THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED

B&H Group, PUNE, INDIA SIVAGANGA

PROJECT NO.: PJ 0041

1 SECTION OVERVIEW............................................................................................................................ 1
2 BOILER START UP ................................................................................................................................ 1
2.1 START-UP OF A COLD BOILER.............................................................................................................. 2
2.1.1 WALK DOWN CHECKS ................................................................................................................. 2
2.1.2 SYSTEM LINE UP ........................................................................................................................ 5
2.1.3 FILLING OF WATER IN THE BOILER ............................................................................................. 5
2.1.4 BED MATERIAL FILLING .............................................................................................................. 7
2.1.5 PROCEDURE FOR BOILER LIGHT UP : .......................................................................................... 7
2.1.6 COMPARTMENT TRANSFER .......................................................................................................... 9
2.2 PRESSURE RAISING/LINE CHARGING : ............................................................................................... 10
2.3 COLD PRESSURE RAISING CURVE ...................................................................................................... 11
3 OPERATIONAL CONTROL ...................................................................................................................12
3.1 PROCEDURE FOR SPENT WASH FIRING .............................................................................................. 12
3.2 LOAD OPERATION............................................................................................................................. 14
3.2.1 COMPARTMENTS IN ACTIVE CONDITION ................................................................................... 14
3.2.2 BED MATERIAL MAKEUP............................................................................................................ 15
3.2.3 BED LEVEL CONTROL (BED HEIGHT MEASUREMENT & CONTROL) ............................................... 15
3.2.4 BED ASH ALKALI CONTROL. ...................................................................................................... 16
3.2.5 ADEQUATE BED TEMPERATURE................................................................................................. 16
3.2.6 FUEL AND BED MATERIAL SIEVE ANALYSIS ................................................................................ 17
4 BALANCE OF PLANT START UP (BOILER) ..........................................................................................18
4.1 ASH HANDLING: ............................................................................................................................... 18
4.2 BAG FILTER (Optional): ..................................................................................................................... 18
4.3 DEAERATOR CHARGING: ................................................................................................................... 18
4.4 SCAPH.............................................................................................................................................. 20
4.5 RAPPING SYSTEM ............................................................................................................................. 21
5 WARM / HOT START UP .....................................................................................................................21
5.1 CASE – I (BED TEMPERATURE > 600˙ C)............................................................................................. 21
5.2 CASE – II (BED TEMPERATURE < 600˙ C)............................................................................................ 22
6 BOILER SHUTDOWN ..........................................................................................................................22
6.1 PLANNED SHUT DOWN ...................................................................................................................... 22
6.2 BOILER EMERGENCY TRIP ................................................................................................................. 24
6.3 BOILER PROTECTION AFTER A TRIP................................................................................................... 24
6.4 BOILER SHUTDOWN DURING SUDDEN TUBE FAILURE ......................................................................... 24
7 DO’S AND DONT ‘S .............................................................................................................................25
7.1 DO’S ................................................................................................................................................ 25
7.2 DON’Ts............................................................................................................................................. 25
8 CONTROLS..........................................................................................................................................26
9 TROUBLE SHOOTING CHART .............................................................................................................27
10 WALK DOWN CHECK LIST DURING OPERATION ..............................................................................30
11 BOILER SAFETY ..................................................................................................................................31
11.1 EMERGENCY PROCEDURES ................................................................................................................ 31
12 OPERATIONAL PRECAUTIONS FOR SAFETY......................................................................................33

SECTION C PAGE I
 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

1 SECTION OVERVIEW
This section describes the start-up and shutdown procedures of the boiler.
Note -
• The procedures explained in this section apply for start up of a boiler already
commissioned. Commissioning a new boiler call for several additional requirements, which
are not explained here.
• It is assumed that the boiler operators are fully familiar with the design and construction
feature described in section A.
• It is assumed that operators are trained in operation of similar boilers and have been
licensed to operate boilers by the concerned authorities.
• The owner is encouraged to evolve standard operating procedures (SOP) based on the
framework and recommendations that are explained in the subsections below. The SOPs
have to be well understood by the utility managers and operators for safe and reliable
operation.
OPERATOR’S RESPONSIBILITY
The boiler operator is responsible not only for the smooth operation of the boiler and its related
equipment, but also for the safety of all the personnel involved. The operator must be aware of
any operating conditions affecting the boiler or related equipment. Should be able to recognise
hazardous conditions and to act properly to avoid injury.
Even though operating procedures are normally given for each piece of equipment, a complete
knowledge of all components their design, purpose, limitations and relationship with other
components is must for the operators.
2 BOILER START UP
This chapter describes the boiler start up and shut down procedures as applicable for the
following boiler conditions:
• Start up of a cold boiler
• Start up of a warm / Hot boiler
• Boiler shut down
NOTE
• Procedures explained in this chapter apply for start up of the boiler already commissioned.
Commissioning a new boiler calls for several additional requirements.
• It is assumed that operators are fully familiar with the design and construction features
described in the earlier section.
• It is assumed that Operators are trained in operation of similar type of boilers and have
been licensed to operate boilers by the State Boiler Authority.
• Owner is encouraged to evolve standard operating procedures (SOP) based on the
framework and recommendations that are explained in the subsections below. The SOPs
have to be well understood by operating personnel for safe and reliable operation.

SECTION C PAGE 1
 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

2.1 START-UP OF A COLD BOILER

Boiler start-up can be termed as cold start-up when there is no pressure or when pressure is
less than 2-bar (g) in the steam drum.
In a cold start up, possibilities of some inspection or maintenance works having been done is
presumed. A walk down check is required and the boiler and its auxiliaries are to be prepared
meticulously for a start up from the DCS/PLC of the control room. Before a walk down check
ensure that all work permits have been returned, safety tags are removed and maintenance
permission for boiler start up is available.
2.1.1 WALK DOWN CHECKS
Using powerful torches or low voltage inspection lamps, inspect the furnace, other generating
sections, auxiliaries, flue and air ducting of the boiler and ensure the following:
BOILER
• Furnace, Super heater, evaporator & Economiser area are clear, all maintenance personnel
have been removed and no scaffolding or inspection devices have been left inside.
• Furnace floor, water walls Super heater, evaporator & screen are clean and there is no
evidence of any water drips, slag or any other deposits.
• Steam drum is clean and manholes are closed properly.
• Confirm the furnace wall drain valves are in closed position.
• Verify that all access doors, inspection doors of furnace and wind box are tightly closed.
• Verify that all peepholes have been tightly closed and sealing/ cooling air connections are
intact and the air valves are open.
• Verify that the air duct, windbox, economiser, SCAPH, dust collecting equipment’s and flue
gas ducts are clear and that all maintenance personnel have been withdrawn. Ensure that
the manhole doors closed properly.
• Verify that the safety valves are not gagged.
• Verify that the illuminators of local level gauges are 'ON'. Inlet valves from steam and
waterside is open and their drain valves are closed.
• Confirm that boiler interlocks are checked and working.
ECONOMISER
• Verify the internal is clean and all the manholes are closed with proper sealing.
• Keep the air vent on the outlet header open.
• Ensure that the drain valves of top and bottom headers are kept closed.
STEAM DRUM
• Ensure that the drum vent valves(SD – 001,002) are kept open
• Open the CBD line isolation valve (CBD - 001) and keep close the CBD valve (CBD-004).
• Open the HP dosing line isolation valve (HPD-003).
• Confirm that the isolation valves to the direct level gauges are kept in open position.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Verify that the drains and vents of standpipes provided for level transmitters, indicator &
gauges are closed.
MAINSTEAM LINE
• Open the start-up vent isolation valve (SSH – 008) and the vent control valve (PV – 401)
• MSSV (M – 402) and by-pass valves (SSH – 007) are in close position.
• Check the manual isolation valve of steam line to the 3 way valve of SPW gun is closed.
ID, FD & SA FANS
• Check that the fan inspection doors are closed.
• Ensure that the bearing lubrication is done properly.
• Check that the coupling and guards are installed properly.
• Check that the manual isolation dampers at inlet and outlet of the fan are kept closed.
• Ensure that the control damper actuator is properly fixed to the operating lever and air
supply is open to actuator and I/P Converter.
DEAERATOR
• Confirm the tank is clean and the manholes are closed.
• Close the tank drain valve (DEA- 007).
• Keep the vapour tank vent valve open(DEA – 001,002)
• Keep the chemical dosing valve open ( LPD - 002)
• Confirm the pegging steam valve (HSH – 005) kept closed.
• Confirm the isolation valves to the level gauges are in open position.
• Confirm the isolation valves to the gauges and transmitters are in open position.
• Confirm the isolation valve to the steam to deaerator in close position.
• Fill up the tank with feed water to the operating level.
BOILER FEED WATER PUMPS
• Verify the bearing lubrication is done properly.
• Check that the coupling and guards are installed properly.
• Ensure that the suction strainers are cleaned and secured in its place.
• Check that the manual isolation valves at pump suction, minimum re-circulation and
balancing lines are kept in open position and the discharge valves are close position.
• Check that the cooling water supply is available.
FEEDWATER AND SPRAY WATER LINE
• Select the drum level and feed water flow controllers in manual mode and close the control
valves (LCV 201) also close the bypass valve H - 202.
• Select steam temperature controller TIC 401 in manual mode with 0% output.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Close the manual isolation valves of the spray water control valve (DSH – 003) along with
the bypass valve (DSH – 004).
• Close the manual isolation valves of the economiser inlet temperature spray control valve
(BFW – 005) along with the bypass valve (BFW – 006).
SAMPLE SYSTEM
• All the sample lines isolation valves to be closed. Sample coolers can be taken into service
once the boiler is pressurised.
• Ensure a slight bleeding through the sample line as the boiler is pressurized to 2 bar to
avoid choking of the line and the cooler coil.
COMBUSTOR
• Verify the bubble caps holes are clear without any blockages.
• Verify the wall refractory is intact without any spalling/damage.
• Verify the elevation of bed thermocouples.
• Ensure the combustor supporting structure is free for expansion without any obstruction.
• Confirm the open/closing operation of compartment dampers and keep the dampers in
close position.
• Verify the air duct pressure transmitter/ draft gauge isolation valves are in open position.
SCREW FEEDERS

• Verify the bearing lubrication is done properly.

• Open the slide gate above the feeder and admit the coal to the feeder.
• Confirm the outlet chutes are clear with out any blockages.
• Confirm spreading air for coal is set as required.

SCAPH
• Ensure temp control valve (TCV 302), upstream and down stream isolation valve and
bypass valve (SCA – 004) in HP SCAPH are kept closed.
• Ensure all drain in LP/HP SCAPH steam lines are kept open.
• Ensure Steam traps in condensate return lines are in service.
BAG FILTER (Optional)
• Keep Bag Filter in bypass mode.
• Switch on the ash handling system below the hopper prior to coal firing.
GENERAL
• Ensure that the battery limit valves are open and the inputs are available:
• Instrument air and Service air.
• Availability of sufficient quantity of feed water.
• Power up the feeders at MCC.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Ensure cooling water supply to the various equipment.

• Fuel bunker is filled up with specified Fuel.
• Availability of initial filling and makeup bed material.
• Availability of chemical for feed and boiler water treatment.
• Availability of lubricants for normal operation.
• Ash handling system is ready for normal operation.
2.1.2 SYSTEM LINE UP
PRELIMINARY REQUIREMENTS
• Power supply: Ensure that the power supply is switched 'ON' and available for all the
feeders in MCC and for all panels.
• Operating station - PLC is ensured for readiness and emergency push buttons are released,
if activated.
• As instrument air is necessary for the operation of most of the valves and actuators, charge
the instrument air header, the branch lines and instruments supply lines elsewhere. Root
valves of all Instruments (Pressure gauges, Pressure transmitters, DP transmitters, Level
gauges, etc.,) must be kept open and their drains if any are to be kept closed. They are not
separately listed.
• Ensure that all the field instruments are lined up mechanically / electronically.
2.1.3 FILLING OF WATER IN THE BOILER
Caution:
Filling water temperature should not be more than 380C of the boiler metal temperature and
minimum feed water temperature acceptable is 200C. During filling of a cold boiler, the ambient
temperature should be used as an indicator of the boiler metal temperature. Assuming an
ambient temperature of 40 0C, the maximum temperature of filling water shall be 78 0C.
The boiler shall be filled by normal filling circuit by BFW pump (Top Fill Up).
NORMAL FILLING CIRCUIT (TOP FILL UP)
Before starting filling water, ensure that the following air vents are kept full open.
• Economiser inlet & outlet header vent.
• Steam drum air vent
• Main steam lines vents and start up vent.
PRE - REQUISITES
• Ensure that air vents enlisted above are kept full open.
• Water analysis report for the quantity of water being filled up should be available and
confirm to the specifications.
• Direct Water Level Gauge should be on-line.
• BFW Pump safety interlocks should be tested and taken on line.
• Valve line up of BFW Pump and feed water piping to Steam drum should be checked.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Feed water control valve should be on line & bypass valves tight shut.
• Gate valves should never be throttled. As per requirement, they may be either fully open or
fully closed.
• Gland cooling water for BFW Pump should be available.
• Pressure gauges at pump, Economiser headers, Steam drum & main steam line should be
reliable.
• Motor and electrical system healthiness to be ensured.
• Instrument air supply for feed water control valve should be available.
• Adequate trained manpower should be available.
• Main steam stop valve and bypass of main steam stop valve shall be kept closed.
PROCEDURE
• During water filling, for assurance of correct steam drum water level, post an attendant at
the drum level to monitor the local gauges and to communicate to the control room when
the level of '50 mm below Normal Water Level (NWL - 50% level of steam drum) is
reached.
• Start the BFW pump . Wait untill the pumps attains rated speed.
• Open the BFW pump discharge valve gradually to full open condition.
• Open the feed control valve to 10 to 15 % and ensure water is started flowing into
economiser.
• Feed water control valve shall not be opened more such that the BFW Motor is not
overloaded or The BFW discharge pressure doesn’t fall below the rated operating pressure.
• Water should be filled up at a very slow feed rate to ensure removal of entrapped air from
the pressure parts.
• Economiser Air vents should be closed after ensuring that the entire air in that system has
been released. This is indicated when the water flowing out of the air vent achieves a
constant flow pattern for at least 2 to 3 minutes.
• The steam drum has to be overflowed to fill water in the super-heater coils.
• Wait until the water comes out of each super-heater vent and close the vent after the water
flows out smoothly. Wait until water flows out from main steam line vent. Once water
comes out main steam line vent, the feed control valve shall be closed followed by BFW
Pump discharge valve & finally BFW Pump shall be switched off.
• The steam drum water level has to be brought down to normal water level (NWL = 50 % of
steam drum) after the super-heater coils and headers are filled. Open the intermittent blow
down valve and start draining the water from steam drum.
• Before draining ensure that vents on super-heater and steam drum are opened again after
the BFW Pump is stopped.
• Close the blowdown valve after the steam drum level is normalised.
• The main steam line drain also shall be opened after filling the super-heaters headers and
coils.

SECTION C PAGE 6
 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

2.1.4 BED MATERIAL FILLING

• Bed material which pass 100% through ASTM Sieve No 10 (below 2 mm) shall be used
during cold start-up.
• Bed material size and chemical property must be maintained strictly as per the specification
for smooth start up and efficient operation. It also necessary to confirm the material must
be dry with out moisture.
• Shift the bed material to the feeding platform.
• Start the ID fan as per fan start-up procedure.
• Adjust the furnace pressure to – 2mmWc.
• Start FD fan as per fan start-up procedure.
• Open first and second compartment windbox dampers.
• Open FD fan suction damper or increase the fan speed and maintain the windbox pressure
100 – 125 mmWC.
• Maintain furnace pressure –2 mmWc.
• Note down the windbox pressure of individual compartments.( First & Second)
• Bed material may be filled manually/bed material feeding system through openings provided
on the sidewall wall panels for view port cum bed material filling opening.
• Bed material filling should be done in batches, it should not be in one stretch as it will cause
accumulation of material at the drop point and restrict the fluidisation of bed material at this
location.
• Bed material shall be filled upto 250-300mm heights above the bubble cap top, which is to be
verified physically.
• Prior to confirm the bed height, it is recommended to fluidise the compartments thoroughly to
spread the material uniformly. It may require fluidising the compartments one by one with
higher windbox pressure so as to distribute the bed materials evenly across the combustor.
• On confirming the uniform distribution of bed material, it is a must to study the minimum
fluidisation windbox pressure. Record the minimum fluidisation windbox pressure and airflow
for the start-up compartment, as the same is a guiding parameter during coal firing.
• It is recommended to check the uniform fluidisation visually in entire compartments before
lighting up the burner.
• Keep bed in maximum fluidisation condition for min. 01 hour after getting required bed
height to remove dust from bed material, so that actual bed height could be measured, if
required top up the bed by additional bed material.

2.1.5 PROCEDURE FOR BOILER LIGHT UP :

Start ID fan according to fan start up procedure.

Maintain furnace pressure of – 2 to – 3 mmWC.
Start FD fan according to fan start up procedure.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

Maintain FD outlet pressure of 600 - 700 mmWC either by adjusting the inlet damper opening or
by fan speed.
Open start up compartment air damper and fluidise the bed and ensure the bed is levelled and
no heaping of bed material in compartment.
Find out the minimum fludising wind box pressure at this stage as the same will be required
during coal firing.
Once this activity is completed, stop all fans.
Make boundary wall between the start up compartment and the adjutant compartment by bed
material, so as to avoid shifting of hot material to the second compartment during start up.
For start up the charcoal being used should be uniformly sized to 15 - 25 mm and free from
moisture, Tamarind wood charcoal is preferred.
Considering the start up bed area, charcoal requirement will calculated per start up. This
quantity may vary with the type of charcoal and the fuel, which needs to be established during
boiler commissioning.
The total quantity of charcoal required for light up can be split as 80 : 20 ratio as dry and wet
(diesel mixed).
Start filling the dry charcoal ( i.e. 80% of total weight) uniformly over the bed and ensure that
charcoal are spread 1 ft away from water wall panel.
Diesel mixed charcoal (i.e. 20 % of total weight) can be uniformly spread over dry charcoal.
Now the boiler is ready for light up.
Start ID and FD as fan start up procedure.
Maintain furnace pressure of – 2 to – 3 mmWC.
Ignite charcoal by throwing 15 to 20 nos. of fire torch (Maashal) of appx. 1” X 300 mm long.
Allow charcoal to burn inside furnace.
Observe increase in furnace temperature.
If required combustion air of 100 – 150 mmWC can be provided by operating start up
compartment modulating damper for burning of charcoal.
Once furnace temperature reaches above 100 0C or charcoal completely burns and became red
hot, sudden bed jerking at higher pressure can be given for 15-20 seconds allowing charcoal to
mix uniformly in bed thereby heating the bed material.
After mixing, maintain the windbox pressure to minimum fluidisation pressure by modulating FD
fan speed or the fan suction damper.
Observe increase in bed temperature as well as furnace temperature which will determine for
introducing fuel into compartment.
Note :
During bed jerking take necessary care to taken by closing all the manholes, peepholes etc and
avoid standing in front of these access doors as there is every chance of back firing during the
activity.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

INTRODUCING FUEL TO COMPARTMENT AND STABILISATION

Prior to start the fuel feeder, ensure spreading air of start up compartment are kept at position
adjusted during fuel spread test.
Once the bed temperature is around 450 - 500 Deg C (in any one of the thermocouple), Switch on
the fuel feeder and run at minimum speed.
Care should be taken while admitting fuel inside the bed. Observe the bed and check the fuel
catches fire or not. With out flame in the bed do not continue fuel feeding for prolonged time.
Slowly increase the fuel feeder rpm to feed fuel to the startup compartment when bed temp. is
around 600 Deg.C or is in rising trend.
Once the fuel is admitted to the bed there will be a rapid bed temperature raise and should be
controlled by adjusting the fuel to the combustor and adjusting air flow to the bed.
Monitor the bed temp. raise ,once the bed temp crosses 600 Deg C allow secondary air by
maintaining SA duct pressure as 200 mmWC initially and observe the FEGT.
Bed temp. needs to be stabilized around 900 0C for fuel. Once bed temperature reaches 9000C
for fuel, bed material addition shall be taken up and bed level ( Static Bed) shall be raised from
the existing level to 580 - 600 mm.

2.1.6 COMPARTMENT TRANSFER

Compartment transfer means, activating a static (cold) compartment of the combustor adjacent to
the activated compartment. This is done by admitting the fluidising air to the compartment to be
activated and mixing the cold bed material with hot bed material of the activated / operating
compartment.
Before activating a static compartment, fuel flow shall be increased to the active compartment to
avoid drastic drop in bed temperature of the operating bed during mixing.
Increase the active bed temp around 925 ˙C and increase the airflow sufficient to maintain the
active compartment windbox pressure while opening the bed to be activated
While mixing the cold bed with hot material, the bed temperature starts rising gradually, however
the bed temp of the operating compartment may drop. Mixing shall be continued till the drop of
50˙C in the operating compartment and close the cold compartment damper.
Mixing to be continued, once the active compartment bed temperature increase to 925 ˙C.
Whenever the cold bed temperature rise to 450˙C, start the fuel feeding and stabilise the
compartment with fuel firing.
In case if the temperature of the operating compartment drops below 800˙C, it necessary to raise
the start-up compartment temperature.
After compartment transfer stabilise the active compartments to the required parameters i.e.
bed temperature and wind box pressure.
Caution:
Please note once the fuel firing is initiated there will be a sharp rise in the bed temperature,
should be controlled by mixing the nearby compartment.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

Once the bed is stabilised with fuel firing, further control can be done through manipulating the
fuel feed rate and airflow.
Maintain the drum level during fuel firing.
Boiler pressure to be raised in accordance with boiler cold start up curve.
Start up vent valve should be in full open condition while pressure raising and till the steady flow
of steam from the boiler to protect super heater coils.
Stabilize the boiler parameter on 50% steam load on coal firing, simultaneously charge the
steam line at appropriate parameters, charge the Deaerator, SCAPH and stabilize the turbine on
min load and changing over of boiler power to TG load if applicable as described below.
Slowly raise the bed temp by adjusting feed rate and airflow and maintain bed temp as 980C.
Bag filter can be made online once its required backend end temp. is attained.
2.2 PRESSURE RAISING/LINE CHARGING :
Close the drum vent valve whenever the pressure reaches to 2 kg/cm2 (g).
Do not close the start up vent on the final S.H steam outlet header.
As the pressure increases, carefully watch the pressure parts for free expansion/movements.
Crack open the CBD valve to avoid blockage of CBD pipe holes and sample cooler coil.
Increase the boiler pressure as per the cold start up procedure. To have control on
the pressure raise, rate of firing is to be varied as per the requirement.
During pressure rising, keep the drum level controller in manual mode.
Once the boiler reaches close to the operating pressure make preparation for charging the main
steam piping and other distribution lines viz. opening the drain valves in the steam line. First
open the by-pass valve of the main steam stop valve (MSSV) to warm up the steam line also to
equalise the pressure at the in/out let of the MSSV. When ever the steam line is warm and
condensate is removed. Close the MSSV by-pass valve after the stop valve is opened fully.
Keep the start-up vent valve open till the steady flow of steam is ensured from the end users.
On confirming steady steam flow, switchover the drum level controller in to automatic control
mode.
It is advisable to keep a watch on the performance of the controller whenever it is put in to
automatic control mode at least for one hour. If the steam flow varies more than 20%, it is
advised to keep it in manual mode till steady steam flow is ensured. At this stage it is helpful if
the furnace draft control is taken to auto mode.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

2.3 COLD PRESSURE RAISING CURVE

Pressurising Curve

50.0
44 Kg/cm2
275 256 Deg C
237 min 45.0
250
40.0
225

35.0
200

Pressure (kg/cm2g)
Sat Temp. (deg C)

175 30.0

150 25.0

125
20.0

100
15.0
75
10.0
50

5.0
25

0 0.0
0 50 100 150 200 250
Time in min
Saturated Steam Temperature Drum Pressure

SECTION C PAGE 11
 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

3 OPERATIONAL CONTROL
3.1 PROCEDURE FOR SPENT WASH FIRING
Preliminary Requirements/Preparations for Spent Wash (SPW) firing
• Check and ensure the Spent Wash Spray Gun is inserted inside the gun holder properly.
• Ensure the availability of aspirating/cooling air to the gun barrel.
• Ensure no leakage in the spent wash system.
• Check for Aspirating air connection SPW gun mounting box.
• Check for Hose connections to the Individual guns from the SPW main header .
• Ensure the SPW line tracing is on and the temperature is maintained as required.
• Ensure readiness of rapping system for operation.
• Boiler steam output should be more than 50% load.
• All the SPW Gun isolation valve should be in close position.
• Ensure the bed operating temperature must be >980ºC
• All the compartment must be in service and the bed temperature, height and chemistry are
stabilised as per requirement.
• Maintain the temperature of the feed water at Economiser inlet as per the design limit.
• SCAPH should be in service and the air temperature to be maintained as per the required
limit.
• The bed level to be raised to 400-450 mm before admitting SPW.

SPENT WASH ( SPW) FIRING

• Ensure spent wash concentration is > 55%.
• The heat tracing element should be in service and the SPW temperature should
be maintained a minimum of 80ºC and maximum of 88ºC during operation.
• Start SPW pump and adjust the SPW pump speed to maintain 1 - 1.5 kg/cm2
pressure at outlet of pump.
• Keep the Spent wash in re-circulation mode for 1-2 hours prior to firing.

Admit Spent wash through SPW Gun 1a (Refer fig.1) and adjust the flow slowly to 50-60% of
MCR flow for the individual gun.
Close the shutoff valve on the return line and adjust the pump speed to maintain the Spent
Wash pressure at the gun inlet @ 0.5 -0.75kg/ cm2 initially.
Adjust the SA pressure at Bottom & Top Elevation and maintain the SA duct pressure around
350-400mmWc (to be adjusted as per requirement).
Maintain the bed temperature around 980 – 10200C by adjusting air flow and coal feed rate as
required.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

Open the SPW Gun 1b ( Refer fig.1 ) isolation valve slowly to admit 50-60% MCR flow for
individual gun.
Observe the spray pattern on to the bed , adjust the gun position to avoid direct spill over the
combustor refractory.
Maintain the bed temperature 980 - 1020 0C keep a close watch on the Compartments
Once the spent wash firing is stabilised in one compartment, Spent wash is to be intruded to
the remaining compartments as per the above procedure.
Maintain the Spent Wash pump outlet pressure 1 - 1.5 kg/cm2, prior to take the next gun in
service by regulating the pump speed.
After taking individual spent wash gun into service the steam purging line isolation
valve of the respective gun should be kept in open condition.

FIGURE 1

After stabilising the boiler with Spent wash firing, maintain the bed temperature by regulating
the coal and primary air flow as required.
Adjust the spent wash and coal flow rate as per the steam demand requirement.

Maintain the bed height to the required level by draining the bed ash at regular intervals, if
required fresh bed material to be added to make up the required bed height.
Analyse the drained bed ash for alkali concentration and bulk density so as standardise the bed
draining frequency and addition of fresh bed material.
In case if any variation in steam flow, SPW flow to be varied by keeping the coal feeding
constant.

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PROJECT NO.: PJ 0041

During spent wash firing it is mandatory to run the Rapping system as per the logic, so as to
remove the soot deposits over the heat transfer sections. Raping on/off frequency to be
decided based on the operating conditions.
Whenever the Spent Wash firing is to be stopped for longer period or during boiler shutdown
the spent wash in the piping to be cleared by circulating fresh water through the system.
Caution :
Compartment bed temperature must be maintained between 980 – 10200C during SPW firing.
Spent Wash temperature must be maintained at 800C.
Frequently check the bed ash condition for bed bulk density.
Bed fluidisation must be verified at regular interval.
In case of any sudden rise in pressure of SPW line, check individual gun for choking and clear
the choking.
Spent wash gun must be cleaned at regular interval.

3.2 LOAD OPERATION

CAUTION:
While loading the boiler care to be taken that the feed and boiler water parameters to be
brought to the recommended limit before increasing the load beyond 50% of the MCR.
To meet the steam flow demand, following parameters are to be maintained to achieve the
desired output;
3.2.1 COMPARTMENTS IN ACTIVE CONDITION
Depending on load requirement compartment can be slumped. Procedure described in section
2.1.6 can be followed for activating a slumped compartment. For slumping a active
compartment following procedure can be followed.
• Reduce the Boiler load.
• Whenever the boiler load reduced b<50% MCR, stop the Spent wash firing.
Adjust the coal feed rate to maintain bed temp around 9500C and operate the
bed with coal alone for 10 to 15min prior to slump the compartment.
• Prior to slump any compartment, drain the bed ash and inspect the bed ash for any traces
of spent wash, if so continue the bed operation till the bed is free from Spent wash.
• Stop the coal feeding of the compartment and continue FD air through compartment till
dropping trend of bed Temp is observed. When the bed temp. drops to 8000C close the
Compartment damper.
• Maintain the air flow for active compartment by adjusting the fan speed or suction damper
opening.
• Intermittent draining of bed ash of slumped compartment (which is accumulated during the
combustion of active bed settling over the Idle bed ) to be done to remove the ash
accumulation.

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PROJECT NO.: PJ 0041

3.2.2 BED MATERIAL MAKEUP

PURPOSE OF BED DRAINING AND MAKEUP
• Rate of bed ash accumulation depends on ash in fuel and size distribution. With higher
percentage of fines in the fuel, ash accumulation in the bed will be less. Coal with very less
percentage of fines contributes for high bed ash accumulation. Apart from sizing, ash content
in the fuel also reflects the ash accumulation levels in the bed.
• Along with fuel stones/shales also enters the furnace which accumulates in the furnace
bottom, and increase the bed bulk density and warrants increase in wind box pressure to
maintain required air flow to the compartment. During higher bed bulk density situations,
bed draining to be done frequently to remove the accumulated stones/shells to maintain the
bed bulk density to the desired limit to avoid de-fluidisation and clinker formation. Also
fresh bed material to be added to maintain the required bed height during bed draining.
• Makeup bed material should be dry and confirm to the specification.
• Make up bed material should be added through the filling port.
• Care must be taken while charging bed material, informs the control room/desk operator to
maintain the furnace draft.
• Bed material filling should be done in batches (@50Kgs/hr); it should not be in one stretch
as it may cause accumulation of material at the drop point and restrict the fluidisation of
bed material at this location.
NOTE:
• Maintain day to day record of charging and draining which will help in stabilisation and for
initialising bed chemistry.
• Static bed level should be 400 - 450mm above bubble cap during boiler full load
operation.
• It is advisable not to use recycled bed material during SPW firing.
• Bed material charging and draining frequency/quantity may vary with the change in fuel
firing, hence draining and charging of fresh bed material can be done according to the
drained bed material density. Hence maintain day to day record of drained bed material
density.

3.2.3 BED LEVEL CONTROL (BED HEIGHT MEASUREMENT & CONTROL)

During boiler operation, portion of ash generated will be accumulated in the bed and should be
drained at regular intervals to maintain required bed level & bed bulk density (1150 Kg/m3) for
effective fluidisation and good combustion to meet the required steam demand.
Pressure drop across the bed will increase with the accumulation of bed ash. This will reflect on
increase in wind box pressure. Gradual increase in wind box pressure (with the same damper
opening) indicates the accumulation of bed ash. Consequently, to increase the quantity of air
flow through the bed, wind box pressure may have to be maintained at higher level at the
expense of high pressure drop. This in turn will increase the power consumption of FD fan.
If the bed height is too low, boiler load cannot be increased to the rated capacity. If the bed ash
is not generated during combustion process due to low ash & fines in fuel being fired, fresh bed
material as per the specification may be added to make up required bed level.

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PROJECT NO.: PJ 0041

Restrict shales/slates and stones entering with Fuel (Coal) before fed to the crusher/bunker.
Adequate arrangement to be made for picking up these foreign particles in the conveying
system suitably.
How low bed level affects performance?
• Elutriation & high unburnt carbon in fly ash.
• Low bed level leads to high bed temperature fluctuations.
• Low bed level leads to high excess air as this is required to keep the bed under controlled
temperatures.
ADEQUATE BED LEVEL WITH DESIRED BED CHEMISTRY
If the load demand is very low and may be for few hours, it is suggested to go for low bed level
operation by reducing the bed level. So as to keep more number off compartments in service.
This will help in avoiding accumulation of ash over the idle bed and cause trouble during
activation.
NOTE:

Bed level should not be less than 350 mm during boiler operation.

During low bed level operation, the bed temperature may be high and possibility of high bed
temperature fluctuation even for small upset in process changes, which is to be taken care
suitably.

While increasing the boiler load it is suggested to increase the bed level to the required level
of around 400 – 450 mm.
During low bed level operation if the boiler trips necessary quick care to be taken to restart the
unit as there is a high possibilities of faster bed cooling and furnace blackout situation may
happen.

3.2.4 BED ASH ALKALI CONTROL.

Bed chemistry needs to be monitored as the fuel bound alkalies like Fe2O3, Na2O, K2O etc may
cause fouling of heat transfer sections and result in low heat pick-up and loss in efficiency.

FOLLOWING ARE THE GUIDELINE FOR THE BED CHEMISTRY CONTROL

1. Regular analysis of bed ash for Fe2O3, Na2O, K2O, Sieve analysis, bulk density etc.
2. Minimise the concentration of fouling alkali constituents by frequent bed draining. Analyse
bed ash for following parameters and decide on draining rate.
♦ Iron Oxide : <4 %
♦ Na2O + K2O : <4%
♦ Bed material agglomerate which is in small egg shape 4 mm:<10%
3.2.5 ADEQUATE BED TEMPERATURE
During Spent wash firing it is utmost important to monitor bed temperature in the range of 980
– 1020 with coal firing. As bed temperature is a function of

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PROJECT NO.: PJ 0041

• Operating load
• No of active compartments
• Bed height
• Bed bulk density
• Bed material chemical composition
• Excess air
• Moisture in fuel.
Bed temperature varies depends on the bed level, quality of fuel & boiler load. Fuel and air
should be adjusted to get the required bed temperatures depends upon the load. Apart from
varying fuel feed rate, air flow and bed level, boiler load also can be controlled by slumping and
activating compartments. While operating with more compartments, for lower load conditions, the
bed temperature may be operated at less than the MCR values. However number off
compartment requirement may be decided in such a way that the bed temperature should not
drop below 980 ˙C for safe / trouble free continuous operation.
Also the bed temperature should be controlled to suit the fuel being fired, as it may leads to
clinker formation if it is exceed.
Along with the rise in boiler load, fuel feed rate with combustion air also increased to maintain the
steam pressure. With the additional fuel firing the bed temperature rise subsequently. During
operation if the required bed level is not maintained, it may leads to high bed temperature
situations and leads to clinker formation. Hence it is a must to maintain proper bed level to control
the bed temperature.
Bed material also plays an important role to maintain this parameter, if the bed material bulk
density is more than the desired limit, it will warrant higher windbox pressure to lift the material.
If sufficient pressure is not available, bed may not fluidise properly and leads to clinker formation.
If the windbox pressure is increased more than the limit, it will erode the inbed coils and may fail
prematurely.
Similarly, if the bed material chemical property is not as per the design recommendations, the bed
temperature may fluctuate during fuel feed upset conditions. If the alumina content in the bed
material is lower than the limit, bed may not retain the heat during interruption in fuel feeding,
also when ever the unit is trips, the bed temperature drops quickly and cause trouble for hot
start-up.
Also if excess air is pumped into the bed, it will cool the bed and warrant additional fuel to
maintain the bed temperature. Hence there should be a balance between the air to fuel ratio
along with the bed height.
Whenever the moisture in the fuel increase, bed temperature drops equally as additional heat
energy is required to evaporate the moisture in the fuel. Similarly, if the moisture is less than the
design value bed temperature increase for the same steam flow conditions.
3.2.6 FUEL AND BED MATERIAL SIEVE ANALYSIS
FUEL:
Quality of fuel plays an important role in the availability and efficiency of the boiler. Hence it is
essential to maintain the fuel as per the design limits.

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PROJECT NO.: PJ 0041

Following are the major factors are to be monitored during operation

♦ Fuel sieve analysis
♦ Fuel moisture
♦ Shales and stones
♦ Alkalis in fuel
♦ GCV
♦ Ash
BED MATERIAL
As explained in the previous chapters, bed material is an important element hence it is
mandatory to maintain the quality of bed material to improve the availability and efficiency of
the boiler.
Following are the major factors are to be monitored during operation
♦ Sieve analysis
♦ Chemical analysis
♦ Bulk density
♦ Shape
♦ Fusion temperature
4 BALANCE OF PLANT START UP (BOILER)
4.1 ASH HANDLING:
Fly ash handling system shall be started one hour prior to coal firing.
4.2 BAG FILTER (Optional):
4.3 DEAERATOR CHARGING:
The procedure for placing the deaerator in service is outlined below:
• It always recommended that the Deaerator have to be taken in line as soon as
the LP steam is made available or at lower loads. It would be easier to control
the parameters and there won't be any hurry in stabilising the system. It is also
recommended to take Deaerator in operation, as the boiler is started and
steaming out, so that the risk of corrosion and pitting will be minimised.
• Open the vent valve at the vapour tank to atmosphere.
• Line up all the instruments on deaerator system.
• Fill the deaerator slowly through the makeup water inlet connection by opening the
deaerator level control valve. Water starts flowing through deaerator to sparger tank and
start overflowing into storage tank. Watch the water level in storage tank through the level
gauges, Ensure that the gauges are indicating the correct water level. Cross check with the
level indication available at control room through the level transmitter LT-101. Stop the
water supply to the deaerator when normal water level has reached.

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PROJECT NO.: PJ 0041

• In the mean time charge the steam up to the pressure control valve to warm up the line
and keep the steam readily available for charging into deaerator. Once, water level has
attained NWL, then slowly admit the steam into deaerator through the pegging steam line.
It will take minutes or one or two hours to heat the water with pegging steam. Whenever
the water temperature reaches 60 to 70 0C, deaerator is ready for charging the steam
through main supply line.
• Open Sparger tank drain valve ( N – 8) and drain sparger tank completely.
• After draining close drain valve of sparger tank.
• Try to maintain a low water level before admitting the steam through the main supply line.
Level may be maintained well above the very low level and below the centreline of the tank.
Due to direct scrubbing of steam with warm or cold water there may be little hammering or
vibration in the storage tank. By keeping the low Water level the quantity of the water in
the storage tank will be less and less steam will be required initially to heat it. Thus
vibration or hammering can be reduced while pressurising the deaerator. Keeping low water
level will have to be done manually watching the level in the direct level gauge and by
maintaining the water intake manually, as the Level Transmitter will be out off its range.
• Start charging the steam gradually by opening the Pressure control valve, water will be
heated up and steam will start coming out of the vent. Whenever the steam vapour start
flows increase the steam flow (slowly) and maintained the pressure as per the desired
value.
• Along with steam, increase water flow simultaneously but gradually. Objective is to maintain
Normal Water Level and to increase deaerator pressure up to the required value. Once
there is considerable rise in temperature, admitting of steam in more quantity will not cause
hammering in the deaerator.
• Water and steam intake should be synchronised so that at no point of time deaerator
pressure shall go beyond the pressure above the desired limit and to vacuum pressure.
More steam flow will lead to increase in deaerator pressure and less steam flow than the
requirement for the water flow will lead to condensing of steam and will result into
reduction in deaerator pressure, even to vacuum pressure.
• As the deaerator pressure increases the water temperature will start increasing. If the water
outflow from deaerator is faster, then the temperature rise will be faster.
• Once the level and pressure are reached the set values the controllers can be put into auto.
Temperature will reach automatically to the operating value.
• Flash steam if any from the boiler system can now be admitted into deaerator.
• The vent valve on the vapour tank can be throttled to optimise the venting steam flow.
• In the event of taking the deaerator into line, if abnormal hammering or vacuum situation is
created, stop admitting the steam and repeat the whole charging process once again.
NOTE:
During charging continuous monitoring of BFP to be done as there are chances of frequent
suction strainer choking.
Normal Operation

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PROJECT NO.: PJ 0041

During the normal operation, although the vent valve (DEA - 001) kept closed, there is a
bypass with a orifice to maintain the vent rate at the minimum for the consistent with efficient
operation of the deaerator. This arrangement prevents accumulation of air and non-
condensable gases in the deaerator. Otherwise it will result in a decreased heating and
incomplete deaeration and known as air blanket resulting from an insufficient vent rate. The
temperature of the deaerated water should always be within 2 or 3 degree of the steam
temperature in the operating space of the deaerator. A wide variation in these temperatures
may be due to air blanketing resulting from an insufficient vent rate. Water temp. not to
exceed designed temperature to avoid FW pump failing to deliver water, due to vaporisation.
Shutting Down.
To close down the deaerator proceed as follows: -
Close the steam inlet valve, steam reducing valve if any.
Open the vent valve and steam drain valves if any.
Close all water inlet valves.
Close the pump supply valve.
If the unit is to be out of service for an appreciable period, drain the storage tank and the
sparger assemblies through the drain connection or the pump supply outlet.

4.4 SCAPH
As soon as steam is made available for SCAPH, steam inlet line to be lined up by keeping TCV –
302 is closed condition, Both upsteam and down stream isolation valve of control valve is to be
kept in open condition. Bypass isolation valve of control valve is to be kept in closed condition.
Condensate return line drain valve ( SCA – 102) is to be kept open and isolation valve in
upstream and down stream of bucket trap should be closed.
Slowly open TCV – 302 and allow steam to SCAPH. Observe TE 302 for air temperature raise at
outlet of SCAPH. Initially condensate may come out from condensate drain line. Ensure steam
coming out of the drain before taking bucket trap ( ST – 001) into service. SCA – 102 can be
closed whenever bucket trap is taken into service.
Closely monitor air temperature rise and simultaneously control valve opening may be varied to
get the desired air temperature.
As soon as LP steam is made available for LP SCAPH, open drain line isolation valve ( SCA –
201) and bucket trap isolation valve is to be kept closed. Charge LP steam line and follow
procedure as described for HP SCAPH.
After LP SCAPH is charged final air temperature can be controlled by putting TCV – 302 in auto
mode which takes input signal from TIC – 302.

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PROJECT NO.: PJ 0041

4.5 RAPPING SYSTEM

PURPOSE:
To clean the ash deposits on the pressure parts located in third pass of the boiler during
operation.

ARRAIGNMENT:
System consisting of number off mechanical hammers, mounted on the common shaft driven
by a geared motor. Separate hammer assembly is provided for Super heater, Evaporator and
Economiser modules.

OPERATION:
Frequency of rapping operation depends on the rate of ash deposit on pressure parts and the
flue gas temperature at Economiser outlet.

During initial start up (clean condition) the frequency of operation will be once in hour and
the run time will be for 3minutes. As the operation period progress with spent wash firing, the
frequency to be increased up to once in 30minuets and run time 3minutes.

Sequence of operation starts from SH section followed with Evaporator and Economiser.

If the Economiser outlet gas temperature increase more than 210ºC, hammering to be
operated continuously for an hour and repeat the cycle at an interval of one hour till the
temperature drops to the required limit.

It is recommended to observe the operation at field once in a shift for any maintenance
requirement.

5 WARM / HOT START UP

5.1 CASE – I (BED TEMPERATURE > 600˙˙ C)
AFTER BOILER TRIPPING IF THE BED TEMPERATURE IS ABOVE 600˙ C OR WITHIN 8 HOURS
OF HOT BOXING UP OF BOILER. FOLLOWING SEQUENCE MAY BE FOLLOWED TO BRING BACK
THE BOILER INTO SERVICE.
• Open the start up vent valve 30%, normalise drum level.
• Close all the Compartments air dampers, Fan suction dampers
• Bring back the fuel feeders to the minimum speed setting.
• Start the ID Fan, FD Fan as per fan start-up procedure.
• Load the ID fan to maintain furnace pressure, load the FD with pressure of 600 mmWC at
the fan outlet respectively.
• Open the windbox damper such that the bed is just bubbling, ensure that fluidisation is
uniform and satisfactory.
• Gradually increase the fuel and airflow, observing the rise in bed temperature.
• Adjust the airflow and fuel flow to stabilise the start up bed temperature.

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PROJECT NO.: PJ 0041

• SPW firing can be started, after stabilising all the compartments with coal firing and the
bed temperature is above 980 deg C only, as per procedure mentioned in previous section.
5.2 CASE – II (BED TEMPERATURE < 600˙˙ C)
AFTER BOILER TRIP IF THE BED TEMPERATURE IS LESS THAN 600˙ C or BOILER BEING OUT
OF SERVICE FOR MORE THAN 8 HOURS, FOLLOWING SEQUENCE MAY BE FOLLOWED TO
BRING BACK THE BOILER INTO SERVICE.
• Open the start up vent valve to 30%, normalise drum level
• Close all the Compartment air dampers, Fan suction dampers and PA fan Compartment
dampers.
• Bring back the fuel feeders to the minimum speed setting.
• Start the ID Fan, FD Fan as per fan start-up procedures. Load the ID fan to maintain
furnace pressure, load the FD with pressure of 600 at the fan outlet.
• If the bed level is too high drain the bed and bring down the bed height to the required
level.
• Check fluidisation of bed, adjust windbox pressure accordingly and if satisfactory start fuel
feeding.
• Observe increase in bed temperatures and other boiler parameters.
• If there is drastically drop in bed temperature, stop fuel feeding.
• Keep bed in minimum fluidisation, dry charcoal can be thrown inside furnace to sustain bed
temperature.
• If bed temperature is stabilised above 450 deg C start fuel feeders at minimum rpm.
• Repeat the cold start-up procedures mentioned earlier and stabilise the boiler with fuel
firing.
NOTE:
• Avoid throwing diesel mixed charcoal in furnace as there are chance of back firing during
this activity
• After boiler is stabilized with coal firing and 50% MCR generation SPW firing can be done as
described in previous section.

6 BOILER SHUTDOWN
Boiler shut down can be of two types:
• Planned Shut Down, where the operator gets advance notice and adequate time to shut
down the boiler in an orderly manner.
• Boiler Trip on interlock protection or emergency shutdown by the Operator.
If the shut down is only for few hours, it is not recommended to cool the bed material.
If the shut down is for few days, it is recommended to cool the bed material.
6.1 PLANNED SHUT DOWN
• Reduce the Boiler load.

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PROJECT NO.: PJ 0041

• Whenever the boiler load reduced b<50% MCR, stop the Spent wash firing. Adjust the coal
feed rate to maintain bed temp around 9500C and operate the bed with coal alone for 10 to
15min prior to slump the compartment.
• Prior to slump any compartment, drain the bed ash and inspect the bed ash for any traces
of spent wash, if so continue the bed operation till the bed is free from Spent wash.
• Once the all inlet isolation valves of guns are closed, stop SPW pumps.
• Flush the SPW line with water( Keep return line shut valve in open condition).
• Bypass the Bag filter whenever backend drops below permissible limits.
• Stop the steam supply to the deaerator.
• Stop phosphate dosing.
• Close the CBD valve.
• Verify the IBD valve is closed.
• Stop the rapping system.
• Close the sample lines.
• Stop the fuel feeders one by one and slump the compartments as per slumping procedure.
• Whenever the load demand reduced below 30%MCR stop the firing, close the main steam
stop valve and open the start up vent valve to maintain at least 10% MCR steam flow.
Continue the bed fluidization and reduce the bed temperature below 300 deg C, whenever
the bed temp. reduced to 300Deg.C and close the startup vent valve.
• Stop the SA fan and close the suction damper
• Stop the FD fan and close the suction damper.
• Stop the ID Fan.
• Maintain normal water level.
• Allow the boiler to cool naturally.
• Whenever the steam drum pressure drops to 2 - kg/cm2 (g), open the steam drum vent and
the start-up vent.
• If the unit is to be shut for a short period, no personnel will be admitted to the boiler. If
the operating personnel need to enter the unit, the boiler, economiser, air heater hoppers,
and the ash collection equipment hoppers of Bag filter must be emptied of any solids and the
enclosure temperature cooled below 50° c.
• All solids must be removed completely from the boiler and the boiler temperature must be
below 50 0C before personal are allowed to enter for maintenance or inspection.
a) Use airflow to fluidise the bed.
b) Start the bed draining system.
• After the bed material flow from the bed drain has stopped, a layer of dead bed material
will remain in the bed.

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PROJECT NO.: PJ 0041

• The bed material temperature must be less than 50° C or less before any attempt to enter
into the boiler. After the unit has cooled to a safe temperature below 50° C, shut the FD, SA
and ID fans, then evacuate the remaining bed material from the furnace.
• Shut down all the auxiliary equipment at this time. This will include the feed water system,
make-up system, bed drain ash removal systems, etc.
6.2 BOILER EMERGENCY TRIP
Boiler may trip either by safety interlock or due to a power failure or by an emergency trip
command by the operator causing the I.D Fan to stop and abruptly stopping the firing.
Under such emergency trip conditions the operator action is -
• Protect the boiler.
• Close the SPW supply of 3 way valve immediately and return line shut off valve to be
opened.Automatically the steam flow will be started.Immidiately close the isolation valve of
steam supply.
• Investigate the cause of trip and if possible to eliminate the cause.
• If the cause is eliminated, restart the boiler.
• If the cause cannot be eliminated immediately, continue the shutdown till the problem is
attended to safe and reliable operation.
6.3 BOILER PROTECTION AFTER A TRIP
• Close main steam stop valve immediately
• Continue to feed the water flow, if the water level requires to be maintained
• Check that fuel feeders are stopped.
6.4 BOILER SHUTDOWN DURING SUDDEN TUBE FAILURE
In case of a sudden tube rupture followed by a severe loss of drum water level, it is advised
immediately to stop the fuel feeders, and also isolate the steam & feed water system. This is to
avoid undue thermal stresses on pressure parts. The drum vent & start up vent have to be
opened whenever the pressure falls to 2kg/cm2 (g). Extent of the damage is to be ascertained
after cooling the boiler completely.
In case of a tube failure and if the water level could be maintained though the fire is not lost, it
is recommended to stop the boiler immediately to avoid major damage to the pressure parts.
The impingement of steam & water from a leaking tube on adjacent tubes can cause additional
failure of tubes. In such cases, the normal planned shutdown procedure is immediately
implemented.

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PROJECT NO.: PJ 0041

7 DO’S AND DONT ‘S

7.1 DO’S
• Maintain all instruments and interlocks in good working condition.
• Maintain the instrument air free from moisture and oily matters and the pressure as
recommended.
• All dampers must be in smooth operating condition.
• Maintain fuel as per the recommendation.
• Use the bed material as per the specification.
• Maintain bed chemistry as per the design limits.
• Maintain feed and boiler water as per the design limits.
• Use proper lubricants as per the manufacturer recommendation.
• Clean all Ash hoppers, feed water and transfer pump suction strainers, spw gun regularly.
• Ensure the proper operation of rapper alternate days.
• Operate the boiler within the recommended operating limits and Maintain proper operation
log sheets regularly.
• Operation & Servicing of individual equipment should be done as per the manufacturer’s
schedule.
• Carry out regular cleaning of Direct water level gauge glass on Feed water tank, Deaerator
and Boiler drum.
• Keep the stand by auxiliaries ready for operation.
• Chemical dosing systems as per recommendation.
• Boiler surroundings and equipment must be properly illuminated.
• Cleared the bed material immediately to make room for emergency.
• Use genuine spares.
7.2 DON’Ts
• Don’t by pass any instruments and safety interlocks.
• Don’t run the Boiler with furnace in pressurized condition.
• Don’t throttle the feed water pump balancing leak off valve while the pump is in operation.
• Don’t operate the furnace wall header drain valves while the Boiler is in operation.
• Don’t leave the furnace door open while the boiler is in operation.
• Do not open the furnace manhole without the permission from control room.
• Do not reuse the drained bed material.
• Do not operate the boiler with clinker.
• Don’t leave the Instrument Control Panel unattended.
• Don’t allow unauthorized persons to operate the boiler and associated equipment.

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PROJECT NO.: PJ 0041

• Avoid continuous operation of boiler at low loads (low back end temperature) to protect
economizer and air preheater corrosion.
• Do not dose chemicals into the boiler in batch wise, they should be done on a continuous
basis.
• Do not slump the in-between compartments, it must be from the last compartment.
• Do not slump the start-up compartment.
8 CONTROLS
FURNACE PRESSURE CONTROL:
• Operate Furnace pressure in auto mode with (–2 to –5) mmWC as set point. Can be
switched over to auto mode after the stabilisation of coal firing in start-up compartment.
During bed activation and slumping control may be taken into manual mode as the air and
gas flow may vary drastically during these operation.
DRUM LEVEL
• During start-up level can be maintained in auto mode with single element control, till the
boiler is connected to steady load. Whenever the steam flow is increased more than 30%
MCR control can be switched over to three-element control mode.
BED TEMP CONTROL
• During normal operation whenever the bed temperature falls below 970 0C and goes above
1020 0C the coal feeder speed can be varied to maintain desired temperature .
SPW PUMP TRIP
• Spentwash Pump to be tripped whenever there is a low drum level and the furnace pressure
being high above 100mmWC.
RETURN VALVE FAIL TO OPEN ON POWER FAILURE
• In case of Power failure the return line valve should open to allow the Spent wash to reach
the day tank.
BAG FILTER BYPASS ON TEMP HIGH, LOW AND O2 ABOVE RECOMMENDED LIMIT
• The bag filter bypass damper to open whenever the inlet gas temperature reaches 175 0C
and O2 level above 8%.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

9 TROUBLE SHOOTING CHART

The following chart is to be used for solving problems arising during operation.

INDICATION PROBABLE PROBABLE REPAIR METHOD &

SOURCE CAUSE PREVENTIVE MEASURES
Unable to • Tube Leak Slight leakage from  Remove boiler from service at
maintain boiler • Hideout pitting or cracking first convenient time.
water of tube or tube seat Hydrostatic test to be done to
concentration leak. locate leak. Repair by welding
or splicing as indicated and as
approved by insurance or
State Inspection. Determine
cause of failure and correct it.
 Operation at normal loads
should put chemical back in
solution.
Sound of steam Tube leak Substantial leak The same as above plus tubes re-
blowing in from tube/tubes. rolling.
furnace or seeing Over-heating as
visible steam from scale or tube
from the stack. seat leakage.
Steam explosion Tube rupture Failure of tube from Remove boiler from the line
in furnace low water, tube immediately. Inspect or determine
followed by blockage or erosion whether tube splicing or wholesale
inability to of exterior metal tube replacement is necessary.
maintain water surface.
level.
High conductivity Solids carry over High boiler water Check for baffle leaks in steam
in the steam or concentrations, drum when out of service, or
high CO2 or NH3 excessive water boiler water contamination. Check
in boiler water level fluctuation of degasified steam sample will
drum baffle leakage indicate if CO2 or NH3 is high
or deposits on
scrubbers
High gas High excess air Improper control Check excess air at furnace boiler
temperature /adjustment of outlet, and correct airflow if
airflow. required

Excessive water Water load or High boiler Correct condition leading to the
level fluctuation control concentrations, problem
conditions extreme load
swings, varying
supply pressure or
control loop
adjustment
Bowed water wall Overheating Internal deposit or Severity of bowing will determine
generating tubes low water. Usually extent of tube replacement.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

INDICATION PROBABLE PROBABLE REPAIR METHOD &

SOURCE CAUSE PREVENTIVE MEASURES
internal deposits Internal scale will call for internal
result in tubes cleaning. If low water is indicated
bowing away from a thorough inspection for drum
the furnace & low damage and tube seat leakage
water /starve must be made. Take steps to
results bowing prevent recurrence or low water
toward the furnace. condition
Tube blisters Localised Internal deposit Repair by re-tubing or welding in
overheating tube section or by heating and
driving back blister depending
upon insurance carrier or State
Inspector’s approval. Clean
internally by turbining or acid
cleaning.
Internal pitting Corrosion Oxygen in Boiler Depth and extent of pitting
sharp edged and water determines need and extent of
covered with tube replacement. Extensive drum
barnacles in drum pitting can be welded but is
or tubes. subject to approval by either the
manufacturer & insurance carrier
or State.
Source of oxygen must be located
and eliminated
Internal loss of Corrosion Overheating Individual inspection will
metal not sharply resulting in determine extent or replacement,
defined and breakdown of internal cleaning and correction of
accompanied by water into H & O2 water conditions are required
black iron oxide Cause is usually
(Fe 3 O4 ) from sludge
letdown or
pluggage.
External pitting Corrosion From corrosive ash  Extent of repair must be
deposit and determined by individual
moisture either inspection. In emergency
from dew point or tubes out of high heat zone
external source can be plugged, being sure
such as leaking they are cut to vent and to
soot blowing tube. prevent differential expansion
with adjacent tubes.
 Proper external cleaning can
prevent out of service
corrosion.
 Locate and eliminate source of
moisture. If dew point is from
in –service corrosion, take

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

INDICATION PROBABLE PROBABLE REPAIR METHOD &

SOURCE CAUSE PREVENTIVE MEASURES
steps to raise metal
temperature

Tube cracking Mechanical Interference with  When accessible and with

stress or a expansion or insurance or State approval,
combination of differential the cracks can be ground out
stress corrosion expansion with and welded, otherwise splice
or tube adjacent parts to in section or replace tube.
variation. give mechanical Locate & eliminate source of
stress or this stress expansion difficulty by
plus corrosion inspection or hot to cold
attack. Vibration expansion measurements.
set up by turbulent  Using tube spacers can stop
gas flow vibration.
characteristics over
tubes.
External metal Erosion Mechanical Where accessible and with
loss. Highly abrasion from soot insurance or State approval pad
polished area blower action. weld or splice in a tube section.
Eliminate channeling of steam
from soot blowers or use tube
shields
External metal Overheating Prolonged or Extent of metal loss will determine
loss. Oxidised fire repeated extent of tube or tube section
scale area. overheating. replacement. Inspection or a
thermocouple installation will
determine cause of overheating

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

10 WALK DOWN CHECK LIST DURING OPERATION

• Check for unusual noises from steam / water leakages.
• Check for unusual traces of water on floor, buck stay or leakage from casing joints.
• Check for SPW spillage around SPW pump/control station.
• Look for valve and gland leakage.
• Discoloration, hot spots and bulging etc. on casing, ducts and hoppers.
• Check for steam and water leaks from connections and fittings to the drum.
• Watch the furnace for any clinker formation. If possible inspect the slogging condition of
furnace walls and super heater coils (if provided) through the observation ports.
• Walk around the furnace exterior and observe for any hot spots or gas leaks.
• Listen for any unusual noise around economiser which may indicate economiser leak (i.e.
hissing noise)
• Inspect penthouse for gas leakages.
• Inspect windbox corners welded joints for any air leakage,
• Inspect all ash hoppers to make sure they are being emptied properly,
• Check around all air/flue ducts for signs of leakage.
• Check position of fan and field dampers.
• Check for any gas leakages from refractory sealing.
• Check for leakages from safety valves at normal operating pressure. Also note the safety
valve blow off and shut off pressure. Check that the drain lines and drip pans are not
plugged.
• Make note of any leaky valves and prepare maintenance schedule to repair them.
• Check to see that proper water level is being shown by the direct water level gauge. Check for
water or steam leaks from ports or drain connections, which will cause a false water level in
the gauge glass. Inspect the glass for discoloration or fouling.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

11 BOILER SAFETY
11.1 EMERGENCY PROCEDURES
LOW WATER LEVEL
CAUSES
• Feedwater control system failure.
• BFP failure
• Tube leak
ACTION
Compare control room indication with gauge glass level. If the water level falls out of sight due
to momentary failure of water supply system, due to negligence of the operator, due to
momentary fluctuations that might occur with extraordinary changes in load, appropriate action
should be taken at once to trip the fuel. Any decision to continue to operate, even if only for a
short time at a reduced rating would have to be made by someone in authority who is
thoroughly familiar with the circumstances that led to the emergency and positively certain that
the water level can be restored immediately without damaging the boiler.
In the absence of such a decision
• Stop the fuel feeders and Fans immediately. Shut off the main steam stop valve .
• Simultaneously, if feedwater has become available and the operator is assured that no
pressure part has been damaged.
• Take the feedwater control system into manual mode.
• Allow the water flow to boiler gradually to normal water level. (Do not hurry up which may
lead to sudden quenching and tube leak) if pressure part damage is suspected.
• Reduce the steam pressure gradually.
• Open the drum air vent when the pressure drops below 2 kg/cm2 .
• Cool the boiler so as to examine the extent of damage.
• Drain the boiler after cooling.
• If any tube rupture and bulging is observed rectify the same.
• If any tube leakage were observed, rectify / repair the leaking tubes and after the repairs
conduct hydro test.
• Determine the cause of low water.
HIGH WATER LEVEL
CAUSES
• Feed water control malfunction.
• Operator error.
• Instrument air supply failure.
• Foaming.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

ACTION
• Take the drum level control loop into manual mode.
• Reduce the water level immediately by operating the intermittent blow down to maintain
the drum level.
• Reduce the steam discharge rate, if necessary.
• Start the stand by compressor if required.
FURNACE PUFFING & BACK FIRING
CAUSES
• Uncontrolled feeding of fuel into the furnace
• Sudden increase in FD fan air
• Tube rupture
ACTION
• Take airflow control system into manual mode and maintain the furnace pressure.
• Never increase fuel / air flow suddenly. Always increase air first then fuel / oil / gas while
taking boiler on load.
• In case of tube failure take the boiler out of service immediately.
• Keep the water wall tubes clean by monitoring the combustion conditions.
BOILER EXPLOSION
CAUSES
• Accumulation of fuel in the furnace due to incomplete combustion.
• Loss of ignition.
• Fuel oil valve leakages.
• Frequent unsuccessful startups.
• In-sufficient purging of furnace.
With the mixture of unburned fuel with air in explosive proportions and the application of heat
sufficient enough to raise the temperature of the mixture to ignition point.
ACTION
• Trip the ID Fan immediately.
• Analyse the reasons for explosion and rectify the system.
• Evacuate or clean the furnace to the possible extend.

CONDITIONS FOR BOILER RESTART AFTER FURNACE EXPLOSION

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B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

After a case of furnace/ boiler explosion, the restart of the boiler has to be carried out only
after a thorough and detailed investigation & understanding of the cause of explosion.
Following necessary actions have to be completed to prevent the repeat incidence of explosion
and before restart of the boiler.
Find out the root cause for the explosion and rectify the same.
• Inspect the furnace for any signs of bulging or damage to the tubes.
• Inspect the furnace refractory for damages.
• Inspect the air and flue ducts for any signs of damage.
• Inspect the expansion bellows in the air and flue ducts for damages.
• Inspect the economizer casing for damages.
• Assess the damage if any and rectify the same.
• Carry out the hydro test of the boiler. In the event of a failure of the hydro test, identify the
tubes that have failed and proceed to rectify the same as explained in the maintenance
section.
12 OPERATIONAL PRECAUTIONS FOR SAFETY
INTRODUCTION
The handling and burning of any fuel is potentially hazardous. Some fuels ignite more readily
than others. Safe handling and operation demands knowledge of the characteristics of the fuel
and careful observance of necessary precautions.
• Operating the boiler with low feed water temperature along with high excess air will result
in exceeding metal temperature. There should be no hesitation to bring down the load on
the boiler if this temperature cannot be brought under control by other means.
• In the case of tube failure which can be identified by hearing the noise in the boiler gallery
and cross checked by difference in steam and water flow, gas and steam temperature, the
boiler should be shut-down at the earliest by regular procedure for maintenance work.
Otherwise large number of tubes may fail due to steam erosion and impingement.
• Boiler washing (when the unit is shut down) can be done effectively by using hot water.
Immediately after washing, the surfaces should be dried.
• Always use deaerated, de-mineralised water for boiler feeding with the recommended feed
water quality.
• Feedwater temperature must also be maintained at the highest level possible either with the
help of drum coil heaters or heating the water in the feed tank. Low feedwater temperature
obtained during low load operation will result in external corrosion of economiser.
• The economiser circulation system if provided should be kept in service when there is fire in
the boiler with no feed flow.
• Steaming in economiser is harmful to economiser unless otherwise it is designed as
steaming type and hence steaming should be prevented by keeping a watch on economiser
outlet water temperature.

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B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Carryover of salts in steam occur either due to mechanical or vapour carry over from steam
drum. Efficient drum internals can only reduce mechanical carry over. Silica is always carried
over in vaporous form. Continuous monitoring of sodium and silica in steam is desirable.
• Before operating a boiler, ensure complete knowledge of water chemistry.
• Whenever boiler is started after a shutdown of more than 3 days, check all safety interlocks
before boiler start up for proper functioning.
• Superheater drain valve should be operated as per recommendations.
• The steam drum should normally be filled upto the point when water is showing in the
bottom part of the gauge glass. This is to allow for the swell on heating and to reduce any
blowing down resulting from this cause to a minimum.
• Firing should be maintained having regard to the instructions for protection of superheater,
which will limit the maximum gas temperature in the superheater zone.
• Once the boiler is boxed up, the water level in the steam drum must be raised to the very
top of the drum. Filling the drum like this will prevent excessive temperature differentials
along the drum wall. The water is then shut-off and the boiler is allowed to cool.
• When starting from cold, the drains on both the inlet and outlet superheater boxes
should be wide open (if applicable)
• While raising pressure on boilers, a technique of continuous firing should be developed if
possible, since intermittent firing may result in recondensation in the tube loops.
• Where spray type attemperator are fitted, it is very important that control of steam or
superheater tube metal temperature is not attempted by the use of the spray during
pressure raising. This can lead to the entry of spray water into the secondary superheater
tube loops.
• Ensure the availability of fuel / bed material / recycle ash in the bunkers
• Never allow SPW to accumulate anywhere, other than in a tank or lines which form a part
of a fuel supply system.
• Purge the furnace completely before introducing any light or spark. On a multiple burner
unit, burners may be ignited without a purge if one or more in service already.
• Have a lighted torch or spark producing device in operation before introducing any fuel into
furnace.
• Maintain a positive airflow through the burners into the furnace and up the stack.
• Maintain adequate oil pressure and temperature for atomisation & also adequate steam or
air pressure in case of steam or air atomisers.
• The raising and lowering of steam parameters should be restricted to the value given in the
starting diagram. Exceeding these values will result in reduced fatigue life of pressure parts.
• Entry of wet steam into superheater and first row or after de-superheaters will result in
removal of oxide film due to thermal shock. Boiler salt in the steam will accelerate
corrosion. Austenitic steel is the worst affected due to stress corrosion in this case. Hence
temperature after the de-superheater should be maintained well above the saturation point
in the case of direct spray type.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Carryover of salts in steam occur either due to mechanical or vapour carryover from steam
drum. Efficient drum internals can only reduce mechanical carry over. Silica is always carried
over in vaporous form. Continuous monitoring of sodium and silica in steam is desirable.
• Before operating a boiler, ensure complete knowledge of water chemistry.
• Whenever boiler is started after a shutdown of more than 3 days, check all safety interlocks
before boiler start up for proper functioning.
PROPER HANDLING OF ACCESS DOOR
• Never open an access door while the unit is operating.
• Any access door can have large amount of material built up behind it even after the bed has
been drained. This material will fall out when the door is opened. Bed material can stay hot
for many days even after boiler shutdown.
• Open the door slowly and always stand to the side of the opening.
• Look at the cavities through the door before entering into the boiler. have sufficiently bright
light available at all times when personnel are in the furnace and or in convection pass.
PROPER HANDLING OF THERMOCOUPLES
• Repair or changing of thermocouple / thermowells during boiler operation is absolutely
prohibited, particularly in the positive pressure zone of the boiler. However if the need
arises, always recall that the furnace is pressurised and that the thermowell may be an
open path to the pressurised furnace. slowly and carefully disconnect the thermocouple
from the well.
• If you encounter resistance in removing the thermocouple, it is an indication that the
thermowell has eroded and is packed with ash and bed material. abort the attempt to
replace the thermocouple and refasten it until the boiler is off the line and cooled.
• If no resistance is encountered then carefully remove the faulty thermocouple and replace
it.
• Never look into the thermowell opening.
HANDLING OF SECONDARY AIR PORTS
• The hand-operated dampers in the secondary air nozzles will be very hot.
• While handling the dampers / ports protective gloves should be worn and enough attention
to be given.
HANDLING OF SOLID PILES
• Always be cautious of piles of bed material.
• The surface of piled material may be cool in the surface while just below the surface still
may be very hot.
• Bed material in a pile can stay hot for several days.
HANDLING OF FURNACE PORTS & OBSERVATION DOORS
• Ports and observation doors are open to the positive pressure in the furnace.
• Never stand directly in front of the ports.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Do not leave the poking rod in the furnace for long. It will heat up quickly making the rod
hot to handle and hazardous when it is removed from port.
• Never look directly into the port or stand directly in front of the open port. If there is a
pressure pulse in the furnace, hot bed material can suddenly and unexpectedly spurt out.
• Never use anything that may burn or melt, such as plastic or rubber, to temporarily blow
the port.
• Properly dispose of all combustible material from the port area. If any hot material blows
out from the boiler it presents a potential fire hazard.
• Be sure aspirating air is on before you open the port door. If the air is not on, a stream of
hot furnace gas, ash and bed media will blow out of the boiler.
• Open the port cap slowly.
• When inserting a probe in the port, stand as far back as you can. Due to pressure some bed
material can blow out.
• When extracting the probe, again stand well back.
• Never leave the port unattended ever for short time while working.
SAFETY PRECAUTIONS
• Do not attempt to open the boiler doors or observation ports without observing the proper
safety procedure.
• Always use a full-face mask with tinted glass.
• Do not stand directly in front of open ports or doors especially when they are opened.
• Use sealing air when opening the doors / observation ports.
• Use ear protection devices, whenever it is necessary.
• Wear protective gloves when working around the boiler.
• Do not use open-ended pipes for rotting observation doors or ports.
• Never enter drums, ducts etc. until all the steam and water valves including the drain and
blow down values have been closed to check and tagged.
• Do not enter a confined space until it has been cooled below 30 °C and property ventilated.
• Completely drain the solids from the bed, hoppers etc. while entering.
• Always use low voltage extension cords and light bulbs with properly connected ground.
• Never open or enter the rotating equipment until it has come to a complete stop and circuit
broken i.e. open
• When entries the furnace ducts etc. be prepared for falling.
• Never step into fly ash or bed material. It can be cold on the surface yet remain hot and
smoulder underneath for extended period of time. Always secure the drive mechanism of
dampers, gates and doors before passing through them.
• Watch for hot water in drum and headers when removing manhole and manhole covers.
• Never use toxic fluids like CTC in confined spaces without adequate ventilation.

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 THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT NO.: PJ 0041

• Never direct an air or water stream into an accumulation of fly ash in a confined area. If the
fly ash is smouldering the situation could result in an explosion.
SAFETY TIPS
• All scaffolding materials are removed and cleaned.
• Check any observation for expansion and dampers operations.
• Ensure that all inspection doors, access doors and openings are closed and pad locked as
required.
• Disconnect and isolate the nitrogen purge if it was used during the outage.
• Open the steam drum vents and the vents.

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