START-UP FROM COLD CONDITIONS
Start-up sequence
Loading of boiler feed water into the steam system
The steam system must be loaded with boiler feed water prior to start-up of the WSA plant.
S.n Job Description Approx Actual start Actual end
o. Time taken time time
in (Hrs.)
1 Ensure that all drain valves in the system and gate valves in the NA
steam outlet line are closed.
2 Ensure that the continuous blow-down valves (HV-3709 for 1 st NA
steam drum and HV-3809 for 2 nd steam drum) and the intermittent
blow-down bypass valves (HV-3711 for 1st steam drum and HV-
3802 for 2nd steam drum) are closed.
3 Close the discharge valves of the BFW pump (205-P-03 A/B) NA
before starting it. And Automatic start/stop logic of BFW pumps
(205-P-03 A/B) should be disabled during start-up and shutdown
4 Close level control valves (LV- 3703 for 1 st steam drum and LV NA
3803 for 2nd steam drum) during filling and respective bypass
valves are to be used for filling.
5 Start BFW pumps (205-P-03 A/B) as per SOP & start filling V- 1hr
06 & V-07 till normal operating levels.
6 Close the steam drum vent valve after filling V-06 & V-07. Line NA
up vent through PV-2204. (regulate pr, to be increased in steps)
7 Close bypass valves (HV-4313 for 1st steam drum and HV-3803 NA
for 2nd steam drum) and crack open control valves (LV-3703 for
1st steam drum and LV-3803 for 2nd steam drum) manually.
8 Now automatic start/stop logic of the BFW pump can be taken in NA
line
Start of the sulphuric acid
system S.n Job Description Approx Actual start Actual end
o. Time time time
taken in
(Hrs.)
1 Ensure that cooling water circulation to/from both the acid cooler is NA
in operation and Ensure that Sulphuric acid has been loaded into
both the sulphuric acid system
2 Ensure that all high point vent & drains are closed in Acid system NA
and Close sulphuric acid export line by closing LV-3501.
3 Open all in-line valves, to ensure complete filling of all the acid 10 min.
lines
4 Partially open the manual valve HV-3515 in the acid circulation 5 min.
line
5 Crack open the discharge valves of the acid pumps (205-P-01 NA
A/B/C) which is to be started & start the acid pump according to
SOP.
6 Gradually open the discharge valve of the selected acid pump until NA
fully open.
7 Adjust the position of the manual valve HV-3515 in the acid NA
circulation line to maintain normal operating flow in the acid
recycle circuit, i.e. the pressure at the outlet of the selected acid
pump corresponding to normal operating pressure 5.5 kg/cm2g.
8 Switch LIC-3501 to automatic control, whereby the level in the acid NA
vessel automatically remained at normal level.
9 Continuously check for leaking flange connections and tighten NA
relevant flanges if required.
Establishing of Initial air flow
S.no. Job Description Approx Time Actual start Actual end
taken in (Hrs.) time time
1 Start 1st cooling air blower (205-K-01 A/B), 2nd cooling air blower (205-K-02 NA
A/B) as per SOP.
2 Open the combustion air damper, UV-1703, (by making IS-1 Healthy) to allow NA
full flow of available air to the combustor by using HWC Bypass switches (to
make IS-1 healthy)
3 Open the 1st BFW preheater temperature control dampers, TV-4401B, to allow NA
equal air flow through the heat exchanger and in the bypass duct.
4 Open the hand valve, HV-2601, bypassing the process gas heater and make sure NA
that HV- 2602 is open as well. The openings of the dampers should be so that
equal flow is present through the heat exchanger and in the bypass duct.
5 Open the waste heat boiler internal bypass damper, TV-1901 A, to allow air flow NA
through the bypass section. Close the waste heat boiler main tube damper, TV-
1901 BA/BB, to force as much flow through the internal bypass of the waste heat
boiler.
6 Slowly increase the speed of 1 st cooling air blower and 2nd cooling air blower to 30mins
obtain an air flow of approx. 50% of normal cooling air flow.
7 Once the 1st & 2nd cooling air blower has been started, subsequently start the 1 st & NA
2nd Combustion air blower (205-K-03 A/B) & (205-K-04 A/B).
8 Once cooling air flow has been established, slowly open HV-3304 B & close HV- NA
3304 A.
9 Slowly increase the speed of 1st combustion air blower to obtain an air flow of 30mins
approx. 50% of normal combustion air flow
10 Close main damper of process gas heater while opening the bypass damper, HV- NA
2601.
Start process gas blower (205-K-05 A/B) and recycle gas blower (205-K-06 A/B)
at low speed as per SOP.
11 Slowly increase the speed of process gas blower to achieve normal operation inlet 30 mins
pressure, PIC-2301, to the 1st WSA condenser.
heating-up using start-up steam
To prevent water from condensing in the catalyst beds once the combustor is started, it is crucial that the catalyst beds in each SO2 converter is heated to at least 110°C before
the inlet temperature to the SO2 converter exceeds 200°C.
S.no. Job Description Approx Time Actual start Actual end
taken in (Hrs.) time time
1 Open all in-line valves in the steam import lines NA
2 Communicate with TPS for consuming MP steam for start up NA
3 Crack open the in-line valves in MP steam import to process gas cooler 205-E- NA
05.
4 Initially close TV-2203AA & open TV-2203AB to admit zero flow of steam NA
through the heat exchanger.
5 Initially close TV-2210A & open TV-2210B to admit zero flow of steam NA
through the heat exchanger.
6 The 1st steam drum pressure is adjusted by manual control of PIC-3712/3703 NA
acting on temperature control valves TV-2203 AA/TV-2203 AB.
7 The 2nd steam drum pressure is adjusted by manual control of PIC-3810/3803 NA
acting on steam vent valve PV-3803 A.
8 When the temperature at the inlet of the 1st WSA condenser reaches approx. 12Hour
100°C (TI- 2209) the in-line valves in the riser to the 1st process gas cooler to
be opened fully.
9 The continuous blow-down valve HV-3709 for 1st steam drum and HV-3809 NA
for 2nd steam drum is to be positioned to maintain a continuous blow-down
rate
10 The level in the steam drums shall be maintained at no higher-than-normal NA
level during the heating-up with start-up steam by operating intermittent
blowdown valve HV- 3710 for 1st steam drum and HV-3801 for 2nd steam
drum.
Heating-up using combustor
S.no. Job Description Approx Time Actual start Actual end
taken in (Hrs.) time time
1 The air flow rate should be at least 90% of the max flow rate (i.e. 143100 NA
kg/hr.) of the unit to provide a sufficient purge rate, by monitoring FY-1723.
2 The DCS controllers should be in the manual mode with output 0%. NA
1. FC-1705 Fuel Gas Flow Controller
2. FC-1724 Off Spec Acid Flow Controller
3. FC-1704 Dilute Acid Flow Controller
4. FC-1701 Acid Gas ex ARU flow controller
5. FC-1702 Sour Gas ex SWS Gas flow controller
TC-1708 Spent Acid Combustor Chamber Temperature
3 Verify that all the BMS alarms shown in TABLE-01 are in their normal, non- NA
alarm states. The permissive to start the purge are shown in Table 2. If these
conditions are met, the PURGE PERMISSIVES MET lamp will be lit (IL-03)
4 If the PURGE PERMISSIVES MET lamp is lit (IL-03), press the START 5mins
PURGE button (PB- 02) on the local control panel. Purge will be done for XX
minutes based on 4 system volume changes.
6 Check whether the combustion air control dampers are fully opened NA
automatically.
6 Once purging is in progress Purge Complete lamp (IL-04) will flicker. NA
7 At the end of 5 minutes, Purge Complete lamp (IL-04) will glow steadily, and NA
combustion air dampers should return to 20% open for pilot ignition.
8 If purge permissive is lost (Table-2) or any alarm as in Table-1 comes before NA
5 minutes (i.e. Purge Sequence) purging is stopped automatically. Operator
has to find the cause and rectify it. Operator must then press reset from
DCS/Field and again go for Purge start when PURGE PERMISSIVES MET
lamp is lit (IL-03)
9 Once Purging is completed & Purge Complete lamp (IL-04) is lit Pilot NA
ignition can be done. Press the START PILOT button (PB-03) on the local
control panel.
10 Pilot Block Valves XV-1703 & XV-1704 will open once PB-03 is pressed. NA
Check for the same
12 Simultaneously Ignition transformer XMR-1701 is energized and begins to 10Sec
spark. A 10-second timer is started within the BMS.
13 Look through the sight port to verify the ignition transformer is sparking. NA
