KP_Boiler startup_SOP_June-2022

KARIANGAU POWER, BALIKPAPAN
2 X 15 MW Power Plant
KP / SOP /
SOP for BOILER STATRTUP BOILER START
UP
Issue Date: Revision Date:
Issue No: 01 05/01/2018 Revision: 02 10/06/2022 File no: 01 Page 1 of 9
WORK INSTRUCTIONS
FOR
BOILER START UP
[KP / SOP / BOILER]
Prepared By: Reviewed by: Approved by:
Signature: Signature: Signature:

Name: Name: S. Giribabu Name: V. Santeeswara Rao
Designation: Designation: Shift Incharge Designation: Plant Manager
KP / SOP /
UP
Amendment Record
Amendment Amendment Nature of Change ACK No.

Date
Rev Page
No. No.

KP / SOP /
UP
1.0 Purpose:
This Procedure is intended to provide guidance and instructions for carrying out the
Boiler Start Up.
2.0 Responsibility:
1. All the personnel involved in carrying out /supervising the above activities are required to
ensure implementation of this procedure.
2. In the event of any changes required in the procedure such changes may be requested
with Site in charge, who would take appropriate action with approval from respective
departmental heads.
3.0 SAFETY AND ENVIRONMENTAL MEASURES/ CHECKS:
1. Ensure all fans (FD, SA, and ID&RC) coupling guard of the fans are properly fixed.
2. Ensure proper earthling connections of all motors all fans (FD, SA, ID & RF Blower).
3. Work area should be clean & no oil, grease spillage should be there.
4. Safety signs should be marked wherever required.
5. Firefighting equipment should be ready.
6. Ensure no oil leak at fans bearing house area. If oil leak is there, collect in suitable
container and transfer to the empty barrels and keep that barrel at waste oil storage
yard.
7. If any fire / smoke due to oil leak is observed, put off the fire and start the standby
pump and stop the running pump.
4.0 CHECKLIST:
1. Check all vents (steam drum, Super heater, main steam line and start-up), keep all open
position.
2. Check all ring header and economiser drains, keep all close position.
3. Check all super heater and MSL drains, keep all partially (20%) open position.
4. Check initial filling line all valves, keep close position.

KP / SOP /
UP
5. Check all sample (steam drum, saturation steam header, and main steam line) lines, keep
close position.
6. Check dosing line valve, keep open position.
7. Check MSSV and its by-pass line valve, keep close position.
8. Check bed drain line gate, keep close position.
9. Check bed material height in furnace and maintain 500MM.
10. Check boiler all man hole (boiler, flue gas path and air path) doors, keep close position.
11. Check water level in steam drum and maintain 50%.
12. Check coal bunker level and maintain >50%.
13. Check HSD tank level and maintain > 50%.
14. Check Steam drum and MSL safety valves, to be free from gagging.
15. Check coal feeders sealing air system, keep all dampers open position.
16. Ensure all instruments are lined up (i.e., pressure, temperature and flow transmitter and
gauges root valve are open).
17. Ensure work permit closed or not, it should be closed before start the boiler.
18. Take clearance from all the departments (Mechanical, Instrument & Electrical).
19. Check the all fans breakers are is in service and remote/local switch in remote position.
20. After pre check is complete for all fans and the start permissive are achieved then only
start the boiler.
6.0 START PERMISSIVES:
1. Switchgear available.
2. EPB not operated.

KP / SOP /
UP
7.0 Start-up Procedure & Sequence for ID Fan, FD, RF Blower & SA Fan
1. Before starting the ID Fan, ensure drum level is normal (50%), ensure SA & FD Fan
Control Dampers are fully closed (Since the fan motor are full speed & air is controlled
by the suction damper opening).
2. ID Fan should be started with its Control Dampers in Full close condition & Isolation
damper shall remain open.
3. Once ID Fan is started, the fan speed reaches to the full speed, the furnace pressure
should be maintained through Control damper to maintain at (-) 100 PA.
4. Once ID Fan is started, FD Fan can be started after satisfying start up permissive ( ID fan
should be running) in DCS. Start the FD fan.
5. Check start up permissive (ID fan running, FD fan running) for Root Seal Blower (RF
Blower) & start blower & maintain pressure of 12 KPA in loop seal air box.
6. With the above condition, Permissive shall be generated for Starting the SA Fan.
7. Start the SA Fan only after STG synchronization (at appx. 3 MW load).
8. Open the FD air flow control dampers to wind box. Maintain the Furnace pressure by
adjusting ID fan and FD fan damper so as to keep furnace pressure -50 to -100Pa.
8.0 Burner Start up Procedure
1. Start any one of the oil pump. Maintain the oil pressure 0.5 MPA.
2. Start ID fan & maintain furnace pressure appx. (-) 100 PA. Start FD fan & maintain wind
box pressure as minimum fluidizing pressure by opening of oil burners combustion air
dampers.
3. Push in the burning torch. Position high energy igniter, then connect power supply
(ignition ON button). Sparks shall be observed via observation holes.
4. Press the ignition button to initiate ignition & open oil solenoid valve when flame turns
on.
5. The torch shall be in for 10 seconds. When flame becomes steady press the check out
button & check the torch come out.
6. When oil torch is ignited, volume of combustion air and LDO flow shall be adjusted in
time to send the high temp. Produced by combustion of oil torch to flow bed.

KP / SOP /
UP
7. Meanwhile check the fluidization through view glass and adjust the wind-box pressure to
minimum, LDO pressure maintain and ensure bed temperature raising trend.
8. When bed temp reaches 450-500 Deg.C. coal feeding is initiated.
9. When bed temp reaches 800 Deg.C, stop the oil burners.
10. Open LHS and RHS Wind-box dampers & gradually close the oil burners combustion air
dampers.
11. When bed temp reaches 900 Deg.C, stop the LDO pump.
12. Start SA fan to supply excess air for combustion.
13. Charge ESP when flue gas temp reaches 120 Deg.C.
9.0 Procedure for Solid Fuel Firing
1. Raise the Bed temperature around 450° C with the help of burners and start the coal
feeder to initiate coal firing.
2. Prior to start the coal feeders ensure seal air to the Coal feeder & Coal feed pipes are
open and maintain the required pressure (≈ 5.50-6.00 KPA).
3. Start one of the coal feeders with minimum speed and admit the coal into the furnace.
4. Along with the boiler pressurization raise the bed temperature gradually & increase the
FD air flow to maintain wind box pressure.
5. Observe the bed temperature carefully, if there is no change in the bed temperature after
admitting the Solid Fuel, discontinue the Solid fuel feeding and increase the bed
temperature to 500° C by oil burners.
6. Again Start one of the fuel feeders with minimum speed and admit the fuel to the furnace.
7. Monitor the bed temperature raise closely whenever the bed temperature reaches 650°C,
Start the second feeder at minimum speed.
8. Adjust the burner oil pressure suitably to have a control on the bed temperature.

KP / SOP /
UP
9. Raise the bed temperature around 800° C by adjusting the fuel feeding rate (Oil & Solid
fuel) and airflow (Combustor & Burner) suitably.
10. Whenever the Bed temperature reaches to 850° C, switch-off the oil angle valve (oil
Burners).
11. Open the FD normal air door and gradually close primary air ignition door & mixed air
door.
12. If the Bed temperature continue to increase even after switching off the burners increase
the FD air flow, regulate the solid fuel feed rate and admit fresh bed material to have a
control on bed temperature.
13. Monitor the O2 level in Flue gas carefully and it should not be dropped below 6%. If the
O2 level drops below 6% increase the primary air without further increase in solid fuel
flow rate.
14. Maintain the furnace pressure normal i.e. (-) 50 to (-) 100 PA.
15. Start the third coal feeder and adjust the speed of all the three feeders as per the
requirement.
16. Raise the Boiler pressure up to rated pressure in accordance with the enclosed Boiler
Cold start up pressure raising curve.
17. Adjust the Fuel feed rate, primary and secondary air flow according to the fuel firing rate
to maintain the boiler outlet pressure and bed temperature.
18. Maintain normal water level (50%) in the Drum.
19. Start-up vent valve should be in full open condition during pressure rising and till the
steady flow of steam from the boiler.

KP / SOP /
UP
10.0 NORMAL OPERATING PARAMETERS:
Parameter Value
Boiler outlet steam pressure 5.10 MPa
Boiler outlet steam temperature 480 ºC
Boiler outlet steam flow 65 TPH
Feed water temp. at eco inlet 150 ºC
Average bed temperature 920 ºC
Furnace temperature 850 ºC
Wind box pressure 11.5 KPa
Cyclone temperature 920 ºC
Loop seal air box pressure 15 KPa
Flue gas temp. ESP outlet 145 ºC
Secondary air pressure 8 KPa
Furnace pressure -100 Pa

KP / SOP /
UP
11.0 Boiler safety interlocks:
Parameter Low low trip High high trip Action

value value
Drum level -200 mm 200 mm MFT
Bed temperature 750 Deg.C 1050 Deg.C MFT
Furnace draft -2500 Pa 2500 Pa MFT
Loop seal pressure 10 KPa NA RF
12.0 Stopping Procedure of Boiler:
1. Cut off coal feeding.

2. At average bed temperature 600°C stop ID, FD, SA and RC fans and keep all dampers
in close position.
3. Reduce steam drum pressure up to 4 Mpa by opening of start-up vent and maintain
water level in steam drum 60%.
4. Isolate all sample cooler lines.
5. At Steam drum pressure 4 Mpa, Close start-up vent and MSSV & its by-pass
Valve.
********


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KARIANGAU POWER, BALIKPAPAN

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

Amendment Amendment Nature of Change ACK No.

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

3.0 SAFETY AND ENVIRONMENTAL MEASURES/ CHECKS:

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

6.0 START PERMISSIVES:

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

8.0 Burner Start up Procedure

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

9.0 Procedure for Solid Fuel Firing

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

10.0 NORMAL OPERATING PARAMETERS:

Boiler outlet steam pressure 5.10 MPa

Boiler outlet steam temperature 480 ºC

Boiler outlet steam flow 65 TPH

Feed water temp. at eco inlet 150 ºC

Average bed temperature 920 ºC

Furnace temperature 850 ºC

Wind box pressure 11.5 KPa

Cyclone temperature 920 ºC

Loop seal air box pressure 15 KPa

Flue gas temp. ESP outlet 145 ºC

Secondary air pressure 8 KPa

Furnace pressure -100 Pa

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

11.0 Boiler safety interlocks:

Parameter Low low trip High high trip Action

12.0 Stopping Procedure of Boiler:

1. Cut off coal feeding.

Prepared By: Reviewed by: Approved by:

Signature: Signature: Signature:

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