300 MW DCRTPP Boiler O&M Manual

HARYANA POWER GENERATION
CORPORATION
PANCHKULA, HARYANA
DESIGN PRIVATE LIMITED

CONSULTING ENGINEER
NEW DELHI
CENTRAL ELECTRICITY AUTHORITY

SEWA BHAWAN, R K PURAM,
NEW DELHI
DCR Thermal Power Project

(2 x 300 MW), Yamunanagar
Boiler Operation and Maintenance
Manual
DOCUMENT No：SC-YW-01
RELIANCE ENERGY LIMITED

REL TOWER, A-2, SECTOR-24
NOIDA (U.P) - 201301
DEVELOPMENT CONSULTANTS PRIVATE

LIMITED CONSULTING ENGINEERS
24B PARK STREET, KOLKATA – 700 016, INDIA
SHANGHAI ELECTRIC (GROUP)

CORPORATION (SEC)
3669 Jindu Road, Shanghai, China
HUBEI FIRST ELECTRIC POWER
CONSTRUCTION ENGINEERING
CORPORATION (HEPEC)
388 Zhongshan Road, Wuhan, China
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HPGC : 2 x 300 MW
Boiler Operation and
Deenbandhu Chhotu Ram
Maintenance Manual
TPP, Yamunanagar
DOCUMENT CONTROL SHEET
PROJECT:DCR THERMAL POWER PROJECT

2 X 300 MW UNITS
CLIENT: RELIANCE ENERGY LIMITED/ SHANGHAI ELECTRIC (GROUP) CORPORATION
DOCUMENT TITLE: Boiler Operation and Maintenance Manual

DOCUMENT No.: SC-YW-01
REV. NO. : 0
ENDORSEMENTS
0 2007-6-30
PREP. BY REVW. BY APPD BY

REV. DATE DESCRIPTION
SIGN.(INITIAL) SIGN.(INITIAL) SIGN.(INITIAL)
HUBEI FIRST ELECTRIC POWER CONSTRUCTION ENGINEERING COMPANY

388 Zhongshan Road, Wuhan, China
DOCUMENT NO: SC-YW-01 Page：1

ORIGINATOR：

HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
CONTENTS
Chapter 1 Boiler Operation and Maintenance ··············································1

1. Boiler Equipment regulation and features ....................................................... 1
1.1 General ........................................................................................................................................ 1
1.2 Boiler design standard ............................................................................................................... 3
1.3 Boiler equipment standard ........................................................................................................ 3
1.4 Main technique and performance ............................................................................................ 4
2. Specification of Auxiliary Equipment ............................................................... 7
2.1 Primary air fan............................................................................................................................. 7
2.2 FD fan and ID fan ....................................................................................................................... 8
2.3 Mill................................................................................................................................................. 9
2.4 Coal feeder ................................................................................................................................ 10
2.5 Air preheater.............................................................................................................................. 10
2.6 Flame scanner cooling air fan ................................................................................................ 11
2.7 Fuel oil pump............................................................................................................................. 12
2.8 Technical parameter of soot blowing ..................................................................................... 12
Chapter 2 Boiler start-up·············································································13

1. Specification and Description of Boiler Start-up ........................................... 13
1.1 Specification of boiler start-up ................................................................................................ 13
1.2 Description of boiler start-up................................................................................................... 13
2. Status Division before Boiler Start-up, Start-up Parameter and Selection
Rules of Start-up Method..................................................................................... 14
2.1 Division of status before boiler start-up................................................................................. 14
2.2 Boiler start-up parameter, method selection rules ............................................................... 14
3. Inspection to Boiler before Start-up and Place Auxiliaries and System in
Service .................................................................................................................. 15
3.1 Attention during the period of boiler start-up ........................................................................ 15
3.2 Inspection before boiler start-up............................................................................................. 15
3.3 Put auxiliary equipment and system into use before boiler start-up ................................. 17
4. Boiler Cold Start-up.......................................................................................... 17
4.1.1 Auxiliaries start-up and fuel oil leakage test ...................................................................... 17
4.1.2 Furnace blowing .................................................................................................................... 19
4.1.3 Boiler light-up......................................................................................................................... 19
4.1.4 Boiler temperature rise and boost pressure...................................................................... 22
4.1.5 Operation to boiler at turbine rolling-up ............................................................................. 24
4.1.6 Operation to boiler during the period of turbine warm-up ............................................... 24
4.1.7 Operation to boiler at boiler synchronization..................................................................... 24
4.1.8 Monitoring at boiler start-up................................................................................................. 24

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Maintenance Manual
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5. Boiler Hot Start-up............................................................................................ 26

6. Boiler Warm-up With Load and Load Increasing........................................... 28
6.1 Warm-up with 15MW load....................................................................................................... 28
6.2 Load increased to 30MW ........................................................................................................ 28
6.3 Load increased to 60MW ........................................................................................................ 29
6.4 Load increased to 105MW ...................................................................................................... 30
6.8 Attention during the period of load increasing ...................................................................... 32
7. Boiler Black Start-up ........................................................................................ 34
Chapter 3 Boiler Normal Operation and Maintenance ·······························35

1. Daily Maintenance and Seasonal Protection Measures ................................ 35
2. Supervisory to Main Operation Parameters................................................... 37
3. Regulation of Boiler Operation Parameter ..................................................... 38
Chapter 4 Boiler Unit Shutdown ·································································45

1. Boiler Shutdown Mode and Rules................................................................... 45
2. Preparation before Boiler Shutdown .............................................................. 45
3. Boiler Shutdown to Cold Standby................................................................... 46
4. Boiler shutdown to heat standby .................................................................... 48
5. Emergency Boiler Shutdown........................................................................... 48
6. Attention to Boiler Shutdown .......................................................................... 49
7. Operation to boiler after generator running out of synchronization............ 50
Chapter 5 Preservation and Freeze-proof After Boiler Shutdown ··············54

1. Preservation after Boiler Shutdown................................................................ 54
2. Boiler Freeze-proof .......................................................................................... 55
Chapter 6 Start, Stop and Operation Maintenance of·································57

Auxiliary Equipment and System ································································57
1. General Inspection Rules before Starting Auxiliary Equipment and System
............................................................................................................................... 57
2. Start (launch), Stop (quit) and Operation Maintenance of Boiler Equipment

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Maintenance Manual
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and System ........................................................................................................... 58

2.1 Operation of pulverization system.......................................................................................... 58
2.2 Operation of ID and FD fan..................................................................................................... 68
2.3 APH Operation .......................................................................................................................... 72
2.4 Operation of drum local water level ....................................................................................... 76
2.5 Operation of periodic blowdown tank .................................................................................... 78
2.6 Operation of continuous blowdown........................................................................................ 79
2.7 Operation of flame scanner cooling air fan........................................................................... 80
2.8 Operation of fuel oil pump ....................................................................................................... 81
2.9 Operation of soot blower ......................................................................................................... 85
2.10 Air compressor operation ...................................................................................................... 91
2.11 Operation and maintenance of ESP ash handling system............................................... 95
2.12 General rules for maintenance of boiler auxiliaries........................................................... 97
2.13 Periodic work to boiler ........................................................................................................... 99

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
Chapter 1 Boiler Operation and Maintenance
1. Boiler Equipment regulation and features

1.1 General
Sub-critical pressure natural circulation boiler SG–1025/17.5–M898 is
manufactured by Shanghai Boiler Works, Ltd. It is sub-critical pressure
intermediate primary reheat natural circulation boiler, single furnace, burner
swinging for temperature regulation, balance ventilation, four corner tangential
burning, intermediate speed mill cooling primary fan with positive pressure direct
blowing coal pulverized system, solid-state continuous deslagging, two sets of
trisection air-preheater (APH) arranged at the afterbody of furnace rear, the boiler
is Π type, complete steel hanging structure and partly arranged in the open air.
The furnace is 16100mm in width and 14120mm in depth, the elevation of furnace
top is 63000mm, drum centreline elevation is 67500mm, the elevation of boiler
ceiling girder bottom is 73000 mm. Complete sealing structure is adopted at boiler
top and sealing encloser. The furnace is composed of Φ60×7mm diaphragm water
wall, the angle of cold hopper at boiler bottom is 55°, water sealing structure is
used at boiler bottom, division panel, rear platen and platen reheater are arranged
at the upper part of furnace, wall radiation reheater is designed at the front wall and
at the front of side wall, the elevation of furnace chamber water wall lower header is
9000mm.
The depth of horizontal flue gas duct is 6528mm, composed of boiler top bypass
reheater which is taken as furnace extension side wall and backpass, where
reheater finish and superheater finish are arranged.
The depth of backpass is 9234mm, and LT superheater and economizer are laid
inside it.
Positive pressure direct blowing coal pulverizing system is used for boiler, there are
six sets of HP intermediate speed mill, in which 4 mills are for operation and two for
standby aiming at design coal type, while five mills are for operation and one for
standby aiming at verifying coal type; they are arranged at the front of boiler.
Pulverized coal and air are coming inside from four corners for burner four-corner
arrangement tangential burning (totally six layers) method, opposite the direction of
tangent by concentric inside furnace and with the burning mode of high and low
concentration separating burning at upper and lower part, which can not only
stabilizing the burning performance by low load but also be effective for preventing
slagging and corrosion by high temperature. Top layer OFA nozzle is opposite the
direction of tangent to lower air flow residual rotary strength inside boiler and
decrease the difference of flue gas temperature at both sides of furnace outlet. It is
designed with adjustable air-input and wide fire-opposite side perimeter air to adapt
the coal type and variation of load; four layer start-up and oil ignition gun are

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designed inside windbox of each corner burner. While designing coal type for
burning, minimum load of burning stabilization without oil is not more than 30%
BMCR.
Boiler structure is complete steel structure and connected by high tension bolts,
there are totally nineteen layers of platforms, in which there are seven layers of
rigid platforms; in order to facilitate operation, partial platforms are arranged at
some place. Except slag collecting device and preheater, all the weight of boiler are
hanged and loaded on top of boiler structure. Expansion center and “0” position
guarantee system are designed for boiler, encloser hot sealing is adopted at boiler
top, complete metal sealing is used for boiler top pipes, light construction with
ladder type metal casing for boiler wall.
Spraying desuperheater is used for regulating superheater steam temperature, two
stages of spraying desuperheater are arranged in superheater system: primary
spraying desuperheater is on the LT SH outlet pipeline while secondary is on the
SH rear platen outlet pipe. Reheater steam temperature regulation is mainly
fulfilled by burner swinging and excess air coefficient.
There are two stages of spraying desuperheater in the reheater system, the
primary stage is emergency spraying desuperheater that is arranged on the RH
inlet pipes and secondary is minim spraying device that is laid on the connection
pipe between platen reheater and reheater finish.
One start-up drain bypass with the capacity of 5%BMCR is designed on the
backpass lower header.
Two sets of Φ10330mm trisection air preheater(heating surface rotary) are
designed at the lower part of flue gas duct end.
There are 72pcs wall soot blowers at the part of furnace, 50pcs long-strike
shrinkable soot blowers are arranged at the upper part of furnace and at the field of
convective flow flue gas duct and four soot blowers arranged at preheater. All the
soot blowers are in process control during operation.
There are 10pcs spring safety valves for boiler body, in which three pieces are on
drum, two are at SH outlet, two pieces on RH inlet pipe and three pieces are on RH
outlet pipe. In order to decrease the tripping times of safety valves, two dynamic
discharge valves.
Flue gas temperature probes are equipped at the left and right side of furnace
outlet and they are used for controlling the flue gas temperature at furnace outlet
while starting-up. Furnace flame TV camera device is installed at the left and right
side of furnace so as to facilitate the observation to burning situation inside furnace.
Safety protection device such as drum water level gauge and water level TV
camera device and furnace safeguard supervisory system (FSSS) are equipped for
boiler.

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1.2 Boiler design standard

Boiler model: sub-critical intermediate primary reheat natural circulation drum
boiler
Type: SG--1025／17.5—M898
Manufacturer: Shanghai Boiler Works, Ltd.
Burning mode: light oil start and stop and stabilize burning. Intermediate speed mill
with positive pressure direct blowing, four-corner tangential
Ventilation mode: balance ventilation
Operation mode: constant pressure, sliding pressure operation
Circulation mode: natural circulation
Ignition mode: light oil side flame ignitor to ignite heavy oil, and then ignite
pulverized coal
Main steam temperature regulating mode: secondary spraying desuperheat
Reheat steam temperature regulating mode: sway burner’s angle of inclination and
change excess air coefficient
Design fuel: light diesel oil, heavy oil and coal
1.3 Boiler equipment standard
1.3.1 Drum
Design pressure: 19.6Mpa (200kg/cm2g)
Design temperature: 365℃
Inside diameter: 1743mm
Total length: 20100mm
Height: 64.5m
Material: SA299
Complete external dimension: 20400x3000x2800mm
Material: BHW35
Quantity of turbo separator: 102pcs
1.3.2 Furnace and water wall
Width: 16100mm
Depth: 14120mm
Breadth depth ratio: 1.14:1
Elevation of water wall lower header: 9000mm
Elevation of furnace top pipe centreline: 62500mm
Furnace cooling coefficient, maximum: 160，000kcal/h- m2
Furnace capacity heat load (BMCR): 80.86kw/m3
Furnace section heat load (BMCR): 3.55MW/m2

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Water wall surface even heat load EPRS (BMCR): 0.159MW/m2

Burner field heat load (BMCR): 1.197 MW/m2
Capacity: 8200m3
1.3.3 Heating surface
Radiation heating area (including division plate): 3900m2
Convective heating area: 42000m2
Total heating area: 47000 m2
1.3.4 Burner:
Type of pulverized coal burner: wide range inclined burner
Quantity: 24sets
Type of oil gun: driving and reversing air atomization
Quantity: 4sets
Usage: heat boiler and raise pressure
Total output: 10%BMCR
Type of oil gun: driving and reversing steam atomization
Quantity: 12sets
Usage: ignition and stabilize burning of neighbourhood pulverized coal nozzle
Total output: 30%BMCR
Centreline elevation of nozzle outlet at uppermost row of burners: 31820 mm
Distance to the bottom of division panel: 18000mm
Centreline elevation of nozzle outlet at the lowest line of burners: 23640 mm
Distance to cold hopper turning angle: 4765 mm
1.4 Main technique and performance
1.4.1 Main parameter of rated condition and BMCE condition
Description Unit BMCR BECR
SH steam flow t/h 1025 926.6
Superheater outlet steam MPa(g) 17.50 17.34

pressure
o
Superheater outlet steam C 541 541
temperature
Reheater steam flow t/h 823 753.3
Reheater inlet steam pressure MPa(g) 3.74 3.43
Reheater outlet steam pressure MPa(g) 3.56 3.29

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o
Reheater inlet steam temperature C 326 318
o
Reheater outlet steam C 541 541
temperature
o
Economizer inlet feed water C 280 274
temperature
1.4.2 Information for fuel

Coal quality analysis data for the designed types of coal and checked types of coal
in this project refers to following table:
Designed types Checked types of

Item Unit
of coal coal
High heat value ar (Qnet.ar) kcal/kg 4000 3150
Industrial analysis (weight %)
Water ar (Mar) % 15 15
Volatilization ar. (Var) % 30 19.27
Ash ar ( Aar) % 34 46
Fixing carbon ar (FC ar) % 21 19.73
Carbon content ar (Car) % 41.22 31.88
Hydrogen content ar (Har) % 2.81 2.13
Oxygen content ar (Oar) % 5.90 4.12
Nitrogen content ar (Nar) % 0.71 0.59
Sulfur content ar (Sar) % 0.35 0.28
Grindability index (HGI) 50 50
Light-up and combustion-supporting oil

Oil type for light-up: light diesel (Indian standard IS 1460-197)
Relative density (at 15℃): 0.86～0.90
Kinematic viscosity: 2.5/15. 7°
Ash in coal:

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Sulphur in coal:
Freezing point （℃ MAX）:
Flash point:
High calorific value (average): 10600 kcal/kg
Combustion-supporting oil
SR. Heavy oil

Item Heavy oil（HFO IS-1593-71）
No. （LSHS）
1. Sulfur 4.5% max 1.0% max
High calorific value

2. 11,000 11,000
（kcal/kg）
3. Flash point (min) 66oC 93oC
Water volume percent

4. 1.0% 1.0%
(max)
Precipitate weight percent

5. 0.25% 0.25%
(max)
Asphalt weight percent

6. 2.5% 2.5%
(max.)
Kinematic viscosity (50oC)

7. 370 500
(max)
8. Ash weight percent (max) 0.1% 0.1%
9. Acidity (mineral) Nil Nil
10. Freezing point (max) 24oC 57oC
1.4.3 Index for the steam water quality

Quality standard of boiler water
Boiler normal continuous blowdown rate (B-MCR): not more than 0.5%
Total hardness: ～0μmol/L
Conductivity: ≤0.30 μS/cm
Oxygen ≤0.007mg/l
Iron ≤0.02mg/l

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Copper ≤0.005mg/l
Hydrazine: 0.01～0.05mg/l
PH value: 9.0～9.5
Oil: ＜0.3 mg/l
Water quality requirement:

Water filling and flushing: deoxygenize condensate water, PH value is 9〜10, its
water quality is as same as boiler water’s, suspension in water≤0.25ppm
Recommended maximum inlet water temperature: 49℃
Secondary cooling water: disposed clean soften water, PH value is 7.
Recommended maximum temperature: 38℃
1.4.4 Drum water level
High Ⅲvalue: normal water level+250mm
High Ⅱ value: normal water level +125mm
High Ⅰ value: normal water level +50mm
Normal water level: drum centreline-50mm
Low Ⅰ value: normal water level-50mm
Low Ⅱ value: normal water level-200mm
Low Ⅲvalue: normal water level-350mm
2. Specification of Auxiliary Equipment

2.1 Primary air fan
SR. No. Item Numerical value Remarks
1 Type 21 18AZ /1 065 2sets for each boiler
2 Model Double inducing double
supports, centrifugal
3 Input air 99.2m3/s
4 Rotary direction One set for left rotary
direction and one for
right
5 Air pressure 16804Pa
6 Rotary speed of 1000r/min Maximum rotary speed and
main shaft critical rotary speed

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7 Motor type Ykk450—4

8 Power 2500Kw
9 Voltage 6600v
10 Current
11 Motor rotary 1485r/min
speed
12 Insulation grade F
13 Manufacturer Shanghai Blower Works,
Co. Ltd
2.2 FD fan and ID fan
SR.
Item FD fan ID fan
No.
1 Type FAF18-9.5-1 14 144Z /1 790
2 Model Axial flow rotating blade Centrifugal double inducing
adjustable fan
3 Input air 122.8m 3/s 303.2m 3/s
4 Air pressure 4426pa 4787pa
5 Shaft power 678kw 1747.8kw
6 Rotary speed 1470rpm 950r/min
7 Quantity of 16 22
blades
8 Material of HF-1 15MnV
blade
9 Regulating The turning direction of fan is Viewing from motor side, start
rotary direction anti-clockwise viewing from direction of regulating valve is
motor shaft extension end. identical with air flow direction
10 Regulating 45° 45°
range
11 Manufacturer Shanghai Blower Works, Co. Shanghai Blower Works, Co.
Ltd Ltd
12 Remarks 2sets for each boiler unit 3sets for each boiler unit
Specification of matched motor

SR.
Items FD fan ID fan
No.
1 Motor type YKK500—4 YKK710—6
2 Power 800kw 2240kw
3 Voltage 6600v 6600v
4 Current
5 Rotary speed 1478rpm 980rpm
Insulation
6 F F
grade
7 manufacturer
Specification of hydraumatic regulating oil station

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SR. Item FD and ID fan Remarks

No.
1 Type of oil pump THW，IP55 2sets for each type
2 Pressure of oil pump 3.5MPa
3 Oil pump flow 90m 3/h
4 Oil level alarm
5 Oil level alarm
6 Alarm of oil filter
differential pressure
7 Oil tank 250L
8 Rotary speed of oil
pump
9 Motor power 2.2kw
10 Motor voltage 380v
11 Motor rotary speed 1450r/min
12 Pressure limiting valve To be regulated at 5.5MPa
13 Heater 2.5Ｋｗ，220ｖ
14 Cooler
15 Cooling water 0.2~0.6ＭＰａ
pressure
16 Cooling water ≤38℃
temperature
17 Temperature of oil ≤41℃
supply
18 Amount of cooling 2.25m 3/h
water
Specified value for axial drunkenness of rotary mechanism 2mm, motor<2―4mm

Specified value for bearing of rotary mechanism
Rotary speed 1500 1000 750 以下
rpm
Amplitude 0.085 0.10 0.13
2.3 Mill
2.3.1 Mill body
Type: HP—863
Model: Bowl-type intermediate speed mill
Maximum output: 44t／h(grinding degree 55, in inches, sieving rate is 75% for
200meshes
Minimum output: 25% of maximum output
Economic output: 37t／h (80～85% of mill maximum output)
Maximum ventilation volume: 1206kg／min

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Specification of gear box: KMP--250

Speed rate of speed reducing box: 25.4
Rotary speed of grinding disk: 38.76r／min
Loading mode: spring loading
Drive mode: screw bevel gear/planet gear secondary drive
Bearing explosion pressure: 345KPa maximum resistance of primary air：3985Pa
Maximum feed particle: 38mm
Mill unit loss: ≯7.35kW.h/t
Manufacturer: Shanghai Heavy Machinery Plant Co. Ltd
2.3.3 Mill lube oil cooling device
Oil pump flow: 150L／min
Motor power: 7.5kW
Cooling water flow (cooling water temperature is 40.5℃): 10.5m3/h
Heater power: 6×1000W
Normal oil supply pressure: 0.15—0.35Mpa
2.4 Coal feeder
Type: 9224
Model: electronic weighing coal feeder
Output regulating range: 10～60t／h
Firm output: 45t／h
Measuring accuracy: ±0.5％
Distance for feeding coal: 2135mm
Thickness of coal layer: 60—230mm
Density of coal feeding: 0.8—1t／m3
Particle size of coal feeding: ＜60mm
Water in coal feeding: ≤25％
Manufacturer: Shanghai Heavy Machinery Plant Co. Ltd
Speed regulating range: 0—1800r ／min(frequency conversion stepless speed
regulation)
2.5 Air preheater
2.5.1 Air preheater body
Type: trisector rotary air preheater
Diameter: Ф10.33m
Heating area: 2×42600m2

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Rotor height: 1676mm

Quantity: 2sets for each boiler
Manufacturer: Shanghai Boiler Works, Ltd.
Design parameters (rated)
Primary air temperature: 28℃／309℃
Secondary air temperature: 23℃／317℃
Flue gas temperature: 348℃／127℃
Rotor speed: rotating with main shaft, it is 1.15r／min, rotating with auxiliary shaft, it
is 0.31r／min
2.5.2 Drive device
A. Speed reducing box
Type: W125
Main speed reducing rate: 130.74
Auxiliary speed reducing rate: 488.44
B. Hydraulic coupling
Type: 280-DT
Power: 9.5—22kW
Rotary speed: 1500r／min
C. Shifting mode of main and auxiliary motor: roller unidirectional overrunning
clutch
2.5.3 Rotor bearing device
A. Supporting bearing
Thrust bearing: thrust endocentric spherical-roller bearing 90394/710
B. Pilot bearing
Radial bearing: biserial endocentric spherical-roller bearing 3153172
2.5.4 Oil flushing system
A. Pilot bearing oil flushing system (thin oil station type: OCS—3)
a. Oil pump: type 3GR25×4—0.8 m3／h／1.0MPa three screw pump
flow 0.8m3／h
pressure 1.0MPa
rotary feed 1450r／min
b. Filter: SPL--25F—z slice-type oil filter
c. Cooler: GCIA--0.8 tubular oil cooler
2.6 Flame scanner cooling air fan
A. Fan

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Maintenance Manual
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Type: centrifugal fan

Capacity: 300-3000FCSM
Horse power: 1.1025-36.75kW
Rotary speed: 3000-36000RPM
Air pressure: 27-46
B. Motor: TEFC
2.7 Fuel oil pump
Boiler fuel oil pump
A. Oil pump
Type: 50ASWA-35×8 multi-stage centrifugal pump
Rotary speed: 2950r／min
Head: 35mH20
Flow: 50m3／h
Quantity: 2sets
2.8 Technical parameter of soot blowing
Specification of soot blower
Long-distance
Wall soot blower shrinkable soot AH soot blower
blower
Type 1R－3 1K－525 1K－AH
Quantity 51 40 2
Position wall SH, RH, economizer Regenerating APH
Rotary angle 360° 360° /
Distance 267mm Approx. 7000mm 970mm
Soot blowing period About 3min About 4－6min About 23min
Steam consumption About 650kg/min About 40-80kg/min About 70kg/min
(each soot blower)
Effective soot blowing 1.5-2.0m 1.5-2.5m About 2m
semi-diameter
Motor 0.18kw 1.1kw 0.18kw

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Maintenance Manual
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Chapter 2 Boiler start-up
1. Specification and Description of Boiler Start-up

1.1 Specification of boiler start-up
1.1.1 General
Chief engineer or operation chief engineer appointed by him, specialty engineer,
production and technical specialty engineer and other specialty personnel must be
present when carry out the following operation:
1.1.1.1 Put new erected boiler into production or initial start-up after overhaul or
minor repairs.
1.1.1.2 Start-up of boiler equipment and system after large improvement, or test
related to new technic at first time.
1.1.1.3 Boiler load rejection test
1.1.1.4 Verifying of boiler main/ reheat steam and drum safety valve
1.1.1.5 Boiler hydraulic test
1.1.2 It is forbidden to carry out start-up or synchronization when any one of
following situation happens to boiler:
1.1.2.1 Boiler main interlock protection function test is not qualified or activity is
abnormal.
1.1.2.2 Any operation subsystem loses the man-machine dialogue function.
1.1.2.3 Main function of power plant protection system is lost.
1.1.2.4 I & C power is lost, each soft operation and remote control is abnormal.
1.1.2.5 Air for instrumentation use is lost or air supply pressure is abnormal.
1.1.2.6 DEH control system is abnormal. CCS system is abnormal or local control
system is abnormal.
1.2 Description of boiler start-up
1.2.1 Boiler main supervision parameters
1.2.1.1 Drum water level
1.2.1.2 Furnace pressure
1.2.1.3 Differential pressure between flame scanner cooling fan and furnace
1.2.1.4 Boiler SH and RH tube wall temperature
1.2.1.5 Differential pressure between main pipe of primary air and furnace
1.2.1.6 Total fuel amount, total air amount and oxygen concentration in flue gas.

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Maintenance Manual
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1.2.2 Boiler main interlock protection

1.2.2.1 Interlock protection of turbine, electric and boiler interlock protection.
1.2.2.2 Boiler MFT tripping function.
1.2.2.3 Boiler interlock function.
2. Status Division before Boiler Start-up, Start-up Parameter and
Selection Rules of Start-up Method
2.1 Division of status before boiler start-up
2.1.1 Division of status
2.1.1.1 Cold status: boiler drum gauge pressure is 0MPa, temperature is normal
temperature.
2.1.1.2 Hot status: boiler drum gauge pressure is more than 0MPa, temperature is
more than normal temperature.
2.2 Boiler start-up parameter, method selection rules
2.2.1 Parameter, attention and method selection rules while filling water into boiler
2.2.1.1 Parameter selection
The water quality for water filling into boiler shall comply with requirement, the
temperature ＞21℃ and ＜104℃
2.2.1.2 Attention
A. Fill water after water quality is qualified, and filling water quality shall be as per
the standard provided by Indian side.
B. Put cooling water system of water level TV and camera into use and open
boiler air vent valve as per rules.
C. Strictly control the inlet water temperature to be within 40～60℃, temperature
shall be not raised quickly during water filling period, it is recommended to fill
water with flow of 30～60t/h, water filling speed in winter is comparatively
lower than in summer.
D. Fill water until the drum water level is properly height that can be seen at the
bottom of level gauge but not over the lowest level line (-200mm). Close feed
water valve, open recycling valve, after completion of water filling, check the
water level to see if there is any change, if water level is raised or lower down,
check the feed water valve to see if it is closed completely or if there is any
leakage.
E. During the period of water filling, pay attention to the wall temperature at upper
and lower part of drum and heat expansion of heating surface to see if those
values are normal.
2.2.1.3 Boiler water filling mode

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A. Use electric pump to fill water into boiler

After starting electric pump and its operation being normal, start economizer inlet
motor-driven valve, slowly feed water into boiler by adjusting electric pump outlet
bypass until drum water level reaches about ＋ 200mm, and then close
economizer inlet motor-driven valve, inform chemical specialty to analyze the
quality of boiler water; if the boiler water is not qualified, drain off the boiler water
and then feed water again until its quality is qualified.
3. Inspection to Boiler before Start-up and Place Auxiliaries and
System in Service
3.1 Attention during the period of boiler start-up
3.1.1 Confirm the boiler has condition of start-up and synchronization
3.1.2 Before boiler synchronization and getting preliminary load or before HP/LP
bypass system being put into use, strictly control the flue gas temperature at
boiler outlet to be less than 540℃.
3.1.3 Before boiler start-up, check if the expansion indication of boiler body is
normal. During start-up period, monitor boiler body expansion situation, if
expansion part is blocked, stop temperature rise, find out the reason.
3.1.4 Before start-up, confirm the quality of condensate water, feed water, DM
water, stator cooling water and boiler water is qualified. During the period of
boiler start-up, chemical specialty to analyze water quality periodically,
ensure qualified steam water quality.
3.1.5 After boiler light-up, put APH soot blower into use immediately. During the
period of oil burning inside boiler, keep APH continuously soot blowing.
3.1.6 Start and stop boiler each auxiliary, check if the situation is satisfied, then
generally it is carried out separately on the corresponding menu in CRT.
3.1.7 In order to ensure the successful light-up and combustion of fuel oil, it is
required to control fuel oil pressure and temperature to make the fuel oil
viscosity controlled below 4°E before putting boiler front oil system into use.
3.2 Inspection before boiler start-up

3.2.1 Overall inspection to boiler and requirement
3.2.1.1 Examination and repair of every specialty to boiler is complete, all the work
permission sheets have been complete as per relevant regulations.
3.2.1.2 Stairs, handrails and platforms are complete; there are no foreign matters
that obstruct the work and passes around passage and equipment.
3.2.1.3 All systems’ connection is complete, various supports and hangers are
firmly fixed, and piping insulation is complete.

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3.2.1.4 Temporary barrier, scaffolding, indication plate and temporary bland on

various piping have been removed.
3.2.1.5 Equipment name, turning direction of rotary mechanism and mark of
medium flow direction of every pipe are complete and correct.
3.2.1.6 Special tools, instruments, gauges and various record form for boiler
start-up are prepared completely.
3.2.1.7 Lighting at every where inside and outside plant is good, emergency
lighting system is normal and can be put into use at any moment.
3.2.1.8 Communication system equipment inside and outside plant is normal.
3.2.1.9 Various relevant operation power, protection power, control power,
instrument power and etc. have been supplied and in normal status.
3.2.1.10 Control panels inside center control room and at local place are complete,
every indication record instrument, alarm device, operation and control
switch are complete and easy for use.
3.2.1.11 Commissioning of base regulating device is complete, setting value is
confirmed to be correct, it is put into automatic.
3.2.1.12 Furnace flame TV camera system is in good condition.
3.2.1.13 The fire-fighting facilities inside plant are normal and available for use.
3.2.1.14 All instrument primary valves and secondary valves are opened.
3.2.2 System inspection and confirmation before boiler start-up
3.2.2.1 After receiving order of boiler start-up, center control header to inform
each specialty fulfil preparation work before start-up and inform soot
control watcher to put relevant electric heating device into use twenty-four
hours in advance.
3.2.2.2 Confirm boiler examination and repair work have been complete, work
permission sheet also have been complete.
3.2.2.3 Check furnace, water wall, SH, RH, economizer and APH have no coking
or accumulated ash, every manhole, fire observation hole, coking
knocking hole, anti-explosion door and observation door are complete,
after ensuring there are no person working inside, close each holes and
doors.
3.2.2.4 The external of burner is complete without coking or burned damage
situation, each fire lighting device is complete and available.
3.2.2.5 The opening and closing of damper and baffle plate are smooth, opening
degree and position indication is correct, drive device is normal.
3.2.2.6 Each valve is complete, its opening and closing are smooth, opening
degree and position indication is correct, drive device is normal.
3.2.2.7 The external of each safety valve and solenoid valve is complete, steam
extraction pipes are complete, and their installation is firm.
3.2.2.8 Furnace flue gas temperature probe is in good condition and available,
smoothly move forward and backward.
3.2.2.9 After overhaul, carry out cold status trial operation to soot blower, the
operation is agile, remote control is normal, each soot blower shall be

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backwards outside boiler.

3.2.2.10 Drum’s each water level gauge is complete, insulation of steam water
connecting pipe is complete, valve opening and closing is agile, water
level indication is clear, water level TV monitor is in good condition and
available, lighting to each water level is enough, put water level gauge into
use.
3.2.2.11 Furnace flame TV camera device is in good condition, cooling damper
shall be opened.
3.2.2.12 The tubes of each oil gun have been well connected, oil gun is at exit
position.
3.2.2.13 Stairs, handrails and platforms at every where of boiler are complete, no
foreign matters obstruct work and passes around passage and equipment.
Construction field is clean, clear and lighting in good condition.
3.2.2.14 All connection of flue gas and air duct and system piping is normal,
supports and hangers is firmly installed, insulation of every equipment and
pipes is complete, and scale of expansion indicator is clear, indication is
normal.
3.2.2.15 No foreign matters in clinker trench, covers are complete, deslagging
device is in good condition, put cold hopper water seal into use, water
overflow is normal.
3.2.2.16 All auxiliary equipment is normal and available.
3.2.2.17 Each local pressure gauge primary valve, primary valve of feed water,
sampling and continuous blowdown, drain valve, and air vent valve shall
comply with required condition before start-up.
3.3 Put auxiliary equipment and system into use before boiler start-up
3.3.1 Put boiler auxiliary equipment and system into use
3.3.1.1 Qualify insulation measurement of every rotary equipment and supply
power to it.
3.3.1.2 Contact I & C specialty to put instrument operation device, alarm device,
automatic device and interlock protection device into use.
3.3.1.3 Contact fuel watcher to feed coal to coal silo.
3.3.1.4 Put air compression system for instrument use into operation.
3.3.1.5 Carry out boiler water filling work until drum water level reaches +200mm.
3.3.1.6 Each oil pump interlock test of auxiliaries is qualified, start auxiliaries oil
pump, check oil pressure is be normal.
3.3.1.7 Contact oil pump house, start fuel oil pump, carry out oil system
circulation.
4. Boiler Cold Start-up
4.1 Boiler start-up
4.1.1 Auxiliaries start-up and fuel oil leakage test
4.1.1.1 Check boiler drum level
4.1.1.2 During the period of filling boiler water, check and put accessory system

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of auxiliaries.
4.1.1.3 Confirm the APH start-up condition is satisfied, start two air preheaters,
when it is normal, put auxiliary motor and main motor interlock and
bearing temperature protection into use.
4.1.1.4 Confirm FD, ID fan start-up condition is satisfied, start two ID/FD fans.
4.1.1.5 Control furnace negative pressure at -0.1kPa, put ID fan regulating
automatic, in the mean time, regulate FD fan rotating blade, make total
input air maintained at 30—40％.
4.1.1.6 Put air heater into use.
4.1.1.7 Confirm the operation of fuel oil pump is normal, fuel oil pressure is
normal, carry out furl oil leakage test:
A. Leakage test shall comply with following conditions:
a. Oil corner valve of each layer oil gun is closed.
b. Fuel oil fast valve is closed.
c. Furl oil return valve is closed.
d. Fuel oil pressure ≥3.8Mpa
e. No MFT condition.
f. Fuel oil inlet regulating valve is opened.
B. If above conditions are satisfied, carry out leakage test as per following
procedures:
a. Open fuel oil fast valve to fill oil to pipeline, if main pipe oil pressure is more
than 3.8Mpa and including 3.8Mpa within one minute, close fuel oil fast
valve; if main pipe oil pressure is not reached 3.8Mpa, oil leakage check is
failed, test is intermitted.
b. If the differential pressure at the front and rear of fuel oil fast valve is more
than 0.1MPa within two minutes, the oil leakage check is failed, test is
intermitted.
c. If the differential pressure at the front and rear of fuel oil fast valve is less
than 0.1MPa, open oil return valve, pipeline discharge oil; if the differential
pressure is more than 0.1MPa, oil leakage check is successful, otherwise if
the differential pressure is still less than 0.1MPa after time prolonged
70seconds, the main pipe oil leakage is unsuccessful, oil leakage checking
is also unsuccessful.
d. If oil leakage test is successful, close oil return valve; after time prolonged
two minutes, if fuel oil pressure is more than 0.1MPa, it shows there is
leakage at fuel oil fast valve; otherwise there is no leakage at fast valve, test
is qualified.
Note: Operation personnel can bypass oil leakage test on OIS according to actual
situation. When the oil system pipeline is in maintenance, or hasn’t put oil system
into use preliminarily or for a long time, or oil leakage test is failing, don’t bypass.

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4.1.2 Furnace blowing

4.1.2.1 Blowing conditions:
A. At least one FD fan is in operation and relevant baffle plates are opened;
B. At least one ID fan is in operation and relevant baffle plates are opened;
C. All oil corner valves are closed;
D. Fuel oil fast valve is closed;
E. No MFT order;
F. Stop all mills and coal feeding machine;
G. Keep drum water level normal;
H. No flame in whole furnace;
I. Keep boiler input air within 30%-40%;
J. Furnace pressure is normal;
K. APH entirely operation;
L. Stop all ESP;
M. All auxiliary air baffle plates are at automatic position;
N. Stop primary air fan;
O. Close mill cold and hot damper outlet valves;
P. Oil leakage checking is complete or bypassed.
4.1.2.2 Blowing procedure:
A. Select blowing page on CRT, confirm above conditions are satisfied and
corresponding standard is reached.
B. Press the button “start blowing” to start blowing, blowing is to be complete five
minutes later. During the blowing period, if blowing condition is not satisfied,
blowing is to be intermitted. Find out the reason, do five-minutes’ blowing
again after problem resolved.
4.1.2.3 After completion of blowing, automatically open fuel oil fast valve, maintain
fuel oil pressure be normal, reset MFT signal.
4.1.2.4 After completion of blowing, regulate the opening degree of auxiliary air
baffle plate to make windbox / furnace differential pressure stabilized at
0.25～0.40KPa, put auxiliary air baffle plate into automatic.
4.1.3 Boiler light-up
4.1.3.1 Confirm 5% bypass valve is opened, drain to periodic blowdown tank valve
is opened and drain to condenser valve is closed.
4.1.3.2 Confirm the operation of electric feed water pump is normal.
4.1.3.3 Economizer recycling valve is opened.
4.1.3.4 Manually or remotely control local flue gas temperature probe, make the
probe inserted into furnace, when the flue gas temperature at furnace outlet
is over 540℃, flue gas temperature probe is alarming and exit automatically.

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4.1.3.5 Make solenoid valve control be automatic.

4.1.3.6 Put soot blow air source from compressed air to APH, APH soot blowing
conditions are satisfied.
4.1.3.7 Start flame scanner cooling fan A (B), confirm flame scanner cooling air /
furnace differential pressure is normal (＞1.5kPa).
4.1.3.8 Put furnace flame monitoring TV
A. Confirm the air pressure of cooling air fan of furnace flame monitoring TV
camera is more than 1.05KPa.
B. Contact I & C specialty, put furnace flame monitoring TV.
4.1.3.9 Check the oil gun start-up condition is satisfied:
A. Blowing is complete.
B. No MFT signal.
C. Fuel oil fast valve and fuel oil regulating valve are opened, oil pressure is
proper.
D. Burner’s swing degree is at horizontal position. Input air is about 30％.
E. Flame cooling air pressure is normal.
F. Oil gun’s local control switch is at “remote control” position.
G. Windbox/furnace differential pressure is satisfied.
4.1.3.10 Start single oil gun
A. Confirm the start-up condition of single oil gun at corner #1 layer “AB” on CRT
is satisfied.
B. Make oil gun at corner #1 layer “AB” sequential control put into automatic,
press oil gun start button, oil gun automatically operates as per following
procedure: insert oil gun, open blowing valve →blowing timing close blowing
valve, insert ignition gun→ fire igniting gun to light up→ open oil corner valve
→ ignite oil gun→stop striking fire→ exit fire igniting gun. Start #1 corner
igniter, open #1 corner valve, boiler front light oil recycling valve is closed
automatically. If execution of sequential control is intermitted, oil gun and
igniter shall be automatically exit; otherwise personnel to make it exit.
C. Take use of same method to put into other oil gun. Put into corner #3, #2 and
#4 oil gun in sequence at intervals of 15s, when fire igniter cooled and
removed, the differential pressure between fire igniter air and furnace must be
maintained above 0.25～0.40KPa, to satisfy the cooling requirement of fire
igniting nozzles. The number of corner is to be start from left side corner at
boiler front face towards boiler, they are #1, #2, #3, #4 respectively at
clockwise direction.
4.1.3.11 Start diagonal corner oil gun

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A. Start corner #1 and #3 oil gun at layer “AB” on CRT cabinet, the corner #1 and
#3 oil gun at layer “AB” shall be inserted automatically and ignited. First ignite
oil gun at corner #1, and then ignite oil gun at corner #3 15min later. After the
oil gun is ignited, corresponding oil flame scanner has “fire” signal, high
energy fire igniting gun shall be exit automatically, otherwise personnel to
make it.
B. After oil gun at corner #1 and #3 are ignited, use inlet oil regulating valve to
regulate oil pressure, oil gun ignition shall be in good condition.
C. Take use of same method to put oil gun at corner #2 and #4 layer “AB” into
use and the oil guns at layer “BC” and “DE”.
4.1.3.12 Oil layer start-up: select oil system menu on CRT and select oil gun at
layer “AB” to start, and then oil gun is started, automatically operates as
per following procedure:
A. Place auxiliary air damper at layer “AB” be at ignition position and make fuel
oil control be at automatic.
B. As per the sequence of corner #1, #2, #3 and #4, start the oil gun of each
corner in sequence at intervals of 15s.
C. Take use of same method to put oil gun at layer “BC”-“DE” into use.
D. Rule for ignition judging at layers is “select three in four”.
4.1.3.13 After putting oil gun into operation, keep fuel oil pressure steady, if oil
pressure is decrease, turn down fuel oil pump outlet recirculation valve,
keep oil pressure steadily above 2.5MPa.
4.1.3.14 When put the bottom layer into use, if ignition is unsuccessful, try two
times again (at intervals of certain time), if three times are unsuccessful,
contact maintenance personnel to dispose it.
4.1.3.15 After oil gun is ignited, check atomization situation; burning shall be in
good condition, check the burning situation through furnace flame
monitoring TV and local observation hole, if burning is not in good
condition—generally the situations are ignition point is not stable, flue tail
on the flame, flame is not bright, spark formed by carbon that is not burnt
to ashes, or irregularly shaped flame, etc. Inform maintenance department
to do necessary burning adjustment.
4.1.13.16 During the period of boiler oil burning, try to keep the oil guns of four
corners at same layer to be burnt simultaneously to make boiler expanse
uniformly.
4.1.13.17 While starting oil gun, if light-up is not successful, try it again; if it is still
not successful, contact maintenance department to dispose.
4.1.3.18 After light-up, put APH compressed air to blow continuously, and enhance

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the monitoring to the change trend of APH inlet and outlet flue gas
temperature and air temperature, avoid oil accumulated on APH heating
element and burnt during the period of light-up.
4.1.3.19 After light-up, enhance the monitoring to drum water level, put feed water
automatic regulation into use according to actual situation. At the same
time, rotary speed control of electric pump is in automatic. After continuous
filling of boiler water, close economizer recirculation valve.
4.1.3.20 After light-up, put air heater into use when the ambient temperature is less
than 20℃.
4.1.4 Boiler temperature rise and boost pressure
4.1.4.1 Regulate the fuel oil flow, or again put more quantity of oil gun into use,
control the speed of temperature rise and boost pressure.
4.1.4.2 Raise temperature and boost pressure is to be done as per boiler cold
status start-up curves.
4.1.4.3 During the period of temperature rise and pressure boost, do pay attention
to the expansion situation of each part. Start-up after boiler overhaul:
record expansion indicator at each part respectively at the time that before
boiler water filling, after water filling and when the drum pressure is at
0.5MPa，2.0MPa， 6.0MPa，10.0MPa，13.0MPa and 16.0MPa. If the
expansion part is blocked, stop temperature rise. Go on temperature rise
after failure being eliminated.
4.1.4.4 Pay attention to the change of drum water level, when the feed water
regulation cannot maintain normal level, take use of periodic and
continuous blowdown valves to control together, keep water level within
±50mm.
4.1.4.5 In the curve, it sets some temperature rise speed after light-up,
temperature rise is controlled through pressure boost, at the preliminary,
less oil guns are put into use, burning is weak, flame permeation degree in
furnace is weak, so warming of evaporation heating surface is
comparatively more uneven and water cycle hasn’t normally set up, etc. all
of which will cause evaporation equipment especially drum to produce
large thermal stress. Hence, at the preliminary stage of boost pressure, do
strictly control temperature rise speed.
4.1.4.6 When carry out cold status start-up, the operation personnel shall do
following works during the period of temperature rise and boost pressure:
6 ℃ --100 ℃ , temperature rise speed--1.33 ℃ /min, control the temperature
difference between drum’s upper and lower wall to be within 50℃;
Above 100 ℃ , temperature rise speed--1.73 ℃ /min, control the temperature

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difference between drum’s inner and outer wall to be within 50℃.

Pay attention to SH temperature rise speed, closely monitor the SH/ RH wall
temperature.
A. When drum pressure is about 0.05～0.1MPa, flush double color water level
gauge, carefully check the water level after flushing, ensure the indication
accuracy.
B. When drum pressure is about 0.15～0.2MPa, close every boiler air vent valve;
when drum pressure is about 0.2～0.3MPa, drain lower part of water wall to
speed up uniform evaporation of heating surface and improve quality of boiler
water. Pay close attention to the change of drum water level during the period
of drainage.
C. Continually check boiler expansion situation, especially the expansion at
lower part of boiler. During the period of boost pressure, if expansion is found
abnormal, pause pressure boost, find out the reason, carry on boost pressure
after disposal.
D. When drum steam pressure is raised to about 0.4MPa, keep it for a certain
time, so it is to facilitate the maintenance personnel to tighten bolts connection
parts (such as boiler roof hanger rod, etc.).
E. When main/reheat steam pressure is at 0.6MPa and temperature is at
150~200℃, supply steam to the systems such as deaerator, turbine shaft seal,
turbine interlayer heating, fuel oil tank steam supply, heavy oil atomization,
etc.
F. When drum pressure is 0.7MPa, close the extraction valve to air of main
steam piping.
G. Temperature rise of main/reheat steam piping and HP/LP bypass steam
piping.
H. When main/reheat steam pressure is 1.0MPa, close SH/RH water drain valve.
I. When main/reheat steam pressure is 1.3MPa, put heavy oil atomization
steam into use. If necessary, put heavy oil burning into use.
J. When main/reheat steam pressure is 1.37MPa, carry out blowing of APH.
K. Fill pressure to the steam piping of other unit who need it, put relevant
equipment steam feeding into use. Turbine piping warming-up to the front of
main steam valve, it better to carry out synchronous with boiler boost pressure,
do enough piping warming-up; when warm up pipes, open the drain valve of
turbine body, main and reheat steam pipes and extraction pipes to keep
smooth drainage.
L. When boiler continuous water filling is set up, close economizer recirculation
valve.
M. While consuming heavy oil gun, simultaneously put preheater soot blower into
use to avoid flammable objects accumulated on heating surface. If there is
only pulverized coal fuel, put preheater soot blower as per operation
regulations.

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N. When the pressure is near rated steam pressure (approx. 80%～90% rated
steam pressure), again flush the double-color water level gauge and check if it
is correct and reliable.
4.1.5 Operation to boiler at turbine rolling-up
4.1.5.1 Keep drum low water level, avoid water level raised to much after turbine
rolling up;
4.1.5.2 Regulate fuel oil, make main steam temperature kept at about 320℃;
4.1.5.3 Regulate 5% bypass drain, make steam pressure kept at about 4.1MPa;
4.1.5.4 Furnace outlet flue gas temperature <540℃;
4.1.6 Operation to boiler during the period of turbine warm-up
4.1.6.1 Stabilize steam temperature at 320℃ and steam pressure at 4.1MPa,
satisfy the requirement of turbine speed rise and warm-up.
4.1.6.2 Furnace outlet flue gas temperature shall be less than 540℃.
4.1.7 Operation to boiler at boiler synchronization
4.1.7.1 When turbine rotary speed is up to 3000r/min, boiler synchronization
operation is started; properly increase amount of furl oil, raise boiler
pressure as per the speed of 0.1MPa/min.
4.1.7.2 All the furnace temperature probes are exit out of boiler, 5% bypass is
closed automatically.
4.1.7.3 Within the time of keeping preliminary load, try to stabilize steam
temperature and pressure.
4.1.8 Monitoring at boiler start-up
4.1.8.1 During the period of boiler light-up and temperature rise and boost
pressure, the temperature difference between lower and upper drum wall,
and between outer and inner drum wall and the difference between any
two points shall be not allowed to beyond the boiler protection limit value, if
any beyond the value, analyze the reason in time, regulate burning, strictly
control speed of temperature rise and pressure boost, and properly
strength the drainage at lower header. If large temperature difference of
drum wall is increasing, stop raise temperature and boost pressure at
once, temperature rise and pressure boost shall be carried out after
situation is normal.
4.1.8.2 During the period of boiler light-up and temperature rise and boost
pressure, always check the expansion situation of each heating surface’s
element and supporting and hanging situation of supports and hangers,
ensure uniform press on hanger rods at hot status. In order to make every
boiler part expanded uniformly, drain lower header at proper time
according to actual expansion situation, strictly control drum level during
draining; when expansion is abnormal, stop boost pressure, find out

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reason, continually boost pressure after expansion is normal.

4.1.8.3 During the period of temperature rise and boost pressure, strictly control
the furnace outlet flue gas temperature to be not more then 540℃ before
turbine rotor initial operation.
4.1.8.4 When put into oil, observe the burning situation of oil gun, if burning is not
in good condition, adjust it immediately.
4.1.8.5 Pay attention to burning while putting into pulverized coal. If it is not ignited
after putting into pulverized coal, stop putting into it at once, and keep
furnace negative pressure at 0.1～0.15KPa, strength ventilation for 5min,
at this time, keep stable burning of oil gun. After problem is found and
resolved, put into pulverized coal secondarily, if it is not ignited twice,
analyze the reason except disposal as per above rules, and then put into
pulverized coal.
4.1.8.6 After turbine rush to turning and load increasing period, strictly control
main steam temperature, reheat steam temperature, main steam pressure
and drum water level (to be controlled within ±50mm), and also strictly
monitor the steam temperature at LT SH outlet and rear panel SH outlet
and in time put every group of desuperheater into use.
4.1.8.7 During the period of light-up and temperature rise and boost pressure,
control it as per specified curves about temperature rise and boost
pressure, it is forbidden beyond required pressure or prolong the time of
temperature rise and boost pressure without reason.
4.1.8.8 During the period of light-up and temperature rise and boost pressure,
strength the monitoring and control to wall temperature of every stage SH
and RH, strictly avoid excess temperature, if it is found that the tube wall
temperature is abnormal, take measures and adjust it in time, control of
every stage SH/RH tube wall temperature refers to boiler protection
limiting value.
4.1.8.9 During the period of start-up, temperature rise speed of saturation
temperature refers to start-up curves.
4.1.8.10 During the period of boost pressure, monitor boiler water quality at any
moment, and the quality shall comply with rules in this manual.
4.1.8.11 During the period of boost pressure, if drum water level control is found not
stable, or vaporization is found in economizer, operation personnel shall
find out if economizer recirculation is surely opened, at this time, do make
water feeding amount beyond required amount with the assistant of
adopting contamination discharging measures to keep water level and
regulating the opening degree of discharge valve and pressure boost
speed. When silica concentration in boiler is beyond standard, stop boost

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Maintenance Manual
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pressure and carry out silicon flushing, operate with decreasing pressure if
necessary.
4.1.8.12 During the period of start-up, fully open the drain valve (i.e. 5% bypass) at
backpass lower header, after pressure raised up, superheat steam
pressure can be controlled through drain valve, mainly turbine bypass
control, close drain valve after TG synchronization. (when there has
turbine bypass, 5% bypass can be not used.)
4.1.8.13 Before light-up, do open drain valves and air vent valve of SH and RH to
ensure pipe draining inside system, when steam formed inside pipes,
close the air vent valve at superheat steam piping. Immediately close the
drain valve on backpass header after TG synchronization, do close reheat
vent valve and drain valve before vacuum setting in condenser.
4.1.8.14 Monitor flue gas temperature at APH outlet to avoid heat transformation
and low temperature corrosion and secondary burning.
4.1.8.15 While turbine is rolling up, firstly put pulverized coal system to adapt the
parameter requirement of turbine high rolling-up. Close turbine main gate
front drain after turbine rolling-up.
4.1.8.16 Observe burning condition through flame monitoring TV, avoid unstable
burning that will cause sharp change of steam temperature and flue gas
temperature. When steam temperature and flue gas temperature sharply
raised, control burning rate, decrease temperature rise speed, pause part
of burners if necessary.
4.1.8.17 Pay attention to the operation of automatic regulating device, when failure
happens or regulation is not in good condition, manually control it and
contact I & C specialty to dispose the problem.
4.1.8.18 After burning is stable, carry out overall soot blowing.
4.1.8.19 Properly adjust input air, excess air coefficient at economizer outlet shall
be maintained at about 1.25 when it is at 100% load.
4.1.8.20 Regulate the fineness of pulverized coal to make it reached design
requirement.
5. Boiler Hot Start-up
5.1 Boiler start-up at hot status
Hot status start-up is boiler starting up at hot standby status, the procedure of boiler
hot status start-up is generally as same as cold status start-up.
5.1.1 Hot status start-up without turbine bypass
5.1.1.1 Preparation
A. Half an hour before light-up, inform turbine to start electric feed water pump to

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fill water into boiler;

B. Start APH;
C. Start ID/FD fan;
D. Start flame scanner cooling air fan;
E. Start ash handling, clinker handling system.
a). Boiler light-up temperature rise start-up procedure is still carried out as per
cold status start-up, turbine rolling-up parameter is to be definite as per
temperature of turbine’s regulating stage, temperature rise and boost
pressure is to be carried out with reference to boiler hot status start-up
curve.
b). Hot status start-up, increase steam temperature as soon as possible after
light-up to satisfy turbine rolling-up requirement; if the steam pressure is
increased quickly but steam temperature is raised too slow, put boiler
bypass into use or largely open 5% start-up bypass valve.
c). During the period of turbine rolling-up, try to keep stable steam temperature
and pressure.
d). Operation for speed rise and during the period of synchronization with
preliminary load refers to cold status start-up.
5.1.1.2 Load rise
A. Raise temperature and boost pressure as per 3%/min(9MW/min) boiler or
turbine load rise requirement, maintain certain parameter raised to rated load,
when operates with constant pressure, raise load as per 5%/min load rise rate.
B. Other operation during the period of load rise refers to cold status start-up.
5.1.2 Hot status start-up with turbine bypass, especially the super-hot status
start-up within 8hrs after stopping of turbine.
5.1.2.1 Preparation before start-up is as same as the hot status start-up without
bypass.
5.1.2.2 Boiler light-up and temperature rise:
A. Contact turbine to put HP/LP bypass system into use;
B. Furnace blowing;
C. Put boiler front oil system into use;
D. Put furnace flue gas probe into use;
E. Operation of boiler light-up and temperature rise refers to cold status start-up,
control to temperature rise and boost pressure refers to “hot start-up curve”;
F. Boiler temperature rise and boost pressure can be regulated through turbine
bypass;
G. Confirm turning parameter as per turbine actual requirement at that time;

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H. During the period of turbine rolling-up to preliminary load, try to maintain boiler
steam temperature be stable.
6. Boiler Warm-up With Load and Load Increasing
6.1 Warm-up with 15MW load
6.1.1 After boiler synchronization, key light of “automatic synchronization” on DEH
operation cabinet is black out, the DEH menu shift from rotary speed to power
indication against actual power, and key light “rotary speed” is lit. According to
requirement, to put regulating stage pressure and power feed back loop into
use.
6.1.2 After synchronization, close 5% bypass, control flue oil flow, maintain boiler
main steam pressure at 4.5MPa and main steam temperature at 350℃～380
℃, 400℃ at most.
6.1.3 After boiler synchronization, when furnace outlet flue gas temperature＞540
℃, check flue gas temperature probe shall be exit automatically, otherwise
personnel to do the work.
6.1.4 After boiler loading to 15MW, warm up for 30min. During the period, if main
steam temperature is raising, extend 1min warm-up time for every 1.7℃
increasing temperature. During the warming-up period, reheat steam
temperature shall comply with the requirement of “Guiding rule of no
load—low load operation”, and do overall inspection to the operation of boiler
and every system that shall be normal.
6.1.5 Put every LP heater into use
6.1.6 If sliding put HP heaters at random, fill water at HP heater water side, when
the HP heater inlet and outlet valve is opened, sequentially put #2, #3, #1 HP
heater steam side into operation, and pay attention to main steam pressure,
feed water temperature and change of main and reheat steam temperature
and make corresponding regulation, pay attention to #3 HP heater drain and
shift it in time.
6.2 Load increased to 30MW
6.2.1 Operation to turbine
6.2.1.1 After the completion of warm-up with preliminary load, contact chief watcher
and carry out temperature rise and pressure boost and load increasing with
reference of following table, load rise rate≯ regulated value in “load change
(increasing or decreasing) operation curve”
Main Reheat
Main steam Saturation Excess
Load steam steam Time
temperature temperature heat
（MW） pressure temperature （Min）
（°Ｃ）（°Ｃ）（°Ｃ）
（MPa）（°Ｃ）

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15 4.5 380 360 30 257.41 122.59

15↑30 4.5↑6.0 380↑420 360↑410 30
30 6.0 420 410 20 275.56 144.4
30↑60 6.0↑7.5 420↑450 410↑440 20
60 7.5 450 440 20 290.51 159.49
60↑105 7.5↑10.5 450↑500 440↑490 30
105 10.5 500 490 10 314.50 185.50
105↑180 10.5↑13 500↑537 490↑530 40
180 13 537 530 10 330.81 206.19
180↑240 13↑16.7 537 530↑537 30
240 16.7 537 537 10 350.78 186.22
240↑300 16.7 537 537 30
After the completion of warm-up, set target load to be 30MW and load rise rate to
be 0.5MW/min, carry out boiler load rise.
6.2.1.2 When load reach 30MW, carry out following inspection and work:
A. Check HP, IP steam piping and HP cylinder body drain valve be automatically
closed.
B. Shift electric pump “A” and warm-up pump “B” to be heat standby status.
C. Overall check the operation of boiler and every system to be normally.
D. If overspeed test is necessary, do keep boiler warm up for 4hrs when load is at
30MW, and then release and do emergency governor gear and ETS overspeed
protection test. After the test is complete with normal result, again carry out
boiler synchronization and increase load to 30MW, overall check boiler
operation to be normal.
6.2.2 Boiler operation
Maintain load rise rate ≤1MW/min; pressure rise rate≤0.12MPa/min
6.2.2.1 Open SH desuperheating water master valve.
6.2.2.2 When load reach 7% (21MW), pulverization system is prepared to be put
into use.
6.2.2.3 Set FD fan “A” and “B” control to be automatic, set oxygen concentration
verification to be automatic.
6.2.2.4 When load reaches 10% (30MW), main steam temperature is about 420℃,
main steam pressure >4.9MPa, reheat steam temperature is about 410℃,
APH secondary air outlet temperature>177℃.
6.3.1 Boiler operation with 10～20% load（30～60MW）.
6.3.2.1 Confirm primary air fan “A” satisfy start condition; start primary air fan “A”,

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confirm outlet damper of primary air fan “A” is automatically opened.

6.3.2.2 Confirm primary air fan “B” satisfy start condition; start primary air fan “B”,
confirm outlet damper of primary air fan “B” is automatically opened.
6.3.2.3 Regulate two primary air fans to make their outlet air pressure be increased
to 8.3Kpa, if ambient temperature <20℃, put air heater into use.
6.3.2.4 Confirm seal air fan “A” is started, differential pressure between sealing air
main pipe and milling bowl is normal.
6.3.2.5 Confirm mill “B” satisfy start condition, start mill “B”, and check its current,
sealing air valve, mill lube oil pump and vibration situation to be normal.
6.3.2.6 Open hot air damper of mill “B”, set primary input air to be automatic,
control mill outlet temperature increased to 65～77℃ under the speed of
3℃/min.
6.3.2.7 Confirm coal feeder “B” satisfy start condition, start coal feeder “B”, observe
burning situation inside furnace, check the current of mill “B” and opening
degree of perimeter air damper at layer “B”.
6.3.2.8 Gradually increase the rotary speed of coal feeder, decrease amount of fuel
oil; control main steam temperature rise speed to be less than <3℃/min
and main steam pressure rise speed be less than ＜0.12MPa/min.
6.3.2.9 When load is raised to 20%（60MW）, main steam pressure reaches
6.8MPa, main steam temperature is up to 450 ℃ and reheat steam
temperature reaches 430℃. At this time, set coal feeder to be automatic,
make boiler main control manually change amount of fuel, ensure steam
parameter be stable.
6.3.2.10 When load is near 20%, regulating valve of electric pump feed water
bypass automatically cut off master valve, when feed water flow or steam
flow >10%MCR, economizer recirculation valve will be closed.
6.4.1 Boiler operation:
6.4.1.1 Maintain load rise rate and pressure boost rate, set target load at 105MW.
6.4.1.2 If silicon concentration in boiler water excesses the regulation, stop boost
pressure and stop raising load, largely open continuous blowdown valve to
carry out silicon flushing. When silicon concentration in boiler water
decreased below limiting value, again boost pressure and raise load.
Relation between silicon concentration in boiler water and drum pressure
refers to following table:

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Drum pressure MPa 8.96 10.33 11.7 13.1 14.48 14.87 16.24 17.62
Maximum
silicon
concentration
in boiler water
while ensuring
silicon
concentration
mg/L 3.6 2.3 1.5 1.0 0.7 0.5 0.3 0.25
in steam is not
more than
0.02mg/L
(corresponding
phosphate
disposal boiler
water PH=10)
6.4.1.3 While load is reaching 35% (105MW), main steam pressure shall reach
10.5MPa, main steam temperature reach 520 ℃ and reheat steam
temperature reach 490℃.
6.4.1.4 After starting electric pump, during the period of juxtaposing with another
electric pump, closely monitor drum water level.
6.5.1.1 Maintain load rise rate and pressure boost rate, set target load at 180MW.
6.5.1.2 Rotary speed of coal feeder “B” increased to 70%, start pulverization
system layer “A”.
6.5.1.3 Gradually increase the rotary speed of coal feeder “A” and make “A” rotates
with the same speed of coal feeder “B”, and put automatic into use.
6.5.1.4 When superheat steam temperature reaches 530℃, set superheat steam
temperature control at automatic.
a. Stop single oil gun:
select sequential control of corner #1 oil gun layer “DE” on CRT. Set sequential
control to be automatic, press “stop” button, action of oil gun will proceed as per
following procedures: close oil corner valve→ insert oil igniting gun→ oil igniting
gun strikes fire→ open blowing valve→ blowing timing→ exit oil igniting gun→
exit oil gun
b. Stop oil guns at single layer as per the sequence of corner #4, #2, #3, #1 at
intervals of 30s.
6.5.1.5 Put control of perimeter air damper into automatic
6.5.1.6 When the load is above 50%, check furnace burning to be in good condition,

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remover oil gun operation from piece to piece or from layer to layer.
6.5.1.7 When the load is above 60% (180MW), reheat steam temperature shall
reach 540℃, set burner swaying control to be automatic, set reheater
spraying desuperheating control to be automatic.
6.6.1.1 When the rotary speed of coal feeder “A” and “B” is beyond 60%, according
to the burning situation, sequentially stop corner #1, #2, #3 and #4 oil gun
at layer “AB”, and then blowing for 5min, after that, exit all of them. While
circulate oil system, continuously silicon flushing, after silicon
concentration is qualified, continuously raise load. Burning inside furnace
shall be in good condition, contact chief watcher, inform soot blowing
control watcher to put ESP and ash removal system into operation.
6.6.1.2 When rotary speed of coal feeder “A” and “B” is up to 70%, start layer “C”
pulverization system, gradually increase the rotary speed of layer “C“ coal
feeders to make its identical rotary speed with coal feeder at layer “A” &
“B”, set coal feeding control to be automatic.
6.6.1.3 When load reaches 80% (240MW), main steam pressure shall reach
17.3MPa. main steam temperature and reheat steam temperature is at
rated value 541℃, entirely check leaking situation.
6.6.1.4 After burning is stable, do entirely soot blowing.
6.6.1.5 Put APH fan plate into automatic control.
6.6.1.6 According to actual situation, put boiler automatic into use.
6.7.1.1 Set target load at 300MW, continuously increase load.
6.7.1.2 According to the situation coal feeder’s rotary speed, put one more set for
pulverization.
6.7.1.3 When load is increased to 300MW, entirely check boiler.
7.7.3 After the entire boiler checked and there is no abnormal situation, report to
chief watcher, center control leader, and then start is end.
6.8 Attention during the period of load increasing
6.8.1 Attention to boiler
6.8.1.1 Monitor drum water level, make the fluctuation range of water level be
controlled within ±50mm of normal water level.

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6.8.1.2 During the starting period, saturation temperature rise rate shall be
controlled within following range:
Drum pressure（MPa） 0～3.43 3.43～17
Temperature rise rate
2.8～3.7 ＜5
（℃/MPa）
During the pressure raising period, test silicon concentration in boiler water at any
moment, duly regulate the opening degree of continuous blowdown valve and
pressure raising speed; when silicon concentration in boiler water excess regulated
standard, stop raising pressure, do silicon flushing, operates with decreasing
pressure if necessary.
6.8.1.3 Before boiler synchronization, strictly control furnace outlet flue gas
temperature to make it lower than 540℃, if it excess the value, check flue
gas temperature probe automatically exit, otherwise, manually intervene it,
properly decrease the amount of fuel.
6.8.1.4 During the period of temperature rise and pressure increasing, always
check expansion situation of each heating surface element and the
situation of supports and hanger rods, when the expansion is abnormal,
stop raising pressure, find out the reason, and continually boost pressure
after expansion is normal.
6.8.1.5 During the starting period, closely monitor and control wall temperature of
each heating surface, it is not allowed to operates with excess
temperature.
6.8.1.6 During the starting period, fully open 5% bypass valve, superheat steam
pressure is controlled through 5% bypass valve. After boiler
synchronization, close 5% bypass valve.
6.8.1.7 During the period of starting boost pressure, strictly control as per regulated
temperature rise and boost pressure curve, it is forbidden to excess
pressure and prolong the time of temperature rise and boost pressure.
6.8.1.8 Economizer recirculation valve is opened all the time before boiler
continuous water feeding is set up to avoid economization vaporizing.
6.8.1.9 At the preliminary time of light-up, strength the burning monitoring
adjustment, monitor the atomization situation of oil gun and flue gas
temperature at APH outlet to avoid secondary burning, heat transformation
and low temperature corrosion.
6.8.1.10 Before light-up, open all RH drain valves and vent valves. Do close the
vent valve that is led to air and drain valve before vacuum is set up in
condenser; open HT/LT reheat steam pipes to condenser drain valve, until
boiler load is raising, that can be closed.
6.8.1.11 After putting pulverization system into use, check ignition situation of

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pulverized coal, if they are not ignited, immediately stop put into pulverized
coal but put into it after strengthening burning.
6.8.1.13 During the period of turbine rush to turning and speed raising for warming
up, maintain boiler parameter and burning be stable.
7. Boiler Black Start-up
When there is no auxiliary steam from external, after charging power, boiler black
start-up shall be carried out strictly as per point 4. procedure of boiler cold status
start-up in Chapter 2. (If APH is stop rotating because of failure before boiler black
start-up, dispose the problem strictly as per 2.3.8.4 Disposal to stopped rotation of
APH rotor in Chapter 6)

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Chapter 3 Boiler Normal Operation and Maintenance
1. Daily Maintenance and Seasonal Protection Measures

1.1 General for daily maintenance
1.1.1 Daily maintenance and requirement
1.1.1.1 Carry out patrol inspection on time, during that period, take necessary
tools and protective tools, seriously look, touch, smell and hear the
ambient, carefully check the situation of every operation and standby
equipment to see whether they are normal or not, correspond indication
in center control room with local gauge to see if the indications are
identical. If abnormal situation is found, find out cause and take
measures to ensure normal boiler operation.
1.1.1.2 Record the gauge reading punctually every one hour for center control
and every two hours in patrol inspection, analyze and compare with the
readings corresponding to each parameter, if any parameter is found
deviated from normal value, find out the cause, take corresponding
measures and report to center control leader and chief watcher.
1.1.1.3 If defects are found, dispose it as per relevant rules in “defects
management system”, prepare necessary countermeasure, to those
defects that will affect safety and economic operation of boiler or
equipment or systems, make record, forecast the accident, and report
center control leader and chief watcher.
1.1.1.4 Complete periodically shift and test as per the requirement in “equipment
periodical shifting and testing system”.
1.1.1.5 Frequently check bearing oil level and oil quality of auxiliary mechanism
and add or change oil.
1.1.1.6 Assistant chemical specialty, supervise condensate water, feed water,
generator stator cooling water, lube oil and EH oil quality.
1.1.1.7 Complete other relevant task assigned by superior department.
1.1.2 Inspection by hearing the sound under following situation
1.1.2.1 Before taking over work.
1.1.2.2 Before handing over work to next shift.
1.1.2.3 Patrol inspection.
1.1.2.4 Work condition is changing, equipment is abnormal.
1.1.3 Regulate the boiler and system operation parameter in time
1.1.3.1 According to dispatch requirement, adjust boiler load in time to satisfy
the requirement of outside load.
1.1.3.2 Regulate boiler burning in due course, maintain normal steam
temperature and pressure, keep boiler evaporation capacity within rated

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value.
1.1.3.3 As per boiler operation situation and seasonal change, rationally
regulate operation mode of circulation water system and open cooling
water system.
1.1.3.4 According to equipment oil, hydrogen, air and water temperature
situation, adjust cooling water to maintain temperature within normal
range.
1.1.3.5 Supervise and adjust the parameter of other equipment and system to
be within normal range.
1.1.4 To keep boiler operated under economic status, followings shall be done:
1.1.4.1 Try to ensure boiler to be operated under rated work condition.
1.1.4.2 Run heat-return system in normal operation, each heater’s water level is
normal, outlet water temperature complies with requirement, drain mode
is rational.
1.1.4.3 Always analyze each parameter and regulate it in time, maintain it
operated at economic operation.
1.1.4.4 As per the situation such as condenser vacuum, end difference and
cooling water temperature rise, etc., adjust the operation mode of
circulation water pump in time and rationally, try to keep condenser
operated at best work condition.
1.1.4.5 If foreign matters are blocked in condenser tube plate, carry out
condenser half side separation maintenance and cleaning.
1.1.4.6 Rationally regulate boiler burning, try to maintain stable burning, decrease
each heat loss and improve boiler efficiency.
1.2 Seasonally protection measures
1.2.1 Protection measures in winter
1.2.1.1 For the cooling water pipes’ valves that are bared in the open air, keep
medium flowing inside them, for the blind zone and the part no medium
flow inside, discharge accumulated water or take insulation measures.
1.2.1.2 To the standby equipment, take necessary anti-freezing measures
according to ambient temperature, drain out the accumulated water
inside equipment that is not used.
1.2.1.3 As per the changer of circulation water temperature, regulate the angle
of rotating blade of circulation pump, decrease flow, ensure condensate
water cooling temperature ＜2℃.
1.2.1.4 Windows and doors inside plant house are complete and tightly closed,
avoid cooling air blowing operation equipment, install air-blocked curtain
if necessary.
1.2.2 Protection measures in summer
1.2.2.1 Complete the heatstroke prevention work inside plant house, ensure AC

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equipment to be normally used, create good work condition.

1.2.2.2 Due to high temperature in summer, do strengthen the monitoring to the
bearing temperature of each rotary machine and temperature of electric
equipment; to those equipment has bad heat conducting condition, take
attempering measures such as increase amount of cooling water,
decreasing cooling water temperature, installing ventilation facilities.
1.2.2.3 According to the change of circulation water temperature, regulate the
angle of circulation pump rotating blade, increase flow, maintain enough
vacuum inside condenser.
1.2.2.4 Strengthen the monitoring to closed cooling water temperature, if too
high temperature affects equipment safety operation, increase amount of
open cooling water or open more open cooling water pump, etc. to
decrease the temperature of cooling water.
1.2.2.5 Strengthen the anti-moisture work for electric equipment in rainy season,
report the leaking part to power generation department. According to
weather forecast, prepare work to prevent typhoon and flood, check the
drain facilities to be complete with normal output.
1.2.3 Precaution to thunderstorm weather
1.2.3.1 Organize accident exercise in pertinence.
1.2.3.2 Forecast the unexpected accident such as boiler load rejection,
intermittent of auxiliary power, intermittent of cooling water, etc., ensure
every lighting-proof equipment is normally run into operation.
2. Supervisory to Main Operation Parameters
2.1 Supervisory to main operation parameters
Supervisory to boiler main operation parameters and operation limits
Item Unit ECR B-MCR Range Alarm value Tripping value
Electric loading MW 300 332
Drum pressure MPa 18.52 19.6 20
Superheat steam t／h 912.4 1025 1025
flow
Superheat steam MPa 17.4 18.3 ±0.2 18.5/16.4
pressure
Superheat steam ℃ 541 541 ±5 546/536
temperature
Reheat steam flow t／h 743.8 828.4
Reheat steam inlet MPa 3.55 3.63 4
pressure
Reheat steam MPa 3.38 3.45 3.8
outlet pressure
Reheat steam inlet ℃ 324.7 330.4
temperature

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Reheat steam ℃ 541 541 ＋5 546

outlet temperature －10 531
Temperature ℃ 0—20
difference of
reheat steam two
sides
Outlet ℃ 415.7 409.6
temperature at LT
SH vertical
segment
LT SH tube wall ℃ 504
temperature
Division panel ℃ 446.6 448.6
outlet temperature
Division panel 482
tube wall
temperature
Rear panel outlet ℃ 507.2 504.8
temperature
Rear panel tube ℃ 558
wall temperature
SH finish tube wall ℃ 576
temperature
Platen RH tube ℃ 548／576
wall temperature
3. Regulation of Boiler Operation Parameter

3.1 General
Stabilization of boiler operation parameter has close relation to the change of
external load and boiler inner factors. Only if any above stated factor is changed, it
will affect the stabilization and safety of boiler operation, hence, a series of control
and regulation to boiler will make the boiler parameter adapted to outer change or
inner variation so as to achieve boiler safe and economic operation.
3.2 Boiler load regulation
General method is coordinated control or boiler tracking mode, when coordinated
control system is in failure or according to actual operation requirement, adapt
boiler basic automatic method to carry out load regulation.
Load change rate cannot be too quick, it is to be controlled at about 1％(3MW／
min) at normal condition and 2％ at most (except accident), set load maximum and
minimum value.
3.2.3 When load increasing or decreasing range is comparatively large, do the
work step by step, and it shall comply with the requirement in “load variation
(increasing or decreasing) operation curve” to ensure boiler safe operation

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and satisfy requirement of other operation.

3.2.4 While increase or decrease load, pay attention to steam temperature, steam
pressure and the corresponding change of coal feeder rotary speed and
regulate input air and furnace negative pressure in time.
3.2.5 During the period of boiler load increasing and decreasing, do preparation in
advance when it is necessary to start and stop mill and other equipment so
as to start and stop them in time.
3.2.6 During the period of load variation, as per requirement, manually adjust the
auto-regulating device that is caused by failure so as to maintain the
stabilization of its operation condition.
3.2.7 Supervise and regulate every water level and temperature to be in normal
range to adapt variation of boiler load.
3.3 Regulation to boiler burning
3.3.1 The purpose is to ensure boiler steam temperature, steam pressure and
evaporation be stable and normal; burning to be stable, burning center be
proper, flame is distributed uniformly, assisted properly with air, avoid
coking, etc. Maintain comparatively higher economic of boiler operation.
3.3.2 Main content and method for regulation
3.3.2.1 According to coal type, confirm the proportion of primary, secondary and
perimeter air, organize good burning condition inside furnace, control
primary, secondary air and perimeter air to achieve rational air proportion
requirement as per designed coal (or actual burning coal type), and pay
attention to supervise the input air rate between left and right side, adjust
and eliminate input air deviation in time (main design parameter of burner
that burned designed coal (BMCR) refers to burner installation instruction).
3.3.2.2 Frequently check the burning condition inside furnace, observe igniting
situation of pulverized coal to see if there is any deflection of flame that
scouring furnace wall.
3.3.2.3 Monitor furnace flue gas temperature difference between left and right
side.
3.3.2.4 Pay attention to the air leaking situation during boiler operation, all the
holes and doors shall be tightly closed during normal operation.
3.3.2.5 According to the analysis to furnace front coal, know the change of coaly
in time and take corresponding measures.
3.3.2.6 According to the best excess air coefficient that satisfying the economizer
outlet and the proportion among auxiliary air, fuel air and top secondary air
to make regulation to secondary air, the excess air coefficient at furnace
outlet at full load condition is 1.25.
3.3.2.7 While changing boiler load, pay attention to the matching rate between air
and coal. When the load change range is not large, regulate the rotary

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speed of coal feeder, the regulating speed shall be not large, try to
decrease the effect to burning. When load change range is not large, start
or stop mill.
3.3.2.8 While regulating burning condition, pay attention to the change of SH
steam and RH steam work temperature at each segment to avoid too high
temperature of tube wall, notice the furnace coking situation, if coking is
found, it shall be remove in time; carry out soot blowing of water wall
periodically, when coking is serious, decrease boiler load.
3.3.2.9 When burning is not stable, stop water wall soot blowing and coking, put
oil gun into operation and stabilize burning.
3.3.2.10 While regulating steam pressure, pay attention to decrease amount of coal
during steam pressure raising period, when the steam pressure goes to be
stable, increase amount of coal properly so as to stabilize steam pressure
but not let it decrease. When steam pressure is too high, pay attention to
decrease air while reducing coal at large amount, if the assistant is not
proper, it will make steam pressure raised in a split second.
3.3.2.11 According to actual burning coal quality, maintain proper coal fineness;
timely regulate the opening degree of separator damper according to
chemical analysis, when it is at low load, properly decrease fineness to
facilitate burning.
3.3.2.12 Put less burners into operation when it is at low load, maintain
comparatively high concentration of pulverized coal. When it is at high
load, put more burners into operation to make uniform heat load inside
boiler and stable burning.
3.3.2.13 Frequently check burner’s work condition and deslagging in time,
especially pay attention to burning of low melting point when it is at high
load.
3.4 Regulation of steam temperature
3.4.1 When boiler is at normal operation, strictly control main steam and reheat
steam temperature within normal range.
3.4.2 During operation period, closely monitor the trends on steam temperature
recording sheet, try to decrease the factor that affects the change of steam
temperature, e.g. decrease rate of change of steam pressure, decrease
load raising or lowering speed, or change the operation mode of
pulverization system according to change of coal quality. Monitor the
change situation of each stage of SH, RH wall temperature and regulate
them in time to make wall temperature not excess regulated value.
3.4.3 Do grip the load change effect to radiation SH steam temperature, properly
and rationally take use of the amount of primary and secondary
desuperheating water.
3.4.4 Regulating means and method to main steam temperature

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3.4.4.1 Regulation to high main steam temperature is as following measures:

A. Slowly open desuperheating water, observe temperature change after
desuperheater, do not increase or decrease desuperheating water sharply.
B. Lower flame burning center, e.g. stop the operation of upper layer of (group
of) burners, put lower layer of (group of) burners into operation.
C. Strengthen the soot blowing to water wall and economizer.
D. Lower load, decrease amount of feeding coal, when burning is not stable,
put oil into use for burning assistant.
E. At the premise of complete burning, try to lower input air, or on the condition
that total input air is not change, properly lower the secondary air at upper
layer (group) and increase the secondary air at lower layer (group).
3.4.4.2 When main steam temperature is low, regulate it according to following
measures:
A. Turn down desuperheating water, observe if the temperature after
desuperheater is normal.
B. If the above procedure doesn’t work, properly elevate flame center, such as
put upper layer of (group of) burners into operation.
3.4.5 When boiler load <10%BMCR, it is forbidden to put SH, RH desuperheating
water into operation.
3.4.6 Regulating means and method to reheat steam
3.4.7 Change inclining degree of burner’s nozzle.
3.4.8 Change excess air coefficient (oxygen content).
3.4.9 If above measures still cannot resolve problem, open RH emergency spay
water when steam temperature is high; increase part RH soot blowing.
3.5 Regulation to feed water
3.5.1 Task of feed water regulation
3.5.2.1 To make amount of feed water to adapt evaporation that necessary to unit
load.
3.5.2.2 Maintain drum water level to be fluctuated within the range of ±50mm.
3.5.2 Method for feed water regulation
3.5.2.1 When it is at boiler start-up and low load, adopt drum water level single
flushing flow to regulate, feed water enter boiler through the bypass
equipped with regulating valve.
3.5.2.2 When boiler load is more than 30%, adopt drum water level, feed water
and main steam flow together to control the rotary speed of steam feed

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pump to make feed water entered boiler through feed water piping.
3.5.2.3 When boiler water level is raised up caused by improper manual
regulation, largely open continuous blowdown to decrease water level.
3.5.2.4 After the feed water flow is continuous and stable, close economizer
recirculation valve.
3.5.2.5 When the operation condition is changed, closely monitor the change of
water level, shift to manual regulation if necessary.
3.5.2.6 When carry out periodic blowdown to boiler, strengthen the monitoring and
regulation to water level.
3.6 Control to steam quality
3.6.1 Guaranteed value of SH steam quality at boiler outlet refers to product
instruction book.
3.6.2 Regulating method to steam quality
3.6.2.1 Ensure feed water and feed water quality
3.6.2.2 Control continuous and periodic blowdown valve, ensure salt content in
boiler water to be less than sub-critical salt content under its steam parameter.
3.6.2.3 Control drum water level to be within the range of ±50mm, monitor the
change of drum water level.
3.6.2.4 Avoid sharp increasing of unit load and sharp lowering of steam
pressure.
3.7 Boiler soot blowing
The purpose of boiler soot blowing is to keep clean on the heating surface and
clear of flue gas duct, pay attention to following items:
3.7.1 Properly improve furnace negative pressure during soot blowing, maintain
stable load, and strengthen the monitoring and regulation of steam
pressure and temperature.
3.7.2 Carry out blowing of preheater one time every group, soot blowing to other
heating surface, considering about the cleaning situation of heating
surface, carry out part or overall soot blowing (soot blow preheater before
or after heat surface soot blowing).
3.7.3 Carry out soot blowing as per the sequence of flue gas flow, and soot blow
simultaneously and symmetrically.
3.7.4 Soot blowing shall be carried out when load is above 70%MCR and
burning is stable. If load during soot blowing is too low, furnace
temperature may be decreased due to entered water vapor and it will
make part of incomplete-burned combustible deposited at the furnace
corner or on the tube bundle at rear of heating surface, it may cause
furnace explosion and secondary burning.
3.7.5 During the soot blowing period, don’t open the holes and doors near soot

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blower, observe burning situation, when the burning inside furnace is not
stable or MFT“”, “RB” acts, stop soot blowing immediately.
3.7.6 It is forbidden to insert soot blower inside furnace when there is no steam
flow inside, before inserting or exiting soot blower out of furnace, keep
steam valves opened, and keep steam flowing through soot blower all the
time so as to avoid burnt out to soot blower.
3.7.7 During the period of soot blowing, when motor is in failure, manually exit
soot blower from furnace immediately, close steam inlet valve after exiting.
3.7.8 After the completion of soot blowing, close drainage of steam source,
restore normal operation of furnace negative pressure.
3.8 Boiler blowdown
3.8.1 In order to ensure quality of steam water and avoid priming of steam water,
do carry out blowdown to boiler.
3.8.2 Boiler blowdown is divided into continuous blowdown and periodic
blowdown. Don’t stop boiler continuous blowdown at will; carry out periodic
blowdown from the informing from watcher of chemical specialty.
3.8.3 Carry out boiler periodic blowdown with periodic blowdown regulating valve,
it is forbidden to open emergency drain valve for blowdown.
3.8.4 The opening angle of regulating valve of boiler continuous blowdown shall
be done as per the requirement from chemical personnel.
3.8.5 Before boiler periodic blowdown, ensure blowdown system equipment is in
good condition and no one work around.
3.8.6 During periodic blowdown, pay attention to the change of drum water level.
3.8.7 It is better to carry out periodic blowdown under low load, and blowdown
period shall be not more than 30s.
3.8.8 After the completion of periodic blowdown, check blowdown valves to be
tightly closed.
3.8.9 It is forbidden to do periodic blowdown when following situation happens:
3.8.9.1 Boiler is in abnormal situation or in failure (except that water level is
high).
3.8.9.2 Periodic blowdown system is in failure.
3.8.9.3 Start/stop feed water pump or switch over it.
3.8.9.4 At the conditions that load is raising or lowering.
3.8.9.5 Drum water level is highly changing.
3.9 Measures for stabilizing burning at boiler low load operation

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While boiler operating with the load is lower than 50% rated load, it is to be
considered as low load operation, during this period, pay attention to the
followings:
3.9.1 Strengthen the monitoring to the operation situation of instruments control
auto-device, if the automatic function is not agile, change to manual control
in time and make record. Strengthen the supervision to furnace flame,
negative pressure, steam temperature, steam pressure and power, forecast
accident, and avoid flameout caused by comparatively low heat load inside
furnace.
3.9.2 Find out the type of coal entered furnace during low load operation,
volatilization shall be not less than 28%. If it is bad weather, the coals to be
entered coal silo are required to be dry as much as possible.
3.9.3 During the period of low load operation, inform oil pump watcher in time,
maintain the operation of fuel oil pump; if oil pressure auto-regulation is not
good, switch to manual regulation, make oil pressure maintained within
regulated value and ensure oil guns are available at any moment.
3.9.4 Adopt sliding pressure operation mode for boiler low load operation.
3.9.5 During the period of boiler low load operation, if burning is not stable, put oil
in time; before putting oil into use, pay attention to the operation layer
sequence of mill, and ensure there are 3/4 flame of oil gun. Prevent from
MFT caused by putting improper oil.
3.9.6 During the period of low load operation, oxygen content shall be controlled
at 5%, automatic control of mill primary air regulating damper is abnormal,
use manual regulation or adopt the method of stopping one mill to control
input primary air not excess.
3.9.7 Definite quantity of operation mill according to load. If three mills are
required at the load of the time, maintain two neighbor mills be in operation,
and rotary speed of coal feeder shall be more than 50%, it is forbidden the
mills are operated with layers separated.
3.9.8 During the period of low load operation, if lower load, control load lowering
rate is less than 1.1％／min.
3.9.9 During the period of low load operation, if the amount of coal inside mill is
comparatively small and vibration is comparatively large, inform the patrol
inspection department to strengthen inspection to mill. If abnormal situation
is found, timely regulate or change mill to operate.
3.9.10 When it is at low load operation, it is forbidden to do soot blowing to boiler
heating surface.

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Chapter 4 Boiler Unit Shutdown
1. Boiler Shutdown Mode and Rules

Boiler shutdown is caused by various reasons, there are scheduled normal
shutdown and also shutdown caused by defects or emergency. Hence, there are
situation of boiler shutdown: normal boiler shutdown and emergency shutdown.
Normal shutdown can be divided into two types: boiler shutdown to cold standby
and boiler shutdown to hot standby.
1.1.1 Boiler shutdown to cold standby: it means after boiler shutdown, the boiler is
cold to normal temperature for standby or maintenance, i.e. normal
shutdown. This mode is generally adopting sliding pressure boiler shutdown,
boiler fuel is gradually decreased along with decreasing of turbine load,
ensure steam temperature, pressure and flow to adapt turbine requirement
until shutdown and boiler flameout.
1.1.2 Boiler shutdown to heat standby, it is arranged according to the requirement
of load dispatch or emergency repair; it is required to maintain
comparatively higher level of furnace of unit metal temperature after boiler
shutdown so as to restart under heat or super heat status, this can shorten
start-up period. Constant pressure boiler shutdown is adopted in this mode.
1.1.3 Boiler emergency shutdown is boiler forced to be stopped caused by unit
accident, such as damage to boiler body heating surface, serious accident
of auxiliary system or failure and defects of turbine and power grids, etc.
under this situation, fuel must be cut off at working load to make boiler
swiftly stopping producing steam.
2. Preparation before Boiler Shutdown
2.1. Do overall check to fuel oil system, ensure fuel oil system is in good work
condition, oil temperature and pressure is normal, and check oil gun one by
one, oil line shall be unblocked, atomization is good to facilitate operation at
any moment.
2.2. Check stored coal in raw coal silo, propose requirement that not feed coal to
raw coal silo according to shutdown time and set down corresponding
measures considering days of boiler shutdown.
2.3. Do overall soot blowing to heating surface before boiler shutdown.
2.4. Check upper and lower water level and carry out periodic blowdown once
before boiler shutdown.
2.5. Remove out the ash and slag inside cold hopper.
2.6. Check each auto-regulating system and confirm its status.
2.7. Do overall inspection to boiler body before boiler shutdown, make detailed

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record to those equipment whose defects cannot be resolved during

operation, so the defects can be resolved after boiler shutdown.
3. Boiler Shutdown to Cold Standby
During the entire shutdown period, the decreasing of boiler load and steam
parameter is carried out as per turbine requirement; according to turbine load
decreasing requirement, gradually weaken burning rate, decrease boiler load,
pressure and steam temperature.
3.1 Load decreased from 100% to 50%
3.1.1 Try to maintain SH steam temperature and RH steam temperature to be not
change, if there is any difficulty, lower it along with lowing burning rate.
3.1.2 Decrease load according to the load change rate not more than 1%（3MW）
every minute.
Sliding parameter shutdown, pressure lowering and load decreasing refers to
following table, in the meat time, it shall comply with the rules in “load change
(increasing or decreasing) operation curve”.
Load Main Main steam Time Saturation Superheat Temperature
（MW） steam temperature （min） temperature degree decreasing
pressure （℃）（℃）（℃） speed
。
（Mpa）（ C/min）
300↓27 16.7 541 10 350.78 186.22
0
270↓18 16.7↓13. 541↓500 40 330.81 169.19 0.925
0 0
180 13.0↓10. 500↓450 40 1.25
0
180。 10.0 450 20 310.96 139.04
180↓10 10.0↓6.0 450↓380 50 1.4
5
105 6.0 380 30 275.56 104.44
105↓60 6.0↓3.5 380↓330 40 1.25
60 3.5 330 30 242.54 87.46
60↓30 3.5↓2.5 330↓300 30 1.0
30 2.5 300 30 223.94 76.06
30↓15 2.5 300 10
3.1.3 Main steam pressure is gradually decreased as per the speed of 0.1Mpa per
second along with decreasing of load. Change automatic status of main
steam temperature, reheat steam temperature and desuperheating water to
manual, during the sliding pressure period, pay attention to burning change
inside furnace and put oil gun into operation at proper time for stabilizing
burning.
3.1.4 Stop the operation of pulverized coal system according to actual situation,

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and gradually decrease the amount of coal powder according to load

decreasing situation. While stopping pulverized coal feeders, first stop the
operation of upper layer (group) feeders. At last, blow and clean pulverized
coal piping.
3.1.5 Soot blow APH once.
3.2 Load decreased from 50% to boiler stoppage
3.2.1 Superheat steam temperature and reheat steam temperature are decreased
along with the decreasing of burning rate.
3.2.2 Continuously decrease burning capacity of pulverized coal to avoid
spontaneous combustion caused by accumulated powder, in the mean time
increase oil guns correspondingly until all of them being put into operation.
Stop air fan once after shift and replace kerosene.
3.2.3 When HP heater is shutdown, pay attention to the change of feed water
temperature and regulate steam temperature in time.
3.2.4 Load decreased to about 35%, manually control following operation:
A. Amount of SH desuperheating water
B. Amount of RH desuperheating water
C. Swaying angle of burner
3.2.5 Along with the decreasing of load and pressure, gradually decrease the
amount of oil guns being put into use.
3.2.6 After generator running out of synchronization , turbine steam valve closed
and shutdown, open economizer recirculation valve.
3.2.7 After turbine shutdown, open SH and RH drain valve and vent valve
according to actual situation. Maintain 30% input air after shutdown until
boiler flameout, and then furnace blowing for 5 to 10min.
3.2.8 Put flue gas temperature probe into use to control furnace outlet flue gas
temperature be less than 540℃.
3.3 Boiler flameout
3.3.1 Stop all oil guns, close fuel oil valve, largely open fuel oil recirculation valve,
and exit oil gun after 5min blowing.
3.3.2 If oil system is required of maintenance, carry out blowing to oil pipeline
3.3.3 Open lower two layers of secondary air after boiler flameout, maintain 30%
total input air to blow 5 to 10min, manually decrease input air of FD fan to be
within allowable range (for axial flow air fan, prevent its operating in stall
range), stop one side FD and ID fan, maintain continuous operation of other
side FD and ID fan, when the preheater inlet flue gas temperature is less than

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200℃, close this side FD fan and also preheater operation can be stopped.
3.3.4 When furnace outlet flue gas temperature is less than 150℃, stop cooling air
fan.
3.3.5 Manually regulate feed water flow, feed water to drum until its maximum
water level, and then stop feed water pump. Close dosing, sampling and
continuous blowdown valves.
3.3.6 After stopping the operation of air fan, keep monitoring the preheater outlet
flue gas temperature, if there is abnormal raising temperature at this position,
check the cause immediately, if it is secondary burning, dispose it as per
fire-fighting method.
3.3.7 When boiler water temperature is less than 95℃, open each drain valve to
drain out water, when pressure is decreased to be less than 0.17MPa, open
all the vent valve at boiler top.
4. Boiler shutdown to heat standby
4.1. Boiler shutdown to heat standby is carried out under the constant pressure
operation, unit plant is above 80% load, gradually turn down turbine speed
regulating valve, decrease load, turbine will automatically maintain main
steam pressure along with the gradual decreasing of boiler burning rate, i.e.
load decreasing with constant pressure, pay attention to main steam and
reheat steam to maintain the excess heat above 50℃. When boiler load
decreased to about 5% then stop burning, open turbine gate and stop
shutdown, or take use of steam from boiler remaining heat continually to
generate part electricity and then shutdown.
4.2. Equipment switching is as same as sliding pressure boiler shutdown.
4.3. In order to maintain boiler heat standby status, close SH and RH drain valve
and vent valve after boiler flameout to avoid boiler sharp cooling.
4.4. Operate two sets of FD fan and three sets of ID fan; only after boiler flameout
and completion of furnace blowing, stop one set of FD fan and ID fan
respectively, continuously operate other one FD fan and two ID fans. Until
preheater inlet flue gas temperature is less than 200℃, stop the one FD fan
and two ID fans, however, APH is still continuously rotating.
5. Emergency Boiler Shutdown
5.1. Conditions for emergency boiler shutdown
A. MFT shall act but refuse to act.
B. Boiler tubes blast and cannot maintain boiler normal water level.
C. All water levels are damaged and cannot monitor drum level.

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D. Intermediate reheat steam is intermitted.

E. Boiler steam and water pipes blast and endanger safety of equipment and
personnel.
F. Secondary burning happens at the tail of flue gas duct, it is useless after
disposal.
G. Explosion happens inside furnace or in flue gas duct and it makes serious
damage to equipment.
H. Boiler pressure exceeds action pressure of safety valve but safety valve
doesn’t act, in the mean time electric release valve cannot open.
I. Safety valve doesn’t restore after action, pressure is decreasing and
temperature change to the unallowed range of turbine.
J. Boiler is seriously short of water, and drum level at any side is less than
-350mm. Boiler cannot automatically trip.
K. Boiler is seriously overfilled with water, and drum level at any side is more
than +250mm. Boiler cannot automatically trip.
L. All FD fans or ID fans are stopped.
5.2. Operation to emergency boiler shutdown
A. Press MFT button by two hands simultaneously (until MFT acts).
B. Switch all automatic into manual operation.
C. Immediately stop FD fan and one ID fan, reset switch of each tripping
equipment, maintain furnace negative pressure, stop other two ID fans
after 5~10min.
D. Pay attention to maintain water level, close primary and secondary steam
desuperheating master valve, stop periodic blowdown and soot blowing.
E. If shut down boiler caused by furnace tube blasting, operation of one ID fan
can be maintained, stop ID fan after the steam in boiler is mainly
disappeared; if boiler shutdown caused by economizer tube blasting, it is
forbidden to open economizer recycling. If secondary burning happens
inside flue gas duct, immediately stop ID fan.
F. If boiler cannot restart again, carry out other operation of boiler shutdown
according to normal sequence of boiler shutdown, if it can restore in a
short time, prepare start-up work and carry out as per hot status start-up.
6. Attention to Boiler Shutdown
A. Strictly control drum wall temperature difference during boiler shutdown
period. When the decreasing rate of saturation temperature inside drum is

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less than 55℃/h, if wall temperature difference exceed drum protection

limiting value, close all drain valves until temperature difference is within
limiting value.
B. Before boiler shutdown, do overall soot blowing to boiler that shall be
complete before disconnection.
C. At preliminary period of boiler shutdown, do tightly close boiler all doors and
holes, soot blowing valve and flue gas duct valves so as to avoid large
amount of cold air leaking into boiler that will make sharp cooling to boiler.
D. In order to avoid boiler sharp cooling, control drain amount and times.
E. When boiler is cooled, maintain drum level to be at normal or comparatively
high level.
F. After winter shutdown, do drain out water in water sealing slot and
ash-removing main pipe.
7. Operation to boiler after generator running out of synchronization
7.1. Flameout and boiler shutdown
7.1.1 After turbine open gate and shutdown, confirm SH and RH desuperheating
main valves are closed.
7.1.2 After turbine vacuum break down, open and start RH air vent valve.
7.1.3 If it is required of dry-type preservation after boiler shutdown, put furnace
outlet flue gas temperature probe into operation, open and start RH outlet air
vent valve, continuously operate oil gun at boiler layer “AB” for one hour,
control boiler burning rate to be not more than 10％MCR and furnace flue
gas outlet temperature to be less than 540℃ so as to dry RH.
7.1.4 If to carry out wet preservation after boiler shutdown, close RH air vent valve
and drain valve and turbine open gate, and then stop the operation of boiler
oil guns.
7.1.5 After opening turbine gate, stop the operation of all oil guns, MFT acts.
Contact oil pump house, largely open oil pump outlet fuel oil recirculation
valve, control fuel oil pressure be normal.
7.1.6 Check all oil guns that shall be exit after automatic blowing, and locally close
manual oil inlet valve of each corner oil gun, if maintenance is required to oil
pipeline, carry out blowing to oil pipeline.
7.1.7 After boiler flameout, keep 30% input air, after 5~10min’s ventilation, stop ID,
FD fan. APH keep on operating.
7.1.8 Stop the operation of air heater.
7.1.9 After flameout, open SH outlet steam extraction valve for 5~10min, close
steam extraction valve considering about the situation of main steam
pressure.
7.1.10 After flameout, close continuous blowdown, dosing and sampling primary

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valve.
7.1.11 After flameout, manually adjust feed water flow, slowly feed water until
visible highest level （＋200mm）. Contact turbine, stop electric pump, close
economizer inlet motor-driven valve, confirm economizer recirculation valve
is opened.
7.1.12 During the period of boiler shutdown and pressure releasing, maintain drum
level be normal. When drum level decreased to visible lowest level, contact
turbine to start electric pump to feed water to boiler by flow of 100t／h
through electric pump outlet bypass regulating valve until it reaches drum
level ＋200mm.
7.1.13 When furnace outlet flue gas temperature is less than 80℃, stop flame
scanner cooling air fan.
7.1.14 When preheater inlet flue gas temperature is less than 100℃, stop the
operation of APH.
7.1.15 After boiler shutdown, keep on monitoring discharged flue gas temperature,
if it raises abnormally, check the cause, if secondary burning happens,
dispose it as per fire-fighting method.
7.1.16 When slag is completely discharged outside of furnace bottom, operate slag
crusher and slag collector for half an hour and then inform ash control to
stop them.
7.1.17 When drum pressure is decreased to 0.17MPa, open all vent valves at boiler
top.
7.1.18 When boiler water temperature is less than 93℃, open each drain valve to
drain out boiler water.
7.1.19 If hot boiler water draining is required, drum pressure is 0.5MPa, boiler water
temperature is less than 150℃, open periodic blowdown regulating valve,
emergency drain valve, economizer inlet header primary and secondary
drain valve, open every boiler vent valve.
7.2. Boiler forced cooling (carry out during the period of rush repair after
boiler shutdown)
7.2.1 After boiler flameout, maintain 30% ventilation, blow boiler for 5min and then
stop one side FD fan and two ID fans, keep on operating other group of FD
and ID fan.
7.2.2 When APH inlet flue gas temperature is decreased to 204℃, keep on
operating one group of FD and ID fan, control cooling speed through
controlling input air, and also it is able to speed up cooling through increasing
times of feeding water and draining water.
7.2.3 Keep drum level normal.
7.2.4 Control pressure releasing speed by controlling main steam drain or other
drain, temperature decreasing rate of boiler water shall be controlled at about

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30℃/h.
7.2.5 When boiler temperature is decreased below 150℃, control the time that
pressure decreasing to zero after flameout: for sliding parameter boiler
shutdown: 8h, for emergency shutdown: 16h.
7.2.6 When drum pressure is decreased to 0.17MPa, open all vent valves at boiler
top.
7.2.7 After boiler pressure releasing, keep on operating one ID fan, carry out
ventilation and cooling.
7.2.8 If it is required to drain boiler water, adopt water draining of hot boiler.
7.3. Boiler shutdown to hot standby

Boiler shutdown to hot standby is carried out under constant pressure operation.
Constant pressure shutdown means turbine gradually turn down speed regulating
steam valve with load decreasing when unit boiler is above 80％ load. Turbine
automatically decrease load along with the gradual decreasing of boiler burning
rate to maintain main steam pressure be constant, main steam temperature excess
heat is at least maintained at 100℃, otherwise properly decrease the setting value
of main steam pressure.
7.4.1 Confirm operation mode at “constant pressure”.
7.4.2 Main steam pressure is set at 13.32MPa.
7.4.3 Switching of other equipment is as same as sliding pressure boiler shutdown.
7.4.4 Select the operation mode “boiler generally automatic” until load is decreased
to 60MW.
7.4.5 After boiler flameout, maintain SH, RH vent valves and drain valves be
closed.
7.4.6 After boiler shutdown, maintain one group of FD and ID fan is in operation,
keep ventilation for 5~10min, stop FD and ID fan, maintain APH continuously
operating, close APH outlet primary and secondary air damper and outlet/inlet
flue gas damper.
7.4. Attention to boiler shutdown
7.4.1 Do overall soot blowing once before boiler shutdown.
7.4.2 After confirming boiler shutdown mode, do contacting work of each post and
specialty.
7.4.3 During the period of pressure decreasing, the boiler water temperature rate of
change shall be not more than 166℃／h.
7.4.4 In the course of boiler pressure decreasing, timely adjust fuel amount and
input air according to load situation, maintain burning be stable, regulate feed
water in time, maintain drum level be normal.

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7.4.5 When it is at hot standby, tightly close boiler each doors and holes, damper,
and flue gas and air damper, try to decreasing of steam pressure.
7.4.6 During the period of boiler shutdown and after shutdown, tightly supervise
drum water level, prevent drum filled with water that overflow into SH, check if
desuperheating water valve is leaking, prevent water entering turbine through
main and reheat steam pipes.
7.4.7 During the period of pressure decreasing, record each part expansion
situation at various load and after boiler flameout so as to find out uneven
expansion in time and resolve it in time.
7.4.8 If contamination to preheater is serious, clean it out after boiler shutdown.

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Chapter 5 Preservation and Freeze-proof After Boiler

Shutdown
1. Preservation after Boiler Shutdown

1.1. Rules for boiler preservation
After boiler shutdown, seriously perform anti-corrosion work no matter it is
standby or maintenance status.
1.1.1 Take operation equipment as standby within 10days in short term, and when
it is going to start at any moment, adopt “warming and pressure filling
method” for preservation.
1.1.2 When operation equipment is in overhaul or repairing or take it as standby
over ten days, adopt “draining water with pressure, remaining heat drying
method” for preservation.
1.1.3 When operation equipment is taken as standby above one month or
comparatively longer time, adopt “hydrazine and ammonia solution” for
preservation; if boiler pressure parts are rigorous, adopt “N2 filling method”
for preservation.
1.1.4 Cold boiler shall be not changed to “dry-type anti-corrosion”, if it is the last
resort, do light-up raise pressure to 30% rated pressure and then decrease
pressure, adopt “remaining heat drying method” for preservation.
1.2. Preservation method

Wet preservation
According to period of preservation, the preservation of each pressure parts is to
be carried out as per following table:
Pressure parts
Main
Economizer +water wall SH RH
steam pipe
Preservation period
Within one Full water+ N2 Without

Short-term
week N2H4=200mg/L Fill in N2 disposal Fill in N2
NH3=10mg/L
Above one
Full water+ N2
week while
Long-term N2H4=300mg/L Fill in N2 Fill in N2 Fill in N2
within one
month NH3=10mg/L
Above one
Full water+ N2
month
N2H4=700mg/L Fill in N2 Fill in N2 Fill in N2
while within
NH3=10mg/L
six months

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Above six Full water+ N2

months N2H4=1000mg/L Fill in N2 Fill in N2 Fill in N2
NH3=10mg/L
After preliminary hydraulic test, fill water into economizer, water wall, SH and RH to
overflow, fill N2 into boiler to the pressure of 0.034MPa.
1.3. Drying preservation
1.3.1 In order to dry RH, open HT RH vent valve after stopping of turbine, keep
boiler on operating for one hour, control fuel oil ≤10%MCR, furnace
outlet flue gas temperature<540℃, in the mean time prevent other system
draining water into RH.
1.3.2 When boiler drum pressure is decreased to 0.2MPa, open N2
pressure-reducing bypass valve, check N2 pressure and when it is above
0.3MPa, open drum and SH N2 filling valve.
1.3.3 Open periodic blowdown valve, continuous blowdown valve, economizer
drain valve, drain valve after SH desuperheating water valve, drain valve
after RH emergency spraying valve, 5% bypass drain valve to drain water,
strengthen the control to drain valve while draining water, drum pressure
shall be not less than 0.1MPa, after draining water for a certain period,
when there is no water inside drum, open economizer N2 filling valve.
1.3.4 After draining out the continuous blowdown tank, close continuous
blowdown valve.
1.3.5 After draining out water wall and economizer, close periodic blowdown
valve, economizer drain valve and other drain valves.
1.3.6 Maintain N2 pressure inside water wall, economizer and SH main steam
pipe system to be above 0.034MPa.
1.3.7 When RH pressure is decreased to 0.2MPa, close HT RH vent valve, open
RH N2 filling valve to start filling N2, when reheat pipe temperature
decreases to 100℃, maintain the N2 pressure inside RH system be at
0.034MPa.
1.3.8 Close N2 pressure-reducing bypass valve, pay attention to maintain N2
pressure inside each system be above 0.034MPa.
1.3.9 If there is no pressure in boiler originally but preservation is required, firstly
draw out vacuum for boiler and RH system, and then fill N2.
1.3.10 Test N2 purity regularly, when N2 purity is decreasing, open N2
pressure-reducing bypass valve, use the method of discharging along with
filling until N2 purity is qualified; during this period, N2 pressure inside each
system shall be not less than 0.034MPa.
2. Boiler Freeze-proof
Freeze-proof of boiler body and auxiliary equipment pipes
2.1. Before winter is coming, do overall freeze-proof inspection, there shall be no

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bare pipes.
2.2. The pipes part in which are not flow in operation, try to drain out it if it is
possible; if the one cannot drain out, periodically drain it or adopt micro-flow
method to prevent pipes frozen.
2.3. Try to adopt dry-type preservation for the boiler has been stopped to use,
when SH wall temperature is less than 20℃, put air heater into use, after
that, maintain APH operation.
2.4. Put all freeze-proof tracing system into operation.
2.5. Maintain auxiliary cooling water be flowing, otherwise stop cooling water
system and drain deposit water.
2.6. Properly largely open sealing water used for cold hopper water sealing and
maintain overflow, prevent freeze. Otherwise, drain out water from seal
groove.
If water exists in boiler, when boiler water temperature is less than 10℃, carry out
water feeding and draining, the water draining shall be carried out alternately at low
place.

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Chapter 6 Start, Stop and Operation Maintenance of

Auxiliary Equipment and System
1. General Inspection Rules before Starting Auxiliary Equipment

and System
1.1 Examine and repair work is complete, work permission ticket is complete,
safety measures have been removed, each equipment and holes are closed,
foundation bolts is fixed well, protective encloser of rotary mechanism have
been covered completely, pipes and their connection is good and supports
and hangers are firm. Insulation of equipment and pipes is complete,
construction site is orderly and clean, passage is clear, stairs, platforms and
handrails are complete, lighting is adequate.
1.2 Check I & C instruments, gauges, signals and interlock protection are
complete, open each instrument primary valve.
1.3 Contact I & C, supply I & C power, check auxiliaries operation are in
stopping status, release interlock switch “manual/auto” and switch it to
“manual”.
1.4 Contact electric specialty, supply the power of motor-driven valve, carry out
trial operation and it shall be agile without block, opening and closing
direction and spacing is correct.
1.5 Contact I & C, supply power of air-driven valve, its operation shall be agile
without block, opening and closing direction is correct, confirm the local
indication of opening degree is as same as in center control room.
1.6 Place each valve at required status as per “valve inspection card”.
1.7 Check the oil level of rotary mechanism’s bearing or oil tank lube oil is
normal and oil quality is qualified, otherwise add oil or change oil. For those
rotary mechanism which can be turning gear, turn coupling confirm its rotary
is agile without block. Initial start-up after the maintenance of pump or motor,
it must be qualified through single trial operation.
1.8 Check liquid level of water tank and oil tank is normal, water quality or oil
quality is qualified, drain out the bottom accumulated water of oil tank.
1.9 Carry out water filling (oil filling) operation to system.
1.10 Supply cooling water for rotary mechanism bearing and slag dipper, water
return or drop of slag dipper shall be normal.
1.11 After the completion of other inspection work of corresponding system,
contact electric specialty, supply power of rotary mechanism, and assist I &
C specialty to complete interlock and protection test of auxiliaries and
motion is normal, setting value is correct (note: for the linkage test of 6KV
motor, firstly contact electric specialty to place switch to “testing” position
and then do the test. Supply power after completion of test).
1.12 Make detailed record to the operation of equipment and system, carry out

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operation supervisory system to important operation.

2. Start (launch), Stop (quit) and Operation Maintenance of Boiler
Equipment and System
2.1 Operation of pulverization system
2.1.1 Start and stop of primary air fan
2.1.1.1 Inspection before start of PA fan
A. Complete the operation stated in general inspection rules before starting
auxiliary equipment and system.
B. Air fan outlet damper and inlet regulating damper is at closing position.
C. Conditions for starting PA fan
a. Outlet damper opens at the start of first PA fan;
b. PA fan inlet regulating damper is closed;
c. APH primary air inlet/outlet damper is opened;
d. At least one group of ID and FD fan is put into operation;
e. Air fan bearing oil level is normal;
f. At least one set of mill cold air damper is opened.
2.1.1.2 Start of PA fan
A. Start PA fan “A” or “B”.
B. Wait until PA fan start current is at normal value, slowly open PA fan inlet
regulating damper, supervise PA fan outlet pressure is at normal value,
launch PA fan inlet regulating damper into automatic.
C. Do overall inspections to PA fans after starting them.
2.1.1.3 Stop of PA fan
A. Before stopping PA fan, again check mill and boiler load to achieve
correctness.
B. Gradually turn down the PA fan inlet regulating damper that is nearly stopped
until completely close it.
C. Stop the operation of PA fan “A” or “B”, make PA fan current reaches zero.
D. Close PA fan outlet damper.
2.1.1.4 Supervisory in the operation of PA fan
A. During the operating period of PA fan, always check fan bearing and motor
bearing’s temperature are normal, if abnormal raising happens, immediately
find out the cause.

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B. During the normal operation period, try to maintain balance output of the two
PA fans.
C. The differential pressure between primary air main pipe and furnace shall be
not less than 7.5kPa.
D. Do periodically inspection to fan bearing oil level.
E. When the automatic device of PA fan inlet regulating damper is in failure,
immediately switch automatic to manual, and strengthen the supervisory to
operation parameters, inform I & C personnel to take measures to repair it.
F. During the normal operation, perform supervisory to the parameters of PA fan,
it shall be not beyond limits:
a. PA fan motor current is normal.
b. Fan bearing vibration is within regulated range.
c. Fan bearing temperature＜75℃.
d. Motor bearing temperature＜65℃
e. Motor coil temperature＜120℃.
2.1.2 Start and stop seal fan
2.1.2.1 Inspection before starting seal fan
B. Seal fan inlet strainer is complete and clean, inlet strainer to burning
windbox back-flushing pneumatic regulating valve is closed and launch into
automatic.
C. Seal fan inlet separation damper local is manually opened.
2.1.2.2 Start of seal fan
After starting PA fan, one seal fan automatically starts, after outlet air pressure
is normal, put seal fan I & C interlock into automatic.
2.1.2.3 Stop of seal fan
After stopping all pulverization system, stop the operation of seal fan.
2.1.2.4 Seal fan operation
A. Under normal situation, one seal fan is in operation while other one is
standby.
B. If the operating fan is tripping caused by failure or the differential pressure
between seal fan main pipe and PA fan main pipe is less than 1200Pa,
standby seal fan shall automatically start, when the differential pressure

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between seal fan main pipe and PA fan main pipe is normal, stop original
operating seal fan.
2.1.3 Start mill
2.1.3.1 Inspection before starting mill
B. Motion of separator regulating damper is agile, opening degree is proper
and fixed.
C. The opening of each damper is agile, drive device is in good condition.
D. Mill hot damper is closing, outlet valve is opening
E. Seal fan inlet manual separation valve is opened, mill and coal feeder seal
fan is opening.
2.1.3.2 Start of mill
A. Start mill lube oil pump, lube oil pressure has been normal, check oil flow is
normal, mill bearing is lubricated.
B. PA fan “A” or “B” has started, and differential pressure between PA fan and
furnace reaches normal value (above 8kPa).
C. Seal fan has been started, the signal of high differential pressure between
seal fan and mill bowl appears.
D. Conditions for starting mill
a. Mill cold air damper is opened;
b. Mill outlet damper is fully opened;
c. Mill outlet temperature(not over 93℃) allows to start mill;
d. Coal feeder local control switch is at remote control position;
e. There is no mill tripping order;
f. Mill lube oil system is normal;
g. Differential pressure between primary air and furnace is not less than （△
>6.5kPa）;
h. Seal fan is operating, differential pressure between seal fan and mill bowl
bottom is not less than 2.0kPa;
i. There is no MFT;
j. Mill starting permission (drum pressure>3.45MPa; boiler load ＞20 ％ ,
secondary air temperature＞177℃; burner inclining angle is at horizontal

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position; total input air<40％; differential pressure between scanning air

and furnace>2.0kPa, or one neighboring coal feeder is in operation and
rotary speed is more than 50％)
k. Mill steam fire valve is closed.
E. Lamp “mill light-up permission” is lighting on CRT while satisfying any one
in following conditions:
a. 3/4 neighboring oil layer have been approved;
b. Boiler load＞35％, and the rotary speed of any neighboring coal feeder＞
50％;
c. Any neighboring coal feeder rotary speed >50 ％ , and 3/4 oil layer
contiguous to the mill is approved.
F. Starting of mill
a. Confirm mill is starting normally;
b. Open mill hot damper;
c. Regulate mill inlet cold and hot air regulating damper and put them into
automatic. Maintain mill inlet air temperature be not more than 150℃ and
outlet temperature be less than 93℃. During hot pulverization period, mill
outlet temperature rise rate is 3℃／min.
2.1.4 Start coal feeder
2.1.4.1 Inspection before starting coal feeder
(launching) auxiliary equipment and system.
B. Proofing of coal feeder weighing system is complete, regulation of belt
tension is proper, and belt is not deviated during operation.
C. Coal feeder seal fan is opened.
D. There are enough coal stored in coal silo, coal feed outlet gate is opened,
inlet coal gate is closed.
E. Coal feeder power is supplied.
2.1.4.2 Starting of coal feeder
A. Mill hot pulverization is complete.
B. Conditions for starting coal feeder
a. No MFT;
b. Mill is in operation;

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c. Coal feeder rotary speed command is at lowest (25％);

d. Coal feeder inlet/outlet coal gate is opened;
e. Mill light-up permission conditions are still exist;
f. Coal feeder local control switch is at remote control position.
C. Press coal feeder starting button, start coal feeder, inlet coal gate is
automatically opened.
D. After 50s’ starting of coal feeder, check coal amount of coal feeder is normal,
and then put coal feeder rotary speed control into automatic.
E. When the rotary speed of neighboring layer coal feeder is more than 70％,
boiler load is more than 40％MCR and burning is stable, stop corresponding
oil guns of the two mills.
2.1.5 Normal operation and maintenance of pulverization system
2.1.5.1 Normal operation and parameter supervisory
A. During the normal operation period, maintain operation parameter of
pulverization system equipment to be within normal range, if parameter is
found changing, regulate it in time, and ensure reliable operation of
pulverization system.
B. During the normal operation period, in order to ensure mill best output, the
rotary speed of coal feeder shall be controlled within the range of 40～80％. If
rotary speed is found too low, timely stop one mill, if rotary speed is too high,
start standby mill in time.
C. When pulverization system is in operation, periodically check each rotary
mechanism that shall be balanced without noise, current is stable, each
bearing and lube oil temperature is normal.
D. Test fineness of pulverized coal one time everyday, the fineness can be
controlled through regulating opening degree of mill separator flection
damper.
E. Strengthen supervisory to mill current and differential pressure of mill bowl to
avoid mill failure caused by blocking.
F. Frequently check mill, coal feeder and other auxiliary system, there shall be
no powder, air or oil leaking situation.
G. Switch standby mill periodically.
H. During normal operation, mill outlet temperature shall be controlled within
normal range, highest temperature shall be not more than 82℃ while lowest
be not less than 65℃.

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I. During the normal operation, if pulverization system automatic regulation is

out of order, immediately switch it into manual, manually regulate its
parameter to be in normal range.
J. Normally operate each parameter supervisory of pulverization system
Item Unit Normal range
Mill outlet temperature ℃ 65～88
Differential pressure of mill inlet
Pa 3000～4000
and outlet
Differential pressure of upper
Pa ＜2030
and lower mill bowl
Differential pressure between
Pa ＞1016
seal air and primary air
Seal air pressure kPa Approx.10～11
Differential pressure between
kPa ＞8.5
primary air and furnace
Mill lube oil pump outlet
MPa 0.7～0. 9
pressure
Mill bearing temperature ℃ ＜80
When Hardgrove grindability
coefficient is 55inches,
Pulverized coal fineness
200meshes, mesh
through-passing rate is 80%.
Mill current A ＜47.4
2.1.5.2 Every operation setting value of pulverization system

A. seal air/primary air differential pressure ΔP＜1016Pa, 10s time lag and
alarm, standby seal fan start automatically.
B. Seal valve/mill bowl lower part differential pressure Δ＜2000Pa, and then
alarm, 1min time lag, mill trips.
C. Alarm when mill outlet temperature＞93℃, turn down hot air regulating
damper, largely open cold air regulating damper, mill input air, temperature
switch from automatic into manual, close hot air fan after 30s.
D. Alarm when mill lube oil pressure is at 0.09MPa, mill trips when the pressure
＜0.07MPa.
E. Primary air/furnace differential pressure ΔP＜6250Pa and mill inlet primary
input air＜40t／h, mill trips.
F. Oil pump is stopped automatically (if any one of following conditions appears,
firstly mill trips, and then oil pump stops automatically):
a. mill lube oil temperature＞65℃.
b. Oil level of mill lube oil tank＜511 L

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c. Mill lube oil pressure＜0.07MPa 2min time lag.

d. Bearing temperature of any point of four points on mill＞80℃.
e. Oil temperature inside oil tank＜15℃.
2.1.6 Stop mill and coal feeder
2.1.6.1 Stop coal feeder
A. Before stopping coal feeder, check the standby status of neighboring oil gun
and it can be put into use at any moment.
B. Make the control of coal feeder that is prepared to quit switched from automatic
into manual, and gradually decrease rotary speed that shall be not over 10%
every time. After speed is reduced, do carry out next stage speed-reducing until
the differential pressure between mill outlet temperature and mill bowl is stable,
reduce speed until coal feeder’s lowest rotary speed. During the entire
speed-reducing period, do strictly control mill outlet temperature be within
normal range, in the mean time pay attention to other coal feeders that their
rotary speed shall be not more than 80％.
C. When coal feeder rotary speed is lower than 40%, if necessary, put neighboring
layer of oil guns.
D. When coal feeder rotary speed is at lowest, mill input air and temperature
control shall be switched into manual.
E. When coal feeder rotary speed is decreased to minimum speed (25％), press
stopping button, and then coal feeder inlet gate shall be closed automatically,
operation of coal feeder shall be stopped, close coal feeder outlet gate.
2.1.6.2 Stop mill
A. After stopping coal feeder, mill continuously operate 5min, when mill outlet
temperature is decreased to 50℃, stop mill operation after pulverized coal
inside mill is blowing completely and clean (judge the cleanness according to
mill current and mill bowl differential pressure).
B. After stopping mill operation, seal fan is closed, mill cold air regulating damper
is closed to 5% opening degree, maintain minimum air pass through mill.
C. Continuously keep on the operation of mill lube oil pump. wait until oil
temperature of gearing box is less than ＜40℃, stop mill lube oil pump. If only
stop mill operation for shot-term, lube oil pump can continuously maintain
operation.
D. During the period of boiler shutdown, boiler is at low load and stopping
pulverization system, ensure boiler burning be stable, maintain neighboring
layer pulverization system be in operating. Before stopping the operation of last

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layer pulverization system, firstly put corresponding layer oil guns into operation
until complete pulverization system is stopped.
2.1.7 Accident disposal of pulverization system
2.1.7.1 Mill shall automatically trip when any one of following conditions appears:
A. MFT exists.
B. Mill outlet valve is closing.
C. PA fan trips, primary air lost or differential pressure between primary air and
furnace (or differential pressure low, 5s time lag)
D. Seal fan tripping over 60s or differential pressure between seal air and mill bowl
lower part ΔP＜2000Pa is over 1min.
E. Mill cold damper is closed.
F. Mill lube oil pump tripping or lube oil pressure ＜0.07MPa.
G. When put coal feeder into use, light-up permission lost.
H. Bearing temperature of mill gearing box ＞80℃.
I. Mill motor power lost.
J. Mill lube oil flow＜105L／min.
K. Mill electric protection actuated.
2.1.7.2 Stop mill operation emergently if following condition happens:
A. Motor is smoking or igniting.
B. Serious vibration happens on mill and even endangers equipment safety.
C. Bearing temperature is too high or lube oil system is in failure.
D. Personnel death accident happens caused by rotating part.
E. It shall be automatically tripped but refused to act.
2.1.7.3 Disposal after mill tripping or emergency shutdown
A. Confirm corresponding coal feeders are automatically stopped, otherwise
manually intervene it.
B. Confirm corresponding hot dampers are closed, seal dampers are closed.
C. Regulate cold air regulating damper according to mill outlet temperature.
D. Find out tripping reason and dispose it, after that, restart, after starting mill,
operate it for several minutes, after blowing stored coal inside mill cleanly, start
coal feeder, and then open hot damper, maintain mill outlet temperature be
normal.
E. If mill cannot be put into operation after mill tripping, close hot damper, cold
damper, seal damper and mill outlet valve, put mill steam to extinguish fire
(when it is igniting inside), wait until the pulverized coal inside mill is not going to
self-ignite, contact maintenance department to clean out stored coal inside mill.

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F. Boiler MFT, starting of all mills after tripping shall be carried out after completion
of blowing, be careful and slowly. Cold air damper shall be controlled manually
and then gradually open it largely to avoid large amount of pulverized coal
entering furnace that will cause explosion.
2.1.7.4 Mill is on fire
A. Mill firing phenomena:
a. Mill outlet temperature is swiftly rising without any reason.
b. Paint color of mill or coal-falling pipes is changed or paint is falling off.
c. Mill bowl differential pressure is fluctuated by a large margin.
d. Mill is caught fire and causing explosion; there is sound, air pressure of
pulverization system is seriously fluctuated, pulverized coal are spurted out at
taut position.
B. Reasons of mill catching fire:
a. Mill temperature regulation is improper or automatic function is out of order
and causes mill outlet temperature is too high.
b. Flammable and explosive substance enter mill.
c. Mills haven’t been blown and cleaned completely before stopping mill,
backfire happens at furnace positive pressure.
d. Foreign matters accumulate inside cone and in other part of mill.
C. Disposal to mill catching fire
a. When mill outlet temperature ＞93 ℃, if hot damper hasn’t automatically
closed, immediately manually close it, and 100% open cold air regulating
damper.
b. If mill is found on fire, manually control coal feeder to feed coal continuously
with high speed, but don’t make mill overload.
c. When mill outlet temperature is decreasing, fire is disappeared, close steam
fire valve.
d. Stop the operation of coal feeder.
e. After operating mill for several minutes, stop mill, close cold, hot damper and
their regulating damper, close seal damper and coal feeder seal damper,
close coal feeder outlet gate and mill outlet valve.
f. After isolating mill, contact electric specialty to pull power.
g. Inform maintenance personnel to thoroughly clean and check the inner part of
mill and its pipes, check main shaft and oil seal on each shaft seal are not
damaged, there shall be no carbonization phenomena of lube oil, otherwise
change the oil.
2.1.7.5 Mill is full of coal:
A. Mill if full of coal
a. Mill current electricity is rising.

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b. Mill outlet temperature is decreasing.

c. Mill bowl differential pressure is rising.
d. Mill ventilation is decreasing.
B. Reasons for mill full of coal
a. Primary air regulation is improper or automatic is out of order, this make
ventilation inside mill is too small.
b. Rotary speed of coal feeder is too high, coal feeding amount is too large or
fineness of pulverized coal is too minute.
c. Mill mechanical loading unit is in failure, this make mill output decreased.
d. Mill inner part is in failure.
C. Disposal to mill full of coal
a. Immediately lower down the rotary speed of coal feeder to minimum.
b. Increase primary air or properly improve primary air pressure.
c. If pulverized coal is too fine, re-regulate the opening degree of separator
damper to maintain proper fineness of pulverized coal.
d. If above disposal method doesn’t work, report to chief watcher, center control
leader, stop the operation of pulverized coal system and inform maintenance
to clean and repair it.
2.1.7.6 Coal feeder automatic tripping
A. Coal feeder will automatically trips if any one of following situation happens:
a. MFT;
b. Mill trips or emergency stop mill;
c. Coal feeder inlet coal gate is opening, no coal is on belt conveyor and mill
current is less than 30A;
d. Coal feeder outlet gate is closing;
e. Within 180s after starting coal feeder, corresponding mill light-up condition is
lost or there is no enough light-up energy to support at this layer.
f. Coal feeder is in failure.
B. Disposal after coal feeder automatically trips
a. Check coal feeder inlet/outlet coal gate is automatically closed.
b. After 60s, hot air damper and hot air damper are automatically closed, mill
ventilation and outlet temperature switch from automatic into manual.
c. Find out the cause of coal feeder tripping, contact maintenance to dispose it, if
it cannot be restored in short time, stop corresponding mill, and put standby
pulverization system into operation.

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d. After the coal feeder tripping failure is eliminated, carry out trial operation, if it
is qualified, put into operation or standby considering the actual situation.
2.2 Operation of ID and FD fan
2.2.1 Start and stop ID fan
2.2.1.1Inspection before starting ID fan
(launching) auxiliary equipment and equipment.
B. Check ID fan inlet regulating damper opening/closing indication is complied
with local, opening/closing is agile, and then place inlet regulating damper
position be at closing status.
C. Ensure oil grease is uniformly filled in bearings and oil pipes.
2.2.1.2 Before starting ID fan, do satisfy following conditions:
A. APH at same side is operating.
B. ID fan inlet damper is closed.
C. ID fan inlet regulating damper is closed.
D. ID fan outlet damper is fully opened.
E. ID fan bearing cooling air fan has been started.
F. Ensure air access is established.
2.2.1.3 Starting of ID fan
A. ID fan starting conditions are satisfied.
B. Start ID fan, after current is back to no load, check inlet damper is automatically
opened. (if inlet damper is not able to fully open within one minute, immediately
stop the operation of air fan).
C. Slowly open air fan inlet regulating damper, regulate it to required work
condition, put inlet regulating into automatic considering situation.
2.2.1.4 Stopping of ID fan
A. Slowly turn down ID fan inlet regulating damper until it is closed.
B. Stop ID fan operation, and inlet damper is automatically closed.
C. Outlet damper is to be closed according to requirement.
D. After ID fan operation stopped for 2h, stop the operation of bearing cooling air
fan.
2.2.2 Start and stop FD fan
2.2.2.1 Inspection before starting FD fan
(launching) auxiliary equipment and equipment.
B. Inspection to hydraulic lube oil system:

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a. Oil tank level indication is at 2/3, oil quality is good.

b. Oil pump and motor is complete, there is no oil leaking at each part of oil
system.
c. Filter is complete, switching is agile, switching handle shall be switched at the
position of one cartridge filter.
d. Oil cooler is complete, cooling water is flowing without block.
e. Each valve is complete, switch is agile and at required position.
f. Each pressure gauge is put into use, setting value of pressure switch and
temperature control is correct.
g. Electric heater is working normally.
C. Check rotating blade regulating device is complete, respectively regulate blade
to the position of “close” and “fully open”, indication is complying with local, and
then place rotating blade to “close”.
D. If air fan hasn’t operated at low temperature for a long time, connect oil
supplying device two hours before starting air fan, and regulate it for several
times within the range of blade regulation.
2.2.2.2 Start and stop FD fan hydraulic lube oil pump
A. Starting
a. Entirely check each valve position of FD fan lube oil system, put all pressure
gauges and thermometer.
b. Start one oil pump, check the operation of oil pump is normal.
c. Check oil delivering and oil return situation, oil flow is normal, hydraulic oil
pressure≥2.5MPa, bearing lube oil pressure is at 0.4～0.6 MPa, put oil pump
interlock into operation.
B. Stopping:
a. Operation of air fan is stopped, air fan bearing temperature is decreased
below 50℃.
b. Quit oil pump interlock switch.
c. Stop oil pump.
2.2.2.3 Before starting FD fan, do satisfy following conditions
A. FD fan rotating blade is closing.
B. FD fan outlet damper is closing.
C. Hydraulic lube oil tank level >200mm.
D. Hydraulic oil pressure >2.5 MPa.
E. Lube oil flow> minimum (10.8m3/h).
F. Bearing temperature<90℃.

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
G. Ensure air access is established.

2.2.2.4 Start FD fan
A. FD fan starting conditions are satisfied.
B. Start FD fan, waiting until starting current return no load, open outlet damper.
C. Slowly open rotating blade regulating damper, regulate it to required input air.
D. According to requirement, put FD fan rotating blade control into “automatic”.
2.2.2.5 Stop FD fan
A. Gradually turn down the adjustable blade of FD fan which is prepared to stop
until it is closed.
B. Stop FD fan operation, close outlet damper after 60s.
C. If FD fan is stopped for a short time, it is necessary to stop lube oil system;
otherwise stop it after air fan bearing temperature<50℃ (or after 5min).
2.2.2.6 Air fan parallel starting and stopping
A. Air fan parallel starting and stopping
a. First air fan has been normally operated and second air fan has starting
conditions;
b. Start second air fan, after starting current returns to no load, open outlet
damper;
c. Turn down the rotating blade of first FD fan (or ID fan inlet regulating damper),
make work condition point below the lowest point of surge line, start the
rotating blade of second FD fan (or ID fan inlet regulating damper) to have
same angle with the rotating blade of first FD fan (or the opening degree of ID
fan regulating damper), so as to make same input air for two air fans;
d. Synchronously open rotating blade of two FD fans (or ID fan inlet regulating
damper), regulate input air to required work condition.
e. Stat third ID fan, the procedure is same as above.
B. Air fan parallel stopping
a. Adjust load, simultaneously regulate the angle of rotating blade of two FD fans
(or the opening of ID fan inlet regulating damper) to be below lowest point of
surge line;
b. Close FD fan rotating blade (or ID fan inlet regulating damper) that is
prepared to stop, largely open another one FD fan rotating blade (or ID fan
inlet regulating damper) to required work condition so as to adapt load
requirement;
c. Stop the air fan that is prepared to stop, close outlet damper;
d. Whether to stop FD fan lube oil system or not depends on requirement.
e. Stop third ID fan, the procedure is same as above.

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HPGC : 2 x 300 MW
Maintenance Manual
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2.2.3 Operation and maintenance of FD fan

2.2.3.1 During the operation of air fan, always supervise the air pressure and air
volume, they shall be normal, automatic regulating position is good.
2.2.3.2 Air fan current indication is normal and stable, and there shall be no
obvious sway.
2.2.3.3 Air fan bearing temperature≤70℃, motor bearing temperature ≤60℃. If
bearing temperature is found rising, check the cause in time and take
necessary measures to resolve it.
2.2.3.4 Entirely and periodically check air fan and its system and hydraulic oil
station. Oil level of oil tank shall be above required line, if it is short, add oil.
Hydraulic oil pressure shall be between 2.5MPa and 3.5MPa, oil
temperature in oil tank＜50℃, filter differential pressure shall be less than
0.2MPa, cooling water of oil cooler is flowing smoothly.
2.2.3.5 It is forbidden for air fan to operate within the surge value, if surge alarms,
immediately close small rotating blade, decrease load to operate until
surge is disappeared.
2.2.4 Operation and maintenance of ID fan
2.2.4.1 During the operation of air fan, always supervise the air pressure and air
volume, they shall be normal, automatic regulating position is good.
2.2.4.2 Air fan current indication is normal and stable, and there shall be no
obvious sway.
2.2.4.3 Air fan bearing temperature＜75℃, motor bearing temperature＜75 ℃. If
bearing temperature is found rising, check the cause in time and take
necessary measures to resolve it.
2.2.4.4 Inspection to ID fan and its system
2.2.4.5 It is forbidden for air fan to operate within the surge value, if surge alarms,
immediately turn down small inlet regulating damper, decrease load to
operate until surge is disappeared. If surge time is over 15s, ID fan will trip.
2.2.4.6 ID fan bearing vibration shall be not more than 0.12mm.
2.2.5 Air fan operation control
Designation Normal value Alarm value Trip value
Air fan surge Trip after 15s
Air fan vibration ≯0.08mm
Air fan bearing 60～70℃ ≥75℃ ≥85℃
temperature
Motor bearing ＜70℃ ≥75℃ ≥85℃
temperature

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HPGC : 2 x 300 MW
Maintenance Manual
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Air fan bearing 0.3～0.5MPa ＜0.3MPa

oil pressure
Air fan hydraulic 2.5～3.5MPa ＜2.5MPa
oil pressure
Oil tank level ≤200mm
Air fan bearing 3～4 ｌ/min ＜3 ｌ/min
lube oil
Oil temperature If ≤30℃, put electric heater into operation, if ≤40℃, stop
in oil tank using electric heater.
Oil filter ＞0.05MPa, it is required to switch oil filter in principle.
differential
pressure
2.3 APH Operation
2.3.1 Start and stop APH
2.3.1.1 Inspection before starting APH
B. Open/close position of valves of APH pilot and supporting bearing lube oil
system is correct, filter handle is at working position, put oil pump into
automatic.
C. Start and stop APH main and auxiliary motor once respectively, check their
turning direction if it is correct. Continuously turn a circle by using of auxiliary
motor, check it and there shall be no block or abnormal situation, rotor turning
is agile and balance.
D. Check APH seal automatic control system can be put into use normally,
sealing gap has been set as per regulated value.
E. Check APH soot blowing system to be good, no block while driving or
retreating it.
2.3.1.2 Start APH
A. Starting of APH must be done before starting ID fan.
B. Check APH and it is normal, APH starting conditions are satisfied, and then
APH can be started.
C. APH starting conditions
a. APH supporting bearing oil temperature＜45℃ or supporting bearing oil
pump has been started.
b. APH pilot bearing oil temperature＜55℃ or pilot bearing oil pump has been
started.
c. APH auxiliary motor is at operation stopping status.
D. Start APH main motor, APH turning direction is correct, current is normal, there
is no obvious sway.

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HPGC : 2 x 300 MW
Maintenance Manual
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E. After starting APH, sequentially open secondary air outlet damper, flue gas inlet
damper and primary air inlet/outlet damper.
2.3.1.3 Stop APH
A. After boiler shutdown, keep APH continuously operating, when APH inlet flue
gas temperature＜100 ℃, stop APH operation.
B. Stop APH operation, sequentially close APH flue gas inlet damper, secondary
air outlet damper and primary air inlet/outlet damper.
2.3.2 APH operation and maintenance
2.3.2.1 There is no noise during APH operation, turning of drive device is agile
and balance without friction, motor current cannot beyond limits, there is
no obvious sway.
2.3.2.2 Oil temperature, oil pressure and oil level of pilot bearing and supporting
bearing lube oil system are normal, and oil quality is qualified.
2.3.2.3 During the period of normal operation, if oil pressure of lube oil system is
found rising. Check oil filter too if it is blocked. If it is blocked, switch oil
filter and contact maintenance personnel to clean out strainer.
2.3.2.4 During the period of normal operation, pilot bearing temperature is 55～80
℃, supporting bearing temperature is 45～70℃; if bearing temperature is
found rising, or lube oil system temperature is rising, find out cause in time
and regulate cooling water amount of oil cooler.
2.3.2.5 Increase the times of APH soot blowing if following situation is found in
operation.
A. APH outlet air pressure is decreasing, flue gas differential pressure is rising.
B. Boiler load is changing in large range.
C. Boiler burning condition is not stable.
2.3.2.6 Check the oil level of APH speed-reducing box to be normal, oil quality is
qualified, oil temperature is 60～70℃.
2.3.2.7 There shall be no leakage of fluid coupling during operation, oil
temperature is less than 90℃ in continuously operation.
2.3.3 APH soot blowing
2.3.3.1 Operate APH soot blowing after boiler light-up, air source for soot blowing
is from compressed air.
2.3.3.2 During the period between boiler light-up to load 10％MCR, soot blow
APH continuously, after load reaches 60％MCR, carry out soot blowing
one time every eight hours.
2.3.3.3 After boiler load reaches 10％MCR, steam source of APH soot blowing
shall automatically switch to boiler steam supply.
2.3.3.4 Soot blow APH once before boiler shutdown.

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HPGC : 2 x 300 MW
Maintenance Manual
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2.3.3.5 During the normal operation period, soot blow APH at least one time every
shift.
2.3.4 APH water flushing
2.3.4.1 Carry out APH water flushing during the period of boiler shutdown, don’t
do it when the air fan is in operation.
2.3.4.2 Before flushing, check all the preheater lower drain valves are opened,
drain pipe and flushing nozzles are not blocked.
2.3.4.3 Alkali liquid flushing water tank to feed water to 4/5, contact chemical
specialty to add into medicine, open steam heating valve, make water tank
heated to 80℃ and then stop heating, start flushing pump to carry out
flushing.
2.3.4.4 Carry out preheating cold and hot end flushing simultaneously.
2.3.4.5 Open flushing pipe water inlet valve, flushing pipe inlet pressure is to be
controlled at 0.53MPa,the flow of each flushing pipe is to be controlled at
150t／h, and make auxiliary motor to turn at low speed.
2.3.4.6 During the flushing period, check all drain pipes at lower APH are
unblocked.
2.3.4.7 After heating surface is flushed and clean, stop flushing pump, close all
water inlet valves, after all remaining water are drained out, close drain
valves.
2.3.4.8 While entering APH for inspection and cleaning, do stop APH operation
and cut off power, take safety precautions; otherwise, it is forbidden for
personnel to enter.
2.3.4.9 Before put APH into operation again, APH rotor and heat transfer
elements shall be dry.
2.3.5 Disposal to APH failure
2.3.5.1 Main motor is overcurrent.
A. Reasons
a. Motor is overload or there is failure of drive device.
b. Seal is over tight or rotor is bend and blocked.
c. Foreign matters enter APH and block it.
d. Pilot bearing or supporting bearing is damaged.
e. APH is on fire.
B. Disposal methods
a. Check preheater each part, find out cause and resolute it.
b. If current is too large and motor is too hot, stop the operation of APH, close
APH flue gas inlet damper, contact chief watcher and center control leader,
decrease load to be below 180MW, contact maintenance department to
dispose it.
c. It main motor trip, check APH auxiliary motor to if it is automatically opening,

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
if it is not able to do that, personnel shall manually turn APH in the mean
time check corresponding flue gas inlet damper, secondary air outlet
damper and primary inlet damper are automatically closed.
2.3.5.2 APH secondary combustion
A. Phenomenon
a. Flue gas temperature and air temperature at APH outlet are abnormally rising.
b. APH main motor’s current is increasing and swaying.
c. APH inlet/outlet flue gas differential pressure is increasing.
B. Reasons
a. The APH is in low load operation for a long time, burning is incomplete, part
fuel accumulated on heating surface.
b. APH soot blower is in failure and it hasn’t been soot blown for a long time, or
soot blowing effect is not good.
c. During the starting period, oil gun atomization is not good, oil drops
accumulated on heating surface.
C. Disposal methods
a. Immediately put APH soot blowing into operation.
b. Maintain preheater operating, observe air and flue temperature.
c. If above disposal methods are not effective, discharged flue gas temperature
is continuously abnormal rising, report to chief watcher and center control
leader to emergently shut down boiler, stop ID/FD fan operation, close all flue
gas dampers, put auxiliary motor at failure side into operation, open all drain
valves, put flushing device to extinguish fire, if flushing pump cannot start,
immediately contact fire-fighting pump, feed fire water into flushing system to
extinguish fire.
d. Confirm fire in APH is extinguished, stop soot blowing and fire-fighting device,
close flushing valve, close all drain valves after draining our all remaining
water.
e. Entirely check the damage situation of rotor and sealing device, if there is any
damage, it’s forbidden to restart APH, it can be only restarted when it is
normal after the resolution from maintenance personnel.
2.3.5.3 APH rotor is stopping running
A. Phenomenon
a. APH rotor is stopping running, discharged flue gas temperature is abnormally
rising.
b. Annunciator is lighting.

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
c. Ammeter of preheater main motor is at zero.

B. Reasons
a. Main and auxiliary motor are in failure or power lost.
b. Drive device or bearing is damaged.
c. Rotating and stationary part is blocked so that motor is over load.
C. Disposal method
a. During the boiler operation, single preheater trip, and the current is normal
without obvious sway before tripping, pull down the auxiliary motor interlock
switch, stop operation of auxiliary motor and restart main motor, if reclose
switch is unsuccessful, immediately reset switch, close preheater inlet flue gas
damper at failure side in the mean time close APH secondary air outlet damper,
primary air inlet/outlet damper, decrease load to be below 60％MCR, and start
auxiliary motor and turning gear, pay attention to the change of discharged flue
gas temperature to avoid second combustion.
b. After rotor is stopped running, if sealing pieces are blocked caused by heat
expansion, it is forbidden to use motor to continuously turn rotor, following
procedures shall be adopted:
1) Stop 15s at every 5s starting, repeat this procedure for several minutes to make
uniform expansion at each part of rotor.
2) If above method is non-effective or unsuccessful, cut off motor power and
manually turn gear, in order to prevent motor and speed-reducing box from
damage, only one person is allowed to operate the handle for turning gear.
3) Rotor can turn freely, immediately start motor to make APH in operation, at the
same time put preheater soot blowing until heating surface is clean.
4) If APH cannot run because of failure of speed-reducing box lube oil device or
bearing, stop APH operation, close its inlet/outlet air and flue damper, report
chief watcher and center control leader and inform maintenance personnel to
dispose it.
5) If FD/ID fan is stopped running, immediately close tripping APH inlet flue gas
damper, isolate primary and secondary air and manually turning gear until APH
inlet flue gas temperature is decreased to 150℃.
2.4 Operation of drum local water level
2.4.1 Operation of water level at boiler cold status.
2.4.1.1 Complete the operation stated in general inspection rules before starting
2.4.1.2 Open and start the primary and secondary valves at water level steam
side.

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HPGC : 2 x 300 MW
Maintenance Manual
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2.4.1.3 Open and start the primary and secondary valves at water level water
side.
2.4.1.4 Close drain valves.
2.4.2 Inspection to cold boiler water level
2.4.2.1 Cold boiler water is actionless, do ensure the level of water level gauge is
real or not.
2.4.2.2 Check level inside local water level and it shall have obvious interface,
double-color water level’s water side is green while steam side is red.
2.4.2.3 The method of defining water level is slightly open drain valve to drain
water, when there is water flowing inside water level and water flowing out
of drain pipe, close the valve, and then water level returns original position,
if there is no water flowing inside water level or no water flowing inside
drain pipe, check the cause, avoid the inaccuracy of water level caused by
blocking of connecting pipes or drain pipes.
2.4.3 Put drum local water level into use when it is at hot status
2.4.3.1 Confirm that water level maintenance work is complete, work permission
ticket is complete, equipment is complete, and lighting is enough.
2.4.3.2 Check water level steam side and water side primary and secondary
valves are at closing position, drain valve is at opening position.
2.4.3.3 Open steam side and water side primary valve.
2.4.3.4 Slightly open steam side secondary valve, warm pipe for 15min.
2.4.3.5 Slightly open water side secondary valve, close drain valve, there shall be
water level appearing in level gauge with slight fluctuating, water level is
clear and visible.
2.4.3.6 Alternately open steam side and water side secondary valve.
2.4.3.7 After put it into operation, proof it with the level gauge operating at other
side.
2.4.4 Operation of local water level
2.4.5.1 During the normal operation period, water level gauge shall be within the
range of visible water level and have slightly fluctuating.
2.4.5.2 During the operation of water level, drain valve shall be closed tightly,
there shall be no steam leaking situation on level gauge and other
connecting pipes.
2.4.5.3 The water level gauge shall be clear during operating period, there is
obvious division between water and steam, if water level is found blurry or
water level is actionless, flush the water level in time.

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HPGC : 2 x 300 MW
Maintenance Manual
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2.4.5.4 Water level flushing shall comply with safety regulations, working
personnel don’t face to water level, they shall wear gloves and operate
slowly, the method is as following:
A. After closing steam and water side secondary valve, restart half circle.
B. Open drain valve, flush with steam and water to water level and steam
water connecting pipes.
C. Close water side secondary valve, flush steam side connecting pipe and
water level.
D. Slightly open water side secondary valve, close steam side secondary
valve, flush water side connecting pipe and water level.
E. Slightly open steam side secondary valve, close drain valve.
F. Alternately open steam water side secondary valve, after water level is
restored to operation, check water level indication of level gauge and this
indication is identical with the level indication of operating one at other side,
if water level indication is abnormal or still not clear, flush it again.
2.4.5.5 While carrying out flushing or putting water level into use at hot status, pay
attention to it, pipe warm-up shall be enough, there shall be no large heat
impact to water level, when check and flush it, stand at the side of water
level and notice retreat so as to not scald or personnel hurt caused by
explosion of water level.
2.4.5 Water level indicator disconnection
Close steam and water side secondary valve.
2.4.5.6 Close steam and water side primary valve.
2.4.5.7 Open drain valve.
2.5 Operation of periodic blowdown tank
2.5.1 Operation of periodic blowdown tank
2.5.5.2 Close periodic blowdown tank drain valve.
2.5.5.3 Open the isolation valve before and after periodic blowdown tank feed
water regulating valve, regulating valve is at regulation status.
2.5.5.4 Few amount of steam emit from steam extraction pipe after putting
periodic blowdown tank into operation.
2.5.5.5 Periodically check it during the operation of periodic blowdown tank, its
operation pressure is about 0.01MPa, if the pressure is high, turn down
blowdown amount or drain to regulate it.

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HPGC : 2 x 300 MW
Maintenance Manual
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2.5.5.6 Stop periodic blowdown tank

2.5.5.7 Close each pipeline drain source that is going to periodic blowdown tank.
2.5.5.8 Close the isolation valve and regulating valve before and after feed water
valve of periodic drain tank.
2.5.5.9 Open periodic drain tank drain valve.
2.6 Operation of continuous blowdown
2.6.1 Inspection before put them into operation
2.6.1.1 Complete the operation stated in general inspection rules before
starting (launching) auxiliary equipment and system.
2.6.1.2 Check the opening of continuous blowdown main valve.
2.6.1.3 Check continuous blowdown regulating valve “A” and “B” are closed.
2.6.1.4 Check isolation valve before and after continuous blowdown regulating
valve “A” and “B” is open.
2.6.1.5 Check continuous blowdown to periodic blowdown tank regulating
valve is opened.
2.6.1.6 Check continuous blowdown to the isolation before and after regulating
valve of periodic blowdown tank is opened.
2.6.1.7 Check continuous blowdown tank to deaerator isolation valve is
opened.
2.6.1.8 Check continuous blowdown to deaerator regulating valve is closed.
2.6.1.9 Check continuous blowdown tank drain to periodic blowdown tank
regulating valve is closed.
2.6.1.10 Check continuous blowdown tank drain to isolation valve before
and after periodic blowdown tank regulating valve is opened.
2.6.1.11 Check continuous blowdown tank drain to bypass valve of periodic
blowdown tank is closed.
2.6.2 Put continuous blowdown tank into operation
2.6.2.1 According to chemical requirement, report to chief watcher or center
control leader that put continuous blowdown tank into operation.
2.6.2.2 Slightly open continuous blowdown tank drain bypass valve.
2.6.2.3 Slightly open continuous blowdown regulating valve “A” or “B”, carry out
pipe warm-up to continuous blowdown tank, pay attention to the water
level and temperature change situation of continuous blowdown tank,
close drain bypass valve after completion.

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
2.6.2.4 After enough pipe warming-up, gradually largely open continuous

blowdown regulating valve “A” and “B”, after the water level of continuous
blowdown tank is rising, use continuous blowdown tank drain regulating
valve to control water level.
2.6.2.5 Gradually adequately open continuous blowdown to deaerator regulating
valve.
2.6.2.6 After the water level of continuous blowdown tank is identical with setting
value, put continuous blowdown tank drain regulating valve into automatic.
2.6.2.7 According to chemical requirement, adjust continuous blowdown
regulating valve “A” and “B” to required opening, and close continuous
blowdown to periodic blowdown tank regulating valve.
2.6.2.8 After putting continuous blowdown tank into operation, do overall
inspection.
2.6.3 Quit the operation of continuous blowdown tank
2.6.3.1 Make continuous blowdown tank drain regulating valve quit automatic.
2.6.3.2 Open continuous blowdown to periodic blowdown tank regulating valve.
2.6.3.3 Close continuous blowdown regulating valve.
2.6.3.4 Close continuous blowdown tank to deaerator regulating valve.
2.6.3.5 When the pressure inside continuous blowdown tank is decreased to zero
(gauge pressure), close continuous blowdown tank drain regulating valve
after draining out water from continuous blowdown tank.
2.6.3.6 If continuous blowdown tank need to be maintained after quit, close the
isolation valve before and after continuous blowdown regulating valve “A”
and “B”, close continuous blowdown tank to deaerator isolation valve,
close the isolation valve and bypass valve before and after continuous
blowdown tank drain regulating valve.
2.7 Operation of flame scanner cooling air fan
2.7.1 Inspection before operation
2.7.1.2 The opening and closing of auto-switch damper of flame scanner cooling
air fan is agile without block, damper indication is correct.
2.7.1.3 At least put one set of FD fan into operation.
2.7.2 Start flame scanner cooling air fan
2.7.2.1 Start air fan “A” or “B” on CRT.

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Maintenance Manual
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2.7.2.2 Check flame scanner cooling air fan outlet damper is automatically
switching to operation side.
2.7.2.3 Check the operation of flame scanner cooling air fan is normal, its outlet
air pressure indication is normal, no scanning air and furnace differential
pressure alarm.
2.7.2.4 Switch pre-selection of flame scanner cooling air fan on CRT to operate air
fan, put I & C and electric interlock.
2.7.3 Stop flame scanner cooling air fan
2.7.3.1 Operation of flame scanner cooling air fan shall be maintained when boiler
is in normal operation; when the furnace outlet flue gas temperature is
below 149℃ after boiler shutdown, stop the operation of flame scanner
cooling air fan.
2.7.3.2 Quit I & C and electric interlock of flame scanner cooling air fan.
2.7.3.3 Stop the operation of flame scanner cooling air fan “A” or “B” on CRT,
green light on CD is lighting while red light is extinguishing.
2.7.3.4 Close inlet damper.
2.7.3.5 During the operation of boiler, periodically check flame scanner cooling air
fan, check air fan connecting pipes, flanges and bolts shall be not loosen,
the vibration of air fan and motor shall be within normal range, motor
temperature, bearing temperature and inlet/outlet differential pressure is
normal, air fan inlet filter differential pressure shall be within regulated
range.
2.8 Operation of fuel oil pump
2.8.1 Start and stop fuel oil pump
2.8.1.1 Inspection before starting fuel oil pump
B. There is no friction sound while manually turning shaft.
C. Oil pump inlet strainer is clean, oil discharge valve is closed.
D. Oil level of oil tank is above 2m.
E. Check bearing oil level is normal and oil quality is qualified.
F. Check cooling water is put into operation and it is normal.
2.8.1.2 Start oil pump
A. Check following valves, they are at open position before starting oil pump.
a. Oil outlet valve of #3 and #4 oil tank

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Maintenance Manual
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b. Oil return valve of #3 and #4 oil tank

c. Connecting valve of #3 and #4 oil tank (it is closed while oil tank in single
operation)
d. Oil pump strainer inlet/outlet valve.
e. Isolation valve before and after oil pump outlet recirculation regulating valve.
f. Oil pump’s bearing cooling water inlet valve.
B. Check following valves to be at closing position before starting oil pump
a. Each air blowing valve of oil system pipes
b. Each waste oil discharge valve of oil system pipes
c. Oil pump outlet valve
d. Recirculation valve bypass valve at oil pump outlet
C. Start oil pump
a. Confirm switch of each valve position is correct, inspection is complete, report
chief watcher, center control leader.
b. After pressing starting order, close oil pump start switch, red light is lighting
while green light is extinguished, pay attention to start current, it shall return to
no load current within regulated time, otherwise stop pump immediately, report
to chief watcher and center control leader.
c. After oil pump starting is normal, slowly open oil pump outlet valve till fully open,
check oil pump outlet pressure gauge indication is normal, use oil pump outlet
recirculation regulating valve to regulate oil pump outlet pressure.
d. Adequately open standby oil pump outlet valve.
e. Check oil pump operation situation, vibration and bearing temperature shall be
normal.
f. After completion of operation, record starting time, report starting situation to
chief watcher and center control leader.
2.8.1.3 Stop oil pump
A. Hot standby after stopping oil pump
a. Start standby oil pump and check its operation, it is normal.
b. Pull down the switch of operating oil pump, check that red light is lighting while
green light is extinguished, current is zero.
B. Maintenance after stopping oil pump
a. After receiving the information that pump is stopped, start standby oil pump,
and check that its operation is normal.

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
b. Pull down the switch of operating oil pump, check that red light is lighting while
green light is extinguished, current is zero and rotary speed is decreasing.
c. Close oil pump outlet valve and isolation valve before strainer, open waste oil
valve before and after strainer to discharge oil, after oil discharging is complete,
close waster oil valve.
d. Report to chief watcher, center control leader, contact electric department to
pull down power, take relevant isolation measures as per requirement in work
permission ticket.
2.8.2 Maintenance of oil pump operation

2.8.2.1 Maintain normal operation for oil pump while boiler is in operation.
2.8.2.2 Operate one oil pump and other one is standby, periodically switch two
pumps.
2.8.2.3 Periodic inspection and supervisory during operating period of oil pump
A. oil pump is in normal operation, bearing vibration ＜ 0.006mm, bearing
temperature＜65℃.
B. Motion of oil pump outlet recirculation regulating valve is good, oil pressure is
normal.
C. Bearing oil level is normal, oil quality is qualified, and cooling water is smooth
flowing.
D. No block at oil pump inlet strainer, when strainer inlet/outlet differential
pressure is large, switch oil pump in time and clean strainer.
E. Check each part of oil system, there is no leakage.
2.8.3 Operation maintenance of fuel oil tank
2.8.3.1 During the period of fuel oil normal operation, patrol check it one time
every two hours, the items and contents are as following:
A. Check vent hole and breather valve of fuel oil tank, keep them free, cover
gaging hatch tightly.
B. Check its temperature measuring point, oil level measuring points and welds
between steel plate and piping joints, etc., there shall be no cracks and oil
leakage.
C. Check fuel oil tank inlet/outlet oil valve, bottom drain valve, blowing valve and
lower part of base plate, there shall be no leakage.
2.8.3.2 Drain fuel oil tank every half a year or according to water accumulating
situation inside the tank, drain water until oil is flowing out. According to

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the oil level situation of oil water inside waste oil pool, contact chemical
department to dispose the oil through waste oil treater and then deliver the
filtrated oil into oil tank, maintain low oil level in waste oil pool.
2.8.3.3 Release pressure of oil inlet pipe of oil storage, judge it as per the
pressure on oil inlet pipe; when the pressure is over 0.15MPa, release
pressure.
2.8.3.4 Oil tank temperature shall be not more than 45℃, when the temperature is
reaching 40℃, open oil tank spraying valve in time, decrease temperature
to oil tank.
2.8.3.5 Periodically check oil tank each measuring point’s temperature, oil
high-level and low-level alarm, if any abnormal situation is found, contact
to resolve the defect in time.
2.8.3.6 Proof local oil level with oil level in control room every shift, if abnormal
situation is found, contact to resolve the defect in time.
2.8.4 Disposal to the failure of oil pump
2.8.4.1 Oil pump vibration
A. Reasons
a. Air is in pump.
b. Oil pump inlet strainer is blocked or oil level of oil tank is too low.
c. Bearing is damaged or impeller is not balance.
B. Phenomenon
a. Oil pump vibration is great, operation is unstable.
b. There is abnormal sound in oil pump operation.
C. Disposal
a. If there is air inside pump, exhaust air.
b. When the inlet/outlet strainer differential pressure is large, switch to standby
pump to operate, clean strainer in time.
c. If pump bearing is damaged, switch to standby pump operation, contact
maintenance department to dispose.
2.8.4.2 Oil supply pressure is low
A. Reasons
a. Oil pump outlet recirculation regulating valve is out of order.
b. Oil level of oil tank is too low or oil pump inlet strainer is blocked.
c. Defects exist in oil pump.

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d. Serious leakage of oil system.

B. Disposal
a. If the oil pump outlet recirculation regulating valve is out of order, contact to
maintain and dispose it.
b. If inlet strainer is blocked or defects exist, switch to the operation of standby
pump, clean strainer in time or contact maintenance department to dispose
it.
c. If there is serious leakage in system, immediately report to chief watcher
and center control leader, stop the operation of oil pump and contact
maintenance department to dispose it, restart it after leakage is resolved.
2.8.5 Disposal to abnormal situation of fuel oil tank
If following situations happen to fuel oil tank, report to chief watcher in time and
adopt emergent isolation, take measures to prevent oil flow out:
A. There are cracks on welds of joint pipe or valves and fasteners are
damaged.
B. Abnormal phenomenon such as cracks, leakage, bulge and concave, etc.
appearing on fuel oil tank.
C. Fire broke out that will directly endanger fuel oil tank.
D. Oil is leaking from the joints of fuel oil tank body, oil and water is leaking
from the lower part of base plate.
2.9 Operation of soot blower
2.9.1 Inspection and preparation before operating soot blower
2.9.1.1 Conditions for operating soot blower
A. Boiler operation is normal, burning is stable, and no other great operation.
B. Furnace soot blowing: load is above 50%, primary and secondary steam
temperature is stable.
C. During the period of boiler starting and stopping, especially feed oil for
burning, continuously soot blow APH.
D. Furnace negative pressure is normal, operation of ID/FD fan is stable.
2.9.1.2 Inspection before operating soot blower
B. At cold status, each drain valve shall be at opening position.
C. Instrument compressed air system has been in operation and it is normal, air

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source of pressure-reducing valve control is in operation.

D. Manual isolation valve of each soot blowing steam pipes is at opening
position, electric isolation valve is at closing position, air pressure of
pneumatic regulating valve is normal and reset.
E. I & C instrument remote control device of soot blowing pressure regulating
system and instrument primary valve and alarm device have conditions to be
put into operation.
2.9.1.3 Inspection to soot blower
A. enough lube oil is filled in soot blower bogie gear box and all nozzles.
B. Soot blower body and strike mechanism are complete, engagement between
bogie drive shaft’s two gears and racks is normal without mistake.
C. Each soot blower is at reset status.
D. Soot blower electric operation box has condition to be put into use, supply
power, soot blower local power switch is at “No.”
E. Check the power of soot blowing control panel has been connected, there is
no power failure alarm and soot blower failure alarm on control panel, each
electric valve isolation and pneumatic regulating valve is at “close” status and
“green light” is lighting, each electric drain valve is at “open” status and “red
light” is lighting, T1, T2 and T3 temperature alarm, P1 and P2 low-pressure
alarm light is lighting.
2.9.1.4 Conditions for APH normal steam source switching to auxiliary air source
A. Boiler load＜10％MCR, supply from auxiliary air source
B. Boiler load＞10％MCR, supply from normal steam source.
Auxiliary air source comes from compressed air main pipe.
Normal steam source comes from rear panel outlet header, P=18.86Mpa, T=505℃
2.9.2 Soot blowing operation
2.9.2.1 Put soot blower into operation
A. Centralize automatic
a. When move the switch “status mode selection of soot blowing control system”
to “centralize automatic”, automatic soot blowing can be carried out as per
process to all soot blowers.
b. Press “process reset” button, restore process to origin.
c. According to boiler ash accumulating situation, confirm the groups and rows
to be put into operation, select the groups and series of soot blowers, press
“groups and series confirmed” button.

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d. Press ”process start” button, soot blower automatically blow soot according to
selected groups and series.
B. Centralize manual
a. When move the switch “status mode selection of soot blowing control system”
to “centralize manual”, centralized manual soot blowing can be carried out all
soot blowers.
b. Open body soot blowing electric valve, “red light” is lighting.
c. Open body soot blowing regulating valve.
d. Carry out pipe warm-up and draining to soot blowing pipes until the drain pipe
low temperature alarm on control panel is disappeared and water drained out.
e. Close drain electric valve.
f. Start soot blower that is required to blow.
g. After the completion of soot blowing, sequentially close body soot blowing
electric valve and regulating valve, open drain electric valve.
h. When it is at centralized manual control status, only one set of equipment can
be operated for one time.
C. Manual control at site
a. Move the switch “status mode selection of soot blowing control system” to
“centralize manual”.
b. Open body soot blowing electric valve, “red light” is lighting.
c. Open body soot blowing regulating valve.
d. Pipe warm-up and drain to soot blowing pipes until it shows on the control
panel that drain pipe low-temperature alarm disappear and it drain thoroughly
e. Close drain electric valve.
f. Switch “soot blowing control system mode selection” to the position of
“manual at site”, it is possible to carry out soot blowing to each soot blower at
site.
g. Start soot blowers for the one is required for soot blowing on the soot blower
local control switch.
h. After the completion of soot blowing, sequentially close body soot blowing
electric valve and regulating valve, open drain electric valve.
i. When manually operated it, only two sets of soot blowers are allowed to soot
blow simultaneously.
D. Simulation

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a. Soot blower quit operation

(1) Switch “soot blowing control system mode selection” to the position of
“simulation”, program performs until one simulated soot blower, it will
automatically skip this soot blower and perform next one.
(2) Select control panel of soot blower that is required to simulate.
(3) Press the button “leapfrogging placed in”.
(4) If it is required to confirm whether it is “leapfrogging” or not, press “leapfrogging
verification”, red light is light for the simulated soot blower.
b. Restore the operation of soot blower
(1) When switch “soot blowing control system mode selection” to simulation
position, program performs until one simulated soot blower, it will automatically
skip this soot blower and perform next one.
(2) Select the” control panel” that quit simulating soot blower.
(3) Press the button “leapfrogging reset”.
(4) If it is required to confirm whether it reset of not, press the button “”, the light of
soot blower is not lighting after quit simulation.
2.9.2.2 APH soot blowing
A. APH soot blowing when boiler load is less than 10% MCR.
a. If the time is after boiler light-up, APH soot blowing must be carried out.
b. Check boiler rear panel to APH soot blowing air source to see if they are
completely isolated.
c. 10% MCR light is not lighting on the soot blowing control panel.
d. Check that soot blowing system valves’ status is normal, open compressed
air to APH soot blowing isolation valves.
e. Press the button “restore AHC program”.
f. Press the button “AHC program automatic”.
g. Press the button “AHC program automatically starts”.
B. APH soot blowing when boiler load is more than 10% MCR.
a. After boiler load is more than 10% MCR, 10% MCR light is lighting on soot
blowing control panel.
b. Isolate compressed air soot blowing air source.
c. Check that soot blowing status is normal, take measure to prevent HP
steam source leaking into LP steam air source, and then open rear panel
soot blowing steam source.

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d. Press the button “restore APH program”.

e. Press the button “APH automatic”.
f. Press the button “APH automatically start”.
2.9.2.3 Soot blowing of APH pulse device
A. When boiler load is above and including 180MW, use APH pulse device soot
blowing.
B. Under normal condition, put pulse device into operation once every day, after
put pulse device into operation, stop steam soot blowing device under the
condition that APH inlet/outlet differential pressure, APH outlet flue gas
temperature change is not large.
C. When the air amount is not adequate caused by low boiler load or pulse
device cannot be put into operation caused by failure, perform operation rules
of APH steam soot blowing device during the period of boiler fuel-firing or
mix-firing of oil and coal.
2.9.2.4 Attention of soot blower operation
A. When put soot blower into operation, pay special attention to the change of
main steam temperature, main steam pressure and furnace negative
pressure.
B. If there is no soot blowing steam or compressed air, it is forbidden to put soot
blower into operation to avoid burn out it.
C. Soot blowing procedure. No matter carry out soot blowing by what kind of
method, the sequence shall be:
Firstly soot blow APH, secondly water wall, thirdly horizontal flue gas duct,
and then rear flue gas duct and at last APH (i.e. APH→furnace→horizontal
flue gas duct→rear flue gas duct→APH)
D. When soot blow furnace body, the general sequence shall be from downside
to upsides, i.e. first layer→second layer→third layer→fourth layer→fifth layer,
at each layer, firstly blow front and rear wall and then the two side wall, soot
blow flue gas duct as per the flow direction of flue gas, the sequence is
furnace outlet division panel bottom→rear panel→suspension hanger tubes
and RH finish→drooping pipe and SH finish→LT SH→economizer
E. Symmetrically put furnace soot blower, horizontal flue gas duct soot blower
and rear flue gad duct soot blower into operation.
F. Soot blowing cycle
a. at boiler normal operation, the soot blowing cycle is once every shift. At
middle shift or night shift, soot blowing can be stopped to the part where less

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Maintenance Manual
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ash accumulated, but soot blow large part of APH and flue gas duct, entirely
blow all the soot blowers once every day shift.
b. To the part of boiler heating surface where ash is easily accumulated, or
when coal type become bad (ash content increased), strengthen soot
blowing.
c. After boiler start-up is normal, boiler load is above 50% or before boiler
shutdown, entirely soot blow heating surface once.
d. After boiler light-up, put APH soot blowing continuously until load reaches
10% MCR, after that time, soot blow once at intervals of eight hours.
e. During the period of soot blowing, it is not allowed to open the hold near soot
blower to observe burning situation, when the boiler burning is not stable
and “MFT” or “RB” acts, immediately stop soot blowing work.
2.9.3 Failure disposal of soot blowing system
2.9.3.1 Steam source in failure
A. Phenomenon
a. T1, T2 temperature low-level alarm.
b. P1 pressure low-level alarm
c. P1 high-level alarm
B. Reasons
a. Remaining slag may exist inside soot blowing pipes.
b. Automatic regulation of regulating valve is out of order.
c. Leakage exists in soot blowing pipes.
d. Drain valves are not fully opened or drain is not clear.
C. Disposal
a. Press the button of “program restore/pause”.
b. Check whether the valves of soot blowing system are correct or not, whether
the regulation of soot blowing steam source regulating valve is normal or not.
c. Pressure switch or drain pipe temperature measuring points are complete or
not.
d. Check if there is leakage of soot blowing pipeline.
e. Check if drain valves are closed tightly.
f. After failure is eliminated and soot blowing steam source is normal, press
“alarm clear up”, and then press “program restore/pause”, the soot blowing
will proceed.
2.9.3.2 Soot blower in failure
A. Phenomenon
a. Soot blower motor overload alarms.

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b. Soot blower operation overtime alarms.

c. Soot blower motor overcurrent alarms.
B. Reasons
a. Soot blower drive mechanism is over tight.
b. Soot blower guiding rail is bent.
c. Motor is blocked.
d. Soot blower coupling pin is broken.
C. Disposal
a. Press “program restore/pause”.
b. If soot blower is not automatically quit, press “emergent return”, check if the
failed soot blower is automatically quit or not.
c. Locally check if failed soot blower is automatically quit or not, if it is
automatically quit, reset this relay, after resetting, clear up control panel alarm.
Press “program restore/pause”, soot blowing is proceeding.
d. If failed soot blower is not quit, think of method to manually quit it, after
quitting, reset the relay of this soot blower, and make this soot blower quit
operation status as per soot blower simulation setting program.
e. Press “program restore/pause”, soot blowing is proceeding.
2.9.3.3 Soot blowing power in failure
A. Phenomenon
a. Power indication light of soot blowing control panel is not lighting.
b. Motive power source failure alarm.
c. Left or right side power failure alarm.
B. Reasons
a. Soot blower control power and motive power source haven’t been put into
operation.
b. Fuse wire of control power is burnt out.
c. Fuse wire of motive power source is burnt out.
C. Disposal
a. Inform I & C personnel to check out the cause of power failure and dispose
it.
b. Locally check if soot blower is quit, if not, manually quit by using handle.
2.9.3.4 During the period of soot blower operation, when boiler MFT acts, soot
blower automatically quit operation, soot blowing system shall automatically stop,
otherwise personnel to intervene it for quit.
2.10 Air compressor operation
2.10.1 Start and stop air compressor

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2.10.1.1 Inspection before starting

A. Check maintenance work is complete, get back the work permission ticket,
site is clean, lighting is good.
B. Check pipeline of air compressor, valves are complete, no leakage, electric
system is complete, external of air compressor is complete, motor insulation
is qualified, power is supplied and cooling air duct is clear.
C. Open waste discharge valve at bottom of body oil separator, check if there is
cooling water, if there has, discharging it and then close the valve.
D. Check lube oil level. Oil level shall be above centerline. If oil level is not short,
inform maintenance department to add oil.
E. Open rear cooler bottom drain valve, close this valve after completion of
drainage.
F. Open air storage tank bottom drain valve, close this valve after completion of
drainage. Open rear cooler cooling water inlet/return valve.
G. Open air compressor outlet globe valve, open drain valve of air compressor’s
air extraction pipe and close this valve after drain out.
H. Check if air compressor to air storage tank outlet system valves position is
correct (refers to valve operation card).
I. Working condition of drying device controller is good, display is correct and
clear. Freezing-type dryer is closed after water drain out through bypass drain
valve, isolation valve at front of trap is opened, pipe filter drain valves are
closed.
J. Check each control button and instrument on control panel are complete with
correct position.
a. The handle of two-position manual valve “separator front～separator rear”
is at the position of “separator front”.
b. Operation selection switch “normal—no load” is at the position of “no load”.
c. Switch “ON/OFF～regulating valve control” is at the position of “ON/OFF”.
d. Power indication light (white color) is lighting.
e. Indication light for oil filter, air filer and automatic start/stop is extinguished.
K. Check cooling water and put it into use.
2.10.1.2 Start air compressor
A. After receiving the order from chief watcher, start air compressor, press the
button “start”.
B. After starting it, check air compressor motor turning direction and it shall be
correct (observing from the other end of motor drive end, the turning direction
shall be clockwise), working condition of motor and body rear cooler cooling

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device is normal. Cooling air goes through sound insulation shield.

C. Observe instrument “pressure indication”, it is not less than 1.7bar at
“separator front”.
D. Observe the lube oil level in peep mirror, it is above centerline.
E. Preheat two minutes at “ON/OFF” “no load”.
F. Place control switch at the position of “Normal”, ”Regulating valve”.
G. Place indicating pressure selection switch to “separator-rear”.
H. Check air compressor system and its work is normal, air extraction pressure
raised to 0.6～0.8MPa.
I. Check rear cooler, drying device, oil remover, air storage tank and their work
condition is good.
J. After completion of starting, report to chief reporter and center control leader.
2.10.1.3 Stop air compressor
A. After receiving the order from chief watcher or center control leader about
stopping air compressor, place the operation selection position “normal～no
load” of the air compressor which is to be stopped to “no load”, place
“ON/OFF regulating valve control” to the position of “ON/OFF”.
B. Operate under no load for two minutes.
C. Press stop button; check the operation of air compressor is stopped.
D. Close air compressor outlet globe valve, open air compressor air extraction
pipe drain valve.
E. The operation is complete, report to chief watcher and center control leader.
2.10.1.4 Normal operation and maintenance of instrumental air compressor
A. Check air compressor oil level is normal, if oil amount is short, add oil in time.
B. Check air compressor oil quality is qualified, if the oil goes bad, contact
maintenance department to change oil or change another air compressor.
C. Check exhausted air temperature is normal (generally it is about 90℃).
D. Check exhausted air pressure is normally between 0.6 MPa and 0.8MPa.
E. Check if oil filter and air filter indicating light is lighting, if light is lighting and
alarming, contact in time to maintain it.
F. Check that the air compressor has no abnormal sound during operation.
G. Drain each drain valve of air system once every two hours.
H. Check that cooling water flow is normal.

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2.10.2 Failure disposal

2.10.2.1 Instrumental air pressure is low
A. Phenomenon
a. Center control instrumental air pressure is low and alarming.
b. Air compressor separator rear pressure gauge shows that pressure is low.
c. Instrumental compressed air pipe pressure instrument shows that pressure
is low.
B. Reasons
a. Leakage exists at air compressed system pipes.
b. Filter, cooler or dryer is blocked.
c. Air compressor is in failure.
C. Disposal
a. Start standby air compressor
b. Check whether air extraction pressure in low-pressure system is correct or
not, if air compressor in failure causes low system pressure, stop that
broken compressor after standby air compressor is in normal operation,
contact maintenance department to dispose it.
c. Check if the system is leaking; if it is because of system leaking, isolate
leaking points and contact maintenance department to dispose it.
d. Check whether filter, cooler and dryer inlet/outlet differential pressure is
normal or not; if the differential pressure is large, open bypass valve, close
its inlet/outlet valve.
2.10.2.2 Air compressor exhausted air temperature is high
A. Phenomenon
a. Thermometer of air compressor exhausted air shows temperature is high.
b. Air compressor outlet pipe is very hot.
B. Reasons
a. Lube oil is dirty or oil level is low.
b. Air compressor cooling water amount is short or fan motor is in failure.
c. Temperature controller is in failure.
d. Air compressor ambient temperature is high.
C. Disposal
a. Start standby air compressor. Stop the broken instrumental air compressor after

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instrumental air pressure is normal.

b. If the standby air compressor cannot be started, open #3 or #4 instrumental air
connecting valve under normal condition, and after keep #3 or #4 instrumental
air pressure is normal, stop broken air compressor.
c. Check cooling water flow, it is normal.
2.11 Operation and maintenance of ESP ash handling system
2.11.1 ESP start-up
Before starting ESP, confirm there is no person inside ESP, all the manholes are
closed, no one in the field of high voltage, and HV isolation switch is on the
operation gear.
Start heating device four to eight hours in advance, heat porcelain bushing,
supporting insulator and electric porcelain rotary shaft of insulator cubicle, avoid
dew and creepage breakdown.
Put hopper heating equipment into operation to remove the moisture on hopper
inner wall.
Start rapping device of ESP dust collecting pole and discharge pole to remove the
dust absorbed on the pole.
Start main fan to preheat and dry pole system in the electric field.
Open earthing device, put HV power.
2.11.2 Operation and inspection to ESP
2.11.2.1 After putting the ESP which is newly installed or after overhaul into
operation, carry out characteristic test under load, raise pressure point by point,
record primary/secondary voltage, current and angle of current flow until flashover
appears, make out voltage current characteristic curve and according to it to define
best parameter, and adjust it operating under best work condition.
During the ESP operation period, supervise instrument and indicating light of each
HV rectifying control cabinet and control station to see if there is any abnormal. In
the operation, record the primary/secondary voltage, current and angle of current
flow once every two hours, carry out twice patrol inspection each shift and make
complete record.
A. Check equipment in LV distribution room, there shall be no such
phenomenon as over heat, color change, scorch smell, abnormal sound or
leakage, etc.
B. Oil color and oil level of rectifying transformer is normal, oil temperature on
the surface of transformer is normal, maximum is not beyond 85℃, silica
gel color doesn’t not change.

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C. Damping resistance is complete without damage, no discharge phenomena.

HV rectifying transformer, HV isolation switch, DC HV leads, connecting
wire and ESP bottom have no obvious discharge phenomena.
D. Temperature inside HV rectifying control cabinet cannot beyond regulated
temperature. If it is over the regulated temperature, start thyristor ventilation
fan.
E. In the operation, it is forbidden to enter inside HV division or open the cover
of HV insulator cubicle for inspection when it is electrified.
F. ESP body, pipe and each manhole are tight without air leakage.
G. Hopper and hopper heating device shall operate normally without the
phenomenon such as blocking ash, leaking ash etc., rotating apparatus
such as rapping device etc. is operating normally without abnormal sound,
vibration and temperature are normal, oil level of speed-reducer is normal
without leakage.
H. Heating device of HV insulator bushing cubicle and temperature are
normal.
I. Lighting for the protective encloser of all movable parts and operation
station must be kept at good status.
J. Add oil to rotating apparatus as per regulated time and keep oil level
normal.
If defects are found in operation, fill record form in time and inform
maintenance personnel. To the serious defects, immediately report the person
in responsibility and make record simultaneously.
2.11.3 ESP shutdown
2.11.3.1 When main equipment is in shutdown, ESP can temporarily shutdown,
place field HV isolation switch to earthing position. After field power is cut, heating
device and rapping mechanism continuously operate until accumulated ash on
pole is cleaned out, then rapping device can stop working. Remove the
accumulated ash in hopper but not remove it completely.
2.11.3.2 When ESP shutdown in a long time because of overhaul and middle range
repair, dispose it as per temporary shutdown, rapping device at least work for four
hours continuously, and then stop heating system. Remove all accumulated ash
inside hopper. Install earthing stick in the field, keep site clean, make complete
shutdown record.
2.11.4 Maintenance of ESP
Main content of normal maintenance for ESP is as following:
A. Clean out accumulated ash on insulation pieces;

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B. Add lube oil to all drive parts once every week;

C. Add sewing machine oil to thyristor cooling air fan once every three months;
D. Timely clean accumulated ash in HV control cabinets and voltage automatic
regulator, check contactor switch, relay coil and contact to see if they are
reliable.
E. Check resistance, heating element once every three months, check
temperature measuring element once every six months.
F. Change drying agent of rectifying transformer absorber once every year, do
oil pressure test to rectifying transformer once every year, its puncture
average value is more than 35kV／2.5mm.
G. Measure ESP earthing resistance once every year (it shall be not more
than 4Ω), the resistance of rectifying transformer working earthing and
electric control device earthing are not more than lΩ;
H. If ESP shutdown period is comparatively long, take measures to prevent
field inner being rust, open rapping mechanism frequently to avoid hammer
and connecting rod be rust and got stuck.
I. Check earthing part of ESP casing, rectifying transformer etc. to ensure no
loosen or serious rust.
2.12 General rules for maintenance of boiler auxiliaries
2.12.1 Motor part
2.12.1.1 Motor current indication is not over regulated value, no abnormal sway of
pointer.
2.12.1.2 Motor bearing oil level is normal, oil quality is qualified, bearing
temperature and vibration is within regulated range.
2.12.1.3 Motor earthing wire is complete, coupling protective encloser is
complete.
2.12.1.4 Motor foundation bolts are firm without loosen.
2.12.1.5 There is no scorch smell at motor air outlet and no water flowing
phenomena inside motor.
2.12.1.6 Motor casing shall be clean without accumulated water.
2.12.1.7 If motor stopping time is beyond regulation, measure insulation before
starting, if it is qualified, it can be started.
2.12.1.8 If abnormal situation is found inside motor, inform electric personnel in
time to dispose it.
2.12.1.9 Including all rotary mechanism, motor vibration shall be not over the

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
value showing in following table:

Rotary circle/mi
3000 1500 1000 Below 750
speed nute
Vibration µm 50 80 100 120
2.12.1.10 Motor shaft drunkenness shall be not more than 2～4mm.
2.12.1.11 HV motor casing temperature is not more than 65℃, LV motor casing
temperature is not more than 60℃, shaft bearing temperature is not over
80℃.
2.12.1.12 In the motor operation, if current is over 10% of regulated value, find
out the cause.
2.12.1.13 Rule for the times of allowable motor start-up: HV motor can be
continuously started twice at cold status at intervals of not less than
5minutes; HV motor can be started once at hot status, under accident
situation, if there is no obvious short circuit or damage to personnel and
equipment, it is possible to increase one time, when carry out dynamic
balance test, starting intervals is: for the motor below 200kW, not less
than half an hour, while for the 200～500kW motor, not less than one to
two hours. While starting HV motor, contact each department, some one
shall stand besides emergency button of motor that is to be started.
2.12.2 Machine part
2.12.2.1 In the operation of ID fan, bearing oil level is normal, cooling water is
flowing smoothly, no foreign matters on bearing, temperature is not
more than rated value, and vibration is within allowable range.
2.12.2.2 In the operation of ID/FD fan, oil inside hydraulic oil tank shall be
maintained clear. oil level is normal, cooling water is flowing smoothly,
no foreign matters on bearing, temperature is not more than rated
value, vibration is within allowable range.
2.12.2.3 Oil circulation of mill gear speed-reducing box is normal, lube oil flow＞
105L／min, oil pressure is normal (＞0.09Mpa), speed-reducing box
bottom bearing temperature is normal (≤75℃, no noise).
2.12.2.4 Oil level indication of motor lube oil tank of mill, ID/FD fan and primary
air fan shall be about 2/3, lube oil pump is stable without noise during
operation.
2.12.2.5 In the operation of PA fan, oil inside bearing box shall be kept clear, oil
level is normal, cooling water is flowing smoothly, no noise of bearing,
temperature is not more than regulated value, and vibration is within
allowable range.

ORIGINATOR：

HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
2.12.2.6 When filter inlet/outlet differential pressure is increasing, switch strainer,

keep oil pressure be normal, contact maintenance department to
dispose it.
2.12.2.7 Cooling water at each part is flowing smoothly, return water
temperature is not over limits.
2.12.2.8 The foundation bolts of each rotary mechanism base and bearing bolts
are complete and firmly fixed.
2.12.2.9 There is neither air, powder and ash leakage at each rotary
mechanism and its inlet/outlet pipe nor vibration, the control rod
connection of each regulating baffle is firm, pins are complete,
servo-motor diverter switch is at electric position.
2.12.2.10 Coupling and protective encloser are complete.
2.12.2.11 Immediately press auxiliary accident button if meet following situations:
A. Equipment is seriously vibrating and it is possible to damage equipment.
B. Bearing is smoking, and bearing temperature is largely over rated
temperature.
C. Motor is on fire, smoking or submerged in water.
D. Other situation that endanger safety of personnel and equipment.
2.13 Periodic work to boiler
2.13.1 Execution of periodic work must be complied with regulated and rules of
relevant operation system.
2.13.2 Execution situation, technical data and abnormal situation for periodic work
shall be detailedly recorded in relevant record notebook; if defects are found, timely
record them in defects register; serious defects shall be reported to related leaders.
2.13.3 Periodic work to boiler refers to “Operation management standard”.

ORIGINATOR：

HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
Annexure
1. Conversion and symbol for common unit
1) Length
1m=100cm=1000cm
1cm=10mm
2) Weight
1ton=1000kg
1kg=1000kg
1g=1000mg
3) Capacity
1m3=1000litre
4) Pressure or liquid column height
1Mpa=10Kpa
1bar=1×105pa
One standard atmospheric pressure: 760mmHg=1.013bar=1ata
One technical atmospheric pressure =1 kilogram force/cm2=1at
1Mpa=10.197at, or, 1at=9.980665Mpa
1at=10mH2O=735.5mmHg
1mmH2O=0.91Pa
1bar=1000mbar
Formula: gauge pressure=absolute pressure- barometric
Negative pressure= barometric- absolute pressure
5) Temperature
T=t(℃)+273.15K
t－in centigrade (℃)
T－absolute temperature （K）
6) Power
1MW=106＝1MW
1MW＝1000KW
7) Heating amount

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
1therm＝1 large calories＝1000 calories, or, 1kal=1000cal

1kcal=4.1828(KJ)
1kj/g=0.24×103kcal·kg=240kcal/kg
8) Several economic indicators
Coal consumption rate B＝B/N while B＝Q1/Qd·η
Standard coal consumption rate b’=B’/N(kg/kw·b)
B’=BQd/7000
Metal consumption rate: weight of consumed metal material for each ton of
evaporation capacity (ton/ton steam)
power consumption rate ： consumed electricity for producing one ton steam
(kilowatt-hour/ton steam)
Metal consumption rate for pulverization: weight of consumed steel ball for making
coal powder by each ton of coal (g/ton coal)
9) Boiler fuel classification is taking volatilization content of coal as standard
It is divided into： Vr>20% bituminous coal；Vr=2~30%
Stone-like coal, gangue: Vr=5~10% anthracite；13< Vr <20% meager coal
2. Saturation water and saturation steam
Enthalpy Enthalpy
Pressure Temperature Pressure temperature
Liquid Steam Liquid Steam
bar ℃ KJ/kg KJ/kg bar ℃ KJ/kg KJ/kg
0.10 45.83 191.84 2580.4 2.0 120.23 504.7 2706.9
0.20 60.09 251.46 2609.6 2.5 127.43 535.4 2714.2
0.35 69.12 289.31 2625.3 3.0 133.54 561.4 2725.5
0.50 81.35 340.57 2646.0 4.0 143.62 604.7 2738.5
0.60 85.95 359.93 2653.6 4.5 147.92 623.2 2743.8
0.70 89.96 376.77 2660.2 5.0 158.84 640.4 2748.5
0.80 93.51 391.72 2660.0 6.0 158.85 670.4 2756.4
0.90 96.71 405.21 2671.1 7.0 164.96 697.1 2762.9
1.0 99.63 417.51 2675.7 8.0 170.42 720.9 2768.4
1.2 104.81 429.36 2683.8 9.0 175.36 742.6 2773.0
1.4 109.32 458.42 2690.8 10.0 179.88 772.6 2777.0
1.6 113.32 475.38 2696.8 11.0 184.06 787.0 2780.4
1.8 116.83 490.70 2702.1 12.0 187.96 798.4 2783.4
13.0 191.60 814.7 2786.0 26.0 226.03 971.7 2801.2
14.0 195.04 830.1 2788.4 28.0 230.04 990.5 2801.7
15.0 198.28 844.7 2790.4 30.0 242.54 1049.8 2801.3
16.0 201.37 858.6 2792.2 35.0 242.54 1049.8 2801.3
17.0 204.30 871.8 2793.8 40.0 250.33 1087.5 2799.4
18.0 207.10 884.6 2795.1 50.0 263.92 1154.6 2792.8
19.0 209.79 896.8 2796.4 60.0 275.56 1213.9 2783.3

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
Enthalpy Enthalpy
Pressure Temperature Pressure temperature
Liquid Steam Liquid Steam
20.0 212.37 908.6 2797.4 70.0 285.80 1267.7 2771.4
22.0 217.24 930.9 2799.1 80.0 294.98 1317.5 2757.5
24.0 221.78 951.9 2800.4 90.0 303.31 3164.2 2741.8
100 318.94 1408.6 2724.4 170 352.26 1691.6 2550.8
110 318.04 1451.2 2705.4 180 356.96 1733.4 2514.4
120 324.64 492.6 2684.8 190 361.44 1778.2 2470.1
130 330.81 1533.0 2662.4 200 365.7 1828.8 2413.8
140 336.63 1572.8 2638.3 210 369.79 1892.2 2340.2
150 342.12 1612.6 2611.6 220 373.68 2007.7 2192.5
160 347.32 1651.5 2582.7
Note：a. 1bar=0.1Mpa
b. critical pressure 2255bat=221.20bar
c. critical temperature is 3.12℃
3. List of symbol and unit used in operation and maintenance manual
Unit
Designation Symbol Remarks
In Chinese In English
Absolute
Pressure P表兆帕 Mpa
pressure
Flow D 吨/时 t/h
Flow D 米 3/时 m 3/h
Flow D 米 3/秒 m 3/s
Centigrade
Temperature t 度 ℃ temperature
standard
Vacuum H 兆帕 Mpa
Consumption rate q 千焦耳/千瓦时 KJ/Kwh
Steam
d 千克/千瓦时 Kg/kwh
consumption rate
Steam extraction
D 千克/时 Kg/h
amount
Temperature rise
(decreasing) 度/分 ℃/min
speed
Rotor position
（differential 毫米 mm
expansion）
Rounds per minute N 转/分 r/min
Vibration value 毫米 mm
Length (height) L(A) 米 m
Area F 米2 m2
Capacity V 米3 m3
Oil level of oil tank H 毫米 mm

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Maintenance Manual
TPP, Yamunanagar
Unit
suction lift H 米 m
Head ΔH 米 m
net positive suction
H 米 m
head(NPSH)
water flowing drag ΔP 米水柱 mH2O
Weight W 吨 t
Diameter O 毫米 mm
Hardness YD 摩尔/升 ml/L
Hardness YD 微摩尔/升 µl/l
Alkalinity JD 毫克当量/升 me/L
Alkalinity JD 微克当量/升 µe/L
Acidity SD 毫克当量/升 me/L
Acidity SD 微克当量/升 µe/L
Silicon SiO2 毫克/升 mg/L
Silicon SiO2 微克/升 µg/L
Sodium Na 微克/升 µg/L
Copper Cµ 微克/升 µg/L
4. Start-up Curves

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
Pressure MPa
Cold Start-up Curve

Temperature ℃
load
18 600 Main steam pressure MW %
Main and reheat steam (17.4MPa)
temperature (541℃)
300MW
15 500 300 100
Rotate speed (rpm)

Main steam temperature
12 400 240 80
320℃ Reheat steam

3000rpm temperature
9 300 3000 180 60
Unit power (1MW/min)

Rotate speed
2000rpm
237℃ 2000 120
6 200 40
5.88MPa
3.45MPa
1000
3 100 1200rpm 60 20
10%
500rpm 3%
0 0 0 0
0 1 2 3 4 5 6 7 8 9 10 11 Time (h)
Rotor initial running (speed

raising rate100rpm/min) Synchronization Unit full load (11h)
Boiler light-up
Note: turbine start mode is HP/IP turbine combined start.

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
Warm Start-up Curve

Temperature ℃
Pressure MPa
Load
18 600 Main steam pressure MW %

(17.4MPa)
Main and reheat steam
300MW
15 500 Main steam temperature 300 100
Rotate speed
410℃
12 400 240 80
(rpm)
Reheat steam
temperature
327℃
3000rpm
9 300 3000 180 60
7.84MPa
Unit power
(3MW/min)
6 200 2000 120 40
Rotate speed
3 100 1000 60 20
500rpm 10%
3%
0 0 0 0
0 1 2 3 4 Time (h)
Synchronization
Light-up Rotor initial running (speed
raising rate 150rpm/min) Unit full load

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
Hot Start-up Curve

Pressure MPa
Temperature℃
Load
Main steam MW %
18 600
Main and reheat steam pressure (17.4MPa)
Main steam
temperature
300MW
15 500 300 100
speed
450℃
417℃
Reheat steam
12 400 240 80
temperature
Rotate
(rpm)
9.81MPa
300 3000 180 60

9
3000rpm
6 200 2000 120 40

Rotate speed
3 100 1000 60 20
500rpm
3%
0 0 0 0
0 0.5 1 1.5 2 Time (h)
Rotor initial running (speed

raising rate 200rpm/min) Synchronization Unit full load
Light-up

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HPGC : 2 x 300 MW
Maintenance Manual
TPP, Yamunanagar
Very Hot Start-up Curve

Pressure MPa
Temperature℃
Load
Main steam pressure MW %
18 600
Main steam (17.4MPa)
temperature Main and reheat steam
510℃
300MW
15 500 300 100
Rotate speed (rpm)

487℃ Reheat steam
temperature
12 400 240 80
11.76MPa
9 300 3000 180 60

3000rpm

6 200 2000 120 40
Rotate speed
3 100 1000 60 20
500rpm
3%
0 0 0 0
0 0.5 1 1.5 Time (h)
Synchronization
Rotor initial running
(speed raising
rate300rpm/min) Unit full load

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HARYANA POWER GENERATION

DESIGN PRIVATE LIMITED

CENTRAL ELECTRICITY AUTHORITY

DCR Thermal Power Project

RELIANCE ENERGY LIMITED

DEVELOPMENT CONSULTANTS PRIVATE

SHANGHAI ELECTRIC (GROUP)

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DOCUMENT CONTROL SHEET

PROJECT:DCR THERMAL POWER PROJECT

CLIENT: RELIANCE ENERGY LIMITED/ SHANGHAI ELECTRIC (GROUP) CORPORATION

DOCUMENT TITLE: Boiler Operation and Maintenance Manual

PREP. BY REVW. BY APPD BY

HUBEI FIRST ELECTRIC POWER CONSTRUCTION ENGINEERING COMPANY

DOCUMENT NO: SC-YW-01 Page：1

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Chapter 1 Boiler Operation and Maintenance ··············································1

Chapter 2 Boiler start-up·············································································13

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5. Boiler Hot Start-up............................................................................................ 26

Chapter 3 Boiler Normal Operation and Maintenance ·······························35

Chapter 4 Boiler Unit Shutdown ·································································45

Chapter 5 Preservation and Freeze-proof After Boiler Shutdown ··············54

Chapter 6 Start, Stop and Operation Maintenance of·································57

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and System ........................................................................................................... 58

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Chapter 1 Boiler Operation and Maintenance

1. Boiler Equipment regulation and features

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1.2 Boiler design standard

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Water wall surface even heat load EPRS (BMCR): 0.159MW/m2

SH steam flow t/h 1025 926.6

Superheater outlet steam MPa(g) 17.50 17.34

Reheater steam flow t/h 823 753.3

Reheater inlet steam pressure MPa(g) 3.74 3.43

Reheater outlet steam pressure MPa(g) 3.56 3.29

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1.4.2 Information for fuel

Designed types Checked types of

High heat value ar (Qnet.ar) kcal/kg 4000 3150

Industrial analysis (weight %)

Volatilization ar. (Var) % 30 19.27

Fixing carbon ar (FC ar) % 21 19.73

Carbon content ar (Car) % 41.22 31.88

Hydrogen content ar (Har) % 2.81 2.13

Oxygen content ar (Oar) % 5.90 4.12

Nitrogen content ar (Nar) % 0.71 0.59

Sulfur content ar (Sar) % 0.35 0.28

Grindability index (HGI) 50 50