Boiler Startup and Shutdown Procedure PDF

NTPC REF. NO.
: CC:PES: 9518:1081:11:9129 / DATE : 30-03-07

SUPPLIER’S REPLY SHEETS DOOSAN REF. NO. : T-DS/NT-1323 / DATE : 30-01-07
SI
No.
ITEM COMMENTS REPLY REMARKS
DOC /DWG TITLE : WRITE-UP ON START-UP & SHUT-DOWN PROCEDURE DOOSAN’S Transmission No : T-DS/NT-1490
Doc. NO. : 9518-108-11-KO-PVM-W-013 /Rev. 04 /Cat. II /App. Date 22/03/07 DOC No. : T04019-PI-D0034 / Submittal Date : 25-05-07
1.Please refer our comments on P&ID no. T04019-PI-D0012&13.This document There is no mention whether condenser is vacuum or not during
is approved subjected to incorporation of NTPC comment in start up system black start-up in the technical specification. Doosan just provide
P&IDs. the bypass facility of start-up flash tank considering with
condenser vacuum condition. The matter of condenser vacuum is
Please further note that Comment from NTPC-OS ( if any ) shall be
communicated separately to be considered by equipment supplier.
---------------- Previous comments on P&ID communicated vide transmittal If NTPC require that the by pass facility for all the 3 units should be
8393 dated 23-02-2007 -------------- provided, Doosan supply only piping and valves for additional 2 units
without installation..
NTPC DRAWING NO:9518-108-11-KO-PVM-L-046
Vendor Drawing No: T04019-PI-D0012
Revision: 05A
Drawing Title: P&ID For Circulation & Start-Up System
Category:II
Comments:
You have indicated facility for black start up for Unit#3 only. As all the units
are identical the facility is need to be provided for all the three units. Kindly
revised the drawing and resubmit the same
NTPC DRAWING NO:9518-108-11-KO-PVM-L-030

Vendor Drawing No: T04019-PI-D0013
Revision: 05A
Drawing Title: P&ID For Boiler Drain & Vent System
Category:II
Comments:
You have indicated facility for black start up for Unit#3 only. As all the units
are identical the facility is need to be provided for all the three units. Kindly
revised the drawing and resubmit the same.
NTPC REF. NO. : CC:PES: 9518:1081:11:9129 / DATE : 30-03-07
SUPPLIER’S REPLY SHEETS DOOSAN REF. NO. : T-DS/NT-1323 / DATE : 30-01-07
SI
No.
ITEM COMMENTS REPLY REMARKS
DOC /DWG TITLE : WRITE-UP ON START-UP & SHUT-DOWN PROCEDURE DOOSAN’S Transmission No : T-DS/NT-1490
Doc. NO. : 9518-108-11-KO-PVM-W-013 /Rev. 04 /Cat. II /App. Date 22/03/07 DOC No. : T04019-PI-D0034 / Submittal Date : 25-05-07
M/S Doosan’s reply OS comments

14/16 The operation of soot blower is not What is the low load Low load means below 30%TMCR, at wet mode operation.
recommended at low load and high below which soot
excess air conditions. But it can be blowing operation is not
operated only where heat input to the recommended.
furnace is at a rate high enough to
prevent a flameout during the soot
blower operation.
Before set up the boiler for cold start-up vent valves are closed.
5/19 All Boiler ,SH and RH drain valves are In general during light –
After LP Bypass valve is operated the vent valves are open.
open and all vent valves are closed up of Boiler , vent valves
When separator pressure is reached at 3.5 kg/cm2g the valves are closed
will be in open position
again. (Please see page 10, 10, i and page 12 No. 26 of procedure)
till certain pressure. Why
it is required to close
initially. It is not clear.
DOCUMENT COVER SHEET
PROJECT NAME : SIPAT SUPER THERMAL POWER PROJECT
STAGE-I (3 x 660MW)
CONTRACT NO. :
ITEM : BOILER OPERATION WRITE UP
DOCUMENT TITLE : Write up on Start up & Shut down procedure
F 25/05/07 Revised as Owner’s Comments S.W.KANG B.S. YOON K.T.LEE
E 29/01/07 Revised as Owner’s Comments S.W.KANG B.S. YOON J.B.KIM

C.H.HWA
D 15/09/06 Revised as Owner’s Comments B.S. YOON
-NG
J.B.KIM
C.H.HWA
C 15/06/06 Revised as Owner’s Comments B.S. YOON
-NG
J.B.KIM
C.H.HWA
B 02/03/06 Revised as Owner’s Comments W.J.CHOI
-NG
J.B.KIM
C.H.HWA
A 25/01/05 First issue W.J.CHOI
-NG
K.SPARK
REV. DATE DESCRIPTION DGN CHK REVIEW APPR
National Thermal Power Corporation Ltd.

(A GOVERNMENT OF INDIA ENTERPRISE)
DOOSAN HEAVY INDUSTRIES &

CONSTRUCTION CO., LTD.
DOOSAN DOCUMENT NO. T04019-IC-D0034
NTPC DOCUMENT NO. 9518-108-11-KO-PVM-W-013 SHEET REV.
CATEGORY APPROVAL F
Steam Generator Start-Up and Shut-Down Procedure for SIPAT STPP
STEAM GENERATOR START-UP AND

SHUT-DOWN PROCEDURE
FOR
SIPAT STPP STAGE- I (3 x 660MW)
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO. LTD

TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION ...................................................................................................................... 1
PRE-OPERATIONAL PROCEDURES ...................................................................................... 1

Cleanup .......................................................................................................................... 1
Chemical Cleaning ........................................................................................................ 1
Steam Line Blowing ...................................................................................................... 1
Setting Safety Valves ................................................................................................... 1
COLD START -UP .................................................................................................................. 2

Cold Start Conditions ................................................................................................... 2
Preparations for Lighting Off ....................................................................................... 2
Warm Water Filling of the Boiler .................................................................................. 5
Water Recirculation via Boiler for Clean-up ............................................................... 6
Start of the Boiler Circulation Pump (BCP) ................................................................. 6
Initial Firing Precautions .............................................................................................. 6
Superheat Steam Temperature Control (Prior to Unit Synchronization) ................... 7
Air Pre-heater Protection During Unit Start-Ups On Oil ............................................. 7
Lighting Off .................................................................................................................... 8
Rolling and Synchronizing the Turbine ..................................................................... 13
Introducing Coal .......................................................................................................... 14
Initial Load Increase .................................................................................................... 15
NORMAL OPERATION -UNIT LOAD CHANGES ................................................................... 17

Decreasing Load ......................................................................................................... 17
Increasing Load ........................................................................................................... 18
NORMAL SHUTDOWN TO COLD .......................................................................................... 19
NORMAL SHUTDOWN TO HOT STANDBY .......................................................................... 21
WARM START -UP ................................................................................................................ 23

Warm Start Conditions ................................................................................................ 23
Preparations, Lighting Off, and Load Increase .......................................................... 23
Lighting Off .................................................................................................................. 23
Rolling and Synchronizing the Turbine ..................................................................... 26
Introducing Coal .......................................................................................................... 27
Initial Load Increase .................................................................................................... 28
HOT START -UP .................................................................................................................... 30

Hot Start Conditions ................................................................................................... 30
Preparations, Lighting Off, and Load Increase .......................................................... 30
Rolling and Synchronization the Turbine .................................................................. 32
TITLE PAGE NO.
BLACK START -UP .............................................................................................................. 33

Black Start Conditions ................................................................................................ 33
Preparations for Lighting Off ..................................................................................... 33
Water Filling of the Boiler ........................................................................................... 36
Water Recirculation via Boiler for Clean-up ............................................................. 37
Start of the Boiler Circulation Pump (BCP) ............................................................... 37
Initial Firing Precautions ............................................................................................ 38
Superheat Steam Temperature Control (Prior to Unit Synchronization) ................. 38
Air Pre-heater Protection During Unit Start-Ups On Oil ........................................... 38
Lighting Off .................................................................................................................. 40
EMERGENCY PROCEDURES ............................................................................................... 44

Reheater Protection .................................................................................................... 44
Master Fuel Trip .......................................................................................................... 45
Low Water wall Flow ................................................................................................... 47
High Water Wall Tube Temperature ........................................................................... 48
Tube Failures ............................................................................................................... 48
APPENDIX A- FEEDWATER SPECIFICATIONS FOR ONCE THROUGH BOILERS ............. 50
Figure 1: Typical Air Flow Curve .......................................................................................... 51

INTRODUCTION
These procedures are intended to serve as a guide during the initial stages of operation.
They include precautions, which must be observed, and the proper operating sequences of
the steam generator, fuel firing equipment and auxiliary equipment. Refer to the General
Arrangement Drawings(DWG. No. T04019-GA-A0001 ~ A0017 in O&M manual, Doc. No.
T04019-SY-M0006) The sequential procedures do not include all detailed reference to
equipment such as the feed pumps, condensate pumps, or the turbine.
Because the steam generator is only one part of a complex power station and all equipment
must operate in unison, all specific procedures and detailed values cannot be included in
this manual. As operating experience is gained and the controls are fine-tuned, the
characteristics and operating requirements of the unit will become apparent.
Refer to the manufacturer's instructions(Doc. No. T04019-SY-M0006, O&M manual) for

further operating details for specific equipment, including pre-operational and operational
procedures.
PRE-OPERATIONAL PROCEDURES
Cleanup
The furnace should be inspected and cleaned both internally and externally before initial
firing and prior to each subsequent cold start-up after maintenance. Remove all foreign
material from the pressure parts. Clear any grating, pipe lines and electric conduit which
may restrict normal expansion of the steam generator. All personnel should be clear and the
access doors closed. A complete check list should be prepared by operating personnel.
Chemical Cleaning
Specific pre-operational chemical cleaning procedures are included else where in this
manual. The fuel firing and circulating pump operating procedures, outlined under COLD
START -UP, Lighting Off, should be used as a guide when operating the fuel firing
equipment.
Steam Line Blowing
Prior to starting up a new steam generator, or following a major pressure part repair, the
main steam and reheat steam lines should be blown out to remove scale and other foreign
matter. Steam line blowing, which prevents damage to the turbine, should be done after
chemical cleaning. Refer to Steam Line Blowing Procedures for recommended operating
procedures and precautions.(Doc. No. T04019-SY-M0003 in O&M manual, Doc. No.
T04019-SY-M0006)
Setting Hydraulically Operated Safety Valves
The hydraulically operated SH safety valves serve the function of over-pressure protection
of the SH sections. Similarly, the RH safety valves are hydraulically operated via pressure
sensing instrumentation. It is important the complete checkout and verification of the
hydraulic power station operation and pressure sensing instrumentation be completed prior
to firing the boiler.
1
COLD START-UP
Cold Start Conditions
1. Greater than 72 hours shutdown.
2. Boiler pressure < 1 kg/cm2 (g)
Preparations for Lighting Off
Before lighting off the steam generator, verify that the following activities have been
completed:
CAUTION: The differential temperature between the feed water and

boiler metal must never exceed 200℉(111℃) (separator during initial
filling or separator and superheater outlet header during filling for
hydrostatic test).
If the metal temperature is less than 100℉ (38℃) and the feed water
temperature is higher, a minimum fill rate should be used.
1. The unit has been chemically cleaned, and the steam lines have been
blown(applicable for the first start-up only).
2. All control systems have been checked and are available for service.
All safety interlock systems should be checked prior to start-up to ensure proper
functioning. Exercise the systems by creating the actual interlock actuating
conditions. Simulate the activating condition if the actual condition cannot be
created.
3. All instrumentation and associated mechanical equipment has been checked out
and is available for service.
4. The oil firing equipment has been checked out to ensure it is properly functioning.
Recheck the following items to make sure that:
a. Warm-up oil guns are inserted and properly coupled. Check gaskets between
unions.
b. All oil gun quick-connect couplings are properly assembled.
c. All manual valves are open.
d. All control valves are closed.
5. The pulverizers and feeders have been checked out and are available for service.
Recheck the following items to ensure that:
a. All pulverizer discharge gates are open.
b. All fuel air dampers are in closed position.
2
c. All Burner inlet knife gates are in open position.
d. All hot air gates are closed and all hot air control dampers are closed.
e. All cold air gates are open and the cold air control dampers are open
approximately 5%.
f. All bunker outlet valves are open and coal is available to the feeders.
g. All pulverizer and feeder seal air valves are open.
h. All classifier vane settings are identical.
i. The pulverizer lube oil systems are available for service.
6. The windboxes have been checked for proper damper positioning and the tilts are
set at horizontal.
7. The feedwater system and at least one feedwater pump, including the
instrumentation and equipment, has been checked out and is available for operation.
During a start-up, the feedwater flow should be controlled remote-manually until a
continuous flow is established.
8. The deaerator auxiliary steam supply is operational and de-aerated feedwater at

105℃ is available. To avoid oxygen corrosion in the boiler, the use of de-aerated
feedwater with a temperature of greater than 102℃ is recommended. Refer to Water
Treatment instructions.(Appendix A: Feedwater specifications for Once Thru Boilers)
9. The boiler circulating pump has been checked out, the suction and discharge
isolation valves are open, and all pump instrumentation is available for service. The
pump differential pressure transmitters must be in service. Ensure that the proper
trip settings have been made.
10. The steam generator start-up system valves are ready for operation (UG, WR, ZR
valves), with isolation valves open. The separator level control for WR and ZR valves
has been checked and is available for service.
11. The startup system drain transfer system is ready for operation. This system includes
WR and ZR valves, the flash tank and connecting pipe to condenser.
12. Auxiliary steam is available from another operating boiler for supplying the deaerator,
feedwater tank, steam coil air pre-heater and heavy oil atomization. When there is no
auxiliary steam is available i. e., black start up condition, the unit shall be started with
Light Diesel Oil firing as per the cold start-up curve. As soon as the steam parameters i.
e. pressure and temperature are available for the above requirements, they shall be
put into service.
13. Steam supply isolating valves to the steam coil air pre-heaters are open.
14. Cooling water system is in operation.
CAUTION: Before starting an ID fan and before adjusting the ID fan

inlet blade pitch, an airflow path through the unit must be established
such as ESP is in service (for boiler start permissive condition,
minimum 2 sections of ESP are to be in service), ESP inlet & outlet
3
dampers open condition, GAH in service and GAH inlet & outlet
dampers open in both air & gas stream and maintained by placing
other dampers in the system in the start-up positions indicated below.
The ID fan inlet blade pitch must be kept closed or at the minimum
open position until after the fan is started. This minimizes the possibility
of developing excessive negative pressure in the unit during the
starting procedure. Furnace draft must be maintained within safe limits
at all times. Extreme care should be taken when draft and airflow
controls are in the manual mode. Be alert for possible malfunctions of
automatic control equipment resulting in abnormal excursions, negative
or positive, in furnace pressure.
NOTE: If the unit is started with only one ID and FD fan, one PA fan in
service, the following damper positions apply to the equipment to be
started. Dampers associated with the idle equipment should be closed.
Refer to the fan manufacturer's instructions for operating details. (Doc.
No. T04019-SY-M0006, O&M manual)
15. All air and gas handling equipment has been checked out and is available for service.
Air and gas duct dampers should be in the start-up position as follows:
a. For the first draft group to be started (ID fan A and FD fan A), the fan outlet shutoff
dampers are closed and the inlet blade pitch is at minimum.
b. For the second draft group (ID fan B and FD fan B), the outlet shutoff dampers
shall be kept closed to enable start up of the Fans.
c. The PA fan outlet shutoff dampers and inlet blade pitch is closed or at the
minimum position.
d. All duct dampers are open.
e. The overfire air dampers are closed.
f. The windbox auxiliary (secondary) air dampers are open or modulating.
g. One pulverizer seal air fan inlet shutoff damper is open with the associated fan
ready.
h. The scanner air fans are ready for operation
16. The gas air heaters have been prepared for service and an adequate means of
extinguishing an gas air heater fire is available and ready for use. Refer to gas air
pre-heater protection during unit start-ups on oil, and to the gas air heater
instructions for details.
17. The soot blowing equipment has been checked for proper operation and the system
is in the start-up mode with all blowers retracted and the main steam supply valve
closed. Refer to the soot blower instructions. (Doc. No. T04019-SY-M0006, O&M
manual)
18. All desuperheater spray water control and block valves are closed.
CAUTION: Prevent possible water damage to the turbine by taking

extreme care to eliminate all water from the main steam line(s), cold
4
and hot reheat lines, and the superheater and reheater elements and
headers before the turbine is rolled. Refer to the turbine manufacturer's
instructions for proper drain valve settings.
19. All boiler, superheater, and reheater drain valves are open, and all vent valves are
closed. The economizer and furnace wall drain valves are closed, and economizer
vent valves are open.
20. The auxiliary steam extraction line from the superheater is isolated.
21. The warming system for the boiler start-up system is isolated (supply from
economizer outlet links and discharge to the SH desuperheater).
22. The furnace gas temperature probe(s) is in working order and available for service.
23. The HP and LP bypass stations are available for service, and hydraulic stations are
in operation. The water supply for desuperheating has been established.
24. The condenser is available for service, with circulation water flow, and vacuum has
been established to accept water flow from the startup flash tank and SCAH drain
tank and LP bypass (condenser pressure setpoint interlock of LP bypass).
25. The main steam stop cum control valve and hot reheat stop and control valves are
closed. Drain valves on the main steam, cold reheat, and hot reheat lines are open.
26. The condensate polishing plant is available for operation.
27. The turbine generator has been prepared and is available for service as described in
the turbine manufacturer's instructions.
Warm Water Filling of the Boiler
The entire economizer, furnace wall, and separator system must be filled with warm de-
aerated water (105℃) and be free of air. The following procedure shall be carried out to
ensure the water system is free of air:
1. The economizer outlet vent valve is open.
2. BFP(M) is started at minimum speed and flow according to feed pump operating
procedures.
3. If the water system of the boiler is empty (economizer, furnace walls, separators), then
the system is to be filled with approximately 10% TMCR feedwater flow. Feedwater
flow is preferably controlled using automatic feedwater control with a set point of 10%
TMCR. When the level in the separator reaches set-point, the WR valve will begin to
open. Ensure that the motorized isolation valve upstream of WR valve is kept open
prior to WR valve opening. When the WR valve reaches >30% open for approximately
one minute, then increase feedwater flow set-point to 30% TMCR. As the drain flow
increases, WR valve will reach full open and ZR valve will begin to open. The water
system is considered full when:
a. The separator water level remains stable for two(2) minutes

and
b. The WR valve is fully opened and ZR valve is >15% open for two(2) minutes.
5
4. After filling the water system, the feedwater pump is stopped. The water level in the
de-aerator must be re-established and maintained and water temperature at 105℃ re-
established.
5. Re-start the feedwater pump and establish feedwater flow of 10% TMCR to the boiler.
6. Close Economiser outlet vent valve 20 secs later than detecting the Economiser inlet
water flow reaches over 10T/hr.
Water Recirculation via Boiler for Clean-up
1. When the feedwater quality at the outlet of deaerator and separator is not within the
specified limits, a feedwater clean-up recirculation via the boiler is necessary.
2. During this time, constant feedwater flow of 10% TMCR or more is maintained.
3. Water flows through the economizer and evaporator, and discharges the boiler through
the WR valve to the flash tank and via connecting pipe to the condenser. From the
condenser, the water flows through the condensate polishing plant, which is in service
to remove impurities, then returns to the feedwater tank.
4. The recirculation is continued until the water quality is within the specified limits.
Start of the Boiler Circulation Pump (BCP)
1. It is assumed that the following preparatory work has been completed:
a. Feed water quality within specified limits.

b. Feed water flow set point at 10% TMCR.
c. Separator water level stable at normal level.
d. Cooling water flow to the HP cooler of the BCP adequate.
e. Suction valves and discharge valves are open.
2. Set the UG valve at minimum position, and start BCP per pump operating instructions.
3. As soon as pump is running, open the UG valve to establish minimum waterwall flow
at 30% TMCR.
4. With BCP in operation, flow through the economizer and waterwall tubes increases
substantially. It is recommended that the water quality at the separator be rechecked.
Initial Firing Precautions
To ensure a maximum safety margin during start-ups, at least 30% of the full load airflow
must be maintained to produce the following conditions:
1. An air-rich furnace atmosphere. This prevents the accumulation of an explosive

mixture due to poor or delayed ignition after fuel is introduced to the furnace.
6
2. High excess air through the gas air heaters. This minimizes the dilution of combustion
air by inert gases carried over by the gas air heater rotors.
Superheat Steam Temperature Control (Prior to Unit Synchronization)
The boiler will normally be started-up de-coupled from the turbine using the HP and LP
bypass systems, which provide a steam flow path through the superheater, to the
reheater, and to the condenser. This provides additional flexibility for adjusting steam
temperatures to match turbine requirements at start-up. The primary methods for
controlling steam temperature will be firing rate and airflow adjustment.
Gas Air Pre-heater Protection During Unit Start-Ups On Oil
It is strongly recommended to have the gas air heater soot blowing system continuously
in service when firing oil to start up a boiler. This measure is intended to help avoid gas
air heater fires due to accumulation of oil vapors on heating surfaces or ash particles in
the gas air heater baskets. A retractable soot blower is installed at the cold end of the
gas air heater on the gas side, arranged close to the changeover of air to gas side when
looking in direction of rotation, opposite the fire detection device. This soot blower is
primarily designed to reduce (knock off) and/or control oil residue deposits and ash
build-up in the gas air heater surface. It is not a cleaning device such as the stationary
wash down nozzles.
For those units where no auxiliary steam is available for cold starts on oil, the fire
detection system must be in service. This system will identify any possible start of a fire
in the gas air heater. Also, the top oil elevations should not be utilized since they are
more prone to cause oil carryover. Special attention must be given to the readings of gas
and air temperatures leaving the gas air heater. An unusual increase in any of these
temperatures must be investigated immediately. Any indication of an gas air heater fire
must be reacted to immediately because once a fire is well under way it can't be stopped
before the gas air heater is severely damaged.
For unit loads below 10% TMCR steam flow, excessive combustion air(more than the
required 30% minimum of full load air flow) or unnecessarily high furnace draft (more
negative than -12 mm w.g.) should be avoided. Burner tilts should not go above the
horizontal position. Changes in the firing pattern should be closely observed in respect
to possible carryover. Also, any steam that is available including saturated steam can
and should be used for gas air heater soot blowing as long as sufficient steam pressure
is available (at least 9 bar / 130 psig). When this minimum steam pressure has been
reached, continuous cold end blowing should be initiated and continued until 10% TMCR
steam flow is reached. After that gas air heater soot blowing can be reduced to
intermittent operation, once every four to eight hours or as required, depending on the
fuel being fired. Once the unit is above 10% TMCR steam flow, normal soot blowing can
be followed using the units own auxiliary steam source as temperature and pressure is
built up.
The following minimum requirements as delineated in the vendor's "Operating

Instructions" should be observed:
Superheated
Blowing Pressure Temperature Enthalpy Saturation
by
[kg/cm2g] [℃] [kcal/kg] [℃] [℃]
9 327 743 179 148
7
Superheated
Blowing Pressure Temperature Enthalpy Saturation
by
[kg/cm2g] [℃] [kcal/kg] [℃] [℃]
11 328 743 187 141
14 332 743 197 135
15 333 743 201 132
17 335 743 206 129
WARNING: The greatest danger, for developing an gas air heater fire,
is in the initial stages of boiler operation, i.e. boiler chemical cleaning
and boiler steam blowing. Experience has shown that during these
stages more than the normal precautions need to be taken. This is
because there is normally insufficient boiler steam capacity and/or soot
blowers are not available for use. Therefore, continuous plant visual
observations must be undertaken so the risk of a gas air heater fire
can be kept to its very minimum.
Once the unit has seasoned on coal, fly ash will have been deposited
in various areas of the boiler (especially in the assemblies of the back
pass). These ash deposits will absorb some of the vapor before it
reaches the gas air heater surfaces so the risk of gas air heater fires
will be somewhat diminished. It goes without saying that prolonged low
Ioad operation firing oil without blowing the gas air heaters should
always be avoided.
Water washing has no positive effects in removing oil unburned

particles / residue. Only soot blowing would be effective by knocking
off these particles. Therefore, when firing oil when sufficient blowing
steam is available, the gas air heater should be continuously cleaned
utilizing its soot blowers.
Gas air heater surfaces should only be water washed, during initial
stages of boiler operation and/or subsequent load operations, if heater
surfaces become plugged with fly ash (high delta-P) when soot blowing
was either ineffective or not available for use.
Gas air heater water washing must be in strict accordance with

vendor's instructions.
Frequent water washing of gas air heater surfaces is not a substitute

for the soot blowing process and should be avoided. Frequent washing
will decrease the life of gas air heater heating elements.
Lighting Off
1. Start the gas air heaters. Refer to the gas air heater instructions for operating details.
CAUTION: The ID fans are capable of developing drafts that exceed

the furnace design pressure. Therefore, an airflow path through the
unit must be established and maintained before starting an ID fan and
before opening the ID fan inlet blade pitch by ensuring that other
dampers in the system are in the start-up positions indicated in
Preparations for Lighting Off, page 2.
8
open position until after the fan is started. This minimizes the
possibility of developing excessive negative pressure in the unit during
start-up.
Furnace draft must be maintained within safe limits at all times.

Extreme care should be taken when draft and airflow controls are in
the manual mode. Be alert for possible malfunctions of automatic
control equipment resulting in abnormal excursions, negative or
positive, in furnace pressure.
2. Start the first draft group: Start one ID fan, then the corresponding FD fan. Open the
outlet shut-off dampers. Adjust the ID fan for proper furnace draft, and set furnace
pressure control to automatic. Adjust unit air flow to minimum 30% air flow, and set
unit air flow control to automatic.
3. Start the selected scanner air fan.
4. Place the gas air pre heater temperature control (steam air pre heaters) to automatic.
5. Adjust the fan and wind box dampers to permit a purge airflow of at least 30% of total
airflow and a furnace draft of approximately -12.0 mmw.g. Refer to Initial Firing
Precautions.
When lighting off an elevation on manual control, the fuel-air dampers should be
closed. Once ignition of the main fuel is established, the fuel-air dampers should be
opened in proportion to the fuel elevation firing rate. When the fuel-air dampers are
fully open, further damper adjustments should be made, if necessary, with the
auxiliary air dampers only. When changing the damper positioning, an entire elevation
should be treated simultaneously, that is, damper positioning at the same elevation
should always be identical in all wind boxes.
When the steam generator reaches a firing rate at which additional air is required to
maintain the design operating excess air, increase the airflow. Refer to the percent
excess air versus load curve.
6. When the fans are started, the secondary air damper control should modulate the
auxiliary air dampers to maintain a programmed set point differential pressure of
102mmw.g. between the wind box and furnace.
7. Check that all other purge permissives are satisfied.
8. Place the gas temperature probes in service.
9. Initiate a furnace purge.
10. Upon completion of the purge cycle, check that all firing prerequisites are satisfied,
including the following control settings:
a. Feed water control is on automatic maintaining minimum feed water flow rate of
approximately 5% TMCR.
b. Start-up system (BCP and UG valve) is on automatic maintaining minimum water

wall flow.
9
CAUTION: It is extremely important that minimum water wall flow be

maintained at all times when firing the boiler to prevent tube damage
due to overheating. If water wall flow falls below the low set point, all
fuel must be automatically tripped with a maximum time delay of five(5)
seconds.
c. Separator level control is on automatic, i.e. the WR, and ZR level control valves
are all in automatic.
d. Furnace pressure control is on automatic.
e. Unit air flow is on automatic maintaining minimum 30% full load air flow.
f. Place HP bypass valve in operation:
(1) Set to "valve position control" and desired preset position of app. 10 - 12% open.
(2) HP bypass valve is set to be controlled along with the pressure rising of boiler.
(3) Pressure and temperature controls for HP bypass valves with safety function, HP
bypass spray valves, and Spray water pressure reducing valves are on automatic.
g. Place LP bypass valve in operation:
(1) Open LP bypass stop valve after establishing sufficient condenser vacuum and
water supply for de-superheating.
(2) Adjust to pre-set minimum position.
(3) The minimum pressure (app. 10 ~ 12 kg/cm2(g)) is automatically controlled.
(4) Place control on automatic.
h. Place SH and RH temperature controls on automatic, with set points of 350℃ for
SH and 320℃ for RH.
i. Open SH division panel vent valves, SH backpass drain valves, and RH outlet
vent valves.
j. Steam coil air pre-heaters are working properly and raising the air temperature to
set point(minimum average cold end temperature-68˚C for Coal firing; 113˚C for
Heavy Fuel Oil firing). Insufficient air temperature can lead to poor oil firing.
Please refer to SQC logic diagram for SCAPH bypass damper for FD and PA Fan-
Document No:T04019-IC-D0023-5.
11. Start one of the PA fans. After fan is started, open the PA fan outlet damper. Bring the
primary hot air duct pressure up to set point by manually adjusting the PA fan inlet
vanes. Then, transfer to automatic control.
Airflow must be maintained through the pulverizers whenever the unit is being fired.
Therefore, the PA fans must be in service.
10
If the pulverizers are out of service the pulverizer discharge gates must be fully open.
The cold air inlet control dampers must be set to the minimum position. The pulverizer
discharge gates are closed during pulverizer maintenance, or when the pulverizers are
idle and full of coal and other pulverizers are being started after a unit trip. Refer to
emergency procedures, Master Fuel Trip.
12. For cold start-ups, the fuel startup sequence should follow this table:
Sequence Step Elevation Notes
1 AB oil Heavy Fuel Oil
2 CD oil Heavy Fuel Oil
3 EF oil Heavy Fuel Oil
4 GH oil Heavy Fuel Oil
5 JK oil Heavy Fuel Oil F
6 B coal If coal elevation B not available, start coal elevation A
7 C coal If coal elevation C not available, start coal elevation A
8 D coal
9 A coal
10 E coal
11 F coal
12 G coal
13. Initiate a light-off sequence of oil elevation AB warm-up oil guns. Refer to the HEA
igniter, retractable oil gun, and the Recommended Burner Management System
To minimize the possibility of adverse visible stack emission, it is desirable to use

the warm-up oil guns until 35 kg/cm2(g) steam pressure is produced and 175℃
secondary air temperature before firing pulverized coal.
14. Set fuel oil flow control to auto and adjust the set point to 3% of TMCR firing rate.
Stabilize the AB elevation for 5 minutes.
15. Initiate an elevation start command for oil elevation CD. Stabilize the CD elevation
for 5 minutes.
16. Progressively increase firing rate to 10% TMCR at a rate of 0.5% per minute.
17. To ensure stable operation of the water system and to ensure sufficient steam flow
through the superheater, firing rate should not be further increased until 8 kg/cm2g is
measured in the water separator.
18. As the pressure is raised, first the WR and then the ZR valves will open when
separator water level increases due to boiler water swell. As pressure further
increases, the WR and ZR valves will start to close as the water level decreases.
19. During all start-ups, control the firing rate to keep the maximum furnace exit gas
temperature below 1000 ℉ (538 ℃ ), as measured by the furnace outlet gas
temperature probe(s) until approximately 10% TMCR steam generation or the
turbine is synchronized. Sufficient steam flow must be maintained at all times to
assure clearing the superheater and reheater elements of condensate. Do not close
the startup drains completely until steam flow through the HP/LP bypass is
established.
20. The superheat backpass drain valve can be closed when separator pressure
11
reaches 3.5 kg/cm2(g)
21. Progressively increase LP bypass set point to 10 kg/cm²(g). As the HP bypass

opens, the reheater will be warmed and pressurized as steam is passed through the
LP bypass and reheat vents. In parallel, close the reheat vent and drain valve to
transfer flow and pressure control to the LP bypass station.
22. Close the RH outlet vent valves when RH pressure reaches 3.5 kg/cm2(g).
23. When steam pressure at HP bypass reaches 12 kg/cm2(g), the HP bypass valve is
released to "pressure ramp" mode. The valves will move to nominal 30%, then
control the boiler pressure ramp-up to 90 kg/cm²(a). Firing rate can now be
increased.
24. Initiate an elevation start command for oil elevation EF.
25. After a five(5) minute stabilization period, Progressively increase firing rate to 15%
TMCR at a rate of 0.5% per minute.
26. The rate of pressure rise should follow the prescribed start-up curves. In parallel,
close SH vent valve to transfer flow and pressure control to the HP bypass station.
27. When boiler pressure reaches 90 kg/cm²(a), the HP bypass valve is released to
"pressure control" mode, and maintains a constant pressure during turbine rolling,
synchronization, and initial loading.
28. After a pressure of 90 kg/cm2(a) is attained, the firing rate can be adjusted to
achieve the required steam temperature for turbine rolling. Target steam conditions
are: 10% BMCR steam flow, SH = 350℃,RH = 320℃.
29. Do not exceed the furnace exit gas temperature limit of 1000℉(538℃) below 10%
TMCR load. Above 10% TMCR load automatic interlocks provide protection from
over-firing. When ready to fire coal, the pulverizer serving a lower elevation of coal
nozzles should be prepared for operation and started in accordance with Introducing
Coal, steps 1 through 5. Adjacent warm-up oil guns supply the required ignition
energy. The feeder should be set to keep the furnace exit gas temperature from
exceeding 1000℉(538℃).
NOTE: The steam pressure should be increased slowly during the

initial start of a new steam generator. This allows sufficient time for
checking expansion movements and permits the operators to become
familiar with the characteristics of the steam generator and auxiliary
equipment. Once these characteristics have been established,
subsequent start-ups may be made at the fastest possible rate
consistent with maintaining the furnace exit gas temperature limitation
of 1000ºF (538℃).
30. While the unit is heating up, check the boiler expansion movements frequently.
Special attention should be given to expansion of the boiler relative to the building
steel. Expansion movements should be recorded for comparison with future start-
ups. Refer to the pressure Parts Connection and Expansion Movement Diagrams.
31. Maintain separator water level at normal and check the boiler water concentrations
and constituents as frequently as necessary to maintain proper boiler water
12
conditions.
Rolling and Synchronizing the Turbine
1. Confirm the steam conditions, i.e. pressure, temperature, and steam purity, at the
turbine are correct for turbine roll. (See turbine manufacturer’s Steam Purity
recommendations)
2. Turbine roll, synchronization, and initial loading are all carried out using reheat
steam. Roll the turbine by opening the reheat stop and control valves to the IP
turbine per the Turbine manufacturer’s procedures. The HP turbine is maintained in
reverse flow using steam from CRH line. During this time, the total steam production
is passed through the HP bypass while it remains on "pressure control' mode.
3. SH and RH steam temperatures are maintained by adjusting firing rate and airflow.
4. Synchronize the generator and put on initial load of app. 10% according to
turbine/generator startup instructions. Initial load is produced by IP/LP sections of
the turbine. The HP section is still in reverse-flow mode.
5. As steam is transferred to the IP turbine during turbine loading, the LP bypass will
close while maintaining RH pressure at 10 kg/cm2 (g).
6. Initiate a start command for oil elevation GH. Stabilize elevation GH for 5 minutes.
7. Progressively increase firing rate to 25%TMCR at a rate of 0.5% per minute.
8. As turbine conditions permit, put feed water heaters into service per manufacturer’s
instructions.
9. De-aerator heating steam source is transferred from auxiliary steam system to LP

extraction when LP extraction pressure is adequate.
CAUTION: Operators should be alert to detect the symptoms of water

carry-over from the boiler and introduction of water into the turbine,
such as:
a. A sudden, unexplained drop in steam temperature in either the

main steam or hot reheat line.
b. Vibration in the steam piping resulting from water hammer.
c. Abnormal vibration and differential expansion readings from the

turbine supervisory instrumentation.
Operators must be prepared to take necessary steps to prevent turbine

damage upon detecting the introduction of water. Refer to the turbine
manufacturer's instructions for specific actions to be taken.
10. The firing rate should never exceed the rate necessary to match the total steam
generation.
If the unit is put on line before design operating pressure is reached, a further
increase of firing rate should be in accordance with a gradual rate of pressure
increase consistent with increasing load. Do not allow steam temperature to exceed
13
the values shown in the steam temperature versus load curve.
11. Start the second set of fans as required. Refer to the fan manufacturer's instructions
for operating details.
Introducing Coal
1. Coal firing can commence when steam flow reaches app. 15%TMCR and LP bypass
is closed.
2. Pulverizer B or alternately pulverizer A, serving the lower elevations of coal nozzles,

should be prepared for operation at this time so that it can be readily started. The
seal air fan must be placed in service at this time. Refer to the Recommended
Burner Management System instructions for start-up sequences and controls.
The condition may exist when an upper elevation of coal will be placed in service for
start-up, with ignition by the associated elevation of oil guns. Start-up by this
procedure is allowable, however, if utilized, care must be exercised not to exceed
the furnace exit gas temperature limitation of 1000 ℉ (538 ℃ ), or the steam
temperature values shown in the steam temperature versus load curve.
3. When placing the first pulverizer in service, make sure the pulverizer start
permissives are satisfied. Refer to the Recommended Burner Management System
instructions. The coal fuel-air dampers should remain closed until ignition is
established. Make sure the nozzle tilts are horizontal. PA fan/fans must be in service.
If the unit start-up follows a master fuel trip, the pulverizer may not be empty.
Operate the pulverizer to clear it of excess coal before starting the feeder. During
the pulverizer clearing procedure, the pulverizer discharge gates of all other idle
pulverizers must be closed. This prevents hot furnace gases from entering the coal
piping and the idle pulverizers. (See emergency procedures) When most of the coal
has been removed from the pulverizer, the pulveriser can be introduced as per
normal procedure Be sure the ignition energy in the furnace is established before
starting the pulverizer.
If ignition does not take place within 5 seconds after coal appears at the coal
nozzles, stop the feeder. Determine the cause of ignition failure before attempting to
restart the feeder .
4. Start the pulverizer. Open the hot air shutoff gate, adjust pulverizer airflow to 100%
by opening the hot air damper, and bring the pulverizer up to the required operating
temperature without coal. Place the pulverizer airflow and temperature control on
automatic. When ready to fire coal, manually start the feeder at minimum rating.
Ignition of the pulverized coal should take place immediately. When the pulverizer is
proven in service, the fuel-air dampers should open automatically. Maintain the fuel
feed at a minimum rate consistent with stable ignition. Watch the fires.
Pulverizer start-up will cause a sudden and sharp increase in steam pressure. The
pressure will level out rapidly as the HP bypass station responds.
Check the pulverizer oil temperature. When the temperature approaches 150 ℉
(66℃) turn on the water to the oil cooler or adjust the lube oil control system. The oil
temperature should never exceed 160℉ (71℃).
5. Maintain the proper coal/air temperature leaving the pulverizers. Regulate the hot
14
and cold air dampers to keep the temperature between 77 ℃ and 82 ℃ at the
pulverizer outlet.
6. At the prescribed load per turbine manufacturer, the HP turbine is transferred to

forward flow. The HP turbine control valves are opened until sufficient flow is
established through the HP section of the turbine. The HP bypass valve
compensates by closing to control the steam pressure at the set-point.
7. Continue the transfer to forward-flow until the first three turbine valves are fully
opened and HP bypass valves are fully closed.
8. Start the second pulverizer when the HP bypass is closed.
9. When the feeder rating of the first pulverizer has reached approximately 50%, place
the second pulverizer, which supplies the adjacent elevation of coal nozzles, in
service in a similar manner. When the second pulverizer is proven in service,
equalize the feeder rating of both. The warm-up oil guns must remain in service until
both feeders proven signal is achieved.
If the adjacent pulverizer is not available for service, place the pulverizer serving the
next closest elevation of coal nozzles in service. Do not remove the warm-up oil
guns from service until the two(2) adjacent coal elevations are in service with feeder
ratings greater than 50%.
10. Increase total firing rate to 30% TMCR.
11. The Burner Management System and secondary air damper controls should close
the auxiliary air dampers which serve compartments adjacent to the coal nozzles out
of service when the unit load reaches 30% TMCR load. These controls should also
gradually increase the windbox-to-furnace differential pressure to approximately 102
mm w.g. as load is increased per the prescribed curve.
12. The airflow to the furnace must be sufficient for the firing rate. Automatic control
equipment is normally arranged to maintain such a balanced draft condition. The
operation of the O2 measuring devices at economizer outlet, often tied in with the
airflow control, should be checked periodically.
Initial Load Increase
1. The third pulverizer can be started after steam flow reaches 25-30% TMCR. Place
additional pulverizers in service in a similar manner. Pre-warm the pulverizer, and
initiate an elevation start command. After the coal elevation is proven in service
(signal from BMS), the feeder is put into automatic.
3. After reaching 30% TMCR load and firing is stable, oil elevation AB is issued an
elevation stop command by the operator .
4. Before and after oil elevation AB is stopped, ensure coal elevation A or B shows
flame through flame scanner indications.
5. Reduce oil firing to minimum. Oil elevation CD is issued an elevation stop command
by the operator.
15
6. After stable firing is established, put into service the second BFP(T) per the
manufacturer procedures.
NOTE: Before increasing the total firing rate above 30% TMCR,
feedwater quality must be verified to be within the limits for normal
firing as defined in Appendix A.
7. Start the ESP per manufacturer’s instructions.
8. During load increase in automatic load control, the BMS shall be given a signal to
start the next available coal elevation. After a coal elevation is proven in service
(signal from BMS), the feeder is put into automatic.
9. The steam temperature at the separator inlet will reach a stable superheated
condition at app. 30% TMCR, causing the level in the separator to decrease and
eventually disappear. The boiler is now in once-through mode(dry mode). The
BCP(Boiler Circulating Pump) will be stopped automatically.
10. When the BCP stops, the warm-keeping system of the start-up system should be put
into operation.
11. The boiler/turbine is now ready for automatic load dispatch. The control system shall
monitor unit loading and will start/stop firing equipment by the automatic load
program.
12. Place additional pulverizers in service as the unit load demand increases. The
pulverizer serving the lowest coal nozzle elevation not already in service should be
started, if available, when the feeders in service reach the 50% rating. As each
pulverizer is placed in service, the required ignition energy must be available. When
the unit firing conditions are stabilized, all warm-up oil guns may be taken out of
service. Refer to the Recommended Burner Management System instructions.
13. Place the steam temperature control and combustion control on automatic when
firing conditions are stable and the temperature and pressure control set points have
been reached. Please refer to the steam temperature and combustion control
document No: T04019-IC-D0024, ABC Logic.
14. Make frequent visual observations of furnace conditions to ensure that no excessive
slag build-up is developing. This is especially important when burning coal with low
ash fusion temperatures. Operate the soot blowers as required to keep the steam
temperature control (nozzle tilts, desuperheaters) within operating range. If
response to soot blowing is sluggish or insignificant, reduce unit load or increase
excess air to assist in lowering steam temperature and take steps to eliminate the
cause of the erratic steam temperatures.
WARNING: Efforts shall be made to ensure that the furnace bottom is

maintained clean such that a situation like hopper full of ash does not
occur.
Under no circumstances should the level of ash in the bottom ash

hopper be allowed to reach the level of the coutant opening, thus
blocking further removal of ash from the furnace.
Under no circumstances should ash or slag be allowed to bridge
16
across the coutant opening.
If bridging starts to occur, load should be reduced in an attempt to

shed the buildup.
If complete bridging across the coutant opening does occur, immediate

steps should be taken to shut the steam generator down to cold
following normal shutdown procedures. The ash should then be
removed by means which preclude damage to the water wall tubes.
Refer to "Preventing Furnace Bottom Overloading" for additional

operating recommendations.
If excessive slagging of furnace walls is experienced, make sure that

the bottom ash removal system is in good working condition to handle
the increased quantity of bottom ash that accompanies higher slagging
rates.
15. Overfire air is used for NOx control and is automatically controlled as a function of
total unit air flow. The effective starting load must be determined during initial unit
operation. Refer to the CCOFA Damper characteristics furnishing the unit air flow Vs
OFA damper opening position under Tilting Tangential Firing system section in O &
M manual.
NORMAL OPERATION UNIT LOAD CHANGES
The normal load range under automatic control is 30% to 100% TMCR. The boiler load
change rates should not exceed 3% per minute (19.8 MW per minute) between 30% and
50% load, and should not exceed 5% per minute (33 MW per minute) above 50% load.
These maximum load change rates can only be achieved if control actions are well
coordinated and well tuned. Below 30% TMCR load, the change rates should not exceed
that shown on the prescribed start-up curves.
During normal operation, with the unit on the line, unit load changes may alter pulverizer
loading rate and/or the number of pulverizers in service. A wide range of load control can
be achieved with the pulverizers on automatic.
Refer to the Recommended Burner Management System instructions for pulverizer start
and stop sequences and ignition energy requirements.(Doc. No. : T04019-IC-M0004, Mill
burner control system write-up)
Decreasing Load
If the unit load decreases to a point at which the feeder rating of the pulverizers in
service is reduced to 40%, a pulverizer should be taken out of service. Normally the
pulverizer serving the lower-most coal elevation is removed.
To remove the pulverizer from service, proceed as follows:
1. Ensure that pulverizer ignition energy is available in the furnace. Start the oil gun
elevation associated with the coal elevation served by the selected pulverizer.
2. Gradually reduce the feeder rating of the selected pulverizer to minimum.
17
3. When the feeder rating is at minimum, close the coal shut off gate above the feeder,
run the feeder until the spout and feeder are empty, and then stop the feeder.
4. Make sure the pulverizer is completely empty by running it for at least 5 minutes.
5. Close the hot air shut off gate.
6. Allow the pulverizer coal/air temperature to drop to 50 ℃ , and then stop the
pulveriser.
7. The associated warm-up oil guns may be shut down when the furnace conditions
have stabilized.
Additional pulverizers can be taken out of service in a similar manner when the feeder
ratings again drop to 40%.
Every effort should be made to keep adjacent pulverizers in service. If, due to
maintenance, a pulverizer is not available, skipping the coal elevation served by that
pulverizer is permissible. Skipping two(2) coal elevations is not recommended and is
only permissible through the use of the associated oil guns.
If the unit load is reduced to a point at which only two(2) pulverizers are required, the
associated oil guns adjacent to the coal nozzles in service must be placed in service to
ensure positive ignition when the feeder ratings drop to 65% or less. Auxiliary supporting
fuel should be used whenever, in the operator's judgment, ignition stabilization is
necessary.
Increasing Load
If, after several pulverizers have been taken out of service due to a load decrease, load
increases again to a point at which the feeder rating of the pulverizers in service
exceeds 50% of maximum, place an additional pulverizer in service as follows
1. Establish the ignition energy required for the coal elevation served by the selected
pulverizer .
2. Start the pulverizer .
3. Open the hot air shutoff gate and damper to 100% airflow and bring the pulverizer
up to operating temperature.
4. Start the coal feeder. The feeder control should be on manual and at minimum
feeder rating.
5. When the pulverizer is grinding and coal ignition has been established, gradually
increase the feeder rating until it equals that of the other pulverizers in service. Then,
place the pulverizer on automatic control.
6. The associated oil guns may be taken out of service when the furnace conditions
have stabilized and at least two(2) pulverizers are in service, each with a feeder
rating of at least 65%.
7. Place additional pulverizers in service in the same manner, as required.
18
NORMAL SHUTDOWN TO COLD
The following procedures for normal shutdown assume that the unit is operating at full
load on automatic control, and the intention is to reduce the unit pressure to zero and
cool the boiler completely.
CAUTION: Exercise care to prevent water from entering the turbine

through the main steam line(s), the hot reheat line(s), or the cold
reheat line(s) during and after the shutdown process. This prevents
water damage to the turbine during a subsequent restart. Possible
water sources are:
a. Overflow from the separator into the superheater when a high

water level exists.
b. Water entering the superheater or reheater through the

desuperheaters due to open desuperheater control valves or valve
leakage with the feed pumps running.
1. Reduce the unit load at a rate of 2% per minute following the prescribed sliding
pressure vs. load curve. Hold pressure constant at app. 125 kg/cm2g until the
turbine is taken off line. Reduce the firing rate in line with the decreasing steam flow.
Reduce the steam temperature at the rate prescribed by the turbine manufacturer.
Leave the steam temperature, combustion and feedwater controls on automatic until
better control can be obtained on manual.
2. When the feeder rating on all pulverizers is reduced to 40% put the upper elevation
of oil guns in service. Place the pulverizer supplying the upper coal elevation on
manual control. Gradually reduce the feeder rating. When minimum rating is
reached, close the coal shutoff gate above the feeder, run the feeder until the spout
and feeder are empty, and then stop the feeder. Make sure the pulverizer is
completely empty by running it for at least Five (5) minutes. Close the hot air shutoff
gate. When the coal/air temperature has dropped to approximately 50℃,then, stop
the pulverizer. Unless an emergency condition exists, the pulverizer should always
be emptied before being stopped.
3. As pulverizers are taken out of service, the secondary air damper control system
should close the associated windbox damper and adjust the other dampers to
compensate for the reduced firing rate.
4. Take the second pulverizer supplying the next highest elevation of coal nozzles out
of service when the feeder rating on all remaining pulverizers reaches 40%.
Continue taking additional pulverizers out of service in the same manner. When only
two(2) pulverizers remain in service, the adjacent oil guns must be placed in service
prior to reducing the feeder rating of either pulverizer to below 65%.
It is recommended that this consecutive elevation shutdown sequence be followed.

Firing coal at separated/non-adjacent coal nozzle elevations without auxiliary
supporting fuel is not permitted.
5. Overfire air will be reduced automatically as the unit load drops per the prescribed
19
control curve. Stop admitting overfire air when the unit load drops below the
predetermined starting load. Keep the overfire air dampers at minimum open
position to prevent the nozzles from overheating.
6. Operate all soot blowers. Refer to the soot blowing philosophy section and to the
soot blower manufacturer's instructions.
7. Reduce the airflow in line with the fuel reduction until 30% BMCR airflow is reached.
Do not reduce the airflow below this rating until all fires are out and the unit is off the
line (Refer to Figure 1, typical air flow curve of this section, and the percent excess
air versus load curve. To avoid firing instability during this period of high airflow, the
auxiliary air dampers at all elevations should open and the windbox-to-furnace
differential pressure reduced to its lower setting per the prescribed control curve.
Refer to the auxiliary air damper characteristics furnishing the unit load Vs windbox
to furnace differential pressure under Tilting Tangential Firing System section in O &
M manual.
8. Check the boiler expansion movements as the load is reduced.
9. At app. 35% steam flow, open the HP and LP bypass valves. Remove the turbine
from service following the turbine operating instructions. Boiler steam production will
be transferred to HP/LP bypass operation.
10. At app. 30% BMCR steam flow, the steam temperature at the separator inlet will fall
below the superheated region, and a water level will develop in the separator. The
boiler must now be returned to recirculation mode, and the BCP must be started to
provide minimum water wall flow when a water level in the separator reaches over 3
meters.
11. After the last pulverizer is shut down, remove the oil guns from service. Shut off the
cooling water to the pulverizers. All fires should be extinguished when the unit is off
the line. With no pulverizers in service, the PA fans and the pulverizer seal air fans
may also be shut down. The PA fans should not be shut down if the gas air heater
gas inlet temperature is above 400℉(205℃).
12. After all fuel firing is removed, close the HP and LP bypass valves.
13. Immediately after closing the HP/LP bypass valves, open all superheater outlet
vents and drains and all reheater vent and drains. Open the steam line and turbine
drains per the turbine manufacturer's instructions.
14. Close the de-superheater isolating valves.
15. Do not exceed the following cool down rates referenced to saturation temperature in
the separator: For pressure above 35 bar: 83℃per 15 minutes; for pressure less
than 35 bar: 42℃ per 15 minutes.
16. If the steam generator will not be entered during the shutdown period, a slower rate
of pressure and temperature decay may be desirable. This can be accomplished as
follows:
a. Purge the unit by running the ID and FD fans for at least Ten (10) minutes at
30% BMCR airflow after the fires are extinguished.
b. Reduce the airflow through the unit to minimum. Keep the fans and gas air
20
heaters in service until the unit has cooled to the desired temperature. Gas air
heaters and fans should not be taken out of service until the gas air heater gas
inlet temperatures have dropped below 400℉ (205℃).
c. Keep the boiler circulating pump in service until the boiler water temperature is
reduced to the desired point ( 290 ℃ i.e. app. 15 ℃ less than the saturation
temperature corresponding to the SHO pressure at 30 % TMCR load). Keep the
water level near normal in the separator, adding makeup water as required.
17. If the cooling process must be accelerated to permit entry into the steam generator
for maintenance, proceed as in step 16, except:
a. Continue running the fans at the desired rate to cool the unit. The gas air
heaters may be shut down when the gas entering temperature has dropped
below 400℉ (205℃). Refer to the gas air heater instructions.
With the gas air heaters stopped and the fans running, deposits of fly ash may
accumulate in the gas air heater and cause a rotor unbalance. Therefore before
stopping the GAHs, fans should be stopped.
b. Keep the boiler circulating pump in service to increase recirculation. Keep the
water level near normal in the separator. Shut down the pump when the boiler
water temperature is reduced to the desired level, which is differential
temperature, 20˚C, between separator outlet water temperature and economizer
inlet water temperature.
18. Do not shut down the scanner air fan until the furnace temperature has dropped to
below 140℉ (60˚C).
19. If the boiler is to be laid up wet, refer to Lay-up Procedures.
20. If the boiler is to be emptied, the boiler water temperature should be reduced to at
least 200℉ (93℃) before draining.
NORMAL SHUTDOWN TO HOT STANDBY
CAUTION: Exercise care to prevent water from entering the turbine

through the main steam line(s), the hot reheat line(s), or the cold
reheat line(s) during and after the shutdown process. This prevents
water damage to the turbine during a subsequent restart. Possible
water sources are:
a. Overflow from the separator into the superheater when a high

water level exists.
b. Water entering the superheater or reheater through the

desuperheaters due to open desuperheater control valves or valve
leakage with the feed pumps running.
During a shutdown to hot standby, it is assumed that the unit will be shut down for a
relatively short period of time and that the existing pressure and temperature conditions
will be substantially maintained. A procedure similar to that for normal shutdown should
be used, with the following exceptions:
21
1. Reduce steam pressure in line with unit load reduction, following the prescribed
sliding pressure curve. After the turbine is off the line and fires removed and HP/LP
bypass closed, the boiler may be bottled up by closing all superheater drains and
vents. Reheater drains and vents are kept open.
If the unit will be restarted soon enough to prevent turbine metal temperatures from
decreasing appreciably, it may be desirable to cool the turbine metal to below 800℉
(427℃) by reducing the steam temperature and pressure, while the unit load is
being reduced. This will reduce the steam/turbine metal differential temperature
upon restart.
2. It is not necessary to close the feeder inlet gates and run the spouts and feeders
empty. As each pulverizer is taken out of service, gradually reduce the feeder rating.
To minimum and then stop the feeder. Make sure the pulverizer is completely empty
by running it for at least Five (5) minutes. Close the hot air shutoff gate. When the
coal/air temperature has dropped to approximately 50℃,then, stop the pulverizer.
3. The boiler circulating pump should be kept in operation to ensure adequate boiler
water circulation. This will prevent possible local overheating due to hot slag
deposits.
WARNING: If the fans are shut down with an gas air heater gas inlet
temperature above 400℉ (205℃), the gas air heater must be kept
rotating. However, running an gas air heater with the gas inlet
temperature above 400℉(205℃) and no air flow through it will cause
seal damage followed by excessive leakage during operation. (Refer to
gas air heater instructions.) The decision to bottle up the unit above
400℉ (205℃) must be made with this in mind.
CAUTION: If combustible deposits are present in the gas air heater

elements, the gas air heater gas inlet temperature ,must be reduced
to 400℉ (205℃) before the FD fans, ID fans and gas air heaters are
shut down. The gas air heaters must be thoroughly cleaned to remove
any combustible products before they are shut down.
4. After the fires are extinguished, keep the ID, FD and PA fans and gas air heaters
running until the gas air heater gas inlet temperatures have dropped to below 400℉
(205℃). Close all gas duct and secondary air duct dampers after the gas air heaters
and fans are shut down. Keep the scanner air fan running.
5. Shut down the boiler circulating pump after the unit has been bottled up. However, if
an immediate hot restart is anticipated, keep the boiler circulating pump in service
for more effective warm-up circulation.

hydrostatic test).
6. The operator should observe the separator level periodically so that he is always
aware of the actual level and can take the appropriate action to re-establish the
water level when the unit is being restarted.
When the boiler circulating pump is shut down, the water level will rise. As the unit
cools and the water shrinks, makeup water should be added intermittently to prevent
22
the water from dropping below normal level. Adding relatively cold feed water will
establish a reservoir of cooler water in the system. If a boiler circulating pump is
then started, this cooler water will produce a cycle of cool and hot temperature
transients to the pump casing and other pressure parts of the boiler. At least one
pump should be operating when makeup water is added.
WARM START-UP
Assuming that the unit has been down for a short period of time (less than app. 36
hours), the unit can be re-started in a similar sequence to Cold Start-up procedure as
outlined below:
Warm Start Conditions
1 Less than 36 hours shutdown

2
2 Boiler pressure ≥ 1 and < 30 kg/cm (g)
Preparations, Lighting Off, and Load Increase
1. Make a general inspection of the steam generator and check the points outlined in
the Preparations for Lighting Off for Cold Start-Ups.
2. Verify that the boiler is filled with water and properly vented of air per the points
outlined for Cold Start-ups.
3. Verify that the boiler water quality is within specified limits per the points outlined for
Cold Start ups.
4. Start the Boiler Circulating Pump per the points outlined for Cold Start-ups.
5. Observe the initial firing precautions and gas air heater protection per the procedure
for Cold Start-ups.
Lighting Off
(Doc. No. : T04019-SY-M0006, O&M manual)
pressure control to automatic. Adjust unit airflow to minimum 30% BMCR air flow,
and place unit air flow control to automatic.
3. Start the second draft group: After closing the outlet shut-off dampers, start the
other ID fan, then the corresponding FD fan. Open the shutoff dampers and adjust
blade pitch to balance with the first group, and place on automatic control.
5. Place the gas air pre heater temperature control (steam coil air pre heaters) to
automatic.
23
6. Adjust the fan and wind box dampers to permit a purge airflow of at least 30% of
BMCR airflow and a furnace draft of approximately negative 12.0 mmwg. Refer to
Initial Firing Precautions.
auxiliary air dampers to maintain a programmed set point differential pressure
between the wind box and furnace.
8. Check that all other purge permissive is satisfied.
10. Initiate a furnace purge. Upon completion of the purge cycle, check that all firing
prerequisites are satisfied, including the following:
b. Start-up system (BCP and UG valve) is on automatic maintaining minimum

water wall flow.
c. Separator level control is on automatic, i.e. the WR, and ZR level control valves
are all on automatic.
e. Unit air flow is on automatic maintaining minimum 30% BMCR air flow.
f. Place HP bypass valve in operation:
1) Set to "valve position control" and desired preset position of app. 10 - 12% open.
2) HP bypass valve is set to be controlled along with the pressure rising of boiler.
3) Pressure and temperature controls for HP bypass valves with safety function, HP
bypass spray valves, and Spray water pressure reducing valves are on
automatic.
g. Place LP bypass valve in operation:
1) Open LP bypass stop valve after establishing sufficient condenser vacuum and
2) Adjust to pre-set minimum position.
3) The minimum pressure (app. 10 ~ 12 kg/cm2(g)) is automatically controlled.
4) Place control on automatic.
h. Place SH and RH temperature controls on automatic, with set-points of 442℃ for

SH and 407℃ for RH.
i. Open SH division panel vent valves, and RH outlet vent valves.
24
j. SH backpass drain valves are open after 10 minutes from light-up.
k. Steam coil air pre-heaters are working properly and raising the air temperature to
setpoint. (Insufficient air temperature can lead to poor oil firing).
11. Start two(2) PA fans per the points outlined for Cold start up.
12. For warm start-ups, the fuel startup sequence should follow this table:
Sequence
Elevation Notes
Step
8 D coal
9 A coal
10 E coal
11 F coal
12 G coal
13. Initiate a light-off sequence of oil elevation AB warm-up oil guns.

To minimize the possibility of adverse visible stack emission, it is desirable to use
the warm-up oil guns until 35 kg/cm²(g) steam pressure is produced and 175℃
14. Set fuel oil flow control to auto and adjust the set-point to 3% of TMCR firing rate.
15. Initiate an elevation start command for oil elevation CD. Stabilize the CD elevation
for 5 minutes.
through the superheater, firing rate should not be further increased until 8kg/cm²(g)
is measured in the water separator.
18. As the pressure is raised, the WR and ZR valves will open when separator water
level increases due to boiler water swell. As pressure further increases, the WR and
ZR valves will start to close as the water level decreases.
temperature probe(s) until approximately 10% steam generation or the turbine is
synchronized. Sufficient steam flow must be maintained at all times to assure
clearing the superheater and reheater elements of condensate. Do not close the
startup drains completely until steam flow through the HP/LP bypass is established.
20. The superheat backpass drain valve can be closed after 10 minutes from valve
25
opening.
21. Progressively increase LP bypass setpoint to 16 kg/cm²(g). As the HP bypass opens,

the reheater will be warmed and pressurized as steam is passed through the LP
bypass and reheat vents. In parallel, close the reheat vents and drains to transfer
flow and pressure control to the LP bypass station.
22. Close the RH outlet vent valves when RH pressure reaches 3.5 kg/cm²(g).
23. When steam pressure at HP bypass reaches 12 kg/cm²(g), the HP bypass valve is
released to "pressure ramp" mode. The valves will move to nominal 30%, then
2
control the boiler pressure ramp-up to 100 kg/cm . Firing rate can now be increased.
24. Initiate an elevation start command for oil elevation EF.
25. After a 5 minute stabilization period, progressively increase firing rate to 15% TMCR
at a rate of 1.0% per minute.
progressively throttle the SH outlet vents to transfer flow and pressure control to the
HP bypass station.
28. After a pressure of 100 kg/cm²(a) is attained, the firing rate can be adjusted to
achieve the required steam temperature for turbine rolling. Target steam conditions
are: 25%TMCR steam flow, SH = 442℃,RH = 407℃.
boiler load. Above 10% boiler load automatic interlocks provide protection from over-
firing.
conditions.
Rolling and Synchronizing the Turbine
1. Confirm the steam conditions, i.e. pressure, temperature, and steam purity, at the
turbine are correct for turbine roll. (See turbine manufacturer’s Steam Purity
recommendations)
steam. Roll the turbine by opening the Reheat Stop and Control Valves to the IP
turbine per the Turbine manufacturer’s procedures. The HP turbine is maintained in
reverse flow using steam from CRH line. During this time, the total steam production
is passed through the HP bypass while it remains on "pressure control' mode.
26
the turbine. The HP section is still in reverse-flow mode.
5. As steam is transferred to the IP turbine during turbine loading, the LP bypass will
close while maintaining RH pressure at 16kg/cm²(g).
6. Initiate a start command for oil elevation GH. Stabilize elevation GH for 5 minutes.
8. As turbine conditions permit, put feedwater heaters into service per manufacturer’s
instructions.

10. The firing rate should never exceed the rate necessary to match the total steam
generation.
11. If the unit was started with one set of fans in service, start the second set of fans as
required. Refer to the fan manufacturer's instructions for operating details. (Doc.
No. : T04019-SY-M0006, O&M manual)
Introducing Coal
1. Coal firing can commence when steam flow reaches app. 25%TMCR and LP bypass
is closed.
2. Pulverizer B or alternately pulverizer A, serving the lower elevations of coal nozzles,

should be prepared for operation at this time so it can be readily started. The
selected pulverizer seal air fan must be placed in service at this time. Refer to the
Recommended Burner Management System instructions for start-up sequences and
controls. (Doc. No. : T04019-PI-M0004, Mill burner control system write-up)
3. When placing the first pulverizer in service, make sure the pulverizer start
permissives are satisfied. Refer to the Recommended Burner Management System
instructions. The coal fuel-air dampers should remain closed until ignition is
established. Make sure the nozzle tilts are horizontal. Both PA fans must be in
service.
If the unit start-up follows a master fuel trip, the pulverizer may not be empty.
Operate the pulverizer to clear it of excess coal before starting the feeder. During
the pulverizer clearing procedure, the pulverizer discharge gates of all other idle
pulverizers must be closed. This prevents hot furnace gases from entering the coal
piping and the idle pulverizers. (See EMERGENCY PROCEDURES) When most of
the coal has been removed from the pulverizer, the pulveriser can be introduced as
per normal procedure. Be sure the ignition energy in the furnace is established
before starting the pulverizer.
If ignition does not take place within five(5) seconds after coal appears at the coal
nozzles, stop the feeder. Determine the cause of ignition failure before attempting to
restart the feeder.
27
4. Start the pulverizer. Open the hot air shutoff gate, adjust the hot air damper to 100%
pulverizer airflow, and bring the pulverizer up to the required operating temperature
without coal. Place the pulverizer airflow and temperature control on automatic.
When ready to fire coal, manually start the feeder at minimum rating. Ignition of the
pulverized coal should take place immediately. When the pulverizer is proven in
service, the fuel-air dampers should open automatically. Maintain the fuel feed at a
minimum rate consistent with stable ignition. Watch the fires.
Pulverizer start-up will cause a sudden and sharp increase in steam pressure. The
pressure will level out rapidly as the HP bypass station responds. Check the
pulverizer oil temperature. When the temperature approaches 150℉ (66℃) turn on
the water to the oil cooler or adjust the lube oil control system. The oil temperature
should never exceed 160℉ (71℃).
5. Maintain the proper coal/air temperature leaving the pulverizers. Regulate the hot
and cold air dampers to keep the temperature between 77 ℃ and 82 ℃ at the
pulverizer outlet.
6. At the pre-scribed load per turbine manufacturer, the HP turbine is transferred to

forward-flow. The first three turbine control valves are opened until sufficient flow is
compensates by closing to control the steam pressure at the set point.
8. Start the second pulverizer when the HP bypass is closed.
9. When the feeder rating of the first pulverizer has reached approximately 50%, place
the second pulverizer, which supplies the adjacent elevation of coal nozzles, in
service in a similar manner. When the second pulverizer is proven in service,
equalize the feeder rating of both. The warm-up oil guns must remain in service until
both feeders proven signal is achieved.
If the adjacent pulverizer is not available for service, place the pulverizer serving the
next closest elevation of coal nozzles in service. Do not remove the warm-up oil
guns from service until the two(2) adjacent coal elevations are in service with feeder
ratings greater than 50%.
11. The Burner Management System and secondary air damper controls should close
the auxiliary air dampers which serve compartments adjacent to the coal nozzles out
of service when the unit load reaches 30% of TMCR load. These controls should
also gradually increase the wind box-to-furnace differential pressure to
approximately 102 mm w.g.
12. The airflow to the furnace must be sufficient for the firing rate. Automatic control
equipment is normally arranged to maintain such a balanced draft condition. The
operation of the O2 measuring devices at economizer outlet, often tied in with the
airflow control, should be checked periodically.
28
Initial Load Increase
1. The third pulverizer can be started after steam flow reaches 25-30% TMCR. Place
additional pulverizers in service in a similar manner. Pre-warm the pulverizer and
Initiate an elevation start command. After the coal elevation is proven In service
(signal from BMS), the feeder is put on automatic.
3. After reaching 30% TMCR load and firing is stable, oil elevation AB is issued an
elevation stop command by the operator.
4. After oil elevation AB is stopped, ensure coal elevation A or C shows flame through
flame scanner indications.
5. Reduce oil firing to minimum. Oil elevation CD is issued an elevation stop command
by the operator .
6. After stable firing is established, put into service the second BFP(T) per the
manufacturer procedures.
NOTE: Before increasing the total firing rate above 30% TMCR, feed
water quality must be verified to be within the limits for normal firing as
defined in Appendix A.
7. Start the ESP per manufacturer’s instructions.
8. During load increase, the BMS shall be given a signal to start the next available coal
elevation. After a coal elevation is proven in service (signal from BMS), the feeder is
put on automatic.
9. The steam temperature at the separator inlet will reach a stable superheated
condition at app. 30% TMCR, causing the level in the separator to decrease and
eventually disappear. The boiler is now in once-through mode. The BCP will be
stopped automatically.
10. When the BCP stops, the warm-keeping system of the start-up system should be put
into operation.
11. The boiler/turbine is now ready for automatic load dispatch. The control system shall
monitor unit loading and will start/stop firing equipment by the automatic load
program.
12. Place additional pulverizers in service as the unit load demand increases. The
pulverizer serving the lowest coal nozzle elevation not already in service should be
started, if available, when the feeders in service reach the 50% rating. As each
pulverizer is placed in service, the required ignition energy must be available. When
the unit firing conditions are stabilized, all warm-up oil guns may be taken out of
service. Refer to the Recommended Burner Management System instructions. (Doc.
No. : T04019-PI-M0004, Mill burner control system write-up)
13. Place the steam temperature control and combustion control on automatic when
firing conditions are stable and the temperature and pressure control set points have
been reached. Refer to the control system manufacturer's instructions for specific
29
procedures. (Doc. No. : T04019-SY-M0006, O&M manual)
14. Make frequent visual observations of furnace conditions to ensure that no excessive
slag build-up is developing. This is especially important when burning coal with low
ash fusion temperatures. Operate the soot blowers as required to keep the steam
temperature control (nozzle tilts, de-superheaters) within operating range. If
response to soot blowing is sluggish or insignificant, reduce unit load or increase
excess air to assist in lowering steam temperature and take steps to eliminate the
cause of the erratic steam temperatures. Refer to Soot Blowing Philosophy. (Doc.
No. : T04019-SY-M0006, O&M manual)
If excessive slagging of furnace walls is experienced, make sure that the bottom ash
removal system is in good working condition to handle the increased quantity of
bottom ash that accompanies higher slagging rates.
15. Overfire air is used for NOx control and is automatically controlled as a function of
total unit air flow. The effective starting load must be determined during initial unit
operation.
HOT START-UP
Assuming the unit has been down for a comparatively short period of time (<8 hours)
and considerable steam pressure has been maintained, use the following procedures to
restart the unit:
Hot Start Conditions

1. Less than 8 hours shutdown
2.Main steam pressure ≥ 30 kg/cm2(g) and < 120 kg/cm2(g)
Preparations, Lighting Off, and Load Increase
1. Make a general inspection of the steam generator and check the points outlined in
the Preparations for Lighting Off for Cold Start Ups.
2. The boiler circulating pump should still be in service.
3. If the gas air heaters and fans were shut down at reduced temperature(see
NORMAL SHUTDOWN TO HOT STANDBY, step 4), start the gas air heaters and
fans as outlined under COLD START -UP, Lighting Off. If the unit was bottled up
hot with the gas air heaters still running start the fans in the normal sequence.
CAUTION: Prevent possible water damage to the turbine by using

extreme care to eliminate all water from the main steam line(s), cold
and hot reheat lines, and superheater and reheater elements and
headers before the turbine is rolled. Refer to the turbine
manufacturer's instructions for the proper drain valve settings.
4. Open wide all superheater drains to allow complete draining of superheater headers
and/or elements. After draining, close all drains the start-up drains (main steam line
vents and drains). Keep the start-up drains open. Reheater drains and vents are
open. Open the de-superheater isolating valves (de-superheater control valves
must be closed).
SH backpass drain valves are open after 5 minutes from light-up and close after 10
30
minutes from valve opening.
5. Set the HP and LP bypass control set-point to the existing pressure in auto mode.
6. For hot start-ups, the fuel startup sequence should follow this table:
Sequence Elevation Notes
Step
7 D coal
8 A coal
9 E coal
10 F coal
11 G coal
7. Initiate a furnace purge and a normal light off sequence of the warm-up oil guns
following the sequence noted above.
8. Set fuel oil flow control to auto and increase oil flow set point to 3% of TMCR firing
rate. Stabilize the AB elevation for 5 minutes.
9. Initiate an elevation start command for CD oil elevation. Stabilize the CD elevation
for 5 minutes.
11. When steam pressure at HP bypass begins to increase, the HP bypass valve is
released to "pressure ramp" mode. The valves will then control the boiler pressure
ramp-up to 160 kg/cm²(a).
12. As the HP bypass opens, the reheater will be pressurized as steam is passed
through the reheat vents and drains. Set the LP bypass station to minimum set-point
in auto mode. The LP bypass will open in response to increasing reheat pressure.
Close the reheat vents and drains to transfer flow and pressure control to the LP
bypass station.
13. Initiate an elevation start command for oil elevation EF and stabilize for 5 minutes.
14. Initiate an elevation start command for oil elevation GH and stabilize for 5 minutes.
16. Increase the firing rate, as prescribed, to raise the pressure and steam production.
The rate of pressure rise should follow the prescribed start-up curves.
31
18. After a pressure of 160 kg/cm²(a) is attained, the firing rate can be adjusted to
achieve the correct steam temperature for turbine rolling. Target steam conditions
are: 25%TMCR steam flow, SH = 530℃,RH = 510℃.
19. When steam is admitted to roll the turbine, there should be a minimum steam-to-
turbine metal temperature differential. This can be achieved by raising boiler load
while on HP/LP bypass.
Rolling and Synchronization the Turbine
1. Confirm the steam conditions, i.e. pressure, temperature, and steam purity (See
turbine manufacturer’s Steam Purity recommendations), at the turbine are correct
for turbine roll.
steam. Roll the turbine by opening the Combined Reheat Valves to the IP turbine
per the Turbine manufacturers procedures. The HP turbine is maintained in reverse
flow using steam from CRH line.
the turbine. The HP section is still in reverse-flow mode. During this time period,
boiler steam production is passed through the HP bypass.
During a hot restart, the turbine metal temperature will normally require a rapid
reloading of the unit.
5. As steam is transferred to the IP turbine, the LP bypass will close while maintaining
RH pressure at 16 kg/cm²(g).
6. As turbine conditions permit, put feed water heaters into service per manufacturer’s
instructions.

8. At the prescribed load per turbine manufacturer, the HP turbine is transferred to

forward-flow. The first three turbine control valves are opened until sufficient flow is
compensates by closing to control the steam pressure at the set-point.
10. Commence coal firing as required to support load increase.
11. Coal firing and load increases generally follow the procedures outlined for cold start-
ups and normal load changes.
32
BLACK START-UP
Black Start Conditions
The black start conditions are assumed to be same as that of a cold start condition which
are as follows:
1. Greater than 72 hours shutdown.
2. Boiler pressure = 0 kg/cm2 (g)
The Black start condition arises due to no external steam being available in the plant. The
start-up fuel is Light Diesel Oil and atomization is by air. It is also regarded that black start is
a rare operating condition particularly in a plant where more than one boiler is installed.
Preparations for Lighting Off
Before lighting off the steam generator, verify that the following activities have been
completed:

hydrostatic test).
If the metal temperature is less than 100℉ (38℃) and the feed water
temperature is higher, a minimum fill rate should be used.
1. All control systems have been checked and are available for service.
All safety interlock systems should be checked prior to start-up to ensure proper
functioning. Exercise the systems by creating the actual interlock actuating
conditions. Simulate the activating condition if the actual condition cannot be
created.
2. All instrumentation and associated mechanical equipment has been checked out
and is available for service.
3. The oil firing equipment has been checked out to ensure it is properly functioning.
Recheck the following items to make sure that:
a. Warm-up oil guns are inserted and properly coupled. Check gaskets between
unions.
b. All oil gun quick-connect couplings are properly assembled.
c. All manual valves are open.
d. All control valves are closed.
4. The pulverizers and feeders have been checked out and are available for service.
Recheck the following items to ensure that:
a. All pulverizer discharge gates are open.
33
b. All fuel air dampers are in closed position.
c. All burner inlet knife gates are in open position.
d. All hot air gates are closed and all hot air control dampers are closed.
e. All cold air gates are open and the cold air control dampers are open
approximately 5%.
f. All bunker outlet valves are open and coal is available to the feeders.
g. All pulverizer and feeder seal air valves are open.
h. All classifier vane settings are identical.
i. The pulverizer lube oil systems are available for service.
5. The windboxes have been checked for proper damper positioning and the tilts are
set at horizontal.
6. The feedwater system and at least one feedwater pump, including the
instrumentation and equipment, has been checked out and is available for operation.
During a start-up, the feedwater flow should be controlled remote-manually until a
continuous flow is established.
7. To avoid oxygen corrosion in the boiler, the use of deaerated feedwater with a
temperature of greater than 102℃ is recommended. Since no external steam is
available during a black start, use of undeaerated water at a temperature less than
102℃ is acceptable as an emergency operating condition. However, the feed water
shall be properly treated de-mineralised water. Efforts shall be taken to cut in the
deaerator as quickly as possible and ensure supply of deaerated water at the
required temperature.
8. The boiler circulating pump has been checked out, the suction and discharge
isolation valves are open, and all pump instrumentation is available for service. The
pump differential pressure switches must be in service. Ensure that the proper trip
settings have been made.
9. The steam generator start-up system valves are ready for operation (UG, WR, ZR
valves), with isolation valves open. The separator level control for WR and ZR valves
has been checked and is available for service.
10. The startup system drain transfer system is ready for operation. This system includes
WR and ZR valves, the flash tank and connecting pipe to condenser.
11. Since the startup drain transfer system is connected to the condenser via the startup
drain flash tank, ensure that the condenser vacuum is raised as required.
However, in case where external steam from any other source in the plant is not
available and raising vacuum in the condenser and Turbine gland sealing are not
possible, then to facilitate black start up of the unit, the following provision is made:
A bypass system consisting of DN150 size piping along with necessary valves and
fittings is envisaged. The piping is tapped off the common line to WR/ZR valves and
34
connected to the common inlet header to Boiler Blow down Tank such that during the
black start up, the start up drain system comprising the WR/ZR valves, Start up flash
tank and subsequent connecting piping to Condenser is bypassed. Please refer to P &
IDs drawing No.: T04019-PI-D0012 and T04019-PI-D0013 for the bypass system.
12. Atomizing air is available at 6 Kg/cm2(g).
13. It should be borne in mind that since no external steam is available from the plant, it
may not be possible to charge the steam coil air-preheater and raise the air
temperature during a black start.
14. Cooling water system is in operation.
CAUTION: Before starting an ID fan and before adjusting the ID fan inlet
blade pitch, an airflow path through the unit must be established and
maintained by placing other dampers in the system in the start-up positions
indicated below. The ID fan inlet blade pitch must be kept closed or at the
minimum open position until after the fan is started. This minimizes the
possibility of developing excessive negative pressure in the unit during the
starting procedure. Furnace draft must be maintained within safe limits at all
times. Extreme care should be taken when draft and airflow controls are in
the manual mode. Be alert for possible malfunctions of automatic control
equipment resulting in abnormal excursions, negative or positive, in furnace
pressure.
NOTE: If the unit is started with only one ID and FD fan, one PA fan in service,
the following damper positions apply to the equipment to be started. Dampers
associated with the idle equipment should be closed. Refer to the fan
manufacturer's instructions for operating details.
15. All air and gas handling equipment has been checked out and is available for service.
Air and gas duct dampers should be in the start-up position as follows:
a. For the first draft group to be started (ID fan A and FD fan A), the fan outlet shutoff
dampers are closed and the inlet blade pitch is at minimum.
b. For the second draft group (ID fan B and FD fan B), the outlet shutoff dampers are
open to provide a flow path through the unit.
c. The PA fan outlet shutoff dampers and inlet control vanes are closed or at the
minimum position.
d. All duct dampers are open.
e. The overfire air dampers are closed.
f. The windbox auxiliary (secondary) air dampers are open or modulating.
g. One pulverizer seal air fan inlet shutoff damper is open with the associated fan
ready.
h. The scanner air fans are ready for operation
16. The gas air heaters have been prepared for service and an adequate means of
35
extinguishing an gas air heater fire is available and ready for use. Refer to gas air
pre-heater protection during unit start-ups on oil, and to the gas air heater
17. The soot blowing equipment has been checked for proper operation and the system
is in the start-up mode with all blowers retracted and the main steam supply valve
closed. Refer to the soot blower instructions.
18. All desuperheater spray water control and block valves are closed.
CAUTION: Prevent possible water damage to the turbine by taking extreme

care to eliminate all water from the main steam line(s), cold and hot reheat
lines, and the superheater and reheater elements and headers before the
turbine is rolled. Refer to the turbine manufacturer's instructions for proper
drain valve settings.
19. All boiler, superheater, and reheater drain valves are open, and all vent valves are
closed. The economizer and furnace wall drain valves are closed, and economizer
vent valves are open.
20. The auxiliary steam extraction line from the superheater is isolated.
21. The warming system for the boiler start-up system is isolated (supply from
economizer outlet links and discharge to the SH desuperheater).
22. The furnace gas temperature probe(s) is in working order and available for service.
23. The HP and LP bypass stations are available for service, and hydraulic stations are
in operation. The water supply for desuperheating has been established.
24. The condenser is available for service, with circulation water flow, and vacuum has
been established to accept water flow from the drain transfer pumps and LP bypass
(condenser pressure setpoint interlock of LP bypass). Turbine Vendor to make
necessary arrangements to raise vacuum in the condenser by other means as no
external steam is available in the plant.
25. The main steam stop cum control valve and hot reheat stop and control valves are
closed. Drain valves on the main steam, cold reheat, and hot reheat lines are open.
During black start, draining of condensate from main steam, cold reheat and hot
reheat lines shall be through atmospheric flask tank.
26. The condensate polishing plant is available for operation.
27. The turbine generator has been prepared and is available for service as described in
the turbine manufacturer's instructions.
Water Filling of the Boiler
The entire economizer, furnace wall, and separator system must be filled with water and
be free of air. The following procedure shall be carried out to ensure the water system is
free of air:
1. The economizer outlet vent valve is open.
36
2. BFP(M) is started at minimum speed and flow according to feed pump operating
procedures.
3. If the water system of the boiler is empty (economizer, furnace walls, separators),
then the system is to be filled with approximately 10% TMCR feedwater flow.
Feedwater flow is preferably controlled using automatic feedwater control with a set
point of 10% TMCR. When the level in the separator reaches set-point, the WR
valve will begin to open. When the WR valve reaches >30% open for approximately
one minute, then increase feedwater flow set-point to 30% TMCR. As the drain flow
increases, WR valve will reach full open and ZR valve will begin to open. The water
system is considered full when:
a. The separator water level remains stable for two(2) minutes

and
b. The WR valve is fully opened and ZR valve is >15% open for two(2) minutes.
4. After filling the water system, the feedwater pump is stopped. The water level in the
de-aerator must be re-established and maintained.
5. Re-start the feedwater pump and establish feedwater flow of 10% TMCR to the
boiler .
6. Close Economiser outlet vent valve 20 secs later than detecting the Economiser inlet
water flow reaches over 10T/hr.
Water Recirculation via Boiler for Clean-up
1. When the feedwater quality at the outlet of deaerator and separator is not within the
specified limits, a feedwater clean-up recirculation via the boiler is necessary.
2. During this time, constant feedwater flow of 10% TMCR or more is maintained.
3. Water flows through the economizer and evaporator, and discharges the boiler through
the WR valve to the flash tank and via connecting pipe to the condenser. From the
condenser, the water flows through the condensate polishing plant, which is in service
to remove impurities, then returns to the feedwater tank.
4. The recirculation is continued until the water quality is within the specified limits.
Start of the Boiler Circulation Pump (BCP)
1. It is assumed that the following preparatory work has been completed:
a. Feed water quality within specified limits.
b. Feed water flow set point at 10% TMCR.
c. Separator water level stable at normal level.
d. Cooling water flow to the HP cooler of the BCP adequate.
e. Suction valves and discharge valves are open.
37
2. Set the UG valve at minimum position, and start BCP per pump operating instructions.
3. As soon as pump is running, open the UG valve to establish minimum waterwall flow
at 30% TMCR.
4. With BCP in operation, flow through the economizer and waterwall tubes increases
substantially. It is recommended that the water quality at the separator be rechecked.
Initial Firing Precautions
To ensure a maximum safety margin during start-ups, at least 30% of the full load airflow
must be maintained to produce the following conditions:
1. An air-rich furnace atmosphere. This prevents the accumulation of an explosive

mixture due to poor or delayed ignition after fuel is introduced to the furnace.
2. High excess air through the gas air heaters. This minimizes the dilution of combustion
air by inert gases carried over by the gas air heater rotors.
Superheat Steam Temperature Control (Prior to Unit Synchronization)
The boiler will normally be started-up de-coupled from the turbine using the HP and LP
bypass systems, which provide a steam flow path through the superheater, to the
reheater, and to the condenser. This provides additional flexibility for adjusting steam
temperatures to match turbine requirements at start-up. The primary methods for
controlling steam temperature will be firing rate and airflow adjustment.
Gas Air Pre-heater Protection During Unit Start-Ups On Oil
It is strongly recommended to have the gas air heater soot blowing system continuously
in service when firing oil to start up a boiler. This measure is intended to help avoid gas
air heater fires due to accumulation of oil vapors on heating surfaces or ash particles in
the gas air heater baskets. A retractable soot blower is installed at the cold end of the
gas air heater on the gas side, arranged close to the changeover of air to gas side when
looking in direction of rotation, opposite the hot spot detection device. This soot blower is
primarily designed to reduce (knock off) and/or control oil residue deposits and ash
build-up in the gas air heater surface. It is not a cleaning device such as the stationary
wash down nozzles.
Steam is the preferred soot blowing media. However, on some units auxiliary steam
sources are not available when starting a unit, and normal soot blowing steam
parameters are not reached until a later stage in the start-up process. If auxiliary steam
is not available, then extra attention must be given to any possible fuel oil carryover
which could deposit in the gas air heater. A device to identify such carryover would be a
water-cooled lance, temporarily located in the gas path leading from the economizer
outlet to the gas air heater gas inlet (102 mm /4" oxygen test ports could be used). This
lance, maintained at 93℃ (200℉) or below, will cause any oil vapor in the flue gas to
condense on it, If the lance is periodically withdrawn by a plant observer, it will indicate if
corrective action to the oil firing system has to be taken.
Additionally, for those units where no auxiliary steam is available for cold starts on oil,
the hot spot detection system must be in service. This system will identify any possible
38
start of a fire in the gas air heater. Also, the top oil elevations should not be utilized since
they are more prone to cause oil carryover. Special attention must be given to the
readings of gas and air temperatures leaving the gas air heater. An unusual increase in
any of these temperatures must be investigated immediately. Any indication of an gas air
heater fire must be reacted to immediately because once a fire is well under way it can't
be stopped before the gas air heater is severely damaged.
For unit loads below 10% TMCR steam flow, excessive combustion air(more than the
required 30% minimum of full load air flow) or unnecessarily high furnace draft (more
negative than -12 mmwg.) should be avoided. Burner tilts should not go above the
horizontal position. Changes in the firing pattern should be closely observed in respect
to possible carryover. Also, any steam that is available including saturated steam can
and should be used for gas air heater soot blowing as long as sufficient steam pressure
is available (at least 9 bar / 130 psig). When this minimum steam pressure has been
reached, continuous cold end blowing should be initiated and continued until 10% TMCR
steam flow is reached. After that gas air heater soot blowing can be reduced to intermit
tent operation, once every four to eight hours or as required, depending on the fuel being
fired. Once the unit is above 10% TMCR steam flow, normal soot blowing can be
followed using the units own auxiliary steam source as temperature and pressure is built
up.
The following minimum requirements as delineated in the vendor's "Operating

Instructions" should be observed:
Blowing Superheated
Temperature Enthalpy Saturation
Pressure by
2
[kg/cm g] [℃] [kcal/kg] [℃] [℃]
9 327 743 179 148
11 328 743 183 145
14 332 743 197 135
15 333 743 201 132
17 335 743 206 129
WARNING: The greatest danger, for developing an gas air heater fire,
is in the initial stages of boiler operation, i.e. boiler chemical cleaning
and boiler steam blowing. Experience has shown that during these
stages more than the normal precautions need to be taken. This is
because there is normally insufficient boiler steam capacity and/or soot
blowers are not available for use. Therefore, continuous plant visual
observations must be undertaken so the risk of a gas air heater fire
can be kept to its very minimum.
Once the unit has seasoned on coal, fly ash will have been deposited
in various areas of the boiler (especially in the assemblies of the back
pass). These ash deposits will absorb some of the vapor before it
reaches the gas air heater surfaces so the risk of gas air heater fires
will be somewhat diminished. It goes without saying that prolonged low
Ioad operation firing oil without blowing the gas air heaters should
always be avoided.
Water washing has no positive effects in removing oil unburned

particles / residue. Only soot blowing would be effective by knocking
off these particles. Therefore, when firing oil when sufficient blowing
steam is available, the gas air heater should be continuously cleaned
utilizing its soot blowers.
39
Gas air heater surfaces should only be water washed, during initial
stages of boiler operation and/or subsequent load operations, if heater
surfaces become plugged with fly ash (high delta-P) when soot blowing
was either ineffective or not available for use.
Gas air heater water washing must be in strict accordance with

vendor's instructions.
Frequent water washing of gas air heater surfaces is not a substitute

for the soot blowing process and should be avoided. Frequent washing
will decrease the life of gas air heater heating elements.
Lighting Off
CAUTION: An airflow path through the unit must be established and

maintained before starting an ID fan and before opening the ID fan
inlet blade pitch by ensuring that other dampers in the system are in
the start-up positions indicated in Preparations for Lighting Off, page 2.
open position until after the fan is started. This minimizes the
possibility of developing excessive negative pressure in the unit during
start-up.
Furnace draft must be maintained within safe limits at all times.

Extreme care should be taken when draft and airflow controls are in
the manual mode. Be alert for possible malfunctions of automatic
control equipment resulting in abnormal excursions, negative or
positive, in furnace pressure.
pressure control to automatic. Adjust unit air flow to minimum 30% air flow, and set
unit air flow control to automatic.
4. Adjust the fan and wind box dampers to permit a purge airflow of at least 30% of total
airflow and a furnace draft of approximately -12.7mmw.g. Refer to Initial Firing
Precautions.
When lighting off an elevation on manual control, the fuel-air dampers should be closed.
Once ignition of the main fuel is established, the fuel-air dampers should be opened in
proportion to the fuel elevation firing rate. When the fuel-air dampers are fully open,
further damper adjustments should be made, if necessary, with the auxiliary air dampers
only. When changing the damper positioning, an entire elevation should be treated
simultaneously, that is, damper positioning at the same elevation should always be
identical in all wind boxes.
When the steam generator reaches a firing rate at which additional air is required to
40
maintain the design operating excess air, increase the airflow. Refer to the percent
excess air versus load curve.
auxiliary air dampers to maintain a programmed set point differential pressure of
102mmw.g. between the wind box and furnace.
6. Check that all other purge permissives are satisfied.
8. Initiate a furnace purge.
9. Upon completion of the purge cycle, check that all firing prerequisites are satisfied,
including the following control settings:
b. Start-up system (BCP and UG valve) is on automatic maintaining minimum water

wall flow.
CAUTION: It is extremely important that minimum water wall flow be

maintained at all times when firing the boiler to prevent tube damage due to
overheating. If water wall flow falls below the low set point, all fuel must be
automatically tripped with a maximum time delay of five(5) seconds.
c. Separator level control is on automatic, i.e. the WR, and ZR level control valves are
all in automatic.
e. Unit air flow is on automatic maintaining minimum 30% full load air flow.
10. Place HP bypass valve in operation:
a. Set to "valve position control" and desired preset position of app. 10 - 12% open.
b. HP bypass valve is set to be controlled along with the pressure rising of boiler.
c. Pressure and temperature controls for HP bypass valves with safety function, HP
bypass spray valves, and Spray water pressure reducing valves are on automatic.
11. Place LP bypass valve in operation:
a. Open LP bypass stop valve after establishing sufficient condenser vacuum and
b. Adjust to pre-set minimum position.
c. The minimum pressure (app. 10 ~ 12 kg/cm2(g)) is automatically controlled.
d. Place control on automatic.
41
12. Place SH and RH temperature controls on automatic, with set points of 350℃ for SH
and 320℃ for RH.
13. Open SH division panel vent valves, SH backpass drain valves, and RH outlet vent
valves.
14. Start one of the PA fans. After fan is started, open the PA fan outlet damper. Bring
the primary hot air duct pressure up to set point by manually adjusting the PA fan inlet
vanes. Then, transfer to automatic control.
i. Airflow must be maintained through the pulverizers whenever the unit is being fired.
Therefore, the PA fans must be in service.
Ii. If the pulverizers are out of service the pulverizer discharge gates must be fully
open. The cold air inlet control dampers must be set to the minimum position. The
pulverizer discharge gates are closed during pulverizer maintenance, or when the
pulverizers are idle and full of coal and other pulverizers are being started after a
unit trip. Refer to emergency procedures, Master Fuel Trip.
15. For black start-up of the unit, the fuel startup sequence should follow this table:
Sequence
Elevation Notes
Step
1 AB oil Light Diesel Oil
7 D coal
8 A coal
9 E coal
10 F coal
11 G coal
16. Initiate a light-off sequence of Light Diesel Oil elevation AB warm-up oil guns. Refer
to the HEA igniter, retractable oil gun, and the Recommended Burner Management
System instructions for details.
To minimize the possibility of adverse visible stack emission, it is desirable to use the
warm-up oil guns until 35 kg/cm2(g) steam pressure is produced and 175 ℃
17. Set fuel oil flow control to auto and adjust the set point to 3% of TMCR firing rate.
18. Progressively increase firing rate to 7.5% MCR at a rate of <0.5% per minute. A slow
increase in firing rate will help in minimum swell flow during black start-up. After
reaching the LDO capacity of 7.5% MCR, maintain the firing rate till such time steam
generation is available for GAPH Sootblowing, charging of SCAPH and then for
steam atomization of HFO at 16 Kg/cm2(g) and 320˚C.
42
through the superheater, firing rate should not be further increased until 8 kg/cm2(g) is
measured in the water separator.
20. As the pressure is raised, first the WR and then the ZR valves will open when
separator water level increases due to boiler water swell. As pressure further
increases, the WR and ZR valves will start to close as the water level decreases.
temperature probe(s) until approximately 10% TMCR steam generation or the turbine
is synchronized. Sufficient steam flow must be maintained at all times to assure
clearing the superheater and reheater elements of condensate. Do not close the
startup drains completely until steam flow through the HP/LP bypass is established.
22. The superheat backpass drain valve can be closed when separator pressure reaches
3.5 kg/cm2(g)
23. Progressively increase LP bypass set point to 12 kg/cm²(g). As the HP bypass opens,
the reheater will be warmed and pressurized as steam is passed through the LP
bypass and reheat vents. In parallel, close the reheat vent and drain valve to transfer
flow and pressure control to the LP bypass station.
24. Close the RH outlet vent valves when RH pressure reaches 3.5 kg/cm2(g).
25. When steam pressure at HP bypass reaches 12 kg/cm2(g), the HP bypass valve is
released to "pressure ramp" mode. The valves will move to nominal 30%, then control
the boiler pressure ramp-up to 90 kg/cm²(a). Firing rate can now be increased.
26. When steam parameters are available at 16 Kg/cm2(g) and 320℃, prepare Heavy
Fuel Oil system and initiate an elevation start command for HFO elevation CD.
Stabilize the CD oil elevation for five minutes.
27. Change over to Heavy Fuel Oil firing in elevation AB from Light Diesel Oil. Stabilize
for 5 minutes.
28. Initiate an elevation start command for EF with HFO and stabilize for five minutes.
Progressively increase firing rate to 15% TMCR at a rate of 0.5% per minute.
close SH vent valve to transfer flow and pressure control to the HP bypass station.
31. After a pressure of 90 kg/cm2(a) is attained, the firing rate can be adjusted to achieve
the required steam temperature for turbine rolling. Target steam conditions are: 10%
BMCR steam flow, SH = 350℃,RH = 320℃.
TMCR load. Above 10% TMCR load automatic interlocks provide protection from
over-firing. When ready to fire coal, the pulverizer serving a lower elevation of coal
nozzles should be prepared for operation and started in accordance with Introducing
43
Coal, steps 1 through 5. Adjacent warm-up oil guns supply the required ignition
energy. The feeder should be set to keep the furnace exit gas temperature from
exceeding 1000℉(538℃).
NOTE: The steam pressure should be increased slowly during the initial
start of a new steam generator. This allows sufficient time for checking
expansion movements and permits the operators to become familiar with
the characteristics of the steam generator and auxiliary equipment. Once
these characteristics have been established, subsequent start-ups may
be made at the fastest possible rate consistent with maintaining the
furnace exit gas temperature limitation of 1000ºF (538℃).
Special attention should be given to expansion of the boiler relative to the building
steel. Expansion movements should be recorded for comparison with future start-ups.
Refer to the pressure Parts Connection and Expansion Movement Diagrams.
conditions.
35. Follow the procedures outlined under cold start-up for rolling and synchronization of
steam turbine, introduction of coal and load increase.
EMERGENCY PROCEDURES
Reheater Protection
Stopping or significantly reducing steam flow through the reheater when the entering gas
temperature is above 1000℉ (538℃) can cause overheating and damage to the reheater
tubing. To prevent this condition, the following measures are taken with the automatic
reheat protection interlocks:
RH FLOW MONITORING
If excessive steam flow is extracted upstream of the reheater, causing flow through the
reheater to be dangerously low, all fuel should be tripped automatically with a maximum
time delay of 10 seconds. Extreme care should be exercised when bringing in feedwater
heaters or when extracting auxiliary steam from the cold reheat lines.
TURBINE VALVE CLOSURE

If a loss of load should cause the turbine valves to close, the HP/LP bypass stations will
automatically open to allow the boiler to stay on-line. If the HP/LP bypass stations do not
open within 10 seconds to provide a flow path through the superheater and reheater, all
fuel should be tripped.
When a master fuel trip is caused by turbine control valve closure, an immediate restart
is feasible in most instances because the turbine is still rolling and will be available to
take steam as soon as the governor has the turbine speed under control. (Refer to
turbine manufacturer's instructions for no-load operating procedures and limitations.) If
an immediate turbine restart is not possible and the turbine is tripped, the reheater
condensate drains should be opened (refer to Turbine Trip below).
44
TURBINE TRIP
If a loss of load occurs in which the turbine is tripped, the HP/LP bypass stations will
automatically open to provide a steam flow path for the superheater and reheater,
allowing the boiler to stay on-line.
The reheater safety valves will protect against overpressure in the reheater. The reheater
condensate drains should be opened to evacuate the steam in the reheater .
POST -TRIP PROCEDURES

The furnace must be purged immediately following a master fuel trip. Empty any
pulverizer containing coal as soon as possible. Refer to Master Fuel Trip, page 38.
To permit firing during start-up, the initiating fuel trip circuits must be disarmed before
opening the turbine valves. They must then be rearmed at a suitable point in the start-up
sequence, such as when synchronizing the turbine.
CAUTION: Operators should be alert to detect the symptoms of water carry-

over from the boiler and introduction of water into the turbine, such as:
a. A sudden, unexplained drop in steam temperature in either the main steam

or hot reheat line.
b. Vibration in the steam piping resulting from water hammer .
c. Abnormal vibration and differential expansion readings from the turbine

supervisory instrumentation.
Operators must be prepared to take necessary steps to prevent turbine

damage upon detecting the introduction of water. Refer to the turbine
manufacturer's instructions for specific actions to be taken.
TURBINE PROTECTION UPON LOSS OF LOAD

Extreme care must be taken following a trip of the turbine and boiler to prevent water
from entering the turbine during a unit restart. Condensation may cause water to collect
in the main steam line(s) and cold reheat lines. Water may be introduced into the
superheater due to overflow from the separator (inadvertent high water level). Water
may be introduced into the superheater and/or reheater through the desuperheaters due
to open or leaking spray water control valves.
Inadvertent introduction of water into the steam lines must be prevented. The lines must
be drained prior to opening the turbine stop valves. Refer to the turbine manufacturer's
instructions.
Master Fuel Trip
When a master fuel trip occurs automatically through normal interlocks, or is initiated
manually by an operator, all fuel should be tripped instantaneously. If coal is being fired,
the pulverizers should be tripped immediately. Tripping the pulverizers will automatically
trip the feeders and close the hot air shutoff gates. If oil was being fired, the fuel trip
valves and individual nozzle shutoff valves should be closed immediately.
The following steps should be taken immediately following an emergency fuel trip:
1. Maintain the unit airflow at the pre-trip value for at least 5 minutes to purge the
system. If a hot restart is anticipated, the airflow may be gradually reduced to a light-
45
off airflow (30% of BMCR load airflow) during the purge. The boiler circulating
pumps should be started to maintain uniform temperatures throughout the boiler
circulation system and to facilitate lighting off. (Refer to Boiler Circulating Pump
manufacturer's Operating Procedures).
2. Procedure after Master Fuel Trip when all ID and FD Fans are off:
The ID and FD fans discharge dampers shall be opened to allow natural ventilation
of the unit. Opening of fan(s) dampers shall be timed or controlled to avoid
excessive furnace pressure excursions during fan(s) coast-down. The fans
discharge dampers shall remain open for a period of at least 15 minutes.
During this 15-minute period, the ID and FD fans shall not be started.
At the end of the 15-minute period, the ID/FD fans may be started in accordance
with ID/FD fan(s) start-up procedures.
If the unit is not possible to restart for an extended time, a flow of air through the
unit shall be maintained.
3. If oil guns were in service when the fuel trip occurred, make sure the individual
nozzle shutoff valves are closed. If an immediate restart is anticipated, the oil guns
will not require cleaning. Otherwise, the oil guns should be retracted, removed,
cleaned and then re-installed. Refer to the Recommended Burner Management
System instructions for emergency oil gun shutdown sequencing.
4. If all auxiliaries are lost during a fuel trip, refer to the Boiler Circulating Pump
manufacturer's Operating Procedures for handling the low pressure cooling water.
The cooling flow must be maintained.
5. If all auxiliary power sources were lost during a trip, start the fans and gas air
heaters when power is restored to purge the furnace for five(5) minutes. Observe
the hot restart precautions in the gas air heater instructions. The boiler circulating
pump, if available, should be placed in service during the purge. (See Boiler
Circulating Pump manufacturer's Operating Procedures for restarting procedures).
6. If pulverizers are in service when the fuel trip occurs, successively clear all
pulverizers containing coal, as soon as possible in the following manner
a. Close the pulverizer discharge gates on all other idle pulverizers containing coal.
This prevents hot furnace gases from being carried back into the pulverizers in
the event of a furnace pressure rise when a pulverizer is started.
b. Establish the ignition energy required to start a pulverizer. Refer to COLD

START -UP, page 2, and to the Recommended Burner Management System
instructions for ignition energy requirements and permissives.
c. Clear the pulverizer .
If, due to load conditions and/or requirements to the Burner Management

System, it is impossible to establish ignition permissives for all pulverizers and
clear them of coal, the discharge gates of any idle pulverizer (including those
still containing coal) should be opened to allow a flow of cooling air through the
pulverizer. Keep the discharge gates open until the pulverizer is ready to be
unloaded and/or restarted.
46
Each time an additional pulverizer is placed in service or unloaded, any idle
pulverizer containing coal should be temporarily isolated again (see item a).
(1) If the pulverizer will be retained in service, start the associated feeder when the
pulverizer amps begin to falloff .When the feeder is started, open the hot air
shutoff gate and bring the pulverizer up to normal operating temperature.
Following a pulverizer trip under load, the pulverizer should be operated with
cold air only until the associated feeder is started.
(2) If the pulverizer will not be retained in service, stop it after completely clearing
the coal. The pulverizer discharge gates should remain open to allow a flow of
cooling air through the empty pulverizer.
d. An emergency trip subjects residual fuel in the pulverizers to conditions which

may cause spontaneous combustion. If the unit cannot be refired within a
reasonable time (45 minutes) to clear the pulverizers, then the pulverizers
should be cooled to ambient temperature and manually unloaded. If this is not
possible, isolate the pulverizers and remove all doors to prevent gases from
entering the furnace.
Low Water Wall Flow
If the water wall flow drops below the minimum set point due to failure of the BCP, UG
valve, feed water supply, controls, or operator neglect, automatically trip the fuel
following a maximum 15 second time delay. The time delay allows for momentary
fluctuations due to valve transfers, etc. Low flow subjects the water wall tubing to
overheating, and potential for failures:
1. Trip all fuel immediately.
2. Shut off all steam being discharged from the unit (trip turbine, steam driven
auxiliaries, and such).
3. Leave the boiler circulating pump in service as long as it is operating normally.
CAUTION: The differential temperature between feed water and boiler

metal must never exceed 200℉(93℃) (separators during initial filling
or separators and superheater outlet header during filling for
hydrostatic test.)
4. If the problem is rectified, re-establish minimum water wall flow.
5. If the boiler circulating pump cannot be kept in service, do not admit feed water to
the unit.
6. Maintain a high airflow at first to hasten the cooling process.
7. If pressure part damage is suspected, reduce the steam pressure gradually by

opening the superheater start-up drains. As the boiler cools, reduce the airflow. Shut
down the gas air heaters and fans as soon as the unit is cool enough to enter. When
the separator metal temperature is 200℉ (93℃), drain the boiler following normal
draining procedures. Determine the cause of low water flow and examine the boiler
47
for signs of overheating, such as leaks and distorted pressure parts.
8. Repair any leaks.
9. Hydrostatically test the boiler at operating pressure before putting the unit back in
service.
High Water Wall Tube Temperature
If water wall tube metal temperatures exceed the set point, automatically trip the fuel
following a maximum 3 second time delay. This trip protects the tubes from overheating,
and potent failure, and therefore immediate action is required.
High water wall tube temperatures are an indication of over-firing, low water wall flow, or
a combination of both. Over-firing could be a result of extreme load change rates. Low
water wall flow could be a result of excessive SH spray flow. Investigate these
parameters and their control before re-firing the boiler .
Tube Failures
If any water or steam carrying tube fails, the best shutdown method will be dictated by
the size of the failure, the ability to maintain a normal water level and the demand for the
unit to remain in service.
The following instructions are general since most of the conditions will require the
judgment of the operators.
WATERWALL TUBES
If a leak or tube failure does not involve a serious drain on the feed water supply, the
water level should be maintained and the unit taken out of service in the normal manner:
1. Operate the soot blowers if conditions permit.
2. Switch the combustion control equipment to manual control and proceed to reduce
the firing rate and air flow in a normal manner.
3. When all fires are extinguished continue the air flow through the unit at a reduced
rate to purge all combustible gases, vapors, etc. Shut down the fans when the unit is
cooled sufficiently.
4. Feed water to the boiler by manual. To hasten cooling, boiler pressure can be
reduced by opening the superheater outlet drains.
5. Allow the boiler to cool at least to 200℉ (93℃) (separator metal temperature);
before draining.
If there is a serious water loss and the water level cannot be maintained with the
feedwater supply available. use the following method:
1. Trip all fuel.
2. Shut off the feed water to the boiler .
48
3. Maintain only enough airflow to carry the escaping steam up the stack.
4. Leave the fans and gas air heaters in service until pressure is off the unit.
5. Once the unit is cool enough to enter, inspect the pressure parts for damage caused
by the loss of water level. After the necessary repairs have been carried out, apply a
hydrostatic test and obtain the approval of the proper authorities before putting the
unit back in service.
ECONOMIZER TUBES
An economizer tube leak can be detected by sound and/or increased makeup water
requirements. Check the leak as soon as possible. Water leaks in the economizer can
cause considerable erosion damage to adjacent tubes. Water carried over from an
economizer tube leak may cause plugging of hoppers and gas air heaters. Any decision
to continue operation with known leaks should be made with this in mind. The unit
should be shut down in a normal manner.
SUPERHEATER AND REHEATER TUBES

A small leak in a superheater or reheater element should be checked as soon as
possible. Steam leaks in the superheater or reheater can cause considerable erosion
damage to adjacent tubes. Any decision to continue operation with known leaks should
be made with this in mind. The unit should be shut down in a normal manner .
A major superheater or reheater tube failure may require an emergency unit shutdown.
The operator must judge the degree of failure, its consequences, and then decide what
type of shut down is required.
49
APPENDIX A FEEDWATER SPECIFICATIONS FOR ONCE THRU BOILERS
Normal Operation Short Periods

Alkaline Combined Start-up
Units
Water Water Procedures (1)
Treatment Treatment
Conductivity at 25℃ measured
After cation-exchanger in H+ form and ㎲/㎝ max. 0.2 max. 0.5 max. 1.0
after Co2 removal (2)
pH-VALUE(25℃) (3) min. 9.0 8.0-8.5 min. 9.0
Oxygen (4) ppb max. 100 30-150 max.100
Silica (5) ppb max. 20 max.20 max.100
Iron (susp. + dissolv.) ppb max. 20 max.20 max.50
Copper (susp.+ dissolv) ppb max. 3 max.3 max.10
Sodium ppb max. 10 max.10 max.50
General requirements clear and clear and clear and
colorless colorless colorless
(1) Values specified in this column may be tolerated for max. 2 hours. However, they
must approach the limits for normal operation and should attain them within 6 hours
after ignition.
(2) If the contamination measured with the conductivity in the feed water are only soluble
salts such as sodium chlorides, sodium sulfates etc., they will concentrate in the
(circulating) water and dissolve in the steam in the evaporating area. They have a
corrosive effect only, if they can settle into the pores of deficient magnetite layers or
already existing corrosion pits formed e.g. through oxygen corrosion during shutdown.
The case is different when the contamination in the feed water consist of hardness
constituents (calcium and magnesium compounds) or free acids from cooling water
leakage. Therefore, observance of the conductivity limit value of 0.2 ㎲/㎝ is still no
guarantee for a proper feed water quality. Rather care should be taken that the
conductivity can be kept at the practically lowest possible level, and at each increase
of this value the reason for the conductivity increase should be sought.
(3) If copper materials are present in the water/steam circuit, the pH-value should be
kept within the limits of 9.1 ± 0.2 in order to prevent undue copper corrosions.
(4) If Combined Water Treatment is practiced the specified oxygen level is controlled by
oxygen dosing into the condensate line between the condensate polishing
plant(CPP) and the low-pressure pre heaters.
(5) The max. allowable silica content should in any case not be higher than the limits
specified by the turbine manufacturer for the turbine steam.
50
51

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NTPC REF. NO.

: CC:PES: 9518:1081:11:9129 / DATE : 30-03-07

NTPC DRAWING NO:9518-108-11-KO-PVM-L-030

M/S Doosan’s reply OS comments

F 25/05/07 Revised as Owner’s Comments S.W.KANG B.S. YOON K.T.LEE

E 29/01/07 Revised as Owner’s Comments S.W.KANG B.S. YOON J.B.KIM

REV. DATE DESCRIPTION DGN CHK REVIEW APPR

National Thermal Power Corporation Ltd.

DOOSAN HEAVY INDUSTRIES &

NTPC DOCUMENT NO. 9518-108-11-KO-PVM-W-013 SHEET REV.

STEAM GENERATOR START-UP AND

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO. LTD

PRE-OPERATIONAL PROCEDURES ...................................................................................... 1

COLD START -UP .................................................................................................................. 2

NORMAL OPERATION -UNIT LOAD CHANGES ................................................................... 17

NORMAL SHUTDOWN TO COLD .......................................................................................... 19

NORMAL SHUTDOWN TO HOT STANDBY .......................................................................... 21

WARM START -UP ................................................................................................................ 23

HOT START -UP .................................................................................................................... 30

TITLE PAGE NO.

BLACK START -UP .............................................................................................................. 33

EMERGENCY PROCEDURES ............................................................................................... 44

APPENDIX A- FEEDWATER SPECIFICATIONS FOR ONCE THROUGH BOILERS ............. 50

Figure 1: Typical Air Flow Curve .......................................................................................... 51

Refer to the manufacturer's instructions(Doc. No. T04019-SY-M0006, O&M manual) for

Steam Line Blowing

Setting Hydraulically Operated Safety Valves

Cold Start Conditions

1. Greater than 72 hours shutdown.

2. Boiler pressure < 1 kg/cm2 (g)

Preparations for Lighting Off

CAUTION: The differential temperature between the feed water and

b. All oil gun quick-connect couplings are properly assembled.

c. All manual valves are open.

d. All control valves are closed.

a. All pulverizer discharge gates are open.

b. All fuel air dampers are in closed position.

g. All pulverizer and feeder seal air valves are open.

h. All classifier vane settings are identical.

i. The pulverizer lube oil systems are available for service.

8. The deaerator auxiliary steam supply is operational and de-aerated feedwater at

14. Cooling water system is in operation.

CAUTION: Before starting an ID fan and before adjusting the ID fan

d. All duct dampers are open.

e. The overfire air dampers are closed.

f. The windbox auxiliary (secondary) air dampers are open or modulating.

h. The scanner air fans are ready for operation

CAUTION: Prevent possible water damage to the turbine by taking

26. The condensate polishing plant is available for operation.

Warm Water Filling of the Boiler

1. The economizer outlet vent valve is open.

a. The separator water level remains stable for two(2) minutes

Water Recirculation via Boiler for Clean-up

Start of the Boiler Circulation Pump (BCP)

1. It is assumed that the following preparatory work has been completed:

a. Feed water quality within specified limits.

Initial Firing Precautions

1. An air-rich furnace atmosphere. This prevents the accumulation of an explosive

Superheat Steam Temperature Control (Prior to Unit Synchronization)

Gas Air Pre-heater Protection During Unit Start-Ups On Oil

The following minimum requirements as delineated in the vendor's "Operating

Water washing has no positive effects in removing oil unburned

Gas air heater water washing must be in strict accordance with