PRAYAGRAJ POWER GENERATION COMPANY LIMITED - 3X660 MW STPP

660 MW UNIT NO. # ___ DATE :-

TURBINE SHUT DOWN CHECKLIST
S No. Activity Description LOCATION RESPONSIBILITY REMARKS
Ensure which type of shutdown is-
Normal Shutdown to Cold
1 CCR SCE
Normal Shutdown to Hot standby
Shutdown in case of Tube Failure

Check if there is any Emergency shut down- Boiler tube leakage,

2 major problems in Turbine, Generator etc, Transmission CCR SCE
constraints.

As soon as intimation received from management to shutdown

3 the unit. Intimate SLDC through mail about unit shutdown CCR SCE/UCE/Commercial
process started.
Desk Engineer/Field
4 Charge HT & LTPRDS Interconnection from running unit CCR
Engineer
Desk Engineer/Field
5 Charge APH Soot Blowing MIV from HTPRDS CCR
Engineer
Intimate chemistry department, take clearance to take out unit
6 from OT mode to AVT mode. CCR UCE/Desk Engineer

Desk Engineer/Field
7 Ensure to isolate CPU O/L Oxygen dosing MIV at 3 mtr 3 mtr Engineer
Desk Engineer/Field
8 Open seal steam manual drain MIV at 8.5 mtr 8.5 mtr Engineer
Maintain seal steam temperature 280-290 ̊C (charge PRDS from Desk Engineer/Field
9 MS line in other unit to prevent from Steam extraction pressure 32 mtr
Engineer
ratio at higher load)
Ensure all MAL drains, HP & LP Flash tank drains manual isolating Desk Engineer/Field
10 4.5 mtr
valves are open. Engineer

Ensure Firefighting water available for Turbine MOT, Generator

11 seal oil System, APH, TDBFP, Transformers. Ensure adequate CCR SCE
hydrant pressure is available at highest and farthest point.

Check both TDBFP barring gear valve supply is in normalized UCE/Desk

12 condition (to ensure that after shutdown TDBFP will come in CCR Engineer/Field
barring). Engineer
Desk Engineer/Field
13 If CRH valve is open for any TDBFP, close the valve CCR
Engineer
14 Take out machine from CMC when load reaches 360 MW CCR UCE/Desk Engineer
UCE/Desk
At about 330 MW load take one MDBFP in service & unload one
15 CCR Engineer/Field
TDBFP. Engineer
16 Put 2nd standby MDBFP in manual. CCR Desk Engineer
Trip unloaded TDBFP. Ensure barring gear valve open & put Desk Engineer/Field
17 CCR
TDBFP on barring ensure its speed 150-200 RPM Engineer
Desk Engineer/Field
18 Isolate top HP Heater HPH-8A & 8B extractions at about 200 MW CCR
Engineer
Desk Engineer/Field
19 Isolate HP Heater HPH-7A & 7B extractions at about 180 MW CCR Engineer
Desk Engineer/Field
20 Isolate HP Heater HPH-6A & 6B extractions at about 160 MW CCR Engineer

21 At around 150 MW with 2 mill/oil gun in service-open CCR Desk Engineer

HP/LPbypass manually

22 Reduce the load up to 150 MW, Maintain MS Pressure about CCR Desk Engineer
100-120 kg/cm², by operating HP & LP Bypass
Reduce the load up to 120 MW, Maintain MS Pressure about
23 CCR Desk Engineer
100-120 kg/cm2, by operating HP & LP Bypass.

At about 120 MW load unload another TDBFP & put it on Desk Engineer/Field
24 barring. Ensure its barring speed in between 150-200 RPM. CCR Engineer

25 If any protection need to be check, then take follow up for this CCR SCE/UCE/Desk Engineer

At about 100 MW Load, MS Pressure 90-100 kg/cm 2, Manually

26 CCR Desk Engineer
trip the turbine from EPB given on Desk.
27 Ensure Generator circuit breaker opened CCR UCE/Desk Engineer
28 Ensure Generator Field breaker opened CCR UCE/Desk Engineer
29 Ensure Turbine ESV'S & CV'S are closed. CCR UCE/Desk Engineer
Ensure CRH NRV and all extraction valves and NRV's closed
30 CCR UCE/Desk Engineer

31 Ensure all HP & LP Heaters extractions MOV closed in auto. CCR UCE/Desk Engineer

Monitor turbine speed, bearing vibrations, brg temp. and

32 CCR UCE/Desk Engineer
turbine supervisory measurements during coasting down.
 PRAYAGRAJ POWER GENERATION COMPANY LIMITED - 3X660 MW STPP
660 MW UNIT NO. # ___ DATE :-
TURBINE SHUT DOWN CHECKLIST
S No. Activity Description LOCATION RESPONSIBILITY REMARKS
33 Ensure LIOP Started at speed 532 RPM CCR UCE/Desk Engineer
34 Ensure barring gear SOV opened at 257 RPM. CCR UCE/Desk Engineer
 PRAYAGRAJ POWER GENERATION COMPANY LIMITED - 3X660 MW STPP
660 MW UNIT NO. # ___ DATE :-
TURBINE SHUT DOWN CHECKLIST
S No. Activity Description LOCATION RESPONSIBILITY REMARKS

Ensure Main turbine came on barring. (Speed approx 50 RPM),

35 CCR UCE/Desk Engineer
Ensure coasting down time not more than 100 minutes.

36 Ensure to close HPBP spray line, BD valve and manual isolating 8.5 mtr Desk Engineer/Field
valve. Engineer
Desk Engineer/Field
37 Ensure to isolate R/H Spray MIV from both TDBFP & both MDBFP 8.5 & 17 mtr
Engineer
Ensure to isolate both TDBFP warm up MOV (MDBFP Warm up Desk Engineer/Field
38 8.5 & 17 mtr
MOV also need to close in U#1) Engineer
Desk Enginner/Field
39 Maintain MOT Lube oil temp after cooler at about 46 ~ 50 ͦC. 8.5 mtr
Engineer
Ensure to stop one CEP after unit tripped, only one CEP kept Desk Engineer/Field
40 running. CCR Engineer
Ensure to stop one Condenser Vacuum pump (in case of two Desk Engineer/Field
41 vacuum pump running) CCR Engineer
Ensure to open all MIV'S & MOV'S of Unit flash tank & charge its Desk Engineer/Field
42 service waterr line CCR Engineer
Desk Engineer/Field
43 Ensure to open all MOV'S of steam drain flash tank/LPFT/HPFT CCR Engineer
Ensure to depressurize all HP/LP Heaters shells by opening Desk Engineer/Field
44 CCR
emergency drain valves to flash tank. Engineer

45 Ensure GCB is in off condition. 8.5 mtr SCE/Electrical Engineer

46 Ensure Generator circuit breaker is in local mode. 8.5 mtr SCE/Electrical Engineer

47 Ensure GCB Isolators are in open condition 8.5 mtr SCE/Electrical Engineer

48 Ensure to press the emergency push button of GCB 8.5 mtr SCE/Electrical Engineer

49 Ensure to close the door & provide lock on the door of GCB. 8.5 mtr SCE/Electrical Engineer

50 Ensure stopping of GT fans/keep Fans in auto. 8.5 mtr SCE/Electrical Engineer

Desk Engineer/Field
51 Ensure to stop Hydrogen Drier, no need to isolate its MIV 8.5 mtr Engineer

52 Ensure to remove one CPU from service, only one CPU to be kept 0 mtr Desk Engineer/Field
in service. Engineer
Confirm with TMD team, is there any requirement of TDBFP Fast
53 CCR SCE/UCE
cooling. (For TDBFP Maintenance work)
UCE/Desk
In case of long shutdown, isolate Exciter cooler DMCW Isolation
54 8.5 mtr Engineer/Field
MIV Engineer

In case of long shutdown, isolate Primary water PHE isolation UCE/Desk

55 8.5 mtr Engineer/Field
MIV (DMCW Side)
Engineer

UCE/Desk
In case of long shutdown, isolate Hydrogen cooler O/L MIV
56 DMCW Side 8.5 mtr Engineer/Field
Engineer
Ask BMD, if hydro need to be performed then ask for continue
57 CCR UCE/Desk Enginner
vacuum pulling by opening MSSV, HPBP & LPBP.
Ensure Ammonia dosing system to be kept running at CPU O/L,
58 0 mtr Desk Engineer/Chemist
ask chemist to maintain the parameters.
After Main turbine Came on Barring gear, if No hydrotest Desk Engineer/Field
59 0 mtr
planned then kill Vacuum as per SOP. Engineer
Desk Engineer/Field
60 Ensure to isolate APH Soot Blowing MIV from APRDS. 32 mtr
Engineer
Desk Engineer/Field
61 Ensure to isolate Main turbine Gland seal MOV from APRDS. 32 mtr
Engineer

62 Ensure to isolate TDBFP AUX Steam MIV from APRDS. 32 mtr Desk Engineer/Field
Engineer

63 Ensure to isolate interconnection APRDS from Other unit. 32 mtr Desk Engineer/Field
Engineer

64 Ensure not to increase Deaerator temp, maintain D/A temp CCR Desk Engineer/Field
approx 110 ͦC. Engineer

65 Ensure to maintain Deaerator level about 500 mmwc. CCR Desk Engineer/Field
Engineer
Desk Engineer/Field
66 Ensure to reduce CW Interconnection valve from 100 % to 5% 0 mtr
Engineer
Ensure to stop one CW Pump (For 2 units three CW Pumps kept Desk Engineer/Field
67 CCR
running) Engineer
 PRAYAGRAJ POWER GENERATION COMPANY LIMITED - 3X660 MW STPP
660 MW UNIT NO. # ___ DATE :-
TURBINE SHUT DOWN CHECKLIST
S No. Activity Description LOCATION RESPONSIBILITY REMARKS
Desk Engineer/Field
68 Ensure to reduce Condenser outlet valve from 60% to 10%. 0 mtr
Engineer

69 If Feed water not required in Boiler, Ensure to stop MDBFP. CCR UCE/Desk Engineer
 PRAYAGRAJ POWER GENERATION COMPANY LIMITED - 3X660 MW STPP
660 MW Unit no. # ___ Date:-
BOILER SHUT DOWN CHECKLIST
S No. Activity Description LOCATION RESPONSIBILITY

Ensure which type of shutdown is-

Normal Shutdown to Cold
1 CCR SCE/UCE
Normal Shutdown to Hot standby
Shutdown in case of Tube Failure

Check if there is any Emergency shut down- Boiler tube leakage, major problems
2 in Turbine, Generator etc, Transmission constraints. CCR SCE/UCE

3 All coal bunkers should be preferably made empty before long shut down. Stop/ CCR SCE/UCE/CHP
regulate coal feeding to bunkers accordingly.

4 As soon as intimation received from management to shutdown the unit. Intimate CCR SCE/UCE/Commercial
SLDC about unit shutdown

Gradually reduce load to 360 MW & cut out 6 th & 5 th feeder, if coal mill A to F
running then first stop E & F Mill. (Ensure feeder & Mill empty) & mill (Reduce load Desk Engineer/Field
5 as per load requirements. Feed water, airflow, fuel flow, and steam temperature 24 mtr Engineer
should remain on automatic control)

6 Ensure to take one MDBFP in service & unload one TDBFP at about 360 MW. 17 mtr Desk Engineer/Field
Engineer
Ensure to start LRSB of Extended pass area, WSB & LRSB of the zone where BTL Desk Engineer/Field
7 Boiler
Suspected. Engineer
After 360 MW, Ensure to cut the coal from bottom Mill (Preferably bottom mill A &
8 CCR Desk Engineer/Field
B). Cut feeder & mill from bottom one by one. Ensure complete empting of mill &
Engineer
coal feeder by isolating Feeder inlet gate.

9 Ensure to maintain SH outlet temperature. Ensure closing of SH spray block valve/ 24 mtr Desk Engineer/Field
MOV/Control valves @ 30% BMCR (215 MW). Engineer
Desk Engineer/Field
10 Ensure warm keeping line NRV Bypass MIV is in close condition 32 mtr
Engineer
Desk Engineer/Field
11 Ensure Both HWL-1 & 2 Isolation MOV are in open condition. 14 mtr
Engineer
UCE/Desk
12 Ensure to take boiler in Wet mode at about 300 MW & start BCP as per procedure. CCR Engineer/Field
Engineer
UCE/Desk
13 Ensure to take Feed water 30% line at about load 300 MW. 17 mtr Engineer/Field
Engineer
Ensure to keep APH soot blowing continously during shut down of the unit to Desk Engineer/Field
14 avoid any fuel accumulation in APH. 14 mtr Engineer
UCE/Desk
Gradually reduce coal flow Keep 2 mill in service & adjacent oil gun in service. .
15 CCR Engineer/Field
Reduce load to 175 MW (Ensure Eco flow.)
Engineer
Slightly reduce the load up to 100 MW, Maintain MS Pressure with in the range of
16 CCR UCE/Desk Engineer
80-100 kg/cm2.
17 Ensure to trip the Boiler from Emergency push button on DCS/Desk. CCR UCE/Desk Engineer
18 Ensure to discharge all ESP Fields's. All CERM & EERM motors kept running. CCR UCE/Electrical Engineer

19 Ensure Boiler flash tank service water is in charged condition. CCR Desk Engineer/Field
Engineer
UCE/Desk
20 Ensure to check BTL either in SH/RH by operating HPBP. CCR Engineer/Field
Engineer/BMD
UCE/Desk
21 Ensure to stop one ID & one FD Fan CCR Engineer/Field
Engineer
Desk Engineer/Field
22 Ensure to run AC Scanner air fan in service. CCR Engineer
Desk Engineer/Field
23 Ensure to isolate LOTV/HOTV (main & bypass line) & Control valves. 24 mtr
Engineer

24 Ensure to isolate all MIV of Oil station line at 24 mtr. 24 mtr Desk Engineer/Field
Engineer
Desk Engineer/Field
25 Ensure to isolate all MIV of LONV/HONV at all elevations. 24 mtr
Engineer
26 Ensure to isolate all MIV of Atomising air/steam (AANV/ASNV) of all elevations. 24 mtr Desk Engineer/Field
Engineer

27 Ensure to establish Secondary air flow between 450 to 500 TPH & maintain CCR UCE/Desk Engineer
furnace draft -10mmwc with running ID Fan in auto.

28 Ensure not to exceed cooling down rate > 167 ̊C/hr of fluid temperature. CCR UCE/Desk Engineer
29 Ensure APH kept running, Emergency motor & Air motor available. CCR UCE/Desk Engineer
UCE/Desk
30 Ensure to isolate MSSV-1 & 2 in case of hot box up. CCR Engineer/Field
Engineer
Desk Engineer/Field
31 Ensure to open back pass rear & front header drains at 10 kg/cm² CCR
Engineer
Desk Engineer/Field
32 Ensure to open all vents when seperator pressure reached 5 kg/cm² CCR Engineer
Desk Engineer/Field
33 Ensure to empty Economizer hopper. CCR
Engineer/AHP

34 If APH need to be stopped, ensure APH Gas inlet temperature < 204 ̊C OR APH CCR UCE/Desk Engineer
hot element temp < 187 ̊C.

35 Ensure feed water temperature should not be less than 111 ̊Cthen the SST metal CCR UCE/Desk Engineer
temperature.

36 Before water washing, Ensure temp <= 55 ̊C metal temp achieved. CCR UCE/Desk Engineer
Ensure to kept run the BCP & BFP in service until the boiler water temperature is
37 reduced to 100 ̊C, keep the water level near normal in SST, adding make up water CCR UCE/Desk Engineer
required.
Ensure not to shut down the Scanner air fan, until the furnace temp has dropped
38 CCR UCE/Desk Engineer
below 149 ̊C.

39 Ensure to run the APH if fans are running, because deposit of fly ash in APH may CCR UCE/Desk Engineer
accumulate cause rotor unbalance.

NOTES:-

1 If required boiler to be draine make sure that BCP suction temp reduced to 93 deg.
2 When flue gas temp. at APH I/L reached 75 deg, stop FD fan and give clearance for water washing and during water washing ID fan Kept running
3 During Water washing Furnace draft in manual & presure maintain -10 MMWC
0 MW STPP

REMARKS

Maintain all paramtere MS and metal and while

reducing load upto technical min. ie. 360 MW,
(60MW/15 min.)

Mill-B,C,D remain in service,may be chances of flame

failure.

make sure MIV & Block valve of RH spray and SH spray

isolated.

Below approximately 30% load over fire will be closed to

minimum position to prevent tip from over heating

Maintain MS temp @ 520 -530 deg celsius

Ensure APH sootblowing after taking gun in service

After boiler tripped make sure purging

 but it will take to much time to cool furnace, for
attending leakages( air flow may be maintain 700-800)

Temp<232 than cooling rate 167 deg./hr

Temp >232 than cooling rate 333 deg/hr.

Inform AHP for Bottom deashing

Keep close watch of vertical water walltemp and spiral

temp difference should not greater than 56 deg

when BCP suction temp reached 95 deg., stop BCP

an Kept running