YB

LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT

Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 01 ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
Start & Running Of Boiler
1. Before starting the boiler, please check the gas and steam-water system, their
position should be at pre-start point.
. !he water le"el of boiler drum should be at start and temperature-increasing
position #-$%mm&.
'. Start () chain con"eyor.
*. +heck and start drainage "al"e from boiler to main steam header, worm the
pipe line with the starting of boiler.
$. ,eep in touch with personnel of production line ++R, fully open the damper
at outlet of boiler, mean while, control the speed of temperature raising by
ad-usting opening of inlet damper of boiler, keep the process stable and
smooth.
.. /onitor water le"el of boiler drum, normal running le"el of it shall be
0
'%mm, limited le"el of it shall be
0
1$mm, when the temperature of boiler
drum is rising, drain out the sewage water appro2imately, if the water le"el is
low, start the water feed pump to fed water, under the condition of keeping
the normal water le"el, raise the temperature & pressure balanced, control
the rising speed of temperature within
o
+ 3min, according to pressure of
drum.
1. (lush & rectify the water le"el meter after the pressure of drum has been
raised to %./pa.
BO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 0& ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
4. 5erform following procedures after the pressure of drum has been raised to
%.'-%.*/pa.
#a& One time drainage of sewage for drum, the drainage "al"e could not be
opened too much, mean while pay attention to changes of water le"el.
#b& (lush sampling tube and instrument tube, perform sampling and chemical
test of boiler water.
#c& +heck boiler body, hot e2pansion status of pipeline and if any distortion
on e2pansion -oint.
#d& 5erform tightening work under hot condition to manhole3 hand-holes and
flanges, check under-pressure elements once.
#e& 6rain water from connection bo2 inside steam drum in turn so as to make
the e2pansion caused by heating e"enly, mean while, and notice the
change of water, when the le"el is less then -1%%, complement water in
time.
7. 8ncrease the pressure & temperature continuously till the pressure of steam
drum up to 1.%-1.1/pa, and then following works should be performed.
#a& ,eep the water le"el of steam drum at low le"el.
#b& (lush water le"el of stem again.
#c& 9d-ust gas damper and close by pass "al"e so as to increase the
temperature and pressure of saturation steam.
#d& 9d-ust e2haust to keep seep steam pressure.
#e& 8nspect boiler system thoroughly, if any abnormal case arise, stop
pressure increasing "al"e immediately, and do not continue the pressure
increasing "al"e until get rid of malfunctioning.
BO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 0+ ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
1%. !he temperature of main seam if more than 1$%
o
+, drainage "al"e opening
degree could turn down and then inform turbine start or synchroni:ation of
boiler stem.
11. 9d-ustments during boiler running ;<R boiler is one important factor
during producing system, there are some mutual influence between it and
cement production line, boiler shall be suitable for re=uirements of cement
production line and pro"ide stem with suitable parameters to ensure
generating normally, so operator of boiler should be familiar with boiler &
au2iliary e=uipments and related operations profoundly, they shall fill the log
sheets of running seriously, make e"ery report clearly, prepare regular tools
and materials and analy:e performance inbo2 & status during running.
#a& 9d-usting of water le"el during normal running, water le"el sold be kept
0'%mm, limit water le"el 01$mm with slightly fluctuating, water feeding
need to be e"en, water feeding stops is forbidden, monitor if any change
of pressure and temperature of feeding water, if e2ceed the regulated
"al"e, inform turbine operator immediately, keep the two water le"el
meters of stem drum under good condition. 8ts indication shall be clear,
its illumination shall be enough, its alarm shall be sensiti"e, flush & clean
water le"el periodically, and the indicating "alue should be same with
actual "alue.
BO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 0, ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
#b& 9d-ustment of pressure & temperature for steam, under the precondition
of normal running of cement production line according to re=uirement of
turbine and boiler#s& load allocation, one shall ad-ust e"aporation "olume
of boiler correspondingly. #,eep in touch with production line& keep
steam pressure around rated 0%.$-%.1/pa. Steam temperature around
rated 01%
o
+. intensify communication with operators of turbine and
electrical. ,eep the load stable. 8f any abnormality analy:es parameters
of instruments, take right measure.
#c& 5atrol inspection> in order to keep safely running of boiler, at least *
times patrol inspection are needed for e"ery shift teams, checking items
include boiler body, au2iliary e=uipments, such as duct3boiler wall3
pipeline for steam and water3"al"es, make sure that there is no leakage,
water le"el manometer3 safety "al"es3thermometers etc, make sure their
normal, rapping system, dust discharging and con"eying de"ices are
normal.
#d& Sewage water drainage for boiler> in order to maintain the =uality of
water and stem, sewage water drainage should be performed in time
according to re=uirements from chemical treatment personnel. +ontact
attendant of boiler running before drainage, keep the le"el of water a
little high, use speciali:ed tools, and take safety protection measure. (irst
open primary "al"e, the time for full open to full close should not be
more than '%sec, it is not allowed tot open or more "al"es at the same
time for drainage, after half an hour, inspect and make sure e"ery "al"e is
closed tightly without leakage. 8f any accident happens during drainage,
please stop drainage immediately #e2cluding the water is full, the steam
and water together&
BO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 0- ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
Start Operation 6escription of !urbine
9. 5reparation before Start of !urbine.
1. !horoughly inspect all the e=uipments3pipelines3"al"es3site instruments
and 6+S parameters on ?+6 monitor #there shall be no leakage in the
system and lubrication oil shall be enough&.
. Start circulating water system of condenser, open water @return A-Bal"e
at two sides, start inlet "al"es at two sides, open water-return air e2haust
"al"e at condenser side, open water-return manual "al"e at cooling water
side, start circulating pump, after e2hausting all the air out, close the air
e2haust "al"e. ,eep water pressure at condenser inlet as %.1C%.1$/pa.
'. Open soft water complement gate of condenser to make up water le"el of
hot water tank under condenser as '%%C*$%mm. open recycle water gate
slightly, start one condensing pump, after running normally, check
another pump if with =ualified standby condition.
*. +heck and make sure the oil le"el tank is normal, start smoke e2haust
fan, start high pressure pump, keep oil temperature at outlet of oil cooler
as '$C*%D+.
$. Switch the turning gear into position, start lubrication cock gate of
turning gear and switch it into use.
.. Open the "al"es at inlet and outlet of 6+ lubrication pump and put
interlock in to use.
1. ,eep the water le"el of de aeration tank as 1$%%C14%%mm, make sure the
good working status of water feeding pump and cooling system.
TO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 0. ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
4. ;ater le"el of water -et is normal.

B. 5ipeline ;arming.
1. Open e2haust A-"al"e of header slightly, opens all the drainage "al"es
ahead of and behind main steam A-"al"e.
. Open the electrical "al"e of boiler to turbine cylinder slowly to warm the
pipeline.
'. Eotice during warming pipeline, check and make sure the position of
=uick stop "al"e and steam "al"e for ad-usting speed as close status, the
barring gear #turning gear& is continuously running.
+. Bacuum /aking
1. Start one water -et pump and make sure it runs normally, after outlet
pressure of pump being tube for rear steam sealing.
. Open steam "al"e of main steam to steam sealing slowly, till there some
steam out of signal tube for rear steam sealing.
TO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 0/ ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
6. Start up
1. +onditions shall be as following, main steam pressure up to %.4C1.%/pa,
temperature abo"e $%D+, "acuum pressure of condenser -%.%. C -%.%1
/pa, temperature of lube oil within '$C*%D+, the oil pressure of lube
main pipe around %.$/pa.
. +heck and make sure control de"ice of =uick "al"e works normally, open
the =uick stop "al"e by using combined =uick stop de"ices.
'. Switch on related protection.
*. 9cti"ate start command through $%$ controller or 6+S.
$. 9fter the turbine has been started, one shall check if the motor of barring
gear is shut off, if not, switch of immediately.
.. ;hen speed of rotor up to .%%rpm, keep it running for $minutes for
machine warning.
1. 9fter $minutes warming, check the system completely and make sure
e"ery thing is normal then input speed as 1%%%rpm manually and keep it
for *%-.%minutes.
TO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 00 ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
4. 9fter abo"e warming, check the system again, if normal, input speed as
*%%rpm and keep it for %-'%minutes.
7. !hen, check the system thoroughly, if normal input speed as '%%%rpm
and after speed is up to '%%%rpm, check if the main pump runs normally
if no problem, shift the high pressure oil pump to main pump.
1%. 9fter speed is up to '%%%rpm check the system thoroughly and make sure
e"ery e=uipment is running normally, then inform electrician to
synchroni:e.
11. !he process of load rising should be slowly performed, closely pay
attention to "ibration3 oil pressure- temperature of bearing3 e2pansion
difference3 shaft displacement.
Stop Operation 6escription of !urbine
1. +ommunicate related attendant after recei"ing command of stop, make
good preparation works before stop.
. !horoughly inspect the system before stop, make good record of
e=uipments, defects in detail and precisely.
'. !est the make sure the high pressure oil pump and dc oil pump is normal,
as well as barring gear #turning gear&.
TO
Reviewed by Approved by Issued by
YB
LUCKY CEMENT LIMITED A YUNUS BROTHERS PROJECT
Department / Section: Waste Heat Recovery(WHR) LQP-WHR-01-WI-001
Scope: Boiler & Turbine Oeration! Issue " 01 #ate$0%-0&-&010
Responsibility: Boiler Oerator (BO)'Turbine Oerator (TO)' Pa(e " 0% ' 0%
)ssistant *ana(er ()*)!
WORK INSTRUCTION Resonsibility
*. 6ecrease the load to :ero gradually, inform electrician on duty to
disconnect the generator, notice speed ad-usting system which should
keep the rotation without load.
$. Start high pressure oil pump and make sure its running is normal.
.. Operate stop knob manually to stop =uick stop "al"e and speed ad-usting
"al"e.
1. +lose the air "al"e and stop the water -et pump.
4. 9d-ust "acuum destroy "al"e make the rotation speed and "acuum turn to
be :ero at the same time, switch on turning gear and stop steam sealing
"al"e. +lose A-"al"e from boiler to header and main steam "al"e, start
drainage "al"e of main steam pipeline and stop "al"e from condenser to
de aeration tank.
7. Switch on low pressure oil pump, if temperature of oil and permitted,
stop oil cools and air cooling.
1%. 8f temperature of e2haust steam F$%D+ stop circulating pump.
11. Stop condensing pump after half an hour.
1. Record necessary data and notice oil pump and turning gear, switch on
interlocks of turning gear.
1'. !he hot water will could not be full. Running of turning gear should be
continuously.
TO
Reviewed by Approved by Issued by