Boiler Operating Procedures: (Guidance Only)

INCOMING Boiler Cold Start/Warm Up:

Ensure that the controllers are in the following mode in FACEPLATES page:

STEAM PRESSURE: MANUAL with SP of 0 and Output 10, LOCAL DEMAND

CA FLOW: REMOTE
FUEL GAS FLOW: REMOTE
FUEL OIL FLOW: REMOTE
OXYGEN TRIM: AUTO with SP 2.5
DRUM LEVEL: MANUAL with SP of -30 and Output 0

1. Ensure that the boiler steam drum Start-Up Steam Vent is OPENED IF STEAM
PRESSURE is less than 2Barg

Note: When the STEAM PRESSURE is above 2Barg, ensure that the Start-Up
Steam Vent is CLOSED.

Note: If starting the boiler from COLD or below 2Barg, follow the boiler warming
timing of 5mins ON and 15mins OFF.

Note: If STEAM PRESSURE is above 2Barg and Start-Up Steam Vent is

CLOSED, boiler can be put under minimum firing continuously to build up pressure.

2. Ensure that the steam drum water level is below 30mmWg, for example-100mmWg.

3. Ensure that the isolation valves upstream and downstream of the Feedwater
Control Valve are fully closed to prevent passing.

4. MDO PUMPS page:

Ensure that the MDO pump is DUTY and STANDBY selected in AUTO mode.

Note: IF there is concern on the slow supply pressure building up of the MDO
pump, then the MDO pump should be started at this time in MANUAL.

5. FEEDWATER PUMPS page:

Ensure that the Feed Pump is DUTY and STANDBY selected in AUTO mode.

6. PORT BOILER>>PORT CONTROL OR STARBOARD BOILER>>STARBOARD

CONTROL page:

BOILER STATUS: Boiler Interlocks Correct & Pre-Purge Available are GREEN

OIL STATUS: FO Pumps Available & FO Interlocks Correct are GREEN

GAS STATUS: FG Interlocks Correct is GREEN

FAN & PURGE STATUS: CA FAN AUTO SELECTED ORANGE & CA Fan
Available GREEN
 SELECT GAS for Gas firing on BURNER STATUS: Fuel Gas Selected GREEN
OR SELECT OIL for Oil firing on BURNER STATUS: Fuel Oil Selected GREEN

If any of item 6 is not correct, try Press Accept and Reset alarms pushbutton and
check what is the active alarm to rectify the problem if any

7. BOILER>>PORT CONTROL or STARBOARD

BOILER>>STARBOARD CONTROL page:

Click on BURNER START GREEN button to start the boiler light up sequence

8. PORT BOILER OR STARBOARD BOILER page:

Observe COMBUSTION AIR FAN starting changing from RED to GREEN

Observe CA fan damper moving up to light up position: AT LIGHT UP and opening

up to purge position of 50% AT PURGE

Observe Purging in progress with the Purge Timer counting down from 180s to 0s.

Observe Pre-purge complete and CA fan damper moving down towards light up
position: AT LIGHT UP 3% for Port and 1% for Starboard.

9. When the burner has lighted, observe the fuel flow (FUEL OIL FLOW PV if OIL
SELECTED or FUEL GAS FLOW PV if GAS SELECTED) increasing and
modulating down to minimum firing (about 20% for FUEL GAS FLOW PV or 10% for
FUEL OIL FLOW PV).

10. Keep the boiler in minimum firing with LOW FIRE HOLD ON and observe the
steam drum water level slowly increasing.

11. When the boiler has warmed up to about 14Barg, get ready and make preparations
to bring the boiler on load.
Bringing Incoming Boiler On load: (Guidance Only)
Ensure that the controllers are in the following mode in FACEPLATES page:

STEAM PRESSURE: MANUAL with SP of 0 and Output 10 to increase in 5% step,

LOCAL DEMAND
CA FLOW: REMOTE
FUEL GAS FLOW: REMOTE
FUEL OIL FLOW: REMOTE
OXYGEN TRIM: AUTO with SP 2.5
DRUM LEVEL: MANUAL with SP of -30 and Output 0 – put to AUTO if RED PV
Value is greater than -10

1. Ensure that boiler is at Minimum Firing on Gas or on Oil with LOW FIRE HOLD ON
and STEAM PRESSURE: MANUAL with SP 0 and Output 10

2. Put the DRUM LEVEL control to AUTO when RED PV Value is more than -10

3. Gradually Open the Main Steam Stop Valves to Full Open when STEAM
PRESSURE RED PV Value has reached 14Barg

4. Observe the increasing of Boiler Steam Pressure and Drum Level. STEAM
PRESSURE RED PV Value and DRUM LEVEL RED PV Value

Note: If Drum Level is not more than +150mm, blow down is NOT required at
this moment.

5. Observe the starting decrease of the DRUM LEVEL RED PV Value. This is an
indication that the STEAM PRESSURE between the two boilers are balancing and
that steam is starting to flow out of the boiler supplying to operation.

6. Observe the DRUM LEVEL RED PV Value decreasing and stabilizing around
GREEN SP -30.

7. When both boilers STEAM PRESSURE RED PV Value has stabilized at about
15.5 to 15.6Barg and with DRUM LEVEL RED PV Value stabilize at around -
30mm:

Incoming BOILER CONTROL page: Double click on GREEN BURNER START to

release the LOW FIRE HOLD ON

8. FACEPLATES: Increase STEAM PRESSURE: MANUAL Output to 5% more

than current Fuel RED PV, for example if boiler is on Gas firing, and FUEL GAS
FLOW RED PV is 20%, then Enter 25% to STEAM PRESSURE: MANUAL Output

9. Observe the other boiler STEAM PRESSURE: AUTO Output decreasing.

10. Observe and wait for both boilers STEAM PRESSURE RED PV Value to
stabilize at about 15.5 to 15.6Barg and with DRUM LEVEL RED PV Value
stabilize at around -30mm:

IMPORTANT: Repeat Step 8 to Step 10 until the other boiler STEAM

PRESSURE: AUTO Output stabilize at minimum at about 20% if Gas Firing or
10% if on Oil firing

11. FACEPLATES: Set STEAM PRESSURE: SP 0 to 15.5

Proceed to STOP the other firing Boiler (Note: Do NOT secure the boiler yet)

FACEPLATES: Set STEAM PRESSURE: MANUAL to AUTO

12. Observe and wait for incoming boiler STEAM PRESSURE: AUTO SP 15.5, RED
PV Value stabilize at 15.5Barg

13. When the incoming boiler has stabilized:

Proceed to secure the other shutdown boiler:-

a. Gradually Fully Close the Main Steam Stop Valve

b. FACEPLATES: Set DRUM LEVEL: AUTO to MANUAL with Output 0

c. Fully close the isolation valves upstream and downstream of the Feedwater
Control Valve to prevent passing

14. The incoming boiler is now on load.

Single Boiler Shutting down: (Guidance Only)
Ensure that the controllers are in the following mode in FACEPLATES page:

STEAM PRESSURE: AUTO with SP 15.5, LOCAL DEMAND

CA FLOW: REMOTE
FUEL GAS FLOW: REMOTE
FUEL OIL FLOW: REMOTE
OXYGEN TRIM: AUTO with SP 2.5
DRUM LEVEL: AUTO with SP -30

1. With the steam load stable, slowly decrease the steam load in steps.

Observe STEAM PRESSURE RED PV Value increase from example 15.5Barg to

15.7Barg and then back to 15.5Barg stably. At the same time, you will also observe
that the FUEL FLOW RED PV Value (oil flow if oil firing, gas flow if gas firing) has
now decreased.

Note: After each decrease of steam load, allow time for the controllers to
modulate and stabilize the load before the next decrement.

2. Repeat step 1 until the steam load has reduced to minimum before stopping the boiler.
For example FUEL OIL FLOW RED PV Value is 10% or FUEL GAS FLOW RED
PV Value is 20% AND STEAM PRESSURE RED PV Value increase and not
decreasing.

3. After the boiler has stopped:

a) Gradually Fully Close the Main Steam Stop Valve

b) FACEPLATES: Set DRUM LEVEL: AUTO to MANUAL with Output 0

c) Fully close the isolation valves upstream and downstream of the Feedwater
Control Valve to prevent passing

4. After the boiler has shut down and fully secured, perform the following:

Ensure that the controllers are in the following mode in FACEPLATES page to warm
up/cold start mode:

STEAM PRESSURE: MANUAL with SP of 0 and Output 10, LOCAL DEMAND

CA FLOW: REMOTE
FUEL GAS FLOW: REMOTE
FUEL OIL FLOW: REMOTE
OXYGEN TRIM: AUTO with SP 2.5
DRUM LEVEL: MANUAL with SP of -30 and Output 0
Single Boiler On load: (Guidance Only)
Ensure that the controllers are in the following mode in FACEPLATES page:

STEAM PRESSURE: MANUAL with SP of 0 and Output 10, LOCAL DEMAND

CA FLOW: REMOTE
FUEL GAS FLOW: REMOTE
FUEL OIL FLOW: REMOTE
OXYGEN TRIM: AUTO with SP 2.5
DRUM LEVEL: MANUAL with SP of -30 and Output 0 – put to AUTO if RED PV
Value is greater than -10

1. Ensure that boiler is at Minimum Firing on Gas or on Oil with LOW FIRE HOLD ON
and STEAM PRESSURE: MANUAL with SP of 0 and Output 10

2. Put the DRUM LEVEL control to AUTO when RED PV Value is more than -10

3. Gradually Open the Main Steam Stop Valves to Full Open when STEAM
PRESSURE RED PV Value has reached 11Barg.

4. Observe the increasing of Boiler Steam Pressure and Drum Level.

Note: There will be a sudden increase of the steam drum water level due to the
initial steam flowing out of the drum, i.e. to 150mmWg. Do not panic as this is
normal. The water level will decrease after sometime.

WARNING: IF the water level increases very much, that is an indication that
the main steam stop valve is opened too fast. Gradually close back the steam
stop valve and then open slowly.

5. After the main steam stop valve is fully opened, observe the starting decrease of the
STEAM PRESSURE RED PV Value and DRUM LEVEL RED PV Value. It is an
indication that the current load is sufficient for the boiler to modulate and stabilize. IF
the DRUM LEVEL is NOT decreasing, gradually increase the load until both the
demand steam pressure and water level is observed to be decreasing.

Note: IF the the steam load is still low and STEAM PRESSURE RED PV Value
is still increasing, stop the boiler and re-start the boiler again.
6. When both STEAM PRESSURE RED PV Value and DRUM LEVEL RED PV Value
are observed to be decreasing:

BOILER CONTROL: Double click on GREEN BURNER START to release the

LOW FIRE HOLD ON

FACEPLATES: Set STEAM PRESSURE: MANUAL to AUTO with SP +0.2

MORE than the RED PV Value, i.e. set SP to 11.8 IF the PV is 11.6.
Note: When DRUM LEVEL RED PV Value has decreased to about -10mmWg, fully
open both the feedwater isolation valves (if not opened yet) and start the feedwater
pump (if not yet started).

Note: During every load increase, initially, the water level will rise slightly and
stabilize. This is normal.

7. Observe STEAM PRESSURE PV and DRUM LEVEL PV stabilizing to their

setpoint SP. Example: STEAM PRESSURE: PV:11.8 SP:11.8, DRUM LEVEL PV:-
30 SP:-30.

8. Gradually increase the STEAM PRESSURE SP in +0.2 steps until the desired
demand steam pressure SP, i.e. increase the demand STEAM PRESSURE SP
from 11.8 to 12Barg and WAIT for the pressure to STABILIZE, continue this
process until the Boiler Steam Pressure reaches 15.5Barg.

9. When STEAM PRESSURE SP is at 15.5 stable, the boiler is now ready to take on
more load.

10. Gradually increase the steam load until required amount.

Note: After each increase of steam load, allow time for STEAM PRESSURE
controller to modulate and stabilize the load before the next increment.