500mw starting procedures

8/10/2019 500MW Starting Procedures

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CONTENTS

SL.NO. DESCRIPTION01. COLD START - UP

02. INTEGRATED START UP PROCEDURE COLD START UP

03. HOT AND WARM START UPS.

04. INTEGRATED START UP PROCEDURE WARM START UP

05. INTEGRATED START UP PROCEDURE HOT START UP.

06.

START UP BY CURVES FOR ABSOLUTE COLD START WITH HP/LP BYPASSSYSTEM.

07. START UP CURVES AFTER 48 HOURS SHAT DOWN WITH HP/LP BYPASSSYSTEM.

08. START UP PROCEDURE AFTER 8 HOURS SHUT DOWN WITH HP/LP BYPASSSYSTEM.

09. TECHNICAL DATA LIMIT CURVES FOR TURBINE VALVES WALL OF THE

CASING SHAFTS.

10. WARMING UP AND STARTING THE TURBINE TEMPERATURE CRITERIA.

11. TECHNICAL DATA REACTIVE CAPACITY CURVE FOR TURBO GENERATORS.

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 isless 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 soakingthe machine at 360 rpm at warming up steam parameters (40kg/cm2, 3600 C), till theTSE margin are satisfactory.

The rifle construction of the water wall combined with the boiler circulating waterpumps permits very high rate of pressure rising of boiler. An upper limit of 2000C/hrsaturation temperature gradient can be allowed, i.e. approximately the boiler pressurecan be brought to 20 kg/cm2within an hour of cold start up. But actual temperaturegradient 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/cm2) asmaximum 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 thirdpump should be started before drum pressure reaches 7 kg/cm2to minimise the
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temperature transients experienced by the pump casing (this is to avoid fast load outback on the boiler in the event of any CC pump tripping).

To get the rolling parameters, normally two elevation oil guns are taken withapprox. 70 to 80t/hr flow through HP-LP bypass. At that time M.S. parameters would be40 kg/cm2and 3600C, HRH parameters would be 12 kg/cm2and 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 at40% of generator load. Fourth and fifth mills are put into operation at 60% and 80% ofgenerator 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 possibleto SH outlet steam temperature Burner tilt, SH spray, RH spray controls has to beadjusted accordingly. The turbine-loading rate is decided by a selection circuit which

compares the external load gradient, TSE margin and time dependant gradient (setinternally) and frequency influence.

INTEGRATED START-UP PROCEDURE

COLD START-UP

(AUXILIARY STEAM AVAILABLE)

REF. DRG NO. 20 BPE691

STEP TIME UNIT CONDITION OPERATION NOTES

0 ..Boiler pr. 0 kg/cm2(g)and Ambienttemperature

Charge Aux. Steamheader 16 ata, 2600C,from existing units.

-

- - -

Charge steam to fueloil pump house,

atomising steam andtracing steamdeaerator warming up.

All the steam tracinglines and electricaltracings in pump house

& boiler to be charged.

- - -Start tank heating ofLSHS oil.

-

- - -

Start one LSHS pumpon recirculation as soonas the sufficient oiltemperature at inlet is

achieved.

-

- - -

Charge LSHS to boilerfront and keep it onlong recirculation, with

heaters control set onAuto to maintain 110-1290C.

-

- - -Fill water in drum upto+200mm.

Ensure that the suctionand discharge valves of

all the CC pumps areopen and the pumpsuction and discharge

lines are vented.


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- - -

Start Bearing coolingwater system pumps

for Boiler, Turbine andTG auxiliaries .

Check all circuits have

sufficient flow. Beforestarting the pumps, theemergency coolingwater tank level to be

checked and madenormal.

- - -

Start instrument aircompressor and checkthat all the lines toBoiler and TG arecharged.

Check that all circuitshave sufficient airpressure.

- - -

Start service aircompressor and fill theair receiver tanks ofSRAPH & PRAPH are

filled.

-

- - -

Ensure that purge air to

HEA is open in allcorners.

-

- - -Line up Air and flue gas

circuits for startup.

Check dampers and

gates register position.

- - -ESP ready in allrespects.

-

- - -Furnace bottom ashsystem and sealthrough lined up.

-

- - - FSSS panel ready in allrespects.

-

- - -EAST panel ready in all

respects.-

- - -Excitation panel readyin all respects.

-

- - -

Generator protection

panel ready in allrespects.

-

- - -Generator H2gas

pressure is 4 kg/cm2

Check purity of H2gas

is normal.

- - -Generator stator watersystem ready in allrespects.

Check purity ofgenerator stator wateris normal.

- - -H2cooling watersystem ready in allrespects with SLC on.

-

- - -LP & HP chemicaldozing system is ready.

Check for level in

Hydrazine, Ammoniaand phosphatepreparation tanks.


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- - - SADC panel readiness.

Check for air pressure

in all the corners andelevations.

- - -Power supply for all thevalves and dampers are

ON.

Ensure Aux. airdampers and

modulating.

- - -

Supply for allauxiliaries of SG,Turbine and Generatoris ensured.

-

- - -Readiness of HP bypasspanel in all respects.

Ensure the oil unit isrunning and all thebypass and sprayvalves are closed.

- - -Start one of the CC

pumps.

Ensure drum level is+200 mm, and the

drum air vents areclosed.

- - -Start the second CCpump.

Ensure drum level isnormal.

- - - Start scanner air fan. -

- - -

Start both thesecondary air

preheaters.

Ensure that all the inletand outlet air gas

dampers are open.

- - -Start both the primaryair preheaters.

Ensure that the gasdampers are closed.

- - -Start one set of ID andFD fans.

Adjust 30% air flow,and furnace draftminus 5 to 10 mmWCL.

- - -

Charge steam coilpreheater concerned

with the running FDfans.

-

- - -Initiate Boiler Purge

(duration 5 minutes).

After purge completionBoiler trip valves willget reset.

- - - -

Also, after purge,adjust the wind boxdampers to get 30-40mm WCL. Wind box

dp.

- -Lub oil system

stopped.

Start one vapourextraction fan, keepother fan standby.

Check oil level in MOT.

- - -Line up lub oil coolerand thrust bearing filterStart one AOP.

Put on SLCs for otherAOP and EOP.

- - - - Check out auto start ofAOP and EOP.


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- -- -Put lub oil temperaturecontroller on.

-

- - - Start one JOP.Put on SLCs for otherJOP and DC-JOP.

- -- - - Check out auto start ofJOP and DC-JOP.

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

-

- - -Open gate valve

gearing.

Switch on SLC gate

valve gearing.

- - -

Start one JOP and

switch on SLCs forJOPs.

-

- - - M/c. comes on barring.

MOT level 50 mm oil

temp. 45

0

C JOP headerpr. 140 kg/cm2speed

80 100 rpm.

- - -

The sequentialoperation narratedabove on Lub oil

system stopped isachieved by SGC mode.

If the programme gets

interrupted, the stepand criteria to bechecked and to befulfilled for the

programme to proceedfurther.

- - M/c on barring.Start centrifuge withboth heaters

-

- -FRF system in stoppedcondition.

Check FRF tank level. +200 mm.

- - -

Line up FRF cooler andduplex filters in 32-barsystem start one CEP.Check auto start ofstandby CEP.

-

- - -

Establish control fluidsupply to variousservices.

FRF tank level O

(normal).

- - - Start one VEF. -

- - -

Start one recirculation

pump and include oneFilters earth and ultrafine.

-

- - -

Switch on FRF heaterand keep SLC ON fortemperature control,

and control fluidpumps.

FRF temperature 550C.

- - -Switch ON control fluidSGC.

-


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- -FRF system, SGC is

on.

The sequential

operation narratedabove in FRF systemstopped condition isachieved by SGC-FRF

system on startingprogramme mode.

If the programme getsinterrupted the stepand criteria to be

checked and fulfilled forthe programme to

proceed further.

01 ooBoiler ready for lightup and Turbine onTurning gear.

Start 4 burners in ABelevation with LSHS.

Check that SH & RHvents are open.

- - - -SH & RH drains areopen.

- - - -

MSVs closed anddrains before MSV

open.

- - -

Regulate oil pressure to

8-10 kg/cm2.

Ensure atomising

steam pressure about 6kg/cm2.

- - -

After 30 minutes, takeadditional burners, soas to ensure a drum

metal temperatureraise of about 20C/min.

Insert furnace probe

and ensure that thetemperature is below5350C.

- - - -Check drum level andgive blow down.

- - - -

Keep open the Eco.recirculation valve

when there is nofeeding to drum.

- - -Start motor driven feedpump on recirculation.

Check deaerator level.

- - -

Charge the feed line

upto feed controlstation.

-

- - -Charge heating steamto deaerator from Aux.PRDS.

-

- - -Start condensatepumps and feed todeaerator as and when

required.

Check hotwell level.

-- - -

Start hotwell make uppumps and feed hotwellas and when required.

-

- - -Aux. PRDS steam15kg/cm2(g) 2600C

-

- - - CW system is charged. -

- - - CW boxes to ensureventilating of water

-


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boxes.

- - -Start one gland steamexhauster fan.

-

- - -

Line up vacuum pumpsand start one by one Gradually admit glandsteam when condenservacuum reaches

0.2kg/cm2(g).

Ensure gland steamadmission temperature

is always above 2000C.

- - -

Vacuum building can be

done through SGC vacuum on startingprogramme mode,gland steam exhausterhas to be started

manually.

-

- -Vacuum 0-9kg/cm2(g).

Open all drainsconnected to flashtanks and flash boxes

connected tocondenser.

-

-- - -Open HPBP warm upvalves.

-

- - - Switch on SLC drains. -

02 60'Boiler pressure 2kg

/cm2

Close SH & RH headervents.

-

- - -Close SH & RH headerdrains.

-

- - -Open MSV by passlines.

MS, HRH, & CRH lineswill get warmed up.

03 100Boiler pressure 5kg

/cm2.

Switch on automaticcontrol interface of LPbypass.

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

-

-

-

Open Main steam

valves.

Automatic controlinterface gets switchedoff when the hot reheat

steam pressure reaches13kg/cm2i.e. aftersynchronisation.

- - - Open HP by pass. -

- - -Start third C.C. pumpwhen boiler pressurereaches 9 kg/cm2.

-

- - -Take additional guns in

CD & EF elevation.

Air heater soot blowing

to be carried out.

- - -Close HPBP warm up

valves.

-

A ROLLING THROUGH HYDRAULIC GOVERNOR


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04 150

Boiler pressure:15kg/cm2

Temperature:180-2000C

HRH Pressure:8-12Kg/cm2

Open HPESVs & IPESVsfor warming up byoperating startingdevice to

approximately 42%.

Check and ensure thatspeed set point is zero

and speeder gear is 0%

position.

- - - -

Ensure TSE influence isswitched on andavailable margins aregreater than = 30 0K.

05 -300

M. S. Pr. 50 kg/cm2

M.S. temp. 3500C

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

HRH temp. : 3500C

Raise the speed setpoint of EHC to 3200

rpm

If the oil system of EHC

is isolated at speedGov. rack, speed set

point need not beraised.

- - -

Gradually raise thestarting device to bring

the speed to 360 rpm

Starting device positionapproximately 56%.

- -Turbine ready forRolling.

Hold the speed at 360rpm for about 35 to 40

mts.

Ensure closure of gate

valve gearing at 240rpm. Monitor bearingvibrations, shaftvibrations, TSE

margins, bearingtemperature &Turbosupervisory

readings at 360 rpm.

06 -360M. S. Pr. 50kg/cm2/3500C. Turbine

running at 360 rpm.

Raise the speed upto

2400 rpm throughstarting device at therate of 600 rpm.

Ensure tripping of JOPat 540 rpm.

- -Raise further speedupto 3000 rpm through

speeder gear.

Starting device will beat 90%.

- - - -

Monitoring bearingtemperature andvibrations, shaftvibrations, TSE marginsand Turbovisory

readings, Seal oil,Primary water and gastemperatures &Generator windingtemperature.

- - - -Ensure trippinf of AOPat 2950 rpm.


9/38

- - - -

Speeder gear position

will be approximatelyat 50 to 60%.

07 370

MS Pr. 50 kg/cm2.Temperature:

3500C Turbine runningat 3000 rpm.

Put AVR on Auto. -

- - - Close field breaker. -

- - -

Set manually thegenerator voltage to

grid voltage.

-

- - -

Synchronise thegenerator with grid.

Pick up 50 MW load by

operating speeder gear.

-

- - -Increase HPBP setpoint.

Ensure closure of HPBPsteam valves & spray

valves.

- - -

Close other drains,

M.S. HRH, keeping SLCdrains on.

Drain pot drains of MS,

CRH & HRH andextraction steam lineswill operate as per theactuation of levelswitches.

B - ROLLING THROUGH EHC.

04 150'

MS Pr.: 15 kg/cm2.Temperature:180-

2000C HRHPressure:8to12kg/cm2.

Open HPESVs & IPESVs

for warming up byoperating startingdevice toapproximately 42%.

Check and ensure thatTSE influences isswitched on and

available margins are

greater than 300K.

- - - -

Check and ensure thatspeed set point is zeroand speeder gear is 0%

position.

05 300'

MS Pressure: 50kg/cm2

MSTemperature:3500C

HRH Pressure:12kg/cm2

HRH Temperature:3500C.

Turbine Ready forrolling

Raise the startingdevice to about 70%.

Check and ensureopening of valves in

HP/IP secondary fluidlines to EHC at speedcontrol rack.


10/38


11/38

picked upto 20MW.

- - -

Raise the speed setpoint and pick up the

load to 50 MW.

-


Ensure closure of HPBPsteam valves & spray

valves.

- - -

Close other drains of

MS, CRH, HRH, keepingSLC drains 'ON'.

Drain pot drains of MS,

CRH, HRH andextraction steam lineswill operate as per theactuation of levelswitches.

C - ROLLING THROUGH SGC - TURBINE.

04 150'


MS Temp.:180-2000C

HRH Pressure: 12kg/cm2

Switch on the start upprogramme of SGC Turbine.

Ensure TSE influence isswitched on.

- - - -

If the programmeinterrupts the particularstep and criteria to be

checked and corrected

for the programme toproceed further.

- - - -

All operations asexplained under EHC

rolling will be carriedout by SHC Turbineprogrammesequentially.

05 300'


MS Temperature:3500C


HRH Temp.: 3500C.


Turbine speed will beraised to 360 rpmthrough SGC

Programme.

Ensure closure of gatevalve gearing at 240rpm.

- - - -

Monitor bearingvibration, bearing

temperature, shaftvibration, TSE margins


12/38


13/38

08 390'

Load : 55 MW

M.S. :54kg/cm2/3500C

HRH : 12kg/cm2/3400C

Start seal air fan andPA fan and take first

mill in service.

Before starting P.A.fan, ensure that air andgas dampers of Primary

Air Preheaters are

open.

- - - Charge ESP fieldsEnsure Ash handling

system is ready.

- - -Start the second set ofID & FD fans.

Make ready SH & RHspray systems.

- - -Cut in L.P. heaters 2 &3.

Ensure switching on ofload controller above

60MW.

- - -

Cut out heating steamfrom Aux. P.R.D.S. toDeaerator.

-

- - -

Peg Deaerator fromCRH steam graduallyupto 2 kg/cm2.

-

- - - Cut in auto controllers. -

- -

Load : 55 MW

M.S. :54kg/cm2/3500C


Charge Aux. PRDSstation from CRH. Cutin spray and maintain atemperature of 2500C.

Ensure energizing ofsolenoid in trimmingdevice at and above100 MW load.

- - -Peg Deaeratorgradually to 4 kg/cm2.

Raise the pressure set

point of Deaeratorpressure controllergradually.

- - -Cut in IInd mill and cutin auto controllers.

-

- - -Start withdrawing oilsupport gradually.

Ensure fire ball scannerhealthiness

- - -Control main steamand reheat steamtemperatures by usingspray if required.

-

10 440'

Load : 160 MW

M.S. :90kg/cm2/3800C


Steam flow : 580t/hr.

Increase the wind box

to furnace differentialpressure to 100mmW.C. by adjustingSADC.

-


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- - -Charge H.P. heaters

5A, 5B, 6A and 6B.-

- - - Put controllers on auto. -

- - -Start first TDBFP &second CEP.

-

- - -

Charge Deareatorpegging steam flowCRH to Extractionaround 200 MW load.

Ensure DeareatorPressure controller

remains as auto.

11 480'

Load : 250 MW

M.S. :120kg/cm2/4200C



Cut in IIIrd mill and cutin auto controllers.

-

- - - Start second P.A. Fan.

Before starting P.A. fanensure that air and gas

dampers of PAPHs areopen.

12 510'

Load : 320 MW

M.S. :125kg/cm2/3500C

HRH : 28-30kg/cm2/3400C


Cut in IVth mill and cut

in auto controllers.

-

- - -Cut of oil supportcompletely.

Ensure healthiness offire ball scanners.

13

550'

Load : 405 MW

M.S. :145kg/cm2/4600C


Steam flow : 1310

t/hr.

Cut in Vth mill and cut

in auto controllers. -

- - -

Cut in second TD BFP

and switch off motordriven BFP.

-

14 590'

Load : 500 MW

M.S. : 170

kg/cm2

/4750

C

If full load is notreached cut in VIth millalong with its

controllers. Increasethe set point of SH &

-


15/38

HRH : 40.5

kg/cm2/4750C

RH spray controllers

such that ratedparametes areachieved gradually.

15 670'

Load : 405 MW

M.S. :145kg/cm2/4600C


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).

STEPTIME INMINUTES

UNIT CONDITION OPERATION NOTES.

- -

One CC pump in

operation and scannerfan in operation.

Motor operated BFP isrun as and whenrequired to maintain

the drum level.

-

- -Both SAPHs and

PAPHs in operation. - -


16/38

- -

Turbine on bearinggear with AOP, JOPand seal oil pumps inoperation.

- -

- -

Control fluid system

ready in all respects.One circulating pumpin operation with oneearth filter and ultrafine filter in circuit.

- -

- -

Generator gassystem, seal oilsystem and primarywater system inoperation.

- -

- -Bearing cooling watersystem in operation.

- -

- -

HT and LT auxiliariespower supply

available.

- -

- -HP bypass systemready in all respects.

- -

- -ESP ready in allrespects.

- -

- -EAST panels ready inall respects.

- -

- -

Furnace bottom ash

system and sealtrough lined up.

- -

- -Vacuum pumps linedup and ready for

operation.

- -

- -

Gland steam and leak

steam controllers arelined up and ready foroperation.

- -

- -

Generator protectionpanel and exciter

panels ready in allrespects.

- -

- -

Boiler drum pressure= 0 kg/cm2. SHtemperature between

1300C and 1500C.

1.Charge auxiliarysteam header fromexisting units. Pr.

16ata temp. 2600C.

-

- - -

2.Charge steam tofuel oil pump house,atomising steam andtracing steam.

-

-

-

-

3.Start tank heating

of LSHS oil. -


17/38

- - -

4.Start one LSHSpump on recirculationas soon as sufficient oiltemp. at inlet is

achieved.

-

- - -

Start instrument oilcompressor andservice aircompressors and checkthat all lines to boiler

and TG are charged.

-

- - -

Charge LSHS pump toboiler front and keep iton long recirculationwith heaters controlset on auto to maintain1200C.

-

- - -

Start circulating waterpump for condenserand deaerate the

condenser waterboxes.

-

- - - Start second CC Pump.

Ensure running ofmotor driven BFPcontinuously formaintaining drum

level.

- - -Start one set of ID and

FD fans.-

- - - Initiate boiler purge. -

- - -Start one CEP andkeep the hot well makeup in service.

-

- - -

Start one of the controlfluid pumps and keepthe second as auto

standby.

-

- - -

Keep the control fluid

temperature control onauto.

-

- - -

Line up main steam,CRH and HRH steamlines for charging by

opening respective linedrains.

-

- - -Line up FSSS panels inall respects

-

- - -

Charge heating steam

line to Deaerator fromAux. PRDS.

-


18/38

01 oo

Boiler ready for lightup and turbine onturning gear.

Start 4 burners in ABelevation with LSHS.

Check that SH & RHvents are open.

- - - -SH & RH drains areopen.

- - - -MSVs closed anddrains before MSVopen.

- - - -Ensure atomisingsteam pressure of

about 6 kg/cm2

- - - -

Ensure motoroperated BFP is inservice.

- - -Start Gland steamExhauster.

-

- - -Start one by onevacuum pumps.

-

- - -

Admit gland steamwhen vacuum reaches0.2 kg/cm2.

Ensure gland steamadmission

temperature is alwaysabove 2000C.

- - -

Vacuum building canbe done through SGCvacuum on startingprogramme mode.

Gland steam exhauster

has to be startedmanually.

-

- - -

Open all drainsconnected to flash

tanks and flash boxesconnected tocondenser.

Ensure condenser

vacuum of 0.8kg/cm2.

- - - Switch on SLC drains. -

- - -Close SH & RH headervents and drains.

Ensure boiler pressureis 2kg/cm2.

- - -Open HPBP warmingup valves. -

- - -Open MSV bypasslines.

-

- - -

Switch Automaticcontrol interface of LP

bypass.

As soon as the fixedset point reaches

12kg/cm2, it seizes.

- - - -

Automatic controlinterface getsswitched off when thehot reheat steampressure reaches13kg/cm2(i.e.) after


19/38

synchronisation.

- - -Open Main steam stopvalves.

Ensure MS, CRH &HRH lines get warmedup.

- - -

Open HP bypass andclose the HPBP warmup valves.

Ensure Boiler pressure

is 5kg/cm2.

- - - Start third CC pump.Ensure Boiler pressureis 9kg/cm2.

- - -

Put HP bypasscontroller on auto and

vary the set point

according to thegradient of pipeline

temperatures.

Ensure Boiler pressure

is 10kg/cm2

- - -Put HP bypass spray

control on auto.-

- - -

Take additional guns

according to therequirement.

Air heater soot

blowing to be carriedout.

A ROLLING THROUGH HYDRAULIC GOVERNOR.

02 180'

MS: 50 kg/cm2/3650C

HRH: 12kg/cm2/3250C

By pass steam flow:170t/hr.

Open HPESV andIPESV for warming up

by operating startingdevice to approx. 42%

Check and ensurethat speed set point is

zero and speeder gearis 0%.

- - - -

Ensure TSE influenceis switched on and

available margins are

greater than 300K.

03 210'

MS: 60 kg/cm2/4000C

HRH: 12kg/cm2/3500C


Raise the speed setpoint of EHC to 3200rpm.

If the oil system ofEHC is isolated atspeed Gov. rack,speed set point need

not be raised.

- - -Gradually rise thestarting device to bringthe speed to 360 rpm.

Starting devicepositionapproximately 56%.

- - -

Hold the speed at 360rpm for about 5minutes.



20/38

- - - -

Monitor bearingvibrations, shaftvibrations, TDEmargins, bearing

temp. & Turbovisory

readings at 360rpm.

04 215'Turbine running at360 rpm.

Raise the speed upto2400 rpm throughstarting device at therate of 600 rpm.


- - -

Raise further speedupto 3000 rpmthrough speeder gear.


- - - -

Monitor bearing temp& vibrations, shaftvibrations, TSEmargins and

Turbovisory readings.Seal oil, Primarywater and gas

temperatures &Generator windingtemperature.

- - - -Ensure tripping ofAOP at 2950 rpm.

- - - -

Speeder gear positionwill be approx. at 50to 60 %.

05 220'Turbine running at

3000 rpmPut AVR on auto. -


- - -Set manually thegenerator voltage to

grid voltage.

-

- - -

Synchronise the

generator with grid.Pick up 50 MW load byoperating speeder

gear.

-


Ensure closure ofHPBP steam valves &spray valves.

- - -Close other drains,M.S. HRH, keeping SLCdrains on.

Drain pot drains ofMS, CRH, and HRHand extraction steamlines will operate as

per the actuation oflevel switches.

-

-

-

-

Further load raisingwill be done by

operating the speedergear according to the


21/38

start up curve.

B ROLLING THROUGH EHC

02 180'

MS: 50 kg/cm2/3650C

HRH: 12kg/cm2/3250C


Open HPESVs and

IPESVs for warming upby operating startingdevice to approx. 42%.

Check and ensurethat TSE influence is

switched on andavailable margins are

greater than 300K.

- - - -

Check and ensurethat speed set point iszero and speeder gearis 0%.

03 210'

MS: 60 kg/cm2/4000C

HRH: 12kg/cm2/3500C


Turbine ready forrolling.


Check and ensureopening of valves in

HP/IP secondary fluidlines to EHC at speedcontrol rack.

- - -

Raise the speed setpoint to 360 rpm and

watch the actualspeed.

If tracking device is

switched on startingdevice position willautomatically trackthe EHC position

- - -Raise the speeder gearto 100%.

Ensure closure of gatevalve gearing at 240

rpm.

- - -


Monitor bearingvibrations bearingtemperatures, shaftvibrations, TSE

margins & turbovisoryreadings.

04 215'Turbine running at

360rpm.

Raise the speed set

point to 3000 rpm.

Ensure tripping ofJacking oil pump at340 rpm.

- - - -

Monitor bearingvibrations and temps,

shaft vibration,turbovisory readingsand TSE margins.



22/38

05 225'Turbine speed: 3000rpm.

Put AVR on auto closeField breaker.

-

- - -Set manuallygenerator voltage togrid voltage.

-

- - -Synchronise thegenerator with grid.

Speed set point willbe raise automaticallyby about 8 rpm & load

will be picked upto 20MW.

- - -Raise the speed setpoint and pick up theload to 50 MW.

-

- - -Increase HPBP setpoints.

Ensure closure ofHPBP steam valves

and spray valves.

- - -

Close other drains ofMS, CRH, and HRHkeeping SLC drains

ON.

Drain pot drains ofMS, CRH, HRH andextraction steam lineswill operate as per theactuation of levelswitches.

C ROLLING THROUGH SGC TURBINE.

02 180'

MS: 50 kg/cm2/3650C

HRH: 12kg/cm2/3250C


Switch on the start upprogramme of SGC

Turbine.

Ensure TSE influence

is switched on.

- - - -

If the programmeinterrupts theparticular step and

criteria to be checkedand corrected for theprogramme toproceed further.

- - - -

All operations as

explained under EHCrolling will be carriedout by SGC Turbineprogramme

sequentially.


23/38

03 210'

MS: 50 kg/cm2/3650C

HRH: 12kg/cm2/3250C



Turbine speed will be

raised to 360 rpmthrough SGC-Programme.


- - - -

Monitor bearingvibration, bearingtemp, shaft vibration,TSE margins and

Turbovisory readings.

- - - -

To achieve the

programme as per thestarting curve, themain steam

temperature shouldbe maintainedsteadily till loadingupto 50 MW.

04 215'

MS: 60 kg/cm2/4000C

Turbine running at

360 rpm.

Turbine speed will beraised upto 3000 rpm

through SGCProgramme.

Ensure tripping of JOPat 540 rpm. Ensure

tripping of A.O.P. at2950 rpm.

- - - -

Monitor bearing temp& vibrations, shaftvibrations, TSE

margin andturbovisory readings,seal oil, primary

water, Hydrogen gasand Generator

windingtemperatures.

05 225'

MS: 60 kg/cm2/4000C

Turbine speed: 3000rpm.

SGC programme will

switch ON fieldbreaker, put AVR onauto, synchronise andpick up load upto 20MW.

Ensure SGC Startup programme iscompleted.

- - -Raise the speed setpoint and pick up loadupto 50 MW.

-


24/38


25/38

- - -Peg Deaeratorgradually upto 4kg/cm2.

Raise the pressure setpoint of Deaeratorpressure controllergradually

- - -

Cut in H.P. heaters and

put the level controlson auto.

-

- - -

Start first TD BFP and

second CEP around aload of 170 MW.

-

- - -

Increase the windboxto furnace diff.pressure to 100mm.W.C. by adjustingSADC.

-

08 270'

Load: 200 MW

MS: 100kg/cm2/4350C

HRH: 19kg/cm2/4000C

Main steam flow:750t/hr.

Cut in IInd mill and cutin auto controllers.

-



- - -Control main steamand reheat steam

temperature by usingspray if required.

-

- - -

Change Deaeratorpegging steam fromCRH to Extraction

steam.

Ensure Deaeratorpressure controllerremains on auto.

- - -Cut in IIIrd mill and

cut in auto controllers.-

- - - Start second P.A. fan.

Before starting P.A.

fan ensure that airand gas dampers ofPAPH are open.

09 300'

Load: 320 MW

MS: 125kg/cm2/4500C

HRH: 30kg/cm2/4300C

Main steam flow:

1080t/hr.

Cut in IVth mill and cut

in auto controllers.-


26/38

- - -Cut off oil supportcompletely.


- - -Cut in Vth coal mill andcut in auto controllers.

-

- - -

Start second TDBFPand switch off motordriven BFP.

-

- - -Cut in VIth coal milland cut in autocontrollers.

-

10 340'

Load: 500 MW

MS: 170kg/cm2/4800C

HRH: 40.5

kg/cm2/4800C


Check all parametersat full load and ensure

them within limits.

-

- - -

Increase the set pointof SH & RH spraycontrollers such that

rated parameters areachieved.

-

11 420'

Load: 500 MW

MS: 170kg/cm2/5350C

HRH: 40.5kg/cm2/5350C


- -

INTEGRATED START UP PROCEDURE

HOT START UP (AFTER 8 HOURS SHUT DOWN)

STEPTIME IN

MINUTES.UNIT CONDITION OPERATION NOTES.

- -Two CC pumps inoperation and scanner

fan in operation.

Motor operated BFP isrun as and whenrequired to maintain

the drum level. Ifnecessary BFP should

-


27/38

be kept runningcontinuously.

- - Both SAPHs andPAPHs in operation.

- -

- -

Turbine on barringgear with AOP, JOPand seal oil pumps inoperation.

- -

- -

Control fluid pump inoperation. Onecirculating pump inoperation with one

earth filter and ultrafine filter in circuit.

- -

- -

Generator gassystem, seal oilsystem and primarywater system inoperation.

- -

- -Bearing cooling watersystem in operation.

- -

- -Condenser circulatingwater system inoperation.

- -

- -Service air andinstrument aircompressors inoperation.

- -

- -

One condensate pumpin operation and hotwell make up in

service.

- -

- -Aux. steam headercharged from existingunits (16ata 2600C).

- -

- -

LSHS pump inoperation on longrecirculation uptoboiler front withheaters control set on

- -

- -HP bypass systemready in all respects.

- -

- -LP & HP and chemicaldosing system ready.

- -

- -ESP panels ready inall respects.

- -

- - EAST panels ready inall respects.

- -


28/38

- -

Furnace bottom ashsystem and sealtrough lined up.

- -

- -

Vacuum pumps linedup and ready for

operation.

- -

- -

Gland steam and leaksteam controllers are

lined up and ready foroperation.

- -

- -

Generator protectionpanel and exciterpanels ready in allrespects.

- -

- -FSSS panel ready in

all respects.- -

- -

Boiler drum Pr. 75kg/cm2SH. Temp.

between 4150C and4300C.

Line up main steam,CRH and HRH steamlines for charging byopening respective linedrains.

Ensure MSV is closed.

- - -Start one gland steam

exhauster.-

- - -Start one by one

vacuum pumps.-

-

-

-

Admit gland steam

when vacuum reaches0.2 kg/cm2.

Ensure gland steam

admission

temperature is alwaysabove 2000C.

- - -

Vacuum building canbe done through SGC

vacuum on startingprogramme mode.Gland steam exhausterhas to be started

manually.

-

-

-

-

Open all drains

connected to flash

tanks and flash boxesconnected tocondenser.

Ensure condenser

vacuum of 0.8kg/cm2.

- - -Ensure condenser

vacuum of 0.8 kg/cm2.-

- - -Open HPBP warming

up valves.-

- - -Switch Automaticcontrol interface of LPbypass.

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


29/38


30/38

- - -Start both P.A. fansand seal air fans.

Before starting P.A.Fans ensure that airand gas dampers ofPrimary air preheaters

are open.

- - - Line up milling systemfor starting.

-

A ROLLING THROUGH HYDRAULIC GOVERNOR

02 40'

MS: 85 kg/cm2/4850C

HRH: 12kg/cm2/4400C

Bypass steam flow:280t/hr.

Cut in first coal mill &cut in auto controllers.

Make ready SH andRH spray system.

- - - Charge ESP fields.

Ensure Ash handlingsystem is ready.

- - -

Increase the windboxto furnace diff.Pressure to 100mm

W.C. by adjustingS.A.D.C.

-

- - -Cut in second mill andcut in auto controllers.

-

- - -Peg the deaerator fromCRH gradually upto 2kg/cm2.

-

- - -

Open HPESVs andIPESVs for warming up

by operating startingdevice toapproximately 42%.

Check and ensurethat speed set point iszero and speeder gear

is at 0%.

- - - -

Ensure TSE influenceis switched on andavailable margins are

greater than 300K.

03 50'





Bypass steam flow:

360t/hr.

Raise the speed setpoint of EHC to 3200rpm.

If the oil of EHC isisolated at speed Gov.rack, speed set pointneed not be raised.


31/38


- - -

Gradually raise thestarting device to bringthe speed to 360 rpm

Starting devicepositionapproximately 56%.

-

-

-

-


valve gearing at 240rpm.

- - - -

Monitoring bearingvibrations, shaft

vibrations, TSEmargins, bearingtemp & Turbovisoryreadings at 360 rpm.

04 52'Turbine running at360rpm.

Raise speed upto 2400rpm through startingdevice at the rate of600 rpm.


- - -

Raise further speedupto 300 rpm throughspeeder gear.


- - - -

Monitor bearing tempand vibrations, shaftvibrations, TSEmargins andturbovisory readings.

Seal oil Primary waterand gas temperaturesand Generator

winding temperature.

- - - -Ensure tripping of

AOP at 2950 rpm.

- - - -

Speeder gear positionwill be approximatelyat 50 to 60%.

05 56'Turbine running at3000rpm

Put AVR on auto. -


- - -

Set manually thegenerator voltage togrid voltage.

-


32/38

- - -

Synchronise theGenerator with grid.Pick up 50 MW load byoperating speeder

gear.

-



- - -Close other drains,M.S. CRH, HRH,keeping SLC drains on.

Drain pot drains ofMS, CRH, and HRHand extraction steamlines will operate asper the actuation oflevel switches.

- - - -

Further load raisingwill be done byoperating the speeder

gear according to thestart up curve.

B ROLLING THROUGH EHC

02 40'








- - - Charge ESP fields.Ensure Ash handlingsystem is ready.

-

-

-

Increase the windbox

to furnace diff.

Pressure to 100mmW.C. by adjustingS.A.D.C.

-

- - -Cut in second mill andcut in auto controllers.

-

- - -Peg the deareator fromCRH gradually upto 2kg/cm2.

-

- - -

Open HPESVs andIPESVs for warming upby operating startingdevice to

approximately 42%.

Check and ensurethat speed set point is

zero and speeder gear

is at 0%.


33/38

- - - -

Ensure TSE influenceis switched on andavailable margins are

greater than 300K.

03 50'

MS Pressure: 85

kg/cm2




Turbine Ready forrolling. Bypass steamflow: 360t/hr.


Check and ensureopening of valves inHP/IP secondary fluidlines to EHC at speed

control rack.

- - -

Raise the speed setpoint to 360 rpm andwatch the actualspeed.

If tracking device isswitched on startingdevice position willautomatically trackthe EHC position.

- - -Raise the speeder gearto 100%.


valve gearing at 240rpm.

- - -


Monitor bearingvibrations, bearingtemperatures, shaftvibrations, TSEmargins andturbovisory readings.

04 52'Turbine reading at360 rpm.

Raise the speed setpoint to 300 rpm.

Ensure tripping ofJacking oil pump at

540 rpm.

- - - -

The rate of

acceleration will be600 to 800 rpm2.

- - - -

Monitor bearingvibrations andtemperatures, shaftvibration, turbovisory

readings and TSEmargins.

- - - -

Monitor and control,seal oil temperatures,primary water

temperature.Hydrogen gastemperature andwinding temperature.


34/38


05 56'Turbine speed: 3000rpm.

Put AVR on auto Closefield breaker.

-

- - -

Set Manually generatorvoltage to grid voltage. -


Speed set point willbe raisedautomatically byabout 8 rpm and load

will be picked upto 20MW.


-

- - -Increase HPBP set

point.

Ensure closure ofHPBP steam valves

and spray valves.

- - -

Close other drains of

MS. CRH and HRH,keeping SLC drains

ON.

Drain pot drains ofMS, CRH, HRH and

extraction steam lineswill operate as per theactuation of level

switches.

C ROLLING THROUGH SGC TURBINE.

02 40'

MS: 85 kg/cm2/4850C

HRH: 12kg/cm2.

Bypass steam flow:

280t/hr.



- - - Charge ESP fields.Ensure Ash handling

system is ready.

- - -

Increase the windbox

to furnace diff.Pressure to 100mmW.C. by adjusting

S.A.D.C.

-

- - -Cut in second mill and

cut in auto controllers. -

- - -

Peg the deaerator from

CRH gradually upto 2kg/cm2.

-

- - -

Switch on the start upprogramme of SGC-Turbine.

Ensure TSE influenceis switched ON.

- - - -

If the programmeinterrupts, theparticular step and

criteria to be checkedand corrected for the


35/38

programme toproceed further.

- - - -

All operations asexplained under EHC

rolling will be carriedout by SGC-Turbineprogrammesequentially.

03 50'


MS: 85 kg/cm2/5000C

HRH: 12kg/cm2/4500C

Bypass steam flow:

360t/hr.

Turbine speed will be

raised to 360 rpm

through SGC-programme.

Ensure closure of gatevalve gearing at 240

rpm.

- - - -

Monitor bearingvibration, bearingtemperature, shaftvibration, TSEmargins andTurbovisory readings.

- - - -

To achieve the

programme as per thestart up curve, themain steam

temperature shouldbe maintainedsteadily till loading of50 MW.

04 52'Turbine reading at

360 rpm.

Turbine speed will beraised upto 3000 rpm

through SGC-programme.

Ensure tripping of JOP

at 540 rpm.


- - - -

Monitor bearingtemperature andvibrations, shaftvibrations, TSEmargins, Turbovisoryreadings, seal oil,

primary water,Hydrogen gas andGenerator windingtemperatures.


36/38

05 56'

Turbine speed: 3000rpm.

MS: 85 kg/cm2/5000C

HRH: 12kg/cm2

/4500

C


SGC Programme willswitch ON fieldbreaker, put AVR onauto synchronise and

pick up load upto 20MW.

Ensure SGC-start upprogramme is

completed.

- - -Raise the speed setpoint and pick up loadupto 50 MW.

-



- - -

Close other drains ofM.S, CRH and HRH,keeping SLC drains

ON.

Drain pot drains of

MS, CRH, HRH andExtraction steam lineswill operate as per theactuation of level

switches.

06 60'

LOAD: 60 MW.

MS: 85 kg/cm2/5000C

HRH: 16kg/cm2/4700C

Cut in L.P. heaters 2

and 3.

Ensure switching onof load controller at60 MW.

- - -

Cut out heating steam

from Aux. PRDS toDeaerator.

-

- - -Raise the generatorpressure from2kg/cm2to 4kg/cm2.

Raise the pressure setpoint of Deaeratorpressure controller.

- - - Cut in auto controller. -



07 65'

LOAD: 150 MW.

MS: 100kg/cm2/5000C

HRH: 20kg/cm2/4800C


Trimming device is inOFF.

Charge Aux. PRDSstation from CRH. Cutin spray and maintaina temperature of

2500C.

-

- - -

Cut in H.P. heaters andput the level controls

on auto.

-


37/38

- - -

Start first TD BFP andsecond CEP around aload of 170 MW.

-

- - -

Control main steamand reheat steam

temperature by usingspray if required.

-

- - -

Change deaerator

pegging steam fromCRH to Extractionsteam.

Ensure Deaeatorpressure controller

remains on auto.

- - -Cut in IIIrd mill andcut in auto controllers.

-

08 70'

LOAD: 230 MW.

MS: 120

kg/cm2/5000C

HRH: 20kg/cm2/4950C


Cut in IVth mill and cutin auto controllers.

-

- - -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 motordriven BFP.

-

- - -

Cut in VIth coal milland cut in autocontrollers.

-

09 86'

LOAD: 500 MW.

MS: 170kg/cm2/5000C

HRH:

40.5kg/cm2/5000C

Main steam flow:

1620t/hr.

Check all parametersat full load and ensurethem within limits.

-

- - -

Increase the set point

of SH & RH spraycontrollers such thatrated parameters are

achieved.

-


38/38

10 135'

LOAD: 500 MW.

MS: 170kg/cm2/5000C

HRH: 40.5kg/cm2/4800C

Main steam flow:1570 t/hr.

- -

********************

500mw starting procedures

Documents