SEMCORP GAYATRI POWER LIMITED – (2 x 660 MW)

Rec. No: OPN/SOP/BTG/001/16

COLD START - UP SOP Date: 10/10/2016
Page: 1 of 15

UNIT: Date:
Reason for Shutdown:

Date & Time of S/D:___________________ Synchronization

time:_______________

Name of Desk Engineer & Signature: Name of SCE & Signature:

TIME /
Sl. No. ACTIVITY CHECK
REMARKS
1 Pre check Before Unit Cold Start Up
1.1 Ensure all PTW related to all system are returned.
Ensure 11KV, 3.3KV, 415V, 220V DC, UPS & Emergency power supply are
1.2 available & buses are charged from respective incomers. Ensure DG set
Available in auto & diesel level normal, if required take trial
Ensure raw water system in service. (Raw water intake, Raw water PTP and
1.3
CT Makeup pumps & DM plant available)
Ensure the voltage level before starting any major 11 kV and 3.3 kV
1.4
equipment’s.
All monitoring & testing instruments are put in service & are reading normal
1.5
value
1.6 All protection & interlocks are available & put in service.
Ensure No restriction for boiler expansion in all the locations & record the
1.7
expansion reading at cold condition.
1.8 Ensure all shoot blowers in retract position.
Ensure H2 & CO2 cylinders are available at filling station (minimum 200 H2 &
1.9
40 CO2 cylinders)
Ensure DM water storage tank levels and CST levels are full. > 9.5 mtrs and CST
1.10
>5 mtrs level
Ensure fire hydrant system is ready & pumps are in auto. Ensure system
1.11 pressure is normal with jockey pump in service and other pump in auto stand
by (min press: 10 ksc at Boiler)
Interlock & Protection checking for all equipment done MFT, FSSS, ETS, TSI,
1.12
DEH, CCS, MEH, METS systems and are fully available.
Ensure Aux Boiler is ready with DM water & LDO tank full & available for
1.13
starting
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1.14 Ensure Coal-Handling system is running & Coal is filled in the bunkers
1.15 Ensure Fly Ash-Handling System is ready.
Ensure Bottom ash-handling system (seal trough over flow and refractory
1.16
cooling). Put Bottom ash system in operation.
1.17 Ensure LDO pumps and HFO pumps are available and lined up.
Ensure ESP insulator & Hopper heater are switched on in auto before 8 hrs of
1.18
light up
1.19 Ensure all MAL drains are open. (Turbine proper drain and vent system)

2 Starting CTBD, OCCW, CW, CCCW & TBD system as per standard procedure

2.1 Ensure PTWs related to CTBD, CW, OCCW, CCCW & TBD system are closed.

2.2 Ensure Fore bay filled to normal level 7.25 mtrs

Ensure CW system chemical dosing available & start in coordination with
2.3
chemist
3 CTBD pump starting
3.1 Ensure PTWs related to CTBD system are close
3.2 Ensure CW fore bay is filled up to normal level
Ensure that the blow down pump discharge line ARV’s and CW pump
3.3
discharge line ARV’s are lined up
Ensure that CWP discharge valves are closed & valve at TBD tank open to
3.4
maintain CTBD pump discharge pressure
3.5 Start one CTBD pump as per SOP & fill CW pump supply line & return line

4 TBD Pump Starting

4.1 Ensure PTWs related to TBD pump closed
4.2 Ensure TBD tank level normal
Ensure TBD pump sluice gate open & all pump Stop log gate in open
4.3
condition
4.4 Ensure TBD pump discharge line ARV’s are lined up
4.5 Ensure TBD pump Discharge MOV power supply is made ON
4.6 Start one TBD pump as per SOP & second BD pump is available
5 OCCW Pump starting
5.1 Ensure PTWs related to OCCW pump & system closed
Ensure that OCCW pump is lined up by opening Inlet from CTBD pump outlet
5.2
header & outlet valve to CW return line
Line up OCCW Automatic washing filter by opening inlet & out let MOV’s &
5.3 bypass MOV kept closed, keep OCCW automatic washing filter in DP OR
Timer Mode
5.4 Line any one PHE & Start one OCCW pump as per SOP
Ensure two CTBD pumps in service to maintain OCCW suction pressure
5.5
adequate & start OCCW pump
6 CW pump starting
6.1 Ensure PTWs related CW pump closed
Ensure CW fore bay level normal > 7.25 mtr, Breaker ready, Racked in, control
6.2
supply on. LPBS in release condition.
6.3 Ensure CW pump Stop log gate in open & Screen in service
Ensure MIV of ARV in supply and return line are open, CW duct are filled by
6.4
CT blow down pump and water is coming from the vent valves.
2x660 MW Cold start-up check list Page 3 of 16

Ensure condenser inlet and outlet supply and return line valve open CW
6.5 pump suction screen clean & in service, CW pump suction & CT basin shut off
lock gates are in open condition.
6.6 Ensure NDCT riser valves are open
Ensure all CW pump discharge valves hydraulic system healthy, valve in
6.7
closed condition and in remote mode.
Ensure oil level in thrust bearing is normal, coolers to bearing, Motor is lined
6.8
up & service water tank level is normal
6.9 Open condenser water box air vents on CW supply and return line.
6.10 Start CW pump & close the vents after venting.
6.11 Observe all parameters, vibration at local & at DCS.
7 CCCW Pump starting
7.1 Ensure PTWs related to CCCW pump & system closed
7.2 Ensure CCCW system lined up to Boiler & Turbine area
Ensure CCCW system line drains closed & Vents at boiler, Turbine & BOP area
7.3
are kept open
7.4 Fill CCW system & Tank to normal level
Ensure one PHE & minimum coolers are lined up to avoid over pressurization
7.5
of system
Line up CCCW pump and start as per SOP maintain overhead tank level
7.6
manually until plant air compressor start
8 Starting Plant Air Compressor
Ensure PTWs related to plant air compressors and Instrument air & Service air
8.1
lines closed
Start plant air compressors as per SOP from local ensure all parameters are
normal, Header pressure 6 ksc charge Instrument air, and Service air header
8.2
along with the receivers for both Boiler and Turbine area Ensure other
compressors available.
Put the air drier system in service and watch the dew point temp of air -20
8.3
Deg C.
9 DM Transfer line charging & starting DM transfer pump
Ensure PTWs related to DM transfer pumps & discharge heater till the CST &
9.1
Aux boiler closed
9.2 Ensure Instruments related to CST are normalized & available
Ensure DM tank levels are full 9.5 mtrs, Start one DM transfer pump and set
9.3
discharge pressure set between 3.5 to 5.5 Ksc
Fill CST to a normal level and start CTP for filling CCCW expansion tank &
9.4
system
10 Condenser & CEP line up
10.1 Ensure PTWs related to Condenser and Hot well is closed.
Fill hot well up to 1000 mm using boiler fill pump or Condensate transfer
10.2
pump
11 Start CEP in recirculation as per procedure
Establish CEP sealing, cooling lines are charged, fill pump discharge header by
11.1
using condensate transfer pump or from boiler fill pump.

Keep pump discharge valves and deaerator level control valves in closed
11.2
condition, LPH-5, 6, 7, 8 I/L & O/L valves are open & bypass closed.

11.3 Ensure Condensate Polishing Unit is bypassed.

11.4 Recirculation valve lined up & control valve in closed condition
2x660 MW Cold start-up check list Page 4 of 16

Start the CEP Ensure R/C control valve force open to fully to 100% and keep
11.5
the other CEPs in standby.
11.6 Ensure LPH#5 outlet drain water Fe<200PPB
11.7 Ensure PTWs related to feed water system & Deaerator is closed.
11.8 Start Deaerator filling by CEP to normal level : 100 mm
12 Boiler Initial Filling:
Ensure ECO, Separator and SH vents are open, boiler 1st pass drains closed &
12.1
SH drains open
Line up Boiler fill pump to Feed water system. (Ensure all BFP discharge
12.2
valves are closed.)
12.3 Start filling boiler at <100TPH to ensure proper venting
Start Dosing chemicals to maintain pH and N2H4. (Stop chemical dosing
12.4
valves before stopping boiler filling to avoid CCCW contamination.)
12.5 Close ECO vents once steady stream of water is observed
13 Starting of LDO system

13.1 Ensure PTWs related to LDO system are closed.(Both FOPH & Boiler area)

13.2 Ensure strainers at pump suction and boiler area cleaned and charged.
13.3 Ensure that all MIVs at oil guns are closed. And Purge valves are closed.

Line up and start LDO transfer pump, maintain > 3 Mpa by operating short
13.4
R/C valve and its bypass MIV Line-up LDO system MIVs at Boiler area.

Auxiliary Boiler start up and Auxiliary Steam header Charging as per

14
procedure

14.1 Ensure DM transfer pump is in service for makeup Aux Boiler DM water tank

14.2 DM plant must be informed for lit up of Aux Boiler

14.3 Chemical dosing Dozing should be done in coordination with chemist.
Ensure that all lines connected to Aux steam header are isolated, keep
14.4
header drain open,
Warm-up the header from Aux Boiler, rise header pressure, temperature
14.5
gradually to 9 ksc and temperature 300 Deg. C
Line up and charge Aux. steam to HFO tank floor heating line, HFO heat
14.6
tracing system, HFO heaters and atomizing line to HFO and LDO system
14.7 Warm up APH soot blowing line.
14.8 Ensure LDO pumps and HFO pumps are available and lined up.
Ensure Bottom ash-handling system (seal trough over flow and refractory
14.9
cooling). Put Bottom ash system in operation.
15 Starting of HFO system

15.1 Ensure PTWs related to HFO system are closed. (Both FOPH & Boiler area)

15.2 Ensure strainers at pump suction and boiler area cleaned and charged.
15.3 Ensure that all MIVs at oil guns are closed. And Purge valves are closed.

Line up and start HFO transfer pump, maintain 1.3 Mpa by operating short
15.4
R/C valve and its bypass MIV Line up HFO system MIVs at Boiler area.

Charge HFO heaters and maintain HFO temperature (> 140 deg C at heater
15.5
outlet)
Ensure HFO system Electric heat tracing system charged and put the HFO in
15.6
long recirculation from boiler 17 mtrs.
2x660 MW Cold start-up check list Page 5 of 16

15.7 Charge APH soot blowing line from Aux. PRDS and carryout APH soot blowing

16 TG Lube Oil, Jacking oil & Putting Turbine on Barring gear

16.1 Ensure PTWs related to turbine lube oil & Jacking oil systems is closed
16.2 Ensure MOT levels are normal. 150 mm, any one filter in service
Start OVEF & Generator seal oil vapor extractor fan. Keep other fan on
16.3
standby.
16.4 TG lube oil cooler is lined up.
Start Turbine Bearing oil pump (BOP) and ensure DC LOP is on interlock.
16.5
Ensure oil temp maintains at 44ºC automatically.
Ensure PTWs on Jacking oil system closed, system charged by taking one filter
16.6
in service
16.7 Start jacking oil pump & other pump in stand by
Ensure Turbine barring gear is engaged & local panel is powered up, Lube oil
16.8 pressure is adequate 33 kpa & Jacking oil pressure normal 15 Mpa & Turbine
shaft is stand still
Start Turbine Barring gear motor from local. Ensure turbine RPM is 2 rpm,
16.9 Eccentricity < 75 microns. (Turbine to be put in barring gear operation at least
3 hrs. before Boiler Light-up)
17 Generator Seal oil & H2 CO2 purging
Ensure all PTWs returned on Seal oil System, line up seal oil system & ensure
17.1 seal oil levels are normal 25 cm, CCCW is charged air side, H2 side coolers &
DPR is lined up
Start air side Seal oil pump and ensure oil pressures & DP 0.084 Mpa and U
17.2
seal levels are normal, keep DC pump on standby.
Start H2 side seal oil pump and ensure oil pressure and tank levels are normal
17.3
by level switch and keep the other pump standby.
17.4 Ensure line up of H2 side, air side coolers and TCV in auto.
Start generator purging as per the procedure and achieve the hydrogen
17.5 purity in generator > 98%. Then rise the hydrogen pressure in generator to 4
ksc.
Lineup and start Stator water cooling system and ensure parameters are
17.6
normal. Keep other pump in standby.(Conductivity < 0.5 micS/cm2)

Take trail of all DC equipment’s and AC standby equipment in Lube oil and
17.7
seal oil system and note down the respective currents and pressures.

18 Start MD- BFP in recirculation as per procedure

Ensure PTWs related to boiler water / steam circuit up to MS stop valves &
18.1
boiler filling systems are returned
Close all boiler drains valves (26 meters), boiler bottom header drain and
18.2 boiler intermediate header drain valves, except back pass divisional & back
pass lower header drain valves
18.3 Start AOP and ensure lube oil pressure is normal.(1.9 ksc)
Line up MDBFP – Open Suction, R/C valve along with both MIV’s, charge
18.4 sealing line, oil coolers & motor coolers, Ensure discharge valve, RH spray
valve are in closed condition
18.5 Line up feed water line. [HP heaters inlet, outlet valves to be kept open]

18.6 Line up CCCW to lube oil cooler, working oil cooler and main motor coolers

18.7 Line up Booster pump sealing water from CEP discharge.

Ensure respective 11KV bus voltage is normal, US-1A/US-1B are charged
18.8
through UT-1A/1B. (MDBFP should not be started with ST power supply)
2x660 MW Cold start-up check list Page 6 of 16

18.9 Ensure Deaerator level is normal (> 150 mm)

Ensure HPBP spray in closed condition, SH and RH spray line isolating MOV
18.10
closed.
Ensure min. scoop 20% and start BFP on recirculation. Stop LOP, Open bypass
18.11
MIV of discharge MOV & discharge MOV
Ensure PTWs related to boiler water, steam circuit up to MS stop valves,
18.12
boiler filling systems are returned and systems are ready
18.13 Start Boiler filling with MDBFP through Economizer with 30% FRS station
18.14 Ensure steam / water sampling system is lined up & charged.
18.15 Open all MIVs of Boiler vent station (85 meters)
19 Boiler filling and Cold flushing Guide lines
Before Filling the Water in Boiler, Ensure the Condensate water Iron content
19.1
<200 ppb.
The FW Temperature must be between 20-70 Deg.C.
19.2 [The Temperature difference between boiler metal temperature and Feed
water shall not be over 90 Deg. C.]
Open the following boiler drain valves:
（a）Wall enclosure ring header drain valve；
（b）Primary superheater inlet header tank drain valve
19.3 （c）Main steam pipe, high pressure bypass pipe low point drain valve
（d）Reheater system drain valve
Open the economizer, SH, RH Vent valve. The water feeding rate is to be
limited to < 5% BMCR flow (i.e. ~100TPH) using 30% feed control valve to
ensure proper venting. FW Quality to be ensured.
During filling, the feed water flow to drain flash vessel through economizer,
water wall, Separator Vessel, storage tank & the water level is controlled with
19.4
Boiler storage vessel overflow control valves-1 & 2 in AUTO（5000～
14000mm)
Ensure Boiler water vessel over flow drain MIV, Boiler separator storage
19.5
vessel over flow pipe control valve, MIVs & MOVs are lined up
Continue cold flushing through water vessel drain valve till iron content <
19.6
1000 ppb.

When feed water iron content < 1000 ppb, Turbidity < 3 NTU, Take water to
19.7 condenser hot well, Take CPU Pre filter in service at Fe < 1000 ppb, When Fe
< 400 PPB take CPU MB in service, continue flushing till Fe < 200 PPB

Start Deaerator pegging using steam from Auxiliary steam header (Temp: 85
19.8
deg C), At Fe < 200 PPB take CPU MB in service.
Continue Cold flushing till the feed water parameters achieved: Positive
19.9 Conductivity: 0.65uS/cm, PH: 9.0~9.6, SiO2 <=30, Fe<=200, Cu<=15,
N2H4:10~50 ppb.
20 Gland steam header charging and gland steam sealing to turbine

20.1 Ensure all Turbine drains are open. (turbine proper drain and vent system)

20.2 Open Gland steam header drains. Do warm-up the line.

20.3 Ensure gland seal dump PCV to condenser is available and operating.
Gland steam line all strainer drain valve open, all supply and return line drain
20.4
line up and through.
Open aux gland seal PCV in steps to maintain hdr pressure of 25 to 30 Kpa
20.5
and temp: 160 deg C.
Switch 'ON' GSC Ex. Fan. Fill the GSC syphon with CEP water for sealing, keep
20.6
the other fan on standby.
2x660 MW Cold start-up check list Page 7 of 16

20.7 Ensure LP turbine exhaust hood spray line up.

Line-up CEP spray to Gland steam system to control LP gland steam temp.
20.8
(150deg C)
20.9 Charge gland steam for TDBFP
Monitor & Record HIP Top & Bot Temp. difference, Casing expansion & Rotor
20.10
Expansion
21 Vacuum Pulling
21.1 Ensure PTWs related to vacuum system are returned.
21.2 Ensure turbine on barring gear.
21.3 Ensure hot well level is normal (~ 1000 mm) & CEP is running
Close Vacuum breaker valve and fill the pipe with condensate water till
21.4
overflow.
21.5 Ensure RH vents are closed.
21.6 Ensure gland steam system is charged and healthy
21.7 Line up & Start Vacuum pumps as per procedure
21.8 Get the vacuum -90kpa before boiler light-up.
22 Starting of Flue Gas & Air system
Ensure PTWs related to APH, ESP, Flue gas, Secondary air, primary air, Mill
22.1 system & main boiler are closed. Ensure that manholes & peepholes are
closed.
Ensure Submerged scrapper conveyor has been filled & Seal trough in
22.2
overflow condition
Line up and start both air pre-heater. Ensure CCCW is lined up for bearing
22.3
cooling and oil level normal
22.4 Line up secondary air system, flue gas path, ID & FD fans.
22.5 Ensure all stand by LOPs of FD and ID are in standby.
22.6 Start AC scanner air fan and put DC scanner fan on standby
22.7 Start ID & FD fans. Maintain furnace pressure @ (-100 Pa to -150 Pa)
22.8 Secondary air control damper position > 55%.
22.9 Maintain air flow between 30 to 40% (720 -750 TPH)
Open SH flue Gas damper to 100% and close RH flue damper to minimum
22.10
30%.
22.11 Insert Furnace temp probe for checking furnace temp.
22.12 SADC to be lined up for Purge condition.
23 Final Checks before Boiler Light up:

23.1 Boiler Cold flushing is completed and iron content in feed water is <=50 ppb.

23.2 All protections are checked and in service. All auto loops are functional.
23.3 Wind box SADC (Fuel, Aux air, SOFA) all dampers are functional.
23.4 All scanners are healthy
23.5 All drains closed and vents are in open position.
23.6 All boiler auxiliaries are running normal.

23.7 All Boiler Metal temperature tags are reading normal value 35 to 40 deg C.

24 Boiler Purge & Light up

Ensure all PTWs main boiler & oil firing system returned. Prepare for Vacuum
24.1
Pulling to start with Boiler Light Up.
24.2 Ensure that all C&I permits related to FSSS are returned.
2x660 MW Cold start-up check list Page 8 of 16

24.3 Carry out LDO leak test and HFO Leak test
24.4 Ensure airflow 750TPH and Feed water flow 250 TPH & Purge the boiler
Open LDO supply and return valve and maintain 3 Mpa LDO pressure. RCV SP
24.5
4.5 Mpa
24.6 Ensure MS stop valve (left and right) and its IBV’s are closed
24.7 Record expansion reading before light up of boiler.
24.8 Ensure back pass lower header drain is open till unit is synchronised
Light up boiler with AB elevation LDO gun by ensuring wind box to furnace dp
24.9
> 0.4 kpa
Cut in First LDO Burner hold for 30 mins. Cut in the Opposite Oil Burner. Keep
24.10
sec air flow at 800TPH
24.11 Note down boiler expansion for every 50ºC.
Keep boiler overflow valves in Auto. Maintain spiral water wall temp < 435ºC,
vertical water wall temp < 450 ºC. Maintain rate of change of metal temp <
24.12
1.1ºC / Min when separator temp < 100ºC. If separator temp > 100ºC,
maintain rate of change of metal temp < 1.5ºC/ Min
Raise Feed water flow to 300 TPH and cut in 3rd LDO Burner. Maintain
24.13
850TPH sec air flow
After 30mins, Raise Feed water flow to 350 TPH and cut in 4th LDO Burner.
24.14
Maintain 950TPH
24.15 Do continuous soot blowing for APH on sequence mode 1KAH
25 MS line Charging at Separator pressure 0.2 MPa (Arch Inlet)
Ensure PTWs on turbine stop valves are returned and valves are in closed
25.1
condition
25.2 Ensure HP bypass is closed. And Condenser vacuum is normal.
25.3 Ensure MS, CRH and HRH line drains are open.
Charge MS line by Slowly opening MS stop valve equalizing valves and
25.4
continue warm up for some time.
25.5 Open MS stop valves left and right.
25.6 Close all boiler vents steam flow is established.
26 HP / LP bypass system line up & charging @ 0.5MPa
Ensure PTWs related to HP/ LP bypass system are closed & HP/LP bypass
26.1
hydraulic skid oil system in service.
26.2 Ensure HRH, CRH drains are open & condenser vacuum is > - 90KPa.
Open LPBP valves 10%, maintain LPBP downstream temp < 70ºC, Ensure third
26.3
stage spray lined up
26.4 Ensure HPBP spray & HPBP warm up line is lined up.
Between 0.5 to 0.8 Mpa, open Open LP Bypass & HP bypass slowly (around
26.5 5%), Keep watch on downstream temperature, spray block valve opens,
adjust spray control valve to maintain downstream temp < 350ºC
Put LPBP CV in auto to maintain set pressure of 0.11 Mpa, and ensure HPBP
CV in manual, opened to 10 to 15% initially, By maintain temp. rise 1.5 to 2
26.6
deg C / Min. & pressure rise 0.05 to 0.1 Mpa limiting Furnace exit temp 538
deg C
Increase Boiler pressure to 0.5 to 0.7MPa and separator outlet temp to max
26.7
170ºC
Hot flushing completion criteria: Fe < 100 PPB, SiO2 < 30PPB, N2H4 > 200
26.8
PPB, Cond. < 0.5 us/cm, DO < 10 PPB
Cut in BC elevation HFO Gun when Sec. Air Temperature is in range of 120 to
26.9
150 Deg.C.
2x660 MW Cold start-up check list Page 9 of 16

Establish all 4 BC elevation HFO oil guns in 20mins interval with HFO oil
temperature > 100 and < 120, HFO oil pressure at oil gun elevation is > 1.3
26.10
MPa. Locally check the flame quality. Increase sec air flow to 1500TPH in
steps
Hold at MS pressure 1 MPa for 30 mins. (Ensure SH coils are evenly heated
26.11
up)

Open Back pass divisional wall lower header (LTSH inlet drain) drain at
26.12
1.2MPa. Operate it every 20mins for 30secs till boiler pressure reaches 5MPa.

Increase MS press to 8MPa at 0.068MPa/Min (4MPa/hr). Accordingly operate

26.13 HP & LP bypass. (While raising boiler firing, ensure HP & LP bypass valves are
open maximum possible to ensure adequate steam flow through SH coils.)

Monitor boiler metal temperature to be within limit. Spiral wall<435deg C;

26.14 Vertical wall<450 Deg C; LTSH<510Deg C; PSH<565Deg C;FSH<620Deg C;
LTRH<580Deg C; FRH<645Deg C

Achieve turbine rolling parameters; MS press-8MPa, MS temp-420Deg C, RH

26.15
press-0.8MPa, HRH temp-380 Deg C.

26.16 Ensure HPBP >25% & LPBP-1/2—10% each opened

Continue steam dumping till chemical parameters are achieved.

26.17 Sio2 : < 15 PPB, Cond. : < 0.3 uS/cm, DO2 : < 10 PPB, Na: < 5 PPB, Chloride :
Nil, Copper : < 5 PPB, Fe : < 10 PPB.

27 Turbine Start Up

27.1 EH Oil system starting as per procedure:

27.2 Ensure PTWs related to EH oil system are closed.
Line up and start HP start up oil Pump and ensure discharge pressure is
27.3
normal
Line up EH oil system and start pump, keep other pump on standby. Start EH
27.4
oil cycle pump.
27.5 Cold startup with bypass system (HIP rolling)
27.6 Ensure Chemistry parameters before admitting steam to Turbine
28 Turbine Rolling
28.1 Following conditions are in limit before TURBINE LATCH
28.1 A Turbine expansion value is under limit
28.1 B LP differential expansion(-3.5 to 27mm)
28.1C Axial displacement(±0.9mm)
28.1D HP & IP & LP up and down differential temperature(<42 °C)
28.1E Eccentricity(<0.073mm)
28.1 F Differential temperature of inner & outer wall of steam chamber
28.1 G Ensure that the steam parameter reached the rolling condition,
28.2 Turbine Latch
Open balancing valve of RSV in MS, RH and Bypass screen before turbine
28.3
latch
Reset turbine by pressing RESET ETS in DEH control screen and press ACK
28.4
button in turbine TSI & ETS Screen
2x660 MW Cold start-up check list Page 10 of 16

28.5 If turbine is not getting RESET, LATCH turbine with help of LOCAL RESET lever.

Ensure that AUTO STOP emergency trip oil pressure low switch got reset at
28.6 DCS and ensure that the pressure got built up above the diaphragm valve at
local > 7 bar
Select “TRIPPED” button on DEH Control menu and click on “AFFIRM”. Now
28.7 the “TRIPPED” indication will change to “LATCHED” and “FORBID ROLL” will
change to “PERMIT ROLL”
28.8 Ensure that both RSV’s are opened after LATCH of turbine
28.9 Select “Auto” in control mode on DEH SCREEN
Select valve position high limitation from Limitation value on DEH screen
28.10
enter 120 and click GO check that HP regulation valves are open
28.11 Select “VALVE MODE” and click on “SINGLE MODE” and “TRANSFER”
28.12 Confirm all RSV, GV are fully opened and all MSV are full closed.
Ensure DEH in Auto mode and Set target speed 400 RPM (for rub check) and
28.13
acceleration as 100rpm/min in CONTROL REF DMD screen
Ensure turning gear disengaged in auto at start of rolling(At turbine speed >3
28.14
RPM)
When running speed reaches to 200r/min, check and make sure that turning
28.15
gear oil spraying solenoid valves are closed automatically
When turbine speed reaches 400 RPM, heat up the turbine for 20min and
28.16
check the following
Listen and make sure that sounds in running parts of turbine-generator are
28.16a
normal
Bearing pad vibration ＜0.125mm, returning oil is normal and bearing
returning oil Temperature ＜77℃.
Metal temperatures of all bearings ＜90.5℃
28.16b Oil cooler outlet oil temperature is 38℃～42℃。
Check and make sure that axial moving, vibration, differential expansion,
Turbine expansion and temperature difference between up & down cylinder
are within permit range.
28.17 Put LP cylinder water spray valve into operation
Ensure the eccentricity value is less than 0.075mm and increase the speed to
28.18
600rpm
28.19 When speed reaches to 600 rpm Hold for 20 min for heating up
When turbine speed reaches to 600rpm, trip turbine from local and make
sure that TV, GV, RV, IV are closed. Check the turbine bearings, steam
28.2
cylinders and gland sealing. listen to the unit and there should be no friction
sounds

Latch turbine again and Raise turbine speed to 2250 RPM with acceleration
rate 150 rpm per Minute.Critical Speeds: HP Rotor - 1510 RPM/3541 RPM;
28.21
LPT Rotor A - 1569 RPM/3885 RPM; LPT Rotor B - 1541 RPM/3414 RPM;
Generator Rotor - 795 RPM/ 2127 RPM

Check the following items when the speed is rising

Jacking oil pump stops at 1200rpm.
No rubbing or abnormal noise inside turbine generator.
28.22
Check bearing and shaft vibration is normal.
Check metal temp of all bearings, lube oil pressure and return oil temp are
normal.
2x660 MW Cold start-up check list Page 11 of 16

Start to calculate soaking time of rotor when IP cylinder inlet steam

28.23
temperature reaches to 260℃.
During heating up, main steam temperature should not exceed 430℃ and
28.24 reheating steam temperature should be higher than 300℃. Temperature rise
should be controlled at 0.92℃/min.
28.25 Hold for 150min at 2250 RPM for soaking of turbine.
28.26 Start 1st TDBFP rolling & put in soaking. (Ensure steam from PRDS)
29 LPH charging
29.1 Ensure All PTWs related to LPH closed
Ensure LPHs are charged from water side inlet, outlet open & bypass closed,
29.2
LPH 7 & 8 levels are under control
29.3 Line up LPHs Emergency drains, Normal drains & charge heater one by one

During LPHs charging observe LPHs out let temperature rise restricted to < 3
29.4
Deg. C / min
29.5 Charge LPH #6 and followed by LPH #5

After completion Soaking time 150 mins Rise Turbine speed to 2950 RPM at
29.6 300 rpm / min IV opening remains unchanged, TV controls the speed of 2950
RPM. (Soaking time: warm-20min: Hot -10mins; Extreme hot-8mins)

Before transferring control from the throttle valves to the governor valves,
29.7 verify that the steam chest inner wall temperature is at least equal to
saturation temperature Corresponding to the throttle pressure.

29.8 Stabilizing at Turbine speed 2950 RPM, proceed the TV/GV changeover.
After completion of TV/GV switching, enter the target speed 3000 RPM 50
29.9
rpm / min, GV controls the speed to 3000 RPM.
Once 3000 RPM reaches, record and monitor TSI parameters, adjust oil temp,
29.10 EH oil temp, hydrogen temp, stator cooling water temps within the allowable
range.
At 3000 RPM transfer the valves from MSV to GV by pressing MSV-GV
29.11
transfer button and Observe GV closing and MSV opening.
After MSV reached full open position GV CONT will lit and TV CONT will go
29.12
off.

Observe turbine shaft vibration, axial displacement, casing expansion, diff

29.13
expansion, bearing temp, pad temperature are within the allowable range.

Stop BOP, Startup oil pump and confirm bearing lube oil pressure is normal >
29.14
82 kpa, BOP and HP start up oil pump are kept in standby mode.

29.15 Coal Firing:

After TG is rolled to 2250rpm, Start One PA fan as per SOP (Both preferably),
29.16 Start one Seal Air Fan and other fan available. Ensure adequate flow through
PA fan.
29.17 Increase hot PA temp > 150Deg C
29.18 Line up Mill-A
29.19 Start 2nd PA fan and parallel it
29.20 Maintain total air flow at 1700TPH
29.21 At TG speed 3000rpm, plan to put Mill-1A into service
29.22 Raise feed water flow to 450 TPH
2x660 MW Cold start-up check list Page 12 of 16

After achieving Secondary air temperature APH Out let > 180 degC & APH
29.23 out let PA temperature > 150 deg C & Furnace temperature > 450 deg C, take
coal Mill A with initial feeding of 15 TPH
Gradually increase coal feeding to 25 TPH after increasing feed water flow to
29.24
550TPH
Before generator synchronisation, Ensure HPBP>40% and LPBP-1/2->20%
29.25
opened. MS pressure-8.5MPa and RH pressure-1MPa.
29.26 Throttle all four HPT ventilator valves to 50% just before sync.
30 Unit Synchronization to Grid
Reset generator relay panel, Check the readiness of AVR, GCB earth switch
30.1
open & Isolator closed, Ensure H2 coolers are charged
Exciter on and rise the terminal voltage to 20 kV manually, Put AVR in auto
30.2
mode.
Ensure that 400 kV GIS is ready for synchronization. (if needed take the help
30.3
of ELM)
Raise the speed of turbine such that the generator frequency is more than
30.4
the grid frequency
Open electrical  Unit SLD  Excitation tab Ensure that all the conditions
30.5 for excitation ON is available and switch on “Request remote select to
excitation”
30.6 Switch on excitation by switching ON “Excitation ON command”
30.7 Ensure that the generator voltage build up
Open electrical  Unit SLD  Synch tab Ensure that all the permissive
30.8
available for GCB AUTO Closing
30.9 Keep the selector switch in AUTO in Synchronization panel
30.10 Press Select GCB for synch button
30.11 AUTO SYNCH ON request to DEH and Excitation system will be generated
Open DEH Control menu and check that the permit available for AS (Auto
30.12
Sync) selection in Control mode.
30.13 Change the DEH control from AUTO to AS.
Generator will automatically synchronize and make sure that generator
30.14
primary load is 33 MW
Close HPT ventilator valves-1 & 3 fully immediately after generator
30.14a
synchronisation
Ensure RH pressure > 0.4MPa at least by opening HPBP and closing LPBP to
30.14b
6% to pick up block load
30.15 Change the selector switch from AUTO to Exit in Synchronization panel

30.16 After Synchronization, observe the Valve control mode changed to Auto

30.17 Give target to 100% at the rate of 5 to 10% and acknowledge and GO
Hold the load at 33 MW for 30 min to warm the machine. during this soak
30.18 maintain the main steam temperature, And Rate of raise should not be >
83°C/hr
30.18a Raise feed water flow to 600TPH and increase coal feed rate
30.19 Close ventilator valves - 2 & 4 fully by monitoring HPT exhaust temperature
30.20 Charge Extraction steam to Deaerator.

30.21 Increase fuel flow maintaining MS temperature & Raise unit load 3MW/Min.
Close HP-LP Bypass gradually & rise unit load by keeping watch on MS pr. &
30.22
Temp.
30.23 Change over FRS from 30 % to 100 % control mode at unit 100 MW
2x660 MW Cold start-up check list Page 13 of 16

Line up second coal mill at load 100 MW MS Pr. 8.7 Mpa Temp. 410 deg. C &
30.24
rise the load
30.24a Load 2nd mill and adjust oil firing. AB 2-3 guns & BC-3guns.
30.25 Roll & Soak 1st TDBFP after 100MW with PRDS steam
30.26 Charge PRDS from CRH at 120 MW load
30.27 Load 1st TDBFP at load 132 MW. (Steam to be sourced from CRH)
At 132MW, take HPH in to service as per SOP MS Pr. 8.7 Mpa, Temp. 410 deg.
30.29
C
30.30 Start 3rd mill at 150MW
At 30% BMCR with respect to fuel firing phase change over take place from
30.31
cold state to dry state
When unit load raise from 132MW to 198MW, there should not be
30.32
any interval, Convert wet to dry mode changeover rapidly
Boiler wet to dry mode conversion will take place, when load is
30.33
between 170 to 200MW
When unit load reached 180MW, ensure following drains closes
30.34
automatically
Drainage valve before motorized valve of supplying steam to feeding
30.35
water pump turbine from CRH
Drainage valve before motorized valve of supplying auxiliary steam
30.36
from fourth steam extraction
30.37 Drainage valve before fifth steam extraction check valve
30.38 Drainage valve after fifth steam extraction motorized valve
30.39 Drainage valve before sixth steam extraction check valve
30.40 Drainage valve after sixth steam extraction motorized valve

In dry state operation, adjust separator outlet degree of superheat by

30.41
maintaining coal water ratio. OHDR operating range 10 to 40 Deg C)

30.42 At 196 MW hold for 20 minutes stabilize the parameters

When unit load reaches to 231 MW and combustion is stable, The

30.44
main controller of boiler can be put into operation automatic

30.47 4th mill start up @ 275MW

30.48 Raise the load as per start up curve, Increase the load up to 330MW

30.49 Remove oil guns slowly by monitoring flame stability.

30.50 ESP Field Charging

Ensure that all oil guns are removed, inform ESP control room for
30.51
charging ESP fields
At 330MW hold for 30 minutes to warm up the machine, put SH and
30.52
RH temperature control valves in AUTO
30.53 At 350MW, Roll and soak 2nd TDBFP with Ext-4 steam
30.54 5th mill start up @ 375MW

Load TDBFP (with steam source from Ext#4) and unload TDBFP with
30.55
CRH source. Keep MDBFP in parallel
2x660 MW Cold start-up check list Page 14 of 16

30.56 Change over steam source for unloaded TDBFP to Ext#4

30.57 Load 2nd TDBFP and unload MDBFP
When unit load is greater than 400MW, and boiler flame is stable
30.58
carry out water wall soot blowing
30.59 At 450MW, changeover the supply steam of AST from CRH to Ext #4
30.60 6th mill start up @ 475MW
30.61 At 530MW carry out vacuum leak test if necessary
30.62 7th mill start up @ 575MW
At 594MW, conform that the boiler pressure is reached 25.0MPa and
30.63
inspect boiler steam and water system
Record boiler expansion after start up, if the expansion is beyond
30.64 normal stop raising temperature in boiler and hold until the expansion
becomes normal
30.65 Increase Unit load to Gradually to full load 660 MW
30.66 Record & monitor all the parameters
30.67 Record all the parameters and snap shots of all screens at full load

Main steam temperature limit Curve

2x660 MW Cold start-up check list Page 15 of 16

Turbine warm up time Curve

 2x660 MW Cold start-up check list Page 16 of 16

 Predicted Performance Parameters

Check Check
Design coal
Sl. coal 1 coal 2
Item UoM
No. 80% 60% 50%
BMCR TMCR HTO BMCR BMCR
TMCR TMCR TMCR
1 Main steam flow Tph 2000 1884.33 1464.04 1080.43 898.9 1628 2000 2000
1651.6
2 Reheat steam flow Tph 1561.55 1232.91 928.55 779.90 1593.78 1651.61
1
ECO inlet feed water
3 Tph 1880 1771.27 1376.2 1015.6 844.97 1530.32 1880 1880
flow
SH 1ST Stage spray water
4 Tph 60 56.53 43.92 32.41 26.97 48.84 60 60
flow
SH 2nd Stage spray water
5 Tph 60 56.53 43.92 32.41 26.97 48.84 60 60
flow
6 RH spray water flow Tph 0 0 0 0 0 0 0 0
7 Main steam pressure Mpa 25.9 25.76 25.31 15.53 12.79 25.47 25.9 25.9
8 CRH steam Pressure Mpa 4.95 4.68 3.686 2.767 2.313 4.853 4.95 4.95
9 HRH steam pressure Mpa 4.7 4.444 3.502 2.623 2.192 4.615 4.7 4.7
10 Separator pressure Mpa 27.44 27.13 26.14 16.37 13.49 26.52 27.44 27.44
11 Feed water pressure Mpa 29.5 29.0 27.35 17.77 14.78 27.98 29.5 29.5
0
12 Main steam Temp C 571 571 571 571 571 571 571 571
0
13 Feed water Temp C 284.8 280.9 265.2 249.1 239.2 181.2 284.8 284.8
0
14 CRH steam temp C 325.8 320.3 300.1 327.6 332.4 329.9 325.8 325.8
0
15 HRH steam temp C 603 603 603 603 603 603 603 603
16 Total fuel fired Tph 447.8 425.9 345.0 265.4 225.9 437.9 400.3 388.9
17 Total air flow to WB Tph 2312.2 2199.2 1825.3 1437.2 1260.8 2261.0 2345.7 2347.3
Total air flow including
18 Tph 2408.5 2290.8 1901.3 1497.1 1313.4 2355.3 2443.4 2445.1
air leakage

 For major / critical activities, starting & ending times may be mentioned.
 The Shift - in - charge engineer shall verify at least 10 important / critical steps, at random.

Reviewed by Approved by Controlled by:

Sign: Sign: Sign:

Head Operations Plant Manager Dy.Head Operations