India Balco 4X300 MW TPP: LV Wei Liu Ping Zhou Shengzhang

INDIA BALCO 4x300 MW TPP
Issue for implementation

DESCRIPTION DATE
PREPARED BY Lv Wei India BALCO Project(4×300MW)
CHECKED BY Liu ping Boiler System
APPROVED BY Zhou Shengzhang Operation Procedure
PART 1 General Description 2

Chapter 1 General Description of Main Equipment..................................................................................3
Chapter 2 Auxiliary Equipment Specification.........................................................................................29
PART 2 Boiler Unit Stadrtup 43
Chapter 1 Trial Operation & Test of Main Equipment of Boiler after Inspection & Repair..................44
Chapter 2 Boiler Startup..........................................................................................................................59
PART 3 Unit Operation 70
Chapter 1 Normal Operation Adjustment................................................................................................71
PART 4 Boiler Shutdown 81
Chapter 1 Preparation before Boiler Shutdown......................................................................................82
Chapter 2 Boiler Shutdown.....................................................................................................................83
PART 5 Handling of Boiler Unit Trouble 88
Chapter 1 General Rules for Trouble Handling......................................................................................89
Chapter 2 Handling of Boiler Trouble.....................................................................................................90
PART 6 Auxiliary Machinery & Public System 110
Chapter 1 General Rules for Auxiliary Machinery................................................................................111
Chapter 2 Pulverizing System...............................................................................................................113
Chapter 3 Air and Flue Gas System.......................................................................................................117
Chapter 4 Air Preheater.........................................................................................................................121
Chapter 5 Sootblowing and Blowdown System....................................................................................124
Chapter 6 Flame Detection and Flue Gas Probe...................................................................................127
PART 1 General Description
Chapter 1 General Description of Main Equipment

Model: HG-1025/17.5-YM28
Type: This boiler is subcritical, once intermediate reheating and natural circulation steam drum boiler with
overhung structure, balanced draft and dry-ash furnace, all-steel construction and outdoor arrangement.
The boiler is designed to be a dead square furnace of 14,048mm wide and 12,468mm deep, the furnace roof
elevation is 709,100mm, the steam drum center line elevation is 640,900mm and the furnace roof plate
girder top elevation is 709,100mm. The roof is light metal cover and the furnace roof is thermally sealed
with big cover casing. The furnace is made up of φ63.5mm membrane wall, the furnace bottom sealing is
water seal, there are division wall, rear platen and platen reheater arranged on the upside of furnace and
there are wall radiant reheaters mounted on the front wall and side walls, water wall lower header elevation
is 6,720mm and operation floor elevation is temporally set to 12.60m.
The furnace has two rotary trisector regenerative air preheaters mounted at the rear, the rotor is 9,970mm in
diameter and rotates reversely, and the angular degree of primary air division is 65º.
The boiler combustion system is designed according to the medium speed mill primary cold air direct firing
pulverizing system, the boiler uses medium speed mill direct firing pulverizing system with each furnace
equipped with five medium speed mills, once four of them are put into operation, the boiler can operate
stably and safely for a long term with BMCR load and each heating surface is noncoking. 20 direct-flow
burners are arranged on the four corners at the lower part of furnace in five layers, the pulverized coal and
air are fed from the four corners and show tangential circle firing in the furnace. The burners can bob and
the maximum swinging angle is ±30%. The burner wind box on each corner has one layer of light oil gun
torch and two layers of heavy oil gun torch.
The boiler is with dry-ash furnace and the bottom ash extraction system uses scraper slag conveyor to
achieve continuous deslagging.
The boiler uses light oil as fuel for startup to 10% BMCR; the combustion-supporting oil is heavy oil
during low load operation, and the light oil and heavy oil system output of the boiler is 30% BMCR. The
steady combustion load of boiler without fuel oil is not higher than 40% BMCR. The boiler can guarantee
output when operating with combustion of design coal and low quality coal.
The superheater steam temperature control mainly uses spray type attemperator, the superheater system has
second stage spray type attemperator with three spraying points, the first stage is arranged on the large-
diameter connecting pipe between low temperature superheater and division wall superheater with one
spraying point, the second stage is arranged on the large-diameter connecting pipe between the rear platen
superheater and the last stage superheater, with two spraying points, one on the left side and the other on
the right side. The attemperator is flute type. The design water spray quantity accounts for 10% of the main
steam flow rate.
The reheater steam temperature control mainly uses burner swinging and excess air coefficient and there
are two emergency sprayers mounted right and left on the inlet piping of reheater, the attemperator uses
mechanical atomizing nozzle. The design flow rate accounts for 5% of the reheated steam flow under
BMCR condition.
The rear shaft lower header of the boiler is equipped with a start-up used water bypass with capacity of 5%,
which is used to deliver water so as to quicken the heating up of the superheater during boiler startup.
The boiler has expansion center and the whole boiler expansion takes the expansion center as zero point
during operation.
The inner diameter of steam drum is Φ1,778mm, wall thickness is 178mm, the material is SA-299 and the
straight length of steam drum shell is 18,000mm. The normal water level is 120mm lower than the steam
drum centerline, the highest and lowest water levels are ± 50mm from the normal water level, the inner
steam purifier is of the structure of cyclone separator + vertical louver, with diameter of Φ254mm, cyclone
separators totals 84 sets, the average steam load of single separator is about 12.2 t/h, and the water capacity
of the whole steam drum is 48,000kg.
Gas temperature probes are mounted at both left and right sides of furnace outlet to control the flue-gas
temperature at furnace outlet during startup. Furnace flame television camera devices are mounted at both
right and left sides of the furnace so as to observe the combustion situation in the furnace. The boiler is
equipped with steam drum water level gauge and water level television camera device, furnace safeguard
supervisory system (FSSS) and etc. safety protection device.
The superheater is mainly composed of 5 parts: 1. last stage superheater 2. rear platen superheater 3.
division wall 4. vertical low temperature superheater 5. horizontal low temperature superheater: roof
superheater and rear pass wall enclosure system.
Boiler steam and water circuit:
Primary steam system
Feed water piping → economizer → steam drum → downcomer → water-cooled wall tube → steam and
water outlet pipe → steam drum → furnace roof, rear flue gas pass wall enclosure tube and extension side
wall → low temperature superheater → stage I spray type attemperator → division wall → rear platen→
stage II spray type attemperator → last stage superheater → main steam pipe.
Secondary steam system
High-pressure cylinder exhaust connecting pipe → reheater emergency spray type attemperator → wall
reheater →platen reheater → last stage reheater → reheated steam piping outlet.
The main boiler fuel is Indian Korba Coalfields coal.
1. Boiler design specification and structure features
1.1 Boiler general description and main data
Table 1-1
General description:
No. Name Description
1 Model HG-1025/17.5-YM28
Subcritical, primary intermediate reheating, natural
2 Type
circulation boiler with steam drum
3 Manufacturer Harbin Boiler Co., Ltd.
4 Furnace Dimension 14.048×12.468×33,300 (mm)
5 Steam drum center elevation 64090 (mm)
Positive pressure direct firing coal pulverizing system,
6 Combustion type
foursquare tangential circle combustion
7 Ventilation type Balanced draft
11 Design fuel Indian coal
12 Coal consumption at rated load 218.2t/h (design) 242.58t/h (maximum)
Guaranteed steam temperature load
13 60% ~ 100%BMCR
in constant pressure operation
Guaranteed steam temperature load
14 50% ~ 100%BMCR
in sliding-pressure operation
Superheated steam temperature
15 Second stage mixing spray attemperating
adjusting mode
Reheated steam temperature
16 Burner swing and emergency trim spray attemperating
adjusting mode
17 Slag discharge mode Mechanical continuous deslagging in solid state
18 Precipitation mode Electrostatic precipitation
Main technical parameters of boiler (provisional)

No. Item Unit Data
I. Boiler parameter
1 Boiler evaporation at the unit’s rated load t/h 960
2 BMCR t/h 1,025
3 Superheater outlet pressure at rated load MPa.g 17.39
4 Superheater outlet steam temperature at rated load ℃ 541
5 Reheater inlet pressure at rated load MPa.g 3.678
6 Reheater inlet steam temperature at rated load ℃ 323.2
7 Reheater outlet pressure at rated load MPa.g 3.512
8 Reheater outlet steam temperature at rated load ℃ 541
9 Feed water temperature at rated load ℃ 276.9
II. Technical performance
1 Min. stable combustion load of boiler without fuel oil %BMCR 40
2 Load range for keeping rated superheated steam %BMCR 50~100
temperature
3 Load range for keeping rated reheated steam %BMCR 50~100
temperature
4 Furnace volume heat release rate (BMCR) kW/m3 99.34
5 Wall heating load of high temperature area of water- MW/m2 1.513
cooled wall (BMCR)
6 Furnace outlet gas temperature (BMCR) ℃ 1,023
7 Gas temperature before entering convection heating ℃ 1,307
surface (BMCR)
8 Rear platen bottom gas temperature ℃ 1,307
9 Furnace design pressure Pa 5,800
10 Load carrying capacity for short-time non- Pa 9,800
deformation of furnace wall
11 Burner method - Swing burner
12 Burner arrangement type - Foursquare tangential
circle
13 Total nozzle Piece 20
14 Ignition oil gun method - Light oil ignition
15 Capacity of single ignition oil gun Kg/h 1500
16 Quantity of ignition oil guns Piece 4
III. Relevant data
1 Boiler exhaust gas temperature (BMCR)
Before correctness ℃ 133
After correctness (inlet air temperature is 20℃) ℃ 128
2 Hot air temperature (BMCR)
Primary air ℃ 316
Secondary air ℃ 331
4 Average velocity of flue gas (BMCR)
Superheater (last stage superheater, low temperature m/s 11.3/11.2
superheater)
Reheater (platen reheater, last stage superheater) m/s 8.5/10.6
Economizer m/s 8.5
5 Air leakage ratio of air preheater (BMCR)
At operation % 6
After one-year’s operation % 8
6 Boiler excess air coefficient
Furnace outlet - 1.25
Economizer outlet - 1.25
7 Steam drum center elevation m 64.09
Steam drum cyclone type Axial-flow type
Steam drum cyclone diameter φmm 254
Steam drum cyclone quantity Piece 84
Design and max evaporation of single cyclone t/h, t/h 12.2, 13.6
8 Quantity of circulation circuits of water-cooled wall 28
Front wall 8
Rear wall 8
Side wall 6
9 Rifled tube arrangement height (front, rear and side m ~28/31.5/28
walls)
10 Minimum circulation ratio at the corner (BMCR) - ~3.0
11 Design mass velocity of water-cooled wall (BMCR) Kg/s 1,000~1,200
12 Design pressure drop of steam and water circuit
(BMCR)
Superheater MPa 1.373
Reheater MPa 0.176
From economizer inlet to steam drum MPa 0.392
13 Pressure drop of air-flue gas circuit (BMCR)
Primary air side of air preheater Pa 670
Secondary air side of air preheater Pa 960
Flue gas side of air preheater Pa 1,155
Flue gas side from furnace to economizer outlet Pa 2,550
14 Steam temperature control method of superheater
Quantity of spray attemperating stages of superheater Stage 2
Design spray water volume of first and second stages Kg/h 68.3/34.1
Superheated steam crossover times Times 1
15 Steam temperature control method of reheater
Steam temperature auxiliary control method of - Swing burner
reheater
Design spray water volume of reheater Kg/h 51.25
Reheated steam crossover times Times 1
IV. Dimensions and materials of furnace and pressure
parts
1 Furnace volume (width, depth, height) 14,048×12,468×53,380
2 Furnace volume m3 7,754.0
3 External diameter and thickness of water-cooled wall Φmm, mm 63.5/7
tube
4 Water-cooled wall tube material - SA-210C
5 Total heating area of water-cooled wall m2 2,838
6 Internal diameter of steam drum φmm 1,778
Thickness of steam drum mm 190
Length of steam drum straight section m 18
Steam drum weight t ~175
7 Fracture appearance transition temperature (FATT)of ℃ -20
steam drum steel plate
8 Steam drum design pressure MPa.g 19.82
9 Steam drum material - SA-299
10 Design pressure of superheater MPa.g 19.82
11 Total heating area of superheater m2 16747
12 Diameter and thickness of division wall superheater φmm, mm See the data table of
tube superheater tube stack
13 Material of division wall superheater tube - See the data table of
superheater tube stack
14 Diameter and thickness of rear platen superheater tube φmm, mm See the data table of
15 Material of rear platen superheater tube - See the data table of
16 Diameter and thickness of last stage superheater tube φmm, mm See the data table of
17 Material of last stage superheater tube - See the data table of
Material weight of austenite and martensite tube used Kg, Kg See the data table of
in superheater superheater tube stack
18 Design pressure of reheater MPa. g 4.38
19 Total heating area of reheater m2 3540
20 Diameter and thickness of reheater tube φmm, mm See the data table of
21 Material of reheater tube
Material of low temperature reheater tube See the data table of
Material of high temperature reheater tube See the data table of
Material weight of austenite and martensite tube used See the data table of
in reheater superheater tube stack
22 Design pressure of economizer MPa.g 20.22
23 Total heating area of economizer m2 9055
24 Diameter and thickness of economizer tube φmm, mm 51, 6
25 Material of economizer tube - SA-210C
26 Air preheater type - 28.5-VI(T)-2133-SMR
27 Heat transfer area of air preheater m2
28 Diameter and height of air preheater rotor φmm, mm 9,970 2,879
29 material of air preheater low temperature section - CORTEN steel
30 Service life of air preheater low temperature section h 50000
31 Burner height m ~9.8
32 Operation layer elevation m 12.6
33 Elevation of ash bucket top m 15.166
34 Deslagging port elevation m 6.72
35 Steel furnace frame dimension (width, depth, height) m 34×38×70.9
V. Total weight of boiler
1 Steam drum weight (including hanger) t 202
2 Steel frame weight t 2,280
3 Water-cooled wall weight t 500
4 Superheater weight t 1,403
5 Reheater weight t 268
6 Economizer weight t 405
7 Air preheater weight t 790
8 Platform, stair, casing weight t 800
9 Other t 1,064
10 Total weight of boiler t 7712
VI. Boiler performance guarantee
1 BMCR t/h 1025
2 Guaranteed thermal efficiency at rated load (BECR, % 87.53
as per high heating value)
Heat loss due to exhaust dry flue gas % 3.92
Heat loss due to moisture in fuel % 2.23
Heat loss due to unburned hydrogen % 3.50
Heat loss due to moisture in air % 0.07
Heat loss due to unburned fuel % 1.70
Heat loss due to surface radiation and thermal % 0.20
convection
Unmeasurable heat loss % 0.35
Manufacturer margin % 0.5
3 Min. stable combustion load of boiler without fuel oil % 40
4 Steam temperature of superheater outlet Rated ±℃ 5
5 Steam temperature of reheater outlet Rated ±℃ +5~-10
VII. Auxiliary equipment performance
1 Sootblower
Combustion chamber sootblower type Retractable
Combustion chamber sootblower quantity Set 80
Combustion chamber sootblower manufacturer Hubei Diamond Power
Machine Co. Inc.
Shanghai CLYDE
Machinery Co., Ltd.
Convection heating surface sootblower type Long retractable
Convection heating surface sootblower quantity Set 24
Convection heating surface sootblower manufacturer Hubei Diamond Power
Machine Co. Inc.
Shanghai CLYDE
Machinery Co., Ltd.
Air preheater sootblower type Retractable
Air preheater sootblower quantity Set 2
Air preheater sootblower manufacturer Hubei Diamond Power
Machine Co. Inc.
Shanghai CLYDE
Machinery Co., Ltd.
2 Safety valve
Quantity of steam drums Set 3
Steam exhaustion of single set Kg/h 277,100/285,600/289,700
Manufacturer
Quantity of configured superheater outlet Set 2
Steam exhaustion of single set Kg/h 114,500/11,480
Manufacturer
Quantity of PCV at the superheater outlet Set 1
Steam exhaustion of single set Kg/h 103,000
Manufacturer
Quantity of configured reheater inlet Set 3
Steam exhaustion of single set Kg/h 191,200/193,300/197,300
Manufacturer DRESSER, CROSBY
Quantity of configured reheater outlet Set 2
Steam exhaustion of single set Kg/h 148,000/155,000
Manufacturer DRESSER, CROSBY
3 Visible steam drum water gauge
Water gauge type Non-fade zone mica
water gauge
Quantity Piece 2
Manufacturer /
4 High-energy ignition device
Type
Quantity Piece 4
Manufacturer /
High-energy ignition method Light oil ignition
1.2 Boiler main design parameters

Thermodynamic data
Table 1-2
Load Unit BMCR BECR 70% 60% Min. Stable HP Heater
Item BMCR BMCR Combustion Removal
Load Of
Boiler
Without
Fuel Oil
Unit load MW 330 300 230 200 130 300
1.Steam and water flow
Superheater outlet t/h 1,025 960 717.5 615 410 777.59
Reheater outlet t/h 847.27 796.15 605.93 525.3 357.03 764.81
Economizer inlet t/h 1,025.0 949.5 671.86 579.31 387.11 694.08
Superheater first stage t/h 0.0 7.0 30.6 23.8 15.3 55.7
spray
Superheater second stage t/h 0.0 3.5 15.1 11.9 7.6 27.8
spray
Superheater third stage t/h / / / / / /
spray
Reheater spray t/h 0.0 0.0 0.0 0.0 0.0 0.0
Normal boiler blowdown t/h <10.25
rate
2.Steam and water
pressure
Superheater outlet MPa.g 17.50 17.39 17.03 12.30 8.39 17.10
pressure
Pressure drop of first MPa 0.536 0.475 0.277 0.208 0.214 0.407
stage superheater
Pressure drop of second MPa 0.285 0.252 0.147 0.111 0.114 0.216
stage superheater
Pressure drop of third MPa 0.317 0.281 0.164 0.123 0.127 0.240
stage superheater
Pressure drop of fourth MPa 0.235 0.208 0.121 0.091 0.094 0.178
stage superheater
Total pressure drop of MPa 1.373 1.216 0.710 0.534 0.549 1.042
superheater
Reheater inlet pressure MPa.g 3.914 3.678 2.785 2.406 1.577 3.589
Pressure drop of first MPa 0.080 0.075 0.057 0.050 0.034 0.072
stage reheater
Pressure drop of second MPa 0.050 0.047 0.036 0.031 0.021 0.045
stage reheater
Pressure drop of three- MPa 0.046 0.043 0.033 0.029 0.019 0.042
stage reheater
Pressure drop of fourth MPa / / / / / /
stage reheater
Reheater outlet pressure MPa.g 3.738 3.512 2.659 2.297 1.503 3.430
Steam drum pressure MPa.g 18.873 18.60 17.73 13.13 8.94 17.93
Water-cooled wall MPa / / / / / /
pressure drop
Economizer pressure drop MPa 0.152 0.135 0.079 0.029 0.060 0.092
(excluding position
difference)
Economizer gravity MPa 0.24 0.24 0.24 0.24 0.24 0.24
pressure drop
Economizer inlet pressure MPa.g 19.265 18.977 18.054 13.428 9.206 18.260
3.Steam and water
temperature
Superheater outlet ℃ 541 541 541 541 533 541
Superheater temperature ℃ ±5 ±5 ±5 ±5 ±5 ±5
deviation
Reheater inlet ℃ 329.8 323.2 299.4 318.5 312.6 325.8
Reheater outlet ℃ 541 541 541 541 524 541
Reheater temperature ℃ +5~-10 +5~-10 +5~-10 +5~-10 +5~-10 +5~-10
deviation
Economizer inlet ℃ 280.4 276.9 260 252.6 229.8 177.2
Economizer outlet ℃ 314 312 302 290 269 256
Attemperating water ℃ 178.9 175 165.6 160.7 145.4 177.2
Steam drum ℃ 361 360 356 332 303 357
4.Air quantity
Air preheater inlet Nm3/h 239,626 228,775 181,687 176,367 155,543 267,456
primary air kg/s 85.53 81.66 64.85 62.95 55.52 95.47
Air preheater inlet Nm3/h 643,647 608,201 505,256 410,864 278,248 585,377
secondary air kg/s 229.75 217.09 180.35 146.66 99.32 208.95
Air preheater outlet Nm3/h 245,697 240,071 208,939 172,907 125,327 235,898
primary air (including kg/s 87.70 85.69 74.58 61.72 44.73 84.20
bypass)
Air preheater outlet Nm3/h 637,647 602,200 499,961 403,451 271,542 579,023
secondary air kg/s 227.60 214.95 178.46 144.01 96.93 206.68
Air leakage ratio of air % 5.19 5.47 6.38 7.65 10.95 5.71
preheater
Air quantity from primary Nm3/h 41,653 41,653 40,947 39,888 39,888 42,360
air side leaking to flue gas kg/s 14.87 14.87 14.62 14.24 14.24 15.12
side
Air quantity from primary Nm3/h 6,001 6,001 6,001 3,883 3,883 5,295
air side leaking to kg/s 2.14 2.14 2.14 1.39 1.39 1.89
secondary air side
Primary air leakage ratio % 19.9 20.8 25.8 24.8 28.2 17.9
Air quantity from Nm3/h 12,002 12,002 11,296 11,296 10,590 11,649
secondary air side leaking kg/s 4.28 4.28 4.03 4.03 3.78 4.16
to flue gas side
Total air quantity from air Nm3/h 53,655 53,655 52,243 51,184 50,478 54,008
side leaking to flue gas kg/s 19.15 19.15 18.65 18.27 18.02 19.28
side
5.Flue gas flow
Furnace outlet Nm3/h 1,005,425 953,450 796,917 650,444 447,878 919,852
kg/s 369.28 350.19 292.24 238.9 164.5 337.85
Superheater outlet Nm3/h 1,005,425 953,450 796,917 650,444 447,878 919,852
kg/s 369.28 350.19 292.24 238.9 164.5 337.85
Reheater outlet Nm3/h 1,005,425 953,450 796,917 650,444 447,878 919,852
kg/s 369.28 350.19 292.24 238.9 164.5 337.85
Economizer outlet Nm3/h 1,005,425 953,450 796,917 650,444 447,878 919,852
kg/s 369.28 350.19 292.24 238.9 164.5 337.85
Air preheater inlet Nm3/h 1,005,425 953,450 796,917 650,444 447,878 919,852
kg/s 369.28 350.19 292.24 238.9 164.5 337.85
Air preheater outlet Nm3/h 1,057,751 1,005,778 847,931 700,301 498,468 973,990
kg/s 388.43 369.34 310.88 257.16 182.51 357.12
6. Dust content of flue gas g/Nm3 67.9
at air preheater outlet
7.Air temperature
Primary air temperature at ℃ 40.5 40.5 40.5 40.5 40.5 40.5
air preheater inlet
Secondary air temperature ℃ 37.2 37.2 37.2 37.2 37.2 37.2
at air preheater inlet
Primary air temperature at ℃ 316 314 306 290 261 257
air preheater outlet
Secondary air temperature ℃ 331 327 314 298 267 272
at air preheater outlet
8.Air rate
Primary air rate % 27.5
Secondary air rate % 67.5
Overfire air rate % 15
Furnace air leakage rate % 5
Δα/α l
9.Flue gas temperature
Furnace outlet ℃ 1,023 1,013 967 912 816 999
Superheater division wall ℃ 1,307 1,306 1,279 1,211 1,108 1,287
inlet
Superheater rear platen ℃ 1,122 1,113 1,067 1012 916 1,097
inlet
Last stage superheater ℃ 813 802 762 716 636 792
inlet
Vertical low temperature ℃ 728 718 686 649 588 709
superheater inlet
Horizontal low ℃ 659 651 622 586 527 646
temperature superheater
inlet
Platen reheater inlet ℃ 1,023 1,013 967 912 816 999
Last stage reheater inlet ℃ 903 892 846 794 703 879
Superheater division wall ℃ 1,122 1,113 1,067 1,012 916 1,097
outlet
Superheater rear platen ℃ 1,023 1,013 967 912 816 999
outlet
Last stage superheater ℃ 736 727 694 658 597 718
outlet
Vertical low temperature ℃ 682 673 644 609 552 668
superheater outlet
Horizontal low ℃ 472 467 453 427 388 470
temperature superheater
outlet
Platen reheater outlet ℃ 914 903 858 806 714 891
Last stage reheater outlet ℃ 831 821 780 734 654 810
Economizer inlet ℃ 472 467 453 427 388 470
Economizer outlet ℃ 353 348 330 312 278 293
Air preheater outlet ℃ 133 131 127 115 97 108
(uncorrected)
Air preheater outlet ℃ 128 127 122 110 92 104
(corrected)
10.Air pressure drop
Primary air pressure drop KPa 0.670
of air preheater
Secondary air pressure KPa 0.960
drop of air preheater
Primary air burner KPa 0.64
resistance
Secondary air burner KPa 1.00
resistance
11.Flue gas pressure and
pressure drop
Furnace design pressure KPa ±5.8
Furnace allowable KPa ±9.8
pressure
Pressure drop of air KPa 1.155
preheater flue gas side
Pressure drop from KPa 2.550
furnace to air preheater
outlet
12.Fuel consumption t/h 215.83 204.67 161.76 139.93 96.52 197.45
13.Heat input GJ/h 2,772.9 2,629.6 2,071.9 1,788.6 1,228.7 2,536.8
14.Boiler heat loss
Heat loss due to exhaust % 3.94 3.92 4.04 3.27 2.54 2.98
dry flue gas
Heat loss due to moisture % 2.24 2.23 2.23 2.21 2.18 2.20
in fuel
Heat loss due to unburned % 3.51 3.50 3.50 3.46 3.42 3.45
hydrogen
Heat loss due to moisture % 0.07 0.07 0.07 0.06 0.05 0.05
in air
Heat loss due to unburned % 1.70 1.70 2.00 2.20 2.60 1.70
fuel
Heat loss due to surface % 0.19 0.20 0.25 0.28 0.41 0.20
radiation and thermal
convection
Unmeasurable heat loss % 0.35 0.35 0.35 0.35 0.35 0.35
Total heat loss % 12.00 11.97 12.44 11.83 11.55 10.93
Thermal efficiency % 88.00 88.03 87.56 88.1789. 88.45 89.07
07
Manufacturer margin % 0.50
15. Guaranteed thermal % 87.53
efficiency at rated load (as
per high heating value)
16. Heat absorption
capacity and furnace
heating load
Superheated steam heat GJ/h 2,210 2,090 1,626 1,447 1,016 2,052
absorption capacity
Reheated steam heat GJ/h 421 406 336 263 167 384
absorption capacity
Heat supply of fuel for the GJ/h 2,772.9 2,629.6 2,071.9 1,788.6 1,228.7 2,536.8
boiler
Cross-section heating load MW/m2 4.398 4.170 3.286 2.837 1.949 4.023
Full furnace volume kW/m3 99.34 94.20 74.22 64.08 44.02 90.88
heating load
Heating load of minimum kW/m3 236.44 224.21 176.66 152.51 104.77 216.30
burn-out area volume
EPRS kW/m3 170.6 161.8 127.5 110.1 75.6 156.1
Heating load of burner MW/m3 1.513 1.435 1.130 0.976 0.670 1.384
area
17.Burner
Coal consumption of one t/h 13.49 12.79 13.48 11.66 12.07 12.34
burner (pulverized coal)
Quantity set 16 16 12 12 8 16
18.Slag removal rate
Furnace slag shaft % 20
Economizer ash hopper % 5
Air preheater ash hopper % 5
19. Ignition oil gun
Output of one ignition oil Kg/h 1,500
gun
Quantity set 4
20.Combustion-
supporting oil gun
Output of one ignition oil Kg/h 2200
gun
Quantity set 8
21. Coal pulverizing
system
Quantity of coal set 4 4 3 3 2 4
pulverizer
Type of pulverized coal Horizontal bias
concentrator
Pulverized coal g/m3 0.5
concentration before
pulverized coal
concentrator
Pulverized coal g/m3 0.7
concentration after
pulverized coal
concentrator
Primary air ratio before % 27.5
pulverized coal
concentrator
Stationary period of S 2.1
pulverized coal in furnace
22.NOx emission ratio (as mg/Nm3 400
per NO2)
23 Power consumption of KW None
boiler circulation pump (if
any)
24.Boiler performance Provide it within two weeks after the contract is signed
curve (extreme hot, hot,
warm, cold start)
1.3 Environment condition of boiler design operation
1.3.1 Combustion and pulverizing system
1.3.2 Adopt positive-pressure direct firing pulverizing system of medium speed mill.
Main auxiliary machinery of combustion and pulverizing system are chosen as follows:
Coal pulverizer: five roller medium speed mills per boiler.
Primary air fan: two adjustable moving blade axial-flow fans per boiler.
Forced draft fan: two adjustable moving blade axial-flow forced draft fans per boiler.
Induced draft fan: two adjustable static blade axial-flow induced draft fans per boiler.
Electric precipitator + bag filter: electric precipitator (2 electric fields) + bag filter, dust collection
efficiency ≥ 99.95%.
Table 1-3
Design Coal
Name Unit 70%THA 50%Tha 40%Mcr Removal
ECR
BMCR Constant Sliding Sliding of All HP
(TRL)
Pressure Pressure Pressure Heaters
Design Coal
CoalName
pulverizer Unit ZGM133G
model
Pulverized coal 18
%
fineness (R90)
Quantity of coal 4 4 3 3 2 4
Set
pulverizer
Total air quantity
at coal pulverizer 291 286.5 218.2 163.5 119.4 284.0
t/h
outlet (including
seal air)
Mixture ℃ 76 76 76 76 76 76
temperature at
outlet
Water content of % 2.4 2.4 2.4 2.4 2.4 2.4
pulverized coal
at coal pulverizer
outlet
Air temperature ℃ 216 210 196 233 226 208
at coal pulverizer
inlet
1.3.3 Ignition oil system and auxiliary machinery
1.3.3.1 Fuel oil system
The fuel for boiler startup is light diesel oil and heavy oil; the combustion-supporting oil during low load
operation is heavy oil.
Fuel oil system is equipped with two oil tanks of 1,000 m3, two of 200m3, and three charging pumps and
two oil drain pumps respectively for light and heavy oil, in addition there is a dirty oil pump and a sewage
pump.
1.3.3.2 Auxiliary machinery
Start-up steam source
This project includes start-up used boiler room, the start-up steam source is connected from start-up boiler.
Air compressor room
Two sets of units in this project use one set of overhaul and instrument air compressor system.
1.3.3.3 Fuel
The boiler mainly uses Indian local coal as fuel, which can achieve guaranteed performance, such as
output, etc. when burning design coal or check coal.
Coal quality:
Proximate Analysis (% by weight)
Sl. No. Name Design coal quality Worst coal quality
1 High heating value (kcal/kg) 3300 3000
2 Ash 41.6 45
3 VAD 22 21
4 Fixed carbon 24.5 19
5 Moisture 11.9 15
6 Total 100 100
7 HGl 45 42
ULTIMATE ANALYSIS OF COAL RECEIVED BASIS

NO. Name Design coal quality Worst coal quality
1 Carbon % 37.5 31.9
2 Hydrogen % 2.1 1.8
3 Oxygen % 5.6 4.8
4 Nitrogen % 0.9 0.9
5 Sulfur % 0.4 0.6
6 Ash % 41.6 45
7 Moisture % 11.9 15
8 High heating value 3300 kCal/kg 3000 kCal/kg
Notes: total moisture is 19% in rainy season. (internal water + external water)
Ash analysis:
Ash Fusion Analysis Symbol Unit Design Coal Check Coal
Deformation temperature DT ℃ 1,290 1,340
Softening temperature ST ℃ 1,350 1,400
Fusion temperature FT ℃ 1,500 1,400
Ash composition analysis
Silicon dioxide SiO2 % 54.9 59.6
Aluminum oxide Al2O3 % 25.4 30.75
Titanium dioxide TiO2 % 1.3 1.75
Ferric oxide Fe2O3 % 9.3 6.5
Calcium oxide CaO % 3.1 0.25
Magnesium oxide MgO % 1.8 0.08
Potassium oxide K2O % 0.3 0.27
Sodium oxide Na2O % 0.3 0.15
Sulfur trioxide SO3 % 2.3 0.03
Phosphorus pentoxide P2O5 % 0.1 0.47
Manganic manganous oxide Mn3O4 % 0.7 0.15
1.3.3.4 Ignition and combustion-supporting fuel

The fuel for boiler startup is light diesel oil and heavy oil; the combustion-supporting oil during low load
operation is heavy oil.
(1) Analysis of fuel oil design parameter is as follows:
Heavy Oil Characteristics Data Unit Data
1 Sulfur content % 4.5
2 Heat quantity kcal/kg 11000
3 Flash point (Min) 66
4 Moisture (Max) % 1.0
5 Deposit (Max) % 0.25
6 Asphalt content (Max) % 2.5
7 Kinematic viscosity (50℃) 180
8 Kinematic viscosity (98.9℃) 20--30
9 Ash content (Max) % 0.1
10 Acidity (inorganics) 0
11 Flow point ≤ 24℃
12 Na --
13 V ppm 25
14 Specific heat kcal/kg.℃ 0.5
Light Oil Characteristics Data Unit Data
1 Flash point (Max) ℃ 12 (summer)
℃ 18 (winter)
2 Kinematic viscosity (at 38℃) 2.5~15.7
3 Moisture (Max) % 0.25
4 Deposit (Max) % 0.10
5 Sulfur content (Max) % 1.8
6 Ash content % 0.02
7 Carbon residue mass (Max) % 1.50
8 Inorganic acidity 0
9 Flash point (closed) (Min) ℃ 66
10 Total acidity (Max) 0
(2) Approximate viscosities of hazard contaminants at different temperatures are as follows:

Temperature (℃) Approximate kinematic viscosity range
60 250 - 290
70 120 - 150
80 80 - 120
90 50 - 80
98.9 30 - 50
100 30 - 50
110 20 - 30
120 10 – 20
1.3.3.5 Boiler feed water

Boiler normal continuous blowdown is 1% BMCR, feed water amount: normal (as per 2% of BMCR)
21t/h, start and emergence (as per 6% of BMCR) 62t/h.
Feed water preparation method: primary demineralization and bed system.
Boiler feed water quality standard:
Attached table 1-7
Item Index Description
Hardness 0 mol/L During boiler startup ≤5.0mol/L
Guarantee the steam silicon
Silicon dioxide During boiler startup ≤80g/L
dioxide is in line with the standard
Dissolved oxygen ≤7g/L During boiler startup ≤30g/L
Iron ≤20g/L During boiler startup ≤75g/L
Copper ≤5g/L
Hydrazine 10~50g/L
PH 9.0~9.5
Oil ≤0.3mg/L
Conductivity (after hydrion
≤0.3s/cm
convection, 25℃)
1.3.3.6 Water capacity of boiler

Attached table 1-8
Steam Water Piping
■ Parts Economizer Superheater Reheater Total
Drum System
■ Hydraulic test 36 52 153 170 94 505
■Normal operation 36 24 153 202
1.4 Technical data of main pressure parts and heating surface tube
Attached table 1-9
No. Name Unit Value
1 Steam drum
Design pressure MPa.g 19.82
Max operating pressure MPa.g 18.873
Steam drum internal diameter mm 1,778
Steam drum external diameter mm 2,158
Length of steam drum straight section mm 18,000
Total length of steam drum mm ~20,134
Steam drum center elevation m 64.09
Steam drum material SA-299
Allowable stress of steam drum steel plate MPa 132.57
FATT of steam drum steel plate ℃ -20
Axial-flow cyclone separator +
Steam purifier type
vertical louver
Cyclone separator diameter mm Ф254
Evaporation and maximum evaporation of one
t/h, t/h 12.2,13.6
cyclone separator
Cyclone separator quantity set 84
Steam drum water capacity kg 48,000
Total weight of steam drum (including steam
t ~175
drum interior fittings)
Steam drum weight t ~179
Steam drum dimension (L×W×H) mm 20,200x3,300x2,500
Combustion chamber, water-cooled wall and
2
combustion equipment
Furnace type Membrane wall
Furnace dimension (W×D×H) mm 14,048×12,468×53,380
Furnace volume m3 7,754.1
Total heating area of furnace m3 4,514
Furnace radiation heating area m3 4,514
Furnace refractory belt area m3 /
Furnace cross-section heating load (BMCR) Mw/m2 4.398
Furnace volume heating load (BMCR) Mw/m2 99.34
Heating load of furnace effective projected
Mw/m2 170.6
radiant surface (EPRS) (BMCR)
Burner area heating load (BMCR) Mw/m2 1.513
Furnace outlet temperature (BMCR) ℃ 1023
Furnace design pressure ± KPa ± 5.8
Load carrying capacity for short-time non-
± KPa ± 9.8
deformation
Water-cooled wall design pressure Mpa.g 19.82
Water-cooled wall circulating mode Natural circulation
Water-cooled wall mass velocity (BMCR) kg/s 1,000~1,200
Quantity of water-cooled wall circulation
28
circuits
Water-cooled wall tube type Rifled tube + light pipe
Water-cooled wall tube external diameter φmm 63.5
Water-cooled wall tube internal diameter φmm 49.5
Water-cooled wall tube pitch mm 76.2
Water-cooled wall quantity Piece 668
Water-cooled wall tube material SA-210C
Arrangement height of water-cooled wall rifled
tube:
Front wall m ~28
Rear wall m ~31.5
Side walls m ~28
External diameter of water-cooled wall rifled
φmm 63.5
tube
Wall thickness of water-cooled wall rifled tube Mm 6.6 (MWT)
Water-cooled wall ribbed quantity Piece 668
Water-cooled wall rifled tube material SA-210C
Corner tube minimum circulation ratio (B－ ~3.0
MCR)
Downcomer external diameter φmm Φ457
Downcomer internal diameter φmm Φ367
Downcomer wall thickness mm 45
Downcomer quantity Piece 4
Downcomer material SA-106C
External diameter of descending water
φmm 159
distribution pipe
Internal diameter of descending water
φmm 123
distribution pipe
Quantity of descending water distribution
Piece 74
pipes
Material of descending water distribution pipe / SA-106C
Cross-section ratio between downcomer and
/ 0.33
riser
Cross section ratio between riser and steam
/ 1.08
lead pipe entering steam drum
2
Heating surface area of water-cooled wall m 2838
Total water volume of boiler kg 125000
Ratio of critical heating load to design
maximum heating load in heat transfer ~1.45
deterioration of water-cooled wall
Direct-flow swing burner, angle
Burner type
arrangement
Total quantity of primary air nozzles of burner 20
Elevation of furnace hopper top m 15.166
Slag discharge hole elevation of slag pit m 6.720
Ignition and low load oil gun type (Quoters fill Heavy oil Light oil
it respectively) system system
Quantity of configured oil guns Set 8 4
Capacity of one oil gun kg/h 2200 1500
Atomization steam pressure MPa.g 0.88 0.686~0.784
Oil supply pressure (steam atomization) MPa.g 1.37 /
Oil supply pressure (mechanical atomization) MPa.g / 2.94
3 Superheater and reheater
Superheater design pressure MPa.g 19.82
Superheater spray design attemperating water
t/h 68.3, 34.2
amount (first and second stage)
Heating area of front platen superheater m2 663
Mass velocity of front platen superheater 2
kg/m .s 1,380
(BMCR)
Flue gas temperatures of rear platen
℃ 1,122 1,023
superheater forepart and afterpart (BMCR)
Flue gas temperature of rear platen superheater
℃ 1,307
bottom (BMCR)
Mass velocity of rear platen superheater
kg/m2.s 1,050
(BMCR)
2
Heating area of rear platen superheater m 1,054
Heating area of division wall superheater m2 663
Flue gas temperatures of division wall
℃ 1,307 1,122
superheater forepart and afterpart (BMCR)
2
Heating area of roof superheater m 269
Heating area of wall enclosure superheater m2 1,427
Flue gas temperatures of last stage superheater
℃ 813; 736
forepart and afterpart (BMCR)
2
Heating area of last stage superheater m 2,306
Total heating area of the superheater m2 16,747
Weight of austenite and martensite tube of
kg 13,400/23,600
superheater
Times of coordinated transposition of
Times 1
superheater left and right
Total pressure drop of superheater (BMCR) MPa 1.373
Steam temperatures at all superheater outlets
(BMCR)
Steam temperature at high temperature
℃ 541
superheater outlet
Steam temperature at rear platen superheater
℃ 504
outlet
Steam temperature at division wall outlet ℃ 446
Steam temperature at low temperature
℃ 408
superheater outlet
External, internal diameters and pitches of all See the data table of superheater
mm
superheater tubes (See Notes) tube stack
Average flue gas velocity of all superheaters See the data table of superheater
m/s
(corrected by altitude) tube stack
See the data table of superheater
Material of all superheaters
tube stack
Max. calculated steam temperature, calculated
metal wall temperature and wall temperature at See the data table of superheater
℃
max temperature point of all superheaters (See tube stack
Notes)
Data table of superheater tube stack
Item Unit Data
I. Low temperature superheater
Horizontal low Vertical low
temperature temperature
superheater superheater
Tube specification (external dia.× wall thickness) mm 516 516
Tube pitch (transverse/longitudinal) mm 136/102 136/102
Average flue gas velocity of tube stack (BMCR) m/s 11.2 10.6
SA-210C
Material SA-213T12 SA-213T22
SA-213T22
454
Allowable temperature for the material ℃ 540 580
580
Outlet steam temperature ℃ 397 408
Max. calculated steam temperature of superheater ℃ 405 413
Metal wall temperature at the outlet ℃ 440 458
Max. metal wall temperature (B-MCR) ℃ 445 460
Quantity of tubes connected in parallel 102/6 102/6
II. Division wall superheater
Tube specification (external dia.× wall thickness) mm 516,7
Tube pitch (transverse/longitudinal) mm 2,810/60.5
Average flue gas velocity of tube stack (BMCR) m/s /
SA-213T22
Material
TP-304H
580
Allowable temperature for the material ℃
704
Total weight of used austenite steel tube and martensite
t 2.0/0
steel tube
Outlet steam temperature ℃ 446
Max. calculated steam temperature of superheater ℃ 450
Metal wall temperature at the outlet ℃ 532
Max. metal wall temperature (B-MCR) ℃ 569
Quantity of tubes connected in parallel 4×6/8
III. Last stage superheater
Tube specification (external dia.× wall thickness) mm 518, 9
Tube pitch (transverse/longitudinal) mm 152.4/102
Average flue gas velocity of tube stack (BMCR) m/s 11.3
SA-213T22
Material
SA-213T23
Allowable temperature for the material ℃
t 0/0
steel tube
Quantity of tubes connected in parallel 90/4
Data table of reheater tube stack
Item Unit Data
I. Wall reheater
Tube specification (external dia.× wall thickness) mm 504
Tube pitch (transverse/longitudinal) mm 50.8
Average flue gas velocity of tube stack (BMCR) m/s /
Material / SA-213T12
Allowable temperature for the material ℃ 540
Max calculated steam temperature of superheater ℃ 396
Metal wall temperature at the outlet ℃ /
Front wall 234 pieces
Quantity of tubes connected in parallel
Sides wall 2×90 pieces
II. Division wall reheater
Tube specification (external dia.× wall thickness) mm 634,4.5,7
Tube pitch (transverse/longitudinal) mm 457.2/72.5
SA-213T22
Material T91
TP-304H
Total weight of austenite steel tube and martensite steel
t/t 6.2/3.7
tube of reheater
580
704
III. Last stage reheater
Tube specification (external dia.× wall thickness) mm 634; 4.5; 7
Tube pitch (transverse/longitudinal) mm 228.6/114
SA-213T22
Material T91
TP-304H
t 4.3/35.0
steel tube of reheater
580
704
Data table of economizer tube stack
Item Unit Data
4 Economizer
Design pressure (BMCR) MPa.g 20.22
Economizer inlet water temperature (BMCR) ℃ 280.4
Economizer outlet water temperature (BMCR) ℃ 314
Heating area (serpentine tube, pendant tube etc.) m2 9,055
Economizer pressure drop (BMCR) MPa 0.392
Flue gas velocity at economizer inlet and outlet
m/s 9.1; 7.9
(BMCR) (corrected by altitude)
Economizer tube arrangement In line arrangement
Economizer tube external diameter mm 51
Economizer tube internal diameter mm 39
Economizer tube wall thickness mm 6.0
Economizer tube pitch mm 127
Economizer tube material SA-210C
Quantity of economizer tubes in parallel 3×110
Wearing plate + spoiler + wearing
Anti-wear facilities of economizer
shield
5 Air preheater
Type 28.5-VI (T)-2133-SMR
Air preheater quantity set 2
Air inlet temperature (BMCR) (primary air) ℃ 40.5
Air inlet temperature (BMCR) (secondary air) ℃ 37.2
Air outlet temperature (BMCR) (primary air/
℃ 316/331
secondary air)
Flue gas temperature at the inlet (BMCR) ℃ 353
Flue gas temperature at the outlet (BMCR)
℃ 133
（before correction）
Flue gas temperature at the outlet (BMCR)（after
℃ 128
correction）
Air leakage ratios at put-in and after one-year’s
6, 8
operation
Whether there is a damper or actuator at the air
Closing damper
preheater outlet
Rotor diameter mm Ф 9970
Rotor height mm 2879
Total rotor weight t 250/set preheater
Rotor rotating speed r/min 1
Quantity of sootblowers per air preheater Set 1
Manufacturer of sootblowers per air preheater Set Clyde, Diamond
Bearing lubricating and cooling mode Oil bath and water cooling
Material of regenerative component on high
Q235-A
temperature section
Plate thickness of regenerative component on
mm 0.5
high temperature section
Area of regenerative component on high
m2 45,000
temperature section
Material of regenerative component on middle-
Q235-A
temperature section
Plate thickness of regenerative component on
mm 0.5
middle-temperature section
Area of regenerative component on middle-
m2 28,000
temperature section
Material of regenerative component on low
CORTEN steel
temperature section
Plate thickness of regenerative component on low
mm 0.8
temperature section
Area of regenerative component on low
m2 13,000
temperature section
Main drive motor type Y160M-6
Main drive motor rotating speed r/min 970
Main drive motor power kW 7.5
Main drive motor quantity set 1/each preheater
Auxiliary drive motor type Y160M-6
Auxiliary drive motor rotating speed r/min 970
Auxiliary drive motor power KW 7.5
Auxiliary drive motor quantity Set 1/preheater
Drive reducer type ZSY
6. Safety valve
Steam drum safety valve type Spring type
Steam drum safety valve quantity 3
Steam drum safety valve nominal diameter mm F75
Steam drum safety valve throat diameter mm /
Steam drum safety valve exhaust volume (each
kg/h 277,100/285,600/289,700
set)
Popping pressure of steam drum safety valve MPa.g 19.82/20.22/20.41
Reseating pressure of steam drum safety valve MPa.g 19.03
Steam drum safety valve manufacturer CROSBY/DRESSER
Technical standard for design and manufacturing
ASME
of steam drum safety valve
Superheater outlet safety valve type Spring type
Quantity of superheater outlet safety valve 2
Superheater outlet safety valve nominal diameter mm F65
Superheater outlet safety valve throat diameter mm /
Superheater outlet safety valve exhaust volume
kg/h 114,500/114,800
(each set)
Popping pressure of superheater outlet safety
MPa.g 18.31/18.34
valve
Reseating pressure of superheater outlet safety
MPa.g 17.58/17.61
valve
Superheater outlet safety valve manufacturer DRESSER, CROSBY
ASME
of superheater outlet safety valve
Silencer type of superheater outlet safety valve Provisional
Silencer quantity of superheater outlet safety
Set 2
valve
Silencer manufacturer of superheater outlet safety
Domestic
valve
Superheater outlet PCV type Pneumatic
Superheater outlet PCV quantity 1
Nominal diameter of superheater outlet PCV mm F65
Throat diameter of superheater outlet PCV mm /
Exhaust volume of superheater outlet PCV (each) kg/h 103,000
Popping pressure of superheater outlet PCV MPa.g 18.13
Reseating pressure of superheater outlet PCV MPa.g 17.77
Manufacturer of superheater outlet PCV DRESSER/CROSBY
Technical standard for manufacturing of
ASME
superheater outlet PCV
Silencer type of superheater outlet PCV To be confirmed
Silencer quantity of superheater outlet PCV set 1
Silencer manufacturer of superheater outlet PCV Domestic
Reheater inlet safety valve type Spring type
Reheater inlet safety valve quantity 3
Nominal diameter of reheater inlet safety valve mm F152
Throat diameter of reheater inlet safety valve mm F114
Exhaust volume of reheater inlet safety valve
kg/h 191,200/193,300/197,300
(each)
Popping pressure of reheater inlet safety valve MPa.g 4.384/4.428/4.516
Reseating pressure of reheater inlet safety valve MPa.g 4.209/4.251/4.335
Manufacturer of reheater inlet safety valve DRESSER, CROSBY
ASME
of reheater inlet safety valve
Type of reheater outlet safety valve Spring type
Quantity of reheater outlet safety valve set 2
Nominal diameter of reheater outlet safety valve mm F150
Throat diameter of reheater outlet safety valve mm /
Exhaust volume of reheater outlet safety valve
kg/h 148,000/155,000
(each)
Popping pressure of reheater outlet safety valve MPa.g 4.105/4.311
Reseating pressure of reheater outlet safety valve MPa.g 3.941/4.138
Manufacturer of reheater outlet safety valve DRESSER, CROSBY
ASME
of reheater outlet safety valve
7 Sootblower and flue gas temperature probe
Hubei Diamond
Sootblower manufacturer
Shanghai Clyde
Type of furnace sootblower Retractable
Length of furnace sootblower m 0.86
Quantity of furnace sootblowers set 80
Type of convection heating surface sootblower Long retractable
Length of convection heating surface sootblower m ~7.0
Quantity of convection heating surface
set 24
sootblower
Type of economizer area sootblower Semi-retractable
Length of economizer area sootblower m ~3.5
Quantity of economizer area sootblower set 6
Type of air preheater sootblower Retractable
Length of air preheater sootblower m 4
Quantity of air preheater sootblower set 2/each boiler
Quantity of each boiler’s sootblower set 112 (including air preheater)
Quantity of sootblower holes reserved for furnace
and convection heating surface on the furnace /
wall
Steam source of sootblower Boiler proper
Manufacturer of pressure relief valve of pressure
Import
relief station
Type of pressure relief valve of pressure relief
/
station
Nominal diameter of pressure relief valve of
mm DN125
pressure relief station
Steam pressure at the inlet of pressure relief valve
MPa.g 18.1
of pressure relief station
Steam pressure at the outlet of pressure relief
MPa.g 3.1
valve of pressure relief station
Air supply amount of pressure relief valve of
t/h 19
pressure relief station
Drainage type of pressure relief valve of pressure
Temperature controlled
relief station
Manufacturer of pressure relief valve of pressure
Inlet
relief station
Type of flue gas temperature probe Retractable
Hubei Diamond Shanghai
Manufacturer of flue gas temperature probe
Clyde
Quantity of flue gas temperature probe set 2
Primary element type of flue gas temperature
/
probe
Temperature range of flue gas temperature probe ℃ 0~570
1.5 Steam and water quality criteria
Attached table 1-10
Index Description
Item
Boiler water Steam
Phosphate radical 0.5~3mg/L
Chlorine ion 1mg/L
Total salt content 20mg/L
Conductivity (25℃) 50s/cm 0.3s/cm (after hydrogen exchange, 25℃)
Silicon dioxide 0.25mg/L 20g/kg
PH 9~9.5
Na 10g/kg
Silicon dioxide
Iron 20g/kg 20g/kg
Copper 5g/kg 5g/kg
1.6 Relative thermodynamic system
(1) Main steam and reheated steam system
Main steam and reheated steam systems are both unit systems. Cold reheated steam is also as the standby
steam source for steam-driven feed water pump during unit startup and under low load as well as one of
steam sources of auxiliary steam system. Turbine bypass adopts HP & LP second stage serial bypasses with
capacity of 60% BMCR, so that the boiler can automatically reduce load during load rejection under
BMCR operating condition.
(2)Regenerative steam extraction system
Turbine adopts eight-stage non-regulated steam extraction, in which the first three stages are used for three
HP heaters respectively, the fourth stage is used for feed water pump turbine, deaerator and auxiliary steam
and the last four stages are used for four LP heaters respectively.
(3) Feed water system
Feed water system is a unit system. One boiler has two steam feed water pumps of 50% BMCR which is
used for normal operation, and one motor-driven variable speed feed water pump of 50% BMC which is
used for startup and as a standby. Bypass of feed water operating floor is 30% BMCR. Feed water system
also supplies attemperating water to reheater, attemperator, attemperator of the superheater and high
pressure bypass system.
(4) Condensate system
Condensate system adopts medium pressure condensate polishing system and each set of unit is equipped
with two condensate pumps of 100%, in which one is for standby application. Condensate will enter
deaerator after pressure raise by condensate pump through polishing device, one shaft seal heater and four
LP heaters.
Each boiler has one condensate make-up water tank and make-up pump to provide make-up water and
startup water for condensate system, as well as make-up water and storing water for water level control of
condenser hot well water level. Make-up pump is also used as boiler feed water pump during unit startup.
(5) Cooling water system of auxiliary machinery
Cooling water system of auxiliary machinery in this project is composed of open circulating cooling water
system and closed circulating cooling water system. Closed circulating cooling water system adopts
demineralized water mainly for cooling parts with relatively higher requirements for water quality, such as
rotating mechanical bearing, motor and etc. While, open circulating cooling water system comes from
circulating water system, mainly cooling surface type heat exchanger and etc. In order to save water, all
cooling water is considered to be complete recovered. Preliminary design parameters of cooling water
system are as follows:
System Design Pressure (MPa) Design Temperature (℃) Water Quality Remarks
Open circulating ~0.41 36 Circulating water
cooling water
Closed circulating ~0.5 41 Demineralized
cooling water water
1.7 Meteorological and geographical conditions of the plant
The construction site of this project is in a climate of high temperature and humidity.
Plant location: Korba District of Chattisgarh, India.
Power plant altitude: 295-300m above MSL (mean sea level)
Atmospheric pressure: 101.3kPa (provisional) according to the altitude
Extreme maximum temperature: 49℃
Extreme minimum temperature: 8℃
Design temperature: 8~50℃
Design temperature of electrical equipment: 50℃
Relative humidity:
Max. 90%
Min. 49%
Design 60%
Mean annual precipitation: 1200mm
Basic wind speed: as per Indian standard (IS-875), 10m high above the ground, once 50 years and
maximum wind speed with 3s is 39m/s.
Earthquake intensity: VII
Earthquake acceleration: 0.15g (as per IS-1893: zone-II)
Site-soil type: Type II (provisional)
Chapter 2 Auxiliary Equipment Specification
1. Forced draft fan

1.1 Introduction of forced draft fan
1.1.1 Version: adjustable moving blade axial-flow fan
1.1.2 Quantity: two sets per boiler
1.1.3 Operating mode: parallel operation of two fans
1.1.4 Adjusting mode: moving blade
1.1.5 Arrangement: horizontal and symmetrical arrangement, vertical air intake and horizontal air out
1.1.6 Installation site: outside in the open air
1.2 Performance guarantee
1.2.1 Air quantity (at test block (TB), 48℃): 132.2m3/s; 139.07kg/s
1.2.2 Total pressure rise (at test block (TB), 48℃): 4,410Pa
1.2.3 Total pressure rise ratio of the fan (under BMCR operating condition): 87.44%
1.2.4 Power consumption of the fan (under BMCR operating condition): 451kW
1.2.5 Total pressure rise ratio of the fan (under BRL operating condition): 87.15%
1.2.6 Power consumption of the fan (under BRL operating condition): 381kW
1.2.7 Deviation value of working point (under BRL operating condition) to stall line: > 10%
1.2.8 Stall margin of working point (under BRL operating condition): > 1.3
1.2.9 Stall margin of working point (at test block (TB)): > 1.3
1.2.10 First critical speed of fan: 1,937r/min
1.2.11Root mean square value of fan bearing vibration velocity: 4.6mm/s
1.2.12 Operating time of whole moving blade adjustment: 30s
1.2.13 Noise level (at 1m from fan casing): 85dB (A)
1.2.14 Temperature rise of fan bearing: 40℃
1.2.15 Final evaluation grade of rotor dynamic balance: G4
1.3 Performance data of forced draft fan
Operating Condition TB Operating BMCR Operating BRL Operating
Condition Condition Condition
Coal Design Check Design Check Design Check
Item Coal Coal Coal Coal Coal Coal
Fan inlet volume flow (m3/s) 132.2 108.9 99.26
Fan inlet mass flow (kg/s) 139.07 119.57 109
Fan inlet temperature (℃) 48 34.5 34.5
Inlet air density (kg/m3) 1.052 1.098 1.098
Fan inlet total pressure (Pa) -442 -364 -337
Fan inlet static pressure (Pa -442 -364 -337
Fan outlet total pressure (Pa) 3,968 3,308 3,046
Fan outlet static pressure (Pa) 3,833 3,213 2,967
Fan total pressure rise (Pa) 4,410 3,672 3,383
Fan static pressure rise (Pa) 4,275 3,577 3,304
Fan outlet temperature (℃) 52.75 38.27 38
Loss of fan accessories (Pa) Included in the loss of system
Fan total pressure efficiency (%) 86.85 87.44 87.15
Fan shaft output (kW) 661 451 381
Fan speed (r/min) 1,490
Notes:
① TB (test block) is the check point of the fan performance, such as air quantity, air pressure.
② BMCR is the operating condition of 1,025T/H boiler maximum continuous rating.
③ BRL is the operating condition equal to 90% BMCR of the boiler, which is the check point of fan
efficiency.
1.4 Technical data of forced draft fan
No. Item Unit Value
1 Fan model FAF19-10-1
2 Fan adjusting device model 100Nm 4-20mADC
3 Impeller diameter mm 1884
4 Shaft material 35CrMoA
5 Wheel boss material 15MnV
6 Blade material HF-1
7 Impeller stage stage 1
8 Blade quantity at each stage piece 16
9 Blade adjusting range degree -30~25
10 Specific speed --
11 Cylinder bore and travel of hydraulic cylinder mm/mm 336/50
12 Rotor weight kg 1800
13 Moment of inertia of rotor kg m2 144
14 First critical speed of fan rpm 1937
15 Material/wall thickness of air inlet box /mm Q235A/5
16 Material/wall thickness of the casing /mm Q235A/14
17 Material/wall thickness of the diffuser /mm Q235A/5
18 Fan bearing type Roller bearing
19 Bearing lubricating type Thin oil
20 Bearing cooling type Oil bath + forced-oil circulation
21 Bearing pad cooling capacity t/h None
22 Fan rotating direction (see from the motor side) anti clockwise
23 Silencer resistance Pa < 200
24 Total weight of the fan kg 10000
25 Max lifting weight during mounting (part name) kg 3700
26 Max lifting weight during mounting m 4.2 (from fan axis)
27 Max lifting weight during maintenance (part name) Kg 1800
28 Max lifting weight during maintenance M 4.2 (from fan axis)
2. Induced draft fan
2.1 Introduction of induced draft fan
2.1.1 Type: adjustable static-blade axial-flow fan
2.1.4 Adjusting mode: fixed blade
2.1.5 Arrangement: horizontal and symmetric arrangement, vertical air inlet and horizontal air outlet; the
cooling fans of two fans and the electric actuator of adjustable front guide blade are at the same side viewed
from the motor.
2.2.1 Air quantity (at test block (TB), 135.59℃): 322.7 m3/s; 234.47kg/s
2.2.2 Total pressure rise (at test block (TB), 135.59℃): 5886Pa
2.2.3 Total pressure rise ratio of the fan (at test block (TB)): 83.85%
Power consumption of the fan (at test block (TB)): 2,216kW
Power consumption of the fan (under BRL operating condition): 1,446 kW
2.2.5 Deviation value of working point (under BRL operating condition) to stall line: > 10%
Stall margin of the working point (under BRL operating condition): > 1.3
Stall margin of the working point (under TB operating condition): > 1.3
2.2.6 First critical speed of fan: 1280.5r/min
2.2.7 Root mean square value of fan bearing vibration velocity: 4.6mm/s
2.2.8 Operating time of whole moving blade adjustment: 30~45s
2.2.9 Noise level (at 1m from fan casing): 85dB(A)
2.2.12 Service life of the blade: 70,000 h
2. 3 Performance data of induced draft fan
Operating Condition TB Operating Condition BMCR Operating BRL Operating
Condition Condition
Coal Item Design coal Check Design Check Design Check
coal coal coal coal coal
Fan inlet mass flow (kg/s) 234.92 235.04 216.99
Fan inlet temperature (℃) 135.59 120.59 120.59
Inlet flue gas density (kg/m3) 0728 0.879 0.879
Fan inlet total pressure (Pa) -5,520 -4,600 -4,515
Fan inlet static pressure (Pa) -5,520 -4,600 -4,515
Fan outlet total pressure (Pa) 366 305 259
Fan outlet static pressure 366 305 259
(Pa)
Fan total pressure rise (Pa) 5,886 4,905 4,774
Fan static pressure rise (Pa) 5,886 4,905 4,774
Fan outlet flue gas 145.04 127.34 127.24
temperature (℃)
Loss of fan accessories (Pa) Included in system loss
Fan total pressure efficiency 83.85 80.99 80.07
(%)
Fan shaft output (kW) 2,216 1,590 1,446
Fan speed (r/min) 985
2.4 Technical data of induced draft fan

No. Item Unit Value
1 Fan model G158/265
2 Fan adjusting device type Variable static blade
3 Impeller diameter mm 2650
4 Shaft material 35CrMo
5 Wheel boss material 15Mn
6 Blade material 15Mn
7 Blade working life Hour ≥70,000
8 Impeller stage Stage 1
9 Blade quantity of each stage Piece 14
10 Specific speed
11 Blade adjusting range Degree -70~+33
12 Rotor weight kg 8,500
13 Moment of inertia of rotor Kg·m2 2,704
14 First critical speed of fan r/min 1,280.5
15 Material/wall thickness of air inlet box /mm Q235/8
16 Material/wall thickness of the casing /mm Q235/22
17 Material/wall thickness of the diffuser /mm Q235/8
19 Bearing lubricating type Grease lubrication
20 Bearing cooling type Forced cooling by cooling fan
21 Bearing pad cooling capacity t/h
22 Fan rotating direction (see from the motor side) Counter-clockwise rotation
23 Total weight of the fan kg 30,000
24 Cooling fan type/quantity 2
25 Cooling fan power kW 5.5
26 Air quantity and air pressure of cooling fan
27 Max lifting weight /height during mounting kg/m 18,000/5
28 Max lifting weight/height during maintenance kg/m 8,500/5
3. Primary air fan
3.1 Introduction of primary air fan
3.1.1 Version: Adjustable moving blade axial-flow fan
3.1.4 Adjusting mode: moving blade adjustment
3.1.5 Arrangement: horizontal and symmetrical arrangement, vertical air intake and horizontal air out
3.2.1 Air quantity (at test block (TB), 48℃): 95.8m3/s; 100.78kg/s
3.2.2 Total pressure rise (at test block (TB), 48℃): 17,015Pa
Power consumption of the fan (under BMCR operating condition): 963kW
Power consumption of the fan (under BRL operating condition): 902kW
3.2.5 Deviation value of working point (under BRL operating condition) to stall line: >10%
Stall margin of the working point (under BRL operating condition) : >1.3
Stall margin of the working point (under TB operating condition) : >1.3
3.2.6 First critical speed of fan: 1937r/min
3.2.8 Operating time of whole moving blade adjustment: 30s
3.2.9 Noise level (1m away from fan casing): 85dB (A)
3.3 Performance data of primary air fan
Coal Design Check Design Check Design coal Check
coal coal coal coal coal
Fan inlet mass flow (kg/s) 100.78 74.8 71.96

Fan inlet temperature (℃) 48 34.5 34.5
Inlet air density (kg/m3) 1.052 1.098 1.098
Fan inlet total pressure (Pa) -469 -348 -337
Fan inlet static pressure (Pa) -469 -348 -337
Fan outlet total pressure (Pa) 16411 12669 12317
Fan outlet static pressure (Pa) 16276 12598 12251
Fan total pressure rise (Pa) 16880 13017 12654
Fan static pressure (Pa) 16745 12946 12588
Fan outlet air temperature (℃) 65.4 47.7 47.5
Loss of fan accessories (Pa) Included in system loss
Fan total pressure efficiency (%) 86.56 88.11 88.07
Fan shaft output (kW) 1749 986 934
Fan speed (r/min) 1490
3.4 Technical data of primary air fan
No. Item Unit Value
1 Fan model PAF18-13.3-2
2 Fan adjusting device model 336/50
3 Impeller diameter mm 1,900
4 Shaft material 35CrMoA
5 Wheel boss material 15MnV
6 Blade material HF-1
7 Impeller stage Stage 2
8 Blade quantity at each stage Piece 28
9 Blade adjusting range Degree -25~15
10 Cylinder bore and travel of hydraulic cylinder mm/mm 336/50
11 Rotor weight kg 6,500
12 Moment of inertia of rotor Kg.m2 409
13 First critical speed of fan r/min 1,937
16 Material/wall thickness of the diffuser /mm Q235A/5
18 Bearing lubricating type Thin oil
19 Bearing cooling type Oil bath + forced-oil circulation
20 Bearing pad cooling capacity t/h None
21 Fan rotating direction (see from motor side) Anti clockwise
22 Silencer (vertical) resistance Pa 200
23 Total weight of fan kg 16,000
24 Max lifting weight/height during mounting Kg/m 7,500/4.5
25 Max lifting weight/height during maintenance Kg/m 3,500/4.5
4. Seal fan
4.1 Introduction of seal fan
4.1.1 Version: Centrifugal fan
4.1.3 Operating mode: parallel operation of two fans, one set operates and the other set is for standby
application, sealing air is from cold primary air duct.
4.1.4 Arrangement: it is a right rotating fan when the impeller rotates clockwise, viewed from motor side;
contrarily, it is a left rotating fan. Each boiler has one right rotating fan and one left rotating fan, with
horizontal air inlet and vertical air outlet of 90 degrees.
4.2.1 Air quantity (under test block (TB), 50℃): 9.94m3/s;10.4kg/s
4.2.2 Total pressure rise (under test block (TB), 50℃): 9,000Pa
Power consumption of the fan (under BMCR operating condition): 92.6kW
4.2.4 Deviation value of working point (under BRL operating condition) to stall line: 10%
4.2.5 First critical speed of fan: 1,924 r/min
4.2.7 Operating time of whole moving blade adjustment: 30~45s
4.2.8 Noise level (1m away from fan casing): 85dB (A)
4.3 Performance data of seal fan
Coal Design coal Check Design coal Check Design coal Check
Item coal coal coal
Fan inlet volume flow (m3/s) 9.94 9.04
Fan inlet mass flow (kg/s) 10.4 9.93
Fan inlet temperature (℃) 50 34.5
Inlet air density (kg/m3) 1.046 1.098
Fan inlet total pressure (Pa) 326.1 283.1
Fan inlet static pressure (Pa) 0 0
Fan outlet total pressure (Pa) 9326.1 7,783.1
Fan outlet static pressure (Pa) 9,000 7,500
Fan total pressure rise (Pa) 9,000 7,500
Fan static pressure rise (Pa) 9,000 7,500
Fan outlet air temperature (℃) 59.95 43.69
Loss of fan accessories (Pa) 26.4 22.9
Fan total pressure efficiency 82.7 71.5
(%)
Fan shaft output (kW) 105.1 92.6
Fan speed (r/min) 1,480 1,480
4.4 Technical data of seal fan
No. Item Unit Value
1 Fan model 2378A/645
2 Fan adjusting device model
3 Impeller diameter mm 1,529
4 Shaft material 45
5 Wheel boss material 16Mn
6 Blade material 16Mn
7 Impeller stage stage 1
8 Blade quantity at each stage piece 10
9 Blade adjusting range degree 0~90
10 Rotor weight Kg 1,600
11 Moment of inertia of rotor Kg.m2 121
12 First critical speed of fan r/min 1,924
16 Bearing lubricating mode Oil-bath self-lubrication
17 Bearing cooling mode Water cooling
18 Bearing pad cooling capacity t/h 1
19 Fan rotating direction (see from motor side)
20 Silencer resistance Pa 200
21 Total weight of fan kg 11000
22 Max lifting weight/height during mounting kg /2.3
m
23 Max lifting weight/height during maintenance kg /2.3
m
5. Technical specification of air preheater
No. Equipment Name Specification Type Material
Heat transfer Intermediate 0.5mm DL3f type Q215-A.F
component layer of hot end
Cold end 1.2mm DL3f type CORTEN steel
Radial seal leaf δ= 2.5mm CORTEN steel

1 Air preheater
Rotor seal - hot
end and cold Rotor center
δ= 6 mm CORTEN steel
end drum seal leaf
Axial seal leaf δ= 2.5mm CORTEN steel

Bypass seal leaf δ= 1.5mm CORTEN steel
Drive device
The normal rotating speed of output shaft is 0.9 rpm
Reducer
Double shaft
Model Y160L-6 B5
extension
Voltage 415 V
Main motor Current 17 A
Power 11 kW
2
Rotating speed 970 r/min
Double shaft
Model Y160L-6 B5
extension
Voltage 415 V
Auxiliary Current 17 A
motor
Power 11 kW
Rotating speed 970 r/min
Normal rotating speed of rotor: 0.9RPM; rotor rotating speed at low gear, adopting inverter speed
regulation: 0.3RPM.
Supporting Type Roller radial-thrust bearing
bearing Model 294/500E
Lubricating Volume 43.5 L

oil capacity
The minimum viscosity at maximum operating temperature is 1000SSU
Double row self aligning spherical
3 Guide Type
roller bearing:
bearing
Model 23072CCK/W33
Lubricating Volume 150 L

oil capacity
The minimum viscosity at maximum operating temperature is 1,000SSU
Recommended lubricating oil of guide bearing and supporting bearing is middle load or heavy load
extreme-pressure industrial gear oil of N680 ~1000#.
4 Sootblower Steam sootblower
Water
5 cleaning Multi-nozzle fixed type purge pipe
device
6. Specification list for pulverizing system equipment
No. Name Specification Remarks
Model: CS2024HP
Delivery capacity: 18.42-91.62t/h
Coal feeding distance (center line distance of coal feeder inlet and
outlet): 3,050mm
Installation site: bunker bay, 17.0m layer
Elevation of interface between inlet coal gate and bunker outlet:
+21.5m
Bunker outlet dimension: φ1000×10mm (provision)
Elevation of interface between outlet coal gate and coal pulverizer
inlet: +11.025 (provision)
Electric
Dimension of coal chute interface in coal pulverizer: φ950×10mm 5 sets per
1 weighing coal
(provision) boiler
feeder
Calculating precision: ±0.25%
Control precision: ±0.5%
Output interface of instrument: RS232/485, 4~20mA, solid state relay
pulse output
Alarm contact: in case of coal interrupt, there will be 4~20mA current
output, temperature alarm, coal jamming delay, belt side skid and 220V
AC5A contact rating.
Motor model: GT9350907
Power supply: 415V, three phase 50Hz
Power: 3kW
Scavenging Motor model: GT9361507
2 machine of Power: 0.25kW 5 sets
coal feeder Voltage: 415V, three phase 50Hz
3 Coal Item Unit Coal 5 sets per
pulverizer & Design Worst furnace
speed reducer coal coal
Coal pulverizer Max output t/h 76.35 73.67
output power Calculated output (BMCR) t/h 54.55 60.65
Guaranteed output t/h 60.61 67.32
Min output t/h 19.09 18.42
Coal pulverizer Max air quantity t/h 105.2 106.95
air quantity Circulated ventilation t/h 91.2 98.14
quantity (BMCR)
Air quantity of guaranteed t/h 95.07 102.65
output situation
Min air quantity t/h 68.36 69.52
Coal pulverizer Max ventilation resistance Pa 7.35k
ventilation Ventilation resistance Pa 6.39k 6.95k
resistance (guarantee output)
Calculated ventilation Pa 6.02k 6.53k
resistance (BMCR)
Unit power Unit power consumption of Kw. 12.67 12.36
consumption of coal pulverizer (BMCR) h/t
coal pulverizer
Unit power consumption in Kw. 12.10 11.85
guaranteed output situation h/t
Coal pulverizer grinding pan speed: 22.3r/min
Coal pulverizer rotation direction: clockwise (top view)
Sealing air quantity: 81.52 Nm3/min
D-value between sealing air pressure and primary air pressure: 2000Pa
Rated air quantity of coal pulverizer: 18.80kg/s
Electric power consumption of coal pulverizer: 6~10kW·h/t
Motor rated power: 1000kW
Motor rated speed: 990r/min
Rated voltage: 6.6kV
Frequency: 50Hz
Lubrication cooling device (model): XYZ350-L
Oil pump flow: 350 l/min
Motor power: 7/11
Normal oil supply pressure: 0.13mpa
Name of lubricating oil: N320
Hydraulic loading device (model)
Oil pump flow: 15l/min
Motor power: 7.5kw
Normal oil supply pressure: 14MPa
Model: XYZ-250L vertical type

Rated flow: 240L/min
Working pressure: ≥0.13MPa
Oil supply temperature: 28~45℃
Working medium: N320 sulfur-phosphorous type heavy-duty
EP industrial gear oil
The
Filter area: 1.3m2
motor is
Thin oil Filter rating: 0.025mm
6 double-
station Original differential pressure: ≤0.03MPa
speed
Cooling surface area: 13 m2
motor
Water inlet temperature: 20~34℃
Water inlet pressure: 0.2~0.4MPa
Water flow: 360L/min
Heating power: 10kW
Motor power: 5/7.5kW
Motor speed: 720/1450r/min
7 High pressure Oil tank volume: 800L
oil station Oil pump model: PFG-327/D
Max flow: 14.8L/min
Max working pressure of oil pump: 17MPa
Direction of rotation: clockwise as view from the pump shaft end
Motor model: Y160L-8
Power: 7.5kW
Speed: 720 r/min
7. Specifications for the burner are as follows:

All-swinging direct-flow type, for the 20 coal nozzles, arranged on
swinging angle, the primary air nozzle is four corners for 5 layers.
±25° and the secondary air nozzle is ±30°.
Pulverized coal That is 2 secondary air
1
burner nozzles on each group of
Over-fire air chamber nozzle angle is
burner, which may be
adjustable.
operated through the manual
swing mechanism on the top.
Steam atomizing oil gun, each with the 4 pieces arranged in the same
output 2.23t/h, pressure 1.37MPa, atomized layer in each secondary air
2 Heavy oil burner steam pressure 0.88MPa, temperature higher nozzle on the fourth layer and
than 250℃ and steam consumption 290kg/h. the eighth layer from the
Thermal power of one oil gun is 29.45MW. below, 8 pieces in all.
4 pieces arranged in the same
Mechanical atomized oil gun, each with the layer in each secondary air
output 1.65t/h, pressure 2.94MPa, steam nozzle on the second layer
3 Light oil burner
purging pressure 0.686-0.784MPa and from below.
temperature higher than 250℃.
High-energy igniter: model XDH-12, output 1 piece for the heavy and
4 Igniter
voltage: 2,500V and spark frequency: 9-15’/s light oil burner each.
Sectional area of nozzle:
Air ratio: 27.5%
5 Primary air
Air speed: 27m/s
Primary air temperature: 316℃
Sectional area of nozzle:
Air ratio: 67.5%
6 Secondary air
Air speed: 47m/s
Air temperature: 331℃
Total pressure: 5.0kPa
2 sets for each furnace, which
Output: 3,500m3/h
Flame test probe must operate when the
7 Voltage: 415V
cooling fan furnace temperature is higher
Speed: 2,900r/min
than 150℃.
Capacity: 11kW
8. Specification table for flue gas temperature probe
No. Equipment Item Specification Unit
Type TS-0 Flexible-type
Quantity 2 set/furnace
Flue gas temperature Advance speed 1.44 m/min
1
probe Travel 4,800 mm
Max measured temperature 570 ℃
Exit temperature 538 ℃
Flue gas temp. probe Voltage 380 V
2
motor Power 1.1 kW
9. Specification for steam air heater

9.1 General description of steam air heater design
It takes wholly-rolled spiral gilled tube as the basic heat transfer element, which has good heat transfer
effect and low resistance, etc. advantages.
Boiler steam air heater mainly consists of heat transfer tube bundles, steam header, drain header and frame.
The heat transfer tube bundles are staggered and the steam in tube crosses the air out of tube once to
convert and exchange heat forcibly. The air heater is of drawer type structure, heat transfer components can
be drew out from the inside of steam air heater frame for the convenience of maintenance; each piece of air
heater is welded so that there is no leakage. Air heater steam inlet is on the same side of 3400 with water
outlet.
9.2 Technical data related to steam air heater are as follows:
No. Item Unit Secondary air heater
1 Model of steam air heater —— GNWCS-1.5/350-340
2 Quantity of sheets in parallel connection Sheet 1
3 Quantity of sheets in series connection Sheet 2
4 Designed pressure of steam air heater MPa.g 0.87 (provision)
5 Designed temperature of steam air heater ℃ 349 (provision)
6 Air side resistance of steam air heater Pa <150
7 Heat exchange area of steam air heater m2 340
3,400×2,800 (outer wall) ×5 (wall
8 Interface dimensions of steam air heater mm
thickness)
9 Steam consumption of air heater t/h 4.9
10 Air input of each air heater Nm3/h 337236.65
10. Specification of sootblower equipment
10.1 Parameter table of sootblowing steam
　　　Item　 Name Pressure Temperature Steam Source
Boiler proper sootblowing 2.5MPa after pressure 334℃ after pressure Outlet of division wall
relief station relief station superheater
Boiler proper sootblower 1.0-1.5MPa <250℃ Outlet of rear platen
superheater (auxiliary steam
during startup)
Air preheater sootblowing 2.5MPa after pressure 421℃after pressure
relief station relief station
Air preheater sootblower 1.0-1.5MPa <350℃
10.2 Specification table for sootblower

No. Equipment Item Spec. Unit
Qty 80 Piece
Sootblowing travel 300 mm
Furnace Sootblowing time 540 mm/min
1
sootblower Sootblowing pressure 0.8-1.5 MPa
Position Water-cooled wall
Type Furnace sootblower V40
Qty 24 piece
Long retractable
2 sootblower PS- Sootblowing time 1440 mm/min
SL
Sootblowing pressure 1.38 MPa
Type Long retractable sootblower PS-SL
Qty 6
Sootblowing travel
Semi-retractable
3 Sootblowing time
sootblower
Sootblowing pressure
Type Semi-retractable type
4 Air preheater Qty 2 Piece
sootblower
Sootblowing time 780 s
Sootblowing pressure 1.0-1.5 MP
No. Equipment Item Spec. Unit
Type Rotary sootblower PS-AT
11. Fuel system equipment specification

11.1. Fuel tank capacity:
Light oil tank capacity: V=200m3 Qty: 1
Heavy oil tank capacity: V=1,000m3 Qty: 2
Heavy oil daily tank capacity:V=200m3 Qty: 1
11.2. Brief characteristics of equipment
Light Oil Feed Light Oil Drain Dirty Oil Heavy Oil Feed Heavy Oil Drain
Item
Pump Pump Pump Pump Pump
Model 50AY35×12 65AY60A 2CY-2/0.6 YSNH660-46 YSNH660-51
Hydrous dirty
Medium LDO LDO HFO，55℃ HFO，55℃
oil: 55
Multi stage Volumetric oil Gear type oil Worm type oil Worm type oil
Type
centrifugal type pump pump pump pump
Set 3 2 1 3 2
Pressure head 4.3MPa 0.4MPa 0.5MPa 3.0MPa 1.0MPa
Output 11m3/h 24m3/h 2m3/h 35m3/h 40m3/h
Shaft output 32.2kW 5.1kW 1.1kW 35.2kW 16.4kW
Rotating
2,970r/min 2,900r/min 1,420r/min 1,450r/min 1,450r/min
speed
Motor type YB225M-2 YB160M1-2 YB100L1-4 YB225M-4 YB180L-4
Power 45kW 11kW 2.2kW 45kW 22kW
Voltage 415V 415V 415V 415V 415V
Rotating
2,970r/min 2,900r/min 1,420r/min 1,470r/min 1,470r/min
speed
11.3. Characteristics of accessory equipment of fuel oil system

11.3.1 Technical data of oil filter of light oil pump
For Light Oil Feed For Light Oil Drain
Content Unit For Dirty Oil Pump
Pump Pump
SDGLQ-11T-60
1 Model SDGLQ-24T-30 mesh SDGLQ-2T-50 mesh
mesh
Vertical single-barrel Vertical single-barrel Vertical single- barrel
2 Type
type type type
3 Quantity set 3 2 1
4 Working medium Light oil Light oil Light dirty oil
Mesh
5 Filter fineness 60 30 50
/inch
6 Design pressure MPa 1.6 1.6 1.6
7 Design temperature ℃ 120 120 120
8 Design flow m3/h 11 24 2
Differential pressure of
9 inlet and outlet during MPa 0.02 0.02 0.02
normal operation
Size of inlet and outlet
10 mm φ76×5.5 φ133×4.0 φ58×4.0
connection
Material and service life
11 1Cr18Ni9Ti/12 years 1Cr18Ni9Ti/12 years 1Cr18Ni9Ti/12 years
of filter element
Material of casing &
12 Q235A Q235A Q235A
support
13 Weight Kg 56 86 38
14 Dimension mm φ450×840 φ440×1025 φ320×580
11.3.2 Technical data table of oil filter for heavy oil pump
For Heavy Oil Feed For Heavy Oil
Content Unit For Sewage Pump
Pump Drain Pump
SDGLQ-35T-60 SDGLQ-40T-30
1 Model SDGLQ-13T-30 mesh
mesh mesh
Vertical single- Vertical single-
2 Type Vertical single- barrel
barrel barrel
3 Quantity Set 3 2 1
4 Working medium Heavy oil Heavy oil Sewage
Mesh
5 Filter fineness 60 30 30
/inch
6 Design pressure MPa 1.6 1.6 1.6
7 Design temperature ℃ 120 120 120
8 Design flow m3/h 35 40 12.5
Differential pressure of
9 inlet and outlet during MPa 0.02 0.02 0.02
normal operation
Size of inlet and outlet
10 mm φ133×4.0 φ133×4.0 φ76×5.5
connections
Material and service life 1Cr18Ni9Ti/12 1Cr18Ni9Ti/12
11 1Cr18Ni9Ti/12 years
of filter element years years
Casing & supporting
12 Q235A Q235A Q235A
material
13 Weight Kg 126 162 56
14 Dimension mm φ500×1,050 φ650×1,115 φ450×840
12. Air cannon specification
Cone part of single coal bunker is equipped with eight air cannons (the capacity of 150L); there are four air
cannons on the upper of the cone (the capacity of 220L), air cannon adopts local/remote control. Air cannon
should be controlled by hierarchy, group and bunker and etc.
12.1 Main technical specification
Main technical specification
Working pressure: 0.4~0.8MPa
Working medium: compressed air
Container class: First class
Design temperature: -20~50℃
Nominal volume: 150L/220L
Hydraulic test pressure: ≥1.1MPa
Impact force: 10000N/14080N
Explosion energy: 20400kgfm/35600 kgfm
Design service life: 30 years
PART 2 Boiler Unit Stadrtup
Chapter 1 Trial Operation & Test of Main Equipment of Boiler after
Inspection & Repair
1.1 Trial operation of auxiliary machinery after inspection and repair
1.1.1 Check before trial operation
1) The check before trial operation of auxiliary machinery shall be done according to the check
requirements before startup on each post.
2) Make sure the inspection and repair of both each auxiliary machinery and electric equipment thereof is
finished, work sheets have been recalled, each damper, baffle and rotating machinery of the air, flue gas
system and pulverizing system all have been calibrated and are in good condition; the main equipment and
related lubricating oil, hydraulic oil and cooling system, as well as each instrument all meet the
requirements for startup; the motor connections are in good condition.
3) After checking it is normal, switch on the motive power source and operating power source and air
source, and put each protection and related instrument and interlocker thereof into operation.
1.1.2 Requirements in trial operation
1) The motor shall be operated in trial operation at no load in correct direction of rotation with the no load
current of motor recorded before the trial operation of auxiliary machinery.
2) When the trial operation of auxiliary machinery is operated, monitor the startup current, the duration of
max startup current and the no load current after return, and keep a record of them.
3) Each set of auxiliary machinery shall be started at no load so as to guarantee the safety of equipment.
4) When the induced draft fan, forced draft fan and primary air fan are operated, the load adjustment test
and max load test under each operating condition shall be carried out and the current shall not exceed the
rating.
5) The continuous trial operation duration of the induced draft fan, forced draft fan and primary air fan shall
not be less than 4 hours; the continuous trial operation duration after replacing main parts shall not be less
than 8 hours (or fixed according to the requirements for inspection and repair, but the record must be kept).
6) When each set of auxiliary machinery of the pulverizing system is operated, make sure there is no
pulverized coal deposit and self-ignition phenomenon.
7) If any abnormal case is founded during trial operation, the running must be stopped immediately and can
be restarted after ascertaining the causes and removing the fault.
8) Each protection and related interlocking test of auxiliary machinery must be finished before trial
operation of the power equipment.
1.2 General rules for the interlocking test & protection test of boiler
1.2.1 The interlocking test and protection test must be performed to the boiler that went through overhaul
and minor repair.
1.2.2 Each interlocking and protection test can be done only as applied by the troubleshooter and approved
by the shift engineer. During the test, the unit supervisor and electric, thermodynamic engineers and related
personnel must be present, and any problem shall be removed in case of being found until passing the test.
1.2.3 The test method includes two types, static and dynamic. During dynamic test, the operating power
source and motive power source all are switched on, but during static test, operating power source is only
switched on for the 6.6kV motor and motive power source is only switched on for the 415V low-voltage
motor. The dynamic test can only be done after static test normal, but is not done generally (if necessary, it
shall be approved by the chief engineer).
1.2.4 The test can be done after the interlocker and protection switch of boiler are switched off.
1.2.5 The electric interlocking and heat engine protection test shall be operated accurately and reliably.
1.2.6 When the unit is operated normally, it is strictly forbidden to switch off the electric interlocking and
heat engine protection; if necessary, the switch off shall be approved by the shift engineer and restored
within a definite time.
1.3 Related thermodynamic and mechanical protection fixed values of boiler are as follows:
1) Steam drum water level:
High limit I +120mm Alarm
High limit II +240mm Boiler shutdown
Low limit I -180mm Alarm
Low limit II -330mm Boiler shutdown
Notes: when the steam drum water level is at +140mm, interlock to open emergency water discharge valve;
when the steam drum water level is at +50mm, interlock to close it.
2) Furnace pressure:
High limit I +980Pa
High limit II +3,240Pa Boiler shutdown
Low limit I -980Pa
Low limit II -2,490Pa Boiler shutdown
3) Fixed values of safety valve operating pressure are as follows:
Reseating Pressure
Name Operating Pressure (MPa)
(MPa)
Saturated I safety valve 19.82
Saturated II safety valve 20.22 19.03
Saturated III safety valve 20.41
Last stage superheater outlet I safety valve 18.31 17.58
Last stage superheater outlet II safety valve 18.34 17.61
Superheater outlet PCV valve 18.13 17.77
Reheater inlet I safety valve 4.384 4.209
Reheater inlet II safety valve 4.428 4.251
Reheater inlet III safety valve 4.516 4.335
Reheater outlet I safety valve 4.105 3.941
Reheater outlet II safety valve 4.311 4.138
4) Air quantity is low:
≤30% total air quantity of boiler rated load Boiler shutdown
5) Turbine trips and load is higher than 30% Boiler shutdown
6) Flame check cooling air pressure is low:
Difference between cooling air pressure and furnace pressure is ≤ 2kPa Boiler shutdown
1.4 Test of motor-operated valve, governing valve, damper and baffle
1.4.1 Contact the thermodynamic personnel to switch on the power source for each motor-operated valve,
governing valve, damper, flue gas damper and baffle servo, and the operators shall cooperate for test.
1.4.2 Check the position of changeover handles of each valve, damper, baffle servo; perform on-off tests to
all motor-operated valves and governing valves, the extent of opening indication shall conform to the actual
extent and direction, and the red and green indicator lamp shall indicate correctly; close control and manual
operation shall be on and off flexibly; remote control test and limit switch shall operate normally, for the
valve and damper with “OFF” button, their stop shall be normal by test; the pneumatically-operated device
shall operate flexibly, air inlet pressure be normal without any leak and abnormal phenomenon.
1.5 The interlocking protection tests of auxiliary machinery shall be done one by one according to the
requirements in the equipment interlocking test card.
1.6 Protection test of boiler FSSS (furnace safeguard supervisory system)
1.6.1 Oil leak test
The fuel oil piping leak test must be finished under the precondition of MFT (master fuel trip) resetting in
the process of boiler startup. The bypass oil leak test is strictly forbidden.
1.6.1.1 Oil leak test: the oil leak test can be done only when all the following conditions are met:
(1) Oil leak test failure signal has reset;
(2) Pressure of fuel oil mains is normal;
(3) No flame is detected;
(4) Trip valves of all oil burners have shut down;
(5) No condition existing for MFT trip.
When the above conditions are all met, the signal “Oil Leak Test 1 Start” will be made to start the leak test
process, the command for opening the fuel oil mains trip valve and oil return mains is made, start the 40S
timer, close oil return fast valve and close the fuel oil fast valve 10s later to fill the oil mains with oil and
raise its pressure, and provide a self-holding circuit so that even if the startup transient signal is lost, the
output signal will still continue. Make the pressure in the fuel oil mains up to the oil supply pressure within
40S (provided no leak). After 40S time out, if no signal of “Oil pressure is normal by the fuel oil leak test”
is made, then the signal of “Leak Test 1 Failure” is made and the test is cancelled; if the signal of “Oil
pressure is normal by the fuel oil leak test” is made, then the system is proved no leak, meanwhile, another
2-minute timer will be triggered. When this 2 minutes time out, if no signal of “Oil pressure is low by the
fuel oil leak test” is made, the system is proved no serious leak and the oil leak test 1 succeeds. Otherwise
there will be the signal of “Leak test 1 failure” and the test is cancelled.
1.6.1.2 Oil leak test 2
After the oil leak test 1 succeeds, if the conditions for oil mains leak test are met, the step 2 test may be
started. Open the oil return shut off valve of fuel oil mains to reduce the pressure of oil mains, when “Oil
pressure is low by oil mains leak test”, close the oil return shut off valve of fuel oil mains, trigger 2-minute
timer, the signal “Oil Leak Test 2 Start” is made after closing the oil return shut off valve of fuel oil mains.
If the signal of “Oil pressure is low by the fuel oil leak test” continues (not triggered) after time out, then
the signal of “Leak test 2 success” will be made. On the contrary, the signal of “Leak test 2 failure” will be
made and the test is cancelled.
The leak test 2 may be started and stopped individually on the basis of leak test 1 success.
1.6.2 Conditions for purging furnace:
The conditions for purging furnace that must be met are as follows:
Condition1:
(1) No flame is detected:
(2) Furnace pressure is normal;
(3) The safety fast valve of fuel oil mains has been closed;
(4) Trips of all oil burners have been closed;
(5) All coal pulverizers have been stopped;
(6) All primary air fans have been stopped;
(7) All precipitators have been stopped;
(8) No condition for MFT trip;
(9) Oil leak test succeeded;
(10) All coal feeders have been stopped;
(11) Flame test cooling air pressure is not low;
(12) At least one air preheater is operated;
(13) At least one induced draft fan is operated;
(14) At least one forced draft fan is operated;
(15) All outlet dampers of coal pulverizers have been closed;
(16) Steam drum level is normal;
(17) Boiler air quantity is not less than 30%
Condition 2:
(1) The swinging nozzle is horizontal;
(2) OFA damper baffle has been closed;
(3) Auxiliary air baffle is on Purge position.
When all conditions above are met, the signal of “Purge Permit” is met, here the button “Purge Start” may
be pressed, 5 minutes for purging boiler is started to be timed, if any condition for purge above is lost
during the 5 minutes, the purging shall be interrupted and the alarm shall be made, the boiler purging may
be restarted only when all conditions above are met with the 5 minutes retimed until time out.
When the 5 minutes for purging time out, a signal of “Purge Finish” shall be made which will reset the
memory signal of “MFT (master fuel trip)”
1.6.3 Related operating commands & condition description of furnace front oil system
1.6.3.1 Allowable conditions for oil burner ignition
(1) After the furnace purging succeeds and the MFT relay OFT reset, the operator makes the command of
“Opening the safety fast valve of fuel oil mains” and command of “Opening the oil return shut off valve of
fuel oil mains”.
(2) Ignition of igniter
When the allowable conditions for boil ignition preparation mode are met, the igniter may be permitted to
be put into operation. In addition, the equipment availability of ignition system and if system conditions are
met will be proved.
(3) Allowable conditions for oil gun to ignite:
1) Boiler air quantity reaches the valve for purging;
2) Flame detector cooling pressure is met;
3) Valves of all burners are closed;
4) Wind box/furnace differential pressure is met;
5) No trip signal of MFT or oil system;
6) Atomized steam pressure is normal;
7) Oil pressure met the requirement for ignition;
8) Ignition system has been ready;
9) Oil temperature is normal;
When all the conditions above are met, “Ignite Permit” will be displayed on the screen of LCD, and when
the ignition conditions for each oil gun are met, the oil gun may be put into operation.
1.6.3.2 Ignition procedure of oil burner (with the oil burner AA1 on layer AA as an example):
1): When the oil burner AA1 is in remote control mode, operate the Start button of oil burner AA1 on the
graphic display of CRT or accept the sequence control oil burner AA1 startup command from the layer
startup to start the ignition program formally;
2): The command for oil gun protruding into is made (3S pulse);
3): The oil gun is detected having been protruded into the designated position 10S after entering the
ignition program formally, and the purge valve of oil burner AA1 is closed, then make the command for
igniter extending (30S pulse);
4): If the igniter is detected having been protruded into the designated position 10S after the command for
igniter protruding into is made, then make the command for opening the oil filling valve of oil burner and
the igniter starts to strike fire at the same time (10S pulse) .
5): If the trip valve of oil burner is detected opening and having been fired after the above command is
made for 10S, then the oil burner AA1 ignites successfully and enters the state to be put into operation.
Once any condition 1) to 4) above for oil burner AA1 being ready is not met in the process of the procedure
above, then the ignition fails.
1.6.3.3 Conditions for oil burner AA1 shutdown (OR)
(1) Ignition failure: no flame is detected 10s after opening oil valve A1;
(2) Oil valve failure: the oil valve does not reach the full opening position 10s after the command for
opening oil valve is made;
(3) Conditions for burner ignition are not met (such as the fuel trip MFT or OFT, etc.);
(4) In remote control mode and the operator makes a shutdown command.
1.6.3.4 Shutdown sequence of oil burner AA1
1): Close the oil valve;
2): If there is no “Condition for disabling purging oil gun”, the oil gun shall be purged;
3): Disengage the oil gun after purging is finished.
1.6.3.5 Conditions for purging AA1 oil gun
In any case as follows, the oil gun shall not be purged:
(1) MFT operates;
(2) OFT operates;
(3) Oil gun is not protruded into;
(4) Purging steam pressure is low;
(5) The central air baffle of the layer where this burner is not in correct position;
(6) The safety fast valve of fuel oil mains is not opened.
1.6.3.6 Process of purging oil burner AA1
Step 1: Protrude the igniter into;
Step 2: If the igniter is detected having been protruded into the designated position 10s after making
protruding command, then make the command for opening the purge valve and the igniter strikes fire for
10s;
Step 3: If the purge valve is detected having been opened to the designated position 5s after the command
for opening purge valve is made, then purge the oil burner for 30s;
Step 4: Shut down the purge valve after purging for 30s, 2s later, disengage the igniter and oil gun.
1.6.4 Control of the safety fast valve of fuel oil mains:
When the conditions as follows are met, it is permitted to open the safety fast valve of fuel oil mains:
(1) Trip valves of all oil burners are closed;
(2) OFT has been reset;
(3) MFT has been reset;
(4) Pressure of fuel oil mains is normal and the safety fast valve of fuel oil mains has been closed;
When the conditions above exist, pressing the button OPEN of the safety fast valve of fuel oil main will
make the command for opening it. With the opening of valve, the oil mains pressure will rise to normal
value. It is designed that the safety fast valve of fuel oil mains shall be opened and the fuel oil mains
pressure shall be up to normal within 5s after it departs from the CLOSE position, and otherwise the
opening is considered failed.
In any case as follows, the safety fast valve of fuel oil mains will be interlocked and closed:
(1) MFT operates;
(2) OFT operates;
(3) Pressure of fuel oil mains is abnormal.
The safety fast valve of fuel oil mains may also be closed manually.
1.6.5 Control of oil return shut off valve of fuel oil mains:
The oil return shut off valve of fuel oil mains is a single-coil solenoid valve. It needs to open when oil
circulation is constituted or oil leak test is carried out and will be closed after the oil burner is put into
operation.
When the conditions as follows are met, it is permitted to open the oil return shut off valve of fuel oil
mains:
(1) OFT has been reset;
(2) MFT has been reset;
(3) Trip valves of all oil burners are closed;
When all conditions above are met, then pressing the button OPEN of oil return shut off valve of fuel oil
mains will open the valve.
In any case as follows, the oil return shut off valve of fuel oil mains will be interlocked and closed:
(1) OFT operates;
(2) MFT operates;
(3) 10s after the oil return shut off valve of fuel oil mains is opened in oil leak test.
The oil return shut off valve of fuel oil mains may be closed manually in any case.
1.6.6 Startup of boiler oil layer:
This boiler fires two fuel oils: light oil for layer AA and heavy oil for layer AB and CD, so atomization with
steam is necessary and it is required to ignite from the oil burner on layer AA on and from bottom up layer
by layer (that is the oil layer AA is started first and then the layer AB and CD). With regard to the control of
oil layer, the startup sequence of oil burner is “1-3-2-4” and shutdown sequence is “4-2-3-1”. When local
operation is required, it may switch to the mode of local control, the command of “Local operation permit”
is made to the local control cabinet. Here the indicator lamp of “Local operation permit” on the local
control cabinet lights, then each set of equipment of oil burner may be operated on the local control cabinet.
1.6.6.1 Layer startup (with the oil burner on layer AA as an example):
When all the oil burners on layer AA are in remote control mode, if any condition as follows is met, the
command for oil layer AA startup will be made:
(1) Oil layer AA is started by the operator;
(2) Oil layer AA is requested to be put into operation before the coal layer A is put into operation.
Layer startup sequence:
(1) Operator confirms all oil burners on this layer have been ready;
(2) Press corresponding layer startup button;
(3) Start the oil burners at intervals of 15S in order of “1-3-2-4”.
1.6.6.2 Layer shutdown sequence:
(1) Press corresponding layer shutdown button;
(2) Shut down the oil burners at intervals of 15S in order of “4-2-3-1”.
1.6.7 Coal layer startup:
The requirement and method for startup of all coal layers of a same boiler are the same, and they all can be
started automatically or manually.
1.6.7.1 Coal layer ignition permit:
Conditions as follows for ignition of coal layer A~D shall be met first:
(1) Conditions for furnace ignition are met;
(2) Primary air pressure is normal;
(3) Coal feeder on adjacent layer prove >50%;
(4) Corresponding oil layer is put into operation;
(5) Air quantity is >30% and <40%, or any coal layer is put into operation;
(6) Primary air temperature is normal;
Before any coal layer (mill) start, the boiler side must have enough energy to ignite the pulverized coal on
this layer and sustain stable combustion of this coal layer, that is the corresponding signal of “Coal layer
ignition permit” shall be constituted.
When any condition as follows is met, the signal of “Coal layer ignition permit” for this coal layer is
constituted:
A. The boiler oil layer adjacent to this coal layer has been put into operation;
B. The other coal layer adjacent to this coal layer has been put into operation and corresponding mill load is
>50%, and boiler load is >30%;
C. The other coal layer adjacent to this coal layer has been put into operation and corresponding mill load is
>50%, and the boiler oil layer adjacent to such a coal layer that has been put into operation also has been
put into operation.
1.6.7.2 Mill startup permit: the signal of “Coal pulverizer startup” also must be constituted before any coal
layer start, referring to the Coal Pulverizing System, Part 6 Auxiliary machinery Part for details.
1.6.8 Boiler trip:
1.6.8.1 In case of MFT, it will interlock the equipment as follows to operate:
(1) Close oil trip valve, oil angle valve, oil filling shut off valve and oil return shut off valve;
(2) All pulverizing systems trip;
(3) Turbine and electric generator trip and bypass shall be put into operation when it is in auto mode;
(4) All primary air fans and seal fans stop;
(5) Sootblower trips and exits automatically;
(6) Automatically close locking valve and governing valve for stage I & II attemperating water of
superheater, and reheater spray locking valve and governing valve;
(7) Automatically open fuel air baffle and auxiliary air baffle of all layers;
(8) Steam-driven feed water pump trips, electrically driven feed water pump automatically starts, adjust the
rotating speed of electrically driven feed pump to make feed pressure a little higher than steam drum
pressure and maintain normal steam drum water level;
(9) Forcefully turn down the opening of induced draft fan static blade to a certain value to maintain the
furnace negative pressure at about - 100Pa;
(10) Adjust the burner swinging angle to horizontal position;
(11) Turbine trips;
(12) Electric generator trips.
1.6.8.2 Causes for boiler trip and first out display system:
For the boiler in operation, if any condition as follows is met, then a command for boiler trip will be
constituted to make MFT operate:
(1) No ignition 60 minutes after purging is finished;
(2) All forced draft fans stopped;
(3) All induced draft fans stopped;
(4) Boiler e-stop button is pressed;
(5) Steam drum water level is high (signal is made with 20s delay after PCV operates);
(6) Steam drum water level is low (signal is made with 20s delay after PCV operates);
(7) Furnace pressure is high;
(8) Furnace pressure is low;
(9) Furnace air quantity is < 25% BMCR
(10) Turbine trips;
(11) Turbine trips when the load is >30%;
(12) Any coal layer has been put into operation, but two primary air fans all stopped;
(13) All air preheaters stopped;
(14) All flames are lost (3s pulse);
When 3/4 oil burners have no flame detected, it is considered that there is no oil flame detected;
When 3/4 coal burners have no flame detected, it is considered that there is no coal flame detected;
When there is no oil flame and no coal flame detected, it is considered that there is no flame detected;
When there is no flame detected but there is the memory of burners being put into operation, loss of all
flame appears. That is no loss of all flame is considered when boiler shutdown.
(15) In case of no coal burner being operated, OFT operates;
(16) Loss of all fuels (5s pulse)
Fuel oil valves of all oil burners or all safety fast vales of fuel oil mains are shut down and all coal
pulverizers stopped. When both coal fuel and oil fuel are lost, it is considered loss of all fuels. This
condition plus “there is the signal of memory of burners being put into operation” makes a complete
condition. This is no loss of all fuels is considered when boiler shutdown.
(17) Flame detection cooling air is lost with a time delay of 20S;
(18) Ignition fails for more than 5 times;
(19) Feed water pumps all trip with a time delay of 2S;
(20) FSSS power failure
There is a “MFT First Out Cause Display” system designed in FSSS that is convenient for the operator to
understand and judge the causes of MFT.
The first cause of MFT shall be displayed on FSSS device correspondingly and the display circuit
corresponding to any other sequent command for boiler trip shall be shut off. Therefore only the first cause
of boiler trip, that is “MFT First-out Cause” can be displayed and kept in memory.
1.6.8.3 Conditions for OFT trip
(1) MFT operates;
(2) OFT command is made on CRT by the operator;
(3) Any oil burner trip valve failed to close;
(4) Oil layer has no flame;
(5) Atomizing pressure is low;
(6) Pressure of oil mains is over low.
In case of the safety fast valve of fuel oil mains not being closed, for the pressure signal of three oil mains,
the logic operation will be made for two selected from three mains and last for 2s.
1.6.9 Interlock control of secondary air baffle:
At different stages of boiler operation, the interlock on-off of the secondary air baffle is controlled by
FSSS, and the analog quantity of baffle and on-off interlock control command of FSSS are controlled and
executed by CCS.
1.6.9.1Control of auxiliary air baffle
A. When the boil MFT, FSSS makes the command of “Open the auxiliary air baffles of all layers with the
max extent of opening in memory and switch to manual position”.
B. When the furnace is purged, the signals of putting all secondary air baffles on Purge position and putting
all over-fire air baffles on Purge position are made to MCS by FSS. MCS is in charge of opening the air
duct and making the air quantity in furnace moderate at 25%~40%BMCR;
C. Coal layer is put into operation and the corresponding air baffle is put into automatic governing
(governed by CCS on the basis of the functional relation between boiler load and wind box/furnace
differential pressure).
1.6.9.2 Control of fuel air baffle
A. When boiler MFT, the command for “Close the fuel air baffles of all layers” is made by FSSS.
B. When there is no MFT, the command for “Close the fuel air baffles of corresponding layer” is made by
FSSS to the corresponding fuel air baffles of tripped-layer thereto.
C. For the coal layer that has been put into operation, the corresponding fuel air baffles are governed by
CSS on the basis of coal feeder speed.
1.7 Hydraulic test of boiler
1.7.1 Pressure and specifications for hydraulic test:
a. After the mounting of all pressure parts of boiler is finished, the hydraulic test shall be done with the
pressure 1.25 times of steam drum designed pressure. Take steam & water system, superheater, economizer
and steam drum of boiler as a whole for hydraulic test, and perform hydraulic test to the reheater
individually with the pressure 1.5 times of the designed inlet pressure of reheated steam.
b. In any case as follows, the overpressure hydraulic test shall be done:
1) Before newly-installed or moved boiler is put into operation.
2) After each overhaul.
3) When the left-unused boiler for more than one year needs to operate again.
4) After the pressure parts of boiler going through heavy repair or replacement, if more than 50% water-
cooled wall pipe is replaced and 100% superheater tube or economizer tube is replaced.
The hydraulic test pressure is as shown in Table 2.1.
Working Pressure Of Hydraulic Test Overpressure Test
Name Unit
Steam drum Pressure Pressure
Primary air system MPa 18.873 18.873 23.59
Secondary air system MPa 3.941 3.941 5.88
c. Hydraulic test scope:

1) Primary air system, economizer, water-cooled wall and superheater part, that is from water pump outlet
to block valve for hydraulic test at superheater outlet.
2) Secondary air system, from the blocking plate for primary reheater inlet hydraulic pressure to the
blocking plate for reheated steam piping hydraulic pressure of final reheater outlet.
3) Piping fittings of boiler proper part.
4) Water gauge is only used for the working pressure test.
1.7.2 Preparation & requirements for hydraulic test
a. The water for hydraulic test shall be qualified demineralized water and be heated to 40~70℃. The
difference between feed water temperature and steam drum wall temperature shall not be more than 28℃.
If the metal temperature of steam drum is lower than 35℃, the hydraulic test shall not be done.
b. All constant hangers on superheated steam and reheated steam piping and spring hangers on boiler roof
shall be fixed with pins or locating pieces and be taken as rigid hangers temporarily.
c. The blocking plate on reheater inlet and outlet piping for hydraulic test shall be connected to the system.
d. Before hydraulic test, the turbine operator shall be informed of cooperating in the check and preparation
of related systems to the hydraulic test of boiler.
e. The motor-operated main valve of superheater attemperating water, and the motor-operated valve,
governing valve, manual isolating valve of attemperating water piping and standby piping at all levels shall
be closed, the motor-operated main valve of reheater emergency spraying and the motor-operated valve,
governing valve and manual isolating valve of branch pipes shall be closed, and the water drain valve,
discharge valve, back wash valve and air damper on each attemperating water piping shall be closed.
f. The feed water motor-operated valve and governing valve of feed water control console shall be closed,
the back wash valve to lower header shall be closed and the economizer recirculation valve shall be closed.
g. The blowdown & water drain valve of centralized downcomer, the primary and secondary drain valve of
economizer lower header shall be closed.
h. Each motor-operated valve and manual intercept valve for periodic blowdown of lower header, and each
header steam valve of bottom heating shall be closed.
i. Motor-operated valve, governing valve, motor-operated emergency water drain valve and dosing valve
for continuous blowdown shall be closed.
j. Each sampling valve of saturated steam, superheated steam, reheated steam and feed water shall be
closed.
k. Each water drain valve of superheater and reheater shall be closed.
l. The balancing vessel valves of each pressure gauge and pressure signal tube shall be opened, the steam
and water valve of water gauge shall be opened and the water drain valve shall be closed. The
thermodynamic engineer shall be informed of switching on power for related thermometer, pressure gauge,
water gauge, motor-operated valve and governing valve, etc., the place where the steam drum pressure is
raised locally and raising pressure is monitored shall be replaced with standard pressure gauge and the
secondary valves of related gauges and meters shall be closed.
m. Each air valve of superheater, reheater and economizer shall be opened.
n. The dump steam atmospheric valve of superheated and reheated steam shall be closed and it is necessary
to make sure that the safety valve has been fixed with special tools.
1.7.3 Boiler water filling
a. Water is tested qualified before filling.

b. The water inlet temperature and water filling time shall be controlled strictly, the water inlet temperature
shall be 40~70℃ and during boiler pressure rise, strictly monitor that the difference between water
temperature and steam drum wall temperature should not exceed 28℃, otherwise the feed water flow shall
be controlled at 30~60t/h, and the difference between upper and lower wall temperature shall be recorded
once every 30 minutes. The water filling shall be slow and even and filling time shall not be less than 2~4
hours.
c. When water filling, the difference between steam drum upper and lower wall temperature shall be strictly
controlled at ≯42℃.
d. The reheater is filled with water through the emergency water spray valve, filling shall be stopped by
closing each roof air valve after water overflowing them for 1~2 minutes, then the manual intercept valve
shall be closed.
e. Boiler proper water filling: the boiler proper is filled with water through the feed water control console
and economizer by way of water filling line and motor-operated feed water pump. The air valve of
economizer shall be closed after it is filled with water to continue filling, and the filling shall be stopped by
closing each roof air valve after water overflowing them for 1~2 minutes.
1.7.4 Primary steam hydraulic test
Test scope:
a. Economizer, water-cooled wall and superheater part, which is from feed water pump outlet to block
valve for hydraulic test at superheater outlet.
b. Pipe fittings of boiler body;
c. Steam drum local water gauge is only used for working pressure hydraulic test, not for overpressure
hydraulic test;
Test procedures:
a. Contact turbine operator of closing turbine main steam valve, high and low pressure bypass valve, water
drain valves before the main steam valve at turbine side;
b. Open all the air valves of primary steam system and close all water drain valves;
c. Start feed water pump for water filling from superheater attemperator or from feed water bypass valve
according to the water filling requirement of cold furnace;
d. Water filling should be performed slowly and steadily to avoid water shock;
e. Perform water filling until all air valves continuously overflow, and then close them one by one. Control
pressure raising rate with superheater attemperator governing valve or feed water bypass valve;
f. When the pressure is ≤ 10.0MPa, pressure raising rate is controlled at 0.294MPa/min, when the pressure
slowly rises to 1.0MPa, stop raising pressure and inform maintenance personnel for check. Continue to
raise pressure after it is stable for 15min;
g. When the pressure rises to 10.0MPa, stop raising pressure and inform maintenance personnel for check,
after completing check, continue to raise pressure, at the time, control pressure raising rate at 0.2MPa/min;
h. When the pressure rises to working pressure, stop raising pressure and close water inlet valve, stop feed
water pump and inform maintenance personnel for check, it is qualified when up to the following
conditions;
 It is qualified if pressure drop does not exceed 0.5MPa during five-minute pressure maintenance;
 Pressure parts have no leakage;
 Pressure parts have no residual deformation;
i. After the hydraulic test is up to standard, relieve pressure by draining water slowly, control pressure drop
at 0.294MPa/min, when the pressure drops to 0.2MPa, open all furnace roof air valves;
j. If it needs overpressure test, control its pressure raising rate at 0.098Mpa/min, when the pressure rises to
the pressure for overpressure test, keep it for five minutes and then reduce it to working pressure, and then
check it, keep the pressure constant during check;
k. After completing overall check, reduce pressure gradually, generally control the speed in the range of
0.3~0.5MPa/min till it is down to zero, when the pressure is zero, close air valve, and perform boiler
maintenance depending on the actual situation;
l. After hydraulic test, restore all systems the state before boiler startup and record test results;
1.7.5 Secondary steam hydraulic test
Test scope:
From the block valve for hydraulic test at primary reheater inlet to the block valve for hydraulic test in
final reheater outlet reheated steam piping.
Test procedures:
a. Inform turbine operator of closing intermediate pressure main steam valve, high-low pressure bypass
valve and high pressure cylinder exhaust check valve to prevent leakage:
b. Open reheater air valve and close all the water drain valves of reheater and reheated steam at turbine
side;
c. Perform water filling from reheater emergency spray type attemperator, after the air valve overflows
continuously, close air valve;
d. Slowly raise the pressure and control pressure raising rate at 0.294Mpa/min, when the pressure rises to
1.0MPa, stop raising pressure temporarily and inform maintenance personnel for check;
e. After completing check, raise pressure at the speed of 0.2Mpa/min to working pressure and inform
maintenance personnel for check;
f. If it needs overpressure test, raise pressure at the speed of 0.098Mpa/min to the overpressure pressure,
keep it for five minutes, and reduce it to the working pressure, maintain the pressure for check;
g. After completing check, open the water drain valve of the reheater to reduce pressure at the decreasing
rate not more than 0.294Mpa/min;
h. When the pressure is down to 0.2MPa, open all furnace roof air valves, when the pressure is zero, close
the air valves, and perform boiler maintenance depending on the actual situation;
i. After hydraulic test, restore all systems to the state before boiler startup, and record test results;
j. The acceptance standard of secondary steam hydraulic test is the same with that of primary steam;
Attentions for hydraulic test:
a. Before hydraulic test, take measures to prevent water from entering the turbine;
b. During primary steam overpressure test, steam drum water gauge shall be paralleled off;
c. During hydraulic test, there should be special-assigned person in charge of air valve and feed water
valve;
d. When the overpressure test pressure exceeds the working pressure, operators should not stay at the
flange, weld junction, valve of pressure parts, etc. places or check equipment, knock at pipes, etc.;
e. During overpressure test, make preparations for emergency pressure relief in advance, if the pressure is
out of limit, take the following measures orderly:
1) Close attemperating water motor-operated valve and governing valve and reduce the speed of feed water
pump scoop tube.
2) Open the continuous blowdown valve wide.
3) Open the water drain valve of superheater steam header.
4) Inform turbine operator of stopping the pump emergently.
f. Increase and decrease of the pressure in hydraulic test should be performed slowly and steadily;
g. Valve test should be performed first for secondary valves and then for primary valves;
h. Before test, motor-operated water drain valve should be in good condition;
1.7.6 Pressure release after hydraulic test:
1) Open the stage I attemperating water discharge valve to reduce pressure.
2) The pressure shall be reduced slowly and evenly at a speed of 0.294MPa/min.
3) When the pressure is reduced to 0.2Mpa, the air valve shall be opened to reduce the steam drum water
level to the lowest visible level, then the economizer recirculation valve shall be opened; each water drain
valve of superheater part shall be opened to try to discharge the water in superheater to the utmost.
4) If water drain is necessary for the water-cooled wall, then each periodic blowdown valve shall be opened
to drain water.
5) When the pressure is released to 0, all water drain valves shall be opened, if the water is tested qualified,
the water shall be discharged to the level for ignition.
6) Details of test results and problems found shall be recorded in the record book.
7) After the hydraulic test is finished, the thermodynamic engineer shall be informed of cleaning the meter
pipe and sampling pipe with chemicals.
1.7.7 Precautions for hydraulic test:
a. All operations during hydraulic test must be under unified command, pressure rise and release shall be
approved by the commander on site.
b. There shall be specially-assigned person in charge of raising pressure and strict precautions shall be
taken against over pressure. When pressure is raised, the indication of steam drum local pressure gauge
shall be taken as standard and there shall be specially-assigned person in charge of monitoring the pressure
indicated by the gauge in the control room. The pressure raising and pressure release operators shall contact
with each frequently, when the difference between raised pressure and released pressure is large, it shall be
checked and judged by the thermodynamic engineer.
c. The pressure raising rate shall be controlled strictly to prevent over pressure. If the pressure exceeds
limit, the following measures may be taken in order:
1) Close attemperating water motor-operated valve and governing valve and reduce the speed of feed water
pump scoop tube.
2) Open the continuous blowdown valve wide.
3) Open the water drain valve of superheater steam header.
4) Inform turbine operator of stopping the pump emergently.
d. The gauge pipe and sampling pipe shall not be cleaned in the process of pressure rise until the hydraulic
test is finished.
e. If only one or two valves are found leaking or not closed tightly in the process of pressure raising or after
up to the rated pressure, such a valve must be operated with the approval of the pressure raising operator in
control room.
f. In the process of pressure rise, the contact and cooperation with the turbine shall be enhanced.
g. For the hydraulic test of boiler proper, attention shall be paid to the pressure of reheater and the pressure
raising and over pressure of reheater shall be prevented.
h. All bulkheads and safety valve padding for hydraulic test shall be removed
i. Because there usually is a time delay between the boiler hydraulic test, the first boiling out and acid
cleaning, the boiler shall be maintained at the state being filled with water and air in shall be avoided
during this time.
j. If filling nitrogen gas, the nitrogen gas shall be drawn into through the exhaust port of steam drum to fill
the boiler to 0.034MPa (gauge pressure).
1.8 Setting of safety valve
a. The safety valve shall be calibrated after boiler installation and overhaul or safety valve inspection and
repair.
b. Safety valve calibration is generally performed in no-load condition, if it needs calibration with load,
sound safety technical measures should be established;
c. The sequence of calibration is first from high pressure to then low pressure, from main steam side and
then reheated steam side so as to calibrate the steam drum, superheater outlet, reheater inlet and outlet
safety valve one by one;
d. Before safety valve calibration, check and test the control loop of electromagnetic relief valve.
1.8.1 Calibrate safety valve with load:
1.8.1.1 Perform check, preparation, ignition, temperature and pressure increase before startup as per
relative specifications and control the furnace outlet flue gas temperature not over 538℃, or diminish the
combustion and reduce the temperature and pressure raising rate;
1.8.1.2 When the boiler pressure rises to 80% of rated pressure (primary steam is about 14.0MPa,
secondary steam is about 3.13MPa), keep the pressure steady, calibrate all the safety valves one by one
with hydraulic device;
1.8.1.3 Set the control switch of electromagnetic relief valve to auto exit state and attach compressing
apparatus to all safety valves except the ones to be calibrated;
1.8.1.4 Raise the pressure at rate of 0.196~0.245MPa per minute to the popping setting pressure of safety
valve, if the safety valve does not pop up, reduce the pressure to 65% of the rated pressure (primary steam
is about 11.31MPa, secondary steam is about 2.5MPa) to make adjustment;
1.8.1.5 When the safety valve operates, record operating pressure, and adjust the combustion to make the
safety valve reseated and record reseating pressure. At the same time strengthen the adjustment of steam
temperature and water level to prevent excessive fluctuation of steam drum water level;
1.8.1.6 After the pressure is down to 80% of boiler rated pressure, calibrate other safety valves with the
same method;
1.8.1.7 If the safety valve operating value is different from the setting value, adjust and calibrate it again till
up to standard;
1.8.1.8 After completing the calibration of the safety valves of steam drum and superheater, calibrate
electromagnetic relief valve;
1.8.1.9 When the steam drum pressure is down to 8~10MPa, calibrate the reheater safety valve through
turbine bypass system, at the same time prevent reheater from overtemperature; After calibrating, safety
valve popping pressure, reseating pressure and valve clack opening height should meet specifications and
be recorded in boiler technical files;
1.8.1.10 The operation of safety valve calibration without load is basically the same with that of safety
valve calibration with load, but the following points shall be paid attention to:
(1) Such measures as preventing steam and water from entering turbine shall be taken for the turbine.
(2) The temperature of superheater and reheater wall shall be monitored not to exceed limit and the flue gas
temperature of low temperature reheater inlet shall be controlled at ≯450℃ and the saturated steam
temperature shall be >≯60℃/h.
1.8.2 Related specifications for safety valve calibration
a. On steam drum and superheater, the total discharge amount of all safety valves should be larger than
boiler maximum continuous evaporation amount;
b. When all safety valves on the boiler are fully open, the boiler overpressure extent should not exceed 6%
of boiler design pressure at any case;
c. Total discharge amount of reheater inlet and outlet safety valve should be larger than the maximum
design flow of reheater;
Safety valve reseating differential pressure is generally 4%-7% of popping pressure, maximally not
exceeding 10% of popping pressure;
1.8.3 Test value of safety valve operating pressure
Name Operating pressure (MPa) Reseating pressure (MPa)
Saturated I safety valve 19.82
Saturated II safety valve 20.22
19.03
Saturated III safety valve 20.41
Last stage superheater outlet I safety valve 18.31 17.58
Last stage superheater outlet II safety valve 18.34 17.61
Superheater outlet PCV valve 18.13 17.77
Reheater inlet I safety valve 4.384 4.209
Reheater inlet II safety valve 4.428 4.251
Reheater inlet III safety valve 4.516 4.335
Reheater outlet I safety valve 4.105 3.941
Reheater outlet II safety valve 4.311 4.138
Chapter 2 Boiler Startup
2.1 General rules

2.1.1 Startup or unit synchronization shall be prohibited if the following situation exists before startup:
2.1.1.1 Any one of unit trip protections is abnormal;
2.1.1.2 Main instruments (main, reheated steam pressure and temperature gauge, steam drum water level
gauge, feed water flowmeter, furnace negative pressure gauge, exhaust gas temperature gauge, oxygen
content gauge) are lacked or abnormal, and there is no other monitoring methods;
2.1.1.3 Abnormal FSSS system affects the start & stop and normal operation of the unit;
2.1.1.4 Coordinated control system (CCS) is abnormal, which affects unit operation, and it can not recover
in a short time;
2.1.1.5 When the total electrical interlocking test of boiler is not up to standard;
2.1.1.6 Steam drum water level protection is not complete;
2.1.1.7 The steam drum local water level gauge, safety valve, etc. fittings can not be put into operation
wholly;
2.1.2 Specification for boiler state
Cold state: The boiler has no pressure (the corresponding turbine is at the metal temperature at velocity
stage of the turbine or the first stage stator blade ring temperature of IP cylinder <121℃).
Hot state: The boiler has pressure (turbine hot state is at the metal temperature at velocity stage of the
turbine or the first stage stator blade ring temperature of IP cylinder ≥ 121℃).
2.2 Check before boiler startup
2.2.1 After receiving boiler starting command, it shall check that all the inspection and repair work are
completed and all working sheets have been recalled. Inform each post of making good preparations for
startup.
2.2.2 Contact chemical, thermodynamic, electrical and fuel departments, etc. to prepare for startup.
2.2.3 Check of boiler body and gas pass;
2.2.3.1 No people, coke residue, foreign matter and tools should be in the boiler body and gas pass;
2.2.3.2 All heating surfaces should be clean with sound appearance;
2.2.3.3 Furnace is air proof with heat preservation, boiler casing is sound, all platforms, stairs and handrails
shall be sound, there is no scaffold, sundries or garbage, roads shall be smooth and illumination shall be
adequate.
2.2.3.4 Sootblower and pipes shall be complete and the sootblowers of furnace and superheater should be at
exit position;
2.2.3.5 TV camera of furnace flame shall be in good condition, cooling water booster pump is put into
operation, steam and water control cabinet is put into operation, water inlet valve is open, cooling air valve
is open;
2.2.3.6 Furnace wall, all steam and water pipes, air and gas duct hangers and brackets should be complete
and firm, steam-water piping and flue gas pass can expand freely, expansion indicator is complete with
clear scale and the pointer in zero position free of jam;
2.2.3.7 Furnace flue gas temperature probe should get in and out flexibly;
2.2.3.8 Burner swing device should be flexible and in good condition;
2.2.3.9 All observation hole, inspection hole, manhole should be complete and tightly closed;
2.2.3.10 Flue gas damper and damper transmission device are in good condition, with correct position
indications and flexible operation;
2.2.3.11 There should be no coke residue in bottom ash hopper, ash hopper water seal water is put into
operation, bottom ash hopper is filled with water to the normal level and kept with a certain amount of
overflow, overflow pipe is smooth, slag tap of ash hopper can be opened and closed smoothly;
2.2.3.12 The lubricating oil for all the bearings and reduction gear box of air preheater is enough, oil level
is normal, cooling water is smooth, steam sootblowing device is in good condition;
2.2.3.13 All the rapping device transmission parts of electrostatic precipitator are in good condition, the
mechanical appearance of ash handling device is good, electric heater has been put into operation for 24
hours, electric field grounding device is up to standard;
2.2.4 Check of steam and water system
2.2.4.1 All steam and water valves should operate flexibly without jam, hand wheels are all available, and
switches are in line with indicated directions;
2.2.4.2 Valve control device is complete, all pins are firmly fixed, actuator is in good condition, manual and
automatic change-over switches are normal;
2.2.4.3 The stop valve and adjusting valve of feed water bypass and main line operate flexibly with sound
appearances, and the water drain valves of feed water pipings are all closed, the attemperating water
systems of superheater and reheater, primary and secondary drain valves and main valve are all closed and
in close position, with well-connected appearances and flexible operation;
2.2.4.4 All the main hand-operated valves and each blowdown valve (manual branch valves) of header
should operate flexibly and hand wheel appearance is good and in close state;
2.2.4.5 The manual stop valve from continuous blowdown system to periodic blowdown flash tank should
be in open position, with sound appearance and hand wheel and flexible operation;
2.2.4.6 Steam drum local water level gauge is in operating state, steam-water connecting vessel is well-
insulated, double color water gauge is clear and leakproof, steam valve, water valve and discharge valve are
leakproof and operate flexibly, water level indication is correct, with clear scale indicative mark, TV water
level monitor is sound and available, and illumination is enough;
2.2.4.7 All the water drain valve hand wheels of superheater and reheater have sound appearance in close
position, 5% water drain bypass is open, the air valve, hand wheel appearance and connection of steam
drum are sound, hand-operated valve is in close position and motor-operated valve is in close position and
all these valves operates flexibly;
2.2.4.8 Economizer recirculation valve and discharge valve have sound appearances, (hand-operated valve
is in close position and operate flexibly, and motor-operated valves are all in close position;
2.2.4.9 Emergency water discharge motor-operated valve has sound appearance and operate flexibly and it
is in close position;　　
2.2.5 Check of boiler-front fuel oil system
2.2.5.1 All the equipment and pipings of boiler-front fuel oil system are sound, without oil leakage, oil filter
is clean, and fuel flow meter rotates flexibly and indicates normally;
2.2.5.2 All the valves and oil pressure gauges of steam purging system of boiler-front fuel oil system are
sound and put into operation, oil trip valve, oil return valve, delivery valve, oil return governing valve,
pneumatic valve, etc. have no jam, oil gun and ignition device are sound, oil gun advancing and regressing
is good after tested;
2.2.5.3 All the angle oil valves of fuel oil system operate normally and they are in close position, the hand-
operated delivery valve of oil gun is open, oil return regulating valve is closed, and all bypass valves are
closed;
2.2.6 Check of boiler auxiliary machinery
2.2.7 Check of boiler pulverizing system.
2.2.8 All the instruments, signals, operating switches and change-over switches of boiler operation board
are sound and the board has complete & correctly named marks, correct indicator lamps and, normal alarm
sound and reliable emergency illumination;
2.2.9 All the system control power supply, motive power and signal power supply of the unit are all
available for standby.
2.2.10 All monitoring instruments and recording gauges have been put into operation for standby.
2.2.11 EDPF, FSSS, DCS and the protection, interlocking and auto devices of auxiliary machinery, etc. are
in normal standby, CRT display corresponds to the actual situation of equipment, and UPS is in normal
standby.
2.2.12 During check, if any problems, contact the maintenance personnel in time to deal with it and then
report it to shift engineer and relative leaders.
2.3 Boiler water filling
2.3.1 Boiler water filling requirement
 Before water filling, the water quality should be qualified after tested;
 The water inlet temperature is 30℃~60℃, if the feed water temperature is higher than the steam drum
wall temperature by more than 50℃, the feed water flow should be controlled within 30~60T/H;
 The water filling time shall not be less than 2 hours in summer and not less than 4 hours in winter;
2.3.2 After completing checking the unit, when the startup condition is satisfied, the boiler can be f illed
with water by electrically driven feed water pump or by turbine demineralized water tank via condensate
transfer pump;
2.3.3 Filling water by feed pump:
2.3.3.1 The boiler water filling in cold state generally adopts condensate transfer pump.
2.3.3.2 Inform the turbine operator of starting condensate transfer pump and opening its outlet valve, after
through boiler hand-operated isolation valve and motor-operated valve, the condensate water enters
economizer via feed water bypass.
2.3.3.3 Open the air valves on both sides of steam drum.
2.3.3.4 Keep the outlet mains pressure of condensate transfer pump within 0.8~0.9MPa.
2.3.3.5 Open the motor-operated valve before feed water bypass governing valve and control the boiler
water filling speed with feed water bypass governing valve.
2.3.3.6 When filled water is up to -100mm on the water level gauge, inform the turbine operator of
stopping filling, at the same time, contact the chemical group to test whether the water quality is up to
standard, if not up to standard, clean the boiler with water till it is up to the standard.
2.3.4 Filling water by electrically driven feed water pump:
2.3.4.1 Start the electrically driven feed water pump.
2.3.4.2 Open all the air valves of steam drum, close the water drain valve in the feed water piping, start the
electrically driven feed water pump as required, control the feed water flow at 30~60T/H with feed water
bypass adjusting valve, at the initial stage of water filling, control feed water flow to prevent feed water
piping from vibration, during water filling, pay attention to checking and recording the expansion indicator
values of all parts and steam drum wall temperature difference not higher than 42℃.
2.3.4.3 When the boiler steam drum water level gauge has water level, the governing valve should be
turned down to make the water level up to -100mm slowly.
2.3.4.4 Close electrically driven feed water pump outlet valve and feed water bypass valve to stop filling
water.
2.3.5 Put-in and parallel off of furnace bottom heating equipment
2.3.5.1 Put-in of furnace bottom heating
a. Open the steam heating valves of high pressure auxiliary steam header to furnace side;
b. Open the water drain valves of heating header and steam supply piping, open the main steam supply
valve of both sides, and start to warm up the piping and header;
c. After completing warming, close the water drain valves of steam supply piping and header, fully open the
main hand-operated steam supply valve, and gradually open the branch valves of furnace bottom heating
equipment to the lower header of water-cooled wall;
d. During furnace bottom heating, attention shall be always paid to the heating steam source pressure till
the steam drum lower wall temperature is up to 100℃, and then stop heating;
2.3.5.2 Parallel off of furnace bottom heating
a. Gradually close the heating branch valves of heating header to the lower header of water-cooled wall and
close the main steam valve on both sides of heating header;
b. Contact turbine operator to close the heating valves of auxiliary steam to steam driving;
c. Open the water drain valves of steam supply piping to heating header;
2.3.5.3 Precautions for furnace bottom heating
a. During heating, the steam drum water level should be controlled at about ±100mm, if water level
increases, steam drum emergency water discharge valve or downcomer blowdown valve can be used to
control the steam drum water level within the normal range;
b. Heating should be slow, during which, the expansion of all parts should be uniform, control the furnace
water temperature rise rate should not be over 1℃/min, temperature difference of upper and lower wall
should not exceed 56℃;
c. Adopt adjacent furnace steam source for heating, strengthen the contact with adjacent furnace, when the
adjacent furnace goes wrong and auxiliary steam can not be guaranteed, stop heating immediately;
d. Pay attention to monitoring the furnace bottom heating steam supply pressure and keep heating steam
supply pressure within 0.7- 0.8Mpa, if heating steam pressure is too low, boiler water can be dumped into
heating steam piping to result in water shock;
e. When the steam drum lower wall temperature is up to 100℃, contact with chemical group to test the
water quality, perform ignition after water quality is up to standard, stop steam heating after ignition;
2.4 Preparations before startup
2.4.1 Contact shift engineer to inform fuel attendant of feeding coal to all raw coal bunkers.
2.4.2 Contact thermodynamic operators to put all instruments and operating device, FSSS, CCS, DCS
systems into operation.
2.4.3 Supply dynamic electricity for all boiler equipment.
2.4.4 Put the axial cooling air machine and lubricating oil station of induced draft fan A and B, lubricating
adjusting oil station of forced draft fan A and B, and primary air fan A and B cooling water into operation,
check that the oil pressures and oil levels of all oil pumps are within required ranges, cooling water inlet
and outlet temperatures are normal, and all equipment operates normally.
2.4.5 Inform ash handling control attendant of starting one ash-flushing pump, at the same time, check that
water storage pond water level is normal and enough.
2.4.6 Inform ash handling control attendant of putting bottom ash hopper water seal into operation, build
water seal and keep a certain amount of overflow, and monitor that bottom ash hopper water temperature is
normal.
2.4.7 Inform fuel oil room attendant of starting oil pump, performing circulation of boiler-front fuel oil
system, and guaranteeing mains pressure is larger than 3.46MPa.
2.4.8 Start closed cooling water pump and keep water pressure normal, open the closed cooling water main
valve at furnace side and the inlet and outlet valve of rotary mechanism.
2.4.9 Start one instrument used air compressor and general air compressor and keep their outlet pressures at
<≯0.7Mpa and <≯0.7Mpa respectively.
2.4.10 Inform ash handling control attendant of putting heating device into operation in advance of 24h and
check that electrostatic precipitator rapping device and ash handling device are normal.
2.4.11 Inform ash handling control attendant of powering on air cooling and drying device in advance of
12h.
2.4.12 Inform patrol inspector of putting the supports, guide bearing oil lubricating devices and oil cooling
devices of air preheater A and B into operation.
2.4.13 Check that the conditions for starting unit are met according to the unit startup check sheet, and
inform relative specialities that boiler is ready for startup.
2.5 Boiler cold start
2.5.1 Preparations before boiler ignition
When the boiler startup conditions are met and the shift engineer command is received, boiler can be
started according to “boiler startup operation sheet”.
2.5.1.1 Inform fuel oil system attendant that boiler is ready for ignition.
2.5.1.2 Start the main motor of air preheater A and B, after the rotating speed is normal, put standby motor
interlock into operation and put boiler electric main interlock into operation.
2.5.1.3 Start flame scanner probe cooling water pump (or compressed air) and put interlock into operation.
2.5.1.4 Start flame scanning cooling fan, open outlet and inlet damper, and put flame scanning cooling
system into operation.
2.5.1.5 Contact thermodynamic operator to put furnace flame industrial television into operation.
2.5.1.6 Start induced draft fan A and B and forced draft fan A and B, adjust the moving blades of forced and
induced draft fans to make the total air quantity of the boiler reach 30%~40%, at the same time, keep the
furnace negative pressure at -100Pa, and put the furnace draft control to “Auto”.
2.5.1.7 Adjust boiler auxiliary air damper to make differential pressure between wind box and furnace not
less than 380Pa.
2.5.2 Boiler ignition
2.5.2.1 Turbine is vacuumized and boiler is ready for ignition.
2.5.2.2 Furnace purging
After checking that the purging conditions are met on CRT, purge furnace at least for above five minutes,
during which, auxiliary air opening is 50%, after completing purging, MFT relay resets, boiler ignition can
be performed.
a. At least one forced draft fan is operating;
b. At least one induced draft fan is operating;
c .At least one air preheater is operating;
d. Two primary air fans stop;
e .Two electrostatic precipitators stop;
f .All oil angle valves are closed;
g. All coal pulverizers stop;
h. Steam drum water level is normal (-150mm ~+150mm);
i. No MFT trip signal;
j. Total secondary air volume is normal (40% > air volume > 25%);
k .All flame detection probes can not detect the flame;
l. All secondary air baffles are in open position. (Opening >5％);
m. Flame detection cooling air pressure is normal;
n. Furnace pressure is normal;
o. Leak test of oil mains is completed;
2.5.2.3 Boiler-front oil leak test
2.5.2.3.1 Test conditions
a. MFT and OFT relays do not trip;
b. Oil trip valve is closed;
c. Oil circulation valve is closed;
d. All oil angle valves are closed;
e. Communication valve is closed;
f. Fuel oil pressure is normal; (>3.26Mpa)
g. Test conditions are ready, and CRT displays “Oil leak test is ready”;
2.5.2.3.2 Circulation valve, oil angle valve and oil piping leak test
a. Check all the hand-operated valves of boiler-front fuel oil system are open except bypass valves, other
oil valves are closed;
b. Press “Start” button, “Oil Leak Test On” indicator lamp lights, meanwhile, open oil trip valve and close
oil circulation valve to charge piping with oil, if the oil piping pressure does not reach the set value (>
3.46Mpa) within 8s, oil charge fails and the test breaks off, and “Oil Leak test On” indicator lamp is out. Or
after the oil pressure is reached, close oil trip valve;
c. Monitor oil pressure for 90s, during which, if the oil mains pressure after oil trip valve is always high
(>3.22 Mpa), test is successful, or “Oil Leak Test On” lamp is out, the test breaks off.
2.5.2.3.3 Oil trip valve test
a. Open the communication valve and close oil filling governing valve to release pressure;
b. Monitor oil pressure for 90s, during which, if the mains pressure after oil trip valve is always high (>
3.22Mpa), the test is successful, or “Oil Leak Test On” indicator lamp is out, test breaks off;
c. When the oil leak test fails, find out the reason and perform the test again after it is normal till it is up to
the standard;
2.5.2.4 Use furnace gas temperature probe to check that roof inlet header and 5% starting water drain valve
are already open.
2.5.2.5 Furnace preignition and oil gun ignition.
Turn on fuel valve interlocked switch, start fuel oil trip valve on CRT, check to make sure the fuel oil
bypass valve is closed, fuel oil stop valve is open , adjust the oil pressure and confirm the following oil
ignition conditions on CRT are met.
a. Oil mains pressure is normal (>3.26MPa);
b. Oil filling stop valve is open;
c. Purging air pressure is normal (>0.56MPa);
d. No MFT and OFT trip signals;
e. Secondary air baffles are all in open position or there is already burner operating in the furnace;
f. Flame detection cooling air pressure is normal;
g. Furnace pressure is normal (-150Pa);
h. Total secondary air volume is >30%;
i. Steam drum water level is normal (-50mm~50 mm);
j. Purging is completed;
k. Flame detection power cabinet is not cut off.
l. Put oil gun of AB layer into operation only after oil ignition conditions are met.
2.5.3 When oil gun of AB layer enters steady combustion, contact turbine operator to start the main valve
of auxiliary steam sootblowing steam source, put air preheater cold end sootblowing into continuous
operation (load < 10%)
2.5.4 When the differential temperature of steam drum wall is likely to increase, keep the steam drum water
level at a little higher level. Discharge water by continuous blowdown or periodic blowdown valve and
adjust feed water quantity with feed water bypass governing valve, when the continuous feed water flow is
formed, close the economizer recirculating valve.
2.5.5 During boiler temperature and pressure rise, it must pay attention to the expansion of all parts and
periodically check them with expansion indicator, if abnormal, find out cause, it the expanded parts are
blocked, it shall stop pressure rise and then continue to increase the pressure after removal of the fault, it
shall pay attention to the expansion of wall type reheater relative to water-cooled wall and boiler lower part.
2.5.6 Control furnace outlet gas temperature not higher than 538℃, when it is higher than 538℃, furnace
gas temperature probe should exit automatically.
2.5.7 Contact chemical water personnel to test whether the qualities of saturated water and steam are up to
standard, if not up to standard, adopt continuous blowdown, periodic blowdown and chemical feeding, etc.
method, if more serious, stop increasing temperature and pressure until up to standard and then continue to
increase temperature.
2.5.8 During kindling, it should build good circulation as soon as possible, which can be realized by
periodic blowdown to parts poorly heated.
2.5.9 Perform boiler temperature and pressure rise according to startup curve, adjust oil return governing
valve opening and the quantity of operating and stopped oil guns. The speed of controlling temperature and
pressure rise is as follows:
Table 3-1:
Pressure Rise Range Pressure Rise Time Stage Remarks
Ignition ~0.20MPa 2.5~3 hours
0.2~0.5MPa 47 minutes
6.0~10.0MPa 35 minutes Silicon cleaning stage
10~11.8MPa 14 minutes Silicon cleaning stage
11.8~14.7MPa 17 minutes Silicon cleaning stage
2.5.10 During boiler temperature and pressure rise, it shall pay special attention to the steam drum water
level adjustment so as to keep it within the normal range of ±50mm, which can be controlled by feed water
governing valve, through adjusting turbine feed water pump rotating speed and by continuous blowdown
valve, periodic blowdown valve and even emergency water discharge valve.
2.5.11 When the steam drum pressure rises to 0.2MPa, close the air valve of steam drum, superheater and
reheater.
2.5.12 When the steam drum pressure rises to 0.3MPa, wash and calibrate the local steam drum water level
gauge, at the same time, inform thermodynamic operator of washing instruments and pipings.
2.5.13When the steam drum pressure rises to 0.5MPa, close the water drain valve of roof inlet header,
contact steam turbine operator to open the high and low pressure bypasses and inform maintenance
personnel of tightening screws in hot state.
2.5.14 When the steam drum pressure rises to 0.6MPa, open the valves of continuous blowdown to
continuous blowdown flash tank, when the boiler water quality is not up to standard, blow down the water
to the periodic blowdown flash tank.
2.5.15 When the steam drum pressure rises to 1MPa, if the steam-water quality is not up to standard,
increase blowdown amount, during blowdown, keep the boiler pressure steady and perform backwash to
the attemperating water system at the same time.
2.5.16 During temperature and pressure rise, it shall strictly control the steam drum wall temperature
difference within 40℃and furnace outlet gas temperature not more than 538℃.
2.5.17 When the main steam pressure rises to 4.1Mpa, it shall reduce oil amount appropriately and keep oil
pressure steady, when the main steam temperature reaches 330℃ and reheated steam temperature reaches
300℃, report it to shift engineer and close high/low pressure bypass and perform turbine impulse starting.
2.5.18 Before turbine impulse starting, keep steam drum water level a little lower (about -100mm) to
prevent steam drum water level rising too high after impulse starting.
2.5.19 During turbine impulse starting and warming up, keep boiler steam temperature and pressure steady.
2.5.20 When warming turbine up, make an overall check on boiler proper and auxiliary equipment, at the
same time, make check and preparations well before starting pulverizing system.
2.5.21 When the turbine rotating speed rises to 3,000rpm, the unit begins to parallel, and then it shall close
all water drain valves and withdraw furnace gas temperature probe.
2.5.22 After parallel of the unit, it has about 5% initial load, keep main steam temperature at
320℃~330℃and main steam pressure at 4.1 Mpa, warm up for 30 mins, during which, keep steam
temperature and pressure steady.
2.5.23 When the unit load rises to 10%, the boiler continues to increase the pressure at the speed of
0.091MPa/min and increase the load at the speed of 1.6MW/min. Increase the fuel pressure and oil gun
quantity as required by synchronous pressure rise and run up.
2.5.24 When the load is higher than 10 ％, the secondary air temperature at air preheater outlet is higher
than 166℃, when the oil gun quantity is more than or equal to nine, start the pulverizing system on layer B
according to combustion and run up.
2.5.24.1 Start primary air fan A and B, at the same time, link seal fan A or B, check seal air mains/primary
air differential pressure is normal, slowly open the inlet dampers of primary air A and B, and maintain the
primary air mains pressure larger than 7.5KPa.
2.5.24.2 Start pulverizing system B as required by boiler combustion and run up.
Conditions for feeding pulverized coal:
 No MFT signal;
 Steam drum pressure is normal (> 3.5MPa);
 Secondary air temperature is appropriate (> 166℃);
 Adjacent oil layer has already been put into operation, or adjacent coal layer has already operated and
boiler load is higher than >40%;
 Air quantity >30%;
 Furnace pressure is normal;
 The differential pressure between wind box and furnace is normal;
 The differential pressure between seal air and primary air is normal;
 The differential pressure between primary air and furnace is normal;
2.5.25 After putting the first coal pulverizer into operation, observe furnace combustion conditions through
furnace flame television, increase coal feeder rotating speed manually and slowly, at the same time, reduce
fuel oil amount, control the main stream temperature rise within 2.5℃/min and the main steam pressure
rise rate within 0.091MPa/min, gradually reduce the operation of oil gun on upper layer EF, when the
boiler-front oil pressure decreases to approach below normal range 0.75Mpa, the oil guns on layer EF can
be stopped.
2.5.26 When the load rises to 15% (put flue gas desulfurization device into operation).
2.5.27 When the load rises to 20%, at the time, the main steam pressure reaches 6.7Mpa, the main steam
temperature reaches 400℃ and reheated steam temperature reaches 360℃, pay attention to monitoring the
changes of steam drum water level, switch the feed water from bypass to the main line as electrically driven
feed water pump rotating speed is very high and when maximum opening of the bypass adjusting valve,
during which, pay attention to the feed water flow value before and after switching and steam drum water
level changes.
2.5.28 When the coal amount of pulverizing system B reaches 40%, start pulverizing system A to operate.
2.5.29 When the load is 75MW and electric speciality switches auxiliary power from HV standby
transformer to HV plant transformer, after notice is received, it is prohibited to start 6KV equipment, at the
same time, monitor the current indications of all auxiliary machinery motors strictly.
2.5.30 Put the upper fuel air damper to automatic adjustment and inform turbine operator, boiler operator
and generator operator of continuing to raise pressure and load.
2.5.31 When the load rises to 35%, the main steam pressure is about 9.3Mpa, the main steam temperature is
475℃, reheated steam temperature is 435℃, at the time, intermit run up, open continuous blowdown valve
wide to clean silicon, the relation between silicon content of boiler water and steam drum pressure is shown
as follows:
Attached table 3-2:
Steam Drum Pressure MPa 9 10.5 12 13 14.5 16 17 18.5

Max silicon content of boiler
water when silicon content
mg/L 3.6 2.3 1.5 1 0.7 0.5 0.3 0.2
of steam is ≯0.02mg/L,
(boiler water PH≈10)
Boiler water volatility
mg/L 0.8 0.8 0.8 0.5 0.3 0.25 0.2 0.2
treatment PH=9.0
2.5.32 Contact turbine operator to start steam-driven feed water pump A or B, when one steam-driven feed
water pump is under boiler control, keep the feed water flows of two pumps (one electrically driven feed
pump and steam-driven feed water pump) are the same basically as far as possible and control the steam
drum water level within the normal range.
2.5.33 When the output of pulverizing system A and B both exceed 50%, the pulverizing system C can be
started, at the same time, inform electrostatic precipitation attendant of putting the fourth electric field into
operation. When the superheated steam temperature reaches 530℃,superheated steam temperature control
automation can be put into operation.
2.5.34 When the load rises to 50%, the main steam pressure should reach 12Mpa, the main steam
temperature reaches 538℃, reheated steam temperature reaches over 500℃, report it to shift engineer and
contact the chemical group to check that the silicon content of boiler water is within 0.8mg/L, or stop
pressure rise and run up to clean silicon.
2.5.35 Start the pulverizing system D as required by combustion and run up, withdraw the oil guns on layer
AB according to the needs, at the same time, contact electrostatic precipitation attendant to put
corresponding electric field into operation.
2.5.36 When the load reaches 60%, reheated steam temperature reaches 538℃, put the control for swinging
angle of burner nozzle into auto and the control for reheater emergency water spray into auto, if the second
heat pump is put into operation for the turbine, gradually switch the load of electrically driven feed water
pump to the second steam-driven feed water pump, and then inform turbine operator of make electrically
driven feed water pump no-load for standby and gradually withdraw oil guns.
2.5.37 When the coal amount of each coal feeder is equal, they can be put into auto.
2.5.38 When the load rises to 80%, the main steam pressure should be controlled within 16.6Mpa, the main
steam temperature and reheated steam temperature is the rated value 540℃, at the same time, make an
overall check on the boiler.
2.5.39 After it is checked to be normal and the combustion is steady, perform overall sootblowing for the
furnace and air preheater.
2.5.40 Contact thermodynamic operator to put the controls for boiler feed water, attemperating, air quantity,
pulverizing, furnace negative pressure into auto state, continue to raise load to 80%~100%, at the time , set
the upper limit of the load as 100% (300MW), the lower limit as 80% (240MW), load object instruction as
100% (300MW), rate of load change as 1.6MW/min and throttle pressure as 17.4Mpa, put the fuel main
controller and boiler main controller into auto, and select turbine follow mode on DCS menu.
2.5.41 Start pulverizing system E and F into operation according to load, when putting a coal feeder into
operation, reduce the coal feed amount of other coal feeders until the load and steam pressure rise at rise
rate uniformly, gradually increase the load to 300MW..
2.5.42 After the turbine follow mode is steady, the CC－TF or CC－BF mode can be selected.
Precautions for cold start process:
 Monitor the steam drum water level changes closely, when the auto of water level get “Failure”, switch
it to “Manual” immediately, control the water level within ±50mm strictly;
 Strictly control the temperature difference between steam drum upper wall and lower wall not over
40℃, if it tends to exceed, it shall reduce the pressure rise rate immediately, after the temperature
difference is up to standard, continue to increase temperature and pressure;
 Make a periodic check and record the expansion indications of all parts, if abnormal, find out cause and
then continue to increase the pressure only after removal of the reason.;
 Control temperature and pressure rise according to the unit startup curve strictly, saturation temperature
rise rate can not exceed 1.5 ℃/min, closely monitor the temperatures of superheater and reheater tube walls
to prevent overheat;
 Strengthen the maintenance and adjustment of the oil gun, guarantee atomization combustion is good,
closely monitor the changes of air preheater outlet gas temperature and exhaust gas temperature to prevent
secondary combustion accident, when the steam temperature and gas temperature increases rapidly, take
corresponding measures immediately, continue to increase the pressure only after it is normal;
2.6 Boiler hot start
2.6.1 Preparations before start
2.6.1.1 Close 5% bypass.
2.6.1.2 If the steam drum pressure is higher than 0.2MPa, all air valves are kept closed.
2.6.1.3 Other preparations are the same with those for cold start.
2.6.2 Boiler ignition and pressure rise
2.6.2.1 The steps of boiler ignition for hot start are the same with those of cold start, take the boiler
minimum pressure after ignition as the starting point, raise temperature and pressure according to hot
startup curve.
2.6.2.2 Open 5% bypass for drainage according to circumstances.
2.6.2.3 After boiler ignition, put high/low pressure bypass into operation. Gradually close 5% bypass.
2.6.2.4 Put a certain quantity of oil guns into operation according to the turbine cylinder temperature,
control steam pressure to correspond to the temperature.
2.6.2.5 During turbine impulse starting, the main steam temperature should have at least 50℃ of superheat
degree, and the reheated steam temperature should approach the main steam temperature as far as possible.
2.6.2.6 During turbine impulse starting, warm up one coal pulverizer.
2.6.2.7 During turbine impulse starting and warming up, boiler should maintain steam pressure and
temperature steady as far as possible.
2.6.3 Boiler run up
2.6.3.1 After unit synchronization, the coal pulverizer should be put into operation, at the same time, one
coal pulverizer should be kept warmed up.
Unit run up should be performed according to boiler hot startup curves, which is similar with that of the
cold start.
2.7 Boiler startup state
1. Cold start (shutdown for over 36 hours): <8 hours;
2. Warm start (shutdown for 10~36 hours): <2.5 hours;
3. Hot start (shutdown for less than 10 hours): <0.75 hours;
4. Synchronize to operate at full load (during hot start): 45 minutes;
5. Control the time of loading down from full load to zero load to 45 minutes.
PART 3 Unit Operation
Chapter 1 Normal Operation Adjustment
1. Tasks of boiler operation adjustment
1.1 Make the boiler capacity meet the demand of unit load.
1.2 Maintain normal steam temperature and pressure.
1.3 Balance water supply to maintain normal steam drum water level.
1.4 Guarantee boiler water and steam quality are up to standard.
1.5 Maintain reasonable combustion, reduce heat loss and increase boiler efficiency.
1.6 Guarantee the safe operation of the unit.
2. Main parameters and limitations of boiler operation control
Attached table 4-1
MCR Rated Variation Alarm Value
No. Name Unit
Cond. Load Range High Low Trip
1 Superheated steam flow T/h 1025 951.8
Superheated steam
2 MPa 17.4 17.28 17.2±0.2
pressure
Superheated steam outlet
3 ℃ 541 541 541±5 546 536
temperature
4 Steam drum pressure MPa 18.75 18.46
5 Reheater inlet pressure MPa 3.917 3.625 4.28
6 Reheater outlet pressure MPa 3.737 3.458 4.5
Reheater inlet
7 ℃ 330.3 322.6 407
temperature
Reheater outlet
8 ℃ 541 541 546~531 546 531
temperature
9 Reheated steam flow t/h 846 785
Low-temperature
10 superheater tube wall ℃ 490
temperature
Division panel wall
11 ℃ 490
temperature
Rear platen tube wall
12 ℃ 575
temperature
Last stage superheater
13 ℃ 585
tube wall temperature
Tube wall temperature of
604
14 division wall reheater ℃
606
and last stage reheater
15 Feed water temperature ℃ 282.6 277.5
Radiant reheater outlet
16 steam temperature not ℃
more than
Rear platen reheater
17 outlet steam temperature ℃
not more than
18 Steam temperature after ℃ 335
left emergency water
spray
Steam temperature after
19 right emergency water ℃ 335
spray
Electric Electric
+240
20 Steam drum water level mm 0 0 ±50 contact contact
-330
I: +120 I:-180
Steam temperature before
21 one-stage attemperating ℃
water not more than
22 one-stage attemperating ℃
water not more than
Steam temperature before
second stage
23 ℃
attemperating water not
more than
second stage
24 ℃
attemperating water not
more than
+3,240
25 Furnace pressure Pa -100 -100 -100~-50 +980 -980
-2,490
Forced draft fan bearing
26 ℃ >85 100
temperature
Induced draft fan bearing
27 ℃ <60 <60 >85 95
temperature
Pressure difference
between upper bowl and
28 KPa >2.5
lower bowl of coal
pulverizer
Coal pulverizer SA &
29 KPa >2 >2 <2
mill bowl DP
Primary air piping
30 KPa 10 10 －7.472 4.98
pressure
Primary air fan bearing
31 ℃ <70 >85 95
temperature
32 Oxygen content % 4 4~5 3~8
Pressure difference
33 between secondary air Pa 1,000 1,000 380
and furnace
34 Purging air pressure MPa 0.6~0.7 > 0.50
Air pressure for
35 MPa 0.6~0.7 < 0.5
instrument control
Coal pulverizer outlet
36 ℃ 77 77 65~80 >80 93
temperature
3. Steam drum water level adjustment and water level gauge maintenance
3.1 Water level adjustment
3.1.1 Water level should be kept within ±20mm, and its adjustment range is within ±50mm, the upper limit
alarm value is +120mm, low limit alarm value is -180m, when the steam drum water level is higher than
+240 or lower than -330mm, boiler protection MFT operates. During boiler operation, the steam drum
water level should be subject to the display instrument with pressure & temperature compensation in DCS
as standard, check and calibrate the local water level gauge and gauge water level gauge every shift, if the
indications are out of line, check the correctness of the water level gauge, and inform the thermodynamic
operator of dealing with it immediately.
3.1.2 When the boiler load is below 30%, automatic feed water adjusting system is under single impulse
control, when the load is above 30%, it is under three-impulse control, when feed water is in auto state, pay
attention to monitoring the change of boiler water level, when auto fails, immediately switch it to manual
control to maintain the steam drum water level within normal range, attendant should report it to unit
supervisor and shift engineer and contact thermodynamic operator to deal with it immediately.
3.1.3 During switching of manual/auto for water level adjustment, adjust the steam drum water level to “0”
position manually, after it is steady, put feed water to auto to prevent automatic adjusting system from big
disturbance.
3.1.4 When the steam drum water level increases due to manual misadjustment, reduce the water level to
the normal value by opening continuous blowdown valve, periodic blowdown valve and emergency water
discharge valve, etc. wide.
3.1.5 During operation, keep all steam drum water level gauges complete, indication correct and clear,
illumination enough, clean water level gauges according to regular working system to guarantee the TV
monitor for water level in the control room is clear.
3.2 Water level gauge maintenance
3.2.1 Check of water level gauge
When checking the water level, slightly open the water discharge valve, when the water level reaches a
certain hole, immediately close it, the indication for discharged part turns red from green and then recovers
to green quickly after water discharge valve is closed, which can be used to determine the correct water
level. If the liquid level of local water level gauge is found to be stagnated or unclear, wash the water level
gauge.
3.2.2 Put-in of water level gauge in cold state
3.2.2.1 Make sure the water level gauge maintenance is completed and the illumination is complete;
3.2.2.2 Open the primary and secondary steam and water valves of water level gauge, close water discharge
valve;
3.2.2.3 Water level gauge temperature and pressure rise is in line with that of the boiler;
3.2.3 Put-in of water level gauge in hot state
3.2.3.1 Make sure the water level gauge maintenance is complete, and the illumination is complete, steam
and water side valve and water discharge valve are all closed;
3.2.3.2 Slightly open the water discharge valve and fully open primary steam and water valves;
3.2.3.3 Slightly open the secondary valve of steam side and preheat water level gauge for 30 minutes;
3.2.3.4 Close the secondary valve of steam side and water discharge valve;
3.2.3.5 Slightly open the secondary valve of water side and lead hot water to the water level gauge;
3.2.3.6 Open the secondary valve of steam side and lead steam to the water level gauge;
3.2.3.7 Fully open the secondary valves of steam and water sides;
3.2.3.8 Observe that the water level of the gauge should have fluctuation;
3.2.4 Washing of local water level gauge
3.2.4.1 During operation, if the water level gauge is found not clear or does not change, perform washing
work immediately.
3.2.4.2 Close the secondary valve of water side and slightly open the secondary valve of steam side;
3.2.4.3 Slightly open the water discharge valve for warming and close it after 3 minutes;
3.2.4.4 Close the secondary valve of steam side and slightly open the secondary vale of water side, and
close it after the water level increases;
3.2.4.5 Open the water discharge valve to wash for five minutes;
3.2.4.6 Slightly open the secondary valve of steam side to wash for 20 minutes;
3.2.4.7 Slowly close the secondary valve of steam side and water discharge valve;
3.2.4.8 Slightly open the secondary valve of water side and lead hot water to the water level gauge;
3.2.4.9 Slightly open the secondary valve of steam side and lead steam to the water level gauge;
3.2.4.10 Fully open the secondary valves of steam and water sides;
3.2.4.11 Before and after washing steam drum water level gauge, pay attention to the water level situation
in the gauge, the water surface has slight fluctuation, if the water level in the gauge increases slowly, it
indicates there is jam, so it shall be washed again.－
3.2.5 Parallel off of local water gauge
3.2.5.1 During operation, if water level gauge leaks or explode, or the water level gauge mica is not clear
even after being washed, stop the water level gauge immediately and hand it over to the maintenance
personnel for treatment.
3.2.5.1 Close the secondary valve of steam side;
3.2.5.2 Close the secondary valve of water side;
3.2.5.3 Close the primary isolation valves of steam and water sides;
3.2.5.4 Slowly open water discharge valve, and then the water level gauge releases pressure;
3.2.6 Precautions for water level gauge operation
3.2.6.1 Operate the water level gauge slowly and carefully during put-in to avoid excessive thermal shock;
3.2.6.2 During the operation of water level gauge, prevent the outside cold air and cold water from
contacting with glass;
3.2.6.3 When operating water level gauge, stand at the side of water level gauge and use safety appliance;
3.2.6.4 During acid cleaning and overpressure test for the boiler, the local water level gauge should be
paralleled off;
3.2.6.5 During normal operation, the primary and secondary valves of steam and water side of water level
gauge should be fully opened.
4. Combustion adjustment
4.1 Fuel oil adjustment
4.1.1 During boiler normal operation, put boiler-front fuel oil circulation system into operation and make
all oil guns ready for put-in at any time;
4.1.2 The pressure of standby fuel oil should be kept larger than 3.26Mpa;
4.1.3 When the boiler load is lower than 150MW or combustion is unsteady, two coal pulverizers operate
and the coal feed rate of one of them is lower than 50%, and combustion-supporting with oil is needed;
4.1.4 When oil layer starts other than coal layer, the auxiliary air of this layer should be turned down to
below 10%, after the ignition of the first oil gun, open the auxiliary air of this layer to a larger extent
immediately, with opening ≥ 50%, and the differential pressure between big wind box and furnace is > 0.38
kPa;
4.1.5 When the oil gun is put into operation, there should be someone to perform local inspection, if it is
found that atomization is poor, oil does not burn or the oil gun leaks oil (including leak oil into the furnace),
withdraw the oil gun immediately, find the cause and remove it;
4.1.6 After the oil gun is put into operation, the oil mains pressure should be kept above 2.8;
4.1.7 Put-in of electrostatic precipitator
a. When only oil or the mixture of oil and coal from single coal pulverizer is fired, don’t put electrostatic
precipitator into operation;
b. When two coal pulverizers operate and the mixture of oil and coal is used for combustion, put No.
4electric field of electrostatic precipitator into operation;
c. When over three coal pulverizers operate or only coal is used for combustion, put all electrostatic
precipitators into operation;
4.1.8 Put air preheater into operation for sootblowing as long as oil is used for combustion;
4.1.9 When the oil layer is below or in the middle of coal layers, the auxiliary air of this oil layer should be
not too big for easier burning of pulverized coal. When the oil layer is above the coal layer, the auxiliary air
of this oil layer should be increased for the complete combustion of this oil layer;
4.2 Coal adjustment
4.2.1 During normal combustion for boiler, the flame is golden yellow and does not deflect, the combustion
in the furnace is steady, the flame should not wash the water-cooled wall directly, the filling degree of
flame is good, the heat load of the furnace is uniform so that they reduce the heat loss due to incomplete
combustion and improve economical efficiency of the boiler and guarantee the heating surfaces at all levels
of the boiler don’t overheat;
4.2.2 Operators should often make overall checks on the operation situation of the combustion system and
adjust it in time if poor combustion is found. Observe the combustion situation in the furnace and the
ignition distance of pulverized coal through flame television and the flame in the furnace and adjust the fire
point of the fuel and the flame center appropriately;
4.2.3 Adjust forced draft quantity and induced draft quantity and keep the negative pressure between
-50Pa~-100Pa to prevent the upper combustion chamber from smoke and ash. When single side fan
operates, the load depends on air quantity and combustion with oxygen lack is strictly prohibited.
4.2.4 Keep the best proportion of primary air and secondary air to guarantee the oxygen content in the
range of 4%-6%, organize good combustion conditions in the furnace, control the deviations of the furnace
outlet temperature and the flue gas temperatures at both sides of each section of gas pass does not exceed
28℃. When the fuel ash fusion point is too low or the mixture of oil and coal is used for combustion,
increase the oxygen content properly to prevent formation of slag;
4.2.5 After the burner is put into operation, check if the ignition situation is good, adjust the air quantity in
time to prevent funnel from black smoke. During combustion adjustment, pay attention to the temperature
change of each section of working medium and prevent coking. If coking, remove it in time, and perform
sootblowing for the water-cooled wall regularly, when the combustion is not steady, it is prohibited to
perform sootblowing for the water-cooled wall and remove coke. When coking is serious, reduce boiler
load;
4.2.6 When the load changes, if the extent is not big, adjust it by changing the coal feeder rotating speed, if
the extent is big, adjust it by starting and stopping pulverizing system; when the load is increased, first
increase air quantity and then the coal feed amount, when the load is reduced, first reduce coal feed
amount, and then the air quantity to guarantee complete combustion;
4.2.7 Master the combustion characteristics of this boiler, set the preact of each coal feeder during load
adjustment to prevent steam temperature and steam pressure from large fluctuation, when the load is lower
than 150MW or combustion is unstable, the oil gun should be put into operation to make combustion
stable;
4.2.8 In order to make sure the economical operation of the boiler, keep fineness of pulverized coal
qualified and make sampling analysis for fly ash and the slag at furnace bottom, make comparison and
adjustment in time;
4.2.9 During boiler operation, know about the chemical analysis for the categories of coal and fuel oil,
and adjust operating conditions in time according to the characteristics of fuel;
4.2.10 In order to keep boiler combustion stable and increase combustion efficiency, reduce air leakage as
much as possible. All observation holes, coke removal gate and manhole, etc. should be tightly closed, if
there is air leakage, stop it in time;
4.2.11 Change the flame center position through swing burner or changing the opening of the secondary air
damper according to the steam temperature and steam pressure to guarantee stable combustion, steam
temperature and steam pressure;
4.2.12 When unstable combustion happens due to any reason, put oil gun into operation in time to make
combustion stable and find out the cause and eliminate the factors of unstable combustion. If fire extinction
happens, it is prohibited to supply fuel to the furnace to avoid boiler explosion;
4.3 Air quantity adjustment
4.3.1 During boiler operation, adjust the air quantity according to the change of fuel amount in time and
keep the oxygen content of economizer outlet flue gas is 3.3~4.2%.
4.3.2 Under high load, properly reduce excess air coefficient to keep the oxygen content of flue gas at the
lower limit of the specified value; under low load, properly increase excess air coefficient to keep the
oxygen content at the upper limit of the specified value;
4.3.3 Under the conditions of low load, unstable combustion or relatively high moisture in the coal,
properly reduce primary air speed and turn down fuel air to make fire point in advance, when the load is
≥250MW, the coal quality is good and the combustion is stable, increase primary air speed and turn up the
fuel air for convenience of complete combustion and preventing water-cooled wall from coking;
5. Adjustment of boiler load and steam pressure
5.1 When the main steam pressure changes, operators should judge the cause of change in time and change
fuel amount according to the speed of steam pressure change; adjust fuel amount, as well as the primary air
quantity and secondary air quantity to keep the combustion stable and complete.
5.2 During combustion adjustment, guarantee the main steam pressure of boiler side is ≤17.3Mpa, reheated
steam pressure is ≤3.23Mpa, and the pressures at velocity stage of turbine side, high pressure heater and
deaerator should not exceed their rated values.
5.3 When the main steam pressure is higher than 18.02Mpa and PCV fails to operate, immediately open
PCV manually, if the steam pressure falls slightly, close PCV.
5.4 When the steam pressure is very low and it fails to recover in a short time after intensified combustion,
contact turbine operator to reduce partial load, and then recover the load after the steam pressure increases,.
When the steam pressure is lower than 14.9Mpa (turbine side), reduce load rapidly to maintain the main
steam pressure more than 14.9Mpa. (except sliding pressure operation－
5.5When the boiler load is within 117~233MW, sliding pressure operation can be adopted. During sliding
pressure operation, the load variation speed can not exceed 10MW/min.
6. Steam temperature adjustment
During normal operation, the main steam and reheated steam temperature should be kept at 541±5℃, when
t combustion conditions change, the main steam and reheated steam temperature should be adjusted within
the allowable value, and the differences of the main steam temperatures and the reheated steam
temperatures at both side should be lower than 14℃.
6.1 Main steam temperature adjustment
6.1.1 During constant pressure operation above 200MW and sliding pressure operation above 166MW, the
main steam temperature should be kept at 541℃ with normal variation range of 541±5℃.
6.1.2 Boiler steam temperature is attempered at two stages. The first stage attemperator is used to adjust the
steam temperature at division wall inlet to keep it at 409℃; the second stage attemperator is used to adjust
the steam temperature at last stage superheater inlet to keep it at 505℃, the proportion of spray water
quantities of the first and second attemperating water is 70% and 30%.
6.1.3 When the coal pulverizer or coal feeder is started by ignition in hot start, the steam temperature
increases rapidly, when the load is lower than 45MW, the motor-operated valve of attemperating water will
automatically lock and can not be opened, which should be paid more attention. The second coal pulverizer
should start after the load is higher than 40MW.
6.1.4 During normal operation, after stopping the high pressure heater, the steam temperature drops first
and then rises rapidly, at the time, open attemperating water valve wide, put water-cooled wall sootblowing
into operation, when necessary, open wide turbine governing valve to reduce combustion.
6.1.5 If the attemperating water governing valve is almost fully open and the steam temperature is still
high, find the cause and remove it, at the same time, reduce the steam temperature with the following
methods:
6.1.5.1 Perform partial sootblowing for the water-cooled wall;
6.1.5.2 Adjust burner swinging angle downwards;
6.1.5.3 Turn down the auxiliary air of lowest layer and turn up the auxiliary air of the uppermost layer;
increase the burner load of lower layer, at the same time, reduce the burner load of the upper layer, and
lower flame center;
6.1.5.4 Turn down total air quantity and the air quantity for fuel;
6.1.5.5 Open the turbine high pressure governing valve wide;
6.1.6 When attemperators are all withdrawn and the steam temperature is still low, take the following
method:
6.1.6.1 Perform partial sootblowing for superheater;
6.1.6.2 Adjust f burner swinging angle upwards;
6.1.6.3 Turn up the auxiliary air of the lowest layer and turn down the auxiliary air of the uppermost layer;
reduce the burner load of the lower layer, at the same time, increase the burner load of the upper layer, and
upraise flame center;
6.1.6.4 Increase total air quantity and the air quantity for fuel;
6.1.6.5 Turn down the turbine high pressure governing valve;
6.2 Reheated steam temperature adjustment
6.2.1 During sliding pressure operation above166MW and constant pressure operation above 200MW, the
steam temperature should be kept at 540℃ with normal variation range of 530~545℃.
6.2.2 Reheated steam temperature adjustment adopts the mode of swinging nozzle angle up and down, and
it don’t use spray attemperating during normal operation. When the reheated steam temperature is out of
limit, and it is still very high after the nozzle is swung and water-cooled wall sootblowing is performed,
adopt spray attemperating, when the reheated steam temperature returns to normal, stop spray
attemperating.
6.2.3 Precautions for steam temperature adjustment:
6.2.3.1 The steam superheat degree should be guaranteed not lower than 50℃ after attemperating in any
case;
6.2.3.2 For reheated steam temperature adjustment, it shall guarantee the outlet temperature is not out of
limit, as well as the difference of the outlet steam temperatures at side A and B not more than 14℃;
6.2.3.3 Be careful about the adjustment with attemperating water adjustment under low load operation and
make sure the superheat degree of steam temperature after attemperating;
6.2.3.4 During boiler operation, the combustion adjustment, start/stop of the burner, start/stop of induced
draft fan and pulverizing system, sootblowing, slag & coke removal, etc., as well as start/stop of HP heater
will result in the changes of superheated steam temperature and reheated steam temperature, therefore,
operators should analyze the cause and direction of steam temperature change and make corresponding
adjustment in time.
7. Boiler sootblowing
7.1 Perform boiler sootblowing only after getting permission from the chief shift engineer, during boiler
sootblowing, increase the furnace negative pressure properly to keep combustion stable, at the same time
pay attention to the change of steam parameters.
7.2 Sootblowing steam parameters
Attached table 4-2
Item Pressure Temperature Steam Source
Name
Boiler proper 2.5MPa after pressure relief 334℃ after pressure relief Division wall superheater
sootblowing station station outlet
Boiler proper 1.0~1.5MPa < 250℃ Rear platen superheater
sootblower outlet (it is auxiliary steam
at startup )
Air preheater 2.5MPa after pressure relief 421℃ after pressure relief
sootblowing station station
Air preheater 1.0~1.5MPa < 350℃
sootblower
7.3 Conditions required for sootblowing
7.3.1 Boiler operation condition is normal, combustion is stable, and there is no other major operation.
7.3.2 The unit load is higher than 60%, and primary and secondary steam temperatures are stable.
7.3.3 Furnace negative pressure is normal, and the induced draft fan has adequate allowance.
7.3.4 Compressed air system is already normally put into operation.
7.3.5 The sootblowing pressure governing valve, program-controlled device signal and alarm device meet
put-in conditions.
7.4 Stop sootblowing immediately for any one of the following states:
7.4.1 The boiler operation condition is abnormal, combustion is unstable or the unit load is lower than 60%;
7.4.2 The unit and system have an accident;
7.4.3 Sootblowing system or sootblowing equipment goes wrong or is damaged;
7.4.4 Combustion chamber negative pressure can not be maintained or decoking can not be performed;
7.4.5 Steam (sootblowing) pressure is lower than 0.8Mpa or steam flow is lower than 91%.
7.5 Sootblowing procedure
7.5.1 Regardless of performing sootblowing manually or automatically, it shall be done for each part in
sequence as follows: air preheater, water-cooled wall (furnace chamber), flue gas pass, and then air
preheater again. (that is: air preheater → furnace chamber → flue gas pass →air preheater.)
7.5.2 For the sootblowing of furnace chamber sootblower, perform it from top to bottom to avoid cross ash
depositing of heating surface, that is: fifth layer →fourth layer→ third layer→ second layer→ first layer, on
each layer, blow the front and rear wall first and then blow the side walls A and B, use one sootblower for
front/rear wall or side wall A/B respectively to perform sootblowing in pairs.
7.5.3 During flue gas pass sootblowing, perform in pairs on side A/B according to the flue gas flow
direction, (the order is: division wall bottom at the furnace outlet, rear platen, platen reheater, last stage
reheater, last stage superheater, low temperature superheater, economizer).
7.6 Sootblowing period:
7.6.1 When the boiler operates normally, perform it every shift; (eight hours)
7.6.2 For the heating surface only which ash deposits easily, perform sootblowing according to its deposit
extent;
7.6.3 When boiler starts normally and before the boiler stops, perform an overall sootblowing for all
heating surfaces;
7.6.4 If the superheat and reheated steam temperatures are high, increase the sootblowing times for furnace;
7.6.5 If the superheat and reheated steam temperatures are low, increase the sootblowing times for
superheater and reheater furnace;
7.7 Precautions for sootblowing:
7.7.1 During the operation of sootblower, pay attention to protecting the furnace negative pressure and
sootblowing parameter to meet requirement, and do not perform sootblowing without steam;
7.7.2 When putting sootblower into operation, perform sootblowing according to the specified sootblowing
procedure, during manual sootblowing, the number of sootblowers can not exceed two sets in operation;
7.7.3 During sootblowing, don’t open the inspection hole to observe combustion and don’t remove coke or
manually remove ash;
7.7.4 When perform sootblowing, make an overall site check on the exit position of each sootblower;
7.7.5 In the process of sootblowing, in case of soot lance jam, overload, overcurrent trip, etc. malfunctions,
timely contact maintenance personnel to remove it, for the soot lance with the fault that can not be removed
timely, swing out it manually and timely contact for defects elimination;
8. Boiler blowdown
8.1 Continuous blowdown: according to chemical requirements, adjust the opening of continuous
blowdown adjusting valve opening in time, control blowdown rate to ensure the boiler water quality.
8.2 Periodic blowdown: the chief shift engineer shall perform program-controlled blowdown for the
downcomer periodically under the supervision of chemical operators according to chemical requirements,
when the boiler water quality worsens, perform manual blowdown for water-cooled wall lower header
when reducing the load to 150MW~180MW, and in normal operation, perform periodic blowdown
according to the normal regular work.
8.2.1 During blowdown, strength monitoring to the water level.
8.2.2 Fully open the primary blowdown valve of water-cooled wall lower header, slightly open the
secondary valve for warming.
8.2.3When there is no water shocking sound in blowdown pipe, fully open secondary blowdown valve, and
after blowdown for 30s, close the secondary valve and then primary valve.
8.2.4 Perform blowdown for the four blowdown loops successively.
8.3 Precautions for periodic blowdown:
8.3.1 Before blowdown, check the blowdown system; when the blowdown system is going through
inspection and repair, do not perform blowdown;
8.3.2 During blowdown, the pipe should not have violent vibration, strength warming work when the
vibration is big;
8.3.3 The blowdown should be performed in proper order, do not open two primary valves for blowdown at
the same time;
8.3.4 During blowdown, operators must wear protective appliance, when the blowdown device is defective
or work site and passage have no illumination, do not perform blowdown;
8.3.5 Open blowdown valve with special wrench, do not cover the wrench with bushing to help start
blowdown valve, during boiler operation, do not check the primary blowdown valve;
8.3.6 When finishing blowdown, fully check that the blowdown valve is in close position and there is no
leakage, report to the chief shift engineer after blowdown;
8.3.7 In the process of periodic blowdown, if the unit has abnormal situation or blowdown system goes
wrong, stop blowdown immediately;
PART 4 Boiler Shutdown
Chapter 1 Preparation before Boiler Shutdown
1.1 Preparation before Boiler shutdown

1.1.1 When receiving the boiler shutdown command from the shift engineer, inform every responsible
attendant to get done with their own preparation before boiler shutdown.
1.1.2 Check over the fuel oil system and make sure its operation is in good condition.
1.1.3 Check the coal storage in coal bunker, and propose the bunkering requirement according to the
shutdown time, and the coal bunker shall be emptied in case of shutdown for more than 15 days, special
cases shall be informed by the factory office will formulate corresponding measures.
1.1.4 Check the upper and lower water level once.
1.1.5 Give the heating surface an overall sootblowing prior to boiler shutdown
1.1.6 Give equipment defects and fill in boiler shutdown work sheet
Chapter 2 Boiler Shutdown
2.1 Sliding-parameter shutdown

Sliding-parameter shutdown means, under the condition that the governing valve of the turbine is fully
opened, the turbine gradually reduce the load with the reduction of boiler combustion rate to guarantee the
steam temperature, pressure and flow to meet the requirements of run down of turbine by sliding pressure
and temperature until boiler shutdown and fire-off. The operation is as follows:
2.1.1 When the load is reduced by 100%~50%, select the turbine follow mode or reduce load manually.
2.1.1.1 Target load is 150 MW and target main steam pressure is 10Mpa;
2.1.1.2 The rate of load change is 3MW/min;
2.1.1.3 The rate of main steam pressure change is 0.15MPa/min;
2.1.1.4 The main steam temperature and reheated steam temperature drops with the reduction of
combustion rate, at the time, control the rate of temperature drop not more than 1.2℃/min, during which,
pay attention to adjusting air quantity and make combustion stable, and control the parameter changes
according to the requirements of turbine sliding-parameter shutdown, when the load drops to 50~60% of
rated load, make combustion-supporting with oil according to the coal storage in the coal bunker and
combustion situation to avoid boiler fire extinction due to continuous drop of the load. When the main
steam temperature drops by 30℃, reduce the temperature after 10min steady operation, the purpose for
which is to control the temperature differences of the main steam and reheated steam and the thermal
expansion and differential expansion of the turbine. When the steam temperature after velocity stage is
lower 30℃ than the inner wall temperature of high pressure inner casing flange, stop reducing temperature
temporarily and control negative differential expansion.
2.1.2 The method to reduce load is usually to reduce the coal feed rate equally to all coal pulverizers till the
coal feeder rotating speed drops to 40%, then empty each coal bunker one by one from the uppermost layer
or stop corresponding coal pulverizer. Set the rotating speed of operating coal feeder of the uppermost layer
to manual mode, then gradually reduce the coal feeder rotating speed to the minimum value 25%, stop this
coal feeder after emptying belt, when the coal pulverizer is clean after purged and the outlet temperature
drops to lower than 50℃, stop the pulverizing system.
2.1.3 When the load is reduced to 60%, contact the turbine operator to stop one steam-driven feed water
pump and start electric pump for spinning reserve, gradually put oil in to stabilize combustion according to
the combustion situation.
2.1.4 When the load is reduced by 50%~30%:
2.1.4.1 Unit operation mode is still in turbine follow mode.
a. Set the target load as 30% and the target main steam pressure as 7.4Mpa;
b. Set the rate of load change as 3MW/min;
c. The rate of main steam pressure change is 0.15MPa/min;
2.1.4.2 When the load is 30%, keep two pulverizing system, the combustion stability under low load should
be taken into consideration, when the rotating speed of any coal feeder reaches 50%, the adjacent oil layer
must be put into operation and then the rotating speed of the coal feeder is reduced with the reduction of the
load.
2.1.4.3 When load is reduced to 30%, cooperate with the turbine operator to stop the other steam -driven
feed water pump and increase the rotating speed of electrically driven feed water pump manually, when the
rotating speed of the other steam-driven feed water pump is gradually reduced to 3,000r/min, set the
electrically driven feed water pump to soft manual operation position, stabilize steam drum water level, pay
attention to the feed water pressure and flow change, perform switching in time, contact with the turbine
operator to stop the steam-driven feed water pump.
2.1.4.4 When the electric load is reduced to 30%, the main steam pressure should be controlled at about
7.4Mpa, the main steam temperature is at about 520℃, after one-hour stableness, continue to reduce the
load at the speed of 1.5MW/min, reduce main steam pressure at the speed of 0.1MPa/min and main steam
temperature at the speed of 1.2℃/min.
2.1.4.5 When the load is 30%, the feed water is switched automatically from three-impulse to single-pulse
feed water auto or manual control, when the load is 75MW and electrical operators switch auxiliary power,
stop starting 6KV motor, at the same time, pay attention to the current change and operation situation of
each auxiliary machinery.
2.1.4.6 When the turbine high pressure heater gradually exits, pay attention to the changes of feed water
temperature and boiler steam drum water level. Stop one pulverizing system and No. 4 electric field.
2.1.4.7 When the load is reduced to 20%, switch the following auto adjustment to manual adjustment:
a. Superheater attemperating water governing valve is switched from auto to manual;
b. Superheater emergency spray attemperating governing valve is switched from auto to manual;
c. Burner swing is switched from auto to manual;
d. The rotating speed of the last coal feeder control is switched to manual;
e. The main line of feed water is switched to bypass;
2.1.4.8 When the load is lower than 20%, stop the pulverizing system of the last layer, after purging and
cooling all pulverizing systems, stop primary air fan and sealing air fan, inform electrostatic precipitator
attendant of stopping electrostatic precipitator, while rap device and heating system will continue to
operate.
2.1.5 When load is reduced to 10%, control the main steam pressure at about 4.7Mpa, the main steam
temperature at about 450℃ and the reheated steam temperature at about 430℃, control the burner nozzle
angle to horizontal position, the method to reduce load can be proper reduction of oil pressure and oil gun
number. When there is continuous feed water amount, close economizer recirculation valve, or open it.
2.1.6 Generator parallel-off and turbine shutdown
2.1.6.1 When the load is reduced to 15MW, turbine trips for shutdown, when the turbine stops, open the
water drain valves of superheater and reheater as required.
2.1.6.2 If it is ready for overhaul after the unit stops, it can operate for 1.5h under the unit load of 10% so as
to cool turbine rotor temperature uniformly, but the main steam temperature should be kept over 50℃
superheat degree, or parallel off for shutdown in advance. (according to the turbine requirements).
2.1.6.3 After paralleling off the turbine, put the flue gas temperature probe at furnace outlet into operation
position.
2.1.6.4 If dry maintenance is required after boiler shutdown, after turbine shutdown, the boiler shall
continue to operate for a period to dry the reheater and it shall guarantee the flue gas temperature at furnace
outlet not over 538℃ and combustion rate not over 10%MCR to the best, and perform continuous
sootblowing for air preheater.
2.1.6.5 After the turbine stops, switch air quantity from auto to manual, keep 30% air quantity till boiler fire
extinction, and perform sootblowing for the furnace for 5-10 minutes.
2.1.6.6 Remove slag once after boiler shutdown and strengthen the ash handling work with electrostatic
precipitator till it is cleared out. Inform chemical operators to stop chemical feed pump and close
continuous blowdown valve, sampling valve and chemical feed valve.
2.1.7 Boiler fire extinction
Do as follows after receiving boiler fire extinction command from shift engineer:
2.1.7.1 Stop all oil guns;
2.1.7.2 Close fuel oil trip valve;
2.1.7.3 After sootblowing, withdraw all oil guns;
2.1.7.4 Check that MFT should operate and give alarm;
2.1.8 After boiler fire extinction, keep 30% air quantity to perform furnace sootblowing for 5-10 minutes, if
there is not special requirement (such as heating surface leakage, first-aid repair for steam and water
system, etc.), stop forced draft fan and induced draft fan.
2.1.9 When the furnace temperature is reduced to lower than 149℃, stop the cooling fan of flame detection
probe.
2.1.10 After boiler fire extinction, slowly feed water to the steam drum to the maximum water level, stop
feed water pump, if the steam drum water level is lower to the minimum water level, start electrically
driven feed water pump, operate feed water bypass valve to feed water to +300mm with flow of lower than
100T/H.
2.1.11 After the fan stops, monitor the flue gas temperature at air preheater outlet, once it is found
abnormal, find out the cause on site, if under secondary combustion, deal with it as preheater ignition.
2.1.12 After the induced draft fan stops, when the flue gas temperature at preheater inlet is reduced to lower
than 150℃, stop air preheater.
2.1.13 Boiler water discharge:
2.1.13.1 Boiler water discharge mode is subject to the arrangement of shift engineer.
2.1.13.2 Normal water discharge should be performed when the boiler water temperature is reduced to
lower than 93℃.
2.1.13.3 Quick water discharge should be performed when the steam drum pressure is reduced to 0.8Mpa,
when the steam drum wall temperature is lower than 200℃, discharge water from the hot boiler with
pressure.
2.1.14 When the pressure is reduced to 0.2Mpa, open all air valves, blowdown valves and water drain
valves.
2.1.15 After boiler shutdown, close each hole valve and flue gas & air baffle to prevent ventilation, after
boiler stops for 8-10hours, open the inlet and outlet baffles of induced draft fan and forced draft fan for
natural ventilation, if quick cooling is required for inspection & repair, start one induced draft fan for
ventilation only after boiler stops for 17 hours and the steam drum wall temperature difference is lower
than 42℃.
2.1.16 In order to increase cooling speed, the steam drum water can be changed, but the water level should
be kept in the range of +250mm~+300mm, if the difference between inlet water temperature and steam
drum wall temperature is higher than 80℃, stop supplementing and changing water.
2.2 Boiler shutdown at rated parameters
Boiler shutdown in reserve state is generally performed in the mode of constant pressure shutdown, usually
the unit plant load is over 80%, the turbine gradually turns down steam adjusting valve to reduce load, the
turbine automatically maintain the steam pressure constant to reduce load with the reduction of boiler
combustion rate, the superheat degree of main steam temperature is not less than 100℃, or the main steam
pressure set value should be properly reduced.
2.2.1 When the load is reduced to 15MW, perform parallel-off shutdown for boiler fire extinction.
2.2.2 In order to keep the hot reserve state of the boiler, after boiler fire extinction, close each attemperating
water valve, after performing furnace purging for 5~10 minutes, stop forced draft fan and induced draft fan,
close each manhole.
2.2.3 After boiler fire extinction, switch feed water adjustment from auto to manual, manually adjust the
feed water flow lower than 100 T/H and fill water to +300mm, stop electrically driven feed water pump,
when the steam drum water level is reduced to -200mm, start electrically driven feed water pump again for
filling.
2.2.4 After boiler fire extinction, inform chemical operators of stopping chemical feed pump and close
continuous blowdown valve.
2.2.5 Pay attention to the changes of steam drum water level and pressure, when the flue gas temperature at
air preheater inlet is over 120℃, strictly monitor the change of flue gas temperature of air preheater.
2.2.6 After completing electric precipitation rapping, the ash in the ash hopper should be removed
completely, and then stop ash hopper heating of the electrostatic precipitator.
2.2.7 The operation and switching of other equipment is the same with that of sliding-parameter shutdown.
When the boiler is in hot reserve state, there should be specially-assigned person to monitor, make overall
checks periodically and record the results clearly.
2.3 Boiler emergency shutdown
2.3.1 If malfunctions occur due to boiler unit external or internal causes, in order to prevent malfunction
from expanding, the boiler unit should not operate for a long time, and then it can be stopped in a certain
period after arranged by electric network dispatcher upon the application of power plant.
2.3.1.1 During emergency shutdown, the load is generally reduced as per the speed rate of normal
shutdown, if the malfunction is likely to expand, increase the rate properly.
2.3.1.2 After boiler fire extinction, keep at least 30% air quantity to perform purging for 5 minutes, after
completing purging, stop forced draft fan and induced draft fan, tightly close each flue gas & air baffle.
When the flue gas temperature at the preheater inlet is reduced to lower than 150℃, stop the air preheater.
2.3.1.3 After boiler stops for 12 hours, open flue gas & air pass to make natural ventilation for the boiler.
2.3.1.4 After the boiler shutdown, when it needs to discharge water, it should be performed after the boiler
water is lower than 93℃.
2.3.1.5 The operation and switching of other equipment is the same with that of sliding-parameter
shutdown.
2.3.2 First-aid repair, shutdown and quick cooling for tube burst of boiler superheater, reheater, water-
cooled wall.
2.3.2.1 After receiving the command of shutdown due to the tube burst of boiler heating surface from shift
engineer, make an overall check and count all equipment faults and input them into the network.
2.3.2.2 Make an overall check on the fuel oil system, atomizing steam system and compressed air
atomizing system, and it should be normal for put-in of oil gun, make overall calibration to the steam drum
water level, at the same time, make an overall sootblowing for the heating surface.
2.3.2.3 Select TF2 mode or manual mode to reduce load and coal amount, in the mode of unit sliding-
parameter shutdown, the main steam pressure change rate is 0.15MPa/min and load change rate is
3MW/min.
2.3.2.4 When the unit sliding-parameter shutdown is down to 2.5Mpa, the main steam temperature is about
300℃ and the unit load is 20~25MW, generator is paralleled off, the turbine trips, the boiler continues to
keep two oil guns operating, and corresponding periodic work before boiler shutdown is done as per
specifications.
2.3.2.5 When the turbine trips, contact the turbine operator to turn up auxiliary steam heating as much as
possible to increase the feed water temperature (turbine stops and high and low pressure heaters exit from
operation).
2.3.2.6 The blowdown and discharge valves of the boiler can be opened orderly for repetitive change of
water.
2.3.2.7 During change of water, gradually reduce temperature and pressure at the speed of 1.2℃/min,
0.15Mpa/min respectively, in whole process of which, strictly control the steam drum wall temperature
difference not over 42℃.
2.3.2.8 When the steam drum wall temperature difference approaches 35℃, fire will be out for the boiler,
manually operate MFT, close the main water discharge valve of lower header and fill the steam drum to up
to the water level of +300mm.
2.3.2.9 After boiler fire extinction, if the reheater leaks, after purging for 15 minutes, stop forced draft fan
and induced draft fan, close tightly flue gas & air baffle and observation hole for banking, if the water-
cooled wall, superheater and economizer leak, keep one set of forced draft fan and induced draft fan
operating with the lowest air quantity for 30 minutes, and then stop them, open flue gas & air baffle for
natural ventilation, but when the difference between upper and lower steam drum wall temperatures is
higher than 42℃, close all flue gas & air baffle tightly to reduce cooling speed.
2.3.2.10 When the steam drum temperature difference is not more than 42℃, increase deaerator
temperature as much as possible(feed water temperature), continue to change water, but the water level
should be kept in the range of +240mm~+300mm, if the difference between the feed water temperature and
steam drum wall temperature is more than 80℃, stop supplementing and changing water.
2.3.2.11 When the pressure is reduced to 0.8Mpa and the steam drum wall temperature is lower than 200℃,
discharge water from hot boiler, when the pressure is reduced to 0.2Mpa, open the air valve, steam
discharge valve and water drain valve. When the flue gas temperature at air preheater inlet is reduced to
150℃, stop the air preheater.
2.3.2.12 Only after boiler stops for 17 hours and steam drum wall temperature difference is lower than
42℃, start one induced draft fan for forced ventilation.
PART 5 Handling of Boiler Unit Trouble
Chapter 1 General Rules for Trouble Handling

1.1 General rules for trouble handling
1.1.1 When trouble occurs, the shift engineer shall give unified command and lead attendants to handle
trouble quickly and decidedly within their own responsibility range, the leaders on site shall give necessary
guide according to the actual conditions on site, but this guide shall not contradict the command given by
shift engineer. If any, the command of shift engineer shall prevail. All commands of shift engineer, except
these that may directly harm safety of person and equipment, shall be executed firmly, in cooperation with
the following principles for handling steadily and calmly.
1.1.2 Rapidly remove the danger to person and equipment, personal safety is the first.
1.1.3 Decrease the trouble scope to the utmost and guarantee normal operation of equipment without
emergency.
1.1.4 Resume normal operation of unit as soon as possible after emergency is removed, satisfy the
requirement of system load and guarantee external power supply. Only when the equipment really does not
have operating condition or will do direct harm to the personal and equipment safety if goes on operating,
can the unit be shut down.
1.1.5 When trouble occurs, all repair and tests shall be stopped. The unit personnel have the right to stop
unconcerned persons to access the trouble site.
1.1.6 When such troubles that are not listed in the rules occur, the operators shall make correct judgment
according to their own experience for specific case, and take countermeasures to give rapid handling
initiatively.
1.1.7 In case of auto device getting fault, the operators shall make correct judgment, switch the related auto
device into manual in time and give in time adjustment, keep normal unit parameters and prevent trouble
enlargement.
1.1.8 After trouble handling is finished, operators shall record occurring time, phenomenon and the
measures adopted of trouble into the log practically and realistically, and call the related personnel together
after coming off work to discuss and analyze the trouble cause, responsibility and measures that shall be
adopted later, summarize experience and learning lessons therefrom.
1.1.9 In case of trouble occurring when handing over to the next shift and taking over from the last shift,
the related shift operator shall cooperate with each other but must obey the unified command of the unit
supervisor and shift engineer on duty, and shall not hand over to the next shift or take over from the last
shift until the trouble is brought to an end.
Chapter 2 Handling of Boiler Trouble

2.1 Boiler shutdown for trouble and fault.
2.1.1 Conditions of boiler emergency shutdown
2.1.1.1 In any case as follows, boiler MFT:
1) Two air preheaters all are stopped;
2) Two induced draft fans all are stopped;
3) Two forced draft fans all are stopped;
4) Any one coal layer is put into operation and two primary air fans all are stopped;
5) Steam drum water level is low;
6) Steam drum water level is high;
7) Furnace pressure is high;
8) Furnace pressure is low;
9) Whole furnace extinction;
10) Loss of fuel
11) Air quantity is less than 30% of rated air quantity;
12) Loss of flame detection cooling air. (Differential pressure is≤2KPa, 5s the standby air fan later is
connected, another 5s later alarm is made and 5min later MFT.)
13) Oil burner fails in ignition for more than twice;
14) FSSSS device is power off;
15) Turbine trips;
16) Touch button MFT with hand;
17) Re-purge request: no ignition 20min after purge is finished.
2.1.1.2 In any case as follows, the boiler shall be shut down manually for emergency:
1) Up to the operating condition for MFT but the protection does not operate.
2) All steam drum water gauges are damaged and cannot monitor the water level.
3) Convection flue gas pass has secondary combustion, but handling takes no effect, which make the
exhaust flue gas temperature rise up to 250ºC abnormally.
4) Pressure exceeds the operating pressure of safety valve but safety valve refuses to operate, meanwhile
the dump steam atmospheric valve can’t be opened.
2.1.2 Handling of boiler emergency shutdown
2.1.2.1 Boiler emergency shutdown after MFT operation
1) When MFT operates, the trouble sound is made and the “boiler emergency shutdown” signal is made,
then all primary air fans, seal fans, coal pulverizers and coal feeders trip, thereby coal pulverizer outlet
valves are closed, all igniters are prohibited to ignite, all oil angle valves are closed, all oil guns are
returned, fuel oil trip valve is closed, the turbine, electrostatic precipitator and program control sootblowing
trip, meanwhile signal is sent to CCS system, and equipment state displayed on CRT picture is not
corresponding.
2) Reset the switch of all trip equipment, keep normal steam drum water level; check and close the
superheated and reheated steam attemperating water main valve, stop blowdown and sootblowing.
3) Keep purging the furnace for 5mins with rated air quantity more than 30%. If it can recover in a short
time, get down preparation for startup which shall be conducted by hot start; if it can’t recover in a short
time, stop the induced & forced draft fans, and do other works as per normal boiler shutdown.
4) If the boiler shutdown is caused by boiler tube burst, preserve one induced draft fan in operation,
maintain slight negative pressure of furnace, and stop the induced draft fan when steam in furnace
disappears basically. If the boiler shutdown is caused by economizer bursting, it is prohibited to open the
recirculation valve of economizer.
5) If the boiler shutdown is caused by secondary combustion of convection flue gas pass, draft is
prohibited.
6) Report the trouble cause and handling course to the shift engineer immediately, and keep detailed
records.
2.1.2.2 Manual boiler emergency shutdown
Press the button “emergency shutdown” with hand, which operation is the same way with that when MFT
operates.
2.1.3 Conditions of asking for boiler shutdown
In any case as follows, it shall ask the shift engineer for shutting down the boiler:
1) Boiler feed water and steam quality deteriorates seriously and can resume normal after handling.
2) Leak occurs in pressure parts of boiler
3) Boiler has much coke, and can’t maintain normal operation after handling in every way.
4) Flue gas pass has much soot deposits, and the normal furnace pressure can’t be maintained after
measures.
5) Safety valve operates and can not be reseated.
6) Boiler steam temperature and heating surface wall temperature are seriously over temperature, and
cannot be decreased by adjustment in every way.
7) Main meters and gauges are out of order that cannot maintain normal operation and cannot recover in a
short time.
2.2 Handling of steam and water circuit fault
2.2.1 High steam drum water level
2.2.1.1 High steam drum water level phenomenon
1) When steam drum water level is indicated higher than the normal water level, high water level signal
alarms.
2) The feed water flow is abnormally larger than the steam flow.
3) When overfeeding, superheated steam temperature decreases sharply and water hammering occurs in
steam piping.
2.2.1.2 Causes for high steam drum water level
1) Fault in feed water governing valve or water pump hydraulic coupling is out of order.
2) Water gauge gives false indication that makes operators give false judgment.
3) Feed water auto adjustment is out of order and is not found in time.
4) Sudden change in operation condition.
5) Feed water is not adjusted in time.
2.2.1.3 Handling of high steam drum water level
1) When steam drum water level is +50mm. it shall check the steam drum water gauge, switch auto mode
of feed water into manual, and do corresponding adjustment. Check if there is any fault in feed water
system valves, and contact turbine operator to cooperate in adjustment.
2) When steam drum water level is +120mm, high limit I alarms.
3) When steam drum water level continuously rises, it shall open the continuous and periodic displacement
valves to discharge water, inform the turbine operator to pay attention to the steam temperature change, and
turn down or turn off the attemperating water valve according to the steam temperature, and open the
superheater water drain valve if necessary.
4) When the steam drum water level is up to +240mm, FSSS water level protection operates, which makes
boiler shut down for emergency, handle such a case as boiler emergency shutdown. Close the superheater
and reheater attemperating water main valves and open the superheated steam piping water drain valve.
5) Report to the unit supervisor and shift engineer to find out causes, remove fault, maintain normal water
level and prepare for reignition.
2.2.2 Low steam drum water level

2.2.2.1 Low steam drum water level being phenomenon
1) When steam drum water lever is indicated lower than the normal water level, low water level signal
alarms.
2) Feed water flow is abnormally lower than the steam flow; however, when leak occurs in water-cooled
wall economizer, phenomenon is on the contrary.
3) In case of serious water lack, superheated steam temperature rises much quickly.
2.2.2.2 Causes for low steam drum water level
1) Fault in feed water governing valve or the pump hydraulic coupling is out of order.
2) The steam drum water gauge gives incorrect indication that makes operators gives false judgment.
3) Feed water auto mode is out of order, and is not found in time.
4) Sudden change in operation condition.
5) Bursting of water-cooled wall or economizer.
6) Fault in feed water pump that causes low pressure of feed water.
7) Leak or too large blowdown quantity of the blowdown valve.
8) Improper feed water adjustment.
2.2.2.3 Handling of low steam drum water level
1) When the steam drum water level decreases to -50mm, it shall check the steam drum water gauge and
switch the feed water auto mode into manual adjustment, and conduct corresponding adjustment. The
periodic blowdown shall be stopped immediately in such a case.
2) When the water level decreases to -100mm, it shall open the bypass feed water valve to increase feed
water quantity. If the water does not show rise still, it is necessary to check if there is any fault in feed or
any leak in water-cooled wall and economizer. Report to the shift engineer and decrease the boiler heat
release rate and power load, if the feed water pressure is too low, it shall contact the turbine operator to
increase feed water pressure.
3) When the water level decreases to -230mm, FSSS water level protection operates which makes boiler
shut down for emergency, and handle such a case as boiler emergency shutdown. If the boiler shutdown
resulted from lack of water, it is prohibited to fill the boiler with water.
4) Find out the causes quickly and report to the unit supervisor and shift engineer, remove fault and wait for
recovery.
2.2.3 Water-cooled wall tube damaged
2.2.3.1 Phenomenon of water-cooled wall tube being damaged
1) Furnace pressure changes to positive, combustion is instable and there is noise in furnace.
2) Steam drum water level decreases rapidly, and the feed water flow is larger than steam flow.
3) If the time is a little longer, steam may be found flowing from the untight place at lower part of bursting
point.
4) The flue gas temperature difference and steam temperature difference between both sides increase, and
flue gas temperature of the damaged side decreases, and also the steam pressure and steam flow decrease.
2.2.3.2 Causes for water-cooled wall tube being damaged
1) Feed water quality is unqualified for long.
2) Tubing, installation and repair quality are bad.
3) Improper installation of burner and sootblower and the tube wall is washed for long.
4) Water circulation is bad for long, heat release is distributed unevenly, heat transfer operation condition
deteriorates and partial tube wall is over temperature.
5) High temperature corrosion
6) Large coke drops and damages the tube
2.2.3.3 Handling of water-cooled wall tube being damaged
1) If it is not damaged seriously, report to the shift engineer, decrease the superheated steam pressure and
maintain the steam drum water level and ask for boiler shutdown.
2) If it is damaged seriously, and the steam drum water level cannot be maintained or fire extinction is
caused, it is necessary to shut down the boiler for emergency.
3) Keep one induced draft fan in operating, maintain the furnace negative pressure, and stop the induced
draft fan after steam disappears. It is strictly prohibited to open the economizer recirculation valve, and
high steam shall be maintained to the utmost.
2.2.4 Economizer tube being damaged
2.2.4.1 Phenomenon of economizer tube being damaged
1) Steam drum water level decreases, and the feed water flow is abnormally larger than the steam flow.
2) Furnace pressure changes to positive, and smoke and ash are found belching from the untight places.
3) Temperature difference between two sides of economizer and preheater increase, and preheater outlet air
temperature and exhaust flue gas temperature decrease.
4) There is the sound of leaking around economizer.
2.2.4.2 Causes for economizer tube being damaged
1) Feed water quality is unqualified for long.
2) Temperature and flow change of feed water are of a large extent, which fatigue the metal.
3) Tubing, installation and repair quality unqualified or boiler over pressure.
4) Worn and torn by fly ash for long.
5) Tubing is burnt out by overheat.
2.2.4.3 Handling of economizer tube being damaged
1) If it is not seriously damaged, report to the unit supervisor and shift engineer, decrease the steam drum
pressure and maintain steam drum water level and ask for boiler shutdown.
2) If it is seriously damaged, in case the steam drum water level can’t be maintained, the boiler shall be shut
down for emergency. Retain one induced draft fan in operating, maintain furnace negative pressure, and
stop the induced draft fan after steam disappears.
3) It is strictly prohibited to open the economizer recirculation valve, and high steam drum water level shall
be maintained to the utmost.
2.2.5 Superheater tube being damaged
2.2.5.1 Phenomenon of superheater tube being damaged
1) Furnace pressure changes to positive, there is the sound of leaking around superheater, and steam and
ash are found belching and spraying from the untight places.
2) Flue gas temperature difference between two sides of superheater at the rear part becomes larger.
3) Steam pressure decreases, change of superheated steam temperature and attemperating water flow are
larger; the steam temperature of bursting part before the steam temperature measuring point is on the high
side and on the low side after the steam temperature measuring point.
2.2.5.2 Causes for superheater tube being damaged
1) Steam quality is unqualified for long.
2) Tubing, design, installation and repair quality are unqualified.
3) Pulverized coal is too coarse, and sootblower is installed improperly, resulting in serious erosion and
wear.
4) Superheater has soot deposits and coke, resulting in partial overheating or long time over temperature in
operation that overheats and fatigues the tube wall.
2.2.5.3 Handling of superheater tube being damaged
1) If it is not seriously damaged, report to the unit supervisor and shift engineer, decrease the superheated
steam pressure and load, maintain stable steam temperature to the utmost and ask for boiler shutdown.
2) If it is seriously damaged and even can’t keep operation, it is necessary to shut down the boiler for
emergency, and retain one induced draft fan in operating, maintain the furnace negative pressure, and stop
the induced draft fan after steam in furnace disappears.
3) Keep high steam drum water level after boiler shutdown.
2.2.6 Reheater tube being damaged
2.2.6.1 Phenomenon of reheater tube being damaged
1) There is sound around the reheater, reheated steam pressure decreases, furnace pressure changes to
positive, and steam or flue gas are found belching or spraying from the untight places.
2) When HT reheater bursts, steam temperature of LT reheater on bursting side is low, and when LT
reheater explodes, steam temperature of HT reheater is high.
3) Flue gas temperature difference between two sides of reheater at the rear part becomes larger, and flue
gas temperature on leaking side decreases.
2.2.6.2 Causes for reheater tube being damaged
1) Steam quality is unqualified for long.
2) Tubing, installation and repair quality are unqualified.
3) Worn and torn by fly ash or sootblower is installed improperly, resulting in erosion and wearing for long.
4) Coking and soot deposits result in over temperature.
2.2.6.3 Handling of reheater tube being damaged
1) If it is not seriously damaged, report to the shift engineer, decrease load, adjust combustion, maintain all
parameters stable and ask for boiler shutdown.
2) If it is seriously damaged and even cannot maintain normal operation, it is necessary to shut down the
boiler for emergency. Retain one induced draft fan in operating, maintain the furnace negative pressure, and
stop the induced draft fan after steam disappears.
3) Maintain high steam drum water level after boiler shutdown.
2.2.7 Over-high steam temperature
2.2.7.1 Phenomenon of over-high steam temperature
1) High steam temperature signal alarms.
2) Steam temperature indications of all sections rise.
3) Wall temperature indications of all sections rise.
2.2.7.2 Causes for over-high steam temperature
1) Steam pressure raising rate is too high.
2) Boiler load increase rate is too high.
3) Air quantity is adjusted improperly or type of coal varied
4) Nozzles of upper layer are overloaded, and the jet burner swinging angle is on the high side.
5) Air leakage in furnace bottom or furnace negative pressure is too high.
6) Attemperating water valve gets fault, attemperator auto mode is out of order that makes the governing
valve be turned down or turned off.
7) Feed water temperature lowers.
8) Water-cooled wall has no sootblowing done for long or has much coke.
2.2.7.3 Handling of over-high steam temperature
1) Handling of high superheated steam temperature
a) Switch the steam auto adjustment into manual adjustment.
b) Conduct corresponding adjustment of air and pulverized coal quantity in time and lower the flame
center. Put in oil to stabilize flame when combustion is instable.
c) Open attemperating water large immediately.
d) Reinforce sootblowing of water-cooled wall.
e) Check water seal of furnace bottom and shut off valve and make them return to normal. Close the
inspection holes of all parts tightly.
f) Rapidly decrease the boiler load.
g) Find out causes for high steam temperature, take handling directing toward which, and report to unit
supervisor and shift engineer in time.
h) When the turbine trips to shut down according to the stipulation for high steam temperature, boiler shall
be shut down for emergency.
i) After the causes are removed, wait for recovery.
2) Handling of high reheated steam temperature
a) Switch the steam temperature auto adjustment into manual adjustment.
b) Make the jet burner swing downward adequately, conduct corresponding adjustment of air and
pulverized coal quantity in time, and lower the flame center.
c) Put the emergency water spray into operation if necessary.
d) Properly decrease the boiler load.
e) Check water seal of furnace bottom and shut off valve and make them return to normal. Close the
inspection holes of all parts tightly.
f) Find out trouble causes, take handling directing toward which, and report to unit supervisor and shift
engineer in time.
g) When reheated steam temperature is up to the temperature limit that causes turbine to trip, the handling
method of boiler is the same with that of high superheated steam temperature.
Notes: the max. allowable temperature for turbine operation is 542~555ºC, and continuously operating time
each time shall not be more than 15min.
2.2.8 Over-low steam temperature
2.2.8.1 Phenomenon of over-low steam temperature
1) Low steam temperature signal alarms.
2) Steam temperature indications of all sections decrease.
3) Water hammering occurs in steam piping in serious case.
2.2.8.2 Causes for over-low steam temperature
1) Attemperating water valve gets fault or attemperating water auto adjustment is out of order, which is not
found in time.
2) Air quantity is adjusted improperly or the burner swinging angle of is adjusted too low.
3) Sudden change of coal type.
4) Serious ash deposit and coking on heating surfaces of superheated steam and reheated steam.
5) Steam pressure decreases greatly.
6) Feed water temperature and attemperating water pressure rise, which is not found and adjusted in time.
2.2.8.3 Handling of over-low steam temperature
1) Handling of low superheated steam temperature
a) Switch the auto adjustment into manual adjustment.
b) Turn down or turn off the attemperating water valve immediately.
c) Conduct adjustment of air and pulverized coal quantity, raise the flame center, pay attention to the steam
temperature rise again and prevent over control.
d) Reinforce the sootblowing of superheater part.
e) Find out causes for low steam temperature, take handling directing toward which, and report to the unit
f) When steam temperature is lower than 510ºC, load shall be decreased according to the turbine
prescription, and when the temperature of main and reheated steam temperature decrease by 50ºC within
10min, turbine shall be shut down for emergency.
2) Handling of low reheated steam temperature
a) Switch the auto adjustment into manual adjustment.
b) Adjust the jet burner swinging angle high, adjust the air and pulverized coal quantity in time, and raise
the flame center.
c) Find out causes for low steam temperature, take handling directing toward which, and report to the unit
d) If turbine trips, the handling method of boiler is the same with that of low superheated steam.
2.3 Handling of boiler combustion and air& flue gas system fault
2.3.1 Boiler fire extinction
2.3.1.1 Phenomenon of boiler fire extinction
1) Furnace negative pressure increases suddenly and abnormally.
2) No fire is detected by the flame monitor, and the fire extinction signal alarms.
3) Flue gas temperature decreases quickly, and oxygen content meter indicates the largest value.
4) Steam pressure, steam temperature and flow decrease quickly.
5) If the cause is boiler tube burst, induced draft fan fault or coal pulverizing system explosion, furnace
pressure is first positive and then negative.
6) All phenomena in case of boiler emergency shutdown as a result of MFT operation.
2.3.1.2 Causes for boiler fire extinction
1) Induced draft fan, forced draft fan, primary air fan, coal pulverizer or coal feeder trip for fault in
operation.
2) Boiler load is too low or load fluctuation is too large.
3) Adjustment is not made in time in case of water-cooled wall tube burst and coal pulverizing system
explosion.
4) Coal quality is too bad, and pulverized coal is too coarse.
5) Coal level of coal bunker is too low, and coal flow from coal feeder is uneven.
6) Oil is not put into operation in time to stabilize flame in case of instable combustion or low load
operation.
7) Operation mode of coal pulverizing system or air quantity use is improper.
8) Slag drop by a large area in furnace.
9) When oil is fired, the oil system gets fault, the solenoid valve is given unwanted operation.
2.3.1.3. Handling of boiler fire extinction
Take such a case as boiler emergency shutdown for handling.
2.3.2 Secondary combustion of convection flue gas pass
2.3.2.1 Phenomenon of secondary combustion of convection flue gas pass.
1) Negative pressure of flue gas pass changes greatly, and furnace pressure changes to positive.
2) Flue gas temperature of each part and exhaust flue gas temperature of flue gas pass rise abnormally, in
case of combustion on one side, then the temperature differences between two sides becomes larger.
3) Temperature of flue gas, air, steam and water at combustion place all rise abnormally.
4) The chimney discharges black smoke, oxygen content becomes smaller, and the untight places even
belch flame in serious case.
5) When secondary combustion occurs in air preheater, the current swinging is large, and casing
temperature is high or burned to red, and even jam fault may occur to the preheater in serious case.
2.3.2.2 Causes for secondary combustion of convection flue gas pass
1) Incomplete combustion when coal and gas mix in firing, resulting in a great deal of unburned
combustible matters depositing in the flue gas pass.
2) Low load operation time is too long and flue gas speed is low, resulting in a great deal of combustible
matters depositing in the flue gas pass.
3) Long time pulverized coal being coarse and air quantity lack, bad cooperation between air and
pulverized coal, incomplete combustion, flame center shift up, resulting in a great deal of combustible
matters depositing in the flue gas pass.
4) When only oil is fired, the oil gun atomization is bad, resulting a great deal of oil dropping and attaching
to the flue gas pass and heating surface.
2.3.2.3 Handling of secondary combustion of convection flue gas pass
1) If the temperature rises to 200℃ abnormally, it shall immediately check the flue gas temperature of
every section, adjust combustion mode, lower flame center, put the steam into sootblowing and report to
the unit supervisor and shift engineer.
2) If the measures take no effect and the exhaust flue gas temperature continues to rise to 250℃
abnormally, the boiler shall be shut down for emergency.
3) After boiler shutdown, the air and flue gas damper shall be tightly closed to keep the whole boiler tight,
air preheater goes on operating and steam sootblower shall be put in to operation for extinction. And give
water washing to the preheater if necessary.
4) Maintain proper amount of feed water to keep normal water level. If necessary, contact the turbine
operator for putting bypass system into operation. Put attemperator into operation in time according to the
steam temperature condition, and if the bypass system cannot be put in, open the dump steam atmospheric
valve.
5) Stop steam sootblowing when the flue gas temperature of each part decreases to normal value, and
inform the maintenance personnel to inspect.
6) The induced draft fan can be started only when confirming the flame is extinguished and receiving the
notice from the shift engineer, keep draft for 5~10min, and if the exhaust flue gas temperature does not rise,
the re-ignition can be done.
2.3.3 Induced & forced draft fan and primary air fan trip.
2.3.3.1 Phenomenon of induced & forced draft fan and primary air fan trip.
1) If one fan trips, the signal of sound and light is made, state displayed on CRT picture is not
corresponding, current is indicated to zero and corresponding auxiliary machinery are interlocked to trip.
2) If one fan trips, the load decreasing protection operates, and the load decreasing indicator lamp of lights.
3) When in auto put-in mode, one fan trips and the current of another air fan increases; if the induced draft
fan trips and the forced drafts is not interlocked to trip, then the furnace pressure changes to positive; if the
forced draft air fan trips, the furnace negative pressure increases or to the end, the secondary air pressure
decreases, and boiler fire will be extinguished in serious case.
4) If a single fan operates (the other is under repair) or two fans trip at the same time, then the boiler fire
will be extinguished.
2.3.3.2 Causes for induced & forced draft fan and primary air fan trip.
1) Fan and motor thermodynamic protection operate.
2) Electrical part or mechanical part gets fault.
3) Interlock operates.
4) Press the emergency button for shutdown.
2.3.3.3 Handling of induced & forced draft fan trip
1) If one trips when both the two fans are in operation, it shall switch the auto mode into manual
adjustment, reset the trip equipment switch, lower the load, put oil into stabilizing combustion, and close
the governing valve of tripped fan and corresponding damper baffle.
2) Enlarge the fan capacity on operating side, and load on according to the air quantity.
3) Report to the shift engineer and contact related staff to find out causes, and reset after the fault is
removed.
4) If the fan trips in single fan operation (the other forced draft fan is still powered on), or two fans trip at
the same time, then the FSSS boiler emergency shutdown protection operates, and such case shall be
handled as boiler emergency shutdown.
5) If the fan trips in single fan operation (the other forced draft fan is powered off for repair), if the MFT
does not operate, then it shall stop the operating primary air fan manually immediately, and make it
interlock the corresponding coal pulverizer, coal feeder and seal fan to trip, close the fuel oil fast valve
manually, and cut off all fuel put into the furnace; and other operations are the same as that in case of boiler
emergency shutdown.
2.3.4 Primary air piping being blocked
2.3.4.1 Phenomenon of primary air piping being blocked
1) If the tube is blocked before the air pressure gauge measuring point, the primary air pressure becomes
smaller, and if the tube is blocked after the air pressure gauge measuring point, the primary air pressure
becomes larger.
2) The jet burner sprays little or no pulverized coal.
3) The pulverizing system load will be influenced in serious case.
2.3.4.2 Causes for primary air piping being blocked
1) Operation is adjusted improperly, and primary air pressure and wind speed is too low.
2) When the primary air pressure is found abnormal in operation, the corresponding coal feeder speed is not
adjusted in time.
3) Jet burner gets slag.
2.3.4.3 Handling of primary air piping being blocked
1) Keep certain furnace negative pressure, decrease the coal feed or stop this coal feeder, use the primary
air to purge, and pay attention to the change of steam temperature, steam pressure and pulverizing system
temperature, if necessary, stop the coal pulverizer manually and start the standby pulverizing system.
2) If blocked seriously, it may use compressed air to purge through the purging hole.
3) If pulverized coal piping is blocked seriously, which can not be cleared by operation, inform the
maintenance personnel to handle.
2.3.5 Air preheater trip
2.3.5.1 Phenomenon of air preheater trip
1) When preheater on one side trips, the current of this preheater turns to zero, and sound and light alarm is
made.
2) Exhaust flue gas temperature of the trip side rises, and the hot air temperature decreases.
3) The turning gear of tripped preheater put in operation automatically.
4) If both sides trip, MFT operates and furnace fire is extinguished.
2.3.5.2 Causes for air preheater trip
1) Fault in mechanical part.
2) Fault in electrical part that causes trip.
3) Press the emergency button for boiler shutdown.
2.3.5.3 Handling of air preheater trip
1) If there is no over current phenomenon before trip, reset the tripped preheater switch, and close it on
forcedly, if succeeds, operation may continue.
2) If forced closing fails, there is no current or current over normal value, it shall be opened immediately,
and the turning motor shall be put into operation, if the turning motor cannot be put into operation, manual
turning shall be done.
3) Report to the unit supervisor and shift engineer in time, decrease the boiler load and put oil into
stabilizing combustion.
4) Find out the causes immediately, and contact with the maintenance personnel for handling.
5) If the exhaust flue gas temperature rises to 250℃, the boiler shall be shut down for emergency.
6) If two preheaters all trip, the boiler shall be shut down for emergency.
2.4.1 Load rejection
2.4.1.1 Load rejection phenomenon
1) Superheated steam flow decreases sharply, and its pressure rises sharply, signal for high superheated
pressure is made, dump steam atmospheric valve opens automatically, the superheater safety valve will
operation in serious case.
2) Reheated pressure decreases.
3) Illuminating lamp is dim first and then bright, and every kinetic current swings much.
4) Superheated and reheated steam temperature rise.
2.4.1.2 Causes for load rejection
1) Electric network system gets fault.
2) Turbine or electrical system gets fault.
2.4.1.3 Handling of load rejection
1) Switch auto mode into manual mode, decrease the coal feed or stop some (or all) pulverizing systems
according to the power load condition, and adjust induced & forced draft quantity correspondingly.
2) Put oil into stabilizing combustion as the case may be, pay attention to the change in steam pressure,
steam temperature and water level, make adjustment and prepare for increasing load.
3) If load rejection is serious, when the main steam pressure rises to value Ⅱ, safety valve will open, and
after pressure returns to normal, close the dump steam atmospheric valve of superheater manually.
4) When load rejection reaches zero and turbine does not trip, maintain boiler operating at min. output, and
wait for recovery according to the command of shift engineer.
5) When load rejection reaches zero and turbine trips, MFT operates, and boiler shall be shut down for
emergency.
2.4.2 Instrument power interruption
2.4.2.1 Phenomenon of Instrument power interruption
1) Signal for thermodynamic instrument power interruption is made, but the alarm signal does not sound,
and the signal lamp does not light.
2) All thermodynamic secondary instruments’ indications are out of order.
3) Thermocouple thermometer indication is on the low side, and electric contact water gauge indication
disappears.
4) All opening extents are indicated to zero, and auto adjustment is out of order. Motor operation of servo
gear does not work.
2.4.2.2 Causes for Instrument power interruption
1) Fuse of instrument main power supply blows or circuit gets fault.
2) The plant service power supply corresponding to the thermodynamic instrument gets fault.
3) Manual misoperation.
2.4.2.3 Handling of Instrument power interruption
1) Confirm the instrument power supply fault, it shall inform the thermodynamic operator to resume the
power supply immediately.
2) Report to the unit supervisor and shift engineer, maintain the stable load, reinforce contact with turbine
operator, and make in time realization of the change trend of steam temperature and pressure.
3) Switch the auto mode into manual mode, take the local water gauge as standard, reinforce contact
between upper and lower water level operator, adjust feed water manually and maintain normal water level.
4) Stabilize combustion and superheated, reheated steam attemperating water quantity, monitor all
thermocouple instruments and change condition of the steam drum local pressure, maintain stable steam
temperature and pressure to the utmost.
5) If the control ability is lost as a result of instrument power supply and boiler operation cannot be
maintained, or instrument power supply of boiler and turbine get fault at the same time, the boiler shall be
shut down for emergency.
2.5 Pulverizing system fault
2.5.1 Condition and handling of coal pulverizer emergency stop.
2.5.1.1 In any case as follows, the coal pulverizer shall be stopped immediately.
1) When boiler emergency shutdown.
2) Self-ignition or explosion occurs in pulverizing system.
3) There is fire around pulverizing system that endangers the equipment safety.
4) Primary air quantity is less than 85% (29,484kg/h) of the min. air quantity.
5) When the separator outlet temperature is ≤55℃ or ≥120℃, and mill roller temperature is ≥120℃.
6) Much vibration occurs (over specified value) and endangers the equipment safety.
7) When the coal pulverizer current increases suddenly or exceeds the rating and cannot return to normal.
8) When fault occurs in electrical equipment and it is necessary to stop coal pulverizing.
9) When there is abnormal metal impact sound in the coal pulverizer.
10) When personnel safety is endangered.
2.5.1.2 In any case as follows, stop the coal pulverizer after reporting to the unit supervisor and shift
engineer.
1) Serious block-up occurs in pulverizing system
2) Coal pulverizer and separator outlet thermometers are out of order.
3) A great deal of pulverized coal leak occurs in pulverizing system.
4) Coal feeder cannot operate normally.
5) Coal feeder coal flow interrupts or coal feed is less than the min. coal feed. (7.72t/h)
6) Sudden vibration of coal pulverizer.
7) Fault in lubricating system.
8) Differential pressure between sealing air and primary (cold) air is ≤1.27kPa.
9) When the separator outlet temperature is ≤60℃ or ≥110℃, and the mill roller temperature is ≥110℃.
10) Plane thrust pad oil basin temperature is ≥70℃.
11) Motor coil temperature of coal pulverizer is ≥130℃.
12) Speed reducer inlet oil pressure is ≤1.0kPa.
13) Primary air quantity is less than the min. air quantity.
2.5.1.3 Handling of coal pulverizer emergency stop
Make the operations as follows when stopping the coal pulverizer manually:
1) Stop the coal pulverizer and coal feeder immediately, close all inlet dampers and outlet baffles of the
coal pulverizer.
2) Put the anti-explosion and fire-fighting steam into operation, and close it after temperature decreases.
3) Find out causes immediately to give handling, report to the unit supervisor, and keep record.
2.5.2 Coal pulverizer trip
2.5.2.1 Coal pulverizer trip phenomenon
1) When coal pulverizer trips, the sound and light alarm are made, state displayed on CRT picture is not
corresponding, and current is indicated to zero.
2) Hot air stop damper closes automatically.
3) Coal feeder trips.
4) Boiler combustion is instable, and steam pressure decreases (except in case of MFT or RB).
5) The corresponding flame monitor displays no fire.
2.5.2.2 Causes for coal pulverizer trip
(1) Any outlet valve closes in coal pulverizer operation;
(2) The command for coal pulverizer trip is made on CRT;
(3) Coal feeder stops (with a time delay 5min)
(4) Loss of flame: 1min after coal pulverizer operates, all coal burners are detected no flame;
(5) Primary air quantity of coal pulverizer is low.
(6) MFT operates
(7) Coal pulverizer outlet air and pulverized coal mixture temperature is≥120℃;
(8) Coal pulverizer sealing air pressure is low.
(9) Lubricating oil system trips.
(10) Coal level of coal bunker is low.
(11) Loading oil pump stops or loading oil pressure is low.
2.5.2.3 Handling of coal pulverizer trip
1) The corresponding coal feeder is interlocked to trip, coal pulverizer cool and hot air damper close
automatically, and it shall find the causes and handle immediately.
2) If trip is not caused by MFT and RB, it shall lower the load rapidly, and start the standby coal pulverizer,
pay attention to the change of furnace combustion, and put oil into stabilizing flame in time in case of
combustion being instable.
3) After fault is removed and startup conditions are met, it shall purge the coal pulverizer as soon as
possible, and restart it to resume normal operation.
2.5.3 Self-ignition inside coal pulverizer
2.5.3.1 Phenomenon
1) Inner temperature or outlet temperature rises abnormally.
2) Coal pulverizer casing and coal chute paint shed or are burned to red in serious case.
2.5.3.2 Causes
1) Coal deposits in coal pulverizer, or there are pulverized coal deposits or combustible matters entered in
the coal pulverizer.
2) Coal pulverizer outlet temperature is high.
3) After the coal pulverizer pebble coal hopper is full, two much pebble coal pile up in lower part wind box
for a too long time and self-ignite.
4) After the coal pulverizer stops or trips, the purge is not conducted or is conducted not thoroughly.
2.5.3.3 Handling
1) Keep the coal pulverizer in operating.
2) Properly increase coal feed, turn down or turn off the hot air valve, open the cool air valve wide to cool
the coal pulverizer. (Put corresponding oil burner into operation in case of combustion being instable.)
3) If the above handling takes no effect, put anti-explosion steam or fire-fighting water into extinguishing
fire.
4) After the self-ignition phenomenon of coal pulverizer is removed, it shall stop the coal pulverizer and
check over every inner part, and resume normal operation after confirming every part is normal.
2.5.4 Overfeed of coal into coal pulverizer
2.5.4.1 Phenomenon
1) Coal pulverizer differential pressure becomes larger.
2) Coal pulverizer current increases, which may result in much vibration of coal pulverizer.
3) Differential pressure between coal pulverizer and furnace decreases, and the differential pressure
between coal pulverizer and coal feeder increases.
4) Coal pulverizer outlet temperature decreases and the primary air quantity decreases
5) Pebble coal hopper lets out good coal.
6) Vibration of coal pulverizer increases.
2.5.4.2 Causes
1) Control system is out of order.
2) Coal feed is too large.
3) Coal pulverizer output decreases (misadjustment of primary air, mill roller, mill bowl and lining board
are worn and torn, and loading force is insufficient), coal quality turns to bad or with too high moisture.
4) There are too many foreign matters in coal pulverizer.
5) Overfeed of coal into pebble coal hopper.
6) Mechanical fault of coal pulverizer.
2.5.4.3 Handling
1) Stop the coal feeder immediately and meanwhile put oil burner into stabilizing combustion.
2) Properly increase primary air quantity for draft.
3) If the fault still cannot be removed with the measures above, it shall stop the coal pulverizer.
2.5.5 Phenomenon, causes, prevention and handling for common faults of coal pulverizer are as follows:
No. Fault Phenomenon Possible Causes Prevention and Handling
There are foreign matters between Stop the coal pulverizer to
mill parts; remove foreign matters,
check over if any part in coal
pulverizer drops;
There is no or little coal in disc Coal chute is blocked up;
mill;
Coal pulverizer operates
1 Guide plate is worn and torn or Replace or adjust the gap.
abnormally.
gap is too large;
mill parts are damaged; Replace;
Accumulator has too little Stop the coal pulverizer and
nitrogen or air pocket is damaged. the high pressure oil station,
and check the accumulator by
gas filling.
Seal fan inlet filter is blocked up; Stop the coal pulverizer, and
wash the filter;
Differential pressure Sealing air inlet piping check Adjust the valve sheet to the
difference between primary valve sheet position is incorrect; correct position;
2
air and sealing air of coal Sealing air piping has air leakage Repair or replace;
pulverizer decreases. or is damaged;
Sealing part is damaged; Repair or replace;
Fault in seal fan. Remove the fault.
Much vibration appears in coal Remove the vibration source,
pulverizer operation; and replace the roller sleeve;
As a result of cold air chilling Avoid the mill roller being
3 Roller sleeve breaks
because the casing inspection influenced by large
valve is opened too early after temperature difference and
coal pulverizer stop. replace the roller sleeve.
Fault in control device of primary Switch the primary air control
air temperature; into manual control and
Separator temperature is remove the fault;
too high or too low during Primary air control is out of order; Switch the primary air control
operation; into manual control and
4 remove the fault;
Inside of coal pulverizer catches Stop the coal pulverizer for
Separator temperature rises fire, and separator temperature is emergency, and put the fire –
too fast. ≥110℃ fighting steam into operation
until the temperature
decreases to normal.
5 Mill roller oil level is low. Sealing part is out of order Stop the coal pulverizer,
repair or replace the sealing
part, and add oil to specified
No. Fault Phenomenon Possible Causes Prevention and Handling
level.
Oil level is low; Stop the coal pulverizer,
repair or replace the sealing
part, and add oil to specified
level;
Mill roller oil temperature
6 Bearing is damaged; Stop the coal pulverizer and
is high.
replace the mill roller
bearing;
Mill roller sealing air piping has Repair and replace.
fault or is worn through.
Scraper drops Fastening bolts drop or break off Refasten or replace bolts
7
Coal pulverizer emergency stop It is normal that pebble coal
or coal pulverizer just starts; increases as a result of coal
pulverizer start or coal
pulverizer emergency stop.
Coal quality is not good; Increase the number of
discharging times and adjust
coal type
Output volume of pebble
8 Mill roller, lining tile and nozzles As for the pebble coal
coal is too large.
are worn and torn seriously in increases as a result of nozzle
later operation; throat being worn and torn, it
shall replace the nozzle in
time;
Coal pulverizer out increases too Readjust the primary air
fast and primary air quantity is quantity once
smaller in operation.
Slide plate shut off valve is Slide plate shut off valve sealing Repair the sealing surface in
not sealed tightly. surface is seriously worn and torn maintenance or open and
9
or locked with substance. close it repeatedly for several
times.
Primary air leaks from the Sealing air quantity is not enough. Check the seal fan;
10
sealed part of frame. Seal is worn and torn. Replace seal.
Oil supply flow is not enough; Check the oil pump flow to
see if the valve throttles the
flow, and if the branch oil
pipe is blocked up;
Cooling effect of oil cooler is bad; Check the cooling water
Oil temperature of speed valve and cooling water
11 reducer thrust pad oil basis quantity;
exceeds normal value.
Water mix into the oil of oil Check if copper tube is
cooler; blocked up and scaling;
Influenced by the primary hot air Handle air leakage.
leaking from the frame sealing
part.
Coal pulverizer are started and Avoid coal pulverizer being
stopped frequently or has much started and stopped frequently
vibration; and remove vibration;
Speed reducer thrust pad is No alarm when oil supply is few Check the alarm device
12
damaged or interrupts; regularly;
Water mix into the oil of oil Replace with qualified oil and
cooler, lubricating oil is bearing bush.
unqualified and deteriorates due
to long time use.
2.5.6 Coal feeder trip
2.5.6.1 Phenomenon of coal feeder trip
1) Sound and light signal of coal feeder trip is made, state of control switch displayed on CRT picture is not
corresponding, and current turns to zero.
2) Coal feed of coal feeder displays zero.
3) Coal pulverizer outlet temperature rises and current decreases.
4) Boiler combustion is instable and steam pressure decreases (except in case of MFT and RB).
2.5.6.2 Causes for coal feeder trip
1) When MFT, MTR (coal pulverizer trips and relay operates) or RB occurs
2) Coal pulverizer is stopped.
3) No coal on belt.
4) Coal feeder is operating and the startup conditions of coal feeder are lost.
2.5.6.3 Handling of coal feeder trip
1) Find out the causes for trip, and put the coal feeder into operation soon after removing the fault.
2) Properly reduce the boiler load according to the steam pressure.
3) If it cannot recover in a short time, switch into standby coal pulverizer operating.
2.5.7 Primary air fan trip
2.5.7 Phenomenon of primary air fan trip
1) Current of primary air fan turns to zero, and air fan stops operation, the sound and light signal is made,
and the state displayed on CRT picture is not corresponding.
2) Primary air pressure decreases sharply, and the alarm of low primary air pressure is made.
3) It may result in coal pulverizer trip.
4) Boiler fire extinction (when two primary air fan trip and no oil for supporting combustion).
2.5.7.2 Causes for Primary air fan trip
1) MFT operates.
2) Primary air fan protection operates.
2.5.7.3 Handling of primary air fan trip
1) Turn the switch of tripped air fan to the stop position.
2) When one primary air fan trips, there will be 50%RB, some coal pulverizer trip and at the same time
some oil guns put into operation automatically, which may result in all operating coal pulverizers trip due
to low primary air pressure.
3) When two primary air fans trip at the same time, all coal pulverizers will trip, and boiler fire is
extinguished, and MFT operates, here such a case shall be handled as per the specification for MFT
operating.
4) After one primary air fan trips, it shall close its inlet damper immediately, then open wide the inlet
damper of the operating primary air fan, and find out causes quickly to conduct handling, and after fault is
removed, restart it immediately, resume normal operation of coal pulverizer, and purge the coal pulverizer
prepared for standby after trip in time.
2.5.8 Seal fan trip
2.5.8.1 Phenomenon of seal fan trip
1) The seal fan trips, the sound and light signal is made, the state displayed on CRT picture is not
corresponding.
2) Standby seal fan starts automatically.
3) Sealing air pressure decreases instantaneously.
2.5.8.2 Causes for seal fan trip
1) Fault in motor or lose of power supply
2) Fault in mechanical part resulting in overcurrent.
2.5.8.3 Handling of seal fan trip
1) Turn the switch of tripped fan to the stop position.
2) Contact maintenance personnel to find out causes and handle.
3) Check if the sealing air pressure of coal pulverizer is normal.
2.5.9 Common fault, causes and handling for thin oil station are as follows:
Fault Causes Handling
1. No cooling water 1. Supply cooling water
Lubricating 2. Cooling water is too little. 2. Increase cooling water quantity
oil 3. Cooler has air inside. 3. Cooler discharges air
temperature is 4. Cooler is too dirty 4. Replace cooler, and wash or replace the dirty
over high piping and parts
1. Problem in heater 1. Repair or replace the heater

Lubricating
2. Reduction gear box is not preheated 2. Wait a minute.
oil
to the operating temperature.
temperature is
3. Cooling water is too much or too 3. Reduce cooling water quantity
too low
cold.
1. Filter is blocked up 1. Switch into the clean filter, and meanwhile wash
or replace filter element and related parts.
2. 2.Fault in safety valve 2. Repair or replace safety valve
3. Oil suction pipe is blocked up 3. Clean the oil suction pipe
4. Air is sucked into oil pump 4. Check oil suction piping and repair the leak.
Lubricating
5. Lubricating oil temperature is too 5. ( As above)
oil pressure is
high
too low
6. Oil viscosity is too low 6. Check oil viscosity, and add correct oil if
necessary.
7. Fault in oil pump 7. Switch into the standby pump, repair or replace
the faulted pump.
8. Fault in pump driving mechanism 8. Check and repair the driving mechanism
1. Reduction gear box is not preheated 1. Wait a minute
to the operating temperature
2. Improper setting of pressure limiting 2. Regulate the pressure of pressure limiting valve
valve
Lubricating
3. Fault in pressure limiting valve 3. Repair or replace the pressure limiting valve
oil pressure is
4. Lubricating oil piping to reduction 4. Find out the blocked piping and clean it
over high
gear box or in reduction gear box 5 is
blocked up.
5. Oil viscosity is too high 5. Check oil viscosity, and add correct oil if
necessary.
6. Piping is too dirty (scale and 6. Wash the piping
welding slag, etc.)
Obvious
7. Residue produced by wear of 7. Check reduction gear box and give repair to the
residue
reduction mechanism faulted part.
gathering on
8. Lubricating oil is too dirty 8. Change oil
filter net.
9. Residue produced by wear of faulted 9. Repair or replace the faulted pump
pump
Fuel 1. Leakage in piping, joint, valve or 1. Tight and the bolts and seal them Seal up.
consumption reduction gear box.
is too high 2. Leakage in shaft end of reduction 2. Check if the seal ring is out of order.
gear box 3. Check if the oil level of lower header is over
3.Leakage in oil cooler high.
Fault Causes Handling
4.Leakage in filter 4. Seal the oil cooler or replace its related parts.
Seal the filter
2.6 Handling of fuel oil system fault
2.6.1 Conditions for oil feed pump emergency stop
a. When motor belches smoke
b. When oil feed pump casing has much vibration.
c. When oil feed pump body has serious oil leakage and smoke belching from the top cover
d. When oil supply piping breaks or fire trouble happens.
2.6.2 Oil filter blocking
a. Phenomenon of oil filter blocking
1) Differential pressure before and after filter becomes larger.
2) Oil pressure swings and oil pump output decreases.
3) Oil pump current swings and decreases.
b. Causes for oil filter blocking
1) Oil temperature in the oil tank is low.
2) Too many foreign matters in oil that plug the net holes or filter net is not washed.
3) Foreign matters are not cleared out after installation or inspection and repair.
c. Handling of oil filter blocking
1) Switch the oil feed pump and its oil filter in time. Start the standby oil feed pump, open air valve of
standby oil filter and slowly open the inlet valve, close the air valve after oil overflowing. Open the outlet
valve of standby oil filter, close the outlet & inlet valves of faulted oil filter after the system oil pressure
becomes normal, stop the original oil feed pump, discharge the oil deposits in the oil filter and report to the
unit supervisor.
2) Wash the faulted oil filter with steam, and take it as standby after washing it through.
3) If it fails to wash it through, contact the maintenance personnel to handle.
2.6.3 Oil feed pump fault
a. Phenomenon of oil feed pump fault
1) Oil pressure decreases.
2) Current swings by a large extent.
3) There is abnormal sound in pump.
4) Pump body temperature rises.
5) Bearing temperature exceeds limit.
b. Causes for oil feed pump fault
1) Unqualified repair
2) Filter is damaged.
3) Packing set is too tight, cooling water is blocked or interrupted, and bearing gets fault.
4) Fault in electrical part.
c. Handling of oil feed pump fault
1) Start the standby pump immediately, maintain oil pressure, close the outlet valve of faulted pump, stop
faulted pump, close inlet valve and report to unit supervisor.
2) Discharge water and oil deposited in pump completely, and contact maintenance personnel to handle.
2.6.4 Oil feed pump trip
a. Phenomenon of oil feed pump trip
1) Current of motor turns to zero.
2) Oil pressure decreases.
3) Trip signal is made.
4) When interlock operates, the standby pump starts automatically.
b. Handling of oil feed pump trip
1) Reset the switch of this motor immediately and start the standby pump.
2) Report to the unit supervisor, find out causes, and contact related staff to handle, recover it as standby
after removing fault, and keep record.
2.6.5 Oil pump house service power interruption
a. Phenomenon of oil pump house service power interruption
1) Operation illumination goes out.
2) Oil pump stops, and oil pressure decreases.
3) Thermodynamic gear power supply is lost, and pressure gauge and temperature meter indicate zero.
b. Handling of oil pump house service power interruption
1) Reset the switch of the stopped pump, and report the trouble to shift leader.
2) Start the oil pump for oil supplying when power supply recovers.
2.6.6 Handling of oil system catching fire
Fire is found in the control scope of oil system:
a. Send out fire alarm signal, report to shift engineer, and inform the fire brigade and explain the fire site.
b. Isolate related piping, and take effective measures for fire extinction to prevent fire from propagating, the
attendant shall extinguish fire rapidly and decisively according to the fire situation, and stop oil pump
operation if necessary.
c. If fire happens in oil tank, take all local fire extinguishing installation to extinguish fire. Close the inlet
and outlet oil valves of oil tank which caught fire, and put the standby oil tank into operation.
d. If fire happens in oil pump house, cut off power supply in serious case, close the outlet valve and oil-
return valve of oil tank, and use the local fire apparatus to extinguish fire.
e. If fire happens in motor, it shall cut off the power supper immediately and use the carbon tetrachloride
fire extinguisher to extinguish fire.
PART 6 Auxiliary Machinery & Public System
Chapter 1 General Rules for Auxiliary Machinery
1.1 General rules for auxiliary machinery
1.1.1 Check before auxiliary machinery startup
a. The inspection and repair of auxiliary machinery is finished, the temporary safety measures for
inspection and repair have been removed, the site is clean without foreign matter, illumination is sufficient,
the equipment are complete in appearance, each hole valve is closed tightly, sole screws are fastened, the
system connection is in good condition and the protective housing of rotary part is in good condition.
b. The auxiliary machinery after inspection and repair shall pass the trial run and the work sheet termination
procedure shall be got done with.
c. The control loop, electric interlock, thermodynamic protection and automatic adjusting device of
auxiliary machinery are tested qualified and operate normally.
d. The adjusting and actuating mechanism of each air damper and baffle (valve) are in good condition and
operate flexibly, the stop device is good , and related signals and indications are normal.
e. Local & remote measurement and display instruments are complete and in good condition, and each heat
control and electric cable appearance is in good condition.
f. The oil sites of auxiliary machinery are greased well, the grease quality is qualified and level meets the
requirement (1/2~2/3), and the oil system operates normally.
g. The cooling system of auxiliary machinery is in good condition, water flows smoothly and water
temperature is normal.
h. The rotation direction of motor is correct and the earth wire of motor casing is reliable.
i. Different auxiliary machinery shall be checked according to their specific requirements and shall not be
started until the conditions availability are confirmed; the standby auxiliary machinery shall be in the
condition of being ready to be started.
1.1.2 Auxiliary machinery startup
a. The auxiliary machinery shall be energized after all checks are finished.
b. When the auxiliary machinery start, the current return period and indicated current value shall be
monitored, the state on CRT corresponds and the red and green indicator lamp on backup panel indicate
correctly.
c. Two set of 6.6kV equipment shall not be started at the same time and the approval from shift engineer or
unit supervisor shall be obtained before startup. There shall be a specially-assigned person to monitor the
equipment locally, if any problem found, he shall stop the equipment by the E-stop button promptly.
d. Related auxiliary machinery are not allowed to be started with load.
e. When the auxiliary machinery start, in the case of fault trip, the auxiliary machinery shall not be restarted
until the causes are found and removed.
f. The auxiliary machinery can be hot started once and cold started continuously not over two times. In case
of trouble, the number of times of start can be once more (excluding winding type). If continuous startup is
necessary, the interval between each start shall not be less than 30minutes.
g. If the auxiliary machinery are started for emergency or thermodynamic and electric interlock operate to
put in automatically, their operation condition shall be checked on site after starting.
1.1.3 Operation maintenance of auxiliary machinery
a. The patrol and inspection system shall be executed strictly in operation, operation shall be inspected
conscientiously and overall, if any abnormal, it shall be handled in time.
b. The auxiliary machinery in operation shall meet the following requirements:
1) Auxiliary machinery and its motor operates stably, without abnormal sound, without leak and attrition
phenomenon.
2) Oil level, temperature, pressure and flow are normal, oil level indicator is clear and oil quality is good.
3) Each bearing is lubricated well and sealing of shaft seals is good.
4) Cooling water is sufficient and water drain is unobstructed.
5) All fasteners and connecting pieces of equipment are not lose and do not drop out. Monitoring and
protective devices operate normally.
6) The temperature, vibration and run-off displacement of each part of auxiliary machinery shall meet the
following requirements:
Bearing oil temperature of coal pulverizer gear box, induced draft fan, forced draft fan and air preheater
shall be ≯60℃－
Sliding bearing temperature shall be ≯70℃, and rolling bearing temperature shall be >≯80℃.
The vibration of rotary equipment shall not exceed the following specified value: as shown in Table 6.1
Table 6.1
Rotating Speed (r/min) 3,000 below 1,500 below 1,000 below 750 below
Specified vibration (mm) 0.06 0.10 0.13 0.16
The max vibration of induced and forced draft fan does not exceed the numerical values as shown in Table
6.2
Table 6.2
Rotating Speed (r/min) 1,500 below 1,000 below
Specified vibration (mm) 0.09 0.12
Requirement (mm) 0.03~0.06 0.04~0.08
Max vibration of coal pulverizer does not exceed 0.10mm.

The temperature rise of motor casing shall not exceed the specified value (for open type motor, the
temperature rise shall not exceed 65℃ and for closed type motor, the temperature rise shall not exceed
75℃).
1.1.4 Emergency stop of auxiliary machinery
a. In case of any fault as follows, the auxiliary machinery shall be stopped for emergency:
1) When the motor or auxiliary machinery has violent vibration, run-off displacement exceeds specified
value and there is a danger of damaging equipment.
2) The bearing temperature rises abruptly and exceeds the specified value.
3) The motor temperature rises to over specified value or there is smoke belching or fire catching.
4) The rotor and casing of auxiliary machinery are attrited or impacted seriously.
5) The auxiliary machinery does not stop running when up to the protective fixed value and specified time
delay.
6) There are other faults that may endanger human body or damage equipment.
b. For important auxiliary machinery, besides that they shall be stopped immediately in case of fault that
may injure human body and damage equipment, generally the standby auxiliary machinery shall be started
before the faulted auxiliary machinery is stopped.
Chapter 2 Pulverizing System
2.1 Operation, maintenance and trouble handling of pulverizing system

2.1.1 Operating parameter table of pulverizing system
Attached table 6-5
Alarm
No. Item Unit Normal Value Trip Value
Value
Sealing air/cooling air differential
1 kPa >1.27 ≤1.27 —
pressure
Primary air/furnace differential
2 kPa >7.5 ≤7.472 ≤4.98
pressure
3 Vibration mm <0.1
4 Current A 46.7
5 Outlet temperature ℃ 65~80 ≥80 ≥93
Coal
6 pulverizer/sealing air kPa ≥2 <2
differential pressure
Coal
Mill bowl differential
7 pulverizer kPa <2 >2 —
pressure
8 Primary air quantity M3/s 17~24 ≤15 —
9 Bearing temperature ℃ <65 ≥75 ≥85
10 Return oil temperature ℃ <45 >49
Motor bearing
11 ℃ <80 ≥85 ≥95
temperature
12 Pressure Mpa >0.09 ≤0.09 ≤0.07
13 Temperature ℃ 30~60 ≥60－≤15 ≥65
Lubricating Screen differential
14 MPa <0.2 >0.2 —
oil pressure
15 Oil level mm >511 <511 —
16 Flow L/min >105 ≤105 —
2.1.2 Check of pulverizing system before startup

In addition to check of the pulverizing system before startup according to the general rules for auxiliary
machinery check before startup, also check the following items:
2.1.2.1 Check of coal pulverizer
a. The oil level in oil tank is normal and the oil quality is good;
b. The lubricating oil tank heater is in auto mode, and the oil temperature is within 30~40℃. If the oil
temperature is lower than 25℃, temporarily close cold water, open it and keep proper opening after the coal
pulverizer starts;
c. Primary sealing air valve of coal pulverizer is open;
d. Make sure that the pebble coal hopper inlet valve is open and the outlet valve is closed;
2.1.2.2 Check of coal pulverizer
a. The sealing air valve of the coal pulverizer is open;
b. There is enough coal in the coal bunker and coal pulverizer inlet and outlet valves are open;
c. Control panel of the computer is powered on, and control of the coal feeder is at “Remote” position;
d. Interlocking switch for cleaning motor is put into operation.
e. Illumination in the coal feeder is perfect.
2.1.3 Startup of pulverizing system
2.1.3.1Make sure the primary air fan and sealing air fan operate normally and check whether the ignition
condition of pulverized coal is met:
a. MFT relay is reset;
b. Steam drum pressure is normal (>3.5MPa);
c. Secondary air temperature is proper (>166℃);
d. There are adjacent oil layers or coal layers operating in the coal layers, and the boiler load is more than
40%;
e. Air quantity >30%－
f. The furnace pressure is normal;
g. Differential pressure of wind box/furnace is normal;
h. Differential pressure of sealing air/primary air is normal;
i. Primary air header pressure is normal;
g. Water level of the steam drum is normal;
k. If coal pulverizer A is in “plasma operating mode”, it should meet the corresponding conditions. (See
plasma ignition operation of auxiliary machinery);
2.1.3.2 Allowable conditions of coal pulverizer startup:
a. There are ignition source and the pulverized coal meets the ignition condition;
b. Trip relay of coal pulverizer is reset;
c. The primary cool/hot air valve is open;
d. The coal pulverizer outlet valve is open;
e. Coal pulverizer lubricating oil system is normal;
f. Oil pump is started;
g. Lubricating oil pressure is larger than 0.09Mpa;
h. Lubricating oil temperature is higher than 15℃;
i. Lubricating oil flow is larger than 105 L/min－
j. Differential pressure of lubricating oil screen in oil station of coal pulverizer A is low;
k. Primary air pressure is normal;
l. Differential pressure of sealing air and coal pulverizer bowl is proper;
2.1.3.3 Start the coal pulverizer when the above conditions are satisfied.
2.1.3.4 Start the coal feeder when the following conditions are satisfied.
a. The coal pulverizer operates normally and the outlet temperature is higher than 65℃;
b. The coal feeder outlet baffle has already been opened;
c. The coal feeder is in “Remote” mode;
d. There is no fault in coal feeder.
2.1.4 When sequentially-controlled start of the coal layer is put into operation, the coal layer should operate
according to the following steps, or perform manual intervention:
a. Open the sealing air valve of coal pulverizer;
b. Start the lubricating oil pump of coal pulverizer;
c. Open the coal pulverizer outlet baffle;
d. Open primary cool/hot air valve;
e. Start the coal pulverizer when the coal pulverizer outlet temperature reaches the required value
(65~80℃);
f. Open the coal feeder outlet baffle;
g. Start the coal feeder;
h. Open coal feeder inlet baffle;
2.1.5 Precautions for pulverizing system startup:
a. When the coal pulverizer is being warmed, keep the temperature rise rate of coal pulverizer lower than
3℃/min, the time of warming coal pulverizer in cold state should not be shorter than 15 min;
b. When the coal feeder has operated for over 60s, and it is verified that there is no coal layer flame, stop
the coal feeder immediately and restart it after the reason is found out;
c. Put the interlocking switch for coal feeder cleaning motor and make sure that the cleaning motor operates
well after starting the coal feeder;
d. Slowly open the coal feeder inlet valve to avoid large amount of dropping coal damaging the coal feeder
belt;
2.1.6 Operation maintenance of pulverizing system
In addition to checks according to general rules for auxiliary machinery check, also check the following
items:
a. When the differential pressure between the inlet and outlet of the lubricating oil filter is larger than
0.2MPa, exchange the screen and inform maintenance personnel handle that;
b. Start the illuminator in the coal feeder and check whether the coal flow in the coal feeder is normal and
the belt is not deviating, loose, and torn up. After the cleaning equipment operates well, turn off the
illuminator in the coal feeder;
c. Do not deposit the coal in the pulverizing system to prevent spontaneous combustion;
d. Pay attention to the coal level of the coal bunker, when the coal level is lower than the normal value,
require the coal conveying operator to add coal in time, and the coal level in the coal bunker should
generally not be too high;
e. Control the coal pulverizer outlet temperature at about 77℃, the outlet temperature should not be higher
than 80℃ or lower than 65℃. When the coal Vad is 30% ~ 32%, the coal pulverizer outlet temperature
should not be higher than 80℃; when Vad is higher than 32%, the coal pulverizer outlet temperature should
not be higher than 78℃;
f. When the coal quality changes, strengthen the check of coal in the coal feeder and current of the coal
pulverizer;
g. Control the primary air quantity according to the coal feed rate to avoid restricting coal feed rate due to
small air quantity;
2.1.7 Stop of pulverizing system
2.1.7.1 The coal layer may automatically operate according to the following steps in sequentially-controlled
stop:
a. Open the cool air valve and close the hot air valve;
b. Close the coal feeder inlet baffle;
c. Lower the rotating speed of coal feeder to the minimum;
d. Stop the coal feeder;
e. Close the coal feeder outlet baffle;
f. Stop the coal pulverizer
g. Close the coal pulverizer outlet valve;
2.1.7.2 Check whether the oil for furnace warming meets the allowable condition or whether there is
enough ignition energy, if not, such oil is not allowed.
2.1.7.3 Check whether all adjacent oil layers operation or coal feed rate of coal feeders on adjacent layer is
higher than 50%, and the boiler load is higher than 40%.
2.1.7.4 Set the rotating speed of coal feeder to the minimum.
2.1.7.5 Close the hot air valve of coal pulverizer.
2.1.7.6 When the hot air valve is closed, the opening of cold air damper is 100% and if the coal pulverizer
outlet temperature is lower than 50℃, stop the coal feeder.
2.1.7.7 Stop the coal pulverizer 10 minutes later.
2.1.7.8 Set the opening of cold air baffle to 5% and close the coal pulverizer outlet valve.
Chapter 3 Air and Flue Gas System
3.1 Operation of induced draft fan and forced draft fan
Operating parameters
Attached table 6 - 4
Name
Forced Draft Fan Induced Draft Fan Remarks
Index
Normal Alarm Trip Normal Alarm Trip
Item
Fan bearing
30~60 ≥ 85℃ ≥ 100℃ 30~60℃ ≥ 85℃ ≥ 95℃
temperature
< 0.8MPa (8 bar)
Hydraulic oil ≥2.5MPa
< 2.5MPa Standby oil pump
pressure (25bar)
starts automatically
0.05MPa 0.05 MPa
Lubricating oil
0.3~0.4MPa — Delay for ≥0.1MPa — Delay for
pressure
15s 15s
Lubricating oil
≥3L/min < 3L/min — ≥3L/min <3L/min —
flow
Motor bearing
25~60℃ ≥ 90℃ ≥ 95℃ 25~60℃ ≥ 90℃ ≥ 95℃
temperature
Motor coil
< 100℃ ≥ 125℃ ≥ 135℃ < 100℃ ≥ 125℃ ≥ 135℃
temperature
Fan and motor oil
2/3~3/4 < 55% — 2/3~3/4 < 55% —
tank
Delay for Delay for
Surge 2kPa 15s after — 2kPa 15s after
alarm alarm
Cooling fan of
— — — — Stop —
bearing box
Fan vibration < 0.08mm 0.08mm 0.10mm <0.08mm 0.08mm 0.10mm
3.2 Check fan before startup

3.2.1 The fan equipment is complete and meets the requirements for startup and the work sheet for
inspection and repair has been recovered and written off.
3.2.2 There are no dirties inside the fan, all inspection holes and manholes are closed.
3.2.3 Check of lubricating oil and control oil system:
3.2.3.1 All valves and baffles are complete, the switches are flexible, connecting rod and servo motor, etc.
are in good condition and in the right positions;
3.2.3.2 Oil pump and motor are complete and clean, all parts of oil system don’t leak and the floor is clean;
3.2.3.3 The oil level of the oil tank is at 3/4, and the oil quality is good;
3.2.3.4 The oil filter can be flexibly switched;
3.2.3.5 All pressure gauges are put into operation, and the indicated values of pressure switch and electrical
resistance thermometer are correct;
3.2.4 Check whether the adjustable moving blade device is normal with adjustable range of (0°~45°),
adjustable static blade device is normal and agrees with dial opening indicator. If the fan is at the low
temperature or is not started for a long time, start control oil and lubricating oil devices one hour before fan
startup, and perform adjustment several times within the blade adjusting range.
3.2.5 Make sure the cooling fan of induced draft fan is normal and can be put into operation.
3.3 Startup of control oil station and lubricating oil station.
a. Make an overall check on the positions of all valves in the fan oil station system, and all gauges are put
into operation;
b. Oil level of each oil tank is high and in the normal position;
c. Turn on oil pump A or B and check whether the oil pressure and flow are all within the normal required
range after they operate normally;－
d. Put interlocking of oil pumps in all oil stations into operation;
3.4 Startup and stop of induced draft fan and forced draft fan.
3.4.1 Induced draft fan startup
3.4.1.1 Check whether all the conditions of fan startup are satisfied, and the total boiler interlocking
switches are put into operation.
Thermodynamic startup conditions are as follows:
a. Motor bearing temperature is normal;
b. Motor stator coil temperature is normal;
c. Induced draft fan bearing temperature is normal;
d. Cooling fans of induced draft fan bearing operate (two sets operate simultaneously);
e. Flue gas baffle at air preheater inlet is open;
f. Air preheaters at the same side operate;
g. Remote operation of induced draft fan is allowed;
h. There is no protection action;
i. There is no surge;
j. Induced draft fan vibration is qualified;
k. If any oil pump of induced draft station operates, the oil pressure is normal;
l. The outlet baffle has been closed;
m. The inlet vane has been closed;
n. The inlet baffle has been open;
o. Cooling fan has already operated;
After the attendant confirms it on site, start the induced draft fan.
3.4.1.2 Turn on switches of induced draft fan A or B and the fan outlet baffle automatically starts 15s later.
Adjust the inlet vane, and adjust the furnace negative pressure within the normal range.
3.4.1.3 When one fan is running, the method to start the other fan to realize parallel running is as follows:
a. Check whether all conditions before fan startup are satisfied;
b. Set the working point for induced draft fan at operating side below the lowest surge line of fan, switch on
the other induced draft fan and the fan outlet baffle automatically opens, pay special attention to furnace
combustion situation, adjust the static blade angle of the fan to be basically same with the static blade angle
of operating fan, so do the current, then adjust the static blade angles of two fans simultaneously to the
required operating condition point and keep the furnace negative pressure value within the required range;
c. After completing starting, make an overall check on the operation situation of induced draft fan and
report it to the unit supervisor;
3.4.2 Stop of induced draft fan
Conditions of induced draft fan trip:
a. The temperature of induced fan motor bearing is higher than 95℃ and it will trip 2s later;
b. Motor stator coil temperature is higher than 135℃;
c. The temperature of induced draft fan bearing is higher than 95℃ and it will trip 2s later－
d. Induced draft fan vibration is more than 0.10 mm ;
e. The lubricating oil pressure of induced draft fan is too low and it will continue for 15S;
f. Cooling fan stops and it will trip 120s later.
g. In the situation that overall interlock of auxiliary machinery is put into operation, main and standby
motors of the air preheater at one side trip, motors on the other side operate and the induced draft fan at the
same side trips 60s later;
h. In the situation that induced drat fan interlock is put into operation, forced draft fans at the same side
trips while the induced draft fans at the same side trips too;
3.4.2.1 Switch “Auto” to “Man”, adjust the static blade angle of induced draft fan according to the load
condition and furnace negative pressure.
3.4.2.2 After the boiler fire extinction and shutdown, close the inlet baffle of induced draft fan and adjust
the static blade to the minimum angle to stop the induced draft fan. When one induced draft fan trips and
the other one operates due to faults, its outlet baffle interlock is closed. When both induced draft fans trip
due to faults, the inlet static blade and outlet damper of induced draft fan are open.
3.4.2.3 When two induced draft fans operate in parallel, the method to stop each of two is as follows:
a. Adjust the load and reduce it to about 150MW, keep three pulverizing systems operating and if necessary,
perform combustion-supporting with oil.
b. Reduce output of the induced draft fan to be stopped, increase the output of the fan at operating side, and
now close the static blade on the stop side to zero position.
C. Stop this fan and its inlet and outlet baffles automatically close.
3.5 Startup of forced draft fan.
3.5.1 Check whether all the conditions of fan startup are satisfied.
Thermodynamic start conditions are as follows:
a. Remote operation of forced draft fan is allowed;
b. Motor stator coil temperature is normal;
c. Forced draft fan bearing temperature is normal;
d. Temperature of forced draft fan motor bearing is normal;
e. Forced draft fan moving blade is closed;
f. Outlet baffle is open;
g. Induced draft fans at the same side operate;
h. Oil station flow is not low and oil pressure is normal;
i. Oil temperature and oil level are normal, screen differential pressure is not high;
j. There is no protection action condition;
3.5.2 Close the inlet moving blade of forced draft fan, open the outlet baffle of forced draft fan, switch on
the forced draft fan A or B and after the current returns to quiescent value, adjust the moving blade opening
to the needed air quantity.
3.5.3 When one fan is running, the method to start the other fan to realize parallel running is as follows:
a. Check all conditions before fan startup are met;
b. Set the working point of forced draft fan at operating side below the lowest surge line of fan, if the
forced draft fan to be started turns reversely, inform the maintenance personnel to handle that. After the
forced draft fan does not turn reversely, switch on the forced draft fan to be started, pay special attention to
furnace combustion situation, adjust the static blade angle of the fan to be started to be the same with the
moving blade angle of operating fan, and adjust the moving blade angles of two fans to keep the moving
blade openings and currents of the two forced draft fans same, keep the air quantity required by furnace
within the required range;
3.6 Stop of forced draft fan
Conditions of forced draft fan trip:
a. Temperature of forced draft fan motor bearing is higher than 95℃ and it will trip 2s later;
b. Motor stator coil temperature is higher than 135℃;
c. The temperature of forced draft fan bearing is higher than 100℃－
d. The forced draft fan vibration is more than 0.10 mm;
e. Lubricating oil pressure of forced draft fan is lower than 0.05MPa and it will continue for 15S;
f. In the situation that overall interlock of auxiliary machinery is put into operation, main and standby
motors of the air preheater on one side trip, 30s-delay protection trips forced draft fan;
g. In the situation that forced draft fan interlock is put into operation, the induced draft fans at the same side
stops while forced draft fans at the same side trips too;
3.6.1 Gradually adjust the moving blade angle to the minimum position and close the fan moving blade.
3.6.2 After boiler fire extinction, stop the forced draft fan according to the demand and relative
requirements, its outlet baffle interlock is closed. When faults result in trips of both forced draft fans and
induced draft fans, the outlet valve of forced draft fan will automatically open.
3.6.3 When both forced draft fan operate, the method to stop each of two is as follows:
a. Normally reduce the load to below 150MW, perform combustion-supporting with oil, and keep three sets
of pulverizing systems operating;
b. Increase the output of the fan at the operating side to the maximum, reduce the output of the fan at the
stop side until the moving blade of the fan at the stop side is in the close position and adjust the boiler to
keep steady negative pressure;
c. Stop this fan, the outlet baffle will automatically close, the fan outlet interconnection valve will
automatically open;
d. Adjust the boiler load according to the air quantity;
Chapter 4 Air Preheater
4.1 Air preheater operation
4.1.1 Operating parameters
Table 6-3
Item Unit Normal Alarm Remarks
Low alarm <0.33
Lubricating oil pressure MPa 0.33~1.6
High alarm >1.6
>50℃, oil pump starts
automatically,
Guide bearing oil temperature ℃ <50℃ 50
<35℃, oil pump stops
automatically
>55℃oil pump starts
Supporting bearing oil automatically,
℃ <50℃ 50
temperature <35℃oil pump stops
automatically
Differential pressure at flue gas
KPa <1.022 —
side
Primary air differential pressure KPa 0.498 —
Secondary air differential
KPa 0.810 —
pressure
Under rated operating
Inlet flue gas temperature ℃ 354 —
condition
Screen differential pressure MPa <1.3 —
4.1.2 Check of air preheater before startup
4.1.2.1 Check whether there is foreign matter on the cold and hot end of the rotor.
4.1.2.2 Check whether the reduction gear box that drives the rotor is filled with oil, whether the oil quality
is qualified and whether the oil level is normal.
4.1.2.3 Check whether there is any damage to the seal leaf of the rotor and whether the clearance is normal.
4.1.2.4 Check whether oil levels of supporting bearing and guide bearing oil systems are normal, oil
temperature is not more than 44℃, the cooling device is put into operation, oil filter handle is in the
working position and whether the oil pump is in auto mode.
4.1.2.5 Check whether the rotor has any blockage or abnormal sound, and whether the rotor rotating
direction is right.
4.1.2.6 Interlock test of main and standby motors is normal.
4.1.2.7 Check whether the sootblower is in the exit position, valves for cleaning and fire fighting device are
tightly closed and whether all flue gas baffle switches are normal and in the closed position.
4.1.2.8 Test operation of oil feed pumps for supporting and guide bearing is normal, cooling water is
smooth without leakage.
4.1.2.9 Preheater sealing device is in good condition.
4.1.2.10 Before air preheater startup, confirm that the following tests are completed and the related device
acts correctly;
a. Interlock test for air preheater main and standby motors.
b. Auto startup/stop test for air preheater oil pump;
4.1.3 Air preheater startup
4.1.3.1 Before air preheater startup, first set up the oil circulation of supporting bearing and guide bearing
according to rules and make an overall check on the related equipment; thermodynamic start conditions are
as follows:
a. The guide bearing oil temperature is normal;
b. The supporting bearing oil temperature is normal;
4.1.3.2 Turn on the main motor switch and put the standby motor interlocking switch into operation until
the main motor rotating speed turns to normal after operating for one minute at low speed.
4.1.3.3 When the air preheater is normal after startup, check whether the current is normal, and whether the
vibration of all parts, bearing temperature, damper linkage and accessory equipment operation are normal.
If something abnormal is found, analyze and deal with it in time and put the air leakage control equipment
of the preheater into operation according to rules.
4.1.4 Operation maintenance of air preheater
4.1.4.1 Frequently monitor the current change of air preheater during operation, if something abnormal is
found, deal with it in time.
4.1.4.2 Check and analyze the oxygen content, flue gas temperature, air pressure difference and flue gas
temperature difference at the inlet and outlet of the preheater so as to determine the situation of air leakage
and ash fouling as well as to judge whether re-burning happens. Check the air preheater whenever the
temperature at any point abnormally increases by 10℃.
4.1.4.3 During operation of air preheater, make periodic overall check on the motor, mechanical parts,
accessory equipment and system. If any defect is found, contact the maintenance personnel to handle that in
time.
4.1.4.4 Check whether the bearing lubricating oil pressure is within 0.33~1.6 MPa, the oil level is normal,
no leakage is in the system, adjust the outlet valve of oil cooler to keep the oil temperature within
30℃~40℃ and whether pressure difference of oil filter is lower than 1.3MPa. If the oil filter is blocked,
inform the related personnel to maintain it.
4.1.4.5 Perform sootblowing for air preheater periodically.
4.1.4.6 Check whether the operating air preheater has no abnormal sound and whether the transmission
device has no abnormal sound.
4.1.4.7 Oil temperature alarm value of bearing lubricating oil system;
a. Oil temperature of supporting bearing oil system reaches 50℃.
b. Oil temperature of guide bearing oil system reaches 50℃.
4.1.4.8 Oil of supporting and guide bearing oil systems should be changed at least once a year.
4.1.4.9 Leakage in reduction gear box during operation is not allowed. In continuous operation, the
working oil temperature should not exceed 80℃, test the working oil after it operates for 3,000 hours and if
necessary, use new oil.
4.1.4.10 During preheater operation, make air leak test periodically and when the air leakage rate increases
to exceed the required value, inform the related personnel to maintain it.
4.1.5 Stop of air preheater:
a. Perform sootblowing for the air preheater for one time before boiler shutdown and stop the air preheater
until the inlet flue gas temperature reduces to lower than 150 ℃. Switch the interlocking switch to “Exit”
position. The conditions for thermodynamic stop are: induced draft fans on the same side stop, forced draft
fans on the same side stop, primary air fans t the same side stop, the outlet dampers of forced draft fan at
the same side close, the outlet dampers of primary air fans at the same side close, flue gas temperature at
the inlet of air preheater is lower than 150℃.
b. Stop the air preheater.
c. After the air preheater stops, check whether the damper and baffle link normally, and stop the air
preheater supporting bearing, guide bearing and lubricating system according to rules.
d. After boiler shutdown due to faults, if the preheater needs to shut down for treatment, perform
sootblowing for air preheater before boiler shutdown. After boiler shutdown, the preheater should continue
to operate until the inlet flue gas temperature is lower than 150℃, the preheater can be stopped.
e. During operation, if one preheater is stopped, close flue gas inlet valve, primary air and secondary air
outlet dampers.
f. When the boiler is shut down for hot reserve, keep the preheater operate.
4.1.6 Air preheater sootblowing
4.1.6.1 During the boiler ignition & fuel burning and coal-oil mixture firing, run the air preheater for
sootblowing in time (steam source is auxiliary steam).
4.1.6.2 During boiler startup, continue performing sootblowing for the air preheater. When the load is
higher than 10% MCR, change the sootblowing steam source to the rear platen sootblowing steam; when
the load is 50% MCR, execute it according to the normal operation rules.
4.1.6.3 For the preheater sootblowing, check whether the sootblowing steam pressure is within
1.0~1.50MPa and whether the steam temperature is higher than 350℃.
4.1.6.4 If any one of situations in the following is found during operation, increase the sootblowing number
or use continuous sootblowing.
a. The preheater outlet air pressure reduces and flue gas pressure difference increases;
b. Rear heating surface leaks air;
c. Early ignition and low-load operation of the boiler take a long time, or the boiler is in coal-oil mixture
firing for a long time;
d. The air preheater outlet temperature abnormally increases;
e. The boiler load substantially changes;
f. Before boiler shutdown, perform continuous sootblowing in order to prevent inflammable matter from
depositing on the heating surface;
4.1.7 Operation of air preheater fire water
4.1.7.1 Normally, main valve for air preheater fire water is tightly closed and the rear water discharge valve
of the fire water main valve should be kept open.
4.1.7.2 When the air preheater temperature abnormally increases, find out reasons and take measures in
time. If the air preheater is considered to be on fire, when fire water is confirmed to be required to put out
the fire and the permission is received from shift engineer, close the fire water discharge valve of the air
preheater immediately, open the manual main valve of air preheater fire water system, and then open fire
water hand-operated valve at hot and cold ends of the air preheater on the firing side and water discharge
valve at the cold end to put out the fire.
4.1.7.3 When it is certain that the air preheater does not need fire water, first close manual main valve of air
preheater fire water system, then close the fire water hand-operated valves at hot and cold ends of the air
preheater respectively and at the same time open fire water discharge valve of the air preheater.
4.1.7.4 When the air preheater needs to be cleaned, clean it according to cleaning measures or operation
introductions.
Chapter 5 Sootblowing and Blowdown System
5. Boiler sootblowing
5.1 Perform boiler sootblowing after receiving the permission from the chief shit engineer and properly
increase the furnace negative pressure during boiler sootblowing to keep combustion stable, while paying
Item－ Name Pressure Temperature Steam source

Boiler proper 2.5MPa after pressure relief 334℃ after pressure relief Division wall superheater
sootblowing station station outlet
Boiler proper 1.0~1.5MPa < 250℃ Rear platen superheater
sootblower outlet (it is auxiliary
steam at startup)
Air preheater 2.5MPa after pressure relief 421℃ after pressure relief
sootblowing station station
Air preheater 1.0~1.5MPa < 350℃
sootblower
attention to the change of the steam parameters.
5.2 Sootblowing steam parameters
Attached table 4-2
5.3 Conditions for put-in of sootblower
5.3.1 Boiler operation condition is normal, combustion is stable, and there is no other important operation.
5.3.2 The unit load is higher than 60%, primary and secondary steam temperatures are steady.
5.3.3 Furnace negative pressure is normal, and margin of induced draft fan is enough.
5.3.4 Compressed air system is normally put into operation.
5.3.5 The pressure governing valve for sootblowing, signal of program controlled device and alarm device
have met the operation condition.
5.4 When any one of the following situation happens, immediately stop sootblowing:
5.4.1 The boiler operation condition is abnormal, combustion is unstable, or the unit load is lower than
60%;
5.4.2 The unit and system have an accident;
5.4.3 Sootblowing system or sootblowing equipment is broken or damaged;
5.4.4 Combustion chamber pressure can not be maintained negative or decoking can not be performed;
5.4.5 Steam (sootblowing) pressure is lower than 0.8Mpa or steam flow is lower than 91%.
5.5 Sootblowing procedures
5.5.1 Whenever manual or automatic mode is used to perform sootblowing, the sootblowing order of each
part: air preheater, water-cooled wall (furnace chamber), flue gas pass, and at last air preheater again. (that
is: air preheater → furnace chamber →flue gas pass →air preheater.)
5.5.2 During furnace sootblower sootblowing, perform it from top to bottom to avoid cross deposi t on
heating surface, the order is: fifth layer →fourth layer→ third layer→ second layer→ first layer, on each
layer, first blow the front and rear wall and then blow the side walls A and B, before sootblowing, use two
sootblowers for front/rear walls or side wall A/B respectively to perform sootblowing in pairs.
5.5.3 During sootblowing for flue gas pass, perform it in pairs for A/B side according to the flue gas
flowing direction, (the order is: division wall bottom at the furnace outlet, rear platen, platen reheater, last
stage reheater, last stage superheater, low temperature superheater, economizer).
5.6 Sootblowing period:
5.6.1 When the boiler operates normally, perform it every shift; (eight hours)
5.6.2 For boiler heating surface on which ash easily deposits, perform sootblowing according to its
deposits;
5.6.3 When boiler operates normally after startup and before shutdown, perform an overall sootblowing for
the whole heating surface;
5.6.4 If the steam temperature of superheater and reheater is high, increase the sootblowing number for
furnace;
5.6.5 If the steam temperature of superheater and reheater is low, increase the sootblowing number for
superheater and reheater furnaces;
5.7 Precautions for sootblowing:
5.7.1 During sootblower operation, pay attention to maintaining the furnace negative pressure and
sootblowing parameter to meet requirements and do not perform sootblowing without steam;
5.7.2 When the sootblower is put into operation, perform sootblowing according to the sootblowing
procedures, and during manual sootblowing, the quantity of sootblowers can not exceed two;
5.7.3 During sootblowing, it is prohibited to open inspection hole to observe combustion situation or
perform decoking or manual ash discharge;
5.7.4 When sootblowing is completed, make an overall site check whether each sootblower is in the exit
position on site;
5.7.5 During sootblowing, if soot lance blocks, overloads or trips due to overcurrent, etc., immediately
contact maintenance personnel to deal with them. For the soot lance, whose faults can not be immediately
dealt with, swing it out manually and contact with related personnel to eliminate defects timely;
5.9 Boiler blowdown
5.9.1 Continuous blowdown: according to chemical requirements, adjust the opening of continuous
blowdown governing valve in time to control blowdown rate to ensure the boiler water quality.
5.9.2 Periodic blowdown: according to chemical requirements, chief shift engineer performs program
controlled blowdown for the downcomer periodically under the supervisor of chemical engineers . When
the boiler water quality degrades, reduce the load to 150MW~180MW to perform manual blowdown of
water-cooled wall lower header. While in normal operation, the periodic blowdown should be performed
according to the normal work.
5.9.3 During blowdown, reinforce the monitor of the water level.
5.9.3.1 Completely open the blowdown valve of water-cooled wall lower header and slightly open the
secondary valve to warm the pipe.
5.9.3.2 When there is no water impact sound in blowdown pipe, completely open secondary blowdown
valve, after blowdown for 30s, close secondary valve and then primary valve.
5.9.3.3 Perform blowdown for the four blowdown loops successively.
5.9.4 Precautions for periodic blowdown:
5.9.4.1 Before blowdown, check the blowdown system; when the blowdown system is maintained, do not
perform blowdown;
5.9.4.2 During blowdown, there should no violent vibration on the pipe and strength pipe warming when it
vibrates violently;
5.9.4.3 Perform blowdown successively and do not open two primary valves for blowdown at the same
time;
5.9.4.4 During blowdown, do wear protective appliance. Blowdown is forbidden when the blowdown
device is damaged or the passage has no illumination;
5.9.4.5 Do open blowdown valve by special spinner and do not cover the wrench with bushing to help start
blowdown valve. During boiler operation, the primary blowdown valve should not be maintained;
5.9.4.6 After blowdown, make an overall check whether the blowdown valve is in the close position
without leakage and report to the chief shift engineer;
5.9.4.7 During the process of periodic blowdown, if abnormal situation occurs to the unit or blowdown
system goes wrong, stop blowdown immediately;
Chapter 6 Flame Detection and Flue Gas Probe

6.1 Operation, maintenance and trouble handling of probe cooling fan
6.1.1 Operating parameter table of probe cooling fan
Attached table 6-7
No. Item Set Value Unit Remarks
1 Low pressure value I 3.2 KPa Alarm
2 Low pressure value II 2.4 KPa Start standby fan
3 Low pressure value III 2.2 KPa Boiler shutdown
4 Screens A, B are dirty 2.0 KPa Alarm
6.1.1 Check before startup
6.1.1.1 Make routine inspection according to general operation principles of auxiliary machinery.
6.1.1.2 Check whether the fan outlet damper is open.
6.1.1.3 Inlet screens of two fans are clean and not blocked by foreign matters.
6.1.3 Start of probe cooling fan
6.1.3.1 Check whether the power source and operating power have been supplied.
6.1.3.2 Turn the control switch of cooling fan for Probe A to “Remote control” and start the cooling fan for
Probe A.
6.1.3.3 Check whether fan A operates normally, turn the local control switch of cooling fan for Probe B to
“Remote control” and local interlocking switch to “ON”. Do not start Fan B, but make it into standby
mode.
6.1.4 Stop of probe cooling fan
6.1.4.1 During boiler operation, keep probe cooling fan run and after boiler shutdown, only when the
furnace outlet temperature is kept lower than 150℃, can the probe cooling fan be stopped.
6.1.4.2 Turn local interlocking switch of the fan to “OFF”.
6.1.4.3 Stop the operating fan at “Local control” or “Remote control” position.
6.1.5 Maintenance of probe cooling fan
6.1.5.1 Check and maintain according to general operation principles.
6.1.5.2 Clean the outlet screens periodically, when low inlet and outlet differential pressure raises an alarm,
timely switch the fan and clean the screen.
6.1.5.3 Switch the operating fan and standby fan every month.
6.1.5.4 Air pressure at fan outlet should be higher than 3.2kPa.
6.1.6 Trouble handling
6.1.6.1 For general abnormal situation, handle according to general operation principles of auxiliary
machinery.
6.1.6.2 Probe cooling fan trip
When probe cooling fan trips, standby fan should automatically start, or immediately turn the interlocking
switch to “OFF” position, and control switch of the standby fan to “Local” position and start the standby
fan. If the standby fan can not start, use the same method to start the fan that has been tripped, if the fan can
not start, it will result in MFT of the boiler after five minutes.
6.2. Flue gas temperature probe
6.2.1 Check before startup
6.2.1.1 Check whether the carriage and motor appearances are normal, and motor is normally grounded.
6.2.1.2 Check whether the lubricating grease is normal.
6.2.1.3 Check whether sliding rail of the carriage is clean, gear rack is normally lubricated and not worn up.
6.2.1.4 Check whether the gun barrel is not deformed or damaged due to corrosion;
6.2.1.5 Check whether the cable lines and power supply system are normal.
6.2.2 Local startup and stop
6.2.2.1 Turn on the power and the “Power” indicator on the local control box lights.
6.2.2.2 Set the selector switch to “Local control”.
6.2.2.3 Press “Forward” button, the motor starts, the gun barrel moves forward and “Run” indicator lights.
When the measured temperature is lower than the set alarm temperature (540℃), the gun barrel will move
forward until:
a. The backward travel switch RLS operates, the gun barrel will automatically move reversely.
b. The operator presses “Backward” button, gun barrel will move reversely immediately on any position of
travel.
c. The operator presses “Stop” position, gun barrel will stop moving at once on any position of travel, so
that temperature probe can monitor temperature of this point ceaselessly.
d. The operator presses “Stop/Reset” button, gun barrel will move reversely on any position of travel until
it is back to the stop position and stops operating.
6.2.2.4 In local operation, instrument in central control room displays the measured flue gas temperature
and the position of gun barrel end.
6.2.2.5 As gun barrel moves forwards or stops moving, press “Backward” button to make gun barrel move
reversely until:
a. The stop travel switch SLS operates, the gun barrel will automatically change to move forward.
b. The operator presses “Forward” button, the gun barrel will change moving direction from backward to
forward immediately on any position of travel.
c. the operator presses “Stop” button, the gun barrel will stop moving at once on any position of travel, so
6.2.2.6 As gun barrel moves forwards or reversely, or the gun barrel stops, press “Stop/Reset” button to
make gun barrel move reversely until it is back to the stop position and stops operating.
6.2.2.7 As furnace temperature monitored by the temperature probe reaches to or beyond the set alarm
temperature (540ºC), gun barrel will move back to the stop position automatically and send out alarm
signal of “High Flue Gas Temperature”.
6.2.3 Remote startup and stop
6.2.3.1 Turn on the power and “Power” indicator on the local control box lights.
6.2.3.2 Set the selector switch to “Remote control” on local control box.
6.2.3.3 Press “Forward” button, the motor starts, the gun barrel moves forward and “Run” indicator lights.
When the measured temperature is lower than the set alarm temperature (540℃), the gun barrel will move
forward until:
a. The backward travel switch RLS operates, the gun barrel will automatically move reversely.
b. The operator presses “Backward” button, gun barrel will move reversely immediately on any position of
travel.
c. The operator presses “Stop” position, gun barrel will stop moving at once on any position of travel, so
d. The operator presses “Stop/Reset” button, gun barrel will move reversely on any position of travel until
it is back to the stop position and stops operating.
6.2.3.4 In remote operation, instrument in central control room displays the measured flue gas temperature
and the position of gun barrel end.
6.2.3.5 As gun barrel moves forwards or stops moving, press “Backward” button to make gun barrel move
reversely until:
a. the stop travel switch SLS acts, the gun barrel will automatically change to move forward.
b. The operator presses “Forward” button, the gun barrel will change moving direction from backward to
forward immediately on any position of travel.
c. The operator presses “Stop” button, the gun barrel will stop moving at once on any position of travel, so
6.2.3.6 As gun barrel moves forwards or reversely, or the gun barrel stops, press “Stop/Reset” button to
make gun barrel move reversely until it is back to the stop position and stops operating.
6.2.3.7 As furnace temperature monitored by the temperature probe reaches to or beyond the set alarm
temperature (540ºC), gun barrel will move back to the stop position automatically and send out alarm
signal of “High Flue Gas Temperature”.
6.2.4 Probe operation in long term shutdown period
Commonly the probe operates frequently, thus its operation capacity can be guaranteed at any time. But if
probe seldom operates, then it shall operate at least once every 14 days to guarantee the action capacity of
moving parts, especially the limit switch.
Attached table:
Motor power table
No. Name Model Voltage Rotating Power Current Torque Qty
V speed KW A N-M
RPM
1 Long retractable sootblower 380 1400 1.1 2.85 7.6 24
2 Semi-retractable sootblower 380 1400 1.1 2.85 7.6 6
3 Furnace sootblower 380 1400 0.18 0.65 1.24 80
4 Flue gas temperature probe 380 1400 1.1 15 7.6 2
5 Main motor of the air 380 970 7.5 17 2
preheater
6 Auxiliary motor of the air 380 970 7.5 17 2
preheater
7 Air preheater sootblower 380 1400 1.1 15 7.6 2
8 Electric fitting for closing 380 605/90° 1.1 5800 6
damper of flue gas pass at
preheater inlet
9 Governing valve for steam 380 0.75 3.5 1
drum’s continuous blowdown
10 First stage attemperating 380 1600 0.33 0.85 800 1
water electric stop valve of
superheater
11 Second stage attemperating 380 1600 0.22 0.59 500 2
water electric stop valve of
superheater
12 Attemperating water electric 380 1600 0.22 0.59 500 2
stop valve of reheater
13 Electric actuated emergency 380 1600 0.33 0.85 800 2
water discharge valve of
steam drum
14 Periodic blowdown electric 380 1600 0.22 0.59 500 8
stop valve of centralized
downcorner
15 Drain electric stop valve of 380 1600 0.22 0.59 500 4
tail ring header
16 Electric stop valve 380 20 1.1 3.4 300 3
DN40, PN32
17 Electric stop valve 380 20 1.5 4.1 450 2
DN65, PN32
18 Electric stop valve DN50, 380 20 1.1 3.4 300 4
PN32
19 Electric stop valve DN100, 380 20 7.5 17 1800 2
PN32
20 Electric stop valve DN125, 380 20 7.5 17 1800 1
PN32
21 Motor-operated gate valve 380 20 7.5 17 1800 1
DN300, PN32
22 First stage attemperating 380 22 0.23 1.5 170 1
water governing valve of
superheater
23 Second stage attemperating 380 22 0.10 1.5 75 2
water governing valve of
superheater
24 Spray water governing valve 380 22 0.10 1.5 75 2
of reheater
25 Governing vale of feed water 380 22 0.81 3.9 597 1
bypass
Equipment water consumption table
No. Item Unit Data Remarks

1 Water cleaning of preheater
Min. pressure Mpa 0.49
Flow of each tube t/h 150
2 Requirements of firefighting equipment on water source:
Min. inlet pressure Mpa 0.49
Min. flow of one preheater t/h 300
3 Requirements of cooling water on water source:
Min. inlet pressure Mpa 0.1
Cooling water temperature ℃ < 20
Min. flow of one preheater t/h 10

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INDIA BALCO 4x300 MW TPP

Issue for implementation

PREPARED BY Lv Wei India BALCO Project(4×300MW)

CHECKED BY Liu ping Boiler System

APPROVED BY Zhou Shengzhang Operation Procedure

PART 1 General Description 2

Chapter 1 General Description of Main Equipment

Main technical parameters of boiler (provisional)

1.2 Boiler main design parameters

ULTIMATE ANALYSIS OF COAL RECEIVED BASIS

1.3.3.4 Ignition and combustion-supporting fuel

(2) Approximate viscosities of hazard contaminants at different temperatures are as follows:

1.3.3.5 Boiler feed water

1.3.3.6 Water capacity of boiler

Chapter 2 Auxiliary Equipment Specification

1. Forced draft fan

2.4 Technical data of induced draft fan

Fan inlet mass flow (kg/s) 100.78 74.8 71.96

Radial seal leaf δ= 2.5mm CORTEN steel

Axial seal leaf δ= 2.5mm CORTEN steel

Lubricating Volume 43.5 L

Lubricating Volume 150 L

4 Sootblower Steam sootblower

Model: XYZ-250L vertical type

7. Specifications for the burner are as follows:

9. Specification for steam air heater

10.2 Specification table for sootblower

11. Fuel system equipment specification

11.3. Characteristics of accessory equipment of fuel oil system

Secondary air system MPa 3.941 3.941 5.88

c. Hydraulic test scope:

a. Water is tested qualified before filling.

Chapter 2 Boiler Startup

2.1 General rules

Steam Drum Pressure MPa 9 10.5 12 13 14.5 16 17 18.5

Chapter 1 Preparation before Boiler Shutdown

1.1 Preparation before Boiler shutdown

Chapter 2 Boiler Shutdown

2.1 Sliding-parameter shutdown

Chapter 1 General Rules for Trouble Handling

Chapter 2 Handling of Boiler Trouble

2.2.2 Low steam drum water level

1. Problem in heater 1. Repair or replace the heater

Specified vibration (mm) 0.06 0.10 0.13 0.16

Specified vibration (mm) 0.09 0.12

Requirement (mm) 0.03~0.06 0.04~0.08

Max vibration of coal pulverizer does not exceed 0.10mm.

Chapter 2 Pulverizing System

2.1 Operation, maintenance and trouble handling of pulverizing system

2.1.2 Check of pulverizing system before startup

3.2 Check fan before startup

Item－ Name Pressure Temperature Steam source

Chapter 6 Flame Detection and Flue Gas Probe

No. Item Unit Data Remarks

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