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TG ROLLING PREPARATION
1. VACUUM PULLING & SEAL
STEAM CHARGING
2. MS LINE WARMING &
CHARGING
3. HP BYPASS CHARGING
4. LPBYPASS CHARGING
VACUUM PULLING
ENSURE DRAIN BEFORE CRH NRV TO SDFT
CRHV 101 , MS/HRH STRAINER DRAINS (to
remove impurities) TO SDFT(MSV109,110 &
HRHV 105,106) ARE OPEN.
STATRT VACUUM P/P 1 RECIRCULATION P/P &
OBSERVE THAT SEAL WATER FLOW (remember
the water ring around impeller!) IS
ADEQUATE,START VACUUM P/P 1.
AIR IV V/V OPENS ON INTERLOCK & VAC STARTS
BUILDINGUP.
START 2ND VAC P/P FOR HOGGING OPERATION
FOLLOWING THE SAME PROCEDURE & THAT
CAN BE STOPPED DURING HOLDING OPERATION
AFTER VAC BUILDS UPTO -0.90 Ksc .
Stage 2 or 3
HP BYPASS CHARGING
Drain v/vs BPV 101 & BPV 102 to UFT of
BP1 & BP2 warm up line are open & also
ensure opening of bypass spray block
v/v(BD v/v) man isolating v/v.
Open BP1 & BP2 line warm up v/vs BPV3,BPV-4 & close their drains to UFT.
Open BP1 & BP2 5% manually & check
HPBP D/S temp is rising & also temp is
maintained by spray control v/vs BPE1 &
BPE2.
Raise boiler firing by increasing HFO pr. &
close SH start up vents.
LP BYPASS CHARGING
Open LPT exh hood spray isolation v/v & charge
LPBP warm up line drains.
LPBP spray from CEP is lined up.
LPBP both temp dependent solenoid v/vs are reset.
Keep LPBP controller in manual mode & give
command to controller until water injection v/v 1 &
3 open, then both bypass stop v/vs & control v/vs
open in sequence. Regulate CVs opening & maintain
HRH pr approx 4-6 ksc.
IF LPBP D/S flow increases > 45%, check & ensure
opening of second stage water injection v/vs.
LPBP operation with ACI: it automatically opens
LPBP CVs to 25% & holds it until HRH pr. reaches 12
Ksc, then ACI switches off.
TYPES OF TG ROLLING
1. Cold Start up If HPC metal
Tempr<1500C.
2. Warm start up If HPC metal tempr
betwn 150 to 3500C.
3.Hot start up If HPC metal temp > 3500C.
HPC METAL TEMP IS THE DEFINING CRITERIA FOR
DIFFERENT TYPES OF ROLLING
PRE-REQUISITES FOR TG
ROLLING
START UP CONSIDERATIONS
During the startup the Turbine is subjected to
Non-Steady state operation.
This covers the operating cond n where Speed, steam
Pressure and temperature change with time.
Under these condn turbine components which are
exposed to temperature changes subjected to thermal
stress and expansion.
For turbine life point of view, it is very much necessary
to limit the extent of these temperature changes.
To take care of the above factor the operator has to
follow the recommendations from Turbine Stress
Evaluator and start the Rolling procedure by following
Criteria curves X1 to X7 right from the beginning.
TURBINE STRESS
EVALUATOR
The Turbine is equipped with the TSE which
provides adequate guidance to the operator
by indicating temp margins and Load margins.
These Margins have been derived on the basis
of Actual Thermal Stress and Material Fatigue.
Frequent and substantial departures from
criteria curves and TSE Indication can result
a. Reduction in total life of Turbine
b. Non permissible deformation.
c. Damage of Turbine Components
ANY ONE HP ESV OPEN AND ANY ONE INTCPT ESV OPEN
2. TURBINE CONTROLLER POSITION SET POINT < O%
OR
STARTING DEVICE > 42 % AND STARTING DEVICE > 56 %
3. GENERATOR BREAKER OFF AND FIELD BREAKER OFF
OR
TURBINE SPEED > 2850 RPM
4. DRAINS BEFORE HPCVs 1 & 2 (MAL 11, MAL 12) : NOT
CLOSED OR
(ANY ONE HP ESV OPEN AND ANY ONE INTCPT ESV OPEN)
OR (TURBINE SPEED > 300 RPM)
SEQUENCE STEP 1
SGC Turbine startup sequence on
COMMAND SLC DRAINS: ON
SEQUENCE STEP 2
1.
2.
3.
SLC DRAINS: ON
All HP & IP ESVs :CLOSED
OR
STARTING DEVICE > 42% AND ESVs: OPEN
ALL HPCVs & ALL IPCVs: CLOSED AND CRH NRV: CLOSED
OR
STARTING DEVICE >56% AND TURBINE POSITION
CONTROLLER SET POINT > 0%
COMMAND
MS STRAINER DRAIN1:
OPEN
MS STRAINER DRAIN2:
OPEN
HRH STRAINER DRAIN1 : OPEN
HRH STRAINER DRAIN2 : OPEN
MONITORING TIME: 2 Secs
SEQUENCE STEP - 3
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEQUENCE STEP - 4
1. DRAINS BEFORE HPCV 1,2 (MAL 11, MAL 12): CLOSED
OR
ESVs: OPEN
COMMAND
:NIL
SEQUENCE STEP 5
1. FLAME IN BOILER: ON
2. HP CF TEMP > 500C
3. STEAM TEMP BEFORE HPBP (BP1,BP2) SUPERHEAT >
300 K
AND STEAM TEMP BEFORE LPBP 1,2 SUPERHEAT > 30 0
K
OR
HPCV 1,2 MIDWALL TEMP < 1000 C
4. DT (MS TEMP BEFORE HPBP 1,2 HPCV 1,2 MIDWALL
TEMP) > X1
NOTE:
CRITERION
X1 BEFORE
& X2 SHOULD
5. DT (WET
STEAM
HPBPBE
1,2FULFILLED
HPCV 1,2
BEFORE
OPENING
THE
HPX2
ESVs
MIDWALL
TEMP
)<
X1 CURVE
60
0
50
0
400
30
0
20
0
10
0
10
0
20
0
300
400 500
600
1.
SEQUENCE STEP 6
COMMAND
NIL
MONITORING TIME: 30 Secs
SEQUENCE STEP 7
1. BOTH HP ESVs: OPEN
NO COMMAND
MONITORING TIME: 60 Secs
SEQUENCE STEP 8
1.
MS FLOW > 15 %
OR
TURBINE SPEED > 2850 rpm
2. STEAM TEMP BEFORE HPBP 1,2 SUPERHEAT >30 0 K
3. STEAM TEMP BEFORE LPBP 1,2 SUPERHEAT> 30 0 K
SEQUENCE STEP 10
1. TRACKING DEVICE: ON
2. BOTH INTCPT ESVs: OPEN
COMMAND : Speeder gear raise
( Condition : Turbine speed <2800 rpm AND Speeder
gear <100% )
SEQUENCE STEP 11
1.
2.
3.
4.
5.
6.
DRAINS: NO FAULT
GLAND STEAM PRESS CONTROL: AUTO
SPEEDER GEAR > 100%
LUB OIL TEMP CONTROL: AUTO
GENERATOR CONDITIONS: FULFILLED
ANY ONE VAPOUR EXTRACTOR: ON
SEQUENCE STEP 12
1. GENERATOR CONDITIONS FULFILLED
2. STEAM PRESS BEFORE HP ESVs
SUPERHEAT > X3
3. DT (STEAM TEMP BEFORE HP ESV 1,2 -HP
CASING) > X4
4. TURBINE SPEED > 15 rpm
5. DT (HRH STEAM TEMP BEFORE LPBP MEAN
TEMP IP CASING TIPT50%)> X5 AND RH STEAM
TEMP BEFORE LPBP > 4800C
OR
TURBINE SPEED > 2850 RPM
6.
DRAIN BEFORE HPCV 1 & 2: NOT CLOSED
OR
TURBINE SPEED > 2850 RPM
7.
POWER SET POINT > 10%
SEQUENCE STEP 13
1. TURBINE SPEED SET POINT > 360 RPM
OR
GENERTOR BREAKER: ON
COMMAND :NIL
SEQUENCE STEP 14
TURBINE SPEED > 300 RPM
SEQUENCE STEP 15
1.
2.
3.
4.
5.
dn/dt PROTECTION
BRINGS DOWN TURBINE SPEED TO SOAKING SPEED (360 RPM)
SEQUENCE STEP - 16
DRAINS BEFORE HPCV 1 & 2: MANUAL
COMMAND :
Turbine Speed set point raise
Drain before HPCV 1 close
Drain before HPCV 2 close
SEQUENCE STEP 17
1.
SEQUENCE STEP 18
1.
COMMAND:AVR in auto
Field breaker ON
SEQUENCE STEP 19
1. AVR: AUTO
OR
GENERATOR BREAKER: ON
2. FIELD BREAKER: ON
COMMAND
DRAIN BEFORE HPCV 1
& 2 : CLOSE
SEQUENCE STEP 20
1. BOTH AOPs OFF TD10s
2. DT (RH STEAM TEMP BEFORE LPBP MEAN TEMP
IP SHAFT) < X7
3. H2 CASING PRESS > 3 Ksc
4. CG TEMP AFTER H2 COOLER A & B < 450 C
5. CG TEMP AFTER H2 COOLER C & D < 450 C
6. DRAIN BEFORE HPCV 1 & 2: CLOSE
SEQUENCE STEP 21
1.
2.
3.
SEQUENCE STEP - 22
1. GENERATOR BREAKER: ON
COMMAND
Speed set point raise
SEQUENCE STEP - 23
1. WAITING TIME: 2 Secs
OR
GENERATOR LOAD >10%
SEQUENCE STEP - 24
1. GENERATOR BREAKER: ON
2. TURBINE SPEED > 2850 RPM
END OF PROGRAMME
SYNCHRONIZATION
SYNCHRONIZATION
The load controller active light glows on Turbine desk.
Ensure tracking device is on.
Increase the load limiter value to about 150MW.
Check the Generator winding, exciter air, cold gas temp.,
generator stator core temp. & all TSI parameter are
normal.
Raise the HP bypass pressure set point to 10KSC more
than throttle steam pr and temp. Set point to about 340C
to avoid HP by pass opening on auto.
Ensure that LP bypass stop valves and spray valves are
closed.
LP HEATER CHARGING
Check that LPH-1 inlet/outlet valves are in open
condition and bypass valve in closed condition.
Ensure all LP heater shell vents to condenser are in
open condition.
Charge both LP heaters 2 and 3 from condensate side
by opening I/L valves and O/L valve and closing their
bypass valve respectively.
Charge LP heater-2 by opening its extraction valve.
Note there is increase in level. Put its cascading drip to
LP heater-1 and emergency drip to auto when the
normal level is reached. Before putting to auto ensures
that level set point of emergency drip is greater than
normal drip set point.
Repeat above for LP heater-3.
Ensure drain valves in extraction line closes once Ext
is charged
Starting Mill
Line-up from local and check all the per
missives.
Start Coal mill A(bottom most available Mill)
open HAG/CAG & dampers to achieve air flow >
80T/Hr & temp>65C
Start feeder and ensure flame gets stabilized.
If pressure rises, Then increase load.
Control MS & HRH temp to get sufficient margin.
Maintain 100C more MS & HRH temp than
HPS/HPC/IPS/HPSV/HPCV.
Raise load as DC/SG. 75MW
Take another mill into service. Load 120MW.
STARTING OF TDBFP
Lube oil system
Jacking Oil system
Turbine on Barring Gear
Steam charging and rolling
TO LINE UP AND TAKE HP HEATER IN
SERVICE
RAISE THE LOAD TO RATED VALUE