500 MW Unit Startup Procedure

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 BYPASS SYSTEM.

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

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

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 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/cm2) 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

0 ..Boiler pr. 0 kg/cm2 (g) and Ambient temperature

Charge Aux. Steam header 16 ata, 2600C, from existing units.

-

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

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

- - - Start tank heating of LSHS oil. -

- - -

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

-

- - -

Charge LSHS to boiler front and keep it on long recirculation, with heaters control set on ‘Auto’ to maintain 110-1290C.

-

- - - 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.

- - -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.

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

Check that all circuits have sufficient air pressure.

- - -

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

-

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

-

- - - Line up Air and flue gas circuits for startup.

Check dampers and gates register position.

- - - ESP ready in all respects. -

- - -Furnace bottom ash system and seal through lined up.

-

- - - FSSS panel ready in all respects. -

- - - EAST panel ready in all respects. -

- - - Excitation panel ready in all respects. -

- - -Generator protection panel ready in all respects.

-

- - - Generator H2 gas pressure is 4 kg/cm2

Check purity of H2 gas is normal.

- - -Generator stator water system ready in all respects.

Check purity of generator stator water is normal.

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

-

- - - LP & HP chemical dozing system is ready.

Check for level in Hydrazine, Ammonia and phosphate preparation tanks.

- - - SADC panel readiness. Check for air pressure in all the corners and

elevations.

- - -Power supply for all the valves and dampers are ON.

Ensure Aux. air dampers and modulating.

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

-

- - - Readiness of HP bypass panel in all respects.

Ensure the oil unit is running and all the bypass and spray valves are closed.

- - - Start one of the CC pumps.

Ensure drum level is +200 mm, and the drum air vents are closed.

- - - Start the second CC pump.

Ensure drum level is normal.

- - - Start scanner air fan. -

- - - Start both the secondary air preheaters.

Ensure that all the inlet and outlet air gas dampers are open.

- - - Start both the primary air preheaters.

Ensure that the gas dampers are closed.

- - - Start one set of ID and FD fans.

Adjust 30% air flow, and furnace draft minus 5 to 10 mm WCL.

- - -Charge steam coil preheater concerned with the running FD fans.

-

- - - Initiate Boiler ‘Purge’ (duration 5 minutes).

After purge completion Boiler trip valves will get reset.

- - - -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.

- - - - Check out auto start of AOP and EOP.

- -- - Put lub oil temperature controller on. -

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

- -- - - Check out auto start of JOP 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 for JOPs. -

- - - M/c. comes on barring.MOT level – 50 mm oil temp. 450C JOP header pr. 140 kg/cm2 speed 80 – 100 rpm.

- - -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.

- - M/c on barring. Start centrifuge with both heaters -

- - FRF system in stopped condition. Check FRF tank level. +200 mm.

- - -

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

-

- - -Establish control fluid supply to various services.

FRF tank level ‘O’ (normal).

- - - Start one VEF. -

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

-

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

FRF temperature 550C.

- - - Switch ON control fluid SGC. -

- - 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.

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

01 ooBoiler ready for light up and Turbine on Turning gear.

Start 4 burners in ‘AB’ elevation with LSHS.

Check that SH & RH vents are open.

- - - - SH & RH drains are open.

- - - - MSV’s closed and drains before MSV open.

- - - Regulate oil pressure to 8-10 kg/cm2.

Ensure atomising steam pressure about 6 kg/cm2.

- - -

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

Insert furnace probe and ensure that the temperature is below 5350C.

- - - - Check drum level and give blow down.

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

- - - Start motor driven feed pump on recirculation. Check deaerator level.

- - - Charge the feed line upto feed control station. -

- - -Charge heating steam to deaerator from Aux. PRDS.

-

- - -Start condensate pumps and feed to deaerator as and when required.

Check hotwell level.

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

-

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

- - - CW system is charged. -

- - -CW boxes – to ensure ventilating of water boxes.

-

- - - Start one gland steam exhauster fan. -

- - -

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

Ensure gland steam admission temperature is always above 2000C.

- - -

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

-

- - Vacuum 0-9kg/cm2 (g).Open all drains connected to flash tanks and flash boxes connected to condenser.

-

-- - - Open HPBP warm up valves. -

- - - Switch on – SLC drains. -02 60' Boiler pressure 2kg

/cm2Close SH & RH header vents. -

- - - Close SH & RH header drains. -

- - - Open MSV by pass lines. MS, HRH, & CRH lines will get warmed up.

03 100’ Boiler pressure 5kg /cm2.

Switch on automatic control interface of LP bypass.

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

- - - Open Main steam valves.

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

- - - Open HP by pass. -

- - -Start third C.C. pump when boiler pressure reaches 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

04 150’

Boiler pressure:15 kg/cm2

Temperature:180-2000C

HRH Pressure:8-12Kg/cm2

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.

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

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 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%.

- - Turbine ready for Rolling.

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.

06 -360’M. S. Pr. 50 kg/cm2/3500C. Turbine running at 360 rpm.

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

Ensure tripping of JOP at 540 rpm.

- -Raise further speed upto 3000 rpm through speeder gear.

Starting device will be at 90%.

- - - -

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

- - - - Ensure trippinf of AOP at 2950 rpm.

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

07 370’MS Pr. 50 kg/cm2. Temperature: 3500C 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.Ensure closure of HPBP steam valves & spray valves.

- - -Close other drains, M.S. 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.

B - ROLLING THROUGH EHC.

04 150'MS Pr.: 15 kg/cm2. Temperature:180-2000C HRH Pressure:8to12kg/cm2.

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

Check and ensure that TSE influences is switched on and available margins are greater than 300K.

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

05 300'

MS Pressure: 50 kg/cm2

MS Temperature:3500C

HRH Pressure: 12kg/cm2

HRH Temperature: 3500C.

Turbine Ready for rolling

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.

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

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

- - - Raise the speeder gear to 100%

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

Ensure closure of gate valve gearing at 240 rpm.

- - - -Monitoring bearing vibrations, bearing temperatures, shaft vibrations, TSE margins

and Turbovisory readings.

06 360'MS Pressure:50 kg/cm2

MS Temperature:3500CRaise the speed set point to 3000 rpm.

Ensure tripping of jacking oil pump at 540 rpm.

- - Turbine speed: 360 rpm. - The rate of acceleration

will be 600 to 850 rpm.

- - - -

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

- - - -

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

- - - - Ensure tripping of AOP at 2950 rpm.

07 370'


MS Temperature: 3500C

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

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

-


- - -Close other drains of MS, CRH, 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.04 150' MS Pressure: 15 kg/cm2

MS Temp.:180-2000C

Switch on the start up programme of SGC – Turbine.

Ensure TSE influence is switched on.

HRH Pressure: 12 kg/cm2

- - - -

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 SHC – Turbine programme sequentially.

05 300'




HRH Temp.: 3500C.


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


- - - -

Monitor bearing vibration, bearing temperature, 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.

06 360'



Turbine running at 360 rpm.

Turbine speed will be raised upto 3000rpm through SGC-programme.



- - - -Monitor bearing temp and vibrations, shaft vibrations, TSE margins

and turbovisory readings seal oil, primary water, Hydrogen gas and Generator winding temperatures.

07 370'



Turbine speed:3000rpm.

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

Ensure SGC – start up programme is completed.

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

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

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

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

08 390'

Load : 55 MW

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

HRH : 12 kg/cm2/3400C

Start seal air fan and PA fan and take first mill in service.

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

- - - Charge ESP fields Ensure Ash handling system is ready.

- - - Start the second set of ID & FD fans.

Make ready SH & RH spray systems.

- - - Cut in L.P. heaters 2 & 3.Ensure switching on of load controller above 60MW.

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

-

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

-

- - - Cut in auto controllers. -

- -

Load : 55 MW

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.

- - - Peg Deaerator gradually to 4 kg/cm2.

Raise the pressure set point of Deaerator pressure controller

gradually.

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

- - - Start withdrawing oil support gradually.

Ensure fire ball scanner healthiness

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

-

10 440'

Load : 160 MW

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

HRH : 20 kg/cm2/3800C

Steam flow : 580t/hr.

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

-

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

- - - Put controllers on auto. -- - - Start first TDBFP &

second CEP. -

- - -Charge Deareator pegging steam flow CRH to Extraction around 200 MW load.

Ensure Deareator Pressure controller remains as auto.

11 480'

Load : 250 MW

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

HRH : 26 kg/cm2/3400C


Cut in IIIrd mill and cut in auto controllers. -

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

12 510'

Load : 320 MW

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

HRH : 28-30 kg/cm2/3400C


Cut in IVth mill and cut in auto controllers. -

- - - Cut of oil support completely.

Ensure healthiness of fire ball scanners.

13 550' Load : 405 MW Cut in Vth mill and cut in auto controllers.

-

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

HRH : 33 kg/cm2/4600C

Steam flow : 1310 t/hr.

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

-

14 590'

Load : 500 MW

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

HRH : 40.5 kg/cm2/4750C

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 achieved gradually.

-

15 670'

Load : 405 MW

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

HRH : 33 kg/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).

STEP TIME IN MINUTES UNIT CONDITION OPERATION NOTES.

- -One CC pump in operation and scanner fan in operation.

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

-

- - Both SAPHs and PAPHs in operation. - -

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

- -

- -

Control fluid system ready in all respects. 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. - -

- -HT and LT auxiliaries power supply available.

- -

- - HP bypass system ready in all respects. - -

- - ESP 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.

- -

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

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

-

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

-

- - - 3. Start tank heating of LSHS oil. -

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

-

- - -

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

-

- - -

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

-

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

-

- - - Start second CC Pump.

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

- - - Start one set of ID and FD fans. -

- - - Initiate boiler purge. -

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

-

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

-

- - -Keep the control fluid temperature control on auto.

-

- - -Line up main steam, CRH and HRH steam lines for charging by

-

opening respective line drains.

- - - Line up FSSS panels in all respects -

- - -Charge heating steam line to Deaerator from Aux. PRDS.

-

01 ooBoiler ready for light up and turbine on turning gear.


Check that SH & RH vents are open.

- - - - SH & RH drains are open.

- - - -MSV’s closed and drains before MSV open.

- - - -Ensure atomising steam pressure of about 6 kg/cm2

- - - - Ensure motor operated BFP is in service.

- - - Start Gland steam Exhauster. -

- - - Start one by one vacuum pumps. -

- - -Admit gland steam when vacuum reaches – 0.2 kg/cm2.


- - -

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

-

- - -

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

Ensure condenser vacuum of – 0.8 kg/cm2.

- - - 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.

Ensure MS, CRH & HRH lines get warmed up.

- - -Open HP bypass and close the HPBP warm up valves.

Ensure Boiler pressure is 5kg/cm2.

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

- - -

Put HP bypass controller on auto and vary the set point according to the gradient of pipeline temperatures.

Ensure Boiler pressure is 10kg/cm2

- - - Put HP bypass spray control on auto. -

- - -Take additional guns according to the requirement.


A – ROLLING THROUGH HYDRAULIC GOVERNOR.

02 180'

MS: 50 kg/cm2/3650C

HRH: 12 kg/cm2/3250C

By pass steam flow: 170t/hr.

Open HPESV and IPESV for warming up by operating starting device to approx. 42%

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

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

03 210'

MS: 60 kg/cm2/4000C



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


- - -Hold the speed at 360 rpm for about 5 minutes.


- - - -

Monitor bearing vibrations, shaft vibrations, TDE margins, bearing temp. & Turbovisory readings at 360rpm.

04 215' Turbine running at 360 rpm.

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


- - -Raise further speed upto 3000 rpm through speeder gear.


- - - -

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


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

05 220' Turbine running at 3000 rpm Put AVR on auto. -



-

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

-


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

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

- - - -

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

B – ROLLING THROUGH EHC

02 180'

MS: 50 kg/cm2/3650C



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

Check and ensure that TSE influence is switched on and available margins are greater than 300K.

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

03 210'

MS: 60 kg/cm2/4000C



Turbine ready for rolling.




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

- - - Raise the speeder gear to 100%.



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

04 215' Turbine running at 360rpm.

Raise the speed set point to 3000 rpm.

Ensure tripping of Jacking oil pump at 340 rpm.

- - - -

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


05 225' Turbine speed: 3000 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.

- - -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’.


C – ROLLING THROUGH SGC – TURBINE.

02 180'

MS: 50 kg/cm2/3650C



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.

03 210'

MS: 50 kg/cm2/3650C




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


- - - -

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.

04 215'

MS: 60 kg/cm2/4000C

Turbine running at 360 rpm.

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

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.

05 225'

MS: 60 kg/cm2/4000C


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

Ensure SGC – Start up programme is completed.

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

-

- - - Increase HPBP set pointEnsure closure of HPBP 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.

06 230'

Load: 60 MW

MS: 60 kg/cm2/4100C


Cut in L.P. heaters 2 and 3.

Ensure switching on of load controller at 60 MW.

- - -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

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

- - - Cut in further oil guns for raising parameters. -

07 245'

Load: 110 MW

MS: 80 kg/cm2/4200C


Main steam flow: 470t/hr.

Trimming device is in ‘OFF’.

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.

-

- - - Peg Deaerator gradually upto 4 kg/cm2.

Raise the pressure set point of Deaerator 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.

-

08 270'

Load: 200 MW

MS: 100 kg/cm2/4350C



Cut in IInd mill and cut in auto controllers. -

- - - 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.

Ensure Deaerator pressure controller remains on auto.

- - - Cut in IIIrd mill and cut in auto controllers. -

- - - Start second P.A. fan.Before starting P.A. fan ensure that air and gas dampers of PAPH are open.

09 300'

Load: 320 MW

MS: 125 kg/cm2/4500C




- - - Cut off oil support completely.


- - - 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. -

10 340'

Load: 500 MW

MS: 170 kg/cm2/4800C

HRH: 40.5 kg/cm2/4800C


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.

-

11 420'

Load: 500 MW

MS: 170 kg/cm2/5350C

HRH: 40.5 kg/cm2/5350C

- -


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.

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

Ensure MSV is closed.

- - - Start one gland steam exhauster. -

- - - Start one by one vacuum pumps. -

- - -Admit gland steam when vacuum reaches – 0.2 kg/cm2.


- - -

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

-

- - - Open all drains connected to flash tanks and flash boxes

Ensure condenser 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.

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.

- - - Start third CC pump.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 ooBoiler ready for light up and turbine on turning gear.


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.

Ensure MS, CRH, HRH lines got warmed up.

- - -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 temperatures.

-

- - - Put HP bypass spray control on auto. -

- - -Take additional guns according to the requirement.


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

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

- - - Line up milling system for starting. -

A – ROLLING THROUGH HYDRAULIC GOVERNOR

02 40'

MS: 85 kg/cm2/4850C


Bypass steam flow: 280t/hr.

Cut in first coal mill & cut in auto controllers.

Make ready SH and RH spray system.

- - - Charge ESP fields. Ensure Ash handling system is ready.

- - -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%.


03 50' MS Pressure: 85 kg/cm2




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


- - - -Ensure closure of gate valve gearing at 240 rpm.

- - - -

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

04 52' Turbine running at 360rpm.

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


- - -Raise further speed upto 300 rpm through speeder gear.


- - - -

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


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

05 56' Turbine running at 3000rpm Put AVR on auto. -



-

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

-

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

valves.

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

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

- - - -

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

B – ROLLING THROUGH EHC

02 40'










-


- - -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%.


03 50'





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




If tracking device is switched on starting device position will automatically track the EHC position.

- - - Raise the speeder gear to 100%.



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

04 52' Turbine reading at 360 rpm.

Raise the speed set 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.


05 56' Turbine speed: 3000 rpm.

Put AVR on auto Close field breaker. -

- - - Set Manually generator voltage to grid voltage. -


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’.


C – ROLLING THROUGH SGC TURBINE.

02 40'

MS: 85 kg/cm2/4850C

HRH: 12kg/cm2.






-


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

-

- - -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.

03 50'


MS: 85 kg/cm2/5000C

HRH: 12kg/cm2/4500C


Turbine speed will be raised to 360 rpm through SGC-programme.


- - - -

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 reading at 360 rpm.

Turbine speed will be raised upto 3000 rpm through SGC- programme.



- - - -

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

05 56'


MS: 85 kg/cm2/5000C

HRH: 12kg/cm2/4500C


SGC Programme will switch ON field breaker, put AVR on auto synchronise and pick up load upto 20 MW.

Ensure SGC-start up programme is completed.

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

-


- - -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.

06 60'

LOAD: 60 MW.

MS: 85 kg/cm2/5000C

HRH: 16kg/cm2/4700C

Cut in L.P. heaters 2 and 3.

Ensure switching on of load controller at 60 MW.

- - -Cut out heating steam from Aux. PRDS to Deaerator.

-

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

Raise the pressure set point of Deaerator pressure controller.

- - - Cut in auto controller. -- - - Start withdrawing oil

support gradually.Ensure healthiness of fire ball scanners.

07 65'

LOAD: 150 MW.

MS: 100 kg/cm2/5000C

HRH: 20kg/cm2/4800C


Trimming device is in ‘OFF’.

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

-

- - -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.

Ensure Deaeator pressure controller remains on auto.

- - - Cut in IIIrd mill and cut in auto controllers. -

08 70'

LOAD: 230 MW.

MS: 120 kg/cm2/5000C

HRH: 20kg/cm2/4950C



- - - Cut off oil support completely.


- - - 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. -

09 86'

LOAD: 500 MW.

MS: 170 kg/cm2/5000C

HRH: 40.5kg/cm2/5000C


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.

-

10 135'

LOAD: 500 MW.

MS: 170 kg/cm2/5000C

HRH: 40.5 kg/cm2/4800C

Main steam flow: 1570 t/hr.

- -

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

500 MW Unit Startup Procedure

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Transcript of 500 MW Unit Startup Procedure