DOS Clean the internals before closing the man holes of pressure parts furnace and ducting.

parts furnace and ducting. Maintain normal water level in Feed water tank, Deaerator tank and boiler. Use proper lubricants recommended by the manufacturer regularly. All the duct joints must be leak proof. Clean all ash hoppers regularly. Maintain water quality as per the recommended limits. All dampers must be in smooth operating condition. Pressure rising from cold start must be done as per the cold start up curve. Carry out regular soot blowing for boiler and economiser (if provided). Maintain proper operation log sheets regularly. All equipment interlocks should be always in line. Start the equipments as per the sequence. Regularly clean feed water and transfer pump suction strainers. Operate the boiler within the recommended operation limits. Boiler, Piping, Ducts, Feed water and Steam piping must be properly insulated. Carry out regular cleaning of direct water level gauge glass on feed water tank, Deaerator tank and boiler drum. Use proper valve gland packing to avoid leakage. Maintain all instruments in good working condition. Use genuine spares. Boiler surroundings and equipments must be properly illuminated. Servicing of equipments should be done as per the manufacturers schedule. Use proper gaskets for flange joints. If the water level goes up above the limits operate the intermittent blowdown valve immediately and maintain the water level to normal. Operate the blow down valves as per recommendation. Boiler surroundings and equipments must be properly illuminated. In case of power failure close the steam valve and stop the fire immediately. Maintain the instrument air free from moisture and oily matters and the pressure as recommended.

Regularly maintain Refractory construction.

Before starting these equipments ensure the following: FEED WATER PUMP ID FAN FD FAN SA FAN Check no foreign material is inside the fan casing ID & FD fan in running condition Close suction damper Check lubrication The Equipment is coupled to the drive Check no foreign material is inside the fan casing ID fan in running condition Close suction damper Check lubrication The Equipment is coupled to the drive Check no foreign material is inside the fan casing Close suction damper fully Check lubrication The Equipment is coupled to the drive Ensure proper water level in the Deaerator tank Open suction valve fully Open recirculating valve fully Open balancing line valve fully Close the discharge valve fully Ensure cooling water supply to stuffing box (if provided) Check lubricating oil level The Equipment is coupled to the drive

DONT S Dont by pass any instruments and safety interlocks Dont use raw water as Boiler feed water Dont throw big size wooden logs inside the furnace for slow firing Dont start any fan with suction damper in open condition Dont start any pump with the delivery valve in open condition Dont run the Boiler with furnace in pressurized condition Dont throttle the feed water pump balancing leak-off valve while the pump is in operation. Dont operate the furnace wall header drain valves while the Boiler is in operation Dont operate the boiler beyond the operation limits Dont leave the furnace door open while the boiler is in operation Dont mix up different lubricants Dont throw water inside the hot furnace Dont alter the equipment maintenance schedule Dont leave the instrument control panel unattended Dont allow unauthorized persons to operate the boiler and associated equipments Avoid continuous operation of boiler at low loads (low back end temperature) to protect economiser and air-preheater corrosion Do not dose chemicals into the boiler in batch wise, they should be done on a continuous basis

EMERGENCY PROCEDURE During emergency conditions it is advisable to initiate the following actions to safe guard men and equipments, UNABLE TO MAINTAIN THE DRUM LEVEL CAUSES Too much load fluctuations Tube leakage in the furnace tubes ACTION

Take the drum level control loop into manual mode Reduce the water level immediately by operating the intermittent blow down to maintain the drum level if it is high Reduce steam discharge rate, if necessary Start the stand by compressor if required Analyze the water quality (alkalinity and solids)

FURNACE PUFFING & BACK FIRING CAUSES Uncontrolled feeding of fuel on to the furnace Malfunctioning of furnace draft control system Sudden increase in FD fan air Tube rupture

ACTION Take the furnace draft and air flow control system into manual mode and maintain the furnace pressure Never increase fuel/auxiliary fuel/air flow suddenly In case of tube failure take the boiler out of service immediately

BOILER EXPLOSION CAUSES Accumulation of fuel in the furnace a. b. c. d. e. Due Due Due Due Due to to to to to incomplete combustion loss of ignition fuel valve leakages frequent valve leakages frequent startups

With the mixture of unburnt fuel with air in explosive proportions and the application of heat sufficient enough to raise the temperature of mixture to ignition point.

ACTION Trip the firing systems immediately Evacuate the furnace to the possible extend Analyze the reasons for explosion and rectify the system