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G HS 024

Appendix 03
DALKIA UK
METHOD STATEMENT
SITE &
LOCATION

Diageo Cameronbridge

REFERENCE

MS 06 21

JOB / TASK DESCRIPTION

Boiler Start Up From Cold


SAFE SYSTEM OF WORK PERMIT TO WORK
Permit 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
1
2
3
4

COMMENTS

Ensure Boiler Pre Start Checks have been


completed
Verify that any safety valve gags previously fitted
have been removed.
Confirm that all safety interlocks checks have been
completed

xRef MS 06-18

Oxygen Analyser
Confirm that the boiler O 2 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% .

Feed water storage tank level control


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

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

Note
Overflow to the IBD @ 82% ?

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%

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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
7

Deaerator pressure control


Gain access to the Feed water & Condensate
System tab of the Enmas HMI.
At the deaerator pressure control block PIC030016
set the SP to a value of 2.3 kg/cm 2

Set the furnace draft pressure control

Note

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

HH + 25 mmWC
H +15 mmWC

At the furnace draft pressure control block


PIC035026 set the SP to a value of -5 mmWC

L - 25 mmWC
LL - 50 mmWC

Ensure the control mode is set to the average of the


2 transmitters PIT035026A/B
9

Drum level control


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

Note
A drum level of between 39 55% is required to
enable a start of the the burners
Note

At the drum level control block LIC031017 set the


SP to a value of between 48%

HH + 200 mm
H +100 mm

=
=

72%
61%

Select single level control for initial start up

L - 100 mm
LL - 200 mm

=
=

39%
29%

Main steam temperature control


10.
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 460C
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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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
IBD tank tempreture control
12.
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 35C

Soot blowing pressure control


13.
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/cm 2
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

Rev A

DWLI ( drum east side )


Vent Isolation Valves
Drain Isolation Valves

V031107 & V031108


V031109 & V031110

DWLI ( drum west side )


Vent Isolation Valves
Drain Isolation Valves

V031123 & V031124


V031125 & V031126

EWLI ( drum west side )


Vent Isolation Valves
Drain Isolation Valves

V031135 & V031136


V031137 & V031138

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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
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
Drain Isolation Valves
Vent Isolation Valves
Drain Isolation Valves
Vent Isolation Valves

V031212, V031213
V031224, V031225
V031226, V031227
V031233, V031234
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

.Note
1.

2.

Top up of the condensate tank is by


automatic cascade fill via the demin plant. X
Ref MS 06-15
Automatic top up of the drum level is by single
element/three element control. For manual top
up procedure MS 06-17

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).

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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
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

18

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

19.

Start a ID Fan

If necessary initiate injections of sand.


X Ref MS 06-30

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

Monitor boiler furnace pressure

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 fans VFD speed controller to


auto and monitor the furnace pressure
20.

Start an FD Fan

Monitor boiler furnace pressure

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.
Confirm that the start permissive is available. Press
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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
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%.

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

Set the airflow to minimum fluidisation flow

Check dp at various airflows and confirm within


acceptable limits xref MS 06-xx

Measure wind box pressure (P1)


PIT035011 / PIT035015

Record the air flow at which fluidisation starts


FIC350008 ( est 60t/hr)

Measure windbag pressure (P2)


Initial P3 value ( xxxxxx

Rev A

mmWC )

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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
22

Combustor starting procedure

Start permissives

Combustor may be started from the Enmas HMI or


at the LCP. Refer to MS 06.24 for detailed start
procedure

Main Interlock start permissives

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

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

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

23

Post Combustor Burner Start Checks

Rev A

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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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
24

Combustor Burner ramp up

Monitor:

The combustor burner may be modulated in auto or


manual as per the recommended start up curve
(1 C per min ).

(1) Furnace pressure


PIT035026

Continue with ramp until an average bed temp of


450C is obtained
Note.
1: The combustor max outlet temperature is
500C. The burner will alarm at 525C. and trip
at 550C.

25

(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
TE0137012
TE0137008
TE0137009

TE0137005
TE0137006
TE0137002
TE0137003.

> 2 bar drum pressure


When a pressure of greater than 2 kg/cm 2 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

26

DWLI ( drum east side )


Vent Isolation Valves
Drain Isolation Valves

V031107 & V01108


V031109 & V01110

DWLI ( drum west side )


Vent Isolation Valves
Drain Isolation Valves

V031123 & V01124


V031125 & V01126

EWLI ( drum west side )


Vent Isolation Valves
Drain Isolation Valves

V031135 & V01136


V031137 & V01138

Gauge glass blow down test

X Ref MS 06:xx

Carry out a gauge glass blow down test on each


level gauge.

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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
27

Monitor drum level and blow down


Note:

Check:

I. A 40C limitation exists on IBC tank


discharge temperature to protect
sump 18 submersible pumps.

(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.

II. A further limit of 35C exists for


transfer from sump 18 to the
process reject tank.

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


temperature, pressure and flow.

III. Transfer from feed water control


station low load control to 100%
control is designed to be bump less
with the system in auto

(4) Blowdown drains to the IBC must be monitored


and controlled.
(5) Monitor Feed Water Storage Tank level.
(6) Monitor condensate tank level.

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

(7) Monitor demin plant water production


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

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

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

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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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
29

30

Post Overfire Burner Start Checks

After burner start:

Set and maintain low fire hold for a minimum of


minimum 30 minutes.

Note quality of burner flame at


burner viewing port.

Burner may be modulated in auto or manual as per


the recommended start up curve (1 C per min).

Note flame strength and quality on


fireye panel

Overfire Burner ramp up

Monitor:

Modulate the burners manually to achieve a ramp


until an average bed temp of 750C is obtained

(1) Furnace pressure


PIT035026

Burner firing rate should be controlled to the boiler


start-up curve (1 C per min ).

(2) Wind box pressure


PIT035011/PIT035015

Sand injection should be continued as required until


the fluidised bed differential pressure () reaches the
target 525 mmWC + 25

(5) Bed differential pressure


(6) Check that the individual boiler bed
thermocouple temperatures rise at
approximately the same rate
TE0137011
TE0137012
TE0137008
TE0137009

31

TE0137005
TE0137006
TE0137002
TE0137003

> 20 bar drum pressure


When a pressure of greater than 50 kg/cm 2 is
obtained open the start up vent isolation valves
MOV031033 and the control valve MOV031034 to
100% open
The following valves must be closed:

Rev A

Primary Super heater


Vent Isolation Valves

V031207, V031208

Secondary Super heater


Vent Isolation Valves

V031210, V031211

Steam Riser
Vent Isolation Valves
Vent Isolation Valves

V031226, V031227
V031235, V031236

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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT
32

> 55 bar drum pressure


When a pressure of greater than 55 kg/cm 2 is
obtained the warm through of the steam line to the
Bypass Station and Condenser can progress.

Xref MS 06.xx

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
Drain Isolation Valves
Drain Isolation Valves

33

V031212, V031213
V031224, V031225
V031233, V031234

Introduction of Biomass (SGG)

Check MS 06/35 Boiler Fuel Changeover


Procedure.

To be compiled

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G HS 024
Appendix 03
DALKIA UK
METHOD STATEMENT

Risk Assessments
Assessment Description
Boiler House Access Risk
Assessment

Assessment Reference

Assessment Date

SPECIALIST COMPETENCE REQUIRED


Individual & / or Company
Requirement / Experience / Qualification etc.
Name
Dalkia Cameronbridge
Plant Operator Competency as detailed in MSP 04
PREPARED BY
Print Name
J Callaghan

Revision
A

Date
03/03/2012

REVISION (Number & Date)

Rev A

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