300 MW Anthracite Coal Fired Power Station Boiler & Auxiliaries

QUANG NINH THERMAL POWER JOINT STOCK COMPANY
2×300 MW
SEC BOILER & AUXILIARIES OPERATION MANUAL
2 × 300 MW – Anthracite Coal Fired Power Station
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Boiler & Auxiliaries .c
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Operation Manual
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Date: 2008-09-15 No.:QN1-SEC-G-04-TP-003 Rev. : A

2×300 MW
Index
1 SCOPE ..................................................................................................................................................... 4
2 SPECIFIC QUOTING DOCUMENTS .................................................................................................... 4
3 BOILER TECHNIQUE SPECIFICATION.............................................................................................. 5
3.1 INTRODUCTION OF BOILER .................................................................................................................. 5
3.2 BOILER NAMEPLATE ............................................................................................................................ 7
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3.3 BOILER DESIGN INFORMATION ............................................................................................................ 8
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3.4 REQUIREMENT FOR QUALITY OF BOILER STEAM............................................................................... 16
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3.5 BOILER AUXILIARY EQUIPMENT TECHNICAL SPECIFICATIONS ............................................................ 19
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4 BOILER AND INTERLOCK PROTECTION VALUE AUXILIARY EQUIPMENT........................... 34
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4.1 BOILER PROTECTING LIMIT VALUE .................................................................................................... 34

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4.2 BOILER AUXILIARY INTERLOCK PROTECTION VALUE AUXILIARY EQUIPMENT. ................................... 35

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5 START-UP.............................................................................................................................................. 44
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5.1 BASIC REGULAR ................................................................................................................................ 44

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5.2 REPAIR TEST AND ACCEPTANCE INSPECTION ...................................................................................... 44

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5.3 CHECK AND PREPARATION BEFORE START-UP..................................................................................... 70
5.4 COLD START-UP SEQUENCE ................................................................................................................ 74
5.5 HOT START-UP .................................................................................................................................... 83
5.6 PARAMETER CONTROL VALUE IN THE PROCESS OF START-UP ............................................................. 87
6 MONITORING AND ADJUSTMENT IN BOILER OPERATION ...................................................... 88
6.1 THE MAIN TASK AND OBJECTIVES OF OPERATION ADJUSTMENT ......................................................... 88
6.2 MAIN PARAMETER AND LIMIT OF OPERATION CONTROL .................................................................... 88
6.3 CHECKING, MONITORING AND MAINTENANCE IN BOILER OPERATION ................................................ 91
Date: 2008-09-15 No.:QN1-SEC-G-04-TP-003 Page 1 Rev. : A

2×300 MW
6.4 BOILER OPERATION MEASURE CONTROL .......................................................................................... 100
7 SHUT-DOWN OF BOILER................................................................................................................. 100
7.1 BASIC REGULAR (GENERALS ) .......................................................................................................... 100
7.2 PREPARATION BEFORE SHUT-DOWN OF BOILER ................................................................................ 101
7.3 SHUT-DOWN WITH SLIDING PARAMETER (NEED COOLING ) .............................................................. 102
7.4 NORMAL SHUT-DOWN (HOT STAND-BY ) .......................................................................................... 104
7.5 EMERGENCY SHUT-DOWN ................................................................................................................ 105
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7.6 SHUT-DOWN MAINTENANCE ............................................................................................................ 105
8 BOILER AUXILIARY EQUIPMENT ..................................................................................................113
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8.1
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BASIC REGULAR OF AUXILIARY EQUIPMENT OPERATION.................................................................. 113
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8.2 MOTOR OPERATION .......................................................................................................................... 117
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8.3 START-UP, STOP AND OPERATIONAL MAINTENANCE OF AUXILIARY EQUIPMENT AND SYSTEM .......... 117
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9 PERIODIC WORK, TEST AND SHIFTING OF THE BOILER AND RELEVANT AUXILIARY
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EQUIPMENT............................................................................................................................................. 171
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10 ACCIDENTS PROCESSING OF BOILER......................................................................................... 172

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10.1 BASIC PRINCIPIA OF ACCIDENTS PROCESSING ................................................................................. 172

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10.2 BOILER EMERGENCY SHUTDOWN .................................................................................................... 174

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10.3 SHUTDOWN APPLICATION OF BOILER .............................................................................................. 178
10.4 BOILER ABNORMAL OPERATION PARAMETER ................................................................................. 178
10.5 LOAD REJECTION OF UNIT ............................................................................................................... 183
10.6 AUXILIARY POWER SUPPLY INTERRUPTION ..................................................................................... 184
10.7 CONTROL&INSTRUMENT AND APPARATUS POWER SUPPLY INTERRUPTION .................................... 185
10.8 FIRE ACCIDENT ................................................................................................................................ 186
10.9 PROCESSING INFERIOR QUALITY OF WATER AND STEAM ................................................................ 188
10.10 BOILER HEATING SURFACE SLAGGING SERIOUSLY...................................................................... 190

2×300 MW
10.11 GAS DUCT REBURNING................................................................................................................ 191
10.12 UNIT TRIP .................................................................................................................................... 192
10.13 STEAM DRUM FULL FEEDED ........................................................................................................ 194
10.14 STEAM DRUM SHORT FEEDED ..................................................................................................... 195
10.15 PRIMING ....................................................................................................................................... 197
10.16 HIGH FURNACE PRESSURE ........................................................................................................... 197
10.17 LOW FURNACE PRESSURE............................................................................................................ 198
10.18 BOILER BURNING OUT ................................................................................................................. 199
10.19 FUEL TRIP .................................................................................................................................... 200
10.20 WATER WALL TUBES TXPLOSION ................................................................................................. 201
10.21 ECONOMIZER TUBES EXPLOSION................................................................................................. 202
10.22 SUPERHEATER TUBES EXPLOSION ............................................................................................... 203
10.23 REHEATER TUBES EXPLOSION ..................................................................................................... 204
10.24 THE BREAK OF STEAM PIPES OR FEEDWATER PIPES OUTSIDE THE BOILER ................................. 205
10.25 HIGH STEAM DRUM PRESSURE .................................................................................................... 206
10.26 AUXILIARY FAILURE .................................................................................................................... 208
11 APPENDIX .......................................................................................................................................... 232
11.1 THE CONTRASTIVE LIST OF THE ABSOLUTE PRESSURE AND TEMPERATURE IN SATURATED STATES .. 232
11.2 BOILER COLD START-UP CURVE ....................................................................................................... 233
11.3 BOILER HOT STAR-TUP CURVE......................................................................................................... 234
11.4 BOILER DRUME LEVEL VS LOAD CURVE ........................................................................................... 237
11.5 BOILER O2 IN FLUE GAS VS LOAD CURVE ........................................................................................ 238

2×300 MW
1 Scope
This operating & maintenance manual provides the principle, methods and
steps of the start-up, shut-down, operating & maintenance, control and adjustment of the
boiler for Vietnam Quang Ninh 2×300MW Project. All the staff engaged in operating
equipment maintenance and management of manufacture and production technology
management in Quang Ninh power plant should be familiar with all or relevant parts of the manual
and execute extremely strictly.
2 Specific Quoting Documents
The items included in the following Chinese standards are made of the items of this manual
by citing it. When this manual was promulgated, all the standards in it are valid
and will be revised .The parties using the manual should explore the possibility
of the latest version of following standard which will be decided whether to apply to this
standard. Besides the following standards, when the equipment manufacturer has the special
requirement which meets the safety operation standards, the special requirement from
the equipment manufacturer should be complied with.
No. Standard Code Standard Name
01 DL/T 607-1996 300MW turbine operation guidelines
02 DL/T 611－1996 300MW boiler operation guidelines
03 DL/T 612－1996 Monitoring regular of power industry boiler and pressure vessel
04 DAS(1994)277 Working regulation of power safety

(Thermal mechanical parts)
Working regulation of power safety
05 DL408-91
(power plants and substations parts)
06 DL558-94 Investigation of production accidents in power industry
07 DL435-91 Explosion-proof of furnace regular for thermal Power Plant

pulverized coal-fired boiler
Vapor and chemical monitoring guidelines of thermal
08 DL/T 561－95
power plant
09 GB/T 12145-1999 The quality of vapor of thermal power generating units and
steam power equipment
Date: 2008-09-15 No.: QN1-SEC-G-04-TP-003 Page 4 Rev. : A

2×300 MW
10 SD223-87 Anti-corrosion guidelines of stand-thermal power plant

equipment
11 GB7596-87 Oil quality standards in turbine in the operation of power plant
25 pieces of key requirement to prevent major

12 GDF(2000)589
accidents in power production
13 Design information and equipment information of manufacturer
3 Boiler Technique Specification
3.1 Introduction of Boiler
 This boiler is designed by Alstom who provides performance-test technique support .It is
manufactured by Shanghai Boiler Works Ltd. This form of boiler is double-
arched,
W-flame with single furnace, then one middle reheat, control circulation and sub-critical
steam drum furnace. Two units are equipped with one start-up boiler for steam source.
 Design coal for boiler is anthracite which is from Vietnam CAM PHA and
HON GAI
mining areas.
 Combustion system: the system adopts hot air feeding, each boiler with 16 duplex-type
feeders, 32 pulverized coal burner. The capacity of pulverized coal
combustions is
100% BMCR with design-coal. Start-up and stable combustion adopt
heavy oil according to TCVN 6239-2002 standards. This boiler adopts two-
stage ignition. The high-energy igniter ignites the HPO burner and then
the heavy-oil burner ignites pulverized coal. Fuel oil burners will be steam
atomized. This project set 2×5000 tons tank and 2 unloading fuel pumps, two 100%
capacity AC, DC supply pump, 1 dirty oil pump and 1 sewage pump. Oil burning
system arranges oil supply pipe and oil return pipe to boiler burners according to oil
supply and return single piping circulation.
 Oil burners: Each arch nose has 8 HFO burners, namely each boiler has 16 burners.
The auxiliary steam which pressure is constantly 5.25 bar (g) makes HFO atomization
and also cleans the burners.HFO will be ignited by high-energy igniter.
Each HFO burner will be equipped with specialized flame detector. Cooling wind will
be provided through two separate specialized circuit burner and the flame
detector .When oil burner
is stopped, it will exit from burner quarrel by about 330 mm to avoid impact of radiation
(prevent the burners from damaged). Low heat value (LHV value) is fuel heat input at
30% BMCR by adopting 12 burners to achieve the burning capacity at 30% BMCR (two
2×300 MW

burners in each arch nose are stopped operation).The adjustment ratio of burner is 1:5

2×300 MW
using J11 burner.
 Flue and air system, pulverized coal system: flue and air system adopts balance draft,
the flue gas will be discharged to the atmosphere passing ESP and
then FGD, or directly to the atmosphere passing the FGD bypass.
Force draft-fan and induced draft-fan is axial flow fan. FDF is moving
blade adjustable and IDF is static blade adjustable. Milling system bin and
flue gas drying milling system with balance draft. Each boiler is equipped
with 2 single way BBI globe mill. Primary air fan adopts centrifugal
fan .The vent will be filtrated pulverized coal through cloth dust collector and then
discharged to atmosphere through vent fan.
 Ash slag removal and ash yard: Adopting dry ash extraction ash at the bottom is
discharged to slag pool through slag crusher and hydro ejector .The
fly ash
collected from AP. economizer and ESP is sent to the large ash silo(total 2
ash silo ,each has 2500 m3 volume), the dry ash is further dealt with through the ash-
water mixture and transported to ash pool and then transported to ash
silo through ash emulsion pump (the method for retaining and comprehensive
utilization of dry ash)；
 Desulphurization and dust removal system: Choose 4 ESP. This project sets
up one
200m-high two-steel cylindrical chimney and also sets up 100% capacity
scrubber adopting Limestone - gypsum wet desulphurization process and GGH；
 Compressed air system: total three 50% capacity compressors

considering little lubrication oil.
 Safety valve: This boiler is equipped with 8 spring safety valves supplied
by Crosby America ,who are located in the following places: 3 valves at the drum, 1
valve at SH outlet piping, 2 valves at RH outlet piping, 2 valves at
RH outlet piping, one electromagnetic relief valve is mounted on SH
outlet piping. The valve is VTI brand supplied by Crosby America. BMCR is
995t/h, the total discharging capacity of drum safety valves is 881.796,
amounting to 88.62 percent of BMCR. The discharging capacity of SH
safety valves is 153.86t/h, amounting to 15.46 percent of BMCR. The discharging
capacity of SH and drum safety valves is 1035.656t /h, amounting to
104.09% percent of BMCR. Max RH steam flow is 848.6t/h. The discharging capacity of
safety valves at RH inlet is 512.94t/h, amounting to 60.45 percent of Max RH steam flow.
The discharging capacity of safety valves at RH outlet is 379.157t/h, amounting to 44.68
percent of Max RH steam flow, The aggregate of discharge capacity at RH outlet and
2×300 MW

inlet is 892.097t/h, amounting to 105.13 percent of the Max RH steam
flow. The

2×300 MW
discharging capacity of electromagnetic Relief Valve is 166t/h, amounting to

16.68%
percent of BMCR, It is not included in Safety Valve capacity whatsoever.
3.2 Boiler Nameplate
Type of boiler Unit SG-995/17.5-M728
Manufacturer SBWL
Fabrication no. 728-1-8069
Double-arched, W-flame with single

Boiler form furnace, then a middle reheat,
control circulation and sub-critical steam
drum
Boiler maximum continues
rating(B － t/h 995
MCR)
Continues rating(RO) t/h 889.1
Rated temp. of main steam(B-MCR／RO) ℃ 541／541
Rated pressure of main steam B-MCR／

M Pa·g 17.29／17.13
RO)
Reheater steam flow(B-MCR／RO) t/h 882.498/736.407
Temp of reheater inlet／outlet(B-MCR) ℃ 320/540
Temp of reheater inlet／outlet(RO) ℃ 309/540
Pressure of reheater inlet／outlet(B-MCR) MPa·g 3.53/3.34
Pressure of reheater inlet／outlet(RO) MPa·g 3.14/2.98
Temp of feed water (B-MCR／RO) ℃ 281/273
Date of starting erection
Date of starting manufacture

2×300 MW
3.3 Boiler Design Information
3.3.1 Water Bulk of Boiler Pressure Parts
No. System Pressure Units Date Total

3
1 Drum m 40
2 Water wall m3 82
Superheater
Primary system 273
economizer and
3 m3 151
header and other
connecting pipe
4 Reheater m3 48
Secondary system Header and 72
5 m3 24
connecting pipe
3.3.2 Boiler Safety Valve Setting Pressure and Discharge
Blow Desi
Set pressure down gn
Dischargi
Specificat
Different temp
N ng
Location Type of valve ion Blo
o. ial
Openi w capacity
(inch)
ng dow pressur t/h ℃
MPa n e%
MPa
19.8
1 DRUM HE-96W 3 M2 6 20.50 3 291.697 369
9
19.7
2 DRUM HE-96W 3 M2 6 20.60 4 293.924 369
8
19.6
3 DRUM HE-96W 3 M2 6 20.70 5 296.175 369
7
Reaheate 18.1
4 HCI-98W 3 L2 6 18.70 3 153.860 557
r outlet 4
Reaheate
5 HCI-46W 6 RR10 4.50 4.37 3 253.574 313
r outlet
Reaheate
6 HCI-46W 6 RR10 4.60 4.46 3 259.366 313
r outlet
Reaheate
7 HCI-48W 6 RR10 4.10 3.98 3 187.347 554
r outlet

2×300 MW
Reaheate
8 HCI-48W 6 RR10 4.20 4.07 3 191.810 554
r outlet
Superhea
ter E0L121N7BWR 18.1
9 2..5″×4″ 18.50 2 166 557
outlet(ER A5P1 3
V)
3.3.3 Thermal Performance Calculation for Boiler Operation
Coal combustion(loads)
Minmum
Items Unit 75% 60%
BMCR RO loads
RO RO
*60% RO
1. Total output of Generator MW 300 225 210
2. Steam flow kg/H
(a) Reheater outlet 995 882.7 639.4 518.9
(b) High-pressure turbin inlet 995 882.7 639.4 518.9
(c) High-pressure turbin
822.5 735.3 543.0 443.8
Exhaust
(d) Mid-pressure turbin inlet 849.4 756.5 555.0 443.8
2
3. Steam pressure kg/cm g
(a) Drum 190.4 186.5 156 127.5
(b) Superheater outlet 176.3 174.7 149 121.9
(c) High-pressure turbin inlet 169 169 145.5 119.1
(d) High-pressure turbin
37.6 33.6 24.7 20.0
Exhaust
(e) Mid-pressure turbin inlet 33.7 30.1 22.1 18.0
4. Steam temp. ℃
(a) Drum 362 360 347 333
(b) Superheater outlet 541 540 539 539
(c) High-pressure turbin inlet 538 538 538 538
(d) High-pressure turbin
323 312 301 304
Exhaust
(e) Mid-pressure turbin inlet 538 538 538 538
2
5. Feedwater pressure kg/cm g
(a) BFP outlet

2×300 MW
(b) High-pressure heaters

outlet
(c) Economizer inlet 193.9 189.4 158.7 129.9
(d) Economizer outlet 193.4 189.0 158.5 129.8
6. Temp. of feedwater ℃
(a) Feedwater pump outlet
(b) Economizer inlet 281 273 254 243
(c) Economizer outlet 299 291 275 267
7. Heat loss (high
heating %
l )
(a) Heat in the dry flue
gas 4.19 3.88
(L ')
(b) Moisture in fuel (L2') 1.13 1.12
(c) The water generated
from the hydrogen 2.36 2.34
combustion in
(d) The moisture in the
0.11 0.12
air((L4')
(e) Un-burned carbon ((L5') 3.00 3.00
(f) The formation of
carbon
id ((L ')
(g) Heat loss due to
radiation 0.20 0.26
((L )
(h) Other((L8) 0.25 0.25
(i) Manufacturing allowance
0.50 0.50
((L9)
Total(ΣL) 11.75 11.48
(j) Ambient air temperature ℃ 24 24 24 24
(k) Relative Humidity % 80 80 80 80
(l) Atmospheric pressure kg/cm2 1.0332 1.033 1.0332 1.033 1.0332
8. Total heat efficiency % 88.25 88.52
9. Fuel consumption (coal) kg/H 129500 99100
10. Heat kcal/kg
(a) LHV of coal 4815 4815 4815 4815 4815

2×300 MW
(b) HHV of coal 4980 4980 4980 4980 4980

11. Furnace heat absorption
(total heat release)
x 103
(a) Per Effective volume 86.9 78.5 59.3 49.9
kcal/m3H
x 106
(b) Per Flat area 2.9 2.6 1.95 1.65
kcal/m2H
(c) Per effective protruding x 103
163.1 147.4 111.2 93.7
radiation surface kcal/m2H
12. Air temp. ℃
(a) Steam heater inlet 29 29 29 29
(b) Steam heater outlet 29 29 29 29
(c) Air preheter inlet
primary 31 31 31 31
i
(d) Air preheter inlet
29 29 29 29
secondary air
(e) Air preheter outlet primary
356 352 324 308
air
(f) Air preheter outlet
333 333 311 297
secondary air
(g) Mill entrance 580 580 580 580
(h) Mill export 110 110 110 110
13. Gas Temperature ℃
(a) Furnace outlet 1015 990 910 860
(b) Superheater inlet 825 800 730 700
(c) Superheater outlet 670 650 610 580
(d) Air preheter inlet 400 392 358 340
(e) Air preheter outlet
(Un-corrected) 131 127 118 109
(Corrected) 124 121 111 102
14. Dew-point of air
preheter 76 TBA TBA TBA TBA
tl t
15. Temp of cold end metal of
80 77 72 69
AP.

2×300 MW
16. Flue gas volume 103 kg/H

(a) Economizer outlet 1332 1205 936 827
(b) air preheater outlet 1422 1291 1020 910
3
17. Combustion air volume 10 kg/H 1216 1101 864 765
18. Maximum speed of flue gas
M/s 11.2 9.8 7.2 6.2
flow in convection section
19. Ash content of economizer
103 kg/H 41.7 37.8 28.7 24.1
outlet
20. Excess air % Vol
(a) Furnace outlet 24 24 28 35
(b) Economizer outlet 25 25 29.5 37
(c) Air preheater outlet 34.4 34.9 42 52
(d) ESP outlet
21. O2 % Vol
(a) Furnace outlet 3.8 3.8 4.3 5.2
(b) Economizer outlet 4.0 4.0 4.5 5.4
(c) Air preheater outlet 5.1 5.1 5.9 6.8
(d) ESP outlet
22. CO2 % Vol
(a) Furnace outlet 14.4 14.4 14.0 13.3
(b) Economizer outlet 14.3 14.3 13.8 13.1
(c) Air preheater outlet 13.4 13.3 12.7 11.9
(d) ESP outlet
x 106
23. Heat absorption
kcal/H
(a) Furnace 264.7 249.2 202.4 172
(b) Superheater 225.0 195.2 139.9 116.8
(c) Reheater 116.5 106.1 77.8 64.3
(d) Economizer 28.5 24.6 19.3 17.1
Total 634.3 575.1 439.4 370.2
(e) Air preheater TBA TBA TBA TBA
(f) Steam air heater 0.0 0.0 0.0 0.0
3
24. The heat intensity of x10
heating surface kcal/m2H

2×300 MW
(a) Furnace TBA TBA TBA TBA

(b) Superheater TBA TBA TBA TBA
(c) Reheater TBA TBA TBA TBA
(d) Economizer TBA TBA TBA TBA
(e) Air preheater TBA TBA TBA TBA
3.3.4 Characteristics of Fuel(coal)
No. Symbol Unit Range Date

I Heat value
High heat value HHV Kcal/kg 4680-5300 4980
Low heat value LHV Kcal/kg 4490-5157 4790
II Analysis
1 Total Moisture(as received) War % 5.55-12.0 9.00
2 Free moisture Ws % 4.81-9.88 7.63
3 Inherent Moisture Win % 0.78-2.35 1.48
4 Moisture in the air dried sample Wad % 0.80-2.41 1.39
5 Fixed carbon (as received) Cfar % 49.54-63.15 53.68
6 Volatile matter(as received) Var % 5.82-8.61 6.83
7 Ash content(air dried basis) Ad % 28.0-37.36 33.5
8 Ash content(as received) Aar % 25.48-34.0 30.49
Total 100.00
III Element analysis
1 C(ADB) Car % 46.83-63.75 54.62
2 H(ADB) Har % 2.56-2.97 2.62
3 O(ADB) Oar % 1.66-2.68 2.09
4 N(ADB) Nar % 0.73-0.86 0.77
5 S(ADB) Saror % 0.27-0.66 0.41
6 A(ADB) Aar % 25.48-34.0 30.49
7 M(ADB) War % 5.55-12.0 9.00
Total 100
IV Physical characteristics
1 Hardness, grindability index - - 45-70 47
2 Pulverized coal particle size - - - 100
(0-15 mm)
+10mm % 6.16-17.5 10.53

2×300 MW
5-10mm % 9.89-18.3 14.22

2.5-5mm % 15.60-21.71 18.62
1.25-2.5mm % 8.73-13.76
0.63-1.25mm % 12.36-18.13 14.89
0.315-0.63mm % 6.80-14.45 10.02
-0.315mm % 11.47-31.47 20.77
3 Density - 0.92-1.10 1.00
4 static angle ° 33-39 37
3.3.5 Characteristics of Burning(ash)
No. Components Symbol Unit Range Design date

Ash components
1 SiO2 % 57.60-64.10 62.83
2 Al2O3 % 23.3-28.64 24.76
3 Fe2O3 % 4.26-6.16 5.41
4 V2O5 % 0.018-0.028 0.026
5 TiO2 % 0.50-0.91 0.68
6 CaO % 0.30-0.77 0.44
7 MgO % 0.67-1.42 1.11
8 K2O % 3.35-4.70 3.64
9 Na2O % 0.15-0.55 0.48
10 P2O5 % 0.19-0.30 0.24
11 SO3 % 0.251-0.481 0.341
12 MnO % 0.006-0.050 0.043
13 Other % 0.00 0.00
Total 100.00
Ash physical characteristic
1 Ash density g/cm3 0.224 - 0.370 0.291
2 2
2 FYI R cm 301x10 - 603x10 525x102
Solubility of ash
Initial deformation 0
1 T1 C 1210 - 1280 1250
temperature
Hemispherical softening 0
2 T2 C 1430 - 1600 1570
temp.
0 0
3 Fluid temp. T3 C C 1530 - 1600

2×300 MW
3.3.6 Characteristics of Fuel(heavy-oil)
3.3.6.1 Characteristics of heavy-oil
Characteristics Date Test method
No.1 No.2A No.2B No.3

=< TCVN 6594:200
Density at 15℃ mt/m3 =< 0.991 =< 0.991 =< 0.991
0.965 (ASTMD1298)
Viscosity at 50℃
=<87 =<180 =<180 =<380 ASTM D445
cSt
Sulphur content, by TCVN67O1:200O
=<2.0% =<2.0% =<3.0% =<3.5%
weight (ASTM
TCVN3753:1995 ASTM
Pour point ℃ =<+12 =<+24 =<+24 =<+24
D97
TCVN2690:1995/ASTM
Ash content % =<0.15 =<0.15 =<0.15 =<0.35
D482
Water content, by TCVN2692:1995/ASTM
=<1% =<1% =<1% =<1%
volume D95
Purity, by weight =< =< 0.15% =< 0.15% =< 0.15% ASTM D 473
TCVN 66O8: 20O0/
Flash point℃ 66 66 66 66
ASTM D382S/ASTM
HHV, kcal/kg >= >= 10,000 >= 10,000 >=10,O00 ASTM D240/ ASTM
10 000 D480
LHV, kj/kg 40,800(usual)
3.3.6.2 The corresponding value of temp. of fuel burner entrance and viscosity of heavy oil (for
detail information refer to viscosity - temperature curve)
Item HFO No.1 HFO No.2A & 2B HFO No.3

viscosity of fuel required
in the entrance of burner 2.5 °E 2.5 °E 2.5°E
Required Matching temp. 95 110℃ 130℃

℃
Required Matching density 0.917 0.934 0.922
3.3.6.3 J11 oil burner design parameter
HFO flow of HFO Atomization Steam

each burner pressure of steam flow of pressure of

2×300 MW
each burner each burner each burner
l/h bar(g) kg/h bar(g)

Maximum
1935 20 110 5.25
30% BMCR, running 12 burners
Standard values
1450 14 115 5.25
30% BMCR, running 16 burners
Minimum 390 2 165 5.25
3.3.6.4 Requirement for oil and steam parameters in burners operation
Fuel oil parameter Steam parameter(dry steam as required)

2.5°E (make the
corresponding
Viscosity at the burners adjustment of the Burner pressure 5.25 bar(g)
temp, Estimated
at
Burner pressure 2 ~ 20 bar (g) Temp. about 200℃
Maximum 30% Max continuous
flow
BMCR heat input,
2.6 t/h,
namely 21280 kg/h.
Flow flow Peak flow is 3.9
The constant flow
t/h (atomization and
in return line is
cleaning are
10% of
t d
3.4 Requirement for Quality of Boiler Steam
3.4.1 Requirement for Date of Quality of Boiler Steam in Normal Operation
Item Unit Normal range

1. Feed water
Conductivity (after cationic resin exchanger) µS/cm
< 0. 3～0. 2
at 25°C Expected values : (microSiemens/cm)
pH obtained by ammonia injection 9. 2～9. 4
Total hardness : i. e. not
detectable by Nil
l i t
Dissolved oxygen at degasser outlet mg/kg (O2) ≤ 0. 01
Hydroxide content at economizer inlet mg/kg (N2H4) > 0. 010～0. 020

2×300 MW
Item Unit Normal range

Total iron (Fe), mg/kg < 0. 010
Total copper (Cu) mg/kg < 0. 003
Silica content, mg/kg (SiO2) < 0. 020
2, Boiler water
Conductivity (at 25℃) µS/cm < 20
pH (at 25℃ ) 9. 2～9. 5

Phosphate content mg/kg (PO43-) 2～3
Free caustic Nil
Silica content, recommended mg/kg (SiO2) 0. 010～0. 300
3.4.2 Alert date for abnormal quality of boiler steam
Steam sample Item Status Date

pH value In the regular scope 9. 1 to 9. 5
Condensate dissolved oxygen More than or equal to 20 ppb
Cation conductivity More than or equal to 0. 5 µS/cm
Feedwater at Degasser
dissolved oxygen More than or equal t 10 ppb
outlet
pH value In the regular scope 9. 1 to 9. 5
Feedwater at Cation conductivity More than 0. 5 µS/cm
economizer inlet Dissolved oxygen Less than 10 ppb
Hydrazine In the regular scope 10 to 20 ppb
More than
Conductivity 50 µS/cm
In the regular
pH value 9. 0 to 10. 0
scope
Boiler Silicic acid 100 ppb
More than
F 1ppm
More than
Na -
More than
Cation conductivity More than or equa 0. 5 µS/cm
Saturated steam to
Na 20 ppb
More than
Silicic acid 50 ppb
M th
Superheated Cation conductivity More than or equa 0. 5 µS/cm
to
steam Na 20 ppb
M th

2×300 MW
Steam sample Item Status Date

Silicic acid More than 50 ppb

2×300 MW
3.5 Boiler auxiliary equipment technical specifications
3.5.1 High-pressure bypass
1 Basic date Parameters

2 Use High-pressure bypass valve
3 Quantity Equipped with 2 units
4 Fluid characteristics
5 Type of fluid steam
6 Maximum control flow(max CV) 750 t/h (75%BMCR)
7 Min differential pressure at max CV 130 bar
8 Minimum inlet pressure at max CV 179. 3 bar
9 Max temp. at max CV 543 ℃
10 Minimum control flow(min. CV) 8 t/h
11 Max differential pressure at min CV 205 bar
12 Max inlet pressure at Min CV. 205 bar
13 Min temp. at Min CV. 420 ℃
14 Quick-opening set pressure 182. 8 bar
15 Slow –opening set pressure 179. 3 bar
Characteristics and specifications of
16
executive body
Differential pressure after the valve is shut
17 205 bar
off
Type of executive body (electric, pneumatic
18 hydraulic
and hydraulic)
19 Fault location indicator open
Solenoid operated control valve (SOV)
20 or yes
it h b d f i k t t
21 Manual control yes
22 Stroke Period (fast& control) 3& 20 sec(from 0％to100％)
23 Limit switch close
24 Pressure switch for air pressure difference no
25 Location transmitter yes
Gas source pressure reducer with
26 no
instrument
27 Characteristics

2×300 MW
28 Design pressure 205 bar is effective

29 Design temp. 543+5 ℃
Tightness rank(selon / acc. to ANSI
30 rank V
B16-104)
3.5.2 Air preheater
Item Unit Design date
Form A. P( trisector, rotating the heating surface )

Type 2-29VI(T)-86”SMRC
Rotor diameter mm 10318
Rotor height mm 2185
Hot section 1000, middle layer of hot section
Height of heating surface mm 880,cold
ti 305
Quality set 2
Manufacturer SBWL
Motor Main Motor Auxiliary Motor

Type Y180M-4B3 Y160L-8B3(Double-axis)
Power kw 18. 5 7. 5
Voltage V 380 380
Rated Current A
Rotating speed r/min 1470 720
Reducer
Type SGW100D
Reducing rate of speed 128. 3
Axis rotating
speed(main r/min 11. 46
t )
Axis rotating
speed(axial r/min 5. 61
t )
Rated Torque output N. m 12300
Support bearing Thrust spherical roller bearing Type: 90394/750

Guild bearing Double-out centripetal roller bearing Type: 3153172
Guidance bearing dilute-Oil Support bearing dilute-Oil

Oil circulation system
station station
Oil station Type OCS-D2A OCS-D2A

2×300 MW
Type of Motor Y802-4B3

Motor power kw 0. 75(2 set)
Motor speed r/min 1390
Type of oil pump 3GR25×4 tri-screw pump
3
Flow m /h 0. 8
Rated pressure MPa 1. 0
Working temp. of Cooler ℃ 60～70
Temp of cooling water ℃ ＜30
Consumption of 0. 8
cooling m3/h
t
Pressure of cooling water MPa 0. 2
Type of oil filter SPL25C-2 net
Type of oil cooler GLC1-0. 8 Tubular
3.5.3 Induced draft fan
Item Unit Design date Remarks
Form Axial adjustable static-blade
Type G158/273
Manufacturer Shanghai Blower works Ltd.
Quality set 2
Rotation direction Anti-clockwise At the direction of air flow
Motor Power Kw 1500
3.5.4 Forced draft fan
Form Axial(hydraulic, adjustable moving-blade)
Type FAF20. 4-10-1
Manufacturer Shanghai Blower works Ltd.

2×300 MW
Quality set 2
Air fan total pressure Pa 5267(T. B) 3660(BMCR)
Speed r/min 1470
Shaft output kw T. B:621,BMCR:405 T. B:650,BMCR:418
Efficiency 84.08(BMCR operating 83.21(BMCR operating

％
condition:86. 50) condition:86. 72)
Range of moving-blade degrees 45
Rotation direction Anti-clockwise(at the direction of end of Motor shaft )
Rotation power kw 1250
Rotation speed r/min 1482
3.5.5 Primary air fan
Form Single-suction centrifugal
Quality set 2
Type 1788AB/940
Manufacturer Shanghai Blower Works Ltd.
Speed r/min 1480
Outlet total pressure Pa TB:14850 Pa BMCR:11000 Pa
Inlet temperature ℃ TB:39 BMCR:24
Power kw 400
Direction Inlet:90o outlet:0o(from Motor side )
3.5.6 Mill fan
Type: M25452 Type: Centrifugal: Media of mill fan: air

2×300 MW
BMCR operating
Item Unit TB operating condition
condition
Standard Flow Nm3/h 151650 144430
Inlet Temp. ℃ 120 110
Inlet Gross Pressure Pa -8500 -8000
Outlet static Pressure Pa -700 -1200
Total Pressure of Air fan Pa 7800 6800
Selection point efficiency ％ 83. 1 76. 8
Compression correction 0. 9735 0. 9767

factor
Axial power kw 622. 5 543. 8
Rotation direction r/min 980
Rotation power kw 710
Rotation speed r/min 980
Motor voltage kv 6. 6
Manufacturer China ChengDu Electrical power machinery factory
3.5.7 Milling
Manufacturer Shanghai Heavy machinery Works Co. Ltd.
Mill cylinder type BBI4796
Mill cylinder effective

mm 4650
diameter
Mill cylinder effective length mm 9740
Milling method Ball mill with drying and purging by hot air

2×300 MW
Main Motor
Manufacturer Shanghai Motor Works
Type YTM900-6
Power kW 3500
Voltage V 6600
Speed r/min 986
Electric heater Power 1200x2 W(used when

V 230
Single-phase voltage shut-down)
Main Motor lubrication dilute-oil station (XYZ-20)
Nominal pressure MPa 0. 5
Nominal flow L/min 20
Primary Lubrication
L 450
Volume
Lubrication Speciation 46 turbine oil L-TSA
Cooling water volume m3/h 2. 5
Power kW 1. 5
Voltage V 400
Speed r/min 1400
Main Reducer
Type ML2PSF150
Speed rate i 9. 275
Lubrication Type Reducer with compulsory lubricating of

independent dilute-oil station

2×300 MW
Power kW 11
Voltage V 400
Primary Lubrication
L 1500
Volume
Lubrication Speciation ISO VG320
Cooling water volume m3/h 8
Low speed driving set [plant reducer(An auxiliary motor)]
Type NMCD560-125
Speed rate i 125
Motor Type YEJ280S-6(B35)
Motor Power kW 45
Motor Speed r/min 970
Motor Voltage V 400
Revolving speed of disk r/min 0. 105
Primary lubrication
L 180
volume
Lubrication Speciation Mid-extreme pressure industry gear oil N220(GB5903-86)
Main bearing HP and LP lubrication dilute-oil station
Type GDR-60/10/170
Lubrication Speciation L 2800
Cooling water volume ISO VG460
Cooling water volume m3/h 18
Electric heater Total 6 (400VAC/3kw x 6)

2×300 MW
LP pump(1 set)
Nominal pressure L/min 170
Nominal flow MPa 1
LP Pump Motor(1 set)
Power Kw 7. 5
Voltage V 400
Speed r/min 1440
Injecting HP oil pump (1 set)
Nominal pressure L/min 4X15
Nominal flow MPa 20
Injecting HP oil pump motor(1 set)
Power Kw 30
Voltage V 400
Speed r/min 1470
Electric wire heater VAC/kW 230/
HP lubrication pump(1set)
Nominal Pressure L/min 2X5
Nominal Flow MPa 10
HP lubrication pump motor(1set)
Nominal Pressure Kw 3
Nominal Flow V 400
Speed r/min 1440

2×300 MW
The girth gear grease circuit lubricating equipment
Type GSPZ-Z-8
Operation Pressure MPa 0. 4~0. 6
Max Pressure MPa 0. 8
Max volume of oil supply g/min 1500 0. 6MPa
Required gas supply

m3/min 0. 42
capacity
Working oil pressure MPa 20
Quantity 8
Lubrication Speciation NLG100-0
Gear sealing air equipment
Air fan type CQ3-J
Flow m3/h 800
Pressure pa 590
Power kw 0. 37
Voltage V 400
Speed r/min 2900
Spring coupling equipment
Primary grease volume kg about 4
Grease speciation NLGI 02 Lithium Grease

lubricants
Gear coupling equipment
Primary grease volume kg About 13

2×300 MW
Grease speciation E. P. Lithium Grease lubricants
Small gear equipment rolling bearing
Grease speciation SKF ALFALUB LGEP 2
3.5.8 Cold feeder
Item Specification Manufacturer
China's Hubei YiDu Electrical and Machinery

Main body MSD100
Engineering Co., Ltd.
Motor YVP160L-6 China Xi An Motor Works
Reducer ZSY250-80 China's JiangYin, JiangSu gear box Works
Output 30～110 Tons／hour
3.5.9 Pulverized Coal feeder
Manufacturer China ShenYang Power Plant Engineering Ltd.
Type SGF－13
Output t/h 3～13
3.5.10 Pulverized Coal Feeder
Manufacturer China ShenYang Power Machinery Works
Type LSG－500
Transmission distance m 32. 2
Motor Power KW 7. 5 2

2×300 MW
3.5.11 classifier
Manufacturer Chian Wuxi Liangxing power equipment Ltd.
Speciation Φ6800mm
3.5.12 Thin pulverized coal separator
Manufacturer China WuXi Joint Venture Power Equipment Co., Ltd.
Speciation Φ3500mm
3.5.13 Vent fan
Manufacturer China's Shenyang Blower Factory
Type SFY15F-C5A
Form Single inhalation double support centrifugal
Direction of air intake 90° left rotation(right rotation)
Direction of air outtake 45° left rotation(right rotation )
Impeller diameter mm 1500 Blade outlet
Rotor critical rotation speed r/min 1930
Inlet flow volume m3/s 28. 36
Air fan total pressure KPa 5. 7
Inlet temperature ℃ 120
Air fantotal pressure effciency % 84
Air fan axial power kW 200
Motor effciency kW 250

2×300 MW
Motor voltage kv 6. 6
3.5.14 Boiler water circulation pump
Form LP head with no seal
Type LUVc250×2-410/1
Manufacturer England Heyward Tyler

HAYWARD TYLER
company
Medium water Single inhalation

double support centrifugal
Quantity set 3 2 operation meet BMCR
Design pressure bar 210
Hydraulic test pressure bar 315
Absorbed pressure bar 198
Medium density S·g 0. 554
Design temperature ℃ 369
Max differential pressure of lower than 56 Higher than 56℃ trip

℃
pump shell and boiler water
Pump flow m3/h 2182 Single
Efficiency ％ 83 Cold/hot
Absorbed efficiency kw 222. 7 Hot:130. 0
Pump inlet and outlet Lower than 0. 11 alarm

MPa about 0. 3(31. 1mH2O )
differential pressure Lower than 0. 055 trip
Motor
Form Three-phase squirrel-cage

2×300 MW
induction
Type LUV55/4FQ20-605
Rated power kw 200
Rated voltage KV 6
Rated speed Rotation speed r/min 1450
Rated current A 27. 5
Start-up current A 135
Motor efficiency ％ 88. 0/87. 0 cold/hot
Power factor 0. 805/0. 72 cold/hot
Input power kw 252. 8/140. 5 cold/hot
Total efficiency of pump ％ 73/72. 2 cold/hot
Water cooler of HP filling water and cleaning water
HP side design pressure MPa 21
HP side hydraulic test 31. 5

MPa
pressure
LP side design pressure MPa 1
LP side hydraulic test 1. 5

MPa
pressure
Motor heat exchanger
HP side design pressure MPa 22
LP side design pressure MPa 3
LP side required pressure MPa 0. 65
HP side design temperature ℃ 343

2×300 MW
LP side inlet temperature ℃ 38 max
LP side outlet temperature ℃ 44 max
HP side motor circulation 11

m3/h
water volume
HP side motor circulation 32～49 normal operation

℃
water temp.
LP side required flow m3/h 8. 5 Lower than 6. 5alarm
Heat exchanging efficiency kJ/s 34. 2 Cold,2 pump operation
Required flow forLP 2 Lower than 1. 5alarm

m3/h
cooling water hot panel
hot panel outlet 50

℃
allowable highest temperature
LP cooling water hot 0. 2

MPa
panel required pressure
At flow 2 m3/h, hot 0. 05～0. 08

KPa
panel pressure drop
3.5.15 Flame scanner cooling air fan
Manufacturer SBWL
Type VC 710 N/2
Air flow m3/h 1153
Total pressure Pa 9480
3.5.16 Intermittent and continuous blowdown flash tank
Manufacturer China Jinan pressure vessel plant

2×300 MW
Continuous blowdown flash tank
Form Vertical
Type LP-3. 5
Volume m3 3. 5
Design pressure MPa 1. 5
Intermittent blowdown flash tank
Form Horizontal
Type DP-20
Volume m3 20
3.5.17 Steam air preheater
Manufacturer China Hankou power equipment plant
Primary air A. P
Type NFZ3. 2-1-2. 645FBZ
Volume m3 185
Secondary air A. P
Type NFZ3. 2-1-2. 690FBZ
Volume m3 607. 5

2×300 MW
Steam air preheater

drain box
Type NSL-16-0. 5
Volume m3 0. 5
4 Boiler and interlock protection value auxiliary equipment.
4.1 Boiler protecting Limit Value
Name Units LL L N H HH Remarks
Drum water level

under the center
Drum water 100％Load:0 line of drum －
mm -425 -240 +100 +200
level 175mm;
50％Load -115
L, H: alarm;
HH/LL B il MFT
Furnace L, H: alarm,
Pa -2500 -2000 -100 +1000 +4000
pressure LL/HH: Boiler MFT
N:HPO isolating valve

allowable L: alarm
Burning oil
Mpa 0. 5 1 2. 5 LL: Burning oil trip
pressure
H:HPO pressure
high alarm
Burning oil N:HPO leaking

Mpa 1. 85 1. 9
pressure test pressure proper

2×300 MW
H: HPO leaking
test pressure low
N:HPO temperature
allowable
Burning oil
℃ 90 95 100 135 L:HPO low
temperature
temperature alarm
LL/H:HPO trip
L: low pressure alarm
Atomization LL: low pressure

steam Mpa 0. 4 0. 5 0. 9 Burning oil trip
pressure
H: high pressure
alarm
L: low temperature
Atomization alarm
steam ℃ 180 230
temperature H: high
temperature alarm
4.2 Boiler auxiliary interlock protection value auxiliary equipment.
1. Air
preheater
N: open allowable;
Bearing H: alarm profit Air

℃ <70 70 85
temperature Preheater open;
HH: Air Preheater trip
L: alarm, delay 10Sjum

1）
r/min 0. 5 0. 8 1 to Motor, then after 3 s
Rotation
open stand-by
speed
M t

2×300 MW
LL: air preheater trip
2） Inlet L: after lower than L

flue gas ℃ 150 419 allow stop Air
temperature Preheater
3） Temp.
of primary ℃ 378 478 H: fire alarm
and
d i
4） Soot
If L: higher than L allow
blowing ℃ 130
soot blowing
Steam temp.
5）
L: soot blower
Soot
Mpa 1. 04 1. 2 allow soot blowing
blowing
Working pressure
steam
6） 2．
ID Fan
Lubrication >3 ID Fan open

L/min 3 4
flow allow;<3alarm
Lubrication 0. 4～ L: alarm; LL:

Mpa 0. 12
pressure 0. 6 alarm, delay 30S trip
LL: stand-by pump

Hydraulic oil automatic;
Mpa 0. 86 2. 5
pressure
L:ID Fan open allow
Oil filter
differential Mpa 0. 35 H: alarm
pressure
Oil position of blanking ID Fan open,

mm 150
oil bank alarm
Bearing ℃ 60～70 90 110 H: alarm;

2×300 MW
temperature HH: ID Fan trip
Temp. of Oil L: open heater

℃ 30 30-40 40
in Oil Bank H: close heater
Oil cooler
outlet ℃ 45 ＞45℃,alarm
temperature
+100 delay 15S ID

Surge Kpa
on site Fan trips
Motor
H: alarm, prohibit
bearing ℃ 85 95
open; HH: trip
temperature
Stator coil H: alarm, prohibit

℃ 90 130 135
temperature open; HH : trip
3．FD Fan
Bearing
℃ 80 90
temperature
Motor
bearing ℃ 90 100
temperature
Motor coil
℃ 130 140
temperature
Vibration mm/s 8 11
Lubrication L: alarm;
Mpa 0. 35
pressure LL: alarm, trip
FD fan
>3FD Fan open
lubrication L/MIN 3
allow;<3alarm
flow

2×300 MW
FD fan L: stand-by pump open
hydraulic oil Mpa 0. 86 2. 5 automatic
pressure H:FD Fan open allow
FD fan
differential Mpa 0. 35 H: alarm
pressure
FD fan oil
location of oil mm 150 L: alarm
tank
FD fan temp. L: open electric heater

of oil in oil ℃ 30 30-40 40
tank H: close electric heater
FD Fan oil
cooler outlet ℃ 45 ＞45℃alarm
temperature
FD fan delay 15S and FD Fan

KPa On site
surge trips
4．
Primary air
fan
Bearing
℃ 80 90
temperature
Motor bearing
℃ 90 100
temperature
Motor coil
℃ 130 140
temperature
Vibration mm/s 8 11
Outlet air L: alarm, LL:

Pa 2400 3000
pressure Pulverized coal

2×300 MW
trip, N: adjustment
5．Pulverized
coal exhauster
Bearing
℃ 80 90
temperature
Motor bearing
℃ 90 100
temperature
Motor Coil
℃ 130 140
temperature
Vibration mm/s 8 11
6．Vent air fan
Vent fan
bearing ℃ 80 90
temperature
Vent fan motor

bearing ℃ 90 100
temperature
Vent fan motor

Coil ℃ 130 140
temperature
Vibration mm/s 8 11
Vent L, H: alarm;
℃ 90 110 120 130
temperature HH: Stop Vent fan
High temp. for

produce ℃ 300 700 800 L, H: alarm
pulverized
Bag type filter ℃ 150

2×300 MW
temperature
7．Mill
Mill
Lubrication
H: Open safety valve
pump outlet Mpa 1. 035
at lube oil pump outlet
main pipe
pressure
HP oil
Mpa 0. 02
pressure
1. 8～23 Mill open

Jacking oil allowable ; HH: Open
Mpa 1. 5
pressure Safety valve at jacking
oil pump outlet
Bearing
rotation oil Mpa 3
pressure
N: Mill open allowable;

Bearing
℃ 45 <85 65 70 H: alarm
temperature
HH: Mill trips
Mill small N: Mill open allowable

gear
℃ <77 77 88 H: alarm
Bearing
temperature HH: Mill trips
Temperature
N: Mill open allowable
of reduction ℃ <85 85 90
H: alarm HH: Mill trip
gearbox
Motor bearing H: alarm

℃ <80 80 90

2×300 MW
Motor coil H: alarm

℃ <120 130 140
＞ LL: allow
opening Lubrication
Lubrication
℃ 24 27 32 46 49 pump; L: put
temp
electric heater; N:
stop electric heater; H:
h t b t l l
Lubrication
filter
MPa 0. 15 0. 25 L: alarm;
differential
pressure
Lubrication
L/min 30 L: alarm
flow
Reducer oil
L/min 60
supply flow
Cooling water ＞ L: Mill open

m3/h 15
flow allowable
Temperature
＜ H: Mill open
of mill 250
allowable
inlet primary
air
Mill inlet ＞ L: Mill open
Primary air Kpa 3 11 allowable

pressure
＞H: Mill trips
Classifier L: Mill open allowable;

outlet primary ℃ 100 150 175
air temp. H: delay 3min Mill trips
Differential ＜ N: open coal
pressure of feeder allowable;

Kpa 3. 5 4. 5
non-drive Inlet ≥H: alarm, delay
and classifier 15M and Mill
ti
2×300 MW
outlet primary
air
Differential
pressure of
＜N: open coal
drive Inlet and
Kpa 3. 5 4. 5 feeder allow;≥H:
classifier
alarm, delay
outlet primary
15M Mill trips
air
Mill
Lubrication ＞H: Require changing
station strainer Kpa 207 242 the strainer;

differential
＞HH: go bypass
pressure
8．
Boiler water
circulation
pump
pump inlet L: Low differential
outlet pressure alarm

Mpa 0. 10 0. 14
differential LL: Low differential
pressure pressure trip
H: high temperature
Motor room alarm

℃ 55 60
temperature HH: high temperature
trip
9．Air
compressor
Compressed L/LL: alarm, shunt

air main pipe Mpa 0. 4 0. 55 0. 75 open stand-by Air
pressure compressor
Air Mpa 0. 7 0. 8 L: load, unload

2×300 MW
compressor
vent pressure
Air
compressor
cooling water ℃ 50
outlet
temperature
10．Soot
blower
Soot blowing
steam supply Mpa 3. 0 3. 5 LL: alarm
pressure
Drain H: close drain valve

℃ 280
temperature and allow soot blowing
Steam air
preheater
Water level of
mm 200 300 550 800 900
drain tank

2×300 MW
5 Start-up
5.1 Basic Regular
5.1.1 Before the start-up of the new erected or overhauled boiler, the trial operation, test and
equipment acceptance of main equipment and auxiliary equipment should be finished. Before
start-up of the boiler having minor repairs, the trial operation and test and equipment
acceptance of the repaired equipment should be finished.
5.1.2 After major or minor repairs, the shift supervisor should have the final report about
improved items of equipment and instruments after finishing system change.
5.1.3 Choose the right method of start-up
5.1.4 If the following arbitrary conditions occur, the start-up boiler should be prohibited:
5.1.4.1 If the repair work of the system or equipment affecting the boiler start-up is not finished or
work sheet is not canceled, inspection test and trial operation is not acceptable.
5.1.4.2 Interlock, protection and trip test are not performed.
5.1.4.3 DCS system is not in service affecting the operation and monitoring of the units.
5.1.4.4 Thermal control main instrument. For e.g., main steam temperature, main steam pressure,
reheat steam temperature, reheat steam pressure, drum water level, furnace pressure,
feed water flow and steam flow can’t be put in service.
5.1.4.5 Quality of boiler water can’t reach the requirement.
5.1.4.6 FFCS can’t be put in service.
5.1.4.7 Thermal control signal system can’t be put in service.
5.1.4.8 The safety valve system for main boiler auxiliary system (e.g. Safety valve, ERV valve,
drum emergency drain valve, burning oil Electromagnetic valve) are not in service.
5.2 Repair test and acceptance inspection
5.2.1 Requirement of acceptance inspection refers to acceptance inspection procedures in

instructions of boiler professional overhaul
5.2.2 Acceptance inspection after repair should be executed acc. to scattered trial operation
acceptance inspection and system trial operation acceptance inspection and whole start-up
acceptance inspection.
5.2.3 All acceptance inspections of thermal control interlock test are confirmed by static test
method.

2×300 MW
5.2.4 All auxiliary scattered trial operation acceptance inspection is through acceptance
inspection of motor empty operation and the method with auxiliary equipment operation.
5.2.5 Classification of repair test
5.2.5.1 First type of test:
A. Hydraulic test of boiler body.
B. Furnace cold air dynamic field test.
C. Procedure control test for soot blower and blowdown.
D. FSSS, CCS cold position simulation test.
E. Safety valve setting test.
F. Each rotation machine Single logic test.
G. Air leaking test of boiler body.
5.2.5.2 Second type of test:
A. Interlock test of Boiler rotation machine (including milling system). B.
Accidents button Test of Boiler rotation machine.
C. Single protection trip test of Boiler rotation machine.
5.2.5.3 Third type of test:
A. Main valve, duct damper single test.
B. Each intermittent work, intermittent test.
5.2.5.4 Test requirement:
A. All tests should be done after overhaul.
B. Before starting the units, minor repair, sudden inspection and the second and third
type of test should be done. If necessary, the first type of test is also required.
C. Make the associated test when the equipment is abnormal.
D. HP motor is usually done the static test
E. The responsible department should write a detailed testing procedure. They shall
report it to higher authorities for approval and the test result with
signature the

2×300 MW
relevant departments authorized is also required.
F. Make the detailed record for the test. Any issues should be reported to the relevant
depart and dealt with till acceptable.
G. Each intermittent work and intermittent switching test is required acc. to the relevant
requirement.
5.2.6 Boiler Hydraulic test
5.2.6.1 The over-pressure test should be performed if any of the following situation
occurs(Working pressure test first):
1） After major repairs or replacement of the heating surface (replacement of water

wall tubes is more than 50%, replacement of any components of superheater,
reheater,
economizer and major repairs of drum).
2） Resume operation after shut-down for more than 1 year.
3） Boiler pressure is seriously more than 1.25 times of working pressure.
4） Large deformation of heating surface occurs after serious shortage of water.
5） Acc. to the operation status, the reliability of safety equipment is suspected.
6） After major and minor repair or repair of local heating surface of boiler,
working pressure test should be done.
5.2.6.2 Boiler Hydraulic test pressure value is as following:
Primary system Secondary system
Working pressure(MPa) 20. 5 4. 5
Overpressure test(MPa) 30. 75(1. 5 times) 6. 75(1. 5 times)
5.2.6.3 Boiler Hydraulic test scope :
1） Primary system includes all the pipes, heating surface and header from non-return flap at
feedwater pump outlet to HT superheater outlet (i.e. including feedwater pipe, economizer,
drum, water wall, LT superheater, HT superheater, connecting pipes and header).
2） Secondary system includes all the pipes, heating surface and header from reheater inlet
to HT reheater outlet (i.e. including LT reheater, HT reheater connecting
pipes and header).
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3） At working pressure, the following valve should be check secondary damper firstly and
then primary damper(Acc. to the test procedure):
A. Lower furnace drum drain valve.
B. Drum Air damper.
C. Economizer outlet pipe Air damper
D. Superheater Air damper.
E. Reheater Air damper.
F. Superheater drain valve.
G. Reheater drain valve.
H. Thermal control instrument pipe valve (If there is not any secondary damper only do
pressure test for primary damper).
4） At working pressure, pressure test will be only done for primary damper of the
following pipe valves:
A. Soot blowing steam primary damper.
B. Primary attemperator drain primary damper.
C. Secondary attemperator drain primary damper.
D. Reheater attemperating water primary damper.
E. Chemical sample primary damper.
F. Intermittent blowdown primary damper.
G. Blowdown primary damper.
5） For blowdown system at the furnace bottom, close motorized valve

firstly. Open completely the former manual valve to do pressure test. If the test is
acceptable, close manual valve to do pressure test.
6） Working pressure test with remote and local water level instruments, i.e. close the
remote water level instrument drain valve and local water level instrument
drain valve and completely open other damper, test water level instrument drain
valve; then close water level instrument and try water side and steam side primary
damper.

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7） At working pressure, perform pressure test with drum safety valve, check seal conditions
but the valve stem should be jammed by the feed screw to prevent trip. Other superheater
and reheater safety valve should be jammed and isolated.
8） Open economizer re-circulation damper when it is fed water. if it is finished

close the damper.
9 ） Perform the overpressure test, withdraw remote and local water level
instrument and isolate or jam each safety valve. Boiler water circulation
pump motor and Boiler is thoroughly isolated. Boiler water circulation pump
plugging plate for overpressure test should be installed.
5.2.6.4 Conditions for Boiler Hydraulic test :
1） All steam pipe valve in pressure test, after heating surface repair work,
should be acceptable; Motorized valve, pneumatic valve, control valve
should be finished adjustment. And acceptance inspection is acceptable.
2） After check, installation and reset of steam system pressure instrument

should be finished. Primary system pressure test is confirmed by drum local pressure
instrument on roof. Secondary system pressure test is confirmed reheater inlet local
pressure. Pressure instrument accuracy is 0.5. The span should meet the test
requirements(span shall be 1.5
to 2.0 times of overpressure test pressure).
3） Each system Suspenders, springs and hangers have been adjusted and forced smoothly.
4） Each valve, Setscrew, Suspenders (Hanger) shouldn’t be fixed too tightly before hydraulic
test.
5） Expansion indicator correction is finished, and direction is correct.
6） Boiler platform, stairs path is Unobstructed, remove all impeding scaffolding
7） Drum wall temperature measurement points is corrected and can be put in service.
8） The scaffoldings of each checking parts are safe and firm with adequate light.
9） Feedwater pump trial operation is acceptable.
10） Pressure test provisional pipes are installed and checked acceptable.
11） HP bypass “quick open ” condition is compulsive.
12） Producing water by Chemical water system is in service. Chemical feed

system and
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chemical is prepared. Water quality and chemical is checked acceptable. Water used by
primary system is about 550t (about 2 times of water Volume ).
Water used by secondary system water is about 180t adopting
dematerialized water. Test water is dematerialized water with 200 ppm
ammonia+ hydrazine treatment and PH value is higher than 10. 5.
13） Emergency pressure drop method must be prepared. Intermittent blowdown valve
and motorized drain valve at lower furnace drum are well stand-by
and pipes are unobstructed to do quick pressure drop if overpressure.
14） Set up local pressure instrument of drum and reheater and make control room with well
communication.
15） When hydraulic test, circumstance temperature is usually higher than

5℃,otherwise make the anti-freeze measures. Water temp. from 30 to 70℃ is suitable
(not lower than
20℃).
16 ） At working pressure hydraulic test shall be chaired by repair

(installation) tech. responsible staff. Overpressure test shall be chaired Chief
Engineer and designated person in charge.
17） All test staff should follow a clear division of labor, subject to a unified command and
insist on jobs.
5.2.6.5 Introduction of hydraulic test method: Open motorized feedwater pump and fill the water
through economizer from main feedwater system. One side of superheater secondary
attemperator water or main feedwater bypass pipes raise pressure, but these two
methods can’t be performed at the same time. Only one can be selected. Reheating
system feeds water to Reheating system through attemperating water pipes. Close main
feedwater pipes valve and then do pressure test.
Test should be performed in order of high to low, i.e. Hydraulic test of steam system,
then hydraulic test of reheater system.
If all tests are finished, do pressure drop and drain. Do pressure test
for some secondary damper and primary damper.
5.2.6.6 Hydraulic test steps
1） Open all air damper of Drum, Superheater and reheater system
2） Close all drain valve of Superheater and reheater system.

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3） Besides drain primary damper of intermittent blowdown, continuous blowdown,

cold
reheater, close all drain primary damper and secondary damper.
4） Close boiler main steam valve and main steam bypass valve, close primary drain valve,
secondary drain valve in front of main steam damper.
5） Before hydraulic test, 3 boiler water circulation pumps should be fed water to
exhaust steam acc. to the manual, (Notice: Hydrazine can only be fed to
deaerator, not to condenser). After filling water and exhausting air, open outlet non-
return flap of 3 boiler water circulation pump.
6） Acc. to normal filling procedure fill the boiler to the visible drum water level. Stop
filling through feedwater pipe and change to filing through superheater water spray
secondary attemperator till air dampers of drum and superheater is continuously
overflowing the water. Close air dampers of superheater and drum and stop filling.
7） Forbid filling the boiler through feedwater control system and superheater water spray
attemperating at the same time.
8） Check HP bypass damper at “closed ” condition and quick open condition

is been compulsory.
9） Check reheater system pressure zero.
10 ） Completely open motorized pump recirculation damper and valve of

some side of secondary superheater attemperator water and motorized isolation
damper. Micro-open motorized control valve. Make use of the open position of the
motorized control valve and feedwater pump rotation speed to control pressure rising
speed ≯0. 3Mpa/min.
11） Before filling, after filling water is full and when working pressure is reached, the record
of indicators of expansion system shall be checked.
12） If whole pressure rising reaches 1～2Mpa, 10M Pa and 75％ of working
pressure, suspend pressure rising and do primary check for Primary
system. if it is normal, continue raising pressure. if working pressure is
approached, decrease pressure rising s peed ≯0. 2Mpa/min to prevent overpressure.
13 ） If primary system pressure reaches 20. 5Mpa, stop pressure rising,

monitor local pressure instrument of drum, record the status of
5min pressure drop and comprehensively check each heating surface and pipe
valves.
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14） Acc. to the scope of pressure test, switch the primary valve and secondary
valve of
primary system. Raise pressure again to 20. 5 Mpa, record the status of 5 min pressure
drop and check each first valve etc.
15） If overpressure test is required, after above check result is normal, confirm boiler
water circulation pump motor and boiler water are isolated and boiler water circulation
pump plugging plate for overpressure test is installed. Drum water level instrument trips.
After the staffs withdraw the scene, with pressure rising speed ≯ 0.
1Mpa/min raise the pressure to 30. 75Mpa .Keep 10～20min and then open final
superheater air valve at roof or cold superheater drain valve to do the pressure drop.
Pay attention to pressure drop speed ≯0. 1Mpa/min. After pressure is dropped to 20.
5Mpa, close pressure drop
air valve or drain valve, record the status of 20 min pressure drop, and comprehensively
check.
16） If pressure test is acceptable or check abnormal, open superheater drain valve, drop
the pressure to zero and pay attention to controlling pressure drop speed≯0.
3～0.
5Mpa/min.
17） When hydraulic test of primary system is finished, do hydraulic test of reheater system.
18） Use reheater attemperating water pipe to fill the reheater, after water
overflows at reheater outlet air damper, close all reheater system air dampers, open
the first reheater exhaust steam valve and stop filling water.
19 ） Control feedwater pump rotation speed. Through reheater attemperating water

control valve with ≯ 0.3Mpa/min pressure rising speed and raise the
pressure to 1
MPa. Comprehensively check reheater system.
20） If the check result is normal, raise pressure to 4. 5Mpa, stop pressure rising,
isolate reheating system, monitor local provisional pressure instrument 5min, record the
status
of pressure drop and comprehensively check reheating system.
21） Acc. to scope of pressure test, switch the primary valve or secondary valve of
primary system, do pressure rising again to 4. 5 Mpa and record the status of 5 min
pressure drop.
22） If the overpressure test is required, after above check result is normal and the staffs
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withdraw the scene. With pressure rising speed ≯0. 1Mpa/min raise the pressure to 6,
75Mpa. Isolate reheating system, keep 10～20min and observe changes in pressure.

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23） Micro-open final reheater air valve at the roof to drop pressure, monitor
provisional
pressure instrument and pay attention to pressure drop speed ≯0.1Mpa/min
when pressure reaches working pressure in the overpressure test. When pressure drop
to 4.
5Mpa, close pressure drop air valve, record the status of 5 min pressure
drop and comprehensively check
24） When reheating system pressure test is acceptable, open final reheater air valve at roof
or reheater drain valve to drop the pressure to zero, monitor provisional
pressure instrument and pay attention to pressure Drop speed ≯0. 3~0. 5Mpa/min.
25） When pressure test of reheating system is acceptable, drop pressure to zero and
open superheater and reheater drain valve to drain. For e.g., if Boiler needs draining,
open lower furnace drum blowdown valve to comprehensively drain for drum and water
wall.
5.2.6.7 The key position for hydraulic test check:
1） Whether the valve of each system after repair is leaking.
2） Whether joint of safety valve is leaking.
3） Whether each heating surface, especially the position having repair work
and the position requiring strict check is leaking and deformation.
4） Whether each expansion indicator, pipes hanger has abnormal expansion.
5.2.6.8 Hydraulic test acceptable standard(Hydraulic test meet the following requirements, i.e.
acceptable ):
1） There are no leaking traces of water on pressure parts, metal wall and welding seam.
2） At primary system working pressure, when stop raising pressure., pressure drop in 5min
is <0. 5Mpa. At secondary system working pressure, when stop raising
pressure, pressure drop in 5min is ≯0. 25MPa.
3） No obvious deformation of pressure parts.
5.2.6.9 Boiler hydraulic test attentions :
1） When boiler is fully filled water, before pressure rising, jam drum and superheater safety
valve; When doing hydraulic test for secondary system, jam reheater safety valve; when
do overpressure test, jam each safety valve.
2） If reheating system has provisional pipes, the pipes should be purged before installation,
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each welding seam should be check acceptable and welded by acceptable welder.
3） Feedwater pump reach the top pressure, completely open recirculation valve and strictly
monitor operation conditions to ensure feedwater pump operation safe.
4） Each drain valve of main steam valve outlet drain, cold reheater and hot reheater should
be opened. Immediately check whether there is any water is drained to prevent cylinder
from water.
5） Each drain valve at main feed water equipment side should be checked whether the valve
is strict leaking and pay attention to the water entering into HP heater at pressure rising.
6） When raising pressure, monitor attemperating water flow. If flow is big and pressure rise
is slow, system leaking may be serious. Check the cause intermediately.
7） Boiler filling shall be performed acc. to filling requirement.
8） Monitor drum wall temp.>20℃ in the test and differential temp.≤50℃. When
drum is checked, heating surface wall temp. should be ≤49℃.
9） After test, open drain valve and air damper firstly to drain. If drain is finished,
dismantle plugging plate valve. Because there is no drain pipe in front of the plugging
plate valve, most of the water can’t be drained. When dismantle plugging plate valve,
firstly ease the plugging plate, let the water leak slowly form plugging plate valve to
prevent steam pipes from full water and then open drain valve of steam pipes to prevent
cylinder from water.
10） When do the hydraulic test, specified staff should monitor pressure instrument.
Drum local and remote pressure instrument should be often checked.
Emergency pressure drop pipes valves shall be unobstructed. The valves
should be operated by specified person to prevent overpressure.
11） When do the pressure test, stop all welding work on boiler body, prohibit opening valve
and striking on the pressure parts arbitrarily.
12） Scaffoldings of each checking parts are complete. The path is unobstructed and full of
light.
13） Specified person should be responsible for pressure rising to

strictly prevent overpressure acc. to local pressure. When pressure reach10% of test
pressure, correct local pressure instrument and control pressure instrument. When the
differential pressure
is large, contact with the relevant person to deal with it.
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14） When do hydraulic test, the relevant person should follow a clear division of
labor,
subject to a unified command and set a clear and reliable communications.
15） Only test staff can be permitted in to the scene.
5.2.7 Boiler safety valve check
5.2.7.1 Conditions and requirement for safety valve check.
1） After major repair of boiler and repair or replacement of the valve, the hot check must be
performed for safety valve to maintain the reliability.
2） Safety valve set value is performed as following:
Design
Setting pressure Blow
temp
Discharging
Specification down
No. Location Type of valve capacity
(inch) Opening reseating Differential
MPa MPa pressure%
t/h ℃
1 DRUM HE-96W 3 M2 6 20. 50 19. 89 3 291. 697 369

2 DRUM HE-96W 3 M2 6 20. 60 19. 78 4 293. 924 369
3 DRUM HE-96W 3 M2 6 20. 70 19. 67 5 296. 175 369
Reheater
4 HCI-98W 3 L2 6 18. 70 18. 14 3 153. 860 557
outlet
Reheater
5 HCI-46W 6 RR10 4. 50 4. 37 3 253. 574 313
outlet
Reheater
6 HCI-46W 6 RR10 4. 60 4. 46 3 259. 366 313
outlet
Reheater
7 HCI-48W 6 RR10 4. 10 3. 98 3 187. 347 554
outlet
Reheater
8 HCI-48W 6 RR10 4. 20 4. 07 3 191. 810 554
outlet
Superheate
E0L121N7BWR
9 r 2..5″×4″ 18. 50 18. 13 2 166 557
A5P1
outlet(ERV)
3） Before igniting the boiler, the safety measures to prevent the turbine from the steam
must be done.
4） The leader from tech. dept. and safety dept. should be on site when checking the valve.

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It is conducted by chief engineer, chaired by repair staff in charge and

operators
participate in it. When test, the relevant person should follow a clear division of labor,
subject to a unified command to prevent overpressure.
5） Set a convenient, clear, reliable communication.
6） Strictly close boiler main steam valve, turbine main steam valve, IP main steam
valve and HP drain valve non-return flap etc. Open turbine main steam
drain valve, cold reheater drain valve and hot reheater steam drain valve.
7） Turbine turning shall be put in service before the unit gets any load.
8） Drum water level high signal is compulsory (Drum water level protection releases ).
9） HP bypass quick open condition is compulsory.
10） When check safety valve, pressure indicator of local pressure instrument and before
operating control panel of drum, superheater, reheater and turbine main reheater steam
must be corrected. The local data and the date on the control panel shall
be same. When there are errors between the data on pressure
instrument of local pressure instrument and control room CRT, local pressure
instrument should be followed. In the process of pressure rise and checking,
paid attention to correcting local and before operating the panel. Specified
person monitor the pressure and contact relevant staff.
11） Checking safety valve shall be performed when boiler is started only or the load of
unit is only 10%—20% ECR load.
12） Pressure rise of boiler shall be performed acc. to pressure rising curve. In the process
of pressure rise, strictly monitor tube temperature of heating surface in the allowable
value.
13） When check, monitoring and adjustment for the burning and water level
shall be strengthened to prevent full water, inadequate water and overpressure.
14） When safety valve is being checked, if the valve is opened, the staff shouldn’t approach
safety valve.
15） When accidents occur, stop checking and acc. to relevant accidents
treatment requirement perform treatment.
16） When check, strengthen the contact and strictly finish each work acc. to each division of
labor.
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17） Check for safety valve is performed in the order of high action
pressure to low.
Unchecked safety valve should be isolated.
18） When check safety valve, firstly check by the opening aid checking equipment. If it is
acceptable, actual opening check can be performed.
19） When check ERV valve, actual opening check after control return circuit
check is acceptable.
5.2.7.2 Drum and superheater safety valve check :
1） Trip water level protection.
2） Open HP bypass and put HP bypass in automatic service to ensure cooling the reheater
system. Open steam exhaust valve at reheater outlet.
3） Control boiler combustion rate, put 4 to 8 oil burners in service.
4） When main steam pressure reach 10bar,stop pressure rising, inform the repair staff of
hot fixing screws and comprehensively checking welding, valve, man hole and hot
expansion conditions of pressure parts. If check is finished, after repair staff
Informing of raising pressure, continue raising pressure.
5） When turbine condenser vacuum reach 300mbar, put LP bypass in service.
6） When pressure reaches 75 ～ 85 ％ of safety valve test pressure

and stability is maintained, repair staff check safety valve by hydraulic check
implement, record opening pressure and reseating pressure till it is checked acceptable.
7） If informed of continuing pressure rise, put bypass control valve in

“manual“ control.
Manual control the position of indicator of HP bypass (mustn’t
close),slowly raise pressure to safety valve design opening value and then
keep it. Repair person shall adjust it.
8） After opening safety valve, major open HP bypass manually and let
safety valve reseating.
9） Record opening pressure and reseating pressure of safety valve.
10） If the action of safety valve is incorrect and adjustment is required, repair
staff shall requires pressure drop or drop pressure to 75～85%of rated pressure. And
then adjust the safety valve acc. to manufacturer requirement.
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11） If adjustment is required for more than 3 times, the adjustment should be performed
after safety valve is cooled. In cooling period, the staff can check other safety valves, but
need locking the cooled safety valve.
12） When check safety valve, if safety valve has no action, keep pressure stable.
13） Raise pressure to safety valve opening pressure, pop safety valve. When safety valve
has action, record the data of opening and reseating pressure.
14） Using the same method to check each safety valve of drum and each safety valve, ERV
valve of superheater in the order of high open pressure into low.
15） If safety valve check is finished, all safety valve lock shall be dismantled and the safety
valve should be in service.
5.2.7.3 Reheater safety valve check:
1） If safety valve of drum and superheater check is finished, resume water level, control
the combustion and control boiler pressure drop speed. If pressure drops to 6～8MPa,
use HP, LP bypass or units load to control the setting pressure of safety
valves of reheating steam to reheater inlet. Stabilize the combustion and maintain stable
pressure.
Repair staff should check reheater safety valve.
2） Adjust opening and reseating pressure of safety valve to 75～85%of test

pressure.
Other operation and record refer to drum and superheater safety valve.
3） Using same method, check each reheater inlet safety valve and outlet safety valve in
the order of high opening pressure to low.
4） If safety valve check is finished, all safety valve lock shall be dismantled, put safety
valve in service.
5.2.7.4 If safety valve check is finished, acc. to the shift supervisor’s order shut-down the boiler
or raise temperature and pressure to start up the boiler.
5.2.7.5 If safety valve check is finished, inform thermal control staff of releasing signal of
compulsory.
5.2.7.6 Attention for safety valve check:
1） When check safety valve, HP bypass can’t be closed completely to prevent

reheater “burning”. Also LP bypass can’t be closed completely; otherwise reheater
outlet steam exhaust valve should be opened.
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2） In order to decrease safety valve center erosion, after the action of

safety valve,
Pressure Drop should be performed to let safety valve reseating.
3） When check safety valve, fluctuation of drum water level is large.

Prevent full or inadequate water accidents lead by false water level.
4） When safety valve takes action, it may lead differential pressure and current fluctuation
of boiler water circulation pump. One boiler water circulation pump can be closed acc. to
the situation (pay attention to it and fill the water in time).
5） Each Superheater metal temperature shall be controlled in allowable scope. When

main steam flow ＜ 150T/H, profit using attemperating water. When air steam
flow≥150T/H, if attemperating water is required, control the speed not too fast.
Control attemperating water in min. scope to prevent temperature from sudden drop
and too much stress to damage the equipment.
6） Checking and monitoring instrument staff follow a clear division of

jobs. Prepare necessary repair implement and implement to prevent noise.
Subject to a unified command and insist on jobs.
5.2.8 Main valve and flue gas damper test
5.2.8.1 Test attention:
1） All motorized valve, Electromagnetic valve, control valve, pneumatic valve and flue gas
damper should be done the reliability test before start-up of boiler.
2） Before test, confirm that there will be not any corresponding movement of the medium
and any repair work etc . Safety of equipment, pipes and duct, and personal security can’t
be affected.
3） Before test, do the manual test to confirm machinery part normal.
4） Specified staff is responsible for monitoring.
5.2.8.2 Acceptable standard for test.
1） When doing local manual operation, opening and closing operation is flexible, accurate
and reliable.
2） Opening and closing operation is flexible and limit switch action is accurate when doing
local electric operation.
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3） When DCS operator does the test, opening and closing operation is flexible
and limit
switch action is accurate. The data on the instrument indicator is consistent
with local actual location.
4） For motorized intercept valve which can be interrupted do the interruption test.
5.2.8.3 Test method and steps:
5.2.8.3.1 Motorized valve check :
1） Confirm that test valve don’t affect operation system. After repair work,
contact with thermal control staff and repair staff should be on site.
2） Valve power has been in service .Signal and indicator is correct.
3） Confirm valve at close position showing the corresponding CRT screen.
4） Put valve manual control at a suitable position of indicator. (keep travel

from the closing direction or opening direction)
5） Motorized test switch is correct. If the valve has “stop” button, test stop
function in service. Limit switch contact and automatic/manual switch also
should be tested in service.
6） Close motorized valve completely and keep remaining travel manually. Thermal
control staff determines break contact for closing direction. Correct local instrument
and CRT screen in the same indicator, and in closed position.
7） Open motorized valve completely. With same method adjust completely

opening remaining travel. Thermal control staff determines breaking signal at opening
direction. Correct local instrument and CRT screen in the same indicator, and in
opened position.
8） Record completely opening period and completely closing period of motorized valve,
travel and remaining travel at opening direction and closing direction.
9） Electric completely open and completely close valve once. Check mechanical dial
of position of indicator, light, signal right. Opening and closing is flexible.
Motor shall automatic trip at the set point, otherwise readjust it again.
10） If test is finished, put valve in position before test.
11） Motorized valve check attention:
A、 When travel limit switch has faults or valve limit body don’t cooperate with travel
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limit switch well, pay attention to preventing travel limit switch from out of control
to damage motor and valve. If necessary replace it.
B、 For non-rising stem valve or rising stem valve whose valve stem is difficult to see,
in the adjustment before travel limit switch is set, don’t depend on motor moment
protection action or method of hearing motor surplus air sound to confirm valve
completely opened, completely closed position. Must manually
perform adjustment.
C 、 Confirming principle of valve remaining travel :At closing

direction after completely closing valve manual open about 0. 5～1 circle(HP
valve low value, LP valve high value ) or acc. to actual conditions confirm that
open about 90%
of full travel at opening direction and max open position of indicator is 95% of full
travel.
D、 In valve switch test opening and closing button can’t be put at the same time
or the switch can’t be turned from opening(closing)direction directly
to closing (opening) direction to prevent damaging Motor.
E、 If the valve is moment limit valve, never manually operate it after test.
F、 For motorized valve with local, remote control perform full travel test for local and
remote control switch once and the result shall be normal.
G、 Motorized valve with interlock will be performed interlock test to make it normal
after check is finished.
5.2.8.3.2 Control valve test :
1） Confirm that test valve don’t affect operation system. After repair work, contact with
Thermal control staff and repair staff.
2） Gas source and valve power is sent. Confirm that air pressure direction is normal
and opening and closing direction are right.
3） When perform local test, put control valve “manual/automatic” switch

handle in manual position. With rotation hand wheel open and close the full
travel of control valve. The actual conditions must be consistent with
travel indicator in check process. Change the handle to automatic position.
4） Show the corresponding CRT screen. Manually operate corresponding switch of

control valve to separately intermittent and continuous open and close full travel
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test once. Check signal, mechanical dial of position Indicator is consistent with the
actual data and control is flexible.
5） Cutting off air test: Cut off air source of control valve, check AO valve automatic
closed after cutting off air source. Check AC valve automatic opened after cutting
off air source. In air cut-off test, prevent system operation from affecting.
5.2.8.3.3 Damper test :
1） Before test, carefully check equipment. If repair work is finished, keep

the site clean.
2） Confirm that test valve don’t affect operation system. After repair work, contact with
thermal control staff and repair staff should be on site.
3） Send relevant air valve, then power of damper, air source, and put
relevant air pressure instrument, negative pressure instrument,
temperature instrument in service.
4） Signal and mechanical dial of position Indicator are normal. Each damper rotation
is good and transmission equipment is also good.
5） Each piece of auxiliary equipment of the system has opening condition.
6） Operate corresponding CRT screen, manually response damper and

separately perform intermittent and continuous opening and closing full
travel once. Check signal direction consistent with mechanical dial of
position indicator and the direction correct.
7） There is not any leaking and other abnormal phenomenon in operating pneumatic
equipment with flexible action and right direction.
5.2.8.3.4 Air fan moving-blade test :
1） Before test, carefully check equipment. If repair work is finished, keep

the site clean.
2） Before test put corresponding hydraulic control oil system in service,

control oil pressure normal and then send control power.
3） Rod and pin of executive body are not loose, bended and exfoliated.
4） Local and main control switch control the moving blade. The direction is right and

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the action is flexible. When the position of indicator on the CRT screen
is from
0~100%, local position should be consistent with it.
5） Record period and angle of opening and closing full travel in the test.
6） In the process of test, when abnormal conditions occur, stop test, check for the
cause and solve it and then test again till it is acceptable.
5.2.9 Opening, closing and accident button test for auxiliary equipment :
5.2.9.1 Test condition and requirement :
1） After auxiliary motorized equipment and control circuit is repaired, must perform test
for auxiliary equipment switch and accident button.
2 ） Acc. to repair work requirement, learn the detail in equipment repair content,
abnormal situation, test requirement and scope. Check and confirm
that repair work of mechanical and motorized parts on site is all finished, work-
sheet is recovered and the test condition is had. Then resume relevant system.
3） If empty trial operate the motor, confirm that motor wiring and earthling
cables are complete, backrest wheel disengages and oil quality of bearing
Lubrication position is normal. After check it normal, contact to send the power. In
trial rotation pay attention
to the correctness of rotation direction of motor.
4） Before trial operation of auxiliary equipment, when motor power is cut off,
rotor is without collision and blocking, oil position oil quality is normal, cooling water
valve, seal water valve is opened, outlet and Inlet instruments of primary
damper are opened, pump is filling water to exhaust air is finished, Inlet valve of
centrifugal pump is confirm
ed opened, outlet valve of volume pump is confirmed opened, inlet and outlet valve of
axial pump is confirmed opened. After all the conditions are normal ,do the test.
5） Auxiliary equipment which can be operated on CRT screen and local operation board
should be operated separately.
5.2.9.2 Test method :
1） Contact with electric staff to put 6KV rotation machine switch into test position.
Before test check the correctness of electric, thermal control instrument,
sound and light signal. Confirm operation button and interlock switch is at stopped
position.
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2） Before trial-operation of coal feeder, coal feeder inlet and outlet valve should be closed

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and coal feeder has no remaining coal.
3） Switch on each rotation machine acc. to normal procedure (A. P, ID

fan, FD fan, primary air fan, seal air fan, mi and coal feeder) once. Each rotation
machine status color should be changed from green to red.
4） In the order of the contrary of above sequence on the CRT screen gradually stop
each rotation machine. Each rotation machine status color should be changed from
red to green.
5） Gradually switch on air preheater, ID fan, FD fan, Primary air fan, and mill and
coal feeder. In the contrary sequence locally put accident button of each rotation
machine. On the CRT screen corresponding rotation machine status
color become yellow, accident speaker sound alarms. If test is finished reset each
switch.
5.2.9.3 Auxiliary equipment protection test :
1） Test condition and requirement :
A. After units are major repaired or minor repaired and auxiliary electric
equipment and control circuit are repaired, must perform auxiliary equipment protection
test.
B. Auxiliary equipment protection test must be performed after auxiliary equipment starting
and stopping test and accident button test is acceptable and meet relevant requirement
for starting auxiliary equipment and accident button.
C. In the test, 6kV can be only operation power. If switch is at test position, 380V auxiliary
equipment is sent as dynamic power.
2） Test method :
A. Stand-by auxiliary equipment shunt opening test :
a) Acc. to normal opening operation, open one piece of auxiliary equipment and check
stand-by auxiliary equipment having opening condition.
b) Put auxiliary equipment interlock switch in service.
c) Turn on accident button to let operation auxiliary equipment trip and send sound
and light alarm signal and stand-by auxiliary equipment is automatic opened.
d) By Using the same method separately test other auxiliary equipment.

If test is
finished, resume auxiliary equipment to the original.
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B. Low oil pressure shunt opening protection test for auxiliary equipment oil pump :
a) Acc. to normal opening operation, open one piece of oil pump

and auxiliary equipment and check stand-by auxiliary equipment having opening
condition.
b) Put oil pressure protection in service. Thermal control staff make low oil
pressure signal. When oil pressure is lower than primarily value, stand-by oil
pump will be automatic started. when oil pressure is lower than
secondary value, auxiliary equipment trip and oil pressure data is recorded. If
it doesn’t match the set value, thermal control staff adjust it to match
c) By using same method separately test other auxiliary equipment. If test is finished,
resume auxiliary equipment to original condition.
C. Low water (oil, Air)pressure shunt opening protection test :
a) Acc. to normal operation, open auxiliary equipment and check stand-by

auxiliary equipment having opening condition.
b) When do the low water (oil, Air) pressure protection, Thermal control staff made
low water (oil, Air)pressure signal. When water (oil, Air)pressure is lower than set
value, stand-by auxiliary equipment should be automatic opened
and water (oil, Air)pressure data is recorded. If it doesn’t match the set value,
thermal control staff adjusts it to match.
D. High temperature protection test for auxiliary equipment bearing
a) Acc. to normal opening operation, open one piece of auxiliary equipment.
b) Put temperature protection in service. Thermal control staff made high

temperature signal. When temperature is high primarily value, alarm
signal should be sent. When temperature is higher than secondary
value, auxiliary equipment trips. Record oil temperature data. If it doesn’t
match the set value, thermal control staff adjusts it to match.
E. Water level of protection test

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a) Acc. to normal opening operation, open auxiliary equipment.
b) Put water level protection in service. Thermal control staff makes water
level low analog signal. When water level drops to some value, alarm signal should
be sent.
If water level is lower than second value, auxiliary equipment trips. Record water
level. If it doesn’t match the set value, thermal control staff adjusts it to match.
F. Air preheater oil circulation test
a) Thermal control staff make guild bearing oil high temp, analog signal, guild bearing
oil pump should be automatically open and then make guild bearing oil low temp.
analog signal, guild bearing oil pump should be automatically stopped, record oil
temp. data, if it doesn’t match the set value, Thermal control staff adjust it to match.
b) Sing same method to support bearing test.
5.2.9.4 Auxiliary equipment power test :
5.2.9.4.1 Test condition and requirement :
1） If auxiliary equipment is repaired, trial operation must be performed. If trial operation is

good and acceptance inspection is acceptable, it can be put in service or stand-by.
2） Relevant system is confirmed trip or adopts reliable safety measures.
3） Power test of auxiliary equipment should be performed after auxiliary

equipment opening and closing test, accident button test and auxiliary equipment
protection test are acceptable and should meet relevant condition and requirement in
auxiliary equipment protection test.
4） Relevant protection around opening auxiliary equipment should be put in service.
5） Operation and dynamic power of auxiliary equipment should be sent.
6） Before trial operation of FD fan and primary air fan, ID fan should be opened to prevent
furnace from producing positive pressure.
7） Continuous operation period after repair of air preheater, primary air fan, seal air fan,
ID Fan, FD fan is 2—4hour. Empty time of mill should not be more than 10min.
Operation period of other rotation machine should be not less than 30min.
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8） When trial operation, relevant mechanical, electric repair staff should be on site.
9） Before trial operation comprehensively check auxiliary equipment.
5.2.9.4.2 Test method and steps:
1） Open Each piece of auxiliary equipment at boiler side in the order of Air preheater, ID fan,
Primary air fan, seal air fan, mill and coal feeder.
2） If equipment in trial operation is abnormal, immediately stop checking the

cause and solve it and then trial operation can be performed again.
5.2.9.4.3 Test acceptance inspection standard :
1） Rotation direction is correct.
2） No abnormal sound, friction and percussive sounds.
3） Bearing temperature and vibration meet in the scope equipment regular value.
4） Equipment system has leaking phenomenon.
5） Equipment output reach nameplate output and motor current shouldn’t be more
than rated current.
5.2.10 Boiler rotation mechanical interlock test
5.2.10.1 Interlock action specification:
1） When main motors of 2 air preheaters are stopped, shunt open air preheater auxiliary
motor, 2 ID Fans trip and boiler MFT trips.
2） When 2 ID Fans are stopped, 2 FD Fan, 2 primary air fans, seal air fan and milling plant
system are shunt tripping.
3） When 2 FD Fans is stopped, 1 ID Fan is shunt tripping, Boiler MFT trips.
4） When 1 Primary air fan is stopped, milling plant system is shunt tripping.
5） When 1 ID Fan is stopped, corresponding side FD Fan is shunt tripping.
6） When 1 FD Fan is stopped, corresponding side ID Fan is shunt tripping. If only one ID
and FD Fan is in service, ID Fan can’t be shunt tripping.
7） Mill is stopped, corresponding mill is shunt tripping, hot air valve is automatically closed
and cold air valve is automatically opened.

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5.2.10.2 interlock test method :
1） Put boiler flue gas system master interlock, air fan interlock and each
pulverizing system interlock, air preheater main and auxiliary motor interlock in service
2） Continuously switch on each air preheater main motor, ID fan, FD fan, primary air fan,
seal air fan, mill and coal feeder.
3） Close 1 Air preheater and its auxiliary Motor should be shunt and the other rotation
machines are normal. switch off 2 Air preheaters, MFT should be performed. Primary
air fan and pulverizing system shall shunt trip. Trip rotation machine
CRT screen status color becomes yellow. Accidents speaker alarms, alarm
window lights and reset each trip switch.
4） Continuously switch on each rotation machine switch. Stop 1 ID fan,

corresponding side FD Fan shunt trip and the other rotation machine is normal.
Switch off 2 ID Fan, MFT should be performed. FD Fan and the following each
rotation machine should shunt trip. Each trip rotation machine status color
on CRT screen become yellow, accidents speaker alarms, alarm window lights
and reset trip switch.
5） Continuously switch on 2 ID Fan and the following each rotation machine. Switch off 1
FD fan, its corresponding side ID Fan shunt trips, the other rotation machine is normal.
Switch off 2 FD Fan, MFT should be performed, one side ID Fan, 2 Primary air fan,
each rotation machine of pulverizing system shunt trip. Tip rotation machine status on
CRT screen becomes yellow. Accidents speaker alarms, alarm window
lights and reset each trip switch.
6） Continuously switch on 2 ID Fan and the following each rotation machine

switch.
Switch off 1 Primary air fan, the other rotation machine is normal. Switch off 2 Primary
air fans, MFT should be performed. Each rotation machine of pulverizing
system shunt trips. Trip rotation machine status on CRT screen becomes yellow.
Accidents speaker alarms, alarm window lights and reset trip switch.
5.2.10.3 Requirement and preparation for rotation mechanical test:
1） Rotation machine with major repair should be performed interlock test and should
be not less than 2 hour trial operation. Before trial operation, confirm rotation machine
and electric equipment and relevant system has no repair work.
2） Shut valve of 6KV rotation machine, accident button and interlock test will only be
static test. Before test contact with thermal control staff, electric staff sends
relevant
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operation power and instrument control power and dynamic switch is put
on test
position.
3） When in trial operation contact with electric staff send dynamic power.
5.2.11 Boiler MFT test
5.2.11.1 Boiler MFT test, thermal machine and electric support test should be chaired by thermal
control staff.
5.2.11.2 MFT test items are listed as follows: If meet any following condition, MFT trips.
1） Control system power can’t be put in service or air pressure for control is not
correct (3 get 2 pressure), delay 3s and then trips.
2） No ID fan is in service.
3） No FD fan is in service.
4） No air preheater is in service.
5） Total air flow is lower than the lowest( delay 2s and then trips).
6） If water temperature is high and steam exhaust doesn’t exist for more than 6s
or water temperature is not high, furnace gas-temperature probe exits or
furnace temperature is high (delay 6s).
7） No steam exhaust condition (delay 6s and then trips )
8） Drum water level is too low (delay 2s then trips)
9） Boiler water level is too high (delay 60s), and Steam flow is
higher than
112%MCR.
10） No circulation pump is in service, delay 2s and then trips.
11） Furnace pressure is high or low.
12） Flame scanner cooling air pressure is too low (delay 600s and then trips)
13） Furnace surge is reset, or all flame scanners fail. If they fail, delay 15s, finally
burners flame scanners fail.
14） Superheating steam pressure is too high (pressure switch), delay 6s and then
trips.
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15） ESP Inlet flue gas temperature is too high, delay 2s and then trips.
16） In load-dump, after delaying T1, steam flow is still higher than x1% of initial flow
before load-dump and only 1 circulation pump is in service.
17） In load-dump , after delaying ts(T1 + T2) , steam flow is still higher than x2% of
initial flow before load-dump and only 1 circulation pump is in service.
18） Any accident button is put.
19） In load-dump, at least 1 coal feeder control circuit is at manual

position and steam flow is higher than y%.
Notice: above x1, x2, y value is per the data on site or is confirmed
by thermal control logical value.

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5.2.12 Drum water level test
5.2.12.1 When Drum water level is higher than first value (+100mm) ,send alarm signal.
5.2.12.2 When Drum water level is raised to protecting value (+200), trigger MFT.
5.2.12.3 When Drum water level is lower than the first value (-240mm) ,send alarm signal.
5.2.12.4 When Drum water level is as low as the protecting value (-425), trigger MFT.
5.3 Check and preparation before start-up
5.3.1 Mechanical check before start-up
5.3.1.1 Before start-up of boiler, must confirm that installation and repair work has been finished,
acceptance inspection is acceptable and all repair work is finished.
5.3.1.2 Each platform, stairs, unobstructed path, railings is firm and integrity, ground is clean, full
of light and fire prevention is complete.
5.3.1.3 No one works in check furnace and duct. Confirm that there is not any implement left,
scaffolding is dismantled., heating surface is cleaned, and refractory belt is complete and
not exfoliated. Switches observation hole and checking hole are flexible and closed
strictly after checking.
5.3.1.4 Insulation of each system (pipes, vessel etc.) is well, hanger is complete, and instrument
is complete and not leaking. Each erosion-proof valve is complete and obstacle is
unobstructed.
5.3.1.5 Air valve, damper and valve are complete. Marks are complete and switch is right and
flexible, direction is clear, remote control equipments is firm.
5.3.1.6 Each expansion indicator is complete with right location and pilot graduate is clear and
correct. Pointer is without jam and record defaults.
5.3.1.7 Burners have good heat insulation. Duct and blast box has no dash, oil and debris to
obstruct expansion of blast box.
5.3.1.8 Burning oil system and steam to purge, oil burners, igniter and control system are
complete and can be put in service.
5.3.1.9 The ash handling equipment is available for service, soot blower transmission is flexible,
the location is showed correctly, and at exit position.
5.3.1.10 Furnace gas-temperature probe retracts flexibly and is put in service. Furnace flame
monitor and cooling system is complete.

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5.3.1.11 Local water level is clear and in service, opening and closing steam valve is flexible and
not leaking. It is full of light and camera system is complete and can be put in service.
5.3.1.12 Safety valve and ERV are complete, steam exhaust is unobstructed and fixed.
5.3.1.13 Inform dash, chemical, combustion operation staff of comprehensively checking each
system, preparing for start-up and having the start-up condition.
5.3.1.14 Check for each auxiliary equipment, rotation machinery and auxiliary equipment is
acceptable. Mechanical parts is with no jam, Lubrication quality is acceptable and oil is
full. Cooling water, seal water and etc. are normal.
5.3.1.15 Check each valve, air valve is in open position.
5.3.1.16 Raw coal and pulverized coal bunkers are filled and available.
5.3.1.17 HFO is available. The associated heat tracing and pretreatment system have been
checked and are available for service.
5.3.1.18 The ESP is available and ready for service. The rapping and the insulator heating
systems are in service. Low temperature or low level alarms are cleared.
5.3.2 Thermal control and electric check before start-up:
5.3.2.1 In center-control room, there is full of light and accident lighting is reliable.
5.3.2.2 Each instrument is sent the power, operation switch and change-over switch, Light of
indicator are complete.
5.3.2.3 Open all transmission and sample valve for signal pipe of measuring instrument and
close blow down valve.
5.3.2.4 Alarm equipment, protection panel, control panel and each monitor instrument, record
instrument and printer are normal and put in service.
5.3.2.5 DCS station is normal. The data on CRT screen and instrument is consistent with
equipment actual status.
5.3.2.6 Check all safety interlock equipment in service. Confirm interlock protection for CCS,
FSSS, PLC, DAS etc. correct.
5.3.2.7 Each piece of auxiliary equipment Motor has good insulation.
5.3.3 Test and prepare before stat-up :
5.3.3.1 All the main test before start-up of boiler:
1. Opening, closing position test for valve and damper

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2. Static opening, closing, change-over and accidents button test and

interlock
logical test.
3. Gang test for auxiliary equipment.
4. Gang test for auxiliary equipment lubrication pump.
5. Air preheater drive equipment test.
6. Boiler interlock protection test i.e. MFT condition test.
7. Turbine, boiler and generator big interlock logical protection test.
8. Other test acc. to repair conditions.
5.3.3.2 Confirm that each valve, air valve, damper meet the requirement.
5.3.3.3 Each auxiliary equipment power and operation power are sent. Each instrument get
power and control power.
5.3.3.4 Put industry water system in service, check operation normal.
5.3.3.5 Open air compressor system, check system operation normal, and keep compressed air
pressure above 0. 65Mpa.
5.3.3.6 Contact with neighbor unit or start up boiler to supply auxiliary steam header with air, and
keep pressure about 0. 525Mpa.
5.3.3.7 Check and put oil circulation of burning oil system in service. Put purging steam in
service to heat the pipe and drain to clean.
5.3.3.8 Put water seal at boiler bottom and fully fill water.
5.3.3.9 According to oil temp conditions, put electric heater in service. If oil temperature is
consistent with the regular, open oil equipment of each mill and air peheater, FD fan oil
station. Acc. to temp. of Oil in Oil tank, put cooling air fan of ID fan in service.
5.3.3.10 At the 12th hour before igniting the boiler, put ESP ash box heating automatic. At 2nd
hour before igniting the boiler put ESP rapping in service
5.3.4 Initial firing precautions:
5.3.4.1 To insure a maximum safety margin during start-up, an air flow of at least 30% of full load
air must be maintained in order to produce the following conditions:
1） An air-rich furnace atmosphere

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2） To avoid the possibility of accumulation or stagnation of explosive mixtures in the

event of poor or delayed ignition after fuel is introduced to the Furnace.
5.3.4.2 As the boiler load is increased, the operators shall check that the air flow is increased to
maintain the design operating excess air. A periodical verification should be made. Refer
to the curve “Design excess air versus boiler load” at the end of this section.
5.3.4.3 Never attempt to light a burner without its associated igniter or without atomizing
/scavenging medium available.
5.3.4.4 If combustion hasn’t started within 15 seconds after the fuel is fed to burner nozzle the
fuel should be cut off and a furnace purge during 5mn should be performed again.
5.3.4.5 During start-up, the boiler firing is done preferably with the oil burners located at the
center of the arch. The required firing rate shall be adjusted to operate without exceeding
the maximum allowable furnace exit gas temperature of 550 °C.
5.3.4.6 As an addition, in order to maintain the Furnace exit gas temperature below 550℃,the
necessary fire rates to obtain the required pressure rise gradient are approximately the
following(airflow% refers to the airflow MCR):
1） 6 % of the BMCR firing rate with an airflow of about 30% during the first stage of the
pressure rise.
2） When the pressure rise slows down, the firing rate can be
increased by approximately 12 % of the BMCR with airflow of about 40%.
5.3.4.7 When the boiler is being warmed up, the saturated steam temperature rise gradient must
be limited to 100 °C/hour during the first hour and to 110°C/hour during the second hour.
Note: It is recommended to follow the shower rate of temp. increases during the initial
start-up of a new unit or after repair works in Furnace This will allow sufficient time for
drying the refractory, checking the expansion movements and to allow the operators to
become familiar with the characteristics of the steam generator and its auxiliaries.

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5.3.4.8 The boiler limits shall not be exceeded. Consult the start-up curves and diagrams given
at the end of this section.
5.3.5 Superheater and reheater protection during cold start-up :
5.3.5.1 This is especially important when there is no demand for steam such as when starting up
and shutting down. During the periods when there is no steam flow through the turbine,
an adequate steam path shall be ensured.
5.3.5.2 During start-up, the superheater is protected by the steam flow passing through the HP
bypass and the reheater is protected by the steam flow passing through the start-up vent
or through the LP by-pass. It is considered that the minimum steam flow required for a
proper protection is 10% of BMCR (approx. 100t/h).
5.3.5.3 During the first phase of the boiler start-up, the generated steam flow is insufficient to
cool down and protect the superheater and reheater elements from high flue gas
temperature. Therefore, particular care must be taken not to overheat the exchangers.
5.3.5.4 In order to protect the superheater and reheater until a sufficient and continuous steam,
the firing rate must be controlled to keep the maximum Furnace exit gas temperature
from exceeding 550
5.3.5.5 When the steam flow is established above the minimum required (steam flow approx
100t/h), the thermocouple probe may be retracted and the firing rate increased. However,
care must be taken to ensure that the totality of the steam flow crosses the reheater, i. e.,
that there is not any auxiliary steam from cold reheater pipes.
5.3.5.6 When steam is taken from cold reheat to feed the auxiliary steam header, never take
more than 20% of the steam flow through HP by-pass during start-up phases.
5.4 Cold start-up sequence
If the period after shut-down is more than 40 hour or remnant drum pressure is lower than 20
bars, it is called cold shut-down.
At Design condition estimated period of cold start-up to full load is 6. 5hour.
5.4.1 Boiler filling
5.4.1.1 If checking work before igniting the boiler is finished, after getting boiler of filling water,
Boiler can be filled and the requirement for boiler filling is as following :
1） Confirm all valves of steam system in right position.
2） Clean the system before filling the boiler. Water quality should be
assayed

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acceptable. Water temperature is decided acc. to drum wall

temp. Try
decreasing differential temp. If it is large, the speed of filling shall be
slow to prevent drum, header and etc. from producing too big hot stress.
3） 3 boiler water circulation pumps are filled water. Air exhaust is finished. Motor
cooling water system are put in service and the cooling water is adequate.
4） Economizer recirculation valve has been opened.
5） Open feedwater bypass motorized valve.
6） Locally open 3 boiler water circulation pump outlet valve.
7） Boiler filling period should be controlled in: Sumer≥２hour, Winter ≥4 hour.
5.4.1.2 Condensate of boiler filling or dematerialized water quality should meet requirement :
Condensate water dematerialized water
Form colorless hardness 0mmol/L
hardness ≤0umol Conductivity ≤0. 5us/cm
Fe ≤1000ug/kg SiO2 ≤20ug/L
Cu ≤200ug/kg pH 9

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5.4.1.3 Temperature of filled water is higher than 20℃ and approach drum wall temp as possible
as it can. The differential temperature of water temperature and drum wall temperature
shall not be over about 28℃.In the process of filling, the differential temperature of drum
upper and lower wall temp can’t be higher than 40℃.
5.4.1.4 Acc. to requirement of filled water temperature required by drum wall temp, open
condensate water pump or steam booster pump (or motorized pump) through feedwater
bypass to fill boiler till economizer air damper overflow water and then close valve
economizer air damper.
5.4.1.5 Open feedwater bypass valve and adjust water pump rotation speed to fill the water
smoothly. Control filling water speed. If water temp approaches drum wall temp, add the
speed suitably. But Drum wall differential temp. can’t be over set value.
5.4.1.6 When water level rise to lowest water level on the drum local water level instrument, turn
down feedwater control valve, control filling speed to let water level rise to high water
level slowly. If perform superheater hydraulic test, continue filling till each air damper of
superheater continuous overflow water and then close each air damper.
5.4.1.7 If filling is finished, close each water intake valve, stop water pump, and monitor drum
water level should be kept constant, otherwise it is required that checking for the cause
and reporting to the shift supervisor.
5.4.1.8 When filling boiler, 3 boiler water circulation pump Motor room continues keeping filling
water till boiler water circulation pump finishes air exhaust, boiler is ignited and pressure
rise to 2. 07MPa and then stop filling water.
5.4.2 Boiler cold igniting pressure rising
5.4.2.1 Start 2 boiler circulating pumps, and readjust drum level to approach the low level if
necessary. Select the third pump in hot stand by.
5.4.2.2 Open the air and gas path, that means:
1） Start both air heaters
2） In the sequence open the breaking damper at burning air outlet.
3） Put the flame scanner cooling air system and the fuel-oil burner
sealing air system service.
4） Start one I. D fan and put the furnace pressure in automatic.
CAUTION: The ID fans are able of developing excessive drafts that may damage

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part of the air/gas circuits. Care shall be taken to establish and maintain an open
air/gas path through the unit prior to starting an ID fan. Ensure that:
 Air dampers to HFO burners are in open position;
 The balancing dampers of secondary air compartments are not closed;
 The shut off damper and the control valves of at least one FD
fan are opened.
5） Start one F. D fan.
6） Take care, during starting the first FD fan to maintain opened the shut-off damper
and control valves of the other FD fan.
7） Increase the secondary air flow at the minimum required, i. e. 30% of full load
airflow.
8） Successively start the second ID fan and the second FD fan.
9） Put in automatic control all the fans and combustion airflow command.
10） Put in automatic control the air dampers on secondary and tertiary air circuits
FCA/B PCV 11A, 11B, 11C, 21A, 21B, 21C, 14, 15, 24,
Check the following recommended positions
FCA/B PCV 11C and 21C are opened 100%
FCA/B PCV 11B and 21B are opened 20%
FCA/B PCV 11A and 21A are closed
FCA/B PCV 14, 15, 24 and 25 are closed

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5.4.2.3 Start the steam air preheaters (if auxiliary steam is available) and verify that the
temperature set point is in automatic.
5.4.2.4 Start both primary air fans and put PA pressure control in automatic control.
5.4.2.5 Put in service the retractable probe.
5.4.2.6 Open the reheater start-up vent FRS UV 01.
5.4.2.7 Open the economizer re-circulating valve FSR UV 002.
5.4.2.8 Open the rear pass and ITS drain valves FSR UV 003 and 005.
5.4.2.9 Verify that the cold reheat drain valve FRS UV 002 is in automatic
5.4.2.10 With airflow of 30 % of nominal flow, perform a Furnace purge during 5 minutes.
“Soot blowing allowable ”condition :
1) Whole security of the units is established. I.e. control system power is in service,
air pressure of instrument is normal.
2) At least one ID fan is in service.
3) At least one FD Fan is in service.
4) Close all oil burners.
5) Pulverized coal feeder is in service.
6) All ESP system is shut down.
7) All flame scanners don’t scan flame.
8) Close burning oil main closure valve.
9) Close all pulverized coal burners, i.e. primary air damper is closed.
10) Burning improving air valve of burners is at purge position (open specified air valve,
close other valve ).
11) Total air flow (primary air and secondary air) is from 25% to 40% BMCR flow.
Furnace purge is correct, and then ignite burning oil burners.
In furnace purge time if any condition can’t be reached, purge will be stopped; 5
min timer must be reset.

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In furnace purge time, finish burning oil circuit leaking test. If “ leaking test is not
finished ” or “leaking test is abnormal” , need reset furnace purge end storage. Check
the cause for failure, re-perform a furnace purge.
5.4.2.11 Check the boiler safeties setting conditions.
5.4.2.12 Open the boiler isolating valve and the HP by pass. Place the HP by-pass in auto with
the HP pressure set point at 60 bars. This will position the HP by pass at a constant
opening (minimum start-up opening, around 20%).
5.4.2.13 Start one after the other, 2 oil burners at the centre of the arch (FBI+FBN or FBH+FBF),
and check locally the correct operation of the burners and the quality of the combustion.
“Furnace igniting allowable” condition:
1） Boiler purge is finished and “Purge end storage” is set up.
2） Control system power can be put in service and air pressure for
control is correct.
3） At least one ID Fan is in service.
4） At least one FD Fan is in service.
5） At least one air preheater is in service.
6） Total air flow is higher than min value.
7） Boiler drum water level is not at high position.
8） Drum water level is correct, i.e. above too low water level.
9） At least one circulation pump is in service, i.e. pump works (Motor contactor
auxiliary switch) and relevant differential pressure is higher than min value.
10） Furnace pressure is correct, i.e. between the highest and lowest
(pressure switch 3 get 2).
11） Flame scanner cooling air equipment is in service, i.e. cooling air is higher than
min value.
12） Superheater outlet steam pressure is not too high (3 get 2).
13） ESP Inlet Flue gas temperature is not too high.

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14） Accidents button is not put.
15） If water temp is high and steam exhaust exists or if water temp is not high,
Furnace gas-temperature probe is in service and furnace temperature
is not high.
Notice: required condition for steam exhaust:
 Open HP cylinder steam intake valve (Open emergency closure valve and close
turbine control valve) and open boiler outlet closure valve (close limit switch).
 HP bypass in not close :
 LP bypass valve is not closed.
 IP steam intake valve is opened (close limit switch) and HP control valve is not
closed.
 Open reheater outlet air draft valve (no closure, limit switch is switched on, no
action).
If all conditions are met, boiler total safety storage can be automatically set up,
and then the burners can be put in service.
“Oil supply to oil burners allowable” condition:
1） Oil pressure is normal.
2） Meet conditions for furnace igniting allowable or any burners is ignited.
3） No MFT condition.
4） No OFT condition.
5） Oil burner’s secondary air damper is at igniting position.
6） Oil a burner steam purge valve and oil valve is closed, oil burner and igniting
burner exit, oil burner power is normal.

2×300 MW
5.4.2.14 If necessary adjust the firing rate. During pressure rise control the firing rate to keep the
maximum furnace exit gas temperature below 550 °C. The rising rate of saturated steam
temperature is about 100 °C/hour during the first hour and to 110°C/hour during the
second hour. The pressure rise of the boiler meets relevant requirement. (see start-up
curve).
5.4.2.15 When the drum pressure increases above 2 bar, close the ITS and motorized drain valve
of the rear pass.
5.4.2.16 As the water in the boiler is warmed up and expands, the level in the drum will increase.
If it is required, open the intermittent blow down valve at the circulating pumps outlet to
decrease and maintain normal water level in the drum.
5.4.2.17 Increase the firing rate. Start more oil burners if it is required. Continue surveying the
furnace exit temperature (<550°C) and the gradient of the saturated steam temperature
(<110 °C/hour).
5.4.2.18 Put feed water control valves in automatic as soon as possible. At this stage, the drum
level is controlled by the start-up valve FSR-LCV-52D.
5.4.2.19 Close the economizer re-circulation valve, as soon as a permanent feed water flow
above 100t/h is established.
5.4.2.20 When the steam flow rate is above 100 t/h, stop the retractable probe.
5.4.2.21 When vacuum is established in the condenser, put in service the LP bypass with and set
the reheater pressure set point to 8 bar. Close the reheater start-up vent when the LP
by-pass starts opening.
5.4.2.22 Check that spray water valves are in automatic and that temperature set points are in
accordance with turbine rolling requirements.
5.4.2.23 As soon as the reheated steam conditions are within the required value, start turbine
rolling
5.4.2.24 When HP pressure reaches 60 bar, the HP by-pass switches from minimum opening
position to automatic pressure control mode. The by pass opens to control the HP
pressure at 60 bar.
5.4.2.25 The Boiler pressure control is in automatic, manually continue increasing the firing rate
by adjusting oil pressure and/or adding burners to obtain a steam flow of 200 t/h. For
information, at this stage 10 to 12 oil burners are expected to be in service.
5.4.2.26 Start the electrostatic precipitator.

2×300 MW
5.4.2.27 When steam flow is >200 t/h, prepare to put pulverized coal burners in service if the coal
silo has pulverized coal. One rotary coal feeder can be started when the permissive
conditions are met.
5.4.2.28 Continue monitoring superheating/reheating steam conditions and prepare for turbo and
generator synchronization.
5.4.2.29 When feed water flow is above 200 t/h open feed regulating valve and differential
pressure is lower than 5 bar . The main feed valve LCV52 takes over drum level control.
5.4.3 Rolling of the turbine and synchronization
5.4.3.1 When the boiler load is around 20% (steam flow 200 t/h), the HP steam pressure is 60
bar, the LP pressure 8 bar. As soon as HP/LP steam temperature conditions are
satisfactory, the turbine can be rolled up.
5.4.3.2 During speeding up of the turbine, the boiler is maintained at constant steam flow 200 t/h.
Maintain steam temperature at 400 °C on HP side and at 390 °C on IP side.
5.4.3.3 When the turbo-generator warm-up is completed and permissive conditions are met
steam is introduced to the turbine.
5.4.3.4 The HP by-pass is closed gradually to let the turbine HP cylinder take over the
superheated steam flow.
5.4.3.5 The LP by-pass closes gradually to let the turbine IP and LP cylinders take over the
reheating steam flow to the turbine and generator are synchronization.
5.4.4 Load rise
5.4.4.1 The maximum boiler load that can be achieved with oil burners can reach 30% at most
5.4.4.2 When steam flow is higher than 200t/h, start one rotary coal feeder and after stabilization
start a second one on the opposite side of the Arch nose. The associated oil burners
should be in service to ensure ignition of the pulverized coal. diving of the flames
5.4.4.3 Adjust the secondary air distribution in the arch compartments, in order to obtain diving of
the flames (the control stations of dampers FCA/B PCV 11A/B/C and 21A/B/C are
operational as soon as a rotary feeder is in service)
5.4.4.4 When steam flow is higher than 250t/h start the milling plant if require.
5.4.4.5 Start more coal burners according to load and pressure rise. The total coal demand can
be put in automatic and the firing rate can be then controlled by the boiler load demand
set point.

2×300 MW
5.4.4.6 When the HP by-pass is closed, raise the pressure gradually by controlling the firing rate.
The saturated steam temperature gradient shall remain below the Design limits (see
start-up curve).
5.4.4.7 Keep the fuel-oil burners in service as long as required and until the expected numbers
of coal burners are operating. Furthermore, it is recommended to keep in service 4 oil
burners after reaching full load to obtain a stabilized temperature on the refractory.
5.4.4.8 Transfer the turbine control and the boiler load demand to automatic. Under this mode
the unit is in the coordinated mode selected by the operator (boiler or turbine following).
Normally the boiler following mode is used: the opening of the turbine valves controls the
load and the firing rate controls the steam pressure.
5.4.4.9 Put the steam temperature control in automatic. Verify that correct set points have been
reached.
5.4.4.10 Check the total airflow which has to be sufficient at all times for the actual firing rate.
5.4.4.11 When the target load is reached, verify that boiler-operating conditions are in
conformance with design data. Refer to expected values and to the sliding pressure and
excess air curves.
5.5 Hot start-up
Hot status boiler is classified as the following types:
• Moderate: Shut-down for 10 to 40 hour, boiler pressure is from 2. 0 to 6. 5 MPa.
•hot: shut-down for 1 to 10 hour, boiler pressure is from 6. 5 to 14. 0 Mpa.
• Extremely hot: shut-down for less than 1 hour, boiler pressure is higher than 14. 0 Mpa.
5.5.1 Check and preparation before hot start-up:
5.5.1.1 Control air source, power is reliable, and control air source pressure normal.
5.5.1.2 Fire scanner and fire-proof system is normal, Air preheater fire extinction equipment is
reliable.
5.5.1.3 Put water seal at boiler bottom in service. Filling water, each piece of equipment of ash
handling system is at stand-by status.
5.5.1.4 Burning oil system and atomization steam system is normal.
5.5.1.5 The following equipment operation is normal, If it is stopped, open it again :
1） 2 Air Preheater.

2×300 MW
2） AC flame scanner cooling air fan, DC air fan are at “interlock”.
3） 2 boiler water circulation pump, and stand-by pump is at “interlock”.
5.5.1.6 The following auxiliary equipment is at stand-by status
1） A, BID Fan
2） A, BFD Fan
3） A, BPrimary air fan
4） A, Bpulverizing system
5） All pulverized coal feeder and oil burner
6） A, BSteam air preheater
7） A, B ESP
5.5.1.7 All soot blowing burners position are correct and at “exit” position.
5.5.1.8 A, B Furnace outlet flue gas temperature probe has been put in service.
5.5.1.9 A, B Furnace flame TV has been put in service.
5.5.1.10 Steam system check is finished and its valve position meets the requirement before
igniting the boiler:
1） Close all air damper of superheater and drum.
2） Open economizer recirculation valve.
3） Open atmospheric relief valve at reheater outlet.
4） Automatic drain valve at cold reheater main pipe is reliable.
5） Each manual valve of attemperating water system is opened, each

motorized valve, control valve are closed.
6） Main steam valve and bypass valve are closed

2×300 MW
5.5.1.11 Close the left drain valve of superheater.
5.5.1.12 Check that drum local or TV water level instrument has been put in service and drum
water level is normal.
5.5.1.13 Each valve position of soot blowing system is right.
5.5.2 Boiler hot start-up steps：
5.5.2.1 Open opening vent valve FRS UV 001 of the reheater.
5.5.2.2 Make sure that there is no drain opened in reheat pipe and automatic drain valve FRS
UV 002 is available and ready for service.
5.5.2.3 Open during a sufficient time (see table) the automatic drain valves on superheater:
1） Drain valve of steam walls of rear pass FSR UV 003.
2） Drain valve of LTS inlet FSR UV 005.
3） Drain valve of superheater outlet steam pipe FSR UV 004.
4） The drains have to be opened before firing the boiler during a time long enough
to eliminate all the water out off the superheater. The time is function of the duration
of the shut down and the pressure in boiler. Follow the indications here below
Residual drum pressure (bar) 150 80 50 10
duration of opening (mn) before firing:
- FSR UV 003 2 5 10 65
- FSR UV 004 2 5 10 60
- FSR UV 005 2 5 10 60

2×300 MW
5.5.2.4 Open drains and conditioning devices of the main steam lines according to the
instructions of the turbine manufacturer.
5.5.2.5 Start, one side after the other, the ID and FD fans.
5.5.2.6 Start the steam air preheaters.
5.5.2.7 Start one after the other both PA fans and put PA pressure control in automatic.
5.5.2.8 Adjust the airflow to 30 % of nominal flow and perform Furnace purge during 5 minutes.
5.5.2.9 Open the HP by-pass gradually by adjusting pressure set point below the actual
remaining pressure.
5.5.2.10 Start 2 diagonals of oil burners as soon as possible.
5.5.2.11 According to turbine conditions, maintain or raise boiler pressure by adjusting HP

by-pass set point and increasing firing rate.
5.5.2.12 Close the economizer recirculation valve, as soon as a permanent feed water flow is
established and put in automatic the drum level control.
5.5.2.13 When the vacuum is established in the condenser, put in service the LP by-pass and
close the reheater start-up vent.
5.5.2.14 Steam flow and steam temperatures will rise rapidly in relation with the firing rate.
5.5.2.15 Open main steam line warm-up lines and boiler stop valve according to turbine
manufacturer. When turbine start-up conditions are reached, start rolling the turbine.
5.5.2.16 Start the Electrostatic precipitator.
5.5.2.17 After synchronization, raise the load by putting in service additional burners. Check
proper airflow.
5.5.2.18 Control firing rate to obtain the load acc. to raise startup curve gradient (110°C/hour).
5.5.2.19 Put the steam temperature and load controls in automatic.
5.5.2.20 Check that firing conditions are stable. Check that pressure and temperature set points
are reached.
5.5.3 Boiler star-up attentions :
5.5.3.1 Metal wall initial temperature and other relevant parameter of turbine HP and MP cylinder
and boiler status decide the start-up status of the unit.
5.5.3.2 In strict accordance with start-up curve of each status, raise temperature and pressure.

2×300 MW
5.5.3.3 When raise the pressure, pay attention to the changes of steam and water quality.
5.5.3.4 When oil is burning, close monitor the changes of temperature of air preheater outlet flue
gas.
5.5.3.5 In the process of start-up, pay attention to burning conditions, especially oil burning.
When each oil burner is put in service, out of service and normal operation, strengthen
the check for oil burner. If oil burner has oil leaking, bad atomization, when oil is leaking,
immediately take measures to solve. When oil burner is stopped, close burning oil input
manual valve, if the defects can’t be solved, “prohibit opening” marks should be put on it.
5.5.3.6 Check the reliable operation of flame scanner equipment at any time.
5.5.3.7 Check economizer protection, i.e. the using condition of economizer recirculation valve.
5.5.3.8 Check protection for superheater and reheater and can’t allow operation of steam with no
path. Pay attention to monitoring metal wall temp. in the allowable scope.
5.5.3.9 For the oil with primary start-up or with major repair, confirm boiler hot expansion of each
parts, especially the low hot expansion. Record each data of boiler expansion indicator
for reference of start-up.
5.6 Parameter control value In the process of start-up
5.6.1 Parameter which should be controlled in boiler cold start-up
Time(min )
Parameter Units
0 60 144 255 390
Main steam pressure bar 0 6 60 60 167
Main steam temperature ℃ ／ 260 400 400 541
Reheat steam temperature ℃ ／ 240 390 390 539
Main steam flow t/h 0 0 200 200 995
unit load MW 0 0 0 15 300
specification boiler igniting turbine impulse starting synchronization full load
5.6.2 Parameter which should be controlled in boiler hot start-up
Parameter Units Time(min )

2×300 MW
0 20 50 60 110
Main steam pressure bar 0 78 100 100 167
Main steam temperature ℃ ／ 400 480 480 541
Reheat steam temperature ℃ ／ 380 460 460 539
Main steam flow t/h 0 120 300 300 995
Unit load MW 0 0 0 15 300
specification Boiler igniting turbine impulse starting synchronization full load
6 Monitoring and adjustment in boiler operation
6.1 The main task and objectives of operation adjustment
6.1.1 Keep evaporative capacity of boiler is in the rated value and meet the requirement of unit
load.
6.1.2 Maintain normal and stable steam pressure, steam temperature and drum water level.
6.1.3 Maintain water and steam quality acceptable.
6.1.4 Keep good combustion, raise boiler efficiency and keep the furnace clean.
6.1.5 Ensure that boiler and subsidiary equipment should be opened, stopped safely and
operated economically and safely.
6.2 Main Parameter and limit of operation control
6.2.1 Different load operation control main Parameter value:
Coal burning(load )
Item Units
75% 60% Min load
BMCR RO
RO RO *60% RO
1. Generator total
MW 300 225 210
output power
2. Steam flow kg/H
(a) Superheat steam 995 882. 7 639. 4 518. 9

2×300 MW
(b) Reheat steam 849. 4 756. 5 555. 0 443. 8
3. Steam pressure kg/cm2g
(a) Drum 190. 4 186. 5 156 127. 5
(b) Superheat steam 176. 3 174. 7 149 121. 9
(c) Reheat steam 33. 7 30. 1 22. 1 18. 0
4. Steam temperature ℃
(a) Superheat steam 541 540 539 539
(b) Reheat steam 538 538 538 538
5. Feedwater pressure kg/cm2g
(a) Economizer Inlet 193. 9 189. 4 158. 7 129. 9
6. Feedwater temperature ℃
(a) Economizer Inlet 281 273 254 243
7.Fuel consumption (coal) kg/H 129500 99100
8. Air temperature ℃
(a) Steam air preheater

29 29 29 29
Inlet
(b) A. P outlet Primary air 356 352 324 308
(c) A. P outlet
333 333 311 297
Secondary air
(d) Mill outlet 110 110 110 110
9. Flue gas temperature ℃
(a) Superheater outlet 670 650 610 580
(b) A. P Inlet 400 392 358 340
(c) A. P outlet 124 121 111 102

2×300 MW
10. O2 content in Flue gas % Vol
(a) Economizer outlet 4. 0 4. 0 4. 5 5. 4
(b) A. P outlet 5. 1 5. 1 5. 9 6. 8
6.2.2 Limited value of boiler operation main Parameter control :
Parameter Name Units Setting value range
Superheat steam pressure bar 175±5 ±2
Superheat steam temperature ℃ 541±5 ±2
Reheat steam temperature ℃ 538±5 ±2
Drum water level mm

2×300 MW
6.3 Checking, monitoring and maintenance in boiler operation
6.3.1 Checking in boiler operation :
6.3.1.1 Intermittently check each operation parameter and equipment operation conditions in
DCS screen in boiler normal operation. If there are abnormal parameters or abnormal
conditions of equipment, immediately analyze and take corresponding control measures.
6.3.1.2 Intermittently check equipment operation conditions in boiler normal operation. If there is
abnormal vibration, abnormal sound or coal leaking, pulverized coal leaking, air leaking,
steam leaking or oil leaking etc. in equipment operation, immediately take isolation
measures.
6.3.1.3 Often analyze each operation parameter, comparative analysis of each data of indicator
of equipment on site and each parameter from DCS. If there is any doubt or big errors,
the cause must be checked carefully and solved.
6.3.2 Combustion control of boiler:
6.3.2.1 In boiler operation immediately control coal quality condition fed to the furnace and per
coal quality condition, adjusts mill outlet temperature and differential pressure between
inlet and outlet.
6.3.2.2 In operation close monitor change of air flow and oxygen content of flue gas. At any time
air flow should be more than lower than 30% BMCR operating condition, keep Flue gas
oxygen content in suitable scope.
6.3.2.3 Often check burning condition in the furnace and observe fire condition pulverized coal .
6.3.2.4 When furnace burning is not stable, immediately put oil burner in service for stable
burning. When Boiler load is lower than 60% BMCR, input oil for stable burning.
6.3.2.5 When raise load, crease air flow and then crease fuel. When drop load, decrease fuel
and then decrease air flow
6.3.2.6 Intermittently check total air flow for boiler burning, adjust to keep appropriate rate of air
/coal to reach good burning operating condition.
6.3.2.7 Acc. to coal quality and burning condition, adjust the position of air valve of air
adjustment and axial blade, keep reasonable pressure drop of burners and alternate
secondary air rotating speed to confirm degree of disturbance of mixture of air and
pulverized coal.

2×300 MW
6.3.2.8 Acc. to boiler combustion system each parameter and steam temperature change trend
immediately adjust the position of indicator of secondary air dampers at front, rear arch A,
B, C row, and minor adjust the position of indicator of each upper and lower tertiary air
valve of front and rear wall to change the length of W flame.
6.3.2.9 Good burning operating condition is that “fuel －air” mixtures is burning in furnace lower
parts, i.e., the mixtures stay longer in the furnace with full of flame which is golden yellow.
If oil is burning, flame is white and light. And don’t impact water wall and plate
superheater. Ignition point of fuel can’t be approached which can cause burners burned
and damaged by around coking easily. And incompletely burned fuel content in ash and
fly ash is low.
6.3.2.10 Turn up external secondary Air damper. Flame ignition point of pulverized coal becomes
remote; Otherwise, turn down external secondary Air damper, ignition point of fuel
become near. Add external secondary air flow and carbon content in the fly ash is
obviously decreased but maintain burning safety at the same time. The final setting value
for the position of indicator of external secondary air shall be a little smaller than critical
position of indicator.
6.3.2.11 Internal secondary air damper should be decreased to make flame closer and make
critical position of indicator of external secondary air become large and make burners air
flow’s direction to external secondary air to make it economical.
6.3.2.12 If burning flame is instable, check primary air flow. Big air flow and thick pulverized coal
will cause flame instability. Otherwise, too low primary air flow may cause pulverized coal
uneven distributed in burner tips to lead burning disturbance.
6.3.2.13 In normal operation, keep furnace negative pressure -100Pa.
6.3.2.14 Furnace outlet oxygen content is decided by different fuel characteristic and load. When
oxygen content is at manual position, control it acc. to oxygen content control setting value.
If oxygen content control is automatic, through “automatic” or “manual” method
change oxygen content setting value to perform automatic control. When oxygen content
in flue gas is at “automatic” measure, acc. to the range in the following table to perform
adjustment.
Boiler load (T/H) 400 500 600 700 800 900 995
Flue gas oxygen content 6. 8 5. 5 4. 7 4. 35 4. 15 3. 95 3. 95

2×300 MW
6.3.2.15 When oil burner is in service, burning oil fire condition should be monitored by flame
scanner. If there is not any oil burner, the corresponding pulverized coal feeder can’t be
put in service.
6.3.2.16 The best operation measure of pulverized coal feeder is that same burning tip is on two
arches to maintain the burning stability. In big load, try to put all pulverized coal feeder in
service and rotation speed should be controlled under 10rpm and can’t be more than
11rpm to prevent pulverized coal feeding pipe of rear wall blockage. When control
rotation speed pulverized coal feeder, the rate of increase or decrease should not be
large to reduce the interference of burning.
6.3.2.17 In operation, try to make rate of air /coal(PA/PC) meet the following requirement
Boiler load (%) BMCR 100%ECR 75ECR 50%ECR 40%ECR
PA/PC(air /coal) rate 1. 03 0. 98 0. 98 1. 17 1. 13

2×300 MW
6.3.2.18 When do combustion adjustment or increase load of the boiler, besides keep steam
temperature and steam pressure normal, keep water wall outlet operating conditions
temperature in normal scope. After burners are put in service, immediately check
whether fire condition is good and immediately adjust air flow to prevent smoke emission
form the chimney.
6.3.2.19 In boiler normal operation, often check air leaking conditions of the body and duct. Check
seal of each section good, each valve and hole are closed strictly and ash handling
equipment seal good.
6.3.2.20 In boiler normal operation, operation conditions of burners and heating surface should be
checked. Strengthen analysis and comparison. If there is phenomenon of slag building,
clogging and fire extinction, immediately adopt adjustment measures.
6.3.3 Steam pressure control:
6.3.3.1 When unit are in the operation with “turbine and boiler coordinating” measure, through
inner control circuit, compare actual measured value of main steam pressure setting
value and actual measured value of boiler outlet main steam pressure to change boiler
load in order to let boiler combustion obtain adjustment and finally reach the objective of
controlling steam pressure to meet requirement of unit load.
6.3.3.2 In the period of starting-up the unit, minimum start-up pressure is controlled by HP
bypass at 60bar and unit is operated at “setting pressure” operation measure.
6.3.3.3 In the process of increasing unit load, gradually close HP bypass till it is completely closed.
HP bypass is changed to operation with “variety gradient” control measure. Unit control
measure is changed to “sliding pressure” operation.
6.3.3.4 Put boiler main load requirement and oxygen content control into “automatic”. The unit
gradually increase load through increasing steam pressure setting value.
6.3.3.5 When the following condition occurs, HP bypass shall be quick opened to control boiler
outlet pressure:
1) Turbine trips.
2) Operate with auxiliary power.
3) Main steam pressure is over 18. 5MPa.

2×300 MW
6.3.3.6 Main steam pressure normal adjustment is controlled in±0. 2 MPa and not more than ±0.
5Mpa. If main steam pressure＞18MPa, it is regarded as “Main steam high pressure”.
6.3.4 Steam temperature control
6.3.4.1 In boiler normal operation, main steam temperature is controlled at 541±5℃, two side
differential temperature is lower than 10℃ and at the same time operation medium
temperature in each section and wall temperature doesn’t exceed regular.
6.3.4.2 Main steam temperature is controlled mainly by water spray attemperator. Superheater
primarily attemperator will perform “rough adjustment” for steam temperature and its
water spray volume is decided temperature before using attemperator. Keep wall
temperature of mid-temperature superheater from exceed the allowable value. By using
secondary attemperator of superheater performs “micro-adjust” to main steam
temperature to keep instability of boiler outlet steam temperature, high sensitivity of
controlling steam temperature by secondary water spray attemperator, and small delay.
Through changing flame center position, main steam temperature can be auxiliary
controlled.
6.3.4.3 Control of reheater steam temperature is mainly performed through combining

attemperating water and burning adjustment, i.e. through changing the position of
indicator of upper and lower third air control damper of front and rear arch to change
flame center position to reach the objective of decreasing or increasing reheat steam
temperature. Adopt water spray attemperating to control reheat steam temperature.
6.3.4.4 Use and attention for attemperating water :
1) Superheater, reheater water spray attemperating control can be used at

main steam flow＞150T/H. Superheater primary water sprays attemperating
is used
to control wall temp. of mid-temperature superheater, prevent over
limited and auxiliary control main steam temperature. Secondary
water spray primary attemperating is the final adjustment for the main steam
temperature. Differential temperature of two side of superheater should
not be more than 10℃, Strictly control that attemperator outlet steam
temperature must be higher than saturated temperature 15℃ at its operation
pressure.
2) When control attemperating water and keep steam temperature,

adjustment of attemperating water can’t be quick increase or quick decrease
for the operation has a certain lag.
3) When control attemperating water, pay attention to differential pressure relation

2×300 MW

2×300 MW
between drum pressure and feedwater main pipe pressure. When

feedwater
pressure is changed, attemperating water control valve should be
correspondingly adjusted. Usually keeping feedwater pipe pressure higher than
drum pressure 20 bar is better.
6.3.4.5 When the following condition occurs, especially pay attention to monitoring steam
temperature to prevent overheating and sharp drop of steam temperature.
1) Increase or decrease load
2) Start or stop burners
3) Start or stop Feedwater pump
4) Start or stop air fan (single side air fan trip or resume)
5) Start or stop pulverizing system
6) Start or stop high temperature heater
7) Instable steam pressure
8) Coal quality is changed.
9) Ash deposit, slag building on heating surface
10) Bad burning condition or changes of flame length
11) Pulverized coal is unbalanced. Pulverized coal fineness is changed
12) Soot blowing occurs.
13) Large fluctuation of drum water level
14) Boiler blowdown
15) When oxygen content in furnace is being changed.

2×300 MW
6.3.4.6 In normal operation, each water spray attemperator shall be put in automatic service.
Pay attention to water spray automatic control in normal service. In changing operating
conditions, strengthen monitoring steam temperature to prevent over temperature. For
e.g. automatic control can’t follow the changes of steam temperature. Switch to “manual”
measure to adjust.
6.3.5 Drum water level control
6.3.5.1 Strictly monitor drum water level. Control variety rule of drum water level and feedwater
pump characteristic. Be familiar with equipment system and performance. In operation
keeping stable normal water level is the chiefly task to maintain boiler safety and
economical operation.
6.3.5.2 The change of water level shows the balance relation between boiler load and Feedwater.
When start the boiler and main pipe pressure of feedwater pump＞50 bar, open
feedwater pump outlet motorized valve. At this time put feedwater pump rotation speed
into “automatic”. On the control console send the opening order to feedwater control
isolation valve to automatically trigger the following procedure: For e.g. if feedwater low
flow control valve FCV52D is closed (ZSL52), open its isolation motorized valve UV20A,
UV20B (ZSH20A ZSH20B), put FCV52D into “automatic” operation. For e.g. If feedwater
main flow control valve FCV52 is closed (ZSL52), when Boiler main steam flow ≥380T/H
and send main flow control isolation valve UV19 opening order. Open FSRUV19 (ZSH19)
and feedwater control is switched from bypass control automatic to main flow control
valve FCV52. In boiler normal operation, through FCV52 control drum water level. When
load drop to flow≤286T/H or feedwater control valve front and rear differential pressure
(PT90-PT85=PPS90) ≥60bar, feedwater control is switched from feedwater control
automatic to bypass control valve FCV52D. Drum water level is controlled through
feedwater control valve and feedwater pump rotation speed. When only through
feedwater pump rotation speed controlling Drum water level, it will cause the fluctuation
of attemperating water pressure which makes steam temperature difficult to control.
Therefore, this measure can’t be adopted. When feedwater has to be controlled through
feedwater pump rotation speed, the staff should be more careful and pay attention to
change of attemperating water volume to prevent fluctuation of steam temperature.
6.3.5.3 Work scope of drum normal water level is -290mm－-175mm. When its water level drop
s to -240mm or rises to +100mm, low or high drum water level alarm is sent. When its
water level drops to -425mm, rise to +200mm, MFT trips.

2×300 MW
6.3.5.4 In normal operation, put feedwater flow control into “automatic”, drum water level is set
“automatic” feedwater pump rotation speed and feedwater control valve is put at
“automatic” measure. And monitor drum water level in the following scope.
Boiler load (％) 50 60 70 800 90 100
Drum water level(mm) -290 -265 -245 -220 -200 -175
6.3.5.5 When boiler operating conditions is changed, e.g. When load, steam pressure, feedwater
pressure are changed, change of feedwater pump operation measure and change of
burning operating condition occur and boiler blowdown etc., strictly monitor change of
water level. If the fluctuation of water level is large, immediately switch water level control
to manual control to prevent the accidents caused by full water, inadequate water. If
emergency occurs, use continuous blowdown and intermittent blowdown valve to
cooperate with control.
6.3.5.6 When attemperating water flow is increased and water spray attemperating control valve
opening position is ≥70%, feedwater pump rotation speed should be automatic increased
and feedwater control valve should be automatic closed about 10%. (but not completely
closed). Keep feedwater main pipe pressure constant to avoid large fluctuation of drum
water level.
6.3.5.7 When drum water level automatic control jumps to “manual” measure, strengthen
monitoring and control of drum water level, feedwater flow and feedwater pressure.
6.3.5.8 If the following condition occurs, strengthen monitor and adjustment of water level :
1) The large fluctuation of feedwater pressure and feedwater flow.
2) When safety valve is opening or reseating and boiler blowdown.
3) When load is changed and HT heater exit operation.
4) When opening or closing feedwater pump, impulse starting, synchronization and

etc in the start-up or shut-down of boiler.
5) When feedwater pump and control equipment fault occurs.
6) When switch over control valve control and feedwater pump rotation
speed control or steam pump and motorized pump.
7) When pressure parts leaking occurs.

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8) When open or close turbine control valve, bypass valve, superheater and main
steam pipe drain valve.
9) When burning is instable or perform fire extinction treatment.
6.3.5.9 Any data on drum remote water level indicator is abnormal, immediately contact with
thermal control staff to deal with If it can’t be resumed, and relieve water level protection.
6.3.6 Boiler blowdown
6.3.6.1 To keep steam, water quality and heating surface internal clean, must perform boiler
blowdown. Classify boiler blowdown to continuous blowdown and intermittent blowdown.
6.3.6.2 Continuous blowdown is controlled blowdown volume acc. to the result of chemical
analysis and boiler water quality parameter and through adjusting position of indicator of
continuous blowdown valve FSRUV17.
6.3.6.3 Intermittent blowdown is performed acc. to the result of chemical analysis and after
receiving the notice from chemical shift supervisor, through intermittent blowdown valve
FSRUV02 or 2 mins blowdown at morning shift every day. Intermittent blowdown shall be
performed at low load
6.3.6.4 Intermittent blowdown operation
1） Check closure valve FSRHV034 at Open condition, micro-open

intermittent blowdown valve FSRUV02 to heat pipe.
2） After heating pipe, fully open intermittent blowdown valve FSRUV02, after 2min,
close this valve.
3） In the process of intermittent blowdown, pay attention to the change of drum

water level and operation conditions of boiler water circulation pump to prevent
water circulation from damaged.
4） If blowdown is finished, blowdown valve FSRUV02 should be checked

closed strictly.
6.3.6.5 If the following condition occurs, stop intermittent blowdown operation :
1) When drum water level is not normal, feedwater control is no good.
2) Blowdown system fault or strong vibration of pipe.
3) Boiler accidents occurs.

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6.3.6.6 Prohibit long period blowdown and blowdown valve leaking. In operation to prohibit boiler
blowdown by boiler water circulation pump inlet header drain valve.
6.4 Boiler operation measure control
6.4.1 Totally there are 5 types of units’ operation measures: manual, Boiler following mode,
turbine following mode and coordinate control and electricity network control.
6.4.2 Manual measure: it is the most basic measure, boiler main controller and turbine main
controller operation measure is at manual measure, i.e. Boiler side, turbine side is manually
kept parameter by operation staff and change unit load or keep stable operation acc. to
requirement.
6.4.3 Boiler following mode: Turbine controls load, Boiler controls inlet pressure. At this time,
turbine main controller is at manual measure, or remote control of DEH system not put in
service. At this measure, turbine controls load, and boiler main controller in automatic measure
operation, automatic closed loop control inlet pressure.
6.4.4 Turbine following mode: Boiler controls load, Turbine controls inlet pressure. At this time,
boiler main controller is at manual measure, but turbine main controller is in automatic measure
operation. Through changing position of indicator of control valve to stable inlet pressure, at
this measured DEH systems put in service.
6.4.5 Coordinate control measure: at this measure, boiler main controller and turbine main
controller is in automatic measure operation.
6.4.6 Electricity network control: at this measure, unit coordinate control is put in service, and
electricity network load dispatch system put in automatic following. Electricity network send
Generator unit load order, Generator unit automatic follows load order and boiler and turbine
make corresponding automatic control to meet requirement of electricity network load order.
7 Shut-down of Boiler
7.1 basic regular (generals )
7.1.1 Boiler normal shut-down must strictly be accordance with shut-down curve control relevant
parameter.
7.1.2 In boiler abnormal shut-down must prevent shut-down in the process of accidents or
enlargement accidents.
7.1.3 Before shut-down of boiler do corresponding check and preparation.
7.1.4 After shut-down of boiler, if emergent repair is needed, accelerate boiler cooling i.e.
compulsory cooling and adopt the following operation:

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7.1.4.1 Keep Drum high water level+300～+500mm, and strengthen changing water, deaerator
water temp. is decided by boiler cooling condition.
7.1.4.2 After shut-down for 6 hour, Boiler is sealed. After shut-down for 6～18hour, Boiler
naturally air draft.
7.1.4.3 At 18 hour after shut-down, open 1 ID, FD Fan, keep about 30％BMCR air flow Boiler to
compulsory air draft.
7.1.4.4 Strictly control Pressure Drop speed, total temperature drop and pressure Drop In the
process of drum upper, lower wall differential temperature≤40℃.
7.1.4.5 Strictly monitor boiler water circulation pump operation conditions, when Drum pressure
＜15bar, close 1 boiler water circulation pump. If boiler water circulation pump has
vaporization Phenomenon, immediately stop boiler water circulation pump operation.
7.1.4.6 When boiler water temperature＜70℃, close boiler water circulation pump, Boiler drain.
7.1.5 After shut-down, in order to prevent heating surface from internal erosion, per different
conditions, perform corresponding shut-down maintenance work.
7.1.6 When boiler pressure doesn’t drop to 0 and Motor power isn’t cut off, giving up monitoring
boiler unit and auxiliary equipment can be allowed.
7.1.7 In the process of shut-down strictly control Pressure Drop speed, seriously operation, and
strictly monitor differential temperature of drum upper, lower wall is less than 40℃.
7.2 Preparation before shut-down of boiler
7.2.1 The shut-down of Boiler unit must obtain the superior order, and the measure, reason and
period of shut-down and then prepare for the shut-down, and inform chemical, burning
operation, desulphurization staff on duty and Thermal control staff of shut-down period.
7.2.2 Before shut-down, inform each staff on duty to comprehensively check system managed
by himself to record all detailed defects condition to solve all the defects after shut-down.
7.2.3 If the period for shut-down is more than 3 days, grind all the coal in the bunker grinding.
Pulverized coal in pulverized coal bunker need be burned out. If the period for shut-down is in 3
days, the position of pulverized coal shall be less than 5 meter.
7.2.4 Comprehensively check Burning oil and Atomization steam system has been put in
stand-by. Atomization steam pressure is normal; each oil burner is reliable which can be put in
service at any time.
7.2.5 Decrease load before shut-down, soot blow boiler body and air preheater.

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7.2.6 Comprehensively check HP bypass system, confirm Hydraulic plant operation normal.
7.3 Shut-down with sliding parameter (need cooling )
7.3.1 Shut-down adopts sliding parameter shut-down; gradually reduce the boiler combustion
with turbine decreasing load to keep steam pressure, temperature and flow suitable for the
requirement for turbine sliding parameter decreasing load.
7.3.2 When decrease fuel, decrease corresponding air flow. Strictly prohibit total air flow ＜
30%MCR till the unit are shut-up.
7.3.3 When pulverizing system thoroughly pumped, stop pulverizing system and keeps
lubrication system of tube mill long operation.
7.3.4 Close moisture absorption valve at pulverized coal bunker.
7.3.5 At 75% of boiler load (Steam flow 750t/h) stop PC burners as required and keep the
associated fuel oil burner in service, continue decreasing load and monitor furnace
temperature.
7.3.6 Switch from “global flame detection” mode to “individual scanning” mode occurs when the
boiler load is below 70% BMCR (618t/h). Stop PC burners as required and keep the associated
fuel oil burner in service (at least until the PC pipes have been purged).And from then on the
measure is mixture of oil and pulverized coal. Put A. P soot blower, keep continuous soot
blowing pattern.
7.3.7 With drop of unit load, slowly decrease main steam pressure setting value, monitor
superheat steam temperature and Reheat steam temperature drop rate should be ＜1℃/min.,
In the process of whole pressure drop, Drum upper and lower wall differential temperature
should be lower than 40℃.
7.3.8 When automatic control is not good, switch to manual adjustment.
7.3.9 Gradually close pulverized coal feeder. Firstly close pulverized coal downcoming gate of
pulverized coal feeder .When pulverized coal is empty, close pulverized coal feeder.
7.3.10 When Boiler Main steam flow≤286T/Hour feedwater control valve front and rear differential
pressure≥60bar, feedwater control is switched form feedwater automatic control to bypass
control.
7.3.11 When Main steam flow＜250T/H, all pulverized coal feeder is stopped unconditional.
Inform of stopping ash handling, keep cathode and anode rapping in operation and ash
handling equipment in operation.

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7.3.12 When Main steam flow＜150T, stop using attemperating water . When water spray
motorized valve and control valve can’t be closed tightly, stop each water spray manual valve,
and make operation record.
7.3.13 When the load is 75MW, switch to auxiliary power. When load is 50MW, switch valve of
turbine, quick decrease load to 0. Generator reverse Power trip, perform shunt tripping of
turbine. Shut-down the boiler and close all burners. Purge all PC pipes correctly. Close burning
oil safety valve and each oil burner input oil manual valve and burning oil control plant inlet oil
manual main valve. Confirm all fuel is cut off.
7.3.14 To prevent Atomization steam from entering into furnace in the period of shut-down of
boiler, close atomization steam main valve.
7.3.15 After boiler trips, close the superheater stop valve FSR UV 004 and the HP by-pass.
Open rear pass drain FSR UV 003, 005. Open the drains and blow down devices of the main
steam piping and main turbine piping, according to the instructions of the turbine manufacturer.
7.3.16 Do not reduce airflow below 30 % of full load airflow. keep total air flow 30%MCR, after
performing furnace purge for 10 mins, gradually stop Primary air fan, FD Fan, ID Fan, confirm
each air fan Inlet and outlet damper closed.
7.3.17 Trip A, B side Steam air preheater
7.3.18 Contact with chemical staff on duty, stop chemical feed pump, and close chemical feed
valve, continuous blowdown valve and ach sampling valve.
7.3.19 Keep 2 Air Preheaters operation, 1 flame scanner cooling air fan in operation, 1 oil burner
cooling air fan operation.
7.3.20 Keep 2 boiler water circulation pump in operation, When drum pressure＜15bar, per the
conditions stop 1 boiler water circulation pump operation. Keep drum high water level +100mm.
Open Economizer recirculation valve.
7.3.21 Control boiler cooling rotation and keep the differential temperature measured by any two
thermal couple is less than 50 °C.
7.3.22 When Drum pressure≤3bar, Open each Air damper of superheater and reheater.
7.3.23 To prevent economizer, air preheater and etc. from secondary burning which damages
equipment. After shut-down boiler, monitor gas temperature of each section. When air
preheater inlet gas temperature ＜120℃, stop A, B air preheater operation, stop flame scanner
air fan and oil burner cooling air fan operation.

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7.3.24 When boiler water temperature≤70℃, stop boiler water circulation pump. Close outlet
non-return flap and heating pump manual valve, power of 3 boiler water circulation pump
should be cut off. Open Drum left, right side interlayer of air damper.
7.3.25 When boiler water temp.≤70℃ and boiler water circulation pump is stopped, if boiler must
be drained, comprehensively check the steam and water system.
7.4 Normal shut-down (hot stand-by )
7.4.1 When shut-down, try to keep main steam pressure and Main steam temperature.
7.4.2 Speed of pressure drop when load is dropped is much lower than cooling speed of normal
shut-down.
7.4.3 Put soot blowing equipment in service for A.P.
7.4.4 When the turbine is off load, the boiler should continue to be fired in order to increase the
pressure above 140 bar before bottling (Per the conditions of hot stand-by equipment).
7.4.5 After boiler fire-off, close main steam valve and HP bypass valve, close all air valve
damper to bottle-up.
7.4.6 Operation of shutting-down each valve of steam, water system for hot stand-by is as
following:
7.4.7 Open Reheater outlet steam exhaust valve, FSRUV001.
7.4.7.1 Open cold Reheater main pipe drain valve FRSUV002.
7.4.7.2 Keep all drain valve and Air damper of drum, Superheater and Reheater closed.
7.4.8 Keep total air flow 30%MCR, after performing furnace purge for 10 mins, stop Primary air
fan, ID Fan, FD Fan.
7.4.9 Steam air preheater trip.
7.4.10 Keep Drum high water level+100mm, completely close Feedwater motorized valve.
7.4.11 If hot stand-by period, keep 2 Air Preheater, 1 flame scanner cooling air fan, 1 oil burner
cooling air fan, 2 boiler water circulation pump operation.
7.4.12 Keep lubrication system of tube mill long operation.
7.4.13 After shut-down for 20 hour, open the following drain valve to drain 1 hour for superheater
system. Keep Air damper of Drum and superheater closed.
7.4.13.1 Open front wall enclosure drain valve FSR UV003
7.4.14 Open rear wall enclosure drain valve FSR UV005

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7.4.14.1 Open Main steam valve front drain valve FSR UV006
7.5 Emergency shut-down
7.5.1 Emergency shut-down is quick shut-down to prevent from serious accidents or enlarging
accidents needed when serious faults of boiler or other main equipment occur.
7.5.2 Emergency adopts the MFT order which will cut off immediately all the fuels to the boiler
furnace (coal and fuel oil).
7.5.3 The sequent operation follows the operation after the boiler fire-off in hot stand-by
shut-down terms
7.6 Shut-down maintenance
7.6.1 Maintenance in short shut-down of boiler (shut-down 3~4 days) :
7.6.1.1 Maintenance in short shut-down of boiler (shut-down 3~4 days), for hot stand-by, Boiler
can be started arbitrarily.
7.6.1.2 Treatment after shut-down refer to “Boiler normal shut-down (hot stand-by)”.
7.6.2 Maintenance in medium-period shut-down of boiler (shut-down 3~4 weeks) :
7.6.2.1 After Boiler fire-off, immediately sub-control closing boiler main steam valve FSRUV04A,
FSRUV04B. When shaft seal of turbine don't use steam, immediately close HP bypass.
7.6.2.2 Open reheater outlet steam exhaust valve FRSUV001, High temp. Reheater inlet, outlet
Air damper: FRSHV006, HV007, HV014, HV008, HV009, and cold reheater main pipe
drain valve FRSUV002.
7.6.2.3 Open Superheater drain valve: Open front wall enclosure drain valve FSRHV019, UV003.
Open rear wall enclosure drain valve FSRHV020, UV005.Open main steam valve front
drain valve FSRHV068, UV005.
7.6.2.4 Close continuous blowdown valve, each sampling valve, chemical feeding valve
7.6.2.5 When Drum pressure≤3bar, open superheater air damper, When Air damper doest
overflow steam, immediately close Air damper, drain is finished, close Each drain valve,
and completely isolate hot seam pipe and of the atmosphere.
7.6.2.6 When reheater drain is finished, close reheater outlet atmospheric relief valve. Each Air
damper of high temperature reheater inlet and outlet, and cold reheater main pipe drain
valve completely isolate reheater steam pipe and the atmosphere.

2×300 MW
7.6.2.7 When boiler water temperature drops below 180℃ and drum water level is at about
-290mm, inform chemical staff of adding N2H4 and NH3, keep boiler water circulation
pump operation to keep N2H4＝200ppm, PH≥10. 5. in boiler water and keep drum water
level+100mm.
7.6.2.8 When boiler water N2H4＜50ppm, immediately add N2H4.
7.6.2.9 When boiler water temperature≤120℃, boiler water circulation pump can be stopped.
7.6.2.10 Superheater system filling N process:
1） When Superheater drain is finished, Boiler pressure drops to

1bar, open superheater filling N valve FSRHV031, and HV029, Open drum inner
layer filling
N valve FSRHV007, and HV005. Notice, must fill N in the boiler cooling process.
In the process of filling N keep Nitrogen pressure in the scope of 0. 1~0. 3bar to
prevent air entering in to furnace.
2） When boiler water circulation pump is stopped, Open drum inter layer filling N
valve :FSRHV045 and HV044to fill N to the furnace, and keep Nitrogen pressure
0. 1～0. 3bar.
7.6.2.11 Filling N Process of reheater system:
1） Check before reheater system filling N
2） In the cooling process of Boiler
3） Close HP bypass valve
4） Each valve of reheater water spray attemperating system closed tightly
5） LP bypass valve close
6） Close turbine HP cylinder steam exhaust non-return flap, Medium

pressure cylinder steam intake valve, and high #section air pump
valve and isolation primary damper on pipe.
7） After cold Reheater main pipe drain is finished, close drain valve.
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2×300 MW
7.6.2.12 After reheater air exhaust is finished, close reheater outlet atmospheric relief valve and
air damper at high temperature reheater inlet and outlet.
7.6.2.13 Open reheater filling N valve FRSHV012 and HV006, HV014 to fill reheater system N,
keep Nitrogen pressure 0. 1~0. 3 bar, to prevent air entering in to reheater system.
7.6.3 Maintenance for boiler long shut-down(shut-down 4weeks~3 months):(wet)
7.6.3.1 Maintenance pricinple:
1） Under normal conditions, after shut-down of boiler perform wet

maintenance for superheater system. Only the major or minor repair and repair
on pressure parts occur, dry maintenance (hot boiler drain) shall be performed.
2） When unit are shut-down for more than 2 weeks, change from feedwater
pressure maintenance or dry maintenance (hot boiler drain) to
ammonia -hydrazine maintenance for superheater.
3） Reheater adopts filling N maintenance.
7.6.3.2 Maintenance method key points:
Drain the remaining left water in Boiler. Fill the boiler superheater with
ammonia
-hydrazine solution maintenance liquid. Prevent Air from entering. Perform
filling N
maintenance for reheater.
7.6.3.3 Superheater system maintenance operation method :
1） At cold status of boiler, open air damper, drain valve and water discharge valve
of steam, water system. Drain the remaining water in feedwater system, water
wall and superheater. When the remaining water in feedwater system, water wall
and superheater is drained,(about 2hour ),close all drain manual or motorized
valve and water discharge valve and intermittent blowdown manual valve and
continuous blowdown manual valve (Open when perform chemical sampling)
2） Chemical staff maintenance makes the maintenance solution

maintenance chemicals box, When water level of feedwater box is highest
after level which can be seen (2800mm). Open pump feed feedwater
with chemical (chemical feed is switched to feedwater box)
3） After receiving the notice that chemical staff finishes feeding chemicals,
open feedwater pump to circulation feed water 30 min, mix the chemicals and
liquid.
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2×300 MW
4） Chemical make the sampling analysis of feedwater that the

concentration of
maintenance liquid:N2H4≥200mg/l,PH 10~10. 5.
5） Open condensate water pump to fill water to boiler water circulation pump motor.
6） When filling water for boiler water circulation pump motor is

finished, open feedwater pump, make use of feedwater bypass to fill boiler to
+100mm, run 3 boiler water circulation pump for 3 times, put #2boiler water
circulation pump in service. At this time, stop filling water for boiler water
circulation pump and stop filling Boiler.
7） Make use of superheater secondary attemperator water

system to fill superheater acceptable maintenance solution, system top
pressure, When Drum pressure reach 0. 3Mpa, close all air damper, boiler filling
is finished.
8） Inform of chemical boiler water sampling analysis, water quality standard is: PH
10~10. 5, N2H4 50~200mg/l.
9） In the period of maintenance, when Drum water level drop to

high water level+500mm, open 1 feedwater pump. Through
superheater secondary attemperator fill water to boiler, top pressure. When
drum pressure reach 1 bar, stop fill water to boiler.
10） When maintenance solution in feedwater box is not enough, inform chemical
staff of making chemical, feed chemicals feed and water feedwater box.
7.6.3.4 Perform filling N maintenance of reheater system, Nitrogen pressure is kept at 0. 3~0. 5
bar and method is as following:
1） Check before reheater system filling N :
a） Boiler has been cooled.
b） HP, LP bypass has been closed.
c） Motorized valve, control valve and manual valve of reheater A,

B side attemperating water have been closed.
d） Close turbine HP cylinder vent non-return flap and bypass

motorized valve ,mid pressure cylinder steam intake valve ,high temperature
heater #7 section steam pump motorized valve and drain manual valve
(AHP HV087), motorized valve at cold reheater to deaerator and
motorized valve at cold
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reheater to auxiliary steam header,
e） Open cold, hot reheater main pipe drain motorized valve (for steam exhaust).
f） Atmospheric relief valve at reheater outlet is closed.
g） Each Nitrogen bottle at Nitrogen station is full filled with nitrogen.
h） Safety valve at Nitrogen station air supply main pipe has been
checked acceptable.
2） Filling N operation :
a） Micro-open air supply valve at each Nitrogen bottle of Nitrogen station.

When the pressure before opening pressure governor valve at air supply
main pipe reach 120bar~150bar, stop opening Nitrogen bottle.
b） Manually control pressure governor valve at Nitrogen station. Keep

Nitrogen pressure after opening pressure governor valve at 5 bar. Fill Nitrogen
pressure governor station with Nitrogen to exhaust air.
c） Close front ,rear manual valve pressure governor valve at pressure governor
station.
d） Manually open pressure governor station bypass manual valve

and make valve outlet Nitrogen pressure 2 bar and reheater system filled
N to exhaust air.
e） After 60min, manual close pressure governor station bypass manual

valve.
Reheater system filling N to exhaust air is finished.
f） Manually close bypass manual valve of pressure regulation station and

close drain motorized valve of cold reheater and hot reheater
main pipe. Purge reheater system and exhausting air is finished.
g） Open reheater system filling N valve FRS HV012, FRS HV006, FRS HV014.
h） Open front ,rear manual valve pressure governor valve at pressure

governor station, manually clockwise control pressure governor valve to make
pressure after opening pressure governor valve 0. 3 bar～0. 5bar.
i） Reheater system filling N is finished. Record Nitrogen pressure of

Nitrogen station and Nitrogen pressure governor station
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7.6.3.5 Monitoring in the period of maintenance:
1） Each shift record boiler drum pressure, reheater Nitrogen pressure twice.
2） Every Monday separately open each boiler water circulation pump

once and each time is 30min. If circulation is finished, inform chemical staff
of sampling and analyze concentration of maintenance solution.
3） In the period of maintenance, boiler water, open feedwater box sampling valve,
and keep flow of 50~200ml/h.
7.6.4 Boiler heating with pressure drain maintenance method:( suitable for mid, long period
shut-down )
7.6.4.1 When in the mid or long period of boiler shut-up boiler or after shut-up, pressure parts
need long repair time and can’t be performed wet measure. And when perform filling N
maintenance, boiler can adopt heating boiler with pressure and drain. When Boiler water
is drained out, make use of boiler remaining heat to dry instrument of pressure parts in
boiler to reach the objective of maintenance.
7.6.4.2 Operation steps
After boiler shut-down, when drum pressure is 10bar:
1） Stop boiler water circulation pump, inform electric staff cut off power.
2） Close boiler water circulation pump outlet valve and boiler water
circulation pump is at isolation condition.
3） Open HP side air exhaust damper of boiler water circulation pump cooler.
4） Boiler drains. Each valve position in the system is listed in the following table :
No. Valve Name Valve No Status
FSR HV032 open

1 Economizer drain valve
FSR HV033 open
FSR HV081 close

2 Continuous blowdown valve HV082 close
UV17 close
3 Drain valve at boiler water FSR HV012 open
circulation

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pump Inlet header FSR HV060 open
Water wall circumferential FSR HV049 HV080 HV062 open

4
header drain valve FSR HV071 HV084 open
FSR HV034 open

5 Intermittent blowdown valve
FSR UV002 open
FSR HV068 open

6 Main steam valve inlet drain valve
FSR UV06 open
5） If drain is finished, close all drain valve in above table.
6） When Drum pressure reach 3bar, open the following Each valve :
1 Economizer outlet air exhaust valve FSR HV074 HV073 HV075 open
2 Drum inner-layer air damper FSR HV005 HV006 HV008 HV009 open
Drum interlayer air damper FSRHV044 HV046 open

3
Drum interlayer air damper FSR SV40 HV047 open
4 Top outlet header air damper FSR HV063 HV064 open
Low temp. superheater outlet

5 FSR HV021 HV022 open
air damper
Mid temp. superheatier outlet header

6 FSRHV054 HV055 HV056 open
air damper
High temp. superheater outlet header

7 FSR HV029 HV030 open
air damper
8 High temp. reheater Inlet air damper FSRHV014 HV006 HV007 open
9 Reheater outlet steam exhaust valve FSRHV013 UV001 open
7） When Boiler drain is finished for 2hour, Open each drain valve of steam side:
No. Valve Name Valve No Status

2×300 MW
1 Drain valve at roof Inlet header FSRHV050 HV059 open
2 Front wall enclosure drain valve FSRHV019 UV003 open
3 Rear wall enclosure drain valve FSRHV020 UV005 open
Drain valve from low temp. open

4 superheater tomedium temp. FSRHV023 HV024 HV035
superheater
5 Main steam valve front drain valve FSRHV068 UV006 open
6 Low temp. reheater Inlet drain valve FSRHV015 UV002 open
a) When above air damper and drain valve is opened for 2hour, close all air damper
and drain valve.

2×300 MW
7.6.5 Points for attention of Boiler maintenance:
7.6.5.1 In the period of boiler maintenance, chemical staff shall assay boiler water quality acc. to
regular, when N2H4 concentration ＜50ppm, it should be added to original content.
7.6.5.2 Before boiler is added hydrazine and ammonia (i.e. N2H4 and NH3), only keep 1 boiler
water circulation pump in operation, other outlet of 2 boiler water circulation pump shall
be closed.
7.6.5.3 Before boiler is filled N after cooling.
7.6.5.4 After filling N maintenance, if entering in to drum to work is needed, perform air draft and
then can enter into it.
7.6.5.5 Boiler adopts maintenance of adding Na3PO4. 12H2O(Na3P04)solution, before open

boiler, must perform drain and rinsing work. Its drain method is as same as shut-down
drain method.
8 Boiler auxiliary equipment
8.1 Basic regular of auxiliary equipment operation
8.1.1 Check before auxiliary equipment is put in service:
8.1.1.1 Check work-sheet is finished, no staff works on the equipment.
8.1.1.2 Full of light on site, clean ground, no debris obstructing operation.
8.1.1.3 Equipment Appearance is in its integrity with heat good insulation. Each hole valve is
strictly closed, connection with the system completely. Instrument is complete and
direction is right.
8.1.1.4 Bearing Lubrication position is normal, oil quality is acceptable, and Lubrication system
at good stand-by status. Grease is added per the regular.
8.1.1.5 Cooling water unobstructed, water flow is adequate and don't overflow.
8.1.1.6 The Anchor Bolt is complete and firm. Motor wiring and earthling cable is good. Insulation
is acceptable.
8.1.1.7 Shields are complete and integrated.
8.1.1.8 The data on DCS of each air valve is consistent with the actual and transmission
machine is complete.
8.1.1.9 Control circuit power, interlock, thermal control staff protection test is acceptable and is in
service, automatic equipment is put in service or has the start condition.

2×300 MW
8.1.2 Auxiliary equipment open principle:
8.1.2.1 Normal open 6KV equipment and 380V equipment. Specified staff stands at the position
of accidents button to monitor it on site. If any problem is found, immediately put accident
button stop operation.
8.1.2.2 The equipments with the same trunk can’t be operated at the same time before opening
2,6 KV equipment inform the electric operation staff. Without permission, it can’t be
opened.
8.1.2.3 In normal condition, squirrel-cage Motor at cold status can be allowed opened twice.
Each interval will not be lower than 5min. At hot status can be allowed opened only once.
Only when there is accident treatment and opening time is not more than 2～3 mins,
motor can be opened once more. Otherwise, it can be opened after 30min (iron core
temperature is hot status when it is above 50℃, below 50℃ it is cold status).
8.1.2.4 Strictly prohibit opening with load.
8.1.2.5 When open auxiliary equipment pay attention to it’s the executing condition of opening
procedure, current returning time, current indicator and other Parameter of equipment.
Pay attention to the display on monitor CRT equipment status is correct.
8.1.2.6 After open equipment local check equipment in good operation, without any abnormal
sound, vibration,, friction and percussive sounds.
8.1.3 General rule for Auxiliary equipment operation maintenance:
8.1.3.1 Cooling water is adequate and lubricating system is normal.
8.1.3.2 Equipment operation is stable without any abnormal noise and abnormal friction and
impact sound. Each parts and inlet or outlet pipes are complete and not loose, non-swing
and etc.
8.1.3.3 Operation of Each valve, air valve and primary dampers flexible, action is normal and
position direction is correct.
8.1.3.4 Each thermodynamic, electric instrument for measure and display is normal.
Thermodynamic, electric protection and relevant automatic control is put in service and is
normal.
8.1.3.5 Control the following parameters according to manufacturer’s requirement. If there is no

requirement, control according to the following requirement:
1） Rolling bearing temperature≯80℃,sliding bearing temperature℃≯65.

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2） The shell temp. of gear gearbox ≯60℃.
3） Opening Motor shell temperature≯65℃,enclosed motor shell ≯humidity 80℃.
4） Rolling equipment axial shaft displacement is ≯2~4mm. Sliding equipment axial

shaft displacement is ≯0. 5mm:
5） Vibration value:
Rotation
≤3000 ≤1500 ≤1000 ≤750
speed(r/min)
Vibration
0. 05 0. 085 0. 10 0. 12
value(mm)
6） When any of the following conditions occurs, emergently stop auxiliary equipment
operation :
a） Bearing temperature abnormal rises or exceeds the regular.
b） When strong vibration on the equipment or axial shaft displacement

or the danger which may damage equipment occurs.
c） Motor or cable smokes and fires.
d） The obvious sound of metal friction in the inner of equipment can be clearly
heard.
e） Other faults which endangers safety of person and equipment.
8.1.4 General rules for rotation equipment fault and treatment
8.1.4.1 When any of the following conditions occurs, emergently stop operation of rotation
equipment :
1） Equipment has strong vibration.
2） The obvious sound of metal friction in the inner of equipment can be clearly heard.
3） Motor or cable smokes and fires.
4） Bearing smokes and fires or sliding bearing temperature exceeds 80℃,

rolling bearing temperature exceeds 100℃.
5） Equipment leaking endangers safety of person and equipment.

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8.1.4.2 When any of the following conditions occurs, firstly open stand-by pump (air fan ),stop
fault pump (air fan ):
1） Gland heats, smokes or with overflowing water, oil leaking, and adjustment is not
efficient.
2） Sliding bearing temperature reaches 65℃,rolling bearing temperature reaches 80

℃ and with rising trend.
3） Motor shell temperature rises to 70℃,and continues rising.
4） Motor Current exceeds rating value.
5） Motor cable is serious overheating. The insulation exude a smell of burning
8.1.4.3 Treatment for operation pump (air fan) trip:
1） Confirm operation pump (air fan) trip and stand-by pump (air fan ) shunt good.
Reset gang pump (air fan )switch. If stand-by pump (air fan )is not gang ,manual
open it.
2） Cut off trip pump (air fan )operation switch.
3） check each section of gang pump (air fan ) normal, check the reason for trip of trip
pump (air fan )and solve it for stand-by.
4） If opening stand-by pump (air fan )don’t take effect, immediately check for the
cause. For the 380V motor ,start trip pump (air fan )again once more . Confirm
6KV power equipment should be checked no obvious fault ,it can be switched on
again.

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8.1.4.4 For important plant service auxiliary equipment, besides the faults which endangers
safety of person and equipment must be immediately stopped. Usually open the stand-by
auxiliary equipment and then stop fault auxiliary equipment.
8.2 Motor operation
8.2.1 Motor can be operated at the temperature of rated cooling air according to the specified
data on manufacturer’s name plate.
8.2.2 The highest monitoring temperature of motor coil and iron core shall not be exceeded
in any case according to manufacturer’s regulation. If manufacturer has no regulation, the
highest temperature of the motor coil and iron core can’t exceed 105℃ and the rise of
temperature can’t exceeds 65℃.
8.2.3 Motor can be operated in the scope of 95%~110% of rated voltage, and its rated output is
constant(5. 7～6. 6 KV, 360～420V). In the period of rated output operation the unbalanced
value of voltage between phases can’t exceeds 5％. In the period of operation at unbalanced
voltage pay attention to over-hot and vibration of the motor.
8.2.4 In normal operation , motor current shall not exceed ＋5％ of rated value. If it exceeds ＋
5％ to ＋10％ , in 15 min shift supervisor can’t decrease the current to rated current. If it is
caused by the accidents of main motor, the above rule needn’t to be followed.
8.2.5 Temperature of motor bearing is controlled according to the following standard (If the
manufacturer has its own requirement, perform according to manufacturer’s regulation):
8.2.5.1 Sliding bearing :can’t exceeds 80℃(Temperature rises by 40℃).
8.2.5.2 Rolling bearing :can’t exceeds 100℃(Temperature rises by 60℃).
8.2.6 Daily check work, maintenance for motor and the detailed requirement of opening and
stopping operation refer to specific terms in “electric operation manual.
8.3 Start-up, stop and operational maintenance of auxiliary equipment and system
8.3.1 High voltage bypass
8.3.1.1 Check-up before the start-up of high voltage bypass.
1) Make sure that every pipeline is perfectly connected with facilities, valves complete, and
test and adjustment fully completed and that movement is flexible and reliable as well.
2) Make sure that the functioning of the hydraulic pressure station is

normal without leakage.
3) Thermal meter and controlling system should be put into use

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4) Open the hand-operated valve of attemperating water HV002.
8.3.1.2 Start-up of high voltage bypass
1) Make sure that the hydraulic pressure station is normally functioning.
2) Put into use the high voltage bypass on DCS.
3) Turn on the pressure-reducing valve controller of the high voltage bypass to

20% by hand.
4) Set main steam pressure and steam pressure lower limit (the stream pressure is set at 60
bar).
5) Set steam temperature of the high voltage bypass outlet at 320℃, press the “automatic”
button on the attemperating water regulating valve controller of high voltage bypass.
6) Send out the start-up order, the “red” indicator light at the HSN001 operation station will
soon be “brightened”.
7) Operate automatic on the pressure-reducing valve of the high voltage bypass, the high
voltage bypass thus enters into operation with a minimum opening of 40%
and “the minimum opening” indicator light is on.
8) When the steam pressure of the boiler outlet is below the minimum fixed value (60bar) on
starting up, set the regulating valve of the high voltage at start-up opening fixed value
(40%).
9) When steam pressure reaches the minimum start-up pressure (60 bar), the “minimum
opening” indicator light is off, while “the minimum pressure” indicator light is on, ensuring
the high voltage bypass is controlled in a state of minimum pressure.
10) Maintain the minimum pressure of start-up when the pressure-reducing valve of the high
voltage bypass gradually opens as the burning is intensified.
11) When the “high-pressure cylinder” switch signal has been sent out,
the “minimum pressure” indicator light is off, while “slip pressure” indicator is on,
bringing the system into an operational state.
12) Close the high voltage valve as turbine valve gradually opens to maintain
the fixed pressure values, and during this process, the PI controller will set the changing
gradients
at the fixed value of 4 bar/min.

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13) As the turbine load increases, the high voltage valve will be narrowed till it is fully closed
when the “slip pressure” indicator light is off while the “normal functioning” indicator light
is on
14) After that, the high voltage pressure-reducing valve will automatically regulate
rate of pressure rise of the boiler.
8.3.1.3 Functional maintenance and parameter
1) High voltage bypass parameters
Items Unit Data
Steam temperature of
℃ 540+5
the high voltage bypass inlet
Pressure of the high voltage

bar 184
bypass inlet
Pressure of the high voltage

bar 44
bypass outlet
Steam temperature of
℃ 337+5(>360℃alarming)
the high voltage bypass
outlet
Flow of high voltage bypass T/H 760
Pressure of
bar 210
attemperating water
Temperature of
℃ 257
attemperating water
The start-up controlling time

S 12
of the high voltage bypass
Swift-opening time of
S 3
the high voltage bypass
Opening time of
attemperating water stop S 3
valve

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Full-opening time of
attemperating water S 8
regulating valve
2) Conditions for swift opening of pressure reducing valve of the system
a) Reach safety ∆P (adjust safety valve to influence load)
b) Reach Pmax safety (adjust safety valve)
c) When turbine is running (high voltage main body of turbine opens), auxiliary power
operates, or else steam turbine will trip, forecasting the full close
down of high voltage main body.
d) Operator can open it by hand (press any button), and under any circumstances, it
can be swifted from the manual-controlled model to the automatic model when the
high voltage valve is opened. It is also suitable for desuperheat-regulating ductwork.
8.3.1.4 Operation of high voltage bypass in the stoppage process of the unit
1) When the set pauses in the phase of “slide pressure”, lower the main steam pressure
setting and ensure high voltage maintains “set” pressure for regulating.
2) When the set enters into the phase of “fixing pressure to reduce load”, as the regulating
valve of the steam machine gradually narrows, the pressure-reducing valve is opened,
maintaining the fixed pressure.
3) Hydraulic pressure station keeps on operating after the boiler stops working to ensure
that the pressure-reducing valve remains in a closed state.
8.3.1.5 Faults and countermeasures of high voltage bypass
1) Causes:
a) Failure of hydraulic pressure station
b) Failure of 380V power supply and tripping of hydraulic pressure oil pump
c) Failure of 48V DC power
2) State
Automatic closing and locking of FCV58, UV59 and TCV59
3) Countermeasures

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Find out the causes and have faults removed immediately
8.3.2 Air preheater
8.3.2.1 Check-up before the start-up of air preheater
1) Make sure that there are no people working and no foreign bodies in the air preheaterhas
no, and that man holes are fully closed when the maintenance of work ticket is finished,
and that the surrounding of the air preheater has no sundries.
2) Make sure that the smoke and air flues are well connected and that the
executive mechanism of sealing device is in a high position.
3) Make sure that executive mechanisms UV03 and UV04 have sent off electricity.
4) Make sure that the speed reducer has been injected with qualified oil, and that hydraulic
couplers has also been oiled without leakage.
5) Make sure that soot-blower is placed in the outlet and that the soot-blowing and steam
pipelines are connected.
6) Make sure that smoke, air pressure, and temperature and fire-measuring devices and
local control switch as well, are in good condition.
7) Fire protection and check-up of cleaning system:
a) Make sure that pipes are fully connected and equipment complete.
b) Close fire protection and fire-extinguishing nozzle manual valveHV001 and HV007,
close fire-fighting water-cleaning manual inlet valveHV002 and cleaner manual valve
as well.
c) Open fire protection hose leak-hunting valveHV003, HV005 to ensure they have no
water, and prove that HV001, HV007, HV002 and HV004 are sealed.
d) Close washing water preparation station hand-operated valveHV008
8) Make sure that position detector and revolution detector have be switched on.
9) Make sure that main motor, low-speed motor and oil pump motor have been switched on
10) Make sure that smoke and gas inlet baffle UV01D, UV01C, heat primary air outlet
baffle UV01B and servo motor heat secondary air outlet baffle UV01A have sent off
electricity and is in the closed state.

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11) Put in bearing oil system and cooling water
a) Open force-bearing bearing oil-receiving valveHV022 and oil removing valveHV024.
b) Open the cooling water-receiving valveHV020 and removing-valveHV021 of the oil

cooler to make sure that the cooling water flows smoothly.
c) Open the cooling water receiving-valveHV010 and removing-valveHV011 of

the guiding bearing oil cooler.
12) Check-up of oil system and duplex strainer
a) Make sure that the filter is complete and that duplex three-way valve HV012 (HV023)
is normally placed and is flexible in switch, and that differential pressure
gauge indication is correct.
b) Use single control on the DCS to launch bearing lubricating oil pump,
check the pressure difference of duplex filter.
c) Examine the oil system to make sure has no there is no oil leakage and see to it that
the safety valve of pipe is in the re-seating state without leakage.
d) Stop the oil pump when the check-up is done
13) Locally try low-speed motor and examine the following items in initial start-up after the
maintenance
a) Make sure that the moving direction of air preheater is right
b) It should be free of blockage and noises, and is flexible in turning
c) Make sure that speed reducer sounds normally and hydraulic couplers have no oil
leakage.
d) If something abnormal is detected in the trial, the trial can not be resumed until errors
have been removed
8.3.2.2 Operation of air preheater
1) Start-up of sub group level
a) Make sure that the check-up before start-up is done
b) Operate the manipulation (HSN001) on the DCS to issue start-up order

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c) Low-speed motor should be tripped if it is in the process of operating, and when it

stops validating, main motor will start working with green light off and red light on.
d) Force-bearing and guiding bearing oil pump enter into linkage back-up uses
e) Smoke and gas inlet baffle and heat secondary air outlet baffle automatically open
f) Heat primary air baffle (UV01B) remains closed until corresponding primary blower
starts
g) When the air preheater is operating at a low speed, the low speed
motor will automatically stop when the subgroup starts, and main motor also starts,
which, if
20mins after start-up, still can not reach normal speed will automatically stop, while
low speed motor automatically restart.
h) Should the above problems are met (1.2.4), resume the subgroup. If it also does not
work, resume until errors have all been removed.
2) Single control start-up
a) Confirmation of check-up before start-up
b) Use the single control start-up order on the DCS and make sure air preheater starts
operating
c) Locally open smoke and gas inlet baffle and heat secondary air baffle
3) Local start-up
a) Start-up check-up confirmation
b) Set the “remote or local” button to be “local”
c) Press the start-up button locally, make sure that air preheater starts
slowly and operates normally
d) Open the smoke and gas inlet baffle and heat secondary air outlet
baffle when necessary.
4) Maintenance and surveillance of air preheater in operation
a) Put air preheating sealing devices into operation after boiler gets ignited,
(when driven by the main motor), and operate HSN005 by using single control.

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b) The right place of sector board is decided by function generator based on load.
c) Position fixed value is invariable when load is low (below 40%), it becomes variable
when the load is between 40% and 100%, and position limit (above and below) can
solely be adjusted by 4 fanning strips.
d) Prevent the device from being clamped as there is an order of automatic receding
every 24 hours.
e) Operator can issue receding order either by operating HSN005 on the DCS, or by
pressing button local.
f) Regularly check up the air preheater to guarantee that it has no noises in operation
and its gearing is normal.
g) Make sure that the force-bearing and guiding bearing system is normal
without leakage and that the temperature of oil is at a normal level.
h) Make sure the smooth circulating of cooling water and normal

temperature of backwater.
i) After the air preheater has been charged (at a normal or lower speed), when the
temperature of bearing increases to over 60℃, oil pump will automatically start up,
and it automatically stop when the temperature return to
50 ℃ (FRA/B,
TSH15,TSH25). Still, check the air duct to guarantee that it is without air leakage
when the oil temperature of guiding bearing increases, if the problem exists, notify
repair workers to work on it in time.
j) Report to chief and shift chief-operator immediately should there be serious leakage
of bearing lubricating oil and cooling water in operation.
k) In operation, rationalize burning to avoid a second time burning, strictly supervise the
temperature of air preheater smoke and gas in and out, and
regularly do soot-blowing, for example, the job of soot-blowing should
be reinforced as the pressure difference between air preheating smoke in and
out increase.
l) During operation, strictly supervise the air preheater outlet and inlet and primary and
secondary air temperature. If any abnormal is detected, take measures immediately.
m) Normal functioning
n) Air preheater soot-blowing

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o) Use the flame measure the temperature difference between air temperature of air
preheater outlet and that of heat-up component outlet. When it exceeds 50℃, the
controlling room should give off warning signal.
8.3.2.3 Halt of air preheater
1) Do not halt the operation of air preheater until the smoke temperature in outlet is at a
degree of more than 175℃ after stopping burning.
2) Stop operation, give subgroup stop order(HSN001) through DCS.
a) Main motor ceases to run
b) Force-bearing and guiding bearing oil pump automatically stops.
c) Heat secondary air outlet baffle automatically closes
d) Smoke and gas inlet baffle automatically close
e) If heat alternative stops burning, yet air preheater keeps on functioning,

normal check-up maintenance should be done
f) If there be repair work after the burning of boiler, cut off main motor and low-speed
motor power
8.3.3 Induced fan
8.3.3.1 Check-up before the start-up of induced fan
1) Check the basic principles and rules for basic check-ups
2) Adjustable baffle can give electricity and normally switch
3) Inlet and outlet baffles can give electricity and completely open and close as well
4) Motor has delivered power
5) Local button is sound
6) Every circuit measuring and protective devices are checked out and put into use
7) Requirements for start-up of themal regulator are met
8.3.3.2 Start-up of induced fan
1) Conditions for start-up

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a) Air preheater on the corresponding side is operating.
b) Vibration of air fan is slight.
c) At least inlet and outlet baffles of one force fan are openned.
d) Corresponding inlet vane is closed.
e) Corresponding outlet truncated baffle is closed.
f) Every oil gun air baffle is opened.
g) Open A, B and C secondary air regulating baffle and tertiary air regulating baffle as
well.
2) Sequential control start-up
a) Using DCS, send out induced fan subgroup control start-up order, with the green light
off and red light on.
b) After conditions for start-up are met, confirm and complete requirements
asked of induced and force fan and inlet and outlet baffles as well.
c) Outlet baffle automatically opens 30 seconds later, and inlet adjustable

baffle is
“automatic”.
d) When the induced fan on the other side is not running, its outlet baffle automatically
closes.
e) When the induced fan on the other side has began functioning, start
the second induced fan, when the motor is started , it will automatically open the
outlet baffle, the inlet adjustable baffle of these two induced fans should be adjusted
correspondingly, and “automatic” should be put in.
3) Start-up by hand
a) Set “manual” on inlet adjustable baffle
b) Make sure that requirements for start-up are met
c) Using DCS, send out induced fan single control start-up order and make sure that the
induced fan starts normally.
d) Open outlet baffle

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e) Set inlet adjustable baffle to be “automatic”.
f) When the induced fan on the other side is not operating, close its inlet
and outlet baffle.
g) If the induced fan on the other side has began operating, open the outlet baffle by
hand when the motor is started, and put in automatic when the opening of these two
inlet adjustable baffles are adjusted consistently.
8.3.3.3 Maintenance and surveillance
1) Regularly check the induced fan
2) Make sure that bearing oil level is at a normal level and is good in quality.
3) Make sure that transmission gear is complete and functions normally.
4) Examine the temperatures of induced fan bearing, motor and bearing, vibration should be
normal and be in line with BTG operational inspection value.
5) Vibration of the air fan should be less than 120μm
6) When bearing temperature reach 90℃, warning signal should be given off, and when it
reaches over 105℃, operation should be stopped.
7) When motor bearing temperature reaches 90℃, a warning signal should be given off,
and when it reaches over 105℃, operation should be stopped.
8) When of coil temperature reach 100℃, a warning signal should be given off, and when it
reaches more than 120℃, operation should be stopped.
9) Current of motor should be less than rated current
8.3.3.4 Out-of-operation of induced fan
1) Sequential control stops
a) Outlet baffle is “automatic”
b) Force fan on the corresponding side has stopped running
c) Use DCS to issue “stop” order
d) This induced fan stops operating with red light off and green light on. The current is
“zero”

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e) When the induced fan on the other side is running, outlet adjustable baffle and inlet
baffle of the former fan automatically close.
f) Stop of the last induced fan:
g) Corresponding force fan and primary fan have stopped operating, and the inlet and
outlet baffles of a force fan automatically start.
h) Use sequential control to stop the last induced fan
i) Outlet baffle of the two induced fan close 15mins after it automatically opens
j) Set the inlet adjustable baffle to be “manual”, and make it “zero”.
2) Manual operation suspension
a) Stop the corresponding force fan
b) Set the inlet adjustable baffle of the suspended fan to be “manual”.
c) Gradually narrow the inlet adjustable baffle and take care to keep the draft of hearth.
d) Manually execute the “stop” order and wait for the stop of the induced fan.
e) Close outlet and inlet baffles.
f) When stopping the last induced fan, open the outlet and inlet baffles of
these two induced fan, and appropriately open the inlet adjustable baffle according to
the draft of hearth, and what is more, close all baffles 15mins after draught.
8.3.4 8.3.4 Force fan
8.3.4.1 Conditions for start-up
1) Corresponding air preheater is running
2) Corresponding induced fan is running
3) Its inlet and outlet baffles should be closed
8.3.4.2 Sequential control start-up
1) Make sure that the inlet baffle of the induced fan is set “automatic”
2) Make sure that the cooling air balanced baffle in the force fan which waits for start-up is
closed.

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3) Open the outlet and inlet baffles of another force fan.
4) After issuing the “start” order for waiting force fan on the DCS, confirm and complete all
conditions for start-up.
5) The force fan then slowly starts, with green light off and red light on.
6) 30 seconds later, inlet baffle will automatically open, manually open inlet adjustable baffle
to 10% (the inlet adjustable baffle can be directly set “automatic”).
7) Cooling air balanced baffle automatically opens.
8) When another force fan is not running, its outlet baffle automatically closes.
9) If the force fan on the other side is already running, outlet and cooling air balanced baffles
will automatically open 30 seconds after the second force fan low-speed
motor gets started. Manually adjust the opening of the two force fan inlet
adjustable baffles and make them consistent. The opening degree is decided by total load
demand multiply 30%,
and the inlet adjustable baffle of the force fan can be set “automatic”.
8.3.4.3 Manual start-up
1) Set inlet manual adjustable baffle of the start-waiting force fan to be “manual”.
2) Open the inlet and outlet baffles of another force fan on the other side.
3) Close cooling air balanced baffle on the waiting side that wait for opening.
4) Operate single control “start” order.
5) Force fan now starts slowly.
6) Open the outlet baffle 30 seconds later.
7) Open the side cooling fan balanced baffle.
8) If the force fan on the other side is not running, make sure that its inlet baffle is closed.
9) Gradually open the inlet adjustable baffle, and set “automatic”.
10) If the force fan on the other side is running, start the second force fan, and 30mins
later, manually open the outlet baffle and cooling balanced baffle, also, adjust the inlet
baffle of the two force fans to be consistent and set “automatic”.

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1) When the force fan is running at a high speed, its current should be less than the rated
current.
2) When the hearth blows, the amount of air should be between 25%MCR and 40%MCR.
3) Amount of air/that of burning should be more than 9kg/kg
4) Vibrating should be less than 120μm
5) Temperature of bearing should be more than 90℃ (warning)
6) Temperature of motor bearing should be more than 90℃(warning)
7) Temperature of coil should be more than 100℃(warning)
8.3.4.5 Operation suspension of force fan
1) Set the inlet adjustable baffle to be “automatic”
2) Using DCS, issue the “stop” order.
3) When the force fan stops running, green light turns on while red light goes out.
4) Automatically close the inlet and outlet baffle if the force fan on the other side is running.
5) Automatically close cooling balanced baffle.
6) Outlet baffle will automatically open after the two force fans have stopped operating, and
it will automatically close 15mins later when inlet adjustable baffle is
switched to
“manual”.
Single control operation suspension of force fan
1) Manually narrow the inlet adjustable baffle until it reaches zero
2) By solely executing the “stop” order, stop the running of force fan.
3) If another force fan is running, make sure that the outlet baffle of the former one is closed.
4) Close the suspended side cooling balanced baffle.
5) After these two force fans stop operating through the single control order, using DCS,
manually open their inlet baffles and have them closed 15mins later.

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8.3.5 Primary air fan
8.3.5.1 Conditions for start-up
1) Air preheater on the corresponding side should be in operation
2) Induced fan on the corresponding side should be in operation.
3) Inlet and outlet baffles of start-waiting primary air fan should be closed.
4) Heat primary air valve of the air preheater outlet on the corresponding side should be
closed.
5) Vibrating of air fan on the start-waiting side should be slight
8.3.5.2 Start up of subgroup control
1) After making sure that conditions for start-up are met, using DCS, issue the subgroup
control order.
2) Primary air fan starts running with green light off and red light on.
3) 1min after the primary air fan starts, its outlet baffle will automatically open, so will heat
primary air valve of the air preheater.
4) Gradually open inlet adjustable baffle and set primary air pressure and inlet baffle to be
“automatic”.
5) After the second primary air fan starts operating, using hand, adjust the opening of 2 inlet
adjustable baffle to be consistent and set them to be “automatic”.
8.3.5.3 Start-up of single control
1) Make sure that conditions for start-up are met
2) Set the inlet adjustable baffle to be “automatic”
3) Through single control, execute the “start” order
4) This primary air fan then starts operating, with red light on and green light off.
5) 1min later, open the inlet baffle plate by hand
Gradually open inlet adjustable baffle plate and set it to be “automatic”.

2×300 MW
1) Normal level of primary air pressure should be at 38mbar, when it drops to 30mbar or
less, sound the alarm
2) Give 10 seconds for coal pulverizer to trip when the primary air pressure reaches 24mbar
or less
3) Current of air fan should be less than 59A
4) Vibration of air fan should be less than 80μm
5) When the temperature of bearing reach 85℃, a warning sign should be given off
6) When temperature of motor bearing reach 90℃, a warning sign should be given off
7) When temperature of coil reaches 100℃, a warning sign should be given off
8.3.5.5 Out-of-operation of primary air fan
1) Subgroup control suspended operation
a) Issue primary air fan subgroup control “stop” order through DCS
b) Make sure that the air fan stops operating
c) Inlet adjustable baffle automatically turn to “zero”
d) Outlet baffle automatically close and heat primary air will automatically shut
down baffle
2) Single control operation suspension
a) Gradually close the inlet adjustable baffle by hand until it reaches zero
b) Execute “stop” order
c) Make sure that the air fan stops operating
d) Close the inlet baffle by hand
e) Make sure heat primary air baffle automatically close
8.3.6 Pulverizing system
8.3.6.1 Check-up before start-up
1) Start and check rotating machine (refer to basic requirements)

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2) Make sure that pipelines of the system are air proof, free of power leakage and power
accumulation and that they have no fire threat
3) Make sure that blast-proof valve of the system is complete
4) Make sure that all air lock HV005,012,022 are flexible in movement and strictly closed
5) Make sure that all thermal signal of control panel and control device are
sound and useable
6) Safety interlock security test is up to standard
7) Fire-fighting equipment is complete
8) Check the lubricating oil system
a) Oil level of oil tank is normal, when it reach over 450 litre, its height should be 2/3
that of the original.
b) Temperature of oil tank is at a normal degree
c) Quality of oil should be fine
d) Oil quality of reducer should be fine and oil level should be at 1/2
height of the original
e) Strainer of main oil system and reducer oil system should be clean and flexible in
swift
f) Connection of system piping should be sound and free of oil and water leakage
g) All valves are rightly placed.
8.3.6.2 Operate all coolers
1) Operate low pressure oil pipe oil cooler:
a) Open cooling water outlet and water inlet valve of cooler, close the bypass valve
b) Make sure there is a cooling water flow (20m3 /h).
c) Put in main reducer cooler
d) Open cooling water outlet of oil cooler and front and rear doors of
temperature-controlling valve (bypass valves closed), and open water inlet valve

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e) Make sure that there is a flow of cooling water
2) Put into use the main motor cooler of ball mill
a) Open cooling water outlet valve of water cooler and water inlet valve, cooling water
outlet valve of main motor bearing and water inlet valve as well.
b) Make sure that the cooling water flow is right
8.3.6.3 Check-up of powder-manufacturing equipment
1) Ensure that coal feeder has no sundries, scraper chain is complete,

pulverized coal discharging pipes are smooth, all inspection holes are closed, and coal
level of raw coal bunker is sufficient.
2) Gear wheel seal cover of ball mill should be sealed and seal fan 008ZV is reliable and
acts as back up.
3) Air drive guide baffles of cyclone separator UV10, UV20 can rightly operate
and are reliable in action.
4) Exterior of feeder is complete, interior strict without accumulated powder and mechanical
parts test normally.
5) The inspection of pulverized coal discharging machine is the same as

that of the pulverized coal conveyer.
6) Pulverized coal bunker is closed tightly, pulverized coal level measuring device is correct.
7) All valves of the system should be in the following positions:
a) Motor-operated main valves for adding steel ball are closed.
b) Motor-operated sub-valves for adding steel ball are closed.
c) Pulverized coal discharging plugboard and hot smoke hand-operated valve of the
coal feeder are open and the air-operated valve is closed.
d) Air cooling valves are closed.
e) Hot air regulating valve is closed.
f) Hot smoke bypass valve of ball mill is in a state of opening of commissioning.
g) Air-operated guide baffle of cyclone separator is directed to the

pulverized coal

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bunker.
h) Air-operated plugboard UV06 between pulverized coal conveyer and pulverized coal
bunker is closed.
i) Pulverized coal-discharging valve of bunker is closed
j) Outlet of cyclone separator is closed
k) Inlet valve of coal pulverizer exhauster is closed, recycled air valve in the outlet is in
the state of opening of commissioning, air fan bearing cooling outlet is closed and
inlet thereof opened.
l) Exhaust air fan inlet regulating baffle is closed and outlet valve is closed.
m) Exhaust air pipe cooling air valves are opened
n) Moisture-absorbing pipe valves of coal bunker are opened, and moisture-absorbing

pipe communicating valves are opened as well.
o) Controlling power and utility power of various rotating machines are reliable.
8.3.6.4 Operation of coal pulverizing system
1) Get lubricating oil system started
a) Controlling Power and utility power are prepared, and lubricating oil system
is in normal condition.
b) Group control start-up (on DCS): execute group control order, lubricating oil system
group control procedures automatically go on
1) Main speed reducer oil pump is got started.
2) When oil temperature of main oil tank is not more than 35℃, low pressure oil
pump will start operating.
3) When oil temperature reaches 10℃ or more, low pressure oil pump get started
4) When oil temperature reaches 35℃ or more, top tiles and jacking oil pump get
started
c) Single control start-up
1) Get it started in sequence on DCS.

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2) Start-up conditions, procedure and group control start-up.
d) Local surveillance of lubricating oil system start-up:
Speed-reducing oil pump starts normally, and the oil flow is not less than
60 litre every second.
Low pressure oil bump starts normally, and oil pipelines have no
vibration and leakage.
Bush oil-pumping pressure gauge should be more than 0.2bar, oil-pumping

flow
(meter) more than 30 litre per second, and jacking oil pump inlet oil pressure (meter)
1.6bar or so.
Jacking oil pump starts normally, oil outlet pipelines have no leakage and top bad oil
pressure is somewhere between 25bar and 50bar.
Jacking oil pump starts normally, oil outlet pipeline have no leakage, and
jacking pressure is somewhere between 35bar and 60bar
2) Setting value of lubricating oil system and their relations
Main oil tank:
a) When oil level is low (less than 450 litre), low pressure oil pump will trip, so will high
pressure oil pump and coal pulverizer chain
b) When oil temperature is less than 10℃, low pressure oil pump will trip
c) When oil temperature is less than 35℃, jacking (oil) pump will trip
d) When oil temperature is less than 35℃, electric heater will automatically
put into action
When oil temperature reaches more than 40℃, electric heater will automatically stop.
Low pressure oil pump exporting oil temperature is 8bar, when it reaches 12bar
or more, safety valve should be in place
Oil temperature after cooler is 45℃, temperature control valve will automatically regulate
When pressure difference of filter reaches 1.5bar or more, a warning signal should be given
off

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When temperature of low pressure pipelines reach 60℃ or more, coal pulverizer will trip
When bush oil flow of coal pulverizer is less than 30L per second, the sub-coal pulverizer will
trip.
When the oil pressure of oil pump inlet of top pad and jacking is 1.6 bar, the constant pressure
valve will automatically adjust; when the oil pressure is equal to or more than 1.8 bar, the safety
valve will trip while PSL111 coal mill trips and the oil pumps of top pad and jacking trip when the oil
pressure is 0.2 bar.
When oil pressure of jacking pump reaches 60bar or more, safety valve trips.
When oil pressure of jacking pump reaches 110bar or more, safety valve trips.
When oil temperature of jacking pump is too low, say 15bar, jacking oil pump will trip (coal
pulverizer trips)
When oil temperature of jacking is too low, say 30bar, jacking oil pump and coal pulverizer will
trip
When oil temperature of speed reducer reaches 65℃ or more, a warning signal should be
given off
1) Pressure difference of filter is too high, the alarm is given.
2) Oil flow is too low, say 60 litre per min, oil pump of speed reducer and coal pulverizer will
trip
Big gear fueling injection equipment: big gear fueling injection air atomizing pressure is less
than PSL201, 4bar, send off warning signal
Stop the operation of lubricating oil system in case of the following situations
Lubricating oil system needs repair
Lubricating oil system lose great amount of oil and stop operating because of accidents
3) Subgroup control start-up of coal pulverizing system
Requirements for start-up
a) Remote and local button of its transmission should be set at remote
b) Lubricating oil system functions normally

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c) Its transmission has no vibration and high alarm
d) When temperature of bush coal mill is less than 70℃, it is at a normal level, as is motor
bearing when its temperature is less than 90℃.
e) Boiler safety protection device should be set MFT resetting, and control and drive power
of all equipment belonging to the coal pulverizing system should be reliable
f) Flow of steam should be more than 270T/H.
g) Inlet adjustable baffles of both air-lack air fan and coal pulverizer exhauster should be
fully closed.
h) Temperature of coal pulverizer inlet should be less than 128℃.
i) Gigger braking device “loose”.
j) At least one of adding steel motor -driven main valve and sub valve should be closed.
k) Thermal signal should be correct, and noise-measuring device of coal pulverizer should
be put into use
l) Revolution local controlling tank switch of coal feeder should be set “on”
m) Star-up preparation on the DCS
Exhaust air quantity should be set between 30000 Nm3 /h and 40000Nm3 /h
Temperature of coal pulverizer outlet should be set at 115℃
Inlet adjustable baffles of air-lack air fan, hot air and cool air should be set “automatic”, rev of
coal supply should be set “zero” and “automatic”
Start-waiting coal pulverizing system will be repositioned
Start the exhaust air circuit (on DCS)
a) Execute subgroup control order
1) Start the exhaust air fan
2) Cooling air baffle of exhaust air fan inlet will be closed while its outlet baffle will be
opened 30 seconds after it gets started
b) Inlet adjustable baffle be set “automatic”, fixed value of exhaust air quantity should be set

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Start mill-exhausting circuit
Execute subgroup control start-up order
1) Mill exhauster gets started
2) Inlet baffle UV02 will open 30 seconds after mill exhauster gets started
Start hot smoke circuit
Execute subgroup control HSN007 start-up order
1) Get hot smoke air-drive truncated baffle UV05 started
2) Inlet adjustable baffle of exhaust air fan automatically open, adjust the fixed
value of exhaust air quantity
3) Adjustable baffle of hot air and cool air automatically adjust, temperature of controlling
coal pulverizer outlet gradually increase until it reaches its fixed value
4) Draft of coal pulverizer outlet and mill exhauster inlet then gradually increase
Start the coal pulverizer
Execute the sub group start-up order when temperature of coal pulverizer inlet reaches more
than 90℃
1) Start auxiliary motor, have ball mill slowly operate, and 2mins later, unplug the auxiliary
motor and plug the main motor
2) Get big gear seal fan started
3) Put big gear oil blooming system into use
If seal fan does not operate, coal pulverizer (main motor) will trip
To restart coal pulverizer, use single control seal fan(on the DCS) when it is normal
Start coal feeder
Execute subgroup control start-up order
1) Local controlling tank is electrified 5 seconds after it gets started
2) Speed-controlling device of coal feeder will be put into a automatical control

state 5
seconds after coal feeder and controlling tank are electrified.

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3) After the coal pulverizing system gets started, see to it that temperature of coal pulverizer
inlet slowly increase until it reaches its fixed value, and that the adjustable baffles of hot
air and cool air are in the automatic position, and that noise-measuring indicator of coal
pulverizer chang from high to low until it reaches normal value
4) Group control of coal pulverizing system
Conditions for start-up
Start preparation on the DCS:
Start-waiting coal pulverizing system reseats.
Exhaust air flow control reture circuit, temperature-controlling circuit and speed-
controlling
A/H order of coal feeder are all “automatic”.
Sub group start-up conditions are met.
Group control start-up
Execute HSN001 group control start-up order.
1) Get exhaust air fan circuit started through automatic sequencing.
2) Get mill exhauster started through automatic sequencing.
3) Start hot smoke circuit through automatic sequencing.
4) Inlet baffle of exhaust air fan automatically adjust exhaust air flow.
5) Adjustable baffles of hot air and cool air automatically adjust coal
pulverizer inlet temperature until it reaches 90℃.
a) If gigger motor is operating, it will trip.
b) Coal pulverizer automatically starts through automatic sequencing.
c) Coal feeder automatically starts through automatic sequencing, rev control circuit of
coal feeder will automatically adjust coal supply quantity.
6) Maintenance and parameter during operation
Adjustment of coal pulverizing system in operation
a) Objectives of adjustment

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1) Make sure that the fineness degree of coal powder is up to standard and is fine in
evenness degree to avoid incomplete burning loss
2) Guarantee the best output of coal pulverizing system, and try to

lower power consumption of milling
3) When boiler functions safely and economically, guarantee coal powder supply and
sufficient coal level to suit the change of load, and ensure that there
is enough buffering time when coal pulverizing system fails
b) Adjustment and instruction in operation
1) Coal feeding speed adjustment
Coal feeding speed adjustment automatically proceeds according to the

signal of noise-measuring device, and it works in the manner of “automatic”.
In face of the problem of manually adjusting coal feeding amount, when

slowing down or quickening speed, ensure that the coal feeding is slow
and consistent, starting or closing the coal feeder to adjust coal feeding is banned
2) Adjustment of exhaust air amount
Inlet adjustable baffle of exhaust air fan should be “automatic”
Flow amount of exhaust air can be changed through exhaust air amount enactment,
and when humidity of raw coal is high, increase exhaust air amount properly
3) Adjustment of coal pulverizer inlet temperature
Adjustable baffles of hot air and cool air should be “automatic”, the opening of hot air
adjustable baffle appropriate, and cool air adjustable baffle closed.
With coal pulverizer outlet temperature enactment, hot air and cool air
adjustable baffles should be automatically adjusted, aimed at adjusting coal
pulverizer outlet temperature.
Restriction loop is used to avoid temperature rise at coal pulverizer entrance, the
temperature of coal pulverizer inlet should always be higher than
secondary air temperature (minimum temperature difference △T=20℃)
If outlet temperature falls too much (about10℃ lower), coal feeding

revolution slowly drops by connecting revolution slide system until it
reaches normal

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temperature value
4) Noise control of coal pulverizer
If coal pulverizer noise drops too much to avoid the blocking of coal pulverizer, coal
feeder revolution is automatically shifted to 20% that of its rated revolution
5) Hot smoke bypass valve HV002 of coal pulverizer
Manual baffle HV002 can control coal powder circulation amount from raw powder
separator to coal pulverizer (when it is closed, the baffle increases the coal powder
circulation amount, and it can only be adjusted once in the test)
6) Mill exhauster recirculating valve HV003
In debugging, fix its opening which should not be changed in operation
Mill exhauster air current carries the powder from coal pulverizer
through raw powder separator into cyclone separator, and to avoid the
accumulation of coal powder in the pipelines, the speed of gas in the pipes
should be as much as that of the fixed minimum value
7) Adjustable baffle of raw powder separator
Its function is to adjust the effect of raw powder separator to ensure the fineness of
coal powder is up to standard, and in debugging, fix its opening
level which is generally not adjusted in operation
When its opening enlarges, draught of the system and coal pulverizer will increase
and coal powder become thick
When the fineness of coal powder passes 200 in normal operation, objective should
be between 92% and 95%.
c) Operational parameters of coal pulverizing system
Temperature monitoring
1) Normal value of coal pulverizer inlet hot smoke air temperature is somewhere between
350 and 700℃, when it reaches upper limit of 800℃ and lower limit of 300℃, a warning
signal should be given off.
2) Normal value of coal pulverizer inlet temperature is 115℃, when it reaches 120℃ or is

2×300 MW
less than 90℃, a warning signal should be given off, when it reaches 130℃, exhaust air
and mill exhauster will trip, so will interlocked coal pulverizing system
Air pressure monitoring
1) Normal value of coal pulverizer outlet draft should be somewhere between 20mbar and
30mbar
2) Inlet draft of mill exhauster should be equal to 70mbar of less
Exhaust air amount should be 40000Nm3/h or less
Powder level of coal bunker should be maintained a level higher than 8 meters, when it is 3
meters high or less, a warning signal will sound and pulverized coal feeder will trip. When it is 11
meters high or more, sound the alarm, and when powder level reaches 12.5 meters, stop the coal
pulverizing system or remove powder to another coal bunker on the other side
Electric current value of rotating machine
1) Value of exhaust air fan should be less than that of rated electric current
2) Rated electric current value of mill exhauster should be less than that of rated current
3) Rated electric current value of coal pulverizer should be less than that of rated electric
current
Inspection and maintenance of coal pulverizing system in operation
Inspectors should regularly check all equipment, checking the functional

status of all equipment, collating local instrument and control room numerical value, and
immediately reporting and acting to deal with problems when something abnormal happens.
Operational parameters of all auxiliary organs should be controlled within the following scope
1) Coal pulverizer
Normal temperature value of bush should be at 45℃ or so and less than 70℃.
Main motor bearing temperature should be less than 90℃
Coil temperature of motor should be less than 100℃
Cooling water flow of main motor cooler should be at a normal level
Cooling water flow of main motor bearing should be at a normal level

2×300 MW
2) Mill exhauster
Bearing temperature should be at a degree lower than 90℃
Bearing temperature of motor should be at a degree less than 90℃
Coil temperature of motor should be at a degree less than 100℃
Bearing vibration should be less than 80μm, when it passes 80μm, air fan will trip
Cooling water amount of motor should be normal
3) Exhaust air fan
Bearing temperature should be at a degree less than 90℃
Bearing temperature of motor should be at a degree less than 90℃
Coil temperature of motor should be at a degree less than 100℃
Bearing vibration should be less than 80μm, when it passes 80μm, air fan will trip
Cooling water amount of motor should be normal
4) Lubricating oil system
Oil temperature of main oil tank should be somewhere between 35℃ and 40℃
Oil level of main oil tank should be 1/2~2/3 of its original height (based on on-site oil level
gauge)
Bush oil-receiving flow amount of coal pulverizer should be more than 30 litre per second
Pressure difference of oil filter should be less than 1.5bar normally, when it reaches 1.5bar or
more (PDSH102), rearrange the oil filter and notify workers for maintenance and clean the oil filter
that has been blocked.
Top pad oil temperature should be somewhere between 25bar and 50bar (normally it is 30bar
or so)
Jacking oil temperature should be somewhere between 35bar and 60bar (normally it is 40bar
or so)
Oil system has no vibration and oil leakage
5) Oil system of speed reducer

2×300 MW
Oil system should be free of oil leakage
Oil flow should be more than 60 litre every minute
When pressure difference of filter is too great, change the filter and notify repair workers for
maintenance and clean the one that has been blocked
Cooling water flow indictor of cooler should be placed in the protection zone
6) Big gearwheel grease-blooming system
Oil in the oil barrel should be sufficient, if oil shortage problem is found, notify oil inspectors to
refuel in time
Motor-driven pump and oil blooming should be normal
When electromagnetic valve rear pressure reaches 4bar (PSL201), sound the alarm.
8.3.6.5 Suspended operation of coal pulverizing system
1) Subgroup control stops (on DCS)
a) Set the speed-controlling device of coal feeder to “manual” status to bring the speed
down to zero
b) Operate the subgroup control stop order and stop coal feeder
c) After the coal feeder stops, make sure that coal in the coal pulverizer have all been
removed and its outlet draft diminish, and when outlet temperature passes 120℃,
operate the subgroup control stop order.30 seconds after coal
pulverizer stops operating, assistant motor gets started (assistant
motors can be stopped by operating the local or emergency
order), and 30 minutes later, seal fan will automatically stop (it can
also be realized by operating the single control stop order
on the DCS).
d) Operate the subgroup control stop order, make sure that hot smoke air drive baffle
and inlet adjustable baffle of exhaust air fan, and hot air and cool air adjustable baffle
plate automatically close
e) Operate the subgroup control stop order, mill exhauster will stop and its inlet baffle
plate will automatically close
f) Operate the subgroup control stop order, exhaust air fan will stop operating, and its
inlet and outlet adjustable baffles will automatically close, whereas cooling air baffle

2×300 MW
in the exhaust air vent will automatically start
2) Group control stop (on the DCS)
a) Carry out the group control stop order and stop proceeding the procedures.
b) Coal feeder stops operating, and the opening speed-controlling device drops to zero
c) 15 minutes after coal feeder stops operating, its subgroup control circuits also cease
successively
8.3.6.6 Emergency automatic stopping and tripping of the pulverizing system
1) The pulverizing system trips when one of the following conditions is met
a) ‘Emergency stop’ command is operated
b) Boiler MFT action is done.
c) A ball mill trips when the pulverizing system is treated with group control.
d) If one of the above conditions occurs, the following steps should be operated at the
same time
e) The coal feeder trips automatically
f) The main motor of coal mill trips automatically and the helper motor starts up after 30
seconds.
g) The hot smoke air circuit trips automatically
h) The pulverized coal exhaust circuit trips automatically
i) The exhaust gas circuit trips automatically
2) The tripping of each subgroup control circuit
The exhaust gas circuit trips when one of the following conditions is met
a) Action of the boiler MFT is done
b) The outlet temperature of the coal mill is equal to or higher than 130 degrees
c) Steam flow<270T/H with 3 minutes’ delay
d) Vibration of exhaust gas fan ≥80μm with 10seconds’ delay

2×300 MW
e) After the start-up command is given two seconds, the exhaust gas fan motor has no
electricity.
f) The group control commands or subgroup control commands are done
The pulverized coal exhaust circuit trips when one of the following conditions is met
a) When the start-up command is given 90 seconds, the entrance truncated baffle is
not open
b) The outlet temperature of the coal mill is equal to or higher than130 degree
c) Action of the boiler MFT is done
d) The pulverized coal exhauster vibrates too sharply with 10seconds’ delay
e) After the start-up command is given 2 seconds, the pulverized coal exhauster motor
is not switched on. The group control commands or subgroup commands are done
The hot smoke wind circuit trips when one of the following conditions is met
a) The exhaust gas fan motor is powered off
b) The pulverized coal exhauster motor is powered off
c) The pulverized coal exhauster entrance baffle is not opened completely
d) The lubricant circuit of the coal mill is not put into operation
e) After the start-up command is given 30 seconds, the hot smoke baffle is not open
f) One tripping command is given from the group control or subgroup control
The coal mill trips when one of the following conditions is met
a) The lubricant circuit of coal mill is not put into operation
b) Any top bearing oil pressure is equal to or less than 30bar (top watt pressure≤15bar)
c) Any top watt oil blooming flow <30litre/minute with 5 seconds’ delay
d) The oil temperature in the oil tank is equal to or higher than 60 degree, or less than
35 degrees.
e) The lubricant circuit of the coal mill is not put into operation.

2×300 MW
f) The lubricant circuit of the coal mill is not put into operation.
g) The alarm issues when cooling water flow is low.
h) The temperature of top watt is equal to or higher than 70 degree.
i) The locking pole of turning gear leaves the position.
j) Both of the two steel tubes with electric valves are not closed
k) After the main motor is started up 2 seconds, the centrifugal intermittent device of
the turning gear is in a closed position
l) After the main motor is started up 2 seconds, the seal fan is not started up
m) Switch to the operation of the turning gear is required
n) The time of the oil blooming system’s fault is more than one hour
o) The hot smoke air baffle is not open
p) Action of the boiler MFT is done.
q) The entrance fuel pressure of the high pressure fuel pumps is equal to or less than
0.2 bar
r) One group control command or subgroup command is done
s) After the main motor of coal mill is powered off 30 seconds, the auxiliary motor is
started up
The coal feeder trips when one of the following conditions is met
b) The pulverized coal level of pulverized coal bunker is too high (LSHH06A/06B)
c) The main motor of coal mill is powered off
d) The baffle of hot smoke air is not open.
e) After the coal feeder is started up 25 seconds, the speed of revolution is too slow
f) After the coal feeder is started up 2 minutes, the coal is not supplied and with 30
seconds

2×300 MW
g) One stop command from the group control command or subgroup command is done
8.3.7 The turning gear of the ball mill
8.3.7.1 Regulations about operation of the turning gear
1) When the pulverizing system is stopped while the rotating equipment has no fault
2) When adopting mechanical supervision to the coal mill
3) Before starting up the coal mill after being stopped a long time, the lubricant system must
be adjusted in the state of turning gear
4) When the main motor is started up, the turning gear motor should be run for 2 min in low
speed.
8.3.7.2 The start-up conditions of turning gear:
1) The lubricant circuit of coal mill is put into operation
2) Speed reducer lubricant circuit is in operation
3) The temperature of bearing of the coal mil is normal
4) The main electromotor of coal mill is powered off
5) The braking device of turning gear is in the “loose” position
8.3.7.3 The start-up of turning gear
1) Start up on the spot
a) When the pulverizing system is stopped, but its rotation machine is

normal, the persons on duty should start up the turning gear until the main motor
starts up
b) Press the on-the-spot startup button to start up the turning gear when mechanical
inspection is needed, or operation of coal mill at slow speed is
needed for adjusting the lubricant system
c) When the start-up command is given, electromagnetism gear and auxiliary motor is
electrified at the same time
8.3.7.4 The tripping conditions of turning gear
1) The lubricant circuit of coal mill is not put into operation
2) The lubricant circuit of speed reducer is not put into operation

2×300 MW
3) The temperature of bush of coal mill is equal to or higher than 70 degree
4) The trouble time of fuel sprinkling system lasts more than one hour.t
5) After the turning gear is started up 2 seconds, the seal fan fails to start up
6) The locking pole of turning gear is not in “loose” position
7) One stop command is given
8.3.8 The pulverized coal conveyer
8.3.8.1 The inspection before start-up
1) The inspection of the mechanical section should be normal
2) The pulverized coal conveyer should not be blocked by pulverized coal
3) Accumulated pulverixed coal, light source should not be found and the lighting should be
sufficient.
4) The gas source of the guide baffle should be normal.
8.3.8.2 The pulverized coal pouring operation of the pulverized coal conveyer(A→B)
1) Open the pulverized conveyer then lead it to the pneumatic flashboard of B pulverized
bunker, and the pneumatic flashboard should be closed when it arrives at A pulverized
bunker.
2) Open the communication valves of the moisture absorption pipe
3) Operate the startup button of the pulverized conveyer from A to B on the spot
4) Make sure that the operation of the pulverized coal conveyer is normal, the direction is
normal, the motor and the transmission device is normal
5) Lead the lowering pulverized coal guide baffle of A side of the cyclone separator to the
pulverized coal conveyer
6) Make sure that the operation of the pulverized coal conveyer is normal, and make sure
the pulverized coal has been conveyed from A to B
7) The changes of the position of pulverized coal in A, B bunker should be monitored.
8.3.8.3 The normal maintenance of pouring pulverized coal (A→B)
1) Inspect the operation of the pulverized conveyer periodically

2×300 MW
2) The signals of the pulverized coal conveyer and the guide baffle of the cyclone separator
should be normal when being monitored by a CRT.
3) When B pulverizing system operates and pulverized coal is poured from A to B, the level
of pulverized coal in B bunker rises rapidly, the changes of the level of pulverized coal
should be should be paid.attention to.
8.3.8.4 The abnormality treatment of pulverized coal pouring:
1) When pulverized coal is poured and the pulverized coal conveyer trips, the guide baffle of
A cyclone separator is should be made sure to be led to the pulverized coal
bunker automatically
2) When the pulverized coal conveyer operates and has sprinkling pulverized coal, it should
be inspected that whether the hand-operated valve of the moisture absorption
pipe is opened.
3) When the chains of the pulverized coal conveyer are broken, the guide
baffle of A
cyclone separator should be led to the pulverized coal bunker at once, and
stop the pulverized coal conveyer
8.3.8.5 Stop pouring pulverized coal
1) Lead the guide baffle of A cyclone separator to the pulverized coal bunker on the spot,
and make sure the position of the pulverized bunker is right
2) Stop the pulverized conveyer when it has no pulverized coal
3) Shut off the pulverized coal conveyer, and lead it to the pneumatic
flashboard of B
pulverized coal bunker
8.3.9 The operation of adding steel balls into coal mill
8.3.9.1 The steel balls should be added during the operation when the current of coal mill is
equal to or less than 190A,.
8.3.9.2 The operation method of adding steel balls
1) Prepare the steel balls that to be added.
2) The quantity of the added steel balls is 1 ton/ times, and the current of ball mill is rose by
about 1A
3) Operate the button of “preparation of adding steel balls” on the spot, the general electric

2×300 MW
valve for adding steel balls are opened, and then the steel balls are filled into the locking
cavity
4) Operate the button of “adding steel balls” on the spot, then the general electric valve of
adding steel balls are closed, the electric sub-valve are opened, and the steel balls are
added into the coal mill
5) 3 minutes later, the electric sub-valve for adding steel balls are closed automatically
8.3.9.3 Attention
1) When both the general electric valve and sub-valve for adding steel balls have no signals,
the coal mill will trip.
2) After adding the steel balls, make sure that the next operation of adding steel balls should
be done only after the electric sub-valve is closed
8.3.10 The pulverized coal burner
8.3.10.1 The inspection and preparation before start-up
1) Open the pulverized coal feeding flashboard of the pulverixed coal feeder,
and the hand-operated valve of the primary air pipe is in the position for adjusting
the opening degree.
2) Various parts of the pulverized coal feeder, the speed governor and the motor should be
checked whether they are all normal.
3) The primary air pipe should not be leaked, and the platform of the coal feeder has no
accumulated pulverized coal and combustible substance.
4) Make sure that the controlled gas source of the primary air pneumatic valve is normal,
and the hand-operated valve of the controlled gas source is opened.
5) The sampling valve of the primary air pressure meter is opened.
6) The switch of the local speed governor is in “ON” position
8.3.10.2 The startup conditions:
1) The general protection of boiler is put into operation, and MFT is reset.
2) The corresponding oil gun torch is put into operation
3) The steam flow is equal to or higher than 250T/H

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4) The level of the pulverized coal in pulverized coal bunker is higher than 5m
5) The hot primary air pressure is not too low.
8.3.10.3 The start-up of subgroup control (on DCS)
1) Regulate the to-be-started-up speed governor of coal feeder to “zero” (SC50A/50B)
2) Operate start-up command for the subgroup control of the front wall coal feeder or back
wall coal feeder
3) The corresponding primary air pneumatic baffle is opened.
4) After the primary air baffle is opened for 10 seconds, the coal feeder is started up
5) After the coal feeder is started up for 5 seconds, the corresponding secondary air baffle is
opened.
6) All the baffles of the A. B, C bellows are placed in the manual state, then
the speed control of coal feeder is put into operation
7) The lowest rotating speed is 3rpm, the corresponding pulverized coal’s quantity is 4T/H.
The automatic control of the fuel increase and switch is operated according to the needs
of load increase, and it should be confirmed that the pulverized coal burns well
8.3.10.4 The single control of start-up (on DCS)
1) Make sure the start-up conditions are ready.
2) The speed of the to-be-started-up coal feeder is regulated to “zero”
3) The start-up command of the single control of the corresponding primary air pneumatic
baffle is operated and the valve should be confirmed opened.
4) The start-up command of single control of coal feeder is operated, and then
the coal feeder is started up.
5) After the speed controller of the coal feeder is put into operation for 5
seconds, the corresponding secondary air baffle is opened.
6) After the coal feeder starts up normally, the rotation speed should be increased manually,
and it should be made sure that the pulverized coal burns well

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8.3.10.5 The running and operation of the pulverized coal jet burner
1) The rotating speed of single coal feeder is set in “automation” (on DCS)
When the number of the coal feeder operation is increased to 8, and the rotating speeds
are all 5rpm, the rotating speed of the single coal feeder can be put into automation in
turn, and SC50A/50B is regulated by the general rotation speed. The
operation is as follows:
a) The opening degree of the general speed governor of the coal feeder is regulated to
40% (on DCS or the spare tray)
b) The speed governor of the single coal feeder is used to regulate its rotation speed in
order to adapt to the signal need of the general speed governor, and the regulation
of the rotating speed of the coal feeder is set to “automation”
c) As the methods described above, other coal feeders are set to “automation” in order.
2) The general speed governor of the coal feeder is set to “automation”
When the quantity of the coal feeder and its rotating speed is adequate, and the volume
of the pulverized coal reaches about 50%, the general speed governor can
be set to “automation” in order to balance the air volume / fuel volume
ratio automatically, the operation is as follows:
a) The demand regulator of the general load should be placed in manual state, and its
opening degree should be 45%
b) The entrance regulation baffle of the induced draft fan and forced draft
fans has been put into “automation”
c) The smoke oxygen content should be normal, and its regulator should be put into
“automation”
d) The general rotating speed of the coal mill should be set to “automation” (FEO HIC
050)
e) At this time, the general load needs, the rotating speed and the air flow of the coal
feeder should be correspondingly increased or decreased.
3) The start-up order of the pulverized coal jet burner
a) In principle, the start-up order should be operated from the middle of the arch to its

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both sides, (FEF, FED) → (FEG, FEC) →(FEH,FEB) and should be

put into
operation correspondingly for the front and back archs.
b) When the second auxiliary ejector is put into operation, put FEE→ (FEI, FEA) to the
coal feeder
c) The operative rate of the pulverized coal jet burner should be consistent with the
startup burning rate curves
4) Operation maintenance and supervision
a) Supervision in the control platform
The primary air pressure should be equal to or higher than 36mbar
The rotating speed change of the coal feeder should be balanced, the rotating
speed should not fluctuate substantially when “automation” is set, otherwise the speed
should
be switched to manual control and the rotating speed of the coal feeder
should be controlled equal to or less than 10rpm in order to prevent the
pulverized coal from blocking of the pulverized coal pipe.
b) Local maintenance
Various parts of the coal feeder, speed governor and motor should be
inspected and confirmed in normal condition.
The coal feeder has no abnormal sounds
The operation of the pulverized coal feeding pipe of the coal feeder is smooth, and the
temperature is normal
The pulverized coal feeding pipe and the primary air pipe has no leakage of pulverized
coal and air leakage
The local place has no blocking pulverized coal and self-ignition phenomenon
8.3.10.6 The stop of the pulverized coal jet burner
When the boiler stops, the pulverized coal feeding flashboard should be switched off before
the coal feeder stops
1) The subgroup command stops (on DCS)
a) The stop command of the subgroup control is stopped.

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b) When the coal feeder stops, the speed governor will automatically return to “zero”
c) After the coal feeder is stopped for 20 seconds, the corresponding

secondary air baffle is switched off. (If the oil gun torch keeps operating, the
secondary air baffle near the oil gun torch should be opened)
d) The primary air pneumatic baffle is closed
2) Stop of the single control
a) The rotating speed of the to-be-stopped coal feeder is reduced to “zero”
b) The stop command of single control is operated and the coal feeder is stopped.
c) After the coal feeder is stopped for 20 seconds, the corresponding

secondary air baffle is closed. (the baffle keeps open when the oil gun torch is
operating) (FEA UV13, FEI UV24 single control is closed)
d) The single control demand is operated and the primary air baffle is switched off
3) The coal feeder’s stops for accident
The coal feeder trips when one of the following conditions is met
b) The operation conditions of the coal burner defined by the flame scanning system
are not fulfilled.
c) When steam flow is less than 440T/H, the corresponding oil gun torch has no flame
monitoring
d) When steam flow is less than 270T/H
e) The related pulverized coal’s level in the bunker is too low

(3m) (FMA/B LSLL06A/06B)
f) The primary air pressure is too low (FSA PSLL03) with 5 seconds’ delay (<24mbar)
g) The corresponding primary air baffle has not been opened
h) The coal feeder fails to be switched on 30seconds after the start-up

command is given.
i) The corresponding secondary air baffle fails to be not opened 2min after the start-up

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command is given.
Note: Because of MFT action, if the oil gun torch is controlled in the distance, the baffle of the
secondary air should be opened, FEA UV14, FEI UV24 should be closed after 60 seconds
8.3.11 Fire detector cooling fan
8.3.11.1 Inspection before start-up
1) The air duct is complete and the system connection is good
2) The strainer at the entrance of the fan is in good condition without blocking
3) The mechanical part and the motor is normal through inspection and the transmission
belt is complete without looseness
4) The motor offers electricity normally.
5) The outlet hand-operated valves of two fans are open
6) Each oil gun torch and the hand-operated valve of flame scanning
cooling fan of pulverized coal ejector should be opened
7) The measuring points of air pressure are complete, and the local indication gauges are
correct.
8.3.11.2 The start-up of the fan
1) The start-up of the subgroup control
a) Switch off interlocking (the light is bright)
b) Operate # 1 fan and choose the command (the light is bright)
c) Operate the start-up command of subgroup control
d) Make sure AC fan is operated, the green light is put out, the red light is bright, and
the outlet air pressure is normal
e) The interlocking in put into operation, then the light is put out
2) The start-up of single control (on DCS)
a) Switch off interlocking (the light is bright)
b) Operate the start-up command of single control of # 1 fan, then #1 fan is started up

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c) After the option command of HSU001 #1 fan is operated, the “ON”

command of
subgroup control should be operated.
d) Switch on the interlocking (the light is put out)
8.3.11.3 The linkage and periodic test for direct current fan
1) The linkage of direct current fan
a) Switch on the interlocking (the light is put out)
b) # 1 fan is tripped, and #2 fan linked
c) When the outlet pressure of cooling air fan is less than 85mbar, and after the alarm
issues with s 5 seconds delay, #2 direct current of cooling fan starts up automatically
d) Make switch operate alternatively and automatically
Note: the switch of the flame scanning cooling fan should be operated only after some safety
measures have been adopted in order to prevent the action of the boiler MFT
2) The periodic test of direct current fan (two fans can operate simultaneously at any time)
a) The 220VDC electrical source is inspected and confirmed normal
b) Operate start-up command of single control of #2 fan on DCS, then #2 fan starts up
c) The operation of #2 fan is checked and confirmed normally running.
d) The start-up command of single control of #2 fan is operated, then #2 fan stops
e) Make sure that the flame scanning cooling air pressure should be
higher than
85mbar, and the interlocking is normal (the light is put out)
8.3.11.4 Operation of maintenance and supervision
1) The operation of the fan should be periodically checked, and it should be made sure that
the fan has no friction noise and its bearing’s temperature and vibration and its motor’s
temperature are normal
2) The entrance strainer of the fan should have not blocking phenomenon,
otherwise, it should be cleaned in time
3) The driven belt has not slippery, loose, and falling phenomenon, the local air pressure
should be normal, the air duct and the connected system has not air leakage

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4) The outlet air pressure of the fan should be higher than 85mbar
5) When the outlet air pressure is lower than 85mbar (PSL02), the alarm will be emitted,
and after 5 seconds delay, the direct current fan is linked
6) When the outlet air pressure is lower than 70mbar (PSLL03) with 10 seconds delays, the
boiler has MFT action
8.3.11.5 Stop of the flame scanning cooling fan
After the boiler is stopped for 24 hours, the operation of the flame scanning cooling fan can be
stopped
1) The subgroup control is stopped (on DCS)
a) Operate stop command of HSN001 subgroup control and group control, then the red
light is put out, the green light is bright
b) Make sure the fan is stopped
2) The single control is stopped (on DCS)
a) Operate HSU002, and switch off interlocking (the light is bright)
b) Operate stop command of single control, then the red light is put out, the green light
is bright
c) Make sure the fan stops
8.3.12 Oil gun torch cooling fan
8.3.12.1 Startup Check
1) Ensure the air duct is complete, and system connection is in good condition
2) Check whether the mechanical part and the motor are normal or not, and
ensure the driving belt is complete and not loose.
3) Ensure motor energization
4) Ensure the hand-operated valves of the outlets of the two fans are open
5) Ensure all cooling dampers of the oil gun torch are open and the HV*5 hand-operated
valve of the burning torch cooling air is open.
6) Ensure the air pressure measuring point is complete, and the local indicator is correct

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8.3.12.2 Fan startup
1) Sub control startup
a) Switch-off interlock (lights on)
b) Select fans to be started (lights on)
c) Operate sub control startup order
d) Confirm the selected fan is started, the green light is off, the red light is on, and the
outlet air pressure is normal
e) Interlock is put into service (lights off)
2) Single control startup (on DCS)
a) Switch off interlock (lights on)
b) Operate single control startup order, and the fan is started
c) Select operation fan (lights on)
d) Operate sub control “ON” order, the green light is off, and the red light is on.
e) Interlock is put into service (lights off)
8.3.12.3 Fan in reserve and transfer
The fan transfer should be locally supervised, and should be started before being stopped.
1) Sub control transfer (on DCS)
a) Check interlock is in service (lights off)
b) Select fan to be started (lights on) and fan to be shutdown (lights off)
and the selection difference light is on.
c) Operate sub control startup order, and the difference light is off when the fan to be
started is started and the fan to be shutdown is shut down.
d) Locally checks and ensures the operation fan is normal and the air pressure is more
than 85mbar
2) Single control transfer (on DCS)
a) Single-control starts the fan to be started

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b) Single-control shut down the fan to be shut down
c) Operation selects the started fan (lights on) and shuts down the fan (lights off)
d) Locally check and ensure the operation of the started fan is normal and
the air pressure is more than 85mbar
e) Ensure the sub control is at a condition of “ON”, the green light is off and the red light
is on.
f) Check interlock is in service (lights off)
3) Linkage of standby fan
a) Interlock is put into service (lights off)
b) Standby fan starts when the operation fan trips.
c) Standby fan starts in five seconds after the pressure of cooling air outlet lowers to
85mbar and an alarm is given.
d) Automatic transfer happens alternatively
8.3.12.4 Operation maintenance and supervising
1) Periodically repair fan operation, and ensure no grating, bearing

temperature and vibration are normal, and motor temperature is normal.
2) Ensure the driving belt has no skidding, looseness and shedding, the local air pressure is
normal, and the air duct and connection system have no air leakage.
3) Outlet air pressure should be more than 85mbar
4) When the fault fan is in maintenance, interlock thereof should be unlocked, the power of
the motor of the fan should be cut, and the outlet valve should be closed.
8.3.12.5 Oil gun torch cooling fan shutting down
1) Shut down the oil gun torch cooling fan after boiler is stopped for 24 hours.
2) Sub control stopped (on DCS)
a) Operate HSN001 shutting down order, the red light is off, and the green light is on.
b) Confirm that the fan is shut down.

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3) Single control shutting down (on DCS)
a) Operate HSU002 to unlock the interlock (lights on);
b) Operate single control shutting down order, and ensure that the red light is off, and
the green light is on;
c) Confirm that the fan is shut down.
8.3.13 Steam air heater
8.3.13.1 Check before startup of the steam air heater
1) Ensure that the valves of the steam air heater and auxiliary device piping
are well connected.
2) Ensure the motor-operated valve has been energized, and air supply
availability is controlled.
3) Ensure the condensate system has been put into operation.
4) Ensure the auxiliary steam and the steam extraction is normal.
5) Ensure all measuring instrument is complete and correct.
6) Ensure the following instrument sampling isolating valves are open.
a) Steam inlet pressure hand-operated valve
b) Condensed water tank pressure gauge hand-operated valve
c) Condensed water tank water level high switch hand-operated valve.
d) Condensed water tank water level low switch hand –operated valve.
e) Condensed water tank water level gauge water inlet valve.
f) Condensed water tank water level regulating signal transmitter signal valve.
7) Open the steam piping upper air valve
8) Shut down the steam control valve; shut down the side valve and open the front and real
hand-operated valve.
9) Open the steam air heater desuperheater water hand-operated valve;

desuperheater water control valve auto on.

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10) Open the steam air heater steam intake valve.
11) Open the steam air heater outlet valve.
12) Open the hand-operated valve of condensed water outlet and inlet of the
secondary steam air heater.
13) Open the hand-operated valve of the condensed water blowdown flash tank, manually
shut down the control valve.
14) Open the water drain valve of the condensed water tank, and close the
valve after remained water is drained.
15) Confirm that the hand-operated valve of the condensed water tank to #2
low water injection and drain tank, and manually close the control valve.
8.3.13.2 Put steam air heater into operation
Natural ventilation is adopted before the boiler ignition, the steam air heater is
put into operation, and the outlet air temperature is more than 90 degrees Celsius; in the normal
operation
of the boiler, the average temperature of the gas is maintained between 100 to
105 degrees Celsius, and the air temperature of the outlet is automatically controlled; the
steam air heater is stopped when the heater is high loaded.
1) Select mode at the “auxiliary steam” position of DCS.
2) Pass out the steam air heater sub control startup order at DCS, to confirm that:
3) The fifth extraction motor-operated valve is closed;
4) The auxiliary steam motor-operated valve is open;
5) The drain water motor-operated valve is open;
6) The stem control valve is manually and gradually opened;
7) The drainage valve is closed when the steam bursts out;
8) Condensed water tank water level gauge is checked and the water level is normal;
9) The water level control valve of the condensed water tank is “auto” on;
10) When turbine operation condition is permitted, the turbine can be set as “auto” on;
11) The steam desuperheater water control valve is set as “auto” on.

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The operation of the steam source being switched over to “five section steam
extraction”
should be carried out when the operation condition of the turbine is permitted, and the specific
operation is as follows:
1) Select mode at the “five section steam extraction” position of DCS;
2) Pass out the steam air heater sub control startup order to confirm that the
the steam supply motor-operated valve is open, the check valve is open
and the drain water motor-operated valve is closed.
8.3.13.3 Operating maintenance and parameter
1) The inlet steam temperature of the steam air heater should be between 130
degrees Celsius to 200 degrees Celsius and the temperature should
be higher than (at corresponding pressure) the saturation temperature by ten
degrees Celsius.
2) Drain water tank outlet water temperature of the steam air heater should be 40 degrees
Celsius.
3) Condensed water tank water level.
Water level is low alarm 300mm
Water level is high alarm 800mm
4) Inlet steam pressure
Pressure is low alarm 2bar
Pressure is high alarm 14bar
5) Secondary air temperature of air pre-heater inlet (according to the load)
6) Air and gas average temperature should be between 100 degrees Celsius
to 110
degrees Celsius.
7) Flue gas temperature should be 150 degrees Celsius.
8) Condensed water tank water level governing
a) The water level control valve should be controlled by the water level control circuit at
“auto” position, thus maintaining the condensed water tank water level constantly.
b) In normal operation, drain water in condensed water tank drains into drain tank of
low-pressure heater.
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c) When the water level of drain tank of low-pressure heater is extremely

high and
alarm is given, the steam supply motor-operated valve will be automatically closed,
and the drain water motor-operated valve will be automatically opened,
and the condensed water gutter static expansion.
d) The water level of the condensed water tank should plus 500mmor plus 600mm.
e) When the water level auto control of the condensed water fails,
the steam supply/drain water regulating valve can be switched to “manual” operation.
8.3.13.4 Steam air heater shutting down
1) Pass out the sub control shutting down order at DCS to confirm that:
a) The motor-operated valve is automatically closed when “auxiliary steam

supplies steam”;
b) When the five section steam extraction supplies steam,
The steam extraction motor-operated valve UV01B and the check valve UV01C are
automatically closed;
The drain water motor-operated valve UV01D is automatically opened;
And the steam control valve TCV75A and the desuperheater water control
valve
(TCV75B) are automatically closed.
2) Automatic shutting down of steam air heater
Steam air heater tripping conditions:
a) Pass out steam air heater sub control shutting down order at DCS;
b) The turbine trips when the five section steam extraction supplies steam.
The fifth extraction motor-operated valve and the check valve should be closed.
8.3.14 Boiler water recycle pump
8.3.14.1 Check before boiler water pump startup
1) The connection of the pump, the motor and the system should be in a good condition;
2) Check whether all valves of the boiler water pump are closed or not;
3) Check whether all instruments and the alarm system are in a good condition or not.

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8.3.14.2 Put cooler into service
1) Ensure the closure cooling water system has been put into operation;
2) Ensure the water drain valve of the cooler inlet is opened, and is closed after the sewage
is drained;
3) Ensure the air valve of the cooler outlet is closed;
4) Ensure the inlet valve of the cooler is opened;
5) Ensure the outlet valve of the cooler is completely opened;
6) Ensure the outlet valve of the cooler is opened largely, and confirm that the flow if the
cooling water is larger than 27m3 /h.
8.3.14.3 Motor water injection piping washing
1) Ensure the condensed water pump is in operation, the water temperature is less that 40
degrees Celsius, the water quality is qualified and no hydrazine is added in;
2) Check whether the water injection dual valve is closed or not;
3) Check whether the water injection valve and the acicular valve are closed or not;
4) Check whether the water injection tube is dismantle d or not;
5) ensure the water injection main valve is opened;
6) Ensure the water drain valve of the water injection main tube and the water drain valve of
the strainer are closed after the clean water is continuously discharged;
7) 7) Ensure the water injection valve and the acicular valve are ajar, and
the water injection valve is closed after the clean water is discharged from water injection
tube.
8.3.14.4 Water injection of the boiler water pump
1) The water injection of the boiler water pump should be carried out the boiler is filled with
water;
2) Check whether the check valve of the boiler water pump outlet and the bypass valve of
which are closed or not;
3) Ensure the high pressure side drainage valve of the cooler;
4) Ensure the pump inlet and outlet differential manometer is in a good condition and open

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the isolation valve of the pump;
5) Ensure the water injection valve and the dual valve is opened;
6) Ensure the acicular valve controls the water injection flow to be less than or
equal to
2.5L/min;
7) Check whether the high pressure side drainage valve of the cooler
continuously discharges the water and the water is clean or not, and ensure the air
outlet valve is closed;
8) Ensure the acicular valve is turned down and the water injection is maintained;
9) When the boiler water pump is spot-turned, the dual valve, water injection valve and the
acicular valve are closed.
8.3.14.5 Boiler water pump spot turn
1) After the water injection is completed, the insulation resistance against earth of the motor
conductor indicated in the 1KV megameter should be more than five megohms;
2) The boiler should be filled to a water level which is 100mm more than drum water level;
3) Ensure the check valve of the boiler water pump outlet is locally opened;
4) Ensure the boiler water pump is stopped after having been started for five seconds, and
20 minutes later, the boiler is started for five seconds and then is stopped, to drain the air
in the motor chamber.
5) The boiler water pump should be put into operation and the water injection should be
stopped after the boiler water pump having been spot turned for three
times and no abnormity having been found.
8.3.14.6 Boiler water pump startup conditions
1) The power supply of the motor is energized;
2) The control power supply is energized;
3) The motor is stopped for more than 20 minutes;
4) The cooling water flow of the motor is more than 27m3 /h;
5) The water temperature inside the motor is less than 55 degrees Celsius;

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6) The outlet valve of the pump is unlocked;
7) The temperature difference of the boiler water and the pump (TDSH10) is less than 56
degrees Celsius;
8) The drum water level is more than 600mm;
9) The boiler water pump is spot-turned
8.3.14.7 Boiler water pump startup
1) The drum water level should be higher than +100mm before the first boiler water pump is
started;
2) The local/remote switch of the pump should be positioned remotely;
3) Single control: the boiler water pump can be singly started on DCS when the
startup conditions are met;
Confirm the pump to be started;
Select the pump on DCS and start the pump;
4) Group control startup;
Check whether the group control exits or not on DCS, (the green light is on);
Select the started pump on DCS ( the red light is on);
Start the pump with group control (the group control red light is on) and check whether
the pump is started or not;
5) Notes after startup;
Check whether the differential pressure of the outlet and inlet, current and the
motor water temperature of the operating pump are normal or not;
The interlock can be put into operation only after the standby pump is stopped for 20
minutes;
The pump should be stopped immediately if the motor temperature rises quickly and no
downtrend appears.
8.3.14.8 Boiler water pump hot reserve
The standby pump startup conditions comprise that:

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1) The bypass valve HV*14 HV*15 of the check valve of the outlet is opened, and the pump
body is heated;
2) The upper interlock of the DCS has been put into operation.
8.3.14.9 Boiler water pump transfer
1) Group control transfer (on DCS);
a) Select the standby pump (lights on), and select the pump to be stopped (lights off);
b) Integrate the group control startup, and check whether the standby pump is started
or not and whether the pump to be stopped is stopped or not
c) The interlock automatically quits, and is put into operation again 20 minutes later.
2) Single transfer
a) Singly start the standby pump;
b) Ensure that the pump is normally started;
c) Stop the pump to be sopped;
d) Ensure that the pump is stopped and the current is reduced to zero, and 20 minutes
later the interlock switch is put into operation.
3) Automatic transfer
The group control is closed, the interlock is put into the standby pump, and the startup
conditions are complete; the standby pump would automatically be started if any of the
operating pump trips; the interlock quits, and can be put into operation again after 20
minutes.
8.3.14.10 The operation and maintenance of the boiler water pump
1) The normal temperature of the motor chamber should be 45 degrees Celsius, and an
alarm will be given at 60 degrees Celsius, and the pump will give an extreme alarm and
trips at 65 degrees Celsius.
2) The normal value of the differential pressure of the boiler water pump is more than 1.4
bar, and the differential pressure value when two pumps are in operation is 1.4 bar and a
boiler MFT action would be carried out when the differential pressure is less than or equal
to 1bar.

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3) The temperature between the boiler water and the pump shell should be less than 50
degrees Celsius, and a high temperature difference alarm will be given at 56 degrees
Celsius.
4) The normal cooling water flow of the cooler is more than 27m3 /h, and when the cooling
water flow is less than or equal to m3 /h, a low cooling water flow alarm will be gave, and
20 seconds later the pump will trip.
5) The load of the boiler is less than or equal to 60 percent MCR when only one boil water
pump is in operation;
6) When the temperature of the standby pump motor chamber rises to approximately 55
degrees Celsius, the standby pump should be started and put into use, and should be
stopped after the temperature is reduced.
7) The attendant should check the leakage of the boiler water pump high pressure
side; when leakage is found, the attendant should report to the
chief attendant, and countermeasures should be taken immediately to prevent the
motor from burning loss.
8.3.14.11 Boiler water pump shutting down
1) Ensure the water temperature of the downcomer of the drum is 90 degrees Celsius, the
inner layer air valve of the drum is opened, and when the water
temperature of the downcomer of the drum is less than 70 degrees Celsius, two
boiler water pumps should
be shut down;
2) The cooling water flow should be maintained when the pump is stopped;
3) Boiler water pump that are stopped for a long period should be periodically
checked whether the motor are filled with water; ensure that the boiler water pump
operates for at least 10 minutes every two months, and should be started and operated
for 10 minutes every 15 days at the period of pressure maintenance.
4) Shutting down operation of the pump
a) Group control shutting down;
Select the group control shutting down order on DCS;
Check whether all operating pump are stopped or not and whether the current is
reduced to zero or not;
The outlet check valve should be closed.

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b) Singly shutting down
Quit the boiler water pump interlock on DCS;
Select the pump to be stopped and stop it with single control;
Ensure that the pump is stopped, and the current is reduced to zero.
8.3.14.12 Boiler water pump operation in boiler acid cleaning
1) All boiler water pumps should be injected with water before acid cleaning
and water filling.
2) Only one boiler water pump should be in operation in acid cleaning, and the other two
pumps are isolated.
3) All cooler of the boiler water pump should be put into operation, and the cooling water
quantity should be more than 27m3 /h.
4) The water injection pressure should be kept higher than pressure of the drum by 6bar in
acid cleaning.
5) Continuous water injection should be carried out to the operation pump in acid cleaning
6) inject the water according to the operation; ensure that the injected water is
drained completely, and the water injection quantity should be maintained more than or
equal to
4.5L/min; the temperature of injection water should be less than 45 degrees Celsius.
7) Before adding the liquor to the boiler, the pump should be started and in operation.
8) Continuous water injection should be carried out to the isolated pumps.
9) The outlet check valve and bypass valve should be closed.
10) High pressure side drainage valve of the cooler should be closed.
11) Inject the water according to the operation; maintain the water injection quantity by
more than or equal to 4.5L/min after the air is completely drained; water injection
should be carried out continuously, and the water injection pressure should be higher
than the drum pressure by 6bar.
9 Periodic work, test and shifting of the boiler and relevant auxiliary equipment
NO. Projects Type Period Remarks

2×300 MW
1 Oil gun torch Periodic test Once a week
Forced draft fan Periodic shift Every half month

2
lubricant station oil pump
Induced draft fan Periodic shift Every half month

3
bearing cooling fan
Flame check cooling Periodic test Once a week

4 fan
(DC)
Standby coal pulverizer Periodic test Once a week
5
lubricant station oil pump
6 Boiler blowdown Periodic work Once a day
Boiler proper soot blowing Periodic work Once a day Part by

7 different tiem
periods and
stations
8 Air preheater soot blowing Periodic work Every eight hours
Local water level Periodic work Once a week

9
gauge washing
electromagnetic relief valve Periodic test Once a month

10
blowdown
operational parameter Periodic work Once a hour

11
record
Devices patrol and Periodic work Every two hours

12
inspection
10 Accidents processing of boiler
10.1 Basic Principia of Accidents Processing
10.1.1 When the unit accidents occur, the operator on duty should quickly identify the cause of the
accidents to restrict further development of accidents and prevent the expansion of
accidents. When the accidents are confirmed to have direct threat on personal safety and
equipment, the risks of personal safety and equipment should be decisively eliminated. At the
same time attention should be paid to continued operation of non-fault equipment as far as
possible so as to meet the

2×300 MW
need of system load.
10.1.2 The operator on duty should seek to ensure power supply of electricity system of the power
plant.
10.1.3 In order to accomplish the above tasks, the operator on duty must stick to his post and
focus his mind to ensure the normal operation of equipment, eliminate all abnormal situations and
correctly and fast implement orders given by superior officers.
10.1.4 When the unit has malfunction, the operator on duty generally should work according to the
following steps to eliminate failures.
10.1.5 Rapidly eliminate the risks on personal safety and equipment and the
equipment with malfunction should be immediately out of synchronization (or stopped) when
necessary.
10.1.6 Correct analysis and judgement should be done to indentify the nature, location and scope
of accidents and then proceed to treatment according to instrument indication, alarming signals of
CRT and alarm window and external Faults of the unit. At the same time attention should be paid
to continued operation of non-fault equipment.
10.1.7 Situation of each stage in failure removal should be reported to the shift supervisor as fast
as possible so as to timely take countermeasures to prevent the failure expansion.
10.1.8 If the failure is caused by failure of the system or other equipment, corresponding measures
should be taken to maintain the unit to operate with a certain parameters so as to make it possible
to quickly recover normal operation of the entire set of unit.
10.1.9 According to the unit operating characteristics, accidents caused in any part of the unit will
have a direct impact on the safe operation of the entire unit. Therefore, all posts should exchange
situations during malfunction occurance and closely coordinate with each other to rapidly treat with
the failure under the unified command of the shift supervisor and the chief supervisor.
10.1.10 The chief supervisor should be administered by the shift supervisor during failure removal,
and should rapidly participate in failure elimination and firstly report to the shift supervisor as much
as possible when the malfunction occurs. At the same time, the chief supervisor should report the
taken measures to the shift supervisor and comply with all correct commands
of the shift supervisor.
10.1.11 During accident treatment, the shift supervisor is entitled to call on

all concerned personnel in the power to be on-site to assist to deal with the failure and
meanwhile, all relevant leaders must quickly hurry to the spot to help deal with the failure and
give necessary instructions
2×300 MW

2×300 MW
to operators (all these instructions should be issued by the shift supervisor in general expect for
special circumstances.)
10.1.12 Careful analysis, correct judgement, decisive manipulation and rapid action
should be necessary during failure treatment. In addition, impatience and panic should be
avoided, otherwise the failure will not be eliminated, but becomes expansive and
difficult to handle. The operator should repeat the received order when in treatment of
malfunctions and make it clear until get the order understood, and promptly make reports to those
who give the orders after having fulfilled the orders.
10.1.13 The operator must promptly report to the chief supervisor the unfamiliar malfunctions so
as to jointly study the causes and deal with the failure. When no specified malfunctions is included
in the manual, the operator should analyze and judge the causes with his own
knowledge, initiatively take countermeasures and report the failure condition to the superiors at all
levels.
10.1.14 The operator on duty is not allowed to leave his post freely during the time when the unit
malfunctions occurs until resuming to the normal condition. When the failure occurs at the shifting
time, the shift should be deferred and the shift person should continue to work with the assistance
of the relieve person to jointly deal with failure. The shift can only be done until failure is removed
and commond is received from the shift supervior.
10.1.15 Forbidden and eliminate the case that people who do not involve in the failure removal
stay at the place where failure occurs.
10.1.16 After the acccidents have been disposed, personnel at all posts should truthfully record in
detail the unit failure situation, occurance time, place and the process of
disposal on the registering book for shift respectively, and analyze the failure treatment on
the meeting after shift
so as to sum up experience and draw a lesson.
10.1.17 The shift supervisor and chief supervisor are not allowed to leave the control room at the
same time when the system failure occurs.
10.2 Boiler Emergency Shutdown
10.2.1 If any one of the following conditions is met, the MFT starts and the boiler automatically
stops:
10.2.1.1 The power failure of control system or abnormality of pressure for

controlling air is delayed for three seconds.
10.2.1.2 No induced draft fan is running

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2×300 MW
10.2.1.3 No forced draft fan is running
10.2.1.4 No air heater is running
10.2.1.5 Total air flow is below the minimum value (two seconds’delay in action)
10.2.1.6 Water temperature is too high (from TE 052I) with no exhaust sustained for above six
seconds or the water temperature is not high (from TE 052I) but the furnace
temperature is abnormal or too high (above six seconds’delay)
10.2.1.7 Steam discharge is undone (six seconds’ delay in action)
10.2.1.8 Drum level is too low (two seconds’ delay)
10.2.1.9 Drum level is too high (60 seconds’ delay) and 12% higher than the MCR flow.
10.2.1.10 Non-biler water circulating pump is in operation and the tripping action is delayed two
seconds.
10.2.1.11 Furnace pressure is too low or too high
10.2.1.12 Air cooling pressure of the flame detector is too low (600 seconds’ delay)
10.2.1.13 Flame detector breaks down; the last burner is delayed 15 seconds after the purge and
storage are re-set or the entire detector breaks down.
10.2.1.14 Superheated steam pressure is too high (pressure switch) with six seconds’ delay in
action.
10.2.1.15 The air temperature of electric precipitation entrance is too high with this action delayed
two seconds.
10.2.1.16 The steam flow after the reflux starts is still greater than x1% before the reflux and only
one circulating pump is in operation after T1.
10.2.1.17 The steam flow when the reflux starts is still greater than x1% before the reflux and only
one circulating pump is in operation after t seconds (T1 + T2).
10.2.1.18 Only one emergency stop button is used.
10.2.1.19 When the reflux starts, control loop of at least one raw coal feeder is in a manual state.
10.2.2 The following processing procedures should be automatically done after the MFT action,
otherwise human intervention should be adopted:

2×300 MW
10.2.2.1 Cut off all fuel;
10.2.2.2 Pulverizer coal feeder and oil gun torch fully stop;
10.2.2.3 Fuel oil inlet solenoid valve is closed;
10.2.2.4 Pulverizing system fully stop;
10.2.2.5 Frontwall balance wind baffle plate and backwall balance wind baffle plate: A is 100%, B
is 20% and C is 0%.
10.2.2.6 Turbine trips and generator runs out of synchronization;
10.2.2.7 High voltage bypass and low voltage bypass starts up automatically.
10.2.3 Manual processing methods after MFT action
10.2.3.1 Confirm that the boiler main stop valve FSRUV04A automatically closes, or the manual
control should be employed to close the boiler main stop valve.
10.2.3.2 Confirm that the high voltage bypass rapidly starts up and automatically resumes to a
certain opening so as to maintain the pressure of 15 bar of the reheater. If the the high voltage
bypass does not start up, manual control should be applied to the hight voltage bypass so as to
make it start. The high voltage bypass is then returned to a proper opening after 15 seconds and
put in automatic control after the pressure of the reheater is set at 15 bar.
10.2.3.3 Attention should be paid to the drum water level. If the water level is too high, continuous
relief valve and stable relief valve can coordinate for water level regulation.
10.2.3.4 Attention should be paid to that the operation of the boiler water pump should be normal
and immediately suspended when there are abnormalities such as the shock, pressure difference,
etc.
10.2.3.5 Confirm that after the secondary air baffle plates are locked for one minute, all secondary
air baffle plates of the oil fuel burner should be in an opened state and the total air volume should
be maintained at 30% MCR; and the purge procedure (for 5 minutes) of the boiler framework is
then done.
10.2.3.6 If the reason of MFT action can not be identified or eliminated at the moment, the decision
of stopping the primary air fan, forced draft fan and induced draft fan should be promptly made and
the inlet baffle plates and the outlet baffle plates should be closed so as to maintain the boiler in a
standly heat state.

2×300 MW
10.2.3.7 Keep the air preheater, flame scanning cooling fan and cooling fan of oil
gun torch
running.
10.2.3.8 If the failure can be eliminated in a short time, the shift supervior after having received the
order of starting up the units should started up the units as soon as possible according to the boiler
stoppage duration and corresponding conditions so as to meet the demand of system load.
10.2.3.9 If the reason of MFT action is caused by the the primary air fan, forced
draft fan or induced draft fan, the boiler framework should be thoroughly purged
before re-ignition; all the primary air pipelines should be purged for 20 minutes before the
pulverized coal is supplied.
10.2.4 Emergency boiler shutdown
10.2.4.1 Any one of the following situations occurs, the “emergency boiler shutdown
button”
should be immediately pressed for boiler shutdown.
a) When in low-load operation, the combustion instability occurs and the boiler framework
pressure substantially fluctuates around ± 5mbar and the steam flow rapidly declines.
b) The safety valve has failure to operate even when boiler pressure exceeds the working
value of safety valve; meanwhile, the high voltage bypass valve and the
low voltage bypass valve and the non-atmospheric relief valve of reheater
are unable to start up automatically or manually.
c) When blast of the main feed water piping, main steam piping, water wall, economizer,
superheater and reheater occurs and endangers adjacent pipings.
d) When all the boiler water level gauges are damaged and unable to monitor water level.
e) When the boiler is overfed with water with the water level higher than +25 mm and MFT
has failure to operate.
f) When the boiler is short of water with the water level lower than -600 mm and MFT has
failure to operate.
g) When the combustibles reburn in the gas dust so that the flue gas temperature rises to
above 200℃ in an abnormal state.
h) When the first and secondary spray attemperators all have failure and
the steam temperature has drastic change and can not be controlled.
10.2.4.2 Treatment methods of “emergency boiler shutdown” are the same as that of “automatic
2×300 MW

2×300 MW
boiler shutdown”.
10.3 Shutdown Application of Boiler
If one of the following cases is met, one should ask for approval of the factory
director in charge and do the boiler shutdown in a normal manner after having received the
order from the shift supervisor:
10.3.1 When pressure retaining parts which have leakage are still able to operate.
10.3.2 When the heating surface of boiler has been scorched and normal operation can not be
maintained even some measures have been taken to deal with it.
10.3.3 When the quality of feed water or steam of the boiler has seriously worsened and normal
operation can not be maintained even efforts have been made for adjustment and treatment.
10.3.4 When the metal wall temperature of the heat absorption area has extremely exceeds the
allowable value and normal operation can not be resumed even great efforts have been made for
treatment.
10.3.5 When the enclosed cooling water source of cooler of the boiler water pump
motor is interrupted and the alternative water source can not be resumed immediately.
10.3.6 When the high voltage bypass after tripping can not be closed.
10.3.7 When the safety valve has defects, failure to operate or can not be reseated.
10.3.8 When main motors of two air preheaters have failure and can not be resumed in a short
time.
10.3.9 When the gas dust has serious deposition of ash and is unable to
maintain normal operation after much effort.
10.3.10 When chief supervisory meter has failure and is unable to maintain normal operation and
can not be resumed in a short time.
10.3.11 When the two electric precipitators have failure and normal operation
can not be maintained after much effort.
10.4 Boiler Abnormal Operation Parameter
10.4.1 High temperature of main steam
10.4.1.1 Faults

2×300 MW
a) Alarm is given due to “high temperature of main steam” (> 560℃);
b) If the heat absorption surface has leakage or explosion, steam temperature of various
sections before the breaking point drops and temperature of various working substances
after the breaking point increases.
10.4.1.2 Causes
a) The high pressure heater is out of operation and feed water temperature drops.
b) The attemperating water system has failure or automatic malfunction the

th t
attemperating water flow reduces abnormally.
c) Decrease of feed water pressure causes attemperating water flow reduction.
d) Gas duct in the rear part reburns.
e) Coal quality or combustion operating condition change.
f) The flame center of boiler framework moves upwards.
g) The heating surface has leakage and blast.
h) Air flow is too much.
i) Coal pulverizing system starts up.
j) The boiler framework is scorched.
10.4.1.3 Countermeasures
a) When water supply system and spray attemperating water system

have failure automatically, manual adjustment should be immediately adopted. The
systems are then put into operation after the steam temperature becomes stable.
b) When in soot blowing of boiler framework, the openings of the upper tertiary air baffle
plate and the lower tertiary air baffle plate should be regulated for
adjustment flame center. The openings of secondary air baffle plates of three rows of A,
B and C should be regulated when neccessary.
c) Adjust the air flow and maintain the best excess air coefficient. (That is, to maintain the
best oxygen content value).
d) Increase attemperating water flow and pay attention to relation between

the drum

2×300 MW
pressure and the main feed water piping pressure.
e) The high steam temperature is caused by leakage or blast of heating

surface, or the reburning of combustibles in gas duct and should be dealt with
according to the relevant provisions.
f) If the temperature of main steam keeps increasing after the above treatment measures
have been taken, the turbine should be adjust together with the boiler
according to relevant provisions. But the temperature of main steam should not
exceed the limit and the unit load can not drop too much.
g) When the temperature of main steam stop valve in front of the turbine reaches 566℃, the
turbine trip should be done.
10.4.2 Low temperature of main steam
10.4.2.1 Faults
a) Alarm is given due to “low temperature of main steam” (< 560℃);
b) Steam temperature of various sections drops and the steam piping has impact in severe
case.
10.4.2.2 Causes
a) The attemperating water system has failure or automatic malfunction so

that the attemperating water flow increases abnormally.
b) The feed water pressure increases abruptly so that the attemperating

water flow increases.
c) Coal pulverizing system is out of operation.
d) Fouling of heating surface area.
a) When the automatic adjustment is abnormal, manual adjustment should be immediately

adopted so as to resume the normal operation.
b) Reduce the attemperating water volume; close motor-operated valve if the

governor valve has serious leakage and then close hand-operated stop
valve in case of emergency.

2×300 MW
c) Soot blowing should be done to the superheater.
d) Timely regulate the air volume and lift the flame center.
e) If the temperature of main steam keeps decreasing after the above treatment measures
have been taken, treatment should then be done according to the turbine manual (when
the steam temperature drops to 510℃, the load of turbine should be properly reduced);
turbine trip should be done when the temperature of main steam drops to 450℃.
10.4.3 High temperature of reheated steam
10.4.3.1 Faults
a) Alarm is given due to “high temperature of reheated steam” (< 560℃);
b) Temperature at various points in the reheating system increases.
c) If the heating surface has leakage or explosion, temperature at various points before the
breaking point drops and temperature at various points after the
breaking point increases.
10.4.3.2 Causes
a) The attemperating water system of reheater has automatic malfunction so

that the attemperating water flow reduces;
b) Air flow is too much;
c) The flame center moves upwards;
d) The heating surface of water wall is not clean;
e) Fuel or fuel operating condition has changed;
f) The coal pulverizing system starts up.
a) When the attemperating system of reheater has failure automatically, manual adjustment
should be immediately adopted so as to ensure the reheated steam is in
a normal condition.
b) If the air volume is too much, the air volume should be properly
reduced and the combustion should be adjusted.

2×300 MW
c) Strengthen soot blowing of the heating surface of water wall and reduce temperture of
main steam when necessary.
d) If the leakage and explosion of heating surface of the reheater causes the
reheated steam temperature to increase, measures of temperature reduction
should be taken immediatedly and treatment should be done according to
corrsesponding provisions as well.
e) The openings of the upper tertiary air baffle plate and the lower tertiary air baffle plate
should be regulated so as to lower the flame center. The openings of secondary air baffle
plates of three rows of A, B and C should be regulated when neccessary.
f) If the temperature of reheated main steam keeps increasing after the above measures of
temperature reduction have been taken, the turbine should be adjusted together with the
boiler according to relevant provisions.
g) When the temperature of reheated main steam increases to 566℃, the turbine trip should
be done.
10.4.4 Low temperature of reheated steam
10.4.4.1 Faults
a) Alarm is given due to “low temperature of reheated steam” (< 520℃);
b) Temperature at various points in the reheater system decreases.
c) If the heating surface has leakage or explosion, temperature at various points before the
breaking point drops and temperature at various points after the
breaking point increases.
10.4.4.2 Causes
a) The attemperating water adjustment of reheater has malfunctions so

that the attemperating water flow of the reheater increases;
b) The flame kernel moves downwards;
c) The unit load is too low;
d) Fuel or fuel operating condition has changed;
e) The main steam stop valve of intermediate-pressure cylinder or high-pressure exhaust

check valve has failure on a single side so that the steam flow deviation between the left

2×300 MW
side and the right side is caused.
f) Safety valve of reheater outlet operates or the outlet section has leakage or explosion.
g) The coal pulverizing system shuts down.
h) Fouling of heating surface area of reheater..
a) When the automatic adjustment of attemperating water of reheater is abnormal, manual

adjustment should be immediately adopted so as to resume the normal operation. The
motor-operated valve should be closed when necessary and the hand-operated
valve should then be closed if the leak volume is too much.
b) If the air volume is too much, the air volume should be properly increased.
c) Regulate the openings of secondary air baffle plates of three rows of A, B and C and the
openings of the upper tertiary air baffle plate and the lower tertiary air baffle plate; lift the
position of flame center.
d) Strengthen soot blowing of the heating surface of the reheater.
e) The turbine load should be reduced according to provisions when the reheated steam
temperature continues to decrease to 510℃.
f) When the temperature of reheated steam continues to decrease to 450℃, the turbine trip
should be done.
10.5 Load Rejection of Unit
Under one of the following cases, the boiler will automatically reduce load.
10.5.1 If one set of induced draft fan trips, the load reduces to 50% MCR.
10.5.2 If one set of forced draft fan trips, the load reduces to 50% MCR.
10.5.3 If one set of primary fan trips, the load reduces to 50% MCR.
10.5.4 If one set of air preheater trips, the load reduces to 50% MCR.
10.5.5 If one set of boiler water pump trips and the standby water pump can not be interlocked, the
load reduces to 60% MCR.
10.5.6 If one set of feedwater pump trips and the standby pump can not be interlocked, the load

2×300 MW
reduces to 60% MCR.
10.5.7 If the turbine trips, the boiler load reduces to 70% MCR.
10.5.8 If operating with auxiliary power, the boiler load reduces to 70% MCR.
10.6 Auxiliary Power Supply Interruption
10.6.1 Faults
10.6.1.1 Turbine trips and the boiler MFT action is done.
10.6.1.2 All running machines trip.
10.6.1.3 Each motor-operated valve stays at the place before power interruption.
10.6.1.4 Pressure of main steam, steam temperature and flow all decrease.
10.6.2 Countermeasures
10.6.2.1 Ensure that DC fan of the flame scanner is in operation and DC motor of air preheater
starts up.
10.6.2.2 Ensure that the TV water level gauge and flame TV of boiler framework are in operation.
10.6.2.3 Check and ensure that emergency drain three-way valve FV003 of boiler water
pump should automatically open and outlet valve of boiler water pump should be closed by hand
when the temperature of motor chamber of boiler water pump keeps on a rise.
10.6.2.4 The seal fan should starts up after the diesel-engine generator operates.
10.6.2.5 If the boiler is treated with soot blowing when auxiliary power interrupts,
immediate maintenance should be done and the soot blowing gun should be withdrawn.
10.6.2.6 The following steps should be done after the power supply is restored.
a) Make up water for the drum to the level of -100mm.
b) Start up the boiler water pump after the closed cooling water system resumes normal
operation.
c) Start up the main motor of air preheater.
d) Start up the AC cooling fan of flame scanner and stop the DC cooling fan
and then conduct the “interlocking”.

2×300 MW
e) Start up the cooling fan of oil gun torch and conduct the “interlocking”.
f) Check and ensure that vaious motor-operated valves and regulating

valves of attemperating water are at the closing position; open the
recirculation valve of economizer.
g) Start up the lubricating oil system of coal mill.
10.6.2.7 Confirm emergency water tanks and supply water to following equipment
when the closed cooling water system interrupts.
a) Supply low-pressure cooling water to boiler water pump.
b) Supply cooling water to bearings of auxiliary equipment.
c) Supply cooling water to various oil coolers.
10.7 Control&Instrument and Apparatus Power Supply Interruption
10.7.1 Faults
10.7.1.1 General power of thermal regulator and instrument lose.
10.7.1.2 After the general power loss alarm signal of thermal regulator and instrument is given, the
power indicator of instrument turns off and the alarm is warning.
10.7.1.3 Survey meters and digital instruments have failure to display. Transmitter of automatic
control device loses power; the indicator turns off; relevant meters indicate zero and automatic
device has failure.
10.7.1.4 The secondary instrument instruction disorders on CRT graphic display.
10.7.1.5 Automatic protection limit device has power failure and the limit
protection has malfunction; the regulator (regulating device) has power failure and
automatically shuts down when in automatic operation.
10.7.1.6 Remote control of equipment on CRT graphic display has failure and the water level can
not be controlled.
10.7.1.7 The rotating speed of coal feeder indicates zero.
10.7.1.8 Unit operation is instable or even has fire-off and tripping.
10.7.2 Causes

2×300 MW
10.7.2.1 Electrical system or power bus has failure.
10.7.2.2 Switch or knife switch has failure and standby power fails to do automatic operation.
10.7.2.3 UPS power loses.
10.7.3.1 If boiler has not fired off and the unit has not tripped when the thermal
regulator and instruments lose power, various control equipment and systems should be
switched to manual control and stably operate in the original operating condition.
Strengthen the supervision and inspection of instruments on the spot and ensure the
unit stable load as much as possible. If operation of corresponding valves and baffles is
required, the manual operation can only be done after the contact work inside and outside the
control room is well done.
10.7.3.2 Ensure the boiler framework stable combustion, supervise the primary meters, strengthen
contact and emphasize on operation analysis referring to other relevant parameters without blind
operation. Send personnel to monitor all water levels and make sure that the water
levels are controlled in a normal range and strictly prevent accidents of overfeeding or short
supply of boiler and water impact of turbine.
10.7.3.3 Inform relevant personnel for thermal regulation and quickly restore control
power of instruments.
10.7.3.4 If the instrument power fails to timely be restored which threatens the
unit safety operation, report should be made to the shift supervisor and the instruments shall shut
down due
to failure.
10.7.3.5 If the protection is caused by loss of power of instruments or total power loss of boiler,
turbine thermal regulator and instruments has met the conditions of emergency
shutdown, treatment should be done according to emergency shutdown.
10.7.3.6 If the boiler has fire-off, treatment should be done according to provisions for fire-off.
10.7.3.7 Make reports to group chief and shift supervisor after the unit shuts down; reignite and
start up the unit in thermal condition according to instructions of the shift supervisor
after the thermal regulator and instrument are done with energization.
10.8 Fire Accident
10.8.1 Countermeasures for fire catching of the oil system.
10.8.1.1 If fire catching is found in the oil system, dry fire extinguisher or foam fire extinguisher
2×300 MW

2×300 MW
should be instantly adopted for fire-fighting and report should be made to the shift supervisor to
promptly notify the firefighters to extinguish fire.
10.8.1.2 If the fire has not yet threatened the unit operation, measures should be taken to prevent
fire spread and put it out as soon as possible.
10.8.1.3 Move away combustibles around the fire spot and cut off power supply of
electrical equipment on the spot.
10.8.1.4 Strengthen the operation supervision and prepare for shut-down.
10.8.1.5 Attention should be paid to that the fire shall not spread around the spot
and wetted fire-retardant materials should be covered around the equipment when necessary
(pay attention to the rotating parts of the unit). Report should be instantly made to the shift
supervisor for shutdown when the fire threatens the unit safety.
10.8.1.6 If the fire threatens the safety of main oil tank, emergency shutdown should be done; start
up the emergency oil relieve valve (ensuring the lubricating oil supply is not interrupted before the
turbine stops) when the rotating speed of turbine decreases.
10.8.2 Fire catching of pulverized coal pipeline
10.8.2.1 Causes
a) The primary air pipeline is worn and has pulverized coal leakage to the extent of heat
insulation and has spontaneous combustion and fire-catching.
b) The pulverized coal pipeline is blocked and is not cleared up in time.
a) Stop the corresponding coal pulverizing system and shut-off valve of coal mill outlet in
accordance with specific conditions and extinguish fire with foam or fire-fighting water.
b) When fire catching occurs due to incomplete block off of pulverized

coal pipeline, personnel for locomotive maintenance should be contacted for
purging of primary air pipeline and corresponding treatment.
10.8.3 Notice items of fire extinguishing
10.8.3.1 If clothes which are not immersed in kerosene, diesel, petrol and other oils and wooden
materials catch fire, foam fire extinguisher, water and sand should be employed for fire fighting.

2×300 MW
10.8.3.2 If oil tanks or oil in other containers catches fire, oil should be discharged
from the
emergency oil relieve valve and foam fire extinguisher or wetted raincloth could be used for fire
fighting.
10.8.3.3 If the energized equipment catches fire, fire fighting should be done after the electricity is
cut off; sand and foam fire extinguisher should not be used for fire fighting when the motor catches
fire.
10.8.3.4 If found fuming, the motor should be promptly stopped running and the shift supervisor
and chief supervisor should be informed of the situation.
10.8.3.5 Observe relevant provisions of Specification for Fire Protection of Electric

Power
Installation during fire fighting.
10.9 Processing Inferior Quality of Water and Steam
10.9.1 Processing value of abnormal water quality of condensate
Standard Processing value

Items
value Stage I Stage II Stage III
With mixed
Electric ≤0.30 030~0.40 0.40~0.65 >0.65
bed
conductivity
(S/cm) Without
≤0.20 0.20~0.35 0.35~0.60 >0.60
mixed bed
With mixed
≤2.0 >2.0 >5.0 >20.0
Hardness bed
(mol/l) Without
≈0 >2.0 - -
mixed bed
Note: emergency shutdown should be done when sodium content in condensate is

more than
400g/l.
10. 9.2 Processing value of abnormal water quality of boiler feedwater
Items Standard Processing value

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value Stage I Stage I Stage I
Electric conductivity (S/cm) ≤0.30 030~0.40 0.40~0.65 >0.65
Dissolved oxygen (g/l) ≤7 >7 >20 -
<8.8 or
pH(25℃) 8.8~9.3 - -
>9.3
10.9.3 Processing value of abnormal water quality of boiler water
Standard Processing value

Items
value Stage I Stage I Stage I
pH(25℃) 9~10 9~8.5 8.5~8.0 <8.0
Note: contents of chloridion and sodium, electric conductivity and alkalinity should
also be measured.
Definition of above processing values of three stages:
Processing value of Stage I: the possibility that corrosion, scaling and salt
deposition are caused by impurities may be existed and the standard value should be resumed
within 72 hours.
Processing value of Stage II: the possibility that corrosion, scaling and salt
deposition are caused by impurities is surely existed and the standard value should be resumed
within 24 hours.
Processing value of Stage III: the corrosion, scaling and salt deposition are forming in a fast
way and the boiler should be shut down within four hours.
During each stage of abnormal processing, if the standard value fails to be resumed within the
required time, processing method of a higher level should be employed and one of the methods to
restore the standard value of water quality is to operate under lower pressure.
10.9.4 Principles of processing for abnormal water steam quality of unit
10.9.4.1 Promptly inspect whether the sampling is representative or not, whether

the testing equipment is in normal condition and whether the test results are correct when the
water steam quality degrades. Comprehensively analyze the change of water and steam quality
in the system and make reports to the chief engineer for the situation after correct confirmation
and judgement and take measures to ensure that the standard value of the water steam quality is
surely resumed within the allowable time.
2×300 MW

2×300 MW
10.9.4.2 When each items of water steam quality reach the processing value of Stage I and the
possibility that corrosion, scaling and salt deposition are caused by impurities may be existed and
the standard value should be resumed within 72 hours.
10.9.4.3 When each items of water steam quality reach the processing value of Stage II and the
possibility that corrosion, scaling and salt deposition are caused by impurities is surely existed and
the standard value should be resumed within 24 hours.
10.9.4.4 When each items of water steam quality reach the processing value of Stage III and the
corrosion, scaling and salt deposition are forming in a fast way and the boiler should be shut down
within four hours if the water quality is still in bad condition.
10.9.4.5 One of the methods to restore the standard value of boiler water quality is to operate
under lower pressure.
10.9.4.6 During each stage of abnormal processing, if the standard value fails to be
resumed within the required time, processing method of a higher level should be employed.
10.10 Boiler Heating Surface Slagging Seriously
10.10.1 Faults
10.10.1.1 When the water wall is scorched, the temperature of main steam and reheated steam
will have an abnormal increase.
10.10.1.2 When the heating surfaces of the superheater and the reheater are
scorched, the temperature of main steam and reheated steam will have an abnormal decrease.
10.10.1.3 The flue gas temperature has an abnormal increase.
10.10.1.4 When the coke slag is shedding, much change will occurs in the boiler
framework pressure, which will impact the stability of combustion.
10.10.2 Causes
10.10.2.1 Low ash melting point in coal combustion;
10.10.2.2 Deflection of flame center during combustion;
10.10.2.3 Overload operation of the boiler for a long time.
10.10.3.1 Adjust the combustion operating condition and properly lower the flame center in order

2×300 MW
not to cause deflection of the flame center;
10.10.3.2 Decrease the flue gas temperature deviation of boiler framework outlet and lower the
temperature of boiler framework outlet;
10.10.3.3 Properly strengthen the soot blowing;
10.10.3.4 Select coal with relatively high ash melting point and conduct according to
specific combustion measures of corresponding coal type when the coal type alternation is
unavailable;
10.10.3.5 Properly reduce the boiler operation load and strengthen the disturbance in the boiler;
10.10.3.6 Strengthen the monitoring for coking performance in the boiler.
10.11 Gas Duct Reburning
10.11.1 Faults
10.11.1.1 Flue gas pressure has a sharp increase in the gas dust;
10.11.1.2 Negative pressure in the gas dust decreases;
10.11.1.3 Flue gas exhausts in the clearance of valves and holes of the gas dust;
10.11.1.4 Fire alarm is given when the recombustion occurs in the air preheater.
10.11.2 Causes
10.11.2.1 Due to long-term application of coarse pulverized coal or improper ratio of air/coal, the
incompletely-burned pulverized coal deposits in the gas duct.
10.11.2.2 Improper operation and adjustment or long-term upward moving of the flame
center causes the incompletely-burned pulverized coal to enter the gas duct.
10.11.2.3 Feed pulverized coal in advance during the start-up.
10.11.2.4 Long-term operation under low load, relatively low temperature of boiler framework or
the relatively small excess air coefficient worsen the combustion and cause a
great deal of combustibles to burn in the gas dust.
10.11.2.5 No purging is done to the boiler framework according to provisions after boiler shutdown.
10.11.3.1 Adjust combustion when the abnormal increase of temperature is found in the gas duct
and instantly conduct the soot blowing with soot blowing gun in the duct.

2×300 MW
10.11.3.2 Make reports to the shift supervisor and do the emergency boiler shutdown if abnormal
increase of temperature in the gas duct or flue gas still occurs after some measures have been
taken.
10.11.3.3 The primary air fan, forced draft fan and induced draft fan should be instantly stopped
after boiler shutdown and all the air valves and baffle plates should be closed for enclosement.
10.11.3.4 The following measures should be taken when the fire catching of preheater occurs:
a) Ask instructions from the shift supervisor and conduct the emergency boiler shutdown.
b) Stop all the primary air fans, forced draft fans, induced draft fans and steam air heaters.
c) Close the air baffle plate and flue gas baffle plates of the air preheater.
d) Open the inspection hole of the lower ash hopper of the air preheater.
e) Instantly put the fire-fighting water device of air preheater into operation for fire fighting.
f) Inspect the water discharge condition of ash hopper of air preheater and timely smoothen
the air hopper so as to prevent the ash hopper collapse.
g) The fire-fighting water supply can only be stopped after the fire completely extinguishes
and the flue gas temperature decreases to a normal value.
h) Water washing should be done to the air preheater if the ash deposition is serious and
the air preheater should be dried with the steam air heater after water washing.
10.11.3.5 Slowly and carefully open the inspection hole for inspection and start up the induced
draft fan only after no fire sources is ensured.
10.11.3.6 Ignition and start-up can only be done after the equipment is checked and ensured no
abnormality and the instruction from the shift supervisor is received.
10.12 Unit Trip
10.12.1 Faults
10.12.1.1 Main steam pressure is rapidly increased, high and low pressure bypass
valves are automatically and swiftly open.
10.12.1.2 Main steam flow is swiftly dropped, high and low pressure bypass valves
return 15
seconds after opening.
10.12.1.3 Reheat steam pressure is rapidly increased and reheater exhaust valve is automatically

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opened.
10.12.1.4 Water level of drum is low before it gets high.
10.12.1.5 Main steam temperature and reheat steam temperature tend to be high before it drops
low.
10.12.1.6 After turbine trips, if low pressure bypass functions abnormally or

is adjusted inappropriately, safety valve of reheater or of drum will start operating.
10.12.1.7 When main steam flow is under 420T/H with oil gun still unused, all coal feeders will trip
and boiler MFT will start operating.
10.12.1.8 When low pressure bypass fails and closes down, reheater exhaust valve
remains closed, boiler MFT will starts operating.
10.12.2.1 Boiler load is automatically dropped to 70%MCR, or make it happen by hand.
10.12.2.2 High and low pressure bypass valves should be swiftly opened or have it opened by
hand.
10.12.2.3 Make sure that exhaust valve of reheater is automatically opened, or open it by hand.
10.12.2.4 Before the oil gun is put into use, stabilize the load above 420T/H to avoid boiler MFT
operation.
10.12.2.5 When the number of oil gun put into use exceeds 4 according to rules, gradually stop the
pulverized coal feeder that has not yet been provided with oil guns and lower oil load to avoid
closing low pressure bypass because of low vacuum in turbine.
10.12.2.6 Properly lower main steam pressure fixed value.
10.12.2.7 When main steam pressure drops, place high pressure bypass under
automatic or manual position to avoid the tripping of boiler because of the closure of
high pressure bypass valve.
10.12.2.8 Attention should be paid to drum water level, when water feeding can
not work automatically, switch to manual regulation.
10.12.2.9 Maintain the superheat steam temperature and reheat steam temperature at above 500
DEG C, attention should be paid to desuperheater water to make sure that it is normal; if not,

2×300 MW
control it manually.
10.12.2.10 If tripping of turbine can not be swiftly restored, boiler combustion

should be maintained and MFT operation be avoided.
10.13 Steam Drum Full Feeded
10.13.1 Faults
10.13.1.1 When “water level height” reaches +25mm, alarm should be sounded, but if 10 seconds
later, water level remains at the same level, operate MFT.
10.13.1.2 Water level of TV water level gauge and local water level gauge is too high to be seen.
10.13.1.3 Feedwater flow is abnormally greater than main steam flow.
10.13.1.4 Steam gas temperature is rapidly dropped, main throttle valve flange emits white vapor,
when it is serious, “water hammer” will take place as a result.
10.13.1.5 Superheat steam gas conductivity is high.
10.13.2 Causes
10.13.2.1 Feedwater automatic regulation fails to work;
10.13.2.2 Errors caused by falseness of water level indication or relaxing of

water level surveillance;
10.13.2.3 Boiler load is low and feedwater regulating valve leaks too much;
10.13.2.4 Load or steam pressure fluctuation is too great;
10.13.2.5 Sudden opening of high pressure bypass or operating of drum safety valve;
10.13.2.6 All furnace water pumps trip;
10.13.2.7 When water level is in the form of “default”, its setting value is too high;
10.13.3.1 When water level reach -75mm and high water level signal has been sent out, feedwater
regulating should be immediately switched to manual status and feedwater flow
should be diminished, if necessary, stable relief valve and continuous relief valve
should be coordinately regulated until drum water level returns to normal.
10.13.3.2 When feedwater regulating valve leaks too much, load should be increased properly, if

2×300 MW
necessary to maintain normal water level.
10.13.3.3 When water regulation and meter indication are inaccurate, thermal engineering experts
should be immediately sent for.
10.13.3.4 During operation, surveillance of drum water level and checking of local
water level gauge should be reinforced, and mistakes should be avoided.
10.13.3.5 Desuperheater water should be disconnected according to steam temperature,

and drainage in superheater and main steam valve should be started.
10.13.3.6 After MFT is operated, address problems according to methods following the operation
of MFT.
10.13.3.7 After the above measures have been taken, if drum water level still rises to pass +25mm,
while MFT is still out of operation, the following emergency measures should be taken:
a) Press “emergency shut down” button;
b) Stop feed (water) pump and make sure that the recirculating valve of coal economizer
has been opened;
c) Make sure that main steam valve is closed;
d) Open all drains of superheater system and main steam drain of turbine as well;
e) Make sure that all desuperheater water valves have been closed;
f) Water discharging should be reinforced until drum water level is seeable;
g) When overflow has been ruled out and drum water level have returned to normal, boiler
will not be restarted until shift supervisor have agreed to do so;
10.14 Steam Drum Short Feeded
10.14.1 Faults
10.14.1.1 Water levels shown in TV and local water level gauges are too low to be seen.
10.14.1.2 “Drum water level” keeps dropping after alarm is sounded when it drops to -415mm, and
when it drops to -600mm, if 10 seconds after the “drumwater level record low” alarm have sounded,
it remains at the same level, MFT should be operated.
10.14.1.3 Feedwater flow is abnormally less than steam flow (the other way round is true of coal
economizer and water cooled wall leakage).

2×300 MW
10.14.1.4 When water shortage is serious, pressure difference of furnace water pump is low and it
shakes.
10.14.2 Causes
10.14.2.1 Feed water control malfunction and feed (water) pump failure result in the decrease of
water allowance or water main pressure becoming too low.
10.14.2.2 Falseness of water level indication results in operation that is wrong.
10.14.2.3 Feed water line leaks too much.
10.14.2.4 Leakage and mis-operation of blow down valve or pollution discharge

contact is inappropriate.
10.14.2.5 Cracking of water wall tube or economizer tube.
10.14.2.6 Load fluctuation is too great.
10.14.2.7 Opening indication of feedwater-regulating valve fall short of actual opening.
10.14.2.8 Feedwater electrically operated valve mis-close or feedwater regulating valve panel falls
off.
10.14.3.1 When water level is (-415mm) with furnace water pump operating normally and alarm is
sounded, feedwater regulation should be immediately switched to manual status, and more water
should be pumped into boiler to return drum water level to a normal level.
10.14.3.2 All drainage operation should be stopped.
10.14.3.3 Attention should be paid to changes of main steam temperature in the process of water
inflow.
10.14.3.4 When the above measures have been taken, water level keep dropping to -600mm at
which MFT begins to operate in 10 seconds, if not, the following measures should be taken.
a) Press “emergency shut down” button
b) Stop the operation of furnace water pump, feed boiler with water when drum water level
is lower than visible water level. If regulating valve panel falls off, furnace water pump
should be immediately stopped, boiler be fully closed, electric unit be notified
to stop furnace water pump power supply, and at the same time, furnace water pump
should be

2×300 MW
closed off and attention paid to drum wall temperature changes.
c) Reasons for water shortage should be identified and it should be properly solved, boiler
can not be restarted until orders to do so have been authorized by shift supervisor.
d) Water inflow time and speed of water-empty boiler should be decided by

director in charge who will issue the order.
10.15 Priming
10.15.1 Faults
10.15.1.1Drumwater level drastically fluctuates and water level inside water level gauge is unclear;
10.15.1.2 Feedwater self regulation is unsound;
10.15.1.3 Main steam temperature is dropped and steam conductivity is increased,

when it is serious, water slug will take place inside the main steam pipes.
10.15.2 Causes
10.15.2. Quality of feedwater or boiler water is unqualified;
10.15.2.2 Boiler load drastically drops or steam pressure drastically drops;
10.15.2.3 Oil entering into the steam system.
10.15.3.1 Report to shift supervisor, decrease and stabilize boiler load;
10.15.3.2 Open continuous relief valve, intensify stable relief valve, and lower the drum water level
to -50mm;
10.15.3.4 Chemist should be notified to stop adding drugs and increase boiler water laboratory
test.
10.16 High Furnace Pressure
10.16.1 Faults
10.16.1.1 “Furnace pressure high I value” alarm sounds;
10.16.1.2 Indication of furnace draft meter skews positively;
10.16.1.3 Fume is emitted from leaking zone of furnace;

2×300 MW
10.16.1.4 When “furnace pressure high II value” alarm sounds, MFT will take place.
10.16.2 Causes
10.16.2.1 Force fan can not track and check in time after single induced fan fails and trips;
10.16.2.2Automatic device of furnace draft fails;
10.16.2.3 Suction guide and outlet damper of induced fan or smoke damper of gas
dust are mis-closed;
10.16.2.4 Combustion operation conditions deteriorate;
10.16.2.5 Pressure-bearing members inside furnace have been seriously burst.
10.16.3.1 Guide vane of induced fan should be switched to manual status and its opening should
be regulated to maintain the furnace negative pressure at a normal level;
10.16.3.2 Baffle plate that has been mis-closed should be restored to its original state in time;
10.16.3.3 When furnace pressure is high and MFT starts, problem should be addressed according
to relevant rules followed by the resolution of the operation of MFT.
10.17 Low Furnace Pressure
10.17.1 Faults
10.17.1.1 “Furnace pressure low” alarm sounds;
10.17.1.2 Indication of furnace pressure meter is increased in the direction of minus value;
10.17.1.3 When “furnace pressure low II value” alarm window sound the alarm, MFT
will take place.
10.17.2 Causes
10.17.2.1 Induced fan can not track and check in time when single force fan fails and trips;
10.17.2.2 Furnace draft self regulation fails to work;
10.17.2.3 Inlet movable vane and outlet damper of force fan and air duct baffle
plates are mis-closed;
10.17.2.4 Assisted wind regulating baffle plate fails or is mis-closed;

2×300 MW
10.17.2.5 Boiler combustion working condition deteriorates or boiler fire goes out.
10.17.3 Countermeasures:
10.17.3.1 Flushing should be burned steadily by adding oil;
10.17.3.2 Regulate the opening of induced fan suction guide; maintain the furnace
draft at a normal level;
10.17.3.3 When draft self regulation fails, manual regulating should be switched on;
10.17.3.4 Return baffle that has been mis-closed to its original state;
10.17.3.5 When “furnace pressure low II value” alarm window sounds the alarm, operate
MFT
according to MFT relevant rules.
10.18 Boiler Burning Out
10.18.1 Faults
10.18.1.1 Furnace pressure suddenly drops on a large scope, and primary and secondary wind
pressures drop simultaneously;
10.18.1.2 “Furnace losing flames” alarm sounds;
10.18.1.3 Flame detector shows no sigh of flame;
10.18.1.4 Flame check of burner at all levels all disappears;
10.18.1.5 MFT operates;
10.18.1.6 Steam temperature, steam pressure and main steam flow rapidly drop;
10.18.1.7 Water level goes down before it goes up.
10.18.2 Causes:
10.18.2.1 Failure and tripping of force fan, induced fan and primary fan, etc. or operation of boiler
tripping protection;
10.18.2.2 When load is low, mixture ratio of wind and coal is seriously maladjusted;
10.18.2.3 When load is low, coal quality become worse and coal powder become thick, resulting in
the deterioration of burning working condition;
10.18.2.4 Oil is not put in to stabilize burning when the combustion is unstable;

2×300 MW
10.18.2.5 Operational manner of burner is inappropriate;
10.18.2.6 When load is low, flame is blown out by furnace soot-blowing and water wall tube blast
or furnace draft is too great;
10.18.2.7 Water wall does not soot-blow, resulting in the falling of coke on a large acreage;
10.18.2.8 Oil system fails or oil-receiving electromagnetic valve is mis-closed when oil is burning;
10.18.2.9 House supply interrupts or MFT mis-operate.
10.18.3 Countermeasures:
10.18.3.1 Problems should be addressed according to relevant rules followed by the resolution of
the operation of MFT;
10.18.3.2 After causes are identified and removed, start induced and force fan with over 30% that
of air volume blowing furnace for 5 minutes, after that, reignite the furnace;
10.18.3.3 After fire is extinguished, the lifting of fire-extinguishing protection is banned and igniting
by deflagration is adopted.
10.19 Fuel Trip
10.19.1 Faults
10.19.1.1 Send out signal alarm to prompt ‘total loss of fuels’.
10.19.1.2 MFT happens to the boil.
10.19.1.3 All pulverizing systems trip and fuel oil supply is stopped.
10.19.1.4 No flame is shown in flame scanner of the furnace.
10.19.2 Causes
10.19.2.1 Coal in all coal silos is run out of.
10.19.2.2 All pulverizing systems trip.
10.19.2.3 Trouble happens to oil system during combustion or oil intake electromagnetic valve is
closed by mistake.
10.19.3.1 Eliminate the trouble according to MFT troubleshooting.

2×300 MW
10.19.3.2 Find out the reason and recover operation as soon as possible.
10.20 Water Wall Tubes Txplosion
10.20.1 Faults
10.20.1.1 Steam pressure is down and water level in drum is dropped.
10.20.1.2 Negative pressure in furnace is reduced or turns to positive pressure.
10.20.1.3 The opening of baffle plates at the entrance to the induced draft fan is
abnormally increased.
10.20.1.4 Smoke comes out from the part where the sealing is not good in the furnace.
10.20.1.5 Steam ejection sound or explosion is heard from the furnace.
10.20.1.6 Water supply is abnormally larger than the steam flow.
10.20.1.7 The combustion is not stable and even may go out.
10.20.1.8 The flue temperature is dropped.
10.20.2 Causes
10.20.2.1 Poor quality of furnace water, which causes serious scale formation in pipelines.
10.20.2.2 The entrance orifice of water wall is blocked, which causes bad water circulation.
10.20.2.3 Serious coking in water wall, which causes uneven heat exposure.
10.20.2.4 Flame deflection, which causes uneven heat exposure in local water wall.
10.20.2.5 Water wall is damaged by large dropping lump coke.
10.20.2.6 Bad welding of water walls.
10.20.2.7 Serious sulfur corrosion.
10.20.3.1 If there is leakage happening to water wall but the water in the drum can be kept at a
normal level, short run operation in proper reduced load is permissible, but the chief attendant
should inform a factory director and ask for arrangement of boiler shut down which should be done
according to regular shut down procedures.
10.20.3.2 If the water wall is seriously damaged and the water in steam drum is not kept at a

2×300 MW
normal level, the following measurements should be conducted.
10.20.3.3 Press ‘emergency shut down’ to stop the furnace quickly.
10.20.3.4 After the boiler is shut down, the induced draft fan should be kept
running and the furnace kept at a negative pressure. Stop the induced draft fan and change
the ventilation into natural ventilation when it is considered to be proper and keep the furnace at
a negative pressure
to emit flue and steam inside.
10.20.3.5 Continue supplying water to the furnace to maintain the water level of the drum; close
static-row and link-row motor-operated valve and hand-operated valve.
10.20.3.6 If the leakage of the water wall is extremely serious, and the water level in the drum can
not be kept after the furnace is stopped, the furnace water pump and feed water pump should be
stopped as well as recirculation valve of economizer.
10.20.3.7 The economizer should be received enough care and ashes

deposited in the economizer and the ash hopper of the air preheater should be
cleared up timely to prevent accidents of ash hopper and flue duct collapse caused by ash
deposit.
10.21 Economizer Tubes Explosion
10.21.1 Faults
10.21.1.1 Water level in drum is dropped.
10.21.1.3 Abnormal noise is heard at economizer part.
10.21.1.4 Ash hopper at the lower part of economizer is blocked by wet ash or ash water is leaked
from the ash hopper.
10.21.1.5 Flue temperature at the water leakage side is dropped.
10.21.1.6 There exists great difference of flue temperature at A side and B side of the entrance of
the air preheater.
10.21.1.7 The opening of baffle plates at the entrance to the induced draft fan is increased.
10.21.2 Causes
10.21.2.1 Poor quality of feed water, which causes serious scale formation in pipelines and to burn
tube.
2×300 MW

2×300 MW
10.21.2.2 It is worn by flying ash.
10.21.2.3 The recirculation valve of economizer is not operated according to provisions in boiler
starting or shutdown.
10.21.2.4 The tube is blocked when installation or maintenance.
10.21.2.5 Poor quality of tube or welding.
10.21.3.1 Increase water supply to keep the water level in the drum.
10.21.3.2 Operate it at a lower load and pressure and ask for factory director to decide the boiler
shut down time.
10.21.3.3 If the water level is not kept at a normal level after water supply increasing, stop the
boiler immediately with the approval of the chief attendant.
10.21.3.4 Try to keep the water level in drum as possible after the boiler shut down and close
continuous drainage valve and regular drainage valve, hand-operated valve and
recirculation valve of economizer.

deposit.
10.22 Superheater Tubes Explosion
10.22.1 Faults
10.22.1.1 Main steam pressure is dropped.
10.22.1.3 The negative pressure in the furnace turns positive and pressure in
flue duct is increased; steam is ejected from the part where the sealing is not good in the flue
tube.
10.22.1.4 Abnormal noise is heard at the leakage of superheater.
10.22.1.5 Flue temperature at the leakage side is dropped.
10.22.1.6 If roof tube, wall enclosure tube or low over leakage cause high over and medium over
steam temperature rising, and if the medium over and high over leak, the main steam temperature
rises.
2×300 MW

2×300 MW
10.22.1.7 Large steam temperature difference between the two sides.
10.22.2 Causes
10.22.2.1 Steam quality is deteriorated in the long run and scale formation in the tube causes over
heat on the tube wall.
10.22.2.2 Over heat or coking happens frequently in superheater.
10.22.2.3 It is seriously worn by flying ash.
10.22.2.4 Recombustion happens to some section of superheater.
10.22.2.5 Ash gun is wrongly installed or trouble comes up during operation and the gun is broken.
10.22.2.6 The tube is not qualified or the welding quality is poor.
10.22.3.1 When the over heater tube leaks, reduce load and pressure for operation and ask for
factory director to arrange to shut down the boiler.
10.22.3.2 If the superheater tube is seriously damaged, it should prevent the worsening of any
accident.
a negative pressure

deposit.
10.23 Reheater Tubes Explosion
10.23.1 Faults
10.23.1.1 The pressure at the outlet of reheater is dropped.
10.23.1.2 Main steam flow is increased.

2×300 MW

2×300 MW
10.23.1.3 Abnormal noise is heard nearby the reheater and when explosion, the negative pressure
in the furnace turns to positive and even steam or flue is ejected from the part where the sealing is
not good in the furnace or flue duct in serious case.
10.23.1.5 The steam temperature difference at the two sides of the reheater is large
and the temperature at the trouble side rises.
10.23.2 Causes
10.23.2.1 The steam quality is poor, which causes scale formation inside or maintenance of the
furnace after shutdown is done improperly, which corrodes the reheater tube.
10.23.2.3 It is worn by flying ash.
10.23.2.4 Poor quality of tube or welding.
10.23.2.5 The furnace temperature is not controlled strictly during operation and steam supplying
protection to the reheater is not sufficient during starting and shutdown.
10.23.3.1 If the reheater tube is not seriously damaged, operate it in a lower load and ask for the
factory director to arrange boiler shut down.
10.23.3.2 If the reheater tube is seriously damaged, do emergency shutdown after consent of the
chief attendant.
a negative pressure
10.24 The Break of Steam Pipes or Feedwater Pipes Outside the Boiler
10.24.1 Faults
10.24.1.1 Humility, water seepage or water leakage or steam leakage in damaged part. And even
leakage noise is heard.
10.24.1.2 Loud noise is heard when the pipe is explodes and steam and water are ejected and
supports and hangers may be damaged.

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10.24.1.3 Steam or feed water pressure and the flow change are abnormal.
10.24.2 Causes
10.24.2.1 Poor material quality and unqualified fabrication, installation and welding, which affect
free expansion.
10.24.2.2 Long run operation under over pressure and over heat conditions.
Local wall of wearable parts (such as parts near elbow and porous plate) get thin, which lower
metal strength.
10.24.2.3 Pipe heating and water drainage are not sufficient during boiler ignition process, which
causes serious water impact.
10.24.2.4 Unqualified feed water quality, which causes pipe wall corrosion.
10.24.2.5 Dramatic changes of media flow, temperature and pressure happen during operation,
which causes fatigue and damage to the duct.
10.24.3.1 If the pipe is not severely damaged and is capable of supporting the normal operation
and will not worsen the troubles:
1) Adjust various parameters of the boiler, properly reduces the load to keep the normal operation
and report to chief attendant and apply for boiler shutdown.
2) Provide security measurement around the damaged part and prevent steam or
water from hurting personnel.
3) Pay close attention to the damaged parts and precast any accident that may happen.
10.24.3.2 Immediately stop the boiler in any emergency case that the severely damaged pipe or
trouble may cause accident.
10.24.3.3 Separate the damaged pipe section from the system as soon as possible after the boiler
shut down.
10.25 High Steam Drum Pressure
10.25.1 Faults
10.25.1.1 High pressure indicated in the pressure gauge of the drum.
10.25.1.2 High pressure indicated in superheat steam pressure gauge. Alarm window is lighted
and alarm is sounded.

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10.25.1.3 When the superheat steam pressure is up to 18.5MPa, the high pressure bypass valve
and the low pressure bypass valve of the turbine are automatically opened (not been provided
yet).
10.25.1..4 When the superheat steam pressure is up to 2.05MPa, the electromagnetic

release valve automatically opens.
10.25.1..5 When the superheat steam pressure is up to 2.25MPa, the safety valve at the outlet of
superheater starts to work.
10.25.1..6 When the superheat steam pressure is up to 20.62MPa, the safety valve of the drum
starts to work.
10.25.1.7 After the electromagnetic release valve or the safety valve starts to work, the water level
in the drum first goes up and then drops.
10.25.2 Causes
10.25.2.1 The load is declined abruptly.
10.25.2.2 The safety valve fails to move.
10.25.2..3 The first valve of the electromagnetic release valve fails to open or the electromagnetic
release valve has not been shifted to automatic status.
10.25.2.4 Coal feeding controller (automatic combustion control) of the boiler is not dislocated or
the turbine speed regulating system fails.
10.25.2.5 The adding of high pressure bypass and the low pressure bypass is not successful.
10.25.2.6 Pulverizing system works at an abnormal status.
10.25.2.7 Automatic control system fails.
10.25.3.1Immediately take depressurization measurements:
a) Reduce coal feeder rotation speed and add oils for facilitating combustion according to
the combustion situation in the furnace. Stop the pulverizing system if necessary.
b) Open high pressure bypass valve and low pressure bypass valve of the turbine.
c) Manually open electromagnetic release valve.

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10.25.3.2 Shift the operation mode of CCS coordination control system to boiler basic mode.
10.25.3.3 When the pressure in drum surpasses the safety valve working pressure and the safety
valve fails to move, stop the boiler manually and takes corresponding measurements to reduce the
pressure.
10.25.3.4 When the boiler pressure is recovered, close the electromagnetic release
valve and contact the turbine group to close the high pressure bypass valve and low pressure
bypass valve.
10.25.3.5 Pay close attention to the work conditions of the automatic regulation control device of
the drum water level and the steam temperature and shift the mode to manual mode to regulate it
manually if necessary.
10.26 Auxiliary Failure
10.26.1 Faults and countermeasures of air preheater
10.26.1.1 Too low rotating speed
1) Faults
a) When the rotating speed of the air preheater during operation is as low as 0.2rpm, the
main motor trips and the red and yellow lamps flash.
b) Alarm for too low revolution is sounded.
c) The low speed motor is automatically started and if the over low speed lasts more than
80s, the low speed motor will automatically stop and the baffle plates of flue and air are
closed.
d) If the control power fails, the main motor trips and the low speed motor starts.
2) Countermeasures
a) Check whether the main motor and hydraulic coupling work normally;
b) Notice thermal operation personnel to check the rotating speed detector;
c) Check whether there is jamming or bump in the air preheater;
d) Control the continuous rotation on spot for a necessary period if possible for cooling;
e) Confirm the baffle plate of the inlet of the flue and the first thermal air baffle plate and the
second thermal air baffle plate are closed when the air preheater fails and is shut down.

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10.26.1.2 High bearing temperature (≥60℃)
1) Faults
a) Alarm is sound for high temperature of bearing (TSH15, TSH25)
b) Lubricating oil pump starts automatically.
2) Countermeasures
a) When the bearing temperature is not less than 60℃ and the lubricating oil pump fails to
start, manually start it on DCS.
b) Check whether the oil pump runs normal and the oil level and the oil quality are regular.
c) If the temperature shows no decline after the starting of oil pump for a long time, check
whether the oil pressure difference of the filter is normal on site. If the pressure difference
is too large, shift to another filter and ask for maintenance of the filter at the trouble side.
d) Check whether the cooling water flows smoothly and whether there is leakage on the oil
pipeline.
e) The oil pump is automatically stopped when the oil temperature is declined to 50℃.
f) Check whether the air duct leaks, if any, notice relative personnel for maintenance.
10.26.1.3 Bearing oil pump trip
1) Faults
a) Yellow lamp and red lamp on the oil pump flash
b) Alarm is sound for high temperature of bearing
2) Causes
a) Oil pump motor fails or leak electrically
b) The mechanical part fails
3) Countermeasures
a) Notice relative personnel to eliminate the motor troubles timely
b) Recover 380V power supply

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c) Eliminate the mechanical part troubles
d) Strictly monitor the air preheater bearing oil temperature and take necessary measures to
cool the oil.
10.26.1.4 Complete shutdown of the air preheater
1) Faults
a) MFT operation;
b) Interlocking trip happens to various auxiliary equipments and flameout happens in the
boiler;
c) Sector-shaped sealing baffle plate withdraws automatically;
d) The alarm that air preheater systems A and B fail is sounded from the alarm window.
2) Causes
a) The power of air preheater motor is lost;
b) The rotating speed of the air preheater is lower than 0.2rpm and the low speed motor fails
to start within 80s.
3) Countermeasures
a) Resolve it according to the method for MFT.
b) Confirm the air preheater is stopped;
c) Confirm the flue baffle plate of the air preheater inlet and the second thermal air baffle
plate of the outlet are closed;
d) Find out the reason and remove the trouble. Prepare the boiler for restart.
10.26.1.5 Trip of one air preheater
1) Faults
a) Lamp at the trip side of the air preheater flash and the alarm trump is sounded;
b) Induced draft fan, force fan and primary air fan at the corresponding side trip;
c) The alarm that air preheater fails at the trip side is sounded from the alarm window;

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d) The load is recovered to 50% of MCR, and six pulverizer coal feeders including FEA,
FEE and FEI trip.
2) Causes
a) Mechanical jamming happens to the air preheater at the trip side;
b) The motor of the tripping air preheater fails or losses power;
c) Shutdown button or emergency button is pressed by mistake.
3) Countermeasures
a) The load is automatically inclined to 50% of MCR, the load of the set is turned to 50% of
MCR and the alarm is trigged.
b) Confirm the flue baffle plate of the air preheater inlet and the primary and the second
thermal air baffle plates of the outlet are closed, otherwise close them manually.
c) Air fan at the corresponding side automatically trips and the baffle plate at the outlet and
the inlet automatically close; otherwise close them manually.
d) Six pulverizer coal feeders including FEA, FEE and FEI trip automatically; otherwise trip
them manually.
e) Provide a proper amount of oil gun torches to facilitate and stabilize combustion.
f) Find out trip Causes and start relative equipment again after they are
inspected and proved to be normal.
g) Monitor the shutdown side.
h) Control the flue temperature and the air temperature at the inlet and the outlet of the air
preheater.
i) Send out a fire alarm.
10.26.2 Induced draft fan faults and countermeasures
10.26.2.1 Complete shutdown of two induced draft fans
1) Faults
a) MFT

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b) The motors of the two induced draft fans are powered off and the outlet baffle plate is
automatically closed.
c) If the electric protections system starts to work, the alarm that induced draft system fails
is sounded from the alarm window.
d) The two force fans are interlocked and the two primary fans are stopped completely, the
total air amount and the air pressure are dropped to zero instantly.
e) The negative pressure in the furnace changes greatly and the fire in the boiler goes out.
2) Causes
a) When the furnace pressure is not less than 41mbar or not more than -25mbar, MFT fails
to start within 5s.
b) The number of the secondary air baffle plates of spark plug which is opened is less than
18.
c) All force fans trip.
d) All air preheaters trip.
e) The motor power is cut off.
3) Countermeasures
a) Dispose it according to the countermeasures to MFT.
b) When the baffle plates of the inlet and the outlet fail to open, open them timely or slowly
open the regulation baffle plate, keep the furnace draft pressure between 0Pa and 100Pa
and the ventilation in the furnace balanced to prevent furnace explosion.
c) If the induced draft fan fails to recover to start, keep the furnace in natural ventilation for
above 15min.
d) If the induced fan recovers to start, strictly conform to the furnace cleaning procedures
when the boiler recovers to start.
10.26.2.2 Trip of one induced draft fan
1) Faults
a) Alarm that induced draft fan fails at the trip side is sounded from the alarm window.

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b) The inlet baffle plate and the outlet baffle plate of the induced draft fan at the trip side are
closed automatically.
c) The furnace draft pressure turns positive.
d) Force draft fan and primary air fan at the side corresponding to the interlinking trip.
2) Causes
a) The fan vibration is not less than 120μm
b) The shutdown button is pressed by mistake
c) Electric baffle plate of the outlet is automatically closed
d) The electric protection system starts to work
e) Mechanical faults
f) The air preheater at the corresponding side trips
g) The drive power supply at the corresponding side is cut off
h) The shift of air fan rotating speed fails
3) Countermeasures
a) If MFT takes place, shoot it according to the troubleshooting method for MFT.
b) The load should be automatically reduced to 50% of MCR, the alarm that the set load is
recovered to 50% of MCR is sounded from the alarm window.
c) Six pulverizer coal feeders of FEA, FEE and FEI trip automatically; otherwise shut down
the six pulverizer coal feeders of FEA, FEE and FEI manually.
d) Provide a proper amount of oil gun torch for facilitating combustion. After the combustion
is stable, determine whether to stop the pulverizer coal feeder according to its rotating
speed to avoid that the feeding is not proper due to the low rotating speed.
e) If the force fan and the primary air fan at the corresponding side fail to trip automatically,
stop them manually but keep the air preheater at the corresponding side running.
f) After the cause for tripping is found out, and the induced draft fan is inspected and proved
to be normal, the induced draft fan then can be restarted.

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g) Monitoring at the shutdown side:
Monitor the flue temperature and the air temperature at the inlet and the
outlet of the preheater and fire alarm.
Check the induced draft fan bearing temperature and the temperature of the motor coil and
the bearing.
10.26.2.3 High temperature at bearing and coil
1) Alarm is sounded when the air fan bearing temperature TE01B, TE01D and the motor bearing
temperature TE01F, TE01H are high.
2) Find out the cause of high temperature at the bearing when the alarm is sounded and remove
it immediately.
3) If the bearing temperature is up to 95℃, the induced draft fan should be stopped.
4) Alarm is sounded when the motor coil temperature TE01I, TE01L and TE01M is high.
5) Find out the cause of high temperature at the coil when the alarm is sounded and remove it
immediately.
6) Check whether the motor is over loaded
7) Check whether the air cooler is normal and whether the filter screen at the inlet is blocked.
8) If the coil temperature is up to 120℃, the induced draft fan should be stopped
10.26.3 Force fan faults and countermeasures
10.26.3.1 Complete shutdown of two force fans
1) Faults
a) Tripping;
b) The baffle plates of the inlet and the outlet of the force fan are automatically closed;
c) The total air pressure and the total air amount are dropped to zero;
d) If the force fan trips due to accidents, the induced draft fans should be
automatically stopped completely as well as the primary air fans
e) Alarm that force fan systems A and B fail is sounded from the alarm window.

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2) Causes
a) All induced draft fans trip;
b) All air preheaters trip;
c) The furnace pressure is more than 41mbar or less than -25mbar while the MFT does not
starts within 5s.
d) The motor power is cut off.
3) Countermeasures
b) If the force fan outlet baffle plate is closed, open it manually in time to keep ventilation in
the furnace and prevent furnace from explosion.
c) If the force fan fails to recover to start, keep the furnace in natural ventilation for above
15min. If the force fan recovers to start, strictly conform to the
furnace cleaning procedures when the boiler recover to start.
10.26.3.2 Trip of one force fan
1) Faults
a) The baffle plates of the tripped force fan inlet and outlet are closed automatically;
b) The cooling air balance disconnection damper is closed;
c) The load of the force fan in operation is increased. When it is running at a low speed, it
should be automatically shifted to high speed;
d) The negative pressure of the furnace is increased instantly, which may cause MFT;
e) The load is automatically reduced to 50% of MCR;
f) Pulverizer coal feeder of FEA, FEE and FEI automatically trip.
2) Causes
a) Air fan vibration is not less than 120μm;
b) The air preheater at the corresponding side trips;
c) The air preheater at the draft fan trips;

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d) Electric protection system starts to work;
e) Mechanical faults;
f) Shutdown button or emergency button is pressed by mistake;
g) The outlet baffle plate of the air fan during operation is automatically closed;
h) The drive power supply is cut off.
3) Countermeasures
b) The load is automatically dropped to 50% of MCR, the load of the set is turned to 50% of
MCR and the alarm is trigged.
c) Six pulverizer coal feeders including FEA, FEE and FEI trip automatically; otherwise shut
them down manually.
d) Provide a proper amount of oil gun torches for facilitating combustion.

After the combustion is stable, determine whether to stop the pulverizer coal feeder
according to
its rotating speed to avoid that the feeding is not even due to the low rotating speed.
e) The baffle plates of the tripped air fan outlet and inlet are automatically closed as well as
cool air balance baffle plate; otherwise it should be closed manually.
f) After the cause for tripping is found out, and the force fan is inspected and proved to be
normal, it then can be restarted.
g) Monitor the shutdown side:
Monitor the flue temperature and the air temperature at the inlet and the
outlet of the preheater and fire alarm.
Check the temperature of the force fan motor and the bearing.
10.26.4 Faults and countermeasures of primary air fan

10.26.4.1 Outage of two sets of primary air fans
1) Faults
a) Alarm that “primary air pressure is very low” is given.
b) MFT takes place, pulverizer coal feeding is stopped and boiler is in fire-off.
c) Furnace draft maximizes instantly.

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d) Auto shutdown of inlet baffle plate and outlet baffle plate of primary air fan as well as hot
primary air baffle plate.
e) Alarm of “fault of primary air system” is given.
2) Causes
a) Outage of all induced draft fans
b) Outage of all air preheaters
c) Power failure
3) Countermeasures
a) Solve by the countermeasure to MFT
10.26.4.2 Tripping of one primary air fan
1) Faults
a) Auto shutdown of inlet and outlet baffle plate of the tripping air fan and auto shutdown of
hot primary air baffle plate of the air pre-heater at the corresponding side
b) Instant increase of furnace draft which may result in MFT
c) Primary air pressure decreases, maybe to very low degree and MFT takes place if the
pressure does not recover in 10 seconds.
d) Auto decrease of loading to 50%of MCR
e) Alarm window gives alarm of “fault of primary air fan” at tripping side.
f) Auto tripping of six sets of FEA, FEE, FEI pulverizer coal feeders.
2) Causes
a) Tripping of air pre-heater at the corresponding side
b) Tripping of induced draft fan at the corresponding side
c) Fan vibration≥80μm
d) Electric protection
e) Mechanical failure
f) Auto shutdown of outlet baffle plate of fan during operation

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g) Shutdown button or emergency button is pushed by mistake.
3) Countermeasures
a) Solve by the countermeasure to MFT.
b) If loading auto decreases to 50% of MCR, alarm window gives alarm that unit loading
recovers to 50% of MCR.
c) Inlet and outlet baffle plates of fan trip, hot primary air baffle plate auto
shuts down, otherwise, manually shut it down.
d) Six sets of FEA, FEE, FEI pulverizer coal feeders auto shut down, otherwise, manually
shut them down.
e) Put proper oil gun torch to support combustion, judge whether to shut down pulverized
coal feeder according to rotating speed of pulverized coal feeder after the combustion is
stabilized, and avoids uneven power feeding due to low rotating speed of pulverizer coal
feeder.
f) The machine can only be started up after ascertaining tripping reason and make sure
there is no other fault through checking up.
g) Monitoring of shutdown side
Smoke temperature and air temperature at the inlet and outlet of air pre-heater as well as fire
alarm
Temperature of primary air fan and motor bearing
10.26.5 Faults and countermeasures of coal pulverizing system
10.26.5.1 Emergency shutdown of coal pulverizing system
1) Coal pulverizing system should be shut down by “emergency shutdown (HSXH001)” in case
one of the following happens:
a) MFT takes place but coal pulverizing system dose not trip.
b) Coal pulverizing system is on fire and in explosion danger or explosion takes place.
c) Rotor emits violent vibration and impact sound.
d) People and equipment are endangered.

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e) Cyclone separator is blocked and exhaust air is filled with lots of pulverized coal, which
results in quick rise of steam temperature and steam pressure of boiler.
f) Coal pulverizer does not trip when one condition for coal pulverizer tripping exists.
2) Coal pulverizer should be shut down in case one of the following happens:
a) Power of main motor abnormally increases or decreases.
b) Outlet temperature cannot be monitored due to display failure of outlet temperature of

coal pulverizer.
c) Cyclone separator is blocked.
d) Cyclone separator is seriously blocked.
e) There is abnormal metal impact sound in coal pulverizer.
f) During pulverized coal pouring, pulverized coal conveyer trips but guiding baffle
plate does not auto guide to pulverized coal bunker.
10.26.5.2 Spontaneous combustion or explosion of coal pulverizing system
1) Faults
a) Outlet negative pressure of coal pulverizer and inlet negative pressure of pulverized coal
exhauster change in large fluctuation.
b) Outlet temperature of coal pulverizer rises abnormally.
c) Spark is found at inspection hole and untight places of system.
d) During explosion, pulverized coal leakage and smoke leakage are found at untight places
of system, explosion valve protrudes or exposes and negative pressure at
furnace changes into positive pressure.
e) Metal wall temperature of pulverized coal bunker rises abnormally during spontaneous
combustion of pulverized coal in pulverized coal bunker.
2) Causes
a) Pulverized coal deposits for a long time in coal pulverizing system.
b) The temperature at broken coal outlet of coal pulverizer is over high.

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c) Raw coal is of high volatile matter and outlet temperature of coal pulverizer in running is
not reduced correspondingly.
d) There is foreign fire or explosive in system.
e) Over high oxygen content in the system
3) Countermeasures
a) In case of spontaneous combustion at inlet of coal pulverizer, properly

increase coal feeding amount, reduce pulverized coal amount at loop of
classifier, reduce or cut off system draft and stop coal feeder; apply fire-
fighting equipment to put out a fire on occasion and all damper baffle plates
should be closed if gas fire-fighting equipment is applied.
b) In case horizontal tube at coal pulverizer inlet is on fire, coal pulverizing system should be
stopped running to extinguish fire.
c) In case of spontaneous combustion of pulverized coal bunker, coal pulverizing system or

pulverized coal conveyer should be stopped running immediately. Must
not convey pulverized coal towards the pulverized coal bunker and close moisture
absorption piping towards the pulverized coal bunker to reduce pulverized coal
completely; after pulverized coal level is reduced to certain height, increase pulverized
coal level immediately and press pulverized coal to extinguish fire; apply fire-fighting
equipment if pulverized coal press does not work (clean and dry pulverized coal bunker
after application).
d) After coal pulverizing system explodes, emergency shutdown of coal pulverizing system
should be carried out, close hand-operated valve and coupling cock valve for moisture
absorption piping of pulverized coal bunker, confirm tight closing of all
damper baffle plates, extinguish internal and external fire source and repair explosion
door.
e) Normal coal pulverizing can only be carried out after water in the system is drained away
as far as possible and the system is fully ventilated and dried if fire water is applied during
the fir fighting process.
10.26.5.3 Coal interruption in coal pulverizer
1) Faults
a) Coal interruption alarm is given and pulverized coal feeder trips after 30 seconds.
b) Noise level of coal pulverizer increases.

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c) Outlet temperature of coal pulverizer rises; outlet temperature first reduces and then rises
if pulverized coal bunker is empty.
d) Negative pressure at pulverized coal bunker decreases.
e) Rotating speed of pulverized coal feeder maximizes during auto rotation.
2) Causes
a) There is no coal in raw coal bunker.
b) Raw coal bunker is blocked.
c) Driving part of pulverized coal feeder is in fault and driving belt skips or loosens.
d) Scraper chain for pulverized coal feeder breaks and falls down.
3) Countermeasures
a) Control outlet temperature of coal pulverizer at setting value and properly turns
down regulation baffle plate at inlet of exhaust air fan.
b) Note man on duty for combustion and conveying to feed coal or dredge coal bunker (start
up air gun).
c) Note maintenance personnel to eliminate equipment fault.
d) In case coal interruption lasts for 15 minutes and coal feeding cannot be recovered, coal
pulverizer should be shut down and pulverized coal exhauster and exhaust air fan should
be shut down on condition.
10.26.5.4 Coal jamming in coal pulverizer
1) Faults
a) Negative pressure at all points of system increase.
b) Power of coal pulverizer increases and power decreases in serious condition.
c) Noise of coal pulverizer decreases.
d) Pulverized coal runs out at inlet and outlet of coal pulverizer.
2) Causes
a) Coal feeding amount is over larger.

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b) Noise measurement signal is incorrect and speed controller of coal feeding

does not
work.
c) Measurement of rotating speed of coal feeding is incorrect.
d) Water content of raw coal is large, grindability decreases and hot smoke air temperature
at inlet is over low.
e) Ventilation decreases and coal feeding amount is not reduced during manual operation.
f) Bypass valve of coal pulverizer is opened by mistake, which results in

over low of ventilation in coal pulverizer and low temperature.
3) Countermeasures
a) Decrease coal feeding amount or shut down pulverized coal feeder on occasion.
b) Properly turn up baffle plate at inlet of exhaust air fan to increase system ventilation and
carry out pulverized coal pumping and attention should be paid to
maintaining outlet temperature of coal pulverizer at 110 DEG C.
c) Turn down coal pulverizer bypass at normal position.
d) In case outlet temperature of coal pulverizer increases, close hot smoke air manual baffle
plate HV001 on occasion and manually open cold air baffle plate TCV62B.
e) In case all above countermeasures do not work, shut down main motor of coal pulverizer
and restart up to carry out pulverized coal pumping after turning runs for 30 minutes.
f) In case pulverized coal pumping does not work, coal pulverizing system should be shut
down and manual drainage towards coal pulverizer should be carried out after relevant
departments approve and there are definite and effective countermeasures.
10.26.5.5 Blocking of classifier
1) Faults
a) Negative pressure at outlet of coal pulverizer decreases.
b) Negative pressure at inlet of pulverized coal exhauster increases.
c) Exhaust air volume decreases.
2) Causes

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a) Air lock for pulverized coal returning pipe is blocked due to over large amount of returning
pulverized power.
b) Large humidity of returning pulverized coal results in blockage.
3) Countermeasure
a) Decrease coal feeding amount and attention should be paid to

maintaining outlet temperature of coal pulverizer at setting value.
b) Knock pulverized coal returning pipe and air lock to dredge pulverized coal
returning pipe.
c) If the above countermeasure does not work, coal pulverizing system should
be shut down and note maintenance personnel to repair.
10.26.5.6 Blockage of pulverized coal separator

1) Faults
a) Negative pressure at outlet of coal pulverizer decreases and negative pressure at inlet of
pulverized coal exhauster increases obviously.
b) When becoming series, pulverized coal exhausting amount and pulverized coal filled in
exhaust air increase, steam temperature and steam pressure rise at the same time and
oxygen content in fuel gas reduces.
c) Rotating speed of pulverized coal feeder reduces during self movement of total fuel.
d) Lock air under cyclone separator at blocking side does not work.
2) Causes
a) Pulverized coal is over damp, which results in blockage of pulverized coal pipe of cyclone
separator.
b) Lock air under separator does not work.
c) Coal pulverizing system is not shut down in time when pulverized coal bunker is full.
d) Pulverized coal conveyer trips and guiding baffle plate does not guide towards pulverized
coal bunker during pulverized coal preparation.
e) Guiding baffle plate guides towards pulverized coal conveyer by mistake.

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f) During pulverized coal pouring, aerodynamic gate (UV06) from pulverized coal conveyer
to pulverized coal bunker is not opened.
3) Countermeasure
a) Knock position of air lock to dredge pulverized coal discharging pipe.
b) Coal pulverizing system should be shut down if pulverized coal bunker is full.
c) Have guiding baffle plate guide towards pulverized coal bunker if guiding baffle
plate moves by mistake.
d) In case pulverized coal conveyer trips during pulverized coal pouring and guiding baffle
plate does not guide towards pulverized coal bunker, have guiding baffle
plate guide towards pulverized coal bunker immediately and coal pulverizing system
should be shut down if guiding baffle plate cannot be rotated for being pressed by
pulverized coal.
e) After coal pulverizer is shut down during serious blockage, maintain

pulverized coal exhausting and operate exhaust air fan, however, baffle plate at inlet
of exhaust air fan cannot be over opened to guarantee normal operation of
pulverized coal feeder and dredge pulverized coal discharging pipe of cyclone
separator.
10.26.5.7 Tripping of exhaust air fan or coal pulverizer

1) Faults
a) Tripping signal is given, green light lights and red light and yellow light sparks.
b) Fan is out of operation.
c) Negative pressure at all points of system reduces to “zero”.
d) Exhaust air volume reduces to “zero”.
e) Hot smoke baffle plate is closed and coal pulverizer and pulverized coal feeder trip.
2) Causes
a) Power and motor are in failure.
b) There are tripping conditions.
c) Local shutdown button is pressed by mistake.
3) Countermeasure
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a) Pulverized coal feeder and coal pulverizer are shut down and turning gear is
put into
service.
b) Check out tripping reason and restart up after solving fault.
10.26.6 Faults and countermeasures of pulverized coal feeder
10.26.6.1 Pulverized coal feeder cannot be started up
1) Causes
a) Without starting up conditions
b) Primary air aerodynamic overall opening signal is not received.
c) Motor of pulverized coal feeder is not powered.
2) Countermeasures
a) Start up once starting up conditions are held.
b) Clear the fault that primary air aerodynamic overall valve cannot be opened in place.
c) Note power department to power motor of pulverized coal feeder.
10.26.6.2 Rotating of pulverized coal feeder cannot be speeded after starting up
1) Causes
a) Switch for local rotating speed control cabinet is not put in place of “ON”.
b) Rotating speed regulator is in fault or not powered.
2) Countermeasures
a) Put switch for local rotating speed control cabinet in place of “ON”.
b) Contact heat engineering personnel and clear fault.
c) Rotating speed regulator is powered.
10.26.6.3 Over large fluctuation of rotating speed of pulverized coal feeder in service
1) Faults
a) Over large fluctuation of rotating speed of pulverized coal feeder

2×300 MW
b) Rotating speed increases or decreases abnormally when all pulverized coal feeders are
in auto operation.
2) Causes
a) Unsmooth blockage of scraper for pulverized coal feeder
b) Damage of mechanical part of pulverized coal feeder
c) Fault of rotating speed regulator
3) Countermeasures
a) Pulverized coal feeder is shut down at once to clear fault
10.26.6.4 Blockage of primary air pipe and pulverized coal discharging pipe
1) Faults
a) Primary air pressure of single pipe is abnormal and alarm is given in DCS, PSH or PSL.
b) Rotating speed of all pulverized coal feeders during auto operation is

increased abnormally and boiler temperature and steam pressure reduce during auto
operation.
c) Outer wall temperature of blocking primary air pipe and pulverized coal discharging pipe
is lower than that of normal pipes and is obviously lower than that of normal pipes during
serious blocking or equal to room temperature.
d) Pipe makes a clunk when being knocked.
2) Countermeasure
a) The pulverized coal feeder is shut down and primary air aerodynamic valve and hand
operated valve are closed.
b) Dredge the primary air pipe and pulverized coal discharging pipe.
10.26.6.5 Pulverized coal feeder does not discharge pulverized coal
1) Faults
a) Rotating speed of all pulverized coal feeders during auto operation

is increased abnormally and steam temperature and steam pressure of
boiler during manual operation reduce.

2×300 MW
b) Temperature of the primary air pipe is lower than or close to room temperature.
c) Pipe makes a hollow sound when being knocked.
2) Countermeasures
a) Make sure all pulverized coal discharging gates should be all opened.
b) Knock upper wall of pulverized coal bunker to exhaust air of pulverized coal.
c) Contact maintenance personnel to check out whether mechanical parts of

pulverized coal feeder are in fault.
d) Carry out pulverized coal drop of pulverized coal bunker regularly subject to regulations.
10.26.7 Faults and countermeasures of fire detector cooling fan
10.26.7.1 Faults
1) Alarm that air pressure at air pressure outlet is low is given and MFT takes place when air
pressure is low to 70mbar.
2) 220V direct fan auto starts up.
10.26.7.2 Causes
1) Driving belt of fan loosens and skips.
2) Screen at fan inlet is blocked by impurities.
3) Hand operated valve at fan outlet is closed by mistake.
4) Electric protection takes place or power is off.
10.26.7.3 Countermeasure
1) When AC fan is in fault and trips or alarm of “low outlet air pressure” is given, DC fan should
auto start up, otherwise, manual starting up should be carried out at once.
2) In case DC fan cannot auto start up, air pressure is low to 70mbar and MFT does not take
place, emergency boiler shutdown button should be pressed to stop boiler operation.
3) Take effective measure to prevent flame scanner from being damaged.
10.26.8 Faults and countermeasures of oil gun cooling fan
10.26.8.1 Low air pressure

2×300 MW
1) Faults
a) Alarm of low air pressure
b) When interlock is put into operation, standby fan is linked.
2) Causes
a) Air leakage of air system
b) Shedding of connecting hose
c) Tripping of fan in operation
d) Driving belt of fan loosens and skips.
3) Countermeasure
a) After standby fan is started up, find out the reason for low air pressure.
b) In case standby fan is not started up, it should be started up manually at once.
c) If the fault is caused by air leakage or mechanical reason, report to man on duty and note
maintenance personnel to clear the fault as soon as possible.
10.26.8.2 Tripping of fan
1) Faults
a) Yellow light of tripping fan sparks and red light sparks.
b) Alarm of low air pressure is given; when interlock is put into operation, standby fan is
started up.
2) Causes
a) Jam fault of machine and overcurrent of motor
b) Motor is off power or in fault.
3) Countermeasure
a) Operate standby fan and clear fault of fan.
b) When standby fan is not started up, standby should be started up at once.
c) Find out reason for motor and power fault and clear faults.

2×300 MW
10.26.9 Faults and countermeasures of steam air heater
10.26.9.1 High water level of condensation water tank
1) Faults
a) Alarm of high water level of condensed water tank (LSH03) is given.
b) High water level of local condensed water tank water level gauge
2) Countermeasure
a) Make sure normal operation of water level control valve LCV05A on-site and open hand
operated valve thereof.
b) Make sure normal operation of water level control valve LCV05B on-site and open hand
operated valve thereof.
c) Contact heat personnel to inspect whether water level controller is in normal operation.
10.26.9.2 Low water level of condensation water tank
1) Faults
a) Alarm of low water level of condensed water tank is given.
b) Low water level of local water level gauge for condensed water tank
2) Countermeasure
a) Check out whether water drain valve is closed.
b) Check out whether water level control valve is in normal operation.
10.26.9.3 High steam pressure
1) Faults
Alarm of high steam pressure (PSH57) is given.
2) Countermeasure
a) Check out whether steam control valve TCV57A is in normal operation.
b) Check out whether bypass valve HV015 thereof is closed.
c) Make sure control valve for water level of condensed water tankand hand operated valve

2×300 MW
thereof are opened, otherwise, manually open HV004 to release pressure.
d) In case steam control valve is in fault, inlet and outlet hand operated valves should be
closed and bypass hand operated valve should be opened to regulate manually.
10.26.9.4 Low steam pressure
1) Faults
Alarm of low steam pressure (PSL57) is given.
2) Countermeasure
a) Check out whether steam control valve PCV57A is in normal operation.
b) Average temperature of air smoke of air per-heater is over setting valve and
opening degree of steam control valve is small, steam air heater can be shut down.
c) Check out positions of all valves of system and make sure there is no leakage.
10.26.10 Faults and countermeasures of boiler water circulating pump
10.26.10.1 Two sets of boiler water pump trip, a standby pump is not started up or a boiler water
pump is in operation with differential pressure<1bar
1) Faults
a) MFT takes place.
b) Emergency indicating light for boiler water pump lights.
c) Alarm of “boiler water pump fault” is given.
2) Causes
a) Closed cooling water is interrupted or closed cooling water <27m3 /h (for 20 seconds).
b) Electric fault makes pump motor power off.
c) Temperature for boiler water pump≥65 DEG C.
d) After two pumps trip, standby pump does not have starting up conditions (temperature of
standby pump>55 DEG C).
e) Boiler water pump sub-control shutdown button is pressed by mistake.
3) Countermeasure

2×300 MW
a) After MFT takes place, solve by the countermeasure to MFT.
b) Comprehensively inspect boiler water pump system at once to find out tripping causes
and take countermeasure.
c) Eliminate tripping reason and restart up boiler water pump after making sure there is no
other fault.
d) In case closed cooling water pump trips and reclosing is not carried out
successfully, emergency three-way valve should be opened at once;
enhance water feeding to emergency water tank, have closed cooling
water operate as soon as possible and prevent over high temperature of boiler
water pump which results in motor.
10.26.10.2 Two sets of boiler water pump trip, a standby pump is started up or a boiler water pump
trips but standby pump is not started up.
1) Faults
a) Loading auto reduces to 60% of MCR and alarm of “loading recovering” is given.
b) FEA, FEE, FEI pulverized coal feeders auto trip.
2) Causes
a) Standby pump does not standby condition (temperature of pump>55 DEG C).
b) Closed cooling water amount of motor of tripping pump<27m3 /h.
c) Temperature of tripping pump≥65 DEG C.
d) Independent shutdown button of pump in operation is pressed by mistake.
e) Power for tripping pump motor is off.
3) Countermeasure
a) Alarm that loading auto recovers to 60% of MCR and alarm window unit loading to 60%
of MCR is given.
b) FEA, FEI pulverized coal feeders auto trip, otherwise, they trip due
to manual interruption.
c) Put proper oil gun torch to support combustion, judge whether to shut down pulverized
coal feeder according to rotating speed of pulverized coal feeder after the combustion is

2×300 MW
stabilized, and avoids uneven power feeding due to low rotating speed of pulverizer coal
feeder.
d) Comprehensively inspect tripping pipe, find out reason for tripping and
take some countermeasure.
e) After fault is cleared and make sure there is no other fault, a boiler water pump can only
be started up and gradually recover system.
10.26.10.3 A boiler water pump strips and standby pump is successfully started up
Find out tripping reason, eliminate the cause as soon as possible and put the
pump into interlocking and standby status.
11 Appendix
11.1 The contrastive list of the absolute pressure and temperature in saturated states
Absolute pressure Saturation temperature Absolute Saturation temperature

pressure
(Mpa) (DEG C) (DEG C)
(Mpa)
0.01 45.83 1.80 207.11
0.02 60.09 1.90 209.80
0.03 69.12 2.00 212.38
0.04 75.88 2.50 223.94
0.05 81.34 3.00 233.84
0.06 85.95 3.50 242.54
0.07 89.96 4.00 250.33
0.08 93.51 4.50 257.41
0.09 96.71 5.00 263.91
0.10 99.63 5.50 269.93
0.11 102.32 6.00 275.55
0.12 104.81 6.50 280.82
0.13 107.13 7.00 285.79
0.14 109.32 7.50 290.55
0.15 111.37 8.00 294.97
0.16 113.32 8.50 299.23
0.17 115.17 9.00 303.31
0.18 116.93 9.50 307.21
0.19 118.62 10.00 310.96
0.20 120.23 10.60 315.30
0.25 127.43 11.00 318.05
0.30 133.54 11.60 322.10

2×300 MW
0.35 138.87 12.00 324.65

0.40 143.62 12.60 328.40
0.45 147.92 13.00 330.83
0.50 151.84 13.60 334.40
0.60 158.83 14.00 336.64
0.70 164.96 14.50 339.40
0.80 170.42 15.00 342.13
0.90 175.36 15.50 344.80
1.00 179.88 16.00 347.33
1.10 184.07 16.50 349.80
1.20 187.96 17.00 352.26
1.30 191.61 18.00 356.96
1.40 195.04 19.00 361.43
1.50 198.29 20.00 365.70
1.60 201.37 21.00 369.78
1.70 204.31 22.00 373.69
11.2 Boiler Cold start-up Curve

VIETNAM QUANG NINH
THERMAL POWER JOINT STOCK COMPANY
Shanghai Electric (Group) Corporation 2×300 MW Anthracite Coal

Fired Power Station BOILER & AUXILIARIES OPERATION MANUAL
11.3 Boiler Hot star-tup Curve
11.3.1 Boiler Warm star-tup Curve

VIETNAM QUANG NINH

11.3.2 Boiler Hot star-tup Curve

VIETNAM QUANG NINH

11.3.3 Boiler Very Hot star-tup Curve

VIETNAM QUANG NINH

11.4 Boiler drume level vs load Curve

VIETNAM QUANG NINH
2×300 MW Anthracite Coal Fired Power Station
Shanghai Electric (Group) BOILER & AUXILIARIES
Corporation OPERATION MANUAL
11.5 Boiler O2 in flue gas vs load Curve

300 MW Anthracite Coal Fired Power Station Boiler &amp; Auxiliaries

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300 MW Anthracite Coal Fired Power Station Boiler &amp; Auxiliaries

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QUANG NINH THERMAL POWER JOINT STOCK COMPANY

SEC BOILER & AUXILIARIES OPERATION MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY

2 × 300 MW – Anthracite Coal Fired Power Station

Date: 2008-09-15 No.:QN1-SEC-G-04-TP-003 Rev. : A

SEC BOILER & AUXILIARIES OPERATION MANUAL

2 SPECIFIC QUOTING DOCUMENTS .................................................................................................... 4

3 BOILER TECHNIQUE SPECIFICATION.............................................................................................. 5

3.1 INTRODUCTION OF BOILER .................................................................................................................. 5

3.2 BOILER NAMEPLATE ............................................................................................................................ 7

4.1 BOILER PROTECTING LIMIT VALUE .................................................................................................... 34

4.2 BOILER AUXILIARY INTERLOCK PROTECTION VALUE AUXILIARY EQUIPMENT. ................................... 35

5.1 BASIC REGULAR ................................................................................................................................ 44

5.2 REPAIR TEST AND ACCEPTANCE INSPECTION ...................................................................................... 44

5.3 CHECK AND PREPARATION BEFORE START-UP..................................................................................... 70

5.4 COLD START-UP SEQUENCE ................................................................................................................ 74

5.5 HOT START-UP .................................................................................................................................... 83

5.6 PARAMETER CONTROL VALUE IN THE PROCESS OF START-UP ............................................................. 87

6 MONITORING AND ADJUSTMENT IN BOILER OPERATION ...................................................... 88

6.1 THE MAIN TASK AND OBJECTIVES OF OPERATION ADJUSTMENT ......................................................... 88

6.2 MAIN PARAMETER AND LIMIT OF OPERATION CONTROL .................................................................... 88

6.3 CHECKING, MONITORING AND MAINTENANCE IN BOILER OPERATION ................................................ 91

Date: 2008-09-15 No.:QN1-SEC-G-04-TP-003 Page 1 Rev. : A

SEC BOILER & AUXILIARIES OPERATION MANUAL

6.4 BOILER OPERATION MEASURE CONTROL .......................................................................................... 100

7 SHUT-DOWN OF BOILER................................................................................................................. 100

7.1 BASIC REGULAR (GENERALS ) .......................................................................................................... 100

7.2 PREPARATION BEFORE SHUT-DOWN OF BOILER ................................................................................ 101

7.3 SHUT-DOWN WITH SLIDING PARAMETER (NEED COOLING ) .............................................................. 102

7.4 NORMAL SHUT-DOWN (HOT STAND-BY ) .......................................................................................... 104

7.5 EMERGENCY SHUT-DOWN ................................................................................................................ 105

8 BOILER AUXILIARY EQUIPMENT ..................................................................................................113

10 ACCIDENTS PROCESSING OF BOILER......................................................................................... 172

10.1 BASIC PRINCIPIA OF ACCIDENTS PROCESSING ................................................................................. 172

10.2 BOILER EMERGENCY SHUTDOWN .................................................................................................... 174

10.3 SHUTDOWN APPLICATION OF BOILER .............................................................................................. 178

10.4 BOILER ABNORMAL OPERATION PARAMETER ................................................................................. 178

10.5 LOAD REJECTION OF UNIT ............................................................................................................... 183

10.6 AUXILIARY POWER SUPPLY INTERRUPTION ..................................................................................... 184

10.7 CONTROL&INSTRUMENT AND APPARATUS POWER SUPPLY INTERRUPTION .................................... 185

10.8 FIRE ACCIDENT ................................................................................................................................ 186

10.9 PROCESSING INFERIOR QUALITY OF WATER AND STEAM ................................................................ 188

10.10 BOILER HEATING SURFACE SLAGGING SERIOUSLY...................................................................... 190

Date: 2008-09-15 No.:QN1-SEC-G-04-TP-003 Page 2 Rev. : A

SEC BOILER & AUXILIARIES OPERATION MANUAL

10.11 GAS DUCT REBURNING................................................................................................................ 191

10.12 UNIT TRIP .................................................................................................................................... 192

10.13 STEAM DRUM FULL FEEDED ........................................................................................................ 194

10.14 STEAM DRUM SHORT FEEDED ..................................................................................................... 195

10.15 PRIMING ....................................................................................................................................... 197

10.16 HIGH FURNACE PRESSURE ........................................................................................................... 197

10.17 LOW FURNACE PRESSURE............................................................................................................ 198

10.18 BOILER BURNING OUT ................................................................................................................. 199

10.19 FUEL TRIP .................................................................................................................................... 200

10.20 WATER WALL TUBES TXPLOSION ................................................................................................. 201

10.21 ECONOMIZER TUBES EXPLOSION................................................................................................. 202

10.22 SUPERHEATER TUBES EXPLOSION ............................................................................................... 203

10.23 REHEATER TUBES EXPLOSION ..................................................................................................... 204

10.25 HIGH STEAM DRUM PRESSURE .................................................................................................... 206

10.26 AUXILIARY FAILURE .................................................................................................................... 208

11 APPENDIX .......................................................................................................................................... 232

11.2 BOILER COLD START-UP CURVE ....................................................................................................... 233

11.3 BOILER HOT STAR-TUP CURVE......................................................................................................... 234

11.4 BOILER DRUME LEVEL VS LOAD CURVE ........................................................................................... 237

300 MW Anthracite Coal Fired Power Station Boiler & Auxiliaries

300 MW Anthracite Coal Fired Power Station Boiler & Auxiliaries