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GT MODE HRSG STARTUP PROCEDURE.

1. ENSURE NATURAL GAS PRESSURE LESSER THAN 32 BARG(<32BARG)


2. ENSURE BATH HEATER IS IN RUNNING CONDITION.
3. NGSS UNIT ESD SHOULD BE OPEN CONDITION
PRESSURE: 30 TO 32 BARG, PILOT GAS TEMP 40 TO 70 DEG C, PREMIX GAS TEMP 70 TO 200
DEG C.
4. ENSURE UNIT CCW (DISCHARGE PR>10BARG) AND COMMON CCW (DISCHARGE
PR>4.5BARG) IS IN RUNNING CONDITION.
5. ENSURE THE COMMON AIR COMPRESSOR IS RUNNING CONDITION ITS DISCHARGE
PRESSURE SHOULD BE GREATER THAN 8 BARG.(>8 BARG)
6. ENSURE HYDRAULIC OIL PUMP IS IN RUNNING CONDITION ITS DISCHARGE
PR: 180 TO 210 BARG, TEMP : <55 DEG C AND TANK LEVEL: 250 TO 300MM.
7. CHECK THE DM TRANSFER PUMP CONDITION AND DISCHARGE PR>6 BARG.
8. INTIAL FILLING OF CONDENSATE STORAGE TANK MORE THAN 1700MM (75%)
9. ENSURE THE STACK DAMPER SHOULD BE CLOSED CONDITION.
10. VACCUM DRAIN TANK AND DUCT DRAIN TANK LEVEL <600MM
11. CLEAN DRAIN TANK LEVEL<900MM
12. CHECK THE CEP PUMP CONDITION AND START IT.
13. CHECK THE DRUM VENT MOVS ARE IN AUTO MODE.
14. ENSURE THE LUBE OIL PUMP BEFORE STARTING BFP AND START IT.
15. CHECK THE WATER PARAMENTERS BEFORE FILLING (conductivity & PH at allowable level)
16. CLOSE THE EVAPARATOR AND CBD MOV WITH MANUAL ISOLATION VALVE ONCE ENSURE IT
THEN FILL THE WATER IN LP, IP & HP DRUM AT DESIRED LEVEL DEPENDS ON MODE
MENTIONED BELOW.
DRUM LEVEL (START UP LEVEL)
1. COLD STARTUP
HP DRUM -580 TO -500MM
IP DRUM - 430 TO -380MM
LP DRUM -430 TO -380MM

2. HOT START UP
HP DRUM -360 TO -260MM
IP DRUM -260 TO -160MM
LP DRUM -420 TO -320MM

17. NOTE: DURING START UP CONDITION FCV OF ALL THREE DRUMS ARE PUT IN MANUAL
MODE AND CONTROLLED BY DCS OPERATOR ONCE MODE OF FLOW CONTROL CHANGED
FROM SINGLE ELEMENT TO THREE ELEMENT THEN PUT INTO AUTO MODE.
18. AUXILLARY STEAM “ON” USING AXILLARY BOILER OR OTHER BOILER WARM UP THE
AUXILLARY HEADER
19. AUXILLARY STEAM MATCHING TEMPERATURE AND PRESSURE BY ADJUSTING PCV
MANUALLY AS PER PRESSURE OUTLET, HEADER DRAIN MOVS, SEAL STEAM DRAIN MOV AND
HOGGING MOV...
20. START HOGGING ( AFTER OPENING STEAM MOV THEN OPEN AIR MOV)
21. START HOLDING <0.150 BARG
22. ONCE THE BY-PASS OPERATION STABLED THEN STOP HOGGING < 0.100 BARG (AFTER
CLOSING AIR MOV THEN CLOSE THE STEAM MOV).
23. ACC AUTO(SET OR CHECK THE MANUAL SETPOINT IS LESSER THAN 0.100BARG(0.08BARG)
24. ONCE VACCUM PULLED <0.100 BARG SHOULD BE INFORM TO TURBINE OPERATOR BECAUSE
THEN THEY WILL PROCEED SEAL STEAM SYSTEM.(PR-9 BARG, TEMP >290 DEG C).
25. NOW HRSG STARTUP
26. HP,IP AND LP STARTUP MOVS PUT IN AUTOMODE AND OPEN THE MSSV MOV OF HP,IP AND
LP DRUM.(HP>15BARG,IP>10BARG & LP>2BARG- STARUP VENT MOVS CLOSED)
27. MAIN STEAM SYSTEM PUT INTO AUTO MODE
28. LETS GT STARTS… AFTER GT FLAME ON
29. SFC(STARTING FREQUENCY CONTROL) STARTS
30. START PURGING UPTO 10 MINUTES(600SEC)
31. THEN GT FLAME ON INCREASING THE TURBINE SPEED UPTO 3000 RPM.
32. ONCE IGNITION STARTS TEMPERATURE PRESSURE OF THE EACH(HP.IP &LP) DRUM
GRADUALLY INCREASES
33. ENSUREIN BOILER BLOWDOWN & EVAPORATOR DRAIN LINE MANUAL ISOLATION VALVES
ARE OPENED CONDITION.
34. AT THE SAME TIME DRUM LEVEL OF HP,IP AND LP SINKING AND SWELLING THAT TIME
DRUM LEVEL SHOULD BE MAINTAIN DESIRED LEVEL USING DRAIN MOV,CBD MOV AND FCV.
35. ENSURE THAT ONCE THE TEMPERATURE INCREASES MORE THAN 200 DEG C PERFORMANCE
HEATER TCV SETPOINT PUT 180DEG C AND PUT AUTO MODE.(NGSS)
36. PRESSURE AND TEMPERATURE OF THE MAIN STEAM OF HP, IP & LP REACHED THEN BY-PASS
OPERATION TAKES PLACE.
37. BY PASS OPERATION IN AUTO MODE TAKES PLACE ONCE THE T11 (STI) & T14
(VACCUM>0.450BARG) CONDITIONS ARE SATISFIED.
38. HRH PCV -STI >30 & PR>18.5 BARG
39. HP PCV -STI>50 & PR>18,27,74 BARG
40. LP PCV -STI>30 & PR>3.6
41. AT BY PASS OPERATION SAFETY VALVE SETPOINTS ARE
1. HRH SETPOINT –PR>36BARG SAFETY VALVE OPENED.
2. LP SETPOINT – PR>6BARG SAFETY VALVE OPENED.
42. UNIT AXILLARY STEAM ALSO IN AUTO MODE.
43. ONCE THE DRUM LEVEL STABLISED AND STEAM FLOW GENERATED AT EACH DRUM AT
DESIRED LEVEL(HP FLOW>77 T/H,IP FLOW>26T/H & LP FLOW>15T/H) THEN FCV
CONTROLLER CHANGED FROM SINGLE ELEMENT TO THREE ELEMENT THEN PUT THE FCV
VALVES IN AUTO CONTROL MODE.
44. THEN GRADUALLY RISE THE LOAD UPTO BASE LOAD WITH RESPECT TO GOVERNORING
VALVE OPENED.
45. NOW BY PASS VALVES ARE 100% OPENED
46. NOW GC-SIMPLE MODE POWER GENERATED OF ITS BASE LOAD 250MW.
47. AFTER GT SIMPLE MODE HP, IP & LP DRUM BLOW DOWN AND EVAPORATOR DRAIN
MANUAL ISOLATION VALVES SHOULD BE CLOSED.

GT MODE TO CC MODE OPERATION.


1. BY VARYING THE HRSG IN GAS TEMPERATURE ( GT EXHAUST TEMP) TRY TO MATCH TURBINE
OPTIMUM HP & HRH STEAM INLET TEMPERATURE
2. THE ABOVE POINT CAN BE DONE BY VARYING THE LOAD AND CONTROLLING THE LINE
DRAIN MOV & HRH STEAM MOV.
3. FOR HP WARM UP COMPLETION OF STEAM FOUR CONDITIONS ARE SATISFIED THEY ARE
1. STI(SATURATION TEMP) OF HRSG STEAM OUTLET TEMP>30DEG C
2. HRSG STEAM TEMP –STEAM TURBINE INLET TEMPERATURE <30 DEG C
3. STI OF HP TURBINE INLET TEMP>20DEG C
4. CRH OUTLET OF HP TURBINE STI >20 DEG C
4. FOR HRH WARM UP COMPLETION OF STEAM TWO CONDITIONS ARE SATISFIED THEY ARE
1. HRHSTEAM TEMP ST>30 DEG C
2. HRH STEAM INLET – STEAM TURBINE IN TEMP<30 DEG C
3. HRH STEAM TURBINE INLET STI> 20DEG C
5. FOR LP WARM UP COMPLETION OF STEAM TWO CONDITIONS ARE SATISFIED THEY ARE
1. STI OF HRSG LP STEAM OUTLET >30 DEG C
2. LP STEAM INLET – LP TURBINE IN TEMP<30 DEG C
3. LP STEAM TURBINE INLET STI >30 DEG C
6. HP,HRH & LP WARM UP COMPLETE THEN ESV OPENED AND GOVERNING VALVE OPENED 5%
GRADUALLY CASING & SHAFT TEMPERATURE RAISED(IT TAKES 20MINUTES).
7. NOW INCREASING THE LOAD GRADUALLY PARALLELY THE BY PASS VALVES OF HP, IP & LP
CLOSED GRADUALLY.
8. ONCE TURBINE IS IN COMBINED CYCLE MODE THEN AUTO SELF SEALING WILL TAKES PLACE.
9. BASE LOAD AT CC MODE IS 400MW.

FOR NORMAL OPERATION:


HP
PRESSURE: 111 BARG
TEMPERATURE: 567 DEG C
FLOW: 239 T/H

LP
PRESSURE: 27.6 BARG
TEMPERATURE: 566 DEG C
FLOW: 285 T/H

IP
PRESSURE: 4.5BARG
TEMPERATURE: 229 DEG C
FLOW: 34 T/H

DRUM TRIP LEVEL


HP
HHH: +280MM
LLL: -650MM
IP
HHH: +170MM
LLL: -540MM

LP
HHH: +140MM
LLL: -540MM

HRSG SHUTDOWN PROCEDURE:

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