SHREE SINGAJI THERMAL POWER PROJECT Doc. No.

: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 0
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 22/12/2016
Boiler start up procedure without Page: 2 of 6
BCP Job No.: 51005

Revision History:

Rev No. Description Date

0 First Issue 22/12/2016

 SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 0
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 22/12/2016
Boiler start up procedure without Page: 3 of 6
BCP Job No.: 51005

Index

1. Preamble
2. Purpose
3. Pre-requisite
4. Procedure
 SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 0
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 22/12/2016
Boiler start up procedure without Page: 4 of 6
BCP Job No.: 51005

1. Preamble:

During boiler start up and wet mode operation the flow through the economizer and water
wall is maintained at about 25% TMCR flow with the help of BFP and BCP.
In this period the WSDT (water separator drain tank) level is maintained by both BR valve and
WDC valves. BCP and BR valve is used to recirculate the water through economizer and water
walls and the WDC valve drains the excess water to condenser, thus maintaining WDC level
within acceptable range. During wet mode operation, the boiler operation is similar to sub
critical drum type boiler.

To maintain the required flow at eco inlet in absence of BCP, the BFP flow is to be increased
to maintain Feed Water flow around 438TPH (90% of 25% TMCR Flow).

When the Boiler is to be operated in wet mode without BCP, to maintain WSDT level, the
water is recovered through condenser via WDC Valve instead of BCP. Therefore, to maintain
WSDT level, the WDC valve is to be modulated as per “without BCP” operation logic, and the
WDC Valve control loop needs to be in auto.

2. Purpose:

This procedure aims to establish the guidelines of starting up the boiler without the help of
boiler circulating pump.

3. Pre-requisite:
i. Implement modified WDC valve logic for No BCP operation and check its
function.
ii. All other system, equipment, and auxiliaries are available and are in service as
mentioned in normal start up procedure.

4. Procedure:
A. Boiler water filling:
After completion of pre-boiler clean up, fill the boiler using BFP as per normal
operation procedure.

B. Boiler cold clean up blow:

This process will be same as followed during normal operation condition.

C. Boiler cold clean up recirculation:

After completion of Boiler cold clean up blow, Boiler cold clean up recirculation can
be started by opening WDC valve. Boiler water will be channelled in condenser from
where it will go back to feed water circuit through condensate polisher. The flow has
to be replenished by BFP to boiler. ECO inlet feed water flow need to be increased
 SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 0
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 22/12/2016
Boiler start up procedure without Page: 5 of 6
BCP Job No.: 51005

up to 45% from 25% TMCR flow in steps of 5% as well as to maintain WSDT level
around 8.5 m (minimum).

D. Boiler light up and hot clean up:

Follow normal boiler light up procedure with the following exceptions:
1. BCP is not available for operation.
2. BR valve is to be kept closed.
3. Boiler feed water flow at Eco inlet is maintained around 438 TPH.
4. Confirm “BCP OFF” mode is selected and WDC valves control loop is in auto.
5. Please ensure to charge SCAPH before light up.
• Note: There may be swelling of WSDT level occasionally during boiler firing rate
change. This has to be taken care of by prudent operation action. One of the
WDC valve may be taken in manual mode to control WSDT level, in case WSDT
level fluctuates heavily.

E. Boiler pressuring for synchronization:

Boiler pressure has to be raised slowly maintaining WDST level by WDC control valve.
Following operation changes has to be done in case of operation without BCP.
i. Increase Eco inlet Feed water temperature as much as possible by injecting more
steam in DA.
Required temperature: 110 deg. C at in ECO inlet.
ii. Required min. Feed water flow: approx. 438 TPH.
* Strict vigil has to be kept in heating profile inside furnace. Boiler metal
temperature and temperature unbalance at intermediate header, furnace O/l
header, roof O/L header, Superheater & Reheater has to be monitored and
maintained below maximum allowable temperature.
iii. Fuel input is expected to be 10% more than the normal operating condition. As
heat is not recovered by forced recirculation with BCP, fuel input has to be more
than that of normal operation until wet stage is over.
iv. Control of furnace outlet temperature:
Since fuel injection will be more, it may so happen that furnace exit gas
temperature will be increased. To control this temperature, following measures
may be taken:
Increase AA damper opening set point: This will cool the furnace as higher
amount of air will be supplied in furnace.
Required setting: normal+30%
* Keep an eye on furnace to windbox DP. It has to be maintained as per normal
setting.
v. As higher rate of fuel will be burnt along with higher cooling air requirement at
AA port, total air flow set-point will also be higher.
Required set-point: Normal+10%
 SHREE SINGAJI THERMAL POWER PROJECT Doc. No.: 92200-2024
STAGE-II (2×660 MW)
Rev. No.: 0
STEAM GENERATOR & AUXILLARIES
L&T-MHPS Boilers Pvt. Ltd. PACKAGE Date: 22/12/2016
Boiler start up procedure without Page: 6 of 6
BCP Job No.: 51005

When pressure and temperature is achieved for steam admission into turbine, admit steam
to turbine and synchronize as per turbine manufacturer procedure.
Note:
- Aux steam should be supplied by auxiliary boilers or auxiliary steam from other running
unit.
- Pay attention to drain valve opening during pressurizing stage, especially on MS drain valve.

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