LIGHT-UP

Boiler filling
1. Close all drains except SH header drains.
2. Open all vents (drum, economizer, superheater)
3. Open ERVs & Eco. Inlet valve (E2)
4. Open DM-1& 2 (ELP to boiler drum)
5. Check the valve position of MS-11,12 ( Always keep them open unless
otherwise demanded for PRDS / TM-II. Check the hanger position of the
main steam line before & after hydraulic test .These should be released
in normal condition.
6. Ensure main isolating valves of soot blowing line is closed, & drains are
open.
7. Fill the boiler through low load line upto three ports, inform to chemist.
8. All vents including reheaters should be open.
9. S/H drains should be open. Economiser vents should be closed.
10. Bottom header drains should be closed.

BOILER LIGHTED
1 Check that sealing truff is cleaned & fill it with water & ensure the
overflow.
2 Inspect the bottom ash hoppers & fill the hopper till its overflow.
3 Take refractory cooling in service.
4 Start AH,ID & FD
1. Maintain 30 % air flow of total air flow & 5 to 10 mm WCL furnace
draft.( Air pressure shall not be more than 40 %)
2. Put sy. Air dampers control system on AUTO & check that aux. air
dampers are modulating to maintain 35-40 mm of WCL wind box to
furnace diff pressure.
5 Keep BT horizontal.
6 Check scanner fan header pr. is 400 mm of WC
7 Keep EBD open during warm up
8 1. Initiate a furnace purge.
2. Complete furnace purging. Light up the boiler on LDO. Firing rate
should be controlled to keep the furnace exit gas temp below
5380C.Incrase the firing rate as required to raise pressure.Take care
not to exceed the furnace exit gas temp limit of 538 0C.
3. Fuel air & auxi. Air supply of oil guns :-When oil guns are in service, the
sec. air dampers function as fuel air & operates as per oil pr., when oil
gun are removed out of service, the sec. air dampers starts functioning
as aux. air dampers & it is controlled by wind box pr. controller.
9 When boiler start steaming, throttle SH vents & drains
10 When drum pressure reaches 2 kg /cm 2 .Close drum vents & out let
header vent.
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11 Close SH DeSH link vent valves.
12 Close platen SH out let like vent valves
13 Throttle following:-
1. SH drain
2. Radiant roof SH inlet header drain & side steam cooled out let
header drain.
3. Rear header drain.
4. SH SWW front roof inlet header.
( Do not close above drain valves fully before rolling the turbine.)
14 Check the MS line drains are opened( near turbine)
15 Open boiler out let valves(MS 11,12)
16 Throttle start up vent valves to control pressure rise. Do not close them
fully until turbine is under light load or HP/LP by pass system is taken into
service.
17 Before raising a vacuum in the condenser, make sure that all reheater
vents or drains that are open to the atmosphere are closed. Leave drains
or vents connected to HP drain flash tank open until the turbine is
carrying a light load.
18 Bring up the boiler steam parameter to 5 kg/cm2,195 0C
BOILER LOADING
1 Before HO firing, check flue gas temp at APH out let is above 90-100 0C
2 Take SCAPH of FD fan in service. Maintain average cold end temp. above
acid dew point. Charge SCAPH (both),watch air temp. after SCAPH and
flue gas temp at AHs. outlet, they should show rising trend. ( At low load
SCAPH should invariably be charged to avoid corrosion & chocking of air
heater elements. Drains of SCAHP should be throttled suitably to get
optimum results.)
3 Check that vacuum is raised in the condenser by the time MS para come to
6 kg/cm2,275 0C.
4 Take HP/LP by pass station I/S.
5 Ensure CEP I/S.
6 BEFORE STARTING OF BFP
1. Confirm feed line is charged, it’s drains and vents are closed.
2. Feed station isolating valves are open and control valves are closed.
S/H spray valve E-13 is closed. (In some units E-13 is provided with
manually operated bypass valve .For initial charging , bypass valve should
be opened but after the main valve is opened , the bypass valve should be
closed.This is very important because subsequently when boiler trips only
E-13 is closed from PCR & if control valves are passing excessive collection
of water may result in the superheater causing hammering & subsequently
drop in final S/H temp. After boiler has tripped, watch temp. before &
after attemperator. If E-13 does not close, reduce BFP discharge pr. to
minimum. In such case let the drum level drop. After closing E-13 water
can be taken into the drum.)

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 3. ERVs are closed.(Before starting of BFP for taking water in the
boiler after a light up , it should be ensured that ERVs are closed.
Otherwise if NRVs are passing the relatively cold water may flow
the path of least resistance & enter the boiler water walls
‘bypassing’ the economizer.The present practice of closing of
recirculation valves only after set synchronizing should be stopped.
START BFP
1. Check inspection drains of CRH/ HRH, there should be no flow of
water.
2. After starting of BFP, see that the temp. after S/H attemperator
& HP bypass does not increase.
3. Ensure that CR-3,4 are closed as any passing of spray valves may
cause entry of water into HP turbine.CR-5,6 should be open. Cold
reheat drains should be open.
7 PRDS spray FW-76.PRDS D&E valves are closed.
8 Ensure steam throw off device condensate spray valves are open
9 Close start up vent valves when flow is established through by pass
system.
10 Give clearance to start turbine rolling.
11 Boiler parameter are raised to MS pressure & temp.
1. Throttle MS line drain valves
2. Drum level protection I/S
3. Warm up MS lines. CRH,HRH & transfer lines.
4. Check MS parameter of ESV.
5. Check MS pipe metal temp. is above 1500C & CR pipe metal above
1000C
6. Check HP transfer pipe metal temp. is above 100 0C & IP transfer
pipe metal temp. 1000C
12 Charge PRDS preferably from self unit.(cooling water to Sulzer valve
should be available from CEP)Confirm that gland steam/ ejector valves are
closed.(Normal idle time of pump should be 4 to 5 min. when system is in
service & more than 5 min when system is not on AUTO.
13 HP/LP by pass system is cut out & turbine rolling is started.
Close MS lines drains & CRH line drains to condenser
14 TG set syn.(load 10-15 MW)
MS pressure 30 kg/cm2,temp. 350 0C before ESV
15 Maintain ave. cold end temp. at APH out let above acid dew point by
controlling steam flow to SCAPH.
Regulate steam supply control valves & check air temp. before & after
SCAPH, check flue gas temp. after APH.
16 Before increasing drum pressure ensure that silica in water is within
permissible limit at operating pressure.
17 Make SH spray control system ready.
18 Make RH spray control system ready.

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19 Close ERV when continuous flow is established through eco.
20 Close:-
1. SH header drain.
2. Radiant SH in let header drain
3. In let header drain
4. Side steam cooled wall out let header drain
5. Steam cooled wall rear header drain .SHS, WWW front roof inlet
header drain
6. Final SH header drain.
21 Pick up 30 MW load
MS pressure 65 kg/cm2,temp. 4300C,RHS temp. 4200C
22 Take main FCV in service.
23 Start coal firing.
1. Keep drum level on lower side just before starting C/M & RCF
2. Mill diff. pressure is less than 250 mm WCL
24 Increase the MS/RH steam para per cold start curve.
25 Maintain SH steam temp. control by spray water.
26 Maintain SH steam temp. control by BT.(RH spray control should be used
as last resort for temp. control.)
27 Start 2nd C/M
28 When load is 70 MW
MS pressure 105kg/cm2,temp. 5000C,HRH temp. 495-5000C
1. Take LPH in service.
2. Drip pump in service
29 At 30 % load furnace to wind box diff. should be 90 mm WCL
30 Start 2nd BFP,CEP
( D/A pressure is increase to 6 kg/cm 2)
31 At load 120 MW
MS pressure 120kg/cm2,temp. 5300C,HRH temp. 5250C
32 Put BFP scoop tube on AUTO (Check that 5 kg/cm2 diff. pressure is
maintained by scoop tube position controller.
33 Put main FW CV on AUTO to control drum level.
34 Check that -10 mm WCL furnace draft. Is maintained.
35 SCAPH can be cut out when flue gas out let temp. increases to or if FO is
removed
36 At load 210 MW
1. Drum pressure 145 kg/cm2
2. MS pressure 134 kg/cm2
3. MS temp. 540 0C
4. RH steam pressure 22 kg/cm2
5. RH S temp. 540 0C
6. FW temp. 2450C
37 Check MS temp. low protection trip interlock comes in to service when MS
temp. 5200C( MS temp. out indication will reset)

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17. Charge deaerator heating and raise the pressure to normal slowly.
18. Start one CT and CW pump
19. Start second CEP
20. Confirm that no water is coming out of inspection drains of CRH/HRH,
21. Close boiler side reheater vents.