CHECKLISTS FOR COMMISSIONING AND BOILER OPERATION

Pre-operational check list Unit Operating Procedure Emergency Operation Walkdown Checks Periodical Checks Boiler Water and Feed Water Limits Preservation of Boiler Dos and Donts

NOTE:

THIS SECTION DESCRIBES THE CHECKLISTS FOR COMMISSIONING / PRE COMMISSIONING AND BOILER OPERATION. FOR VENDOR EQUIPMENTS LIKE FANS, PUMPS, CONTROLS & INSTRUMENTATION, VALVES, ETC. THE RELEVANT INFORMATION FROM THE VENDORS SHALL BE REFERRED. BEFORE BOILER START UP AND OPERATION, THE OPERATORS SHOULD BE FAMILIAR WITH THE OPERATION OF VENDOR EQUIPMENT AND CONTROLS.

PRE-OPERATIONAL CHECK LIST

This pre-operational check list is intended as a guide for commissioning and operation engineers. It lists items to be checked prior to putting a boiler in operation. Certain items are given detailed descriptions where it is felt desirable. Check the unit for cleanliness with attention to the following : All foreign material such as wiremesh, hand tools or insulation, etc., must be removed from all the areas to prevent damages. All foreign materials on air preheater tubes must be removed. Ducts must be cleaned. Accumulations of dirt etc., in duct expansion joints must be completely cleaned. Ducting and burner sections should be cleaned and any dripping of oil near the burner should be cleaned out. Check roof tubes and panels and outer casing for provision of expansion movement of line vents, spring hanger rods, drains, steam sample connections, thermo-well connections and other pressure part attachments extending through casing. Check for the proper opening and closing of the peep holes and manhole doors. Keep them closed after inspection. Check hangers on headers, ducts and pipelines. See that all are carrying load, properly and are within their travel range. Disengage the spring stops and hang it from the hanger itself. Check damper shaft packing and replace the damaged ones. Check up whether all the damper flaps are in proper position if not, rectify the same. Check for proper sealing of all the flaps in closed condition. Mark on the outer casing of the damper frame, the open and close positions of the dampers. Expansion trams are to be installed at locations marked or as decided by the site engineer. Check furnace guides for correct installation and clearances. Check entire boiler to make sure that all temporary welded structures to the main structural steel are removed. Check rotating equipments for proper operation as per the recommendation of vendors.

Inspect and clean all fuel strainers and see that the entire fuel system is free from foreign material. Have oil guns made up with clean atomisor tips. The burner management system and the master control panel system should be operational and shall not be bypassed.

UNIT OPERATING PROCEDURE

INTRODUCTION :

The procedure outlined in this section are intended to serve as a guide during initial stages of commissioning and operation. The procedures include precautions which should be observed and explains the proper operating sequences of the boiler, the fuel firing equipment and auxiliaries. The boiler is only one part of the overall process complex and other equipments must operate in unison. Specific procedures and detailed values have not been included in this manual for the entire process complex. There shall be close coordination between boiler and plant operation particularly during start up. It is essential that boiler start up is synchronised with plant operation, to meet the specific steam demands of the plant. As operating experience is gained and controls are fine-tuned, the boilers characteristics and actual operating requirements will become evident to the operators. References should be made to the boiler interlocks and other control loop instructions for further operation details. Reference should also be made to the respective manuals regarding operational and preoperational procedures for the boiler auxiliary equipments.

NORMAL COLD START UP OF THE BOILER:

Before lighting up the boiler, be sure to adequately purge the furnace, by sending sufficient air to evacuate any combustible gases/material left in the furnace. To ensure maximum safety during cold start-ups, it is recommended that a high air flow of atleast 30% MCR be used in order to produce an air rich furnace atmosphere. It is recommended that this high air flow be maintained during the light-up until the boiler is on the line and reaches a load where additional air is required to maintain the design operating excess air. When bringing the unit upto the rated pressure and temperature, the saturated steam temperature rise, should be limited to 50 C per hour. The corresponding rate of drum pressure raise will then be maintained.

During all start-ups the firing rate must be controlled to keep the maximum temperatures of the gases leaving the furnace below 500 C. this is to avoid over heating of tubes down stream of the furnace. This restriction is relaxed when once there is continuous steam production with pressures above 6 Kg./Sq.cm(g). NOTE : IT IS RECOMMENDED THAT DURING INITIAL START-UP OF A NEW UNIT, A SLOWER RATE OF TEMPERATURE INCREASE BE FOLLOWED IN ORDER TO ALLOW SUFFICIENT TIME FOR CHECKING EXPANSION MOVEMENTS AND TO PERMIT THE OPERATORS TO BECOME FAMILIAR WITH THE CHARACTERISTICS OF THIS STEAM GENERATOR AND ITS AUXILIARIES. The following steps outline the procedure for bringing a cold boiler upto working pressure and temperatures. It is assumed that the boiler has been chemically cleaned and prepared for operation. The boiler should be filled with demineralised water. The water level in the steam drum should be at normal operating level. The pre-commissioning checks given below should have been carried out before start-up of the boiler.

PREPARATION : Check the following items prior to start-up :

All access doors closed. Starting equipment and interlocks are checked and satisfied. Retractable soot blower elements are away from gas path. All boiler fittings and valves are in proper order. Feed water regulating valves are closed and on manual control. All blowdown and drain valves on boiler and water walls closed. Soot blower master steam supply valves closed. Main steam line stop valve closed. Drum vent valves open. Water level gauge valves kept open.

Main steam line drains kept open. Check the auxiliary equipments for adequate lubrication and / or cooling water flow. Put all automatic control equipments on manual control and see that all control equipments are ready for service. All instruments control connections are kept open. Instruments should have been calibrated and checked with master gauges for corrections. Instrument panel power and compressed air is available. Power for fan / pump starting is available.

FILLING OF BOILER WITH WATER :

Before starting the filling up, open the vent valves on economiser, boiler drum including start-up vent valve provided at the outlet. It is also possible to fill up the economiser simultaneously through the drain valves or through the main feed line. The boiler is to be filled with DM water upto normal level.

STARTING THE FIRE :

1.

Purge the furnace with FD fan and ID fan running for about three (3) minutes and stop the FD fans. Keep the dampers of ID fan open in order to have a natural draft inside the furnace. Light up the LDO burner as per the instructions given in the burner catalogues. After the flame is well established adjust the ID fan to maintain the proper furnace draft of (-) 5 mm wc. Gradually increase the load by increasing the fuel and air so that the boiler is heated up uniformly. Close the drum vents when the drum pressure reaches 2 Kg./Sq.cm(g).

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During the warm up period, the water level inside the drum will rise due to swelling. When the water level reaches high, operate the blow down valves and gradually reduce the water level in the drum during the warm up period to normal water level. During the boiler start up the firing rate can be increased gradually keeping the furnace exit gas temperature below 500 C. When the drum pressure reaches 5 kg/sq.cm(g), the steam outlet drain valves shall be closed and start up vent valve is to be throttled to allow sufficient flow and increase the boiler pressure gradually. While the pressure is rising, make frequent checks of the boiler expansion movements. Expansion movements should be recorded for comparison with future start-ups. Check boiler water concentrations and constituents frequently to maintain proper boiler water conditions. At 6 kg/sq.cm(g) pressure operate the water wall header drains individually for one (1) minute to bring down the solid content in the water, keeping the drum level under control. Increase the firing rate further as necessary. Do not close start up vent completely until steam flow through the main steam line is established. As the load demand increases, the firing rate has to be increased by increasing the fuel feed and air. Adjust the feed water supply to the boiler as necessary to maintain normal water level. Feed water control should be placed on automatic as soon as possible and when continuous feed water flow is established. If the setting of the safety valves on the drum and superheater has not been checked previously this should be done prior to taking the boiler on line. Heavy Fuel Oil firing could be started at 30% of boiler load and slowly HFO can be admitted into the burner observing necessary precautions. HFO quantity can be increased slowly.

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NORMAL OPERATION - UNIT LOAD CHANGES :

During normal operation with the unit on the line, changes in boiler load can be achieved by controlling the fuel feed and combustion air supply.

NORMAL SHUT DOWN TO COLD :

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Gradually reduce load on the unit; reduce the firing rate in line with the decreasing flow. Allow the pressure to drop with the reduction in load to accelerate cooling. Reduce the steam temperature at the rate prescribed. The rate of temperature drop should be maintained @ 50 C/hr. It is recommended to have the decrease of air flow lead the reduction of fuel slightly to maintain more stable furnace conditions. All fires should be cut out when the boiler is off the line. Check the expansion movement of the unit as load is being reduced. Immediately after the boiler is off the line, open the start up vents. Purge the unit by running the induced draft and forced draft fans for atleast five minutes (at a minimum of 30% air flow) after the fires are extinguished. Continue running the fans to cool the unit at the desired rate. Maintain the water level near normal in the gauge glass. Open the drums vents when the unit pressure has been reduced to 2 kg./sq.cm(g). If the boiler is to be emptied, the boiler water temperatures should be reduced to atleast 90 C before draining. HFO line to be purged after unit shut-down.

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HOT RE-START :

Assuming the boiler has been down for a comparatively short period of time and considerable drum pressure was maintained, the following procedures should be used in restraining the unit : 1. Make a general inspection of the boiler and check the points as mentioned under normal start up.

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Crack open steam outlet drain to remove the condensate. Start ID fan, and FD fan as outlined under Normal start-up. Light up the unit. The rate of firing and duration of warming period depends entirely on the boiler pressure and temperature. Care must be taken to control the firing rate within the limits (furnace outlet temperature of flue gas shall not exceed the recommended limit). The working period should be long enough to allow complete boiling out of the condensate in the pipes and get drained. Open wide all main steam line drains and vents to allow complete draining of the line. After draining close all drains and vents except the outlet header drain. Stabilise the firing conditions to maintain the maximum furnace exit gas temperature without exceeding it. Start shutting down the start-up vent to raise the steam pressure as prescribed rate of pressure increase.

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EMERGENCY OPERATION

LOWER WATER LEVEL : If the water level falls out of sight in the water gauge, due to failure of the feed water supply (except in the case of momentary fluctuations that might occur with extraordinary changes in load) appropriate action should be taken at once to trip the boiler. Any decision to continue to operate, even if only for a short time at a reduced rating would have to be made by someone in authority who is thoroughly familiar with the circumstances that led to the emergency and positively certain that the water level can be restored immediately without damaging the boiler. In the absence of such a decision, 1. 2. 3. 4. Secure the burners immediately and trip the FD Fan. Close the feed water valves. Shut of all steam being discharged from the unit. Simultaneously, if feed water has become available and the operator is assured that no pressure parts have been damaged, the flow of feed water to the boiler should be gradually increased by manual regulation. The purpose of handling the feed in this manner is to avoid quenching pressure parts with relatively cold water by raising the water level. The feed water regulating valve should be closed completely when all steam flow from the unit has ceased. If pressure parts damage is suspected, reduce the steam pressure gradually by opening the start up vent. Open the drum vents when the pressure drops below 1.5 kg/sq.cm(g). Drain the boiler when the drum metal temperature is 90 C following normal draining procedures. Determine the cause of low water and examine the boiler for the effects of possible overheating such as leaks and distortion of pressure parts. Repair any leaks, etc. Hydrostatically test the boiler at working pressure before putting the unit back in service.

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HIGH WATER LEVEL :

Abnormally high water level should be avoided as it may lead to carryover and even priming if the water level rises above the recommended normal operating range, proceed as follows :1. 2. Reduce the water level immediately by opening the blowdown valves. Reduce the steaming rate, if necessary, and place feed water control in manual mode.

If priming should occur, as indicated by rapid fluctuations in outlet steam temperature, proceed as follows :1. 2. Reduce the steaming rate. If the water level is abnormally high, reduce the level by opening the intermittent blowdown valves and place feed water control on manual. Investigate the water condition (alkalinity and solids). Investigate the condition of the drum internals as soon as an opportunity is afforded.

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TUBE FAILURE : WATER WALL TUBES

In the event of failure of one or more water carrying tubes, the best method for shutting down the unit will be dictated by the size of the failure, the ability to maintain normal water level and the demands for the service of the unit. The following instructions regarding tube failures are of a general nature. It must be understood that conditions may rise which will require exercise of judgement by the operators. In case of a leak or tube failure which does not involve serious drain on the feed water supply, the water level should be maintained and the unit taken out of service in normal manner. (Refer to normal shut down procedures).

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If the tube failure results in a loss of water so great that the water level cannot be maintained with the feed water supply available the following method outlined below shall be adopted :1. 2. 3. 4. 5. Trip all fuel. Shut off feed water to the boiler. Maintain only enough air flow to carry the escaping steam up the stack. Leave ID fan in service until pressure is off the unit. After the unit has cooled enough to permit a man to enter it, make a thorough inspection of pressure parts for any indication of damage resulting from loss of water level. After the necessary repairs have been made apply a hydrostatic test and obtain the approval of the proper authorities before putting the unit back in service.

ECONOMISER TUBES

An economiser tube leak can be detected by sound and / or increased make up water requirements. The leak should be investigated at the earliest possible time and the unit shut down in a normal manner.

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WALK DOWN CHECKS

One of the most important benefits of a walk-down of a unit is derived from the operator keeping his eyes and ears open for any unusual condition and reporting his findings to his supervisor. Potential damage to equipment can be avoided if abnormal conditions are detected in time. The following are some of the items that an operator should be looking for :-

GENERAL

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Listen for unusual noises that may indicate leaks of steam or water. Look for any unusual traces of water on the floor, buckstays or leaking from casing joints. Look for valve and valve packing leaks. Be on look-out for any unusual condition (discoloration hot spots etc.) on casing of boiler and on duct work. Look inside the furnace through observation posts to detect any abnormal condition of the fires which may indicate improper air damper settings. Check for unusual noises, overheating of bearings and for adequate lubrication of all rotating equipment. Look for leaks in gauge glasses and water columns. Check the soot blower system including packing on retractable blowers for possible leaks. Look for leaking vent valves. Look for leaking safety valves. Check soot blowing operation by following each blower as it operated to see that the operation is correct. Check for proper expansion of boiler to ensure no hold-ups occur. Check spring hangers on boiler support and on steam lines for proper functioning.

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Make a routine inspection of all equipments to ensure proper lubrication, cooling water supply, etc. Look at the stack to ensure that adequate combustion air for burning of the fuel is provided and the stack gases are at acceptable limits. Listen for any tube leaks in the furnace. Look for damages of the local gauges so that it can be replaced in the subsequent shut downs. Look inside the burner for proper fire conditions and operation of the burners. Check for flame scanner and ensure that scanner shows flame only while flame is present in the furnace. Look for open peep holes, manholes, etc., and close them to avoid air ingress. Look for proper access on platforms and remove unwanted material from hindrance on the platforms. If not operated continuously put the pilot ignitor in service and check that they operate correctly. Look for adequate pressure in the gas manifold for ignitor.

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