500 MW Unit Startup Procedure

CONTENTS

SL. N O .

DESCRIPTION

01.

CO L D ST AR T - U P

02.

IN T E GRA T E D ST AR T U P PR O C EDU R E – C O LD S TAR T U P

03.

H O T AN D WA RM S TA RT U PS.

04.

IN T E GRA T E D ST AR T U P PR O C EDU R E – WAR M S TAR T UP

05.

IN T E GRA T E D ST AR T U P PR O C EDU R E – H O T ST AR T U P .

06.

10.

STA RT U P B Y CU RV ES F O R ABS O LU T E CO L D ST AR T W IT H HP /L P B YP ASS SYS T E M. STA RT UP CU RV ES AFT E R 4 8 H OUR S SH AT D O W N W IT H H P/ LP BY PA SS SYS T E M. STA RT U P P RO C E DU RE A FT E R 8 H O URS S HU T D O W N W IT H HP/ L P B YP ASS SYS T E M. T EC H N ICA L DA TA – L IM IT CUR V ES F O R T URB IN E VA LV E S – WA LL OF T H E CAS IN G – S HA FT S. WAR M IN G – UP A N D S TAR T IN G T H E TUR B IN E – T EM P ER AT UR E CR IT E R IA.

11.

T EC H N ICA L DA TA – RE AC T IV E CA PAC IT Y CU RV E F OR TUR B O G E N ERA T ORS .

07. 08. 09.

COLD START UP (With Aux Steam available) A cold start up is by definition, one of which the maximum of HP casing and HP shaft is less than 1500C. This normally means that the unit is shut down from the maximum load for more than five days. If machine is started from ambient temperature (HPC/HP shaft temp approx. 400C), heating up of casting is required. This is accomplished by soaking the machine at 360 rpm at warming up steam parameters (40kg/cm2, 3600 C), till the TSE margin are satisfactory. The rifle construction of the water wall combined with the boiler circulating water pumps permits very high rate of pressure rising of boiler. An upper limit of 2000C/hr saturation temperature gradient can be allowed, i.e. approximately the boiler pressure can be brought to 20 kg/cm2 within an hour of cold start up. But actual temperature gradient is limited by the thick walled Y piece provided in the main steam and HRH lines. A main steam line heating is to be started as early as possible (at approx. 4 kg/cm 2) as maximum differential temperature allowed between inner (98%) and mid wall temperature (50%)

is  400C. So boiler loading is accordingly regulated. It may be preferably to start only two CC pumps in order to minimise flashing in down comers (and subsequent vibration) when the boiler water is in range of 850C to 1250C. The third pump should be started before drum pressure reaches 7 kg/cm2 to minimise the temperature transients experienced by the pump casing (this is to avoid fast load out back on the boiler in the event of any CC pump tripping). To get the rolling parameters, normally two elevation oil guns are taken with approx. 70 to 80t/hr flow through HP-LP bypass. At that time M.S. parameters would be 40 kg/cm2 and 3600C, HRH parameters would be 12 kg/cm2 and 3600C. As soon as the turbine loading has started, HP/LP bypass closes and gets completely closed as the turbine reaches the boiler load. First mill is put into operation around 10% of generator load. Second mill is put into operation around 25% while third mill is at 40% of generator load. Fourth and fifth mills are put into operation at 60% and 80% of generator load respectively. Sixth mill is taken to reach full generator load. During loading the RH outlet steam temperature has to be kept as close as possible to SH outlet steam temperature Burner tilt, SH spray, RH spray controls has to be adjusted accordingly. The turbine-loading rate is decided by a selection circuit which compares the external load gradient, TSE margin and time dependant gradient (set internally) and frequency influence.

INTEGRATED START-UP PROCEDURE COLD START-UP (AUXILIARY STEAM AVAILABLE) REF. DRG NO. 20 – BPE – 691 STEP

TIME

UNIT CONDITION

OPERATION

NOTES

2

0

..

Boiler pr. 0 kg/cm (g) Charge Aux. Steam and Ambient header 16 ata, 2600C, temperature from existing units.

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Charge steam to fuel oil pump house, atomising steam and tracing steam deaerator warming up.

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Start tank heating of LSHS oil.

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Start one LSHS pump on recirculation as soon as the sufficient oil temperature at inlet is achieved.

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Charge LSHS to boiler front and keep it on long recirculation, with heaters control set on ‘Auto’ to maintain 1101290C.

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All the steam tracing lines and electrical tracings in pump house & boiler to be charged.

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Fill water in drum upto +200mm.

Ensure that the suction and discharge valves of all the CC pumps are open and the pump suction and discharge lines are vented.

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Start Bearing cooling water system pumps for Boiler, Turbine and TG auxiliaries .

Check all circuits have sufficient flow. Before starting the pumps, the emergency cooling water tank level to be checked and made normal.

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Start instrument air compressor and check that all the lines to Boiler and TG are charged.

Check that all circuits have sufficient air pressure.

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Start service air compressor and fill the air receiver tanks of SRAPH & PRAPH are filled.

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Ensure that purge air to HEA is open in all corners.

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Line up Air and flue gas circuits for startup.

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ESP ready in all respects.

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Furnace bottom ash system and seal through lined up.

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FSSS panel ready in all respects.

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EAST panel ready in all respects.

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Excitation panel ready in all respects.

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Generator protection panel ready in all respects.

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Generator H2 gas pressure is 4 kg/cm2

Check purity of H2 gas is normal.

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Generator stator water system ready in all respects.

Check purity of generator stator water is normal.

Check dampers and gates register position.

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H2 cooling water system ready in all respects with SLC on.

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Check for level in LP & HP chemical dozing Hydrazine, Ammonia system is ready. and phosphate preparation tanks.

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SADC panel readiness.

Check for air pressure in all the corners and elevations.

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Power supply for all the valves and dampers are ON.

Ensure Aux. air dampers and modulating.

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Supply for all auxiliaries of SG, Turbine and Generator is ensured.

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Readiness of HP bypass panel in all respects.

Ensure the oil unit is running and all the bypass and spray valves are closed. Ensure drum level is +200 mm, and the drum air vents are closed. Ensure drum level is normal.

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Start one of the CC pumps.

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Start the second CC pump.

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Start scanner air fan.

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Ensure that all the inlet Start both the secondary and outlet air gas air preheaters. dampers are open.

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Start both the primary air preheaters.

Ensure that the gas dampers are closed.

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Start one set of ID and FD fans.

Adjust 30% air flow, and furnace draft minus 5 to 10 mm WCL. After purge completion Boiler trip valves will get reset.

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Charge steam coil preheater concerned with the running FD fans.

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Initiate Boiler ‘Purge’ (duration 5 minutes).

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Also, after purge, adjust the wind box dampers to get 30-40 mm WCL. Wind box ‘dp’.

Lub oil system stopped.

Start one vapour extraction fan, keep other fan standby.

Check oil level in MOT.

Line up lub oil cooler and thrust bearing filter Start one AOP.

Put on SLCs for other AOP and EOP.

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Put lub oil temperature controller on.

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Start one JOP.

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Put off SLCs JOP 1, 2 & 3. Stop running JOP.

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Open gate valve gearing.

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Start one JOP and switch on SLCs for JOPs.

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Check out auto start of AOP and EOP. Put on SLCs for other JOP and DC-JOP. Check out auto start of JOP and DC-JOP. Switch on SLC gate valve gearing. -

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M/c. comes on barring.

MOT level – 50 mm oil temp. 450C JOP header pr. 140 kg/cm2 speed 80 – 100 rpm.

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The sequential operation narrated above on ‘Lub oil system stopped’ – is achieved by SGC – mode.

If the programme gets interrupted, the step and criteria to be checked and to be fulfilled for the programme to proceed further.

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M/c on barring.

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FRF system in stopped Check FRF tank level. condition.

Start centrifuge with both heaters

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Line up FRF cooler and duplex filters in 32-bar system start one CEP. Check auto start of standby CEP.

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Establish control fluid supply to various services.

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Start one VEF.

+200 mm.

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FRF tank level ‘O’ (normal). -

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Start one recirculation pump and include one Filter’s earth and ultra fine.

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Switch on FRF heater and keep SLC ON for FRF temperature 550C. temperature control, and control fluid pumps.

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Switch ON control fluid SGC.

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FRF system, SGC is on.

The sequential operation narrated above in FRF system stopped condition is achieved by SGC-FRF system on starting programme mode.

01

oo

Boiler ready for light up and Turbine on Turning gear.

Start 4 burners in ‘AB’ elevation with LSHS.

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SH & RH drains are open.

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MSV’s closed and drains before MSV open.

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Regulate oil pressure to 8-10 kg/cm2.

Ensure atomising steam pressure about 6 kg/cm2. Insert furnace probe and ensure that the temperature is below 5350C.

If the programme gets interrupted the step and criteria to be checked and fulfilled for the programme to proceed further. Check that SH & RH vents are open.

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After 30 minutes, take additional burners, so as to ensure a drum metal temperature raise of about 20C/min.

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Check drum level and give blow down.

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Keep open the Eco. recirculation valve when there is no feeding to drum.

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Start motor driven feed pump on recirculation.

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Charge the feed line upto feed control station.

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Charge heating steam to deaerator from Aux. PRDS.

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Check deaerator level.

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Start condensate pumps and feed to deaerator as Check hotwell level. and when required.

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Start hotwell make up pumps and feed hotwell as and when required.

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Aux. PRDS steam 15kg/cm2 (g) 2600C

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CW system is charged.

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CW boxes – to ensure ventilating of water boxes.

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Start one gland steam exhauster fan.

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Line up vacuum pumps and start one by one – Gradually admit gland steam when condenser vacuum reaches – 0.2kg/cm2(g).

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Vacuum building can be done through SGC – vacuum on starting programme mode, gland steam exhauster has to be started manually.

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Open all drains connected to flash tanks and flash boxes connected to condenser.

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Vacuum 09kg/cm2 (g).

Ensure gland steam admission temperature is always above 2000C.

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Open HPBP warm up valves.

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Switch on – SLC drains.

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02

60'

Close SH & RH header vents.

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Close SH & RH header drains.

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Open MSV by pass lines.

MS, HRH, & CRH lines will get warmed up.

03

100’

Switch on automatic control interface of LP bypass.

As soon as the fixed set point reaches 12 kg/cm2, it seizes.

Boiler pressure 2kg /cm2

Boiler pressure 5kg /cm2.

Automatic control interface gets switched off when the hot reheat steam pressure reaches 13kg/cm2 i.e. after synchronisation.

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Open Main steam valves.

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Open HP by pass.

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Start third C.C. pump when boiler pressure reaches 9 kg/cm2.

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Take additional guns in CD & EF elevation.

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Close HPBP warm up valves.

Air heater soot blowing to be carried out. -

A – ROLLING THROUGH HYDRAULIC GOVERNOR Boiler pressure:15 kg/cm2 04

150’

Temperature:1802000C

Open HPESVs & IPESVs for warming up by operating starting device to approximately 42%.

Check and ensure that speed set point is zero and speeder gear is 0% position.

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Ensure TSE influence is switched on and available margins are greater than = 300 K.

HRH Pressure:812Kg/cm2 -

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M. S. Pr. 50 kg/cm2 M.S. temp. 3500C

05

-300’

H. R. H. Pr. 12 kg/cm2

Raise the speed set point of EHC to 3200 rpm

If the oil system of EHC is isolated at speed Gov. rack, speed set point need not be raised.

Gradually raise the starting device to bring the speed to 360 rpm

Starting device position approximately 56%.

Hold the speed at 360 rpm for about 35 to 40 mts.

Ensure closure of gate valve gearing at 240 rpm. Monitor bearing vibrations, shaft vibrations, TSE margins, bearing temperature & Turbosupervisory readings at 360 rpm.

HRH temp. : 3500C -

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Turbine ready for Rolling.

06

-360’

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Raise the speed upto M. S. Pr. 50 2400 rpm through 2 0 kg/cm /350 C. Turbine starting device at the running at 360 rpm. rate of 600 rpm.

Ensure tripping of JOP at 540 rpm.

Raise further speed upto Starting device will be at 3000 rpm through 90%. speeder gear.

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Monitoring bearing temperature and vibrations, shaft vibrations, TSE margins and Turbovisory readings, Seal oil, Primary water and gas temperatures & Generator winding temperature.

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Ensure trippinf of AOP at 2950 rpm.

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Speeder gear position will be approximately at 50 to 60%.

MS Pr. 50 kg/cm2. Temperature: Put AVR on Auto. 3500C Turbine running at 3000 rpm.

07

370’

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Close field breaker.

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Set manually the generator voltage to grid voltage.

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Synchronise the generator with grid. -

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Pick up 50 MW load by operating speeder gear.

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Ensure closure of HPBP Increase HPBP set point. steam valves & spray valves.

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Drain pot drains of MS, CRH & HRH and Close other drains, M.S. extraction steam lines HRH, keeping SLC drains will operate as per the on. actuation of level switches.

B - ROLLING THROUGH EHC.

04

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150'

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MS Pr.: 15 kg/cm2. Temperature:1802000C HRH Pressure:8to12kg/cm2.

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Check and ensure that Open HPESVs & IPESVs TSE influences is for warming up by switched on and operating starting device available margins are to approximately 42%. 0 greater than 30 K. -

Check and ensure that speed set point is zero and speeder gear is 0% position.

MS Pressure: 50 kg/cm2 MS Temperature:3500C 05

300'

HRH Pressure: 12kg/cm2 HRH Temperature: 3500C.

Check and ensure opening of valves in Raise the starting device HP/IP secondary fluid to about 70%. lines to EHC at speed control rack.

Turbine Ready for rolling

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Raise the speed set point to 360 rpm and watch the actual speed.

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Raise the speeder gear to 100%

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Hold the speed at 360 rpm for about 35 to 40 mts.

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MS Pressure:50 kg/cm2 06

360' MS Temperature:3500C

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Turbine speed: 360 rpm.

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Raise the speed set point to 3000 rpm.

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If tracking device is switched ON, starting device position will automatically track the EHC position

Ensure closure of gate valve gearing at 240 rpm. Monitoring bearing vibrations, bearing temperatures, shaft vibrations, TSE margins and Turbovisory readings. Ensure tripping of jacking oil pump at 540 rpm. The rate of acceleration will be 600 to 850 rpm.

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Monitor bearing vibration and temperatures, shaft vibrations, Turbovisory readings and TSE margins

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Monitor and control, SEAL oil temperatures, Primary water temp. Hydrogen gas temperature and winding temperature.

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Ensure tripping of AOP at 2950 rpm.

MS Pressure: 50 kg/cm2 07

370'

MS Temperature: 3500C

Put AVR on auto, Close Field Breaker.

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Set manually generator voltage to grid voltage.

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Turbine speed: 3000 rpm. -

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Speed set point will raise automatically by 8 rpm and load will be picked upto 20MW.

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Synchronise the generator with grid.

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Raise the speed set point and pick up the load to 50 MW.

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Ensure closure of HPBP Increase HPBP set point. steam valves & spray valves.

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Drain pot drains of MS, CRH, HRH and extraction steam lines will operate as per the actuation of level switches.

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Close other drains of MS, CRH, HRH, keeping SLC drains 'ON'.

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C - ROLLING THROUGH SGC - TURBINE. MS Pressure: 15 kg/cm2 04

150'

0

MS Temp.:180-200 C HRH Pressure: 12

Switch on the start up programme of SGC – Turbine.

Ensure TSE influence is switched on.

kg/cm2

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If the programme interrupts the particular step and criteria to be checked and corrected for the programme to proceed further.

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All operations as explained under EHC rolling will be carried out by SHC – Turbine programme sequentially.

MS Pressure: 50 kg/cm2 MS Temperature: 3500C 05

300'

HRH Pressure: 12 kg/cm2

Turbine speed will be raised to 360 rpm through SGC – Programme.

Ensure closure of gate valve gearing at 240 rpm.

HRH Temp.: 3500C. Turbine Ready for rolling

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Monitor bearing vibration, bearing temperature, shaft vibration, TSE margins and Turbovisory readings.

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To achieve the programme as per the starting curve, the main steam temperature should be maintained steadily till loading upto 50 MW.

MS Pressure: 50 kg/cm2 06

360'

MS Temperature: 3500C

Turbine speed will be raised upto 3000rpm through SGCprogramme.

Ensure tripping of JOP at 540 rpm.

Turbine running at 360 rpm. -

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MS Pressure: 50 kg/cm2 07

370'

MS Temperature: 3500C Turbine speed:3000rpm.

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Ensure tripping of AOP at 2950 rpm.

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Monitor bearing temp and vibrations, shaft vibrations, TSE margins and turbovisory readings seal oil, primary water, Hydrogen gas and Generator winding temperatures.

SGC programme will switch ON field breaker, Ensure SGC – start up put AVR on auto, programme is synchronise and pick up completed. load upto 20 MW.

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Raise the speed set point and pick up the load upto 50 MW.

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Ensure closure of HPBP Increase HPBP set point. steam valves and spray valves.

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Drain pot drains of MS, Close other drains of CRH, HRH extraction M.S. CRH and HRH, steam lines will operate keeping SLC drains ‘ON’. as per the actuation of level switches.

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Load : 55 MW

08

390'

M.S. : 54kg/cm2/3500C HRH : 12 kg/cm2/3400C

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Before starting P.A. fan, Start seal air fan and PA ensure that air and gas fan and take first mill in dampers of Primary Air service. Preheaters are open.

Charge ESP fields

Ensure Ash handling system is ready.

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Start the second set of ID & FD fans.

Make ready SH & RH spray systems.

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Cut in L.P. heaters 2 & 3.

Ensure switching on of load controller above 60MW.

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Cut out heating steam from Aux. P.R.D.S. to Deaerator.

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Peg Deaerator from CRH steam gradually upto 2 kg/cm2.

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Cut in auto controllers.

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Load : 55 MW

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M.S. : 54kg/cm2/3500C HRH : 12 kg/cm2/3400C

Charge Aux. PRDS station from CRH. Cut in spray and maintain a temperature of 2500C.

Ensure energizing of solenoid in trimming device at and above 100 MW load.

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Raise the pressure set Peg Deaerator gradually point of Deaerator to 4 kg/cm2. pressure controller gradually.

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Cut in IInd mill and cut in auto controllers.

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Start withdrawing oil support gradually.

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Control main steam and reheat steam temperatures by using spray if required.

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Increase the wind box to furnace differential pressure to 100mm W.C. by adjusting SADC.

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Ensure fire ball scanner healthiness

Load : 160 MW M.S. : 90kg/cm2/3800C 10

440' HRH : 20 kg/cm2/3800C Steam flow : 580t/hr.

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Charge H.P. heaters 5A, 5B, 6A and 6B.

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Put controllers on auto.

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Start first TDBFP & second CEP.

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Charge Deareator Ensure Deareator pegging steam flow CRH Pressure controller to Extraction around 200 remains as auto. MW load.

Load : 250 MW M.S. : 120kg/cm2/4200C 11

480' HRH : 26 kg/cm2/3400C

Cut in IIIrd mill and cut in auto controllers.

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Steam flow : 820t/hr. -

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Start second P.A. Fan.

Before starting P.A. fan ensure that air and gas dampers of PAPHs are open.

Load : 320 MW M.S. : 125kg/cm2/3500C 12

510' HRH : 28-30 kg/cm2/3400C

Cut in IVth mill and cut in auto controllers.

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Steam flow : 1040t/hr. -

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Cut of oil support completely.

Ensure healthiness of fire ball scanners.

Load : 405 MW M.S. : 145kg/cm2/4600C 13

550'

HRH : 33 kg/cm2/4600C

Cut in Vth mill and cut in auto controllers.

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Cut in second TD BFP and switch off motor driven BFP.

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If full load is not reached cut in VIth mill along with its controllers. Increase the set point of SH & RH spray controllers such that rated parametes are

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Steam flow : 1310 t/hr. -

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Load : 500 MW

14

590'

M.S. : 170 kg/cm2/4750C HRH : 40.5 kg/cm2/4750C

achieved gradually. Load : 405 MW M.S. : 145kg/cm2/4600C 15

670'

HRH : 33 kg/cm2/4600C

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Steam flow : 1310 t/hr.

WARM AND HOT START UPS (With Aux. Steam Available). A warm start up is, by definition, one which the maximum of HP casing/HP shaft temperature is between 1500C and 3500C. This normally means that the unit is shut down from the maximum load for one to four days. Depending upon the absolute temperature of HP casing and HP shaft, steam parameters are derived. A hot start up is by definition one which the maximum of HP casing/shaft temperature is more than 3500C. In this case to get the rolling parameters two mills are taken into service keeping HP, LP by pass in operation. (Again the flow rate is restricted by the ‘Y’ pieces constraints i.e., ± 400C). In both the cases, curves are given to derive the rolling parameters. In case when machine is rolled through EAST, curve generators, calculate and give permissive for rolling.

INTEGRATED START-UP PROCEDURE WARM START UP (AFTER 48 HOURS SHUT DOWN). TIME IN MINUTES

UNIT CONDITION

OPERATION

NOTES.

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One CC pump in operation and scanner fan in operation.

Motor operated BFP is run as and when required to maintain the drum level.

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Both SAPHs and PAPHs in operation.

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STEP

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Turbine on bearing gear with AOP, JOP and seal oil pumps in operation.

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Control fluid system ready in all respects. One circulating pump in operation with one earth filter and ultra fine filter in circuit.

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Generator gas system, seal oil system and primary water system in operation.

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Bearing cooling water system in operation.

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HT and LT auxiliaries power supply available.

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HP bypass system ready in all respects.

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ESP ready in all respects.

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EAST panels ready in all respects.

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Furnace bottom ash system and seal trough lined up.

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Vacuum pumps lined up and ready for operation.

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Gland steam and leak steam controllers are lined up and ready for operation.

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Generator protection panel and exciter panels ready in all respects.

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Boiler drum pressure = 0 kg/cm2. SH temperature between 1300C and 1500C.

1. Charge auxiliary steam header from existing units. Pr. 16ata temp. 2600C.

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2. Charge steam to fuel oil pump house, atomising steam and tracing steam.

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3. Start tank heating of LSHS oil.

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4. Start one LSHS pump on recirculation as soon as sufficient oil temp. at inlet is achieved.

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Start instrument oil compressor and service air compressors and check that all lines to boiler and TG are charged.

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Charge LSHS pump to boiler front and keep it on long recirculation with heaters control set on auto to maintain 1200C.

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Start circulating water pump for condenser and deaerate the condenser water boxes.

Ensure running of motor driven BFP continuously for maintaining drum level.

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Start second CC Pump.

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Start one set of ID and FD fans.

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Initiate boiler purge.

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Start one CEP and keep the hot well make up in service.

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Start one of the control fluid pumps and keep the second as auto standby.

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Keep the control fluid temperature control on auto.

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Line up main steam, CRH and HRH steam lines for charging by opening respective line drains.

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Line up FSSS panels in all respects

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01

oo

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SH & RH drains are open.

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MSV’s closed and drains before MSV open.

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Ensure atomising steam pressure of about 6 kg/cm2

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Ensure motor operated BFP is in service.

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-

-

Start Gland steam Exhauster.

-

-

-

-

Start one by one vacuum pumps.

-

-

-

-

Admit gland steam Ensure gland steam when vacuum reaches – admission temperature 0.2 kg/cm2. is always above 2000C.

-

Vacuum building can be done through SGC vacuum on starting programme mode. Gland steam exhauster has to be started manually.

-

-

-

Charge heating steam line to Deaerator from Aux. PRDS.

-

Boiler ready for light up and turbine on turning gear.

Start 4 burners in ‘AB’ elevation with LSHS.

Check that SH & RH vents are open.

-

-

-

-

Open all drains connected to flash tanks Ensure condenser and flash boxes vacuum of – 0.8 connected to kg/cm2. condenser.

-

-

-

Switch on ‘SLC’ drains.

-

-

-

-

Close SH & RH header vents and drains.

Ensure boiler pressure is 2kg/cm2.

-

-

-

Open HPBP warming up valves.

-

-

-

-

Open MSV bypass lines.

-

-

-

-

Switch Automatic control interface of LP bypass.

As soon as the fixed set point reaches 12kg/cm2, it seizes.

-

Automatic control interface gets switched off when the hot reheat steam pressure reaches 13kg/cm2(i.e.) after synchronisation.

-

-

-

-

-

-

Open Main steam stop valves.

-

-

-

Open HP bypass and Ensure Boiler pressure close the HPBP warm up is 5kg/cm2. valves.

-

-

-

Start third CC pump.

Ensure MS, CRH & HRH lines get warmed up.

Ensure Boiler pressure is 9kg/cm2.

-

-

-

Put HP bypass controller on auto and vary the Ensure Boiler pressure set point according to is 10kg/cm2 the gradient of pipeline temperatures.

-

-

-

Put HP bypass spray control on auto.

-

-

-

-

Take additional guns according to the requirement.

Air heater soot blowing to be carried out.

A – ROLLING THROUGH HYDRAULIC GOVERNOR. MS: 50 kg/cm2/3650C 02

-

180'

-

Open HPESV and IPESV HRH: 12 kg/cm2/3250C for warming up by operating starting device to approx. 42% By pass steam flow: 170t/hr.

-

-

MS: 60 kg/cm2/4000C Raise the speed set HRH: 12 kg/cm2/3500C point of EHC to 3200 rpm. By pass steam flow: 200t/hr.

Check and ensure that speed set point is zero and speeder gear is 0%. Ensure TSE influence is switched on and available margins are 0 greater than  30 K. If the oil system of EHC is isolated at speed Gov. rack, speed set point need not be raised.

03

210'

-

-

-

Gradually rise the starting device to bring the speed to 360 rpm.

Starting device position approximately 56%.

-

-

-

Hold the speed at 360 rpm for about 5 minutes.

Ensure closure of gate valve gearing at 240 rpm.

-

-

04

215'

-

-

-

-

Raise the speed upto Turbine running at 360 2400 rpm through rpm. starting device at the rate of 600 rpm. -

Monitor bearing vibrations, shaft vibrations, TDE margins, bearing temp. & Turbovisory readings at 360rpm. Ensure tripping of JOP at 540 rpm.

Raise further speed Starting device will be upto 3000 rpm through at 90%. speeder gear.

-

-

-

-

Monitor bearing temp & vibrations, shaft vibrations, TSE margins and Turbovisory readings. Seal oil, Primary water and gas temperatures & Generator winding temperature.

-

-

-

-

Ensure tripping of AOP at 2950 rpm.

-

-

-

-

Speeder gear position will be approx. at 50 to 60 %.

05

220'

-

-

-

-

Turbine running at 3000 rpm

Put AVR on auto.

-

-

Close field breaker.

-

-

Set manually the generator voltage to grid voltage.

-

-

-

-

-

Synchronise the generator with grid. Pick up 50 MW load by operating speeder gear.

-

-

-

Increase HPBP set point.

-

Drain pot drains of MS, CRH, and HRH and Close other drains, M.S. extraction steam lines HRH, keeping SLC will operate as per the drains on. actuation of level switches.

-

-

Ensure closure of HPBP steam valves & spray valves.

-

-

-

-

Further load raising will be done by operating the speeder gear according to the start up curve.

B – ROLLING THROUGH EHC MS: 50 kg/cm2/3650C 02

-

180'

-

Open HPESVs and HRH: 12 kg/cm2/3250C IPESVs for warming up by operating starting device to approx. 42%. By pass steam flow: 170t/hr. -

-

Check and ensure that TSE influence is switched on and available margins are 0 greater than 30 K. Check and ensure that speed set point is zero and speeder gear is 0%.

MS: 60 kg/cm2/4000C HRH: 12 kg/cm2/3500C 03

210'

By pass steam flow: 200t/hr.

Raise the starting device to about 70%.

Check and ensure opening of valves in HP/IP secondary fluid lines to EHC at speed control rack.

Turbine ready for rolling.

-

-

-

If tracking device is Raise the speed set switched on starting point to 360 rpm and device position will watch the actual speed. automatically track the EHC position

-

-

-

Raise the speeder gear to 100%.

Ensure closure of gate valve gearing at 240 rpm.

Hold the speed at 360 rpm for about 5 minutes.

Monitor bearing vibrations bearing temperatures, shaft vibrations, TSE margins & turbovisory readings.

Raise the speed set point to 3000 rpm.

Ensure tripping of Jacking oil pump at 340 rpm.

-

-

04

215'

-

-

-

Turbine running at 360rpm.

-

-

Monitor bearing vibrations and temps, shaft vibration, turbovisory readings and TSE margins.

-

-

05

225'

-

-

Turbine speed: 3000 rpm.

-

Ensure tripping of AOP at 2950 rpm.

Put AVR on auto close Field breaker.

-

-

Set manually generator voltage to grid voltage.

Speed set point will be raise automatically by about 8 rpm & load will be picked upto 20 MW.

-

-

-

Synchronise the generator with grid.

-

-

-

Raise the speed set point and pick up the load to 50 MW.

-

-

-

Increase HPBP set points.

Ensure closure of HPBP steam valves and spray valves.

-

Close other drains of MS, CRH, and HRH keeping SLC drains ‘ON’.

Drain pot drains of MS, CRH, HRH and extraction steam lines will operate as per the actuation of level switches.

-

-

-

C – ROLLING THROUGH SGC – TURBINE. MS: 50 kg/cm2/3650C 02

180'

HRH: 12 kg/cm2/3250C By pass steam flow: 170t/hr.

-

-

-

-

-

-

Switch on the start up programme of SGC – Turbine.

Ensure TSE influence is switched on.

-

If the programme interrupts the particular step and criteria to be checked and corrected for the programme to proceed further.

-

All operations as explained under EHC rolling will be carried out by SGC – Turbine programme sequentially.

MS: 50 kg/cm2/3650C HRH: 12 kg/cm2/3250C

03

210'

By pass steam flow: 170t/hr. Turbine ready for rolling.

-

-

-

-

-

-

Turbine speed will be raised to 360 rpm through SGCProgramme.

Ensure closure of gate valve gearing at 240 rpm.

-

Monitor bearing vibration, bearing temp, shaft vibration, TSE margins and Turbovisory readings.

-

To achieve the programme as per the starting curve, the main steam temperature should be maintained steadily till loading upto 50 MW.

MS: 60 kg/cm2/4000C 04

-

215'

-

Turbine speed will be Turbine running at 360 raised upto 3000 rpm rpm. through SGC Programme.

-

MS: 60 kg/cm2/4000C 05

225'

-

-

Turbine speed: 3000 rpm.

-

-

Ensure tripping of JOP at 540 rpm. – Ensure tripping of A.O.P. at 2950 rpm. Monitor bearing temp & vibrations, shaft vibrations, TSE margin and turbovisory readings, seal oil, primary water, Hydrogen gas and Generator winding temperatures.

SGC programme will switch ON field breaker, Ensure SGC – Start up put AVR on auto, programme is synchronise and pick up completed. load upto 20 MW. Raise the speed set point and pick up load upto 50 MW.

-

-

-

-

-

-

Ensure closure of HPBP Increase HPBP set point steam valves and spray valves.

-

Close other drains of M.S., CRH and HRH, keeping SLC drains ‘ON’.

Drain pot drains of M.S., CRH, HRH and Extraction steam lines will operate as per the actuator of level switches.

Cut in L.P. heaters 2 and 3.

Ensure switching on of load controller at 60 MW.

Load: 60 MW 06

230'

MS: 60 kg/cm2/4100C HRH: 14 kg/cm2/3600C

-

-

-

Cut out heating steam from Aux. PRDS to Deaerator.

-

-

-

-

Peg Deaerator from CRH steam gradually upto 2 kg/cm2.

-

-

-

-

Cut in all auto controllers.

-

-

-

-

Start seal air fan and P.A. fan

-

-

-

Cut in further oil guns for raising parameters.

Before starting P.A. fan, ensure that air and gas dampers of Primary Air Preheaters are open. -

Load: 110 MW MS: 80 kg/cm2/4200C HRH: 19 kg/cm2/3800C 07

Cut in 1st coal mill and cut in Auto controllers.

Make ready SH & RH spray system.

-

Charge ESP Fields.

Ensure Ash handling system is ready.

-

Charge Aux. PRDS station from CRH. Cut in spray and maintain a temperature of 2500C.

245' Main steam flow: 470t/hr. Trimming device is in ‘OFF’.

-

-

-

-

-

-

-

-

Raise the pressure set Peg Deaerator gradually point of Deaerator upto 4 kg/cm2. pressure controller gradually

-

-

-

Cut in H.P. heaters and put the level controls on auto.

-

-

-

-

Start first TD BFP and second CEP around a load of 170 MW.

-

-

Increase the windbox to furnace diff. pressure to 100mm. W.C. by adjusting SADC.

-

-

-

Load: 200 MW MS: 100 kg/cm2/4350C 08

270'

Cut in IInd mill and cut HRH: 19 kg/cm2/4000C in auto controllers.

-

Main steam flow: 750t/hr. -

-

-

-

-

Start withdrawing oil support gradually.

-

Control main steam and reheat steam temperature by using spray if required.

-

-

-

Change Deaerator pegging steam from CRH to Extraction steam.

-

-

-

Cut in IIIrd mill and cut in auto controllers.

-

-

-

Start second P.A. fan.

Ensure healthiness of fire ball scanners. -

Ensure Deaerator pressure controller remains on auto. Before starting P.A. fan ensure that air and gas dampers of PAPH are open.

Load: 320 MW MS: 125 kg/cm2/4500C 09

300'

Cut in IVth mill and cut HRH: 30 kg/cm2/4300C in auto controllers. Main steam flow: 1080t/hr.

-

-

-

-

Cut off oil support completely.

Ensure healthiness of fire ball scanners.

-

-

-

Cut in Vth coal mill and cut in auto controllers.

-

-

-

-

Start second TDBFP and switch off motor driven BFP.

-

-

-

-

Cut in VIth coal mill and cut in auto controllers.

-

Check all parameters at full load and ensure them within limits.

-

Increase the set point of SH & RH spray controllers such that rated parameters are achieved.

-

Load: 500 MW MS: 170 kg/cm2/4800C 10

340'

HRH: 40.5 kg/cm2/4800C Main steam flow: 1620t/hr.

-

-

-

Load: 500 MW MS: 170 kg/cm2/5350C 11

420'

HRH: 40.5 kg/cm2/5350C

-

-

Main steam flow: 1570t/hr.

INTEGRATED START UP PROCEDURE HOT START UP (AFTER 8 HOURS SHUT DOWN)

STEP

TIME IN MINUTES.

UNIT CONDITION

OPERATION

NOTES.

-

-

Two CC pumps in operation and scanner fan in operation.

Motor operated BFP is run as and when required to maintain the drum level. If necessary BFP should be kept running continuously.

-

-

Both SAPHs and PAPHs in operation.

-

-

-

Turbine on barring gear with AOP, JOP and seal oil pumps in operation.

-

-

-

Control fluid pump in operation. One circulating pump in operation with one earth filter and ultra fine filter in circuit.

-

-

-

-

Generator gas system, seal oil system and primary water system in operation.

-

-

-

-

Bearing cooling water system in operation.

-

-

-

-

Condenser circulating water system in operation.

-

-

-

Service air and instrument air compressors in operation.

-

-

-

-

One condensate pump in operation and hot well make up in service.

-

-

-

-

Aux. steam header charged from existing units (16ata 2600C).

-

-

-

-

LSHS pump in operation on long recirculation upto boiler front with heaters control set on

-

-

-

-

HP bypass system ready in all respects.

-

-

-

-

LP & HP and chemical dosing system ready.

-

-

-

-

-

-

-

-

ESP panels ready in all respects.

-

-

-

-

EAST panels ready in all respects.

-

-

-

-

Furnace bottom ash system and seal trough lined up.

-

-

-

-

Vacuum pumps lined up and ready for operation.

-

-

-

Gland steam and leak steam controllers are lined up and ready for operation.

-

-

-

-

Generator protection panel and exciter panels ready in all respects.

-

-

-

-

FSSS panel ready in all respects.

-

-

-

-

Boiler drum Pr. 75 kg/cm2 SH. Temp. between 4150C and 4300C.

-

-

-

Start one gland steam exhauster.

-

-

-

-

Start one by one vacuum pumps.

-

-

-

-

Admit gland steam Ensure gland steam when vacuum reaches – admission temperature 0.2 kg/cm2. is always above 2000C.

-

Vacuum building can be done through SGC vacuum on starting programme mode. Gland steam exhauster has to be started manually.

-

-

-

Line up main steam, CRH and HRH steam lines for charging by opening respective line drains.

Ensure MSV is closed.

-

-

-

-

Open all drains connected to flash tanks Ensure condenser and flash boxes vacuum of 0.8 kg/cm2. connected to condenser.

-

-

-

Ensure condenser vacuum of 0.8 kg/cm2.

-

-

-

-

Open HPBP warming up valves.

-

Switch Automatic control interface of LP bypass.

-

-

-

-

-

-

-

Start third CC pump.

As soon as the fixed set point reaches 12 kg/cm2, it seizes. Automatic control interface gets switched off when the hot reheat steam pressure reaches 13 kg/cm2(i.e.) after synchronisation. Ensure differential temp. is within permissible limits. Ensure running of motor driven BFP continuously for maintaining drum level.

-

-

-

-

-

-

-

Start both ID & FD fans

-

-

-

-

Initiate boiler purge.

-

-

-

-

Charge heating steam line to Deaerator from Aux. PRDS.

-

01

oo

Boiler ready for light up and turbine on turning gear.

Start 4 burners in ‘AB’ elevation with LSHS.

Ensure atomising steam pressure of about 6kg/cm2.

Drum Pr. 75 kg/cm2 SH. Temp. 4150C and 4300C.

-

Ensure motor operated BFP is in service.

-

-

-

Open drains before MSV.

-

-

-

-

Open MSV by pass lines.

-

-

-

-

Open Main steam stop valves.

-

-

-

Open HP bypass and close the HPBP warm up valves.

-

-

Put HP bypass controllers on auto and vary the set point according to the gradient of pipeline

-

-

-

Ensure MS, CRH, HRH lines got warmed up.

temperatures.

-

-

-

Put HP bypass spray control on auto.

-

-

Take additional guns according to the requirement.

Air heater soot blowing to be carried out.

-

-

-

Before starting P.A. Fans ensure that air Start both P.A. fans and and gas dampers of seal air fans. Primary air preheaters are open.

-

-

-

Line up milling system for starting.

-

A – ROLLING THROUGH HYDRAULIC GOVERNOR MS: 85 kg/cm2/4850C 02

40'

-

-

HRH: 12 kg/cm2/4400C Cut in first coal mill & cut in auto controllers. Bypass steam flow: 280t/hr.

Make ready SH and RH spray system.

Ensure Ash handling system is ready.

-

Charge ESP fields.

-

-

-

-

Increase the windbox to furnace diff. Pressure to 100mm W.C. by adjusting S.A.D.C.

-

-

-

Cut in second mill and cut in auto controllers.

-

-

-

-

Peg the deaerator from CRH gradually upto 2 kg/cm2.

-

-

Open HPESVs and IPESVs for warming up by operating starting device to approximately 42%.

Check and ensure that speed set point is zero and speeder gear is at 0%.

-

Ensure TSE influence is switched on and available margins are 0 greater than  30 K.

-

-

-

-

-

MS Pressure: 85 kg/cm2 MS Temperature: 5000C HRH Pressure: 12 kg/cm2 03

50' HRH Temperature: 4500C.

Raise the speed set point of EHC to 3200 rpm.

If the oil of EHC is isolated at speed Gov. rack, speed set point need not be raised.

Gradually raise the starting device to bring the speed to 360 rpm

Starting device position approximately 56%.

Bypass steam flow: 360t/hr. Turbine Ready for rolling -

-

-

-

-

04

-

-

-

Turbine running at 360rpm.

52'

-

-

-

-

-

Ensure closure of gate valve gearing at 240 rpm.

-

Monitoring bearing vibrations, shaft vibrations, TSE margins, bearing temp & Turbovisory readings at 360 rpm.

Raise speed upto 2400 rpm through starting device at the rate of 600 rpm.

Ensure tripping of JOP at 540 rpm.

Raise further speed upto 300 rpm through speeder gear.

Starting device will be at 90%.

-

-

-

-

Monitor bearing temp and vibrations, shaft vibrations, TSE margins and turbovisory readings. Seal oil Primary water and gas temperatures and Generator winding temperature.

-

-

-

-

Ensure tripping of AOP at 2950 rpm.

-

-

05

56'

-

-

-

-

Turbine running at 3000rpm

-

Speeder gear position will be approximately at 50 to 60%.

Put AVR on auto.

-

-

Close field breaker.

-

-

Set manually the generator voltage to grid voltage.

-

-

-

-

-

Synchronise the Generator with grid. Pick up 50 MW load by operating speeder gear.

-

-

-

Increase HPBP set point.

-

Drain pot drains of MS, CRH, and HRH and Close other drains, M.S. extraction steam lines CRH, HRH, keeping SLC will operate as per the drains on. actuation of level switches.

-

Further load raising will be done by operating the speeder gear according to the start up curve.

-

-

-

-

-

Ensure closure of HPBP steam valves & spray valves.

B – ROLLING THROUGH EHC MS Pressure: 85 kg/cm2 MS Temperature: 4850C 02

40'

HRH Pressure: 12 kg/cm2

Cut in first coal mill & cut in auto controllers.

Make ready SH & RH spray systems.

Charge ESP fields.

Ensure Ash handling system is ready.

HRH Temperature: 4400C. Bypass steam flow: 280t/hr. -

-

-

-

-

-

Increase the windbox to furnace diff. Pressure to 100mm W.C. by adjusting S.A.D.C.

-

-

-

Cut in second mill and cut in auto controllers.

-

-

-

-

Peg the deareator from CRH gradually upto 2 kg/cm2.

-

-

Open HPESVs and IPESVs for warming up by operating starting device to approximately 42%.

Check and ensure that speed set point is zero and speeder gear is at 0%.

-

Ensure TSE influence is switched on and available margins are 0 greater than  30 K.

-

-

-

-

-

-

MS Pressure: 85 kg/cm2 MS Temperature: 5000C

03

50'

HRH Pressure: 12 kg/cm2

Raise the starting device to about 70%.

HRH Temperature: 4500C.

Check and ensure opening of valves in HP/IP secondary fluid lines to EHC at speed control rack.

Turbine Ready for rolling. Bypass steam flow: 360t/hr.

-

-

-

If tracking device is Raise the speed set switched on starting point to 360 rpm and device position will watch the actual speed. automatically track the EHC position.

-

-

-

Raise the speeder gear to 100%.

Ensure closure of gate valve gearing at 240 rpm.

Hold the speed at 360 rpm for about 5 minutes.

Monitor bearing vibrations, bearing temperatures, shaft vibrations, TSE margins and turbovisory readings.

-

-

-

04

52'

-

-

-

-

Turbine reading at 360 Raise the speed set rpm. point to 300 rpm. -

-

Ensure tripping of Jacking oil pump at 540 rpm.

-

The rate of acceleration will be 600 to 800 rpm2.

-

Monitor bearing vibrations and temperatures, shaft vibration, turbovisory readings and TSE margins.

-

-

-

-

Monitor and control, seal oil temperatures, primary water temperature. Hydrogen gas temperature and winding temperature.

-

-

-

-

Ensure tripping of AOP at 2950 rpm.

05

56'

-

-

Turbine speed: 3000 rpm. -

Put AVR on auto Close field breaker.

-

Set Manually generator voltage to grid voltage.

-

-

-

-

Synchronise the generator with grid.

Speed set point will be raised automatically by about 8 rpm and load will be picked upto 20 MW.

-

-

-

Synchronise the generator with grid.

-

-

Increase HPBP set point.

Ensure closure of HPBP steam valves and spray valves.

-

Close other drains of MS. CRH and HRH, keeping SLC drains ‘ON’.

Drain pot drains of MS, CRH, HRH and extraction steam lines will operate as per the actuation of level switches.

-

-

-

-

C – ROLLING THROUGH SGC TURBINE. MS: 85 kg/cm2/4850C 02

40'

HRH: 12kg/cm2. Bypass steam flow: 280t/hr.

Cut in first coal mill & cut in auto controllers.

Make ready SH & RH spray systems.

-

-

Ensure Ash handling system is ready.

-

Charge ESP fields.

-

-

-

-

Increase the windbox to furnace diff. Pressure to 100mm W.C. by adjusting S.A.D.C.

-

-

-

Cut in second mill and cut in auto controllers.

-

-

-

-

Peg the deaerator from CRH gradually upto 2 kg/cm2.

-

-

-

-

Switch on the start up programme of SGCTurbine.

Ensure TSE influence is switched ‘ON’.

-

-

-

-

-

-

-

If the programme interrupts, the particular step and criteria to be checked and corrected for the programme to proceed further.

-

All operations as explained under EHC rolling will be carried out by SGC-Turbine programme sequentially.

Turbine ready for rolling. Turbine speed will be raised to 360 rpm through SGCHRH: 12kg/cm2/4500C programme. MS: 85 kg/cm2/5000C 03

50'

Ensure closure of gate valve gearing at 240 rpm.

Bypass steam flow: 360t/hr.

-

-

-

-

-

-

-

Monitor bearing vibration, bearing temperature, shaft vibration, TSE margins and Turbovisory readings.

-

To achieve the programme as per the start up curve, the main steam temperature should be maintained steadily till

loading of 50 MW.

04

52'

-

-

-

-

Turbine speed will be Turbine reading at 360 raised upto 3000 rpm rpm. through SGCprogramme. -

-

Ensure tripping of JOP at 540 rpm.

-

Ensure tripping of AOP at 2950 rpm.

-

Monitor bearing temperature and vibrations, shaft vibrations, TSE margins, Turbovisory readings, seal oil, primary water, Hydrogen gas and Generator winding temperatures.

Turbine speed: 3000 rpm. SGC Programme will switch ON field breaker, Ensure SGC-start up put AVR on auto programme is HRH: 12kg/cm2/4500C synchronise and pick up completed. load upto 20 MW. Bypass steam flow: 360t/hr. MS: 85 kg/cm2/5000C 05

56'

-

-

-

Raise the speed set point and pick up load upto 50 MW.

-

-

-

Increase HPBP set point.

Ensure closure of HPBP steam valves & spray valves.

-

Close other drains of M.S, CRH and HRH, keeping SLC drains ‘ON’.

Drain pot drains of MS, CRH, HRH and Extraction steam lines will operate as per the actuation of level switches.

Cut in L.P. heaters 2 and 3.

Ensure switching on of load controller at 60 MW.

-

-

-

LOAD: 60 MW. 06

60'

MS: 85 kg/cm2/5000C HRH: 16kg/cm2/4700C

-

-

-

Cut out heating steam from Aux. PRDS to Deaerator.

-

-

-

Raise the generator pressure from 2kg/cm2 to 4kg/cm2.

-

-

-

Cut in auto controller.

-

-

-

Start withdrawing oil support gradually.

Raise the pressure set point of Deaerator pressure controller. Ensure healthiness of fire ball scanners.

LOAD: 150 MW. MS: 100 kg/cm2/5000C HRH: 20kg/cm2/4800C 07

65' Main steam flow: 1620t/hr.

Charge Aux. PRDS station from CRH. Cut in spray and maintain a temperature of 2500C.

-

Trimming device is in ‘OFF’. -

-

-

Cut in H.P. heaters and put the level controls on auto.

-

-

-

-

Start first TD BFP and second CEP around a load of 170 MW.

-

-

Control main steam and reheat steam temperature by using spray if required.

-

-

-

-

-

-

Change deaerator pegging steam from CRH to Extraction steam.

-

-

-

Cut in IIIrd mill and cut in auto controllers.

-

Cut in IVth mill and cut HRH: 20kg/cm2/4950C in auto controllers.

-

Ensure Deaeator pressure controller remains on auto.

LOAD: 230 MW. MS: 120 kg/cm2/5000C 08

70'

Main steam flow: 820t/hr. -

-

-

Cut off oil support completely.

Ensure healthiness of fire ball scanners.

-

-

-

Cut in Vth coal mill and cut in auto controllers.

-

-

-

-

Start second TD BFP and switch off motor driven BFP.

-

-

-

-

Cut in VIth coal mill and cut in auto controllers.

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Check all parameters at full load and ensure them within limits.

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Increase the set point of SH & RH spray controllers such that rated parameters are achieved.

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LOAD: 500 MW. MS: 170 kg/cm2/5000C 09

86'

HRH: 40.5kg/cm2/5000C Main steam flow: 1620t/hr.

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LOAD: 500 MW. MS: 170 kg/cm2/5000C 10

135'

HRH: 40.5 kg/cm2/4800C

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Main steam flow: 1570 t/hr.

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