Below mentioned are the start-up processes in sequence for the Cold Start-up

of a Tangential Fired Sub-critical Boiler Unit

1. Charging of Auxiliary Equipments from the Station Transformer

2. Charging of Service Water from the Storage Tank
3. Starting of Service Air and Instrumentation Air Compressors
4. Charging of DM Make-up System
5. Opening Boiler Side Vents & Drains
6. Filling of Boiler Drum with Boiler Fill Pump or any other arrangement
7. Starting of AC Scanner Air Fan
8. Starting of APH(Air Pre Heaters A & B)
9. Starting of one ID (Induced Draught) Fan followed by the respective FD (Forced Draught)
fan or in some case both the FD and ID are started.
10. Establish 30% to 40% of Air Flow by controlling the FD Fan
11. Put the Furnace Pressure Control on Auto after adjusting the furnace pressure to -10
mmwc to -30 mmwcby controlling the ID (Induced Draught) Fan.
(** -10 mmwc is for 210 MW capacity Unit)

12. Start the LDO system and charge the lines

(** Charging means to make the system or equipment ready for operation)

13. Initiate Purging of Boiler

14. After controlling the Furnace DP, go for Light-up with LDO(Light Diesel Oil) with a AB
Elevation Pair 1-3 and 2-4
15. Next step is to Fill up the Feed Storage Tank(FST)
16. Then go for Deaerator & GSC (Gland Steam Cooler) Heating and Pegging by Auxiliary
Steam.
17. Close all the Drum Vents, super-heater Vents and Drains
18. After FST charging, go for charging the Cooling Water System and Cooling Water Pump.
19. Then go for Filling of Hotwell.
20. Now, charge the Condensate Extraction Pump and charge the Condensate Cycle.
21. Charge the LP Heaters from the Water Side
22. Put the Deaerator level & Hotwell level control on Auto
23. Before proceeding to the next step, it is now time to make the generator system ready
(** If hydrogen cooling generator then Seal oil system and hydrogen cooling system has to be
started)

24. Now, take the 30%/50% FRS line (**Lower Capacity Line) in service.
 25. Take the Turbine Lube oil in Service for the Turbine and after starting JOP (Jacking Oil
Pump) put the Turbine on Barring Gear.
26. Start one BFP (Boiler Feed Pump) for Low load operation.
Now as the Condensate & the Feed Water lines are in service, you can go for Turbine Rolling
Process now. We also go for interlayer heating of turbine casing for minimizing the differential
expansion. The Turbine Rolling processes are different and temperature dependent, depending
on the design of the turbine. The turbine rolling criteria in Chinese design are different from Indian
designs, but the objective behind the Rolling Process is same in all the designs.

Significance of Rolling Process:

In the Rolling Process, Sufficient time is given to the turbine to increase its parameters like;
Temperature of the Casing, Blades & Flow in order to limit the Differential Expansion within a
permissible limit.

Differential Expansion:
It is defined as the relative difference in expansion of the Casing and Rotor Unit. It can be both
Positive and Negative.

Initially, for Turbine Rolling as we supply steam to increase the parameters like temperature,
pressure & flow, the expansion of both rotor and casing units occur. As the rotor is of lighter mass
than the casing unit so initially the expansion of the rotor is more than the casing unit. This is called
Positive Expansion.

After a certain amount of time, the casing expansion becomes more than the rotor expansion and
this is called as Negative Expansion.

In the Rolling Process, the objective is to maintain the Positive & Negative Differential expansions in
a permissible region to avoid any contact between the rotor and the casing, which may lead to
erosion or blade damage.