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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

BAJAJ ENERGY PVT LTD


6190 TPH CFBC Boiler
Project
KHAMBARKHERA,BARKHERA,MAQSOODAPUR
UTTAR PRADESH

BAJAJ ENERGY PVT LTD


Purchaser / End User

2 26.09.2014 B&PP

1 16.07.2014 B&PP

Rev. Date Description Approved By

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

Index
A. Boiler Trip Values & Interlock Settings

B. Fan start up procedure (To be followed for both Cold and Hot Start Up)

1. ID Fans
2. SA Fans
3. PA Fans

C. Cold Start Up of Boiler

1. Pre-requisites
2. Filing of Boiler drum with DM Water

D. Hot Start Up of Boiler

1. Pre-conditions
2. Plant Response
3. Actions required to be taken

E. Shut down Procedure


1. Hot box up
2. Cold box up
3. Black out condition

F. Trip Analysis - Immediately after any Trip-out

1. Pre-conditions
2. Plant Response
3. Actions required to be taken

G. SOP after Tripping of boiler on Furnace Pressure High after Tube Leakage/stopped due to tube leakage

1. Pre-conditions
2. Post tripping/shutdown Actions

H. SOP-When Water side tube leakage is confirmed and boiler is running (not tripped).

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

A. Boiler Trip Values & Interlock Settings:

Sl.
Description Set Point Action Remarks
No.
(-) 150 mmWC
1 Furnace Pressure Very Low Boiler Trip Both ID fans trips

SA, PA, CF,HGG


2 Furnace Pressure Very High (+) 100 mmWC Boiler Trip
Trips

900 deg C-First coal


feeder trip
3 Bed Temp. High 900 C and 910 C Coal Feeder trips
910 deg C-second
coal feeder trip

5 Drum level Very Low (-) 320 mmWC Boiler Trip PA, CF,HGG trips

6 Drum level Very High (+) 150 mmWC Boiler Trip PA, CF, HGG trips

PA Discharge Pressure Very High (If


PA, CF, HGG
7 any one or both Coal Feeder are 1750 mmWC Boiler Trip
trips
running)

8 PA flow < Minimum ( kg/s) Fuel Trip CF, HGG trips

9 Bed Temp Sensors Faulty 3 out of 4 Nos. Fuel Trip CF, HGG trips

10 Bed level Very High 1400 mmWC Boiler Trip PA,CF,HGG trips

11 Bed level Very Low 500 mmWC Fuel Trip CF ,HGG trips

12 SA Flow Very Low Boiler Trip PA, CF,HGG trips

13 TA Flow Very Low Boiler Trip PA, CF,HGG trips

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

Fan start up procedure:


B. Starting of Fans (To be followed for both cold and hot start up)
1. ID Fans:

After thorough inspection of the boiler and ensuring readiness in all aspects, ID fans can be started in the
following manner:

a. Ensure supply and control power is on. All bearings (motor & fan) are filled with proper lubrication.

b. Free movement of the dampers and cleanliness of the area and all bearing vibrations, temperatures
and motor winding temperatures are showing in DCS.

c. Ensure ACW water for Voith coupling oil cooler is available and cooling water pressure is also
adequate.

d. Ensure CO vent is open.

e. Ensure inlet and outlet dampers of all the SA and PA Fans are in closed condition.

f. Ensure Inlet and Outlet dampers of both the ID fans are in close condition.

g. Start both the ID fans one after another and instruct site operator to check for any abnormal sound,
vibration, abnormal heating/rubbing of the rotating parts. If no problem observed first open discharge
damper then suction damper.

h. Slowly increase the speed of the fan and set desired Furnace Draft of (-) 30 mmWC for hot start up.

i. For cold start up with bed material Furnace draft set point can be maintained around (-) 20 mmWC
during oil firing but before putting coal in the furnace set point should be increased to (-) 30 mmWC.

j. Set Draft to normal and put draft on Auto control mode.

k. Observe for the entire f l u e gas path pressure profile.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

Fan start up procedure:

2. SA Fans:

For starting of the SA fans, at least one of the ID fans must be running for the last 5 minutes(300 seconds)
and CO must be less than 300 ppm with furnace draft set point (-) 30 mmWC.

a. Ensure supply and control power is ON, all bearings are filled with proper lubrication, free movement
of the dampers and cleanliness of the area and all bearing temperature and vibration signals are
showing in DCS.

b. Ensure CO vent is open .

c. Ensure inlet and outlet dampers of all the SA and PA Fans are in closed condition.

d. Ensure SA air to Furnace and tertiary air dampers are in open condition.

e. Start both SA fans one after another and instruct site operator to observe for any abnormal sound /
vibration / abnormal heating / rubbing of the rotating parts.

f. If no problem observed open dischargedamper and start opening IGV of the fans.

g. Adjust speed to get a minimum SA flow of 6 kg/s and tertiary air flow of 3 kg/s (for hot startup) and
for cold start up keep SA and TA flow well above tripping limit.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

Fan start up Procedure:

3. PA Fans:

For starting of the PA fans, SA fans should be running for the last 5 minutes with SA flow more than 6
kg/s.

a. Ensure CO vent valve is open.

b. Ensure supply and control power is ON, all bearings are filled with proper lubrication, free movement
of the dampers and cleanliness of the area and all bearing temperature, vibration and motor winding
temperature are showing in DCS.

c. Please ensure that fluidizing air lines to siphon are in OPEN condition.

d. Ensure proper Oxygen and CO level at Economizer inlet. Before Starting of PA fan CO level at
Economiser inlet shall be less than 300 ppm and oxygen at PA duct should be greater than 18%.

e. Drum level is normal and boiler Air protection OK.

f. Ensure PA Fan discharge dampers and IGV are in CLOSE condition.

g. Start PA Fan and instruct site operator to observe for any abnormal sound / vibration / abnormal
heating / rubbing of the rotating parts.

h. If no abnormalities are observed then open the IGV of the fan.

i. Open the IGV of the fan and Maintain PA discharge pressure below 600 mmWC. Maintain the pressure
for 300 seconds. After completion of 300 seconds CO vent valve will close automatically. Do not
increase the pressure within 300 seconds then counter will start counting again. After Closing of CO
vent valve start increasing the Fan speeds to get minimum PA flow.

j. For hot start up, PA flow should be maintained as per the requirement depending upon bed
temperatures; but it should always be maintained above minimum fluidization set point. For Cold start
up with bed material, PA flow should be maintained above fluidization set point before putting HGG
into service.

k. While increasing PA flow, closely observe the furnace draft and in hot start up it should be maintained
(-) 30 mmWC.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

NOTE: In case of any tube leakage observed in the furnace and boiler tripped or shutdown, DO NOT
START PA FANS for force cooling of the bed. Once the boiler is tripped or shutdown, the operation
manager should ensure that both the PA fans are electrically isolated and their panels are racked out
and tag out and feed water flow to the boiler should be stopped and all feed control stations valves
should be closed.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

C. Cold Start Up of Boiler

1. Pre-requisites :

Pre-startup checks before taking Boiler into service after a long or annual shutdown.

1.1. Ensure no equipment is left under permit and satisfactory trial run of all ESP fields, all HT/LT
motors and related drives, Motorized valves and Dampers, Pneumatic valves and Dampers are
taken.

1.2. Ensure all instruments fitted in the area as well as control systems are working properly.

1.3. Further ensure no person / foreign material is in the air and flue gas path.

1.4. Ensure all manholes of boiler are tight closed and furnace bed is filled with appropriate bed
material up to the specified level.

1.5. Pre-Operation Checks to be carried out as following :

SI.
Check Points Required Status
No.
1. Flue gas path Clean, no foreign material is left, all manholes closed.

B o i l e r tested hydraulically (If after an O/H or repair) for no leakage, Required


2. Pressure Parts portions should be protected with the protection plates / sleeves, GD plates are in
proper position, drum filled up to proper level.
All the hoppers are empty and clean recirculation system & siphons, siphon
Cyclones and ash
3. nozzles are in good condition, good condition of the cyclone path and refractory,
recirculation system
siphon air system ready
Testing for any tube leakage carried out and leaking tubes replaced / plugged,
4. APH
manholes ( Ai r / f l u e gas sides) closed
Properly cleaned, hoppers empty, mechanically checked for proper fitment, proper
5. ESP
rapping action, electrically checked for operation in a i r .
Ash H a n d l i n g All systems should be properly fitted and operative in AUTO mode through PLC, No
6.
system leakage of air through air / ash conveying lines.
Drives motorized Mechanically and electrically tested by trial runs, kept in remote operation mode,
7.
actuators All instrumentation in place and working normal
Pneumatic actuators
8. Free movement, calibration c h e c k e d
/ dampers / CV's
All the instrumentation points should be in line with proper c a l i b r a t i o n . All
Measurements and
9. control logics / protections should be properly tested by simulation / creating
controls / protections
actual condition as far as practicable.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

SI.
Check Points Required Status
No.
LDO circuit & pump, no leakage of LDO, Burner assembly cleaned, combustion
10. Hot Gas generator
and dilution dampers checked, protection system, LDO stock
PA Nozzles should be cleaned by compressed air and then Bed material filled up
11. Furnace
to proper level,
Availability of cooling water, compressed air (Instrument & Service), Lighting,
12. General
housekeeping

13. Fuel Ensure proper level of coal bunkers and LDO tank

Required control & protection logics healthy, personnel with adequate safety
14. Safety
appliances, equipments with recommended safety measures

2. Filing of Boiler drum with DM Water:

2.1. Ensure all Drains of the Feed Water circuit are tight closed and all vents of Superheaters,
Economizers and Drum are open and Drains of Superheaters and MS line are open.

2.2. Open Economiser-1 drain valve and boiler filling pump's suction valve, start Filling pump and
open discharge valve.

2.3. Fill the Boiler drum through ECO-1 and then ECO -2. Ensure sufficient and constant water coming
out of the Economizer vent line then close the Economizer vent valve.

2.4. Start both DM Transfer Pumps and throttle the recirculation valve. Maintain the DM Water Tank
Level within the normal range.

2.5. Maintain RFW Tank Level. Operator to manually regulate the flow of DM water going to the boiler
if the tank level falls remarkably.

2.6. Ensure proper level of Boiler Drum then stop Boiler Filling Pump and tight close the Economizer
drain valve. Close boiler filling pump's suction and discharge valves.

3. Ensure that CO vent valve is open.

4. Ensure Emergency Stop Push Buttons of all electrical drives are released.

5. Ensure Power supply of all the HT / LT Motors are on and selection of operation mode should be at
remote position. All flags to be reset.

6. Start one ID Fan first then second ID fan and allow them to run for 5 minutes, maintaining the furnace
draft to (-) 30 mmWC. Only then SA fans are allowed to start. After 5 minutes of ID fans running, start
SA fans and get a flow of 6kg/s for 5 minutes to ensure complete purging of the furnace.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

7. After achieving the permissive to start PA Fan, start PA fan and open the discharge damper start
increasing the opening of IGV.

8. Maintain PA pressure below 600 mmWC for 300 seconds for closing of CO vent valve. After closing of
CO vent valve increase the IGV opening and raise the PA flow more than Fluidization level.

9. Ensure proper fluidization of the furnace bed. Check for any abnormal sound, vibration or heating of
the various drives in service.

10. Start LDO Pump and ensure LDO header pressure of 9.0 - 10.0 kg/cm2 by adjusting the recirculation
valve. Ensure service air pressure of 5.5 - 6.5 kg/cm2 at HGG floor. Charge service air line to the boiler
furnace sight glasses, HGG Flame scanner & HGG oil gun, HGG view glass. Ensure LPG pressure is also
adequate.

11. Adjust PA flow through both Hot Gas Generators by adjusting IGV of both the fans.

12. Ensure ESP fields are not charged during oil firing. Keep emergency push button of the ESP fields
pressed during oil firing.

13. Start Boiler Feed pump and condensate pump for maintaining drum and Deaerator level. Ensure
appropriate make up water to the hot well.

14. Start both HGG one by one and set the oil flow such that refractory temperature at HGG outlet should
not exceeds 850C . Ensure slow heating of the refractory and boiler bed.

15. Raise the temperature of boiler furnace bed slowly to avoid unusual thermal expansion. While water
starts boiling, close the drum vent at a drum pressure of 2.0-3.0 kg/cm2. Throttle the superheater
drains to crack open.

16. Close all super heaters vent at 5.0 kg/cm2 drum pressure.

17. Ensure proper opening of the startup vent for proper steam flow through Superheaters. Maintain drum
level.

18. After attaining bed temperature of 530C, and start one coal feeder at lower speed for sprinkling
coal. Wait for starting of coal combustion. Maintain bed temperature by adjusting PA flow. When
oxygen will start decreasing stop the coal feeder.

19. Again start coal feeder if coal combustion has been established. Take another coal feeder into service
Adjust PA and SA flow as per requirement. Put both the coal feeders into service and Maintain Bed
Temperature <800C and raise slowly MS pressure to 97 kg/cm2. Open MS Stop Valve Bypass at 25

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

kg/cm2 and MSSV at 40 kg/cm2 and give clearance to the turbine side for starting necessary line
heating.

20. Charge Attemperator station as per requirement.

21. Take-out Hot Gas Generators from service after establishing coal firing and charge ESP fields after
achieving flue gas exit temp above 130 Deg.C.

22. With appropriate current loading after attaining the ESP inlet flue gas temperature above 130C.
Stop LDO Pumps and close their suction / discharge valves.

23. Secondary and Tertiary air can be adjusted as per combustion requirements. The oxygen % at ECO-1
I/L should NOT fall below 3.2% in any condition.

24. Maintain MS Temp, MS pressure and various other parameters as specified. All controls can be put to
auto mode after stabilizing the combustion.

25. Put cyclone and bed ash evacuation system in service. Put bed temperature control in auto at 850 to
860C range.

26. Gradually raise the boiler loading as per the requirements of turbine side.

27. Put ash conveying system in service with Auto control through PLC.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

D. Hot Start Up of Boiler:

1. Pre-conditions :

Boiler tripped on any of the protections / tripped manually under loaded condition .

2. Plant Response:

2.1. In case of boiler trip PA, SA, Coal feeder will trip and only ID fan will continue running,
except case of furnace draught negative trip. In case of furnace draught negative trip, ID fan
will also trip. For single boiler - single turbine configuration, TG will also trip along with
boiler trip causing the total generation to zero, but except for the Blackout condition, grid
power will remain alive.

2.2. CO vent will open automatically. Please ensure the opening of CO vent Valve physically in
the field also.

3. Actions required to be taken:

3.1. Ensure CO vent and evacuation line valves are open. Closely monitor the action of EMSV
and if it is not opening then try to control the Drum/MS line pressure by regulating the
start up vent valve, provided controller supply is available.

3.2. Restore Grid power and charge the MCCs. Ensure supply to all drives normal with remote
access.

3.3. Start both ID fans keeping in view the required logics for its permissive. Maintain the
furnace draft to (-) 30 mmWC. Establish the cause of trip and suitable corrective
measures, hot start up can be preceded as following:

3.4. Restore auxiliary systems e.g. ACW, CW, Compressed Air etc.

3.5. Crack Open drains of Super heater / main steam line.

3.6. Start one ID fan first then another ID fan and adjust speed to make furnace draft to -30
mmWC. Put draft control in auto mode.

3.7. Start BFP and maintain drum level. Start DM transfer pump/CEP and maintain Deaerator
level.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

3.8. Purge furnace with ID fan for at least 15 minutes, before starting SA fan ensure that CO
level reaches below 300 ppm. After CO reaches below 300 ppm start SA fan and open
discharge damper and increased SA flow by increasing IGV opening. Maintain SA and TA
flow above tripping limit (4 kg/s for SA and TA) before starting PA fans. Before starting SA
fan ensure that SA dampers are minimum 50% open and TA damper is minimum 40 %
open. SA and TA flow to be adjusted as per oxygen percentage and bed temperature.

3.9. Watch for any abnormal reading in the O2 and CO analyzer at Economizer inlet.

3.10. Ensure that both the HGG bypass dampers are open before starting PA fan .

3.11. Start PA fan only when oxygen level at PA duct reaches above 18%, Open discharge
damper and maintain PA discharge pressure around below 600 mm wc for 300 seconds
and then start increasing PA flow by opening IGV. Increased PA flow more than air
required for fluidization (May be increased as per the requirements). Closely watch bed
height, Wind box pressure, PA fan Discharge pressure, bed temperature and oxygen. If
bed temperature is in increasing trend wait till it comes to decreasing trend before
charging coal.

3.12. After charging of coal closely watch Oxygen and freeboard temperature if coal starts
burning, oxygen will comes down and free board temperature starts increasing. If after
charging coal Oxygen did not decreases stop coal feeding and watch oxygen. In case bed
temperature falls below 530C during the start up, take HGG in service immediately.
No coal should be charged to the furnace until bed temperature is >530C.

3.13. Control the MS pressure by regulating the start up vent.

3.14. Open bypass valve of the main steam stop (If in case of Main steam stop valve closed
after tripping) valve at 25Kg/cm2, and necessary line heating in the turbine side can be
initiated.

3.15. Open main steam stop valve after equalizing the MS line pressure.

3.16. Maintain the MS pressure as recommended by regulating the startup vent. Allow steam
for TG rolling and synchronizing activities.

3.17. Close the Superheater and MS line drain valves.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

3.18. Increase the coal firing rate as per steam demand. Adjust the air demand by SA / PA
flow keeping in view the combustion requirements. Ensure that Oxygen % never comes
below 3.2%.

3.19. Put all controls in auto mode.

3.20. Take ESP fields in line after APH O/L temperature attains 130 Deg.C.

3.21. Start ash conveying systems.

3.22. Boiler is ready for further load steam demand from turbine

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

E. Shut Down Procedure:

1. Hot Box up:

A. Pre-Conditions:

Boiler is running with all parameters normal and need to be stopped for a short period for carrying out
any outside job or any maintenance activity in any other system.

1. Start decreasing the boiler load slowly as per turbine requirement by decreasing the speed of both the
coal feeders.

2. Control boiler outlet pressure either by start up vent valve or by turbine HP bypass valve.

3. First stop both the coal feeders and Coal feeder outlet gate should close automatically.

4. Keep running PA fans and when oxygen will be in increasing mode start decreasing PA flow. As PA flow
reaches below Fluidization level Stop PA fan. After stopping PA fan Close the IGV(100% close) and ensure
that discharge damper also in close condition. Closely monitor CO level after PA stop.

5. Please ensure that CO vent valve at the PA APH outlet duct got open, evacuation line valves on PA duct
above HGG to APH hopper are open and Isolation dampers on PA duct are close after PA fan stop.

6. After PA fan stop continue running SA fan for another 15 mins with reduced SA flow then stop SA fan one
by one. After stopping SA fans close SA and TA dampers to furnace, SA fan IGVs and Discharge damper.

7. Keep on one ID fan running with minimum furnace draft.

8. Closely monitor drums level, Oxygen percentage and CO level.

2. Cold Box up:

A. Pre-conditions:

Boiler is running with all parameters normal and to be stopped for considerable time(For annual
overhauling or inside maintenance and will not need to be started within 24-36 hours.

Please follow the same steps from 1 to 3 as stated above.

4. After stopping both the coal feeders keep on running all the fans till bed temperature reaches below 500
deg c.

5. When Bed temperature reaches around 100 deg c, stop PA fans one by one by slowly closing IGVs. As PA
flow reaches below Fluidization level Stop PA fan. After stopping PA fan close the IGV and discharge
damper. Full closing of IGV and discharge dampers to be insured.

6. After PA fan stop please ensure that CO vent valve at the PA APH outlet duct is open, HGG combustion,
dilution and bypass dampers are closed.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

7. Closely monitor CO level and Oxygen percentage.

8. After PA fan stop let SA running for another 15 mins with reduced SA flow then stop SA fan1 by one.
After stopping SA fans close SA and TA dampers to furnace,SA fan IGVs and Discharge damper.

9. Keep on one ID fan running with minimum furnace draft .

10. After Boiler box up closely monitor and maintain drum level till below screen temperature reaches
below 150 deg c.

11.When drum pressure reaches 5 kg/cm2 open super heater drains ant when pressure reaches below 2
kg/cm2 open drum and super heater vents.

NOTE: Before carrying any internal job start PA fan again and fluidize the bed to ensure that bed is properly
cooled.

3.Black Out Condition:

During Black out condition all fans will stop simultaneously. First ensure that CO vent valve got open,
evacuation line valves open and isolation dampers got closed and Main steam stop valve, PA,SA,ID fan
discharge dampers, SA and TA to Furnace dampers are close.

After Power restoration start one ID fan first and continue running for at least 15 minutes. Closely monitor
CO level and Oxygen percentage. Start BFP and maintain drum level.

Before starting SA fan ensure that CO level reaches below 300 ppm.

Then after please follow hot start up procedure.

F. Trip Analysis - Immediately after any Trip-out:

1. Pre-conditions :

Boiler tripped on any of the protections / tripped manually under loaded condition with coal feeders
running.

2. Plant Response:

2.1. In case of boiler trip PA, SA, Coal feeder will trip and only ID fan will continue running, except in
case of furnace draught negative trip. In case of furnace draught negative trip, ID fan will also
trip. For single boiler - single turbine configuration, TG will also trip along with boiler trip causing
the total generation to zero, but except for the Blackout condition, grid power will remain alive.

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Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

2.2. CO vent, evacuation line valves will open automatically. Please ensure the opening of CO vent
Valve , evacuation line valves and closing of isolation dampers physically in the field also.

3. Actions required to be taken

3.1. Restore Grid power and charge the MCCs. Ensure supply to all drives normal with remote
access.

3.2. Start both ID fans keeping in view the required logics for its permissive. Maintain the furnace
draft to -30 mmWC.

3.3. Establish the cause of trip. In case of High furnace pressure trip (Without tripping any ID fan), a
thorough inspection from outside should be done before starting the Fans. If any hissing sound
is observed from inside, the same would confirm the tube leakage. Establish whether the same
is from first pass or second pass.

3.4. In case of other cause of trips, following checks are required.

SI.
Cause of trip Required Checks
No.
Ash recirculation circuit, fuel quality, Thermocouple
1 Bed Temperature High
Measurements
Ash recirculation circuit, fuel quality, Bed height measurement
2 Bed Level High
in DCS
Air flow , Flue gas circuit, ID/SA/PA fans and various IGV's /
3 Furnace Pressure Low
control dampers
PA flow Low / C.F. Running /
4 PA Fans / Dampers / Flow transmitter readings
Siphon Purge Air stopped
Bed Drain slide gates, Ash recirculation circuit, Fuel quality,
5 Bed Level Low
Air Flow
6 ID I/L Pr Low Air/flue gas flow

7 Drum Level High / Low Feed water system, FCS valves

Prepared By : SN
Checked By : PG
Page 17 of 19 Boiler Service Division
http://boilersinfo.com

Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

G. SOP of Boiler - Tripping On Furnace Pressure High after Tube Leakage: or stopped due to tube leakage

1. Pre-conditions :

Boiler tripped on "Furnace Pressure High" under loaded condition with coal feeders running.

2. Post tripping Actions:

2.1. We must refrain from forced cooling of the boiler in case of tube leak in the boiler.

2.2. The boiler purging sequence should be completed to purge out any combustible substances in
the flue gas path as following:

2.2.1. Restore auxiliary systems e.g. ACW, CW, Compressed Air etc.

2.2.2. Crack Open drains of Superheater / main steam line.

2.2.3. Ensure CO vent valve is open. HGG combustion, dilution, bypass dampers are closed
and SA,TA dampers near to furnace are tightly shut off.

2.2.4. Ensure power of PA Fans is made OFF and breaker raked out. Ensure no water is fed to
the boiler for maintaining drum level. Don't run BFP and rake out the breaker of BFP
also.

2.2.5. Start one ID fan and make furnace draft to -30 mmWC. Put draft control in auto mode

2.2.6. After through purging the flue gas path, open the manholes near furnace bed.
Allow the boiler to cool down until the bed temperature falls down to <100C.

NOTE: IN CASE OF FURNACE TUBE LEAKAGE, DO NOT START PA FANS FOR FORCE COOLING OF THE
BED. BOILER SHOULD BE ALLOWED FOR NATURAL COOLING ONLY AND FEED WATER FLOW TO BOILER
SHOULD BE STOPPED IMMIDIATELY AND ALL FEED CONTROL STATION VALVES SHOULD BE ISOLATED.

Prepared By : SN
Checked By : PG
Page 18 of 19 Boiler Service Division
http://boilersinfo.com

Project : 6x190 TPH CFBC Boiler


Project No. : 2M.0020,0021,0022
ThyssenKrupp Industries India
Doc. No. : 7808-W-001-1 Rev.: 2 WBSe Description : CFBC Boiler SOP
Date : 26.Sep.2014 WBSe No. :

Document BOILER STANDARD SOP

H. SOP-When Water side tube leakage is confirmed and boiler is running (Not tripped).

1. Pre-Conditions:

Tube leakage is confirmed either from Feed water Flow and Steam Flow difference or by hissing

Sound from furnace.

2. SOP:

2.1 Start decreasing Coal Flow then trip both the coal feeders.

2.2 After Stopping both the Coal feeders stop boiler outlet Main steam stop valve.

2.3 Stop feed water flow to boiler and close all feed control stations valves.

2.4 Keep on running PA fans till it trips on Drum level Low- Low. Once PA fans trips confirm PA
discharge dampers, IGVs, HGG bypass dampers and combustion, dilution dampers , isolation dampers
are fully closed and CO vent valves, evacuation line valves are open.

2.5 10 minutes after PA fan trips stop SA fans and confirm SA discharge dampers, SA, TA dampers to
furnace are closed.

2.6 Keep running ID fan with furnace draft more than -40 mm WC.

2.7 Closely watch CO and Oxygen percentage. If CO starts decreasing increase furnace draft set point.

NOTE: This SOP is prepared on the basis of modification in logic only as decided during meeting on 25th
Sep,2014.When all other recommendation will be implemented modified SOP will be issued
accordingly.

Prepared By : SN
Checked By : PG
Page 19 of 19 Boiler Service Division