BOILER OPERATION

OBJECTIVES
Production of steam at desired
parameters and purity
Protection of pressure parts from
corrosion, overheating, thermal
stresses etc
Prevention of furnace explosions

BOILER OPERATION
DIFFERENT PHASES
START UP PROCEDURES

Cold start
Hot start
CARE DURING NORMAL RUNNING

Load changes
Routine checks
OPERATION UNDER ABNORMAL CONDITIONS
SHUTDOWN PROCEDURES

To cold
To hot stand by

BOILER COLD START

MAJOR ACTIVITIES
Pre checks
Boiler filling
Starting draught system
Charging steam to scaph
Boiler purging
Light up with oil (L.D.O.)
Switching over to H.F.O.firing
Raising the parameters
Switching over to P.F. firing
Loading the boiler

PRE CHECKS FOR BOILER

LIGHTUP

CHECK AND ENSURE THAT

All systems to be started are free
from man and material and all work
permits/line clears are returned.
Local drum level indicator is in
service.
Furnace temperature probe is
available for service
All soot blowers are in retracted
condition
Safety valves gags/test plugs are
removed.

PRE CHECKS FOR BOILER

LIGHTUP

CHECK AND ENSURE THAT

Impulse safety valve/e.m.r. valve is in
service position and its isolating valve
is open.
All drives of valves and dampers are in
perfect condition and operetable from
control desk.
All control and interlock circuits are in
healthy condition.
Bottom ash hopper and seal trough are
filled with water and adequate water
supply is available

PRE CHECKS FOR BOILER

LIGHTUP

CHECK AND ENSURE THAT

All ash hoppers are emptied and E.S.P.is
cleaned and ready for operation.
All sy.air dampers and burner tilt are freely
operating and burner tilt is in horizontal
position.
All oil guns and spark plug assemblies are
cleaned.
All boiler,super heater,re heater drains and
vents are in start up position.

PRE CHECKS FOR BOILER

LIGHTUP
CHECK AND ENSURE THAT
All de super heater spray control
valves are in closed condition and
available for service.
Fire fighting system is ready.
Adequate fuel oil quantity is
stored.
Raw coal bunkers are filled.
D.M. water tank is filled.

PRE CHECKS FOR BOILER

LIGHTUP
CHECK AND ENSURE THAT
Bearing cooling water system is
started.
Compressed air from instrument
air and service air compressors
are available and air pressures are
adequate.

BOILER FILLING
All vent valves on feed line,
economiser,drum,headers and
m.s.line are kept open.
All drain and blow down valves are
kept closed.
Do not fill the water above the
boiling point.
Do not fill with excessive cold water.
If possible fill with water 100c above
boiler metal to avoid temp. stresses

BOILER FILLING
Open and close gauge glass cocks
and drains on the water column to
make sure that these connections
are unobstructed and free.
Fill till free jet of water comes out
through economiser vent and drum
vents.
Bring down level in drum to normal
by draining after closing
economiser vent.

STARTING DRAUGHT
SYSTEM

Lineup lub.oil system of all fans and air

heaters and take them into service
Lineup flue gas path
Lineup air path
Start air heater A
Start air heater B
Start one I.D. fan
Start corresponding F.D. fan
Raise load on I.D.&F.D. to maintain 30%
of full load air flow through Boiler and
necessary furnace draught
Start scanner air fan
Draught system ready for light up

STARTING DRAUGHT SYSTEM

LINE UP FLUEGAS PATH

Ensure all man hole doors
are closed
Ensure ESP hoppers are
sealed
Ensure sufficient flow
through furnace water seal
Establish power supply to all
flue gas path dampers
Establish power supply to all
flue gas path instruments
Close suction and discharge
dampers of both I.D.fans
Keep I.D.fan control devices
in minimum position
Keep open flue gas inlet and
outlet dampers to both air
heaters

LINEUP AIR PATH

Ensure all air path man
hole doors are closed
Establish power supply
to all air path dampers
Establish power supply
to all air path
instruments
Close discharge
dampers of both
F.D.fans
Keep F.D.fan control
devices in minimum
position
Keep open sy.air inlet
and outlet dampers to
both air heaters

STARTING AIR HEATERS

Check support bearing and guide bearing
lub. oil systems are in service.
Check air and flue gas paths are lined up.
Check air heater water wash lines are
closed.
Check service air supply to air heater is
available.
Establish electric supply to air heater
motor.
Start the motor.
Observe whether motor current is normal.
Observe for rubbing/abnormal noise at
local.
Open water inlet and outlet valves in lub.
oil systems.
Start second air heater as above

BOILER PURGING
CHECK THE FOLLOWING PURGE PERMISSIVES
ARE SATISFIED

A.C.& D.C.power supply to F.S.S.S.is available

Drum level is normal.
Atleast one I.D.fan and one F.D.fan are in service
Minimum 30% of full load airflow is maintained.
All oil trip valves and nozzle valves are proven closed
All auxiliary air dampers are modulating to maintain
adequate windbox to furnace differential pressure
All pulverisers and feeders are off
All hot air gates are closed and cold air dampers are
less than 5% open.
All flame scanners sense no flame.
No boiler trip command is present

BOILER PURGING
Satisfy purge
permissives
Give purge start
command
Purge on
indicationcomes
Purge complete
indication comes

LIGHTOIL FIRING
Open ignitor oil trip
valve
Open light oil trip
valve
Select light oil firing
in AB elevation
Ensure elevation
permissives
Start one pair of oil
guns
Start second pair of
oil guns
Check 3 out of 4 L.O.
guns are proven on
in timed sequence

ON LIGHTUP WITH LIGHT OIL

Ensure adequate light oil / atomising air
pressure
Check boiler expansion is free
Control firing rate in such away that
steaming starts only after 45 minutes
Keep economiser re circulation valve open
When drum pressure reaches 2 kg/cm2close
drum vents
Control firing rate according to start up
curve and FOT not exceeding 5400c
Start closing S.H. vents and drains except
start up vent
Increase steam pressure
Warm up main steam lines

HEAVY OIL FIRING

Ensure auxiliary steam lines are charged
Ensure atomising steam lines are charged
Ensure H.O.system is started through re
circulation
SCAPHcorresponding to F.D.in service is
charged
Open H.O. trip valve
Ensure CD elevation permissives
Start one pair of CD elevation guns
Start second pair
Ensure minimum 3 out of 4 corners are
proven on
Change over to H.O. firing in AB elevation

HEAVY OIL FIRING

Control firing rate as per start up curve

Close R.H.vents and drains
Pull vacuum in condenser
Take HP/LP by pass into service
Close start up vent
Maintain drum level by intermittently
feeding
Start feeding through low load FCV if drum
level continue to recede
Close economiser re circulation valve
Monitor boiler expansion
Ensure F.G. temp. after A.H.above acid dew
point by regulating steam to SCAPH
Raise steam to rolling parameters
Turbine rolled,synchronised

DRAIN

TO
S.H.ATTEMPERATION

DRAIN

TO
S.H.ATTEMPERATION

F.C.V.

DRAIN

DRAIN

FEED WATER FROM

TO

H.P.HEATER

ECO
.

DRAIN

DRAIN

DRAIN

DRAIN

FEED REGULATING
STATION

DRAIN

PREPARATION FOR COAL

FIRING
Check boiler water quality
Maintain boiler water pH through
phosphate dozing
Ensure silica level and TDS are in
permissible levels
Start scrapper conveyor and slag crusher
Check E.S.P. rapping mechanism in
service
Start one P.A.fan
Start seal air fan
Keep S.H/R.H spray control system ready

STARTING COAL FIRING

Ensure mill ready permissives for mill A

Make ignition energy availableto mill A
Start mill A
Open hot air gate
Start R.C.feeder A
Increase feeder speed gradually
Maintain drum level
Maintain furnace draught
Switch on E.S.P.hopper heaters
Control firing rate according to start up
curve

STARTING COAL FIRING

Prepare for starting mill B when first mill
is loaded to 50%
Start mill B in same way as mill A
Start R.C.feeder B and equalise loading in
both feeders
Control firing rate by reducing oil firing
rate
Change over to 100% F.C.V. when low load
feed control valve is more than 80% open
Increase air flow proportional to boiler
load when load crosses 30%
Control S.H. temp.by attemperation and
R.H.temp.by burner tilting
Gradually increase boiler load

WHEN BOILER LOAD APPROCHES

50%

Start second I.D.fan

Equalise loading on both i.d.fans
Start second F.D.fan
Equalise loading on both F.D.fans
Take SCAPH of second F.D.into service
Ensure adequate wind box to furnace
differential pressure is maintained
Start second P.A.fan
Equalise load on both P.A.fans

GOING TO FULL LOAD

Start third mill when first two mills are
loaded to 80%
Start third R.C.feeder
Equalise loading on all three mills
Start fourth mill when first three mills
are loaded to 80%
Start fourth R.C.feeder
Equalise loading on all four mills
Increase boiler loading to full load

ON NEARING FULL LOAD

Feed control valve can be put on auto

S.H/R.H steam temp. control on auto
Furnace draught control on auto
E.S.P. fields are charged
Oil firing can be stopped when boiler load
is more than 6o% and more than two
mills are in service at minimum 50%
loading and atleast two adjacent mills
are in service
Steam to SCAPH s cut off when flue gas
outlet temperature more than 1500c

ROUTINE CHECKS
Make a round of boiler to inspect
Flame condition/ stability
Pressure parts for leakage
Leakage in air/flue gas paths
Running auxiliaries for abnormal noise
vibration,high bearing temp. etc.
Maintain hourly log. Identify deviations
and take corrective actions

ROUTINE CHECKS
Compare unit operating parameters with
predicted readings.Any deviation should
be reasoned and corrected
Compare local instruments reading with
remote instruments once a day.Any
discrepancy to be corrected
Maintain feed water,steam quality
Ensure flow of sampling water is
maintained
Analyse F.G. through orsat apparatus
once a day
Check fineness of p.f.

ROUTINE CHECKS
Check pr.drop of F.G.,feed water temp before
and after economiser, steam temp at various
stages of S.H., metal temp. of S.H. and R.H.
Carry out soot blowing as and when required
Carry out soot blowing of A.H. once in a shift
Ensure no choking in bunkers
Maintain mill parameters
Empty the bunker if the mill is taken for long
shut down
Ensure satisfactory operation of slag
conveyors slag crushers,fly ash system

ROUTINE CHECKS

Control R.H. temp. by burner tilt

Load pulverisers only to 80%
Keep clean ignitor spark plugs,atomisers.
Maintain H.O.and atomising steam
temp.and pr.
Parallel running fans are loaded equally
Change over to stand by equipment of
following aux. once a week

Seal air fan

Hydrazine pump
Coal mills
Lub.oil pumps

BOILER SHUT DOWN

PROCEDURE
Reversal of light up procedure
Take all controls on manual mode
By pass Turbine trip on Temp.
protection
Reduce speed of running R.C feeders
gradually
Ensure the firing rate is decreased in
such a way that the rate of saturated
steam temp drop at boiler drum is not
exceeding the limits prescribed in the
shut down curve (830 C per Hr ) all
the time till the boiler is shut down

BOILER SHUT DOWN

PROCEDURE
Maintain drum level and furnace
draught
Take oil support at the adjacent
elevation to the top coal elevation in
service
Trip the top elevation R.C.feeder when
its speed nears to minimum
Share the load on other feeders
Run the mill corresponding to the
feeder tripped for some more time till
it is cleared of coal
Stop the mill and isolate it

BOILER SHUT DOWN

PROCEDURE
Reduce load further by reducing
speed of feeders, tripping the
feeder after taking oil support etc.
When the load drops below 50%
stop one F.D.fan, one I.D.fan
Ensure the tripped fans suction and
discharge dampers are fully closed
Reduce load further by reducing
speed of feeders, tripping the
feeder after taking oil support etc

BOILER SHUT DOWN

PROCEDURE
When the load drops below 30%
Change over to low load feed control valve
Ensure the wind box to furnace Diff. Pr. is
changed to low set point
Maintain air flow to the boiler at 30 to
40% of full load air flow on further
reduction of load

On further reduction of firing rate in

the above manner at one stage the
boiler will be running only with oil
guns

BOILER SHUT DOWN

PROCEDURE
When the load drops below 10%
trip the boiler through protection
Ensure all the oil valves are fully
closed
Carry out boiler purging
Do not stop the air heaters till the
gas inlet temperature drops to
1000C
Carry out cooling of the boiler on
the method desired

COOLING THE BOILER

ON SHUT DOWN
METHODS OF COOLING
NATURAL COOLING
FORCED COOLING
BOX UP

BOILER IS COOLED
Internally
Externally
By Radiation

NATURAL COOLING
On tripping of the boiler bring the
drum level to very high level and
stop feeding
After purging stop F.D.and I.D.fans
All the dampers in air and flue gas
path remain in open position
Start up vent in open position
Internal cooling takes place due to
circulation of water inside tubes
Top up water in drum when the
level recedes

NATURAL COOLING
External cooling takes place by
the air flow due to natural
draught effect which is at a slow
rate
Also cooled by radiation
When the pressure drops to
5kg/cm2 open the S.H.,R.H. vents
When the pressure drops to
2kg/cm2 open the drum vents
Natural cooling will take more
time

FORCED COOLING
On tripping of the boiler bring
the drum level to very high
level and stop feeding
After purging do not stop
F.D.and I.D.fans
Adjust air flow according to the
cooling rate desired
Ensure the saturated steam
temperature drop is not more
than 830C per hour

FORCED COOLING
Start up vent in open position
Internal cooling takes place
due to circulation of water
inside tubes
Top up water in drum when the
level recedes
External cooling takes place by
the air flow at a faster rate
according to air flow rate
Also cooled by radiation

FORCED COOLING
When the pressure drops to
5kg/cm2 open the S.H.,R.H.vents
When the pressure drops to
2kg/cm2 open the drum vents
Boiler will be cooled at a faster
rate in forced cooling
Not healthy for boiler as it
induces stresses in boiler tubes
Used only in emergencies

BOX UP
On tripping of the boiler bring the
drum level to very high level and stop
feeding
After purging stop F.D.and I.D.fans
Keep all the vents and drains
including start up vent in closed
condition
As such there will not be any circulation
and so no internal cooling

Keep all dampers in air and flue gas

path in closed condition
As such there will not be any air flow
through boiler and so no external cooling

BOX UP
Cooling can be only through
radiation
Heat inside the boiler can be
retained for more time
Adopted for keeping the boiler
ready for hot start up on shut
down