Boiler Operating Rules.pdf

KMPCL
KMPCL
KMPCL
KMPCL 6
6
6
6 x
x
x
x 600
600
600
600 MW
MW
MW
MW Subcritical
Subcritical
Subcritical
Subcritical Coal-fired
Coal-fired
Coal-fired
Coal-fired Power
Power
Power
Power Plant
Plant
Plant
Plant Project
Project
Project
Project
KSK
KSK
KSK
KSK Mahanadi
Mahanadi
Mahanadi
Mahanadi Power
Power
Power
Power Company
Company
Company
Company Limited
Limited
Limited
Limited
6
6
6
6 x
x
x
x 600
600
600
600 MW
MW
MW
MW Thermal
Thermal
Thermal
Thermal Power
Power
Power
Power Project
Project
Project
Project Nariyara,
Nariyara,
Nariyara,
Nariyara, Chhattisgarh,
Chhattisgarh,
Chhattisgarh,
Chhattisgarh, India
India
India
India
S
S
S
SEPCO
EPCO
EPCO
EPCO ELECT
ELECT
ELECT
ELECT IC
IC
IC
IC POWER
POWER
POWER
POWER CONSTRUCTION
CONSTRUCTION
CONSTRUCTION
CONSTRUCTION CORP.
CORP.
CORP.
CORP.
No. Boiler Operating Rules Total 175 pages
Boiler
Boiler
Boiler
Boiler Operating
Operating
Operating
Operating Rules
Rules
Rules
Rules
SEPCOI
Drafted by:
Reviewed by:
Approved by:

1
Content
Content
Content
Content
Part 1 Brief Introduction of Boiler Equipment................................................................................................ 1
Chapter 1 Main Design Features and Specifications of Boiler................................................................1
Chapter 2 Boiler Technical Specifications and Performance Parameters of Main Components............. 5
Chapter 3 Calculated Data Table Of Boiler Thermal Performance..........................................................8
Chapter 4 Induced Draft Fan................................................................................................................. 12
Chapter 5 Forced Draft Fan................................................................................................................... 16
Chapter 6 Primary Air Fan.....................................................................................................................19
Chapter 7 Air Preheater..........................................................................................................................22
Chapter 8 Pulverizing System................................................................................................................23
Chapter 9 Air Heater..............................................................................................................................28
Chapter 10 Air Compressor and Its Dryer............................................................................................. 29
Chapter 11 Boiler Water Circulation Pump........................................................................................... 33
Chapter 12 Flame Check Cooling Fan...................................................................................................34
Chapter 13 Startup Boiler...................................................................................................................... 35
Chapter 14 Soot Blowing System..........................................................................................................37
Part 2 Startup and Shutdown of Boiler.......................................................................................................... 39
Chapter 1 Rules & Conditions of Unit Startup...................................................................................... 39
Chapter 2 Boiler Cold Start................................................................................................................... 41
Chapter 3 Hot Start................................................................................................................................ 52
Chapter 4 Very Hot Start........................................................................................................................53
Chapter 5 Boiler Shutdown....................................................................................................................54
Chapter 6 Normal Shutdown of Boiler..................................................................................................57
Chapter 7 Boiler Cooling.......................................................................................................................58
Chapter 8 Precautions for Boiler Shutdown.......................................................................................... 59
Chapter 9 Boiler Shutdown Preservation...............................................................................................60
Part 3 Operation & Maintenance of Boiler....................................................................................................63
Chapter 1 Operation Adjustment........................................................................................................... 63
Chapter 2 Unit Operation Mode............................................................................................................ 67
Chapter 3 Operation Mode of Boiler Water Circulating Pump System.................................................70
Chapter 4 Operation Mode of Pulverizing System................................................................................ 71
Chapter 5 Monitoring of Parameters in Normal Operation................................................................... 72
Chapter 6 Boiler Periodic Working System Schedule........................................................................... 74
Part 4 Boiler Interlocking Protection and Test...............................................................................................75
Chapter 1 Boiler Interlocking Protection...............................................................................................75
Chapter 2 Boiler Test Procedures...........................................................................................................79
Part 5 Handling of Boiler Unit Trouble......................................................................................................... 87
Chapter 1 Rules for Trouble Handling...................................................................................................87
Chapter 2 Boiler Accident Shutdown.................................................................................................... 89
Chapter 3 Boiler MFT........................................................................................................................... 91
Chapter 4 Loss of Service Power...........................................................................................................92
Chapter 5 Loss of Service Air Supply....................................................................................................93
Chapter 6 Automatic load shedding.......................................................................................................94
Chapter 7 Overfeed of Water into Drum................................................................................................96
Chapter 8 Water Shortage of Drum........................................................................................................97

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Chapter 9 Surge of Forced Draft Fan and Induced Draft Fan................................................................98
Chapter 10 Tripping of Air Preheater.....................................................................................................99
Chapter 11 Leakage of Boiler Heating Surface................................................................................... 100
Chapter 12 Secondary Combustion of Boiler Tail Flue.......................................................................101
Chapter 13 Abnormalities of Steam Parameters.................................................................................. 102
Chapter 14 Unit Load Swinging.......................................................................................................... 104
Chapter 15 Unit Load-rejection........................................................................................................... 105
Chapter 16 Auxiliary Equipment Fault................................................................................................106
Chapter 17 Fire Disaster...................................................................................................................... 110
Chapter 18 DCS Fault..........................................................................................................................112
Chapter 19 Operation Measures for Pulverizing System.....................................................................113
Chapter 20 Anti-accident Measures against Furnace Explosion..........................................................115
Part 6 Startup and Shutdown of Boiler Auxiliary Equipment......................................................................117
Chapter 1 General Rules for Auxiliary Equipment..............................................................................117
Chapter 2 Startup and Shutdown of Air Preheater...............................................................................122
Chapter 3 Startup and Shutdown of Induced Draft Fan.......................................................................125
Chapter 4 Startup and Shutdown of Forced Draft Fan.........................................................................128
Chapter 5 Startup and Shutdown of Primary Air Fan.......................................................................... 131
Chapter 6 Startup and Shutdown of Air Compressor...........................................................................133
Chapter 7 Startup and Shutdown of Fire Check Cooling Fan..............................................................137
Chapter 8 Startup and Shutdown of Fuel Oil System.......................................................................... 138
Chapter 9 Treatment of Fuel Oil System Accidents.............................................................................144
Chapter 10 Startup and Shutdown of Pulverizing System...................................................................147
Chapter 11 Startup and Shutdown of Drum Two-color Water Gauge..................................................151
Chapter 12 Startup and Shutdown of Air Heater................................................................................. 153
Chapter 13 Operation of Boiler Sootblower........................................................................................ 155
Chapter 14 Startup and Shutdown of Boiler Water Circulating Pump.................................................158
Appendix:.................................................................................................................................................... 163

1
Part
Part
Part
Part 1
1
1
1 Brief
Brief
Brief
Brief Introduction
Introduction
Introduction
Introduction of
of
of
of Boiler
Boiler
Boiler
Boiler Equipment
Equipment
Equipment
Equipment
Chapter 1 Main Design Features and Specifications of Boiler
1.1 Model: SG-2069/17.47-M921, manufactured by Shanghai Boiler Works Co., Ltd.
1.2 The boiler is subcritical pressure intermediate primary reheat control circulation boiler with swing type
temperature adjusting, four corners arrangement, tangential firing, positive pressure direct firing
pulverizing system, single furnace, II-type outdoor arrangement, all-steel overhung construction, dry-ash
furnace and balanced ventilation. The furnace is 21,082mm in width and 17,829.5mm in depth, the furnace
roof elevation is 77,300mm, the drum center line elevation is 78,300mm and the furnace roof plate girder
bottom elevation is 85,800mm. The boiler roof adopts metal fully sealed structure and is set with big cover
casing made up of Φ51×6 membrane water wall. The furnace bottom ash hopper is at an angle of 55º, the
furnace bottom sealing is water seal, there are division wall, rear platen and platen reheater arranged on the
upside of furnace and there are wall radiant reheater mounted on the front wall and side walls, the furnace
lower header elevation is 9000mm. The horizontal gas pass is 8548mm in depth, made up of the extension
of water wall and rear flue gas pass and has last stage reheater and last stage superheater arranged inside.
The rear flue gas pass is 13908mm in depth and has low temperature superheater and economizer mounted
inside.
1.3 The furnace has three LP boiler circulating pumps mounted at the front of boiler and two trisector
regenerative Ljungstrom air preheater mounted at the rear with rotor diameter of 14.236m, the rotor rotates
reversely, and the angular degree of primary air division is 50°.
1.4 The boiler adopts positive pressure direct firing pulverizing system equipped with 7 sets of
HP1103DYN type medium speed coal mill, which is amounted at the front of boiler. 6 coal mills are with
MCR load and 1 is for standby. Direct-flow burner is arranged on four corners with tangential firing and the
outlet of each coal mill is connected to one layer pulverized coal spray by 4 pulverized coal piping. The
upper most burner nozzle center line elevation is 37500mm, which is 23000mm away from the bottom of
platen and the lowest burner nozzle center line elevation is 27440mm, which is 5934mm away from the
furnace hopper angle. The burner wind box on each corner has five layers of startup and
combustion-supporting oil gun torch, three layers of heavy oil gun torch and two layers of light oil gun
torch.
1.5 Steam temperature governing mode: Superheated steam temperature governing mainly depends on
spray temperature governing except for the affect of burner nozzle sway. It is equipment with two stages of
spray attemperator, the first stage attemperator is arranged on the division wall superheater inlet pipe for
controlling the steam temperature getting into the division wall superheater; the second stage attemperator
is arranged on the final stage superheater inlet pipe for controlling the outlet steam temperature of final
stage superheater. The maximum design water spray capacity of first stage attemperator is 206t/h and that
of the second stage attemperator is 40t/h.
The reheat steam temperature governing mainly adopts titling burner nozzle angle to change the height of
flame center and thus to change the furnace outlet flue gas temperature. The swing angle of primary air
nozzle is ±20° and the swing angle of secondary air nozzle is ±30°. As the reheaters are arranged at the
furnace outlet high temperature flue gas area, the temperature governing to swing nozzle is of relatively
large sensitivity. Temperature governing can be done by increasing excess air coefficient when the load is
lower than the certain value. Furthermore, there are two emergency water spray attemperator at the reheater

2
inlet, of which the nozzle is Monok nozzle, controlling the reheated steam inlet steam temperature at
emergency status. The attemperator is arranged on the wall type reheater inlet pipeline with maximum
design water spray capacity of 90t/h.
1.6 This boiler has 5%BMCR startup bypass system as the method of controlling superheated steam
pressure and temperature when boiler starts up to shorten startup time. When the boiler starts up in cold
state, the medium temperature in this system should be the saturation temperature under the pressure of
4.14MPa and the drain valve are fully opened. Increase the superheating steam temperature by increasing
the furnace combustion rate to quicken startup speed. When the boiler starts up in hot state, the drain valve
should be also opened to exhaust the condensate in the superheater system, therefore, the pipeline design
pressure and temperature behind the motor-operated valve is the same as that of the enclosure superheater.
The superheated steam temperature is controlled by furnace combustion rate and the superheated steam
pressure is controlled by drain valve during startup; close this drain valve after synchronization of steam
turbine.
1.7 The boiler adopts dry ash extraction and the furnace ash hopper bottom slag extracting adopts
mechanical slag extracting
1.8 There are 80 wall type soot blower in the furnace part, 44 long retractable soot blower on the upper part
of furnace and convection pass area and 1 retractable soot blower on the flue gas inlet and outlet end of
each preheater; all soot blowers will be program control during operation.
1.9 There are 16 spring safety valve in the boiler proper part, of which 6 are at the drum, 2 at the
superheater outlet, 6 at the reheater inlet pipe and 2 at the reheater outlet pipe. 3 power discharge valves are
installed at the superheater outlet to reduce take-off times of safety valve.
1.10 This boiler has the expansion center. The whole boiler will expand by taking the expansion center as
the base point during operation, the vertical expansion zero point of boiler is set on the top of big cover
casing, the expansion zero point in depth and width direction of boiler is set at the furnace center. Three
layers of guiding device are set in the height direction of furnace to control the expansion direction of
boiler heating surface and horizontal load of boiler.
1.11 The length of drum shell straight part is 26216mm, which is made by rolling of steel plate with inner
diameter ofΦ1743mm; the two ends adopt spherical heads; the total length is 28585mm including heads;
the drum shell and head adopt the materials of SA-299. The drum shell upper part is welded with 29Φ159
saturated steam extraction pipe base and 87Φ159 steam-water leading-in pipe base and is equipped with
auxiliary steam tube and air vent pipe base. The shell bottom is welded with 6 pieces of downcomer and 3
pieces of feed water pipe base. The head has manhole, 6 safety valve pipe base with 3 on each side, 8
couples of water level monitoring pipe base for connecting 2 two-color water level gages, 4 water level
balance containers and 2 electrode pitting water level gauges. The normal water level of drum is 220mm
below center line.
1.12 Each side of furnace outlet has one non-cooled flue gas probe; the flue gas probe extend to the furnace
to monitor the furnace outlet flue gas temperature during boiler startup stage. The highest measured
temperature of flue gas probe is 600℃, therefore, when the flue gas temperature reaches 538℃, alarm will
be given and flue gas probe will drop out automatically. Then decrease fuel amount to prevent burning of
wall type reheater for overheat. Flue gas probe model is TS-O with travel of 7000mm.
1.13 Operating mode of boiler: the boiler has base load and is of peaking capability. The lowest load of
stable flame without fuel is not higher than 40% of boiler maximum continuous rating in fuel design of

3
burning, under which the boiler can operate stably and safely in a long time.
1.14 Boiler steam water process:
1.14.1 Boiler water circulation process:
E1, E2 Economizer inlet pipeline F8 Circulating pump F22 Water cooling screen pipe
E3 Economizer inlet header F9 Pump outlet valve F23
Water cooling screen pipe
outlet header
E4 Economizer piping F10 Pump outlet pipeline F24
Screen pipe outlet header
extraction pipe
E5
Economizer hanging pipe inlet
header
F11
Lower boiler barrel admitting
pipe base
F25 Side lower boiler barrel
E6 Economizer hanging pipe F12 Front boiler barrel F26 Side wall water wall
E7
Economizer hanging pipe outlet
header
F13 Front water wall F27
Extension side wall water
wall
E8 Economizer outlet connecting pipe F14 Front water wall upper header F28
Side wall water wall upper
header
F1 Boiler F15
Front water wall extraction
pipe
F29
Side wall water wall
extraction pipe
F2 Downcomer base F16 Rear lower boiler barrel F30 Exhaust pipe
F3 Downcomer F17 Rear water wall F31 Recirculating inlet base
F4 Confluence header inlet three-way F18 Rear water wall hanging pipe F32 Recirculating pipeline
F5 Confluence header F19 Hanging pipe outlet header F33 Recirculating valve
F6 Confluence header outlet three-way F20
Hanging pipe header
extraction pipe
F34 Recirculating pipeline
F7 Pump induction stub pipe F21 Rear arch water wall pipe F35 Recirculating outlet base

4
1.14.2 Primary steam system
1.14.3 Reheated steam system process
Wall enclosure system bypass pipe
Ceiling bypass pipe
Drum Saturated steam
outlet pipe
Ceiling pipe
inlet header
Ceiling
pipe
Ceiling pipe
outlet header
Rear flue gas
pass ceiling
pipe
Rear flue gas
pass rear wall
pipe
Rear flue gas
pass rear wall
lower header
Rear flue gas pass side
wall lower header
(rear)
Rear flue gas pass
rear end side wall
pipe
Rear flue gas
pass front wall
pipe
Rear flue gas pass
front wall lower
header
Rear flue gas pass extension
side wall lower header
Rear flue gas pass side wall
lower header (front)
Rear flue gas pass
extension side wall pipe
Rear flue gas pass front
end side wall pipe
Rear flue gas
pass side wall
upper header
Low temperature
superheater inlet
connecting pipe
Horizontal low
temperature superheater
inlet header
Horizontal low
temperature
superheater
Vertical low
temperature
superheater
Vertical low temperature
superheater outlet header
Superheater
division wall
Division wall
inlet header
First stage attemperator
outlet connecting pipe
Superheater first
stage attemperator
First stage attemperator
inlet connecting pipe
Division wall
outlet header
Connecting pipe between
division wall and rear platen
Rear platen inlet
header
Superheater
rear platen
Rear platen
outlet header
Final stage
superheater
Final stage superheater
inlet header
Second stage attemperator
outlet connecting pipe
Superheater second
attemperator
Superheater outlet conduit
Second stage
attemperator inlet
connecting pipe
Final stage superheater
outlet header
(Cold reheater pipeline)
Reheater spray
attemperator (Cold reheater pipeline)
Wall type reheater
inlet header
Front wall
radiation reheater
Side wall
radiation reheater
Wall type reheater
outlet header
Connecting pipe from wall type reheater outlet
header to reheater front platen inlet header
Reheater front platen
inlet header
Reheater front
platen
Final stage
reheater
Final stage reheater
outlet header
Reheater outlet
conduit

5
Chapter 2 Boiler Technical Specifications and Performance Parameters of Main
Components
2.1 The evaporation capacity under BMCR is 1.02 times as the admission capacity under turbine VWO.
Main parameters table of TMCR working condition and BMCR working condition:
Name Unit BMCR TMCR
Superheated steam flow t/h 2069 1878
Steam pressure at superheater outlet MPa (g) 17.47 17.31
Steam temperature at superheater outlet ℃ 541 541
Reheated steam flow t/h 1751 1598
Steam pressure at reheater inlet MPa (g) 3.97 3.69
Steam pressure at reheater outlet MPa (g) 3.76 3.50
Steam temperature at reheater inlet ℃ 332 325
Steam temperature at reheater outlet ℃ 541 541
Economizer inlet feed water temperature ℃ 282 277
2.2 Heating surface structure dimension
Heating surface name
Outside
diameter
Transverse
pitch
Longitudina
l pitch
Heating
area
Number of
row
Number
of piece
mm mm mm m2
Wall type reheater 60 63.5 0 623.4 1 558
Division wall superheater 57 3012 67 1616.8 6 60
Platen superheater 70/63 1016 73 1764.7 20 18
Platen reheater 63 508 73 3177 40 20
Final stage reheater 63 254 114 3476 82 10
Final stage superheater 51 190.5 102 5025 108 6
Low temperature superheater 57 142 114 17615 147 5
economizer 42 100 90 21926 209 4
Trisector preheater
Rotor diameter is 13492m; heating surface height is 2185; primary air sector
50°; reverse
2.3 Coal quality
The coal of this project is India soft coal of high ash content and low heat value.
Design coal type Worst coal type Best coal type
A) Technical analysis
Fixed carbon 31.00% 27.00% 42.00%
Volatile matter 22.00% 18.00% 27.90%
Ash content 36.00% 40.00% 21.00%
Moisture 11.00% 15.00% 9.10%
Gross calorific value as received basis (kCal/kg) 4200 3800 4900
B) Elemental analysis
Carbon 43.10 % 38.00 % 53.90 %
Hydrogen 2.85 % 2.50 % 3.00 %
Nitrogen 0.9 % 0.50 % 1.20 %
Sulfur 0.4 % 0.60 % 0.30 %
Moisture 11.0 % 15.00 % 9.10 %
Oxygen 5.75 % 3.40 % 11.50 %
Ash content 36.00 % 40.00 % 21.00 %
Fixed moisture 6% 7%
Gross calorific value as received basis (kCal/kg) 4200 3800 4900
C) Deformation temperature 1170 ℃ 1170 ℃ 1170 ℃
Softening temperature 1300 ℃ 1300℃ 1300 ℃
Flow temperature 1400 ℃ 1400℃ 1400℃
D) Grindability coefficient 50 45 55

6
2.4 Ignition & combustion-supporting oil
2.4.1 The ignition method of this combustion system is three-stage ignition, that is, the high-energy ignitor
ignites the light oil, the light oil ignites the heavy oil and then the heavy oil ignites the pulverized coal. The
burner secondary air nozzle is equipped with 2 layers of total 8 light oil gun and adopts mechanical
atomization method. The fuel used is light oil when the boiler starts up to 10%BMCR; the
combustion-supporting oil is heavy oil during low load operation and the boiler heavy oil system output is
30%BMCR. The ignition unit adopts high-energy electric spark ignitor.
The design output of light oil gun/heavy oil gun: 12/42 t/h(oil)
2.4.2 Oil quality performance data
Light oil characteristic data table:
Name Unit Average value
Kinematic viscosity (at 38℃) cst 2.5-15.7
Pour point ℃ Summer : ≮12, winter: ≮18
Mechanical impurities ℃ >66
Closed cup flash point % ≮1.8
Sulphur content % ≮0.25
Water content % ≮0.02
Ash content % ≮1.5
Heavy oil characteristic data table:
Characteristic HFO
Acidic, inorganic 0.1
Ash, mass percent % 11000cal/g
Gross calorific value >66℃
Flash point, min ≮180cst
Kinematic viscosity at 50℃ (cst), max ≮0.25
Residue, mass percent (%), max ≮4.5
Sulphur, total mass percent (%), max ≮1.0
Water content, mass percent (%), max ≮2．5
Asphalt mass percent (%), max
2.5 Boiler steam water quality
Normal blowdown rate of boiler (BMCR) is 10.5 t/h counted as per 0.5 %.
It is strictly required to control the boiler feed water and boiler water according to the following quality
standards for the purpose of guarantee qualified steam quality
2.5.1 Quality standard table for boiler feed water:
Item Unit Guaranteed value
PH value (25℃) 9.0~9.6
Hardness μmol/l ~0
Dissolved oxygen (O2) μg/l ≤7
Iron (Fe) μg/l ≤20
Copper (Cu) μg/l ≤5
Oil mg/l ≤0.3
Hydrazine (N2H4) μg/l ≤30
Conductivity 25℃ μs/cm ≤0.3
Silicon dioxide Comply with the standards

7
2.5.2 Quality standard table for boiler water:
PH value (25℃) 9~10
Hardness μmo l/l ~0
Total salt content mg/l ≤20
Silicon dioxide (SiO2) mg/l ≤0.25
Chloride ion CL-1 mg/l ≤1
Phosphate radical mg/l 0.5~3
2.5.3 Quality standard table for steam:
Iron (Fe) μg/kg ≤20
Copper (Cu) μg/kg ≤5
Sodium (Na) μg/kg ≤10
Silicon dioxide (SiO2) μg/kg ≤20
Conductivity (25℃) μs/cm ≤0.30
2.6 Site weather and geographic condition
The region that this project construction site located has the features of high temperature and high humidity.
Extreme max temperature: 48℃
Extreme min temperature: 8℃
Design temperature: 8~50℃ (performance guaranteed value is below 34.5℃)
Design temperature of electrical equipment: 50℃
Relative humidity:
Design: 60%
Mean annual precipitation: 1500mm
Earthquake intensity: Grade VII (as per IS-1893 located at zone-II)
Number of annual operation hours of boiler: above 30 years

8
Chapter 3 Calculated Data Table Of Boiler Thermal Performance
Performance data (Design coal type)
A. Design parameters
No. Item Unit BMCR TMCR HPHO* 80%TMCR 60%TMCR 40%BMCR
1 Main steam flow rate t/h 2068.6 1877.9 1640.2 1474.2 1105 836.4
2 Superheated steam outlet pressure Mpa 17.47 17.31 17.14 15.24 11.55 8.82
3
Superheated steam outlet
temperature
℃ 541 541 541 541 541 529
4 Reheated steam flow rate t/h 1751.4 1597.9 1612.6 1272.6 968.5 748.1
5 Reheated steam inlet pressure Mpa 3.95 3.69 3.83 2.93 2.22 1.65
6 Reheated steam outlet pressure Mpa 3.74 3.50 3.63 2.78 2.10 1.56
7 Reheated steam inlet temperature ℃ 332.1 324.8 333.3 316.6 321.3 313.8
8
Reheated steam outlet
temperature
℃ 541 541 541 541 541 514
9 Feed water pressure Mpa 19.24 18.82 18.36 16.38 12.45 9.55
10 Feed water temperature ℃ 280 275 183 261 245 229
11 Attemperating water temperature ℃ 182 179 182 170 159 148
12
Superheater water spray quantity
(first stage)
t/h 31.0 68.7 179.0 110.7 98.7 72.8
13
Superheater water spray quantity
(second stage)
t/h 0.0 0.0 0.0 0.0 0.0 0.0
14 reheater water spray quantity t/h 0.0 0.0 0.0 0.0 0.0 7.4
15 Boiler barrel pressure Mpa 18.84 18.46 18.02 16.06 12.17 9.28
16 Boiler barrel temperature ℃ 361.2 359.5 357.5 348.1 326.3 306.3
17
Exhaust gas temperature (before
correction)
℃ 139.5 138.0 117.0 134.5 125.5 112.5
18
Exhaust gas temperature (after
correction)
℃ 135.0 133.0 113.5 129.0 119.5 105.5
B Heat loss and heat load
1
Heat loss carried off by exhaust
dry flue gas
% 4.18 4.12 3.23 3.96 3.57 3.17
2
Heat loss carried off by the
moisture in fuel
% 1.64 1.64 1.61 1.63 1.62 1.61
3
moisture produced by hydrogen
burning
% 3.76 3.76 3.7 3.75 3.7 2 3.69
4
moisture in air
% 0.17 0.17 0.13 0.16 0.15 0.13
5 Heat loss due to unburned fuel % 1.5 1.5 1.5 1.5 1.8 2
6 Heat loss due to radiation % 0.17 0.22 0.21 0.26 0.34 0.43
7 Inestimable heat loss % 0.35 0.35 0.35 0.35 0.35 0.35
8 Manufacturer margin % 0.7 0.7 0.7 0.7 0.7 0.7
9 Total loss % 12.47 12.46 11.43 12.31 12.25 12.08
10 High heat efficiency % 87 53 87.54 88.57 87.69 87.75 87 92
11 Fuel consumption t/h 345.6 318.7 324.8 259.9 202.0 155.7
12 Burner operating layer 6 6 6 5 4 3
13 Excess air coefficient 1.25 1.25 1.25 1.25 1.25 1.25

9
C Steam temperature
No. Item Unit BMCR TMCR HPHO* 80%TMCR 60%TMCR 40%TMCR
1
Wall type reheater inlet
temperature
℃ 332 325 333 317 321 303
2
Wall type reheater outlet
temperature
℃ 371 366 372 363 371 353
3
Furnace roof superheater inlet
temperature
℃ 361 359 358 348 326 306
4
Furnace roof superheater outlet
temperature
℃ 363 362 361 352 332 313
5
Division wall superheater inlet
temperature
℃ 398 393 382 378 358 338
6
Division wall superheater outlet
temperature
℃ 443 440 428 432 424 411
7
Rear platen superheater inlet
temperature
℃ 443 440 428 432 424 411
8
Rear platen superheater outlet
temperature
℃ 499 499 493 501 505 501
9 Platen reheater inlet temperature ℃ 371 366 372 363 371 353
10 Platen reheater outlet temperature ℃ 468 468 470 470 477 458
11
Final stage reheater inlet
temperature
℃ 468 468 470 470 477 458
12
Final stage reheater outlet
temperature
℃ 541 541 540 540 540 515
13
Final stage superheater inlet
temperature
℃ 499 499 493 501 505 501
14
Final stage superheater outlet
temperature
℃ 541 541 541 541 541 529
15
Steam cooled pipe inlet
temperature
℃ 363 362 361 352 332 313
16
Steam cooled pipe outlet
temperature
℃ 364 362 362 353 334 316
17
LV superheater straight part inlet
temperature
℃ 394 396 413 400 398 384
18
LV superheater straight part outlet
temperature
℃ 404 407 429 414 415 402
19
Reversing chamber economizer
hanging pipe inlet temperature
℃ 323 320 275 310 296 279
20
hanging pipe outlet temperature
℃ 325 322 279 312 299 282
21
Reversing chamber enclosure tube
inlet temperature
℃ 364 362 362 353 334 316
22
outlet temperature
℃ 365 364 364 356 339 322
23
LV superheater horizontal part
inlet temperature
℃ 365 364 364 356 339 322
24
outlet temperature
℃ 394 396 413 400 398 384
25
temperature
℃ 323 320 274 310 295 279
26
temperature
℃ 323 320 275 310 296 279
27 Economizer inlet temperature ℃ 282 277 185 262 246 231
28 Economizer outlet temperature ℃ 323 320 274 310 295 279

10
D Flue gas temperature
1
Furnace outlet flue gas
temperature
℃ 1045 1033 1018 983 911 841
2
Wall type reheater inlet
temperature
℃ 1327 1330 1311 1312 1235 1165
3
Wall type reheater outlet
temperature
℃ 1327 1330 1311 1312 1235 1165
4
Furnace roof superheater inlet
temperature
℃ 1327 1330 1311 1312 1235 1165
5
Furnace roof superheater outlet
temperature
℃ 1327 1330 1311 1312 1235 1165
6 Division wall superheater inlet ℃ 1327 1330 1311 1312 1235 1165
7
Division wall superheater outlet
temperature
℃ 1143 1134 1115 1088 1017 949
8
Rear platen superheater inlet
temperature
℃ 1143 1134 1115 1088 1017 949
9
Rear platen superheater outlet
temperature
℃ 1045 1033 1018 983 911 841
10 Platen reheater inlet temperature ℃ 1045 1033 1018 983 911 841
11 Platen reheater outlet temperature ℃ 932 918 908 867 800 730
12
Final stage reheater inlet
temperature
℃ 923 909 899 858 791 721
13
Final stage reheater outlet
temperature
℃ 837 823 816 777 721 657
14
Final stage superheater inlet
temperature
℃ 813 799 793 753 697 634
15
Final stage superheater outlet
temperature
℃ 731 718 714 682 639 592
16
Steam cooled pipe inlet
temperature
℃ 731 718 714 682 639 592
17
Steam cooled pipe outlet
temperature
℃ 724 711 707 674 632 584
18
LV superheater straight part inlet
temperature
℃ 724 711 707 674 632 584
19
LV superheater straight part outlet
temperature
℃ 686 674 673 640 599 554
20
hanging pipe inlet temperature
℃ 686 674 673 640 599 554
21
hanging pipe outlet temperature
℃ 678 667 665 633 593 548
22
inlet temperature
℃ 678 667 665 633 593 548
23
outlet temperature
℃ 662 651 649 616 575 529
24
inlet temperature
℃ 662 651 649 616 575 529
25
outlet temperature
℃ 488 481 484 459 431 399
26
temperature
℃ 488 481 484 459 431 399
27
temperature
℃ 486 478 482 457 428 397

11
28 Economizer inlet temperature ℃ 486 478 482 457 428 397
29 Economizer outlet temperature ℃ 342 336 279 316 292 269
30 Preheater inlet temperature ℃ 342 336 279 316 292 269
31
Preheater outlet temperature
(corrected)
℃ 135 133 114 129 120 106
E Average velocity of flue gas
1
Rear platen superheater flue gas
velocity
m/s 8.7 8.0 8.0 6.3 4.6 3.3
2 Platen reheater flue gas velocity m/s 9.5 8.7 8.8 6.8 5.0 3.6
3
Final stage reheater flue gas
velocity
m/s 12.0 11.0 11.1 8.6 6.3 4.5
4
Final stage superheater flue gas
velocity
m/s 11.5 10.5 10.6 8.2 6.1 4.3
5
Horizontal part low temperature
superheater flue gas velocity
m/s 9.9 9.3 9.5 7.3 2.7 3.9
6 Economizer flue gas velocity m/s 8.5 7.8 7.6 6.2 4.6 3.4
F Flue gas flow rate
No. Item Unit BMCR TMCR HPHO* 80%TMCR 80%TMCR 60%TMCR
1
Primary air flow rate entering
preheater
Kg/h 580183 556376 680792 510512 450868 400738
2 Preheater secondary air flow rate Kg/h 1790510 1619370 1589234 1238461 936317 643036
3
Flue gas flow rate entering
preheater
Kg/h 2699532 2489411 2537100 2030083 1575601 1113196
4
Attemperating primary air flow
rate
Kg/h 211248 218808 164304 215424 156888 95400
5
Primary air flow rate out of
preheater
Kg/h 399460 377456 500792 332672 276988 226498
6
Secondary air flow rate out of
preheater
Kg/h 1771070 1599570 1567994 1219021 915797 621796
7 Flue gas flow rate out of preheater Kg/h 2899692 2688131 2738340 2227363 1770001 1308676
8
Air leakage quantity from air to
flue gas
Kg/h 200160 198720 201240 197280 194400 195480
9
Air leakage quantity from primary
air to secondary air
Kg/h 23040 22320 21600 21600 19440 19800
10
Air leakage quantity from
secondary air to flue gas
Kg/h 42480 42120 42840 41040 39960 41040
11
Air leakage quantity from primary
air to flue gas
Kg/h 157680 156600 158400 156240 154440 154440
G Air temperature
1
Preheater inlet primary air
temperature
℃ 44.5 44.5 44.5 44.5 44.5 44.5
2
Preheater inlet secondary air
temperature
℃ 37.3 37.3 37.3 37.3 37.3 37.3
3
Preheater outlet primary air
temperature
℃ 302.0 298.5 245.0 287.0 269.5 244.5
4
Preheater outlet secondary air
temperature
℃ 312.0 307.5 254.5 294.0 275.0 249.0

12
Chapter 4 Induced Draft Fan
4.1 General introduction of induced draft fan
Model: fixed blade adjustable axle induced draft fan
Quantity: each boiler is equipped with 2 sets.
Operating mode: 2 sets of fan operate in parallel.
Adjusting mode: fixed blade adjustment.
Arrangement mode: horizontal symmetric arrangement, vertical inlet air and horizontal outlet air.
Single set of fan is of 60%BMCR of boiler capacity.
4.2 Induced draft fan parameters requirements:
4.2.1 Parameters of fan at each working condition point:
No.
Working condition
Coal type Parameters
TB
working
condition
BMCR working condition
TMCR working
condition
Design coal type Check coal type Design coal type
1 Fan inlet volume flow rate (m³/s) 690 547 549 500
2 Fan inlet static pressure (Pa) -6580 -5220 -5205 -5065
3 Fan inlet flue gas temperature (℃) 150 134.5 130.0 132.1
4 Fan inlet medium density (kg/m³) 0.741 0.779 0.785 0.785
5 Inlet flue gas dust content (mg/Nm³) ≤230
6 Fan static pressure rise (Pa) 7479 5983 6057 5593
Instruction:
① TB (test bl℃k), the air quantity and air pressure of this working condition point is the check point of fan
capacity.
② B-MCR is the max continuous output working condition of boiler, which is the check point of fan
efficiency.
③ TMCR is equivalent to 93.37% B-MCR working condition of boiler.
4.2.2 Technical data of induced draft fan:
No. Item Unit Induced draft fan
1 Fan model G158/343
2 Fan regulating device model 8000Nm 4~20mA
3 Impeller diameter mm 3430
4 Bearing material 42CrMo
5 Hub material 15MnV
6 Blade material 15MnV
7 Impeller series Level 1
8 Blade number of each stage Piece 18
9 Blade adjustable range Degree -70~+30
10 Bore and stroke of hydraulic cylinder mm/mm N/A
11 Rotor weight kg ~7500
12 Rotor moment of inertia Kg.m2
6524
13 Fan first critical speed r/min >956

13
14 Air inlet box material/wall thickness /mm Q235/6
15 Casing material/wall thickness /mm Q235A/16
16 Diffuser material/wall thickness /mm Q235/6
17 Fan bearing type Roll
18 Bearing lubrication type Thin oil
19 Bearing cooling type
Forced oil circulation + cooling
wind
20 Bearing bush cooling water volume t/h N/V
21 Fan rotation direction (view form motor side) Anticlockwise
22 Muffler resistance Pa ------
23 Fan total weight kg ~55000
24
Max lifting weight/max lifting height in
installation
kg ~25000
m >3.8 (start from fan axial)
25
maintenance
Kg ~7500
m >3.8 (start from fan axial)
4.2.3 Fan performance data
Working condition
Item
Induced draft fan
TB condition BMCR condition TMCR condition
Fan inlet volume flow rate (m3/s) 690 547 500
Fan inlet mass flow rate (kg/s) 511.29 426.11 392.5
Fan inlet temperature (℃) 48 48 48
Inlet air density (kg/m3
) 0.741 0.779 0.785
Fan inlet total pressure (Pa) -6580 -5220 -5065
Fan inlet static pressure (Pa) -6580 -5220 -5065
Fan outlet total pressure (Pa) 968 818 583
Fan outlet static pressure (Pa) 968 818 583
Fan total pressure rise (Pa) 7548 6038 5648
Fan static pressure rise (Pa) 7548 6038 5648
Fan outlet wind temperature (℃) 161.63 143.55 140.98
Fan accessory loss (Pa) Included in efficiency loss Included in efficiency loss Included in efficiency loss
Fan total pressure efficiency (%) 85.06 83.7 79.2
Fan shaft output (kW) 5949 3857 3485
Fan speed (r/min) 745 745 745
4.2.4 Integrated data table of supporting motor
No. Parameter name Unit Induced draft fan
1 Model STMKS900-8
2 Electromotor type Three phase squirrel cage asynchronous motor
3 Rated power kW
6250
J=6524 kgm2

14
4 Rated voltage kV 11
5 Rated current A 393
6 Rated power Hz 50
7 Rated speed rpm 745
8 Number of poles 8
9 Degree of protection IPW55
10 Insulation level F
11 Cooling mode IC81W
12 Installation mode IMB3
13 Working system S1
14 Efficiency %
Efficiency at rated load % 96.0
3/4Efficiency at rated load % 95.6
1/2Efficiency at rated load % 94.2
15 Power factor
Power factor at rated load 0.88
Power factor at 3/4 rated load 0.85
16 Maximum torque/rated torque 2.2
17 Locked rotor torque/rated torque 0.45
18 Locked rotor current/rated current 6.0
19
Accelerating time and starting time
(under rated load working condition)
s 17
20 Motor moment of inertia Kg.m2
21 Noise dB(A) 85
22 Vibration amplitude at bearing pedestal mm 0.076
23 Bearing vibrating velocity mm/s
24 Stator temperature rise K 70
25 Number of phases Three
26 Temperature measuring element Pt100
27 Bearing model Domestic sliding
Bearing model trademark 46# steam turbine oil L-TSA
Bearing lubrication type Forced thin lubricating oil
Bearing cooling mode Oil cooling
28 Motor weight Kg 45000
29 Bearing lubricating oil flow (L/min) 16
30 CT mode ratio/accuracy level Confirmed by design liaison meeting
31 Rotating direction Confirmed by fan manufacturer
32 Threading pipe adaptor box
33 Threading pipe inlet
34 Allowed locked rotor time s 41
35 Starting torque
36 Min starting torque
37 Recommended lubricant 46# steam turbine oil L-TSA

15
38
Resistance and temperature detector & model
for stator use
Pt100
39 Bearing temperature detector & model Pt100, bimetal thermometer
4.2.5 Main technical data of oil system
1 Flow rate l/min 40 (shared by fan and motor)
2 Pressure MPa 0.4
3 Oil quality trademark N46 or N68
4 Oil tank material/volume /m3 Q235/0.6
5 Oil filter filtering precision μ 25
6 Oil cooler water quantity 2.5
7 Oil cooler water pressure MPa
8 Oil cooler model Plate type
9 Oil pump model Gear pump
10 Oil pump number Set 2
11 Oil pump speed r/min 1470
12 Oil pump power 5.5
13 Quantity of oil tank electric heater Set 1
14 Power of oil tank electric heater KW 3
4.2.5 Cooling water data table
Equipment Equipment name
Water quality
requirement
Water pressure
requirement
Water
temperature
requirement
Water
quantity
requirement
Induced
draft fan
Lubricating oil station
cooling water flow rate
Common
industrial water
1MPa 38 6.3 T/h

16
Chapter 5 Forced Draft Fan
5.1 Overview: Model: moving blade adjustable axle induced draft fan.
Quantity: each set of boiler is equipped with 2 set.
Operating mode: 2 sets of forced draft fan operate in parallel, single set of fan can meet the requirement of
boiler 60% BMCR working condition air quantity.
Adjusting mode: moving blade adjustment.
Arrangement mode: horizontal & symmetry arrangement, vertical inlet air and horizontal outlet air
The forced draft fan bearing adopts rolling bearing and oil bath lubrication. The motor bearing adopts
rolling bearing and grease lubrication and adopts water cooling mode.
5.2 Requirements of forced draft fan parameters
5.2.1 Parameters of fan at each working condition point (the initial data):
No.
Working condition
Parameters
TB working
condition
BMCR working
condition
TMCR
Design coal
quality
Design coal
quality
Design coal
quality
1 Fan inlet Flow rate (m3
/s) 303 275 248
2 Fan inlet cross section static pressure (Pa) -950 -875 -823
3 Fan inlet temperature (℃) 48 48 48
4 Fan static pressure rise (Pa) 4584 3820 3688
5 Inlet air density (kg/m3) 1.038 1.038 1.038
5.2.2 Technical data of forced draft fan
No. Item Unit forced draft fan
1 Fan model ANN-2575/1250C
2 Fan regulating device model 5t hydraulic cylinder
5 Hub material Forging steel
6 Blade material Cast aluminum alloy
9 Blade adjustable range Degree 30~85
10 Bore and stroke of hydraulic cylinder mm/mm 250/96
11 Rotor weight kg 3597
12 Rotor moment of inertia Kg.m2
387
13 Fan first critical speed r/min 1287
14 Air inlet box material/wall thickness /mm Q235A/6

17
No. Item Unit forced draft fan
16 Diffuser material/wall thickness /mm Q235A/6
17 Fan bearing type Rolling bearing
18 Bearing lubrication type Oil bath lubrication
19 Bearing cooling type Natural cooling
20 Bearing bush cooling water volume t/h /
21 Fan rotation direction (view form motor side) Clockwise
22 Muffler resistance Pa 150
23 Fan total weight kg 16087
24 Max lifting weight/max lifting height in installation
kg 7620
m 3.7
25 Max lifting weight/max lifting height in maintenance
Kg 1600
m 3.7
5.2.3 Fan performance data
Working condition
Item
Forced draft fan
TB working
condition
B-MCR working
condition
TMCR working
condition
Fan inlet volume flow rate (m3
/s) 303 275 248
Fan inlet mass flow rate (kg/s) / / /
Inlet air density (kg/m3
) 1.038 1.038 1.038
Fan accessory loss (Pa) Included Included Included
Fan total pressure efficiency (%) 85 87.3 88.0
Fan shaft output (kW) 1636.8 1209.1 1042.2
Fan speed (r/min) 990 990 990
5.2.4 Technical data of electromotor:
Item Unit Secondary fan motor
Model STMKS500-6 (tentative)
Rated power kW 1800
Rated voltage kV 11
Synchronous speed r/min 1000
Startup current A 690
Rated current A 115
Frequency Hz 50

18
Main features
Efficiency 95.8
Power factor 0.88
Locked rotor torque 0.5
Locked rotor current 6.0
Max torque 2.0
Insulation level F/B
Weight kg 18000
Cooling mode Air water cooling
5.2.5 Main technical data of oil system
No. Item Unit Value (forced draft fan hydraulic pressure)
1 Flow rate l/min 10~12
2 Pressure MPa 8.0
3 Oil quality trademark ISO VG 32
4 Oil tank material/volume /m3 Low carbon steel spray paint/0.203
5 Oil filter filtering precision μ 10
6 Oil cooler water quantity 0.24
7 Oil cooler water pressure MPa 0.2~0.4
8 Oil cooler model Plate type
9 Oil pump model Gear pump
10 Oil pump number Set 2
11 Oil pump speed r/min 1430
12 Oil pump power 2.2
13 Quantity of oil tank electric heater Set 2
14 Power of oil tank electric heater kW 1.0
5.2.6 Forced draft fan cooling water data table
Equipment name
Water quality
requirement
Water pressure
requirement
Water temperature
requirement
Water quantity
requirement
Lubricating oil station
cooling water flow rate
/ / / /
HP oil station cooling
water flow rate
/ 0.4~0.6Mpa <40℃ tentative

19
Chapter 6 Primary Air Fan
6.1 Overview:
Model: moving blade adjustable axle induced draft fan.
Quantity: each set of boiler is equipped with 2 sets.
Operating mode: 2 sets of primary air fan operate in parallel, single set fan can meet the requirements of
boiler 60%BMCR working condition air quantity.
Adjusting mode: moving blade adjustment.
Arrangement mode: horizontal & symmetry arrangement, vertical inlet air and horizontal outlet air
The bearing adopts rolling bearing and forced lubrication. The motor bearing adopts domestic sliding
bearing and forced lubrication and the motor adopts water cooling mode.
6.2 Primary air fan parameter requirements
6.2.1 Parameters of fans at each working condition point:
No.
Working condition
Parameters
TB working
condition
B-MCR working
condition
TMCR
Design coal
quality
Design coal
quality
Design coal
quality
1 Fan inlet Flow rate(m3/s) 178 162 156
2 Fan inlet cross section static pressure(Pa) -550 -458 -446
3 Fan inlet temperature (℃) 48 48 48
4 Fan static pressure rise (Pa) 13500 11180 10829
5 Inlet air density (kg/m3) 1.044 1.044 1.044
6.2.2 Technical data of primary air fan
No. Item Unit Primary air fan
1 Fan model ANT-2062/1250N
2 Fan regulating device model 10t hydraulic cylinder
5 Hub material Forging steel
6 Blade material Cast aluminum alloy
9 Blade adjustable range Degree 10~55
10 Bore and stroke of hydraulic cylinder mm/mm 250/96
11 Rotor weight kg 4117
12 Rotor moment of inertia Kg.m2 674
13 Fan first critical speed r/min 1938
14 Air inlet box material/wall thickness /mm Q235A/5
16 Diffuser material/wall thickness /mm Q235A/5
17 Fan bearing type Rolling bearing
18 Bearing lubrication type Forced lubrication
19 Bearing cooling type Forced cooling
20 Bearing bush cooling water volume t/h
21
Fan rotation direction (view form motor
side)
Clockwise
22 Muffler resistance Pa 150

20
No. Item Unit Primary air fan
23 Fan total weight kg 15797
24
installation
kg 4320
m 2.8
25
maintenance
Kg 2640
m 2.8
6.2.3 Performance data of primary air fan
Working condition
Item
Primary air fan
TB working
condition
BMCR working
condition
TMCR working
condition
Fan inlet volume flow rate (m3/s) 178 162 156
Fan inlet mass flow rate (kg/s) / / /
Inlet air density (kg/m3) 1.044 1.044 1.044
Fan accessory loss (Pa) Included Included Included
Fan total pressure efficiency (%) 87 88.0 88.0
Fan shaft output (kW) 2653.2 1993.9 1861.7
Fan speed (r/min) 1490 1490 1490
6.2.4 Technical data of primary air fan motor:
Item Unit Primary air fan motor
Model STMKS560-4 (tentative)
Rated power kW 2800
Rated voltage kV 11
Startup current A 1038
Rated current A 173
Frequency Hz 50
Main features
Efficiency 95.6
Power factor 0.89
Locked rotor torque 0.5
Locked rotor current 6.0
Max torque 2.2
Insulation level F/B
Weight kg 21300
Cooling mode Air water cooling
6.2.5 Main technical data of primary air fan oil system
No. Item Unit
Value (Hydraulic oil
station)
Value (Lubricating oil
station)
1 Flow rate l/min 10~12 15~18
2 pressure MPa 8.0 1.5~2.0
3 Oil quality trademark ISO VG 32 ISO VG 46
4 Oil tank material/volume /m3 Low carbon steel spray
paint/0.203
Low carbon steel
spray paint/0.369
5 Oil filter filtering precision μ 10 10
6 Oil cooler water quantity 0.24 0.6
7 Oil cooler water pressure MPa 0.2~0.4 0.2~0.4

21
No. Item Unit
Value (Hydraulic oil
station)
Value (Lubricating oil
station)
8 Oil cooler model Plate type Plate type
9 Oil pump model Gear pump Gear pump
10 Oil pump number Set 2 2
11 Oil pump speed r/min 1430 1430
12 Oil pump power 2.2 0.75
13 Quantity of oil tank electric heater Set 2 2
14 Power of oil tank electric heater kW 1.0 1.0
6.2.6 Data of primary air fan oil station cooling water
Equipment name
Water quality
requirement
Water pressure
requirement
Water temperature
requirement
Water quantity
requirement
Lubricating oil station cooling
water flow rate
/ 0.4~0.6Mpa <40℃ Tentative
HP oil station cooling water
flow rate
/ 0.4~0.6Mpa <40℃ Tentative

22
Chapter 7 Air Preheater
7.1 Air preheater data parameters
Name Height
Component
thickness
Component
material
Heat transmission
component
Hot section layer 1000 mm 0.8mm SPCC-SD
Hot section intermediate layer 880 mm 0.8mm SPCC-SD
Cold section layer 305 mm 1.2mm corten-A
Inner diameter of
rotor
14236 mm
Actuator
Model of speed reducer SGW600-01A
Main motor Y225S-4B3 37KW 1480 r/min
Auxiliary motor Y160M-4B5 11KW 359 r/min
SGZJ11-4
right angle
speed reducer
Air motor
INGERSOLL-
RAND
7.5 HP 103 r/min
Main speed reducing ratio 123.835
Output shaft speed Main transmission 11.95 r/min
Rated output torque 57500 N·m
Pedestal bearing Spherical roller thrust bearing 294/710EF
Guide bearing
Biserial centripetal spherical roller bearing
23192
Oil circulation
system
Guide bearing, pedestal bearing
thin oil station
Model: ℃S-8E
Electromotor: Y9OL-4 1.5KW
Three-screw pump: 3GR30X4-1.6/1.0
Double cylinder oil filter: SXU-A100
Tubular oil cooler: GLC2-1.3
Soot blower Retractable sootblower

23
Chapter 8 Pulverizing System
8.1 Brief introduction of pulverizing system
Model: HP1103DYN type medium speed coal mill cold primary fan positive pressure direct firing pulverizing
system; each boiler is equipped with 7 medium speed coal.
Fineness of coal: Design coal type and check coal type meet the requirements of the following coal fineness
that is R90= 18.38% and uniformity index ≥1.2.
Boiler (BMCR) coal consumption: 345.7 t/h (Design coal type)
386.7 t/h (Check coal type, worst coal)
294.5 t/h (Check coal type, best coal)
Theoretical air quantity (dry air): Design coal type 4.41 Nm3/kg
Check coal type 3.95 Nm3
/kg
Furnace outlet excess air ratio (B-MCR): 1.14 (tentative)
8.2 Coal feeder
8.2.1 Model: electronic weighing coal feeder.
Quantity: each set of coal mill is equipped with 1 set of coal feeder.
Continuous coal feed rate: 10~100 t/h
Measuring accuracy: ±0.25%
Control accuracy: ±0.5%
Raw coal granularity: ≤30mm
The noise should be lower than 85dB (A) at the position 1m away from the shell during normal operation
of coal feeder.
8.2.2 Technical data table of coal feeder of
No. Item Unit Supplied by manufacturer
1 Coal feeder model EG2490
2 Output range t/h 115
3
Coal feeding distance (coal feeder inlet and outlet central
line distance)
mm 3100
4 Inlet coal chute length/diameter (outer dia.) / wall thickness mm/mm/mm 1405/φ629/8
Outlet coal chute length/diameter (outer dia.) / wall
thickness
mm/mm/mm 5400/φ610/8
5 Coal inlet flange inner dia. (coal inlet gate inner dia.) mm φ629
Coal outlet flange inner dia. (coal outlet gate inner dia.) mm φ610
6 Main driven motor model JRTKAF87100L4
Power kW 3.0
Power supply 415
7 Cleaning chain motor model JRTSF77R37D71D4
Power kW 0.37
Power supply 415
8 Engine body seal
Seal wind pressure (differential pressure with pulverizing
mill inlet)
Pa +500
Seal air quantity Nm3/min 12
9 Model and power of inlet & outlet coal gate drive motor kW 1.1
AUMA/ROTORK

24
8.2.3 Technical data of coal feeder motor
Item Unit Data
Model KF87-DV100L4 (SEW)
Rated power kW 3
Rated voltage kV 415
Startup current A 4~7 times
Rated current A 6.4
Frequency Hz 50
8.3 Coal mill
8.3.1 Mill inlet coal granularity: ≤30 mm
Boiler (BMCR) coal consumption: 345.7 t/h (design coal type)
386.7 t/h (Check coal type, worst coal)
294.5 t/h (Check coal type, best coal)
Drying medium temperature of coal mill inlet: the max temperature of air preheater outlet primary air is
326.7 ℃ (design coal type B-MCR working condition, tentative).
Medium temperature of coal mill outlet: <75 ℃.
Pulverized coal moisture: 80% of air drying machine moisture.
Pulverized coal pipeline number of each set of coal mill: 4.
8.3.2 Technical data table of coal mill
No. Item Unit
1 Model HP1103/Dyn
2 Separator model Dynamic separator
3 Ground roll loading mode Spring variable load
4 Base mode Cement fixed base
5 Primary air inlet dimension mm×mm 743×2438
6 Central coal chute dimension/wall thickness mm/ mm Φ610/10
7 Pulverized coal pipeline interface dimension/wall thickness mm/ mm Φ734/17
8 Volume of slagoff box m3 1.0
8.3.3 Coal mill performance data
No. Item Unit Design coal type Worst coal Best coal
1 Output of coal mill (R90= 18.38 %)
Maximum output t/h 87.2 80.2 93.3
Calculated output t/h 57.62 64.45 57.3
Guaranteed output (consider that 10% of output
decrease)
t/h 78.48 72.18 83.9
Minimum output t/h 19.62 18.045 23.3

25
No. Item Unit Design coal type Worst coal Best coal
2 Ventilation quantity of coal mill
Maximum ventilation quantity kg/s 36.3
Calculated ventilation quantity kg/s 31.4 33.48 30.7
Ventilation quantity under guaranteed output kg/s 34.8
Minimum ventilation quantity kg/s 22.7
3 Drying medium temperature of coal mill inlet ℃ 188 240 178
4 Rotated speed of coal mill r/min 30.0
5
Ventilation resistance of coal mill (including
segregator and coal dust distributor box)
Maximum ventilation resistance Pa ≤5000
Ventilation resistance (guaranteed output) Pa 4608
Calculated ventilation resistance Pa 3740 4250 3577
6 Seal air system of coal mill
Seal air quantity of coal mill m3
/min 100
Seal air pressure of coal mill (or the difference
with primary air pressure)
Pa >2000
7
Unit power consumption of coal mill (BMCR
working condition) (including oil station and
dynamic separator motor)
kW.h/t 11.4 11.77 10.5
Unit power consumption under guaranteed
output (including oil station and dynamic
separator motor)
kW.h/t 10.2 11.46 9.5
8 Unit wear rate of coal mill g/t 2.5 on average
9 Life of main parts
Grinding roller sleeve h ≥10000
Mill bowl back block h ≥10000
Seal part of grinding roller bearing h ≥20000
Other main seal parts h ≥20000
Stone coal scraper h ≥20000
10 Material of easy wear parts
Grinding roller sleeve Cemented carbide
Mill bowl back block Abrasion resistant cast iron
Stone coal scraper Overlay welding wear-resistant steel plate
11 Air delivery of seal fan/ pressure head m3/h /Pa 64032/6481
Motor power of seal fan KW 185
8.3.4 Summary table of main electromotor performance parameters

26
No. Parameter name Unit Value
1 Model YHP630-6
2 Electromotor type Squirrel cage asynchronous motor
3 Rated power kW 850
4 Rated voltage V 11000
5 Rated current A 62.5
6 Rated power Hz 50
7 Rated speed r/min 985
8 Number of poles 6
9 Degree of protection IP54
10 Insulation level F
11 Cooling mode IC611 (air-air cooling)
12 Installation mode IMB3 (vertical)
13 Working system S1 (continuous)
14 Efficiency %
Efficiency at rated load % 93
Efficiency at 3/4 rated load % 92.5
Efficiency at 1/2 rated load % 90
15 Power factor
Power factor at rated load 0.79
16 Maximum torque/rated torque 2.0
17 Locked rotor torque/rated torque 2.8
18 Locked rotor current/rated current 6.3
19
Accelerating time and starting time
(under rated load working condition)
S 2
20 Motor moment of inertia kg.m2
120
21 Noise dB(A) 85 (at 1.5m)
22 Vibration amplitude at bearing pedestal mm /
23 Bearing vibrating velocity mm/s 2.8
24 Stator temperature rise K 80
25 Number of phases 3
26 Temperature measuring element Pt100
27 Bearing model Rolling bearing
Bearing model trademark 3# lithium based grease
Bearing lubrication type Grease lubrication
Bearing cooling mode Natural cooling
28 Motor weight kg 9700
29 Bearing lubricating oil flow (m3/s) /
30 CT mode ratio/accuracy level /
31 Rotating direction Bidirection
32 Terminal box Subject to the official drawing
33 Terminal box inlet (dimension, quantity) Subject to the official drawing
34 Allowed locked rotor time s 3
35 Figuration drawing and drawing number
36 Starting torque 2.8Me
37 Min starting torque /
38 Recommended lubricant 3# lithium based grease
39
Stator temperature measuring element quantity
and model
6 pc/pt100
40
Bering temperature measuring element quantity
and model
2 pc/pt100
41 Vibration meter interface

27
8.3.5 Integrated data table of other supporting equipment
No. Item Unit
1 Actuator
Speed reducer (Model) KMP340
Transmission mode
Spiral bevel gear and planet gear second stage vertical
transmission
Transmission ratio 32.435
Lubrication cooling device (Model) OWTS10 (double pump)
Oil pump flow rate l/min 228
Motor power KW 11
Normal oil supply pressure MPa 0.15~0.35
Cooling water quantity m3/h 17
Cooling water pressure MPa 0.4
Oil tank electric heater/quantity 6
Rated voltage V 415
Rated power KW 1.7kW/set
Oil return pipe electric heat tape/quantity N/A
Rated voltage V /
Rated power KW /
Lubricating oil trademark ISO VG 320
2 Lubricating oil station device (Model) OWTS10
Oil pump flow rate l/min 228
Motor power KW 11
Normal oil supply pressure MPa 0.15~0.35
Oil tank electric heater/quantity 6
Lubricating oil trademark ISO VG 320
8.4 Data table of coal mill cooling waters
No. Equipment name
Water quality
requirement
Water pressure
requirement
Water temperature
requirement
Water quantity
requirement
1
Lubricating oil
station cooling water
Demineralized water 0.4MPa <41℃ 17m3
/h/set coal mill
8.5 Seal fan performance parameters
Seal fan (Model) 9-26 type 16D-4
Rated air flow m3
/h 64032
Rated hoisting head pressure Pa 6481
Seal fan motor (Model) Y355M2-6
Rated power KW 185
Rated speed r/min 960
Rated voltage V 415
Air filter (Model) 60M
Chamber number of each set 16
Air capacity of each chamber M³/h 4245
Resistance Pa 1370
Filtration index (particle diameter≥5um filter ratio) 95%

28
Chapter 9 Air Heater
9.1 Installation location of air heater: outdoor
Installation and operating conditions: it is used for heating secondary air when the ambient temperature is
low.
Arrangement mode: the secondary air heater is equipped on the forced draft fan outlet vertical air duct.
Quantity: each set of boiler is equipped with 2 sets of secondary air heater.
9.2 Technical data table of air heater:
No. Item Unit Secondary air heater
1 Model of air heater —— GNWCS-1.6/350-620
2 Number of sheets in parallel connection Sheet 2
3 Number of sheets in series connection Sheet 1
4 Air heater design pressure MPa 1.6
5 Air heater design temperature ℃ 350
6 Air heater draining pressure MPa 0.4~0.6
7 Air heater draining temperature ℃ Saturation temperature 159
8 Air heater inlet air temperature ℃ 8
9 Air heater outlet air temperature ℃ 20
10 Air heater air side resistance Pa <150
11 Air heater heat exchange area m2 620
12 Air heater interface dimension mm 8571 X5130
13 Air heater thickness mm 450
14 Air heater arrangement mode ——
Horizontal installation of horizontal vertical
air duct
15 Air heater weight kg 4.5
16 Adjusting mode Steam adjustment

29
Chapter 10 Air Compressor and Its Dryer
10.1 Overview of air compressor
Purpose of equipment: for supplying compressed air for instrument use of the whole factory and
maintenance use.
Allocation of equipment: heat engineering of this project is equipped with w compressed air rooms for
guaranteeing the compressed air for instrument and maintenance use. 1 compressed air room has 3 sets of
unit and is equipped with 4 sets of screw oil-free air compressor and 2 sets of screw slight oil air
compressor.
Design temperature: 8~50℃.
10.2 (instrument use) Main technical specifications of oil-free screw air compressor:
Model: SM250
Compressing medium: air
Air delivery: ≥ 41.5 m3/min (normal air is 101.3KPa (absolute), 20℃)
Exhaust pressure: ≥0.85Mpa
Exhaust temperature: ≤ cooling water temperature +8 ℃
Exhaust auto control range: 0%-100%
Adjusting mode: ON/OFF;
Max design temperature of Ingersoll Rand: 50℃
Indoor indraft and water cooling.
Quantity of equipment: 8 set (there are 6 sets of boiler in the whole factor, every 3 sets of boiler is
considered as one unit; each unit has 4 sets, of which 3 for operation and 1 for standby)
10.3 (Maintenance use) main technical specifications of oil injection screw air compressor:
Model: ML350
Compressing medium: air
Air delivery: ≥ 60.7 m3/min (normal air is 101.3KPa (absolute), 20℃)
Exhaust pressure: ≥0.75Mpa
Exhaust temperature: ≤cooling water temperature +8 ℃
Exhaust auto control range: 0%-100%
Adjusting mode: ON/OFF; air flow adjustment; ACS auto adjustment
Max design temperature of Ingersoll Rand: 50℃
Indoor indraft and water cooling.

30
Equipment quantity: 4 set (whole factory)
10.4 Performance data table of air compressor
No. Items Unit
Screw air compressor 40 Nm3/min 60 Nm3
/min
1 Model SM250 ML350
2 Type Oil-free screw Oil injection screw
3 Dimension (length×width×height) mm 3048 x 1930 x 2438 4650×1930 ×2146
4 Installation mode S1 S1
5 Adjusting mode ON/OFF;
ON/OFF; air flow adjustment;
ACS auto adjustment
6 Rated air capacity Nm3
/min 41.5 60.2
7 Rated exhaust pressure MPa (g) 0.85 0.75
8
Compressor speed
Male rotor of first stage rotor
Male rotor of second stage rotor
rpm 8292
13945
2185
9 Exhaust temperature ℃ Water temperature+8 Water temperature+8
10 Outlet air pressure dew point temperature ℃ Water temperature+8 Water temperature+8
11 Noise (at 1m) dB (A) 76 82
12 Weight kg 4306 7670
13 Rotor material
first stage: Carbon steel
second stage: stainless steel 304
Carbon steel
14 Oil content of exhaust ppm 0 3
15 Guaranteed service life Year 30 30
16 Cooling mode Water cooling Water cooling
17 Cooling water consumption t/h 19.1 18.2
18
Heat exchange area (the cooler area should
have 20% margin)
m2
19 Lubricating oil trademark/oil mass
IR-SL200
91L
Super cooling agent /204L
20 Shaft power of compressor KW 252.8 315
21 Rated air capacity KW 252.8 315
No load KW 53.2 64.3
Air compressor weight kg 4306 7670
22
Name/weight of the largest component for
maintenance
Motor/1890 Motor/1960
Clearance height of min maintenance m 2 2
Model & place of origin of screw and
motor bearing
SKF/ Sweden SKF/ Sweden
10.5 Air compressor motor data table
No. Motor Unit Oil-free 40 Nm3/min Slight oil 60 Nm3
/min
1 Quantity Set 1 1
2 Manufacturer Wuxi Hwada Motor Co., Ltd.
3 Motor model Squirrel cage motor
4 Degree of protection IP54 IP54
5 Speed/number of magnetic pole Piece 1475 4 1482
6 Full load output power of motor KW 287.5 345
7 Frame Y400 Y400
8 Weight 1860 7670
9 Number of motor electric heater 2 2
10 Voltage/power of motor electric motor 220v/200W 110v/200w

31
10.6 Overview of air compressor dryer
10.6.1 Equipment model: micro heat regeneration type after-treatment device (no air remover).
Purpose of equipment: for purifying the whole factory instrument use compressed air.
Installation site of equipment: indoor.
Allocation of equipment: this project is totally equipped with 8 sets of 45Nm3/min instrument use
compressed air drying and purifying device and 2 sets of 12Nm3/min instrument use air drying and
purifying device.
Design temperature: 8~50℃.
10.6.2 Main technical specification (instrument use 45Nm3
/min compressed air drying and purifying
device)
a. Model: SLAD-45MXF
b. Quantity: 8 sets.
c. Inlet compressed air pressure: 0.86Mpa (g).
d. Rated treated air delivery: ≥45Nm3
/min.
e. Inlet compressed air temperature: ≤45℃.
f. Inlet compressed air oil content: 0mg/m3.
g. Granularity of dust in outlet air: ≤1μm.
h. Regenerated air consumption: ≤5%.
j. Temperature of pressure dew point: ≤-40℃.
h. Water removal rate of dryer: ≥95%.
10.6.3 Main technical specification (maintenance use 65Nm3
/min compressed air drying and purifying
device)
a. Model: SLAD-65MXF.
b. Quantity: 4 sets.
c. Inlet compressed air pressure: 0.86Mpa(g).
d. Rated treated air delivery: ≥65Nm3/min.
e. Inlet compressed air temperature: ≤45℃.
f. Inlet compressed air oil content: <5mg/m3.
g. Granularity of dust in outlet air: ≤1μm.
Oil content of outlet compressed air: <1mg/m3.
h. Regenerated air consumption: ≤5%.
j. Temperature of pressure dew point: ≤-40℃.
h. Water removal rate of dry: ≥95%.

32
Chapter 11 Boiler Water Circulation Pump
Boiler water circulation pump
Model HLAV2×300-480/1C
Design temperature of pump
and insulator
365.3℃
Design pressure 20.56MPa Test pressure 30.84MPa
Dependable flow of single pump operation 3939m³/h Inlet pressure 194.36kg/ cm2
Total head 29.6m NPSH 19.5m
Boiler water circulating pump motor
Model Rated power 500kW
Rated voltage 11000V Rated current 43A
Rated speed 1465 r/min Start current 279A
Start time 1.4S Motor winding insulation PE2/PA
Design pressure 205.6kg/ cm2
g Design temperature 90℃
Maximum working
temperature
Alarm 63℃ Insulation level Y
Trip 66℃
Cooling water of boiler water circulating pump motor
Unit Cooling water Boiler water
Heat exchange content KJ/h 307700
Discharge ratio L/min 409 175
Inlet temperature ℃ 38 50
Outlet temperature ℃ 41 43
Design pressure kg/ cm2
g 10 205.6
Design temperature ℃ 50 90
Test pressure kg/ cm2
g 15 308.4
Normal discharge 10 m³/h Water supply pressure 0.2~0.4 MPa
Suspended matter content ≤5 PPm PH value 8~9.5

33
Chapter 12 Flame Check Cooling Fan
Flame check cooling fan
Model 9-19-NO.5.6A -18.5KW Max inlet temperature
Air flow rate 4200-7800 m3/h Rated air pressure of fan 7kPa
Turning
Flame check cooling fan motor
Motor model Y160-2 Rated current 35.5A
Motor power 18.5 kW Voltage 415V
Speed 2900r/min Manufactured by Wannan motor

34
Chapter 13 Startup Boiler
13.1 Equipment name: fuel oil startup boiler
Model: fuel oil, micro positive pressure, ready package and outdoor arrangement
Model: SZS35-1.2/320-YC
Boiler efficiency is not lower than 91%
Operating mode: continuous operation
Induced draft fan is not set.
13.2 Operating parameters of fuel oil startup boiler
Item Unit Value
Rated steam flow rate t/h 35
Rated pressure MPa 1.2
Rated temperature ℃ 320
Fuel Light oil
13.3 Main technical parameters of startup boiler
Item Unit Parameters Remark
Max continuous evaporation capacity BMCR T/h 35
Rated steam capacity T/h 35 Overload 110%
Rated steam pressure MPa (g) 1.2
Rated steam temperature ℃ 320
Rated inlet water temperature ℃ 20
Hot wind temperature ℃ 20
Heat exchange area M2 665 Whole boiler
Exhaust gas temperature ℃ 160
Heat efficiency % 92.4
Boiler computational efficiency % 92.4
Boiler guaranteed efficiency % 91.2
Boiler max continuous blowdown rate % 3
Boiler max air leakage rate % 0
Superheated steam temperature deviation ±15
Operating time at 10% boiler overload 15
Burner model and arrangement mode
Mechanical atomization
front wall arrangement
Furnace pressure ±10KPa
Max withstand
pressure
Furnace volume 52
Furnace basic size (depth×width×height)
2160x11370x2210
(on average)
Drum working pressure 1.32MPa
Min load of boiler 30%
Net weight of boiler T 88
Boiler full water weight T 110
Weight of largest hoisting element for
maintenance
2t
Burning mode
Micro positive pressure
chamber burning

35
Burning djusting mode Proportional control
Fuel LDO
Burner oil pressure
Burner fuel valve unit
inlet oil pressure
3.0-3.5MPa
Fuel consumption kg/h 2730
Superheater temperature adjusting mode Plate type attemperating
Water wall material SA-106 Gr.B
Superheater material SA213-T12
Total electric power kW 270
Oil pump kW 16.5
Lighting and maintenance kW 30+50
Feed water pump kW 55
Fan kW 110 Supplied alone
Furnace volume 52
Max transportation dimension m 13x4.7x4.4
Chimney height m 20
Chimney diameter and wall thickness m 1.2m t12

36
Chapter 14 Soot Blowing System
Soot blower of boiler is to keep the heating surface clean and produce good heating effect. The whole soot
blowing system has two parts of boiler proper heating surface sootblowing and preheater sootblowing. The
boiler proper part has 80 furnace soot blowers arranged in the furnace part, 44 long retractable soot blowers
arranged at the upper part of furnace and convection pass area. The outlet end of each set of preheater flue
gas side is equipped with 1 retractable soot blower; the sootblowing steam of proper part is received by the
division wall superheater outlet header with steam temperature 443℃ and pressure 18.20MPa (gauge); the
preheater sootblowing steam is received by rear platen superheater outlet header with temperature 501℃
and pressure 17.8MPa (gauge); they will get into each soot blower passing through pressure reducing valve;
there is automatic drainage point in the pipeline and sootblowing control of boiler is realized by DCS; the
system design always take into consideration that 2 long retractable, 2 furnace soot blower and 2 air
preheater are put into operation at the same time; the long retractable type and furnace soot blower on the
opposite side of wall has 1 soot blower putting into operation respectively or it can be set as user requires.
14.1 Soot blowing system of boiler proper
The soot blowing system of boiler proper is equipped with one set steam pressure reduction station; the
sootblowing steam gets into two division wall superheater outlet headers and get together, then passes
through 2″ pneumatic file pressure reducing valve for reducing pressure, the setting value is 2.94MPa
(30kgf/cm2) and temperature is about 330℃; the optimum application value is determined by various
situations after soot blower is put into operation and this pressure should be regulated by user as needed.
There is a manual stop valve and a motor-operated stop valve at the pressure reducing valve front pipeline
for closing steam source
A safety valve is set on the pressure reducing valve rear pipeline to prevent steam overpressure. There is
also pressure measuring point on the pipeline to monitor the pressure reducing valve outlet pressure. The
sootblowing steam is divided into two ways to get to the furnace soot blower after pressure reduction and
the long retractable soot blower is used for purging steam. Flow switch is set on each blowing pipe and
connected with program control; the set value of flow switch contact is to keep the minimum cooling flow
rate required by soot blower. Drain water system is set in the blowing pipeline to ensure proper dryness of
sootblowing; the proper sootblowing part has 4 drain points, of which 2 in furnace soot blower and long
retractable soot blower; each drain point drain pipeline has one motor-operated stop valve for temperature
control and water drainage and the open and close set value of the valve is 300℃; the horizontal pipeline
should keep 0.025m/m slope at least to ensure thorough drainage.
Note: The final setting values of steam pressure and drainage temperature subject to the instruction of soot
blower manufacturer.
14.2 Soot blowing system of preheater
The steam of air preheater sootblowing comes from rear platen superheater outlet header; the pressure will
be reduced by passing 1.5″ pneumatic film pressure reducing valve, of which the setting value is 2.94MPa
(30kg/cm2) and temperature is about 420℃ (this value can be regulated according to the operating
conditions). There is also stop valve in the front of pressure reducing valve and safety valve and pressure
measuring point, etc. behind the valve. The steam divides into two ways in the header pipe and then gets
into the air preheater soot blower. This system has one drain point for temperature control and drainage; the
drain valve is motor-operated stop valve, of which the open and close set value is 350℃; the superheat

37
degree of temperature controller should be set as high as possible in the building site when setting
temperature.
Note: The final setting values of steam pressure and drainage temperature subject to the instruction of soot
blower manufacturer.
There is also soot blower auxiliary steam pipeline on the header pipe; the auxiliary steam comes from the
auxiliary steam mains arranged by the design institute with steam pressure of 0.95~1.1MPa (gauge pressure)
and temperature of 325~360℃; the steam passes gets to the blowing pipeline by passing through the stop
valve and check valve; the switching conditions of auxiliary steam and normal steam valve:
(1) The pressure reduction station of air preheater sootblowing steam source will open for supply
sootblowing steam when the boiler load is larger than 30%MCR.
(2) The auxiliary steam source valve will open for supplying auxiliary steam when the boiler load is smaller
than 30%MCR or in startup stage.
Note: the switching conditions of final auxiliary steam and normal steam valves subject to the materials of
supplier.
Main design parameters of soot blowing
No. Items Soot blower of furnace Long retractable soot blower Air preheater soot blower
1 Model V04 PS-LL PS-AT
2 Travel (mm) 255 10600 970
3 Purging angle 3600 3600 Vertical
4
Effective purging radius
(mm)
2500 1500~3500 2000
5
Travel speed of blowing
pipe (m/min)
0.5 2.0 1.44
6
Rotation speed of
blowing pipe (rpm)
2.7 24 24
7 Purging time (s) 50 606 Undetermined
8 Working time (s) 55 630 Undetermined
9
Steam consumption
(kg/min) (single unit)
82 170 80
10 Motor model M2QA71M4B M2QA90S4A M2QA90S4A
10-1 Power (kW) 0.25 1.1 0.55
10-2 Speed (rpm) 1400 1390 1400
10-3 Insulation level F F F
10-4 Level of protection IP55 IP55 IP55
11
Recommended purging
pressure (MPa)
1.0~1.5 1.0~1.5 1.0~1.5

38
Part
Part
Part
Part 2
2
2
2 Startup
Startup
Startup
Startup and
and
and
and Shutdown
Shutdown
Shutdown
Shutdown of
of
of
of Boiler
Boiler
Boiler
Boiler
Chapter 1 Rules & Conditions of Unit Startup
1.1 Startup rules
1.1.1 Shift engineer directs the normal startup of unit and takes charge of the centralized control staff to
start up according to the instruction, and specialist engineer in Operation Department take charge of the
technical supervision and technical director on site.
1.1.2 Check the reports for the relevant equipment & system abnormal action, completion and oil
qualification are complete prior to startup after the overhaul or minor maintenance of unit.
1.1.3 Verify that all the check & maintenance work of unit have been finished completely, all the
worksheets are taken back, sanitation on site is accorded with the standard, the relevant temporary work
platform of check & maintenance is dismantled and check and acceptance of cold state is qualified.
1.1.4 Transmission test of each valve is done by Department of production technology that takes charge of
unified coordination and arrangement and Operation Department that cooperates after the overhaul and
minor maintenance of unit.
1.1.5 Contact the thermal technical staff to do the interlock and protection test work of relevant equipment
and system and keep records.
1.1.6 All kinds of record lists and vibration gauge, thermo detector and listening rod etc. instruments &
tools prior to startup shall be prepared ready.
1.1.7 All the level meters are bright and clean and each signal primary valve of relevant pressure gauge,
flow gauge and protection gauge is opened.
1.1.8 Contact the thermal technical staff to supply power to all the thermo technical instrument, signal and
protection device of main control.
1.1.9 Check that oil level of each rotating equipment bearing is normal, oil circulation is normal, oil
pressure is normal and oil quality is qualified.
1.1.10 All the motor-operated valves, governing valves and modulating dampers are powered on and
display status is accorded with the practice.
1.1.11 Power on after verifying the insulation of all electrical equipment is qualified and grounding line of
enclosure is in good condition.
1.1.12 Hydraulic test of boiler needs to be done after overhaul or minor maintenance of unit or finishing
displacing the heating surface that leaks.
1.1.13 Check that expansion indicator shall be put into operation and record the original value.
1.2 Selection of unit start mode
1.2.1 The unit starts up in cold start mode when the boiler and steam turbine are in cold state.
1.2.2 The unit starts up in hot start mode when the boiler and steam turbine are in hot state.
1.2.3 The unit selects pressure boosting rate and temperature rising rate in cold start mode and impulse time
of unit and unit warm-up time of initial load is selected in hot start mode when the boiler is in cold state but

39
the steam turbine is in hot state.
1.2.4 Division of unit boiler startup condition
1.2.4.1 Boiler cold state: shutdown time is more than 36 hours without pressure of boiler.
Boiler hot state: shutdown time is less than 10 hours.
1.2.4.2 The time from ignition of boiler to unit with full load (BMCR) (matching with steam turbine)
Start state Cold Warm Hot
Time <8 hours <2.5 hours <0.75 hours
1.2.5 Division of startup condition of unit steam turbine
Startup mode Definition of startup mode
Cold state
Shutdown for more than 36h (mental temperature reduces to lower than 40% of the
testing point temperature with full load, T<305℃)
Warm state
Shutdown for 10~36h (mental temperature reduces to between 40% and 80% of the
testing point temperature with full load, 305℃≤T<420℃)
Hot state
Shutdown within 10h (mental temperature reduces to higher than 80% of the testing
point temperature with full load, 420℃≤T<490℃)
Very hot state
Shutdown within 1h (mental temperature is close to the testing point temperature with
full load, 490℃<T)

40
Chapter 2 Boiler Cold Start
2.1 Check & preparations prior to boiler start
2.1.1 All the check & maintenance work that influence the start of unit has been finished and work sheets
have been finished according to the relevant rules. Safety measures are removed, and the operators have
known the condition of check & maintenance and device improvement clearly.
2.1.2 Interlock & protection test of each main unit & auxiliary equipment has been finished and qualified;
baffle of each motor valve, pneumatic valve and air valve has been finished adjusting and testing and their
switch directions are right; the auxiliary equipment that is checked & maintained has been normal through
trial run part by part.
2.1.3 Any faults in each part that obstruct expansion are to be checked and removed and each expansion
indicator is mounted on correct position. Messes and rubbish around boiler were removed to guarantee the
platform, stairs and railing complete and firm and there are no sundries in the passage and around the
equipment obstructing the operating and passing.
2.1.4 All the system connections are in good condition and all pipeline supports are firm and pipeline
insulation is complete. The hangers of steam-water pipeline, air and flue gas duct and burner etc. are
complete and bear pressure evenly, and spring hanger has been in normal working condition.
2.1.5 Temporary fence, signboard of each site and temporary cover plate of all kinds pipelines have been
dismantled.
2.1.6 Each site illumination of workshop inside and outside is in good condition and accident illumination
system is in normal condition that can be put into operation at any moment.
2.1.7 Centralized control room and local control panel & cabinet are complete and all kinds of indicating
recorder, alarm device and operation & control switch are in complete and good condition.
2.1.8 Plant fire-fighting system is put into operation normally and fire-fighting device is complete.
2.1.9 All kinds of relevant operating power source, control power source and instrument power source shall
be powered on and in normal condition.
2.1.10 All the primary and secondary valves of local measurement device are opened and meters indicate
correctly.
2.1.11 Verify the setting value is correct and put it into “AUTO” after the adjustment & test of
local-mounted control device is finished.
2.1.12 Communication between each post is smooth.
2.1.13 Special tool, instrument, gauge and all kinds of record paper of unit startup and work sheet that are
used in startup have been prepared; the staff has been arranged well.
2.1.14 Control & monitor systems such as DCS, DAS, FSSS, BMS, D-EHG, MEH, HITASS, TSI, PRP,
ASS and bypass etc. are put into normal operation; each parameter indication on the CRT is correct.
2.1.15 Each manhole valve of boiler proper and air & flue gas ducts is closed tightly; all the air valves and
flue pipe baffles are opened and closed flexibly; local switch position of baffle shall be accorded with the
indication of meter, and spring support of proper and steam water pipe is in good condition without

41
expansion obstacles.
2.1.16 Each sootblower of boiler exits from the boiler to be in standby condition.
2.1.17 Furnace gas temperature probe exits to be in standby condition.
2.1.18 All valves are to be check for on the correct start-up position, no leak, operate flexibly, the
motor-operated and pneumatic actuator operates normally, and the opening extent indication is in
accordance with actual position.
2.1.19 The steam drum water gauge pointer is complete, indicates correctly and is lighted well, the water
level videotaping system works normally.
2.1.20 TV Taking lens of furnace flame is in good condition and cooling air is put into operation.
Combustion system shall be checked with the doper position, furnace front oil system and burner wind-box.
Ash & slag handling system and boiler water circulating pump and control system can be put into operation
normally.
2.1.21 Check the actuating device, sealing clearance and lubricating cooling system of rotary air preheater
and each indicator is in normal position. Confirm sealing clearance sector panel of air preheater hoists to
maximum and hotspot detection system is put into operation well.
2.1.22 The following parameters shall be monitored and adjusted with emphasis when the unit starts up:
Steam drum pressure and temperature difference between upper wall and lower wall of steam drum; main
& reheated steam temperature & steam pressure;
Furnace negative pressure; furnace air flow; opening of adjustable vane of induced draft fan & air blower;
Opening of guide vane of primary air fan; flue gas temperature of each section of flue gas duct; hot primary
& secondary air temperature;
Outlet air powder temperature & primary air flow of pulverizing mill;
2.2 Test rules prior to start
2.2.1 Test and trial run of device must be presented with a written application by maintainer and can be
performed only when it is approved by shift engineer and test command is issued.
2.2.2 Device test is coordinated by maintainer in charge and is matched operation by operator and relevant
staff is on site.
2.2.3 Test method of device is divided into two kinds: static state and dynamic state; when it is static state
test, boiler running with above 11kV is only supplied test power source, 2.215V LV power source is given
dynamic power source; when it is dynamic state test, both operation & dynamic power source are
connected.
2.2.4 The above test is carried out after the overhaul or minor maintenance of unit. Some tests can be
carried out separately after the check & maintenance as required. Dynamic state test can only be carried out
after the static state test is qualified.
2.2.5 Oil pump and air & flue gas baffle position etc. shall satisfy the conditions of program control
requirement prior to the protection & interlock test. Test can be carried out only when the relevant
conditions are forced to be satisfied by thermo technical staff.

42
2.2.6 Test operation of each interlock, protection and accident button shall be accurate and reliable; audible
and visual alarm and CRT menu condition indication are normal.
2.2.7 Motor-operated valve, control valve and air valve baffle are qualified through teste.
2.2.8 Test requirements:
2.2.8.1 The system that has been put into operation and the motor valves & control valves that are under
pressure cannot be tested.
2.2.8.2 Both remote control and local control shall be tested for the servo mechanism that has local control
and remote control and have specially-assigned person record the time of opening and closing and test
condition.
2.2.9 Test method:
2.2.9.1 Full open and full close test of remote & local control shall be carried out for all the motor valves
and air valve baffle according to the test card, the opening indication and local indication shall be accordant,
the motor-operated valve and damper baffle with intermediate stop should be normal at the intermediate
stop position.
2.2.9.2 Pneumatic control device shall operate flexibly without air leak or abnormal phenomena.
2.2.10 Opening and closing and accident button tests (static)
2.2.10.1 Start all the equipment separately, and they are good as verified in the opening and closing test,
then resume their closing position.
2.2.10.2 Stop all the auxiliary equipment with the accident button on site respectively, and the
corresponding auxiliary equipment should trip and audible and visible signal alarm should be normal.
2.3 Operations prior to impulse starting in cold start
2.3.1 System put-in
Put in the following systems gradually and check that it is in normal operation according to the check card
and the relevant content in chapter Start and Stop of Auxiliary equipment & System of Unit. The balance of
load distribution of each section shall be considered comprehensively when it puts into the system.
2.3.1.1 Fire fighting water system;
2.3.1.2 Plant-service compressed air system;
2.3.1.3 Auxiliary steam system is put into operation;
2.3.1.4 Industrial cooling water system;
2.3.1.5Open cooling water system;
2.3.1.6 Closed cooling water system;
2.3.1.7 Boiler slag hopper water seal system;
2.3.1.8 Lubricating oil system of each auxiliary engine;
2.3.1.9 Fuel system;
2.3.1.10 Boiler bottom water seal system;

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2.3.1.11 Demineralized cooling water system;
2.4 Water filling and heating of deaerator
2.4.1 Water tank of deaerator is made up with water up to normal level and contact the chemical staff to
feed chemical to the deaerator.
2.4.2 Verify that turning gear of main unit is put into operation normally.
2.4.3 Start up the electrically driven feed pump or booster pump of steam pump and put the auxiliary steam
of deaerator into operation to heat, adjust the auxiliary steam to pressure control valve of deaerator to make
the water temperature of deaerator rise slowly, which is close to the steam drum wall temperature as much
as possible. Make adjustment and open the deaerator to start exhaust to guarantee qualified dissolved
oxygen.
2.4.4 Water filling and deflating of feed pump
2.5. Boiler water filling
2.5.1 Filling water prior to startup of boiler shall be checked according to the check operation card and
carried out after the startup conditions are met.
2.5.2 If the boiler had water originally, ask for instruction from the shift engineer according to the chemical
assay result to confirm whether drain off water or not.
2.5.3 Start up the electrically driven feed pump to start filling water to the boiler.
2.5.4 The temperature difference between boiler water filling temperature and steam drum wall temperature
should be <90℃ and water quality must be qualified.
2.5.5 Verify that boiler water circulating pump has been put into continuous flushing water.
2.5.6 Verify that the startup conditions of electrically driven feed pump are met.
2.5.7 Start up the electrically driven feed pump to check that its motor current is normal.
2.5.8 Open the recycle valve of economizer to make the feed water enter the lower header of water wall,
which is convenient for exhausting air.
2.5.9 Adjust the rotating speed of electrically driven feed pump and control the feed water flow 30~60t/h
and the entire time of water inlet is that summer is >2 hours and winter is >4 hours.
2.5.10 Reduce the rotating speed of electrically driven feed pump to make the water level rise to +200mm
slowly when water level appears in the water level gauge of steam drum.
2.5.11 Close the outlet valve of electrically driven feed pump to stop filling water.
2.5.12 Inch for exhaust of boiler water pump when the water level of steam drum is high.
2.5.13 Close the air valve on the top of steam drum and start up B boiler water pump.
2.5.14 Stop boiler water circulating pump B and fill water to +200mm when the water level of steam drum
reduces to minimum visible water level.
2.5.15 Start up the boiler water circulating pump A and then start up boiler water circulating pump B & C
after the water level is stable.

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2.5.16 Contact the chemical staff to feed chemical to the steam drum.
2.5.17 Check that all the spray water control valves and stop valves of spray type attemperator are closed.
2.5.18 Check that all the drain valves and vent valves are in the position of opening.
2.5.19 Open the drain valve of superheater.
2.6 Put-in of air & flue gas system of boiler
2.6.1 Check and verify that boiler proper, each manhole valve of air & flue gas dust and fire observation
valve are closed tightly and bottom water seal is put into operation normally.
2.6.2Start up the pneumatic motor of air preheater A & B and after rotation is normal, start up the
electromotor of air preheater A & B and confirm the pneumatic motor is stopped, put the pneumatic motor
to “AUTO”. Confirm the air & flue gas baffle has been opened. Put the upper & lower bearing oil pump
interlock of air preheater into operation, adjustment device of sealing clearance exits “AUTO” and
clearance is to maximum position.
2.6.3 Start up the induced draft fan of one side and check everything is normal. Open the adjustable vane
slightly to adjust the furnace negative pressure to be about -50Pa and put the adjustable vane into “AUTO”.
2.6.4 Start up the air blower on the same side to check that everything is normal.
2.6.5 Start up the induced draft fan of the other side to check that everything is normal; adjust the furnace
negative pressure to about 50Pa and put the adjustable vane into automatic.
2.6.6 Start up the air blower on the other side to check that everything is normal.
2.6.7 Adjust the furnace negative pressure to be about -50Pa and total air flow ≥30%MCR by adjusting the
opening of adjustable vane of induced draft fan & air blower.
2.6.8 Adjust the auxiliary air baffle to make the pressure difference between big bellow and furnace about
381MPa.
2.6.9 Put the swinging burner to horizontal level.
2.6.10 Start up one fire detector fan and put the standby fan into standby.
2.6.11 Put the air heater into operation as required.
2.7 Oil leakage test
2.7.1 Trigger the oil leakage test simultaneously as the furnace purging starts.
2.7.2 Allowable conditions of oil leakage test:
2.7.2.1 Oil supply pressure is normal;
2.7.2.2 There is no fire in the whole furnace;
2.7.2.3 All the doper solenoid valves are closed;
2.7.2.4 No MFT trip condition;
2.7.3 Oil (light fuel) leakage test shall be carried out according to the following steps when all the
conditions are met:

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2.7.3.1 Control valve of fuel oil inlet is put into operation manually and open the control valve of fuel oil
inlet;
2.7.3.2 Open the fast valve of oil inlet and oil return to fill the pipeline with oil, and close the fast valve of
oil return after delaying 10 seconds.
2.7.3.3 If the oil header pressure does not reach the set value in 40s, oil charge fails and the test breaks off;
or after the oil pressure is reached, header oil charge succeeds and close the oil inlet fast closing valve.
2.7.3.4 Start the oil pressure monitoring process for 3 minutes. If the oil header pressure is lower than the
setting value (light oil pressure is lower than 3.5Mpa and heavy oil pressure is lower than 1.9MPa) in the
process, it indicates there is leak in pipeline and the test is broken off; if not, open the oil return valve 3
minutes later and pipeline leaks oil, close the oil return valve after the oil pressure is lower and start the oil
pressure monitoring process for 3 minutes. If the front & rear differential pressure of oil inlet fast valve is
lower than the setting value (uncertain) in the process, it indicates there is leak of oil inlet fast valve and the
test is broken off; if not, the whole test is successful after 3 minutes.
2.7.3.5 In addition, bypass oil leakage can be tested, which is forced to generate the normal condition of
check leakage test.
2.7.4 If test is in failed in the process of test, inform the thermodynamic staff and maintainer to check and
re-test after treatment.
2.7.5 Conduct the oil leakage test of heavy fuel oil system according to the above conditions and sequence.
2.8 Furnace purge
2.8.1 Conditions for purging furnace:
(1) There is air blower in operation;
(2) There is induced draft fan in operation;
(3) All the oil angle fast valves are closed;
(4) Fuel trip valve is closed;
(5) No MFT command
(6) All the coal feeders are stopped;
(7) All coal mills have been stopped;
(8) Steam drum level is normal;
(9) All the fire detectors indicate no fire;
(10) Air volume is appropriate;
(11) Fire detection cooling air is normal
(12) Preheater is in operation;
(13) Cottrell stops operation;
(14) Baffle of secondary air valve is in the adjustment position;
(15) Oil leak test is finished.

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(16) Power source of FSSS system is normal;
(17) Power source of MCS system is normal;
(18) S SOFA baffle is closed;
(19) Primary air fan is shut down;
2.8.2 Verify all the conditions for purging furnace are provided.
2.8.3 Press the key of “Purging Request” on the LCD screen and the timing purging of 5 minutes will be
started. “Purging” signal is appeared on the LCD screen.
2.8.4 If any one purging condition is not met in the timing purging process for 5 minutes, break off purging.
It can be re-started purging after all the purging conditions are met again.
2.8.5 “Finish Purging” signal is appeared on LCD screen and first trip signal of MFT is reset automatically
after the timing purging of 5 minutes is finished. Slag handling system of boiler is put into operation; ash
conveying system is put into operation.
2.9 Ignition of boiler
2.9.1 Main protection of boiler and supervision TV of furnace flame shall be put into operation and local
flue gas temperature probe shall be put into operation to make the probe enter the furnace manually or
remote control as ruled prior to ignition of boiler.
2.9.2 Open the inlet header of roof tube and drain valve of superheater and open the recycle valve of
economizer.
2.9.3 Start the ignition of light doper of BC layer after verifying that all the ignition conditions are met.
2.9.4 If the ignition of boiler I sin failure, it must re-purge the furnace and ignite again.
2.9.5 Verify the oil recycle valve shall be closed automatically after ignition of the first doper.
2.9.6 Keep the gas temperature of furnace outlet lower than 538℃ after confirming ignition is successful.
2.9.7 Verify ignition for three times is in failure, it can be re-ignited after furnace re-purging.
2.9.8Observe the firing condition locally after ignition and verify the oil atomization is in good condition
and air distribution is proper. If some doper is found no fire, close the oil supply solenoid valve of this
doper immediately and exit operating position. It can be re-put into operation after purging.
2.9.9 Verify that recycle valve of economizer is opened when feed water flow is less than 25%.
2.9.10 Maintain the normal water level of steam drum and drain off contamination of boiler as required
according to the quality of boiler water.
2.9.11 Put air preheater into operation to continue sootblowing after ignition of boiler.
2.9.12 When all the permissive conditions are met, igniters of two coal seams can be allowable logically to
ignite once if header pressure is normal.
a) All the permissive conditions are met and the oil header pressure of AB layer is normal;
b) All the permissive conditions are met and the oil header pressure of BC layer is normal;
c) All the permissive conditions are met and the oil header pressure of CD layer is normal;

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d) All the permissive conditions are met and the oil header pressure of EF layer is normal;
e) All the permissive conditions are met and the oil header pressure of FG layer is normal.
2.9.13 No matter whether the first doper succeeds in ignition or not, the other doper will be prohibited to
ignite in 60 seconds.
2.9.14 Put the first doper into operation and so does the second one after 60 seconds. Observe if the STV
and fire inspection indicator of furnace flame are normal.
2.9.15 If there is not any one pair of dopers succeeding in ignition within 10 minutes from MFT tripping
relay resetting, the operation of ignition protection will be delayed to touch off MFT.
2.9.16 Put the furnace gas temperature probe into operation after the ignition of boiler. Put the PCV valve
into "AUTO". Confirm the recycle valve of economizer is opened. Put the air preheater into operation to
continue sootblowing. Inform the person on duty to put the electric precipitation shaking device into
operation.
2.9.17 Initial steam boosts pressure at the pressure rising rate of 0.015MPa/min and0.85℃/min.
2.9.18 Switch over the doper regularly during 0.5~1 hour of cold start beginning.
2.9.19 Check the swelling value condition of each site and record the swelling value in the process of boiler
temperature rising gradually.
2.9.20 Pay attention to the change of steam drum water level anytime in the process of boosting pressure
and maintain the water level between +50mm. Monitor the upper & lower wall temperature of steam drum
inside not higher than 50℃ closely.
2.9.21 Water level gauge is flushed when the steam drum pressure rises to 0.1MPa.
2.9.22 Close the air valve of steam drum when the pressure of steam drum rises to 0.15MPa.
2.9.23 Close all the air valves when the pressure of steam drum rises to 0.2MPa.
2.9.24 Close the drain motor valve of inlet header of roof tube when the pressure of steam drum rises to
0.5MPa.
2.9.25 Stop the continuous filling water of boiler water circulating pump when the pressure of steam drum
rises to 2.0MPa.
2.9.26 Put the solenoid safety valve of superheater outlet into “AUTO” when the pressure of steam drum
rises to 3.5MPa.
2.9.27 The boiler controls parameter according to the requirements of steam turbine and steam turbine
prepares to impulse when the steam drum pressure rises to 6.0MPa, main steam temperature rises to 335℃
and reheater temperature rises to 315℃.
2.9.28 Increase the dopers that are put into operation and keep firing stable prior to the impulse of steam
turbine.
2.10 Impulse starting parameters of cold state:
2.10.1 Impulse starting parameters in IP cylinder startup mode:
a. Cold start (long-term shutdown):

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Main steam pressure: 6.0MPa; Main steam temperature: 335℃;
Reheated steam pressure: 1.10MPa; Reheated steam temperature: 315℃;
Condenser vacuum: >74kPa; HP bypass flow: >140t/h;
b. Cold start (shutdown for 72h):
Main steam pressure: 6.0MPa; Main steam temperature:370℃;
Condenser vacuum: >74kPa; HP bypass flow: >120t/h;
2.10.2 Impulse starting parameters in HP cylinder startup mode:
a. Cold start (shutdown for long-term):
Main steam pressure: 6.0MPa, Main steam temperature: 325℃;
Reheated steam temperature: 300℃, Main steam flow: >100t/h;
Condenser vacuum: >74KPa
b. Cold start (shutdown for 72h):
Main steam pressure: 6.0MPa; Main steam temperature: 350℃;
Reheated steam temperature: 320℃; HP bypass flow: >100t/h;
Condenser vacuum: >74KPa;
2.10.3 Pay attention to the water level change of steam drum and in the process of impulse. Strengthen the
coordination of boiler and turbine, stable the combustion and maintain the water level of steam drum
normal. Make an overall check and tighten each drain valve after the conversion operations are finished.
2.11 Start and check adjustment of pulverizing coal system
2.11.1 Verify that the secondary air temperature is higher than 177℃, primary air system is in normal
operation and start up the first pulverizing coal system (choose B or A if no abnormal). Continue to run up
the load and keep main steam pressure 6.0MPa constant at this moment with main steam & reheated steam
temperature rise rate 0.125℃/min and load rate 3MW/min.
2.11.2 Put the slag handling system of boiler into operation (has been put into operation before ignition); it
can put one electric field of Cottrell into operation.
2.11.3 Check that the lubricating oil system and MEH system of feed water pump steam turbine are normal
when the load is 150MW, then start up the first feed water pump steam turbine. After the water level of
drum is stable, put drum water level to AUTO according to the operation conditions of steam-driven feed
water pump.
2.11.4 Start up the second pulverizing coal system and put it into operation when the load increases to
150MW.
2.11.5 Verify that main steam pressure is 6.0MPa and oxygen is put into operation automatically and load is
kept for 20min when the load increases to 200MW.
2.11.6 Fully check and close the steam-driven drain valve in LP section and check that the indications of all

49
motor-operated and steam-driven drain valves on LCD are correct when the load increases to 200MW.
2.11.7 Run up to 300MW after warming up for 20min with 200MW load with increasing rate of 3MW/min.
The rising temperature rate of main steam is 1.5℃/min and rising pressure rate of main steam is
0.1MPa/min.
2.11.8 The third pulverizing coal system can be started up and put into operation when the load of boiler is
270MW.
2.11.9 Keep the load for 20min when it is 300MW and confirm the main steam pressure rises to 10.0MPa,
main steam temperature is 520℃ and reheated steam temperature is 510℃.
2.11.10 Verify the control mode for over fire air baffle is put into “AUTO”.
2.11.11 Start up the second steam-driven feed water pump, when its speed is the same as that of the first
operating pump, put the speed to auto control.
2.11.12 Lower the output of motor feed water pump gradually; after the two steam pumps are in normal
operation, stop the motor feed water pump and put it into standby.
2.11.13 Verify that burning in furnace is stable and all the monitoring parameters of boiler are stable, and
stop the operation of doper that shall be exited after purging clean and open the fuel recirculation valve
when the unit load reaches to 300MW. Inform the fuel person on duty.
2.11.14 Verify the control mode for attemperating water of superheater and reheater is in “AUTO” and
confirm steam temperature adjustment of superheater and reheater is normal.
2.11.15 Verify all the systems are in normal operation and contact thermodynamic personnel to put them
into automatic control.
2.11.16 When the initial steam pressure reaches 10.0MPa, increase the opening of continuous blowdown
flash tank to perform silicon cleaning; the pressure can be boosted continuously when the silicon content in
the boiler water reaches the allowable silicon content of next degree pressure according to the chemical
analysis. Perform silicon cleaning according to the requirements under each pressure in the following table.
Pressure (MPa) 9.8 11.8 14.7 16.7 17.7
SiO2 content (mg/L) 3.3 1.28 0.5 0.3 0.2
2.11.17 Start up the fourth pulverizing coal system and put it into operation and run up to 600MW after
warming up for 20min with 300MW load with increasing rate of 6MW/min. The rising temperature rate of
main steam temperature is 1.5℃/min and rising pressure rate of main steam pressure is smaller than
0.2MPa/min.
2.11.18 Start up the fifth pulverizing coal system and put it into operation when the load is 400MW.
2.11.19 Carry out overall sootblowing to the boiler when the load is 400MW. The air preheater is changed
to regular sootblowing from continuous sootblowing.
2.11.20 Start up the sixth pulverizing coal system and put it into operation and run up to 600MW when the
load is 500MW.
2.11.21 The main steam pressure will be 16.7MPa, main steam temperature will be 538℃, reheated steam
pressure will be 3.30MPa and reheated steam temperature will be 538℃ when load is 600MW.

50
2.11.22 When the unit is of full load, make an overall check and adjust the equipment of unit to make them
in the best operation condition; the unit will be put into normal operation if there is no abnormity and count
the current faults of the unit.
2.12 Precautions in the process of boiler startup
2.12.1 Check that boiler front fuel oil system is normal regularly and keep the air preheater continue
sootblowing during fuel oil injection.
2.12.2 Prevent the initial steam temperature and reheated steam temperature from fluctuating and prevent
the steam with water strictly after startup of the steam turbine.
2.12.3 Gas temperature of furnace outlet shall not exceed 538℃ when steam flow is <7%MCR or before
the generator parallels off.
2.12.4 Close the recycle valve of economizer and exit the furnace gas temperature probe when the feed
water flow or steam flow >7%MCR.
2.12.5 Temperature rise rate of boiler water is <1.5℃/min.
2.12.6 Pressure boosting shall be stopped and open wide the continuous blowdown valve for silicon
cleaning when the SiO2 content exceeds the limit in the whole process of boosting pressure.
2.12.7 Pulverizing mill is in normal operation after startup, primary air flow shall be kept 60%~80% to
operate. If the primary air flow of pulverizing mill is lower than 40% (or lower than 25% when choose a
pair of burner), the corresponding doper shall be put to supporting combustion.
2.12.8 Putting the burner into operation shall be carried out from the lower layer to upper layer as much as
possible.
2.12.9 The adjustment of fuel shall be even in order to prevent too significant fluctuation of steam drum
water level, main steam temperature, reheated steam temperature and furnace negative pressure.
2.12.10 Pay attention to monitoring the change of air preheater parameters to prevent secondary burning
from occurring in the process of boiler startup. When the outlet flue gas temperature is found to rise
abnormally, put the preheater into operation to continue sootblowing and do necessary treatment.
2.12.11 Pay attention to monitoring the working condition of furnace negative pressure, air output and coal
feeder etc. automatic control and if something is abnormal, deal with it immediately.
1.12.12 Pay attention to monitoring the combustion condition and adjust the combustion in time to make
burning stable, especially when the doper is started and stopped and the pulverizing mill is started and
stopped.
2.12.13 Pay attention to monitoring the wall temperature of superheater and reheater to prevent pipe
explosion caused by over-temperature strictly in the process of boiler startup and operation.
2.12.14 Fuel system shall be in circulation and standby condition after full-stop-oil and check all the dopers
have been exited from the furnace on site.

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Chapter 3 Hot Start
3.1 Hot start shall raise speed, warm up and load on according to the hot start curve besides that it performs
the relevant rules and operation steps of cold start strictly.
3.1.1 Impulse starting parameters in IP cylinder hot start are as follows:
Main steam pressure: 8.62MPa; main steam temperature: 440℃;
Condenser vacuum: >74KPa; HP bypass flow: >190t/h;
Rising rate: 300 rpm/min;
3.1.2 Impulse starting parameters in HP cylinder hot start are as follows:
Main steam pressure: 8.62MPa; main steam temperature: 450℃;
Main steam flow: 170t/h; Reheated steam temperature: 430℃;
Condenser vacuum: >74KPa; rising rate: 300 rpm/min;
3.2 Main reheated steam that enters steam turbine has 50℃ degree of superheat at least.
3.3 Put the pulverizing coal system and bypass system into operation immediately after the ignition of
boiler, control the main reheated steam temperature strictly according to the temperature & pressure rising
rate so as to satisfy the requirements of unit life.

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Chapter 4 Very Hot Start
4.1 The unit is tripped in the operation, if the fault can be removed quickly and the unit prepares to start up
immediately, it will not damage the vacuum.
4.1.1 Impulse starting parameters in IP cylinder very hot start:
Main steam pressure: 12.9MPa main steam temperature: 500℃
Reheated steam pressure: 1.10MPa Reheated steam temperature: 480℃
Condenser vacuum: >74KPa HP bypass rear flow: 190t/h
Rising rate: 300 rpm/m
4.1.2 Impulse starting parameters in HP cylinder very hot start:
Main steam pressure: 12.9MPa main steam temperature: 490℃
Reheated steam temperature: 465℃ rising rate: 300 rpm/m
Condenser vacuum: >74KPa HP bypass rear flow: 170t/h
4.2 When very hot start uses IP cylinder impulse, drain off the water to make the main steam pressure of
boiler lower than 9.6MPa and reheated steam pressure lower than 1.5MPa and at this moment bypass
system can be put into operation.
4.3 Relevant rules & precautions for hot start
4.4 Steam turbine can impulse started, raise speed and synchronize quickly according to the operations of
cold start and load on quickly according to the corresponding curve of cylinder temperature so as to prevent
the cylinder from cooling.
4.5 Keep higher vacuum as much as possible in the process of startup.

53
Chapter 5 Boiler Shutdown
5.1 Preparations prior to shutdown
5.1.1 Inform the staff of each post to make an overall check for the device & system and add up all the
faults and make the preparations for shutdown. Inform the peripheric post of chemical, fuel and grey water
etc. to make the preparations for shutdown.
5.1.2 Fuel oil system requires overall check in which its operation is to be confirmed for good, oil
temperature and pressure to be confirmed for normal and oil guns are to be checked one by one, its oil
circuit shall be smooth and atomization shall be good for availability at any time.
5.1.3 The belt of operating coal feeder shall be run out and the bunker is decided if it is burned out
according to the arrangement of chief engineer if shutdown of boiler is within 5 days. The bunker shall be
burned out (including the corresponding bunker of pulverizing mill that stops using) if the shutdown of
boiler is more than 15 days.
5.1.4 Collate the upper & lower water level gauge of steam drum once.
5.1.5 Heating surface of boiler requires overall soot blowing prior to shutdown.
5.1.6 Ash and slag inside the bottom ash hopper are to be cleared out; All automatic governing systems
require check in which their conditions are to be confirmed.
5.2 Sliding shutdown of boiler
5.2.1 After receiving the sliding shutdown demand from shift engineer, reduce the unit load to 540MW and
reduce the temperature of boiler according to the requirements of sliding shutdown curve of steam turbine.
5.2.2 Reduce the unit load to 300MW.
5.2.3 Set target load to 300MW and main steam pressure to 10.0MPa; set main steam pressure change rate
to <0.1MPa/min and main steam temperature constant. Reduce the load to 50% of rated load and select
“Run” with 1%/min load change rate.
5.2.4 Verify on the LCD that the unit load and steam pressure reduce gradually. Pulverizing coal system can
be shut down from top to bottom when the rotating speed of coal feeder in the operation reduces to about
50%.
5.2.5 Pay attention to controlling the main reheated steam temperature, and air preheater is sootblowing
once in the process of running down load.
5.2.6 Put AB oil layer into operation and remain three suit pulverizing coal systems in operation when the
unit load reduces to 300MW. Stop the cottrell and put the air reheater into operation to continue
sootblowing. Start up electrically driven feed pump and after the pump is in normal operation, stop one
steam pump and put the low-power unit into manual control and put the rotating speed of electrically driven
feed pump into “AUTO”. Verify that the main steam pressure is 10.0MPa and keep the load for 5min.
5.2.7 Set target load to 180MW and main steam pressure to 8.62MPa; set main steam pressure change rate
to<0.1MPa/min and main steam temperature change rate to 1.0℃/min. Reduce the load to 30% of rated
load with 1.5%/min load change rate.
5.2.8 Increase the dopers in service and stop one pulverizing coal system when the load of unit reduces to

54
180MW.
5.2.9 Reduce the load of second low-power unit gradually and stop its operation; keep the water level of
steam drum stable in the operation.
5.2.10 Reduce the unit load to 60MW
5.2.11 The unit continues to run down at load change rate 1.0%/min and main steam pressure keeps at
8.62MPa.
5.2.12 Increase the dopers in service and remain one pulverizing coal system in operation.
5.2.13 he following operations shall be carried out when the load of unit reduces to 60MW:
a. Main steam temperature is 400℃, reheated steam temperature is 325℃ and main steam pressure is
8.62MPa when the load of unit is 60MW.
b. Stop the last pulverizing coal system. Boiler is in all fuel operation. Stop the operation of primary air fan
and seal fan.
5.2.14 Start up TOP and MSP to check for normal. Reduce the active power to zero quickly, reactive power
close to zero and generator parallels off.
5.2.15 Trip the steam turbine manually.
5.2.16 Control the fuel flow and put the furnace gas temperature probe into operation and control the
furnace outlet temperature ≤538℃ after the unit parallels off.
5.2.17 Stop all the dopers that are operating and confirm MFT alarm window is on and furnace is fire off
after the generator parallels off and steam turbine stops operating. The used dopers shall be purged clean
after the dopers stop operating and the last doper is not purged, which just exits in place
5.2.18 Close the oil supply manual valve of doper at each angle and verify the recycle valve of fuel is
opened. Inform the staff on duty in oil region.
5.2.19 Maintain 30% rated air flow to purge in the furnace after the boiler is flameout. After purging is
finished, air blower and induced draft fan can be stopped and close all the air and flue gas baffles to block
out the boiler after confirming there is no flame in the furnace and there is no oil leak of doper.
5.2.20 Use electrically driven feed pump to continue filling water to steam drum until it reaches +200mm.
5.2.21 If stop the electrically driven feed pump, verify the recycle valve of economizer has been opened.
5.2.22 Put the condensation water into boiler water pump when the steam drum pressure is 2.0MPa.
5.2.23 Stop the two air preheaters when the gas temperature of air preheater inlet is lower than 125℃.
5.2.24 Stop the probe cooling fan when the furnace temperature is lower than 50℃.
5.2.25 Stop the operation of two boiler water pumps and then stop the third boiler water pump when the
boiler water temperature is lower than 150℃.
5.2.26 Water drainage with pressure is carried out as follows: open all the air valves, drain valves and blow
down valves when the steam drum pressure is 0.5MPa.
5.2.27 No-pressure water drainage is carried out as follows:

55
a. Open the drain valves of superheater and reheater when the pressure of steam drum is 0.5MPa.
b. Open the air valves in the left & right side of steam drum when the pressure of steam drum is 0.2MPa.
c. Drain operation of boiler is allowable when the boiler water temperature is lower than 90℃.
5.2.28 It may notify to stop the slag handling system when the boiler ash conveying system is verified no
slag.
5.2.29 Precipitator shakes and ash handling system keeps operating until ash bucket is verified no ash
falling.

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Chapter 6 Normal Shutdown of Boiler
6.1 The operation of shutdown in constant pressure mode is the same with that of shutdown at sliding
parameters.
6.2 Set the target load to 300MW, main steam pressure unchanged, main steam temperature unchanged and
reduce load to 50% of rated load and select “RUN” at load change rate of 2.5%/min.
6.3 Operate for 5 minutes when the unit load reaches 300MW and start to run down the load with setting
the target load 180MW. Reduce the load to 30% of the rated load and select “Perform” with constant main
steam pressure, 0.5MPa/min change rate of main steam temperature and 0.5%/min load change rate.
6.4 Reduce the load to 60MW at 0.5%/min load change rate and 0.2%/min pressure change rate when the
load of unit is 180MW, main steam temperature is 408℃ and reheated steam temperature is 370℃.
6.5 Trip the turbine manually and check HP & LP main steam valve & control valve are closed; rotating
speed starts to reduce and generator parallels off.
6.6 Other operations are the same with the operations of shutdown at sliding parameters.

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Chapter 7 Boiler Cooling
7.1 Normal cooling mode
a) Open the air blower outlet and the relevant air valves and baffles to make the boiler natural ventilation
and cooling after the boiler is shut down for 6 hours.
b) Start the induced draft fan and air blower to maintain 30%MCR air vacuum to force the boiler
ventilation and cooling after the boiler is shut down for 18 hours.
c) Use the drain valve of superheater to control the pressure reducing speed. Open the air valve of steam
drum, each drain valve of water wall and economizer to make the boiler drain off water fully when the
steam pressure of superheater outlet reduces to 0.1MPa and steam drum wall temperature is ≤121℃.
7.2 Forced cooling
7.2.1 When the heating surface of boiler has emergent maintenance work or the boiler needs quick cooling
to relieve pressure due to other reasons, the following methods can be used:
a) Stop the operation of all the induced draft fan and air blower and close the baffle blanking of air & flue
gas system after the boiler is shutdown and finished purging, open the relevant baffle of air & flue gas
system to build the natural ventilation 4 hours later; start up the induced draft fan and air blower to
maintain 30％MCR air flow to carry out forced ventilation and cooling after shutdown for 6 hours.
b) If heating surface of boiler blows up and has serious leak, stop one suit of induced draft fan and air
blower to carry out forced cooling with keeping 30%MCR air flow after the boiler is finished purging.
c) It shall be approved by chief engineer if forced ventilation and cooling will be carried out immediately
after shutdown and stopping purging of boiler.
d) Maintain the water level of steam drum to be high level as far as possible until drain off water.
e) Use the drain valve of superheater to control the pressure reducing speed. Open each drain valve of water
wall and economizer and air valve of steam drum to drain off the water when the steam pressure of
superheater outlet reduces to 0.1MPa and lower wall temperature of steam drum is ≤100℃. If the hot boiler
should be drained off (dried after drinage) and dried, inform sewage plant when the steam drum pressure
reduces to below 0.5MPa.
7.2.2 Attention: Forced cooling shall be stopped when the temperature difference of steam drum wall is
≥50℃ in the process of quick cooling.

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Chapter 8 Precautions for Boiler Shutdown
8.1 Steam turbine and boiler shall be coordinated well and temperature reducing and pressure reducing
shall not rise again in the process of sliding shutdown. Close attention shall be paid to the change of main
steam pressure & temperature, furnace pressure and steam drum water level when pulverizing mill stops.
Pay attention to the reducing speed of steam temperature and cylinder wall temperature and steam
temperature reducing speed shall be satisfied the requirements of sliding shutdown curve strictly. If steam
temperature reduces 50℃ sharply in 10min, it shall be tripped off and shut down.
8.2 Pay attention that each water level is normal in the process of running down load and the HP & LP
heater exits operation immediately. Minimum flow valve of feed pump can be opened manually in advance
according to the load condition.
8.3 Pay attention to strengthen the monitoring and measurement of each bearing vibration in the process of
sliding shutdown, trip off immediately if abnormal vibration occurs.
8.4 Inform the chemical personnel to stop the dosing pump prior to closing the dosing valve of steam drum.
8.5 The unit shall be avoided operating for long time under the load of 60MW until the rotor eccentricity
recovers to normal.
8.6 If the boiler is for hot standby, parallel off the furnace front fuel system completely and stop induced
draft fan, air blower and primary air fan and close all the baffle banking after purging. All the valve holes,
ash valves and flue gas duct valves of boiler shall be closed tightly in the early stage of shutdown in order
to prevent the boiler from cooling sharply caused by large amount of cold air leak in the boiler.
8.7 Control the temperature difference of boiler drum wall strictly that cannot be higher than 55℃ when
shutdown. If the wall temperature difference exceeds the protection limit value of boiler drum, close all the
drain valves until the temperature difference is within the limit value.
8.8 Stop the operation of air preheater when the gas temperature of air preheater inlet is lower than 121℃;
fire detector fan can be stopped when the gas temperature is lower than 50℃.
8.9 When the steam drum pressure of boiler is 0.5MPa, thermal drainage mode will be used to protect or
heating charging, dry maintenance, nitrogen charging etc. preservation methods will be used according to
the command of chief engineer.
8.10 Oil system of all auxiliary equipment shall be kept operating when there is no maintenance and
cooling water of equipment shall be kept unobstructed. Open the drain valve of pipeline to drain off the
water if cooling water is stopped using, if no drain valve, contact the maintainer to open the flange to drain
off water;
8.11 Drainage with pressure shall be used when the boiler drains off, open all the discharge valves, drain
valves and vent valves of pipeline header of boiler proper fully. If not drain off, it shall be put into furnace
bottom to heat and maintain the steam drum pressure 0.2~0.5MPa;
8.12 All the steam system and water system that stop operating shall drain off the stored water;
8.13 General valve and branch valve for inert displacement system of pulverizing mill are closed in order to
prevent seeper in mill caused by leak. Close the bearing cooling water.
8.14 Doors and windows of boiler house and auxiliary equipment room shall be closed tightly.

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Chapter 9 Boiler Shutdown Preservation
The preservation method after boiler shutdown. The preservation method will be chosen according to the
time length after shutdown. Wet preservation is usually adopted by boiler, in some special situations, dry
preservation by nitrogen is also adopted.
9.1 Maintenance principles
9.1.1 Operating equipment is used for short-time standby, pressure-containing parts has no check &
maintenance work and mostly “” will be used for maintenance when it prepares to start up at any moment.
9.1.2 When the operating equipment is overhaul or minor maintenance or standby for more than 10 days,
“Drain with pressure and drying with remaining heat” will be generally used for maintenance.
9.1.3 When the operating equipment is standby for a long time that is more than one month, it shall use
“hydrazine & ammonia solution method” for maintenance, but pay attention that the chloride ion content in
the water cannot exceed 2μg/L in order to avoid the intergranular corrosion. If the pressure-containing part
of boiler is tight, it can use “ammonia charging” for maintenance.
9.1.4 The cold furnace should not be switched to “dry-type anti-corrosion”. For the last resort, it must ignite
to boost up to 30% of rated pressure, and then reduce the pressure, using the “drying with remaining heat”
method for preservation.
9.2 Wet preservation
9.2.1 Refer to the table below for the preservation during shutdown of each heating surface of boiler:
Equipment Time Economizer water wall Superheater Reheater Main steam line
Within 1 week
Full water+N2 pressurizing 0.034MPa
N2H3=2000ppm; NH3=10ppm
N2 No treatment N2
More than 1 week
Within 1 month
N2 N2 N2
More than 1 month
Within 6 months
N2 N2 N2
More than 6 months
N2 N2 N2
9.2.2 The water injection PH value for wet preservation equals to 10.
9.2.3 Use nitrogen to maintain the drum pressure to 0.034MPa if the economizer, water wall, superheater
and reheater overflow during the initial operation period after hydraulic test.
9.2.4 Operating method for short term preservation:
9.2.4.1 Open the air valve of reheat steam line immediately after unit parallel-off to let the boiler continue
operating for drying out (the temperature displayed on the flue gas thermometer is <538℃).
9.2.4.2 Close each water discharge valve and sampling valve after flameout of boiler and feed water with
the flow rate of 100T/H to +200mm of drum water level.
9.2.4.3 Inform the chemical personnel for dosing N2H4=200ppm and PH=10 when the boiler water
temperature is below 180℃; when boiler water continues decreasing to 150℃, shut down the boiler water
pump.
9.2.4.4 Blanket nitrogen for preservation of drum superheater when the drum pressure is 0.196MPa.

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9.2.5 The procedure for unit long term preservation is the same as that of short term preservation, of which
the operation are as follows:
9.2.5.1 Inform the chemical personnel for dosing N2H4=300~1000ppm when the boiler water temperature is
180℃ and shut down the boiler water pump when the temperature is 150℃.
9.2.5.2 When the drum pressure is 0.196MPa, blanket nitrogen for preservation of superheater and main
steam line; the nitrogen pressure will be al little higher than the drum pressure when the main steam line
temperature is above 100℃.
9.2.5.3 Stop nitrogen blanketing and use the superheater back washing system to fill N2H4 and NH3
deaerated water to superheater with the water temperature at above 50℃ and slowly open each air valve at
the same time, and close it when the air valve overflow.
9.2.5.4 Blanket nitrogen again after water filling.
9.2.5.5 Close the air valve of reheater system when the reheater pressure is <0.196MPa; fill water to
reheater by using the attemperating water valve when the steam line temperature is 100℃ (N2H4 and NH3
deaerated water with temperature above 50℃). Slowly open the air valve and keep the pressure in reheater
>0.0196MPa during water filling.
9.2.5.6 Stop filling water and blanket nitrogen for preservation when the reheater air valve overflows; if
there is no pressure during reheater preservation, extract the vacuum before performing the above
operation.
9.3 Nitrogen replacement dry preservation
9.3.1 The boiler will maintain certain combustion rate after unit shutdown; open the air valve of reheater
pipe and dry out the interior; close the air vent valve for nitrogen blanketing when the reheater pressure
decreases to 0.196MPa.
9.3.2 Maintain the nitrogen pressure at above 0.034MPa when the reheater temperature is 100℃.
9.3.3 When the drum pressure is 0.196MPa, blanket nitrogen to drum, superheater system and the nitrogen
blanketing pressure is a little higher than drum pressure.
9.3.4 Keep the outlet valve open when the boiler water pump shuts down.
9.3.5 Vent the water inside the continuous blowdown flash tank and close the continuous blowdown
intercept valve of drum.
9.3.6 Keep the nitrogen pressure in boiler at 0.034MPa when discharging water from boiler; close all water
discharge valves after water discharging.
9.3.7 Regularly check that the nitrogen pressure is maintained at 0.034MPa during preservation period;
regularly test the purity of N2 by chemical personnel, make up nitrogen again to keep the pressure constant
until it is qualified if it is unqualified.
9.4 Preservation during boil maintenance
9.4.1 Perform preservation as required, such as using NH3-N2H4 for passivating treatment before boiler
shutdown if there are boiler maintenance works after the unit shuts down.
9.4.2 Add NH3-N2H4 to drum.

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9.4.3 When the N2H4 concentration of boiler water reaches 300~400ppm and PH=10.5, start up boiler water
pump to mix them evenly and keep for 2h.
9.4.4 When the drum is at 8.0MPa and 4.0MPa, blow down periodically every half minute.
9.4.5 When the drum pressure decreases to 0.5MPa, open all air valves, blowdown valves, and drain valves
quickly for water draining with pressure.
9.4.6 If the maintenance time is more than 1 month, place silica gel inside the drum and water wall lower
header on the base of drying by remaining heat and check the drier and internal corrosion once a month.
9.5 Anti-freezing of boiler
Make an overall check for anti-freezing measures that there cannot be bare pipeline and anti-freezing
heating device of each part of pipeline proper is put into operation prior to winter. Heating pipe of fuel
pipeline is put into operation perennially and it cannot be checked & maintained in winter. Seeper in the
gauge tube shall be drained off. Each hole valve and baffle of standby boiler shall be closed and the
maintained boiler shall have the measures that prevent the cold air from flowing into. Shutdown boiler shall
be used dry mode protection in winter as far as possible, air heater shall be put into operation when the
superheater pipe wall temperature <20℃ and air preheater shall keep operating after the air heater is put
into operation. If there is water in the boiler and boiler water temperature is lower than 10℃, filling water
and drainage water shall be carried out and drainage shall be done at each low point in turn.

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Part
Part
Part
Part 3
3
3
3 Operation
Operation
Operation
Operation &
&
&
& Maintenance
Maintenance
Maintenance
Maintenance of
of
of
of Boiler
Boiler
Boiler
Boiler
Chapter 1 Operation Adjustment
1.1 Purposes and tasks of operation adjustment
1.1.1 Ensure that the main parameters are in the normal range during operation, find out and handle the
existed defects of equipment in time, take full advantage of monitoring function of the computer to make
the unit operate safely, economically and efficiently.
1.1.2 Adjust water filling and combustion of boiler to meet the demands of unit load.
1.1.3 Keep the furnace combustion conditions good and the heating surface clean, reduce exhaust gas
temperature and heat loss, and improve the boiler efficiency.
1.1.4 Keep steam temperature, steam pressure, steam drum and water level normal.
1.1.5 Keep various steam water qualities by means of continuous blowdown and periodic blowdown of
boiler.
1.1.6 Operation modes of equipment and system should be arranged reasonably to make sure they operate
in the best conditions and to improve the economical efficiency of the unit.
1.2 Governing of steam temperature
1.2.1 Governing of superheated steam
1.2.1.1 Governing of superheated steam is divided into two stages of spray governing, the first stage acts as
rough governing at the division wall inlet and the second stage spray acts as fine governing between rear
platen and final stage superheater.
1.2.1.2 The governed parameter of first stage spray is the outlet temperature of division wall and that of the
second stage spray is the outlet steam temperature of superheater.
1.2.1.3 Adjust the combustion center and normal soot blowing appropriately.
1.2.2 Governing of reheat steam temperature
1.2.2.1 The reheat steam temperature is governed depending on the sway of burner during boiler normal
operation. Reheat steam spray is used in emergency circumstance.
1.2.3 When boiler load is more than 50%MCR, the outlet steam temperature of superheater and reheater
should be controlled at rated 541℃. When the load is less than 50%MCR, the steam temperature of
superheater and reheater should be controlled according to the steam temperature curve of turbine start.
1.2.4 In normal condition, the steam temperature at the outlet of low temperature superheater should be
controlled ≯415℃, the steam temperature at the outlet of platen superheater ≯461℃, and steam
temperature of superheater and reheater should be controlled according to the starting curve with the
maximum ≯541℃.
1.2.5 Superheater steam temperature governing uses two stage spray attemperator, the first stage
attemperator controls steam temperature at the inlet of platen superheater and the second stage controls the
outlet. When boiler operates stably, the automatic spray of first and second stages are input, when steam
temperature fluctuate wildly, manual adjustment can be applied. The steam temperature should be with
superheat of above 11℃ at least after each stage of attemperator.
1.2.6 The spray volume control of superheater should not be changed radically, water spray on both sides
should be close, and steam temperature deviation of both sides is not more than 15℃. If water spray is
excessive or water spray deviation and steam temperature deviation of both sides are excessive, adjustment
measures such as soot blowing, burning, and etc. should be taken.
1.2.7 The governing of reheater steam temperature mainly relies on burner swing angle governing, if burner
swing angle can not meet the demands of temperature governing, reheater attemperating water can be used

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to assist governing.
1.2.8 When boiler load is ≤10%MCR, spray attemperator should not be put into operation generally. If the
water spray must be put in, working personnel should note the steam temperature change after water spray
in case the steam with water. Especially, when the electric pump is operating, the steam temperature change
after water spray should receive more attention.
1.2.9 Make comprehensive analysis of the reason of steam temperature changes and adjust overall, but not
one-sided rely on water spray to control the steam temperature.
1.2.10 Coal mill trip or other load rejection conditions occur in the unit operation, automatic control of
attemperating water should be lifted and switch to manual adjustment to avoid the large lag of automatic
adjustment causing wide fluctuations of main and reheater steam temperature.
1.3 Load adjustment
1.3.1 Run up
Start and stop the coal mill according to the following procedure:
1.3.1.1 Start up the primary fan and start up the coal mill.
1.3.1.2 Open the hot wind isolating valve PASOD to make the coal mill reach the operating temperature.
1.3.1.3 Start up coal feeder, of which the control should be in “MANUAL” and started up by min speed.
1.3.1.4 When coal mill start pulverizing and pulverized coal fire is on, increase the coal rate gradually and
balance each coal mill output, and then switch coal mill control to “MANUAL”.
1.3.1.5 Adjust the air flow to stabilize combustion.
1.3.1.6 When the boiler operating condition is stable, at least two coal mills are operating and coal feeder
speed of each set of coal mill is above 50%, cut off the combustion-supporting oil.
1.3.2 Run down
1.3.2.1 If the rundown of unit makes the operating coal feeder speed decrease to 40% of maximum speed,
stop one set of coal mill. The operators determine to stop the nozzle of the upper most layer or undermost
layer according to the steam temperature and combustion situations.
1.3.2.2 Increase the output of other operating coal mill to keep stable decrease of load after stopping one set
off coal mill. When the operating coal feeder speed decreases to 40% of the maximum speed once again,
stop one more coal mill in the same way. Stop the coal feeder before stopping coal mill; the coal mill
should operate for a while and then stop the coal mill after the pulverized coal is exhausted.
1.3.2.3 When the coal mill stops, the coal mills with nozzles at adjacent layers should be in operation. If
combustion is stable, it is allowed to operate without one layer of nozzle, but not operate without two layers
of nozzle. Put the oil gun next to the operating pulverized coal nozzle if load decreases to the situation that
two sets of coal mills are in operation and the output decreases to below 50%.
1.3.2.4 The boiler is equipped with 7 sets of positive-pressure direct firing pulverizing system with
medium-speed mill cold primary air fan, as firing the design coal, 6 mills are for operation, and 1 mill for
standby.
1.3.3 Normal load change rate
1.3.3.1 It is 15MW/min during sliding pressure operation.
1.3.3.2 18MW/min during constant pressure operation.
1.3.3.3 Normal load change is allowed for 5min and then keep for 5~10min.
1.3.4 Max load change rate
1.3.4.1 It is 18MW/min during sliding pressure operation.
1.3.4.2 It is 30MW/min during constant pressure operation.

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1.4 Adjustment of combustion
1.4.1 Determine the proper primary, secondary and fuel air proportion according to the coal quality, thus
organize good furnace combustion conditions, control and adjust primary, secondary and fuel air to reach
the reasonable air proportion requirements and monitor air proportion of left and right side to adjust and
eliminate air volume deviation in time.
1.4.2 Observe furnace flame and chimney gas discharge in boiler operation. Maintain stable and good
combustion, gas temperature of both sides of heating surface in each stage should be close, gas temperature
deviation at the inlet of air preheater on both sides <15℃, check over the combustion situation inside the
furnace frequently, inspect the ignition condition of pulverized coal, whether there is the phenomenon of
deflect and furnace wall erosion, secondary air adjustment is based on meeting the requirements of optimal
excess air coefficient of economizer outlet, as well as the distribution of auxiliary air, fuel air and top
secondary air, excess air coefficient of furnace outlet is 1.25 at full load.
1.4.3 The flame should show bright white in fuel combustion of boiler, while the flame should show golden
yellow in coal combustion.
1.4.4 In boiler normal operation, the furnace draft and air volume should be put into automatic control. The
furnace draft should be controlled at around -50Pa~-100Pa. No smoke belches from the upper part of
furnace.
1.4.5 It should monitor whether furnace draft, air volume and other automatic control are normal in boiler
operation, and automatic controls of operating coal pulverizing system should be put into operation. Adjust
and handle in time when abnormity is found.
1.4.6 Check the operation states of flame monitor, burner sleeve and baffle, coal mill PASOD and BSOD in
boiler operation. Regularly and on-site check the operation condition of burners, secondary air boxes and
throttle, once the problem is found, contact and handle immediately.
1.4.7 In boiler operation, furnace front fuel system should be in good standby state.
1.4.8 In boiler normal operation, boiler exhaust gas temperature and oxygen volume of flue gas should be
kept in rated range. When changing the boiler load, notice the match of coal-air ratio. If the load changes a
little, coal feeder speed can be adjusted but should not be too large. If the load changes a lot, the coal mill
should be started or stopped.
1.4.9 The opening of standby coal mill burner sleeve and baffle should in or below ignition position, and
only after the burner temperature exceeds the alarm limit, the auxiliary air baffle can be started to cooling.
When the end temperature alarms, working personnel should check whether the burner cokes or the internal
pulverized coal combusts spontaneously.
1.4.10 Try to keep opposed firing of operating coal mill, and coal mill current should be maintained within
the specified range. If the burner flame is not stable in operation, the corresponding oil gun should be put
into operation timely, and the working fluids and change of superheater steam and reheater steam should be
noted at each stage to avoid the wall overtemperature. Pay attention to furnace coke, once found, it should
be eliminated in time, regularly conduct soot blowing to the water cooled wall, and reduce boiler load when
coking is severe.
1.4.11 When adjusting steam pressure, reduce coal amount in advance in the steam pressure rising process,
when steam pressure tends to be stable, increase coal amount appropriately to stabilize the steam pressure
and avoid decreasing. In case steam pressure is too high and coal amount reduces largely, pay attention to
reducing air at the same time; if not cooperate well, the steam pressure will increase instantly instead. Keep
the reasonable pulverized coal fineness on the basis of coal quality, adjust the baffle opening of separator in
time on the basis of chemical analysis, when the load is low, appropriately reduce fitness for combustion.
1.5 Governing of water level
1.5.1 Refer to the table below for the allowable changing range of control circulation boiler drum water
level, alarm value and boiler shutdown value:
Boiler type
Allowable changing range
(mm)
Alarm value (mm)
Boiler shutdown value
(mm)
Control circulation boiler ±50 +120/-170 +250/-300

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1.5.2 The inspection and adjustment of steam drum should subject to differential pressure level meter.
1.5.3 In boiler normal operation, the boiler feed water should be kept continuous and uniform, the water
level of steam drum should be kept normal and stable. Local water level gauge should be consistent with
the water level indication in control room.
1.5.4 In boiler normal operation, the steam drum water level should be put into “Auto”. Regularly check
whether the working condition of each filling control system is good, if the automatic and water level are
found of any abnormality, switch to manual adjustment immediately and inform the thermodynamic
operator to handle it.
1.5.5 If the load increases or decreases too fast, main steam pressure changes too large or the safety valve
pops, it should pay attention to the steam drum water level change, consider the impact of false water level
change and coordinate and control the steam drum water level.
1.5.6 In case of water pump start and stop, furnace circulating pump and feed water system automatic
malfunctioning, boiler leakage and HPH critical drain action, it should strengthen the monitoring and
adjustment of water level.
1.5.7 When steam drum water level is high, it should reduce the amount of feed water in time and
coordinated and handle by increasing continuous blowdown valve opening and emergency water drainage.
In case of steam drum water level being low and large filling water being needed, it should pay attention to
the operation of high and low pressure heater to prevent the heater from running out of synchronization
because of no time to drain at overload.

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Chapter 2 Unit Operation Mode
2.1 Control of the unit
2.1.1 The unit can run in coordinated control mode at the load ranging 30%~100%, which should be put in
as much as possible as long as the system has no fault. In the process of start-up, after 4 mills are put into
automatic control, the unit should be put into coordinated mode step by step, with priority to BCS. In
normal operation, the unit control mode should be selected according to the health level of main and
auxiliary equipment, with abnormal side as the tracking target. In case of the following cases, it should
release the coordinated control immediately and switch to manual adjustment to avoid the extension of
accident:
2.1.1.1 RB condition occurs, but RB function fails to realize automatically;
2.1.1.2 Regulating properties get worse, the unit main parameters deviate from normal control range, and
no reply for a long time;
2.1.1.3 When the unit operates with high-load, main steam pressure continues to rise while main steam
temperature declines sharply;
During the unit shutdown at sliding parameters, the HP-IP first stage cylinder temperature of turbine should
not be less than 400℃, or it should ask permission of the chief engineer. After the generator-transformer
unit trips, it should release the hot standby of generator-transformer unit and make the 400kV system run
with looping-in.
2.1.2 Control mode of the unit
2.1.2.1 Basic mode (BASE)
When the boiler controller and turbine controller are in manual mode, the control mode is basic mode.
2.1.2.2 Boiler following mode (BF1, BF2)
Turbine control is independent of LDC, boiler control in automatic mode is boiler following mode1 (BF1).
Meanwhile, if LDC is in BF1 mode, thus CCBF mode of turbine control in automatic mode is selected as
boiler following mode 2 (BF2), turbine control coordinates with LDC at this moment.
Whenever the turbine control in manual mode while the boiler controller in automatic mode, LDC will be
forced to boiler following mode 1. LDC can be switched from boiler following mode 1 to basic mode by
switching the boiler controller in manual mode. If LDC is in TF2 mode, choose BF2 mode directly, and
then LDC will enter BF2 mode.
2.1.2.3 Turbine following mode (TF1, TF2)
When boiler controller is in manual mode and turbine control is in automatic mode, it is turbine following
mode 1 (TF1). Meanwhile, if LDC is in TF1 mode, it enters turbine following mode 2 (TF2) when boiler
control is selected in automatic mode. It can only choose turbine following mode 2 from turbine following
mode 1. If LDC is in coordinated mode, choosing TF2, and LDC will enter TF2 mode. In TF2 mode, as
long as the boiler controller is switched to manual mode, LDC will switch from TF2 mode to TF1 mode.
When it is necessary to exit coordinated control, it should exit progressively and avoid switching directly.
2.1.2.4 Coordination mode (CCS)

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When the boiler controller and turbine controller are in automatic mode, CCS control mode can be
achieved, and CCS has two ways, which are CBF (boiler master controller for main track) and CTF
(turbine master controller for main track).
2.1.2.5 Remote automatic dispatch system (ADS)
LDC in BF2, TF2 or CCS mode is able to enter ADS mode, in which the remote dispatcher can control the
unit load by ADS. ADS mode may occur in BF2, TF2 or CCS mode, so it is possible to switch among these
modes. ADS mode will be switched to original control mode automatically in the following cases: load
increase locked, load decrease locked, remote dispatch invalid and load rejection. The maximum and
minimum load limits in ADS mode is still valid.
2.1.3 Load rejection (RB)
2.1.3.1 The unit operates in CCS mode, load rejection of LDC will occur in one of the following cases:
a. Two forced draft fans are operating, one stops;
b. Two induced draft fans are operating, one stops;
c. Two preheaters are operating, one stops;
d. Only one feed water pump remained is operating;
e. Two primary air fans are operating, one stops;
f. Only one boiler water recirculation pump remained is operating.
2.1.3.2 In case of load rejection, if control mode is ADS, it will be removed forcibly and minimum LDC
velocity setting doesn’t work. After the load rejects to the set target value, LDC will lock any load
instruction in 60 seconds.
2.1.4 Strong load shedding (RUN DOWN)
2.1.4.1 RUN DOWN will start strong load shedding, in the following cases:
a. Coal controller is at the maximum but fuel quantity is much less than the demand of instruction;
b. Forced draft fan output is at the maximum but air flow is much less than the demand of instruction;
c. Feed water quantity is at the maximum but water fed quantity is far much than the demand of instruction;
d. Induced draft fan output is at the maximum but furnace negative pressure is much less than the demand
of instruction;
e. Primary air fun output is at the maximum but primary air pressure is much less than the demand of
instruction.
2.1.5 Load change lockout
2.1.5.1 Load decrease will be locked, if one of the following cases occurs:
a. Feed water flow is more than instruction or feed water quantity is at the maximum;
b. Air flow is more than instruction or forced draft fan output is at the minimum;
c. Coal quantity is more than instruction or coal controller output is at the minimum;

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d. Furnace negative pressure is larger than the instruction or induced draft fan output is at minimum;
e. Primary air pressure is larger than the instruction or primary air fan output is at minimum;
2.1.5.2 Load increase will be locked, if one of the following cases occurs:
a. Coal controller output is at maximum or fuel quantity is less than the instruction;
b. Forced draft fan output is at maximum or air flow is less than the instruction;
c. Feed water is at the maximum or feed water flow is less than the instruction;
d. Induced draft fan output is at maximum or furnace negative pressure is smaller than the instruction;
e. Primary air fan output is at maximum or primary air pressure is smaller than the instruction;
2.2 Protection interlock operation mode of the unit
2.2.1 All the protection and interlock of all the operating and standby equipment should be put into service.
When it needs to quit running because of problem, it must go through the specified approval procedures. If
any abnormal condition of parameter is founded in operation, when confirming measuring loop or
measuring element fault, in order to prevent protection malfunction, thermodynamic operator should be
contacted to remove possible malfunction protection. After the tripping of power equipment, it is necessary
to check whether electric protection operates, and then confirm the thermal protection, if the trip reason is
unclear, equipment should not be put into operation again (except for incident handling). After standby
equipment is interlocked, interlock reason should be checked out completely, if causing by original
equipment fault, it should be stopped for maintenance.
2.2.2 For generator-transformer unit, part of protections can be stropped in emergency, but two main
protections can not be stopped at the same time.
2.2.3 After the unit trips, “Turbine trips Electrical” and “Electrical trips Turbine” protection, as well as “low
primary air pressure MFT” protection should be removed. After grid-connect, “Electrical trips Turbine” and
“Turbine trips Electrical” protection should be put in immediately. After pulverizing system puts into
operation, “low primary air pressure MFT” protection should be put in to service

69
Chapter 3 Operation Mode of Boiler Water Circulating Pump System
3.1 Water filling of boiler water circulating pump
3.2 In case of using condensation water as flushing water, the flushing water of boiler water circulating
pump can be stopped after boiler ignition and when steam drum pressure has reached 0.2~2.0MPa.
3.3 Another feed water acts as standby water source.
3.4 Cooling water of boiler water circulating pump
3.5 During normal operation, chemical desalination cooling water pump is used to supply water.
3.6 When the pressure of chemical desalination cooling water is low, deaerator feed water pump should be
start immediately to supply water.
3.7 Set three boiler water circulating pumps for each boiler, 3 sets are operating in normal operation of
which 2 sets can operate with full load and 1 set can operate with 60% BMCR load.

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Chapter 4 Operation Mode of Pulverizing System
4.1 The unit with load between 360~500MW, should keep 5 mills operating, or it is necessary to start
another mill or stop one.
4.2 In normal operation, try to keep coal mill operate at rated condition. In the process of unit peak pitching
load decrease, when all the operating coal mills’ output reduces to less than 60t/h, one coal mill must be
stopped operating. In the process of load increase, when all the operating coal mills’ output are close to
maximum output but still can not meet the demands, one standby coal mill must be started and each
operating coal mill output should be balanced.
4.3 When starting or stopping the pulverizing system in coordinated mode, the “LDC” control mode should
be switched to “HOLD” to prevent disturbance due to load increase or decrease in the coal mill starting
process; in mill warming and coal mill blowing process, the air flow should be increase or decrease slowly
to avoid causing air flow sudden change of other coal mill
4.4 In normal condition, the standby coal mill should be switched in night shift everyday. When it is at
valley on the eve, one coal mill should be stopped, when it is meeting the peak in the morning, another coal
mill shutdown for longtime should be started. If there is no exceptional circumstance, the continuous
standby time of coal mill should be no more than 3 days. Switch the mill oil pump before the mill is
stopped.
4.5 The coal mill current should maintain normal.
4.6 The coal mill stopped normally should be blown down. After emergency stop, it should charge inert gas
as ruled. In case of the inert gas charge valve inner leakage, the manual stop valve should be stopped, it
should be started when charged inert gas and stopped until charging is finished.
4.7 For the shutdown coal mills in winter, it should stop its bearing cooling water, keep oil system
operating, inject oil and heat in case oil return unsmooth.

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Chapter 5 Monitoring of Parameters in Normal Operation
5.1 Limits for main parameters of boiler in normal operation
Item Unit Normal value
Alarm
Trip value Remarks
Max Mini
Boiler capacity t/h 1878 2069
Steam drum pressure MPa 18.87 19.79
Superheater outlet steam pressure MPa 17.31 17.47
Superheater outlet steam temperature ℃ 541(+5/-10) 546 531
Reheater outlet steam pressure MPa 3.50 3.76
Reheater outlet steam temperature ℃ 541(+5/-10) 546 531
Steam drum water level mm ±50 120 -170 +250 /-300
Furnace negative pressure KPa -0.125 0.996 -0.996 +3.240 /-2.490
Fuel main-pipe pressure (light) MPa 3.5 4.0 2.5 1.8
Fuel main-pipe pressure (heavy) MPa 1.0 1.8 0.4 0.3
Coal mill outlet temperature ℃ 70 75.0 70.0 110
Compressed air pressure MP 0.6~0.8 0.8 0.45
Primary air pressure KPa
Boiler water pump circulating differential pressure kPa 300 148.3 117.2
Boiler water pump motor chamber temperature ℃ 5~60 60 5 65
Sealed air/coal mill primary air differential pressure kPa ≥2 1.5 1.0
5.2 Limits for operating parameters of induced air fan
No. Parameter Unit Normal Max Mini Trip
1 Motor lubricating oil pressure MPa 0.4
2 Motor lubricating oil temperature ℃ 20~40 50 15
3 Oil screen differential pressure KPa 50 150
4 Bearing vibration mm 4.6 7.1
5 Bearing temperature of fan ℃ 90 110
6 Bearing temperature of motor ℃ <80
7 Fan surge KPa 6
8 Motor winding temperature ℃ 120 130
5.3 Limits for operating parameters of forced draft fan
1 Control oil pressure MPa 2 5.5 0.7
2 Control oil temperature ℃ 20~40 50 15
3 Oil filter differential pressure KPa 50 450
4 Bearing vibration mm/s 4.5 7.1
5 Fan bearing temperature ℃ 95 110
6 Motor bearing temperature ℃ 90 95
7 Fan surge KPa 0.2
5.4 Limits for operating parameters of primary air fan

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1 Control oil pressure MPa 2 `7 0.7
2 Oil filter differential pressure KPa 50 450
3 Bearing vibration mm/s 4.5 7.1
4 Fan bearing temperature ℃ 85 100
5.5 Limits for operating parameters of coal mill
1 Outlet air temperature ℃ 65 77 82
2 Lubricating oil pressure MPa 0.3 0.09 0.07
3 Oil filter differential pressure MPa 0.2
4 Lubricating oil temperature ℃ 40 60 30 < 25; > 65
5 Lubricating oil flow L/h >160
7 Motor bearing pad temperature ℃ 75 80
8 Sealing wind differential pressure KPa 2.0 1.5 1.0

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Chapter 6 Boiler Periodic Working System Schedule
No. Time Content Person in charge Remarks
1
When each shift
takes over
Emergency sound and
thermodynamic signal test
Chief attendant Good
2 Once per shift Air preheater sootblowing
Sootblowing
operator
3 Once per shift Oil gun purge Patrol inspector No block
4 Once per shift Steam drum water gauge check Patrol inspector Identical
5 Every day shift Boiler proper overall sootblowing
Sootblowing
operator
Sootblowing is prohibited
at low load or instable
combustion
6
According to the
stopping cycle
Pulverizing system switching Vice attendant
Suitable for coal mill not
used for long
7
Day shift on 1st
of
every month
Emergency water discharge valve
ON-OFF test
Vice attendant
The primary and secondary
valves cannot be opened at
the same time
8
Day shift on 2nd
of
every month
Dump steam atmospheric valve
ON-OFF test, for superheater in
odd months, and for reheater in
dual months
Vice attendant
The primary and secondary
valves cannot be opened at
the same time
9
Day shift on 3rd of
every month
For light oil mains pressure lower
header pump, pressure high alarm;
for heavy oil mains pressure lower
header pump, pressure high alarm
Patrol inspector
10
When there is
chemical notice
Periodic blowdown Patrol inspector Chemical supervision
11
Day shift on 5th
of
every month
Switch over flame detection cooling
fan
Chief attendant
Contact the thermodynamic
engineer to remove
differential pressure
protection.
12 Day shift on Friday
Switch over flame detection cooling
fan filter
Vice attendant
13
Day shift on 5th of
every month
Switch over induced draft fan
bearing cooling fan
14
Day shift on 10th
of
every month
Switch over induced draft fan
motor oil pump
15
Day shift on 10th of
every month
Switch over oil pump of induced
draft fan station
16
Day shift on 10th
of
every month
Switch over motor and oil pump of
primary fan
17
Day shift on 20th
of
every month
Switch over seal fan Vice attendant
engineer to remove
differential pressure
protection.
18
Day shift on 25th
of
every month
Oil-on and ignition tests of oil gun Chief attendant Good
19
Day shift on 25th
of
every month
Water level high & low value I
alarm tests
Vice attendant
engineer to remove water
level protection
20
Prior to boiler
shutdown for each
overhaul and minor
repair
Superheater & reheater safety valve
operation tests
Chief attendant
Obtain instruction from the
chief engineer, and notify
the thermodynamic and
boiler staff for maintenance
21 After overhaul Air preheater air leakage test Thermal test team member

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Part
Part
Part
Part 4
4
4
4 Boiler
Boiler
Boiler
Boiler Interlocking
Interlocking
Interlocking
Interlocking Protection
Protection
Protection
Protection and
and
and
and Test
Test
Test
Test
Chapter 1 Boiler Interlocking Protection
1.1 Main protection of boiler MFT
1.1.1 Boiler MFT will occur under one of the following conditions.
No. Protection description Remark
1 Manual emergency boiler shutdown
2 All forced draft fans trip
3 All introduced draft fans trip
4 All preheaters trip
5 MCS power supply is lost
6 The drum water level is higher the limit of 250mm
7 The boiler ignition is failed
8 The drum water level is lower than the limit of -300mm
9 The furnace pressure is higher than the limit of 3240pa (two-out-of-three)
10 The furnace pressure is lower than the limit of -2490pa (two-out-of-three)
11 All furnace fuel are lost
12 All furnace flame is lost
13 Fire check cooling fan is lost(time delay) (two-out-of-three)
14 The air quantity is lower than the minimum value (two-out-of-three)
15 All boiler water recirculating systems trip
16 Reheater protection is lost
17 All feed water pumps trip
18
The economizer inlet flow rate is lower than the min specified value
(two-out-of-three)
19 FSSS power supply is lost
20 The temperature at the superheater outlet is too high
21 The temperature at the reheater outlet is too high
1.1.2 When MFT tripping relay operates, send out operation order to the equipment as below:
(1) Large screen display sends out urgent audible and visual alarm signal, LCD displays alarm.
(2) Close the furnace oil heater tripped valve.
(3) Remove all coal feeders.
(4) Remove all coal mills.
(5) The mode of forced draft fan and induced draft fan switches from “AUTO” to “MANUAL”.
(6) Remove the programmed soot forced draft fan.
(7) Open all secondary air damper baffles.
(8) Close the attemperating water governing valve.
(9) Close main stop valve.
(10) Send signal to SCS and MCS.

75
(11) Dust collector trips.
(12) Close all quick-closing valves.
(13)·Remove the high-energy igniter.
(14)·Close primary air fan.
(15)·Send signal to the bypass control system.
1.2 Boiler OFT protection
1.2.1 OFT will occur if any of the following conditions is true.
1 Boiler MFT
2 Oil angle has no fire (pulse) and fuel angel valve is not fully closed. Delay for 5S
3 Heavy fuel oil header pressure is ≤ 0.3MPa
4 Light fuel oil header pressure is ≤ 0.3MPa
5 The fuel layer catches fire.
6 Any one of the oil gun fails three times in ignition.
6 Manual OFT
1.2.2 When OFT occurs, perform the following operations automatically:
A. Close oil tripping valve quickly.
B. Close all oil gun and oil valve and drop out the ignition gun.
C. Large screen display sends out urgent audible and visual alarm signal, which is indicated and printed on
LCD.
D. Stop the test for oil leakage.
1.3 Interlocking protection of coal mill
1.3.1 The operating coal mill will trip when any of the following condition is true.
1 MFT
2 Related primary air is lost.
3 Outlet valve of coal mill is not open
4
The permissive condition for coal mill ignition will be lost within 5min after
startup of coal mill
5 RB order trips corresponding coal mill
6 Trip condition of coal mill itself
1.3.2 The following operation will be automatically performed when MTR occurs.
A. Stop the coal feeder.
B. The “AUTO” mode is removed from the coal feeder.
C. Stop the coal mill.
D. Close the cold and hot air baffle.
E. Put the steam fire-extinguishing system into operation.

76
F. Large screen sends out signal and the trip tip of coal mill presents the trip causes to operators.
1.3.3 Trip the coal feeder automatically when any of the following condition occurs.
A MFT;
B The coal mill stops.
C The trip condition for coal feeder itself.
1.4 Interlocking protection of induced draft fan
Induced draft fan will trip under any of the following conditions:
1 The furnace pressure is lower than 2.49KPa
2 Stalling protection interlock Unrelieved 60s after alarm
3 The vibration speed of main air duct exceeds 7.1mm / s Delay for 5S
4 The bearing temperature of induced draft fan is higher than 105℃
5 Air preheater stops. Delay for 300s
6 The motor coil temperature of induced draft fan exceeds 130℃
7 Forced draft fan trips
8
The induced draft fan has been in operation, but the inlet flue gas
baffle can not be opened.
Delay for 60s
9 The lubricating pressure of lubricating oil station is low
10 Press local emergency button to stop the forced draft fan
1.5 Interlocking protection of forced draft fan
The forced draft fan will trip under any of the following conditions:
1 Induced draft fan at the corresponding side trips
2 The bearing temperature of forced draft fan is >110℃
3 The motor bearing temperature of forced draft fan is >95℃
4 The motor coil temperature of forced draft fan is >145℃ Manual
5 The furnace pressure is up to 3240Pa
6 The vibration speed of fan bearing box is > 7.1mm/s
7 Press local emergency button to stop the forced draft fan
8 Stalling protection interlocking Unrelieved 60s after alarm
1.6 Interlocking protection of primary air fan
Primary air fan trips when any of the following condition occurs:
1 MFT
2 Primary air fan operates but the outlet baffle door is not open Delay for 60s
3 Air preheater stops
4 The vibration speed of fan bearing box exceeds 7.1mm/s
5 Stalling protection interlocking Unrelieved 60s after alarm
6 Primary air fan bearing temperature is up to100℃
7 Motor bearing temperature is up to85℃
8 Motor winding temperature is up to 145℃ Manual
9 The lubricating oil temperature in oil station is low

77
1.7 Interlocking protection of seal fan:
Seal fan trips when any of the following condition occurs:
1 Two sets of primary air fan both stop
2 Seal fan bearing temperature is up to 85℃
3 Seal fan motor bearing temperature is up to 85℃
4 After startup of seal fan, the inlet switch-off baffle is still in “OFF” position. Delay for 60s
5 MFT
1.8 Interlocking protection of air preheater:
No. Content Remark
1 The main motor of air preheater trips Start up standby motor
2 The air preheater bearing oil temperature is up to 85℃ Manual trip
3 The rotating speed of air preheater is low Air preheater tips after 10s time delay
4 Air preheater rotor stalls Trip after 10s time delay
5
Air preheater pedestal bearing temperature is up to70℃
and guide bearing temperature is up to 80℃
Alarm
6 Air preheater fire alarm Alarm
1.9 Perform Interlocking protection of boiler water pump when any of the following condition occurs
1.9.1 Boiler water pump trips:
No. Content Remark
1 Motor chamber temperature is ≥65℃ Delay for 5s
2 The outlet valve is not fully open.
3 LP cooling water is lost Delay for 5min
4 The differential pressure between pump inlet and outlet is ≤60kPa
5 The drum water level is lower than -300mm
1.9.2 Boiler water pump will give alarm when any of the following conditions occurs:
No. Content Remark
1 Motor chamber temperature is ≥60℃
2 The outlet valve is not fully open.
3 LP cooling water flow is 75% of normal flow (the flow is <8 m3/h)

78
Chapter 2 Boiler Test Procedures
2.1 Check and acceptance after maintenance
2.1.1 There should be equipment unusual report and maintenance instruction if the related equipment has
any change after boiler overhaul and repair.
2.1.2 Operators should attend acceptance work during trial running of all systems and equipment and make
detailed inspection for the equipment in the acceptance, after which the approval procedure of work ticket
can be dealt with, and then make records.
2.1.3 Report to the person-in-charge of maintenance once any defect is found in the equipment during
acceptance and the safe unit operation can not be ensured. Before the equipment is put into operation, the
defect must be eliminated and entered into microcomputer for file.
2.1.4 The original facility has been restored, and the temporary facilities for maintenance should be
removed. The site should be clean, and the passage should be clear and smooth, the railing should be
complete, lighting should be in good condition, insulation should be complete and brackets and hangers
should be complete and firm.
2.1.5 The boiler proper and all auxiliary systems and equipment should be complete with no sundries
inside.
2.1.6 The pipeline valves are well connected, the valve can be opened and closed flexibly, the hand wheel
and nameplate are complete, and there should be paint color and flow mark which is in compliance with
rules of “Regulations on Technical Management Of Power Industry”.
2.1.7 Switches of all observation hole, manhole valve and check hole are flexible and can be tightly closed.
2.1.8 The centralized control room control panel, local control plates, cabinets, etc. are complete, each
indicator light has correct indication and can be put into use; audible and visual alarm device is intact.
Meter, keyboard, operating handle and button on all control panels are complete and in good condition;
CRT display is clear and there is reliable indoor emergency lighting.
2.2 General rules for test
2.2.1 After boiler overhaul and rrepair, protection and interlocking test for main and auxiliary equipment
must be done firstly, it is allowed to do the trail running and put the equipment into operation only after
passing the test.
2.2.2 All tests should be based on the requirements of the test measures and strictly in compliance with
regulations
2.2.3 Perform corresponding test when dealing with temporary fault repair or maintenance for equipment
system and maintenance for components used in protection and interlocking as well as circuit and the test
should be qualified, and only perform shutdown and operation test to other protection interlock.
2.2.4 The close control, remote control electric valves, pneumatic valves, servo mechanism and close
control & remote control should be tested, of which the opening and closing time should be recorded. The
system having been put into operation and the electric valve and control valve bearing the pressure should

79
not be tested
2.2.5 Equipment test has static and dynamic test methods: in static test, auxiliary equipment of above 11kV
should only have power supply test, all 400V LV power supply should be powered by dynamic power; in
dynamic test, both operational and dynamic power supply should be sent. Dynamic test can be carried out
only after the static test is qualified.
2.2.6 The thermal staff should meet the relevant conditions compulsorily before the test of boiler and
equipment interlocking protection. Before equipment interlocking test, perform the manual startup and
shutdown test on site and in centralized control room and confirm it is qualified.
2.2.7 All interlocking protection test operation and audible and visual alarm should be normal, and all
lighting indication and screen state display should be correct.
2.2.8 The regular test during normal boiler operation should be done when the unit operation is stable and it
should be in strict accordance with the operation ticket. Partial isolation measure should be well prepared
for the test of equipment in operation without affecting the safety of equipment operation. Make accident
expectation for the possible results that may be caused in the test.
2.2.9 After test, recover the mandatory condition and put the corresponding protection interlocking into
operation without random change, otherwise, it should go through specified approval procedures.
2.2.10 Do the recovery of system and equipment well, calibrate that the protection value is correct, analyze
the test result and make detailed record after test.
2.2.11 The power supply of all equipment should be cut off after test. Measures for preventing improper
startup should be prepared if the power supply is not cut off and the switch of equipment that should be
started up should be in “REMOTE” position.
2.3 Boiler hydraulic test
2.3.1 Hydraulic test conditions
a. Once every six years for the boiler in operation (after overhaul)
b. Newly installed boiler, before operation
c. Make routine hydraulic test after the boiler overhaul and repair or inspection for partial heating surface
(it depends as for reheater), of which the test pressure is equal to the maximum allowable working pressure.
Person-in-charge of maintenance will be responsible for hydraulic test and both operating and maintenance
personnel should participate in the test.
d. The superheater pipes or the economizer pipes should have 100% replacement if above 50% water wall
pipes are replaced after major repair or replacement of boiler pressure parts,.
2.3.2 Purposes of hydraulic test: check the tightness, deformation and damage of boiler pressure part in
cold state to ensure safe, stable and reliable operation.
2.3.3 Regulation for the pressure of boiler hydraulic test:
The test pressure is 1.25~1.5 times of the design pressure of the pressurized part.
System
Rated working
pressure (MPa)
Routine hydraulic test
pressure (MPa)
Super-hydraulic test pressure (MPa)
1.25 times 1.5 times
Main steam
system
19.79 19.79 24.74 29.685

80
Reheat steam
system
4.44 4.44 5.55 6.66
Water volume table of all parts involved in hydraulic test
Component name Economizer Water circulating system Superheater Reheater Total
Water volume (m³) 140
285M3
(the boiler drum is 62.6M3
)
345 235 1005
2.3.5 Test scope of boiler hydraulic pressure
2.3.5.1 Primary steam system:
The rear part of main feed water rear check valve to economizer inlet header tank pipeline, economizer,
drum, downcomer, circulating pump casing (including temporary blocking plate), four-side water wall,
ceiling superheater, wall enclosure superheater, low-temperature superheater, division wall superheater, rear
platen superheater, final stage superheater, main steam pipeline to main stop valve front part.
2.3.5.2 Secondary steam system
The rear of cold pipeline hydraulic test block valve to radiation reheater inlet header tank pipeline, radiation
reheater, rear platen reheater, final stage reheater to the front part of hot pipeline hydraulic test block valve.
2.3.5.3 The bearing pipeline and accessories in the scope of boiler proper: boiler water draining and
blowdown pipeline to primary air valve; dosing, sampling and air-discharging pipeline to primary air valve.
2.3.5.4 Drum water level gauge is used in the hydraulic test but not used in super-pressure test.
2.3.6 Temperature and quality of water for hydraulic test:
Hydraulic test should be done in ambient temperature higher than 5℃, and anti-freezing measures should
be taken when the temperature is lower than 5℃. The water temperature of hydraulic test should be higher
than the surrounding dew point temperature to prevent condensation on the boiler surface. The water
temperature should be higher than 20°C whenever the hydraulic test is done, but the temperature should not
be too high to avoid vaporization and excessive thermal stress, and temperature should also be controlled
less than 50°C. Boiler hydraulic test should adopt demineralized water or condensate or water treated by
10ppm ammonia and 200ppm hydrazine with CL-<0.2mg / L and pH value of 9 ~ 10.
Item
Ammonia
concentration
Hydrazine
concentration
Ferric chloride pH value
Visible solid
object
Standard 10 ppm 200 ppm 100 ppm About 10 < 1 ppm
2.3.7 Wind pressure test for pressurized parts should be performed before formal hydraulic test:
Install a ball valve at the place from air supply header of air compressor to the boiler bottom, of which the
outlet is divided into two parts: one is connected to the water filling pipeline of front water wall lower
header water discharging joint and equipped with a check valve; the other part is connected to the rear part
of a valve connecting to the economizer, wall enclosure and wall reheater water filling header. Perform
wind pressure test for primary and secondary air system by pressurizing pipe with test pressure of 0.3 MPa.
And the outlet pressure of air compressor is about 0.6-0.8MPa.
2.3.8 Preparation and check before boiler hydraulic test
2.3.8.1 Check that the maintenance work of steam and water system related to boiler hydraulic test has
been finished and the work sheet is finished. Confirm there is no one working in the furnace and flue.

81
2.3.8.2 Local pressure gauge with accuracy of grade 0.5 is installed at the outlet of drum and reheater, and
the outlet pressure indication of drum and reheater in the control room has been calibrated correctly.
2.3.8.3 The communication tools required for local and central control room communication is well
prepared. The passage, stairs, platform, railing and temporary scaffold necessary for hydraulic test are all in
good condition; sufficient expansion clearance is reserved for the heating surface expansion parts according
to the drawings and the expansion indicator clips are well installed; all welding parts meet the requirements
and the expansion indicator disc and pointer of main monitoring points are well installed and in zero.
2.3.8.4 All the boiler safety valves should adopted blowdown preventing measures at 85% pressure and the
control switch of electrical pressure relief valve is in “OFF” position to prevent the opening of valve during
hydraulic test. Before any hydraulic test, of which pressure is higher than the normal operating pressure, all
safety valves should be mounted with blocking plate according to related instruction of manufacturer, and
just close the safety valve if the test pressure equals to or is lower than the normal operating pressure.
2.3.8.5 Make sure the boiler steam and water system has been isolated from steam turbine and all water
drain valves at the rear of steam turbine main steam valve, proper, front of HP steam exhaust vale and rear
intermediate valve and all drain valves of low power steam turbine out of the scope of hydraulic test have
been opened.
2.3.8.6 In hydraulic test, the ambient temperature is generally above 5℃, otherwise, there should be
reliable winter proofing and anti-freezing measures. The water temperature for hydraulic test should not be
lower than 21℃, generally at 30℃~50℃ and the maximum value should not exceed 80℃.
2.3.8.7 The boiler water inlet temperature should not be lower than 21℃ and the maximum value should
not exceed 90℃.
2.3.8.8 Check that all boiler valves are in the right state according to the check card of hydraulic test before
filling water to boiler.
2.3.8.9 The spring hanger of main steam pipeline within the scope of hydraulic pressure should be well
fixed before test.
2.3.8.10 Superheater and reheater attemperating water electrical valve interlocking has been relieved.
2.3.8.11 The water used for hydraulic test should be qualified. Demineralized or condensate treated by
adding ammonia and hydrazine should be adopted: the concentration of hydrazine is 200ppm and PH is
10~10.5.
2.3.8.12 Before filling water to the water wall and superheater, make sure the drum and all foreign
substance in the header tank have been cleaned out, all water drain valve are closed and all air release
valves are open.
2.3.8.13 Do the check and preparation work of electrical feed water pump well according to the operating
instruction of feed water pump.
2.3.8.14 The hydraulic test should be done before the installation of furnace circulating pump motor, at this
time, the pump casing receiving the test should be closed by special hydraulic plate. During the test,
manhole and hand-hole, etc. of pressurized parts should not use temporary sealing equipment, closure plate
of pipe joint, flange cover and angle weld seam of valve base should have enough intensity. Check the
drum and lower water drum and the manhole door is well sealed.
2.3.9 Operational method of hydraulic test

82
2.3.9.1 There must have uniform command in hydraulic test, pressure rising and reducing cannot be done
until receiving the permission of site commander.
2.3.9.2 The order for hydraulic test is from LP to HP. Perform hydraulic test to reheater system at first and
then to the economizer, water wall and superheater system.
2.3.9.3 During reheater hydraulic test, use the intermediate stage bleed-off of electrical feed water pump to
fill water and increase the pressure through reheater attemperating water pipe.
2.3.9.4 During reheater hydraulic test, fill water to superheater in normal water filling method to full, and
then use superheater attemperating water pipe to increase the pressure. During the over pressure test, use
the plunger pump to test the pressure.
2.3.9.5 Close all air valves along the water flow direction when there is water overflowing continuously
after the water is filled to boiler.
2.3.9.6 Before boiler pressurizing, it is necessary to check that the drum wall temperature is not lower than
21℃, then use electrical feed water pump to increase the pressure through attemperating water pipe with
pressure rising speed of ≯0.3MPa/min.
2.3.9.7 Primary and secondary air respectively uses their corresponding attemperating water control valve
to increase the pressure with pressure rising speed not exceeding 0.3 MPa/min.
2.3.9.8 When the pressure rises to about 10% of the maximum allowable boiler working pressure (drum
pressure is 1.9MPa and the reheater pressure is 0.5MPa), stop pressure rising and perform initial inspection,
and then continue increasing the pressure if there is no abnormity.
2.3.9.9 When the pressure rises to 80% of the minimum setting pressure of safety valve (i.e. drum pressure
is 15.7MPa and reheater pressure is 3.4MPa), pause pressure rising and continue increasing the pressure
after tightly impacting the drum, superheater and reheater safety valve by compressing device.
2.3.9.10 When the pressure rises to the boiler working pressure or design pressure, close the feed water
valve for 5min and record the pressure decreasing valve, and then open the feed water valve slightly to
maintain the working pressure or design pressure and perform an overall check.
2.3.9.11 Parallel off the drum water level gauge when perform over pressure hydraulic test. Continue
increasing the pressure to over pressure test pressure after the check work is normal, and then close the feed
water valve and keep for 5min, and record the pressure reducing valve and then maintain the stable
pressure to perform overall check.
2.3.9.12 After the test, open the continuous blowdown or water drain valve to decrease the pressure in the
speed of 0.3~0.5MPa/min. Perform overall check when the pressure is down to working pressure or design
pressure.
2.3.9.13 When the pressure is down to zero, open the air valve and water drain valve for water drainage and
contact the maintenance personnel to remove the compressing device; if the boiler is prepared to be put into
operation and the water is qualified, discharge water to the ignition water level. Drainage in the superheater,
main steam pipeline and reheater should be discharged.
2.3.9.14 After the hydraulic test for reheater, close the reheater attemperating water electrical isolating
valve to release the pressure naturally and then do the hydraulic test for the economizer, water wall and
reheater.

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2.3.9.15 After the hydraulic test, use continuous blowdown or drain valve to release the pressure with
pressure reducing speed of 0.3~0.5MPa/min. Pressure reducing should be paused when the drum pressure
decreases to 85% of rated working pressure, and then continue reducing the pressure after the measures for
preventing safety vavle popping are removed.
2.3.9.16 When the pressure is down to zero, open all air valves and water drain valves to discharge water. If
the boiler is ready to be put into operation and the water is qualified, discharge the water to the normal
drum water level and the seeper in superheater and reheater should be drained out.
2.3.9.17 If the boiler is not put into operation in short term, close all air valves and water drain valves to
stop pressure releasing when the pressure is down to 0.5MPa, perform nitrogen blanketing protection or
other reliable shutdown maintenance measures.
2.3.10 Approval standard of boiler hydraulic test
2.3.10.1 5min after closing the feed water valve to stop the feed water pump, the primary air pressure
reducing should not exceed 0.5MPa and secondary air pressure should not exceed 0.25MPa; the pressure
reducing of economizer, water wall and superheater system should not exceed 0.1MPa/min and reheater
system pressure reducing should not exceed 0.05MPa/min.
2.3.10.2 The metal wall and welding seam of bearing parts has no leakage trace (no any water drops and
mist trace).
2.3.10.3 There is no significant residual deformation on the pressurized parts after macroscopic
examination
2.3.11 Precautions in boiler hydraulic test
2.3.11.1 During hydraulic test, there should be special person in charge of pressurizing to prevent
over-pressure. The pressure should be subject to the indication on drum local pressure gauge and there
should be special person monitoring LCD pressure in control room. Also, the local pressure gauge should
be monitored by special personnel, who should reduce the pressure rising speed when it is close to the test
pressure to prevent overpressure; the personnel monitoring the upper and lower pressure should contact
with each other very often and the thermal workers should check and confirm when the upper and lower
pressure indication has large difference.
2.3.11.2 During hydraulic test, continuous and intermittent blowdown electrical valves and reheater inlet
water drain valves, etc. are used as quick pressure relief measures to prevent overpressure.
2.3.11.3 To prevent overpressure of LP system related to hydraulic test, the related water drain valve should
be started except for reliable isolation.
2.3.11.4 All HP heaters should parallel off during hydraulic test.
2.3.11.5 The interlocking of related equipment should be recovered after the hydraulic test.
2.3.11.6 Pressure rising and reducing should be even and stable, the pressure rising speed should be strictly
controlled to prevent exceeding the specified pressure. Adjustment of water inflow should be slow and even
to prevent water impact.
2.3.11.7 It is not allowed to flush the pressure gauge tube and sampling tube during pressure rising.
2.3.11.8 During the hydraulic test of economizer, water wall and superheater, it is necessary to monitor the
pressure condition of reheater to prevent overpressure and strengthen the monitoring to steam turbine

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cylinder temperature.
2.4 Boiler safety valve calibration
2.4.1 Principles for safety valve calibration
2.4.1.1 After unit overhaul or maintenance for safety valve, calibrate the operating value of safety valve.
Electromagnetic pressure release valve thermal control test and electrical circuit test should be done once
during each unit shutdown, and gas release test for safety valve and EBV valve should be done once before
every shutdown for overhaul and repair.
2.4.1.2 The calibration of safety valve should be in the charge of principal of boiler maintenance, the
maintenance personnel should be responsible for the operation of safety valve system calibration,
operational personnel is responsible for DCS operation. There must be perfect technology and organizing
measures for calibration of safety valve.
2.4.1.3 Generally, the calibration of safety valve should be done under the working condition that the unit
has no load; if the test is done with load, it must be approved by the chief engineer and there should be
perfect technical measures.
2.4.1.4 The calibration content includes seating, blowdown and valve lift, etc.
2.4.1.5 The order for calibrating safety valve is HP and then LP, check the drum safety valve, superheater
safety valve, reheater inlet and outlet safety valves one by one.
2.4.2 Essential conditions for safety valve calibration
2.4.2.1 Boiler maintenance has been finished and the work sheet has been finished. The maintenance
explanation and log has been filled. Check the boiler proper and auxiliary machine before startup to
confirm that it meets the requirements of startup.
2.4.2.2 Communications tools are set between calibration site and centralized control room.
2.4.2.3 Steam turbine bypass system and vacuum system operates normally and the condenser vacuum is
normal.
2.4.3 Parameters of safety vale
Boiler barrel safety valve Model
Setting
pressure
MPa
Blowdown
pressure
MPa
Discharge
capacity T/H
Proportion in maximum
evaporation capacity %
1 1749WB 19.79 19.00 284
84.9
2 1749WB 19.79 19.00 284
3 1749WB 20.19 18.98 296
4 1749WB 20.19 18.98 296
5 1749WB 20.40 18.97 298
6 1749WB 20.40 18.97 298
Superheater outlet safety
valve
Model
Setting
pressure
MPa
Blowdown
pressure
MPa
Discharge
capacity
T/H
1 1750WD 18.30 17.75 160 15.5

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2 1750WD 18.30 17.75 160
Pneumatic discharge valve Model
Setting
pressure
MPa
Blowdown
pressure
MPa
Discharge
capacity
T/H
1 3538W 18.27 17.9 156
22.6
2 3538W 18.27 17.9 156
3 3538W 18.27 17.9 156
Reheater inlet safety valve Model Setting
pressure
MPa
Blowdown
pressure
MPa
Discharge
capacity
T/H
1 1705RR
WB
4.44 4.31 240
83.5
2 1705RR
WB
4.44 4.31 240
3 1705RR
WB
4.51 4.37 244
4 1705RR
WB
4.51 4.37 244
5 1705RR
WB
4.57 4.43 247
6 1705RR
WB
4.57 4.43 247
Reheater outlet safety
valve Model
Setting
pressure
MPa
Blowdown
pressure
MPa
Discharge
capacity
T/H
1 1705RW
D
4.13 4.00 188
21.5
2 1705RW
D
4.13 4.00 188
2.4.4 Use hydraulic calibration device to do the calibration of safety valve
2.4.4.1 Increase the drum pressure to 80% safety valve minimum setting pressure and stabilize the unit load
for setting according to the temperature and pressure rising curves. The control switch of electrical pressure
relief valve should be in “OFF” position.
2.4.4.2 After calibration for superheater outlet safety valve, set the control switch of electrical release valve
in the position of “AUTO”, which should be calibrated.
2.4.4.3 Use hydraulic calibration device to perform the calibration for reheater safety valve. Maintain the
reheater pressure after reaching 4.0MPa and perform calibration for safety valve.
2.4.5 Precautions in calibration for boiler safety valve
2.4.5.1 Strengthen the monitoring to steam temperature and pressure and water level when calibrating the
safety valve.
2.4.2.5 After calibration of safety valve, make detailed record about the seating and blowdown pressure.
2.4.2.6 During boiler operation, it is not allowed to increase the seating pressure of safety valve at will or
use compaction device to crush the safety valve.
2.4.2.7 During calibration of safety valve, stop immediately if there is abnormity.

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Part
Part
Part
Part 5
5
5
5 Handling
Handling
Handling
Handling of
of
of
of Boiler
Boiler
Boiler
Boiler Unit
Unit
Unit
Unit Trouble
Trouble
Trouble
Trouble
Chapter 1 Rules for Trouble Handling
1.1 When trouble occurs, unit supervisor shall lead the unit personnel to handle trouble quickly under the
direct guidance of shift engineer according to the rules stipulation. All commands of shift engineer, except
these that may directly harm safety of person and equipment, shall be executed promptly. Or the commands
can be refused with reason statement offered and any persisting from shift engineer shall be reported to
superior leaders.
1.2 When trouble occurs, operators shall quickly identify the initial causes for trouble and remove the threat
to personal and equipment safety and simultaneously try to guarantee the normal operation of equipment
without trouble. During trouble handling, effects of each operation step on relevant system shall be
considered comprehensively to prevent trouble expansion. Emergency shutdown shall be executed on the
condition that service power is not cut off.
1.3 When unit trouble occurs, operators shall handle the trouble according to the following steps:
A. When the unit trouble is verified according to conditions of parametric variation, CRT display,
equipment linkage, screen alarm, light card alarm, malfunctioned printing and unit external phenomenon,
then:
1) Remove the threat to person and equipment promptly and immediately disconnect fault equipment if
necessary;
2) Quickly identify the trouble nature, location and scope, and then do the handling and reporting;
3) Maintain normal operation of non fault equipment;
4) Each stage of trouble handling shall be reported to shift engineer and unit supervisor as quickly as
possible so as to report and ask for instructions timely and take measures correctly in case trouble
propagates.
B. When it proves to be system or other equipment fault, measures shall be taken to maintain unit operation
so as to make it possible to restore the normal operation of whole unit as soon as possible.
C. During trouble handling, chief& vice attendant and all positions shall inform each other and cooperate
closely, under united command of shift engineer and unit supervisor, to handle trouble quickly according to
rules stipulation to prevent trouble expansion.
D. Trouble handling shall be quick and accurate. Repeat the order once after it is received and quickly
report the execution condition to the order sender after order is executed.
1.4 When troubles which are not listed in the rules occur, operators on duty shall make correct judgment
according to their own experience and take countermeasures to give rapid handling initiatively. If time
allows, ask the shift engineer and unit supervisor for instructions and handle the troubles under the guide of
shift engineer and unit supervisor.
1.5 During trouble handling, immediately press button “MFT” or switch off manually when the protection
does not operate with the conditions for boiler or equipment emergency shutdown reached; and
immediately stop the auxiliary equipment when the protection does not operate with the auxiliary

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equipment emergency shutdown reached.
1.6 If unit trips suddenly, restore the unit operation as soon as possible after the trouble handling and causes
identified.
1.7 When trouble occurs or during trouble handling, operators shall not leave their working posts without
permission. Shift exchange shall be prolonged if trouble occurs during hand-over time. The previous shift
shall go on working before processing hand-over procedures till trouble handling is finished or has come to
an end. The next shift shall cooperate with the previous shift to handle the trouble.
1.8 It is forbidden to allow irrelevant personnel huddling around in the centralized control room or non
qualified personnel staying in the place where trouble occurs during trouble handling.
1.9 Once trouble handling is completed, chief attendant shall promptly and accurately report trouble
occurring and handling to higher-up supervisors level-by-level and make a detailed record of trouble
occurring time, phenomenon, development, handling process and cause analysis. Trouble analysis shall be
performed after the shift meeting with the whole shift personnel.

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Chapter 2 Boiler Accident Shutdown
2.1 Conditions of boiler emergency shutdown:
In any case as follows, boiler emergency shutdown shall be applied:
2.1.1 When boiler heating surface, main steam pipe, reheated steam pipe and feed water piping severely
burst which threatens the personal and equipment safety and fails to maintain the normal water level of
steam bubble.
2.1.2 When secondary combustion occurs in boiler tail flue and is not handled effectively in a short period
of time;
2.1.3 When boiler pressure exceeds safety valve operation pressure and the safety valve does not operate
while the electric relief valve does not open;
2.1.4 When all of the bubble water gauges are damaged.
2.1.5 When DOS system abnormities make the monitoring impossible.
2.1.6 When the control gas supply is lost and cannot be restored shortly.
2.1.7 When service power, either 6KV or 11KV, is all cut off.
2.1.8 When all of the fire detecting fans trip and cannot be restored in 5 minutes.
2.1.9 When MFT protection operation conditions are met but MFT does not operate.
2.1.10 When the midterm reheated steam is cut off.
2.1.11 When explosion occurs in the boiler chamber or flue and it seriously damages the equipment.
2.1.12 When there is an acute shortage of water in boiler and the level of water gauge at each side of steam
drum is lower than -350mm making the boiler automatic disconnection impossible.
2.1.13 When the boiler is full of water and the level of water gauge at each side of steam drum is higher
than +250mm and the boiler fails to disconnect automatically.
2.1.14 When both forced draft fan and induced draft fan are disabled.
2.1.15 When safety valve is not reseated after operation and pressure declines while the temperature varies
until it is not allowed according to the turbine side parameter.
2.2 Conditions of boiler fault shutdown
In any case as follows, ask the shift engineer for stopping boiler operation:
A. Boiler feed water and steam quality deteriorates seriously.
B. When leakage occurs in boiler pressure parts (Decide to ask for boiler shutdown or not according to
specific situation and position).
C. Boiler has much coke and the normal operation cannot be maintained after handling in multi-way.
D. There is much ash deposit in boiler flue and the normal furnace pressure could not be maintained after
measures are taken.

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E. Boiler steam temperature and heating surface wall temperature are seriously overheated and cannot be
reduced through multi-way adjustment.
F. When the normal operation of two kinds of water gauges cannot be guaranteed.
2.3 Handling of boiler emergency shutdown
2.3.1 MFT operation will perform boiler emergency shutdown automatically, or MFT shall be operated
manually.
2.3.2 Check the following leakage operations shall be normal, or they shall be operated manually:
1) All of the coal mills, coal feeders and primary fans trip, and the tripped coal miller will fill inerting
automatically.
2) Fuel oil trip valve and all oil inlet valves of oil guns are closed and oil gun purging is disabled.
3) Hot air damper of coal mill, auxiliary air baffle, primary air shut off damper and jet burner shut off
damper are in normal condition.
4) Control valve and holding valve of super heater stage I and II spray and reheater emergency spray are
closed.
5) Sootblowing shall be locked. If the sootblowing of boiler is in operation when MFT occurs, the
sootblowing will be stopped. Locally verify the sootblower exits.
6) The turbine trips.
7) The electric precipitator trips.
8) Boiler shall be blown for 5 minutes. If all of the forced draft fan and induced draft fan trip, natural
ventilation shall be applied for 15 minutes before starting forced draft fan and induced draft fan to blow the
boiler before the boiler ignition.
2.3.3 Control the super heater pressure within the allowable range.
2.3.4 Adjust the steam bubble level at the normal value and start the economizer recirculation valve after
water feeding is done.
2.3.5 Other operations shall be conducted according to the rules for normal boiler shutdown or relevant
emergency handling.

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Chapter 3 Boiler MFT
3.1 Boiler MFT phenomena:
A. MFT sound-light alarm.
B. There is no flame display on TV of furnace flame.
C. All pulverizing system in operation and primary fans trip.
D. Oil trip valve is closed.
E. Electric master valve of attemperating water is closed.
F. Electric precipitator trips.
G. Sootblowing program is cut off.
3.2 Handling after boiler MFT operation:
1) Immediately stop manually primary fans, coal mills and coal feeders which haven’t tripped
automatically.
2) Verify that the oil trip valve and attemperating water master valve are closed. Or immediately close them
manually.
3) Automatic feed water pump shall start itself automatically or it shall be started manually to maintain the
steam bubble level.
4) No fault in air-flue gas system. And the boiler furnace shall be blown.
5) If boiler is disconnected by air-flue gas system fault, prolong the furnace blowing time after fault is
removed.
6) Inerting shall be applied to the coal mill which has tripped.
7) The electric precipitator shall be stopped manually if it does not stop automatically.
8) Exit the sootblower which hasn’t exited from the furnace.
9) Identify the primary cause for MFT from the first BMS trip display.
10) Timely remove the fault and get prepared for hot start.
11) If the fault cannot be removed shortly, conduct boiler shutdown as a common practice.

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Chapter 4 Loss of Service Power
4.1 Phenomena when all service power is lost:
A. The unit, boiler MFT and turbine trip and the generator disconnects; alarm rings and each corresponding
light alarm board lights up.
B. Voltage of each segment of service bus drops to zero and its power switch has green indicator on.
C. All AC auxiliary equipments in operation stops and there is no linkage in standby AC auxiliary
equipment; Electric valve does not work under operation.
D. There is linkage in each DC equipment.
E. AC lighting lamps are off while the DC lighting lamps are on and the control room dims.
4.2 Causes:
The generator disconnects and working power of each segment of 6KV is lost and the standby power
supply does not succeed in automatic switching. Or the high-voltage standby transformer trips and the first,
secondary emergency power supply don/t succeed in automatic switching.
4.3 Treatment:
1) Put the pneumatic motor of air preheater into operation. Close the manually-operated door of boiler-front
fuel oil trip valve and oil-return valve.
2) Unit supervisor shall notify Peripheral positions to conduct corresponding treatment for loss of service
power and notify air compressor operators on duty to startup all air compressors for emergency power
supply. Restore all tripped equipments and disable the interlock of standby equipments.
3) Put the lubrication system of each auxiliary equipment into operation.
4) Check and adjust all the ventilation doors and baffles of pulverizing system out of operation to the right
position. And the spray water valve and holding valve of super heater and reheater are to be closed.
5) Restore the service power level-by-level and gradually restore each system according to the unit
situation.
6) Ask the chief engineer to feed boiler with water according to the range of temperature of steam bubble
wall so as to maintain the steam bubble level and deaerator water temperature to be normal.
7) Gradually conduct other operations to restore unit operation.

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Chapter 5 Loss of Service Air Supply
5.1 Phenomenon when service air supply is lost:
A. Low pressure alarm of the service air supply rings.
B. Pneumatic control valve does not work and relevant water level and temperature cannot be adjusted
automatically.
C. Particular pneumatic control valve is changed in position, all switched on or all switched off.
5.2 Causes:
a. Air compressors in operation trip and standby air compressors are not put into operation or air
compressors in operation are not loaded enough.
b. There is a serious leakage in service air supply pipe and the air pressure cannot be maintained.
c. Master air valve are closed mistakenly or the master interconnection valve of the adjacent engine is
opened mistakenly.
5.3 Treatment
1) Immediately contact air compressor operators on duty to increase the output of running air compressor,
start the standby air compressor and conduct a comprehensive inspection and adjustment for compressed
air system.
2) Comprehensively check whether there is serious leakage point in the system, if any, try to isolate it.
3) Before air pressure restores, conduct local adjustment manually of some crucial control valves or bypass
manually operated valves to guarantee the normality of vital parameters such as water level of deaerator,
condenser and temperature of host lubrication oil.
4) Conduct corresponding manual adjustment to other pneumatic valves, air doors and baffles which are
allowed for manual adjustment.
5) Closely monitor the unit operation conditions and conduct boiler emergency shutdown when the unit
operation cannot be maintained.
6) Corresponding pneumatic valves, air doors and baffles shall still be operated locally after boiler stops, in
case the equipment is damaged.

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Chapter 6 Automatic load shedding
6.1 Automatic loading shedding phenomena (RB):
A. There is trip sound-light alarm of crucial auxiliary equipment and fluctuation of parameters controlled
by tripped auxiliary equipment.
B. Running coal mill is programmed to trip.
C. Unit load declines rapidly to and is stable at 300MW.
D. Main steam flow, feed water flow and steam pressure drop by a large margin and the steam temperature
declines to some degree.
6.2 Causes:
a. A primary fan trips.
b. An induced draft fan trips
c. A forced draft fan trips.
d. A steam pump trips.
e. A preheater trips.
f. Two forced circulation pumps trip.
6.3 Treatment
6.3.1 When RB automation succeeds
1) When there is 50%RB, the automatic tripping sequence of the coal mill from top to bottom is: F→E→D
mill trip with the interval of 10 seconds until the last three mills remain in operation.
2) When the unit load≤60%MCR and generator stator cooling water lost the genetic horizon RB, the
automatic tripping sequence of coal mill is: F→E→D→C→B with the tripping interval of 5 seconds until
the last mill remains in operation.
3) Unit control mode is switched from CCS to “turbine follow mode” and reduce the load to 50%MCR
according to RB load reduction setting.
4) Operators shall closely monitor the parameter variation and put oil gun into operation timely for
combustion-supporting during automatic RB. No interference shall be applied only if the automatic
operation is normal until the unit goes steady.
5) If it is one steam pump trips, immediately turn up its outlet differential pressure valve to adjust the water
feeding manually after linkage start of electric pump. Pay attention to disabling the automatic control of
running minicomputer.
6) Boiler load>50%MCR, and two steam pumps trip while the electric pump succeeds in automatic startup
and the load shedding comes up to 46%MCR.
7) Immediately switch automatic operation into manual operation for adjustment if abnormalities happen
during automatic RB process.

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6.3.2 When RB automation does not succeed
1) Immediately trip an upper coal mill manually and put the oil gun of one bottom running coal mill into
operation for combustion-supporting. Remove the furnace pressure automation, adjust parameters like
steam bubble water level, steam bubble pressure, furnace pressure, oxygen content within allowable range
according to specific case. Simultaneously adjust the compressor control valve to reduce electrical load
until it matches with the boiler thermal load. Keep stopping the operation of some coal mills if necessary.
2) When primary fan trips, immediately disable the furnace pressure automation and closely monitor
primary air pressure variation. If it is not allowed for operation of three pulverizing systems, trip one coal
mill every 5 seconds until the last one coal mill is maintained to operate, and timely put oil gun of this mill
into operation as well as reduce electrical load down to 150MW.
3) During manual RB operation, pay attention to the variation of main steam temperature and reheated
steam temperature preventing low temperature protection operation when sharply reducing boiler thermal
load to choose coal mills to be tripped.
4) Restore the system with load after fault is cleared.

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Chapter 7 Overfeed of Water into Drum
7.1 Phenomena
A. Water level of each steam drum is indicated high and alarm window gives high level alarm.
B. Feed water flow probably exceeds steam flow abnormally.
C. In case of extreme high water level, main steam temperature drops dramatically with water impact in
steam pump.
D. When main steam temperature gets too low until it reaches the protection operation value, the protection
operates and turbine trips.
7.2 Causes
a. Feed water auto adjustment does not work, and the minicomputer speed control goes abnormal or the
adjustment of outlet differential pressure valve is out of order during electrical pump operation.
b. Reading of water level is incorrect and manual or auto adjustment is improper.
c. Dramatic change of operation condition caused wrong steam bubble level. Judgment is incorrect and
adjustment isn’t timely.
7.3 Treatment
1) Immediately disable the feed water automation and turn down the minicomputer speed or feed water
valve of electrical pump when water level reading is up above 102mm. Open the accident water drain valve
if water level of steam drum still remain high.
2) In case of accident, water level adjustment shall be subject to differential pressure water gauge and
manual adjustment shall be made according to the bull’s eye level gauge.
3) Immediately open the water drain valves of super heater system if water penetrates super heater and
close them till the steam temperature restores normal.
4) Emergency shutdown shall be conducted if protection does not operate 5 seconds after water
level≥250mm.
5) Report to shift engineer, and get prepared to start after fault is cleared and steam drum is maintained with
normal water level.

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Chapter 8 Water Shortage of Drum
8.1 Phenomena
A. Reading of steam drum water level is low and alarm window gives low level alarm.
B. If leakage occurs in boiler heating surface, the feed water flow will exceed steam flow abnormally.
C. If it is feed water system fault, feed water flow will be less than steam flow abnormally.
8.2 Causes
a. Feed water auto does not work, minicomputer speed control goes abnormal and the adjustment of
differential pressure valve of electric pump outlet is out of order.
b. Sudden trip during minicomputer operation, untimely startup of electrical pump or extremely high unit
load caused incapability of timely feed water.
c. Program disorder during high pressure heater disconnection caused feed water interruption or the
motor-operated valve at economizer inlet is closed mistakenly.
d. Feed water pipe and boiler heating surface burst.
e. Dramatic change of operation condition caused wrong steam bubble level. Judgment is incorrect and
adjustment isn’t timely.
8.3 Treatment
1) Immediately disable the feed water automation and turn up the minicomputer speed or feed water valve
of electrical pump for feed water increasing when water level reading is down to -102mm.
2) In case of accident, water level adjustment shall be subject to differential pressure water gauge and
manual adjustment shall be made according to double-color water gauge. Check whether high pressure
heater feed water system is normal and immediately startup it locally if it cannot be started on CRT caused
by mistakenly closing of valves.
3) Boiler leakage can be suspected if the steam water level still drops when feed water flow is greater than
steam flow. It can be verified by careful listening to sound locally and once it is verified, boiler shall be
shut down.
4) Protection shall operate when steam drum water level drops to protection operation value, or shutdown
the boiler manually.
5) Report to shift engineer and relevant supervisors, rapidly identify causes and conduct treatment, and then
restart the unit.

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Chapter 9 Surge of Forced Draft Fan and Induced Draft Fan
9.1 Phenomena
A. Light board of blower surge gives alarm.
B. Furnace negative pressure or wide fluctuations of air flow. Frequent auto adjustment of other side of fan
moving blade during fan moving fan operation and instability of furnace combustion.
C. Large-scale sway occurs to surging fan current and there is serious abnormal sound in local inspection.
D. Delay tripping when fan surging is seriously up to trip value.
9.2 Causes
a. Heavy ash deposit in heating surface and air preheater or mistakenly closing of flue gas system baffle
caused increased system resistance giving rise to inaptness between fan moving blade opening and air or
flue gas inflow. That will lead the fan to stall region.
b. Wide fluctuation will lead the fan into stall region during fan moving blade operation.
c. Adjusting property of moving blade is becoming poor and contrary wind occurs in two parallel running
fans or auto control fails to work which leads one of the fans into stall region.
d. Sootblower is put into operation with unit in high load or airflow is too large.
9.3 Treatment
1) Immediately set the fan moving blade control to manual mode and turn down the moving blade of the
other non stalled fan. Properly turn down the moving blade of the stalled fan while harmoniously adjust the
forced draft fan and induced draft fan to keep furnace negative pressure within the allowable range.
2) If surge occurs during fan parallel operation, parallel operation shall be stopped and stalled fan moving
blade shall be turned down. Only after causes are identified and surge is removed, can parallel operation be
conducted.
3) If the reason for fan surge is that damper and baffle of air flue gas system are mistakenly turned off,
immediately turn them on and meanwhile adjust the moving blade opening. If it is damper or baffle fault,
immediately reduce boiler load and contact maintenance personnel for treatment. If it is caused by
sootblowing, immediately stop the sootblowing.
4) If surge is removed after the above mentioned treatment, keep operation conditions stable and further
check causes for corresponding measures to be taken before increasing fan loading gradually; and
immediately stop the fan operation if the above treatments are ineffective or seriously threaten equipment
safety.

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Chapter 10 Tripping of Air Preheater
10.1 Phenomena
A. Air preheater current reaches zero, pneumatic motor automatically switches over and the corresponding
sound-light signal gives alarm.
B. If pneumatic motor does not switch into operation, air preheater stops running and gives alarm while the
tripping side flue temperature rises high.
10.2 Causes
a. Mechanical part of air preheater get stuck and motor is overloaded.
b. Electric protection operates.
c. Pneumatic motor does not switch over automatically.
10.3 Treatment
1) If there is no over current phenomenon before tripping, switch on forcedly. If it succeeds, operation may
continue.
2) If the forcible switch on is not successful or the current exceeds the limit after start, immediately stop the
running and check whether pneumatic motor runs normally.
3) If pneumatic motor cannot operate normally and air preheater stops running, flue gas baffle of tripped air
preheater inlet & outlet shall be closed immediately for isolating primary and secondary airflow to reduce
load down below 300MW.
4) Shut down the equipment if fault cannot be removed shortly.
5) MFT shall be operated manually promptly when exhaust gas temperature rises up to 250℃.

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Chapter 11 Leakage of Boiler Heating Surface
11.1 Phenomena
A. There is abnormal sound near explosion tube in furnace or flue.
B. When the leakage is serious, steam drum level will drop and its normal water level cannot be maintained
though feed water flow is much greater than steam flow.
C. When there is leakage in water-cooled wall, furnace pressure rises and steam emerges from untight place
of the furnace wall.
D. When there is leakage in economizer, flue gas temperature at air preheater inlet is abnormal and water
flows from lower ash hopper of the economizer.
E. When there is leakage in super heater and reheater, steam temperature before bursting point drops and
that behind bursting point rises or attemperating water amount increases.
F. Current of inducted draft fan rises and flue gas temperature at air preheater inlet drops.
11.2 Causes
a. Tube material and installation technology are unqualified.
b. Long-term fly ash wear.
c. Heating surface is overheated and burnout.
d. Sootblower cannot exit and keeps blowing at fixed time for long.
e. Steam quality is unqualified for long which causes the corrosion, scaling and heat transfer deterioration.
f. Foreign body stuck in tube causes poor water circulation.
11.3 Treatment
1) Increase feed water quantity to maintain normal level of steam drum. Report to shift engineer for boiler
shutdown requirement.
2) Reduce boiler load and super heater pressure properly.
3) Maintain parameters, like main and reheated steam temperature, furnace pressure and induced draft fan
current, within the normal range.
4) Emergency shutdown shall be done when steam drum level cannot be maintained because of serious
leakage until it reaches protection operation value
5) Try to maintain steam drum level after boiler shutdown. If the water level cannot be maintained or the
differential temperature between upper and lower wall of steam drum reaches up to 90℃. All feed water
pumps shall be stopped so as to stop water filling and the economizer recirculation valve is prohibited to be
open.
6) After blowing the furnace, keep one induced draft fan running to maintain a normal furnace negative
pressure. The induced draft fan can be stopped after steam disappears and natural ventilation shall be
applied. In cooling process, stop the induced draft fan and maintain natural ventilation when differential
temperature between upper and lower wall of steam drum reaches up above 90℃.

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Chapter 12 Secondary Combustion of Boiler Tail Flue
12.1 Phenomena
A. Flue gas temperature at air preheater inlet & outlet and exhaust flue gas temperature rise high while flue
gas pressure goes abnormal. Oxygen content goes small and the hot point detecting device give alarm.
B. Air preheater current fluctuates to a large degree. Bearing and case temperature rises high and stagnation
occurs when situation is serious.
C. Heated primary and secondary air temperature rises high.
D. Furnace pressure fluctuates and induced draft fan blade automatically opens wide with induced draft fan
current rising.
E. When re-burning occurs at reheater side, reheated steam temperature will rise high abnormally and flue
gas baffle automatically turns off. Simultaneously, the temperature at separation screen rises and primary
water spray amount is increasing.
12.2 Causes
a. Mixed combustion time with coal and oil is too long during boiler startup (shutdown) process, so that
fuel materials accumulate at tail heating surface and corrugated plated of air preheater.
b. Time of boiler running with low load is too long that combustible materials pile up in tail flue.
c. Coarse pulverized coal or improper combustion adjustment causes unburnt pulverized coal to enter boiler
tail flue.
d. Sootblower fault makes long-term operation abnormal.
12.3 Treatment
1) When flue gas temperature of air preheater inlet is rising high abnormally, causes shall be analyzed and
corresponding adjusting measures taken. Meanwhile, sootblowing shall be conducted to flue and air
preheater heating surface.
2) If the handling is invalid and flue gas temperature at air preheater outlet rises up to 250℃, report to shift
engineer for boiler emergency shutdown.
3) After boiler shutdown, stop the induced draft fan and forced draft fan. No ventilation shall be applied to
furnace and relevant sootblower shall be put into operation for fire-extinguishing.
4) When air preheater is burning fiercely, put water washing in operation for fire-extinguishing. Keep the
air preheater running during fire-extinguishing but it’s forbidden to open its manhole door for inspection.
5) Verify that the fire is extinguished and conduct ventilation and blowing to prepare for restoring after
receiving order from shift engineer.

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Chapter 13 Abnormalities of Steam Parameters
13.1 Phenomena
A. Pressure and temperature of main and reheated steam is too high or too low.
B. Parameters overrun causes alarm.
C. Unit load varies.
D. Axial displacement and differential expansion of host are changing.
13.2 Causes
a. Fault occurs in pressure and temperature control system or attemperating water is improperly adjusted.
b. Load-rejection occurs in unit suddenly.
c. High pressure heater runs out of synchronization suddenly.
d. Safety valve of steam system suddenly gets open.
e. Coal quality mutation occurs or pulverizing system operation is out of order.
13.3 Treatment
1) Control system fault shall be handled respectively according to fault degree. Switch into manual mode if
necessary to adjust pressure and temperature right and do the adjustment via regulating combustion and
load.
2) As to the necessity of adjusting rate of load change caused by rapid increase and decrease of load, and
the load variation caused by protection operation, handle them according to relevant provisions.
4) If pulverizing system runs abnormally extracting uneven pulverized coal which will cause instable boiler
heating load, the pulverizing system shall be adjusted and shut down if necessary.
5) When main steam temperature and reheated steam temperature are abnormal, the treatment shall be in
accordance with the following provisions:
① When main steam temperature and reheated steam temperatures vary within the range 538+8℃, the unit
is allowed for long-term operation.
② When main steam temperature and reheated steam temperatures rise up to 552℃, the max unit operation
time per year shall be within 400 hours with 30 minutes as the max operation time for each operation, or
unit fault shutdown will happen.
③ When main steam temperature and reheated steam temperature rise up to 566℃, the maximum
allowable unit operation time per year is 80 hours with 15 minutes as the maximum operation time for each
operation, or unit fault shutdown will happen. When main steam temperature and reheated steam
temperature keep rising high, burning capacity of upper layer burner shall be reduced properly and
sootblowing shall be conducted.
④ Under rated steam pressure conditions, steam temperatures shall be restored to normal value as soon as
possible if main steam temperature and reheated steam temperature drop to 520℃; when main steam
temperature and reheated steam temperature keep dropping and cannot be rebounded, unit load shall be

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reduced and main steam pressure lessened to make sure both the main steam temperature and reheated
steam temperature are higher than 50℃, the corresponding first-stage metal temperature of cylinders.
⑤ Manual boiler shutdown shall be conducted when steam temperature falls below protection operation
value but protection does not work.

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Chapter 14 Unit Load Swinging
14.1 Causes
a. System impact and surging.
b. Generator is out of synchronism.
c. Control circuit fault.
d. EH oil pressure fluctuates.
14.2 Treatment
1) Causes shall be identified quickly according to CRT display, relevant instrument indication and external
signs.
2) Relevant operations shall be executed as shift engineer ordered if system surges.
3) As to motor out of synchronism, active power of motor shall be reduced and excitation increased
manually.
4) If rapid change of unit load is caused by grid frequency variation, unit output shall be controlled strictly
as overload operation is prohibited.

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Chapter 15 Unit Load-rejection
15.1 Phenomena
A. Sudden drop of unit load, rapid change of local sound and variation of axial displacement.
B. Steam pressure rises and boiler safety valve may operate.
C. Pumping pressure of each segment declines.
D. When unit load-rejection reaches operation conditions of power load imbalance relay and acceleration
relay, PLU and ACC operate.
E. When there is working condition “RUN BACK”, relevant interlock operates on boiler side.
15.2 Causes
a. Fault occurs in electric power system and power transmission sequence trips.
b. Unit protection operates.
c. Fault occurs in speed-governing system, control valve is closed mistakenly or main auxiliary equipment
trips.
15.3 Treatment
1) Closely monitor variation of main steam parameter and reheated steam parameter and try to keep boiler
parameters normal.
2) Comprehensively check unit operation situations, identify causes as soon as possible and do
corresponding treatment; if no obvious fault found, immediately report shift engineer to get ready for load
increasing.
3) If it is fault in speed-governing system which is cannot be handled during operation, equipment shall be
shut down for fault handling.
4) Check conditions of air pump operation and automatic feed water adjusting and disable main feed water
and minicomputer automation as well as pay attention to operation condition of feed water pump min flow
valve if automatic feed water adjusting cannot meet the boiler demand.
5) Pay attention to service power operation condition; and the condenser vacuum and low-pressure cylinder
steam temperature; Monitor and adjust the water level of condenser, deaerator and heater; maintain
auxiliary steam mains pressure normal.
6) Pay attention to deaerator pressure and steam supply for shaft seal.
7) Immediately report to shift engineer and execute order from shift engineer if unit protection operates
mistakenly.

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Chapter 16 Auxiliary Equipment Fault
16.1 Stop the operating equipment urgently in any one of the following cases
1) Violent vibration and dynamic and static friction occurs to equipment.
2) Metal friction sound is obviously heard inside equipment.
3) Motor smokes and catches fire.
4) Bearing is short of oil or smokes.
5) There are other faults threatening safety of personal and equipment operation.
16.2 Start the standby auxiliary equipment before stop the fault equipment in the following cases:
1) Equipment gives abnormal sound.
2) Motor current increases abnormally, insulation gives burning smell or motor coil temperature overruns.
3) Two phase operation of the motor.
4) Vaporization occurs in running pump.
5) Bearing temperature overruns.
6) Fault occurs in air cooling system of large motor.
7) There is overheating, smoking; massive oil and water leakage in packing set and corresponding
adjustment is ineffective.
8) Other cases threatening safety operation of auxiliary equipment happen.
16.3 Immediately stop the motor during startup in any one of the following cases:
1) Long time no return of the current after motor startup.
2) Motor does not work and buzzes after switch is turned off.
3) Spark or smoking appears in motor.
4) Abnormal vibration occurs in equipment and serious leakage in connecting pipe and flanges.
16.4 Violent vibration of auxiliary equipment
16.4.1 Phenomena
A. Both local measurement and remote indication of vibration value are large, and vibration value of
corresponding auxiliary equipment is high which may lead to alarms. The auxiliary equipment with
vibration protection will trip when vibration reaches protection value.
B. Abnormal sound can be heard locally and bearing temperature may rise high.
C. There is loud abnormal sound when surging of induced draft fan and forced draft fan or vaporization in
pumps causes violent vibration.
16.4.2 Causes
a. Clutch alignment is unqualified or clutch is damaged.

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b. Rotor center is misaligned.
c. Bearing is installed with big clearance or bearing is damaged.
d. Foundation screws are loose or mechanical connecting part is loose.
e. Fan surges or water pump vaporizes.
16.4.3 Treatment
1) Make alignment for rotor center which is misaligned.
2) Check whether bearing is damaged; fasten the loose foundation screws or mechanical connecting part.
3) Effective adjustment shall be applied immediately at time of surge or vaporization.
4) Equipment without vibration protection shall be shut down when vibration increases to limit value.
5) It’s considered as the great vibration when auxiliary equipment vibration exceeds the value in the
following table:
Rated speed (r/min) 7600 3000 1500 1000 ≤750
Vibration value (double amplitude um) 40 50 85 100 120
16.5 Motor fault
16.5.1 Motor fault shutdown conditions
Motor operation shall be shut down immediately in any one of the following cases:
1) When personal safety is threatened;
2) Motor and the electric device to which it subordinates smoke and catch fire;
3) The motor-driving mechanical equipment fails to run;
4) Violent vibration or internal impact happen and cause friction of rotor and stator;
5) Motor speed drop sharply and current rises high or declines to zero;
6) Motor and bearing temperature rises sharply and exceeds the allowable value;
7) Flood and fire occurs threatening motor safety operation.
16.5.2 Motor fault shutdown conditions
If any of the following cases, for important service motor, standby equipment shall be started first before
the motor is shut down:
1) Abnormal sound exists in motor and insulation gives burning smell;
2) Spark or smoking occurs inside of motor or starting and regulating device;
3) Stator current exceeds the normal operation value (with same load);
4) Cable lead of the motor is seriously overheated;
5) Fault occurs to cooling system of large motor;
6) Three-phase imbalance current of the motor exceeds above 10%.

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16.5.3 If the tripped motor affects unit output or safety operation but there is standby motor or the standby
motor can/’t be started promptly, the tripped motor can be switched on once expect in the following cases:
1) There is obvious short circuit or damage phenomenon in motor starting and regulating device or power
cable;
2) Personal injury occurs requiring a sudden shutdown;
3) Motor-driving mechanism is damaged;
4) The motor tripped via protection operation.
16.5.4 When important motor loses voltage or voltage declines, it is forbidden to cut off service motor
manually in one minute.
16.5.5 Automatic trip during motor operation
16.5.5.1 Causes
A. Interturn and interphase short circuit of the stator coil.
B. Power cable fault.
C. Motor-driven mechanism gets stuck.
D. Voltage declines.
E. Relay protection operation or operator/s misoperation.
16.5.5.2 Treatment
a. Start the standby equipment.
b. If there is no standby equipment, promptly check reasons and start the equipment with problem cleared.
Motor can be started immediately after misoperation is verified.
c. If the motor trips during startup, another startup shall not be conducted with causes unidentified.
d. Inspection shall be executed to tripped motor as follows:
(I) Check which the protection operation it is;
(II) Check whether motor coil or cable has phenomenon like short circuit, grounding or line disconnection;
(III) Check whether the motor driven mechanism gets stuck, safety wire is fused or interlock circuit is in
good condition;
(IV) Check whether the switch mechanism is good or power switch and knife switch is completely turned
on;
(V) Measure if motor insulation resistance (including cable) is good.
16.6 Motor smokes and catches fire giving a burning smell
16.6.1 Causes
A. As the bearing center is misaligned or bearing bush is worn, stator and rotor collide.
B. As stator coil insulation is damp, nasty and aged, interphase short-circuit or grounding fault occurs.

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C. Squirrel-cage bar is unsoldered or fractured.
16.6.2 Treatment
1) Immediately turn off the motor power switch.
2) Apply powder fire extinguisher, 1211 fire extinguisher, carbon dioxide fire extinguisher or mist sprayer.
It is forbidden to apply large water stream, sand or foam extinguishing.
3) Detailed inspection to motor
16.7 Violent motor vibration
16.7.1 Causes
A. Motor center does not coincide with the equipment center, main shaft is bended and mechanism is
damaged.
B. Unit bearing is damaged or counterbalance is displaced and out of balance.
C. Friction exists between stator and rotor or the fan has fallen off.
D. Rotor squirrel-cage bar is unsoldered or fractured.
E. Mechanism vibrates and foundation screws are loose.
16.7.2 Treatment
1) Start standby motor.
2) If no standby motor, reduce motor load and check whether vibration is reduced or removed, or contact
maintenance personnel for treatment.
16.8 As to abnormal motor temperature rise, inspection shall be executed as follows:
1) Check whether voltage is lower than or the current exceeds the specified value;
2) Check whether cooling air is above 35℃, cooling system blocked and fan runs normally;
3) Check whether three-phase current is balanced or exceeds specified value;
4) Check whether the mechanism gets stuck and causes overload.

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Chapter 17 Fire Disaster
17.1 If operators find fire within their responsibility scope, they shall:
1. Not leave their positions without permission or run about in panic on the condition their personal safety
is guaranteed.
2. Enhance unit operation maintenance and handle incidents as stipulated in rules.
3. Immediately execute the correct order from higher positions.
17.2 Fire treatment
1. When fire alarm signal is sent and order received, rush to the fire scene, master the fire situation and
check whether the fire extinguishing system works well and extinguish fire with the relevant fire
extinguishers correctly.
2. When fire occurs to electrical equipment, cut off power supply first and extinguish fire with
extinguishers. When fire occurs nearby electrical equipment and the equipment safety is threatened,
relevant professionals shall stop the operation and cut power off.
3. When fire does not threaten unit operation yet, try to prevent fire from spreading and take away
combustible materials around fire scene and put out the fire as soon as possible.
4. Strengthen operation monitoring and get ready for equipment shutdown.
5. Shut down the equipment promptly if the unit safety is seriously threatened by fire.
6. If fierce fire is on or near oil tank, threatening oil tank safety, open the accident oil drain valve of oil
tank while destroying the vacuum and shutting equipment down. But consideration shall be taken into
keeping lubrication oil uninterrupted in case bearing gets burnt before unit stops operation.
7. When seal oil system catches fire and cannot be put out shortly which threatens equipment safety,
emergency shutdown shall be executed and hydrogen shall be discharged promptly during idling. And
the seal oil system shall be maintained as it possibly can until unit stops running.
8. Emergency shutdown shall be executed immediately when fire occurs to motor or hydrogen cooling
system. And fill CO2 into motor to exclude H2 so as to extinguish the fire while the water cooling
system is maintained running.
17.3 Extinguishing mode, applied apparatus and precautions
1. Fire on sundries without being oil-immersed can be extinguished with water, foam extinguisher and
sands, etc.
2. Fire on oil-immersed sundries shall be extinguished with foam extinguisher and sand, etc.
3. Fire on oil in oil tank or other containers shall be extinguished with foam extinguisher, CO2, CCL4,
1211 extinguisher. Wet cloth extinguishing or air isolation can be applied if necessary but sand and
water faucet without nozzle is prohibited for extinguishing.
4. Fire on charged equipment shall be extinguished with CO2, CCL4 and powder extinguisher after
power cutoff but foam extinguisher shall not be applied. It is prohibited to extinguish fire of motor by
filling sand or large stream of water into the motor.

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5. When charged equipment is on fire, CO2 and CCL4 extinguisher can be applied for extinguishing if
the power cannot be immediately cut off. It is forbidden to employ other non-insulated extinguisher.
6. When steam pipe or other high temperature components are on fire, CO2 extinguisher shall be
prohibited and water applying shall also be cautious in case thermal stress damages the equipment.
7. If running part and speed-regulating system of the equipment is on fire, sand is not to be applied for
extinguishing. And meanwhile, execute extinguishing fire according to the above mentioned
provisions.
8. Fire on hydrogen system is mainly extinguished with CO2 and 1211 extinguisher.

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Chapter 18 DCS Fault
18.1 DCS system is constituted with a wide variety of hardware, software and networks, with complicated
fault point distribution and fault analysis. However, the central idea of fault handling shall be clear, that is,
both personal and unit equipment safety shall be guaranteed. The operation shall never be maintained with
lucky psychology but shut down when the fault has seriously threatened unit safety operation or when it is
hardly probable to remove DCS fault.
18.2 DCS faults can be classified into three cases for handling as follows:
(1) When all operator stations crashed or data does not update, for example, press emergency shutdown
when unit safety cannot be guaranteed by LCD disc parameter monitoring. The relevant operated items
shall be correct and timely.
(2) When some operator stations have fault, the unit monitoring task shall be undertaken by available
operator stations. And then stop all important operations and meanwhile contact instrument operator
for quick fault clearing. If fault can’t be cleared, then handle it accordingly make relevant accident
assumption based on the practical operation.
(3) If it is system controller fault or corresponding power fault, timely contact instrument operator and
handle fault according to the following principles:
A. If it is auxiliary equipment controller fault or corresponding power fault, switch it into backup control
if there is backup manual mode, or exit operation of this auxiliary equipment.
B. If it is circuit controller or corresponding power fault, switch automatic operation to manual operation
and take corresponding measures based on handling.
C. If it is controller or corresponding power fault concerning unit protection, immediately notify
instrument operator for handling and make accident assumption for accident shutdown.
(4) During accident handling (especially when it involves operations like unit protection module
replacement, power restoring, etc), take measures for initialization of relevant controllers.

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Chapter 19 Operation Measures for Pulverizing System
19.1 Technical measures against pulverizing system explosion
1) Strictly implement the regulations, and keep coal mill running under optimum condition. Strictly
control parameter for each item within the specified range.
2) Maintain coal mill running in normal operation mode, and singe operation of coal mill or double
operation of jet burners can be applied as approved by operation VP under special circumstances, in
which irregular operation mode has to be adopted.
3) Strengthen contact with fuel operators and make sure coal quality is qualified without burning wet coal
or other coal types. Corresponding operation mode shall be taken when non design coal has to be
applied for combustion.
4) Chemical branch send coal quality analysis report everyday to central control room and relevant
professions.
5) When disable pulverizing system operation normally, ash remains in system shall be pumped out with
no less than 15 minutes of blowing while the air flow is guaranteed at above 40t/h. Coal mill shall be
stopped after verifying there is no coal to be pulverized.
6) When pulverizing system is shut down for internal inspection, fill an inert conversion more after coal
miss stops running. Contact maintenance personnel to open manhole door behind PASOD and coal
feeder end capping for sufficient ventilation before work sheet can be processed to work.
7) Internal inspection is prohibited after coal mill trips. Make corresponding measures if inspection is a
must.
8) When there is a stop to prepare a standby coal mill, regularly check temperature variation of coal mill
outlet and timely feed inert gas for treatment when abnormities found; closely monitor temperature at
each point of jet burner and strictly implement Operational Measures against High Temperature at Jet
Burner Outlet.
9) Timely learn CO content inside coal mill out of operation through CO monitoring system.
10) During maintenance for coal mill, operators shall keep informed of the state of coal mill under
maintenance. When coal mill outlet temperature rises up to 70℃, notify maintenance personnel to stop
maintenance work and retract work sheets and close coal feeder end capping and other openings for
inert gas feeding. Restart working after each part is normal.
11) After coal mill explosion, immediately stop the operation and maintenance work of this coal mill and
do corresponding treatment like feeding inert gas and fire extinguishing based on the field situation.
And contact maintenance personnel for inspection. Get it into standby mode only after all parts
restored.
19.2 Operational measures against blocking
1) If operation cannot be restored within 24 hours after boiler MFT emergency shutdown, close inert
conversion manual door of all coal mills. When coal mill is in inching mode or temperature inside coal mill
rises to 70℃, corresponding operations can be conducted by opening inert conversion manual door. After
the operation, close inert conversion manual door.

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2) When coal mill has water inside, it shall be warmed after its startup. The warm time can be decided by
specific situation but it shall not be less than 40 minutes and coal mill outlet temperature shall be warmed
up to 60~65℃ and verify no water is inside coal mill before coal feeder operation can be started.
3) When it is level display fault of coal mill, coal mill shall be stopped as emergency standby; when it is
level display fault or any air display fault, disable coal mill and start it only after defects are removed.
4) Low level operation mode shall be taken when wet coal (with moisture content above 12%) is applied
for combustion.
5) Coal feeding shall be stopped and blowing with increased air flow conducted when blocking in coal mill
is found during operation.
19.3 Operational measures for coal mill wet coal
1) Operators shall enhance monitoring on each operational parameter and specially assigned person shall be
in charge of coal mill adjustment and monitoring.
2) Coal feeding quantity shall be adjusted even and continuous. Immediately contact maintenance
personnel for corresponding treatment if coal chute is blocked.
3) Regularly check operation state of coal feeder scrapper and contact maintenance personnel for clearing if
necessary.
4) Take monitoring on primary air pressure, coal mill outlet primary air pressure, separator inlet & outlet
differential pressure and so on against coal overflow of coal mill or separator blocking.
5) Take monitoring on bearing bush and return oil temperature of the coal mill and strictly control coal mill
bearing bush temperature below 57℃. Reduce the coal mill output when bearing bush temperature rises up
to 54℃ and stop the coal mill operation when it rises to 57℃.
6) Reduce coal feeding quantity and contact with other supervisors when coal is too much in coal mill. Pay
attention to the monitoring and adjustment on parameters of main steam pressure and temperature, furnace
pressure and electric loading.

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Chapter 20 Anti-accident Measures against Furnace Explosion
20.1 Check before startup
1. Check and verify boiler-front oil system cycles normally and fuel oil temperature>15℃, or put fuel
heating system into operation.
2. Check whether oil guns per layer are complete and intact without oil or air leakage phenomenon. Fire
detecting cooling air pressure shall be normal and fire detecting cooling air valve opening proper.
3. All flue gas system baffles shall be normal in full travel test without stagnation and are positioned
correctly.
4. FSSS control system and protection inputs are normal. Disabling of boiler protection shall be approved
by general engineer.
5. Before first ignition after repair of each degree, conduct advance and retreat test of all oil guns and
ignition test of all high-energy igniters and make sure operations are good and records shall be made.
20.2 Boiler startup
1. Boiler-front oil circulation shall be put into operation only after induced draft fan and forced draft fan
have started with air flow reaching above 25%.
2. Boiler ignition can be allowed only after fuel mains leakage test is qualified. If fuel mains leakage test is
unqualified, identify causes and don’t start the equipment before removing the defects.
3. When put oil guns into operation at initial ignition period, observe oil gun combustion conditions locally
or via flame monitoring TV. If fire detecting signal exists though oil gun is not on fire, immediately stop the
oil gun manually and contact maintenance personnel for causes identifying. It is prohibited to ignite
repeatedly before causes are identified.
4. Timely contact maintenance personnel for oil gun cleaning when atomization is poor. Operators shall
timely adjust air feeding quantity according to ignition conditions of oil guns to guarantee complete
combustion of fuel oil.
5. All oil guns of selected igniters shall be put into operation when start coal mill. Sufficient energy for oil
guns to ignite pulverized coal shall be guaranteed after coal mill discharges pulverized coal. When coal mill
primary air flow>40 %( two pairs of igniters in operation) or >25 %( one pair of igniters in operation),
there is coal level displaying of coal mill. Oil guns can be stopped for combustion-supporting after the
combustion is stable.
6. Only after one coal mill is started and runs stably, can another coal mill be started. It is prohibited to
simultaneously start two coal mills to feed boiler with pulverized coal.
7. Air preheater shall be put into operation for continuous sootblowing against combustible material
depositing on heating surface when boiler is ignited and burns a mixture of oil and pulverized coal; A
comprehensive sootblowing shall be applied when oil supply to boiler is all cutoff.
8. In any oil gun operation, oil combustion pressure shall be guaranteed not less than 0.3MPa and
atomizing air pressure at least higher than layer oil pressure 0.2MPa.
20.3 Normal operation

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1. In normal operation, oxygen content in flue gas shall be guaranteed >3%. Once large oxygen content
deviation at observation point is found, timely contact thermal technician for inspection. And it is
prohibited to put automatic oxygen content control into operation when oxygen content observation point is
not accurate.
2. When boiler is in low-load operation, avoid coal mills running at the minimum steady burn load nearly
(Primary air flow of coal mill is around 40-50%). One coal mill can be stopped to guarantee that other coal
mills are running with relatively high load.
3. FSSS protection and automatic combustion control system which have been put into operation shall not
be disconnected casually. Problems discovered, timely contact maintenance personnel for treatment.
4. Boiler heating surface sootblowing shall be conducted while load ≥360MW and is prohibited when load
is low or combustion is unstable. Sootblowing program shall be terminated during accident treatment.
5. The primary air coal pipes shall be blown once after coal mill trips, and corresponding oil gun shall be
put into operation. Gradually start a pair of auxiliary air baffles and blow another pair of primary air coal
pipes after 5 minutes blowing.
6. When unstable combustion working conditions like coal quality deteriorates, coal mill trips and
single-side fan trips happen, immediately feed oil for combustion-supporting.
7. When that furnace fire is extinguished but MFT does not operates is verified, immediately conduct MFT
manually and sootblowing for furnace. Close fuel oil inlet master valve, front &rear manual doors of fuel
oil recycle valve; all manual doors of oil guns shall be closed if boiler shutdown time exceeds 8 hours.
8. If the oil tank level drops unreasonably or fuel consumption meter indicates wrongly during normal
operation without oil put into it, contact maintenance personnel for checking if there is internal leakage of
oil guns.
9. When pulverizing system is under maintenance in boiler operation, reliable isolation from furnace shall
be guaranteed, and it is prohibited to open coal mill BSOD.
20.4 Boiler stop
1. In boiler sliding shutdown, Pulverized coal in mill shall be blown before stopping coal mill operation.
2.。All the oil guns of 4 burners shall be put into operation during sootblowing after mill is shut down so as
to make sure all the coal are completely burned when the mill is being blown.
3. After boiler stops, make sure all oil guns have been blown and exited; verify locally all primary fan and
coal mills trip, BSOD is closed, and all oil guns have exited and oil inlet manual doors are closed.
4. After the tripping of all forced draft fans and induced draft fans, and emergency shutdown of boiler,
natural ventilation at maximum air volume shall be maintained for 15 minutes in case combustible gas
accumulates.
5. Forced draft fan and induced draft fan are not be stopped before closing fuel oil system inlet master
manual door and front & rear manual doors of fuel oil recycle valve.

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Part
Part
Part
Part 6
6
6
6 Startup
Startup
Startup
Startup and
and
and
and Shutdown
Shutdown
Shutdown
Shutdown of
of
of
of Boiler
Boiler
Boiler
Boiler Auxiliary
Auxiliary
Auxiliary
Auxiliary Equipment
Equipment
Equipment
Equipment
Chapter 1 General Rules for Auxiliary Equipment
1.1 Conditions for recovering the operation of equipment and system after maintenance
1.1.1 Equipment or systems are well connected, pipe supports and hangers are reliable, thermal insulation is
sound.
1.1.2 Valves and equipment are in good condition, all manhole and inspection doors are closed.
1.1.3 Bearings of power equipment, motors, etc. are filled with qualified lubricating oil and protection
covers, grounding wires of equipment case, cooling pipes, etc. are well connected.
1.1.4 If any change has been made on equipment during maintenance, then maintenance personnel should
offer report of changes and relevant drawings and communicate operating precautions to operators.
1.1.5 On-site equipment and ground should be clean and free of debris, ground cover is accurately
positioned, stairs and railings are sound, clear road, the illumination is sufficient.
1.1.6 Relevant thermal meters and electric meters of equipment and systems are sound.
1.1.7 Work sheet has been terminated, safety precautions, signboards and warning boards have been
removed.
1.2 Inspection before the startup of auxiliary equipment
1.2.1 Work sheet has been terminated, safety precautions, signboards and warning boards have been
removed.
1.2.2 Protection cover of coupling is sound, the disc coupling has at least two coils that are flexible and
movable.
1.2.3 Open primary and secondary insulating valves of relevant meters, and accordingly close relevant
balance valves, test valves, blowdown valves, energize the thermal control meters, make sure all meters
work well, interlock and protection devices are approved sound in static check, electric valves, pneumatic
valves and adjusting valves can work well during examination.
1.2.4 Pressure of control air source is normal, insulating valves of equipment control air have been opened.
1.2.5 The indication of status of relevant equipment and valves on CRT is correct and all alarm signals are
correct.
1.2.6 Energize relevant electronic valves, and make sure it is in good condition by “ON/OFF” test.
1.2.7 Bearing oil level of rotating machines is higher than 2/3 and oil is qualified.
1.2.8 Make sure that all valves are at “pre-startup” position, discharge air in relevant pumps and systems.
1.2.9 All auxiliary equipment cooling water inlet valves are open and adjust cooling water quantity by
water outlet valves.
1.2.10 Energize after verifying insulating devices of motor are qualified.
1.3 Regulations for electric valves test

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1.3.1 Make sure electric valves test will not cause any influence on working equipment and systems before
performing it, also make sure relevant personnel are on site and power supply of electric valves is normal.
1.3.2 Check that the relevant displays on CRT and MCC are consistent with on-site states after the electric
valve is energized.
1.3.3 Check there is no jam on the mechanical parts by manual operation before electric valve test.
1.3.4 Close the valve electrically to make the CLOSE limit switch operate, check that the opening
indication is in the “CLOSE” position, fasten valves by manual operation, check if the circles of closing the
valve meet the specification and keep record.
1.3.5 Open the valve electrically to make the OPEN limit switch operate and check that opening indication
is in “open” position.
1.3.6 Open and close the electric valve once in the whole travel, check that the opening indication and light
signals are correct and record the time of open/close in the whole travel.
1.3.7 The LOCAL/REMOTE control mode of electric valve should be tested and be qualified.
1.4 Startup of auxiliary equipment and precautions
1.4.1 Contact the relevant operating personnel before starting up the auxiliary equipment, monitor and
inspect operating conditions.
1.4.2 Generally, the startup and shutdown of auxiliary equipment should be operated by deputy operator or
above, test operating must be monitored on site, and immediately report to the higher level and perform
emergency shutdown.
1.4.3 Check if the voltage of corresponding 6kV busbar is normal before starting up the 6kV auxiliary
equipment, monitor the voltage of 6kV busbar and starting current and starting time of auxiliary equipment
during startup, and keep basic balance of load in each part of busbar during shutdown.
1.4.4 Restarting if 6kV auxiliary equipment should conform to relevant electric regulations. It is allowed to
start up twice in cold and once in hot in normal condition.
1.4.5 When starting the motor with electric heating device, the electric heating device should drop out
before startup.
1.4.6 Positive displacement pumps are not allowed to start while outlet valves are closed, centrifugal pump
are allowed to start while outlet valves are closed, but the outlet valves should be opened immediately after
startup.
1.4.7 After problem-free startup of auxiliary equipment, the standby auxiliary equipment should be put to
“AUTO” or “INTERLOCK” in time.
1.4.8 Duration of starting current during startup of auxiliary equipment should not exceed the regulation
made by manufacturer, otherwise, shut down instantly.
1.4.9 Auxiliary equipment is forbidden to start when it rotates reversely.
1.5 Inspecting items after the startup of auxiliary equipment
1.5.1 First check the motor by spot if it rotates correctly in the first trial run after overhaul, repair or motor
connection..

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1.5.2 Motor current, inlet & outlet pressure, flow rate, and differential pressure of inlet filter are normal.
1.5.3 Cooling water is normal, temperature of bearing and motor coil is normal.
1.5.4 Confirm that the interlock and relevant adjustment system are normal.
1.5.5 Standby pump check valve is closed tightly and has no reverse rotation.
1.5.6 Listen to confirm there is no abnormal friction sound in its proper and motor parts.
1.5.7 The vibration of each part meets the specification.
1.5.8 Confirm that the system has no leakage.
1.5.9 Check that the temperature of each bearing is normal. Execute the standards in the following table if
the manufacturer has no special regulations.
Bearing type
Rolling bearing Sliding bearing
Motor Machinery Motor Machinery
Bearing temperature ≤80℃ ≤100℃ ≤70℃ ≤80℃
1.5.10 Check that the temperature rise of motor does not exceed the value in the following table. (ambient
temperature is 40℃)
Insulation level Level A Level E Level B Level F
Temperature rise of motor 65℃ 80℃ 90℃ 115℃
1.5.11 Verify each bearing vibrates normally, refer to standards below if no special regulation from
manufacturer.
Rated speed (rmp) 3000 1500 1000 750 and above Remark
Vibration (mm) 0.05/0.06 0.085/0.1 0.1/0.13 0.12/0.16 Motor/machinery
1.6 Maintenance during the operation of auxiliary equipment
1.6.1 Perform periodical inspection according to tour inspection items during auxiliary equipment normal
operation, analyze the abnormity if there is any and fill out the defect table and contact the relevant
personnel for treatment if there are any defects in the equipment.
1.6.2 Regularly call out the system displays on CRT to check if the operating parameters, operating mode,
valve state are correct. Targeted inspection should be performed on site both before and after important
operation.
1.6.3 Perform periodical switch and examination to equipment according to relevant regulation.
1.6.4 Periodically check oil level and oil quality according to operating cycle of equipment.
1.6.5 Ensure each controlling parameter is within the allowed range, instantly perform adjustment and
treatment if any abnormity is found.
1.6.6 Make good measures against thunders, moistures, typhoons, floods and freezes and accident
anticipation according to the changes of season and climate.
1.6.7 Keep equipment and nearby ground clean.
1.7 Auxiliary equipment shutdown
1.7.1 Contact with the relevant positions before shutting down an auxiliary equipment, carefully consider if
the shutdown of an auxiliary equipment will bring unsafe influence to relevant systems or equipment, if it

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is, take corresponding measures.
1.7.2 Quit “AUTO” or release self starting “INTERLOCK” of standby auxiliary equipment before
shutdown.
1.7.3 Rotating speed should reduce to zero and has no reverse rotation after shutdown of auxiliary
equipment. Close the outlet valve to eliminate reverse rotation if there is reverse rotation, which should not
be eliminated by the method of closing the inlet valve first.
1.8 Operation from shutdown of auxiliary equipment or system to maintenance
1.8.1 Before passing the system or equipment to maintenance, approval should be obtained from chief
operator, relevant work sheet should be prepared, safety measures should be well performed according to
the work sheet and signboards and warning boards should be well hanged.
1.8.2 Make good measures for power interruption, pressure relief and isolation of equipment.
1.8.3 Disconnect the power supply and control power supply of motor.
1.8.4 Close pump outlet insulating valves to make sure the valves are tightly closed.
1.8.5 Close the air valve connecting the inlet valve and inlet of pump; closely monitor the inlet pressure
gauge and operate slowly when closing the inlet valve especially it is almost fully closed to prevent untight
close of outlet valve and other insulating valves connecting with HP system from damaging LP pipeline
and flange duel to overpressure.
1.8.6 Close the bearing cooling water inlet and outlet valves, open water drain valves and air valves of
pump and relieve pressure to zero.
1.8.7 Pressure relief of pressure vessel and pipeline
(1) Close all working medium inlet valves of pressure vessel and make sure the inlet valves are closed
tightly.
(2) Close all working medium outlet valves of pressure vessel and make sure the outlet valves are closed
tightly.
(3) Open water drain valves of pressure vessels and pay attention that the internal pressure of the vessels
should be reduced. After finishing water draining, close water drain valves connecting with flash chamber
and open the single water drain valve to trench.
(4) Open air valves of pressure vessel to confirm internal pressure is thoroughly relieved.
(5) Cut off the power of electric valve through which the external working medium may get into the vessel
and break off the pneumatic valve and prepare anti-misoperation measures.
(6) Hang warning boards marked “people on working, no operation” on all electric, pneumatic and manual
insulating valves connecting with pressure vessel.
(7) Fulfill safety measures for maintenance according to requirements of thermal work; after the safety
measures are checked and approved by work sheet licensor and director, approval for beginning of work
sheet should be accomplished and relevant record should be well prepared.
1.9 Accident treatment during the operation of auxiliary equipment
1.9.1 Immediately shut down the fault auxiliary equipment in any one of the following situations.

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1. Equipment vibrates heavily.
2. There are emergency situations that directly threat the safety of operator and equipment.
3. Obvious metal friction sound or striking sound arises in internal equipment.
4. Motor catches fire or smokes.
5. Motor current suddenly exceed the limit and cannot recover to normal and the equipment has abnormal
sound.
6. Bearing smokes or temperature suddenly rises exceeding the rated value.
7. Motor is flooded.
Operating parameter exceeds the rated protection value but the protection does not work.
1.9.2 First start up the standby auxiliary equipment and then shut down the breakdown auxiliary equipment
in one of the following situations.
(1) Centrifugal pump has vaporization, no pumping or output of fan is not sufficient.
(2) Smoke or big water leakage arises in axle sealing area, and adjustments do not work.
(3) Bearing temperature exceeds alarm value and has the tendency of continuing rising.
1.9.3 Perform following treatment if the auxiliary equipment trips for faults during operation.
(1) Reset the operating switch of interlock auxiliary equipment and tripped auxiliary equipment after
tripping of operating auxiliary equipment and put-in of standby auxiliary equipment normal interlock
startup and check the relevant interlock action of the tripped auxiliary equipment and rotation of interlock
auxiliary equipment is normal.
(2) Immediately start up the standby auxiliary equipment when the operating auxiliary equipment trips but
the standby auxiliary equipment does not interlock.
(3) Forced startup can be done if it is found that the tripped auxiliary equipment has no fault alarm and no
electric fault signal when operating auxiliary equipment trips, the startup of standby auxiliary equipment is
failed or there is not standby auxiliary equipment. Find out the trip causes if forced startup succeeds and it
is not allowed to start again if it fails. Confirm the influence of auxiliary equipment shutdown to the normal
operation of main machine and take local insulating measures or rundown. Apply for shutdown if the
operation of main machine cannot be maintained.

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Chapter 2 Startup and Shutdown of Air Preheater
2.1 Inspection and preparation before air preheater startup
2.1.1 Perform air preheater inspection according to general regulation of auxiliary equipment.
2.1.2 Rotating rotator manually to confirm the air preheater can rotates flexibly.
2.1.3 Confirm that turning handle is disassembled from motor end shaft and all protection covers are stable
and reliable.
2.1.4 Confirm all soot blowers have dropped out and in place. Confirm the nozzle of sootblowing device is
smooth in the whole travel and the injection surface of sootblower nozzle is covered by heat transfer
elements and soot blowing system meets the requirements.
2.1.5 Put the fire monitoring device into operation and check that the local cabinet operates normally.
2.1.6 Check and confirm fire water is normal.
2.1.7 Confirm alarm device for rotor stall operates well.
2.1.8 Open cooling water valve of top guide bearing.
2.1.9 Confirm the main motor, secondary motor and pneumatic motor meet the startup condition.
2.1.10 Check every oil level meter, confirm lubricating oil of all bearing base and reduction gearbox is
sufficient. For avoiding oil overflow, do not exceed the indicated level when adding oil. Add oil to fluid
coupling as specified.
2.1.11 Check if rotating direction of main, secondary motor driving gear is the same with the rotator of
original air preheater. Incorrect rotating direction may damage rotator seals.
2.2 Air preheater startup
2.2.1 Check and open inlet and outlet valves of upper and lower bearing lubrication system, put upper
bearing oil cooler into operation and put in oil pump interlock.
2.2.2 Check and confirm that the solenoid valve controlled by air preheater pneumatic motor is closed.
Open air inlet isolating valve of the pneumatic motor and open compressed air supply valve.
2.2.3 Put in the rotor stall alarm device.
2.2.4 Start up the pneumatic motor of air preheater and put “AUTO” after it operates normally.
2.2.5 Start main motor of air preheater.
2.2.6 Confirm pneumatic motor can automatically shut down.
2.2.6 Startup procedures of air preheater.
(1) Start pneumatic motor of air preheater and put it to “AUTO”.
(2) Perform delay start to main motor of air preheater.
(3) Perform delay shutdown to pneumatic motor of air preheater.
(4) Open primary air outlet damper of air preheater.

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(5) Open secondary air outlet damper of preheater.
(6) Open flue gas inlet damper of air preheater;
(7) Startup program is finished.
2.3 Operation and maintenance of air preheater
2.3.1 After boiler is ignited, perform continuous soot blowing to air preheater by auxiliary steam until the
fuel is cut off. Perform soot blowing once a shift in normal operation. The boiler should be put into
operation according to the resistance rising of preheater after it is in full load, and generally, it need not to
be put into operation. If hot end soot blower is required, it is advised to perform soot blowing once every
24 hours.
2.3.2 During air preheater startup, contact thermal personnel to switch automatic sealing clearance
adjusting device to “AUTO” when the unit load is >60% MCR and operates continuously with load for
more than 6 hours. During air preheater shutdown, release “AUTO” mode of automatic sealing clearance
adjusting device and lift it to maximum position manually when working load reduces to 50% MCR.
2.3.3 There should be no abnormal sound during air preheater operation, transmission device operates
stably with no friction and motor current is stable and within a normal range. If the current changes
abnormally, immediately switch the automatic sealing clearance adjusting device manually and adopt flue
gas temperature reducing measure and other relevant measures.
2.3.4 Monitor flue gas differential pressure of preheater inlet and outlet, air pressure difference and changes
of inlet and outlet flue gas temperature and instantly analyze causes and take relevant measures against any
abnormity.
2.3.5 Instantly perform soot blowing for air preheater when the flue gas differential pressure of inlet and
outlet increases.
2.3.6 There is no leakage in lubricating oil system, oil level and oil temperature is normal. Start and stop
manually if the interlock of oil pump is abnormal.
2.3.7 Air preheater motor should be started at first and in operation for 5min before starting the air
preheater, and then put in the main electric machine after checking that it is normal.
2.3.8 Start up main motor by frequency converter.
2.4 Checking terms during operation
2.4.1 Body case has good thermal insulation and proper has no air leakage or flue gas leakage.
2.4.2 There is no static friction and abnormal sound.
2.4.3 Washing water and its heating system should be closed and the system has no leakage.
2.4.4 Check oil temperature of upper and lower bearing, oil pump should start automatically when oil
temperature is >38℃ and automatically shut down when oil temperature is <32℃. Contact the maintenance
department for treatment if the interlock is abnormal.
2.5 Air preheater shutdown
2.5.1 Switch pneumatic motor of air preheater to “MANUAL” mode.
2.5.2 Stop air preheater main motor and send alarm according to the air preheater zero speed signal.

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2.5.3 Shutdown procedures of air preheater:
(1) Close the air preheater inlet flue gas damper.
(2) Close the air preheater outlet primary air damper.
(3) Close the air preheater outlet secondary damper.
(4) Stop main motor, auxiliary motor and pneumatic motor.
(5) The program is finished.
2.6 Soot blowing of air preheater.
2.6.1 Check that water drain of soot blowing pipeline is normal with soot blowing steam pressure of
1.0~1.37MPa and stream temperature ≮310℃.
2.6.2 Put in continuous air preheater soot blowing during boiler startup put-in.
2.6.3 Strengthen soot blowing in any one of the following situation:
A. Differential pressure between inlet and outlet of air preheater flue gas side is ≥ 1.4KPa.
B. Boiler combustion is not stable and put oil for supporting combustion.
C. The tail heating surface has leakage.
D. Perform soot blowing before boiler shutdown.
2.7 Water washing of air preheater
2.7.1 Pneumatic motor should be used if the air preheater must be started when washing the air preheater.
If air preheater needs starting when water washing is ongoing, use pneumatic motor.
2.7.2 Water washing should be performed when boiler is shut down and flue gas temperature of air
preheater inlet educes to 70℃.
2.7.3 Confirm water draining valves are all opened and the water discharging pipe and nozzle are not
blocked before washing.
2.7.4 Water washing devices in cold end and hot end should work simultaneously.
2.7.5 After water washing is qualified, close washing valves and water draining valves.

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Chapter 3 Startup and Shutdown of Induced Draft Fan
3.1 Check before startup of induced draft fan
3.1.1 Perform check before startup of induced draft fan as specified in general rules.
3.1.2 Confirm induced draft fan is energized.
3.1.3 Confirm lubricating oil system and bearing cooling fan is energized.
3.1.4 Check and put motor oil station of induced draft fan into operation:
1) Check that the oil level and oil temperature of oil tank are normal.
2) Open the manual isolating valve of pressure meter.
3) Open bearing oil supply valve, inlet & outlet oil stop valves of oil cooler and oil pump outlet
valve, close bypass valve of oil cooler and each oil drain valve.
4) Switch shuttle valve of oil filter to work position.
5) Check that the temperature of oil tank is normal (20~40℃). Electric heater will automatically
start when temperature is lower than 15℃ and it will automatically stop when temperature is
higher than 25 ℃, cooling water will be put in automatically when temperature is higher than
50℃.
6) Select and start up oil pump #1 (or #2), switch oil pump #2 (or#1) to “AUTO” mode.
7) Check that the oil pump outlet pressure, differential pressure of oil filter and outlet oil pressure
of oil cooler are normal.
8) Put in oil cooler cooling water.
3.1.5 Start up two bearing cooling fans of induced draft fan.
3.1.6 Open outlet dampers of induced draft fans and forced draft fans that are not in operation, fully open
the inlet static blades and moving blades to form a natural air duct.
3.1.7 Confirm interlock protection device has been put in.
3.1.8 Confirm oil returns normally in induced draft fan motor bearing oil return window.
3.2 Startup of induced draft fan
3.2.1 Startup of induced draft fan should meet the following conditions:
3.2.1.1 Oil pimp #1 or #2 of oil station is in operation.
3.2.1.2 At least one set of cooling fan is in normal operation.
3.2.1.3 Inlet static blades of the induced draft fan are in minimum position (-75%).
3.2.1.4 Inlet damper of the induced draft fan is fully closed.
3.2.1.5 Outlet damper of induced draft fan is fully open.
3.2.1.6 Air preheater of this side has been put into operation.

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3.2.1.7 Bearing temperature of induced draft fan is< 70℃.
3.2.1.8 Pressure of induced draft fan motor lubricating oil station is normal.
3.2.1.9 Inlet flue gas damper of air preheater is open.
3.2.2 Start up the induced draft fan motor.
3.2.3 Open the inlet dampers automatically; stop the fan immediately if inlet damper is not fully opened in
1min.
3.2.4 Adjust static blades of induced draft fan to keep furnace negative pressure at about -100Pa, and check
following items:
3.2.4.1 The induced draft fan operates without any abnormal sound.
3.2.4.2 Bearing temperature of induced draft fan is < 70℃.
3.2.4.3 Motor bearing temperature of induced draft fan is < 80℃.
3.2.4.4 Motor current of induced draft fan is normal.
3.2.5 In cold startup, guiding blade opening cannot be adjusted too quick or too big, motor current should
be monitored against overload.
3.2.6 Precautions for induced draft fan startup.
a. Induced draft fan should not be started with load.
b. Induced draft fan should not be started when it rotates reversely.
c. Avoid starting other 6KV motors on the same busbar during startup.
3.3 Operating maintenance of induced draft fan
3.3.1 Working load deviation between draft fans should not be too big when adjusting working load of
induced draft fan to prevent the induced draft fan from operating in unstable working condition.
3.3.2 Check and periodically record the induced draft fan current, motor lubricating oil temperature,
cooling water temperature and bearing temperature during induced draft fan operation.
3.3.3 Periodically switch the operation of oil cooler. First charge oil to the standby oil cooler and discharge
air and then shut down the original operating oil cooler during switching.
3.3.4 Switch to standby filter screen in time and contact maintenance personnel for cleaning when
differential pressure of filter screen of oil system is too large.
3.3.5 If oil level in any place of draft fan is low, contact the relevant personnel for adding in time. Monitor
and make sure oil temperature of oil tank is indicated at 20~40℃.
3.3.6 The induced draft fan should not be shut down before thorough parallel-off of boiler front oil system.
3.3.7 It will give an alarm when the induced draft fan bearing temperature is >90℃, and then start up
another bearing cooling fan by interlock.
3.4 Procedures for starting the induced draft fan in parallel:
1) Make sure outlet dampers of induced draft fan that should be in parallel are fully opened and the

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inlet dampers are fully closed meeting the startup conditions.
2) Adjust the static blade of operating induced draft fan to keep furnace pressure at -100Pa.
3) Start up the induced draft fan that should be in parallel and the inlet damper will automatically open.
4) Slowly open the induced draft fan that should be in parallel, turn down the static blade of operating
induced draft fan to keep furnace pressure at -100Pa.
5) Paralleling of two induced draft fan will be finished when static blades opening and current of two
induced draft fans are basically the same, induced draft should then be adjusted according to working
load, and induced draft fans should be switched to “AUTO” mode.
3.5 Shutdown of induced draft fan
3.5.1 Gradually close inlet moving blades and slowly turn down the inlet guiding blades of induced draft
fan until it is fully closed, pay attention to keep furnace negative pressure normal.
3.5.2 Press “OFF” button on CRT to shut down induced draft fan, of which the outlet damper and other
dampers of air & gas system interlock is normal.
3.5.3 Shut down the bearing cooling fan of induced draft fan 3h after shutdown of induced draft fan.
3.5.4 Shut down the induced draft fan motor oil pump.
3.6 Emergency shutdown has to be performed in following situation
3.6.1 Double amplitude of induced draft fan is ≥0.198mm.
3.6.2 Bearing temperature of induced draft fan increases sharply and is ≥ 90℃.
3.6.3 Motor bearing temperature of induced draft fan increases sharply and is ≥ 90℃.
3.6.4 Motor smokes and catches fire.
3.6.5 People or equipment safety is threatened.

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Chapter 4 Startup and Shutdown of Forced Draft Fan
4.1Check before the startup of forced draft fan
4.1.1 Perform check before the startup of forced draft fan as specified in general rules.
4.1.2 Confirm forced draft fan is energized.
4.1.3 Confirm oil system is energized and put forced draft fan oil system into operation.
1) Check that the oil level of oil tank is normal.
2) Check that the oil tank temperature is normal which is at 20℃~40℃; put electric heater into operation
when oil temperature is lower than 20℃.
3) Start up the pressure meter and manual insulating valve of pressure switch and switch shuttle valve of
filter screen to work position.
4) Start up oil pump #1 (#2) and switch oil pump #2 (#1) to “AUTO” mode.
5) Check and keep oil pressure at 2.5~3.5MPa.
6) Put in cooler cooling water.
4.1.4 Check the moving blade hydraulic adjust device, perform full open & full close test to moving blades,
make sure indication of dial (local and control room) conforms to actual position of moving blades and then
put the moving blade to OFF.
4.1.5 Check that the startup of forced draft fan meets the following conditions:
4.1.5.1 Oil temperature of oil station is > 20℃.
4.1.5.2 Control the oil pressure to be > 205MPa.
4.1.5.3Oil level of oil tank is > 75% of oil tank height.
4.1.5.4 Oil pump operates normally and the time is >30s.
4.1.5.5 Lubricating oil flow is > 3L/min.
4.1.5.6 Bearing temperature of fan is < 80℃.
4.1.5.7 Bearing temperature of motor is < 80℃.
4.1.5.8 Outlet damper has been closed.
4.1.5.9 Inlet moving blades has been closed.
4.1.5.10 The induced draft fan of this side is in operation.
4.1.5.11 The secondary air outlet dampers of air preheater has been opened.
4.1.6 Start up the forced draft fan. Startup forced draft fan A and it will be isolated automatically, after
which forced draft fan A will be started and the outlet damper on forced draft fan A side will be opened
automatically; after the outlet damper is fully opened, adjust the damper of induced draft fan A to keep
furnace negative pressure at -100Pa and open the moving blade of forced draft fan A; forced draft fan and
induced draft fan B will be isolated automatically.

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4.1.7 Procedures for starting the forced draft fan in parallel:
1) Confirm moving blades and outlet dampers of the forced draft fan ready for startup are fully closed
meeting the startup conditions.
2) Start up the forced draft fan that should be in parallel and outlet damper will automatically open.
3) Slowly open the moving blades of the forced draft fan that should be in parallel, make sure air volume
and current increases, turn down the inlet moving blades of the operating forced draft fan to keep total air
volume and thermal secondary air header pressure unchanged.
4) Paralleling will be finished when moving blades opening, current and air volume of two forced draft fan
are basically the same.
4.1.8 Set differential pressure between air box and furnace at 380Pa and switch auxiliary air damper to
“AUTO”.
4.2 Operating maintenance of forced draft fan
4.2.1Outlet air pressure of forced draft fan should not exceed 2.3KPa in normal operation, and apply for
reducing unit output if air pressure cannot be maintained caused by clogging in the air preheater, etc.
4.2.2 Standby lubricating oil will be put into operation automatically when one of following conditions is
met:
1) The operating lubrication oil pump trips for fault.
2) Control oil pressure is ≤1MPa.
4.2.3 Heater inside oil tank will be put in or cut off automatically when one of the following conditions is
met:
1) Electric heater will be put in automatically when oil temperature of oil tank outlet is ≤15℃.
2) Electric heater will be cut off automatically when oil temperature of oil tank outlet is ≥30℃.
3) Cooling water will be put in automatically when oil temperature of oil tank outlet is ≥50℃.
4.2.4 Forced draft fan is strictly forbidden to work in surging region; when surge alarm arises, instantly turn
down the adjusting moving blades and reduce the load of forced draft fan until surging disappears. When
surge alarm arises, check if it is caused by close of outlet damper at first, if it is, immediately open the
outlet damper.
4.2.5 Check, monitor and make sure the parameters such as oil pressure, oil temperature and oil quantity of
forced draft fan control oil system and air fan bearing temperature are normal.
4.2.6 Check that the vibrating of forced draft fan does not exceed 4.5mm/s.
4.2.7 Check that the oil level of oil tank is normal and oil system has no leakage.
4.2.8 Check that the differential pressure indication of forced draft fan oil station filter is <0.25MPa; switch
to standby filter and contact the maintenance personnel for cleaning the filter when differential pressure is
>0.25MPa.
4.2.9 Check that the meters of draft fan, air system, oil system and cooling water system indicate correctly.
4.2.10 Standby oil pump should be switched periodically, during which attention should be paid to

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lubricating oil pressure and control oil pressure.
4.2.11 Main control indexes (refer to the table below)
Index
Item
Alarm value Trip value
Motor bearing temperature 95℃ 110℃
Fan bearing temperature 90℃ 95℃
Control oil pressure of fan
Oil level of oil tank
Normal operating ≥2.5MPa
Normal operating ≥ 75%
Oil temperature of oil tank
Put heater into operation when the temperature is ≤15℃;
stop the heater when the temperature is ≥30℃ and put in
cooling water when the temperature is ≥50℃.
Control oil volume of fan
<3~4L/min
< 3－4L/min
Front and rear differential pressure of oil filter ≯ 0.25 MPa, otherwise, switch the oil filter.
Fan surge value 2kPa Trip after delaying for 60s
4.3 Shutdown of forced draft fan
4.3.1 Gradually turn off the moving blades of forced draft fan that should be shut down.
4.3.2 Close outlet damper of forced draft fan.
4.3.3 Shut down forced draft fan.
4.3.4 Stop lubricating oil system according to as maintenance may require.
4.4 The forced draft fan should be shut down for emergency in the following situations
4.4.1 Vibration of forced draft fan is ≥7mm/s
4.4.2 Forced draft fan or motor smokes and catches fire.
4.4.3 Forced draft fan bearing temperature increases sharply and exceeds 110℃.
4.4.4 Forced draft fan motor bearing temperature increases sharply and exceeds 95℃.
4.4.5 People and equipment safety is threatened.

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Chapter 5 Startup and Shutdown of Primary Air Fan
5.1 Startup of primary air fan
5.1.1 Perform check to primary fan before startup as specified in general rules part.
5.1.2 Confirm the primary air fan is energized.
5.1.3 Confirm lubricating oil system is energized.
5.1.4 Check and put primary air fan motor oil station into operation.
1) Check that the oil level and oil temperature of oil tank is normal.
2) Open manual insulating valve of pressure meter.
3) Open the primary air fan motor bearing oil supply valve, inlet & outlet oil stop valve of oil cooler
and oil pump outlet valve, close bypass valve of oil cooler and each oil drain valve.
4) Switch shuttle valve of oil filter to working position.
5) Check that the oil tank temperature is normal (20~40℃).
6) Start up oil pump #1 (or #2), switch oil pump #2 (or #1) to “AUTO”.
7) Check the oil pump outlet pressure, oil filter differential pressure and oil cooler outlet oil pressure is
normal.
8) Put in cooling water of oil cooler.
5.1.5 Monitor meter indicates correctly, interlock and protection devices have been put into operation.
5.1.6 Confirm oil return of primary air fan bearing oil return window is normal.
5.1.7 Conditions for primary air fan startup:
5.1.7.1 Primary air fan bearing temperature is < 80℃.
5.1.7.2 Primary air fan motor bearing temperature is < 75℃.
5.1.7.3 Primary air fan motor winding temperature is < 120℃.
5.1.7.4 Primary air fan inlet moving blades are closed.
5.1.7.5 At least one set of forced draft fan is in operation.
5.1.7.6 Primary air fan outlet hot and cold primary air dampers have been open.
5.1.7.7 Air preheater has been in operation.
5.1.7.8 Primary air outlet dampers of this side air preheater are open.
5.1.7.8 No MFT.
5.1.8 Startup of primary air fan:
5.1.8.1 Start up the oil station.
5.1.8.2 Close the outlet cold air and hot air electric valves of primary air fan.

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5.1.8.3 Start up the primary air fan.
5.1.8.4 Open the outlet cold air and hot air electric valves of primary air fan
5.1.8.5 Open primary air fan outlet interconnection dampers.
5.1.9 Start up another primary air fan by the same way and evenly increase output of two primary air fan;
put the primary air fan inlet adjusting dampers to “AUTO” when header pressure is ≥12.4KPa.
5.2 Operating adjustment and monitoring
5.2.1 Inlet moving blades should be put to “AUTO” mode during primary air fan operation and the primary
air header pressure should be kept above 12.4KPa.
5.2.2 Check that the primary air fan bearing cooling water and motor lubricating oil is normal.
5.2.3 Check that the primary air fan vibration is <7.1mm/s.
5.2.4 Check that the primary air fan bearing temperature is < 80℃.
5.2.5 Check that the primary air fan motor bearing temperature is < 75℃.
5.2.6 Check that the primary air fan motor winding temperature is < 120℃.
5.3 Shutdown of primary air fan
5.3.1 Switch primary air fan inlet moving blades from “AUTO” mode to “MANUAL”.
5.3.2 Gradually close primary air fan inlet moving blades.
5.3.3 Shut down primary air fan and close primary air fan outlet dampers manually.
5.3.4 Close primary air fan outlet cold air dampers and primary air fan outlet hot air dampers.
5.4 The primary air fan must be shut down for emergency in the following situations.
5.4.1 Vibration of primary air fan is ≥7.1mm/s.
5.4.2 Primary air fan or motor smokes or catches fire.
5.4.3 Primary air fan bearing temperature increases sharply and is ≥100℃.
5.4.4 Primary air fan motor bearing temperature increases sharply and is ≥85℃.
5.4.5 Safety of people and equipment is threatened.

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Chapter 6 Startup and Shutdown of Air Compressor
6.1 Check before air compressor startup
6.1.1 Maintenance for system and equipment is well finished and qualified; it is clean and free of debris
nearby air compressor; electric wires are well connected while each thermal meter and protection device
has been normally put into operation.
6.1.1 Check and put air compressor water cooling system into operation, adjust water pressure within
0.2~0.4MPa and confirm water temperature is around 5~32℃.
6.1.2 Check and confirm air compressor oil level and oil quality are qualified.
6.1.3 Open blow-off valve of oil water separator and close it when pollution is thoroughly discharged.
6.1.5 Open air compressor outlet valve and air storage tank inlet/outlet valves.
6.1.6 Open freeze dryer inlet/outlet valves.
6.2 Air compressor startup
6.2.1 Open air compressor service water entrance valve.
6.2.2 Open air compressor service water returning valve.
6.2.3 Check and confirm temperature and pressure of service water are normal.
6.2.4 Check and confirm each part of air compressor is normal without operational obstacles.
6.2.5 Confirm air compressor “emergency shutdown” button has sprung.
6.2.6 Turn on small switch in electric control cabinet of air compressor.
6.2.7 Check and confirm local control panel of air compressor displays normally.
6.2.8 Switch control mode selecting switch of air compressor to “remote”.
6.2.8 Start air compressor on DCS screen.
6.2.9 Confirm each part of the air compressor rotates normally without abnormal sound, and check out if
there is air leakage or water leakage and control panel has alarm message.
6.2.10 Check and confirm the air compressor is well loaded with pressure above 0.7MPa.
6.2.11 Check and confirm each part runs normally.
6.3 Operating maintenance for air compressor
6.3.1 Keep oil tank level of air compressor body within normal range.
6.3.2 Cooling water flows smoothly.
6.3.3 Monitor and confirm each indication of the following meters is within a normal range:
1) Adjust the water pressure within 0.2~0.4MPa;
2) Water temperature shall be within the range 5~32℃;
3) Air discharging pressure shall be within the range 0.7~0.8MPa.

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4) Keep at least one air compressor working during normal operating, standby air compressor should be
in good standby condition. Instantly start standby compressor when header pressure gets less than
0.7MPa.
5) Perform periodical switch between working air compressor and standby air compressor as specified.
6) Each shift shall regularly perform water drain for air storage tank during operating.
6.4 Air compressor shutdown
6.4.1 Click “air compressor shutdown” button on DCS.
6.4.2 Locally check unloading and automatic stop of air compressor.
6.5 Conditions for emergency shutdown of air compressor
6.5.1 When motor current exceeds rated value.
6.5.2 When motor smokes and catches fire or personal injury happens.
6.5.3 Certain-stage air exhaust pressure suddenly increases and exceeds rated value; there is serious
crashing sound in pipeline, air storage tank and air cylinder.
6.5.4 Temperature of any part of air compressor exceeds the allowable value .
6.5.5 Supply of cooling water is interrupted.
6.5.6 When abnormal sound arises in air compressor and motor and air compressor body vibrates violently.
6.6 Freeze dryer startup
6.6.1 Check and confirm each freeze dryer part is in good condition without operational obstacles.
6.6.2 Check and confirm air inlet valve of freeze dryer is at “open” position.
6.6.3 Check and confirm air outlet valve of freeze dryer is at “open” position.
6.6.4 Check and confirm compressed air pressure gauge of freeze dryer indicates above 0.65MPa.
6.6.5 Open freeze dryer service water inlet/outlet valve.
6.6.6 Switch the option switch of freeze dryer control cabinet to “remote” position.
6.6.7 Start freeze dryer on DCS.
6.6.8 Adjust refrigerant LP at 0.4MPa and refrigerant HP at 1.5MPa.
6.6.9 Freeze dryer selects tower A to conduct absorption operation for 300S and tower B to conduct
pressure relief regeneration for 240S with the uniform pressure of 10S.
6.6.10 Operation of tower B is same as that of tower A.
6.7 Check and confirm the following parameters are within the corresponding normal range:
a. Refrigerant LP shall be within 0.38~0.52MPa and the optimum value 0.4MPa;
b. Heat medium HP shall be within the range 1.2~1.8MPa with optimum value at 1.5MPa;
c. Cooling water temperature shall be within the range 5~32℃.

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6.8 Frequent startup and shutdown of freeze dryer should be avoided; number of starts shall be less than 6
times per hour with the interval of more than 10minuts and startup waiting time of 300s.
6.9 Shutdown of frozen type freeze dryer
6.9.1 Click button “air compressor shutdown” on DCS.
6.9.2 Open manual blow-off valve and discharge the remnant condensed water.
6.10 Common faults
Faults Cause analysis Solutions
A. Freeze dryer doesn’t
work
1. No power supply.
2. Safety wire is fused.
3. open circuit or loose circuit
1. Check power supply system
2. Replace the safety wire
3. Check the circuit according to circuit
diagram.
B. Air compressor doesn’t
run
1. Default phase or voltage exceeds allowable
range.
2. Incorrect wiring.
3. Relay and contactor is not pulled in.
4. If the air compressor is of capacitor start,
starting capacitor is broken.
5. High voltage/Low voltage protection
switch is not sound.
6. Air compressor has mechanical fault,
such as cylinder jam.
1. Check power supply and maintain the
power voltage within rated range.
2. Check the circuit according to circuit
diagram.
3. Check out reasons for replacement or
repairing.
4. Replace the starting capacitor
5. Adjust setting value of pressure switch or
replace the pressure protection switch.
6. Replace the air compressor
C. Too high a refrigerant
HP leads to the lighting up
of refrigerant pressure fault
lamp
1. Thermal load is too large and air inlet
temperature is too high
2. Too high an ambient temperature
3. Condenser gets blocked with debris and
cooling water volume is insufficient and
cooling water temperature is too high.
4. Air is interfused in refrigerating system.
5. The fan rotates in the wrong direction or
there is a fan motor fault.
6. Expansion valve is abnormal.
7. Dry filter is blocked
8. Too much refrigerant is fed.
1. Reduce thermal load and air inlet
temperature.
2. Improve draughty condition and reduce
ambient temperature.
3. Clean the condenser or increase cooling
water volume and reduce cooling water inlet
temperature.
4. Find out reasons for maintenance.
5. Swap two phase lines randomly from three,
or replace the fan.
6. Replace the expansion valve.
7. Replace the dry filter
8. Discharge some refrigerant medium(this
operation can only be conducted after the
above reasons are excluded)
D. Too low a Refrigerant
LP leads to the lighting up
of refrigerant pressure fault
lamp
1. Insufficiency or leakage of refrigerant.
2. Air flow or working load is too small.
3. Heat flow bypass valve is closed or is in
bad condition.
4. Too low an ambient temperature
1. Detect leakage and vacuumize again to
feed refrigerant.
2. Increase compressed air flow or working
load.
3. Adjust or replace the heat flow bypass
valve
4. Reduce cooling water flow or shut down
cooling water.
E. Too big a compressor
operating current causes
thermal overload fault
lamp to light up
1. Too big a thermal load or too high an air
inlet temperature.
2. Too high an ambient temperature.
3. Shortage of refrigerant makes the
superheat degree is too high
4. Compressor gets overloaded.
5. Compressor oil shortage or too low an oil
level.
6. Compressor bearing wear or cylinder
block.
1. Reduce thermal load and air inlet
temperature.
2. Improve draught condition and reduce
ambient temperature.
3. Feed refrigerant.
4. Reduce number of compressor startups.
5. Check compressor oil level and
supplement lubricating oil.
6. Replace the compressor.

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F. It is frozen inside
evaporator with the main
phenomenon that: the
drainer doesn’t work and
ice particles are blown out
when blow-off valve is
opened.
7. Too small an air flow volume or working
load.
8. Hot air bypass valve is closed or in bad
condition while expansion valve is
opened too wide.
9. Water discharge valve of evaporator is
blocked and too much water causes ice
barrier.
7. Increase compressed air flow or working
load.
8. Adjust or replace heat flow bypass valve
and expansion valve or replace new one.
9. Dredge water discharge valve, and
thoroughly discharge condensed water of
evaporator.
G. Equipment runs
normally, but pressure drop
is large.
1. Air inlet pressure is low.
2. Pipeline valves are not fully open.
3. Too small a pipe caliber, too many bends
or too long a pipeline.
4. Evaporator gets blocked with ice.
5. Air compressor suction filter is blocked.
6. Too much accumulated water in
equipment.
7. Working capacity of selected equipment
model is too small.
8. Air system is blocked with debris.
1. Increase air inlet pressure.
2. Open all air pipeline valves.
3. Improve air pipeline system.
4. Refer to F1~3.
5. Clean or replace filter.
6. Check water discharge system for
repairing or replacement.
7. Add more equipment or replace it with
equipment model of higher working
capacity.
8. Clean reversely with detergent.
H. Equipment operating
noise is too loud.
1. Fan blades are bended.
2. Fan motor bearing is worn.
3. Refrigerant floods back.
4. Compressor is damaged (Cylinder
blocking, bearing wear).
5. Compressor is in lack of oil.
1. Adjust or replace.
2. Replace the fan.
3. Check the expansion valve for adjustment
or replacement.
4. Replace compressor.
5. Check oil level, add lubricating oil and
confirm heater works normally.
I. Fluid pipeline frosts.
1. HP side valve is blocked.
2. Dry filter is blocked.
1. Open the valve and remove the blocking.
2. Replace.
J. Air suction pipeline
frosts.
1. The expansion valve is abnormal.
2. Heat flow bypass valve is closed or is
in bad condition.
1. Replace expansion valve.
2. Adjust or replace the heat flow bypass
valve

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Chapter 7 Startup and Shutdown of Fire Check Cooling Fan
7.1 Startup of fire check cooling fan.
7.1.1 Perform check to fire check cooling fan before startup as specified in general rules.
7.1.2 Confirm fire check cooling fan is energized.
7.1.3 Start up the fire check cooling fan and confirm outlet valve opens automatically.
7.1.4 Adjust inlet air valve to make cooling air pressure >6KPa.
7.1.5 Put the standby fire check cooling fan to “AUTO” after checking it is normal.
7.2 Operating maintenance of fire check cooling fan
7.2.1 Keep one set of fire check cooling fan in operation and another fire check cooling fan in standby
under normal conditions.
7.2.2 Keep fire check cooling fan in operation after boiler shutdown until the air preheater inlet flue gas
temperature is < 50℃.
7.2.3 Frequently check inlet filter screen of fire check cooling fan; instantly contact relevant personnel to
clean filter screen when outlet air pressure is lower than 2.9.0KPa.
7.2.4 Check that the fire check cooling fan vibrates normally and motor temperature is normal.
7.3 Shutdown of fire check cooling fan.
7.3.1 Check that it meets the conditions for shutdown and release the interlock of fire check cooling fan.
7.3.2 Shut down the fire check cooling fan.
7.3.3 For switching fire check fire cooling fan, first start up standby fire check cooling fan and then shut
down the operating fire check cooling fan and put it to “standby”.

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Chapter 8 Startup and Shutdown of Fuel Oil System
8.1 Precautions
8.1.1 “No Smoking or Fire” signboard should be hanged in oil area.
8.1.2 It is forbidden to enter oil area while wearing shoes with iron palm and chemical cloth that easily
generate static electric spark, kindling material should be handed out and recorded while entering
oil area.
8.1.3 All electric facilities in the oil area should be explosion proof type.
8.1.4 Oil area should be clean and free of weeds and greasy dirt, inflammables and explosives are
forbidden to store there. Watchman should frequently perform routine inspection for fear of oil
spill, oil bleeding and oil leakage.
8.1.5 During oil unloading, if thunder strike occurs above oil area or fire alarm is released nearby,
immediately stop oil unloading.
8.1.6 When fuel equipment maintenance needs fire work, the fire work sheet should be handled, and the
open flame regulations should be observed.
8.1.7 All tools used for operation in oil area must be made of copper or other nonferrous metals having
anti-static function.
8.1.8 After oil gun is ignited, check the combustion condition, immediately close oil inlet valve if it is
not ignited or combustion is bad, reignite the oil gun after finding out and removing the reasons.
8.2 Put-in and shutdown of light oil system.
8.2.1 Check prior to the light oil system put-in
8.2.1.1 Check that there is no fire in light oil system or nearby, pipelines and valves are completely
connected, and illumination is sufficient.
8.2.1.2 Open the primary and secondary valves for light oil tank supply oil to the light oil pump and oil
return, open oil pump inlet air valve, then open oil pump inlet valve, immediately close the air
valve after oil flows out.
8.2.1.3 Check that outlet valve and bypass valve of light oil pump are closed.
8.2.1.4 Check that three inlet filters of oil supply pump are operating, and three are in standby.
8.2.2 Light oil system put-in
1) Put each system valve to correct position according to valve check card.
2) Open light oil-supply pipe air valve.
3) Start the light oil supply pump, open outlet valve, close air valve immediately after oil flows out of the
oil-supply pipe air valve.
4) Adjust oil return control valve to maintain normal oil pressure of mains.
8.2.3 Operating maintenance of fuel oil system

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8.2.3.1 Strictly monitor oil level and oil temperature of oil tank, when oil level reduces to 2m, switch to
standby oil tank operating, parallel off the original operating oil tank and report to the section
leader.
8.2.3.2 Open oil tank water discharge valve to check accumulated water condition every week, close it
after make sure no accumulated water exists.
8.2.3.3 Oil supply mains pressure should not be less than 3.5MPa.
8.2.3.4 When the ambient temperature is high in summer (oil temperature exceeds 55℃), oil tank water
spray device should be put into operation.
8.2.3.5 Operating oil tanks can not unload oil simultaneously.
8.2.4 Shutdown of light oil system
8.2.4.1 When shut down the fuel oil system, close light oil pump outlet valve and shut down light oil
pump.
8.2.5 Light oil unloading system:
8.2.5.1 Open oil inlet valve of oil storage tank.
8.2.2.5 Insert the oil unloading crane into the bottom of oil tank truck.
8.2.2.6 Open the oil unloading inlet valve, close oil unloading pipe stop valve, open steam siphonic valve,
close stream siphonic valve when oil unloading pipe is full of steam, open the oil unloading pipe stop valve
when stream condenses into water and forms vacuum. Dual to the vacuum effect, fuel oil in oil tank truck is
led into oil unloading pump, close blowdown oil discharge valve immediately when oil flows out of the
blowdown oil unloading valve at oil unloading pump outlet.
8.3 Put-in and shutdown for heavy oil system.
8.3.1 Check prior to heavy oil system put-in
8.3.1.1 Check that there is no fire work is ongoing in heavy oil system or nearby, pipelines and valves are
completely connected, and illumination is sufficient.
8.3.1.2 Open the primary and secondary valves for heavy oil tank supply oil to the light oil pump and oil
return, open oil pump inlet air valve, then open oil pump inlet valve, immediately close the air
valve after oil flows out.
8.3.1.3 Check that outlet valve and bypass valve of heavy oil pump are closed.
8.3.1.4 Check that three inlet filters of oil supply pump are operating, and three are in standby.
8.3.2 Put-in of heavy oil system
8.3.2.1 Put each system valve to correct position according to valve check card.
8.3.2.2 Open heavy oil-supply pipe air valve.
8.3.2.3 Start the l heavy oil supply pump, open outlet valve, close air valve immediately after oil flows out
of the oil-supply pipe air valve.
8.3.2.4 Slowly put heavy oil heater into operation, keep oil temperature of oil pressure output valve more
than 102℃.

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8.3.2.5 Adjust oil return control valve to maintain normal oil pressure of mains.
8.3.2.5 Put heavy oil cooler into operation, and keep oil temperature of oil pressure output valve less than
65℃.
8.3.3 Operating maintenance of fuel oil system
8.3.3.1 Strictly monitor oil level and oil temperature of oil tank, when oil level reduces to 2m, switch to
standby oil tank operating, parallel off original operating oil tank and report to section leader.
8.3.3.2 Open oil tank water discharge valve and check accumulated water condition every week, close it
after make sure no accumulated water exists.
8.3.3.3 Oil supply mains pressure should not be less than 1.9MPa.
8.3.3.4 When the ambient temperature is high in summer, oil tank water spray device should be put into
operation.
8.3.3.5 Operating oil tanks can not unload oil simultaneously.
8.3.4 Shutdown of heavy oil system
When shut down the fuel oil system, close heavy oil pump outlet valve, and shut down heavy oil pump.
8.3. 5 Heavy oil unloading system:
8.3.5.1 Open oil inlet valve of oil storage tank.
8.3.2.5 Insert the oil unloading crane into the bottom of oil tank train, and put stream heating into operation
(used in winter).
8.3.2.6 Open oil unloading inlet valve, close oil unloading pipe stop valve, start donkey pump, open oil
unloading pipe stop valve after oil unloading pump is full of oil, dual to the donkey pump, fuel oil in oil
tank train is led into oil unloading pump, close blowdown oil discharge valve, start train oil-unloading
pump and lead oil into oil tank immediately when oil flows out of the blowdown oil discharge valve at oil
unloading pump outlet.
8.4 Put-in and shutdown of oil gun
8.4.1 Check and preparation before put-in of boiler front oil system.
1) Boiler front fire fighting equipment are complete and sound.
2) Boiler front oil system has been well checked according to checking card.
3) Fuel oil control valve, tripping valve, recycle valve have been checked and operate normally.
4) Check that the boiler front stream blowing pressure is 0.45~0.8MPa, and temperature is 250℃.
5) Check that the fire check cooling air valves from fire check cooling fan to each oil gun are opened to a
normal degree.
6) Oil system is qualified in leakage test.
8.4.2 Put-in of boiler front fuel oil system:
1) Verify that oil supply pump runs normally, and boiler front fuel oil pressure is standard.

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2) Open boiler front oil master inlet valve.
3) Open fuel oil tripping valve and oil recycle valve to run oil circulation.
8.4.3 Oil gun put-in:
8.4.3.1 Allowable conditions for oil gun put-in:
1) Fuel oil pressure is 3.8MPa.
2) Fire check cooling air pressure > 6KPa.
3) Fuel oil tripping valve is open.
4) MFT has been reset.
5) OFT has been reset.
6) Total air volume > 25%.
7) Total air volume ≤ 40%
8) Oil valve is opened with fire, and closed without fire.
8.4.3.2 Oil reservoir startup:
1) Verify that the allowable conditions for oil gun startup have been met.
2) Press “oil reservoir startup” button, corner #1 oil gun starts operating, in order put corner #3, #2, #4 oil
gun into operation every 60s.
8.4.4 Check and maintenance during oil gun operation:
1) Start fuel oil heating system after confirming boiler front oil pressure is normally at 3.8MPa, fuel oil
temperature ≤ 15℃.
2) Check that there is no leakage in oil pipeline and gas pipeline.
3) Check the firing condition of on operating oil gun, instantly quit operation to remove defects once
finding any abnormal fire.
4) After oil gun shutdown, immediately blow the oil pipeline, and then quit oil gun.
5) Check that the oil gun is in good standby state during boiler operation.
6) Check that the oil guns and igniters that out of operation are right at exit position.
7) During boiler operation, fuel oil tripping valve and recycle valve should be opened, this is in order to
keep continuous operation of boiler front oil system, and thereby ensure stable combustion of boiler,
and fulfill oil feeding in low working load or unstable combustion.
8.4.5 Shutdown conditions of oil gun
A. No flame 10s after opening oil gun oil inlet solenoid valve;
B. Sleeve dampers still away from ignition position 10s after opening oil gun oil inlet solenoid valve;
C. Oil gun oil inlet solenoid valve does not fully open 10s after “open” command is output;
D. Oil gun oil inlet solenoid valve is not closed, and oil gun does not extend;

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E. Oil gun oil inlet solenoid valve is not closed, and oil gun has not been coupled;
F. Shutdown command is issued;
G. MFT working condition exists, or MFT relay tripped;
H. IFT working condition exists, or IFT relay tripped.
Oil gun oil inlet solenoid valve will automatically close in any of above cases, if oil gun oil inlet solenoid
valve does not close in 15s, CRT will display signal of oil gun stop failure.
8.4.6 Oil gun blowing
Request signal of oil gun blowing will be triggered if oil gun oil inlet solenoid valve is closed, blowing
procedures are as follows:
1) Check that MFT relay did not operate and MFT condition does not exist;
2) Check that oil gun is coupled, and oil gun oil inlet solenoid valve is closed;
3) After input “stop” command of oil gun, extend the high energy igniter, open blowing valve, and keep
blowing for 45s. If stream pressure is low or blowing valve is in incorrect position 20s after opening
blowing valve, then blowing failure signal will be released;
4) When blowing finishes, oil gun will quit and blowing finished signal will be released.
8.4.7 Block conditions of oil gun blowing
1) Control power supply breakdown;
2) Oil gun does not extend to right position 10s after blowing command is released;
3) In blowing mode, oil gun oil inlet solenoid valve is not closed in place, oil gun is not coupled or oil gun
does not reach right position;
4) IFT or MFT working condition occurs in blowing process.
8.4.8 Oil gun stop:
1) Press oil reservoir button to stop oil guns by the sequence of corner #1, #3, #2 and #4;
2) Oil gun quits after blowing.
8.5 Shutdown of boiler front fuel oil system
8.5.1 After boiler fire-off, close fuel oil tripping valve and oil return cut valve, and make sure the fuel oil
control valve is closed.
8.5.2 Close oil inlet master valve.
8.6 Stop of oil system
8.6.1 Oil supply pump:
8.6.1.1 Release the oil pump from interlock.
8.6.1.2 Stop the oil supply pump.
8.6.2 Oil unloading pump:

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8.6.2.1 Stop oil unloading pimp when oil is thoroughly unloaded from oil tank truck.
8.6.2.2 For continuous oil unloading, restart the oil unloading pump when the oil unloading pipe is well
inserted. If oil unloading process is finished, stop valve between oil unloading platform and oil unloading
crane (under truck style oil unloading situation, close insulating valve between truck oil unloading pipe and
dirty oil pump, close master valve of oil unloading pump mains), and close oil tank oil inlet insulating
valve.
8.6.4 Oil system stop
8.6.4.1After receiving the command of stopping burning oil from section leader:
A. If oil system circulation is required, then keep normal operating of oil pump, and strictly monitor
changing of oil temperature and oil pressure in oil system;
B. In case of long-term circulation in summer, put oil tank water spray device into operation, and perform
following switching:
1) Open water discharge valve of standby tank, and close it when accumulated water is thoroughly
discharged;
2) Open furnace oil return valve of standby tank, and close furnace oil return valve of working tank;
3) Open oil output valve of standby tank, and close oil output valve of working tank;
4) If it is required to stop oil system, stop the oil pump.
8.6.4.2 Stream blowing:
1) Slowly open stream blowing mains master valve and open blowing valves of each equipment, perform
stream blowing on equipment one by one.
2) Standby equipment and systems should be blown as oil system operating, insulate standby equipment
and systems with operating equipment and systems during blowing process, and recover to standby state
after blowing.

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Chapter 9 Treatment of Fuel Oil System Accidents
9.1 Conditions for oil supply pump emergency shutdown:
A. Motor smokes.
B. Pump case of oil supply pump vibrates violently.
C. Oil leakage of oil supply pump body is serous and pump bearing smokes.
D. Oil supply pipe breaks or fire bursts out.
9.2 Oil supply pump fault
9.2.1 Phenomenon of oil supply pump fault:
A. Oil pressure decreases.
B. Current sways in a wide range.
C. Pump has abnormal sound inside.
D. Pump body temperature rises.
E. Bearing temperature overruns.
9.2.2 Causes for oil supply pump fault:
A. Maintenance is unqualified.
B. Filter screen is damaged.
C. Packing set is too tight and bearing has fault.
D. Electric part has fault.
9.2.3 Treatment for oil supply pump fault:
1) Immediately start up the standby pump, maintain oil pressure, stop the fault pump and report to unit
supervisor.
2) Isolate the fault pump, drain out oil deposit from pump and contact maintenance personnel for treatment.
9.3 Trip of oil supply pump
9.3.1 Phenomenon of oil supply pump trip:
A. Motor current is at zero.
B. Oil pressure decreases.
C. Trip signal is sent out.
D. Standby pump starts up automatically as interlock is put into operation.
9.3.2 Treatment for oil supply pump trip:
1) Start up the standby pump.
2) Report to unit supervisor to identify causes and contact relevant personnel for treatment. Restore the

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standby pump and make records.
9.4 Power interruption of oil pump house
9.4.1 Phenomenon for power interruption of oil pump house:
A. Operation illumination goes out.
B. Oil pump stops and oil pressure decreases.
C. Thermodynamic gear power is lost. Pressure gauge and temperature meter indicate zero.
9.4.2 Treatment of oil pump room power interruption:
1) Reset the switch of the stopped pump and report the accident to unit supervisor.
2) Start the oil pump for oil supplying when power supply recovers.
9.5 Treatment of oil system catching fire:
1) Once fire is found in fuel oil system, send out fire alarm signal, report to unit supervisor, and inform the
fire brigade and explain the fire site.
2) Isolate related pipeline, and take effective measures for fire extinction to prevent fire from expanding,
the attendant should extinguish fire according to the fire situation, and stop oil pump operation if necessary.
3) If fire occurs in oil tank, put foam extinguishing system and water spray cooling device into operation.
Close the inlet and outlet oil valves of oil tank on fire, and put the standby oil tank into operation. If fire
occurs in oil pump house, cut off power supply in serious case, close the outlet valve and oil return valve of
oil tank, and use the local fire apparatus to extinguish fire.
4) When the motor is on fire, cut off the power supply immediately and apply carbon tetrachloride fire
extinguisher to extinguish fire.
9.6 Foam extinguishing system of fuel oil pump room
9.6.1 Overview
Fire extinguishing system of fuel oil pump house employs low-multiple foam fixed top automatic injection
extinguishing system, of which the startup process is: When fire occurs to oil tank, manually confirm it
when extinguishing control cabinet receives the fire alarm signal sent from detectors distributed in
protected area. Start the solenoid valve on deluge valve, the system will operate and oil tank top will spray
foam to extinguish the fire. During fire extinguishing, conduct water cooling to both oil tank on fire and
adjacent oil tanks. Oil tank cooling adopts fixed water-curtain cooling mode and water-curtain cooling
system for each oil tank is designed with one set of deluge valve apparatus which is installed in foam
extinguishing compartment. Extinguishing water supply pipes are arranged in a ring around oil tanks and
the outdoor basement fire hydrants are installed as well, which are 15 meters away from oil tanks. When oil
tanks are on fire, first start up low pressure fire pump, and low pressure fire water goes through foam mixer
where water and foam liquid will blend at the ratio of 6% and that will form the foam solution which will
pass through the pipes into foam generator. Air will be pumped in by suction port of foam generator and
forms foam to flow through internal wall of oil tanks via guiding cover to oil surface on fire forming a thick
layer of foam covering on oil surface to get the fire suffocated and finally extinguished.
9.6.2 Check and test on foam extinguishing system

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9.6.2.1 Weekly check: Conduct startup test weekly on electric low pressure fire pump and diesel low
pressure fire pump and maintain them under good standby conditions after test.
9.6.2.2 Seasonal check: Check and confirm the appearance of foam extinguishing system is complete and
intact without damage, rust or corrosion and each valve is flexible and reliable.
9.6.2.3 Annual check: Do comprehensive cleaning for pipes of foam extinguishing system and
comprehensive inspection on all equipment, pipes and fittings of foam extinguishing system. Check and
replace foam liquid, and do foam spray test of the system. After the test, clean and restore the system to
normal standby state.
9.6.2.4 Semiannual check: Conduct a leakage detecting test on capsule, of which the method is to open the
water discharge valve to check if there is foam in the discharged water.
9.6.2.5 Shift check
Check the sealing of foam mixer and foam tank is good without rust or corrosion and the valve switch is
correct. Check if there is foreign body in foam generator and clear it if it is found. Check the foam pipe is
free of corrosion or rust or mechanical damage.
9.6.3 Startup of foam extinguishing system
9.6.3.1 Operators should confirm the fire control cabinet alarm after fire control cabinet receives the alarm
signal distributed at oil tank temperature observation point.
9.6.3.2 Start up the low pressure fire pump
9.6.3.3 Manually start the foam deluge valve of oil tank on fire and solenoid valves of two fire water
cooling deluge valves on fire control cabinet.
9.6.3.4 If oil tank is on fire, operators should start up the low pressure fire pump locally in foam room and
open the cover of manual pressure relief valve on foam deluge valve and two fire cooling deluge valves of
oil tank on fire. And the pull down the manual pressure relief valve and the system will operate.
9.6.4 Stop of foam extinguishing system
9.6.4.1 Check and close all the solenoid valves and manual pressure relief valves on all the deluge valves
and close the cover of manual pressure relief valve after foam extinguishing
9.6.4.2 Stop the low pressure fire pump as the circumstance may require.
9.6.4.3 Recharge the used foam tank with foam liquid to make sure it is in good standby condition.

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Chapter 10 Startup and Shutdown of Pulverizing System
10.1 Check and preparation before startup
10.1.1 Perform overall inspection to coal mill, coal feeder, primary fan and sealing fan as specified in the
general rules to confirm they meet the requirements for startup.
10.1.2 Seal air valves at each part of coal mill should be open and each manometer and temperature meter
are put into operation.
10.1.3 Mill reject hoppers are complete and intact with clean inside and well lighted.
10.1.4 Interlock protection systems of coal feeder, coal mill and their supporting equipment are in good
condition and have been put into operation.
10.1.5 Open the inlet air damper of sealing fan and cold air shutoff damper of coal mill.
10.1.6 The lubrication system equipment of coal mill is complete, oil level of gear case is normal and oil is
qualified. Start the thin oil lubrication station.
10.2 Startup conditions
10.2.1 Permissive conditions for pulverized coal put-in
1) Coal layer ignition is permitted;
2) Mill trip has been released;
3) Mill hydraulic discharge gate is opened;
4) Mill lubricating oil system conditions are met;
5) Hot air baffle has been opened;
6) Mill primary air/sealing air differential pressure is >2kPa;
7) All mill outlets valves are opened;
8) Cold air baffle is open;
9) Mill lubricating oil pump is operating;
10) Mill outlet air and pulverized coal temperature is normal (65℃≤T≤82℃);
11) Mill primary air quantity is≥0.7Q;
12) Mill is not on local control mode;
13) Hydraulic loading oil pump has been started.
10.3 Startup of coal mill
Step 1: Start up the coal mill lubricating oil pump; the output of proportional overflow valve is permitted
(the proportional overflow valve is energized.)
Step 2: Start up the coal mill loading oil pump;
Step 3: Open the coal mill sealing air damper; open the coal mill outlet valve;

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Step 4: Open the cold-hot air shut-off baffle of coal mill;
Step 5: Open the cold air baffle of coal mill;
Step 6: Open the hot air baffle of coal mill and adjust the pulverized coal and air mixture temperature of
coal mill outlet to 65℃ for mill warming;
Step 7: Open the coal feeder inlet and outlet baffles;
Step 8: Lift the mill roller;
Step 9: Start up the coal mill if the startup permissive conditions for coal mill are met 20s after the mill
roller is lifted to the designated position;
Step 10: Start up the coal feeder in lowest speed if the startup conditions for coal feeder are met 60s after
the startup of coal mill;
Step 11: Lower the mill roller 20s after the startup of coal feeder start;
Step 12: Adjust the pulverized coal and air mixture temperature of coal mill outlet to 77℃, and then load
the mill roller.
Thus, the coal mill is put into normal operation.
10.4 Pulverizing system is generally stopped automatically according to the procedures including the whole
process of coal feed reducing, coal mill cooling and blowing.
Stop of pulverizing system is divided to normal mill stop, quick mill stop and emergency mill stop.
(1) Confirm furnace combustion is stable and the load meets the requirements for stopping pulverizing
system before the stop of pulverizing system.
(2) Check and confirm there is no abnormality in coal mill, coal feeder, separator and hydraulic oil pump
and confirm that each damper baffle is normal.
10.4.1 Normal mill stop
① Adjust the coal feed quantity to the minimum value and reduce the separator outlet temperature before
the mill stops.
② The cold air valve is OPEN and the hot air valve is CLOSED; stop the coal feeder when the separator
outlet temperature lowers to ≤60℃ and stop the coal mill after its running without load for 60s~120s.
10.4.2 Quick mill stop and emergency mill stop
Faults tend to occur to coal mill and the boiler it serves, try to clear faults timely and it’s the last resort to
apply quick mill stop and emergency mill stop.
① Quick mill stop should be applied in following cases:
l) Coal feeder coal flow interrupts or coal feed is less than the min. coal feed.
2) Coal mill vibrates suddenly.
3)The lubricating system has fault.
4) Differential pressure between sealing air and primary air is ≤1.5kPa.

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5) Primary air quantity is less than the min. air quantity.
6) The separator outlet temperature: t2≤60℃ or t2≥110℃.
7) Speed reducer inlet oil pressure is ≤0.1 MPa.
8) Plane thrust pad oil basin temperature is≥70℃.
9) Motor coil temperature of coal mill is ≥130℃.
②Emergency mill stop should be applied in following cases:
l) Boiler safety protection MFT.
2) Primary air quantity is less than 40t.
3) Separator outlet temperature is ≥120℃.
4) Motor stops running.
5) Differential pressure between sealing fan and primary air is low and is less than 1KPa.
6) 3/4 of burner corners are not on fire.
7) Unit RB
10.5 Operation adjustment and monitoring
10.5.1 When load of the added coal mill is increasing, the coal feed should be gradually increased until its
load equals to load of other operating coal mills. And then the coal mill control should be set to “AUTO”.
10.5.2 Disturbance of rapid load increase and decrease should be prevented during startup and shutdown of
pulverizing system; air flow during mill warming and blowing should be gradually increased or decreased
against sudden change of air flow of other coal mills.
10.5.3 The coal mill should be cleaned by purging during normal stop. After emergency stop, the mill
should be fed with inert gas as specified. Close the manual stop valve if there is internal leakage of the
insert gas valve. Open it when charging starts and close it when charging is done.
10.5.4 Generally, the uppermost layer coal mill should be stopped if the rundown of unit makes the
operating coal feeder speed decrease to 40% of maximum speed.
10.5.5 The output of other operating coal mill should be increased correspondingly to keep stable rundown
of load after stopping one coal mill. When the operating coal feeder speed decreases to 40% of the
maximum speed once again, stop one more coal mill of uppermost layer in the same way. The coal mill
should be cleaned by purging until the pulverized coal is discharged and coal mill outlet temperature
decreases before the coal mill is stopped.
10.5.6 The oil gun adjacent to the operating pulverized coal nozzle layer should be put into operation to
make sure the combustion is stable if load decreases to the amount only requiring two coal mills operation
while the coal feeder speed lowers to below 50%. Operators should make judgment based on their
experience and put combustion-supporting oil into operation in any situation in which stable combustion is
required.
10.5.7 Differential pressure of sealing air at each part should be guaranteed normal when adjusting the coal
mill load.

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10.5.8 Secondary air damper should be adjusted timely and secondary air pressure and oxygen content in
flue gas should be controlled within normal range. Timely check if the pulverized coal combustion is
normal.
10.6 Coal feeder
10.6.1 The following items should be checked during coal feeder operation:
1) There is no belt deviation of the coal feeder and the weight indicates correctly.
2) Inspection hole of coal feeder is clean and the illumination inside coal feeder is good.
3) Weight-supporting roller is running normally without sticking coal on the roller.
4) No foreign body or large coal block is jammed in coal feeder.
5) Belt cleaning scrapper is in good condition and operates normally.
6) Local control panel displays normally without alarm signal and the accumulative work of coal quantity
display is normal.
7) Adjustment should not be made on coal feeder mechanical equipment and microcomputer control system
by the operators. Timely contact the maintenance personnel or thermal control personnel for treatment
when any abnormity is found.
8) Coal feeder should be stopped when the belt is deviated.
10.7 Operations of coal mill inertia replacement system
10.7.1 Make sure boiler auxiliary steam header is in normal operation.
10.7.2 Open the manual master valve from boiler auxiliary steam header to coal mill inertia replacement.
10.7.3 Open manual valves from coal mill inertia replacement to coal mill separator and coal mill proper.
10.7.4 During start and stop process of coal mill, keep separator outlet of coal mill open, input the startup
demand of coal mill inertia replacement and the inertia replacement system will stop running automatically
after its electric valve fully opens for 5min.
10.7.5 Inertia replacement will be put into operation automatically after coal mill trips and it can also be put
into operation manually at any time.
10.7.6 Inertia replacement will be automatically put into operation but coal mill separator outlet should be
closed during MFT.

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Chapter 11 Startup and Shutdown of Drum Two-color Water Gauge
11.1 Starting process of two-color water gauge when boiler is in cold state:
1) Confirm the illumination is good and locally check the water gauge is intact and complete after water
gauge maintenance.
2) Fully open the primary and secondary valves on steam& water side and close water drain valve.
3) The water gauge should be washed if steam-water interface is not clear after it has been started. Contact
maintenance personnel for treatment if washing cannot be recovered to normal.
4) The water gauge should be stopped and contact maintenance personnel to fasten the screws on orifice
cover plate of the inspected water gauge when drum pressure and water level is stable after 3-5 hours
operation of water gauge. And then put it into operation again after hot fastening.
11.2 Startup process of two-color water gauge when boiler is in hot state:
1) Confirm the illumination is good and locally check the water gauge is intact and complete after water
gauge maintenance.
2) Make sure the primary and secondary valves on steam and water sides of water gauge is at “CLOSE”
position and water drain valve at “START” position.
3) Fully open primary valves on steam and water sides and properly open steam side secondary valve to
preheat water gauge for 15 minutes.
4) Close water drain valve of water gauge to make water gauge be full of condensed water.
5) Gradually open the secondary valves on steam and water sides alternately until they are fully opened.
11.3 Normal operation maintenance for two-color water gauge:
A. In normal situations, liquid level of the local water gauge indicates within ±50mm with slight fluctuation.
There should be no leakage and the level is clearly visible while the ambient illumination is good.
B. Timely washing should be conducted when local water level is not clear and the washing steps are:
1) Close secondary valves on steam and water sides.
2) Gradually open the water drain valve of water gauge.
3) Properly open the secondary valves on steam side of the water gauge to clean the water gauge.
4) Close the water drain valve after secondary valve on steam side are open for 30s.
5) If the water gauge is still vague, the above mentioned operations can be repeated until the water level is
washed clear to be seen.
6) Close water drain valve and fully open secondary valves on steam and water sides after water gauge is
washed clean.
11.4 Operation process for isolation of two-color water gauge:
1) Slowly close secondary valves on steam and water sides alternately.
2) Gradually open the water drain valve of water gauge.

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3) Close primary valves on steam and water sides and get them identified with cards respectively.
11.5 Precautions for two-color water gauge operation:
A. Stand beside the water gauge instead of facing it directly when checking the water gauge.
B. When there is serious leakage or explosion in water gauge, unit personnel conforming to safety
qualifications should immediately close the isolating valve with chains under the supervision of unit safety
supervisors. If the isolation can’t be conducted, heat insulation clothes, shoes, gloves and masks should be
worn as specified in safety requirements when it is necessary to close primary valve on steam side. Target
working medium spraying direction, apply the mop strips for verifying, detour to approach the isolation
point and operates on the side. And the isolation operation is forbidden when steam and vapor blurs the
working medium spraying direction. Pressure reducing measure can be taken for operation as the
application is approved.
C. Operations for water gauge should be conducted slowly and do not operate over against the water gauge.
Timely handle the defects after water gauge isolation as it should not be out of operation for long.
D. When the level transmitter and level switch that should be isolated during operation, safety measures
against auto control and protection misoperation should be taken, and then the isolation should be
implemented under the supervision of thermal control personnel.
E. If one set of water level measuring apparatus exit operation for certain reasons, generally, it should
recover in 8 hours, if not, measures should be taken. The time limit for the project can be delayed as
approved by the general engineer but the delay cannot exceed 104 hours maximally and meanwhile it
should be reported to superior department for archival filing.

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Chapter 12 Startup and Shutdown of Air Heater
12.1 Start and stop principles for air heater
1) Air heater is put into operation after the startup of air blower during the startup of boiler.
2) Put the air heater into operation when the average value of sum temperature of inlet air and outlet flue
gas of air preheater is ≤68℃ during normal operation of boiler.
12.2 Check before the start of air heater
1) Header pressure of auxiliary steam is 0.6~0.8MPa, all the gauges are complete and indications are
correct, adjustment device of outlet air temperature of air heater and water level of drain tank is in
MANUAL position.
2) Check that air heater and drain tank are normal and the position of each valve meet the requirements of
check card.
12.3 Pipeline drainage and warming before the start of air heater
1) Check and confirm that each drain valve of pipeline from auxiliary steam header to air heater A & B is
opened.
2) Confirm that the front insulation valve of pressure regulator of air heater A & B is closed.
3) Contact the thermotechnical staff to put the temperature adjustment device of air heater A & B to
“AUTO”.
4) Slightly open the insulation valve from auxiliary steam header of steam turbine to air heater and warm
the pipeline for 1 hour.
5) Close all the drain valves after warming the pipes.
6) Slowly open the insulation valves until they are fully opened and pay attention to the operating condition
of adjustment valve.
12.4 Start of air heater
1) Confirm that drain valves of air heater A & B are fully opened.
2) Confirm that top air valves of drain tank of air heater A & B are fully opened.
3) Confirm the drain valve from drain tank of air heater to trench is fully opened.
4) Slightly open the steam inlet valve of side air heater A & B and drain water to warm up the pipe and
open the steam inlet valve gradually. Pay attention that no water hammer is allowed until the steam inlet
valve is fully opened.
5) Close the top air valve of drain tank of air heater A & B after the air in the system is exhausted.
6) Drain water to the trench via drain tank and start up the drain pump of air heater A & B after the drain
water is qualified by chemical assay. Charge the drain water to the deaerator and put the drain pump into
“AUTO” and close the drain valve that is to trench.
12.5 Operation maintenance of air heater operation

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1) Control the outlet air temperature of air heater to setting value.
2) It is prohibited to drain into the deaerator when the water quality in the drain tank is unqualified.
3) It is strictly prohibited to open the manual intercept valve to extraction no. 6when the outlet steam of
drain tank is unqualified.
4) Air heater has no leakage.
12.6 Stop of air heater
1) Close the main valve from auxiliary steam header to air heater.
2) Open the drain valve from drain tank to trench, close the outlet valve of drain pump and stop the drain
pump and cut off the power supply.
3) Switch the adjustment device of outlet air temperature of air heater A & B to MANUAL and close the
front intercept valve.
4) Open the drain valves of inlet steam header A & B of air heater and close the steam inlet valve of air
heater.
5) Open the top air valve of drain tank of air heater A & B to drain off the stored water in the drain tank and
system pipeline and then close all the air valves and drain valves.

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Chapter 13 Operation of Boiler Sootblower
13.1 Check of sootblower system
1) Maintenance work of sootblower system is finished and finality formality of work sheet has been
finished.
2) Trial run should be done to the sootblower that has been checked and maintained to confirm it is in
normal operation.
3) Control system of sootblower is in good condition and each thermotechnical setting value and
mechanical setting value is correct.
4) Confirm sootblowing steam pipeline and support and hanger are in good condition and the appearance of
safety valve is in good condition.
5) Check and operation of sootblowing steam system before startup is finished.
6) Check of V910 type sootblower
a. Control box is in good condition and joggle & clearance of each gear wheel is normal.
b. Connection and sealing of flange of steam inlet pipe is in good condition.
c. Ground line of motor casing is in good condition.
d. Appearance of screwed pipe is in good condition without corrosion and screwed pipe is in the DROP
OUT position.
e. Joggle and lubrication of drive pinion shaft, pinion and bull wheel are in good condition.
f. Oil level in the reduction box is normal.
7) Check of PS-SL type sootblower.
a. Check the installation position of sootblower is correct.
b. Sootblower can move with furnace wall after the hanging fixed point in front of sootblower is in place.
The axis deviation of sootblower caused by horizontal thermal expansion of furnace wall will be borne by
rear hanger of sootblower.
c. Sootblowing pipe should be in tilted condition when the boiler is in cold state but it should be in
horizontal condition when the boiler is in hot state.
d. The position of IN/OUT limit switch is correct.
e. Oil level of reduction box is normal.
f. Ground line of motor casing is in good condition; joggle and lubrication of driving gear and rack are in
good condition and the pedestal roller can slide freely on the guide rod.
13.2 Start of sootblower
13.2.1 Program sootblowing mode:
1) The check of program operation & startup conditions are as follows:

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A. Dynamic power has no fault.
B. Remote control state.
C. Load is more than 70%MCR.
2) Switch the LCD to sootblowing flow diagram display and press the ON button to start the program.
3) Select the required program number and the program starts to operate.
4) Send out the signal of opening the main valve and the main valve will be opened automatically.
5) Pressure reducing station will start warming up the pipe after opening the main valve and adjust the
opening of drain valve according to the local pipeline temperature.
6) Drain valve is closed and pressure reducing valve starts adjusting after pipe warming is finished.
7) Sootblower starts working after the pressure is normal.
8) The operation of program will be broken off when sootblower has fault in its operation. The program
will be recovered to operate after the fault is removed.
9) Main valve will be closed once the sootblower finishes operating.
10) Program is reset.
13.2.2 Manual sootblowing mode:
1) Press the button of “Manual Startup” and the indicator light will turn red. One sootblower can start up
and the “SOOTBLOWER IN/OUT” turns green.
2) Press the required sootblower button until the light of “SOOTBLOWER IN” turns red on the boiler flow
diagram.
3) Send out the signal of opening the main valve and the main valve will be opened automatically.
4) Pressure reducing station starts warming pipe, in the meanwhile, adjust the opening of drain valve
according to the local pipeline temperature after opening the main valve.
5) Drain valve is closed and pressure reducing valve is started to be adjusted after pipe warming is finished.
6) Sootblower starts working after the pressure is normal.
7) The operation of program will be broken off when sootblower has fault in its operation. The program
will be recovered to operate after the fault is removed.
8) Main valve will be closed once the sootblower finishes operating.
9) Program is reset.
13.3 Regular check of operating or standby equipment
1) Check that steam source pressure is qualified.
2) Check the selected sootblower unit and open the steam and drain valve to warm up the pipe before
sootblowing.
3) Check that the program of sootblower is correct. The operating sootblower should drop out when steam
pressure is lower than minimum allowable pressure.

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4) Check that each sootblower is well sealed without leakage during operation.
5) Check the safety valve of steam source has no operation.
6) Check that all the instrument valves have no leakage.
7) Sootblowing program will be broken off automatically to drop out of all sootblowers when MFT occurs.
Interlock all the sootblowers before boiler MFT signal is reset.
13.4 Fault treatment of sootblower system
13.4.1 Steam pressure is low.
1) Pressure switch sends out the signal of low steam pressure and the operation of program will be broken
off once receiving this signal.
2) The program recovers to operate after removing the faults.
13.4.2 Overtime operation
1) If the sootblowing time of sootblower exceeds the normal sootblowing time, which includes two
overtime conditions: IN and OUT, overtime alarm will occur.
2) PC will relieve operation when this alarm occurs and send out OUT signal automatically in the condition
of out of IN overtime condition; or cut off 415V power supply automatically in the condition of OUT over
time.
3) STOP/RESET button will flash until the fault is removed and sootblower returns to reset position. Press
the button of STOP/RESET to restart the sootblower.
13.4.3 Overload motor
1) Trigger the thermal relay to send out motor overload alarm signal, the operation of program will be
broken off once receiving the signal.
2) Program recovers to operate after removing the fault.
13.4.4 Startup fault of sootblower
1) If PC has not received the startup signal of sootblower when the signal is sent out for 5s, fault alarm
should be sent out and the operation of program will be broken off.
2) Press the button of STOP/RESET when the faulted sootblower is confirmed by operator and the program
will recover operation after the operating sootblower returns to initial position.

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Chapter 14 Startup and Shutdown of Boiler Water Circulating Pump
14.1 Water injection and air exhaust in boiler water circulating pump
1) Check the boiler water circulating system according to the check card.
2) Open the master valve of normal LP demineralized cooling water, the inlet valve of boiler water pump
washing water cooler LP cooling water, the outlet valve of boiler water pump washing water cooler LP
cooling water, the inlet valve of boiler water pump motor cooler LP cooling water, the outlet valve of boiler
water pump motor cooler LP cooling water, the inlet valve of boiler water pump insulator LP cooling water,
the outlet valve of boiler water insulator LP cooling water and the inlet & outlet valves of boiler water
insulator LP cooling water flow switch and close the bypass valve of boiler water pump insulator LP
cooling water flow switch.
3) Close outlet valve of boiler water pump.
4) Close the boiler water pump outlet bypass valve.
5) Open the boiler water pump inlet bypass valve, boiler water pump inlet exhaust valve and master drain
valve of boiler water pump.
6) Open insulator water drain valve.
7) Close and lock the primary water discharge valve of boiler water chamber, open the washing water
header master valve supplied by condensate, washing water primary and secondary valves supplied by
condensate, boiler water pump washing water screen inlet and outlet valves, boiler water pump washing
water and water supply control valves and boiler water chamber secondary water discharge valve to
connect the water filling pipeline.
8) Adjust the opening of boiler water pump washing water and water supply control valves and keep the
flow at 6L/min to wash the pipeline. Close and lock boiler water pump chamber secondary water discharge
valve after the qualified assay.
9) Slowly open the boiler water pump washing water and water make-up screen front and rear isolating
valves, boiler water washing water and water supply master valves and fill condensate into water
circulating pump.
10) Close the insulator water drain valve when the boiler water pump inlet and outlet water drain master
valves discharge water without air. Continue filling water until the boiler water pump inlet and outlet water
drain master valves discharge water without air again, and then close and lock the water drain master valves
of boiler water pump inlet and outlet. Then continue filling water until the boiler water pump inlet exhaust
valve discharges e water without air, then close the boiler water pump inlet exhaust valve.
11) Open boiler water pump outlet valve, outlet bypass valve and insulator water drain valve after the work
of water injection and air exhaust for boiler water circulating pump and before boiler water filling.
12) Time of stopping washing water: stop washing water for boiler water circulating pump when drum
pressure is up to 10.0MPa
13) Operation of stopping supply washing water for boiler water circulating pump:
(1) Close three sets of boiler water circulating pump washing water and water supply master valves

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(2) Close three sets of boiler water circulating pump washing water and water supply screen front and
rear isolating valves.
(3) Close three sets of boiler water circulating pump washing water and water supply control valves.
14) Inject washing water continuously into the boiler water circulating pump in the following conditions:
(1) Boiler boiling out, acid cleaning, water cleaning.
(2) Boiler water is too dirty.
(3) Motor HP cooling water has leakage.
(4) Drum pressure is up to 10.0MPa from boiler water filling to boiler ignition.
(5) Before boiler water discharging and after water discharging.
14.2 Startup of boiler water circulating pump
14.2.1 Check before boiler startup:
1) Confirm the water injection and air exhaust of boiler has been finished.
2) Check that all instruments are complete.
3) Check the pump control system and differential pressure transmitter have been put into operation.
4) The drum water level is at +1000mm.
14.2.2 Permissive conditions for the startup of boiler water circulating pump:
1) The LP cooling water flow of motor cooler is >8m3/h
2) The temperature difference between pump shell and inlet header pipe is <55℃
3) The minimum starting temperature of motor chamber is ≥4℃
4) Boiler water pump outlet valve is fully opened.
5) There is no tripping demand.
14.2.3 Startup of boiler water circulating pump
14.2.3.1 Startup of boiler water circulating pump:
1) The method of initial startup after boiler water circulating pump installation or repair as well as after
water filling and air exhaust is to start the boiler water circulating pump and run for 5s, then shut down for
15min and then restart to operate for 5s, which should be repeated for three times.
2) Start up the motor of boiler water circulating pump
14.3 Normal operation maintenance of boiler water circulating pump
1) Monitor that the boiler water circulating pump current is ≤43A.
2) Monitor that the differential pressure between inlet and outlet of water circulating pump is >117.10kPa.
3) Check that the boiler water circulating pump chamber temperature is <63℃.
4) Shut down the boiler water circulating pump when the drum water level is down to -300mm. Start up the

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boiler water circulating pump when the drum water is filled up to +200mm. The interval of starting time
should be ≥15min.
5) Check that the LP cooling water flow of boiler water circulating pump motor cooler is >8m3/h.
6) Check the standby feed pump of deaerator is in good condition.
7) Check that there is no abnormal sound during operation of pump unit.
8) Check that there is no leakage in the system.
14.4 Shutdown of boiler water circulating pump
14.4.1 Stop the boiler water circulating pump for hot reserve:
1) Shut down the boiler water circulating pump motor
2) Open the boiler water pump outlet valve and keep the water supply master valve of normal LP
demineralized cooling water, LP cooling water inlet and outlet valves of boiler water pump washing water
cooler, LP cooling water inlet and outlet valves of boiler water pump motor cooler, LP cooling water inlet
and outlet valves of boiler water pump insulator and LP cooling water flow switch inlet and outlet valves of
boiler water insulator open.
3) Open the boiler water pump inlet and outlet bypass valves and boiler water pump insulator water drain
valve.
14.4.2 Boiler water circulating pump is the cold standby status:
1) Stop the boiler water circulating pump motor.
2) Open the LP cooling water inlet and outlet valves of boiler water circulating pump motor cooler.
3) Open boiler water circulating pump outlet valve and keep boiler water circulating pump inlet and outlet
bypass valves and boiler water circulating pump insulator water drain valves open.
14.5 Water discharging of boiler water circulating pump
1) Check that the power of boiler water circulating pump has been cut off.
2) Check that the washing water supply in boiler water circulating pump has been stopped.
3) Check that the boiler water circulating pump motor chamber temperature is <50℃.
4) Open boiler water circulating pump inlet bypass valve, the water discharge master valve of boiler water
circulating pump shell and the water discharge valve of boiler water circulating pump insulator.
5) Open the washing water and water supply control valves of boiler water circulating pump, the washing
water valve and water supply screen front and rear isolating valves of boiler water circulating pump and
washing water and water supply master valves of boiler water circulating pump. Flush the boiler water
circulating pump and motor with 3~5m3/h washing water. After water filling, close the HP water filling
pipeline.
6) Open the water discharge primary and secondary valves of boiler water circulating pump motor chamber.
7) Close the LP cooling water inlet and outlet valves of boiler water circulating pump motor cooler and
close the LP cooling water inlet and outlet valves of boiler water circulating pump isolator.

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14.6 Fault treatment of boiler water circulating pump
14.6.1 Stop the circulating pump manually when any of the following condition occurs
A. The drum water level is lower than -300mm.
B. The boiler water circulating pump motor chamber temperature rises to 66℃.
C. Boiler water circulating pump motor current suddenly rise to >43A or indicate to zero.
D. The LP cooling water flow of boiler water circulating pump is at zero.
E. There is leakage out of control in boiler water circulating pump HP cooling water loop.
F. The temperature difference between boiler water circulating pump shell and boiler water circulating
pump inlet header tank is more than 55℃.
14.6.2 Treatment on boiler water circulating pump motor chamber temperature rising to 60℃
1) Inject HP cleaning water to boiler water circulating pump.
2) Check that the LP cooling water flow of boiler water circulating pump motor cooler is >8m3/h and there
is no leakage in the pipeline.
3) Check that the boiler water circulating pump motor has no leakage and there is no leakage inside boiler
water circulating pump cooler.
4) Check if the boiler water circulating pump temperature sensor and alarm device are failed.
5) Shut down the valve urgently if the boiler water circulating pump motor chamber temperature rises to
66°C.
6) If the cause of boiler water circulating pump motor chamber temperature rising is unclear, contact the
maintenance personnel to disassemble the pump to check the components such as bearing and cooler, etc
after the pump is cooled.
14.6.3 Treatment on alarm caused by low flow of LP cooling water system
1) The boiler water circulating pump should give alarm and close and lock the startup boiler water
circulating pump when the LP cooling water flow of boiler water circulating pump motor cooler is ≤8m3/h.
2) Start up the feed pump of deaerator within 4min; stop the operation of faulty boiler water circulating
pump motor and close boiler water circulating pump motor chamber LP cooling water supply valve and
backwater valve if there is insufficient cooling water flow in the water pump
3) Stop the operation of boiler water circulating pump urgently when the boiler water circulating pump
motor chamber temperature is ≥66°.
14.6.4 Treatment on leakage of HP cooling water system
1) The HP filling water temperature and washing water temperature is <50°C. Fill water continuously to the
boiler water circulating pump motor when the drum pressure is less than 10.0MPa and during the chemical
cleaning.
2) Adjust the boiler water circulating pump water filling and washing water control valves to keep the
temperature of boiler water circulating pump motor chamber at 40°C~55°C.

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3) Shut down the boiler water circulating pump if the boiler water circulating pump motor chamber
temperature is ≥66°C.
14.6.5 Treatment on blocking of boiler water circulating pump filter
1) Close the washing water filter inlet and outlet valves.
2) Open filter primary and secondary water discharge valves and close them after water drainage.
3) Reinstall the cleaned screen.
4) Open the filter inlet valve.
5) Open the filter outlet valve.

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Appendix:
Appendix:
Appendix:
Appendix:
Figure 1 Cold Start Curve (IP cylinder startup)
Figure 2 Warm Start Curve (IP cylinder startup)
Figure 3 Hot Start Curve (IP cylinder startup)
Figure 4 Very Hot Start Curve (IP cylinder startup)
Figure 5 Cold Start Curve (HP cylinder startup)
Figure 6 Warm Start Curve (HP cylinder startup)
Figure 7 Hot Start Curve (HP cylinder startup)
Figure 8 Very Hot Start Curve (HP cylinder startup)
Figure 9 Boiler Shutdown Curve (sliding pressure mode)
Figure 10 Boiler Shutdown Curve (constant pressure mode)

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Figure 1 Cold Start Curve (IP cylinder startup)

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Figure 2 Warm Start Curve (IP cylinder startup)

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Figure 3 Hot Start Curve (IP cylinder startup)

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Figure 4 Very Hot Start Curve (IP cylinder startup)

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Figure 5 Cold Start Curve (HP cylinder startup)

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Figure 6 Warm Start Curve (HP cylinder startup)

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Figure 7 Hot Start Curve (HP cylinder startup)

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Figure 8 Very Hot Start Curve (HP cylinder startup)

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Figure 9 Boiler Shutdown Curve (sliding pressure mode)

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Figure 10 Boiler Shutdown Curve (constant pressure mode)

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