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
http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#COLDSTARTUPhttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#COLDSTARTUPhttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#INTEGRATEDSTARTUPPROCEDURECOLDSTARTUPhttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#INTEGRATEDSTARTUPPROCEDURECOLDSTARTUPhttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#INTEGRATEDSTARTUPPROCEDURECOLDSTARTUPhttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#INTEGRATEDSTARTUPPROCEDURECOLDSTARTUPhttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20AND%20HOT%20START%20UPS%C2%A0http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20AND%20HOT%20START%20UPS%C2%A0http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20START%20UP%20(AFTER%2048%20HOURS%20SHUT%20DOWN).http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20START%20UP%20(AFTER%2048%20HOURS%20SHUT%20DOWN).http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20START%20UP%20(AFTER%2048%20HOURS%20SHUT%20DOWN).http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20START%20UP%20(AFTER%2048%20HOURS%20SHUT%20DOWN).http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#hothttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#hothttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#hothttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#hothttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#hothttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20START%20UP%20(AFTER%2048%20HOURS%20SHUT%20DOWN).http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#WARM%20AND%20HOT%20START%20UPS%C2%A0http://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#INTEGRATEDSTARTUPPROCEDURECOLDSTARTUPhttp://www.bhelpswr.co.in/Technical/COMMISSIONING%20PROCEDURES/comm%20proced11.htm#COLDSTARTUP -
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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.
-
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- - - -
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.
-
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-
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picked upto 20MW.
- - -
Raise the speed setpoint and pick up the
load to 50 MW.
-
- - -Increase HPBP setpoint.
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 Pressure: 15kg/cm2
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 Pressure: 50kg/cm2
MS Temperature:3500C
HRH Pressure: 12kg/cm2
HRH Temp.: 3500C.
Turbine Ready forrolling
Turbine speed will beraised to 360 rpmthrough SGC
Programme.
Ensure closure of gatevalve gearing at 240rpm.
- - - -
Monitor bearingvibration, bearing
temperature, shaftvibration, TSE margins
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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
HRH : 12kg/cm2/3400C
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
HRH : 20kg/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
HRH : 26kg/cm2/3400C
Steam flow : 820t/hr.
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
Steam flow : 1040t/hr.
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
HRH : 33kg/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 &
-
-
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HRH : 40.5
kg/cm2/4750C
RH spray controllers
such that ratedparametes areachieved gradually.
15 670'
Load : 405 MW
M.S. :145kg/cm2/4600C
HRH : 33kg/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. - -
-
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- -
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. -
-
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- - -
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.
-
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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
-
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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
By pass steam flow:200t/hr.
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.
Ensure closure of gatevalve gearing at 240rpm.
-
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- - - -
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.
Ensure tripping of JOPat 540 rpm.
- - -
Raise further speedupto 3000 rpmthrough speeder gear.
Starting device will beat 90%.
- - - -
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. -
- - - Close field breaker. -
- - -Set manually thegenerator voltage to
grid voltage.
-
- - -
Synchronise the
generator with grid.Pick up 50 MW load byoperating speeder
gear.
-
- - -Increase HPBP setpoint.
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
-
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start up curve.
B ROLLING THROUGH EHC
02 180'
MS: 50 kg/cm2/3650C
HRH: 12kg/cm2/3250C
By pass steam flow:170t/hr.
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
By pass steam flow:200t/hr.
Turbine ready forrolling.
Raise the startingdevice to about 70%.
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.
- - -
Hold the speed at 360rpm for about 5minutes.
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.
- - - -Ensure tripping ofAOP at 2950 rpm.
-
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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
By pass steam flow:170t/hr.
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.
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03 210'
MS: 50 kg/cm2/3650C
HRH: 12kg/cm2/3250C
By pass steam flow:170t/hr.
Turbine ready forrolling.
Turbine speed will be
raised to 360 rpmthrough SGC-Programme.
Ensure closure of gatevalve gearing at 240rpm.
- - - -
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.
-
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-
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- - -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.
-
- - -Start withdrawing oilsupport gradually.
Ensure healthiness offire ball scanners.
- - -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.-
-
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- - -Cut off oil supportcompletely.
Ensure healthiness offire ball scanners.
- - -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
Main steam flow:1620t/hr.
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
Main steam flow:1570t/hr.
- -
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
-
-
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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.
- -
-
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- -
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.
-
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-
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- - -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'
MS Pressure: 85kg/cm2
MS Temperature:5000C
HRH Pressure: 12kg/cm2
HRH Temperature:4500C.
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.
-
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Turbine Ready forrolling
- - -
Gradually raise thestarting device to bringthe speed to 360 rpm
Starting devicepositionapproximately 56%.
-
-
-
-
Ensure closure of gate
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.
Ensure tripping of JOPat 540 rpm.
- - -
Raise further speedupto 300 rpm throughspeeder gear.
Starting device will beat 90%.
- - - -
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. -
- - - Close field breaker. -
- - -
Set manually thegenerator voltage togrid voltage.
-
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- - -
Synchronise theGenerator with grid.Pick up 50 MW load byoperating speeder
gear.
-
- - -Increase HPBP setpoint.
Ensure closure ofHPBP steam valves &spray valves.
- - -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'
MS Pressure: 85kg/cm2
MS Temperature:4850C
HRH Pressure: 12kg/cm2
HRH Temperature:4400C.
Bypass steam flow:280t/hr.
Cut in first coal mill &cut in auto controllers.
Make ready SH & RHspray systems.
- - - 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%.
-
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- - - -
Ensure TSE influenceis switched on andavailable margins are
greater than 300K.
03 50'
MS Pressure: 85
kg/cm2
MS Temperature:5000C
HRH Pressure: 12kg/cm2
HRH Temperature:4500C.
Turbine Ready forrolling. Bypass steamflow: 360t/hr.
Raise the startingdevice to about 70%.
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%.
Ensure closure of gate
valve gearing at 240rpm.
- - -
Hold the speed at 360rpm for about 5minutes.
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.
-
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- - - -Ensure tripping ofAOP at 2950 rpm.
05 56'Turbine speed: 3000rpm.
Put AVR on auto Closefield breaker.
-
- - -
Set Manually generatorvoltage to grid voltage. -
- - -Synchronise thegenerator with grid.
Speed set point willbe raisedautomatically byabout 8 rpm and load
will be picked upto 20MW.
- - -Synchronise thegenerator with grid.
-
- - -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.
Cut in first coal mill &cut in auto controllers.
Make ready SH & RHspray systems.
- - - 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
-
8/10/2019 500MW Starting Procedures
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programme toproceed further.
- - - -
All operations asexplained under EHC
rolling will be carriedout by SGC-Turbineprogrammesequentially.
03 50'
Turbine ready forrolling.
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.
- - - -Ensure tripping ofAOP at 2950 rpm.
- - - -
Monitor bearingtemperature andvibrations, shaftvibrations, TSEmargins, Turbovisoryreadings, seal oil,
primary water,Hydrogen gas andGenerator windingtemperatures.
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05 56'
Turbine speed: 3000rpm.
MS: 85 kg/cm2/5000C
HRH: 12kg/cm2
/4500
C
Bypass steam flow:360t/hr.
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.
-
- - -Increase HPBP setpoint.
Ensure closure ofHPBP steam valves &spray valves.
- - -
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. -
- - -Start withdrawing oilsupport gradually.
Ensure healthiness offire ball scanners.
07 65'
LOAD: 150 MW.
MS: 100kg/cm2/5000C
HRH: 20kg/cm2/4800C
Main steam flow:1620t/hr.
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.
-
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- - -
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
Main steam flow:820t/hr.
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.
-
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10 135'
LOAD: 500 MW.
MS: 170kg/cm2/5000C
HRH: 40.5kg/cm2/4800C
Main steam flow:1570 t/hr.
- -
********************