TALWANDI SABO POWER LIMITED,

3 x 660MW POWER PLANT, MANSA.

QESH MANAGEMENT SYSTEM

Standard Operating Procedure for

Auxiliary Boiler

DOC NO. TSPL /OPN/SOP/077 PREPARED BY REVIEWED BY APPROVED BY

REV NO.

REV DATE:
Ravinder
Maheswara Rao
Thakur
VERSION NO.

VERSION DATE:

INDEX

Page 1 of 9
 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM

S.No Description Page No.

3
1 Purpose
3
2 Scope
3
3 Input
3
4 Output
3
5 Responsibility
3
6 System Description

7 Equipment Details 4

8 Electrical Feeder Details 5

9 Alarms and Safety valves Parameters 5

10 Starting Procedure 6

11 Shutdown Procedure 8

12 Isolation Procedure 8

13 Emergency operation 8

14 Reference 8

15 Safety Measures 9

16 Environmental Measures 9

1.0 PURPOSE:
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 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM
1.1 This Procedure is intended to provide guidance and instructions for carrying out start-up
& shutdown of Auxiliary Boiler.

2.0 SCOPE:
2.1 This Procedure is applicable Auxiliary Boiler of 3x660MW .

3.0 INPUT:
3.1DM water, HSD/LDO Oil, Power & Air.

4.0 OUTPUT:
4.1 Steam.

5.0 RESPONSIBILITY:
5.1 Auxiliary Boiler Operator.

6.0 SYSTEM DESCRIPTION:

6.1 The function of Auxiliary Boiler is to produce Steam which is used in Plant light –up for
Auxiliary header charging.

6.2 Working Principle:

Power generation projects require an auxiliary boiler system to provide steam on
start-up, during maintenance of steam turbine gland systems, etc.

A basic auxiliary boiler is a machine with the simplest arrangement of the internal
parts. The main job of a boiler is to make high pressure steam. The feed water supplied to the boiler
drum utilizes the heat of the energy released by burning the fuel. This energy of the burning fuel is
stored in the form of steam with high temperature and pressure. The fuel is burnt in a combustion
chamber inside the boiler. To attain high efficiency and complete combustion, air is supplied to this
combustion chamber through a separate arrangement. The heat generated in this combustion
chamber is transferred to the water from the boiler drum through a large surface area, which enables
the highest rate of energy transfer.

In our TSPL, Auxiliary Boiler is a forced draft boiler. Every Auxiliary Boiler have two
burners and every burner have one Fuel Oil pump.

7.0 EQUIPMENT DETAIL:

7.1 Technical parameters:

TYPE CNDQ-10/3.2
Aux Boiler Company name Max Steam
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 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM
Auxiliary Boiler Capacity 20T/H
High Pressure Cut-Off 14Kg/Cm2(We can change also)
Working Pressure 8-12 Kg/Cm2
Working Temperature of Aux 200-205⁰C (Out let of Aux Boiler)
Boiler
Working Temperature of Super 240-250⁰C(Out let of Super Heater)
Heater
Fuel Oil Motor Current 5A
Fuel Oil Motor voltage 415V
Fuel Oil Motor speed 1420RPM
Fuel Oil Motor power 2.2KW
Fuel Oil Pump Capacity
100L/H
Fuel Oil Pump discharge
5-8Kg/Cm2
Pressure
Burner inlet pressure 4-8 Kg/Cm2
Burner outlet pressure 2-4 Kg/Cm2
BFP Motor current 50A
BFP Motor voltage 415V
BFP Motor Power 22KW
BFP Motor speed 2950RPM
Feed Pump Head 180m
Feed Pump discharge Pressure
10-15Kg/Cm2
Feed Pump capacity 30T/H
Blower Motor power 11KW
Blower Motor Voltage 415V
Blower Motor Speed 2920RPM
Blower Motor current 20A

Aux header pressure 8-10 Kg/Cm2(Depends upon requirement)

3.7 KW
SH Blower motor power
SH Blower motor voltage 415V

SH Blower motor Speed 2875rpm

SH Blower motor current 7.6 A

83%
SH Blower motor efficiency

Page 4 of 9
 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM

8.0 ELECTRICAL FEEDER DETAILS:

No. Description Feeder No. KKS

1 Auxiliary Boiler-1 CSS-4
2 Auxiliary Boiler-2 CSS-2

9.0 ALARM VALUES

9.1 AUXILIARY BOILER HIGH PRESSURE CUT-OFF

01 Auxiliary Boiler-1 High Pressure Cut-Off 14Kg/Cm2

02 Auxiliary Boiler-2 High Pressure Cut-Off 14Kg/Cm2

9.2 BOILER SAFTY VALVES OPERATING PARAMETERS

AUX BOILER-1
1. Boiler High Pressure Auto Cut-Off
Auto cut- 14 Kg/cm2
2. Boiler Drum 1st Safety Valve.
Pop Up- 16.0 Kg/cm2
Reset- 15.0 Kg/cm2
3. Boiler Drum 2nd Safety Valve.
Pop Up- 15.5 Kg/cm2
Reset- 14.5 Kg/cm2
4. Super Heater Safety Valve.
Pop Up- 16.5 Kg/cm2
Reset- 16.0 Kg/cm2

AUX BOILER-2
1. Boiler High Pressure Auto Cut-Off
Auto cut-off 14 Kg/cm2
2. Boiler Drum 1st Safety Valve.
Pop Up- 16.0 Kg/cm2
Reset- 15.0 Kg/cm2
3. Boiler Drum 2nd Safety Valve.
Pop Up- 15.5 Kg/cm2
Reset- 14.5 Kg/cm2
4. Super Heater Safety Valve.
Pop Up- 16.5 Kg/cm2
Reset- 16 Kg/cm2

10.0 OPERATION PROCEDURE

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 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM
PRE START

 Check the power supply to MCB.

 No PTW status.
 Ensure level of DM tank is 70-80%.
 Ensure level of HSD/LDO oil tank is 70-80%.
 Maintain the Boiler drum level ≤80%.
 Ensure blower-damper should be open.
 Ensure Boiler drum vent is open condition.
 Ensure Super Heater drain valve should be in open condition.
 Ensure Boiler blow down valve is closed condition.
 Check the line up from Fuel Oil tank to Burner.
 Check the line up from DM tank to Boiler through BFP.
 Ensure the availability of Fuel pumps (Aux Boiler) and BFP.
 Ensure one HSD/LDO Supply pump is running condition in FOPH.
 Ensure that burner normal flame and high flame modulation switch working
properly.
 Ensure all drain valves of Steam header are in open condition.

PROCESS

 Start the main power supply.

 Check the condition of BFP weather it is auto or not and Ensure BFP should be in
auto condition.
 Open the vent of DM water to BFP line vent and proper ventilation until water not
come out.
 Fill the DM water to Boiler drum and maintain the level ≤80% with BFP.
 Then start the blower.
 After 2 minutes give the start-up command for Fuel oil Pump then burner will start
in auto mode and ensure that there is no abnormality and its generating required
pressure.
 Then check the burner condition .If it is catch the fire/flame or not? If burner doesn’t
catch the fire then do venting of Fuel oil pump Steiner/filter then start the Fuel Oil
pump
 Check the healthiness of fire/flames through the burner mirror.
 Then boiler drum pressure will raise gradually.
 Maintain the DM Water tank level and Fuel tank level more than 50%.

Page 6 of 9
 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM
POST START

 When the Boiler drum pressure comes greater than 2Kg/Cm2, then close the vent
valve of boiler drum.
 When the boiler drum pressure comes 3 to 4 Kg/Cm2, then open the main stop
valve (MSV) very slowly to charge the Super Heater.
 Now, if we want more temperature then we can start the fuel pump of Super Heater
burner
 Then, Super Heater pressure will raise gradually.
 When super Heater pressure comes more than 5-6Kg/Cm2, we can warm up the
AUX header for charging.
 Drain the aux header till all the condensate drained out, then close all the drain
valves near about 90%.
 At beginning keep the header pressure 2-3Kg/Cm2 and then slowly raise the
header pressure up-to 8-9Kg/Cm2.
 Now, the header is charged.
 Then maintain the header pressure 6-8Kg/Cm2(As per requirement)
 If the Steam consumption is heavy, we can change the flames normal condition to
High flames condition by using MODULATION ON switch
 Then the Boiler pressure is raises gradually and keep the header pressure as per
requirement by contact with CCR Desk Engineer.
 Open the blow down valve for 1-2minutes in between 4 hours during working
condition for the maintenance and to increase the lifetime of Aux Boiler.

AUTOMATIC STARTUP MODE

 Check the panel power supply and main power supply.

 Check the condition of BFP weather it is auto or not and Ensure BFP should be in
auto condition.
 Check the condition of burner and healthiness of fire/flames through the burner
mirror.
 If burner doesn’t catch the fire then do venting of Fuel oil pump Steiner/filter then
start the Fuel Oil pump

DM WATER MAKE UP

 Required DM water tank level is ≤ 80%

 When the DM tank level below 50% then makeup (MIV) will start and stop at 80%
of level.
 Ensure no hazards chemicals are not mix to that DM water.
 Use feed water pump to pump the DM Water to Aux Boiler drum.
 Check the sample by DM plant chemist.

FUEL OIL TANK MAKE UP

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 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM
 Required Fuel oil tank level is ≤ 80%
 Fuel Oil makeup line is a tapping taken from HSD/LDO Supply line to main Boiler
area in FOPH.
 Check the sample by DM plant chemist.

11. SHUTDOWN PROCEDURE

 Switch off the Fuel Oil Pump then burner will stopped in auto mode.
 BFP will stopped in auto mode.
 After 2-3 minutes give the stop command for the blower.
 Then Aux Boiler pressure will deceases gradually.
 Now, open the vent valve of Aux Boiler and remove the steam by venting.
 Open the blow down valve of Aux Boiler for 3-5minutes.
 Switch off the power supply.

12. ISOLATION PROCEDURE

 Shutdown the Auxiliary Boiler.
 Remove the steam in the boiler drum by venting.
 Isolate the power supply.

13. EMERGENCY OPERATION

In case of accident and Steam leakage from the plant in a large
amount, cut off the power immediately and ventilate; analyse the cause and remove the
trouble as soon as possible. For information about personnel hazards and potential health
effects read the MSDS of Auxiliary Boiler and HSD/LDO Oil.

Condition of Steam leakage:

 Aux Boiler pressure is high.

 Aux Boiler outlet temperature is high.
 Any of the valve (MIV) or flange gasket damaged.
 Aux Boiler/super Heater pressure high and safety valve not operated.

14. REFERENCE:-
O&M Manual-Auxiliary Boiler

15. SAFETY MEASURES:

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 TALWANDI SABO POWER LIMITED,
3 x 660MW POWER PLANT, MANSA.
QESH MANAGEMENT SYSTEM
Evacuate immediate area: Eliminate any possible sources of ignition, and provide
maximum explosion- proof ventilation. Shut off source of Auxiliary Boiler, if possible. If
leaking from Auxiliary Boiler, or valve, call the fire emergency phone number.
Fire Fighting Measures:-
Fire Fighting Instructions:
CO2, dry chemical, water spray or fog for surrounding area
Special Fire Fighting instruction: Evacuate all personnel from danger area.
Immediately cool container with water spray from maximum distance, taking care not to
extinguish flames. If flames are accidentally extinguished, explosive re-ignition may occur.
Stop flow of gas if without risk while continuing cooling water spray.
Unusual fire and Explosion hazards: Burns with a pale blue, nearly invisible flame.
HSD/LDO is easily ignited with low-ignition energy, including static electricity. Auxiliary
Boiler is very danger area and can accumulate in the upper sections of enclosed spaces.
Pressure in a container can build up due to heat, and it may rupture if pressure relief
devices should fail to function.

16. ENVIRONMENTAL MEASURES

 Auxiliary Boiler cleanliness to be ensured
 Prevent the usage of mobile phones in Auxiliary Boiler area
 Prevent the entry of flammable materials, hot works, smoking in Auxiliary Boiler
premises.
 Monitor steam and oil leakage regularly during operation.
 In case of high amount of steam leakage or accident time follow emergency
operation procedure and inform shift in charge (SCE) about the same.
 Information to be passed on to concerned maintenance department and
Equipment to be isolated from operation side and permit to be issued .

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