The document provides standard operating procedures for a boiler and steam turbine in a waste heat recovery unit. For the boiler, it describes startup and shutdown procedures, monitoring parameters, maintenance schedules, and safety precautions. For the steam turbine, it outlines startup steps including gradually increasing rpm over time, monitoring key parameters like oil pressure and temperature, and checks to perform before startup. The overall purpose is to safely and efficiently operate the boiler and turbine system to recover heat from waste gases.

1. Standard Operating Procedure of Boiler and Turbine of
Waste Heat Recovery Unit
Table of Contents
Chapter 01 boiler 1
1.1 Definition of Boiler 1
1.2 Working Principle of Boiler 1
1.3 Monitoring and tuning up of the boiler 1
1.4 Normal Operation of the boiler 2
1.5 Necessary Step before start up of Boiler 3
1.6 Damper Opening: (cold state) 3
1.7 Damper Opening (Hot State) 4
1.8 Shut Down 5
1.9 Blow Downs 6
1.10 Maintenance of the boiler 7
Chapter 02 Steam Turbine 9
2.1 Turbine Start Up and Operation 9
2.2 Before turbine start up 9
2.3 Starting of Turbine 11
2.4 Shutdown 12
2.5 Operation maintenance and downtime maintenance 13
2.6 Synchronization Process 13

2. Chapter 01 Boiler
1.1 Definition of Boiler
Steam boiler or simply a boiler is basically a closed vessel into which water is heated until the
water is converted into steam at required pressure. This is most basic definition of boiler.
1.2 Working Principle of Boiler
The basic working principle of boiler is very simple and easy to understand. The boiler is
essentially a closed vessel inside which water is stored. Fuel (generally coal) is bunt in a furnace and hot
gasses are produced. These hot gasses come in contact with water vessel where the heat of these hot
gases transfer to the water and consequently steam is produced in the boiler. Then this steam is piped
to the turbine of thermal power plant. There are many different types of boiler utilized for different
purposes like running a production unit, sanitizing some area, sterilizing equipment, to warm up the
surroundings etc.
1.3Monitoring and tuning up of the boiler:
The operating conditions of the waste heat boiler are directly related with that of the kiln. To
ensure the stability of the operating parameters and the highest safety of the operation, the close
communication with the kiln operators is extremely necessary for the best coordination; meanwhile, the
change of the boiler operating parameters, and the operating conditions shall be closely monitored and
analyzed for timely tuning and adjustment.
During the operation, the main purpose for the monitoring and tuning is:
Under the normal kiln operating conditions, to tune up the system to keep the normal operation and
maintain the normal pressure of the medium, maintain the normal water level by evenly feeding water
to the boiler to ensure the steam quality, and ensure the normal operation of the ash handling system.
1. Precaution for the boiler operation:
I. When the boiler is operating, pay attention to the steam pressure, steam temperature,
drum level, water flow, feed water temperature and pressure, the exhaust gas temperature
at boiler inlet, furnace minus pressure etc. In case there is a change in the exhaust gas flow
and temperature at boiler inlet but no effective result after tuning up, timely
communication is needed with the related department for an adjustment of inlet gas
temperature in order to ensure the boiler safe operation and the stable parameters of the
boiler.
II. Walk down inspection: In order to ensure the safe operation, at least 4 walk down
inspections shall be carried out for each operation shift. The items included in the
inspections are: all the equipment in the boiler building; check of the boiler casing for any
damage and air leak of the manholes; check of all the valves for abnormality; check of all the

3. water level gauges, pressure gauges, temperature gauges for abnormality, check of all the
sections and portions of the heating surfaces for soot deposition, wear and tear and check
of the boiler flue gas temperature.
III. Continuous recording on the logs. Once per hour logging shall be carried out. The purpose of
recording and logging is to analyze the operation condition and overall regularity of loading
alteration of the entire systems for better and reasonable operation.
IV. The regular sampling on the boiler feed water, boiler water, blow down water, steam and
produced water shall be carried out for chemical analysis to achieve the goal for economical
operation.
V. Based on the water quality and the chemical examination. The regular blow down of the
boiler convection tubing banks will be executed. The amount of blow down water shall be
determined based on the chemical examination result
VI. Feed water samples shall be inspected regularly to ensure the feed water quality.
VII. Regular and rules for shift alternation shall be strictly followed and the clear records shall be
kept on the daily logs.
1.4 Normal Operation of the boiler:
During the normal operation of the boiler, the water level shall be maintained normal, the
pressure stable, and the steam temperature normal. The monitoring of all the equipment and
instruments shall be continued to ensure the safe operation.
1) Requirement for the feed water: the boiler feed water shall be de-mineralized and
the quality of the de-mineralized waster shall comply with the appropriate national
criteria on the water quality.
2) The boiler water shall be kept within 75 mm of normal level, however slight
fluctuation shall be considered as normal. If the water level stays fixed, it might
indicate a plugging, requiring a washout of the water level gauge
1.5 Necessary Step before start up of Boiler:
By field supervisor
• Field supervisor should get a detailed round of Boiler Physically.
• Inspection doors of Boiler should be properly closed.
• Ensure that the level of the water in the steam drum is at half full.
• Feed water and steam valves should be in proper working condition.

4. • Dampers should be verified before start up of Boiler.]
• Water level should be maintained at required level.
• R-O plant operator should be informed for preparation.
• Drain valve of steam line should be opened.
• Air vent of steam drum should be opened.
• Exhaust valve of steam should be opened.
• Hammering device of SP boiler should be ready.
By operator
• First of all drain, water and steam valve for required operational condition.
• Feeding water to boiler by feed pump till half of steam drum.
• Keep the boiler vents open until a heavy steam jet is flowing out (until a boiler pressure of about
1 bar is reached).
• Co-operating with kiln operator about their required parameter and then opening dampers
accordingly.
1.6 Damper Opening: (cold state)
When the hot gases temperature at the cooler exhaust is at 150-200 C thenᵒ
10% inlet damper open
10% outlet damper open
90% by pass damper open
After 30 minutes
When temperature at cooler exhaust is at 200-250 C thenᵒ
20% inlet damper open
20% outlet damper open
80% by pass damper open
When the temperature at the super heater now reaches up to 400 C then we take the boiler in lineᵒ
because our steam temperature & pressure reaches 310-350 C and 1.2MPa respectivelyᵒ
100% inlet damper open

5. 100% outlet damper open
100% by pass damper closed
According to the careful estimation, opening of the damper with respect to time is enlisted
as under:
Sr.No Outlet Inlet Damper (%age)
By Pass Damper
(%age)
Hot Gas Temperature
( C)ᵒ
Time
(min)
1 10 90 150-200 30
2 20 80 200-250 45
3 30 70 250-300 65
4 40 60 300-350 85
5 50 50 350-400 105
6 100 0 400-450 120
1.7 Damper Opening (Hot State):
When there is a stoppage for some hours, then the boiler still carries some temperature &
pressure and in that case how, the damper opening will be executed .It is given as
Sr.No Outlet Inlet Damper (%age)
By Pass Damper
(%age)
Hot Gas Temperature
( C)ᵒ
Time
(min)
2 20 80 250 15
3 40 60 300 25
4 60 40 350 35
5 80 20 400 45
6 100 0 450 60
1.8 Shut Down:-
The boiler shutdown is depending on the kiln operation on one hand and the boiler operation
on the other hand. Boiler shutdown may proceed in three ways based on how long the shutdown shall
last: temporary shutdown, complete shutdown and emergency shutdown.
1. Temporary shutdown and complete shutdown may proceed in the following steps:
I. Open the by-pass flue, and close the inlet gas butterfly valve
II. Watch the water level and continue to make up for the feed water
III. Reduce the boiler pressure to the “0” , and then close the main steam stop valve.

6. 2. Emergency shutdown:
One of the following situations calls for the emergency shutdown (the steps for the
emergency shutdown are similar to the temporary shutdown):
i. The water level of the boiler drops down beyond the lowest limit of the specified
level range;
ii. Water level continues to drop down despite the increased water feeding or other
necessary action for water filling;
iii. The water level of the boiler rises beyond the upper limit of the specified level
range;
iv. Feed water equipment is all in malfunction.
v. Failure of all the instruments such as the water level gauges, pressure gauges and
safety valves.
vi. Serious damage to the boiler walls, steel structure overheated purling the safe
operation of the boiler.
vii. Explosion or burning in the flue, severely threatening the safety of the boiler and
personal life.
viii. Kiln requires boiler emergency shutdown
ix. Other abnormality requires the emergency shutdown of the boiler because of the
safety limits are exceeded.
Whenever there is a shutdown taken, the drains of steam lines are opened but the water should
be there in the boiler so that shrinkage and other metallurgical effects can be avoided. Also the steam
drum is filled with water, Hence the rusting effect is avoided to a larger extent.
On the other hand, when there is a planned shut down and tubes are to be replaced, and then
boiler should be cooled down slowly under normal parameters. When the temperature goes down to
the required or optimum value (40-50 C) then drains will be opened followed by the cutting of the tubesᵒ
for replacement.
1.9 Blow Downs:-
a. Regular blow down shall be carried out when the boiler is operated at a low load, at least
once per shift. In addition, more blow downs may be applied in consideration of the dosing
and the boiler water quality.
b. Before each blow down, the check with the piping and the valves for abnormal conditions
shall be conducted. Besides, the water level shall be adjusted to about 35 mm higher than

7. normal, and each blow down shall be controlled such that the water level drops down by
about 35 mm.
c. Neither long lever, nor hammer is allowed to forcedly open the valve or peen the valve to
prevent the dangers. When two or more than two boilers share the same blow down
header, the simultaneous blow downs for these boilers are strictly prohibited.
(They are installed on the headers and points)
Limitations:
4-5 tons water is wasted for blow downs.
Dozing:
 To attain parameter standards in boiler
 To avoid scaling, corrosion
 To improve efficiency
 For smooth turbine operation
Drum:
Ph – sphate (5-20)
Alkalinity (OH +ve)
PH (10-12)
Hardness Removal Nil
To Remove O₂ (‹.005)
For passivation of all boiler surfaces.
 Drain valves are closed now
Auxiliary oil pump stops, now the turbine is ready to be synchronized with the power plant.
Oil Pressures:
Lubricating oil pressure = 0.30MPa
Control Oil Pressure = 0.9MPa
Oil Temperature Inlet = 40~50 Cᵒ

8. Oil Temperature Outlet= 35~45 Cᵒ
Oil temperature should not be less than 35 Cᵒ
Maintain De-Aerator Vacuum = -0.080MPa
Maintain Condenser Vacuum = -0.085~ -0.090MPa
Check vibrations of turbine front Bearing , turbine rear Bearing limits= 2~22µm
Bearing Temperature should be 40~70 Cᵒ
Axial displacement limits should be between (-0.3 ~ +0.3)
Condenser Hot level should be from (424 ~ 464mm)
1.10 Maintenance of the boiler
After 5-6 months of the boiler operation, the boiler should be down for maintenance.
(1) To clean off the deposits in the drum, headers of the boiler
(2) To clean off the soot on the heating surface.
(3) Inspection on the internal or external sections of the boiler, such as check of the welds
of the pressure parts and steel sheets for corrosion. Severe defects shall be subject to
immediate remedy action. If the suspicious defects are located but not impacting the
safe operation, records shall be taken for future reference.
(4) Check the induced draft fan for bearing abnormality, check the impeller and the casing
for wears and tears. The user shall keep sufficient spare parts for the impellers.
(5) Some portions of the boiler walls can be removed for thorough inspection, if necessary.
When the inspection locates the serious damage, the complete repair has to be carried
out before start up. All the findings from the inspection and the repairs after the
inspections shall be entered into the boiler safety technical logs.
(6) Preservation for the boiler out of service for a long time:
a. Water preservation: fill up the boiler with the treated water, and then boil up the
water to remove the air. Fully close all the doors and openings. Or fill up the boiler
with the de mineralized water of high alkalinity to prevent the corrosion. The
chemicals added into the de mineralized water usually are NaOH (2kg/mᶾ) or
Na₃PO₄ (5 kg/m ), and that added into the boiler water are NaOH (5ᶾ kg/m ) orᶾ
Na₃PO₄ (15-20 kg/m ). This method is only for short time shutdown preservationᶾ
with the heating surfaces and the boiler walls properly dried.

9. b. Pressure preservation: After removal of deposits from inside the boiler, all the
valves shall be closed. Preservation solution is to be added up to the lowest point
of boiler outlet header. Heat up the boiler to create a pressure of 0.1-0.2MPa, and
then hold the pressure for 2-3 hours. After pressure is dropped down, the
preservation solution should be used again to fill up the boiler, and then keep the
pressure of 0.2MPa by using a hydraulic way. The preservation solution is
composed of caustic soda (100mg/L), phosphorus pent oxide (100mg/L), sodium
sulfate (250mg/L). During the preservation period, regular inspection for the
proper concentration of the solution is required. When the concentration of
sodium sulfate is found to be lower than 50mg/L, more of that chemical shall be
added to keep the specified concentration.
c. Nitrogen preservation(omitted)
When the boiler is down for a quite long time, the nitrogen preservation can be
applied.

10. Chapter 02 Steam Turbine
2.1 Turbine Start Up and Operation:
 Start the main auxiliary oil pump for 30 minutes before the turbine starts. Condensate pump
and jet water pump start along with circulating water pump.
 Reset turbine and ensure the both ESV are fully opened.
 Open boiler stop valve from the headers
 Open main stop valve of the turbine
 Check steam temperature and pressure are normal.
 Push “Run” button at 505 turbine control (turbine will start @ 600rpms limited)
 600 rpm are maintained for 30 minutes
 After 30 minutes, push ENTER + 1000+ ENTER=1000rpm
At 1000 rpm running time is 90 minutes.
 Next Enter+2600+Enter, the rpm will reach 2600 rpm
 After 20 minutes, Enter +3000+ Enter, the speed will increased up to 3000rpm.
 Before Pushing to the RUN command ensure the DCS system RESET and ALLOW Start Up and
505 system RESET
 Reset guarding system , slightly move up the handle of emergency sliding valve, set the pressure
of quick stop oil, turn clockwise start up control valve by 90 (1839). Then start up oil pressureᵒ
will slowly rise at 0.85MPa. Where quick stop control valve should be twirled counter clockwise.
The quick stop oil pressure will slowly rise at 0.85MPa,and then start up control valve should be
twirled counter clockwise by 90 with a result that start up oil pressure should become lowerᵒ
slowly and the closed quick stop valve opens gradually to full extent then
2.2 Before turbine start up:
1. Before the start the rigorous inspection must be carried out;
a. Check the systems of vapor , drainage system;
b. Inspect the instrument measuring point must be normal and right;

11. c. Be sure components should be intact, and rotational part is flexible, non-jam situation. The
fastening screws should be tightened. Turning devices to listen carefully to check the sound
without friction;
d. Check normal condition of condensing steam system.
e. Check the location of speed control system, the correctness of Emergency Trip throttle
position in a release.
2. Warm pipes and hydrophobic
a. Isolation valve open slightly so that the pressure to maintain the tube at about 0.25MPa.
heating pipes, the temperature rise rate of 5~ 10 °C/min;
b. Tube wall temperature should arrive 130 ~ 140 °C , in order to speed 0.25MPa/min pressure
riser to rise to the provisions of values.
When warm tube, the trap door should open as much as possible so that condensation water
can discharge, with the tube wall temperature and pressure rise, a gradual clearance of small
hydrophobic door to prevent substantial leakage of steam.
Warming tube Notes:
I. Must be strictly to prevent leakage of steam into the cylinder that can cause rotor
deformation;
II. The temperature of the various parts pipeline (such as flange and bolts, etc.) should
not different too much;
III. Wall temperature should not less than the corresponding saturation temperature
under the pressure.
At the same time, start circulating water pump, then water to the condenser space.
Start up condensation pumps and recirculation door, so that condensation water
between the exhaust and the condenser can cycle, at last start up the main exhaust
opening and the total exhaust device to warm tube.
3. Running the oil cycle and check it
4. Starting condensing steam system, check the vacuum system are in normal conditions.
5. Check the level of following items:
I. cooling tower water level = 2800mm
II. Jet water tank level = 1500mm
III. Oil tank level = 234mm

12. IV. De Aerator water level = 1600mm
Check all parameters and all drain valves should be opened.
2.3 Starting of Turbine
1. Start up disk car devices, keep status to listen to any disc friction sound
2. Wear Emergency throttle
3. Low speed warm up, when warm tube finished, close the trap door. When the vacuum up to
400 ~ 500mm Hg, become the slow gradual warm up, maintain speed at 600rpm around about
20 ~30 minutes. Pay attention to oil temperature that should be at 35 ~ 40 °C, if it too low spur
or speed is not allowed.
4. Speed
a. When the unit is operating normally, speed at 200rpm. Near critical speed when the
rotational speed (2140 rpm) to accelerate a smooth crossing;
b. Using governor control steam conditioning valve, and speed will be up to rating;
c. A new installation or repaired unit should start up at low speed. When passing the test
should do excess speeding security test. Method as follows: when the quick closing valve
open, operate WOODWARD505 conditioning units to speed up to hit a critical security
devices. Close quick closing valve, at speed below 2900rpm following re wear Emergency
Trip throttle, and then allows speed to rated speed;
d. Check the normal operation and the vacuum has reached rating.
5. With Load
a. Speed at 100 kw/min or so to full load speed;
b. Check the normal work conditioning system , hydraulic and oil motivated second opening ,
load mutual adaptation;
c. Check unit sound, vibration, axial displacement, thrust bearings watts and temperature,
differential expansion, steam and metal temperature rise speed, temperature normal;
d. Adjust the water condenser level timely, water level and pressure de-aerator, steam seal
pressure, Oil Cooler oil temperature , generator cooling water inlet temperature and
pressure, water level changes in the attention of the heater.
2.4 Shutdown
1. Normal shutdown

13. a. Gradually unload load in order to shutdown, before charge load examinate the pump oil,
and the charge rate of less than 100 KW/min;
b. Hand Emergency Trip throttle hand and turn off shoot quick closing valve;
c. Monitor the oil down to 0.08MPa (g), then start the auxiliary fuel pump;
d. Record the time go lazy;
e. Open the steam to the steam valve marshaling, speed to critical speed, then turn off valve
to send steam;
f. Open the cylinder and the main steam pipe trap door;
g. After the turbine stop, turn off exhaust device (turn off the exhaust valve first);
h. Regular car plate until steam cool;
i. Rear cylinder temperature is below 50 °C turn off the water cycle;
j. The back oil temperature is below 45 °C, stop lubricating oil.
2. Emergency shutdown
The following situations happen should have an emergency shutdown.
a. Unit speed excess more than 12 percent rating stands;
b. Unit sudden has strong vibration or hear clearly the voice of the internal metal;
c. Turbine seal occurred spark;
d. A bearing unit off oil or smoke;
e. Oil down to 0.05MPa (g), failure cannot be eliminated;
f. Bearing oil temperature more than 75 °C or axial displacement of more than 0.7 mm
without automatic shutdown;
g. Turbine oil system fires, and cannot be quickly extinguished, and threat to the safe
operation of generating units;
h. Tank oil level down to the lower limit, unexplained oil spill;
i. The main steam or feed water pipe rupture, endangering the safety crew.
2.5 Operation maintenance and downtime maintenance
1. The personal on duty should do the following tasks well during the operation time:

14. a. Units of heat engine protection device, interlock protection devices, the start switch of the
auxiliary should be put at the location;
b. Recording the instrument readings in the daily form per hour. If the readings are abnormal,
you should find out the reasons and take some necessary measures;
c. Recording the instrument readings entirely in the monthly form every day, and analyzing the
readings according to the operation conditions;
d. Inspecting the units overall per hour. If there are deficiencies in equipment, fill in the
equipment defects report form in time and pay attention to the significant deficiency;
e. Measuring, recording and analyzing the various bearing vibration regularly every day.
2. Downtime maintenance
a. If starting immediately after a short period of downtime, lower the load or load rejection
gate to fight the emergency shutdown quickly, this can greatly shorten the start up time
again;
b. Parking overhaul, make sure reduce the load slowly and operate stably at low load for a
certain period of time;
c. Vehicle should always be set, shot term park and start again, in half an hour before start up
should be changed regularly for car plate. Unit overhaul downtime, continuous disk first and
then changed to regular car plate. Bell gradually increasing time intervals until completely
cooled;
d. Long time out, should make the necessary anti corrosion treatment. Hot air drying can be
used through flow part of : sealing equipment, such as add lime or calcium chloride
desiccant and carefully adjusted bearings and other components of the corrosion prone
parts of the anti corrosion treatment, such as surface corrosion resistant material. Pipeline
related equipment, instrumentation and all water pipes in a net release. And maintenance
during the regular checks are carried out in accordance with the regulations to ensure
quality maintenance.
2.6 Synchronization Process:
 Inform the electrical operator to connect the grid after testing the governing valve tightness and
the emergency breaker activation.
 The operator shall focus on the air supply for the air sealing after synchronized, carefully
monitor the sound and vibration, also don’t forget to check the bearing oil temperature, the oil
pressure of each system as well as the opening of governing/regulating valve. After everything is
going smooth, start the turbine protection.

15.  When the generator was synchronized to the grid, emergency trip system should be put in to
the practice.
 After grid connection, immediately load on 1000kw,for 10 minute and then increase the load to
3000kw at the speed of 150kw/min and maintaining it for the next 10 min. later on increase the
load once time to 10000kw of the speed of 150kw/min
 It was not recommended to perform no load running if without any special requirements. The
generator shall be with 10% rated load at the moment connected with turbine. The back
cylinder temperature will be less than 100 C ~ 120 C at no load running and less than 60 C ~ᵒ ᵒ ᵒ
70 C at no load runningᵒ
 Record all the parameters and on loading duration in the operation log book
 Switch off the steam supply valve between the new steam and the bearing gland , and adjust
the steam supply based on any steam leakage phenomenon at the turbine end.
 Cooling water should be supplied to generator cooler and keep the inlet air temperature around
30~ 40 C, If the inlet air temperature is over 40 C.ᵒ ᵒ
 Pay attention to adjust the normal position of the condensing water level(1/2 of the water level
gauge)
 After the condensing water being test to be qualified, switch off the water discharge valve and
open the valve to the de-aerator to supply water to the de-aerator.
 Open the ejector pump, extract the condenser to vacuum.
Hot start time and vibration values:
R/min Min vibration value (mm)
speed accelerated
0~600 3
0.03
warm unit
600 5
speed accelerated 1000 3
warm unit
1000 10
speed accelerated 2600
5
~6
0.10 over the critical
state
warm unit
2600 5 0.03
speed accelerated 3000 3 0.03

16. Cold state start procedure:
Operations RPM
Time
(min)
speed rise to after driven the Rotor 0~600 2~3
check and Maintain 600 25~30
Smoothly raise speed to 600~1000 2~3
check and Maintain 1000 25~30
Smoothly raise speed to 1000~2600 5~6
check and Maintain 2600 15~20
speed accelerated to 2600~3000 2~3
Total 6~95(min)
1. Switch on the AC and DC supplies from LTP Panel.
2. Turn on MK switch
3. Start the DC field from Scada.
4. Check the generator voltage; shown on LTP Panel, when it reaches 6.3KV, generator is ready
for synchronization.
5. From computer, select the breaker of generator. Give the synchronization command by
clicking on synchronization “start” button
6. On synchronoscope when the Dot reaches the midpoint and turns green, that means
voltage and frequency are matched and generator is synchronized.
7. Now turbine operator will start taking the load
8. Maintain the power factor around 0.95.