JSWSL CPP-1x100MW

COLD START-UP CHECK LIST Rec. No: Date: Page:

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Applicable when casing temperature is less than 220oC Date: 12-10-2008 Reason for shutdown: Date & time of S/D: Sl. NO ACTIVITY Ensure 6.6KV, 415V (PMCCA, PMCCB, NE, CWPH, BVDC, TVDC), 220V DC, UPS are available and charged& emergency power supply by taking DG SET trial. Synchronization time: CHECK REMARK S

Reset under voltage relays on, 6.6 kV bus, 415V buses. Ensure islanding mode-1 condition selected . Ensure fire system is ready & pumps are in auto. Jockey pump is running. Ensure all PTW related CW,ACW,Compressed air system,and any all PTWs including corex and BF system returned & Start N2 purging for corex and BFsystems as per procedures and check for O2 percentage at both C headers and before trip valve. Corex and BF seal pots are filled and over flow is ensured. All gas line drains to seal pots are open. If O2 before TV is less than 0.5 %, pressurize before TV header up to 400 mmwc with Nitrogen and close N2 vent before TV. Drain U seal and open the goggle valve of Corex and BFG. Boiler drum filling (If drained) (a) Ensure CST 1& 2 levels are normal (> 7 mt.).If not start DM tank filling from JSWEL (b)Ensure PTWs related to boiler water / steam touched parts up to MS stop valves & boiler filling systems are returned. Ensure Boiler safety valve gags are removed (c) Ensure steam / water sampling system (SWAS)is lined up & charged. (d)Open Boiler PSH, De SH, Drum, ECO vents & start up vents.

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Sl. NO

ACTIVITY

CHECK

REMARK S

(e) Check low point header drains are open. Close the header isolation valves to IBD tank. (f) Open De SH, SSH drain, PSH drain & MS line drains. (g)Ensure MS - 1, 2, 3 & 4are closed. Drains in MS line are open (h)Isolate one CST and add chemicals as per chemist instruction. Run boiler fill pump on recirculation. Line up HP dosing to boiler, for chemical dozing. (i) Close boiler fill pump line to de-aerator and ACW o/h tank .Line up and start Boiler fill pump in re-circulation to bottom header through LPD for economizer and boiler filling. Maintain fill pump flow such that the pump current is normal. (j) Fill drum level upto (-)75 mm. (k) Close all the low point header drains (both isolation valves) and stop fill pump. Starting CW & ACW system (a) Ensure PTWs related to CW & ACW system are closed. (b) Ensure fore bay level is above normal (-250mm) (c) Line up CW system. Open condenser water box inlet outlet both sides and its vents & air vents on CW pump discharge. Open 4 cells of CT raisers till the marking on valve (40%) (d)Ensure that CW hot tunnel & cold tunnel is filled through service water back charge line. (when water falls down to CT basin through risers close service water filling). (e) Permissive for starting the pump to be checked. (f) Start CW pump & close the vent after opening of discharge valve and condenser vents also to be closed after air venting. (g)Ensure standby CW pumps are available. Start chlorine and acid dosing system and SSF.Charge two PHEs from CW side. (h)Fill ACW over head tank from fill pump and add chemicals as per chemist instruction. Charge ACW system slowly, by opening the overhead tank outlet and vent all coolers in boiler side, turbine side, compressor and generator. Vent ACW system at SWAS room. All 3 pumps inlet outlet open and vent out air. Start two pumps one by one and maintain header pressure. Charge PHE from ACW side 27 Starting compressed air system

Cold start-up check list

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Sl. NO

ACTIVITY Start one compressor. Ensure instrument air & service air systems are charged and backup N2 system is charged. Other compressor is selected auto s/b. (a) Ensure PTWs related to feed water system & Deaerator is closed. (b)Start Deaerator filling using Boiler fill pump. (Ensure boiler and ACW filling valve is closed). (c) Line up BFPs & feed water line. [At least one BFP suction & discharge valves and HP heaters I/L, O/L & bypass valves should be kept open]. Ensure Standby pump is available (d) Keep feed control station valves in open condition and vent through eco. Inlet vent. Vent air through all the vents in BFD. Close vents after completing the venting. (e) Check operation of FCV 30 and 100% CV. Starting condensate system (a) Ensure PTWs related to condenser & hot well makeup systems are closed. (b) Fill hot well using H/W makeup pump, up to + 1300mm.Put hot well make up pumps in auto (c) Open re-circulation control valve fully and ensure condensate line up (a) Keep pump discharge valves are closed and de-aerator level control valve in closed condition. LPH-1 & 2 I/L, O/L valves & bypass valves are open. (b)Ensure CEP header vent, re-circulation valve are open. (c) Ensure HP bypass spray valves are closed. (d)Check pump local line up. Canister vent, discharge sol vent and its bypass MIV in open condition. (e) Start one CEP. charge the discharge header .Do venting properly in the condensate line. Close vents after evacuating air .Keep the other CEP in standby (f) Charge LP Economiser condensate side slowly and after venting take in service.

CHECK

REMARK S

(g) Starting of LDO system. (a) Ensure PTWs related to LDO system are closed. (b) Line up and start LDO forwarding pump with 10ksc set point for the re-circulation valve. (c) Ensure standby LDO transfer pump is available. Starting of Fans (a) Ensure PTWs related to Flue gas system, LP eco, Chimney, Secondary air & main boiler are closed. Ensure that manholes & peepholes are closed.

Cold start-up check list

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Sl. NO

ACTIVITY

CHECK

REMARK S

(b)Ensure SADC are in auto. (c) Line up secondary air system, flue gas path, LP economizer and ID & FD fans. (d)LP economizer is isolated in flue gas side with bypass damper full open and close inlet damper Ensure that DC scanner is available by taking its trial and its discharge dampers are operating. Start AC scanner air fan. Ensure header pressure is normal. Select DC fan and its discharge valve in auto. (e) Start one stream of ID & FD fans after ensuring local line up. Put furnace pressure control in auto (SP -7mmwc). Purge & LDO system line up (a) Ensure that all I&C permits related firing system is returned. All oil guns ,igniters and scanners and its 43 feedbacks are ok (b)Ensure >140 t/hr airflow and Purge the boiler. (c) Open LOTV and ensure that pr. after LOTV >10ksc & atomizing air pr. > 6 ksc. Starting of Lube & Jacking oil system (a) Ensure PTWs related to turbine & their oil systems are returned. (b)Ensure MOT level is normal.(> 640 mm) (c) Start one OVEF and open suction and discharge (mot vac>100 mm hg). Keep other fan in standby. Oil cooler ACW side is charged (d)Line up lube oil system with cooler and filter and start one lube oil pump. Ensure other pumps availability. Running AOP is in auto and other AOP is selected standby. EOP selected in auto. Ensure OHT level is building up. (e) Start AC Jacking oil pump and put turbine on barring gear. Ensure DC JOP is standby AC JOP in auto and barring selected auto. Trial run of DC AOP, DC JOP and standby AOP is to be taken. Boiler Light up (a)Light up boiler with 2 LDO guns at A elevation. Burners change over to be done after 1 hr. Ensure startup vent is 51 open. (b) Check Furnace condition, Expansion measurements, and oil leaks if any. 55 ( (e) Monitor Hydrastep and all three drum level Tx.cross 56 check with drum local gauge. 57 Start CEP in re-circulation.

Cold start-up check list

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Sl. NO

ACTIVITY

CHECK

REMARK S

(a)Keep pump discharge valves are closed and de-arator level control valve in closed condition. LPH-1 & 2 I/L, O/L valves & bypass valves are open. (b)Ensure CEP header vent, re-circulation valve are open. Pump discharge sol. Valve and its bypass MIV in open condition Ensure HP bypass spray MIV at 4MTR in open and Spray block valves are closed. (d)Start one CEP. Slowly charge the discharge header .Do venting properly in the condensate line. Close vents after evacuating air. Keep the other CEP in standby with bypass MIV in open condition. (e)Start LP dosing system. Start BFP in recirculation. (a) Ensure all BFP and BFD related permits closed. Start lube oil pumps of all pumps & keep in auto. Line up BFPs and HPHeaters. All HP Heaters inlet outlet and bypass open. (b) Ensure min. scoop, R/C valve MIVs for all BFPs at 64 deaerator are open. ACW is charged. BFP discharge valve is closed and start BFP. Open the discharge valve IBV and then discharge valve .Slowly charge the line. Ensure that LOP stops when lube oil pr is normal. (c) Keep another BFP in standby .Take 30% FCS into service to maintain the drum level. (a) At drum pressure 3 ksc; Close SH, Drum, Eco vents and throttle start up vents to 20%. Close SH header drains at 5 KSC (b)Give blow down at approx 20KSC from low point header drains around 3 times & collect the sample. (c) As per chemist start LP and HP dosing systems with required stroke. (d)Start second pair of oil guns in A elevation. Control oil system and HP bypass oil system (a) Ensure PTWs related to control oil system are closed. (b)Line up Control oil system and start pump. Running pump selected auto and other pump is selected in 71 standby (c) Line up & start control oil-circulating pump. (d)Ensure PTWs related to HP bypass system are closed. (e) Line up and start HPBP oil pump. Panel switches are selected auto 77 MS line Charging at drum pressure 10 Ksc.

Cold start-up check list

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Sl. NO

ACTIVITY

CHECK

REMARK S

(a) Ensure PTWs on turbine stop valves, MS, HP/BP are returned. MS drains at turbine side are open. Ensure MS vents at turbine end and seat drain are open. Ensure Turbine is on barring (b)Ensure PRDS isolation valves closed. (c) Ensure HP bypass is closed. (d)Charge line by slowly opening MS-3 & MS-4. Equalize pr across MSSV (e) Open boiler stop valves MS 1&2 when upstream and downstream pressures are equal. (f) Close MS-3, MS-4 throttle start up vent opening to limit rate of pressure and temp (g) Close MS drains bef ore MS stop valve. Ensure MS 83 spray MIV s open. 84 (h) If corex & BF clearance is available, Ensure corex and BF N2 purging is in progress & O2 in corex and BF- C header sample through vent less than 0.5%. (a) Check corex C header O2 is less than 0.5% (b) Open corex trip valve. Maintain C header pr .Take corex burners in A elevation. Ensure corex flame in 85 local and remove oil burners. Maintain the firing to get the pr rise of (15-20)ksc/hr apprx. (c) Take LP eco in service and bypass damper is kept 25% open Line up & start second stream of ID, FD fans. Match the currents of FD & ID fans. Check ID fan draft control in auto (-7mm). Charge PRDS at 15 ksc (a) Ensure PTWs related to PRDS, MS lines, Gland Steam are returned. (b)Ensure De-aerator pegging line and initial heating lines from PRDS are closed. (c) (d)Ensure PRDS drains and sprays MIVs are open. Gland 92 steam and ejector MIVs are closed condition (e) Slowly open Low capacity control valve to charge header. Slowly raise the header pressure. (f) Maintain PRDS temperature. Charge slowly APRDS hi capacity Line by opening the CV. (g)Put PRDS pressure & temperature controls in auto with SP -9 ksc. Hi cap PRDS is in service. Throttle the drains to min position
(a)

Cold start-up check list

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Sl. NO

ACTIVITY Gland steam header charging and Vacuum pulling (a) Open Gland steam header drains & vents to atmosphere (b)Open GS header inlet MIV at PRDS and slowly charge GS line (c) Ensure PTWs related to vacuum system are returned.

CHECK

REMARK S

(d)Ensure turbine on barring gear. (e) Ensure hot well level is normal & CEP is running (f) Close Vacuum breaker valve, keep in auto & establish water seal. (g)Start 4 CT fans for which raisers are open (h) Charge gland seal. Control temperature of GS as per required condition. Select FG seal steam in auto. Auto 99 selected GSC fan starts and other fan is standby. Seal steam upstream header Pr 12 KSC, Degree of SH >50, temp not less than casing by 200 deg C. PRDS temp. 250 C (i) Charge ejector steam. Line up and start starting ejector with drain after starting ejector in crack open condition (j) Open GS drain to condenser when vacuum is greater than-0.4 ksc, close atmospheric drain. Change over to main ejector and remove starting ejector at 0.15 bar A. Charge Dea-erator pegging slowly from PRDS. Close de-aerator start up vent valve. Keep Deaerator & hotwell level controls in auto. 11 HP bypass charging 4 (a) Ensure condenser vacuum is < 0.4 bar a. Cl (b) (c) Ensure spray block valve, control valve and bypass valve in auto and downstream MOV open. Spray MIV in the condensate line is open (d)Open HPBP valve 5% slowly. (e) Open HPBP spray to maintain the downstream temperature (f) Close start up vents if HPBP CV >10%. (g)Start second CW pump .Open all CT raisers to the required opening. Start remaining CT fans. CW pump standby is selected on auto Ensure that boiler water temp. raise is within 55.5c/hr and expansions are normal. Raise boiler pr to 40 Ksc

Cold start-up check list

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Sl. NO

ACTIVITY Check Generator relay panel is resetted. AVR is ready.GT1 and 2 are ready. Reset turbine trip. Reset hydraulic trip. Check other conditions are satisfied Open ESV. (Minimum parameters 32 bara, 290 deg C and maximum parameters 70 bara and 420 deg C at turbine inlet). Minimum degree of SH required is 50 deg C and steam temperature to be more than casing temp- 50 degC

CHECK

REMARK S

Check JOP stops at 900 rpm. Lube oil temp min 32deg at 30% speed, 40deg at 70% speed Monitor turbine parameters, mainly vibrations. Field bkr. Closes at 95 % speed & excitation control in auto. 3000 rpm is reached within 70 min. Select Frequency controller in auto Match Gen. Frequency & voltage. Switch on synchronoscope .Take clearance from MSDS and JSWEL Synchronize generator to grid by closing GT-1 and Gt-1 breakers. Load gradually rises to up 13.6 MW. Put Load controller on auto and raise load. Monitor boiler drum, hot well and de-aerator levels and put in auto. Now check for turbine vibrations ,axial shift and general checkup for all equipments parameters Close HP bypass and put auto/manual station in auto. Close MS/PRDS drains . Increase the load by watching load. curve Increase corex firing and air flow . 13 Charge LPH 1&2 at 15 MW. 5 (a) Ensure PTW related to LPH-1&2 are returned. (b)Ensure heaters are charged from waterside (I/L & O/L valves are open & bypass valve is closed for both heaters). (c) Extraction line drains are open. (d)Ensure service vent is open & shell vent to atmosphere is close for both heaters (e) Line up cascading drains of both heaters. Control valves are open 50%. (f) Open slowly LPH-1 extraction by seeing the heater level & shell pressure. (g)After the level is build up, level control in auto (sp 110 &130 mmwcl), Ensure extraction MOVs, Heater inlet /outlet MOVs, Heater bypass MOVs and drain MOVs are selected remote

Cold start-up check list

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Sl. NO

ACTIVITY

CHECK

REMARK S

(h)Open slowly LPH-2 extraction by seeing the heater level & shell pressure Put normal & emergency drains valves in auto (SP110 & 130mmwc). Ensure extraction MOVs, Heater inlet /outlet MOVs, Heater bypass MOVs and drain MOVs are selected remote Start second BFP & ensure third BFP in auto standby mode. Increase firing and raise load as per the load curve. Steam chemical parameters are controlled with CBD and dosing. Monitor Diff. Expansion and vibrations. Deaerator charging at 20MW (a) Open drain traps & its bypass valves before & after extraction line NRV 's & ensure drains are open (b) Slowly Open De-aerator extraction. (c) After matching upstream & downstream pressure, fully open the valve Close bypass of traps of the drains. Aux 13 steam line from pegging to be stopped. 9 Change over to Low capacity PRDS (set pt 11 ksc and 260 deg C). Hi cap PRDS set point(9 ksc) Cut in second elevation corex burners in C elevation (If steam flow >117tph) Changeovers drum level control to 100 % FCV in service. Ensure standby FWCV and line is through. Line up & Charge HPH - 1 at 30 MW (a) Ensure PTW related to HPH-1 are closed. (b)Ensure heater is charged from waterside (I/L &O/L valves are open & bypass valve is closed). (c) Open extraction line drains & ensures service vent & atmosphere vent is close. 14 (d)Line up emergency drain control valve & normal drain 5 control valve. (e) Open slowly block valve by seeing the level & shell pressure. (f) Fully open the valve. Drains are kept in auto after level is build up. Ensure extraction MOVs, Heater inlet /outlet MOVs, Heater bypass MOVs and drain MOVs are selected remote 14 Line up & Charge HPH 2 at 40 MW. 9 (a) Ensure PTW related to HPH-2 are closed. (b)Ensure heater is charged from waterside (I/L &O/L valves are open & bypass valve is closed). (c) Open extraction drains & service vent & close atmosphere vent. (d)Line up drains.

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Sl. NO

ACTIVITY (e) Open slowly extraction from local by seeing the heater level & shell pr. (f) Put HP heater 2 level (normal, alternate & emergency) controls in auto after level is build up. Ensure extraction MOVs, Heater inlet /outlet MOVs, Heater bypass MOVs and drain MOVs are selected remote Increase load and firing to 55 MW Starting BF firing at 55 MW (BF clearance is available) (a) Check BF C header O2 % < 0.5% .Open BF trip valve (b) Cut in BF B elevation one by one. Maintain MS temp by spray control. (c) IF BF clearance is not available take E elevation corex and raise the load (d) cautionWhile cutting in BF burners allow sufficient time, till temperature stabilization. (e) Adjust LP Economiser damper as per fuel type and combination. Islanding mode 2 selected if conditions ok. Check GT fans started on auto. Chemistry of Boiler parameters and CW parameters to be monitored.

CHECK

REMARK S

15 3 c Check SWAS system values and sample lines to Lab are through. Check level of EOT of turbine /Generator. Check ups load and relays in GRP panel Cut in second elevation BF and Gradually raise the load to 104MW based on drum water silica. Maintain excess air. O2 %1.8. Ensure HP bypass pressure set point 90KSC and pressure/spray system in auto. Standby auxiliaries (BFP, CWP, CEP, Compressor, ACW, lube oil system) to be kept ready. Aux system like fire system, AC ventilation and SSF are in service. Ensure EMRV isolation valves are open and EMRV selected auto. 16 7 16 8 16 9

Cold start-up check list

Approved by: Sign: CONTROL STATUS Sign:

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Issued & Controlled by:

HOD - OPERATION

OPERATION SUPPORT ENGINEER