjusting the
fan speed or fan suction damper opening.After completion of hot draining operation re start the
firing and increase the pressure as per cold pressurizing curve.
Whenever the furnace temperature reaches around 400 0C initiate the Bagasse firing.
Start the S.A fan as per the fan startup procedure and maintain 200 to 300mmWC pressure
(PT-9018) at the pneumatic spreader air ducting. Then start the air-modulating damper.
Keep the pneumatic spreader trajectory plate in horizontal position.
Bagasse should be loose with moisture <54 %, and free from foreign materials like steel,
stone, bricks, binding wire and wood etc. Presence of foreign material may jam the fuel feeders
and damage the Travagrate grate and fuel feeder components. Start the bagasse carrier and fill
up the silo.
Prior to start the bagasse feeder, ensure the furnace temperature is adequate for the
combustion of bagasse, otherwise there will be un-burnt in the flue gas, which may create
problem of choking the cinder re-firing system, APH tubes and ESP hoppers. Hence it is
recommended to start the feeders whenever the furnace temperature (TE-5001) is achieved
>400° C.
Whenever the required furnace temperature is achieved, start the screw feeders and run at
minimum speed then start the twin drum feeder one by one and run at minimum speed,
however it may require to operate the feeders intermittently depends on furnace conditions.
Watch the furnace for fuel throw/spreading pattern and combustion. If the fuel is falling close
to the front plate, increase the SA pressure at the spreader duct. Initially there will be heaps in
the furnace, during such conditions, stop the feeder of the section where the fuel pile up on the
travagrate and wait for the heaps to burn. Pocking may also require in such condition to disturb
the heap for quick burning. Feeder can be started once the heaps are cleared.
While viewing the furnace utmost care to be taken, as in the event of fuel feeding
interruption there will be a possibility of furnace puffing. View the furnace condition
through the peep hole in the access door at the travagrate front panel, it also
advised to use safety goggle while viewing to avoid accident.
During start-up, there will be mouth feeding and un-burnt in the bottom ash, due to low

furnace temperature, which will be gradually reduced when the furnace temperature/load is
increased.
Furnace pressure is to be maintained between (-) 2 to (-) 5 mmWC, if the furnace pressure is
too negative fine bagasse particles will either fire close to S.H. zone or fly as unburned. Firing at
free board is to be avoided for the protection of S.H. coils from over heating.
COAL FIRING
Start the ID fan and FD fan in sequence, keeping the suction damper fully closed. Operate the
I.D fan suction damper to maintain the furnace pressure between –3 to -5 mmWc through the
furnace pressure controller (PIC-5007) i.e. by varying the speed of the fan.
Switch ON the coal spreaders and drag chain feeders (DCF), operate the DCF at the lowest
speed through the speed controller (HIC-6013) and spray a thin layer (40-mm) of coal over
the grate. Stop the Fan & DCF spreaders.
Cover the coal over the grate surface with firewood and spray kerosene / Diesel over it. Light
up the fuel bed from the wood-firing door with the kerosene/ Diesel soaked torch.
When the furnace temperature reaches to 450 0C , start the ID, FD fan & DCF and feed light
shower of coal to the furnace intermittently. Do not feed the fuel continuously and do not
operate the travagrate.
When the fire intensity has increased sufficiently and a layer of coal ash starts depositing on the
grate surface, increase the fuel feed rate. Supply required amount of air to the plenum by
operating F.D fan speed controller (HIC-4003 & 4004). Also, adjust the hydraulic drive speed
through the oil flow control valve mounted on the hydraulic drive according to the furnace
condition.
At this stage the secondary air fan is to be started by keeping the suction damper fully closed.
When furnace temperature starts rising rapidly, increase the fan discharge pressure to 300
mmWC by slowly adjusting the fan speed controller (HIC-4001 & 4002).
While starting coal-firing care should be taken that, initial coal bed thickness should not be
more than 50 mm at any location. In addition, the fire should start close to the rear wall. If the
fire moves away from the rear wall that will cause the fire slippage and fresh light up will have
to do be carried out. Operate the Travagrate intermittently at lower speed to maintain the
above. It is also required charging of fire wood and jerking of bed with poking rod, to assist for
establishing the coal fire throughout the grate.
Increase the coal feed rate progressively along with the under-grate and over fire air. Once the
fire is well spread and across the grate area, run the coal feeders and Travagrate continuously.
Close the wood-charging door once the continuous coal feeding is initiated.
Maintain furnace pressure between-2 to-5 mmWc through the furnace pressure controller
(PIC-5007) and switch over the controller into auto mode immediately after the continuous
coal firing is established

PRESSURE RISING
Cold Start Up
Close the drum vent valve (V-0229/0230) when the pressure reaches to 2-kg/cm2 (g).
Keep the start up vent in open position.
As the pressure increases, carefully watch the pressure part for free expansion/movements.
Increase the boiler pressure as per the cold start up curve, rate of firing is to be varied as per
the requirement, at times it may require stopping the feeders, but ensuring that the feeding is
not discontinued for a long time so as to maintain the furnace temperature.
During pressure rising, keep the drum water level controller (LIC-1001) in manual or single
element control mode; however furnace pressure control can be switched over to auto mode.
Raise boiler pressure up to 10 - 12 bar with start up vent valve. At this pressure, open MSSV
by-pass valve (MV-1005) and charge HP steam line. Ensure all drain valves downstream of
MSSV are open to remove condensate. After removal of condensate & main steam line warm
up, open MSSV (MV-1004) and close the bypass valve (MV-1005).
Charge auxiliary PRDS and supply steam to turbine gland sealing & Deaerator pegging steam,
as required. Adjust steam flow generated in the boiler to 5.1 t/hr to turbine by mean of start up
vent valve (PCV-1001) appropriate aperature.
Raise boiler pressure up to 15 bar. At this stage wait for the sufficient vacuum in condensate to
charge the turbine bypass.
Close start up vent valve (PCV-1001) once 30% MCR steam flow from the boiler achives and
adjust steam flow to turbine 7.7 t/hr by appropriate aperature of the turbine bypass.
Further raise boiler pressure to 40 bar by adjusting fuel firing and adjust the turbine bypass
aperature to maintain the defined the steam flow as function of pressure from 7.7 t/hr at 15
bar to 20.5 t/hr at 40 Bar. At this pressure initiate turbine rolling activity. Futher pressurizing
will be done as per the cold pressurizing curve or turbine curve which ever is slower.
On confirming steady steam flow, take the drum level controller (LIC-1001) in to automatic
control mode. It is advisable to keep a watch on the performance of the controller whenever it
is put in to automatic control mode at least for one hour. If the steam flow varies more than
20% better to keep it in manual mode till steady steam flow is ensured.
As the steam flow demand increases, required quantity of the fuel and airflow to be increased
to maintain the boiler outlet steam pressure (PT-1115).During initial firing and load up to
35%MCR, both the fuel and airflow to be controlled manually through the respective
controller(HIC-6001/6007/6013 ) ( HIC-4001/2/3/4).
Whenever the steam flow from the boiler is increased more than 35% of MCR switch over the
fuel flow controller in to auto mode along with the main steam pressure controller. Initially the
airflow to be controlled manually and once the opreration is stable the steam pressure controller
can be put into auto mode. On confirmation of satisfactory working of controller switch over the
air flow controller into automatic control mode along with the O2 trimming controller

While loading the boiler care to be taken that the feed and boiler water parameters to be
brought to the recommended limit before increasing the load beyond 50% of the MCR.
This boiler is not having a single button start operation. Manual interventions are
required in case of problems or abnormal situations such as sudden load change etc.
PRESSURE RISING CURVE

Hot Start Up
Restarting a boiler immediately after a trip when the boiler is still hot and with steam
pressure (PT-1003A/B/C) not less than around 65 kg/cm2 (g) is termed as Hot Start-
up. As the boiler was in service till the trip out, the required valve line up (as stated for the
cold start up) will be available and can be quickly checked by visual inspection. Hot restart
requires operations to be done fast, within the maximum permissible firing rates so as to
obtain quickly the required main steam pressure and temperature conditions. Boiler can be
pressurized to the rated pressure and temperature by using start up vent valve, and can be
connected to plant mains after achieving the rated parameters.
Following are the steps involved in the hot start-
up:
1. Normalize the steam drum level by modulating the feed water flow control valve
(100% -FCV-1001 OR 30% -LCV-1002).
2. Start the fuel firing.
3. As soon as the firing starts, open the Start up vent valve (MV-1006)
4. Once the f i r i n g is stabilized, increase the firing rate according to the
rate of pressurization specified in the pressurization curve.
5. Maintain the drum level (LT-1001/1002/1003).
6. Once rated pressure and temperature is reached connect the boiler to the main
header and close the start up vent( MV-1006).

Warm start up
Re-start of the boiler with steam pressure (PT-1003A/B/C) not less than 10-
kg/cm2(g) is termed as a warm start-up.
The preparations and valve line up required is as for HOT restart. However as the BOILER
has been idle for several hours, the valve line up requires to be verified.
Opening of Main steam line drains (V-0268/69/70/71), is required in warm start up.
These drain valve need to be closed when condense is drained completely at 5Kg/cm2(g).
The time taken for a warm start may be more than that hot start but less than that of a cold
start. Boiler can be pressurized to the rated pressure and temperature by using start up vent
valve (MV-1006), and can be connected to plant mains after achieving the rated
parameters.

Warm Start Up Curve

SUPER HEATER COIL PROTECTION DURING PRESSURE RISING
During boiler start-up, rate of fuel firing and furnace conditions changes frequently which may
resulting to wide variation in super heater steam temperature. During such situations if the
super heater temperature is not controlled within the safe limit (TIC-1006 520±5 0C), it may
leads to the premature failure of the coil due to over heating. Hence, care to be taken while
pressure rising to maintain the super heater steam temperature with in the safe limit by
adjusting the fuel feed rate and sufficient flow through the super heater coil.
To ensure cooling of super heater coil, it is mandatory to keep the start up vent valve (MV-
1006 ) full open till steady steam flow from the boiler is established through PRDS. If required,
firing may be reduced to maintain the temperature under control range.
Also fuel sizing and moisture to be analysed prior to start the boiler as the quality of fuel plays
an important role in super heater performance during start-up and operation. If fines are more
in fuel it may burn in free board and increase the super heater temperature. Hence, it is
recommended to maintain fuel quality as per the specification for smooth and trouble free start-
up and operation.
OPERATION
Fuels distribution
During first few days of operation, adjustment of Travagrate speed and spreader air pressure
may require to bring the firing system to its fullest efficiency.
For fuel spreading adjustment, system is provided with trajectory plate, air pressure control
dampers along with air modulating dampers.
Position of trajectory plate and air pressures setting depends on the fuel quality and firing
conditions. To throw the fuel towards the rear wall, trajectory plate is to be kept horizontal and
the air pressure to be adjusted so as the fuel spreading is beyond the grate centreline. Larger
particle and high moisture fuels require high pressure air for spreading, however the air
pressure to be reduced if the fuel is with low moisture and small size fibre.
During start up, there will be mouth feeding of fuel close to the front wall, as the furnace
temperature will be less during this period. Hence the fuel falling close to the front wall burning
will be slow and looks like mouth feeding, this pile will be burnt and cleared as the boiler load
increases; at times it may require to assist the fire by manual poking to clear the pile.
GRATE SPEED
Oil flow control valve located at the front of the hydraulic drive unit controls speed of the grate.
By tuning the control knob, counter clockwise from ‘0’ setting, the speed can be increased from
0 to 13.7mtrs/ hour maximum.
Quantity of fuel burnt and ash content of the fuel being fired determine the speed of the grate.
Travagrate under high loads, burning fuel with a high ash content will require an accelerated
grate speed to keep the ash bed level at an optimum height. Travagrate under lower loads,
burning fuel with low ash content will require slow grate speed.

Operator should adjust the drive speed accordingly, any adjustments should not be radical or
made in rapid succession. The time between changing a setting and the effects could be several
hours.
COMBUSTION AIR
For the complete combustion of fuel being fired, air is fed into the furnace from various
sections.
Primary air from FD fan through the Air per heater (APH), helps the combustion of fuel on the
grate. Air flow to be adjusted according to the quantity of fuel feeding and bed ash thickness.
The exact quantity of air requirements can be adjusted as per the excess air from the O2
measurement in flue gas and furnace conditions.
During start-up Air Pre Heater (APH) is by-passed from airside, to avoid gas condensation
because low gas temperature and tube corrosion. To maintain the APH tube metal temperature
air flow through the APH is to controlled by adjusting the dampers provided in the F.D fan to
APH (TV-9029 ) and APH by-pass (TV-9027) ducts. These dampers are to be adjusted to
maintain the gas temperature (TE-5005) at APH outlet at 140ºC.
Over fire from SA fan is fed to furnace at various elevations, provides turbulence, which
thoroughly mixes with volatile gases and fine fuels, thus assuring complete combustion.
Dampers at the individual elevation ducts are to be adjusted to maintain (TV-9030 & TV-
9028) the required air pressure to create good penetration into the furnace and vigorous air
turbulence above the grate.
SECONDARY AIR PRESSURE SETTING
Whenever the plant is stabilised and boiler loaded is around 35% MCR , adjust the
secondary air pressure at various levels, as per the enclosed chart and record the same for
future reference. Note that the air pressure at pneumatic spreader inlet is to adjusted according
to the quality of bagasse viz. moisture and fibber size. Spreading of bagasse depends on the
pressure at the spreader inlet and the position of trajectory plate. During plant commissioning
the quality of bagasse varies frequently, under such condition there is always a possibility of
chute jamming and mouth feeding of bagasse happens. To overcome such situations it is
advisable to keep little high pressure at pneumatic spreader inlet.

SECONDARY AIR PRESSURE SETTING CHART FOR BAGASSE FIRING
DAMPER OPENING %
250 to 350mmwc 250 to 350mmwc

TO CINDER
RECOVERY
SYSTEM

300 to 350 mmwc
300 to 350 mmwc
150 to 300mmwc
100-125mmwc
150 to 175mmwc
S.A
O/L PRESSURE = mmWC FAN
Damper OP% or Speed =

TYPICAL SECONDARY AIR PRESSURE

SETTING FOR COAL FIRING
Boiler front
TOP DUCT
200 to 250mmwc
TOP DUCT
200 to 250mmwc
CINDER FIRING
300 to 350mmwc
LOWER DUCT
100 to 150mmwc
FINE THROW NOZZLE

200 to 400mmwc
Note:- secondary air pressure setting chart is shown for reference point of view. The
secondary air pressure will be set at site during commissioning.
Pressure to be adjusted at site depends upon the fuel quality. When the fines are more in the
fuel, fine through air nozzle pressure is to be increased to throw the fuel far from front plate.
Pressure provided is for reference only, actual setting will be carried out at site depends on the

performance of fuel throw and firing performance.
TRAVAGRATE
Operation
In stoker firing, part of the fuel is burned in suspension and remaining on the grate. Fuel is
sprayed across the furnace by the series of fuel feeders with a uniform spreading action,
permitting suspension burning of the fine particles during travel. The larger pieces fall on the
grate for combustion, forming a thin fast burning fuel bed. This method of firing fuel provides
for extreme load fluctuation as ignition is almost instantaneous on increase of firing rate and
the thin fuel bed can be burned out rapidly when required. Specifically designed air - metering
grates for under grate air, over fire air system, to reduce carbon loss. Combustion controls are
furnished to coordinate fuel and air supply with load demand. The travelling grate has an
extraordinary ability to burn any type of fuel with a wide range of burning characteristics with
no limit on the ash content. An over fire air system is provided for successful suspension
burning. This air mixes with the furnace gases and creates the turbulence required to complete
combustion. To compensate for variation of the ash content in the fuel, the grate speed can be
adjusted up to 13.7mtrs/ hour. The ash is continuously discharged over the front end of the
grate into an ash hopper.
Travagrate is extremely sensitive to load fluctuations since ignition is almost instantaneous on

increase of firing rate and burn out of the thin fuel bed can be rapidly effected when desired.
The grates employ the basic design concepts of high resistance with air metering to avoid
blowholes through the thin bagasse pith bed. With pneumatic distribution feeding, fresh
bagasse pith is distributed uniformly over the surface of the burning fuel bed. It is ignited from
the fire bed beneath and burns upward. Thus the grates are always protected from high
temperature by a layer of ash.
Control of both the quantity and the distribution of combustion air are important and are
generally done with the help of the damper at the fan inlet or by varying the speed.
Speed control
To control the speed of the grate, it is equipped with a flow control valve, which is located at
the front of the drive. Turning its control knob anti clock wise increase the quantity of fluid
flowing into the cylinder, thus making the piston travel at the faster rate. Increasing the rate of
piston travel in turn increases speed of the grate. Turning the control knob clockwise will
decrease the oil-flow and speed of the grate
Capacity of the flow control valve and hydraulic system is such that the rotation of the drive
shaft can be adjusted up to 45 foot per hour. The speed at which the drive should operate will
depend on the amount of fuel being burned and its ash content.
ESP
Following care to be taken in ESP operation.

• Monitor the gas inlet temperature (TE-5005) during start up and low load operation, as the
ESP to be charged once the gas temperature is increased above 125ºC.
• During start up, ESP to be charged 4hrs after the flue gas temperature is reached 125ºC,
this is to avoid mild explosions due to the presence of “CO” in flue gas, as “CO” generation
is common during start up because of transient conditions.
• If the boiler operation is not stable, it is advised to switch off the transformer, but keep the
heater and rapping mechanism in operation.
• It is recommended to switch off the ESP Transformer, if the ESP ash handling system is not
in service.
• Ensure proper functioning of insulator heater, presence of moisture can cause cracking of
Insulator.
• Check and confirm the healthiness safety interlocks.
• Monitor the ESP gas outlet temperature (TE-5006).
• Verify the normal operation of purge air fan and cleanliness of the suction filter.
STEAM TEMPERATURE CONTROL

As the steam flow demand increases, the firing rate also increases which in turn rise the
temperature of flue gas at super heater inlet. With the higher firing rate, the super heater
steam temperature also increases considerably. To maintain the steam temperature to the
desired limit, boiler is provided with a spray type attemperator between the outlet of primary
super heater and inlet of secondary super heater headers. Water spray requirement is
controlled through the controller and the control valve (TCV-1001 & TCV-1109).
Steam temperature controller to be switched over to auto mode when the steam flow increased
to 35 % of MCR.
CHEMICAL DOSING SYSTEM

To maintain the feed and boiler water concentration, boiler is provided with HP & LP dosing
system.
Dosing system should be started as soon as the boiler operation is stable, so as the
recommended water limits can be achieved prior to load the boiler >50%MCR.
Dosing requirement to be decided as per the analysis of the samples collected from the sources.
At times the dosing may be stopped, during such situations, close the mixing tank outlet valve
and open the flushing line valve, operate the pump for 2 hrs. In this process, the chemically
concentrated water is replaced with the clear water; thus choking of piping can be avoided.
BLOW-DOWN SYSTEM
Dissolved and suspended solids entering into the boiler through feed water system remain in
the boiler, as steam is generated continuously. During steaming process the solids retain the
boiler which increase the concentration of boiler water gradually. There is a limit for the
concentration level of solids in the boiler water depends on the operating pressure, exceeding
the limit of Total Dissolved Solids (TDS) may produce undesirable foaming and carryover.
To control the concentration limit, part of the water is to be drained off, and replaced with fresh

water keeps the TDS level under control.
Blow down rate is determined by the TDS of the boiler water, blow-down may be controlled
either intermittently (IBD) or continuously (CBD).
Intermittent Blow-down (IBD)

Through this system blow-down is carried out intermittently to control the water concentration,
whenever the drum level increase above the safe limit, to control the level water can be drained
though this system.
IBD is tapped from water drum
Continuous Blow-down (CBD)

Through this system a small portion was water is drained from boiler continuously, depends on
the TDS level. Apart from maintain the concentration level, the heat from the drain is recovered
as the flash steam from CBC tank is connected to the deaerator. Along with heat a portion of
water also saved from CBD.
AIR PRE-HEATER
Air pre heater provided is of tubular type and the purpose is to recover a portion of the sensible
heat from flue gases thereby improving combustion efficiency. The arrangement consists of
tubes set vertically in a surrounding ductwork. The ends of the tubes are expanded into the
supporting tube sheets. The flue gas passes through the tubes while the incoming air for
heating passes from the out side of the tubes.
SOURCES OF TROUBLES AND PREVENTION
Fouling
Tubular heater elements are susceptible to fouling due to fly ash accumulation, particularly at
the air inlet to the heater and near the exit of gas from Air Pre Heater.
Dust build up on the gas side of the tubes can be detected by observing the following
conditions.
♦ Increased draft loss across the heater.

♦ Increased gas temperature leaving the heater.
♦ Decreased air temperature at the APH outlet can often be prevented or minimized.
Fouling can be prevented or minimized by proper operation of firing equipment and maintaining
APH tube metal temperature above the gas dew point limit. To minimise the dust deposit, APH
is provided with air By-pass arrangement. As there will be gas condensation inside the tubes,
during boiler start up due to low back-end gas temperature. Hence during start up the by pass
damper to be kept open 100% open and the inlet damper to be kept closed. Opening of these
dampers to be adjusted in such a way to maintain the gas outlet of APH at 140ºC

Corrosion
When fly ash deposited in the gas path of cold end tubes, they often form a hard bonded
material that acts as insulation. This insulation lowers the tube metal temperature until it
approaches the incoming air temperature. This temperature is usually below the dew point of
the flue gas, acid constituents within the ash, which become corrosive in the presence of
moisture. Conditions causing corrosion can be minimized by keeping the tube surface free of
deposits through proper combustion and by maintaining safe flue gas temp. i.e. 145ºC at APH
exit.
Fires
Tubular air-heater can be damaged or go out of shape by fires occurring in the gas passes.
Generally these fires are caused by the deposition of large quantities of unburned combustible
materials within tubes and on the tube sheets. Unbound fly ash may be deposited on the tube
surface during initial start up and on abrupt changes of firing rate, may ignite this deposits
leading to damage of the tubes.
APH fire is indicated by a very rapid increase in temperature of gas or air flowing from the APH.
If this occurs, following steps should be taken.
♦ Discontinue firing immediately.

♦ Shut down all fans & dampers.
♦ Floor area of fire with CO2 or suitable fire extinguisher.
Ensuring complete combustion of fuel can prevent APH fires.
DEAERATOR
Start Up
It is recommended to charge the steam to the Deaerator as soon the LP steam is made
available, if the steam charging is done at boiler load conditions may cause thermal shock and
water hammering due to imbalance in steam and water flow till the stabilization of Deaerator.
Procedure for placing the Deaerator in to service is as below:

Open the vent valve on the vapour tank(V-0022)
Open the Deaerator level control valve and fill up the Deaerator up to normal operating
level.
Check and ensure the water level indication is matching with the direct level gauge (LT-
7001 & LT-7002) (LG-7001/7002/7003).
Open the drains in the steam to Deaerator pipeline and ensure the removal of
condensate if any.
Open the pegging steam pipeline valve (V-0017) gradually and admit steam to the
Deaerator. Whenever the water temperature (TE-7002) rise above 60°C, open the
Deaerator pressure control valve (PCV-7002) gradually, till steam starts flowing out
from the vapour tank. Adjust the valve opening to maintain the steam pressure (PT-
7002A) as per the requirement.

During initial steam admission, it is recommended to control the feed water entry to
Deaerator, so as to maintain the balance in steam and water flow to avoid condensation
and water hammering.
Steam and water flow to be increased simultaneously and appropriately to avoid thermal
shock.
It also recommended to switch over the pressure and level control to auto mode as soon
the Deaerator pressure is achieved (PCV-7002A & LIC-7001)
Operation
During the normal operation, vent valve should be closed as the required volume of
steam will be vented out through the by-pass line with orifice. Also the pegging line
isolation valve is kept in closed position whenever the Deaerator pressure is stable. It
also recommended monitoring the steam supply pressure and Deaerator operating
pressure to maintain required outlet water temperature.
Shutting Down
To isolate the Deaerator from service;
Close the steam to the Deaerator (PCV-7002 & V-0013)
Open the vapour tank vent valve (V-0022)
Open the drain valves in the steam pipeline (V-0012)
Maintain water level as required (LT-7002).
SOOT BLOWER
Soot blower operation is depend on fuel type, steam flow, steam temperature and boiler
arrangement. In general, frequency of cleaning may be determined by observing flue gas exit
temperatures raised from the boiler, economiser, air heaters, draft loss across the flue gas
system and steam outlet temperature. It may be more economical on the other hand to operate
soot blowers as required rather than to adopt a fixed blowing schedule.
Based on surface cleaning requirements appropriate no’s of Soot blowers Retractable / Rotary
Are provided in Boiler, Economiser & APH Section.
Soot blowing system is provided with a manual start up arrangement. Hence, during start up
and normal/ operation, the soot blower control should be kept off or in manual mode along with
the steam pressure control (PCV-1002). Soot blower panel to be switched on and put into
auto timer operation mode along with the steam pressure controller in auto mode, during soot
blowing. It is recommended to operate soot blowers, whenever the steam flow from the boiler
crosses 60% (FE-1002).
While operating the soot blower, Prior to start up, furnace draft should be increased
considerably to ensure sufficient draft to carry soot through the boiler. Secondly, open soot
blower steam piping drain valve (MV-1008/1009/1010) and steam trap valves. Keep the
steam pressure control valve in auto mode and open the main steam valve (MV-1007) & keep
the drain open till all the condensed water is removed from the piping. Once the steam
temperature (TE-1004) reaches to the specified limit operate the blowers as per the order

specified. On completion of blowing cycle main valve to be closed and the drain valve to be kept
open to remove the condensate. Also the furnace pressure control to be made normal.
STEAM WATER ANALYSIS SYSTEM (SWAS)
To monitor the steam, boiler water and feed water parameters like pH, conductivity and
silica system id provided with a SWA. Based on the analysis corrective action like chemical
dosing and blowdown quantity can be decided.
Start-up: Open the cooling water to SWAS. Keep the drain valve in open position. Open the
sample isolation valves gradually and flush the piping till the dirt and sediments if any are
removed so as to ensure a clean sample with out any contamination.
After flushing, adjust the required sample flow rate and observe the temperature of the sample.
On confirming temperature of the sample, collect the sample.
During operation, periodically check the sample quantity and temperature. Also the quality of
the cooling water to be monitored so as to avoid fouling and damages to the cooler coil.
Shutdown: Whenever the system needs to be shutdown, stop the sample first and run the
cooling water for 30 minutes to cool the coil and keep the drain valve in open position to drain
the sample trapped in between the system.
SCAPH (Steam Coil Air Pre Heater )
As soon as steam is made available for SCAPH, steam inlet line to be lined up by keeping
TCV is closed condition (TCV-1221/1222), Both upstream and down stream isolation
valve of control valve is to be kept in open condition. Bypass isolation valve of control valve
(V-0419/0423) is to be kept in closed condition. Condensate return line isolation valve is
to be kept open.
Slowly open (TCV-1221/1222) and allow steam to SCAPH. Observe (TE-1221 & TE-
1222) for air temperature raise at outlet of SCAPH. The SCAPH Condensate water is
recovered by Condensing Tank and it is connected with de-aerator.
Closely monitor air temperature rise and simultaneously control valve opening may be varied
to get the desired air temperature.
After that final air temperature can be controlled by putting in auto mode which takes input
signal from TIC (TIC-1221/22 ).

WALK DOWN CHECK LIST DURING OPERATION
♦ Check for unusual noises from steam/water leakage.

♦ Check for unusual traces of water on floor, buck stay or leakage from casing joints.
♦ Look for valve and gland leakage.
♦ Discoloration, hot spots and bulging etc. on casing, ducts and hoppers.
♦ Check for steam and water leaks from connections and fittings to the drum.
♦ Watch the furnace for any clinker formation and bagasse pile up. If possible inspect the
slagging condition of furnace walls and super heater coils through the observation ports.
♦ Walk around the furnace exterior and observe for any hot spots or gas leaks.
♦ Listen for any unusual noise around economiser which may indicate economiser leak
(i.e. hissing noise)
♦ Inspect penthouse for gas leakage.
♦ Inspect wind-box/plenum hopper for any air leakage, signs of overheating that may
indicate wind-box fires or hot gas re-circulation within the wind-box.
♦ Inspect all ash hoppers to make sure they are being emptied properly,
♦ Check around all air/flue ducts for signs of leakage.
♦ Check position of fan and field dampers.
♦ Check for any gas leakage from refractory sealing.
♦ Check for leakage from safety valves at normal operating pressure. Also note the safety
valve blow off and shut off pressure. Check that the drain lines and drip pans are not
plugged.
♦ Make note of any leaky valves and prepare maintenance schedule to repair them.
♦ Check to see that proper water level is being shown by the direct water level gauge.
Check for water or steam leaks from ports or drain connections, which will cause a false
water level in the gauge glass. Inspect the glass for discoloration or fouling.
♦ While doing routine operation of soot blowing, inspect for condensate, steam and leaks
from the soot blowers.

NORMAL SHUTDOWN PROCEDURE

For known reasons if the boiler is to be stopped for few hours or few days, it is suggested to
follow the following procedures.
If the shut down is only for few hours, it is not recommended to cool the furnace.
If the shut down is for few days, it is recommended to cool the furnace.
SHUT DOWN PROCEDURES - LONG DURATION

♦ Reduce boiler load at the rate established by the turbine or as per process
requirements until the minimum load point.
♦ Reduce the steam flow by reducing the fuel feed rate and combustion airflow
(primary).
♦ In either manual or automatic operation, the airflow follows the fuel flow on decreasing
load.
♦ On confirming the zero demand of steam from boiler stop the fuel feeders, and close
the main steam stop valve. Open the start-up vent valve till the boiler pressure drops to
85% of the operating pressure. And keep the boiler in hot banking for natural cooling.
♦ Stop the boiler by shutting off the fuel feed systems as follows:
Close the gate below fuell bunker outlet above each feeder.
Empty out the fuel feeders and stop the same.
Keep the airflow to furnace till the all the remains over the great is cleared off.
Continuously run the Travagrate to dump all the remains over the grate surface.
♦ When the flue gas temperature (TE-5005) drops below 125˙C remove the ESP from
the service but keep the raping and heating system into service. Also the ash handling
system into service for 4 to 6 hrs after switching of the I.D. fan.
♦ Keep the cooling water flow to the water cooled equipment till the body temperature
drops to <50˙C.
♦ Once the drum pressure (PT-1001A/B) drops to 2Kg/cm2 (g) open the drum air vent
valve.
♦ If the unit is to be shut for a short period, NO PERSONNEL WILL BE ADMITTED TO

THE BOILER. If the operating personnel need to enter the unit, the boiler,
economiser, air heater hoppers, and the ash collection equipment hoppers (ESP) must

be emptied of any solids and the enclosure temperature cooled below 50°C.
♦ All ash must be removed completely from the boiler and hopper and the boiler
temperature must be below 50°c before personal are allowed to enter for maintenance
or inspection.
♦ Shut down all the auxiliary equipment at this time. This will include the feed water
system, make-up system, ash removal systems, etc.
♦ It is recommended that a positive pressure of nitrogen be maintained in the drainable

components anytime the unit is out of service, whether the boiler is filled with or without
water, for longer than two weeks. A nitrogen blanket should be maintained through a “T”
fitting on the drum vent.
SHUTDOWN PROCEDURES - SHORT DURATION

There may be situations the boiler may be kept under shutdown for small duration’s for
some work outside the boiler plant or may be due to the failure of some auxiliary
equipments. During such situations the following procedure may be followed,
♦ Reduce the steam flow gradually and stop the steam outlet to the downstream
equipments.
♦ Stop the fuel feeding also stop the travagrate so as to keep some heat inventory to
restart.
♦ Stop the S.A, F.D and I.D fans.
♦ Maintain the drum water level.
♦ Boiler can be restarted with out any external assistance if it is restarted with in 4hrs
time from shutdown, otherwise to retain the furnace temperature, firewood may be
charged at regular intervals. The quantity wood firing may be controlled so as to avoid
considerable amount of pressure raise.
If the boiler needs to be kept under shut for overnight it can be kept hot by intermittent
firing of coal or by manual charging of firewood.
EMERGENCY SHUTDOWN PROCEDURES
TYPES OF EMERGENCY SITUATIONS

The critical emergency situation in boiler plant is, low water situations, which directly affect the
boiler pressure parts.
EMERGENCY RESPONSE ACTIONS AND PRIORITIES

Following are the required actions to be taken in response to the above emergency situations
to ensure protection of the boiler pressure parts.

Loss of feed water supply.
Start the stand-by boiler feed pump to restore the feed water supply to the boiler. If the feed
water pump could not be started immediately, the following actions should be taken:
♦ Fuel feeder, F.D and S.A fan will trip automatically though the drum level very low interlock
(level switch/transmitter). It is mandatory to shut the unit down completely till BFP system
is available.
♦ Stop all the steam and water outlet from the boiler. If required establish steam flow
through the super heaters through start up vent (PCV-1001) immediately after tripping
to protect steam cooled section from overheating. Though there is loss of water due to
venting through startup vent valve; controlled venting of small amount of steam may
reduce pressure rise and prevent lifting of safety valves to the large extent.
♦ If loss of feedwater is due to a power failure, start the emergency generator or switch over
to alternate power source to restore the drum level.The goal is to maintain safe water
level; if not in the normal operation range, at least up to the minimum visibility of drum
direct level gauge glass (LG-1001/1002). The target is to restore a water feed to the
drum within 5 to 7 minutes of the trip.

Boiler De-Pressurising Curve
Note: Refer above curve for Boiler Force Cooling Depressurisation only.
Failure of draft system

When the draft system fails, the boiler unit comes to a forced shut down, during such
emergencies, the fuel feeder will trip through the F.D fan running interlock to start the DCF.
During such situations maintain water level in the drum as the feed water pumping system is
available.
As soon the draft system is ready for operation, switch the fan controls to manual mode and start
the ID fan. Followed with F.D and S.A fan.

DO’S AND DON’T S FOR BOILER
DO’S
• Clean the internals before closing the manholes of pressure parts furnace and ducting.
• During Economizer bypass care should be taken that economizer tube is filled with Feed
water.
• Maintain all instruments in good working condition.
• Equipment safety interlocks should be always in line.
• Maintain normal water level in boiler.
• Maintain water quality as per the recommended limits.
• All the control and isolation dampers must be in smooth operating condition.
• Maintain hydraulic drive oil pump pressure as per the recommended set pressure.
• Pressure raising from cold start must be done as per the cold start up curve.
• Use proper lubricants recommended by the manufacturer schedule.
• Start the equipment as per start-up sequence
• Carry out regular soot blowing for boiler and economiser.
• Operate the boiler within the recommended operation limits.
• Boiler, Piping, Ducts, Feed water and Oil tank must be properly insulated.
• Equipments maintenance should be done as per the manufacturer’s schedule.
• Maintain operation log sheets regularly.
• Maintain the instrument air free from moisture and oil matters and the pressure as
recommended.
• Use proper valve gland packing to avoid leakage.
• Use proper gaskets for flange joints.
• Boiler surroundings and equipments must be properly illuminated.

• In case of power failure close the steam stop valve and stop the fire immediately.
• Use genuine spares.
Before starting rotary equipment’s ensure the following.
ID Fan
• Ensure flue path duct and hopper manholes are closed.
• Close the fan suction and discharge damper fully.
• Verify bearing lubrication.
FD Fan
• ID Fan in running condition

• Close the fan suction damper
SA Fan
• ID, FD Fan in running condition

• Close the fan suction damper
DON’TS
• Don’t by pass any instruments and safety interlocks.
• Don’t use raw water as Boiler feed water.
• Don’t throw big size wooden logs inside the furnace for slow firing.
• Don’t run the Boiler with furnace in pressurized condition.
• Don’t increase the set pressure of the TRAVAGRATE hydraulic oil pressure beyond the
recommended limit.
• Don’t allow super heater steam temp. to go beyond the designed limits.
• Don’t operate the furnace wall header drain valves while the Boiler is in operation.
• Don’t operate the boiler beyond the operation limits.
• Don’t leave the furnace door open while the boiler is in operation.
• Don’t mix up different lubricants.
• Don’t by pass compressed air, dryer, if any problem attend to it at the earliest.

• Don’t throw water inside the hot furnace.
• Avoid continuous operation of boiler at low loads (low back-end temperature) to protect
Economiser, ESP and Air Pre-Heater corrosion.
• Do not dose chemicals into the boiler in batch wise, they should be done on a continuous
basis.
• Do not open any of the ESP manholes, while the I.D. Fans in operation.
• Do not charge the ESP at lower flue gas temperature (>120º C)

Filosofia Standard Operacion Caldera Thermax

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Filosofia Standard Operacion Caldera Thermax

Hochgeladen von

Copyright:

Verfügbare Formate

CLIENTE/CLIENT CONTRATISTA PRINCIPAL/MAIN CONTRACTOR

APCC SAN PEDRO BIOENERGY EYRA INTERNACIONAL

APROBADO / APPROVED (APR).

Incorporar comentarios y reenviar documento, el

RECHAZADO. VER COMENTARIOS / REJECTED. SEE COMMENTS (REJ). COGENERATION FACILITY

Date: 2015.06.16 15:54:20 +02'00'

Fecha/Date: Firma/Signature: TÍTULO DEL DOCUMENTO/DOCUMENT TITLE:

STANDARD OPERATING PHILOSOPHY

ANSWER TO Thermax reply to comments on V-SPB1-CO-0001-PRO-2002_comAITE FROM 6 MAY ARE PENDING

STANDARD OPERATING PROCEDURE

1 x 140TPH TRAVGRATE BOILER

PROJECT: EYRA INTERNACIONAL

THERMAX JOB NO.: PB 1301

Operation Philosophy Page 1

PREPARED BY REVIEWED BY APPROVED BY

Note: - This is a Computer generated document and hence require no Signature.

Operation Philosophy Page 2

WATER FILLING ............................................................................. 9

Operation Philosophy Page 3

SOURCES OF TROUBLES AND PREVENTION ................................. 25

Operation Philosophy Page 4

Operation Philosophy Page 5

Operation Philosophy Page 6

Following valves to be kept in open position:

Following valves are to be kept in closed position:

Operation Philosophy Page 7

B. Field dampers are to be kept open/close as per the following instruction:

Keep the ID fan inlet/outlet damper (PCV-5001/5002 & UV-9021/9022) open.

C. Verify the readiness of following equipment’s:

D. Verify the readiness of following instruments:

E. Switch over the following controls in manual mode;

Operation Philosophy Page 8

Fuel flow (HIC-6001 , HIC-6007 & HIC-6013)

Following Valve keep in close position

Operation Philosophy Page 9

Following Valve keep in close position

Operation Philosophy Page 10

Tg1= Flue Gas Temperature at Economiser-1 Inlet

Operation Philosophy Page 11

Operation Philosophy Page 12

Operation Philosophy Page 13

Operation Philosophy Page 14

PRESSURE RISING CURVE

Operation Philosophy Page 15

Operation Philosophy Page 16

Operation Philosophy Page 17

Warm Start Up Curve

Operation Philosophy Page 18

SUPER HEATER COIL PROTECTION DURING PRESSURE RISING

Operation Philosophy Page 19

SECONDARY AIR PRESSURE SETTING

Operation Philosophy Page 20

SECONDARY AIR PRESSURE SETTING CHART FOR BAGASSE FIRING

250 to 350mmwc 250 to 350mmwc

250 to 350mmwc 250 to 350mmwc

200 to 250mmwc 200 to 250mmwc

300 to 350 mmwc

Operation Philosophy Page 21

TYPICAL SECONDARY AIR PRESSURE

FINE THROW NOZZLE

Operation Philosophy Page 22

performance of fuel throw and firing performance.

Travagrate is extremely sensitive to load fluctuations since ignition is almost instantaneous on