START-UP OF TURBINE

COLD START-UP PROCEDURE FOR 4 X 210 MW TPS-II UNITS

TIME ACTIVITIES:

PREPARATION OF BOILER FOR COLD LIGHT UP.

THOROUGH INSPECTION OF FURNACE FOR COMPLETE CLOSING OF PEEP HOLES

AND MANHOLES. AFTER FILLING THE SLAG BATH, ENSURE RUNNING OF SLAG

CONVEYOR AND ABG'S.

-04.30 HRS TURBINE:

START PREHEATING OF FEED WATER IN DEAERATOR AND RAISE THE WATER

TEMPERATURE TO 70 ºC TO 80 ºC.

START WARM-UP OF BFPS, KEEPING CASING DRAINS, VENT CRACK OPEN

CONDITION.

BOILER:

CLOSE WATER SIDE DRAINS VALVES.

OPEN SH1 I/L AIR VENT, OTHER AIR VENTS, STARTUP VENTS AND DRAINS OF SH

& RH.

-03.00HRSTURBINE:

START ONE CWP, ACWP AND ACWBP.

CHARGE THE CONDENSER, PHE’S AND TURBINE LUB OIL COOLERS.

-02.30HRSTURBINE:

MAKE UP SYSTEM IS MADE READY.

-02.00HRSTURBINE:

START ONE BFP. START BOILER FEEDING.

PEGGING STEAM TO DEAERATOR CAN BE MADE THROUGH AND PRE HEATING

STEAM MAY BE ISOLATED.

KEEP THE OIL IN CIRCULATION.

BOILER:

KEEP THE OIL IN RE-CIRCULATION.

CHARGE TRACE-HEATING SYSTEM IN BOILER.

CHECK THE POSSIBLE LEAKS IN EACH OIL BURNERS.

ENSURE THE HEALTHINESS OF OIL BURNER SYSTEM.

AFTER BOILER CONTOUR FILLING, CHECK WHETHER ALL AIR VENTS, STARTUP

VENTS AND SH, RH DRAINS ARE IN OPEN CONDITION.

ENSURE THAT LSHS OIL TEMPERATURE IS MORE THAN 90 ºC.

‘GENERAL INTERLOCKING FOR OIL FIRE EXISTING' IS AVAILABLE NOW.

BOILER IS READY FOR LIGHT UP.

START ID & FD FANS.

CHARGE SCAPH.

START PURGING.

-00.00 HRS BOILER:

LIGHT UP BOILER BY CUTTING IN 2 OBS WITH LDO.

CHANGE OVER TO HFO AFTER 10 MINUTES ONE BY ONE.

OIL PRESSURE IS 6 KSC.KEEP DRUM LEVEL AT 300 MM.

NOTE DOWN THE DRUM METAL TEMPERATURE (DMT), OIL FLOW AND OIL

PRESSURE.

WHILE CUTTING IN OB RAISE OIL PRESSURE TO 12 KSC. THEN REDUCE PRESSURE

TO 6 KSC.

TURBINE:

CONDENSER VACUUM RISING CAN BE STARTED.

AST HEADER TEMPERATURE SHOULD BE BETWEEN 250◦C -280◦C.

KEEP OPEN THE FOLLOWING DRAIN VALVES.

MS 25 & 26, HR 47 & 48, CR 51 &52,HR 15 & 16,CR 11 &12,HP B/P ATMOSPHERIC

DRAIN VALVES,ALL MAL DRAIN VALVES AND THEIR BEFORE GATE VALVES.

-01.00 HRS BOILER:

WATCH THE DMT. WHEN IT REACHES 90 ºC, SURGING OF DRUM LEVEL MAY START. WHEN

SURGING OF DRUM LEVEL IS OBSERVED, OPEN EBD.

CUT OUT ONE BURNER AND IF NECESSARY OPEN CBD ALSO TO CONTAIN DRUM

LEVEL.

DOZING PUMPS ARE TO BE STARTED.

OIL PRESSURE TO BE RAISED TO 12 KSC.

01.30 HRS BOILER:

CUT IN 3RD OB WITH HFO 4TH OB AFTERWARDS.

AFTER NORMALISING DRUM LEVEL CLOSE CBD & EBD, CUT IN 3RD OB.

WHEN SH1 -I/L TEMPERATURE IS MORE THAN 110 ºC, CLOSE SH1 INLET VENT &

ALL VENTS AT 44 ML.

CLOSE THE SH DRAINS IN ORDER, WHEN STEAM TEMPERATURE IN SH SHOWS RISING

TREND AND STEAM TEMPERATURE AT O/L HEADER IS GREATER THAN I/L

HEADER.

WHEN SH3 O/L PRESSURE IS 1KSC START CLOSING START UP VENT GRADUALLY

WITHIN 10 MINUTES.

WHEN SH3 O/L PRESSURE IS 5KSC OPEN HP BYPASS AND CHARGE RE HEATERS.

OPEN MS25&26, MAL-11&12&HR-47&48.

REDUCE OIL PRESSURE TO 10 KSC.

BEFORE OPENING HP BYPASS VALVES CHECK FOR

1) SAFE DRUM LEVEL.

2) FULL OPEN CONDITION OF MS-001 & 002.

3) CLOSING OF STARTUP VENT VALVES.

4) VACUUM IS STABLE.

02.00 HRS BOILER:

RAISE OIL PRESSURE TO 8 KSC.

TURBINE:

OPEN HP BYPASS ACCORDING TO THE SH3 O/L PRESSURE RISE. WHEN

THE RH PRESSURE IS 2KSC OPEN LP BYPASS WITHOUT AFFECTING VACUUM.

SWITCH ON LPB/P AUTOMATIC CONTROL INTERFACE AND CHECK THE

PERFORMANCE OF LPB/P THERE AFTER.

(AT THIS STAGE HP BYPASS OPENING SHALL BE AROUND 30 %.) RATE OF

PRESSURE RAISE IS MS: 1KSC / 2 MIN & HRH: 1KSC / 4 MIN

RATE OF TEMP RISE IS 2.5 ºC /MIN UPTO 350 ºC.

02.30 HRS BOILER:

RAISE OIL PRESSURE TO 10 KSC.

PREPARE INJECTION SCHEME FOR TEMPERATURE CONTROL.

CHECK INJECTION STATION DRAINS AND VENTS FOR CLOSED CONDITION. HAND OPERATED

ISOLATION VALVES IN OPEN CONDITION.

S-92 BYPASS VALVE IS TO BE USED FOR INJECTION TO HAVE FINE CONTROL.

TURBINE:

HP BYPASS SHALL BE OPERATED MANUALLY SO AS TO MAINTAIN MS PRESSURE AT 23 KSC.

SELECT LP BYPASS IN AUTO AT AT HRH PRESSURE OF 7 KSC.

AT MS PRESSURE 23 KSC & MS TEMPERATURE 300 ºC

START WARMING UP OF STOP & CONTROL VALVES.

MAINTAIN MS TEMPERATURE NOT MORE THAN 350 ºC.

FOR 23 KSC SAT. TEMPERATURE IS 225 ºC.

IN TSE RECORDER AND CONFIRM RISE IN TEMPERATURE.

03.00 HRS RAISE OIL PRESSURE TO 12 KSC.

RAISE MS PRESSURE AT A RATE OF 1KSC/MIN UP TO 40KSC AND WHEN THE PRESSURE IS

STEADY AT 40 KSC SELECT HP BYPASS IN AUTO.

DURING WARMING UP MS & HRH TEMP SHOULD NOT DROP BELOW 320 ºC.

03.30 HRS START ROLLING.

MS PRESSURE: 40 KSC & MS TEMP: 350 ºC.

HRH PRESSURE: 7 KSC & HRH TEMP: 350 ºC.

HP B/P OPENING > 50%.

ROLLING CAN BE STARTED AFTER CONFIRMING 5TH & 6TH POINTS TO REACH ITS

SATURATION VALUE.

REACH 600 RPM.

04.00 HRS AFTER WATCHING HP SHAFT & HP CASING (PTS.7TH & 9TH AND 8TH & 10TH)

FOR ITS WARMING UP AND CROSS CHECKING WITH HP SHAFT & HP CASING

STRESS MARGIN (NOT LESS THAN 30 ºK) FURTHER SPEED RAISING TO 3000 RPM

CAN BE STARTED.

04.05 HRS SYNCHRONISATION.

SYNCHRONISE THE UNIT WITH THE GRID AND KEEP THE TEMPERATURE STEADY AT 350 ºC

FOR 20 MINUTES AND OBSERVE FOR THE STRESS MARGINS.

ACCORDINGLY LOADING CAN BE DONE AND HP B/P CLOSED.

WATCH DRUM LEVEL.

WAIT TILL HP CASING & IP SHAFT MARGIN (7TH & 9TH POINT) SATURATES.

PREPARE THE MILL & FEEDER SYSTEM.

04.35 HRS RAISE OIL PRESSURE SLOWLY SUCH THAT FLOW RISES TO 16 T/HR.

RAISE THE LOAD TO 50 MW.

MS PRESSURE: 60 KSC MS TEMPERATURE : 400 ºC .

LP HEATERS MAY BE TAKEN INTO SERVICE.

FOR FURTHER LOAD RAISING HP CASING MARGIN MUST BE MORE THAN 10 ºK

05.00 HRS START 1ST MILL

RAISE THE LOAD TO 70 MW (RATE 2 MW/MIN)

MS PRESSURE: 80 KSC & MS TEMPERATURE: 440 ºC (RATE 4 ºC/MINUTE)

OPEN S-92 VALVE & CLOSE ITS BYPASS VALVE FOR MORE INJECTION FLOW.

COMMISSION ESP. SH1 INLET TEMP. SHALL BE > 450 ºC

05.15 HRS START 2ND MILL.

RAISE THE LOAD TO 90 MW.

MS PRESSURE: 100 KSC MS TEMPERATURE : 440 ºC .

REDUCE OIL PR. 10 TO 12 KSC.

START WARM-UP OF HP HEATERS ON STEAM SIDE AT 70 MW.

WARM-UP OF HP HEATERS AT LEAST FOR 20 MINUTES.

05.30 HRS START 3RD MILL.

REDUCE OIL FLOW TO 7 T/HR.

RAISE THE LOAD TO 110 MW .

MS PRESSURE: 120 KSC & MS TEMPERATURE : 490 ºC

05.45HRS START 4TH MILL & CUT OUT OIL BURNERS ONE BY ONE.

RAISE THE LOAD TO 125 MW .

MS PRESSURE: 130 KSC & MS TEMPERATURE : 490 ºC .

BEFORE TAKING OUT OIL BURNERS, STABLE CONDITION OF FIRING SHOULD BE ENSURED WITH

IR SCANNERS.

TAKE EHC INTO IP MODE

06.00 HRS START 5TH MILL .

RAISE THE LOAD TO 150 MW.

MS PRESSURE: 140 KSC & MS TEMPERATURE : 500 ºC .

TAKE CMC IN AUTO.

06.30 HRS RAISE FIRING TO FULL LOAD.

RAISE THE LOAD TO 210 MW.

MS PRESSURE: 150 KSC MS TEMPERATURE : 540 ºC