Cold startup CheckList

Document No.
CHECK LIST For Cold Startup che
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Turbine
Rolling
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Prepared By

NANDHALAL B
 SEPC POWER PRIVATE LIMITED

1 X 525 MW THERMAL POWER PLANT, TUTICORIN; TAMILNADU

Cold startup CheckList

MEIL/CheckList/Turbine/Operation/67/Cold startup CheckList

CHECK LIST For Cold Startup checklist

Local Operator (LO) (Name / Signature)

Local Engineer (LE) (Name / Signature)

Desk Engineer (DE) (Name / Signature)

Unit In-charge (UIC) (Name / Signature)

Shift In-charge (SIC) (Name / Signature)

Description

NO PTW is pending & clearance given by all departments

Ensure Station bus supply is available and unit board power supply is in charge condition

Ensure power supply is available to the aux system required for boiler light up.

Ensure all peep hole and manholes of boiler are closed & manholes (55 m floor & 11 m floor)
cooling line opened.

Take trial of MSV-1 and MSV-2.

Ensure BCW cooling Emergency overhead tank level is Full.

Ensure HP LP heater vent line is isolated and Normal and emergency drip line MIV opened and
lined up condition.

Maintain normal drum level (-50 mm).

Ensure all 3 BCW pumps discharge valve is in full open condition.

Ensure at least 2 BCWPs are running.

Boiler drum vents B1, B2, B28 & B29 are in open condition.

All SH & RH drains and vents are in open condition.

Ensure before MSSV drain valve MSV 101/102 are opened.

Eco recirculation MOV E15 is in open condition

Ensure CBD and EBD lines all manual valves are in open conditions.

Both APH-A & APH-B are in service & Air motor trial taken.

Ensure all the 4 passes of ESP are lined up as per requirement.

All ESP hopper heaters, CERM and EERM are running in auto mode.

Ensure Air and Flue gas path should be through.

Ensure Bottom ash hoppers & fly ash system is ready and lined up.

Ensure Seal trough, bottom ash hoppers are filled up and refractory cooling water line is also
lined up.

All ID Fans, FD Fans & PA Fans & its LOPs are lined up and ready to start.

Ensure VFD room AC system, reactor air washer units are in service.

SCAPH is through for FD and PA, and drains are lined up to IBD tank.

Ensure blade pitch operation for fans are ok and connecting links are ok.

Ensure all SH and RH and APRDS spray lines are lined-up condition.

Ensure AC scanner fan is running and DC scanner fan trial taken.

Ensure Boiler drum metal temp has been noted down.

Ensure all soot blowers & LRSB are in home position

Ensure APH soot blower are line up with APRDS header.

Ensure APH oil carry probe is working and is in inserted condition and cooling water is charged.

Ensure all sample lines MIVs are opened and sample cooler is charged from SGECW.

Ensure igniters cooling line MIV are opened.

All ERV are lined up and power supply is ON.

Ensure all boiler expansion indicator are available, format of expansion measurement is
available.

Ensure burner tilt should be horizontal.

BOP side check list before light up

Ensure at least One CW & 10 cells both riser valves is open.

Ensure two ACW pumps are running.

Ensure two SACW pumps are in service with two cells of aux CT fan in service.

Ensure both CST level is >5 mtr.

Ensure CT make up line is charged either through gravity or at least one CT make up pump is
running.

Ensure Emergency DG tank level is adequate and its trial is taken.

Ensure either fire hydrant water pump running or fire booster pump trial taken and movable fire
tender is available at site.
Ensure both DM storage tanks are filled up with 10mtr of DM water and at least 2 streams are
available.

Ensure CHP, AHP, DM plant and Fire & safety department is duly informed about boiler light up.

Ensure LDO &HFO tank level is ok and at least one LDO/HFO pump is running for maintain 20-
25 kg/cm2 header pressure and short re circulation CV is in Auto.

HFO to be taken on short recirculation and HFO temperature to be increased to 120˚C.

Ensure power supply for all stand by pumps are healthy.

Ensure two instrument air compressor with respective drier and one service air compressor
should be running and line should be charged in TG side & Boiler side with pressure more than
6.5 kg/cm2

Confirm from AHP for ESP evacuation system has been lined up for evacuation.

Ensure CHP has been informed for making conveyors stream ready for bunker feeding.

Turbine side check list before Boiler light up

Ensure at least 2 TG ECW is running and at least 2 PHE is charged with ACW system.

Ensure at least 1 SG ECW is running and at least 1 PHE is charged with ACW system.

Ensure all coolers are in charged condition from water side.

Ensure all MOT, TDBFPA&B , Seal Oil Vacuum tank, HPCF, HPBP, LPBP oil tank levels should
be normal.
Ensure Turbine is on barring gear and DC EOP and DC JOP trial taken and its temp CV is in
auto. (Set pt. 50˚C)

Ensure one HPCF oil pump is running.

Ensure oil system all SLC is on.

Ensure one CEP is running and ensure line up for PRDS, LP exhaust hood spray, LPBP &
Turbine flash tank.(Ensure CV are in auto, check set points)

Ensure Primary water pump is running and its temp CV is in Auto.

Ensure Seal oil pump is running and DC seal oil pump trial is already taken.

Ensure hydrogen is filled, its purity (99%) and pressure (>4.5kg/cm2) is OK and its temp CV is
in Auto. (Set point 40˚C)

Both TDBFPs lube oil pumps are running and their respective EOPs trails taken.

Ensure both TDBFPS are in barring.

Ensure all drains are opened for MS, CRH, HRH, HPBP, LPBP, MAL, Gland Steam
&Extractions.(MSV-105, MSV-106, BPV-101, BPV-102, BPV-5, BPV-6, HRHV-105, HRHV-106,
R-84, SV-25, R-96, SV-27, R-90, SV-26, R-102, SV-28, CRHV-101, HRHV-105,EXV-101, EXV-
102, HRHV-113, HRV-114, HRHV-109, HRHV-110, EXV-158, EXV-159, EXV-147, CRHV-135,
EXV-118, EXV-119, CRHV-115, CRHV_122,CRHV-129,ASV-104,ASV-109, CRHV-135, CRHV-
141, CRH-147, CRHV153, CRHV-159,EXV-109,EXV-115)

Ensure MAL drains are in auto and their manual isolating valve is in open condition. (MAL-
11,26,22,32,31,47,12,27,23,51,52,57,54,55,58,81,65)

Ensure all temp control valves are healthy and are in Auto.

Ensure all spray lines are lined-up condition. (MAC01AA001, MAC02AA001, Manual isolation
valve of HPBP spray line, BD1 and BD-2, BPE-1, BPE-2)
Ensure chemical dosing system is ready.( Ensure chemicals are available, mixing tanks are
filled, power supply for local panel and pumps, agitator motors are available, dozing line valves
for D/A, condensate and drum are open.)

Ensure Excitation system is ready and all GRP relays are reset.

Ensure IPBD air pressurisation unit is in service.

Ensure SWAS is in lined up.

Ensure deaerator level is normal (+400mm) and its drain to flash tank is in close condition.

MDBFP is ready to start.

Ensure APRDS is charge from Second unit.

Ensure One ID and FD fan is running with airflow 750T/h and furnace draft -10 mmwc.

Ensure MDBFP or One TDBFP is running with recirculation.

Check APRDS pr/temp maintained around 12 kg/cm2 / 320-350˚C.

Ensure HT to LT PRDS header is charged.

Ensure Purge permit available.

After purge, put aux damper control in auto and set point for wind box to furnace DP is
40mmwc.
Open LOTV/HOTV and maintain LDO pressure 17 kg/cm² and HFO pressure around 10-15
kg/cm².

Charge atomising air and steam lines after proper draining.

After HFO temperature rises >120 deg C, charge HFO to boiler gradually and put in long
recirculation.

Light up the boiler with 2 LDO guns in AB Elev.

Maintain oil pressure up to 10 kg/cm2 to prevent unburned.

After 15 min take another 2 LDO guns in AB elevation.

Check temp in FG is raising, BCWP cavity temp & Drum metal temp starting increasing

Check drum metal temperature difference for TOP & Bottom should not exceed more than 50˚C

Ensure temp rise in metal temp of SH/RH is not more than 1 to 2˚C per min.

At drum pressure reaches 2 kg/cm2 than close all drum vents after ensuring sufficient steam
flow from local.

Ensure both APH soot blower is running

Check oil carry over probe.

At drum pressure 5 kg/cm2, close all the SH vents and drains except start-up vent.

Charge the MS line by opening MSV-3, MSV-4, and MSV-5 & MSV-6 at MS Pressure of 5-10 kg
/cm2

Charge MS line by opening MSV-1 & MSV-2 by ensuring both sides pressures equal.

Take HFO guns in CD elevation (Flue gas temperature before platen above 100 ˚C).

Charge Deaerator pegging steam from APRDS.

Start vacuum pulling by starting all vacuum pumps

Charge Gland steam system (Steam temperature before CV > 280˚C and header pressure
400mmwc).

Maintain vacuum around 0.10abs.

Open LP and HP bypass around 10%. Ensure their respective warm-up lines are already open.
Ensure the CRH and HRH drains open from local

Close start-up vent full after charging HP/LP bypass.

LP bypass in AUTO. Observe fixed set point is set at 6 kg/cm2

Close HPBP warm-up and LPBP warm up MOV.

Raise MS pressure and temp as 40 kg/cm2/350˚C.

Raise HRH temperature and pressure to 330 deg C and 6 kg/cm2.

Ensure chemical parameters for MS before rolling (Silica < 40ppb) and drum are ok.

Note down Boiler expansion readings.

Ensure all lube oil cooler are in service.

Ensure Temp curves X1 & X2 are satisfied for opening ESV during HP/LP Bypass running.

Ensure EHG is enable.

Bring starting device to zero position this will cause generation of trip oil, check trip oil pressure
and Start up Oil pressure around 8 kg/cm2.

Ensure Speeder gear open position (100%).

Raise the Starting device position to approx 27-30% & ensure start up oil pressure zero and
check HP/IP turbine Stop valve is full opened. Same ensure from local.
Raise starting device position to 55% and ensure CRH NRV open & not open status in EHG
console.

Further raise the starting device up to 100%.

 Checks before TG rolling

MS pressure 40-45 kg/cm2, MS temp= 350˚C

HRH pressure=6 kg/cm2, HRH Temp= 330˚C.

Ensure lube oil temp and control oil temp controls are in AUTO and set point is 50˚C.

Ensure temp curves X3, X4 and X5 are satisfied.

Ensure exhaust hood spray line up and CV is in auto mode.

Raising the speed up to 360 rpm (Soaking Speed):

Drum level should be -100 mm.

Ensure all SLC & pump selection are in ‘ON’ condition.

Inform all concern persons about TG rolling (TMD/C&I/ EMD).

Ensure HP turbine evacuation valve to condenser is in closed condition.

Put “360” rpm in rpm ref in EHTC page and check that turbine speed is rising. DN/DT is ok.

Check that TG barring gear is stopped at 240 rpm otherwise stop it manually.

Observe MOT oil level is rise after barring gear stopped.

Check all bearing vibration & other turbovisory parameters are within permissible range. If not
trip the turbine and search the cause.

Check the TSE margin is > 30k

Check drains are operating as per SLC logic. Temp. is in increasing trend.

Raising the speed up to 3000 rpm:

After APH Secondary air temperature is >180˚C, Start one PA Fan and check Seal air fan start
in auto, Maintain PA header pressure around 800 mmWC and seal air pressure 1200 mmWC.
Line up for one mill (Lowest Elev possible).

Start one mill & keep it in warm-up condition

Check all mill conditions and keep other mills ready for start.

Ensure Temp curves X6 criteria are satisfied.

Start rolling the turbine by giving speed reference to ‘3000 rpm’ and check turbine speed is
rising.

Observe JOP is cut off at 540 rpm.

Observe AOP is cut off at 2850 rpm otherwise stop it manually.

Check all bearing vibration & other turbovisory parameters are within permissible range. If not
trip the turbine and search the cause.

Record vibration readings at critical speed.

Check turbine oil system, seal oil system, Hydrogen and primary water system for any
abnormality.

If everything ok, Start the running mill feeder and keep running mill on min loading.

Start second set of ID, FD and PA fan.

Synchronization of the unit/loading of the unit:

Load mill around 20 to 30 TPH.

In EHTC page load ref. 50 -60 MW.

In EHTC page Pr. max 80-100 MW

In EHTC page starting/speeder gear 100%.

Make trim device ‘’ON’’ at load 120 MW.

Check the X7 criteria are satisfied.

Take clearance from Elect dept for Sync.

Inform the switch yard and SLDC.

Close all the isolator for GEN main breaker and TIE breaker.

Close the field breaker from “Gen & 400KV“ graphics page

Select the excitation channel to be kept in AUTO (channel-1 or Channel-2).

Switch ‘ON’ the Excitation system and check voltage building across the generator terminal up
to 21KV.

Select GT breaker to be sync.

Switch ‘ON’ the synchroscope.

The speed of the needle in synchroscope will indicate the “FAST” or “SLOW” speed of
generator. So, increase or decrease the TG speed accordingly so that rotation of needle
becomes slow.
Close GCB manually or in Auto to synchronize the unit.

Observe that unit load is reached up to 50-60 MW.

Switch “OFF” the synchroscope.

Ensure “LOAD CONTROL ON” is being displayed in EHTC page.

Enter load gradient value up to 10 MW.

Increase the load reference to increase the load.

After Unit synchronisation close slowly HP and LP Bypass and close all line drain valves.

Start Coal Mill B and load as per requirement.

Charge all LP heater Extraction on load above 80 MW.

Fast bus transfer from station to unit board at 80 -100 MW.

Charge Deareator from Extraction @ 120MW.

Charge all HPH extraction on200 MW.

Start Coal Mill C and increase load upto 270 MW.

Optimise HFO and LDO pressure.

Take Coal mill D & E in service @ 350 MW and 450 MW respectively.

Take out all gun after ensuring intensity and frequency of flame at 350 to 400 MW.

Take Coal Mill F to further increase load upto 600 MW.

Prepared By

NANDHALAL B
 IN; TAMILNADU

Issue No R0 

kList Date
ecklist
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Responsibility Status Remarks

Reviewed By Approved By