CHAPTER XIX STARTUP OF START-UP BOILER

SECTION I CHECKING ITEMS BEFORE THE STARTUP

Maintenance of startup boiler is finished, work permit has been concluded, and
security measures have been restored.The workplace ground, stairs, platforms railings
are clean and neat, there is enough light and there is no water, no oil and no fouling.
System piping and valves connections are intact. There is no leakage and the valve
switching is flexible and can reach the target poison.Furnace, superheater, convection
tubes, economizers maintenance work has ended. Check and make sure that there is
no people working in, no debris; the heating surface has no cinder blocking, no
cracks, no deformation and no weariness. The adjustment of the combustion
regulating valve is good, oil gun is intact and the oil inlet and return hose is
connected correctly, advancement and re-treatment is flexible. There is no coking and
blocking to the oil gun.The quick closing valves for feeding oil are flexible and
reliable; the oil inlet/return valve for oil guns of #1 (#2) boiler are closed tightly and
there is no leakage. Steam purge pipeline is isolated, adjacent boiler oil and steam
system is isolated.
Check and make sure that the flame observation hole, access door, man hole
are close tightly; the explosion-proof door closes tightly, without sundries on it.The
drum water level meter is intact and put into use. There is enough light and the water
level is clear and correct.The connection of coupling of ID fan and FD fan is secure
and the protective cover is complete, ground screw is not loose.The regulators of FD
fan inlet damper and ID fan inlet/outlet damper are flexible, there is no jam
phenomenon and local indications are consistent with that in the control room, and in
the "electric" position.
If the FD fan and ID fan are started after disassembling and maintenance,
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there should be at least 30 minutes test running.The ID fan and FD fans bearing oil
level is normal and the oil quality is up to standard and there is no oil leakage. The
upper water level meter of the feedwater tank is above 1/2 position and the cooling
water of the feedwater pump is normal.The safety valve should be adjusted, the
calibration is correct and activation is reliable.Check and make sure the burning
devices and the oil pipes are in good conditions and the igniter has no ash
accumulation and the trial igniting is normal.
The wire connecting of the motor of the ID fan and FD fan is correct and the
insulation is good and the grounding wire is great and the power source has been
connected.The I&C instruments, switches, interlock protection and alarming are
accurate and correct and reliable and have been put into use. The local primary valve
for instruments and meters has been opened. Check the valves according to the valve
checking card before system startup.

SECTION II WATER FEEDING FOR STARTUP BOILER

After the boiler startup comprehensive inspection finishes, report this to the
shift leader and then the water can be fed. Feedwater temperature is 5 , and 60
, the boiler water quality should meet the requirements. The drum water level
control is under manual mode. The boiler water feeding speed should be strictly
controlled, the water feeding speed in summer time should be 0.5 hour, and in
winter it should be 1 hour.
The boiler water feeding should be stopped when the water reaches the minimum
visible water level and the water level should keep unchanged. If there is serious
change, identify the reasons and the eliminate them.
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SECTION III BOILER IGNITION

The inspection before the startup is completed, and after getting the
agreement of the shift leader, then it can start up. Confirm that the ID fan inlet
damper is close and outlet damper is open and start the ID fan. Confirm ID fan starts
normally, slowly open the inlet damper. Confirm that the inlet damper of FD fan is
close and then start the FD fan and slowly open inlet damper.
Appropriately open the main air valve of the combustion chamber, adjust the
negative pressure of chamber is -50 -100Pa, purge for at least 5 minutes. After
purge has been finished, close down the air valve of combustion chamber, and the
cooling fans should start normally, start the auto-ignition process. If the auto-ignition
process has faults, press the ignition button on the second door of the combustion
cabinet to manually complete the ignition process.
If the ignition does not light the oil gun in 10 seconds, fuel oil quick closing
valves should be cut off immediately, high-energy ignition device should exit and cut
off the power source, afar re-purging, the ignition can be restarted. After the oil-gun
has been lighted and the combustion and atomization is good, adjust the air flow and
furnace negative pressure.
After the combustion is stable, slowly start the oil inlet isolation valve of
main oil gun , ignite the main oil gun, regulate return oil pressure and if the
atomization is good, exit the ignition oil gun.

295

SECTION IV BOILER PRESSURE INCREASE

After the oil gun is ignited, the boiler pressure should begin to increase
slowly and inspect the thermal expansion of the boiler timely. If there is abnormality,
stop pressure increase, after the reasons is identified and handled, the pressure can be
increased (Usually, the time duration from ignition to parallel should be no less than 2
hours).Close the economizer recirculation after the water is continuously fed.
During the pressure increasing process, monitor the drum water level change
and keep the water level within the normal range. When the pressure of the drum
increases to 0.050.1Mpa, flush the water level meter. When the drum pressure
increases to 0.0980.196Mpa, close the air vent valve and the superheater drain
valve.
When the drum pressure increases to 0.1960.294Mpa, flush the pressure
meter pipe and other meters pipes. Open the main steam electric valves bypass
valve and the drain valve behind main steam isolation valve of #1(#2) startup boiler.
As the boiler pressure is increasing, warm the auxiliary steam main pipe by draining
water.
When the drum pressure increases to 0.1960.392Mpa, conduct the first
time water discharge for the lower water drum and during the discharging process,
pay attention to the water level change and the check whether the blowdown valve of
the lower water drum is normal or not.
The cold state pipe warming time duration should be 5060 minutes and
that of the hot state pipe warming should be 30-40 minutes. After the pipe warming is
finished, close the drain water valve.
When the drum pressure increases to 0.294Mpa, inform the maintenance
personnel to tighten screws of the flange, man hole and hand hole.When the drum
pressure increases to 0.6373Mpa, check the boiler comprehensively. If there is
abnormality, stop pressure increasing and after the faults have been handled, then
continue increase the pressure.
When the drum pressure increases to 0.98Mpa, and the steam pressure is
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stable, test the boiler steam quality and make sure the steam quality is up to the
standard.
When the superheating steam pressure increases to 0.98Mpa, contact the
main control room to drain water to the main power plant buildings auxiliary steam
pipes and headers for pipe warming.
After the pipe warming is finished, open the #1#2main steam electric
valve, close the electric main steam valves bypass valve and various drain water
valves, close exhaust steam valve and provide auxiliary steam.
Manually adjust the pressure of the auxiliary steam leading to the main building, keep
it at 1.27Mpa. Manually adjust the auxiliary steam temperature leading to the main
building, keep it at 250 . Adjust the # 1 (# 2) drum water level, keep it within the
normal range. # 1 (# 2) boiler operates normally, and put the drum water level control
in auto mode.
The auxiliary steam leading to the main building is operating normally and
switch auxiliary steam desuperheater regulator to "Auto" position.

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SECTION V STARTUP OF PARALLEL

The auxiliary steam header of the main turbine under cold state:
If the operation parameter for parallel has achieved, report this to the shift leader and
after getting the agreement, parallel can be conducted. When paralleling, steam
temperature should be adjusted properly to keep the steam pressure stable, and
monitor steam pressure and steam temperature changes.
Before parallel, washing drum water level meter, calibrate the indications of
the water level gauge and the pressure gauges.
Specific requirements of the parallel:
The equipment has been fully checked and normal. The combustion is stable.

Drum water level is -50mm.

Steam temperature is 220230
Drum pressure is 1.181.27Mpa.
After testing, the steam and water quality is qualified.
When the steam temperature is 230, and the pressure reaches the rate
pressure, close the exhaust steam valve and drain water valve of superheater. Confirm
electric main steam valve of the adjacent boiler is closed and report this to the shift
leader. The boiler can be officially restarted for parallel.
During the parallel process, slowly open the main steam valve. Pay attention
to the expansion and supporting of the pipeline, and if there is abnormality, stop
sending steam, identify the reasons for the failure and after eliminate them steam can
be sent again. Pay close attention to steam temperature and water level changes.
When the steam temperature is 230 , close exhaust steam valve and drain
valve of superheater and the boiler can be officially paralleled.
During the parallel process, if the steam temperature dropped sharply, or
there is impact of water to the steam pipes, immediately stop parallel. Reduce
combustion and increase drain water. When it is resumed to normal condition,
parallel can be started again.
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After parallel, there should be a comprehensive inspection and if there is no

abnormality, the feedwater supply can be put into automatic mode, other interlocking
should also be put into.
If a startup boiler has been put into operation, before another startup boiler
begin to send steam to the main pipe, ensure the steam parameter should be
consistent. Otherwise the steam is not allowed to send into the main pipe.
If the main turbines auxiliary steam header is under hot conditions:
Auxiliary steam header hot condition means: single unit is under operation, but for
some reasons a shutdown is necessary. Before the shutdown, the steam is provided by
the startup boiler to the auxiliary steam header to thermal users.
Under this condition, the boiler ignition, pressure increase and pipe warming of the
startup boiler are the same as the above mentioned situations.
During the parallel, the steam parameters (P = 1.27Mpa, t = 350 ) should
be slightly higher than the steam parameters in the auxiliary steam header.

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SECTION VI PRECAUTIONS FOR STARTUP

Boiler pressure increase speed should be controlled at 1.5-2 / min.
Before the boiler starts, the fuel oil quick close valve should be tested and after confirm
that it can activate normally and it is reliable, the ignition can be started.
Before the ignition for boiler, inlet oil and return oil pressure should be adjusted
within the limits prescribed.If boiler ignition has failed, immediately turn off the fuel oil
fast close valve, and it must be re-purged for 5 minutes before re-ignition is
conducted.
During the boiler ignition and pressure increase process, monitor the drum
water level closely to avoid that it is full of water or it lacks water. During the boiler
ignition and pressure increase process, drum water level should be controlled manually.
During the boiler pressure increase process, monitor the exhaust gas
temperature closely and make sure it is no more than 240. If there is abnormality, treat
it immediately to avoid the reburning in the tail flue. When it is being ignited, the air
valve of air chamber should be at the smallest position (1-2), properly adjust the
openness of the air adjusting valve of oil gun for igniting.
According to the load adjustment and pressure increase speed, adjust the
openness of the air valve of the air chamber. During the boiler pressure increase process,
monitor the superheating steam temperature closely and make sure the superheating
steam temperature is not more than the rated value.
During the boiler ignition and pressure increase process, control the pressure
increase and temperature increase speed closely. When the boiler rated pressure increase
to 2 from the cold startup, the hot startup pressure increase time should be 0.5 hours or
so.

CHAPTER XXI NORMAL STARTUP AND MAINTENANCE OF

START-UP BOILER
SECTION I OPERATION LIMIT

Boiler monitoring and adjusting during the operation

Main parameters need monitoring during the boiler operation
Table 20-1
Controlled

No

Item

Unit

Evaporation

T/H

40

Drum pressure

MPa

1.37

MPa

1.27

350

30

160

mm

Pa

-30-50

35

Pa

>1200

Superheating
steam pressure

value

Alarming value
High

Low

360

335

+50

-50

+85

-85

Trip

Superheating
4

steam
temperature

5
6
7

8
9

Feedwater
temperature
Exhaust gas
temperature
Drum water
level
Furnace negative
pressure
Oxygen

1800Pa
1200Pa

Air pressure of
10

the cooling air

1200

fan
301

11

Inlet oil pressure

Mpa

3.2

1.76

12

ID fan current

<139.7

13

FD fan current

<139.7

<69.8

14

Feedwater pump
current

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SECTION II WATER LEVEL ADJUSTMENT

Feeding water to boiler should be even and the boiler water level should be
maintained at the normal water level. It should be forbidden to stop the water during
the operation so as to prevent the over-temperature of the economizer and the damage
of the water circulation.
Boiler feedwater should be adjusted according to the indications of the drum
water level meter. If the auto feedwater regulator and electrical contacting water level
meter, electronic water level meter and water level alarmed are in good condition,
adjust the boiler water level based on the indications of the electrical contact,
electronic water level meter.
When the auto feedwater regulator is put into operation, the monitoring for
changing of water level is still needed and the changing of feedwater flow should be
even, and the regulation range should not be too much, so as to prevent damage to the
water circulating. Frequently compare the feedwater flow and steam flow and see if
they are compliable. If auto feedwater adjustment fails, the control mode should be
changed to manual and strengthen the monitoring and regulation of water levels, and
notify I&C staff to eliminate to defects.
When the water level is high, turn down the feedwater regulating valve
properly but it is forbidden that there is no water supply. If necessary, open the
emergency valve to discharge the water.
If the water level is low, turn on feedwater regulating valve. If there are
difficulties in the water feeding, the bypass valve can be opened to strengthen water
supply, but at this time the feedwater pressure should meet the requirements, and the
water supply for adjacent boiler should be considered. If the water level is low,
decrease the feedwater pressure and operation load.
Regularly compare the indications of the low water level meter and local
drum water level meter, at least 2 times each shift and the interval should be even. If
the indications are inconsistent, wash local water level meter, calibrate low water
level meter. If the low water level meters indications is
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incorrect, the operation staff should notify the I&C personnel, and adjust the water level
according to the indications of the low water level meter.