ENMAS O & M SERVICES PVT LTD

1.0

OBJECTIVE:
Standard operating procedure for startup or light up of a CFBC

boiler.
2.0

SCOPE:
Scope of this procedure is limited to the start up or light up of a

CFBC boiler.
3.0

RESPONSIBILITY:
Boiler operator, Panel officer and Shift- In charge.

4.0

SAFETY:
Use of PPEs (Safety shoes, helmet, dust mask, safety goggle).

5.0

BOILER LIGHT UP PROCEDURE

Requirements : Bed materiall, Diesel (LDO), Coal & DM

Water
Bed material specification
Maximum Particle size

: <1 MM

Bulk density

: 1200 to 1600 Kg/M3

Chemical composition

: Alumina 45% to 35%

: Silica

Fusion temperature

55% to 65%

: 1400 Deg. C
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2*35 MW CFBC BOILER

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Qty required for startup

: 40 MT

Diesel

Qty required for startup

: 20 K LTRS

Preparation before light up

Fill the bed material in the furnace in such an extent that the
level of the bed height shall be 550 mm to 600 mm from grid
panel (750 bags).
Fill DM water in the boiler drum through initial fill up water line of
economizer, Headers and remove the air locks through the air
vents given on boiler drum top. Maintain the drum level between
35-40%.
Ensure CBD and IBD valves are in operation by operating once &
keep close during start up
Before startup, check and ensure following important
points.
1.

All access doors of boiler are closed.

2.

No persons are present inside the boiler.

3.

All foreign materials (scaffold pipe, clamps, refractory debris,

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2*35 MW CFBC BOILER

ENMAS O & M SERVICES PVT LTD

tarpaulin, coir ropes etc.) are to be removed from furnace
and pressure parts.
4.

All equipment required for boiler startup is functioning as per

requirement during the trial.

5. All interlocks have been checked, found OK

Ensure that that, following equipments are having
adequate lubrication.
1. SA, PA & ID Fans and their motors.
2. Boiler Feed pumps and motors.
3. Fuel feeders i.e. DCF and controllers with trials.
4. Burners and ignition guns are to be clean.
5. LDO pumps & motors.

Ensure that, the dry coal (0-6 MM size) is available in coal

bunker and gates below bunker are in open condition so that the
coal is available at coal feeder inlet.

Ensure that the, instrument air compressor and service air

compressor is in operation & required pressure (6 Kg/sq cm) is
available for instrumentation & its control.
Ensure that the following valves of boiler are in closed
condition.
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2*35 MW CFBC BOILER

ENMAS O & M SERVICES PVT LTD

1. Boiler feed water control valve and its bypass valve.
2. Boiler blow down valve. (CBD & IBD)
3. Main steam stop valve and pilot valve of main steam supply
header.
4. Drain valves of water level gauge of boiler drum.
Ensure that the following valves are kept in open
condition.
1. Vent valves of steam drum and main steam supply line.
2. Isolation valves of drum water level gauge, pressure gauge
isolation valve and isolation valves of level transmitters/all
primary isolation valves.
3. Isolation valves before and after feed control valve in feed
water pipe line & eco feed check valve.
4. Valves on the boiler feed water pipe line connecting to the
boiler feed water pumps operation.
5. Startup vent Manual & MOV valve on main steam supply
header.
6.
7.
8.
9.

Wing wall SH drain valve

Cage panel (steam cooled wall)
Final Super Heater drain valve
Main Steam Line Start up vent (min 30% open)

10. Bunker Isolation gates

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2*35 MW CFBC BOILER

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Boiler light up
The general procedure will be to start one (1), the ID fan, the loop
seal blower, Secondary fan and the Primary Airflow is then set as
for the requirements. Purging will be accomplished and fans will be
left in operation for subsequent start-up.
PA fan flow minimum
30 TPH
SA fan flow at air buzzle
- 12 TPH, > 200 MMWC
SA header pressure
- >400 MMWC
Step-1: Start ID Fan and maintain furnace draught of -3 to -5 mm
of WC
Step -2: Start the loop seal blower. ( delivery valve should be
open and air vent at 40 % open).
Step-3: Start SA Fan and Maintain header pressure of 500 mm of
WC.
Step-4: Start the PA and the PA flow 30 TPH.
Step-5: Start the LDO oil pump and maintain the oil pressure at
12.0 to 15.0 kg/sq.cm.

Burner oil gun pressure is always less than service air

compressor pressure.

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2*35 MW CFBC BOILER

ENMAS O & M SERVICES PVT LTD

2 nd burner (any) should be start after one hour of previous
started burner, also before starting oil flow should be increased ,
furnace draught also to be increase.
Purging should be done before Light up the burners.
Increase the SA fan air flow at coal feeding air buzzle up to 12
tons and pressure200 mmwc.
When bed temperatures reaches between 550-600 deg. C, start
the drag chain coal feeder to introduce coal.
Maintain the feeding control to avoid the coal dumping.
Observe the bed temperature. Once the bed temperature
stabilized, stop the diesel oil burners and LDO pumps.When the
drum pressure reaches between 3 to 5 kg/cm.sq close all
isolation valves of air vents of boiler drum.
Close drain valves of super heater at 5 to 10 Kg/cm^2.
It should be ensured during the light up of the boiler, that feed
water is flowing always through the economizer & there is no
steaming in the economizer.
Maintain the drum level and take CBD in line.

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2*35 MW CFBC BOILER

ENMAS O & M SERVICES PVT LTD

Open Pilot valve of the Stop valve when the steam pressure
reaches 40 - 45 kg/sq.cm and temperature reaches between 400
to 450 deg.C.
Open Stop valve when the steam pressure reaches 65 - 75
kg/cm.sq. And temperature reaches between 400 to 450 deg.C.
and close the Pilot valve.

O2% may maintain up to 13 % before synchronizing

(without burner).
Put on the ESP hopper heaters
Start ash convey system at ECO/APH and ESP.
Charge the ESP fields at flue gas temp reaches 120 deg C.
Dearator should be charge after the load raised up to 12 MW.
HP heater should be charged after 16 MW.
ACW pressure should be maintain at 5 Kg/cm^2.

BFP and scoop (60 % before starting) should be at manual mode

till the plant reach 25 MW, after that BFP, scoop and 100 % control
valve put in auto (3 ELEMENT).

De superheating control valve should put in auto when load

reaches 5 MW.
TULSYAN NEC LTD
2*35 MW CFBC BOILER

ENMAS O & M SERVICES PVT LTD

TULSYAN NEC LTD

2*35 MW CFBC BOILER