SH1 DHI P0100 GE M01 PRO 5304 - Plant Startup & Shutdown Procedure - Rev.3 (Replace)

DOCUMENT SUBMISSION STATUS: FOR CONSTRUCTION
3 07.12.2018 FOR CONSTRUCTION J.M.SHIN H.W.NAM J.H.PARK
2 26.07.2018 FOR CONSTRUCTION J.M.SHIN H.W.NAM K.H.KIM

REV DATE DESCRIPTION PREPARED CHECKED APPROVED
PROJECT TITLE
SONG HAU 1 THERMAL POWER PLANT (2x600MW)
OWNER OWNER’S CONSULTANT
VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING
EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT
VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES

CORPORATION (LILAMA) COMPANY LIMITED - TEPSCO
SUB-CONTRACTOR
DATE NAME SIGN DOCUMENT TITLE
PREPARED 07.12.2018 J.M.SHIN
CHECKED 07.12.2018 H.W.NAM Plant Startup & Shutdown Procedure
APPROVED 07.12.2018 J.H.PARK
DOCUMENT NO. REV.

SH1-DHI-P0100-GE-M01-PRO-5304 3
SONG HAU 1 THERMAL POWER PLANT PROJECT
CONTENTS
1. ABBREVIATIONS ............................................................................................................... 3
2. INTRODUCTION................................................................................................................ 5
3. SCOPE .................................................................................................................................. 5
4. PLANT START-UP AND SHUTDOWN DURATION .................................................... 5
5. PLANT START UP ............................................................................................................. 5
5.1. START-UP PREPARATION ............................................................................................. 5
5.1.1. START-UP POWER AVAILABILITY ............................................................................. 5
5.2. BALANCE OF PLANT SYSTEMS START-UP .............................................................. 5
5.2.1. INITIAL FILL ..................................................................................................................... 7
5.2.2. LOW PRESSURE SYSTEM START-UP.......................................................................... 7
5.2.3. HIGH PRESSURE SYSTEM START-UP ........................................................................ 8
5.2.4. AUXILIARY STEAM SYSTEM LINE UP ....................................................................... 9
5.2.5. GLAND SEALING AND VACUUM PULLING .............................................................. 9
5.2.6. CONTINUOUS EMISSION MONITORING SYSTEM .................................................. 9
5.3. BOILER START-UP ......................................................................................................... 10
5.3.1. DRAUGHT PLANT START AND BOILER PRE-LIGHT OFF SEQUENCE ........... 10
5.3.2. LIGHT-OFF BOILER....................................................................................................... 13
5.3.3. MAIN STEAM SYSTEM CHARGING .......................................................................... 14
5.3.4. RH STEAM SYSTEM CHARGING................................................................................ 14
5.3.5. BOILER WET- DRY STATE CHANGEOVER............................................................. 15
5.3.6. CHANGEOVER FROM OIL FIRING TO COAL FIRING ......................................... 15
5.4. TURBINE START-UP ...................................................................................................... 16
5.4.1. ROTOR PREWARMING ................................................................................................. 17
5.4.2. CHEST WARMING .......................................................................................................... 18
5.4.3. FINAL PREPARATION FOR ROLLOFF ..................................................................... 18
5.4.4. TEMPERATURE MATCHING ....................................................................................... 20
5.4.5. ST ROLLING ..................................................................................................................... 20
5.4.6. SYNCHRONIZATION ..................................................................................................... 21
5.4.7. DA PEGGING STEAM SOURCE CHANGEOVER ..................................................... 22
5.4.8. LOADING UP AFTER INITIAL LOAD ........................................................................ 22
5.4.9. EXTRACTION STEAM SYSTEM START-UP ............................................................. 22
5.4.9.1. EXTRACTION STEAM SYSTEM FOR LP HEATERS .............................................. 22
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5.4.9.2. EXTRACTION STEAM SYSTEM FOR HP HEATERS .............................................. 23

5.4.9.3. UNIT MASTER CONTROL ............................................................................................ 24
5.4.10. T-BFP START-UP ............................................................................................................. 24
5.4.11. T-BFP STEAM AND PEGGING STEAM CHANGEOVER FROM CRH TO IP
EXTRACTION .................................................................................................................................... 25
5.4.12. AUX. STEAM SUPPLY .................................................................................................... 25
5.4.13. ST GLAND SELF SEALING ........................................................................................... 25
6. PLANT SHUTDOWN ....................................................................................................... 26
6.1. LOAD REDUCTION......................................................................................................... 26
6.2. COAL TO OIL FUEL CHANGEOVER ......................................................................... 26
6.3. FIRST T-BFP STOP .......................................................................................................... 26
6.4. AUX. STEAM REQUIREMENT DURING SHUTDOWN ........................................... 26
6.5. ONE CEP STOP .............................................................................................................. 26
6.6. START UP OF BRP ........................................................................................................ 27
6.7. CHANGEOVER FROM T-BFP TO M-BFP ................................................................ 27
6.8. HEATER EXTRACTION SYSTEM ............................................................................... 27
6.9. ST TRIP AND BYPASS OPERATION ........................................................................... 27
6.10. BOILER SHUTDOWN ..................................................................................................... 28
6.11. AUX. SYSTEMS SHUTDOWN........................................................................................ 28
7. REFERENCE DOCUMENTS .......................................................................................... 29
ATTACHMENT I START UP AND SHUTDOWN CURVE오류! 책갈피가 정의되어 있지 않습니다.
ATTACHMENT 2 OIL IGNITION FOR PULVERIZER STARTUP & SHUTDOWN오류! 책갈피가 정의되어
ATTACHMENT 3 CHECK LIST FOR PREREQUISITE CONDITIONS오류! 책갈피가 정의되어 있지 않습
SH1-DHI-P0100-GE-M01-PRO-5304 2 of 38
1. Abbreviations
APC Automatic Plant Control

APS Automatic Plant startup & shutdown Sys.
BFP Boiler Feedwater Pump
BLR Boiler
BNR Burner
BMCR Boiler Maximum Continuous Rating
BOP Balance of Plant
BRP Boiler Recirculation Pump
CC Coordinated Control
EMS Continuous Emission Monitoring System
CEP Condensate Extraction Pump
CID fan Combined Induced Draft fan
CPP Condensate Polishing Plant
CRH Cold Reheat
CRV Combined Reheat Valve
CW Circulating Water
CWP Circulating Water Pump
DA Deaerator
DCS Distributed Control System
DOLT Start the Diesel oil Leak Test (DOLT)
DHI Doosan Heavy Industry
ESP Electro Static Precipitator
EVN Vietnam Electricity
FCV Flow Control Valve
FD fan Forced Draft fan
FGD Flue Gas Desulfurization System
FW Feed Water
GAH Gas Air Heater
GCB Generator Circuit Breaker
GR fan Gas Recirculation fan
H/W Hot Well
HDR Header
HFO Heavy Fuel oil
HIP High-Intermediate Pressure
HP High Pressure
HRH Hot Reheat
HSPV Heating Steam Pressureizing Valve
HTR Heater
HVCB High Voltage Circuit Breaker
ID fan Induced Draft fan
IP Intermediate Pressure
IV Intercept Valve
LDO Light Diesel Oil
LP Low Pressure
M-BFP Motor driven-Boiler Feedwater Pump
MCV Main Control Valve
MFT Master Fuel Trip
Misc. Miscellaneous
MOV Motor Operated Valve
NRV Non Return Valve
O&M manuals Operating & Maintenance manuals
OFA Over Fire Air
P&I diagrams Piping & Instruments diagrams
PA fan Primary Air fan
PRDS Pressure Reducing and Desuperheating station
RFV Reverse Flow Valve
RPM Revolution Per Minute
RO Rated Output
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SA Secondary Air
SAH Steam Air Heater
SB Standby
SCAH Steam Coil Air Heater
SCR Selective Catalytic Reduction
SDCC Submerged Drag Chain Conveyor
SSDV Steam Seal Dump Valve
STG Steam Turbine Generator
SVBV Main Stop Valve Bypass Valve
SW Sea Water
T-BFP Turbine driven-Boiler Feedwater Pump
TBN Turbine
TCS Turbine Control System
TMCR Turbine Maximum Continuous Rating
TRCP Transformer Control Panel
UMC Unit Master Control
VV Ventilator Valve
VWO Valve Wide Open
W Working
SH1-DHI-P0100-GE-M01-PRO-5304 4 of 38
2. Introduction
This document contains guidelines for plant startup and shutdown procedure for Song Hau 1 Thermal
Power Plant. Plant Start-up & Shutdown Sequence Diagram can also be referred, along with this
document, for graphical sequence of plant start-up programmed in DCS.
3. Scope
Scope of this document is to describe the start-up and shutdown procedure for the complete power
plant system. This document is subject to revision based on the further detailed engineering and
vendor/OEM information.
4. Plant Start-up and Shutdown Duration

Plant start-up is envisaged in following three modes based on boiler and turbine thermal condition.
1. Cold Start
2. Warm Start
3. Hot Start
Start-up time is considered from the time the first oil ignition. The start-up time for various modes is
as given in the table below:
Mode of Mode of start-up time Start-up time from Push

Duration of
start-up From Boiler Ignition to Button Activation to
shutdown (hr)
Full Load (min) Full Load(min)
Cold start-up >48 hr 550 920
Warm start- <48 hr but >8 hr 380 530

up
Hot start-up <8 hr 200 315
Note: The start-up mode will be decided by operator after checking condition of STG and BLR.
5. Plant Start up
5.1. Start-up Preparation
5.1.1. Start-up power availability
Auxiliary power required for plant start-up is taken from the grid. Unit auxiliary transformers are
charged from the grid power (500 kV). Unit switch gear bus-A & B (11 kV) are charged from UAT to
supply power to the various plant auxiliaries.
BOP system Since required electricity during start-up is supplied from external grid, operator must 3
obtain permission from EVN informing them of the time of start-up, synchronization, load-up to
scheduled load.
5.2. Balance of Plant Systems Start-up
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Before initiating plant start-up, following utility systems are considered to be commissioned and in
service.
• CW system
CW water system will be started manually by operator from DCS. After starting of circulating water
pumps will be started. The, circulating water supply to condenser will be established manually by
operator from DCS.
• ACW system
When circulating water system is started and water is available up to ACW pump (P1PCB09AP001,
P1PCB10AP001) suction, operator starts any one of 2 X 100% (1W+1SB) ACW pump 3
(P1PCB09AP001, P1PCB10AP001) from DCS to supply cooling water to the CCW heat exchanger
(P1PGB05AC001, P1PGB06AC001, P1PGB07AC001), vacuum pump seal water coolers
(P1PCB31AC001, P1PCB32AC001, P1PCB33AC001) and SDCC cooling system as per requirements.
• CCW system
CCW water system will be started manually by operator from DCS. 2х100% CCW pump
(P1PGB02AP001, P1PGB03AP001) along with three CCW heat exchangers (P1PGB05AC001,
P1PGB06AC001, P1PGB07AC001) will be kept in operation. Cooling water supply to for various
coolers will be charged filled manually by operator as per operational requirements. The level in the
overhead tank (P1PGB80BB001) will be maintained by tank inlet LV (P1GHC77AA081).
• Compressed Air system
As soon as cooling water for air compressor is available from CCW system, operator will give
compressed air system group start command from DCS. Start-up of Compressed Air system includes
start-up of 3 х 50 % air compressors (2W+1SB) (P0SCA01AN001, P0SCA02AN001,
P0SCA03AN001), 2 х 100 % air dryer plant (1W+1SB) (P0SCA30AT001, P0SCA30AT002), air
receivers and charging of instrument air and service air as per operational requirements.
• DM water system
DM water system will be group started manually by operator as group start sequence from DCS. DM
water storage tank will be filled by DM water supply pump. DM water storage tank level is
maintained by opening/closing MOV at tank inlet. 2х 100% (1W+1SB) (P0GHC11AA001,
P0GHC11AA002) DM water supply pump will be running operated to supply water for condensate
storage tank (P0GHC50BB001, P0GHC50BB002).
• Condensate Storage and Transfer System
Once DM water system is in operation, running, operator will initiate filling of condensate storage
tank. Operator will start one of 2 X 100% (1W+1SB) condensate transfer pump (P0GHC61AP001,
P0GHC62AP001) from DCS to fulfill initial fill up requirement of various systems as well as hotwell
make up water requirement. The various sytems which require initial filling are as below
- Condensate System
- Condensate System(For Stator Cooling System)
- Boiler
- Deaerator
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• Service Water & Fire fighting system

Service & Fire Fighting Water Storage Tank (P0GHD02BB001, P0GHD03BB001) will be filled by
tap water. Start-up of service water system includes filling charging of service water storage
tank(P0GHD02BB001, P0GHD03BB001), start-up of one of 2 X 100% (1W+1SB) service water.
Filling Charging of service water distribution lines will be done by operator as per operational
requirements.
Once service water storage tank in filled, entire fire fighting water system is filled charged and kept in
auto to avoid any potential hazard in the plant.
• Diesel oil forwarding system
Diesel oil system start-up will be done manually by operator from DCS. Any one of 3 х 50 % 3
(2W+1SB) diesel oil forwarding pump will be started to fulfill the diesel oil requirement during start-
up. Diesel oil storage tank level will be made up by running the filled with diesel oil from diesel oil
unloading pump (in the ship).
• Water treatment system
Water treatment system will be group started by operator as group start from DCS.
5.2.1. Initial Fill

Before initiating condensate/ feedwater system fill up, auxiliary systems including DM water system
and ‘condensate storage and transfer system’ must be in operation. One DM water supply pump
(P0GHC31/32AP001) will be running operated to maintain the condensate storage tank water level.
One condensate transfer pump (P0GHC61/62AP001) will be running operated to supply water to
condensate distribution system for initial filling of system.
Condenser hotwell is filled up to the normal water level by opening bypass line MOV
(P1GHC80AA105). The condensate system piping will be filled by opening manual valve
(P1GHC75AA101) at filling line. Initial fill Water for deaerator (P1LAA10AC001) initial fill is
supplied from condensate transfer pump by opening MOV (P1GHC74AA001) installed at supply line
connected to deaerator inlet pipe.
Feedwater/boiler piping filling is done from with condensate transfer pump (P0GHC61AP001,
P0GHC62AP001).
System low point drain valves and vent valves are operated during initial filling. Once filling is
completed, vent and drain valves are closed.
Once initial filling is done, low pressure system is started-up which contains start-up of including
condensate system.
5.2.2. Low Pressure System Start-up

Low pressure system startup includes start-up of condensate system and charging filling the circuit up
to deaerator LCV (P1LCA90AA081). Once the following start-up permissives are fulfilled, operator
will initiate condensate system group start sequence from DCS.
Condensate group start-up permissive:
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 CEP A/B/C (P1LCB21/22/23AP001) ready to start

 CPP ready
 Condensate clean-up LCV (P1LCA92AA081) closed
 Condenser to Waste Water Treatment LCV (P1LCA93AA081) closed
 Recirculation FCV (P1LCA41AA081) set to Auto.
 Operator permissive (This permissive shall be manually given by the operator after ensuring the
status of all manual valves in condensate system, through field check)
 Condensate system drives and CV, to be operated in auto, are in auto mode.
Condensate system group start includes sequential start-up of LP heater 1 (P1LCC11/12AC001) &
drain cooler(P1LCC11/12AC002), primary CEP (P1LCB21/22/23AP001), Condensate Polishing
Plant. Start-up of LP heater 2(P1LCC20AC001), 3(P1LCC30AC001), 4(P1LCC40AC001) and Gland
Steam Condenser(P1MAW60AC001) will be done manually by operator.
Until Deaerator level is decreased due to feedwater supply to boiler after firing, condensate is
recirculated via minimum recirculation line to condenser.
DA level will be controlled by controlling adjusting condensate flow from LP heater 4 to deaerator
(P1LAA10AC001) by modulating deaerator 30% start up LCV (P1LCA90AA081) based on with 3
single element level control based on DA level measured by triple redundant level transmitters
P1LAA10CL001/2/3.
When condensate system start-up is completed, operator will further proceed with start up of the high
pressure system start-up which contains start-up of including feedwater system.
5.2.3. High Pressure System Start-up

High pressure system start-up includes start-up of feedwater system and charging filling the circuit up
to economiser inlet FCV. Once the following start-up permissives are fulfilled, operator will initiate
feedwater system group start sequence from DCS.
Feedwater group start-up permissive:
 Start-up M-BFP (P1LAC10AP001) ready to start
 FW system drives/ CV in auto
 Recirculation FCV (P1CA41AA081) set to Auto.
Feedwater system group start includes start-up of start-up M-BFP (P1LAC10AP001) and HP heater 6,
7 and 8.
During start-up, M-BFP (P1LAC10AP001) will be operated to fulfill the feedwater requirement of
boiler. Feed control valve (P1LAB60AA081) at economizer inlet will control the feedwater flow to
the economizer during start-up, up to 30% load.
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5.2.4. Auxiliary Steam System Line up

During start-up, auxiliary steam will be initially provided from Auxiliary Boiler if not available from
other power neibouring unit of SH1, by opening the MOV (P0LBG01AA001/002). When the Main
steam pressure is above 35 bar(a) (preliminary, to be verified), source of steam supply will be changed
over to Main steam line. 3
During start-up except above case, the auxiliary steam will be initially provided from another
neibouring unit or Auxiliary Boiler at 15 bar(g) and 300°C. As the CRH steam pressure increases
beyond the requirement of unit auxiliary steam header pressure, Aux steam will be provided from
CRH by opening MOV (P1LBC32AA001).
Normally, as plant load increases, auxiliary steam consumption is reduced. And if auxiliary steam
consumption is less than 6 tons per hour, CRH Secondary PRDS will operate in place of CRH Primary
PRDS.
Auxiliary steam consumption during start-up includes the following consumers:
 Feed water storage tank initial heating
 Deaerator pegging
 Steam coil air heater
 Turbine pre-warming and gland sealing
 BFP Turbines
 FGD damper sealing
 Soot blower for GAH
BFPT will be started by utilizing cold reheat steam. Quality of steam source is already secured
because generation of cold reheat steam means BFPT steam admission event is after steam admission
to main turbine. Then and at 25% load, steam source will be changed to IP turbine extraction steam.
generation of IP turbine extraction steam also means steam quality is secured. And main steam is used
for the steam source of BFPT for transient condition like load rejection, this codition also means
steam quality is secured because steam aleady had been admitted into turbine.
5.2.5. Gland sealing and vacuum pulling

Once condensate systems are started running, supply of turbine gland sealing can be initiated.
Auxiliary steam source during this period will be steam supply from neighboring unit or auxiliary
boiler. Once turbine gland seals are established(Required Steam Seal Header Pressure : 0.28 barg),
condenser vacuum pulling will be started. During start-up, vacuum pumps will be operated running in
hogging mode.
Once condenser initial hogging is completed (254 mmHga = 33.864 Kpa), one vacuum pump will be
stopped in holding mode.
5.2.6. Continuous Emission Monitoring System
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CEMS will be kept in operation before boiler light up. During normal operation guaranteed emission
values are as given in the table below. All the emission values are based on the reference condition of
6% O2-dry at 25°C and 1 atmosphere.
Guaranteed Emission Values Concentration
NOx 450 mg/Nm3

SOx 300 mg/Nm3
Particulates 116 mg/Nm3
5.3. Boiler Start-up

Boiler start-up is envisaged in following three modes based on separator metal temperature.
1. Cold Start
2. Warm Start
3. Hot Start
Separator Outlet
Separator Metal Approx. Duration of Mode of Start-
Pressure at Start P,
Temp, (deg.C) shutdown (hr) up
(barg)
P≤5 T≤158 >48 hr Cold
5<P≤40 158<T≤251 <48 hr but >8 hr Warm
P>40 T>251 <8 hr Hot
After feedwater system is started, the initial water filling of boiler is started. The water level required
to start the boiler recirculation pump should be established in the storage vessel. Drains and vents
should be opened or closed to the light off position.
5.3.1. Draught Plant Start and Boiler Pre-Light off Sequence

Boiler air and flue gas path will be established once feedwater system start-up is completed. Both
3
draught plant streams are taken into service, i.e. starting in sequence, first Air Preheater, first CID fan
group start (P1HNC10AN001, P1HNC20AN001) and Furnace Pressure Control Auto, then first FD
fan group start and Air Flow control Auto. Then the second Air Preheater/CID/FD fan group start. For
starting CID/FD fans, the outlet dampers shall be in closed position and inlet blade pitch is at in the
minimum position.
1) Operator initiates Boiler Start sequence.

2) Start-up feed water supply pump. The boiler is filled and a stable level is obtained in the storage
vessel by BFP in operation. Thereafter boiler recirculation pump is started automatically.
SH1-DHI-P0100-GE-M01-PRO-5304 10 of 38
Note: The circulating water quality must be monitored constantly and appropriate action shall be
taken to rectify any failure to meet the specified quality.
3) Start Diesel oil pumps (if not already running).
4) Start Put in service Gas air heater/ID/FD fan and coal mills lube / hydraulic oil systems.
5) Start the scanner cooling air fan and purge air fan.
6) Set the boiler drains and vents to boiler start up positions.
7) The furnace purge sequence will set the Air & Gas dampers to purge position.
8) Start rotation of gas air heaters A and B rotating.
9) Start ID fan A against closed dampers.
Closes discharge damper and blade pitch then ID fan a run-ups and open discharge damper and
release blade pitch to AUTO furnace pressure control. Furnace pressure setpoint is minus
10mmH2O.
10) Start FD fan A against closed dampers.
Closes discharge damper and blade pitch to min. position, then FD fan A run-ups to speed, opens
discharge damper and releases blade pitch to AUTO flow control (min flow control set point is
35% of BMCR flow*).
* Min. flow control set point can be adjusted during commissioning stage according to
combustion condition at low load.
11) Start ID fan B against closed dampers (similar to ID Fan A above).
12) Start FD fan B against closed dampers (similar to FD Fan A above).
13) Open ID Fan blade pitch and set to Auto Furnace pressure control.
14) Start Furnace Purge Sequence timer of 15 minutes when the following permissive are present:
In order to remove accumulated combustible gases or combustible dust in any part of the boiler,
boiler purging is performed during start-up. Purging will be performed in accordance with NFPA
85 requirements. Once all purge permissives are fulfilled purge sequence is initiated either
automatically or by operator which continues for 15 minutes (5 furnace volume changes).
Air Purge Time calculation

(a) Total Air flow@BMCR : 574.1 kg/s (PA 151.784 kg/s + SA 422.321 kg/s) 3
- SH1-DHI-P0ZEN-M-M01-DAS-0001
(b) Fluid Specific Volume(@40oC, 0.1KPag)=0.9 m3/kg
(c) Purge Air Flow(25~35%BMCR-permissive condition)
• 574.1 (A) X 0.25 = 143.5 kg/s
143.5 X 0.9 (B) x 60 = 7750.4 m3/min
• 574.1 (A) X 0.35 = 200.9 kg/s
200.9 X 0.9 (B) x 60= 10850.6 m3/min
(d) Required Purge time
• Furnace Volume : 17,492 m3 - SH1-DHI-P0HAD-M-M01-CAL-0001
• Back Pass Volume : 6,594 m3 - Attachment
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• Total Boiler Internal Volume : 24,086 m3 (D1+D2)

• Required Purge time( D3 x 5 / C1 ~ D3 x 5 / C2)
- 24,086 x 5 / 7750.4 (C1) = Approx. 15 min
- 24,086 x 5 / 10850.6 (C2) = Approx. 11 min
• Any ID fan running

• Any FD fan running
• Diesel oil ignition and burner header main and return trip valves closed
• All individual burner oil valves closed
• No boiler trip condition present
• Any gas air heaters running
• Air flow at 25~35% of BMCR flow
This step purges the furnace,GAH A/B, EP A/B(supplied by others). If any furnace purges
permissive fails during purge timing, the fault must be rectified and the furnace purge restarted.
The total airflow for the Furnace Purge condition is 35% of BMCR load volumetric flow , which
should be maintained through purge and light off of the first oil burners. 3
This flow will effectively remove gaseous combustibles and replace with air. Start the Diesel oil
Leak Test (DOLT).
15) Start the diesel oil leak test(DOLT). Following satisfactory completion of Stage 2 oil leak test
open MFSSOV (Master Fuel Safety Shut-off valve,P1EGD50AA051) to establish oil flow to
burner rails and return line.
Diesel oil forwarding suppy system should be in service prior to leak test.
Note for leak test:
• Stage 1- pressurizes the system and tests for any pressure decay which would indicate
leaks in the burner valves or return valve.
• Stage 2- releases the system pressure by opening the return valve. The return valve is then
closed and the system checks for a rise in pressure which would indicate a leak on the
MFSSOV.
After Furnace Purge is completed, The MFT Relays are reset. And then Diesel oil Leak Test is
completed. The Master Diesel oil Safety Shutoff Valves are opened and The Diesel oil control
valve is put to auto. Initiate light-up of diesel oil burners and Atomising air & diesel oil control
loops on auto.
16) Release the atomizing air control valves and atomizing air control valves to AUTO control
setpoint.
17) Insert the furnace temperature thermo-probes.
18) Initiate GAH sootblowing; Aux. steam must be available.
19) Open the diesel oil header main trip valves when the following are completed.
• Furnace purge is completed.
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• The MFT relay has been reset.

• Oil Leak Tests are completed
20) Boiler now ready for light off
If light off has not been achieved within 30 minutes of MFT Reset then a new Furnace Purge
will be required.
5.3.2. Light-off Boiler

1) Operator will monitor firing permissive if all available, gives the Light Off command to start.
2) All dampers should be the light off position (as at end of purge).
3) Put Hot secondary air pressure control into auto.
4) Put superheater and reheater temperature controls on auto.
5) Oil firing is established for initial pressure raising and to provide support for coal introduced on
the first and all subsequent mills. Progressively add additional oil burners to achieve desired
pressure raising rate.
6) Start the 1st (Mill C), 2nd (Mill E), 3rd (Mill B), 4th (Mill A) Mill Group oil burners as required,
refer to table below. The respective burners should be operated at full rating prior to coal ignition
on that burner row as per NFPA 85 requirements to stable flame. Firing rate is adjusted to
achieve the pressure/temperature raising rate required per the start up curves.
Control rate of firing to satisfy the following conditions. If necessary, reduce the number of
burners in service.
Burner identification notation
Burner Front Wall, Top Burner Row
Row D
Burner Front Wall, Middle Burner Burner Rear Wall, Middle Burner
Row B Row Row A Row
Burner Front Wall, Bottom Burner Burner Rear Wall, Bottom Burner
Row C Row Row E Row
Note:
Control the rate of firing to satisfy the following conditions. If necessary, reduce the number of
burners in service.
3
• Gas temperature at primary superheater inlet the nose top must not exceed 540 ºC(from
thermo probe) until an adequate flow of steam is established through the reheater.
• The steam pressure should be increased slowly during the initial start of a new steam
generator. This allows sufficient time for checking expansion movements and permits the
operators to become familiar with the characteristics of the steam generator and auxiliary
equipment.
• During start-up a minimum feedwater flow through the circuit is maintained by running
boiler recirculation pump (BRP (P1HAG31AP001)) to prevent water wall tube overheating.
7) As separator outlet pressure increases, progressively close the superheater steam line drains in
use according to predetermined sequence.
SH1-DHI-P0100-GE-M01-PRO-5304 13 of 38
8) After light off of oil minimum air flow of 35%BMCR is maintained. (Note MFT occurs if purge
flow falls below 25%BMCR air flow).
9) PF can only be fed to a burner row once the associated oil burners are firing.
Note : The number and position of burners will be determined by the type of start-up and
commissioning experience., but typically would be as follows: Details are refer to attachment 2.
10) Start seal air fan, followed by first PA fan (note, seal air fan suction is from PA fan discharge) ,
then start second PA fan as required for mill warming. Mill outlet temperature may be put into
auto during mill warming.
5.3.3. Main Steam System Charging

HP bypass valves(P1LBH10/20AA081, capacity is 60 % of HP steam at BMCR condition) are
provided to control the main steam pressure. During start-up, once boiler is fired and all permissives
for HP bypass system are satisfied, HP bypass system will be put into service under auto control.
Initially, HP bypass valve opens to the minimum opening condition Ymin (10%).
Spray water for HP bypass valve is supplied from BFP discharge line. Once bypass valve opens more
than 2%, spray water line shut off valves (P1LAE53AA051/52) open and the HP bypass temperature
control valves (P1LAE53AA081/82) will be operated in auto mode. TCVs will be modulated based on 3
the feedback signal from HP bypass valve downstream temperature measurement

(P1LBH11CT001/002 & P1LBH21CT001/002).
When main steam pressure increases beyond Pmin (99.6 barg) HP bypass controller mode will be
changed to minimum pressure control mode. HP bypass valve will open to maintain the main steam
pressure constant. The bypass valve opening set point is set to Ymax (25%). Main steam temperature
keeps on increasing at a predefined gradient. As soon as bypass valves opening reaches to Ymax (25%),
HP bypass controller mode will be changed to pressure rise mode.
In pressure rise mode, set point for HP bypass valve is set to synchronization pressure Psync (49 barg).
As boiler firing is started and steam production increases, main steam pressure increases at a
predefined gradient depending up on the cold, warm or hot mode of start-up. HP bypass valves will be
modulated to control the pressure gradient till main steam pressure reaches to synchronizing pressure.
Once the main steam pressure reaches to synchronizing pressure, HP bypass controller mode is
changed to fixed pressure control mode.
During fixed pressure control mode, HP bypass is operated so as to maintain the main steam pressure
constant at synchronizing pressure.
During warm or hot start-up, the minimum opening mode and the minimum pressure control mode is
skipped since initial main steam pressure is high enough to operate in pressure rise mode.
When steam generation meets with load on the curve, bypass valve starts to close. And after this point
it will be converted into monitoring mode by DCS.
5.3.4. RH Steam System Charging
SH1-DHI-P0100-GE-M01-PRO-5304 14 of 38
LP bypass valves(P1LBH31/41AA081) are provided for reheat steam pressure control. LP bypass
valves will be kept closed until the minimum reheat pressure is reached. Once reheat steam pressure
reaches to Pmin (18 barg), LP bypass valves controller will be changed to minimum pressure control
mode. LP bypass valve opening set points is set to Ymax (45%) depending up on the reheater flow.
Spray water for LP bypass valve desuperheater is supplied form the CEP (P1LCB21/22/23AP001)
discharge line. Once LP bypass PCV opens more than 2%, respective LP bypass valve TCV
(P1LCE41AA081/42AA081) operate in auto mode. Enthalpy based temperature control is realized for
LP bypass downstream temperature control.
Once LP bypass valve opens to Ymax (45%), respective LP bypass controller mode is changed to
pressure rise mode. During pressure rise mode set point for LP bypass controller is set to
synchronizing pressure Psync (14 barg). Reheat steam pressure increases towards synchronizing
pressure at a predefined gradient depending up on the cold, warm or hot mode of start-up.
As soon as synchronizing pressure is reached, LP bypass valve controller mode is changed to fixed
pressure control mode so as to maintain the constant reheat steam pressure.
3
5.3.5. Boiler Wet- Dry state changeover
As boiler steam production increases, the water level of the water separator decreases. At around 35%
TMCR load (about 210 MW), water separator level eventually disappears. boiler mode of operation
changes over from wet state to dry state. The boiler now operates in once through mode and boiler
recirculation pump (P1HAG31AP001) will shutdown at 40 TMCR load (5 percentage points above
Benson load).
Note) Benson load is 35% TMCR to ensure the furnace tubes are adequately cooled whilst operating
at start up and at loads up.
5.3.6. Changeover from Oil firing to Coal firing

Start-up is envisaged with Diesel oil as a firing fuel. Coal mills will be started depending up on the
furnace temperature and load requirement. As coal mills start, oil firing is decreased gradually.
During startup, oil firing can be stopped once boiler load is above 40%. But to light up the coal burner
in order to increase the load, adjacent oil burner should be in operation. Therefore the last oil burner
can be taken out only after 4th coal mill is cut in. The oil support is completely cut off beyond 70-
75% load.
1) Start Ash Handling system (Ash Handling System should be in service prior to Mill operation).
2) All the light-up oil burners associated with the coal mill end(s) to be put into service must be in
operation during the coal mill start-up sequence before mill PA and classifier outlet valves are
opened for mill warming.
3) The first mill will be required to be brought into service after synchronizing Turbine Generator
Note: For warm and hot starts the sequence of introducing mills will be brought into service
prior to steam turbine rolling.
SH1-DHI-P0100-GE-M01-PRO-5304 15 of 38
4) Start up of the 1st mill at minimum turndown can then proceed as required by boiler loading.
5) Put 1st mill outlet temperature control to auto.
Note: a warming sequence will be required per manufacturer’s instructions.
6) SA to BNRs of 1st mill will already be in auto.
7) Put PA to 1st mill on auto.
8) Put feeder to 1st mill on auto.
9) Put Mill Master on auto.
10) Start SCAH system (P1HLC51AH001, P1HLC52AH001) when 1st coal feeder is operated.
Start steam air heater after PF burner is lit and set to control the gas air heater inlet air
temperature to 68 ºC
11) Start up of the 2nd Mill can proceed at any time after the 2nd Mill Group oil burners are firing
and when required by boiler loading. Proceed to Mill Master for the 2nd mill.
12) Select O2 trim to auto. O2 trim will be allowed to operate above boiler load 40%.
13) The unit may be placed on Boiler Master Control when operating conditions dictate. It is
recommended that a minimum of two mills are in service and mill load is shared equally.
14) Increase boiler load and start up of the 3rd, 4th (and 5th as required with worst coal) can then
proceed in a similar way at any time as required by boiler loading having first started as
associated oil burners.
15) Before these subsequent mills are put onto Boiler Master Control it is recommended that the load 3
on each mill to be raised on Mill Master to equalize the load with the existing mills to ensure a
bumpless transfer.
16) Reduce number of oil burners in service commensurate with mill start requirements and boiler
heat input requirements.(set during commissioning)
17) Throughout any start the operator should monitor:
Combustion, pressure raising rate, lower furnace spiral wall tube temperatures, furnace outlet
metal temperatures, furnace outlet steam temperatures, storage vessel temperature differentials,
thermoprobe temperatures, dead space metal temperatures of the superheater and reheater
18) As the load increases, the superheat and reheater temperature approaches its target of 569C.
Check that the attemperators limit the final steam temperature to 569C.
19) Increase load steadily to 100% TMCR or at a load specified by the Grid Controller.
5.4. Turbine Start-up

Turbine start-up is envisaged in following three modes based on thermal condition of turbine rotor.
1. Cold Start
2. Warm Start
3. Hot Start
HP turbine 1st stage shell metal temperature is communicated from turbine control system to DCS
based on which operator may select the mode of start-up.
SH1-DHI-P0100-GE-M01-PRO-5304 16 of 38
HP turbine 1st stage shell metal Approx. Duration of

Mode of Start-up
temperature (deg.C) Shutdown (hr)
T < 265 > 48hr Cold
265 < T < 442 < 48hr but > 8hr Warm
T > 442 < 8 hr Hot
Turbine start-up is performed by automatic turbine start-up (ATS) sequence which is a part of turbine
control system.
The Automatic Turbine Start-up (ATS) function of the control system provides acceleration, load rates,
and hold times directly to the primary controls or guide messages for the operator.
The ATS function will furnish guidance messages to the operator in which set points should be
selected for proper operation. The operator will follow these guidelines in respect to pre-start
temperature and stress conditions, recommended acceleration rates and whether to implement speed
holds.
Normal starting and operation would be in control system’s under automatic mode of operation, 3
because it provides for the most time-efficient operation. The control system’s manual mode will be
used if the operator wants to have more influence over set point selection using guide messages on the
control system CRT.
Following turbine auxiliary systems need to be in operation before turbine startup:
• Turbine lube oil system
• Turning gear system (min. four hours before turbine rolling)
• Steam seal system
• Hydraulic fluid system
• Seal oil system
• Hydrogen gas system
All the turbine drain valves will be opened at the time of turbine start-up.
5.4.1. Rotor prewarming

Turbine rotor prewarming needs to be done if the high pressure rotor bore temperature is less than
149°C and the reheater bowl and reheat exhaust temperatures are less than 54°C.
The steam supply should be limited to an enthalpy range of 662.2~714.9 Kcal/kg (1192~1287
BTU/lb) to raise the HP shell (and rotor) surface temperature to 149°C or higher more when
pressurized to 3.79~4.82 barg. Simultaneous with pressurization, the reheat section should be
prewarmed to 54.4°C by maintaining allowable condenser back pressure with the steam seals in
operation. The time required for the reheat section to reach 54.4°C may exceed the time required to
prewarm the high pressure part to 149°C.
The reheat section is considered granted to be prewarmed when all the metal temperature
thermocouples in this section read 54.4°C or higher. The turbine may be reset or tripped. If sufficient
SH1-DHI-P0100-GE-M01-PRO-5304 17 of 38
steam conditions are available at auxiliary steam header, steam can be admitted to the HP turbine and
the reheat pipes via the HSPV.
In Automatic mode, the turbine control system will pressurize HP turbine and reheat pipes in a
controlled manner. The pressure setpoint will be ramped at approximately 0.39 barg/min until 14
bar(g) is reached, with the provision that the error between setpoint and actual pressure does not to
exceed a certain limit. 3
HSPV Inlet Pressure Limiter will begin to close the HSPV if the auxiliary header pressure decreases
below 14 bar(g). Regulation is 10%, and the HSPV will be closed at 12.6 bar(g).
5.4.2. Chest warming

Control valve chest warming sequence needs to be entered initicated if the turbine control system
issues a message that chest prewarming is required. This is the case if the difference between main
steam temperature and control valve chest outer surface temperature is greater than the allowable
temperature difference across the valve wall.
Chest warming consists of two phases:
1) Control Valve Chest Pressurization — Open the SVBV by selecting MSV position set point and
slowly pressurize the CV chest in compliance with messages given. Hold chest warming if
requested. A request for slow pressurization indicates the need for a low set point as follow;
a. TSAT – CVO > CVALLOW
TSAT: Saturation Temperature of Main Steam
CVO : CV Outer Temperature
CVALLOW : CV Allowable temperature.
b. Main Steam Temp - CV Outer Temp < Allowable Temperature diff. * 1.2
c. CV Inner Temp. – CV Outer Temp < Allowable Temperature diff. * 0.4
2) Control Valve Chest Heat Soaking — Heat soaking begins after the chest pressure has reached
85% of main steam pressure. The differences between chest wall temperatures (inner–outer) and
between main steam and chest wall outer temperatures (main steam– CV outer) must be less than
the heat soak targets (allow) for the CV chest to be ready for rolloff.
Once chest warming is completed, turbine control system will issue the message “Chest warming
completed” to DCS.
5.4.3. Final Preparation for rolloff

The turbine control system will continuously monitor turbine auxiliary systems, turbine temperatures
and several generator parameters as a preparation for rolloff.
Following checks need to be performed before turbine rolloff:
1) All trip inputs to the turbine control system should be reset.
The Valve Position Limit shall be set at 120% maximum.
No problems should be indicated on TCS alarm lists.
2) All data on displays should be in acceptable ranges, and no alarms present on displays.
SH1-DHI-P0100-GE-M01-PRO-5304 18 of 38
3) Condenser pressure should be -0.85 bar (g) maximum. (- 637.55 mmHg (g))
4) Steam seal header pressure should be 0.17 to 0.31 barg. An alarm will be given for a pressure
outside a 0.13 to 0.41 barg range and operate valves in automatic mode.
5) All turbine drain valves should be open.
6) Hydraulic fluid pressure should be 131 to 165.4 barg. Hydraulic fluid temperature should be 29.4
to 49° C. Turbine control system will alarm below 131 barg, below 18° C and above 65.6° C.
7) Auxiliary Bearing Oil Pump should be running, the Emergency Bearing Oil Pump should be off
and its control switch should be in the AUTO position.
8) Bearing lube oil temperature should be between 27 and 32° C. Bearing header pressure should be
greater than 1.03 barg. An alarm will be given below 1.03 barg and outside a 10 to 32° C range.
9) Start-up BFP shall be in service.
The main cooling water shall be in service.
The auxiliary cooling water shall be in service.
LP bypass flows shall be ready for turbine roll.
Main turbine shall have normal eccentricity and bearing metal temperatures.
10) Generator Ready Checks:
A hold will be issued if the generator’s hydrogen and stator coolant systems indicate problems.
An event message will be provided if generator field prewarming is required at 3000 rpm, as
indicated by the hydrogen cooler gas inlet temperature being less than 20° C.
11) Required steam purity:
12) Rub check (for initial start-up)
SH1-DHI-P0100-GE-M01-PRO-5304 19 of 38
a. Select turbine speed rate : 100rpm/min

b. Check turning gear disengage
c. Close valve or master trip after turbine speed reaches in 200rpm
- Confirm there is not any abnormal noise at each gland sealGenerator Ready Checks:
5.4.4. Temperature matching

Matching of steam temperature to turbine inlet metal temperature is very critical step before steam
admission to turbine. Optimal steam to metal temperature matching delivers the best start-up times.
HP turbine 1st stage temperature signal is used for main steam temperature matching. IP turbine bowl
temperature signal is used for IP steam temperature matching.
ATS provides values for maximum and minimum recommended steam temperatures which are
calculated from current steam pressure, current stresses and metal temperatures.
Additionally, although the selected steam temperature is above the minimum value, the steam
temperature should be higher than 41.7°C (75°F) above saturation temperature.
In Reverse Flow mode, turbine control system is designed to affect regulate the temperature in the
highpressure turbine, including the first stage, by with operation of the Reverse Flow Valve
(RFV(P1LBC10AA081)) and Ventilator Valve (VV(P1MAB10AA504)) to admit steam to the HP 3
turbine exhaust. Therefore, the primary consideration before rolling the turbine should be is to match
reheat steam temperature to the reheat bowl inner surface metal temperature by adjusting the steam
generator accordingly.
5.4.5. ST rolling
The turbine will be rolled by the ATS sequence at suitable speed and having acceleration rate based
on the thermal stress of HIP rotor. Generally, recommended turbine acceleration rate during various
modes of start-up is given in table below:
Mode of start-up Acceleration rate (RPM/minute)
Cold start-up 100

Warm start-up 150
Hot start-up 300
In automatic mode, turbine will be started in reverse flow mode. In reverse flow mode, speed/load
control is conducted with the intercept valves until transfering to forward flow at low loads. During
this phase, MCV will remain closed and steam to the turbine will flow only through the IP and LP
turbines. LP bypass valve starts closing as IV(P1MAB10/11AA053)s gradually open.
VV(P1MAB10AA504) will be opened at roll-off point and will keep the HP turbine at near vacuum
condtion during most of the acceleration period. When the speed reaches approximately 2200 RPM,
the RFV(P1LBC10AA081) will be opened in a programmed manner to provide suitable reverse flow
SH1-DHI-P0100-GE-M01-PRO-5304 20 of 38
which is entering from this valve and venting through the VV(P1MAB10AA504) to prevent
overheating of the HP turbine.
Turbine is accelerated to high speed hold (2500 RPM). It is recommended that the holding period at
high speed to be maintained for heat soaking and lube oil heating. Holding period for various modes
of start-up is as given in the table below: 3
Mode of start-up Holding period (min) Purpose
Cold start-up 60 min IP turbine Heat Soaking
Warm start-up 10 min Lube oil Heating
Hot start-up 10 min. Lube oil Heating
Once holding period is completed, turbine accelerates to full speed. Field excitation will be applied to
the generator excitation system when it is close to rated speed.
During acceleration speed holds will be implemented by the ATS, if:
1) Lookahead stresses are calculated to be greater than allowable limits.
(Lookahead stresses are stresses predicted for the next higher speed target considering current
and allowable stresses and current mismatch between steam and metal temperatures.)
2) At 2500 rpm, the rotor bores are found to be not heated sufficiently, the generator field is
prewarmed insufficiently, or the bearing oil cooler outlet temperature is less than 38° C.
3) A high vibration alarm is present.
4) A manual hold has been selected by the operator.
5) Oil trip test malfunction occurred before reaching rated speed.
Once turbine full speed is reached, the following checks will be performed by the turbine control
system:
1. Bearing Header Pressure –1.03 barg minimum
2. Operating Bearing Header Pressure – 1.72±0.20 barg
3. Inlet Lube Oil Temperature - 43–49° C
6) High speed heat soak
Cold Start Mode: High speed heat soaking during 20 min.
Warm/Hot Start Mode: High speed heat soaking during 10 min.
5.4.6. Synchronization
Generator synchronization will be done from turbine control system in automatic mode. Automatic
synchronizing consists of automatically speed matching, voltage matching, phase matching and
commanding the generator breaker to close within the predefined band of positive slips.
Since the facility of synchronization is provided for both Generator Circuit Breaker (GCB) and High
Voltage Circuit Breaker (HVCB), proper selection of the synchronizing breaker will be necessary
SH1-DHI-P0100-GE-M01-PRO-5304 21 of 38
through selector switch external to turbine control system. However during normal hot, warm or cold
start-up condition always GCB will be closed for synchronization since HVCB is already in closed
condition. turbine control system will receive inputs and issue a synchronizing command to a
respective breaker as per the selection made externally at synchronizing panel. After synchronization,
block load (5%) will be obtained. Thereafter, operator shall select a target load and a loading rate limit.
Then loading will continue at a calculated loading rate which will be equal to or less than the selected
limit. A loading rate is calculated based on actual rotor stress and change of stress and steam 3
temperatures.
Synchronization Permissive Condition :
- Turbine Rated Speed
- Generator Voltage Established (over 0.95pu)
- ES for GCB Opened
- GCB not Fault
- GPR not operated
*block load: obtained power right after synchronization
5.4.7. DA pegging steam source changeover

When CRH pressure reaches to 10 barg, DA pegging steam line MOV (P1LBC31AA001) from CRH
steam is opened automatically (or by operator) from DCS. Once CRH steam line MOV is opened,
pegging steam line MOV (P1LBG31AA001) in the aux steam line is closed automatically (or by
operator).
Hereafter DA pegging steam will be supplied from CRH steam.
5.4.8. Loading Up after Initial Load

After reaching the initial load or completion of initial load holding, steam turbine controller follows
the operator’s or plant DCS’s instruction to increase the load and operate at the target load. The ramp
rate (load up rate) should be determined in accordance with the Start-up Curves.
First mill will be started as per the sequence (on a cold start superheater temperature control may
require coal to be put on the first mill after the turbine has been synchronised). The subsequent mills
will be started as the load increase.
Duty mill seal air fan and PA Fans shall be in service before mill start. PA fan controls Hot PA duct
pressure.
5.4.9. Extraction Steam System Start-up

All HP and LP heaters tube side shall be filled are charged from with feedwater and condensate side
during the start-up of feedwater and condensate systems.
Extraction line drain valves will be operated automatically.
Heaters are included in group start sequence, so they are started automatically.
5.4.9.1. Extraction Steam System for LP Heaters
SH1-DHI-P0100-GE-M01-PRO-5304 22 of 38
As soon as HIP turbine starts rolling LP heater extraction steam group command can be manually
issued by operator to initiated to start LP heater extraction steam group sequence. It comprises of all
drives/systems of the extraction steam system and ‘heater drain and vent system’ to achieve automated
sequential charging of complete LP heaters from steam side. Startup vent MOV for all LP heaters will
be opened when hogging pressure is reached in the condenser.
The LP heater extraction steam group command can be issued only when all the following permissive
are fulfilled
 All participating drives and control valves of extraction steam system and ‘heater drain and vent
system’ are in auto mode of operation.
 LP heater 1 (P1LCC11/12AC001) in-line (condensate charged)
 All LP heaters extraction steam NRV and MOV open permissives satisfied
 Steam turbine rolls.
 Operator permissive (This permissive shall be manually given by the operator after ensuring that LP
heaters 2(P1LCC20AC001), 3(P1LCC30AC001) and 4(P1LCC40AC001) are in line (condensate
charged).
Group start sequence for LP heater includes sequential start-up of steam extraction to LP heater
2(P1LCC20AC001), 3(P1LCC30AC001) & 4(P1LCC40AC001). The start-up vent MOV for each LP
heater will be closed once turbine is synchronized and respective heater level is not low. The LP
heater extraction steam group sequence is considered to be completed when LP heater 4 pneumatically
3
actuated NRV (P1LBS40AA051) and motor operated isolation valve is fully opened.
5.4.9.2. Extraction Steam System for HP Heaters

The HP heater extraction steam group command can be manually issued by operator to initiated to
start HP heater extraction steam group sequence. The HP heater extraction steam group comprises of
all drives/systems of the extraction steam system and ‘heater drain and vent system’ to achieve
automated sequential charging of complete HP heaters from steam side. Start-up vent MOV for all HP
heaters will be opened once deaerator (P1LAA10AC001) atmospheric vent is opened.
The HP heater extraction steam group command can be issued only when all the following
permissives are fulfilled
 All participating drives and control valves of extraction steam system and ‘heater drain and vent
system’, in auto mode of operation.
 All HP heaters in-line (feedwater charged)
 HP heater (6,8)’s extraction steam NRV (P1LBQ30AA051, P1LBQ10AA051) and HP heaters
(6,7,8)’s MOV (P1LBQ30AA001, P1LBQ20AA001, P1LBQ10AA001) open permissives
satisfied.
Group start sequence for HP heater includes sequential start-up of steam extraction to HP heater 6, 7,
8 and deaerator (P1LAA10AC001)/ T-BFP (P1LAC20/30AP001). Extraction to heater 7
(P1LAD20AC001) is initiated once CRH pressure reaches to 10 barg. Once 20% load is achieved,
extraction for HP heater 6 (P1LAD10AC001) is commenced. Once heater 6 is in service, extraction
SH1-DHI-P0100-GE-M01-PRO-5304 23 of 38
for heater 8 is started. IP steam extraction for deaerator (P1LAA10AC001) at 30% load and for BFPT
is started at 30% load. The start-up vent MOV for each HP heater will be closed once respective
heater extraction starts and respective extraction NRV is opened for more than 10 sec. The HP heater
extraction steam group sequence is considered to be completed when deaerator pneumatically
actuated NRV and motor operated isolation valve is fully opened.
5.4.9.3. Unit Master Control

During start-up, once load increases beyond 10 % and UMC is permitted from TCS, operator enables
Unit Master Controller from DCS.
Once following conditions are true then turbine follow mode shall be enabled in UMC:
3
 Unit is synchronized
 Block load is applied
 No turbine limiting conditions are present
 UMC mode is permitted from turbine control system
 HP/LP Bypass PCVs are closed.
From 15 % to 40 % TMCR, Turbine follow mode is operated. Boiler fuel firing will be under “load
control”. Setpoint for load controller shall be from UMC with loading rate as per pre-defined start-up
mode. Turbine governor valve control shall be under pressure control from UMC. These governor
valves shall be modulated to control turbine inlet pressure at pre-define setpoint.
Beyond 40 % TMCR and up to 100 % TMCR load CC (Coordinate Control) mode is activated. Boiler
follow mode shall only be activated if the following permissives are fulfilled:
 At least one mill master is released to auto
 One CID fan is released to auto
 One FD fan released to auto
During turbine follow mode, boiler fuel firing control remains under “pressure control”. Turbine
governor valve shall be increased gradually open with respective rate by increasing flow rate. The
governor valves shall remain in the same position (wide open) unless there is frequency correction is
required. From 40 % TMCR to 100 % TMCR load range the load demand will be given to both Boiler
fuel firing control loop as well turbine governor demand control loop.
Turbine governor demand from UMC will be under “load control” mode. The governor valve will be
modulated for any change in load.
Constant Pressure Mode will be operated from 0 % TMCR to 40 % TMCR load range and Sliding
Pressure Mode will be operated from 40 % TMCR to 100 % TMCR load.
5.4.10. T-BFP (P1LAC20/30AP001) start-up
SH1-DHI-P0100-GE-M01-PRO-5304 24 of 38
At around 25% TMCR load load primary T-BFP (P1LAC20/30AP001) will be started in recirculation
mode.
As soon as following permissives are fulfilled, “Primary T-BFP (P1LAC20/30AP001) auto run-up
command” is issued from DCS:
 Primary T-BFP (P1LAC20/30AP001) change over command issued
 FW system in auto mode
 Primary T-BFP (P1LAC20/30AP001) ready for auto run-up
Primary T-BFP (P1LAC20/30AP001) is kept in pressure sync mode first. Once primary T-BFP
(P1LAC20/30AP001) discharge pressure difference is within limit, T- BFP discharge MOV
(P1LAB22/23AA001) opens and then start-up M-BFP discharge MOV (P1LAB21AA001) close
command is issued. As soon as T-BFP discharge MOV (P1LAB22/23AA001) is opened and M-BFP
discharge MOV (P1LAB21AA001) is closed, economiser inlet MOV (P1LAB50AA006) open 3
command is issued. After MOV close for M-BFP, M-BFP will be stopped. With the close feedback of
eco inlet MOV (P1LAB21AA001), T-BFP (P1LAC20/30AP001) on speed control mode is enabled
and eco inlet FCV (P1LAB60AA081) is closed.
At 40% RO load, secondary T-BFP (P1LAC20/30AP001) will be started to meet the overall
feedwater requirement.
5.4.11. T-BFP (P1LAC20/30AP001) steam and Pegging steam changeover from CRH to IP extraction
As soon as turbine load reaches to 25%, isolation MOV (P1LBQ70AA001) and NRV
(P1LBQ50AA051) in the line from IP extraction to T-BFP open. Now steam to operate T-BFP will be
supplied from IP extraction.
Isolation MOV (P1LBQ60AA001) and NRV (P1LBQ60AA051) in the IP extraction line to deaerator
(P1LAA10AC001) open and pegging steam line MOV (P1LBC33AA001) from CRH to deaerator
(P1LAA10AC001) closes. Now pegging steam to deaerator (P1LAA10AC001) will be supplied from
IP extraction.
5.4.12. Aux. steam supply

As soon as Main steam pressure reaches to 34 barg, Aux. steam supply from Main steam line by
opening MOV (P1LBA30AA001) and Aux. steam supply from auxiliary boiler is cut off completely
by closing MOV (P0LBG11AA001/002).
Aux steam will be supplied from CRH steam at 230 MW by opening MOV (P1LBC32AA001) and
close MOV (P1LBA30AA001) which placed in CRH supply line.
Hereafter all aux. steam requirements will be fulfilled from CRH steam supply.
5.4.13. ST gland self sealing

Turbine gland system is in self sealing mode once load reaches to 70% TMCR load (about 420 MW).
So, during start-up seal steam supply from aux. steam header gets gradually reduced by closing the
seal steam line control valve(P1LBC11AA081) as the turbine load increases. During self sealing
SH1-DHI-P0100-GE-M01-PRO-5304 25 of 38
operation seal steam line control valve(P1LBC11AA081) will be kept in auto mode to maintain the
seal steam header pressure in case it reduces below the pre-set value.
6. Plant Shutdown
The normal plant shutdown is considered from the unit operating at full load. At this point plant is
operating at 100% TMCR condition. Four coal mills are in operation. Boiler feedwater requirement is
being fulfilled by two T-BFP (P1LAC20/30AP001). CEP (P1LCB21/22/23AP001) are in operation.
Both HP and LP bypass systems are available and valves are in closed condition.
6.1. Load Reduction

From 100% TMCR condition turbine load is reduced to 90% in constant pressure mode. After that
turbine load will be reduced in a sliding pressure mode at a predefined gradient (as per shutdown
curve) by reducing boiler firing.
Turbine seal steam supply is started from auxiliary steam header once turbine load reduces below
3
70% load.
Down to 40% TMCR, turbine and boiler load is simultaneously decreased in CC Mode. Then at 40%
TMCR, boiler maintains its load and only turbine load will be decreased. After turbine trip at certain
load, boiler load will start to decrease for boiler shut down.
6.2. Coal to Oil fuel changeover

When the output starts reducing, the coal burners are turned off in order according to the decrease of
the fuel flow rate. The subsequent shutdown is completed with the support of oil firing. Once all the
coal mills are stopped, PA fans will be stopped.
6.3. First T-BFP (P1LAC20/30AP001) stop

As load reduces, boiler feedwater flow also reduces. Then and at 40% load, the feedwater flow
requirement reduces to the extent where only one T-BFP (P1LAC20/30AP001) can fulfill the
feedwater requirement. At this point pre-selelcted T-BFP (P1LAC20/30AP001) will be stopped with
operator verification button.
6.4. Aux. Steam requirement during shutdown

Steam turbine shutdown is envisaged with vacuum maintained in the condenser as per turbine OEM’s
recommendation. Aux. steam supply for gland sealing and pulverizer inerting (if required) during
shutdown will be supplied from CRH steam or main steam line.
6.5. One CEP stop (P1LCB21/22/23AP001)

At 40% load CEP (P1LCB21/22/23AP001) can be stopped automatically. First any one CEP
(P1LCB21/22/23AP001) will be stopped. After that only one CEP (P1LCB21/22/23AP001) will be
running to supply condensate flow to the deaerator (P1LAA10AC001).
SH1-DHI-P0100-GE-M01-PRO-5304 26 of 38
6.6. Start up of BRP (P1HAG31AP001)

At 35% steam load, the steam temperature at separator inlet will fall below the superheated region,
and water level will start to develop in the separator. BRP (P1HAG31AP001) is started to provide the
minimum flow and boiler is operated in recirculation mode.
6.7. Changeover from T-BFP (P1LAC20/30AP001) to M-BFP (P1LAC10AP001)

Normal shutdown can be performed using T-BFP (P1LAC20/30AP001) itself. M-BFP
(P1LAC10AP001) may be (on operators discretion) manually started by operator once the steam load
comes down to 30% and flow pressure is reached during shutdown. Once M-BFP (P1LAC10AP001)
is on load, T-BFP (P1LAC20/30AP001) can be stopped by operator. The subsequent feedwater
requirement to accomplish the shutdown will be fulfilled via M-BFP (P1LAC10AP001). The FCV
(P1LAB60AA081) at feed control station will be operated in order to control the feedwater flow to 3
the boiler and feed control station MOV (P1LAB50AA006) is closed.
When M-BFP is not available(P1LAC10AP001) for shutdown, T-BFP(P1LAC20/30AP001) will be
operated by auxiliary steam and it is same procedure for shutdown by T-BFP(P1LAC20/30AP001).
6.8. Heater Extraction System

As steam turbine load reduces, feedwater heater extractions get cut off automatically according to
absence of available extraction steam. Below 20% load, IP extraction for DA pegging and T-BFP
(P1LAC20/30AP001) gets cut-off and CRH steam cuts-in. once load reduces below 20%, HPH
extraction for heater 8 and 6 closes sequentially.
Extraction for HPH 7 will continue until BLR trips. All LP heaters will also get cut-off as soon as
steam turbine is tripped.
6.9. ST Trip and Bypass Operation

As turbine load is decreased under TMCR 40% while boiler maintains its MSL (TMCR 40%), HP-LP
bypass valve(P1LBH10/20AA081, P1LBH31/41AA081) will open to maintain the upstream pressure.
After the minimum shutdown load is reached (LOAD AT TARGET) and this load is above 5%, it is
recommended that the remaining load `be dropped quickly with the RAPID UNLOAD feature ON,
and the unit tripped without delay at, or below 5–10% load. After desynchronization steam turbine
speed decreases at a predefined gradient and once speed reaches to zero speed, turning gear is started.
Turbine is kept on turning gear until maximum temperature of the inner surface metal of the casing,
corresponding to the rotor system shell surface metal temperature is less than 250° C.
Turbine is envisaged to be shutdown with vacuum maintained which requires continuous seal steam
supply till turbine reaches to zero speed. When condenser vacuum reaches to atmospheric pressure
gland sealing is stopped.
Once seal steam system is stopped, vacuum pump will be stopped. M-BFP (P1LAC10AP001) and
running CEP (P1LCB21/22/23AP001) will be stopped by the operator.
SH1-DHI-P0100-GE-M01-PRO-5304 27 of 38
6.10. Boiler Shutdown

Once steam turbine is tripped, boiler shutdown is performed. Diesel oil flow is decreased and
gradually all oil burners are turned off as per burner stop sequence. Once boiler is fired out, boiler
recirculation pump is stopped. Boiler is converted into MFT Condition when all burner flame is off.
When final oil burner is turned off, the furnace purge with min.air flow is performed. After
completion of furnace purging, FD fans (P1HLB10AN001, P1HLB20AN001) and CID fans
(P1HNC10AN001, P1HNC20AN001) will be stopped.
6.11. Aux. Systems shutdown

After completion of main plant shutdown, the plant auxiliary systems may be shutdown manually by
the operator depending on the reason of unit shutdown.
SH1-DHI-P0100-GE-M01-PRO-5304 28 of 38
7. Reference Documents
- PID’s
No. Document No. Description

1 SH1-DHI-P1LBA-M-M01-PID-5314
2 SH1-DHI-P1LBC-M-M01-PID-5315 Main & Reheat Steam System
3 SH1-DHI-P1LBB-M-M01-PID-5316
4 SH1-DHI-P1LAB-M-M01-PID-5311
5 SH1-DHI-P1LAB-M-M01-PID-5312 Feedwater System
7 SH1-DHI-P1LBD-M-M01-PID-5317
8 SH1-DHI-P1LBD-M-M01-PID-5318 FeedWater Heater Extraction Steam
9 SH1-DHI-P1LBD-M-M01-PID-5319 System
10 SH1-DHI-P1LBD-M-M01-PID-5320
11 SH1-DHI-P1LBG-M-M01-PID-5326 Auxiliary Steam System
12 SH1-DHI-P1LCA-M-M01-PID-5304
15 SH1-DHI-P1LCA-M-M01-PID-5307 Condensate System
19 SH1-DHI-P1MAA-M-M01-PID-3129 Turbine
20 SH1-DHI-P1HAH-M-M01-PID-1005
24 SH1-DHI-P1HAH-M-M01-PID-1009 Boiler
29 SH1-DHI-P0EGA-M-M01-PID-5201
Diesel oil System
30 SH1-DHI-P0EGA-M-M01-PID-5202
31 SH1-DHI-P0ETA-M-M01-PID-1001 Bottom Ash Handling System
32 SH1-DHI-P0GA-M-M01-PID-5201 Raw Water Supply System
33 SH1-DHI-P0GHC-M-M01-PID-5331 Demineralized Water System
SH1-DHI-P0GHC-M-M01-PID-5332 Condensate Storage and Transfer
34
System
35 SH1-DHI-P0GHD-M-M01-PID-5201
Service Water System
36 SH1-DHI-P0GHD-M-M01-PID-5202
37 SH1-DHI-P0GKB-M-M01-PID-5201 Potable Water System
38 SH1-DHI-P0GM-M-M01-PID-5201
Waste Water Transfer System
42 SH1-DHI-P0LCB-M-M01-PID-5201 Condensate Pump
43 SH1-DHI-P0LD-M-M01-PID-5401 Condensate Polishing Plant
44 SH1-DHI-P0MAV-M-M01-PID-5201 Clean and Dirty Oil System
45 SH1-DHI-P0QFB-M-M01-PID-5202 Instrument Air System
SH1-DHI-P0100-GE-M01-PRO-5304 29 of 38
46 SH1-DHI-P0QFB-M-M01-PID-5203
47 SH1-DHI-P0QH-M-M01-PID-5201 Aux Boiler
48 SH1-DHI-P0QJA-M-M01-PID-5333 N2 Gas System
49 SH1-DHI-P0SCA-M-M01-PID-5201 Compressed Air System
54 SH1-DHI-P1LAB-M-M01-PID-3191 BFP
59 SH1-DHI-P1LCH-M-M01-PID-5321
FeedWater Heater Drain System
60 SH1-DHI-P1LCJ-M-M01-PID-5322
61 SH1-DHI-P1PAB-M-M01-PID-5324 Circulating Water System
62 SH1-DHI-P1PCB-M-M01-PID-5325 Aux. Cooling Water System
63 SH1-DHI-P1PGB-M-M01-PID-5327
Closed Cooling Water System
7.1. System Description:
No. Document No. Description

1 SH1-DHI-P1LBA-M-M01-PHL-5307 Main & Reheat Steam System
3 SH1-DHI-P1LBG-M-M01-PHL-5308 Auxiliary Steam System
4 SH1-DHI-P1LCA-M-M01-PHL-5305 Condensate System
5 SH1-DHI-P1LAB-M-M01-PHL-5306 Feedwater System
FeedWater Heater Extraction Steam
6 SH1-DHI-P1LBD-M-M01-PHL-5309
System
FeedWater Heater Drain & Vent
7 SH1-DHI-P1LBD-M-M01-PHL-5310
System
8 SH1-DHI-P0EGA-M-M01-PHL-5201 Diesel oil System
9 SH1-DHI-P0GA-M-M01-PHL-5201 Raw Water System
Demineralized Water Storage &
10 SH1-DHI-P0GHC-M-M01-PHL-5313
Transfer System
11 SH1-DHI-P0GHC-M-M01-PHL-5314 Condensate Storage & Transfer System
12 SH1-DHI-P0GHD-M-M01-PHL-5201 Raw Water Supply System
13 SH1-DHI-P0GKB-M-M01-PHL-5201 Potable Water System
14 SH1-DHI-P0LD-M-M01-PHL-5401 Condensate Polishing Plant
15 SH1-DHI-P0MAV-M-M01-PHL-5201 Clena and Dirty Lube Oil System
16 SH1-DHI-P0QH-M-M01-PHL-5201 Aux Boielr
17 SH1-DHI-P0SCA-M-M01-PHL-5201 Compressed Air System
18 SH1-DHI-P1MAA-M-M01-PHL-3137 Steam Turbine and Auxiliaries
Gen Stator Winding Liquid Cooling
19 SH1-DHI-P1MKF-M-M01-PHL-3172
System
20 SH1-DHI-P1MKG-M-M01-PHL-3173 Generator Gas Control System
SH1-DHI-P1MKW-M-M01-PHL-
21 Generator Hydrogen Seal Oil System
3171
22 SH1-DHI-P1PCB-M-M01-PHL-5311 Aux. Cooling Water System
23 SH1-DHI-P1PGB-M-M01-PHL-5312 Closed Cooling Water System
SH1-DHI-P0100-GE-M01-PRO-5304 30 of 38
- Plant Operation Philosophy (SH1-DHI-P0100-GE-M01-PHL-5301)

- Plant Start-up and Shutdown Curve(Attachment)
- Plant Start-up & Shutdown Sequence Diagram – Cold, Warm, Hot Start up, Shut down
3
(SH1-DHI-P0CJD-I-M01-DLG-5502~5505)
- Key Single Line Diagram(SH1-DHI-P0ZEN-E-M01-DSL-5601)
- Technical Specification & Datasheet for CEMS(SH1-DHI-P0ZEN-I-M01-TDR-5532)
SH1-DHI-P0100-GE-M01-PRO-5304 31 of 38
ATTACHMENT I START UP AND SHUTDOWN CURVE
SH1-DHI-P0100-GE-M01-PRO-5304 31 of 37
ATTACHMENT 2 OIL IGNITION FOR PULVERIZER STARTUP & SHUTDOWN
SH1-DHI-P0100-GE-M01-PRO-5304 32 of 37
1. Definition of Minimum stable load
<Contract Description>
2.2 PLANT DESIGN AND OPERATING DUTIES
The Facility shall be capable to operate on sliding pressure, typically, between 40% and 90% TMCR while the pressure will remain constant above 90% and
below 40% TMCR. The minimum stable load achievable without oil firing shall be 40% TMCR or below.
3.1 STEAM GENERATOR AND ACCESSORIES

3.1.1.3. Performance design parameters
The unit and all auxiliary equipment shall be capable of safe, stable and continuous operation without overstressing or damaging any components over the
following ranges of operating parameters and conditions:
- All loads above 40% on the worst coal without using auxiliary fuel.
 A minimum stable load defines that the load could be sustained with main fuel only without any
Definition of auxiliary fuel.
Minimum Stable  This minimum stable load can be determined at steady condition, not transient conditions such as
Load boiler start-up or shut-down.
 The combustion system is designed to satisfy the safe operation and the availability.
Basic Concept
Operating
In any case of lighting-off, the fuels must be in service of its igniters using auxiliary fuels for main fuel
Concept burning equipment so as to support the ignition energy.
Transient condition(ex. during load-up)

The igniters shall be used for lighting-off the main fuel.
Steady condition(ex. Full load)

Ignition source is not required to support the main fuel.
It must be in service of oil burners as an igniters for lighting-off the main fuel in order to keep safe
and steady for furnace condition, when any pulverizer has to be shut-down or start-up during the
boiler load-down or load-up.
0
2. Oil support according to NFPA 85 code
<NFPA 85 Code >

 6.8.5.1.1.4 The igniter for the burner shall always be used.
 6.8.5.1.1.5 Burner shall not be lighted using a previously lighted burner or from the hot refractory.
 6.7.5.2.3.6 Each burner shall be shut down in the following sequence:

(1) The igniter shall be placed in to service on the particular burner to be shut down.
 6.8.5.1.5.6 Burner Operation

(C) The pulverizer loading and primary air flow shall be permitted to be used as a guide in maintaining the necessary fuel flow for
each burner and shall be maintained within the prescribed limits as follows:
(4) The associated igniter shall be placed in service prior to admitting coal to any burner.
(5) When the burner(s) and furnace fuel input are within the predetermined prescribed limits necessary to maintain stable flame
without the aid of igniters (as determined by test), the igniters shall be permitted to be removed from service.
A basis of burner operating in accordance with NFPA 85 is that ;

NFPA Code
Requirement  The igniters for the associated main burners shall be used always, in particular, it is not allow
to be ignited by previous lighted adjacent burner or hot refractory.
 Igniters should be in service enough time until main fuel flame is stable without ignition energy.
DHI complies with NFPA 85 requirement.

NFPA
Application  Whenever, the main coal burners shall be lighted-off by the associated oil burners as an igniter
during start-up & shutdown of pulverizer.
 If oil burners are not in service, the coal burner could not be start-up and/or shut-down logically.
1
ATTACHMENT 3 CHECK LIST FOR PREREQUISITE CONDITIONS
SH1-DHI-P0100-GE-M01-PRO-5304 33 of 37
Cold Start Up
Activity Check
WATER TREATMENT SYSTEM NORMAL
CONDENSATE STORAGE & TRANSFER SYSTEM NORMAL
TWO(2) CWP, CTCS AND DEBRIS FILTER ARE IN SERVICE
CLOSED COOLING WATER SYSTEM NORMAL
AIR COMPRESSOR SYSTEM NORMAL
AUX. COOLING WATER SYSTEM IN SERVICE
DM WATER STORAGE & TRANSFER SYSTEM IN SERVICE
AUXILIARY STEAM SYSTEM NORMAL (14BAR HDR)
HP/LP BYPASS HYDRAULIC SYSTEM NORMAL
ALL MANUAL VALVES IN ALL SYSTEM PROPERLY POSITIONED
ALL EQUIPMENTS (TRAIN GROUP, PUMPS) PRESELECTED
BLR FILL UP COMPLETED
WTR LEVEL IN DEAERATOR STORAGE TK AND STG CONDENSER
ARE NORMAL
CLEAN UP OF CONDENSATE SYSTEM COMPLETED
TWS AND CHLORIDE INJECTION IS IN SERVICE
LDO FORWARDING SYSTEM IN OPERATION
COND. WATER BOX (CW SIDE) VACUUM IN SERVICE
BLR FLUSHING COMPLETED
SERVICE WATER & FIRE FIGHTING SYSTEM IN SERVICE
CONDENSATE AND CIRCULATING WATER SYSTEM IN SEREVICE
CEMS NORMAL
CPP IN SERVICE
SCANNER COOLING AIR FAN IN SERVICE
OPERATOR VERIFY FLOW PATH FWH #1,2,3,4
ESP HEATING COMPLETED
BFPT LUBE OIL, TURNING GEAR IN SERVICE
SAMPLING SYSTEM NORMAL
TBN LUBE OIL SYSTEM NORMAL
GENERATOR SEAL OIL SYSTEM NORMAL
H2 GAS FILL UP COMPLETED IN THE GENERATOR
STG TURNING GEAR IN SERVICE
STG HYDRAULIC SYSTEM IN SERVICE
GEN STATOR COOLING SYSTEM NORMAL
TBN STEAM SEAL SYSTEM AVAILABLE
SH1-DHI-P0100-GE-M01-PRO-5304 34 of 37
Warm Start Up
Activity Check
ARE NORMAL
CEMS NORMAL
CPP IN SERVICE
SH1-DHI-P0100-GE-M01-PRO-5304 35 of 37
Hot Start Up
Activity Check
ARE NORMAL
CEMS NORMAL
CPP IN SERVICE
MS PR MAINTAINED MORE THAN 40 BARG
CONDENSER VACUUM IS AVAILABLE
SH1-DHI-P0100-GE-M01-PRO-5304 36 of 37
SH1-DHI-P0100-GE-M01-PRO-5304 37 of 37

SH1 DHI P0100 GE M01 PRO 5304 - Plant Startup & Shutdown Procedure - Rev.3 (Replace)

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DOCUMENT SUBMISSION STATUS: FOR CONSTRUCTION

3 07.12.2018 FOR CONSTRUCTION J.M.SHIN H.W.NAM J.H.PARK

2 26.07.2018 FOR CONSTRUCTION J.M.SHIN H.W.NAM K.H.KIM

1 18.07.2017 FOR CONSTRUCTION J.M.SHIN H.W.NAM K.H.KIM

0 22.05.2017 FOR CONSTRUCTION J.M.SHIN H.W.NAM K.H.KIM

SONG HAU 1 THERMAL POWER PLANT (2x600MW)

OWNER OWNER’S CONSULTANT

EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT

VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES

DATE NAME SIGN DOCUMENT TITLE

PREPARED 07.12.2018 J.M.SHIN

CHECKED 07.12.2018 H.W.NAM Plant Startup & Shutdown Procedure

APPROVED 07.12.2018 J.H.PARK

DOCUMENT NO. REV.

5.4.9.2. EXTRACTION STEAM SYSTEM FOR HP HEATERS .............................................. 23

APC Automatic Plant Control

4. Plant Start-up and Shutdown Duration

Mode of Mode of start-up time Start-up time from Push

Warm start- <48 hr but >8 hr 380 530

• Service Water & Fire fighting system

5.2.1. Initial Fill

5.2.2. Low Pressure System Start-up

 CEP A/B/C (P1LCB21/22/23AP001) ready to start

5.2.3. High Pressure System Start-up

5.2.4. Auxiliary Steam System Line up

5.2.5. Gland sealing and vacuum pulling

5.2.6. Continuous Emission Monitoring System

Guaranteed Emission Values Concentration

NOx 450 mg/Nm3

5.3. Boiler Start-up

5.3.1. Draught Plant Start and Boiler Pre-Light off Sequence

1) Operator initiates Boiler Start sequence.

Air Purge Time calculation

• Total Boiler Internal Volume : 24,086 m3 (D1+D2)

• Any ID fan running

• The MFT relay has been reset.

5.3.2. Light-off Boiler

5.3.3. Main Steam System Charging

the feedback signal from HP bypass valve downstream temperature measurement

5.3.4. RH Steam System Charging

5.3.6. Changeover from Oil firing to Coal firing

5.4. Turbine Start-up

HP turbine 1st stage shell metal Approx. Duration of

5.4.1. Rotor prewarming

5.4.2. Chest warming

5.4.3. Final Preparation for rolloff

12) Rub check (for initial start-up)

a. Select turbine speed rate : 100rpm/min

5.4.4. Temperature matching

Mode of start-up Acceleration rate (RPM/minute)

Cold start-up 100

Mode of start-up Holding period (min) Purpose

Cold start-up 60 min IP turbine Heat Soaking

Warm start-up 10 min Lube oil Heating

Hot start-up 10 min. Lube oil Heating

5.4.7. DA pegging steam source changeover

5.4.8. Loading Up after Initial Load

5.4.9. Extraction Steam System Start-up

5.4.9.1. Extraction Steam System for LP Heaters

5.4.9.2. Extraction Steam System for HP Heaters

5.4.9.3. Unit Master Control

5.4.10. T-BFP (P1LAC20/30AP001) start-up

5.4.12. Aux. steam supply