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1.

Purpose
The purpose of the SOP of “Boiler Cold start-up” is to train and guide operation personnel for optimum and safe
operation of the system.
2. Scope
This SOP defines the lineup, pre checks, permissive, operation procedure, Post startup checks, interlocks &
protections for Boiler cold start up.

3. Roles & responsibility matrix


Sl
n Jobs Responsibility Competency Desired output / efficiency
o

1 Distribution Head- CPP/ Head- Operation Decide the need of start-up.

2 Compliance Station in charge/ Shift in charge Knowledge of Cold start up


procedure
Safe and Efficient Start up
Desk engineers Knowledge of Cold start up of Boiler
procedure

Field operators Field knowledge for cold


start-up & operation.

4. Environment health & safety matrix


Hazards Environmental Safety Precautions PPEs required
considerations

 Burn due to  Stack Emission  Ensure PTW returned


spillage of hot  Coal Dust/  Ensure Proper PPE’s & Proper Pep-Talk (Tool Box Talks)
water/steam/ Ash Leakage  Ensure first aid box is available nearby.
oil.  Noise  Ensure proper insulation
 Fall / slip due Pollution  Ensure coupling guards in position.
 Water/ Steam  Ensure area barricading
to oil spillage
Leakage  Ensure all inspection door and cover closed.
due to oil gun
 Oil Spillage  Ensure all fire extinguishers and sand buckets filled with
leakages
 Heat sand are kept in its place which is approachable in boiler
 Fire due to
Radiation area.
oil / coal dust  Ensure fire pump and fire engine are kept in auto after their
leakage
trial run.
 Falling of
 Ensure fire hoses are kept in fire boxes.
foreign  Ensure fire hydrant line to be kept charged and hydrant
materials. pressure is maintained.
 High Noise  Ensure proper housekeeping.
Level  Ensure sufficient illumination is available.
5. Legal & regulatory requirements: As per Boiler Act.
NOTE: FOR CLAUSE NO. 6, 7, 8, 9, 10, 11,12,13,14, & 15 refer annexures
- For Aditya : ANN_AAP_E17_OPSOP_01
- For Dahej : ANN_BCD_E17_OPSOP_01_U_1,3,4

: ANN_BCD_E17_OPSOP_01_U_2

- For Hirakud : ANN_HKD_E17_OPSOP_01

- For Mahan : ANN_MAH_E17_OPSOP_01

- For Muri : ANN_MUR_E17_OPSOP_01

- For Renukoot : ANN_RKT_E17_OPSOP_01_U_1

: ANN_RKT_E17_OPSOP_01_U_2

: ANN_RKT_E17_OPSOP_01_U_3

: ANN_RKT_E17_OPSOP_01_U_4

- For Renusagar : ANN_RPD_E17_OPSOP_01

- For Utkal : ANN_UAL_E17_OPSOP_01

6. O & M parameters: Refer annexure


7. Checks before start up: Refer annexure
8. Startup sequence: Refer annexure
9. Operation monitoring & control: Refer annexure
10. Shutdown Procedure: Refer annexure
11. Best practices followed (If any): Refer annexure
12. Exception/ Emergency handling : Refer annexure

13. Dos & Don’t s: Refer annexure


14. Performance KPIs: Refer annexure

15. Abbreviation: Refer annexure


ANNEXURE: ANN_AAP_E17_OPSOP_01

 Reference SOP : E17_OPSOP_01


 Applicability to generating unit(s) : U# 1,2,3,4,5,6

 Scope : This annexure covers the 6,7,8,9,10,11,12,13,14,15 clauses of SOP E17_OPSOP_01

6. O & M parameters
 No. & Capacity: 1 per unit

Design Code Specification

Type of Boiler Single Drum, Pulverised Coal Fired Boiler

Type of firing Tangential Corner Firing

Boiler Efficiency 85.57% @ BMCR

Design Coal GCV 3510 Kcal/Kg

Steam Flow at Superheater Outlet 510 TPH @ BMCR

Steam Pressure at Superheater Outlet 139 Kg/Cm2 (g) @ BMCR

Steam Temp. at Superheater Outlet 540 o C @ BMCR

Reheat Steam Flow 407.1 TPH @ BMCR

Steam Pressure at Reheat Inlet 36.57 Kg/Cm2 (g) @ BMCR

Steam Temp at Reheat Inlet 353.4 o C @ BMCR

Steam Pressure at Reheat Outlet 34.58 Kg/Cm2 (g) @ BMCR

Steam Temp. at Reheat Outlet 540 o C @ BMCR

7. Checks before start up (Unit Specific)


7.1 Physical Check
1. Ensure all PTWs are returned & all the associated equipment’s are available.
2. All boiler interlock & protections are checked (For cold startup of Boiler after AOH)
3. Ensure healthiness of lube oil system of all equipment’s.
4. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
5. Ensure power availability of all Equipment.
6. Both ID Fans are available.
7. Both FD Fans are available.
8. Both Scanner Air Fans are available.
9. LDO/ HSD/ HFO/ Bottom Oil system is available.
10. All Pulverisers & Feeders are available.
11. All PA Fans are available.
12. All seal air Fans are available.
13. Regenerative/ Tubular APH are available.
14. Both pass of ESP are available.
15. Coal Bunker level is sufficiently maintained.
16. Sufficient DM water is available.
17. Light up clearance available from all service departments and to be signed by all concerned personal.
18. Main Steam Stop Valve & Its Equalizer are operative.
19. All Motorized & Control Valves are operative.
20. APH Soot Blowing system must be available.
21. Ensure availability of Bottom ash & Fly ash system.
22. Ensure that Bottom Ash conveying system (Magaldi) is operating.
23. Ensure availability of Mill reject system.
24. Ensure availability of all Flame Scanner.
25. Ensure availability of BFP.
26. Open igniter cooling air valve.
27. Availability of Flue Gas Path
28. Availability of Air Path
29. Ensure that Ring Header Drains are closed.
30. Ensure that all wall soot blowers & LRSB's are in home position.
31. Cooling water system of all Boiler related equipment should be charged.
32. Ensure availability of Instrument air to all equipment’s.
33. Ensure availability of service air.
34. Check availability & healthiness of Oil guns & Igniter system.
35. Ensure drum vents/ SH vents/ RH vents/ Economizer vent/ DSH vent kept in open position.
36. Ensure that all SH drains are open.
37. Ensure all low pressure boiler filling line valves kept closed.
38. Ensure that Main Steam Stop valve & its equalizer are closed.
39. Ensure SH spray control station is isolated.
40. Ensure RH spray control station is isolated.
41. Ensure Startup vent is opened.
42. All instrument gauges and impulse lines are charged and functional.
43. DM water filled up along with N2H4& NH3 up to boiler Lit-Up level.
44. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
45. All sample coolers are charged.
46. Check the burner tilt operation from -30 to +30 degrees for its smooth operation and symmetry of tilt at
each corner.
47. Ensure Burner tilt is at horizontal position.
48. Ensure that all safety valve in operative condition.
49. Ensure readiness of ERV (Manually pilot valve checking)
50. Check the smooth operation of the following dampers, gates and valves before lit up-
 ID fan inlet damper/ gate
 ID/FD/PA fan outlet damper/gate
 Flue Gas/FD/PA fan I/L & O/L outlet damper of APH is open.
 Coal mill HAG, CAG, HAD ,CAD and seal air solenoid valve
 Feed water control valves.
 Spray water control valve.
 Oil combustion control valves
 All auxiliary and coal air damper
 Eco inlet feed valve with equalizer.
 Flue gas damper Pass-A &B
 APH bypass Sec. Air damper Pass-A &B.
7.2 Permissive for startup (Purge Permissive)
1. No boiler trip
2. All LONV/ HONV closed
3. LOTV/ HOTV closed
4. All Scanners “NO flame”
5. All pulveriser “OFF”
6. All feeders “OFF”
7. Both PA “OFF”
8. All HAG closed and CAD < 5% open
9. All auxiliary air damper modulating
10. Air flow >30% and <40%
11. Drum level normal

7.3.1 Interlocks & Protections (Boiler Trip Interlock)


Interlocks Protections

ALL ID FANS OFF


ALL FD FANS OFF
EMERGENCY TRIP
FLAME FALIURE TRIP
LOSS OF ALL FUEL TRIP
F.B & LOSS OF AC
REHEATER PROTECTION TRIP
FURNANCE PRESSURE VERY HIGH
FURNANCE PRESSURE VERY LOW
DRUM LEVEL VERY HIGH
DRUM LEVEL VERY LOW
LOSS OF 220V DC
LOSS OF 24V DC
LOW AIR FLOW<30%

7.3.2 Oil Gun Trip Interlocks


Interlocks Protections
Atomizing Air pressure Low & Minimum one LONV in LOTV/ HOTV close
open position
Oil pressure Low & Minimum one LONV in open position LOTV/ HOTV close

7.3.3 On MFT pickup

Sr. NO. Action

1 All Coal Mill Tripped

2 All Coal Feeder Tripped

3 All PA Fan Tripped

4 LOTV/ HOTV closed


5 All HAG closed

6 SH/ RH spray valve closed

7 SADC 100% opened

8.1 Startup sequence


1. Charge Instrument air & service air to all equipment’s.
2. Boiler filled up to Normal Drum Level.
3. Start both Air preheaters.
4. Charge LDO/ HFO system at boiler.
a. LDO/ HSD/ HFO/ Bottom Oil pump is in service with short recirculation maintaining header pressure
24 Kg/Cm2
b. Slowly charge the Boiler LDO/ HFO.
5. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
6. Start one ID Fan.
7. Start one FD Fans.
8. Start second ID Fan & FD Fan.
9. Maintain total air flow more than 30% & less than 40%.
10. Check the boiler PURGE permissive is satisfied.
11. Start boiler purging. During purging ensure all SADC are opened 100%.
12. After completion of purging push reset SADC.
13. Maintain wind-box DP as per curve (around 40mmWC initially)
a. All Coal elevation- A, B, C, D, E Fuel air dampers are in auto & closed.
b. All auxiliary air dampers of elevation AB, BC, CD & DE are in modulating, if not then adjust SADC to
maintain the wind box DP as per boiler loading Vs Wind-box DP curve.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
14. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
15. Keep Magaldi system in service continuously & convey bottom ash from first stage hopper to second stage
(For Aditya)
16. Keep inspection doors of Magaldi conveyors open & monitor it for checking of any oil accumulation (For
Aditya).
17. Start APH soot blowing from Air/ Steam in every 2 hours interval (up to oil gun in service).
18. During warming up period keep open the economizer recirculating line valve. (For Aditya/ Mahan)
19. Blow down the unit as required maintaining the drum water level insight in the gauge glass.
Note: The firing rate should be controlled to keep the furnace exit gas temperature below 500 deg C until steam
flow through Reheater is established. Establish a slight flow through Superheater by opening its start-up vent.
20. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
21. Close drum vents at 2Kg/Cm2.
22. Open the CBD valve 100% and regulate it as per requirement.
23. Establish feed water flow through feed control station
a. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
b. 30% FCV to be taken in service initially & if it can’t be taken in service then only100% FCV can be
taken in service.
c. Economizer recirculation to be kept opened till continuous flow is established through economizer.
24. Maintain drum water level at normal level.
25. Close all SH drain & vents at 5-8 Kg/Cm 2.
NOTE: SH flow to be maintained through start up vent and drain before Main Steam Stop Valve to be kept opened
till MS-1 does not opened fully.
26. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling)
27. Give boiler hot blow down through bottom ring header drain up to drum pressure 10 Kg/Cm 2. Further blow
downs to be done in view of Drum water/ Steam silica condition. No blow down to be done from bottom ring
header after drum pressure reaches 10 kg/cm2.
28. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per chemical department.
29. Open Main Steam By-pass valve at 12 Kg/Cm 2, keeping Turbine side steam line drains in open condition.
30. Open Main Steam Stop Valve at 15 Kg/Cm 2, keeping in view of Main Steam line Temperature greater than 110
o
C.
31. Raise the pressure in boiler as per Boiler startup curve and requirement of turbine.

8.2 Checks during boiler Lit- Up.


1. Check for any igniter oil leakages/ seepages.
2. Check oil flame condition and any oil spillage in the furnace.
3. Check for any oil leakages/ seepages.
4. Check drum metal top-bottom differential temperatures should not exceed 50 o C.
5. Maintain drum level up to Normal level.
6. SH drain no-4 should be open right from the very beginning.
7. Open CBD to maintain continuous flow from economizer.
8. Check that phosphate dozing in boiler drum is done.
9. Check for continuous rotation of oil guns at 30 min time interval.
9. Operation monitoring & control
1. Check the bearing temperature & vibration.
2. Permission to start any two coal elevation through FSSS.
3. Maintain the PA header pressure normal.

10. Shutdown Procedure: Refer Shut down SOP


11. Best practices followed (If any):

12. Exception/ Emergency handling :

13. Dos & Don’ts


DO’s DON’Ts
1. Check all the permissive before purging. 1. Exceed drum metal differential temperature
2. Monitor the expansion of the boiler. >50 C
3. Monitor the drum metal rise temperature. 2. Close SH drain-4 before synchronization of
4. Check for the flame healthiness through the peep machine.
hole when oil gun firing is done. 3. Close the APH bypass damper and gate
5. Hot flushing through Lower drain (Ring header) when the flue gas temperature <150oC.
should be done very carefully and safely. 4. Don’t bypass any protection.
6. Always follow the start-up curve provided by 5. Never force any oil gun.
manufacturer.
7. Check for oil leakages during oil firing.
8. Monitor the Drum water/ Steam silica.
9. Maintain LDO/ HFO Oil pressure between 6 to 7.5
Kg/Cm2

14. Performance KPIs

Time taken LDO HFO STEAM PARAMETER DRUM TURBINE


in light-up consumption CONSUMPTION PRESSURE LOADING
PH/CONDUCTIVITY/SILICA RISE LIMIT
minute KL KL
-, µS/cm , ppb Kg/cm2

330 12-15 10-15 8.5-10 / 4.5 -5.5 / <20 1.5 As per


TSE

15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve

11 MFT Master fuel trip

ANNEXURE: ANN_BCD_E17_OPSOP_01_U_1,3,4
 Reference SOP : E17_OPSOP_01
 Applicability to generating unit(s) : U# 1,3,4

 Scope : This annexure covers the 6,7,8,9,10,13 clauses of SOP E17_OPSOP_01

6. O & M parameters
 No. & Capacity: 1 per unit
Design Code CFBC # 1 CFBC # 3& 4

Type of Boiler Single Drum, CFBC Single Drum, CFBC

Type of firing Over Bed Over Bed

83.3 +/- 0.5@


Boiler Efficiency 87 +/- 0.5@ BMCR
BMCR

Design Coal GCV 6490 Kcal/Kg 6490 Kcal/Kg

Steam Flow at Superheater


150 TPH @ BMCR 150 TPH @ BMCR
Outlet

Steam Pressure at 65 Kg/Cm2 (g) @ 96 Kg/Cm2 (g) @


Superheater Outlet BMCR BMCR

Steam Temp. at Superheater 505 +/- 5 o C @ 535 +/- 5 o C @


Outlet BMCR BMCR

7. Checks before start up (CFBC # 1,3,4)


7.1 Pre Checks
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Ensure healthiness of lube oil system of all equipments.
3. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
4. Ensure power availability of all Equipments

5. All Fans are available.

6. LDO system is available.


7. APH are available.
8. Coal Bunker level is sufficiently maintained.
9. Sand Bunker level should be sufficient.
10. Sufficient DM water is available.
11. Light up clearance available from all service departments and to be signed by all concerned personal.
12. Main Steam Stop Valve & Its Equalizer is operative.
13. All Motorized & Control Valves are operative.
14. Ensure availability of Bottom ash & Fly ash system.
15. Ensure availability of BFP.
16. Availability of Flue Gas Path
17. Availability of Air Path
18. Ensure that Ring Header Drains are closed.
19. Cooling water system of all Boilers related equipment should be charged.
20. Ensure availability of Instrument air to all equipments.
21. Ensure availability of service air.
22. Check availability & healthiness of Oil guns & Igniter system.
23. Ensure drum vents/ SH vents/ RH vents/ Economizer vent/ DSH vent kept in open position.
24. Ensure that all SH drains are open.
25. Ensure all low pressure boilers filling line valves kept closed.
26. Ensure that Main Steam Stop valve & its equalizer are closed.
27. Ensure SH spray control station is isolated.
28. All instrument gauges and impulse lines are charged and functional.
29. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
30. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
31. All sample coolers are charged. Ensure that all safety valve in operative condition.
32. Ensure readiness of EMSV (Manually pilot valve checking)
33. Check the smooth operation of the following dampers, gates and valves before lit up-
 ID/SA/PA fan inlet damper/ gate
 ID/SA/PA fan outlet damper/gate
 HGG
 Feed water control valves.
 Spray water control valve.
 Oil combustion control valves
 All auxiliary and coal air damper
 Feed check valve.
 APH bypass Sec. Air damper.

7.3 Interlocks & Protections (Boiler Trip Interlock)


Interlocks Protections

ID FAN OFF

SA FAN OFF

PA FAN OFF

EMERGENCY TRIP

FLAME FALIURE TRIP

FURNANCE PRESSURE VERY HIGH

FURNANCE PRESSURE VERY LOW

DRUM LEVEL VERY HIGH

DRUM LEVEL VERY LOW

LOW PA AIR FLOW

FURNACE BED TEMPERATURE HIGH-HIGH

PRIMARY AIR PRESSURE AT APH INLET

SA & TA FLOW LOW


8. Startup sequence
1. Start ID fan by checking all start up permissive and purge the boiler.
2. Adjust furnace draft @ -55mmwc & kept ID fan draft control in ‘Auto’ mode.
3. Start SA fan by gradually increase up to 500 RPM & adjust SA flow @ 5 TO 6 Kg/sec.
4. Start any one roots blower with minimum speed (30%) & increase gradually up to 75%.Roots blower discharge
pressure should be kept 1000-1100 mmwc.
5. Open APH bypass damper.
6. Start PA fan by gradually increase up to 1100 RPM. And set Primary air flow up to 20 kg/sec.
7. Start sand feeding through sand feeder & increase bed ht. gradually up to 1000mmwc.
8. Start LDO pump and set oil pressure at 4 Kg/cm2.
9. Atomizing air pressure should be 5 kg/cm2 (g).
10. Start one HGG with minimum oil firing (250-300 kg/hr) .Also start another HGG with minimum oil firing after
stabilization of 1st HGG.
11. Raise bed temp. At the rate of 120 0C per hr. gradually. And follow as per start-up curve.
12. Increase Oil firing in Both HGG gradually up to 800kg/hr. The firing rate should be controlled to keep O/L flue
gas temp. < 870C & HGG refractory temp. < 1150C.
13. Establish a slight flow through superheater by opening its start-up vent.
14. Charge Coal when bed temp. Is @ 500 0C by keeping minimum (@ 10%) reference of coal feeders.
15. Close all drum vents & SH steam vents when drum pressure reaches up to 2 kg/cm2 (g).
16. Blow down the unit as required maintaining the drum water level insight in the gauge glass.
17. Establish feed water flow through feed control station
18. Start BFP & line up feed water system. (Keeping FW flow through HPHs)
19. 40% FCV to be taken in service.
20. Close all SH drain v/v except final SH drain when drum pressure increase more than 5 kg/cm2 (g).
21. Maintain drum level around 40 % by control valve of 0-40 %.
22. At 10kg/cm2 (g) drum pressure close SH-3 O/L header drain valve and open Start up vent v/v such that
increase of drum pressure can be kept within permissive gradient of 2kg/cm2 (g).per min. overheating of
super heater must be avoided.
23. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling)
24. Give boiler hot blow down through bottom ring header drain at drum pressure 10 Kg/Cm2. Further blow
downs to be done in view of Drum water/ Steam silica condition.
25. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per chemical department.
26. HGG oil firing cut down gradually with raise of bed temp. & stopped when bed temp. Rise up to 850C. Also
stop LDO pump.
27. Charge ESP fields after FG temp. Before ESP >120C and ensure that LDO Firing in stop condition
28. Take APH in line when Air heater O/L gas temp, reaches up to 130C to avoid AH Cold end corrosion.
29. Open HGG bypass air dampers. Close combustion dampers & dilution dampers after HGG O/L gas temp. <
200C.
30. Increase the SH steam pressure gradually up to 95 kg/cm2 (g) & final steam temp. Up to 530C by increasing
coal feeding & air flow. (PA & SA flow.) Control final steam pressure & steam temp. By modulating start up
vent v/v and attemprator control valve.
31. Ensure all TGs tripping interlock must be in line for steam temperature very low.
32. CFBC boiler pressure should be slightly higher @ 2 kg/cm2 than a running boiler at time of paralleling.
33. Steam temperature difference of CFBC and running CFBC should be less than 30 C.
34. Open main steam line drain after MSSV.
35. Start chemical dozing to boiler drum for maintaining drum water PH.
36. Open bypass valve of MSSV and maintain steam parameter.
37. After 10-15 minutes, open MSSV valve and take in line steam with running boilers. And close drain valve and
start up vent valve.
38. Increase steam flow gradually by increase coal feeding.
39. Take in line control valve of 30-100 % when load increase up to 40 TPH. Put in auto mode after closing of 0-
40% control valve.
9. Operation monitoring & control

Checks during boiler Lit- Up.


1. Check for any igniter oil leakages/ seepages.
2. Check oil igniters flame condition and no any oil spillage in the furnace.
3. Check for any oil leakages/ seepages.
4. Maintain drum level up to Normal level.
5. SH outlet drain should be open right from the very beginning.
6. Open CBD to maintain continuous flow from economizer.
7. Check that phosphate dozing in boiler drum is done.

Temperature Vs Time
Checks during boiler Lit- Up.

1. Check the bearing temperature & vibration.


2. Maintain the PA header pressure normal.
3. Maintain bed temperature up to 900 C by utilizing of ESP recirculation ash from APH & ESP First /second field
4. through denseveyor.
5. Observe the siphon temperature; it should be near about ECO -1 inlet flue gas temperature.
6. Maintain bed height around 800 mmwc.

10. Shutdown Procedure

1. Reduce steam generation up to 60 TPH by adjusting coal and air flow. And reduce load on TG as per pressure.
2. Maintain steam temperature as per design value 535 C by adjusting attemprator control valve in manual
mode.
3. Maintain drum level by 0-40 % valve.
4. Stop ash recirculation to boiler and divert ash from all fields, APH to main ash silo side.
5. Close gate valve of coal feeder inlet chute and empty both coal feeder. And close attemprator manual
isolation valve.
6. Then send the operator to MSSV floor with valve key.
7. When temperature comes 505 C then close Main steam stop valve. And check it is fully closed or not.
8. Confirm the close limit switch of MSSV. If not confirm, then close the valve manually immediately.
9. All fans kept running condition.
10. Stop one boiler feed pump.
11. Discharge ESP all field.
12. Keep operation of rapping system
13. Operate ash conveying system to Main ash silo side till all hoppers not empty.
14. Open Drum vent valve at Drum pressure comes 3.0 kg/cm2.
15. After complete depressurizing of boiler open both valve of start up vent.
16. When bed temperature comes 70 C then stop the PA, SA fan.
17. Adjust the furnace draft around -15 to -20 MMWC.
18. Drain furnace bed material if there is a requirement related to maintenance.

11. Best practices followed (If any): Not Available

12. Exception/ Emergency handling: Not Available

13. Dos & Don’ts


DO’s DON’Ts

Check all the permissive before purging.  Exceed drum metal differential temperature >50 C

Monitor the expansion of the boiler.  Close SH drain-4 before synchronization of

Monitor the drum metal rise temperature. machine.

Check for the flame healthiness through the peep  Close the APH bypass damper and gate when the
hole when oil gun firing is done. flue gas temperature <150 oC.

Hot flushing through LPD (Ring header) should be
 Don’t bypass any protection.
done very carefully and safely.
  Never force any oil gun.
Always follow the start-up curve provided by
manufacturer.

Check for oil leakages during oil firing.

Monitor the Drum water/ Steam silica.

Maintain HSD/ LDO/ HFO/ Bottom Oil pressure
between 5 to 6.5 Kg/Cm2

14. Performance KPIs

15. Abbreviation

SI No Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve

11 MFT Master fuel trip


ANNEXURE : ANN_BCD_E17_OPSOP_01_U_2

 Reference SOP : E17_OPSOP_01


 Applicability to generating unit(s) : U# 2

 Scope : This annexure covers the 6,7,8,9,10,13 clauses of SOP E17_OPSOP_01

6. O & M parameters
 No. & Capacity: 1 per unit

Design Code Specification

Type of Boiler Double Drum, AFBC

Type of firing Over Bed

Boiler Efficiency 86 +/- 0.5@ BMCR

Steam Flow at Superheater Outlet 75 TPH @ BMCR

Steam Pressure at Superheater Outlet 65 Kg/Cm2 (g) @ BMCR

Steam Temp. at Superheater Outlet 485 +/- 5 o C @ BMCR

7. Checks before start up (Unit Specific)


7.1 Pre Checks
1. Check PA Fans motorized damper operation.
2. Clean main burner oil gun & check spark of pilot burner.
3. Check coal bunker level. (It should be healthy)
4. Check operation of FCVS, Attemperator c/v operation, Start up vent v/v & Stop v/v operation
5. Ensure availability of Bed material.(@ 8t)
6. Take normal Drum level @ 40%
7. Ensure complete box up of Boiler & ESP.
8. Take clearance from Mech.& Electrical for Fans, BFP & ESP.
9. Check All fans brgs.oil level/ lubrication before start up. Ensure all PTWs are returned & all the associated
equipments are available.

10. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
11. Ensure power availability of all Equipments
12. All Fans are available.
13. LDO system is available.
14. APH are available.
15. Coal Bunker level is sufficiently maintained.
16. Sand Bunker level should be sufficient in furnace.
17. Sufficient DM water is available.
18. Light up clearance available from all service departments and to be signed by all concerned personal.
19. Main Steam Stop Valve & Its Equalizer is operative.
20. All Motorized & Control Valves are operative.
21. Ensure availability of Bottom ash & Fly ash system.
22. Ensure availability of BFP.
23. Availability of Flue Gas Path.
24. Availability of Air Path.
25. Ensure that Ring Header Drains are closed.
26. Cooling water system of all Boilers related equipment should be charged.
27. Ensure availability of Instrument air to all equipments.
28. Ensure availability of service air.
29. Check availability & healthiness of Oil guns & Igniter system.
30. Ensure drum vents/ SH vents/ RH vents/ Economizer vent/ DSH vent kept in open position.
31. Ensure that all SH drains are open.
32. Ensure all low pressure boilers filling line valves kept closed.
33. Ensure that Main Steam Stop valve & its equalizer are closed.
34. Ensure SH spray control station is isolated.
35. All instrument gauges and impulse lines are charged and functional.
36. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
37. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
38. All sample coolers are charged.
39. Ensure that all safety valve in operative condition.
40. Ensure readiness of EMSV (Manually pilot valve checking)
41. Check the smooth operation of the following dampers, gates and valves before lit up-
42. ID/SA/PA fan inlet damper/ gate
43. ID/SA/PA fan outlet damper/gate
44. HGG should healthy.
45. Feed water control valves.
46. Spray water control valve.
47. All auxiliary and coal air damper
48. Feed check valve.
7.3 Interlocks & Protections ( Boiler Trip Interlock)
Interlocks Protections

ID FAN OFF

FD FAN OFF

PA FAN OFF

EMERGENCY TRIP
FURNANCE PRESSURE VERY HIGH

FURNANCE PRESSURE VERY LOW

DRUM LEVEL VERY HIGH

DRUM LEVEL VERY LOW

DRUM PRESSURE

8. Startup sequence
1. Start ID fans, PA fans & FD fans.
2. Maintain furnace draught @ -3 mmwc.
3. Open PA & FD damper of compartments no.1 &4.
4. Set FD air flow @ 50 TPH.
5. Charge Bed material from compt.no.1 & 4.
6. Open PA & FD dampers of compartment no.2 & 4 intermittently to allow fluidisation/bed material flow.
7. Charge Bed material till wind box pre.>450mmwc in all four compartments.(Static Bedht. should be
350mmwc)
8. Check fluidization in all compartments.
9. After satisfactory fluidization & bed ht. achieved close PA & FD dampers of compartments no.2, 3 & 4 .Keep
open only 1st compartment PA & FD damper.
10. Keep open Bleed off v/v of compartments no.2, 3, & 4.
11. Start boiler fill pump & ensure water flow through compt.no.1 DP plate.
12. Set FD air flow through compt.no.1 @ 35-40 TPH.
13. Start pilot burner.
14. Take one main oil burner after ensuring stable flame of pilot burner.
15. Take 2nd main burner in line only after achieving HGG O/L temp.>250c.
16. HGG O/L Temp. Should not increase more than 800c.
17. Clean all PA lines of compt.-1 & increase PA header pressure @ 1200mmwc.
18. Gradually raise bed temperature of compt.1 up to 550 C.
19. Start coal feeding through coal feeder with minimum speed.(@ 20% reference)
20. Check furnace for proper fluidization & sparking of coal/flame of coal in furnace.
21. Adjust coal feeding & raise bed temperature up to 850 C .
22. Give short mixing (@ 2 to3 min.) in compartment no.2 by opening PA & FD dampers to
23. raise bed temperature .At the time of mixing bed temp. of compt.1 dropped sharply.
Note: Do not allow to drop bed temperature below 800C in compartment no.1 at the time of mixing in

compt.2 i.e. closes PA & FD line dampers of compt.2 when bed temp.in compt.1 reaches up to 800C.
24. After @ three to four mixing bed temp. in compt.2 raise upto 600C.
25. Then Keep open PA & FD line dampers of compartment no.2 & charge coal through coal feeders with
minimum speed. Adjust the coal feeding & raise bed temperature upto 850C.
26. Close all steam side vents when drum pressure increase 2 to 3 kg/cm2.Keep start up vent fully open to raise
steam temp.& for circulation of steam flow through tubes.
27. Close steam side drains when drum pressure reaches more than 5kg/cm2.
28. Adjust air flow & coal feeding in compt.1 & 2 to maintain bedtemperature@850C.
29. Stop the burner when bed temperature in both the compartments are healthy.
30. Raise the steam pressure & temperature gradually.
31. When boiler steam pressure reaches upto 58kg/cm2 & steam outlet temp.upto 480C open stopv/v.
32. Close startupventv/v gradually by maintaining steam pressure & temperature.
33. Now boiler in line with another running boiler(CFBC).
34. Increase coal feeding as per requirement to maintain boiler pressure & steam temperature.
35. Give three to four mixings as mention above in 3rd compartment & raise its bed temp. upto 600C.
36. Charge coal with minimum speed in compartment no.3 & raise bed temp. @850C by adjusting air flow(65TPH)
& Coal feeding.
37. Adjust attemperature c/v to maintain steam outlet temperature.
38. Same way compartment no.4 to betaken in service as per steam load demand.
39. Stop the boiler fill pump when HGG O/L temp.<250C.
40. Close HGG augmentation air damper.Start ID fan by checking all start up permissive and purge the boiler.
9. Operation monitoring & control
1. Check the bearing temperature & vibration.
2. Maintain the PA header pressure normal.
3. Maintain bed temperature up to 900 C by.
4. Maintain bed height around 600 mmwc.

10. Shutdown Procedure

1. Reduce steam generation by adjusting coal and air flow. And reduce load on TG as per pressure or taking
load on other boiler.
2. Maintain steam temperature as per design value 485 C by adjusting attemprator control valve in manual
mode.
3. Maintain drum level by main FCS control valve.
4. Then send the operator to MSSV floor with valve key.
5. When temperature comes 475 then close Main steam stop valve. And check it is fully closed or not.
6. Confirm the close limit switch of MSSV. If not confirm, then close the valve manually immediately.
7. All fans kept running condition.
8. Discharge ESP all field.
9. Keep operation of rapping system
10. Operate ash conveying system to Main ash silo side till all hoppers not empty.
11. Open Drum vent valve at Drum pressure comes 3.0 kg/cm2.
12. After complete depressurizing of boiler open both valve of start up vent.
13. When bed temperature comes 70 C then stop the PA, SA fan.
14. Adjust the furnace draft around -05 MMWC.
15. Drain furnace bed material if there is a requirement related to maintenance.
11. Best practices followed (If any): Not Applicable

12. Exception/ Emergency handling : Not Applicable

13. Dos & Don’ts


DO’s DON’Ts

Check all the permissive before purging.  Close SH drain in startup condition.

Monitor the expansion of the boiler.
  Don’t bypass any protection.
Check for the flame healthiness through the peep
 Never force any oil gun.
hole when oil gun firing is done.

Hot flushing through LPD (Ring header) should be
done very carefully and safely.

Always follow the start-up curve provided by
manufacturer.

Check for oil leakages during oil firing.

Monitor the Drum water/ Steam silica.

Maintain HSD/ LDO/ HFO/ Bottom Oil pressure
between 5 to 6.5 Kg/Cm2

14. Performance KPIs:

15. Abbreviation

Sl No. Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve


ANNEXURE : ANN_HKD_E17_OPSOP_01

6. O & M parameters

S.N. Design Code Specification

1 Type of Boiler Circulating fluidised bed combustion boiler

2 Type of firing Over bed Coal Firing

3 Boiler Efficiency 87.4 % @ MCR

4 Design Coal GCV 3610 Kcal/Kg

5 Steam Flow at Super heater Outlet 155 TPH @ MCR

6 Steam Pressure at Super heater Outlet 90.2 Kg/Cm2 (g) @ MCR

7 Steam Temp. at Superheater Outlet 515 ˚C @ MCR

7. Startup Sequence:
7.1 Physical Checks:
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Light up clearance available from all service departments and PROTOCOL to be signed by all concerned
personal.
3. Ensure healthiness of lube oil system of all equipments.
4. Ensure cooling water system (like ID fan, Static ash cooler, Bad ash cooler etc.) of boiler related equipment is
charged.
5. Ensure availability of Instrument air & service air to all equipments & pressure is greater than 5kg/cm 2.
6. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
7. Ensure all motorized & control valves are available & operative.
8. Ensure all IGV & dampers are available & operative.
9. Ensure all instrument gauges and impulse lines are charged and functional.
10. Ensure all the drives ID, SA & PA Fans are available & electrically normalised.
11. Ensure Coal Bunker level is sufficiently maintained for start-up.
12. Ensure both DCC is available & bunker coal rod gate is in open condition.
13. Ensure both CASF & both BAC is available & electrically normalised.
14. Ensure availability of bottom ash & Fly ash conveying system.
15. Ensure LDO system is available & LDO tank level is sufficient for lit-up.
16. Check availability & healthiness of Oil guns & Igniters system.
17. Ensure ESP rapper is started and ESP hopper heater switched ON before boiler lit-up.
18. Ensure Sufficient DM water is available for boiler start-up.
19. Ensure availability of BFP.
20. Ensure DM water filled up by cold filling line along with N 2H4 & NH3 up to boiler Lit-Up drum level.
21. Ensure power availability of all Equipment
22. Ensure that all safety valve is in operative condition & gagged were in removed.
23. Ensure following valves are in closed condition before cold start up:
24. All feed control station drains, down comer LHS & RHS drains, both Eco-1 & 2 drains, Evaporator drain, Rear
wall drains, side wall drains, attemperation stage-1 & 2 drains,
25. All Feed water station & attemperation station valves (FW # 202, FW-209, FW-210, FW-211, FW # 264, FW #
265, FW # 266, FW # 267, FW # 268, and FW # 269).
26. Main Steam stop valve & its equalizing valve (MS #202 A, MS #202 B).
27. Main steam vent (i.e. 80NB vent).
28. Ensure following valves are in open condition.
29. Steam Drum vent, MS line steam vent & super heater-1 outlet vent.
30. Super heater 1, 2 & 3 drain valves, MS line drain (MS-204 & MS-205), isolation valves of Electrometric safety
valve, Feed water station isolation manual valve (FW #215), attemperation stage-1 & 2 manual valves (FW-
270, FW-271, FW-272 & FW-273,).
31. Open all three manual valve after feed water control valves (FW CV 104-A, 104-B & 104-C)
32. “Primary air” to both siphon manual valve.
33. Both Bad ash cooler’s bottom ash inlet manual valve.
34. Both Cyclone screw feeder ash inlet manual valve.
35. Variable/constant load hanger supports are unlocked.

7.2 Permissive for startup:


1. No boiler trip.
2. Emergency push button is in release condition.
3. Boiler Drum Level normal. ( i.e. < 100 MM & > -150 MM)

7.3 Interlocks & Protections


Interlocks Protections
1. Drum level very low (-320 MM.)
2. Drum level very high. (150 MM.)
3. Furnace pressure very low (-150 MMWC.)
4. Furnace pressure very high. (100 MMWC.)
5. PA discharge pressure very low. (900 MMWC)
6. PA discharge pressure very high. (1900 MMWC)
7. Bed height very low. (200 MMWC)
8. Bed height very high. (1400 MMWC )
9. Bed temperature very high. (980 ° C)
10. Bed temperature very low. (350 ° C)
11. Total PA flow min. (54 TPH)
12. SA flow min. (7.2 TPH)
13. TA flow min. (3.6 TPH)
8. Operating Procedure:
1. Start the induced draught fan as per ID fan SOP.
2. Maintain the furnace draught between -20 to -25 MMWC by adjusting ID fan speed (by Scoop / VFD).
3. Open the Secondary air & Tertiary air controlling damper (CD-277 A/B & CD-280) 100% and 50% respectively.
4. Start Secondary air fan A & B as per SA fan SOP.
5. Open the discharge damper (VAR-1 & VAR-2) of both SA Fan & increase the VFD speed to ensure SA flow and TA
flow above the permissive limit i.e. greater than the 7.2 TPH & 3.5 TPH respectively.
6. Open the air pre-heater by pass damper (CD-228) 100% & close the air pre-heater inlet damper (CD-229) to
avoid acid dew point temperature at ESP inlet during LDO firing.
7. Fully open the both HGG combustion dampers (CD-235A & CD-235B) and dilution dampers (CD-236A & CD-
236B).
8. Fully close the both HGG by pass damper (VAR-37A & VAR-37B).
9. Reset Master Fuel trip (MFT) relay.
10. Start the both primary air fan as per PA fan SOP.
11. Open the both PA fan’s discharge damper (VAR-34 & VAR-35 ) & slowly Increase the PA flow by operating the
IGV/ VFD and adjust PA flow greater than the permissive limit (i.e. > 54 TPH), simultaneously increase the speed
of both ID fans to adjust the furnace drought between -20 to -25 MMWC.
12. Maintain the PA flow 75-80 TPH before taking HGG in service.
13. Start the LDO pump as per SOP & ensure the LDO pressure at HGG station is greater than the 15 Kg/cm 2.
14. Take HGG A & B in to line one after another as per SOP of HGG start-up.
15. Increase the firing rate and maintain the bed temperature as per temperature rising rate curve.
16. Sand can be taken from sand silo to maintain the bed height in between 900 to 950 MMWC.
17. At a steam drum pressure greater than the 2kg/cm², close the all steam side vent valves like drum vent, SH-1
outlet vent & main steam line vent.
18. At a steam pressure > 5kg/cm² close the steam side drain valves except main steam line drains (MS-204 & MS-
205).
19. Open the start up vent (MS-208 & MS-209) & adjust such that there is slow rise in drum pressure and the rate is
< 1 kg/cm² per minute, as well as the steam temperature increases proportionately.
20. Charge the Feed water station by opening the FW valve (FW-211 & CV-104C) & maintain the drum level by
taking feed water through BFP.
21. At 10 kg/cm2 give hot water blow down from down comers & ring header drains, as per silica contents.
22. Start TSP dosing at 20 kg/cm2 & charge the SWAS.
23. Open CBD (BD-7 & BD-8) for drum water blow down to maintain silica level in drum.
24. As the furnace bed temperature reaches above 530 °C start the one Drag chain conveyor and charge coal slowly
& follows the rising rate of bed temperature curve.
25. With the gradual increase in bed temperature, reduce the oil firing in both HGG and at bed temperature 700 °C
stop one HGG and another at bed temperature 750 °C.
26. Observe the bed temperature rising rate & adjust the SA & TA flow by increasing the speed of SA fan.
27. Open the both HGG bypass damper (VAR-37A & VAR-37B) at bed temperature 850 °C.
28. As the flue gas temperature reaches (>120 °C), charge the ESP.
29. Slowly open the air pre-heater inlet damper (CD-229) & simultaneously close the air pre-heater bypass damper
(CD-228).
30. Maintain the drum steam pressure and raise the super heater #3 outlet temperatures greater than 420 0C by
operating the start-up vent (MS-209).
31. At MS pressure > 40 kg/cm² Charge the main steam line by opening Main steam equalizing valve (MS-202A) and
start the heating of line up to interconnection valve.
32. As the main Steam pressure approaches the turbine inlet header pressure (i.e. > 80 kg) and MS temperature >
480 °C respectively. Slowly open MS stop valve (MS-202B) and close equalizing valve (MS-202A) of main steam.
33. Slowly close the start-up vent (MS-209) so that the steam starts flowing towards TG.(i.e. making the Boiler
parallel with running Boiler)
34. Close the Main steam line drain valves (MS-204 & MS-205)
35. As the steam flow and temperature increases normalize attemperation system (FW-202, FW # 264, FW # 265,
FW # 266, FW # 267, FW # 268, and FW # 269) and maintain steam temperature 510 ±5 °C by taking both
attemperation in service (CV-116 & CV-121).
36. Put drum level control valve & attemperation in auto mode.
37. Check the start permissive & start the cyclone ash screw feeder.
38. Start the ash conveying system as per SOP.
39. Start the bed ash cooler.
40. Normalize the air flow as per Boiler loading and put the furnace draught as well PA air flow in auto mode.
9. Operation monitoring & control
1. Check for any igniter’s oil leakages/ seepages.
2. Check for any steam, water & duct ash leakages.
3. Check for any abnormal sound & vibration in all the equipment.
4. Maintain drum level up to Normal level.
5. Watch the oil differential pressure & oil pressure in ID fans. ( If Scoop control)
6. Check the all drives were taking normal current.
7. Open CBD to maintain continuous flow from economizer.
8. Check that phosphate dozing in boiler drum is done.
9. Follow the Temperature rise in Thyssen Krupp Boiler during cold start up.

1st hour 2nd hour 3rd 4th hour 5th hour 6th hour
hour

Temperature at end of hour in degree 100 190 320 450 600 850

Temperature rise rate (deg/min) 1.0 1.5 2.2 2.2 2.5 4.2

Bed
temp
in
˚C

Time in Minutes

10. Shutdown Procedure:


 Refer to Boiler Shutdown procedure SOP
11. Best practices followed (If any):

12. Exception/ Emergency handling : Refer to Boiler Emergency handling procedure SOP
13. Dos & Don’ts:
DO’s DON’Ts

 Check all the permissive.  Close the APH bypass damper and gate
when the flue gas temperature <120 o C.
 Monitor the expansion of the boiler.
 Don’t bypass any protection.
 Check for the flame healthiness through the peep hole
when oil gun firing is done.

 Hot flushing through down comer drain should be done


very carefully and safely.

 Always follow the start-up curve provided by


manufacturer.

 Check for oil leakages during oil firing.

 Monitor the Drum water/ Steam silica.

 Maintain LDO pressure between 5 to 6.5 Kg/Cm 2

14. Performance KPIs:


15. Abbreviation:
SN Abbreviation used Stands for
1. CPP Captive power plant
2. PTW Permit to work
3. BFP Boiler feed pump
4. LOTOTO Lock out tag out try out
5. PA FAN Primary air fan
6. ID FAN Induce draft fan
7. SA FAN Secondary air fan
8. CBD,IBD Continuous/intermittent blow down
9. IGV Inlet guide vane
10. MS Main steam
11. MFT Master fuel trip
12. LDO Light diesel oil
13. APH Air Pre heater
14. ESP Electro static precipitator
15. HGG Hot Gas Generator
16. VFD Variable frequency drive
ANNEXURE: ANN_MAH_E17_OPSOP_01

 Reference SOP : E17_OPSOP_01


 Applicability to generating unit(s) : U# 1 to 6

 Scope : This annexure covers the 11,12,14 &15 clauses of SOP E17_OPSOP_01

6. O & M parameters
 No. & Capacity: 1 per unit

Design Code Specification

Type of Boiler Single Drum, Pulverised Coal Fired Boiler

Type of firing Tangential Corner Firing

Boiler Efficiency 85.57% @ BMCR

Design Coal GCV 3510 Kcal/Kg

Steam Flow at Superheater Outlet 510 TPH @ BMCR

Steam Pressure at Superheater Outlet 139 Kg/Cm2 (g) @ BMCR

Steam Temp. at Superheater Outlet 540 o C @ BMCR

Reheat Steam Flow 407.1 TPH @ BMCR

Steam Pressure at Reheat Inlet 36.57 Kg/Cm2 (g) @ BMCR

Steam Temp at Reheat Inlet 353.4 o C @ BMCR

Steam Pressure at Reheat Outlet 34.58 Kg/Cm2 (g) @ BMCR

Steam Temp. at Reheat Outlet 540 o C @ BMCR

7. Checks before start up (Unit Specific)


7.1 Physical Check
51. Ensure all PTWs are returned & all the associated equipment’s are available.
52. Ensure healthiness of lube oil system of all equipment’s.
53. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
54. Ensure power availability of all Equipment.
55. Both ID Fans are available.
56. Both FD Fans are available.
57. Both Scanner Air Fans are available.
58. LDO/ HSD/ HFO/ Bottom Oil system is available.
59. All Pulverisers & Feeders are available.
60. All PA Fans are available.
61. All seal air Fans are available.
62. Regenerative/ Tubular APH are available.
63. Both pass of ESP are available.
64. Coal Bunker level is sufficiently maintained.
65. Sufficient DM water is available.
66. Light up clearance available from all service departments and to be signed by all concerned personal.
67. Main Steam Stop Valve & Its Equalizer are operative.
68. All Motorized & Control Valves are operative.
69. APH Soot Blowing system must be available.
70. Ensure availability of Bottom ash & Fly ash system.
71. Bottom hopper filled up with water and ensure that water is overflowing.
72. Water charged into seal trough and ensure that water is overflowing.
73. Ensure availability of Mill reject system.
74. Ensure availability of all Flame Scanner.
75. Ensure availability of BFP.
76. Open igniter cooling air valve.
77. Availability of Flue Gas Path
78. Availability of Air Path
79. Ensure that Ring Header Drains are closed.
80. Ensure that all wall soot blowers & LRSB's are in home position.
81. Cooling water system of all Boiler related equipment should be charged.
82. Ensure availability of Instrument air to all equipment’s.
83. Ensure availability of service air.
84. Check availability & healthiness of Oil guns & Igniter system.
85. Ensure drum vents/ SH vents/ RH vents/ Economizer vent/ DSH vent kept in open position.
86. Ensure that all SH drains are open.
87. Ensure all low pressure boiler filling line valves kept closed.
88. Ensure that Main Steam Stop valve & its equalizer are closed.
89. Ensure SH spray control station is isolated.
90. Ensure RH spray control station is isolated.
91. Ensure Startup vent is opened.
92. All instrument gauges and impulse lines are charged and functional.
93. DM water filled up along with N2H4& NH3 up to boiler Lit-Up level.
94. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
95. All sample coolers are charged.
96. Check the burner tilt operation from -30 to +30 degrees for its smooth operation and symmetry of tilt at
each corner.
97. Ensure Burner tilt is at horizontal position.
98. Ensure that all safety valve in operative condition.
99. Ensure readiness of ERV (Manually pilot valve checking)
100. Check the smooth operation of the following dampers, gates and valves before lit up-
 ID/FD/PA fan inlet damper/ gate
 ID/FD/PA fan outlet damper/gate
 Coal mill HAG, CAG, HAD ,CAD and seal air solenoid valve
 Feed water control valves.
 Spray water control valve.
 Oil combustion control valves
 All auxiliary and coal air damper
 Feed check valve with equalizer.
 Flue gas damper Pass-A &B
 APH bypass Sec. Air damper Pass-A &B.
7.2 Permissive for startup (Purge Permissive)
12. No boiler trip
13. All LONV/ HONV closed
14. LOTV/ HOTV closed
15. All Scanners “NO flame”
16. All pulveriser “OFF”
17. All feeders “OFF”
18. Both PA “OFF”
19. All HAG closed and CAD < 5% open
20. All auxiliary air damper modulating
21. Air flow >30% and <40%
22. Drum level normal

7.3.1 Interlocks & Protections (Boiler Trip Interlock)


Interlocks Protections

ALL ID FANS OFF


ALL FD FANS OFF
EMERGENCY TRIP
FLAME FALIURE TRIP
LOSS OF ALL FUEL TRIP
F.B & LOSS OF AC
REHEATER PROTECTION TRIP
FURNANCE PRESSURE VERY HIGH
FURNANCE PRESSURE VERY LOW
DRUM LEVEL VERY HIGH
DRUM LEVEL VERY LOW
LOSS OF 220V DC
LOSS OF 24V DC
LOW AIR FLOW<30%

7.3.2 Oil Gun Trip Interlocks


Interlocks Protections
Atomizing Air pressure Low & Minimum one LONV in LOTV/ HOTV close
open position
Oil pressure Low & Minimum one LONV in open position LOTV/ HOTV close

7.3.3 On MFT pickup

Sr. NO. Action

1 All Coal Mill Tripped

2 All Coal Feeder Tripped

3 All PA Fan Tripped

4 LOTV/ HOTV closed


5 All HAG closed

6 SH/ RH spray valve closed

7 SADC 100% opened

8.1 Startup sequence


40.Charge Instrument air & service air to all equipment’s.
41.Boiler filled up to Normal Drum Level.
42.Start both Air preheaters.
43.Charge LDO/ HSD/ HFO/ Bottom Oil system at boiler.
a. LDO/ HSD/ HFO/ Bottom Oil pump is in service with short recirculation maintaining header pressure
24 Kg/Cm2
b. Slowly charge the Boiler LDO/ HSD/ HFO/ Bottom Oil line.
44. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
45. Start one ID Fan.
46. Start one FD Fans.
47. Start second ID Fan & FD Fan.
48. Maintain total air flow more than 30% & less than 40%.
49. Check the boiler PURGE permissive are satisfied.
50. Start boiler purging. During purging ensure all SADC are opened 100%.
51. After completion of purging push reset SADC.
52. Maintain wind-box DP as per curve (around 40mmWC initially)
a. All Coal elevation- A, B, C, D, E Fuel air dampers are in auto & closed.
b. All auxiliary air dampers of elevation AB, BC, CD & DE are in modulating, if not then adjust SADC to
maintain the wind box DP as per boiler loading Vs Wind-box DP curve.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
53. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
54. Keep Magaldi system in service continuously & convey bottom ash from first stage hopper to second stage
(For Aditya)
55. Keep inspection doors of Magaldi conveyors open & monitor it for checking of any oil accumulation (For
Aditya).
56. Start APH soot blowing from Air/ Steam in every 2 hours interval (up to oil gun in service).
57. During warming up period keep open the economizer recirculating line valve. (For Aditya/ Mahan)
58. Blow down the unit as required maintaining the drum water level insight in the gauge glass.
Note: The firing rate should be controlled to keep the furnace exit gas temperature below 500 deg C until steam
flow through Reheater is established. Establish a slight flow through Superheater by opening its start-up vent.
59. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
60. Close drum vents at 2Kg/Cm2.
61. Open the CBD valve 100% and regulate it as per requirement.
62. Establish feed water flow through feed control station
a. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
b. 30% FCV to be taken in service initially & if it can’t be taken in service then only100% FCV can be
taken in service.
c. Economizer recirculation to be kept opened till continuous flow is established through economizer.
63. Maintain drum water level at normal level.
64. Close all SH drain & vents at 5-8 Kg/Cm 2.
NOTE: SH flow to be maintained through start up vent and drain before Main Steam Stop Valve to be kept opened
till MS-1 does not opened fully.
65. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling)
66. Give boiler hot blow down through bottom ring header drain after killing the fire at drum pressure 10 Kg/Cm 2.
Further blow downs to be done in view of Drum water/ Steam silica condition.
67. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per chemical department.
68. Open Main Steam By-pass valve at 12 Kg/Cm 2, keeping Turbine side steam line drains in open condition.
69. Open Main Steam Stop Valve at 15 Kg/Cm 2, keeping in view of Main Steam line Temperature greater than 110
o
C.
70. Raise the pressure in boiler as per Boiler startup curve and requirement of turbine.

8.2 Checks during boiler Lit- Up.


1. Check for any igniter oil leakages/ seepages.
2. Check oil flame condition and any oil spillage in the furnace.
3. Check for any oil leakages/ seepages.
4. Check drum metal top-bottom differential temperatures should not exceed 50 o C.
5. Maintain drum level up to Normal level.
6. SH drain no-4 should be open right from the very beginning.
7. Open CBD to maintain continuous flow from economizer.
8. Check that phosphate dozing in boiler drum is done.
9. Check for continuous rotation of oil guns at 30 min time interval.
9. Operation monitoring & control
4. Check the bearing temperature & vibration.
5. Permission to start any two coal elevation through FSSS.
6. Maintain the PA header pressure normal.

10. Shutdown Procedure: Refer Shut down SOP


11. Best practices followed (If any):

12. Exception/ Emergency handling :

13. Dos & Don’ts


DO’s DON’Ts
10. Check all the permissive before purging. 6. Exceed drum metal differential temperature
11. Monitor the expansion of the boiler. >50 C
12. Monitor the drum metal rise temperature. 7. Close SH drain-4 before synchronization of
13. Check for the flame healthiness through the peep machine.
hole when oil gun firing is done. 8. Close the APH bypass damper and gate
14. Hot flushing through Lower drain (Ring header) when the flue gas temperature <150oC.
should be done very carefully and safely. 9. Don’t bypass any protection.
15. Always follow the start-up curve provided by 10. Never force any oil gun.
manufacturer.
16. Check for oil leakages during oil firing.
17. Monitor the Drum water/ Steam silica.
18. Maintain LDO/ HFO Oil pressure between 6 to 7.5
Kg/Cm2

14. Performance KPIs

Time taken LDO HFO STEAM PARAMETER DRUM TURBINE


in light-up consumption CONSUMPTION PRESSURE LOADING
PH/CONDUCTIVITY/SILICA RISE LIMIT
minute KL KL
-, µS/cm , ppb Kg/cm2

330 12-15 10-15 8.5-10 / <40 / <450 1.5 As per


TSE

15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve

11 MFT Master fuel trip

ANNEXURE: ANN_MUR_E17_OPSOP_01
6. O & M parameters
 No. & Capacity: 1 per unit
Design Code Specification

Type of Boiler Single Drum, Coal Fired Boiler

Type of firing Over feed

Steaming capacity (TPH) 140

Steam pressure at MSSV outlet Kg/cm2 51

Steam temperature at MSSV outlet Deg C 460(+-)5

Boiler design pressure Kg/cm2 66.5

Feed water temperature at Eco inlet Deg C 190

Boiler Efficiency 87% @ BMCR

Turn down ratio 1:4

Design Coal GCV 3500 Kcal/Kg

7. Checks before start up


7.1 Pre Checks
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Ensure healthiness of lube oil system of all equipments.
3. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
4. Ensure power availability of all Equipments.
5. Both ID Fans are available.
6. Both PA Fans are available.
7. Both SA Fans are available.
8. Both wall seal blowers are available
9. Both Scanner Air Fans are available.
10. HSD and BMS system are available.
11. Both coal Feeders are available.
12. ESP is available.
13. Coal Bunker level is sufficiently maintained.
14. Sufficient DM water is available.
15. Light up clearance available from all service departments and to be signed by all concerned personal.
16. All Motorized & Control Valves are operative.
17. Ensure Soot Blowing system is available.
18. Ensure availability of Bottom ash & Fly ash system.
19. Ensure BFP is available.
20. Ensure that Ring Header Drains are closed.
21. Ensure that all wall soot blowers & LRSB's are in home position.
22. Cooling water system of all Boiler related equipment should be charged.
23. Ensure availability of Instrument air to all equipments.
24. Ensure availability of service air.
25. Ensure drum vents/ SH vents/ convection cage vents kept in open position.
26. Ensure that all SH drains are open.
27. Ensure DSH system is ready.
28. Ensure all low pressure boiler filling line valves kept closed.
29. Ensure that Main Steam Stop valve & its equilizer are closed.
30. Ensure SH spray control station is isolated.
31. Ensure Startup vent is opened.
32. All instrument gauges and impulse lines are charged and functional.
33. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
34. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
35. All sample coolers are charged.
36. Ensure that all safety valve in operative condition.
37. Ensure readiness of EMRV and open condition of manual isolation valve.
38. Check the smooth operation of the following dampers, gates and valves before lit up-
39. ID/SA/PA/WSB fan inlet damper/ gate
40. ID/SA/PA/WSB fan outlet damper/gate
41. Stripper gate and CVs of Stripper air
42. DCF and coal gates
43. Feed water control valves.
44. Spray water control valve.
45. Oil combustion control valves.
46. All auxiliary and coal air damper.
47. Feed check valve with equalizer.
48. APH bypass Sec. Air damper and PA air damper.
49. Both solid transfer line valves.
50. Ensure availability of 2000 bags of bed material at drag chain feeders.
51. Ensure return leg, stripper cooler 1, 2 and 3 charged with bed material
52. Ensure opening SA and PA bypass dumpers

7.2 Permissive for startup


1. Common trip interlock ok for both burners.
1a. HSD pump running
1b. Emergency stop button not pressed
1c. Oil inlet pressure Lo Lo
1d. Oil outlet pressure Hi Hi
1e. Instrument air pressure Lo Lo
1f. BMS start permissive ok
1g. Burner 1 or 2 flame not fail
1e. Atomising inlet pressue Lo Lo
1f. Scanner cooling air pressure Lo
1g. Combustion air pressure Lo
1h. Command and feedback mismatch
1e. Combustion air fan running

2. Start up interlock
2a. HSD pump running
2b. HSD pressure high
2c. Burner gun atomising pressure lo
2d. HSD pressure Lo
2e. HSD to burner-1 gun shut off valve close condition
2f. HSD to burner-2 gun shut off valve close condition
2g. Scavenging air to Burner-1 valve close condition
2h. Scavenging air to Burner-2 valve close condition
2i. Atomising air to burner-1 shut valve close condition
2j. Atomising air to burner-1 shut valve close condition
2k. BMS start permissive ok
2l. Emergency stop push button not released
2m. Scanner cooling air pressure low
2n. Combustion air pressure low
2o. Instrument air pressure Low
2p. Oil outlet pressure low
2q. Fire control valve at low fire condition
3. Purge permissive
3a. Any burner scavenging not started
3b. Common trip interlock ok
3c. Start up interlock ok
4. Air flow >30% and <40%
5. Burner start permissive
5a. HSD to burner-1 gun shut off valve close condition
5b. HSD to burner-2 gun shut off valve close condition
5c. Scavenging air to Burner-1 valve close position
5d. Scavenging air to Burner-1 valve close position
5e. Purge complete
5f. Flame on
5g. Atomising air to burner gun shut off valve close position
5h. Common trip interlock condition ok for both burner
6. Burner ready to fire
6a. Burner start command
6b. HSD to burner shut off valve close condition
6c. Combustion air damper at low fire position
6d. Burner start permissive
6e. Burner start delay after scavenging
6f. burner running
6g. Burner trip interlock ok
6gi. Burner flame not fail
6gii. Oil inlet pressure Lo Lo
6giii. Oil inlet pressure Hi Hi
6giv. Atomising air pressure Lo Lo

7.3 Interlocks & Protections( Boiler Trip Interlock)


Protections
Interlocks
Alarm Trip
1. Drum level Hi 100 mmWC 150 mmWC

2. Drum level Lo -125 mmWC -175 mmWC

3. Furnace pressure Hi 100 mmWC 150 mmWC

4. Furnace pressure Lo -100 mmWC -150 mmWC

5. Instrument air header pressure <min 4 Kg/cm2

6. ALL ID fan OFF

6a. Bearing temp Hi Hi 75 Deg C 90 Deg C

6b. Command fault

6c. Overload trip 37 A

6d. Fluid coupling not healthy

6f. Furnace pressure Lo Lo

6h. Bus under voltage

7. ALL PA fan OFF

7a. Bearing temp Hi Hi 90 Deg C 110 Deg C

7b. Command fault

7c. Both SA trip

7d. Both ID fan trip

7e. Furnace pressure Hi Hi

7f. Motor overload 38 A

7g. Drum level Hi Hi or Lo Lo

7h. Bus under voltage

8. All SA fan OFF

8a. bearing temp Hi Hi 90 Deg C 110 Deg C

8b. Command fault

8c. Both ID fan trip

8d. Both WSB trip

8f. Motor overload 18 A

8g. Furnace pressure Hi Hi

8h. Bus under voltage

8i. Drum level Hi Hi or Lo Lo


8j. WSB discharge pr Lo Lo

9. Total air flow> purge Any PA-19000 M3/hr Burner Trip

Any SA >9000m3/hr

Both burner air>4000 m3/hr

10. Wall seal Boiler header pressure Lo 3500mmWC 3000mmWC

11. Start up interlock sequence FCP-ID fan-


WSB-SA fan-PA fan

8. Startup sequence
41. Charge Instrument air & service air to all equipments.
42. Boiler filled up to Normal Drum Level.
43. Start fluid coupling pump with scoop position to zero.
44. Start one ID Fan with scoop position zero and open discharge and suction damper establish furnace draft to -5
mmWC.
45. Start W.S.B. Keeping discharge damper in open position and observe the discharge pressure > 4000 mmwc
and it should not go beyond 5500 mmwc. If wall seal blower discharge pressure goes beyond 5500 mmwc , it
will result in blower vibrations and failure. (If required the vent valve in the wall seal blower to be opened
minimally to keep the pressure below 5500mmwc. Wall seal blower has a safety valve in the discharge piping
at the back side, it is adjusted at 5400 – 5500mmwc. The settings of this safety valve should not be disturbed.
Always keep the exhaust fan in wall seal blower acoustic hood in running condition to provide good
ventilation for the blower and the motor. Incase of any problem with the exhaust fan, the acoustic hood doors
to be kept opened when the blower in running condition.
46. Check return leg fluidization and solid transfer line
47. Check stand blower discharge pressure by taking it in service and keep other in standby mode.
48. Close combustor manhole.
49. Start one SA fan with suction IGV and discharge damper in close condition.
50. Start one PA Fan with suction IGV and discharge dumper in close condition.
51. Start AC Scanner Air Fan
52. Start second ID Fan & PA Fan.
53. Carry out the DP test carrying PA air flow to 90 TPH with maintaining the furnace draft. At air flow of 90 TPH
windbox pressure should be below 700mmWC.
54. Open SA and PA bypass dampers. Open CAD 204 and 205(SA nozzles) 5% and Burner Dampers 206 and 207 up
to 20%.
55. Slowly increase SA Flow by opening discharge damper and suction IGV. Establish 20,000 m³/ hr SA Flow.
Maintain furnace pressure – 5 to –10 mmwc. Keep SA disch Press after A/H around 300 mmwc (1PT 210).
Minimum SA air flow to be maintained through each oil burner is 4000 m³/ hr
56. Slowly increase PA Flow up to 22,000 m³/hr.
57. For oil firing, start Fuel oil ( HSD ) pump keeping suction & discharge valve in fully open position and the oil
pressure will be around 12kg/cm2. Keep oil flow Control Valve 10% open and atomizing air Valve 26% open.
58. Select the oil burner and open the SA damper up to 80% of selected Oil Burner.
59. Check all the boiler safety interlock is in healthy (green) condition.
60. Check the boiler PURGE permissive are satisfied.
61. Start boiler purging. During purging ensure all SADC are opened 100%.
62. After 5 minutes, Purge complete signal will occur. Then bring down the SA damper opening of selected burner
from 80% to 20%. Reduce opening of 2nd Burner Damper from 20% to 15%, Maintain the air flow through
each burner 7-7.5 tph while burner start up.
63. Set furnace Draft at - 15 mmWC. Start the selected burner. Control oil flow at 10 - 13 LPM.
64. Open atomising air PCV 50% and oil PCV 15% and oil presure 5-5.5 kg and take 2nd burner.
The Burner inlet pressure to maintained at 2-2.3 kg/cm2 while start up.
65. For raising Furnace temp strictly follow Boiler Cold start curve for Cold start up curve.
66. Note: The firing rate should be controlled until steam flow through superheater is established.
67. Establish feed water flow through feed control station
68. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
69. 40% FCV to be taken in service & if it can’t be taken in service then only100% FCV can be taken in service.
70. Maintain drum water level at normal level.

71. Close drum vents at 2.5 kg/cm² pressure..


72. It is advisable to start feeding the bed material inside the combustor after raising drum pressure above 1.5
kg/cm2. As the boiler drum level fluctuation will be more during startup, up to 1.5 kg/cm2 due to swelling
effect, fans may trip on drum level fluctuation.
73. Check all the bed pressure readings are showing 0 mmwc when there is no bed material inside the combustor.
Also note down the wind box pressure during this time. Slowly increase the PA air flow to 40 TPH and note
down the wind box pressure after obtaining 40 TPH air flow.
74. Slowly start adding Sieved Bed material (Either fresh or used one) If old bed material is used after sieving, it
should be checked visibly that there is no unburnt carbon present in it. Also note down that wet Bed material
should not be used. During bed material feeding, if for any reason the PA fans trip, the feeding to be stopped
immediately and should be started only after obtaining 40 TPH air flow through PA fans. Keep the cold
primary air damper tor stripper cooler in closed conation when running with only one PA Fan.
75. Charge both the stipper with bed material.
76. Gradually increase the bed height to 200 mmwc, also cross check the bed pressure readings with the wind box
reading. Bed pressure tapping is taken 200 mm above the nozzle grid.
77. For raising Boiler pressure strictly follow pressure raising curve for Hot and Cold start ups.
78. At 5kg/cm² press – close all super heater drains and vents.
79. Open all the manual drains (steam trap bypass) of Main Steam line up to H.P. header.
80. Give boiler hot blow down through bottom ring header drain after killing the fire at drum pressure 10
Kg/Cm2. Further blow downs to be done in view of Drum water/ Steam silica condition.
81. At 12kg/cm² open Main steam bypass valve MV 044. CHECK the condensate flow through all the Steam line
drains.
82. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling)
83. At 15kg/cm² slowly open MV 038. Boiler side common steam header warm-up will start. Check the
condensate flow through drains.
84. When slight amount of steam will start to flow from drains then throttle the drains and slowly open (inching)
MV 035. Close by pass v/v.
85. Coal firing to be initiated when the Bed temperature reaches 550 deg.C.
86. Initially coal to be sprinkled and bed temperature to be slowly raised, also O2 in flue gas to be monitored and
to be maintained always more than 5 % till obtaining bed temperature around 850 deg.C.
87. While carrying out coal firing the return leg temperature to be noted down, it should not be 100 deg.C below
the bed temperature. Also presence of suction through the pockets of the return leg to be checked and flow
of material inside the combustor will be visible through these pockets when the bed temperature reaches
around 800 deg.C. If suction is not present in the pockets or the return leg temperature is very less then air
flow to the lift and down legs to be momentarily raised by using bypass on the lift and down leg pipe line.
Care should be taken during this process that if the wall seal blower discharge pressure reduces below
3500mmwc for a period of 20 seconds then the boiler will trip. The settings of the Ball valve after the flow
orifice of wall seal blower line in lift leg and down leg of RHS and LHS is set once by the OEM and should not
be disturbed. If the return leg temperature is very less, it indicates improper flow of return material or the
seal is empty. In this case please contact the OEM for any further adjustments if needed.
88. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per chemical department.
89. When slight amount of steam will start to flow from drains then throttle the drains and slowly open (inching)
Main steam stop Valve MV 043. Keep a close look on drum level. After full opening of main steam stop valve
Close by pass valve. Open the main steam stop valve only after obtaining the Boiler pressure above 60 % of
rated steam pressure.
90. At 25 kg/cm² pressure – H.P. steam header warming may be started.
91. Oil burners can be withdrawn one by one slowly above 725 deg.C bed temperature.
92. After establishing the steam flow in turbine gland seal and ejector, open steam trap valves and close the
bypass valves of all the drains of main steam line up to H.P. header.
93. Increase the steam temperature and pressure as per startup curve up to 40 Kg/cm2 and 380 Dec C
94. After synchronization, load (MW) can be raised up to 3 - 4 MW.
95. All the hopper heaters and Insulator heaters of the ESP in all fields should be kept in service before coal firing.
96. ESP Fields to be charged after withdrawing the oil burners from service, keeping the IDC set point increasing
from Field NO: 1 to Field no: 4. Regular checking of running of the rapping mechanism of emitting and
collecting electrodes to be carried out in field as well as in the panel. Physical Working of rapping mechanism
to be checked
97. After steady operation of Boiler for a period of 8 hours auto combustion loops can be taken in service.
98. Stripper coolers are to be charged as per the Stripper cooler Logics given.

NOTE: SH flow to be maintained through start up vent. Drain before Main Steam Stop Valve to be kept opened till
MS-1 does not opened fully.

9. Operation monitoring & control


1. Monitor and maintain Boiler drum level.
2. Monitor and maintain Boiler furnace draft.
3. Monitor and Maintain Boiler main steam pressure and temperature by adjusting coal feed and
attemperator flow.
4. Monitor and maintain excess oxygen levels.
5. Reduce exit flue gas temperature by soot blowing as per SOP.
6. Monitor and maintain Boiler bed level and bed temperature.
7. Monitor and maintain Boiler water and steam parameters within range.
8. Monitor fan and motor bearing temperature.
9. Monitor oil level of Fluid coupling, WSB.
10. Check and report oil leakages, abnormal sound and vibration.
11. Monitor collection of coal sample and coal quality.
12. Monitor Boiler efficiency and report heat loss area.
13. Monitor Boiler instruments and their feedback positions.
14. Monitor Boiler auxiliary loading.
15. Monitor Boiler ash conveying system for normal operation.
16. Log Boiler operating parameters on regular basis.

Boiler cold start up curve:


10. Shutdown Procedure
Follow Shutdown SOP.

11. Best practices followed (If any):

12. Exception/ Emergency handling :


13. Dos & Don’ts

DO’s DON’Ts
19. Check all the permissive before purging.
20. Monitor the expansion of the boiler.
11. Don’t bypass any protection.
21. Monitor the drum metal rise temperature.
22. Check for the flame healthiness through the peep
hole when oil gun firing is done.
23. Hot flushing through Ring header should be done
very carefully and safely.
24. Always follow the start-up curve provided by
manufacturer.
25. Check for oil leakages during oil firing.
26. Monitor the Drum water/ Steam silica.

14. Performance KPIs

15. Abbreviation

Sno Abbreviation used Stands for

1 CGPP Co genration power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 PA FAN Primary air fan

6 ID FAN Induce draft fan

7 SA FAN Secondary air fan

8 CBD,IBD Continuous/intermittent

9 IGV Inlet guide vane

10 MSSV Main steam stop valve

ANNEXURE: ANN_RKT_E17_OPSOP_01_U_1
Reference SOP: E17_OPSOP_01_B#1
6. O & M parameters
 No. & Capacity: 1 per unit
Design Code Specification

Type of Boiler Bi- Drum, Pulverised Coal Fired Boiler

Type of firing Tangential , Front Firing

Boiler Efficiency 85.0% +/- 1.5 % @MCR

Design Coal GCV 2950 Kcal/Kg

Steam Flow at Superheater Outlet 80 TPH @MCR

Steam Pressure at Superheater Outlet 52.5 Kg/Cm2 (g) @MCR

Steam Temp. at Superheater Outlet 450 o C @MCR


7. Checks before start up
7.1 Pre Checks
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Ensure healthiness of lube oil system of all equipments.
3. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
4. Ensure power availability of all Equipments.
5. Both ID Fans are available.
6. FD Fan is available.
7. PA Fan is available.
8. Bottom Oil system is available.
9. Ball Mill & Feeders are available.
10. APH are available.
11. ESP is available.
12. Coal Bunker level is sufficiently maintained.
13. Sufficient DM water is available.
14. Light up clearance available from all service departments and to be signed by all concerned personal.
15. Main Steam Stop Valve & Its Equalizer is operative.
16. All Motorized & Control Valves are operative.
17. PRDS station is available.
18. Ensure availability of Bottom ash & Fly ash system.
19. Bottom hopper filled up with water and ensures that water is overflowing.
20. Water charged into seal trough and ensures that water is overflowing.
21. Ensure availability of Mill lift & lube oil pumps, gear oil umps and grease spray system are available.
22. Ensure availability of all Flame Scanner.
23. Ensure availability of BFP.
24. Open igniters cooling air valve.
25. Availability of Flue Gas Path
26. Availability of Air Path
27. Ensure that Ring Header Drains are closed.
28. Ensure that all wall soot blowers & LRSB's are in home position.
29. Cooling water system of all Boilers related equipment should be charged.
30. Ensure availability of Instrument air to all equipments.
31. Ensure availability of service air.
32. Check availability & healthiness of Oil guns & Igniter system.
33. Ensure drum vents/ SH vents/ Economizer vent/ DSH vent kept in open position.
34. Ensure that all SH drains are open.
35. Ensure line drains up to inter connection valve are open.
36. Ensure all low pressure Boiler filling line valves kept closed.
37. Ensure that Main Steam Stop valve & its equilizer are closed.
38. Ensure SH spray control station is isolated.
39. Ensure Startup vent is opened.
40. All instrument gauges and impulse lines are charged and functional.
41. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
42. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
43. All sample coolers are charged.
44. Ensure that all safety valve in operative condition.
45. Ensure readiness of ERV (Manually pilot valve checking).
46. Check the smooth operation of the following dampers, gates and valves before lit up-
47. ID/FD / PA Fan inlet damper/ gate.
48. ID/FD/PA Fan outlet damper/gate.
49. Mill HAG, CAG, PASO
50. Feed water control valves.
51. Spray water control valve.
52. Oil combustion (LOTV) control valves.
53. All auxiliary and coal air damper.
54. Feed check valve with equalizer.

7.2 Permissive for startup (Purge Permissive)


1. No boiler trip
2. All LONV closed
3. LOTV closed
4. All Scanners “NO flame”
5. Pulveriser “OFF”
6. All feeders “OFF”
7. All air register damper modulating
8. Air flow >30% and <40%

7.3 Interlocks & Protections (Boiler Trip Interlock)


Interlocks Protections

Both ID FANS OFF

Both FD FANS OFF

EMERGENCY TRIP

FLAME FALIURE TRIP

LOSS OF ALL FUEL TRIP

F.B & LOSS OF AC

FURNANCE PRESSURE VERY HIGH

FURNANCE PRESSURE VERY LOW


DRUM LEVEL VERY HIGH

DRUM LEVEL VERY LOW

LOSS OF 110V DC

LOSS OF 24V DC

LOW AIR FLOW<30%

7.4 Oil Gun Trip Interlocks

Interlocks Protections

Atomizing Air pressure Low (3.0 Kg/Cm 2) & Minimum one LOTV close
LONV in open position

Oil pressure Low (3.0 Kg/Cm2) & Minimum one LONV in LOTV close
open position

7.5 On MFT pickup

Sr. No. Action

1 Coal Mill Tripped

2 Coal Feeder Tripped

3 LOTV closed

4 Air Register 30% opened

8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Charge Bottom Oil system at boiler.
4. Bottom Oil pump is in service with short recirculation maintaining header pressure 18 Kg/Cm 2
5. Slowly charge the Boiler Bottom Oil line.
6. Start one ID Fan.
7. Start FD Fans.
8. Start second ID Fan.
9. Maintain total air flow more than 30% & less than 40%.
10. Check the boiler PURGE permissive is satisfied.
11. Start boiler purging for 5 minutes and wait for “purge complete” signal to come.
12. Light up boiler according to the BMS procedure and take two bottom oil guns in service at low flow (0.2 to 0.3
tph) and raise pressure as per the start-up curve.
13. Raise boiler water temperature 110-115°C. Kill fire and drain boiler, if CBD water conductivity is more than 24
micro mhos/cm.
14. Stop the FD Fan.
15. Again fill fresh hot DM water.
16. Start the FD Fan and lit up the boiler keeping furnace draft -5 to -10 mmwc.
17. Give Blow down the unit as required maintaining the drum water level insight in the gauge glass.
Note: The firing rate should be controlled to keep the furnace exit gas temperature below 525 deg C.
18. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
19. Close drum vents at 2Kg/Cm2.
20. Open the CBD valve 100% and regulate it as per requirement.
21. Establish feed water flow through feed control station
22. Start BFP & line up feed water system.
23. Maintain drum water level at normal level.
24. Close all SH drain & vents at 5-8 Kg/Cm 2.
25. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help of
service department (only after Annual Overhauling).
26. Raise the pressure in boiler as per Boiler startup curve.
27. Give boiler hot blow down through bottom ring header after killing the fire at drum pressure 15, 25 and 35
kg/cm2 to control boiler water silica.
28. Charge the main Steam line through boiler stop valve equalizer.
29. Raise the super heater outlet pressure above process header pressure (> 40 Kg/cm2), open motorized stop valve
gradually, keeping in view of Main Steam line Temperature greater than 110 o C.
30. Gradually, open PRDS control Valve. Increase the flow of the bottom oil guns and increase steam load 5 to 10
TPH.
31. Take top two oil guns in service one-by-one and adjust oil flow. Close line drains.
32. Bring 20% steam load on Boiler and close SH drains. Check line temperature. It should not increase above 440°C.
33. Maintain steam temperature 440°C during the above operation.
34. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per requirement.
35. Put ID fan, FD fan on Auto.
36. Check all the running equipments, inspect the furnace and stack. Stack emission should not be black.
37. Start PA fan and bring PA duct pressure to 480 mm WC.
38. Reset MTR and check PA fan.
39. Start purging of bottom coal conduit and wait for ‘AADB OK to release’ signal to come on BMS panel.
40. Release auxiliary air to auto.
41. Remove top oil guns for controlling SH temperature.
42. Open seal air SO damper.
43. Open BSD pair bottom.
44. Keep PA flow control damper at minimum 30%.
45. Start lube and lift pump.
46. Confirm lube oil flow 4.0 LPM before Ball Mill start up.
47. Start Ball Mill.
48. Open PASO.
49. Open hot air damper and bring Ball Mill temperature about 65°C.
50. Watch the SHS temperature increase. It should be 1 to 1.5°C/minute control by opening super heater drain on
reducing oil flow.
51. Charge spray water and bring super heater temperature to normal.
52. When Ball Mill level (low) comes down to 30% start coal feeders and increase coal feeding rate corresponding to
Mill temperature and level.
53. Bring 60% steam load on bottom coal burners and oil guns slowly.
54. Take top two oil guns in service one-by-one and adjust oil flow to control super heater steam temperature.
55. Start purging of top coal conduits and wait for ‘AADT OK to release’ signal to come.
56. Release auxiliary air to auto.
57. Open BSD pair top and increase the steam load gradually to full load. Maintain normal boiler parameters.
58. Put feed water control on auto.
59. Put ESP in service after removal of oil support and 80% steam load.
9. Operation monitoring & control
17. Monitor and maintain Boiler drum level.
18. Monitor and maintain Boiler furnace draft.
19. Monitor and Maintain Boiler main steam pressure and temperature by adjusting coal feed and
attemperator flow.
20. Monitor and maintain excess oxygen levels.
21. Reduce exit flue gas temperature by soot blowing as per SOP.
22. Monitor and maintain Boiler bed level and bed temperature.
23. Monitor and maintain Boiler water and steam parameters within range.
24. Monitor fan and motor bearing temperature.
25. Monitor oil level of Fluid coupling, WSB.
26. Check and report oil leakages, abnormal sound and vibration.
27. Monitor collection of coal sample and coal quality.
28. Monitor Boiler efficiency and report heat loss area.
29. Monitor Boiler instruments and their feedback positions.
30. Monitor Boiler auxiliary loading.
31. Monitor Boiler ash conveying system for normal operation.
32. Log Boiler operating parameters on regular basis.

10. Shutdown Procedure: Refer Shut down SOP

11. Best practices followed (If any):

12. Exception/ Emergency handling : Refer Shut SOP

13. Dos & Don’ts


DO’s DON’Ts
27. Check all the permissive before purging. 12. Exceed drum metal differential temperature >50 C
28. Monitor the expansion of the boiler. 13. Close steam drain before stop valve before
29. Monitor the drum metal rise temperature. continuous flow of steam.
30. Check for the flame healthiness through the peep
14. Don’t bypass any protection.
hole when oil gun firing is done.
15. Never force any oil gun.
31. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
32. Always follow the start-up curve provided by
manufacturer.
33. Check for oil leakages during oil firing.
34. Monitor the Drum water/ Steam silica.
35. Maintain Bottom Oil pressure.

14. Performance KPIs: Not Applicable


15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve

11 MFT Master fuel trip

ANNEXURE: ANN_RKT_E17_OPSOP_01_U_2
Reference SOP: E17_OPSOP_01_B#2
6. O & M parameters
 No. & Capacity: 1 per unit
Design Code Specification

Type of Boiler Bi- Drum, AFBC Boiler

Type of firing Under Bed Firing

Boiler Efficiency 82.0% +/- 1.5 % @MCR

Design Coal GCV 2950 Kcal/Kg

Steam Flow at Superheater Outlet 80 TPH @MCR

Steam Pressure at Superheater Outlet 52.5 Kg/Cm2 (g) @MCR

Steam Temp. at Superheater Outlet 450 o C @MCR

7. Checks before start up


7.1 Pre Checks
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Ensure healthiness of lube oil system of all equipments.
3. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
4. Ensure power availability of all Equipments.
5. Both ID Fans are available.
6. Both FD Fan is available.
7. Both PA Fan is available.
8. Coal Feeders are available.
9. APH are available.
10. ESP is available.
11. Coal Bunker level is sufficiently maintained.
12. Sufficient DM water is available.
13. Light up clearance available from all service departments and to be signed by all concerned personal.
14. Main Steam Stop Valve & Its Equalizer is operative.
15. All Motorized & Control Valves are operative.

16. PRDS station is available.

17. Ensure availability of Bottom ash & Fly ash system.

18. Ensure all CTA lines are cleaned


19. Check and attend all CTA line leakages after running of P.A. Fan
20. Bottom hopper filled up with water and ensures that water is overflowing.
21. Water charged into seal trough and ensures that water is overflowing.
22. Ensure availability of all Bed temperature sensors is available.
23. Ensure availability of BFP.
24. Availability of Flue Gas Path
25. Availability of Air Path
26. Ensure that Ring Header Drains are closed.
27. Cooling water system of all Boilers related equipment should be charged.
28. Ensure availability of Instrument air to all equipments.
29. Ensure availability of service air.
30. Ensure drum vents/ SH vents/ Economizer vent/ DSH vent kept in open position.
31. Ensure that all SH drains are open.
32. Ensure line drains up to inter connection valve are open.
33. Ensure all low pressure Boiler filling line valves kept closed.
34. Ensure that Main Steam Stop valve & its equalizer are closed.
35. Ensure SH spray control station is isolated.
36. Ensure Startup vent is opened.
37. All instrument gauges and impulse lines are charged and functional.
38. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
39. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
40. All sample coolers are charged.
41. Ensure that all safety valve in operative condition.
42. Check the smooth operation of the following dampers, gates and valves before lit up-
43. ID/FD / PA Fan inlet damper/ gate.
44. ID/FD/PA Fan outlet damper/gate.
45. FAD & PAD
46. Feed water control valves.
47. Spray water control valve.
48. Feed check valve with equalizer.

7.2 Permissive for startup (Purge Permissive)


1. No boiler trip
2. All LONV closed
3. LOTV closed
4. All Scanners “NO flame”
5. Pulveriser “OFF”
6. All feeders “OFF”
7. All air register damper modulating
8. Air flow >30% and <40%

7.3 Interlocks & Protections (Boiler Trip Interlock)


Interlocks Protections

Both ID FANS OFF

Both FD FANS OFF

EMERGENCY TRIP

FLAME FALIURE TRIP

LOSS OF ALL FUEL TRIP

F.B & LOSS OF AC

FURNANCE PRESSURE VERY HIGH

FURNANCE PRESSURE VERY LOW

DRUM LEVEL VERY HIGH

DRUM LEVEL VERY LOW


LOSS OF 110V DC

LOSS OF 24V DC

LOW AIR FLOW<30%

7.5 On MFT pickup

Sr. No. Action

1 Coal Mill Tripped

2 Coal Feeder Tripped

3 LOTV closed

4 All HAG closed

5 SADC 100% opened

8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Start one ID Fan.
4. Start one PA Fan.
5. Start one FD Fans.
6. Start second ID Fan & FD Fan.
7. Start charging bed material by keeping total air flow between 120-125 Cu M / Hr (Keep FD fans inlet damper
on 85% position). After charging bed material, measure the dead bed height and ensure it for 300-325 mm.
8. Check fluidization in all 4 compartments keeping FD air flow between 120-125 Cu M / Hr. And for
compartment -1, check for minimum air required to fluidize the bed. This may be around 40-45 Cu M / Hr.
again fluidized the all compartment for 5 minute.
9. Stop PA & FD fans and keep one ID fan running.
10. Check the Bed-material leakage from DP, inside the wind-box, and attend it, if found.
11. Spray dry charcoal in compartment -1. The quantity may be around 240 Kgs (60 bags). After that charge
Kerosene / HSD mixed charcoal. The quantity may be around 240 Kgs (60bags).
12. Spread charcoal to be ignited by means of fire torches, with sufficient suction, (-) 8 to (-) 10 mmwc.
13. Start PA & FD fan. Maintain PA duct pressure between 1050-1100 mmwc. Throttle Comp-1 CTA line air, up to
70% and ensure 100-120 mmwc differential pressure.
14. Open PAD & FAD of Comp -1. Increase FD air flow to 38 CuM / Hr and wait till bed top temperature starts
increasing.
15. Increase airflow further to 42 Cu M / Hr, so that fired charcoal is mixed evenly into bed and to bring top and
bottom bed temperature even. Wait till bed temperature (top and bottom both evenly) increases near to 550
Deg C. If required, charcoal charging may be continued from outside through manhole.
16. Ensure all feeders are selected on Remote (GUS).
17. Run the coal feeders of Comp-1 and gradually start increasing RPM from 0.10 to 7 RPM, depending upon
temperature variation and furnace physical condition. Stop charging charcoal, when temperature of bed
increases more than 550 deg.C. .
18. If the bed temperature starts increasing rapidly, decrease coal flow suitably and give a kick of FD air (50-55
CuM / Hr). Ensure that the bed temperature should not come down below 550 Deg C and coal feeders are
running at optimum rate to maintain bed temperature.
19. Open the throttled CTA line valve further and maintain CTA line differential pressure between 120-150
mmwc.
20. Boiler pressure should be raised gradually as per BHEL procedure (i.e. 1.5 to 2.0 degree C per minute or as
slow as possible, in case of cold start-up) and keeping bed temperature up to the range of 820-870 Deg C
accordingly.
21. Differential of Drum-metal Temperature (top & bottom, both sides) should not exceed > 50 deg. C, in any
case.
22. Close DRUM vents, when drum pressure is 5.0 KGSC.
23. Raise the pressure in boiler as per Boiler startup curve.
24. Charge the main Steam line through boiler stop valve equalizer.
25. Raise the super heater outlet pressure above process header pressure (> 40 Kg/cm2), open motorized stop
valve gradually, keeping in view of Main Steam line temperature greater than 110 o C. Charge the steam
header by opening MSSV up to interconnection.
26. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling).
27. Raise steam pressure to 1.5 KGSC above header pressure and open interconnection valve.
28. Gradually, open PRDS control Valve & increase steam load 5 to 10 TPH.
29. Raise the boiler pressure till we achieve steam flow on boiler. Close startup vent and super heater drains,
after ensuring continuous steam flow of around 20 TPH. It is essential to note that bed super heater drain
and 20% (minimum) start-up vent is opened, if the boiler load is running less than 10 TPH.
30. To activate Comp-2, increase the bed temperature of Comp-1 in the range of 925-950 Deg C. Activate Comp-
2 and watch the bed temperature of Comp-1. Do not allow Comp-1 bed temperature to come down below
700 Deg C. Accordingly stop Comp-2. Again raise Comp-1 bed temperature and reactivate Comp-2. By this
way, Comp-2 to be activated and to keep both compartment temperatures in the range of 850-870 Deg C. Air
flow may be increased accordingly.
31. After stabilization of two compartments, Comp-3 & Comp-4 are to be activated by following same procedure
as in point- No 30.
32. Give spray water control valve in service and maintain Sup. Heated steam temperature within design limit
(not more than 450 Deg C).
33. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per requirement.
34. Once the boiler is put into steady state operation, feed water control valve & furnace draft control are to be
turned into auto mode.
35. Check all the running equipments, inspect the furnace and stack. Stack emission should not be black.
36. Put ESP in service, when boiler load is 80% of MCR. (i.e. 65 TPH).
37. Monitor SPM of stack and check the rappers and KV of each field.
Important notes:-Use PPE (Gloves, helmet, apron, goggles and dust mask) while startup and operation of
boiler. Maintain SPM of stack less than 150 mg/NM3 after putting ESP in service
38. Use ear plug during steam venting & safety valve settings.
39. If the boiler is lit up in rainy season and feed coal is having high moisture, spread feed coal on the feeder
firing floor, in advance, before startup of the boiler and use this for initial feeding (manually), till two
compartments activation.
40. To ensure skilled manpower at firing floor as well as on control desk.
41. The quality of received charcoal to be recorded. The recommended quality parameters are as under: -
42. Size: -10-15 mm
43. Fines less than 15% (3 mm & below)
44. CV 5500 Kcal/Kg (Min)
45. Ash < 10%
9. Operation monitoring & control
1. Check the bearing temperature & vibration.
2. Permission to start any two coal elevation through FSSS.
3. Maintain the PA header pressure normal.
10. Shutdown Procedure: Refer Shut down SOP
11. Best practices followed (If any):N.A.

12. Exception/ Emergency handling : Refer SOP

13. Dos & Don’ts

DO’s DON’Ts
36. Check all the permissive before purging. 16. Exceed drum metal differential temperature >50 C
37. Monitor the expansion of the boiler. 17. Close steam drain before stop valve before
38. Monitor the drum metal rise temperature. continuous flow of steam.
39. Check for the flame healthiness through the peep
18. Don’t bypass any protection.
hole.
40. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
41. Always follow the start-up curve provided by
manufacturer.
42. Monitor the Drum water/ Steam silica.

14. Performance KPIs

15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve


ANNEXURE: ANN_RKT_E17_OPSOP_01_U_3

Reference SOP: E17_OPSOP_01_B#3


6. O & M parameters
 No. & Capacity: 1 per unit
Design Code Specification

Type of Boiler Bi- Drum, Pulverised Coal Fired Boiler

Type of firing Tangential Corner Firing

Boiler Efficiency 83.94% @MCR

Design Coal GCV 2950 Kcal/Kg

Steam Flow at Super heater Outlet 140 TPH @MCR

Steam Pressure at Super heater Outlet 111 Kg/Cm2 (g) @MCR

Steam Temp. at Super heater Outlet 535 o C @MCR

Reheat Steam Flow Not Applicable

Steam Pressure at Reheat Inlet Not Applicable

Steam Temp at Reheat Inlet Not Applicable

Steam Pressure at Reheat Outlet Not Applicable

Steam Temp. at Reheat Outlet Not Applicable

7. Checks before start up


7.1 Pre Checks
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Ensure healthiness of lube oil system of all equipments.
3. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
4. Ensure power availability of all Equipments.
5. Both ID Fans are available.
6. Both FD Fans are available.
7. Both Scanner Air Fans are available.
8. Bottom Oil system is available.
9. All Pulverisers & Feeders are available.
10. Regenerative APH are available.
11. ESP is available.
12. Coal Bunker level is sufficiently maintained.
13. Sufficient DM water is available.
14. Light up clearance available from all service departments and to be signed by all concerned personal.
15. Main Steam Stop Valve & Its Equalizer is operative.
16. All Motorized & Control Valves are operative.

17. Ensure availability of Bottom ash & Fly ash system.


18. Bottom hopper filled up with water and ensures that water is overflowing.
19. Water charged into seal trough and ensures that water is overflowing.
20. Ensure availability of Mill reject system.

21. Ensure availability of all Flame Scanner.

22. Ensure availability of BFP.


23. Open igniters cooling air valve.
24. Availability of Flue Gas Path
25. Availability of Air Path
26. Ensure that Ring Header Drains are closed.
27. Ensure that all wall soot blowers & LRSB's are in home position.
28. Cooling water system of all Boilers related equipment should be charged.
29. Ensure availability of Instrument air to all equipments.
30. Ensure availability of service air.
31. Check availability & healthiness of Oil guns & Igniter system.
32. Ensure drum vents/ SH vents/ Economizer vent/ DSH vent kept in open position.
33. Ensure that all SH drains are open.
34. Ensure line drains up to PRDT-01/Common Header open.
35. Ensure all low pressure Boiler filling line valves kept closed.
36. Ensure that Main Steam Stop valve & its equilizer are closed.
37. Ensure SH spray control station is isolated.
38. Ensure Startup vent is opened.
39. All instrument gauges and impulse lines are charged and functional.
40. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
41. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
42. All sample coolers are charged.
43. Ensure that all safety valve in operative condition.
44. Ensure readiness of ERV (Manually pilot valve checking)
45. Check the smooth operation of the following dampers, gates and valves before lit up-
46. ID/FD fan inlet damper/ gate.
47. ID/FD fan outlet damper/gate.
48. Coal mill HAG, CAG, HAD ,CAD
49. Feed water control valves.
50. Spray water control valve.
51. Oil combustion (LOTV) control valves.
52. All auxiliary and coal air damper.
53. Feed check valve with equalizer.

7.2 Permissive for startup (Purge Permissive)


1. No boiler trip
2. All LONV closed
3. LOTV closed
4. All Scanners “NO flame”
5. All pulveriser “OFF”
6. All feeders “OFF”
7. All HAG closed and CAD < 5% open
8. All auxiliary air damper modulating
9. Air flow >30% and <40%

7.3 Interlocks & Protections (Boiler Trip Interlock)


Interlocks Protections
Both ID FANS OFF

Both FD FANS OFF

EMERGENCY TRIP

FLAME FALIURE TRIP

LOSS OF ALL FUEL TRIP

F.B & LOSS OF AC

FURNANCE PRESSURE VERY HIGH

FURNANCE PRESSURE VERY LOW

DRUM LEVEL VERY HIGH

DRUM LEVEL VERY LOW

LOSS OF 110V DC

LOSS OF 24V DC

LOW AIR FLOW<30%

7.4 Oil Gun Trip Interlocks

Interlocks Protections

Atomizing Air pressure Low (3.0 Kg/Cm 2) & Minimum one LOTV close
LONV in open position

Oil pressure Low (3.0 Kg/Cm2) & Minimum one LONV in LOTV close
open position

7.5 On MFT pickup

Sr. No. Action

1 All Coal Mill Tripped

2 All Coal Feeder Tripped

3 LOTV closed

4 All HAG closed

5 SADC 100% opened

8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Start Air pre heaters
4. Charge Bottom Oil system at boiler.
a. Bottom Oil pump is in service with short recirculation maintaining header pressure 18 Kg/Cm 2
b. Slowly charge the Boiler Bottom Oil line.
5. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
6. Start one ID Fan.
7. Start one FD Fans.
8. Start second ID Fan & FD Fan.
9. Maintain total air flow more than 30% & less than 40%.
10. Check the boiler PURGE permissive is satisfied.
11. Start boiler purging. During purging ensure all SADC are opened 100%.
12. After completion of purging push reset SADC.
13. Maintain wind-box DP around 30 mmwc.
a. All Coal elevation- A, B, C, D Fuel air dampers are in auto & closed.
b. All auxiliary air dampers of elevation AB, BC & CD are in modulating, if not then adjust to maintain
the wind box DP as per boiler loading Vs Wind-box DP curve.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
14. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
15. Give Blow down the unit as required maintaining the drum water level insight in the gauge glass.
16. Start APH soot blowing from Steam in every 2 hours interval (up to oil gun in service).
17. Note: The firing rate should be controlled to keep the furnace exit gas temperature below 500 deg C.
18. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
19. Close drum vents at 2Kg/Cm2.
20. Open the CBD valve 100% and regulate it as per requirement.
21. Establish feed water flow through feed control station
a. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
b. 30% FCV to be taken in service & if it can’t be taken in service then only100% FCV can be taken in
service.
22. Maintain drum water level at normal level.
23. Close all SH drain & vents at 5-8 Kg/Cm 2.
24. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with
help of service department (only after Annual Overhauling).
25. Raise the pressure in boiler as per Boiler startup curve.
26. Give boiler hot blow down through bottom ring header after killing the fire at drum pressure 15, 25 and
35 kg/cm2 to control boiler water silica.
27. Charge the main Steam line through boiler stop valve equalizer
28. At 40 Kg/cm2 super heater outlet pressure, open motorized stop valve gradually, keeping in view of Main
Steam line Temperature greater than 110 o C.
29.
a. Raise the super heater outlet pressure above common header pressure or process header pressure if
Turbine is not in service.
b. Open HPT01 & PRDT01 for common header and PRDT-02 for process header for supplying the steam
to the process.
c. Raise the Boiler pressure and temperature till we achieve steam load about 10% of MCR. Close start-
up vent and drains before main Steam stop valve and maintain constant Steam flow on oil firing by
adjusting the steam load on Boiler #1 & 2.
30. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler
water conditions & start TSP dosing as per requirement.
31. For placing the first Pulveriser (A or B) in service, following conditions to be satisfied :
i. Minimum 3 out of 4 oil guns of elevation 'AB' must be in service.
ii. Cooling water of bearings opened.
iii. Coal burner shut off gates opened.
iv. Ensure all classifier vanes are identical.
v. Lubrication pump is running and ensure discharge pressure is > 3 Kg/cm 2.
vi. Coal gate to feeder is open.
vii. Exhauster / Mill discharge valve fully opened and vent valve closed.
viii. Hot air gate and hot air control dampers closed.
32. Ensure pulveriser ready condition on BMS panel / screen is present.
a. Start pulveriser.
b. Open hot air gate and increase the Pulveriser outlet temperature to 70ºC.
c. Start coal feeder at minimum rating. Regulate hot air control damper to maintain the required
temperature. Ensure the ignition of coal has started.
d. Adjust Pulveriser loading keeping current normal.
e. Charge the spray water to maintain super heater outlet temperature 535ºC +0ºC/-5ºC.
f. Place the second Pulveriser in service in a similar manner keeping pressure and temperature
parameters within limits. When the second Pulveriser is proven in service then equalize the feeder
rating of two Pulverisers.
33. Place the third pulveriser in service in a similar manner keeping pressure and temperature parameters
within limits. When the third Pulveriser is proven in service then equalize the feeder rating of all three
Pulverisers.

9. Operation monitoring & control


1. Check the bearing temperature & vibration.
2. Permission to start any two coal elevation through FSSS.
3. Maintain the PA header pressure normal.
10. Shutdown Procedure: Refer Shut down SOP
11. Best practices followed (If any):N.A.

12. Exception/ Emergency handling : Refer SOP

13. Dos & Don’ts


DO’s DON’Ts
43. Check all the permissive before purging. 19. Exceed drum metal differential temperature >50 C
44. Monitor the expansion of the boiler. 20. Close steam drain before stop valve before
45. Monitor the drum metal rise temperature. continuous flow of steam.
46. Check for the flame healthiness through the peep
21. Don’t bypass any protection.
hole.
47. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
48. Always follow the start-up curve provided by
manufacturer.
49. Monitor the Drum water/ Steam silica.

14. Performance KPIs

15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan


7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve


ANNEXURE: ANN_RKT_E17_OPSOP_01_U_4

Reference SOP: E17_OPSOP_01_B#4


6. O & M parameters
 No. & Capacity: 1 per unit
Design Code Specification

Type of Boiler Bi- Drum, Pulverised Coal Fired Boiler

Type of firing Tangential Corner Firing

Boiler Efficiency 85.19% @MCR

Design Coal GCV 2950 Kcal/Kg

Steam Flow at Superheater Outlet 150 TPH @MCR

Steam Pressure at Superheater Outlet 111 Kg/Cm2 (g) @MCR

Steam Temp. at Superheater Outlet 535 o C @MCR

Reheat Steam Flow Not Applicable

Steam Pressure at Reheat Inlet Not Applicable

Steam Temp at Reheat Inlet Not Applicable

Steam Pressure at Reheat Outlet Not Applicable

Steam Temp. at Reheat Outlet Not Applicable

7. Checks before start up


7.1 Pre Checks
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Ensure healthiness of lube oil system of all equipments.
3. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
4. Ensure power availability of all Equipments.
5. Both ID Fans are available.
6. Both FD Fans are available.
7. Both PA Fans are available.
8. Both Scanner Air Fans are available.
9. Bottom Oil system is available.
10. All Pulverisers & Feeders are available.
11. All seal air Fans are available.
12. Tubular APH are available.
13. ESP is available.
14. Coal Bunker level is sufficiently maintained.
15. Sufficient DM water is available.
16. Light up clearance available from all service departments and to be signed by all concerned personal.
17. Main Steam Stop Valve & Its Equalizer is operative.
18. All Motorized & Control Valves are operative.
19. Ensure availability of Bottom ash & Fly ash system.

20. Bottom hopper filled up with water and ensures that water is overflowing.
21. Water charged into seal trough and ensures that water is overflowing.
22. Ensure availability of Mill reject system.

23. Ensure availability of all Flame Scanner.

24. Ensure availability of BFP.

25. Open igniter cooling air valve.


26. Availability of Flue Gas Path
27. Availability of Air Path
28. Ensure that Ring Header Drains are closed.
29. Ensure that all wall soot blowers & LRSB's are in home position.
30. Cooling water system of all Boilers related equipment should be charged.
31. Ensure availability of Instrument air to all equipments.
32. Ensure availability of service air.
33. Check availability & healthiness of Oil guns & Igniter system.
34. Ensure drum vents/ SH vents/ Economizer vent/ DSH vent kept in open position.
35. Ensure that all SH drains are open.
36. Ensure line drains up to PRDT-01/Common Header open.
37. Ensure all low pressure Boiler filling line valves kept closed.
38. Ensure that Main Steam Stop valve & its equilizer are closed.
39. Ensure SH spray control station is isolated.
40. Ensure Startup vent is opened.
41. All instrument gauges and impulse lines are charged and functional.
42. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
43. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
44. All sample coolers are charged.
45. Ensure that all safety valve in operative condition.
46. Ensure readiness of ERV (Manually pilot valve checking)
47. Check the smooth operation of the following dampers, gates and valves before lit up-
48. ID/FD/PA fan inlet damper/ gate
49. ID/FD/PA fan outlet damper/gate
50. Coal mill HAG, CAG, HAD ,CAD and seal air solenoid valve
51. Feed water control valves.
52. Spray water control valve.
53. Oil combustion (LOTV) control valves.
54. All auxiliary and coal air damper.
55. Feed check valve with equalizer.
56. Flue gas damper primary & secondary pass

7.2 Permissive for startup (Purge Permissive)


1. No boiler trip
2. All LONV closed
3. LOTV closed
4. All Scanners “NO flame”
5. All pulveriser “OFF”
6. All feeders “OFF”
7. Both PA “OFF”
8. All HAG closed and CAD < 5% open
9. All auxiliary air damper modulating
10. Air flow >30% and <40%
7.3 Interlocks & Protections (Boiler Trip Interlock)
Interlocks Protections

Both ID FANS OFF

Both FD FANS OFF

EMERGENCY TRIP

FLAME FALIURE TRIP

LOSS OF ALL FUEL TRIP

F.B & LOSS OF AC

FURNANCE PRESSURE VERY HIGH

FURNANCE PRESSURE VERY LOW

DRUM LEVEL VERY HIGH

DRUM LEVEL VERY LOW

LOSS OF 110V DC

LOSS OF 24V DC

LOW AIR FLOW<30%

7.4 Oil Gun Trip Interlocks

Interlocks Protections

Atomizing Air pressure Low (3.0 Kg/Cm 2) & Minimum one LOTV close
LONV in open position

Oil pressure Low (3.0 Kg/Cm2) & Minimum one LONV in LOTV close
open position

7.5 On MFT pickup

Sr. No. Action

1 All Coal Mill Tripped

2 All Coal Feeder Tripped

3 PA Fan Tripped

4 LOTV closed
5 All HAG closed

6 SADC 100% opened

8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Charge Bottom Oil system at boiler.
a. Bottom Oil pump is in service with short recirculation maintaining header pressure 18 Kg/Cm 2
b. Slowly charge the Boiler Bottom Oil line.
4. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
5. Keep the flue gas damper of air pre-heater primary side in fully closed position
6. Keep the flue gas damper of air heater secondary side in open position
7. Start one ID Fan.
8. Start one FD Fans.
9. Start second ID Fan & FD Fan.
10. Maintain total air flow more than 30% & less than 40%.
11. Check the boiler PURGE permissive is satisfied.
12. Start boiler purging. During purging ensure all SADC are opened 100%.
13. After completion of purging push reset SADC.
14. Maintain wind-box DP around 30 mmwc.
a. All Coal elevation- A, B, C, D Fuel air dampers are in auto & closed.
b. All auxiliary air dampers of elevation AB, BC & CD are in modulating, if not then adjust to maintain
the wind box DP as per boiler loading Vs Wind-box DP curve.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
15. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
16. Give Blow down the unit as required maintaining the drum water level insight in the gauge glass.
17. Note: The firing rate should be controlled to keep the furnace exit gas temperature below 500 deg C.
18. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
19. Close drum vents at 2Kg/Cm2.
20. Open the CBD valve 100% and regulate it as per requirement.
21. Establish feed water flow through feed control station
a. Start BFP & line up feed water system. (Keeping FW flow through HPHs.)
b. 30% FCV to be taken in service & if it can’t be taken in service then only100% FCV can be taken in
service.
22. Maintain drum water level at normal level.
23. Close all SH drain & vents at 5-8 Kg/Cm 2.
24. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with
help of service department (only after Annual Overhauling).
25. Raise the pressure in boiler as per Boiler startup curve.
26. Give boiler hot blow down through bottom ring header after killing the fire at drum pressure 15, 25 and
35 kg/cm2 to control boiler water silica. Charge the main Steam line through boiler stop valve equalizer
27. At 40 Kg/cm2 super heater outlet pressure, open motorized stop valve gradually, keeping in view of Main
Steam line Temperature greater than 110 o C.
28.
a. Raise the super heater outlet pressure above common header pressure or process header pressure if
common header is not charged.
b. Open HPT01 & PRDT01 for common header and PRDT-02 for process header for supplying the steam
to the process.
c. Raise the Boiler pressure and temperature till we achieve steam load about 10% of MCR. Close start-
up vent and drains before main Steam stop valve and maintain constant Steam flow on oil firing by
adjusting the steam load on Boiler #1 & 2.
29. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler
water conditions & start TSP dosing as per requirement.
30. For placing the first Pulveriser (A or B) in service, following conditions to be satisfied :
i. Minimum 3 out of 4 oil guns of elevation 'AB' must be in service.
ii. Cooling water of bearings opened.
iii. Coal burner shut off gates opened.
iv. Ensure all classifier vanes are identical.
v. Lubrication pump is running and ensure discharge pressure is > 3 Kg/cm 2.
vi. Coal gate to feeder is open.
vii. Exhauster / Mill discharge valve fully opened and vent valve closed.
viii. Hot air gate and hot air control dampers closed.
31. Before start Mill following activities to be carried out.
32. Start PA fan.
33. Open the flue gas outlet damper of primary air pre-heater and PA fan discharge damper. Maintain header
pressure above 750 mmwc.
34. Start SEAL air fan and maintain header pressure above 1400mmWC.
35. Ensure pulveriser ready condition on BMS panel / screen is present.
a. Start pulveriser.
b. Open hot air gate and increase the Pulveriser outlet temperature to 70ºC.
c. Start coal feeder at minimum rating. Regulate hot air control damper to maintain the required
temperature. Ensure the ignition of coal has started.
d. Adjust Pulveriser loading keeping current normal.
e. Charge the spray water to maintain super heater outlet temperature 535ºC +0ºC/-5ºC.
f. Place the second Pulveriser in service in a similar manner keeping pressure and temperature
parameters within limits. When the second Pulveriser is proven in service then equalize the feeder
rating of two Pulverisers.
36. Place the third pulveriser in service in a similar manner keeping pressure and temperature parameters
within limits. When the third Pulveriser is proven in service then equalize the feeder rating of all three
Pulverisers.

9. Operation monitoring & control


4. Check the bearing temperature & vibration.
5. Permission to start any two coal elevation through FSSS.
6. Maintain the PA header pressure normal.
10. Shutdown Procedure: Refer Shut down SOP
11. Best practices followed (If any):N.A.

12. Exception/ Emergency handling : Refer SOP

13. Dos & Don’ts

DO’s DON’Ts
50. Check all the permissive before purging. 22. Exceed drum metal differential temperature >50 C
51. Monitor the expansion of the boiler. 23. Close steam drain before stop valve before
52. Monitor the drum metal rise temperature. continuous flow of steam.
53. Check for the flame healthiness through the peep
24. Don’t bypass any protection.
hole.
54. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
55. Always follow the start-up curve provided by
manufacturer.
56. Monitor the Drum water/ Steam silica.

14. Performance KPIs


15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve


ANNEXURE: ANN_RPD_E17_OPSOP_01

 Reference SOP : E17_OPSOP_01


 Applicability to generating unit(s) : unit #1 to #10

 Scope : This annexure covers the 6 to 15 clauses of SOP E17_OPSOP_01

6. O & M parameters
Boiler

Sl.No Boiler#1 &2 Boiler#3 & 4 Boiler#9 & 10

1 Type Balanced draft, Dry Balanced draft, Dry Balanced draft, Dry Bottom
Bottom Bi-Drum, Bottom Bi-Drum, Hopper, Bi-Drum, Natural
Natural Circulation Natural Circulation Circ, Tilting Tangential
-firing

2 Manufacturer ALSTOM ALSTOM BHEL

3 Capacity 275 TPH 302 TPH 320 TPH

4 Drum design pressure 103.73 kg/cm2 112.5 kg/cm2 117 kg/cm2

5 Drum working 97.40 kg/cm2 103.2 kg/cm2 109 kg/cm2


pressure

6 Design pr. and Temp at 91.4 kg/cm2 and 515 0 C 93kg/cm2 and 530 0 C 96 kg/cm2 and 535 0C
SH outlet

7 Fuel Oil/Coal Oil/Coal Oil/Coal

8 Type of APH Tubular, Gas through Tubular, Air through tube Tubular, Gas through tube
tube

Sl.No Boiler#Spare & 5 Boiler#6 & 7 Boiler#8

1 Type Balanced draft, Dry Balanced draft, Dry Balanced draft, Dry Bottom
Bottom Hopper, Bi- Bottom Hopper, Bi-Drum, Hopper, Bi-Drum, Natural
Drum, Natural Circ, Natural Circ, Tilting Circ, Tilting Tangential
Tilting Tangential Tangential -firing -firing
-firing

2 Manufacturer BHEL BHEL BHEL

3 Capacity 275TPH 290 TPH 290 TPH

4 Drum design pressure 110 kg/cm2 114 kg/cm2 114 kg/cm2

5 Drum working pressure 104.5 kg/cm2 107 kg/cm2 107 kg/cm2

6 Design pr. and Temp at 95 kg/cm2 and 530 oC 96 kg/cm2 and 530 oC 96 kg/cm2 and 535oC
SH outlet

7 Fuel Oil/Coal Oil/Coal Oil/Coal


8 Type of APH Rotary Rotary Rotary

7. Checks before start up


7.1 Pre Checks
1. Ensure all PTWs are returned & all the associated equipments are available.
2. Ensure healthiness of lube oil system of all equipments.
3. Ensure that all Inspection door/ Man hole/ Peep hole of boiler are closed.
4. Ensure power availability of all Equipments
5. Both ID Fans are available.
6. Both FD Fans are available.
7. Both Scanner Air Fans are available.
8. LDO/ HSD/ HFO/ Bottom Oil system is available.
9. All Pulverisers & Feeders are available.
10. All PA Fans are available.
11. All seal air Fans are available.
12. Regenerative/ Tubular APH are available.
13. Both pass of ESP are available.
14. Coal Bunker level is sufficiently maintained.
15. Sufficient DM water is available.
16. Light up clearance available from all service departments and to be signed by all concerned personal.
17. Main Steam Stop Valve & Its Equalizer are operative.
18. All Motorized & Control Valves are operative.
19. APH Soot Blowing system must be available.
20. Ensure availability of Bottom ash & Fly ash system.
21. Ensure that bottom hopper filled up and water is overflowing.
22. Water charged into seal trough and water is overflowing.
23. Ensure availability of Mill reject system.
24. Ensure availability of all Flame Scanner.
25. Ensure availability of BFP.
26. Open gun and igniter cooling air valves.
27. Availability of Flue Gas Path
28. Availability of Air Path
29. Ensure that Ring Header Drains are closed.
30. Ensure that all wall soot blowers & LRSB's are in home position.
31. Cooling water system of all boiler related equipment should be charged.
32. Ensure availability of Instrument air to all equipments.
33. Ensure availability of service air.
34. Check availability & healthiness of Oil guns & Igniter system.
35. Ensure drum vents/ SH vents/ RH vents/ Economizer vent/ DSH vent kept in open position.
36. Ensure that all SH drains are open.
37. Ensure all low pressure boiler filling line valves kept closed.
38. Ensure that Main Steam Stop valve & its equilizer are closed.
39. Ensure SH spray control station is isolated.
40. Ensure Start-up vent is opened.
41. All instrument gauges and impulse lines are charged and functional.
42. DM water filled up along with N2H4 & NH3 up to boiler Lit-Up level.
43. ESP rapper started and ESP hopper heater switched ON before boiler lit-up.
44. All sample coolers are charged.
45. Check the burner tilt operation from -30 to +30 degrees for its smooth operation and symmetry of tilt at
each corner.
46. Ensure Burner tilt is at horizontal position.
47. Ensure that all safety valve in operative condition.
48. Ensure readiness of ERV (Manually pilot valve checking)
49. Check the smooth operation of the following dampers, gates and valves before lit up-
50. ID/FD/PA fan inlet damper/ gate
51. ID/FD/PA fan outlet damper/gate
52. Coal mill HAG, CAG, HAD ,CAD and seal air solenoid valve
53. Feed water control valves.
54. Spray water control valve.
55. Oil combustion control valves
56. All auxiliary and coal air damper
57. Feed check valve with equalizer.
58. Flue gas damper Pass-A &B
59. APH bypass Sec. Air damper Pass-A &B.(Only for tubular APH)

7.2 Permissive for startup (Purge Permissive)


1. No boiler trip
2. All LONV/ HONV closed
3. LOTV/ HOTV closed
4. All Scanners “NO flame”
5. All pulveriser “OFF”
6. All feeders “OFF”
7. Both PA “OFF”
8. All HAG closed and CAD < 5% open
9. All auxiliary air damper modulating
10. Air flow >30% and <40%

7.3 Interlocks & Protections (Boiler Trip Interlock)


Interlocks Protections

23. ALL ID FANS OFF


24. ALL FD FANS OFF
25. EMERGENCY TRIP
26. FLAME FALIURE TRIP
27. LOSS OF ALL FUEL TRIP
28. F.B & LOSS OF AC
29. REHEATER PROTECTION TRIP
30. FURNANCE PRESSURE VERY HIGH
31. FURNANCE PRESSURE VERY LOW
32. DRUM LEVEL VERY HIGH
33. DRUM LEVEL VERY LOW
34. LOSS OF 220V DC
35. LOSS OF 24V DC
36. LOW AIR FLOW<30%

7.4 Oil Gun Trip Interlocks

Interlocks Protections
37. Atomizing Air pressure Low & Minimum 38. LOTV/ HOTV close
one LONV in open position
39. Oil pressure Low & Minimum one LONV 40. LOTV/ HOTV close
in open position

7.5 On MFT pickup

Sl. No. Action


1 All Coal Mill Tripped

2 All Coal Feeder Tripped

3 All PA Fan Tripped

4 LOTV/ HOTV closed

5 All HAG closed

6 SH spray valve closed

7 SADC 100% opened

8. Startup sequence
1. Charge Instrument air & service air to all equipments.
2. Boiler filled up to Normal Drum Level.
3. Start both Air preheaters.
4. Charge LDO/ HSD/ HFO/ Bottom Oil system at boiler.
a. LDO/ HSD/ HFO/ Bottom Oil pump is in service with recirculation maintaining header pressure.
b. Slowly charge the Boiler LDO/ HSD/ HFO/ Bottom Oil line.
5. Start AC Scanner Air Fan (Also ensure the power normalization of DC Scanner Air Fan)
6. Start one ID Fan.
7. Start one FD Fans.
8. Start second ID Fan & FD Fan.
9. Maintain total air flow more than 30% & less than 40%.
10. Check the boiler ‘’PURGE’’ permissive are satisfied.
11. Start boiler purging. During purging ensure all SADC are opened 100%.
12. Maintain wind-box DP around 30 to 40 mmwc.
a. All Coal elevation- A, B, C, D, E Fuel air dampers are closed.
b. All auxiliary air dampers of elevation AB, BC, CD & DE are in modulating.
c. Lower manual AA damper to be kept at 50% but it may be adjusted as per flame condition.
13. Light up the boiler at AB elevation oil gun keeping Furnace draft -5 to -10 mmwc.
14. Start APH soot blowing from Steam in every 2 hours interval (up to oil gun in service) and start the sonic soot
blower.
15. Blow down the unit as required maintaining the drum water level insight in the gauge glass.
16. Control the firing rate as required within permissible limit (as per startup curve) to raise the pressure.
17. Close drum vents at 2Kg/Cm2.
18. Open the CBD valve 100% and regulate it as per requirement.
19. Establish feed water flow through feed control station and start BFP & line up feed water system.
20. Maintain drum water level at normal level.
21. Close all vents at 2 to 3 Kg/Cm2.
22. Close all SH drains 1,2 &3at 10 Kg/Cm 2 and ensure that final SH drain is full open till synchronization.
23. While the boiler is heating up, frequent checks should be made of the boiler expansion movements with help
of service department (only after Annual Overhauling)
24. Give boiler hot blow down through bottom ring header drain after killing the fire at drum pressure 10, 20, 30
&40 Kg/Cm2. Further blow downs to be done in view of Drum water/ Steam silica condition.
25. Check boiler water concentrations and constituents as frequently as required to maintain proper boiler water
conditions & start TSP dosing as per chemical department.
26. Open Main Steam equalizer valve at 20 Kg/Cm 2, keeping Turbine side steam line drains in open condition.
27. Open Main Steam Stop Valve at 30 Kg/Cm 2and close Main Steam equalizer valve.
28. Raise the pressure in boiler as per Boiler startup curve and requirement of turbine.
8.1 Checks during boiler Lit- Up.
1. Check for any igniter oil leakages/ seepages.
2. Check oil igniters flame condition and no any oil spillage in the furnace.
3. Check for any oil leakages/ seepages.
4. Check drum metal differential temperatures should not exceed 50 o C.
5. Maintain drum level up to Normal level.
6. Final superheater drain should be open right from the very beginning.
7. Open CBD to maintain continuous flow from economizer.
8. Check that phosphate dozing in boiler drum is done.
9. Check for continuous rotation of oil guns at 15 min time interval.

9. Operation monitoring & control


1. Check the bearing temperature & vibration of all fans in boiler area.
2. Permissive to start coal firing through any elevation by FSSS.
3. Maintain the PA header pressure to normal.
10. Shutdown Procedure
Follow boiler shutdown SOP.

11. Best practices followed (If any): NA

12. Exception/ Emergency handling : NA

13. Dos & Don’ts


DO’s DON’Ts
57. Check all the permissive before purging. 25. Exceed drum metal differential temperature >50 C
58. Monitor the expansion of the boiler. 26. Close SH drain-4 before synchronization of machine.
59. Monitor the drum metal rise 27. Close the APH bypass damper and gate when the flue gas
temperature. temperature <150 oC.
60. Check for the flame healthiness
28. Don’t bypass any protection.
through the peep hole when oil gun
29. Never force any oil gun.
firing is done.
61. Hot flushing through LPD (Ring header)
should be done very carefully and
safely.
62. Always follow the start-up curve
provided by manufacturer.
63. Check for oil leakages during oil firing.
64. Monitor the Drum water/ Steam silica.
65. Maintain HSD/ LDO/ HFO/ Bottom Oil
pressure between 5 to 6.5 Kg/Cm 2

14. Performance KPIs : NA


15. Abbreviation

S.no Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 PRDS Pressure reducing and de superheating


Station

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve

11 MFT Master fuel trip

ANNEXURE: ANN_UAL_E17_OPSOP_01
 Reference SOP (SMP) :ANN_UAL_E17_OPSOP_01
 Applicability to generating unit(s) : U# 1,2,3

 Scope : This annexure covers the 6,7,8,13 clauses of SOP (SMP) E17_OPSOP_01

6. O & M parameters

No. & Capacity: 1 per unit

Design Code Specification


Balance draft ,Dry bottom, Natural
Type of Boiler circulation ,Single Drum, Pulverised Coal Fired
Boiler

Type of firing Tangential Corner Firing

Boiler design/warranty efficiency 90.4% (LHV)/90% (LHV)

Boiler Efficiency 85.27% @ BMCR


Design Coal GCV 3390 Kcal/Kg
Steam Flow at Superheater Outlet 300 TPH @ BMCR

Maximum pressure allowed 7.4 MPa

Feed water temperature 160oC


Steam Pressure at Superheater Outlet 69 Kg/Cm2 (g) @ BMCR
Rate of blowdown 2%
Inlet temp. of air at APH 30oC
Hot gas temp. 315oC
Exit flue gas temp. 155oC
Steam Temp. at Superheater Outlet 490O C @ BMCR

7. Checks before start up:

A. Mechanical check list:


Sl. No. Action Remarks Responsibility Status (Y/N)
A SCE & SCO
Cooling Water System:

1 Ensure all permit to work has been cancelled SCE Control room

2 Ensure water level in absorption pond >3.2m Field Operator

3 Check line up is complete Field engineer

4 Start one CW pump CRE (opn.), Field


operator

Charge condenser flow waterside by opening condenser


5 inlet/outlet valve & cooling tower water valve Field operator

6 Air venting complete, close vent Field operator

CRE (Opn), Field


7 Start cooling tower fan operator

8 Check CW parameters Field operator

CRE (Opn), Field


9 Put stand by CW pump on ‘Auto’ start operator

B ACW System:

All ACW circuits are lined up at IDF, FDF, PAF,


1 APH,Compressor& mills lub oil system etc Field Operator

2 Start the ACW pump CRE (opn),

3 Put another booster pump in ‘Auto’ CRE(opn)

C Compressed Air System:

1 Ensure ACW flow Field Operator

Check line up for compressed air system, air receivers &


2 air driers Field Operator

Start one compressor, observe for receiver pressure build CRE (opn), Field
3 up engineer

4 Put another compressor in ‘Auto’ mode CRE (Opn)

D Other:

1 All manholes are securely closed Boiler Operator

2 Ensure all permit to work has been cleared SCE

Ensure all scanner air filter & HFO filter are clean & SCO & SCE
3 vented (mechanical)

SCO, Boiler
4 Check oil gun are clean Operator& SCE

5 Ensure AC power supply for FSSS & hydra step are normal SCE(electrical)

DM plant
7 Ensure DM plant tank level is normal (80%) operator/SCO

8 Check bottom ash hopper & seal trough filled with water Boiler Operator

9 Ensure overflowing of seal trough Boiler Operator

Ensure fly & bottom ash handling system are ready & AHP field
10 available operator/SCO
11 Ensure availability of ESP

12 Line up Boiler fill pump towards drum Boiler Operator

Ensure drum & S/H, Eco., De- S.H. vents are open & all
14 drains are closed Boiler Operator

Ensure ring header drain valves close & economiser


15 recirculation valve are open Boiler Operator

16 Ensure availability of stack path Boiler Operator

17 Check line up for chemical dosing line & sampling line Boiler Operator/SCO

Check up for proper positioning of all expansion pointer


18 and set at ‘0’ position Boiler Operator/SCO

B. E & I check list:


Status
Sl.No. Action Remarks Responsibility
(Y/N)
All motorized and pneumatic valves and dampers have CRE(Opn),SCO,SCE,
1 passed static test, Opening and closing freely in the right
SCE(E & I)
direction under remote control

Each alarm system have passed static test, with alarm


2 CRE (Elec)
window indicating Correctly

Emergency button for each rotating equipments are Boiler Operator


3
effective
Sequence control system of each auxiliary plant has
passed test, showing logic iscorrect for start-up and SCE (C & I)
4
shutdown and plant items operate reliably for the
followings:

A Start-up conditions of oil system of each of fan SCE (C & I)

B Interlocks of Fuel oil pumps SCE (C & I)

Start-up and shutdown conditions and interlocks of IDF,


C SCE (C & I)
FDF, and PA fans

Interlocks of dampers SCE (C & I)


D

E Testing of sequence start-up and shutdown of each fan SCE (C & I)


SCE (C & I)
FSSS have passed static test, correct in logic and reliable
5
in action as follows: SCE ( Opn )

SCE(C&I),SCE(Opn),
A Conditions of furnace purging
SCO WIN

SCE (C & I)
Conditions of boiler MFT, and interlocked actions
B
initiated by MFT WIN/UAIL

D Conditions of oil ignition SCE (C & I)

E Programmed start-up and stop of oil guns SCE (C & I)

H Start up conditions of each mill and coal feeder SCE (C & I)

I Conditions of mill start-up and shutdown SCE (C & I)

Automatic weighing system of each coal feeder has been SCE (C&I)
6
adjusted and tested accurate with correct indication
Furnace gas temperature probes have been adjusted SCE (C & I)
8
and set and tested freely being protruded and retracted
Programmed control system of soot blowing and
9 intermittent blow down has been adjusted statically, and SCE (C & I)
operated correctly and reliably in simulation test
Simulation testing of boiler interlocks and protections
10 has been finished, showing correct in logic and reliable SCE (C & I)
in action

11 Availability of communication system SCE ( Opn )

8. Cold start up sequence:

1. Start filling of Boiler by running DM transfer pump & filling up .If de-aerator in service Water can be taken
through starting the BFP’s
2. Stop filling when drum level increases to <= 20 % But not less than 10%.
3. Start-up one IDF A or B side then start the corresponding opposite corner FDF A or B side before that Start
respective ID Fan and FD Fan lube oil system.(Refer to Doc No For FD F & ID F start up )
4. In all fans lube oil system Start one lube oil pump & put other stand by pump in auto (Please ensure cooling
water line in charge condition, lube oil tank level must be <=75%, pressure should be maintained 2.4 bar and
maintained oil level at both bearing side <75%).
5. After starting of one FDF & IDF maintain the air flow around 30% (1,00,000 m³/hr to 1, 20,000 m³/hr) of the
total air flow (4,00,000 m³/hr).Ensure Furnace draft should be maintained between -2 to -5 mmWC.
6. Put the furnace purging for 10-15 min.
7. Start one Scanner air fan & check the pressure should be between 6 to 7 KPa. Put the other stand by fan in
Auto interlock.
8. Start LDO supply pump and put in long recirculation mode, check the oil pressure (10 to15 bars) in Boiler
floor of 12 meter

9. Start all Mill lube oil system after mill lube oil temperature reaches 40-45 deg (Start the heaters to raise the
lube oil temperature to 40-45 deg )

10. After ensuring boiler ignition conditions are satisfied, open main fuel oil valve, get ready to ignite the

furnace

11. Start ignition after receiving the order

· The lower oil guns should receive priority when applying oil guns.

· Apply oil guns on the cross.

· Change over oil guns regularly.

i. .Operate or change over oil guns depending on firing condition & carefully watch

for Drum metal temperature difference not >50 0C.


12. Open drain valves of super heaters.
13. Oil gun should be circulating for evenly raising the temperature. Temperature raise should be 1.5 deg C / min
Up to drum pressure 1-2 kg/cm2
14. Wait for pressure raise of 3 bars close all vent at 42 m and Super heater drain to be closed.
15. Wait for pressure raise of 3 bar, open start up vent.
16. Wait for pressure raise of 10 bars, kill the fire & go for HOT blow down, Drum man hole door bolt tightness to
be done if required.
17. Again boiler should be light up with same sequence.
18. Wait for pressure raise of 10bar and temperature 220 deg C charge the PRDS.
19. Starts the HFO pump observe the pressure boiler floor should be 15-20 bar by putting the long recirculation
mode.(For HFO pump start up follow the SOP -49 804 3P )
20. Wait for flue gas temperature raise >250 deg C take HFO gun into service. Oil gun should be circulating for
evenly raising the temperature.
21. Wait for flue gas temperature raise >500 deg C start PA fan & take mill into service.(for starting the mill
minimum 03 oil burners should be in adjacent elevation)
22. Start another ID Fan & FD Fan and maintain the furnace draft.
23. When ESP inlet temperature >120 deg C, Charge the ESP fields one by one.
9. Operation monitoring & control
7. Check the bearing temperature & vibration.
8. Permission to start any two coal elevation through FSSS.
9. Maintain the PA header pressure normal.
10. Shutdown Procedure: Refer Shut down SOP
11. Best practices followed (If any):N.A.

12. Exception/ Emergency handling : Refer SOP


13. Dos & Don’ts

DO’s DON’Ts
66. Check all the permissive before purging. 30. Exceed drum metal differential temperature >50 C
67. Monitor the expansion of the boiler. 31. Close steam drain before stop valve before
68. Monitor the drum metal rise temperature. continuous flow of steam.
69. Check for the flame healthiness through the peep
32. Don’t bypass any protection.
hole.
70. Hot flushing through LPD (Ring header) should be
done very carefully and safely.
71. Always follow the start-up curve provided by
manufacturer.
72. Monitor the Drum water/ Steam silica.

14. Performance KPIs

15. Abbreviation

Sno Abbreviation used Stands for

1 CPP Captive power plant

2 PTW Permit to work

3 BFP Boiler feed pump

4 LOTOTO Lock out tag out try out

5 FD FAN Force draught fan

6 ID FAN Induce draft fan

7 HTPRDS High temperature pressure reducing and de superheating

8 CBD,IBD,EBD Continuous/intermittent/emergency

9 IGV Inlet guide vane

10 MS Main steam stop valve