MAITHAN ISPAT LTD.

JAKHAPURA

BOILER CAPACITY : 60 TPH, FBC BOILER.

BOILER NO. : BF050
BOILER PR/TEMP : 66 KSC/485±5ºC

BOILER COLD STARTUP PROCEDURE

1. Check and ensure the furnace is cleaned from any foreign materials.

2. Take the pre-trail of ID, PA, FD Fans; allow air to the furnace for 10 minutes duration to flush
the Air nozzles & PA Nozzles.

3. Check and ensure the PA Lines are free from any choke. If there any choke, just open the
particular PA Line drain gate and remove the jam until the PA mixing nozzle getting in take of
atmosphere air.

4. Stop PA & FD Fan and charge proper size bed materials manually by going in side the furnace.
The quantity of the bed material will be approximately 14 tones.

5. Charge the fine bed materials in the start up compartment for easy start up of the boiler.
Remaining bed may be charged by coarse materials. Fluidize individual or double compartment
at a time except start up compartment by setting the PA HDR pr. 850 mmwc Apx. Air box pr.
500 to 550 mmwc. The start up compartment should be fluidized separately, so that, other
compartment materials may not mix with start up compartment. Check min and max fluidization.
After fluidization, check and ensure the bed height of 280-300 in start up compartment and
others are to be 340-360.During fluidization check and ensure the particular compartment PA
Lines are free from any jam.

6. Whenever the fans are to be required to start for fluidization or start up of the boiler, firstly the
PA header pr. To be set at 500 to 600mmwc before opening the FD compartment or increasing
the FD air, so that the PA air will not allow the bed material to get enter into the PA Lines and
get chokes.

7. Border of the start up compartment may be increased by pouring approx. 5-6 bags of bed
materials all around, so that, the charcoal spillage to the adjacent compartment may be avoided.

8. Add the 280-300Kgs of 15 to 25 mm size Dry charcoal in the start up compartement.Charcoal

may be added in the area of keeping the one feet distance from the border.

9. Check and ensure the diesel oil level at the tank. Switch ON the Diesel Oil pump and raise the
oil pressure up to 5ksc.Spray the oil through gun and ensure the proper oil flow. Place all the oil
guns in the burner.

10. Check/Ensure the automation air valve & combustion air valves are opened.

11. Check/Ensure the Drum level (40-50%), Drum vent/start up vent and Drains in main steam line
are opened.

12. Check/Ensure the coal availability at the bunker; ensure the surge hopper coal gates are opened.
13. Check/Ensure the PA/FD Dampers are opened in start up compartment and remaining are closed.

14. Start ID, PA, FD Fans and set the PA Header pr. 550-650mmwc by opening the PA suction
damper (RPC). Now open the FD Fan suction damper (RPC) set the air box pressure at 500 to
550 mmwc. If PA Hdr Pr. Is found more than 850 mmwc and reduce the PA suction damper
(RPC) to set 850 mmwc.

15. Fire the oil burner by small swab. At the time of firing, the setting pressure are called minimum
fluidization condition (i.e. MFC) are as follows
Air Box pressure 500 to 550 mmwc
PA header pressure 830 to 850 mmwc

16. Once the burners are fired, furnace has to be kept on watching, charcoal will get sparking slowly.
Now the air flow and the air box pressure are to be reduced gradually according to the fire pick
up in the furnace. While reducing the air from MFC to MCR care to be taken that, bed should
not become static. Air box pressure must be considered by reducing 20 mmwc each time. The
time duration of reducing the air/air box pressure from MFC to MCR must be 10 to 15
minutes(It may vary according to the fire pick up). The fire pick up will be fast at the time of the
parameters are nearer to the MCR condition. Once the bed material reaches red hot and the
temperature reaches above 400 degree Celsius, the coal feeding must be started

Air box pressure 300 to 300 mmwc

Air flow 17 to 19 mmwc
PA header pressure 830 to 850 mmwc

Please note that, before stating the fuel feeders PA Header pressure has to be raised up to 850 to
900mmwc

17. After starting the coal feeder the coal will take one or two minutes to enter into the furnace due
to first empty vertical PA pipe will get fill up then it comes to the furnace. Once the get ignited
observe the bed temperature, and it will raise drastically with the support of charcoal fire, if the
temperature reaches around 900 deg C it can be controlled by pouring the bed material from
outside or by giving the mixing to the adjacent compartment, or by varying the fuel feeding rate.

18. After stabilization of the start up compartment it go for mixing with the adjacent compartment
by opening the FD line damper. First two mixing may be given without increasing the FD
suction damper/air flow to safe guard the running compartment temperatures. After two or three
mixing by increasing the FD suction damper/air flow.

19. If the drum pressure reaches 4 to 5 KSC, drum vent may be closed.

20. After giving the sufficient mixing to the adjacent compartment the may reaches 400 deg C and
above, then the adjacent compartment may be taken into line by giving the feeding. Kindly note
that before going for second compartment operation main steam line pressure must be reached to
above 20 ksc.

21. Once the steam pressure/steam temperature is reached to the rated parameters, the stop valve
may opened, and give the steam to process. Like wise number of compartments may be put it in
operation according to the load demand. After giving the steam to the process all the drains /
vents must be closed.