MS 06 21 - Boiler Startup Frim Cold (Rev a - 03.01.12)

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DALKIA UKMETHOD STATEMENT

SITE & LOCATION

Diageo CameronbridgeREFERENCE MS 06 21

JOB / TASK DESCRIPTION

Boiler Start Up From ColdSAFE SYSTEM OF WORK – PERMIT TO WORKPermit required Y/N No – Standard Operating Procedure

JOB / TASK SEQUENCE

NB: Boiler start up can be termed as a cold start when the drum pressure is less than 2 barg ACTION COMMENTS

1Ensure Boiler Pre Start Checks have been completed

xRef MS 06-18

2 Verify that any safety valve gags previously fitted have been removed.

3 Confirm that all safety interlocks checks have been completed

4 Oxygen Analyser Confirm that the boiler O2 analyser AIT035031 is serviceable and available.

5. Condensate tank level control

Gain access to the Feed water & Condensate System tab of the Enmas HMI.

Confirm that the condensate feed water tank water level has been established at the normal operating level and that the set point has been set to between 50% - 70% .

Ensure that condensate transfer pumps TRF-P1 & TRF-P2 are available and select Duty / Standby as required

Note The filling of the feed water storage tank and the initial make up of the condensate tank is normally under automatic cascade control

6 Feed water storage tank level control


Confirm that the condensate feed water transfer tank water level has been established at the normal operating level and that the set point has been set to 70%

At the feed water level control block LIC030009 set the SP to a value of 70%

Note Overflow to the IBD @ 82% ?

Rev A Page 1 of 12This document becomes uncontrolled when in hard copy

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7 Deaerator pressure control


At the deaerator pressure control block PIC030016 set the SP to a value of 2.3 kg/cm2

8 Set the furnace draft pressure control

Gain access to the Air & Flue Gas tab of the Enmas HMI.

At the furnace draft pressure control block PIC035026 set the SP to a value of -5 mmWC

Ensure the control mode is set to the average of the 2 transmitters PIT035026A/B

Note

HH + 25 mmWC H +15 mmWC

L - 25 mmWC LL - 50 mmWC

9 Drum level control

Gain access to the Water & Steam tab of the Enmas HMI.

At the drum level control block LIC031017 set the SP to a value of between 48%

Select single level control for initial start up

NoteA drum level of between 39 – 55% is required to enable a start of the the burnersNote

HH + 200 mm = 72% H +100 mm = 61%

L - 100 mm = 39% LL - 200 mm = 29%

10.

Main steam temperature control

Gain access to the Water & Steam tab of the Enmas HMI.

At the steam temperature control block TIC031025 set the SP to a value of 460°C

Ensure the control mode is set to the average of the 2 transmitters TIT031030A/B

11 CBD tank level control

Gain access to the Blowdown system tab of the Enmas HMI.

At the CBD tank level control block LIC039005 set the SP to a value of 50%


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12.

IBD tank tempreture control

Gain access to the Blowdown system tab of the Enmas HMI.

At the IBD tank temperature control block TIC039008 set the SP to a value of 35°C

13.

Soot blowing pressure control

Gain access to the Soot blow system tab of the Enmas HMI.

At the soot blow pressure control block PIC038003 set the SP to a value of 18 kg/cm2

14 FD discharge pressure control

Gain access to the Air & Flue Gas system tab of the Enmas HMI.

At the FD fan discharge pressure control block PIC035003 set the SP to a value of 570 mmWC

15 Steam Drum Valve State Check

The following valves must be confirmed as open:

Steam Drum ( drum east side )Vent Isolation Valves V031101 & V031102

Steam Drum ( drum west side ) Vent Isolation Valves V031139 & V301140

DWLI ( drum east side ) Vent Isolation Valves V031107 & V031108 Drain Isolation Valves V031109 & V031110

DWLI ( drum west side ) Vent Isolation Valves V031123 & V031124 Drain Isolation Valves V031125 & V031126

EWLI ( drum west side ) Vent Isolation Valves V031135 & V031136 Drain Isolation Valves V031137 & V031138


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16 Steam Line Valve State Check

The following valves must be confirmed as open: Primary Super heater Vent Isolation Valves V031207, V031208

Secondary Super heater Vent Isolation Valves V031210, V031211

Steam Riser Drain Isolation Valves V031212, V031213Drain Isolation Valves V031224, V031225Vent Isolation Valves V031226, V031227Drain Isolation Valves V031233, V031234Vent Isolation Valves V031235, V031236

Valve 031207 / Valve 031208

Valve 031210 - 9th floor, 23.6 meter level, east side, largest pipe, left of centre.

Valve 031211 – 8th floor, 20.5 meter level, east side, steam vent chest, 3rd pipe from left.

Valve 031212 – 8th floor, 20.5 meter level, east side, behind largest pipe, on left hand side.

Valve 031213 – 6th floor, 15.3 meter level, east side, adjacent to sand hopper.

Valve 031224 – 8th floor, 20.5 meter level, east side, centre of largest pipe, bottom of pipe.

Valve 031225 – 6th floor, 15.3 meter level, east side, adjacent to sand hopper.

Valve 031226 – 8th floor, 20.5 meter level, east side, largest pipe, right of centre.

Valve 031227 - 8th floor, 20.5 meter level, east side, largest pipe, right of centre.

Valve 031233 / Valve 031234

Valve 031235 – 8th floor, 20.5 meter level, north side, left of chaff/dust hopper.

Valve 031236 – 8th floor, 20.5 meter level, north side, left of chaff/dust hopper.

16 Establish the drum water level

Check all alarms are clear and that the system is fully available.

Confirm that the drum level local gauges are in the correct operating position with inlet valves to the steam and water side open and drain valves shut

Confirm that the drum vent valves (V031101, V011102) and (V031139, V031140)are open prior to establishing the drum level

Check boiler drum level is at the normal operating level 50% ( NWL = 0 +/-50 mm).

.Note1. Top up of the condensate tank is by

automatic cascade fill via the demin plant. X Ref MS 06-15

2. Automatic top up of the drum level is by single element/three element control. For manual top up procedure MS 06-17


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17 Furnace bed Inventory

Ensure that sufficient sand has been dosed to cover the bed tubes. All compartments are to have a minimum bed depth of 300 - 350 mm prior to start up

If necessary initiate injections of sand.X Ref MS 06-30

18 ESP heaters

Ensure all ESP insulator heaters are switched on and up to temperature

NoteESP heaters should be put on at least 16 hrs in advance of a planned boiler start up

19. Start a ID Fan

To start either ID Fan A or ID Fan B

Select the respective ID Fan faceplate and confirm that all trip interlocks are clear and that a start permissive is available.

Click on the respective fan`s VFD speed controller and set to manual and adjust the CV to 10% using the ± buttons.

Confirm that the fan pressure controller CV is also set to 10%

Select the respective ID Fan faceplate and press the start command button and confirm that the selected ID fan is running. and that relevant dampers have opened

Fan A dampers - MOD 044/MOD 042 , Fan B dampers - MOD043 / MOD 041

Set the respective fan’s VFD speed controller to auto and monitor the furnace pressure

Monitor boiler furnace pressure

20. Start an FD Fan

Start either FD Fan A or FD Fan B

Select the respective FD Fan faceplate. Press the >> button to open the permissive tabs.

Confirm that all trip interlocks are clear. If any interlock is showing red click on the respective button and attempt to reset. If it does not reset investigate the cause.

Monitor boiler furnace pressure


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Confirm that the start permissive is available. Press Start and confirm that the selected FD fan is running.

Open the FD dampers MOV006 & MOV057 to allow fluidisation of the bed to begin

21 Furnace bed dp check

Select the Over Fire Air Damper PCV035010 to manual and close to 0%.

Ensure FD dampers MOV035006 & MOV035057 are set to manual and fully open 100%.

Set the airflow to minimum fluidisation flow

Measure wind box pressure (P1)PIT035011 / PIT035015

Measure windbag pressure (P2)

Initial P3 value ( xxxxxx mmWC )

P1 = P2 = P1 + P2 = P3 =(P1 + P2) - P3 =

Check dp at various airflows and confirm within acceptable limits xref MS 06-xx

Record the air flow at which fluidisation starts – FIC350008 ( est 60t/hr)


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22 Combustor starting procedure

Combustor may be started from the Enmas HMI or at the LCP. Refer to MS 06.24 for detailed start procedure

Ensure the burner manual gas isolating valves are in the in-service position and that the preferred fuel source ( Biogas / NG ) is selected on the burner control panel configured

Ensure the guillotine gate valve MOD035012 at the wind box is set to open.

Ensure all non volatile alarms have been reset at the burner LCP by pressing and holding the reset button for a min of 3 seconds

Ensure Main Interlocks Satisfied Signal is present

Ensure Purge Permissive Signal is present

Initiate a burner start

Ensure burner complete a purge sequence and fires to low fire hold.

Visually confirm that the flame quality and flame strength is good

Start permissives

Main Interlock start permissives

Any 1 FD fan running & air flow >30% Any 1 ID fan running Drum level not LL or HH Combustor temp not H Furnace Pressure not LL or HH Instrument Air Pressure not L Boiler Trip signal not present Estop P @ LCP not operated

Purge Permissive Main Interlocks Satisfied All fuel valves closed No flame detected

23 Post Combustor Burner Start Checks

Set and maintain low fire hold for a minimum of minimum 30 minutes.

Note quality of burner flame at burner viewing port.


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24 Combustor Burner ramp up

The combustor burner may be modulated in auto or manual as per the recommended start up curve (1° C per min ).

Continue with ramp until an average bed temp of 450°C is obtained

Note.

1: The combustor max outlet temperature is 500°C. The burner will alarm at 525°C. and trip at 550°C.

Monitor:

(1) Furnace pressure PIT035026

(2) Wind box pressure PIT035011/PIT035015

(3) Bed differential pressure

(4) Check that the individual boiler bed thermocouple temperatures rise at approximately the same rate

TE0137011 TE0137005 TE0137012 TE0137006 TE0137008 TE0137002 TE0137009 TE0137003.

25 > 2 bar drum pressure

When a pressure of greater than 2 kg/cm2 is obtained the following valves may be closed

Steam Drum ( drum east side )Vent Isolation Valves V031101 & V01102

Steam Drum ( drum west side ) Vent Isolation Valves V031139 & V01140

DWLI ( drum east side ) Vent Isolation Valves V031107 & V01108 Drain Isolation Valves V031109 & V01110

DWLI ( drum west side ) Vent Isolation Valves V031123 & V01124 Drain Isolation Valves V031125 & V01126

EWLI ( drum west side ) Vent Isolation Valves V031135 & V01136 Drain Isolation Valves V031137 & V01138

26 Gauge glass blow down test

Carry out a gauge glass blow down test on each level gauge.

X Ref MS 06:xx


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27 Monitor drum level and blow down

Check:

(1) Drum water level is maintained at NWL

(2) Blowdown as required when water swelling occurs but avoid repeated fill/ dump feed water operations where possible.

(3) Target level in auto control is - 0 mm at full

temperature, pressure and flow.

(4) Blowdown drains to the IBC must be monitored and controlled.

(5) Monitor Feed Water Storage Tank level.

(6) Monitor condensate tank level.

(7) Monitor demin plant water production

Note:

I. A 40°C limitation exists on IBC tank discharge temperature to protect sump 18 submersible pumps.

II. A further limit of 35°C exists for transfer from sump 18 to the process reject tank.

III. Transfer from feed water control station low load control to 100% control is designed to be bump less with the system in auto

CAUTIONLarge feed water losses quickly occur when the vent valve is open.

28 Start the overfire burners

Ensure burner is manual gas isolating valves are in the in service position and that the preferred fuel source ( Biogas / NG ) is selected on the burner control panel configured

Ensure all non volatile alarms have been reset at the burner LCP by pressing and holding the reset button for a min of 3 seconds

Ensure Main Interlocks Satisfied Signal is present

Ensure Purge Permissive Signal is present

Initiate a burner start

Ensure burner complete a purge sequence and fires to low fire hold.

Visually confirm that the flame quality and flame strength is good

Main Interlock start permissives

Any 1 FD fan running & air flow >30% Any 1 ID fan running Drum level not LL or HH Combustor temp not H Furnace Pressure not LL or HH Instrument Air Pressure not L Boiler Trip signal not present Estop P @ LCP not operated

Purge Permissive Main Interlocks Satisfied All fuel valves closed No flame detected

Note.

1: Overtire burners may be started from the Enmas HMI or at the LCP. Refer to MS 06.23 for detailed start procedure

2: Burner #3 will normally be started first


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29 Post Overfire Burner Start Checks

Set and maintain low fire hold for a minimum of minimum 30 minutes.

Burner may be modulated in auto or manual as per the recommended start up curve (1° C per min).

After burner start:

Note quality of burner flame at burner viewing port.

Note flame strength and quality on fireye panel

30 Overfire Burner ramp up

Modulate the burners manually to achieve a ramp until an average bed temp of 750°C is obtained

Burner firing rate should be controlled to the boiler start-up curve (1° C per min ).

Sand injection should be continued as required until the fluidised bed differential pressure () reaches the target 525 mmWC + 25

Monitor:

(1) Furnace pressure PIT035026

(2) Wind box pressure PIT035011/PIT035015

(5) Bed differential pressure

(6) Check that the individual boiler bed thermocouple temperatures rise at approximately the same rate

TE0137011 TE0137005 TE0137012 TE0137006 TE0137008 TE0137002 TE0137009 TE0137003


When a pressure of greater than 50 kg/cm2 is obtained open the start up vent isolation valves MOV031033 and the control valve MOV031034 to 100% open

The following valves must be closed: Primary Super heater Vent Isolation Valves V031207, V031208

Secondary Super heater Vent Isolation Valves V031210, V031211

Steam Riser Vent Isolation Valves V031226, V031227Vent Isolation Valves V031235, V031236


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When a pressure of greater than 55 kg/cm2 is obtained the warm through of the steam line to the Bypass Station and Condenser can progress.

Ensure that the drain and vent valves downstream of the main steam stop are open.

Ensure that the steam outlet valves to Diageo are closed and chained shut.

progressively open the mainstream stop bypass valve MOV031036 whilst simultaneously closing the start up control valve MOV031034

Close the following drains

Steam Riser upstream of main Steam Stop

Drain Isolation Valves V031212, V031213Drain Isolation Valves V031224, V031225Drain Isolation Valves V031233, V031234

Xref MS 06.xx

33 Introduction of Biomass (SGG)

To be compiled

Check MS 06/35 Boiler Fuel Changeover Procedure.


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Risk AssessmentsAssessment Description Assessment Reference Assessment DateBoiler House Access Risk Assessment

SPECIALIST COMPETENCE REQUIREDIndividual & / or Company Name

Requirement / Experience / Qualification etc.

Dalkia Cameronbridge Plant Operator Competency as detailed in MSP 04

PREPARED BYPrint Name Revision DateJ Callaghan A 03/03/2012

REVISION (Number & Date)


Documents

MS 06 21 - Boiler Startup Frim Cold (Rev a - 03.01.12)