NTPC UNCHAHAR

Integrated Unit startup Procedure Checklist

(Warm start up) Unit # Date:
Before Boiler Light up
Activity
Status
(write data
s no or tick) Remarks
A Equipment cooling water lined up
1.Number of PHE,s charged on both sides
2.Equipment cooling water pumps in service
3.RW pumps/CLCW pumps /ARCW pums in service
4. DMCW/ACW pr: ksc.
5.CLCW/ARCW/RW pr: ksc.

B Instrument air system

1.Compressors in service
2.Instrument air pressure: ksc.

C Plant air system

1.Compressors in service
2.Plant air pressure: ksc.

D Boile drains/vents
1.Boiler ring header drains closed
2.Boiler Superheater drains opened
3.Drum vents/Superheater vents /Startup ventopened
4.MS line drains /CRH/HRH line drains on Boiler side opened

5.Superheater /Reheater spray isolating valves closed.To be opened before rolling

Turbine & temperature drop tobe monitored across desuperheating station after
opening isolating valves
6.Economiser recirculation valves are opened
7.Boiler Inspection doors /peep holes closed

E Gas path

1.ESP fields earthing removed.

2.ESP Passes charged from gas side
3.ESP Hopper/insulation heaters & rapping system in service.
4.ESP Hoppers/ECO Hoppers/APH hoppers flushing apparatus charged & Gates
opened.
5.All ducts inspection doors closed
6.ID fans lined up & available.
7.Furnace pr after ID/FD fans startup: mm of wc.
F Air path Status Remarks
1.FD/PA/Seal air/Scanner Fans lined up& available
2.All ducts inspection doors/drains closed
3.All mills cold air gates opened
4.Schaph in charged condition
5.Scanner air fan pr: mm of wc.
6.Total air flow: TPH.
7.Wind box pr after boiler purging: mm of wc.

G Aux PRDS
1.Header pressure and temperature:
(Aux PRDS charged from station header)

2.Scaph line ,Atomising line,oil gun Tracing lines,APH sootblowing line are charged

H Oil guns
1.Guns cleaned and clamped & lined up
2.Tracing steam availablev & Steam traps lined up.
3.Oil trip valve close & short recirculation opened
4.Atomising steam charged & controller in auto
5.Atomising steam pressure & temperature :

I Bottom ash hopper

1.LP/HP water chagred.
2.Bottom ash Hoppers filled with water
3.Bottom ash hopper seal trough charged
4.Grinder supplies on & seal water charged
5.Scrapper conveyors in service & slag bath charged with water

J Lube oil system

1.Mill LOP in service & standby LOP lined up & supply on
2.FD/PA/ID Fans LOP 's in service & standby LOP lined up & supply on
3.APH A/B Guide& Support bearing LOP in service & standby LOP lined up &
supply on
K Boiler Status Remarks
1.All PTW's cancelled & Boiler filled upto normal drum level
2.BFP inservice & standby BFP lined up & supply on.(no watre thr' IBD)
3.Boiler stop valves in closed condition
4.Boiler protections checked & inservice

5.Boiler spring loaded safety valves gags removed & ERV's lined up & in auto
6.All wallblowers & LRSB's in retracted condition
7.Burner front fire water is charged/Deluge valve lined up
8.Drum pr/temp: ksc/ ⁰ C.
9.Feedwater temp at Economiser inlet: ⁰ C.

L Milling system
1.All mills PTW cancelled & lined up
2.Mill reject system lined up
3.Mill lube oil systems& grease systems are in service & standby pumps are
available
4.Seal air fans lined up& supply on
5.RC feeders supplies on & lined up
6.Bunker gates& feeders gates open
7.Bunker levels:

M APH
1.APH A/B inservice & all dampers in open condition
2.APH A/B Lube oil system in service
3.APH A/B air motors lined up & air pressure:
4.Soot blowres supply on& steam lined up
5.Fire water charged up to last valve
6.All manhole doors closed
7.Guide& support bearing area clean
8.Oil carry over probes put in place & cooling water charged
9.APH fire detection system inservice & values normal

N Dearator
1.Dearator level:
2.Dearator pr: ksc.
3.Dearator temp: ⁰ C.
4.Dearator pr controller in auto
5.Dearator pegging control valve position: %.
6.Dearator level controllers both lined up (stage II/III)
O Condesate system
1.Condenser charged from CW side
2.Hotwell level normal & make up lined up
3.CEP in service & on recirculation
4.Standby CEP on auto (SLC ON )
5.LPH's lined up on condensate side & drip/vent side
6.CST lined up

P Feedwater system
1.BFP's lined up & one BFP in service
2.HPH's linedup on feed water side/drip side

Q TURBINE
1.MOT level: & level normal (+/- 20 mm on barring)
2.MOT vapour fan in service
3.MOT Centrifuge in service

4.AOP in service : lube oil pr : ksc.(after filter >3.0 ksc)

lube oil temp: (43 to 45⁰C)
lube oil cooler charged from cooling water side:
lube oil temp controller in auto : SGC oil system ON:
5.JOP in service: & discharge pr: (110 to 130ksc)
6. All AOP's/ All JOP's & EOP supplies on & all SLC ON
7.Turbine on barring gear
8.Turbine barring speed:
9.Bearing chamber blower in service
10.EHC lined up
11.Speed reference set point for the Speed Controller is zero or less than the
barring speed
12.Load reference set point for the Load Controller and the load limiter output are
> 10%.
13.Speeder gear position is 100%. & Starting device is at 0%.
14.The alarms "TSE influence off / TSE trouble" not coming

15.Extraction NRV's (A2, A3, A4, A5) and CRH line NRV's L/R are closed.
16.Turbine Stop valves Test Valve in open condition
17.All mal drains open& isolating valves open as checked physically
& SLC ON
18.All MS /CRH/HRH strainer draines /line drains open & their isolating valves
open condition
 19.Strainer drains line upto UFT
20.All extraction drains open (including isolating valves)

21.TSI & other Prameters:

Axial shift/HPT/IPT/LPT Diff exp:
HP/IP Overall exp:
Brg oil temp: Brg vibrations: 1/2/3/4/5/6/7:
Shaft vibrations:HP(F)/HP(R)/IP(R)/LP(R)/EXCITOR:
HPS(50%)/IPS(50%)/HPC(50%)/IPC(50%)metal temp:
TSI margin:upper/lower: HPT Exhaust temp:
LPT exhaust temp:
Condenser wall temp(L&R):
HPC (top/bottom) DT: IPC Front/Rear (top/bottom) DT:
22.All Turbine side protections checked & I/S

R Seal oil system

1.AC seal oil pump on & discharge pr:
2.Other seal oil pump SLC ON.
3.Seal oil DP:
4.Governing oil to seal oil lined up
5.Seal oil vac p/p in service & vacuum:
6.seal oil cooler charged from water side

P Generator
1.GRP all relays reset
2.GT line&bus isolator closed
3.Generator and field breakers are in RESET condition and Generator /Field
breakers tripped" & "Generator trip relay operated" alarms are reset.
3.GT marshalling box supply on& cooler suuply on (both sources)
4.Generator coolers & excitor coolers charged from water side
5.Generator H2 pressure: (stageI: 3.3 ksc & stage II&III:1.80 KSC)
6.Generator H2 purity: (should be 98%)
7.Generator stator water flow&conductivity: m³/hr & mho
8.Stator water standby pump supply on & in auto
9.LLD position: (no alarm in UCB & LLD clear at local)
10.H2 Drier on&lined up:
11.All Switch gear charged from normal I/C

S DCDB (220V & 24 V)

1.DCDB all modules on
2.DCDB main chrger in service & standby charger supply on.

T HP/LP Bypass
1.HP Bypass oil supply unit in service
2.HP Bypass spray manual valve closed &to be opened at HP Bypass down stream
temp of 250 ⁰ C.
 3.HP Bypass warm lines open
4.LP Bypass governing system charged
5.LP Bypass injection v/v's manual isolating valve open
6.LPT exhaaust spray line isolating v/v open
U Vacuum pulling

Start vacuum pulling just before Boiler lightup:

(CEP in service,Condenser CW passes are charged,Hotwell level normal)

a.Puto seal steam header drain/before seal steam controller drain in auto.
b.Open seal steam supply line manual drain .
c.Keep GSC blower in service.
d.Ensure close position of AS 51 &AS 51A & open their isolating valves
e.Open seal steam supply line isolating valve from PRDS (also open AS17 in ST#1 ,
AS 09 in ST#2 & st#3) f.seal sream temp before seal staem pr control v/v is ~
250 ⁰ C.
f.Start vac p/p OR take starting ejector into service.
g.At a vacuum of -0.7 ksc ,charge seal steam into seal steam header by opening
AS51 Valve
h.Maintain seal steam header pr ~ 100 mmof wc./temp of ~ 250 ⁰ C. & obseve
for improvement in vacuum)
i. vacuum:
 After BLU Status
(write data
or tick) Remarks
1.Oil flme condition at local
(Preferably CD guns for Hot startup & AB for cold& warm startup)
2.Oil flame intensity :1/2/3/4:

3.Flue gas temp at platen superheater:

~ 30 min after BLU:
~ 60 min after BLU:

4.Start APH sootblowing.

Steam pressure at local before sootblower:
Puppet valve condition:
5.Check for oil carryover with Oil carry over probe
(no oil traces)
6.Drum metal temp:
7.SH/RH max. metal temp: (should be within limits)
8.APH A/B Flue gas outlet temp: (no abnormal rise)
9.Drum level:
(Should be within + / - 100mm of wc)
10.Drum pressure raise:
(should not exceed saturation temp of 100 ⁰ C / hr)
11. Rate of raise of SH temp:
(Max 5 ⁰ C / min)
12.Close drom vents at 2.0 ksc
13. Drum metal temp raise:
(max 100 ⁰ C / hr)
14. Dozing in service:
15. Condenser vac:
16.HP/LP Bypass available:
17. MS/CRH/HRH line, strainer drains/MAL drains open on turbine side
18.Turbine stop/control valves closed
19.Close SH vents at 3.5 ksc & startup vent open/HPBypass warm up open
Cond vacuum:

20.Open integral bypass valves of boiler stop valves at 4 ksc

a.Observe for raising of steam temp before MS strainer L/R
b.Check for heating of MS strainer by touching strainer drains.
21.Open boiler stopvalves in inching mode at 5 ksc pr
a.Observe steam pr raise before MS strainer L/R

22.Charge HP Bypass gradually

a. Observe for raise of Hp bypass downstream temp L/R to 260⁰ C
b.Then set HP Bypass down stream temp to 260⁰ C & regulate it to 260⁰ C
c.maintain cond wall temp < 90 ⁰ C.
22a.take second BFP into service.
23.Close strtup vent,HP Bypass warm up valves.
24.Charge LPBypass gradually
a.raise MS pr to 15 ksc/temp 200 ⁰ C & raise HRH pr to <10ksc & maintain
24a.start PA Fan & take I Mill into service
Sec air temp after APH preferably > 170 ⁰ C .

25.raise steam parameters for stop v/v opening

(MS pr 25ksc / temp >300 ⁰ C)--Max.min SH steam temp with respect to mid
HPCV(50%) metal temp from X1,X2 & X3 startup curves
Say for a HPCV (50 %) metal temp of 200 ⁰ C ,required main steam temp is a
minimum of 250 ⁰ C before HP Bpass.
a.by raising gradually ,the opening of HP Bypass /LP bypass valves & with oil firing
b.switch on 'warm up controller' & observe HPCV before drains opening

26.keep speeder gear to 100% open & starting device to 0%

a.trip oil pr ~ 8ksc
b.raise starting device slowly & observe startup oil pr coming down
c.stop raising starting device if any stop v/v is opening
d.at around 2.0 ksc startup oil pr all 4 stop valves opens.
e.observe for any raise in speed after opening stop v/v's

27.raise steam parameters for rolling turbine to 600 rpm

(from X4 & X5 curves depending on HP Shaft 50% temp.)
a.MS pr/temp: 60 ksc/ 425 ⁰ C (st#1) & 55ksc /380 ⁰C (st#2/3)
b.MS temp depending on HP Shaft (50%) temp
Say for a HP Sahft(50%) temp of 300 ⁰ C ,required MS temp before HP stop
valve is a minimum of 330 ⁰ C .
c.lube oil temp :43 to 45 ⁰ C & temp controller in auto
d.lube oil pr > 3.0ksc
e.H2 pr:3.3 (st#1) ,1.8 (st#2/3)
f.TSE margin :

28.raise speed reference to 600 rpm and observe speed raising to 600 rpm
a.keep watch on
TG brg vibns:1/2/3/4/5/6/7
TG Shaft vibrns:1/2/3/4:
Overall exp:HP/IP:
Diff expn:HPT/IPT/LPT:
brg temp:1/2/3/4/5/6/7:
TSE margin:
HPC/IPC DT
29.Soak turbine at 600 rpm until margins improve
30.steam parameters for rolling to 3000 rpm. (from X6 curve)
MS pr/temp: 33 ksc/300 ⁰ C (st#1) & 45ksc /350 ⁰C (st#2/3)
b.MS temp depending on HP Casing (50%) temp
Say for a HP Caing(50%) metal temp of 300 ⁰ C ,required max MS temp before
HPSV is 400 ⁰ C .
c.lube oil temp :43 to 45 ⁰ C & temp controller in auto
d.lube oil pr > 3.0ksc
e.H2 pr:3.3 (st#1) ,1.8 (st#2/3)

31.raise speed reference to 3000 rpm and observe speed raising to 3000 rpm
a.keep watch on
TG brg vibns:1/2/3/4/5/6/7
TG Shaft vibrns:1/2/3/4:
Overall exp:HP/IP:
Diff expn:HPT/IPT/LPT:
brg temp:1/2/3/4/5/6/7:
TSE margin:
HPC/IPC DT
32.Line and bus isolators closed

33.Soak until until margins improve & steam parameters as specified by turbine
startup curve X 7
a.keep watch on
TG brg vibns:1/2/3/4/5/6/7
TG Shaft vibrns:1/2/3/4:
Overall exp:HP/IP:
Diff expn:HPT/IPT/LPT:
brg temp:1/2/3/4/5/6/7:
TSE margin:
HPC/IPC DT
34.MOP discharge pr. is adequate after transfer of load from AOP to MOP
35.AOP cut out at speed >2800 rpm.
36.Lub oil, seal oil, temperatures are within limit
(45 0C, 40 0C).
37.S.W., Cold gas, Exciter air temp. are within limit (~ 40, 36, 55) 0C
38.Ensure before closing the field breaker ,Generator excitation control is on
remote
39.Close field breaker
Field voltage
40.G.T. fans and oil pumps are running.
41.Oil in generator LLD and alarm healthiness to be confirmed.
42.H2 driers are in service.
43.Turbine lub oil, filters DP High / Not High
44.Steps bypassed during rolling.
45.Put synchroniser in check mode & make on auto synchroniser
46.After syncronisation load raise by speed reference upto 4o MW.
(EHC in speed control mode.)
47.close HP bypass
close LPbypass
48.Close MS/HRH/CRH line/strainer drains
put MAL drains in auto
 After Synchronisation Status
(write data
or tick) Remarks
1.raise load as per DC/Check MVAR,Gen volts
2.take EHC on load control
3.charge LPH1,2,3 on staem side after ensuring Extraction drains in open
condition
4.Charge dea extraction
(pegging v/v in auto)

5.Charge HP heater on steam side

(after taking 2 nd mill in stage I)

6.attemperation lined up
a.attemperation need not be given until BLI is 120 TPH
b. later to be controlled as per start up curve temp
c.or as per steam temperatures allowed as per TSE upper margin)
7.start 2nd mill
8.start 2nd PA Fan
take 2nd PA Fan & load (balancing to be done st#2/3)
9.CBD position:
silca

10.start 3rd mill

(take 3rd mill at above 105 MW (see startup charts for rated parameters))
11.control SH/RH temp as per TSE upper margins
12.charge ESP fields at APH gas outlet temp of 110 ⁰ C.
13.Start 4th mill
(take 4th mill at above 150MW) (see startup charts for rated parameters)
14.control SH/RH temp as per TSE upper margins
15.take out oil gun one by one after seeing flame condition at local & at flame
panel
16.raise steam temp to rated values as allowed as per TSE upper margin
17.raise load to full
18.Turbine & Generator parameters
Shaft vibns:
Brg vibrations:
Brg temp1/2/3/4/5/6/7:
HPC(50%)/HPS (50% ) temp:
IPC(50%)/IPS(50%) temp:
HPC DT: IPC DT F/R:
Diff expn HP/IP/LPT:
Overall HP/IP:
cold gas temp: stator water /cold gas DT: ( <5 ⁰C.)
Max core temp: Max wdg/slot temp:
excitor hot air temp: seal oil temp:
H2/seal oil DP: H2/stator water DP:
H2 Dew point: H2 purity: