Start up system and seperator logics 660MW (DHI make) boiler

BOILER START-UP AND OPERATIONAL PROCEDURES

Cold Start Up conditions
Greater than 72 hours shutdown. Boiler pressure < 1 kg/cm2 (g)

Preparation for BLU

Chemical cleaning and steam blowing completion (for the first time) All interlocks and protections in service All instrumentation and associated mechanical equipment has been checked out and is available for service.

 Oil firing equipment checked out to ensure proper functioning

Warm-up oil guns have been inserted properly and coupled. All oil guns quick connect couplings are properly assembled. All manual valves are opened. All control valves are closed.

Pulverisers and feeders are available for service SADC checking complete & burner tilt horizontal Feedwater system is through and atleast one feed water pump available.

 The deaerator aux. steam supply is available and feedwater in deaerator is at 105C. BCP checked out completely
Suction and discharge iso. Valves open All pump instrumentation available in service Pump diff. pressure transmitters in service Ensure proper trip settings have been made

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.

 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. Steam supply isolating valves to the steam coil air pre-heaters are open. Cooling water system is in operation All air and gas handling equipment has been checked and is available for service. Air heater ready for service & means for extinguishing APH fire is available. 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.

 All desuperheater spray water control and block valves valves are closed. 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. The aux. steam isolation line from the superheater is isolated. The warming system of the boiler superheaters is isolated. The furnace gas temperature probe(s) is in working order and available for service. The HP and LP bypass stations are available for service, and hydraulic stations are in operation. The water supply for desuperheating has been established.

 The condenser is available in service, with circulation water flow and vacuum has been established to accept water flow from Start-up flash tank and the SCAPH drain tank and LP bypass (condenser pressure set point interlock of LP bypass). The main steam stop cum control valves and the hot reheat stop and control valves are closed. Drain valves on the main, cold reheat and hot reheat lines are open. The condensate polishing plant is available for operation. The TG has been prepared and is available for service

Warm water filling

The entire economizer, furnace wall and seperator system should be filled with warm deaerated water (105C)

 The following procedure shall be carried out to ensure that the water system is free of air : The economiser outlet vent valve is open. BFP (M) is started at minimum speed and flow according to feed pump operating procedures. Water system is to be filled with approx. 10 % BMCR feedwater flow. When level in the seperator reaches set-pt., the WR valve will begin to open. When the WR valve reaches > 30% open for approx. 1 min., feedwater flow set pt. is increased 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 : The seperator water level remains stable for two minutes. And The WR valve is fully opened and ZR valve is >15 % opened for two (2) minutes.

After filling of water system, the feedwater pump is stopped. Water level in deaerator must be re-established and maintained and water temperature at 105C is reestablished.

 Restart the feed water pump and establish feedwater flow of 10 % BMCR to the boiler.

Water recirculation for clean up

Feed water clean up recirculation is required to ensure that feedwater quality at the o/l. of seperator and deaerator is within specified limits. During this time, a constant feedwater flow of 10 % BMCR is maintained. Feed water flows through
Ecomomiser and Evaporator and discharges the boiler through the WR valve to the flash tank and via connecting pipe to the condenser. From condenser, water flows through the CPP, which is in service to remove impurities,then returns to the feedwater tank.

 Start of Boiler Circulation Pump

The following preparatory work needs to be completed : Feed water quality within specified limits. Feed water flow set point at 10% BMCR. Seperator water level stable at normal level. Cooling water flow to the HP cooler of BCP adequate. Suction valves and discharge valves are open.

Set the UG valve at min. position and start BCP as per pump operating instructions. As soon as pump is running, open the UG valve to establish min. water wall flow at 30% TMCR. With BCP in operation, flow through the economiser and water wall tubes increases substantially.

Initial firing precautions

Atleast 30% of the TMCR load air flow must be maintained to produce the following conditions : An air rich atmosphere to prevent accumulation of an explosive mixture High excess air through the APHs

 Boiler Light Up
Start the Secondary Air Preheater Start one ID fan, then the corresponding FD fan and adjust air flow to a max. of 30% TMCR Start the second draft group Start the selected scanner air fan. Adjust fan and SADC to permit a purge air flow of atleast 30% of TMCR and furnace draft of approx. 12.7 mmWC. When fans are started, SADC should modulate the aux. air dampers to maintain WB to furnace DP at 102 mmWC(g). Check that all other purge permissives are satisfied. Place FTPs in service. Initiate a furnace purge.

 After furnace purge check the following conditions

FW control is on auto maintaining FW flow rate of approx. 5% TMCR. Start-up system (BCP and UG valve) is on automatic maintaining minimum waterwall flow. Seperator level control is on auto, i.e the WR and ZR level control valves are all in automatic. Furnace pressure control is on auto. Unit air flow is on auto maintaining 30% TMCR air flow. Place HP bypass valve in operation Place LP bypass valve in operation Place SH and RH temp. controls on auto. With setpoints of 350 C for SH and 320 C for RH.

 Open SH division panel vent valves, SH backpass drain valves and RH outlet vent valves. Initiate a light-up sequence of oil elevation AB warmup oil guns. Set fuel oil flow control to auto and adjust the TMCR to 5 % of TMCR firing rate. When elevation AB is in service, close the economizer vent valves. After a 5 minute stabilization period, progressively increase firing rate to 10 % TMCR at a rate of 0.5% per minute. To ensure stable operation of the water system and to ensure sufficient steam flow through the superheater, firing rate shouldnot be further increased until 8 kg/cm2 (g) is measured in the water seperator.

 As the pressure is raised, first the WR and then the ZR valves will open when seperator water level increases due to boiler water swell. As the pressure further increases,the WR and ZR valves will start to close as the water level decreases. During all start-ups, control the firing rate to keep the max. FEGT below 538 C, as measured by the furnace temperature probes until approx. 10% steam generation or the turbine is synchronized. The superheat backpass drain valve can be closed when seperator pressure reaches 5 kg/cm2 (g). Progressively increase LP bypass set point to 12 kg/cm2(g). Close the RH o/l. vent valves when RH pressure reaches 5 kg/cm2.

 Increase LP bypass set pt. to 12 kg/cm2(g). As the HP bypass opens, the reheater will be warmed and pressurized cas steam is passed through the LP bypass and reheater vents. Close the reheat outlet vent valves when RH pressure reaches 5 kg/cm2(g). When steam pressure at HP bypass reaches 12 kg/cm2(g), the HP bypass valve is released to pressure ramp mode Initiate an elevation start command for other oil elevations. After a 5 minute stabilization period, progressively increase firing rate to 15% TMCR at a rat of 0.5% per minute. The rate of pressure rise should follow the prescribed start up curves When boiler pressure reaches 90 kg/cm2(A), the HP bypass valve is released to pressure control mode and maintains a constant pressure during rolling.

 After a pressure of 90 kg/cm2 is attained the firing rate can be adjusted to achieve the reqd. steam temperature for turbine rolling. Target steam conditions are:- 10% TMCR steam flow, SH = 350 C, RH = 320 C. Maintain seperator water level at normal and check the boiler water concentrations and constituents as frequently as necessary to maintain proper boiler water conditions.

Turbine rolling and synchronisation

Confirm the steam conditions, i.e. pressure, temperature Roll turbine using reheat steam. During this time total steam passes through HP bypass while it remains on pressure control mode. SH and RH steam temperatures are maintained by adjusting firing rate and air flow.

 Synchronize generator and put on initial load of app. 10% according to TG start up instructions. After synchronization, all superheat and reheat vent and drain valves should be closed. As steam is transferred to the IP turbine during turbine loading, the LP bypass will close while maintaining reheat pressure at 12 kg/cm2. Increase firing rate to 20 % TMCR at a rate of 0.5% per minute. As turbine conditions permit, put feed water heaters into service as per manufacturers instructions. The firing rate should never exceed the rate necessary to match the total steam generation. If the unit was started with one set of fans in service, start the second set of fans as required.

 Introduction of coal
Coal firing can commence when steam flow reaches approximately 20% TMCR and LP bypass is closed. Start the first pulverizer At a prescribed load as per turbine manufacturer, the HP turbine is transferred to forward flow. At first three 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 set point. Continue the transfer to forward flow until the first three turbine valves are fully opened and HP bypass valves are fully closed. Start the second pulverizer when the HP bypass is closed. Increase the total firing rate to 30% TMCR at a rate of 0.5% per minute by increasing each coal elevation loading.

 Initial load increase

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 initiate an elevation start command. After the coal elevation is proven in service the feeder is put into automatic. Increase total firing rate to 35% TMCR. After reaching 30% TMCR load and firing is stable, oil elevation AB is issued an elevation stop command by the operator After oil elevation AB is stopped ensure that coal el. A or C shows flame through flame scanner indications. Reduce oil firing to minimum After stable firing is established, put into service the second BFP(T) as per manufacturers procedures. Start the ESP as per manufacturers instructions.

 The steam temperature at the seperator inlet will reach a stable superheated condition at approximately 30% TMCR, causing the level in the seperator to decrease and eventually disappear. The boiler is now in once-through mode (dry mode). The BCP will be stopped automatically. When the BCP stops, the warm-keeping system of the start-up system should be put into operation.

Wet mode and Dry mode of operation

Operational Logics for Mixing Piece Upstream Valve or BCP circ. Shut-off MOV
Open permissive
If WET mode of operation is selected AND DRY mode is not selected

Close permissive
BCP off

Auto opening
Open permissives present AND any of the following conditions are present
MFT has operated OR Open command from start sequence for BCP circ. Shut off valve (Mixing piece upstream valve) OR System in wet mode of operation for 3 seconds

Auto closing
If system is in dry mode of operation for 3 seconds.

Operational logics for Boiler recirculation Pump

Start permissive
UG valve opening > min. (15 %) AND BCP circ. Shutoff MOV opened AND BCP inlet shut off MOV opened AND BCP outlet shut off MOV opened AND BCP inlet manual valve opened AND BCP cooling water flow not low AND Seperator storage tank level > 1100 mm AND Economiser inlet flow > 111 T/hr AND No BCP trip override exists AND No BCP MCC disturbance exists

 Trip permissives
Dry mode of operation of the boiler

Auto starting of BCP

BCP will get auto started if either BCP auto start signal is present OR Start BCP FR. W & steam start seq. signal from Start seq. is present. BCP auto Start signal

 Auto stopping of BCP

BCP will stop on auto if either BCP auto stop signal OR BCP MCC disturbance signal is present.

 BCP trip override logic

Operational logics for BCP Inlet Shut-off MOV

Open permissive
If WET mode of operation is selected OR BCP not tripped

Close permissive
BCP not running (stopped)

Auto opening
Open permissives present AND any of the following conditions are present
MFT has operated OR Open command from start sequence for BCP inlet shut off MOV OR System in wet mode of operation for 3 seconds OR BCP auto start signal is present

Auto closing
BCP trip signal

Operational logics for BCP Outlet Shut-off MOV

Open permissive
If WET mode of operation is selected OR BCP not tripped

Close permissive
BCP not running (stopped)

Auto opening
Open permissives present AND any of the following conditions are present
MFT has operated OR Open command from start sequence for BCP outlet shut off MOV OR System in wet mode of operation for 3 seconds OR BCP auto start signal is present

Auto closing
BCP trip signal

Operational logics for BCP Circulation Line Vent MOV

Open permissive
If Auto Dry Mode of operation is not selected AND If BLI is less than 15 % BMCR OR BCP is not running

Auto opening
Open permissives present and also if any of the following conditions are present
MFT has operated OR Open command from start sequence for BCP circ. Line vent MOV OR BCP is not running

Auto closing
If Auto Dry Mode of operation is selected OR If BLI > 15 % BMCR and BCP running (proven for 20 secs.

Operational logics for WR Line Isolation MOV

Open permissive
If BLI is lesser than 1000 T/hr AND Either Main steam bottle up OFF OR All feedwater pumps not off.

Close permissive
BLI > 960 T/hr OR If all FW pumps are off AND BCP is off AND all scanners show no flame

Auto opening
Open permissives present AND also if any of the following conditions are present
MFT has operated OR Open command from start sequence for WR line isolation MOV OR Auto wet mode of operation OR Seperator storage tank level > 1100 mm OR BLI < 890 T/hr.

Auto closing
BLI >1000 T/hr OR Main steam bottle up ON AND All feedwater pumps off

Manual close
After manual control is enabled, this will take place If Manual close command is sent from LVS / OWS AND Seperator storage tank level is not greater than 1100 mm.

Operational logics for ZR Line Isolation MOV

Open permissive
If BLI is lesser than 1000 T/hr AND Either Main steam bottle up OFF OR All feedwater pumps not off.

Close permissive
BLI > 960 T/hr OR If all FW pumps are off AND BCP is off AND all scanners show no flame

Auto opening
Open permissives present AND also if any of the following conditions are present
MFT has operated OR Open command from start sequence for ZR line isolation MOV OR Auto wet mode of operation OR Seperator storage tank level > 1100 mm OR BLI < 890 T/hr.

Auto closing
BLI >1000 T/hr OR Main steam bottle up ON AND All feedwater pumps off

Manual close
After manual control is enabled, this will take place If Manual close command is sent from LVS / OWS AND Seperator storage tank level is not greater than 1100 mm.

Operational logics for Storage tank drain MOV / Seperator water leg level control blocking MOV
Open permissive
Dry mode of operation

Auto opening
If seperator water leg control valve demand > 5 %.

Auto closing
Close seperator water leg CV demand from Start sequence. OR MFT operated OR BCP on and Wet mode of operation OR Seperator water leg CV demand < 2% AND Close position < 5 %.

Operational logics for Start up system warming MOV

Open permissive
Dry mode of operation

Auto opening
Open permissives present AND also if any of the following conditions are present
Seperator storage tank level is less than 4000 mm

Auto closing
If wet mode of operation OR If MFT gets operated OR Close start up system warming valve command is present from Start up sequence. OR Seperator storage tank level > 1100 mm AND BCP On.

Operational logics for BCP Drain MOV

Open permissive
BCP not running

Auto closing
BCP running

Open permissive
BCP not running

Operational logics for BCP outlet drain MOV

Auto closing
BCP running

Separator logic (Seperator storage tank wet leg level)

Separator logic (Seperator storage tank level)

Separator logic (Control of flow through BCP)