
Welcome to the Boiler Start up! Step by Step
[Intro] [Pre-Verse] Welcome to the Boiler Start up! step by step, If you got a problem! You can call your Union Rep. Now listen close if you want to run the CUP... The Operator Turnover is the first one up! [Verse 1] Step one, check the log book for the previous shift's deets, Talk to the plant operator, get up to speed, complete. Next up, visual inspection around your boilers right, Make sure man-holes and hand-holes are fastened tight, No leaks, all secure, no drips in sight. Confirm all blow-down valves are closed, alright. [Chorus] Welcome to the Boiler Start up! step by step, If you got a problem! You can call your Union Rep. Now listen close if you want to run the CUP... The Feedwater System is the next one up! [Verse 2] Next, check your D-A tank, ensure enough water before the boiler fill, Then line up that feedwater system still, Open suction and discharge valves on your feedwater pumps, you know the drill. Now you're clear to open your boiler's vent, Get rid of non-condensable gases and all they represent. Open superheater vent to prevent overheating tubes, no doubt, Most don't have superheat, but know it inside out. Next, open the feedwater valve in bypass mode, fill the boiler to one-third sight glass view, That's roughly two or three inches below the N-O-W-L, true. Switch the feedwater pump to hand operations, Once level's right, turn off the pumps, congratulations. [Chorus] Welcome to the Boiler Start up! step by step, If you got a problem! You can call your Union Rep. Now listen close if you want to run the CUP... The Fuel System and Purge Cycle are the next ones up! [Verse 3] Line up the fuel system, keep this in mind, Notice the yellow piping, it's one of a kind. Open main gas cock and check the gauge, Five to six p-s-i-g, it's all the rage. At the boiler control panel, turn the burner on, Kicking off the pre-purge cycle, combustibles gone. It takes around forty-five to sixty seconds to clear the air. Forced draft fan starts, draft damper opens wide, Three to five air changes in the firebox, purges combustibles inside. Before igniting pilot flame, to stay safe that's the rule, Once purge cycle's done, forced draft damper to minimum airflow, cool. [Chorus] Welcome to the Boiler Start up! step by step, If you got a problem! You can call your Union Rep. Now listen close if you want to run the CUP... The Combustion System is the next one up! [Verse 4] Imagine this, a high-voltage spark, Ten thousand volts from step-up transformer, no walk in the park. Igniting the pilot flame in a fit of rage, Safety device called the Fire eye detects the flame, out of its cage. Now with permission, main gas valve opens up, Main combustion starts, pilot flame shuts off, yup. Now that's your cue to set burner to hand, we want it slow, Set that dial to minimum with fire rate low, About ten percent, slow and steady glow. Slowly and steady wins the race, Warm up the boiler from there, no rush, keep the pace. [Chorus] Welcome to the Boiler Start up! step by step, If you got a problem! You can call your Union Rep. Now listen close if you want to run the CUP... Take a quick moment to scratch your balls, It's time to build some pressure and bring that boiler up! [Bridge] Once you're done scratching your balls and dreaming of men, It's time to saddle up, cuz here we go again! This is the last chapter and then you're free to go, We are almost there, you already know! Now that you're done picking your nose, Wash your fucking hands and let's see where this goes! [Verse 5] Watch for pressure to hit around fifteen to twenty-five p-s-i-g, Or steady steam flow from the vent line you can see. Now close the boiler vent and seal it tight, Wait for boiler pressure to reach seventy-five percent of header pressure, time to take flight. Open up the automatic non-return valve and let it through, Open up the condensate drain and leave it cracked open too. This drains condensate built up between main steam stop valve and header, nothing better. Lastly, when drum pressure comes within two to three p-s-i-g of the header near, Time to open the boiler steam stop, nothing to fear, Increase your fire rate to establish steam flow, you've got the brains. Now's a good time to close superheater vents and close up all the drains! [Final Chorus] Switch the master control and pumps to automatic and done, Startup complete, boiler runnin' like the sun. Put your aviators on and walk away. Hop in the convertible; top down; It's time to play!

