COLD STARTUP

(with Aux. Steam available)

Integrated Startup Procedure
Step Time Unit Operation Notes
condition
0 0’ Boiler pr. -Charge Aux. Steam header 16 ata
‘0’ kg/cm2 260°C, from existing units.
(g) and
ambient -Charge steam to fuel oil pump house, -All the steam tracing lines in pump
temp. atomising steam and tracing steam, house & boiler to be charged.
deaerator warming up.

- Start tank heating of HFO.

- Start one HFO pump on recirculation
as soon as the sufficient oil temperature
at inlet is achieved.
-Charge HFO to boiler front and keep it
on long recirculation, with heaters
control set on “Auto” to maintain
110°C- 120°C.
-Fill water in drum up to +200 mm. -Ensure that the discharge valves of all
(wet layup pump to be kept in service the CC pumps are open and the pump
with NH3 AND N2H2) suction and discharge lines are vented.

-Check all circuits have sufficient flow.

Before starting the pumps, the
-Start Equipment cooling water system emergency cooling water tank level to
pumps for Boiler, Turbine & TG be checked and made normal.
auxiliaries. (ECW system)
Step Time Unit Operation Notes
condition

0 0’ Boiler pr. -Start instrument air compressor -Check that all circuits have
‘0’ kg/cm2 and check that all lines to Boiler sufficient air pressure.
(g) and and TG are charged.
ambient —Start plant air compressor and fill
temp. the air receiver tanks of SRAPH &
PRAPH
—Ensure that purge air to HEA is
open in all corners.

—Line up Air and flue gas circuits -Check dampers and gates and
for start up. register position.
—ESP ready in all respects.
—Furnace bottom ash system and
seal trough lined up.

—FSSS panel ready in all respects.

—EAST panel ready in all respects.
—Excitation panel ready in all
respects.
—Generator protection panel
ready in all respects.
Step Tim Unit Operation Notes
e condition
0 0’ Boiler pr. —Generator H2 gas pressure is 4 -Check purity of H2 gas is normal.
‘0’ kg/cm2 kg/cm2. -Check purity of generator stator
(g) and —Generator stator water system water is normal.
ambient ready in all respects.
temp. —H2 cooling water system ready in
all respects with Controller auto.

—LP & HP chemical dozing systems -Check for level in Hydrazine,

are ready. Ammonia & phosphate
preparation tanks.

—SADC panel readiness. -Check for air pressure in all the

corners and elevations.
—Power supply for all the valves -Ensure Aux. air dampers are
and dampers are ON. modulating.
Step Time Unit Operation Notes
condition
0 0’ Boiler Pr. --Supply for all auxiliaries of SG,
‘0’ Turbine and Generator is ensured.
kg/cm2 -Readiness of HP bypass panel in all -Ensure the oil unit is running and
(g) and respects. all the bypass and spray valves are
ambient closed.
temp. -Start one of the CC pumps. -Ensure drum level is +200 mm,
-Start the second CC pump. and the drum air vents are closed.
-Ensure drum level is normal.
-Start scanner air fan.
-Start both the secondary air -Ensure that all the inlet and
preheaters. outlet air gas dampers are open.
-Ensure that the gas dampers are
-Start both the primary air closed.
preheaters. -Adjust 30% air flow, and furnace
-Start one set of ID and FD fans. draft minus5to 10mm WCL.
-Charge steam coil air preheater
concerned with the running FD fan. -After purge completion boiler trip
-Initiate Boiler ‘Purge’ (duration 5 valves will get reset.
minutes). -Also after purge, adjust the wind
box dampers to get 30-40 mm
WCL. wind box “dp”
Step Time Unit Operation Notes
condition
0 0’ Lub Oil -Start one vapour extraction fan, keep -Check oil level in MOT.
System other fan standby.
stopped. -Line up lub oil cooler and thrust
bearing filter. Start one AOP. -Check out auto start of AOP and EOP.
-Put on SLCs for other AOP and EOP.
-Put lub oil temp. controller ON.
-Start one JOP.
-Put on SLCs for other JOP and DCJOP
-Put off SLCs JOP 1,2&3, Stop running
JOP.
-Open gate valve gearing. -Check out auto start of JOP and DC-
-Switch on SLC gate valve gearing. JOP
-Start one JOP and switch on SLCs for -MOT level - 50mm oil temp. 45°C JOP
JOPs. header pr. 140 kg/cm2 speed 80-100
-M/c. comes on barring. rpm.

-The sequential operation narrated If the programme gets interrupted, the

above on “Lub Oil system stopped” is step and criteria to be checked and to
achieved by SGC-oil system on starting be fulfilled for the programme to
M/c on programme mode. proceed further,
Barring.

-Start centrifuge with both heaters.

Step Time Unit Operation Notes
condition
0 0’ FRF -Check FRF tank level ± 200 mm.
(Control -Line up FRF cooler and duplex
Fluid) filters in 32 bar system. Start one
system in CEP. Check auto start of standby
stopped CEP.
condition -Establish control fluid supply to -FRF tank level “0” (normal)
. various services.
-Start one recirculation pump and
include one Fuller’s earth and ultra
fine filter.
-Switch on FRF heater and keep SLC -FRF temp. 55°C.
ON for temperature control, and
control fluid pumps.
-Switch ON control fluid SGC.

FRF -The Sequential operation narrated -If the programme gets

System, above in FRF system stopped interrupted the step and criteria to
SGC is on condition is achieved by SGC-FRF be checked & to be fulfilled for the
system on starting programme programme to proceed further.
mode.
Step Time Unit Operation Notes
condition
01 30’ Boiler -Start condensate pumps and feed -Check hot well level.
ready for to deaerator as and when required. LEVEL LO-600MM,LOLO—
light up -Start hotwell make up pumps and 1100MM
and feed hotwell as and when required.
Turbine -Aux. PRDS steam 15 kg/cm2 (g)
on 260°C.
Turning -CW system is charged.
gear. -CW boxes - to ensure venting of
water boxes.
-Start one gland steam exhauster
fan.
-Line up vacuum pumps and start
one
by one
-Gradually admit gland steam when
condenser vacuum reaches -0.2 -Ensure gland steam admission
kg/cm2 (g). temperature is always above
-Vacuum building can be done 200oC.
through SGC - Vacuum on starting
programme mode. gland steam
exhauster has to be started
manually.
Step Time Unit Operation Notes
condition
01 30’ Boiler -Start 4 burners in “AB” elevation -Check that SH & RH vents are
ready for with LSHS. open.
light up -SH & RH drains are open.
and -MSV”S closed & drains before
Turbine MSV open.
on -Air heater soot blowing to be
Turning -Regulate oil pr. to 8-10 kg/cm2. carried out.
gear. -After 30 minutes, take additional
burners, so as to ensure a drum -Ensure atomising steam pr. of
metal temp. rise of about 2 about 6 kg/cm2
°C/minute. -Insert furnace probe and ensure
that the temp. is below 535°C.
-Check drum level and give blow
-Start motor driven feed pump on down.
recirculation.
-Charge the feed line up to feed -Keep open the Eco - recirculation
control station. valve when there is no feeding to
-Charge heating steam to deaerator drum.
from Aux. PRDS.(2 KSC) -Check deaerator level.
Step Time Unit Operation Notes
condition
Vacuum - -Open all drains connected to flash MS10,12,14,16,18 HR
0.9 tanks and flash boxes connected to 08,18,20,22,24,CR12,DW02,04
kg/cm2 condenser.
(g) -Open HPBP warm up valves. MAL VALVES
-Switch on SLC drains.
02 60’ Boiler -Close SH & RH header vents.
pressure: -Close SH & RH header drains -MS line will get warmed up.
2 kg/cm2. -Open MSV by pass lines.

03 100’ Boiler -Switch on automatic control
pressure: interface of LP bypass.
5 kg/cm2. -Open main steam valves.
-Open HP by pass.
-Start third CC pump. , when boiler
pressure reaches 9 kg/cm2.
-Take additional guns in CD & EF
elevation.
-Close HPBP warm up valves.
-As soon as the fixed set point
reaches 12 kg/cm2, it seizes.
-Automatic control interface gets
switched off when the hot reheat
steam pressure reaches 13 kg/cm2
i.e. after synchronization.
 ROLLING THROUGH EHC
Ste Time Unit condition Operation Notes
p
04 150’ MS Pr: 16 kg/cm2. -Open HPSVs& IPSVs for warming -Check and ensure that TSE
MS Temp: 180- up by operating starting device to influence is switched on and
200°C. approximately 42%. available margins are greater than
HRH Pr: +30°K
8 to 12 kg/cm2. -Check and ensure that speed set
point is zero and speeder gear is 0%
position.
(it is always done through the ATRS
PROGRAMME)
05 300’ 2
MS Pr: 16 kg/cm . -Raise the starting device to about -Check and ensure opening of valves
MS Temp: 350°C. 70%. in HP/IP secondary fluid lines to
HRH Pr: 12 EHC at speed control rack. ALSO
kg/cm2. FOR EHC COIL ON
HRH Temp: 350°C. -Raise the speed set point to 360
-Turbine Ready for rpm (speed reference) and watch the -If tracking device is switched ON,
Rolling actual speed. starting device position will
-Raise the speeder gear to 100%. automatically track the EHC
position.
-Hold the speed at 360 rpm for -Ensure closure of gate valve gearing
about 35 to 40 mts. at 240 rpm.
-Monitor bearing vibrations bearing
temperatures, Shaft vibrations, TSE
margins and turbovisory readings.
Step Time Unit Operation Notes
condition
06 360 MS Pr: 50 -Raise the speed set point to 3000 -Ensure tripping of jacking oil pump at
kg/cm2. rpm. 540 rpm.
Temp. : -The rate of acceleration will be 600 to
350°C. 850 rpm2.
Turbine -Monitor bearing vibration, and
Running at temperatures, shaft vibration,
360 rpm. Turbovisory readings and TSE margins.
-Monitor and control, Seal oil
temperatures, Primary water temp,
Hydrogen gas temperature and winding
temperatures.
-Ensure tripping of AOP at 2950 rpm.
07 370 MS. Pr: 50 -Put AVR on auto, Close Field
kg/cm2 breaker,
Temp.: 350°C -Set manually generator voltage to (ALWAYS USE AUTO SYNC)
Turbine grid voltage.
speed: 3000 -Synchronise the generator with grid. -Speed set point will rise automatically
rpm. -Raise the speed set point and pick up by 8 RPM and load will be picked up to
the load to 50 MW. 20 MW.

-Increase HPBP set point. -Ensure closure of HPBP steam valves

& spray valves.
-Close other drains of MS. CRH and -Drain pot drains of MS. CRH, HRH,
HRH, keeping SLC drains “ON”. and extraction steam lines will operate
as per the actuation of level switches.
 ROLLING THROUGH SGC Turbine
Step Tim Unit condition Operation Notes
e
04 150’ MS Pr: 16 kg/cm2. -Switch on the start up -Ensure TSE influence is switched on.
MS Temp: 180- programme of SGC - Turbine. -If the programme interrupts the
200°C. particular step and criteria to be
HRH Pr: checked and corrected for the
8 to 12 kg/cm2. programme to proceed fruther.
-All operations as explained under EHC
rolling will be carried out by SGC -
Turbine programme sequentially.

05 300’ MS Pr: 16 kg/cm2. -Turbine speed will be raised to -Ensure closure of gate valve gearing at
MS Temp: 350°C. 360 rpm through SGC - 240 rpm.
HRH Pr: 12 Programme -Monitor bearing vibration, bearing
kg/cm2. temperature, shaft vibration, TSE
HRH Temp: 350°C. margins and turbvisory readings.
-Turbine Ready for -To achieve the programme as per the
Rolling starting curve, the main steam
temperature should be maintained
steadily till loading up to 50MW.
Step Time Unit Operation Notes
condition
06 360 MS Pr: 50 -Turbine speed will be raised up to -Ensure tripping of JOP at 540 rpm.
kg/cm2. 3000 rpm through SGC - -Ensure tripping of AOP at 2950 rpm.
Temp. : programme. -Monitor bearing temp. and vibrations,
350°C. shaft vibrations, TSE margins and
Turbine turbovisory reading seal oil, primary
Running at water, Hydrogen gas and Generator
360 rpm. winding temperatures.

07 370 MS. Pr: 50 -SGC Programme will switch ON -Ensure SGC - start up programme is
kg/cm2 field breaker, put AVR on auto, completed.
Temp.: 350°C synchronise and pick up load upto 20
Turbine speed: MW.
3000 rpm. -Raise the speed set point and pick
up the load upto 50 MW.

-Increase HPBP set point -Ensure closure of HPBP steam valves

& spray valves.
-Close other drains of MS. CRH and -Drain pot drains of MS, CRH, HRH,
HRH, keeping SLC drains “ON” extraction steam lines will operate as
per the actuation of level switches.
Step Tim Unit condition Operation
e
08 390’ Load:55MW -Start seal air fan and PA fan and take
MS: first mill in service.
54 kg/cm2/350°C
HRH: -Charge ESP fields.
12 kg/cm2/340°C -Start the second set of ID & FD fans.
-Cut in L.P. heaters 2 and 3
-Cut out heating steam from Aux.
P.R.D.S. to Deaerator.
-Peg Deaerator from CRH steam
gradually upto2 kg/cm2.
-Cut in all auto controllers.
09 420’ Load: 110MW -Charge Aux. PRDS station from CRH.
MS: Cut in spray and maintain a temperature
70kg/cm2/370°C of 250°C.
HRH: -Peg Deaerator gradually to 4 kg/cm2.
18kg/cm2/360°C. -Cut in 2nd mill and cut in auto
controllers.
-Start withdrawing oil support gradually.
-Control main steam and reheat steam
temperatures by using spray if required.
-Raise the pressure set point of
Deaerator pressure controller gradually.
Notes
-Before starting P.A. fan, ensure
that air and gas dampers of
Primary Air preheaters are open.
-Ensure Ash handling system is
ready
-Make ready SH & RH spray
systems.
-Ensure switching on of load
controller above 60MW.
-Ensure energising of solenoid in
trimming device at and above 100
MW load.
-Ensure fire ball scanner
healthiness.
Step Time Unit condition Operation Notes

10 440’ Load : 160 MW -Increase the wind box to furnace diff.

MS : pressure to 100mm W.C. by adjusting
90 kg/cm2 /380°C SADC.
HRH : -Charge H.P. heaters 5A, 5B, 6A and 6B.
20 kg/cm2 /380°C -Put controllers on auto.
Steam flow : -Start first TDBFP & second CEP.
580 t/hr. -Charge Deaerator pegging steam from -Ensure Deaerator pressure
CRH to Extraction around 200 MW load. controller remains on auto.
11 480’ Load : 250 MW -Cut in 3rd mill and cut in auto controllers.
MS : -Start second P.A Fan. -Before starting PA. fan, ensure
l20 that air and gas dampers of
kg/cm2/410°C PAPHs are open.
HRH :
26 kg/cm2 /400°C
Steam flow :
820 T/hr.
Step Time Unit condition Operation Notes

12 510’ Load : 320 MW -Cut in 4th mill and cut in auto

MS : controllers.
125 kg/cm2/420°C -Cut off oil support completely. -Ensure healthiness of fire
HRH : ball scanners.
28-30 kg/cm2 /420°C
Steam flow :
1040 t/hr.

13 550’ Load : 405 MW -Cut in 5th mill and cut in auto

MS : controllers
145 kg/cm2 /460°C -Cut in second TD BFP and
HRH : Switch off motor driven BFP.
33 kg/cm2 /460°C
Steam flow :
1310 T/hr.
Step Time Unit condition Operation Notes

14 590’ Load: 500 MW. -If full load is not reached

MS : cut in VI mill along with its
l70 kg/cm2 /475°C controllers. Increase the set
HRH : point of SH & RH spray
40.5 kg/cm2 /475°C controllers such that rated
parameters are achieved
gradually.

15 670’ Load : 500MW

MS:
l70 kg/cm2 /535°C
HRH:
40.5 kg/cm2 /535°C
Steam flow
: 1570 t/hr.
SHUT DOWN PROCEDURE FOR
RAMAGUNDAM STAGE-Il UNITS
Step Operation Notes

1 Start reducing the pulveriser coal flows -Check that load reduction is
gradually in all the mills. approx.5MW/niin.
2 Take the attemperation control in manual mode
and slightly raise the controller output to bring
down MS / HRH temperatures.
3 Reduce the AVR set point by pressing the lower
button.
4 Gradually reduce the throttle pressure set point - The ESV/Control valve temperatures
to about 130 kg/cm2 and load to 400 MW start dropping followed by mean
temperatures.
5 Turn the burner tilt down.
6 With the reduction in the coal flow, reduce the
total air flow.
7 Further drop the main steam and reheat -Check the decreasing trend on TSE 12
temperatures to cool the turbine. point recorder.
8 Stop the topmost pulveriser to reduce the firing
(after emptying the feeder).
Step Operation Notes
9 Close the extraction block valves to HP heater 6B - As the extraction block valve closes, notice the
and 5B. closure of drain control valve as there is no steam
flow to the heater.
- The boiler pressure increases momentarily and
then drops.
10 Further reduce the coal firing. - Ensure that the unit is in Turbine follow mode
with initial pressure control mode in service.
- Check the furnace pressure, drum level and PA
header pr.

11 Stop one more pulveriser to reduce the firing. - Check the furnace pressure, drum level and PA
Take blade pitch control of one PA fan into header pr.
manual and stop it after unloading. - Check the flame intensity at elevations
corresponding to running feeders.
12 Reduce the main steam temperature and hot
reheat steam temperature by raising the
attemperation flow.
13 Transfer the furnace pressure controller to manual
mode and reduce the loading on one ID fan and
load the other fan.
14 Unload one FD fan corresponding to above ID -Maintain furnace pressure and air flow.
fan which is unloaded.
15 Stop one ID fan and one FD fan by giving a stop - Ensure flame stability within furnace. If
command from UCB. necessary cut in oil support. Three feeders with
loading above 75% may not need the oil support.
Step Operation Notes
16 Check that the inlet/outlet dampers of ID fan and
discharge damper of FD fan close on auto.

17 Adjust the HP Bypass pressure set point to match

the existing throttle pressure.

18 Transfer the initial pressure mode to limit

pressure mode and reduce the throttle pressure set
point to keep the deviation positive.

19 Reduce the target load set (load reference) value - Ensure that LP Bypass controller is kept on auto
from the governing console i.e., Pr (ref) & P(lim) with fixed set point slightly below the sliding set
comes down at a rate set by the load gradient. point.
20 As the throttle pressure increases on reduction of
load the HP Bypass valves will open on auto
causing the cold reheat pressure to go up. Once
this pressure exceeds the sliding set point, LP
Bypass valves will also open.
21 Further reduce the load set point from governing - Check that the opening of HP Bypass valves
console. increases further. The
HRH temperature can be controlled by controlling
CRH temp. by HP Bypass attemperation valves.

22 Change over from unit supply to station supply

for 6.6KV ‘A’ and ‘B’buses.
Step Operation Notes
23 Cut in oil support at AB elevation with minimum - Ensure at least three guns prove.
oil pressure to stabilise the flame.

24 Reduce the loading on top most of the three

running mills and take out the pulveriser after
emptying the feeder.

25 Close the extraction block valves of LPH 2&3 - Check that the drain control valve closes.
once the load has come
below20%. Open the drains of extraction lines.

26 Transfer the 30% FRS to auto mode and take the Maintain hot well, deaerator and drum level
50% FRS to manual mode. during transient operation.

27 Stop one CEP after unloading it.

28 Cut in one more elevation of oil guns and

maintain oil pressure and temp.
29 Change over the l6ata header from existing unit
by opening the tie valve.

30 Reduce the attemperation if the main steam

temperature has come to around 380°C.
Step Operation Notes

31 Stop the remaining two pulverisers one after -Check that all fuel air dampers close from
the other after emptying the feeders and top to bottom.
mills. Stop the second PA fan after
unloading it.

Close both primary air pre-heaters’ gas

outlet dampers.
32 Bring the burner tilt to horizontal position.

33 Remove the oil guns at CD elevation by - Check that scavenging operation is

pressing stop button. complete and gun retracts.

34 Remove the oil guns at AB elevation.

35 The moment oil nozzle valve for 4th corner

closes, the boiler will trip and loss of all fuel
to furnace alarm will come.
Step Operation Notes

36 MFR Trip alarm will -Check the following:

come. Both the MFR
A/B relays trip red BOILER SIDE:
lamp comes. - Check that HOTV closes.
- Check furnace pressure.
- Close the Boiler MS Stop valves.
- Open Eco Recirculation valves.
-Close the SH/RH attemperation block valves.
-Ensure that the scanners are sensing no flame.

TURBINE SIDE:
- Turbine trips on Boiler trip protection.
- Ensure the closure of Turbine Stop valves/Control valves.
- Ensure that the Turbine is coasting down.AOP takes start at 2800 RPM.
- Ensure that all MAL valves open.
- Ensure that at about 540RPM, the JOP takes start and jacking oil pressure
comes to about 125 kg/cm2.
-At about 210RPM, check that the barring gear valve starts opening and
turbine speed is maintained to about 190RPM.
-Check that the seal steam pressure/temp. is maintained and condenser
vacuum satisfactory.

GENERATOR SIDE:
-Generator trips on low forward power protection.
-Ensure opening of generator breakers (2552 & 2452).
- Ensure the opening of field breaker.
Step Operation Notes
37 If Aux steam is not lined up for TDBFPs Trip
them and take MDBFP into service

38 Bring the air flow to less than 40% by FD fan

blade pitch.

39 Check that all the purge permissives are satisfied

and purge ready lamp comes.

40 Close the HP/LP Bypass manually and increase

the set pressure higher than the existing pressure.
41 Push the ‘Push to purge’ switch from FSSS -The purging light glows and stays for 5 minutes
console. and purge complete light comes once purging is
over. The MFR A and B relays reset.
-Wait till the fuel air dampers start closing from
top. Maintain air flow in between 30% to 40%.

42 - Increase feed water flow -Ensure that the blow down valves are closed.
- Stop the drum filling once all the ports of the
hydrastep are indicating water (green lamps on).
to top up the drum level.
43 Stop the chemical dosing pumps.

44 Close the manual isolating valve to HP Bypass

desuperheating valve from local.
Step Operation Notes

45 The boiler can be cooled fast after shut down by keeping

one ID fan and one FD fan in service. Air flow is to be
regulated to to effect desired rate of cooling. When the
drum level drops to -180mm it must be topped up to
+300mm by running BFP.

46 Open the boiler vents and drains at 2 kg/cm2.

47 Do water washing of APHs when the gas inlet temperature

is approx.250°C.

48 Stop the ID and FD fans when flue gas temperatures at

APH inlet are reduced below 100°C. At this temperature,
the APHs can also be stopped.

49 Drain the boiler when the maximum drum metal

temperature is <93°C.