BOILER COLD START UP PROCEDURE :In boiler operation page,

1. ID Fan(VFD mode)
a) Fan REDcolor is no running ( stop condition)
b) Fan GREEN color is running indication.
c) RPC , VFD selector switch , for using VFD mode It should be selected VFD
mode.
d) In VFD mode, We can increase or decrease the fan speed.
e) A / M Auto / Manual selector switch.
- it should be in manual mode before start the fan.
f) Interlock for fan start only drum level.
- It should above 22% and below 88%(normal 50%)
- For cold startup drum level should be kept 40%.
g)
SP Set point we can change the set point only in Auto mode.
h) To start the fan select RPC mode and open 100%(open command 0%)
- Select the VFD mode and set the speed 0%.
- move the cursor to the fan and left click and start.
- Check the green indication to confirm the fan running.
2. PA Fan (star / delta )
a) Fan REDcolor is no running ( stop condition)
b) Fan GREEN color is running indication.
c) Interlock Suction damper should be kept in close condition (Red close , Green
open) and ID fan running indication.
d) To start the fan - Ensure the suction damper in close condition.(Red)
- move the cursor to the fan and left click and start.
- Check the green indication to confirm the fan running.
- wait 30 sec to open the suction damper and ensure the green
indication for open.
- Before open the suction damper manual damper should be
closed.
- After open the suction damper, slowly open the manual screw
damper and set the PA header pressure 500 mmwc.
3. FD Fan: (VFD mode)
a) Fan REDcolor is no running ( stop condition)
b) Fan GREEN color is running indication.
c) RPC , VFD selector switch , for using VFD mode It should be selected VFD
mode.
d) In VFD mode, We can increase or decrease the fan speed.
e) A / M Auto / Manual selector switch.
a. it should be in manual mode before start the fan.

f) Interlock for fan start PA fan running indication and furnace pressure below +20
mmwc.
g) To start the fan - select RPC mode and open 100%(open command 100%)
- Select the VFD mode and set the speed 0%.
- move the cursor to the fan and left click and start.
- Check the green indication to confirm the fan running.
4. Open the PA first compartment damper (open green & close red).
5. Open the FD first compartment damper (open green & close red).
6. ID fan put into auto mode and set the set point value -5 mmwc.
7. Slowly increase the FD fan speed and closely watch the first compartment air box
pressure up to 600 mmwc and ensure PA header pressure should be above 1000 mmwc if
required slowly increase the suction screw damper and set.
8. Check the PA mixing nozzle (suction) and ensure no jam.
9. Slowly reduce the FD speed up to the Air box pressure 300mmwc.
10. Open the second compartment PA damper and increase the screw damper to maintain
the PA header pressure above 1000 mmwc.
11. Close the first compartment FD damper and open the second compartment FD
damper.
12. Slowly increase the FD fan speed and closely watch the second compartment air box
pressure up to 600 mmwc and ensure PA header pressure should be above 1000 mmwc if
required slowly increase the suction screw damper and set.
13. Close the second compartment FD and PA damper and open the third comportment
PA and FD damper for fluidizing.
14. Close the third compartment FD and PA damper and open the fourth comportment
PA and FD damper for fluidizing.
15. Slowly reduce the FD speed up to 200 rpm and stop the FD fan , PA fan and ID fan.
16. Check the bed height in all compartment.
17. Ensure the bed height is 300 mm from DP plate in all compartments.(if the bed height
is more we can drain the bed material from bottom bed material drain for maintaining the
bed height.
18. After check the bed height 300 mm we can charge the char coal in first compartment
(startup compartment)
19. Dry char coal 140 Kgs and 80 Kgs diesel mixed char coal charged into the first
compartment(as per CVL engineers procedure, all four sides in first compartment gap
should be maintain 300 mm from corners.
20. 5 Kgs cotton waste mixed with diesel and spread over the char coal.
21. Close the ID suction damper 50%(Change RPC mode and set 50%) and put the fire in
char coal.
22. Wait 3 minutes .
23. Open the suction damper 100% and select the VFD mode .
24. Select the manual mode (M) and set the ID speed 0%.
25. Start the ID fan and put the auto mode and set the set point -3 mmwc.
26. Close the PA suction damper and start the PA fan.
27. Open the first compartment PA and FD damper.

28. Wait 30 sec to open the suction damper and adjust the PA screw damper and set the
PA header pressure 500 mmwc.
29. Select the RPC mode and Open the suction damper 100% and select the VFD mode .
30. set the FD speed 0%.
31. Start the FD fan and slowly increase the FD speed up to maintain the first
compartment air box pressure 50 mmwc.
32. Wait 3 minutes .
33. Slowly increase the FD speed up to maintain the first compartment air box pressure
100 mmwc and wait 2 minutes.
34. Slowly increase the FD speed up to maintain the first compartment air box pressure
150 mmwc and wait 1 minutes.
35. Closely watch the furnace temperature increasing.
36. When it reaches above 175 deg.C we can give mixing of char coal and bed material.
37. Close all manhole doors in furnace.
38. Slowly increase the FD speed up to air box pressure 575 mmwc.
39. Wait 15 second.
40. slowly reduce the FD speed up to air box pressure 375 mmwc.
41. Closely watch the first compartment bed temperature increasing.
42. Ensure the bed temperature reaches(bottom and top) up to 500 Deg.C, we can start
the coal feeders.
43. Before start the coal feeders PA header pressure should be kept 750 to 800 mmwc by
adjusting the PA suction screw damper.
44. Start the coal feeder with 50% of speed(Feeder 1& 2).
45. Closely watch the furnace and coal burning, if bed temperature decreases we can
reduce the air box pressure up to 290 mmwc by decreasing the FD fan speed.
46. Bed temperature reaches above 950 Deg.C, we should charge the bed material to
control the bed temperature raising.(5 Bags)
47. After stabilaizing the bed temperature we can set the air flow of 18 mmwc for one
compartment.
48. Close the Feed control valve fully (100% command for close ), Start the feed pump
and increase the speed 2000 rpm.
49. Close the drum and steam line air vents(1 size) at 3 Kg/cm2.
50. Carefully watch and maintain the drum level to avoid tripping (trip level 22% and
88%).
51. After stabilaizing the first compartment , we can give the mixing the second
compartment .
52. Slowly open the PA suction screw damper and set the PA header pressure 1000
mmwc and open the second compartment PA damper and ensure the PA header pressure
above 800 to 850 mmwc.
53. Open the second compartment FD damper and increase the FD fan speed for maintain
the air box pressure up to 450 mmwc in 1 and 2 compartment.
54. Closely watch the first compartment bed temperature, when it decreasing 20 Deg.C
we should reduce the FD fan speed and close the second compartment FD damper.
55. Set the previous air flow (18 mmwc) for first compartment.
56. The above said mixing can be given every half hour to increase the second
compartment bed temperature .

57. When the second compartment bed temperature reaches above 450 Deg.C we can
start the coal feeder (3 & 4 Feeders) and air flow 36 to 40 mmwc for two compartments.
58. After stabilaizing the second compartment the same procedure to take the third
compartment and fourth compartment in to operation.
59. Steam temperature should be control by opening of spray water through temperature
control valve and minimize the coal feeding in running compartments.
60. Startup vent motorized valve should be kept open for increasing the steam
temperature.
61. The main steam line drain valve can be closed at steam temperature 350 Deg.C .
62. The boiler comes in rated temperature and pressure, we can charge the steam line
through bypass valve for warming up.