PLTU Nagan Raya NAD 2X110MW

Boiler Operation Manual

(Startup Boiler Operation Manual)
Vol.1 4A

PT.PLN (PERSERO) JASA ENJINIRING

SINOHYDRO CORPORAION LIMITED
SHAANXI NORTHWEST POWER GENERATION CO., LTD
2012.10.04

Project Name

PLTU Nagan Raya NAD 2X110MW Coal-fired

Power Plant

File Number

YNYQ-01-01-004-A/2

Contract No.

SAC/HTB/SC/060/11

Startup Boiler Operation Manual

Sinohydro Corporation Limited

Shaanxi Northwest Power Generation Co., Ltd

First edition

Compiled
by

Initial
Checked
by

Peng
Zengping

Qi Zhiyong

Date

Checked
by

Date

2012.10.1

Second
edition
Third edition
Fourth edition
Final edition approved by

Edition

Translated
by

Date

CONTENTS
Preface

Startup Boiler

1.1

General Introduction to Startup Boiler

1.2

Technical Specifications

1.3

Technical Specification of Boiler Auxiliaries

1.3.1

Specification of FDF

1.3.2

Technical Specification of IDF

1.3.3

Specification of Feedwater Pump

Boiler Startup

2.1

Preparation and Inspection before Boiler Startup

2.1.1

Preparation before Boiler Startup

2.1.2

Inspection before Boiler Startup

2.2

Boiler Cold State Startup

2.3

Boiler Hot State Startup

Inspection and Adjustment During Normal Operation

3.1

Inspection During Operation

3.2

Boiler Operational Tune-up

3.2.1

Boiler Operation Tune-up Items

3.2.2

Adjustment of Boiler Water Level

3.2.3

Steam Pressure and Temperature Adjustment 10

3.2.4

Boiler Combustion Regulation 10

3.2.5

Boiler Blowdown

10

Boiler Shutdown

11

4.1

Boiler Outage to Cold Standby State

11

4.2

Boiler Shutdown to Hot Standby State

11

Failures and Solutions

5.1

Boiler System

5.1.1

Boiler Water Over-limit

5.1.2

Water Loss in Boiler

5.2

Solutions Against Boiler Auxiliary Malfunction 13

5.2.1

Solutions Against Forced Draft Fan Failures

13

5.2.2

Solutions Against Induced Fan Malfunction

13

5.2.3

Solutions Against Feedwater Pump Malfunction

5.2.4

Solutions Against Burner Malfunction 15

1
1

1
1

1
2
2

2
2

11

11

12
12

14

Operation Manual Vol.1 4A

Startup Boiler Operation Manual

Preface
The CFB Startup Boiler Operation Manual
is compiled in accordance with all the
descriptions and corresponding drawings
provided by Jiangsu Taihu Boiler Co. Ltd
and manufacturers from the 2110MW
coal-fired power plant project in Aceh,
Indonesia. This version is just applicable to
the CFB boiler auxiliaries operation of
2110MW coal-fired power plant project in
Aceh, Indonesia.
The relevant set values and interlock
conditions in the operation manual need to
be supplemented and modified after the
site commissioning.
There may be some mistakes and flaws in
the manual as a result of incomplete
materials.

As

the

material

gradually

becomes complete, the manual will be

modified and improved continually.

Operation Manual Vol.1 4A

Startup Boiler Operation Manual

Startup Boiler

1.1

General Introduction to Startup Boiler

This startup boiler, structured in D-shaped furnace, is composed of upper and lower
steam drum, convective and radiating heating surface, superheaters, economizers,
boiler walls, platform escalator, steel frame and other components. It's of compact
structure and high thermal efficiency.

1.2

Technical Specifications
Table 1-1 Main Technical Specification of Starting Boiler

Parameter

Unit

Design Data

Boiler Model

SZS10-1.27/270-Y

Boiler Rated Output

t/h

10

Boiler Maximum Continuous Rate

t/h

11

Steam Pressure under Rated Condition

MPa

1.27

Steam Temperature under Rated Condition

270

Feedwater Temperature

20

Economizer Outlet Water Temperature

89

Boiler Fume Discharging Temperature

166

Rated Oil Consumption

t/h

733

Oil Pressure on Burner

MPa

2.8~3.5

1.3

Technical Specification of Boiler Auxiliaries

1.3.1

Specification of FDF
Table 1-2 Technical Specification of FD Fan

Parameter

Unit

Air Volume

m /h

10800

Air Pressure

Pa

6000

Motor Power/Voltage

KW/V

30/400

Current

54.1

Protection Grade

Data

IP55
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Startup Boiler Operation Manual

Rotary Speed

rpm

2965

Technical Specification of IDF

1.3.2

Table 1-3 Technical Specification of Induced Draft Fan

Name

Unit

Air Volume

m /h

31554

Air Pressure

Pa

2041

Motor Power/Voltage

KW/V

37/400

Protection Grade
Rotary Speed

Data

IP54
rpm

1450

Specification of Feedwater Pump

1.3.3

Table 1-4 Technical Specification of Feedwater Pump

Parameter

Unit

Data

Quantity

Set

Volume

t/h

12.5

Head

175

Motor Power/Voltage

KW/V

15/400

Current

27

Protection Grade
Rotary Speed

IP54
rpm

2900

Boiler Startup

2.1

Preparation and Inspection before Boiler Startup

2.1.1

Preparation before Boiler Startup

2.1.1.1
2.1.1.2

Check boiler equipment to confirm all auxiliaries are connected with power supplies.

2.1.1.3

Contact I& C personnel to check and calibrate related instruments. If everything is

good, run them and put boiler protection interlocks into operation.

2.1.1.4
2.1.1.5

Put compressed air system into operation.

Contact I&C personnel to run the monitoring devices continuously for 4 hours earlier
before ignition.

Contact chemical personnel to prepare abundant and standard demineralized

water and test boiler water quality. Boiler cannot be started unless the water
2

Operation Manual Vol.1 4A

Startup Boiler Operation Manual

damper works smoothly

with high sensitivity.

9) Check

quality is good.

2.1.1.6

2.1.1.7

2.1.2
2.1.2.1

Confirm one oil supply

pump is in service and
circulating
state.
Oil
pressure must be greater
than 2.5MPa.

is

indication
signal
from
control panel is in line with
the real condition.

11) Check every damper, valve

and pin in every part is not
only tight and secure, but
also in appropriate control
and flexible motion.

Inspection before
Boiler Startup

12) Check rods and joints for

each transmission device
are not only tight and
secure,
but
also
in
appropriate control and
flexible motion.

Boiler Proper Inspection

1) Check

all
heating
surface is proper in
appearance
and
clean.
is clean and nobody is
on work.

panel

10) Check and confirm every

Inform shift operators to

make records in order to
start
boiler
operation
permit.

2) Check boiler periphery

control

clean.

2.1.2.2

3) Check every manhole,

observation port and
fire inspection port is
tightly closed.

4) Check boiler roof, all

channels of operation
floor,
ground
and
operation periphery is
clean and without
foreign matters.

5) Check boiler house is

in good illumination
and
emergency
illumination is reliable.

6) Check all platforms,

stairs,
fences,
coverplates
inside
boiler house are wellequipped.

7) Check compressed air

system pressure is
proper (fixed value
after operation)

8) Check pipe supporters

are
under
good
condition, every flue
gas duct is without
crack and every air 2.1.2.3

Steam Water System Inspection

1) Check steam and water

connector of water level
gauge is clear and proper in
insulation.

2) Check water level gauge

indication is clear, steam
valve, water valve and
water discharge valve are in
zero leakage and switch is
working freely.

3) Check to ensure every

steam and water valves,
flanges and bonnet bolts
are tight and secure, pilot
wheel is well-equipped,
valve stem is clean and
without bend and rust, and
switch is working freely.

4) Check

rod
joints
on
adjusting devices is wellequipped, pins are tight and
secure and motor-driven
devices are under good
condition.

5) Check steam drum and all

pressure parts are in zero
leakage.
Boiler Air Fan Inspection

1) Check all protection

houses
are
wellequipped and tight,
coupling is in good
connection, foundation
and base bolts are
tight
and
secure,
coupling is in flexible
rotation.

2) Check

air
fan
dampers and its
actuators
are
working
freely,
switches are in

proper direction
zero leakage.

and

3) Check junction boxes on

motor is tight and secure
and earthing wire is under
good condition (convenient
for electrical personnel to
check).

4) Check motor periphery is in

good
illumination
without scaffolding
other

and
and
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Operation Manual Vol.1 4A

Startup Boiler Operation Manual

foreign matters.

2.1.2.4

Feedwater Pump Inspection

1) Check all protection houses are well-equipped and tight, coupling is in good
connection, foundation and base bolts are tight and secure, coupling is in flexible
rotation.

2) Check junction boxes on motor is tight and secure and earthing wire is under
good condition (convenient for electric personnel to check).

3) Check feedwater inlet and outlet valves, flanges and bonnet bolts are tight and
secure, pilot wheel is well-equipped, valve stem is clean and is without bend and
rust, and switch is flexible.

2.1.2.5

Fuel Oil System Inspection

1) Check oil supply pump motor, base bolts on pump and protection house are tight
and secure.

2)
3)
4)
5)

Check and confirm fuel oil pump has been started and in circulating state.
Check oil is abundantly reserved.
Check burner is properly installed.
Check each oil pipeline, blowing pipeline, compressed air pipeline and valves
are in zero leakage.

6) Check igniter is under good condition and without jam.

7) Check to make sure motor-driven valves and control valves work freely while
being closed and opened, and remote actuator work smoothly and at REMOTE
position.

8) Check compressed air pressure is proper (determine the set value after
commissioning)
Table 2-1 Inspection of Boiler Valves
Items

Before Ignition

During Ignition

During Operation

Water makeup valve of feedwater

Closed

Open

Open

A Inlet valve of feedwater pump

Closed

Open

Open

B Inlet valve of feedwater pump

Closed

Open

Open

A outlet valve of feedwater pump

Closed

Open

Open

B outlet valve of feedwater pump

Closed

Open

Open

The manual stop valve before

main Closed

Open

Open

The manual stop valve after

main Closed

Open

Open

tank

feedwater valve (motor driven

feedwater valve (motor driven

Main feedwater valve

Closed

Regulating

Regulating

Main feedwater bypass valve

Closed

Open

Closed

Air valve of feedwater pipe

Closed

Closed

Closed

Inlet valve of economizer

Closed

Open

Open

Operation Manual

Vol.1 4A

Startup Boiler Operation Manual

Drain valve of economizer inlet

Closed

Closed

Closed

economizer Outlet valve

Closed

Open

Open

Vent valve of economizer outlet

Open

Closed

Closed

Vent valve of upper steam drum inlet

Open

Closed

Closed

before Closed

Open

Open

valve

After Closed

Open

Open

Desuperheating water valve

Closed

Regulating

Regulating

Air valve of desuperheating water

Closed

Closed

Closed

Primary valve of upper steam drum

Closed

Open

Open

Air valve of upper steam drum

Closed

Open

Closed

Steam side valve of upper steam

Closed

Open

Open

Water side valve of steam drum local

Closed

Open

Open

Discharging valve of upper steam

Closed

Closed

Closed

Chemical dosing stop valve of upper

Closed

Open

Open

Blowdown valve of lower steam drum

Closed

Closed

Closed

Drain valve of superheater inlet

Closed

Open

Closed

Drain valve of superheater outlet

Closed

Open

Closed

Air valve of superheater outlet header

Closed

Open

Closed

Superheater outlet valve

Closed

Closed

Open

Outlet manual isolating valve of

Closed

Open

Open

Superheat steam sampling valve

Closed

Open

Open

Feedwater sampling valve

Closed

Open

Closed

Boiler water sampling valve

Closed

Open

Open

Saturated steam sampling valve

Closed

Open

Open

Inlet motor-driven damper of Induced

Closed

Regulating

Regulating

Outlet damper of Forced Draft

Closed

Open

Open

header

header
pipe

manual

stop

manual

stop

valve

desuperheating water valve

desuperheating water valve

pipe

local pressure gauge

drum local water level meter

water level meter

drum local water level meter

steam drum

header
header

superheater

Draft Fan(IDF)
Fan(FDF)

2.2

Boiler Cold State Startup

2.2.1

Open primary and secondary saturated steam vent valve, primary and secondary
5

Operation Manual Vol.1 4A

Startup Boiler Operation Manual

furnace at -100Pa.

2.2.9
valve of superheater inlet
and outlet header, and air
valve of feed water pipe.

2.2.2
2.2.3

2.2.4

Open atmospheric relief

valve and drain valve of
2.2.10
superheater.
Open
inlet
valve
of
feedwater pump and close
2.2.11
outlet
valve.
Press
feedwater pump Startup 2.2.12
button in the control panel
and slowly open outlet
valve after checking and
making sure that the pump
operates normally (value
2.2.13
set after regulation).
Open manual valve and
control valve of feedwater
pipe and inlet valve of
economizer. Open manual
valve of economizer outlet
2.2.14
header to upper steam
drum. Inject dematerialized
water into boiler. The
temperature of inlet water
should be within 90.

2.2.14.1

2.2.5

Close
air
valve
of
feedwater pipe when there2.2.14.2
is water.

2.2.6

Close control valve of feed

2.2.14.3
water pipe and economizer
inlet valve, shut down feed
2.2.14.4
water pump, and switch
2.2.14.5
the control button of
feedwater pump to AUTO
2.2.15
position.

2.2.7

Record expansion value of

boilers every part once.

2.2.8

Close inlet damper of

Induced Draft Fan (IDF)
and press IDF Startup
button in the control panel.
2.2.16
Regulate inlet damper of
IDF after checking and
making sure that IDF
operates normally and
keep negative pressure of

Close FD Fan outlet damper

and press the Start button to
start it. Then, open the outlet
damper after confirming that the
FD Fan is running normally.
Switch air volume control
damper of burner to AUTO
position.
Switch IDF inlet damper to
AUTO position.
Check and make sure front oil
pressure in oil regulating valve
of boiler front oil system at
2.5MPa
(value
set
after
regulation).
Adjust to ensure intake air >
30%total air (the value is to be
determined after testing and
commissioning) and keep the
negative pressure of furnace at
-100Pa.
Check and make sure program
control operates normally and
then start boiler purging. The
purging time is 60s. Ignite after
purging.
Move forward the igniter.
Burner nozzle will be opened
after the solenoid valve is
energized.
When flame is detected by flame
detector
Withdraw the igniter.
Switch
mode.

burner

to

automatic

If boiler ignites successfully, it

will operate with minimum load.
If boiler fails to ignite, do not
ignite compulsively. Ascertain
the causes, eliminate problems
and then reignite after purging
furnace.
Automatically start up feedwater
pump according to water level
(value set is determined after
testing) during boiler heating
and boosting.

2.2.17

2.2.18

Use
AUTO
regulation
mode to increase load. It is
required that a minimum2.2.18.1
time of 2 hours is needed
to increase boiler pressure
to the rated operating
pressure (1.27MPa).

of upper steam drum is 0.05

0.1Mpa:

Flush water level meter of

upper drum once as
follows when the pressure

3) Close water level meter

Water flushing

1) Close water level meter

steam side valve.

2) Open water level meter

drain valve to fully open.
drain valve.
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Operation Manual Vol.1 4A

Startup Boiler Operation Manual

4) Flushing is finished.
Open
water
level
meter steam side
valve and operate 2.3.1
water level meter.

2.2.18.2

Steam flushing

1) Close
meter
valve.

water
water

Close inlet regulating damper of

IDF. Press the START button to
start it. Open inlet regulating
damper after checking and
making sure IDF operates
normally.

2.3.3

Close outlet damper of Forced

Draft Fan (FDF). Press FDF
STARTUP button to start up
FDF. Adjust to allow intake air >
30% total air (value set will be
determined after testing and
commissioning) and keep the
negative pressure of furnace at
-100Pa.

2) Open

3) Close

water
level
meter drain valve.

4) Flushing is finished.
Open
water
level
meter water side valve
and operate water
level meter.

2.2.19

2.2.20

2.2.21

2.2.22

2.3

Close
primary
and
secondary vent valve of
2.3.4
saturated steam when the
pressure of upper steam
drum is 0.150.2MPa.
Close
primary
and
secondary vent valve of
superheater
inlet
and
outlet header, and drain
valve of superheater when
the pressure of upper
2.3.5
steam drum is 0.15
0.2MPa.
Slowly open main steam
valve when the pressure of
steam raise to 0.4
0.5MPa.
Close
2.3.6
atmospheric relief valve of
superheater after opening
main steam valve.
Open
desuperheating
water valve according to
the temperature change of
main steam.

Boiler Hot State

Startup

Open atmospheric relief valve

and drain valve of superheater.

2.3.2

level
side

water
level
meter drain valve to
fully open.

manufacturers
references
available, we can not ascertain
boiler temperature and pressure.
Here we only provide the
procedures on hot state startup.

Because there is no boiler2.3.7

Feedwater pump should be at

automatic position. The outlet
valve of feedwater pump A
should be closed. The valve of
the feedwater pipeline should
also be closed. The feedwater
pump
should
be
started
according to the boiler water
level automatically.
After program control mode runs
normally, you can start boiler
purging. The time of purging is
determined by the boiler control
system. After purging, perform
boiler ignition.
Press the START BURNER
button to ignite the boiler.
Operate with lowest load after
successful
ignition.
Cannot
conduct forced ignition if the
boiler ignition failed. Re-ignite
the boiler after checking and
solving the problems. Re-ignition
should be followed by furnace
purging.
The adjustment of the load in

boiler should be automatic.

The load of boiler should
increase and the pressure 2.3.9
of it should increase to the
set pressure (1.27Mpa),
and which should be not
less than 1 hour.

2.3.8

The
drain
valve
of
superheater should be
closed when the pressure

of
the
drum
0.15~0.2Mpa.

reaches

The main steam MOV should be

opened slowly when the main
steam pressure increases to
0.4~0.5Mpa. The atmospheric
relief valve of the superheater
should be closed when the MOV
of the main steam is opened.
7

Operation Manual Vol.1 4A

2.3.10

Startup Boiler Operation Manual

The superheating water valve should be opened to let the superheating water enter
the boiler according to the main steam temperature.

Inspection and Adjustment During Normal

Operation

3.1

Inspection During Operation

3.1.1

Check the boiler observation hole and inspection hole closed tightly. Take immediate
methods once theres air leakage.

3.1.2

Check the operation of fans, water pumps and oil pumps whether stable or not.
Check the sound of the equipment whether normal or not. The boiler should be
shutdown to find out the cause if theres any abnormality.

3.1.3

Check the bolts for fans, feedwater pump and anchor bolts for oil pumps for
looseness.

3.1.4

Check the temperature and vibration of fans and bearing of makeup water pump
whether within the specified scope.

3.1.5

Check the dial of the oil pressure gauge whether stable or not. The boiler should be
shutdown to find out the cause in time if the pressure is abnormal. Special attention
should be paid if theres any fuel leakage.

3.1.6

Check the dial of the steam pressure gauge and makeup water pressure gauge
whether stable or not. Immediate shutdown should be carried out if the pressure is
abnormal.

3.1.7

Check the water level gauge, valves, pipes and flange of the steam drum whether
theres any leakage

3.1.8

Monitor the water level of the water level gauge whether theres huge fluctuation.
Immediate shutdown should be implemented to find out the cause if theres any
abnormality.
Monitor the water level of boiler to be normal(050mm). The water level is neither

3.1.9

allowed to be lower than the lowest water level (-50mm) nor higher than the highest
water level (+50mm). Meanwhile, amount of water and steam flow must be observed
to make sure they are as required. In addition, changes of the water flow should be
steady and without sudden fluctuation.

3.1.10

Water level in steam drum should be calibrated every shift, and the water level gauge
should be cleaned every day.
Table 3-1 Monitoring data during operation

Items

Set Value

Main steam flow

Set 10t/h, Max 11t/h

Main steam temperature

270

Main steam pressure

1.27Mpa

Steam drum water level

050mm
8

Notes

Operation Manual Vol.1 4A

Startup Boiler Operation Manual

oil pressure

2.5Mpa

Furnace pressure

50100 Pa

Exhaust Temperature

To be determined after testing

I.D. fan current

66.7A

I.D. fan motor bearing temperature

90

To be determined after testing

I.D. fan bearing vibration

6.3mm/s

To be confirmed after testing

F.D. fan current

54.1A

F.D. fan motor bearing temperature

90

To be determined after testing

F.D. fan motor vibration

xmm/s

To be determined after testing

Feedwater pump current A,B

27A

Feedwater pump motor bearing temperature

90

leakage in packing chest

15ml/min

3.2

To be determined after testing

Boiler Operational Tune-up

3.2.1

Boiler Operation Tune-up Items

3.2.1.1
3.2.1.2

Keep the evaporation of the boiler less than 10t/h, no more than 11t/h at most
Ensure the steam pressure and temperature are less than 1.27Mpa and 270

3.2.1.3

respectively
Balance the inlet water and keep it fluctuating within the scope of 050mm.

3.2.1.4
3.2.1.5

Guarantee the quality of the saturated steam and the superheated steam.
Ensure the safe and economical operation of the boiler

3.2.2

Adjustment of Boiler Water Level

3.2.2.1

Boiler feedwater should be well distributed. The fluctuation scope of the steam drum
water level is 50mm. Boiler feedwater disruption is forbidden during the operation.

3.2.2.2

The feedwater control valve should be switched to Automatic after water level is
settled when the steam drum pressure is higher than 1MPa (the final value will be
determined after testing).

3.2.2.3

The fluctuation of boiler water level should be monitored to make sure that the water
level change is steady avoiding severe regulation. Moreover, check the flow of
feedwater whether meets up with the flow of steam or not.

3.2.2.4

The fluctuation of feedwater pressure and temperature should be monitored during

operation.

3.2.2.5

The steam drum water level should be calibrated at least twice every shift during
operation. Maintenance personnel should be informed immediately once the level
gauge indicates incorrectly.

3.2.2.6

The water level in steam drum should be working properly and easy to read. The
lighting should be adequate. The water level gauge should be cleaned once a
day. 9

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Startup Boiler Operation Manual

Regulation
3.2.3

Steam
Pressure
and Temperature
Adjustment

3.2.3.1

The amount of evaporation

of the boiler should be
adjusted according to the
demands. The evaporation
should not be less than the
minimum permissible value
(value set after regulation)
to ensure the steady
combustion of the boiler
and
normal
water
circulation.

3.2.3.2

3.2.4.1

1) Flame with dark smoke and

emitting from stack means
inadequate air. Widely open
the forced air valve.

2) Flame appearing orange

color, furnace full of flames
and
colorless
and
transparent smoke mean
complete combustion

The permissible fluctuation

scope of the steam
pressure in boiler: steam
pressure 0.05Mpa. And the
permissible
fluctuation
scope of the steam
temperature
in
boiler: 3.2.4.2
steam temperature 5.

3.2.3.3

The flow of superheating

water should be regulated
according to the variation
of boiler temperature to 3.2.4.3
ensure
a
constant
temperature
of
superheated steam.

3.2.3.4

The duration of boiler

operation with excessive
load should not be over 2 3.2.5
hours and the main steam
3.2.5.1
flow is less than 11t/h.

3.2.3.5

The pressure gauge and

thermometer of steam
should be checked once in
every shift to make sure
that the parameter of
steam supply is normal.
I&C personnel should be
informed instantly if theres
any irregular action taking
place.

3.2.4

Boiler Combustion

The combustion status should

be
observed.
Complete
combustion depends on the
proper ratio of fuel and air,
which should follow the criteria
below:

3.2.5.2

3) Flame

appearing white,
splashing sparks and white
smoke emitting from stack
means excessive air flow.
Close the forced air valve
according to the demands.

The pressure in combustion

chamber should be within 50
100 Pa during operation.
Operation with positive pressure
is forbidden.
Adjust fuel quantity timely
according to the variation of
boiler load to make sure that the
steam
pressure
and
temperature
in
boiler
is
constant.

Boiler Blowdown
Carry out the blowdown once a
day during operation. Boiler
operates with low load and high
water level when blowdown. The
blowdown
time
for
each
circulation loop cannot exceed
30 seconds. Two or more valves
cannot be opened at the same
time. This boiler is designed with
manual blowdown operation
mode.
Monitor
the
variable
of
feedwater pressure and drum

water level to maintain

normal water level of the 3.2.5.4
steam drum. Thoroughly
check after blowdown to
make sure every valve is
tightly closed.

3.2.5.3

Open
the
primary
blowdown
valve
and3.2.5.5
secondary blowdown valve
at the upper steam drum.
Close them after 30
seconds (firstly close the
secondary valve in prior to

primary one).
Open the primary blowdown
valve and secondary blowdown
valve at the lower steam drum.
Close them after 30 seconds
(firstly close the secondary valve
in prior to primary one).
Slowly perform the blowdown to
prevent water impact. Stop
blowdown immediately
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Operation Manual Vol.1 4A

Startup Boiler Operation Manual

4.1.7

Press the STOP button for I.D.F

on the control panel to stop the
induced air. Close the regulating
damper from I.D.F inlet and cut
back flue gas system.

when 4.1.8

Close economizer inlet valve

after water gets to the highest
water level in the steam drum
and close feedwater motordriven valve to stop supplying
water to the boiler.

when severe vibration is

occurred in pipelines.

3.2.5.6

Stop

blowdown

immediately
emergency

events

are

happened to bailer during

blowdown,

except

that

drum water level is too

high.

4
4.1

4.1.1
4.1.2
4.1.3

4.1.4

4.1.5

4.1.6

4.1.9

Boiler Shutdown
Boiler Outage to
Cold
Standby
State
4.1.10
Boiler blows down once.
Gradually
load.

lower

boiler

4.2

Set the feedwater control

valve for boiler piping at
4.2.2
manual
mode.
Close
desuperheating valve for
superheater based on the
4.2.3
actual temperature of the
boiler.
Close main steam solenoid
valve when the main
system does not need 4.2.4
steam
supply.
Open
atmospheric relief valve for
superheater to maintain
normal water level (0
50mm) in steam drum.
4.2.5
When the load of boiler
drops to the lowest value,
press
the
Deactivate
button for the burner on 4.2.6
the control panel to stop
firing and close the fuel
valves at the corners.
Press STOP button for
4.2.7
F.D.F on the control panel
to stop the forced air and
close damper from the
F.D.F outlet.

Press FEEDWATER PUMP

STOP to stop operating the
feedwater
pump
when
feedwater pump is set to the
manual mode and close outlet
of feedwater pump.
Close atmospheric relief valve of
superheater. The boiler is
enclosed.

Boiler Shutdown to
Hot Standby State
Lower boiler load gradually and
reduce main steam pressure of
boiler.
Close desuperheating water
valve for superheater gradually
and set the feedwater control
valve for boiler piping at manual
mode.
Close main steam solenoid
valve when the main system
does not need steam supply.
Open atmospheric relief valve
for superheater.
Press EXIT THE BURNER
button on the control panel and
close corner-arranged fuel valve
to stop burner operating.
Press F.D.F STOP button on the
control panel to stop the forced
air and close damper from the
F.D.F outlet.
Press I.D.F STOP button on the
control panel to stop the
induced air. Close the regulating
damper from I.D.F inlet and cut
back flue gas system.

4.2.8

Set feedwater pump at

automatic mode and go on
feeding water in the steam
drum until it reaches
normal
water
level(050mm).
5.1

enclosed.

5 Failures and
Solutions

4.2.10

Close
superheater
atmospheric relief valve
gradually. The boiler is

Boiler System
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Operation Manual Vol.1 4A

Startup Boiler Operation Manual

and accuracy of water level

indication.

5.1.1

Boiler Water Overlimit

5.1.1.1

Descriptions

2) Turn down regulation valve

to reduce feedwater when
feedwater
automatic
regulator is out of order,
influencing water level. Turn
down feedwater valve when
regulation valve cannot
control feedwater.

1) Water level exceeds

the
normal
level
50mm.
b) High water level signal
is on when water level
alarming apparatus
rings.

3) Open the blow-off valve for

steam drum when water
level is rising.

3) Temperature

of
superheat steam falls.

4) Saltness

of

4) Go on turning down or

steam

increases.

5) Feedwater

flow
exceeds steam flow
abnormally.

6) There would be water

attack in steam piping
and bubbles in flange
when water overflows
severely.

5.1.1.2

Causes

1) Feedwater automatic
regulator is out of
order and feedwater
regulation
device
breaks down.

5) Shut down the boiler as

water level in steam drum
exceeds upper visible water
level.

5.1.2

Water Loss in Boiler

5.1.2.1

Descriptions

2) Operators' misjudging
results
in
misoperation
due
to
incorrect indication of
water meter, steam
flow meter or water
5.1.2.2
flow meter.

3) Boiler load increases

1) Water level is under normal

level.

2) Low water level signal is on

when water
rings.

level

alarm

3) Feedwater flow is less than

steam flow abnormally.

4) Superheat

steam
temperature rises due to
lack of water severely.

Causes

1) Malfunction of Feedwater

swiftly.

automatic control valve.

4) Feedwater

2) Incorrect indication of water

pressure
increases suddenly.

5) Operators

cannot
regulate water level in
time or mis-operate
because
of
their
careless in observing
water level.

5.1.1.3

close the valves controlling

feedwater when the three
measures are used but
water level is still rising,
exceeding
100mm
of
normal level.

Solutions

1) Confirm the rightness

level and steam flowmeter

of steam or water, which
resulted in an mis-just and
misoperation .

3) Boiler

load

decreases

suddenly.

4) Feedwater

pressure

decreases.

5) Boiler

blowdown

pipe

overflows. The valve

leaks severely.

6) Water wall pipes or

economizer
crack.

pipes

7) Inadvertently watch against

water level or failure to do
right adjustment or
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2

Operation Manual Vol.1 4A

Startup Boiler Operation Manual

mis-operate level.

5.1.2.3

Solutions

1) Confirm the rightness and accuracy of water level indication.

2) Turn up regulation valve to increase feedwater when feedwater automatic
regulator is out of order, influencing water level.

3) Go on feeding feedwater when the two measures are used but the water level is
lowering, 100mm less than normal level. Close all blow off valves and
discharging valves to decrease evaporation capacity properly.

4) Shut down boiler immediately and close main steam valve to feed feedwater in
the boiler when the water level in steam drum keeps on decreasing and the
water level in the level gauge is out of sight.

5.2

Solutions Against Boiler Auxiliary Malfunction

5.2.1

Solutions Against Forced Draft Fan Failures

Table 5-1 Solutions against forced draft fan failures

Malfunction

Causes

Solutions

a) Misalignment

between

fan

bearing and motor

bearing; a)
b)
b) Insufficient foundation rigidity
c)
c) Loosening of bolt at
the
d)
bottom of bearing seat.
coupling tilt.

Severe

vibration on

bearing box

inlet and
space
between air
impeller.
e) Check, clean and repair.
Perform
dynamic balance test if necessary.

d) Friction between air inlet and

impeller.

e) Blade imbalance due to oil

scaling and friction.
a) Severe vibration on
bearing
box.
b) Over fastening or loosening of
bearing cap.
c) Excessive space
between
bearing raceway or damage in
bearing.
d) Imbalance of rotor.
a) Excessive
conveying
gas
density.

Overheat of
bearing

b) Current and voltage in excess

Excessive
motor current
and over heat

to set value.

c) Extreme low inlet voltage of

motor or single phase power
supply outage.
d) Coupling

misalignment,

uneven clearance.

Realign and reassemble.

Reinforce and repair.
Inspect and tighten every bolt.

a)
b)
c)
d)

Adjust

Adopt the above solutions.

Check and adjust.
Check and change bearing.
Check and rebalance rotor.

a) Check whether the density excesses set

value.
b) Check and restrict operation point.

c) Check and adopt solutions.

d) Check, align and adjust.

or e) Adjust control valve or change motor.

e) Actual
operating
power
exceeds the rated power.

5.2.2

Solutions Against Induced Fan Malfunction

Table 5-2 Solutions against induced fan malfunction
13

Operation Manual Vol.1 4A

Malfun
ction

Startup Boiler Operation Manual

Causes
a) Misalignment between fan

Severe
vibratio
n

on

bearing
box

Overhe

and motor bearing, coupling tilt.

b) Insufficient foundation rigidity.

Reinforce
and and
tighten
repair.
every bolt
c) Loosening of bolt
at the bottom of c) Check
d)

d)
e)
a)
b)

at
of c)
bearing
d)
a)
Excessi

Solutions
bearing a) Realign and reassemble.
b)

bearing seat.
Friction between air inlet and impeller.
Blade imbalance due to oil scaling and
friction.
Severe vibration on bearing box.
Over fastening or loosening of bearing
cap.
Excessive space between bearing
raceway or damage in bearing.
Imbalance of rotor.
Excessive conveying gas density.

b) Excessive values of current and

ve

c) Extreme low inlet voltage of motor or

and

d) Coupling

heat

e) Required power for operation in

excess to rated power.

over

single phase power supply outage.

connection

impeller.

e) Check, clean and repair. Perform

dynamic balance test if necessary.
a) Adopt the above solutions.
Check and adjust.
c) Check and change bearing.
b)
d) Check and change rotor.

a) Check whether the density excesses set

value.

voltage.

motor
current

Adjust space between air inlet and

b) Check and restrict operation point.

misalignment, d)
c) Check
solutions.
Check,and
alignadopt
and adjust.

space nonuniformity.

e) Adjust control valve or change motor.

Solutions Against Feedwater Pump Malfunction

5.2.3

Table 5-3 Solutions against feedwater pump malfunction

Malfunction

Causes

Pump

not suck

severe

vibration

Solutions

water; Insufficient water

injection to Reinject water into pump; block
on pump; gas leakage on pipe and
indicator of pressure gauge
and stop leakage.
gauges.
and vacuum gauge.
Seat valve closed or clogged;
Pump
not suck
water, strong resistance to
suction Correct or change seat valve
extreme vacuum indication

pipe;

on vacuum gauge.

height.

Pressure

indicated

pressure gauge but

outlet water from pump.

over

high

suck water condition;

change

suction

Strong resistance to outlet water

on pipe; wrong swirling direction; Check or shorten pipe; check and
no

impeller

clogged;

pump rotating speed.

clean impeller;

insufficient rotating speed.

Pump clogged; excessive wear

design on sealing ring; insufficient pump
rotating speed.
Over tightness of packing gland;
Excessive pump consumed stuffing box heated;
impeller
power.
worn; increase in pump water
supply.
Excessive water flow; strong
Abnormal sound in pump,
resistance inside suction pipe;
no water sucked from
air leaked into suction water
pump.
pipe; overheat of sucked water.
Water flow under
requirements.

increase

Vol.1 4A

pump

Clean pump and pipes; change

sealing ring, increase
rotating
speed of outlet water pump.
Loosen packing gland; change
impeller; increase outlet water
pump resistance
to decrease
water flow.
Increase outlet water pipe
resistance to increase flow; check
pump and pipes; check seat
valve; lower suck water height;

14
Operation Manual

pipe;

lower suck water height.

Startup Boiler Operation Manual

block the leakage.

Vibration on pump.
Over heat of bearing.

5.2.4

Misalignment between
shaft center and motor
center.

pump Align the pump shaft and motor

shaft shaft.

No oil on bearing; misalignment

between pump and motor shaft.

Inject oil; align the pump and

motor shaft; check or clean

bearing body.

Solutions Against Burner Malfunction

Table 5-4 Solutions to burner malfunction

Malfunction

Nozzle: uneven atomization; no

oil flow; nozzle leaking.

Igniting failure

No flame: fan locked shortly after

shartup; nozzle stopping
injecting oil due to malfunction

Unshaped flame

Lock occurring after flame

formed
Oil flowing to combustion
chamber

Causes

Solutions

Loose cyclone plate;

Clogging in nozzle;
Clogging in filter;
Wearing due to use;
Clogging in
nozzle and
malfunction of nozzle shut
down device.
Air damper unable to turn
to full load;
Improper cam installation;
Wearing
or
extreme
contamination in igniting
electrodes
and insulation
failure;
Igniting cable failure;
Igniting sensor failure.
Low pressure in oil pump;
Clogging or
damage in
nozzle;
Malfunction in
solenoid
valve;
Malfunction in
control
circuit;
Malfunction in
solenoid
valve;
Wear and damage in loops
or cable.
Malfunction in
solenoid
valve;

Disassemble
the nozzle and
fasten the cyclone plate;
Disassemble and clean;
Disassemble and clean;
Change;
Disassemble, clean or change.

Change;
Correct;
Change or change;
Change;
Change.

Regulate, clean or change;

Reinstall;
Clean or change;
Change;
Change the
hydraulic solenoid
valve;
Change the trouble unit.

Malfunction in
solenoid Change the faulty parts;
valve or damages in loops Disassemble, clean or change;
and cable;

Malfunction in module unit; Change.

Malfunction
in
nozzle
valve.
Improper
burner Regulate;
regulation;
Clean;
Contaminant filter;
Repair or change.
Clogging in nozzle.
Leakage in nozzle valve;
Damage in nozzle;
15

Operation Manual Vol.1 4A

Clean, repair or change;

Change;

Startup Boiler Operation Manual

Malfunction

in

solenoid Change.

Flame monitoring malfunction

Atomizing device burning-out

valve.
Improper position of flame
detector;
Contaminate
flame
detector;
Weak flame;
Malfunction
in
flame
detector;
Malfunction in
control
module.
Improper space
between
atomizer and nozzle;
Improper position of
regulator or atomizer;

Improper nozzle size

type;
Damage in nozzle.

16

Move the flame detector to proper

position;
Clean;
Check to see if the burner is
properly adjusted;
Change it;
Change it.

Change;
gas Adjust until it is in good condition;
or Adjust;
Replace with a proper nozzle.