Start-up Preparation

Start-up Power Availability

Plant shall be provided with two numbers of Station Transformer, used to draw unit
start-up and Station auxiliary power from 138kV switchyard. STG shall step down switch
yard voltage of 138 kV to 4.16 kV level and feed station and unit loads.
Balance of Plant System Availability
Before initiating plant start-up, following utility systems are considered to be in
service/lined up for start-up.

CW system in service and Circulating Water to condenser circuit is established.

DM Water system in service an DM transfer pumps running
Condenser/Hotwell, are filled up to the normal water level.
ACW system.
CCW system
Compressed Air System in service, Instrument Air and Service Air pressure
adequate
Turbine Bypass system is on Auto and available.
Boiler Drum is filled up to optimum level
Service Water System
Fire Water System
Fuel Oil Forwarding System in service and fuel oil pressure at Boiler Terminal
adequate
Chemical Dosing System
All Boiler and Turbine drain valves are properly positioned for star up based on
OEM philosophy.
All MOVS are in auto and available.
All maintenance valves are closed
All prior trips of Boiler and Turbine are reset and NO fault conditions exist.
HVAC system in service.

Boiler Pre- Operation Checks

Flue gas path-to be clean and free of foreign objects

Cyclones and ash recirculation system-empty hoppers and clean recirculation
system
ESP-Cleaned and empty hoppers

Bed Ash Coolers-No leakage of air, and filled with sand up to required level.
Hot Gas Generators-System checked for leakage and protections
Furnace-Bed material filled up to proper level
Fuel-Proper level in coal bunkers and Fuel Oil tank
Safety-required control and protection logics healthy
Pre-start up checks of the burners are satisfied.
All the HV/LV Motors are on / Auto selected and in Remote position

Boiler Start-up in Cold condition-COLD START-UP

Start one ID Fans

Start SA fans and get a flow of 10 kg/s for 5 minutes for complete purging of the
furnace.

Start PA fans to get PA flow more than 34 kg/s

Ensure proper fluidization of the furnace bed.

Start Fuel pump and ensure adequate fuel oil header pressure.

Start Boiler Feed pump and condensate pump for maintaining drum and
deaerator level. Ensure appropriate make up water to the hot well.

Start both HCG one by one and set the oil flow such that refractory temperature
does not go beyond 850C. Ensure slow heating of the refractory and the boiler
bed.

Raise the temperature of boiler furnace bed slowly to avoid unusual thermal
expansion. While water starts boiling, close the drum vent at a drum pressure of
2.0-3.0 kg/cm2. Throttle the super heater drains to crack open.

After attaining bed temperature of 350oC, start one centre coal feeder

Take another coal feeder into service adjust PA and SA flow as per requirement.
Maintain Bed Temperature <800C and raise slowly drum pressure to 93 kg/cm2.
The Main steam drain valves are operated during system start-up to drain the
condensate from the main steam piping and also to warm the system piping as
steam is admitted. Main Steam line charging will be initiated by opening Boiler
main steam stop valve when steam pressure reaches 5 kg/cm2 (or at high
pressure in case of warm / hot start).

Maintain MS Temp. 515oC (5C), MS pressure and various other parameters as

specified. All controls can be put to auto mode after stabilizing the combustion.

Gradually raise the boiler loading as per requirements of turbine side.

Auxiliary Steam Line and Gland Seal system Charging

Auxiliary steam during start-up will be supplied from the main steam line. Auxiliary
steam consumption during start-up includes the following consumers.

Deaerator initial heating

Deaerator Pegging steam
Turbine Gland sealing
Turbine Steam Jet Air Ejector

Auxiliary steam source to turbine gland seal system to be established (including

required pipe warming) upon achieving auxiliary steam inlet pressure of 5 kg/cm2.
Auxiliary steam isolation valve is opened to warm up the line first and upon achieving
appropriate temperature the gland steam system can be put into service.
Main Steam Line Charging and Turbine Bypass System into Service.

The Main steam drain valves are opened during system start-up to drain the
condensate from the Min steam piping and also to warm the system piping as steam is
admitted. Main steam line charging will be initiated by opening boiler main steam stop
valve when steam pressure reaches 5 kg/cm2 (or at higher pressure in case of
warm/hot start).
1x 60% (BMCR) Turnbine bypass system is provided to control the main steam
pressure. During start-up before boiler is fired and all permissive for turbine bypass
system are satisfied turbine bypass will be put in to service under auto control.
Once main steam pressure reaches 10 kg/cm2, turbine bypass valves are opened.
Steam pressure is then controlled by turbine by turbine bypass and shall be increased
gradually as per boiler pressurisation curves.
Turbine bypass will be operated as per boiler supplier recommendation from boiler light
off till the parameter (pressure and temperature) required for turbine steam admission
are achieved.

VACCUM UP
For condenser vacuum building, gland sealing system to be established first. Once
gland seals are established, condenser vacuum pulling can be initiated. During start-up
both the ejectors inlet isolation valves are closed. Thereafter, both main and hogging
ejectors are started and their inlet isolation valves are opened for hogging operation.
Once sufficient vacuum is established (to 0.3 kg/cm2) standby hogger shall be stopped
and respective inlet isolation valve to be closed.

6.07.00 Bypass Control Mode

Turbine bypass valve controls builds up the main steam pressure by preset ramp rate
until the pressure reaches STG admission pressure of 30 kg/cm2 (for cold and warm
start up) and 40 kg/cm2 (hot start up). And maintains at that pressure till main steam
control valve takes over the control and therafter turbine bypass system changes over
to tracking mode.
Once the main steam pressure reaches to steam admission pressure, turbine bypass
controller mode changes to pressure control mode. Turbine bypass is operated so as to
maintain the main steam pressure constant at steam admission pressure.
As steam flow to turbine will gradually increases, turbine bypass will start closing
automatically. Once HP bypass Valve opening is less than 2%, turbine bypass
valve will be fully closed. Then after turbine bypass will remain in auto mode
(back up mode) to cater to any emergency conditions.

Turbine Start-up
Turbine start-up is performed by automatic turbine run up system (ATRS) which
is a part of turbine control system, by providing acceleration, load rates and hold
times directly to the primary controls.
STG Rolling
Turbine start-up sequence is composed of three main phases:
1. Speed acceleration ramp from 0 rpm to 1st warm up speed (IDLE
Speed)

2. Speed holding for the 1st warm p for required time (to be confirmed)
3. Speed acceleration ramp from 1st warm up to rated speed

The turbine will be rolled by the ATRS sequence at suitable speed and
acceleration rate based on the casing temperature.
After all the STG pre requisites/ready to start conditions are ensured, and the
boiler steam parameters are matched to the STG admission needs (as per STG
start up mode), steam shall be admitted to the STG.
The STG will be rolled off and brought up to synchronization speed in
accordance with the STG accelerating program.

STG Synchronizing and initial Load

Generator synchronization will be done through auto synchronization sequence (ASS)
automatic synchronizing consist of automatically speed matching and voltage matching,
checking of phrase matching and commanding the GSUT HV side breaker to close.
Once synchronization is completed, turbine will be loaded to 5% (to be confirmed
later) initial load.
Further STG load is increased at a loading rate commensurate with the STG
start mode, by increasing steam flow into the turbine, accordingly the turbine
bypass valves will start closing gradually. When the turbine bypass valve is
opened less than 10%, the STG changes the mode from the load control to the
inlet pressure control. Thereafter, turbine bypass valve changes from control
mode to the tracking mode.
Shutdown Procedure
The normal plant shutdown is considered from the unit operating at full load. At this
point plant is operating at 100% TMCR condition. Two/three coal feeders are in
operation depending upon the coal being used. Boiler feedwater requirement is being
fulfilled by one BFP. One CEP in operation. Turbine bypass system in auto and valves
are in closed condition.
Target load to which load reduction is to be done automatically will be selected by
operator, also whether shutdown is to be done with condenser vacuum up or not is to
be selected by operator. However, if any of the following condition occurs then vacuum
break mode will be selected automatically

1. Condenser vacuum breaker valve open

2. Condenser vacuum>later
Depending up on the selection, shutdown will be performed automatically by executing
various break points.
Steam turbine load will be reduced at a predefined rate of 1.5% / min up to 50% load (to
be confirmed later). Once load is reduced to 50%, load hold of around 30 min. (to be
confirmed later). Will be initiated. Then load will be reduced to minimum load condition
at a predefined load rate of 1% /min(to be confirmed later)..
Changeover from Coal to Oil Firing
Once all permissive for Fuel oil burner light off are satisfied, 3rd coal mill is cut off
below 35% load. Electrostatic precipitator shutdown sequence will be imitated.
Oil firing will be introduced to support further shutdown. Remaining two coal
feeders will be gradually cut off as the load reduces towards 20%. Once all coal
burners are cut off and at least one oil burner is n operation then fuel changeover
is deemed to be completed. Subsequent shutdown will be performed with the
help of oil firing only.
STG Trip and Bypass Operation
Turbine load will be reduced to minimum load condition. After the minimum
shutdown load is reached (<5%) STG shall trip on reserve power protection due
to the closing of tha main steam stop valve and respective STG GSUT circuit
breaker shall open.
As soon as turbine is desynchronized, turbine speed decreases at a predefined
gradient and once speed reaches near to zero speed, turning gear is started.
Turbine bypass valve will open to maintain the upstream pressure at floor
pressure.

Boiler Shutdown
Once steam turbine is tripped, boiler shutdown is performed in following steps:

Last fuel oil burner shutdown

Primary air fans shutdown

When oxygen reaches above 15% and bed temperature reaches below 700 degc
stop PA fans one by one.

Ensure the CO vent valve is open after PA fan stop

After stopping PA fans keep running SA fan for another 10 minutes. Then stop
SA fans one by one.

Keep running ID fans with furnace draft-30 to -40 mmwc for another 30 minutes.

Then stop one ID fan but keep running another fan and reduced furnace to -10 to
-15 mmwc.

Maintain drum level.

Maintain drum level till below screen or bed temperature reaches below 150
degC

BFP Shutdown

Air & Flue gas draft group shutdown

Chemical injection group shutdown