FOR APPROVAL

0 10/16/2019 HRS ICK RTN FOR APPROVAL

REV DATE PREPARED CHECKED APPROVED STATUS
Owner

Owner's Engineer
11/13/2019

Contractor

Sub-Supplier

Project

MUARA TAWAR COMBINED CYCLE

POWER PLANT BLOCK 2, 3 & 4 ADD-ON PROJECT
Document Title

STARTUP & COMMISSIONING PROCEDURES

Document No.

MRT-DN05-P0QHY-125419
 STARTUP AND COMMISSIONING PROCEDURES
(MRT-DN05-P0QHY-125419)

MUARA TAWAR COMBINED CYCLE

POWER PLANT BLOCK 2, 3 & 4
ADD-ON PROJECT
FIRE TUBE BOILER 10 TPH, 8 BARG, SUPERHEATED STEAM 190 °C

Created By:
PT. MAXITHERM BOILERS INDONESIA
BOILERS, PRESSURE VESSELS AND ACCESSORIES

Jl. Kebantenan Raya No. 2A, Semper Timur,

Cilincing, Jakarta 14130, Indonesia
Phone : +62 21 448 33323, Fax : +62 21 448 33325
Email : engineering@maxithermboilers.co.id
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CHAPTER 1

COMISSIONING PROCEDURE

1.1 CLEANING

Debris and foreign material that accumulate during shipment, storage, erection or repairs
must be removed. Debris on the waterside can restrict circulation or plug drain lines.
Debris on the gas side can alter gas or air flows. Combustible material on the gas side
can ignite and burn at uncontrollable rates and cause considerable damage. Glowing
embers can be the source of ignition at times when ignition is not desired.

1.2 HYDROSTATIC TEST

After the pressure, parts are assembled but before the refractory and casing are
installed; a hydrostatic test at 1.5 times the boiler design pressure is applied to all new
boilers and maintained for a sufficient time to detect any leaks. Testing is equally
important following pressure part replacements at pressures specified in local code
requirements .The hydrostatic test is normally the first time the new boiler is filled with
demin water, therefore, this is the time to begin using demin water for the prevention of
internal fouling and corrosion. Clear filtered water or demin water is suitable for
components that shall be drained immediately after the hydrostatic test. Demin water
parameter is as specified at point 1.8 below.
Temperature plays an important part in hydrostatic testing. The metal temperature and
therefore the water temperature must be at or above applicable code restrictions for
hydrostatic testing. For example, these restrictions, as stated in the ASME code, specify
that the hydrostatic test temperature will not be below 70 F (21 C) to take advantage of
the inherent toughness of carbon steel materials as related to temperature. It should not
be so high that water escaping from small leaks evaporates immediately or flashes to
steam. Also, the water temperature should not be more than 100F (56C) above the metal
temperature to stay away from excessive metal stress transients finally, no air should be
trapped in the unit during the hydrostatic test. As the unit is being filled, each available
vent should be open until water appears. Local government body (DEPNAKER) must be
witness and approve for the hydrostatic test of boiler and steam line which commenced
at shop only.
Test procedure:
1) Follow all safety precautions listed elsewhere in this section.
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2) Installed newly calibrated pressure gauges. These pressure gauges should have
maximum reading of not more than 50% and not less than 25% greater than test
pressure. Also installed these pressure gauges directly visible to operator.
3) Installed hydraulic test clamps (sometimes called gags) on the safety valves to
prevent their opening during the test procedure or remove safety valves and blank off
connection by using blind flange.
4) Open the boiler vent valves to expel air while unit is being filled.
5) Be sure hydrostatic test water qualities shall be as mentioned above in feed water
quality requirements.
6) Fill boiler and auxiliary equipment that are to be hydrostatically tested by using
separate filling pump or with boiler feed pump running condition and follow instruction
of feed pump.
a) Make certain valves between drum and water column and gauge glass are
open.
b) Inspect all valve positions.
c) Introduce water slowly in to the boiler so as to remove air.
d) The hydrostatic test temperature will not be below 70 0 F (21 0 C).
e) The water temperature should not be more than 100 0F (56 0 C).
f) Introduce water in a sufficient quantity so that after 3 to 4 steps the boiler will
be full. Wait 20 to 30 minutes between each step.
g) Fill in the water gradually or through feed line, till vent valves start bleeding
with water.
h) Close the vent valves.
i) Start pressurizing water till 4 to 5 Kg/cm2.
j) Stop the pressurizing activity and if pressure drops, open vent valve slowly to
vent out air bubbles till pressure comes to zero.
k)
l) After raising pressure, wait for half an hour and observe any pressure drop in
the system.
m) If pressure drop in the system, repeat the same procedure and mentioned
above in earlier points.
n) If no pressure drop is there increase the pressure up to specified hydro test
pressure.
o) Hold the pressure for 30 minutes and observe the steady test pressure.
p) Check all points and see that operating pressure is maintained till inspection
is over.
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q) If test pressure is steady, then de-pressurized the system by gradual

opening of the vent valve till operating pressure is reached. Check all the
points and see that operating pressure is maintained till inspection is over.
r) Do not take hydraulic test in hot condition. Ensure an ambient condition while
pressure testing is going on. During early hours of the day is preferable for
hydraulic testing.
s) Make enough inspection of piping connection, field welds, tubes, headers
and other pressure parts for leaks.

DO NOT APPLY PRESSURE IF THE TEMPERATURE OF THE UNIT IS

LESS THAN 70 DEG. F AND MORE THAN 120 DEG. F AFTER BEING
FILLED WITH WATER TO PREVENT DAMAGE OF EQUIPMENT.

DO NOT LEAVE HYDROSATAIC PRESSURE TEST PUMPS RUNNING

UNATTENDENTLY AS EXCESSIVE PRESSURE CAN BUILD UP AND
CAUSE DAMAGE TO THE EQUIPMENT.

7) Use hydraulic test pump, do not use boiler feed pumps.

8) If leak or defect is found during test is going on
a) Stop pressurizing pump.
b) Relieve pressure by opening a vent valve.
c) Drain equipments by opening a drain valve.
d) Repair any leak for defect found.
e) Refill equipment as described above.
f) Raise hydrostatic pressure as mentioned in above procedure.
g) Hold for 10 to 15 minutes.
h) Inspect components again at design pressure of boiler.

1.3

1)
common to any boiler, furnace, steam generator or water heaters.
2) When and if such setting develops large cracks, the efficiency of the unit is impaired
by the infiltration of air, the bypassing of gases around unit heating surfaces, etc. In
addition, soot and smoke may issue from such cracks in some cases the stability
may be destroyed and causing the walls to collapse.
3) When first assembled, or erected, this setting is damp and has slightly greater
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impossible to take
treated to a drying process (as some lumber is kiln or oven dried) to remove
moisture, This loss of moisture is accompanied by a shrinkage of the setting .
4) With time and the maintenance of greatly increased temperatures, a further
shrinkage of the setting due to thermo chemical changes, occurs. The setting has

5) While a prolonged a period of air-drying will usually reduce the moisture content of
the setting, it cannot, in view of the chemical structure of the materials, completely

available from the atmosphere, is necessary.

6) The amount of heat or temperature necessary is dependent upon such factors as the
type of setting, thickness of walls , amount of moisture contained, etc.

FOLLOW:
7) The closer one can approach even the well-distributed heat of an oven, the better.
8) The longer the period of low temperature drying, the better.
9) The more moisture the setting contains the lower the initial and drying rate should be.
Steam formed in the center of a masonry mass should filter or seep through the
material without developing pressure.

DRYING OUT

1) If the rate of heating is too great, the wall area closest to the source of heat will be
markedly hotter than the balance of the structure and the setting closest to the
source of heat will dry first and shrink away from adjacent wall area and cracks will
develop.
2) The design of masonry walls, etc. proves expansion absorbing joints so arranged
and located, that any usual change of dimensions due to temperature changes can
be accommodated without unduly stressing adjacent wall sections.
3) It is almost impossible to prevent some small cracks developing during the drying-out
process. This section of refractory will dry first and may be expected to crack with
less abuse.
4) Heavy, thick walls require a greater length of time for drying than the thin refractory
backing used in water cooled walls. The temperatures should not be any greater for
thick walls.
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5) Unless special considerations require it, do not proceed with the drying out until it

Section, have been complied with.

6) All unnecessary hazards such as scaffolds, ladders, insecure platforms and
obstructions should be removed.
7) Dampers , pressure gauges , water gauge glasses , safety valves and all other
appurtenances that would be used during normal operation should be in place and
operable .
8) The boiler should be filled to normal water level with clean water, either containing
er.
9)
considered. Mica backed glasses should usually not be subjected to caustic
solutions. (See Instructions furnished by gauge glass manufacturer).
10) Provide control of the amount of drying-out heat supplied (if necessary). This may be
either a small fire wood, a small oil or gas flame (Provided it can be well distributed
and cause no excessive localized heating) or admission of hot gases from another
source.
11) A temperature within the furnace enclosure of about 500 F should not be exceeded
during the first 48 hours. After that period an increase of about 100 F per day for two
or more days, depending on the amount and condition of the setting and based on
the good judgment of the person responsible for the drying out, and one final day at
800 F should be attempted. During this period, the outlet dampers should be
adjusted to that position which results in the most even temperature throughout the
unit.
12)
procedure. If this is done, it should be so arranged that the requirements of proper
drying out procedure govern the first four days of heat application.
13) Correct Shell water level should be maintained at all times. Since the Shell vent
should be open during this period, some water may have to be added to the unit
during the drying out interval.
14)
amount of heat in the setting .This will cause the evaporation of water from internally
wetted surfaces and so prevent internal corrosion , if the unit is not to be operated for
some period of time . Its not be subjected, while empty, to temperature above 300 F.
Damp air or gases should also be excluded from the unit during such outage.
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15) Setting may be dried out without filling the unit with water providing the firing rate is
controlled so that the maximum temperature of the gases leaving the furnace the unit
do not at any time exceed 300 F.

1.4 INSTRUMENTATION AND CONTROLS

Every boiler has at least two indicating instruments: a water / steam pressure gauge and
a water level gauge glass. Boilers have flow meters and temperature indicators. These
indicators are important because the pressure, temperature, levels and flows indicated
by them, must be controlled within the design limits. These indicators must be correct.
Operation should not attempt, until these instruments are calibrated. The calibrations
should be include corrections for actual operating conditions.
Most modern boilers are controlled automatically once they are fully commissioned.
However, before these boilers can be start up, the controls must be operated on manual
Mode until the automatic controls have been adjusted for site specific conditions.
Automatic control operations should not be attempt until the automatic functions have
been calibrated and proven reliable over the load range.

1.5 AUXILIARY EQUIPMENT

The auxiliary equipment must also be prepared for operation. This equipment includes
fans to supply air for combustion, Fuel burner for uniform firing of fuel and feed water
pumps to supply water. This equipment also include an economizer to heat the water
and cool the flue gas.

1.6 CHEMICAL CLEANING

Water side cleanliness is important for all boilers because water side impurities can
lead to boiler Pipes & Shell Internal failures. They can also lead to carryover of solids in
the steam, resulting in Process Failure. The flushing of all loose debris from the feed
water system and boiler, and the use of demin water for the hydrostatic test, must be
supplemented with proper water side cleaning before startup. To remove
accumulations of oil, grease and paint phosphate flushing can be carried out. The once
through boiling and its associated pre- boiling equipment are given a similar flushing.
This boiling out and / or flushing should be accomplished before operation.
After boiling out and flushing completed, products of corrosion still remain in the feed
water system and boiler in the form of iron oxide and mill scale. It is recommended that
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high capacities have carried loose scale and oxides from the feed water system to the
boiler. This results in a cleaner boiler for subsequent operation.

1.6.1 PROCEDURE FOR CHEMICAL BOILING OUT

Initial preparation:

a) Boiler hydraulic test is completed.

b) Power supply is available to run the drives.
c) Water and chemicals are available.
d) Boiler filling arrangements are completed.
e) Fuel is available.

In order to prevent fouling of internal parts, having small clearances during the internal
boil out and acid cleaning is required. However, they are to be thoroughly cleaned with
wire brush air or steam blown before installation.
It is essential to have spare gaskets for inspection doors; those are to be used after alkali
boil and after chemical cleaning to ensure effectiveness of the alkali boil out and
chemical cleaning.

Alkali cleaning
This is a most commonly used method of boiler cleaning and case of newly fabricated
boilers. It should be carried out on completion of drying out operation.
It is must, chemicals never be introduced in solid form but first to be dissolved in water
and introduced in to the boiler system either through chemical injection equipment or
shell manhole directly. In the later stage, water level must be lowered by draining and
then restored afterwards.
All phosphate formula is used for alkali boil out of boiler to minimize the potential for
stress corrosion cracking of stainless steel components. TRISODIUM PHOSPHATE and
DISODIUM PHOSPHATE are used for alkali boil out. These are to be mixed with warm /
hot water before injection into system.

a. Atmospheric boiling out

a) Open air vent and shell manhole. Fill boiler with properly treated dematerialized
water up to first port of Shell level glass.
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b) Prepare the boil out chemical solution in hot dematerialized water in the chemical
mixing tank. The solution is formulated by dissolving following proportionate QTY.
of chemicals depending on the volume of the system to be cleaned.
c) 0.05 % Na2PO4 7H2O. (500 ppm di-sodium phosphate)
d) 0.1 % Na3PO4 12 H2O. (1000 ppm tri-sodium phosphate)
e) Mix dissolved chemicals and introduce solution in to shell while at the same time
slowly feeding water to effect a more even distribution along the Shell length.
f) Close manhole door and secure tightly.
g) Now raise the temperature within boiler is by following -up Procedure to
bring water up to atmospheric boiling point.
h) Increase slowly the heat input to boiler to raise the pressure.
i) At a pressure of approximately 30 psig (2.1 Kg/cm 2) a good flow of steam from air
release valves will be noticed. Close the air release valves.
j) Continue increase boiler pressure to 15% of normal working pressure.
k) Maintain 15 % of normal working pressure to 12 hrs. This will ensure a rapid
circulation of water through boiler.
l) Give blow down at every 2 hrs with interval drain for 1 min. each.
m) Extinguish fire and blow down boiler manifolds individually by giving blow down
for a period of 2 to 3 min. each.
n) Allow boiler to cool down naturally. When pressure reaches to 2.5 kg/cm2 with
manifold, blow down should be closed. Blow down until water level falls below
gauge glass.
o) Following this, the entire boiler can be blow down as quickly as possible using all
manifold and blow down drains.
p) When pressure falls afterwards open, Air release valve.
q) Close all manholes using new gaskets necessarily.
r) Close all blow down and drain valves.
s) The boiler is now ready for the pressure boil out.

b. Pressures boil out

a) Fill boiler with water in the same manner as for atmospheric boil out.
b) Dissolve following chemicals in hot / warm water.
c) Tri-sodium phosphate.
d) Di-sodium phosphate.
e) Concentration shall be maintained 500 ppm during pressure boils out.
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f) Introduce solution into drum while at the same time slowly feeding water to effect
a more even distribution along drum length.
g) Close manhole doors and secure tightly.
h) Continue to fill boiler up to 1/3 gauge glass level. Do not further raise level initially
as water will swell while heating and any blow down for level control will lead to
chemical loss.
Caution:
Water level in gauge will rise to ½ glass as heat is absorbed and water expands.
This level must be maintained.

i) Continue to raise the pressure. At a pressure of approximately 30 psig (2.1

Kg/cm2 g) steam will be seen freely issuing from open air release valve. This
may be closed.
j) Raise gradually pressure to 75 % of the normal working pressure and hold it for
12 hrs. While raising pressure give blow down at 15%, 25%, 35%, 50% pressure
from blow down valves for one minute each.
k) During this period of gradual pressure raising the plant should be under constant
observation and following inspection is to be made:
Check all bolted flanges, manhole doors and inspection caps for leaks and
tightness.
Check amount of movement due to thermal expansion against witness marks.
Restriction to free parts of pressure parts can result in over stressing and rupture
and any such restriction observed must be investigated.
Check dampers under hot conditions to ensure that they do not bend
throughout their extend of travel and isolation dampers seal efficiency when
closed.
Check all combustion equipment and auxiliaries for correct functioning. Take
note of any irregularities, which cannot be rectified without shutting down.
l) Boiler water samples are to be obtained from CBD and analyzed for alkalinity,
phosphate content, dissolved silica and oil content. Repeat every 2 hrs. Till oil
level in the sample fall below 5 ppm. Firing is to be stopped after oil level falls
below 5 ppm or 12 hrs. boil out span, whichever is later.
m) Operate each blow down and drain valve successively for a few seconds to
discharge any accumulated sludge. Repeat several times meanwhile maintaining
drum water level at ½ glasses.
n) Allow boiler to cool down naturally and when pressure come down to 2.5 kg/cm2.
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down system) to completely blow down the boiler. When pressure comes down to
15 psig open all air release valves.

1.7 SAFETY VALVES

Safety valves are essential to the safe operation of any pressure vessel, allowing
adequate relief of excess pressure during abnormal operating conditions. The set point
of each safety valve is normally checked and adjusted if necessary after reaching full
operating pressure for the first time with steam. Safety valve seats are susceptible to
damage from wet steam or grit. This is an essential reason for cleaning the boiler. This
generally requires that the boiler pressure be raised until the valve opened and then
reduced for the valves at close condition.
The testing of safety valves always requires caution. Safety valves exhaust piping and
vent piping should not exert any excessive forces on the safety valve. Gags should
always be used as a safety measure while adjusting the valves.
As an alternate, safety valves can be tested and set with the boiler pressure below the
safety valve design pressure by supplementing the boiler pressure with a hydraulic lift,

hydraulic assist method reduces the risk of damage to the valve seat from extended
steam flow in a conventional test.

1.8 WATER SPECIFICATION

Water characteristics for boilers pressure operating up to 8 barg.

Demin Water Parameters:

Total hardness in term of CaCO3 : 2 mg/kg, max
O
PH value at 25 C : 8.5 to 9.5
Oxygen as O2 : 0.02 mg/kg, max
Fe total : 0.1 mg/kg, max
Cu total : 0.1 mg/kg, max
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CHAPTER 2
STARUP PRE-CHECK

2.1. CHECK POINTS BEFORE STARTING YOUR BOILER

1. Is the stack high enough to comply with the state Government and Local
Council Air Pollution Control Requirements?
2. Does the plant room have sufficient ventilation to provide the necessary air for
combustion?
3. Is the feed water tank filled with demin water of sufficient capacity and height
above pump.
4. Are the feed water tanks and pipe lines of non-corrosive material?
5. Are the blow down pipe lines of all welded construction and firmly anchored?
Blow down lines are subject to every high stock loads and can be dangerous
if badly installed.
6. Have the steam lines been checked for leakage before lagging? A steam lake
will quickly erode the pipe joint and destroy the insulation.
7. Does the fuel oil installation comply with the relevant Oil Fuel Code (if
applicable)?
8. Are the oil suction lines all in one piece? As few joints are possible. A leak will
cause loss of prime and can lead to ignition failure and possibly dangerous
blow backs on starting up. Check the fuel tanks foot valve for back leakage
and thus loss of prime. Only a metal seated vertical check valve situated at
the bottom of the suction drop pipe should be used.
9. Have the heavy fuel oil lines been steam traced and insulated? A fluctuating
fuel oil temperature will cause smoky combustion and poor efficiency (if
applicable).
10.
applicable).
11. Has a gas regulator of sufficient capacity can be fitted? (if applicable).
12. Are the electric power and fuses of sufficient capacity to handle the high
starting loads without voltage fluctuation?

2.2. COMBUSTION CHAMBER

The main access to the furnace area is through the rear hole. The admission
door can be opened by removing the bolts on the rear plate. Examine the heat
resistance material in the burner cone if there are signs of damage. If the
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fireproof materials the insulation are damaged, these are to be repaired before
the burner started.
2.3. BURNER

The burner consists of an air box with leading blades and air damper, gas electric

atomizer and flame scanner. Check whether these components are mounted
correctly and undamaged. The burner manual can be used as guide.

2.4. FUEL PIPING

Inspect the pipe system to ascertain whether it was assembled in accordance

with the drawings and whether component like check valve are properly oriented.
All gauges should be provided with stopcocks and the switches to be wired in
accordance with the external wiring diagram furnished with this manual.
Check the connections of the fuel feeding equipment. If you are using gas, check
pressure and parity. If fuel oil is used, check supply, pre-heater (If Applicable),
return piping and pressure relief valves. The oil pump should be checked as a
rotation, pressure output and pressure relief. If the oil is heated, check wiring and
piping of the oil heater.

2.5. FEED PIPING

The feed water piping and the chemical feed piping should be examined to
ascertain, whether all joints are tight and the valves in proper orientation. The
direction of flow through the check valve to be towards the boiler. Check the feed
tructions to determine
whether the control equipment is operating correctly.

2.6. STEAM PIPING / DRAIN PIPING

All steam piping should be inspected as to things like: securely bolted flanges,
properly, oriented valves, no open spigot ends, correct installation of gauging and
proper actuation of vent and drain valves. Check the installation of all orifices and

should be inspected from the connection on the boiler to the blow-down tank or
pit. These should be no shut-off or obstructions between the boiler and the
collection tank. Items are which normally have drain provisions are: boiler, water
column, water gauge glass, safety valves and economizers.
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2.7. WATER LEVEL CONTROL

As the safety device in connection with alarm and shutdown of firing at too low
water level and the feed water regulator are vital to the boiler operation, they
should be inspected carefully. As to description of the water level control,
complete separate data sheet.

2.8. DESCRIPTION OF THE LEVEL : NWL, LWL, AND LLWL

At NWL (Normal Water Level) the regulator maintain the normal water level
inside the boiler by start and stop the feed-water pump.
At LWL (Low Water Level) an alarm is activated, and the burner automatically
stops working when the water reaches a dangerous level in order to avoid
damage caused by overheating. The condition will automatically recovered to the
initial condition when the water level reach the normal level.
At LLWL (Low-low Water Level) an extra safety stop of the burner as well as the
alarm will be activated. If the condition occurs the regulator should be reset
manually after the level back to the normal level.

2.9. SAFETY VALVES

Check the safety valve to make sure that the outlets are not blocked or shut off.
The vent pipes should not be supported by the valves as the weight of the pipes
could cause the valves to deform. The valves to be preset in accordance with the
details.

2.10. SAFETY CONTROL

Before you inspect the safety control circuit study the electrical diagram provided
with this manual. Examine all components and make preliminary adjustment in

items like : excess steam, limit switch, flame providing safe guards, high and low
oil pressure switches, high and low gas pressure switches, water level alarms
and cut-off, plus any other special controls furnished to fulfill the requirements of
the boiler system.
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CHAPTER 3
OPERATIONAL PROCEDURE

3.1 PREPARATIONS FOR STARTUP

A systematic approach is required when a new boiler is being installed or when

any boiler has undergone major repairs or alterations. The procedure varies with
boiler design; however, certain steps are required for all boiler. The steps may be
classified as inspection, cleaning, hydrostatic testing, pre calibration of
instruments and controls, auxiliary equipment preparation, refractory conditioning,
chemical cleaning, steam line cleaning (blowing), safety valve testing and
settings and initial operations for adjustments and testing.

3.2 INSPECTION

An inspection of the boiler and auxiliary equipment serves two purposes:

1. It familiarizes the operator with the equipment.
2. It verifies the condition of the equipment.
The inspection should begin during the construction phase and continue until all
items are completed.
One item frequently overlooked during the inspection is the provision or lack of
provision for expansion the boiler expands as the temperature and pressure are
increased, as do steam lines, flues and duct, soot-blower piping and drain piping.
Before pressure is raised in the boiler, temporary braces, hangers or ties used
during construction must be removed.

3.3 BOILER

1. Check the boiler to make sure that all maintenance work has been completed,
all tools and debris have been removed, the handhole plates and manhole
covers have been installed, and all access doors have been replaced.
2. Make sure there are no attachments between the boiler and support steel that
would restrict normal expansion.
3. Check the safety valves to see that the gags have been removed, the lifting
levers have been replaced and the valves are not fouled or hung up.
4. Close the water drain, blow down, continuous blow down and chemical feed
line.
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5. Open isolation valve the steam line vent, ensure control valve vent on open
condition, water gage shutoff, water level shutoff, steam gage shutoff, feed
water stop and feed water check done.
6. If the boiler is empty, fill until the level is just in sight in the water gauge and
the low-level alarm is cleared. If hot water is used to fill a boiler, care should
be exercised to feed slowly to avoid severe temperature strains.
7. Have all boiler auxiliary equipment lined up for operation or in operation prior
to attempting a light-off.
8. Before lighting a fire, the operator should check the water level in the boiler by
blowing down the water column and gauge glass. A liberal blow down may
serve to clear the drain valve seats of any foreign matter that may be present.
This procedure should be repeated several times while warming up a new
boiler. Routine checks of the water level should always be made at least once a
shift while a boiler is in operation. If the action of the water in the gauge is
sluggish when the drain valve is opened or closed. An investigation should be
made of the cause and the condition should be corrected immediately.
9. Pre-operational Equipment Checks
Have all Package Boiler auxiliary equipment lined up for operation prior to
allowing burner operation.
Make sure that:
(a) All instrument valves should be lined up for service.
(b) All sample line valves should be closed.
(c) All chemical feed valves should be closed.
(d) All drain valves should be closed.
Open and close the following valves to ensure that water level gauges and
level transmitter are reading correctly:

a. Close Steam Drum Level Gauge Drains.

b. Close Steam Drum Tie Bar
c. Close Steam Drum Level Transmitter
d. Open Level Gauge / Tie Bar Isolation Valve.
e. Open Level Transmitter Isolation.
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3.4 OIL BURNER AND TRAIN INSPECTION

Inspect and clean all fuel strainers and see that the entire fuel system is free from
foreign material.
Inspect the burner wind box to be certain no oil has dripped into it, creating a fire
hazard.
Have oil gun(s) made up with clean atomizer tip components. Refer to Burner
Instruction Manual for the proper assembly procedures.
Inspect carefully all equipment under oil and gas Trains.
Be sure that the manual oil and atomizing air valves at each gun are closed.
The burner management or flame safeguard systems should be operational and
not bypassed. Have the oil/gas system in service.

3.5 PRE-STARTING PROCEDURES

On arrival of our MAXITHERM boiler, check all component parts for damage in
transport and re-assemble component components removed at factory to
facilitate handling and transport of the boiler. Tighten all electrical connections.
On completion of your installation, that is after electricity, gas, water, fuel, drains
and stack have been connected. Check that the electricity supply has been
connected correctly. It is important to the electronic controls used on the boiler
that the voltage be kept within ±10% of its rating. Check for correct rotation of all
motors.
Before closing the main switch, check that the control switches on the boiler

Check all valves between the feed water tank and the boiler are open and ensure
that the water level control valves are in the correct operating position.
Manual start water pump and check for correct rotation of the pump as indicated
by an arrow on the pump casing. If rotation is incorrect, stop and reverse the
wires coming into the main switch of the Panel.

NOTE:
Where modulating feed water controllers are fitted, the feed water pump may be
separately wired. On some unattended boilers, it is necessary to fill manually the
boiler to normal working level before the feed water pump can be started.
The low water alarm will continue to ring until a safe working level water has been
reached and the Low Water Reset Button has been reset. When the level of
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water has reached approximately of the visible glass length, stop the pump and
close the main stop valve and your Boiler is now ready for operation.

3.6 ALARM

The Alarm provide first out ringing of those shown on the alarm work properly.
Depressing the alarm acknowledge button will silence the audible alarm horn.
When an acknowledge button pressed the alarm to "Normal" will turn off.

3.7 OPERATIONAL PRECAUTIONS

Prior to initial operation, check out flame failure and burner control system. Check
fuel control piping and wirings to conform with drawings.
Please ensure, sequence will purge the furnace before lighting off. In
conformance with NFPA, a purge cycle is incorporated in the burner control
system, making it mandatory to purge the unit before any automatic valves can
be opened.
Be sure that the main fuel and ignition fuel inlet valves on idle burners are closed
tightly and do not leak.
Watch the fire when lighting off and observe the fires frequently during operation,
so that improper or unusual furnace conditions can be detected and corrected in
time, thereby avoiding emergency conditions and outages. When observing
abnormal furnace conditions, check fuel-air ratio setting of controls.
If the fires are lost, trip all main and ignition fuel immediately. Please check all trip
valves and burner valves and confirm in working condition. Purge the furnace for
at least 5 minutes after shut down with 25% (minimum) air flow.
Make sure that atomizing air proper and sufficiently at the burner.
Do not jumper or bypass any safety interlocks or other controls, correct the
equipment rather than eliminating the interlock.

3.8 INITIAL FILLING

This section describes the recommended procedure for filing an empty boiler with
water. When filling with hot water, be sure to feed slowly to avoid severe
temperature induced stresses. Filling a hot boiler with cold water must also be
done very slowly. Make sure all drains are closed and that the unit is properly
vented. Fill until water is visible in the gage glass. The shell vent must remains
open during filling and initial firing until all air is vented from the unit and an
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Proceed as follows:
1. Prepare feed water pumps and plant feed piping for start-up.
2. Align all boiler valves.
3. Make sure all drain valves are closed.
4. Before starting the Feed water Pump, all feed system control valve stations
should be positioned to allow for filling of the boiler, including the following
(Refer to Piping and Instrumentation Diagram):
a. Open Vent Valves.
b. Open Feed water Stop Valves.
c. Select the mode in MANUAL position and open Feed water Control Valve
by tuning the lever of manual mode to allow shell filling.

5. Start the one feed water pump by manual mode, fill the boiler until the NWL
(normal water level) has been achieved in the shell. DO NOT OVERFILL THE
SHELL.
6. Maintain the level of the steam drum by running the feed water pump until
NWL (normal water level) position
7. After the Shell filling is complete, close feed water control valve via manual
stop at panel view.
8. Stop feed water pump and change mode to auto mode
9. Place all feed system control valve stations including its associated drum
level control and select mode in AUTO MODE.
10. Close Vent Valves.

3.9 PURGING
Considerable attention has been given to the prevention of furnace explosions,
especially on units burning fuel in suspension. Most furnace explosions occur
during start up and low load periods. Whenever the possibility exists for the
accumulation of combustible gases or combustible dust in any part of the unit, no
attempt should be made to light the furnace until the unit has been thoroughly
purged.

3.10 PROTECTION OF ECONOMIZER (IF APPLICABLE)

Very little water, if any, is added to the boiler during the pressure raising period;
consequently, there is no feed water flow through the economizer. Economizers
are located in relatively low temperature zones. Never the less, some
economizers generate steam during the pressure raising period. This steam
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remains trapped until feed water is fed through the economizer. It not only makes
the control of Shell water level difficult; it also causes water hammer. This
problem can overcome, if feed water is supplied continuously by venting the
economizer steam or by re-circulating boiler water through the economizer. If a
re-circulating line is available, the valve in this line must remain open until feed
water is being fed continuously through the economizer to the boiler.

3.11 VALVE POSITION

VALVE HYDROTEST DRYING OUT BOILING OUT OPERATION

Main steam shut- closed closed closed open
off
Feed water closed closed closed open
regulator
Regulator closed closed closed open
isolation
Regulator by- open open open closed
2)
pass
Vent 1) Open / closed open Part open closed
Safety valves Gauged free free free
Blow-off Closed closed Part open closed
Economizer vent Open / closed Open / closed Open / closed closed
1)

Economizer closed closed closed closed

drain
Economizer by- closed closed closed closed
pass 8)
Chemical feed closed closed closed open
Water gauge closed closed closed closed
drain

1) The valves to be opened to fill the boiler with water.

2) The valve to be opened as required to control the water level.
3) The valve to be opened in emergency case only.
4) Use a test gauge during the pressure test.
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3.12 GENERAL PROCEDURE FOR STARTING UP A NEW BOILER OR

AFTER A MAJOR OVERHAUL

Observe the following rules when starting a boiler:

1. Make a complete inspection, to determine definitely whether the boiler has
been closed, with all hand hole caps and manhole covers in place. See that
all access doors in the setting ducts and breeching are closed.
2. Be sure that all control dampers are free, and in good working order.
3. Check the water gauges, to see that the gauge cocks are open and the drain
valve is closed.
4. Check all blow off valves and other drain valves, to be sure they are closed.
5. When first starting a new boiler, it is good practice to fill the boiler until water
is insight in the water gauge. Occasionally, an error is made in the piping
which allows water to be trapped in the water gauge and a level may show,
even though a boiler is empty. In several instances, boilers have been badly
damaged because of this type of piping error.
6. Fill the boiler with water, bringing the level to about 75 mm in the water
gauge. Always use feed water from the normal source of supply, when
possible. Add such water-treatment chemicals as are needed to establish the
proper alkalinity, phosphate and sulphite concentration in the boiler water.
7. Open the uptake damper, to ventilate the furnace and boiler setting
thoroughly. Purge at least five minutes before lighting off. This is of particular
importance where gas or oil are used, as either the principal or the auxiliary
fuel.

3.13 LIGHT- OFF

While raising steam pressure, use burner at minimum fuel pressure. Do not
exceed burner and minimum fuel pressure until the boiler is on load.
- Do not allow oil to accumulate on furnace bottom.
- Please ensure purge furnace before all light-off periods.
- Steam vent is to remain open until 180 kPa shell pressure is reached.
- Check water level at all times.
Boiler operation is more critical during the light-off period than at any other time. It
is during this time that the boiler can be damaged by over-firing, failure to purge,
furnace puffs, explosions and implosions.
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The time required to bring a cold boiler up to operating pressure and temperature
will depend on the type and size of the unit as well as firing conditions. With a
new unit, particularly, it is required to proceed slowly, taking longer than normal to
reach operating pressure because of refractory. During initial startup, keep the
unit at a minimum firing rate for as long as necessary to verify proper operation of
instruments and recorders and test the safety interlocks. Check expansion of the
unit and make sure that casing, drum, piping, etc. have freedom of movement,
relative to structural steel.
NOTE: The low firing rate must be maintained until the boiler is carrying load.

3.14 Normal Light-off

This section describes the recommended procedure for starting the Boiler from a
cold condition with no pressure in the Boiler sections. Proceed as follows:
1. A Furnace purge is required before fuel can be fired. Purge prior to the light
off of the boiler shall be accomplished by at least five volume changes and for
duration of not less than 5 minutes. Before furnace purge, ensure the
following condition is undertaken :
a. Start fan by manual mode to satisfy the permissive/limit interlock.
b. Ensure, by visual inspection, that the safety block valves are closed.
c. Ensure by visual inspection that all equipment is secured, enclosures are
closed, and all test and maintenance equipment removed.

d. Ensure the Boiler Control System is ready to perform air/fuel ratio control.
e.
f. Clear, if any existing alarm condition. Confirm no alarm present.
g. Prior to initiating a purge, the following are purge permissive required
before an automatically sequence furnace purge started. The operator
shall also put all dampers in auto position on the Boiler Control System.
- Fan Running
- Airflow > 25% M.C.R
- Damper Open

- No fuel trip Condition

- All Burner Oil Shutoff Valves Closed
- No Flame Detected
2. With All purge permissive met, press stop fan from panel view.
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3. Please ensure feed-water pump and fuel pump already selected (Pump1 or
pump2)
4. Select all control loop at auto mode position, except control load firing to
manual position for cold boiler start up and auto mode if boiler at hot
condition.
5. Prior to start up, check in the feed water control system to ensure that the
water levels in the drum is just above the NWL. System by automatically use
the opening intermittent blow down valve as necessary to reduce the water
level if level water is over.
6. Check feed water line valve to be positioned as follows :
a. Open isolation the Feed water Stop Valves

b. Open the Feed water Control Valve Isolation Valves.

c. Close Bypass valve at control valve.
7. Open the Steam Startup Vent.
8. During the Purge Cycle: The Fan damper will be open until limit switch max
touched. or more
minute purge period. While furnace purge in progress, the purge sequence
lamp will illuminate.
9. All of the purge permissive must be maintained during the purge period or the
purge will be interrupted and cannot begin again until the permissive are
again met.
10. While furnace purge in progress, the system will automatically initiate safety
shutoff valves
11. When purge is complete, please check to ensure the Shutoff fuel valve at
close position. The fan damper is positioned to minimum opening for light-off.
12. Start Burner from the panel interface and by automatically fan running.
13. Fuel oil control valve is positioned at minimum opening for light off.
14. The air damper burner will automatically commanded to the minimum load
position. The logic verifies that the damper is in minimum position. Upon
verification of the damper minimum position, the following takes place:
a. Ignition transformer is energized.
b.

c. Pilot ignition timer (10 second) begins its timing cycle.

15. Assuming that flame is detected within the ten (10) second period, the
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a.
indication is displayed as soon as the flame is detected).
b. Ignition transformer is de-energized.
c. Before shutoff fuel valves begin to open, system will check fuel control
valve at minimum opening.
16. If pilot flame is not detected at the end of the ten (10) second period, flame
failure logic will automatically active alarm. Investigate the cause of inability to
light up the pilot. Perform necessary repair.
17. After the pilot ignition, time is complete and the pilot flame is detected and
proven, the fuel safety shutoff valves will be

starts its timing cycle and the following takes place. The air damper is
commanded to open at minimum position simultaneously with the opening of
main fuel control valve at minimum position also.
18. Upon the successful light off of the main burners, a discrete signal from the
Burner Management System will:
- Releases the Air Flow Controller to modulate allowing full range-ability
of the Air Damper within the limits of the set point selection
configuration.
- Releases the Fuel Flow Controller to modulate allowing full range-
ability of the Fuel Flow Control Valve within the limits of the set point
selection configuration.

19. The sequent burner can be initi

20. While the boiler is being brought up to pressure, all cold steam piping should
be gradually heated and drained of condensate.
21. Please note the following when the boiler is brought from the cold condition:
a. Shell temperature can be raised 55°C per hour if drum temperature have
reach 100oC.
b. Steam temperature is 100°C when shell temperature is 100°C and reaches
MCR steam temperature 1/2 hour after the steam pressure reaches MCR
operating pressure.
c. Steam flow is 0 Kg/Hr until Shell temperature reaches 100°C.
d. Steam flow is 10% MCR from 1/2 hour after Shell temperature reaches 100°C
until drum pressure reaches MCR operating pressure.
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e. Steam flow is 100% MCR 1 hour after Steam pressure reaches MCR
operating pressure.
22. Startup Vent Valves must stay opened to ensure a positive flow of steam that
will reduce thermal expansion. To warm the piping downstream, slightly open
Main Steam Stop Valve and Non Return Valve, for gradual pressure build up
and piping warm-up and draining. Next, open a drain or vent downstream to
allow the steam to warm the piping. Ensure that all steam piping downstream
of the boiler piping is drained prior to admitting steam.
23. When a measurable steam flow is established (approximately 10% of full
flow), gradually open Main Steam Stop Valve & Non Return Valve and the
.
24. Reset the water level set points in the feed water control system for the Shell
Level to the normal operating water level settings.
25. Open the continuous Blow down Stop Valve.
26. Ensure each chemical dosing is working satisfactorily.
27. Turn on cooling water to the water sample coolers and sample isolators if
samples are required

3.15 Hot Restart

A hot restart occurs any time the drum pressure is above 180 kPa. Hot restarts
are the results of brief shutdowns (up to 24 hours) due to low steam demand, trip
outs, or minor maintenance outages that do not involve entering the furnace or
shell.
For hot restarts, we recommend the following:
(a) A full furnace purge is required. Even though the introduction of cold air to the
furnace will result in rapid pressure decay, this essential safety practice must
not be omitted.
(b) The steam vent need not be opened, if the shell pressure remains above 180
kPa.
(c) The normal start-up must be followed.
(d) This section describes the recommended procedure for starting the package
boiler from a warm condition.
Please note the following when the boiler is brought from the cold condition:
a. Shell temperature can be raised 100 °C per hour if Shell temperatures have
reach 100oC. Drum pressure is saturation pressure at drum temperature.
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b. Steam flow is 0 Kg/Hr for the first ½ hours.

c. Steam flow is 10% MCR from 1/2 hour after Shell temperature reaches 100
°C until Shell pressure reaches MCR operating pressure.
d. Steam flow is 100% MCR 1 hour after Shell pressure reaches MCR operating
pressure.

3.16 RAISING PRESSURE

As a general rule, the boiler should be brought up to operating pressure as slowly

as plant conditions permit, so as to avoid unnecessary expansion strains.
Furnace and setting refractory must be warmed up to normal operating
temperatures gradually, to prevent spalling and cracking. Any refractory surfaces
in the furnace and boiler setting must be warmed up slowly to drive off the
moisture added while laying the brick. The time required for this drying process
depends upon the thickness of the walls. This drying-out of the refractory and the
boiling-out of the boiler may be carried out as one operation.
Refractory furnaces should be heated very slowly for at least 24 to 48 hours,
before building up the fire enough to raise pressure to the figure required for the
boiling-out period of 24 hours. After boiling-out is completed and the unit is ready
for service, the pressure should be raised slowly and the boiler operated at low
steaming rates for two or three days before bringing up to maximum rating.
The use of water walls in Maxitherm boilers minimizes the need for refractory in
the furnace, and thereby decreases the time needed for drying. Fully water
cooled furnaces have a minimum of refractory exposure and require no special
attention.
As a general rule, one to two hours warming up time should be allowed for new
boilers with operating pressure below 500 kPa. If the furnaces are fully water
cooled, 1 to 1 ½ hours is satisfactory. Partially water-cooled or solid refractory
furnaces require more time.
The schedule for warming up a high-pressure boiler should be based on raising
the temperature at a uniform rate. For operating pressures to 600 kPa the boilers
can be warmed up at a rate of about 69 °C per hour. The curve shows the gauge
pressures that will correspond to a constant temperature rise at any time interval
after lighting off.
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6300

4900
CHART TO DETERMINE 3500
TIME REQUIRED FOR
PRELIMINARY 2100

HEATING OF A BOILER 700

UNIT
0 1 2 3 4 5 6 7

TIME FROM LIGHTING UP HOURS

3.17 OPERATION

A number of general rules may be given covering safe operation of

boilers. Some may seem trivial and needless to state, but a large proportion of
the boiler failures on record are due to neglecting to follow the most elementary
rules.
1. Do not hesitate to kill the fire if the water is lost. If the water has been lost,
immediately after killing the fire close the steam stop or take other steps to
reduce the steam demand so that whatever water remains is not
evaporated.
2. Be certain of the water level at all times. Do not depend entirely on
automatic alarm devices and automatic feed water regulators. If in doubt,
blow the water gauge to aid in detecting the correct level.
3. Always blow the water gauges when taking over the watch, to be sure the
gauge connections are clear. Bear in mind that clear glass water gauges
look the same when full as they do when empty; do not be misled by a dirt
mark in the gauge which may look like the surface of the water.

The minimum firing rate should not exceed manufacturer's recommendation's for
warming up the unit as damage to refractory, etc., can results. When the unit is at
the operating pressure and/or temperature, proceed as follows:

1. Increase the firing rate manually from the minimum, "roughing in" control
valve setting to achieve a satisfactory fire by visual observation at each
position. Fires should be clear with a bluish to straw colored flame with
yellow ends without furnace pulsation. (Furnace pulsation may result from
either insufficient or excess air).
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2. At the maximum firing position, adjust the fuel control valve and the air
control to achieve an optimum full capacity firing rate. Fans are normally
sized to deliver air for at least 10% over the maximum capacity rating
(against the register draft loss plus the furnace back pressure) at its
normal operation speed. In actual service, damper adjustment or fan
speed changes may be necessary to establish a proper efficient
maximum firing rate.

CAUTION:
Do not exceed the firing rate for more than rated output of the unit being
fired.

3. Having established the maximum firing rate and minimum firing rate, set
the fuel-air ratio through the entire range.

4. Optimum firing conditions should be assured by analysis of stack gases.

5. Position the guide pipe assembly in the throat where required for the best
mixing and flame pattern. Mark the guide pipe to record the position.

6. Adjust the modulating controller to the desired operating set point.

7. Place the unit on automatic control and carefully observe for proper
operation over the entire range.

3.18 SHUTDOWN

Shutting Down The Boiler

- Transfer the combustion controls to manual and proceed to reduce load.
Continue to feed water to the boiler either on automatic or manual, maintaining a
high level in the gage glass.
- When minimum load has been reached, shut down t

- When the fire is extinguished, please ensure fan still run a few minute for post
purge sequence.
- Fan will be off by automatically if post purge is complete
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- Open the drum vent enough to reduce the saturation temperature by

approximately 38°C per hour. Close the main stop and auxiliary steam valves.
- When the shell pressure reaches 180 kPa, open the vent (if not already opened)
and allow the boiler to cool at least to 66°C before draining (if it is to be drained).
This step is important to prevent formation of a vacuum causing leakage of
gasket joints. The boiler may be drained when the furnace is cool enough to
permit a person to enter it.

Burner Shutdown
- As the boiler load decrease, and the air has reached a minimum and the fuel
control valve is at its minimum. The burners should be taken out of service
following the reverse order of that used during the startup, i.e. take the top burner
out of service first and then the lower burner. To take a burner out of service,

- Burner air damper will close as long as the air flow is above 25%
Note:
A flame failure alarm will not be generated when the burner shutdown is operator
initiated
When the last burner is shutdown
- Burner Safety Shutoff Valves closes.
-
was the cause of trip, the air flow is maintained at the value in the moment of trip
for five (5) minutes (Freeze Air Flow). A fifteen (15) minute post trip purge is
performed, with all air dampers open.
- Air fan now be shutdown.

3.19 EMERGENCY PROCEDURES

High Water Level

Abnormally high water levels should be avoided, as it may lead to carry-over and
even priming.
In the event of a high water level, there will be a high high drum level alarm (at
this moment if control is work properly by automatically burner is shutdown).
Proceed as follows:
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Push and lock Emergency Shut Down (ESD) button at control panel Blow
down the steam generator until the water is approximately at the normal
level. Use the Intermittent Blow down Valves

Low Water Level

If the water level falls out of sight in the water gauge, due to failure of the feed
water supply or neglect of the operator, appropriate action should be taken at
once. The only exception is in the case of momentary fluctuations that might
occur with extraordinary changes in load. Any decision to continue to operate,
even if only for a short time at a reduced rating, would have to be made by
someone in authority who is thoroughly familiar with the circumstances that led to
the emergency and positively certain that the water level can be restored
immediately without damaging the boiler. In the absence of such a decision:
- Push and lock Emergency Shut Down (ESD) button at control panel
- Close the Feed water Stop Valve or Feed water Control Valve.
- Shut off all steam being discharged from the unit. Close the Main Steam Stop
Valve & Non Return Valve or any downstream isolation valve.
- Open the Main Steam Drain Valves.
- Close the Drum Continuous Blowdown Stop Valve
- Check all systems to determine the cause of the low water level.
- Re-establish proper drum levels, unlock ESD button & Alarm, restart the unit.
CAUTION:
Do not attempt to add water until the steam generator has cooled down sufficiently to
where the drum metal temperatures are within 38oC of the feedwater
temperature; otherwise, damage may result due to relatively cool water coming in
contact with heated pressure parts.
Loss of Fire
- Push and lock Emergency Shut Down (ESD) button at control panel
- Ensure or action to trip the fuel immediately; watch drum level
- Reduce the forced draft airflow to about 25 percent for a post-purge and to slow
the boiler cool down rate.
- Identify the cause and make corrections if possible. If the tube failure resulted
from low water in the boiler, stop operation and make a report.

Furnace Explosions
Furnace explosions are generally a result of the following conditions.
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The accumulation of unburned fuel in the furnace due to incomplete combustion, loss
of ignition or fuel valve leakage.
The mixture of this unburned fuel with air in explosive proportions.
The application of sufficient heat to raise the temperature of a portion of this mixture
to the ignition point.
The fuel may enter the furnace in the unburned state in a number of ways, for
instance:
1. Through leaky main fuel or ignition fuel inlet valves on idle burners.
2. If the fires are extinguished and the fuel is not shut off promptly. (See note).
3. If the fuel is not burning as rapidly as it is entering the furnace.
4. In starting up, if difficulty is experienced in establishing ignition.

NOTE:
Furnace explosions can be avoided by taking certain precautions during operation
and by a conscientious maintenance and inspection program that will ensure
availability and proper operation of burner equipment and controls.